How To Debug Flender Gearbox?

1. Preparation before commissioning

Please pay attention to the following preparations before commissioning the gearbox:
● Please pay attention to the operating instructions.
● Replace the locking bolt with an air filter or a humid air filter.
● Gearbox with backstop: Please pay attention to the preparations before debugging the gearbox with backstop.
● Gearbox with auxiliary drive: Please pay attention to the preparation work before adjusting the gearbox with auxiliary drive.
● Fill the gear box with oil.
● Gearbox with oil supply equipment: check whether the oil supply equipment can work normally.
● Check the oil level.
● Check the tightness of the gearbox.
● Check whether the monitoring device is connected to the box.
● Gearbox with oil supply equipment: Please pay attention to the preparation work before debugging the gearbox with oil supply equipment.
● Make sure that all pipes and components are filled with oil.

1.1 Gearbox with backstop

Please pay attention to the following preparations before adjusting the gearbox with backstop:
● Fill the oil quantity specified on the prompt plate through the oil filling screw of the backstop.
Please use oil of the same type and viscosity as the gearbox.
● Check whether the backstop can rotate in the idling direction without increasing power consumption. At this time, please pay attention to the direction of rotation arrow on the gearbox.
● Before connecting the motor, use the rotation direction indicator to determine the rotating magnetic field of the three-phase power grid.
Connect the motor according to the determined direction of rotation.

1.2 Gearbox with auxiliary drive

Please pay attention to the following preparations before commissioning the gearbox with auxiliary drive:
● Please pay attention to the data in the auxiliary drive operating instructions.
● Fill the release coupling with oil through the intermediate flange. Please use oil of the same type and viscosity as the gearbox.
● If necessary, ventilate the brake on the auxiliary motor.
● Check whether the release coupling can rotate in the idling direction without increasing power consumption.
To do this, please rotate the motor shaft of the auxiliary drive in the direction of the direction arrow on the gearbox.
● Before connecting the motor, use the rotation direction indicator to determine the rotating magnetic field of the three-phase power grid. Connect the motor according to the determined direction of rotation.
● Make electrical connections between the main motor and the auxiliary motor, so that only one of the motors can be connected at the same time.
● For maintenance drives: check the shutdown function of the speed monitor

1.3 Oil level monitor

The gearbox can be equipped with an oil level monitor with a liquid level limit switch.
The oil level monitor is designed to check the oil level when the gearbox is stationary.

1.4 Gearbox with cooling coil

Please pay attention to the following preparations before commissioning the gearbox with cooling coil:
● Check whether the connecting cable is firm and sealed.
● Fully open the shut-off valve of the coolant inlet and outlet pipes in the cooling system.
● Ensure that the maximum pressure allowed in the cooling coil is not exceeded.
● Ensure that the maximum temperature allowed by the cooling water is not exceeded.

1.5 Gearbox with heater

Please pay attention to the following measures when commissioning the gearbox with heater:
● Make sure that the heating rod is not empty.
● Check the switch point of the temperature monitor.

1.6 Gearbox with oil supply equipment

Please pay attention to the following preparations before commissioning the gearbox with oil supply equipment:
● Ensure that the maximum pressure allowed in the fuel supply equipment components is not exceeded.
● Ensure that the maximum temperature allowed by the fuel supply equipment components is not exceeded.
● The gearbox is pre-lubricated for 2 minutes through the pre-lubrication phase of the oil supply equipment. During this period, sufficient lubricating oil for starting will be supplied to the rolling bearings and gear systems.

1.7 Add lubricant to the gearbox equipped with backstop or auxiliary drive

Follow the steps below to add lubricant to the gearbox equipped with a backstop or auxiliary drive:
1. Determine the amount and type of oil to be injected according to the information on the nameplate or additional label.
2. Remove the locking bolt on the release coupling or backstop.
3. Inject lubricating oil through the oil injection filter (maximum filtration accuracy 25 μm).
4. Re-tighten the locking bolt.
5. Check the function of the release coupling before commissioning.

2. Preparations during commissioning

Please pay attention to the following gearbox debugging measures and check:
● Gearbox with oil supply equipment: check whether the oil supply equipment can work normally.
● Check the oil level.
● Measure the temperature of the oil sump after the gearbox is running in.
● Check the tightness of the shaft seal on the gearbox.
● Check whether the rotating parts will not be touched.
● Check the open state of the shut-off valve
● Make sure all drain valves are closed
● Please make sure that all other shut-off valves are open
● Check whether the existing connecting cables are firm and sealed.
● Gearboxes with bearing vibration measurement: Measure the vibration of rolling bearings (Page 139) to generate output and comparison values.
● On gearboxes with bearing monitoring via the resistance thermometer Pt 100: Measure the temperature of the rolling bearing (Page 140) in order to obtain the original value and the comparison value.
● When debugging, bridge the pressure monitor signal for about 20 seconds. Because you have to wait for the pressure in the gearbox to stabilize. If oil pressure does not develop after 20 seconds, the time can be extended slightly after consultation with the manufacturer.
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