Siemens SIMOGEAR BA 2039 User manual

BA 2039
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SIMOGEAR
Adapter for gearbox
BA 2039
Operating Instructions
Supplement to the SIMOGEAR gearbox operating
instructions BA 2030
Translation of the original instructions
04/2016
A5E37431501A/RS
-AC
General information and
safety notes
1
Technical description
2
Installing
3
Operation
4
Service and maintenance
5
Spare parts
6

Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E37431501A/RS-AC
Ⓟ
04/2016 Subject to change
Copyright © Siemens AG 2013 - 2016.
All rights reserved
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
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.
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
maint
enance 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.

BA 2039
Operating Instructions, 04/2016, A5E37431501A/RS-AC 5
Table of contents
1 General information and safety notes ...................................................................................................... 7
1.1 General Information ..................................................................................................................7
1.2 Copyright...................................................................................................................................9
1.3 Intended use .............................................................................................................................9
1.4 Obligations of the user ............................................................................................................10
1.5 Particular types of hazards .....................................................................................................11
2 Technical description ............................................................................................................................ 13
2.1 Permissible input torque .........................................................................................................13
2.2 Flexible coupling .....................................................................................................................13
2.3 Backstop K2X, K3X.................................................................................................................14
3 Installing ............................................................................................................................................... 15
3.1 Unpacking ...............................................................................................................................15
3.2 General information on installation .........................................................................................15
3.3 Thread sizes and tightening torques for fastening bolts.........................................................17
3.4 Mounting an input or output element on the gearbox shaft ....................................................17
3.5 Mounting the motor .................................................................................................................19
3.5.1 Fit the standard motor to the K2 or K3 adapter ......................................................................20
3.5.2 Mount the standard motor to the K4 or K5 short adapter .......................................................22
3.5.3 Mount the servomotor with parallel key to the KQ or K8 adapter...........................................24
3.5.4 Mount servomotor without parallel key to the KQS adapter ...................................................26
4 Operation.............................................................................................................................................. 29
5 Service and maintenance...................................................................................................................... 31
5.1 General notes about maintenance..........................................................................................31
5.2 Maintenance of the friction clutch ...........................................................................................31
6 Spare parts ........................................................................................................................................... 33
6.1 Stocking of spare parts ...........................................................................................................33
6.2 Lists of spare parts..................................................................................................................34
6.2.1 K2 and K3 adapters with elastic coupling...............................................................................34
6.2.2 K4 and K5 short adapters with plug-in connection .................................................................36
6.2.3 KQ, K8 and KQS adapters for mounting a servomotor ..........................................................37

Table of contents
BA 2039
6Operating Instructions, 04/2016, A5E37431501A/RS-AC

BA 2039
Operating Instructions, 04/2016, A5E37431501A/RS-AC 7
General information and safety notes
1
1.1
General Information
ATEX version gearboxes
Instructions and measures applying in particular to ATEX version gearboxes.
Note
Siemens
AG does not accept any liability for damage and failures that result from the non-
observance of these operating instructions.
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 the best way of ensuring safe and trouble-free
operation.
The operating instructions supplement the SIMOGEAR gearbox operating instructions
BA 2030.
These operating instructions apply to the adapters of the standard SIMOGEAR gearbox
version:
●Adapter K2 - coupling adapter with flexible coupling for fitting an IEC motor
●Adapter K3 - coupling adapter with flexible coupling for fitting a NEMA motor
●Adapter K4 - short adapter with plug-in connection for fitting an IEC motor
●Adapter K5 - short adapter with plug-in connection for fitting a NEMA motor
●Adapter KQ, KQS - coupling adapter for fitting a servomotor of the
SIMOTICS S-1FK7/-1FT7 series
●Adapter K8 - coupling adapter for fitting a servomotor of the
SIMOTICS M-1PH8 series
Table 1- 1 Article number code
SIMOGEAR adapter
Article number position
Adapter K2 for fitting an IEC motor 2
Adapter K3 for fitting a NEMA motor
3
Short adapter K4 for fitting an IEC motor
4
Short adapter K5 for fitting a NEMA motor
5
Adapter KQ, KQS for fitting a servomotor
7
Adapter K8 for fitting a servomotor
8

General information and safety notes
1.1 General Information
BA 2039
8Operating Instructions, 04/2016, A5E37431501A/RS-AC
Note
In addition to these operating instructions, special contractual agreements and technical
documentation apply to a special gearbox design and the associated supplementary
equipment.
Please refer to the other operating instructions supplied with the product
.
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 are designed to improve performance and
safety. The significant features are retained. The operating instructions are updated regularly
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 in
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: [phone]
[e-mail]
America
Telephone: [phone]
[e-mail]
Asia / Australia / Pacific
Telephone: [phone]
[e-mail]
Valid operating instructions for SIMOGEAR
●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 2039 - operating instructions for motors for mounting on SIMOGEAR gearboxes
●BA 2535 operating instructions of SIMOGEAR gearboxes for overhead conveyor drive
●BA 2730 - operating instructions for SIMOGEAR geared motors with encoder for safety-
relevant applications

General information and safety notes
1.2 Copyright
BA 2039
Operating Instructions, 04/2016, A5E37431501A/RS-AC 9
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.
1.3
Intended use
ATEX version gearboxes
The ATEX gearbox fulfills the requirements of the Explosion Protection
Directive 2014/34/EU.
In the case of ATEX version gearboxes, please observe the instructions marked
with this symbol.
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 5,000 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 in
the BA 2030 Operating Instructions for SIMOGEAR gearboxes. Do not operate the
gearboxes outside the specified power limits. Other operating conditions must be
contractually agreed.
Do not climb on the gearbox. Do not place any objects on the gearbox.

General information and safety notes
1.4 Obligations of the user
BA 2039
10 Operating Instructions, 04/2016, A5E37431501A/RS-AC
1.4
Obligations of the user
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.
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".
For all work, observe the relevant regulations for work safety and environment protection.
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.

General information and safety notes
1.5 Particular types of hazards
BA 2039
Operating Instructions, 04/2016, A5E37431501A/RS-AC 11
1.5
Particular types of hazards
WARNING
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
Hot, escaping oil
Before starting any work wait until the oil has cooled down to below +30 °C.
WARNING
Poisonous vapors when working with solvents
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 prescribed personal protection gear, also wear suitable protective gloves
and safety glasses.

General information and safety notes
1.5 Particular types of hazards
BA 2039
12 Operating Instructions, 04/2016, A5E37431501A/RS-AC

BA 2039
Operating Instructions, 04/2016, A5E37431501A/RS-AC 13
Technical description
2
2.1
Permissible input torque
Do not exceed the input torque in continuous operation. It is permissible for the input torque
to increase to 2.5 times the value for brief periods.
Table 2- 1 Permissible input torque
Adapter /
[Nm]
Frame size
K2
80
90
100
112
132
160
180
200
225
250
280
315
[Nm]
10
13
33
33
95
121
160
215
325
400
650
1450
K3
56
140
180
210
250
280
320
360
-
-
-
-
[Nm]
-
13
33
95
121
160
215
325
-
-
-
-
K4
63
71
80
90
100
112
132
160
180
200
225
250
[Nm]
3.2
3.2
10
13
33
33
95
121
160
215
325
400
K5
56
140
180
210
250
280
320
360
-
-
-
-
[Nm]
3.2
13
33
95
121
160
215
325
-
-
-
-
KQ
703
704
706
708
710
-
-
-
-
-
-
-
[Nm]
3.2
13
13
33
121
-
-
-
-
-
-
-
K8
808
810
813
816
818
822
-
-
-
-
-
-
[Nm]
33
121
160
265
650
1450
-
-
-
-
-
-
2.2
Flexible coupling
Generally use a flexible coupling for the gearbox input and output.
If a rigid coupling or other input or output elements are to be used that give rise to additional
radial and / or axial forces (e.g. gear wheels, belt pulleys), this must be contractually agreed.
Refer to the relevant operating instructions for details of how to use the coupling.

Technical description
2.3 Backstop K2X, K3X
BA 2039
14 Operating Instructions, 04/2016, A5E37431501A/RS-AC
2.3
Backstop K2X, K3X
ATEX version gearboxes
The drive speed in the table "Drive speed when using backstops" must be
maintained in continuous operation.
Starting and stopping operations ≤20 starts / stops per hour are permissible.
NOTICE
Service life limited
Drive speeds below 1,000 rpm or frequent starting and stopping operations
(≥20 starts / stops per hour) will limit service life.
Ensure that the backstop is replaced in time when frequent starting and stopping operations
are performed.
NOTICE
Damage or destruction due to incorrect direction of rotation
Do not run the motor against the backstop.
Note the directional arrow on the motor.
The gearbox can be fitted with a mechanical backstop in the coupling adapter. The backstop
permits only the correct direction of rotation during operation. The adapter is indicated by an
arrow pointing in the corresponding direction.
The backstop is fitted with centrifugally operated sprags. When the gearbox is running in the
specified direction, the inner ring and the cage with the sprags also rotate while the outer
ring remains stationary.
If the drive speed exceeds the speed listed in the table, the sprag rises. The backstop is
wear-free.
Table 2- 2 Minimum drive speed when using backstops
Frame size
Backstop
Speed
K2X - IEC
K3X - NEMA
[rpm]
80
56
FXN46-25DX
> 890
90
140
> 860
100, 112
180
FXN51-25DX
> 860
132
210
FXN76-25DX
> 750
160
250
> 730
180
280
> 670
200
-
FXN101-25/DX
> 670
225, 250
320, 360
> 630

BA 2039
Operating Instructions, 04/2016, A5E37431501A/RS-AC 15
Installing
3
3.1
Unpacking
NOTICE
Transport damage impairs the correct function of the geared motor
Never commission faulty or defective motors.
Check the motor for completeness and damage. Report any missing parts or damage
immediately.
Remove and dispose of the packaging material and transport equipment in compliance with
regulations.
3.2
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
e
nsure potential equalization. The information on grounding and equipotential
bonding provided by the motor supplier must be observed.
WARNING
Operating under load
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.
NOTICE
Destruction caused by welding
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.

Installing
3.2 General information on installation
BA 2039
16 Operating Instructions, 04/2016, A5E37431501A/RS-AC
NOTICE
Overheating caused by solar radiation
Overheating of the gearbox due to exposure to direct sunlight
Provide suitable protective equipment such as covers or roofs. Prevent heat accumulation.
NOTICE
Malfunction resulting from foreign objects
The operator must ensure that no foreign objects impair the function of the gearbox.
NOTICE
Damaged components impair the correct 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.
NOTICE
Violation of the maximum permissible oil sump temperature
The oil sump temperature may be exceeded if the temperature monitoring equipment is
incorrectly set.
A warning must be given 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.

Installing
3.3 Thread sizes and tightening torques for fastening bolts
BA 2039
Operating Instructions, 04/2016, A5E37431501A/RS-AC 17
3.3
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 3- 1 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
M8 25 35 41
M10
50
70
85
M12 90 120 145
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
3.4
Mounting an input or output element on the gearbox shaft
WARNING
Risk of burns caused by hot parts
Do not touch the gearbox without protection.
NOTICE
Damage to shaft sealing rings caused by solvent
Avoid any contact of solvent or benzine with the shaft sealing rings.
NOTICE
Damage to shaft sealing rings caused by heating
Use thermal shields to protect shaft sealing rings from heating above 100 °C due to radiant
heat.

Installing
3.4 Mounting an input or output element on the gearbox shaft
BA 2039
18 Operating Instructions, 04/2016, A5E37431501A/RS-AC
NOTICE
Premature wear or material damage due to misalignment
Misalignment caused by excessive angular or axis displacement to the connecting shaft
ends.
Ensure precise alignment of the individual components.
NOTICE
Damage caused by improper handling
Bearings, housing, shaft and locking rings are damaged due to improper handling.
Do not use impacts or knocks to force the input and output elements to be mounted onto
the shaft.
Note
Deburr the parts of elements to be fitted in the area of the hole or keywa
ys.
Recommendation:
0.2 x 45°
Where couplings are to be fitted in a heated condition, observe the specific operating
instructions for the coupling. Unless otherwise specified, apply the heat inductively using a
torch or in a furnace.
Use the center holes in the shaft end faces.
Use a fitting device to fit the input or output elements.
Image 3-1 Example of a fitting device
Observe the correct mounting arrangement to minimize stress on shafts and bearings due to
lateral forces.

Installing
3.5 Mounting the motor
BA 2039
Operating Instructions, 04/2016, A5E37431501A/RS-AC 19
Correct
Incorrect
a
Hub
F
Force
Image 3-2 Mounting arrangement for low stress on shafts and bearings
Procedure
1. Use either benzine or solvent to remove the anti-corrosion protection from the shaft ends
and flanges or remove the applied protective skin.
2. Fit the drive input and output elements to the shafts. Fasten the elements when
necessary.
You have now fitted the input or output element.
3.5
Mounting the motor
NOTICE
Moisture penetrates an inadequately sealed geared motor
If the geared motor is to be installed outdoors or for an installation requiring a high degree
of protection (≥IP55):
•Seal the flange, bolts 1505 or integrated elements such as proximity switches, using an
appropriate sealing compound.
•The flange-mounted motor must be sealed across the entire contact surface.
•Seal the geared motor in the outer area.

Installing
3.5 Mounting the motor
BA 2039
20 Operating Instructions, 04/2016, A5E37431501A/RS-AC
3.5.1
Fit the standard motor to the K2 or K3 adapter
ATEX version gearboxes
Impacts can cause sparks.
Apply adhesive (medium strength, e.g.
Loctite 243) to the grub screw 1564 and
bolts 1505.
Note
Dimension
z12 applies for standard assignment of the coupling. If a special assignment is
required, consult the appropriate special dimension drawing.
1505
Bolt
1555
Coupling half
1556
Coupling half
1557
Flexible element
1564
Grub screw
Image 3-3 Adapter K2 and K3