SIMOGEAR Worm geared motor S KA 2032 Compact Operating Instructions Translation of the original instructions

Transcription

1 SIMOGEAR Worm geared motor S 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. 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 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. Siemens AG All rights reserved A5E A/RS-AD, 02/2018 1

2 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 observed for the mounted motor. 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 motor frame sizes 63 and 71. In addition to these operating instructions, special contractual agreements and technical documentation apply to a special version 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 ( You can find technical configuration data, spare parts lists and certificates of compliance on the Intranet at Once Delivered ( You can find the contact data of your Technical Support in the Database of contacts at Siemens AG ( If you have any technical questions, please contact Technical Support ( Europe and Africa Telephone: support.automation@siemens.com America Telephone: support.america.automation@siemens.com Asia / Australia / Pacific Telephone: 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. 2 A5E A/RS-AD, 02/2018

3 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 (VDE 0530). LA motors are not approved for operation in hazardous zones and areas. 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. The performance data assumes an ambient temperature of -25 C to +40 C and an installation altitude of up to 2000 m above sea level. Data deviating from this is specified on the rating plate. For different installation altitudes and ambient temperatures, please 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. 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. A5E A/RS-AD, 02/2018 3

4 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 safetyrelevant instructions and the following five safety rules according to EN 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! 4 A5E A/RS-AD, 02/2018

5 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 Degree of protection EN Cooling EN Mounting position according to modular system EN Terminal marking and direction of rotation EN Noise emission EN Thermal protection EN Starting characteristics for rotating electrical motors EN Vibration severity levels EN IEC standard voltages IEC Safety of machinery EN 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. A5E A/RS-AD, 02/2018 5

6 2.3 Cooling 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 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. ATEX version gearboxes As standard, the gearbox is not painted. The gearbox is optionally delivered complete with primer and paint finish. ATEX version gearboxes When applying conductive paint, the operating company must ensure that the paint remains in a perfect state. The paint finish must be checked at intervals of approximately 2-3 years. ATEX version gearboxes An excessively high electrostatic charge must be avoided. Ensure that highly active mechanisms that cause the paint finish to generate a charge are avoided. Highly active mechanisms that can generate charges: 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) 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 Failure of the external protection Do not damage the paint finish. 6 A5E A/RS-AD, 02/2018

7 Destruction of the seals Sealing lips must not come into contact with paint. Cover the shaft sealing rings. 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 Painted version The corrosion protection system is classified according to the corrosiveness categories in DIN EN ISO 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 Corrosiveness category C3 for medium environmental stress 2-component epoxy zinc phosphate base coat, Indoor and outdoor installation 2-component polyurethane top coat 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. A5E A/RS-AD, 02/2018 7

8 2.5.3 Primed version Table 2-3 Primer according to corrosiveness category Paint system Unpainted corrosiveness category C1 Cast iron parts immersion primed, steel parts primed or zinc-plated, aluminum and plastic parts untreated Primed according to corrosiveness category C2 G 2-component epoxy zinc phosphate, desired coat thickness 60 μm Can be overpainted with Synthetic paint, synthetic resin paint, oil paint 2-component polyurethane paint 2-component epoxy paint 2-component - polyurethane paint 2-component - epoxy paint 2-component - acrylic paint Acid-hardening paint 3 Incoming goods, transport, and storage 3.1 Incoming goods Transport damage impairs correct functioning Do not commission faulty gearboxes or geared motors. Do not open or damage parts of the packaging that preserve the product. 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 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). 8 A5E A/RS-AD, 02/2018

9 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 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 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. A5E A/RS-AD, 02/2018 9

10 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 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. 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. 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. Malfunction resulting from foreign objects The operator must ensure that no foreign objects impair the function of the geared motor. 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 26). 4.3 Installation conditions for the motor 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. 10 A5E A/RS-AD, 02/2018

11 Figure 4-1 Installation condition for the SIMOGEAR motor The permissible coolant temperature (ambient temperature at installation location) is -20 C to +40 C for an installation altitude of up to m above sea level. Any alternative requirements are stamped 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. 4.4 Gearbox with foot mounting 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. If the inserted sealing ring is located on the top of the gearbox, neither water nor dirt can collect. We recommend the use of a protection cover (optional). A5E A/RS-AD, 02/

12 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. Damage to shaft sealing rings caused by solvent Avoid any contact of solvent or benzine with the shaft sealing rings. 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. 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. 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. 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 12 A5E A/RS-AD, 02/2018

13 Observe the correct mounting arrangement to minimize stress on shafts and bearings due to lateral forces. Correct Incorrect a F Hub 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. 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 A5E A/RS-AD, 02/

14 Procedure 1. Unscrew the screws 1 and remove the protection cover 2 together with the flat gasket 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 Screw on the protection cover 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 General information on installing the shaft-mounted gearbox Damage to shaft sealing rings caused by solvent Avoid any contact of solvent or benzine with the shaft sealing rings. 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. Coat the contact surfaces with the mounting paste supplied with the product or any suitable lubricant to prevent frictional corrosion. Observe the permissible concentricity tolerance of the cylindrical shaft end of the machine shaft to the housing axle according to DIN 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 14 A5E A/RS-AD, 02/2018

15 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 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] 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. Subjecting stress to the hollow shaft causes bearing failure It is essential to prevent misalignment when removing the unit. 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 A5E A/RS-AD, 02/

16 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 Frame size b10 b11 b12 d10 d11 s11 tmax u [mm] [mm] [mm] [mm] [mm] [mm] [mm] M M M M 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. 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-oftrue. 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. Damage to the rubber elements caused by solvent Solvents, oils, greases, and fuels damage rubber elements. Avoid contact at all times. 16 A5E A/RS-AD, 02/2018

17 Figure 4-7 Attaching the torque arm The torque arm can be fitted in various positions, depending on the hole circle pitch. 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 Mounting the motor 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 A5E A/RS-AD, 02/

18 4.11 Connecting the motor in the terminal box 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. 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 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 Terminal box 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. 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. 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 Terminal marking For terminal designations, the following principle definitions apply to three-phase motors: 18 A5E A/RS-AD, 02/2018

19 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 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 Connecting the cables in the terminal box 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 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. Place the spring washer under the screw head. Observe the tightening torque for the locking screw, see Installation and routing (Page 20). A5E A/RS-AD, 02/

20 Table 4-4 Maximum conductor connection for external grounding Motor size M Installation and routing Match the screw connection to the connection cable used: Seal insert Armor Braid Shielding Thread size 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. M Type of conductor connection Angle DIN cable lug down for connection. DIN Connection of an individual conductor with the terminal clamp. Connection of two conductors of approximately the same thickness with the terminal clamp. 1 Link rail 2 Line connecting cable 3 Motor connecting cable 4 Cover washer 20 A5E A/RS-AD, 02/2018

21 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 Cable gland 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 M25 x Converter operation Permissible voltage stress 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. 1 Upk t Standard insulation Pulse voltage Rise time Figure 4-10 Limit curves of the pulse voltage A5E A/RS-AD, 02/

22 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 load, grease service life 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. Switch on the anti-condensation heating only 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. 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 terminals. 22 A5E A/RS-AD, 02/2018

23 If the critical insulation resistance is less than or equal to this value, the windings must be dried or, if the fan is removed, cleaned thoroughly and dried. that the insulation resistance of dried, clean windings is lower than that of warm 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 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 = MΩ. 5.3 Checking the motor Protect the motor against overload. Do not exceed or undershoot limit speeds, e.g during operation with a backstop. 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. 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. Check all the touch protection measures for both moving and live parts. Check that the monitoring instruments are connected and set correctly. A5E A/RS-AD, 02/

24 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 24 A5E A/RS-AD, 02/2018

25 7 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. If you need the help from the Technical Support, please have 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. Improper maintenance Only authorized qualified personnel may perform the maintenance and servicing. Only original parts supplied by Siemens AG may be installed. 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 Daily; if possible, more frequently Operation (Page 24) unusual noise, vibrations, and changes. during operation. 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 26) Clean the geared motor. Depending on degree of soiling, at least every 6 months. Cleaning a geared motor (Page 26) A5E A/RS-AD, 02/

26 Measure Time interval Description of the work Check that fastening screws on After 3 hours, and then every 2 years. gearboxes and add-on elements are securely tightened. Check that covers and plugs are securely fastened. Check the torque arm's plastic bushing. Every 6 months. Checking tightness of fastening bolts (Page 26) Torque arms with shaft-mounted gearboxes (Page 16) 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 s Film of moisture on the shaft sealing ring Film of moisture as a result of the inherent principle of operation (apparent leakage) Identifiable small trickle, formation of drops, also after the running-in phase 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. 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. Leakage at the shaft sealing ring Replace the sealing ring, determine the possible cause of the sealing ring failure and rectify. 8.3 Cleaning a geared motor Dust deposits cause higher housing temperatures Dust deposits prevent heat radiation. Keep the geared motor free from dirt and dust. 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. 8.4 Checking tightness of fastening bolts ATEX version gearboxes Loose parts can cause sparks through impact. Entry of foreign bodies can cause sparks. 26 A5E A/RS-AD, 02/2018