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INSTRUCTION MANUAL

FOR

SOLAR TURBINES INC.

PROJECT: STD-GS

SOLAR P/N: 1010944-72571

14905
SERIAL NUMBER

P.O. Box 8447, Mankato, MN 56002-8447, (507) 625-4011 Fax (507) 345-2798 www.kato-eng.com
1
SERIAL NUMBER
14905

CIRCULATING OIL LUBRICATION

LUBRICATE BEARING WITH A CIRCULATING LUBE OIL


SYSTEM WHICH MAINTAINS OIL LEVEL AT
THE CENTER OF THE SITE GLASS

USE A HIGH QUALITY, DOUBLE INHIBITED OIL


WITH VISCOSITY, PRESSURE AND FLOW RATES INDICATED
BELOW. THE OIL SHOULD CONTAIN OXIDATION AND RUST
INHIBITORS AND DEFOAMANTS

OPPOSITE DRIVE END DRIVE END


BEARING NUMBER

012-68329-02 012-68329-04
SUMP CAPACITY

1.6 US GAL 1.6 US GAL


OIL VISCOSITY

ISO VG 32 ISO VG 32
OIL FLOW RATE (GPM)

1.3-1.6 GPM 1.3-1.6 GPM


157-00128-00
OIL PRESSURE

55 PSIG @ ORIFICE 55 PSIG @ ORIFICE

ORIFICE DIAMETER: .098" DE & ODE

Kato Engineering
PUBLICATION: 350-01015-00
PUBLICATION DATE: JULY 1995

INSTRUCTION MANUAL
REVOLVING FIELD
BRUSHLESS
AC GENERATOR
SLEEVE BEARING

FOR

SOLAR TURBINES, INC.

INCLUDES
Principles of Operation
Installation Instructions
Adjustment and Operation Instructions
Maintenance and Troubleshooting
Drawings and General Information

P.O. Box 8447, Mankato, MN 56002-8447, (507) 625-4011 Fax (507) 345-2798 www.kato-eng.com
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Power Transmission
OLLERN BHW Plain Bearing
Installation and Operating Instructions ZM

Code:ZM-00
Parts List for Centre Flange Bearing ZM

1.1 Upper bearing housing* 10 Loose oil ring


1.2 Lower bearing housing* 15.1 Seal carrier
1.3 Bearing housing retaining screws* 15.2 Seal carrier retaining screws*
1.5 Sealing plug with seal* (Oil inlet for circulated oil) 20.1 Floating labyrinth seal*
1.6 Cable screw or plug PG7 20.2 Spring key for floating labyrinth seal*
1.7 Sealing plug with seal*(Temperature sensor port) 21.1 Floating labyrinth seal (machine side)*
1.8 Sealing plug with seal* 21.2 Spring key for floating labyrinth seal (machine
(Connection for heater, sump thermometer or cooler) side)*
25.1 Bolt on baffle
1.9 Sealing plug with seal* (drain) 25.2 Bolt on baffle retaining screws*
1.10 Sealing plug with seal* (oil fill) 30.1 Machine seal upper half*
1.11 Oil level sight gauge (or oil outlet for circulated oil) 30.2 Machine seal lower half*
1.12 Oil sight window* 30.3 Machine seal strip*
1.13 Sealing plugs* - lower and upper part (atmospheric 30.4 Machine seal retaining screws*
pressure balance)
1.14 Eye Bolt* 30.5 Machine seal split line screw
5.1 Bearing shell upper half* 40.1 Upper bearing housing retaining screws
5.2 Bearing shell lower half* 40.2 Lower bearing housing retaining screws
5.3 Anti-rotation pin* 40.3 Dowel pin (not supplied by the manufacturer)

*For spare or replacement requirements, these parts can only be supplied as subassemblies, and not as individual parts. Normal
spare parts are listed in section 11

990225/h520

2
1 Safety Recommendations
Zollern flange bearings (type ZM) are incorporated into various types of machinery and any safety regulations specific to the
machinery must be observed.
During bearing operation, assembly, maintenance and repair, accidents and injuries must be avoided at all costs. The following
points require special attention:
During maintenance and repair ensure that rotating machinery is at a standstill, isolated from electrical supply with interlocks
such the supply cannot be resumed unintentionally.
Loads and speeds must not exceed those specified in Zollern’s data sheets, drawings or calculation sheets.
Rotating parts must be fixed so that accidental movement is not possible.
BEWARE: After use, the bearings will be hot. There is risk of receiving burns during repairs and maintenance if the bearing is
not allowed to cool.
The shaft tolerances set out in our specifications and drawings may not be exceeded.
The bearing may become detached if screws are allowed to loosen. Tighten the screws to the specified torque.
Alterations to the ZM bearing may only be carried out with the express permission of Zollern, who must also be consulted in the
event of load specifications being exceeded. On request, Zollern can provide supervisory personnel to assure that the repairs and
modifications are done properly.

2 Bearing Types and Designations


Type Z Bearing for horizontal mounted shaft
Housing M Finned centre flange bearing
Cooling N Natural convection
Z Forced oil with external cooling
W Water cooler in oil sump
Lubrication L Cylindrical bore with loose oil ring
Thrust bearing B Plain white metal with oil grooves
K Tapered pad for bi-directional rotation
D Tapered pad for uni-directional rotation
A Round tilted pads, spring supported
Q Without thrust bearing
Note Insulated bearing shells are designated ‘insulated’
Example : Finned centre flange bearing with forced oil lubrication externally cooled having plain
cylindrical bore with loose oil ring. Tapered thrust pad for bi-directional rotation size 9,
ZMZLK 9-90 shaft diameter 90mm. The bearing is uninsulated since it is not designated as insulated.

3 Introduction
Please pay careful attention to all points covered by this manual to ensure the safe and efficient operation of the bearing. Care needs
to be taken to keep all bearing parts and the workplace clean. Provision is made for thermometers (1.7, 1.8), oil level gauges (1.11),
oil inlet (1.5) and outlets to be fitted to either side of the bearing. These devices can be fitted to either left or the right as required.
Where a bearing is force oil lubricated, the oil outlet pipe is fitted into the tapping for the oil level gauge (1.11). The oil drain plug
(1.9), which can also act as an oil flow connection, is positioned at the centre underneath the bearing.
With electrically insulated bearings, there is a non-conductive layer on the spherical seat of the bearing housing. This layer is both
wear-resistant and temperature-resistant. The shaft seals (see chapter 6 - “shaft seals”) and the anti-rotating pins (5.3) are
manufactured from non-conductive material and prevent any spark erosion of either bearing shell or. Any temperature control
instrumentation installed by the user should be insulated using appropriate measures, such as isolated protective piping and plastic
screws. Zollern can, of course, provide help when required.
Eyebolts (1.14) are fastened to the upper part of the bearing to assist handling of the complete and assembled bearing. It is
important to remember that they are not suitable for the handling of the assembled machine and that the eyebolts are only to be
used as tension elements.

3
4 Packing
All bearings are delivered fully assembled without oil. The oil ring (10) and other accessories are packed as separate items. The
bearings are protected against corrosion and other influences by a preserving film, according to individual application.

5 Installation
Once the upper housing (1.1), the seal carrier (15.1), the shaft seals (20.1) and the bearing seal (5.1 and 5.2) have been dismantled,
carefully clean the interior of the bearing and the bearing shell and check for any damage caused during transport.
Ensure that the shaft is clean and that dimensions and tolerances correspond to our recommendations. We recommend that the
appearance of the bearing surface on the shaft is checked and that it is checked that non-moving seals have not become jammed in
the shaft (see chapter 6 “shaft seals”).
Align the cleaned lower part of the housing (1.2) with the machine frame and fasten.
Tighten the fixing screws (40.2) of the lower casing to the following torque values:
Bearing Size 9 11 14 18 22 28
Torque (Nm) * 51 87 215 430 740 1500
* Torque in lb.f = Torque in Nm X 0.7373
Continue with installation as follows depending on the machine shield design:
1. Single Piece Machine Shield
The locating spigot is situated in the lower half of the shield. In the upper half there is a larger location with a larger radius this is
closed off post assembly with a thin metal sheet.
2. Split Machine Shield
The machine shield is split with a thick walled lower half, the upper part being of thinner sheet which is attached to the upper casing
post bearing assembly.
3. Split Machine Shield with constant wall thickness
In this instance assemble as per 2 above
Secure the lower half of the machine seal (30.2) loosely to the lower casing (1.2). Coat the corresponding sealing surface with a
thin film of non-hardening sealing compound.
Apply a film of oil to both the spherical seats in the lower part of the bearing housing (1.2) and to the lower part of the bearing
shell (5.2) (use the same oil as is to be used during operation of the bearing).
Place the lower part of the bearing shell (5.2) onto the shaft seat and turn it to the correct position in the lower part of the
housing. Take care that thrust bearing surfaces are not damaged while the shell is turned.
Align the surface of the shell with that of the housing.
Next assemble the loose oil ring (10), which must first be disassembled. Position both halves of the oil ring on the shaft and
around the lower half of the shell using the notch provided, then press both halves together on the dowel pins. Following this,
tighten the fixing screws to the following torque values:
Bearing Size 09 - 14 18 - 28
Torque (Nm) * 1.4 2.7
* Torque in lb.f = Torque in Nm X 0.7373
After tightening to the proper torque, it is recommended to swage the ring at each bolt edge to positively prevent loosening
during operation.
Apply a film of oil to the shaft seat and lower the shaft into the lower part of the shell (5.2).
Having positioned the shaft, fit the loose lower half of the machine seal (30.2) against the lower half of the shaft. With the seal in
this position tighten the flange fixing screws (30.4) of the lower half of the machine seal (30.2) to the following torque values:
Bearing Size 09 - 14 18 - 28
Torque (Nm) * 10 25
* Torque in lb.f = Torque in Nm X 0.7373
(During operation the seal is running on an oil film, so there is no seal-to-shaft contact)
Apply a film of oil to the upper part of the bearing shell (5.1). Lower shaft into the lower part of the shell (5.2) and place the
upper part of the shell onto the lower part (it is impossible to turn both halves of the shell together as they would become
misaligned).
Coat the surface of the split line in the lower part of the bearing housing with a thin film of non-hardening sealingcompound.

4
Very slowly lower the upper part of the housing (1.1) onto the lower half. Ensure that during lowering the already assembled
flange-side seal (21.1) locates into the groove provided. Avoid jamming at all costs. The upper part must be correctly aligned (to
ensure this one possibility is to pass a rod through the upper through hole and align accordingly). Tighten the cover screws
(1.3) crossways to the following torque values :
Bearing size 9 11 14 18 22 28
Torque (Nm) * 41 70 172 344 592 1200
* Torque in lb.f = Torque in Nm X 0.7373
With machines that are prone to vibration, it is essential that measures be taken to prevent screws from loosening. To this end
secure with Loctite or similar thread locking compound.
After coating the corresponding sealing surface of the upper casing half (1.1) and the split line surface of the machine seal
(30.2) with non-hardening sealing compound, fasten the upper half of the machine seal (30.1) to the upper casing (1.1).
Tighten first the split line screws (30.5) of the machine seal and then the flange retaining screws of the upper half of the
machine seal (30.1) with the torques given above for the lower half flange screws (30.4).
Connect the bearing shield to the upper casing (1.1) according to the machine shield design.
Prepare the exterior floating labyrinth seal (20.1) for assembly in the same way as the flange-side seal and attach to the shaft
before fastening the seal carrier (15.1) to the housing.
Coat the split lines and flange surfaces of the seal carrier with non-hardening sealing compound.
Place the seal carrier (15.1) around the floating labyrinth seal, push both into the bearing housing and tighten the seal carrier
screws (15.2) to the following torque values :

Bearing Size 09 - 14 18 - 28
Torque (Nm) * 10.5 26
Torque in lb.f = Torque in Nm X 0.7373

5.1 Additional Information for Bearings with External Oil Supply


When using an external oil supply the pipe diameters should be chosen such that the inlet flow does not exceed 1.5 m/s and the
outlet flow 0.15m/s.
If the inclination of the oil outlet pipes for structural or design reasons cannot be set to 15°, pipes with correspondingly larger
diameters need to be used. Pipes with inclinations or diameters which are too small may create back-flow, which could in turn lead to
overflowing or leakage.
Heat-treated (welded or hot-worked) pipes and/or those showing any signs of rust or dirt must be scoured and cleaned prior to
assembly. Following assembly of the pipes the entire oil circulating system must be flushed to prevent dirt entering the bearing or
fittings.
Prior to cleaning all measuring and switch fittings (pressure control, flow gauge) and their connections must be removed. The
bearings must not be left intact during cleaning, and following cleaning all filters must be rinsed. All connections to the bearing must
be free of vibration and tension.
CAUTION: If external lubrication oil flow is provided, means should be included at the oil outlet connection piping to set the proper
oil level. Zollern can supply a connection pipe with a built-in weir to set the oil level if requested.
If insulated bearings are used on both ends of electric motors and generators, it may be required to include an earthing connection to
short out the insulation during operation to be sure that electrical current pitting of the bearing surface cannot occur.
The correct oil flow rate should be controlled externally (usually with an orifice sized for the oil pressure of the lubrication system).

5.2 Additional Information for Bearings with Water Cooler in the Oil Sump
When attaching the water cooler care must be taken to ensure that there are no leaks from the cooler or its connecting pipes. The
joint seals must not be damaged. During fitting a stop tap or valve should be provided in the inlet. Any oil should be free to drain from
the housing (no pressure should be required). The cooling flow can be in either direction.

5.3 Pressure Equalization


It is not uncommon that the machines using the ZM bearing types can cause a negative pressure to occur near the bearing housing
internal side. To prevent such negative pressure from occurring, Zollern bearings have two different air passages that equalize this
pressure on the machine side of the floating seal. If negative pressures may occur, it is necessary to assure that at least one of the
passages has the plug removed to allow this protective feature to function.

5
6 Shaft Seals
Zollern bearings can be supplied with various seal types or seal systems depending on the required application, with seals
conforming to DIN 40050 or IEC 529. Special seals can be supplied for particular applications on request.

6.1 Floating Labyrinth Seals


For standard applications ZM bearings are equipped with floating labyrinth seals (see fig. 2) which achieve IP44. The labyrinth seals
float on the shaft at circumferential speeds above 100 m/s. They are manufactured from a rigid, unbreakable and temperature
resistant polymer. The seals are seated within a seal carrier or directly seated in the housing such that they are not subject to loading
due to radial shaft displacements.

Oil drain holes are provided in the lower part of the floating labyrinth seal. An anti rotation pin on the split line prevents the seal from
being assembled incorrectly and damaged.
Unassemble the seals prior to bearing assembly so that the hook and eye of the spring key (20.2 & 21.2) are separated.
Prepare the seal for installation and coat the surface of the split line and the exterior of the spring guide (see fig. 2) with a thin
layer of non-hardening sealing compound (supplied by Zollern).
Place the lower part of the seal onto the shaft and turn it into the correct position make sure the oil drain holes in the seal are
facing towards the bearing and the anti rotating pin must sit in the groove of the split line).
Place the upper part of seal onto the lower
Insert the spring key through the sealing groove and lock into place.
Check the alignment of the seal and housing split line

6.2 Floating Labyrinth Seal with Bolt on Baffle


The bolt-on baffle can be combined with either a floating labyrinth seal (chapter 6.1) or a rigid seal (chapter 6.4) to achieve IP55. The
inserted seal strip is temperature resistant withstanding high circumferential speed. The coefficient of friction is minimal as is the
‘stick/slip’ coefficient. The electrical insulation properties are very good and independent of temperature and environmental
influences.

6
Insertion to be done as follows:
Spread the sealing compound onto the surface of the split line and coat the movement surface with the seal carrier of the
floating labyrinth seal (fig. 3)
Next gently press the lower part (the half with a drain hole visible on the outer surface) from underneath against the shaft and
tighten the fixing bolts equally.
Finally position the upper part, align on the split line and attach with the bolts.

6.3 Floating Labyrinth Seal with Labyrinth Ring


The labyrinth is clamped onto the shaft and inserted into a groove in the seal carrier of the floating labyrinth seal (fig. 4), thus
preventing dirt and water from entering the bearing. The groove can be filled with grease when necessary.

After placing onto the shaft the labyrinth ring must be so placed that it is not possible for it to run into the groove. The axial
movement of the shaft is limited.

6.4 The Rigid Seal


Fig. 5 shows a rigid seal with two separate labyrinth systems. Where axial movement is minimal a shaft collar can be provided
between the labyrinths.

A thin layer of sealing compound initially retains the rigid seal. During assembly the lower half of the seal is lightly pressed onto
the shaft from below and the screws then tightened (during operation the shaft is raised).
ATTENTION The baffles must be removed during assembly and disassembly of the shaft or damage to the shaft may ensue.

7 Commissioning
Remove the oil sight glass (1.11) or the plug (1.9) fill to the recommended level with the recommended oil grade. The oil is at the
correct level when it reaches the middle of the oil level glass (1.10). The minimum oil level is when the oil only reaches the lower part
of the sight level glass when the machine is stationary.
WARNING
Insufficient oil level will lead to ineffective lubrication, bearing overheating and subsequent damage leading to failure. Too high a
level of oil will not hinder the operation of the bearing, but could lead to leakage at the seals. Prior to commissioning of the bearing it
must be checked for leaks. All oil port plugs and securing screws are correctly fitted and tightened.

7
ATTENTION
Should, at any time during commissioning or operation, the bearing temperature exceed that specified by Zollern the machine should
be stopped and the causes investigated.

8 Maintenance
The oil level must be checked at regular intervals with the machine at a standstill. The minimum oil level is where the oil only reaches
the lower part of the sight level glass.
The bearing housing must be kept clean as heat transfer can be hindered by dirt and dust leading to bearing overheating and
subsequent damage leading to failure.
Should, during operation, there be unusual variations in bearing temperature or oil level the causes must be investigated.
Our technicians are available should any assistance be required.

8.1 Oil change intervals


For self contained and bearings using mineral oils we recommend flushing and oil change after 8000 operating hours, for forced oil
lubricated bearings we recommend an interval of 20000 hours. Longer intervals may be possible subject to Zollern approval. Shorter
intervals are necessary where there is frequent starting or where oil temperatures are high or where there is an excessively dirty
environment. To change the oil, take out the oil drain port which is positioned at the centre beneath the bearing (allow the oil to drain
while it is hot). Should unusual oil discoloration or smell be apparent the causes must be investigated. Should any chemical cleaning
or compounds be used, they must be thoroughly flushed away prior to further operation.
The oil is refilled through the oil sight glass (1.11) or plug (1.9). Use only the recommended oil grade as shown by the manufacturer’s
plate. The oil is at the correct level when it reaches the middle of the oil level glass (1.10). There is always a possibility of overfilling -
too high a level of oil will hinder the operation of the bearing.
WARNING
If regular checks are not made there is a chance of insufficient oil leading to ineffective lubrication, bearing overheating and
subsequent damage leading to failure.

8.2 Inspection
Should unusual oil colour changes or increases in temperature be apparent an inspection must be made. Remove the upper half of
the bearing housing (1.1) leaving the lower half in place. Prior to disassembly thoroughly clean the bearing casing such that no dirt
can accidentally enter the bearing itself.

8.3 Disassembly
Loosen the fixing screws to the upper half of the bearing (40.1) and the split line screws (1.3) and the screws (15.2) on the
upper half of the seal carrier.
Remove the upper part of the seal carrier (15.1).
Remove the bearing shield (depending on the machine shield design) from the upper casing. Loosen flange fixing screws (30.4)
and split line screws (30.5) of the upper part of the machine shield (30.1) and remove it.
Raise and remove the upper casing half (1.1).
Dismantle the floating labyrinth seals (20.1 & 21.1) by raising the upper half and tilting it then open the spring key and dismantle
together with the lower half.
Carefully raise the upper half of the bearing shell (5.1). Release the loose oil ring (10) screws, separate and remove both parts.
Remove any probes or sensors if present.
Raise the shaft far enough to give sufficient clearance to turn the lower shell (5.2) half through 180° and lift it away.

8.4 Visual Check


During disassembly check that all bearing surfaces remain in good condition. Bear in mind that , depending on the total operating of
the bearing, the shell should show consistent polishing of the surface. Any light scar marks should be smoothed prior to rebuilding of
the bearing. The shaft seals should be changed should they show excessive wear or have broken edges.

8
9 Transport and Storage
During transportation of the machine the bearings should never be subject to shock while loading, and must be protected from
environmental humidity. Care must be taken to prevent dry sliding within the bearing. Storage facilities must be dry and not subject to
severe variations in temperature or humidity. In good conditions the bearings can be stored for up to one year without attention or
inspection.

10 Troubleshooting

10.1 Increased Bearing Temperature


Cause : lack of lubrication
Solution : Regularly check the oil level, inspect the bearing surface for scar marks. Check that the filter does not restrict oil flow.

10.2 Excessive scoring of the bearing shell


Cause : Dirt particles in oil
Solution : Change oil (possibly polish out scars on bearing surface). Change oil filter.

11 Ordering Spare Parts


Every bearing has a part and order number embossed onto the manufacturer’s plate. In order to ensure the delivery of the correct
parts please quote these numbers in all correspondence or return the part to Zollern for repair or replacement.
The following parts are supplied as sub-assemblies:

Sub-assembly Position (fig. 1)


Bearing Shell 5.1 to 5.3
Loose oil ring 10
Seal Carrier 15.1
Floating labyrinth seal (machine side) 21.1 & 21.2
Floating labyrinth seal (exterior) 20.1 & 20.2
Bolt on baffle with Teflon bronze strips 25.1
Labyrinth ring N/A
Machine seal with or without Teflon bronze strips (30.1 & 30.2)

Zollern BHW do Brasil


Av. Manoel Inácio Peixoto, 2.147
36770-000 – Cataguases – MG
e-mail:zollern@zollern.com.br
Phone.: 5532-3-429-2002
Fax: 5532-3-429-2003

OLLERN Zollern North America


9364 Wallisville Rd Suite 150
Houston Tx 77013
e-mail:zollernna@aol.com
Phone 1- 713-673-7902
Fax: 1- 713-673-7950