Siemens BA 2030 User Manual
SIMOGEAR gearbox
BA 2030
Operating Instructions · 06/2012
SIMOGEAR
Answers for industry.
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BA 2030
SIMOGEAR
Gearbox
BA 2030
Operating Instructions
General information and
_________________
safety notes
_________________
Technical description
Incoming goods, transport,
_________________
and storage
_________________
Installation
_________________
Commissioning
_________________
Operation
_________________
Faults, causes and remedies
_________________
Service and maintenance
_________________
Disposal
_________________
Technical data
_________________
Spare parts
_________________
Declaration of Incorporation
1
2
3
4
5
6
7
8
9
10
11
12
Original Operating Instructions
06/12
70000004040207
Legal information
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
70000004040207
Ⓟ 07/2012 Technical data subject to change
Copyright © Siemens AG 2012.
All rights reserved
Table of contents
1 General information and safety notes ........................................................................................................ 7
1.1
1.2
1.3
1.4
1.5
2
Technical description............................................................................................................................... 13
2.1
2.2
2.3
2.4
2.5
2.5.1
2.5.2
2.5.3
Incoming goods, transport, and storage................................................................................................... 19
3
3.1
3.2
3.2.1
3.2.2
General information .......................................................................................................................7
Copyright........................................................................................................................................8
Intended use ..................................................................................................................................9
Obligations of the user ...................................................................................................................9
Particular types of hazards ..........................................................................................................11
General technical description.......................................................................................................13
Shaft seals ...................................................................................................................................14
Cooling.........................................................................................................................................14
Rating plate..................................................................................................................................15
Surface treatment ........................................................................................................................15
General information on surface treatment ...................................................................................15
Painted version ............................................................................................................................16
Primed version .............................................................................................................................18
Incoming goods............................................................................................................................19
Transport......................................................................................................................................20
General information on transport .................................................................................................20
Fastening for suspended transport ..............................................................................................21
3.3
3.3.1
3.3.2
3.3.3
3.3.3.1
3.3.3.2
3.3.3.3
Installation ............................................................................................................................................... 25
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
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Operating Instructions, 06/12, 70000004040207
Storage.........................................................................................................................................22
General information for storage ...................................................................................................22
Storage up to 6 months................................................................................................................22
Storage up to 36 months with long-term preservation (optional).................................................23
Notes for storage up to 36 months ..............................................................................................23
Gearbox filled with operating oil and anti-corrosive agent...........................................................23
Gearbox completely filled with oil.................................................................................................23
Unpacking ....................................................................................................................................25
General information on installation ..............................................................................................25
Thread sizes and tightening torques for fastening bolts ..............................................................27
Fastening in the case of high shock loads...................................................................................28
Gearbox with foot mounting.........................................................................................................28
Gearboxes in foot or flange version.............................................................................................29
Mounting an input or output element on the gearbox shaft .........................................................29
3
Table of contents
4.8 Removing and installing the protection cover ............................................................................. 32
4.9 Installing and removing the shaft-mounted gearbox................................................................... 33
4.9.1
4.9.2
4.9.2.1
4.9.2.2
4.9.3
4.9.3.1
4.9.3.2
4.9.3.3
4.9.3.4
4.9.4
4.9.5
4.9.5.1
4.9.5.2
4.9.5.3
Commissioning ........................................................................................................................................ 47
5
General information on installing the shaft-mounted gearbox .................................................... 33
Mounting and removing the hollow shaft with feather key.......................................................... 34
Mounting the hollow shaft with parallel key................................................................................. 34
Removing the hollow shaft with parallel key ............................................................................... 35
Mounting the hollow shaft with shrink disk.................................................................................. 37
Mounting the hollow shaft with shrink disk.................................................................................. 37
Mounting the shrink disk ............................................................................................................. 38
Pulling off the shrink disk ............................................................................................................ 41
Cleaning and lubricating shrink disks.......................................................................................... 41
Mounting the hollow shaft with splines........................................................................................ 42
Torque arms with shaft-mounted gearboxes .............................................................................. 43
General information regarding torque arms................................................................................ 43
Mounting torque arms on parallel shaft gearboxes..................................................................... 44
Mounting torque arms on bevel gearboxes................................................................................. 45
5.1
5.2
5.3
6
Operation................................................................................................................................................. 49
7
Faults, causes and remedies................................................................................................................... 51
8
Service and maintenance ........................................................................................................................ 55
8.1
8.2
8.2.1
8.2.2
8.2.3
8.2.4
8.2.5
8.2.5.1
8.2.5.2
8.2.5.3
8.2.5.4
8.2.6
8.2.7
8.2.8
8.2.9
General information for commissioning ...................................................................................... 47
Checking the oil level prior to commissioning............................................................................. 47
Mounting the oil expansion unit .................................................................................................. 48
General notes about maintenance work ..................................................................................... 55
Checking and changing lubricants .............................................................................................. 57
General safety notes for checking and changing lubricants ....................................................... 57
Checking the oil level .................................................................................................................. 58
Checking the oil level using the oil sight glass (optional)............................................................ 59
Checking the oil quality ............................................................................................................... 59
Changing the oil .......................................................................................................................... 60
General safety notes for changing the oil ................................................................................... 60
Draining the oil ............................................................................................................................ 61
Flushing the gearbox when changing between incompatible oils............................................... 62
Filling in oil................................................................................................................................... 63
Topping up with oil ...................................................................................................................... 64
Changing the roller bearing grease............................................................................................. 64
Service life of the lubricants ........................................................................................................ 65
Recommended lubricants ........................................................................................................... 67
8.3
8.4
8.5
8.6
8.7
8.8
BA 2030
Checking the gearbox for leaks .................................................................................................. 69
Replacing the vent valve............................................................................................................. 69
Checking the oil level sensor (optional) ...................................................................................... 70
Cleaning the gearbox.................................................................................................................. 70
Checking tightness of fastening bolts ......................................................................................... 71
Inspecting the gearbox or geared motor..................................................................................... 71
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Table of contents
9 Disposal................................................................................................................................................... 73
10 Technical data ......................................................................................................................................... 75
10.1
10.2
10.3
10.4
10.5
10.5.1
10.5.2
10.5.3
10.5.4
10.6
10.6.1
10.6.2
10.6.3
Spare parts............................................................................................................................................ 107
11
11.1
11.2
11.3
11.4
11.5
Type designation..........................................................................................................................75
General technical data .................................................................................................................76
Weight..........................................................................................................................................78
Sound energy level ......................................................................................................................78
Mounting positions .......................................................................................................................79
General notes on mounting positions ..........................................................................................79
Two- and three-stage helical gearboxes......................................................................................80
Parallel shaft gearbox ..................................................................................................................87
Bevel gearboxes ..........................................................................................................................93
Oil quantities ..............................................................................................................................102
Helical gearbox ..........................................................................................................................102
Parallel shaft gearbox ................................................................................................................104
Bevel gearboxes ........................................................................................................................105
Stocking of spare parts ..............................................................................................................107
Helical gearboxes D / Z, sizes 19 - 89 .......................................................................................108
Parallel shaft gearboxes F sizes 29 - 89....................................................................................110
Bevel gearbox B sizes 29 - 49 ...................................................................................................113
Bevel gearbox K sizes 39 - 89 ...................................................................................................116
12
Declaration of Incorporation................................................................................................................... 119
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Table of contents
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General information and safety notes
1.1 General information
NOTICE
Siemens does not accept liability for any damage or outages resulting from non-compliance
with these operating instructions.
These operating instructions are an integral part of the gearbox supplied and must be kept in
its vicinity for reference at all times.
These operating instructions apply to the standard version of SIMOGEAR gearboxes:
● Helical gearboxes Z and D, sizes 19 to 89
● Parallel shaft gearboxes FZ and FD, sizes 29 to 89
● Bevel gearboxes B, K, sizes 29 to 89
The precise type designation is described in Section Type designation (Page 75).
1
Table 1- 1 Order number code
SIMOGEAR gearbox
Helical gearbox Z 2 K J 3 1
Helical gearbox D 2 K J 3 2
Parallel shaft gearbox FZ 2 K J 3 3
Parallel shaft gearbox FD 2 K J 3 4
Bevel gearbox B, K 2 K J 3 5
Note
In addition to these operating instructions, special contractual agreements and technical
documentation apply to special gearbox designs and the associated supplementary
equipment.
Please refer to the other operating instructions supplied with the product.
Structure of the order number - Position
1 2 3 4 5
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General information and safety notes
1.2 Copyright
The gearboxes described here correspond to the state of the art at the time these operating
instructions were printed.
In the interest of technical progress we reserve the right to make changes to the individual
assemblies and accessories which we regard as necessary to preserve their essential
characteristics and improve their efficiency and safety.
If you have any technical questions, please contact Technical Support.
Europe - Germany
Phone: +49 (0) 911 895 7222
Fax: +49 (0) 911 895 7223
America - USA
Phone: +1 42 32 62 25 22
Asia - China
Phone: +86 10 64 75 75 75
Email: support.automation@siemens.com
Internet German: http://www.siemens.de/automation/support-request
Internet English: http://www.siemens.com/automation/support-request
Applicable operating instructions
BA 2030 operating instructions for SIMOGEAR gearboxes.
BA 2330 operating instructions for LA / LE motors for mounting on SIMOGEAR gearboxes.
1.2 Copyright
The copyright to these operating instructions is held by Siemens AG.
These operating instructions must not be wholly or partly reproduced for competitive
purposes, used in any unauthorized way or made available to third parties without our
agreement.
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General information and safety notes
1.3 Intended use
1.3 Intended use
The SIMOGEAR gearboxes described in these operating instructions have been designed
for stationary use in general engineering applications.
Unless otherwise agreed, the gearboxes have been designed for use in plants and
equipment in industrial environments.
The gearboxes have been built using state-of-the-art technology and are shipped in an
operationally reliable condition. Changes made by users could affect this operational
reliability and are forbidden.
Note
The performance data assumes an ambient temperature of -20 °C to +40 °C and an
installation altitude of up to 2 000 m above sea level.
In the case of other ambient temperatures and installation altitudes, please contact Technical
Support.
The gearboxes have been designed solely for the application described in Technical data
(Page 75). Do not operate the gearboxes outsi
de the specified power limits. Other operating
conditions must be contractually agreed.
Do not stand or walk on the gearbox or place objects on the gearbox.
1.4 Obligations of the user
The operator must ensure that all persons assigned to work on the gearbox have read and
understood these operating instructions and that they follow them in all points in order to:
● Eliminate the risk to life and limb of users and others
● Ensure the safety and reliability of the gearbox
● Avoid disruptions and environmental damage through incorrect use.
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General information and safety notes
1.4 Obligations of the user
Note the following safety information:
Shut down the geared motors and disconnect the power before you carry out any work on
them.
Make sure that the drive unit cannot be turned on accidentally, e.g. lock the key-operated
switch. Place a warning notice at the drive connection point which clearly indicates that work
is in progress on the geared motor.
Carry out all work with great care and with due regard to safety.
Ensure compliance with the relevant safety and environmental regulations during transport,
mounting and dismantling, operation, and care and maintenance of the unit.
Read the instructions on the rating plates attached to the geared motor. The rating plates
must be kept free from paint and dirt at all times. Replace any missing rating plates.
In the event of changes during operation, immediately switch off the drive unit.
Take appropriate protective measures to prevent accidental contact with rotating drive parts,
such as couplings, gear wheels or belt drives.
Take appropriate measures to prevent accidental contact with parts and equipment that heat
up to over +70 °C during operation.
When removing protective equipment, keep fasteners in a safe place. Re-attach removed
protective equipment before commissioning.
Collect and dispose of used oil in accordance with regulations. Remove oil spillages
immediately with an oil-binding agent in compliance with environmental requirements.
Do not carry out any welding work on the gearbox. Do not use the gearbox as a grounding
point for welding operations.
Carry out equipotential bonding in accordance with applicable regulations and directives.
Such work must be carried out by qualified electrical personnel only.
Do not use high-pressure cleaning equipment or sharp-edged tools to clean the gearbox.
Observe the permissible tightening torque of the fastening bolts.
Replace damaged bolts with new bolts of the same type and strength class.
We will only accept liability for original spare parts supplied by Siemens AG.
If the geared motor is being installed in a plant or equipment, the manufacturers of such
plant or equipment must ensure that the contents of these operating instructions are
incorporated into their own instructions, information, and descriptions.
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General information and safety notes
1.5 Particular types of hazards
1.5 Particular types of hazards
WARNING
Depending on operating conditions, the gearbox may exhibit extreme surface
temperatures.
Hot surfaces over +55 °C pose a burn risk.
Cold surfaces below 0 °C pose a risk of damage due to freezing.
Do not touch the gearbox without protection.
WARNING
Danger of scalding caused by hot oil emerging from the unit.
Before starting any work wait until the oil has cooled down to below +30 °C.
WARNING
Avoid breathing in vapors when working with solvents.
Ensure adequate ventilation.
WARNING
Risk of explosion when working with solvents.
Ensure adequate ventilation. Do not smoke!
WARNING
Risk of eye injury.
Rotating parts can throw off small foreign particles such as sand or dust. Wear protective
eyewear!
In addition to the required personal protective equipment, wear suitable protective gloves
and eyewear when working with the gearbox or the geared motor.
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General information and safety notes
1.5 Particular types of hazards
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Technical description
2.1 General technical description
The gearbox is supplied with two or three transmission stages.
The gearbox is suitable for various mounting positions. Observe the correct oil level.
Housing
The housings for sizes 19 and 29 are made of die-cast aluminum.
Depending on the gearbox type, the housings of sizes 39 and 49 are made of die-cast
aluminum or cast iron.
Table 2- 1 Housing material
Gearbox type
Helical gearbox Aluminum Cast iron
Parallel shaft gearbox Cast iron Cast iron
Bevel gearbox B Aluminum Aluminum
Bevel gearbox K Cast iron Cast iron
Size
39 49
2
From size 59, the gearbox housings are made of cast iron.
Geared components
The geared components are hardened and ground.
The bevel gear stage is lapped in pairs.
Lubrication
The geared components are supplied with adequate lubricant by means of dip lubrication.
Shaft bearings
All shafts are mounted in roller bearings. The roller bearings are lubricated by means of dip
lubrication or oil spray lubrication. Bearings that are not supplied with lubricant are closed
and grease-lubricated.
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Technical description
2.2 Shaft seals
2.2 Shaft seals
The shaft seals on the output side prevent lubricant from escaping from the housing at the
shaft outlet and prevent pollution from entering the housing.
The optimum use of the seals depends on the ambient conditions and the lubricant being
used.
Radial shaft sealing ring
A high-quality radial shaft sealing ring is used as standard seal. It is provided with an
additional dust lip to protect against contaminants from outside.
Seal for a longer service life (optional)
The radial shaft sealing ring with dust lip has an additional buffer axial seal towards the
inside of the gearbox. This has a sinusoidally shaped sealing lip to protect against the
ingress of pollution in the oil in the sealing ring.
Seal to handle increased environmental stress (optional)
This seal is equipped with an additional fiber washer. In addition to a longer service life, it
also provides higher protection against increased environmental stress as a result of
humidity and dust.
2.3 Cooling
NOTICE
Dust deposits prevent heat radiation and cause high housing temperatures.
Keep the gearbox free from dirt, dust, etc.
The gearbox does not normally require additional cooling. The generously dimensioned
housing surface is sufficient for dissipating heat losses where there is free convection. If the
housing temperature exceeds a value of +80 °C, please contact Technical Support.
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Technical description
2.4 Rating plate
2.4 Rating plate
The rating plate on the gearbox or geared motor is of coated aluminum foil. It is covered with
a special masking film which ensures permanent resistance to UV radiation and media of all
kinds, such as oils, greases, salt water and cleaning agents.
The adhesive and the material ensure firm adhesion and long-term legibility within the
operating temperature range from -40 °C to +155 °C.
The edges of the rating plate are paint-finished to match the color of the gearbox or motor to
which it is affixed.
2.5 Surface treatment
2.5.1 General information on surface treatment
All paint finishes are sprayed on.
NOTICE
Any damage to the paint finish will destroy the exterior protection and cause corrosion.
Do not damage the paint finish.
Note
Information about repaintability is not a guarantee of the quality of the paint product
purchased from your supplier.
Only the paint manufacturer is liable for the quality and compatibility.
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Technical description
2.5 Surface treatment
2.5.2 Painted version
The corrosion protection system is classified according to the corrosiveness categories in
DIN EN ISO 12944-2.
Table 2- 2 Paint according to corrosiveness categories
Paint system Description
Corrosiveness category C1, unpainted for gearbox housings made of aluminum
Corrosiveness category C1 for normal environmental stress
1-component hydro paint, top coat
Corrosiveness category C2 for low environmental stress
2-component polyurethane base coat
2-component, polyurethane top coat
Indoor installation
Heated buildings with neutral atmospheres
Resistance to greases and some resistance
to mineral oils, aliphatic solvents
Standard
Indoor installation
Heated buildings with neutral atmospheres
Resistance to greases and some resistance
to mineral oils, aliphatic solvents
Standard paint for gearbox casings made of
cast iron
Indoor and outdoor installation
Unheated buildings with condensation,
production areas with low humidity,
e.g. warehouses and sports facilities
Atmospheres with little contamination, mostly
rural areas
Resistance to greases, mineral oils and
sulfuric acid (10 %), caustic soda (10 %) and
some resistance to aliphatic solvents
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Technical description
2.5 Surface treatment
Paint system Description
Corrosiveness category C3 for medium environmental stress
2-component polyurethane base coat
2-component, polyurethane top coat
Corrosiveness category C4 for high environmental stress
2-component epoxy
zinc phosphate base coat
2-component polyurethane top coat
Corrosiveness category C5 for very high environmental stress
2-component epoxy
zinc phosphate base coat
2-component epoxy iron mica intermediate coat
2-component polyurethane top coat
Indoor and outdoor installation
Production areas with high humidity and some
air contamination, e.g. food production areas,
dairies, breweries and laundries
Urban and industrial atmospheres, moderate
contamination from sulfur dioxide, coastal
areas with low salt levels
Resistance to greases, mineral oils, aliphatic
solvents, sulfuric acid (10 %), caustic
soda (10 %)
Indoor and outdoor installation
Chemical plants, swimming pools, wastewater
treatment plants, electroplating shops, and
boathouses above seawater
Industrial areas and coastal areas with
moderate salt levels
Resistance to greases, mineral oils, aliphatic
solvents, sulfuric acid (10 %), caustic
soda (10 %)
Indoor and outdoor installation
Buildings and areas with almost constant
condensation and high contamination,
e.g. malt factories and aseptic areas
Industrial areas with high humidity and
aggressive atmosphere, coastal areas and
offshore environments with high salt levels
Resistance to greases, mineral oils, aliphatic
solvents, sulfuric acid (10 %), caustic
soda (20 %)
In case of corrosiveness category C1, can be overpainted with 1-component hydrosystem
after prior rubbing down.
In case of corrosiveness categories C2 to C5, can be overpainted with 2-component
polyurethane paint, 2-component epoxide paint and 2-component acrylic paint after prior
rubbing down.
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Technical description
2.5 Surface treatment
2.5.3 Primed version
Table 2- 3 Primer according to corrosiveness category
Paint system Can be overpainted with
Unpainted corrosiveness category C1
Cast iron parts immersion primed, steel parts
primed or zinc-plated, aluminum and plastic parts
untreated
Primed according to corrosiveness category C2 G
2-component metal primer, desired coat
thickness 60 μm
Primed according to corrosiveness category C4 G
2-component epoxy zinc phosphate, desired coat
thickness 120 μm
On gearbox or geared motor versions which are primed or unpainted the rating plate and the
masking film are covered with a paint-protective film. These facilitate repainting without
further preparation, e.g., masking with adhesive tape.
Plastic paint, synthetic resin paint, oil paint,
2-component polyurethane paint,
2-component epoxide paint
2-component polyurethane paint,
2-component epoxide paint and
acid-hardening paint, 2-component acrylic paint
2-component polyurethane paint,
2-component epoxide paint and
acid-hardening paint, 2-component acrylic paint
Peeling off the paint-protective film
The paint coat must have fully hardened before the paint-protective film is peeled off (be at
least "touch-proof").
① Company logo
② Masking film
③ Rating plate
④ Paint-protective film
⑤ Peeling tab
Figure 2-1 Rating plate with paint-protective film
Procedure
1. Pull the peeling tab
2. Carefully peel the paint-protective film
the plate).
⑤ up.
④ off diagonally from one corner (not parallel to
3. Blow any paint fragments away or wipe them off with a clean cloth.
You have now removed the paint-protective film.
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Incoming goods, transport, and storage
3.1 Incoming goods
NOTICE
Make sure that damaged gearboxes or geared motors are not put into operation.
Note
Do not open or damage parts of the packaging that preserve the product.
Note
Check that the technical specifications are in accordance with the purchase order.
Inspect the delivery immediately on arrival for completeness and any transport damage.
Notify the freight company of any damage caused during transport immediately (this is the
only way to have damage rectified free of charge). Siemens AG will not accept any claims
relating to items missing from the delivery and which are submitted at a later date.
3
The gearbox or geared motor is delivered in a fully assembled condition. Additional items
may be delivered packaged separately.
The products supplied are listed in the dispatch papers.
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