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Siemens SIMOGEAR BA 203-A, Mounting And Operating Instructions

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Siemens SIMOGEAR BA 203-A Mounting And Operating Instructions Download Page 23

significant features are retained. The operating instructions are updated regularly with new 
contents.

The latest versions of the operating instructions, the declaration of incorporation and the 
declarations of conformity are available in Industry Online Support (

https://

support.industry.siemens.com/cs/ww/en/ps/13424/man

).

2.2

Intended use

Ex-version gearboxes
The Ex gearbox fulfills the requirements of the Explosion Protection Direc‐
tive 2014/34/EU and the UK Directive UK SI 2016:1107.
In the case of Ex-version gearboxes, please observe the instructions marked with this 
symbol.

Note

Gearboxes and geared motors are partly completed machines for installation into machinery, or 
other partly completed machinery or equipment or plants, within the meaning of the current EC 
Machinery Directive 2006/42/EC and the UK directive "Supply of Machinery (Safety) Regulations 
2008".

Based on the area of validity of these directives, commissioning is prohibited until it has been 
absolutely identified that the end product is in conformance with these directives.

Unless otherwise agreed, the gearboxes and geared motors are intended for use in commercial 
applications in machinery, other partly completed machinery, or equipment or plants.

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.

The gearboxes have been designed solely for the application described in Technical Data in the 
BA 2030 Operating Instructions for SIMOGEAR gearboxes. Do not operate the gearboxes 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.

2.3

Specific hazard types and fundamental obligations

WARNING

Hot, escaping oil

Before starting any work wait until the oil has cooled down to below +30 °C.

Specific safety instructions

2.3 Specific hazard types and fundamental obligations

SIMOGEAR adapters for gearboxes - KS, K2, K3, K4, K5, KQ, KQS, K8, A, AZ
Operating Instructions, 05/2022, A5E37431501A/RS-AL

21

Summary of Contents for SIMOGEAR BA 203-A

Page 1: ...ORIGINAL MOUNTING AND OPERATING INSTRUCTIONS Adapter for gearbox Edition 05 2022 BA 2039 KS K2 K3 K4 K5 KQ KQS K8 A AZ www siemens com SIMOGEAR ...

Page 2: ......

Page 3: ... Instructions Supplement to the SIMOGEAR gearbox operating instructions BA 2030 Original instructions 05 2022 A5E37431501A RS AL Introduction Fundamental safety instructions 1 Specific safety instructions 2 Technical description 3 Installing 4 Operation 5 Service and maintenance 6 Spare parts 7 ...

Page 4: ...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...

Page 5: ...levels changed Specific hazard types and fundamental obligations Page 21 Attention deleted General information on installation Page 25 z12 and z values changed in the KS adapter size KS8 1 Mounting SIEMENS servomotors without parallel key onto adapter KS Page 30 Assignment of coupling size and IEC B5 corrected Fit the standard motor to the K2 or K3 adapter Page 33 New sentence on the ambient tempe...

Page 6: ...n describes the functionality of the product The machine builder documents any modifications or changes to the product made by it This documentation cannot contain all of the detailed information on all of the product types Moreover this documentation cannot take into consideration every possible type of installation operation and maintenance Text features In addition to the notes that you must ob...

Page 7: ... documentation To do so click My Documentation Note If you want to use this function you must register once Later you can log on with your login data You can create your own personal library under mySupport using the following procedure Precondition You have registered for and logged on to Siemens Industry Online Support hereinafter referred to as SIOS SIOS https support industry siemens com cs de...

Page 8: ... https support industry siemens com cs de en Procedure 1 Click on Your direct way to the Support Request or follow the link Support Request https support industry siemens com cs de en my 2 Follow the instructions in the online form Websites of third parties This document includes hyperlinks to websites of third party companies Siemens is not responsible for and shall not be liable for these websit...

Page 9: ...s person related data on the same data medium e g hard disk thus personalizing these data he has to ensure compliance with the applicable data protection stipulations Introduction SIMOGEAR adapters for gearboxes KS K2 K3 K4 K5 KQ KQS K8 A AZ Operating Instructions 05 2022 A5E37431501A RS AL 7 ...

Page 10: ...Introduction SIMOGEAR adapters for gearboxes KS K2 K3 K4 K5 KQ KQS K8 A AZ 8 Operating Instructions 05 2022 A5E37431501A RS AL ...

Page 11: ...allation 25 4 3 Thread sizes and tightening torques for fastening bolts 27 4 4 Mounting an input or output element on the gearbox shaft 27 4 5 Mounting the motor 29 4 5 1 Mounting SIEMENS servomotors without parallel key onto adapter KS 30 4 5 2 Fit the standard motor to the K2 or K3 adapter 33 4 5 3 Mount the standard motor to the K4 or K5 short adapter 36 4 5 4 Mount the servomotor with parallel...

Page 12: ...with elastic coupling 52 7 3 3 K4 and K5 short adapters with plug in connection 54 7 3 4 KQ K8 and KQS adapters for mounting a servomotor 55 7 3 5 A AZ adapter 57 Table of contents SIMOGEAR adapters for gearboxes KS K2 K3 K4 K5 KQ KQS K8 A AZ 10 Operating Instructions 05 2022 A5E37431501A RS AL ...

Page 13: ...rotective 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...

Page 14: ...I high voltages can be present at open exposed parts which when touched can result in death or severe injury Ground the device in compliance with the applicable regulations WARNING Arcing when a plug connection is opened during operation Opening a plug connection when a system is operation can result in arcing that may cause serious injury or death Only open plug connections when the equipment is ...

Page 15: ...achines and can therefore put people in danger or lead to property damage Therefore if you move closer than 20 cm to the components be sure to switch off radio devices cellphones or WLAN devices Use the SIEMENS Industry Online Support app only on equipment that has already been switched off WARNING Unrecognized dangers due to missing or illegible warning labels Dangers might not be recognized if w...

Page 16: ...elds Electromagnetic fields EMF are generated by the operation of electrical power equipment such as transformers converters or motors People with pacemakers or implants are at particular risk in the immediate vicinity of this equipment If you have a heart pacemaker or implant maintain the minimum distance specified in chapter Correct usage from such motors WARNING Active implant malfunctions due ...

Page 17: ... in the case of a fault the motor can overheat resulting in fire and smoke This can result in severe injury or death Further excessively high temperatures destroy motor components and result in increased failures as well as shorter service lives of motors Operate the motor according to the relevant specifications Only operate the motors in conjunction with effective temperature monitoring Immediat...

Page 18: ...is necessary to implement and continuously maintain a holistic state of the art industrial security concept Siemens products and solutions constitute one element of such a concept Customers are responsible for preventing unauthorized access to their plants systems machines and networks Such systems machines and components should only be connected to an enterprise network or the internet if and to ...

Page 19: ...ollowing residual risks emanating from the control and drive components of a drive system 1 Unintentional movements of driven machine or system components during commissioning operation maintenance and repairs caused by for example Hardware and or software errors in the sensors control system actuators and cables and connections Response times of the control system and of the drive Operation and o...

Page 20: ...etc if they are too close 5 Release of environmental pollutants or emissions as a result of improper operation of the system and or failure to dispose of components safely and correctly 6 Influence of network connected communication systems e g ripple control transmitters or data communication via the network For more information about the residual risks of the drive system components see the rele...

Page 21: ...ng safe and trouble free operation The operating instructions supplement the SIMOGEAR gearbox operating instructions BA 2030 These operating instructions apply to the adapters of the standard SIMOGEAR gearbox version Adapter KS coupling adapter only for fitting a SIEMENS servomotor of the SIMOTICS S 1FK7 1FT7 SIMOTICS M 1PH8 SIMOTICS S 1FK2 SIMOTICS S 1FL6 series Adapter K2 coupling adapter with f...

Page 22: ...ions for SIMOGEAR gearboxes BA 2031 operating instructions for permissible mounting position deviations of SIMOGEAR gearboxes KA 2032 compact operating instructions for SIMOGEAR worm geared motor S BA 2039 operating instructions for adapters for mounting on SIMOGEAR gearboxes BA 2330 operating instructions for LA LE LES motors for mounting on SIMOGEAR gearboxes BA 2331 operating instructions for g...

Page 23: ...tely identified that the end product is in conformance with these directives Unless otherwise agreed the gearboxes and geared motors are intended for use in commercial applications in machinery other partly completed machinery or equipment or plants The gearboxes and geared motors are designed and built according to state of the art technology and are shipped in an operationally safe condition Cha...

Page 24: ... Comply with 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 Collect and dispose of used oil in accordance with regulations Immediately remove any oil spills with an oil binding agent Do not use high pressure cleaning equipment or sharp edged tools to clean the geared motor The...

Page 25: ...e used that give rise to additional radial and or axial forces e g gear wheels belt pulleys this must be contractually agreed Refer to the relevant operating instructions for details of how to use the coupling 3 4 Backstop K2X K3X Ex version gearboxes The drive speed in the table Drive speed when using backstops must be maintained in continuous operation Starting and stopping operations 20 starts ...

Page 26: ...h centrifugally operated sprags When the gearbox is running in the specified direction the inner ring and the cage with the sprags also rotate while the outer ring remains stationary If the drive speed exceeds the speed listed in the table the sprag rises The backstop is wear free Table 3 1 Minimum drive speed when using backstops Size Backstop Speed K2X IEC K3X NEMA rpm 80 56 FXN46 25DX 890 90 14...

Page 27: ...t When mounting the gearbox on or connecting it to the machine take care to ensure potential equalization The information on grounding and equipotential bonding provided by the motor supplier must be observed WARNING Operating under load Under load the system can start or reverse in an uncontrolled fashion The entire system must be load free so that there is no danger during this work NOTICE Destr...

Page 28: ...e geared motor is shut down then this can cause the machine to come to a stop Exercise particular care during mounting and installation The manufacturer cannot be held liable for damage caused by incorrect mounting and installation Make sure that there is sufficient space around the gearbox or geared motor for mounting maintenance and repair On geared motors with a fan leave sufficient free space ...

Page 29: ...000 2 400 M36 2 500 3 600 4 200 4 4 Mounting an input or output element on the gearbox shaft WARNING Risk of burns caused by hot parts Do not touch the gearbox without protection NOTICE Damage to shaft sealing rings caused by solvent Avoid 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 r...

Page 30: ...e 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 1 Example of a fitting device Observe the correc...

Page 31: ...netrates 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 bolts 1505 or integrated elements such as proximity switches using an appropriate sealing compound The flange mounted motor must be sealed across the entire contact surface Seal the geared motor in the outer area Note The fla...

Page 32: ...lf 1556 and motor shaft completely free from grease Do not use soiled cleaning cloths or contaminated solvents Note Dimension z12 applies for standard assignment of the coupling If a special assignment is required consult the appropriate special dimension drawing Note Reduce assembling force Lightly grease or oil the gear ring tooth flanks of the elastomer 1557 The following are permitted Mineral ...

Page 33: ...may be used in this version The recessed version cannot be mounted on the KS adapter Permissible SIMOTICS S 1FT7 1FT7XXX XXXX1 XXXX 1FT7XXX XXXX4 XXXX SIMOTICS S 1FK2 IP65 The IP65 version of SIMOTICS S 1FK2 is mechanically not compatible with the KS adapter However the degree of protection IP65 is nevertheless complied with by attaching the motor to the gear Permissible SIMOTICS S 1FK2 1FK2XXX XX...

Page 34: ...ighten both alternately in equal steps with the specified tightening torques 6 Insert the elastomer 1557 in the already assembled coupling half 1556 on the motor shaft end 7 Lightly grease or oil the tooth flanks to reduce the mounting force 8 Apply adhesive medium strength e g Loctite 243 to the bolts 1505 9 Fasten the motor using the bolts 1505 with the specified torque based on the table in Thr...

Page 35: ...he K2 or K3 adapter Ex version gearboxes Impacts can cause sparks Apply adhesive medium strength e g Loctite 243 to the grub screw 1564 and bolts 1505 Ex version gearboxes The flange mounted motor must be sealed across the entire contact surface in order to prevent the penetration of a potentially explosive atmosphere Note Dimension z12 applies for standard assignment of the coupling If a special ...

Page 36: ...z12 and z 3 Apply adhesive medium strength e g Loctite 243 to the grub screw 1564 4 Tighten the grub screw 1564 to the specified torque TA SW and across flats dimension SW 5 On motors balanced with half a parallel key code H remove projecting visible parts of the parallel key 6 Place the flexible element 1557 inside the coupling half 1555 Installing 4 5 Mounting the motor SIMOGEAR adapters for gea...

Page 37: ...2 1 5 M8 10 4 M16 180 42 59 132 1 5 M8 10 4 M16 200 42 60 133 1 5 M8 10 4 M16 225 48 84 164 5 1 5 M8 10 4 M16 250 55 75 166 1 5 M10 17 5 M16 280 75 51 171 2 M10 17 5 M16 315 90 33 5 173 2 M12 40 6 M20 Table 4 4 Adapter K3 NEMA TC Coupling size z12 z Grub screw 1564 TASW SW Bolt 1505 TA for 1505 mm mm Nm mm Nm 56 19 27 5 66 5 1 M5 2 2 5 3 8 31 140 19 28 67 1 M5 2 2 5 3 8 31 180 24 36 5 82 5 1 M5 2 ...

Page 38: ...rect position The plastic ring prevents fretting corrosion on the cylinder surface of the motor shaft To prevent fretting corrosion on the feather key of the motor shaft apply a suitable lubricant to the contact surfaces e g Castrol Apply Optileb Paste NH1 Note The contact surfaces between adapter and motor must always be sealed using a suitable sealing compound Correct Incorrect Plastic ring Shaf...

Page 39: ... 320 360 Bolt 1505 3 8 3 8 1 2 1 2 1 2 1 2 5 8 5 8 TA for 1505 in Nm 31 31 75 75 75 75 150 150 4 5 4 Mount the servomotor with parallel key to the KQ or K8 adapter Ex version gearboxes Impacts can cause sparks Apply adhesive medium strength e g Loctite 243 to the grub screw 1564 and bolts 1505 Ex version gearboxes The flange mounted motor must be sealed across the entire contact surface in order t...

Page 40: ...ible element 1555 Coupling half 1564 Grub screw 1556 Coupling half Figure 4 6 KQ and K8 adapters Procedure 1 Fit the coupling half 1556 onto the motor shaft end as described in Mounting an input or output element on the gearbox shaft Page 27 2 Maintain the clearances z12 and z 3 Apply adhesive medium strength e g Loctite 243 to the grub screw 1564 4 Tighten the grub screw 1564 to the specified tor...

Page 41: ...8 23 5 76 1 M8 4 4 M10 808 28 43 5 96 1 M8 4 4 M10 710 810 38 33 99 1 5 M8 4 4 M12 813 42 60 133 1 5 M8 4 4 M16 816 42 60 133 1 5 M8 4 4 M16 818 75 73 193 2 M10 5 5 M16 822 90 58 5 198 2 M12 6 6 M16 4 5 5 Mount servomotor without parallel key to the KQS adapter Ex version gearboxes Impacts can cause sparks Apply adhesive medium strength e g Loctite 243 to the bolts 1505 and 1 or 1 Ex version gearb...

Page 42: ... drawing Note Reduce assembling force Lightly grease or oil the gear ring tooth flanks of the flexible element 1557 or the hub The following are permitted Mineral oil based oils or greases Silicon based lubricants Vaseline Note The force required to join the coupling halves is released after assembly meaning that there is no danger of excessive axial load on the bearings Note The contact surfaces ...

Page 43: ...flats dimension SW KQS 710 Tighten the bolt 1 with across flats dimension SW evenly and gradually in a crossways pattern Repeat the procedure until the specified TA SW torque has been reached 6 Place the flexible element 1557 inside the coupling half 1555 7 Lightly grease or oil the tooth flanks to reduce the mounting force 8 Apply adhesive medium strength e g Loctite 243 to the bolts 1505 9 Faste...

Page 44: ...8 38 z12 in mm 18 14 15 23 5 33 z in mm 40 5 0 5 53 1 61 1 76 1 99 1 5 Bolt 1 1 M3 M6 M6 M8 M6 TA SW in Nm 1 34 10 5 10 5 25 10 SW in mm 2 2 5 2 5 4 4 Bolt 1505 M6 M6 M8 M10 M12 Installing 4 5 Mounting the motor SIMOGEAR adapters for gearboxes KS K2 K3 K4 K5 KQ KQS K8 A AZ 42 Operating Instructions 05 2022 A5E37431501A RS AL ...

Page 45: ...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 fault as described in Section Faults causes and remedies in the gearbox operating instructions Remedy faults or have faults remedied Check the gear unit during operation for Excessive operating temperature Smooth and vibra...

Page 46: ...Operation SIMOGEAR adapters for gearboxes KS K2 K3 K4 K5 KQ KQS K8 A AZ 44 Operating Instructions 05 2022 A5E37431501A RS AL ...

Page 47: ...anufacturer s factory and at trained partners Maintenance work on an Ex stamped product is only allowed to be performed by SIEMENS or authorized partners 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...

Page 48: ...r every 10 C increase in temperature the grease service life is reduced by a factor of 0 7 of the value in the table max 20 C factor 0 5 At an ambient temperature of 25 C the grease service life can be expected to be doubled Irrespective of the number of operating hours renew the roller bearing grease or the bearing 2Z bearing after 3 or 4 years at the latest Table 6 1 Roller bearing and shaft sea...

Page 49: ... 7 3 1 3 2 4 1 4 2 56 71 703 7 80 80 704 80 9 5 1 5 2 5 3 90 140 90 706 90 15 6 1 6 2 100 180 100 100 24 000 20 8 1 112 112 708 808 112 45 10 1 10 2 132 210 132 710 810 132 24 000 75 160 250 160 160 17 000 90 180 180 813 180 110 200 280 200 200 225 320 225 816 225 Grease service live bearing service life 250 360 250 250 Service and maintenance 6 3 Lubrication SIMOGEAR adapters for gearboxes KS K2 ...

Page 50: ...Service and maintenance 6 3 Lubrication SIMOGEAR adapters for gearboxes KS K2 K3 K4 K5 KQ KQS K8 A AZ 48 Operating Instructions 05 2022 A5E37431501A RS AL ...

Page 51: ...cepts 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 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 Part number 4...

Page 52: ...er Serial number Figure 7 2 Enter a sample article and serial number in Spares on Web Procedure 1 Open the spare parts list with the link provided 2 In the field enter the Article No stated on the rating plate or SIMOGEAR Example 2KJ3102 1CE11 2AU Z or SIMOGEAR 3 In the field Serial number enter the production number stated on the rating plate or only the abbreviated number Example FDUN1 255255701...

Page 53: ...king ring 1505 Bolt 1525 Shaft sealing ring 1506 Washer screw lock 1528 Washer 1508 Bolt 1530 Bearing 1509 Nut 1556 Coupling half 1512 Washer 1557 Elastomer 1513 O ring Figure 7 3 Adapter KS for mounting a SIEMENS servomotor Spare parts 7 3 Lists of spare parts SIMOGEAR adapters for gearboxes KS K2 K3 K4 K5 KQ KQS K8 A AZ Operating Instructions 05 2022 A5E37431501A RS AL 51 ...

Page 54: ...g 1506 Plate locking ring 1540 Backstop 1508 Bolt 1541 Parallel key 1510 Screw plug 1543 Supporting disk 1513 O ring 1544 Shim 1514 Locking ring 1545 Shim 1515 Shaft 1546 Shim 1519 Sleeve 1554 Sleeve 1520 Bearing 1560 Coupling 1521 Locking ring 1561 Parallel key 1522 Locking ring 1569 Reduction piece 1524 Locking ring 1570 Proximity switch Figure 7 4 K2 and K3 adapters with elastic coupling Spare ...

Page 55: ... Figure 7 5 Adapter K2 sizes 280 315 Spare parts 7 3 Lists of spare parts SIMOGEAR adapters for gearboxes KS K2 K3 K4 K5 KQ KQS K8 A AZ Operating Instructions 05 2022 A5E37431501A RS AL 53 ...

Page 56: ...Bolt 1521 Locking ring 1506 Plate locking ring 1522 Locking ring 1507 Nut 1525 Shaft sealing ring 1508 Bolt 1528 Washer 1509 Nut 1530 Bearing 1513 O ring 1539 Screw plug Figure 7 6 K4 and K5 short adapters with clamp connection Spare parts 7 3 Lists of spare parts SIMOGEAR adapters for gearboxes KS K2 K3 K4 K5 KQ KQS K8 A AZ 54 Operating Instructions 05 2022 A5E37431501A RS AL ...

Page 57: ...nt filter 1525 Shaft sealing ring 1501 Adapter 1528 Washer 1502 Screw plug 1529 Bearing 1504 Bearing shield 1530 Bearing 1505 Bolt 1531 Locking ring 1506 Plate locking ring 1533 O ring 1507 Nut 1539 Screw plug 1508 Bolt 1543 Supporting disk 1513 O ring 1544 Shim 1514 Fuse 1545 Shim 1515 Shaft 1546 Shim 1517 Flange 1554 Sleeve Spare parts 7 3 Lists of spare parts SIMOGEAR adapters for gearboxes KS ...

Page 58: ...oupling 1519 Sleeve 1561 Parallel key Figure 7 8 K8 sizes 818 822 Spare parts 7 3 Lists of spare parts SIMOGEAR adapters for gearboxes KS K2 K3 K4 K5 KQ KQS K8 A AZ 56 Operating Instructions 05 2022 A5E37431501A RS AL ...

Page 59: ...522 Locking ring 1523 Sealing washer 1525 Shaft sealing ring 1526 Seal Loctite 574 1528 Washer 1530 Bearing 1531 Locking ring 1532 Locking ring 1535 Shaft sealing ring 1561 Parallel key Figure 7 9 A AZ adapter Spare parts 7 3 Lists of spare parts SIMOGEAR adapters for gearboxes KS K2 K3 K4 K5 KQ KQS K8 A AZ Operating Instructions 05 2022 A5E37431501A RS AL 57 ...

Page 60: ...Spare parts 7 3 Lists of spare parts SIMOGEAR adapters for gearboxes KS K2 K3 K4 K5 KQ KQS K8 A AZ 58 Operating Instructions 05 2022 A5E37431501A RS AL ...

Page 61: ......

Page 62: ...formation Germany IndustryMall Industry Online Support Service and Support SIMOGEAR on the Internet Siemens AG Digital Industries Motion Control Postfach 3180 91050 ERLANGEN www siemens com simogear www siemens com online support www siemens com industrymall ...

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