Siemens SIMOGEAR BA 2535 Service manual

ORIGINAL MOUNTING AND OPERATING INSTRUCTIONS
Electric monorail gearboxes
Edition 01/2024
BA 2535 - BH, KH
www.siemens.com/simogear
SIMOGEAR

Geared motors
SIMOGEAR electric monorail
gearbox
Operating Instructions
Translation of the original instructions
01/2024
A5E53220855A/RS-AA
Introduction 1
Fundamental safety
instructions 2
Speci󹪝c safety instructions 3
Technical description 4
Incoming goods, transport,
and storage 5
Mounting 6
Commissioning 7
Operation 8
Faults, causes and
remedies 9
Service and maintenance 10
Disposal 11
Technical data 12
Spare parts 13
Declaration of
incorporation of partly
completed machinery,
Declaration of Conformity
14

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.
Quali󹪝ed Personnel
The product/system described in this documentation may be operated only by personnel quali󹪝ed for the speci󹪝c
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Quali󹪝ed 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 Innomotics products
Note the following:
WARNING
Innomotics 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 Innomotics. 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 identi󹪝ed by ® are registered trademarks of InnomoticsGmbH. 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.
Innomotics GmbH
Vogelweiherstr. 1-15
90441 NÜRNBERG
GERMANY
A5E53220855A/RS-AA
Ⓟ 11/2023 Subject to change
Copyright © Innomotics 2024.
All rights reserved

Table of contents
1 Introduction ........................................................................................................................................... 7
1.1 About SIMOGEAR................................................................................................................. 7
1.2 Sales legislation ................................................................................................................... 7
1.3 About this manual ............................................................................................................... 8
1.3.1 Content ............................................................................................................................... 8
1.3.2 Target group ........................................................................................................................ 8
1.3.3 Preventing hazards............................................................................................................... 9
1.3.4 What's new in BA_2535_0619? ............................................................................................ 9
1.3.5 Standard scope .................................................................................................................... 9
1.3.6 Websites of third-party companies...................................................................................... 10
1.4 SIMOGEAR documentation................................................................................................. 10
1.5 Documentation on the Internet.......................................................................................... 11
1.6 Service and support ........................................................................................................... 11
1.6.1 Siemens Industry Online Support on the Web..................................................................... 11
1.6.2 Spare parts services ........................................................................................................... 12
1.7 Important product information .......................................................................................... 12
1.7.1 Use as prescribed............................................................................................................... 12
1.7.2 Predictable incorrect use.................................................................................................... 13
2 Fundamental safety instructions......................................................................................................... 15
2.1 General safety instructions ................................................................................................ 15
2.2 Equipment damage due to electric 󹪝elds or electrostatic discharge ..................................... 20
2.3 Cybersecurity information.................................................................................................. 20
2.4 Residual risks of power drive systems ................................................................................. 22
3Speci󹪝c safety instructions .................................................................................................................. 25
3.1 General overview............................................................................................................... 25
3.2 Installation notes ............................................................................................................... 26
3.3 Speci󹪝c hazard types and fundamental obligations............................................................. 27
4 Technical description ........................................................................................................................... 29
4.1 General technical description ............................................................................................. 29
4.2 Cooling.............................................................................................................................. 29
4.3 Clutch................................................................................................................................ 30
4.4 Rating plate ....................................................................................................................... 30
4.5 Surface treatment.............................................................................................................. 30
4.5.1 General information on surface treatment.......................................................................... 30
4.5.2 Painted version .................................................................................................................. 31
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4.5.3 Primed version................................................................................................................... 33
5 Incoming goods, transport, and storage ............................................................................................. 35
5.1 Incoming goods................................................................................................................. 35
5.2 Transport........................................................................................................................... 35
5.2.1 General information on transport....................................................................................... 35
5.2.2 Fastening for suspended transport ..................................................................................... 36
5.3 Storage.............................................................................................................................. 37
5.3.1 General information for storage ......................................................................................... 37
5.3.2 Storage up to 36months with long-term preservation (optional) ........................................ 37
5.3.2.1 General notes for storage up to 36months......................................................................... 37
5.3.2.2 Gearbox 󹪝lled with operating oil and anti-corrosive agent................................................... 38
5.3.2.3 Gearbox completely 󹪝lled with oil....................................................................................... 38
6 Mounting ............................................................................................................................................. 39
6.1 Unpacking ......................................................................................................................... 39
6.2 General information concerning the installation................................................................. 39
6.3 Thread sizes and tightening torques for fastening bolts....................................................... 40
6.4 Mounting an input or output element on the gearbox shaft................................................ 41
6.5 Mounting the clutch lever .................................................................................................. 43
7 Commissioning .................................................................................................................................... 45
7.1 General information about commissioning ......................................................................... 45
7.2 Checking the oil level prior to commissioning ..................................................................... 45
8 Operation............................................................................................................................................. 47
8.1 General information about operation ................................................................................. 47
8.2 Operating the clutch .......................................................................................................... 47
9 Faults, causes and remedies................................................................................................................ 49
10 Service and maintenance .................................................................................................................... 53
10.1 General notes about maintenance work ............................................................................. 53
10.2 Checking and changing lubricants...................................................................................... 54
10.2.1 General safety instructions................................................................................................. 54
10.2.2 Checking the oil level ......................................................................................................... 55
10.2.3 Checking the oil level using the oil sight glass (optional)..................................................... 56
10.2.4 Checking the oil quality...................................................................................................... 56
10.2.5 Changing the oil ................................................................................................................ 57
10.2.5.1 General safety notes for changing the oil............................................................................ 57
10.2.5.2 Draining the oil.................................................................................................................. 58
10.2.5.3 Flushing the gearbox when changing between incompatible oils........................................ 59
10.2.5.4 Filling in oil........................................................................................................................ 60
10.2.6 Topping up with oil ............................................................................................................ 60
10.2.7 Change the roller bearing grease........................................................................................ 61
10.2.8 Service life of the lubricants ............................................................................................... 61
10.2.9 Recommended lubricants................................................................................................... 63
10.2.10 BA 2535 lubricant table...................................................................................................... 64
Table of contents
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10.3 Replace bearings................................................................................................................ 65
10.4 Checking the gearbox for leaks........................................................................................... 65
10.5 Replacing the vent valve .................................................................................................... 66
10.6 Cleaning the gearbox or geared motor ............................................................................... 66
10.7 Checking the tightness of fastening bolts ........................................................................... 67
10.8 Thread sizes and tightening torques for fastening bolts....................................................... 67
10.9 Inspecting the gearbox ...................................................................................................... 68
11 Disposal ............................................................................................................................................... 69
12 Technical data...................................................................................................................................... 71
12.1 Type designation................................................................................................................ 71
12.2 Rating plate data................................................................................................................ 72
12.2.1 General technical data ....................................................................................................... 72
12.2.2 Rating plate SIMOGEAR geared motors without a UL/CSA design......................................... 72
12.2.3 Rating plate SIMOGEAR geared motors with a UL/CSA design .............................................. 74
12.3 Weight............................................................................................................................... 76
12.4 Sound energy level ............................................................................................................ 76
12.5 Mounting positions and oil quantities................................................................................. 76
13 Spare parts........................................................................................................................................... 79
13.1 Stocking of spare parts....................................................................................................... 79
13.2 Spares on Web ................................................................................................................... 80
13.3 Spare parts lists.................................................................................................................. 81
13.3.1 Electric-monorail-gearboxes BHZ29, BH39, BHZ39.............................................................. 81
13.3.2 Electric-monorail-gearboxes KHF 49 - 79 ............................................................................ 83
14 Declaration of incorporation of partly completed machinery, Declaration of Conformity ................. 85
Table of contents
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Table of contents
SIMOGEAR electric monorail gearbox
6Operating Instructions, 01/2024, A5E53220855A/RS-AA

Introduction 1
Note
The following pages contain the Siemens logo and the Siemens legal information.
Please note that since July 1st, 2023 the Siemens Businesses Large Drives Applications
and Low Voltage Motors are part of InnomoticsGmbH, Germany.
All rights to and product information on the following pages have been transferred from
Siemens to Innomotics.
The re-branding of the document will take place in due course.
1.1 About SIMOGEAR
Description
SIMOGEAR is the Siemens product family of geared motors in Digital Industry.
1.2 Sales legislation
Typical use cases are listed in this product documentation and in the online help to illustrate
possible application areas for our products. These are purely exemplary and do not constitute a
statement relating to the suitability of the respective product for use in speci󹪝c individual cases.
Unless explicitly agreed as part of a contract, Siemens assumes no liability relating to such
suitability. Suitability for a particular application in speci󹪝c individual cases must be assessed by
the user on a case-for-case basis, taking into account all technical, legal and other requirements.
Always observe the descriptions of the technical features and the relevant constraints of the
respective product provided in the product documentation.
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1.3 About this manual
1.3.1 Content
Description
These operating instructions provide you with information about the geared motors and their
associated components. You will learn about safely and professionally handling the geared
motors – from the initial delivery up to 󹪝nal disposal:
• Transporting and storing
• Setup and mounting
• Connecting
• Commissioning
• Testing
• Operating
• Searching for and eliminating faults
• Disassembly
• Disposal
Keeping the documentation in a safe place
This documentation should be kept in a location where it can be accessed. Make the
documentation available to the personnel that have been deployed.
Description
This documentation includes recommendations relating to third-party products. Siemens is
aware of the fundamental suitability of these third-party products. You can use equivalent
products from other manufacturers.
Siemens does not accept any warranty when using third-party products.
1.3.2 Target group
Description
These operating instructions address all personnel who work on a geared motor or use a geared
motor.
Introduction
1.3About this manual
SIMOGEAR electric monorail gearbox
8Operating Instructions, 01/2024, A5E53220855A/RS-AA

1.3.3 Preventing hazards
The safety instructions provided in these operating instructions are intended to avoid personal
injury and material damage. They also guarantee the function and a long service life of the
geared motors.
• Read these operating instructions before handling the geared motors.
• Always follow the safety instructions and notices in these operating instructions.
The warning note concept is explained at the beginning of this documentation.
1.3.4 What's new in BA_2535_0619?
Main changes in this edition
Revisions
• Address changed from Siemens AG to Innomotics GmbH
• Front covers U1 and U4 adapted
1.3.5 Standard scope
Description
This documentation describes the functionality of the standard scope. This scope may di󹪜er
from the scope of the functionality of the system that is actually supplied. The functions of the
system delivered can only be found in the order documents.
Additional functions may be able to be executed in the system, which are not explained
in this documentation. However, these functions cannot be claimed in the case of a new
delivery or service.
This documentation does not contain all detailed information on all product types.
Furthermore, this documentation cannot take into consideration every conceivable type of
installation, operation and service/maintenance.
The machine manufacturer must document any additions or modi󹪝cations made to the
product.
Introduction
1.3About this manual
SIMOGEAR electric monorail gearbox
Operating Instructions, 01/2024, A5E53220855A/RS-AA 9

1.3.6 Websites of third-party companies
Description
This document may contain hyperlinks to third-party websites. Siemens is not responsible for
and shall not be liable for these websites and their content. Siemens does not check the
information that appears on these websites and is not responsible for the content and
information provided there. The user bears the full risk when visiting these websites.
1.4 SIMOGEAR documentation
Description
Comprehensive documentation on SIMOTICS, SIMOGEAR and on the SINAMICS converter family
are provided in Internet (https://support.industry.siemens.com/cs/de/en/ps/13204/man).
You can display documents or download them in the PDF and HTML5 format.
The documentation is divided into the following categories:
Table 1-1 SIMOTICS / SIMOGEAR / SINAMICS documentation
Information Documentation
class1)
Content Target group
General information Con󹪝guration Man‐
ual
Rules, guidelines and tools for con󹪝g‐
uring products, systems, and plants.
Further: Information about the operat‐
ing and ambient conditions for hard‐
ware and software, the use of func‐
tions, as well as about circuit diagrams
and terminal diagrams and the instal‐
lation of software assuming that this is
necessary for commissioning.
Planners, application engineers
Device information Installation Instruc‐
tions
All relevant information on setting up,
installing and cabling as well as the re‐
quired dimension drawings and circuit
diagrams
Installation personnel, commissioning
engineers, service and maintenance
personnel
Introduction
1.4SIMOGEAR documentation
SIMOGEAR electric monorail gearbox
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Information Documentation
class1)
Content Target group
Basic information Operating instruc‐
tions
Comprehensive collection of all infor‐
mation necessary for the safe opera‐
tion of products, plant/system parts
and complete plants (IEC82079)
Machine operators, plant operators
Compact instruc‐
tions
Essential contents of the operating in‐
structions in abbreviated and com‐
pressed form
Machine operators, plant operators
Product Information Information that only becomes known
shortly before or even after start of de‐
livery and is therefore not included in
the associated user documentation
Planners, con󹪝guration engineers,
technologists, installation personnel,
constructors; commissioning engi‐
neers, machine operators, program‐
mers, service and maintenance per‐
sonnel
Online help Instructions for con󹪝guring, program‐
ming and commissioning
Application engineers, programmers,
commissioning engineers
1) Not all documentation classes are available for every SIMOTICS / SIMOGEAR / SINAMICS product.
1.5 Documentation on the Internet
The manuals for the motors, gearboxes and geared motors are available here: SIOS web site
(https://support.industry.siemens.com/cs/ww/en/ps/13424/man)
1.6 Service and support
1.6.1 Siemens Industry Online Support on the Web
Description
The following is available via Siemens Industry Online Support (https://
support.industry.siemens.com/cs/ww/en/), among others:
• Product support
• Global forum for information and best practice sharing between users and specialists
• Local contact persons via the contact person database (→ Contact)
• Information about 󹪝eld services, repairs, spare parts, and much more (→ Services)
• Search for product info
Introduction
1.6Service and support
SIMOGEAR electric monorail gearbox
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• Important topics at a glance
• FAQs (frequently asked questions)
• Application examples
• Manuals
• Downloads
• Compatibility tool
• Newsletters with information about your products
• Catalogs/brochures
1.6.2 Spare parts services
Description
The online spare part service "Spares on Web" o󹪜ers certain spare parts for the product:
• Website: SOW address (https://www.sow.siemens.com/?lang=en).
1.7 Important product information
1.7.1 Use as prescribed
The SIMOGEAR gearboxes described in these Operating Instructions have been developed for
use as travel drives in monorail conveyors.
Unless otherwise agreed, the gearboxes have been designed for use in plants and equipment
in industrial environments.
They are used to transport goods in roofed over industrial applications. They can be used
outdoors if the necessary contractual arrangements are made.
The gearboxes are shipped in an operationally safe condition. Changes made by users could
a󹪜ect 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 di󹪜erent installation altitudes and ambient temperatures, contact Technical Support.
The gearboxes have been designed for only the applications described in theTechnical data
(Page71). Do not operate the gearbox outside the speci󹪝ed power limit. Other operating
conditions must be contractually agreed.
Introduction
1.7Important product information
SIMOGEAR electric monorail gearbox
12 Operating Instructions, 01/2024, A5E53220855A/RS-AA

Do not climb on the gearbox. Do not place any objects on the gearbox.
1.7.2 Predictable incorrect use
WARNING
Injuries due to incorrect use
Death or severe injury can occur if you use the gearbox or the geared motor other than in the
way intended by Siemens. You destroy or damage the gearbox or the geared motor.
Incorrect use includes, for example
• Not complying with the operating instructions
• Not observing the data on the rating plate
• Using the gearbox or geared motor in hazardous zones
• Using the gearbox or geared motor outside the permissible ambient conditions
• Using the gearbox or geared motor as generator
• Using the motor holding brake as an operating brake to reduce the motor speed
• Using the gearbox or geared motor as a result of its size, its weight, its shape or its material
for applications other than those precisely described in this manual
Introduction
1.7Important product information
SIMOGEAR electric monorail gearbox
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Introduction
1.7Important product information
SIMOGEAR electric monorail gearbox
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Fundamental safety instructions 2
2.1 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 quali󹪝ed for this job.
• Always observe the country-speci󹪝c safety rules.
Generally, the following steps apply when establishing safety:
1. Prepare for disconnection. Notify all those who will be a󹪜ected 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 speci󹪝ed 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.
SIMOGEAR electric monorail gearbox
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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 speci󹪝ed 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 in 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
Insu󹪟cient tightening torques or vibration can result in loose power connections. This can
result in damage due to 󹪝re, 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
2.1General safety instructions
SIMOGEAR electric monorail gearbox
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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 speci󹪝ed 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 o󹪜 radio
devices, cellphones or WLAN devices.
• Use the "SIEMENS Industry Online Support App" or a QR code scanner only on equipment
that has already been switched o󹪜.
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.
Fundamental safety instructions
2.1General safety instructions
SIMOGEAR electric monorail gearbox
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WARNING
Unexpected movement of machines caused by inactive safety functions
Inactive or non-adapted safety functions can trigger unexpected machine movements that
may result in serious injury or death.
• Observe the information in the appropriate product documentation before commissioning.
• Carry out a safety inspection for functions relevant to safety on the entire system, including
all safety-related components.
• Ensure that the safety functions used in your drives and automation tasks are adjusted and
activated through appropriate parameterizing.
• Perform a function test.
• Only put your plant into live operation once you have guaranteed that the functions
relevant to safety are running correctly.
Note
Important Safety instructions for Safety Integrated
If you want to use Safety Integrated functions, you must observe the Safety instructions in the
Safety Integrated documentation.
WARNING
Active implant malfunctions due to electromagnetic 󹪝elds
Electromagnetic 󹪝elds (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 this a󹪜ects you, maintain the minimum distance to such equipment that is speci󹪝ed in the
"Important product information" chapter.
WARNING
Active implant malfunctions due to permanent-magnet 󹪝elds
Even when switched o󹪜, electric motors with permanent magnets represent a potential risk for
persons with heart pacemakers or implants if they are close to converters/motors.
• If this a󹪜ects you, maintain the minimum distance to such equipment that is speci󹪝ed in the
"Important product information" chapter.
• 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.
Fundamental safety instructions
2.1General safety instructions
SIMOGEAR electric monorail gearbox
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