Siemens SIMOGEAR BA 2039 User manual

BA 2039 (2KJ4)
SIMOGEAR
Adapter for gearbox
BA 2039 (2KJ4)
Operating Instructions
Supplement to the SIMOGEAR gearbox operating
instructions BA 2030 (2KJ4)
12/2022
A5E50009089A/RS
-AJ
Introduction
Fundamental safety
instructions
1
Specific safety instructions
2
Technical description
3
Installing
4
Operation
5
Service and maintenance
6
Spare parts
7

Siemens AG
Digital Industries
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E50009089A/RS
-AJ
Ⓟ
12/2022 Subject to change
Copyright © Siemens AG 2020 - 2022.
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
Target group
This manual is aimed at planning, project, and design engineers as well as electricians, fitters,
and service personnel.
Avoiding dangers
Avoid dangers. Ensure safe, problem-free operation and a maximum service life:
•Before you start using the motor, you must read these Operating Instructions
•Always follow the safety instructions and notices in these operating instructions.
The warning notice system is explained at the beginning of this document.
This documentation should be kept in a location where it can be easily accessed and made
available to the personnel responsible.
About this documentation
These Operating Instructions inform you about the motor and its components. You will learn
how to handle the motor properly and safely from delivery to disposal:
•Assembly and mounting
•Connecting
•Commissioning
• Checking
•Operation
•Troubleshooting
•Disassembling
•Transporting and storage
•Disposal
This documentation describes the functionality of the product. The machine builder
documents any modifications or changes to the product made by it.
This documentation cannot contain all of the detailed information on all of the product types.
Moreover, this documentation cannot take into consideration every possible type of
installation, operation, and maintenance.

Introduction
BA 2039 (2KJ4)
4Operating Instructions, 12/2022, A5E50009089A/RS-AJ
mySupport
Extensive assistance and more information can be found under the following link:
My Support Links and Tools (https://support.industry.siemens.com/cs/cn/en/my)
You can individually compile your personal library, e.g. for your documentation based on
Siemens content, and adapt it for your own machine documentation.
To do so, click "My Documentation".
Note
If you want to use this function, you must register once.
Later, you can log on with your login data.
You can create your own personal library under "mySupport" using the following procedure.
Precondition
You have registered for and logged on to "Siemens Industry Online Support", hereinafter
referred to as "SIOS".
SIOS (https://support.industry.siemens.com/cs/cn/en/)
Procedure for creating a personal library
1. Open SIOS and log on.
2. Enter the product you are looking for under "Search for product info" and press "Enter".
3. Select the doc. class you want, e.g. "Manual", under "Entry type".
4. Click on your desired manual under the entries.
5. Click on "Add to mySupport documentation".
6. Enter a title.
7. Press "OK".
❒
The selected manual can be found under "mySupport". To find further functions, click on the
icon located to the right of the document.
In this way, you can create your own library and quickly access your documentation.
Provide feedback
Siemens strives continually to improve the quality of information provided in these operating
instructions.
Your questions, suggestions and corrections of the technical documentation are welcome.
For this purpose, please use the "Send feedback" link in Siemens Industry Online Support at
the end of an entry or send an Email (mailto:[email protected]).

Introduction
BA 2039 (2KJ4)
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Technical support
If you have any technical questions, contact Technical Support
(https://support.industry.siemens.com/cs/cn/en/).
To make a support request, proceed as follows:
Precondition
You have registered for and logged on to "Siemens Industry Online Support", abbreviated
"SIOS".
SIOS (https://support.industry.siemens.com/cs/cn/en/)
Procedure
1. Click on "Your direct way to the Support Request" or follow the link Support Request
(https://support.industry.siemens.com/cs/cn/en/my).
2. Follow the instructions in the online form.
❒
Websites of third parties
This document includes hyperlinks to websites of third-party companies. Siemens is not
responsible for and shall not be liable for these websites and is not responsible for the
content or information they provide. Siemens does not control the information on these
websites and is not responsible for the content and information provided there. The user
bears the risk for their use.
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........................................................................................................... 9
1.1 General safety instructions................................................................................................... 9
1.2 Equipment damage due to electric fields or electrostatic discharge..................................... 13
1.3 Security information .......................................................................................................... 14
1.4 Residual risks of power drive systems ................................................................................. 15
2 Specific safety instructions.................................................................................................................. 17
2.1 General overview............................................................................................................... 17
2.2 Intended use ..................................................................................................................... 18
2.3 Specific hazard types and fundamental obligations............................................................. 19
3 Technical description........................................................................................................................... 21
3.1 General technical description ............................................................................................. 21
3.2 Maximum permissible operation ........................................................................................ 21
3.3 Flexible coupling................................................................................................................ 21
3.4 Backstop K2X..................................................................................................................... 22
4 Installing .............................................................................................................................................. 23
4.1 Unpacking ......................................................................................................................... 23
4.2 General information on installation.................................................................................... 23
4.3 Thread sizes and tightening torques for fastening bolts ...................................................... 25
4.4 Mounting an input or output element on the gearbox shaft................................................ 25
4.5 Mounting the motor .......................................................................................................... 27
4.5.1 Mounting SIEMENS servomotors without feather key onto adapter KS................................ 28
4.5.2 Mounting the standard motor to the K2 adapter................................................................. 31
4.5.3 Mounting the standard motor to the K4 short adapter........................................................ 33
4.5.4 Mounting the servomotor with feather key to the K8 adapter............................................. 35
5 Operation............................................................................................................................................. 37
6 Service and maintenance .................................................................................................................... 39
6.1 General notes about maintenance...................................................................................... 39
6.2 Maintenance of the friction clutch...................................................................................... 39
6.3 Lubrication ........................................................................................................................ 40

Table of contents
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7 Spare parts........................................................................................................................................... 41
7.1 Stocking of spare parts....................................................................................................... 41
7.2 Spares on Web................................................................................................................... 42
7.3 Lists of spare parts ............................................................................................................. 43
7.3.1 Adapter KS ........................................................................................................................ 43
7.3.2 K2 adapter with elastic coupling ........................................................................................ 44
7.3.3 K4 short adapter with plug-in parts .................................................................................... 46
7.3.4 K8 adapter for mounting a servomotor .............................................................................. 47
7.3.5 A, AZ adapter..................................................................................................................... 48

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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 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
1.1 General safety instructions
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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
1.1 General safety instructions
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NOTICE
Damage to equipment due to unsuitable tightening tools.
Unsuitable tightening tools or fastening methods can damage the screws of the equipment.
•Only use screw inserts that exactly match the screw head.
•Tighten the screws with the torque specified in the technical documentation.
•Use a torque wrench or a mechanical precision nut runner with a dynamic torque sensor
and speed limitation system.
•Adjust the tools used regularly.
WARNING
Unexpected machine movement caused by radio devices or mobile phones
Using radio devices, cellphones, or mobile WLAN devices in the immediate vicinity of the
components can result in equipment malfunction. Malfunctions may impair the functional
safety of machines and can therefore put people in danger or lead to property damage.
•Therefore, if you move closer than 20 cm to the components, be sure to switch off radio
devices, cellphones or WLAN devices.
•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.

Fundamental safety instructions
1.1 General safety instructions
BA 2039 (2KJ4)
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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 smoke and fire. Possible
consequences can be serious injury or death. This can also result in increased failures and
reduced service lives of motors.
•Comply with the specified cooling requirements for the motor.

Fundamental safety instructions
1.2 Equipment damage due to electric fields or electrostatic discharge
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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.
1.2 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).

Fundamental safety instructions
1.3 Security information
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1.3 Security information
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 threats, it is
necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial
security concept. Siemens’ products and solutions constitute one element of such a concept.
Customers are responsible for preventing unauthorized access 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. firewalls and/or network segmentation)
are in place.
For additional information on industrial security measures that may be implemented, please
visit
https://www.siemens.com/industrialsecurity (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 are
available and that 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 under
https://www.siemens.com/cert
(https://new.siemens.com/global/en/products/services/cert.html#Subscriptions).
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.

Fundamental safety instructions
1.4 Residual risks of power drive systems
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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.

Fundamental safety instructions
1.4 Residual risks of power drive systems
16
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Specific safety instructions
2
2.1 General overview
Note
Siemens
AG does not accept any liability for damage and failures that result from the non-
observance of these operating instructions.
Note
European RoHS directive
SIMOGEAR geared motors comply with the stipulations laid down in Directive 2011/65/EU.
These operating instructions are part of the gearbox delivery. Store the operating instructions
near the gearbox. Please read the operating instructions prior to handling the gearbox and
observe the information they contain. This is the best way of ensuring safe and trouble-free
operation.
The operating instructions supplement the SIMOGEAR gearbox operating instructions
BA 2030 (2KJ4).
These operating instructions apply to the adapters of the standard SIMOGEAR gearbox
version:
•Adapter KS - coupling adapter only for fitting a SIEMENS servomotor of the
SIMOTICS S-1FK7/1FT7, SIMOTICS M-1PH8, SIMOTICS S-1FK2, SIMOTICS S-1FL6,
SIMOTICS M-1PH1, and SIMOTICS M-1PH3 series
•Adapter K2 - adapter with flexible coupling for fitting an IEC motor
•Adapter K4 - short adapter with plug-in parts for fitting an IEC motor
•Adapter K8 - coupling adapter for fitting a servomotor of the
SIMOTICS M-1PH8 series
•Adapter A, AZ - adapter with free drive shaft
Table 2- 1 Article number code
SIMOGEAR adapter Article number position
12
Supplement
Adapter KS for mounting a SIEMENS servomotor
1
-
Adapter K2 for fitting an IEC motor
2
-
Short adapter K4 for fitting an IEC motor
4
-
Adapter K8 for fitting a servomotor
8
-
Adapter A
9
M1A
Adapter AZ
9
M1B
Example of an article number code for a SIMOGEAR gearbox with coupling adapter KS
2KJ4xxx-xxA01-xxxx.

Specific safety instructions
2.2 Intended use
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Note
In addition to these operating instructions, the special designed gearbox and the
associated
supplementary equipment must also comply with the special contractual agreements and
technical documentation.
When using additional components, carefully observe the notes in the associated
documentation.
Refer to the other operating instruction
s and safety instructions supplied with the product.
Valid operating instructions for SIMOGEAR
can be found in SIOS (https://support.industry.siemens.com/cs/cn/en/ps/27868/man)
•BA 2030 (2KJ4) - operating instructions for SIMOGEAR gearboxes
•BA 2039 (2KJ4) - operating instructions for adapters for mounting on SIMOGEAR
gearboxes
•BA 2330 (2KJ4) - operating instructions for LEN/LHN/LJN motors for mounting on
SIMOGEAR gearboxes
The described gearboxes correspond to the state-of-the-art at the time these operating
instructions were printed.
Siemens AG reserves the right to change individual components and accessory parts in the
interest of further development. The changes serve to improve the performance and safety.
The significant features are retained. The operating instructions are always being updated
with new contents.
2.2 Intended use
Note
Gearboxes and geared motors are partly completed machines for installation into machinery,
or other partly completed machinery or equipment or plants, within the meaning of the
current EC Machinery Directive
2006/42/EC.
Based on the area of validity of these directives, commissioning is prohibited until it has been
absolutely identified that the end product is in conformance with these directives.
The SIMOGEAR gearboxes described in these operating instructions have been designed for
stationary use in general engineering applications in machinery, other partly completed
machinery, or equipment or plants.
Unless otherwise agreed, the gearboxes have been designed for use in plants and equipment
in industrial environments.
The gearboxes have been built using state-of-the-art technology and are shipped in an
operationally reliable condition. Changes made by users could affect this operational
reliability and are forbidden.
The gearboxes have been designed solely for the application described in Technical Data in
the BA 2030 (2KJ4) Operating Instructions for SIMOGEAR gearboxes. Do not operate the
gearboxes outside the specified power limits. Other operating conditions must be
contractually agreed.
Do not climb on the gearbox. Do not place any objects on the gearbox.