Siemens BA 2030 SERIES Operating Instructions Manual
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SIMOGEAR
Gearbox
BA 2030
Operating Instructions
Translation of the original instructions
11/2017
A5E37880173A/RS
General information and
safety notes
1
Technical description
2
Incoming goods, transport,
and storage
3
Installation
4
Commissioning
5
Operation
6
Faults, causes and remedies
7
Service and maintenance
8
Disposal
9
Technical data
10
Spare parts
11
Declaration of incorporation,
declaration of conformity
12
Your suggestions
13
-AE
Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E37880173A/RS-AE
Ⓟ
Copyright © Siemens AG 2013 - 2017.
All rights reserved
Legal information
Warning notice system
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
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
Qualified Personnel
personnel qualified
Proper use of Siemens products
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
Disclaimer of Liability
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.
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.
The product/system described in this documentation may be operated only by
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.
Note the following:
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
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.
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.
for the specific
01/2018 Subject to change
Table of contents
1 General information and safety notes ...................................................................................................... 7
2 Technical description ............................................................................................................................ 13
3 Incoming goods, transport, and storage................................................................................................. 21
4 Installation ............................................................................................................................................ 25
1.1 General information .................................................................................................................. 7
1.2 Copyright ................................................................................................................................... 9
1.3 Intended use ............................................................................................................................. 9
1.4 Geared motor with encoder for safety-relevant applications .................................................. 10
1.5 Obligations of the user ............................................................................................................ 10
1.6 Particular types of hazards ..................................................................................................... 12
2.1 General technical description ................................................................................................. 13
2.2 Shaft seals .............................................................................................................................. 15
2.3 Cooling .................................................................................................................................... 15
2.4 Rating plate ............................................................................................................................. 16
2.5 Surface treatment ................................................................................................................... 16
2.5.1 General information on surface treatment .............................................................................. 16
2.5.2 Painted version ....................................................................................................................... 17
2.5.3 Primed version ........................................................................................................................ 19
3.1 Incoming goods ....................................................................................................................... 21
3.2 Transport ................................................................................................................................. 21
3.2.1 General information on transport ............................................................................................ 21
3.2.2 Fastening for suspended transport ......................................................................................... 22
3.3 Storage ................................................................................................................................... 23
3.3.1 General information for storage .............................................................................................. 23
3.3.2 Storage up to 36 months with long-term preservation (optional) ............................................ 24
3.3.2.1 General notes for storage up to 36 months ............................................................................ 24
3.3.2.2 Gearbox filled with operating oil and anti-corrosive agent ...................................................... 24
3.3.2.3 Gearbox completely filled with oil ........................................................................................... 24
4.1 Unpacking ............................................................................................................................... 25
4.2 General information on installation ......................................................................................... 25
4.3 Thread sizes and tightening torques for fastening bolts ......................................................... 27
4.4 Gearbox with foot mounting .................................................................................................... 28
4.5 Gearbox with flange fastening ................................................................................................ 29
4.6 Gearboxes in foot or flange version ........................................................................................ 30
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Table of contents
5 Commissioning ..................................................................................................................................... 51
6 Operation .............................................................................................................................................. 59
7 Faults, causes and remedies................................................................................................................. 61
8 Service and maintenance ...................................................................................................................... 65
4.7 Mounting an input or output element on the gearbox shaft ................................................... 31
4.8 Removing and installing the protection cover ........................................................................ 33
4.9 Installing and removing the shaft-mounted gearbox .............................................................. 34
4.9.1 General information on installing the shaft-mounted gearbox ............................................... 34
4.9.2 Hollow shaft with parallel key ................................................................................................. 35
4.9.2.1 Mounting the hollow shaft with parallel key ........................................................................... 35
4.9.2.2 Removing the hollow shaft with parallel key .......................................................................... 36
4.9.3 Hollow shaft with shrink disk .................................................................................................. 38
4.9.3.1 Mounting the hollow shaft with shrink disk ............................................................................. 38
4.9.3.2 Mounting the shrink disk ........................................................................................................ 39
4.9.3.3 Pulling off the shrink disk ....................................................................................................... 42
4.9.3.4 Cleaning and lubricating shrink disks..................................................................................... 42
4.9.4 SIMOLOC assembly system .................................................................................................. 43
4.9.4.1 General notes for the SIMOLOC assembly system ............................................................... 43
4.9.4.2 Installing SIMOLOC ............................................................................................................... 44
4.9.4.3 Removing SIMOLOC ............................................................................................................. 46
4.9.5 Hollow shaft with splines ........................................................................................................ 47
4.9.6 Torque arms with shaft-mounted gearboxes ......................................................................... 48
4.9.6.1 General information regarding torque arms ........................................................................... 48
4.9.6.2 Mounting torque arms on parallel shaft gearboxes................................................................ 49
4.9.6.3 Mounting torque arms on bevel gearboxes and helical worm gearboxes ............................. 50
5.1 General information for commissioning ................................................................................. 51
5.2 Checking the oil level prior to commissioning ........................................................................ 51
5.3 Mount the oil expansion unit .................................................................................................. 52
5.4 Installing the oil temperature monitoring device .................................................................... 54
5.5 Options of the VLplus heavy-duty bearing system ................................................................ 55
5.5.1 Automatic regreasing device .................................................................................................. 55
5.5.2 Dry-well version with oil sensor .............................................................................................. 58
8.1 General notes about maintenance work ................................................................................ 65
8.2 Checking and changing lubricants ......................................................................................... 67
8.2.1 General safety notes .............................................................................................................. 67
8.2.2 Checking the oil level ............................................................................................................. 68
8.2.3 Checking the oil level using the oil sight glass (optional) ...................................................... 70
8.2.4 Checking the oil level using the oil dipstick (optional)............................................................ 70
8.2.5 Checking the oil quality .......................................................................................................... 71
8.2.6 Changing the oil ..................................................................................................................... 72
8.2.6.1 General safety notes for changing the oil .............................................................................. 72
8.2.6.2 Draining the oil ....................................................................................................................... 73
8.2.6.3 Flushing the gearbox when changing between incompatible oils .......................................... 73
8.2.6.4 Filling in oil ............................................................................................................................. 75
8.2.7 Topping up with oil ................................................................................................................. 76
8.2.8 Change the roller bearing grease .......................................................................................... 76
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Table of contents
9 Disposal ................................................................................................................................................ 87
10 Technical data ...................................................................................................................................... 89
11 Spare parts ......................................................................................................................................... 141
8.2.9 Service life of the lubricants .................................................................................................... 77
8.2.10 Recommended lubricants ....................................................................................................... 79
8.3 Lubrication of the XLplus and VLplus heavy-duty bearing systems ....................................... 80
8.4 Replace bearings .................................................................................................................... 82
8.5 Checking the gearbox for leaks .............................................................................................. 83
8.6 Replacing the vent valve ......................................................................................................... 84
8.7 Checking the oil level sensor (optional) .................................................................................. 84
8.8 Cleaning the gearbox .............................................................................................................. 84
8.9 Checking tightness of fastening bolts ..................................................................................... 85
8.10 Inspecting the gearbox............................................................................................................ 85
8.11 Replacing the hose of the oil expansion unit .......................................................................... 86
10.1 Type designation ..................................................................................................................... 89
10.2 General technical data ............................................................................................................ 91
10.3 Weight ..................................................................................................................................... 94
10.4 Sound energy level ................................................................................................................. 94
10.5 Mounting positions .................................................................................................................. 95
10.5.1 General notes on mounting positions ..................................................................................... 95
10.5.2 Single-stage helical gearboxes ............................................................................................... 96
10.5.3 Two- and three-stage helical gearbox .................................................................................... 98
10.5.4 Parallel shaft gearbox ........................................................................................................... 105
10.5.5 Bevel gearbox ....................................................................................................................... 111
10.5.6 Helical worm gearbox ........................................................................................................... 120
10.5.7 Tandem gearboxes - Intermediate helical gearboxes .......................................................... 126
10.6 Oil quantities ......................................................................................................................... 128
10.6.1 Helical gearbox ..................................................................................................................... 129
10.6.2 Parallel shaft gearbox ........................................................................................................... 130
10.6.3 Bevel gearbox ....................................................................................................................... 131
10.6.4 Helical worm gearbox ........................................................................................................... 133
10.6.5 Tandem gearbox - intermediate helical gearbox .................................................................. 134
10.6.5.1 Two- and three-stage helical gearboxes............................................................................... 134
10.6.5.2 Parallel shaft gearboxes ....................................................................................................... 135
10.6.5.3 Bevel gearbox ....................................................................................................................... 137
10.6.5.4 Helical worm gearboxes........................................................................................................ 139
11.1 Stocking of spare parts ......................................................................................................... 141
11.2 Lists of spare parts ................................................................................................................ 142
11.2.1 Helical gearbox E, sizes 39 - 149 ......................................................................................... 142
11.2.2 Helical gearbox D / Z, sizes 19 - 189 .................................................................................... 144
11.2.3 Parallel shaft gearbox F, sizes 29 - 189 ............................................................................... 146
11.2.4 Bevel gearbox B, sizes 19 - 49 ............................................................................................. 148
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Table of contents
12 Declaration of incorporation, declaration of conformity .......................................................................... 159
13 Your suggestions ................................................................................................................................. 161
11.2.5 Bevel gearbox K, sizes 39 - 189 .......................................................................................... 150
11.2.6 Helical worm gearbox C, sizes 29 - 89 ................................................................................ 152
11.2.7 SIMOLOC assembly system, sizes 29 - 89 ......................................................................... 154
11.2.8 XLplus and VLplus heavy-duty bearing systems, sizes 89-169 .......................................... 156
12.1 Declaration of incorporation ................................................................................................. 159
12.2 EU declaration of conformity ................................................................................................ 160
BA 2030
6 Operating Instructions, 11/2017, A5E37880173A/RS-AE
1
1.1
General information
ATEX version gearboxes
Instructions and measures applying in particular to ATEX version gearboxes.
Note
Siemens
observance of these operating instructions.
SIMOGEAR gearbox
Article number position
1 2 3 4 5
Helical gearbox E
2 K J 3 0
Helical gearbox D
2 K J 3 2
Helical gearbox Z
2 K J 3 1
Parallel shaft gearbox FD
2 K J 3 4
Parallel shaft gearbox FZ
2 K J 3 3
Bevel gearbox B, K
2 K J 3 5
Helical worm gearbox C
2 K J 3 6
AG does not accept any liability for damage and failures that result from the non-
These operating instructions are part of the gearbox delivery. Store the operating instructions
near the gearbox. Please read the operating instructions prior to handling the gearbox and
observe the information they contain. This is how you ensure safe and disturbance-free
function.
These operating instructions apply to the standard version of SIMOGEAR gearboxes:
● Helical gearboxes E, D and Z, sizes 19 to 189
● Parallel shaft gearboxes FD / FZ, sizes 29 to 189
● Bevel gearboxes B, K, sizes 19 to 189
● Helical worm gearboxes C, sizes 29 to 89
For the description of the precise designation see Type designation (Page 89).
Table 1- 1 Article number code
BA 2030
Operating Instructions, 11/2017, A5E37880173A/RS-AE
7
General information and safety notes
Note
In addition to these operating instructions, special contractual agreement
documentation apply to a special gearbox design and the associated supplementary
equipment.
Please refer to the other operating instructions supplied with the product.
Valid operating instructions for SIMOGEAR
1.1 General information
s and technical
The described gearboxes correspond to the state-of-the-art at the time these operating
instructions were printed.
Siemens AG reserves the right to change individual components and accessory parts in the
interest of further development. The changes serve to improve the performance and safety.
The significant features are retained. The operating instructions are always being updated
with new contents.
The latest versions of the operating instructions, the declaration of incorporation and the
declarations of conformity are available in electronic form in the Industry Online Support
(https://support.industry.siemens.com/cs/ww/de/ps/13424/man
).
You can find technical configuration data, spare parts lists and certificates of compliance on
the Intranet at Once Delivered (https://c0p.siemens.com:8443/sie/1nce_delivered
).
You can find the contact data of your Technical Support in the Database of contacts at
Siemens AG (www.siemens.com/yourcontact
).
If you have any technical questions, please contact Technical Support
(https://support.industry.siemens.com/cs/ww/en/sc/2090
).
Europe and Africa
Telephone: +49 (0) 911 895 7222
support.automation@siemens.com
America
Telephone: +1 800 333 7421
support.america.automation@siemens.com
Asia / Australia / Pacific
Telephone: +86 400 810 4288
support.asia.automation@siemens.com
● BA 2030 - operating instructions for SIMOGEAR gearboxes
● BA 2031 - operating instructions for permissible mounting position deviations of
SIMOGEAR gearboxes
● KA 2032 - compact operating instructions for SIMOGEAR worm geared motor S
● BA 2039 - operating instructions for adapters for mounting on SIMOGEAR gearboxes
● BA 2330 - operating instructions for LA/LE/LES motors for mounting on SIMOGEAR
gearboxes
● BA 2535 - operating instructions for SIMOGEAR gearboxes for monorail conveyors
● BA 2730 - operating instructions for SIMOGEAR geared motors with encoder for safety-
relevant applications
BA 2030
8 Operating Instructions, 11/2017, A5E37880173A/RS-AE
General information and safety notes
1.2
Copyright
1.3
Intended use
ATEX version gearboxes
The ATEX gearbox fulfills the requirements of the
Directive 2014/34/EU.
In the case of ATEX version gearboxes, please observe the instructions marked
with this symbol.
Note
The performance data assumes an installation altitude of up to 2000
the following ambient temperatures:
•
•
For different installation altitudes and ambient temperatures, please contact Technical
Support.
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
agreement of Siemens AG.
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 based on 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.
-15° C to +40° C for gearbox types E, Z, D, F, K
-25° C to +40° C for gearbox types B, C
Explosion Protection
m above sea level and
The gearboxes have been designed solely for the application described in the Technical data
(Page 89). Do not operate the gearbox outside the specified power limit. Other operating
conditions must be contractually agreed.
Do not climb on the gearbox. Do not place any objects on the gearbox.
BA 2030
Operating Instructions, 11/2017, A5E37880173A/RS-AE
9
General information and safety notes
1.4
Geared motor with encoder for safety-relevant applications
1.5
Obligations of the user
Note the following safety information:
1.4 Geared motor with encoder for safety-relevant applications
For a SIMOGEAR geared motor with encoder for safety-relevant applications, it is crucial
that you observe the operating instructions BA 2730. These operating instructions are valid
for the functionally safe encoders that are mounted onto SIMOGEAR geared motors. The
functionally safe encoders are in compliance with the relevant standards for safety-relevant
applications listed in the declaration of conformity of BA 2730.
The SIMOGEAR geared motor with functionally safe encoder has a signal yellow marking on
the fan cover. Marking SI04 for the functionally safe encoder is stamped on the rating plate.
The safety level is marked on the functionally safe encoder.
Figure 1-1 Marking for functional safety
The operator must ensure that all persons assigned to work on the geared motor 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 other persons.
● Ensure the operational safety of the geared motor.
● Avoid disruptions and environmental damage through incorrect use.
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".
For all work, observe the relevant regulations for work safety and environment protection.
BA 2030
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General information and safety notes
1.5 Obligations of the user
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, switch off the drive unit immediately.
Take appropriate protective measures to prevent accidental contact with rotating drive parts,
such as couplings, gear wheels or belt drives.
Take appropriate protective 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 geared motor. Do not use the geared motor as a
grounding point for welding operations.
Carry out equipotential bonding in accordance with applicable regulations and directives by
electrotechnology specialists.
Do not use high-pressure cleaning equipment or sharp-edged tools to clean the geared
motor.
Observe the permissible tightening torque of the fastening bolts.
Replace damaged bolts with new bolts of the same type and strength class.
Siemens AG accepts the warranty only for original spare parts.
The manufacturer who installs the geared motors in a plant must include the regulations
contained in the operating instructions in its own operating instructions.
BA 2030
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11
General information and safety notes
1.6
Particular types of hazards
WARNING
Extreme surface temperatures
WARNING
Hot, escaping oil
WARNING
Poisonous vapors when working with solvents
WARNING
Risk of explosion when working with solvents
WARNING
Risk of eye injury
1.6 Particular types of hazards
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.
Before starting any work wait until the oil has cooled down to below +30 °C.
Avoid breathing in vapors when working with solvents.
Ensure adequate ventilation.
Ensure adequate ventilation.
Do not smoke!
Rotating parts can throw off small foreign particles such as sand or dust.
Wear protective eyewear!
In addition to the prescribed personal protection gear, also wear suitable protective gloves
and safety glasses.
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2
2.1
General technical description
Gearbox housing
Gearbox type
Size
39
49
Helical gearbox E
Cast iron
Cast iron
Parallel shaft gearbox
Cast iron
Cast iron
Bevel gearbox K
Cast iron
Cast iron
Helical worm gearbox C
Cast iron
Cast iron
Geared components
Lubrication
Shaft bearings
The gearbox is supplied with one, two or three transmission stages.
The gearbox is suitable for various mounting positions. Observe the correct oil level.
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
Helical gearbox D/Z Aluminum Cast iron
Bevel gearbox B Aluminum Aluminum
From size 59, the gearbox housings are made of cast iron.
The geared components are hardened and ground.
For the helical worm gearbox, the worm is hardened and ground. The gear is manufactured
from high-quality bronze.
The bevel gear stage of the bevel gearbox is lapped in pairs.
The geared components are supplied with adequate lubricant by means of dip lubrication.
All shafts are mounted in roller bearings. The roller bearings are lubricated using splash
lubrication or oil-spray lubrication. Bearings that are not supplied with lubricant are closed
and grease-lubricated.
BA 2030
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Technical description
XLplus and VLplus heavy-duty bearing systems
①
Grease nipple
②
Automatic regreasing device (optional)
③
Screw plug
④
Dry-well oil sight glass (optional)
⑤
Dry-well oil sensor (optional)
2.1 General technical description
Figure 2-1 XLplus and VLplus heavy-duty bearing systems
The multi-stage helical gearbox sizes 89-169 can be supplied with an XLplus or VLplus
heavy-duty bearing system.
The parallel-shaft gearbox and the helical gearbox sizes 89-169 can be supplied with a
VLplus heavy-duty bearing system.
With an upstream locating bearing, the bearing system is suitable for high external forces.
The absorbed radial and axial loads are transmitted to the machine via the flange.
The bearings are lubricated independently of the frame size. Initial greasing has already
been carried out. The relubrication is made with the provided grease nipple.
Options for the VLplus heavy-duty bearing system:
An automatic regreasing device
device
A dry-well version with oil sight glass
well version offers increased protection against oil leaks when the output shaft points down.
The flange captures any escaping gear oil for leakages at the oil chamber. The escaping oil
is signaled optically with an oil sight glass
sensor
disconnector approved for ATEX.
② can be installed at any position and can be used underwater.
⑤ is deployed in ATEX version gearboxes, the sensor must be operated with a
② can be supplied as option. The automatic regreasing
④ or oil sensor ⑤ can be supplied as option. The dry-
④ or electronically by an oil sensor ⑤. If the oil
BA 2030
14 Operating Instructions, 11/2017, A5E37880173A/RS-AE
Technical description
2.2
Shaft seals
Radial shaft sealing ring
Sealing ring for a longer service life (optional)
Sealing ring to handle increased environmental stress (optional)
2.3
Cooling
NOTICE
Dust deposits prevent heat radiation
2.2 Shaft seals
The shaft sealing rings 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.
A high-quality radial shaft sealing ring is used as standard seal. The ring is provided with an
additional dust lip to protect against contaminants from outside.
The radial shaft sealing ring with dust lip has an additional buffer axial seal towards the
inside of the gearbox. The buffer axial seal has a sinusoidal sealing lip that protects the
sealing ring from contaminations.
The sealing ring is equipped with an additional fiber disk. In addition to the longer service life,
the disk also provides increased protection against higher environmental stress as a result of
moisture and dust.
Dust deposits prevent heat radiation and cause a high housing temperature.
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.
BA 2030
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15
Technical description
2.4
Rating plate
2.5
Surface treatment
2.5.1
General information on surface treatment
ATEX version gearboxes
The gearbox is delivered complete with primer and paint finish.
If the gearbox is delivered with primer only or unpainted, a paint finish must be
applied which meets the applicabl
primer does not provide adequate corrosion protection.
ATEX version gearboxes
When applying conductive paint, the operator must ensure that the paint rem
in a perfect state.
The paint finish must be checked at intervals of approximately 2 - 3 years.
ATEX version gearboxes
An excessively high electrostatic charge must be avoided.
Ensure that highly
charge are avoided.
Highly active mechanisms that can generate charges:
•
•
•
2.4 Rating plate
The rating plate on the gearbox or geared motor is of coated aluminum foil. The rating plate
is glued using a special masking film. The film 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.
All paint finishes are sprayed on.
e guidelines for the specific application. The
Fast air with high dust content directed past the gearbox
Sudden escape of compressed gases that contain particles
Harsh abrasive processes (this does not mean manual cleaning / wiping with
cleaning cloths)
active mechanisms that cause the paint finish to generate a
ains
BA 2030
16 Operating Instructions, 11/2017, A5E37880173A/RS-AE
Technical description
NOTICE
Failure of the external protection
Note
Information ab
product supplied by your supplier.
Only the paint manufacturer is liable for the quality and compatibility.
2.5.2
Painted version
Paint system
Description
Corrosiveness category C1, unpainted for gearbox and motor housings made of aluminum
Corrosiveness category C1 for normal environmental stress
2.5 Surface treatment
If the paint finish is damaged, the geared motor may corrode.
Do not damage the paint finish.
out the ability to be repainted does not guarantee the quality of the paint
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
-
1-component hydro paint, 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 housings made of cast
iron
BA 2030
Operating Instructions, 11/2017, A5E37880173A/RS-AE
17
Technical description
Paint system
Description
Corrosiveness category C2 for low environmental stress
Corrosiveness category C3 for medium environmental stress
Corrosiveness category C4 for high environmental stress
2.5 Surface treatment
2-component - polyurethane top coat
2-component epoxy zinc phosphate base
coat,
2-component polyurethane top coat
2-component epoxy zinc phosphate base
coat,
2-component polyurethane top coat
• 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
• 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 %)
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18 Operating Instructions, 11/2017, A5E37880173A/RS-AE
Technical description
Paint system
Description
Corrosiveness category C5 for very high environmental stress
2.5.3
Primed version
Paint system
Can be overpainted with
Unpainted corrosiveness category C1
Primed according to corrosiveness category C2 G
Primed according to corrosiveness category C4 G
2.5 Surface treatment
2-component epoxy zinc phosphate base
coat,
2-component polyurethane intermediate
coat,
2-component polyurethane top coat
• 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, overpainting with a 1-component hydrosystem after
prior rubbing down is possible.
In case of corrosiveness categories C2 to C5, overpainting with 2-component polyurethane
paint, 2-component epoxide paint and 2-component acrylic paint after prior rubbing down is
possible.
Table 2- 3 Primer according to corrosiveness category
Cast iron parts immersion primed,
steel parts primed or zinc-plated,
aluminum and plastic parts untreated
2-component epoxy zinc phosphate,
nominal layer thickness 60 µm
2-component epoxide zinc phosphate,
desired coat thickness 120 μm
• Synthetic paint, synthetic resin paint, oil paint
• 2-component polyurethane paint
• 2-component epoxy paint
• 2-component polyurethane paint
• 2-component epoxy paint
• 2-component acrylic paint
• Acid-hardening paint
• 2-component polyurethane paint
• 2-component epoxy paint
• 2-component acrylic paint
• Acid-hardening paint
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Technical description
2.5 Surface treatment
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20 Operating Instructions, 11/2017, A5E37880173A/RS-AE
3
3.1
Incoming goods
NOTICE
Transport damage impairs correct functioning
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 immed
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 item
3.2
Transport
3.2.1
General information on transport
NOTICE
The use of force will damage the gearbox or geared motor
Do not commission faulty gearboxes or geared motors.
iately on arrival for completeness and any transport damage.
s missing from the delivery and which are submitted at a later date.
The gearbox or geared motor is delivered in a fully assembled condition. Additional items are
sometimes delivered packaged separately.
The products supplied are listed in the dispatch papers.
Transport the gearbox or geared motor carefully. Avoid knocks.
Before putting the drive into operation, remove any transport fixtures and keep them safe or
render them ineffective. You can then use them again for transporting further items or you
can apply them again.
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Operating Instructions, 11/2017, A5E37880173A/RS-AE
21
Incoming goods, transport, and storage
This way up
Center of gravity
Fragile
Do not use hand hook
Keep dry
Attach here
Keep cool
3.2.2
Fastening for suspended transport
WARNING
Inadequately secured gearbox or geared motors can free themselves
3.2 Transport
Different forms of packaging may be used, depending on the size of the gearbox or geared
motor and the method of transport. Unless contractually agreed otherwise, the seaworthy
packaging complies with HPE Packaging Guidelines (Bundesverband Holzpackmittel
Paletten Exportverpackungen e.V., the German Federal Association for wooden packaging,
pallets, and export packaging).
Note the symbols which appear on the packaging. These have the following meanings:
Use only the transport eye or eyebolt of the gearbox to transport the gearbox or geared
motor. Because they are designed only for the weight of the gearbox or geared motor, it is
not permissible to add additional loads.
Do not rig eyebolts to the front threads at the shaft ends for transportation purposes.
Do not use the integrally cast lifting eyes on the motor for transport because of the risk of
breaking.
If necessary, use additional, suitable lifting accessories for transport or during installation.
When attaching by a number of chains and ropes just two strands must be sufficient to bear
BA 2030
the entire load. Secure lifting accessories against slipping.
22 Operating Instructions, 11/2017, A5E37880173A/RS-AE
Incoming goods, transport, and storage
Thread size
m
d3
Thread size
m
d3
[kg]
[mm]
[kg]
[mm]
M8
140
36
M20
1 200
72
M10
230
45
M24
1 800
90
M16
700
63 - -
-
3.3
Storage
3.3.1
General information for storage
WARNING
Danger of serious injuries caused by falling objects
Danger of damage to the gearbox when stacked
NOTICE
Failure of the external protection
3.3 Storage
Table 3- 1 Maximum load of the eyebolt on the gearbox
M12 340 54 M30 3 200 108
The eyebolt corresponds to DIN 580.
Do not stack gearboxes or geared motors on each other.
Mechanical damage, chemical damage and thermal damage, such as scratches, acids,
alkalis, sparks, welding beads and heat cause corrosion.
Do not damage the paint finish.
Unless contractually agreed otherwise, the guarantee period for the standard preservative
lasts 6 months from the date of delivery.
In the case of storage in transit over 6 months, special arrangements must be made for
preservation. Please contact Technical Support.
Store the gearbox or geared motor in dry, dust-free rooms that are maintained at a constant
temperature.
The storage location must be vibration- and shock-free.
The free shaft ends, sealing elements and flange surfaces must have a protective coating.
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Operating Instructions, 11/2017, A5E37880173A/RS-AE
23
Incoming goods, transport, and storage
3.3.2
Storage up to 36 months with long-term preservation (optional)
3.3.2.1
General notes for storage up to 36 months
3.3.2.2
Gearbox filled with operating oil and anti-corrosive agent
NOTICE
Damage to the gearbox caused by incorrect oil quantities
3.3.2.3
Gearbox completely filled with oil
NOTICE
Damage to the gearbox caused by incorrect oil quantities
3.3 Storage
Store the gearbox or geared motor in dry, dust-free rooms that are maintained at a constant
temperature. Special packing is then not necessary.
If such premises are not available, pack the gearbox or the geared motor in plastic film or airtight sealed film and materials. The films and materials must be able to accept moisture.
Cover them to provide protection against heat, direct sunlight and rain.
The permissible ambient temperature is -25 °C to +50 °C.
The life of the corrosion protection is 36 months from delivery.
Check the oil level before commissioning.
Observe the information and procedures for Checking the oil level (Page 67).
The gearbox is filled with oil corresponding to the mounting position so that it is ready for
operation, and is sealed airtight using a screw plug or with a pressure breather valve with
transport fixture.
For storage up to 36 months, a VCI anti-corrosion agent (Volatile Corrosion Inhibitor) is
added.
Prior to commissioning, remove excessive oil until it has the correct oil level.
Observe the information and procedures for Correcting the oil level (Page 67).
When biodegradable oils or oils for the food-processing sector are used, the gearbox is filled
completely with operating oil. The gearbox is closed air-tight with a sealing plug or a
pressure venting with transport fixture.
Do not lower the oil level during short-time commissioning for 10 minutes in no-load
operation.
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24 Operating Instructions, 11/2017, A5E37880173A/RS-AE
4
4.1
Unpacking
NOTICE
Transport damage impairs the correct function of the gearbox
4.2
General information on installation
ATEX version gearboxes
Effect on bearings of stray electric currents from electrical equipment.
When mounting the gearbox on or connecting it to the machine, take care to
ensure potential equalization. The information on grounding and equipotential
bonding provided by the motor supplier must be observed.
WARNING
Operating under load
NOTICE
Destruction caused by welding
Never commission faulty gearboxes.
Check the gearbox for completeness and for damage. Report any missing parts or damage
immediately.
Remove and dispose of the packaging material and transport equipment in compliance with
regulations.
Under load, the system can start or reverse in an uncontrolled fashion.
The entire system must be load-free so that there is no danger during this work.
Welding destroys the geared parts and bearings.
Do not weld on the gearbox. The gearbox must not be used as a grounding point for
welding operations.
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25
Installation
NOTICE
Overheating caused by solar radiation
NOTICE
Malfunction resulting from foreign objects
NOTICE
Damaged components impair the correct function of the gearbox
NOTICE
Violation of the maximum permissible oil sump temperature
4.2 General information on installation
Overheating of the gearbox due to exposure to direct sunlight.
Provide suitable protective equipment such as covers or roofs. Prevent heat accumulation.
The operator must ensure that no foreign objects impair the function of the gearbox.
If any components are damaged, the correct function of the gearbox will no longer be
ensured.
Do not install any damaged gearbox components.
The oil sump temperature may be exceeded if the temperature monitoring equipment is
incorrectly set.
An alarm must be output when the maximum permissible oil sump temperature is reached.
The geared motor must be switched off when the maximum permissible temperature is
exceeded. If the geared motor is shut down, then this can cause the machine to come to a
stop.
Exercise particular care during mounting and installation. The manufacturer cannot be held
liable for damage caused by incorrect mounting and installation.
Make sure that there is sufficient space around the gearbox or geared motor for mounting,
maintenance and repair.
On geared motors with a fan, leave sufficient free space for the entry of air. Observe the
installation conditions for the geared motor.
Provide sufficient lifting gear at the start of mounting and fitting work.
Observe the mounting position specified on the rating plate. This ensures that the correct
quantity of lubricant is provided.
Use all the fastening means that have been assigned to the particular mounting position and
mounting type.
Cap bolts cannot be used in some cases due to a lack of space. In such cases, please
contact Technical Support quoting the type of gearbox.
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26 Operating Instructions, 11/2017, A5E37880173A/RS-AE
Installation
4.3
Thread sizes and tightening torques for fastening bolts
Thread size
Tightening torque for strength class
8.8
10.9
12.9
[Nm]
[Nm]
[Nm]
M4 3 4
5
M5 6 9
10
M6
10
15
18
M10
50
70
85
M16
210
295
355
M20
450
580
690
M24
750
1 000
1 200
M30
1 500
2 000
2 400
M36
2 500
3 600
4 200
4.3 Thread sizes and tightening torques for fastening bolts
The general tolerance for the tightening torque is 10 %. The tightening torque is based on a
friction coefficient of μ = 0.14.
Table 4- 1 Tightening torques for fastening bolts
M8 25 35 41
M12 90 120 145
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Operating Instructions, 11/2017, A5E37880173A/RS-AE
27
Installation
4.4
Gearbox with foot mounting
NOTICE
Impermissible housing loadings when unevenness present
Helical gearbox
Parallel shaft
gearbox F
Bevel gearbox
B, K
Helical worm
gearbox C
Thread size
E
D/Z
Size
M8 - 19, 29, 39
29, 39
B19, B29, B39
29
M10
39 - 49
B49, K39, K49
39, 49
M12
49
49, 59, 69
69, 79
K69, K79
69
M16
69, 89
79, 89
89, 109
K89
89
M20
109, 129
109
129
K109
-
M24
-
129
149
K129
-
M30
149
149
169
K149
-
M36
-
169, 189
189
K169, K189
-
4.4 Gearbox with foot mounting
Do not subject the gearbox to excessive stress when tightening the fastening bolts.
The foundation must be level and free from dirt.
The deviation in flatness of the gearbox's contact surface may not exceed the following
values:
For gearboxes up to size 89: 0.1 mm
For gearboxes from size 109: 0.2 mm.
The foundation should be designed in such a way that no resonance vibrations are created
and no vibrations are transmitted from adjacent foundations.
The foundation structure on which the gearbox is to be mounted must be torsionally rigid. It
must be dimensioned according to the weight and torque, taking into account the forces
acting on the gearbox. If the substructure is too weak, it will cause radial or axial
displacement offset during operation that cannot be measured at a standstill.
If the gearbox is fastened to a concrete foundation, use foundation blocks for the appropriate
recesses.
Align and grout the slide rails into the foundation.
Align the gearbox carefully with the units on the input and output side. Take into account the
elastic deformation due to operating forces.
Prevent displacement from external forces due to lateral impacts.
Use stud bolts or headless screws of strength class 8.8 or higher for the mounting foot.
Observe the tightening torque.
Table 4- 2 Thread size of the fastening bolt
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28 Operating Instructions, 11/2017, A5E37880173A/RS-AE
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