中速磨主减速机说明书样本.doc

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Date of issue: Jan.
Version number: : 05A

ML20 vertical roller mill reducer
Manual instruction

Executive standard: Q/3201NGC009-

· Driving device & gear reducer should be operated by skilled operators. Please read this operation manual through before using.
·Oil in the gear reducer has be drained out before delivery. Therefore, please refill oil into the reducer according to the operation manual before starting up.
·Please let the operator holds one copy of this operation manual.
·Please keep this Operation Manual.

Nanjing High Speed & Accurate Gear (Group) Co., Ltd.

Safety Consideration during operating
● Before using (installation, running, maintenance, inspection, etc), operators must read this manual and its annexes through in order to operate this product properly. The operator must read up the whole operation manual including general knowledge of this product, points for safe operation and other points need to be noticed before starting up this reducer. After finish reading, the operators should keep this manual at arm’s length.
● Handling, setting up, pipe preparing, machine running, operating, maintaining and inspection must be carried out by skilled person who has this kind of professional knowledge, or people may be injured or the equipment may be broken.
● When using man-carrying device, there should be some protection on sides of this device, since it may cause injury or equipment broken by speedy movement of this device.
● When using lifting device, there should be some protection on sides of this device to avoid falling of some parts, or it may cause injury or equipment broken by the dropt of lifting device.
● Do not disassemble this reducer while it’s running. Besides, even though the it stops, as the input & output shafts of the reducer are connected to the electromotor and other equipment, it is also forbidden to disassemble these parts except oil inspection pole, oil inlet, oil outlet and inspection cover.
● Do not drive this reducer under other conditions that exceed its specification, or it may cause injury or equipment broken, etc.
● Keep fingers and things away from open parts of the reducer, as it may cause injury or equipment broken, etc.
● Do not use damaged reducer, as it may cause injury or equipment broken, etc.
● Our company will not guarantee the quality of this reducer if the custom redevelops it.
● Do not remove the nameplate.
● Please check the specification of the oil station if it is separate from the reducer.

CONTENTS

Ⅰ. GENERAL INTRODUCTION
Ⅱ.CHARACTERISTIC PARAMETERS
1.OPERATING ENVIRONMENT
2.CHARACTERISTIC PARAMETERS FOR THIS REDUCER
Ⅲ.INSPECTION UPON RECEIPT OF THE REDUCER
1.PRECAUTIONS
2.INSPECTION REQUIREMENTS
Ⅳ.LIFTING, TRANSPORTATION & STORAGE
1.LIFTING
2.TRANSPORTATION
3.STORAGE
Ⅴ.INSTALLATION & ALIGNMENT
1.POINTS NEED TO BE NOTED DURING INSTALLING
2.FOUNDATION
3.ALIGNMENT
Ⅵ.RECORDS OF FIELD INSTALLATION, DEBUGGING AND COMMISSINING
Ⅶ.OPERATION AND MAINTENANCE OF THE REDUCER
1.START-UP
2.SHUT-DOWN
3.MAINTENANCE
Ⅷ. REGULAR INSPECTION
Ⅸ. NOTES FOR DISASSEMBLY AND REASSEMBLY OF THE REDUCER
1.DISASSEMBLY
2.INSPECTION
3.ASSEMBLY
Ⅹ．GUARANTEE

Ⅰ. GENERAL INTRODUCTION
ML20 vertical roller mill reducer transmit through the bevel gears combined with planet gears, a pair of bevel gears with a right angle transmission are connected with a set of planet transmission which input shaft is perpendicularly upward through double-tooth coupling. The sun wheel is supported on the thrust disc by the spherical bearing, the axial support of the vertical mill is endured by the tilted thrust bearing with fan-shaped oil film, and this two freedom of motion make the inner ring and three planet wheels under the equal stress. Internal gear is rigidly fixed in the housing, the designed cylindrical housing provide the ideal support to the axial thrust bearing. In addition, cylindrical housing configure symmetrical ribs both at inside and outside, which let the house have strong rigidity. The output shaft welded with the planet carrier, which make the configuration simple and reasonable.
Bevel gears are Klingelnberg helix gears, and the sun gear and planet gears are involute spur gears. These gears all apply to the carburized carbon steel, gears feature high accuracy after carburizing and grinding.
All the block bearings are the rolling bearings. Axial thrust bearings are the tilted thrust bearings composed of several fan-shaped bearing bushing, which can stand the axial force of the vertical mill. During operation, bearing bushing are directly submerged into the oil tank and supplied fresh lubrication oil through the ring-type nozzles, to keep the tank always in a certain oil level, in such a manner, the mill can work for a period time when the lubrication system suddenly stop or other mechanical errors occur.
Lubrication system is applied to separate oil pump station with pressure and self-protective system, which let the whole unit work safe and reliable.

II. Characteristic parameter
1. Operating environment
Ambient temperature: -20ºC － +40 ºC
Ambient humidity: below 85%
Environmental conditions: no corrosive gas, explosive gas or vapor. No dust and at better air exchange place.
·If have other special requirements besides the above ones, please contact us.
·If there are requirement for anti-explosion in open on the purchase order, our designers will consider it. It will be safe to install our products under our specification.
·The reducer should be installed at this kind of place where it is convenient to carry out the inspection and maintenance work.
·The reducer should be installed on rigid support.
2. Characteristic parameter
Type
ML20
Input power kW
220
Input speed n1 rpm
990
Output speed n2 rpm
46.85
Reduction ratio i
21.128
Weight G kg
6390
Oil product
Industrial gear oil N320
Static load

Dynamic load

Oil mass L/min
80
Inlet oil pressure Mpa
0.15-0.25
Inlet oil temperature ºC
25-50

Ⅲ.Inspection upon receipt of reducer
1. PRECAUTIONS
· Please confirm whether the packing is still in good condition before opening. Please take care when opens the packing.
·Check whether received goods are coordinate with goods listed in the purchasing order. If improper products are used, it may cause injury or equipment broken.
·Do not remove the nameplate.
2.INSPECTION REQUIREMENTS
The following should be inspected when the driving device or gear reducer arrives. If there are some confusion or problems, please contact our sales department.
(1) Whether items on the nameplate or things on the packing list are the same as them in the purchasing order.
(2) Whether there are some damage caused by transportation.
(3) Whether bolts or nuts are loose.
Ⅳ.Lifting, transportation & storage
1. Lifting
·When lifting the reducer, it’s forbidden to stand below the reducer, as the dropt reducer may cause injury.
·Please note the lifting position shown in the drawing and lift the reducer with care.
·Please be careful when lifting the reducer since it may drop down or turn over. If there are lifting bolts or holes, one must use them when lifting. When lifting the whole set of reducer, one must use lifting holes in the lower housing, while it is forbidden to use them in the upper housing. However, after the reducer is installed to the equipment, do not use lifting bolts or holes to lift the equipment as it may cause injury or machine broken.
·Please clarify the reducer’s weight before lifting from the nameplate, package, outline drawing or sample copy. If it exceeds the maximum lift capacity of the lifting device, please do not lift the reducer, as it may cause injury or machine broken.
Note: It is forbidden to lift the reducer with the output flange.

2. Transportation
·The lubrication oil must be drained out before transportation.
·The reducer must be fastened tightly.
·Anti-wind, anti-rain and anti-moist protection must be adopted.
·It is forbidden to place the reducer directly on the ground.
3. Storage
If the driving device or reducer stops for a short period, it should be stored as follows:
1) Proper place for storing
·The reducer should stay in a clean and dry place. Do not lay it out door or at this kind of place where may be humid, dusty and the temperature is changeful or contains corrosive gas.
·Rust preventative oil must be painted to the input and output shafts.
·After dismantlement the lubrication oil pipes should be packed with vinyl resin to prevent foreign substances from getting inside.
·Anti-wind, anti-rain and anti-moist protection must be adopted.
·It is forbidden to place the reducer directly on the ground.
2) Storage period
·This period should not exceed the rust preventing period.
·If the storage period is longer than rust preventing period, the special anticorrosive specification is needed, please contact us.
·If this reducer is an exportation product, the anticorrosive specification for export products are needed, please contact us.
·Standard rust prevention
① Outside prevention
The reducer has been painted with rust preventative oil before delivery. The anti-rust status must be inspected in 6 months after delivery, and if it is necessary, it should be painted again.
② Inside rust prevention
Rust prevention period
6 months
Storing Condition
There should be no humidity, no dust, less temperature change, no corrosive gas. Normally it should be lie in doors or in the storage area.
3) Usage after storage
·Being effected by temperature, ultraviolet radiation and other factors, seals are easily aging and metamorphosing. Thus, the seals should be inspected before restart up the reducer after a long time storage, if the above mentioned happens, please replace them with new ones.
·When restarting up the reducer, please inspect whether there are abnormal noise, vibration or heating. If a brake is attached, please check whether it works well. If there is any abnormal phenomenon, please contact our after-sale service department.
V. Installation and alignment
1. Notes for installing
·Do not running the reducer in the place where there has explosive factors, or it may cause explosion, fire breakout, electric shock, injury, fire hazard or equipment broken. If it is really necessary to run the reducer under this kind of condition, be sure to use an anti-explosion motor.
·When choosing an anti-explosion motor, be sure that it's a suitable type for using in dangerous places (where has the danger of gas or vapor eruption).
·It is forbidden to stay any combustibles near the driving device, or it may arise fire hazard.
·Do not put any article that may effect the ventilation around the driving device and gear reducer, as it may cause equipment broken or fire hazard because of less cooling or abnormal heat.
·It is forbidden to stand upon the driving device or reducer. Do not hanging the reducer, or it may cause injury or equipment broken.
2. Foundation
The reducer shall be mounted on the foundation with good rigidity, level and without vibration, e.g. the reducer can be mounted on framework of foundation which support surface is machined, this framework of foundation shall be molded with the roller foundation. After aligning, first fix the reducer by the locating pin, and then connect the foundation with bolts.
3. Aligning
1) Aligning between the main reducer and main motor
The output shaft which connects the reducer and the main motor must be concentric with the motor when operation. In order to meet this requirement, the specialized instrument must measure the axial and radial run out, more details as the following drawing:

Coupling type
Radial run out
Axial run out(R=200)
Rigidity coupling
0.03
0.02
Flexibility coupling
0.08
0.08
If R>200mm is needed; the axial run out may be increased accordingly.

2) Installation and aligning between the reducer and the mill
·Confirm the rotation direction before connecting to the machine of other side. Otherwise, the wrong rotation direction may cause injury or machine damage.
·Avoid imposing impact force or too much load on the shaft when installing the coupling. Otherwise, it may cause broken or fallen off to bearing or seal ring.
·The installation of the reducer and the mill should be carried out correctly and delicately. Clean the disc mill and thrust pillow block, without any inclusion. The fitting rabbet dimension between the disc mill and thrust pillow block must be recorded in details. Tighten the connection bolts between the disc mill and thrust pillow block, and make sure the thrust pillow block is free from deformation or distortion. The tolerance of axial run out is no more than 0.13mm.
·During installing the reducer , if no oil or lubricate system doesn’t work, the reducer mustn’t run slowly.
VI. The records of field installation, debugging and commissioning
1. The type of the reducer
2. The delivery Serial No. of the reducer
3. The specification of mill
4. The specification, type, power, revolution, pressure, current of the main drive motor
5. Rotation direction (from motor end)
6. Detailed records during installation and aligning
The result of the aligning between the reducer and the motor
The result of the aligning between the reducer and the mill
7. Test run record
The beginning time: Month Day Year
The ending time: Month Day Year
The load on the mil: Month Day Year

Running time:
Item
Beginning time
Ending time
Load on main motor (T)
Voltage of electric machine stator (V)
Start-up Current of electric machine stator (A)
Work current of electric machine stator
Temperature ºC
Remark
Max.
Min.
Room temperature
Oil tank temperature
Before test
After test

Ⅶ.Operation and Maintenance
1. Start-up

1) Preparation work before start-up
·{0>·减速机出厂时已将润滑油排出, 因此, 运行前必须加入推荐的润滑油; <}0{>Lubrication oil has been discharged from the reducer before delivery, so recommended lube must be filled in before operation. <0}
·{0>·外接润滑油管路安装完毕, 安装时应特别注意不能将棉纱、 铁屑等留在管内, 管道必须清洗干净; <}0{>Assemble the external lubrication piping completely. The pipes should be clean and free of any cotton or chips inside before fitting.<0}
·{0>·检查安全控制和自动保护系统工作可靠; <}0{>Make sure by inspection that the safety controlling and automatic protection systems function reliably.<0}
·{0>·检查油箱的油位是否正常, 否则应补充至正常油位; <}0{>Check oil level in the tank.
·{0>·检查各仪器仪表、 控制装置、 开关等是否安装完毕, 安装是否牢固可靠, 能否正常工作, 电器元件引出线绝缘情况是否良好; <}0{>Check whether all instruments, gauges, apparatus and meters have been installed completely;
{0>·检查各螺栓螺母等紧固件是否紧好; <}0{>

·Check the oil leakage of the lubrication system after 1 hr lubricating
·Check the