Rollstar Montage- Und Betriebsanleitung v04.1_Stand 20080905_englisch

GENERAL INSTALLATION AND OPERATING INSTRUCTIONGeneral installation and operating instruction - Planetary gears - Hydraulic motors and hydraulic gear motors - Locking brakes and return stops - Add-on components Rollstar AG / CH-5704 Egliswil / Switzerland www.rollstar.com © ROLLSTAR AG - Version v04.1 1 / 20 GENERAL INSTALLATION AND OPERATING INSTRUCTION This instruction is revised and edited by: QS Engineering AG Erlenstrasse 31 CH 4106 Therwil Tel. Nr.: 0041 (0) 61 722 04 00 Fax Nr.: 0041 (0) 61 722 04 01 www.qs-engineering.ch Contract Nr. MB-06.1310 In case of conflict, the german original of this instruction is prevailing Applied directives: 2006/42/EC „Machinery“ Applied standards: EN 62079:2001 – Preparation of instructions EN 12100-1:2004 and EN 12100-2:2004 – Safety of machinery © ROLLSTAR AG - Version v04.1 2 / 20 CAUTION! Smaller injuries or damages can occur in case the corresponding precautions are not met. The manufacturer cannot be claimed guilty in case of accidents or damages because of disregard of safety instructions.GENERAL INSTALLATION AND OPERATING INSTRUCTION SAFETY INSTRUCTIONS This installation instruction contains hints for your personal safety and useful tips to avoid damages. WARNING! Partly completed machineries must only be used for the provided scopes as defined in the technical description and only in combination with the Rollstar authorized resp. Qualified personnel Only qualified personnel are authorized to install the equipment.1 3 / 20 .are persons. All information in this document are checked regularly. These hints are marked by warning triangles and represent the following grades of hazard: DANGER! Serious injuries and death and considerable damages will occur in case the corresponding precautions are not met. WARNING! Serious injuries and death and considerable damages can occur in case the corresponding precautions are not met. recommended components or foreign equipment. its handling or to a particular section of the documentation. setup and installation. which is not according to the regulations. Nonliabiity We have audited the content of this document regarding the correspondence with the described hardware. A satisfactory and safe operation of the product presupposes an appropriate transport. starage. We express our gratitude for suggestions for improvements. necessary corrections are incorporated in the following issues. However deviations cannot be excluded. which are educated and trained in the use of the system. which you have to follow up. Qualified personnel . HINT! This sign draws your attention to important information about the product. Contraventions are liable for indemnification. of inproper actions or a use. For a full agreement we do at assume responsibility. © Rollstar AG 2008 Rollstar AG CH-5704 Egliswil © ROLLSTAR AG . To be observed: Copyright © Rollstar AG 2008 All rights reserved Passing on to others or copying of this document or using or transmission of its content is not permitted if not explicitly admitted.with regard to the safety instructions of this document .Version v04. that you have read and understood this instruction manual. installation and startup of ROLLSTAR – aggregates demand total dediction of trained experts. Obligation of the operator The operator is obliged. please contact us immediately. hydraulic motors. © ROLLSTAR AG . HINT! In addition to the installation instruction. Starting up the equipment means. HINT! In case of change of function of the equipment without approval by ROLLSTAR AG. to run the partly completed machinery in perfect operating condition. Design.GENERAL INSTALLATION AND OPERATING INSTRUCTION PREFACE / IMPORTANT HINTS Scope of this installation instruction Selection of aggregate and construction Readership This instruction is to support you during the installation of partly completed machineries of ROLLSTAR AG. accidents can occur. engineers and mechanics. This installation instruction must be read carefully until its end. In case of vagueness. Areas of hazard.1 4 / 20 . Obligation to inform Extent of validity of this instruction This installation instruction applies to all gears. wich are entrusted with the planning. DANGER! If the partly completed machine is inproper operated or used in incorrect condition. Do not start operation of the equipment as long as vaguenesses exists. the general and obliging accident prevention regulations must be observed and assigned. hydraulic gear motors. existing between ROLLSTAR AG partly completed machineries and the operator must protect customer provided installations. execution and installation of partly completed machineries within the scope of complete machines. The installation and maintenance personnel must keep this installation instruction and the applicable regulation in a place that is easily accesible. locking brakes and return stops and also to further add-om components according to the type-key in chapter 2.Version v04. guarantee and liability expire. This installation instruction is directed to project managers. ... 10 3................5 Sense of rotation .................................... 12 © ROLLSTAR AG ................................................7............................................................................................................................ 10 4 Operation............................................................................................ 10 2.......6 Scope of supply ......................................................................................................... 9 2..............................1 Delivery........ 9 2............................................................ manifolds........... 10 3....... error identification and elimination ................................................................................1 EC – Conformity of the ROLLSTAR-equipment.................................................................................................. 10 3 Installation.............................................. 10 3...............................................3 Nameplate........................................................................................................................................................... 12 9 Disturbances.....................................................4 Unpacking................................................. 11 4........................................ 6 2............................................................................................1 Start-up restriction ...................................................................1 Installation......................1 5 / 20 .......................................................................................................................................................................................................................................................................2 Description of the system components ............................................................................................................................................................. 7 2................................................................................................................................................7..............................................................................................................................GENERAL INSTALLATION AND OPERATING INSTRUCTION List of contents 1 Introduction...................... 9 2............................................................................................................................... 6 2..5 Positioning ................................................................................................................................................................................7.............. 10 3.................. 11 5 Maintenance / Lubrication / Cleaning ................6 Storage ....................7.................................. 8 2.....Version v04......................................3 Transport ................................................................................. 11 4..................................... 7 2............................7.........7 Transportation and installation hints ..2 Output .................... 11 7 Operating instructions ..........................................................................................2 Condition of delivered goods .................5 Type designation ................................................................... 6 2 Use according to the regulations................ 10 3........................................ 9 2.................2 Start-up ................................... 11 6 Spare parts.........................................................................4 Product data...............................................................................................................................................................7...................... operating problems......3 Fixing ................................................................................... 11 8 Waste management ................... customer service ................................. 9 2............................................................................................................. 7 2.......................................... 9 2..........................................................................................................................4 Piping......................... 12 10 Guarantee ................................. the manufacturer refuse to accept liability with regard to operational dependability and harms to personnel. Also equipment damages can occur and surrounding installations are endangered. understood and observed. mainly the chapter „safety“. The planetary gear is used either to increase or to decrease the torque at the power take-off. Only by observing the information as given by this instruction.Version v04. installed and maintained. hydraulic or mechanical energy into a rotating motion. caused because of ignoring the safety instructions and because of improper actions or because of use not according to the regulations. Therefore it is absolutely essential that the following list of hazards is read completely. ROLLSTAR machines work safe. © ROLLSTAR AG . Appropriate safeguards must be provided for all driven machines to ensure safety.GENERAL INSTALLATION AND OPERATING INSTRUCTION 1 Introduction This installation instruction is issued for a reliable installation of the ROLLSTAR products. dismount. start-up. operate and maintain the equipment. Ignoring of given instructions. a troublefree operation can be achieved. 2. which are assigned to install.1 6 / 20 . built and tested according to directive 98/37/EC respectively according to the amendment directive 2006/42/EC “Machinery“ In addition to the aforesaid directives and EN standards. the equipment will operate to your full satisfation and reach a large service life. As part of delivery of all ROLLSTAR products. This installation instruction is specially compiled for those groups of persons. HINT! In the case of accidents or damages. anex IIB is issued.1 EC – Conformity of the ROLLSTAR-equipment The equipment is designed. the equipment is a source of danger for operating and maintenance personnel. Any other use is not according to the regulations and hence forbidden. the EC declaration for Installation 2006/42/EC. provided they are correctly selected. If you observe the following hints. 2 Use according to the regulations The ROLLSTAR machines are to convert electrical. DANGER! ROLLSTAR-products must be operated outside of explosion hazard areas! The operator must clarify the explosion hazard of the entire installaion. the Swiss Safety and Accident Prevention Regulations were observed. The nameplate does not show the CE mark because the ROLLSTAR equipment is considered as a partly completed machine according to regulation 2006/42/EC anex IIB. Caption of illustration 2: Nameplate EDV-Nr. loading capacity as well as special requirements regarding space are given in attached binding dimensional drawing and in our order confirmation. etc.GENERAL INSTALLATION AND OPERATING INSTRUCTION 2.2 Description of the system components The system components of the ROLLSTAR equipment are shown in illustration 1. Serie-Nr. Type-Nr. Fixing Output (shaft. Electric motor. 1 2 3 4 5 Illustration.4 Product data All data with regard to features of performance. Rollstar part number Type code according Rollstar productcatalogue Consecutive number with year of construction Illustration 2: Nameplate 2.) 2.) Gear. 1: System components Locking brake. © ROLLSTAR AG .1 7 / 20 . etc. hub.Version v04. as required by the directives. Drive (Hydraulic motor. return stop. the year of construction.3 Nameplate Besides the unmistakable identification of the machine. This illustration in its details serves as common information and does not represent a customer made design or execution. Caption of illustration 1: Pos. capacity. the nameplate contains. arrange for sufficient space around the equipment. speedo. (Planetary gear. etc. etc). pick-off gear. HINT! • For maintenance purposes. It is mounted on an acessible place of the machine. Coding sample type Option output Gear combination Option drive Drive Option output Reduction gear ratio Option drive Drive Specification according catalogue © ROLLSTAR AG . case Manual or hydraulic gear shift Mounting angular gear Hub Hub feather key Hub toothed Oil hook-up radial Oil hook-up axial Mounting spur gear / pick-off gear Second shaft end for tachogenerator Output specific Special fastening flange Manual or hydraulic gear shift Hub special design. Type M Brake Mounting foreign motor Return stop Impulse generator incl. suitable for shaft fastening Shrink disc coupling B G/Z N N(W) S Coding sample part no.GENERAL INSTALLATION AND OPERATING INSTRUCTION 2.Version v04. continuous Special design: E. reinforced Shaft Shaft reinforced Shaft feather key Shaft feather key reinforced Shaft toothed Shaft toothed reinforced AM / M B G H I K/Z L N NP NZ R S T Drive specfc Hydraulic motor Rollstar Type AM. cooling.1 8 / 20 . Flange Flange.5 Type designation planetary gear drive A D E output F FV W WV WP WVP WZ WVZ General Sealed between motor and gear Hollow shaft. oil level indicator etc.g. technical data and possible special features. Use appropriate appliances and a correct technique when lifting the equipment • Before installation and after desmounting. Before lifting of the good.2 Condition of delivered goods Prior to shipment ROLLSTAR equipment is tested for tightness.1 Delivery Normal transport: Shipment by sea: Airfreight: The equipment is properly packed according to the instructions of the shipping agent and complies with the regulations of the country of the consignee. Before transporting the machine.4 • • Unpacking Carefully remove all packing and possible fasteners. observe the danger signs. Hydraulic motors are tested under different operation conditions.7. Machines are primed (color similar to RAL 6019 green).7.6 Scope of supply Before you start unpacking and installing the ROLLSTAR equipment. which are binding for the equipment to assure a safe operation of the ROLLSTAR equipment and which contain all customer related information with regard to layout. The CTU-packing directives have to be applied. please contact our customer service) • Damages. Use appropriate appliances and a correct technique when lifting the equipment. Move the fork between the longitudinal guides of the wooden pallet. Inspect equipment for visible damages. all persons within the range of the fork list must leave. © ROLLSTAR AG . CAUTION! • Heavy object: can cause muscle stress and backache. Hence all machines are delivered ready for use. CAUTION! • Lifting heavy objects can cause muscle stress and backache. HINT! • Check the delivery for completness with the help of the enclosed bill of delivery. impacts. 2. If desired. the machines can be preserved for a longer period. vibrations.1 9 / 20 . store the object in a safe and stable position. (In case of incomplete delivery.7 Transportation and installation hints 2. independently of the means of transportation! Without consultation with the manufacturer. • Heavy loads can drop and cause serious injuries! • The personnel must wear safety shoes. Internal parts and blank external parts are covered with a conservation agent.Version v04. which can cause surface damages.GENERAL INSTALLATION AND OPERATING INSTRUCTION 2.7. to the shipping agent and to the shipping insurance company. caused because of inadequate packing or during transportation must be reported without delay to our customer service. however because of safety reasons without oil filling.3 Transport The shipment of ROLLSTAR – units across long distances has basically to be carried out in horizontal position. HINT! • Transport the ROLLSTAR equipment carefully and take care of transport fasteners. The most important element of this installation instruction is the dimensional drawing and the order confirmation. The test results are recorded. make sure that the scope of supply coincides with the delivery note. 2. • Use appropriate lifting equipment. centrifugal forces and accelerations do not have to overstep ± 2 g. 2.7. DANGER! The driver of the fork list must be authorized to operate the same. 2. See dimensional drawing. The admissible storage temperature is between –20°C and +40°C. The relative humidity must not exceed 70%. External parts must be treated with a conservation agent. In order to avoid damages. incoming sense of rotation is equal to outgoing sense of rotation.Version v04. Size the pipe section adequatly to maintain a low flow loss. 2.2 Output Standard drives and output shafts respectively toothed hubs are only designed to transmit torques. • It is prohibited to perform any kind of welding to the gear! HINT! • Qualified personnel must execute the installation only. you must consult ROLLSTAR regarding special conservation measures. to say. 3. as you like.1 10 / 20 . • Before starting with the work. humidity. 3. it is essential to contact ROLLSTAR for the purpose of suitability. protected against atmospheric influences like dirt.3 Fixing For fixing of Rollstar equipment use bolts of 12.6 Storage If the equipment is stored for a period over 6 months before installation or startup. which are trained and familiar with the system. Qualified personnel with regard to this instruction and safety advice are persons.GENERAL INSTALLATION AND OPERATING INSTRUCTION 2. No radial forces are permitted.4 Piping. © ROLLSTAR AG . the personnel must have read and understood the installation instruction and the applicable safety measures as well. Conservation agents on internal parts must not be removed before startup. If the installation position is not horizontal. which can lessen the safety or function of the equipment. Drives and output shafts which are mounted into the toothed hub of the hydraulic motor or planetary gear must have an axial clearance of 3 – 5 mm to avoid a possible axial pressure caused during installation or because of inaccuracy during fabrication. a specific working position cannot be assigned. 3. 3 3. Whenever possible bend steel pipes in cold condition. the equipment must be stored in a covered area. additions or alterations are permitted.7.9 quality only and tighten them with the specified torque. At shocklike or reversing operation. otherwise the EC conformity expires. pickled and rinsed afterwards. 3. Welded pipes must be cleaned internally. The sense of rotation depends on the oil hook-up of the high-pressure side. Special attention must be paid to angular screw fittings. dust. recommendation of installation and oil filling.5 Positioning HINT! • Fixing sufficient • Protection guard of revolving parts Because this partly completed machine cannot be used as it is.5 Sense of rotation The sense of rotation of the hydraulic motor and the planetary gear is. the mounting flange must be additionally secured with a pin against the counterpart or close tolerance bolts must be provided. manifolds The installation of the manifolds must be performed meticulously.7.1 Installation Installation DANGER! • No modifications. The planetary gear does not change the sense of rotation. chemical agents and excessive warmup and also against mechanical damages. • See appendix E: Lubrication instructions! 6 Spare parts. These instructions simplify repeated procedures.1 Operation Start-up restriction HINT! • The start-up is forbidden until the complete installation including all auxiliaries are installed and connected and tested and until the personnel is instructed and until the safety commissioner has given his authorization. reduce the risk of operating errors and are valuable instruments for training of new personnel. After start-up. (See nameplate) ROLLSTAR AG Schlattweg 323 CH 5704 Egliswil / Switzerland Phone: Fax.1 11 / 20 . High surface temperatures may occur which lead to burnings.Version v04. operate the hydraulic motor. only original ROLLSTAR sparte parts must be used as long as such parts are standard machine parts. Check the oil filling. at first.2 Start-up Before start-up observe the installation and operation instructions. the planetary gear respectively the hydraulic gear motor under idle load and slowly increase the load whilst observing the temperature.: e-mail +41 (0) 62 769 80 40 +41 (0) 62 769 80 41 info@rollstar. repairs. customer service In order to maintain a troublefree function. which are described in this manual. DANGER! • Do not touch the surfaces of the ROLLSTAR machine during operation. type and ROLLSTAR EDV number. lubrication and cleaning we recommend to prepare operating instructions and to enclose them to this installation instruction. Our liability expires if foreign. copied or non-authorized parts are used. © ROLLSTAR AG . 5 Maintenance / Lubrication / Cleaning HINT! • Only such repair und maintenance works are permitted. Direct your queries and requests / orders for spare parts directly to our customer service department and always mention the contract number.GENERAL INSTALLATION AND OPERATING INSTRUCTION 4 4.com Manufacturer’s CUSTOMER SERVICE 7 Operating instructions For the operation. which are available in the market. maintenance. All other works must be authorized by ROLLSTAR. 4. error identification and elimination Disturbances are eliminated by professionals only. © ROLLSTAR AG . • Other parts and parts of non-metallic or organic origin must be disposed off at special collection centers. Replacement of spare and wearparts are excluded from guarantee. which are trained by the manufacturer of the equipment. • When disposing off by yourselves.Version v04. Handle waste disposals carefully or contract a waste disposal company. Directive 94/67/EC Incineration of hazardous waste.GENERAL INSTALLATION AND OPERATING INSTRUCTION 8 Waste management HINT! • Follow local disposal instructions! • Prior to disposal.1 12 / 20 . remove hazardous residuals from parts. These professional personnel for ROLLSTAR equipment belong to the inhouse service staff of the plant. Directive 94/904/EC List of hazardous waste. if all technological requirements were disclosed prior to fabrication. The disposal of lubricants requires special care. operating problems. follow the EC directives as listed hereafter (a selection): Directive 2000/76/EC Incineration of waste. ROLLSTAR AG assumes guarantee for the suitability of the equipment only. 10 Guarantee Guarantee ends at the date as spelled out in the order confirmation. • Metal parts are disposed off at metal collection centers • Plastic parts are disposed off at plastic collection centers. Repair and maintenance works during the guarantee period by our specialists only or upon our written agreenment. Directive 75/439/EEC Waste oil elimination. We ensure the availability of identical spare parts over a period of 10 years. 9 Disturbances. counting from date of delivery. 1 13 / 20 . 7 Operating instructions According to the general installation and operartion instructions. All manifolds and fittings must be connected according to the dimensional drawing and must be checked daily for tightness. Exceeding of the max. operating problems. At larger capacities the oil temperature must be monitored.Version v04. 2 Use according to the regulations According to the general installation and operartion instructions. possible occuring oil mist must not be inhaled. 9 Disturbances. Open flames and smoking in the surroundlings of the planetary gear is prohibited. check operartion mode. 8 Waste management According to the general installation and operartion instructions. © ROLLSTAR AG . 4 Operation Prior to start-up. insufficient lubrication of the planetary gear will cause damage to the motor and gear. as laid down in the technical installation data.GENERAL INSTALLATION AND OPERATING INSTRUCTION APPENDIX A: Additional requirements for ROLLSTAR . 5 Maintenance / Lubrication / Cleaning Maintenance personnel must wear protection gear. An oil leak resp. admissible limits.GEARS 1 Introduction According to the general installation and operartion instructions. Refer to general installation and operarting instruction appendix E. 6 Spare parts. Possible oil mist or oil leaks can catch fire. 10 Guarantee According to the general installation and operartion instructions. error identification and elimination According to the general installation and operartion instructions. 3 Installation According to the general installation and operartion instructions. Customer service According to the general installation and operartion instructions. can lead to serious accidents. Protection devices to avoid accidents must cover accessible rotating parts. the filling pressure of the hydraulic motor must be at least 8 bars. The better the filtration. If open circuits are used. permanent pressure and/or max.GENERAL INSTALLATION AND OPERATING INSTRUCTION APPENDIX B: Additional requirements for ROLLSTAR – Hydraulic motors and hydraulic gear motors 1 Introduction According to the general installation and operartion instructions. the filtration is decisive for a long service life. Our hydraulic motors are not very suitable for an operation in series and we recommend to backcheck with the manufacturer. 5 Maintenance / Lubrication / Cleaning Lubrication with leak-oil Oil quality: HLP-oils according DIN 51524 with a viscosity of at least 40 cSt at operating temperatures with regard to the lubrication of the planetary gear. make sure that there is no motor cavitation at all operating conditions. In this case. When a filter is used in the return manifold. to say. the equipment must be filled with hydraulic oil through the leak-oil connection to prevent a dry run during operation. Closed circuits require a flush valve. the longer the service life. Therefore the leak-oil manifolds must not be connected to the return-manifold because pressure peaks in the leak-oil manifols cannot be controlled then. There is no additional lubrication necessary. admissible number of revolutions. the hydraulic motor is sealed against the planetary gear. The admissible temperature at the hydraulic motor at continuous duty is –10°C to +60°C (during a short period –20°C to +80°C only) Lubrication with leak-oil and additional thoroughly rinsing At higher ambient temperatures and/or operation at max. 3 Installation The leak-oil hook-up is always at the highest point of the hydraulic motor resp. an additional thorough rinsing with hydraulic oil is necessary. The oil returns together with the leak-oil. The additional flush oil connection is at the hydraulic motor. Filtration Besides the oil quality. Avoid a high banking-up pressure at low outside temperatures and also avoid long leak-oil manifolds. Change the oil every 5’000 operating hours or at least once a year and also drain the planetary gear.1 14 / 20 . 2 Use according to the regulations According to the general installation and operartion instructions. A filter mesh size of 10 . the pipe diameter must be oversized to avoid the build-up of banking-up pressure. 4 Operation According to the general installation and operation instructions. Prior to start-up. for the planetary gear appendix E applies. the leak-oil must flow back to the oiltank without pressure. to say: the pressure at the leak-oil connection must not exceed 1 bar. © ROLLSTAR AG . in some cases also at the first (smallest) planetary gear stage. For the hydraulic motor the above said applies „Lubrication with leak-oil“.Version v04. via the leak-oil manifold Gears with seperate splash lubrication In this case. With regards to a long service life of the shaftseal.15 µm is recommended. the hydraulic gear motor to assure a satisfactory lubrication of all moving parts. 1 15 / 20 . 10 Guarantee According to the general installation and operartion instructions. 7 Operating instructions According to the general installation and operartion instructions. 9 Disturbances. 8 Waste management According to the general installation and operartion instructions. Customer service According to the general installation and operartion instructions. © ROLLSTAR AG .Version v04. operating problems. error identification and elimination According to the general installation and operartion instructions.GENERAL INSTALLATION AND OPERATING INSTRUCTION 6 Spare parts. ). hydraulic liquids etc. 8 Waste management According to the general installation and operartion instructions.Version v04. 9 Disturbances. 5 Maintenance / Lubrication / Cleaning Because safety relevant components are used. Exceeding of the max. 4 Operation Prior to starup. To ensure full braking moment you have to assure. 6 Spare parts. 3 Installation Because machine elements are used this can accumulate mechanical energies (Pressure springs. admissible limits. immediately inform the plant operator. clarify whether the installation can remain in operation and contact the manufacturer of the equipment. 2 Use according to the regulations Rollstar brakes are designed as brakes to hold during standstill only but not to brake moving masses. Return stops are used to prevent a change of the sense of rotation of the planetary gear. operating problems.GENERAL INSTALLATION AND OPERATING INSTRUCTION APPENDIX C: Additional requirements for ROLLSTAR – Locking brakes and return stops 1 Introduction According to the general installation and operartion instructions. as laid down in the technical installation data. their function must be tested under idle load condition weekly. make sure. Whenever a defect is detected or wearing is evident.1 16 / 20 . can lead to serious accidents. which could cause accidents. © ROLLSTAR AG . 10 Guarantee According to the general installation and operartion instructions. that the return flow manifold of the brake is pressureless. that eventually accumulated energies are not discharged during installation. Customer service According to the general installation and operartion instructions. 7 Operating instructions According to the general installation and operartion instructions. error identification and elimination According to the general installation and operartion instructions. check operartion mode under idle load condition. 2.GENERAL INSTALLATION AND OPERATING INSTRUCTION APPENDIX D: Additional requirements for ROLLSTAR – Add-on components 1 Introduction Add-on components are elements. brake in action or not). On the other hand.2 Sensor Sensors are used to control specified components or to meter velocities. vent the system.1 Water-cooling Up to now (1-piece): the surface of the gear must be clean and without painting.6 Shrink disk coupling Shring disk couplings are used to transmit the torque by positve locking. Dropping parts may cause injuries. return stops etc. It must not cause furring or sedimentation on the cooling surfaces. The cooling water must comply with special requirements. Its hardness should not exceed 10°dH (german grade). e. fill up the cooling circuit and and if the need arises. Components are added in case an additional function is required.4 Angular gear Angular gears are used to transmit a torque from one shaft to an other shaft. Preference is given to closed circuits! Exceeding the admissible standard values.3 Cardan joint Cardan joints are used to transmit a torque from one shaft to an other shaft. brakes. Contracting a specialist in water treatment offers the folliwng advantages: • Reduction of stop periods • Minimization of energy and water costs • Optimization of operating safety © ROLLSTAR AG . Open cooling circuits are exposed to contamination. New (2-pieces): the surface of the gear must be clean. The temperature and quantity of cooling water depend on the specific type of equipment and is defined on the corresponding dimensional drawing of the gear. 2.Version v04.5 Oil level indicator The oil level indicator is used to visualize the oil level of the Rollstar planetary gear or hydrogearmotor. which can be added as an option to Rollstar planetary gears. Cooling water inlet and outlet can be connected. Cooling water must be free of manganese and iron. Wear adequate protection gear.1 17 / 20 . During installation the gaskets should not be damaged. 2. hydraulic motors. Carry out a water analysis before using the cooling system. Furring in cooling chambers drastically reduces cooling efficiency. The admissible water pressure in the cooling jacket is limited to 16 bars. It is not designed for this purpose and accidents can be the consequence. The content of organic matter must be kept low to avoid sludge deposits on the cooling surfaces. hydraulic gear motors. a treatment of the water is necessary. 2 Use according to the regulations 2. 3 Installation 3. 2.g. too soft cooling water attacs pipes and cooling surfaces.1 Water-cooling Rollstar water-cooling serves to remove heat from Rollstar planetary gears. The indicator must not be used as handle or object to step on. Before start-up of the installation. as you like. which cause clogging-up of pipes. which is generated at high capacities. With it it is possible to transmit torques angularly. 2. During installation the gaskets should not be damaged. With it it is possible to transmit torques angularly. number of revolutions of shafts or status of the brake circuit (open or closed. 4 Angular gear According to the installation and operartion instructions of the relevant supplier. 4. calcium carbonate.GENERAL INSTALLATION AND OPERATING INSTRUCTION Characteristics pH-value Water hardness [°dH] Matter in suspension [ppm] Filter mesh [micrometer] Standard values 6.1 Water cooling Before start-up check all connections and contact surfaces for tightness and tightening moment. During start-up raise the water pressure slowly up to its operating pressure. 4. Open flames and smoking close to the oil level indicator are forbidden because oil-mist or oil leaks can catch fire.Version v04. 4. 4 Operation The integration of components e.g.. A leaking water-cooling can cause water damage with the consequence of an overheating of the components and the installation.6 Shrink disk coupling According to the installation and operartion instructions of the relevant supplier. A leaking oil level indicator can cause damage to the motor and gear. like an absorbent. At shut down and standstill of the machine and subsequently no cooling water flow. (max. e.5 Oil level indicator Before start-up check all connections and contact surfaces for tightness and tightening moment because damages during transport and installation cannot be excluded. During operation check the oil level indicator for tightness every day.2 Senor According to the installation and operartion instructions of the relevant supplier. 4. 3. 3.3 Cardan joint According to the installation and operartion instructions of the relevant supplier. 9 <10 <30 <100 Remaining specification according to DIN 50930 Relation of matter in suspension to hardness: The smaller the amount of matter in suspension.5 Oil level indicator Do not damage gaskets and hoses during installation. Ions and particles settle at the suspended matter. Recommended as well is the addition of a corrosion inhibitor to the cooling water. 3. Check the water-cooling during operation for tightness every day. the higher the hardness grade.2 Sensor According to the installation and operartion instructions of the relevant supplier. admissible 16 bars). 4.1 18 / 20 . sensors or water-cooling into the process control system is not provided by Rollstar. grew in size and can block the flow of the cooling system..6 Shrink disk coupling According to the installation and operartion instructions of the relevant supplier.3 Cardan joint According to the installation and operartion instructions of the relevant supplier. 4.g. 3.4 Angular gear According to the installation and operartion instructions of the relevant supplier.5 . the content of matter in suspension in the cooling water should be kept very low Optimum < 10ppm This is necessary because the suspended matter at standstill reacts with the ions and particles. © ROLLSTAR AG . 3. The Netherlands Tel: 31-71-524-1100 • Fax: 31-71-524-1197 In order to ensure a constant cooling capacity of the water-cooling. 6 7 8 9 Spare parts.1 Water cooling In order to achieve a constant cooling efficiency at the cooling surfaces.3 Cardan joint According to the installation and operartion instructions of the relevant supplier. The surveillance of the temperature at cooling water inlet as well as the cooling water flow is a key requisit for a troublefree operation. Indications for inadmissible contamination are: E.Version v04. 5. 5. 5. 10 Guarantee According to the general installation and operartion instructions.6 Shrink disk coupling According to the installation and operartion instructions of the relevant supplier. error identification and elimination According to the general installation and operartion instructions. 2300 AP Leiden.GENERAL INSTALLATION AND OPERATING INSTRUCTION 5 Maintenance / Lubrication / Cleaning 5. 5. the oil level indicator can be used to drain the gear but must be cleaned immediately afterwards according chapter 3. they need to be maintained from time to time Informative values for a cleaning: Circuit Cleaning interval * Open Closed >1 year >5 years * These intervals refer to deviations of the admissible limit values of water hardness and suspended matters of the used cooling water and depend on the actual contamination of the cooling chamber and manifolds of the installation. At lower temperatures.5 and remounted. Of great importance is the surveillance of the temperature of the gear because a malfunction of the water-cooling can be detected and a possible gear damage prevented. • Chemical cleaning by authorized and trained personnel only! For protection measures when using such products. According to the general installation and operartion instructions. the surveillance and maintenance of the cooling circuit is indispensable.4 Angular gear According to the installation and operartion instructions of the relevant supplier. According to the general installation and operartion instructions. 5. In emergency cases. consult the corresponding safety data sheets. higher pressure drop and / or warm up at unchanged operating conditions ATTENTION! Cleaning agents must not attac the standard material NBR 70 and the installed O-rings.O. Customer service Operating instructions Waste management Disturbances.2 Sensor According to the installation and operartion instructions of the relevant supplier. Specialists for water treatment ONDEO Nalco European Operations 2342 BV Oegstgeest P. © ROLLSTAR AG . Box 627. operating problems.1 19 / 20 .5 Oil level indicator The oil level indicator is maintenence free if operated according to the instructions. a freeze-up of the water cooling circuit must be avoided. According to the general installation and operartion instructions. mainly at plant standstill.g. 500 operating hours / at least every 12 months every 12 months or after 2'500 operating hours together with oil change together with oil change every 12 months Remarks see oil change see oil analysis see oil analysis Oil change When changing oil. 19/17/14 Viscosity approx. sand etc. Action check oil temperature check for changed gear sound check oil level check gear tightness first oil change after start-up oil analysis further oil changes cleaning of vent screw cleaning of gear casing check fastening crews for solid seating Interval daily daily daily weekly after 50 operating hours after approx. always use the same oil type as before. Change oil immediately and flush with new oil several times. Oil analysis When the oil in use appears dark black. filtered Admissble for operation Change of oil or change of filter required Lubricants-Selection table Viscosity ISO-VG DIN Lubricant 51517 CLP 40°C mm2/S (cSt) VG 460 Purity class ISO 4406 min. We recommend having the oil tested in a laboratory for: • Oil quality • Contamination caused by external influences (water. Continuous operating temperatures >70°C should be avoided. Particularly synthetic oils must not be mixed with mineral oil or other synthetic oils. 16/14/11 17/15/12 max.GENERAL INSTALLATION AND OPERATING INSTRUCTION APPENDIX E: Maintenance / Lubrication / Cleaning Maintenance instruction for gear lubrication with constant filling General maintenance hints Trained personnel only must perform all maintenance works carefully. The safe operation and service life depend on a correctly executed maintenance works.1 20 / 20 . the gear must be thoroughly flushed with the new oil. It is recommenden to disassemble the gear and check the parts for corrosion damages.Version v04. admissible temperature is 90°C When the oil appears turbid. Change oil at warm operating conditions and remove the oil filling screw.) Purity recommendations for: New oil. As a consequence. The max.) • Wear particles produced during use (metals etc. Mixing of oil of different kinds is not permitted. aging increased which menas that the oiliness is reduced. operating temperatures above 100°C have occurred. at 50° C mm2/S (cSt) 251 ARAL Aral Degol BG 460 BMB 460 **) Aral Degol BG 320 BMB 320 **) Aral Degol BG 220 BMB 220 **) Aral Degol BG 150 BMB 150 **) MOBIL OIL Mobilgear 634 Mobil SHC 634 *) Mobilgear 632 Mobil SHC 632 *) Mobilgear 630 Mobil SHC 630*) Mobilgear 629 Mobil SHC 629 *) SHELL Shell Omala Oil F 460 Omala HD 460 *) Shell Omala Oil F 320 Omala HD 320 *) Shell Omala Oil F 220 Omala HD 220 *) Shell Omala Oil F 150 Omala HD 150 *) VG 320 Gear oil VG 220 180 126 VG 150 *) full synthetic **) with solid additives 89 © ROLLSTAR AG . When changing over from mineral oil to synthetic oil or from synthetic oil to an other synthetic oil of different pattern. water has entered. Oil changes must follow then in shorter intervals.