Siemens MOTOX BA 2010 User manual

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MOTOX
Input Units
BA 2019
Operating Instructions
Supplement to MOTOX gearbox operating instructions
BA 2010 and BA 2515
Translation of the original instructions
08/2018
A5E38094087A/RS
-AE
General information and
safety notes
1
Technical description
2
Installation
3
Operation
4
Service and maintenance
5
Spare parts
6

Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E38094087A/RS-AE
Ⓟ
09/2018 Subject to change
Copyright © Siemens AG 2012 - 2018.
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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Operating Instructions, 08/2018, A5E38094087A/RS-AE 3
Table of contents
1 General information and safety notes ...................................................................................................... 5
1.1 General information ..................................................................................................................5
1.2 Copyright...................................................................................................................................7
1.3 Intended use .............................................................................................................................7
1.4 Obligations of the user ..............................................................................................................8
1.5 The five safety rules..................................................................................................................9
1.6 Particular types of hazards .....................................................................................................10
2 Technical description ............................................................................................................................ 11
2.1 Flexible coupling .....................................................................................................................11
2.2 Backstop .................................................................................................................................11
3 Installation ............................................................................................................................................ 13
3.1 Unpacking ...............................................................................................................................13
3.2 General information on installation .........................................................................................13
3.3 Thread sizes and tightening torques for fastening bolts.........................................................15
3.4 Mounting an input or output element on the gearbox shaft ....................................................15
3.5 Mounting the motor .................................................................................................................17
3.5.1 Mounting a standard motor on a coupling lantern with a flexible coupling (K2, K2TC)..........18
3.5.2 Mounting a standard motor on a short coupling lantern with a clamp connection (K4,
K5TC)......................................................................................................................................20
3.5.3 Mounting a servomotor on lanterns with a zero-backlash coupling (KQ, KQS) .....................23
3.6 Adjusting the height of the piggy back ....................................................................................27
3.6.1 General information on adjusting the piggy back ...................................................................27
3.6.2 Piggy back for IEC motor up to size 112 ................................................................................28
3.6.3 Piggy back for IEC motor sizes 132 to 200 ............................................................................29
3.6.4 Piggy back for IEC motor size 225 and above .......................................................................30
4 Operation.............................................................................................................................................. 31
5 Service and maintenance...................................................................................................................... 33
5.1 General notes about maintenance..........................................................................................33
5.2 Regreasing the roller bearing .................................................................................................34
6 Spare parts ........................................................................................................................................... 35
6.1 Stocking of spare parts ...........................................................................................................35
6.2 Spare parts lists ......................................................................................................................36
6.2.1 Input units A, A5......................................................................................................................36
6.2.2 Input units K2, K2TC...............................................................................................................37
6.2.3 Input units K4, K5TC...............................................................................................................40

Table of contents
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4Operating Instructions, 08/2018, A5E38094087A/RS-AE
6.2.4 Input units KQ, KQS............................................................................................................... 41
6.2.5 Input unit P ............................................................................................................................. 42

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Operating Instructions, 08/2018, A5E38094087A/RS-AE 5
General information and safety notes
1
1.1
General information
ATEX version gearboxes
Instructions and measures that apply 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.
These operating instructions supplement the BA 2010 and BA 2515 MOTOX gearbox
operating instructions.
They apply to the input units of the standard version of the MOTOX gearbox:
●Input units A, A5 - input units with additional input shaft
●Input unit K2 - coupling lantern with coupling for connecting an IEC motor
●Input unit K2TC - coupling lantern with coupling for connecting a NEMA motor
●Input unit K4 - short coupling lantern with clamp connection for connecting an IEC motor
●Input unit K5TC - short coupling lantern with clamp connection for connecting a
NEMA motor
●Input units KQ, KQS - lanterns for servomotor with zero-backlash coupling for connecting
a servomotor
●Input unit P - input unit with free input shaft and piggy back for connecting an IEC motor,
foot-mounted version

General information and safety notes
1.1 General information
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Table 1- 1 Order number code
Input unit for MOTOX gearbox
Order code
Input unit A
A00
Input unit A5 A02
Input unit K2
A03
Input unit K2TC A05
Input unit K4
A04
Input unit K5TC
A06
Input unit KQ
A07
Input unit KQS
A08
Input unit P
A09
Note
In addition to these operating instructions, special contractual agreements and technical
documentation apply to special gearbox designs and the associated supplementary
equipment.
Please read these operating instructions and the operating instructions for
the MOTOX
gearboxes BA
2010 or BA 2515 before working with the gearbox.
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 serve to improve the 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 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: [phone]
[e-mail]

General information and safety notes
1.2 Copyright
BA 2019
Operating Instructions, 08/2018, A5E38094087A/RS-AE 7
America
Telephone: [phone]
[e-mail]
Asia / Australia / Pacific
Telephone: [phone]
[e-mail]
Valid operating instructions for MOTOX
●BA 2010 - operating instructions for MOTOX gearboxes
●BA 2011 - operating instructions for MOTOX worm gearbox SC
●BA 2012 - operating instructions for MOTOX worm gearbox S
●BA 2019 - operating instructions for MOTOX input units
●BA 2310 - operating instructions for three-phase and single-phase AC motors and
motors equipped with brake with accessories
●BA 2320 - operating instructions for LA/LG and LAI/LGI motors
●BA 2330 - operating instructions for LA/LE/LES motors
●BA 2510 - operating instructions for MOTOX optional add-on units
●BA 2515 - operating instructions for MOTOX gearboxes for overhead conveyors
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 satisfies the requirements of the Explosion Protection
Directive 2014/34/EU.
In the case of ATEX version gearboxes, please observe instructions marked with
this symbol.
The MOTOX 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 machinery and
plants in industrial environments.

General information and safety notes
1.4 Obligations of the user
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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 data on the rating plate assumes an installation altitude of up to 1
000 m above sea
level.
The permissible ambient temperature is stamped on the rating plate.
For different installation altitudes and ambient temperatures, contact Technical Support.
The gearboxes are designed only for the area of application described in Chapter
Technical data in the operating instructions BA 2010 or BA 2515 for MOTOX gearboxes
Do not operate the gearboxes outside the specified performance limits.
Any different operating conditions require new contractual agreements.
Do not climb on the gearbox. Do not place any objects on the gearbox.
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.

General information and safety notes
1.5 The five safety rules
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Operating Instructions, 08/2018, A5E38094087A/RS-AE 9
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.
1.5
The five safety rules
For your own personal safety and to prevent material damage when carrying out any work,
always observe the safety-relevant instructions and the following five safety rules according
to EN 50110-1 Working in a voltage-free state. Apply the five safety rules in the sequence
stated before starting work.
Five safety rules
1. Disconnect.
Also disconnect the auxiliary circuits, for example the anti-condensation heating.
2. Secure against reconnection.
3. Verify absence of operating voltage.
4. Ground and short circuit.
5. Cover or safeguard neighboring live parts.
After the work has been completed, undo the measures taken in the reverse order.

General information and safety notes
1.6 Particular types of hazards
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1.6
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.

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Technical description
2
2.1
Flexible coupling
NOTICE
A coupling with a peripheral speed of up to 30 m/s at the outer diameter must be statically
balanced
A coupling with a peripheral speed of more than 30 m/s requires dynamic balancing.
A flexible coupling is generally used 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.
Please refer to the relevant operating instructions for details of how to use the coupling.
2.2
Backstop
ATEX version gearboxes
The drive speed in the table "Drive speed when using backstops" must be reached
in continuous operation.
Starting and stopping operations ≤20 starts / stops per hour are permissible.
NOTICE
Replacing the backstop
Drive speeds below 1 000 rpm or frequent starting and stopping operations
(≥20 starts / stops per hour) will limit service life.
Do not use the same backstop for prolonged periods; replace backstops regularly.
NOTICE
Damaged or destroyed backstop
Do not run the motor against the backstop.
Note the directional arrow on the gearbox.

Technical description
2.2 Backstop
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12 Operating Instructions, 08/2018, A5E38094087A/RS-AE
The gearbox can be fitted with a mechanical backstop. The backstop can be fitted either in
the coupling lantern or in the 2nd stage of the bevel helical gearbox. It permits only the
correct direction of rotation during operation. This 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.
Where the backstop is used in the coupling lantern, lifting of the sprags is ensured when the
drive speed is above the speed listed in the table. The backstop is wear-free. It does not
require maintenance.
Table 2- 1 Drive speed when using backstops
Motor size
Backstop
Minimum speed
[rpm]
80/90
FXM-46 DX
> 820
100
FXM-51 DX
> 750
112 FXM-61 DX > 750
132, 160
FXM-76 DX
> 670
180/200, 225, 250 FXM-101 DX > 610
280
FXM-100 SX
> 400
When used in the bevel helical gearbox (gearbox intermediate shaft), the backstop operates
at speeds below the lift-off speed of the sprags in a separate oil chamber. The oil must be
changed at the same intervals as the gearbox.

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Installation
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.

Installation
3.2 General information on installation
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14 Operating Instructions, 08/2018, A5E38094087A/RS-AE
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.
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.

Installation
3.3 Thread sizes and tightening torques for fastening bolts
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Operating Instructions, 08/2018, A5E38094087A/RS-AE 15
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.

Installation
3.4 Mounting an input or output element on the gearbox shaft
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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
keyways.
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.
Figure 3-1 Example of a fitting device

Installation
3.5 Mounting the motor
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Operating Instructions, 08/2018, A5E38094087A/RS-AE 17
Observe the correct mounting arrangement to minimize stress on shafts and bearings due to
lateral forces.
Correct
Incorrect
a
Hub
F
Force
Figure 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, screws 505 and any screw plugs 502 or 503 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 outside areas.

Installation
3.5 Mounting the motor
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3.5.1
Mounting a standard motor on a coupling lantern with a flexible coupling (K2,
K2TC)
ATEX version gearboxes
Impact can cause sparks.
Apply adhesive (medium strength, e.g.
Loctite 243) to the grub screw 564 and
screws 505.
ATEX version gearboxes
The flange
-mounted motor must be sealed across the entire contact surface in
order to prevent the penetration of a potentially explosive atmosphere.
Note
Dimension
z12 applies for standard assignment of the coupling. If a special assignment is
required, consult the appropriate special dimension drawing.
IEC B5 80 - 315, NEMA TC 56 - 145
NEMA TC 182 - 365
502
Screw plug
556
Coupling half
505
Bolt
557
Flexible element
555
Coupling half
564
Grub screw
Figure 3-3 Coupling lantern with flexible coupling