Siemens MOTOX BA 2515 Operating Instructions Manual
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Siemens MOTOX BA 2515 Operating Instructions Manual

Siemens MOTOX BA 2515 Operating Instructions Manual

Gearboxes for overhead conveyor
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Summary of Contents for Siemens MOTOX BA 2515

  • Page 3 General information and ___________________ safety notes ___________________ Technical description Incoming goods, transport, ___________________ MOTOX and storage ___________________ Installation Gearboxes for overhead conveyors BA 2515 ___________________ Commissioning ___________________ Operation Operating Instructions ___________________ Faults, causes and remedies ___________________ Service and maintenance ___________________ Disposal ___________________ Technical specifications...
  • Page 4 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.

  • Page 5: Table Of Contents

    Table of contents General information and safety notes ...................... 9 General information ........................9 Copyright ..........................11 Intended use ........................... 11 Obligations of the user ......................11 Particular types of hazards ..................... 13 Technical description ..........................15 General description ......................... 15 Surface treatment ........................
  • Page 6 Table of contents Vent filter ..........................34 Operation .............................. 35 Faults, causes and remedies......................... 37 Service and maintenance ........................41 General notes about maintenance work ................41 Checking and changing lubricants ..................43 8.2.1 General safety instructions ....................43 8.2.2 Checking the oil level ......................
  • Page 7 Table of contents 11.2 Spare parts lists ........................70 11.2.1 Bevel helical gearboxes BHF38, BHB38, KHF48, KHF46, KHZ48 ........70 11.2.2 Helical worm gearboxes CHF28, CHF48, CHF68, CHZ48............. 73 Declaration of Incorporation ........................77 BA 2515 Operating Instructions, 10/2016, A5E38123453A/RS-AB...
  • Page 8 Table of contents BA 2515 Operating Instructions, 10/2016, A5E38123453A/RS-AB...

  • Page 9: General Information And Safety Notes

    General information and safety notes General information 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 part of the gearbox delivery. Store the operating instructions near the gearbox.
  • Page 10 (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).

  • Page 11: Copyright

    General information and safety notes 1.2 Copyright 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.
  • Page 12 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.

  • Page 13: Particular Types Of Hazards

    General information and safety notes 1.5 Particular types of hazards 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.
  • Page 14 General information and safety notes 1.5 Particular types of hazards BA 2515 Operating Instructions, 10/2016, A5E38123453A/RS-AB...

  • Page 15: Technical Description

    Technical description General description The gearbox is supplied as a helical worm gearbox CH., as a 2-stage bevel helical gearbox BH., or as a 3-stage bevel helical gearbox KH. It is equipped with a mechanical clutch. The gearbox is suitable for use as an overhead conveyor drive in accordance with VDI guideline 3643.
  • Page 16 Technical description 2.1 General description Cooling NOTICE Dust deposits prevent heat radiation. Dust deposits prevent heat radiation and cause a high housing temperature. Keep the gearbox free from dirt, dust, etc. The gearbox does not normally require additional cooling. The generously dimensioned housing surface is sufficient for dissipating heat losses where there is free convection.

  • Page 17: Surface Treatment

    Technical description 2.2 Surface treatment Surface treatment 2.2.1 General information on surface treatment All paint finishes are sprayed on. NOTICE Failure of the exterior protection If the paint finish is damaged, the geared motor may corrode. Do not damage the paint finish. Note Information about the ability to be repainted does not guarantee the quality of the paint product supplied by your supplier.
  • Page 18 Technical description 2.2 Surface treatment Paint system Description Corrosiveness category C2 for low environmental stress 2-component polyurethane base coat, Indoor and outdoor installation • 2-component polyurethane top coat Unheated buildings with condensation, production • areas with low humidity, e.g. warehouses and sports facilities Atmospheres with little contamination, mostly rural •...

  • Page 19: Primed Version

    Technical description 2.2 Surface treatment Paint system Description Corrosiveness category C5 for very high environmental stress 2-component epoxy zinc phosphate base Indoor and outdoor installation • coat, Buildings and areas with almost constant • 2-component epoxy iron mica condensation and high contamination, e.g. malt intermediate coat, factories and aseptic areas 2-component polyurethane top coat...
  • Page 20 Technical description 2.2 Surface treatment Peeling off the paint-protective film The paint coat must have fully hardened before the paint-protective film is peeled off (be at least "touch-proof"). ① Company logo ② Masking film ③ Rating plate ④ Paint-protective film ⑤...

  • Page 21: Incoming Goods, Transport, And Storage

    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.

  • Page 22: Transportation

    Incoming goods, transport, and storage 3.2 Transportation Transportation 3.2.1 General information on 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.

  • Page 23: Fastening For Suspended Transport

    Incoming goods, transport, and storage 3.2 Transportation 3.2.2 Fastening for suspended transport WARNING Inadequately secured gearbox or geared motors ③ Observe the maximum load for the transport eye of the bevel helical gearbox or the ④ eyebolt axis ③ ④ Use only the transport eye or eyebolt of the gearbox to transport the gearbox or...
  • Page 24 Incoming goods, transport, and storage 3.2 Transportation The maximum load m in kg generated by the geared motor to be attached, with pull ↑ in direction F is listed in the following tables: Table 3- 1 Maximum load of the transport eye on the bevel helical gearbox Size Size [kg]...

  • Page 25: Bearings

    Incoming goods, transport, and storage 3.3 Bearings Bearings 3.3.1 General information for storage WARNING Danger of serious injuries caused by falling objects Danger of damage to the gearbox when stacked Do not stack gearboxes or geared motors on each other. NOTICE Failure of the external protection Mechanical damage, chemical damage and thermal damage, such as scratches, acids,...

  • Page 26: Gearbox Filled With Operating Oil And Anti-Corrosive Agent

    Incoming goods, transport, and storage 3.3 Bearings 3.3.2.2 Gearbox filled with operating oil and anti-corrosive agent NOTICE Damage to the gearbox caused by incorrect oil quantities Check the oil level before commissioning. Observe the information and procedures for Checking the oil level (Page 43). The gearbox is filled with oil corresponding to the mounting position so that it is ready for operation, and is sealed airtight using a screw plug or with a pressure breather valve with transport fixture.

  • Page 27: Installation

    Installation Unpacking NOTICE Transport damage impairs the correct function of the geared motor Never commission faulty or defective motors. Check the motor for completeness and damage. Report any missing parts or damage immediately. Remove and dispose of the packaging material and transport equipment in compliance with regulations.
  • Page 28 Installation 4.2 General information concerning the installation NOTICE Malfunction resulting from foreign objects The operator must ensure that no foreign objects impair the function of the gearbox. NOTICE Damaged components impair the correct function of the gearbox If any components are damaged, the correct function of the gearbox will no longer be ensured.

  • Page 29: Thread Sizes And Tightening Torques For Fastening Bolts

    Installation 4.3 Thread sizes and tightening torques for fastening bolts Thread sizes and tightening torques for fastening bolts The general tolerance for the tightening torque is 10 %. The tightening torque is based on a friction coefficient of μ = 0.14. Table 4- 1 Tightening torques for fastening bolts Thread size...

  • Page 30: Gearbox With Foot Mounting

    Installation 4.5 Gearbox with foot mounting Gearbox with foot mounting NOTICE Impermissible housing loadings when unevenness present Do not subject the gearbox to excessive stress when tightening the fastening bolts. The foundation must be level and free from dirt. The levelness deviation of the gearbox support must not exceed the following values: For gearboxes up to size 88: 0.1 mm For gearboxes as of size 108: 0.2 mm The foundation should be designed in such a way that no resonance vibrations are created...

  • Page 31: Mounting An Input Or Output Element On The Gearbox Shaft

    Installation 4.7 Mounting an input or output element on the gearbox shaft 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.
  • Page 32 Installation 4.7 Mounting an input or output element on the gearbox shaft Use a fitting device to fit the input or output elements. Figure 4-1 Example of a fitting device Observe the correct mounting arrangement to minimize stress on shafts and bearings due to lateral forces.

  • Page 33: Commissioning

    Check the oil level before commissioning. Correct the oil quantity when required. Note Checking and changing lubricants (Page 43). Siemens AG recommends a complete oil change after a storage time longer than 24 months: ● For gearboxes with long-term preservation.

  • Page 34: Vent Filter

    Commissioning 5.3 Vent filter Vent filter Vent filter without securing clip In the case of gearboxes with housing ventilation, the necessary vent filter or pressure breather valve without a securing clip is delivered separately. They must be replaced with the appropriate vent plug before starting up the gearbox. Observe the symbol in the type of construction diagrams, see Mounting positions (Page 63): Ventilation Procedure...

  • Page 35: Operation

    Operation 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 (Page 37). Remedy faults or have faults remedied.
  • Page 36 Operation Operating the clutch WARNING Disengaging the motor brake The motor brake will not work after it has been disengaged. NOTICE Damage to gearboxes caused by impact of acceleration Avoid impact of acceleration when engaging clutch. When setting off, use circuitry to ensure that the motor brake is vented. The gearbox can be disengaged under load during operations.

  • Page 37: Faults, Causes And Remedies

    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.
  • Page 38 Faults, causes and remedies Faults Causes Remedy Unusual noise from Drive unit bearing not lubricated Regrease the bearing (Page 51). the drive unit. (motor size 160 and higher). Excessive bearing play and / or Check the bearing and replace if bearing defective.
  • Page 39 Faults, causes and remedies Faults Causes Remedy Oil leak at the Incorrect oil level for the mounting Check the venting position, the gearbox vent. position used and / or incorrect mounting position (Page 63) and the oil venting position. level (Page 43). Frequent cold starts during which the Call Technical Support.
  • Page 40 Faults, causes and remedies Faults Causes Remedy Geared motor only Incorrect oil level for the mounting Check the mounting position (Page 63) starts with difficulty position being used. and the oil level (Page 43). or not at all. Incorrect oil being used (e.g. Checking the oil quality (Page 45).

  • Page 41: Service And Maintenance

    Improper maintenance Only authorized qualified personnel may perform the maintenance and servicing. Only original parts supplied by Siemens AG may be installed. Only qualified personnel may perform the inspection, maintenance and servicing work. Note the General information and safety instructions (Page 9).
  • Page 42 Service and maintenance 8.1 General notes about maintenance work Measure Interval Description of work First oil change after After approximately Checking and changing commissioning. 10000 operating hours or at the lubricants (Page 43) latest after 2 years. Subsequent oil changes. Every 2 years or 10000 operating hours Visual inspection of the gearbox...

  • Page 43: Checking And Changing Lubricants

    Service and maintenance 8.2 Checking and changing lubricants Checking and changing lubricants 8.2.1 General safety instructions WARNING Danger of scalding from escaping hot oil Before starting any work wait until the oil has cooled down to below +30° C. WARNING Risk of slipping on oil Remove any oil spillage immediately with an oil-binding agent in compliance with environmental requirements.

  • Page 44: Checking The Oil Level

    Service and maintenance 8.2 Checking and changing lubricants 8.2.2 Checking the oil level NOTICE The volume of gearbox oil changes with temperature If the temperature rises, the volume increases. Where temperature differences and filling quantities are significant, the volume difference can amount to several liters. The oil level must therefore be checked while still slightly warm, approximately 30 minutes after switching off the drive unit.

  • Page 45: Checking The Oil Level Using The Oil Sight Glass (Optional)

    Service and maintenance 8.2 Checking and changing lubricants 8.2.3 Checking the oil level using the oil sight glass (optional) ① If there is an oil sight glass to check the oil level , the oil must be visible in the center of ①...

  • Page 46: Changing The Oil

    Service and maintenance 8.2 Checking and changing lubricants Procedure 1. Allow the geared motor to run for a short time. Wear and contaminant particles are visible in the oil shortly after shutting down. 2. Switch off the power supply to the drive unit. 3.

  • Page 47: Draining The Oil

    Service and maintenance 8.2 Checking and changing lubricants NOTICE Contaminations of the oil impair the lubricity Do not mix the gearbox oil with other substances. Do not flush with paraffin or other solvents, as traces of these substances will always remain inside the gearbox.

  • Page 48: Flushing The Gearbox When Changing Between Incompatible Oils

    Service and maintenance 8.2 Checking and changing lubricants 8.2.6.3 Flushing the gearbox when changing between incompatible oils WARNING Impermissible mixing of oils results in damage Residual quantities of original oil can impair the specific properties of the new oil. A flushing process is required with biodegradable and physiologically safe oils. The residual corrosion protection oil must amount to no more than 1% of the operating oil volume.

  • Page 49: Filling In Oil

    Service and maintenance 8.2 Checking and changing lubricants 7. After flushing, immediately seal the gearbox using the sealing elements. 8. Repeat this step for the second rinse. You have now flushed the gearbox twice and can pour in the new oil. 8.2.6.4 Filling in oil NOTICE...

  • Page 50: Topping Up With Oil

    Service and maintenance 8.2 Checking and changing lubricants 8.2.7 Topping up with oil If the mounting position of the gearbox is changed or oil lost because of leakage, check the oil level. If you notice oil escaping, locate the leak and seal the affected area. Check and correct the oil level.

  • Page 51: Change The Roller Bearing Grease

    10 K halves the service life by the amount as shown in the figure titled "Guide values for oil change intervals". For a +80 °C oil sump temperature, the following service life can be expected when observing the properties specified by Siemens AG: Table 8- 4 Service life of the oils...

  • Page 52: Recommended Lubricants

    8.2.11 Recommended lubricants The released and recommended lubricants are listed in the table T 7300 (http://support.automation.siemens.com/WW/view/en/44231658). DANGER Used lubricants only have conditional approval The used lubricants are not or only conditionally approved for use in the foodstuff or pharmaceutical industry.
  • Page 53 Service and maintenance 8.2 Checking and changing lubricants NOTICE Incorrect operating temperatures impair lubricity of the gearbox oil Operating temperatures outside the permitted range impair the lubricating property of the gearbox oil. Maximum permissible temperature for: • Mineral oil +90 °C, for brief periods +100 °C •...

  • Page 54: Replace Bearings

    8.3 Replace bearings The oil quality must meet the gearbox lubricant requirements specified in the T 7300 table. The Siemens warranty is otherwise null and void. We recommend the use of one of these gearbox lubricants These gearbox oils are subject to constant testing and meet the specified requirements.

  • Page 55: Cleaning The Vent Filter

    Service and maintenance 8.5 Cleaning the vent filter Cleaning the vent filter Clean the vent filter at least every 6 months, or more regularly depending on the degree of soiling. Procedure 1. Unscrew the vent filter. 2. Flush out the vent filter with benzine or a similar cleaning agent. 3.

  • Page 56: Inspecting The Gearbox

    Service and maintenance 8.8 Inspecting the gearbox The general tolerance for the tightening torque is 10 %. The tightening torque is based on a friction coefficient of μ = 0.14. Table 8- 6 Tightening torques for fastening bolts Thread size Tightening torque for strength class 10.9 12.9...

  • Page 57: Disposal

    Disposal 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.
  • Page 58 Disposal BA 2515 Operating Instructions, 10/2016, A5E38123453A/RS-AB...

  • Page 59: Technical Specifications

    Technical specifications 10.1 Type designation Table 10- 1 Example of the type designation structure Main gearbox Input unit Example: 38 - (100) Gearbox type Monorail conveyor Mounting Size Input unit (for motor size) (100) Table 10- 2 Type designation code Gearbox type Helical worm gearbox Bevel helical gearbox, two-stage...

  • Page 60: General Technical Data

    Figure 10-1 Rating plate example Data matrix code Applicable standard Factory serial number FDU = Siemens AG, Bahnhofstr. 40, 72072 Tübingen, Germany CE marking or other marking, if required Article number Type designation Mounting position Degree of protection acc. to IEC 60034-5...
  • Page 61 Technical specifications 10.2 General technical data Frequency 1 Rated frequency f [Hz] Gearbox output speed n [rpm] Geared motor output torque T [Nm] Service factor f Frequency 2 Rated frequency f [Hz] Gearbox output speed n [rpm] Geared motor output torque T [Nm] Service factor f Motor and brake data...

  • Page 62: Weight

    If repeat measurements on site do not produce conclusive results, which can be verified by measuring technology, the measurement obtained on Siemens AG test benches will apply. External noises Noises not generated by the gearbox but emitted from it are not taken into consideration here.

  • Page 63: Mounting Positions

    Technical specifications 10.5 Mounting positions 10.5 Mounting positions The type of construction designations are compliant with IEC 60034-7 (Code I). The geared motors must be operated only in the type of construction specified on the rating plate. This ensures that the correct quantity of lubricant is provided. Note Depending on operating mode (e.g.

  • Page 64: Helical Worm Gearbox Chf28

    Technical specifications 10.5 Mounting positions 10.5.1 Helical worm gearbox CHF28 Figure 10-3 Designs for CHF28 BA 2515 Operating Instructions, 10/2016, A5E38123453A/RS-AB...

  • Page 65: Bevel Helical Gearboxes Bhf38, Bhb38

    Technical specifications 10.5 Mounting positions 10.5.2 Bevel helical gearboxes BHF38, BHB38 Figure 10-4 Designs for BHF38, BHB38 Figure 10-5 Position of output shaft BA 2515 Operating Instructions, 10/2016, A5E38123453A/RS-AB...

  • Page 66: Helical Worm Gearboxes Chz48, Chf48, Chf68

    Technical specifications 10.5 Mounting positions 10.5.3 Helical worm gearboxes CHZ48, CHF48, CHF68 Figure 10-6 Designs for CHZ48, CHF48, CHF68 Figure 10-7 Position of output shaft BA 2515 Operating Instructions, 10/2016, A5E38123453A/RS-AB...

  • Page 67: Bevel Helical Gearboxes Khz48, Khf48, Khf68

    Technical specifications 10.5 Mounting positions 10.5.4 Bevel helical gearboxes KHZ48, KHF48, KHF68 Figure 10-8 Designs for KHZ48, KHF48, KHF68 Figure 10-9 Position of output shaft BA 2515 Operating Instructions, 10/2016, A5E38123453A/RS-AB...

  • Page 68: Oil Quantities

    Technical specifications 10.6 Oil quantities 10.6 Oil quantities NOTICE Incorrect oil quantities damage the gearbox The oil quantities listed in the tables are guide values for changing the oil. They are used, for example, for lubricant storage and procurement. The precise values depend on the number of stages and transmission ratio of the gearbox.

  • Page 69: Spare Parts

    Siemens AG states explicitly that only spare parts and accessories supplied by Siemens have been tested and approved by Siemens AG. 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.

  • Page 70: Spare Parts Lists

    Spare parts 11.2 Spare parts lists 11.2 Spare parts lists 11.2.1 Bevel helical gearboxes BHF38, BHB38, KHF48, KHF46, KHZ48 Figure 11-2 Bevel helical gearboxes BHF38, BHB38 BA 2515 Operating Instructions, 10/2016, A5E38123453A/RS-AB...
  • Page 71 Spare parts 11.2 Spare parts lists Figure 11-3 Bevel helical gearboxes KHF48, KHF68, KHZ48 BA 2515 Operating Instructions, 10/2016, A5E38123453A/RS-AB...
  • Page 72 Spare parts 11.2 Spare parts lists Spare parts list for bevel helical gearbox BH.38, KH.48 - 68 Gearbox housing Supporting disk / shim Bearing Locking ring Supporting disk / shim Snap ring Locking ring Threaded bolt Bearing Screw Locking ring Supporting disk / shim Seal Housing cover...

  • Page 73: Helical Worm Gearboxes Chf28, Chf48, Chf68, Chz48

    Spare parts 11.2 Spare parts lists 11.2.2 Helical worm gearboxes CHF28, CHF48, CHF68, CHZ48 BA 2515 Operating Instructions, 10/2016, A5E38123453A/RS-AB...
  • Page 74 Spare parts 11.2 Spare parts lists Gearbox housing Supporting disk / shim Bearing Locking ring Locking ring Snap ring Supporting disk / shim Threaded bolt Spacer ring Worm shaft Sealing cap Worm wheel Bearing Deep-groove ball bearing Locking ring Locking ring Supporting disk / shim Locking ring Sealing cap...
  • Page 75 Spare parts 11.2 Spare parts lists BA 2515 Operating Instructions, 10/2016, A5E38123453A/RS-AB...
  • Page 76 Spare parts 11.2 Spare parts lists Gearbox housing Supporting disk / shim Bearing Locking ring Bearing Operating lever Supporting disk / shim Screw Locking ring Dowel pin Locking ring Threaded bolt Output flange Spacer / bush Screw Sealing cap Locking ring Output shaft Adapter plate Parallel key...

  • Page 77: Declaration Of Incorporation

    Declaration of Incorporation Document No. A5E37802169AA Declaration of Incorporation according to Directive 2006/42/EC Annex II 1 B. Manufacturer: Siemens AG Division Digital Factory DF MC Address: Bahnhofstraße 40, 72072 Tübingen, Germany Product designation: MOTOX gearboxes with input units A, K, P •...
  • Page 78 Declaration of Incorporation BA 2515 Operating Instructions, 10/2016, A5E38123453A/RS-AB...

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