Siemens SIMOTICS S-1FG1 User manual

SIMOTICS S-1FG1 servo geared motor

SIMOTICS
Drive technology
SIMOTICS S-1FG1 servo geared
motor
Operating Instructions
07/2019
A5E47360747B AA
Introduction
Fundamental safety
instructions for the
SIMOTICS documentation
1
Description
2
Preparing for use
3
Mounting
4
Connecting
5
Commissioning
6
Operation
7
Faults
8
Service and maintenance
9
Decommissioning and
disposal
10
Appendix
A

Siemens AG
Digital Industries
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E47360747B AA
Ⓟ
07/2019 Subject to change
Copyright © Siemens AG 2019.
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
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.

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Introduction
This documentation should be kept in a location where it can be easily accessed and made
available to the personnel responsible.
Target group and use
Target group
These Operating Instructions are intended for installation engineers, commissioning
personnel, machine operators, and service and maintenance personnel.
Utilization phase
Planning and engineering phase, implementation phase, installation and commissioning
phase, application phase, maintenance and service phase.
About these operating instructions
These operating instructions apply to the SIMOTICS S-1FG1 servo geared motor.
The Operating Instructions provide information about the components that enable the target
group to install, set up, test, commission, operate, and troubleshoot the products and
systems correctly and safely.
The operating instructions inform you about how to handle the SIMOTICS S-1FG1 servo
geared motor from delivery to final disposal.
Before you start using the 1FG1 servo geared motor, you must read these Operating
Instructions to ensure safe, problem-free operation and to maximize the service life.
Siemens strives continually to improve the quality of information provided in these Operating
Instructions.
●If you find any mistakes or would like to offer suggestions about how this document could
be improved, contact the Siemens Service Center.
●Always follow the safety instructions and notices in this Product Information.
The warning notice system is explained on the rear of the inside front.
Conventions
The following terms are defined in these operating instructions:
●"1FG1" indicates a SIMOTICS S-1FG1 servo geared motor, hereinafter referred to as
"servo geared motor" or "1FG1 servo geared motor" also.
●"motor" indicates the drive component of a SIMOTICS S-1FG1 servo geared motor.
●"gear unit" indicates the gear component of a SIMOTICS S-1FG1 servo geared motor.

Introduction
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Text features
In addition to the notes that you must observe for your own personal safety as well as to
avoid material damage, in this document you will find the following text features:
Operating instructions
Handling instructions with a specified sequence start with the word "Procedure":
The individual handling steps are numbered.
1. Execute the operating instructions in the specified sequence.
❒
The square indicates the end of the operating instruction.
Operating instructions without a specified sequence are identified using a bullet point:
●Execute the operating instructions.
Enumerations
●Enumerations are identified by a bullet point without any additional symbols.
–Enumerations at the second level are hyphenated.
Notes
Notes are shown as follows:
Note
A Note is an important item of information about the product, handling of the product or the
relevant section of the document. Notes provide you with help or further suggestions/ideas.
More information
Information on the following topics is available at:
●Ordering documentation / overview of documentation
●Additional links to download documents
●Using documentation online (find and search in manuals / information)
More information (https://support.industry.siemens.com/cs/de/en/view/108998034)
If you have any questions regarding the technical documentation (e.g. suggestions,
corrections), please send an e-mail to the following address E-mail
(mailto:[e-mail]).

Introduction
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My support
Information on how to produce individual contents for your own machine documentation
based on Siemens contents is available under the link:
My support (https://support.industry.siemens.com/My/ww/en/documentation)
Note
If you want to use this function, you must register once.
Later, you can log on with your login data.
Training
The following link provides information on SITRAIN - training from Siemens for products,
systems and automation engineering solutions:
SITRAIN (http://siemens.com/sitrain)
Technical Support
Country-specific telephone numbers for technical support are provided on the Internet under
Contact:
Technical Support (https://support.industry.siemens.com)
Internet address for products
Products (http://www.siemens.com/motioncontrol)
Websites of third parties
This publication contains hyperlinks to websites of third parties. Siemens does not take any
responsibility for the contents of these websites or adopt any of these websites or their
contents as their own, because Siemens does not control the information on these websites
and is also not responsible for the contents and information provided there. Use of these
websites is at the risk of the person doing so.
Compliance with the General Data Protection Regulation
Siemens respects the principles of data protection, in particular the data minimization rules
(privacy by design).
For this product, this means:
The product does not process neither store any person-related data, only technical function
data (e.g. time stamps). If the user links these data with other data (e.g. shift plans) or if he
stores person-related data on the same data medium (e.g. hard disk), thus personalizing
these data, he has to ensure compliance with the applicable data protection stipulations.

Introduction
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Table of contents
Introduction............................................................................................................................................. 3
1 Fundamental safety instructions for the SIMOTICS documentation........................................................ 11
1.1 Fundamental safety instructions .............................................................................................11
1.1.1 General safety instructions .....................................................................................................11
1.1.2 Equipment damage due to electric fields or electrostatic discharge ......................................15
1.1.3 Industrial security ....................................................................................................................16
1.1.4 Residual risks of power drive systems....................................................................................17
2 Description............................................................................................................................................ 19
2.1 Use for intended purpose .......................................................................................................19
2.2 Technical features and ambient conditions ............................................................................20
2.2.1 Directives and standards ........................................................................................................20
2.2.2 General technical features of the 1FG1 servo geared motor .................................................22
2.2.3 Environmental conditions........................................................................................................23
2.2.4 Address of CE-authorized manufacturer ................................................................................24
2.3 Derating factors.......................................................................................................................24
2.4 Structure of the article number ...............................................................................................25
2.5 Rating plate specifications of the servo geared motor............................................................28
2.6 Type designation of the gearbox ............................................................................................29
2.7 Mounting and options..............................................................................................................30
2.7.1 Warning labels on the servo geared motor.............................................................................30
2.7.2 Cooling of the servo geared motor .........................................................................................31
2.7.3 Holding brake..........................................................................................................................31
2.7.3.1 Properties................................................................................................................................31
2.7.3.2 Motor-side connection of the holding brake............................................................................32
2.7.3.3 Protective circuitry for the brake .............................................................................................33
2.7.3.4 Permanent-magnet brake .......................................................................................................34
2.7.3.5 Spring-loaded brake................................................................................................................34
2.7.4 Increased chemical resistance ...............................................................................................39
3 Preparing for use .................................................................................................................................. 41
3.1 Shipping and packaging .........................................................................................................41
3.2 Transportation and storage.....................................................................................................42
3.2.1 Transporting the servo geared motor .....................................................................................42
3.2.2 Storing the servo geared motor ..............................................................................................44
3.3 Mounting and properties of the gearboxes .............................................................................45
3.4 Mounting positions ..................................................................................................................47
3.4.1 Two- and three-stage helical gearbox ....................................................................................48
3.4.2 Parallel shaft gearbox .............................................................................................................55
3.4.3 Bevel gearbox .........................................................................................................................61
3.4.4 Helical worm gearbox .............................................................................................................70

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4 Mounting............................................................................................................................................... 77
4.1 Safety instructions.................................................................................................................. 77
4.1.1 Danger to life when lifting and transporting ........................................................................... 77
4.2 Checklists for mounting.......................................................................................................... 79
4.3 Mounting instructions ............................................................................................................. 80
4.4 Gearbox with foot mounting ................................................................................................... 82
4.5 Gearbox with flange fastening ............................................................................................... 83
4.6 Gearboxes in foot or flange version....................................................................................... 84
4.7 Mounting an input or output element on the gearbox shaft ................................................... 84
4.8 Mounting the protection cover................................................................................................ 86
4.9 Installing and removing the shaft-mounted gearbox.............................................................. 87
4.9.1 Mounting or removing the hollow shaft with feather key........................................................ 87
4.9.2 Mounting or removing the hollow shaft with shrink disk ........................................................ 91
4.9.3 Installing or removing the SIMOLOC connection................................................................... 95
4.9.4 Mounting the hollow shaft with splines .................................................................................. 99
4.9.5 Torque arms with shaft-mounted gearboxes ....................................................................... 100
4.10 Mount the oil expansion unit ................................................................................................ 103
4.11 Vibration response ............................................................................................................... 106
5 Connecting ..........................................................................................................................................107
5.1 Safety instructions................................................................................................................ 107
5.2 Permissible line system types.............................................................................................. 108
5.3 Circuit diagram..................................................................................................................... 108
5.4 System integration ............................................................................................................... 109
5.4.1 Connection notes ................................................................................................................. 109
5.4.1.1 Motor connection.................................................................................................................. 109
5.4.1.2 Rotating the connector at the motor .................................................................................... 111
5.4.2 Power connection................................................................................................................. 113
5.4.3 Signal connection................................................................................................................. 113
5.4.3.1 Motors with DRIVE-CLiQ interface ...................................................................................... 113
5.4.3.2 Motors without a DRIVE-CLiQ interface .............................................................................. 115
5.4.3.3 Design of the signal connectors........................................................................................... 116
5.4.4 Connecting-up a converter................................................................................................... 116
5.4.4.1 Selecting and connecting the cables ................................................................................... 116
5.4.4.2 Instructions for handling the RJ45 connector ...................................................................... 119
5.4.4.3 Handling the quick-action locking ........................................................................................ 122
5.4.4.4 Routing cables in a damp environment ............................................................................... 124
6 Commissioning ....................................................................................................................................125
6.1 Safety instructions................................................................................................................ 125
6.2 Checklists for commissioning............................................................................................... 127
6.3 Preparing commissioning..................................................................................................... 129
6.4 Commissioning procedure ................................................................................................... 129
6.5 Switching on and switching off............................................................................................. 130

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7 Operation............................................................................................................................................ 131
7.1 Safety instructions.................................................................................................................131
7.2 Switching on and switching off..............................................................................................132
7.3 Operation ..............................................................................................................................133
7.4 Measures for longer non-operational periods .......................................................................133
8 Faults.................................................................................................................................................. 135
9 Service and maintenance.................................................................................................................... 139
9.1 Safety instructions.................................................................................................................139
9.2 Inspection and maintenance.................................................................................................142
9.2.1 Maintenance and inspection intervals...................................................................................142
9.2.2 Thread sizes and tightening torques for fastening bolts.......................................................144
9.2.3 Bearing replacement interval ................................................................................................145
9.2.4 Checking and changing lubricants........................................................................................145
9.2.4.1 Checking the oil level ............................................................................................................145
9.2.4.2 Checking the oil level using the oil sight glass (optional) .....................................................147
9.2.4.3 Checking the oil quality .........................................................................................................147
9.2.4.4 Changing the oil ....................................................................................................................148
9.2.4.5 Recommended oil types .......................................................................................................152
9.2.4.6 Change the roller bearing grease .........................................................................................152
9.2.4.7 Service life of the lubricants..................................................................................................153
9.2.4.8 Recommended lubricants .....................................................................................................154
9.2.4.9 Oil quantities .........................................................................................................................156
9.2.5 Checking the gearbox for leaks ............................................................................................156
9.2.6 Cleaning the gearbox............................................................................................................157
9.2.7 Checking tightness of fastening bolts ...................................................................................158
9.3 Corrective maintenance ........................................................................................................158
9.3.1 Replacing the vent valve.......................................................................................................158
9.3.2 Replacing an encoder...........................................................................................................158
10 Decommissioning and disposal ........................................................................................................... 159
10.1 Safety instructions.................................................................................................................159
10.2 Decommissioning..................................................................................................................162
10.2.1 Preparing for dismantling ......................................................................................................162
10.2.2 Dismantling the motor...........................................................................................................162
10.3 Disposal ................................................................................................................................162
A Appendix............................................................................................................................................. 163
A.1 Certificate for the "PS Premium" painting system from ECOLAB.........................................163
A.2 ECOLAB cleaning recommendation .....................................................................................165
Index................................................................................................................................................... 167

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Fundamental safety instructions for the SIMOTICS
documentation
1
1.1
Fundamental safety instructions
1.1.1
General safety instructions
WARNING
Electric shock and danger to life due to other energy sources
Touching live components can result in death or severe injury.
•Only work on electrical devices when you are qualified for this job.
•Always observe the country-specific safety rules.
Generally, the following six steps apply when establishing safety:
1. Prepare for disconnection. Notify all those who will be affected by the procedure.
2. Isolate the drive system from the power supply and take measures to prevent it being
switched back on again.
3. Wait until the discharge time specified on the warning labels has elapsed.
4. Check that there is no voltage between any of the power connections, and between any
of the power connections and the protective conductor connection.
5. Check whether the existing auxiliary supply circuits are de-energized.
6. Ensure that the motors cannot move.
7. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or
water. Switch the energy sources to a safe state.
8. Check that the correct drive system is completely locked.
After you have completed the work, restore the operational readiness in the inverse
sequence.
WARNING
Electric shock due to connection to an unsuitable power supply
When equipment is connected to an unsuitable power supply, exposed components may
carry a hazardous voltage. Contact with hazardous voltage can result in severe injury or
death.
•Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV-
(Protective Extra Low Voltage) output voltages for all connections and terminals of the
electronics modules.

Fundamental safety instructions for the SIMOTICS documentation
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WARNING
Electric shock due to damaged motors or devices
Improper handling of motors or devices can damage them.
Hazardous voltages can be present at the enclosure or at exposed components on
damaged motors or devices.
•Ensure compliance with the limit values specified in the technical data during transport,
storage and operation.
•Do not use any damaged motors or devices.
WARNING
Electric shock due to unconnected cable shield
Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected
cable shields.
•As a minimum, connect cable shields and the conductors of power cables that are not
used (e.g. brake cores) at one end at the grounded housing potential.
WARNING
Electric shock if there is no ground connection
For missing or incorrectly implemented protective conductor connection for devices with
protection class I, high voltages can be present at open, exposed parts, which when
touched, can result in death or severe injury.
•Ground the device in compliance with the applicable regulations.
WARNING
Arcing when a plug connection is opened during operation
Opening a plug connection when a system is operation can result in arcing that may cause
serious injury or death.
•Only open plug connections when the equipment is in a voltage-free state, unless it has
been explicitly stated that they can be opened in operation.
NOTICE
Property damage due to loose power connections
Insufficient tightening torques or vibration can result in loose power connections. This can
result in damage due to fire, device defects or malfunctions.
•Tighten all power connections to the prescribed torque.
•Check all power connections at regular intervals, particularly after equipment has been
transported.

Fundamental safety instructions for the SIMOTICS documentation
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WARNING
Unexpected movement of machines caused by radio devices or mobile phones
When radio devices or mobile phones with a transmission power > 1 W are used in the
immediate vicinity of components, they may cause the equipment to malfunction.
Malfunctions may impair the functional safety of machines and can therefore put people in
danger or lead to property damage.
•If you come closer than around 2 m to such components, switch off any radios or mobile
phones.
•Use the "SIEMENS Industry Online Support app" only on equipment that has already
been switched off.
WARNING
Unrecognized dangers due to missing or illegible warning labels
Dangers might not be recognized if warning labels are missing or illegible. Unrecognized
dangers may cause accidents resulting in serious injury or death.
•Check that the warning labels are complete based on the documentation.
•Attach any missing warning labels to the components, where necessary in the national
language.
•Replace illegible warning labels.
WARNING
Unexpected movement of machines caused by inactive safety functions
Inactive or non-adapted safety functions can trigger unexpected machine movements that
may result in serious injury or death.
•Observe the information in the appropriate product documentation before
commissioning.
•Carry out a safety inspection for functions relevant to safety on the entire system,
including all safety-related components.
•Ensure that the safety functions used in your drives and automation tasks are adjusted
and activated through appropriate parameterizing.
•Perform a function test.
•Only put your plant into live operation once you have guaranteed that the functions
relevant to safety are running correctly.
Note
Important safety notices for Safety Integrated functions
If you want to use Safety Integrated functions, you must observe the safety notices in the
Safety Integra
ted manuals.

Fundamental safety instructions for the SIMOTICS documentation
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WARNING
Active implant malfunctions due to electromagnetic fields
Electromagnetic fields (EMF) are generated by the operation of electrical power equipment,
such as transformers, converters, or motors. People with pacemakers or implants are at
particular risk in the immediate vicinity of this equipment.
•If you have a heart pacemaker or implant, maintain the minimum distance specified in
chapter "Correct usage" from such motors.
WARNING
Active implant malfunctions due to permanent-magnet fields
Even when switched off, electric motors with permanent magnets represent a potential risk
for persons with heart pacemakers or implants if they are close to converters/motors.
•If you have a heart pacemaker or implant, maintain the minimum distance specified in
chapter "Correct usage".
•When transporting or storing permanent-magnet motors always use the original packing
materials with the warning labels attached.
•Clearly mark the storage locations with the appropriate warning labels.
•IATA regulations must be observed when transported by air.
WARNING
Injury caused by moving or ejected parts
Contact with moving motor parts or drive output elements and the ejection of loose motor
parts (e.g. feather keys) out of the motor enclosure can result in severe injury or death.
•Remove any loose parts or secure them so that they cannot be flung out.
•Do not touch any moving parts.
•Safeguard all moving parts using the appropriate safety guards.
WARNING
Fire due to inadequate cooling
Inadequate cooling can cause the motor to overheat, resulting in death or severe injury as a
result of smoke and fire. This can also result in increased failures and reduced service lives
of motors.
•Comply with the specified cooling requirements for the motor.

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WARNING
Fire due to incorrect operation of the motor
When incorrectly operated and in the case of a fault, the motor can overheat resulting in fire
and smoke. This can result in severe injury or death. Further, excessively high
temperatures destroy motor components and result in increased failures as well as shorter
service lives of motors.
•Operate the motor according to the relevant specifications.
•Only operate the motors in conjunction with effective temperature monitoring.
•Immediately switch off the motor if excessively high temperatures occur.
CAUTION
Burn injuries caused by hot surfaces
In operation, the motor can reach high temperatures, which can cause burns if touched.
•Mount the motor so that it is not accessible in operation.
Measures when maintenance is required:
•Allow the motor to cool down before starting any work.
•Use the appropriate personnel protection equipment, e.g. gloves.
1.1.2
Equipment damage due to electric fields or electrostatic discharge
Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules
or devices that may be damaged by either electric fields or electrostatic discharge.
NOTICE
Equipment damage due to electric fields or electrostatic discharge
Electric fields or electrostatic discharge can cause malfunctions through damaged
individual components, integrated circuits, modules or devices.
•Only pack, store, transport and send electronic components, modules or devices in their
original packaging or in other suitable materials, e.g conductive foam rubber of
aluminum foil.
•Only touch components, modules and devices when you are grounded by one of the
following methods:
–Wearing an ESD wrist strap
–Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring
•Only place electronic components, modules or devices on conductive surfaces (table
with ESD surface, conductive ESD foam, ESD packaging, ESD transport container).

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1.1.3
Industrial security
Note
Industrial security
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threa
ts, it is
necessary to implement
– and continuously maintain – a holistic, state-of-the-art industrial
security concept. Products and solutions from Siemens constitute one element of such a
concept.
Customers are responsible for preventing unauthorized acc
ess to their plants, systems,
machines and networks. Such systems, machines and components should only be
connected to an enterprise network or the Internet if and to the extent such a connection is
necessary and only when appropriate security measures (e.
g. using firewalls and/or network
segmentation) are in place.
For additional information on industrial security measures that can be implemented, please
visit:
Industrial security (
https://www.siemens.com/industrialsecurity)
Siemens’ products and solutions undergo continuous development to make them more
secure. Siemens strongly recommends that product updates are applied as soon as they
become available, and that only the latest product versions
are used. Use of product
versions that are no longer supported, and failure to apply the latest updates may increase
customer’s exposure to cyber threats.
To stay informed about product updates, subscribe to the Siemens Industrial Security RSS
Feed at:
I
ndustrial security (https://www.siemens.com/industrialsecurity)
Further information is provided on the Internet:
Industrial Security Configuration Manual
(https://support.industry.siemens.com/cs/ww/en/view/108862708)
WARNING
Unsafe operating states resulting from software manipulation
Software manipulations, e.g. viruses, Trojans, or worms, can cause unsafe operating states
in your system that may lead to death, serious injury, and property damage.
•Keep the software up to date.
•Incorporate the automation and drive components into a holistic, state-of-the-art
industrial security concept for the installation or machine.
•Make sure that you include all installed products into the holistic industrial security
concept.
•Protect files stored on exchangeable storage media from malicious software by with
suitable protection measures, e.g. virus scanners.
•On completion of commissioning, check all security-related settings.
•Protect the drive against unauthorized changes by activating the "Know-how protection"
converter function.

Fundamental safety instructions for the SIMOTICS documentation
1.1 Fundamental safety instructions
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1.1.4
Residual risks of power drive systems
When assessing the machine- or system-related risk in accordance with the respective local
regulations (e.g., EC Machinery Directive), the machine manufacturer or system installer
must take into account the following residual risks emanating from the control and drive
components of a drive system:
1. Unintentional movements of driven machine or system components during
commissioning, operation, maintenance, and repairs caused by, for example,
–Hardware and/or software errors in the sensors, control system, actuators, and cables
and connections
–Response times of the control system and of the drive
–Operation and/or environmental conditions outside the specification
–Condensation/conductive contamination
–Parameterization, programming, cabling, and installation errors
–Use of wireless devices/mobile phones in the immediate vicinity of electronic
components
–External influences/damage
–X-ray, ionizing radiation and cosmic radiation
2. Unusually high temperatures, including open flames, as well as emissions of light, noise,
particles, gases, etc., can occur inside and outside the components under fault conditions
caused by, for example:
–Component failure
–Software errors
–Operation and/or environmental conditions outside the specification
–External influences/damage
3. Hazardous shock voltages caused by, for example:
–Component failure
–Influence during electrostatic charging
–Induction of voltages in moving motors
–Operation and/or environmental conditions outside the specification
–Condensation/conductive contamination
–External influences/damage
4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a
risk to people with a pacemaker, implants or metal replacement joints, etc., if they are too
close
5. Release of environmental pollutants or emissions as a result of improper operation of the
system and/or failure to dispose of components safely and correctly
6. Influence of network-connected communication systems, e.g. ripple-control transmitters
or data communication via the network
For more information about the residual risks of the drive system components, see the
relevant sections in the technical user documentation.

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