© Siemens AG 2015 - 2018. All rights reserved
A5E39968267A/RS-AE, 11/2018 1
SIMOGEAR
Worm geared motor S
KA 2032
Compact Operating Instructions
Translation of the original instructions
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.
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1
General information and safety notes
1.1
General information
ATEX version gearboxes
Instructions and measures applying in particular to ATEX version gearboxes.
For gearboxes in the ATEX version, the operating instructions of the motor supplier must be obse
rved for the
mounted motor.
Note
Siemens
AG does not accept any liability for damage and failures that result from the non-observance of these operating
instructions.
These operating instructions are included with the gearbox or the geared motor when delivered. Keep the operating
instructions close to the geared motor. Please read the operating instructions prior to handling the geared motor and
observe the information they contain. This is the best way of ensuring safe and disturbance-free operation.
These operating instructions apply to the standard version of the SIMOGEAR worm gearbox S frame sizes 09, 19 and 29,
and LA/LE motor frame sizes 63 and 71.
Note
In addition to these operating instructions, special contractual agreements and technical documentation apply to a special
versi
on of the gearbox or the geared motor and the associated supplementary equipment.
Please refer to any other operating instructions supplied with the product.
The described gearboxes or geared motors are 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 augmented with the new contents.
The latest versions of the operating instructions, the declaration of incorporation and the declarations of conformity are
available in electronic form in the Industry Online Support (https://support.industry.siemens.com/cs/ww/de/ps/13424/man).
You can find technical configuration data, spare parts lists and certificates of compliance on the Intranet at Once Delivered
(https://c0p.siemens.com:8443/sie/1nce_delivered).
You can find the contact data of your Technical Support in the Database of contacts at Siemens AG
(www.siemens.com/yourcontact).
If you have any technical questions, please contact Technical Support
(https://support.industry.siemens.com/cs/ww/en/sc/2090).
Europe and Africa
Telephone: +49 911 895 7222
support.automation@siemens.com
America
Telephone: +1 800 333 7421
support.america.automation@siemens.com
Asia / Australia / Pacific
Telephone: +86 400 810 4288
support.asia.automation@siemens.com
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.
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1.3
Use for the intended purpose
ATEX version gearboxes
The ATEX gearbox fulfills the requirements of the Explosion Protection Directive 2014/34/EU.
In the case of ATEX version gearboxes, please observe the instructions marked with this symbol.
The SIMOGEAR worm geared motors described in these operating instructions have been designed for stationary use in
general engineering applications.
They comply with the harmonized standards of the series EN 60034 (VDE 0530). The use of LA/LE motors in hazardous
zones and areas is forbidden.
Unless otherwise agreed, the gearboxes have been designed for use in plants and equipment in industrial environments.
The gearboxes and geared motors are designed and built according to state-of-the-art technology and are shipped in an
operationally safe condition. Changes made by users could affect this operational reliability and are forbidden.
Note
The data on the rating plate assumes an installation altitude of up to 1
000 m above sea level.
The permissibl
e ambient temperature is stamped on the rating plate.
For different installation altitudes and ambient temperatures, contact Technical Support.
The gearboxes and geared motors have been designed solely for the application described in the technical data. Do not
operate
the gearbox or the geared motor outside the specified power limit. Other operating conditions must be contractually
agreed.
Do not climb on the gearbox. Do not place any objects on the gearbox or the geared motor.
1.4
Obligations of the user
The operator must ensure that all persons assigned to work on the geared motor have read and understood these operating
instructions and that they follow them in all points in order to:
● Eliminate the risk to life and limb of users and other persons.
● Ensure the operational safety of the geared motor.
● Avoid disruptions and environmental damage through incorrect use.
Note the following safety information:
Shut down the geared motors and disconnect the power before you carry out any work on them.
Make sure that the drive unit cannot be turned on accidentally, e.g. lock the key-operated switch. Place a warning notice at
the drive connection point which clearly indicates that work is in progress on the geared motor.
Carry out all work with great care and with due regard to "safety".
For all work, observe the relevant regulations for work safety and environment protection.
Read the instructions on the rating plates attached to the geared motor. The rating plates must be kept free from paint and
dirt at all times. Replace any missing rating plates.
In the event of changes during operation, switch off the drive unit immediately.
Take appropriate protective measures to prevent accidental contact with rotating drive parts, such as couplings, gear wheels
or belt drives.
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.
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Do not carry out any welding work on the geared motor. Do not use the geared motor as a grounding point for welding
operations.
Carry out equipotential bonding in accordance with applicable regulations and directives by electrotechnology specialists.
Do not use high-pressure cleaning equipment or sharp-edged tools to clean the geared motor.
Observe the permissible tightening torque of the fastening bolts.
Replace damaged bolts with new bolts of the same type and strength class.
Siemens AG accepts the warranty only for original spare parts.
The manufacturer who installs the geared motors in a plant must include the regulations contained in the operating
instructions in its own operating instructions.
1.5
The five safety rules
For your own personal safety and to prevent material damage when carrying out any work, always observe the safety-
relevant instructions and the following five safety rules according to EN 50110-1 Working in a voltage-free state. Apply the
five safety rules in the sequence stated before starting work.
Five safety rules
1. Disconnect.
Also disconnect the auxiliary circuits, for example the anti-condensation heating.
2. Secure against reconnection.
3. Verify absence of operating voltage.
4. Ground and short circuit.
5. Cover or safeguard neighboring live parts.
After the work has been completed, undo the measures taken in the reverse order.
1.6
Particular types of hazards
WARNING
Extreme surface temperatures
Hot surfaces over +55 °C pose a burn risk.
Cold surfaces below 0 °C pose a risk of damage due to freezing.
Do not touch the gearbox without protection.
WARNING
Hot, escaping oil
Before starting any work wait until the oil has cooled down to below +30 °C.
WARNING
Poisonous vapors when working with solvents
Avoid breathing in vapors when working with solvents.
Ensure adequate ventilation.
WARNING
Risk of explosion when working with solvents
Ensure adequate ventilation.
Do not smoke!
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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.
2
Technical description
2.1
General technical description
The gearbox housing is made from die-cast aluminum. The gear is manufactured from high-quality bronze. The gearbox is
lubricated for life with high-quality synthetic oil.
The motor complies with the following regulations:
Table 2-1 Overview of the standards
Topic
Standard
Dimensions and operation characteristics
EN 60034-1
Degree of protection
EN 60034-5
Cooling
EN 60034-6
Mounting position according to modular system
EN 60034-7
Terminal marking and direction of rotation
EN 60034-8
Noise emission
EN 60034-9
Thermal protection
EN 60034-11
Starting characteristics for rotating electrical motors
EN 60034-12
Vibration severity levels
EN 60034-14
IEC standard voltages
IEC 60038
Safety of machinery
EN 60204-1
The motor is equipped with grease-lubricated roller bearings. The bearings are permanently lubricated.
In the standard version, the rotor corresponds to vibration severity level A.
The technical data for the optional monitoring equipment can be viewed in the circuit diagrams, on the rating plate or in the
special order documents.
The stator housing and bearing shields are made of die-cast aluminum or cast iron.
The surface of the stator housing is equipped with cooling fins and a mounted terminal box or motor connector.
2.2
Shaft seals
The shaft sealing rings on the output side prevent lubricant from escaping from the housing at the shaft outlet and prevent
pollution from entering the housing.
The optimum use of the seals depends on the ambient conditions and the lubricant being used.
Radial shaft sealing ring
A high-quality radial shaft sealing ring is used as standard seal. The ring is provided with an additional dust lip to protect
against contaminants from outside.
Permitted oil sump temperatures from -40 °C to +80 °C.
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High temperature-resistant seal (optional)
Radial shaft seals made from a temperature-resistant material are used and are able to tolerate higher temperatures.
Permitted oil sump temperatures from -25 °C to +110 °C.
2.3
Cooling
NOTICE
Dust deposits prevent heat radiation.
Dust deposits prevent heat radiation and cause a high housing temperature.
Keep the geared motor 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
Technical Support.
The motor is designed to be cooled by means of fins. An external fan draws in the cooling air through the aperture in the fan
cover and blows the air over the surface of the stator housing.
2.4
Rating plate
The rating plate on the gearbox or geared motor is made 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.
2.5
Surface treatment
2.5.1
General information on surface treatment
Standard-version gearboxes or geared motors are not painted at the factory. If necessary, they can be painted with any kind
of commercially available paint.
tatic charge must be avoided.
Fast air with high dust content directed past the gearbox
Sudden escape of compressed gases that contain particles
Harsh abrasive processes (this does not mean manual cleaning / wiping with cleaning cloths)
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WARNING
Danger due to electrostatic discharge
For paint finishes in explosion group III, the paint can be electrostatically charged as a result of intensive dust turbulence or
processes with high levels of electrostatic charging.
Risk of explosion as a result of processes with high levels of electrostatic charging
Minimize the risk of electrostatic charging by applying effective measures according to IEC 60079-32-1.
NOTICE
Failure of the external protection
Do not damage the paint finish.
NOTICE
Destruction of the seals
Sealing lips must not come into contact with paint.
Cover the shaft sealing rings.
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 the quality and compatibility.
Note
C1 paints are not suitable for ambient air temperatures under
-20 °C.
2.5.2
Painted version
The corrosion protection system is classified according to the corrosiveness categories in DIN EN ISO 12944-2.
Table 2-2 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 - hydropaint, 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
Corrosiveness category C2 for low environmental stress
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
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Paint system
Description
Corrosiveness category C3 for medium environmental stress
2-component epoxy zinc phosphate 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%)
In case of corrosiveness category C1, overpainting with a 1-component - hydrosystem after prior rubbing down is possible.
2.5.3
Primed version
Table 2-3 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 epoxy zinc phosphate,
desired coat thickness 60 μm
• 2-component - polyurethane paint
• 2-component - epoxy paint
• 2-component - acrylic paint
•
Acid-hardening paint
2.6
ATEX ignition hazards in accordance with DIN EN 80079-37
ATEX version gearboxes
ATEX marking
Regardless of the type of protection, the letter »h« is always assigned. In addition to the marking on the rating
plate, the valid types of protection below are applied:
Constructional safety "c"
The constructional safety is ensured by the selection of suitable materials and components, the dimensioning
of the product for the customer's application, suitable sealing systems, adequate lubr
ication of rolling bearings,
geared components and seals, and
by thermal testing.
Liquid immersion "k"
The liquid immersion is achieved through oil bath lubrication. Refer to the rating plate and the Op
erating
I
nstructions for the original oil filling.
Control of ignition sources "b"
Control of ignition sources is achieved by a temperature check and/or electrical oil level check.
ATEX version gearboxes
Servicing and maintenance work that are relevant for the type of protection shall only be carried out by
SIEMENS service personnel or by SIEMENS authorized partners.
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3
Incoming goods, transport, and storage
3.1
Incoming goods
NOTICE
Transport damage impairs correct functioning
Do not commission faulty gearboxes or geared motors.
Note
Do not open or damage parts of the packaging that preserve the product.
Note
Check that the technical specifications are in accordance with the purchase order.
Inspect the delivery immediately on
arrival for completeness and any transport damage.
Notify the freight company of any damage caused during transport immediately (this is the only way to have damage
rectified free of charge). Siemens AG will not accept any claims relating to items missing
from the delivery and which are
submitted at a later date.
The gearbox or geared motor is delivered in a fully assembled condition. Additional items are sometimes delivered packaged
separately.
The products supplied are listed in the dispatch papers.
3.2
Transport
NOTICE
The use of force will damage the gearbox or geared motor
Transport the gearbox or geared motor carefully. Avoid knocks.
Before putting the drive into operation, remove any transport fixtures and keep them safe or render them ineffective. You
can then use them again for transporting further items or you can apply them again.
Different forms of packaging may be used, depending on the size of the gearbox or geared motor and the method of
transport. Unless contractually agreed otherwise, the seaworthy packaging complies with HPE Packaging Guidelines
(Bundesverband Holzpackmittel Paletten Exportverpackungen e.V., the German Federal Association for wooden packaging,
pallets, and export packaging).
Note the symbols which appear on the packaging. These have the following meanings:
This way up
Center of gravity
Fragile
Do not use hand hook
Keep dry
Attach here
Keep cool
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3.3
Storage
WARNING
Injuries and damage
Danger of serious injuries caused by falling objects.
Danger of damage to the geared motor when stacked.
Do not stack gearboxes or geared motors on each other.
Unless contractually agreed otherwise, the warranty period for the standard preservative lasts 6 months from the date of
delivery.
In the case of storage in transit over 6 months, special arrangements must be made for preservation. Contact the Technical
Support.
Store the gearbox or geared motor in dry, dust-free rooms that are maintained at a constant temperature.
The storage location must be vibration- and shock-free.
The free shaft ends, sealing elements and flange surfaces must have a protective coating.
Do not store the geared motor on the fan cover.
4
Assembly
4.1
Unpacking
NOTICE
Transport damage impairs the correct function of the geared motor
Never commission faulty or defective geared motors.
Check the geared motor for completeness and for damage. Report any missing parts or damage immediately.
Remove and dispose of the packaging material and transport equipment in compliance with regulations.
4.2
General information concerning the installation
ATEX version gearboxes
Effect on bearings of stray electric currents from electrical equipment.
When mounting the gearbox on or connecting it to the machine, take care to ensure potential equ
alization. The
information on grounding and equipotential bonding provided by the motor supplier must be observed.
WARNING
Operating under load
Under load, the system can start or reverse in an uncontrolled fashion.
The entire system must be load-free so that there is no danger during this work.
NOTICE
Destruction caused by welding
Welding destroys the geared parts and bearings.
Do not weld on the gearbox or the geared motor. The gearbox or the geared motor must not be used as a grounding point
for welding operations.
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NOTICE
Overheating caused by solar radiation
Overheating of the gearbox or the geared motor due to exposure to direct sunlight.
Provide suitable protective equipment such as covers or roofs. Prevent heat accumulation.
NOTICE
Malfunction resulting from foreign objects
The operator must ensure that no foreign objects impair the function of the geared motor.
Note
Use headless screws of strength class
8.8 or higher to fasten the motor to the gearbox.
Exercise particular care during mounting and installation. The manufacturer cannot be held liable for damage caused by
incorrect mounting and installation.
Make sure that there is sufficient space around the gearbox or geared motor for mounting, maintenance and repair.
On geared motors with a fan, leave sufficient free space for the entry of air. Observe the installation conditions for the
geared motor.
Provide sufficient lifting gear at the start of mounting and fitting work.
Use all the fastening means that have been assigned to the particular mounting position and mounting type.
Cap screws cannot be used in some cases due to a lack of space. In such cases, please contact Technical Support quoting
the type of gearbox.
Please observe Checking tightness of fastening bolts (Page 28).
4.3
Installation conditions for the motor
NOTICE
Danger of overheating due to insufficient cooling
Protect intake and outlet ports against blockages and coarse dust.
The cooling air must flow unimpeded into the air inlets and flow out through the air outlets. Exhaust air should not be drawn
back in again.
Figure 4-1 Installation condition for the SIMOGEAR motor
The permissible coolant temperature (ambient temperature at installation location) is -20° C to +40° C as standard for an
installation altitude of up to 1 000 m above sea level. Deviating data are specified on the rating plate.
For the vertical mounting position with the fan cover facing upwards, provide protection to prevent foreign objects falling in,
e.g. with an appropriate cover.
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4.4
Gearbox with foot mounting
NOTICE
Impermissible housing loadings when unevenness present
Do not subject the gearbox to excessive stress when tightening the fastening screws.
The foundation must be level and free from dirt.
The deviation in flatness of the gearbox's contact surface must not exceed 0.1 mm.
The foundation should be designed in such a way that no resonance vibrations are created and no vibrations are transmitted
from adjacent foundations.
The foundation structure on which the gearbox is to be mounted must be torsionally rigid. It must be dimensioned according
to the weight and torque, taking into account the forces acting on the gearbox. If the substructure is too weak, it will cause
radial or axial displacement offset during operation. The displacement cannot be measured at a standstill.
If the gearbox is fastened to a concrete foundation, use foundation blocks for the appropriate recesses.
Align and grout the slide rails into the foundation.
Align the gearbox carefully with the units on the input and output side. Take into account the elastic deformation due to
operating forces.
Prevent displacement from external forces due to lateral impacts.
Use stud bolts or headless M8 size screws of strength class 8.8 or higher for the mounting foot. Observe the tightening
torque.
4.5
Gearbox with C-type housing flange
The gearbox with C-type housing flange is delivered ready for mounting on machines. It is mounted using an inner centering.
Depending on the version, the sealing rings are pressed in deeper at the DE and/or NDE so that simple mounting is
ensured.
Note
If the inserted sealing ring is located on the top of the gearbox, neither water nor dirt can collect. We recommend the use o
f
a protection cover (optional).
4.6
Mounting an input or output element on the gearbox shaft
WARNING
Risk of burns caused by hot parts
Do not touch the gearbox without protection.
NOTICE
Damage to shaft sealing rings caused by solvent
Avoid any contact of solvent or benzine with the shaft sealing rings.
NOTICE
Damage to shaft sealing rings caused by heating
Use thermal shields to protect shaft sealing rings from heating above 100 °C due to radiant heat.
NOTICE
Premature wear or material damage due to misalignment
Misalignment caused by excessive angular or axis displacement to the connecting shaft ends.
Ensure precise alignment of the individual components.
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NOTICE
Damage caused by improper handling
Bearings, housing, shaft and locking rings are damaged due to improper handling.
Do not use impacts or knocks to force the input and output elements to be mounted onto the shaft.
Note
Deburr the parts of elements to be fitted in the area of the hole or keyways.
Recommendation:
0.2 x 45°
Where couplings are to be fitted in a heated condition, observe the specific operating instructions for the coupling. Unless
otherwise specified, apply the heat inductively using a torch or in a furnace.
Use the center holes in the shaft end faces.
Use a fitting device to fit the input or output elements.
Figure 4-2 Example of a fitting device
Observe the correct mounting arrangement to minimize stress on shafts and bearings due to lateral forces.
Correct
Incorrect
a
Hub
F
Force
Figure 4-3 Mounting arrangement for low stress on shafts and bearings
Procedure
1. Use either benzine or solvent to remove the anti-corrosion protection from the shaft ends and flanges or remove the
applied protective skin.
2. Fit the drive input and output elements to the shafts. Fasten the elements when necessary.
You have now fitted the input or output element.
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4.7
Removing and installing the protection cover
The protection cover of the hollow shaft is delivered ready-fitted to the gearbox flange. Dismantle the protection cover for
installation of the output shaft.
①
Screw
③
Flat seal
②
Protection cover
④
Gearbox housing
Figure 4-4 Protection cover for hollow shaft
Procedure
1. Unscrew the screws ① and remove the protection cover ② together with the flat gasket ③.
2. Fit the output shaft.
3. Use a suitable cleaning agent to clean the contact surface of the protection cover ② on the gearbox.
4. Ensure that the flat seal ③ is correctly seated.
5. Wet the screws ① with medium-strength adhesive, e.g. Loctite 243.
6. Screw on the protection cover ②.
7. Protect all remaining bare areas with a suitable permanent anti-corrosive agent.
You have now installed the protection cover for operation.
4.8
Installing and removing the shaft-mounted gearbox
4.8.1
General information on installing the shaft-mounted gearbox
NOTICE
Damage to shaft sealing rings caused by solvent
Avoid any contact of solvent or benzine with the shaft sealing rings.
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NOTICE
Subjecting stress to the hollow shaft causes bearing failure
Skewing or stressing the hollow shaft increases the loading. This can cause bearing failure.
The hollow shaft must be flush with the machine shaft to avoid misalignment.
Do not subject the hollow shaft to axial and radial stress.
Note
Coat the contact surfaces with the mounting paste supplied with the
product or any suitable lubricant to prevent frictional
corrosion.
Note
Observe the permissible concentricity tolerance of the cylindrical shaft end of the machine shaft to the housing axle
according to DIN
42955.
4.8.2
Mounting the hollow shaft with feather key
*
Not included in scope of supply
①
Machine shaft / plug-in shaft
⑥
Circlip
②
Hollow shaft
⑦
Feather key
③
Hexagon nut
⑧
Mounting paste
④
Threaded spindle
⑨
Screw
⑤
Disk
⑩
Sealing caps
Figure 4-5 Mounting the hollow shaft with feather key
Procedure
1. Use benzine or a solvent to remove the anti-corrosion protection from the shaft ends and flanges.
2. Check the seats or edges of the hollow and machine shaft / plug-in shaft for damage. Contact Technical Support if you
notice any damage.
3. Apply the mounting paste ⑦ to the machine shaft / plug-in shaft ①. Apply the paste uniformly.
4. Fit the gearbox using the disk ⑤, threaded spindle ④ and nut ③. Support is provided by the hollow shaft ②.
5. Replace the nut ③ and the threaded spindle ④ with a screw ⑨. Tighten the screw ⑨ to the specified torque.
6. Close the open hollow shaft end using a sealing cap ⑩.
You have now mounted the hollow shaft with feather key.
Table 4-1 Tightening torque for the screw
Thread size
M5
M6
M8
M10
Tightening torque [Nm]
5
8
8
14
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4.8.3
Removing the hollow shaft
WARNING
Inadequately secured gearbox or geared motors can free themselves
Before driving out the machine shaft, fasten a suitably dimensioned means of absorbing load to the gearbox.
Slightly pretension the pulling equipment so that the gearbox does not drop onto it when the plug-in shaft is released.
NOTICE
Subjecting stress to the hollow shaft causes bearing failure
It is essential to prevent misalignment when removing the unit.
Note
If frictional corrosion has occurred on the seat surfaces, use
rust solvent to facilitate the removal of the gearbox. Allow an
adequately long time for the rust solvent to take effect.
Items ① to ⑤ are not included in the scope of supply.
①
Disk
②
Threaded block
③
Feather key
④
Hexagon nut
⑤
Threaded spindle
Figure 4-6 Removing the hollow shaft with feather key
Procedure
1. Remove the axial locking element from the hollow shaft.
2. Drive out the machine shaft using the disk ①, threaded block ②, feather key ③, threaded spindle ⑤ and hexagon
nuts ④.
You have now removed the hollow shaft.
Design suggestion for threaded block and disk
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Frame size
b10
b11
b12
d10
d11
s11
tmax
u
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
[mm]
09
3
5
-
15.9
-
M5
18
5
19
3
6
-
17.9
-
M6
20.5
6
29 3 15 10
19.9
10
M6
22.5
6
24.9
14
M8
28
8
4.9
Torque arms with shaft-mounted gearboxes
Torque arms can absorb the reaction torque and the weight force of the gearbox.
ATEX version gearboxes
Worn or irreparably damaged rubber elements do not function properly.
Impacts can cause sparks.
Damaged rubber elements must be replaced immediately.
NOTICE
Dangerous transient torques due to excess backlash
Take care to prevent the torque arm from causing excessive constraining forces, e.g. due to the driven shaft running
out-of-true.
NOTICE
Impermissible gearbox loading caused by incorrect mounting
Do not tension torque arms when mounting.
The torque arm bush must be supported by bearings on both sides.
NOTICE
Damage to the rubber elements caused by solvent
Solvents, oils, greases, and fuels damage rubber elements.
Avoid contact at all times.
Figure 4-7 Attaching the torque arm
The torque arm can be fitted in various positions, depending on the hole circle pitch.
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Figure 4-8 Toggle lever design
For a toggle lever design, derive the force in the range of 90° ±20°.
Procedure
1. Clean the contact surfaces between the housing and the torque arm.
2. Tighten the M6 screws to 10 Nm torque.
You have now mounted the torque arm.
4.10
Mounting the motor
NOTICE
Moisture penetrates an inadequately sealed geared motor
If the geared motor is to be installed outdoors or for an installation requiring a high degree of protection (≥ IP55):
• Seal the flange, screws or integrated elements using an appropriate sealing compound.
• The flange-mounted motor must be sealed across the entire contact surface.
•
Seal the geared motor in the outer area.
Figure 4-9 Motor assembly
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4.11
Connecting the motor in the terminal box
4.11.1
General information on motor connection
DANGER
Unintentional starting of the drive unit
Any work on the stationary machine must be performed with the machine isolated from the supply and secured so that it
cannot be switched back on again. This also applies to auxiliary circuits, e.g. anti-condensation heating.
Check that the unit is in a no-voltage condition.
Deviations in the voltage, frequency, curve shape and/or symmetry of the line feed increase the heating.
This also affects the electromagnetic compatibility.
Before starting work, make sure that a protective conductor is securely connected.
Note
Pre
-assembled conductors may only be used with fixed routed at temperatures below -30 °C.
Alternating bends are not allowed at these temperatures.
Connect the motor in such a way that a permanently safe electrical connection is ensured. Wire ends must not protrude. Use
matching cable end pieces.
Connect the line supply voltage in the terminal box. Arrange the disconnecting link according to the circuit diagram for star or
delta connection in the terminal box.
Select the connection cables according to DIN VDE 0100. Take into account the rated current and the plant-specific
conditions.
The following required information for connection is specified in the technical data:
● Direction of rotation
● Number and arrangement of the connections
● Circuit / connection of the motor winding.
4.11.2
Terminal box
NOTICE
Electrical connections can loosen
Please observe the tightening torques for cable glands, nuts and bolts.
When performing a test run, secure the featherkeys without output elements.
NOTICE
Malfunctions
It must be ensured that there are no foreign bodies, dirt or moisture in the terminal box.
The terminal box must be sealed so that dust and water cannot enter.
Seal the terminal box with the original seal. Seal cable entries to the terminal box and other open cable entries with an
O-ring or suitable flat gasket.
Do not damage the terminal box or other functional parts inside the terminal box.
Note
For a standard terminal board with 6
terminal studs, the terminal box can be turned 4 x 90 degrees on the terminal base of
the stator housing.
The temperature sensor and anti-condensation heating are connected in the terminal box.
Please note that the motor degree of protection is only obtained after correctly connecting up and tightening the cable glands
and blanking plugs.
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4.11.3
Terminal marking
For terminal designations, the following principle definitions apply to three-phase motors:
Table 4-2 Terminal designations using the example 1U1-1
1
U
1
-
1
Designation
x Index showing the pole assignment for pole-changing three-phase motors
(lower number = lower speed)
or, in special cases, for a subdivided winding
x
Phase designation (U, V, W)
x Index showing winding start (1)
Index showing winding end (2)
Additional indexes if there is more than one connection per winding
x Additional indices if it is obligatory to connect parallel line feeder cables to several terminals
with otherwise identical designations
4.11.4
Direction of rotation
The motors are suitable for clockwise and counter-clockwise rotation.
When the line feeder cables are connected in the phase sequence L1, L2, L3 to U, V, W, the motor rotates clockwise when
looking at the drive end of the shaft extension (DE). If two of the connections are swapped, the resulting direction of rotation
is counter-clockwise, e.g. L1, L2, L3 to V, U, W.
In the case of geared motors intended for only one direction of rotation, e.g. with backstop, the prescribed direction of
rotation is marked by a direction arrow on the geared motor.
Table 4-3 Direction of rotation of the geared motor with a view of the output shaft
Gearbox type
View of
Direction of rotation
Output shaft
Input shaft
NO
DE of the output shaft
Right
Left
NDE of the output shaft
Right
4.11.5
Connecting the cables in the terminal box
Note
Direct contact between the cable lug surfaces and the contact nuts ensures that the connection can carry current.
In the case of terminals with terminal clamps, distribute the conductors in such a way that the clamping heights are about the
same on both sides of the fillet. This method of connection requires a single conductor to be bent into a U shape or
connected with a cable lug. The same applies to the inner and outer terminals of the ground conductor.
Select the cable lug size according to the required cable cross-section and stud size. A sloped / angular arrangement is
permitted if the required clearances and creepage distances are maintained.
Remove the insulation from the conductor ends so that the remaining insulation is almost long enough to reach the cable
lug.
4.11.6
External grounding
Ensure the following when making connections:
● The connecting surface must be bare. Protect the surface against corrosion with a suitable substance, e.g. acid-free
Vaseline.
● Insert the cable lug between the contact bracket and the grounding bracket. Do not remove the contact bracket which is
pressed into the housing.
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● Place the spring washer under the screw head.
● Observe the tightening torque for the locking screw, see Installation and routing (Page 21).
Table 4-4 Maximum conductor connection for external grounding
Motor size
Thread size
63 … 71
M4
4.11.7
Installation and routing
Note
Match the screw connection to the connection cable used:
•
Seal insert
•
Armor
•
Braid
• Shielding
Screw the screw connection into the housing. Or secure the screw connection with a locknut.
Terminal board connection
Table 4-5 Tightening torque for terminal board connection
Thread size
Tightening torque [Nm]
Min.
Max.
M4
0.8
1.2
Type of conductor connection
Angle DIN cable lug down for connection. DIN 46234
Connection of an individual conductor with the terminal clamp.
Connection of two conductors of approximately the same thickness with the terminal clamp.
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①
Link rail
②
Line connecting cable
③
Motor connecting cable
④
Cover washer
Grounding connection type
Connection of an individual conductor under the external
grounding bracket.
Connect with the DIN cable lug under the external
grounding bracket DIN 46234.
Cable gland
NOTICE
Damage to the cable jacket
An excessively high tightening torque with a different cable jacket material will damage the cable jacket.
When different cable jacket materials are used, apply a lower tightening torque.
For metal or plastic cable glands, please use the following tightening torques for direct mounting. The O-ring cross-section is
2 mm.
Table 4-6 Tightening torque for cable glands and blanking plugs
Thread size
Tightening torque [Nm] ±10%
Metal
Plastic
M16 x 1.5
10
4
M25 x 1.5
12
4.12
Operation on the converter
Permissible voltage stress
NOTICE
Damage to the motor insulation
The motor insulation will be damaged by impermissible voltage peaks produced by converters without an output filter.
Reduce the maximum motor voltage to noncritical values by using an output filter on the converter.
The table below shows a comparison between the maximum admissible peak-peak voltage at the motor terminal as
stipulated by DIN EN 60034-18-41 and the peak-peak voltage tolerance of SIMOTICS insulation systems.
Line voltage UN
400 V
480 V
IVIC C
Siemens1
IVIC C
Siemens1
Û
phase-to-ground
1 680
2 200
2 016
2 200
Û
phase-to-phase
2 360
3 000
2 832
3 000
1 The information specified refers to the standard (basic) insulation system. Other insulation systems on request.
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The following applies for the voltage rise time: Ta > 0.3 ± 0.2 μs.
The voltages specified are peak-peak values (Vpk/pk).
Bearing currents
Additional bearing currents due to steep voltage edges when switching. Without output filters, significant voltage variations
can occur at the winding terminals. Make sure the drive system is installed in accordance with EMC requirements.
Mechanical stress and grease lifetime
High speeds that exceed the rated speed and the resulting increased vibrations alter the mechanical running smoothness
and the bearings are subjected to increased stress. This reduces the service life of the grease and bearings.
Optional add-on units
Connect the temperature sensor of the monitoring system and the anti-condensation heating according to the appropriate
circuit diagram. Only switch on the anti-condensation heating after the motor has been switched off.
5
Commissioning
5.1
General information for commissioning
WARNING
Unintentional starting of the drive unit
Secure the drive unit to prevent it from being started up unintentionally.
Attach a warning notice to the start switch.
WARNING
Risk of slipping on oil
Remove any oil spillage immediately with an oil-binding agent in compliance with environmental requirements.
WARNING
Hazardous voltage and rotating parts
Before starting commissioning, mount the covers required for the correct air guidance. Avoid contact with active, live or
rotating parts.
5.2
Checking the insulation resistance
Only qualified personnel may work on power installations.
WARNING
Hazardous voltage at the terminals
In some cases, the terminals can be at hazardous voltage levels during the measurement and immediately afterwards. The
terminals must not be touched.
Carry out a check on the power cables connected to ensure that no voltage can be applied.
Note
The insulation resistance must be checked before commissioning and after lengthy periods of storage or non
-use.
Before you begin measuring the insulation resistance, please read the operating manual for the insulation resistance meter
you are going to use. Before measuring the insulation resistance, disconnect any main circuit cables that are connected to
the termin
als.
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Note
If the critical insulation resistance is less than or equal to this value, the windings must be dried or, if the fan is remov
ed,
cleaned thoroughly and dried.
Note that the insulation resistance of dried, clean windings is lower than that of w
arm windings. The insulation resistance
can only be properly assessed after conversion to the reference temperature of +25° C.
If the measured value is close to the critical value, you must check the insulation resistance at suitably frequent intervals
.
Measure the minimum insulation resistance of the winding to the motor housing at a winding temperature between +20° C
and +30° C. Other insulation resistance values apply to temperatures outside this range. When making the measurement,
wait until the final resistance value is reached, approx. 1 minute.
Measure the critical insulation resistance at the operating temperature of the winding.
Limit values
The following limit values are valid for the insulation resistance at a rated voltage of UN < 2 kV and a winding temperature of
+25° C.
500 V
Measurement voltage
10 MΩ Minimum insulation resistance for new, cleaned or repaired windings
0.5 MΩ/kV
Critical specific insulation resistance after a long operating time
Note the following:
● If you measure a winding temperature other than +25° C, convert the measured value to the reference temperature
+25° C. The insulation resistance is halved for every 10 K increase in temperature, and it is doubled for every 10 K
decrease in temperature.
● If the insulation resistance is close to or below the minimum value, the cause could be humidity and dirt accumulation.
Dry the windings.
● During operation, the insulation resistance of the windings can fall to the critical insulation resistance due to ambient and
operational influences. To calculate the critical insulation resistance value for a winding temperature of +25° C, multiply
the rated voltage kV by the specific critical resistance value (0.5 MΩ/kV). Example: Rated voltage
UN 690 V: 690 V x 0.5 MΩ/kV = 0.345 MΩ.
5.3
Checking the motor
Note
Protect the motor against overload.
Do not exceed or undershoot limit speeds, e.g
during operation with a backstop.
Note
With a brake motor:
Before commissioning, check the constancy of the rated air gap of the brake. The brake motor must be
current-free. Check
the gap between the armature disk and the solenoid at 3
points with a feeler gauge.
Note
Additional tests are also required, depending on the particular plant
-specific situation.
After checking and ensuring the following items, you can start commissioning the motor:
● Compare the details on the rating plate with the operating conditions.
● Compare the voltage and frequency of the motor with the line supply values.
● Check the direction of rotation.
● A Y / Δ start is switched from star to delta when the starting current of the star stage has decayed.
● Check that the electrical connections are fixed securely.
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● Check all the touch protection measures for both moving and live parts.
● Check that the monitoring instruments are connected and set correctly.
● Check the coolant temperature.
● Check any supplementary equipment being used.
● Check that air inlet ports and cooling surfaces are clean.
● Create the appropriate connections for grounding and equipotential bonding.
● Properly mount and fix the motor.
● Check that the ventilation is not impeded and that the discharged air - including that from adjacent units - cannot be
drawn back in.
● Check the belt tension if a belt drive is being used.
● Seal the terminal box cover and seal the cable entries.
5.4
Commissioning a geared motor
After mounting, the geared motor is ready for use.
Procedure
1. Run the geared motor for a short period of time under no-load operation.
2. Check for any irregularities such as oil leakages, strong vibration and noise.
3. Switch in the load.
4. Allow the geared motor to run.
The running-in process should take approximately 24 hours of operation at full load. In most cases, the catalog values
will then be reached.
You have now started up the geared motor.
6
Operation
ATEX version gearboxes
The difference between the temperature of the housing and the ambient temperature of max.
+40° C must not
exceed 70
K.
Using a suitable temperature sensor, measure the temperature at the
lowest point of the housing (oil sump) or
at the mounting surface in the case of output units. We recommend that you monitor the gearbox temperature
indirectly by monitoring the motor current.
Changes are an indication of possible incipient damage.
CAUTION
Malfunctions can cause injuries or gearbox damage
In the event of changes during operation, the drive unit must be switched off immediately.
Determine the cause of the fault using the fault table. Remedy faults or have faults remedied.
Check the gearbox or the geared motor during operation for:
● Excessive operating temperature
● Changes in gear noise
● Possible oil leakage at the housing and shaft seals
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7
Faults, causes and remedies
Note
Faults and malfunctions that occur during the warranty period and requiring repair work on the gearbox must
be remedied
only by Technical Support. If faults occur without a clearly identifiable cause, Siemens
AG recommends the services of the
Technical Support even after the warranty period has elapsed.
If you need the help from the Technical Support, please ha
ve the following information ready:
•
Rating plate data
•
Nature and extent of the fault
• Suspected cause
8
Service and maintenance
8.1
General notes about maintenance work
ATEX version gearboxes
All measures, checks, and their results must be documented by the operator and records kept in a safe place
for 10 years.
WARNING
Unintentional starting of the drive unit
Secure the drive unit to prevent it from being started up unintentionally.
Attach a warning notice to the start switch.
NOTICE
Improper maintenance
Only authorized qualified personnel may perform the maintenance and servicing. Only original parts supplied by
Siemens AG may be installed.
Note
The gearbox is lubricated for life.
Lubricant changes are not required.
Only qualified personnel may perform the inspection, maintenance and servicing work. Please observe the General
information and safety notes.
Table 8-1 Maintenance measures
Measure
Time interval
Description of the work
Monitor and check the geared motor for
unusual noise, vibrations, and changes.
Daily; if possible, more frequently
during operation.
Operation (Page 25)
Check the housing temperature. After 3 hours, on the first day,
thereafter monthly.
Check the gearbox for leaks. After the first day, thereafter monthly. Checking the gearbox for leaks
(Page 27)
Clean the geared motor. Depending on degree of soiling, at
least every 6 months.
Cleaning a geared motor (Page 27)
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Measure
Time interval
Description of the work
Check that fastening screws on
gearboxes and add-on elements are
securely tightened. Check that covers
and plugs are securely fastened.
After 3 hours, and then every 2 years. Checking tightness of fastening bolts
(Page 28)
Check the torque arm's plastic bushing. Every 6 months. Torque arms with shaft-mounted
gearboxes (Page 17)
8.2
Checking the gearbox for leaks
Oil or grease escaping in small quantities from the shaft sealing ring should be regarded as normal during the running-in
phase of 24 hours operating time.
If the quantities escaping are significant or leaking continues after the running-in phase, the shaft sealing ring must be
replaced to prevent consequential damage.
Shaft sealing rings are subject to natural wear. The service life depends on the operating conditions. We recommend that
shaft sealing rings are included in periodic maintenance and servicing work on the system.
Table 8-2 Description and measures
Status
Description
Measures
Notes
Film of moisture on the
shaft sealing ring
Film of moisture as a result
of the inherent principle of
operation (apparent leakage)
Remove using a clean cloth
and continue to observe.
This does not represent a fault;
frequently, in the course of
operation, the sealing ring dries off.
Leakage at the shaft
sealing ring
Identifiable small trickle,
formation of drops, also after
the running-in phase
Replace the sealing ring,
determine the possible
cause of the sealing ring
failure and rectify.
During the running-in phase, the
shaft sealing ring beds into the
shaft. A visible track can be seen
on the shaft. Optimum
preconditions for a perfect seal are
obtained after the running-in
phase.
8.3
Cleaning a geared motor
NOTICE
Dust deposits cause higher housing temperatures
Dust deposits prevent heat radiation.
Keep the geared motor free from dirt and dust.
NOTICE
Cleaning with a high-pressure cleaning appliance
Water can penetrate into the geared motor. Seals can become damaged.
Do not use a high-pressure cleaning appliance to clean the geared motor.
Do not use tools with sharp edges.
Switch off the power supply to the drive unit before cleaning it.
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8.4
Checking tightness of fastening bolts
ATEX version gearboxes
Loose parts can cause sparks through impact.
Entry of foreign bodies can cause sparks.
Note
Replace damaged headless bolts with new bolts of the same type and strength class.
Switch off the power supply to the drive unit. Check all fastening bolts for tightness using a torque wrench.
The general tolerance for the tightening torque is 10%. The tightening torque is based on a friction coefficient of μ = 0.14.
Table 8-3 Tightening torques for fastening screws
Thread size
Tightening torque at strength class
8.8
10.9
12.9
[Nm]
[Nm]
[Nm]
M4
3
4
5
M5
6
9
10
M6
10
15
18
M8
25
35
41
M10
50
70
85
8.5
Inspecting the gearbox
Carry out a scheduled inspection of the gearbox once a year in accordance with the possible criteria listed in General notes
about maintenance work (Page 26).
Check the gearbox in accordance with the criteria set out in General information (Page 2).
Touch up damaged paintwork carefully.
8.6
Servicing the brake
8.6.1
Wear of the spring-operated brake
The friction lining and the mechanical components of the brake are subject to wear due to their inherent function. For safe
and fault-free operation, the brake must be regularly checked and adjusted, and if necessary, replaced.
8.6.2
Maintenance intervals for the brake
For safe and trouble-free operation, check and maintain the spring-operated brake at regular intervals.
For operational braking, the maintenance intervals depend on the loading on the brake in the application. Take all causes of
wear into account when calculating the maintenance intervals. Siemens AG recommends a regular inspection at fixed time
intervals for low loaded brakes, e.g. holding brakes with an emergency stop.
Failure to maintain the brake can lead to operating faults, production outage or damage to the plant. Specify a maintenance
plan for each application that is appropriate to the operating conditions and loading of the brake. The maintenance intervals
and maintenance work for the pneumatic brake are listed in the table.
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Table 8-4 Maintenance interval for the brake
Brake
Maintenance interval
Operational brake
According to service life calculation
Otherwise every six months
After 4 000 operating hours at the latest
Holding brake with emergency stop
Minimum every 2 years
After 1 million cycles at the latest
Shorter intervals for frequent emergency stops
8.6.3
Adjusting the air gap
WARNING
Unintentional starting of the drive unit
Switch off the power supply to the drive unit.
The brake must be in a torque-free condition.
Secure the drive unit to prevent it from being started up unintentionally.
Attach a warning notice to the start switch.
WARNING
Decrease of braking effect due to contamination
Do not allow oil or grease to come into contact with friction surfaces.
Figure 8-1 Setting dimension for air gap
Procedure
1. Remove the fan cover.
2. Loosen the fastening screws of the brake.
3. Screw the sleeve screws further into the solenoid using an open-ended spanner.
4. Tighten the fastening screws of the brake.
5. Check the air gap sLN in the vicinity of the screws using a feeler gauge.
6. If necessary, correct the air gap sLN and then check it again.
7. When combined with manual brake release:
Check the setting dimension sHL and correct sHL if necessary.
8. Mount the fan cover.
You have now set the air gap.
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Table 8-5 Air gap values
Brake type
Nominal air gap sLN
(+0.1 / -0.05)
Maximum air gap for
Setting dimension sHL
Standard excitation sLmax.
Overexcitation sLmax.
[mm]
[mm]
[mm]
[mm]
L4/1,4
0.2
0.65
0.7 1.0
L4/2
0.6
L4/3
0.55
L4
0.5
L4/5
0.4
Table 8-6 Tightening torque for the brake screw
Brake type
Thread size
Tightening torque
Siemens
Brake supplier
[Nm]
L4
INTORQ BA BFK458 (06E)
3 x M4
2.8
8.6.4
Replacing the friction lining
WARNING
Unintentional starting of the drive unit
Switch off the power supply to the drive unit.
The brake must be in a torque-free condition.
Secure the drive unit to prevent it from being started up unintentionally.
Attach a warning notice to the start switch.
Procedure
1. Remove the fan cover.
When combined with manual release:
Unscrew the manual brake release lever.
With external fan:
Remove the fan cover together with the external fan.
2. Detach the connection cable.
3. Remove the fan locking ring and pull out the fan.
4. Loosen the brake screws evenly and remove the screws completely. Adjust the solenoid, see .
5. Pull the rotor completely off the hub.
6. Check the teeth on the hub.
7. Check the friction surface on the bearing shield. If there is severe scoring on the friction plate or flange, replace the
friction plate or flange. Rework the friction surfaces if there is severe scoring on the bearing shield.
8. Measure the thickness of the new rotor and the head height of the sleeve screws with a caliper gauge.
9. Calculate the gap between the solenoid and the armature disk as follows:
Gap = rotor thickness + sLN - head height.
10. Unscrew the sleeve screws evenly until the calculated gap between the solenoid and the armature disk is reached.
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11. Mount the new rotor and solenoid. Set the air gap of the brake, see Adjusting the air gap (Page 29).
12. Connect the connection cable.
13. Mount the fan cover.
You have now replaced the friction lining of the brake.
Table 8-7 Brake data
Brake type
Nominal air gap
s
LN
(+0.1 / -0.05)
Minimum rotor
thickness
Maximum permissible
operating speed if max.
permissible operating energy
utilized
No-load speed
with emergency stop function
Normal
friction lining
Wear-resistant
friction lining
Normal friction
lining
Wear-resistant
friction lining
[mm]
[mm]
[rpm]
[rpm]
[rpm]
[rpm]
L4
0.2
4.5
4 000
3 600
6 000
6 000
9
Disposal
Recycling and disposal of SIMOGEAR geared motors
For environmentally friendly recycling and disposal of your old device, please contact a company certified for
the disposal of old electrical and/or electronic
devices and dispose of the device in accordance with the
regulations in your country.
WARNING
Old oil disposal
Incorrect disposal of used oil is a threat to the environment and health.
After use, oil must be taken to a used oil collection point. The addition of foreign substances such as solvents, brake and
cooling fluid is prohibited.
Avoid prolonged contact with the skin.
Empty the used oil from the gearbox. The used oil must be collected, stored, transported and disposed of in accordance with
regulations. Do not mix polyglycols with mineral oil. Dispose of polyglycols separately.
Please observe country-specific laws. Under German law, to allow optimal treatment of the oil (§4 VI Used Oil), oils with
different disposal codes must not be mixed with one another.
Collect and dispose of used oil in accordance with regulations.
Remove oil spillages immediately with an oil-binding agent in compliance with environmental requirements.
Dispose of the housing parts, gears, shafts, and roller bearings of the geared motor as scrap metal.
Dispose of packaging material in accordance with regulations.
Table 9-1 Disposal codes for gear oils
Type of oil
Designation
Disposal code
Polyglycols CLP ISO PG VG220,
CLP ISO PG VG460,
CLP ISO H1 VG100,
CLP ISO H1 VG460
13 02 08
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10
Technical specifications
10.1
Type designation
Table 10-1 Example of the type designation structure
Example:
Main gearbox
Motor
NO
F
19
LA/LE
71
W
4
L4/2
IN
Gearbox type
NO
Design
F
Frame size
19
Motor type
LA/LE
Motor size
71
Special features
W
Number of poles
4
Brake
L4/2
Encoder IN
Table 10-2 Type designation code
Gearbox type
NO
Worm gearbox or worm geared motor
Design
Shaft
(-)
Solid shaft
A
Hollow shaft
E
Plug-in shaft
Mounting
(-) Foot-mounted design
F
Flange-mounted design (A type)
Z Housing flange (C type)
D
Torque bracket
Motor type
LA, LE, LES
Three-phase induction motors, integrated
Special features
W
Protective canopy
Brake
L
Spring-operated single-disk brake, DC excited
4
Size
../5
Adjusted braking torque
N
Standard version
G
Enclosed version
H
Manual ventilation
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Encoder
IN
Incremental encoder
IR Resolver
IA
Absolute encoder
10.2
General technical specifications
The most important technical data appears on the rating plate of the gearboxes and geared motors.
This data, together with the contractual agreements for the geared motors, determines the limits of intended use.
Figure 10-1 Example of a gearbox rating plate
1
Data matrix code
2
Factory serial number
3
Article number
4
Type designation
5
Mounting position
6
Degree of protection acc. to IEC
60034-5
7
Weight m [kg]
8
Ambient temperature
9
Total transmission ratio i
Frequency 1
10
Rated frequency f [Hz]
11
Gearbox output speed n2 [rpm]
12
Geared motor output torque T2 [Nm]
13
Service factor fB
Frequency 2
14
Rated frequency f [Hz]
15
Gearbox output speed n2 [rpm]
16
Geared motor output torque T2 [Nm]
17
Service factor fB
Brake data
18
Symbols (IEC 60617-2): = brake
19
Rated braking torque TBr [Nm]
20
Brake supply voltage U [V]
21
Country of origin
KA 2032
34 A5E39968267A/RS-AE, 11/2018
Example of a 1LA motor rating plate
Figure 10-2 Example of a 1LA motor rating plate
1
Number of phases
2
Type designation
3
Balancing type (H = half-key balancing)
4
CE marking or other marking, if required
5
ID number
6
Degree of protection acc. to IEC 60034-5
7
Size
8
Mounting position
9
Applicable standard
10
Temperature class Th. Cl. and operating temperature range
Frequency 1
11
Rated frequency f [Hz]
12
Rated voltage UN [V] and circuit, graphic symbols according to DIN EN 60617 Part 6 / IEC 60617-6
13
Rated output PN [kW]
14
Rated current IN [A]
15
Power factor cos φ
16
Rated speed nN [rpm]
17
Wide range voltage [V] and circuit
18
Current for wide range voltage [A]
Frequency 2
19
Rated frequency f [Hz]
20
Rated voltage/range UN [V]
21
Rated output PN [kW]
22
Rated current IN [A]
23
Power factor cos φ
24
Rated speed n
N
[rpm]
25
Wide range voltage [V] and circuit
26
Current for wide range voltage [A]
27
Duty type
28
Material number
KA 2032
A5E39968267A/RS-AE, 11/2018 35
Example of a 1LE motor rating plate
Figure 10-3 Example of a 1LE motor rating plate
1
IE efficiency class
2
Half-key balancing
3
Standards and regulations
4
Headquarters
5
Manufacturer's address
6
Motor type: Three-phase low voltage motor
7
Motor type number (MT)
8
Article number
9
Date of manufacture YYMM / serial number
10
Applied standard
11
Frame size
12
Type of construction
13
Degree of protection
14
Weight m [kg]
15
Temperature class Th. Cl.
16
Ambient temperature
17
Bearing size DE
18
Bearing size NDE
19
Rated voltage [V]
20
Winding connections
21
Frequency f [Hz]
22
Rated current IN [A]
23
Rated output PN [kW]
24
Power factor cos φ
25
Efficiency
26
Rated speed nN [rpm]
27
IE efficiency class
28
Material number
29
Duty type
KA 2032
36 A5E39968267A/RS-AE, 11/2018
30
Voltage range
31
Maximum current
32
IE value at specified voltage
Example of a 1LE motor rating plate with CCC version
Figure 10-4 Example of a 1LE motor rating plate with CCC version
1
CCC marking
2
IE efficiency class
3
Half-key balancing
4
Headquarters
5
Manufacturer's address
6
Motor type: Three-phase low voltage motor
7
Motor type number (MT)
8
Article number
9
Date of manufacture YYMM / serial number
10
Applied standard
11
Frame size
12
Type of construction
13
Degree of protection
14
Weight m [kg]
15
Temperature class
16
Ambient temperature
17
Bearing size DE
18
Bearing size NDE
19
Rated voltage [V]
20
Winding connections
21
Frequency f [Hz]
22
Rated current I
N
[A]
23
Rated output P
N
[kW]
KA 2032
A5E39968267A/RS-AE, 11/2018 37
24
Power factor cos φ
25
Efficiency
26
Rated speed nN [rpm]
27
IE efficiency class
28
Material number
29
Duty type
30
Voltage range
31
Maximum current
32
IE value at specified voltage
10.3
Mounting positions
Only operate the gearbox in the mounting position specified on the rating plate. This ensures that the correct quantity of
lubricant is provided.
Note
Gearboxes are lubricated for life. There are no openings to check the oil level
.
The lubrication for life has been designed to enable the gearbox to be operated in all the frame sizes and mounting positions
shown.
M0 is a universal mounting position. The geared motor can be installed in all mounting positions.
Figure 10-5 Mounting positions for worm gearbox S, frame size 09 - 29
A, B
Position of plug-in shaft / solid shaft
KA 2032
38 A5E39968267A/RS-AE, 11/2018
11
Spare parts
11.1
Stocking of spare parts
By stocking the most important spare and wearing parts at the installation site, you can ensure that the gearbox or geared
motor is ready for use at any time.
NOTICE
Safety impairment caused by inferior products
The installation and/or use of inferior products can have a negative impact on the design characteristics of the geared
motor and might consequently impair the active and/or passive safety features of the machine.
Siemens AG states explicitly that only spare parts and accessories supplied by Siemens have been tested and approved
by Siemens.
If you do not use original spare parts and original accessories, Siemens AG excludes every liability and warranty.
Siemens AG accepts the warranty only for original spare parts.
Note that special manufacturing and delivery specifications often apply to individual components. All spare parts offered by
Siemens AG are state-of-the-art and conform to the latest legal regulations.
Please state the following data when ordering spare parts:
● Serial number shown on the rating plate
● Type designation shown on the rating plate
● 3-digit and/or 4-digit item number from the spare parts list
● Quantity
For motors with their own rating plate, the spare parts documentation in the original operating instructions applies.
11.2
Worm geared motor S spare parts
001
Worm gearbox, complete
002
Motor, complete, LAI/LEI63/71
003
Terminal box, complete
1160
Shaft sealing ring
2516
Terminal board, complete
2601
Fan
2605
Fan cover
Figure 11-1 Worm geared motor S, frame size 09 - 29
KA 2032
A5E39968267A/RS-AE, 11/2018 39
12
Explanations
12.1
Declaration of Incorporation
Document No. A5E36963968AD
Declaration of Incorporation according to Directive 2006/42/EC Annex II 1 B.
Manufa
cturer:
Siemens AG
Division Digital Factory DF MC
Address:
Bahnhofstraße 40, 72072 Tübingen, Germany
Product designation:
SIMOGEAR gearboxes with adapter K
/ A.
•
Worm gearboxes S.09, S.19, S.29
The designated product is an incomplete machine in the sense of Article 2 g of Directive 2006/42/EC. It is designed
exclusively for incorporation into another machine or for assembly with one or more other machines.
The following essential safety and health requirements of Directive 2006/42/EC, Annex I, are applied for the incomplete
machine specified above and are complied with. The risks not relevant for the product are not listed.
•
1.1.1, 1.1.2, 1.1.3, 1.1.5
•
1.2.4.4, 1.2.6
•
1.3.1, 1.3.2, 1.3.3, 1.3.4, 1.3.6, 1.3.8.1
•
1.4.1, 1.4.2, 1.4.2.1
•
1.5.1, 1.5.2, 1.5.4, 1.5.5, 1.5.6, 1.5.8, 1.5.9, 1.5.10, 1.5.11, 1.5.13, 1.5.15
•
1.6.1, 1.6.2
•
1.7.1, 1.7.1.1, 1.7.2, 1.7.3, 1.7.4, 1.7.4.1, 1.7.4.2, 1.7.4.3
When developing and manufacturing the above designated product, the following standards and specifications were applied:
EN ISO 12100-1: 2011
The special technical documents according to Annex VII, B of the Directive 2006/42/EC were generated and will be provided
to the appropriate authorities when justifiably requested in an electronic form.
The named person for compiling the technical documents:
Georg Böing, Head of Research & Development
Before the final product is commissioned, in which the incomplete machine described here is to be incorporated, it must be
ensured that this is in conformance with Directive 2006/42/EC.
Tübingen, April 24, 2018
Georg Böing
Head of Research & Development
Florian Hanisch
Vice President Lead Factory Simogear
KA 2032
40 A5E39968267A/RS-AE, 11/2018
12.2
EU Declaration of Conformity DIN EN 80079-36
Document No. A5E43968284AB
Manufacturer:
Siemens AG
Division Digital Factory DF MC
Address:
Bahnhofstraße 40, 72072 Tübingen, Germany
Product designation:
SIMOGEAR gearbox series
Gearbox types:
S
Sizes:
09 - 29
Adapter for gearbox:
K. / A.
The designated product complies with the regulations of the following European Directive:
Directive 2014/34/EU, OJ L 96/309 of March 29, 2014 of the European Parliament and of the Council of February 26, 2014
on the harmonization of the laws of the Member States relating to equipment and protective systems intended for use in
potentially explosive atmospheres.
Conformance with the regulations laid down in these Directives is proven by fully complying with the following standards:
•
DIN EN 1127-1: 2011
•
DIN EN 80079-36: 2016
•
DIN EN 80079-37: 2016
•
DIN EN 80079-34: 2012
•
DIN EN 60079-0: 2014
•
DIN EN 15198: 2007
Explosion protection type for equipment group II of categories 2 and 3:
•
II 2G Ex h IIB T4 Gb
•
II 2G Ex h IIC T4 Gb
•
II 2D Ex h IIIB T120° C Db
•
II 2D Ex h IIIC T120° C Db
•
II 3G Ex h IIB T4 Gc
•
II 3G Ex h IIC T4 Gc
•
II 3D Ex h IIIB T120° C Dc
•
II 3D Ex h IIIC T120° C Dc
The specific marking of the gearbox is noted on the rating plate.
The technical documentation for Category 2 gearboxes has been subjected to a voluntary validation. The documentation has
been filed with the designated body under No.
0123, TÜV SÜD PRODUCT SERVICE GmbH, Ridlerstraße 65, 80339 München, Germany.
Tübingen, April 24, 2018
Georg Böing
Head of Research & Development
Florian Hanisch
Vice President Lead Factory Simogear
KA 2032
A5E39968267A/RS-AE, 11/2018 41
12.3
EC/EU Declaration of Conformity
Document No. A5E36964102AE
Manufacturer:
Siemens AG
Division Digital Factory DF MC
Address:
Bahnhofstraße 40, 72072 Tübingen, Germany
Product designation:
Low-voltage motors, types
Sizes:
LA/LAI/LEI 63 - 71, LE 63 - 71
Where relevant in conjunction with
SIMOGEAR gearbox types:
S
The designated product complies with the regulations of the following European Directive:
Directive 2014/35/EU, OJ L 96/357, 29.3.2014, of the European Parliament and of the Council of 26 February 2014 on the
harmonisation of the laws of the Member States relating to the making available on the market of electrical equipment
designed for use within certain voltage limits (Low-Voltage Directive).
Conformance with the regulations laid down in these Directives is proven by fully complying with the following standards:
•
EN 60034-1: 2010
•
EN 60034 - all other relevant sections in the latest version in each case
•
EN 60664-1: 2007
•
EN 60204-1: 2006 +A1: 2009 +AC: 2010
EC/EU Declarations of Conformity and / or manufacturer's declarations for all subassemblies, integrated and add-on units
are available.
Specifically, these are:
● Electromagnetic brakes L, FDX with connected accessories such as rectifiers and switching devices
● External fan units F
● Shaft encoders IA, IM, IN, IR
● SINAMICS G110M motor integrated frequency inverters
The designated product also complies with the regulations of the following legal acts:
● Commission Regulation (EC) No 640/2009 of 22 July 2009 implementing Directive 2005/32/EC of the European
Parliament and of the Council with regard to ecodesign requirements for electric motors.
● Directive 2009/125/EC of the European Parliament and of the Council of 21 October 2009 establishing a framework for
the setting of ecodesign requirements for energy-related products.
● Commission Regulation (EU) No 4/2014 of 6 January 2014 amending Regulation (EC) No 640/2009 implementing
Directive 2005/32/EC of the European Parliament and of the Council with regard to ecodesign requirements for electric
motors.
Conformance with the regulations laid down in this legislation is proven by fully complying with EN 60034-30: 2009.
The designated product is intended for installation in a machine. Commissioning is prohibited until it has been established
that the end product conforms with Directive 2006/42/EC.
First time that the CE marking was applied: 2012
Tübingen, April 24, 2018
Georg Böing
Head of Research & Development
Florian Hanisch
Vice President Lead Factory Simogear
This declaration certifies compliance with the Directives named above, but does not guarantee any specific properties or
durability in the sense of § 443 BGB (Section of the German Civil Code governing guarantee provisions). Please observe the
safety information in the supplied product documentation.
KA 2032
A5E39968267A/RS
-AE, 11/2018
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 co
ntents 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 regular
ly and any
necessa
ry corrections are included in subsequent editions.
Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY