Siemens MOTOX BA 2515 User manual

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MOTOX
Gearboxes for overhead conveyors
BA 2515
Operating Instructions
Translation of the original instructions
10/2016
A5E38123453A/RS
-AB
General information and
safety notes
1
Technical description
2
Incoming goods, transport,
and storage
3
Installation
4
Commissioning
5
Operation
6
Faults, causes and remedies
7
Service and maintenance
8
Disposal
9
Technical specifications
10
Spare parts
11
Declaration of Incorporation
12

Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E38123453A/RS-AB
Ⓟ
01/2017 Subject to change
Copyright © Siemens AG 2012 - 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
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.

BA 2515
Operating Instructions, 10/2016, A5E38123453A/RS-AB 5
Table of contents
1 General information and safety notes ...................................................................................................... 9
1.1 General information ..................................................................................................................9
1.2 Copyright.................................................................................................................................11
1.3 Intended use ...........................................................................................................................11
1.4 Obligations of the user ............................................................................................................11
1.5 Particular types of hazards .....................................................................................................13
2 Technical description ............................................................................................................................ 15
2.1 General description.................................................................................................................15
2.2 Surface treatment ...................................................................................................................17
2.2.1 General information on surface treatment ..............................................................................17
2.2.2 Painted version .......................................................................................................................17
2.2.3 Primed version ........................................................................................................................19
3 Incoming goods, transport, and storage................................................................................................. 21
3.1 Incoming goods.......................................................................................................................21
3.2 Transportation.........................................................................................................................22
3.2.1 General information on transport ............................................................................................22
3.2.2 Fastening for suspended transport .........................................................................................23
3.3 Bearings..................................................................................................................................25
3.3.1 General information for storage ..............................................................................................25
3.3.2 Storage up to 36 months with long-term preservation (optional)............................................25
3.3.2.1 General notes for storage up to 36 months ............................................................................25
3.3.2.2 Gearbox filled with operating oil and anti-corrosive agent......................................................26
3.3.2.3 Gearbox completely filled with oil ...........................................................................................26
4 Installation ............................................................................................................................................ 27
4.1 Unpacking ...............................................................................................................................27
4.2 General information concerning the installation .....................................................................27
4.3 Thread sizes and tightening torques for fastening bolts.........................................................29
4.4 Fastening in the case of high shock loads..............................................................................29
4.5 Gearbox with foot mounting....................................................................................................30
4.6 Gearboxes in foot or flange version........................................................................................30
4.7 Mounting an input or output element on the gearbox shaft ....................................................31
5 Commissioning ..................................................................................................................................... 33
5.1 General information for commissioning ..................................................................................33
5.2 Checking the oil level prior to commissioning.........................................................................33

Table of contents
BA 2515
6Operating Instructions, 10/2016, A5E38123453A/RS-AB
5.3 Vent filter ................................................................................................................................ 34
6 Operation.............................................................................................................................................. 35
7 Faults, causes and remedies................................................................................................................. 37
8 Service and maintenance...................................................................................................................... 41
8.1 General notes about maintenance work ................................................................................ 41
8.2 Checking and changing lubricants ......................................................................................... 43
8.2.1 General safety instructions .................................................................................................... 43
8.2.2 Checking the oil level ............................................................................................................. 44
8.2.3 Checking the oil level using the oil sight glass (optional) ...................................................... 45
8.2.4 Checking the oil level using the oil dipstick (optional)............................................................ 45
8.2.5 Checking the oil quality .......................................................................................................... 45
8.2.6 Changing the oil ..................................................................................................................... 46
8.2.6.1 General safety notes for changing the oil .............................................................................. 46
8.2.6.2 Draining the oil ....................................................................................................................... 47
8.2.6.3 Flushing the gearbox when changing between incompatible oils.......................................... 48
8.2.6.4 Filling in oil ............................................................................................................................. 49
8.2.7 Topping up with oil ................................................................................................................. 50
8.2.8 Regreasing the roller bearing................................................................................................. 50
8.2.9 Change the roller bearing grease .......................................................................................... 51
8.2.10 Service life of the lubricants ................................................................................................... 51
8.2.11 Recommended lubricants ...................................................................................................... 52
8.3 Replace bearings ................................................................................................................... 54
8.4 Checking the gearbox for leaks ............................................................................................. 54
8.5 Cleaning the vent filter ........................................................................................................... 55
8.6 Cleaning the gearbox............................................................................................................. 55
8.7 Checking the tightness of fastening bolts .............................................................................. 55
8.8 Inspecting the gearbox........................................................................................................... 56
9 Disposal................................................................................................................................................ 57
10 Technical specifications ........................................................................................................................ 59
10.1 Type designation.................................................................................................................... 59
10.2 General technical data ........................................................................................................... 60
10.3 Weight .................................................................................................................................... 62
10.4 Sound energy level ................................................................................................................ 62
10.5 Mounting positions ................................................................................................................. 63
10.5.1 Helical worm gearbox CHF28 ................................................................................................ 64
10.5.2 Bevel helical gearboxes BHF38, BHB38 ............................................................................... 65
10.5.3 Helical worm gearboxes CHZ48, CHF48, CHF68 ................................................................. 66
10.5.4 Bevel helical gearboxes KHZ48, KHF48, KHF68 .................................................................. 67
10.6 Oil quantities .......................................................................................................................... 68
11 Spare parts ........................................................................................................................................... 69
11.1 Stocking of spare parts .......................................................................................................... 69

Table of contents
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Operating Instructions, 10/2016, A5E38123453A/RS-AB 7
11.2 Spare parts lists ......................................................................................................................70
11.2.1 Bevel helical gearboxes BHF38, BHB38, KHF48, KHF46, KHZ48 ........................................70
11.2.2 Helical worm gearboxes CHF28, CHF48, CHF68, CHZ48.....................................................73
12 Declaration of Incorporation .................................................................................................................. 77

Table of contents
BA 2515
8Operating Instructions, 10/2016, A5E38123453A/RS-AB

BA 2515
Operating Instructions, 10/2016, A5E38123453A/RS-AB 9
General information and safety notes
1
1.1
General information
Note
Siemens
AG does not accept any liability for damage and failures that result from the non-
observance of these o
perating instructions.
These operating instructions are part of the gearbox delivery. Store the operating instructions
near the gearbox.
These operating instructions apply to the standard version of the MOTOX gearbox for
overhead conveyors BHF38, BHB38, KHF48, KHF68, KHZ48, CHF28, CHF48, CHF68 and
CHZ48.
Table 1- 1 Order number code
MOTOX gearbox
Structure of the order number position
Order code
1
2
3
4
5
14
Bevel Helical Gearbox B and K
2
K
J
1
5
Helical Worm Gearbox C
2
K
J
1
6
Overhead conveyor H
G00
Flange F
F
Foot / flange-mounted design B
B
Centering flange Z
Z
Note
In addition to these operating instructions, special contractual agreements and technical
documentation appl
y to special gearbox designs 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 serve to improve the performance and safety.
The significant features are retained. The operating instructions are updated regularly with
new contents.

General information and safety notes
1.1 General information
BA 2515
10 Operating Instructions, 10/2016, A5E38123453A/RS-AB
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]
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 2510 - operating instructions for MOTOX optional add-on units
●BA 2515 - operating instructions for MOTOX gearboxes for overhead conveyors

General information and safety notes
1.2 Copyright
BA 2515
Operating Instructions, 10/2016, A5E38123453A/RS-AB 11
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
The MOTOX gearboxes described in these operating instructions have been developed for
use as travel drives in overhead conveyors.
Unless otherwise agreed, the gearboxes have been designed for use in machinery and
plants 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 2000
m above sea level.
In the case of other ambient temperatures and installation altitudes, please contact Technical
Support.
The gearboxes are designed only for the area of application described in Section Technical
specifications (Page 59).
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.

General information and safety notes
1.4 Obligations of the user
BA 2515
12 Operating Instructions, 10/2016, A5E38123453A/RS-AB
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 2515
Operating Instructions, 10/2016, A5E38123453A/RS-AB 13
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
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14 Operating Instructions, 10/2016, A5E38123453A/RS-AB

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Operating Instructions, 10/2016, A5E38123453A/RS-AB 15
Technical description
2
2.1
General description
The gearbox is supplied as a helical worm gearbox CH., as a 2-stage bevel helical
gearbox BH., or as a 3-stage bevel helical gearbox KH. It is equipped with a mechanical
clutch.
The gearbox is suitable for use as an overhead conveyor drive in accordance with
VDI guideline 3643. Gearbox types CHF28 and BH.38 correspond to VDI guideline 3643.
They are used to transport goods in roofed over industrial applications. They can be used
outdoors if the necessary contractual arrangements are made.
The gearbox is suitable for various mounting positions. Observe the correct oil level.
Housing
The gearbox housing is made of gray cast iron.
Geared components
The geared components are hardened. For the helical worm gearbox, the worm is hardened
and ground. The gear is manufactured from high-quality bronze. The bevel gear stage of the
bevel helical gearbox is lapped in pairs.
Lubrication
The geared components are supplied with adequate lubricant by means of dip lubrication.
Shaft bearings
All shafts are mounted in roller bearings. The roller bearings are lubricated using splash
lubrication or oil-spray lubrication. Bearings that are not supplied with lubricant are closed
and grease-lubricated.
Shaft seals
The radial shaft sealing ring, combination shaft sealing ring, labyrinth seal, and slide ring
seal at the shaft outlet prevent lubricant from escaping from the housing and impurities from
entering it.

Technical description
2.1 General description
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16 Operating Instructions, 10/2016, A5E38123453A/RS-AB
Cooling
NOTICE
Dust deposits prevent heat radiation.
Dust deposits prevent heat radiation and cause a high housing temperature.
Keep the gearbox free from dirt, dust, etc.
The gearbox does not normally require additional cooling. The generously dimensioned
housing surface is sufficient for dissipating heat losses where there is free convection. If the
housing temperature exceeds a value of +80° C, please contact the Technical Support.
Flexible coupling
NOTICE
Balancing the coupling
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 at the outer diameter 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.
Clutch for overhead conveyors
Actuation of the operating lever interrupts the force flow in the positive claw coupling on the
output shaft. The output shaft can then freely rotate while the motor is stopped or in no-load
operation.
Rating plate
The rating plate on the gearbox or geared motor is of coated aluminum foil. The rating plate
is glued using a special masking film. The film ensures permanent resistance to UV radiation
and media of all kinds, such as oils, greases, salt water and cleaning agents.
The adhesive and the material ensure firm adhesion and long-term legibility within the
operating temperature range from -40° C to +155° C.
The edges of the rating plate are paint-finished to match the color of the gearbox or motor to
which it is affixed.
In special cases, riveted or bolted metal plates are used.

Technical description
2.2 Surface treatment
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Operating Instructions, 10/2016, A5E38123453A/RS-AB 17
2.2
Surface treatment
2.2.1
General information on surface treatment
All paint finishes are sprayed on.
NOTICE
Failure of the exterior protection
If the paint finish is damaged, the geared motor may corrode.
Do not damage the paint finish.
Note
Information about the ability to be repainted does not guarantee the quality of the paint
product supplied by your supplier.
Only the paint manufacturer is liable for quality and compatibility.
2.2.2
Painted version
The corrosion protection system is classified according to the corrosiveness categories in
DIN EN ISO 12944-2.
Table 2- 1 Paint according to corrosiveness categories
Paint system
Description
Corrosiveness category C1, unpainted for gearbox and motor housings made of aluminum
- •Indoor installation
•Heated buildings with neutral atmospheres
•Resistance to greases and some resistance to
mineral oils, aliphatic solvents
•Standard
Corrosiveness category C1 for normal environmental stress
1-component hydro paint, top coat •Indoor installation
•Heated buildings with neutral atmospheres
•Resistance to greases and some resistance to
mineral oils, aliphatic solvents
•Standard paint for gearbox housings made of cast
iron

Technical description
2.2 Surface treatment
BA 2515
18 Operating Instructions, 10/2016, A5E38123453A/RS-AB
Paint system
Description
Corrosiveness category C2 for low environmental stress
2-component polyurethane base coat,
2-component polyurethane top coat
•Indoor and outdoor installation
•Unheated buildings with condensation, production
areas with low humidity, e.g. warehouses and sports
facilities
•Atmospheres with little contamination, mostly rural
areas
•Resistance to greases, mineral oils and sulfuric
acid (10 %), caustic soda (10 %) and some
resistance to aliphatic solvents
Corrosiveness category C3 for medium environmental stress
2-component polyurethane base coat,
2-component polyurethane top coat
•Indoor and outdoor installation
•Production areas with high humidity and some air
contamination, e.g. food production areas, dairies,
breweries and laundries
•Urban and industrial atmospheres, moderate
contamination from sulfur dioxide, coastal areas with
low salt levels
•Resistance to greases, mineral oils, aliphatic
solvents, sulfuric acid (10 %), caustic soda (10 %)
Corrosiveness category C4 for high environmental stress
2-component epoxy zinc phosphate base
coat,
2-component polyurethane top coat
•Indoor and outdoor installation
•Chemical plants, swimming pools, wastewater
treatment plants, electroplating shops, and
boathouses above seawater
•Industrial areas and coastal areas with moderate salt
levels
•Resistance to greases, mineral oils, aliphatic
solvents, sulfuric acid (10 %), caustic soda (10 %)

Technical description
2.2 Surface treatment
BA 2515
Operating Instructions, 10/2016, A5E38123453A/RS-AB 19
Paint system
Description
Corrosiveness category C5 for very high environmental stress
2-component epoxy zinc phosphate base
coat,
2-component epoxy iron mica
intermediate coat,
2-component polyurethane top coat
•Indoor and outdoor installation
•Buildings and areas with almost constant
condensation and high contamination, e.g. malt
factories and aseptic areas
•Industrial areas with high humidity and aggressive
atmosphere, coastal areas and offshore
environments with high salt levels
•Resistance to greases, mineral oils, aliphatic
solvents, sulfuric acid (10 %), caustic soda (20 %)
In case of corrosiveness category C1, overpainting with a 1-component hydrosystem after
prior rubbing down is possible.
In case of corrosiveness categories C2 to C5, overpainting with 2-component polyurethane
paint, 2-component epoxide paint and 2-component acrylic paint after prior rubbing down is
possible.
2.2.3
Primed version
Table 2- 2 Primer according to corrosiveness category
Paint system
Can be overpainted with
Unpainted corrosiveness category C1
Cast iron parts immersion primed,
steel parts primed or zinc-plated,
aluminum and plastic parts untreated
•Synthetic paint, synthetic resin paint, oil paint
•2-component polyurethane paint
•2-component epoxy paint
Primed according to corrosiveness category C2 G
2-component metal primer,
desired coat thickness 60 μm
•2-component polyurethane paint
•2-component epoxy paint
•2-component acrylic paint
•Acid-hardening paint
Primed according to corrosiveness category C4 G
2-component epoxide zinc phosphate,
desired coat thickness 120 μm
•2-component polyurethane paint
•2-component epoxy paint
•2-component acrylic paint
•Acid-hardening paint
A paint-protective film must be applied to the rating plate and the masking film for the primed
or unpainted variant. They can be repainted without further preparation, e.g. masking with
adhesive tape.

Technical description
2.2 Surface treatment
BA 2515
20 Operating Instructions, 10/2016, A5E38123453A/RS-AB
Peeling off the paint-protective film
The paint coat must have fully hardened before the paint-protective film is peeled off (be at
least "touch-proof").
①
Company logo
②
Masking film
③
Rating plate
④
Paint-protective film
⑤
Peeling tab
Figure 2-1 Rating plate with paint-protective film
Procedure
1. Pull the peeling tab ⑤up.
2. Carefully peel the paint-protective film ④off diagonally from one corner (not parallel to
the plate).
3. Blow any paint fragments away or wipe them off with a clean cloth.
You have now removed the paint-protective film.