70RW400 V99 4421 Gearbox Part List Pg.120-127

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... ... .. . . - - .... ...

-·EI<ATO RMT
.
PROJECT TITLE: BTR SINGAPORE PROJECT

DOCUMENT TITLE MA~U ~ AGU~II\f[1 PATA & CK -fD Rwfroo
SITE:
SINBTR1
PO NUMBER:
AREA:
V700 I SUBAREA:
AU70/AU76/BA81
310238840
EQUIPMENT:
70RW400
SUPPLIER
6100-\0
DOCUMENT NO.
BUILDING:
CLIENT DOCUMENT NO: C30001-EKT01-MAN-008
B139/136/119
e
PROJECT TITLE: BTR SINGAPORE PROJECT
EQUIPMENT TITLE AGITATORS (FINISHING)
FW PROJECT NO. DOCUMENT NO. SUPPLIER REVISION
1-P0-0353 6100-10 ~ 1
PO NUMBER FW REQUISITION NO. EQUIPMENTTAG NO
310238840 0353C-1391 B/01 70RW400
DOCUMENT TYPE CODE DSN FWREVISION
~ \!Ci~ 4421 1
e STATUS CODE
s;
ENGI~OUP
/P.9t
DATE
_2.g - ftpr-- 12-
COMMENT STATUS CODE:
1-Rejected For Reasons State. Change The Drawing/Document And Reissue For Comment FW.
2-lncorporate Comments Indicated and Re-issue Drawing/Document For Comments to FW.
3-Acceptable- lncorporate(Minor) Comments Indicated And Re-Issue Drawing/Document As Fin~~~ed~ {J
4-No Comments -Accepted As Final Certified. J(. Ck lf
5-Received For Information Only. c.8 r m 9S
1~2012
1 29.02.2012 Revision ace. Agreement dated 07th Feb. 2012 TDA PST PST
0 12.05.2011 For Information Mrz KTH LD
REV DATE DESCRIPTION BY CHKD APPD
0
EKATO RMT
Service Instructions
- Intended Use
-Transport
-Storage
-Assembly
-Start-up
- Maintenance
- Troubleshooting
-Overhaul
for the Agitator
HWL 2060 N
EKATO-App.No.: 11-80053-0040
Project: BTR SINGAPORE
P.O. No.: 310238840
Item: 70RW400
Compiled by: SCK Checked and released by: rff')(

Date: 13.10.2011 Date: Z9. FEB. 1011 \ ~
EKATO Ruhr- und Mischtechnik GmbH +49 171 771 94 94

PO Box 11 10/ 20 •
• In the United States:
D-79641 Schopfheim 1-800-750-7471
EKATO RMT
Revision Index
& CAUTION
The agitator has been designed and manufactured for a particular mixing task (see specification -t chapter 1)
Deviations from the specification such like changes of product data, changing the impeller position or
changing the rotational speed will in any case lead to a voidance of warranty, perhaps even to dangerous
resonance effects with the result of a failure of the agitator shaft, of flanges or bearings
Therefore modifications of the agitator's building standard as well as changes to the mixing task are
permitted only after full approval by EKATO
Index Date Name Description

Basic edition by documentation group
0 13.10.2011 SCK
EKATO Ruhr- und Mischtechnik GmbH
1 29.02.2012 TDA Revision acc. Agreement dated 07th Feb. 2012
Basic document:inpro_e.chp Agitator-type: HWL 2060 N Table of contents

Version: 12.09.1995 Customer ref.: 70RW400
Printed: 13.10.2011 EKATO-App.Nr.: 11-80053-0040 Page II
EKATO RMT
Table of Contents
1. Specification 1
General Arrangement Drawing . . . . 930-20194614-00 . . . 4
2. Not applicable . . . . . . . 5
3. Safety Instructions - must be read! 6
3.1 Permissible Users/Operators . . . . . . 6
3.2 Using these Instructions . . . . . . . . 6
3.3 Intended Use and Foreseeable Misuse . 7
3.4 Residual Hazards . . . . . 7
3.5 Noise .......... . 8
3.6 Documentation-Feedback 9
3. 7 Clearance- Certificate . . 10
4.0 Safety Instructions 13

4. Transport, Storage, Assembly, Start-up . ... 15
4.1 Transport . . . . . . . . . . . . 15
Lifting the Agitator Shaft . . . . 15
Rehanging the Agitator Shaft . . 16
1st Alternative . . . . . . 16
2nd Alternative . . . . . 17
Erecting the Agitator Drive . 18
Lifting the Agitator Drive . . 18
Removing the Drive . . . . . 18
Lifting the Agitator Lantern with the Drive already removed . 19
1st Alternative . . 19
2nd Alternative ........... . . 19
4.2 Storage . . . . . . . . . . . . . . . . . . . 20
Storage at Site and during Transportation . 20
Coated Surfaces (when applicable) . 20
Short-Term Storage . . . . . . . . 20
4.3.0 Mounting Instruction . . . . . . . 21
Means of Protection Measures . . 21
Marking . . . . . . . . . . . . . 21
Usage of Nord-Lock Washers . . 22
4.3 Assembly . . . . . . . . . . 23
Required Tools . . . . . . . . . 23
Preparatory Works/Checks . . . 23
Assembling Bolted Connections . 23
Inserting the Agitator Shaft . . . . 23
Connecting the Agitator Shaft to the Agitator drive head . . 24
Connecting the Agitator to the Vessel . . 24
Junction Agitator Shaft- Impeller Hub . . 25

Printed: 13.10.2011 EKATO-App.Nr.: 11-80053-0040 Page Ill
EKATO RMT
Checking the Agitator Shaft Run-out . . 26
Earthing the Agitator . . . . . . . 27
4.4 Start-up . . . . . . . . . . . . . . 28
Safety Information for Start-up . . 28
Checks prior to Start-up . 29
Agitator Shaft . . . . . . . . . 29
Impeller . . . . . . . . . . . . 29
Connecting the Agitator to the Vessel . 29
Overview Bolt Tightening Torques . 30
Test Runs . . . . . . . . 34
Starting Procedures . 34
Test Run in Air . . . . 34
Test Run in Water . . 34
Test Run during Emptying of the Vessel . 34
Retightening of Threaded Joints . . . . . 34
Procedure of Measurement at Shock Pulse Detectors (SPM nipples) . . 35
Start-up under Process Conditions . 35
4.5 Operation of the Plant . 36

5. Maintenance 40
5.1 Preface . . . . 40
5.2 Maintenance Measures . . 41
Agitator Drive . 41
Drive . . . . . . . . . . 43
Impeller . . . . . . . . 44
Lubrication Schedule . 45
Threaded Joints/Fall Off Lockings . 46

6. Troubleshooting 49
6.1 Preface . . . . . . . 49
6.2 Troubleshooting Chart . 49

7. Overhaul . . . 54
7.1 Major Overhaul . 54
Cooling Down the Vessel . 54
Safety Rules . . . . . . . . 54
Note on Outdoor Installation . 55
Usage of Nord-Lock Washers . . 56
Dismantling the Agitator . 57
Replacing the Bearing . . 57
Assembling the Agitator . 58

Printed: 13.10.2011 EKATO-App.Nr.: 11-80053-0040 Page IV
EKATO RMT
7.3 Decommissioning . . . . . . . 59
Safety Rules . . . . . . . . . . 59
Instructions for Disassembly . 59
Instructions for Disposal . . . 59
8. EKATO-Parts list and Drawing(s) 60

Reading the EKATO-Parts List . . 60
Example: . . . . . . . . . . . . . . . . . . 60
Parts List Agitator HWL 2060 N . . . . . . . 20193338 . . 61
Drawing Bearing Housing HWL 2040-2220 120-10082771-00 . .72
Drawing Clamping Flange . . . 950-20178507-00 . . 73
Drawing Flange Connection . . . . . . . . 615-20075060-00 . . 74
Drawing Grounding Connection . . . . . . 325-20191344-00. . 75
9. Instructions and Parts Lists of non-EKATO-Components 76

9.1 Motor VEM IE2-KPR 100 LX4 .
EC Declaration of Conformity
Data Sheet ..... .
Dimension Drawing . . IE2-KPR 100 LX4 . IMB5 FF215
Torque Characteristics
Connection Diagram . KP 0001
Instructions . . . . . . 68238 01
Additional Instructions 5022901
9.2 Flat Gear Flender FZF68B-K2-1 00
Dimension Drawing . FZF68B-K2-100.
Spare Parts Drawing 369101c; 87973c .
Parts List . . . . . . . SL 15089182-020
Works Certificate . . 15089182-000020
Operating Instructions BA 2010/05.10; BA 2019/05.10
10. Manufacturing Data Book for 70RW400 (Page 298 onwards)

Printed: 13.10.2011 EKATO-App.Nr.: 11-80053-0040 Page V
EI<ATO RMT
EKATO AGITATOR SPECIFICATION
Customer : LANXESS Butyl Pte, Ltd

Project : BTR Singapore
Project-Item : 70-RW400
Specification-No.: 0533.86051.01 I pb
Order-No. : 80053-40
AGITATOR
Type: HWL2060 N
Quantity: 1
MIXING T ASK(S)
suspending,
MATERIAL DATA
Density max. kg/m 3 975
Viscosity min./ max. mPas 0.354/ 0.354
VESSEL DATA
Length: mm 1500
WidthiD: mm 1500
Overall height of vessel incl. support beams: mm 3050
Height support beams: mm 250
Bottom shape: flat
Top shape: flat
Filling height: mm 2200 /1780 I 670
Filling volume: m3 4.95/4/1.5
Minimum required opening for passing the impeller,
manhole ID mm 300
For installation, customer to ensure accessibility to vessel inside.
Baffles are not required.
DESIGN DATA
Operating conditions for agitator
Temperature: min./max. oc 45/91
Pressure: min./ max. bar (abs.) 1.0 /1.0
Design conditions for agitator
Temperature: min./max. oc 40 /121
Pressure: min./ max. bar (abs.) 1.0 /1.0
Design conditions for mounting flange
temperature: min./ max. oc 40 /121
Pressure: min./ max. bar (abs.) 1.0/1.0
Ambient temperature: min./ max. oc 5.0/40.0
The agitator is mechanically designed for operation during filling and emptying.
Minimum liquid level for operation mm 1290
Level control device by customer.
For liquid level below the min. level for operation a minimum velocity of liquid
alteration must be assured m3 /h [mm/min] 5.4 resp. [40]
The agitator must not be started when impeller(s) are covered with settled solids.
ELECTRIC MOTOR
MakeVEM Type IE2-KPR 1OOLX4
Frame size: IEC-100
Nominal power: kW 3.0
Nominal speed: rpm 1455
Voltage: v 3 x400
Nominal frequency: Hz 50
Protection class: IP 65
Explosion protection: EEXNA
Insulation class: F, usage ace. to class 8
Efficiency class IE2
Mounting arrangement: V1, with drip cap
19.02.2011' pb
EI<ATO RMT

Specification-No. : 0533.86051.01 I pb
Order-No. : 80053-40
PARALLEL HELICAL GEARBOX:

Make SIEMENS-FLENDER, Type: FZF68
Gear ratio: 10.31 Output speed: rpm 141
According to AGMA 6010, service factor: min. 2.5
Cooling: air
Accessories:
- without oil filling
- with flexible coupling
-with dessicant breather
AGITATOR BEARING
Agitator lantern in cast iron design
Type: HWL2060 N
With radial bearing
Bearing life time Lh10: h >100000
with grounding connection
MOUNTING PLATE
Size 400mm x 400mm
Agitator will be supported on top of the tank by means of a supporting
structure provided by others.
With bolting elements, locking washers: NORD-LOCK included in the scope of supply
AGITATOR-SHAFT
Diameter mm 60
Length mm 2750
Rotation (viewing from drive to impeller) Clockwise
Connection with flange coupling inside the vessel, diameter mm 145
With bolting elements, locking washers: NORD-LOCK
Shaft designed for impeller height adjustment: lower impeller + 450 mm
upper impeller +- 450 mm
IMPELLERS
EKATO VISCOPROP, 2-bladed Qty. 2
Diameter mm 600
Pumping direction pumping away from drive
Mounted with smooth hub design
With EKATO set screws, locking by punch strokes
Bottom clearance approx. mm 300
Impeller clearance approx. mm 600
MATERIALS (PRODUCTSIDE)
Mounting plate Stainless steel 1.4571 ( eqv. 316Ti)
3.1 certificate
Shaft Stainless steel1.4571 (eqv. 316Ti)
3.1 certificate
Impellers Stainless steel1.4571 (eqv. 316Ti)
3.1 certificate
Connection elements in the vessel A4 (eqv. 316, 316Ti)
EXTERNAL AGITATOR COMPONENTS

All parts not made of stainless steel are primed and painted to EKATO's standard Type 100.
Agitator colour RAL 5003
ARRANGEMENT I WEIGHT I OVERALL HEIGHT

Top-entry, vertical, centrical, on the vessel
Agitator including drive approx. kg 350
From agitator support to uppermost edge of drive approx. mm 1350
2 19.02.2011, pb
EI<ATO RMT

Specification-No.: 0533.86051.01 I pb
Order-No. : 80053-40
LOCATION DATA
Plant elevation over sea level (SL): m <= 1000
Location: outdoor
The agitator is designed for installation in a non Ex-area and for outdoor installation without sun roof.
GENERAL INFORMATION
EKATO has no knowledge on how the contents of the product in the vessel will affect the materials of construction
and therefore cannot assume any responsibility. Product wetted parts like metals, elastomers, coatings and gaskets
must be specified or approved by customer. Unless otherwise stated by the customer the product wetted parts will
be supplied as indicated in the agitator specification.
Should specific agitator requirements exist that might directly affect the product quality, e.g. gap-free design,
surface quality, etc., then these must be specified by the customer. This applies particularly to agitators that are
used in the production of foodstuffs, cosmetics or pharmaceutical products where a risk of infection, disease or
contagion exists.
Should any risk be present based on hazardous substances (those harmful to health or that are toxic, corrosive,
explosive, (micro-) biological, etc.) or hazards be present in the mixing vessel or with the mixing process (e.g.
substances that can be inhaled, swallowed or come into contact with skin, eyes or mucous membranes) and therefore
present specific requirements on the agitator and/or the sealing system (e.g. pressure overlay), then these requirements
for the agitator and/or sealing system must be specified by the customer.
In case the customer has not specified any particular requirements at the time of order, then this means that the design
EKATO RMT has offered has been checked and approved by the customer.
ELECTRIC AND OTHER CONNECTIONS

Required utilities (electricity, cooling water, nitrogen, etc.) to be provided on site.
FINAL INSPECTION
Before dispatch the agitator will be inspected in accordance with EKATO's design rules and inspection procedures.
If applicable, with the documentation we will supply a declaration of incorporation according to Appendix liB of the
EC Machinery Directive.
QUALITY ASSURANCE
The design, manufacture, assembly and inspection of the agitator follow the QA instructions based on EKATO
quality system management according to DIN EN ISO 9001.
WARRANTY
The EKATO-warranty is based on the design of the agitator and the operating conditions described in this
specification. Any changes or modifications must be approved in writing by EKATO otherwise all warranty
claims will become null and void. EKATO cannot accept liabilities for damages which are caused by the
design or workmanship of the agitator support structure, the vessel, the agitator supports and of
components delivered by other suppliers (such as supports, tubes, heating I cooling bundles vessel
internals, etc.).
3 19.02.2011' pb
~~~~~~------~~~~~~--~~~~~~~--~~~-----~~~~~~~~------.---~~~~~---~~~~~~--~~~~~~~--~~~~~~---~~~~~-----~~-~
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GEARBOX: FLENDER
TYPE: FZF68
TECHNICAL DATA ACC. SPECIFICATION
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AGITATOR BEARING UNIT

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MOUNTING PLATE
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FLANGE CONNECTION
0145
H I H
DIRECTION OF ROTATION
2200
____51__
+ !
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AGITATOR SHAFT
I
G 1780 G
____51__
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0
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MOUNTING PLATE DIMENSIONS
NTS 400
F 25 350
I I l
I
; VISCO PROP
I
! 2-BLADED
FIXED WITH SLIDING HUB
AND EKATO SET SCREWS
E I I ADJUSTABLE +/- 450 @ E
650
0
0
I I
<D
I I VISCOPROP
~L_----~~:·_6o_0--6~~r 1
2-BLADED
FIXED WITH SLIDING HUB
AND EKATO SET SCREWS
~ ~
ADJUSTABLE + 450
! I I BTR SINGAPORE PRO.I:CT
D D
0 FLOW DIRECTION
0
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COI.I~OIT ST~TUS COOE

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1 01500 ~·llo<.....,.h-oo"'I"'"'""''~'"~O!Itd.
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CONTRACT Nc. \-f'0-0353 S'I'S1EI.\ No.: t.b.o SCALE: l:B

CONST'N AREA : t.b.o. OSN No.:4~0!! ORIGINAl : Al
FWA!>oc OWG No :
SUPPLIER LOGO AND ADDRESS

SHOWN IN PRINCIPLE
CUENT:
MIN. OPENING FOR PASSING INTANK PARTS: 0300
PRODUCT WETTED METALLIC PARTS MADE OF 1.4571
LANXESS
B (EO: AISI 31 6TI) ~~~~--~~~N~XES~s~~~~~L~~~L~TD~~~~~B
f'ROJEClllTLE:
BTR SINGAPORE PROJECT
INTANK BOLT CONNECTIONS A4 ACC. ISO 3506
DRAWING TilLE:
WEIGHTS @ GENERAL rB~~6l\llfljJ DRAWING
min max stat start average CLIENT: LANXESS Butyl Pte. Ltd ® sm: SINBTR1 I AREA:v7oo sua "~EJ7o IEouiP1b~w4oo
MOTOR 34 kg PROJECT: BTR Singapore PONUIASER: 3102JBB40
Axial force F,[N] -2800 -2500 -3100 - -2600 _ _
lateral force fo[N] -140
GEARBOX 60 kg ITEM: 70RW400 ® SUPPLIER DOCUMENT No:
930 20194614 00
SHEEl: ~~EV
140 0 0
Bending moment Me[Nm) -240 430 91 91 COMPLETE BEARING UNIT 79 kg ORDER NO.: 80053-40 FEL3 OWG No.:
CLIENT OWG No.: C30001-EKT01-GAA-oo3l""'~f3g

Torque Mr[Nm] 150 270 620 210 BEARING SHAFT 21 kg Dote Nome Type :
, !~e dynamic port of the lateral forces and of the bending moments is revolving.
A •The calculation of the dynamic loads is done without regard of the vessel pressure.
5
~-~~- ~{;~~~~o; ,support must be checked by the customer with respect to strength
AGITATOR SHAFT 55 kg
B) Revision 11.07.11 KGE
""''d
nooood
td cnoekod
22.02.11
22.02.11
DMI
SCR
HWL2060N EI<ATO A
li~it- for the angular deflection of the agitator support during operation; +/- 0,05'.
IMPELLER P"A:.L)_Rc_oe:_::vi-"'si;.can'---~~~f'2"'2.D::c:_3-:_:_llt'IT'-"C'-----jscole: Drawing No.:
T~e agitator nozzle must be arranged horizontal. 2x4, 7 kg Nome :
Allowable deviation: 0,2' (3.5mm/m). (field arrangement) Chocg" Dote Nome 18 Ef<ATO AGITATOR 930-20194614-00 B
The vessel with attachments and compenents must be designed to avoid resonances
caused by agitator operation.
TOTAL WEIGHT 310 kg Thfo drn-~lng lo p!lvol• ood eonnd.,!lol eommunicotlon
ondlhoptopo,jyof8<ATO
11 "''"''no! ~~ cop:oa or loot •I!Oout conoont ol E'GITO - GENERAL ARRANGEMENT DRAWING f;~plocemont for :
D Replccedby:
7 6 4
AI
EKATO RMT
2. Not applicable
Basic document: 2platz_e.chp Agitator-type: HWL 2060 N 2. Declaration by the Manufacturer

Printed: 13.10.2011 EKATO-App.Nr.: 11-80053-0040 Page 5
EKATO RMT
3. Safety
Instructions
must be read!
3.1 Permissible
Users/Operators
EKATO agitators are intended for commercial use
only. They must only be handled and operated by
skilled personnel.
3.2 Using these

1. 2.
Instructions These instructions must be read and understood
by every person who is to install, maintain or
If preliminary documentation has been compiled,
repair the agitator.
it must be discarded upon receipt of the final
documentation. The same applies to the instructions provided by
all sub-suppliers (chapter 9)
These instructions describe the handling and use of
the EKATO agitator, i.e. In addition to these instructions and the mandatory
rules and regulations for accident prevention
-Transportation applicable to the country and place of use of the
-Storage equipment, the generally recognized technical
-Assembly guidelines for safe and proper working conditions
and procedures must also be complied with when
- Start-up handling or working with the agitator. This includes
- Maintenance the use of personal protective equipment such as
helmets, industrial footwear, goggles and gloves.
- Troubleshooting
Specific safety measures must be taken before
-Overhaul entering a vessel that has been used to process
and toxic or corrosive products (protective clothing,
breathing apparatus).
-Disposal.
These instructions do not describe the control
system of the agitator, nor do they deal with
process matters. For information on these topics
3.3 Intended Use and
please refer to the documentation provided by the Foreseeable Misuse
system supplier, plant contractor or operator.
The agitator is designed solely for the mixing task
CAUTION
as described in the specification (chapter 1). This
includes the specified product/process data
Illustrations in these instructions are usually
(viscosity, density, temperature, pressure).
symbolic, i.e. they do not reveal the exact details
of the agitator described. The agitator must only be operated in accordance
with the terms of the specification.
For the components to be used, see the parts list All special conditions required in the specification
(-+chapter 8), the dimensional sheet(-+ chapter 1) (-+ chapter 1) must be specifically complied with
or the drawin s when ordered,-+ chapters 1 or 8).
Basic document: 31_e.chp Agitator-type: HWL 2060 N 3. Safety instructions

Version: 0.0-27.01.2010 Customer ref.: 70RW400
EKATO RMT
Any deviation will be considered to be unintended
use and foreseeable misuse. EKATO disclaims all 3.4 Residual Hazards
responsibility for any damage resulting from this.
There are residual hazards that cannot be fully
WARNING removed by design alone. Certain actions could
lead to damage and hence long-term adverse
The agitator must be operated in accordance effects on safety.
with all relevant regulations, directives, statutory For these cases these instructions can include the
requirements, etc. in order to prevent its following safety notices:
incorrect use.
&~
The agitator has been manufactured to a
state-of-the-art design and in compliance with DANGER
internationally recognized safety rules. As supplier
of the agitator without a control system, EKATO has Disregarding this safety instruction will
no influence on the safe design of the control inevitably result in fatal accidents
system and the access to the vessel. EKATO
therefore prohibits the start-up of the agitator if it is
& DANGER
not guaranteed that the plant complies with the Disregarding this safety instruction WILL
requirements of the European Machinery Directive inevitably result in severe injuries or even fatal
(2006/42/EC), the Equipment and Protective accidents.
systems intended for use in a potentially Explosive
Atmospheres "Atex" Directive (94/9/EC} and, if
applicable, the European Pressure Equipment
& WARNING
Directive (97/23/EC} and that the applicable local Disregarding this safety instruction COULD
laws and regulations for the safe operation of plants result in severe injuries or even fatal accidents.
and machinery are being complied with.
In particular, the system shall provide means that
& CAUTION
prevent an unintended start-up and any contact Disregarding this safety instruction MAY result in
with moving parts. Protective devices must be material damage or minor injuries.
applied when hot surfaces are in "accessible areas"
(i.e. accessible without aids such as ladders).
However, system cooling must not be impeded by
these.
The agitator shall only be started when all intended Additional important instructions on protection
protective grids and covers are installed. from explosions especially for ATEX agitators.
Modifications, extensions or alterations shall be These agitators are marked specially and are
carried out only after full approval by EKATO. delivered with a Declaration of Conformity
Intended use also includes the observation of all Observe these instructions and comply with the
instructions (including the instructions of safety rules at all times!
subsuppliers, chapter 9) and maintenance
regulations as well as the immediate remedy of any
malfunctioning and defects, the agitator otherwise
being shut down until the problems are rectified.
3.5 Noise
All spare parts must comply with the requirements In order to prevent damage to hearing due to
specified by EKATO and must be supplied or long-term exposure to noise, hearing protection
released by EKATO. must be worn during any prolonged periods of time
Only by using genuine EKATO spare parts can the spent in the close vicinity of the agitator when it is
ongoing validity of the EC Declarations of in operation.
Incorporation, any Declaration of Conformity and The noise level depends on the vessel, the
guarantees be ensured. supporting structure and the stirred product.
Therefore a definitive measurement of noise level
can only be made on site.
The ATEX certification (when applicable) in

accordance with 94/9/EC ceases to be valid if
modifications not authorized by EKATO are made
or spare parts not released by EKATO are used.

EKATO RMT
3.6 Documentation-Feedback

- Technische Dokumentation -
Postfach 111 0/20
D-79641 Schopfheim
Germany
Dear user of EKATO-agitators

Certainly you had questions regarding installation and operation of the agitator. We spent a lot of care to
answer these questions in this manual. Therefore we would like to know whether we were successful. Please
fill in a copy of this sheet and let us know about your findings.
We DO need your feedback when you find descriptions incomprehensible or faulty, particularly when you
identify a safety risk, either by design or by insufficient description.
Yours sincerely
For your comments:
Sender:

EKATO RMT
3. 7 Clearance- Certificate
All repairs/complaints received must always be sent to us accompanied by a Clearance- Certificate that has
been filled in correctly.
In order that we follow the standard regulations for the chemical industry, the workshops can only begin to
dismantle components once they have first been adequately cleaned and rinsed.
This ensures that it is also to the benefit of our customers that, during transportation, no-one is injured and
that there is no danger to the environment.
For incoming goods where the customer has not filled in a Clearance- Certificate, the goods are to be marked
and stored accordingly until the customer submits a Clearance- Certificate.
An appropriate form is to be found on the following page of these service instructions.

EKATO RMT
Clearance - Certificate
You return I returned to EKATO RMT GmbH for repair I modification:
D Agitator D Mechanical shaft seal
D Motor I Gearbox D Mechanical shaft seal rings
D Agitator shaft D Others
D Impeller
Agitator type
Serial-no.
Company name (Address):
Contact person
Phone
E-Mail
You herewith confirm, that the parts you sent to EKATO are not contaminated with any
substances that are hazardous to health and that any endangering of EKATO personal
during inspection, maintenance and repair of these parts is excluded. The agitator is
completely drained, washed and decontaminated.
Disassembly or inspection of the agitator or of the parts sent to EKATO for repair or
modification will only take place after we have received this certificate duly signed.
Place, Date Stamp I Signature - Customer
Will be filled out by EKATO RMT:
On the face of it, the parts are okay! (visual check)

Release through EKATO-Safety-skilled person Date I Signature - EKATO

EKATO RMT
Clearance - Certificate (Additional specification)
Last operating medium :

(Product in the vessel)
Material safety data sheet of the Dyes D no
last operating medium enclosed
The last operating medium was rated as follows: (Please mark the relevant points)
D Flammable D Oxidizing
D Corrosive D Harmful to
environment
Recommended safety/protective measures: (Please mark the relevant points)
D Respiratory protection
Additional remarks
Place, Date Stamp I Signature - Customer

EKATO RMT
CAUTION
4.0 Safety Do not use vessels, pipes or the agitator lantern as
climbing aids
Instructions
Use a safe workin latform
CAUTION
It must be ensured that the system is in a safe & CAUTION

condition before carrying out any work on the
a itator Structural installations (monitoring, pressure
supply, cooling water supply etc.) should be
separated from the aqitator
WARNING
Before all maintenance work and/or WARNING

troubleshooting either
- completely disconnect agitator from mains For pressurized vessels:
or
- switch off and shut switch into Check for leaks when starting up.
OFF osition. There is a risk of hot, toxic or corrosive materials
esca in
CAUTION
Work on electrical equipment should only be

carried out by authorized personnel (e.g. company
electricians)
A'
£.U X DANGER
for vessels with lids:
the agitator must only be operated when the

CAUTION vessel lid is closed and secured. The operator
must ensure that the agitator can not be
The relevant laws, accident prevention regulations operated when a vessel opening is open
and recognized technical regulations for safe and
specialized work with this agitator should be
observed for open vessels:
This includes using protective equipment such as
helmets, shoes, protective goggles and gloves the operator must ensure by means of suitable
Special safety measures should be taken when a safety measures that any contact with circulating
vessel in which a poisonous or corrosive product agitator parts is impossible (there is a risk of
has been processed needs to be entered being pulled in)
( rotective clothin , breathin apparatus).
WARNING
& CAUTION
Never work inside vessels without supervision

For pressurized pipes:
Never use pipes as handles or for attaching

lifting tools
In the event of leaks or ruptures, liquid escaping

at high pressure can pierce the skin and cause
oisonin , in'ur or death.
Basic document: 4GEF50_e.chp Agitator-type: HWL 2060 N 4.1 Transport

EKATO RMT
CAUTION •& DANGER
Particular attention should be paid to identifying
Explosive atmosphere must not occur at hot "invisible hazards" which can arise from
machine or installation parts dismantling parts which have been in contact
with the product if this is toxic or corrosive.
Process conditions, such as when the vessel is
heated, result in agitator components (gasket, The operator must take every precaution to
mounting flange, agitator shaft, impellers) and eliminate any hazards.
vessel internals also reaching the process
temperature. Appropriate additional explosion
protection measures must therefore be taken, e.g.
allowin sufficient time for coolin to take lace
I& CAUTION
&
'
X DANGER
The underside of the seal and the top of the
suspension device can be contaminated with
product - if necessary provide protective
High-temperature processes result in heating of •P-nuinment and cleaninQ measures
the shaft as far as the upper section of the agitator
There is a risk of damage to the a-rings if the In the presence of other interfaces between agitator
buffer fluid is drained from the sliding ring seals and structural installation:
too early or sliding ring seals are pulled onto hot
shafts CAUTION
There is a risk of corrosion of bearings and

bushing guides if attempts are made to pull sliding
ring seals away from hot shafts or pull them onto es before separatin them
hot shafts
Before beginning work, let the vessel cool down

so the shaft temperature directly above the seal is
& CAUTION
at most 50° C. Wear protective clothes Impulsive stress can damage agitator components
such as the bearing or flushing ring.
During operation, pressure peaks and rapid
&
'
><:DANGER
A suspension device does not seal the vessel!

changes in pressure must be avoided.
When dismantling the upper part of the agitator,

vapour can escape from the vessel
If the vessel contains poisonous or corrosive

product, it must be emptied and cleaned before
continuing.
CAUTION
Do not carry out any work inside the vessel when

the shaft is sus ended
Basic document: 4GEF50_e.chp Agitator-type: HWL 2060 N 4.1 Transport

EKATO RMT
& CAUTION
4. Transport, Avoid large temperature changes
(formation of condensation)
Storage, & CAUTION
Assembly, Always keep stainless steel parts away from

carbon steel
Start-up e Remove corrosion protection immediately
preceding installation
(non-coated/rubber-lined agitator shaft with flanged
coupling)
Lifting the Agitator Shaft
NOTE: Sketches are schematic. The agitator shaft is
shown without impeller(s).
Before beginning work on the agitator, make sure
When lifting an agitator shaft with impellers already
that no explosive atmosphere exists.
attached, make sure that the rope/belt does not
make contact with the impeller blades during the
lifting procedure
4.1 Transport CAUTION
WARNING
Do not stay underneath

suspended loads WARNING
Use suitable and Danger of damaging rope/belt slings when

coming into contact with (sharp) edges on
properly dimensioned
lifting gear only a itator shaft e ui ment
(for weights see parts • Make sure that during the complete lifting
list -+ chapter 8) procedure the rope/belt slings can not come into
contact with equipment such as keys, blade
Never use ancillary holders, carrier discs or impellers that may be
equipment or piping for already attached to the agitator shaft.
the attachment of
liftin ear
e Remove all detachable keys from the agitator
shaft before attaching the rope/belt slings and
reinsert after completing the lifting procedure
& CAUTION
Do not use force
Lift unpacked parts with rope or belt slings only;

for direct attachment only use slings made of
non-metallic material, on coated/rubber lined
surfaces slings made of non-metallic material
must be used
Do not put shafts on an edge- Shafts and

impellers are carefully trued and would otherwise
bend
Basic document: 40c_e.chp Agitator-type: HWL 2060 N 4.1 Transport

EKATO RMT
Rehanging the Agitator Shaft
1st Alternative
e Attach a rope/belt sling of sufficient length to
both ends of the agitator shaft (instruction
I D -+ previous page)
e Create loops at both

ends of a rope/belt
& CAUTION
c~o
sling of sufficient length Tighten the eye-bolts
co~ ~
loosely only- Risk of
damaging the flange
surface
e Attach two eye-bolts to
I D the flange
e Draw a short rope/belt
sling through the
eye-bolts
e Put the sling into a
hook with slip-off
e Put the loops around protection
the agitator shaft and
tighten them
CAUTION
e Put the rope/belt sling

into a hook with slip-off
protection
e Lift the shaft
e Lift the agitator shaft

with the long rope/belt
sling

EKATO RMT
e Tighten the slings and
t rotate them such that

they point in opposite
directions
--'.71111111111111f..J e Put the slings into a
e Lift the other hook ~iililll::i.......- hook with slip-off
protection
& WARNING
e Lift the agitator shaft
The agitator shaft could with the long rope/belt
swing out during sling
rehanging
e Take the full weight on the second hook

e Remove the long sling
The agitator shaft is ready for lowering into the
vessel
2nd Alternative
e Attach a rope/belt sling of sufficient length to
both ends of the agitator shaft (instruction
- previous page)
e Lift the other hook
e Attach a short rope/belt

sling behind the flange
e Attach another short

rope/belt sling behind
the flange
e Take the full weight on the second hook

e Remove the long sling
The agitator shaft is ready for lowering into the
vessel

EKATO RMT
Erecting the Agitator Drive Lifting the Agitator Drive
(flat gear) Note: The eyes, shackles and eye-bolts on the
motor and the gear unit are dimensioned only to lift
the respectively part (-+ chapter 9)
e Attach a rope/belt sling

made from e Put a rope/belt sling
non-metallic material made from
underneath the flange non-metallic material
between the drive and around the gearbox
the lantern housing
e Create a loop from the e Tighten the loop and

free end of the sling put the sling into a
and put it around the hook with slip-off
lower end of the motor protection
e Lift the agitator drive
e Tighten the loops and

put the sling into a Removing the Drive
hook with slip-off
protection CAUTION
Attach the lifting gear such that the holding point

is above the center of gravity- Hazard of
overturn in
e Put a rope/belt sling made from non-metallic
CAUTION material around the gearbox housing (see above)
e Attach an additional rope/belt to a suitable
Do not lay the agitator high-lying attachment point on the motor (e.g.
drive onto the shaft eyebolt)
e Lay the agitator drive e Put the lifting gear into a hook with slip-off
on the flange protection and tighten it
e Disconnect the drive from the lantern and lift it
Basic document: 41e_e.chp Agitator-type: HWL 2060 N 4.1 Transport

EKATO RMT
Lifting the Agitator Lantern with
the Drive already removed
1st Alternative
• Attach min. 2, better 4 eye-bolts to the upper
flange of the agitator lantern
• Attach the lifting gear to the eye-bolts and to a
hook with slip-off protection
2nd Alternative
• Create loops on both
ends of a long
rope/belt sling from
non-metallic material
and attach them
underneath the upper
flange of the agitator
lantern
• Tighten the loops and
put the sling into hook
with slip-off protection
• Instead of one long sling two identical short

slings can be used
Basic document: 41e_e.chp Agitator-type: HWL 2060 N 4.1 Transport

EKATO RMT
8 Keep shafts on wooden
4.2 Storage beams and prevent
from rolling
Storage at Site and during 8 Protect from dust and

humidity (cover)
Transportation 8 Store vibration-free
8 See packing list 8 Avoid contact between
8 Follow the instruction from non-EKATO stainless steel parts
components (-+Chapter 9) and carbon steel or
between other different
8 Note that the time frame starts with the exworks
metallic parts (e.g.
delivery date (-+ Delivery note)
titanium, tantalum etc.)
8 Components have to stay in the original package
or have to be repacked until mounting 8 Outdoor storage only on wooden bases, never
right on the ground
Coated Surfaces (when applicable)

& CAUTION
Do not store rubber lined parts below -20° C (-4 F)

-danger of cracks due to thermal strain
When storing outdoor, shelter from light (cover)-

danger of embrittlement from UV-radiation
Use upholstered pads, protect edges- coated

surfaces are susceptible to damage
Avoid contact with oils or solvent
Assembly of parts with coated surfaces is only

allowed to be started at ambient
temperarure >5oC
8 Whenever possible store coated parts indoor in
their original package only
Short-Term Storage
Short-term storage means storage during erection
and installation
Basic document: 42_e.chp Agitator-type: HWL 2060 N 4.2 Storage

EKATO RMT
4.3.0 Mounting Instruction
Means of Protection Measures

& WARNING
The operator (user) must ensure by means of

suitable protection measures (e.g. safety
screens) that any contact with agitator rotating
elements is impossible (Danger of burning or of
being pulled in )
Marking
NOTE: In order to identify the required mounting
orientation, components of the rotating system may
have markings
e Check the flange connections and impeller hubs
for markings and only assemble the parts
accordingly
e Marking:
XXXXX-XXX = serial number
Y = part number (if applicable)

e.g.: lower impeller
Z = sub-part number (if applicable)

e.g.: if impeller consists of more than one part
e Example for marking:
XXXXX-XXX Y.Z = 12345-010 1.2
Basic document: 4mark_e.chp Agitator-type: HWL 2060 N 4.3 Assembly

EKATO RMT
Usage of Nord-Lock Washers
8 Check the sectional drawing (when in scope of

supply,-+ chapter 8) or the parts list
(-+ chapter 8) to find out where to apply
Nord-Lock washers
8 At each location
combine two
Nord-Lock washers as
shown (when delivered
the washers are glued
together in this
orientation)
8 Tighten the bolts evenly with 15 percent higher

torque than regularly recommended for the bolt
size, material and operating temperature
(regular torque values -+table chapter 4.4) -
when the general assembly drawing, if provided
(-+ chapter 1), or the agitator cross sectional
drawing, if provided (-+chapter 8), give torque
values, these values already include the increase
due to the Nord-Lock washers
Basic document: 4nord_e.chp Agitator-type: HWL 2060 N 4.3 Assembly

EKATO RMT
4.3 Assembly Assembling Bolted Connections

e Lubricate the threads of the bolted connections
before assembly
Required Tools
e Check the sectional drawing (-+chapter 8 ) for
& WARNING
special torque values and pre-loads.
If there are no values given on the drawing, use
the EKATO standard torque values (-+ table
Works on hanging loads chapter 4.4)
Before work study e Check the sectional drawing or the parts list
lifiting procedures (-+chapter 8 ) to find out where to apply wire
(-+chapter 4.1), check locking
weights in the parts list e Check the sectional drawing or the parts list
(-+ chapter 8) and (-+chapter 8 ) to find out where to apply
select suitable lifting Nord-Lock washers. Tighten bolted connections
gear with Nord-Lock washers with a 15 percent higher
torque recommended in table (-+ chapter 4.4)
- 2 cranes (alternatively
1 crane and another
e Always tighten bolts in a diagonally opposite
sequence and in several stages
device for the lifting of
the agitator shaft) e Finally ensure that all bolted connections were
tightened according to the specified torques.
- Ropes or belts It is highly recommended to record the torque
- if required eye-bolts values in case of warranty claims
and shackles
- 2 clean beams
Inserting the Agitator Shaft
(alternatively rubber
plated U- or !-beams), Note: Retain flange covers for reuse during
with holes and fixing overhaul works
screws
- other beams to support CAUTION
the erected agitator
Protect the flange
- generals tools
surface from dama e
cover
e Pick up the agitator
shaft and bring it to a
Preparatory Works/Checks vertical position (lifting
e Check that the nozzle seal face complies with the procedures
requirements (roughness) and is free from -+ chapter 4.1)
damage
e Lower the agitator shaft
Only for vertically mounted agitators: into the vessel
+ make sure that the e Put two clean beams
orientation of the onto the flange
nozzle seal face to
the horizonal lies
e Lay the agitator shaft
onto the beams
inside of the
tolerance range e Secure thebeams with
specified on the screws (alternatively
assembly drawing or with clamps or
in the loads on the ropes/belts)
agitator support
(-+ chapter 1)
+ if necessary rearrange the vessel

Basic document: 43zds_e.chp Agitator type: HWL 2060 N 4.3 Assembly
Printed: 13.10.2011 App.Nr.: 11-80053-0040 Page 22
EKATO RMT
Connecting the Agitator Shaft to ---.,..--....,---- e Attach the remaining
bolted connections
the Agitator drive head (6110-6130)
e Pick up the agitator drive e Version with gasket:

(lifting procedures--+ chapter 4.1) • Center the gasket
e Tighten the flange joint
crosswise with half the
final torque value
eVersion with gasket: e Tighten all flange joints
• Place the gasket for crosswise with the full
the vessel flange final torque value
e Remove the flange
cover from the bearing
shaft
Connecting the Agitator to the
e Make sure that the mating surfaces are free from
Vessel
dirt and damage e Version with gasket:
e version with slinger disk between the flanges: NOTE: Due to the gap between the mounting
• put the slinger disk onto the lower flange flange and the vessel flange application of standard
torque values might deform the mounting flange.
Special torque values apply instead.
e Make sure that pairs of • Mount the agitator to the vessel flange with
Nord-Lock washers are bolted connection (481 0-4830). Final torque
oriented as shown value of the bolted connection = XXX Nm
(when delivered the
• Tighten the flange joint crosswise with half the
washers are glued
final torque value
together in this
orientation) • Tighten the flange joint crosswise with the full
final torque value
e Version without gasket:
• Mount the agitator to the vessel flange with
e Lower the agitatordrive onto the agitator shaft bolted connection (4810-4830). Use the torque
NOTE: Final torque value of the bolted connection values recommended in table(--+ chapter 4.4).
(6110-6130) = 4508 Nm. Because of the Nord-Lock • Tighten the flange joint crosswise with half the
washers the connections are to be tightened with a final torque value
15 percent higher torque
• Tighten the flange joint crosswise with the full
e Connect the agitator final torque value
shaft to the bearing
shaft with two bolted
connections (611 0-
6130) in opposite
position
e Tighten the flange joint
crosswise with half the
final torque value
e Lift the agitator drive a little

e Remove the beams
Basic document: 43zds_e.chp Agitator type: HWL 2060 N 4.3 Assembly

Printed: 13.10.2011 App.Nr.: 11-80053-0040 Page 23
EKATO RMT
Junction Agitator Shaft - Impeller Hub
(Hub with Set Screw DIN 913, 914, 915, 916 or EKATO-Set Screws)
~sw DIN 913,

DIN 914
~sw
DIN 915
~sw
DIN 916
@
8 8
@ ~sw
EKATO
NOTE: After tightening the set screws or EKATO-set With set screws DIN913/914:
screws must be locked with 2 centre punch strokes • Make sure there are spot facings/drillings for
e See the parts list (-+ chapter 8) for applicable the set screw(s) on the shaft or the parallel key
parts resp. yet
e Bring the impeller(s) into the vessel e Slip the hub onto the shaft (note the indicator for
& CAUTION
the sense of rotation and the pumping direction)
With set screws:
In any case the impeller(s) MUST be installed • Position the hub such that the spot
where specified facings/drilling on the shaft or the parallel key
line up with the set screw positions
Impeller placement different from what specified
may cause operation too near to the critical speed
e Insert the set screw(s) or EKATO-set screw(s)
e Tighten the set screw(s) or EKATO-set screw(s)
e For positioning follow the dimensional (evenly, avoid bracing) and lock each set screw
sheet (-+ chapter1) or the general assembly or EKATO-set screw with 2 centre punch strokes
drawing (when ordered, -+ chapter 1 or 8)
Tightening torques for set screws/EKATO-set
e Remove corrosion protection screw(s):
e Check shaft seat, possibly key way and key, hub M10 16 Nm
and attachment parts for damage M12 30 Nm
With key and key way: M16 68 Nm
M24 230 Nm
• Make sure the parallel key(s) is/are in position
(and fastened with screws if provided) NOTE: For special materials check the data of
tightening torque on the assembly drawing,
(-+ chapter 1), or the cross sectional drawing
(-+ chapter 8)
Basic document: 44neu_e.chp Agitator-type: HWL 2060 N 4.3 Assembly

EKATO RMT
The maximum total indicated run-out Xmax shall
Checking the Agitator Shaft Run-out comply with the following condition:
CAUTION
X maxiY ~ 211000
Never work inside vessels without su ervision
i.e. per meter shaft length the total indicated run-out
shall not exceed 2 mm (1/12")
in other words: the deviation from the imaginary
center line of an absolutely true shaft shall not
exceed 1 mm (1/24") per meter shaft length
For rubberlined shafts:

+ If possible, carry out the measurement on a
turned surface, e.g. on the cap nut. When the
measurement is taken on a rubberlined shaft
the run-out limit may be increased by 3 mm in
order to compensate for the uneveness of the
rubberlining, particularly at the seam.
When the run-out exceeds the permissible value

and there is a flanged coupling between the bearing
shaft and the agitator shaft:
+ Check that there are no foreign bodies
between the coupling flange halves
If the T.I.R. stills exceeds the permitted value
or
the agitator comes without a flanged coupling but
with a threaded coupling or integrated bearing
agitator shaft instead:
y + Contact the EKATO Service department (either
the bearing shaft or the agitator shaft resp. the
bearing agitator shaft has suffered bending
during transport or a flange was damaged and
must be trued)
e Provide access to the drive (e.g. coupling or fan

wheel) so that the the agitator can be rotated by
hand
e Apply a dial-indicator to the end of the agitator
shaft
e Fully rotate the agitator shaft by hand (e.g. by
turning the fan wheel)
e Measure the total indicated run-out X (T.I.R), read
the length of the agitator shaft from the
specification (-+ chapter 1)
Basic document: 47 _e.chp Agitator-type: HWL 2060 N 4.3 Assembly

EKATO RMT
Earthing the Agitator
4D See drawings (--+Chapter 1, 8) for earthing point
e Mounting flange must be earthed by means of
provided thread/screw.
Basic document: 414ea_e.chp Agitator-type: HWL 2060 N 7. Overhaul

EKATO RMT
4.4 Start-up
Safety Information for Start-up

&. CAUTION
All electrical connections are to be made by

qualified personnel
All electrical equipment must be installed

according to the manufacturers' instructions.
All electrical apparatus used must comply with EN

60079-14
CAUTION
The installer shall be responsible for connecting

an additional equipotential bonding conductor to
any external matin components
CAUTION
Before an agitator can be operated in the

explosive range, it must be ensured that the
details or category and temperature class agree
with the re uired values.
CAUTION
Before starting up, check the operating

instructions of the individual components for any
additional preparations and requirements for use
in the ex losive ran e.
&CAUTION®
Before starting up, make sure that the impellers

are at a sufficient distance from the agitator vessel
walls and any mounting parts, to eliminate
possible contact of rotating parts with the vessel.
Basic document: 415sic_e.chp Agitator-type: HWL 2060 N 4.4 Start-up

EKATO RMT
Checks prior to Start-up
(Version without seal or with labyrinth-seal)
& CAUTION
During execution of the checks the motor must

not be connected to the power supply
e All joints tightened with prescribed torque values

(for dimensions and materials of threaded joints
-+parts list chapter 8)
e All transport locks removed, drive ready to run
(oil quantity?, venting screw? see instructions
from motor and gear manufacturer, -+ chapter 9)
e All provided protection devices mounted (covers,
grids)
Version with earthing device
+ earthing device is connected
Agitator Shaft
e Agitator shaft true (-+ chapter 4.3 "Checking the
Agitator shaft Run-out")
Impeller
e Pumping direction in accordance with
Connecting the Agitator to the Vessel

e Surfaces from the mounting flange and the
vessel surfaces are free from dirt and damage?
e The gasket between mounting flange and the
vessel is correctly mounted?
e All joints between agitator and vessel are
calculated and selected corresponding, all joints
tightened with prescribed torque values ?
Version with pressurized Vessels

DANGER
When putting onto operation check for leakage.

Danger of emmision of hot, poisonous or
caustically fluids
Basic document: 415a_e.chp Agitator-type: HWL 2060 N 4.4 Start-up

Version:0.0-07.07.2011 Customer ref.: 70RW400
EKATO RMT
Overview Bolt Tightening Torques
& CAUTION
Bolts secured with Nord-Lock washers must be tightened to 15% more torque than the values shown in
this table.
If Loctite 243 is applied, the below tightening torques have to be increased by 50%.
The tolerance for hand powered torque tools may not exceed +/- 4% (calibration according to DIN EN ISO
6789).
Apply the values to bolting connections between EKATO components.

For bolting connections of subsuppliers' components refer to the values given in the subsuppliers' manual
(-+ chapter 9)
This values apply only to screws not mentioned on the sectional drawing (-+chapter 8).
Do not apply the values to clamping hubs made from bent plates, not to EKATO set screws, .ll.Q! to standard
set screws and not for mounting flanges; see separate data (-+chapter 4.3)
For special materials not mentioned here check the data on the following page or on the assembly drawing,
(-+ chapter 1), or the agitator cross sectional drawing (-+ chapter 8)
The values apply to optimum lubricated threads, i.e. both the thread and the nut seat shall be lubricated with
thread grease based on molybdenum disulphide (MoS2) or chlorinated paraffin; remove excess-lubricant
from the parts in contact with product; if necessary use special grease with food compatibility
For threaded joints outside the vessel normally the ambient temperature applies; exception: boltings
between seal or lantern and mounting flange, in these cases the process temperature applies
Basic document: 415mom_e.chp Agitator-type: HWL 2060 N 4.4 Start-up

EKATO RMT
Temperature in oc (1°C = 33,8°F)
Material Bolt
-60 -50 -10 +20 +50 +100 +200 +250/ +300 +400
/type size
Bolt tightening torques in Nm (1 Nm = 0,7376 lbf ft) (thread and seat lubricated!)
M6 - - 4 4 4 4 3 3 3 -
M8 - - 10 10 9 9 7 7 6 -
M10 - - 19 19 18 17 15 14 12 -
M12 - - 33 33 31 30 25 23 21 -
M14 - - 52 52 50 47 40 37 34 -
M16 - - 81 81 77 73 62 57 53 -
M20 - - 158 158 150 143 121 112 103 -
carbon M22 - - 216 216 205 195 166 153 141 -
steel M24 - - 273 273 259 246 209 193 177 -
M27 - - 401 401 381 361 308 284 261 -
5.6 M30 - - 546 546 519 492 419 387 355 -
ISO 898 M30x3 - - 562 562 534 506 431 398 365 -
M33 - - 738 738 701 664 565 522 479 -
M33x3 - - 758 758 720 682 581 537 492 -
M36 - - 949 949 902 854 728 672 617 -
M39 - - 1227 1227 1160 1104 941 869 797 -
M42 - - 1520 1520 1444 1368 1166 1077 988 -
M45 - - 1895 1895 1801 1706 1453 1342 1232 -
M48 - - 2293 2293 2178 2063 1758 1624 1490 -
M52 - - 2941 2941 2794 2646 2254 2083 1911 -
M52x3 - - 3136 3136 2979 2822 2404 2221 2038 -
M56 - - 3666 3666 3483 3300 2811 2597 2383 -
M60 - - 4540 4540 4313 4086 3481 3216 2951 -
M6 - 9 9 9 8 8 7 7 6 -
M8 - 21 21 21 20 19 18 17 16 -
M10 - 41 41 41 40 38 34 33 31 -
M12 - 70 70 70 68 65 59 56 53 -
M14 - 111 111 111 108 103 94 89 84 -
M16 - 173 173 173 168 159 146 138 130 -
M20 - 338 338 338 327 311 285 269 253 -
carbon M22 - 461 461 461 447 425 389 368 346 -
steel M24 - 582 582 582 564 537 491 464 437 -
M27 - 856 856 856 830 789 722 682 642 -
8.8 M30 - 1165 1165 1165 1129 1074 983 929 874 -
ISO 898 M30x3 - 1200 1200 1200 1162 1106 1012 956 900 -
M33 - 1574 1574 1574 1524 1451 1328 1254 1180 -
M33x3 - 1616 1616 1616 1566 1490 1364 1288 1212 -
M36 - 2025 2025 2025 1962 1867 1709 1614 1519 -
M39 - 2617 2617 2617 2536 2413 2208 2086 1963 -
M42 - 3244 3244 3244 3142 2990 2737 2585 2433 -
M45 - 4043 4043 4043 3917 3727 3412 3222 3032 -
M48 - 4891 4891 4891 4738 4509 4127 3898 3668 -
M52 - 6273 6273 6273 6077 5783 5293 4999 4705 -
M52x3 - 6690 6690 6690 6481 6167 5645 5331 5018 -
M56 - 7821 7821 7821 7577 7210 6599 6232 5866 -
M60 - 9686 9869 9869 9383 8929 8173 7719 7265 -

EKATO RMT
Material Bolt
-60 -50 -10 +20 +50 +100 +200 +250/ +300 +400
/type size
Bolt tightening torques in Nm (1 Nm = 0,7376 lbf ft) (thread and seat lubricated!)
M6 - 13 13 13 12 12 11 10 9 -
M8 - 31 31 31 30 28 26 24 23 -
M10 - 60 60 60 58 56 50 48 45 -
M12 - 103 I 103 103 101 96 87 82 77 -
M14 - 164 164 164 159 152 138 130 123 -
M16 - 254 254 254 247 236 214 202 191 -
M20 - 496 496 496 483 462 417 395 372 -
carbon M22 - 678 678 678 660 631 570 539 508 -
steel M24 - 855 855 855 832 796 719 680 641 -
M27 - 1258 1258 1258 1224 1171 1057 1000 943 -
10.9 M30 - 1711 1711 1711 1666 1593 1438 1361 1284 -
ISO 898 M30x3 - 1762 1762 1762 1715 1640 1481 1401 1321 -
M33 - 2311 2311 2311 2250 2151 1942 1838 1733 -
M33x3 - 2374 2374 2374 2311 2210 1995 1888 1780 -
M36 - 2975 2975 2985 2896 2769 2500 2366 2231 -
M39 - 3844 3844 3844 3742 3578 3231 3057 2883 -
M42 - 4764 4764 4764 4637 4435 4004 3788 3573 -
M45 - 5939 5939 5939 5781 5528 4991 4722 4454 -
M48 - 7184 7184 7184 6993 6687 6037 5713 5388 -
M52 - 9214 9214 9214 8969 8577 7743 7327 6910 -
M52x3 - 9826 9826 9826 9565 9147 8258 7814 7370 -
M56 - 11487 11487 11487 11182 10693 9654 9135 8615 -
M60 - 14226 14226 14226 13848 13243 11956 11313 10670 -
M6 - 15 15 15 14 14 12 12 11 -
M8 - 36 36 36 35 33 30 28 27 -
M10 - 70 70 70 68 65 59 56 53 -
M12 - 121 121 121 118 112 102 96 91 -
M14 - 192 192 192 186 178 161 152 144 -
M16 - 297 297 297 289 276 250 236 223 -
M20 - 581 581 581 565 538 488 462 435 -
carbon M22 - 793 793 793 771 735 667 631 595 -
steel M24 - 1001 1001 1001 974 928 842 796 751 -
12.9
M27 - 1472 1472 1472 1432 1365 1238 1171 1104 -
M30 - 2003 2003 2003 1948 1857 1684 1593 1502 -
ISO 898 M30x3 - 2062 2062 2062 2005 1912 1734 1640 1546 -
M33 - 2705 2705 2705 2631 2508 2274 2151 2028 -
M33x3 - 2778 2778 2778 2702 2576 2336 2210 2084 -
M36 - 3481 3481 3481 3386 3228 2927 2769 2611 -
M39 - 4499 4499 4499 4376 4171 3783 3578 3374 -
M42 - 5575 5575 5575 5423 5169 4688 4435 4181 -
M45 - 6949 6949 6949 6760 6444 5844 5528 5212 -
M48 - 8406 8406 8406 8177 7795 7069 6687 6305 -
M52 - 10783 10783 10783 10488 9998 9067 8577 8086 -
M52x3 - 11499 11499 11499 11185 10662 9669 9147 8624 -
M56 - 13442 13442 13442 13076 12465 11304 10693 10082 -
M60 - 16648 16648 16648 16194 15437 13999 13243 12486 -

EKATO RMT
Material Bolt
-60 -50 -10 +20 +50 +100 +200 +250/ +300 +400
/type size
Bolt tightening torques in Nm (1 Nm = 0,73761bf ft) (thread and seat lubricated!)
M6 3 3 3 3 3 3 3 2 2 2
M8 8 8 8 8 7 7 6 6 6 5
M10 15 15 15 15 14 13 12 12 11 11
M12 26 26 26 26 24 22 21 20 19 18
M14 41 41 41 41 38 35 33 32 31 29
M16 64 64 64 64 59 54 51 50 48 45
stainless M20 125 125 125 125 116 106 100 97 94 88
steel M22 171 171 171 171 159 146 137 133 129 120
M24 216 216 216 216 200 183 172 167 162 151
A2-50 M27 318 318 318 318 295 270 255 247 239 223
A4-50 M30 432 432 432 432 401 368 346 335 324 303
A5-50
M30x3 447 447 447 447 415 380 358 346 335 313
ISO 3506 M33 585 585 585 585 544 498 468 454 439 410
M33x3 603 603 603 603 560 513 483 468 453 422
M36 752 752 752 752 699 640 602 583 564 527
M39 974 974 974 974 905 828 780 755 731 682
M42 1206 1206 1206 1206 1120 1025 965 935 905 844
M45 1506 1506 1506 1506 1399 1280 1205 1167 1130 1054
M48 1820 1820 1820 1820 1690 1547 1456 1411 1365 1274
M52x3 2519 2519 2519 2519 2339 2141 2015 1952 1889 1300
M52 2339 2339 2339 2339 2172 1988 1871 1813 1754 1208
M56 2915 2915 2915 2915 2707 2478 2332 2259 2186 1505
M60 3615 3615 3615 3615 3357 3073 2892 2802 2712 1867
M6 7 7 7 7 6 6 5 5 5 5
M8 16 16 16 16 15 14 13 13 12 11
M10 32 32 32 32 30 27 26 25 24 23
M12 56 56 56 56 52 47 44 43 42 39
M14 88 88 88 88 82 75 70 68 66 62
M16 137 137 137 137 128 117 110 106 103 96
stainless M20 268 268 268 268 250 228 214 208 201 188
steel M22 367 367 367 367 343 312 294 285 275 257
M24 462 462 462 462 431 393 370 358 347 323
A2-70 M27 682 682 682 682 636 580 545 528 511 477
A4-70 M30 927 927 927 927 865 788 741 718 695 649
A5-70
M30x3 958 958 958 958 894 814 766 741 718 670
ISO 3506 M33 1254 1254 1254 1254 1171 1066 1003 972 941 878
M33x3 1293 1293 1293 1293 1207 1099 1034 1002 970 905
M36 1612 1612 1612 1612 1505 1371 1290 1250 1209 1129
M39 2088 2088 2088 2088 1949 1775 1670 1618 1566 1462
M42 2585 2585 2585 2585 2412 2197 2068 2003 1939 1809
M45 3228 3228 3228 3288 3012 2744 2582 2501 2421 2259
M48 3901 3901 3901 3901 3641 3316 3121 3023 2926 2731
M52x3 5397 5397 5397 5397 5037 4587 4318 4183 4048 3778
M52 5012 5012 5012 5012 4678 4260 4010 3885 3759 3509
M56 6246 6246 6246 6246 5830 5309 7997 4841 4685 4372
M60 7747 7747 7747 7747 7231 6585 6198 6004 5810 5423

EKATO RMT
Test Runs Starting Procedures
(version without steady bearing; running during 8 EKATO recommendation:
filling & emptying allowed) to avoid damages at the components, especially
at the seal, start the agitator slowly and by
progressive stages
&WARNING ® Test Run in Air
Agitators for use in the explosive range must be e Switch on the motor
run in for at least 3 hours under observation e Observe the agitator shaft running for 1 to 2
(accaustically, visually, thermically) without an minutes
explosive atmosphere being present. Only then
When the agitator runs with a low vibration level:
may the agitator be used in the explosive range.
e Let the agitator run for 5 to 10 minutes
e Switch off the agitator
&WARNING ®
Test Run in Water
Explosive atmosphere present during filling, e Fill the vessel with water to the design level
emptying, opening of the vessel, maintenance,
shutting down and disassembly. Appropriate
e Switch on the motor
safety precautions must be taken on site and the e Observe the agitator shaft running for 1 to 2
technical rules for safe working practice and minutes
good workmanship complied with. When the agitator runs with a low vibration level:
e Connect the motor e Let the agitator run for 5 to 10 minutes
e Bump the motor (max. 10 sec) for rotation just to e Switch off the agitator
check that the rotation direction is in accordance
with the specification (-+ chapter 1)
Test Run during Emptying of the Vessel
CAUTION
& CAUTION
Observe the limitations given in the specification
Observe the possible limitations given in the
(-+ chapter 1) with regard to the permissible speed
specification (-+ chapter 1) with regard to the
ran e
emptying
&WARNING ® Keep the time span short while the impeller

passes through the liquid level -this condition
puts the maximum loads onto the impeller and
shaft
If the vessel is filled while the agitator is running,
i.e. the liquid surface rises past the rotating e Switch on the motor
impeller, a dangerous build-up of electrostatic e Empty the vessel- level sinking speed min.
charge can occur if the liquid enters as a spray. 40 mm/min (1.5"/min)
Appropriate measures must therefore be taken
by others to prevent this, such as introducing the e Switch off the agitator
product below the surface of the liquid or
directing it against the vessel wall, flow velocity Retightening of Threaded Joints
< 5 m/s.
e Retighten all threaded joints, also inside the
vessel, except for those that are secured by
&WARNING ® means of locking plates, double nuts or tack
welding
A dangerous buildup of electrostatic charge can

be caused by stirring the product. Appropriate
measures must therefore be taken on site to
counteract this
Basic document: 416b_e.chp Agitator-type: HWL 2060 N 4.4 Start-up

EKATO RMT
Procedure of Measurement at Shock
Pulse Detectors (SPM nipples)
e Disconnect agitator drive from power supply
e Remove the protective guard from the lantern
e Connect the measuring tool to the SPM nipple
e Mount the protective guard to the lantern
e Connect the agitator drive to the power supply
and carry out the measurement
Start-up under Process Conditions

After successful test runs:
e Make sure that the vessel contains no other
installations than are intended for operation and
that all process conditions are as per design
e Start up the agitator
Basic document: 416b_e.chp Agitator-type: HWL 2060 N 4.4 Start-up

EKATO RMT
4.5 Operation of the Plant &WARNING @
The system operator shall be responsible for safe
WARNING operation.
A dangerous buildup of electrostatic charge can
for vessels with lid: be caused by stirring the product. Appropriate
measures must therefore be taken on site to
the agitator can only operate when the vessel lid counteract this
is closed and secured. The operator (user) must
8 Make sure that the heating up/cooling down rate
ensure that the agitator cannot operate when
does not exceed 2 Kpm (Kelvin per minute, equal
the vessel is opened
to Celsius per minute)
8 Make sure that the filling, draining and sampling
for opened vessels: takes place via suitable ports
8 Make sure that during operation all nozzles
remain firmly closed, protective guards remain
installed and safety devices cannot be deactivated
& CAUTION
CAUTION Never let the steady bearing run dry
The agitator must not be subjected to vibrations

when turned off- Risk of damage to the roller & WARNING
bearin sand possibl sealin rin s
Agitators with steady bearings for use in the

i & WARNING explosive area must always be operated with the
steady bearing covered with liquid.
During filling, sampling, draining and cleaning
there is a risk of contact with product. The Dry running is not permitted.
product may be poisonous or caustic or
otherwise dangerous to health.
Dispose of any escaped product correctly. If

&WARNING @
necessary wear adequate protective clothing and Zone 0:
use protective equipment. To ensure that the steady bearing is permanently
covered with product, failsafe level monitoring
must be installed on site
WARNING (see EN1127-1 or EN 13463-6)
Too rapid heating up and cooling down may Zone 1:

cause damage to the vessel and components To ensure that the steady bearing is permanently
covered with product, single-channel level
monitoring must be installed on site.
& CAUTION
Impulsive stress can damage agitator components


Basic document:418a_e.chp Agitator-type: HWL 2060 N 4.5 Operation

EKATO RMT
&CAUTION ®
When operating the agitator, the specifications in
these operating instructions must be strictly
adhered to.
Before an agitator can be operated in the

explosive range, it must be ensured that the
details or category and temperature class agree
with the required value
~CAUTION ®
Agitators for use in the explosive range (all
categories G and D) may only be operated at
ambient temperatures between -20 and +40°C.
For operating conditions which differ from this,

EKATO must be consulted.
Heat Trap Base (if applicable)

~CAUTION
The cooling water supply rate for the heat trap

base has to be adjusted at the jobsite. The surface
temperature of the heating-cooling flange must
never exceed 85° C/185 F
e To avoid inadmissible excess pressure of the

cooling circuit, the pressure has to be limited by
the operator to the permissible operating
pressure on the cooling side of the heat trap (e.g.
pressure relief valve)
Basic document:418a_e.chp Agitator-type: HWL 2060 N 4.5 Operation

EKATO RMT
CAUTION
climbing aids
Instructions
& CAUTION
It must be ensured that the system is in a safe CAUTION

agitator Structural installations (monitoring, pressure
se arated from the a itator
& WARNING

or
-switch off and shut switch into Check for leaks when starting up.
OFF position. There is a risk of hot, toxic or corrosive materials
esca in
& CAUTION

electricians)
&
'
X DANGER

& CAUTION vessel lid is closed and secured. The operator
(protective clothing, breathing apparatus).
& WARNING
& CAUTION


lifting tools

poisoning, injury or death.
Basic document: 5GEF50_e.chp Agitator-type: HWL 2060 N 5. Maintenance

EKATO RMT
CAUTION &DANGER

& CAUTION
&
'
X DANGER
product- if necessary provide protective
High-temperature processes result in heating of equipment and cleaning measures
There is a risk of damage to the 0 rings if the In the presence of other interfaces between agitator
shafts CAUTION

ring seals away from hot shafts or pull them onto
hot shafts
Before beginning work, let the vessel cool down CAUTION

&
'
X DANGER
chan es in ressure must be avoided.


continuing.
CAUTION

the shaft is suspended
Basic document: 5GEF50_e.chp Agitator-type: HWL 2060 N 5. Maintenance

EKATO RMT
5. Maintenance
5.1 Preface
& CAUTION®
Explosive atmosphere present during filling, emptying,

opening of the vessel, maintenance, shutting down and
disassembly. Appropriate safety precautions must be
taken on site and the technical rules for safe working
practice and good workmanship complied with
WARNING
Prior to all maintenance work either

-fully disconnect the agitator from the power supply
or
- switch off the a itator and lock the switch
Before beginning work on the agitator, make sure that

no explosive atmosphere exists
& CAUTION
Protect bearings from water jet or steam cleaning with

covers
Bearings that were accidentally exposed to water jet or

steam must be replaced
Immediately remove cleaning agents near bearings
Fully remove this covers prior to restart
NOTE: The following maintenance chart may refer to components which are not part of your agitator. Variants
are indicated in italics.
e After cleaning check all pipes and joints for leakages, loosened connections, chafing, damage etc.
e The given intervals are average values for uninterrupted operation. Contact your EKATO service agent for
your individual application
e The user MUST study the pertinent sub-suppliers documentation, verify the data and adjust it if necessary
Also check the nameplates of the electric motor, gear unit and if possible the seal, for supplementary
information
Basic document: 51 b_e.chp Agitator-type: HWL 2060 N 5. Maintenance

EKATO RMT
5.2 Maintenance Measures
Agitator Drive
Maintenance interval
by calendar by operating hours

(at the latest) (at the latest)
Module Instruction
(J)
..c ..c *
..c
~
Q)
+""
c .... ....
(J)
....
(J)
..c ..c 0 0
>-
co Q) 0 co
Q)
co
Q)
co
Q) 0 0 0 0
-a :5: E >- >- >- 0
0
0
0
0
CD
0
1..0
...- ...- CD ...- N M co ...- N
"""
Refill each bearing with
approx. 12 g of heavy
duty lithium saponified,
Replenishment interval:
Bearing(s) in mineral oil based, e.g.
Fuchs Renolit 4000 h *
the lantern
H443-HD88, bearing
grease
For
Replace
• •
ATEX-Agitators
(G
All categories
Replace
• •
with bushing
to prevent
flame
propagation
see the manufacturer maintenace instructions (-+ chapter 9)

Bearing(s) in
the If the suppliers' manuals do not contain different requirements, refill each bearing with heavy
mechanical duty lithium saponified mineral oil based bearing grease or use product- compatible or if
seal specified, food-compatible bearing grease
Check
bearings for
strange noises
-+chapter 6
•
Remove crusts and dirt
Surfaces
Check for wear,
corrosion and damage
• •
Basic document: 51b_e.chp Agitator-type: HWL 2060 N 5. Maintenance

EKATO RMT

Module Instruction
~
(/)
..c
...... (/) (/) ..c *..c
Q) c ..... ..... ..... ..c ..c 0 0
>
CIJ
Q) 0 CIJ
Q)
CIJ
Q)
CIJ
Q) 0 0 0 0
"0 3 E > > > 0
0
0
0
0
CD
0
1.!}
.-- .-- CD .-- N M o:::t CX) .-- N
Check tightening
Threaded
joints
torques (Overview
torque values-+ chapter
4.3, 4.4 and drawings)
• •
Check the effectiveness
of the bolt lockings • •
Product
wetted parts
Clean thoroughly
• •
@ Check gap widths
• •
The ventilation holes
Bushing to
prevent flame
propagation**
must be kept free and
must not be closed •
Check for dust inside
@ and out, remove dust
layer if appropriate
Entire agitator (Thickness of dust layer
must never
•
exceed5mm)
Entire agitator Overhaul

•
*For agitators on heated vessels with temperatues >150°C, the intervals should be halved
** The resistance of the bearing's grease and sealing has to be checked by the operator.
Basic document: 51b_e.chp Agitator-type: HWL 2060 N 5. Maintenance

EKATO RMT
Drive
(Version with gearmotor)

Module Instruction
tJ)
..c
...... ..c ..c
c .....
tJ)
..... ....
Vl
..c ..c 0 0
>
co 0 co
(J)
co
(J)
co
(J) ..c 0 0 0 0
"0 E > > > '<:!"
0
0
0
0
0
<0
0
1..0
...- <0 ...... N C") N '<:!" CX) ...... N
Follow the motor manufacturer's maintenance instructions

Motor (-+ chapter 9 & nameplate)
Follow the gear manufacturer's maintenance instructions

(-+ chapter 9 & nameplate)
Bearing(s) (for ATEX-agitators type HWL):
If the manufacturer's manuals does not prescibe shorter intervals:
@
Gear unit
For ATEX-agitators
All category • •
Replace bearing(s)
Check bearing(s) for

strange noise
-+chapter 6
• •
When elastic
transmission
part(s) exist,
Visual check of
elastic coupling(s) • •
either in the
drive or inside
the agitator
lantern:
Elastic
Replace when worn
• •
coupling(s)
When Follow the cardan shaft manufacturer's maintenance instructions

Cardan shaft (-+ chapter 9 )
Entire drive Overhaul

•
Basic document: 52a_e.chp Agitator-type: HWL 2060 N 5. Maintenance

EKATO RMT
Impeller
(Version without coated surfaces)

Module Instruction
rn
..c
..... ..c ..c
..!><: .... rn
.... rn
.... ..c ..c
Q) c 0 0
Q) 0 co co co 0 0 0 0
Q) Q) Q)
3: E > > > 0
0
0
0
0
{()
0
1..0
..-- {() ..-- N ("') <::t CX) ..-- N
Check for bending

• •
Impeller
Check for erosion
and corrosion • •
Check threaded
joints for proper
tightening torque • •
Basic document: 54a_e.chp Agitator-type: HWL 2060 N 5. Maintenance

Schmierplan EKATO RMT
Lubrication Schedule
Pos. App.-Nr. Schmierstelle Schmiermittel Wechsel Bemerkung

Item s/n Lubrication Point Lubricant Change Remarks
Art Kennzeichnung Menge Einh. erster weitere
Kind Designation Qty Unit first subseg. HWL 2060 N
[ h] [ h] Rev.: 0
70-RW400 80053-40 MotorVEM bearingr DS grease Asonic GHY 72 n.a. g 20000 20000 renew filling, lifetime 100000 h
KPR100LX4 bearing NS grease Asonic GHY 72 n.a. g 20000 20000 renew filling, lifetime 100000 h
gear unit Flender oil sump oil CLP PG VG 220 -3,5 I 10000 10000 see BA 501 O,BA 7300
FZF68b-K2-1 00
agitator bearing grease Fuchs Renolith H443 12 g 4.000 25.000 lifetime 100000 h
Diese Schmierliste ist nur eine Hilfe fOr das Schmierpersonal. Die Anleitungen der Hersteller
sind mal3.gebend.
This lubrication schedule shall be a help for the lubrication staff only. The instructions
from the suppliers are authoritative.
Erstellt/prepared: I Mrz GeprOft/checked: IPST

Datum/date: 118.05.2011 Datum/date:
Lub.80053_ VEM-Fiender.xls Form erstellt/prepared: MT

lub40 Seite/sheet3von/of5 Rev.: 0
EKATO RMT
Threaded Joints/Fall Off Lockings

Module Instruction
rJ)
..c
..... rJ) rJ) ..c ..c
~
Q) c ..... ..... ..... ..c ..c 0 0
Q) 0 co
Q)
co
Q)
co
Q) 0 0 0 0
~ E > > > 0
0
0
0
0
co
0
I!)
.-- co .-- N (Y) "<:!" co .-- N
Tighten all threaded

joints with the
Threaded
prescribed torque
values (-+table • •
chapter 4.4)
joints in vessel
Check that
bolt lockings and fall
off lockings are
effective
• •
Basic document: 57 _e.chp Agitator-type: HWL 2060 N 5. Maintenance

EKATO RMT
CAUTION
climbing aids
Instructions
CAUTION
It must be ensured that the system is in a safe & CAUTION

separated from the a!litator
WARNING

-completely disconnect agitator from mains For pressurized vessels:
or
esca in
CAUTION

electricians)
&
'
~DANGER

(protective clothin , breathin ap aratus).
WARNING
& CAUTION


lifting tools

oisonin , in"ury or death.
Basic document: 6GEF50_e.chp Agitator-type: HWL 2060 N 6 . Troubleshooting

EKATO RMT
CAUTION & DANGER

& CAUTION
&
'
X DANGER

product - if necessary provide protective
shafts & CAUTION
There is a risk of corrosion of bearings and Observe safety measures for handling the other
bushing guides if attempts are made to pull sliding subsystems, e.g.
ring seals away from hot shafts or pull them onto depressurising pipes before separating them
hot shafts
Before beginning work, let the vessel cool down CAUTION


A Xt
£..U DANGER
chan es in ressure must be avoided.


continuing.
CAUTION

the shaft is suspended
Basic document: 6GEF50_e.chp Agitator-type: HWL 2060 N 6 . Troubleshooting

EKATO RMT
6. Troubleshooting
6.1 Preface
& WARNING
Prior to all troubleshooting either

-fully disconnect the agitator from the power supply
or
- switch off the agitator and lock the switch
Before beginning work on the agitator, make sure that no explosive

atmosphere exists.
• After the execution of any repair work test runs have to be

performed (- chapter 4.4)
6.2 Troubleshooting Chart

NOTE: The following chart may refer to components which are not part of your agitator. Variants are indicated
in italics.
NOTE: In any case EKATO shall be informed about any trouble with the agitator
Indication Possible cause Remedy
Remove the foreign body

Foreign body in the fan wheel
Replace the fan wheel, when
damaged
Lack of lubrication in a bearing Replace the bearing
Incorrect oil level in gear/geared Fill oil to the proper level; search
motor or ancillary equipment for leakage where applicable
Strange noise from outside the Check that the correct oil quality
vessel has been used
Incorrect oil quality
If not, empty, clean and refill with
correct oil
Check bearings and gears for wear
Worn or damaged parts In case of excessive wear: search

for the cause and remedy, then
repair/replace as necessary
V-belts slips Adjust to prescribed belt tension

Components inside the vessel (e.g.
Strange noise inside the vessel impeller, baffle plates, bolts) have Check the interior of the vessel
loosened
Basic document: 6_e.chp Agitator-type: HWL 2060 N 6. Troubleshooting

Version:2.0 19.10.2010 Customer ref.: 70RW400
EKATO RMT
Agitator shaft rotates at critical Position the impeller(s) on the shaft

speed, caused by incorrect according to the specification
impeller placement (-+ chapter 1)
Adjust speed according to the

Unauthorized alteration of speed
Vibrations/oscillations
Bearing damage Replace bearings
Crustation of product Remove crustations
Bushing of the steady bearing worn Replace the bushings

Tighten bolts and nuts with the
Loose agitator components
prescribed torque values
Threaded agitator shaft: Set direction of rotation according

Incorrect direction of rotation to arrow
Flange coupling:
Agitator shaft loosens Insert new bolts and secure it
overstretched or failed bolts
Agitator shaft or bearing shaft Agitator shaft under lateral tension Adjust the steady bearing to the
bends or breaks caused by the steady bearing free-hanging agitator shaft
Agitator support/ vessel flange

Level agitator support/vessel
inclination exceeds the permissible
flange (-+ chapter 4.3)
value
Product data deviates from
Consult EKATO
specification
Position impellers according to
Improper positioning of impellers
specification or dimensional sheet
(pumping direction, altitude)
(-+ chapter 1)
Insufficient agitation
Variable drive not adjusted to the
Adjust to the specified speed
correct speed
Rectify baffle plate installation
Baffle plates not according to according to specification
(-+ chapter 1)
Overload due to changed product

Consultation of EKATO
data
Adjust to the specified speed
Overload due to incorrect speed
(-+chapter 1)
Install impeller type, quantity,
Motor switched off by overload number of blades and diameter
Overload due to incorrect impellers
protection according to specification
(-+ chapter 1)
Overload due to crustation, caused Consult EKATO with respect to

by too large particles product data
Release the gland and tighten
Overload due to overtightened
again, if necessary overhaul
stuffing box (-+section 7.2)

Version:2.0 19.10.2010 Customer ref.: 70RW400
EKATO RMT
Lack of oil Refill oil

Lack of cooling water Check cooling water supply
Excessive heating of gear unit Empty, clean and refill with correct
Incorrect oil quality
oil
Bearing damage Replace bearings
More causes see "Strange noise.. "
Seal rings worn or broken Replace parts (-+ seal

Mechanical seal: manufacturer instructions chapter
Falling buffer liquid level or gas 0-rings damaged 9)
bubbles in the buffer liquid
Tubing connections loose or Tighten or repair the connections
damaged
Shaft seal rings worn Replace
Gear unit leaks
Too high oil level Drain oil to the correct level
Defective coupling (plastic drive
Repair coupling
pins)
Friction rings/friction cone worn Replace parts
V-belts slips Adiust to prescribed belt tension
Destroyed gear wheels Repair gear

Release, retighten, replace packing
if necessary
Drive rotates, agitator does not
Stuffing box overtightened
Check for successive damage
(failed coupling parts, worn friction
elements
Remedy the cause (process?)
Impellers block due to crusts
Check transmitting parts, shafts
and impellers for damage
Components (e.g. parallel key)
Retrofit
omitted during assembly

Version:2.0_ 19.10.2010 Customer ref.: 70RW400
EKATO RMT
CAUTION
climbing aids
Instructions
CAUTION
It must be ensured that the system is in a safe CAUTION

se arated from the a itator
WARNING

or
esca in
CAUTION

electricians)
&
'
X DANGER

(protective clothin , breathin a paratus).
CAUTION
WARNING

lifting tools

poisonin , in'ur or death.
Basic document: 7GEF50_e.chp Agitator-type: HWL 2060 N 7. Overhaul

EKATO RMT
CAUTION & DANGER

& '
~DANGER
& CAUTION
product- if necessary provide protective
shafts

hot shafts

& CAUTION

A
£.U t
~DANGER


continuing.
CAUTION

the shaft is sus ended
Basic document: 7GEF50_e.chp Agitator-type: HWL 2060 N 7. Overhaul

EKATO RMT
Caution
7. Overhaul The relevant laws, accident prevention regulations
(suspension device or clamp flange without shut-off) specialized work with this agitator should be
observed
7.1 Major Overhaul helmets, shoes, protective goggles and gloves
Special safety measures should be taken when a
vessel in which a poisonous or corrosive product
Cooling Down the Vessel has been processed needs to be
entered( rotective clothin , breathin a paratus).
& CAUTION
High-temperature processes result in heating of • Switch-off the agitator

• According to the local
There is a risk of damage to the 0 rings if the regulations either
buffer fluid is drained from the sliding ring seals + lock the main switch
too early or sliding ring seals are pulled onto hot or
shafts + pull the pertinent
slide-in module at
There is a risk of corrosion of bearings and the control centre
hot shafts
& CAUTION
so that the shaft temperature directly above the Do not use the vessel,
seal is at most 50° C pipes or agitator drive
as a climbing aid
Safety Rules Provide a safe working

platform
WARNING
& CAUTION
Work on the electrical

installation may only be
WARNING carried out by
authorized personnel
The suspension device does not seal the vessel! (e.g. company
electricians)
If the vessel contains poisonous or caustic
product, you must empty and decontaminate the
vessel before roceedin further
& WARNING • Disconnect the drive from the power supply

When other interfaces exist between the agitator
The bottom of the mechanical seal and the top of and local facilities:
the suspension device can be contaminated with
product - if necessary provide protective CAUTION
e ui ment and cleanin measures
Obey safety rules when handling other
subsystems, e.g. depressurize lines prior to their
& CAUTION disconnection
• Disconnect other local installations (monitoring
Do not carry out work inside the vessel while the circuits, pressure supply, cooling water supply)
shaft is suspended from the agitator
Basic document: 700b_e.chp Agitator-type: HWL 2060 N 7. Overhaul

Version: 1.2.-12.1 0.2011 Customer ref.: 70RW400
EKATO RMT
Note on Outdoor Installation
When the agitator is assembled for installation at an

outdoor location, all mating surfaces of
components that are bolted together but not in
contact with the product (e.g. intermediate flange to
agitator lantern, agitator lantern to mounting flange)
must be sealed with a corrosion protection material
(seam sealers) to prevent crevice corrosion.
Seam sealers are not included in the scope of

supply.
Basic document: 701f_e.chp Agitator-type: HWL 2060 N 7. Overhaul

EKATO RMT
Usage of Nord-Lock Washers
• Check the sectional drawing (when in scope of

supply, -+ chapter 8) or the parts list
(-+ chapter 8) to find out where to apply
Nord-Lock washers
• At each location
combine two
Nord-Lock washers as
shown(when delivered
the washers are glued
together in this
orientation)
• Tighten the bolts evenly with 15 percent higher

torque than regularly recommended for the bolt
size, material and operating temperature
(regular torque values-+ table chapter 4.4)-
when the general assembly drawing, if provided
(-+ chapter 1), or the agitator cross sectional
drawing, if provided (-+ chapter 8), give torque
values, these values already include the increase
due to the Nord-Lock washers
Basic document: 701 nor_e.chp Agitator-type: HWL 2060 N 7. Overhaul

EKATO RMT
Dismantling the Agitator Replacing the Bearing
(HWL with slotted coupling, groove ball bearing) NOTE: Use bearing pullers and presses respectively
& CAUTION
Do not hammer in bearings
e Remove the lateral

This agitator was delivered with a clamping device hexagon bolts (3300)
(either clamping flange or clamping segments).
These parts are not mounted when the agitator is
e Remove the bearing
housing (3290)
ready for operation. Make sure they are at hand
before dismantling of the agitator starts. e Version with slinger
disk:
e Remove the protective grids (3080, 3090, 3100)
• Remove the slinger
e Attach the clamping disk (3360)
flange to the shaft ---~=:----- e Remove the a-ring
(3700 or 6000) and to (3350)
the mounting flange
(4500) e Remove the locking
ring (3380)
e Remove the bolting
(3250, 3260, 3270) e Press the bearing
between the flange (3370) out of the
coupling (3160) on the bearing housing (3290)
by means of thrust
= drive and the flange
coupling (3180) on the bolts
shaft (3700/6000)
e Attach lifting gear to the drive (lifting procedures

-+chapter 4.1) and tension the lifting gear
e Remove the bolting (2950, 2960, 2970) between e Press the new bearing
the drive and the lantern (301 0) (3370) into the bearing
e Now the clamping flange (5780) carries the housing (3290) (exert
weight of the shaft (3700 or 6000) the pressure onto the
outer ring)
e Remove the drive
e Remove the central

hexagon bolt (3230)
together with the lock
washer (3240) and the
disk (31 90) from the
flange coupling (3180) e Insert the locking ring
e Remove the cylinder (3380)
bolts (3200)
In order to widen the
flange coupling:
e Insert and tighten one

of the cylinder bolts
(3200) on the back side
e Remove the parallel
key (3280)
e Remove the flange
coupling (3180)
Basic document: 730a5k_e.chp Agitator-type: HWL 2060 N 7. Overhaul

EKATO RMT
Assembling the Agitator e Reestablish the flange
connection (2950,
e Pull the shaft (3700/6000) into the lantern from 2960,2970)between
underneath the drive and the
agitator lantern (3010)
e Press the bearing -first tighten the bolts
housing (3290) crosswise with half the
together with the final torque value, then
bearing (3370,3380) crosswise with the full
onto the shaft (3700 or torque value
6000)- exert the
• Remove the lifting gear
pressure onto the inner
ring using a piece of e Insert the hexagon
tube screws (3250) of the
e Fasten the bearing flange coupling
housing (3290) to the together with lock
agitator lantern (3000) washers (3270) and
with the lateral nuts (3260)
hexagon bolts (3300) e Tighten the nuts (3260)
and lock washers (3330) crosswise with half the
torque value
e Version with slinger disk:
+ Put on the slinger disk (3360) with the a-ring e Tighten the nuts (3260)
crosswise with the full
(3350)
torque value
e Insert the parallel key e Remove the clamping
(3280) flange (9400)
e Put the flange coupling
e Version with slinger disk:
(3180) onto the shaft
+ Press the slinger disk (3360) down onto the
bearing housing (3290) leaving a gap of 1 mm
e Mount the protective grids (3080, 3090, 3100)
_ _ _.........._ _....__[L>l!l......_, e Remove the cylinder
I
,...
I•···
- , I
bolt (3200) from the
flange coupling (3180)
(this causes the flange
coupling to contract)
~
::;; e Insert the cylinder bolts

I ""~ •:a::::C:J (3200) and tighten them
e
[~
Put on the disk (3190)
NOTE: The lock-washer
I (3240) is equipped with
i
two small pins as
distortion lock. The lock
washer must be aligned
in a way, that the pins rise
into the key way.
e Insert the hexagon
screw (3230) together
with a lock washer
(3240) and tighten it
Basic document: 730a5k_e.chp Agitator-type: HWL 2060 N 7. Overhaul

EKATO RMT
7.3 Decommissioning Instructions for Disposal
• To EKATO's knowledge the agitator is otherwise
not fitted with any components regarded at the
Safety Rules present time as hazardous to health or to the
environment, and must be disassembled into its
component parts, which can then be sorted and
WARNING recycled as scrap metal
• Please refer to the instructions of subsuppliers
Depending on the product processed, the
(-+ chapter 9)
agitator may be contaminated with residues of
substances hazardous to health • Used gearbox oil must be correctly disposed of
• The mechanical seal buffer fluid (if used) can be
contaminated with product and may need to be
disposed of as hazardous waste
• Electrical components may need to be disposed
.& WARNING
of separately (electrical/electronic scrap)
During the decontamination procedure, special

safety measures must be taken (personal
protective equipment, breathing apparatus)
Particular attention must be paid to the "hidden

dangers", such as when the product is toxic or
corrosive and concealed residues are exposed
during the disassembly of product-contacted
components
The mandatory rules and regulations for accident

prevention of the country and place of use of the
equipment and the generally recognized technical
rules for safe and proper working conditions and
procedures must be complied with when handling
the agitator
• Before disassembling the agitator ensure that no

residues of substances hazardous to health
remain in or on it
Instructions for Disassembly

WARNING
with pressurized components
Risk of in"ur due to sudden release of ressure
• Before disassembly ensure that the pressure is

vented from all pressurized components
• The mechanical seal (if fitted) contains springs in
compression, which are not a source of danger,
however, when correctly disassembled
Basic document:790_e.chp Agitator-type: HWL 2060 N 7. Overhaul

EKATO RMT
8. EKATO-Parts List and Drawing(s)

Note: On the following pages you will find the parts list for the complete
agitator and one or more illustrations.
For the further breakdown of non-EKATO-components (e.g. motor, gear,
mechanical seal incl. installation}: --. chapter 9.
Reading the EKATO-Parts List
The enclosed parts lists has been generated by the EKATO production
planning and control system. This guarantees a maximum completeness and
correctness. The assemblies from which the agitator is made up during its final
assembly carry the code ".1" underneath the position index. If this assembly
contains sub-assemblies or parts they will be listed right after the assembly
and the code " .. 2". If this sub-assembly in turn contains parts they will be listed
right after the sub-assembly and carry the code " ... 3".
Example:
0110 yyy-yyyyy-yy
.1 ~ assembly of the agitator, position index 0110 xxxxxxxx
0001 yyy-yyyyy-yy drawing no. of the assembly or part (for EKATO

.. 2 ~ part of the assembly 0110 xxxxxxxx ~ internal use only)
0120 ~ part no. of the assembly or part

.1 ~ assembly of the agitator, position index 0120 xxxxxxxx
0010
.. 2 ~ sub-assembly of assembly 0120 xxxxxxxx
0002
... 3 +-- part of the sub-assembly 0010 xxxxxxxx
0020
.. 2 ~ sub-assembly or part of the assembly 0120 xxxxxxxx
When ordering spare parts please quote the 8digit part. no. of the part, its
complete designation incl. position index and refer to the "EKATO-App. Nr." of
this agitator: 11-80053-0040.
Basic document: 8sapk_e.chp Agitator-type: HWL 2060 N 8. EKATO-Drawings and Parts Lists
V = Verschleissteile/ wear parts/ les pieces d'usure E = Ersatzteile/ spare parts/ les pieces detachee
EI<ATO RMT
Auftragnummer/Order no./No. de commande 80053 I 40
Ruhrwerktyp/ Agitator type/Agitatoreur type HWL2060N
Stuckliste/Bill of materials/Liste des pieces 20193338
Zeichnungnummer/Drawing no./No. plan
Kundenposition/ltem/No. de pas.
Teil StUck Benennung Zeichnung/Teii-Nr Werkstoff Grosse Gewicht (kg)

part piece denomination drawing/part-no material Size weight (kg)
part piece denomination plan/piece no materiaux dimension poids (kg)
1000 1 E-Motor 34,0

1 electric motor 20195540
moteur electrique
1110 4 Sechskantschraube 051-29-032 8.8-ZN M12X30 < 0,1
1 hexagon bolt 10000245 C.S./Zinc coated
vis a tete hexagonale
1130 4 Nord-Lock-Sicherungsscheibe < 0,1
1 Nord-Lock washer 10073206
rondelle de securite Nord-Lock
1500 1 EKATO-Stirnrad-Fiachgetriebe 60,0
1 EKA TO helical flat gearbox 20195446
reducteur plat a engrenages droits E
2000 1 Zwischenflansch 212-20107094-08 22,9
1 intermediate flange 20107110
bride intermediaire
Letzte Anderung/last modification/derniere modification: 20.04.2011
gedruckt am/printed at/edite le: 13.10.2011 von/by/de: POSTS Seite/page/page 1 von 9

EKATO ROhr- und Mischtechnik GmbH
V = Verschleissteile/ wear parts/les pieces d'usure E = Ersatzteile/ spare parts/les pieces detachee
EI<ATO RMT
Ruhrwerktyp/ Agitator type/ Agitatoreur type HWL2060N
Stuckliste/Bill of materials/Lists des pieces 20193338
Kundenposition/ltem/No. de pos.
Teil Stuck Benennung Zeichnung/Teii-Nr Werkstoff Grosse Gewicht (kg)


3000 1 Lagerung 120-10082771-03 99,0
1 bearing unit 10082771
palier
3010 1 Laterne 323-68812-01 50,0
2 lantern 10004527
lanterne 320.001
3080 1 Schutzgitter komplett 490-10081355-01 0,6
2 protective guard 10081355
grille de protection
3110 12 Schutzgitterschraube komplett A2/1.4300 M4X8 MIT SI-RING < 0,1 i
2 screw for safety screen 20171049 s.s.
vis pour grille de protection 490.005
3140 4 Halbrundkerbnagel 053-10-001 < 0,1
2 round headed notched nail 10001183
clou cannele a tete demi-ronde 909.039
3180 1 Flanschkupplung geschlitzt 223-10070688-00 8,0
2 flange coupling 10070688
accouplement a brides 223.009
3190 1 Scheibe 223-20104003-06 0,3
2 disk 20104657
rondelle 223.010

V = Verschleissteile/ wear parts/ les pieces d'usure E = Ersatzteile/ spare parts/ les pieces dtHachee
EI<ATO RMT
Teil Stuck Benennung Zeichnung/Teii-Nr Werkstoff Grosse Gewicht {kg)

part piece denomination drawing/part-no material Size weight {kg)
part piece denomination plan/piece no materiaux dimension poids {kg)
3195 2 Zylinderkerbstift 053-06-001 < 0,1

2 grooved dowel pin 10001152
goupille cannelee cylindrique
3200 3 Zylinderschraube 051-21-072 8.8-ZN M10X55 < 0,1
2 socket head cap screw 10000385 C.S./Zinc coated
vis a tete cylindrique 223.021
3230 1 Sechskantschraube 051-29-038 8.8-ZN M16X50 0,1
vis a tete hexagonale 223.030
rondelle de securite Nord-Lock 223.031
3260 8 Sechskantmutter 051-31-004 8-ZN/GALV.CS M12 < 0,1
2 hexagon nut 10001040 C.S./Zinc coated
ecrou hexagonal 223.033
rondelle de securite Nord-Lock 223.034

EI<ATO RMT
Stuckliste/Bill of materials/Liste des pieces 20193338 I
Teil Stuck Benennung Zeichnung/Teii-Nr Werkstotf Grosse Gewicht (kg)

3280 1 Passteder < 0,1

2 parallel key 10082787
clavette
3290 1 Lagergehiiuse 323-1 0080428-00 7,5
2 bearing housing 20159216
carter de palier 320.003
3310 1 Schmiernippel 066-01-004 0,1
2 grease nipple 10002770
graisseur 320.026
3320 1 Verliingerung 062-14-005 1,0
2 extension 10006649
rallonge 320.082
3340 2 Verschlu!Sstopten 062-09-012 1,0
2 closing plug 10001850
bouchon de termeture 320.033
3350 1 0-Ring 063-42-059 0,1
2 0-ring 10001137
E joint to rique 320.034

EI<ATO RMT
Ruhrwerktyp/Agitator type/Agitatoreur type HWL2060N

3360 1 Schleuderscheibe 356-10080349-00 0,9

2 slinger disk 20098850
disque centrifuge 320.010
3370 1 Rillenkugellager 0,8
2 groove ball bearing 10060864
E roulement a billes a rainures 320.022
3380 1 Sicherungsring fUr Bohrung 055-05-008 < 0,1
2 locking ring 10001726
circlip 909.038
3120 1 Typenschild < 0,1
1 name plate 10018802
plaque d'identite
3150 1 Erdungseinrichtung 325-20191344-00 1,0
1 grounding connection 20196982
dispositif de mise a Ia terre
3151 1 Stiftschraube 8.8-ZN M20X70 1,0
2 stud bolt 10039348 C.S./Zinc coated
boulon filete
3152 1 Sechskantmutter 051-31-006 8-ZN M20 < 0,1
ecrou hexagonal

- -··-
EI<ATO RMT

3154 1 Erdungslasche 325-20056955-02 0,3

2 grounding lug 20056955
eclisse de mise a Ia terre
3160 1 Flanschkupplung A komplett 223-20105835-00 11,0
accouplement a brides
3160 1 Flanschkupplung A 223-1 0083256-26 1,3
accouplement a brides
3170 1 Scheibe 223-201 04003-06 0,3
2 disk 20104657
rondelle
3175 2 Zylinderkerbstift 053-06-001 < 0,1
2 grooved dowel pin 10001152
goupille cannelee cylindrique
3700 1 Lagerwelle 323-1 0080623-00 21,0
1 bearing shaft 20109777
arbre de palier

EI<ATO RMT

3910 11 Stiftschraube 051-38-018 8.8-ZN M20X60 0,2

1 stud bolt 10001013 C.S./Zinc coated
boulon filets
3920 11 Sechskantmutter 051-31-006 8-ZN M20 < 0,1
ecrou hexagonal
4500 1 Montageplatte 477-20196849-00 37,0
1 mounting plate 20196849
plaque de montage
4820 4 Sechskantmutter 051-31-007 8-ZN M24 0,1
ecrou hexagonal
6000 1 Ruhrwelle 646-20196894-00 55,0
1 agitator shaft 20196894
arbre d'agitation

EI<ATO RMT

6100 1 Flanschverbindung 615-20075060-02 1,3

1 flange connection 20075068
raccord a bride
6110 6 Sechskantschraube 051-28-056 A4-70 M16X85 0,2
2 hexagon bolt 10000283 s.s.
vis a ti:lte hexagonale
6120 6 Sechskantmutter 051-32-006 A4-70 M16 < 0,1
2 hexagon nut 10001052 s.s.
ecrou hexagonal
7300 2 Visco prop 736-20096365-00 4,7
1 Visco prop 20196861
Viscoprop
7820 4 Kraftschraube 652-20272-00 A4-50 M16XL20 < 0,1
2 EKA TO set screw 10004025 s.s.
vis a pointeaux EKATO
9400 1 Klemmflansch fur D/N 950-20178507-02 8,0
1 clamp flange 20179646
bride de serrage

EI<ATO RMT
Teil StOck Benennung Zeichnung/Teii-Nr Werkstoff Grosse Gewicht (kg)

9411 2 Scheibe 052-01-006 < 0,1

2 disk 10000506
rondelle
9415 4 Sechskantschraube 8.8-ZN M8X80 < 0,1

EKATO RMT
Drawing Bearing Housing HWL 2040-2220 120-1 0082771-00
ll v: / ~
~ 3175 ©
/~ (
®~:~:~::~n.A~u~ft~ra~g------~b:~---+~ cftb~~~/~-L- v 3080
V IL_______,3e_c_1__,_,1o=---
~3~17~0----------++./4---~1 / / I ~~~~ v 3210
© 322o " ~ ""' I rT-n ""~""' ""' 3230

© 3240 / 'i:: ~~~~ ""'""'" v 3010
:~:: ~ u~ ~ ~'-----t-------f-v-tt-----------'3::_c_1_::_:9o=-
1 \
-"-'-"-"-------------.1+-b.Lf----------l-------\,--"'".
__,3=2=oo,___________ _ _ J ~ 1"
"
6v ·
/ 3280
©
@~ ~ ~ V. 3195 G
~ ~ ~ " /
335o ~
~
--'=~------------~4-----~------~1
·""
::::,. vvr--- ""
~~ ~
v
3360 F===F==r--------t------trt--------------
3380 / 3050
3310 ~
~ ~~
~ ~
3320
3290 /_
3300 n/~ "'-J \ tJ
® 3330 w 7:- 'J "' ~
3340 1/, l""lli'
/ '-LJ
3370 ~
--'3~1=20~--------~~~v/
3140 v' -
/, according to order
~~~
bearing housing bearing housing
one piece for size 2040-2100 split design for size 2120-2220
Basic document: 082771_e.chp Agitator-type: HWL 2060 N 8. EKATO-Drawings and Parts Lists
EKATO RMT
Drawing Clamp Flange 950-20178507-00
$_
I
"'"" I
~
I
~
iK:
~
~
I
I
I
I I I
9411
9410
EKATO RMT
Drawing Flange Connection 615-20075060-00
t
6120
6130
6110
--
6 I 5 I 4 I 3 I 2 I 1
llllljlfll,lllljlilllllli[illlllllljlllllliltjlltllltlljlllillliijlillllllljiliillllljiltlllliljlllll
M 1: 1
50 100
.---------------------------------------
f--- 3151
3152
3153 ,.,..
c 3154
r \ I
/
-------- 1"7///
V//1. IIf::: I
~ \ I
'7=1:::::::1
-
3153
~
" I I
I I
"'/=t=/; I
/~t;
B /~b:
-
Stllc~ Benennung I Teil I Zchngs. Nr. IMaterial I Mod.,DIN
Datum Name Type :
..q-
Anderungen Datum Name
gezelchnet
geprUft
NormgeprUft
14.12.10
14.12.10
SoS
HM HWL EI<ATO
..q- A ~Kanten nach DIN ISO 13715 MaBstab: Bezeichnung : Zeichnungs-Nr. :
I") MaBe ahne Taleranzangabe
NTS
...--
(J)
~ nach DIN ISO 2768-mK
FUr diese Ze\chnung behalten wlr uns aile Rechte vor. Ohne unsere vor-
Erd u n g se in ric htu n g 325-20191344-00
...--
0
herige Zustimmung darf sie weder vervie\HUtigt noch Dritten zugOnglich
gemacht warden, und sle dorf durch den EmpfCinger oder Drltte ouch
Mikrover- GROUNDING CONNECTION Ersatz fUr :
filmtD Ersetzt durch :
N I nlcht in anderer Weise m!BbrCiuchlich verwendet warden.
Urso.Zn.Nr.: 325-20056958-00 A4
EKATO RMT
9. Instructions and Parts Lists of

non-EKATO-Components
This chapter contains the following publications:
9.1 Motor VEM IE2-KPR 100 LX4

Data Sheet
Dimension Drawing IE2-KPR 100 LX4 IMB5 FF215
Torque Characteristics
Connection Diagram KP 0001
Instructions 68238 01
Additional Instructions 5022901
9.2 Flat Gear Flender FZF68B-K2-100

Dimension Drawing FZF68B-K2-100
Spare Parts Drawing 369101c;87973c
Parts List SL 15089182-020
Works Certificate 15089182-000020
Operating Instructions BA 2010/05.10; BA 2019/05.10
Basic document: 9_e.chp Agitator-type: HWL 2060 N 9. lnstr./Parts Lists non-EKATO

Customer ref.: 70RW400
VEM motors GmbH VEM motors Thurm GmbH
Cari-Friedrich-Gaull-Str. 1 Aur..ere Dresdener Str. 35
D-38855 Wernigerode D-08066 Zwickau
(according to Annex X or Article 8 of EU Directive 94/9/EG)
The electrical apparatus

Explosion-protected three-phase asynchronous motors with squirrel-cage rotor of the series K •.. , W ... ,
B..
~ 113 D, Ex tD A22 IP55 T xxx oc (IP 65 with combustible dust)

~ 112 D, Ex tO A21 IP65 T xxx °C
~ 113 G Ex nA II T2, T3 or T4
~ 112G Ex e II T2, T3 or T 4
~ II2G Ex d(de) liB T3-T6, Ex d(de) IIC T3-T6
Combinations of equipment groups and equipment categories
~ 113G
and
Ex nA II T2, T3 or T4

or
& 112 D, Ex tD A21 IP65 T xxx °C
& 112 G
and
Ex e II T2, T3 or T4

or
~ 112 D, Ex tD A21 IP65 T xxx °C
& 112 G,
and
Ex d(de) liB T3-T6, Ex d(de) IIC T3-T6
& 1120 Ex tD A21/P6x T 200°C-T 85°C
are in conformity with the instructions of the following EU Directives:
94/9/EC, 2006/95/EC, 2004/108/EC
The conformity with the instructions of these Directives is proved by the observation of following standards:
EN 60079-0, EN 60079-1, EN 60079-7, EN 60079-15,
EN 61241-0, EN 61241-1, IEC 60072
EN ISO 12100-2, EN ISO 13857
EN 60034-1, EN 60034-5, EN 60204-1, EN 60529
EN 61000-6-1, EN 61000-6-2, EN 61000-6-3, EN 61000-6-4
The designated product is intended for incorporation into a machinery, and it must not be put into operation until
the relevant machinery into which the product has been incorporated has been declared being in conformity with
the provisions of Directive 2006/42/EC.
The Quality Management System has been certified by IBExU lnstitut fOr Sicherheitstechnik GmbH with the
Approval No. IBExU08ATEXQ007 and IBExU05ATEXQ009.
\~~~\rniger~ode, 16.07.2009 : V ; I}; .€-. &.-.J::t

., . \ ~ . /t.j
1 ( IGe-vu..
S~ er - Reinhardt
M~naging Dire tor Factory manager
This certificate attests the conformity with the named Directives; however, it is not a promise of properties in the meaning of product liability.
27.04.2011
Data sheet
MADE WITH VERSION: 6.5
Manufacturer Customer
VEM motors Thurm GmbH
AuBere Dresdener Str. 35
D-08066 Zwickau
Three-phase motors with squirrel cage rotor, explosion protected version, zone 22
device group II, category 3D
Type IE2-KPR 100 LX4 ExtDA22
Duty type S1
Design output ( kW) 3.0
Number of poles (-) 4
Design frequency (Hz) 50
Voltage ( v) 400/690
Design speed [rpm] 1455
Connection (- ) DIY
Current (A) 6.50/3.75
Power factor (-) 0.77
Relative pull-in current (-) 9.0
Relative starting torque (-) 3.3
Relative pull-up torque (-) 3.1
Relative pull-out torque (-) 3.9
Efficiency, IE class (-) IE2-86.5%
Th. cl. 155(F/B)
Coolant temperature ( oc) 40
Altitude above sea level ( m) 1000
Degree of protection IP65
2
Moment of inertia ( kgm ) 0.011
Motor weight (kg ) 45
Bearing, D-side 6206 2Z C3
Bearing, N-side 6206 2Z C3
Relubrication interval (h)
Grease type Asonic GL Y 32
Grease amount (g )
max. surface temperature ( oc) 105
Special details to bearings 1 none
Special details to bearings 2 none
Bearing monitoring none
Winding protection TPM 100
Winding protection 2 none
Anti-condensation heating none
Special versions 1 none
Limit values to vibration velocity Class A
Balancing with half key
Colour system 2x2K
Colour shade special
Layer thickness 90 ~m
Delivery conditions and/or official regulations: IEC I EN 60034-1, DIN EN 60079-0, DIN EN 60079-15
Page 1/1
VEM motors GmbH Telefon: 0 39 43 I 68-0 GeschaftsfOhrer. Rechtsform: GmbH Commerzbank AG Dresdner Bank AG Deutsche Bank AG
Carl-Friedrich-Gaui1-Stral1e 1 Telefax: 0 39 43 I 68 21 20 Sitz: Wemigerode Dresden Wemigerode Wemigerode
D-38855 Wemigerode JOrgen Sander Amtsgericht
Postfach-Nr. 101252 E-Mail: motors@vern-group.com Dr. Dietmar Puschkeit Stendal HRB 112964 BLZ 850 400 00 BLZ BOO BOO 00 BLZ 810 700 00
D-38842 Wemigerode www.vem-group.com Ust.-ld. Nr. DE 212 649 455 Kto.-Nr. 800 15 BB Kto.-Nr. 350 50 30 00 Kto.-Nr. 250 04 03
Drehstrom-Kafiglaufer-Motoren
Manbi ld I Dimension Drawing

IE2 - KPR100LX4 Ex IMB5 FF215
451 Sp.2474
422
60 200
98
142 111
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VEM motors GmbH 12.05.2011
000 Thurm
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Drehmomentkennlinie/Torgue characteristics Typ/Type: IE2-KPR100LX4 FTII/2474 ; 3,0kW; U-400V; f- 50Hz;
100 100
90 90
_,__.. ---- . - .. ......
.-~~ ~~
. ...
80 I
,. ,. -· ....,. ... ---·"' ' . I 80
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70 I. • -... • _ ........ ..- • - • - • - ' 70 E
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0 0
0 200 400 600 BOO 1000 1200 1400 1600
Drehzahi/Speed n [min-1]
- - 1 - · - · Md I
VEM motors Thurm GmbH, PrOffeld

Conn. diagram
Three-phase Motor/Three-phase Generator KP 0001
6 - connection Y - connection
V2 W1 V2 W1
~
Q)
O"l
2
0
>
~
U2
W2
0
V1
U1
-o
Q)
2
O"l
0
>
..c:
O"l
:.c
:! V1
U1
o-
L1 L2 L3 L1 L2 L3
For use of star-delta switch: remove the star resp. delta interconnections.
Connect all terminals with the corresponding star-delta-switch terminals.
for special marking: RSR- reverse locking, sense of rotation ON (clock-wise)
RSL- reverse locking, sense of rotation CON (counter clock-wise)
the motor is internally connected in the respective sense of rotation. Connect always L1 - U1; L2- V1; L3- W1
according to terminal board. DO NOT CHANGE THE CONNECTIONS!!!
Datum 22.11.2o04
Bearb Kresse
Gepr
Norm
Zeichnungs-Nr.
1---t----+-----t------i •
1-0_1----1,__----+---f----1 Elektromotorenwerk
KP 0001 e
Zust. Mitteilung Datum Name Wemigerode
Installation, operating and
maintenance instructions
Three-phase asynchronous motors

with squirrel-cage rotor for low voltage applications
Three-phase asynchronous motors

with slip-ring rotor for low voltage applications
Translation
KP ./KPE./K1 O./K11./K12./K20./K21./K25
K22. 355/ 822. 355
WE1./W20./W21.
YP ./YPE./Y1 O./Y11./Y20./Y21.
8P./8PE./810./811./820./821
A1 O./A11./A20./A21.
KU ../KV../8U .. /YU ..
Motors that comply with the Regulation 2005/32/EC and
the order No. 640/2009 receive the marking lEx before
the type designation, whereas x= 1,2,3 (ace. to EN
60034-30). (Example IE1-K21R 132 S4)
A world full of motion
Edition 11.2009 VEM-Ident-No. 68238 01

Installation, Operating and Maintenance Instructions (Translation) English
1. General
To prevent damage to motors and the driven equipment the procedures laid down in the Operating and
Maintenance Instructions must be followed. Especially to avoid risk of injury, the separately enclosed Safety
Regulations must be adhered to strictly.
Since for reasons of clarity the Operating and Maintenance Instructions cannot contain specific information with
regard to all conceivable special applications and areas with special requirements, the user himself has to make
appropriate protection arrangements during the installation process.
1.2. Qualified personnel

Installation work, commissioning and operation of motors must only be done by qualified personnel. Installation
work shall only be done by qualified personnel who is skilled because of a technical education, expertise and
schooling of knowledge about
• security regulations,
• accident prevention regulations,
• standards and approved rules of technique
(for example VDE-regulations, standards).
The qualified personnel must have the ability to assess the assigned job, identify possible dangers and avoid
them. The qualified personnel must be authorized by the person in charge for security of the plant to carry out the
necessary work and tasks.
1.3. Intended use

This motor is only approved for the intended use given by the manufacturer in his catalogue and the
corresponding technical documentation. Other or additional use is not intended. This includes consideration of all
corresponding product documents. Changes or reconstruction of the motor are not allowed. External products and
components that shall be used together with the motor must be approved or recommended by the manufacturer.
1.4. Disclaimer
Observance of this manual and the conditions and methods used for installation, operation, use and maintenance
of the electric motor can not be monitored by the manufacturer. An improper installation can result in property
damage and thus result in personal injuries. We therefore do not accept responsibility and liability for losses,
damages or costs resulting from improper installation, improper or wrong use and maintenance or connected with
this in any kind. We strive to improve our products continuously. Consequently technical data and illustrations
remain subject to change without prior notice. Specifications may only be considered binding after written
confirmation by the supplier.
2
2. Description
The motors have been manufactured in accordance with IEC 34-1, EN 60034-1 and other appropriate European
standards. Motors can also be supplied complying with special regulations (e.g. classification regulations,
regulations for explosion protection).
Separate additional instructions apply for the following motor versions:
Roller table motors
Motors in explosion protected design
The details on the relevant order confirmation constitute the scope of supply.
3. Efficiency
The efficiency is determined according to the specifications of EN 60034-2-1. For motors < 1kW the direct
measurement method is used. The measurement uncertainty of this method is rated ,low". For motors;::: 1kW the
individual loss method is used. The additional losses of this method are determined from the residual losses. The
measurement uncertainty of this method is also rated as "low''. Efficiency and Efficiency class complying with EN
60034-30 are listed on the name plate of energy saving motors.
4. Degree of Protection
The degree of protection of the motors is indicated on their rating plate. The degree of protection of additional
devices fitted to the motor can be different than the degree of protection of the motor. This needs to be taken into
consideration during the installation of the motors. If motors are installed in the open (degree of protection ::0: IP
44), they should be protected against direct effects of the climate (freezing of the fan due to direct fall of rain,
snow and formation of ice).
5. Type of Construction
The type of construction of the motors is indicated on the rating plate. The motors can be used in different types of
construction only with permission of the manufacturer and if necessary after modification carried out in accordance
with the manufacturer's instructions. Especially with types of construction with vertical shaft the user has to ensure
that foreign particles cannot fall into the fan cowl.
6. Transport & Storage

If possible the motors should only be stored in closed and dry rooms. Outdoor storage under cover is permitted for
a short time only and requires adequate protection against all harmful effects of the climate. The motors also have
to be protected against mechanical damage. Never transport or store the motors resting on their fan cowls. The
eye bolts/attachment eyes of the motors together with appropriate lifting tackle must be used for transport. The
eye bolts/attachment eyes are intended for the lifting of the motors only, without any additional parts such as bed
plates, gears etc. If eye bolts/attachment eyes are removed after installation, the tapped holes must be blanked off
permanently according to the Protection Standard. For longer periods of storage a low vibration environment shall
be provided so that bearing damages due to downtime can be avoided. After a storage period of more than 12
months the condition of the grease must be checked before putting the motor into operation.
7. Removal of the Transport Safety Device

On motors with transport safety device (roller bearing), the hexagon head screw provided for the fastening of the
transport safety device is to be loosened and taken off together with the transport safety device. Subsequently the
bearing cover bolt packed in a bag inside the terminal box is to be screwed into the bearing cover. If it is
necessary for the motor type the bag will also contain a lock washer that is to be placed onto the bearing end
shield bolt before screwing it into the bearing cover. After removal of the transport safety device micro movements
of the rotor must be prevented by suitable measures (risk of downtime damages).
8. Installation and Fitting

Since during normal operation of electric motors, temperatures in excess of 100 'C can occur on their
surface, any contact with them must be prevented if the motors are installed in accessible areas .
• Because of this temperature sensitive parts must never be fitted to them or have contact with them.
In types of construction IM B14 and IM B34 it must be ensured that the maximum usable screw depth specified in
the table below is not exceeded, otherwise the winding will be damaged.
Vent holes must be kept free and the minimum distances stated in the dimensional drawings must be maintained
so that the flow of cooling air is not obstructed. Care must be taken that the discharged warmed up cooling
medium is not sucked up again.
For constructions with shaft end upwards the user must prevent liquid entry from the shaft!
The key in the shaft end is secured by the shaft protective sleeve for transport and storage only.
Because of the danger that the key may be thrown aside, a start-up or a trial run with the key protected
3
by the shaft sleeve only is strictly forbidden.

Transmission components (such as couplings, pinions or belt pulleys) should be drawn onto the shaft by means of
pull-on devices or by heating-up the part to be drawn onto the shaft. For the purpose of drawing the transmission
components onto the shaft, the shaft ends are provided with tapped centering holes according to DIN 332 Part 2.
Transmission components must never be driven onto the shaft using hammer blows because the shaft, the
bearings and other components of the motor could be damaged.
All components that are to be fitted to the shaft end must be balanced dynamically according to the balancing
system of the motor (full or half key). The rotors of the motor are balanced with half key; this is indicated by letter
H after the serial number on the rating plate. Motors with letter F after the serial number are balanced with full key.
If possible the motors are to be installed in such a way that they are free from vibrations. With precision balanced
motors special instructions are to be followed. When the installation is completed the user must ensure protection
of movable parts and safety of operation.
Direct coupling to the driven machine requires a particularly accurate alignment. The shafts of both machines
must be in alignment. The shaft height is to be adjusted to that of the driven machine using appropriate shims.
Belt drives put a lot of stress on the motor because of relatively high radial forces. When dimensioning belt drives,
apart from the instructions and calculation programmes issued by the manufacturers of the belts, it must be
ensured that the radial force permissible at the shaft end of the motor as stated in our data is never exceeded by
the pull and pre-tensioning of the belt. When pre-tensioning the belt during installation the instructions of the belt
manufacturers must be strictly adhered to.
The threaded holes of the flange types listed in the table are through holes (type IMB14, IMB34 ).
To avoid damage to the winding overhang of the motor winding, observe the maximum permissible tap depths
in conformity with the following table.
Flange type Old flange type Tap depth

(EN 50347) (DIN 42948) (mm)
FT65 C80 6,5
FT75 C90 8
FT85 C105 8,5
FT100 C120 8
FT115 C140 10
FT130 C160 10
FT165 C200 12
FT215 C250 12
If a motor of type IMB34 without flanged attachments is used, the user has to take appropriate measures at the
through holes to maintain the specified degree of protection.
9. Insulation Check & Replacement of Grease I Bearings

When the motor is first commissioned and especially after extended storage, the insulation resistance of the
winding is to be measured to earth and between phases. The check must take place using the rated voltage, but at
least 500 V.
A During and immediately after the measurements dangerous voltages are present at the terminals.
~ Therefore never touch the terminals and follow the operating instructions of the insulation resistance
meter closely!
Depending on the rated voltage UN, the following minimum values must be maintained with a winding temperature
of 25 'C:
Rated Power PN in Insulation Resistance
kW referred to Rated
Voltage in kQJV
1 < PN :-::; 10 6,3
10 < PN:o::; 100 4
100 < PN 2,5
If the minimum values are lower, the winding must be dried properly until the insulation resistance corresponds to
the required value.
When the motor is commissioned after a prolonged period of storage inspect the bearing grease visually and
replace it if hardening and other irregularities occur. If the motors are to be commissioned by the manufacturer
after more than three years following their delivery then the bearing grease must always be replaced. With motors
4
fitted with covered or sealed bearings the bearings must always be replaced with new bearings of the same type
after a storage period of four years.
10. Motor connection

The connection has to be done by qualified personnel according to the valid security
regulations. Outside of Germany the required national standards must be applied.
Name plate designations have to be observed under all circumstances!
Take extra care when connecting the supply cables in the terminal box of the motor. The nuts of the connection
screws have to be fastened without force. Before connecting the power line, the existing motor connections must
eventually be retightened.
Terminal box overview
Terminal box type Rated current Connecting Tightening

Terminal board
thread torque
[A] [Nm]
KA05 K1M4 30 M4 1,8 ± 0,2

KA 05-13 K1M4 30 M4 1,8 ± 0,2
KA 05-13 K1M5 30 M5 2,4 ± 0,2
KA25A SB 5 25 M5 2,5 ± 0,5
KA25ASS SB 5 25 M5 2,5 ± 0,5
K 63/25 A SB 5 25 M5 2,5 ± 0,5
KK63A SB 6 63 M6 4±1
KK 100 A SB 8 100 M8 7,5 ± 1,5
KK 200/100 A SB 8 100 M8 7,5 ± 1,5
KK200 A SB 10 200 M10 12,5 ± 2,5
KK400 A SB 12 400 M12 20±4
KK400 B KM 12 400 M12 20±4
KK400 B KM 16 630 M16 30±4
KK 630 A KLP 630-16 630 M16 30±4
KK 630 A KLP 630-20 630 M20 30+4
KK 1000 A KLSO 1000 1000 current bar -
11. Commissioning
Please follow the Safety Regulations closely. All work is to be carried out only when there is no voltage on the
motor. The installation must be carried out according to the valid regulations by qualified skilled personnel. Initially
the mains conditions (voltage and frequency) must be compared with the data on the rating plate of the motor. The
dimensions of the connecting cables must be adjusted in line with the rated currents of the motor.
The connection points of the motor are marked in accordance with EN 60034-8 (VDE 0530 Part 8). In Section 19
of these instructions the most common circuit diagrams for three phase motors in basic design are provided,
according to which the connection will be implemented. For all other versions, the special circuit diagrams are
glued to the inside of the terminal box cover or placed in the terminal box. An additional terminal box can be
provided for the connection of auxiliary and protection devices (e.g. anti-condensation heaters); the same
regulations apply as for the main terminal box.
Always start the motors with an over-current protection device that is set in accordance with the relevant nominal
values of the motor (""1 ,05 lnom). Otherwise warranty claims with respect to damaged windings become void.
Before the motor is connected for the first time it is recommended to check the insulation resistances between
winding and earth and between phases (see Section 9). After prolonged storage it is absolutely essential that the
insulation resistance is measured. Before coupling the motor to the driven machine, check the direction of rotation
of the motor to prevent possible damage being caused to the driven machine. If the power lines are connected
with the phase sequence L 1, L2, L3 to U, V, W, the direction of rotation is clockwise (view to shaft end on drive
side OS). If two terminals are changed, the direction of rotation is counterclockwise (i.e. L 1, L2, L3 to V, U, W). For
machines with only one direction of rotation the required sense of rotation is marked by an arrow on the machine.
For the permissible tightening torques for the terminal board bolts refer to the table below:
Tightening torques for bolts (terminal box, end shield, bearing cover)
Series KPER/0 63 to 132T, KPR/0 56 to 100
5
Type Type of End shield Fixed bearing Terminal box

construction cover
KPER/0 KPR/0 OS NS OS I NS or adapter cover
Bolts/tightening torque for bolts MA
63 ... 56 ... M4 M4 M4
71 ... 63 ... 2,0 Nm 2,0 Nm 1,5 Nm
80 ... 71 ... M5 M5 (for M4
90 ... 80 ... all 4,0 Nm 4,0 Nm KPER/0 1,5
100 L 90 ... 100 L Nm M5
M6 M6 M5 1,0
7,0 Nm 7,0 Nm
2,0 Nm) Nm
M4
M8
B3 2,5 Nm
100 10,0 Nm
100 ...
LX, 112 ... M8
B5, B14 M5
15,0 Nm M8 M5
2,0
B3, B14- M8 10,0 Nm 2,0 Nm
Nm M4
FT130 10,0 Nm
132 S ... T - M8
2,0
B5, B14 Nm
15,0 Nm
Series K1.R 112 to 355
Thread 0 M5 M6 M8 M10 M12 M16 M20

End shield - - 25 45 75 170 275
Bearing cover 5 8 15 20 20 - -
Terminal box - 4 7,5 12,5 - 20 -
Before closing the terminal box make absolutely sure that:
-the connection has been made in accordance with the wiring diagram
-all terminal box connections are tightened
-all minimum values of air paths are maintained (larger than 8 mm up to 500 V, larger than 10 mm up to 750 V,
larger than 14 mm up to 1000 V)
- the interior of the terminal box is clean and free from foreign particles
- unused cable entries are blanked off and the threaded plugs with seals are tightened
- the seal in the terminal box cover is clean and tightly glued and all sealing surfaces
are in the correct state to ensure that the relevant degree of protection is maintained.
Before starting up the motor check that all safety regulations are strictly adhered to, that the machine is correctly
installed and aligned, that all fixing parts and earthing connections are tightened, that the auxiliary and additional
devices are functionally and correctly connected and if a second shaft end is fitted that the key is secured against
being thrown aside.
If possible the motor is to be connected without load. If the motor is running smoothly and without any abnormal
noises, the load of the driven machine is to be applied onto the motor. When the motor is started up it is
recommended to monitor the current consumption if the motor is loaded with its driven machine so that any
possible overloads and asymmetries occurring in the mains can be recognised immediately. The starter must
always be in the starting position during starting. With slip ring motors the correct running of the brushes must be
monitored. They must be absolutely spark-free.
For mountings like encoders, brakes and others please observe the corresponding operating and maintenance
instructions of the manufacturer.
12. Maintenance
You are once again referred to the Safety Regulations, in particular to isolation, to securing against reconnection,
to checking whether all components connected to a voltage source are in dead state. If it is necessary to
disconnect the motor from the mains for maintenance work particular care must be taken to ensure that any
possibly existing auxiliary circuits (e.g. anti-condensation heaters, forced ventilators, brakes) are also
disconnected from the mains.
If the motor is to be dismantled during maintenance work, the sealing compound on the centering shoulders is to
be removed. When re-assembling the motor these need to be re-sealed using a suitable motor sealing compound.
Existing copper sealing washers must always be refitted.
6
Installation, Operating and Maintenance Instructions {Translation) English
Careful and regular maintenance, inspections and revisions are necessary to detect and clear faults in time, before
consequential damages will happen. As individual operating conditions can not be defined for all applications the
listed terms represent a general advice for undisturbed operation. Individual local conditions (degree of pollution,
load, etc.) must be taken into account when adjusting these terms.
What to do? Time period Terms

First inspection After about 500 operating hours Yz year at the latest
Control of air circulation Depending on local environmental
and surface of motor pollution
Relubrication (as option) See name plate or relubrication sign
Main inspection After about 10,000 operating hours Once a year
Remove condensate water Depending on the local environmental
conditions
13. Bearings and Lubrication

The anti-friction bearings of the motors in standard design are filled with anti-friction bearing grease in the factory
(or with sealed bearings by the bearing manufacturer) according to DIN 51825 in compliance with the table below:
Motor type Designation of grease Design. ace. to Temperature Base oil/

DIN 51825 range in 'C thickener
Standard therm. class F (from
size 132M)
KIOber Ester
Therm. class H rise F KE2/3R-40 -40 up to +180
Asonic GHY 72 oil/polyurea
Smoke exhaust design FV,
FV1, FV2 (up to 300'C/1h)
Special design therm. class F
Ester
Therm. class H rise F KIUberquiet BQ 72-72 KE2/3R-40 -40 up to +180
oil/polyurea
Standard Til, AS, NS, VL, LL
Standard therm. class F rise B KPE2N-50
KIUber Ester
size 56 - 132S .. T (ace. to DIN -50 up to +140
Asonic GLY 32 oil/lithium
for low temperatures 51502)
Power plant design Bechem Mineral
KP3N-30 -30 up to +140
Motors complying with VIK HIGH- LUB LM 3 EP oil/lithium
KPFK3U-30
For very high ambient KIUber Perflourpoly-
(ace. to DIN -30 up to +260
temperatures Barrierta L55/3 HV ether/PTFE
51502)
Customer request Only after consultation with design department of VEM
Under normal load and climatic conditions, the quality of grease guarantees an operation of the motor for approx.
10,000 service hours with two pole design and 20,000 service hours with multipole design. If not otherwise agreed
the grease of anti-friction bearing must never be refilled during this period. However, the condition of the grease
should be checked occasionally even before this time limit. The bearing itself or the grease of permanently
lubricated bearings should be changed after approximately 3 years independent of operating hours. This is due to
the reduction of lubrification properties of the grease. The indicated number of service hours is only valid for
operation at rated speed. When using inverter feeding the indicated relubrication periods are reduced by 25%
because of the higher temperature increase. If during operation of the motor via an inverter the nominal speed is
exceeded then the regreasing period reduces approximately in the opposite ratio to the increase in the motor
speed.
Regrease the bearings only after a thorough cleaning using suitable solvents. The same type of grease must be
used. When replacing the grease only the equivalent types specified by the motor manufacturer can be used.
Please bear in mind that the bearings should only be filled up to about 2/3 of their free space. A complete filling of
the bearings and bearing covers with grease leads to increased bearing temperature and therefore to increased
wear.
The regreasing of bearings with regreasing facility is carried out at the grease nipple when the motor is running
using the grease quantity required for the respective motor. For the re-greasing intervals please refer to the table
below:
7
Frame size 2-pole design Design with 4-

poles and more
Series IEC/DIN Series
Transnorm
132 bis 280 100 bis 250 2.000 h 4.000 h
315 280 bis 315 2.000 h 4.000 h
355 - 2.000 h 3.000 h
The quantities of grease required for the re-greasing are stated in the below table (Please note that for the first re-
greasing approx. twice the amount of grease is required because the grease lubrication pipes are still empty). The
used grease is collected in the grease chamber of the external bearing cap. After approx. 5 re-greasings this old
grease should be removed, e.g. as part of inspection work.
Series Overall Quant~ty of ~rease Series Overall length Quantity of ~rease in

Trans- length m em IEC/DIN pole number em
norm pole number
Size D-end N-end Size D-end N-end
112 aile 10 10 132 M4, MX6 17 17
132 aile 17 17 160 L2, MX2, L4, 6, 8 23 20
160 aile 23 20 M2, L4 23 23
180
2 23 23 M4, L6, 8 23 20
180
>4 31 31 L2, L4, 6, 8, LX 6 31 23
200
2 31 31 LX2 31 31
200
;:::4 35 31 M2 31 31
225
2 35 35 M4, 6, 8, S4, 8 35 31
225 ;:::4 41 35 M2 35 35
250
2 41 41 M4, 6, 8 41 35
250 ;:::4 52 41 2 41 41
280
2 52 52 ;:::4 52 41
280
;:::4 57 52 S,M2 52 52
S2 57 52 S,M ;:::4, MX2 57 52
M,L,LX2 57 57 315 MY,L,LX2 57 57
315
S4, 6,8 64 52 MX4, 6, 8 64 52
M,L,LX4,
78 57 MY,L,LX4, 6, 8 78 57
6, 8
2 57 57 2 57 57
355 4 90 57 355 4,6,8 90 57
6,8 90 57
The necessary relubrication periods for roller bearings differ from the inspection periods and must be
observed separately!
The motors up to size 315M are equipped as standard with anti-friction bearings with life-time lubrication. From
size 315MX upwards they are equipped with relubrication devices which can be ordered for smaller motors as
option. Information about bearings and relubrication can be found in the general installation, maintenance and
operation manual or on the name plate or relubrication sign .
.f.\ Maintenance works (without relubrication) has to be done at standstill of the motor.
~ It_ has to be assured that the machine is secured against re-connection and labelled with an appropriate
s1gn.
In addition the security advices and accident prevention regulations of the manufacturers for the use of oils,
lubricants and detergents has to be observed!
.f.\ Adjacent live parts have to be covered or secured! It has to be assured that the auxiliary circuits like anti-
~ condensation heating are dead (zero potential).
For design versions with condensate drain hole please observe that the drain plug screw has to be lubricated with
a suitable sealant (for example Epple 28) before relocking.
8
14. Long term storage (more than 12 months)

Long term storage must be done indoors in vibration-free, dry rooms with temperatures not below -20'C and not
above +40'C. The storage environment must not contain aggressive gas, vapours, dusts and salts. Preferably
motors shall be moved and stored only in original packing. Storage and transport with motors standing on their fan
covers is not allowed. Additionally unprotected metal surfaces like shaft ends and flanges must be protected with a
medium for long-time corrosion protection in addition to the exisiting factory-provided temporary corrosion
protection. If there is a risk of motors being covered by moisture from condensation, please provide precautionary
measures against humidity. Than a special packing in airtight sealed plastic foil is necessary or as alternative
packing in plastic foil with desiccants. Please put desiccant bags in the terminal box as well.
For the transport please use the eye bolts/attachment eyes of the motors together with suitable lifting accessories.
The eye bolts/attachment eyes must only be used for lifting the motors without additional mountings like
foundation plates, gears and others.
Motors with reinforced bearings are supplied with a transportation safety device. The transportation safety device
at the shaft end must only be removed during installation of the motor and before switching on.
15. Slipring Contact System

The slipring contact system is to be inspected at regular intervals. It is advisable to check the slip rings 2- 3 times
immediately after commissioning, at intervals of approx. 50 operating hours. Subsequently regular maintenance is
to be carried out at intervals that depend on the relevant operating conditions.
A thin layer of patina should be formed on the surface of the slip rings. Generally such patina layer is formed after
an operation of between 100 to 500 hours. If intensive scoring or burnt spots on the slip ring surface occur they
must be removed immediately either by cleaning or if necessary by re-machining. If slight scoring appears it is not
necessary to re-machine. The pressure of the carbon brushes must be checked. It should be between 18.5 kPa
and 24 kPa. When replacing the brushes the same type of brush must always be used. New carbon brushes must
be bedded-in. With box type brush holders care must be taken to ensure that the carbon brushes do not jam due
to contamination.
The carbon brushes wear naturally and the abrasion can amount to 3- 5 mm per 1,000 hours of operation.
16. Draining of condensation water

On installation sites where formation of dew and thus occurrence of condensation water can be expected inside
the motor, the accumulated condensation water has to be drained at regular intervals through the opening at the
lowest point of the end shield. Subsequently the opening must be closed up again.
17. Cleaning
So that the effects of cooling air are not interferred with, all parts of the motor must be cleaned at regular intervals.
In the majority of cases it is sufficient to clean the machine with compressed air that is free from water and oil.
Especially the vent holes and the spaces between the ribs must be kept clean. The dust generated by natural wear
and deposited in the interior of the motor or in the slip ring space must be removed at regular intervals. It is
recommended to include the electric motors in the regular routine inspections of the driven machine.
18. Auxiliary devices

As option the motors can be equipped with auxiliary devices.
18.1 Motors with Thermal Winding Protection

For monitoring the stator winding temperature it is possible to have thermo couples installed in the motor (PTC
thermistors, KTY or PT1 00). For their connection suitable auxiliary clamps for auxiliary circuits are available in the
main terminal box or in additional terminal boxes. The connection is done according to the attached connection
diagram.
A continuity test of the thermistor sensor circuit using a test lamp, a hand generator and such like is strictly
prohibited because this would destroy the sensors immediately. If it becomes necessary to verify the cold
resistance of the sensor circuit (at approx. 20°C) then the measuring voltage must never exceed 2.5 V DC. It is
recommended to carry out the measurement using a Wheatsone bridge with a 4.5 V DC supply voltage. The cold
resistance of the sensor circuit must never exceed 810 Ohms; a measurement of the hot resistance is not
necessary.
With motors that are fitted with thermal winding protection, care must be taken that when the thermal winding
protection responds and after the cooling down of the motor, no hazards can occur due to spurious automatic
reconnection.
18.2 Anti-condensation heating

The input supply voltage is indicated on the name plate of the motor. For their connection either in the main
terminal box or in the auxiliary terminal boxes suitable clamps for auxiliary circuits are provided. The connection is
9
done according to the attached connection diagram. The anti-condensation heating has to be switched on only
after disconnection of the motor. It shall not be switched on while the motor is in operation.
18.3 Forced ventilation unit

The forced ventilation unit is dissipating the lost heat at operation of the main motor. During operation of the main
motor the motor of the forced ventilation unit has to be switched on. After disconnection of the main motor the
forced ventilation has to continue depending on the temperature. For motors with forced ventilation units that are
dependent of the sense of rotation, the sense of rotation has to be observed unconditionally (see rotation mark).
Only manufacturer approved forced ventilation units shall be used. The forced ventilation unit has to be connected
according to the connection diagram that is supplied inside of the terminal box.
19. Warranty, Repair, Spare Parts

Unless expressly agreed otherwise only our contractual workshops are permitted to carry out repairs during the
warranty period. Other repairs that may potentially be required can also be carried out by skilled personnel in these
workshops. Details about Customer Service network can be obtained from the manufacturer on request. The spare
parts are listed in Section 24 of these Operating & Maintenance Instructions. Maintenance carried out
appropriately (provided it is as described in Section "Maintenance") does not constitute a breach of warranty
provisions. The contractual warranty liability on the part of the manufacturer is not prejudiced by this.
20. Electromagnetic Compatibility

The motors, as non-independently working unit, have been checked with regard to their conformity with the EMC
Standards. It is the responsibility of the equipment operator to ensure by suitable measures that the apparatus or
plant in their entirety comply with the relevant electromagnetic compatibility standards.
21. Trouble Shooting

General mechanical and electrical faults are to be rectified according to the Schedule in Section 25. All Safety
Regulations must be strictly observed when rectifying faults.
22. Terminal board circuits

For a machine with only one shaft end or with two shaft ends that have different diameters, the sense of rotation is
that rotational direction which is seen, if a person looks at the front end of the only or thicker shaft end.
For each motor the correct connection diagram is attached. The connection must be done accordingly.
For the connection of auxiliary circuits please see the additional connection diagram, which is also
attached.
10
Single speed squirrel-cage motors: Single speed squirrel-cage motors:

Li low voltage Y high voltage
I:J, :- Schaltung Y-Schaltung

V2 ...-
W1
-
·-.
~ \1
V2 \f.{.!
-
V1
- -
W2 U1
=
c
:::;
c
U?l _.
l .1
- - c
"'
=-
(/)
"'
..c
1/112
-
0
..c.
L1 L2 L3 L1 L2 L3
Star-delta switch connection:
W2 U2 V2
0 0 0 For star-delta switch without bridges,
connection according to the switch scheme
Motor with thermal winding protection
Terminal board connection as above
The connection will be implemented according to the connecting

diagramme of the tripping device
eingebaute FUhler TPM
11
Slip ring motor

Stator
fi low voltage Y high voltage
!:A :- Schaltung Y-Schaltung

WJ
I-
\.1
- V1-
U2
V2 ~
-
- - =
c U2
~
-
WJ. lL1
-
:::l
c
c
""
0..
Ul
"'
-<=
0
W2 U1
-
=
L1 L2 L3
L1 L2 L3
Rotor
Rotor connection according to type either to rotor terminals or brush holders
to the starter
23. Disposal
When disposing of the motors please observe applicable national law.
In addition please take care that all oil and grease is disposed according to the ordinance of waste oils
(Aitolverordnung). They must not be contaminated with solvents, cold cleaners and paint residues.
Before recycling the individual materials must be separated. Most important components are grey cast iron
(housing), steel (shaft, stator and rotor sheets, consumables), aluminium (rotor), copper (windings) and plastics
(insulation materials like for example Polyamide, Polypropylene and others). Electronic components like printed
circuit boards (inverter, encoder, etc.) must be recycled separately.
12
24. Construction of the motor

Item No. Bezeichnung Designation
1.01 Lagerschild D-Seite End shield Drive end
1.02 Lagerdeckel, D-Seite, aur..en Bearing cover, Drive end, external
1.03 Lagerdeckel, D-Seite, innen Bearing cover, Drive end, internal
1.04 Tellerfeder I Wellfeder, D-Seite, nicht bei Rollenla- Disc spring I wave washer, Drive end, not for roller
gern bearinQs
1.05 Walzlager D-Seite Antifriction bearing, Drive end
1.06 V-Ring D-Seite V-type rotary seal, Drive end
1.07 Flanschlagerschild Flange end shield
1.08 Filzring D-Seite Felt rinQ, Drive end
2.01 Lagerschild N-Seite End shield Non-drive end
2.02 Lagerdeckel, N-Seite, aur..en Bearing cover, Non-drive end, external
2.03 Lagerdeckel, N-Seite, innen Bearing cover, Non-drive end, internal
2.04 Walzlager N-Seite Antifriction bearinQ, Non-drive end
2.05 V-Ring N-Seite V-type rotary seal, Non-drive end
2.06 Wellfeder Wave washer
2.08 Filzring N-Seite Felt ring, Non-drive end
3.01 1 Paar Motorf013,e 1 pair of motor feet
3.02 LOtter Fan
3.03 LOfterhaube, Kunststoff Fan cowl, plastic
3.04 LOfterhaube, Stahlblech Fan cowl, sheet steel
3.05 LOfterhaube mit Schutzdach Fan cowl with canopy
3.06 Ringschraube Lifting eye bolt
4.0114.02 Klemmenkastendeckel Terminal box cover
4.0314.04 Dichtung Klemmenkastendeckel Terminal box cover gasket
4.0514.06 Klemmenkastenunterteil Terminal box base
4.07 Dichtung Klemmenkastenunterteil Terminal box base gasket
4.08 Klemmenplatte Terminal plate
4.09 KabeleinfOhrung Cable gland
4.10 Verschluf3.schraube Screw plug for Qland opening
4.11 KabeleinfOhrung fOr thermischen Wicklungsschutz Cable gland for thermal winding protection
4.12 Anschluss fOr thermischen Wicklungsschutz Terminal for thermal winding protection
4.13 Schelle Clamp
4.14 Verschlussstocken Sealing Components
4.15 Zwischen platte Adapter plate
4.16 Flacher Anschlusskasten Flat terminal box
4.17 Normalienbeutel Standard parts bag
5.01 Laufer, komplett Rotor, complete
6.01 Schleuderscheibe, D-Seite Grease thrower ring, Drive end
6.02 Schleuderscheibe, N-Seite Grease thrower ring, Non-drive end
6.03 Labyrinthbuchse, D- u. N-Seite Labyrinth gland, Drive and Non-drive end
6.04 Leitscheibe, D-Seite Guide disc, Drive end
6.05 Leitscheibe, N-Seite Guide disc, Non-drive end
7.01 Schleifringlaufer mit Schleifringen Slip ring rotor with slip rinQs
8.01 BOrstenhalter Brush holder
8.02 BOrstentragerplatte mit BOrstenbolzen Brush carrier plate with brush rod
8.03 Schutzdeckel fOr SchleifrinQraum Protective cover for slip rinQ compartment
8.04 Dichtung fOr Schutzdeckel Gasket for protective cover
8.05 Deckel fOr LOfterhaube Cover for fan cowl
9.01 Klemmenkastendeckel fOr Lauferklemmenkasten Terminal box cover for Rotor Terminal Box
9.02 Dichtung Klemmenkastendeckel fOr Gasket for terminal box cover for Rotor Terminal Box
Lauferklemmenkasten
9.03 Klemmenplatte fOr Lauferanschluss Terminal board for rotor connection
9.04 Klemmenkastenunterteil fOr Lauferanschluss Terminal box base for rotor connection
9.05 KabeleinfOhrung fOr Lauferanschluss Cable gland for rotor connection
9.06 Zwischenflansch fOr Lauferklemmenkasten Adapter flange for rotor terminal box
9.07 Verschlussschraube fOr Lauferanschluss Screw plug for rotor connection
13
Three phase asynchronous motor with squirrel cage rotor I basic version K2.R 56 -132T
(example, delivered version may differ in details)
~
~ ~ 4.02
~
~ ~~ ~
~
~
4.01 ~
1.07 ~
4.03~
4.09 4.16
405~
~ ~
4.07
~
4.07
~
3.06
4.08 ((/
4.07~
1.07
3.04
2.03
~~ 2.04
3.05
14
Three phase asynchronous motor I basic version K1.R I K2.R 112-355

('() 1.[)
0 q
('() ('()
('J
0
(
('()
0
('J
('()
0
0
\ \
r---
0 0
('J
"""
0 0
15
Three-phase asynchronous motor with slip ring rotor I basic version S11R I SPER, S11H ISPEH
16
25. Trouble shooting

25.1 Electrical Faults
Motor doesn't start
Motor runs up heavily
Humming noise during start
Humming noise during operation
Hum in time of the double slip frequency
Excessive warming up at no-load

operation
Excessive warming up atrated output
Excessive warming up of individual winding sections
!Possible cause of fault Remedial measure
•• Overload Decrease the load
Interruption of a phase in the supply

conductor check the switch and the supply conductor
Interruption of a phase in the supply

••• conductor after switching-on check the switch and the supply conductor
• Mains voltage too low, frequency too high check the mains conditions
Mainsvoltage too high, frequency too low check the mains conditions
•••• Stator winding misconnected check the winding connections
••• Turn-to-turn fault check the winding and the insulation resistance,
repair in authorized service workshop
••• Phase-to-phase short circuit check the winding and the insulation resistance,
repair in authorized service workshop
• Interruption in the squirrel cage winding repair in authorized service workshop
17
25. 2 Mechanical Faults

Dragging noise
Excessive warming up
Strong vibrations
Bearing warming up excessively
Bearing noises
IPossible cause of fault Remedial measure
•• • Rotary parts are dragging Determine the cause, re~align parts
• Air supply reduced Check the ventilation passages
• Unbalance of the rotor Take rotor off, re-balance it
• Rotor not circular, shaft deformed Take rotor off, co-ordinate further measures with the
manufacturer
• Imperfect alignment Align motor & driven machine, check the coupling
• Unbalance of the coupled machine Re-balance coupled machine
• Shocks from the coupled machine Check the coupled machine
• Irregularities from the gear Check and repair the gear
• Resonance with the foundation Stiffen the foundation after consultation
• Changes in the foundation Determine the cause; eliminate itand re-align the machine
• Too much grease in the bearing Remove excess grease
• Coolant temperature higher than 40 'C Regrease bearing with suitable grease
• V-type rotary seal or gamma ring are Replace V-type rotary seal or gamma ring, maintain the
dragging prescribed installation clearance
•• Lubrication insufficient Lubricate according to instructions
•• Bearing is corroded Replace bearing
•• Bearing clearance too small Use bearing with larger bearing clearance
• Bearing clearance too large Use bearing with smaller bearing clearance
• Chatter marks in the bearing track Replace bearing
• Standstill marks Replace bearing
• Cylindrical roller bearing operated at Change the bearing according to manufacturer's instructions
low load
• Coupling pushes or pulls Re-align motor & driven machine
• Belt tension too high Adjust the belt tension according to instructions
•• Bearing not aligned or stressed Check the bearing bore, consult the manufacturer
18

Cari-Friedrich-GauP..-Str. 1 Aur..ere Dresdener Str. 35

three-phase asynchronous motors with squirrel-cage rotor,
three-phase asynchronous motors with slip-ring rotor
of the series
KP./KPE./K1 O./K11./K12./K20./K21./K25. G1 O./G11./G20./G21./GS1 O./GS1.

8P ./8PE./81 0./811./820./821. CP ./CPE./C1 O./C11.
AR., 8R. YP .NPE.N1 O.N11.N20.N21.
A10./A11./A20./A21. K81 RIK82R/882RIK85./K86.
SP./SPE./S10./S11. 581.
WE1./W20./W21. KU •./KV. ./8U •.NU ..
R10./R11./R20./R21.
K22. 355 I 822. 355 Gear motors S(R)I14.. , S(R)P4, S(R)K4 .•. , SG ... , SP •..
K2.8 •• KIX8 •.. ARG •..
' ~-· ' ... ,.........
~~.....,,. ~-..,_;
followed by the motor type
Motors that comply with the Regulation 2005/32/EC and the order No. 640/2009 receive the marking lEx
before the type designation, whereas x= 1,2,3 (ace. to EN 60034-30)
2006/95/EG
Directive of the European Parliament, and the Council from 12th December 2006 for harmonisation
of legislative provisions of the member states concerning electrical
equipment for operation within certain voltage limits
2004/1 08/E:G
Directive about Electromagnetic Compatibility
European Standard I German Standard
EN 61000-6-1, EN 61000-6-2, EN 61000-6-3, EN 61000-6-4
EN 55014-1, EN 55014-2
EN 61000-3-2, EN 61000-3-3
EN 60034-1, EN 60034-2-1, EN 60034-5, EN 60034-6, EN 60034-9, EN 60034-30
IEC60038
EN 60204-1
The specified product is exclusively intended for fitting into another machine/installation. Start of operation is
permitted until conformity of the end product with the directive 2006/42/EC is established.
Wernigerode, 2009-1 0~01
\~~
s~~r (u. I j
Reinfia;dt
{&LMltCL~
M~naging Director Factory Manager
This certificate attests the conformity with the named Directives; however, it is not a promise of properties in
the meaning of product liability. In case of electronic communication, the signature does not appear.
EWN-1200, Blatt 1, Seite 2
19
VEM motors GmbH
Cari-Friedrich-Gauf3.-Straf3.e 1
D-38855 Wernigerode
fon: +49-(0)39 43-68-0
fax: +49-(0)39 43-68-21 20
email: motors@vem-group.com
web: www.vem-group.com
Auf3.ere Dresdner Strasse 35

D-08066 Zwickau
fon: +49-(0)375-427-0
fax: +49-(0)375-427-383
email: motorsthurm@vem-group.com
web: www.vem-group.com
20
Additional
Installation, Operating and
Maintenance Instructions
rc:\Explosion protected three-phase asynchronous motors

\E:,Y with squirrel-cage rotor for low voltage
Type of protection increased safety ,e"
Type of protection ,n"
Motors for use in areas with combustible dusts <G II 20, <G II 30

Edition 11.2009 VEM-Ident-No. 50229 01
Additional Installation, Operating and Maintenance Instructions
General
Attention! Read installation, operation and maintenance instructions, connection diagram,
additional connection diagram and safety regulations before transportation, installation,
start-up, maintenance and repair. Mind the information!
The existing additional operation and maintenance manual is valid together with the already mentioned
documents and the operation and maintenance manual for standard motors, where the basic specifications
for connection, installation, operation and maintenance as well as the spare parts lists are included.
This manual shall help the user to ease the secure and proper transportation, installation, start-up and main-
tenance of the explosion-protected electric machine.
The compliance of this manual and the conditions and methods for installation, operation, usage and main-
tenance of the electric motor can not be controlled by the manufacturer. An incorrect installation can result
in damage to property and thus can lead to risks for persons. Therefore we do not assume responsibility and
warranty for losses, damages or costs resulting directly or indirectly from incorrect installation, faulty opera-
tion or usage and maintenance.
Technical drawings and pictures are simplified illustrations. Due to improvements and changes it might hap-
pen that they do not correspond in detail with the supplied electric machine. Our policy is one of constant
product improvement. Therefore we reserve the right to change the product, technical data or installation,
operating and maintenance instructions without prior notice. Designs, technical data and illustrations are not
binding until confirmed in writing by the supplier's works.
Symbols
In this manual three symbols will be used, that indicate important passages:
Security and warranty advices,

possible damage to persons included.
Warning against electric voltage, danger of life.

Advice that damages to the electrical machine and/or
the auxiliary devices can happen.
Additional advice for electrical Ex-motors of Group II of

category 2 (zone 1, 21) or Group II of category 3 (zone 2, 22).
Security regulations
The security regulations, accident prevention regulations, standards and approved rules of technique must
be observed unconditionally!
The non-observance of the security advices can result in endangering people and/or damaging of the ma-
chine.
Operation according to regulations

This manual is valid for explosion-protected, surface-cooled, low voltage electric machines. The type of
protection according to EN 60035, part 5 is at least IP 54 for motors for operation in zones 1 and 2, at least
IP 55 for operation in zone 22 and IP 65 for operation in zones 21 and 22 with conducting dust.
For combinations always the highest required type of protection has to be used. The type of protection is
always declared on the name plate of the motor.
In areas with risk of explosion only electric motors with the permitted type of protection may be used.
A Electric machines of Group II, category 2 (assigned to zones 1, 21)

~ or Group II, category 3 (assigned to zones: 2, 22)
Other or different operations are not classified in accordance to the regulations.

For damages and operational disturbances that result from faults at installation, ignorance of this manual or
improper repair no warranty can be claimed.
Areas with risk of explosions

Which areas outdoors or indoors have to be considered at risk of explosion according to the relevant rules
and regulations must be left at the responsibility of the operator or the supervisory authority if there is any
doubt about the localisation of areas with risk of explosion.
The responsibilities for the operator of such plants are described in the regulation 99/92/EG- ATEX 137
(former ATEX 118a), occupational health and safety regulation. The directive 94/9/EG- ATEX 95 (former
ATEX 100a) contains the fundamentals for explosion-protected products.
Edition 11.2009 2 VEM-Ident-No. 50229 01
The requirements for products for operation in areas with risk of explosion are determined in this directive.
They will be supported by corresponding regulations (see below).
Explosion-protected electrical machines, that will be covered by this manual, have been designed according
to the regulations of series EN 60034 (VDE 0530), EN 60079-0, EN 61241-0 and the regulation for the cor-
responding type of protection EN 60079-7, EN 60079-15, EN 50281 or EN 61241-1.
They shall only be put into operation according to the measures of the appropriate supervisory authority.
The supervisory authority is responsible for acknowledgement of the risk of explosion.
A Type of protection, temperature class and characteristics

~ have to be taken from the name plate of the motor.
-Group II, category 2 (assigned zones: 1, 21)

In this category electrical machines of type of protection ,increased safety" "e" and ,flame-proof enclosure"
"d" can be found. In addition electrical machines for operation in areas with combustible dusts and type of
protection "protection by enclosure" are included in this group.
-Group II, category 3 (assigned zones: 2, 22)

In this category electrical machines with type of protection "n" and electrical machines for operation in areas
with combustible dusts and type of protection "protection by enclosure" can be found.
A If the certification number includes the letter X, special requirements have to be observed that are
~ listed in the corresponding type examination certificate.
Characterisation of explosion-protected motors

Nr. RL 94191EG New name EN 60079 ff., 61241 ff. Old name (EN 50014 ff., EN
NB 50281)
ENIIEC 60079-0 I ENIIEC 60079-7 EN 500141 EN 50019
CE 0637 Ex II 2G Ex e II T2, T3 or T4 EEx e II T2, T3 or T4
ENIIEC 60079-0 I ENIIEC 60079-15 DIN EN 50014/50021, IEC 79-15
CE 0637 Ex II 3G Ex nA II T2, T3 or T4 EEx nA II T2, T3 or T4
EN/IEC 61241-0 I ENIIEC 61241-1 EN 500141 EN 50281-1-1
CE 0637 Ex II 2D Ex tD A21 T 125'C IP65 IP65 T 125'C
ENIIEC 61241-0 I EN/IEC 61241-1 EN 500141 EN 50281-1-1
(IP 65 for combustible dust) (IP 65 for combustible dust)
combination gas or dust

Ex 112G Ex e II T2, T3 orT4 EEx e II T2, T3 or T4
Ex 112G Ex e II T2, T3 orT4 EEx e II T2, T3 or T4
CE 0637 Ex 112D Ex tD A21 T 125'C IP55 IP65 T 125'C
Ex II 3G Ex nA II T2, T3 or T4 EEx nA II T2, T3 or T4
Ex II 3G Ex nA II T2, T3 or T4 EEx nA II T2, T3 or T4
OS certification from NB 0637 ... IBExU Freiberg

[When indicating a maximum surface temperature: for zone 2 (gas): total surface including rotor and wind-
ings; for zone 21,22 (dust): outer surface (enclosure, shaft}!]
General advice for inverter operation

Inverter operation of explosion-protected three-phase motors is only permissible if the motors are manufac-
tured, tested, certified and especially marked for this kind of operation. The special manufacturer's instruc-
tion must be observed unconditionally. For the type of protection "increased safety" "e" and for motors for
operation in zone 21 special EC-type examination certificates are required, in which inverter operation is
explicitly allowed and in which the required conditions and parameters of the system motor-inverter-security
device are listed.
Edition 11 .2009 3 VEM-Ident-No. 50229 01

For protection type ,n" the motors, that will be fed by inverter with a variable frequency and/or voltage,
have to be tested with the predefined inverter or with an inverter, that is comparable according to the speci-
fication for output voltage and current.
The necessary parameters and conditions have to be taken from the name plate or the documentation of
the motor.
The motors must always be equipped with thermal winding protection to avoid unacceptable temperatures.
The data from the thermal winding protection device must be analysed by suitable equipment. Motors shall
not be operated as multimotor drive.
For installation and start of operation of the frequency inverter please observe the instructions and the man-
ual of the manufacturer unconditionally.
Frequency inverter operation in zone 2 (Ex II 3G) or zone 22 (Ex II 3D)

Operation with frequency inverter is permissible only within the operational data given on the name plate. It
is permissible to exceed the rated motor current for a very short time (max. 1 min within a period of 10 min)
up to 1,5 times of the rated current. The given maximum torque and frequency shall not be exceeded under
all circumstances. By selecting an appropriate inverter and/or using filters it must be ensured that the maxi-
mum permissible pulse voltage at the motor terminals is not exceeded.
For the individual series/options the following values for max. pulse voltage are defined:
Series K21./K20.
size 56-132T 1l 0:,; 1,000 v
size 56-132T 1l (ace. to Sp. 2945) 0:,; 1,350 v
size 132 [K20. 112] to 355 0:,; 1,350 v
Series KU1./KUO.
size 56-132T 1l (ace. to Sp 9382) 0:,; 1,560 v
size 132 [KUO. 112] to 355 0:,; 1,800V
Series KV1./KV4./KVO.
size 132 [KVO. 112] to 355 0 :5:2,500V
1) 132T .... shaft height 132 delivered by production site VEM motors GmbH Thurm
It must be ensured that the operating voltage at the motor terminals complies under all circumstances with
the rating on the name plate. The data from the thermal winding protection device has to be analysed either
by a separc!lte relay or by the inverter.
Frequency inverter operation in zone 21 (Ex II 20)

Motors for operation in zone 21 must always be certified by a notified body before using frequency opera-
tion. The limit values that are determined in the EC type examination certificate and printed on the name
plate must be kept under all circumstances. This means especially a control of the motor current in relation
to the frequency. Only use frequency inverters that fulfil the requirements of the EC type examination cer-
tificate.
Frequency inverter operation in zone 1 (Ex II 2G)

Motors of protection type "increased safety" "e" for use in zone 1 must always be certified by a notified body
before using frequency operation. The limit values that are determined in the EC type examination certifi-
cate and printed on the name plate must be kept under all circumstances. This means in particular monitor-
ing of the continuous current as a function of the frequency. Only use frequency inverters that fulfil the re-
quirements of the EC type examination certificate. Analysis of thermal winding protection data must be done
by using a trip unit with Ex-mark II (2) G that fulfils the requirements of the directive 94/9/EC. The given
values for maximum torque and frequency must not be exceeded under all circumstances. The maximum
allowable pulse voltage of 1560 V for sizes 56 to 132T and 1800 V for sizes 132 [K10. 112] to 355 at the
motor terminals have to be limited by choosing a suitable inverter and/or using filters. It has to be secured
that the operating voltage at the motor terminals always complies with the data indicated on the name plate
(please observe voltage drop in connection with filters!). If the terminal voltage of the motor is lower as the
rated voltage indicated on the name plate due to voltage drops at the frequency inverter, the cables and
possible chokes or filters, the edge frequency must be adjusted to a smaller value according to the linear
voltage/frequency relation. This results in a smaller possible speed control range.
Efficiency classes
The specification of the efficiency class (IE class) according to EN 60034-30 is allowed for explosion pro-
tected motors. Indicated are IE class and rated efficiency. The determination of the motor efficiency is done

with direct measurement complying with EN 60034-2-1 for motors up to 1 kW (chapter 8.1.1) and with the
summation of losses method and determination of residual losses for motors> 1kW (chapter 8.2.2.5.1 ). The
type designation is extended with a prefix (example IE1-K11R 132M2... ).
Installation and electrical connection

At installation and start of operation the security advices that are enclosed with the motor have to be ob-
served. Installation work shall only be done by qualified personnel who is skilled because of a technical edu-
cation, expertise and schooling of knowledge about
• security regulations,
• accident prevention regulations,
• standards and approved rules of technique
(for example VDE-regulations, standards).
The qualified personnel must have the ability to assess the assigned job, identify possible dangers and
avoid them. The qualified personnel must be authorized by the person in charge for security of the plant to
carry out the necessary work and tasks.
In Germany the construction of electrical systems in areas with risk of explosion is liable to the following
regulations:
• BetrSichV "Operational Safety Act",

•TRBS "Technical rules for industrial safety"
• GefStofN "Hazardous Goods Regulations"
• EN 60079-14 "Explosive atmospheres- Part 14: Electrical installations design, selection
and erection"
Outside of Germany the correct national regulations have to be observed.
The permissible coolant temperature (room temperature at place of installation) according to EN 60034-
1/IEC 60034-1 is max. 40"C/min. -20"C without label ling and the permissible altitude of site is up to 1000 m
above sea level (other than the given values have to be specified on the name plate of the motor and must
be certified separately if necessary).
Please make sure that the cooling air can enter and leave the air in/outlet without hindrance and without
getting sucked in again. Inlet and outlet openings have to be protected against pollution and dirt particles.
The minimum distance of air inlet of the fan cover against any
obstacles (dimension Bl) has to be observed under all circum-
stances.
Bl
For type of constructions with shaft end upwards the operator has to ensure that no foreign substances can
fall inside from above.
During installation of surface cooled motors it has to be observed that the condensate drain holes are lo-
cated at the lowest possible place. If the condensate drain holes are closed, the screws must be reinserted
with a sealant after drainage of condensation water. If the condensate drain holes are open, the direct con-
tact with a jet or gush of water must be avoided. A careful installation of the motors on an exactly level sup-
port has to be ensured to avoid strain when tightening the machine. Machines that shall be coupled must be
adjusted exactly. If possible elastic couplings shall be used.
Motor connection
The connection has to be done by qualified personnel according to the valid security regulations.
Outside of Germany the required national standards must be applied.
Name plate designations have to be observed under all circumstances!

Compare current type, mains voltage and frequency!

AMind connection type!
~ Mind rated current for motor protection switch setting!
For motors with type of protection ,increased safety" "e" the tE- time has to be observed!
Connect the motor according to the connection diagram inside of the terminal box!
Earthing shall be done with the earthing clip that can be found at the enclosure or at the end shield depend-
ing on the type of construction. In addition all motors are equipped with a ground conductor clamp inside of
the terminal box. Unused cable glands of the terminal box have to be closed for protection against dust and
humidity. For electrical connection the standard security and starting instructions are valid. The cable glands
or screwed sealing plugs must be admitted for use in Ex-applications. The installation torques, sealing areas
and clamp ranges of the cable clamps given by the manufacturer have to be observed unconditionally.
Supply cables have to be selected according to DIN VDE 0100 taking into account rated current and opera-
tional conditions (i.e. ambient temperature, method of cable installation etc. complying with DIN VDE 0298
and IEC I EN 60204-1).
For room temperatures of more than 40'C cables have to be used, that are allowed for an operation
A of at least 90'C. This is also valid for motors that are marked with X on the supplemental sheet of
~ the EC-type examination certificate which indicates special requirements for the cable design.
Take extra care when connecting the supply cables in the terminal box of the motor. The nuts of the con-
nection screws have to be fastened without force.
Terminal box overview

Terminal I Bmax Osmax Connecting a M Anzug
Terminal board Terminal type
box type [A] [mmL] thread [mm] [Nm]
25A KB 3Ex (KS 1OA) 53 10 slot terminal S10 x 1 4,3 ± 0,1 6
63A KB 4Ex (KS 14A) 72 16 slot terminal S14 x 1,25 6,3 ± 0,2 10
100 A KB 4Ex (KS 14A) 72 16 slot terminal S14 x 1,25 6,3 ± 0,2 10
200A KB 5Ex (KS 18A) 118 35 slot terminal S18x1,5 9,2 ± 0,2 20
KA 05-13 KB 5580 Ex/d 4.3 30 2,5 U-clamp terminal M4 - 1,2
25AV KL 155 30 4 U-clamp terminal M5 - 2
25AV KB 5591 Ex/d 5,2 37 4 U-clamp terminal M5 - 2
63AV KB 5121Ex-3 64 10 U-clamp terminal M5 - 2
100AV KB 5121Ex-3 64 10 U-clamp terminal M5 - 2
100AV KB 5130Ex 118 35 U-clamp terminal M6 - 3
200AV KB 5130Ex 118 35 U-clamp terminal M6 - 3
100/63 AV KM 8/6 63 10 U-clamp terminal M6 - 3
200 A-SB KM 10/8 100 70 saddle terminal M8 - 6
200 A-SB KB 5130 Ex 118 35 U-clamp terminal M6 - 3
400A KM 10/8 100 70 saddle terminal M8 - 6
400A KM 16/12 250 120 saddle terminal M12 - 15,5
400AV KM 10/8 100 70 saddle terminal M8 - 6
630A KLP M20 315 240 screw terminal M12/M8 - 15,5/6
K1X200 A KM 10/8 100 70 saddle terminal M8 - 6
K2X200 A KM 10/8 100 70 saddle terminal M8 - 6
K1X 400 A KM 16/12 250 120 saddle terminal M12 - 15,5
K2X400 A KM 16/12 250 120 saddle terminal M12 - 15,5
1000 A KLSO 1000 1000 2x 240 current bar M10 - 10
Is max max. rated current Q 8 max max. rated cross-section

a slot width of the slotted bolt (terminal board according to DIN 22412)
M Anzug max. tightening torque for connecting thread
For motors with a terminal board fitted with slotted bolts according to directive 94/9/EC only cable lugs com-
plying with DIN 46295 shall be used. The cable lugs are fixed with pressure nuts with integrated spring
washer. Alternatively a solid round wire can be used. The diameter of the wire must be suitable for the slot
width of the slotted bolt.

When inserting the feed line in the terminal box it has to be secured that no tensile loading acts on the ca-
bles. The inside of the terminal box must be kept clean. The seals must be undamaged and have to be fit-
ting. The terminal box must always be closed when the motor is in operation.
A Attention, do not open terminal boxes in atmospheres with risk of dust explosions when they are still
_Lm. hot from operation!
On order type AK 16/5 can be delivered as additional separate terminal box for motors KPRIKPER 56-
132S .. T. The installer must have the permission to install electric equipment in areas with risks of explo-
sions and must implement the motor connection diagrams. The creepage distances and air gaps are kept by
preassembly of the terminal board (connection plate) and the block for connecting PTC thermistors or anti
condensation heating. The type of protection IP55(66) is kept by using a closed base plate with 4 x M4
threads and dimensions 56 x 56, as well as the included seals and standard parts.
Series KPER/0 63 to 132T, KPR/0 56 to 100
Type Type of con- End shield Fixed bearing cover Terminal box
struction
KPER/0 KPR/0 OS NS OS I NS or adapter cover
bolts/tightening torque for bolts MA
63 ... 56 ... M4 M4 M4
71 ... 63 ... 2,0 Nm 2,0 Nm 1,5 Nm
M4
80 ... 71 ... M5 M5 (for KPER/0
all 1,5
90 ... 80 ... 4,0 Nm 4,0 Nm 100 L
Nm
100 L 90 ... M6 M6 M5 M5
7,0 Nm 7,0 Nm 2,0 Nm) 1,0 Nm
M8 M4
B3 2,5 Nm
100 10,0 Nm
100 ...
LX, 112 ... M8
B5, B14 M5
15,0 Nm M8 M5
2,0
M8 10,0 Nm 2,0 Nm
B3, B14-FT130 Nm
10,0 Nm M4
132 S... T - M8 2,0 Nm
B5, B14
15,0 Nm
Series K1.R 112 to 355
Thread 0 M5 M6 M8 M10 M12 M16 M20

End shield - - 25 45 75 170 275
Bearing cover 5 8 15 20 20 - -
Terminal box - 4 7,5 12,5 - 20 -
Motors with type of protection ,increased safety" "e" and with outgoing cable (including the design
version with flat terminal box with separate certificate according to directive 94/9EC)
The outgoing cable is led through with 4 or 7 conductors according to the demands of the customer.
If the entire terminal box is delivered and the connection is done in an Exe-protected surrounding, than the
following instructions have to be observed:
1. When mounting the terminal box at least the requirements for type of protection IP54 must be fulfilled.
2. For compliance with the required clearances the terminal socket has to be fastened according to the
indicated drawing of holes.
3. The inner earth conductor from the motor (green/yellow) with crimped lug has to be placed under the
clamping yoke of the earth connection.
4. The outgoing cables of the motor have to be soldered into the angled lugs of the terminal socket. The
correct connection U1, V1, W1 (U2, V2, W2) has to be observed.
When mounting the aggregate please take note that the motor number on the name plate agrees com-
pletely with the number on the riveted plate inside of the terminal box cover.

Protective measures against unacceptable warming

If there is no other information on the test certificate or on the name plate concerning duty type and toler-
ances, electrical machines are designed for continuous duty and normal, not frequently recurring starts, at
which no significant warming occur. The motors shall only be operated in the duty type indicated on the
name plate.
The range A of the voltage and frequency limits of DIN EN 60034-1 (DIN VDE 0530, part 1)- voltage± 5
%, frequency± 2 %, shape of curve, mains symmetry- has to be observed, so that the warming is kept
within the permissible limits. Bigger deviations from design values can result in excess warming of the elec-
trical machine to unacceptable temperatures. These deviations have to be indicated on the name plate. The
motor has to be protected against unacceptable warming at starting for example with a motor protection
switch. That means a current-dependent delayed protection switch according to DIN VDE 0660 or a similar
device for all phases has to be installed, so that unacceptable warming is prevented. The protective device
must be adjusted to the rated current. Windings in delta-connection have to be protected by connecting the
release or relay in series with the phase windings. Selection and adjustment of the releases must be based
on the rated value of the phase current (x0,58 rated current of the motor). If such a connection is not possi-
ble, suitable protection switches must be used, for example with phase failure control. For pole-changing
motors current-dependent delayed releases or relays have to be provided for each rotational speed level
that can be locked against each other.
For type of protection ,increased safety" "e" the starting will be controlled as well. Therefore the pro-
tection device must switch off within the time period tE that is given for the corresponding tempera-
ture class when the rotor is blocked. The requirement is fulfilled if the release time (it can be taken
from the release characteristics (starting temperature 20'C) for the ratio I iJIN) is not higher than the
indicated tE time.
Electrical machines of type of protection ,increased safety" "e" for heavy starting (start-up time> 1,7 x tE
time) must be protected by a starting control according to the information of the certificate of conformity.
They have to be certified accordingly.
Thermal motor protection by means of direct temperature monitoring of the winding is permissible if
this is certified and indicated on the name plate. The protection consists of thermo couples accord-
ing to DIN 44081 I 44082 that ensures explosion protection together with a tripping device with type
of protection marking® II (2) G. For pole-changing motors it is necessary to have separate protec-
tion
devices for each rotation speed level, that can be locked against each other.
Auxiliary devices
Explosion-protected motors can be equipped with different auxiliary devices as option:
Additional thermal motor protection

For monitoring the stator winding temperature it is possible to have thermo couples installed in the motor
(PTC thermistors, KTY or PT100). For their connection suitable auxiliary clamps for auxiliary circuits are
available in the main terminal box or in additional terminal boxes. The connection is done according to the
attached connection diagram.
Thermal motor protection as inherent protection

The use of thermal winding protection as inherent motor protection is only permissible if the operation is
tested separately and certified by a notified body. On the name plate instead of the tE time a tA time is
marked. In addition the following text will be printed on the name plate: "operation only with tested PTC
tripping device and marking® II (2) G".
Anti-condensation heating
The heating tapes must comply with the directive 94/9/EC. The heating power and the input supply voltage
are indicated on the name plate of the motor. For their connection either in the main terminal box or in the
auxiliary terminal boxes suitable clamps for auxiliary circuits are provided. The connection is done accord-
ing to the attached connection diagram. The anti-condensation heating has to be switched on only after
disconnection of the motor. It shall not be switched on while the motor is in operation.
Forced ventilation unit

The fans must comply with the directive 94/9/EC. The forced ventilation unit is dissipating the lost heat at
operation of the main motor. During operation of the main motor the motor of the forced ventilation unit has
to be switched on. After disconnection of the main motor the forced ventilation has to continue depending
on the temperature. For motors with forced ventilation units that are dependent of the sense of rotation, the
sense of rotation has to be observed unconditionally (see rotation mark). Only manufacturer approved
forced ventilation units shall be used. The forced ventilation unit has to be connected according to the con-
nection diagram that is supplied inside of the terminal box.
Special design for terminal box on N-side

The terminal box for this special design is located on N-side of the motor before the fan cover. To realise
this design the stator housing was turned during production. Special marking for type designation:
KNS ... for sizes 56 to 132 .. T (VEM motors Thurm GmbH)
KN ... for sizes 112 to 355 (VEM motors GmbH)
External heat and cooling sources

No extra measures will be necessary for existing external heat and cooling sources, if the temperatures at
the installation site are not exceeded. If the temperatures are exceeded or impacts on operational tempera-
tures or maximum surface temperatures can be expected provisions will have to be made to maintain and
confirm explosion protection. If in doubt please contact the manufacturer.
Maintenance and repair

In Germany maintenance, repair and changes of explosion-protected machines have to be done taking the
workplace safety ordinance (BetrSichV), the explosion protection ordinance (ExVO, 11.GSGV), the security
advices and the description of the general maintenance manual into account.
Outside of Germany the required national standards must be applied.
More information about testing and maintenance of electrical systems or repair and reconditioning of electric
equipment can be found in EN 60079-17 and IEC 60079-19. Activities that will influence the explosion pro-
tection such as:
- repair of the stator winding and of the terminals,
- repair of the ventilation system
-repair of the bearings and of the sealing of dust explosion protected motors (Ex 2D, 3D)
must only be done by VEM service personnel or by authorized workshops with trained personnel which is
qualified for such tasks by industrial training, experience and special schooling.
For dust explosion-protected motors the dust explosion protection is depending very much on the local envi-
ronmental conditions. For that reason the motors have to be checked and maintained regularly.
Thick layers of dust will result in a temperature rise on the surface of the motor due to thermal
insulation. Layers of dust on the motors or even the total coverage should be avoided as far as
possible by suitable installation and constant maintenance.
The indicated surface temperature of the motor is only valid, if the dust layer on the motor is max. 5 mm.
The securing of these conditions (dust type, maximum layer thickness and other) has to be assured. The
motor shall not be opened before a suitable time has passed to reduce the inner temperatures to values that
are not ignitable. If the motors have to be opened for maintenance or repair, the work has to be done in a
dust-free room if possible. If this is not possible suitable measures have to be taken to prohibit that dust can
collect inside of the enclosure.
At disassembly take extra care that the sealing parts like sealing, end faces and other are not damaged.
Careful and regular maintenance, inspections and revisions are necessary to detect and clear faults in time,
before consequential damages will happen. As individual operating conditions can not be defined for all
applications the listed terms represent a general advice for undisturbed operation. Individual local conditions
(degree of pollution, load, etc.) must be taken into account when adjusting these terms.
What to do? Time period Terms

First inspection After about 500 operating hours % year at the latest
Control of air circulation Depending on local environmental poilu-
and surface of motor tion
Relubrication (as option) See name plate or relubrication sign
Main inspection After about 10,000 operating hours Once a year
Remove condensate water Depending on the local environmental
conditions

The necessary relubrication intervals for anti-friction bearings are different to these inspection in-
tervals. They have to be observed as well!
The motors up to size 315M are equipped as standard with anti-friction bearings with life-time lubrication.
From size 315MX upwards they are equipped with relubrication devices which can be ordered for smaller
motors as option. Information about bearings and relubrication can be found in the general installation,
maintenance and operation manual or on the name plate or relubrication sign.
A Maintenance works (without relubrication) has to be done at standstill of the motor.

~ It has to be assured that the machine is secured against re-connection and labelled with an appro-
priate sign.
In addition the security advices and accident prevention regulations of the manufacturers for the use of oils,
lubricants and detergents has to be observed!
Adjacent live parts have to be covered or secured! It has to be assured that the auxiliary circuits like anti-
condensation heating are dead (zero potential).
For design versions with condensate drain hole please observe that the drain plug screw has to be lubri-
cated with a suitable sealant (for example Epple 28) before relocking.
The work has to be marked with an additional repair sign including the following information:
-date,
-executive company,
- if necessary type of repair,
- if necessary marking of the person legally authorised in accordance with the BetrSichV.
If the operations are not done by the manufacturer, they must be approved by a person legally
authorised in accordance with the BetrSichV. He has to issue a written confirmation or mark the
machine with his test mark. Outside of Germany the relevant state regulations have to be observed.
Spare parts
Except for standard, commercially available and equivalent parts (like anti-friction bearings) only
original spare parts (see spare parts list) shall be used; this applies especially for seals and connec-
tion parts. For spare parts orders the following information is necessary:
Spare parts name
Motor type
Motor number
Terminal board connections

In standard design surface cooled motors are adapted for both rotational directions. The types K12R
355/2-pole are an exception. They are equipped with a fan dependent on the direction of rotation. If
such fans or return stops (zone 22) are used a sign for sense of rotation has to be fixed on the fan
cover.
The connections U1, V1, W1 at phases L1, L2, L3 (in alphabetical or natural order) result always in clock-
wise rotation. The sense of rotation can be reversed at direct starting if two main connections at the terminal
board are changed.
For a machine with only one shaft end or with two shaft ends that have different diameters, the sense of
rotation is that rotational direction which is seen, if a person looks at the front end of the only or thicker shaft
end.
For each motor the correct connection diagram is attached. The connection must be done
accordingly. For the connection of auxiliary circuits please see the additional connection
diagram, which is also attached.
Hints for screwed cable glands that are admitted for explosion protection
The terminal boxes are designed as standard with metric threaded holes according to EN 50262 or on re-
quest with NPT-threaded holes according to ANSI 81.20.1-1983. At delivery the holes are closed with plugs
or AlEX-certified cable glands.
For connection of the motor only use cable entries and plugs that are designed according to directive
94/9/EC (ATEX) and have at least IP 55 type of protection.
For motors in type of protection "flameproof enclosure" "to" (IP 6X necessary!) the cable entries and plugs
must be designed according to directive 94/9/EC (ATEX) and have at least IP 65 type of protection.
All unused cable entry points must be closed with plugs according to the minimum type of protection listed
in directive 94/9/EC (ATEX). Existing plugs must be checked accordingly and if necessary they have to be
changed.
The specification of thread type is given on the equipment (name plate or terminal box). Alterna-
tively
the instruction about cable entry thread, number and position of cable entries can be given in the
dimensional drawing of the motor.
The indication of the thread type is done on the equipment (on nameplate or terminal box). As alternative
the note concerning the threads, their number and location is included in the dimensional drawing of the
motor.
For explosion protected VEM-motors cable glands of the company Jacob are used, if not ordered otherwise.
The following specifications must be observed for these special cable glands:
Ex-brass screw connection, metric thread,

ECd ecara
I t"10n of con f orm1ry
"t DMT99ATEXE016
thread Part-No. For cable diameter Width across flats Installation torque
mm mm Nm
M 12,x1,5 50.612 M/EX 3... 6 14 5
M 12x1 ,5 50.612 M1/EX 3... 6,5 14 5
M 16x1,5 50.616 M/EX 5... 9 17 5
M 20x1,5 50.620 M1/EX 6 ... 12 22 7,5
M 20x1,5 50.620 M/EX 9 ... 13 22 7,5
M 25x1,5 50.625 M/EX 11 ... 16 27 10
M 32x1,5 50.632 M/EX 14... 21 34 15
M 40x1,5 50.640 M/EX 19 ... 27 43 20
M 50x1,5 50.650 M/EX 24 ... 35 55 20
M 63x1,5 50.663 M/EX 32 .. .42 65 20
M 63x1,5 50.663 M1/EX 40 .. .48 65 20
M 75x1,5 *) Fa. HAWKE International 54,5 ... 65,3 95 20
M 80x1 ,5 **) Fa. HAWKE International 67 ... 73 106,4 20
*)BAS 01 ATEX2070X, **)BAS 01 ATEX2294X
Ex-EMC-brass screw connection, metric thread 016

ECd ecIarat1on
. of con f ormny
"t DMT99ATEXE016
thread Part-No. For cable diameter Width across flats Installation torque
mm mm Nm
M 12,x1,5 50.612 M/EMV/EX 3... 6 14 5
M 12x1 ,5 50.612 M1/EMV/EX 3... 6,5 14 5
M 16x1,5 50.616 M/EMV/EX 5... 9 17 5
M 20x1,5 50.620 M1/EMV/EX 6... 12 22 7,5
M 20x1,5 50.620 M/EMVEX 9... 13 22 7,5
M 25x1,5 50.625 M/EMV/EX 11...16 27 10
M 32x1,5 50.632 M/EMV/EX 14 ... 21 34 15
M 40x1,5 50.640 M/EMV/EX 19 ... 27 43 20
M 50x1,5 50.650 M/EMV/EX 24 ... 35 55 20
M 63x1,5 50.663 M/EMV/EX 32 .. .42 65 20
M 63x1,5 50.663 M1/EMV/EX 40 .. .48 65 20
If screwed cable glands or plugs according to directive 94/9/EC (ATEX) from other manufacturers are used
please observe the corresponding manufacturers information.


Cari-Friedrich-Gau~-Str. 1 Au~ere Dresdener Str. 35
(according to Annex X or Article 8 of EU Directive 94/9/EG)

Explosion-protected three-phase asynchronous motors with squirrel-cage rotor of the series K ... , W ..• ,
B ..
~ II 3D, Ex to A22 IP55 T xxx •c (IP 65 with combustible dust)
~ 1120, Ex to A21 IP65 T XXX "C
~ 113G Ex nA II T2, T3 or T4
~ 112G Ex e II T2, T3 or T4
~ 112G Ex d(de) liB T3-T6, Ex d(de) IIC T3-T6
Combinations of equipment groups and equipment categories
~ 113 G
and
Ex nA II T2, T3 orT4
~ 113 D, Ex to A22 IP55 T xxx •c (IP 65 with combustible dust)

or
~ 1120, Ex to A21 IP65 T XXX "C
~ 112G Ex e II T2, T3 orT4

and
~ II 3D, Ex tD A22 IP55 T xxx •c (IP 65 with combustible dust)
or
~ 1120, Ex to A21 IP65 T xxx ·c
~ 112G,
and
Ex d(de} liB T3-T6, Ex d(de) IIC T3-T6
~ 1120 Ex to A21/P6x T 200"C-T 85"C
94191EC, 2006/951EC, 2004/1081EC
EN 60079-0, EN 60079-1, EN 60079-7, EN 60079-15,
EN 61241-0, EN 61241-1, IEC60072
EN ISO 12100-2, EN ISO 13857
EN 60034-1, EN 60034-5, EN 60204-1, EN 60529
EN 61000-6-1, EN 61000-6-2, EN 61000-6-3, EN 61000-6-4
The designated product is intended for incorporation into a machinery, and it must not be put into operation until
the relevant machinery into which the product has been incorporated has been declared being in conformity with
the provisions of Directive 2006/42/EC.
The Quality Management System has been certified by IBExU lnstitut fur Sicherheitstechnik GmbH with the
Approval No. IBExU08ATEXQ007 and IBExU05ATEXQ009.
Wernigerode, 16.07.2009
~t~~'
;_v_ .11, fZeLu/t ,~.JJ~
Reinhardt
Factory manager
This certificate attests the conformity with the named Directives; however, it is not a promise of properties in the meaning of product liability.

VEM motors GmbH
Cari-Friedrich-Gaur.,-strar.,e 1
D-38855 Wernigerode
phone: +49-(0)39 43-68-0
fax: +49-(0)39 43-68-21 20
email: motors@vem-group.com
internet: www.vem-qroup.com
A.ur.,ere Dresdner Strasse 35

D-08066 Zwickau
phone: +49-(0)375-427-0
fax: +49-(0)375-427-383
email: motorsthurm@vem-qroup.com
internet: www.vem-group.com
Edition 11.2009 13 VEM-Ident-No. 50229 0 1

Dokumentationsi.ibersicht Bauart 1 Type
Documentation chart GnS[).e 1 Size
Kennwort I Keyword:
Bei Korrespondenz bitte angeben I Please quote in correspondence l No. 4598330 EN
Ekato-Best.-Nr. I Order-No.: 411220062
Ekato-Projekt I Project:
Ekato-Kundenauftr. I Customer-order: 80053, HP40
Ekato-ltem-Nr. /Item-No.: 70RW400 -Agitator Fines Recovery Tank
Pos. Produkt Betriebsanleitung I Dokumente Reg.-Nr.

Item Product Operating instructions I documents Reg. no.
MaP-,zeichnung/
FZF68B-K2-100
Dimension drawing
E rsatztei lzeich nung/
Getriebe I 369 101 c, 87 973 c
Spare parts drawinq
Gear unit StOckliste/
0050 SL 15089182-020
Parts list
FZF68B-K2-1 00
Werkszeugnis/
15089182-000020
Works certificate
Betriebsanleitung/ BA2010 .. 05.10,
Operating instructions BA 2019 .. 05.10,
• = geanderte Unterlage, bitte austauschen

modified document, please replace
D = erganzte Unterlage, bitte hinzufligen

completed document, please add
SIEMENS AG, I DT MD AP DA OM DOC, D - 46393 Bocholt Datum/Date Name Abt.

Tel. 02871/92-0; TX 0813841; Fax 02871/921551 18.06.2011 Runte DAOD.FR
Nur zur Information
60 8
SIEMENS
396
~t=9m~
~-----' DIN 5885
z
39 138,5 M12
~-II
~~<g 10 z
15 ~~r+-----1-~t ~ ~ -=::]---
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1 ~~_l
CfJ
I'-
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112
L-Jl6
7? 165
X y
DIN 6885
~
-~) '' __ Ln
"'
Ln
M12x21 ltem-Nr.: 70RW400- Agitator Fines Recovery Tank
FZF68B-K2-1 00
Oarstellung gemar.. gewahlter Einbaulage siehe 20/30-0atei
Zeichnung nicht mai?,stablich, aile Mai?,e in mm; ACHTUNG: Nicht aile Optionen werden dargestellt. Motox 7.3.028
* Langeres Mal?, fOr Motoren mit Option Bremse, Fremdbeluftung, Rucklaufsperre, Geber, Schutzdach oder 2tes Wellenende
~-
~------~8~----~------~7~----~--~--~6-------r------=5------~----~~4------,-------3~-----,------~2~-----,------~------,
Ordnungsnummer
Sachnummer
340 301 401 210 107 325 305 110 310 108
F F
091
::\ 001
~225
109
021\\ 201
220 311
E
025 E
030
205
330
070-=----11 305 307
345
305
~331
131 r~~ 141
D D
133 145
130 144
150 140
143
135
150
c 045 CI=>
':::::
040~ ltem-Nr.: 70RW400-

o5fB Agitator Fines Recovery Tank
132 055 345 050
MaGgebend is t die j ewe i Lige StOe kLis te
The respective parts-List is decisive em C®
Liste de pieces respective est determinante Pos. 125 war/was 117 2008-10-20 KEV WEI J2o08-I0-20
AM4788 2005-02-17 PSK WEI 12005-02-25
IB
~ J~:
117entfernen J2003-08-16 JAY WE I J2003-09-IO
RIF IFA AI I Feld Datum Name Norm

Auftr.-Nr. Jgesichert
ToLerierung nach DIN ISO 8015 ALLgemeintoLeranzen nach DIN ISO 2758-mH
105 +-_j [?[18~[[)8[;3
Werk-
stoff
Benennung
Z-ZE!CHNUNG 686
Sch L. -Nr. : I 41 4
/-Nr.
FAS 1 ~/~wffi>~12o FAT 415 Nicht gekennzeich-

nete Oberfl~chen:
. Gez. EG 2003-08-15 JAYAKUMAR FD./FZ. 588 , BAK3
I
413 Gepr. EG 2003-0B-15 SCHNURR Rohtei L nach Zeichnung sonst nach Zeichnung
418 I
E3~ Rauhwerte Ra in ~m Norm . . . , 1A
. _I. 1. I . Abt. Datum Name Format Art Zeichnunas Nr. AI
411 _ . .. 1:. J ·.,. I . Ma~stab M Gew i cht Ckgl
c
3 6 5 3
r- 8 7 6 5 4 3 2
-I
Ordnungsnummer
Sachnummer I SIS 528 525 522 520 542 501 S40 S41 S44 530 531 532 503 570 S02* S60 506 S05
560n• CEJ
0 0
@
®
CD
c C I~
SIS 561 S5S S57 S56 564
ltem-Nr.: 70RW400- Agitator Fines Recovery Tank CEJ 560n
* Wenn ke in Impu lsgeber verwende t wird, dann VerschluGs top fen C502l
D5/E6 12006-03-17 MMM SRR 2006-03-23J
• When no Prox imit~ switch is used, then Stopper C502l
eraanzt und Texte hinzuaefu 12002-07-25 MON ARD 2002-07-251
BI rh'\ 12000-11-30 KOP SIE 2000-II-30J B
~ n Te i l 560 CRo tex-Kupp lung) bes teh t aus:
AI I Fe ld Datum Name Norm
Kupplungstei l I CPos.5S6l mit Stellschraube CPos.564l Auftr. -Nr. ges ichert
Zahnkranz CPos.5S7l, Kupplungstei l 2 CPos.5S5l
Tolerierung nach DIN ISO 8015 Allgemeintoleranzen nach DIN ISO 2768-mH
mit Stellschraube (Pos. S64l
Werk- Benennung Sch l. -Nr. : 1414
n part S60 CRotex-couplingl consists of:
coupling part I CPos.556l with set crew CPos.S64l
[?[1[][KJ [[)[][2 stoff
/-Nr. Z-ZEICHNUNG K2
Ni cht gekennze i ch- ANTRG IEC BGR 100 u. NEMA 180
gear rim CPos.5S7l, coupling part 2 CPos.555l
nete Oberfl~chen:
with set crew CPos.S64l. 0 8\ilil Rauhwer te Ra in ~m
Rohtei l nach Zeichnung sonst noch Ze ichnung
A
Ma0gebend ist die jewei Lige StOckliste
CEJ •n Tei l 560 CRutschkupplungl besteht aus Pos.Nr.CD-@ The respective parts-List is decisive I I· I· I IMaPstabI Abt. I Datum
%
Name
Gew1cht Ckgl
'Format Art AI
•n part 560 Cslip clutch coupling) consists of Pos.Nr. CD-@ Liste de pieces respective est determinante Basi s-Nr. I AI Traghe i tsmoment c
Mode ll-Nr. IAnz. J Ckam 2 l
3 8 7 6 5 3
Stuckliste (SL) Auftrag 2049233 Seite
Parts list Endku ndenauft ragsnr Page
SIEMENS4 411220062 HP 40/50/60 1 I
FZF68B-K-(1 00)
Obersetzung 10,310
Bei Korrespondenz bitte angeben
Please quote in correspondence SL15089182-020 DE/EN
Hierzu gehort Zeichnungs-Nr.
Please refer to DWG No.
Teii-Nr. Menge Benennung Zeichnungs-Nr. Materiai-Nr. Gw(kg)
Part No. No. off Description Drawings No. Ident no. Weight
E 0000 1 ST WDR-KOMBI 65X100X10/18 NBR 70000004081893 0,126

SHAFT SEAL 65X100X10/18 NBR
E 0000 1 ST GRIPBEUTEL 160 X 220 X 0,09 PE 70000004328428 0,010
BAG 160 X 220 X 0,09 PE
E 0001 1 ST GETRGEH FDZ68B BAK3BEARB 368784/B 70000004368784 17,100
GEAR HOUSING FDZ68B BAK3BEARB
E* 0000 1 ST GETRGEH FDZ68B BAK3 ROH 368784/B 70000004368783 17,100
GEAR HOUSING FDZ68B BAK3 ROH
E* 0401 4 ST SHR-VSHL G3/8A A2B MIT DICHTR W0003082/- 70000004003365 0,027
PLUG G3/8A A2B MIT DICHTR
E 0010 3,5 L OEL PG CASTROL TRIBOL 800/220 (Tank) D0051502/- 70000004005818 1, 074
OIL PG CASTROL TRIBOL 800/220 (Tank)
E 0012 1 ST KUPL ROTEX 24 D28/28 6136114/- 70000004084674 0,324
COUPLING ROTEX 24 D28/28
E 0015 0,2 KG 2-K-PUR-L-M24 SAPHIRBLAU RAL5003 70000004017959 1,000
2-K-PUR-VARNISH-WIEREGEN-ACU-M24 RAL5003
E 0016 0,3 KG 2-K-EP-GEHOPON-E5-750 KORROGRUND 70000004017916 1,000
2-K-EP-GEHOPON-E5-750 KORROGRUND
E 0020 1 ST KEGROLLAGER 30305 D0000720/- 70000004085475 0,273
BEARING 30305
E 0021 1 ST PASSHEIB 54X62X1,5 D0000988/- 70000004085486 0,011
SHIM RING 54X62X1,5
E 0022 1 ST PASSHEIB 54X62X0,1 D0000988/- 70000004084641 0,010
SHIM RING 54X62X0,1
E 0022 1 ST PASSHEIB 54X62X0,3 D0000988/- 70000004367767 0,002
SHIM RING 54X62X0,3
E 0025 1 ST SICHERUNGSRING 62X2 DIN472 D0000472/- 70000004051312 0,011
CIRCLIP / SNAPRING 62X2
E 0030 1 ST KEGROLLAGER 30304 D0000720/- 70000004101094 0,175
BEARING 30304
E 0040 1 ST GETRFLA K68/F68 A250 BEARE 81857/F 70000004081857 5,500
OUTPUT FLANGE K68/F68 A250 BEARE
E* 0000 1 ST GETRFLA C/F/K68 A250 ROH 81856/- 70000004081856 5,500
OUTPUT FLANGE C/F/K68 A250 ROH
E 0045 6 ST I6KTSHR M12X40-8.8 A2F D0000912/- 70000004050856 0,048
SCREW M12X40-8.8 A2F
E 0050 1 ST GETRDEKL F68B ST 368799/- 70000004368799 1,140
HOUSING COVER F68B ST
E 0051 10 ST 6KTSHR M8X16-8.8 A2F D0024017/- 70000004050683 0,010
HEXAGON HEAD SCREW M8X16-8.8
E 0055 1 ST DICHT F68B 214X119X0,75 368819/- 70000004368819 0,006
GASKET F68B 214X119X0,75
E 0065 1 ST VERSHLKAP 52X6,5 N0062601/A 70000004439126 0,023
PLUG 52X6,5
E 0070 1 ST VERSHLKAP 62X8 N0062601/A 70000004517887 0,034
PLUG 62X8
Die mit * gekennzeichneten Teile gehoren zu einer Baugruppe (G). Die Baugruppe ist nur komplett auszutauschen.
Siemens Geared Motors GmbH, Postfach 1709, 72072 Tubingen, Datum Dat~
r--------------------.-----------4
Tel.+ 49(0)0 7071/707-0, http://www .siemens.com/getriebemotoren 04.04.20 11 Rev.: I
Parts list Endkundenauftragsnr Page
SIEMENS~
411220062 HP 40/50/60 2 I
FZF68B-K-(1 00)
Obersetzung 10,310
E 0101 1 ST ABTRWEL FIK68 WE50X100 85555ID 70000004085555 5,826

OUTPUT SHAFT FIK68 WE50X100
E* 0000 9,9 KG RUND 75 C45+N GEWALZT 70000004019659 0,010
ROUND SECTION ROD 32 ST
E 0105 1 ST PASSFED A14X9X80 D0006885I- 70000004051616 0,079
PARALLEL KEY A14X9X80
E 0118 1 ST VERSHLKAP 100X12 N0062601IA 70000004866695 80,094
PLUG 100X12
E 0130 1 ST KEGROLLAGER 32013X D0000720l- 70000004085062 830,630
BEARING 32013X
E 0131 1 ST STUESHEIB 88X100X3,5 D0000988I- 70000004989644 0,045
CSSNORTING WASHER 88X100X3,5
E 0131 1 ST PASSHEIB 88X100X0,1 D0000988l 70000004989647 0,003
SHIM RING 88X100X0,1
E 0131 1 ST PASSHEIB 88X100X0,15 D0000988l- 70000004989648 0,002
SHIM RING 88X100X0,15
E 0132 1 ST STUESHEIB 65X85X3,5 D0000988l- 70000004654019 0,300
E 0133 1 ST NILOSRG 32013XAV 70000004085519 0,014
NILOS RING 32013XAV
E 0135 1 ST SICHERUNGSRING 100X3 D0000472l- 70000004051331 0,041
CIRCLIP I SNAPRING 100X3
E 0140 1 ST KEGROLLAGER 32013X D0000720l- 70000004085062 830,630
BEARING 32013X
E 0143 1 ST NILOSRG 32013XAV 70000004085519 0,014
NILOS RING 32013XAV
E 0146 1 ST SICHERUNGSRING 100X3 D0000472l- 70000004051331 0,041
E 0201 1 ST ADAPTPL Z48 BGR71-100 AL BEARE ***** 70000004014745 0,446
FLANGE FOR GEAR Z48 BGR71-100 AL BEARE
E* 0010 1 ST ADAPTPL Z48 BGR71-100 AL ROH 7500982IA 70000004014744 0,425
ADAPTPL Z48 BGR71-100 AL ROH
E 0205 4 ST I6KTSHR M6X25-10.9 A2B DIN912 D0000912I- 70000004012318 0,007
SCREW M6X25-10.9 A2B DIN912
E 0205 4 ST SCHEIBE ISO 7089- 616,4- 300HV A2B 7630021- 70000004014759 0,001
WASHER ISO 7089- 616,4- 300HV A2B
E 0210 8 ST I6KTSHR M8X20-8.8 A2F D0000912l- 70000004050826 0, 013
SCREW M8X20-8.8 A2F
E 0220 1 ST DICHT BGR71-100 101X101X0,5 83277 I- 70000004083277 0,004
GASKET BGR71-100 101X101X0,5
E 0225 1 ST DICHT ADPT B1=140 175X160X0,5 832731- 70000004083273 0,004
GASKET ADPT B1=140 175X160X0,5
E 0301 1 ST ESTERITZ MN2,5 Z20 D16 83540IA 70000004083540 0,491
SHANK PINION MN2,5 Z20 D16
Siemens Geared Motors GmbH, Postfach 1709, 72072 Tiibingen, Datum Datl-~----------.------1
Tel.+ 49(0)07071 1707-0, http:ffwww .siemens.comfgetriebemotoren 04.04.2011 Rev.: I
Stilckliste (SL) Auftrag 2049233 Seite
SIEMENS4 411220062 HP 40/50/60 3 I
FZF68B-K-(1 00)
Obersetzung 10,310
Please quote in correspondence SL15089182-020 DEl EN
E* 0 00 0 1, 8 KG RUND 70 ZF6 N0040009ID 70000004010117 0,010

RODS-HARDENED 70 ZF6
E 0305 1 ST STIRAD MN2,5 Z34 BAK3 83538IC 70000004083538 0,900
HELICAL GEAR WHEEL MN2,5 Z34 BAK3
E* 0001 2, 4 KG RUND 110 ZF6 N0040009ID 70000004029053 0,010
E 0306 1 ST PASSFED B8X7X20 GEH N0053305I- 70000004051574 0,008
PARALLEL KEY B8X7X20 GEH
E 0340 1 ST RITZWEL FZ68B 6,067 Z15 MN2 3681701- 70000004368170 0,502
PINION SHAFT FZ68B 6,067 Z15 MN2
E* 0 00 0 1,1 KG RUND 40 (STANGE 3M) ZF6 N0040316IE 70000004972570 0,010
RODS-HARDENED 40 (STANGE 3M) ZF6
E 0345 1 ST STIRAD FDZ68B MN2 Z91 I=6,07 3687601- 70000004368760 6,050
HELICAL GEAR WHEEL FDZ68B I=6,07 Z91 MN
E* 0 00 0 13,3 KG RUND 200 ZF6 N0040009ID 70000004029057 0,010
E 0346 1 ST PASSFED B12X8X36 GEH N0053305I- 70000004441902 0,026
PARALLEL KEY B12X8X36 GEH
E 0401 1 ST SHR-VSHL G3I8A A2B MIT DICHTR W0003082I- 70000004003365 0,027
PLUG G3I8A A2B MIT DICHTR
E 0405 1 ST OELAUGE G3l8 ED 70000004020579 0,016
OIL SIGHT GLASS G3l8 ED
E 0408 1 ST OELHAHN G3l8 SHWENKVERSH 324285IA 70000004324285 0,440
OIL DRAIN TAP CPL G3l8 SHWENKVERS
E 0420 1 ST DRUKVENT G3I8A 0,2-0,3 MSTRANS ***** 70000004369014 0,034
BREATHER G3I8A 0,2-0,3 MSTRANS
E 0501 1 ST LATERNE K2 BGR 100 BEARE BAK3 84266IF 70000004084266 13,000
DOUBLE FLANGE K2 BGR 100 BEARE BAK3
E* 0000 1 ST LATERNE K2 BGR 100 ROH BAK3 84266IF 70006470490000 13,000
DOUBLE FLANGE K2 BGR 100 ROH BAK3
E 0502 1 ST STOPFEN 7,2X6 GPN300F N0050803IB 70000004797928 0,010
PLUG 7 ,2X6 GPN300F
E 0503 2 ST STOPFEN 14,6X5,5 GPN300F N0050803IB 70000004052855 0,007
PLUG 14,6X5,5 GPN300F
E 0515 1 ST ANWE K2 BGR 100 ESTE D16 84449IB 70000004084449 0,010
INPUTSHAFT SHANKED K2 BGR 100 ESTE D16
E 0520 1 ST RILKUGLAGER 6307-2Z D0000625I- 70000004016224 0,470
RADIAL BALL BEARING 6307-2Z
E 0525 1 ST WDR A35X52X7 NB D0003760I- 50000531000003 0,020
SEAL-R A35X52X7 NB
E 0528 1 ST SPRITZSHB 35X52X4,5 217935ID 70000004978001 0,007
CENTRIFUGAL DISC 35X52X4,5
E 0530 1 ST RILKUGLAGER 6308-2Z D0000625I- 70000004082974 0,010
RADIAL BALL BEARING 6308-2Z
E 0531 2 ST SICHERUNGSRING 90X3 D0000472I- 70000004051327 0,010
E 0532 1 ST SICHERUNGSRING 40X1,75 D0000471I- 70000004051296 0,006
CIRCLIP I SNAPRING 40X1,75
Siemens Geared Motors GmbH, Postfach 1709, 72072 Tiibingen, Datum Dat~f----------~------l
Tel.+ 49(0)07071 1707-0, http:ffwww .siemens.comfgetriebemotoren 04.04.2011 Rev.: I
SIEMENS4 411220062 HP 40/50/60 4 I
FZF68B-K-(1 00)
Obersetzung 10,310
Teil-Nr. Menge Benennung Zeichnungs-N r. M aterial-N r. Gw{kg)
E 0561 1 ST PASSFED ASX7X20 D0006885/- 70000004051573 0,007

PARALLEL KEY ASX7X20
E 0705 1 ST TYPENSCHILD 23X59+23X10 TTR 70000004107134 0,004
INFORMATION LABLE 23X59+23X10 TTR
E 0705 1 ST ABDECKETIK 30X67 +LACKSHZ 70000004115859 0,003
INFORMATION LABLE 30X67 +LACKSHZ
Siemens Geared Motors GmbH, Postfach 1709, 72072 Tiibingen, Datum Oat~
r------------------,----------1
Tel.+ 49(0)07071/707 -0, http://www.siemens.com/getriebemotoren 04.04.2011 Rev.: I
MOTOX gearbox
BA 2010
Operating Instructions · 05/2010
MOTOX
Answers for industry.
General information and
BA 2010 ___________________
safety notes 1
___________________
Technical description 2
Incoming goods, transport,
___________________
and storage 3
MOTOX
4
___________________
Installation
Gearbox
BA 2010 Commissioning 5
___________________
6
___________________
Operation
Operating Instructions
___________________
Faults, causes and remedies 7
___________________
Service and maintenance 8
9
___________________
Disposal
10
___________________
Technical data
___________________
Spare parts / Accessories 11
Declaration of Incorporation,
___________________
Declaration of Conformity 12
05/2010
Legal information
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
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
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 for the specific task, in particular its warning notices and
safety instructions. Qualified personnel are those who, based on their training and experience, are capable of
identifying risks and avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be adhered to. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG Copyright © Siemens AG 2010.

Industry Sector Ⓟ 06/2010 Technical data subject to change
Postfach 48 48
90026 NÜRNBERG
GERMANY
Table of contents
1 General information and safety notes ........................................................................................................ 9

1.1 General information .......................................................................................................................9
1.2 Copyright......................................................................................................................................11
1.3 Intended use ................................................................................................................................12
1.4 Obligations of the user .................................................................................................................13
1.5 Particular type of risk and personal protective equipment...........................................................14
2 Technical description ............................................................................................................................... 15
2.1 General description......................................................................................................................15
2.2 Housing ........................................................................................................................................15
2.3 Geared components ....................................................................................................................15
2.4 Lubrication....................................................................................................................................15
2.5 Shaft bearings ..............................................................................................................................15
2.6 Shaft seals ...................................................................................................................................16
2.6.1 Radial shaft sealing ring...............................................................................................................16
2.6.2 Combination shaft sealing ring (optional) ....................................................................................16
2.7 Cooling .........................................................................................................................................16
2.8 Backstop ......................................................................................................................................17
2.9 Rating plate ..................................................................................................................................18
2.10 Surface treatment ........................................................................................................................19
2.10.1 General information on surface treatment ...................................................................................19
2.10.2 Painted version ............................................................................................................................20
2.10.3 Primed version .............................................................................................................................22
3 Incoming goods, transport, and storage................................................................................................... 23
3.1 Incoming goods............................................................................................................................23
3.2 Transport......................................................................................................................................24
3.2.1 General information on transport .................................................................................................24
3.2.2 Fastening for suspended transport ..............................................................................................25
3.3 Storage.........................................................................................................................................27
3.3.1 General information for storage ...................................................................................................27
3.3.2 Storage up to 6 months................................................................................................................27
3.3.3 Storage up to 36 months with long-term preservation (optional).................................................28
4 Installation ............................................................................................................................................... 29
4.1 Unpacking ....................................................................................................................................29
4.2 General information on installation ..............................................................................................29
4.3 Tightening torque for fastening bolts on the gearbox ..................................................................31
4.4 Fastening in the case of high shock loads...................................................................................31
BA 2010
Operating Instructions, 05/2010 5
Table of contents
4.5 Gearbox with foot mounting ........................................................................................................ 32

4.6 Gearboxes in foot or flange version ............................................................................................ 33
4.7 Gearbox with C-type housing flange........................................................................................... 33
4.8 Mounting the input or output element on the gearbox ................................................................ 36
4.9 Removing and installing the protection cover ............................................................................. 38
4.10 Removing and installing the shaft-mounted gearbox.................................................................. 40
4.10.1 General information on installing the shaft-mounted gearbox .................................................... 40
4.10.2 Removing and installing the hollow shaft.................................................................................... 41
4.10.2.1 Mounting the hollow shaft ........................................................................................................... 41
4.10.2.2 Removing the hollow shaft with parallel key ............................................................................... 43
4.10.3 Shrink disk................................................................................................................................... 45
4.10.3.1 Mounting the shrink disk ............................................................................................................. 45
4.10.3.2 Pulling off the shrink disk ............................................................................................................ 47
4.10.3.3 Cleaning and lubricating shrink disks.......................................................................................... 47
4.10.4 Torque arms with shaft-mounted gearboxes .............................................................................. 48
4.10.4.1 General information for torque arms with shaft-mounted gearboxes ......................................... 48
4.10.4.2 Mounting torque arms on parallel shaft gearboxes..................................................................... 49
4.10.4.3 Mounting torque arms on bevel helical gearboxes and helical worm gearboxes ....................... 50
5 Commissioning ........................................................................................................................................ 51
5.1 General information for commissioning ...................................................................................... 51
5.2 Checking the oil level prior to commissioning ............................................................................. 51
5.3 Fitting the gearbox ventilation ..................................................................................................... 51
5.3.1 Screwing in the vent filter or pressure breather valve without securing clip ............................... 51
5.3.2 Installing the pressure breather valve with securing clip (optional) ............................................ 52
5.4 Gearbox with backstop (optional) ............................................................................................... 52
6 Operation................................................................................................................................................. 53
7 Faults, causes and remedies ................................................................................................................... 55
8 Service and maintenance ........................................................................................................................ 59
8.1 General notes about maintenance.............................................................................................. 59
8.2 Checking and changing lubricants .............................................................................................. 61
8.2.1 General safety notes for checking and changing lubricants ....................................................... 61
8.2.2 Checking the oil level .................................................................................................................. 62
8.2.3 Checking the oil level using the oil sight glass (optional)............................................................ 65
8.2.4 Checking the oil level using the oil dipstick (optional)................................................................. 65
8.2.5 Checking the oil quality ............................................................................................................... 66
8.2.6 Changing the oil .......................................................................................................................... 67
8.2.6.1 General safety notes for changing the oil ................................................................................... 67
8.2.6.2 Draining the oil ............................................................................................................................ 68
8.2.6.3 Flushing the gearbox when changing between incompatible oils............................................... 69
8.2.6.4 Filling in oil................................................................................................................................... 70
8.2.7 Topping up with oil ...................................................................................................................... 70
8.2.8 Changing the roller bearing grease............................................................................................. 71
8.2.9 Changing the oil when using backstops in bevel helical gearboxes........................................... 71
8.2.10 Service life of the lubricants ........................................................................................................ 72
8.2.11 Recommended lubricants ........................................................................................................... 74
8.3 Replacing bearings ..................................................................................................................... 75
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6 Operating Instructions, 05/2010
Table of contents
8.4 Checking the gearbox for leaks ...................................................................................................75

8.5 Cleaning the vent filter .................................................................................................................76
8.6 Checking the oil level sensor (optional) .......................................................................................76
8.7 Cleaning the gearbox...................................................................................................................76
8.8 Checking tightness of fastening bolts ..........................................................................................77
8.9 Inspecting the gearbox or geared motor......................................................................................78
8.10 Maintenance of the friction clutch ................................................................................................78
9 Disposal................................................................................................................................................... 79
10 Technical data ......................................................................................................................................... 81
10.1 Type designation..........................................................................................................................81
10.2 General technical data .................................................................................................................83
10.3 Weight ..........................................................................................................................................85
10.4 Sound-pressure level ...................................................................................................................86
10.5 Types of construction...................................................................................................................87
10.5.1 Single-stage helical gearboxes ....................................................................................................88
10.5.2 Two- and three-stage helical gearboxes......................................................................................89
10.5.3 Parallel shaft gearboxes ..............................................................................................................92
10.5.4 Bevel helical gearboxes ...............................................................................................................93
10.5.5 Helical worm gearboxes...............................................................................................................95
10.5.6 Tandem gearboxes - Intermediate helical gearboxes..................................................................96
10.6 Oil quantities ................................................................................................................................96
10.6.1 Helical gearboxes ........................................................................................................................97
10.6.2 Parallel shaft gearboxes ..............................................................................................................98
10.6.3 Bevel helical gearboxes ...............................................................................................................99
10.6.4 Helical worm gearboxes.............................................................................................................100
10.6.5 Tandem gearboxes - Intermediate helical gearboxes................................................................101
10.6.5.1 Two- and three-stage helical gearboxes....................................................................................101
10.6.5.2 Parallel shaft gearboxes ............................................................................................................103
10.6.5.3 Bevel helical gearboxes .............................................................................................................104
10.6.5.4 Helical worm gearboxes.............................................................................................................106
11 Spare parts / Accessories ...................................................................................................................... 107
11.1 Stocking of spare parts ..............................................................................................................107
11.2 Spare parts lists .........................................................................................................................108
11.2.1 Single-stage helical gearboxes sizes 38 - 148 ..........................................................................108
11.2.2 Two- and three-stage helical gearboxes sizes 38 - 188 ............................................................110
11.2.3 Parallel shaft gearboxes sizes 38B - 188B, 208 ........................................................................112
11.2.4 Bevel helical gearboxes sizes B38, 38 - 188 .............................................................................116
11.2.5 Helical worm gearboxes sizes 38 - 88 .......................................................................................119
12 Declaration of Incorporation, Declaration of Conformity......................................................................... 121
12.1 Declaration of Incorporation.......................................................................................................121
12.2 EC Declaration of Conformity ....................................................................................................122
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Table of contents
BA 2010
General information and safety notes 1
1.1 General information
ATEX version gearboxes

Instructions and measures applying in particular to ATEX version gearboxes.
CAUTION
Siemens does not accept liability for any damage or outages resulting from non-compliance
with these operating instructions.
These operating instructions are an integral part of the gearbox supplied and must be kept in
its vicinity for reference at all times.
These operating instructions apply to the standard version of the MOTOX gearboxes:
● E, Z, and D helical gearboxes, sizes 18 to 188
● EK cooling tower version helical gearboxes, sizes 88 to 148
and ZK sizes 68 to 188
● FZ and FD parallel shaft gearboxes, sizes 28, 38B to 188B, 208
● B, K bevel helical gearboxes, sizes 28 to 188
● C helical worm gearboxes, sizes 28 to 88
Table 1- 1 Order number code
MOTOX gearbox Structure of the order number - Position

1 2 3 4 5
Helical gearbox E, EK 2 K J 1 0
Helical gearbox Z, ZK 2 K J 1 1
Helical gearbox D 2 K J 1 2
Parallel shaft gearbox FZ 2 K J 1 3
Parallel shaft gearbox FD 2 K J 1 4
Bevel helical gearbox B, K 2 K J 1 5
Helical worm gearbox C 2 K J 1 6
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General information and safety notes
Note
In addition to these operating instructions, special contractual agreements and technical
documentation apply to these special gearbox designs and the associated supplementary
equipment.
Please refer to the other operating instructions supplied with the product.
The gearboxes described here correspond to the state of the art at the time these operating
instructions were printed.
In the interest of technical progress we reserve the right to make changes to the individual
assemblies and accessories which we regard as necessary to preserve their essential
characteristics and improve their efficiency and safety.
If you have any technical questions, please contact Technical Support.
Europe - Germany
Phone: +49 (0) 911 895 7222
Fax: +49 (0) 911 895 7223
America - USA
Phone: +1 42 32 62 25 22
Asia - China
Phone: +86 10 64 71 99 90
Email: support.automation@siemens.com
Internet German: http://www.siemens.de/automation/support-request
Internet English: http://www.siemens.com/automation/support-request
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1.2 Copyright
Applicable operating instructions
Table 1- 2 MOTOX gearbox operating instructions
Title Product
BA 2010 MOTOX gearboxes
BA 2011 MOTOX helical worm gearboxes and geared motors
BA 2019 MOTOX input units
BA 2510 MOTOX optional add-on units
BA 2515 MOTOX gearboxes for overhead conveyors
Table 1- 3 Motor operating instructions
Title Product
BA 2310 Three-phase and single-phase alternating current motors and brake motors with
accessories
BA 2320 LA / LG and LAI / LGI motors for fitting to MOTOX and CAVEX gearboxes
Table 1- 4 CAVEX gearbox operating instructions
Title Product
BA 6610TU CAVEX worm gearboxes, type C.., size 63 to 630
BA 6611TU CAVEX worm gearboxes, type CS.., size 63 to 630
BA 6612TU CAVEX worm gearboxes, type CD.., size 100 to 630
BA 6800TU CAVEX elevator drives, type CG 26, size 100, 112, 135, 170
BA 6801TU CAVEX elevator drives, type CG 45, size 120
BA 6802TU CAVEX escalator drives, type CG 26, size 100, 112, 135, 170
1.2 Copyright
The copyright to these operating instructions is held by Siemens Geared Motors GmbH.
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 our
agreement.
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1.3 Intended use
1.3 Intended use

The ATEX gearbox meets the requirements of the Explosion Protection Directive
94/9/EC.
In the case of ATEX version gearboxes, please observe instructions marked with
this symbol.
The MOTOX gearboxes described in these operating instructions have been designed for
stationary use in general engineering applications.
Unless otherwise agreed, the gearboxes have been designed for use in plants and
equipment in industrial environments.
The gearboxes have been built using state-of-the-art technology and are shipped in an
operationally reliable condition. Changes made by users could affect this operational
reliability and are forbidden.
Note
The performance data assume an ambient temperature of -20 °C to +40 °C and an
installation altitude of up to 5,000 m above sea level.
In the case of other ambient temperatures and installation altitudes, please contact Technical
Support.
The gearboxes have been designed solely for the application described in Technical data
(Page 81). Do not operate the gearboxes outside the specified power limits. Other operating
conditions must be contractually agreed.
Do not stand or walk on the gearboxes.
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1.4 Obligations of the user

The operator must ensure that all persons assigned to work on the gearbox 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 others
● Ensure the safety and reliability of the gearbox
● Avoid disruptions and environmental damage through incorrect use.
Note the following safety information:

Shut down the geared motors and disconnect the power before you carry out any work on
them.
Make sure that the drive unit cannot be turned on accidentally, e.g. lock the key-operated
switch. Place a warning notice at the drive connection point which clearly indicates that work
is in progress on the geared motor.
Carry out all work with great care and with due regard to safety.
Ensure compliance with the relevant safety and environmental regulations during transport,
mounting and dismantling, operation, and care and maintenance of the unit.
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, immediately switch off the drive unit.
Take appropriate protective measures to prevent accidental contact with rotating drive parts,
such as couplings, gear wheels or belt drives.
Take appropriate 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.
Do not carry out any welding work on the gearbox. Do not use the gearbox as a grounding
point for welding operations.
Carry out equipotential bonding in accordance with applicable regulations and directives.
Such work must be carried out by qualified electrical personnel only.
Do not use high-pressure cleaning equipment or sharp-edged tools to clean the gearbox.
Replace damaged screws with new screws of the same type and strength class.
We will only accept liability for original spare parts supplied by Siemens AG.
If the geared motor is being installed in a plant or equipment, the manufacturers of such
plant or equipment must ensure that the contents of these operating instructions are
incorporated into their own instructions, information, and descriptions.
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1.5 Particular type of risk and personal protective equipment
DANGER
Depending on operating conditions, the gearbox may exhibit 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.
DANGER
Danger of scalding caused by hot oil emerging from the unit.
Before starting any work wait until the oil has cooled down to below +30 °C.
DANGER
Avoid breathing vapors when working with solvents.
Ensure adequate ventilation.
DANGER
Risk of explosion when working with solvents.
Ensure adequate ventilation. Do not smoke!
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 required personal protective equipment, wear suitable protective gloves
and eyewear when working with the gearbox.
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2.1 General description
The gearbox is supplied with one, two or three transmission stages.
The gearbox is suitable for various mounting positions. Observe the correct oil level.
2.2 Housing
The housings for sizes 18 and 28 are made of die-cast aluminum. The housings for sizes 38
to 208 are made of grey cast iron.
2.3 Geared components

The geared components of the gearboxes are hardened. In the case of helical worm
gearboxes the worm is hardened and ground, and the gear is manufactured from bronze.
The bevel gear stage of the bevel helical gearbox is lapped in pairs.
2.4 Lubrication
The geared components are supplied with adequate lubricant by means of dip lubrication.
2.5 Shaft bearings

All shafts are mounted in roller bearings. The roller bearings are lubricated by means of dip
lubrication or oil spray lubrication. Bearings that are not supplied with lubricant are closed
and grease-lubricated.
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Technical description
2.6 Shaft seals
2.6 Shaft seals

The radial shaft sealing ring, combination shaft sealing ring, labyrinth seal, and slide ring
seal at the shaft outlet prevent lubricant from escaping from the housing and impurities from
entering it.
2.6.1 Radial shaft sealing ring

The radial shaft sealing ring is used as the standard type of seal. It is provided with an
additional dust lip to protect against contaminants from outside.
At higher ambient temperatures over +40 °C to +80 °C, shaft sealing rings of temperature-
resistant material are used, subject to contractual agreement.
2.6.2 Combination shaft sealing ring (optional)

The combination shaft sealing ring offers an improved oil seal, for example, additional
sealing lips prevent the ingress of dirt. The separate sealing system prevents shaft shrinkage
due to corrosion or dirt. The grease packing prevents the sealing lips from running dry.
When carrying out repairs, e.g., if the shaft has shrunk, you can replace the standard seal
with a combination shaft sealing ring.
2.7 Cooling
CAUTION
Dust deposits prevent heat radiation and cause high housing temperatures.
Keep the gearbox free from dirt and 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.
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2.8 Backstop
2.8 Backstop

The drive speed in the table "Drive speed when using backstops" must be
reached in continuous operation.
Starting and stopping operations ≤ 20 starts / stops per hour are permissible.
CAUTION
Drive speeds below 1,000 rpm or frequent starting and stopping operations
(≥ 20 starts / stops per hour) will limit service life.
Do not use the same backstop for prolonged periods; replace backstops regularly.
CAUTION
Damage or destruction of the backstop due to incorrect direction of rotation.
Do not run the motor against the backstop.
Note the directional arrow on the gearbox.
The gearbox can be fitted with a mechanical backstop. The backstop can be fitted either in
the coupling lantern or in the 2nd stage of the bevel helical gearbox. It permits only the
correct direction of rotation during operation. This is indicated by an arrow pointing in the
corresponding direction.
The backstop is fitted with 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.
Where the backstop is used in the coupling lantern, lifting of the sprags is ensured when the
drive speed is above the speed listed in the table. The backstop is wear-free. It does not
require maintenance.
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2.9 Rating plate
Table 2- 1 Drive speed when using backstops
Motor size Backstop Minimum speed

[rpm]
80/90 FXM-46 DX > 820
100 FXM-51 DX > 750
112 FXM-61 DX > 750
132, 160 FXM-76 DX > 670
180/200, 225, 250 FXM-101 DX > 610
280 FXM-100 SX > 400
When used in the bevel helical gearbox (gearbox intermediate shaft), the backstop operates
at speeds below the lift-off speed of the sprags in a separate oil chamber. The oil must be
changed at the same intervals as the gearbox.
2.9 Rating plate

The rating plate on the gearbox or geared motor is of coated aluminum foil. It is covered with
a special masking film which ensures permanent resistance to UV radiation and media of all
kinds, such as oils, greases, salt water and cleaning agents.
The adhesive and the material ensure firm adhesion and long-term legibility within the
operating temperature range from -40 °C to +155 °C.
The edges of the rating plate are paint-finished to match the color of the gearbox or motor to
which it is affixed.
In special cases, riveted or bolted metal plates are used.
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2.10 Surface treatment
2.10.1 General information on surface treatment

All paint finishes are sprayed on.

The gearbox is delivered complete with primer and paint finish.
The conductivity requirement and the limit on the thickness of the applied coat of
paint correspond to DIN EN 13463-1. The maximum permissible coat thickness
results from explosion group IIA, IIB or IIC and according to the ignition energy.
No electrostatic charge is expected for coating thicknesses below 200 μm.

If the gearbox is delivered with primer only, a paint finish must be applied which
meets the applicable guidelines for the specific application. The primer does not
provide adequate corrosion protection.
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 of charge generation can be:
 fast air with high dust content directed past the gearbox
 sudden escape of compressed gases containing particulates
 harsh abrasive processes (not referring to manual cleaning / wiping with
cleaning rags).
CAUTION
Any damage to the paint finish will destroy the exterior protection and cause corrosion.
Do not damage the paint.
Note
Information about repaintability is not a guarantee of the quality of the paint product
purchased from your supplier.
Only the paint manufacturer is liable for the quality and compatibility.
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2.10.2 Painted version

The corrosion protection system is classified according to the corrosiveness categories in
DIN EN ISO 12944-2.
Table 2- 2 Paint according to corrosiveness categories
Paint system Description

Corrosiveness category C1 paint for normal environmental stress
Dip primer  Indoor installation
1-component hydro paint  Heated buildings with neutral atmospheres
 Resistance to greases and some resistance to
mineral oils, aliphatic solvents
 Standard paint
Corrosiveness category C2 paint for low environmental stress
Dip primer  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
areas
 Resistance to greases, mineral oils and sulfuric
acid (10 %), caustic soda (10 %) and some
resistance to aliphatic solvents
Corrosiveness category C3 paint for medium environmental stress
2-component polyurethane base coat  Production areas with high humidity and some air
contamination, e.g. food production areas, dairies,
2-component polyurethane top coat
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 %)
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Paint system Description

Corrosiveness category C4 paint for high environmental stress
2-component epoxy zinc phosphate  Chemical plants, swimming pools, wastewater
treatment plants, electroplating shops, and
2-component polyurethane top coat
boathouses above seawater
 Industrial areas and coastal areas with moderate
salt levels
Corrosiveness category C5 paint for very high environmental stress
2-component epoxy zinc phosphate  Buildings and areas with almost constant
condensation and high contamination, e.g. malt
2-component epoxy iron mica
factories and aseptic areas
2-component polyurethane top coat  Industrial areas with high humidity and aggressive
atmosphere, coastal areas and offshore
environments with high salt levels
In case of corrosiveness category C1, can be overpainted with 1-component hydrosystem

after prior rubbing down.
In case of corrosiveness category C2 to C5, can be overpainted with 2-component
polyurethane paint, 2-component epoxide paint and 2-component acrylic paint after prior
rubbing down.
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2.10.3 Primed version
Table 2- 3 Primer according to corrosiveness categories
Paint system Can be overpainted with

Unpainted (corrosiveness category C1 G)
Cast iron parts immersion primed, steel Plastic paint, synthetic resin paint, oil paint,
parts primed or zinc-plated, aluminum 2-component polyurethane paint,
and plastic parts untreated 2-component epoxide paint
Primer according to corrosiveness category C2 G
2-component metal primer, desired coat 2-component polyurethane paint,
thickness 60 μm 2-component epoxide paint and acid-hardening paint,
2-component acrylic paint
Primer according to corrosiveness category C4 G
2-component epoxide zinc phosphate, 2-component polyurethane paint,
desired coat thickness 120 μm 2-component epoxide paint and acid-hardening paint,
2-component acrylic paint
On gearbox or geared motor versions which are primed or unpainted the rating plate and the
masking film are covered with a paint-protective film. These facilitate repainting without
further preparation, e.g., masking with adhesive tape.
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 Peeling tab
Figure 2-1 Rating plate with paint-protective film
Procedure
1. Pull the peeling tab ⑤ up.
2. Carefully peel the paint-protective film ④ off diagonally from one corner (not parallel to
the plate).
3. Blow any paint fragments away or wipe them off with a clean cloth.
You have now removed the paint-protective film.
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Incoming goods, transport, and storage 3
3.1 Incoming goods
CAUTION
Make sure that damaged gearboxes or geared motors are not put into operation.
Note
Do not open or damage parts of the packaging that preserve the product.
Note
Check that the technical specifications are in accordance with the purchase order.
Inspect the delivery immediately on arrival for completeness and any transport damage.
Notify the freight company of any damage caused during transport immediately (this is the
only way to have damage rectified free of charge). Siemens Geared Motors GmbH 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
may be delivered packaged separately.
The products supplied are listed in the dispatch papers.
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Incoming goods, transport, and storage
3.2 Transport
3.2 Transport
3.2.1 General information on transport
CAUTION
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. For further transports reuse or reactivate them again.
Different forms of packaging may be used, depending on the size of the gearbox or geared
motor and the method of transport. Notwithstanding contractual agreements to the contrary,
the packaging complies with the HPE Packaging Guidelines (Bundesverband Holzpackmittel
Paletten Exportverpackungen e.V., the German Federal Association for wooden packaging
means, pallets and export packaging).
Note the symbols which appear on the packing. These have the following meanings:
This way up Center of gravity
Fragile Do not use hand hook
Keep dry Attach here
Keep cool
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3.2 Transport
3.2.2 Fastening for suspended transport
DANGER
Gearboxes or geared motors may come loose and fall down during transport if not secured
sufficiently.
Observe the maximum load for the transport eye ③ of the bevel helical gearbox or the
eyebolt axis ④.
Use only the transport eye ③ or eyebolt ④ of the gearbox to transport the gearbox or
geared motor.
Do not use the integrally cast lifting eyes ① on the motor for transport because of the risk
of breaking. Only use the eyebolt ② on the motor to transport the motor prior to mounting
or following removal.
If necessary, use additional, suitable lifting accessories for transport or on installation.
When attaching by a number of chains and ropes just two strands must be sufficient to bear
the entire load. Secure lifting accessories against slipping.
CAUTION
Do not rig eyebolts to the front threads at the shaft ends for transportation purposes.
Transport eye on the bevel helical gearbox Eyebolt on the helical gearbox, parallel shaft
gearbox, helical worm gearbox
) )
G G

① Integrally cast eye on the motor

② Eyebolt on the motor
③ Transport eye on the bevel helical gearbox
④ Eyebolt on the gearbox
Figure 3-1 Fastening the gearbox or geared motor for suspended transport
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3.2 Transport
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 m d2 Size m d2
[kg] [mm] [kg] [mm]
K.38 200 22 K.128 800 40
K.48 250 22 K.148 1,300 44
K.68 350 26 K.168 1,800 55
K.88 600 30 K.188 2,300 55
K.108 750 35
Table 3- 2 Maximum load of the eyebolt on the gearbox
Thread size m d3 Thread size m d3

[kg] [mm] [kg] [mm]
M8 140 36 M20 1,200 72
M10 230 45 M24 1,800 90
M12 340 54 M30 3,600 108
M16 700 63
Procedure
1. Mount the geared motor on the transport device by the heaviest permissible weight to be
attached. This will normally be on the main gearbox.
2. Check that the eyebolt is firmly seated.
The geared motor is slung for transport.
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3.3 Storage
3.3 Storage
3.3.1 General information for storage
DANGER
Do not stack gearboxes or geared motors one on top of another.
CAUTION
Mechanical damage (scratches), chemical damage (acids, alkalis) and thermal damage
(sparks, welding beads, heat) cause corrosion which may render the external protective
coating ineffective.
Do not damage the paint.
Note
Notwithstanding contractual agreements to the contrary, the guarantee 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. Please contact Technical Support.
3.3.2 Storage up to 6 months

The gearbox or geared motor must be covered and stored in its position of use on a
horizontal wooden support in a dry place not subject to significant temperature fluctuations.
The storage location must be vibration- and shock-free.
The free shaft ends and flange surface are painted for protection.
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3.3 Storage
3.3.3 Storage up to 36 months with long-term preservation (optional)
CAUTION
The gearbox is completely filled with operating oil and closed airtight with a plug or by
pressure venting with transport fixture.
Check the oil level before commissioning.
Store the gearbox or geared motor in dry, dust-free, and temperate locations. Special
packing is then not necessary.
Otherwise, the gearbox or geared motor must be packed in plastic film or packed in airtight
sealed film and water absorbing agents. Cover them to provide protection against sun and
rain.
The storage location must be vibration- and shock-free.
The free shaft ends, sealing elements and flanges must be coated with a protective layer of
grease.
The life of the corrosion protection is 36 months from delivery.
Do not reduce the oil level during short-time startup for 10 minutes in no-load operation.
Carry out the following precautionary measures after every period of 6 months in storage:
Table 3- 3 Preventive action
Action Storage period in months

6 12 18 24 30 36
Checking the insulation resistance - - x x x x
Short-time startup: - - x x x x
no-load operation, approximately 10 minutes at rated
voltage
Touch up / re-apply the protective layer of grease - - x x x x
Check the cover and preservation x x x x x x
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Installation 4
4.1 Unpacking
CAUTION
Check the gearbox or geared motor for completeness and for damage. Report any missing
parts or damage immediately.
Remove packaging and transport fixtures and dispose of them properly.
4.2 General information on installation

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.
WARNING
The entire system must be load-free so that there is no danger during this work.
CAUTION
Overheating of the gearbox due to exposure to direct sunlight.
Provide suitable protective equipment such as covers or roofs. Prevent heat accumulation.
CAUTION
Malfunction resulting from foreign objects.
The operator must ensure that no foreign objects impair the function of the gearbox.
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Installation
CAUTION
Exceeding the permissible oil sump temperature due to incorrect settings of temperature
monitoring equipment.
A warning must be given when the maximum permissible oil sump temperature is reached.
The geared motor must be switched off when the maximum permissible oil sump
temperature is exceeded. This switching off can cause plant shutdown.
CAUTION
Irreparable damage to geared components and bearings due to welding.
Do not carry out any welding work on the gearbox. The gearbox must not be used as a
grounding point for welding operations.
Note
Use headless screws of strength class 8.8 or higher to fasten 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.
Observe the type of construction specified on the rating plate. This ensures that the correct
quantity of lubricant is provided.
Use all the fastening means which have been assigned to the relevant type of construction.
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.
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Installation
4.3 Tightening torque for fastening bolts on the gearbox
4.3 Tightening torque for fastening bolts on the gearbox

The general tolerance for the tightening torque in Nm is 10 %. The friction coefficient is
0.14 μ.
Table 4- 1 Tightening torques for fastening bolts
Thread size Tightening torque at strength class

8.8 10.9 12.9
[Nm] [Nm] [Nm]
M4 3 4 5
M5 6 9 10
M6 10 15 18
M8 25 35 41
M10 50 70 85
M12 90 120 145
M16 210 295 355
M20 450 580 690
M24 750 1,000 1,200
M30 1,500 2,000 2,400
M36 2,500 3,600 4,200
4.4 Fastening in the case of high shock loads

In the case of high shock loads provide additional suitable positive fastenings such as
cylindrical taper pins or spring pins.
CAUTION
Do not use spring washers, serrated lock washers, spring or toothed lock washers, cup
washers or conical spring washers as a substitute for the above positive fastenings.
Do not subject the housing to excessive stress when tightening the fastening bolts.
BA 2010
Installation
4.5 Gearbox with foot mounting
4.5 Gearbox with foot mounting
CAUTION
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 from size 108: 0.2 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 structures on which the gearbox is to be mounted must be rigid. They must
be designed 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, which
cannot be measured at a standstill.
When using foundation blocks to fasten the gearbox to concrete foundations, suitable
recesses should be made in the foundation.
Align and grout the slide rails into the foundation.
Align the gearbox carefully with the units on the input and output side. Take the elastic
deformation due to operating forces into account.
Prevent displacement from external forces due to lateral impacts.
Use stud bolts or headless screws of strength class 8.8 or higher for the foot mounting.
Observe the tightening torque.
BA 2010
Installation
4.6 Gearboxes in foot or flange version
4.6 Gearboxes in foot or flange version
CAUTION
Do not subject gearbox housings to overstress from add-on elements on the foot or flange.
Add-on elements must not transmit forces, torques and vibration to the gearbox.
The gearbox must be fastened for force and torque transmission only to either the flange or
the foot mounting to prevent overstress on the gearbox housing, see Gearbox with foot
mounting (Page 32).
The second mounting option (foot or flange) is intended for add-on elements, e.g. protection
covers with an intrinsic weight of up to max. 30 % of the weight of the gearbox.
4.7 Gearbox with C-type housing flange

In the case of sizes 108 to 188, the customer's interface can be pinned on the C-type
housing flange. The output flange has been designed to ensure the reliable transmission of
the permissible torque and radial force by the bolt connections.
For additional fastening, e.g., in the case of high shock loads, the existing drilled pin holes
can be used.
The gearboxes can also be drilled and pinned together with the machine. Compliance with
the listed dimensions is mandatory in this case.
BA 2010
Installation
CAUTION
Observe the maximum drilling depth (A-A).
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Spring pins, heavy-duty design, to DIN 1481:

Use pin holes provided in the housing flange.
Cylindrical grooved pin with chamfer to DIN EN 28740 / ISO 8740:
Drill connecting component together with housing.
Figure 4-1 C-type case flange helical gearbox
BA 2010
Installation
CAUTION
Observe the maximum drilling depth (A-A).
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Spring pins, heavy-duty design, to DIN 1481:

Use pin holes provided in the housing flange.
Cylindrical grooved pin with chamfer to DIN EN 28740 / ISO 8740:
Drill connecting component together with housing.
Figure 4-2 C-type housing flange parallel shaft gearbox and bevel helical gearbox
BA 2010
Installation
4.8 Mounting the input or output element on the gearbox
DANGER
Danger of burns due to hot parts.
CAUTION
Damage to shaft sealing rings caused by solvent or benzine.
Avoid contact at all times.
CAUTION
Damage to shaft sealing rings caused by heating over 100 °C.
Protect shaft sealing rings from heating up due to radiant heat using thermal shields.
CAUTION
Alignment errors caused by excessive angle or axial displacement of the shaft ends to be
joined lead to premature wear or material damage.
Ensure precise alignment of the individual components.
CAUTION
Damage to bearings, housing, shaft, and locking rings due to improper handling.
Do not use impacts or knocks to force the input and output elements to be mounted onto
the shaft.
Note
Deburr the parts of elements to be fitted in the area of the hole or keyways.
Recommendation: 0.2 x 45°
Where couplings are to be fitted in a heated condition, observe the specific operating
instructions for the coupling. Unless otherwise specified, the heat can be applied inductively,
using a torch or in a furnace.
Use the centering holes in the shaft end faces.
BA 2010
Installation
Use a fitting device to fit the input or output elements.
Figure 4-3 Example of a fitting device
Observe the correct mounting arrangement to minimize stress on shafts and bearings due to
lateral forces.
Correct Incorrect
) )
D D
a Hub
F Force
Figure 4-4 Mounting arrangement for minimum stress on shafts and bearings
Procedure
1. Using either benzine or solvent, remove the anti-corrosion protection from the shaft ends
and flanges and remove the protective skin provided.
2. Fit the input and output elements onto the shafts and secure them if necessary.
You have now fitted the input or output element.
BA 2010
Installation
4.9 Removing and installing the protection cover
ATEX version gearbox

with shrink disk
Sparks may be caused by a damaged protection cover.
Replace damaged protection covers immediately.
The protection cover is delivered ready-fitted to the gearbox flange. The protection cover
must be removed in order to fit the output shaft.
Protection cover for hollow shaft Protection cover for hollow shaft with shrink disk
)$6

① Screw
② Protection cover
③ Gearbox housing
④ Intermediate ring
⑤ O-ring
Figure 4-5 Protection covers
The O-ring ⑤ is only present with the ATEX version.

The intermediate ring ④ is only supplied on the foot version of the bevel helical gearbox in
sizes 68, 108 to 168.
BA 2010
Installation
Procedure
1. Undo the screws ① and remove the protection cover ②.
2. Fit the output shaft.
3. Using a suitable cleaning agent, clean the support surface of the protection cover ② on
the gearbox.
4. With the protection cover for shrink disk in the ATEX version, ensure that the O-ring ⑤ is
correctly seated.
5. Coat the supporting surface of the protection cover ② with a suitable sealing agent.
6. Screw on the protection cover ②.
7. Protect all remaining bare areas with a suitable permanent anti-corrosive agent.
You have now installed the protection cover for operation.
BA 2010
Installation
4.10 Removing and installing the shaft-mounted gearbox
4.10.1 General information on installing the shaft-mounted gearbox
CAUTION
CAUTION
Misalignment of and stress on the hollow shaft can lead to increased load and cause the
bearings to fail.
The hollow shaft must be flush with the machine shaft to avoid misalignment.
Do not subject the hollow shaft to axial and radial stress.
CAUTION
Shrink disks:
Lubricants in the area between the hollow shaft and machine shaft impair torque
transmission.
Keep the bore in the hollow shaft and the machine shaft completely grease-free.
Do not use impure solvents and soiled cleaning cloths.
Note
Coat the contact surfaces with the mounting paste supplied with the product or any suitable
lubricant to prevent frictional corrosion.
Note
Observe the permissible concentricity tolerance of the cylindrical shaft end of the machine
shaft to the housing axle according to DIN 42955.
BA 2010
Installation
4.10.2 Removing and installing the hollow shaft
4.10.2.1 Mounting the hollow shaft

Figure 4-6 Installing the hollow shaft with parallel key

Figure 4-7 Installing the hollow shaft with splines
D E E
a Greased
b Absolutely grease-free
Figure 4-8 Installing the hollow shaft with shrink disk
* Not included in scope of supply
BA 2010
Installation
① Machine shaft
② Hollow shaft
③ Hexagon nut
④ Threaded spindle
⑤ Disk
⑥ Locking ring
⑦ Parallel key
⑧ Bronze bush
Instead of the nut and threaded spindle shown in the diagram, other types of equipment such
as hydraulic lifting equipment may be used.
Procedure
1. Using benzine or a solvent, remove the anti-corrosion protection from the shaft ends and
flanges.
2. Check the seats or edges of the hollow and machine shafts for damage. Please contact
Technical Support if you notice any damage.
3. Fit the gearbox using a disk ⑤, threaded spindle ④ and nut ③. The counterforce is
provided by the hollow shaft ②.
4. For hollow shaft with parallel key and hollow shaft with splines:
Replace the nut ③ and threaded spindle ④ with a setscrew and tighten it with the
specified torque.
For hollow shaft with shrink disk:
Remove the disk ⑤, threaded spindle ④ and nut ③.
You have now installed the hollow shaft.
Table 4- 2 Tightening torque for setscrews
Thread size M5 M6 M8 M10 M12 M16 M20 M24 M30

Tightening torque [Nm] 5 8 8 14 24 60 120 200 400
BA 2010
Installation
4.10.2.2 Removing the hollow shaft with parallel key
CAUTION
Before driving out the machine shaft, fasten a suitably dimensioned means of absorbing
load to the gearbox.
Slightly pretension the drive element so that the gearbox does not drop into the drive
element when the insert shaft is released.
CAUTION
It is essential to prevent misalignment when removing the unit.
Note
If frictional corrosion has occurred on the seat surfaces, use rust solvent to facilitate the
removal of the gearbox. Allow the rust solvent to work in sufficiently.

① Disk
② Threaded block
③ Parallel key
④ Hexagon nut
⑤ Threaded spindle
Figure 4-9 Removing the hollow shaft with parallel key
Item ① to item ⑤ are not included in the scope of supply.
Procedure
1. Remove the axial fastening from the hollow shaft.
2. Drive out the machine shaft using the disk ①, threaded block ②, parallel key ③,
threaded spindle ⑤ and hexagon nuts ④.
You have now removed the hollow shaft with parallel key.
BA 2010
Installation
Design suggestion for threaded block and disk
X E E
G
G
V
W
G E
Size b10 b11 b12 d10 d11 s11 tmax u

[mm] [mm] [mm] [mm] [mm] [mm] [mm]
28 3 15 10 19.9 10 M6 22.5 6
24.9 14 M8 28 8
38 - 15 10 - 14 M8 28 8
6 29.9 18 M10 33
38 10
48 6 15 5 34.9 24 M12 43 10
39.9 28 12
68 7 20 7 39.9 28 M16 48.5 12
44.9 33 14
88 7 20 10 49.9 36 M16 64 14
59.9 45 18
108 10 24 10 59.9 45 M20 74.5 18
69.9 54 20
128 10 24 5 69.9 54 M20 85 20
79.9 62 22
148 10 24 7 79.9 62 M20 95 22
89.9 72 25
168 10 30 8 99.9 80 M24 106 28
109.9 90 116
188 10 30 11 119.9 95 M24 127 32
BA 2010
Installation
4.10.3 Shrink disk
4.10.3.1 Mounting the shrink disk
DANGER
Risk of injury due to freely rotating parts.
Fit a cover cap or protection cover.
CAUTION
The shrink disk is delivered ready for installation.
Do not dismantle the shrink disk before initial fitting.
CAUTION
Lubricants in the area of the shrink disk seat impair torque transmission.
Keep the bore in the hollow shaft and the machine shaft completely grease-free.
Do not use impure solvents and soiled cleaning cloths.
CAUTION
Plastic deformation of the hollow shaft when tightening the tightening bolts before fitting the
machine shaft.
First fit machine shaft. Then tighten the tightening bolts.
CAUTION
Avoid overloading the individual bolts.
Do not exceed the maximum tightening torque for tightening bolt.
Size 28:
Tighten tightening bolts ③.
Sizes 38 - 208:
The alignment of the end faces of outer ring ① and inner ring ② has priority. If this
alignment is not achieved when tensioning, the tolerance of the insert shaft must be
checked.
BA 2010
Installation
Note
The hollow shaft is axially secured on the machine shaft by means of a shrink disk
connection.
Note
Apply a thin layer of grease to the shrink disk seat on the hollow shaft.
Note
Coat with a suitable lubricant to prevent frictional corrosion of the contact surface on the
customer's machine shaft in the vicinity of the bronze bush.
Size 28, 208 reinforced Sizes 38 - 208
D D D D D
E E

a Greased
b Absolutely grease-free
① Outer ring
② Inner ring
③ Tightening bolt
④ Hollow shaft
⑤ Machine shaft
Figure 4-10 Mounting the shrink disk
BA 2010
Installation
Procedure
1. Tighten the tightening bolts ③ handtight initially.
2. Working round several times, evenly tighten the tightening bolts ③ by a 1/4 turn each
time (not crosswise).
3. Fit the rubber cover cap or protection cover included in the scope of delivery, see
Removing and installing the protection cover (Page 38).
You have now installed the shrink disk.
Table 4- 3 Tightening torque for tightening bolt
Gearbox size Thread size Strength class Tightening torque

[Nm]
28 M5 8.8 5
38, 48, 68 M8 12.9 35
88, 108, 128 M10 12.9 70
148 M12 12.9 121
168, 188 M14 12.9 193
208 M16 12.9 295
M20 12.9 570
4.10.3.2 Pulling off the shrink disk

1. Working round several times, loosen the tightening bolts ③ one after the other, by a
1/4 turn each time.
2. Pull the shrink disk off the hollow shaft.
Sizes 38 - 208:
If the outer ring does not come away from the inner ring, remove some of the tightening bolts
and insert them into neighboring forcing threads.
You will then be able to release the rings without difficulty.
4.10.3.3 Cleaning and lubricating shrink disks

Soiled shrink disks must be cleaned and regreased prior to fitting.
Loosened shrink disks need not be dismantled and regreased before being retensioned.
BA 2010
Installation
Procedure
1. Only grease the inner friction surfaces of the shrink disks. Use for this a solid lubricant
with a friction coefficient of μ = 0.04.
2. Use a paste containing MoS2 to grease the bolts, applying the paste to the thread and
underneath the head.
The shrink disk is now ready for fitting.
Table 4- 4 Lubricants for shrink disks
Lubricant Sold as Manufacturer

Molykote 321 R (lubricant paint) Spray DOW Corning
Molykote spray (powder spray)
Molykote G Rapid Spray or paste
Molykombin UMFT 1 Spray Klüber Lubrication
Unimily P5 Powder
Aemasol MO 19 P Spray or paste A. C. Matthes
4.10.4 Torque arms with shaft-mounted gearboxes
4.10.4.1 General information for torque arms with shaft-mounted gearboxes

Torque arms can absorb the reaction torque and, if necessary, the weight force of the
gearbox.

Worn or irreparably damaged rubber elements will not function properly.
Impact can cause sparks.
Damaged rubber elements must be replaced immediately.
CAUTION
Dangerously high transient torques due to excess backlash.
Take care to prevent the torque arm causing excessive constraining forces, e.g., due to the
driven shaft running out-of-true.
CAUTION
Worn or irreparably damaged rubber elements will not function properly.
Solvents, oils, greases and fuels damage rubber elements. Keep them away from the
rubber elements.
BA 2010
Installation
4.10.4.2 Mounting torque arms on parallel shaft gearboxes

We recommend using pretensioned, damping rubber elements.
Fixing accessories such as angles, bolts, nuts, etc., are not included in the scope of delivery.
\
\
5D
\ 5D
[
Figure 4-11 Mounting suggestion for torque arm on F.28, 38B - 188B
Size 28 38B 48B 68B 88B 108B 128B 148B 168B 188B
x [mm] 14 13.1 18.2 17 27.2 26 35.8 34.8 46.2 45.1
Size 208
DANGER
The torque arm bush must be supported by bearings on both sides.
Figure 4-12 Mounting suggestion for torque arms on F.208
Procedure
1. Clean the contact surfaces between the housing and the torque arm.
2. Tighten the M30 bolts, strength class 8.8 with 1,500 Nm tightening torque.
You have now mounted the torque arm.
BA 2010
Installation
4.10.4.3 Mounting torque arms on bevel helical gearboxes and helical worm gearboxes
DANGER
The torque arm bush must be supported by bearings on both sides.
Figure 4-13 Mounting suggestion for torque arm on foot
Figure 4-14 Mounting suggestion for torque arm on flange
The torque arm can be fitted in various positions, depending on the hole circle pitch.
Procedure
1. Clean the contact surfaces between the housing and the torque arm.
2. Tighten the bolts with the specified torque.
You have now mounted the torque arm.
Table 4- 5 Tightening torque for bolt of strength class 8.8 if torque arm is mounted
Thread size M8 M10 M12 M16 M20 M24 M30

Tightening torque [Nm] 25 50 90 210 450 750 1,500
BA 2010
Commissioning 5
5.1 General information for commissioning
WARNING
Secure the drive unit to prevent it from being started up unintentionally.
Attach a warning notice to the start switch.
WARNING
Remove any oil spillage immediately with an oil-binding agent in compliance with
environmental requirements.
CAUTION
On cylindrical-roller bearings in the input unit, undershooting the minimum radial force can
damage bearings.
Prolonged test runs when off-load must be kept to a minimum.
5.2 Checking the oil level prior to commissioning

Check the oil level before commissioning and correct it if necessary, see Checking and
changing lubricants (Page 61).
Gearboxes with long-term preservation are delivered with a full tank of oil. We recommend a
complete oil change if your unit is left in storage for more than 24 months, see Checking and
changing lubricants (Page 61).
5.3 Fitting the gearbox ventilation
5.3.1 Screwing in the vent filter or pressure breather valve 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.
BA 2010
Commissioning
5.4 Gearbox with backstop (optional)
Observe the symbol in the type of construction diagrams, see Types of construction
(Page 87):
Ventilation
Procedure
1. Unscrew the vent plug.
2. Seal the gearbox with the vent filter or the pressure breather valve without securing clip.
You have now replaced the vent filter or pressure breather valve with the vent plug without
the securing clip.
5.3.2 Installing the pressure breather valve with securing clip (optional)
The pressure breather valve with securing clip ① is fitted to gearboxes which require
housing ventilation.

Figure 5-1 Pressure breather valve with securing clip
Remove the transport fixture by pulling the securing clip ① in the direction of the arrow.
5.4 Gearbox with backstop (optional)
CAUTION
Running in the wrong direction of rotation can damage the geared motor.
Check the direction of rotation before starting up.
Turn the input side or motor over manually.
Use the phase sequence to check the direction of motor rotation and swap the two external
conductors if necessary.
BA 2010
Operation 6
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.
Changes are an indication of possible incipient damage.
CAUTION
In the event of changes during operation, the drive unit must be switched off immediately.
Use the fault table in the section titled "Faults, causes, and remedies" to determine the
cause of the fault.
Remedy faults or have faults remedied.
CAUTION
damage bearings.
Check the gearbox during operation for:

● Excessive operating temperature
● Changes in gear noise
● Possible oil leakage at the housing and shaft seals.
BA 2010
Operation
BA 2010
Faults, causes and remedies 7
Note
Faults and malfunctions occurring during the warranty period and requiring repair work on
the gearbox must be remedied only by Technical Support. In the case of faults and
malfunctions occurring after the warranty period, the cause of which cannot be precisely
identified, we advise our customers to contact our Technical Support.
If you need the help of our Technical Support, please provide the following information:
 Data on the rating plate
 Nature and extent of the fault
 Suspected cause.
Table 7- 1 Faults, causes and remedies
Faults Causes Remedy

Unusual noises on the gearbox Oil level too low Check the oil level, see
Checking and changing
lubricants (Page 61)
Foreign bodies in oil (irregular Check the oil quality, see
noise) Checking the oil quality
(Page 66). Clean the gearbox.
Change the oil, see Checking
and changing lubricants
(Page 61)
Excessive bearing play and / or Check bearing and replace if
bearing defective necessary
Teeth defective Check teeth and replace if
necessary
Fastening bolts loose Tighten bolts / nuts, see
Checking tightness of fastening
bolts (Page 77)
Excessive external load on drive Check load against rated data
input and output (you might need to correct the
belt tension, for example)
Damage in transit Check the gearbox for damage
in transit
Damage due to blocking during Call Technical Support
commissioning
BA 2010
Faults, causes and remedies

Unusual noises from drive unit Drive unit bearing not lubricated Regrease the bearing, see
(motor size 160 and higher) Changing the roller bearing
grease (Page 71)
Fastening bolts loose Tighten bolts / nuts, see
bolts (Page 77)
Unusual noises on the motor Excessive bearing play and / or Check bearing and replace if
Motor brake rubbing Check air gap and adjust if
necessary
Inverter parameterization Correct parameterization
Oil leak Incorrect oil level for type of Check type of construction, see
construction used Types of construction
(Page 87). Check the oil level,
see Checking and changing
Overpressure due to lack of Mount the ventilation as
ventilation appropriate for the type of
construction, see Fitting the
gearbox ventilation (Page 51).
Overpressure due to soiled Clean the ventilation, see
ventilation Cleaning the vent filter
(Page 76)
Shaft sealing rings defective Replace the shaft sealing rings
Cover / flange bolts loose Tighten the bolts / nuts, see
bolts (Page 77). Continue to
monitor the gearbox
Surface sealing defective (e.g., Reseal
on cover, flange)
Damage in transit (e.g., hairline Check the gearbox for damage
cracks) in transit
BA 2010

Oil leakage on gearbox Incorrect oil level for the type of Check ventilation position and
ventilation construction used and / or type of construction, see Types
incorrect ventilation position of construction (Page 87).
Check the oil level, see
Frequent cold starts, during Call Technical Support
which the oil foams up
Gearbox overheating Motor fan cover and / or Clean the fan cover and surface
gearbox heavily soiled of the geared motor, see
Cleaning the gearbox (Page 76)
Incorrect oil level for type of Check type of construction, see
construction used Types of construction
Incorrect oil being used (e.g., Check the oil in the tank, see
incorrect viscosity) Checking the oil quality
(Page 66)
Oil beyond expiry date Check date of last oil change
and change oil if necessary, see
Backstop not running freely Replace backstop
Output shaft does not turn when Force flow interrupted by Call Technical Support
motor is running breakage in gearbox
BA 2010

Geared motor starting up with Incorrect oil level for type of Check type of construction, see
difficulty or not at all construction used Types of construction
Incorrect oil being used (e.g., Check the oil in the tank, see
incorrect viscosity) Checking the oil quality
(Page 66)
Excessive external load on drive Check load against rated data
input and output (you might need to correct the
belt tension, for example)
Motor brake not releasing Check switching / connection of
brake. Check brake for wear
and readjust if necessary
Geared motor runs against Change direction of motor or
backstop backstop rotation
Excessive play on drive input Flexible elements worn (e.g., on Replace flexible elements
and output couplings)
Positive connection disrupted by Call Technical Support
overload
Drop in speed / torque Belt tension too low (in case of Check belt tension and replace
belt drive) belt if necessary
BA 2010
8.1 General notes about maintenance

All measures, checks, and their results must be documented by the operator and
records kept in a safe place.
WARNING
CAUTION
Service and maintenance must only be carried out by properly trained and authorized
personnel. Only genuine parts supplied by Siemens Geared Motors GmbH can be used for
servicing and maintenance.
All inspection, maintenance, and repair work must be carried out with care by trained
personnel only. Observe the information in Section General information and safety notes
(Page 9).
Table 8- 1 Maintenance measures
Remedy Interval Description of work

Monitor and check the geared Daily; if possible, more See Operation (Page 53)
motor for unusual noises, frequently during operation
vibrations, and changes
Check housing temperature After 3 h, on the first day,
thereafter monthly
Check the oil level After the first day, thereafter See Checking and changing
monthly lubricants (Page 61)
Check the oil level sensor Regularly and after oil changes See Checking the oil level
sensor (optional) (Page 76)
BA 2010
Service and maintenance
Remedy Interval Description of work

Check the oil quality Every 6 months See Checking the oil quality
(Page 66)
First oil change after After approximately See Checking and changing
commissioning 10,000 operating hours or at the lubricants (Page 61)
latest after 2 years
Subsequent oil changes Every 2 years or
10,000 operating hours 1)
Check gearbox for leaks After the first day, thereafter See Checking the gearbox for
monthly leaks (Page 75)
Clean the gearbox ventilation or Depending on degree of soiling, See Cleaning the vent filter
replace if necessary at least every 6 months (Page 76)
Clean the gearbox See Cleaning the gearbox
(Page 76)
Check the friction clutch and After 500 h, thereafter once a See Maintenance of the friction
adjust if necessary year and after every blockage clutch (Page 78)
Check the coupling For the first time after 3 months Please refer to the separate
operating instructions
Carry out a complete inspection Every 12 months See Inspecting the gearbox or
of the geared motor geared motor (Page 78)
Check that fastening bolts on After 3 h, regularly thereafter See Checking tightness of
gearboxes and built-on fastening bolts (Page 77)
accessories are securely
tightened. Check that covers
and plugs are securely fastened
Change the roller bearing When the oil is changed See Changing the roller bearing
grease grease (Page 71)
Replace bearings - See Replacing bearings
(Page 75)
Check rubber buffers on torque Every 6 months See Torque arms with shaft-
arms mounted gearboxes (Page 48)
1) When using synthetic oils, the intervals can be doubled. The data specified is valid for an oil
temperature of +80 °C. See the figure titled "Guide values for oil change intervals" for oil change
intervals for other temperatures.
BA 2010
8.2 Checking and changing lubricants
8.2.1 General safety notes for checking and changing lubricants
DANGER
After removing the oil level screw, up to and including gearbox size 128, the oil level may
not be more than 3 mm and from gearbox size 148, not more than 5 mm below the
recommended filling level.
DANGER
Danger of scalding from the hot oil emerging from the unit.
WARNING
Remove any oil spillage immediately with an oil-binding agent in compliance with
environmental requirements.
CAUTION
The oil quantity and the position of the sealing elements are determined by the type of
construction.
Note
For data such as type of oil, oil viscosity, and oil quantity required, refer to the rating plate.
For oil compatibility see Recommended lubricants (Page 74).
Note
Gearbox sizes 18 and 28 are lubricated for life.
No oil changes are required.
Note
Where tandem gearboxes are concerned, each individual gearbox is to be considered
separately.
Gearbox sizes 28 and 38 on the 2nd gearbox are lubricated for life. An oil change is not
required.
BA 2010
8.2.2 Checking the oil level
CAUTION
The volume of gear oils changes with temperature.
If the temperature rises, the volume increases. Where temperature differences and filling
quantities are significant, the increase 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.

Figure 8-1 Oil level in the gearbox housing
Procedure
1. Switch off the power supply to the drive unit.
2. Unscrew the oil level screw, see Types of construction (Page 87).
3. Check the oil level ①.
4. Rectify the oil level ① if necessary and check it again.
5. Check the condition of the sealing ring on the sealing element and replace the sealing
ring if necessary.
6. Seal the gearbox with the sealing element.
You have now checked the oil level in the gearbox housing.
Checking the oil level on size 38 gearbox housings with no screw plug for checking the oil
level
Size 38 gearboxes have no screw for checking the oil level.
In some versions of the B 38 and BF 38 bevel helical gearbox, there is an additional screw
plug so that the oil level can be checked as described above.
BA 2010
(() '')==) %%) ..) )')=

① Dipstick
② Mark
③ Screw plug
Figure 8-2 Checking the oil level on size 38 gearbox
Procedure
2. Remove the geared motor and set it down as illustrated in the figure. The screw plug ③
must be on the top.
3. Remove the screw plug ③.
4. Make a mark ② on a suitable dipstick ①.
5. Insert the dipstick ① vertically into the opening until the mark ② is level with the surface
of the gearbox.
6. Pull the dipstick ① out vertically.
7. Measure the distance "x" on the dipstick ①.
8. Compare the value "x" with the value for distance "x".
9. Rectify the oil level if necessary and check it again.
10.Check the condition of the sealing ring on the screw plug ③ and replace the sealing ring
if necessary.
11.Seal the gearbox using the screw plug ③.
12.Mount the geared motor.
You have now checked the oil level in the size 38 gearbox housing.
BA 2010
[sPP

① Dipstick
② Mark
Figure 8-3 Distance "x"
Table 8- 2 Values for max. distance "x"
Gearbox type Distance "x"

[mm]
B5 V1 V3
B14 V18 V19
E.38 44 24 18
Z.38 87 56 33
D.38 81 31 26
B3 B6 B7 B8 V5 V6
E38 43 37 37 31 23 19
Z38 93 83 83 83 75 32
D38 89 82 82 82 52 35
B3-00 B8-00 B7-00 B6-00 V5-00 V6-00

H-01 H-02 H-03 H-04 H-05 H6
B, BA, BAS, BAT38 126 74 30 89 95 112
K, KA, KAS, KAT38 64 35 21 52 40 46
B5-01 B5-03 B5-02 B5-00 V1-00 V3-00

H-01 H-02 H-03 H-04 H-05 H-06
B.38 126 74 30 89 95 112
K.38 66 40 20 54 45 50
FZ.38B 137 152 137 137 87 73
FD.38B 110 147 132 132 110 65
BA 2010
8.2.3 Checking the oil level using the oil sight glass (optional)
If you are using an oil sight glass to check the oil level ①, the oil must be visible in the
center of the sight glass if the oil is cool. If the oil is hot, the oil level ① is above the center of
the sight glass. The oil level ① of cold oil is below the center of the sight glass.

Figure 8-4 Oil level in the oil sight glass
Rectify the oil level ① if necessary and check it again.
8.2.4 Checking the oil level using the oil dipstick (optional)
To measure the oil level, push the oil dipstick into the hole but do not screw it in.
The oil level must be between the lower and upper min.-max. marks on the oil dipstick.
If you are using the electric oil level monitoring system, the oil must be level with the upper
max. mark on the oil dipstick.
Rectify the oil level if necessary and check it again.
BA 2010
8.2.5 Checking the oil quality

Signs of changes in the oil can be seen with the naked eye. Fresh oil is clear to the eye and
has a typical smell and a specific product color. Clouding or a flocculent appearance
indicates water and / or contamination. A dark or black color indicates residue, serious
thermal decomposition or contamination.
Observe the symbols in the type of construction diagrams, see Types of construction
(Page 87):
Ventilation Oil filling Oil level
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.
3. Remove the sealing element at one of the points marked with the symbols listed above.
4. Remove some oil, using a suction pump and a flexible hose, for example.
ring if necessary.
7. Check the oil for abnormalities. If you detect any abnormalities, change the oil
immediately.
8. Check the oil level.
You have now checked the oil quality.
BA 2010
8.2.6 Changing the oil
8.2.6.1 General safety notes for changing the oil
CAUTION
An impermissible mixture of oils will lead to clouding, depositing, foam formation, changes
to the viscosity or reduced protection against corrosion and wear.
When changing oil of the same type, the residual volume of oil in the gearbox should be
kept as low as possible. Generally speaking, a small residual volume will cause no
particular problems.
Gear oils of different types and by different manufacturers must not be mixed. Have the
manufacturer confirm that the new oil is compatible with the remaining volume of used oil.
If changing very different types of oil or oils with very different additives, always flush out
the gearbox with the new oil. When changing from mineral oil to polyglycol oil (PG) or vice
versa, it is vital to flush the gearbox twice. All traces of old oil must be completely removed
from the gearbox.
CAUTION
Gear oils must never be mixed with other substances. Do not flush with paraffin or other
solvents, as traces of these substances will always be left behind inside the gearbox.
Note
The oil must be warm. If it is too cold, it will flow too sluggishly to drain properly. If necessary,
run the gearbox for 15 to 30 minutes to warm it up.
BA 2010
8.2.6.2 Draining the oil

(Page 87):
Ventilation Oil filling Oil level Oil drain
Procedure
2. Unscrew the vent plug.
3. Unscrew the oil level screw.
4. Place a suitable and sufficiently large receptacle underneath the oil drain plug.
5. Remove the oil drain plug and drain all the oil into the receptacle.
ring if necessary.
7. Seal the gearbox using the sealing elements.
You have now drained the oil from the gearbox.
Draining the oil from B38 with no additional screw plug type V5-00/V1-00/H-05 and
V6-00/V3-00/H-06
Procedure
2. Place a suitable and sufficiently large receptacle underneath the gearbox.
3. Unscrew the oil filler screw.
4. Using a length of hose, siphon off all the oil into the receptacle.
ring if necessary.
Or:
2. Unscrew the cover
3. Drain all the oil into the receptacle.
4. Change the seal in the cover.
5. Seal the gearbox with the cover.
You have now drained the oil from the B38 gearbox.
BA 2010
8.2.6.3 Flushing the gearbox when changing between incompatible oils
CAUTION
Polyglycol oil has a higher density than mineral oil. Therefore, it sinks down towards the oil
drain and the mineral oil floats on top.
This makes the required complete draining of mineral oil from the gearbox extremely
difficult.
CAUTION
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.
Note
We recommend that, after the second flush, the quality of the rinse is checked by an expert
analyzer.
(Page 87):
Ventilation Oil filling Oil drain
Procedure
1. After the oil has been drained, wipe the gearbox clean of any remaining mineral oil using
a cloth.
2. Remove the vent plug or oil filler screw.
3. Fill the gearbox with a detergent oil, using a filter (filter mesh max. 25 μm). For the
detergent oil, use either the new oil or one that is compatible with the new oil.
4. Allow the gearbox to run for 15 to 30 minutes under a low load.
5. Place a suitable and sufficiently large receptacle underneath the oil drain plug.
6. Remove the oil drain plug and drain all the oil into the receptacle.
7. 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.
BA 2010
8.2.6.4 Filling in oil

(Page 87):
Ventilation Oil filling
Procedure
1. Remove the vent plug or oil filler screw.
2. Fill the gearbox with fresh oil, using a filter (filter mesh max. 25 μm).
When refilling, use the same type of oil with the same viscosity. If changing mutually
incompatible oils, flushing cycles are required, see Flushing the gearbox when changing
between incompatible oils (Page 69).
ring if necessary.
You have now filled up the gearbox with oil.
8.2.7 Topping up with oil

You may need to top the gearbox up with oil if the gearbox type of construction changes or if
oil is lost due to a leak. If you notice oil escaping, locate the leak and seal the affected area.
Check and correct the oil level.
At the time of going to print, the following types of oil are being used for initial filing of the
gearbox:
CLP ISO VG220: ARAL Degol BG 220
CLP ISO PG VG220: Castrol Tribol 800/220
CLP ISO PG VG460: Castrol Tribol 800/460
CLP ISO PAO VG68: Addinol Eco Gear 68S-T
CLP ISO PAO VG220: Addinol Eco Gear 220S
CLP ISO E VG220: Fuchs Plantogear Bio 220S
CLP ISO H1 VG460: Klüber Klüberoil 4 UH1 460 N
If, following agreement, gearboxes are filled at the factory with special lubricants for the
special applications referred to above, this is shown on the rating plate.
BA 2010
8.2.8 Changing the roller bearing grease

The roller bearings are filled with a lithium-saponified roller bearing grease at the factory
prior to delivery.
Clean the bearing before filling it with fresh lubricant.
In the case of the bearings of the output shaft or intermediate shafts the grease quantity
must fill 2/3, and in the case of bearings on the input side 1/3, of the space between the
bearing bodies.
8.2.9 Changing the oil when using backstops in bevel helical gearboxes
The oil must be changed at the same intervals as the gearbox.
Table 8- 3 Oil quantity for backstop
Size K.88 K.108 K.128 K.148 K.168

Oil quantity [l] 0.04 0.06 0.09 0.104 0.44
This oil quantity is valid for all gearbox types of construction.
① Oil level
Figure 8-5 Oil level when using backstops in bevel helical gearboxes
For the standard temperature range from 0 °C to +60 °C, the backstops are filled with
Klüber-Summit HYSYN FG68.
In the case of ambient temperatures of less than -20 °C and greater than +60 °C, please
contact Technical Support.
The backstop can also be filled with the oil used in the gearbox.
BA 2010
8.2.10 Service life of the lubricants
Note
In case of ambient conditions deviating from normal conditions, e.g. high ambient
temperatures, high relative humidity, aggressive ambient media, the intervals between
changes should be shorter. In such cases please contact Technical Support for assistance in
determining the individual lubricant change intervals.
Note
Oil sump temperatures above +80 °C can reduce service life. In this context, the rule is that
increasing the temperature by 10 K will approximately halve the service life, as illustrated in
the figure titled "Guide values for oil change intervals".
Note
In the case of roller bearings with grease filling, we recommend changing the grease at the
same time as the oil.
At an oil sump temperature of +80 °C the following service life can be expected subject to
compliance with the properties required by Siemens Geared Motors GmbH:
Table 8- 4 Service life of the oils
Type of oil Service life

Mineral oil 10,000 operating hours or 2 years
Biodegradable oil
Physiologically safe oil according to USDA-H1/-H2
Synthetic oil 20,000 operating hours or 4 years
BA 2010
7>r&@

,>K@
① Mineral oil
② Synthetic oil
T Oil-bath long-term temperature [°C]
I Oil change interval in operating hours [h]
Figure 8-6 Guide values for oil change intervals
Grease service life of roller bearing greases

The service life of the grease is approximately 4,000 operating hours. This is based on a
maximum ambient temperature of +40 °C or a maximum temperature in the grease chamber
of +80 °C. Grease service life is reduced by a factor of 0.7 for every increase in temperature
of 10 K.
BA 2010
8.2.11 Recommended lubricants
DANGER
The lubricants used have not been approved to USDA -H1/-H2 (United States Department
of Agriculture). They are not or only conditionally approved for use in the foodstuffs or
pharmaceutical industry. If lubricants with USDA -H1/-H2 approval are required, please
contact Technical Support.
CAUTION
If you are working outside the temperature range specified in the Flender Operating
Instructions BA 7300, please contact Technical Support for advice on which oil to use.
If the housing temperature exceeds a value of +80 °C, please contact Technical Support.
Note
The lubricants used are not or are only conditionally biodegradable. If lubricants classified as
biodegradable are required, please contact Technical Support.
Note
These recommendations are not a guarantee of the quality of the lubricant provided by your
supplier. All lubricant manufacturers are responsible for the quality of their own products.
The oil selected for use in the gearbox must be of the viscosity stated on the rating plate
(ISO VG class). The viscosity class indicated applies for the contractually agreed operating
conditions.
In the case of different operating conditions, please contact Technical Support.
BA 2010
8.3 Replacing bearings
The lubricants suitable for use in the gearbox are listed in the Flender Operating Instructions
BA 7300. We are familiar with the composition of these lubricants and, as far as we are
currently aware, they possess state-of-the-art properties with regard to load-bearing
capacity, corrosion resistance (FZG test DIN 51354 = force level > 12), resistance to gray
staining and compatibility with seals and interior paint finishes as necessary for the type of
gearbox concerned. Therefore, we advise our customers to select one of the lubricants listed
in this table, taking into account the VG class specified on the rating plate.
If, following agreement, gearboxes are filled at the factory with special lubricants for the
special applications referred to above, this is shown on the rating plate.
The warranty conditions are valid only for the lubricants listed in the Flender Operating
Instructions BA 7300 . If you decide to use a different oil, you are responsible for the
technical suitability of the lubricant.
8.3 Replacing bearings

Bearing life depends very much on operating conditions. It is, therefore, very
difficult to calculate it reliably. In the operating conditions specified by the
operator, bearing life can be calculated and indicated on the rating plate. If no
information is given, changes in vibration and noise pattern can serve as an
indicator that an immediate bearing replacement is necessary.
8.4 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 running 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. Service life depends on operating conditions.
We recommend that shaft sealing rings are included in periodic maintenance and servicing
work on the system.
BA 2010
8.5 Cleaning the vent filter
8.5 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. Blow the vent filter out with compressed air.
4. Seal the gearbox with the vent filter.
You have now cleaned the vent filter.
8.6 Checking the oil level sensor (optional)

The oil level sensor indicates the oil level only when the gearbox is shut down.
Lower the oil level and fill it up again until the oil level sensor gives a switching
signal.
Please refer to the separate operating instructions for the oil level sensor.
8.7 Cleaning the gearbox
CAUTION
Dust deposits prevent heat radiation and cause high housing temperatures.
Keep the gearbox free from dirt and dust.
CAUTION
Do not use a high-pressure cleaning appliance to clean the gearbox.
Do not use tools with sharp edges.
Switch off the power supply to the drive unit before cleaning it.
BA 2010
8.8 Checking tightness of fastening bolts
8.8 Checking tightness of fastening bolts

Loose parts can cause sparks through impact.
Entry of foreign bodies can cause sparks.
Note
Replace damaged headless screws with new screws of the same type and strength class.
Switch off the power to the drive unit and use a torque wrench to check the seating of all
fastening bolts.
The general tolerance for the tightening torque in Nm is 10 %. The friction coefficient is
0.14 μ.

8.8 10.9 12.9
[Nm] [Nm] [Nm]
M4 3 4 5
M5 6 9 10
M6 10 15 18
M8 25 35 41
M10 50 70 85
M12 90 120 145
M16 210 295 355
M20 450 580 690
M24 750 1,000 1,200
M30 1,500 2,000 2,400
M36 2,500 3,600 4,200
BA 2010
8.9 Inspecting the gearbox or geared motor
8.9 Inspecting the gearbox or geared motor

Carry out a scheduled inspection of the geared motor once a year in accordance with the
possible criteria listed in Section Faults, causes and remedies (Page 55).
Check the geared motor in accordance with the criteria set out in Section General
information and safety notes (Page 9).
Touch up damaged paintwork carefully.
8.10 Maintenance of the friction clutch
Note
Check the condition of the friction clutch initially after 500 operating hours and then at least
once yearly and after every blockage of the machine.
If necessary, readjust the friction torque or replace the wearing parts, e.g., friction lining and
bushes. Friction linings must always be replaced in pairs. We recommend replacing worn
bushes in sets.
Please refer to the relevant operating instructions for the clutch.
BA 2010
Disposal 9
DANGER
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 material
such as solvents and brake and cooling fluid is prohibited.
Avoid prolonged contact with the skin.
Empty the used oil from the gearbox. The used oil must be collected, stored, transported and
disposed of in accordance with regulations. Do not mix polyglycols with mineral oil.
Polyglycols must be disposed of separately.
Please observe country-specific laws. Under German law, oils with different disposal codes
may not be mixed with one another to allow optimal treatment of the oil (§4 VI Used Oil).
Collect and dispose of used oil in accordance with regulations.
Remove oil spillages immediately with an oil-binding agent in compliance with environmental
requirements.
Dispose of the housing parts, gears, shafts, and roller bearings of the geared motor as steel
scrap. The same applies to grey cast iron parts, if no separate collection is made.
The worm wheels are made partly from non-ferrous metal. Dispose of them accordingly.
Dispose of the packing material according to regulations or recycle it.
Table 9- 1 Disposal codes for gear oils
Type of oil Name Disposal code

Mineral oil CLP ISO VG220 13 02 05
Polyglycols CLP ISO PG VG220 13 02 08
CLP ISO PG VG460
Polyalphaolefins CLP ISO PAO VG68 13 02 06
CLP ISO PAO VG220
CLP ISO H1 VG460
Biologically degradable oils CLP ISO E VG220 13 02 07
BA 2010
Disposal
BA 2010
Technical data 10
10.1 Type designation
Table 10- 1 Example of the type designation structure
Main gearbox Intermediate helical Input unit

gearbox
Example: F D F 108 B -Z 38 - K4 (100)
Gearbox type F
Transmission stage D
Type F
Size 108
Revision marks B
Transmission stage Z
Size 38
Input unit K4
(for motor size) (100)
Table 10- 2 Type designation code
Gearbox type
(-) Helical gearbox
B Bevel helical gearbox, two-stage
K Bevel helical gearbox, three-stage
F Parallel shaft gearbox
C Helical worm gearbox
Transmission stage
(-)
E Single-stage
Z Two-stage
D Three-stage
BA 2010
Technical data
10.1 Type designation
Type
Shaft
(-) Solid shaft
A Hollow shaft
Mounting
(-) Foot-mounted version
F Flange version (A type)
Z Housing flange (C type)
D Torque arm
G Flange (A type) opposite output shaft
R Agitator flange
K Cooling tower version
M Mixer flange
E Extruder flange
U Underwater version (slide ring seal)
Connection
(-) Parallel key
S Shrink disk
T Hollow shaft with splines
Backstop
X Backstop in intermediate stage
Intermediate helical gearbox
Transmission stage
Z Two-stage
D Three-stage
Input unit
A / A5 Input unit with free input shaft
K2 Coupling lantern with coupling for connecting an IEC motor
K2TC Coupling lantern with coupling for connecting a NEMA motor
K4 Short lantern with clamp connection for connecting an IEC motor
K5TC Short coupling with clamp connection for connecting a NEMA motor
KQ(S) Lantern for servo motor with zero-backlash coupling for connecting a servo motor
P Input unit with free input shaft and piggy back for connecting an IEC motor
P5 Input unit with free input shaft and piggy back for connecting a NEMA motor
BA 2010
Technical data
10.2 General technical data

The most important technical data appears on the rating plate of the gearboxes and geared
motors.
This data, together with the contractual agreements for the geared motors, determines the
limits of intended use.
In the case of geared motors, a rating plate attached to the motor usually indicates the data
for the entire drive.
In certain cases separate rating plates are mounted on the gearbox and the motor.
SIEMENS IEC60034
SIEMENS 1 2
KAF108-LA160L4-L150/100GH 3
2KJ1506-5JR13-2FD1-Z FDU1001/8999999 nnn 254kg 4 5 6
IP55 (IM) H-01-A 7 8
G. 6.2L OIL CLP PG VG220 i=12.9 9 10 11 12
50Hz 113/min 60Hz 136/min 13 14 17 18
1266Nm fB=1.5 1264Nm fB=1.5 15 16 19 20
3~Mot. ThCl.155(F) TP-PTC 100Nm 190-240V AC 21 22 23 24 25 26
50Hz 400/690V D/Y 60Hz 460V Y 27 28 29 35 36 37
29/16.74A cosPhi 0.84 28.6A cosPhi 0.87 30 31 38 39
15kW IE1-90% 1460/min 15kW 1755/min 32 33 34 40 41 42
Figure 10-1 Rating plate example
1 CE marking or other marking, if required

2 Applied standard
3 Model - Type - Size
4 Order No.
5 Serial No.
6 Weight m [kg]
7 IEC 60034-5 or IEC 60529 protection
8 Type of construction (IM)
9 Oil quantity [l] main gearbox / intermediate gearbox + extruder flange
10 Type of oil
11 Oil viscosity ISO VG class to DIN 51519 / ISO 3448
12 Total transmission ratio i
Frequency 1
13 Rated frequency f [Hz]
14 Speed at output n2 [rpm]
15 Torque at output T2 [Nm]
16 Service factor fB
Frequency 2
BA 2010
Technical data
Motor data
21 Phase number and type of current for the motor
22 Temperature class Th.Cl.
23 Motor protection (TP)
24 Symbols (IEC 60617-2): = brake
25 Braking torque TBr [Nm]
26 Brake supply voltage U [V]
Frequency 1
28 Rated voltage / range U [V]
29 Circuit, graphical symbols as per DIN EN 60617 T6 / IEC 60617-6
30 Rated current I [A]
31 Power factor cos φ
32 Rated output P [kW], mode (if ≠ S1)
33 Efficiency class designation
34 Rated speed n1 [rpm]
Frequency 2
36 Rated voltage / range U [V]
37 Rated current I [A]
38 Power factor cos φ
39 Circuit, graphical symbols as per DIN EN 60617 T6 / IEC 60617-6
40 Rated output P [kW], mode (if ≠ S1)
41 Efficiency class designation
42 Rated speed n1 [rpm]
Rating plate for ATEX version gearboxes
SIEMENS 1 2
3
4 5 6
7 8
9 10 11 12
13 14 17 18
15 16 19 20
21
1 CE marking or other marking, if required

2 Applied standard
3 Model - Type - Size
4 Order No.
5 Serial No.
BA 2010
Technical data
10.3 Weight
6 Weight m [kg]
7 IEC 60034-5 or IEC 60529 protection
8 Type of construction (IM)
9 Oil quantity [l] main gearbox / intermediate gearbox + extruder flange
10 Type of oil
11 Oil viscosity ISO VG class to DIN 51519 / ISO 3448
12 Total transmission ratio i
Frequency 1
Frequency 2
21 Explosion-hazard symbol and explosion-hazard marking

Figure 10-2 ATEX rating plate
10.3 Weight
The weight of the entire geared motor is given in the shipping papers.
If the weight exceeds 30 kg, the weight of the entire geared motor is indicated on the rating
plate of the gearbox or geared motor.
Where there are several rating plates on one geared motor, the specification on the main
gearbox is decisive.
The weight specification refers only to the condition of the product on delivery.
BA 2010
Technical data
10.4 Sound-pressure level
10.4 Sound-pressure level

The A rated sound-pressure level LWA of a selection of gearboxes in the following figure has
been measured to DIN EN ISO 1680 with meters to DIN IEC 60651.
The noise depends mainly on speed, output, and transmission ratio.
/:$>G%@

3>N:@
Figure 10-3 MOTOX geared motors sound-pressure level
The sound-pressure levels of MOTOX geared motors fall mainly in the dark-colored part of
the range. Gearboxes with very small transmission ratios, high output, and high input speed
may fall into the cross-hatched part.
If repeat measurements on site do not produce conclusive results which can be verified by
measuring technology, the measurement obtained on the Siemens Geared Motors GmbH
test benches will apply.
External noises
Noises not generated by the gearbox but emitted from it are not taken into consideration
here.
Similarly, noises emitted from the input and output machines and from the foundation are not
taken into consideration here, even if transmitted to these by the gearbox.
BA 2010
Technical data
10.5 Types of construction

The type of construction designations are compliant with IEC 60034-7 (Code I).
The gearbox 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
Gearbox sizes 18 and 28 are lubricated for life.
Screw plugs are not provided.
Explanation of symbols in type of construction diagrams:
Ventilation Oil filling Oil level Oil dipstick Oil drain
A, B Position of insert shaft / solid shaft

V Gearboxes of size 38 are fitted as standard with a screw plug at point "V";
ventilation is not required.
* On opposite side
② Two-stage gearbox
③ Three-stage gearbox
④ Tandem gearbox
⑤ Optional oil hole facing output side
--- Alternatively
BA 2010
Technical data
10.5.1 Single-stage helical gearboxes

( %,0% ( %,0% ( %,0%

9
9
9
( %,0% ( 9,09 ( 9,09
Figure 10-4 Type of construction options for E sizes 38 - 148
()(. %,0% ()(. 9,09 ()(. 9,09

(= %,0% (= 9,09 (= 9,09
9
9
()(. %,0% ()(. %,0% ()(. %,0%

(= %,0% (= %,0% (= %,0%

9 9
Figure 10-5 Type of construction options for E. sizes 38 - 148
BA 2010
Technical data
10.5.2 Two- and three-stage helical gearboxes

'= %,0% '= %,0% '= %,0%
9
9

'= %,0% '= 9,09 '= 9,09
9
9
9
Figure 10-6 Type of construction options for D/Z sizes 18 - 88
'= %,0% '= %,0% '= %,0%
'= %,0% '= 9,09 '= 9,09

Figure 10-7 Type of construction options for D/Z sizes 108 - 168
BA 2010
Technical data
'= %,0% '= %,0% '= %,0%

'= %,0% '= 9,09 '= 9,09

Figure 10-8 Type of construction options for D/Z size 188
=.')=)'5=5 %,0% 9,09 9,09

'=== %,0% 9,09 9,09
9

9
=.')=)'5=5 %,0% %,0% %,0%

'=== %,0% %,0% %,0%
9 9
Figure 10-9 Type of construction options for DF/ZF, DZ/ZZ sizes 18 - 88, DR/ZR sizes 68 - 88
BA 2010
Technical data
=.')=)'5=5 %,0% 9,09 9,09

'=== %,0% 9,09 9,09
=.')=)'5=5 %,0% %,0% %,0%

'=== %,0% %,0% %,0%
Figure 10-10 Type of construction options for D./Z. sizes 108 - 168
=.')=) %,0% 9,09 9,09

'=== %,0% 9,09 9,09

=.')=) %,0% %,0% %,0%

'=== %,0% %,0% %,0%
Figure 10-11 Type of construction options for D./Z. size 188
BA 2010
Technical data
10.5.3 Parallel shaft gearboxes
Note
On types of construction V3-00/H-06, use the opening marked "F" to check the oil level.
)=)) %,0% )=)) %,0% )=)) %,0%

)$ + )$ + )$ +
9
%%
% $
%% 9
$ %
%%
9 %%
)=)) %,0% )=)) 9,09 )=)) 9,09

)$ + )$ + )$ +
$
%% )
%
9
9 9
%
$ %%
Figure 10-12 Type of construction options for F.28, F. sizes 38B - 188B
)= %,0% )= %,0% )= %,0%

)$ + )$ + )$ +

% $

$ %
)= %,0% )= 9,09 )= 9,09

)$ + )$ + )$ +
$
%
%

$
Figure 10-13 Type of construction options for F.208
BA 2010
Technical data
10.5.4 Bevel helical gearboxes
% %,0% % %,0% % %,0%

%=%) %,0% %=%) %,0% %=%) %,0%
%$ + %$ + %$ +
% %,0% % 9,09 % 9,09

%=%) %,0% %=%) 9,09 %=%) 9,09
%$ + %$ + %$ +
Figure 10-14 Type of construction options for B. sizes 28 - 38 without additional screw plug
% %,0% % %,0% % %,0%

%=%) %,0% %=%) %,0% %=%) %,0%
%$ + %$ + %$ +
% %,0% % 9,09 % 9,09

%=%) %,0% %=%) 9,09 %=%) 9,09
%$ + %$ + %$ +
Figure 10-15 Type of construction options for B.38 with additional screw plug
BA 2010
Technical data
The type of construction positions shown apply also to the foot- / flange-mounted housing in
size 188.
Figure 10-16 Image of foot- / flange-mounted housing K.188
Note
On types of construction B3-00/H-01, use the opening marked "K" to check the oil level.
. %,0% . %,0% . %,0%

.$ + .$ + .$ +
9
.
9
9
. %,0% . 9,09 . 9,09

.$ + .$ + .$ +
% $

9 9
9
$ %
Figure 10-17 Type of construction options for K, KA, KAS, KAT sizes 38 - 188
. %,0% . %,0% . %,0%

.$ + .$ + .$ +
9

9
9
. %,0% . 9,09 . 9,09

.$ + .$ + .$ +
% $
9
9
$ %
Figure 10-18 Type of construction options for KZ, KF, KM, KAD, KAZ, KAF, KAM, KADS, KAZS,
KAFS, KADT, KAZT, KAFT sizes 38 - 188
BA 2010
Technical data
10.5.5 Helical worm gearboxes

& %,0% & %,0% & %,0%
&$ + &$ + &$ +
& %,0% & 9,09 & 9,09

&$ + &$ + &$ +

% $
$ %
Figure 10-19 Type of construction options for C, CA, CAS, CAT sizes 28 - 88
&=&) %,0% &=&) %,0% &=&) %,0%

&$ + &$ + &$ +
&=&) %,0% &=&) 9,09 &=&) 9,09

&$ + &$ + &$ +
% $
$ %
Figure 10-20 Type of construction options for CZ, CF, CAD, CAF, CAZ, CADS, CAFS, CAZS, CADT,
CAFT, CAZT sizes 28 - 88
BA 2010
Technical data
10.6 Oil quantities
10.5.6 Tandem gearboxes - Intermediate helical gearboxes
Note
In a horizontal operating position the bulging part of the housing of the 2nd gearbox
generally faces vertically downwards.
Note
Where tandem gearboxes are concerned, each individual gearbox is to be considered
separately.
Gearbox sizes 28 and 38 on the 2nd gearbox are lubricated for life.
Screw plugs are not provided.
Horizontal operating position Vertical operating position

E
D E E

a Main gearbox
b 2nd gearbox (intermediate helical gearbox)
* On opposite side
② 2-stage gearbox
③ 3-stage gearbox
Figure 10-21 Operating position for tandem gearbox
10.6 Oil quantities
CAUTION
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.
The precise oil quantities are stated on the gearbox or geared motor rating plate.
The oil level must be checked before commissioning.
BA 2010
Technical data
10.6 Oil quantities
10.6.1 Helical gearboxes
Table 10- 3 Oil quantities [l] for E. sizes 38 - 148
Type Type of construction

B3 B5 B5-00 B5-02 B5-03 B6 B7 B8 V1 V3 V5 V6
B14 B14-00 B14-02 B14-03 V18 V19
E.38 0.2 0.2 0.23 0.23 0.4 0.3 0.3 0.4 0.5 0.6 0.5 0.6
E.48 0.3 0.3 0.5 0.5 0.7 0.6 0.5 0.7 0.7 1.1 0.7 1.1
E.68 0.5 0.5 1.0 1.0 1.4 1.0 1.1 1.5 1.7 1.9 1.8 1.9
E.88 0.8 0.7 1.6 1.6 2.5 1.6 1.6 2.5 2.2 3.8 2.3 3.8
E.108 1.3 1.0 2.7 2.7 4.5 2.7 2.8 4.6 3.7 6.6 3.8 6.6
E.128 2.3 2.3 5.2 5.1 7.2 5.3 5.2 7.2 6.4 10.9 6.4 10.9
E.148 4.0 2.8 6.7 6.7 10.3 7.0 7.0 10.3 9.3 14.5 9.5 14.8
Table 10- 4 Oil quantities [l] for D./Z. sizes 18 - 188

B3 B5 B5-00 B5-02 B5-03 B6 B7 B8 V1 V3 V5 V6
B14 B14-00 B14-02 B14-03 V18 V19
Z.18 0.2 0.2 0.3 0.35 0.4 0.35 0.3 0.4 0.5 0.5 0.5 0.5
Z.28 0.25 0.25 0.4 0.45 0.6 0.45 0.4 0.6 0.6 0.7 0.6 0.7
Z.38 0.5 0.5 0.6 0.6 0.6 0.6 0.6 0.6 0.8 1.2 0.7 1.1
Z.48 1.1 1.0 1.4 1.7 1.5 1.6 1.3 1.5 1.8 2.4 1.9 2.4
Z.68 1.8 1.7 2.4 2.8 2.5 2.7 2.3 2.5 3.0 4.1 3.2 4.1
Z.88 4.1 3.7 5.5 6.3 5.7 6.1 5.3 5.7 6.8 8.3 7.5 8.8
Z.108 7.3 6.0 10.0 11.2 8.6 10.5 9.3 8.6 13.8 14.0 13.2 13.6
Z.128 9.5 7.0 15.4 17.3 13.2 16.0 14.1 13.2 18.5 20.7 19.9 20.9
Z.148 13.0 9.9 19.9 22.4 26.9 20.8 18.3 26.9 23.9 27.7 25.7 27.4
Z.168 21.0 15.3 33.0 37.7 32.1 34.8 30.1 32.1 48.0 45.6 48.0 41.7
Z.188 18.5 18.5 46.0 50.0 75.0 50.0 46.0 75.0 72.0 70.0 72.0 70.0
D.18 0.2 0.2 0.3 0.35 0.4 0.35 0.3 0.4 0.5 0.5 0.5 0.5
D.28 0.25 0.25 0.4 0.45 0.6 0.45 0.4 0.6 0.6 0.7 0.6 0.7
D.38 0.5 0.5 0.6 0.6 0.6 0.6 0.6 0.6 0.9 1.1 0.9 1.1
D.48 1.1 1.0 1.5 1.6 1.5 1.5 1.4 1.5 2.3 2.4 2.4 2.4
D.68 1.7 1.6 2.5 2.7 2.6 2.6 2.4 2.6 3.9 4.0 4.0 4.0
D.88 4.0 3.6 5.6 6.1 5.9 5.9 5.4 5.9 8.7 8.9 9.3 8.9
D.108 7.1 5.7 10.2 11.0 10.0 10.3 9.5 10.0 16.3 14.2 15.6 13.7
D.128 9.4 6.8 16.1 17.1 14.1 15.8 14.8 14.1 24.6 21.8 24.4 21.5
D.148 12.5 9.4 20.7 22.0 23.4 20.4 19.1 23.4 30.6 28.2 32.2 27.9
D.168 19.0 16.0 32.7 35.6 33.8 34.1 31.2 33.8 53.0 43.7 54.4 42.2
D.188 18.4 18.4 46.0 48.0 73.0 48.0 46.0 73.0 69.0 68.0 69.0 68.0
BA 2010
Technical data
10.6 Oil quantities
10.6.2 Parallel shaft gearboxes
Table 10- 5 Oil quantities [l] for F. sizes 28, 38B - 188B, 208

B5-01 B5-03 B5-02 B5-00 V1-00 V3-00
H-01 H-02 H-03 H-04 H-05 H-06
FZ.28 0.6 0.45 0.5 0.5 0.65 0.85
FZ.38B 0.7 0.6 0.7 0.7 1.0 1.1
FZ.48B 1.6 1.0 1.3 1.3 1.8 2.1
FZ.68B 2.5 2.3 2.4 2.3 3.3 3.8
FZ.88B 4.5 5.0 4.8 4.6 7.0 6.6
FZ.108B 7.4 9.2 8.4 8.1 11.1 13.1
FZ.128B 13.8 13.7 15.5 14.8 22.1 22.7
FZ.148B 19.5 20.8 22.7 22.3 34.5 33.5
FZ.168B 32.8 30.0 37.0 35.8 53.8 53.0
FZ.188B 41.4 40.7 44.2 46.5 68.0 66.4
FZ.208 77.0 64.5 73.8 66.3 108.7 112.2
FD.28 0.6 0.45 0.5 0.5 0.65 0.75
FD.38B 0.9 0.6 0.7 0.7 0.9 1.1
FD.48B 2.0 0.9 1.3 1.3 1.8 2.0
FD.68B 3.3 2.3 2.4 2.3 3.2 3.8
FD.88B 6.3 5.0 4.7 4.7 6.8 6.7
FD.108B 10.6 9.1 8.2 8.2 11.1 13.0
FD.128B 16.8 13.5 15.2 14.8 21.6 22.5
FD.148B 24.7 20.3 21.8 22.3 33.6 32.6
FD.168B 44.0 28.8 36.0 35.8 52.4 51.9
FD.188B 52.0 38.4 44.5 54.1 66.0 65.2
FD.208 95.4 61.5 71.5 66.2 104.6 108.6
BA 2010
Technical data
10.6 Oil quantities
10.6.3 Bevel helical gearboxes
Table 10- 6 Oil quantities [l] for B, BA, BAS, BAT sizes 28 - 38; K, KA, KAS, KAT sizes 38 - 188

B3-00 B8-00 B7-00 B6-00 V5-00 V6-00
H-01 H-02 H-03 H-04 H-05 H-06
B.28 0.25 0.6 0.9 0.55 0.5 0.5
B.38 0.7 1.1 1.6 1.0 0.95 0.8
K.38 0.5 1.1 1.5 0.8 1.0 0.9
K.48 0.7 1.6 2.1 1.4 1.5 1.8
K.68 1.6 3.2 4.2 2.7 3.0 3.0
K.88 2.6 5.7 7.8 5.0 4.9 5.2
K.108 5.5 9.5 13.0 8.8 8.7 8.3
K.128 8.3 19.6 24.7 15.8 16.9 16.1
K.148 14.8 30.2 40.1 22.0 25.8 27.0
K.168 21.6 45.6 62.0 34.2 40.2 38.5
K.188 33.8 82.5 105.0 63.4 70.7 69.4
Table 10- 7 Oil quantities [l] for BZ, BF, BAD, BAF, BAZ, BADS, BAFS, BAZS, BADT, BAFT, BAZT sizes 28 - 38; KZ, KF,
KM, KAD, KAZ, KAF, KAM, KADS, KAZS, KAFS, KADT, KAZT, KAFT sizes 38 - 188

B5-01 B5-03 B5-02 B5-00 V1-00 V3-00
H-01 H-02 H-03 H-04 H-05 H-06
B.28 0.25 0.6 0.9 0.55 0.5 0.5
B.38 0.7 1.1 1.6 1.0 0.95 0.8
K.38 0.5 1.1 1.6 0.8 1.0 0.9
K.48 0.7 1.7 2.2 1.4 1.6 1.8
K.68 1.6 3.2 4.4 2.6 2.8 3.0
K.88 2.6 5.8 8.1 5.0 5.1 5.0
K.108 6.2 9.9 14.2 8.9 10.0 8.9
K.128 8.7 19.6 25.4 14.8 17.5 16.6
K.148 14.8 30.1 42.0 25.0 26.0 28.1
K.168 21.7 46.3 64.0 34.8 41.1 39.4
K.188 33.8 82.5 105.0 63.4 70.7 69.4
BA 2010
Technical data
10.6 Oil quantities
10.6.4 Helical worm gearboxes
Table 10- 8 Oil quantities [l] for C, CA, CAS, CAT sizes 28 - 88

B3-00 B8-00 B7-00 B6-00 V5-00 V6-00
H-01 H-02 H-03 H-04 H-05 H-06
C.28 0.2 0.4 0.6 0.2 0.6 0.35
C.38 0.5 1.2 1.3 1.2 1.2 1.2
C.48 0.7 1.6 1.7 1.6 1.3 1.3
C.68 1.5 3.3 4.1 3.3 2.8 2.9
C.88 1.7 6.1 6.5 5.1 4.5 4.5
Table 10- 9 Oil quantities [l] for CZ, CF, CAD, CAF, CAZ, CADS, CAFS, CAZS, CADT, CAFT, CAZT sizes 28 - 88

B5-01 B5-03 B5-02 B5-00 V1-00 V3-00
H-01 H-02 H-03 H-04 H-05 H-06
C.28 0.2 0.4 0.6 0.2 0.6 0.35
C.38 0.4 1.2 1.3 1.1 1.0 1.0
C.48 0.5 1.7 1.8 1.6 1.3 1.3
C.68 1.5 3.6 4.2 3.3 3.1 3.2
C.88 1.7 5.9 7.3 5.2 4.8 4.8
BA 2010
Technical data
10.6 Oil quantities
10.6.5 Tandem gearboxes - Intermediate helical gearboxes
10.6.5.1 Two- and three-stage helical gearboxes
Table 10- 10 Oil quantities [l] for Z.38, D. sizes 48 - 188

B3 B5 B5-00 B5-02 B5-03 B6 B7 B8
B14 B14-00 B14-02 B14-03
Z.38-D/Z28 0.5+0.25 0.5+0.25 0.6+0.25 0.6+0.25 0.6+0.25 0.6+0.25 0.6+0.25 0.6+0.25
0.75 0.75 0.85 0.85 0.85 0.85 0.85 0.85
D.48-D/Z28 1.1+0.25 1.0+0.25 1.5+0.25 1.6+0.25 1.5+0.25 1.5+0.25 1.4+0.25 1.5+0.25
1.35 1.25 1.75 1.85 1.75 1.75 1.65 1.75
D.68-D/Z28 1.7+0.25 1.6+0.25 2.5+0.25 2.7+0.25 2.6+0.25 2.6+0.25 2.4+0.25 2.6+0.25
1.95 1.85 2.75 2.95 2.85 2.85 2.65 2.85
D.88-D/Z28 4.0+0.25 3.6+0.25 5.6+0.25 6.1+0.25 5.9+0.25 5.9+0.25 5.4+0.25 5.9+0.25
4.25 3.85 5.85 6.35 6.15 6.15 5.65 6.15
D.108-Z38 7.1+0.5 5.7+0.5 10.2+0.5 11.0+0.5 10.0+0.5 10.3+0.5 9.5+0.5 10.0+0.5
7.6 6.2 10.7 11.5 10.5 10.8 10.0 10.5
D.108-D38 7.1+0.5 5.7+0.5 10.2+0.5 11.0+0.5 10.0+0.5 10.3+0.5 9.5+0.5 10.0+0.5
7.6 6.2 10.7 11.5 10.5 10.8 10.0 10.5
D.128-Z38 9.4+0.5 6.8+0.5 16.1+0.5 17.1+0.5 14.1+0.5 15.8+0.5 14.8+0.5 14.1+0.5
9.9 7.3 16.6 17.6 14.6 16.3 15.3 14.6
D.128-Z48 9.4+1.0 6.8+1.0 16.1+1.0 17.1+1.0 14.1+1.0 15.8+1.0 14.8+1.0 14.1+1.0
10.4 7.8 17.1 18.1 15.1 16.8 15.8 15.1
D.128-D38 9.4+0.5 6.8+0.5 16.1+0.5 17.1+0.5 14.1+0.5 15.8+0.5 14.8+0.5 14.1+0.5
9.9 7.3 16.6 17.6 14.6 16.3 15.3 14.6
D.148-Z38 12.5+0.5 9.4+0.5 20.7+0.5 22.0+0.5 23.4+0.5 20.4+0.5 19.1+0.5 23.4+0.5
13.0 9.9 21.2 22.5 23.9 20.9 19.6 23.9
D.148-Z48 12.5+1.0 9.4+1.0 20.7+1.0 22.0+1.0 23.4+1.0 20.4+1.0 19.1+1.0 23.4+1.0
13.5 10.4 21.7 23.0 24.4 21.4 20.1 24.4
D.148-D38 12.5+0.5 9.4+0.5 20.7+0.5 22.0+0.5 23.4+0.5 20.4+0.5 19.1+0.5 23.4+0.5
13.0 9.9 21.2 22.5 23.9 20.9 19.6 23.9
D.168-Z48 19.0+1.0 16.0+1.0 32.7+1.0 35.6+1.0 33.8+1.0 34.1+1.0 31.2+1.0 33.8+1.0
20.0 17.0 33.7 36.6 34.8 35.1 32.2 34.8
D.168-Z68 19.0+1.7 16.0+1.7 32.7+1.7 35.6+1.7 33.8+1.7 34.1+1.7 31.2+1.7 33.8+1.7
20.7 17.7 34.4 37.3 35.5 35.8 32.9 35.5
D.168-D48 19.0+1.0 16.0+1.0 32.7+1.0 35.6+1.0 33.8+1.0 34.1+1.0 31.2+1.0 33.8+1.0
20.0 17.0 33.7 36.6 34.8 35.1 32.2 34.8
D.188-Z48 18.4+1.0 18.4+1.0 46.0+1.0 48.0+1.0 73.0+1.0 48.0+1.0 46.0+1.0 73.0+1.0
19.4 19.4 47.0 49.0 74.0 49.0 47.0 74.0
D.188-Z68 18.4+1.7 18.4+1.7 46.0+1.7 48.0+1.7 73.0+1.7 48.0+1.7 46.0+1.7 73.0+1.7
20.1 20.1 47.7 49.7 74.7 49.7 47.7 74.7
D.188-D48 18.4+1.0 18.4+1.0 46.0+1.0 48.0+1.0 73.0+1.0 48.0+1.0 46.0+1.0 73.0+1.0
19.4 19.4 47.0 49.0 74.0 49.0 47.0 74.0
BA 2010
Technical data
10.6 Oil quantities
Table 10- 11 Oil quantities [l] for Z.38, D. sizes 48 - 188

V1 V3 V5 V6
V18 V19
Z.38-D/Z28 0.8+0.6 1.2+0.7 0.7+0.6 1.1+0.7
1.4 1.9 1.3 1.8
D.48-D/Z28 2.3+0.6 2.4+0.7 2.4+0.6 2.4+0.7
2.9 3.1 3.0 3.1
D.68-D/Z28 3.9+0.6 4.0+0.7 4.0+0.6 4.0+0.7
4.5 4.7 4.6 4.7
D.88-D/Z28 8.7+0.6 8.9+0.7 9.3+0.6 8.9+0.7
9.3 9.6 9.9 9.6
D.108-Z38 16.3+0.8 14.2+1.2 15.6+0.8 13.7+1.2
17.1 15.4 16.4 14.9
D.108-D38 16.3+0.9 14.2+1.1 15.6+0.9 13.7+1.1
17.2 15.3 16.5 14.8
D.128-Z38 24.6+0.8 21.8+1.2 24.4+0.8 21.5+1.2
25.4 23.0 25.2 22.7
D.128-Z48 24.6+1.8 21.8+2.4 24.4+1.8 21.5+2.4
26.4 24.2 26.2 23.9
D.128-D38 24.6+0.9 21.8+1.1 24.4+0.9 21.5+1.1
25.5 22.9 25.3 22.6
D.148-Z38 30.6+0.8 28.2+1.2 32.2+0.8 27.9+1.2
31.4 29.4 33.0 29.1
D.148-Z48 30.6+1.8 28.2+2.4 32.2+1.8 27.9+2.4
32.4 30.6 34.0 30.3
D.148-D38 30.6+0.9 28.2+1.1 32.2+0.9 27.9+1.1
31.5 29.3 33.1 29.0
D.168-Z48 53.0+1.8 43.7+2.4 54.4+1.8 42.2+2.4
54.8 46.1 56.2 44.6
D.168-Z68 53.0+3.0 43.7+4.1 54.4+3.0 42.2+4.1
56.0 47.8 57.4 46.3
D.168-D48 53.0+2.3 43.7+2.4 54.4+2.3 42.2+2.4
55.3 46.1 56.7 44.6
D.188-Z48 83.0+1.8 68.0+2.4 83.0+1.8 68.0+2.4
84.8 70.4 84.8 70.4
D.188-Z68 83.0+3.0 68.0+4.1 83.0+3.0 68.0+4.1
86.0 72.1 86.0 72.1
D.188-D48 83.0+2.3 68.0+2.4 83.0+2.3 68.0+2.4
85.3 70.4 85.3 70.4
BA 2010
Technical data
10.6 Oil quantities
10.6.5.2 Parallel shaft gearboxes
Table 10- 12 Oil quantities [l] for FD. sizes 38B - 188B, 208

B5-01 B5-03 B5-02 B5-00 V1-00 V3-00
H-01 H-02 H-03 H-04 H-05 H-06
FD.38B-D/Z28 0.9+0.25 0.6+0.25 0.7+0.25 0.7+0.25 0.9+0.6 1.1+0.7
1.15 0.85 0.95 0.95 1.5 1.8
FD.48B-D/Z28 2.0+0.25 0.9+0.25 1.3+0.25 1.3+0.25 1.8+0.6 2.0+0.7
2.25 1.15 1.55 1.55 2.4 2.7
FD.68B-D/Z28 3.3+0, 25 2.3+0.25 2.4+0.25 2.3+0.25 3.2+0.6 3.8+0.7
3.55 2.55 2.65 2.55 3.8 4.5
FD.88B-D/Z28 6.3+0.25 5.0+0.25 4.7+0.25 4.7+0.25 6.8+0.6 6.7+0.7
6.55 5.25 4.95 4.95 7.4 7.4
FD.108B-Z38 10.6+0.5 9.1+0.5 8.2+0.5 8.2+0.5 11.1+0.8 13.0+1.2
11.1 9.6 8.7 8.7 11.9 14.2
FD.108B-D38 10.6+0.5 9.1+0.5 8.2+0.5 8.2+0.5 11.1+0.9 13.0+1.1
11.1 9.6 8.7 8.7 12.0 14.1
FD.128B-Z38 16.8+0.5 13.5+0.5 15.2+0.5 14.8+0.5 21.6+0.8 22.5+1.2
17.3 14.0 15.7 15.3 22.4 23.7
FD.128B-Z48 16.8+1.0 13.5+1.0 15.2+1.0 14.8+1.0 21.6+1.8 22.5+2.4
17.8 14.5 16.2 15.8 23.4 24.9
FD.128B-D38 16.8+0.5 13.5+0.5 15.2+0.5 14.8+0.5 21.6+0.9 22.5+1.1
17.3 14.0 15.7 15.3 22.5 23.6
FD.148B-Z38 24.7+0.5 20.3+0.5 21.8+0.5 22.3+0.5 33.6+0.8 32.6+1.2
25.2 20.8 22.3 22.8 34.4 33.8
FD.148B-Z48 24.7+1.0 20.3+1.0 21.8+1.0 22.3+1.0 33.6+1.8 32.6+2.4
25.7 21.3 22.8 23.3 35.4 35.0
FD.148B-D38 24.7+0.5 20.3+0.5 21.8+0.5 22.3+0.5 33.6+0.9 32.6+1.1
25.2 20.8 22.3 22.8 34.5 33.7
FD.168B-Z48 44.0+1.0 28.8+1.0 36.0+1.0 35.8+1.0 52.4+1.8 51.9+2.4
45.0 29.8 37.0 36.8 54.2 54.3
FD.168B-Z68 44.0+1.7 28.8+1.7 36.0+1.7 35.8+1.7 52.4+3.0 51.9+4.1
45.7 30.5 37.7 37.5 55.4 56.0
FD.168B-D48 44.0+1.0 28.8+1.0 36.0+1.0 35.8+1.0 52.4+2.3 51.9+2.4
45.0 29.8 37.0 36.8 54.7 54.3
FD.188B-Z48 52.0+1.0 38.4+1.0 44.5+1.0 54.1+1.0 66.0+1.8 65.2+2.4
53.0 39.4 45.5 55.1 67.8 67.6
FD.188B-Z68 52.0+1.7 38.4+1.7 44.5+1.7 54.1+1.7 66.0+3.0 65.2+4.1
53.7 40.1 46.2 55.8 69.0 69.3
FD.188B-D48 52.0+1.0 38.4+1.0 44.5+1.0 54.1+1.0 66.0+2.3 65.2+2.4
53.0 39.4 45.5 55.1 68.3 67.6
FD.208-D68 95.4+1.6 61.5+1.6 71.5+1.6 66.2+1.6 126.5+3.9 108.6+4.0
97.0 63.1 73.1 67.8 130.4 112.6
FD.208-Z68 95.4+1.7 61.5+1.7 71.5+1.7 66.2+1.7 126.5+3.0 108.6+4.1
97.1 63.2 73.2 67.9 129.5 112.7
FD.208-Z88 95.4+3.7 61.5+3.7 71.5+3.7 66.2+3.7 126.5+6.8 108.6+8.3
99.1 65.2 75.2 69.9 133.3 116.9
BA 2010
Technical data
10.6 Oil quantities
10.6.5.3 Bevel helical gearboxes
Table 10- 13 Oil quantities [l] for K, KA, KAS, KAT sizes 38 - 188

B3-00 B8-00 B7-00 B6-00 V5-00 V6-00
H-01 H-02 H-03 H-04 H-05 H-06
K.38-D/Z28 0.5+0.25 1.1+0.25 1.5+0.6 0.8+0.7 1.0+0.25 0.9+0.25
0.75 1.35 2.1 1.5 1.25 1.15
K.48-D/Z28 0.7+0.25 1.6+0.25 2.1+0.6 1.4+0.7 1.5+0.25 1.8+0.25
0.95 1.85 2.7 2.1 1.75 2.05
K.68-D/Z28 1.6+0.25 3.2+0.25 4.2+0.6 2.7+0.7 3.0+0.25 3.0+0.25
1.85 3.45 4.8 3.4 3.25 3.25
K.88-D/Z28 2.6+0.25 5.7+0.25 7.8+0.6 5.0+0.7 4.9+0.25 5.2+0.25
2.85 5.95 8.4 5.7 5.15 5.45
K.108-Z38 5.5+0.5 9.5+0.5 13.0+0.8 8.8+1.2 8.7+0.5 8.3+0.5
6.0 10.0 13.8 10.0 9.2 8.8
K.108-Z48 5.5+1.0 9.5+1.0 13.0+1.8 8.8+2.4 8.7+1.0 8.3+1.0
6.5 10.5 14.8 11.2 9.7 9.3
K.108-D38 5.5+0.5 9.5+0.5 13.0+0.9 8.8+1.1 8.7+0.5 8.3+0.5
6.0 10.0 13.9 9.9 9.2 8.8
K.128-Z38 8.3+0.5 19.6+0.5 24.7+0.8 15.8+1.2 16.9+0.5 16.1+0.5
8.8 20.1 25.5 17.0 17.4 16.6
K.128-Z48 8.3+1.0 19.6+1.0 24.7+1.8 15.8+2.4 16.9+1.0 16.1+1.0
9.3 20.6 26.5 18.2 17.9 17.1
K.128-D38 8.3+0.5 19.6+0.5 24.7+0.9 15.8+1.1 16.9+0.5 16.1+0.5
8.8 20.1 25.6 16.9 17.4 16.6
K.148-Z38 14.8+0.5 30.2+0.5 40.1+0.8 22.0+1.2 25.8+0.5 27.0+0.5
15.3 30.7 40.9 23.2 26.3 27.5
K.148-Z68 14.8+1.7 30.2+1.7 40.1+3.0 22.0+4.1 25.8+1.7 27.0+1.7
16.5 31.9 43.1 26.1 27.5 28.7
K.148-D38 14.8+0.5 30.2+0.5 40.1+0.9 22.0+1.1 25.8+0.5 27.0+0.5
15.3 30.7 40.9 23.1 26.3 27.5
K.168-Z48 21.6+1.0 45.6+1.0 62.0+1.8 34.2+2.4 40.2+1.0 38.5+1.0
22.6 46.6 63.8 36.6 41.2 39.5
K.168-Z.68 21.6+1.7 45.6+1.7 62.0+3.0 34.2+4.1 40.2+1.7 38.5+1.7
23.3 47.3 65.0 38.3 41.9 40.2
K.168-D48 21.6+1.0 45.6+1.0 62.0+2.3 34.2+2.4 40.2+1.0 38.5+1.0
22.6 46.6 64.3 36.6 41.2 39.5
K.188-Z68 33.8+1.7 82.5+1.7 105.0+3.0 63.4+4.1 70.7+1.7 69.4+1.7
35.5 84.2 108.0 67.5 72.4 71.1
K.188-Z88 33.8+3.7 82.5+3.7 105.0+6.8 63.4+8.3 70.7+3.7 69.4+3.7
37.5 86.2 111.8 71.7 74.4 73.1
K.188-D68 33.8+1.6 82.5+1.6 105.0+3.9 63.4+4.0 70.7+1.6 69.4+1.6
35.4 84.1 108.9 67.4 72.3 71.0
BA 2010
Technical data
10.6 Oil quantities
Table 10- 14 Oil quantities [l] for KZ, KF, KAD, KAZ, KAF, KADS, KAZS, KAFS, KADT, KAZT, KAFT sizes 38 - 188

B5-01 B5-03 B5-02 B5-00 V1-00 V3-00
H-01 H-02 H-03 H-04 H-05 H-06
K.38-D/Z28 0.5+0.25 1.1+0.25 1.6+0.6 0.8+0.7 1.0+0.25 0.9+0.25
0.75 1.35 2.2 1.5 1.25 1.15
K.48-D/Z28 0.7+0.25 1.7+0.25 2.2+0.6 1.4+0.7 1.6+0.25 1.8+0.25
0.95 1.95 2.8 2.1 1.85 2.05
K.68-D/Z28 1.6+0.25 3.2+0.25 4.4+0.6 2.6+0.7 2.8+0.25 3.0+0.25
1.85 3.45 5.0 3.3 3.05 3.25
K.88-D/Z28 2.6+0.25 5.8+0.25 8.1+0.6 5.0+0.7 5.1+0.25 5.0+0.25
2.85 6.05 8.7 5.7 5.35 5.25
K.108-Z38 6.2+0.5 9.9+0.5 14.2+0.8 8.9+1.2 10.0+0.5 8.9+0.5
6.7 10.4 15.0 10.1 10.5 9.4
K.108-Z48 6.2+1.0 9.9+1.0 14.2+1.8 8.9+2.4 10.0+1.0 8.9+1.0
7.2 10.9 16.0 11.3 11.0 9.9
K.108-D38 6.2+0.5 9.9+0.5 14.2+0.9 8.9+1.1 10.0+0.5 8.9+0.5
6.7 10.4 15.1 10.0 10.5 9.4
K.128-Z38 8.7+0.5 19.6+0.5 25.4+0.8 14.8+1.2 17.5+0.5 16.6+0.5
9.2 20.1 26.2 16.0 18.0 17.1
K.128-Z48 8.7+1.0 19.6+1.0 25.4+1.8 14.8+2.4 17.5+1.0 16.6+1.0
9.7 20.6 27.2 17.2 18.5 17.6
K.128-D38 8.7+0.5 19.6+0.5 25.4+0.9 14.8+1.1 17.5+0.5 16.6+0.5
9.2 20.1 26.3 15.9 18.0 17.1
K.148-Z38 14.8+0.5 30.1+0.5 42.0+0.8 25.0+1.2 26.0+0.5 28.1+0.5
15.3 30.6 42.8 26.2 26.5 28.6
K.148-Z68 14.8+1.7 30.1+1.7 42.0+3.0 25.0+4.1 26.0+1.7 28.1+1.7
16.5 31.8 45.0 29.1 27.7 29.8
K.148-D38 14.8+0.5 30.1+0.5 42.0+0.9 25.0+1.1 26.0+0.5 28.1+0.5
15.3 30.6 42.9 26.1 26.5 28.6
K.168-Z48 21.7+1.0 46.3+1.0 64.0+1.8 34.8+2.4 41.1+1.0 39.4+1.0
22.7 47.3 65.8 37.2 42.1 40.4
K.168-Z68 21.7+1.7 46.3+1.7 64.0+3.0 34.8+4.1 41.1+1.7 39.4+1.7
23.4 48.0 67.0 38.9 42.8 41.1
K.168-D48 21.7+1.0 46.3+1.0 62.6+2.3 34.8+2.4 41.1+1.0 39.4+1.0
22.7 47.3 64.9 37.2 42.1 40.4
K.188-Z68 33.8+1.7 82.5+1.7 105.0+3.0 63.4+4.1 70.7+1.7 69.4+1.7
35.5 84.2 108.0 67.5 72.4 71.1
K.188-Z88 33.8+3.7 82.5+3.7 105.0+6.8 63.4+8.3 70.7+3.7 69.4+3.7
37.5 86.2 111.8 71.7 74.4 73.1
K.188-D68 33.8+1.6 82.5+1.6 105.0+3.9 63.4+4.0 70.7+1.6 69.4+1.6
35.4 84.1 108.9 67.4 72.3 71.0
BA 2010
Technical data
10.6 Oil quantities
10.6.5.4 Helical worm gearboxes
Table 10- 15 Oil quantities [l] for C, CA, CAS, CAT sizes 38 - 88

B3-00 B8-00 B7-00 B6-00 V5-00 V6-00
H-01 H-02 H-03 H-04 H-05 H-06
C.38-D/Z28 0.5+0.25 1.2+0.25 1.3+0.6 1.2+0.7 1.2+0.25 1.2+0.25
0.75 1.45 1.9 1.9 1.45 1.45
C.48-D/Z28 0.7+0.25 1.6+0.25 1.7+0.6 1.6+0.7 1.3+0.25 1.3+0.25
0.95 1.85 2.3 2.3 1.55 1.55
C.68-D/Z28 1.5+0.25 3.3+0.25 4.1+0.6 3.3+0.7 2.8+0.25 2.9+0.25
1.75 3.55 4.7 4.0 3.05 3.15
C.88-D/Z28 1.7+0.25 6.1+0.25 6.5+0.6 5.1+0.7 4.5+0.25 4.5+0.25
0.95 6.35 7.1 5.8 4.75 4.75
Table 10- 16 Oil quantities [l] for CZ, CF, CAD, CAF, CAZ, CADS, CAFS, CAZS, CADT, CAFT, CAZT sizes 38 - 88

B5-01 B5-03 B5-02 B5-00 V1-00 V3-00
H-01 H-02 H-03 H-04 H-05 H-06
C.38-D/Z28 0.4+0.25 1.2+0.25 1.3+0.6 1.1+0.7 1.0+0.25 1.0+0.25
0.65 1.45 1.9 1.8 1.25 1.25
C.48-D/Z28 0.5+0.25 1.7+0.25 1.8+0.6 1.6+0.7 1.3+0.25 1.3+0.25
0.75 1.95 2.4 2.3 1.55 1.55
C.68-D/Z28 1.5+0.25 3.6+0.25 4.2+0.6 3.3+0.7 3.1+0.25 3.2+0.25
1.75 3.85 4.8 4.0 3.35 3.45
C.88-D/Z28 1.7+0.25 5.9+0.25 7.3+0.6 5.2+0.7 4.8+0.25 4.8+0.25
1.95 6.15 7.9 5.9 5.05 5.05
BA 2010
11.1 Stocking of spare parts
By stocking the most important spare and wearing parts on site, you can ensure that the
gearbox or geared motor is ready for use at any time.
CAUTION
Please note that spare parts and accessories not supplied by us have not been tested or
approved by us.
The installation and / or use of such products can therefore have a negative impact on the
design characteristics of the geared motor and might consequently impair the active
and / or passive safety features of the machine.
Siemens Geared Motors GmbH will accept no liability or warranty whatsoever for damage
occurring as the result of the use of non-original spare parts or accessories.
We can only accept liability for original spare parts supplied by Siemens Geared Motors
GmbH.
Please note that single components often have special production and supply specifications.
We always supply spare parts which meet state-of-the-art technical standards and comply
with the latest legal requirements.
Please state the following data when ordering spare parts:
● Serial no. see rating plate ⑤
● Type designation see rating plate ③
● Part no. (3-digit item no. from spare parts list, 6-digit code no. or 7-digit article no.)
● Quantity
SIEMENS IEC60034
SIEMENS 1 2
KAF108-LA160L4-L150/100GH 3
IP55 (IM) H-01-A 7 8
G. 6.2L OIL CLP PG VG220 i=12.9 9 10 11 12
50Hz 113/min 60Hz 136/min 13 14 17 18
1266Nm fB=1.5 1264Nm fB=1.5 15 16 19 20
50Hz 400/690V D/Y 60Hz 460V Y 27 28 29 35 36 37
29/16.74A cosPhi 0.84 28.6A cosPhi 0.87 30 31 38 39
15kW IE1-90% 1460/min 15kW 1755/min 32 33 34 40 41 42
For motors of series 1LA / 1LG with their own rating plate, the spare parts documentation in
the original operating instructions applies.
BA 2010
Spare parts / Accessories
11.2 Spare parts lists
11.2.1 Single-stage helical gearboxes sizes 38 - 148

001 Gearbox housing

101 Output shaft
103 Spacer / bush
105 Parallel key
130 Bearing
135 Locking ring
136 Locking ring
140 Bearing
145 Locking ring
160 Shaft sealing ring
201 Adapter plate
205 Screw
210 Screw
211 Screw lock
220 Seal
225 Seal
BA 2010
301 Plug-in pinion

305 Helical gear wheel
335 Parallel key
401 Screw plug
420 Vent filter
430 Eyebolt
Figure 11-2 Single-stage helical gearboxes sizes 38 - 148
BA 2010
11.2.2 Two- and three-stage helical gearboxes sizes 38 - 188

* 2-stage
001 Gearbox housing
020 Bearing
025 Locking ring
030 Bearing
050 Housing cover
051 Screw
055 Seal
101 Output shaft
103 Spacer / bush
105 Parallel key
130 Bearing
135 Locking ring
140 Bearing
141 Supporting disk / shim
145 Locking ring
BA 2010

201 Adapter plate
205 Screw
210 Screw
211 Screw lock
215 Cylindrical pin
220 Seal
225 Seal
301 Plug-in pinion
306 Parallel key
315 Bearing
320 Bearing
325 Pinion shaft
331 Parallel key
335 Locking ring
340 Pinion shaft
346 Parallel key
401 Screw plug
420 Vent filter
430 Eyebolt
Figure 11-3 Two- and three-stage helical gearboxes sizes 38 - 188
BA 2010
11.2.3 Parallel shaft gearboxes sizes 38B - 188B, 208

Figure 11-4 Parallel shaft gearbox sizes 38B - 188B
BA 2010

Figure 11-5 Parallel shaft gearbox size 208
BA 2010
Table 11- 1 Spare parts list for parallel shaft gearbox sizes 38B - 188B, 208
001 Gearbox housing

020 Bearing
025 Locking ring
030 Bearing
034 NILOS ring
040 Output flange
045 Screw
050 Housing cover
051 Screw
055 Seal
065 Sealing cap
070 Sealing cap
074 Screw
078 O-ring
090 Torque arm
091 Rubber bush
095 Screw
096 Locking ring
097 Nut
101 Input shaft
109 Locking ring
110 Locking ring
114 Protection cover (optional)
120 Shrink disk
130 Bearing
132 Spacer / bush
133 NILOS ring
135 Locking ring
140 Bearing
141 Spacer / bush
143 NILOS ring
146 Locking ring
161 Bearing cover
BA 2010
162 O-ring
163 Screw
167 O-ring
168 Bearing cover
179 Screw
201 Adapter plate
205 Screw
210 Screw
211 Screw lock
220 Seal
225 Seal
301 Pinion
306 Parallel key
307 Spacer / bush
310 Locking ring
315 Bearing
320 Bearing
321 Locking ring
325 Pinion shaft
331 Parallel key
340 Pinion shaft
346 Parallel key
401 Screw plug
420 Vent filter
BA 2010
11.2.4 Bevel helical gearboxes sizes B38, 38 - 188
%

Figure 11-6 Bevel helical gearbox sizes B38, 38 - 188
BA 2010
Table 11- 2 Spare parts list for bevel helical gearbox sizes B38, 38 - 188
001 Gearbox housing

020 Bearing
027 Locking ring
030 Bearing
040 Output flange
045 Screw
050 Housing cover
051 Screw
055 Seal
060 Bearing
063 NILOS ring
065 Locking ring
070 Sealing cap
090 Torque arm
091 Rubber bush
095 Screw
096 Screw lock
101 Output shaft
130 Bearing
133 NILOS ring
135 Locking ring
140 Bearing
143 NILOS ring
146 Locking ring
201 Adapter plate
205 Screw
210 Screw
211 Screw lock
220 Seal
225 Seal
301 Plug-in pinion
320 Bevel gear pair
325 Bevel pinion shaft
BA 2010
327 Parallel key

328 Locking ring
331 Parallel key
335 Locking ring
340 Pinion shaft
346 Parallel key
351 Parallel key
401 Screw plug
411 Screw
413 Disk
415 Locking ring
418 Plug / sealing cap
420 Vent filter
BA 2010
11.2.5 Helical worm gearboxes sizes 38 - 88

001 Gearbox housing

020 Bearing
030 Bearing
035 Locking ring
037 Locking ring
040 Output flange
045 Screw
070 Sealing cap
090 Torque arm
091 Rubber bush
095 Screw
101 Output shaft
130 Bearing
133 NILOS ring
BA 2010
135 Locking ring

140 Bearing
143 NILOS ring
146 Locking ring
201 Adapter plate
205 Screw
210 Screw
211 Screw lock
220 Seal
225 Seal
301 Plug-in pinion
331 Parallel key
335 Locking ring
340 Worm shaft
345 Worm wheel
346 Parallel key
401 Screw plug
411 Screw
412 Screw lock
413 Disk
415 Locking ring
418 Plug / sealing cap
420 Vent filter
430 Eyebolt
Figure 11-7 Helical worm gearbox sizes 38 - 88
BA 2010
Declaration of Incorporation, Declaration of
Conformity
12.1 Declaration of Incorporation
12
Declaration of Incorporation according to Directive 2006/42/EC Annex II 1 B.
The manufacturer Siemens Geared Motors GmbH, 72072 Tübingen, declares for the partly
completed machine
● Single-stage helical gearboxes of types
E.38, E.48, E.68, E.88, E.108, E.128, E.148
● Two- and three-stage helical gearboxes of types
D./Z.18, D./Z.28, D./Z.38, D./Z.48, D./Z.68, D./Z.88, D./Z.108, D./Z.128, D./Z.148,
D./Z.168, D./Z.188
● Parallel shaft gearboxes of types
F.28, F.38B, F.48B, F.68B, F.88B, F.108B, F.128B, F.148B, F.168B, F.188B, F.208
● Bevel helical gearboxes of types
B.28, B.38, K.38, K.48, K.68, K.88, K.108, K.128, K.148, K.168, K.188
● Helical worm gearboxes of types
C.28, C.38, C.48, C.68, C.88:
The special technical documentation was generated according to Annex VII B.
The following essential health and safety requirements from Directive 2006/42/EC Annex I
apply and have been fulfilled:
● 1.1, 1.1.2, 1.1.3, 1.1.5
● 1.2.4.4, 1.2.6
● 1.3.1, 1.3.2, 1.3.3, 1.3.4, 1.3.6, 1.3.8.1
● 1.4.1, 1.4.2, 1.4.2.1
● 1.5.1, 1.5.2, 1.5.4, 1.5.5, 1.5.6, 1.5.8, 1.5.9, 1.5.10, 1.5.11, 1.5.13, 1.5.15
● 1.6.1, 1.6.2
● 1.7.1, 1.7.1.1, 1.7.2, 1.7.3, 1.7.4, 1.7.4.1, 1.7.4.2, 1.7.4.3
The partly completed machine may only be commissioned once it has been established, if
applicable, that the machine in which the partly completed machine is to be incorporated
meets the provisions of Directive 2006/42/EC.
The manufacturer is obligated to transmit the special technical documentation for the partly
completed machine in electronic form to national authorities upon legitimate request.
Person authorized to compile the relevant technical documentation:
Georg Böing, Head of Research and Development Gears.
Tübingen Date March 10, 2010
Georg Böing Jürgen Pflaum

Head of Research & Development Gears Head of Quality Management
BA 2010
Declaration of Incorporation, Declaration of Conformity
12.2 EC Declaration of Conformity
12.2 EC Declaration of Conformity

Document no. D87.1 10.09
Equipment Gearbox series MOTOX

designation:
Gearbox types: E, Z, D, F, K, C
Sizes: 38 to 208
Input units: A, K, P
The designated equipment conforms to the requirements of Explosion Protection

Directive 94/9/EC, ATEX 95. It has been developed and manufactured in compliance with
the following European standards:
● DIN EN ISO 14121-1: 2007
● DIN EN 1127-1: 2007
● DIN EN 13463-1: 2001
● DIN EN 13463-5: 2003
● DIN EN 13463-6: 2005
● DIN EN 13463-8: 2003
Type of explosion protection for equipment group II or categories 2 and 3:
● II2 G / D IIB ck T4 / 120 °C
● II2 G / D IIB bck T4 / 120 °C
● II3 G / D IIB ck T4 / 120 °C
EC Declarations of Conformity and / or EC-type examination certificates for further
equipment added to the gearbox and / or for safety systems are enclosed. These may be
specifically:
● Rotating electrical machines
● Safety systems for oil level and / or temperature monitoring equipment
The technical documentation for category 2 gearboxes has undergone voluntary inspection
and has been filed with the designated body under no. 0123, TÜV SÜD PRODUCT
SERVICE GmbH, Ridlerstraße 65, 80339 München.
Tübingen Date October 1, 2009
Georg Böing Jürgen Pflaum

Head of Research & Development Gears Head of Quality Management
BA 2010
Further information
MOTOX geared motors on the Internet:
www.siemens.com/gearedmotors
Siemens AG Subject to change

Industry Sector
Postfach 48 48 © Siemens AG 2010
90026 NÜRNBERG
GERMANY
www.siemens.com/automation
MOTOX input units
BA 2019
Operating Instructions · 05/2010
MOTOX
Answers for industry.
General information and
BA 2019 ___________________
safety notes 1
___________________
3
___________________
Installation
MOTOX
4
___________________
Operation
Input units
BA 2019 ___________________
___________________
Operating Instructions
Supplement to MOTOX gearbox operating instructions

BA 2010 and BA 2515
05/2010
Legal information
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
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
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 for the specific task, in particular its warning notices and
safety instructions. Qualified personnel are those who, based on their training and experience, are capable of
identifying risks and avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be adhered to. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG Copyright © Siemens AG 2010.

Industry Sector Ⓟ 10/2010 Technical data subject to change
Postfach 48 48
90026 NÜRNBERG
GERMANY
Table of contents
1 General information and safety notes ........................................................................................................ 7

1.1 General information .......................................................................................................................7
1.2 Copyright........................................................................................................................................9
1.3 Intended use ................................................................................................................................10
1.4 Obligations of the user .................................................................................................................11
1.5 Particular type of risk and personal protective equipment...........................................................12
2 Technical description ............................................................................................................................... 13
2.1 Flexible coupling ..........................................................................................................................13
2.2 Backstop ......................................................................................................................................14
3 Installation ............................................................................................................................................... 15
3.1 Unpacking ....................................................................................................................................15
3.2 General information on installation ..............................................................................................15
3.3 Tightening torques for fastening bolts..........................................................................................17
3.4 Mounting the input or output element on the gearbox .................................................................18
3.5 Mounting the motor ......................................................................................................................20
3.5.1 Mounting a standard motor on a coupling lantern with a flexible coupling (K2, K2TC) ...............21
3.5.2 Mounting a standard motor on a short coupling lantern with a clamp connection (K4,
K5TC)...........................................................................................................................................23
3.5.3 Mounting a servomotor on lanterns with a zero-backlash coupling (KQ, KQS) ..........................26
3.6 Adjusting the height of the piggy back .........................................................................................29
3.6.1 General information on adjusting the piggy back.........................................................................29
3.6.2 Piggy back for IEC motor up to size 112 .....................................................................................30
3.6.3 Piggy back for IEC motor sizes 132 to 200..................................................................................31
3.6.4 Piggy back for IEC motor size 225 and above.............................................................................32
4 Operation................................................................................................................................................. 33
5 Service and maintenance ........................................................................................................................ 35
5.1 General notes about maintenance...............................................................................................35
5.2 Regreasing the roller bearing.......................................................................................................36
6 Spare parts / Accessories ........................................................................................................................ 37
6.1 Stocking of spare parts ................................................................................................................37
6.2 Spare parts lists ...........................................................................................................................38
6.2.1 Input units A, A5...........................................................................................................................38
6.2.2 Input units K2, K2TC....................................................................................................................40
6.2.3 Input units K4, K5TC....................................................................................................................43
6.2.4 Input units KQ, KQS.....................................................................................................................45
6.2.5 Input unit P ...................................................................................................................................46
BA 2019
Table of contents
BA 2019
General information and safety notes 1

Instructions and measures applying in particular to ATEX version gearboxes.
CAUTION
Siemens does not accept liability for any damage or outages resulting from non-compliance
with these operating instructions.
These operating instructions are an integral part of the gearbox supplied and must be kept in
its vicinity for reference at all times.
These operating instructions supplement the BA 2010 and BA 2515 MOTOX gearbox
operating instructions.
They apply to the input units of the standard version of the MOTOX gearbox:
● Input units A, A5 - input units with additional input shaft
● Input unit K2 - coupling lantern with coupling for connecting an IEC motor
● Input unit K2TC - coupling lantern with coupling for connecting a NEMA motor
● Input unit K4 - short coupling lantern with clamp connection for connecting an IEC motor
● Input unit K5TC - short coupling lantern with clamp connection for connecting a
NEMA motor
● Input units KQ, KQS - lanterns for servomotor with zero-backlash coupling for connecting
a servomotor
● Input unit P - input unit with free input shaft and piggy back for connecting an IEC motor,
foot-mounted version
BA 2019
Table 1- 1 Order number code
Input unit for MOTOX gearbox Order code

Input unit A A00
Input unit A5 A02
Input unit K2 A03
Input unit K2TC A05
Input unit K4 A04
Input unit K5TC A06
Input unit KQ A07
Input unit KQS A08
Input unit P A09
Note
In addition to these operating instructions, special contractual agreements and technical
documentation apply to these special gearbox designs and the associated supplementary
equipment.
Please read these operating instructions and the operating instructions for the MOTOX
gearboxes BA 2010 or BA 2515 before working with the gearbox.
Please refer to the other operating instructions supplied with the product.
The gearboxes described here correspond to the state of the art at the time these operating
instructions were printed.
In the interest of technical progress we reserve the right to make changes to the individual
assemblies and accessories which we regard as necessary to preserve their essential
characteristics and improve their efficiency and safety.
If you have any technical questions, please contact Technical Support.
Europe - Germany
Phone: +49 (0) 911 895 7222
Fax: +49 (0) 911 895 7223
America - USA
Phone: +1 42 32 62 25 22
Asia - China
Phone: +86 10 64 75 75 75
E-mail: support.automation@siemens.com
Internet German: http://www.siemens.de/automation/support-request
Internet English: http://www.siemens.com/automation/support-request
BA 2019
1.2 Copyright
Applicable operating instructions
Table 1- 2 MOTOX gearbox operating instructions
Title Product
BA 2010 MOTOX gearboxes
BA 2011 MOTOX helical worm gearboxes and geared motors
BA 2019 MOTOX input units
BA 2510 MOTOX optional add-on units
BA 2515 MOTOX gearboxes for overhead conveyors
Table 1- 3 Motor operating instructions
Title Product
BA 2310 Three-phase and single-phase alternating current motors and brake motors with
accessories
BA 2320 LA / LG and LAI / LGI motors for fitting to MOTOX and CAVEX gearboxes
Table 1- 4 CAVEX gearbox operating instructions
Title Product
BA 6610TU CAVEX worm gearboxes, type C.., size 63 to 630
BA 6611TU CAVEX worm gearboxes, type CS.., size 63 to 630
BA 6612TU CAVEX worm gearboxes, type CD.., size 100 to 630
BA 6800TU CAVEX elevator drives, type CG 26, size 100, 112, 135, 170
BA 6801TU CAVEX elevator drives, type CG 45, size 120
BA 6802TU CAVEX escalator drives, type CG 26, size 100, 112, 135, 170
1.2 Copyright
The copyright to these operating instructions is held by Siemens Geared Motors GmbH.
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 our
agreement.
BA 2019
1.3 Intended use
1.3 Intended use

The ATEX gearbox meets the requirements of the Explosion Protection
Directive 94/9/EC.
In the case of ATEX version gearboxes, please observe instructions marked with
this symbol.
The MOTOX gearboxes described in these operating instructions have been designed for
stationary use in general engineering applications.
Unless otherwise agreed, the gearboxes have been designed for use in plants and
equipment in industrial environments.
The gearboxes have been built using state-of-the-art technology and are shipped in an
operationally reliable condition. Changes made by users could affect this operational
reliability and are forbidden.
Note
The performance data assumes an ambient temperature of -20 °C to +40 °C and an
installation altitude of up to 5,000 m above sea level.
In the case of other ambient temperatures and installation altitudes, please contact Technical
Support.
The gearboxes have been designed solely for the application described in Technical Data in
the BA 2010 or BA 2515 operating instructions for MOTOX gearboxes. Do not operate the
gearboxes outside the specified power limits. Other operating conditions must be
contractually agreed.
Do not stand or walk on the gearboxes.
BA 2019

The operator must ensure that all persons assigned to work on the gearbox 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 others
● Ensure the safety and reliability of the gearbox
● Avoid disruptions and environmental damage through incorrect use.
Note the following safety information:

Shut down the geared motors and disconnect the power before you carry out any work on
them.
Make sure that the drive unit cannot be turned on accidentally, e.g. lock the key-operated
switch. Place a warning notice at the drive connection point which clearly indicates that work
is in progress on the geared motor.
Carry out all work with great care and with due regard to safety.
Ensure compliance with the relevant safety and environmental regulations during transport,
mounting and dismantling, operation, and care and maintenance of the unit.
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, immediately switch off the drive unit.
Take appropriate protective measures to prevent accidental contact with rotating drive parts,
such as couplings, gear wheels or belt drives.
Take appropriate 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.
Do not carry out any welding work on the gearbox. Do not use the gearbox as a grounding
point for welding operations.
Carry out equipotential bonding in accordance with applicable regulations and directives.
Such work must be carried out by qualified electrical personnel only.
Do not use high-pressure cleaning equipment or sharp-edged tools to clean the gearbox.
Replace damaged screws with new screws of the same type and strength class.
GmbH.
If the geared motor is being installed in a plant or equipment, the manufacturers of such
plant or equipment must ensure that the contents of these operating instructions are
incorporated into their own instructions, information, and descriptions.
BA 2019
DANGER
Depending on operating conditions, the gearbox may exhibit 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.
DANGER
Danger of scalding caused by hot oil emerging from the unit.
DANGER
Avoid breathing vapors when working with solvents.
Ensure adequate ventilation.
DANGER
Risk of explosion when working with solvents.
Ensure adequate ventilation. Do not smoke!
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 required personal protective equipment, wear suitable protective gloves
and eyewear when working with the gearbox.
BA 2019
2.1 Flexible coupling
CAUTION
A coupling with a peripheral speed of up to 30 m/s at the outer diameter must be statically
balanced.
A coupling with a peripheral speed of more than 30 m/s requires dynamic balancing.
A flexible coupling is generally used for the gearbox input and output.
If a rigid coupling or other input or output elements are to be used that give rise to additional
radial and / or axial forces (e.g. gear wheels, belt pulleys), this must be contractually agreed.
Please refer to the relevant operating instructions for details of how to use the coupling.
BA 2019
2.2 Backstop
2.2 Backstop

The drive speed in the table "Drive speed when using backstops" must be reached
in continuous operation.
Starting and stopping operations ≤ 20 starts/stops per hour are permissible.
CAUTION
Drive speeds below 1,000 rpm or frequent starting and stopping operations
(≥ 20 starts / stops per hour) will limit service life.
Do not use the same backstop for prolonged periods; replace backstops regularly.
CAUTION
Damage or destruction of the backstop due to incorrect direction of rotation.
Do not run the motor against the backstop.
Note the directional arrow on the gearbox.
The gearbox can be fitted with a mechanical backstop. The backstop can be fitted either in
the coupling lantern or in the 2nd stage of the bevel helical gearbox. It permits only the
correct direction of rotation during operation. This is indicated by an arrow pointing in the
corresponding direction.
The backstop is fitted with 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.
Where the backstop is used in the coupling lantern, lifting of the sprags is ensured when the
drive speed is above the speed listed in the table. The backstop is wear-free. It does not
require maintenance.
Table 2- 1 Drive speed when using backstops
Motor size Backstop Minimum speed

[rpm]
80/90 FXM-46 DX > 820
100 FXM-51 DX > 750
112 FXM-61 DX > 750
132, 160 FXM-76 DX > 670
180/200, 225, 250 FXM-101 DX > 610
280 FXM-100 SX > 400
When used in the bevel helical gearbox (gearbox intermediate shaft), the backstop operates
at speeds below the lift-off speed of the sprags in a separate oil chamber. The oil must be
changed at the same intervals as the gearbox.
BA 2019
Installation 3
3.1 Unpacking
CAUTION
Check the gearbox or geared motor for completeness and for damage. Report any missing
parts or damage immediately.
Remove packaging and transport fixtures and dispose of them properly.

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.
WARNING
The entire system must be load-free so that there is no danger during this work.
CAUTION
Overheating of the gearbox due to exposure to direct sunlight.
Provide suitable protective equipment such as covers or roofs. Prevent heat accumulation.
CAUTION
Malfunction resulting from foreign objects.
The operator must ensure that no foreign objects impair the function of the gearbox.
BA 2019
Installation
CAUTION
Exceeding the permissible oil sump temperature due to incorrect settings of temperature
monitoring equipment.
A warning must be given when the maximum permissible oil sump temperature is reached.
The geared motor must be switched off when the maximum permissible oil sump
temperature is exceeded. This switching off can cause plant shutdown.
CAUTION
Irreparable damage to geared components and bearings due to welding.
Do not carry out any welding work on the gearbox. The gearbox must not be used as a
grounding point for welding operations.
Note
Use headless screws of strength class 8.8 or higher to fasten 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.
Observe the type of construction specified on the rating plate. This ensures that the correct
quantity of lubricant is provided.
Use all the fastening means which have been assigned to the relevant type of construction.
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.
BA 2019
Installation
3.3 Tightening torques for fastening bolts
3.3 Tightening torques for fastening bolts

The general tolerance for the tightening torque in Nm is 10%. The friction coefficient is
0.14 μ.

8.8 10.9 12.9
[Nm] [Nm] [Nm]
M4 3 4 5
M5 6 9 10
M6 10 15 18
M8 25 35 41
M10 50 70 85
M12 90 120 145
M16 210 295 355
M20 450 580 690
M24 750 1,000 1,200
M30 1,500 2,000 2,400
M36 2,500 3,600 4,200
BA 2019
Installation
DANGER
Danger of burns due to hot parts.
CAUTION
CAUTION
Damage to shaft sealing rings caused by heating over 100 °C.
Protect shaft sealing rings from heating up due to radiant heat using thermal shields.
CAUTION
Alignment errors caused by excessive angle or axial displacement of the shaft ends to be
joined lead to premature wear or material damage.
Ensure precise alignment of the individual components.
CAUTION
Damage to bearings, housing, shaft, and locking rings due to improper handling.
Do not use impacts or knocks to force the input and output elements to be mounted onto
the shaft.
Note
Deburr the parts of elements to be fitted in the area of the hole or keyways.
Recommendation: 0.2 x 45°
Where couplings are to be fitted in a heated condition, observe the specific operating
instructions for the coupling. Unless otherwise specified, the heat can be applied inductively,
using a torch or in a furnace.
Use the centering holes in the shaft end faces.
BA 2019
Installation
Use a fitting device to fit the input or output elements.
Figure 3-1 Example of a fitting device
Observe the correct mounting arrangement to minimize stress on shafts and bearings due to
lateral forces.
Correct Incorrect
) )
D D
a Hub
F Force
Figure 3-2 Mounting arrangement for minimum stress on shafts and bearings
Procedure
1. Using either benzine or solvent, remove the anti-corrosion protection from the shaft ends
and flanges and remove the protective skin provided.
2. Fit the input and output elements onto the shafts and secure them if necessary.
You have now fitted the input or output element.
BA 2019
Installation
3.5 Mounting the motor
CAUTION
If geared motors are inadequately sealed, moisture may find a way in.
If the geared motor is to be installed outside or in an installation requiring a high degree of
protection (≥ IP55),
seal the flange, bolts 505 and any screw plugs 502 or 503 or integrated elements such as
proximity switches, using an appropriate sealing compound.
The flange-mounted motor must be sealed across the entire contact surface.
BA 2019
Installation
3.5.1 Mounting a standard motor on a coupling lantern with a flexible coupling (K2,
K2TC)

Impacts can cause sparks.
Secure the grub screw 564 and bolts 505 with Loctite 243.
Note
Dimension z12 applies for standard assignment of the coupling. If a special assignment is
required, consult the appropriate special dimension drawing.
IEC B5 80 - 315, NEMA TC 56 - 145 NEMA TC 182 - 365
] ]

502 Screw plug

505 Hexagon bolt
555 Coupling half
556 Coupling half
557 Flexible element
564 Grub screw
Figure 3-3 Coupling lantern with flexible coupling
BA 2019
Installation
Procedure
1. Fit the coupling half 556 onto the motor shaft end, see Mounting the input or output
element on the gearbox (Page 18).
2. Maintain the clearance z12.
3. Secure the coupling half 556 with the grub screw 564 to prevent axial movement.
4. On motors balanced with half a featherkey (code "H"), remove projecting, visible parts of
the featherkey.
5. Place the flexible element 557 inside the coupling half 555.
6. Apply adhesive (medium strength, e.g. Loctite 243) to the grub screw 564 and bolts 505.
7. Flange-mount the motor to the coupling lantern and secure it with the bolts 505 using the
specified torque.
You have now mounted the standard motor on the coupling lantern with a flexible coupling.
Table 3- 2 Clearance z12 for K2
IEC B5 80 90 100 112 132 160 180 200 225 250 315
z12 [mm] 15 25 30 30 45 66 59 60 90 75 33
Table 3- 3 Clearance z12 for K2TC
NEMA TC 56C 143TC / 182TC / 213TC / 254TC / 284TC / 324TC / 364TC /

145TC 184TC 215TC 256TC 286TC 326TC 365TC
z12 [mm] 27.5 28 36.5 45.5 50 60.5 71 78
BA 2019
Installation
3.5.2 Mounting a standard motor on a short coupling lantern with a clamp connection
(K4, K5TC)

Impacts can cause sparks.
Secure the grub screw 564, hexagon socket-head screw 561 and bolts 505 with
Loctite 243.
CAUTION
The grub screw 564 must not butt against the hexagon socket-head screw 561 when it is
tightened.
CAUTION
Be careful not to axially distort the motor shaft when flange-mounting the motor.
Keep the motor shaft completely free from grease in the vicinity of the clamping ring.
In the case of brake motors, release the brake before mounting the motor.
CAUTION
The ventilation-side motor bearing can become distorted when pushing the motor onto the
drive shaft of the input unit.
Above size 100, if the motor is mounted in a vertical position the weight of the rotor shaft
prevents the bearing from being distorted.
When mounting the motor in a horizontal position and in a vertical position up to motor
size 90, please observe steps 6 to 8.
Note
The connection between the shafts is rigid and without axial compensation. Therefore we
recommend using motors with a fixed bearing on the drive side for optimum service life.
BA 2019
Installation
D

a Torque wrench
502 Mounting plug
503 Mounting plug
505 Hexagon bolt
515 Drive shaft
560 Clamping ring
561 Hexagon socket-head screw (component of item 560)
563 Featherkey
564 Grub screw
Figure 3-4 Short coupling lantern with clamp connection
Procedure
1. Remove the mounting plugs 502 and 503.
2. Turn the drive shaft 515 and clamping ring 560 of the gearbox to align them with the
mounting holes for the mounting plugs 502 and 503.
3. Apply adhesive (medium strength, e.g. Loctite 243) to the grub screw 564, hexagon
socket-head screw 561 and bolts 505.
4. Secure the clamping ring 560.
5. Flange-mount the motor to the short coupling lantern and secure it with the bolts 505
using the specified torque.
6. Remove the fan cover.
BA 2019
Installation
7. Release the tension on the bearing by lightly pressing ① your hand on the end of the
shaft.

Figure 3-5 Pressure on motor shaft
8. Mount the fan cover.

9. Screw the grub screw 564 to the featherkey 563 until a slight resistance is felt, then turn
the grub screw 564 half a turn back.
10.Insert the socket wrench into the grub screw 564 through the hole for the mounting
plugs 503. This prevents the shaft from twisting.
11.Tighten the hexagon socket-head screw 561 with torque TA SW2 and width across
flats SW2.
12.Tighten the grub screw 564 with torque TA SW1 and width across flats SW1.
13.Seal the mounting holes with the mounting plugs 502 and 503.
You have now mounted the standard motor on the short coupling lantern with a clamp
connection.
Table 3- 4 Torque and width across flats for K4
IEC B5 63 71 80 90 100 112 132 160 180 200 225 250 280
TA SW1 [Nm] 1.3 1.3 1.3 2.9 2.9 2.9 5.8 9.9 9.9 9.9 9.9 9.9 48
SW1 [mm] 2 2 2 3 3 3 4 5 5 5 5 5 8
TA SW2 [Nm] 15 15 15 35 35 35 70 120 120 295 295 295 580
SW2 [mm] 5 5 5 6 6 6 8 10 10 14 14 14 17
Table 3- 5 Torque and width across flats for K5TC
NEMA TC 56C 143TC / 145TC 182TC / 184TC 213TC / 215TC

TA SW1 [Nm] 1.3 2.9 2.9 5.8
SW1 [mm] 2 3 3 4
TA SW2 [Nm] 15 15 35 70
SW2 [mm] 5 5 6 8
BA 2019
Installation
3.5.3 Mounting a servomotor on lanterns with a zero-backlash coupling (KQ, KQS)
Note
Dimension z12 applies for standard assignment of the coupling. If a special assignment is
required, consult the appropriate special dimension drawing.
Mounting version KQ - for motor shaft with featherkey

]
505 Hexagon bolt

555 Coupling half
556 Coupling half
564 Grub screw
Figure 3-6 Lantern for servomotor KQ
Procedure
3. Secure the coupling half 556 with the grub screw 564 to prevent axial movement.
4. On motors balanced with half a featherkey (code "H"), remove projecting, visible parts of
the featherkey.
6. Flange-mount the motor to the servomotor lantern and secure it with the bolts 505 using
the specified torque.
You have now mounted the servomotor on the KQ lantern with a zero-backlash coupling.
BA 2019
Installation
Mounting version KQS - for motor shafts without featherkey
CAUTION
Any impurities in the vicinity of the shaft / hub connection will have a detrimental effect on
the torque transmission.
Keep the drill hole and motor shaft completely free from grease.
Do not use soiled cleaning cloths or contaminated solvents.
Sizes 71 to 112 Size 132

] ]
505 Hexagon bolt

555 Coupling half
556 Coupling half
1 Bolt
Figure 3-7 Lantern for servomotor KQS
BA 2019
Installation
Procedure
1. Loosen the bolt 1 slightly.
4. KQS 71 - 112:
Tighten bolt 1 with the specified torque.
KQS 132:
Tighten the bolt 1* evenly and gradually in a crossways pattern. Repeat the procedure
until the specified to torque has been reached.
6. Flange-mount the motor to the servomotor lantern and secure it with the bolts 505 using
the specified torque.
You have now mounted the servomotor on the KQS lantern with a zero-backlash coupling.
Table 3- 6 Clearance z12 for KQ / KQS
Sizes z12 Sizes z12

[mm] [mm]
71.1 34.5 90.4/5 61
71.2/3 41.5 112.1/2 62.5
80.1/2 39 112.3 77.5
80.3/4 54 132.1/2 76
90.1/2/3 50 132.3 96
BA 2019
Installation
3.6 Adjusting the height of the piggy back
3.6.1 General information on adjusting the piggy back

The piggyback version is supplied without belt, belt pulley or guard.
Friction linings or impact can cause sparks.
A safety system must be used to ensure that
• the belt cannot slip and cause a spark
• no foreign bodies can enter the vicinity of the belt drive.
DANGER
Rotating drive parts
Always attach appropriate guards to cover the belt drive, chain drive or other open drive
components.
CAUTION
Incorrect belt tension can cause the belt to break and damage the bearings.
Refer to the operating instructions for V belt drives.
Fit the belt pulley onto the drive shaft 515 as described in "Mounting the input or output
element on the gear shaft".
CAUTION
After mounting or adjusting the piggy back protect unpainted areas against corrosion.
Use a suitable, long-lasting anti-corrosion agent.
The piggy back holds a conventional IEC motor, which is primarily used for driving a V belt
drive. Install the motor in accordance with the manufacturer's operating instructions.
For other drive types, such as chain drives, please refer to the corresponding operating
instructions or manufacturer's information.
BA 2019
Installation
3.6.2 Piggy back for IEC motor up to size 112

515 Drive shaft
585 Bolt
588 Bolt
590 Motor plate
Figure 3-8 Piggy back for IEC motor up to size 112
Procedure
1. Loosen the bolts 585.
2. Adjust the height of the motor plate 590 by evenly turning the bolt 588.
3. After setting the correct height, tighten the bolts 585 using the specified torque.
You have now mounted the piggy back for IEC motors up to size 112.
BA 2019
Installation
3.6.3 Piggy back for IEC motor sizes 132 to 200
DANGER
The piggy back can slip out of the support.
Do not move to a downward facing mounting position.

515 Drive shaft

585 Grub screw
586 Column
588 Bolt
589 Hexagon nut
590 Motor plate
Figure 3-9 Piggy back for IEC motor sizes 132 to 200
Procedure
1. Loosen the grub screws 585.
3. After setting the correct height, tighten the grub screws 585.
You have now mounted the piggy back for IEC motors sizes 132 to 200.
BA 2019
Installation
3.6.4 Piggy back for IEC motor size 225 and above
CAUTION
When tightening the hexagon nuts 592, do not distort or force the motor plate 590 into a
different position.

515 Drive shaft

585 Grub screw
586 Column
588 Bolt
589 Hexagon nut
590 Motor plate
592 Hexagon nut
Figure 3-10 Piggy back for IEC motor size 225 and above
Procedure
1. Loosen the grub screws 585.
2. Loosen the hexagon nuts 592 on the support.
4. After setting the correct height, tighten the grub screws 585.
5. Tighten the hexagon nuts 592 on the support.
You have now mounted the piggy back for IEC motors size 225 and above.
BA 2019
Operation 4
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.
Changes are an indication of possible incipient damage.
CAUTION
In the event of changes during operation, the drive unit must be switched off immediately.
Use the fault table in the section titled "Faults, causes, and remedies" to determine the
cause of the fault.
Remedy faults or have faults remedied.
CAUTION
damage bearings.
Check the gearbox during operation for:

● Excessive operating temperature
● Changes in gear noise
● Possible oil leakage at the housing and shaft seals.
BA 2019
Operation
BA 2019

All measures, checks, and their results must be documented by the operator and
records kept in a safe place.
WARNING
CAUTION
Service and maintenance must only be carried out by properly trained and authorized
personnel. Only genuine parts supplied by Siemens Geared Motors GmbH can be used for
servicing and maintenance.
All inspection, maintenance, and repair work must be carried out with care by trained
personnel only. Observe the information in Section General information and safety notes
(Page 7).
BA 2019
5.2 Regreasing the roller bearing
5.2 Regreasing the roller bearing
CAUTION
When regreasing, do not mix greases of different soap bases!
Drive units of motor size 160 and above need to be regreased for K2, A and P and drive
units of motor size 225 and above need to be regreased for K4. Regrease at least every
12 months or every 4,000 operating hours.
The bearings are supplied greased.
The standard lubricating grease used is a mineral-oil-based lithium-saponified grease of
NLGI class 3/2.
Figure 5-1 Grease nipple
Using a grease gun, inject the grease into the bearing point via the lubricating nipples
provided. Inject 50 g grease per lubricating point, unless otherwise specified in the vicinity of
the lubricating point.
BA 2019
6.1 Stocking of spare parts
By stocking the most important spare and wearing parts on site, you can ensure that the
gearbox or geared motor is ready for use at any time.
CAUTION
Please note that spare parts and accessories not supplied by us have not been tested or
approved by us.
The installation and / or use of such products can therefore have a negative impact on the
design characteristics of the geared motor and might consequently impair the active
and / or passive safety features of the machine.
Siemens Geared Motors GmbH will accept no liability or warranty whatsoever for damage
occurring as a result of the use of non-original spare parts or accessories.
GmbH.
Please note that single components often have special production and supply specifications.
We always supply spare parts which meet state-of-the-art technical standards and comply
with the latest legal requirements.
Please state the following data when ordering spare parts:
● Serial no. see rating plate ⑤
● Type designation see rating plate ③
● Part no. (3-digit item no. from spare parts list, 6-digit code no. or 7-digit article no.)
● Quantity
SIEMENS IEC60034
SIEMENS 1 2
KAF108-LA160L4-L150/100GH 3
IP55 (IM) H-01-A 7 8
G. 6.2L OIL CLP PG VG220 i=12.9 9 10 11 12
50Hz 113/min 60Hz 136/min 13 14 17 18
1266Nm fB=1.5 1264Nm fB=1.5 15 16 19 20
50Hz 400/690V D/Y 60Hz 460V Y 27 28 29 35 36 37
29/16.74A cosPhi 0.84 28.6A cosPhi 0.87 30 31 38 39
15kW IE1-90% 1460/min 15kW 1755/min 32 33 34 40 41 42
For motors of series 1LA/1LG with their own rating plate, the spare parts documentation in
the original operating instructions applies.
BA 2019
6.2.1 Input units A, A5

E

D

BA 2019
a with backstop
b without backstop
210 Bolt
225 Gasket
501 Cover
510 Tapered grease nipple
515 Drive shaft
520 Cylindrical-roller bearing
521 Locking ring
522 Locking ring
523 Sealing disk
524 Supporting disk
528 Oil splasher
529 O-ring
530 Deep-groove ball bearing / cylindrical-roller bearing
531 Locking ring
532 Locking ring
533 Deep-groove ball bearing
536 Ring for shaft sealing ring
537 O-ring
540 Backstop
541 Featherkey
542 Supporting disk
561 Featherkey
Figure 6-2 Input units A, A5
BA 2019
6.2.2 Input units K2, K2TC

D

E

BA 2019

D

E

BA 2019
Spare parts list for input units K2, K2TC
a with backstop
b without backstop
100 Featherkey
210 Bolt
225 Gasket
501 Lantern
502 Plug
503 Plug
505 Bolt
506 Locking ring
511 Grub screw
515 Drive shaft
520 Cylindrical-roller bearing
522 Locking ring
523 Sealing disk
524 Supporting disk / socket
528 Oil splasher
529 O-ring
531 Locking ring
532 Locking ring
533 Four-point bearing
534 Socket
540 Backstop
541 Featherkey
542 Supporting disk
543 Shim
544 Socket
555 Coupling part 2
556 Coupling part 1
557 Gear ring
560 Coupling
561 Featherkey
564 Set screw
570 Proximity switch
BA 2019
6.2.3 Input units K4, K5TC

BA 2019
435 Stud bolt

436 Locking ring
437 Hexagon nut
501 Lantern
502 Plug
504 Cover
505 Bolt
506 Locking ring
508 Bolt
511 Grub screw
515 Drive shaft
521 Locking ring
522 Locking ring
526 Locking ring
528 Oil splasher
529 O-ring
532 Shim
560 Clamping ring
561 Bolt (component of Item 560)
564 Locking screw
Figure 6-3 Input units K4, K5TC
BA 2019
6.2.4 Input units KQ, KQS
Sizes 71 – 112 Size 132

.4 .4
.46 .46

501 Lantern
505 Bolt
506 Locking ring
515 Drive shaft
528 Oil splasher
531 Locking ring
555 Coupling part 2
556 Coupling part 1
557 Gear ring
560 Coupling
564 Set screw
Figure 6-4 Input units KQ, KQS
BA 2019
6.2.5 Input unit P

Figure 6-5 Input unit P for IEC motor up to size 112

Figure 6-6 Input unit P for IEC motor up to sizes 132 to 280 on helical gearbox
BA 2019

)'= .

)'=
+
Figure 6-7 Input unit P for IEC motor up to sizes 132 to 280 on parallel shaft gearbox and bevel
helical gearbox
Spare parts list for input unit P
581 Intermediate cover

582 Disk
583 Bolt
585 Grub screw / bolt
586 Column
588 Bolt
589 Nut
590 Piggy back plate
591 Threaded rod
592 Nut
593 Disk
594 Bracket
595 Nut
596 Bolt
597 Disk
598 Belt guard
599 Bolt
BA 2019
BA 2019
Further information
MOTOX geared motors on the Internet:
www.siemens.com/gearedmotors
Siemens AG Subject to change

Industry Sector
Postfach 48 48 © Siemens AG 2010
90026 NÜRNBERG
GERMANY
www.siemens.com/automation
EKATO ROhr- und Mischtechnik GmbH EI<ATO R T
LANXESS Butyl Pte. ltd
FW REVISION
DATE
COMMENT STATUS CODE

Best. - N r.: 31 0238840 1· Rejected for reasons stile. Change the dlawingidocument and ~~Sue forccmmeniiO FW
2-lncorporate comments indicaled and re-ISSue drawing/document for convnents to FW •
3· Acceptab~ • Incorporate (mrno~ comments indicated ancl re-iSsue d!IWinglcloo.imellt.as final cenifiad.
Order no.: 4- No commerrts. aca!pted as linal <:ertified.
5· Re<:eive<i for informalion only.
Projekt: BTR Singapore Agitators (Finishing)

Project:
Pos.: 70RW400- Agitator Fines Recovery Tank

Item:
EKATO Auftrags- Nr.: 80053-40

EKA TO serial no.:
Fertigungs- Dossier I
Manufacturing Data Book
EKATO ROhr- und Mischtechnik GmbH, 79650 Schopfheim

EI<ATO RMT
LANXESS Butyl Pte. Ltd
Best. - Nr.: 310238840

Order no.:
Projekt: BTR Singapore Agitators (Finishing)

Project:
Pos.: 70RW400- Agitator Fines Recovery Tank

Item:
EKATO Auftrags- Nr.: 80053-40

EKATO serial no. :
Fertigungs - Dossier I
Manufacturing Data Book
EKATO Ruhr- und Mischtechnik GmbH, 79650 Schopfheim
TUV SUD Chemie Servica Gmbl:l
G)
9'Witnes~ew
Hoppa
T()v.c~rt: 07 ·502·1 osso
EI<ATO RMT
lnhaltsverzeichnis
List of Contents
1. QS - Plan I QA- Plan

\. 2. Materialzeugnisse I Material Certificates
3. FertigungsOberwachung I Manufacturing Test Reports (NDE Reports)
4. TOV Zertifikate Montageflansch I TOV Certificates Mounting Flange
5. EKATO Probelauf Protokolll EKATO Test Run Certificate
6. Komponenten Dokumentation I Documentation of Components
7. Sonstige Zertifikate I Miscellaneous Certificates

EI<ATO RMT
lnhaltsverzeichnis
List of Contents
1. QS- Plan I QA- Plan
2. Materialzeugnisse I Material Certificates
3. Fertigungsuberwachung I Manufacturing Test Reports (NDE Reports)
EKA TO ROhr- und Mischtechnik GmbH, 79650 Schopfheim

QS-PLAN I QA-PLAN EKATOI
App.-Nr: I Serial-No: 80053 Kunde/Customer: LANXESS Bu!XI Pte. Ltd Erstellt von /Prepared by: PB Seite/page 1 von/of 1
Posltlons~r.ntem~No.: 10; 20; 30; 40; 50; 60 ProjektJProject: BTR Singapore Agitators (Finishing) Freigabe durchl Released by: KTH
Be& teii.-NrJOrder-No.: 310238840 Datum I Date: 02.02.2011
Rev. Oatuml O~te Name/Name Modifikation I Anderung folgender Zeilen
c cQ
BESCHREIBUNG
d
;;
-'
Basis
. Ookument PrOfungiTeilnehmer
j Ooc:ument Te-sts/Participants ! .,;

:;; 01 12.05.2011 PB
t7: Ultlasonic cheeks of welding nemt on agitat« shafts; 20: TW onty for item 81RW700:
31 : Aeeeptatlce Test at EKATO workshop. ecading to EKATO inspection and test proe. v.itnessed (hold point)
0
:~ ~
~ ~
·- · Sault:!ill Arbeltsgang
DESCRIPTION
Componont/Procedure
~0 ·~•
0:
~6 An~:l
Qty. s ~·l~l';llJ ~ ~
3,)
i "' .
0
02
03
10.09.2011
26.09.2011
PB
PB
29: Gear teeth contaet test (item 3.4. 14.1 o or OO/M.021At0060) Is not included in manufacturec's standard tnt procedure
3S: Cleanino and oalntlno oroeecrure eeeordina to EKATO standard oroeedure
20; Mounlin nan e of item 81RW700 without eheelt b Garman ins eetion authoritlesTW
I AYstegungl Design U=Haken ; I:~Pu n l<t 04
2 Verfahrenstechnik/Mixing Oaslgn ./ 10088509 05
3 Getriebe/Gearbox ./ 10066417
~
v 06
1- 4 Lagedebensdauer/Bearing life Time ./ 10088511 v 07
5 Welle u. Oraano/Shafl and lmoeUers ./ 10088511 v
6 Kri1isehe Orehzahi/Crilleal Speed ./ 1008851 1
I~ Bemerkungen/ Remarks
7 Belastung auf ROhrwerksaunag& I
Loads on Agitator Support ./ 10068397 v
8 Montagenansch!MounUng Flange
9
./ 10068400 1<A
- - r-
10 FertlgungsOberwachung/Production Supervision
11 Ma.Bkontrolle Fertigung IOimen-sional Check ./ 10068399
~ '
1-
t2 Mallbescheinigung PfOffeld /Dimensional Certificete • 10068399 p
~ • ~ E MOE Kontrone der Hauplabmessungen mil Prolokol bei Endabnahme I Cheek or main dimen$ions at flnalln$pection induding verification of Cl"itieal 1olefanee.-s
13 PT-PNfungfOye Penetration Test • 10047005 p 2 • ~ J E MOE 10%aller Schweissnahte an den produktberOhrten Teilen 1 109~ of all welding seems on product wetted pam
~
~
§
14 Sch'WeillOberwachungl Welding Supervision
1S 'A'uehtgUtefBalancing
16 Speklralanalysel
•
./ ASV
10068392
10065648
1-
p 2 . I ~: E MOE Slalisches VIAJchten der ROhrorgane naeh ISO 1940 040 I static balland ng of Impellers ace to DIN ISO 1940 G•o
/ ~
10029!14
~ Spectrum Analysis p
-
j - 17 UJtrasehaltprOfungl Ultrasonic Check
• ~ 2 • II Trn:: l E MOE SehwtJunlhte on Rotvwenen und Lo ge~llen, mil Protokol I Welding seems on Agitator Shafts and bearing shorts '<'.4th PfOtoeol
muss mr aile WeDen bel ATEX· ROhnote~ktn durchger\lhrt \verden (Zonenunabhangi.g)l has to be done for all shafts of ATEX· agitators (independant of the zone)
--• ' --..

p
18 Ultroschollpr!lfungATEX I Ultrasonic Checl< ATEX
19 MaterialzertirlkaU Material Certiricate5
"'
~
i
20 MontageplaUe/Mounl.ing PlateJMounting Flange
2 1 Wellenabdichtung/Shaft Seal
22 Welle u. OrganeiShaH and lmp&llers
• 10068766
./ 10068766
• 10068766
'P 2
'zE
p 2 •
I~
~
1R-
~
"J
E
E
MOe For Items 70RWt00, 70RW201, 70RW202, 70RW400, 76RVY900, 81RW700: EN 10204 -3.1
NIA
MOE EN 10204 -3.1
23 ABV/ Shaft Suspension ./ 10068766 p ~,.,
.,/ 10068766 p
24 Produktberiihr!e Schraubenl Product Welled Bolting ...l
25 Wellenfangring/ Shaft OeOectlonLimiting Ring • 10068766 p 2 • -'R'- ''"'. E MOE EN 10204 -3.1
26 ~
27 Abnahme und Tests/Acceptan ce and Tests
- 7.. ...... ;c- - --
28 Motor • 10068396 z. 2 • .....¥; ;..1:1 u MOE Probelauf mit ProtokoQ {Typ T est) nach Std. des lleferanten I Teat run v.\lh (Typ T&$1) protoeol according to lhe standard of sub-supplier.
MOE ~~!""it Protokon nach Std. des Lieferanten I Test run Wlh ptotocol&eeording to the standard of suJ)..supphr. Gear teeth contact test according item 3.4.1 •. 10 of001M.0211V0060 not
1-
29 Getriebe/Gearbox • 10068396
~. 2
• :;_!( / u
I .
,-
30 Oichtung/Shaft Seal .,/ 10068396 ZE NIA
- Gem liB EKATO standard lnspcktlon,... und Testablauf, (siehe Ookumentenriste) 1 A~ording to EKATO standard Inspection Md Tnt Procedure {ref. to doeumentlit1)
rw:
~-
p
(
31 ROhrwerk/Agilalor • 10068395 2 E MOE ROhrwerke 70RWtOO. ?ORW201, 70RW202 Obcrscl\relten die Kt~pazjt&tsgren~en des EKATO PrOfstands.l Agitators 70 RWIOO, 70 RW201, 70 RW202 are exceeding the eap.acity of the
~ ~ EKATO teit eguiement. Oe$halb nur ROBT Ku!:!frobelauf in Luft.l Theref01e Short t~netional test, runnr.; In air of at tator ck-iving head onll·
32
l 33 OberfUichenprUfungiSurfaee examination
34 ./ 10068393 p According to EKATO Standard
- Produktber. Teile/ Product Welled Parts
- -- ,_ - - - --
I
t
35
37
38
• Aullenlieg&nde TeilefExtemal Parts
36 Prufung/Check
- Verpacl<ung/Pacl<ing
• Gerluseh/Noise
./ 10068393
./ 10069325
• 10068160
p
p
p
-
-
-
..
-
~
R' "'j(
According to EKATO Standard. Rer. To EKATO peintlng procedure doe. number tOi2·1 o..so {C30001·EKT01PRC-OOS)
According to EKATO Slandard

MOE GemllB EKATOstandard '"factory Acceptance Tell'"'/ Aceording to EKATO $lDndard "factory Aeeeptance Te.st·
i 2
tR:: SJ
E
ROhrwerke 70RW100, 70RW2:01 , 70RW202 Oberschrelten die KapazjtAlsgrenzen des EKATO PrO !stands. I Agitators 70 RWI 00, 70 RW201, 70 RW202 ate exceeding the capacity of the
§
39 -Vibration
• p 2 E MOE EKATO test equipme.nt. Oeshalb nur ROBT Kurz robelaul ln luft. / Therefore $hOI1 functional test, running in air of aai1ntor driving head ool .
- 40 r"-
.,/ V.~UOO.~Gtf
- -- According 10 EKATO Standard
41 Kennzeichnung derTeileiMarklng of parts p
Wi1004713.5
1•• W: T••n•i'lrntfW.,n"S (hOtcl poent) 2.) ~ . EK.ATO. Standard 3.) S= Spraehe/ Language d• deutsch: e• engllsch 6,t V• Venri•bl Sa!•• O•l).trtnw~nt
SWz Slichprobl/ Spot ~tn•••
R• PrOfung/ Gttnthmigung (OolWmt~~ta); fe ...!ew/acec~pl.ane• ~cklcurnont)
• • Kundenzusat:lfordttrung I Addf1ional Customer R equirements; 4.) E• EKATO
Oolt.urnt:ntation in PAD/ Documents included in Test and FineI
C• Kundel Cu1tomer
A c AbnahmebtthOrdel Accepll•nce Authority
:.;:.;!',:n'~o~~ti-1• Oe~ ./
, ~
Documentation U • Untefliefl!ranV SubsuppJier ZE• Z•ntt•lei
= • '
1e S~ f!1bHf,.--
Gt
MDB•Moout ' ' - •
)
;;...; ~~ ~
c:.- _.,-q[jv.r6'~osso
EKATO RUhr- und Mischtechnik GmbH
EI<ATO RMT
lnhaltsverzeichnis
List of Contents
1. QS - Plan I QA- Plan

~ 2. Materialzeugnisse I Material Certificates
3. FertigungsUberwachung I Manufacturing Test Reports (NDE Reports)
5. EKATO Probeiauf Protokoll I EKATO Test Run Certificate

Aultrag: 21i281 Komm.schein: 839722 KIB1denr.1 .1292 Jhre Ref.: 411_140472111052011 / .,10
~·GEI<::J~~
SID EN OR
-
ABNAHMEPRUFZEUGNIS
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·Dill 17••o - : o!l.1.996 ; EN l.027S - 01.10.1.!199 .· ; ASIM M7!1-A479M ·- 2008.
DCE MR0103-2005 ·- 2005 ; 1\SME SAJBB-S7.388M ; 2001 : EN 10228- -\:99 - 01.08.1999
s:IDENOR .si:n-EU.OS 0 :n.03.2005 t Jio 2000-MER!BLATT W2 . - 07.2006
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EN 10204 :2004 OCT. 2004 3.1
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VERAHTWO!to:rr.ICH!J\ 1 ALBE:RTO COBERO ZABALA IIRTERSCII!ll:ET:.
~:18 .04 .20~1. sei.t:e ~ von 2
s
80053-40 Lagerwelle I bearing shaft

AUfbag: 21Zz81 Komm.scheln: 839722 Kundenr:·11292 lhre Ref.: 411140472111052011
' ~<5~~fU . ~N~PRUFZE~GNIS . ®§1

Bas~ Standort tso !001 - moirs UH!I Produkt hergestellt in Sp~
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AuKrag:.2122B1 . Komm.schein: 839722 Kundenr. 11292 lhre Ref.: 411140472111052011
•
MILL TEST CERTIFICATE
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CUSTOMER: DAHS'1'ADL GIIBK WORKS RBFBlml!TCE:l.487478
REFEREI.VCE: 331. 8J.ct SALES ORDER:230553-77 ~ NOMBER:99550
PRODUCT NR.:29317 .. MASTER RUERENCB:141080 ROLLBD:09.03.201L
RBQUZRBD PJIOD'DC'l.' · . . ..
1.45-niJIL!IX 315·'!';1. 110U8D B1U1S 'tOIIN1!:D SOr.D'l'.ICI!I Al!liiE:ALING .55 +0/+0,46 ""'· ISO.~U
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DIU 17440 • .09.1.!196 1 Bill 10278 - 01.10.1!199 ; AS'll'l M79-M7.9H - 2008
IIIICK MROlOl-2005 • 20~5 : ASMK SIU88-SA38BM·· 2001 .: Bill 10228-4:99 • 01.08.1999
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BHCE KR0175/ISD lS156-]:Z003/00R.1:2005 l"BDICION 15.12.2003
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~0053-40 Lagerwelle I bearing shaft

AuHrag: 212281 Komm.schein: 839722 Kuridenr: 11292 lhre Ref.: 411140472/11052011
•
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Basauti Pl.'llllt
MILL TBST CERTIFICATE
:mo 91101 - . DIO/'I:S 1115U
CI:JSTOMlm: D.UrSDBL GIIIBB WORKS RBJ!'BRENCE:1487478

REPEREWCE:331.810 SALES ORDER:230553-77 HEAr 111DMBER:99550
.P.!WDUC'l' .NR: 2.9317 MASTER REFBRENCE: 141080 RoLLED:a9~03.2011
l"t&t:e:ml1 clehct:a at-a.u:«(ll (STAHL EISEIJ SEP1921-01.12 .191141

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SMST Deutschland GmbH (A01)
~ -~'.S-ALZGfTT~ : Poslfach 16 01 20 • D-42830 Remscheid· DEUTSCHLAND
, ..~, Jj MANJ\JESMANN.
\WIW.cm&t-tubes.com Page/Selte
..# STAINLESS :TusES
INSPECTION CERllRCATE
Abnahmoprilfzougnis 1/4
No/Nr/W (AD3)
Cortlficat de reception
237371-005332 EN 102().4: 2004 TYPE 3.1 (A02)
Cusiomor order noJKunde Auftragsnr./N° Commando eli om (A07)
ThyssenKrupp MetaiServ GmbH s iJM-5401985530

VVESTFALJASTR . 185 SMST·Tubes ardor n o/AuftTagsnrJN• Commando (AOB)
44147 DORTMUND 0000237371
Deutschland SMST-Tubos Item Part numbor/Tellenummer/N• d'artlcle (A09)

Purchaser/BestelleriAcheteur 0000237371-DOOOOS HL457106000400
Product Oescrlptlon/Produkt 8eschrelbung1Descrlptlon du produh (801) (802) (804)

Seamles.s Stainless Steel Hot Anlshed Tubes ?no_ heat_treatment_type? Free From Scale Plain Ends Square Cut Deburred
Warmgefertlgte, nahdose Edelstahlrohre ?no.)leat.treatment_type? En12Undert Enden Glatt Abgeschnilten
Tubi:S en Acler In ax Sans Soudure Anls il Chaud 7no_heaUneatment_type7 Sans oxydalion Coupes d'equerne, lisses. ebavurt:
""--I nl"'....._ifi II A312M CHEMISTRYMECH TEST 09/CTS 06010 HB Tl/ EN 10088-1 2006/EN 10216-5 09.200. AC:2008
Spe cfficalion siSpe2u""'t one ....,...'"" CD ons TC1 I EN 10297·2 2005
Gradei'Nsrl<stoff/Nuance 1.4571/ TP 316TI
Tolerances/To!eranzen/Tol6rance& STD OD-0+2•.4_1D+o-2%_MIN 1MM
~.ARKING:
DMV-0 -1.4571 . TP 316TI -HEAT ·60140- E N 10216-&-TC1 -ASTM A 312M· 237371/5 ·SML-LOT NO.- HFD- GERMANY - WA
Quantlty/Menge/Quantlte Dimensions Abmessungen

Heat no Quafrtylot Pieces Total weight Total length Tube length
SMST
Sctvnelze Nr. Oualltatslos Stock Gesamtgevncht Gesamtlange OD WT Rohriange
Item
N"deCoulee Lotque.Dte Pieces Masse tot ale Longueur tatale Longueur tube
(808) (813) (809) (610) min (611) max
070100 QL20002074 000005 12 622 kg 47.95 m 60.00 mm 10.00 mm 3000 mm 6400 mm
1371 Lbs 157.32 Ft 2.362" 0.394. 9.&4 Ft 21.00 Ft
Chemical Analysis I Chemlsche Zusammensetzung I Analyse chimique (C71 • C92)

Heat no/Schmelzen Nr./N• de coulee 070100
Melting Prousl;/Emdunetzungsart!Baboration {C70) E + ADD
Country of origin I Herstel!ungsland/Pays d'origlne Italy
Heat Analysis I Analyse de coulee
c Sl Mn p s cr NJ Mo N Oo Tl
Min 0.00 0.00 o.oo o.oo 0.00 16.50 10.50 2.00 0.00 0.00 ;o c·s•(t
Max 0.080 0.75 2.00 O.Q.oiO 0.0150 18.0 13.50 2.50 0.10 99.00 0.70
0.0« 0,4ll 1,59 0,022 0,009 16,75 11,83 2,06 0,019 0,07 0,36
This cetll!lcato ll bauod by • cornputorlzad eylllom and Ia vlllld Oloact Z~ 112\11. Clau Bllldlablili'-"G •Mdo mll H!.'lo d4r EOV Co celllllcal olllnldlga Ara!do d"un 1111!t<mW ~ada domees
"""lh<M ~~~~ L1 case Oto o..nor ofU10 orl¢nal~ rchaso e -ell undiSid• >eU.dendlrittg<llig. VentndOIUlgeUSOMo ot est applia:hlo "''" 6ignabft. TOUI dutJg-( ou oPI'ka~on pour
CCI1'/ rJ h he II'IUII lltaSI ftl..nomtlly- WI be 1111pc:nalblo lor Vorwonctung lllr andoro E.....uo ·~all d"auiiBS piDdiJ!Is &on>rll CDnaldtirea comma IIIWft:alion do dOQJIII..U
"''"' 111laotA~ or no1 ~uso. Jvrt ah.,auons ,.-h!hifiQ!IIon wiD l/J1<ultdenfS!sdlll!lg wtd 8oWg $crolredodi<lt v.rfdgl. ol lraud• c:1 '"''"'' s.(ot61ofurldtdiol\p:.uf::.
be SIJ!ljoct"' law.
Salzgltter Mannesmann Stolnless T ubes Deutsehland GmbH • ISO 9001 • LRQA Nr. 923284
80053-40 ROhrwelle I agitator shaft_0003

# SALZGITTER SMST Doutschland GmbH (A01)
I ~ ~ MANNESMANN Postfach 16 01 20- D-42830 Remscheid- DEUTSCHLAND

Page/SeHe
=!' STAINLESS TUBES www•.smst4ubes,com
INSPECTION CERTlACATE 214
Abnahmepriifzeugnls
No/NrJN• (A03)
Certlflcat de reception
237371-005332 EN 10204: 2004 TYPE 3.1 (A02)
Mechanical testing
Quality Lot: QL20002074
Tensile test at room tempera!Ure/Zugversuch bel RaumtemperaturlEssa! do traction ato111>orature amblante (C10)
ASTM A 370 EN 10002-1
Test no Direction Tensile strength
Proben Nr. Probenrlcht Yield strength/Dehngrenzen...Jmije I Zugfestlgl<e~ I Reduction
Elongation/Bruchdehnungli\llongenlerd
N• ung d'lllastidtll Rl!slstance 4 Ia of area Z%
d'ochantil/on DlrectiDil traction
(COO) (C02) (C11) (C12) (C 13)
0.2% 0.5 'Yo f% 2" 50mm 50 5,65 ../so 40

MPa I MPa MPa % % I % I I
Min 205 I 225 515 I 35 I 35 I I
I Max I I I 690 I I I I I I
20004819 lOHGITUDIHAI. 241 I 2n 557 50,0 52.40 I 54.00 I I
Hardness testiHdrteprtlfung/Essal de durete (C30)

NACE MR0175
load I
Test no
Proben Nr.
N• HB HRC HV HRB HR 15-T HR 30-T
d'echanbll
on
Min I I I I I I I I I I I I I I I I I I
Max I I I I I I I I I I I I I I I I I I
min max avg min max avg min max 8V!J min max avg min max avg min max avg
20004819 I I I 10,0 10,0 10,00 I I I 75,0 7.of,O 7.of.50 I I I I I I
Ring expanding testiRingaufdomversuch/Essai d'expansion sur anneau (CSS)

EN 10236
Other testing
Quality Lot : QL20002074
Thla ...UIIca!Dialaaue<l bra compu101tlad 1181""' and lalllllld Ol...,ot Zeugnls llrolt. Dlase Bascl!Dinl~g W\JTdontQ Hilled or EDV Cft c:et11ftea1 cal~ 6 f alde d\mtrallentanl aadranlquedo domlios
""f'YdilllemusiG!IoSI IIS =nlctmlty and VIii bo responsilolo for

enyU11HN! ar~dlcmeduso. Al!yallenlllco•s., foklllce:lconril
v...,endung lllr.,.,..
wilhciJUignaluro.t>..,.elho-oiUte orig!ndwllldd n:loa$ea etSidll undlstohnal.hler>cflriRg!llig, Von11ndDftD1111lf1&CMio
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et astGjlll(ic:allbsaru signallft. Taulc;Nnvemonl aut>pf)tiall>anpour
d'oW:sptoiUIS • •mn1Consid61'6s commoll!sificeliondodoc:unanu
d lrwude o1 5Cilll1ls<.jel41aj\.rfciaion p&.alc.
beu.t.jocUolaw.
Salzgltter Mennosmann Stalnloss Tubos Deutschland GmbH -ISO 9001 - LRQA Nr. 9232.84
80053-40 Ruhrwelle I agitator shaft_0003

SMST Deulschland GmbH (A01)
,., SALZGITTER
I ~§I MANNESMANN Postfach 16 01 20 • D-42830 Remsclleld - DEUTSCHLAND
~ STAINLESS TUBES WIWt.sm&l-lubes.com

INSPECTION CERTIRCATE
Abnahmepriifzeugnis
No/NrJN• (AD3) Certlfical de reception
237371-005332 EN 10204: 2004 TYPE 3.1 (AOZ)
Jntargranular conusian test/Priifung lnterlafstalllnen Korroslon/Essal de corrosion lntergranulalre

ASTM A 282 PRACTICE E EN ISO 3651·2 PRACTICE A
~·
'lb!aCIIIIIIlcabolslalwed by a compulllll%lld ayatem end Ia llil!ld Dlaaet Zllugnls IDw.ll!eae BIISChelnlgung wunlamllle'aderEOV Ca celtlfk:alestllldigiAralde d'lln trallamlllll oilec:lranlquadad011116sa
llrilhoul6ignaluls. fncaseiiiD-afiiiD origlnlllwlll4dRI!ease a ersld!UIIdi&tahnel..!nknehrift-g. VIIO'Inii"""'B'ft&ewla et..st~lllln5 signalllll:. TGUichangllllllntou~on-
CGpJditlut -lllleSIIIs canfllllllilyandvril liD nospansllile rar V-endung IDranclere E121wgrisreWIIl1lenels d'Bulm JIRICIUils st:IDIItccnsldl!nls comlllolalllllcatiGn dodDc:umiii!IS
anywlswfularneullcoraclllSa.Anyallcrall-«falsllleallonwil Ulkundlll1!lllselwngulldlleavg&llll!n:dUIICII1110tfclgt. ollnludooi&.,.,US1.4ollllafUIIdltllonpOnale.
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Salzgltter Mannesmann Stalnlass Tubes Deutaahland GmbH -ISO 9001 - LRQA Nr. 923284

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f"~
SMST Deutschland GmbH (A01)
SALZGITTEFl
~ 1:JJ MANNESMANN Postfach 16 01 20- 0-42830 Remscheid- DEUTSCHLAND
~ ST:'AINLESS TUBES Y.w.N.smst.wbes.com
INSPECTION CERTIACATE
Abn~ep~ougms
NoiNr/N" CA03)
Coltific81 de reception
237371-005332 EN 10204: 2004 TYPE 3.1 (AOZ)
Other Tests and Declarations I Andere Pri.lfungen und Priiffoststellungen I Autros tests et d6claratlons
VISUAL AND DIMENSIONAl INSPECTION: SATISFACTORY I BESfCHTIGUNG UNO MASSKONTROLLE: BESTANOEN

MATERJAI.JOENTlFICATlON TEST OF ALL TUBES BY SPECTROGRAPHIC ANALYSIS: SATISFACTORY
VERWECHSLUNGSPRUEFUNG ALLER ROHRE DURCH SPECTRAL ANALYSE: BESTANDEN
HYDROSTATIC TEST. 70 BAR (1 BAR .. 100 KPA): SATISFACTORY
INNENDRUCKVERSUCH MIT WASSER 70 BAR (1 BAR = 100 KPA) : BESTAN DEN
HOT EXTRUDED I WARM GEPRESST
No Weld repair I Keine Reparatursci'I'M!isaung I Aucune rtlpara!IO!l par soudure

The material Is W~f<mting to directive 2000163/EC. 2002195/EC and CO 20051618/EC. I Das Material entspricht den Anforderungen der Rlchtlinlen
2000153/EC, 2002195/EC und CO 2005/618/EC.I Le malt!riau est confcnne sux directfves 2000153/EC, 2002/95/EC d CO 20051618/EC.
Tubes arc free frtm mercuJY C0111amination and frtm radioactille contamination I Die Rohre sind frel von Quecksilbelverunreinlgungen und frel vom
radioak!iver Verunre!nlgung I Les tubes sont exempts de contamination par le mercure e1 de contamination r~oacti~
Cardirmallon with reference to Pressure EqUipment Directive 97123/EC:
.The works operates a quality management system thai has undergone a specific assessment tcs materials tcs pressure equipment and is certified by a
~ body (T0V..Celt.No:012028111Q-020025)
Bestatlgung in Ben~g auf Druclcgeraterith!Enie 97123/EC:
Das Wem wendel ein Qu~llatsmanagementsystem an, das In Bezug auf WetiGIDffe fOr Druckgerate einer speziflsdlen Bewertung unterzogen vude und
11011 elner 211sUindJgen Stele (T0V-cert.No:01202811/Q-020025) zertlfi2JB1 1st.
Confirmation contemant Ia Directive Equlpenu:nts sous Pression 97123/EC : L'uslne applique un system de management de Ia quaite qui a fait robjet d'une
~alkwt s~ue pour les rnalmfaux pour equipaments sws pre.<;slnn e! qui est certlfie par un ~anlsme canpc!tent (T0V-Cett.No:01202811/Q-020025)
SMST certify thai the defn.elld produc1s CC/tT1flly with the requirements slipulated in the order. I Die Erzeugnisse wurden bestellungsgerntl6 geprtlft und fOr in
Ordnung betundcn,/ SMST-Tubes aneste que lcs prodults fivres sont conformes aux sdpl4at!cns de Ia ctmmande.
Validation by manufadun:r's represent!ll~ I Valldlerung dUTch Vcrtreter des Herstellers
Mill'& Inspector
Weft<sachverstandigcr D.~
Le cantrclleur usine
Date of edttion
Ausgabedetum 15N012010
Date d'ecfl!ion
lhls a:II!Oc:al!otslseuedbyawnJ>Ufe4Ude}r.llemandla ...ud Oloaos ZougUs blw. Dleto Besd>olnl~ wlmle mft Hllfe dor EOV Co Ultlftellt eat l1ldlg8 6 Tal de cl'un tnlltomont Olodronlqlle de d..,..,.
~aul~e.t1casotllo.....,.,.dUtson~Niwoo41~• en:l<lt und ~tRot.lnlersdviftgll:i~ Ve.~::n 101rie ot osl ~ealb Ul,. oignallln:.. Toutd"'"llornmt ou tp;~Ueotionpcu
r.opy d~ho miiSI a11es1 iu contoomilyond.,l betnpenSiblol« V<JWcnlb1qlll7~~seii/CIIl:nols d"l!llnsproc11u•an>ntCOMid,;,;sc:ornmeroht~c8lionclodoeu:n..,u
enylmlnfl.tl«not.allo'll1edusa. Anyellotllllons ot rolsmcedon'ril
bo~oc:tto!Mt.
UIIMldonfOI, dl\11'9 und BoCnJgall'lllnlehl!ldolltffolgl e1 flwdo etset'CIIIt •<4•• &lajl#ldic:tlvn l'dl&lle.
Solzglttor Mannosmann Stainless Tubes Deutschland GmbH . ISO 9001 • LRQA Nr. 923284

Au~trap: 209886 Komm.schein: 837593 Kundem: 11292 lhre Ret.: 2001411140422 }(0
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Basauri Standort
. ABNAm~PRUFZEUGNIS
ISO !1001 - ISO/TS 169.U Produkt hergeste.l l t in SpanieiJ
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KONDE: DAMSTAHL GMBH
ADFTRAGSN•.:331.810 .. · AUFTRAGSN": 230553-~17
PROZESSNUMMER:~487478
CHARGENU • ; 99550
MTIKELliJOMMER: 293 17 DATENBLATT:141080 ~TUH:09.03 ~2011
PRODUKT Df AUFTRAG
1..457+/.AISX~Jl.~-Ti._llOblil<! ~ C£SCHA.E'LT A'BC2SCHREC':T 65 +0/+4,4.6 mm :ISO la.J
.. .. . .
4.300/5.'300 1IVII • Noi:lMALE
EXPEDI'. I:IONSDATEN IZD'STELLWC:B0337660 ClNICHT (KG) :2.674 BfmDEL:2 B.ARREJi: 2 0
EN 1.0272 - 2007 ; , A5'!M A276 - 2002 EN :LOOBB-3 - 2005 'IBD100 - 01.08 . 19!10
Dni 1.7440 - .09 :1.~96 : ; E:N 10278 - 01.:LO.L999 .'; .As-1M A479-A479M - 2008
~· MROI.03-200S. - 2005 ; ASME SA389-SA399M- 2001; EN 10228-4 :99 - 01.08.1.999'
SIDENOR SID-EU.OS 0 21..03.2005 1 AO 2000-MERXBLATT W2 - 07.2006
AD 2000-I'!E:Il!lll.ATT. Wl.O - 01.10 .2000 ; EN DrREi:n:VA 97/-23/C£.:97 - 29.05.L997
ASME SA479 -~4.79M SECTION r r , P.ART A 200~ .
~CE MROl.75/ISO 1Sl.56-3:2003/COR.l:2005 1•EDICION 15.12.2003
EN 10204 :2004. OCT. 2004 3.1.
..
CBl'Xt:SCBE ZO'S.Al!!l!!ENSEl'ZONG GOSS U:% CB:ARGmr· .• : 99550
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Mn Si p Cr l\Ti Mo 'Xi s
N
Jli.o.. 16,500 10,"500 2,qoo
ll4x. 0 080 2 000 1 000 0 045 . 0 030 18 000 13 500 .•2 ·500 0 7000 0 1000
@ep. 0 041: 1 480 0,400 o· 032 · o."o:i3 16 690 10 680 '2 a·4o 0 3610 0 011 0
14 0000<=Ni+2Moc=20 0000:14,76'00 20 OOOO<=FPREN=Cr+3 3lMa+O ·5W)+16N<-30 0000:23,6838
.
~~1iCBE ,;.IEFJmBEDJ:NGONG.e:N ..._:.__ _ _ _ _ _ _ _ __ _ _ _ _ _ __ _ --J

ltll.tnahme Prnb6at:fu:k:I.2. S _; vcm .ll.and Tean:>era.t:u.r 'VCI1: (1) :Abqesel:lreclct: 1..04.0 •c · Ablalbl.wur: ·11 1 :Lut:t
ILic::lU:ang PJ:Qtreot::iiclc .zngprobf. · (laeogst:) :1a.engut ' ·: · Proben n:l. .;- 1!12 fSl.S/700 Mi'A) :S8S MPA
a.e{I.l .(Bp{o;2t) ,_ :U.o MPA) ·:~(0,2'U 2-t·t .JKP.A; acl2l (Ill!>= z.s .i•u.•AJ;(l\j 290 MPA
A (tSd) .>- 40 t ) : (Sd} 47 , 4 'II : Z (>oo <10 l) :72~ 4 'II
.ll.icht:wlg .Prcbeat:G.ck Jterbscbl..ag-:r:ih.ig (la~st)':iaengot 1 Tn> Prab-...,t:iiclt J:Ubeduag-:r:A.higkai.t ( KVJ •ltV

Temperat:ux Jr:erba~gzi.higk8i.tsprobo 120. •) :20 . • ; ·JC(1) . (>= 100 J) :2H J 1 It (2) .: 274 J ; lt(3} :274 ;r
li'ODll C~K EN IsO · ~506-1 - 0006 .2000) ; lliiri:e · (<a Zl.S RB} :1.40 i£B
Proben JL:2 ; l!lll:~90 MP.II. ; l!.e{l.} :llp(0,211) 24.9 .I!PA J B.e(2): (1.11} 291i MPA ; .11.: (5<1) 47,2 \ ; Z:72,,1 t . .
Uc:ht=g Probcotdck lte:rbac:hlag:6.hig:l..aeagot' ; Typ l'rabertiiq: J:eibscblagdhi.gke:it:J[V
:r.._cra.tur Kerb~C::hJ..qdlr.ia'la::itOIDrobo:20 · ~c;.~ ~· IC(l:);%70 ;r • Kl21:26; J ··' ttlll. :26!1' ';r · · Jri.rto:1-i2rm ·
Proben Ju3 ; 1111U~96 MP.A ; ll.e{l.) :llp{0,2"} 253 l!IPA ; lle(2}: {1.\) 301.' l!IPA ; .11.: {Sd} 47 'Is .; %::71,9 '
l!i.~ Prob9a.t:iick .: ICe.l:bBCbl.agziihigJl..aen~ . ; :"l'yf} Prcbeatiick II:Ub~Wglalit:ICV
'l'~aba: Jtarbach.'1.o~ahicrlce:itaoprobo:2Q . •c IC(l.)::Z&S .J 1t(2):264 J KC3l•263 :r Blrt:o•U.2 BB
l!roben n:<t 1 :am. sao ·MPA ., 11.~(~1 :llp(0,2"l 24.(1 H.P.L .; 'llo(2l • (1.11;) 28&. KPI\. : .L: (5dl 4.7,6" 1 !::72 ;7 \o
l!i.c.htung Prilbe~ck ltel:bscb.l.agzihig:l~eoga_c ; Tn> P.mbeat:iiclt lt~schl.ag:ihiglcei.t: : KV
'%eaz;J(I:I:l't:Ur lto:bscb1~~.<nllh:i<dce it:SDrobo:20 •c' - 11:(1) t279 J • J:(2) :278 J : : X(ll :280 :r · 1Jb:t:etl.3 9 I!IB
Cefi.getAwltCIOi.t. .AtJli'1'EinTA 1 Yo~ (AS'IK E1.12-9&- .19"1 J:~oaeiAuart:mdtd...oah '

lllo.z:m(~J (A.Sl'M A26'2-0l-20Clll r ll=m(2.1 (ISO 3651-2·L998. I ; Tl.po/Mlitodo !Practice E)
Xttt~krist::alline xorrosion:D-X.
St:<mdAr11 J:.nnce £ehl.er(l {STAHL s:t:SEH SEPI.921-01.l.2.L9S4)
~~o!Jmt'J'iEN\ E:Nl'SJ?B..J:CHT
·-
ABTEJ:LmiG n:<:HNDt &.. QWU.I:VoT VERSTOfERT • . DASS OAS PRODOJn' DEN IM AonRAG FES'rGJ;::IJ::;G/J:EN
VEll.Ul'1'WOl1.CREJl: ALBE:RTO C0BER0 ZJUIALA tmTEI!.Sc:mLl::F'.l' : .
caxam:1s.o•.2ou Seit:e · 1 von 2

R£f'. :J..o o1SUJe:roao sc
80053-40 Ru hrwelle I agitator shaft_0004

Auftlag: 209SBS Komm.schein: 837593
~~f~~ftu .
Basanri Standort
~E:DAMSTAHL ~H .. ·-
AUFTRAGSN°.:33l.BIO
:
Kundenr.-11292
.
..
lhre Ref.: 2001411140422
.. _, --·--
.
ABNAHMEPRUFZEUG:NIS
rso 9001. - rso/TS UMJ
··--AUFTRAGSN;: 230S53 -7 7
Produkt hergestellt .i n Spaxu.en
PROZBSSNUMME!R:.~4.~.:!-47 8
CHARGBN°. : 99550
®e
ARTIKELNDMMER: 293l.7 DATENBLATT:141080 WALZDATOM:09.03.20~
-
StandArd I.nnere fehler(2) (Ell 1.0228-4: 99-0l.. 0~ .1.999)
Standard rnnere fchTe.-(~) (liSMI: Slllii8-SA188M-:l001) ·
Art: 'l'OD ia:o.eren fehl~(l.J (P~fs=ppe 3 - Fehl~r ·c~ E:/e)
Art '00!1 t.ane.i-e;a- fehlernC21 (Tah1a 4, Tipo l.a, ·Claaa J) ; 1.00 % tll.t.raschal.l.prii.fung: olm.G Befwl.d
l.OD \: Xontroll:e ...~ Ob..rf.l.khen:l:ehler: aline Be:l:u:n.d : ·1 00 'II Verwecha1nn~a: · o1m.a Ba.fund
Olt:ra.scb.Ui-lle.CL.erlon.atecb::trlk:ll.ii.c:lamlldecho (a~t}. Otme Sicrulll.. > 50'11 Rii.dkv
ZOsATZINFORMATION ·
...
~------~-------------------- ·-
Al!TE:ILOI>lG TECKNilt & O~.ii:.r VER.SICBER'I',
VERAl1'1"111ClCHER:ALBlZRTO ctmE:RO ZllBJUA

OAXCK~l8.04.20~ Seite 2 von 2
tiiiiTI!:i.SCBlUl"'r '·
·-
:R.F.F. :~0015UHDO OO St

Auftrag: 209886 Komm.sctiein: 837593 Kundenr: 11292 Jhre Ref.: 2001411 140422
~~GERDAU
SIDENOR MILL TEST CERTIFICATE
:Ba.almri PI.a.a.t XSO 9GC1 - 130/~ 1&9~9 ProdDc:t
CUSTOMER: DAMSTABL GI!IBR WORKS REFERBNCE:I.487478
.
REFERENCE:33I..81 0 SALES ORDER-:230553-77 HEAT NUI'ffiER:.9.9550
PRODUCT NR:29317 .. MASTER REFERENCE:l410BO ROLLED:09.03.20ll
-
REQtrnUID PRODUCT
1.4571/JUS:t 316"-T.i ROtntD BARS ~ 90LUTI:O!II' Al>lNEALINQ 65 +0/+0,46 ..., ISO k ll
4. 300/5.300
""" Rl\NOOM
IaPROrnoN IDBLIVKKr: &o3l7&6o WIC:<ml' (KG) r2674 8tlliDf,SS 12 Dli'I'rSr20
..
l!!ADR ACCORDING TO
EN ' ioz72 - 2007 ; ASIM .A276 - 2002 ·, EN 10088-3 - 2005 ; TR0100 - 01.08 . 1990
ODI 17440 - .09.1996 : EN 1.0278 - 01.10 . 1999 ; M'lM A479-M79H- 2008
NACE MR0103·200S -· 2005 : ASME SAl88-SA.388M.- 2001 ' ; 69. 1Q2ZB-4:99 - . 01.08.1999 ·
SID!!NOR .SID-Et1.05 0 21 .. 03. 2005 1 l'\0 2000- MERJQlLA'I:T ~ - 07.2006
AD 2000-)IE:RJaiLI>:TT .W10 - 01.10.2000 ; 'EN Dl'RECI'IVA 97/23/0!.: 97 - 29.05.1.9 97
ASHE SA479 -SA479M SECTrCN XI, PART A 2007
mu:E HR017S/ISO 15156-3:Z003/COR.1:200S l"EDICION 15:.12.2003
EN 10204 :2004 OCT. 200~ 3.1
CHEMrCAL ANALYSIS OF BBM' Ot1! ~ NUMBBR:99550

c. Ml2 S:i p s Cr . Ni Mo Ti li ·
. WL• . 16,5~0 1.0,500 2,00~
...... 0 oao 2 000 · 1 000 0 045 0 030 1.8 000 l3 500 2 500 0 7000 0 1 000
C.c. 0_._041 1 ,480 0,400 0,032 0,023 ~6 690 10,680 2,040 ' 0 , 3610 0,0110 ·-
1~. ' 0000<=Ni+2M0<.:20 ·oooo: 14, 76oo 2.0 a·aao<-PPRRNcCr+:f 3 (Ho+O, 5W) U ·6N<=30 0000:23 6838'
St&nda:rct (AS:m P:4505El200S) ; .l..rZ,S 8r2 Ct1,S r Dol.
.. ,,
MECIIAN.ICAL PROPRIU"l:XS AS SOPPLrBD (C'CINDITI:OHS)
·Spea- %•.-t l~ oat: 12,5 - . t,.,.,... t:ha .......:face I %'eooporab.t.ro ofr (1)oSolo~ aaaa&l~ 1 . 040 •c
-· COO ~Ulgl ~~, ,.u.r - .
. . MRCHANl:CAL PROP.B.:RTIES ~AS SOPPLIBD ('l'BST) .. ·. . .
-r--ue teet .pad-: ~ti.cn (Longit.udinal.) ·~~ ; 'r•t, '11.:1. ..
Tcmorila Bt:reaght (515/7 00 MPA):S:85 ~ ; :i~c! s=-~tll.l (l!p (O,:Zl) >2 21.0 MPA) <ap(0 .2\) 2 « 11PJI.
~iou ((Sd) >• . 40, t'l1 ( Sd.l
rLol4 Streught(2) I IU! >= 245 'MPAJ : 11'1;) ~0 l!Pll. :
''·' ~
.....
lloduc:tiDI1 of Area . (>- 40 l)r7Z, 4 ' ; lrotch im;pact: a~le direet:.lou ( C.Onsit:~) : I'Ot>gibldinal.
Botch ~ct · a.mplo t)'pe
'(ICV) :z:v : ~ :t:apact teat r~tw:e (20 •Jr20 : ][(l.) ( :.= I.OO J) :274 j
1[(2) :27f J ; lt(l) z274 J · ; Sbu:ldarcS (UND EN ISO 6506-1-000&.ZOOO) ; ~ ( ~ > 215 HB) : 1f0 HB
7 .... t ~:2 ; · 7t1<1BU& Sl::X't~DghtrS9D ~ ; Yiolct .st:XODghti1)•RpiD,2\l 2U 'KPA :
'Ji o1.4 St:e:Dgbtt2) a (l,) JIPA ; ll:l.aupticnl (54) U,l ~. ; Re4w:ticn of &xeat72,~ ' :.
29~
, ll'otch iJapact: aupl.e di.rec:tion:t.oog;.~ : :IIOtch Ilopact: &lll!lple type: EV
.' Bot:cb x-ct: to~t 'r z20 •c: II: (1) • 270 J .. li:t2):26§ J :a:(l) r26t J · · ~or142 II:B
're.at o:l ; razurlle S~ts 5,& JEPA ; Yi.old. St.reaghtll) tRp(0,2\) :i!Sl KP.&
Tio14 Sb:aD~t:(2) .i !n) .301. liP& ; El.cmgald.ou.:,(S d) n ' ·, Rechu:t:toil of Areaon,g '
liotcb .bpact e-Pl.o <11ro~cmrLoa¢tutt::l-t I .JI'otch ~ &IIQPlO l:nle:EV.
l!l«ch Xlapec:_t: teat Te:op~ r20 •c : 11:(1) r265 J -
X(2)•264 J ; 1:(3):263 J 1 ~arU:I liB
: :
1 renaLLe St:reaght:r 580 'MPA ; ~.t.el.c! S~t(:l·) rllp(0,2\) 2-&0 lill'.Pt.
'J."eet ""'"
1:lelc! StreDg!lt CZI : (U) 286 KPA : ~~: (Sd) 47.-6 ' ; .aaduct:iol:l of .a..
....., 72. 7 '
llotell illpact: illlllp].a ~t:i-:Lang:.tt::tid:usal ; JJol:ch Ilopact eemple 1:}11e: EV
lllotch ~t t....t: · r-rat:uJ:e: 2 0 •c ·: ][(1) : 279 J J 1:(2) r27B 3 ][(l) : 210 J llaz:daeD8: 13ll BB ·'
St:nct:JI.ro..&wrteait:e. ~ 1 S~ ·(A.9'Df Inl2-9G- • .1996) 1 C2raizl •.be:.lwJt.:dt:J.a 6

St:D4a:rd(1) (AS'TM A262-01-2001) • Bbnc!:ar4(2) (ISO 3651-2-1998 .) · 1'ypo / llet:boc! (Prac:t:ic:e 'E)
UPIOV&D BT<ALBERTO COBE:RO ZABALA Sl:Gif•. .

on-Er18. oi. 20U Page l of 2
REF. :1DOl.5Ul40CifQ

Aultrag; 209886 Komm.schein: 837593 Kundenr: 11292 lhre Ret.: 2001411-140422
~G~U
SIDENOR
:Ba.Bauri. Pl:au.t
MILL TEST .CERTIFICATE
xso 'not - xsetrs l&gts Product Made
~~~
ins~
COSTOI'lER: D.lU£STlLBL GMBH WORKS REFERENCE:1487478
REFERENCE:33~.8~0 SALES ·ORDER:230553-77 HEAT NOMBER:99550
PRODUCT" NR.:2.93~7 ~msTBR REF!m.ENCE:141080 ROLLED:09.03.2011
NON D2STR.UCrrvB TRSTS

Ictex:::uo.l. defects ,;tlmdal:¢(1) (STAHL E:I.SEN SSP192l-Ol.J.2 .1,84)
i:zte:ma1 defects atlmdardll) ·(EN J.022B-4:99-0l.08.1999)
:In~ dafec:t:1J atlm4a.r(l) (ASMB SA388-SA388M-2001)
m...,..x <Sarects eypa/me~(ll. (Test: group 3 - i:lef el::t: <= s/el
X:atexnal. .defects t:ype/motbo(l) (Tabla 4, 'l."i.po l a; Claae 31 .I IILn.II.SCIIIZC m!IPllCnOl!J 100'11 I 0.1[.
c:::KACB:s a::an:liOL 10011 tOI: ; .atr.I:n!!XlJiG mr SPBCil!OSr:tJl'I" 100' 11 OJC
R...fl~cm ~eebaoloqy Back ~ (P&rp-cRc:ul.&rJ. Wit:haut Si~ > Slnr · B<aclc ocbo
ADDITIONAL DIIFORMATION
:·
..
.li.1PJIOVED. BY:ALBERTO CtlBERO Z}WALA · BIGIFJ.

Inn:l8 . 04.20ll Page 2 of 2

LarroodoLOIU (VlZCAYA)Espafta
P.O. Box !323/48080 Bilbao
n
• Tr!L 34-{4) 4 13 00
Fax.34-(4) 4 53 16 36
..
THYSSENKRUPP METALSERV GMBH.

WESTFALIASTRASSE, 185
44147 DORTMUND- ALEMANIA
TradeMark- Zeic:hm des Li efawakes
Anagram a del suministrador 0
WorksinspcctorStamp- Werkssac:hverstandigct ~~
Sello del Inspector ·
Cestificatel}pe-APZ Nach
Certificado tipo EN 10204/3.1
Certificate n°-
Certificado no
PrO~Nr
55912 I
Dale-Datum-Fecha
21-10-2010
Our order N° Heat Your order NO
Werts- Nr 441237 Schmelze 30256.2 Bestell- Nr S1 HM-5401956494
N"deReferencia Colada Pedido N°
Steel Grade According to
Wertstoff X-6-CRNIMOTI-17-12-2/1 .4571 MECAMAX Entsprechend EN 10.272-2007.
Cali dad Corresponde
Shape and Size- Gegenstad Tolerance- Toleranz Bundles Bars Weight
Perfa y dimensi6n Tolerancia Bunde St!!be Gewichl
5 2354 Kg
RUND45mm K 12/ISO 286-1110060 Bullos Barras Peso
Requirements- Anforderungen- Exigencies
EN 10.088-3.2005.
TRB-100 /AD-2000-W2 /ADW-10.
iACE MR-0175/ISO 15156-3 2003.
LV 4571 GR REV.6 2000.
Conformityletter.0JstimrrungsgmreibbennJVBAOEN28.01.1969
WaivingofCountersing/Gegenzeichnungsverzicht:01.03.1977
PED 97/23/EC, Annex I, Parag.4.3/DGR 97/23/EG
Anhang I Bsatz 4.3 Certificate/Zertitikat Nr. 348/2008/MUC
Melting process I Erschmelzungsart I Proceso de Fusi6n Heat lrealmeni/Warmebehandlung I Tratamiento lermico

1060C 4H/Std WATERM/ASSER/AGUA
E.A.F ./ A.O.D.
Solution annealed/Abgeschreckt/Hipertemple-Tumed/Drehen/Tomeado-
Test results· Ergebnis der PrUfungen- Resultados de los ensayos

Dimension of Specimen Rp0,2% Rp1% Rm A A z Hardness Impact test I Kersbschlag I Resl6encia
Atmessungen desProbestabes Nhnm2 Nhnm2 Nhnm2 "ALSO "AL4D % Harte ISOV Jules
Medida de las probetas MPA MPA MPA HBw
RD. 10,00 mm. Min. 200 235 500 40 100
.
" - •.emperabJre "C Spec. N°.
Max.
1
700
71
215
163 232/230/235
309 343 586 49
20 ProbeNr.
ProN°. 2 311 346 589 49 71 163 230/227/232
c Si Mn p s Cr Mo Ni Ti N Co
Mn. 16,50 2,00 10,50 5X%C
Male. 0,080 1,00 2,00 0,045 0,030 18,50 2,50 13,50 0,700
0,015 0,56 1,87 0,031 0,028 16,55 2,04 11,15 0,130 0,0165 0,20
Visualanddimensionalinspection Radioactivity inspection Antimixing test Grain Size
Besichtingung und Ausmessung O.K. RadioaktMt!!tskontrolle O.K. ~Verwechslungspr O.K. KomgrOsse
Control visual y dimensional ContrddeRadioactMdad Antimezcla Tamafio de grano
Remarts • Bemertungen • ObseMlciones
IC test acc./IK prafung nach EN 114. OK
EDV/EDP
IC test acc./IK prafung nach ASTM A 262 E02. OK Ace. EN 10.204
IC test acc./IK profung nach EN ISO 3651-2/98 Met.A. OK Alfredo Molina
Freedom from internal defects guaranteed by process control. OK Certification
Eddy current test for cracksi\NirbelstromrissgeprOft. OK Mng.
Worts Inspector
Oct Werkssac:hvCISIAndige
Inspcdor de tabrica

......... -..... .. _..... -·------- .. --· ........... ----- -·-------- - - ---"7""--------·- ·--.. - .,
I
· .,1 ;1{a
r
(~~·~
· Umstempelungsbescheinigung Hw:t fn·i-St:dd t ;<"i!'ll'l'id r.;mbll
• 1·.t:j'?-' ~.,.. i~J
r :5v:.r~:;-
"<.;
_,..,.,"',.. . .
." r. .
marr.mg trans f er certr'fi cale .~n~o !·ktpht:u-Dt·n:t.
T~l.: 1127371!>4)082
.,... ~·'';7,·,~~~~tl"''''""
... ...·•·'" nach/comply with El..J '10204- 3.1 F:t~:. : ll.OJ//_'; 1 1:\0l:~
FB OS 07.03111.2006
RFSG - ~~i. / uidcr no .KAI 1005914

'
Besteller I Purchaser: 115003
EKATO
Ri'IHR- liND MISCiiTECHNIK GMBII
KiiPPEI.EMATTWE<I 2
() 79650 SCIIOPFiiEIM
Bcstcii.-Nr. I order no.: 4 111 20766
I2. J{/J
Anforderungen I Requirements: EN 10088-2
Wir bescheinigen, dass die gelieferten Zuschnitte:

Herewith we certify, that the delivered parts:
Pos St. Abmcssung WStNr. Schmclzc Pmbc-Nr. gcfert. RFSGZeugnis RFSG-

1-
Item
-
Pes
- Dimensions Material prod.by RFSGCert No.
Heat No. Test No. ldcntNr
I 4 Fonns1Uck in 6mm Dicke 1.4571 410554 003 074144 20110618 763910301
2 4 FomlstUck in I Omm Dicke 1.'1571 110257 3002 074132 20110654 764260401
3 2 Formslilck in 6mm Dicke 1.457 1 410554 003 074144 ::!011061!1 763910301
6 4 Forms1Uck in IOmm Dicke 1.4571 110257 3002 074132 20110654 764260401
9 I Reehteck: 92 x 50 x 8mm 1.4571 402114 1206 074132 20102963 755350401
10 I Rcclllcck: 9:2 x 50 x 8mm 1.4571 402114 1206 074132 20102963 755350401
II 8 FClrmsiUck in IOmm Dicke 1.4571 403167 1202 074132 :20110697 764690101
1:2 6 r:ormslllck in IOmm Dicke 1.4571 403167 1:202 074132 20 110697 764690101
13 2 FurmsiOck in 6mm Dicke 1.4571 410554 003 074 144 201106 18 763910301
14 8 r:ormsiUck in 6mm Dicke 1.4571 410554 003 074144 20110618 763910301
15 8 FormsiUck in 15mm Dicke 1.457 I V8A7 04V8A7 074102 20110423 761870201
16 8 Formslliek in 8mm Dicke 1.4571 110028 2206 074132 20 111 298 770700101
17 3 FClrmslilck in I Omm Dicke 1.4571 110257 3002 074132 20110654 764260401
18 I Ronde: 90mm 0 x 5mm 1.4 571 037073 49 076505 20110 189 759610101
--
19
-I ·- Ronde: 84mm 0 x 2mm 1.4571 001095 14 076505 20101217 738590301
20 I Ring: 47011 80mm 0 x 5mm 1.4571 037073 49 076505 :20110189 7596 10 101
durch das Zeugnis nach EN 10204 3.1 ausgewiesen und die Stempelung vor dem Trennen ubertragen wurde.
accounted through certificate EN 10204 3.1, before cutting the products were stamped.
Zum Zeichen der ordnungsgemaaen Umstempelung wurden die Zuschnitle mit unserem Stempel versehen.
To confirm. that the products were correctly stamped, we equipped them with our stamp ~~
Das Umstempeln erfolgte mil Zustimmung des TOV NORD Systems
The marking transfer was done with consent of the TOV NORD Systems
Rostfrci-Stahl 0~-:isw~.:id
(imt-.11
llatu•u I O.O:l II i)ll : 17 h
80053-40 Visco prop_ 0002

I~¢ERTIFICATE- lEUGNl~_: cERiitlCAT J l /I
EN 10204-3.1
Avesta Wort:s Lood • lbdu:lg • Chorgum Uo Con.l"o • Zcu;pu> llo "l
OCM Johan NordstrOm 02-Mar-2011 DE10.0266 1985821-DE
YIJUI• O<dor . lhrc Be:.tcllun;l · Votre er.mm:~_:__]-·- -- I Avesta ordor. Au:ua_~ :.Ordft! lnvuia.r. ltCLMung .. r &C1utl! I
-
81 100169
-·
Purchaser - BostoDcr • Achctous
., 651/110144 661/1151279
ROSTFREI-STAHL GE!SWEID GMCI: ( f!cquifomonts · AI.S""~"'UJ.gL-1• <b,igettc.~~ ~

POSTFACH 1352 ASTM 1\240-10
, DE-57237 NETPHEN-DEUZ ASME SA-240 2010
DEUTSCHLAND EN 10088-2:2005
EN 10028-7:2007
AD 2000 W2, W10 & EN 1002~7
EN 10051/1\.STM A 480
Don. I
ROSTFREI-S t AHL GEISWEID GMBH
Product - Erti!U!Jrllsform - Produit J
Roslfreies wanngewalztes, Blech aus Band
Ausffihrungsart 10, besaumt
Grado • Worutorr - N~
I
OU1okumpu 17-11-ZTl
lYPE 316TI/1.4571
&Yl~ ~
Orend metk lnspoctors stomp Molting pnoco"
H~rslollono ichon Abnamo - Stom;>el EnchrneiUungsart E+AOD
Slgno du pnoduetcur £sump do l"oaport Proccidci do luslon
Exlont or delivery • Uolonnnleng • Etonduo do llwo
It am Pes Dimonolons - Ab!M$Sungct> · Oim<Jmion,s Hoot No Lot No
Pos An:tDhl Schrnobe Nr Los Nr
Poste Nombre kg mm Coulk No lot Nr
5 3 1716 6.00 2000 6000 41 0554 - 003

Cl>omlcal composition - Chemische ZusommonsoUung • Composition chlmiquo
c Si Mn p s Cr Ni Mo Ti Nb Cu Co N
Schmelze .053 .45 1.39 .029 .001 16.70 10.66 2.03 .48 .006 .30 .220 .011
Messung auf Radioakti vitat gem. IAEA Rekommendationen: Ohne Beanstaodung

lost results · PrUlorgebnisse • Rcnults desS.OI$ (lN/mm 2 - 1 MPa) F • front- Anlong • Oebul B • Bock· Endo. fin T a Ttllm:vorso. Quor . Travers
Test Ref Temp RP 0.2 RP 1.0 RM .1\S :z • HB

Probe Ref
Eprouv Ref oc N/MM2 N/MM2 N/1'00 \ t HB
Min +20 240 270 540 40 10
Max G90 217
p T +20 291 330 610 50 so 167
B T 310 365 615 49 19 174
Korrosion gem. ASTM A 262-E, EN ISO 3651-2A: Ohne Beanstandung

Warmebehandlung: Materiallemperatur 1100 •c I Abgeschreckt (Pressluft + Wasser)
Verwechslungsprufung (PMI-Speldralanalyse): Ohne Beanstandung
~chtigung und Au~ Ohne Beanstar}dung
U~rOft nach AD 2000 M latt WO durch TlN NORD S~ms mit Vetzicht auf Gegenzeictmung
Zerti "ert nach O~d<gerate-Rlchtlinle =lEG) durch die T\N CERT-Zertifizierungsste!Je fiir
Drud<gerate der TIN NORD Systems; nte Stelle, Kenn-Nr. 0045.
-
Outob.mpu Stoll.... All T...,....,. ; • •r.lOll2f.BIH7 Olo Qr.l""lerl .........._ _ . clnd orlim
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SES5'001814801
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SCI IW£0EN
5-77~ 21 AVE!;li\
A.eontllcn: Stod:.tllf'\lrn Swlildllut.kbOI'IIR! !I~JI..tl/ 4 8 Wm1t.':SIIdwcr.;lsind~

--
"••n:•..
eN ISO 110:J1
EN 1&01400t
80053-40 Viscoprop_0002
9 lOOO-doJdO:)S!J\ Ov-£9009
2~1}~]".15. • ~~ifTIF!fj•.j ; I
tRJW~
~
l_'CERTIFICJl.!_E •
Ef-.t 10204-3.1
Avesta Wort;s I Oale • Ootum I.DIId • I "~'u'9 · Chorg~'.':'. ~~ 1""9"'~ No
02-1...\ar-2011 0E1(}.{)265 1985821-El~
OCM. Johan Hordsttom
Your ordu< -lhte llc•~~D~ :~~~· CUI'!'_~";~-~ .. ~-···- rA.vt.-s~ cudcr • Autu:'g~ .~~-~~ ln11otee • nocltoUII:J_:.!...'.~£]
--
81100169 6611110144 651/1151279
Pun:ha>Of • S...tello< • Acl,.te•n __ __ j
ROSTFREI-STAHI,. GEIS\"'EID GMBH I R~quirttments . Antoadc:mngt; :·r~Kjc:n~~---- - I
POSTFACH 1352 ASTM A t4G-10
bE-57237 NETPHEI-1-DEUZ ASME SA-240 2010
GERMANY EN 10086-2:2005
EN 10028-7:2007
AD 2000 W2, W10 & EN 10028-7
EN 10051/ASTM A 480
De st.
I
ROSTFREI·STAHL GEJSWEID GMBH
Product - Enougnlsrorm • Produit I
Stainless Steel Hot RoDed, CoiJ..Plate
finish 10, cut edge
Grado • Workstorr • Nuance I
Outokumpu 17-11-2TI
TYPE 316TV1.4571
f----
· -·
&Yl~ ~
Brand mnr1< Inspectors stJoonp Melting process
Ho~tellonofchoro 1\bname • Steonpol E1Schmoluungsao1 E+AOD
Signo du produeteur E.stamp do I'export Ptocl>de de fusion
Extont of dollvory • Uerorumrang • Etondue do llvro

Item Pes Olmcnsions • Abmossungon • Dimensions Hoot No lot No
Pos Ant.ahl Schmel2e Nr los Nr
Posto Nombto kg mm Coull!<~ No lot Nr
5 3 1716 6.00 2000 6000 410554 - 003
Chemic31 com~tion • Chemisclle Zus.ommenseuung • Composition ehimlque
c Si Hn p s Cr Ni Mo Ti Nb cu Co N
Heat .053 .45 1.39 .029 .001 16.70 10.66 2.03 .49 .006 .30 .220 .011
Radioactive contamination check ace. IAEA recommendations: Satisfactory

Test resUlts· Ptidergebni>.., ·Results do$sois (1N/mm 2• 1 MPa) F • front · Anlnng . D•but 8 • Bado • Endo ·Fin T - Ttansv~ • Quer • Tnrvurs
Test Ref Temp RP 0.2 RP 1.0 RM AS 2" HB
Probe Ref
Eprouv Ref •c N/MM2 N/MM2 N/MM2 t
Min
Max
+20 240 270 540
690
40 "
10
HB
217
F T +20 291 330 610 so 50 167
B T 310 365 615 49 49 1.74
Corrosion ace. ASTM A 262-E, EN ISO 3651-2A: Satisfactory

Heat treatment I Solution annealed: Material temperature 1100 •c I Quenched (forced air + water)
Steel grade verification (PMI-spectroscopic): OK
Mar10ng, visual insp. and~ measurem~nt Satisfactory
App.roved ace. AD 2000 latt WO by TIN NORD Systems with renounce of countersignment
Certified ace. Pressure EquipmEtf~t Directive (97/23/EC) bylW CERT-Certification body
for pressure equipment of the TtN NORD Systems; notified body, reg-no. 0045.
n.a .,...,.,. .._ ~-. ~ -"• cwdar ..,..fWnnQI.

~-AD
au.-- Unit s.-.o COl t.r1n1o
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Av~toWCNb VAT ooo : S~!l1.rMtftl4nDt
eox 74. s-774
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I!H 190 11001
...g1 ISO 14001
[ C~_f3J"IFIC~J~:::.?_~~-GNI~ ~- CERTfFICA(_} ],"]
EN 10204-3.1
Ont&· Onium l011d • ladwtg - Chergom Nn CM.Jolo • 7.ougnls l~o
Avesta Wort.s
QCM. Johan 1-JortlstrOm 02-Mar-2011 DE10-0266 1985821-FR
Y001t order ·lhre llesonllung -~-Vntu;;.on,.;,.,-~-~'-------r~--------·- . . -- -·--· I Aver.dll ardor .. Auftnrg - Ordre
~~--~~~--~~~--~~--~~--.--------
lnVOICO - nechnur~- --!.~~_:j
81100169 661/110144 661/1151279

l'urclulsor • Um;lnllnr • Acheteur ]
ROSTFREI-8TAHL GEISWEIO GMBH 1koquuftments • Anlonlt!rungen • Exi;JC<1fi!O OJ
POSlFACH 1352 ' ASTM A 240-10
0~·57237 NETPHEN-OEUZ ASME SA-240 2010
ALLEMAGNE EN 10088-2:2005
EN 10028-7:2007
AD 2000 W2, W10 &EN 10026-7
Dost. _j EN 10051/ASTM A 480
ROSTFREJ-STAHL GEISWEIO GMBH
Product - Eneugnisform - Prodult I
Acier inox. laminee A chaud, Tole en Banda
Gamma de fabrication 10, bords clsaiUI1:5
Gracie • Werkstoff • Nuance f
Outokumpu 17-11-2TI
TYPE 316Tl/1.4571
Brand mark lnspoctors stamp Melting~

Harstellen:efchen Abnllme • Stempel Etschmollzungsart E+AOD
Slgne du productaur Estamp da I'expert Proald& de hlslon
Extent or delivwy • Liarerumrang - Etandue .., livre
!tam Pes DlmonsioM • Al>mossungen • Dlmonslons Hoat No lot No
Pos Alwlhl Schmelze Nr los Nr
Posta Nombre kg mm Courllo No lot Nr
5 3 1716 6.00 2000 6000 410554 - 003
Chomk:al compositiOn • Chomisdte Zusammensauung • Composition chimique
C Si Mn P S Cr Ni Mo Ti Nb Cu Co N
Coul6e .053 .45 1.39 .029 .001 16.70 10.66 2.03 .48 .006 .30 ;220 .011
Oontr61e de contamination radioactive aelon recomendation d' IAEA: Satisfaisant

Test results - PrW"'lJ"bnisse • Rcisollts d&Ssais (1 N/mm 2a 1 MPa) F • Front • Anl'ang • Dobut 8 a Back. Endo • Fin T a Tnmsvorso • Quor. Tt:IVI!B
Test Ref Temp RP 0.2 RP 1.0 RM AS 2" HB
Probe Ref
Eprouv Ref •c N/MM2 N/MK2 N/MM2 t t HB
Min +20 240 270 540 40 40
Max 690 217
F T +20 291 330 610 so so 167
B T 310 365 615 49 49 174
Corrosion seton ASTM A 262-E. EN ISO 3651-2A: Satisl'aisant

Trail 1henniQue: Temp. de matiere 1100 ·c 1Refroidi brusque
Verification (PMI-speclroscopique) de Ia nuance: Sans remarques
Examen visuel et controle dimel'lSlOOnel: Satisfaisant
Approuve suivant AD 2000 Metkblatl wo par TOv NORD~ sans countresignature
Cer!ifl6 ~uivant Ia Direcliye Appareils a Pression C9I/231CEl par T0v CERT. Corps de
certification pour Apparails a Pression de groupe 'rOV NO~ Corps notifie, enregistrement no 0045.
lalophono :< 4G(li)Z2681417

Fm : • 46 (0)22& 813 IG
A'IDUIWorlto
BOX 74. S-774 22 AVESTA
V.A.T no : SE55&001B74801
at,,(,;~~.r,-?t--··
SIJeOE
"-"""'· s"r.:ld-· -..s<ngno: ~5IKJO•-at4n Canlr!ilmlr Au!orls6
80053-40 Viscoprop_0002
EKATO Ri.ihr- und Mischtechnik GmbH
EI<ATO RMT
In haltsverzeich nis
List of Contents
4. TOV Zert"fikate Montageflansch I TOV Certificates Mounting Flange

EKATO Rl.ihr- und Mischtechnik GmbH ED<ATO RMT 10092376
1 von 1
,Oberflachenri~pri.ifung" Abnahmepri.ifzeugnis 3.1 EN 10204
,surface crack examination" Inspection certificate 3. 1 EN 10204
EKATO-Auftrags-Nr. I EKATO order no.:
Kundenposition I customer item:

Fertigungsauttrags-Nr. I job no.:
Gepruttes Teill examined component:
Zeichnungs·Nr. I drawing no.:
Anzahl I quantity: _ __ __ _ _ _
._/ _ _ _ __ __ StOck I piece
Grundwerkstoff I base material: ~C.f.F:J/f
Prufverfahren I examination method: Farbeindringverfahren I dye penetration check

gem. I ace. to: ~AD 2000 (HP 513) DIN EN 473, Werknorm I works norm 906· 10047005
~Fa. Helling
Prufflachenzustand I surface condition: '¢ geschweil?.t I welded 0 geschlitfen I grinded

0 geburstet I brushed 0 elektropoliert I electropolished
y ·gedreht I machined
Prufmittelsystem /testing system: '¥Nord-Test U-Serie
Verfahren I procedure:
Eindringminel I penetrant: '?-_ Kontrastrot U88 0 Ch./lot: __;~=---:::-'/(;--'9_)::.___.,:::.(_,___ __

Reiniger I penetrant remover: '<f Reiniger 87 0 Ch./lot: _1.:::..;~~~r-,_;p;....~....,-,_c
_ __
Entwickler I developer: "j Entwickler 89 0 Ch./lot: _:...!/h:.....:....:::}_O_ ::..._
}-tr _' _ _
Temperatur I temperature: 2o
-----...,..------- oc
Einwirkdauer I dwell time: _____3_'0-::--- - - - - min
Beurteilungszeit I evaluation time: ____,.0'-----J--=-o____ min
Beleuchtungsstarke I lighting intensity: '...;'"'GO L
-----~~--------- ux
Ergebnisse I results:
Naht zwischen Teilen I Lage I location Bewertung I Bemerkungen I
welding seam between G*) U*l S*l classificadon remarks
parts 1. ") 0"")
/ 0 0 0 0 0
4/Z- 0 ~ ~ 'ef 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
•1 G = GrundwerkstoH I base materiel; U = Obergangszone 1 relined zono; S • SchweiBgut 1 weld metal
• •1 1 = keine Beanstandung I no objections; 0 = keine Beanstandung nach Nacharbcit 1 no objections after tcfinishing
-----~lePrufung wurde oti'iiElaeanstandung abgeschlossen.

The test was passed without objecdons.
Prufer I examiner, Datum I date:
,2 ?{/
/ 2v v?qQf:l
~- ...:; • p· T2
- ,.. 9. ,JI.fN. ?TJ11
Abnahmebehorde I Acceptance authority, Datum I date:
Prufprotokoll gesehen I test record review:
Kunde I customer, Datum I date:
Dokument aktualisiert: SMN geprOft: PJ?) Freigabe: SCA ~11
es-. a. /{)...fv Sf?A/ zs.cc,iv' l~-fi> A'-
\
SCHWEIZERISCHER VEREIN FUR SCHWEISSTECHNIK 278-UT-3
~
SYSXASS ASSOCIATION SUISSE POUR LA TECHNIQUE DU SOUDAGE
Blatt: von:
~ SWISS WELDING ASSOCIATION
page: 1 1
deJot
CH-4006 Basel SlAlban-Rhe!nweg 222 Telefon 061-317 84 84
fi':!\ U ltraschaii-Priifbericht
nach I selon/ ace.: A-Nr.:
0-No.: 278/11
~ Rapport d'Examen Ultrasonique UT EN 1714
1----·· --· .........
PB-Nr.
sTs 14e Ultrasonic Examination Report R-No.:
Auftraggeber: EKA TO Riihr- und Mischtechnik GmbH Kunden-Bestell Nr:

Commenant No. de convnande: 214/411110293
. ~u:t~'!H'!:__ .. __ q_ D- !9650 Schopfheim Customer's Order No.:
Objekt: Lagerwellen 0 60 Zeichnungs Nr.:

.~!'' bje~--- 0
Kom._!.Jr. 80053 __________ -···-- ·-· ~~-~~~~~~-~'.~------- __ ..
Profort: EKATO Ruhr- und Mischtechnik GmbH Position:
Ueu d'examen:
Repere /Item:
40
Examinalionsite: D- 79650 Schopfheim
PrOfbereich: Schweissverbindung Profumfang:
.!! W If Ff h 100 %
-· .- - --~~:~~~20~-~---~~;:=~~ft.-
C Secllon examinee: Etendue crexamon:
~ ~~-2~~~;f~; . - --. 1.4571. --· ·- - =·~~~=-- · - -· ·

Cl CD "l:i Moment of examin.: Material:
C ' C C I - - - - - · - - - - - ... -·--- -··-- ·- ---··-----------······--··-··-·-··-··-··-···· -·----·----·-----·---------·-·---
:0 j!! 8 PrOfflachenzustand: Schweissverfahren: Nahtform:
_g o .... Etatdesurface: bearbeitet Pnx:ed4desoudage: MSG typedejoint K-Naht
~ E t;.
: f----------------------·'------':..:...----.....----------l.!.!...:........!.:.::.:_.
SteteofWiface: We/dingprocess: typeofjoint
:;::, , _____________ ..
D: g Akzeptanz-Standard: Schweisser. Name und Nr.:
0 Crittlresd'accepta~on: EKATO 906-10062458 Soudeur:nomeiN': 1706
Acceptance Cliteda: Welder. name and N'.:
Q)
c
~~;:,~ ~~ ~=:::=~:
PrOfkOpfe:
ee
PrOfgerat Typ:
Paipeurs:
_ _ _ _ _ ·------~o_n_iC:... ~~---·---I-'~'-=':::::JJd'::::m~:.::,"-~="=ao=-~=
MSEB4, MWB45°
12
Justiert<orper.
Frequenz:
Fr6quence:
Stufenkeif, Objekt, K2
_____....:9:..:0=..6=:.-_1:...:0:..:0=..6:::2=4--=-=-5-=8:__
4, 2
-------1
MHz
~
::..
! :::1
!
Q, Search units:
1-P=:=rota=..::nw::::e=-is_u_n_g._N_r_-:----------------I..:,R:=eg:t:=istri;;,'c:...e_rgre-n-ze_:_8_0_o_Yo_B_S_H_+_6_d_B
Frequency:
___________ -
D.. e N" do p!OC6duru d'examen: Uml!o d'ennlgJstrument :
II. &eminat/onprocedutBN: Umitofteglstrallon: 50% OAK
Profzone Ergebnis Bemerkungen
Zone 8J(lJIJ!in6e
E.Nr.
s <): llV1 p H llH L Q Ill 8
~~~ullats Romerques
Testadzone Remarlls
0
mm dB % dB mm mm mm mm e ne
80053 LW
Pos.40 1+3 31 o• - - - - - - - - X
Zch. Nr. 10080623-00
FA-Nr. 2102&4815
---·· ---------···· ---- 1--·--- f-- --·-· -- ---- ~-- --- - - - ------ ···-··· ···- - .. ····- ----- --------
·- ----- ·1-·--- ·-- --- -----·· ... -·· ·-···-- ------- ······--·· -- ··- ·-·---- f-----·- -·-···----f-.... ·- .... ---·-
I - -- -
I
l
f. _ _ JI. . . .
. ··- -···-- ··-····-- -· --· . ------ ·---- - - - t - - --------+---1----+--··--·· ----- - ···-- ----·--·· ··- -· --- ---1--1-- 1----- -----·--- .
Einschallrichtung PrDfdlcke in mm Transferverlustkorrektur in

S: IJ.V,: dB
E Nr.: Direction de sondage
Scanning direction
..c: Epalsoeur examin6e on rrm/7hfckn8ss exsmln. In mm
EchohOhe in% (OAK= 100 %)

Con-dolranalollen
Tnmalar-in
Differenz zu OAK In
~ H: Heute1ir d'6cho en 'II. I Echo low/In" (OAC= I~} llH: Dlll6renco par'-' a DAC eo dB
c ~ DltlenW fo DAC in
(j)_ Cl)e
r:1?
X Distanz Bezugsspunkt - Fehfer (X) in mm Regfstriertange in
Ol.Q
C.Q L: Dialanoepcinldor6f*enco· dalall1 (X) en mrn Ill: Longueur enf6tlls1r6e on mm
:::l<t DisiBncepcinlol--dolot:I{XJinnwn ~lunglltln
1::!- Distanz Bezugsspunkt- Feh!er M in mm Bezugsspunkt
=I! Q: P:
~
-Ko Dlotancopcinldonll6ronco-d4bwtM enmm Point de r818ntnce I Point o/IDfeiDnce
.C;:I Oisl"""'pcinlc/,.,.,.,-dolvd(l?inmm
---
c(i B:
Fehlertiefenfage (Z) in mm ---!!! ~ -
e : erfOIIt I confonne I accepted
-------- ---
.c Diatan<eiiUIIaca-daflad(Z)onmm .5;
v l .c
<
OisiBn<OpcinloltOietonce-dolvd (ZJ/n.,.,
~~~ 1------------- ·-- . . . ·-·- .
'2 j" ne _ nicht erfilllt
cgr--+ ~-·--® Einschai!winkei in • J!!.'!li!
"*: Angle do nlfradicn on • I Beam anglo In ' aaa:..! - non conforme I not aggepted
SVS PrOfer. B.Geistert EN 473 • UT2 Kunde: lnspektor von:
ASS Examinateur Client
;?
lnspecteur de:
SWA Examinator: Customer. Inspector from:
-----------t--...:....-'-----------~-----·- -----·-···--·-------- -----· ----·-···
Datum 1 Date: 08.06.2011
---~ .. r=-~'- ------ -----------·-·- --------------·-···- - -·-
Datum/Date: Datum/Date:
Visum Superviser.
Signature superviseur: j
1
.
1:
\- · '
,i
·
$'~f ~) vrsum:
Signature:
!
j
Visum:
Signature:
Dieser Pn11bllllcht bezieht slcfl nur euf des ertdlhnlo Pr\ifobjokt
ec.rappor~cr...... C\CitltlfiDIDqarobjDIMIUI'IIii;Aroaaa:t
lla lnl ' - - ' ,.,_. t:Jdrlo,.,_ tut.d
PW""' (P) I PrlltprOI I \IOd8gel1 I UTI - - 8.2001-FB
~ SCHWEIZERISCHER VEREIN FOR SCHWEISSTECHNIK Z78-UT-14
svs XASS ~
ASSOCIATION SUISSE POUR LA TECHNIQUE DU SOUDAGE
SWISS WELDING ASSOCIATION Blatt: von:
page: 1 delof: 1
CH-4006 Basel St.Aiban-Rheinweg 222 Telefon 061-317 84 84
nach I seton 1 ace.:
~ Ultraschaii-Prufbericht A-Nr.:
0-No.: 278/11
~ Rapport d'Examen Ultrasonique UT EN 1714
----·
PB-Nr:
- ...... --···--- --·· -·- -
srs 146 Ultrasonic Examination Report R-No.:
Auftraggeber: EKATO Ruhr- und Mischtechnik GmbH Kunden-Beslell Nr:

Commenant No. de commands: 214/411110293
_9_'!~~-- __ __ D - 79650 Schopfheim __________ ·---·-. ________ _ Customet's Order No.:
Objekt: Lager-Ruhrwellen ~ 60 Zeichnungs Nr.:

ObJet/ObJect: Kom. Nr. 80053 No plan I Drawing Nr.
·----- ---+-------------------·------ ··--·-··--
Prilfort: EKA TO Ruhr- und Mischtechnik GmbH Position:
Ueu d'examen:
Re~re/ltem:
40
Examinalionsite: D- 79650 Schopfheim
Prilfbereich: Schweissverbindung Protumfang:
Section examint!e: Elondue d'examen: 100 %
Exatr/nalion range: ___ • __ __ __ ___ Welle - Flansch EJCamjnaiJon scope:
Priifzeitpunkt Werkstoff:
Slade d'exemen: 15.06.2011 Matt!riau: 1.4571
Moment of examln.: Material:
Priifllilchenzustand: Schweissverfahren: Nahtform:
~lal de surface: bearbeitet Proc6d6 de soudage: MSG type de joint K-Naht
State--
of surface:
We!_ding_l'f'OCBss: -· ··- . __ . ·-·· . ·-- _-:- type ~fj3i'!E_ . _.
Akzeptanz-Standard: Schweisser: Name und Nr.:
Cr116res d'accepiBUon: EKATO 906-10062458 Soudeur. nom et N": 1818
Acceptance criteria: Welder. n/JIII& and N".:
c Priifgerat Typ: Justierkorper: Stufenkeil, Objekt, K2
:ii ~ I! Type d'apparell: Sonic 1200 Btocd't!tatonnage:
,C =.g Testequlpmenttype: ------------ll-::C~aU.:c.bra:.:.c.rJon'-"-"-bl.:.:.bclc=-·----9=-0=-6=---=1.-=:0..=.0..=.6=24..::..5=-8=----- ___ _
~ ~ 8 PrOfkOpfe: Frequenz:
CD ! e Palpeurs: MSEB4, MWB45° Fr6quence: 4, 2 MHz
~ -5 ,! Sean:ll un/13: Frequency:
'2 '3 :3 PrOfanweisung Nr.: Registriergrenze: 80% BSH + 6d8
ll. e .,; . N" de ptt>C8dura d'l!liiiiTien: Umllo d'erriglsllvmont :
D. Examination ptoe9dutB N: Umltofreglstralion: 50% OAK
PrOfzone Ergebnis Bemerkungen
5 p H t.H L Q t.L 8 Res..- RP11111n!U8S
Zono 9XBJilln6e
Tested zone
E.Nr. ~esui!L-- Romo:ks
mm dB dB mm mm mm mm e ne
80053RW Zl:h.Nr.201-
Pos.40 1+3 3Z o· X FA-Hr. 210264817
Pos.1+2
----·-- - - - · --
-------- ·--- ---- -----·--·-""f----~---- - - - - - - - - r - · ·----r---- ----·· -- - I· . . . . -.. -

- ----· -- ------··----·-·+-·~f--------------·---- ----r- -- -~--- - - -- - ··- j- !_ ... --. -
--- --,---·. ---· .. -- ····- -----·--··-------- -···- 1-- ·- ---·--
I
Einschallrichtung
I I S: Pnlfdicke In mm Transferverlustkorrektur in
E Nr. : Direction de sondage Epslsseur exoiiiiMe en 11!1111711ic1u>u exam/n. in mm llV1: CGmodlan do 1nlllsfod en dB
Ttrtnider-in
Scanning direction
H : EchohOhe in% (OAK= 100 %) Dilferenz zu OAK in
Houtour d'llctlo en 'II./ Echo lelll>l in" (DAC=100'!6} .1H: ~par-ODACISI dB
DiflatrJnltDDACin
Dlstanz Bezugsspunkt - Fehler (X) In mm Registrierlllnge in
L: Ol&lancopobltdotef6renco·dillslll (X) en mm Ill: ...._ enr4glslr6e .. mm
Dirfanca pdnlol,.,.,.,., • dolad PQbJ mm RegialeRJd ltmglh in
Dlstanz Bezugsspunkt - Fehler (Y) In mm Bezugsspunkt
Q: Dlalam:opobltdotef6r..... cfMautM enmm P: Point de n!lt!ranca I Poln/ of mlaronce
Dialanl:opolnlol-·delal:I{Y)blmm
Fehlertiefenlage (Z) in mm /---.!!?~~- . - - - - - ·-·----·--· .. -· ----- ....
B: --·di!IIM(Z)enmm 15 ; e: erfilllt I conforme 1 accepted
Dirfancapolnloi--defod(ZlbJmm
..;: Einschallwinkel in • fHr---·-=--:--:----::,.,---------··

ne : nicht erfilllt
'2 j 11
··- -·· -
Angle de r61racUon en • I Beam sng/8 in •
a. a: I! non conforme I not accepted
svs
ASS
PrOfer:
Examlnateur
~r~-~--
EN473, tn_:_ Kunde:
- lnspektor von:
, Client lnsplldeur de:
SWA Examinator: . CUstomer: lnspectorfrom:
·--·-----· ----·--· --- --- - --- -------- --~- -·· .. - .. -· - ···--- ·- - ---. -·- -- -· --
~:':: ::::~i-ser: . . 1~6·~-~01

~ ~tv;~-;)-·. ~;~;!_~~te: _ j- __ . _ ··---:::;:'Date: _
Signature superviseur: s1gnature: 1 Signature:
Oiaser PtUfbericht bezioht sich nur aut das eJWahl!le Plilfobjekl
eo fiiiiPOI1 croua~,. c:onoamD que robjo1 ~ • rO&IIIi
T1a lnl •P«t ,.,.,_ onlY lo Ute jonq totll«<
PW 811f(P) I"'""""' I Vorlllgen I UTI
1\usgBbo 8.2001-fB
9
1 von 1
EI<ATO RMT 10092376
,OberfUichenriBprufung" Abnahmeprufzeugnis 3.1 EN 10204
,surface crack examination" Inspection certificate 3.1 EN 10204
EKATO-Auftrags-Nr. I EKATO order no.:
Kundenposition I customer item:

Fertigungsauftrags-Nr. I job no.:
Gepruftes Teil I examined component:
Zeichnungs-Nr. I drawing no.:
Anzahl I quantity: 2 Stuck I piece
Grundwerkstoff I base material:
Prufverfahren I examination method: Farbeindringverfahren I dye penetration check

gem. I ace. to: Jt{AD 2000 IHP 5/31 DIN EN 473, Werknorm I works norm 906-10047005
;lFa. Helling
Prufflachenzustand I surface condition: J( geschweiBt I welded 0 geschliffen I grinded
0 geburstet I brushed 0 elektropoliert I electropolished
0 gedreht I machined
PrGfmittelsystem I testing system: J( Nord-Test U-Serie
Verfahren I procedure:
Eindringmittel I penetrant: J{ Kontrastrot USB 0 Ch./lot: Alt 77}/ ()6/ Of

Reiniger I penetrant remover. . ( Reiniger 87 0 Ch./lot: f) 2o220 /0 lt fA?
Entwicl<ler I developer: ~ Entwicl<ler 89 0 Ch.llot: (? ?(!)22/1/05 {4-1
Temperatur I temperature: C..tt.ZD oc
Einwirkdauer I dwell time:
Beurteilungszeit I evaluation time:
=====:(A:~-~=v=========
~. lt~
------~~~~---------
min
min
Beleuchtungsstarl<e I lighting intensity: _ __,>~S-=-0=0____ Lux
Ergebnisse I results:
Naht zwischen Teilen I lage I location Bewertung I Bemerkungen I
welding seam between G*) U*) S*) classification remarks
parts 1 **) 0**)
0 0 0 0 0
0 ~ J( J( 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
•J G = Grundwerkstoff I IHI!;s mBtflfiBI; U = Obargangsione I rellned zans ; S ~ SchwaiBgut I weld metal
• •J 1 = kaina Beanstandung I no objections ; 0 = keina Beanstandung nach Nacharbait I no objections after refinishing
OlePrU"fung wuraeohne Beanstandung abgeschlossen.
The test was passed without objections.
Prufer I examiner, Datum I date: Ucf ~6, IJ/;, 2o;tl4 rrz
Abnahmebehorde I Acceptance authority, Datum I date:
PrOfprotokoll gesehen I test record review:
Kunde I customer, Datum I date:
Dokument aktualisiert: SMN " /
u,: a.lo."'o Jf71V
gepruft:
z.f;.a;;.Jo
PJ?J Freigabe: SCA
zr-." ,...
<..$-4
EI<ATO RMT
lnhaltsverzeichnis
List of Contents
1. QS - Plan I QA - Plan
5. EKATO Probelauf Protokoll I EKATO Test Run Certificate

EKATO Riihr- und Mischtechnik GmbH
EI<ATO RMT
lnhaltsverzeichnis
List of Contents
1. OS - Plan I QA- Plan
EKATO Ruhr- und Mischtechnik GmbH , 79650 Schopfheim

EKATO Ruhr- und Mischtechnik GmbH EI<ATO RMT
10065329
Ri.ihrwerks-Probelauf I Agitator Test-Run Certificate
Kunde I customer : Lanxess Datum I date : 29.09.11

EKATO Nr. I serial no. : 80053-40
Pes./ item : 70-RW 400 Prufer I examinor : Ahrens, Daniel
----~~~~~~---
Ruhrwerkstyp I agitator type : HWL 2060 N Motor-Serien-Nr./ engine serial no.: 0967645001105 H
Getriebe-Serien-Nr./ gearbox serial no.: FDU110512049233-001
FunktionsprOfung auf PrOfgrube I functional check on testpit
Kritisch e Drehzahl nk I critical speed nc RundlaufprOfung I shaft run-o ut measurement ( WN 10029072 l

( 9emessen am RW-Ende in Luft I measured at the shalt-end in air )
gemessen I yes ~---'2=-~:.8.: ___ min-1/ rpm
measured: no gem essen I yes []] 1,1 mm
measured: no D
Toleranz I tolerance: 2 mm/m
Leistungs messwerte I Power measurements :
Leistungsmessung ( elektrische Wirkleistung ) am Prtifpult I power measurement (efficient electric power) at the testdesk
1. Lauf in Luft I run in air : Bemerkung I remarks~

Laufeigenschaft I run Am~ kW Volt r~m
Igut I g_ood I I 1,7 I 0,8 I 400 1144,8 1 •• gerechnete Werte I calc. data
2. Lauf in Wasser I run in water: I

Laufeigenschaften I run Am~ kW Volt r~m
Igut I g_ood I 4 ,3 I I I 2,4 400 1144,51 I
Rechnerische Leistung bezogen auf ProdukU I 2,4 I

calc. power drawn in product: •• Motorleistung ausreichend/ [K]Ja I yes
Motorwirkleistungtl 3,46 engine power adequate: I 0Neinlno
effective engine power: ••
zusatzliche Messungenl Gerauschmessung nach AFV 1001 7620 I noise
special measurements: 1m MeBstab I measuring distance
in Luft I in air: 59 dB(A)
in Wasser I in water: 66 dB(A)
Vibrationsmessung nach AFV 10017620 I vibration measurement
Messunqen nicht mit starrem Prufbock I measured with flexible testpit
in Luft I in air: 0,35 mm/s
in Wasser I in water: 0,45 mm/s
Temperaturmessung I temperature measurement
nach I after : 30 min
Getriebetemperatur I g_earbox temp.: 35,7 •c
Dichtungstemperatur I gasket temp.: •c
Bemerkung I remarks : Motortemp measurement after 30min. -- 29,9•c
Powermeasurement 105% /149r~m /2,6kw
- ' .,
~-·----------~
·c•'>"EI<Ato':O~
:? [¥:raat
\(!lpp Jrllfl ~\Ill>
l' ~
"'
·· .
' i't • ·
•akzeptiertl Ja I yes 0 Kunde 1 customer : TUV s.Jo Ghe~
!~
-- \WVItne~
,c Suv" G:nooi
uvi~
Datum I aate: . ·' ' '' ,,orl· Nein I no D Datum I date: --t-J~
~~c·~'l"
~ ~..._;-;;-zSC~~/~+--
~ ~~v ~m~
Version: 1.1 I Aug-09 7 'Te?
""•:l.J;, HN !:UiJ ('I··:),' S:"P' .o: '·· 1'

~fJ· ~~ fl.:"'"'.ll :· ,.,
~~-~- r.~i;v
TO'I . C· ..,
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, , , I 1 l'"t' ·· ··-
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EI<ATO RMT
lnhaltsverzeichnis
List of Contents

~ 2. Materialzeugnisse I Material Certificates

SIEMENS Test report 2.2
DIN EN 10204
Siemens Geared Motors GmbH, Postfach 1709, 72007 Tublngen
Siemens AG Order Number /Item:

I DTMD FB BCH 15089182 I 000020
Fachbereiche Bocholt
Alfred-Fiender-Str. 77
D-46395 BOCHOLT Order No. I Date:
411220062 HP 40/50/60 /21.03.2011
Numbers Object Type

Paral. shaft geared mot FZF688-K-(1 00)
Serial No.: 2049233
Material Application
17 CrNiMo 6 gear wheel/pinion shaft bevel gear/bevel pinion shaft sun pinion, plan etarv gear
16 MnCrS 5 CAVEX worm shaft non gears internal parts coupling parts
34 CrNiMo 6 gear wheel/pinion shaft, CAVEX worm shaft, ring gear, coupling parts
42 CrMoS 4 gear wheel/pinion shaft, CAVEX worm shaft, ring gear, coupling parts
C45 N C 60 N shaft (normal: C 45 N high stress: C 60 N) coupling parts
GZ-CuSn 12 CAVEX wheel rim
GG housing parts, coupling parts disc
GGG planetary carrier disc coupling parts
S235J2G3/S3!-i housing parts torque arms base plates
ST60-2 Input- intermediate-, output shafts
VL22 Worm gears
Material c Sl Mn p s Cr Ni Mo Mg e:u ZN Pb Sn liensile

% % % % % %> % % % % % % % strength
<= <=
17 CrNiMo 6 0,17 0,26 0,52 0,035 0,035 1,65 1,46 0,26 - - - - - >=1 100 N/mm2
16 MnCrS 5 0,17 0,28 1,15 0,035 0,035 0,95 - - - - - - - >=785 N/mm2
2
34 CrNiMo 6 0,38 0,18 0,534 0,035 0,035 1,49 1,51 0.205- - - - - >=800 N/mm
42 CrMoS 4 0,42 0,23 0,524 0,035 0,035 1,03 - 0,18 - - - - - >=880 N/mm2
C45 N 0,46 0 ,25 0,65 0,045 0,045- - - - - - - - >=620 N/mm2
C60 N 0,59 0,25 0,75 0,045 0,045- - - - - - - - >=735 N/mm2
GZ-CuSn 12 - - - - - - 1,55 - - 85,73 0,30 0,32 12,1 >=300 N/mm2
Ni
GG-20 3,35 1,50 0,55 0,15 0,15 - - - - - - - - >=200 N/mm2
up to up to up toup to up to
GG-30 3,20 1,40 0,60 >=300 N/mm2
GGG-35 3,67 2,04 0,074 0,024 0,007 0,0 0,508- 0,052- - - - >=350 N/mm2
up to up to up toup to up to up to up to up to up to up to
2
GGG-80 3,60 2,45 0,80 0,0 0,0 1,0 0,0 0,050 >=900 N/mm
2
S235J2G3 0,17 - 1,4 0,035 0,035 - - - - - - - - >=340 N/mm
S355J2G3 0,2 0,55 1,6 0,035 0,035 - - - - - - - - >=490 N/mm 2
ST60-2 0,40 - - 0,050 0,05C - - - - - - - - >=600 N/mm2

VL22 - 0,50 2,00 - - - - - - 58,00- - 1.4 >=280 N/mm2
This document was electronically generated and is therefore valid without signature.
15.06.2011 shop authority
SIEMENS Certificate of compliance with order 2.1
DIN EN 10204
Siemens Geared Motors GmbH, Postfach 1709, 72007 TO bingen
SiemensAG Order Number I Item :

I DTMD FB BCH 15089182 I 000020
411220062 HP 40!50/60 I 21.03.2011
Numbers Object Type

Paral. shaft geared mot FZF68B-K-(1 00)
Serial No.: 2049233
The parts were submitted to a thorough, final test and passed with regard to the required
characteristics of working accuracy to the tolerances given in the drawing and qualitity of the
material.
We confirm herewith that the equipment is in full accordance with our works regulations.
SIEMENS Test Report 2.2 - Drive
DIN EN 10204
Siemens Geared Motors GmbH, Poslfach 1709, 72007 TObingen
SiemensAG Order Number I Item:

I DTMD FB BCH 15089182 I 000020
411220062 HP 40/50/60 I 21.03.2011
Numbers Object Type

1 Para!. shaft geared mot. FZF68B-K-(1 00)
Serial No.: 2049233
Gear Data
Gear type FZF68B
Gear type (CAVEX)
Output torque 206
Output speed
Ratio 10,310
Input speed
Mounting position V1-00-A
Service factor
Output shaft V50x 100
Flange diameter 250
Kind of oil1 CLP PG VG220
Oil quantity 1 3,50
Oil quantity 2
Motor [)ata
Motor type 100
Power (K'N)
Current
Voltage
Voltage
Frequency
Cos Phi
Speed
Protection IP55
Insulation class
gn r.l Page-No.
2.2 ace. to DIN 50 049 1 EN 10 204 Blatter I total:
nach DIN 50 049 I EN 10 204 Prufber.Nr.fTest Rep. No.
ace. to DIN 50 049 I EN 10 204
Empfanger I Consignee Bestellung Nr. I Order No.
1031411220063
Vertrag Nr./Contract No.
k12696C9
Lieferbedingungen undlod. amtliche Vorschrilten:
IS~teciticattiorls and/or Official Regulations:
EN 60034·60079·61241
Kuhlmitteltemperatur KL 155
temperature
Schaltung I Connection 40 "C IP 65
DN
400 I 690 A 6,50 I 3,75 Hz/ cis 50 kW 3.0
cos q> 0,77 86,5 % 1455 Kuhlungsart/Cooling system IC 411
Betriebsart S1 NEMA IM V1FF215 kg 45
Temp.-Kiasse T3
e 113G EExnAII T3
Tern class
Wicklungsschutz:
Winding protection:
Sp.2474 Festlager:
Other indications: Fixed bearing: Drive-side Not drive-side
Lager 61geschutzt: D-SeiteO N-SeiteO
Bearing oil-proof: Drive-side Not drive-side
Lager staubgeschutzt: D-SeiteO N-SeiteO
Not drive-side
run:
Strom Leist.-Aufn. cos cp Drehmom. Leist.-Abg. Drehzahl

Current Input Torque Output Speed
A kW Nm kW min· 1
KurzschluB 400 50 54,886 25,086 0,660

Locked rotor
Verhaltnis: 8,444 3,680 MK I M: 4,110
Relation: current Pull·out
lsolationsmessung bei warmer Maschine I Insulation measurement at warmed-up state: >50 MQ

Stator-Temperaturerhohung bei Bemessungsleistung I Stator temperature rise at rated load: 32,9 K
(gemessen nach Widerstandsmethode I measured by resistance method)
Stator-Wicklungswiderstand bei 20 "C I Stator winding resistance 20"C: 3,44 Q
Stator-Wicklungsprufung gemaB DIN EN 600341 Winding test according to DIN EN 60034
Fur das Erzeugnis ist die elektrische und mechanische Funktionstiichtigkeit durch eine Stiickpriifung nachgewiesen.
For the product the electrical and mechanical servicebility has been proved by piece testing.
Es wird bestiitigt, das die Lieferung den Vereinbarungen der Bestellung entspricht.
We hereby certify, that the product described above complies the terms of the order.
Dieses Dokument wurde elektronisch erstellt und ist auch ohne Unterschrift gultig.
This document is created electronically and therefore valid without signature.
Datum 05.05.11 Pruffeld: Grafe

Date:
EI<ATO RMT
lnhaltsverzeich nis
List of Contents
1. OS- Plan I QA- Plan
4. TOV Zetiifikate Montageflansch I TOV Certificates Mounting Flange

EKATO Ruhr- und Mischtechnik GmbH EI<ATO
Customer: LANXESS Butyl Pte. Ltd.
Project: Lanxess BTR, Singapore, Agitators (Finishing)
Customer PO no.: 310238840
EKATO order no.: 80053-10-60,
Items: 70RW1 00, 70RW201, 70RW202, 70RW400, 76RW900, 81 RW700
Lackiervorschrift I Painting Specification: System STREICOLOR
"
:!·[-,·,,-,
ErhOhter Korrosionschutz/''' ·· ,..., •. ·TFD
Increased Corrosion Protection (*)
J.l.ffi
Untergrund I Alu., Stahl, GrauguBI
Substrates Aluminium, Steel, Cast Iron
Untergrund Vorbehandlung I Rz > 10 11m
Substrates Pretreatment SA 2,5 (DIN EN ISO 12944-4)
Verarbeitung I Druckluft Becherpistolel
Application method Air Spraying
Grundierung I Typ I Type: STREICOLOR 2K EPM-C 40
Primer Coat Blei- und Chromatfreie 2- Komponenten
Korrosionsschutzgrundierung auf Basis
amingehartetem Epoxidharz
Unleaded and chromate free 2- component
primer based on amine hardned Epoxyde
Resin
Decklack I Typ I Type: STREICOLOR 2K KAD-EMAIL, 30
Final Coat PU-240-50
2 Komponenten Polyurethan Lack I
RAL 5003 2 component Polyurethane Paint
Gesamt-Trockenschichtdicke I 70
Total Dry Film Tickness
Schichten I Layers 2
Temperaturbereich I Temperatur Range
- Dauer I Permanent: -60"C + 150"C (-76°F + 302"F)
- Kurzzeitig I Short Term: 180 "C (356 °F)
Anwendung I Location Au Ben und lnnen I Outdoors and Indoors

(•) TFD. Trochenschtchtdtcke I Dry Film Thtckness
EKATO Riihr- und Mischtechnik GmbH
1 von 1
EI<ATO RMT 10065174
Werksbescheinigung gem. DIN EN 10204 2.1

declaration of compliance ace. to DIN EN 10204 2.1
Wir bestatigen hiermit die Einhaltung der spezifizierten und in den technischen Unterlagen dokumentierten
RuhrwerksausfUhrung.
We herewith certify that the. agitators have been manufactured ace. to the specifications.
Dokument aktualisiert: ~ gepriift: PJ Q) Freigabe: SCA

JO. tJ<t.U}tD :!P-04· Zo-IC !J J·-~- l ~..r- Jvt
e
1 von 1
EI<ATO RMT 10014838
Werksbescheinigung ,MaBkontrolle"
certificate of compliance ~dimensional check"
Die Mal?.kontrolle der Hauptabmessungen und Anschlussmal?.e der RGhrwerke bzw. RGhrwerkteile wurde
nach den EKATO- Richtlinien im Prlrfgang durchgefuhrt.
Wir bestatigen hiermit die Einhaltung der in lhren Bestellunterlagen spezifizierten und in den technischen
Unterlagen dokumentierten RuhrwerksausfGhrung.
Main dimensions and fitting dimensions of the agitator parts resp. were checked ace. to EKA TO- rules
during the final inspection.
We herewith certify that the agitator has been manufactured ace. to your specification and ace. to the
technical documents.
h~
Ab na me ·eau ragter mspectJOn
. representative
·
Dokument aktualisiert: SM'A..,J

4£>. O't."Z.D.-t 0 .,Yll
gepriift: PJ
6o .b'f .2o _! o
f7 Freigabe: SCA
.l. S11•
~
'"'/f
\
1 von 1
EI<ATO RMT 10014751
Werkszeugnis gem. DIN EN 1 0204 2.2
test report ace. to DIN EN 10204 2.2
Wir bestatigen hiermit, dass die gelieferten Erzeugnisse den Vereinbarungen der Bestellung entsprechen
und dass die festgelegten Prufungen nach den EKATO- internen PrGfvorgaben durchgefiihrt und die
erforderlichen Freigaben erteilt wurden.
We herewith confirm that the delivered goods comply with the agreements stipulated in the order and
that the agreed tests according to the EKATO- internal Test Procedure were carried out and the required
releases were given.
Abnahmebe
Dokument aktualisiert: SM
."L.. ar: zo-lO
gepruft: PJ .
A 2 f1-o.. cP./r;
r'JJ
"/'
Freigabe: SCA
fl.S: I~ JC-,t
\

70RW400 V99 4421 Gearbox Part List Pg.120-127

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PROJECT TITLE: BTR SINGAPORE PROJECT

for the Agitator

P.O. No.: 310238840

Compiled by: SCK Checked and released by: rff')(

EKATO Ruhr- und Mischtechnik GmbH +49 171 771 94 94

Index Date Name Description

1 29.02.2012 TDA Revision acc. Agreement dated 07th Feb. 2012

Basic document:inpro_e.chp Agitator-type: HWL 2060 N Table of contents

4.0 Safety Instructions 13

Basic document:inpro_e.chp Agitator-type: HWL 2060 N Table of contents

5.0 Safety Instructions 38

6.0 Safety Instructions 47

7.0 Safety Instructions 52

Basic document:inpro_e.chp Agitator-type: HWL 2060 N Table of contents

8. EKATO-Parts list and Drawing(s) 60

9. Instructions and Parts Lists of non-EKATO-Components 76

10. Manufacturing Data Book for 70RW400 (Page 298 onwards)

Basic document:inpro_e.chp Agitator-type: HWL 2060 N Table of contents

Customer : LANXESS Butyl Pte, Ltd

Customer : LANXESS Butyl Pte, Ltd

PARALLEL HELICAL GEARBOX:

EXTERNAL AGITATOR COMPONENTS

ARRANGEMENT I WEIGHT I OVERALL HEIGHT

Customer : LANXESS Butyl Pte, Ltd

ELECTRIC AND OTHER CONNECTIONS

AGITATOR BEARING UNIT

COI.I~OIT ST~TUS COOE

CONTRACT Nc. \-f'0-0353 S'I'S1EI.\ No.: t.b.o SCALE: l:B

SUPPLIER LOGO AND ADDRESS

CLIENT OWG No.: C30001-EKT01-GAA-oo3l""'~f3g

Basic document: 2platz_e.chp Agitator-type: HWL 2060 N 2. Declaration by the Manufacturer

3.2 Using these

Basic document: 31_e.chp Agitator-type: HWL 2060 N 3. Safety instructions

The ATEX certification (when applicable) in

Basic document: 31_e.chp Agitator-type: HWL 2060 N 3. Safety instructions

EKATO Ruhr- und Mischtechnik GmbH

Dear user of EKATO-agitators

For your comments:

Basic document: 32_e.chp Agitator-type: HWL 2060 N 3. Safety instructions

An appropriate form is to be found on the following page of these service instructions.

Basic document: 32_e.chp Agitator-type: HWL 2060 N 3. Safety instructions

You return I returned to EKATO RMT GmbH for repair I modification:

D Agitator D Mechanical shaft seal

D Motor I Gearbox D Mechanical shaft seal rings

D Agitator shaft D Others

Company name (Address):

Place, Date Stamp I Signature - Customer

Will be filled out by EKATO RMT:

On the face of it, the parts are okay! (visual check)

Basic document: 32_e.chp Agitator-type: HWL 2060 N 3. Safety instructions

Clearance - Certificate (Additional specification)

Last operating medium :

Material safety data sheet of the Dyes D no

last operating medium enclosed

Recommended safety/protective measures: (Please mark the relevant points)

Place, Date Stamp I Signature - Customer

Basic document: 32_e.chp Agitator-type: HWL 2060 N 3. Safety instructions

It must be ensured that the system is in a safe & CAUTION

Before all maintenance work and/or WARNING

Work on electrical equipment should only be

for vessels with lids:

the agitator must only be operated when the