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Technische Dokumentation
Technical Documentation
Documentation Technique
Inbetriebnahme / Instandhaltung / Wartung
Commissioning / Service / Maintenance
Mise en service / Utilisation / Entretien

Kunde | Customer | Client


HEGENSCHEIDT-MFD GMBH & CO. KG
Endkunde | End Customer | Client finale
Hegenscheidt-MFD GmbH & Co. KG
Projekt | Project | Projet
209000498 / 10-03-2009
Mayfran Systemnr. | System no. | No. de système
09W3582
Projektleiter | Project Manager | Présider de Projet
H. Jacobs
Anlage Umschreibung/Referenz | System description/reference | Description/référence de système

Mayfran International B.V. Mayfran GmbH Niederlassung Süd


P.O. Box 3103 Edisonstraat 7/ 9 Hüttenstraße 7 Richthofenstraße 32
6370 AA Landgraaf 6372 AK Landgraaf 52068 Aachen 73312 Geislingen/Steige
The Netherlands Germany Germany

+31 (0) 45 532 92 92 +49 (0) 241 93 87 20 +49 (0) 7331 95 53 0


+31 (0) 45 532 93 00 (fax) +49 (0) 241 17 50 80 (fax) +49 (0) 7331 95 53 55 (fax)

info@mayfran.eu sales@mayfran.eu
www.mayfran.nl www.mayfran.de
Prepared
Preparedby K.
by K. Marijnen
Marijnen

Inhalt Allgemein
Inhalt Allgemein | General |table
General table of contents
of contents | Index
| Index d'général Print
Print version
version
d'général 21/7/2009
21/7/2009
0
Mayfran Systemnr. | System no. | No. de système : 09W3582
Mayfran Systemnr. | System no. | No. de système : 09W3582
Pos.nummern laut Übersichtszeichnung | Item number according general drawing | No. de Position d'après le plan gererale

I SICHERHEITSHINWEISE (UND GEWÄHRLEISTUNG, LAGERUNG, ENTSORGUNG)

SAFETY INSTRUCTIONS (AND GUARANTEE, STORAGE, DISPOSAL)

CONSIGNES DE SÉCURITÉ (ET LA GARANTIE, LE STOCKAGE, LE TRAITEMENT DES DÉCHETS)

II DOKUMENTATION MAYFRAN KOMPONENTEN


DOCUMENTATION MAYFRAN COMPONENTS
DOCUMENTATION MAYFRAN COMPOSANTS

III DOKUMENTATION ZULIEFERANTEN


SUPPLIER DOCUMENTATION
DOCUMENTATION SUPPLEMENTAIRE

____________________________________________________________________________________
MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS - Tel.: (31) 45 5329 292 info@mayfran.eu
I
I
• Vorbemerkungen (Gewährleistung, Lagerung, Entsorgung etc.)
• Preliminary remarks (guarantee, storage, disposal etc.)
• Předběžné poznámky (záruka, uschovávání, užívání atd.).

TRUE
de en cs


• Die Einhaltung dieser Anleitungen • A requirement of fault-free • Požadavek bezvadného fungování
und Hinweise ist die Voraussetzung operation and fulfilment of any a plnění jakýchkoli práv
für Störungsfreienbetrieb sowie die rights to claim under warranty is potvrzených zárukou bude přijat
Erfüllung eventueller that these instructions and notes pouze při dodržování těchto
Gewährleistungsansprüche. Lesen are followed. Therefore read these instrukcí a poznámek. Takže si
Sie deshalb zuerst diese Anleitung, instructions before working with the přečtěte tyto instrukce před prací s
bevor Sie mit die Anlage arbeiten! Installation! instalací.

• Die Anleitung enthält auch wichtige • These instructions also contain • Tyto instrukce také obsahují

' Hinweise zum Service. Sie ist


deshalb in der Nähe der Anlage
aufzubewahren.
important information concerning
service. They are therefore to be
kept near the installation.
důležité informace týkající se
servisu. Takže by se měly uschovat
i při instalaci.

• Wenn bestimmte Sektionen der • If certain sections of the operating • Jestliže podle Vašeho názoru určité

' Bedienungsanleitung nach ihrer


Ansicht nicht verständlich sind,
oder fehlen, melden sie dies
unverzüglich an Mayfran. Schäden
instruction are not clear or missing,
in your opinion, than report this
immediately to Mayfran. Damage
due to false interpretation or false
části instrukcí nejsou jasné nebo
chybí, okamžitě kontaktujte
Mayfran. Škoda kvůli špatné
interpretaci nebo nedodržení
infolge falscher Interpretation oder acceptance of the operating instrukcí nespadá do záruky!
falscher Annahmen der instruction does not fall under the
Bedienungsanleitung fallen nicht warranty!
unter die Garantie!

• Jede Maschine wird nach den bei • 'Each machine is manufactured • Každý stroj se vyrábí a testuje

L Mayfran gültigen technischen


Unterlagen hergestellt und geprüft.
and tested to current Mayfran
technical specifications.
podle současných technických
specifikací Mayfran.

• Untersuchen Sie die Lieferung • Check the delivery for possible • Zkontrolujte dodávku kvůli možným

1 sofort nach Erhalt auf etwaige damage, which may have occurred
Transportschäden. Teilen Sie diese during transportation as soon as
sofort Mayfran mit. you receive it. Inform Mayfran
škodám, ke kterým mohlo dojít
během přepravy, ihned po převzetí.
O jakékoli škodě informujte
Verspäte Meldungen können nicht immediately of any damage. Mayfran okamžitě.
akzeptiert werden. Belated reporting cannot be
accepted.

• Wenn Sie die Anlage nicht sofort • If the installation is not being • Neprovádíte-li instalaci ihned,

à einbauen, lagern Sie ihn in einem


trockenen, staubfreien und
schwingungsarmen Raum bei -5
bis +40 °C.
installed immediately, store in a
dry, dust-free and almost vibration-
free room at -5 to +40 °C.
uchovejte stroj na suchém místě
bez prachu a otřesů při teplotě od -
5 do +40°C.

• Entsorgung (Bitte beachten Sie die • Disposal (Please observe the • Užívání (prosím sledujte pravidla

l
aktuellen Bestimmungen) applicable waste disposal pro nakládání s odpady) Podle
Entsorgen Sie die Anlage je nach regulations) Depending on the toho, z jakého materiálu jsou
Beschaffenheit und existierenden material they are made of, the vyrobeny, mělo by se s instalací
Vorschriften als installation has to be disposed of in nakládat v souladu s pravidly pro
–Metalle accordance with the applicable nakládání s odpady pro -kovy -
–schädliche Flüssigkeiten waste disposal regulations for kapaliny -plasty -elektroodpad
–Kunststoff –metals
–Elektronikschrott –liquids
–plastics
–elec. waste

13-07-2009 MAYFRAN INTERNATIONAL - PO-BOX 31032- 6370 AA LANDGRAAF - NETHERLANDS TEL: (31) 45 5329 292 1/5
Sicherheitshinweise/Safety instructions/Consignes de sécurité
TRUE

de en cs
• Diese Betriebsanleitung enthält • These operating instructions • Tyto instrukce obsahují základní

1
wichtige Hinweise und contain fundamental information informace a bezpečnostní
Warnvermerke. Bitte vor Einbau, and precautionary notes. Please poznámky. Prosím, pročtěte
elektrischem Anschluß und read the manual thoroughly prior to manuál prioritně před instalováním
Inbetriebnahme unbedingt lesen. installation of unit, electrical jendotky, elektrickým zapojením a
Weitere Betriebsanleitungen, die connection and commissioning. it's uvedením do provozu. Je nutné si
zusätzliche Komponenten essential to read all other additional přečíst všechny další uživatelské
betreffen, sind zusätzlich zu operation manuals. manuály.
berücksichtigen.
• Zur Vermeidung von Sach- oder • In order to prevent damage to the • Abyste předešli poškození zařízení

1
Personenschäden dürfen nur equipment or personnel, only nebo personálu, může stroj
fachkundiges Personal Eingriffe an authorized trained staff is allowed obsluhovat pouze proškolený
der Anlage vornehmen. Die to operate the system. The relevant zaměstnanec. Měly by se
einschlägigen UVV- und VDE - local safety regulations as well as respektovat místní bezpečnostní
Sicherheitsvorschriften, sowie special conditions of the authorities pravidla stejně jako speciální
spezielle Auflagen der zuständigen in charge are to be respected. podmínky zainteresovaných autorit
Behörden sind zu beachten.

• Um eventuell auftretende • In order to spot possible leakage of • Abyste si vždy a spolehlivě všimli

1
Undichtigkeiten an der Anlage the system in a quick and reliable možnému unikání kapalin ze
schnell und zuverlässig erkennen way, the system always has to be systému, systém v běhu musí být
zu können, darf die Anlage stets under supervision while in vždy pod dozorem.
nur unter Aufsicht betrieben operation.
werden.

1 •
Benutzen Sie die Anlage nicht
zweckentfremdend!

• Arbeiten an der elektrischen



Do not use system for different
purposes !

• Works at the electrical system


• Nepoužívejte k jiným účelům !

• Práce s elektronickým systémem

2
Anlage dürfen nur von must be carried out by specialists musí být prováděny specialisty na
Elektrofachkräften vorgenommen for electronics respecting the legal elektroniku s ohledem na místní
werden unter Beachtung der vor local regulations. legální pravidla.
Ort geltenden gesetzlichen
Bestimmungen.
• Bei Reparatur und • Always Turn off main switch (the • Vždy vypněte hlavní spínač

2
Wartungsarbeiten sowie bei power) for Repair or Maintenance (elektrika) při opravách nebo
Störungen immer den Work and Lock out or secure the údržbě a zamkněte nebo
Hauptschalter ausschalten! und die system against unintentional start zabezpečte systém proti
Anlage vor unbeabsichtigter up neúmyslnému nastartování.
Inbetriebnahme sichern!

z • Bei Berührung mit Spänen oder/mit • Use safety clothing, safety shoes • Používejte bezpečnostní oblečení,

8
KSS; Schutzkleidung, and gloves when coming in contact boty a rukavice, když přicházíte do
Sicherheitsschuhe und with chips or/and coolant. kontaktu s odštěpky nebo/a s
Schutzhandschuhe tragen chladící kapalinou.

• Schließ immer die • Always close ball valves and turn • Fermez toujours les vannes et

w
Rohrleitungsschieber und setz die off the pressure before Repair and coupez la pression avant toute
Anlage drucklos bei Reparatur und Maintenance Work and for Faults, intervention afin d’éviter éviter les
Wartungsarbeiten sowie bei to prevent coolant from leaking fuites au sol. Jetez le lubrifiant
Störungen.Kühlschmierstoffe onto the plant floor! dans un conteneur destiné à cet
dürfen nicht in die Umwelt effet.
gelangen
• Niemals Sicherheitseinrichtungen • Never bypass safety installations! • Vždy zavřete kulové ventily a

1
überbrücken! The function of the safety vypněte tlak před opravnými a
Die Funktion von installations always has to be údržbovými pracemi, abyste
Sicherheitseinrichtungen muß guaranteed. předešli úniku kapaliny z chladiče
immer gewährleistet sein! na podlahu.

13-07-2009 MAYFRAN INTERNATIONAL - PO-BOX 31032- 6370 AA LANDGRAAF - NETHERLANDS TEL: (31) 45 5329 292 2/5
Sicherheitshinweise/Safety instructions/Consignes de sécurité
TRUE

de en cs
• Bei kundenseitigem Anbringen von • Equipment parts added by the • Když kontejner na

1
Bauteilen auf sachgemäße customer have to be mounted materiál/odštěpky není zabezpečen
Befestigung achten! properly. proti přetížení, bod vytlačení musí
být viditelný.

• Arbeiten an der Anlage für nicht • Unqualified staff is not allowed to • Nikdy nestůjte na/v otvoru na

1
qualifizierte Personen verboten! operate the system! příjem materiálu a nesahejte do
tohoto prostoru.

• Alle Angaben und Anweisungen der • All of the instructions and notes of • Před uvedením stroje do chodu

1
mitgelieferten Betriebsanleitungen the included operation manuals zkontrolujte, zda všechny pohonné
stets beachten! have to be followed. části jsou přikryté (je-li to možné).
Také zkontrolujte, zda všechny
bezpečnostní opatření jsou funkční.
• Kleben Sie die mitgelieferten • Stick the included stickers on easily- • Nikdy nesahejte do otvoru na

1
Aufkleber auf eine gut sichtbare visible places on the nabíjení/vybíjení!
Stelle an dem Förderer/die conveyor/Machine.
Maschine.

• Überzeugen sie sich vor • Check before putting the • Nikdy neobcházejte bezpečnostní

X
Inbetriebnahme davon das alle installation into operation if all předpisy! Fungování
Antriebselemente, falls möglich, driven elements are covered (if bezpečnostních instalací musí být
abgedeckt sind und das alle possible). Also check if all safety zaručeno.
Sicherheitseinrichtungen measures are operational.
funktionsfähig sind..

Y • Abdeckungen bei Betrieb der


Anlage nicht entfernen!
• Never remove covering materials
while the unit is in use!

• Bei laufendem Betrieb nicht in die • Never reach into the discharge/ Součástky vybavení dodané

X
Ab-/Einwurföffnung greifen! Charge opening! zákazníkem musí být řádně
namontovány.

Y
• Wenn die Anlage nicht • Use audible or visual warning • Nekvalifikovaní zaměstnanci nesmí

1
kontinuierlich benutzt wird, soll bei signals or both to warn off the systém obsluhovat!
jeder Inbetriebsetzung ein audio- conveyor's actuation, especially if
visuelles Signal gegeben werden the conveyor is not operated
continuously.

• Bei auftretenden Störungen bzw. By occurring disturbances or Všechny instrukce a poznámky v

1
Beschädigungen der Anlage ist damages of the system shutdown provozních manuálech se musí
diese unverzüglich stillzulegen, um the installation immediately, in dodržovat.
weitere Schäden zu vermeiden. order to avoid further damage.
WICHTIG!!! Die Störungen bzw. IMPORTANT!!! Report the
Beschädigungen sind unverzüglich disturbances or damages
bei Mayfran zu melden. Wird die immediately to Mayfran. When the
Anlage ohne unsere ausdrückliche installation without our
Zustimmung weiter betrieben, sind authorization is continued to
etwaige weitere Schäden von operate, any further damage is
unserer Haftung ausgeschlossen. excluded from our responsibility.

13-07-2009 MAYFRAN INTERNATIONAL - PO-BOX 31032- 6370 AA LANDGRAAF - NETHERLANDS TEL: (31) 45 5329 292 3/5
Sicherheitshinweise/Safety instructions/Consignes de sécurité
TRUE

de en cs
• Tragen Sie immer Augenschutz • Wear eye protection and a helmet • Nalepte si dodané samolepky na

0
und Helm bei Arbeiten mit oder an if it is essential to work close to or dobře viditelná místa na pás/stroj.
die Anlage/Förderer. on the machine/conveyor.

9
• Arbeiten an die Anlage mit lose • Keep loose clothing (cuffs, tie etc) • Před uvedením do provozu

=
hängendem, langem Haar und/oder and long hair well out of the way of zkontrolujte, zda všechny části jsou
lose hängender Kleidung ist nicht moving parts. zakryté (je-li to možné). Také
gestattet. zkontrolujte, zda všechny
bezpečnostní opatření jsou
• Nehmen Sie Ihre Ringe und • Remove rings, wrist watch etc. • dodržovány.

1
Armbänder, Halsketten usw. vor before working on the conveyor, Nikdy neodstraňujte krycí
Beginn des Arbeiten an die Anlage especially the electrical system. materiály, je-li jednotka v provozu!
ab. Dies gilt insbesondere für
Elektroarbeiten.

• 'Transport mit Kran: Original oder • Transport with crane: Original or • Přeprava jeřábem: originální nebo

p
nicht original verpackt! other (not original) packaging! jiné (neoriginální) balení!
Immer die vorgesehenen Always use the original lifting eye Vždy použijte originální zvedací
Anhängevorrichtungen bolts. pásy. Nestůjte pod pohybující se
gebrauchen. Do not stand under the moving jednotkou.
Nicht unter der schwebenden Last unit!
aufhalten!
• Transport mit Hubstapler: Nur • Transport with forklift truck: • Přeprava vysokozdvižným

o
original auf Holzpalette verpackt Transport only on the original vozíkem: přepravujte pouze na
transportieren. wooden pallet. originálních dřevěných paletách.
Auch gegen Umfallen oder Also secure equipment against Také zajistěte zařízení proti
Abrutschen sichern. Nur original falling or slipping. spadnutí nebo sklouznutí.
auf Holzpalette verpackt
transportieren. Auch gegen
Umfallen oder Abrutschen sichern.

• Das ausgetragene Fördermaterial • Operational requirements make it • Požadavky na provoz neumožňují

1
muß auf verantwortungsbewußte impossible to fully enclose the plně přidat nakládací sekci
Weise weiter charge section of the stroje/dopravníků nebo systému
gefördert/verarbeitet/entsorgt machine/conveyors or conveyor dopravníků, Vaše pozornost je tedy
werden. Am Abwurf der Maschine/ systems, your attention is therefore upoutána na následující
Förderers können folgende drawn to the following potential potencionální rizika: * Zněčištění

l
Gefahren auftreten.: hazards: životního prostředí kvůli
• Umwelt-Verschmutzungsgefahr • Environmental pollution by neopatrnému nakládáním nebo
durch nicht korrekte careless disposal or wrongful future špatnému zpracování vyloženého
Entsorgung/Weiterverarbeitung des processing of the discharged materiálu z dopravníku. * Zranění
Austrags! material from the conveyor. způsobené padajícím materiálem
• Verletzungsgefahr durch • Injury caused by falling material at na vykládce dopravníku.
abfallenden Austrag! the discharge end of the conveyor.

13-07-2009 MAYFRAN INTERNATIONAL - PO-BOX 31032- 6370 AA LANDGRAAF - NETHERLANDS TEL: (31) 45 5329 292 4/5
Sicherheitshinweise/Safety instructions/Consignes de sécurité
TRUE

de en cs
• Der Verfahrensverantwortliche der • Those who are responsible for the • Ti, kteří jsou zodpovědní za

1
vollständigen Förder-/Versorgungs- conveying system have to take dopravní systém, musí efektivně
/Verarbeitungs-Anlage muß effective action to ensure personal zajistit bezpečnost zaměstnanců a
wirksame Maßnahmen treffen, um safety and environmental ochranu životního prostředí proti
die Sicherheit des Personals und protection against the above výše zmíněným rizikům. Tento
der Umwelt gegen die described hazards. This conveyor dopravník je navržen tak, aby

IIB obengenannten Gefahren zu


gewährleisten. Dieser Förderer
is designed to meet specification
requirements and has been
wurde für seine Aufgabe konstruiert delivered as part of a conveying
splňoval specifické požadavky a
dodává se jako součást
přepravního systému v souladu s
und wird als Teillieferung einer system in line with Machinery vyhláškou o strojích 98/37/EEC, čl.
Anlage geliefert gemäß EG Directive 98/37/EEC, Art. 4.2 4.2, příloha II, pod. B. Tato
Richtlinie 98/37/EWG Artikel 4.2 Annex II Sub B. dodávka nezahrnuje ochranu proti
und Anhang II Sub. B. Diese This delivery does not include výše zmíněným rizikům.
Lieferung enthält keine spezifische protection against the above Analýza rizik přepravního systému
Absicherung gegen oben described hazards. bude určovat bezpečnostní rizika a
aufgeführte Gefahren. A risk analysis of the conveying zároveň bude určovat, která
Aus einer Risikoanalyse, aufgestellt system will determine the safety bezpečnostní ochrana musí být
durch den risks and which safety protection / provedena. Tudíž Mayfran nemůže
Verfahrensverantwortlichen der actions must be taken. Therefore, být zodpovědný za osobní zranění
Vollständigen Anlage, geht hervor, Mayfran cannot be made v jakékoli podobě.
welche Absicherungen notwendig responsible for personal injury in
sind. Mayfran kann daher nicht any form.
verantwortlich gestellt werden für
Personenschaden in irgendwelcher
Form.

13-07-2009 MAYFRAN INTERNATIONAL - PO-BOX 31032- 6370 AA LANDGRAAF - NETHERLANDS TEL: (31) 45 5329 292 5/5
II
II
Prepared by K.
Prepared Marijnen
by K. Marijnen

Print
Printversion
version
21-Jul-2009
21/7/2009

Technische Dokumentation
Technical Documentation
Documentation Technique
Inbetriebnahme / Instandhaltung / Wartung
Commissioning / Service / Maintenance
Mise en service / Utilisation / Entretien

Maschine | Machine | Machine


BRECHER TA-4/ CRUSHER TA-4/ BROYEUR DE COPEAUX TYPE TA-4

Kunde | Customer | Client


HEGENSCHEIDT-MFD GMBH & CO. KG
Endkunde | End Customer | Client finale
Hegenscheidt-MFD GmbH & Co. KG
Projekt | Project | Projet
209000498 / 10-03-2009
Mayfran Auftragsnr. | Order no. | No. de Commande
09W3583
Mayfran Artikelnummer | articlenumber | No. de Article
P14.09W3582.01
Pos.nummer-Zeichnung Nr. | Item number-Drawing Nr. | No. de Position-No. le plan

Projektleiter | Project Manager | Présider de Projet


H. Jacobs

Mayfran International B.V. Mayfran GmbH Niederlassung Süd


P.O. Box 3103 Edisonstraat 7/ 9 Hüttenstraße 7 Richthofenstraße 32
6370 AA Landgraaf 6372 AK Landgraaf 52068 Aachen 73312 Geislingen/Steige
The Netherlands Germany Germany

+31 (0) 45 532 92 92 +49 (0) 241 93 87 20 +49 (0) 7331 95 53 0


+31 (0) 45 532 93 00 (fax) +49 (0) 241 17 50 80 (fax) +49 (0) 7331 95 53 55 (fax)

info@mayfran.eu sales@mayfran.eu
www.mayfran.nl www.mayfran.de
CHIP CRUSHER, TYPE TA-4 PAGE 1

TABLE OF CONTENTS

1 GENERAL ......................................................................................................................................2
2 IMPORTANT NOTES ....................................................................................................................3
3 COMMISSIONING .........................................................................................................................4
4 MAINTENANCE .............................................................................................................................5
4.1 LUBRICATION ............................................................................................................................5
4.2 REGULAR CHECKS .....................................................................................................................6
5 FAULT ANALYSIS.........................................................................................................................7
6 SPECIFICATION FOR CHIP CRUSHER TYPE TA-4 ...................................................................8
6.1 SPECIFICATION - APPLICATION ...................................................................................................8
6.2 SPECIFICATION - DRIVE..............................................................................................................8
7 SPARE PARTS LISTS...................................................................................................................9
7.1 GENERAL ..................................................................................................................................9
7.2 PARTS LIST CHIP CRUSHER TYPE TA-4 - DRAWING NO. D725.1012..........................................10
7.3 PARTS LIST CRUSHER COMB DRAWING T104447 ......................................................................11

REV. 0 / 07-09 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 info@mayfran-europe.com FILENAME: P14-01-en (TA4)
CHIP CRUSHER, TYPE TA-4 PAGE 2

1 GENERAL

The Mayfran chip crusher is used in for


breaking up metal cutting into small chips.
Depending on the requirements and the
purpose, various types of blades and
screens with various perforations can be
used.
The motor drives the cutting mechanism by
means of a clutch and two gears. This
cutting mechanism is driven in such a way TA-4 Crusher

that the cutting blades rotate in opposite


directions.
A perforated screen is attached below the blade. Depending on the type of perforations, this
screen determines the size of the chips after being broken up and the flow rate of the coolant.

There are various control options.


The variants planned for your area of application can be seen from the wiring diagrams supplied.

Coarse pieces can lead to loss of capacity, premature wear or even to damage. Coarse pieces
should therefore not be allowed into the chip crusher.

REV. 0 / 07-09 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 info@mayfran-europe.com FILENAME: P14-01-en (TA4)
CHIP CRUSHER, TYPE TA-4 PAGE 3

2 IMPORTANT NOTES

These operating instructions should be available to the staff responsible for maintaining
the machine. Our guarantee is only valid if these instructions are accurately followed.

The operator must ensure that all maintenance, inspection and assembly work is carried
out by authorised and qualified personnel who have sufficient information from studying
the operating instructions closely.

For all the maintenance work described in these operating instructions, first ensure that
the chip crusher cannot start up accidentally.

Protective glasses and gloves must always be worn because of the risk of injury from
the cutting mechanism and the chips.

The breaking up of inflammable containers or explosive substances (e.g. aerosol cans)


is prohibited.

When breaking up oil-contaminated substances, an oil receptacle is required.

If you are ordering parts or have questions about your Type TA-4 chip crusher, please
quote the crusher type and the Mayfran serial number. These can be found on the type
plate of the chip crusher.

CAUTION:
The aforementioned safety measures must always be followed.

The chip crusher must not be operated until the covers, hoppers etc have all been re-
assembled in their original form.

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CHIP CRUSHER, TYPE TA-4 PAGE 4

3 COMMISSIONING

The chip crusher must only be transported on the load carrier provided for the purpose.

1. Check that the machine has been delivered complete and undamaged.
2. Remove the extraneous material attached for transport purposes.
3. Check that the motor and control voltages match the operating voltage and that all the
parts have been securely and correctly set up. If necessary, secure them or set them up
again.
4. Install the chip crusher and accessories in accordance with the installation diagram
supplied. The crusher must stand on a firm, level base.

Crushers with a motor protection switch can be connected directly to the mains. If the motor
protection switch is not supplied by MAYFRAN, you must connect the chip crusher in accordance
with the wiring diagram.

The chip cutting mechanism can be supplied with a standard control or an SPS control, as
desired. The control is connected in accordance with the accompanying wiring documents.

After switching on the chip crusher, it should run unloaded for 2 hours.

During this period check:


1. The current consumption; this should be below the nominal value;
2. The stability of the crusher; the crusher should run smoothly, if not, please inform the
MAYFRAN Service department;
3. The motor for excess heat; if the temperature is too high, see fault analysis.

The chip crusher can now be continuously and evenly fed with chips.

REV. 0 / 07-09 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 info@mayfran-europe.com FILENAME: P14-01-en (TA4)
CHIP CRUSHER, TYPE TA-4 PAGE 5

4 MAINTENANCE

4.1 LUBRICATION

Bearings and gears should be lubricated with grease every 40 operating hours.
For this purpose the crusher is equipped with grease nipples (x 5) or with a progressive
grease distributor.

Lubricate the grease nipple every 40 operating hours in accordance with table 5.1.

TA-4 chip crusher


Grease lubrication Shell Alvania
Type Lubricant WR-2
Standard Grease of type K2K in accordance
with DIN 51502
3
Lubricating points: 4 cm per nipple/40 h
Bearings and labyrinth seal, bearing type SKF 22213CC\W33
3
Lubricating points: 6 cm per nipple/40 h
Cutting mechanism gear
Table 5.1

If present!!
Lubricate the grease distributor every 40 operating hours in accordance with table 5.2

TA-4 chip crusher


Grease lubrication Shell Alvania WR2
Type Lubricant

Standard Grease of type K2K in accordance with DIN 51502


3
Special design: crusher with 6/5 22 cm
DPM grease distributor 40 h
Table 5.2

Grease distributor

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CHIP CRUSHER, TYPE TA-4 PAGE 6

4.2 REGULAR CHECKS

Name: To : Check for:

Cutting blade 40 hours Damage

Perforated screen 40 hours Damage


Electrical pars (connectors... 40 Std. Correct fixation
etc.)

Signal transmitter 40 hours Operation

Gear motor 40 hours Connections/joints


as prescribed by the oil level
manufacturer

The drive unit must be maintained as per manufacturer's instructions. The oil level must be
checked at regular intervals. Under normal operating conditions, an oil change is required
after approximately 10.000 operating hours.

Always keep an eye on the functioning of the crusher.


Changes in flow rate, chip size, vibration noise and heat generation, current consumption etc. are
indications of a blunt blade, screen wear, bearing defects etc.
The cause of any change must be tracked down and remedied.

REV. 0 / 07-09 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 info@mayfran-europe.com FILENAME: P14-01-en (TA4)
CHIP CRUSHER, TYPE TA-4 PAGE 7

5 FAULT ANALYSIS

Fault Cause Remedy

1. Drive motor does not 1.1 Main switch not 1.1 Switch on main
start. switched on or switch. Free the
emergency stop emergency stop.
activated.
1.2 Control current fuse 1.2 Free the fuse.
blown.

2. Crusher functions but 2.1 Too little lubricant 2.1 Lubricate between
with a "squeaking" between the cutting the cutting blades.
sound. blades.
2.2 Gears are dry. 2.2 Refill the gear grease
in the container so
that the edges of the
gears are covered
with grease.

3. Chips are broken too 3. Cutting edge of the 3. Change the cutting
long. cutting blade has blade.
become rounded off.

4. Crusher is blocked 4.1 There is play 4.1 Change the cutting


but there are no between the cutting blade.
coarse pieces. blades.
4.2 Cutting blades worn. 4.2 Change the cutting
blade.

REV. 0 / 07-09 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 info@mayfran-europe.com FILENAME: P14-01-en (TA4)
CHIP CRUSHER, TYPE TA-4 PAGE 8

6 SPECIFICATION FOR CHIP CRUSHER TYPE TA-4

6.1 SPECIFICATION - APPLICATION

REMARK:
The chip crusher must only be used for the applications for which it was bought.

6.2 SPECIFICATION - DRIVE

Manufacturer : SEW

Type : KF87 DRS100 LC4

Power : 4,0 kW
-1
Revolutions : 14 min

Design : M4

Voltage/Ph/Frequency : 380 +/- 10% / 3 / 50 Volt/Ph/Hz

Protection rating : IP55

Insulation : F

REV. 0 / 07-09 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 info@mayfran-europe.com FILENAME: P14-01-en (TA4)
CHIP CRUSHER, TYPE TA-4 PAGE 9

7 SPARE PARTS LISTS

7.1 GENERAL

NOTE: Always quote the relevant data of this crusher when requiring information or ordering
replacement or wear parts.
This data is mentioned in the following:

1 Mayfran article number


2 Parts list no. and part number

Mayfran address
http://www.mayfran.com
Mayfran International B.V. Mayfran GmbH Niederlassung Süd
P.O. Box 3103 Edisonstraat 7/ 9 Hüttenstraße 7 Richthofenstraße 32
6370 AA Landgraaf 6372 AK Landgraaf 52068 Aachen 73312 Geislingen/Steige
The Netherlands Germany Germany

+31 (0) 45 532 92 92 +49 (0) 241 93 87 20 +49 (0) 7331 95 53 0


+31 (0) 45 532 93 00 (fax) +49 (0) 241 17 50 80 (fax) +49 (0) 7331 95 53 55 (fax)

info@mayfran.eu sales@mayfran.eu
www.mayfran.nl www.mayfran.de

Mayfran UK Limited Mayfran France S.A.R.L.


Unit 38 Bradley Fold Trading Estate Centre d'Affairs Paris-Nord
Bradley Fold Road Immeuble Ampère
Radcliffe 93153 LeBlanc Mesnil CEDEX
Bury France
BL2 6RT
United Kingdom +33 (0) 1 48 65 78 00
+33 (0) 1 48 65 66 55 (fax)
+44 12 04 36 64 69
+44 12 04 36 68 40 (fax) sales@mayfran.eu
www.mayfran.fr
sales@mayfran.eu
www.mayfran.co.uk

Mayfran International, Inc.


P.O.Box 43038
6650 Beta Drive
Cleveland, OH 44143
USA

+1 440 461-4100
+1 440 461-0147 (fax)

info@mayfran.com
www.mayfran.com

REV. 0 / 07-09 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 info@mayfran-europe.com FILENAME: P14-01-en (TA4)
CHIP CRUSHER, TYPE TA-4 PAGE 10

7.2 PARTS LIST CHIP CRUSHER TYPE TA-4 - DRAWING NO. D725.1012

Item no. Description/Manufacturer Type/Quality/DIN Number

1 Gear wheel z=31 1


2 Gear wheel z=44 1
3 Labyrinthring fixed 4
4 Labyrinthring mobile 4
5 Crusher knive 18
6 Distance ring 18
7A Shaft (drive) 1
7B Shaft (not drive) 1
8 Sieve 1
9 Clutch Hadeflex 100/98 XW 1
10 SKF Bearing 22213-cc/w33 4
11 Counter nut M55x2 - Special 3
12 Dubo- Snap rings for hexagon socket M12 / Plastic 20
head cap srews
13 Dubo- internal tooth cup washers M12 20
14 Hexagon bolt M16x1.5x50/DIN 960 8
17 Nilos ring 22213AV 4
18 O-ring No.246 (113.89x3.53) NBR 70° 4
19 O-ring No.234 (75.8x3.53) NBR 70° 4

REV. 0 / 07-09 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 info@mayfran-europe.com FILENAME: P14-01-en (TA4)
CHIP CRUSHER, TYPE TA-4 PAGE 11

7.3 PARTS LIST CRUSHER COMB DRAWING T104447

Item no. Description/Manufacturer Type/Quality/DIN Number

1 Crusher comb material Combs CR4800 2


2 Support plate 2

REV. 0 / 07-09 MAYFRAN INTERNATIONAL - P.B. 31032- 6370 AA LANDGRAAF - THE NETHERLANDS : (31) 45 5329 292 info@mayfran-europe.com FILENAME: P14-01-en (TA4)
III
III
SUPPLER MANUALS / DOKUMENTATION ZULIEFERANTEN
TAB ORDER QTY UOM PART NO. DESCRIPTION MANUFACTURER / SUPPLIER PSM PO_NUM CATEGORY
NO.
TAB ORDER ANZ EINH ART. NR UMSCHREIBUNG HERSTELLER / LIEFERANT PSM PO_NR KATEGORIE
NR.
1 09W3583 1 ST 13.GPEU0055 MOTOR / GEARING KF87DRS100LC4 MOTOR POWER : 4,0 KW SEW / VECTOR AANDRIJFTECHNIEK BV P A25764 DRIVE
REVOLUTIONS: 14 REV/MIN SPANN.,FREQ.,PH :400V +10/-6 procent

09W3582 - 21-07-2009 - 11:30 Mayfran International Confidential Page 1


Drive Technology \ Drive Automation \ System Integration \ Services SEW-EURODRIVE – Driving the world

Gear Units, R..7, F..7, K..7, S..7 Series,


SPIROPLAN® W

Edition 02/2008
11691026 / EN
Operating Instructions
Contents Contents

Contents 6 Inspection/Maintenance ................................................................................... 61


6.1 Preliminary work regarding gear unit inspection/maintenance ................. 61
1 General Information ............................................................................................ 5
6.2 Inspection/maintenance intervals.............................................................. 62
1.1 How to use the operating instructions ......................................................... 5
6.3 Lubricant change intervals ........................................................................ 62
1.2 Structure of the safety notes ....................................................................... 5
6.4 Inspection/maintenance for the AL/AM/AQ adapter ................................. 63
1.3 Rights to claim under limited warranty ........................................................ 6
6.5 Inspection/maintenance for the AD input cover ........................................ 63
1.4 Exclusion of liability..................................................................................... 6
6.6 Inspection/maintenance for the gear unit.................................................. 64
2 Safety Notes ........................................................................................................ 7
7 Mounting Positions ........................................................................................... 79
2.1 Preface........................................................................................................ 7
7.1 Designation of the mounting positions ...................................................... 79
2.2 General information .................................................................................... 7
7.2 Key............................................................................................................ 80
2.3 Target group ............................................................................................... 8
7.3 Helical gearmotors R ................................................................................ 81
2.4 Designated use ........................................................................................... 8
7.4 Helical gearmotors RX .............................................................................. 84
2.5 Other applicable documentation ................................................................. 8
7.5 Parallel shaft helical gearmotors F............................................................ 86
2.6 Transportation ............................................................................................. 9
7.6 Helical-bevel gearmotors K ....................................................................... 89
2.7 Extended storage........................................................................................ 9
7.7 Helical-worm gearmotors S....................................................................... 94
2.8 Installation/assembly................................................................................... 9
7.8 SPIROPLAN® W gear units .................................................................... 100
2.9 Startup/operation ........................................................................................ 9
8 Technical Data................................................................................................. 106
2.10 Inspection/Maintenance .............................................................................. 9
8.1 Extended storage.................................................................................... 106
3 Gear Unit Design ............................................................................................... 10
8.2 Lubricants ............................................................................................... 107
3.1 Basic design of helical gear units.............................................................. 10
9 Malfunctions/Service ...................................................................................... 115
3.2 Basic design of parallel shaft helical gear units ........................................ 11
3.3 Basic design of helical-bevel gear units .................................................... 12 9.1 Gear unit ................................................................................................. 115
3.4 Basic design of helical-worm gear units.................................................... 13 9.2 AM / AQ / AL. adapter............................................................................. 116
3.5 Basic design of SPIROPLAN® W10-W30 gear units ................................ 14 9.3 AD input cover ........................................................................................ 116
3.6 Basic design of SPIROPLAN® W37 gear units......................................... 15 9.4 Customer service .................................................................................... 117
3.7 Nameplate/unit designation ...................................................................... 16 9.5 Disposal .................................................................................................. 117

4 Mechanical Installation..................................................................................... 17 10 Address List .................................................................................................... 118

4.1 Required tools/resources .......................................................................... 17 Index................................................................................................................. 127


4.2 Prerequisites for assembly........................................................................ 18
4.3 Installing the gear unit............................................................................... 19
4.4 Gear units with solid shaft......................................................................... 24
4.5 Torque arms for shaft-mounted gear units................................................ 26
4.6 Shaft-mounted gear unit with keyway or splined hollow shaft .................. 29
4.7 Shaft-mounted gear units with shrink disk ................................................ 36
4.8 Shaft-mounted gear units with TorqLOC® ................................................ 40
4.9 Installing the protective cover ................................................................... 46
4.10 AM adapter coupling ................................................................................. 48
4.11 AQ adapter coupling ................................................................................. 52
4.12 AD input cover .......................................................................................... 54
5 Startup................................................................................................................ 59
5.1 Checking the oil level ................................................................................ 59
5.2 Helical-worm and SPIROPLAN® W gear units ......................................... 59
5.3 Helical/parallel shaft helical/helical-bevel gear units ................................. 60
5.4 Gear units with backstop........................................................................... 60

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 3 4 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
General Information General Information
How to use the operating instructions
1 1 Rights to claim under limited warranty

1 General Information 1.3 Rights to claim under limited warranty


1.1 How to use the operating instructions Adhering to the operating instructions is a prerequisite for fault-free operation and the
fulfillment of any right to claim under warranty. Read the operating instructions before
The operating instructions are an integral part of the product and contain important in- you start working with the unit.
formation on operation and service. The operating instructions are written for all employ-
ees who assemble, install, startup, and service this product.
The operating instructions must be accessible and legible. Make sure that persons re-
sponsible for the system and its operation, as well as persons who work independently 1.4 Exclusion of liability
on the unit, have read through the operating instructions carefully and understood them. You must comply with the information contained in these operating instructions to en-
Consult SEW-EURODRIVE if you have any questions or if you require further informa- sure safe operation of the R..7, F..7, K..7, S..7 series and SPIROPLAN® W gear units
tion. and to achieve the specified product characteristics and performance requirements.
SEW-EURODRIVE assumes no liability for injury to persons or damage to equipment or
property resulting from non-observance of these operating instructions. In such cases,
any liability for defects is excluded.
1.2 Structure of the safety notes
The safety notes in these operating instructions are structured as follows:

Symbol SIGNAL WORD


Nature and source of hazard.
Possible consequence(s) if disregarded.
• Measure(s) to avoid the hazard.

Symbol Signal word Meaning Consequences if disre-


garded
Example: HAZARD! Imminent hazard Severe or fatal injuries

WARNING! Possible hazardous situation Severe or fatal injuries

General hazard

CAUTION! Possible hazardous situation Minor injuries

Specific hazard,
e.g. electric shock CAUTION! Possible damage to property Damage to the drive system or its environ-
ment

NOTE Useful information or tip.


Simplifies handling of the drive
system.

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 5 6 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Safety Notes Safety Notes
Preface
2 2 Target group

2 Safety Notes 2.3 Target group


The following basic safety notes are intended to prevent injury to persons and damage Any mechanical work may only be performed by adequately qualified personnel. Quali-
to property. The operator must ensure that the basic safety notes are read and ob- fied personnel in this context are persons who are familiar with the setup, mechanical
served. Make sure that persons responsible for the system and its operation, as well as installation, trouble shooting and maintenance for this product. Further, they are quali-
persons who work independently on the unit, have read through the operating instruc- fied as follows:
tions carefully and understood them. If you are unclear about any of the information in
• They are educated in the mechanics field (e.g. mechanical or mechatronic
this documentation, please contact SEW-EURODRIVE.
engineers) having successfully passed a final exam.
• They are familiar with these operating instructions.

2.1 Preface
Any electronic work may only be performed by adequately qualified electricians. A qual-
The following safety notes are primarily concerned with the use of gear units. If using ified electrician in this context are persons who are familiar with the, electronic installa-
gearmotors, please also refer to the safety notes for motors in the corresponding oper- tion, startup, trouble shooting and maintenance for this product. Further, they are qual-
ating instructions. ified as follows:
Also consider the supplementary safety notes in the individual sections of these operat-
• They are educated in the electronics field (e.g. electronic or mechatronic engineers)
ing instructions.
having successfully passed a final exam.
• They are familiar with these operating instructions.

2.2 General information


All work in further areas of transportation, storage, operation and waste disposal may
HAZARD! only be carried out by persons who have been adequately trained.

During operation, the motors and gearmotors can have live, bare and movable or ro-
tating parts as well as hot surfaces, depending on their enclosure.
Severe or fatal injuries.
2.4 Designated use
• All work related to transportation, storage, setup/mounting, connection, startup,
maintenance and repair may only be carried out by qualified personnel, in strict The gear units/gearmotors are intended for industrial systems and may only be used in
observation of: accordance with the information provided in the technical documentation of
– the relevant detailed operating instructions SEW-EURODRIVE and the information given on the nameplate. They correspond to the
– The warning and safety signs on the motor/gearmotor
applicable standards and regulations. Using these products in potentially explosive at-
– all other project planning documents, operating instructions and wiring
diagrams belonging to the drive mospheres is prohibited, unless specifically designated otherwise.
– The specific regulations and requirements for the system
– The national/regional regulations governing safety and the prevention of
accidents
2.5 Other applicable documentation
• Never install damaged products
• Immediately report any damages to the shipping company The following publications and documents have to be observed as well:
Removing covers without authorization, improper use as well as incorrect installation or • Operating Instructions "AC Motors, Asynchronous Servomotors" for gearmotors
operation may result in severe injuries to persons or damage to property.
• Operating instructions of installed options, if applicable
Consult the documentation for additional information.
• "Gear Units" catalog or
• "Gearmotors" catalog

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 7 8 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Safety Notes Gear Unit Design
Transportation
2 3 Basic design of helical gear units

2.6 Transportation 3 Gear Unit Design


Immediately upon receipt, inspect the shipment for any damage that may have occurred
NOTE
during transportation. Inform the shipping company immediately. It may be necessary to
preclude startup. The following figures are block diagrams. Their purpose is only to make it easier to as-
sign components to the spare parts lists. Discrepancies may occur depending on the
Tighten installed eyebolts. They are only intended for the weight of the motor/gearmotor; gear unit size and version!
do not attach any additional loads.
The built-in lifting eyebolts comply with DIN 580. Always observe the loads and regula-
tions listed in this standard. If the gearmotor is equipped with two suspension eye lugs
or lifting eyebolts, then both of the suspension eye lugs should be used for transporta- 3.1 Basic design of helical gear units
tion. In this case, the tension force vector of the slings must not exceed a 45° angle ac-
cording to DIN 580.
[59]
Use suitable, sufficiently rated handling equipment if necessary. Remove any transpor- [20]
[24]
tation fixtures prior to startup.
[515] [101]
[516]
[517] [100]
[47] [1]
2.7 Extended storage [102]
[2] [45]
[59]
Observe the notes in section "Extended storage" (see page 106). [43]
[181]
[42] [3]
[41]
[6] [25]
[88]
[22]
2.8 Installation/assembly
[11] [17]
[12]
Observe the notes in section "Mechanical Installation" (see page 17)! [9]
[19]
[521]
[522]
[8] [7] [523]
2.9 Startup/operation
Check the oil level before startup as described in chapter Inspection/Maintenance [59]
(see page 61). [31] [30]
[32]
Check that the direction of rotation is correct in decoupled status. Listen out for unusual
grinding noises as the shaft rotates.
[34] [4]
Secure keys for test mode without output elements. Do not deactivate monitoring and [5]
protection equipment even in test mode.
[37]
Switch off the gearmotor if in doubt whenever changes occur in relation to normal oper- [506]
[39] [507]
ation (e.g. increased temperature, noise, vibration). Determine the cause and contact [131] [508]
SEW-EURODRIVE, if required. 19194251

[1] Pinion [19] Key [42] Anti-friction bearing [507] Shim


[2] Gearwheel [20] Breather valve [43] Key [508] Shim
[3] Pinion shaft [22] Gear unit housing [45] Anti-friction bearing [515] Shim
2.10 Inspection/Maintenance [4] Gearwheel [24] Eyebolt [47] Circlip [516] Shim
[5] Pinion shaft [25] Anti-friction bearing [59] Screw plug [517] Shim
Observe the notes in chapter "Inspection/Maintenance" (see page 61)!
[6] Gearwheel [30] Anti-friction bearing [88] Circlip [521] Shim
[7] Output shaft [31] Key [100] Gear cover plate [522] Shim
[8] Key [32] Spacer tube [101] Hex head bolt [523] Shim
[9] Oil seal [34] Anti-friction bearing [102] Seal
[11] Anti-friction bearing [37] Anti-friction bearing [131] Closing cap
[12] Circlip [39] Circlip [181] Closing cap
[17] Spacer tube [41] Circlip [506] Shim

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 9 10 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Gear Unit Design Gear Unit Design
Basic design of parallel shaft helical gear units
3 3 Basic design of helical-bevel gear units

3.2 Basic design of parallel shaft helical gear units 3.3 Basic design of helical-bevel gear units

[2] [45] [20]


[515] [59] [100] [102]
[516] [43] [22] [1]
[517] [20]
[3] [3] [536]
[41] [42]
[43] [537] [533] [59]
[181] [161] [538] [534] [22]
[4] [30] [535]
[32] [45] [2]
[59] [114]
[31]
[5] [101]
[506] [113]
[37]
[507] [39] [183] [165] [42] [119] [59]
[131] [508]
[116]
[523] [89] [59]
[522]
[160] [521] [88]
[19] [25]
[84] [1]
[102] [19]
[88]
[94]
[25] [521] [100] [7] [59]
[92] [522] [8]
[93]
[91] [523] [101] [6] [59]
[7]
[59]
[83] [17]
[17]
[6] [11]
[9] [12]
[11]
[81] [9] [161]
[132]
[133]
[14] [31]
[30] [542]
[16]
[543]
[135] [544]
19298059
[4]
[1] Pinion [22] Gear unit housing [91] Circlip [506] Shim [5]
[2] Gearwheel [25] Anti-friction bearing [92] Disc [507] Shim [131] [37]
[3] Pinion shaft [30] Anti-friction bearing [93] Lock washer [508] Shim [506]
[4] Gearwheel [31] Key [94] Hex head bolt [515] Shim [507]
[5] Pinion shaft [32] Spacer tube [100] Gear cover plate [516] Shim [137] [508]
[6] Gearwheel [37] Anti-friction bearing [101] Hex head bolt [517] Shim 19301131
[7] Hollow shaft [39] Circlip [102] Seal [521] Shim
[9] Oil seal [41] Circlip [131] Closing cap [522] Shim [1] Pinion [25] Anti-friction bearing [102] Seal [522] Shim
[11] Anti-friction bearing [42] Anti-friction bearing [160] Closing plug [523] Shim [2] Gearwheel [30] Anti-friction bearing [113] Slotted nut [523] Shim
[14] Hex head bolt [43] Key [161] Closing cap [3] Pinion shaft [31] Key [114] Multi-tang washer [533] Shim
[16] output flange [45] Anti-friction bearing [165] Closing plug [4] Gearwheel [37] Anti-friction bearing [116] Thread locker [534] Shim
[17] Spacer tube [59] Screw plug [181] Closing cap [5] Pinion shaft [39] Circlip [119] Spacer tube [535] Shim
[19] Key [81] Nilos ring [183] Oil seal [6] Gearwheel [42] Anti-friction bearing [131] Closing cap [536] Shim
[20] Breather valve [88] Circlip [7] Output shaft [43] Key [132] Circlip [537] Shim
[8] Key [45] Anti-friction bearing [133] Supporting ring [538] Shim
[9] Oil seal [59] Screw plug [135] Nilos ring [542] Shim
[11] Anti-friction bearing [83] Nilos ring [161] Closing cap [543] Shim
[12] Circlip [84] Nilos ring [506] Shim [544] Shim
[17] Spacer tube [88] Circlip [507] Shim
[19] Key [89] Closing cap [508] Shim
[20] Breather valve [100] Gear cover plate [521] Shim
[22] Gear unit housing [101] Hex head bolt [521] Shim

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 11 12 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Gear Unit Design Gear Unit Design
Basic design of helical-worm gear units
3 3 Basic design of SPIROPLAN® W10-W30 gear units

3.4 Basic design of helical-worm gear units 3.5 Basic design of SPIROPLAN® W10-W30 gear units

[100] [101]

[65]
[66]
[102] [68]
[71] [143]
[59] [72]
[101] [20] [1]

[100] [22]
[506]
[131] [507]
[39] [137]
[37] [102]
[22]
[5] [89]
[43] [30] [2] [61] [59] [88]
[521]
[522]
[1] [523]
[25]

[6]

[19] [250]
[251]
[19] [17]
[8]
[89] [7]
[59]
[523] [88]
[25] [522]
[521]
[11]
[7] [518]
[519]
[12] [520]
[9]
[6]
19307275
[11]
[520]
[1] Pinion [19] Key [88] Circlip [251] Circlip
[12] [519]
[518] [6] Gearwheel [22] Gear unit housing [89] Closing cap [518] Shim
[9]
[7] Output shaft [25] Anti-friction bearing [100] Gear cover plate [519] Shim
19304203 [8] Key [65] Oil seal [101] Hex head bolt [520] Shim
[1] Pinion [20] Breather valve [88] Circlip [518] Shim [9] Oil seal [66] Anti-friction bearing [102] Seal [521] Shim
[2] Gearwheel [22] Gear unit housing [89] Closing cap [519] Shim [11] Anti-friction bearing [71] Supporting ring [132] Circlip [522] Shim
[5] Worm [25] Anti-friction bearing [100] Gear cover plate [520] Shim [12] Circlip [72] Circlip [183] Oil seal [523] Shim
[6] Worm gear [30] Anti-friction bearing [101] Hex head bolt [521] Shim [17] Spacer tube [143] Supporting ring [250] Circlip
[7] Output shaft [37] Anti-friction bearing [102] Seal [522] Shim
[9] Oil seal [39] Circlip [131] Closing cap [523] Shim
[11] Anti-friction bearing [43] Key [137] Supporting ring
[12] Circlip [59] Screw plug [506] Shim
[19] Key [61] Circlip [507] Shim

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 13 14 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Gear Unit Design Gear Unit Design
Basic design of SPIROPLAN® W37 gear units
3 3 Nameplate/unit designation

3.6 Basic design of SPIROPLAN® W37 gear units 3.7 Nameplate/unit designation
3.7.1 Nameplate
[521]
[89]
[522]
[523] [88]
Bruchsal/Germany
[6] [25] Typ RF 47 /A
Nr. 01.11124560001.00001.07
[22] Pe kW 0,55 Ma Nm 90
n r/min 57
IM M1 i 1: 23,59
[19] 23,4
kg
[7]

[8] Schmierstoff CLP HC 220 Synt. Öl /1,5l Made in Germany 181 861 9.14
[59] [5]
[518] 210927627
[33]
[519] [11]
[520] [32] fb = Service factor
[12] FRa max [N] = Maximum overhung load on the output side
[9] [59]
[44] [133] [1] FRe max [N] = Maximum overhung load on the input side (with input shaft assembly AD)
[506] [37] i = Gear unit reduction ratio
[5] IM = Mounting position
[31]
IP.. = Enclosure
[30] ne max [rpm] = maximum input speed
[137] na [rpm] = output speed
[2] Memax [Nm] = maximum input torque
Ma [Nm] = Output torque
[61] MR [Nm] = Overload torque when using an AR adapter
[26] [36] MRS [Nm] = Locking torque of the backstop
605872395

[1] Pinion [22] Gear unit housing [44] O-ring [137] Shim 3.7.2 Unit designation
[2] Gearwheel [24] Eyebolt [59] Screw plug [150] Hexagonal nut
[5] Pinion shaft [25] Deep groove ball bearing [61] Circlip [183] Oil seal NOTE
[6] Gearwheel [26] Housing stage 1 [68] Circlip [506] Shim
For a detailed overview of unit designations and additional information, refer to the fol-
[7] Output shaft [30] Deep groove ball bearing [72] Circlip [518] Shim
[8] Key [31] Key [80] Key [519] Shim
lowing publications:
[9] Oil seal [32] Spacer tube [88] Circlip [520] Shim • "Gear Units" catalog or
[11] Deep groove ball bearing [33] Circlip [89] Closing cap [521] Shim • "Gearmotors" catalog
[12] Circlip [36] Hex head bolt [106] Stud [522] Shim
[19] Key [37] Deep groove ball bearing [133] Shim [523] Shim
Example: Helical
gear unit
RF 47 /A
For direct motor mounting

Gear unit size

Helical gear unit series (flange mounted)

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 15 16 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
Required tools/resources
4 4 Prerequisites for assembly

4 Mechanical Installation 4.2 Prerequisites for assembly


4.1 Required tools/resources CAUTION!
• Set of wrenches Improper assembly may result in damages to the gear unit/gearmotor.
• Torque wrench for: Possible damage to property!
– Shrink disks • Do closely observe the notes in this chapter.

– AQH motor adapter


– Input shaft assembly with centering shoulder Ensure that the following conditions have been met:
• Mounting device • The entries on the nameplate of the gearmotor match the voltage supply system.
• Compensation elements (shims, spacing rings) • The drive has not been damaged during transportation or storage.
• Fasteners for input and output elements • Ensure that the following requirements have been met:
• Lubricant (e.g. NOCO® Fluid) For standard gear units:
• Bolt locking compound (for input shaft assembly with centering shoulder), e.g. – Ambient temperature according to the technical documentation, nameplate and
Loctite® 243 lubricant table in section "Lubricants" (see page 107).
• Standard parts are not part of the delivery – No harmful oils, acids, gases, vapors, radiation etc. in the vicinity
For special versions:
4.1.1 Installation tolerances
– The drive is designed in accordance with the ambient conditions. Refer to the in-
formation on the nameplate.
Shaft end Flanges For helical-worm/SPIROPLAN® W gear units:
Diameter tolerance in accordance with DIN 748 Centering shoulder tolerance to DIN 42948
• ISO k6 for solid shafts with ∅ ≤ 50 mm • ISO j6 for b1 ≤ 230 mm
– No large external mass moments of inertia which could exert a retrodriving load
• ISO m6 for solid shafts with ∅ > 50 mm • ISO h6 with b1 > 230 mm on the gear unit.
• ISO H7 for hollow shafts
• Center bore in accordance with DIN 332, shape [for Ș’ (retrodriving) = 2 – 1/Ș < 0.5 self-locking]
DR
• You must clean the output shafts and flange surfaces thoroughly to ensure they are
free of anti-corrosion agents, contamination or similar. Use a standard solvent. Do
not let the solvent come into contact with the sealing lips of the oil seals – danger of
damage to the material!
• When the drive is installed in abrasive ambient conditions, protect the output end oil
seals against wear.

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 17 18 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
Installing the gear unit
4 4 Installing the gear unit

4.3 Installing the gear unit If you change the mounting position, make sure that you change the lubricant fill
quantities and the position of the breather valve accordingly. Observe section "Lu-
The gear unit or gearmotor is only allowed to be installed in the specified mounting po- bricant fill quantities" (see page 110) and chapter "Mounting Positions" (see page 79).
sition. Refer to the information on the nameplate. Apart from the W37, SPIROPLAN®
gear units do not imply a particular mounting position. Consult the SEW customer service if you intend to change the mounting position of K
gear units to or between M5 and M6.
The support structure must have the following characteristics:
Consult the SEW customer service if you intend to change the mounting position of S
• Level gear units sizes S47 ... S97, to M2 and M3.
• Vibration damping In case there is a risk of electrochemical corrosion between the gear unit and the driven
• Torsionally rigid machine, use plastic inserts that are 2 to 3 mm thick. The material used must have an
electrical leakage resistance; 109 ȍ. Electrochemical corrosion can occur between var-
The Maximum permitted flatness error for foot and flange mounting (guide values with ious metals, for example, cast iron and high-grade steel. Also fit the bolts with plastic
reference to DIN ISO 1101): washers! Ground the housing additionally – use the grounding bolts on the motor.
• Gear unit size ≤ 67: max. 0.4 mm
• Gear unit size 77 ... 107: max. 0.5 mm 4.3.1 Tightening torques for retaining screws
• Gear unit size 137 ... 147: max. 0.7 mm Mount the gearmotors with the following tightening torques:
• Gear unit size 157 ... 187: max. 0.8 mm Tightening torque screw/nut
Screw/nut Strength class 8.8
Do not tighten the housing legs and mounting flanges against one another and ensure
[Nm]
that you comply with the permitted overhung and axial loads! Observe chapter "Project
Planning" in the Gear unit/gearmotor catalog for calculating the permitted overhung and M6 11
axial loads. M8 25
M10 48
Secure gearmotors using quality 8.8 screws.
M12 86
Secure the following gearmotors using quality 10.9 screws:
M16 210
• RF37, R37F with flange ∅ 120 mm M20 410

• RF47, R47F with flange ∅ 140 mm M24 710


M30 1450
• RF57, R57F with flange ∅ 160 mm
M36 2500
• and RZ37, RZ47, RZ57, RZ67, RZ77, RZ87 M42 4600
M48 6950
M56 11100
NOTE
When installing the gear unit, make sure that the oil level and drain plugs as well as the
breather plugs are easily accessible! Mount the helical gearmotors in flange-mounted design with the following increased
tightening torques:
Tightening torque screw/nut
Screw/nut
At the same time, also check that the oil fill corresponds to the specifications for the in- Flange Gear unit Strength class 10.9
tended mounting position (see section "Lubricant fill quantities" (see page 110) or refer [Nm]
to the information on the nameplate). The gear units are filled with the required oil vol- 120 RF37 M6 14
ume at the factory. There may be slight deviations at the oil level plug as a result of the
140 RF47 M8 35
mounting position, which are permitted within the manufacturing tolerances.
160 RF57 M8 35
60ZR RZ37 M8 35
70ZR RZ47 M8 35
80ZR RZ57 M10 69
95ZR RZ67 M10 69
110ZR RZ77 M12 120
130ZR RZ87 M12 120

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 19 20 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
Installing the gear unit
4 4 Installing the gear unit

4.3.2 Securing the gear unit 4.3.3 Installation in damp locations or in the open
Foot-mounted gear The following table shows the thread sizes of the gear units in foot-mounted design de- Drives are supplied in corrosion-resistant versions with an according surface protection
unit pending on the gear unit type and size: coating for use in damp areas or outdoors. Repair any damage to the paint work (e.g.
on the breather valve or the eyebolts).
Gear unit type
Screw R / R..F RX F/ K / KH..B / S W When mounting the motors onto AM, AQ, AR, AT adapters, seal the flange areas with a
FH..B / FA..B KV..B / KA..B suitable sealing compound, e.g. Loctite® 574.
M6 07 10/20
M8 17/27/37 27/37 37 30/37 4.3.4 Breather
M10 57 47 37/47 47/57
The following gear units do not require a breather:
M12 47/57/67 67 57/67 57/67 67
M16 77/87 77/87 77/87 77 77 • R07 in mounting positions M1, M2, M3, M5 and M6
M20 97 97/107 97 87 87 • R17, R27 and F27 in mounting positions M1, M3, M5 and M6
M24 107 107 97 97
• SPIROPLAN® W10, W20, W30 gear units
M30 137 127 107/167
SEW-EURODRIVE supplies all other gear units with the breather valve installed and ac-
M36 147/167 157 127/157/187
tivated according to the particular mounting position.
Exceptions:
Gear unit with B14 The following table shows the thread sizes of the gear units with B14 flange and/or hol-
flange and/or hol- low shaft depending on the gear unit type and size: 1. SEW supplies the following gear units with a screw plug on the vent hole provided:
low shaft – Pivoted mounting positions, if possible
Gear unit type
Screw RZ FAZ / FHZ KAZ / SA / WA – Gear units for mounting on a slant
KHZ / KVZ SAZ / SHZ
The breather valve is located in the motor terminal box. Before startup, you must re-
M6 07/17/27 37 10/20/30
place the highest screw plug with the provided breather valve.
M8 37/47 27/37/47 37/47 47/57 37
M10 57/67
2. SEW supplies a breather valve in a plastic bag for gear head units requiring venting
on the input end.
M12 77/87 57/67/77 57/67/77 67/77
M16 87/97 87/97 87/97 3. Enclosed gear units are supplied without a breather valve.
M20 107/127 107/127
M24 157 157

Gear unit with B5 The following table shows the thread sizes of the gear units with B5 flange depending
flange on the gear unit type,size and flange diameter:
Gear unit type
∅- Screw RF / FF / KF / KAF / SF / WF / WAF
Flange R..F / RM FAF / FHF KHF / KVF SAF /SHF
[mm]
80 M6 10
110 M8 20
120 M6 07/17/27 37 10/20/30/37
140 M8 07/17/27
160 M8 07/17/27/37/47 27/37 37 37/47 30/37
200 M10 37/47/57/67 47 47 57/67
250 M12 57/67/77/87 57/67 57/67 77
300 M12 67/77/87 77 77
350 M16 77/87/97/107 87 87 87
450 M16 97/107/137/147 97/107 97/107 97
550 M16 107/137/147/167 127 127
660 M20 147/167 157 157

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 21 22 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
Installing the gear unit
4 4 Gear units with solid shaft

Activating the Check whether the breather valve is activated. If the breather valve has not been acti- 4.4 Gear units with solid shaft
breather valve vated, you must remove the transport fixture from the breather valve before starting up
the gear unit! 4.4.1 Assembling the input and output components

1. Breather valve with transport fixture CAUTION!


Bearing, hosing or shaft may be damaged due to improper assembly.
Potential damage to property!
• Only assemble the input and output components with a mounting device. Use the
center bore and the thread on the shaft end for positioning.
• Never force belt pulleys, couplings, pinions, etc. onto the shaft end by hitting them
with a hammer.
• In the case of belt pulleys, make sure the belt is tensioned correctly in accordance
with the manufacturer's instructions.
211319051
• Power transmission elements should be balanced after fitting and must not give
2. Remove transport fixture rise to any impermissible radial or axial forces (see the "Gearmotors" or
"Explosion-Proof Drives" catalog for permitted values).

Assembly with The following figure shows a mounting device for installing couplings or hubs on gear
mounting device unit or motor shaft ends. Should you be able to tighten the screw without any problems,
you may not need the thrust bearing on the mounting device.

[1] [2]

211316875 [3]

3. Activated breather valve 211368587

[1] Gear shaft end


[2] Thrust bearing
[3] Coupling hub

211314699

4.3.5 Painting the gear units

CAUTION!
Breather valves and oil seals may be damaged during the painting or re-painting pro-
cess.
Potential damage to property.
• Thoroughly cover the breather valves and the sealing lip of the oil seals with strips
prior to the painting process.
• Remove the strips after the process.

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 23 24 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
Gear units with solid shaft
4 4 Torque arms for shaft-mounted gear units

Avoid excessive Avoid high overhung loads by: Installing the gear or chain sprocket according to figure 4.5 Torque arms for shaft-mounted gear units
overhung loads B if possible.
CAUTION!
[1] [1] Improper assembling may result in damages to the gear unit.
Potential damage to property!
• Do not place torque arms under strain during installation.
• Use bolts of quality 8.8 to fasten torque arms.

4.5.1 Parallel shaft helical gear units


The following figure shows the toque arm for parallel shaft helical gear units.

[A] [B] d
211364235 [3]
c 'L
[1]
[1] Hub

øa
[A] Incorrect [2]

øb +0.5
[B] Correct

NOTE
Mounting is easier if you first apply lubricant to the output element or heat it up briefly
(to 80 ... 100 °C). 211366411

[1] Screw
[2] Washer
4.4.2 Assembling the couplings [3] Nut

CAUTION!
Input and output elements such as belt pulleys, couplings etc. are in fast motion during Proceed as follows to mount the rubber buffers:
operation. 1. Use screws [1] and washers according to the following table.
Risk of jamming and crushing. 2. Use two nuts to secure the screw connection [3].
• Cover input and output elements with a touch guard. 3. Tighten the screw until the initial stress "ǻ L" of the buffers is reached according to
the table.
Adjust the following misalignments according to the coupling manufacturer's specifica-
tions when mounting couplings. rubber buffer
a) Maximum and minimum clearance Gear unit Diameter Internal Length Washer width ǻ L (taut)
diameter (loose)
b) Axial misalignment [mm] b [mm] c [mm] d [mm] [mm]
FA27 40 12.5 20 5 1
c) Angular misalignment FA37 40 12.5 20 5 1
FA47 40 12.5 20 5 1.5
b) c) FA57 40 12.5 20 5 1.5
a)
FA67 40 12.5 20 5 1.5
FA77 60 21.0 30 10 1.5
FA87 60 21.0 30 10 1.5
FA97 80 25.0 40 12 2
FA107 80 25.0 40 12 2
FA127 100 32.0 60 15 3
FA157 120 32.0 60 15 3

211395595

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 25 26 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
Torque arms for shaft-mounted gear units
4 4 Torque arms for shaft-mounted gear units

4.5.2 Helical-bevel gear units 4.5.4 SPIROPLAN® W gear units


The following figure shows the toque arm for helical-bevel gear units. The following figure shows the toque arm for SPIROPLAN® W gear units.
• Bushing [1] with bearings on both ends. • Bushing [1] with bearings on both ends.
• Install connection end B as a mirror image of A.

45˚
[1]

[1]
211362059

Gear unit Screws Tightening torque


211489547
KA37 4 × M10 × 25 – 8.8 48 Nm
KA47 4 × M10 × 30 – 8.8 48 Nm Gear unit Screws Tightening torque
KA67 4 × M12 × 35 – 8.8 86 Nm WA10 4 x M6 × 16 11 Nm
KA77 4 × M16 × 40 – 8.8 210 Nm WA20 4 x M6 × 16 11 Nm
KA87 4 × M16 × 45 – 8.8 210 Nm WA30 4 x M6 × 16 11 Nm
KA97 4 × M20 × 50 – 8.8 410 Nm WA37 4 x M8 × 20 25 Nm
KA107 4 × M24 × 60 – 8.8 710 Nm
KA127 4 × M36 × 130 – 8.8 2500 Nm
KA157 4 × M36 × 130 – 8.8 2500 Nm

4.5.3 Helical worm gear units


The following figure shows the toque arm for helical-worm gear units.
• Bushing [1] with bearings on both ends.

[1]

211491723

Gear unit Screws Tightening torque


SA37 4 x M6 × 16 – 8.8 11 Nm
SA47 4 x M8 × 20 – 8.8 25 Nm
SA57 6 x M8 × 20 – 8.8 25 Nm
SA67 8 x M12 × 25 – 8.8 86 Nm
SA77 8 x M12 × 35 – 8.8 86 Nm
SA87 8 x M16 × 35 – 8.8 210 Nm
SA97 8 x M16 × 35 – 8.8 210 Nm

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 27 28 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
Shaft-mounted gear unit with keyway or splined hollow shaft
4 4 Shaft-mounted gear unit with keyway or splined hollow shaft

4.6 Shaft-mounted gear unit with keyway or splined hollow shaft 2B: Installation with SEW-EURODRIVE installation and removal kit (see page 34)
– customer shaft with contact shoulder
NOTE
Concerning the configuration of the customer shaft, please also refer to the design
notes in the Gearmotors catalog!

[1]
[2]
4.6.1 Installation notes [3]
[4]
1. Apply and thoroughly spread NOCO® Fluid
B
®

C
O I
N U
O
[5]
L
F

O
® 211520523
C
O I
N U
L
F
[1] Retaining screw
[2] Lock washer
[3] Washer
[4] Circlip
[5] Customer shaft with contact shoulder
211516171

2. Install the shaft and secure it axially


(mounting is facilitated by using a mounting device)
2C: Installation with SEW-EURODRIVE installation and removal kit (see page 34)
The three mounting types are described below:
– customer shaft without contact shoulder
• 2A: standard scope of delivery
• 2B: installation and removal kit for customer shaft with contact shoulder
• 2C: installation and removal kit for customer shaft without contact shoulder
[1] [2]
[3]
2A: Installation with standard scope of delivery [4]
[5]

C
[1]
[6]
[2]
[3]
[4]
211522699
A
[1] Retaining screw
[2] Lock washer
[3] Washer
[4] Circlip
[5]
[5] Spacer tube
211518347 [6] Customer's shaft without contact shoulder

[1] Short retaining screw (standard scope of delivery)


[2] Lock washer
[3] Washer
[4] Circlip
[5] Customer shaft

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 29 30 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
Shaft-mounted gear unit with keyway or splined hollow shaft
4 4 Shaft-mounted gear unit with keyway or splined hollow shaft

3. Tighten the retaining screw to the appropriate torque (see table). 4.6.2 Removal notes
This description is only applicable when the gear unit was assembled using the installa-
tion and removal kit (see page 34) from SEW-EURODRIVE. Observe section "Installa-
tion notes" (see page 29), 2B or 2C.
1. Loosen the retaining screw [1].
2. Remove parts [2] to [4] and, if applicable, the distance piece [5].

[1]
[2]
[3]
[4]
211524875 [5]

Screw Tightening torque [Nm]


M5 5
M6 8
M10/12 20 [6]

M16 40
M20 80 211527051
M24 200
[1] Retaining screw
[2] Lock washer
[3] Washer
NOTE [4] Circlip
[5] Spacer tube
To avoid contact corrosion, we recommend that the customer shaft should turn freely [6] Customer shaft
between the two contact surfaces!

3. Insert the forcing disc [8] and the fixed nut [7] from the SEW-EURODRIVE installa-
tion/removal kit between the customer shaft [6] and the circlip [4].
4. Re-install the circlip [4].

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 31 32 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
Shaft-mounted gear unit with keyway or splined hollow shaft
4 4 Shaft-mounted gear unit with keyway or splined hollow shaft

5. Screw the retaining screw [1] back in. Now you can force the gear unit off the shaft 4.6.3 SEW installation and removal kit
by tightening the bolt.
The SEW-EURODRIVE assembly/disassembly kit can be ordered by quoting the
specified part number.

[1] [1]

[4]
[7]
[8]
[7]

[8] [7]
[6]

211529227

[1] Retaining screw


[4] Circlip
[6] Customer shaft
[1]
[7] Fixed nut
[8] Forcing washer

211531403

[1] Retaining screw


[7] Fixed nut for disassembly
[8] Forcing washer

Type DH7 M1) C4 C5 C6 U-0.5 T -0.5 D3-0.5 L4 Part number of


[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] installation/
removal kit
WA..10 16 M5 5 5 12 4.5 18 15.7 50 643 712 5
WA..20 18 M6 5 6 13.5 5.5 20.5 17.7 25 643 682 X
WA..20, WA..30, SA..37, WA..37 20 M6 5 6 15.5 5.5 22.5 19.7 25 643 683 8
FA..27, SA..47 25 M10 5 10 20 7.5 28 24.7 35 643 684 6
FA..37, KA..37, SA..47, SA..57 30 M10 5 10 25 7.5 33 29.7 35 643 685 4
FA..47, KA..47, SA..57 35 M12 5 12 29 9.5 38 34.7 45 643 686 2
FA..57, KA..57, FA..67, KA..67, SA..67 40 M16 5 12 34 11.5 41.9 39.7 50 643 687 0
SA..67 45 M16 5 12 38.5 13.5 48.5 44.7 50 643 688 9
FA..77, KA..77, SA..77 50 M16 5 12 43.5 13.5 53.5 49.7 50 643 689 7
FA..87, KA..87, SA..77, SA..87 60 M20 5 16 56 17.5 64 59.7 60 643 690 0
FA..97, KA..97, SA..87, SA..97 70 M20 5 16 65.5 19.5 74.5 69.7 60 643 691 9
FA..107, KA..107, SA..97 90 M24 5 20 80 24.5 95 89.7 70 643 692 7
FA..127, KA..127 100 M24 5 20 89 27.5 106 99.7 70 643 693 5
FA..157, KA..157 120 M24 5 20 107 31 127 119.7 70 643 694 3
1) Retaining screw

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 33 34 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
Shaft-mounted gear unit with keyway or splined hollow shaft
4 4 Shaft-mounted gear units with shrink disk

4.7 Shaft-mounted gear units with shrink disk


NOTE 4.7.1 Installation notes
The SEW installation kit for attaching the customer shaft is a recommendation by SEW- CAUTION!
EURODRIVE. You must always check whether this design can compensate the axial
loads. In particular applications (e.g. mounting mixer shafts), a different design may Tightening the screws without installed shaft may result in the hollow shaft being de-
have to be used to secure the shaft axially. In these cases, customers can use their formed.
own devices. However, you must ensure that these designs do not cause potential Potential damage to property!
sources of combustion according to DIN EN 13463 (for example, impact sparks). • Only tighten the locking screws with the shaft installed.
1. Loosen the locking screws by a few turns (do not unscrew them completely!).

A B

211533579

2. Carefully degrease the hollow shaft hole and the input shaft.

211535755

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 35 36 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
Shaft-mounted gear units with shrink disk
4 4 Shaft-mounted gear units with shrink disk

3. Hollow shaft/input shaft after degreasing. 5. Install the input shaft.


– Make sure that the locking collars of the shrink disk are installed in parallel to each
other.
– For gearcases with shaft shoulder:
Mount the shrink disk onto the stop on the shaft shoulder.
– For gearcases without shaft shoulder:
Install the shrink disk with a 1 to 2 mm distance from the gearcase.
– Tighten the locking screws by working round with the torque wrench several times
from one screw to the next (not in diametrically opposite sequence). For tighten-
ing torques, refer to the following table.

211537931

4. Apply NOCO® Fluid to the input shaft in the area of the bushing.
It is essential to make sure that the clamping area of the shrink disk is free from
grease! Never apply NOCO® Fluid directly to the socket, since the paste may get into
the clamping area of the shrink disk when the input shaft is put on.

1-2mm s>0mm

211542283

211540107 6. After the installation, make sure the remaining gap between the outer ringsis > 0 mm.
7. Grease the the area around the shrink disk outside of the hollow shaft to prevent cor-
rosion.
Gear unit type Screw Nm max.1)
SH37 WH37 M5 5
KH37...77 FH37...77 SH47...77 M6 12
KH87/97 FH87/97 SH87/97 M8 30
KH107 FH107 M10 59 60°
KH127/157 FH127/157 M12 100
KH167 M16 250
KH187 M20 470
1) Maximum tightening angle per rotation

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 37 38 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
Shaft-mounted gear units with shrink disk
4 4 Shaft-mounted gear units with TorqLOC®

4.7.2 Removal notes 4.8 Shaft-mounted gear units with TorqLOC®


CAUTION! 1. Clean the customer shaft and the inside of the hollow shaft. Ensure that all traces of
grease or oil are removed.
Risk of jamming and crushing due to improper removal of heavy components.
2. Install the stop ring and the bushing on the customer shaft.
Risk of injury.
• Observe the following removal notes.
• Removing the shrink disk properly.
1. Loosen the locking screws one after the other by a quarter rotation to avoid tilting the
outer rings.
2. Unscrew the locking bolts evenly one after the other. Do not remove the locking
screws completely.
3. Remove the shaft or pull the hub off the shaft. (remove any rust that may have formed
between the hub and the end of the shaft beforehand).
4. Remove the shrink disk from the hub.
211941003

4.7.3 Cleaning and lubrication


There is no need to dismantle removed shrink disks before they are reinstalled. 3. Apply and thoroughly spread NOCO® Fluid on the bushing.
Clean and lubricate the shrink disk if it is dirty.
O
C
®

Lubricate the tapered surfaces with one of the following solid lubricants: O D
N UI
L
F

Lubricant (Mo S2) Sold as


Molykote 321 (lube coat) Spray
Molykote spray (powder spray) Spray
Molykote G Rapid Spray or paste
Aemasol MO 19P Spray or paste
Aemasol DIO-sétral 57 N (lube coat) Spray

Grease the locking screws with a multipurpose grease such as Molykote BR 2 or similar. 211938827

4. Push the gear unit onto the customer shaft.

211936651

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 39 40 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
Shaft-mounted gear units with TorqLOC®
4 4 Shaft-mounted gear units with TorqLOC®

5. Preassemble the torque arm (do not tighten the bolts). 8. Secure the bushing with the split ring. Tighten the split ring on the bushing using the
appropriate torque as specified in the following table:

K...

F...
S...

211943179
212000907

Type nickel-plated stainless steel


6. Push the busing onto the gear unit up to the stop.
[Standard]
KT/FT ST Torque [Nm] ([in-lb])
- 37 18 7.5
37 47 18 7.5
47 57 18 7.5
57, 67 67 35 18
77 77 35 18
87 87 35 18
97 97 35 18
107 – 38 38
127 – 65 65
157 – 150 150
211945355

9. Make sure that all screws are loosened and slide the shrink disk onto the hollow
7. Tighten all the retaining screws of the torque arm. shaft.

211947531

212003083

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 41 42 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
Shaft-mounted gear units with TorqLOC®
4 4 Shaft-mounted gear units with TorqLOC®

10.Slide the counter bushing onto the customer shaft and into the hollow shaft 14.Manually tighten the bolts of the shrink disc and ensure that the end rings of the
shrink disc are parallel.

212005259
212011787

11.Make sure the shrink disk is properly seated.


12.Tap lightly on the flange of the counter bushing to ensure that the socket is fitted se- 15.Tighten the locking screws with a torque wrench by working round several times from
curely in the hollow shaft. one bolt to the next (not in diametrically opposite sequence) according to the follow-
ing table:

> 0mm

212007435
212013963

13.Make sure that the customer shaft is seated in the counter bushing. Type nickel-plated stainless steel
[Standard]
KT/FT ST Torque [Nm] ([in-lb])
- 37 4.1 6.8
37 47 10 6.8
47 57 12 6.8
57, 67 67 12 15
77 77 30 30
87 87 30 50
97 97 30 50
107 – 59 50
127 – 100 120
212009611 157 – 100 120

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 43 44 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
Shaft-mounted gear units with TorqLOC®
4 4 Installing the protective cover

16.After the installation, make sure the remaining gap between the outer rings 4.9 Installing the protective cover
is > 0 mm.
17.The remaining gap between counter bushing and hollow shaft end as well as stop CAUTION!
ring bushing and split ring must be > 0 mm. During operation, output components are in fast motion.
Risk of jamming and crushing.
> 0 mm • Disconnect the motor from the power supply before starting work and safeguard
against accidental startup.
> 0 mm • Cover input and output elements with a touch guard.

4.9.1 Installing the rotating cover

212016139

1
1. Slide the rotating cover onto the shrink disk until it snaps in.

4.9.2 Installing the fixed cover

1 2
1. To fasten the cover, remove the plastic plug on the gearcase (see figure 1)
2. Use the delivered screws to mount the cover to the gearcase (see figure 2).

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 45 46 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
Installing the protective cover
4 4 AM adapter coupling

4.9.3 Installation without cover 4.10 AM adapter coupling


In certain individual cases (e.g. through-shaft), you cannot install the cover. In such 4.10.1 IEC adapter AM63 - 280 / NEMA adapter AM56 - 365
cases, the cover is not necessary if the system or unit manufacturer provides corre-
sponding components to guarantee for the compliance with the required degree of pro-
tection.
If this results in additional maintenance, you have to describe this in the operating in-
structions for system/component.

212099979

[1] Motor shaft


[479] Coupling half
[481] Setscrew
[484] Key
[491] Spacer tube

1. Clean the motor shaft and the flange surfaces of the motor and the adapter.
2. Remove the key from the motor shaft and replace it with the supplied key [484] (not
AM63 and AM250).
3. Heat the coupling half [479] to approx. 80 - 100 °C and push the coupling half onto
the motor shaft. Position as follows:
– IEC adapter AM63 - 225 Until stop at motor shaft shoulder.
– IEC adapter AM250 - 280 to dimension A.
– NEMA adapter with spacer tube [491] to dimension A.
4. Secure the key and coupling half using the setscrew [481] and tightening torque TA
according to the table on the motor shaft.

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 47 48 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
AM adapter coupling
4 4 AM adapter coupling

5. Check the dimension A. Permitted loads


6. Seal the contact surfaces between the adapter and motor using a suitable sealing CAUTION!
compound.
Imperissibly high loads may occur when mounting a motor.
7. Mount the motor on the adapter. Ensure that the coupling claw of the adapter shaft
is engaged in the plastic cam ring. Potential damage to property!
• The load data specified in the following table are not to be exceeded.

IEC AM 63 / 71 80 / 90 100 / 112 132 160 / 180 200 225 250 / 280
A 24.5 31.5 41.5 54 76 78.5 93.5 139
X
TA 1.5 1.5 4.8 4.8 10 17 17 17
Thread M4 M4 M6 M6 M8 M10 M10 M10
NEMA AM 56 143 / 145 182 / 184 213 / 215 254 / 256 284 / 286 324 / 326 364 / 365
A 46 43 55 63.5 78.5 85.5 107 107
TA 1.5 1.5 4.8 4.8 10 17 17 17
Thread M4 M4 M6 M6 M8 M10 M10 M10

NOTE
To avoid contact corrosion, we recommend applying NOCO® Fluid to the motor shaft Fq
before mounting the coupling half.
18513419

CAUTION! Adapter type Fq1) [N]

Dampness might enter the adapter when mounting a motor to the adapter. IEC NEMA x1) [mm] IEC adapter NEMA adapter
AM63/71 AM56 77 530 410
Potential damage to property!
AM80/90 AM143/145 113 420 380
• Seal adapter with anaerobic fluid seal
AM100/112 AM182/184 144 2000 1760
AM1322) AM213/21522) 1600 1250
186
AM132.. AM213/215 4700 3690
AM160/180 AM254/286 251 4600 4340
AM200/225 AM324-AM365 297 5600 5250
AM250/280 - 390 11200 -

1) The maximum permitted weight of the attached motor Fqmax must be reduced linearly as the cen-
ter of gravity distance x increases. If this distance is reduced, the maximum permitted weight
Fqmax cannot be increased.
2) Diameter of the adapter output flange: 160 mm

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 49 50 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
AM adapter coupling
4 4 AQ adapter coupling

AM adapter with Check the direction of rotation of the drive prior to assembly or startup. Please inform 4.11 AQ adapter coupling
AM../RS backstop the SEW-EURODRIVE service in the case of incorrect direction of rotation.
4.11.1 AQA80 - 190 adapter / AQH80 - 190 adapter
The backstop is maintenance-free in operation, and does not require any further main-
tenance work. Backstops have a minimum lift-off speed depending on the size (see fol-
lowing table).
. AQA AQH

CAUTION! 479
479
If the minimum lift-off speeds are exceeded, the backstops are subject to wear, and the
resulting friction causes the temperature to increase.
Potential damage to property!
• In rated operation, the lift-off speeds must not drop below the minimum values. 1
• During startup or braking, the lift-off speeds may drop below the minimum levels. 1

2 3
Maximum locking torque of backstop Minimum lift-off speed
Type
[Nm] [rpm]
AM80/90/RS,
45 800 A A
AM143/145/RS
AM100/112/RS,
200 670
AM182/184/RS
AM132/RS,
470 660
AM213/215/RS 212114955
AM160/180/RS,
630 550 1 Motor shaft
AM254/286/RS
2 Setscrew
AM200/225/RS, 3 Screw
1430 600
AM324-365/RS
AQA = With keyway
AQH = Without keyway

1. Clean the motor shaft and the flange surfaces of the motor and the adapter.
2. Type AQH: Loosen the screws of the coupling half (479) and loosen the conical con-
nection.
3. Heat up the coupling half (80 °C - 100 °C) and slide it onto the motor shaft.
AQA / AQH design: up to clearance "A" (see table)

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 51 52 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
AQ adapter coupling
4 4 AD input cover

4. Type AQH: Tighten the screws evenly in diametrically opposite sequence, working 4.12 AD input cover
round several times. Make sure that all the screws are tightened with the tightening
torque TA according to the following table. Observe section "Assembling the input and output components" (see page 24) when in-
stalling input components
Type AQA: Secure the coupling halves using the setscrew (see table).
5. Check the position of the coupling half (clearance "A", see table).
4.12.1 AD../P – cover with motor mounting platform
Install motor onto the adapter making sure that the dogs of the two coupling halves
Mounting the motor and adjusting the motor mounting platform.
engage in each other. The force that must be applied when joining the two coupling
halves is dissipated after final assembly, so there is no risk of any axial load being
applied to adjacent bearings.

NOTE
Only for AQA, not permitted for AQH: To avoid contact corrosion, we recommend
applying NOCO® Fluid to the motor shaft before mounting the coupling half.

CAUTION!
Dampness might enter the adapter when mounting a motor to the adapter.
Potential damage to property!
• Seal adapter with anaerobic fluid seal

4.11.2 Setting dimensions/tightening torques

Type Coupling size Clearance "A" Bolts DIN 912 Tightening torque TA
[mm] [Nm]
AQA AQH AQA AQH
AQA /AQH 80 /1/2/3 44,5
AQA /AQH 100 /1/2 39 212119307
19/24 M5 M4 2 3
AQA /AQH 100 /3/4 53
AQA /AQH 115 /1/2 62 [1] Motor mounting platform
AQA /AQH 115 /3 62 [2] Stud bolt (only AD6/P / AD7/P)
24/28 M5 M5 2 6
AQA /AQH 140 /1/2 62 [3] Support (only AD6/P / AD7/P)
AQA /AQH 140 /3 74,5 [4] Nut
28/38 M8 M5 10 6
AQA /AQH 190 /1/2 76,5 [5] Threaded column
AQA /AQH 190 /3 38/45 100 M8 M6 10 10
1. Set the motor mounting platform to the required mounting position by evenly tighten-
ing the adjusting nuts. Remove the lifting eyebolt from helical gear units in order to
achieve the lowest adjustment position. Touch up any damage to the paint work.
2. Align the motor on the motor mounting platform (shaft ends must be in alignment)
and secure it.
3. Mount the input elements on the input shaft end and the motor shaft, line them up
with one another and correct the motor position again, if necessary.
4. Put on the traction elements (V-belt, chain, etc.) and apply a preload by evenly ad-
justing the motor mounting platform. Do not stress the motor mounting platform and
the columns against each other when doing this.
5. Tighten all the nuts not used for adjustment in order to fix the threaded columns.

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 53 54 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
AD input cover
4 4 AD input cover

4.12.2 Only AD6/P and AD7/P 4. Clean the threads of the new bolts and apply a bolt locking compound
(e.g. Loctite® 243) to the first few threads.
Unscrew the nuts on the stud bolts before adjustment to allow the stud bolts to move
axially in the support without restriction. Do not tighten the nuts until the final adjustment 5. Attach the application to the centering shoulder and tighten the retaining screws with
position has been reached. Do not adjust the motor mounting platform using the support. the specified tightening torque TA (see table).
Screw-in Tightening torque
Retaining thread
4.12.3 AD../ZR – input cover with centering shoulder Type depth TA for connection screws of strength class
s
t [mm] 8.8 [Nm]
Mounting applications on the input cover with centering shoulder. AD2/ZR 25,5 M8 25
1. Retaining bolts of a suitable length must be used to secure the application. The AD3/ZR 31,5 M10 48
length l of the new bolts is calculated as follows: AD4/ZR 36 M12 86
AD5/ZR 44 M12 86
AD6/ZR 48,5 M16 210
AD7/ZR 49 M20 410
AD8/ZR 42 M12 86

212121483

[l] t+a
[t] Screw-in depth (see table)
[a] Thickness of the application
[s] Retaining thread (see table)

Round down the calculated screw length to the next smaller standard length.
2. Remove the retaining screws from the centering shoulder.
3. Clean the contact surface and the centering shoulder.

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 55 56 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mechanical Installation Mechanical Installation
AD input cover
4 4 AD input cover

Permitted loads 4.12.4 AD../RS – cover with backstop

CAUTION! Check the direction of rotation of the drive prior to assembly or startup. Please inform
the SEW-EURODRIVE service in the case of incorrect direction of rotation.
Imperissibly high loads may occur when mounting a motor.
The backstop is maintenance-free in operation, and does not require any further main-
Potential damage to property! tenance work. Backstops have a minimum lift-off speed depending on the size (see fol-
• The load data specified in the following table are not to be exceeded. lowing table).

x CAUTION!
If the minimum lift-off speeds are exceeded, the backstops are subject to wear, and the
resulting friction causes the temperature to increase.
Potential damage to property!
• In rated operation, the lift-off speeds must not drop below the minimum values.
• During startup or braking, the lift-off speeds may drop below the minimum levels.

Maximum locking torque of backstop Minimum lift-off speed


Type
[Nm] [rpm]
AD2/RS 45 800
Fq AD3/RS 200 670

212123659 AD4/RS 470 660


AD5/RS 630 550
AD6/RS 1430 600
x1) Fq1) AD7/RS 1430 600
Type
[mm] [N]
AD8/RS 1430 600
AD2/ZR 193 330
AD3/ZR 274 1400
AD4/ZR2) 1120
361
AD4/ZR 3300
AD5/ZR 487 3200
AD6/ZR 567 3900
AD7/ZR 663 10000
AD8/ZR 516 4300

1) Maximum load values for connection screws of strength class 8.8. The maximum permitted weight of
the attached motor Fqmax must be reduced linearly as the center of gravity distance x increases. When
this distance is reduced, Fqmax cannot be increased.
2) Diameter of the adapter output flange: 160 mm

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 57 58 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Startup I Startup
Checking the oil level
5 5 Helical/parallel shaft helical/helical-bevel gear units
0

5 Startup 5.3 Helical/parallel shaft helical/helical-bevel gear units


5.1 Checking the oil level No special startup instructions are required for helical, parallel shaft helical and helical-
bevel gear units providing the gear units have been installed in accordance with section
Before startup, make sure that the oil level corresponds to the mounting position. Ob- "Mechanical installation" (see page 17).
serve section "Checking the oil level and changing the oil".

5.4 Gear units with backstop


5.2 Helical-worm and SPIROPLAN® W gear units
The purpose of a backstop is to prevent undesirable reverse rotation. During operation,
NOTES the backstop permits rotation in only one specified direction of rotation.

Note: The direction of rotation of the output shaft in series S..7 helical-worm gear units CAUTION!
has been changed from CW to CCW; this is different from the S..2 series. Change in
Operating the motor in the direction that is blocked could destroy the backstop.
direction of rotation: Swap over two motor feeder cables.
Potential damage to property!
• Do not start up the motor in the blocking direction. In order to achieve the desired
5.2.1 Run-in period direction of rotation, observe the correct power supply for the motor.
®
SPIROPLAN and helical-worm gear units require a running-in period of at least 48 h • The backstop can be operated in blocking direction with half the output torque
before reaching their maximum efficiency. A separate run-in period applies for each di- once for control purposes.
rection of rotation if the gear unit is operated in both directions of rotation. The table
shows the average power reduction during the run-in period.

Helical-worm gear
unit
Worm B
i range Ș reduction
1 start ca. 50 ... 280 approx. 12 %
2 start ca. 20 ... 75 approx. 6 %
CCW CW
3 start
4 start
ca. 20 ... 90
-
approx. 3 %
-
A
5 start ca. 6 ... 25 approx. 3 %
CW
CCW
6 start ca. 7 ... 25 approx. 2 %
659173899

Spiroplan® gear The direction of rotation is determined with a view to the output shaft (LSS).
units
W10 / W20 / W30 W37 • Clockwise (CW)
i range Ș reduction i range Ș reduction • Counterclockwise (CCW)
ca. 35 ... 75 approx. 15 %
The permitted direction of rotation is indicated on the housing.
ca. 20 ... 35 approx. 10 %
ca. 10 ... 20 approx. 8 % ca. 30...70 approx. 8 %
ca. 8 approx. 5 % ca. 10 ... 30 approx. 5%
ca. 6 approx. 3 % ca. 3...10 approx. 3%

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 59 60 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Inspection/Maintenance I Inspection/Maintenance
Preliminary work regarding gear unit inspection/maintenance
6 6 Inspection/maintenance intervals
0

6 Inspection/Maintenance 6.2 Inspection/maintenance intervals


The following gear units are lubricated for life and are thus maintenance-free:
• Helical gear units R07, R17, R27 Time interval Action

• F27 Parallel Shaft Helical Gear Units • Every 3000 operating hours, at least every 6 • Check oil and oil level
months • Check running noise for possible bearing
• SPIROPLAN® gear units damage
• Visually check the seals for leakage
Depending on external factors, the surface/corrosion protection might have to be re- • For gear units with a torque arm: Check the
paired or renewed. rubber buffer and change it, if necessary
• Depending on the operating conditions (see • Change mineral oil
The following inspection and maintenance intervals apply for all the other gear units. illustration below), at the latest every 3 years
• Replace anti-friction bearing grease
• according to oil temperature
(recommendation)
• Replace oil seal (do not install it in the same
track)
6.1 Preliminary work regarding gear unit inspection/maintenance • Depending on the operating conditions (see • Change synthetic oil
illustration below), at the latest every 5 years
Observe the following notes before you start with the inspection/maintenance work. • Replace anti-friction bearing grease
• according to oil temperature
(recommendation)
• Replace oil seal (do not install it in the same
HAZARD! track)

Risk of crushing if the drive starts up unintentionally. • Varying (depending on external factors) • Touch up or renew the surfaces /
anticorrosion coating
Severe or fatal injuries.
• Disconnect the gearmotor from the power supply before starting work and protect it
against unintentional re-start.
6.3 Lubricant change intervals
WARNING! The following figure shows the change intervals for standard gear units under normal
environmental conditions. Change the oil more frequently when using special versions
Danger of burns due to hot gear unit and hot gear unit oil.
subject to more severe/aggressive environmental conditions!
Fatal injuries.
• Let motor cool down before beginning work! 30000
• Only remove the oil level and oil drain plug very carefully. [h]

CAUTION! 25000
Filling in the wrong oil may result in significantly different lubricant characteristics. [3]
Potential damage to property! 20000
• Do not mix different synthetic lubricants and do not mix synthetic with mineral lubri-
cants.
• Mineral oil is used as standard lubricant. 15000
[4]

NOTE [1]
The position of the oil level plug, oil drain plug and the breather valve depends on the 10000
mounting position. Refer to the diagrams of the mounting positions. See chapter [5]
"Mounting Positions" (see page 79).
5000

0
70 80 90 100 110 115 120
[2] [°C]

[1] Operating hours [3] CLP PG


[2] Sustained oil bath temperature [4] CLP HC / HCE
• Average value per oil type at 70 °C [5] CLP / HLP / E Oil

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 61 62 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Inspection/Maintenance Inspection/Maintenance
Inspection/maintenance for the AL/AM/AQ adapter
6 6 Inspection/maintenance for the gear unit

6.4 Inspection/maintenance for the AL/AM/AQ adapter 6.6 Inspection/maintenance for the gear unit
Time interval Action 6.6.1 Checking the oil level and changing the oil
• Every 3000 operating hours, at least every 6 months • Check torsional play The procedure when checking the oil level and changing the oil depends on the following
• Visually check the elastic annular gear
• Check running noise for possible bearing
factors:
damage
• Visually check the adapter for leakage
• Gear unit type
• After 25 000 - 30 000 hours of operation • Renew the anti-friction bearing grease • Size
• Replace oil seal (do not install it in the
same track) • Mounting position
• Change the elastic annular gear
Observe the references to the respective sections as well as the following table. Refer
to chapter "Mounting Positions" (see page 79) for notes on the mounting positions. You
cannot check the oil level of gear units in pivoted mounting position. The gear units are
6.5 Inspection/maintenance for the AD input cover delivered with the correct oil level. Observe the designations and fill quantities on the
nameplate if you have to change the oil.
Time interval Action
• Every 3000 operating hours, at least every 6 months • Check running noise for possible bearing
damage Code letter Section "Checking the oil level and changing the oil" Reference
• Visually check the adapter for leakage
A: • Helical gear units... (see page 65)
• After 25 000 - 30 000 hours of operation • Renew the anti-friction bearing grease • Parallel shaft helical gear units...
• Change the oil seal • Helical-bevel gear units...
• Helical-worm gear units...
with oil level plug
B: • Helical gear units... (see page 67)
• Parallel shaft helical gear units...
• SPIROPLAN® gear units...
without oil level plug, with cover plate
C: • S37... helical-worm gear units (see page 71)
without oil level plug and cover plate
D: • SPIROPLAN® W37... (see page 74)
in mounting positions: M1, M2, M3, M5, M6 with oil level plug
EN: • SPIROPLAN® W37... (see page 76)
in M4 mounting position without oil level plug and cover plate

Code letter for section "Checking the oil level and changing the oil"
Rows Gear unit
M1 M2 M3 M4 M5 M6
R07...R27 B
R47...R57 A B A
R
R57...R167 A
RX57...R107 A
F27 B
F
F37..F157 A
K K37...K187 A
S37 C
S
S47...S97 A
W10...W30 B
W
W..37 D E D

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 63 64 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Inspection/Maintenance Inspection/Maintenance
Inspection/maintenance for the gear unit
6 6 Inspection/maintenance for the gear unit

6.6.2 Helical, parallel shaft helical, helical-bevel and helical-worm gear units with oil level plug Checking the oil Proceed as follows to check the oil of the gear unit:
Checking the oil Proceed as follows to check the oil level of the gear unit: via the oil drain
1. Observe the notes in section "Preliminary work regarding gear unit inspection/main-
levelvia the oil plug
1. Observe the notes in section "Preliminary work regarding gear unit inspection/main- tenance" (see page 61).
level plug tenance" (see page 61). 2. Determine the position of the oil drain plug using the mounting position sheets. See
2. Determine the position of the oil level plug and the breather valve using the mounting chapter "Mounting Positions" (see page 79).
position sheets. See chapter "Mounting Positions" (see page 79). 3. Remove a little oil from the oil drain plug.
3. Place a container underneath the oil level plug. 4. Check the oil consistency.
4. Slowly remove the oil level plug. Small amounts of oil may leak out as the permitted – Viscosity
max. oil level is higher than the lower edge of the oil level bore.
– If you can see that the oil is heavily contaminated, we recommend that you
5. Check the oil level according to the following figure and the corresponding table. change the oil even if this is outside the service intervals specified in "Inspection
and maintenance intervals" (see page 62).
[1] 5. Check the oil level. See previous section.

[2] Changing the oil


Ø
via the oil drain
Oil X max. plug and the
min. X breather valve

WARNING!
Danger of burns due to hot gear unit and hot gear unit oil.
Fatal injuries.
18634635 • Let motor cool down before beginning work!
[1] Oil level bore • The gear unit must still be warm otherwise the high viscosity of excessively cold oil
[2] Reference oil level will make it harder to drain the oil correctly.

∅ Oil level bore min and max fill level = x [mm] 1. Observe the notes in section "Preliminary work regarding gear unit inspection/main-
M10 x 1 1 tenance" (see page 61).
M12 x 1.5 1 2. Determine the position of the oil drain plug, the oil level plug and the breather valve
M22 x 1.5 2 using the mounting position sheets. See chapter "Mounting Positions"
M33 x 2 2 (see page 79).
M42 x 2 2 3. Place a container underneath the oil drain plug.
6. Proceed as follows if the oil level is too low: 4. Remove the oil level plug, the breather valve and the oil drain plug.
– Remove the breather valve. 5. Drain all the oil.
– Fill in additional oil of the same type via the vent hole until the oil level is at the 6. Re-insert the oil drain plug.
lower edge of the oil level bore. 7. Fill in new oil of the same type via the vent hole (otherwise consult the customer ser-
– Re-insert the breather valve. vice). Do not mix synthetic lubricants.

7. Re-insert the oil level plug. – Observe the oil fill quantities according to the specifications on the nameplate or
according to the mounting position. See sect "Lubricant fill quantities"
(see page 108).
– Check the oil level at the oil level plug.
8. Re-insert the oil level plug and the breather valve.

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 65 66 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Inspection/Maintenance Inspection/Maintenance
Inspection/maintenance for the gear unit
6 6 Inspection/maintenance for the gear unit

6.6.3 Helical, parallel shaft helical, SPIROPLAN® gear units without oil level plug with cover plate 5. Compare the determined value "x" to the max. distance between oil level and sealing
Checking the oil For gear units without oil level bore, the oil level is checked via the cover plate opening. surface of the gear case specified in the following table. Adjust the fill level if required.
level via the cover Proceed as follows: Gear unit type Max. distance x [mm] between oil level and sealing surface of the gear-
plate 1. Observe the notes in section "Preliminary work regarding gear unit inspection/main- case for mounting position

tenance" (see page 61). M1 M2 M3 M4 M5 M6


2-stage 52 ± 1 27 ± 1 27 ± 1 27 ± 1 27 ± 1 27 ± 1
2. For the cover plate to be on top, you have to set up the gear unit in the following R07
mounting position. 3-stage 49 ± 1 21 ± 1 21 ± 1 21 ± 1 21 ± 1 21 ± 1
2-stage 63 ± 1 18 ± 1 46 ± 1 18 ± 1 46 ± 1 46 ± 1
– R07 - R57 in M1 mounting position R17
3-stage 58 ± 1 11 ± 2 40 ± 2 11 ± 2 40 ± 2 40 ± 2
– F27 in M3 mounting position 2-stage 74 ± 1 22 ± 1 45 ± 1 22 ± 1 45 ± 1 45 ± 1
R27
– W10 - W30 in M1 mounting position 3-stage 76 ± 1 19 ± 1 42 ± 1 19 ± 1 42 ± 1 42 ± 1
2-stage – – – – 39 ± 1 –
3. Loosen the screws [1] of the cover plate [2] and remove the cover plate [2] and the R47
corresponding seal [3] (see following figure). 3-stage – – – – 32 ± 1 –
2-stage – – – – 32 ± 1 –
R57
[1] 3-stage – – – – 28 ± 1 –

[2]
2-stage 78 ± 1 31 ± 1 72 ± 1 56 ± 1 78 ± 1 78 ± 1
F27
[3] 3-stage 71 ± 1 24 ± 1 70 ± 1 45 ± 1 71 ± 1 71 ± 1

irrespective of the mounting position


W10 12 ± 1
W20 19 ± 1
W30 31 ± 1

18643211

4. Determine the vertical distance "x" between oil level and sealing surface of the gear-
case (see following figure).

90°

18646283

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 67 68 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Inspection/Maintenance Inspection/Maintenance
Inspection/maintenance for the gear unit
6 6 Inspection/maintenance for the gear unit

6. Close the gear unit after the oil level check: Checking the oil Proceed as follows to check the oil of the gear unit:
via the cover plate
• Re-attach the seal of the cover plate. Make sure that the sealing surfaces are 1. Observe the notes in section "Preliminary work regarding gear unit inspection/main-
clean and dry. tenance" (see page 61).
• Screw on the cover plate. Tighten the cover screws with the rated tightening 2. Open the cover plate of the gear unit according to section "Checking the oil via the
torque according to the following table from the inside to the outside in the order cover plate" (see page 67).
illustrated in the figure. Repeat the tightening procedure until the screws are 3. Take an oil sample via the cover plate opening.
properly tightened. Only use impulse drivers or torque wrenches in order to
prevent the cover plate from being damaged (no impact drivers). 4. Check the oil consistency.
– Viscosity
7 8 – If you can see that the oil is heavily contaminated, we recommend that you
change the oil even if this is outside the service intervals specified in "Inspection
and maintenance intervals" (see page 62).
5. Check the oil level. See section "Checking the oil level via the cover plate"
1 2 (see page 67).
5 6 1 2 6 8 6. Screw on the cover plate. Observe the order and the tightening torques according to
7 5
2 section "Checking the oil level via the cover plate" (see page 67)
3 4
1 2
1 2 1 Checking the oil
via the cover plate
3 4 3
3 4 4 3 5 4 WARNING!
5 6
A B C D E Danger of burns due to hot gear unit and hot gear unit oil.
18649739 Fatal injuries.
Gear unit Fig- Retaining Rated tightening torque TN Minimum tightening torque TN • Let motor cool down before beginning work!
type ure thread [Nm] [Nm] • The gear unit must still be warm otherwise the high viscosity of excessively cold oil
R/RF07 E M5 6 4
will make it harder to drain the oil correctly.
R/RF17/27 D 1. Observe the notes in section "Preliminary work regarding gear unit inspection/main-
R/RF47/57 A M6 11 7 tenance" (see page 61).
F27 B 2. Open the cover plate of the gear unit according to section "Checking the oil via the
W10 C M5 6 4 cover plate".
W20 C 3. Completely drain the oil in to a vessel via the cover plate opening.
M6 11 7
W30 A
4. Fill in new oil of the same type via the cover plate opening (otherwise consult the cus-
tomer service). Do not mix synthetic lubricants.
– Pour in the oil in accordance with the mounting position or as specified on the
nameplate. See section "Lubricant fill quantities" (see page 108).
5. Check the oil level.
6. Screw on the cover plate. Observe the order and the tightening torques according to
section "Checking the oil level via the cover plate" (see page 67)

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 69 70 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Inspection/Maintenance Inspection/Maintenance
Inspection/maintenance for the gear unit
6 6 Inspection/maintenance for the gear unit

6.6.4 S37 helical-worm gear units without oil level plug and cover plate 5. Determine the size of the section "x" of the dipstick covered with lubricant using a cal-
Checking the oil The S37 gear unit is not equipped with an oil level plug or a cover plate. This is why the iper (see following figure).
level via the oil level is checked via the control bore.
breather plug 1. Observe the notes in section "Preliminary work regarding gear unit inspection/main-
tenance" (see page 61).
2. Set up the gear unit in M5 or M6 mounting position, i.e. control bore always on top.
3. Remove the screw plug [1] (see following figure).

[1]
X

18661771

6. Compare the determined value "x" to the min. value depending on the mounting po-
sition specified in the following table. Correct the fill level if required.
Oil level = wetted section x [mm] of the dipstick

Gear unit Mounting position


type M1 M2 M3 M4 M5 M6
18655371 S37 10 ± 1 24 ± 1 34 ± 1 37 ± 1 24 ± 1 24 ± 1

4. Insert the dipstick vertically via the control bore all the way to the bottom of the gear- 7. Re-insert and tighten the screw plug.
case. Pull out the dipstick vertically (see following figure).

90°

18658699

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 71 72 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Inspection/Maintenance Inspection/Maintenance
Inspection/maintenance for the gear unit
6 6 Inspection/maintenance for the gear unit

Checking the oil 1. Observe the notes in section "Preliminary work regarding gear unit inspection/main- 6.6.5 SPIROPLAN® W37 in mounting positions: M1, M2, M3, M5, M6 with oil level plug
via the screw plug tenance" (see page 61). Checking the oil Proceed as follows to check the oil level of the gear unit:
2. Open the cover plate of the gear unit according to section "Checking the oil via the levelvia the oil 1. Observe the notes in section "Preliminary work regarding gear unit inspection/main-
screw plug". level plug tenance" (see page 61).
3. Take an oil sample via the screw plug bore. 2. Set up the gear unit in M1 mounting position.
4. Check the oil consistency. 3. Slowly remove the oil level plug (see following figure). Small amounts of oil may leak
– Viscosity out.
– If you can see that the oil is heavily contaminated, we recommend that you
change the oil even if this is outside the service intervals specified in "Inspection
and maintenance intervals" (see page 62).
5. Check the oil level. See previous section.
6. Re-insert and tighten the screw plug.

Changing the oil


via the screw plug

WARNING!
Danger of burns due to hot gear unit and hot gear unit oil. 787235211
Fatal injuries. 4. Check the oil level according to the following figure.
• Let motor cool down before beginning work!
• The gear unit must still be warm otherwise the high viscosity of excessively cold oil [1]
will make it harder to drain the oil correctly.

1. Observe the notes in section "Preliminary work regarding gear unit inspection/main- [2]
tenance" (see page 61).
Ø
2. Open the cover plate of the gear unit according to section "Checking the oil via the Oil X max.
min. X
screw plug".
3. Completely drain the oil via the screw plug bore.
4. Fill in new oil of the same type via the control bore (otherwise consult the customer
service). Do not mix synthetic lubricants.
– Observe the oil fill quantities according to the specifications on the nameplate or 634361867
according to the mounting position. Observe section "Lubricant fill quantities"
[1] Oil level bore
(see page 107).
[2] Reference oil level
5. Check the oil level.
∅ Oil level bore min and max fill level = x [mm]
6. Re-insert and tighten the screw plug. M10 x 1 1

5. If the oil level is to low, fill in new oil of the same type via the oil level bore until the
oil level reaches the lower edge of the bore.
6. Re-insert the oil level plug.

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 73 74 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Inspection/Maintenance Inspection/Maintenance
Inspection/maintenance for the gear unit
6 6 Inspection/maintenance for the gear unit

Checking the oil Proceed as follows to check the oil of the gear unit: 6.6.6 SPIROPLAN® W37 in M4 mounting position without oil level plug and cover plate
via the oil level Checking the oil The W37 gear unit is not equipped with an oil level plug or a cover plate. This is why the
1. Observe the notes in section "Preliminary work regarding gear unit inspection/main-
plug level via the oil level is checked via the control bore.
tenance" (see page 61).
breather plug 1. Observe the notes in section "Preliminary work regarding gear unit inspection/main-
2. Remove a little oil at the oil level plug.
tenance" (see page 61).
3. Check the oil consistency.
2. Set up the gear unit in M5 or M6 mounting position.
– Viscosity
3. Remove the screw plug.
– If you can see that the oil is heavily contaminated, we recommend that you
change the oil even if this is outside the service intervals specified in "Inspection 4. Insert the dipstick vertically via the control bore all the way to the bottom of the gear-
and maintenance intervals" (see page 62). case. Mark the point of the dipstick where it exits the gear unit. Pull out the dipstick
vertically (see following figure).
4. Check the oil level. See previous section.

Changing the oil


via the oil level
plug
A B
WARNING!
Danger of burns due to hot gear unit and hot gear unit oil.
Fatal injuries.
• Let motor cool down before beginning work!
• The gear unit must still be warm otherwise the high viscosity of excessively cold oil
will make it harder to drain the oil correctly.

1. Observe the notes in section "Preliminary work regarding gear unit inspection/main-
tenance" (see page 61).
2. Set up the gear unit in M5 or M6 mounting position. See chapter "Mounting Posi-
tions" (see page 79).
784447371
3. Place a container underneath the oil level plug.
5. Determine the section "x" between the wetted part and the marking using a caliper
4. Remove the oil level plugs on the A and B side of the gear unit. (see following figure).
5. Drain all the oil.
6. Re-insert the lower oil level plug.
7. Fill in new oil of the same type via the upper oil level plug bore (otherwise consult the
customer service). Do not mix synthetic lubricants.
– Observe the oil fill quantities according to the specifications on the nameplate or
according to the mounting position. See section "Lubricant fill quantities"
(see page 108).
X
– Check the oil level according to section "Checking the oil level via the oil level
plug" 785020811

8. Re-insert the upper oil level plug.

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 75 76 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Inspection/Maintenance Inspection/Maintenance
Inspection/maintenance for the gear unit
6 6 Inspection/maintenance for the gear unit

6. Compare the determined value "x" to the min. value depending on the mounting po- 6. Re-insert the lower screw plug.
sition specified in the following table. Correct the fill level if required.
7. Fill in new oil of the same type via the upper screw plug bore (otherwise consult the
Oil level = wetted section x [mm] of the dipstick customer service). Do not mix synthetic lubricants.
Mounting position during the check – Observe the oil fill quantities according to the specifications on the nameplate or
Gear unit type M5 M6 according to the mounting position. See section "Lubricant fill quantities"
Lying on the A side Lying on the B side (see page 108).
W37 in M4 mounting 37 ± 1 29 ± 1
position – Check the oil level according to section "Checking the oil level via the oil level
plug"
7. Re-insert and tighten the screw plug.
8. Re-insert the upper screw plug.

Checking the oil Proceed as follows to check the oil of the gear unit:
via the screw plug 6.6.7 Changing the oil seal
1. Observe the notes in section "Preliminary work regarding gear unit inspection/main-
tenance" (see page 61). CAUTION!
2. Remove a little oil at the oil screw plug. Oil seals with a temperature below 0 °C may get damaged during installation.
3. Check the oil consistency. Potential damage to property.
– Viscosity • Store oil seals at ambient temperatures over 0 °C.
• Warm up the oil seals prior to installation if required.
– If you can see that the oil is heavily contaminated, we recommend that you
change the oil even if this is outside the service intervals specified in "Inspection 1. When changing the oil seal, ensure that there is a sufficient grease reservoir between
and maintenance intervals" (see page 62). the dust lip and protective lip, depending on the type of gear unit.
4. Check the oil level. See previous section. 2. If you use double oil seals, fill one-third of the gap with grease.

Changing the oil 6.6.8 Painting gear units


via the screw plug
CAUTION!
WARNING! Breather valves and oil seals may be damaged during the painting or re-painting pro-
Danger of burns due to hot gear unit and hot gear unit oil. cess.

Fatal injuries. Potential damage to property.


• Let motor cool down before beginning work! • Thoroughly cover the breather valves and the sealing lip of the oil seals with strips
• The gear unit must still be warm otherwise the high viscosity of excessively cold oil prior to the painting process.
will make it harder to drain the oil correctly. • Remove the strips after the process.

1. Observe the notes in section "Preliminary work regarding gear unit inspection/main-
tenance" (see page 61).
2. Set up the gear unit in M5 or M6 mounting position. See chapter "Mounting Posi-
tions" (see page 79).
3. Place a container underneath the screw plug.
4. Remove the screw plugs on the A and B side of the gear unit.
5. Drain all the oil.

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 77 78 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mounting Positions kVA n Mounting Positions
Designation of the mounting positions
7 7 f
Key
i
P Hz

7 Mounting Positions 7.2 Key


7.1 Designation of the mounting positions NOTE
SEW differentiates between the six mounting positions M1 ... M6. The following illustra- The SPIROPLAN® gearmotors are not dependent on the mounting position, except for
tion shows the position of the gear unit in mounting positions M1 ... M6. W37 in M4 mounting position. However, mounting positions M1 to M6 are also shown
for SPIROPLAN® gearmotors to assist you in working with this documentation.
Note: Apart from W37, the SPIROPLAN® gearmotors cannot be equipped with breather
M6 M6 valves, oil level plugs or drain plugs.

M1 M1 7.2.1 Symbols used


M2 M2 The following table shows the symbols used in the mounting position sheets and what
M5 M5
M4 M4
they mean:
Symbol Meaning

Breather valve
R..
M3 M3
Oil level plug

Oil drain plug

M6 7.2.2 Churning losses


M6 M1
M2
M2 Churning losses may occur in some mounting positions. Contact SEW-EURODRIVE in
M1
case of the following combinations:
M5 Input speed
Mounting position Gear unit type Gear unit size
M5 M4 [rpm]
M4
97 ... 107 > 2500
M2, M4 R
> 107 >1500
F.. 97 ... 107 > 2500
F
M3 > 107 > 1500
M3
M2, M3, M4, M5, M6 77 ... 107 > 2500
K
> 107 > 1500
S 77 ... 97 > 2500

M6

M1
M1 M6
M2 M2
M5
M5
M4
K..
M4 W..
S.. M3
M3

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 79 80 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mounting Positions kVA n kVA n Mounting Positions
Helical gearmotors R
f 7 7 f
Helical gearmotors R
i i
P Hz P Hz

7.3 Helical gearmotors R 7.3.2 RF07 ... RF167, RZ07 ... RZ87

7.3.1 R07 ... R167

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 81 82 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mounting Positions kVA n kVA n Mounting Positions
Helical gearmotors R
f 7 7 f
Helical gearmotors RX
i i
P Hz P Hz

7.3.3 R07F ... R87F 7.4 Helical gearmotors RX


7.4.1 RX57 ... RX107

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 83 84 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mounting Positions kVA n kVA n Mounting Positions
Helical gearmotors RX
f 7 7 f
Parallel shaft helical gearmotors F
i i
P Hz P Hz

7.4.2 RXF57 ... RXF107 7.5 Parallel shaft helical gearmotors F


7.5.1 F27 ... F157 / FA27B ... F157B / FH27B .. FH157B / FV27B ... FV107B

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 85 86 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mounting Positions kVA n kVA n Mounting Positions
Parallel shaft helical gearmotors F
f 7 7 f
Parallel shaft helical gearmotors F
i i
P Hz P Hz

7.5.2 FF27 ... FF157 / FAF27 ... FAF157 / FHF27 ... FHF157 / FAZ27 ... FAZ157 / FHZ27 ... FHZ157 / FVF27 7.5.3 FA27 ... FA157 / FH27 ... FH157 / FV27 ... FV107 / FT37 ... FT157
... FVF107 / FVZ27 ... FVZ107

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 87 88 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mounting Positions kVA n kVA n Mounting Positions
Helical-bevel gearmotors K
f 7 7 f
Helical-bevel gearmotors K
i i
P Hz P Hz

7.6 Helical-bevel gearmotors K 7.6.2 K167 ... K187 / KH167B ... KH187B
7.6.1 K37 ... K157 / KA37B ... KA157B / KH37B ... KH157B / KV37B ... KV107B

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 89 90 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mounting Positions kVA n kVA n Mounting Positions
Helical-bevel gearmotors K
f 7 7 f
Helical-bevel gearmotors K
i i
P Hz P Hz

7.6.3 KF37 ... KF157 / KAF37 ... KAF157 / KHF37 ... KHF157 / KAZ37 ... KAZ157 / KHZ37 ... KHZ157 / 7.6.4 KA37 ... KA157 / KH37 ... KH157 / KV37 ... KV107 / KT37 ... KT157
KVF37 ... KVF107 / KVZ37 ... KVZ107

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 91 92 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mounting Positions kVA n kVA n Mounting Positions
Helical-bevel gearmotors K
f 7 7 f
Helical-worm gearmotors S
i i
P Hz P Hz

7.6.5 KH167 ... KH187 7.7 Helical-worm gearmotors S


7.7.1 S37

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 93 94 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mounting Positions kVA n kVA n Mounting Positions
Helical-worm gearmotors S
f 7 7 f
Helical-worm gearmotors S
i i
P Hz P Hz

7.7.2 S47 ... S97 7.7.3 SF37 / SAF37 / SHF37

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 95 96 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mounting Positions kVA n kVA n Mounting Positions
Helical-worm gearmotors S
f 7 7 f
Helical-worm gearmotors S
i i
P Hz P Hz

7.7.4 SF47 ... SF97 / SAF47 ... SAF97 / SHF47 ... SHF97 / SAZ47 ... SAZ97 / SHZ47 ... SHZ97 7.7.5 SA37 / SH37 / ST37

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 97 98 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mounting Positions kVA n kVA n Mounting Positions
Helical-worm gearmotors S
f 7 7 f
SPIROPLAN® W gear units
i i
P Hz P Hz

7.7.6 SA47 ... SA97 / SH47 ... SH97 / ST47 ... ST97 7.8 SPIROPLAN® W gear units
7.8.1 W10 ... W30

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 99 100 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mounting Positions kVA n kVA n Mounting Positions
SPIROPLAN® W gear units
f 7 7 f
SPIROPLAN® W gear units
i i
P Hz P Hz

7.8.2 WF10 ... WF30 / WAF10 ... WAF30 7.8.3 WA10 ... WA30

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 101 102 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mounting Positions kVA n kVA n Mounting Positions
SPIROPLAN® W gear units
f 7 7 f
SPIROPLAN® W gear units
i i
P Hz P Hz

7.8.4 W37/WA37B/WH37B 7.8.5 WF37/WAF37/WHF37

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 103 104 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Mounting Positions kVA n kVA n Technical Data
SPIROPLAN® W gear units
f 7 8 f
Extended storage
i i
P Hz P Hz

7.8.6 WA37 / WH37 / WT 37 8 Technical Data


8.1 Extended storage

NOTE
For storage periods longer than 9 months, SEW-EURODRIVE recommends the "Ex-
tended storage" design. Gear units in this design are designated with a corresponding
label.
In this case, a VCI corrosion inhibitor (volatile corrosion inhibitor) is added to the lubri-
cant in these gear units. Please note that this VCI corrosion inhibitor is only effective in
a temperature range of -25 °C ... +50 °C. The flange contact surfaces and shaft ends
are also treated with an anti-corrosion agent.
Observe the storage conditions specified in the following table for extended storage:

8.1.1 Storage conditions


The gear units must remain tightly sealed until taken into operation to prevent the VCI
corrosion protection agent from evaporating.
Gear units will be supplied with an oil fill according to the mounting position (M1 ... M6)
and are ready for operation. Check the oil level before you start operating the gear unit
for the first time!
Climate zone Packaging1) Storage location2) Storage duration
Packed in containers, with Up to three years with regular
desiccant and moisture With roof, protected against rain and snow, no checks of the packaging and
Temperate indicator sealed in the plas- shock loads. moisture indicator (rel. humid-
(Europe, USA, tic wrap. ity < 50 %).
Canada, China Under roof, enclosed at constant temperature and
and Russia, atmospheric humidity (5 °C < ϑ < 60 °C, < 50 % Two years or more with regu-
excluding tropi- relative humidity). lar inspections. Check for
cal zones) Open cleanliness and mechanical
No sudden temperature fluctuations. Controlled damage during inspection.
ventilation with filter (free from dust and dirt). Pro- Check corrosion protection.
tected against aggressive vapors and shocks.
Packed in containers, with
desiccant and moisture
indicator sealed in the plas- Up to three years with regular
tic wrap. checks of the packaging and
Under roof, protected against rain and shocks.
Tropical (Asia, moisture indicator (rel. humid-
Protected against insect ity < 50 %).
Africa, Central damage and mildew by
and South Amer- chemical treatment.
ica, Australia,
New Zealand Under roof, enclosed at constant temperature and
excluding temper- atmospheric humidity (5 °C < ϑ < 50°C, < 50 % Two years or more with regu-
ate zones) relative humidity). lar inspections. Check for
Open No sudden temperature fluctuations. Controlled cleanliness and mechanical
ventilation with filter (free from dust and dirt). Pro- damage during inspection.
tected against aggressive vapors and shocks. Check corrosion protection.
Protected against insect damage.
1) Packaging must be carried out by an experienced company using the packaging materials that have been explicitly specified for the
particular application.
2) SEW-EURODRIVE recommends to store the gear units according to the mounting position.

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 105 106 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Technical Data kVA n kVA n Technical Data
Lubricants
f 8 8 f
Lubricants
i i
P Hz P Hz

8.2 Lubricants Anti-friction bear- The anti-friction bearings in gear units and motors are given a factory-fill with the
ing greases greases listed below. SEW-EURODRIVE recommends regreasing anti-friction bearings
Unless a special arrangement is made, SEW-EURODRIVE supplies the drives with a with a grease fill at the same time as changing the oil.
lubricant fill adapted for the specific gear unit and mounting position. You have to specify
the mounting position (M1...M6, see section. "Mounting Positions") when you order the Ambient temperature Manufacturer Type
Gear unit anti-friction
drive. You must adapt the lubricant fill in case of any subsequent changes made to the bearings
–40 °C ... +80 °C Fuchs Renolit CX-TOM 15
mounting position (→ Lubricant fill quantities).
-30°C ... +40°C Aral Eural Grease EP 2

8.2.1 Lubricant table -20°C ... +40°C Aral Aralube BAB EP2
Oil

The lubricant table on the following page shows the permitted lubricants for
SEW-EURODRIVE gear units. Observe the following legend with regards to the lubri-
cant table. NOTE
The following grease quantities are required:
Key to the lubricant Abbreviations used, meaning of shading, and notes: • For fast-running bearings (gear unit input end): Fill the cavities between the rolling
table CLP = Mineral oil elements one-third full with grease.
CLP PG = Polyglycol (W gear units, conforms to USDA-H1) • For slow-running bearings (gear unit input side): Fill the cavities between the rolling
CLP HC = Synthetic hydrocarbons elements two-thirds full with grease.
E = Ester oil (water hazard class 1 (German regulation))
HCE = Synthetic hydrocarbons + ester oil (USDA - H1 certification)
HLP = Hydraulic oil
= Synthetic lubricant (= synthetic-based anti-friction bearing grease)
= Mineral lubricant (= mineral-based anti-friction bearing grease)

1) Helical-worm gear units with PG oil: Please coordinate with SEW


2) Special lubricant for Spiroplan® gear units only
3) Recommendation: Select SEW fB ≥ 1.2
4) Pay attention to critical starting behavior at low temperatures!
5) Low-viscosity grease
6) Ambient temperature
Lubricant for the food industry (food grade oil)

Biodegradable oil (lubricant for agriculture, forestry, and fisheries)


Oil

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 107 108 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
6)
Oil ISO,NLGI Mobil®
DIN (ISO) Tribol Optimol TO T A L
°C -50 0 +50 +100
Lubricant table
Standard Mobilgear 600 Shell Omala Klüberoil Aral Degol BP Energol Tribol Alpha SP 220 Renolin
R... -10 +40 CLP(CC) VG 220 Meropa 220 Carter EP 220
XP 220 220 GEM 1-220 N BG 220 GR-XP 220 1100/220 Optigear BM 220 CLP 220
Mobil Shell Tivela Klübersynth Aral Degol BP Enersyn Synlube Tribol Alphasyn PG 220
-25 +80 CLP PG VG 220 Carter SY 220
Glygoyle 30 S 220 GH 6-220 GS 220 SG-XP 220 CLP 220 800/220 Optiflex A 220
Alphasyn T 220
4) Mobil Shell Omala Klübersynth Aral Degol Pinnacle Tribol Renolin Unisyn
-40 +80 VG 220 Optigear Synthetic
SHC 630 HD 220 GEM 4-220 N PAS 220 EP 220 1510/220 X 220 CLP 220
K...(HK...) CLP HC
4) Shell Omala Klübersynth Pinnacle Alphasyn T 150
-40 +40 Mobil Carter SH 150
VG 150 Optigear Synthetic
SHC 629 HD 150 GEM 4-150 N EP 150 X 150

-20 CLP (CC) VG 150 Mobilgear 600 Shell Omala Klüberoil Aral Degol BP Energol Tribol Alpha SP/100/150 Renolin
+25 Meropa 150 Carter EP 100
VG 100 XP 100 100 GEM 1-150 N BG 100 GR-XP 100 1100/100 Optigear BM 100 CLP 150
VG 68-46 Mobil Shell Tellus Klüberoil Aral Degol Rando EP Tribol Hyspin AWS 32 Renolin
-30 +10 HLP (HM) Equivis ZS 46
F... VG 32 D.T.E. 13M T 32 GEM 1-68 N BG 46 Ashless 46 1100/68 Optigear 32 B 46 HVI
4) Mobil
-40 +20 CLP HC VG 68
SHC 626
Mobil Klüber-Summit Alphasyn T32 Dacnis SH 32
-40 +10 CLP HC VG 32 HySyn FG-32
SHC 624 Optilieb HY 32
4) -40
VG 22 Mobil Shell Tellus Isoflex BP Energol Rando Hyspin
-20 HLP (HM) Equivis ZS 15
VG 15 D.T.E. 11M T 15 MT 30 ROT HLP-HM 15 HDZ 15 AWS 22
Standard Mobilgear 600 Shell Omala Klüberoil Aral Degol BP Energol Tribol Alpha SP 680 Renolin
0 +40 CLP (CC) VG 680 Meropa 680 Optigear BM 680
Carter EP 680
XP 680 680 GEM 1-680 N BG 680 GR-XP 680 1100/680 SEW 680
1) Shell Tivela Klübersynth BP Enersyn Synlube Tribol Optiflex
-20 +60 CLP PG VG 680
S 680 GH 6-680 SG-XP 680 CLP 680 800/680 A 680
4) Mobil Shell Omala Klübersynth Pinnacle Optigear
-30 +80 VG 460
SHC 634 HD 460 GEM 4-460 N EP 460 Synthetic X 460
S...(HS...) CLP HC
4) Mobil Shell Omala Klübersynth Pinnacle Optigear
-40 +20 VG 150 Carter SH 150
SHC 629 HD 150 GEM 4-150 N EP 150 Synthetic X 150
VG 150 Mobilgear 600 Shell Omala Klüberoil Aral Degol BP Energol Tribol Alpha SP/100/150 Renolin
-20 +10 CLP (CC) Meropa 150 Carter EP 100
VG 100 XP 100 100 GEM 1-150 N BG 100 GR-XP 100 1100/100 Optigear BM 100 CLP 150
1) Mobil Shell Tivela Klübersynth Aral Degol BP Enersyn Synlube Tribol Alphasyn PG 220 Carter SY 220
-25 +20 CLP PG VG 220 Optiflex A 220
Glygoyle 30 S 220 GH 6-220 GS 220 SG-XP 220 CLP 220 800/220
Mobil

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
-40 +20 CLP HC VG 68
SHC 626
4) Mobil Klüber-Summit Cetus Dacnis SH 32
-40 0 CLP HC VG 32 Alphasyn T32
SHC 624 HySyn FG-32 PAO 46
4) -30 Shell Cassida Klüberoil Aral Eural Optileb
+40 HCE VG 460
R...,K...(HK...), Fluid GL 460 4UH1-460 N Gear 460 GT 460
F...,S...(HS...) -20 +40 Klüberbio Aral Degol Tribol Bio Top
E VG 460 1418/460
Oil CA2-460 BAB 460
Standard 2) Klüber SEW
W...(HW...) -20 +40 SEW PG VG 460
HT-460-5
4) SAE 75W90 Delvac Synth.
-40 +10 API GL5 GearOil LS 75
Lubricants
Technical Data

(~VG 100) W90


-20 +40
3) Klübersynth
CLP PG VG 460
UH1 6-460
i

Glygoyle Shell Tivela Klübersynth Multifak Spheerol


R32 -25 +60 00 GL 00 Marson SY 00
Grease 00 GE 46-1200 6833 EP 00 EPL 0
kVA

DIN 51 818
R302 Standard Mobilux Shell Alvania Aralub BP Energrease Multifak CLS Grease Renolin
f

-15 +40 5) 000 - 0 GL 00 LS-EP 00 Multis EP 00


01 805 10 92

EP 004 MFL 00 EP 000 Longtime PD 00 SF 7 - 041


P Hz
n
8

109
8

110
units
8.2.2
i
kVA
f
P Hz
n

Helical (R) gear


R..,

R97
R87
R77
R67
R57
R47
R37
R27
R17
R07

RF..
R167
R147
R137
R107

RF97
RF87
RF77
RF67
RF57
RF47
RF37
RF27
RF17
RF07

RF167
RF147
RF137
RF107
Lubricants

Gear unit
Gear unit
Lubricant fill quantities
Technical Data

0.25
0.12
0.25
0.12

M11)
M11)

9.5/25.0
6.3/14.9
5.1/10.2
2.40/6.0
6.0/13.7
4.60/9.8
2.30/6.0

26.0/70.0
16.4/42.0
1.20/2.60
1.20/2.50
0.80/1.70
0.65/1.50
0.35/0.95
0.25/0.40
27.0/70.0
15.4/40.0
10.0/25.0
1.20/3.00
1.10/2.30
0.80/1.70
0.70/1.50
0.30/0.95
0.25/0.40
mounting position M1 ... M6.

82.0
47.0
27.0
15.9
1.80
1.60
0.90
0.70
0.55
0.20
82.0
46.5
28.0
16.3
1.90
1.60
0.85
0.70
0.55
0.20

M21)
M21)

6.4/8.2
6.4/8.1

11.9/14.0
11.7/14.0

3.10/4.10
2.50/3.20
3.30/4.20
2.40/3.20

7.1
M3
7.2
M3

11.2
11.7

78.0
48.0
29.0
17.0
3.30
2.70
1.70
1.50
0.95
0.50
0.35
0.20
78.0
48.0
29.5
16.9
3.60
2.80
1.70
1.50
0.95
0.50
0.35
0.20
level plug since it indicates the precise oil capacity.

M4
M4

7.2
7.2

88.0
52.0
32.5
19.2
14.0
3.60
2.80
2.00
1.65
1.05
0.70
0.55
0.20
88.0
52.0
31.5
19.2
13.4
3.80
2.90
2.10
1.65
1.05
0.70
0.55
0.20

Fill quantity in liters


Fill quantity in liters

6.3
M5
6.3
M5

11.2
11.3

65.0
42.0
25.0
13.1
2.40
1.90
1.70
1.50
0.75
0.50
0.35
0.20
66.0
39.5
25.0
13.2
2.50
1.80
1.70
1.50
0.75
0.50
0.35
0.20

1) The larger gear unit of multi-stage gear units must be filled with the larger oil volume.
1) The larger gear unit of multi-stage gear units must be filled with the larger oil volume.

6.4
M6
6.5
M6

11.8
11.7

71.0
42.0
25.0
15.9
3.00
2.10
1.70
1.50
0.95
0.50
0.40
0.20
69.0
41.0
25.0
15.9
3.40
2.00
1.70
1.50
0.95
0.50
0.40
0.20
The specified fill quantities are recommended values. The precise values vary depend-

The following tables show guide values for lubricant fill quantities in relation to the
ing on the number of stages and gear ratio. When filling, it is essential to check the oil

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Technical Data kVA n kVA n Technical Data
Lubricants
f 8 8 f
Lubricants
i i
P Hz P Hz

RX.. Parallel shaft heli- F.., FA..B, FH..B, FV..B


Fill quantity in liters
cal (F) gear units Fill quantity in liters
Gear unit Gear unit
M1 M2 M3 M4 M5 M6 M1 M2 M3 M4 M5 M6
RX57 0.60 0.80 1.30 1.30 0.90 0.90 F..27 0.60 0.80 0.65 0.70 0.60 0.60
RX67 0.80 0.80 1.70 1.90 1.10 1.10 F..37 0.95 1.25 0.70 1.25 1.00 1.10
RX77 1.10 1.50 2.60 2.70 1.60 1.60 F..47 1.50 1.80 1.10 1.90 1.50 1.70
RX87 1.70 2.50 4.80 4.80 2.90 2.90 F..57 2.60 3.50 2.10 3.50 2.80 2.90
RX97 2.10 3.40 7.4 7.0 4.80 4.80 F..67 2.70 3.80 1.90 3.80 2.90 3.20
RX107 3.90 5.6 11.6 11.9 7.7 7.7 F..77 5.9 7.3 4.30 8.0 6.0 6.3
F..87 10.8 13.0 7.7 13.8 10.8 11.0
F..97 18.5 22.5 12.6 25.2 18.5 20.0
F..107 24.5 32.0 19.5 37.5 27.0 27.0
RXF..
F..127 40.5 54.5 34.0 61.0 46.3 47.0
Fill quantity in liters F..157 69.0 104.0 63.0 105.0 86.0 78.0
Gear unit
M1 M2 M3 M4 M5 M6
RXF57 0.50 0.80 1.10 1.10 0.70 0.70
RXF67 0.70 0.80 1.50 1.40 1.00 1.00 FF..
RXF77 0.90 1.30 2.40 2.00 1.60 1.60
RXF87 1.60 1.95 4.90 3.95 2.90 2.90 Fill quantity in liters
Gear unit
RXF97 2.10 3.70 7.1 6.3 4.80 4.80 M1 M2 M3 M4 M5 M6
RXF107 3.10 5.7 11.2 9.3 7.2 7.2 FF27 0.60 0.80 0.65 0.70 0.60 0.60
FF37 1.00 1.25 0.70 1.30 1.00 1.10
FF47 1.60 1.85 1.10 1.90 1.50 1.70
FF57 2.80 3.50 2.10 3.70 2.90 3.00
FF67 2.70 3.80 1.90 3.80 2.90 3.20
FF77 5.9 7.3 4.30 8.1 6.0 6.3
FF87 10.8 13.2 7.8 14.1 11.0 11.2
FF97 19.0 22.5 12.6 25.6 18.9 20.5
FF107 25.5 32.0 19.5 38.5 27.5 28.0
FF127 41.5 55.5 34.0 63.0 46.3 49.0
FF157 72.0 105.0 64.0 106.0 87.0 79.0

FA.., FH.., FV.., FAF.., FAZ.., FHF.., FHZ.., FVF.., FVZ.., FT..
Fill quantity in liters
Gear unit
M1 M2 M3 M4 M5 M6
F..27 0.60 0.80 0.65 0.70 0.60 0.60
F..37 0.95 1.25 0.70 1.25 1.00 1.10
F..47 1.50 1.80 1.10 1.90 1.50 1.70
F..57 2.70 3.50 2.10 3.40 2.90 3.00
F..67 2.70 3.80 1.90 3.80 2.90 3.20
F..77 5.9 7.3 4.30 8.0 6.0 6.3
F..87 10.8 13.0 7.7 13.8 10.8 11.0
F..97 18.5 22.5 12.6 25.2 18.5 20.0
F..107 24.5 32.0 19.5 37.5 27.0 27.0
F..127 39.0 54.5 34.0 61.0 45.0 46.5
F..157 68.0 103.0 62.0 104.0 85.0 77.0

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 111 112 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Technical Data kVA n kVA n Technical Data
Lubricants
f 8 8 f
Lubricants
i i
P Hz P Hz

Helical-bevel (K) K.., KA..B, KH..B, KV..B Helical-worm (S) S


gear units Fill quantity in liters
gear units Fill quantity in liters
Gear unit Gear unit
M1 M2 M3 M4 M5 M6 M1 M2 M31) M4 M5 M6
K..37 0.50 1.00 1.00 1.25 0.95 0.95 S..37 0.25 0.40 0.50 0.55 0.40 0.40
K..47 0.80 1.30 1.50 2.00 1.60 1.60 S..47 0.35 0.80 0.70/0.90 1.00 0.80 0.80
K..57 1.10 2.20 2.20 2.80 2.30 2.10 S..57 0.50 1.20 1.00/1.20 1.45 1.30 1.30
K..67 1.10 2.40 2.60 3.45 2.60 2.60 S..67 1.00 2.00 2.20/3.10 3.10 2.60 2.60
K..77 2.20 4.10 4.40 5.8 4.20 4.40 S..77 1.90 4.20 3.70/5.4 5.9 4.40 4.40
K..87 3.70 8.0 8.7 10.9 8.0 8.0 S..87 3.30 8.1 6.9/10.4 11.3 8.4 8.4
K..97 7.0 14.0 15.7 20.0 15.7 15.5 S..97 6.8 15.0 13.4/18.0 21.8 17.0 17.0
K..107 10.0 21.0 25.5 33.5 24.0 24.0 1) The larger gear unit of multi-stage gear units must be filled with the larger oil volume.
K..127 21.0 41.5 44.0 54.0 40.0 41.0
K..157 31.0 62.0 65.0 90.0 58.0 62.0
K..167 33.0 95.0 105.0 123.0 85.0 84.0
K..187 53.0 152.0 167.0 200 143.0 143.0 SF..
Fill quantity in liters
Gear unit
M1 M2 M31) M4 M5 M6
KF..
SF37 0.25 0.40 0.50 0.55 0.40 0.40
Fill quantity in liters SF47 0.40 0.90 0.90/1.05 1.05 1.00 1.00
Gear unit SF57 0.50 1.20 1.00/1.50 1.55 1.40 1.40
M1 M2 M3 M4 M5 M6
KF37 0.50 1.10 1.10 1.50 1.00 1.00 SF67 1.00 2.20 2.30/3.00 3.20 2.70 2.70
KF47 0.80 1.30 1.70 2.20 1.60 1.60 SF77 1.90 4.10 3.90/5.8 6.5 4.90 4.90
KF57 1.20 2.20 2.40 3.15 2.50 2.30 SF87 3.80 8.0 7.1/10.1 12.0 9.1 9.1
KF67 1.10 2.40 2.80 3.70 2.70 2.70 SF97 7.4 15.0 13.8/18.8 22.6 18.0 18.0
KF77 2.10 4.10 4.40 5.9 4.50 4.50 1) The larger gear unit of multi-stage gear units must be filled with the larger oil volume.
KF87 3.70 8.2 9.0 11.9 8.4 8.4
KF97 7.0 14.7 17.3 21.5 15.7 16.5
KF107 10.0 21.8 25.8 35.1 25.2 25.2
KF127 21.0 41.5 46.0 55.0 41.0 41.0 SA.., SH.., SAF.., SHZ.., SAZ.., SHF.., ST..
KF157 31.0 66.0 69.0 92.0 62.0 62.0
Fill quantity in liters
Gear unit
M1 M2 M31) M4 M5 M6
S..37 0.25 0.40 0.50 0.50 0.40 0.40
KA.., KH.., KV.., KAF.., KHF.., KVF.., KAZ.., KHZ.., KVZ.., KT.. S..47 0.40 0.80 0.70/0.90 1.00 0.80 0.80
Fill quantity in liters S..57 0.50 1.10 1.00/1.50 1.50 1.20 1.20
Gear unit S..67 1.00 2.00 1.80/2.60 2.90 2.50 2.50
M1 M2 M3 M4 M5 M6
K..37 0.50 1.00 1.00 1.40 1.00 1.00 S..77 1.80 3.90 3.60/5.0 5.8 4.50 4.50
K..47 0.80 1.30 1.60 2.15 1.60 1.60 S..87 3.80 7.4 6.0/8.7 10.8 8.0 8.0
K..57 1.20 2.20 2.40 3.15 2.70 2.40 S..97 7.0 14.0 11.4/16.0 20.5 15.7 15.7
K..67 1.10 2.40 2.70 3.70 2.60 2.60 1) The larger gear unit of multi-stage gear units must be filled with the larger oil volume.
K..77 2.10 4.10 4.60 5.9 4.40 4.40
K..87 3.70 8.2 8.8 11.1 8.0 8.0
K..97 7.0 14.7 15.7 20.0 15.7 15.7 Spiroplan® (W) The fill quantity of Spiroplan® gear units W10, W20 and W30 does not vary, regardless
K..107 10.0 20.5 24.0 32.4 24.0 24.0
K..127 21.0 41.5 43.0 52.0 40.0 40.0
gear units of the mounting position. Only the Spiroplan® W37 gear unit has a different fill quantity
K..157 31.0 66.0 67.0 87.0 62.0 62.0 in M4 mounting position.
K..167 33.0 95.0 105.0 123.0 85.0 84.0
Gear unit Fill quantity in liters, regardless of mounting position
K..187 53.0 152.0 167.0 200 143.0 143.0
W..10 0.16
W..20 0.24
W..30 0.40
W..37 0.50
W..37 in M4 0.70

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 113 114 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Malfunctions/Service kVA n Malfunctions/Service
Gear unit
f 9 9 AM / AQ / AL. adapter
i
P Hz

9 Malfunctions/Service 9.2 AM / AQ / AL. adapter

CAUTION! Malfunction Possible cause Remedy


Unusual, regular running Meshing/grinding noise: Bearing damage. Contact SEW-EURODRIVE customer service
Improper handling of the gear unit and the motor may lead to damages. noise
Potential damage to property! Oil leaking Seal defective Contact SEW-EURODRIVE customer service
• Any repair work on SEW drives may be performed by qualified personnel only. Output shaft does not turn Connection between shaft and hub in gear Send the gear unit to SEW-EURODRIVE for repair.
• Only qualified personnel is permitted to separate drive and motor. although the motor is run- unit interrupted
ning or the input shaft is
• Consult SEW-EURODRIVE customer service. rotated
Change in running noise Annular gear wear, short-term torque transfer Change the annular gear
and / or vibrations. through metal contact
Bolts to secure hub axially are loose. Tighten the screws
9.1 Gear unit
Malfunction Possible cause Remedy Premature wear in annular • Contact with aggressive fluids / oils; Contact SEW-EURODRIVE customer service
gear ozone influence; too high ambient
Unusual, regular running Meshing/grinding noise: Bearing damage Check the oil →see "Inspection/maintenance for the temperatures etc, which can cause a
noise gear unit" (see page 64), change bearings. change in the physical properties of the
Knocking noise: Irregularity in the gearing Contact customer service annular gear.
• Impermissibly high ambient/contact
Unusual, irregular running Foreign bodies in the oil • Check the oil →see "Inspection/maintenance for temperature for the annular gear;
noise the gear unit" (see page 64), maximum permitted temperature: 20°C to
• Stop the drive, contact customer service +80°C
• Overload
Oil leaking 1) Rubber seal on the gear cover plate leaking Tighten the screws on the gear cover plate and
• From gear unit cover observe the gear unit. If oil still leaks: Contact customer
• at the motor flange service
• at the motor oil seal Seal defective Contact customer service
• at the gear unit flange 9.3 AD input cover
• From the output end oil
seal Gear unit not ventilated Vent the gear unit → see "Mounting Positions"
(see page 79) Malfunction Possible cause Remedy

Oil leaking from breather Too much oil Correct the oil fill quantity →see "Inspection/mainte- Unusual, regular running Meshing/grinding noise: Bearing damage. Contact SEW-EURODRIVE customer service
valve nance for the gear unit" (see page 64), noise

Drive operated in incorrect mounting position • Properly adjust the breather valve → see Oil leaking Seal defective Contact SEW-EURODRIVE customer service
"Mounting Positions" (see page 79) Output shaft does not turn Connection between shaft and hub in gear Send the gear unit to SEW-EURODRIVE for repair.
• Correct the oil level →see "Inspection/maintenance although the input shaft is unit or cover interrupted
for the gear unit" (see page 64), rotated.
Frequent cold starts (oil foams) and/or high oil Use an oil expansion tank
level.
Output shaft does not turn Connection between shaft and hub in gear unit Send in the gear unit/gearmotor for repair.
although the motor is run- interrupted
ning or the input shaft is
rotated
1) Short-term oil / grease leakage at the oil seal is possible in the run-in phase (48 hours running time).

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Malfunctions/Service Address List
Customer service
9 10 Disposal

9.4 Customer service 10 Address List


Germany

Please have the following information available if you require customer service assis- Headquarters Bruchsal SEW-EURODRIVE GmbH & Co KG Tel. +49 7251 75-0
tance: Production Ernst-Blickle-Straße 42 Fax +49 7251 75-1970
• Nameplate data (complete) Sales D-76646 Bruchsal http://www.sew-eurodrive.de
P.O. Box sew@sew-eurodrive.de
• Type and extent of the problem
Postfach 3023 • D-76642 Bruchsal
• Time the problem occurred and any accompanying circumstances
Service Compe- Central SEW-EURODRIVE GmbH & Co KG Tel. +49 7251 75-1710
• Assumed cause tence Center Ernst-Blickle-Straße 1 Fax +49 7251 75-1711
D-76676 Graben-Neudorf sc-mitte@sew-eurodrive.de
North SEW-EURODRIVE GmbH & Co KG Tel. +49 5137 8798-30
Alte Ricklinger Straße 40-42 Fax +49 5137 8798-55
D-30823 Garbsen (near Hannover) sc-nord@sew-eurodrive.de
9.5 Disposal East SEW-EURODRIVE GmbH & Co KG Tel. +49 3764 7606-0
Dänkritzer Weg 1 Fax +49 3764 7606-30
Dispose gear units in accordance with the regulations in force regarding respective ma- D-08393 Meerane (near Zwickau) sc-ost@sew-eurodrive.de
terials:
South SEW-EURODRIVE GmbH & Co KG Tel. +49 89 909552-10
• Steel scrap Domagkstraße 5 Fax +49 89 909552-50
D-85551 Kirchheim (near München) sc-sued@sew-eurodrive.de
– Housing parts
West SEW-EURODRIVE GmbH & Co KG Tel. +49 2173 8507-30
– Gears Siemensstraße 1 Fax +49 2173 8507-55
D-40764 Langenfeld (near Düsseldorf) sc-west@sew-eurodrive.de
– Shafts
Electronics SEW-EURODRIVE GmbH & Co KG Tel. +49 7251 75-1780
– Anti-friction bearing Ernst-Blickle-Straße 42 Fax +49 7251 75-1769
D-76646 Bruchsal sc-elektronik@sew-eurodrive.de
• Parts of the worm gears are made of non-ferrous metals. Dispose of the worm gears
Drive Service Hotline / 24 Hour Service +49 180 5 SEWHELP
as appropriate. +49 180 5 7394357
• Collect waste oil and dispose of it according to the regulations in force. Additional addresses for service in Germany provided on request!

France
Production Haguenau SEW-USOCOME Tel. +33 3 88 73 67 00
Sales 48-54, route de Soufflenheim Fax +33 3 88 73 66 00
Service B. P. 20185 http://www.usocome.com
F-67506 Haguenau Cedex sew@usocome.com
Production Forbach SEW-EUROCOME Tel. +33 3 87 29 38 00
Zone Industrielle
Technopôle Forbach Sud
B. P. 30269
F-57604 Forbach Cedex
Assembly Bordeaux SEW-USOCOME Tel. +33 5 57 26 39 00
Sales Parc d'activités de Magellan Fax +33 5 57 26 39 09
Service 62, avenue de Magellan - B. P. 182
F-33607 Pessac Cedex
Lyon SEW-USOCOME Tel. +33 4 72 15 37 00
Parc d'Affaires Roosevelt Fax +33 4 72 15 37 15
Rue Jacques Tati
F-69120 Vaulx en Velin
Paris SEW-USOCOME Tel. +33 1 64 42 40 80
Zone industrielle Fax +33 1 64 42 40 88
2, rue Denis Papin
F-77390 Verneuil I'Etang
Additional addresses for service in France provided on request!

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Address List Address List
Disposal
10 10 Disposal

Algeria Cameroon
Sales Alger Réducom Tel. +213 21 8222-84 Sales Douala Electro-Services Tel. +237 33 431137
16, rue des Frères Zaghnoun Fax +213 21 8222-84 Rue Drouot Akwa Fax +237 33 431137
Bellevue El-Harrach reducom_sew@yahoo.fr B.P. 2024
16200 Alger Douala

Argentina Canada
Assembly Buenos Aires SEW EURODRIVE ARGENTINA S.A. Tel. +54 3327 4572-84 Assembly Toronto SEW-EURODRIVE CO. OF CANADA LTD. Tel. +1 905 791-1553
Sales Centro Industrial Garin, Lote 35 Fax +54 3327 4572-21 Sales 210 Walker Drive Fax +1 905 791-2999
Service Ruta Panamericana Km 37,5 sewar@sew-eurodrive.com.ar Service Bramalea, Ontario L6T3W1 http://www.sew-eurodrive.ca
1619 Garin http://www.sew-eurodrive.com.ar marketing@sew-eurodrive.ca
Vancouver SEW-EURODRIVE CO. OF CANADA LTD. Tel. +1 604 946-5535
Australia
7188 Honeyman Street Fax +1 604 946-2513
Assembly Melbourne SEW-EURODRIVE PTY. LTD. Tel. +61 3 9933-1000 Delta. B.C. V4G 1 E2 marketing@sew-eurodrive.ca
Sales 27 Beverage Drive Fax +61 3 9933-1003
Montreal SEW-EURODRIVE CO. OF CANADA LTD. Tel. +1 514 367-1124
Service Tullamarine, Victoria 3043 http://www.sew-eurodrive.com.au
2555 Rue Leger Fax +1 514 367-3677
enquires@sew-eurodrive.com.au
LaSalle, Quebec H8N 2V9 marketing@sew-eurodrive.ca
Sydney SEW-EURODRIVE PTY. LTD. Tel. +61 2 9725-9900
Additional addresses for service in Canada provided on request!
9, Sleigh Place, Wetherill Park Fax +61 2 9725-9905
New South Wales, 2164 enquires@sew-eurodrive.com.au Chile
Townsville SEW-EURODRIVE PTY. LTD. Tel. +61 7 4779 4333 Assembly Santiago de SEW-EURODRIVE CHILE LTDA. Tel. +56 2 75770-00
12 Leyland Street Fax +61 7 4779 5333 Sales Chile Las Encinas 1295 Fax +56 2 75770-01
Garbutt, QLD 4814 enquires@sew-eurodrive.com.au Service Parque Industrial Valle Grande http://www.sew-eurodrive.cl
LAMPA ventas@sew-eurodrive.cl
Austria
RCH-Santiago de Chile
Assembly Wien SEW-EURODRIVE Ges.m.b.H. Tel. +43 1 617 55 00-0 P.O. Box
Sales Richard-Strauss-Strasse 24 Fax +43 1 617 55 00-30 Casilla 23 Correo Quilicura - Santiago - Chile
Service A-1230 Wien http://sew-eurodrive.at
sew@sew-eurodrive.at China
Production Tianjin SEW-EURODRIVE (Tianjin) Co., Ltd. Tel. +86 22 25322612
Belarus
Assembly No. 46, 7th Avenue, TEDA Fax +86 22 25322611
Sales Minsk SEW-EURODRIVE BY Tel.+375 (17) 298 38 50 Sales Tianjin 300457 info@sew-eurodrive.cn
RybalkoStr. 26 Fax +375 (17) 29838 50 Service http://www.sew-eurodrive.cn
BY-220033 Minsk sales@sew.by
Assembly Suzhou SEW-EURODRIVE (Suzhou) Co., Ltd. Tel. +86 512 62581781
Sales 333, Suhong Middle Road Fax +86 512 62581783
Belgium
Service Suzhou Industrial Park suzhou@sew-eurodrive.cn
Assembly Brüssel SEW Caron-Vector S.A. Tel. +32 10 231-311
Jiangsu Province, 215021
Sales Avenue Eiffel 5 Fax +32 10 231-336
Guangzhou SEW-EURODRIVE (Guangzhou) Co., Ltd. Tel. +86 20 82267890
Service B-1300 Wavre http://www.sew-eurodrive.be
info@caron-vector.be No. 9, JunDa Road Fax +86 20 82267891
East Section of GETDD guangzhou@sew-eurodrive.cn
Service Compe- Industrial Gears SEW Caron-Vector S.A. Tel. +32 84 219-878 Guangzhou 510530
tence Center Rue de Parc Industriel, 31 Fax +32 84 219-879
BE-6900 Marche-en-Famenne http://www.sew-eurodrive.be Shenyang SEW-EURODRIVE (Shenyang) Co., Ltd. Tel. +86 24 25382538
10A-2, 6th Road Fax +86 24 25382580
service-wallonie@sew-eurodrive.be
Shenyang Economic Technological Develop- shenyang@sew-eurodrive.cn
ment Area
Brazil
Shenyang, 110141
Production Sao Paulo SEW-EURODRIVE Brasil Ltda. Tel. +55 11 6489-9133
Additional addresses for service in China provided on request!
Sales Avenida Amâncio Gaiolli, 152 – Rodovia Presi- Fax +55 11 6480-3328
Service dente Dutra Km 208 http://www.sew.com.br
Colombia
Guarulhos – 07251-250 - SP sew@sew.com.br
SAT – SEW ATENDE – 0800 7700496 Assembly Bogotá SEW-EURODRIVE COLOMBIA LTDA. Tel. +57 1 54750-50
Sales Calle 22 No. 132-60 Fax +57 1 54750-44
Additional addresses for service in Brazil provided on request!
Service Bodega 6, Manzana B http://www.sew-eurodrive.com.co
Bulgaria Santafé de Bogotá sewcol@sew-eurodrive.com.co

Sales Sofia BEVER-DRIVE GmbH Tel. +359 2 9151160


Croatia
Bogdanovetz Str.1 Fax +359 2 9151166
Sales Zagreb KOMPEKS d. o. o. Tel. +385 1 4613-158
BG-1606 Sofia bever@fastbg.net
Service PIT Erdödy 4 II Fax +385 1 4613-158
HR 10 000 Zagreb kompeks@inet.hr

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Address List Address List
Disposal
10 10 Disposal

Czech Republic Hungary


Sales Praha SEW-EURODRIVE CZ S.R.O. Tel. +420 220121234 Sales Budapest SEW-EURODRIVE Kft. Tel. +36 1 437 06-58
Business Centrum Praha Fax +420 220121237 Service H-1037 Budapest Fax +36 1 437 06-50
Lužná 591 http://www.sew-eurodrive.cz Kunigunda u. 18 office@sew-eurodrive.hu
CZ-16000 Praha 6 - Vokovice sew@sew-eurodrive.cz
India
Denmark Assembly Vadodara SEW-EURODRIVE India Private Limited Tel. +91 265 2831086
Assembly Kopenhagen SEW-EURODRIVEA/S Tel. +45 43 9585-00 Sales Plot No. 4, GIDC Fax +91 265 2831087
Sales Geminivej 28-30 Fax +45 43 9585-09 Service POR Ramangamdi • Vadodara - 391 243 http://www.seweurodriveindia.com
Service DK-2670 Greve http://www.sew-eurodrive.dk Gujarat sales@seweurodriveindia.com
sew@sew-eurodrive.dk subodh.ladwa@seweurodriveindia.com

Egypt Ireland
Sales Cairo Copam Egypt Tel. +20 2 22566-299 + 1 23143088 Sales Dublin Alperton Engineering Ltd. Tel. +353 1 830-6277
Service for Engineering & Agencies Fax +20 2 22594-757 Service 48 Moyle Road Fax +353 1 830-6458
33 EI Hegaz ST, Heliopolis, Cairo http://www.copam-egypt.com/ Dublin Industrial Estate info@alperton.ie
copam@datum.com.eg Glasnevin, Dublin 11 http://www.alperton.ie

Estonia Israel
Sales Tallin ALAS-KUUL AS Tel. +372 6593230 Sales Tel-Aviv Liraz Handasa Ltd. Tel. +972 3 5599511
Reti tee 4 Fax +372 6593231 Ahofer Str 34B / 228 Fax +972 3 5599512
EE-75301 Peetri küla, Rae vald, Harjumaa veiko.soots@alas-kuul.ee 58858 Holon http://www.liraz-handasa.co.il
office@liraz-handasa.co.il
Finland
Assembly Lahti SEW-EURODRIVE OY Tel. +358 201 589-300 Italy
Sales Vesimäentie 4 Fax +358 3 780-6211 Assembly Milano SEW-EURODRIVE di R. Blickle & Co.s.a.s. Tel. +39 02 96 9801
Service FIN-15860 Hollola 2 sew@sew.fi Sales Via Bernini,14 Fax +39 02 96 799781
http://www.sew-eurodrive.fi Service I-20020 Solaro (Milano) http://www.sew-eurodrive.it
Production Karkkila SEW Industrial Gears OY Tel. +358 201 589-300 sewit@sew-eurodrive.it
Assembly Valurinkatu 6 Fax +358 201 589-310
Ivory Coast
Service FIN-03600 Karkkila sew@sew.fi
http://www.sew-eurodrive.fi Sales Abidjan SICA Tel. +225 2579-44
Ste industrielle et commerciale pour l'Afrique Fax +225 2584-36
Gabon 165, Bld de Marseille
Sales Libreville Electro-Services Tel. +241 7340-11 B.P. 2323, Abidjan 08
B.P. 1889 Fax +241 7340-12
Japan
Libreville
Assembly Iwata SEW-EURODRIVE JAPAN CO., LTD Tel. +81 538 373811
Great Britain Sales 250-1, Shimoman-no, Fax +81 538 373814
Assembly Normanton SEW-EURODRIVE Ltd. Tel. +44 1924 893-855 Service Iwata http://www.sew-eurodrive.co.jp
Sales Beckbridge Industrial Estate Fax +44 1924 893-702 Shizuoka 438-0818 sewjapan@sew-eurodrive.co.jp
Service P.O. Box No.1 http://www.sew-eurodrive.co.uk
Korea
GB-Normanton, West- Yorkshire WF6 1QR info@sew-eurodrive.co.uk
Assembly Ansan-City SEW-EURODRIVE KOREA CO., LTD. Tel. +82 31 492-8051
Greece Sales B 601-4, Banweol Industrial Estate Fax +82 31 492-8056
Sales Athen Christ. Boznos & Son S.A. Tel. +30 2 1042 251-34 Service 1048-4, Shingil-Dong http://www.sew-korea.co.kr
Service 12, Mavromichali Street Fax +30 2 1042 251-59 Ansan 425-120 master@sew-korea.co.kr
P.O. Box 80136, GR-18545 Piraeus http://www.boznos.gr Busan SEW-EURODRIVE KOREA Co., Ltd. Tel. +82 51 832-0204
info@boznos.gr No. 1720 - 11, Songjeong - dong Fax +82 51 832-0230
Gangseo-ku master@sew-korea.co.kr
Hong Kong Busan 618-270
Assembly Hong Kong SEW-EURODRIVE LTD. Tel. +852 2 7960477 + 79604654
Sales Unit No. 801-806, 8th Floor Fax +852 2 7959129 Latvia
Service Hong Leong Industrial Complex contact@sew-eurodrive.hk Sales Riga SIA Alas-Kuul Tel. +371 7139253
No. 4, Wang Kwong Road Katlakalna 11C Fax +371 7139386
Kowloon, Hong Kong LV-1073 Riga http://www.alas-kuul.com
info@alas-kuul.com

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Address List Address List
Disposal
10 10 Disposal

Lebanon Peru
Sales Beirut Gabriel Acar & Fils sarl Tel. +961 1 4947-86 Assembly Lima SEW DEL PERU MOTORES REDUCTORES Tel. +51 1 3495280
B. P. 80484 +961 1 4982-72 Sales S.A.C. Fax +51 1 3493002
Bourj Hammoud, Beirut +961 3 2745-39 Service Los Calderos, 120-124 http://www.sew-eurodrive.com.pe
Fax +961 1 4949-71 Urbanizacion Industrial Vulcano, ATE, Lima sewperu@sew-eurodrive.com.pe
gacar@beirut.com
Poland
Lithuania Assembly Lodz SEW-EURODRIVE Polska Sp.z.o.o. Tel. +48 42 67710-90
Sales Alytus UAB Irseva Tel. +370 315 79204 Sales ul. Techniczna 5 Fax +48 42 67710-99
Naujoji 19 Fax +370 315 56175 Service PL-92-518 àódĨ http://www.sew-eurodrive.pl
LT-62175 Alytus info@irseva.lt sew@sew-eurodrive.pl
http://www.sew-eurodrive.lt 24 Hour Service Tel. +48 602 739 739
(+48 602 SEW SEW)
Luxembourg
serwis@sew-eurodrive.pl
Assembly Brüssel CARON-VECTOR S.A. Tel. +32 10 231-311
Sales Avenue Eiffel 5 Fax +32 10 231-336 Portugal
Service B-1300 Wavre http://www.sew-eurodrive.lu Assembly Coimbra SEW-EURODRIVE, LDA. Tel. +351 231 20 9670
info@caron-vector.be Sales Apartado 15 Fax +351 231 20 3685
Service P-3050-901 Mealhada http://www.sew-eurodrive.pt
Malaysia
infosew@sew-eurodrive.pt
Assembly Johore SEW-EURODRIVE SDN BHD Tel. +60 7 3549409
Sales No. 95, Jalan Seroja 39, Taman Johor Jaya Fax +60 7 3541404 Romania
Service 81000 Johor Bahru, Johor sales@sew-eurodrive.com.my Sales Bucureúti Sialco Trading SRL Tel. +40 21 230-1328
West Malaysia Service str. Madrid nr.4 Fax +40 21 230-7170
011785 Bucuresti sialco@sialco.ro
Mexico
Assembly Queretaro SEW-EURODRIVE MEXIKO SA DE CV Tel. +52 442 1030-300 Russia
Sales SEM-981118-M93 Fax +52 442 1030-301 Assembly St. Petersburg ZAO SEW-EURODRIVE Tel. +7 812 3332522 +7 812 5357142
Service Tequisquiapan No. 102 http://www.sew-eurodrive.com.mx Sales P.O. Box 36 Fax +7 812 3332523
Parque Industrial Queretaro scmexico@seweurodrive.com.mx Service 195220 St. Petersburg Russia http://www.sew-eurodrive.ru
C.P. 76220 sew@sew-eurodrive.ru
Queretaro, Mexico
Senegal
Morocco
Sales Dakar SENEMECA Tel. +221 338 494 770
Sales Casablanca Afit Tel. +212 22618372 Mécanique Générale Fax +221 338 494 771
5, rue Emir Abdelkader Fax +212 22618351 Km 8, Route de Rufisque senemeca@sentoo.sn
MA 20300 Casablanca ali.alami@premium.net.ma B.P. 3251, Dakar

Netherlands Serbia
Assembly Rotterdam VECTOR Aandrijftechniek B.V. Tel. +31 10 4463-700 Sales Beograd DIPAR d.o.o. Tel. +381 11 347 3244 / +381 11 288
Sales Industrieweg 175 Fax +31 10 4155-552 Ustanicka 128a 0393
Service NL-3044 AS Rotterdam http://www.vector.nu PC Košum, IV floor Fax +381 11 347 1337
Postbus 10085 info@vector.nu SCG-11000 Beograd office@dipar.co.yu
NL-3004 AB Rotterdam
Singapore
New Zealand
Assembly Singapore SEW-EURODRIVE PTE. LTD. Tel. +65 68621701
Assembly Auckland SEW-EURODRIVE NEW ZEALAND LTD. Tel. +64 9 2745627 Sales No 9, Tuas Drive 2 Fax +65 68612827
Sales P.O. Box 58-428 Fax +64 9 2740165 Service Jurong Industrial Estate http://www.sew-eurodrive.com.sg
Service 82 Greenmount drive http://www.sew-eurodrive.co.nz Singapore 638644 sewsingapore@sew-eurodrive.com
East Tamaki Auckland sales@sew-eurodrive.co.nz
Christchurch SEW-EURODRIVE NEW ZEALAND LTD. Tel. +64 3 384-6251 Slovakia
10 Settlers Crescent, Ferrymead Fax +64 3 384-6455 Sales Bratislava SEW-Eurodrive SK s.r.o. Tel. +421 2 49595201
Christchurch sales@sew-eurodrive.co.nz Rybniþná 40 Fax +421 2 49595200
SK-83554 Bratislava sew@sew-eurodrive.sk
Norway http://www.sew-eurodrive.sk
Assembly Moss SEW-EURODRIVE A/S Tel. +47 69 24 10 20 Žilina SEW-Eurodrive SK s.r.o. Tel. +421 41 700 2513
Sales Solgaard skog 71 Fax +47 69 24 10 40 ul. Vojtecha Spanyola 33 Fax +421 41 700 2514
Service N-1599 Moss http://www.sew-eurodrive.no SK-010 01 Žilina sew@sew-eurodrive.sk
sew@sew-eurodrive.no

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Address List Address List
Disposal
10 10 Disposal

Slovakia Turkey
Banská Bystrica SEW-Eurodrive SK s.r.o. Tel. +421 48 414 6564 Assembly Istanbul SEW-EURODRIVE Tel. +90 216 4419164, 3838014,
Rudlovská cesta 85 Fax +421 48 414 6566 Sales Hareket Sistemleri San. ve Tic. Ltd. Sti. 3738015
SK-97411 Banská Bystrica sew@sew-eurodrive.sk Service Bagdat Cad. Koruma Cikmazi No. 3 Fax +90 216 3055867
TR-34846 Maltepe ISTANBUL http://www.sew-eurodrive.com.tr
Slovenia sew@sew-eurodrive.com.tr
Sales Celje Pakman - Pogonska Tehnika d.o.o. Tel. +386 3 490 83-20
Ukraine
Service UI. XIV. divizije 14 Fax +386 3 490 83-21
SLO - 3000 Celje pakman@siol.net Sales Dnepropetrovsk SEW-EURODRIVE Tel. +380 56 370 3211
Service Str. Rabochaja 23-B, Office 409 Fax +380 56 372 2078
South Africa 49008 Dnepropetrovsk http://www.sew-eurodrive.ua
Assembly Johannesburg SEW-EURODRIVE (PROPRIETARY) LIMITED Tel. +27 11 248-7000 sew@sew-eurodrive.ua
Sales Eurodrive House Fax +27 11 494-3104
USA
Service Cnr. Adcock Ingram and Aerodrome Roads http://www.sew.co.za
Aeroton Ext. 2 dross@sew.co.za Production Greenville SEW-EURODRIVE INC. Tel. +1 864 439-7537
Johannesburg 2013 Assembly 1295 Old Spartanburg Highway Fax Sales +1 864 439-7830
P.O.Box 90004 Sales P.O. Box 518 Fax Manuf. +1 864 439-9948
Bertsham 2013 Service Lyman, S.C. 29365 Fax Ass. +1 864 439-0566
Telex 805 550
Capetown SEW-EURODRIVE (PROPRIETARY) LIMITED Tel. +27 21 552-9820
http://www.seweurodrive.com
Rainbow Park Fax +27 21 552-9830
cslyman@seweurodrive.com
Cnr. Racecourse & Omuramba Road Telex 576 062
Montague Gardens dswanepoel@sew.co.za Assembly San Francisco SEW-EURODRIVE INC. Tel. +1 510 487-3560
Cape Town Sales 30599 San Antonio St. Fax +1 510 487-6433
P.O.Box 36556 Service Hayward, California 94544-7101 cshayward@seweurodrive.com
Chempet 7442 Philadelphia/PA SEW-EURODRIVE INC. Tel. +1 856 467-2277
Cape Town Pureland Ind. Complex Fax +1 856 845-3179
Durban SEW-EURODRIVE (PROPRIETARY) LIMITED Tel. +27 31 700-3451 2107 High Hill Road, P.O. Box 481 csbridgeport@seweurodrive.com
2 Monaceo Place Fax +27 31 700-3847 Bridgeport, New Jersey 08014
Pinetown dtait@sew.co.za Dayton SEW-EURODRIVE INC. Tel. +1 937 335-0036
Durban 2001 West Main Street Fax +1 937 440-3799
P.O. Box 10433, Ashwood 3605 Troy, Ohio 45373 cstroy@seweurodrive.com
Dallas SEW-EURODRIVE INC. Tel. +1 214 330-4824
Spain
3950 Platinum Way Fax +1 214 330-4724
Assembly Bilbao SEW-EURODRIVE ESPAÑA, S.L. Tel. +34 94 43184-70 Dallas, Texas 75237 csdallas@seweurodrive.com
Sales Parque Tecnológico, Edificio, 302 Fax +34 94 43184-71
Additional addresses for service in the USA provided on request!
Service E-48170 Zamudio (Vizcaya) http://www.sew-eurodrive.es
sew.spain@sew-eurodrive.es
Venezuela
Sweden Assembly Valencia SEW-EURODRIVE Venezuela S.A. Tel. +58 241 832-9804
Sales Av. Norte Sur No. 3, Galpon 84-319 Fax +58 241 838-6275
Assembly Jönköping SEW-EURODRIVE AB Tel. +46 36 3442-00
Service Zona Industrial Municipal Norte http://www.sew-eurodrive.com.ve
Sales Gnejsvägen 6-8 Fax +46 36 3442-80
Valencia, Estado Carabobo ventas@sew-eurodrive.com.ve
Service S-55303 Jönköping http://www.sew-eurodrive.se
sewfinanzas@cantv.net
Box 3100 S-55003 Jönköping info@sew-eurodrive.se

Switzerland
Assembly Basel Alfred lmhof A.G. Tel. +41 61 417 1717
Sales Jurastrasse 10 Fax +41 61 417 1700
Service CH-4142 Münchenstein bei Basel http://www.imhof-sew.ch
info@imhof-sew.ch

Thailand
Assembly Chonburi SEW-EURODRIVE (Thailand) Ltd. Tel. +66 38 454281
Sales 700/456, Moo.7, Donhuaroh Fax +66 38 454288
Service Muang sewthailand@sew-eurodrive.com
Chonburi 20000

Tunisia
Sales Tunis T. M.S. Technic Marketing Service Tel. +216 71 4340-64 + 71 4320-29
5, Rue El Houdaibiah Fax +216 71 4329-76
1000 Tunis tms@tms.com.tn

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 125 126 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
Index Index

Index P
Painting the gear unit .............................................23
A Parallel shaft helical gear units ..............................11

AD input cover .......................................................54


Anti-friction bearing greases ................................108 R
H
Repair ..................................................................117
Helical gear units ...................................................10
B Rights to claim under limited warranty .....................6
Helical-bevel gear units .........................................12
Run-in period .........................................................59
Breather .................................................................22 Helical-worm gear units .........................................13

S
C I
Safety notes
Changing the mounting position ............................20 Inspection ..............................................................61
.............................................................................5
Changing the oil .....................................................64 AD input cover ...................................................63
Securing the gear unit ............................................21
Checking the oil .....................................................64 AL/AM/AQ adapter.............................................63
Service .................................................................117
Checking the oil level .............................................64 Changing the Oil ................................................64
Shaft-mounted gear units
Via oil level plug ...............................65, 74, 75, 78 Checking the oil .................................................64
Keyway ..............................................................29
Via the breather plug....................................71, 76 Checking the oil level.........................................64
Splined hollow shaft ...........................................29
Via the cover plate .............................................67 Inspection intervals ................................................62
Churning losses .....................................................80 Installation tolerances ............................................17 TorqLOC® ..........................................................40
Customer service .................................................117 Installing the gear unit............................................19 SPIROPLAN® W10-W30 gear units.......................14
SPIROPLAN® W37 gear units ...............................15
D L Structure of the safety notes ....................................5
Design Lubricant change intervals.....................................62
Helical gear units ...............................................10 Lubricant fill quantities ......................................... 110 T
Helical-bevel gear units......................................12 Lubricant table .....................................................109 Tightening torques .................................................20
Helical-worm gear units .....................................13 Lubricants ............................................................107 Torque arm for shaft-mounted gear units
Parallel shaft helical gear units ..........................11 SPIROPLAN® W gear units ...............................28
SPIROPLAN® W10-W30 gear units...................14 M Torque arms for shaft-mounted gear units
SPIROPLAN® W37 gear units ...........................15 Maintenance ..........................................................61 Helical-bevel gear units......................................27
Disposal ...............................................................117 AL/AM/AQ adapter.............................................63 Helical-worm gear units .....................................27
Changing the oil.................................................64 Torque arms for shaft-mounted gear units
E Checking the oil .................................................64 Parallel shaft helical gear units ............................26
Checking the oil level.........................................64
Exclusion of liability ..................................................6
Input cover AD ...................................................63
Extended storage .............................................9, 106
Maintenance intervals............................................62
Malfunctions
F
AM / AQ / AL. /AL ............................................ 116
Flatness errors .......................................................19
Gear unit .......................................................... 115
Input cover AD .................................................116
G Mounting positions
Gear unit design.....................................................10 Designation........................................................79
Helical gear units ...............................................10 Key.....................................................................80
helical-bevel gear units ......................................12 Symbols .............................................................80
Helical-worm gear units .....................................13
Parallel shaft helical gear units ..........................11 O
SPIROPLAN® W10-W30 gear units...................14 Other applicable documentation ..............................8
SPIROPLAN® W37 gear units ...........................15

Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W 127 128 Operating Instructions – Gear Units R..7, F..7, K..7 S..7 Series, SPIROPLAN® W
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AC Motors DR/DV/DT/DTE/DVE, A6.C01

Asynchronous Servo Motors CT/CV

Edition 08/2004
11291613 / EN Operating Instructions
Important Notes
Contents 1

1 Important Notes................................................................................................. 4 1 Important Notes


Betriebsanleitung

2 Safety Notes ...................................................................................................... 5


Safety and Always follow the safety and warning instructions in these operating instructions!
3 Motor Design ..................................................................................................... 6 warning notes
3.1 Basic structure of AC motors .................................................................... 6
3.2 Nameplate, unit designation ..................................................................... 7 Electrical hazard
4 Mechanical Installation ..................................................................................... 9 Possible consequences: Severe or fatal injuries.
4.1 Before you begin ....................................................................................... 9
4.2 Preliminary work........................................................................................ 9
4.3 Installing the motor.................................................................................. 10
4.4 Installation tolerances ............................................................................. 11 Hazard
5 Electrical Installation ...................................................................................... 12 Possible consequences: Severe or fatal injuries.
5.1 Wiring notes ............................................................................................ 12
5.2 Special aspects for operation with a frequency inverter.......................... 12
5.3 Special aspects of single-phase motors.................................................. 12
5.4 Improving the grounding (EMC) .............................................................. 13 Hazardous situation
5.5 Special aspects of torque motors and low-speed motors ....................... 13 Possible consequences: Slight or minor injuries.
5.6 Special aspects in switching operation ................................................... 14
5.7 Environmental conditions during operation ............................................. 14
5.8 Connecting the motor.............................................................................. 15
5.9 Preparing motor sizes 56 and 63 – knockout.......................................... 16 Harmful situation
5.10 Connecting DT56 motor...+/BMG............................................................ 16 Possible consequences: Damage to the drive and the environment.
5.11 Single-phase version ET56 ..................................................................... 17
5.12 Connecting the motor using the IS plug connector ................................. 17
5.13 Connect the motor using plug connectors AB.., AD.., AM.., AS.............. 21
5.14 Connecting the motor using ASK1 plug connector ................................. 21
5.15 Connecting the brake .............................................................................. 23 Tips and useful information.
5.16 Accessory equipment.............................................................................. 24
6 Startup.............................................................................................................. 28
6.1 Prerequisites for startup .......................................................................... 28
6.2 Altering the blocking direction on motors with a backstop ...................... 29
You must adhere to the operating instructions to ensure:
7 Malfunctions .................................................................................................... 31
7.1 Motor Malfunctions.................................................................................. 31 • Trouble-free operation
7.2 Brake problems ....................................................................................... 32 • Fulfillment of any rights to claim under limited warranty
7.3 Malfunctions during operation with a frequency inverter......................... 32
Consequently, read the operating instructions before you start operating the drive!
8 Inspection / Maintenance................................................................................ 33
8.1 Inspection and maintenance intervals..................................................... 33 The operating instructions contain important information about servicing. Therefore,
8.2 Preliminary work for motor and brake maintenance................................ 34 keep the operating instructions close to the drive.
8.3 Inspection / maintenance on the motor .................................................. 37
8.4 Inspection / maintenance of the BMG02 brake ....................................... 39
8.5 Inspection / maintenance of the brake BR03 .......................................... 40 Waste disposal Dispose of the following materials in accordance with the regulations in force:
8.6 Inspection / maintenance for BMG05-8, BM15-62 brakes ...................... 44 • Iron
8.7 Inspection / maintenance of the BMG61/122 brake ................................ 49
• Aluminum
9 Technical Data ................................................................................................. 52
9.1 Work done, braking torque BMG02......................................................... 52 • Copper
9.2 Information for ordering a replacement BMG02...................................... 52 • Plastic
9.3 Work done, working air gap, braking torques of BMG05-8, BR03 .......... 53
9.4 Work done, working air gap, braking torques of BM15 - 62 .................... 54 • Electronic components
9.5 Operating currents .................................................................................. 55
9.6 Permitted ball bearing types.................................................................... 59
9.7 Lubricant table for anti-friction bearings of SEW motors......................... 59
10 Appendix .......................................................................................................... 60
10.1 Index of changes..................................................................................... 60
10.2 Index ....................................................................................................... 61

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchronous Servo Motors CT / CV 3 4 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Safety Notes Motor Design
2 3 Basic structure of AC motors

2 Safety Notes 3 Motor Design


Preface The following safety notes are concerned with the use of motors. If using gearmotors,
also refer to the safety notes for gear units in the corresponding operating instructions. The following illustration is intended to explain the general structure. Its only purpose is
to facilitate the assignment of components to the spare parts lists. Discrepancies are
Please also consider the supplementary safety notes in the individual sections of possible depending on the motor size and version!
these operating instructions.
3.1 Basic structure of AC motors
General During and after operation, motors and gearmotors have live and moving parts and their
information surfaces may be hot. 31 20 44 41
All work related to transport, putting into storage, setting up/mounting, 1
connection, startup, maintenance and repair may only be performed by trained
personnel observing 3
• The corresponding detailed operating instructions and wiring diagrams 12
11
• The warning and safety signs on the motor/gearmotor 10
• The specific regulations and requirements for the system 7
9
• The national / regional regulations governing safety and accident prevention
Severe injuries and damage to property may result from 106
• Improper use 107 13
2
• Incorrect installation or operation 100
101 22
• Unauthorized removal of necessary protection covers or the housing 103 35

Designated use These electric motors are intended for industrial systems. They fulfill the applicable
standards and regulations: 32
36
• Low voltage directive 73/23/EEC
Technical data and information about the permitted conditions can be found on the 37
nameplate and in the documentation. 42
116
It is essential to observe all the specified information! 118
117
119
Transportation Inspect the shipment for damage as soon as you receive the delivery. Inform the 111
shipping company immediately. It may be necessary to preclude startup. 16 112
123
135
Tighten installed eyebolts. They are only designed for the weight of the 134
motor/gearmotor; do not attach any additional loads. 130 115
113
The installed lifting eyebolts comply with DIN 580. Observe the loads and regula- 129 131
132
tions specified in this standard. If the gearmotor is equipped with two suspension
02969AXX
eye lugs or lifting eyebolts, then both of the suspension eye lugs should be used
for transportation. In this case, the tension force vector of the slings must not
exceed a 45° angle in accordance with DIN 580. [1] Rotor, cpl. [31] Key [107] Oil-flinger ring [131] Sealing washer
Use suitable, sufficiently rated handling equipment if necessary. Remove any transpor- [2] Circlip [32] Circlip [111] Gasket [132] Terminal box cover
tation fixtures prior to startup. [3] Key [35] Fan guard [112] Terminal box lower part [134] Screw plug
[7] Flanged end shield [36] Fan [113] Machine screw [135] Sealing washer
[9] Screw plug [37] V-ring [115] Terminal board
Installation / Follow the instructions in the section "Mechanical Installation"! [10] Circlip [41] Equalizing ring [116] Terminal yoke
assembly [11] Grooved ball bearing [42] Non drive-end [117] Hex head bolt
bearing shield
[12] Circlip [44] Grooved ball bearing [118] Lock washer
Inspection / Follow the instructions in the section "Inspection and Maintenance"! [13] Hex head screw (tie rod) [100] Hex nut [119] Machine screw
maintenance [16] Stator, cpl. [101] Lock washer [123] Hex head bolt
[20] Nilos ring [103] Stud [129] Screw plug
[22] Hex head bolt [106] Oil seal [130] Sealing washer

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 5 6 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Motor Design Motor Design
Nameplate, unit designation
3 3 Nameplate, unit designation

3.2 Nameplate, unit designation Nameplate


Nameplate Example: CT90L4 / BMG / TF / ES1S servo brake motor
Example: DFV 160 M4 /BM brake motor

CT90L4 BMG TF / ES1S


01.3410069302.0001.00
30.5
10.5 3000
103 345 7.9
B5 28 54 F

230~ 20 BGE 1.5

51358BXX

03214BXX Unit designation


Unit designation Examples: Servo (brake) motors CT / CV
Example: DR / DT / DV / DTE / DVE AC (brake) motors
CFV 132M4 / BM / TF / EV1S

DFV 132M2 / BM /TF / AMA1 / EV1T Motor option: Sine/cosine incremental encoder
Motor option: 5 V TTL incremental
encoder Motor option: TF thermistor sensor

Motor option: AMB1 plug connector


Motor option: Brake

Motor option: TF thermistor sensor


Size 132M and 4-pole

Motor option: Brake


Flange-mounted motor

Size 132M and 2-pole

Flange-mounted motor Example: Serial number

Example: Serial number 01. 3009818304. 0002. 99


Year number end digits of the year of manufacture (2-
01. 3009818304. 0002. 99 digit)

Year number end digits of the year of manufacture (2- Part number (4-digit)
digit)

Part number (4-digit) Order number (10 digits)

Order number (10 digits) Sales organization

Sales organization

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 7 8 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Mechanical Installation Mechanical Installation
Before you begin
4 4 Installing the motor

4 Mechanical Installation Drying the motor Heat up the motor


• with hot air or
• using an isolation transformer
It is essential to comply with the safety notes in Section 2 during installation!
– Connect the windings in series (→ following figure)
– Auxiliary AC voltage supply max. 10 % of the rated voltage with max. 20 % of the
rated current
4.1 Before you begin
The drive may • The entries on the nameplate of the drive and/or the output voltage of the frequency
only be installed inverter match the voltage supply system Transformer
if • The drive is undamaged (no damage caused by transportation or storage)
• It is certain that the following requirements have been met:
– Ambient temperature between –20 °C and +40 °C1) 01730AEN

– No oil, acid, gas, vapors, radiation, etc. The drying process is finished when the minimum insulation resistance has been
– Installation altitude max. 1000 m above sea level attained.
– Note the restrictions for encoders Check the terminal box to see whether
– Special versions: Drive configured in accordance with the ambient conditions
• The inside is clean and dry
• The connections and fixing parts are free from corrosion
4.2 Preliminary work
• The joint seals are OK
Motor shaft ends must be thoroughly cleaned of anti-corrosion agents, contamination or • The cable glands are sound, otherwise clean or replace them.
similar (use a commercially available solvent). Do not allow the solvent to penetrate the
bearings or shaft seals – this could cause material damage!
4.3 Installing the motor
Extended storage • Please note the reduced grease utilization period of the ball bearings after storage The motor or gearmotor may only be mounted or installed in the specified mounting
of motors periods exceeding one year. position on a level and torsionally rigid support structure which is not subjected to
• Check whether the motor has absorbed moisture as a result of being stored for a long shocks.
time. Measure the insulation resistance to do this (measuring voltage 500 V). Carefully align the motor and the driven machine to avoid placing any unacceptable
strain on the output shafts (observe permissible overhung load and axial thrust data!).
The insulation resistance (→ following figure) varies greatly depending on the Do not butt or hammer the shaft end.
temperature! The motor must be dried if the insulation resistance is not adequate. Use an appropriate cover to protect motors in vertical mounting positions from
objects or fluids entering (protection cowl C).
Ensure an unobstructed cooling air supply and that air heated by other apparatus cannot
[M ] be drawn in or reused.
100 Balance components for subsequent mounting on the shaft with a half key (motor shafts
are balanced with a half key).
Any condensation drain holes will be sealed by plastic plugs and should only be
10
opened when necessary; open condensation drain holes are not permitted, as
this would invalidate higher classes of enclosure.
1 If using brake motors with manual brake release, screw in either the hand lever (with
self-reengaging manual brake release) or the setscrew (with lockable manual brake
release).
0,1 Note the following for encoder mounting:
0 20 40 60 80
[°C] Foot-mounted motors CT/DT71, CT/DT90, CV/DV132M, CV/DV160L must be mounted
01731AXX on supports because the radius of the cover is greater than the shaft height.
For foot-mounted (brake) motors sizes DTE90L and DVE132M, the shaft height corre-
sponds to the IEC standard motor of the next higher power level (100 mm or 160 mm).
The foot dimensions of DTE90, DVE180, and DVE225 motors differ from the IEC dimen-
1) Minimum temperature for motors with backstop: –15 °C. Note that the temperature range of the gear unit
sions; see Sec. "Dimension Sheet Notes" in the Gearmotors catalog.
may also be restricted (→ gear unit operating instructions)

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 9 10 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Mechanical Installation Electrical Installation
Installation tolerances
4 5 Wiring notes

Installation in If possible, arrange the terminal box so the cable entries are pointing downwards. 5 Electrical Installation
damp locations Coat the threads of cable glands and pocket caps with sealant and tighten them well –
or in the open It is essential to comply with the safety notes in section 2 during installation!
then coat them again.
Switch contacts in utilization category AC-3 to EN 60947-4-1 must be used for
Seal the cable entry well. switching the motor and the brake.
Thoroughly clean the sealing surfaces of terminal boxes and terminal box covers prior
to reassembly; gaskets must be glued in on one side. Install new gaskets to replace
embrittled ones! Using the wiring The motor must only ever be connected as shown in the wiring diagram included with
diagrams the motor. Do not connect or start up the motor if this wiring diagram is missing.
Restore the anticorrosive coating if necessary. You can obtain the valid wiring diagram free of charge from SEW-EURODRIVE.
Check the enclosure.

5.1 Wiring notes


Comply with the safety notes during installation.
4.4 Installation tolerances
Protecting brake Do not route brake cables alongside switched-mode power cables, as otherwise there
Shaft end Flanges control systems is a risk of disrupting brake control systems.
against Switched-mode power cables include in particular:
Diameter tolerance in accordance with DIN 748 Centering shoulder tolerance in accordance with
• ISO k6 at Ø ≤ 50 mm DIN 42948 interference
• ISO m6 at Ø > 50 mm • ISO j6 at Ø ≤ 230 mm – Output cables from frequency and servo controllers, converters, soft start units and
• Center bore in accordance with DIN 332, shape • ISO h6 at Ø > 230 mm brake units
DR..
– Feeder cables for brake resistors and similar options

Protecting motor To protect SEW motor protection devices (temperature sensors TF, winding thermostats
protection TH) against interference:
devices against – Route separately shielded feeder cables together with switched-mode power lines in
interference one cable
– Do not route unshielded feeder cables together with switched-mode power lines in
one cable

5.2 Special aspects for operation with a frequency inverter


When motors are powered from inverters, you must adhere to the wiring instructions
issued by the inverter manufacturer. It is essential to observe the operating instructions
for the frequency inverter.

5.3 Special aspects of single-phase motors


Bear in mind that SEW single-phase motors are supplied without accessory equipment
such as capacitors, starting relays or centrifugal switches (exception: ET56L4 → Sec.
"Single-phase version ET56"). Any parts you need must be obtained from your dealer
and connected according to the corresponding instructions and wiring diagrams.

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 11 12 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Electrical Installation Electrical Installation
Improving the grounding (EMC)
5 5 Special aspects in switching operation

5.4 Improving the grounding (EMC) 5.6 Special aspects in switching operation
For improved, low-impedance grounding at high frequencies, we recommend using the When the motors are used in switching operation, possible interference of the switch-
following connections with the DR/DV/DT AC motors: gear must be excluded by ensuring suitable wiring. According to EN 60204 (electrical
• Sizes DT71 ... DV 132S: [1] M5x10 thread rolling screw and 2 serrated lock washers equipment of machines), motor windings must have interference suppression to protect
to DIN 6798 in the stator housing. the numerical or programmable logic controllers. As it is primarily switching operations
that cause interference, SEW-EURODRIVE recommends installing protective circuitry
in the switching devices.
[1]

5.7 Environmental conditions during operation


Ambient The temperature range of -20 °C to +40 °C must be ensured unless specified otherwise
temperature on the nameplate. Motors intended for use in higher or lower ambient temperatures have
the appropriate designation on the nameplate.

Altitude The maximum installation altitude of 1000 m above sea level must not be exceeded as
otherwise this causes a derating as specified in the following diagram.
fH
1.0

0.9
• Sizes DV112M ... DV280: Screw and 2 serrated lock washers in the bore of the eye
bolt.
0.8
Thread size of the eye bolt:
– DV112 / 132S: M8 0.7
– DV132M ... 180L: M12
– DV200 ... 280: M16
1000 2000 3000 4000 m

5.5 Special aspects of torque motors and low-speed motors


Due to the design of torque motors and low-speed motors, very high induction voltages Hazardous Motors must not be subjected to hazardous radiation. Contact SEW-EURODRIVE if
may be generated when they are switched off. Consequently, SEW-EURODRIVE radiation necessary.
recommends using the varistor circuit shown below for protection. The size of the varis-
tors depends, amongst other factors, on the starting frequency – note for project plan-
ning!

U U U

U1 V1 W1
01732CXX

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 13 14 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Electrical Installation Electrical Installation
Connecting the motor
5 5 Preparing motor sizes 56 and 63 – knockout

5.8 Connecting the motor 5.9 Preparing motor sizes 56 and 63 – knockout

In case of operation with electronic control units, it is essential to adhere to the Important: Wear safety glasses – danger of injury from fragments!
corresponding operating instructions / wiring diagrams!
• Put on the terminal box cover and screw it into place
• Define which cable entries to open
Connecting the • According to the circuit diagram provided
motor via • Open the cable entries
• Check the line cross section
terminal boxes – with a chisel or similar (hold at an angle)
• Arrange terminal links correctly
– by a light tap with a hammer
• Screw connections and protective earth conductors on firmly
• In terminal boxes: Check winding connections and tighten them if necessary

Small connection Note: In the case of motor sizes DR63 - DV132S, the small connection accessories
accessories (connection nuts for feeder cables, terminal links, lock washer and washers) are
supplied in a bag. Depending on the type of terminal board, install the parts in accor-
dance with the figure below. In the connection type shown on the right in the figure
below, the second retaining nut, the lock washer and the washer are not used. The
external connection [6] can be installed directly or as a lug [4] below the connection disk
[5]. The tightening torque of the hex net in the figure on the right is:
• 1.6 Nm ± 20 % for M4 01733AXX

• 2 Nm ± 20 % for M5 Caution – Do not knock through into the inside of the terminal box!
• Open the terminal box, remove the knockout cover if it has broken off
1 5
• Secure the cable screw fittings with the supplied lock nuts
6
2 1
2 5
5.10 Connecting DT56 motor...+/BMG
3
The motor has a star point with three fixed connection points in the winding overhang.
7 3 6
The supply system leads (L1, L2, L3) are connected to a spring cage terminal block [2]
4 8 4 in the terminal box [1]. The BMG02 brake is controlled using the BG1.2 brake rectifier
[3]. As an alternative, the brake can be controlled from the switch cabinet using BM
series rectifiers.

50926AXX 1

1 Terminal stud 1 Terminal stud


2 Lock washer 2 Hex nut with flange
3 Connection disk 3 Terminal link
4 Motor terminal lead 4 Motor connection with Stocko connection
5 Top nut 5 terminal
6 Washer 6 Connection disk
7 External connection External connection
8 Bottom nut 3

The asynchronous servomotors of the CT/CV series are supplied with connected
terminal links according to the nameplate.
TF TF U V W

04861AXX

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 15 16 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Electrical Installation Electrical Installation
Single-phase version ET56
5 5 Connecting the motor using the IS plug connector

5.11 Single-phase version ET56 Wiring the upper • Loosen the housing cover screws
section of the – Remove the housing cover
The ET56 single-phase motor is supplied with a running capacitor that is mounted and plug connection
connected: • Remove the screws from the upper section of the plug connector
1~230 V, 50 Hz CB = 4 μF – Remove the upper section of the plug connector from the cover
1~230 V, 60 Hz CB = 4 μF • Strip the insulation off the connection lead
1~110 V, 60 Hz CB = 20 μF – Strip about 9 mm insulation off the connecting leads
• Pass the cable through the cable gland
No full-load startup is possible with the running capacitor alone! The single-
phase motor cannot be combined with a TF.

Wiring up as • Connect the lines as shown in the circuit diagram


shown in circuit – Tighten the clamping screws carefully!
diagram DT82,
DT83 • Install the plug connector (→ Sec. "Installing the plug connector")
5.12 Connecting the motor using the IS plug connector

Wiring up as For 댴 / 쑶 startup:


shown in wiring • Connect with 6 lines
diagram DT81
– Tighten the clamping screws carefully!
– Motor contactors in the switch cabinet
• Install the plug connector (→ Sec. "Installing the plug connector")

For 댴 or 쑶 operation:
• Connect as shown in the wiring diagram
• Install the variable terminal link as shown in the following figures according to the
required motor operation (쑶 or 댴)
• Install the plug connector (→ Sec. "Installing the plug connector")

03075AXX

The IS plug connector is supplied from the factory with its base fully wired-up, including
additional features such as a brake rectifier. The upper section of the IS connector is
included in the scope of delivery and must be connected as shown in the wiring diagram.
The IS plug connector has CSA approval up to 600 V. Note for application according to
CSA regulations: Tighten the M3 terminal screws to a torque of 0.5 Nm! See the
following table for American Wire Gauge (AWG) line cross sections!

Line cross Make sure the type of line corresponds to the applicable regulations. The rated currents
section are specified on the motor nameplate. The line cross sections that can be used are listed
in the following table. 01734AXX 01735AXX

Without variable termi- With variable termi- Link cable Double assignment
nal link nal link (Motor and brake/SR)
0.25 - 4.0 mm2 0.25 - 2.5 mm2 max. 1.5 mm2 max. 1 x 2.5 and 1 x 1.5 mm2
23 - 12 # AWG 23 - 14 # AWG max. 16 # AWG max. 1 x 14 # and 1 x 16 # AWG

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 17 18 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Electrical Installation Electrical Installation
Connecting the motor using the IS plug connector
5 5 Connecting the motor using the IS plug connector

Brake control For 댴 operation: Installing the plug The housing cover of the IS plug connector can be screwed onto the lower section of
system BSR – On the 댴 side of the variable terminal link as shown in the following figure: Remove only connector the plug connector depending on the required position of the cable lead. The upper
preparing the the bare metal pin of the marked prong horizontally – touch guard! section of the plug connector shown in the following figure must first be installed in the
variable terminal housing cover so it will match the position of the lower section of the plug connector:
link • Define the required mounting position
• Install the upper section of the plug connector into the housing cover in accordance
with the mounting position
• Close the plug connector
50429AXX • Tighten the cable gland

For 쑶 operation:
On the 쑶 side of the variable terminal link as shown in the following figure: Completely
remove two prongs horizontally.

50430AXX

01739AXX
Wiring according to • At terminal point for double assignment:
the DT81 wiring – Connect the link cable
diagram for 댴 or
• When operation is as required: Mounting position of the upper section of the plug connection in the housing cover
쑶 operation with
double terminal – Insert the link cable in the variable terminal link
assignment • Install the variable terminal link
• At terminal point for double assignment:
– Connect the motor lead above the variable terminal link
• Connect the other lines as shown in the wiring diagram.
• Install the plug connector (→ Sec. "Installing the plug connector")

01738AXX

01740AXX

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 19 20 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Electrical Installation Electrical Installation
Connect the motor using plug connectors AB.., AD.., AM.., AS
5 5 Connecting the motor using ASK1 plug connector

5.13 Connect the motor using plug connectors AB.., AD.., AM.., AS factory fully wired up, including additional features such as a brake rectifier.

• The customer must obtain the system cable pre-fabricated according to the
AMA1 ASE1 ECOFAST specification from a specialist retailer.
• For installation integrated in the motor according to the ECOFAST specifica-
tion, the customer must obtain the carrier plate from SEW-EURODRIVE by
quoting part number 0187 390 3. Carrier plates from other manufacturers do
not fit on SEW-EURODRIVE motors.

Position of the Possible positions of the ASK1 plug connector are "X" (= normal position), "1", "2" or "3".
plug connector Unless specified otherwise, the unit is supplied with the plug connector in position "3".
For installation integrated in the motor (using the carrier plate), units are exclusively
supplied with the plug connector in position "3".

ASK1
2

50956AXX
1 3
The installed plug connector systems AB.., AD.., AM.., AC.. and AS.. are based on the
plug connector systems made by Harting. X

• AB.., AD.., AM.. → Han Modular® 51323AXX


• AC.., AS.. → Han 10E / 10ES
The plugs are mounted on the side of the terminal box. They are locked either using two
Installing the • Unscrew and remove four retaining screws [1] below the terminal box (→ Fig. A)
clamps or one clamp on the terminal box.
carrier plate • Place the carrier plate [2] against the holes for the retaining screws and install it by
UL approval has been granted for the plug connectors.
screwing in the four retaining screws [1] (→ Fig. B).
The mating connectors (sleeve housing) with contact tubes are not included in
the scope of delivery.
The enclosure is only applied when the mating connector is mounted and locked.

5.14 Connecting the motor using ASK1 plug connector

ASK1
ASK1

1
1

A B
51081AXX

Drives with ASK1 plug connectors are certified according to the ECOFAST specification
ECO FAST (version 1.1). Switchgear or control units which also have to be certified can be
certified
connected to SEW-EURODRIVE motors using a pre-fabricated system cable or a carri-
er plate (installation integrated in the motor → Fig. B). The ASK1 plug connector with
single-clip locking is mounted on the side of the terminal box and is supplied from the

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 21 22 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Electrical Installation Electrical Installation
Connecting the brake
5 5 Accessory equipment

5.15 Connecting the brake 5.16 Accessory equipment


The brake is released electrically. The brake is applied mechanically when the voltage
is switched off. Connect supplied accessory equipment according to the wiring diagrams included.
Comply with the applicable regulations issued by the relevant employer's liability
insurance association regarding phase failure protection and the associated
circuit/circuit modification! TF temperature sensor
• Connect the brake according to the wiring diagram supplied with the brake.
• Note:In view of the DC voltage to be switched and the high level of current load, it is Do not apply voltage!
essential to use either special brake contactors or AC contactors with contacts in
utilization category AC-3 to EN 60947-4-1.
• Attach one of the following options for the version with manual brake release The positive temperature coefficient (PTC) thermistors comply with DIN 44082.

– Hand lever (for self-reengaging manual brake release) Resistance measurement (measuring instrument with V ≤ 2.5 V or I < 1 mA):
– Setscrew (for locking manual brake release) • Standard measured values: 20...500 Ω, thermal resistance > 4000 Ω
• After replacing the brake disc, the maximum braking torque is reached only after sev- • Measured values pole-changing with separate winding: 40...1000 Ω,
eral cycles. Thermal resistance > 4000 Ω
When using the temperature sensor for thermal monitoring, the evaluation function must
be activated to maintain reliable isolation of the temperature sensor circuit. If the
Connecting the The DC disk brake is powered from a brake control system with a protection circuit. It is temperature reaches an excessive level, the thermal protection function must be
brake control located in the terminal box / IS lower part or must be installed in the switch cabinet (→ effective immediately.
system Sec. "Wiring notes").
TH winding thermostats
• Check the line cross sections - braking currents (→ Sec. "Technical Data") The thermostats are connected in series as standard and open when the permitted
winding temperature is exceeded. They can be connected in the drive monitoring loop.
• Connect the brake control system according to the wiring diagram supplied with the
brake VAC VDC
• For motors in thermal class H, install the brake rectifier in the switch cabinet! Voltage U [V] 250 400 60 24
Current (cos ϕ = 1.0) 2.5 0.75 1.0 1.6
[A]
Current (cos ϕ = 0.6) 1.6 0.5
[A]
Contact resistance max. 1 ohm at 5 V = / 1 mA

Forced cooling
fan
Motor sizes 71 - 132S
VS system
• 1 x 230 VAC, 50 Hz
• Connection in separate terminal box
• Max. connection cross section 3 x 1.5 mm2
• Cable screw fitting M16x1.5

Refer to the VS wiring diagram for information about connecting the VS forced cooling
fan (order number: 0975 8385).

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 23 24 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Electrical Installation Electrical Installation
Accessory equipment
5 5 Accessory equipment

Motor size 132M - 280


VR system V system
• 24 VDC ± 20 % • 3 x 400 VAC, 50 Hz
• Plug connector • Connection in separate terminal box
• Max. connection cross section 3x1 mm2 • Max. connection cross section 4 x 1.5 mm2
• Pg7 cable gland with 7 mm inside diamater • Cable gland M16x1.5

The VR forced cooling fan is available for 24 V DC voltage and for 100 ... 240 V AC Refer to the V wiring diagram for information about connecting the V system (order
voltage. number: 0975 8385).

A transformer may be present in the VS system to adapt to a voltage other than the
2 standard. The VS and V systems are also available for 60 Hz.
24V DC -
+ 1
Overview of
50990AXX
encoders
The AC voltage type includes a VR forced cooling fan and the UWU51A switch-mode Encod Specifica-
power supply (→ following figure). For SEW motor Encoder type Shaft Supply Signal
er tion
• Input: 90 ... 265 VAC – 6 % / + 10 %, 50/60 Hz 1)
EH1T 5 VDC regulated 5 VDC TTL/RS-422
• Output: 24 VDC – 1 % / + 2 %, 1.3 A EH1S2) 1 Vss sin/cos
DR63... Encoder Hollow shaft -
• Connection: Terminal screws 0.2 ... 2.5 mm2, separable EH1R 24 VDC 5 VDC TTL/RS-422
EH1C 24 VDC HTL
• Enclosure: IP20; mounted on mounting rail EN 60715TH35 in the switch cabinet
ES1T1) 5 VDC regulated 5 VDC TTL/RS-422
ES1S2) CT/DT/CV/DV71...100 1 Vss sin/cos
ES1R DTE/DVE90...100 24 VDC 5 VDC TTL/RS-422
ES1C 24 VDC HTL
Spreadshaft
ES2T1) 5 VDC regulated 5 VDC TTL/RS-422
ES2S2) 1 Vss sin/cos
CV/DV(E)112...132S Encoder -
77

ES2R 24 VDC 5 VDC TTL/RS-422


ES2C 24 VDC HTL
EV1T1) 5 VDC regulated 5 VDC TTL/RS-422
EV1S2) CT/CV71...200 1 Vss sin/cos
DT/DV71...280 Solid shaft
EV1R DTE/DVE90...225 24 VDC 5 VDC TTL/RS-422
38 76
86.5 EV1C 24 VDC HTL
NV11 A track 1 pulse/revolution, nor-
NV21 A+B tracks mally open contact
54411AXX
NV12 DT/DV71...132 A track 2 pulses/revolution,
Proximity sensor Solid shaft 24 VDC
NV22 DTE/DVE90...132S A+B tracks normally open contact
Refer to the VR wiring diagram for information about connecting the VR forced cooling
NV16 A track 6 pulses/revolution,
fan (order number: 0880 3198)
NV26 A+B tracks normally open contact

MSSI interface and 1


AV1Y CT/CV71...200 absolute encoder 15/24 VDC
Vss sin/cos
DT/DV71...280 ®
Solid shaft -
DTE/DVE90...225 HIPERFACE RS485 interface and 1
AV1H3) 12 VDC
encoder Vss sin/cos
®
1) Recommended encoder for operation with MOVITRAC 31C
2) Recommended encoder for operation with MOVIDRIVE®
3) recommended encoder for operation with MOVIDRIVE® compact

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 25 26 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Electrical Installation I I Startup
Accessory equipment
5 6 Prerequisites for startup
0 0

• Refer to the following wiring diagrams for information about connecting 6 Startup
ES1./ES2./EV1./EH1. encoders and AV1Y and AV1H absolute encoders:
6.1 Prerequisites for startup
• Wiring diagrams for ES1./ES2./EV1./EH1. encoders: Order number 0918 6832
• Wiring diagram AV1Y absolute encoder: Order number 0918 6808
• Wiring diagram AV1H absolute encoder: Order number 1052 9705
It is essential to comply with the safety notes in Sec. 2 during startup!

• Maximum oscillation load for encoder ≤ 10 g ≈ 100 m/s2 (10 Hz ... 2 kHz)
• Shock resistance ≤ 100 g ≈ 1000 m/s2
Before startup, • The drive is undamaged and not blocked
make sure that • The measures stipulated in the "Preliminary work" section are performed after
Encoder When connecting the encoders to the inverters, always follow the operating instructions extended storage
connection for the relevant inverter! • All connections have been made properly
• Maximum line length (inverter - encoder): • The direction of rotation of the motor/gearmotor is correct
– 100 m with a capacitance per unit length ≤ 120 nF/km – (motor rotating clockwise: U, V, W to L1, L2, L3)
• Core cross section: 0,20 ... 0.5 mm2 • All protective covers have been fitted correctly
• Use a shielded cable with twisted pairs of insulated conductors (exception: cable for • All motor protection equipment is active and set for the rated motor current
HTL sensor) and connect the shield over a large surface area at both ends:
• The self-reengaging manual brake release is used in case of hoist drives
– to the encoder in the cable gland or in the encoder plug
• There are no other sources of danger present
– to the inverter on the electronics shield clamp or to the housing of the sub D plug
• Install the encoder cables separately from the power cables, maintaining a distance
of at least 200 mm. During startup, • The motor is running correctly (no overload, no speed fluctuation, no loud noises,
make sure that etc.)
• The correct braking torque is set according to the specific application (→ Sec. "Tech-
nical Data")
• In case of problems (→ Sec. "Malfunctions")

In brake motors with self-reengaging manual brake release, the manual brake
release lever must be removed after startup. A bracket is provided for storing the
lever on the outside of the motor.

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 27 28 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Startup I I Startup
Altering the blocking direction on motors with a backstop
6 6 Altering the blocking direction on motors with a backstop
0 0

6.2 Altering the blocking direction on motors with a backstop Do not start up the motor in the blocking direction (note the phase angle when
connecting). Note the direction of rotation of the output shaft and the number of stages
when mounting the motor on a gear unit. The backstop can be operated once in the
blocking direction at half the motor voltage for checking purposes.
9 8 5 3 4 2 1 1. Isolate the motor from the supply, safeguarding it against unintentional power-
up.
2. Remove fan guard [1] and fan [2], unscrew hexagon socket head cap screws [3]
3. Remove the V-ring [4] and sealing flange with felt ring [5]. (Collect the grease for
subsequent use.)
4. Remove the circlip [6] (not for DT71/80); for DV132M-160M, also remove the
equalizing rings [10].
5. Pull the carrier [8] and wedge element train [9] completely off the threaded holes [7],
turn them by 180° and press them back on.
6. Refill the grease.
7. Important: Do not exert pressure on or hit the wedge element train – danger of
X damaging the material!
8. During the press-in operation – shortly before the wedge element penetrates the
locking collar – slowly turn the rotor shaft by hand in the direction of rotation. This
allows the wedge element to slide into the locking collar more easily.
9. Install the remaining parts of the backstop by following steps 4. to 2. in reverse order.
Note the installation dimension "x" for the V-ring [4].
7 10 6
50447AXX

[1] Fan guard [5] Felt ring [9] Wedge element train
[2] Fan [6] Circlip [10] Equalizing ring
[3] Hexagon socket head cap [7] Threaded hole
screw [8] Carrier
[4] V-ring

Dimension "x"
after installation
Motor Dimension "x" after instal-
lation
DT71/80 6.7 mm
DT90/DV100 9.0 mm
DV112/132S 9.0 mm
DV132M-160M 11.0 mm
DV160L - 225 11.0 mm
DV250-280 13.5 mm

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 29 30 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Malfunctions Malfunctions
Motor Malfunctions
7 7 Brake problems

7 Malfunctions 7.2 Brake problems


7.1 Motor Malfunctions Problem Possible cause Remedy
Brake does not release Incorrect voltage on brake control unit Apply correct voltage
Problem Possible cause Remedy
Brake control unit failed Install a new brake control system, check internal resis-
Motor does not start up Interruption in connecting harness Check connections, correct if necessary tance and insulation of brake coil, check switchgear
Brake does not release → Sec. "Brake Problems" Max. permitted working air gap exceeded Measure and set working air gap
Fuse blown Replace fuse because brake lining worn down

Motor protection has tripped Check motor protection for correct setting, correct error if Voltage drop along connecting harness > 10 Provide for correct connection voltage; check cable cross
necessary. % section

Motor protection does not switch, error in Check motor protection control, correct error if necessary. Inadequate cooling, brake overheats Replace type BG brake rectifier with type BGE
control Brake coil has interturn fault or short circuit to Replace complete brake and brake control system (spe-
Motor does not start or only Motor designed for delta connection but Correct circuit exposed conductive part cialist workshop), check switchgear
with difficulty used in star connection Rectifier defective Replace the rectifier and brake coil
Voltage and frequency deviate markedly Provide better power supply system; check cross section Motor does not brake Working air gap not correct Measure and set working air gap
from setpoint, at least during switch-on of connecting harness
Brake lining worn down Replace entire brake disk
Motor does not start in star Torque not sufficient in star connection Switch on directly if delta inrush current is not too great;
connection, only in delta otherwise use a larger motor or a special version (contact Incorrect braking torque Change the braking torque (→ Sect. "Technical Data")
connection SEW) • By the type and number of brake springs
• BrakeBMG 05: By installing the same brake coil body
Contact fault on star delta switch Rectify fault design as in brakeBMG 1
Incorrect direction of rotation Motor connected incorrectly Swap over two phases • BrakeBMG 2: By installing the same brake coil body
design as in brakeBMG 4
Motor hums and has high Brake does not release → Sec. "Brake Problems"
current consumption BM(G) only: Working air gap so large that set- Set the working air gap
Winding defective Send motor to specialist workshop for repair ting nuts come into contact
Rotor rubbing Only BR03, BM(G): Manual brake release Set the setting nuts correctly
Fuses blow or motor protec- Short circuit in line Rectify short circuit device not set correctly
tion trips immediately Brake is applied with time Brake is switched on AC voltage side Switch on DC and AC voltage sides (e.g. BSR); please
Short circuit in motor Send motor to specialist workshop for repair
lag refer to wiring diagram
Lines connected incorrectly Correct circuit
Noise in the brake area Gearing wear caused by jolting startup Check project planning
Ground fault on motor Send motor to specialist workshop for repair
Pulsating torques due to incorrectly set fre- Check/correct setting of frequency inverter according to
Severe speed loss under Overload Perform power measurement, use larger motor or reduce quency inverter operating instructions
load load if necessary
Voltage drops Increase cross section of connecting harness
Motor heats up excessively Overload Perform power measurement, use larger motor or reduce 7.3 Malfunctions during operation with a frequency inverter
(measure temperature) load if necessary
Inadequate cooling Correct cooling air supply or clear cooling air passages,
The symptoms described in the "Motor Malfunctions" section may also occur when the
retrofit forced cooling fan if necessary motor is operated with a frequency inverter. Please refer to the frequency inverter
Ambient temperature is too high Adhere to permitted temperature range operating instructions for the significance of the problems which occur and to find
information about rectifying the problems.
Use delta connection for motor rather than Correct circuit
star connection as provided for
Loose contact in connecting harness (one Rectify loose contact Customer service
phase missing)
Fuse blown Look for and rectify cause (see above); replace fuse Please have the following information to hand if you require the assistance of our
Supply voltage deviates from rated motor Adapt motor to supply voltage
customer service:
voltage by more than 5 %. A higher voltage • Data from the nameplate (complete)
has a particularly unfavorable effect in • Nature and extent of the fault
motors with a low-speed winding since in • Time and peripheral circumstances of the fault
these, the no-load current is already close • Presumed cause
to the rated current even when the voltage
is normal.
Rated operation type (S1 to S10, DIN Adjust rated operation type of motor to required operating
57530) exceeded, e.g. through excessive conditions; if necessary call in a specialist to determine
starting frequency correct drive
Excessively loud Ball bearing compressed, contaminated or Re-align motor, inspect ball bearing (→ Sect. "Permitted
damaged ball bearing types"), grease if necessary (→ Sect. "Lubri-
cant Table for Anti-Friction Bearings of SEW Motors"),
replace
Vibration of rotating parts Rectify cause, possibly imbalance
Foreign bodies in cooling air passages Clean the cooling air passages

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 31 32 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Inspection / Maintenance Inspection / Maintenance
Inspection and maintenance intervals
8 8 Preliminary work for motor and brake maintenance

8 Inspection / Maintenance 8.2 Preliminary work for motor and brake maintenance
• Use only genuine spare parts in accordance with the valid parts list!
• Always install a new brake control system at the same time as replacing the brake Isolate the motor and brake from the power supply before starting work,
coil! safeguarding them against unintentional power-up!
• Motors can become very hot during operation danger of burns!
• Secure hoist drives or lower them (danger of falling).
Removing the EV1. incremental encoder / AV1H absolute encoder
• Isolate the motor and brake from the supply before starting work, safeguarding them
against unintentional power-up!
234 369 361 703 234 369 251 232 361
8.1 Inspection and maintenance intervals

Unit / unit part Frequency What to do? EV1.


• If used as a working brake: Inspect the brake
• Measure the brake disk thick-
At least every 3000 hours of opera-
ness
tion1) 220 EV1.
• Brake disk, lining
• Measure and set working air gap
• Pressure plate 220
Brake BMG02, BR03, • Carrier / gearing
BMG05-8, BM15-62 • Pressure rings AV1.
AV1.

• If used as a holding brake: • Extract the abraded matter.


• Inspect the switch elements and
Every 2 to 4 years, depending on
change if necessary (e.g. in case
operating conditions 1)
of burn-out)
236 233 366 251 232
Motor Inspect the motor:
• Check ball bearings and change
if necessary
• Change the oil seal
• Clean the cooling air passages 550 236 366 233
• Every 10,000 hours of operation
Motor with backstop • Change the low-viscosity grease 51322AXX 51324AXX
in the backstop
Removing EV1. / AV1 encoders from motors up to size 225 Removing EV1. / AV1 encoders from motors from size
Tacho-generator • Inspection / maintenance as 250 upwards
described in the enclosed oper-
ating instructions
Drive • Varies • Touch up or renew the sur-
face/anticorrosion coating. [220] Encoder [236] Adapter flange [369] Cover plate
(depending on external factors) [232] Hexagon socket head cap screw [251] Conical spring washer [550] Brake
1) The periods of wear are affected by many factors and may be short. The machine designer must calculate [233] Coupling [361] Protective canopy / fan guard [703] Hex head screw
[234] Hex head screw [366] Hexagon socket head cap screw
the required inspection/maintenance intervals individually in accordance with the project planning docu-
ments (e.g. "Drive Planning").

• Remove the protective canopy [361]. If a forced cooling fan is fitted, remove it first.
• Unscrew the screw [366] from the adapter flange and remove the cover plate [369].
• Unscrew the clamping hub connection of the coupling.
• Loosen the retaining screws [232] and turn the conical spring washers [251]
outwards.
• Remove the encoder [220] together with the coupling [233].
• Lever off the intermediate flange [236] after removing the screws [234].

Note:
During re-assembly, make sure the runout of the shaft end is ≤ 0.05 mm.
Brakes for the encoder mounting must be completely replaced.

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 33 34 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Inspection / Maintenance Inspection / Maintenance
Preliminary work for motor and brake maintenance
8 8 Preliminary work for motor and brake maintenance

Incremental encoder ES1. Removing / ES2. / EH1. Removing the proximity sensor NV1. / NV2.

1 733 367 220 361 220 367

3.5
01114CXX

Caution! It is essential for the fan wheel to be stationary!

54196AXX
• Disconnect plug
[220] Encoder [361] Protective canopy • Pull off the fan guard including NV1. / NV2. Do not tilt it, in order to avoid damaging
[367] Retaining screw [733] Retaining screw for torque arm the proximity switch.
• Remove the protective canopy [361]. • If the mounting block has been removed from the fan guard or has come loose, it is
• Unscrew the retaining screws [733] for the torque arm. essential to ensure the following during re-assembly:
• Open the screw cover at the rear of the encoder [220]. The switching surface of the proximity switch must be calibrated to a distance of
3.5 mm from the edge of the prismatic block (→ figure above).
• Unscrew the central retaining screw [367] by about 2-3 turns and loosen the cone by
tapping lightly on the head of the screw. Then unscrew the retaining screw and pull
off the encoder.

During re-assembly:
– Apply Noco® fluid to the encoder spigot
– Tighten the central retaining screw [367] to 2.9 Nm.

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 35 36 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Inspection / Maintenance Inspection / Maintenance
Inspection / maintenance on the motor
8 8 Inspection / maintenance on the motor

8.3 Inspection / maintenance on the motor Sequence


Example: Motor DFT90
Isolate the motor and brake from the supply, safeguarding them against uninten-
tional power-up!
11 12
9 1. Remove the forced cooling fan and encoder, if installed (→ Sec. "Preliminary work
for motor and brake maintenance")
8 2. Remove flange or fan guard [19], fan [17].
7
6 3. Remove the hex head bolt [15] from the drive end bearing end shield [5] and the non-
4 drive end bearing end shield [14], release the stator [13] from the drive end bearing
5
end shield.
3 4. Motors with BM/BMG brake:
2
1 15 – Open the terminal box cover, unfasten the brake cable from the rectifier
20 – Push the non-drive end bearing end shield and the brake off the stator and
carefully lift them off (if necessary, run the brake cable along with trailing wire)
– Pull the stator back by approx. 3 to 4 cm
19 5. Motors with BMG02, BR03 brake:
– Remove the complete brake with the releasing lever (on version with manual
18 brake release)
17
6. Visual inspection: Are there traces of gear oil or condensation inside the stator?
16 – If not, continue with 9
14 – If there is condensation, continue with 7
– If there is gear oil, have the motor repaired by a specialist workshop
13
7. If there is moisture inside the stator:
54008AXX
– With gearmotors: Remove the motor from the gear unit
– With motors without a gear unit: Remove the drive end flange
Key – Remove the rotor [9]
8. Clean the winding, dry it and check it electrically (→ Sec. "Preliminary work")
1 Circlip 8 Circlip 16 V-ring
9. Replace the ball bearings [7], [11] (only use authorized ball bearings → Sec.
2 Oil-flinger ring 9 Rotor 17 Fan
"Permitted ball bearing types")
3 Oil seal 11 Ball bearing 18 Circlip
10.Reseal the stator seat ("Hylomar L Spezial") and grease the V-ring or labyrinth seal
4 Screw plug 12 Equalizing ring 19 Fan guard (DR63)
5 Drive end bearing end shield 13 Stator 20 Housing screw 11.Install the motor, brake and accessories
6 Circlip 14 Non drive-end bearing shield
12.Check the gear unit (→ gear unit operating instructions)
7 Ball bearing 15 Hex head bolt

Lubrication of the The backstop is supplied with Mobil LBZ low-viscosity grease as a lubricant and
backstop anticorrosion protection. If you want to use a different grease, make sure it complies with
NLGI class 00/000, with a base oil viscosity of 42 mm2/s at 40 °C on a lithium saponified
and mineral oil base. The temperature range extends from –50 °C to +90 °C. See the
following table for the amount of grease required.
Motor type 71/80 90/100 112/132 132M/160M 160L/225 250/280
Grease [g] 9 15 15 20 45 80

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 37 38 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Inspection / Maintenance Inspection / Maintenance
Inspection / maintenance of the BMG02 brake
8 8 Inspection / maintenance of the brake BR03

8.4 Inspection / maintenance of the BMG02 brake 8.5 Inspection / maintenance of the brake BR03
Measure the The status of the brake disk is ascertained by measuring the brake disk thickness. Install
brake disk a new BMG02 brake once the brake disk thickness reaches the minimum value (→ fig-
thickness, install ure below). It is not possible to adjust the working air gap.
a new brake
BMG02 13
1
12 14
11

2 10

16 15
9
17
18
8
d
5 4 3 7
12
6

4
5

50345AXX
3
2
1
1. Isolate the motor and brake from the supply, safeguarding them against
unintentional power-up.
2. Unscrew the hand lever [1] (on version with manual brake release), remove the fan
5
guard and the fan.
3. Loosen the screws [2] and remove the complete brake with the releasing lever (on 50067AXX
version with manual brake release).
4. Measure the thickness "d" of the brake disk [3]: Key
Brake Thickness "d" of the brake disk [mm] Max. braking torque
1 Carrier 7 Brake disk 13 Hand lever
Type Maximum Minimum [Nm]
2 Clip 8 Pressure plate with stud 14 Releasing lever
5.4 0.8
BMG02 6 3 Circlip 9 Damping plate 15 Sealing washer
5.6 1.2
4 Friction plate 10 Brake springs 16 Self locking counter nut
5. Replace the complete brake if the brake disk thickness has reached the
minimum value. 5 Screw 11 Brake coil body 17 Conical coil spring

6. Install the complete brake in the motor: 6 Guide ring 12 Screw 18 Sealing element

– Make sure that the gearing of the brake disk [4] engages in the gearing of the
carrier [5]
– Route the electric connection leads through the non drive-end bearing shield and
the inside of the motor into the terminal box
7. Use screws [2] to install the brake back onto the non drive-end bearing shield
8. Refit the fan and fan guard, screw the hand lever [1] (on version with manual brake
release)

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 39 40 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Inspection / Maintenance Inspection / Maintenance
Inspection / maintenance of the brake BR03
8 8 Inspection / maintenance of the brake BR03

Inspect brake The working air gap cannot be adjusted and can only be measured by means of the 8. Reassemble the removed parts. Connect the complete new brake (replaced if the
BR03, measure stroke of the pressure plate when the brake is released. working air gap ≥ 0.8 mm) to the motor (→ following figure)
the working air – Make sure the gearing of the brake disk engages in the gearing of the carrier and
gap that the plug on the motor end fits into the socket on the brake end.

1. Isolate the motor and brake from the supply, safeguarding them against
unintentional power-up.
2. Unscrew the hand lever [13] (on version with manual brake release), remove the fan
guard and the fan.
3. Remove the self locking counter nuts [16] and, if manual brake release is fitted,
remove the conical coil springs [17] and the releasing lever [14]
4. Measure clearance x (→ following figure) with the brake at rest:

50175AXX

X
Changing the The braking torque can be changed in steps (→ Sec. "Work done, working air gap,
BR03 braking braking torques of brake BR03, BMG05-8")
torque • by installing different brake springs
50066AXX
• by changing the number of brake springs
– From the end of the stud on the pressure plate [8] to the brake coil body [11]
5. Release the brake electrically
1. Isolate the motor and brake from the supply, safeguarding them against
6. Measure clearance x with the brake released: unintentional power-up!
– From the end of the stud on the pressure plate [8] to the brake coil body [11] 2. Unscrew the hand lever [13] (on version with manual brake release), remove the fan
7. The differential corresponds to the working air gap, i.e. the stroke of the pressure guard and the fan.
plate [18]: 3. Loosen the screws [12] and remove the complete brake with the releasing lever (on
– If the working air gap ≤ 0.8 mm, reinstall the conical coil springs [17], releasing version with manual brake release).
lever [14] and self locking counter nuts [16] 4. Loosen the screws [5] and remove the guide ring [6] with friction plate [4], brake disc
– If the working air gap ≥ 0.8 mm, install a complete new brake [7], pressure plate [8] and damping plate [9]
– Use setting nuts to set the floating clearance "s" between the conical coil springs
(pressed flat) and the setting nuts (→ following figure) 5. Remove the brake springs [10] from the brake coil body [11] and replace them with
new ones.
6. Position the new brake springs symmetrically
7. Slide the damping plate [9] over the two studs attached to the pressure plate [8] so
the embossing pattern is located with the projecting side facing the pressure plate.
8. Pressure plate [8]:
– Place on the brake springs [10] together with the damping plate [9]
s – Guide the studs attached to the pressure plate [8] through the holes in the brake
coil body [6] and make sure the pressure plate is in the correct position

01111BXX
9. Place the flat side of the brake disk [7] on the pressure plate [8].
Note: Do not bring the disk into contact with grease or oil!
Brake Floating clearance s [mm]
10.Place the guide ring [6] and friction disk [4] onto the brake disk [7], press down and
BR03 2
install the screws [5].
Important: The floating clearance "s" is necessary so that the pressure plate
can move up as the brake lining wears. Otherwise, reliable braking is not
guaranteed.

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 41 42 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Inspection / Maintenance Inspection / Maintenance
Inspection / maintenance of the brake BR03
8 8 Inspection / maintenance for BMG05-8, BM15-62 brakes

11.Design with manual brake release: 8.6 Inspection / maintenance for BMG05-8, BM15-62 brakes
– Put on the conical coil springs [17] and releasing lever [14], install the self locking BM(G)05-08 brakes
counter nuts [16]
– With manual brake release: Use setting nuts to set the floating clearance "s"
between the conical coil springs (pressed flat) and the setting nuts (→ following
figure) 9
8
7
6

5
4
3
2
s
1
01111BXX

Brake Floating clearance s [mm]


BR03 2

Important: The floating clearance "s" is necessary so that the pressure plate
can move up as the brake lining wears. Otherwise, reliable braking is not 22
guaranteed. 21
e
10 20
12.Connect the complete brake back onto the motor (→ following figure):
c 19
– Make sure the gearing of the brake disk engages in the gearing of the carrier and b
that the plug on the motor end fits into the socket on the brake end a 18
17
16
15
14
11 12 13

01955AXX

Key
1 Motor with brake bearing end shield 10a Stud (3 pcs.) 15 Release lever with hand lever
2 Carrier 10b Counter spring 16 Stud (2 pcs.)
3 Circlip 10c Pressure ring 17 Conical coil spring
4 Niro disk (BMG only) 10e Hex nut 18 Setting nut
5 Rubber sealing collar 11 Brake spring 19 Fan
6 Annular spring 12 Brake coil body 20 Circlip
7 Brake disk 13 In BMG: Gasket 21 Fan guard
50175AXX
8 Pressure plate In BM: V-ring 22 Housing screw
13.Refit the fan and fan guard, screw the hand lever [10] (on version with manual brake 9 Damping plate (BMG only) 14 Dowel pin
release)

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 43 44 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Inspection / Maintenance Inspection / Maintenance
Inspection / maintenance for BMG05-8, BM15-62 brakes
8 8 Inspection / maintenance for BMG05-8, BM15-62 brakes

BM15-62 brake BMG05-8, BM15-62 brakes, set the working air gap

1. Isolate the motor and brake from the supply, safeguarding them against
unintentional power-up.
2. Remove the following:
– If installed, forced cooling fan, tacho/encoder (→ Sec. "Preliminary work for motor
10 and brake maintenance")
e
– Flange cover or fan guard [21]
d 3. Push the rubber sealing collar aside [5]
20
a
– Release the clip to do this, if necessary
19
– Extract the abraded matter.
18
17 4. Measure the brake disc [7], [7b]:
16
15 If the brake disk is
14
13 – ≤ 9 mm on brake motors up to size 100
12 – ≤ 10 mm on brake motors up to size 112
11
Install a new brake disk (→ Sec. "Changing the brake disk BMG 05-8, BM 15-62"),
8
otherwise
5. With BM30-62:
7b
Loosen the setting sleeve [10d] by turning it towards the bearing end shield
6. Measure the working air gap A (→ following figure)
7 (use a feeler gauge and measure at three points offset by 120°)
6 – In BM, between the pressure plate [8] and the brake coil body [12]
– In BMG, between the pressure plate [8] and the damping plate [9]
2 3 5
7. Tighten the hexagon nuts [10e]
01956AXX
– Until the working air gap is set correctly (→ Sec. "Technical Data")
– In BM 30-62, until the working air gap is initially 0.25 mm
Key 8. With BM30-62:
1 Motor with brake bearing end shield 8 Pressure plate 14 Dowel pin Tighten the setting sleeves
2 Carrier 9 Damping plate (BMG only) 15 Release lever with hand lever – Against the brake coil body
3 Circlip 10a Stud (3 pcs.) 16 Stud (2 pcs.) – Until the working air gap is set correctly (→ Sec. "Technical Data")
4 Niro disk (BMG only) 10b Counter spring 17 Conical coil spring 9. Install the rubber sealing collar back in place and re-install the dismantled parts
5 Rubber sealing collar 10c Pressure ring 18 Setting nut
6 Annular spring 10e Hex nut 19 Fan
7 Brake disk 11 Brake spring 20 Circlip
7b Only BM 32, 62: 12 Brake coil body 21 Fan guard
Brake stationary disk, annular spring, 13 In BMG: Gasket 22 Housing screw
Brake disk In BM: V-ring

01957AXX

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 45 46 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Inspection / Maintenance Inspection / Maintenance
Inspection / maintenance for BMG05-8, BM15-62 brakes
8 8 Inspection / maintenance for BMG05-8, BM15-62 brakes

Changing the BMG05-8, BM15-62 brake discs Change braking The braking torque can be changed in steps (→ Sec. "Technical Data")
When fitting a new brake disk (in BMG05-4 ≤ 9 mm; in BMG62 ≤ 10 mm) inspect the torque of BMG05- • by installing different brake springs
other removed parts as well and install new ones if necessary. 8, BM15-62
• by changing the number of brake springs
• by changing the brake coil body:
1. Isolate the motor and brake from the supply, safeguarding them against
– BMG05: if the maximum braking torque is not sufficient for the specific
unintentional power-up!
application, install the brake coil body [12] of brake BMG1 of the same design to
2. Remove the following: ensure safe braking
– If installed, forced cooling fan, tacho/encoder (→ Sec. "Preliminary work for motor – BMG2: if the maximum braking torque is not sufficient for the specific application,
and brake maintenance") install the brake coil body [12] of brake BMG4 of the same design to ensure safe
– Flange or fan guard [21], circlip [20] and fan [19]. braking
3. Remove the rubber sealing collar [5] and the manual brake release:
– Setting nuts [18], conical coil springs [17], studs [16], release lever [15], dowel pin 1. Isolate the motor and brake from the supply, safeguarding them against unin-
[14] tentional power-up
4. Unscrew hexagon nuts [10e], carefully pull off the coil body [12] (brake cable!) and 2. Remove the following:
take out the brake springs [11]. – If installed, forced cooling fan, tacho/encoder (→ Sec. "Preliminary work for motor
5. Remove the damping cable [9], pressure plate [8] and brake disc [7], [7b], clean the and brake maintenance")
brake components – Flange or fan guard [21], circlip [20] and fan [19].
6. Install a new brake disk 3. Remove the rubber sealing collar [5] and the manual brake release:
7. Re-install the brake components – Setting nuts [18], conical coil springs [17], studs [16], release lever [15], dowel pin
– Except for the rubber sealing collar, fan and fan guard, set the working air gap (→ [14]
Sec. "Inspecting brake BMG 05-8, BM 30-62, setting the working air gap", points 4. Unscrew hex nuts [10e], pull off the coil body [12].
5 to 8) – by approx. 50 mm (watch the brake cable!)
8. With manual brake release: Use setting nuts to set the floating clearance "s" between 5. Change or add brake springs [11]
the conical coil springs (pressed flat) and the setting nuts (→ following figure)
– Position the brake springs symmetrically
6. Re-install the brake components
– Except for the rubber sealing collar, fan and fan guard, set the working air gap (→
Sec. "Inspecting brake BMG 05-8, BM 15-62", points 5 to 8)
7. With manual brake release: Use setting nuts to set the floating clearance "s" between
the conical coil springs (pressed flat) and the setting nuts (→ following figure)
s

01111BXX

Brake Floating clearance s [mm]


BMG05-1 1.5
s
BMG2-8 2
BM15-62 2
01111BXX
Important: The floating clearance "s" is necessary so that the pressure plate
can move up as the brake lining wears. Otherwise, reliable braking is not Brake Floating clearance s [mm]
guaranteed. BMG05-1 1.5
9. Install the rubber sealing collar back in place and re-install the dismantled parts. BMG2-8 2
Notes • The lockable manual brake release (type HF) is already released if resistance is BM15-62 2
encountered when operating the grub screw.
Important: The floating clearance "s" is necessary so that the pressure plate
• The self-reengaging manual brake release (type HR) can be operated with normal can move up as the brake lining wears. Otherwise, reliable braking is not
hand pressure. guaranteed.
Important: In brake motors with self-reengaging manual brake release, the 8. Install the rubber sealing collar back in place and re-install the dismantled parts.
manual brake release lever must be removed after startup/maintenance! A
bracket is provided for storing the lever on the outside of the motor. Note Install new setting nuts [18] and hexagon nuts [10e] if the removal procedure is repeat-
ed!

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 47 48 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Inspection / Maintenance Inspection / Maintenance
Inspection / maintenance of the BMG61/122 brake
8 8 Inspection / maintenance of the BMG61/122 brake

8.7 Inspection / maintenance of the BMG61/122 brake BMG61/122 brake without encoder mounting, set the working air gap

BMG61/122 brakes with encoder mounting are only used as a holding brake. 1. Isolate the motor and brake from the supply, safeguarding them against
Maintenance work is only allowed to be performed by SEW-EURODRIVE. unintentional power-up.
2. Remove the following:

BMG61/122 brakes – Remove the forced cooling fan, if installed (→ Sec. "Preliminary work for motor
and brake maintenance")
– Flange cover or fan guard [27]
8 9 11 15 17 21 23 25 3. Push the rubber sealing collar aside [5]
16 19 – Release the clamping strap to do this, if necessary
– Extract the abraded matter.
4. Measure the brake discs [6], [10]:
If the brake disc ≤ 12 mm, change it (→ Sec. "Changing the BMG 61/122 brake disc),
otherwise
5. Loosen the setting sleeve [9] by turning it towards the bearing end shield
6. Measure the working air gap A (→ following figure)
(use a feeler gauge and meausure at three points offset by 120° between the
pressure plate [13] and the magnet [14])

7. Tighten the hexagon nuts [16]
1 2 3 4 5 6 7 10 12 13 14 18 20 22 24 26 27
– Until the working air gap is initially 0.25 mm
54318AXX 8. Tighten the setting sleeves [9]
– Against the magnet [14]
Key
– Until the working air gap is set correctly (→ Sec. "Technical Data")
1 Brake end shield 10 Brake disc, complete 2 19 Release lever
9. Refit the rubber sealing collar [5] and re-install the dismantled parts
2 Intermediate flange 11 Stud 20 Stud
3 Hex head bolt 12 Annular spring 2 21 Conical coil spring
4 Carrier 13 Brake stationary disc 22 Hex nut
5 Rubber sealing collar 14 Magnet, complete 23 Hand lever
6 Brake disc, complete 1 15 Brake spring 24 Fan
7 Annular spring 1 16 Hex head bolt 25 Circlip
8 Brake stationary disc 17 V-ring 26 Hex head bolt
A
9 Setting sleeve 18 O-ring 27 Fan guard

01957AXX

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 49 50 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Inspection / Maintenance kVA n Technical Data
Inspection / maintenance of the BMG61/122 brake
8 9 f
Work done, braking torque BMG02
i
P Hz

BMG 61/122 brake without encoder mounting, change the brake disc 9 Technical Data
When fitting a new brake disk (≤ 12 mm), inspect the other removed parts as well and
install new ones if necessary. 9.1 Work done, braking torque BMG02
Brake For motor size Work done until Thickness of brake Braking torque
Type maintenance disk [mm]
1. Isolate the motor and brake from the supply, safeguarding them against
unintentional power-up! [106 J] max. min [Nm]
DT56 5.6 1.2
2. Remove the following: BMG02
ET56
30 6
5.4 0.8
– Forced cooling fan, if installed (→ Sec. "Preliminary work for motor and brake
maintenance")
– Flange or fan guard [27], circlip [25] and fan [24]. 9.2 Information for ordering a replacement BMG02
3. Remove the rubber sealing collar [5] and the manual brake release: Brake Voltage Braking torque Brake part number
– Hex nuts [16], conical coil springs [21], studs [20], release level [17] Type

4. Loosen the hex nuts [16], remove the connection cable to the plug connector for the [VDC] [Nm]
magnet [14], remove the magnet, and remove the brake springs [15]. 0.8 0574 319 2
BMG02 24
5. Remove the complete pressure plate [8], the complete brake disc [10] as well as the 1.2 0574 323 0
brake stationary disk and complete brake disc [6] for BMG122, clean the brake 0.8 0574 327 3
BMG02/HR 24
components. 1.2 0574 331 1
6. Install a new brake disk
7. Re-install the brake components Brake Voltage Braking torque Brake part number
– Except for the rubber sealing collar, fan and fan guard, set the working air gap (→ Type
Sec. "Inspecting brake BMG 61/122, setting the working air gap", points 5 to 8) [VAC] [Nm]
8. With manual brake release: Use setting nuts [22] to set the floating clearance "s" 0.8 0574 320 6
230
between the conical coil springs [21] (pressed flat) and the setting nuts (→ following 1.2 0574 324 9
figure) 0.8 0574 321 4
BMG02 400
1.2 0574 325 7
0.8 0574 322 2
460/500
1.2 0574 326 5
0.8 0574 328 1
230
1.2 0574 332 X
0.8 0574 329 X
s BMG02/HR 400
1.2 0574 333 8
0.8 0574 330 3
01111BXX 460/500
1.2 0574 334 6
s = 2 mm

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 51 52 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Technical Data kVA n kVA n Technical Data
Work done, working air gap, braking torques of BMG05-8, BR03, BC, Bd
f 9 9 f
Work done, working air gap, braking torques of BM15 - 62
i i
P Hz P Hz

9.3 Work done, working air gap, braking torques of BMG05-8, BR03, BC, Bd 9.4 Work done, working air gap, braking torques of BM15 - 62
Brake For Work done Working air gap Braking torque settings Brake For Work done Working air gap Braking torque settings
type until type until
motor [mm] Braking Type and no. of brake Order number of brake motor [mm] Braking Type and no. of Order number of
maintenanc maintenanc
size torque springs springs size torque springs springs
e e
[106 J] min.1) max. [Nm] standard red standard red [106 J] min.1) max. [Nm] standard red standard red
3.2 6 - 150 6 -
2.4 4 2 125 4 2
BR03 63 200 - 0.8 185 815 7 185 873 4
1.6 3 - 100 3 3
132M, ML
0.8 - 6 BM15 1000 75 3 - 184 486 5 184 487 3
160M
50 - 6
5.0 3 -
35 - 4
4.0 2 2
71 25 - 3
BMG052) 60 0.25 0.6 2.5 - 6 135,017 X 135 018 8
80 0.3 1.2
1.6 - 4 160L 300 8 -
BM30 1500
1.2 - 3 180 250 6 2
200 4 4
10 6 - 150 4 -
BMG1 80 60 0.25 0.6 7.5 4 2 135,017 X 135 018 8 187 455 1 187 457 8
200 125 2 4
6.0 3 3 BM31 1500 100 - 8
225
20 3 - 75 - 6
16 2 2 50 - 4
90
BMG23) 130 0.25 0.6 10 - 6 135 150 8 135 151 6
100 300 4 -
6.6 - 4
250 2 4
5.0 - 3 BM322) 180 1500 200 - 8
10 6 - 150 - 6
BMG4 100 130 0.25 0.6 30 4 2 135 150 8 135 151 6 100 - 4
24 3 3
600 8 -
75 6 - 0.4 1.2 500 6 2 187 455 1 187 457 8
55 4 2 400 4 4
45 3 3 200 300 4 -
BM622) 1500
112M 37 3 - 225 250 2 4
BMG8 300 0.3 0.9 184 845 3 135 570 8 200 - 8
132S 30 2 2
19 - 6 150 - 6
12.6 - 4 100 - 4
9.5 - 3
600 8 -
1) Please note when checking the working air gap: Parallelism tolerances on the brake disk may give rise to deviations of ± 0.1 mm after 500 6 2
a test run. BMG61 0.3 400 4 4
300 4 -
2) BMG05: If the maximum braking torque (5 Nm) is not sufficient, it is possible to install the brake coil body of the BMG1 brake. 250 200 - 8
2500 1.2 186 838 1 186,839 X
3) BMG2: If the maximum braking torque (20 Nm) is not sufficient, it is possible to install the brake coil body of the BMG4 brake. 280 1200 8 -
1000 6 2
BMG1222) 0.4 800 4 4
600 4 -
400 - 8
1) Please note when checking the working air gap: Parallelism tolerances on the brake disk may give rise to deviations of ± 0.15 mm after
a test run.
2) Double disc brake

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 53 54 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Technical Data kVA n kVA n Technical Data
Operating currents
f 9 9 f
Operating currents
i i
P Hz P Hz

9.5 Operating currents BMG 05 - BMG 4


brake
The current values IH (holding current) specified in the tables are r.m.s. values. Use only BMG05 BMG1 BMG2 BMG4
units to measure the r.m.s. values. The inrush current (acceleration current) IB only flows Motor size 71/80 80 90/100 100
for a short time (max. 120 ms) when the brake is released or during voltage dips below Max. braking torque [Nm] 5 10 20 40
70 % of rated voltage. There is no increased inrush current if the BG brake rectifier is Braking power [W] 32 36 40 50
used or if there is a direct DC voltage supply – both are only possible with brakes up to
Inrush current ratio IB/IH 4 4 4 4
motor size BMG4.

BMG02, BR03 Rated voltage VN BMG05 BMG 1 BMG 2 BMG 4


brake IH IG IH IG IH IG IH IG
BMG02 BR03 VAC VDC
[AAC] [ADC] [AAC] [ADC] [AAC] [ADC] [AAC] [ADC]
Motor size 56 63
24 1.38 1.54 1.77 2.20
Max. braking torque [Nm] 1.2 3.2
24 (23-25) 10 2.0 3.3 2.4 3.7 - - - -
Braking power [W] 25 25
42 (40-46) 18 1.14 1.74 1.37 1.94 1.46 2.25 1.80 2.80
Inrush current ratio IB/IH - 4
48 (47-52) 20 1.02 1.55 1.22 1.73 1.30 2.00 1.60 2.50
Rated voltage VN BMG02 BR03 56 (53-58) 24 0.90 1.38 1.09 1.54 1.16 1.77 1.43 2.20
IH IG IH IG 60 (59-66) 27 0.81 1.23 0.97 1.37 1.03 1.58 1.27 2.00
VAC VDC
[AAC] [ADC] [AAC] [ADC]
73 (67-73) 30 0.72 1.10 0.86 1.23 0.92 1.41 1.14 1.76
24 - 0.72 - 0.72
77 (74-82) 33 0.64 0.98 0.77 1.09 0.82 1.25 1.00 1.57
24 (23-26) 10 - - 1.5 1.80
88 (83-92) 36 0.57 0.87 0.69 0.97 0.73 1.12 0.90 1.40
42 (40-45) 18 - - 0.81 1.01
97 (93-104) 40 0.51 0.78 0.61 0.87 0.65 1.00 0.80 1.25
48 (46-50) 20 - - 0.72 0.90
110 (105-116) 48 0.45 0.69 0.54 0.77 0.58 0.90 0.72 1.11
53 (51-56) 22 - - 0.64 0.80
125 (117-131) 52 0.40 0.62 0.48 0.69 0.52 0.80 0.64 1.00
60 (57-63) 24 - - 0.57 0.72
139 (132-147) 60 0.36 0.55 0.43 0.61 0.46 0.70 0.57 0.88
67 (64-70) 27 - - 0.50 0.64
153 (148-164) 66 0.32 0.49 0.39 0.55 0.41 0.63 0.51 0.79
73 (71-78) 30 - - 0.45 0.57
175 (165-185) 72 0.29 0.44 0.34 0.49 0.37 0.56 0.45 0.70
85 (79-87) 36 - - 0.40 0.51
200 (186-207) 80 0.26 0.39 0.31 0.43 0.33 0.50 0.40 0.62
92 (88-98) 40 - - 0.35 0.45
230 (208-233) 96 0.23 0.35 0.27 0.39 0.29 0.44 0.36 0.56
110 (99-110) 44 - - 0.31 0.40
240 (234-261) 110 0.20 0.31 0.24 0.35 0.26 0.40 0.32 0.50
120 (111-123) 48 - - 0.28 0.36
290 (262-293) 117 0.18 0.28 0.22 0.31 0.23 0.35 0.29 0.44
133 (124-138) 54 - - 0.25 0.32
318 (294-329) 125 0.16 0.25 0.19 0.27 0.21 0.31 0.25 0.39
147 (139-154) 60 - - 0.22 0.29
346 (330-369) 147 0.14 0.22 0.17 0.24 0.18 0.28 0.23 0.35
160 (155-173) 68 - - 0.20 0.25
400 (370-414) 167 0.13 0.20 0.15 0.22 0.16 0.25 0.20 0.31
184 (174-193) 75 - - 0.17 0.23
440 (415-464) 185 0.11 0.17 0.14 0.19 0.15 0.22 0.18 0.28
208 (194-217) 85 - - 0.16 0.20
500 (465-522) 208 0.10 0.15 0.12 0.17 0.13 0.20 0.16 0.25
230 (218-243) 96 0.14 0.18 0.14 0.18
254 (244-273) 110 - - 0.12 0.16
290 (274-306) 125 - - 0.11 0.14 Key
318 (307-343) 140 - - 0.10 0.13
IB Accelerator current – brief inrush current
360 (344-379) 150 - - 0.09 0.11
IH Holding current r.m.s. value in the connecting harness to the SEW brake rectifier
400 (380-431) 170 0.08 0.10 0.08 0.10
IG Direct current with direct DC voltage supply
460 (432-500) 190 0.07 0.09 0.07 0.09
VN Rated voltage (rated voltage range)
Key
IB Accelerator current – brief inrush current
IH Holding current r.m.s. value in the connecting harness to the SEW brake rectifier
IG Direct current with direct DC voltage supply with rated voltage VN
VN Rated voltage (rated voltage range)

Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV 55 56 Operating Instructions – AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Technical Data kVA n kVA n Technical Data
Operating currents
f 9 9 f
Operating currents
i i
P Hz P Hz

BMG 8 - BM 32/62 BMG61, BMG122


brake brake
BMG8 BM 15 BM30/31; BM32/62 BMG61 BMG122
Motor size 112/ 132S 132M-160M 160L-225 Motor size 250M...280S
Max. braking torque [Nm] 75 150 600 Max. braking torque [Nm] 600 1200
Braking power [W] 65 95 120 Braking power [W] 200
Inrush current ratio IB/IH 6.3 7.5 8.5 Inrush current ratio IB/IH 6

Rated voltage VN BMG61/122


IH
Rated voltage VN BMG8 BM 15 BM 30/31; BM 32/62 VAC
[AAC]
IH IH IH
VAC VDC 208 (194-217) 1.50
[AAC] [AAC] [AAC]
230 (218-243) 1.35
24 2.771) 4.151) 4.001)
254 (244-273) 1.20
42 (40-46) - 2.31 3.35 -
290 (274-306) 1.10
48 (47-52) - 2.10 2.95 -
318 (307-343) 1.00
56 (53-58) - 1.84 2.65 -
360 (344-379) 0.85
60 (59-66) - 1.64 2.35 -