Rotary Lock

Operating manual
Specification sheet
SMD FRDERTECHNIK GmbH
Robert-Bosch-Str. 7
D-42477 Radevormwald, Germany
Tel.: 0049 (0)2195-931910
Fax.: 0049 (0)2195-931909
E-Mail: info@smd-foerdertechnik.de
Internet: www.smd-foerdertechnik.de
SMD Cellular wheel sluice
Specification sheet*)
General :
SMD identification no.
Type
Year of construction
Net weight
Dimensions W x H x L
(kg)
(mm)
: KM08/3344-0101
: ZRS 630x630x800 with bush
: 2008
: 873
: 750 x 800 x 2240
Operating data :
Conveyed material
Density
Grain size
Temperature of material
Humidity
Exist. Conveying capacity
Exist. Conveying capacity
Theor. Conveying capacity
Fill factor
(t/m)
(mm)
(C)
(%)
(t/h)
(m/h)
(m/h)
(%)
: cement raw meal

: 0,8
: dry and trickling
: max. 100
: dry
: 120
: 150
: 258 ( in case of fill factor 100% )
: 58
Technical data and usage to the intended purpose:

Type of drive
: Gear motor
Drive description (brand/type)
: SEW Eurodrive / RF97 DVE100L4, mounting position M1
Rated power of motor
(kW)
: 3,0
Output speed of gear unit
(min-1)
: 22
Voltage
(V AC) : 220-240/380-415
Frequency
(Hz)
: 50
Amount of oil at changing (litre)
: 5,1
Gear oil (type/recommendation)
: Synthetic oil DIN 51502 CLP PG ISO VG220 /
Shell Tivela S220
Coupling (brand/type)
: HFB / EK 250 A
Speed monitoring (brand/type)
: ifm electronics / DI0001
Housing:
Design
Material of housing
Material of wear bush
Cellular wheel :
Design
Nominal diameter
Quantity of cells
Material of cells
Shaft proctection sleeve
Bearing
Shaft sealing
Matrial of sealing strips
: welded construction
: S235JR
: HARDOX 400
(mm)
: closed
: 630
:8
: S235JR
: existing
: Roller bearing
: Gland sealing
: HARDOX 400
*) This specification sheet is provided for each purchase and is an applicable and valid part of the operating
manual. This specification sheet lies above the operating manual.
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Operating manual
Specification sheet
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Operating manual
SMD Cellular wheel sluice

Robert-Bosch-Str. 7
Tel.: 0049 (0)2195-931910
Fax.: 0049 (0)2195-931909
Date : 07.12.2007
Page 1
Operating manual
Table of content
- blank page -
Page 2
Operating manual
Table of content
Table of content
1
General
5
1.1
Introduction ........................................................................................... 5
1.2
Description ............................................................................................ 5
1.3
EC Declaration of conformity ............................................................... 5
1.4
Copyright............................................................................................... 5
Validity, warranty, liability

6
2.1
Validity of the operating manual........................................................... 6
2.2
Other valid document ............................................................................ 6
2.3
Field of application and usage to the intended purpose ........................ 6
2.4
Warranty and liability............................................................................ 7
2.5
Operational preconditions ..................................................................... 7
Safety
8
3.1
Symbols, warning signs and terminilogy .............................................. 8
3.2
Basic safety instructions........................................................................ 9
3.3
Special instructions ............................................................................... 9
3.4
Organisational measures ....................................................................... 9
3.5
Protective equipment........................................................................... 10
3.6
Informal safety measures .................................................................... 10
3.7
Training personnel............................................................................... 10
3.8
Cellular wheel sluice control............................................................... 10
3.9
Safety measures during normal operation........................................... 10
3.10 Risks from electrical energy................................................................ 10
3.11 Escape of hazardous gases, vapours and dusts.................................... 11
3.12 Maintenance, servicing and repairs..................................................... 11
3.13 Structural changes to the cellular wheel sluice ................................... 11
3.14 Cleaning the Sluice and disposal of wastes......................................... 11
3.15 Noise from the cellular wheel sluice ................................................... 12
3.16 Changing the location of the cellular wheel sluice ............................. 12
Transport and storage

13
4.1
Sensitivity............................................................................................ 13
4.2
Extent of delivery ................................................................................ 13
4.3
Intermediate storage ............................................................................ 13
Installation
14
5.1
General informations........................................................................... 14
5.2
Installation informations ..................................................................... 14
5.3
Installation of drive unit ...................................................................... 15
5.4
Installation of speed monitoring.......................................................... 15
5.5
Elektrical installation........................................................................... 16
5.6
Protection against contact by hot material conveying......................... 16
5.7
Tightening torques for boltings ........................................................... 16
5.8
Checks at the end of installation ......................................................... 17
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Operating manual
Table of content
6
Commissioning
18
6.1
Notes.................................................................................................... 18
6.2 Visual check ........................................................................................ 18
6.3
Trial run without material ................................................................... 19
6.4
Trial run with material......................................................................... 19
Operation
20
7.1
Normal operation................................................................................. 20
7.2
What to do in the event of faults ......................................................... 20
7.2.1
Emergency stop .................................................................................. 20
7.2.2
Re-starting after a malfunction ............................................................... 21
7.2.3
Troubleshooting .................................................................................. 21
7.3
Before a longer standstill period ......................................................... 22
7.4
After a longer standstill period............................................................ 22
Maintenance
23
8.1
Notes for routine maintenance and inspection .................................... 23
8.2
Routine maintenance ........................................................................... 23
8.2.1
Care.................................................................................................. 23
8.2.2
Routine maintenance and inspeciton list................................................... 24
8.3
Repairs................................................................................................. 24
8.3.1
Drive unit .......................................................................................... 25
8.3.2
Chain drive ........................................................................................ 25
8.3.3
Gland packing .................................................................................... 25
8.3.4
Replacing rubber sealing....................................................................... 25
8.3.5
Adjustment of the gap .......................................................................... 25
8.3.6
Disposal ............................................................................................ 25
8.4
Lubrication .......................................................................................... 26
8.4.1
Correct lubrication............................................................................... 26
8.4.2
Grease lubricant .................................................................................. 26
8.4.3
Mixing lubricating greases .................................................................... 26
8.4.4
Lubrication of the drive unit .................................................................. 26
8.4.5
Lubricant dispensers ............................................................................ 26
8.4.6
Rolling bearing ................................................................................... 26
8.4.7
Disposal ............................................................................................ 27
8.4.8
Lubrication instructions ........................................................................ 27
8.4.9
Lubrication chart ................................................................................. 28
8.4.10 List of lubricating points ....................................................................... 28
Spare parts stocking / Customer service

29
9.1
Spare parts stocking ............................................................................ 29
9.2
Spare parts sales / Customer service address ...................................... 29
9.3
List of spare parts / spare part drawing ............................................... 29
10
Layout drawing
31
11 Documentation of suppliers
33
11.1 Speed monitor ..................................................................................... 33
11.2 Drive motor ......................................................................................... 35
11.3 Coupling .............................................................................................. 37
Page 4
Operating manual
1 General
1 General
1.1 Introduction
This information has been written with the intention that it be read, understood and all points herein
observed by those persons responsible for the SMD cellular wheel sluice. The complete technical
documentation should always be kept in the vicinity of the cellular wheel sluice. These operating
instructions refer to particularly important details for working with the cellular wheel sluice.
Errors on the cellular wheel sluice can only be avoided and a trouble-free operation guaranteed with
an knowledge of these operating instructions. It is thus very important that the person responsible is
in fact familiar with these operating instructions.
We recommend that these operating instructions be read carefully before commissioning since we
can accept no liability for damages and breakdowns which are due to a non-observance of these
operating instructions.
Should difficulties nevertheless arise, please contact our customer service or spare parts department
which will be pleased to be of assistance (see operating instructions "Spare parts stocking/Customer
service").
1.2 Description
SMD cellular wheel sluices can be used for conveying, dosing and continuously discharging
powdery and granular bulk materials with different physical properties. They are also suited for
blocking under cyclones and filters. The sluices can be mounted to containers, under bins, product
shafts or continuative conveyors.
The cellular wheel sluices are composed of a housing, an internal cellular wheel and an external
drive unit.
SMD cellular wheel sluice are designed and manufactured according to the ordering requirements.
The materials, the kind of drive and drive power depend on the respective usage.
1.3 EC Declaration of conformity

The cellular wheel sluice which is described here and specified in the specification sheet (see chapter
2.2) has been produced by SMD FRDERTECHNIK GmbH in agreement with the valid EC
machine directive.
The declaration of conformity and manufacturer confirmation are separately filed in the quality
documentation.
1.4 Copyright
Copyright on these operating instructions remains with the firm of SMD FRDERTECHNIK
GmbH. These operating instructions are for the operator and their personnel only.
They contain information and instructions which may be neither wholly nor partly :
- copied,
- distributed or
- otherwise propagated.
Contraventions may entail criminal proceedings.
We reserve the right to make technical changes to illustrations and data in these operating
instructions which may become necessary to improve the cellular wheel sluice.
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Operating manual
2 Validity, warranty, liability

2.1 Validity of the operating manual
This operating manual are valid for SMD cellular wheel sluices with the following manufacturing
variants (types):
SMD cellular wheel sluice
with free shaft end (drive provided by customer in aggreement with SMD FRDERTECHNIK
GmbH),
with foot-mounted motor (-gear motor) and chain drive,
with flange-mounted gear motor and coupling with latern,
with flange-mounted gear motor and coupling without latern.
2.2 Other valid document

The specification sheet provided for each order is an applicable and valid part of this documentation.
This specification sheet lies above this operating manual.
It contains following indicatings:
SMD identification number of cellular wheel sluice.
This number specifies the ordering requirements, the design and particularly the field of
application of the SMD cellular wheel sluice for which it is determined.
Type and description of cellular wheel sluice, year of construction, weight, operating data and the
technical data of cellular wheel sluice
Other valid documents are the documents of suppliers, operating and maintenance instructions of the
drive unit manufacturer for example.
2.3 Field of application and usage to the intended purpose

The cellular wheel sluice has been manufactured exclusively for the field of application described in
the ordering requirements and specification sheet.
It is not permitted to use the SMD cellular wheel sluice for an application that does not comply with
the design and operating conditions described in the specification sheet and ordering requirements.
Any different use or use exceeding this field of operation shall not be deemed to be proper use.
When it is used under changed operational conditions, permission for this changed application has to
be obtained in writing from SMD FRDERTECHNIK GmbH.
This cellular wheel sluice has exclusively been designed for the materials and material properties
decribed in the ordering requirements and operating data. Any other materials and those with
markedly different properties constitute an improper use of the cellular wheel sluice and must be
avoided.
Persons might get injured or killed if handling improper materials that constitute a fire or explosion
risk or are prone to chemical reactions.
Any different use or use exceeding this field of operation shall not be deemed to be proper use.
SMD FRDERTECHNIK GmbH shall not be held liable for any damages arising from such
improper use. SMD FRDERTECHNIK GmbH shall not be held liable in the event of improper
use; any warranty shall expire immediately.
The proper use of this cellular wheel sluice also content the proper compliance of all information
from this operating manual and particularly the proper maintenance specification.
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Operating manual
2.4 Warranty and liability

All warranties and liabilities subject to our Standard Business Conditions ("Allgemeine Lieferungsund Zahlungsbedingungen"). These have been handed over to the customer upon conclusion of the
purchasing contract or earlier. No warranty and/or liability in the event of damages or injuries due to
one or several of the following causes:
Improper use of the cellular wheel sluice.
Improper assembly, commissioning/starting, operation and maintenance of the cellular wheel
sluice.
Operation despite defective safety equipment or improperly mounted or non-functional safety and
protection equipment.
Disregard of instructions with respect to transport, storage, assembly, commissioning/starting,
operation, maintenance and set-up of the cellular wheel sluice.
Unauthorized changes in the design and construction of the cellular wheel sluice.
Unauthorized technical changes (e.g. drive condition, output and/or speed).
Insufficient checking and inspection of components which are prone to wear.
Improper repairs.
Disastrous external events and force majeure.
In principle, the first initial commissioning of the cellular whee sluice delivered by SMD
FRDERTECHNIK GmbH may be procedured only by the company SMD FRDERTECHNIK
GmbH, if this is not regulated differently by contract. All rights to claim under guarantee are
dropped by nonobservance.
SMD FRDERTECHNIK GmbH shall not be held liable for any damages arising from improper
commissioning by other personal!
2.5 Operational preconditions

Prevent product accumulation!
Provide for a buffer space behind the cellular wheel sluice, continuative conveyors must have a
higher conveying capacity.
Facilitate maintenance!
Install a slide valve in front of the inlet of cellular wheel sluice to make the maintenance sure and
easier , a slide valve like SMD slide valve for example.
Energy supply of drive unit!
Connect the energy supply according to the details given in the specification sheet. Observe the
regulations of the operator country.
Page 7
Attention !
Operating manual
3 Safety
3 Safety
3.1 Symbols, warning signs and terminilogy
The following terms and symbols will be used for warnings in the operating instructions:
Danger:
Danger notice, which if ignored can lead directly to serious injury or death.
Danger
Warning:
Danger notice, which if ignored can lead to serious injury or death.
W arning
Caution:
Danger notice or anger of uncertain handling which can lead to considerable injuries or
material damage.
!
Caution
Warning of electrical voltage:

Touching live parts can lead to immediate death. Doors and covers (e.g. cowls and
covers) bearing this sign may only be opened by "Experts and/or trained personnel"
after the corresponding line voltage (feed, working or external) has been switched off
beforehand.
Danger to operating safety of the system:

Non-observance of these instructions affects the operating reliability and can lead to
system damage.
Attention : The attention symbol identifies all safety instructions in this manual which refer to
regulations, guidelines or operating sequences which must be observed.
Non-observance of these instructions can lead to disturbances at the slide valve and in the
surroundings.
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Attention !
Operating manual
3 Safety
3.2 Basic safety instructions

Pay attention to the information in the operating instructions:
A basic precondition for the safe and trouble-free operation of this cellular wheel sluice is a
knowledge of the basic safety instructions and regulations.
These operating instructions contain the most important information needed to operate the cellular
wheel sluice safely.
These operating instructions, in particular the safety instructions, are to be observed by all persons
working at the cellular wheel sluice.
In addition, the rules and regulations for the prevention of accidents applicable at the place of use
must also be observed.
Operator's obligation:
The operator promises to only let persons work at the cellular wheel sluice who
re familiar with the basic regulations on job safety and accident prevention and have been trained
in the operation of the cellular wheel sluice,
have read and understood the chapter Safety and warnings in these operating instructions and
have confirmed this through their signature.
The safety-conscious working of the personnel will be checked at regular intervals.
Personnel obligation:
All persons commissioned to work on and with the cellular wheel sluice promise, before starting
work, to
observe the basis regulations on job safety and accident prevention,
to read the chapter Safety and warnings in these operating instructions and confirm that they
have understood these through their signature.
Risks associated with the cellular wheel sluice:
This cellular wheel sluice has been designed and built according to the state of the art and in respect
of the approved technical rules. Nevertheless, hazards to the life and limb of operators or third
persons or damages to the cellular wheel sluice or other property cannot be excluded. This cellular
wheel sluice shall be operated only:
within the framework of proper use;
in a safe condition;
by personnel who are aware of the hazards and observe these instructions.
Immediately clear all disturbances that might affect the safety of this cellular wheel sluice.
3.3 Special instructions

We point out that the final manufacturer is obliged to equip the machine with the relevant
emergency-off devices!
The final manufacturer must take protective measures against touching hot surfaces (EN 563)!
Besides, the final manufacturer must earth the machine via an earthing cable which has to be
connected to the machine.
3.4 Organisational measures

The necessary personal protective equipment is to be provided by the operator.
All existing safety equipment is to be checked on a regular basis.
The operating instructions must be supplemented by instructions including supervisory and
reporting obligations in order to take into account special on-the-job circumstances, e.g. with
respect to labour organisation, job sequences, employed personnel, etc..
The personnel may not wear long hair open, loose clothing or jewellery including rings. Risk of
injuries, e.g. these could get caught in or be drawn into the cellular wheel sluice.
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Operating manual
3 Safety
3.5 Protective equipment

All protective equipment must be correctly installed and operational before the cellular wheel
sluice is started.
Protective equipment may only be removed
- after the cellular wheel sluice comes to a standstill and
- the cellular wheel sluice has been secured against restarting.
If part components have been delivered the protective equipment must be installed correctly by the
operator.
3.6 Informal safety measures

The operating maunal must always be kept at the place where the cellular wheel sluice is used.
In addition to the operating instructions, the generally applicable and local regulations with respect
to accident prevention and environmental protection must be provided and observed.
All safety signs and warnings on the cellular wheel sluice are to be kept in a legible condition.
Publish the location and operation of fire extinguishers.
Pay attention to the fire alarm and fire fighting facilities.
3.7 Training personnel

Only trained and instructed personnel may work on and with the cellular wheel sluice.
The responsibilities of the personnel must be clearly defined for the installation, commissioning,
operation, set-up, maintenance and repairs.
Trainee personnel may only work on and with the cellular wheel sluice under the supervision of an
experienced person.
3.8 Cellular wheel sluice control

Only trained personnel may operate the control system.
Do not change any programs at the software.
3.9 Safety measures during normal operation

Only operate the cellular wheel sluice when all safety equipment has been installed and is
operational.
Before switching the cellular wheel sluice on make sure that nobody can be endangered by the
cellular wheel sluice when it starts up.
Check the cellular wheel sluice for externally visible damages and the operability of the safety
equipment at least once per shift. If necessary, stop the cellular wheel sluice immediately, secure
against restarting and remedy the fault.
Do not perform any actions which could jeopardize safety.
Extraction and ventilation equipment may not be switched off whilst the cellular wheel sluice is
running.
3.10 Risks from electrical energy

Work on the power supply may only be carried out by qualified electricians and according to the
rules of electrical engineering.
The cellular wheel sluice's electrical equipment should be checked regularly. Loose connections
and scorched cables should be remedied immediately.
The switch cabinet must always be kept closed. Access only for authorized personnel with a key or
tool.
If work has to be carried out on live parts a second person must be present to switch off the main
switch if and when necessary.
The cellular wheel sluice / system must be stopped immediately in the event of faults in the
electrical power supply.
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Operating manual
3 Safety
3.11 Escape of hazardous gases, vapours and dusts

Noxious gases, fumes and/or dusts may escape from open covers and hoods. Make sure that
sufficient ventilation and/or exhaustion is ensured.
When handling dangerous materials take special safety measures, e.g. have eye-rinsing devices
available when handling caustic agents.
Do not effect welding or grinding or other jobs involving fire without prior permission. There
might be fire or explosion or other hazards.
When working in small rooms be sure to observe your local and national regulations.
3.12 Maintenance, servicing and repairs

Take care that all required set-up, maintenance and servicing jobs are carried out in the required
intervals.
Inform the operators before maintaining and servicing the cellular wheel sluice.
Secure all components and equipment connected to the cellular wheel sluice against accidental restart.
When maintaining, checking or repairing the cellular wheel sluice remove all electric supplies and
potentials and secure main switch against accidental operation.
- Lock main switch and remove key.
- Put up warning sign against re-start.
When handling big components use lifting and hoisting devices and secure carefully.
Check screws and bolts for tight fit.
After finishing maintenance jobs check safety equipment for good working order.
When working high use safe ladders and working platforms. Never climb on cellular wheel sluice.
When working at great heights secure against falling down.
Keep all grips, steps, hand rails, platforms, ladders, etc. free of dirt, snow and ice.
Remove defective cellular wheel sluice components immediately.
Use genuine SMD wearing and spare parts only.
Third-party products cannot guarantee to offer appropriate safety in design and construction.
3.13 Structural changes to the cellular wheel sluice

No modifications, alterations or conversions may be carried out on the cellular wheel sluice
without the consent of the manufacturer. This also applies for welding work on load-carrying
parts.
Any conversion work requires written confirmation from the firm of SMD FRDERTECHNIK
GmbH.
Under no circumstances may modifications be made to the control system or the control software
program modified!
3.14 Cleaning the Sluice and disposal of wastes

All materials used must be handled and disposed of correctly, in particular
- during work on lubricating systems and equipment,
- during cleaning with solvents.
Do not use any aggressive cleaning agents.
Use fibre-less cleaning cloths.
Before cleaning the cellular wheel sluice with water or steam (high-pressure cleaner) or other
cleaning agents, cover/seal all openings into which no water/steam/cleaning agent may penetrate
for reasons of safety and/or function. Electric motors and switch cabinets are particularly
endangered.
Make sure to remove all covers/seals after cleaning!
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Operating manual
3 Safety
3.15 Noise from the cellular wheel sluice

A higher sound pressure level may arise depending on the local conditions and this can cause
impaired hearing. In this case the operating personnel must be protected with corresponding
protective equipment or measures.
3.16 Changing the location of the cellular wheel sluice

Use only lifting gear and load-suspension devices with a suitable load-carrying capacity during
loading and unloading.
Appoint an experienced supervisor for the lifting procedure.
Only raise the cellular wheel sluice properly according to the operating instructions (points of
attachment for load-suspension devices, etc.)!
Do not stay or work under suspended loads.
Use only a suitable transport vehicle with adequate load-carrying capacity.
Secure the load safely. Use suitable points of attachment!
Secure the cellular wheel sluice/system against accidental changes in position before or
immediately after completion of the loading work! Attach corresponding warning signs! Remove
the transportation locking devices correctly before re-starting the cellular wheel sluice!
Parts which have had to be removed for transportation purposes must be carefully refitted and
fastened before restarting.
Disconnect the cellular wheel sluice or system from all external energy supplies, even if only
moving a short distance! Reconnect to the mains correctly before restarting the cellular wheel
sluice!
Proceed in accordance with the operating instructions during restarting.
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Operating manual
4 Transport and storage
4 Transport and storage

4.1 Sensitivity
The level of dismantling for the cellular wheel sluice depends on the transport conditions, the local
circumstances and the lifting gear available. The cellular wheel sluice is delivered completely
assembled, unless otherwise agreed.
Take care when transporting the cellular wheel sluice so as to avoid damage through the effects of
force or loading and unloading. The existing protective coating may not be destroyed.
The SMD cellular wheel sluice must be transported by transport experts!
Pay attention to chapter Safety as well as the local and general accident prevention regulations.
The SMD cellular wheel sluice has to be slung carefully and professionally according to its type
of construction!
Transport the cellular-wheel sluice only by the provided transport eyes.
The cellular wheel sluice mustnt never sling or lift at its drive or drive section!
All suspension aids and lifting gear are to be fastened professionally and mustnt slip or
become loose during transportation.
Caution! Lifting equipment like chains, ropes, shackle, lifting crossbeam etc. are not part of
SMDs scope of delivery.
4.2 Extent of delivery

The extent of delivery must immediately be checked on receipt for completeness. Any damage
incurred during transportation and/or missing parts must be reported immediately in writing to SMD
FRDERTECHNIK GmbH.
4.3 Intermediate storage

If the cellular wheel sluice are not assembled immediately they must be protected/stored carefully
and correctly against all atmospheric influences. Protect all blank parts against corrosion with an oil
film for example The cellular wheel sluice must be secure against accidental position changes.
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Operating manual
5 Installation
5 Installation
5.1 General informations
When delivered to the construction site the parts of the cellular wheel sluice are to be lifted from the
transport vehicle according to the transport instructions in chapter 4.
Preconditions that have to be met by the customer for a successful installation are exactly aligned
foundations, substructures and connecting flanges with respect to their angularity, flatness and
dimensional accuracy.
If these preconditions are not fulfilled great difficulties can arise during installation.
In order to install and align the cellular wheel sluice it may be necessary to provide provisional bases
(not included in the SMD extent of delivery).
The complete installation of the cellular wheel sluice must be carried out by qualified
installation experts!
Supports or suspension are to be affixed safely and professionally. No persons may walk under
the supported or suspensioned parts!
Pay attention to the local safety regulations and chapter Safety of this operating
instructions!
Wear personal protective gear!
Ensure adequate lighting during installation!
All installations must always be carried out in such a way that no persons are put in danger!
!
Danger
!
Caution
Check all delivered parts for any damage incurred during transport before any installation
work.
5.2 Installation informations

Mounting informations:
Empty all containers and pipelines before starting the assembly.
Danger of injury! Switch off the plant and secure against unintentional restarting. Inform the
control room and/or superior!
Assemble the cellular wheel sluice in this way that no high forces are load the housing.
Support cantilevered drive units.
Choose the mounting position so that the bulk material enters the cellular wheel sluice vertically.
Clean the flange surfaces, put on sealing (cellular rubber, silicone, neoprene etc.).
Align the flanges plane-parallel and firmly tighten the connection screws crosswise.
Checking:
whether a set-up plan is available for the cellular wheel sluice,
the condition of the ground and adjacent components,
the dimensional accuracy of the connections,
the free space required for assembly, maintenance, repair,
the environment conditions (dust, climate etc.),
the alignment of the cellular wheel sluice,
the predefined distances to other parts of the plant,
the possibilities of electrical installation,
the accessibility of the inspection openings.
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Operating manual
5 Installation
After completition of works the boltings should be checked and retightened if necessary.
On completition of all installation work the "Checks the end of installation" must be carried
out. The cellular wheel sluice may not be commissioned before these have been completed!
5.3 Installation of drive unit

The drive unit of the SMD cellular wheel sluice consists of different variants depending on purchase
order and ordering requirements. The following kinds are applicable:
with free shaft end (drive provided by customer in arrangement with SMD FRDERTECHNIK
GmbH),
with foot-mounted motor (-gear motor) and chain drive,
with flange-mounted gear motor and coupling with latern,
with flange-mounted gear motor and coupling without latern,
For the assembly or dismantling descriptions of the individual drive components, please refer to the
instructions given by the manufacturer, see chapter Documentation of suppliers.
Check the oil level with gear motors and fill in or refill oil if necessary; pay attention to the
instructions of the gear manufacturer.
Check the gear venting, remove or replace the plug, bolt the bleeder screw.
5.4 Installation of speed monitoring

When the speed monitor is triggered the drive unit has to switch off basicly.
The connecting cables of the proximity switch must sag by an appropriate amount.
The pulses are evaluated with an evaluation unit (unless otherwise specified in the contract, the
evaluation unit is not included in the SMD scope of supply).
Proceed during installation:
Set the switching gap X according to manufacturer information.
Proceed the trial run according chapter Commissioning and possibly adjust the gap.
1 = Proximity switch
( Brand and type is specified in the specification sheet and Documentation of suppliers )
2 = Housing
3 = Pulse disk
X = Switching gap according to manufacturer information, see chapter Documentation of
suppliers.
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Operating manual
5 Installation
5.5 Elektrical installation

Danger to life!
The electrical connection of control lines and the lines to the power unit may only be carried out by
qualified personnel according to the available wiring diagrams.
Pay attention to its scheduled direction of rotation by the connection of the three-phase motor! Pay
attention to the rotation arrow on the housing!
The proximity switch for speed monitoring is connected to the evaluation unit and adjusted
according to the manufacturer's instructions(if not even integrated in initiator). The evaluation unit
should be mounted at a suitable place, protected against dirt and damage.
The effective power monitor for drive monitoring is adjusted according to manufacturer's
instructions and should be mounted at a suitable place, protected against dirt and damage. (unless
otherwise specified in the contract, the evaluation unit is not included in the SMD scope of supply!
If the drive unit is not integrated into an overall control system, install a motor protecting switch.
Does the existing supply voltage comply with the value stipulated by the motor manufacturer
( data plate of motor )?
Check the direction of rotation after connection(correct terminal-phase connections). Pay attention
to the rotation arrow on the housing!
On completition of all installation work the "Checks the end of installation" must be carried
out. The cellular wheel sluice may not be commissioned before these have been completed!
5.6 Protection against contact by hot material conveying

Due to safety technical reasons a protection against contact and touching is to supply and install at
site by others (no SMD supply!). This protection is necessary when the cellular wheel sluice surfaces
are heated up due to hot material conveying.
5.7 Tightening torques for boltings

Tightening torques for electrically galvanised hexagon bolts in Nm
(coefficient of friction = 0,125)
Normal thread
Strenght class
(metrical)
5.6
8.8
10.9
M6
4,3
9,9
14
M8
10,5
24
34
M10
21
48
67
M12
36
83
117
M16
88
200
285
M20
171
390
550
M24
295
675
960
M30
590
1350
1900
12.9
16,5
40
81
140
340
660
1140
2280
Page 16
Operating manual
5 Installation
5.8 Checks at the end of installation

On completion of the electrical and mechanical installation the following checks should be carried
out before commissioning:
a) Foreign bodies :
Make sure that there are no foreign bodies (bolts, pieces of iron, etc.) in the cellular wheel
sluice or valve line which could block the cellular wheel sluice.
b) Fastening screws:
All fastening screws must sit tight on completion of the installation work. All screws should
be checked carefully after approx. 4 weeks of operation and tightened if necessary. The
screws which fasten the gear are to be tightened with a torque wrench.
c) Speed monitoring:
The proximity switch for speed monitoring must be mounted, electrical connected and
adjusted according to the manufacturer's instructions.
d) Effective power monitoring:
In case of existing, the effective power monitor for drive monitoring must be mounted,
electrical connected and adjusted according to manufacturer's instructions.
e) Electrical connections/Motors:
Check that all connections are complete. Similarly check the direction of rotation of the
motors. If the direction of rotation does not correspond to that specified on the data plate you
should exchange the phases.
f) Safety devices:
All doors and inspection openings must be closed and tight fitting.
The covers are safety devices and should also be installed.
g) Bearings:
All bearings must be lubricated with the lubricants specified in the chapter Lubrication. If
lubricant dispenser are provided for lubrication these still must be activated at the
commissioning according to the manufacturer's instructions and the hoses (if existing) must
be filled up with lubricant, see chapter Lubrication and Documentation of suppliers.
h) Gear unit:
Check the oil level with gear motors and fill in or refill oil if necessary; pay attention to the
instructions of the gear manufacturer.
Check the gear venting, remove or replace the plug, bolt the bleeder screw.
Page 17
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Operating manual
6 Commissioning
6 Commissioning
6.1 Notes
In principle, we declare that the commissioning is forbid as long as until the cellular wheel
sluice or plant, in which this cellular wheel sluice is installed or of which this cellular wheel
sluice represents a component, corresponds as a whole to the regulations of guideline
89/392/EWG as well as to the corresponding, national right decree for the translation of the
guideline into national right and the corresponding declaration of conformity is exhibited.
In principle, the first initial commissioning of the cellular wheel sluice delivered by SMD
FRDERTECHNIK GmbH may be procedured only by the company SMD FRDERTECHNIK
GmbH, if this is not regulated differently by contract. All rights to claim under guarantee are
dropped by nonobservance.
SMD FRDERTECHNIK GmbH shall not be held liable for any damages arising from improper
commissioning by other personal!
For preparing of commissioning it is important that all checks have been carried out according to
chapter Checks at the end of installationat the end of the installation work.
Read chapter Safety before commissioning!
Ensure adequate illumination during commissioning so that any disturbances or faults that may occur
can be safely detected.
Before commissioning the cellular wheel sluice and its electrical equipment must be checked by a
qualified electrician in accordance with the regulations for installing electrical power installations
with rated voltages of up to 1000 V (DIN VDE 0100, VBG 4).
Commissioning is procedured in the following sequence:
1. Visual check
2. Trial run without material
3. Trial run with material
6.2 Visual check

The visual check comprises those items listed under "Checks at the end of installation" in chapter
Installation as well as a check for obvious defects.
Check:
the functioning of the electrical equipment.
the safety.
Only commission the cellular wheel sluice if
all safety devices and safety-related monitoring devices are present and operational.
it has been made sure that no foreign objects can get into the cellular wheel sluice during
commissioning without product.
Therefore, previously verify at the cellular wheel sluice that
this has been set up and connected as described,
all electrical installations have been implemented,
all foreign objects at, in and above the cellular wheel sluice (particularly in the filter element) have
been removed,
all safety and monitoring devices are present and operational,
nobody is in the dangerous area of the cellular wheel sluice,
all inspection openings are secured or closed,
all bearings and gears are provided with the required amount of oil and/or grease,
Page 18
Operating manual
6 Commissioning
If lubricant dispenser are provided for lubrication these still must be activated at the commissioning
according to the manufacturer's instructions and the hoses (if existing) must be filled up with
lubricant, see chapter Lubrication and Documentation of suppliers.
Remove all transport devices which might have been used on or in the cellular wheel sluice !
6.3 Trial run without material

First proceed a non-load running, that means the cellular wheel sluice operates without any material
and check the following:
Check the following functions of cellular wheel sluice:
Make sure that the direction of rotation of the motor and/or cellular wheel is correct!
Start the cellular wheel sluice without product first. The cellular wheel sluice can be damaged if it
is started in the wrong direction.
If the cellular wheel sluice is installed as a component of complete plant check the operability of
the electrical interlock.
Display of the speed monitoring and other monitoring devices if existing.
Running noise.
Ensure that all bearings run easily and smoothly, loud noises, sluggishness and excessive heating
are indications of an installation error or fault.
Check the gap between side wall and cellular wheel.
Check the gap at the sealing strips.
If lubricant dispenser are provided for lubrication these still must be activated at the
commissioning according to the manufacturer's instructions.
6.4 Trial run with material

After the checks at the end of installation have been repeated according to chapter Checks at the
end of installation, if necessary, a trail run with material can then be carried out.
Only commission the plant with the product when no faults occurred during the functional test
without product! For malfunctioning refer to the chapter Trouble shooting!
Start the cellular wheel sluice without product first. Gradually load the cellular wheel sluice then
up to its maximum conveying capacity with the respective product.
If existing, the presetting of effective power monitor and the overload point of the cellular wheel
sluice must be checked now. The setting of effective power monitor must be corrected to the real
existing process value of the under load operating cellular wheel sluice. The overload detection of
monitor must be setted and adjusted to the overload point of cellular wheel sluice to realize the
overload monitoring.
Note: Unless otherwise specified in the contract, the evaluation unit is not included in the SMD
scope of supply!
Check after approximately eight operating hours under full load:
the machine components for heating up,
the glands for leakage (leaked product),
all screw connections for a firm seat.
For malfunctioning refer to the chapter Trouble shooting.
The trial run is finished on completion of all of these checks.
Page 19
Operating manual
7 Operation
7 Operation
7.1 Normal operation
Normal operation is usually carried out automatically from the control desk. Ensure adequate
illumination of the overall system during operation so as to ensure a safe handling of any faults that
may arise. Pay attention to the instructions in chapter Maintenance!
Only start the cellular wheel sluice if:
all safety devices and safety-related monitoring devices are present and operational.
nobody is in the dangerous area of the cellular wheel sluice,
all inspection openings are secured or closed.
Operating informations:
The cellular wheel sluice may only be operated by the personnel having been instructed in this
respect.
Check the cellular wheel sluice for externally visible damages and defects at least once per shift!
Immediately inform the responsible person about any changes (also in the operating performance)
that have arisen!
In case of malfunctioning, immediately switch off and secure the cellular wheel sluice in this state.
Have any malfunctioning remedied at once!
When switching on and off, pay attention to the control displays if available!
Before switching on, make sure that nobody can be endangered by the starting cellular wheel
sluice!
In normal operation the cellular wheel sluice is operated with other machines or parts of the plant
from a control room.
The correct running of the cellular-wheel sluice can be monitored via the speed monitor.
The current consumption also indicates any changes of the operating state.
When starting the cellular wheel sluice, make sure that:
the direction of rotation of the cellular wheel is correct,
the plant on the discharge side starts first and then the product feed starts only afterwards.
When switching off the cellular wheel sluice, make sure that:
the product feed stops first,
the cellular-wheel sluice runs empty and then the plant on the discharge side is switched off last.
7.2 What to do in the event of faults

The local safety regulations apply in every case when operating the cellular wheel sluice
irrespective of the information and instructions below.
Make sure that the cellular wheel sluice is at a standstill as long as the trouble is remedied at the
cellular wheel sluice by the relevant personnel. Interlock electrically the cellular wheel sluice and
ensure against unintentionally switching on, see chapter 7.2.1 Emergency stop.
Have the trouble only remedied by personnel qualified and instructed in trouble-shooting.
Pay attention to any danger might arise from the trouble.
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Immediately stop the cellular wheel sluice if:

abnormal operating noises can be heard,
the cellular wheel sluice is overloaded.
7.2.1 Emergency stop
We urgently recommend a lockable local switch which prevents an accidental starting of the cellular
wheel sluice during repairs or faults. As for the rest, please refer to the pertinent accident prevention
regulations of the respective employer's liability insurance associations.
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Operating manual
7 Operation
7.2.2 Re-starting after a malfunction

Pay attention to the chapter Checks at the end of installation and chapter Commissioning!
7.2.3 Troubleshooting
Fault
Cause
Amount of discharged Amount of feeded material is

material is too little or
too much, overfilling /
no discharged material
blockage of ZRS
ZRS stops
No discharge of material
Blockage due to foreign
bodies.
No material feeding
No electrical voltage
Jammed bearing
Drive unit, motor or gear is
defective
Abnormal noise
development of ZRS
Motor, gear unit,
bearing or gland are
heated
No pulses from speed

monitoring
Foreign body/blockage in
ZRS
Gap of sealing strips is too
small
Incorrectly installed bearing,
lubricant failure
bearing defective
Drive unit, motor, gear, or
coupling defective
Worn gland packing
Proximity switch is defective
or adjusted incorrectly
ZRS stops
Pulse disc defective
ZRS is damaged
Blockage due to foreign
bodies
Material leakage, dust

development
Leaky glands
Remedy
Remedy by
Shut off the material

MP
feeding, discharge the ZRS,
switch on downstream
aggregates,
restart the discharged ZRS
with local control,
adapt the feeded amount of
material according to the
throughput
Guarantee a free discharge MP
flow of material
Remove any foreign bodies MP
Check material feeding
Check and restore electrical
connections/cables
Check bearing, replace if
necessary
See chapter
Documentation of
suppliers
See above remedy
MP
ET
Aligne sealing strips ,

repalce if necessary
Maintain the bearing
MP
See chapter
Documentation of
supplier
Renew gland packing
Check gap, correct the
switching gab
See above
Renew pulse disc
Check the scope of damage
and repair
Remove any foreign bodies
MP, ET
Tighten glands or renew

packing
Flange sealing is defective
Renew sealing
Covers or inspection openings Close covers or inspection
are not tight or not closed
opening, renew the sealing
MP
MP, ET
MP
MP
MP
ET
MP
MP
MP
MP
MP
MP
MP
ZRS = Cellular wheel sluice

ET = electricity specialist, MP = maintenance personnel
Page 21
Operating manual
7 Operation
7.3 Before a longer standstill period

If the cellular wheel sluice is not used for a period of around 2 months pay attention to the following
points:
Sensitive parts such as electric motors, gears, bearings, etc. must be protected against moisture,
heat, dust and impacts, possibly preserve.
Treat external parts according to the Documentation of suppliers.
Secure cellular wheel sluice against accidental starting.
7.4 After a longer standstill period

Remove protective coating against moisture, heat, dust and impacts of sensitive parts / Remove
preservative.
Replace any safety parts that may have been removed.
Carry out trial run without material.
Page 22
Operating manual
8 Maintenance
8 Maintenance
8.1 Notes for routine maintenance and inspection
Pay attention to the operating instructions chapter Safety during maintenance and inspection
work !
The set-up work and maintenance work (repairs and service work including cleaning) must be
carried out when the cellular wheel sluice is at a standstill. A lockable local switch should prevent
accidental restarting of the cellular wheel sluice. Procedure:
1. interrupting the energy supply
2. locking the main control devices
3. removing the key required for this
4. attaching a warning sign at the main switch.
Malfunctions due to inadequate or incorrect maintenance can lead to very high repair costs and
long downtimes for the cellular wheel sluice. Regular maintenance is thus indispensable.
The operational safety and service life of the cellular wheel sluice also depend, amongst others, on
correct maintenance.
Ensure adequate illumination during maintenance and inspection work !
Maintenance and inspection work may only be carried out by qualified personnel.
Do not use machine parts for climbing up !
Use the stepladders and working platforms intended for this purpose or other safe aids.
Thoroughly fasten and secure the individual parts and bigger structural components to the lifting
devices for replacement.
Only use suitable and technically perfect lifting devices and load suspension devices with
sufficient carrying capacity !
In case of electric welding, never conduct the welding current over sliding and roller bearings or
other moving connections or measuring devices in order to avoid damage to these parts!
Always directly connect the return cable to the part to be welded !
Retighten all screw connections having been loosened for maintenance and repair work!
After having finished maintenance and repair work, immediately mount all safety devices!
Carry out all adjusting, maintenance and inspection activities including the replacement of parts or
partial equipment prescribed in the operating instructions and keep to the schedule.
8.2 Routine maintenance

8.2.1 Care
Avoid any dirt accumulation at the cellular wheel sluice!
Clean the cellular wheel sluice and particularly all connections and screw connections from oil,
fuel or maintenance agents at the beginning of repair and maintenance work!
Do not use any aggressive cleaning agents. Use lint-free cleaning rags!
Before cleaning the cellular wheel sluice with water or steam jet (high-pressure cleaning) or other
cleaning agents, cover all openings in which no water/steam/cleaning agent may penetrate for
safety and/or functional reasons!
Electro-motors, speed monitors and other monitoring and/or safety devices are particularly at risk!
Remove the coverings completely after cleaning!
Check all machine parts for damages after cleaning!
Remedy all noticed defects at once!
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Operating manual
8 Maintenance
8.2.2 Routine maintenance and inspeciton list

The maintenance contents the following items of the maintenance and inspection list:
Jobs to be executed ( if the component is existing )
Visual inspection of the cellular wheel sluice and current connection
Check the sealing strips and lateral disks for wear (for hazardous location
use the check might be necessary daily)
Check the cellular wheel sluice for smoothness of running, replace
bearings in case of trouble
Check the chain tension and adjust if necessary
Check the star coupler (elastic intermediate pieces) for wear and replace if
necessary
Check the screw connections at the cellular-wheel sluice for firm seat and
retighten if necessary
Check the gland packing for tightness, retighten or replace rubber sealing
if necessary
Repalce the gland packing
Check the rubber sealing for tightness, retighten or replace rubber sealing
if necessary
Replace the rubber sealing
Disassemble and clean the cellular wheel sluice
Check the boundary disk for wear
Check the housing and/or wear bush for wear
daily
every 3
months
yearly
X
(X)
X
X
X
X
X
X
X
X
X
X
X
8.3 Repairs
The repair of the cellular wheel sluice presupposes specialized knowledge and experience and
only may be executed by repair specialist staff! Depending on the complexity of the cellular
wheel sluice the specialist staff of SMD FRDERTECHNIK GmbH should be engaged for
repairs.
The SMD FRDERTECHNIK GmbH does not assume any liability for damages because of an
improper repair by other staff!
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Pay attention to the safety instructions in these operating instructions!

Use only original SMD spare parts for repairs.
If screws or bolts become unusable after dismantling they must be replaced in the same quality
(strength, material) and design.
The cellular wheel sluice must be secured against accidental starting before any maintenance
and repair work is started!
Work on the electrical installation (connecting/disconnecting) or the electro-motor may only be
carried out by a qualified electrician.
Before starting to work on the cellular wheel sluice, inform the person responsible for safety!
Danger to life!
Connecting and disconnecting only by electrician!
Danger of injury!
Secure the SMD cellular wheel sluice against unintentional operation!
Only dismount the inspection cover when the product feed shaft is empty!
Never reach into the open SMD cellular wheel sluice, Danger of mutilation!
In case any hot or harmful substances are conveyed, provide for suitable protection such as
protective clothing, safety glasses, gloves, breathing equipment. Provide for a collection container.
Before working on the cellular wheel sluice, make sure that the above product container is
emergency blocked!
Empty and switch off the plant before starting extensive work on the SMD cellular wheel sluice!
Prevent the product from running by closing any stop valves or other suitable means!
Page 24
!
Caution
Operating manual
8 Maintenance
8.3.1 Drive unit

For the assembly or dismantling descriptions of the drive elements like couplings, please refer to the
instructions given by the manufacturer, see chapter Documentation of suppliers.
8.3.2 Chain drive

If the cellular wheel sluice is driven by chain drive, then the following instrcuctions have to be taken
into account for change the chain:
Always disconnect the motor before replacing the chain.
In order to replace the chain, remove the protection box, loosen the adjusting screws at the
pivoting motor base, release the chain. Open the chain joint and remove the chain.
Put on a new chain with the same chain pitch and dimensions, and lock the chain with a new chain
joint. Tensioning the chain by adjusting the tensioning screws of the pivoting motor base.
Caution! Damage to material! Do not over-tension the chain. This will increase wear of the chain
and the chain wheels. The bearings at the cellular wheel sluice and the gear will be unnecessarily
strained. Check the alignment of the chain wheels with a ruler, fix the tensioning screws with a
lock nut.
8.3.3 Gland packing
If the cellular wheel sluice is equipped with gland packings, then the following instrcuctions have to
be taken into account:
Loosen the clamping frame and push it backwards.
Remove the gland packing.
Clean the seat of packing from the packing remains.
Insert a new set of sealing rings, generously stagger the joints of the rings.
Clean the clamping frame and put it on the packing, evenly tighten the screws.
Retighten if necessary after commissioning.
8.3.4 Replacing rubber sealing

If the cellular wheel sluice is equipped with rubber sealings, then the following instrcuctions have to
be taken into account:
Outer side:
Dismount drive unit and speed monitoring.
Remove adjusting ring of the rubber sealing.
Replace rubber sealing.
Mount in a reverse way.
Inner side
Dismount drive unit and speed monitoring.
Dismount the bearings incl. their housing
from the side wall.
Replace rubber sealing
Mount in a reverse way
8.3.5 Adjustment of the gap

Loose the screws and adjust the sealing strip. The gap or clearance between the housing / wear bush
and the sealing strips should be 1 - 2mm.
8.3.6 Disposal
Carry out the disposal and disassembly of the cellular wheel sluice according to the relevant
statutory regulations in force. Discharge the cellular wheel sluice completely, remove dirt
accumulations and disassemble the cellular wheel sluice into its structural components.
If possible, dispose of all machine parts separately based on their material, for example
metal parts as steel scrap
non-ferrous metal at the metal recycling plant
plastics and compounds at the plastics recycling plant
Collect waste oils, greases and other harmful substances in suitable containers and have them
disposed of professionally according to the statutory regulations.
Page 25
Operating manual
8 Maintenance
8.4 Lubrication
Correct lubrication at all times is a basic precondition for a trouble-free operation and long service
life of the cellular wheel sluice. The following instructions describe all points of lubrication,
lubricating intervals, lubricants and the type of lubrication.
8.4.1 Correct lubrication
The rolling bearings must have an adequate supply of grease. They are filled with grease by SMD
FRDERTECHNIK GmbH according to the specified amount for initial filling which is declared by
bearing manufacturer. At the same time the grease filling serves as corrosion protection for the
bearings.
8.4.2 Grease lubricant
The used and approved grease lubricants can be gathered from the enclosed list of lubricating points.
The list of lubricating points indicates the essential grease characteristic values.
8.4.3 Mixing lubricating greases
Lubricating greases with different soap bases, in particular lithium and soda soap greases, may not
be mixed together. Drop point, milling stability and working temperature of such mixtures normally
drop considerably. Thus, if a different type of grease has to be used at one point the bearing should
be cleaned beforehand to avoid damage to the bearing.
8.4.4 Lubrication of the drive unit
All motors and gears are provided with the appropriate amount of lubricant as standard. The used
and approved oil lubricants can be gathered from the enclosed list of lubricating points.
We refer to the special details and instruction from manufacturer for the roller bearings inside the
gears like shaft bearing and electrical motors, see the chapter Documentation of suppliers.
8.4.5 Lubricant dispensers
If lubricant dispenser are provided for lubrication these still must be activated at the commissioning
according to the manufacturer's instructions. The dispensing time is described in lubrication list and
the dispensing quantity per day must be adjusted at the lubricant dispensers according to the
manufacturer`s instructions, see chapter Documentation of suppliers.
Before connecting the lubricant dispensers with the hose, the hoses have to filled up with lubricant if
this have not done in workshop and the hoses are existing.
The lubricant filled up in hose must be identical with the lubricant of dispensers, see chapter 8.4.3.
8.4.6 Rolling bearing
All greased bearings are filled with grease by SMD FRDERTECHNIK GmbH according to the
specified amount for initial filling which is declared by bearing manufacturer. The bearings should
be cleaned and refilled every year.
Rolling bearings should be washed out with petroleum spirit, benzene or trichlorethylene, dried and
filled with suitable grease.
Pay attention to the following points:
a) Treatment instructions for rolling bearings
The correct choice of bearings, careful storage, professional installation and correct maintenance are
a precondition for the trouble-free running of rolling bearings.
b) Installation
Pay attention to chapter 8.3 when installing roller bearings. Before installation the bearings should
be stored in a dry room to prevent damage from rust. The relative atmospheric humidity in the
storeroom with small temperature fluctuations may not exceed 55%.
Only remove from the original packaging shortly before installation. Protect against dust, sand, file
dust and moisture. Do not lay on workbenches or the floor when open. Wash out dirty bearings in
pure petroleum and then re-grease. Do not blow through with compressed air. The bearings doe not
have to be washed out before installation sine only small amounts of the anticorrosive stick to the
bearing. Clean all mounting parts thoroughly. Check the seats on the shaft and in the housing for
dimensional accuracy. Provide suitable tools.
When installing a bearing with a tapered bore make sure that the radial gap is not excessively
reduced. Nuts and bolts which secure bearing rings must always be secured.
Page 26
Operating manual
8 Maintenance
c) Commissioning
Lubricate the bearings with the specified amount declared by bearing manufacturer during
installation if possible, though at the latest before the trial run.
During commissioning make sure that the bearing runs smoothly and quietly. Loud noises,
sluggishness and excessive heating are indications of an installation error or fault (inadequate
lubrication, internal tension, dirt, foreign body, etc.). Impurities cause uneven running. In such cases
remove the bearing immediately; wash out dirty bearings, fill with new lubricant or remedy the
installation error.
Damaged bearings should be returned to the manufacturer with a description of the problem. They
may not be washed out beforehand.
d) Relubricating
From time to time the lubricant has to be checked for his quality and has to be replaced if necessary.
Bearings must be relubricated if service life of the used grease is lower than the expected emperic
service life. The relubricating should always be procedured as long as a reliable lubrication is still
ensured by the available grease. For normally stressed bearings which do not run with very high
rotational speeds, are not exposed to strong external heating or pollution the service life of the used
grease will be increased.
Please contact the rolling bearing manufacturer should you require lubricants for the rolling
bearings, and quote the bearing size, temperature, speed and other operating conditions.
e) Removal
The practical sequence for removal should be determined beforehand on the basis of drawings. Do
not hit bearings.
8.4.7 Disposal
The lubricants originating from the gear and the bearings or stuffing box packing are special refuse.
At any rate, they have to be disposed of according to the local statutory regulations in force!
8.4.8 Lubrication instructions

A. General
The purpose of these lubrication instructions is to provide documents which offer detailed and
specific information on the lubrication of every slide valve.
B. Extent
The slide valves which require any type of lubrication are shown here. All points of lubrication
including subordinate ones are listed.
C. Lubrication chart
All lubricating points or their exact position details are shown on the enclosed lubrication chart. The
lubricating points are marked with a reference line and positioned with a serial number from 1 to n.
Identical points of lubrication may be summarised under one number.
D. List of lubricating points
The approved lubricants and the type of lubrication are specified in the list of lubricating points.
Others as the listed lubricants may not be used.
Page 27
Operating manual
8 Maintenance
8.4.9 Lubrication chart

The approved lubricants and the type of lubrication are specified in the list of lubricating points.
Others as the listed lubricants may not be used.
Example of a cellular wheel sluice
1 = Gear of drive
2 = Flange bearing
8.4.10 List of lubricating points

Lubricating
point
Item 1
Gear of drive
Item 2
Flange bearing
Lubrication interval
Lubricant
The special instruction of the gear motor Gear oil:

see specification sheet
manufacturer are to be considered!
See Documentation of suppliers!
Amount of oil:
Oil level check after the first day,
afterwards monthly.
Recommendated product:
Oil change after 10.000h operation
and/or 2 years
A relubrication of the bearing is usually
unnecessary, if
the loads and rotation speed are
moderately
no vibration are existed
the operation temperature is not
exceeded
Bearing grease according to

DIN 51825 - KP2K-20
with the
NLGI-classification 2 acc. to DIN 51818
Amount of lubricant for flange bearing:
To relubricate the flange bearings the grease
has to be slowly pressed in by rotating
bearing, until fresh grease is emerged out of
the seal. Excessive pressure is to be avoided,
because otherwise the seal can be damaged!
In the case, that the bearings

are exposed to extremely moisture
or stronger contamination
have to take up high loads
Recommended product:
run longer with high numbers of
ESSO
Beacon EP2
revolutions and/or run over the
operation temperature
the bearings are to be relubricated to use
the full bearing life and to prevent
damages
Page 28
Operating manual
9 Spare parts stocking / Customer service

9.1 Spare parts stocking
A stock of most important spare and wearing parts at the place of installation is an important
precondition for the constant function and readiness for operation of the cellular wheel sluice.
Please refer to the spare parts list when ordering spare parts.
The spare parts drawings listed in the spare parts list serve for your further information.
We can only assume a warranty for original spare parts supplied by us!
Attention !
We would like to expressly emphasize that original spare parts and accessories which are not
supplied by us have not been check and approved by us either. The installation and/or use of such
products may thus under certain circumstances have a negative effect on the structural features of the
SMD cellular wheel sluice and thus impair the active/passive safety. Any liability and warranty on
the part of SMD FRDERTECHNIK GmbH for damages caused by the use of non-original spare
parts and accessories is excluded.
Please note that special manufacturing and delivery specifications often exist for own and external
parts and that we always offer you spare parts according to the state-of-the-art and in line with the
latest statutory regulations.
9.2 Spare parts sales / Customer service address

Our address for spare parts sales / customer service:
Abteilung Ersatzteilvertrieb / Kundendienst
Robert-Bosch-Str. 7
Tel. 0049 (0)2195-931910
Fax. 0049 (0)2195-931909
9.3 List of spare parts / spare part drawing
Page 29
Operating manual
- blank page -
Page 30
Ersatz- und Verschleiteilliste

LIST OF SPARE AND WEAR PARTS
Zellenradschleusen 630x630x800 mit Buchse/
cellular wheel sluice 630x630x800 with inner bush
Kunde / Client:
Gebr. Pfeiffer AG
Maschine / Machine:
Projekt / Project:
Hasanoglan
Ersatzteil- Zeichnungs-Nr.: / Drawing No.:
SMD Nr. / SMD No.:
KM07/3344-0101
KKS-Nr.
KKS-No.
TAG-No.
Bezeichnung, Einsatzort bzw. Verwendung, Fabrikat, Typ

description, location, implementation, product, typ
Gehuse / housing
Innenbuchse / Inner bush**
Stopfbuchsenpackung / packing for gland 8x8 ; 0,95 m
Flanschlager / flange bearing UCFC 216
Drehzahlwchter / speed monitor IFM DI0001
Getriebemotor / gear motor RF97 DVE100L4
Brechleiste Rotor / crushing rail of rotor
Kupplung / Coupling HFB EK 250A
elastisches Packet fr Kupplung / Flexible Coupling Elements
Zellenradrotor / Cellular Rotor
Teile-Nr./
Zchn.Nr./Ident-Nr.
Pos.-Nr.
drawing-no/
part-no./item identif.-no.
1
1
2
3
4
5
6
7
8
9
65-00-00-00-0017-ET
Verschleiteil
wear part
"W"
65-05-00-00-0001
65-50-00-10-0001
65-40-00-00-0001/3
65-15-00-00-0001/9
65-25-00-00-0001/4
65-05-00-00-0001/6
65-10-00-10-0003
65-05-00-00-0001/7
Stckzahl
Lieferzeit
Ersatzteil
eingebaut
(in Wochen)
spare part
number of
delivery time
"S"
items
(in weeks)
installed
W
W
W
W
S
S
W
S
S
S
65-10-00-00-0004
Stckzahl
angeboten
number of
items
offered
Einzelpreis Gesamtpreis
Bemerkung
(EUR)
(EUR)
remarks
piece price total price
1
1
2
1
1
1
8
1
1
1
**nurinVerbindungmitPos.1/onlyinconjunctionwithitem1
Datum / Date: 17.08.2007
Revision / Revision: 0
Seite / Page 1 von / of 1
Aussteller / Editor: Alberts
65-00-00-00-0017-ET_Zellenradschleuse 630 x 630 x 800 geschr mit Buchse und Wellenschutzrohr.xls
Operating manual
- blank page -
Operating manual
- blank page -
Operating manual
10 Layout drawing
10 Layout drawing
Page 31
Operating manual
10 Layout drawing
- blank page -
Page 32
Operating manual
- blank page -
Operating manual
11.1 Speed monitor
Page 33
Operating manual
- blank page -
Page 34
Evaluation systems, power supplies
DI0001
Compact speed monitor M30
DIA2010-ZROA/5-300 I/MIN
Cable
Sensing range 10mm [f]
flush mountable
Application
Electrical design
Output
Setting range [pulses/min.]
Nominal voltage [V]
Current rating (continuous) [mA]
Current rating (peak) [mA]
Minimum load current [mA]
simple evaluation of rotating and linear movement with regard to

underspeed; blocking
AC/DC
normally open
5...300
20...250 AC/DC
350 AC (...50 C) / 250 AC (...80 C) / 100 DC
2200
>6
Voltage drop [V]
< 6.5
Leakage current [mA]
< 1.5
Damping frequency (max.)

[pulses/min]
Correction factors
1500
mild steel = 1 / stainless steel approx. 0.7 / brass approx. 0.5 / Al approx. 0.4 /
Cu approx. 0.3
Reverse polarity/overload
protection
Hysteresis [% / Sr]
10
Short-circuit protection
Start-up delay [s]

Switching function
Adjustment of the switch point
Operating temperature [C]
Protection
Housing material
Function display
Switching status LED
Connection
Wiring
12
output is switched during the start-up delay and if (f actual) is greater than (f
preset)
multiturn potentiometer
-25...80
IP 67
brass special coated; PBT (Pocan)
green
PVC cable / 2 m; 2 x 0.5 mm
Core colours
BN brown
BU blue
ifm electronic gmbh Teichstrae 4 45127 Essen
We reserve the right to make technical alterations without prior notice. GB DI0001 23.01.2006
Operating manual
- blank page -
Montageanleitung
Installation Instructions
Notice de Montage
R
Drehzahlwchter
Compact
Compact Speed Monitor
Contrleur de vitesse
de rotation compact
Sachnr.: 701092/02
03/2004
DIA
Bestimmungsgeme Verwendung
Der Drehzahlwchter Compact erfat berhrungslos, ob eine MindestDrehzahl eingehalten wird, und meldet die Unterschreitung durch ein
Schaltsignal.
Nennschaltabstand (Sn) 10mm; Solldrehzahl einstellbar, siehe Typaufkleber.
Montage
Befestigen Sie das Gert mit Hilfe
einer Montagehalterung. Sichern
Sie es mit den mitgelieferten Muttern gegen Loslsen.
Bndig einbaubar.
Justierung
LEDs
Grne LED:
Ausgang durchgeschaltet
(Istdrehzahl > Solldrehzahl)
Gelbe LED
(optional bei 2-Leiter AC/DC):
Sensor bedmpft
Mehrgangpotentiometer
Sollwert
Halten Sie die zu berwachende Drehzahl in der Anlage konstant. Die

gelbe LED mu blinken (Bedmpfungsimpulse werden erfat). Nach der
Anlaufberbrckungszeit* (A siehe Typaufkleber) kann mit dem
Abgleich nach A oder B begonnen werden:
Fr optimale Funktion sollten folgende Mae eingehalten werden:
Grne LED leuchtet
Grne LED leuchtet nicht
Poti nach rechts drehen, bis die LED

verlischt.
Poti langsam nach links drehen, bis

die LED aufleuchtet.
Poti langsam wieder nach links

drehen, bis die LED aufleuchtet.
E
B
D
A
B
C
mindestens Durchmesser
des Drehzahlwchters
mindestens 2 x A
1/2 x S n
Betrieb
C
A
Auslieferungszustand: Poti in Rechtsanschlag.
Elektrischer Anschlu
Schalten Sie die Anlage spannungsfrei. Schlieen Sie das Gert
nach den Angaben auf dem Typenschild an.
Prfen Sie, ob das Gert sicher funktioniert.

Der Betrieb ist wartungsfrei. Fr einwandfreies Funktionieren ist zu
beachten:
Die aktive Flche und der Freiraum sollten von metallischen Ablagerungen und Fremdkrpern freigehalten werden; insbesondere bei
Montage mit aktiver Flche nach oben.
Gerte mit hoher Nahfeldstrke (z. B. Sprechfunkgerte) nicht in
unmittelbarer Nhe des Drehzahlwchters betreiben.
*) Die Anlaufberbrckung (A) unterdrckt eine Fehlermeldung, solange die Anlage anluft
und die Nenndrehzahl noch nicht erreicht ist.
Sie ist nach Anlegen der Betriebsspannung nur einmal wirksam. Wird der Antrieb hufig
ein- und ausgeschaltet, sollte die Spannungsversorgung von Antrieb und DIA gekoppelt
werden. Dadurch ist die Anlaufberbrckung bei jedem Anlaufen der Anlage wirksam.
Function and features
Adjustment
The speed monitor compact detects without contact whether a minimum speed is reached and signals underspeed by means of a switching
signal. Nominal sensing range (Sn) 10 mm. Preset speed adjustable, see
type label.
LEDs
Green LED: output switched
(actual speed > preset speed)
Yellow LED
(optional for 2-wire AC / DC):
sensor damped
Installation
Mounting by means of a mounting device. Secure by means of the
nuts provided so that it cannot
work loose. Flush installation.
multiturn
potentiometer
preset value
Keep the speed to be monitored in the plant on a constant level. The

yellow LED must blink (damping pulses are detected). When the
start-up delay* (A see type label) has elapsed, the adjustment
according to A or B can be started:
For optimum functioning the following dimensions should be adhered

to:
Green LEDis lit
Green LED is not lit
Turn the pot clockwise until the LED

goes off.
Turn the pot slowly anticlockwise

until the LED is lit.
Turn the pot slowly anticlockwise

until the LED is lit.
E
B
D
A
B
C
at least the diameter of

the speed monitor
at least 2 x A
1/2 x Sn
Operation
C
A
Unit delivered with pot in right stop position.
Electrical connection
Disconnect power before connecting the speed monitor.
Connect according to the indications on the type label.
Check the safe functioning of the speed monitor.

The operation of the speed monitor is maintenance-free. For perfect
functioning make sure that:
the active face and the open space are kept free of metal deposits and
foreign bodies, particularly for installation with the active face facing
upwards;
units with high field intensity (e.g. walkie-talkies) are not used at close
range to the speed monitor.
*) The start-up delay (A) suppresses an error signal as long as the machine is in the process
of starting and has not yet reached its nominal speed.
After application of the operating voltage the start-up delay is active only once. If the drive
is often turned on and off, couple the supply voltage of the drive and the monitor. By doing
so, the start-up delay is active every time the drive is turned on.
Rglage
Emploi prescrit par les usages

Le contrleur de vitesse de rotation compact dtecte sans contact si une
vitesse de rotation minimum est atteinte et signale la sous-vitesse par
un signal de commutation. Portee nominale (Sn) 10mm. Valeur de
consigne rglable, voir ltiquette.
LEDs
LED verte: sortie commute
(vitesse de rotation actuelle >
vitesse de rotation
de consigne)
LED jaune
(en option pour des
appareils 2 fils AC / DC):
came dtecte
Montage
Montage laide dune flasque de
fixation. Utiliser les crous fournis
avec le DIA pour une fixation
optimale. Montage encastr
possible.
Lors du rglage maintenir stable la vitesse de rotation. La LED jaune doit

clignoter (les impulsions transmises par les cames sont dtectes).
Quand la temporisation de dmarrage est coule*(A voir ltiquette)
le rglage selon A ou B peut tre commenc:
A
Afin de garantir un fonctionnement optimal, les dimensions suivantes devraient tre respectes:
E
B
D
LED verte est allume

Tourner le potentiomtre droite
jusqu ce que la LED soit teinte.
LED verte est teinte

Tourner le potentiomtre lentement
gauche jusqu ce que la LED est
allume.
Tourner le potentiomtre lentement

gauche jusqu ce que la LED est
allume.
A
B
C
au moins le diamtre du
contrleur de vitesse de
rotation
au moins 2 x A
1/2 x S n
C
A
potentiomtre
multitour
valeur de consigne
Raccordement lectrique
Mettre linstallation hors tension avant le raccordement du contrleur de vitesse de rotation.
Raccordement selon les indications de ltiquette.
Appareil livr rgl en bute droite.
Fonctionnement
Vrifier le bon fonctionnement du contrleur de vitesse de rotation.
Pour un bon fonctionnement il faut respecter les indications suivantes:
La face active et lespace libre doivent tre dgags de toute prsence
de dpts et de corps trangers mtalliques, notamment en cas de
montage avec la face active vers le haut.
Ne pas faire fonctionner des appareils champ de grande intensit
(par exemple talkie-walkies) proximit immdiate du contrleur de
vitesse de rotation.
*) La temporisation de dmarrage (A) supprime les alas de fonctionnement quand
linstallation est en train de dmarrer et na pas encore atteint sa vitesse nominale.
Aprs la mise sous tension la temporisation de dmarrage nest effective quune seule fois.
Lorsque le moteur est souvent mis en marche et arrt, coupler la tension dalimentation
du moteur et du contleur. Ainsi la temporisation de dmarrage est effective chaque fois
que le moteur est mis en marche.
Operating manual
11.2 Drive motor
Page 35
Operating manual
- blank page -
Page 36
Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services
Gear Units, R..7, F..7, K..7, S..7 Series,

SPIROPLAN W
Edition 05/2004
11226811 / EN
A6.B01
Operating Instructions
SEW-EURODRIVE Driving the world
Contents
Important Notes................................................................................................. 4
Safety Notes ...................................................................................................... 6
Gear Unit Structure ........................................................................................... 9

3.1 Basic structure of helical gear units .......................................................... 9
3.2 Basicstructure of parallel shaft helical gear units.................................... 10
3.3 Basic structure of helical-bevel gear units .............................................. 11
3.4 Basic structure of helical-worm gear units .............................................. 12
3.5 Basic structure of SPIROPLAN gear units ............................................ 13
3.6 Nameplate, unit designation ................................................................... 14
Mechanical Installation................................................................................... 15
4.1 Required tools / aids ............................................................................... 15
4.2 Prerequisites for assembly...................................................................... 15
4.3 Installing the gear unit............................................................................. 16
4.4 Gear unit with solid shaft......................................................................... 19
4.5 Torque arms for mounted gear units....................................................... 21
4.6 Mounted gear unit with keyway or splined hollow shaft .......................... 23
4.7 Mounted gear units with shrink disc........................................................ 27
4.8 Mounted gear units with TorqLOC ........................................................ 30
4.9 AM adapter coupling ............................................................................... 36
4.10 AQ adapter coupling ............................................................................... 38
4.11 AD input shaft assembly ......................................................................... 40
Startup.............................................................................................................. 44
5.1 Startup of helical-worm and SPIROPLAN W gear units........................ 44
5.2 Startup of helical, parallel shaft helical and helical-bevel gear units....... 44
Inspection and Maintenance .......................................................................... 45

6.1 Inspection and maintenance intervals..................................................... 45
6.2 Lubricant change intervals ...................................................................... 45
6.3 Inspection and maintenance of the gear unit .......................................... 46
6.4 Inspection / maintenance of AM / AQA adapters .................................... 47
6.5 Inspection / maintenance of AD adapters ............................................... 47
Malfunctions .................................................................................................... 48
7.1 Gear unit malfunctions ............................................................................ 48
7.2 AM / AQA / AL adapter malfunctions ...................................................... 48
7.3 AD input shaft assembly malfunctions .................................................... 49
Mounting Positions......................................................................................... 50
8.1 General information on mounting positions ............................................ 50
8.2 Key to the mounting position sheets ....................................................... 51
8.3 Mounting positions for R helical gearmotors........................................... 52
8.4 Mounting positions of RX helical gearmotors.......................................... 55
8.5 Mounting positions for parallel shaft helical gearmotors ......................... 57
8.6 Mounting positions for helical-bevel gearmotors..................................... 60
8.7 Mounting positions for helical-worm gearmotors .................................... 65
8.8 Mounting positions for SPIROPLAN W gearmotors.............................. 71
Lubricants........................................................................................................ 74
9.1 Lubricant table ........................................................................................ 74
9.2 Lubricant fill quantities ............................................................................ 77
10
Appendix.......................................................................................................... 82
10.1 Index of changes..................................................................................... 82
11
Index................................................................................................................. 83
Operating Instructions Gear Unit, R..7, F..7, K..7, S..7 Series, SPIROPLAN W
Important Notes
1
1
Important Notes
Safety and
warning
instructions
Operating instructions
Always follow the safety and warning instructions in this publication!
Electrical hazard
Possible consequences: Severe or fatal injuries.
Hazard
Hazardous situation
Possible consequences: Slight or minor injuries.
Harmful situation
Possible consequences: Damage to the drive and the environment.
Tips and useful information.
You must adhere to the operating instructions to ensure:
Trouble-free operation
Fulfillment of any rights to claim under guarantee
Consequently, read the operating instructions before you start working with the gear
unit!
The operating instructions contain important information about servicing. Therefore,
keep the operating instructions close to the gear unit.
Adjust the lubricant fill volume and position of the breather valve accordingly in the
event of a change of mounting position (see Sec. "Lubricants" and "Mounting
Positions").
Follow the instructions in Sec. "Mechanical installation" / "Installing the gear unit"!
Important Notes
Waste disposal
Please follow the latest instructions: Dispose of the following materials in accordance
with the regulations in force:
Steel scrap:
Housing parts
Gears
Shafts
Anti-friction bearing
Gray-cast iron (if there is no special collection)
Parts of the worm gears are made of non-ferrous metals. Dispose of the worm gears
as appropriate.
Collect waste oil and dispose of it correctly.
Safety Notes
2
2
Safety Notes
Preface
The following safety notes are primarily concerned with the use of gear units. If using
gearmotors, please also refer to the safety notes for motors in the relevant operating
instructions.
Please also consider the supplementary safety notes in the individual sections of
these operating instructions.
General
information
During and after operation, gearmotors, gear units and motors have:
Live parts
Moving parts
Hot surfaces (may be the case)
Only qualified personnel may carry out the following work:
Transportation
Putting into storage
Installation / assembly
Connection
Startup
Maintenance
Servicing
The following information and documents must be observed during these processes:
Relevant operating instructions and wiring diagrams
Warning and safety signs on the gear unit / gearmotor
System-specific regulations and requirements
National / regional regulations governing safety and the prevention of accidents
Serious injuries and property damage may result from:
Designated use
Improper use
Incorrect installation or operation
Unauthorized removal of necessary protection covers or the housing
Gearmotors / gear units from SEW are intended for industrial systems. They correspond
to the applicable standards and regulations.
Technical data and information about the permitted conditions can be found on the
nameplate and in the documentation.
It is essential that you follow all the instructions!
Safety Notes
Transportation
Inspect the shipment for any damage that may have occurred in transit as soon
as you receive the delivery. Inform the shipping company immediately. It may be
that you are not permitted to startup the drive due to the damage.
Tighten installed eyebolts. The eyebolts are only designed for the weight of the
gearmotor / gear unit. Do not attach any additional loads.
The installed lifting eyebolts comply with DIN 580. The loads and regulations specified
in this standard must always be observed. If two eyebolts are available, use both of them
for transport. In this case, the tension force vector of the slings must not exceed a 45
angle in accordance with DIN 580.
Use suitable, sufficiently rated handling equipment if necessary. Remove any
transportation fixtures prior to startup.
Extended storage of gear units
Gear units of the "extended storage" type have:
An oil fill suitable for the mounting position so the unit is ready to run (mineral oil CLP
and synthetic oil CLP HC). You should still check the oil level before startup (see Sec.
"Inspection / Maintenance" / "Inspection and maintenance of the gear unit").
A higher oil level in some cases (synthetic oil CLP PG / food grade oil). Correct the
oil level before startup (see Sec. "Inspection / Maintenance" / "Inspection and
maintenance of the gear unit").
Comply with the storage conditions specified in the following table for extended storage:
Climate zone
Temperate
(Europe, USA,
Canada, China
and Russia,
excluding tropical zones)
Tropical (Asia,
Africa, Central
and South America, Australia,
New Zealand
excluding temperate zones)
Packaging1)
Storage location
Storage time
Packed in containers, with

desiccant and moisture
indicator sealed in the plastic wrap.
With roof, protected against rain and snow, no

shock loads.
Up to three years with regular

checks on the packaging and
moisture indicator (relative
atmospheric humidity
< 50 %).
Open
With roof, enclosed at constant temperature and

atmospheric humidity (5 C < < 60 C, < 50 %
relative atmospheric humidity).
No sudden temperature fluctuations and controlled ventilation with filter (free from dirt and
dust). No aggressive vapors and no shock loads.
Two years or more given regular inspections. Check for

cleanliness and mechanical
damage as part of the inspection. Check corrosion
protection.
Packed in containers, with

desiccant and moisture
indicator sealed in the plastic wrap.
Protected against insect
damage and mildew by
chemical treatment.
With roof, protected against rain, no shock loads.
Up to three years with regular

checks on the packaging and
moisture indicator (relative
atmospheric humidity
< 50 %).
Open
With roof, enclosed at constant temperature and

atmospheric humidity (5 C < < 60 C, < 50 %
relative atmospheric humidity).
No sudden temperature fluctuations and controlled ventilation with filter (free from dirt and
dust). No aggressive vapors and no shock loads.
Protection against insect damage.
Two years or more given regular inspections. Check for

cleanliness and mechanical
damage as part of the inspection. Check corrosion
protection.
1) Packaging must be performed by an experienced company using the packaging materials that have been expressly specified for the
particular application.
Safety Notes
Installation /
assembly
Observe the instructions in the sections "Installation" and "Assembly/Removal"!
Startup /
operation
Check that the direction of rotation is correct in decoupled status. Listen out for unusual
grinding noises as the shaft rotates.
Secure the shaft keys for test mode without drive components. Do not render monitoring
and protection equipment inoperative even for test mode.
Switch off the gearmotor if in doubt whenever changes occur in relation to normal
operation (e.g. increased temperature, noise, vibration). Determine the cause; contact
SEW-EURODRIVE if necessary.
Inspection /
maintenance
Follow the instructions in the section "Inspection and Maintenance"!
Gear Unit Structure

Basic structure of helical gear units
Gear Unit Structure

The following figures are block diagrams. Their purpose is only to make it easier to
assign components to the spare parts lists. Discrepancies may occur depending on the
gear unit size and version!
3.1
Basic structure of helical gear units
03438AXX
Figure 1: Basic structure of helical gear units
Key
1
Pinion
19 Key
42
507
Shim ring
Gear
20 Breather valve
43
Key
508
Shim ring
Pinion shaft
22 Gearcase
45
515
Shim ring
Gear
24 Lifting eyebolt
47
Circlip
516
Shim ring
Pinion shaft
25 Anti-friction bearing
59
Screw plug
517
Shim ring
Gear
88
Circlip
521
Shim ring
Output shaft
31 Key
100
Gearcase cover
522
Shim ring
Key
32 Spacer
101
Hex head bolt
523
Shim ring
Oil seal
102
Gasket
131
Closing cap
12 Circlip
39 Circlip
181
Closing cap
17 Spacer
41 Circlip
506
Shim ring
Gear Unit Structure

Basicstructure of parallel shaft helical gear units
3
3.2
Basicstructure of parallel shaft helical gear units

2
181
43
515
516 42
517
41
20
45
22
59
1
161
30
4
32
59
31
131
506
507 39
508
37
183
165
160
19
91
92
93
94
102
521 88
25 522
523
100
101
7
59
17
81
9 11
14
16
05676AXX
Figure 2: Basic structure of parallel shaft helical gear units
Key
1
Pinion
22
Gearcase
91
Circlip
506 Shim ring
Gear
25
92
Washer
507 Shim ring
Pinion shaft
30
93
Lock washer
508 Shim ring
Gear
31
Key
94
Hex head bolt
515 Shim ring
Pinion shaft
32
Spacer
100 Gearcase cover
Gear
37
101 Hex head bolt
517 Shim ring
Hollow shaft
39
Circlip
102 Gasket
521 Shim ring
Oil seal
10
516 Shim ring
41
Circlip
131 Closing cap
522 Shim ring
42
160 Closing plug
523 Shim ring
161 Closing cap
14 Hex head bolt
43
Key
16 Output flange
45
165 Closing plug
17 Spacer
59
Screw plug
181 Closing cap

183 Oil seal
19 Key
81
O-ring
20 Breather valve
88
Circlip
Gear Unit Structure

Basic structure of helical-bevel gear units
3.3
Basic structure of helical-bevel gear units

100
102
536
3 43 537
538
20
533
534
535
22
45
59
2
114
113
101
42
59
119
(116)
523
89 59
522 88
521
19
8
84
25
1
59
12
11
83
59
17
161
132
133
542
30 543
544
135
31
5
131
39
37
506
507
137 508
05675AXX
Figure 3: Basic structure of helical-bevel gear units
Key
1
Pinion
102 Adhesive and sealing

compound
522 Shim ring
Gear
113 Slotted round nut
523 Shim ring
Pinion shaft
31 Key
114 Multi-tang washer
533 Shim ring
Gear
116 Thread lock
534 Shim ring
Pinion shaft
39 Circlip
119 Spacer
535 Shim ring
Gear
131 Closing cap
536 Shim ring
Output shaft
43 Key
132 Circlip
537 Shim ring
Key
133 Spacer
538 Shim ring
Oil seal
542 Shim ring
59 Screw plug
135 Nilos ring
83 Nilos ring
161 Closing cap
543 Shim ring
12 Circlip
84 Nilos ring
506 Shim ring
544 Shim ring
17 Spacer
88 Circlip
507 Shim ring
19 Key
89 Closing cap
508 Shim ring
20 Breather valve
100 Gearcase cover
521 Shim ring
22 Gearcase
101 Hex head bolt
521 Shim ring
11
Gear Unit Structure

Basic structure of helical-worm gear units
3
3.4
Basic structure of helical-worm gear units

101
59
20
100
131
39
137
506
507
102
37
5
43
30
61
22
59
19
25
523
522
521
88
89
59
11
520
12 519
518
50884AXX
Figure 4: Basic structure of helical-worm gear units
Key
12
Pinion
20
Breather valve
88
Circlip
518
Shim ring
Gear
22
Gearcase
89
Closing cap
519
Shim ring
Worm
25
100 Gearcase cover
520
Shim ring
Worm gear wheel
30
101 Hex head bolt
521
Shim ring
Output shaft
37
102 Rubber seal
522
Shim ring
Oil seal
39
Circlip
131 Closing cap
523
Shim ring
11
43
Key
137 Spacer
12
Circlip
59
Screw plug
506 Shim ring
19
Key
61
Circlip
507 Shim ring
Gear Unit Structure

Basic structure of SPIROPLAN gear units
3.5
Basic structure of SPIROPLAN gear units

100
101
102
65
71
66 143
68
72
22
89
25
88
521
522
523
6
19
250
251
17
11
12
518
519
520
9
05674AXX
Figure 5: Basic structure of SPIROPLAN gear units
Key
1
Pinion
19 Key
88
Circlip
251
Circlip
Gear
22 Gearcase
89
Closing cap
518
Shim ring
Output shaft
100
Gearcase cover
519
Shim ring
Key
65 Oil seal
101
Hex head bolt
520
Shim ring
Oil seal
102
Gasket
521
Shim ring
11
71 Spacer
132
Circlip
522
Shim ring
12
Circlip
72 Circlip
183
Oil seal
523
Shim ring
17
Spacer
143 Spacer
250
Circlip
13
Gear Unit Structure

Nameplate, unit designation
3
3.6
Sample nameplate
06687ADE
Figure 6: Sample nameplate

fb
FRa max
FRe max
i
IM
IP..
ne max
na
Me max
Ma
MR
MRS
= Service factor
= Maximum overhung load on the output side
= Maximum overhung load on the input side (with input shaft assembly AD)
= Gear unit reduction ratio
= Mounting position
= Enclosure
[1/min] = Maximum input speed
[1/min] = Output speed
[Nm]
= Maximum input torque
[Nm]
= Output torque
[Nm]
= Overload torque when using an AR adapter
[Nm]
= Locking torque of the backstop
[N]
[N]
Unit designation
Example: Helical gear unit, category II2GD
RF
47 / A
/ II2GD
Explosion-proof design to directive 94/9/EC
For direct motor mounting
Gear unit size
Helical gear unit series (flange mounted)
Example: Serial number

3229561201.
0001.
03
Year number end digits of the year of manufacture (2-digit)
Part number (4-digit)
Order number (10 digits)
14
Mechanical Installation
Required tools / aids
4.1
Required tools / aids
Set of spanners
Torque wrench for:
Shrink discs
AQH motor adapter
Input shaft assembly with centering shoulder
Mounting device
Shims and distance rings if necessary
Fixing devices for input and output elements
Lubricant (e.g. NOCO Fluid)
Bolt adhesive (for input shaft assembly with centering shoulder), e.g. Loctite 243
Standard parts are not part of the delivery
Installation
tolerances
4.2
Shaft end
Flanges
Diameter tolerance in accordance with DIN 748

ISO k6 for solid shafts with 50 mm
ISO m6 for solid shafts with > 50 mm
ISO H7 for hollow shafts
Center bore in accordance with DIN 332, shape
DR
Centering shoulder tolerance in accordance with

DIN 42948
ISO j6 with b1 230 mm
ISO h6 with b1> 230 mm
Prerequisites for assembly

Check that the following conditions have been met:
The data on the nameplate of the gearmotor matches the voltage supply system.
The drive has not been damaged during transportation or storage.
Ensure that the following requirements have been met:

For standard gear units:
Ambient temperature according to the lubricant table in Sec. "Lubricants" (see
standard).
The drive must not be assembled in the following ambient conditions:
Potentially explosive atmosphere
Oil
Acids
Gas
Vapors
Radiation
For special versions:
The drive configured in accordance with the ambient conditions.
For helical-worm / SPIROPLAN W gear units:
No large external mass moments of inertia which could exert a retrodriving load
on the gear unit.
[At (retrodriving) = 2 1/ < 0.5 self-locking]
15
Installing the gear unit
4.3
You must clean the output shafts and flange surfaces thoroughly to ensure they are
free of anti-corrosion agents, contamination or similar. Use a commercially available
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.

The gear unit or gearmotor is only allowed to be installed in the specified mounting
position. SPIROPLAN gear units are not dependent on the mounting position.
The support structure must have the following characteristics:
Level
Vibration damping
Torsionally rigid
Maximum permitted flatness error for foot and flange mounting (approximate values with
reference to DIN ISO 1101):
Gear unit size 67: max. 0.4 mm
Gear unit size 77 ... 107: max. 0.5 mm
Do not tighten the housing legs and mounting flanges against one another and ensure
that you comply with the permitted overhung and axial loads!
Secure the gearmotors with bolts of quality 8.8.
Secure the following gearmotors with bolts of quality 10.9:
RF37, R37F with flange 120 mm
The oil checking and drain screws and the breather valves must be freely
accessible!
At the same time, also check that the oil fill is as specified for the mounting position (see
Sec. "Lubricants" / "Lubricant fill quantities" or refer to the information on the nameplate).
The gear units are filled with the required oil volume at the factory. There may be slight
deviations at the oil level plug as a result of the mounting position, which are permitted
within the manufacturing tolerances.
16
Adjust the lubricant fill volumes and the position of the breather valve accordingly
in the event of a change of mounting position.
Please contact our SEW customer service if you change the mounting position of K gear
units to M5 or M6 or between M5 and M6.
Please contact our SEW customer service if you change the mounting position of size
S47 S97 S gear units to mounting position M2.
Use plastic inserts (2 ... 3 mm thick) if there is a risk of electrochemical corrosion
between the gear unit and the driven machine. The material used must have an electrical bleeder resistor < 109 . Electrochemical corrosion can occur between various
metals, for example, cast iron and high-grade steel. Also install the bolts with plastic
washers! Ground the housing additionally use the grounding bolts on the motor.
Installation in
damp locations or
in the open
Drives are supplied in corrosion-resistant versions for use in damp areas or in the open
air. Repair any damage to the paint work (e.g. on the breather valve).
When mounting the motors onto AM, AQ, AR, AT adapters, seal the flange areas with a
suitable sealing compound, e.g. Loctite 574.
17
Gear unit venting
No breather plug is required for the following gear units:
R07 in mounting positions M1, M2, M3, M5 and M6
R17, R27 and F27 in mounting positions M1, M3, M5 and M6
SPIROPLAN W gear units
SEW-EURODRIVE supplies all other gear units with the breather valve installed and
activated according to the particular mounting position.
Exceptions:
1. SEW supplies the following gear units with a screw plug on the vent hole provided:
Gear units for extended storage

Pivoted mounting positions, if possible
Gear units for mounting on a slant
The breather valve is located in the motor terminal box. Before startup, you must replace the highest screw plug with the breather valve supplied.
2. SEW supplies a breather valve in a plastic bag for gear head units requiring venting
on the input end.
3. Enclosed gear units are supplied without a breather valve.
Activating the
breather valve
As a rule, the breather valve is already activated at the factory. If the breather valve has
not been activated, you must remove the transport fixture from the breather valve before
starting up the gear unit!
1. Breather valve with

transport fixture
2. Remove the transport fixture
02053BXX
Painting the gear

unit
18
02054BXX
3. Breather valve activated
02055BXX
If you paint or respray the drive, ensure that you cover the breather valve and oil seals
carefully. Remove the strips of tape after completing the painting work.
Gear unit with solid shaft
4.4
Installing input
and output
elements
The following figure shows a mounting device for installing couplings or hubs on gear
unit or motor shaft ends. It may be possible to dispense with the thrust bearing on the
mounting device.
1) Gear shaft end

2) Thrust bearing
3) Coupling hub
03371BXX
Avoid impermissibly high overhung loads: Install the gear or chain sprocket according
to figure B.
1 = Hub
A = Unfavorable
B = Correct
03369BXX
Only use a mounting device for installing input and output elements. Use the center
bore and the thread on the shaft end for positioning.
Never drive belt pulleys, couplings, pinions, etc. onto the shaft end by hitting
them with a hammer This will damage the bearings, housing and the shaft!
In the case of belt pulleys, make sure the belt is tensioned correctly in accordance with the manufacturer's instructions.
Power transmission elements should be balanced after fitting and must not give rise
to any impermissible radial or axial forces (see the "Gearmotor" or "Explosion-Proof
Drives" catalogs for permitted values).
Note:
Assembly is easier if you first apply lubricant to the output element or heat it up briefly
(to 80 ... 100 C).
19
Installing
couplings
Couplings must be mounted and balanced according to the information provided by the
coupling manufacturer:
a) Maximum and minimum clearance
b) Axial misalignment
c) Angular misalignment
a)
b)
c)
03356AXX
Figure 7: Clearance and misalignment for coupling installation
Input and output elements such as belt pulleys, couplings, etc. must be protected
against contact!
20
Torque arms for mounted gear units
4.5

Do not place torque arms under strain during installation!
Parallel shaft
helical gear units
01029BXX
Figure 8: Torque arm for parallel shaft helical

gear units
Helical-bevel gear
units
Bush with bearings on both ends (1).
Install connection end B as a mirror image of A.
01030CXX
Figure 9: Torque arm for helical-bevel gear units

Gear unit
Bolts
Tightening torque
KA37
4 M10 25 8.8
48 Nm
KA47
4 M10 30 8.8
48 Nm
KA67
4 M12 35 8.8
86 Nm
KA77
4 M16 40 8.8
210 Nm
KA87
4 M16 45 8.8
210 Nm
KA97
4 M20 50 8.8
410 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
21
4
Helical-worm
gear units
Bush with bearings on both ends (1).
01031CXX
Figure 10: Torque arm for helical-worm gear units

Bolts
Tightening torque
M6 16 8.8
11 Nm
SA47
M8 20 8.8
25 Nm
SA57
M8 20 8.8
25 Nm
SA67
M12 25 8.8
86 Nm
SA77
M12 35 8.8
86 Nm
SA87
M16 35 8.8
210 Nm
SA97
M16 35 8.8
210 Nm
Bush with bearings on both ends (1)
45
SPIROPLAN W
gear units
Gear unit
SA37
(1)
Figure 11: Torque arm for SPIROPLAN W gear units
22
02050CXX
Gear unit
Bolts
Tightening torque
WA10
M6 16
11 Nm
WA20
M6 16
11 Nm
WA30
M6 16
11 Nm
Mounted gear unit with keyway or splined hollow shaft
4.6

For the configuration of customer shafts, please also refer to the design notes in the
Gearmotors catalog!
Installation notes
1. Apply NOCO fluid.
C
O I
N U
L
F
C
O I
N U
L
F
02042BXX
2. Distribute the NOCO fluid carefully.
02043AXX
3. Install the shaft and secure it axially

(mounting is facilitated by using a mounting device)
3A: Mounting with standard scope of delivery
1
2
2
3
4
6
Short retaining bolt

(standard scope of delivery)
Lock washer
Washer
Circlip
Customer shaft
6
03361BXX
23
3B: Assembly with SEW-EURODRIVE assembly/disassembly kit ( page 26)

Customer's shaft with contact shoulder
1
2
1
2
3
4
6
Retaining bolt
Lock washer
Washer
Circlip
Customer's shaft with contact
shoulder
6
03362BXX
3C: Assembly with SEW-EURODRIVE assembly/disassembly kit ( page 26)

Customer's shaft without contact shoulder
1
23
1
2
3
4
5
6
4
5
Retaining bolt
Lock washer
Washer
Circlip
Spacer
Customer's shaft without
contact shoulder
6
03363AXX
4. Tighten the retaining bolt to the appropriate torque (see table).

Bolt
Tightening torque
[Nm]
M5
M6
M10/12
20
M16
40
M20
80
M24
200
03364AXX
Note:
To avoid contact corrosion, we recommend that the customer's shaft should additionally
be recessed between the two contact surfaces!
24
Removal notes
This description is only applicable when the gear unit was assembled using the installation/removal kit from SEW-EURODRIVE( page 26) (see the previous description,
point 3B or 3C).
1. Loosen the retaining bolt [1].
2. Remove parts 2 to 4 and, if fitted, spacer 5.
1
2
1
2
3
4
5
6
4
5
Retaining bolt
Lock washer
Washer
Circlip
Spacer
Customer shaft
03366AXX
3. Insert the forcing washer [8] and the fixed nut [7] from the SEW-EURODRIVE installation/removal kit between the customer's shaft [6] and the circlip [4].
4. Re-insert the circlip [4].
5. Screw the retaining bolt [1] back in. Now you can force the gear unit off the shaft by
tightening the bolt.
1
4
6
7
8
4
7
8
Retaining bolt
Circlip
Customer shaft
Fixed nut
Forcing washer
6
03367AXX
25
SEW
installation/remo
val kit
The SEW-EURODRIVE installation/removal kit can be ordered under the following part
number.
03394AXX
Figure 12: SEW-EURODRIVE installation/removal kit

1
7
8
Retaining bolt
Fixed nut for disassembly
Forcing washer
DH7
[mm]
M1)
C4
[mm]
C5
[mm]
C6
[mm]
U-0.5
[mm]
T -0.5
[mm]
D3-0.5
[mm]
L4
[mm]
Part number of
installation/removal kit
WA..10
16
M5
12
4.5
18
15.7
50
643 712 5
WA..20
18
M6
13.5
5.5
20.5
17.7
25
643,682 X
WA..20, WA..30, SA..37
20
M6
15.5
5.5
22.5
19.7
25
643 683 8
FA..27, SA..47
25
M10
10
20
7.5
28
24.7
35
643 684 6
FA..37, KA..37, SA..47, SA..57
30
M10
10
25
7.5
33
29.7
35
643 685 4
FA..47, KA..47, SA..57
35
M12
12
29
9.5
38
34.7
45
643 686 2
FA..57, KA..57, FA..67, KA..67, SA..67
40
M16
12
34
11.5
41.9
39.7
50
643 687 0
SA..67
45
M16
12
38.5
13.5
48.5
44.7
50
643 688 9
FA..77, KA..77, SA..77
50
M16
12
43.5
13.5
53.5
49.7
50
643 689 7
FA..87, KA..87, SA..77, SA..87
60
M20
16
56
17.5
64
59.7
60
643 690 0
FA..97, KA..97, SA..87, SA..97
70
M20
16
65.5
19.5
74.5
69.7
60
643 691 9
Type
FA..107, KA..107, SA..97
90
M24
20
80
24.5
95
89.7
70
643 692 7
FA..127, KA..127
100
M24
20
89
27.5
106
99.7
70
643 693 5
FA..157, KA..157
120
M24
20
107
31
127
119.7
70
643 694 3
1) Retaining bolt
The SEW assembly kit for mounting the customer shaft is a recommendation from SEW-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 have to be used to secure the shaft axially. In these cases,
customers can use their own devices. However, you must ensure that these designs do not cause potential
sources of combustion according to DIN EN 13463 (for example, impact sparks).
26
Mounted gear units with shrink disc
4.7
Installation notes
Do not tighten the locking bolts unless the shaft is installed - the hollow shaft could
become deformed!
1. Loosen the locking bolts by a few turns
(do not unscrew them completely!).
2. Carefully degrease the hollow shaft hole

and the input shaft.
51092AXX
3. Hollow shaft/input shaft after degreasing
51093AXX
4. Apply NOCO fluid to the input shaft1) in

the area of the bushing.
51094AXX
1)
51095AXX
It is essential to make sure that the clamping area of the shrink disk is free from
grease!
For this reason, never apply NOCO fluid directly to the bushing as the paste may
be able to get into the clamping area of the shrink disk when the input shaft is put
on.
27
5. Install the input shaft, making sure that the locking collars of the shrink disk are installed in parallel to each other2). For gear unit housing with a shaft collar, mount
the shrink disc to the stop on the shaft collar. For gear unit housing without a
shaft collar, mount the shrink disk with a clearance of 1 to 2 mm from the gear
unit housing. Tighten the locking bolts with the torque wrench by working round
several times from one bolt to the next (not in diametrically opposite sequence) until
the bolts cannot be tightened any more. See the following table for tightening
torques.
1-2mm
s>1mm
51096AXX
2)After
installation
There must be a gap s > 1 mm between the locking collars
Grease the outside of the hollow shaft in the area of the shrink disk to prevent corrosion.
Gear unit type
Bolt
Nm
SH37
M5
KH37...77
FH37...77
SH47...77
M6
12
KH87/97
FH87/97
SH87/97
M8
30
KH107
FH107
M10
59
KH127/157
FH127
M12
100
KH167
M16
250
KH187
M20
470
max.1)
60
1) Maximum tightening angle per cycle
28
Notes on
removing the
shrink disk
1. Unscrew the locking bolts evenly one after the other. Each locking bolt may only be
unscrewed by about one quarter turn in the initial cycle. This is in order to avoid tilting
and jamming the locking collars. Do not fully unscrew the locking bolts!
2. Remove the shaft or pull the hub off the shaft. (You must first remove any rust that
may have formed between the hub and the end of the shaft.)
3. Pull the shrink disk off the hub.
Caution!
Risk of injury if the shrink disk is not removed correctly!
Cleaning and
lubricating the
shrink disk
There is no need to strip down and re-grease disassembled shrink disks before they are
screwed back on.
The shrink disk only needs to be cleaned and re-greased if it is contaminated.
Use one of the following solid lubricants for the tapered surfaces.
Lubricant (Mo S2)
Sold as
Molykote 321 (lube coat)

Molykote spray (powder spray)
Molykote G Rapid
Aemasol MO 19P
Aemasol DIO-stral 57 N (lube coat)
Spray
Spray
Spray or paste
Spray or paste
Spray
Grease the locking bolts with a multipurpose grease such as Molykote BR 2 or similar.
29
Mounted gear units with TorqLOC
4
4.8

1. Clean the inside of the hollow shaft and the customer shaft. Ensure that all traces of
grease or oil are removed.
2. Install the split ring and the bushing on the customer shaft.
52089AXX
3. Apply NOCO fluid to the bushing and distribute it carefully.

O
C
O D
N UI
L
F
52090AXX
4. Push the gear unit onto the customer shaft.
52091AXX
30
5. Preassemble the torque arm (do not tighten the bolts).
K...
F...
S...
52092AXX
6. Push the busing onto the gear unit up to the stop.
52093AXX
7. Tighten all the retaining bolts for the torque arm.
52094AXX
31
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.
52095AXX
Type
Torque [Nm]
KT/FT
ST
Nickel plated
Stainless steel
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
9. Slide the shrink disk onto the hollow shaft. Ensure that all bolts have been loosened.
52096AXX
32
10.Push the counter bushing onto the customer shaft and into the hollow shaft or shrink
disk right into the seat.
52097AXX
11.Tap lightly on the flange of the counter bushing to ensure that the socket is fitted securely in the hollow shaft.
52098AXX
12.Ensure that the customer shaft is fitted in the counter bushing.
53478AXX
33
13.Tighten the bolts of the shrink disk by hand and ensure that the end rings of the shrink
disc are parallel.
52100AXX
14.Tighten the locking bolts by working round several times from one bolt to the next
(not in diametrically opposite sequence). See the table for tightening torques.
After installation, the remaining gap between the outer rings of the shrink
discs must be > 0 mm.
> 0mm
52101AXX
Type
34
Nickel plated
Stainless steel
KT/FT
ST
37
4.1
Torque [Nm]
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
15.The distance between the counter bushing and the hollow shaft end and between the
split ring and the clamping ring must not exceed the following values. The following
table lists the maximum and minimum gap width.
a
a
52102AXX
Type
Distance [mm]
KT/FT
ST
a min.
a max.
37
3.3
5.6
37
47
3.3
5.6
47
57
5.0
7.6
57, 67
67
5.0
7.6
77
77
5.0
7.6
87
87
5.8
8.6
97
97
5.8
8.6
35
AM adapter coupling
4
4.9
AM adapter coupling
IEC adapter AM63

225 / NEMA
adapter AM56
365
04469CXX
1 = Motor shaft
1. Clean the motor shaft and flange surfaces of the motor and 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, push the coupling half onto the
motor shaft.
Until stop at motor shaft shoulder (position to point A except for AM25 / AM280 and
NEMA).
4. Secure key and coupling half using grub screw (481) and tightening torque TA on motor shaft according to the table.
5. Check point A.
6. Seal the contact surfaces between the adapter and motor using a suitable sealing
compound.
7. Mount the motor on the adapter. When doing this, make sure the coupling dogs of
the adapter shaft engage in the plastic spider.
IEC AM
36
63 / 71
80 / 90
100 / 112
132
160 / 180
200
225
250 / 280
24.5
31.5
41.5
54
76
78.5
93.5
139
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
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
AM adapter coupling
To avoid contact corrosion, we recommend applying NOCO fluid to the motor shaft
before mounting the coupling half.
When installing a motor onto the adapter, you must use an anaerobic fluid seal to
ensure that moisture cannot penetrate the adapter.
Permitted loads
The load data specified in the following table must not be exceeded when a motor
is mounted.
Fq
51102AXX
Fq1) [N]
Adapter type
IEC
NEMA
x1) [mm]
IEC adapter
NEMA adapter
AM63/71
AM56
77
530
410
AM80/90
AM143/145
113
420
380
AM100/112
AM182/184
144
2000
1760
AM132 2)
AM213/2152)
1600
1250
AM132..
AM213/215
4700
3690
186
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 proportionally as the distance between the adapter flange and the middle of the motor (x) increases. When this distance is reduced, the maximum permitted weight Fqmax cannot be increased.
2) Diameter of the adapter drive flange: 160 mm
37
AQ adapter coupling
Adapter AM with
backstop AM../RS
Check the direction of rotation of the drive before installation and startup. Please inform
the SEW-EURODRIVE customer service if the direction of rotation is incorrect.
The backstop is maintenance-free in operation, and does not require any further maintenance work.
The backstops have a minimum lift-off speed depending on the size ( following table).
If the minimum lift-off speeds are violated, the backstops are subject to wear, and the
resulting friction causes the temperature to increase.
Maximum locking torque of backstop
[Nm]
Minimum lift-off speed

[1/min]
AM80/90/RS,
AM143/145/RS
90
640
AM100/112/RS,
AM182/184/RS
340
600
AM132/RS,
AM213/215/RS
700
550
AM160/180/RS,
AM254/286/RS
1200
630
AM200/225/RS,
AM324-365/RS
1450
430
Type
In rated operation, the lift-off speeds must not drop below the minimum values.
The lift-off speeds are only permitted to drop below the minimum values during
start-up or braking.
4.10 AQ adapter coupling
AQA
AQH
479
479
1
2
3
Motor shaft
Setscrew
Bolt
1
2
AQA = With keyway

AQH = Without keyway
53512AXX
1. Clean the motor shaft and flange surfaces of the motor and adapter.
2. Type AQH: Unscrew the bolts of the coupling half (479) and loosen the conical
connection.
3. Heat the coupling half (80 C 100 C) and push it onto the motor shaft.
Type AQA / AQH: Up to clearance "A" (see table).
4. Type AQH: Tighten the bolts on the coupling half in diametrically opposite sequence
38
AQ adapter coupling
(work round several times tightening the bolts evenly one after the other) until all
bolts reach the tightening torque TA specified in the table.
Type AQA: Use a setscrew to secure the coupling half (see table).
5. Check the position of the coupling half (clearance "A", see table).
Install motor onto the adapter making sure that the dogs of the two coupling halves
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.
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.
When installing a motor onto the adapter, you must use an anaerobic fluid seal to
ensure that moisture cannot penetrate the adapter.
Setting dimensions, tightening

torques
Type
Coupling size
AQA /AQH 80 /1/2/3

AQA /AQH 100 /1/2
AQA /AQH 100 /3/4
AQA /AQH 140 /1/2

AQA /AQH 140 /3
AQA /AQH 190 /1/2
AQA /AQH 190 /3
Bolts DIN 912
Tightening torque TA
[Nm]
AQA
AQH
AQA
AQH
M5
M4
M5
M5
M8
M5
10
M8
M6
10
10
44,5
19/24
AQA /AQH 115 /1/2

AQA /AQH 115 /3
Clearance "A"
[mm]
39
53
62
24/28
28/38
38/45
62
62
74,5
76,5
100
39
AD input shaft assembly
4
4.11

Please refer to Sec. "Installing input and output shafts" for information on mounting of
input elements.
Cover with motor

mounting platform AD../P
Mounting the motor and adjusting the motor mounting platform.
1
2
3
4
5
Motor mounting platform

Stud bolt (only AD6/P / AD7/P)
Support (only AD6/P / AD7/P)
Nut
Threaded column
03519BXX
1. Set the motor mounting platform to the required mounting position by evenly tightening the adjusting nuts. It may be necessary to 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. Correct the motor position again if necessary.
4. Put on traction elements (V-belt, chain, etc.) and apply a preload by evenly adjusting
the motor mounting platform. Do not stress the motor mounting platform and the
columns against one another when doing this.
5. Tighten the threaded columns using the nuts which are not used for adjustment.
Only AD6/P and

AD7/P:
40
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
position has been achieved. Do not adjust the motor mounting platform using the
support.
Type with centering shoulder

AD../ZR
Mounting applications on the input shaft assembly with centering shoulder.

1. Retaining bolts of a suitable length must be used to secure the application. The
length l of the new bolts is calculated as follows:
l= t+a
t = Screw-in depth (see table)
a = Thickness of the application
s = Retaining thread (see table)
02725CXX
Round down the calculated bolt length to the next smaller standard length.
2. Remove the retaining bolts from the centering shoulder.
3. Clean the contact surface and the centering shoulder.
4. Clean the threads of the new bolts and apply a bolt locking compound (e.g. Loctite
243) to the first few threads.
5. Position the application against the centering shoulder and tighten the retaining bolts
to the specified tightening torque TA (see table).
Type
Screw-in depth
t [mm]
Retaining thread
s
Tightening torque
TA for connection bolts in strength class 8.8
[Nm]
AD2/ZR
25,5
M8
25
AD3/ZR
31,5
M10
48
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
41
4
Permitted loads
The load values specified in the following table must not be exceeded.
Fq
53513AXX
Type
x1)
[mm]
Fq1)
[N]
AD2/ZR
193
330
AD3/ZR
274
1400
AD4/ZR2)
AD4/ZR
361
1120
3300
AD5/ZR
487
3200
AD6/ZR
567
3900
AD7/ZR
663
10000
AD8/ZR
516
4300
1) Maximum load values for connection bolts in strength class 8.8. The maximum permitted weight of the
attached motor Fqmax must be reduced proportionally as the distance between the adapter flange and the
middle of the motor (x) increases When this distance is reduced, the Fqmax cannot be increased.
2) Diameter of the adapter output flange: 160 mm
42
Cover with backstop AD../RS
Check the direction of rotation of the drive before installation and startup. Please inform
the SEW-EURODRIVE customer service if the direction of rotation is incorrect.
The backstop is maintenance-free in operation, and does not require any further maintenance work.
The backstops have a minimum lift-off speed depending on the size ( following table).
If the minimum lift-off speeds are violated, the backstops are subject to wear, and the
resulting friction causes the temperature to increase.
Maximum locking torque of backstop
[Nm]
Minimum lift-off speed

[1/min]
AD2/RS
90
640
AD3/RS
340
600
Type
AD4/RS
700
550
AD5/RS
1200
630
AD6/RS
1450
430
AD7/RS
1450
430
AD8/RS
2860
430
In rated operation, the lift-off speeds must not drop below the minimum values.
The lift-off speeds are only permitted to drop below the minimum values during
start-up or braking.
43
Startup
Startup of helical-worm and SPIROPLAN W gear units
Startup
Prior to startup check that the oil level is as specified for the mounting position.
The oil checking and drain screws and the breather valves must be freely accessible.
5.1
Startup of helical-worm and SPIROPLAN W gear units

Note: The direction of rotation of the output shaft in series S..7 helical-worm gear units
has been changed from CW to CCW; this is different from the S..2 series. Change
direction of rotation: Swap over two motor feeder cables.
Run-in period
5.2
SPIROPLAN and helical-worm gear units require a run-in period of at least 24 hours
before reaching their maximum efficiency. A separate run-in period applies for each
direction 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.
Spiroplan
Worm
No. of
starts
Power reduction
i range
1 start
ca. 12 %
2 start
ca. 6 %
3 start
4 start
Power reduction
i range
ca. 50...280
ca. 15 %
approx. 40 ... 75
ca. 20...75
ca. 10 %
ca. 20...30
ca. 3 %
ca. 20...90
ca. 8 %
ca. 15
ca. 8 %
ca. 10
5 start
ca. 3 %
ca. 6...25
ca. 5 %
ca. 8
6 start
ca. 2 %
ca. 7...25
Startup of helical, parallel shaft helical and helical-bevel gear units

No special startup instructions are required for helical, parallel shaft helical and helicalbevel gear units providing the gear units have been installed in accordance with Sec.
"Mechanical Installation".
44
Inspection and Maintenance

Inspection and maintenance intervals
6.1

Frequency
What to do?
Every 3000 machine hours, at least every 6

months.
Check oil and oil level.

Check the seals visually for leakage.
For gear units with a torque arm: Check the
rubber buffer and change it, if necessary
Depending on the operating conditions (see chart

below), every 3 years at the latest.
According to oil temperature.
Change mineral oil.
Replace anti-friction bearing grease (recommendation).

Replace oil seal (do not install it in the same
track).
Depending on the operating conditions (see chart

below), every 5 years at the latest.
According to oil temperature.
Change synthetic oil
Replace anti-friction bearing grease (recommendation).

Replace oil seal (do not install it in the same
track).
6.2
Gear unitsR07, R17, R27, F27 and Spiroplan are have lubrication for life and are therefore maintenance-free
Varying (depending on external factors).
Touch up or renew the surface/anticorrosion

coating.
Lubricant change intervals

30000
[h]
25000
[3]
20000
15000
[4]
[1]
10000
[5]
5000
70
80
110
100
90
[2]
115
120
[C]
53232AXX
Figure 13: Oil change intervals for standard gear units under normal environmental conditions
[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
Oil
45

Inspection and maintenance of the gear unit
6
6.3
Inspection and maintenance of the gear unit

Do not intermix synthetic lubricants and do not mix synthetic and mineral lubricants
together!
The standard lubricant is mineral oil (except for Spiroplan gear units).
The position of the oil level and oil drain plug and the breather valve depends on
the mounting position. Refer to the diagrams of the mounting positions.
Checking the oil

level
1. De-energize the gearmotor and secure it to prevent it from being switched on

inadvertently!
Wait until the gear unit has cooled off Danger of burns!
2. Refer to Sec. "Installing the gear unit" when changing the mounting position!
3. For gear units with an oil level plug: Remove the oil level plug, check the fill level and
correct it if necessary. Screw the oil level plug back in.
Checking the oil

inadvertently!
2. Remove a little oil from the oil drain plug.
3. Check the oil consistency.
Viscosity
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 periods".
4. For gear units with an oil level plug: Remove the oil level plug, check the fill level and
correct it if necessary. Screw the oil level plug back in.
Changing the oil
Only change the oil when the gear unit is at operating temperature.
De-energize the gearmotor and secure it to prevent it from being switched back
on inadvertently!
Wait until the gear unit cools down - Danger of burns!
Note: The gear unit must still be warm otherwise the high viscosity of excessively
cold oil will make it harder to drain the oil correctly.
With oil drain plug /

oil level screw
1. Place a container underneath the oil drain plug

2. Remove the oil level plug, breather plug/breather valve and oil drain plug.
3. Drain all the oil.
4. Screw in the oil drain plug.
5. Pour in new oil of the same type through the vent hole (if changing the oil type, please
first contact our customer service). Do not mix synthetic lubricants.
Pour in the volume of oil in accordance with the mounting position (see Sec. "Lubricant fill quantities") or as specified on the nameplate.
Check at the oil level plug.
6. Screw the oil level plug back in
7. Screw in the breather plug/breather valve.
46

Inspection / maintenance of AM / AQA adapters
Without oil drain

plug / oil level plug
1. Remove cover plate.

2. Drain the oil through the cover plate opening.
3. Pour in new oil of the same type through the vent hole (if changing the oil type, please
first contact our customer service). Do not mix synthetic lubricants.
Pour in the volume of oil in accordance with the mounting position (see Sec. "Lubricant fill quantities") or as specified on the nameplate.
4. Check the oil level ( Sec. "Check oil level for gear units with oil level plug")
5. Attach cover plate (observe the tightening torque and series Sec. "Check the oil
level for gear units without an oil level plug")
Changing the oil

seal

inadvertently!
2. When changing the oil seal, ensure that there is a sufficient grease reservoir between
the dust lip and protective lip, depending on the type of gear unit.
3. If you use double oil seals, the space has to be filled one-third with grease.
6.4
Inspection / maintenance of AM / AQA adapters

Frequency
What to do?
Every 3000 machine hours, at least every 6 months
Check torsional play

Visually check the elastic annular gear
Check the adapter visually for leakage
After 25000 - 30000 machine hours
Renew the anti-friction bearing grease

Replace oil seal (do not install it in the
same track)
Change the elastic annular gear.
6.5
Inspection / maintenance of AD adapters

Frequency
What to do?
Every 3000 machine hours, at least every 6 months
After 25000 - 30000 machine hours
Check running noise for possible bearing

damage
Check the adapter visually for leakage
Renew the anti-friction bearing grease
Change the oil seal
47
Malfunctions
Gear unit malfunctions
7
7
Malfunctions
Customer service
Please have the following information to hand if you require the assistance of our
customer service:
Data from the nameplate (complete)
Nature and extent of the fault
Time and peripheral circumstances of the fault
Presumed cause
7.1
Gear unit malfunctions
Problem
Possible cause
Remedy
Unusual, regular running

noise
A
B
Meshing/grinding noise: Bearing damage.

Knocking noise: Irregularity in the gearing
B
Unusual, irregular running
noise
Foreign bodies in the oil
leaking1)
Oil
From the gear cover
plate
From the motor flange
From the motor oil seal
From the gear unit
flange
From the output end oil
seal
Oil leaking from breather

valve
A
B
B
C
C
Output shaft does not turn
although the motor is running or the input shaft is
rotated
Rubber seal on the gear cover plate leaking

Seal defective
Gear unit not vented
Too much oil

Drive operated in incorrect mounting position
Frequent cold starts (oil foams) and/or
high oil level
Connection between shaft and hub in gear unit

interrupted
B
C
Check the oil (see Sec. "Inspection and Maintenance"), change bearings
Contact customer service
Check the oil (see Sec. "Inspection and Maintenance")
Stop the drive, contact customer service
Tighten the bolts on the gear cover plate and
observe the gear unit. Oil still leaking: Contact customer service
Contact customer service
Vent the gear unit (see Sec. "Mounting Positions")
Correct the oil level (see Sec. "Inspection and

Maintenance")
Mount the breather valve correctly (see Sec.
"Mounting Positions") and correct the oil level (see
"Lubricants")
Send in the gear unit/gearmotor for repair
1) Short-term oil/grease leakage at the oil seal is possible in the run-in phase (24 hours running time).
7.2
AM / AQA / AL adapter malfunctions
Problem
Possible cause
Remedy

noise
Meshing/grinding noise: Bearing damage
Contact SEW-EURODRIVE customer service
Oil leaking
Seal defective

although the motor is running or the input shaft is
rotated
Connection between shaft and hub in gear

unit interrupted
Send the gear unit to SEW-EURODRIVE for repair.
Change in running noise

and / or vibrations occur
Annular gear wear, short-term torque

transfer through metal contact
Bolts to secure hub axially are loose.
A
B
Contact with aggressive fluids / oil; ozone

influence; too high ambient temperatures
etc, which can cause a change in the
physical properties of the annular gear.
Impermissibly high ambient/contact temperature for the annular gear; maximum
permitted temperature 20 C to +80 C.
Overload
B
Premature wear in annular
gear
B
C
48
Change the annular gear

Tighten the bolts
Malfunctions
AD input shaft assembly malfunctions
7.3
AD input shaft assembly malfunctions
Problem
Possible cause
Remedy

noise
Meshing/grinding noise: Bearing damage.
Oil leaking
Seal defective

although the input shaft is
rotated.
Connection between shaft and hub in gear

unit or cover interrupted
Send the gear unit to SEW-EURODRIVE for repair.
49
Mounting Positions
General information on mounting positions
M1 M6
Mounting Positions
8.1
General information on mounting positions
Mounting position designation

SEW differentiates between six mounting positions M1 ... M6 for gear units. The following figure shows the
spatial orientation of the gearmotor in mounting positions M1 ... M6.
M6
M6
M1
M1
M2
M2
M5
M5
M4
M4
R..
M3
M3
M6
M6
M1
M2
M2
M1
M5
M5
M4
M4
F..
M3
M3
M6
M1
M1
M6
M2
M5
M5
M2
M4
K..
W..
S..
M4
M3
M3
03203AXX
Figure 14: Depiction of mounting positions M1 ... M6
50
Mounting Positions
Key to the mounting position sheets
8.2
M1 M6
Key to the mounting position sheets

SPIROPLAN gearmotors do not depend on any particular mounting position. However,
mounting positions M1 to M6 are also shown for SPIROPLAN gearmotors to assist you
in working with this documentation.
Important: SPIROPLAN gearmotors cannot be equipped with breather valves, oil
level plugs or drain plugs.
Symbols used
The following table shows the symbols used in the mounting position sheets and what
they mean:
Symbol
Meaning
Breather valve
Oil level plug
Oil drain plug
Churning losses
Increased churning losses may arise in some mounting positions. Contact

SEW-EURODRIVE in case of the following combinations:
Mounting position
M2, M4
Gear unit type
Gear unit size
Input speed
[1/min]
97 ... 107
> 2500
> 107
>1500
97 ... 107
> 2500
> 107
> 1500
77 ... 107
> 2500
> 107
> 1500
77 ... 97
> 2500
F
M2, M3, M4, M5, M6
K
S
51
M1 M6
8.3
Mounting Positions
Mounting positions for R helical gearmotors
R07-R167
* page 51
52
Mounting Positions
Mounting positions for R helical gearmotors M1 M6
RF07-RF167
* page 51
53
M1 M6
Mounting Positions
R07F-R87F
* page 51
Important: See the

axial loads."
54
information in the "Gearmotors" catalog, section "Project Planning for Gear Units/Overhung and
Mounting Positions
Mounting positions of RX helical gearmotors
8.4
M1 M6
RX57-RX107
* page 51
55
M1 M6
Mounting Positions
RXF57 - RXF107
* page 51
56
Mounting Positions
Mounting positions for parallel shaft helical gearmotors
8.5
M1 M6
F/FA..B/FH27B-157B, FV27B-107B
* page 51
57
M1 M6
Mounting Positions
FF/FAF/FHF/FAZ/FHZ27-157, FVF/FVZ27-107
* page 51
58
Mounting Positions
M1 M6
FA/FH27-157, FV27-107, FT37-97
* page 51
59
M1 M6
8.6
Mounting Positions
Mounting positions for helical-bevel gearmotors
K/KA..B/KH37B-157B, KV37B-107B
* page 51
Important: See the

axial loads."
60
Mounting Positions
M1 M6
K167-187, KH167B-187B
* page 51
Important: See the

axial loads."
61
M1 M6
Mounting Positions
KF/KAF/KHF/KAZ/KHZ37-157, KVF/KVZ37-107
* page 51
62
Mounting Positions
M1 M6
KA/KH37-157, KV37-107, KT37-97
* page 51
63
M1 M6
Mounting Positions
KH167-187
* page 51
64
Mounting Positions
Mounting positions for helical-worm gearmotors
8.7
M1 M6
S37
Important: See the

axial loads."
65
M1 M6
Mounting Positions
S47 - S97
* page 51
Important: See the

axial loads."
66
Mounting Positions
M1 M6
SF/SAF/SHF37
67
M1 M6
Mounting Positions
SF/SAF/SHF/SAZ/SHZ47-97
* page 51
68
Mounting Positions
M1 M6
SA/SH/ST37
69
M1 M6
Mounting Positions
SA/SH/ST47-97
* page 51
70
Mounting Positions
Mounting positions for SPIROPLAN W gearmotors
8.8
M1 M6
W10-30
71
M1 M6
Mounting Positions
WF/WAF10-30
72
Mounting Positions
M1 M6
WA10-30
73
Lubricants
Lubricant table
9
9
Lubricants
General
information
9.1
Unless a special arrangement is made, SEW-EURODRIVE supplies the drives with a

lubricant fill adapted for the specific gear unit and mounting position. The decisive factor
is the mounting position (M1 ... M6, Sec. "Mounting Positions and Important Order
Information") specified when ordering the drive. You must adapt the lubricant fill to any
subsequent changes made to the mounting position ( Lubricant fill quantities).
Lubricant table
The lubricant table on the following page shows the permitted lubricants for
SEW-EURODRIVE gear units. Please note the following key to the lubricant table.
Key to the
lubricant table
Abbreviations used, meaning of shading and notes:

CLP
= Mineral oil
CLP PG
= Polyglycol (W gear units, conforms to USDA-H1)
CLP HC
= Synthetic hydrocarbons
= Ester oil (water pollution danger category WGK 1)
HCE
= Synthetic hydrocarbons + ester oil (USDA-H1 certification)
HLP
= Hydraulic oil
= Synthetic lubricant (= synthetic anti-friction bearing grease)
= Mineral lubricant (= mineral-based anti-friction bearing grease)
1)
Helical-worm gear units with PG oil: Please contact 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 use in agriculture, forestry and water resources)
Oil
Oil
74
Lubricants
Lubricant table
Anti-friction
bearing greases
The anti-friction bearings in gear units and motors are given a factory-fill with the
greases listed below. SEW-EURODRIVE recommends regreasing anti-friction bearings
with a grease fill at the same time as changing the oil.
Anti-friction bearing in
gear unit
Anti-friction bearing in
motor
Ambient temperature
Manufacturer
Type
-20 C ... +60 C
Mobil
Mobilux EP 2
Mobiltemp SHC 100
-40 C ... +80 C
Mobil
-20 C ... +80 C
Esso
Unirex EQ3
-20 C ... +60 C
Shell
Alvania RL3
+80 C ... +100 C
Klber
Barrierta L55/2
-45 C ... -25 C
Shell
Aero Shell Grease 16
-30 C ... +40 C
Aral
Eural Grease EP 2
-20 C ... +40 C
Aral
Aralube BAB EP2
Special greases for anti-friction bearings in gear units:
Oil
The following grease quantities are required:
For fast-running bearings (motor and gear unit input end): Fill the cavities between
the rolling elements one third full with grease.
For slow-running bearings (in gear units and at gear unit output end): Fill the cavities
between the rolling elements two thirds full with grease.
75
76
R32
R302
W...(HW...)
R...,K...(HK...),
F...,S...(HS...)
S...(HS...)
F...
K...(HK...)
R...
4)
4)
4)
4)
4)
4)
4)
4)
4)
-20
+40
+40
-15
+80
+40
+60
+40
+10
+40
Standard
-25
-20
-40
Standard
-20
-30
-40
+20
-25
+10
+80
+80
+60
+40
+10
Standard
-20
+10
+10
+25
+40
-20
-40
-30
-20
-40
-40
-30
-20
-40
-40
-25
+40
+50 +100
0
Standard
-10
C -50
6)
Oil
5)
DIN 51 818
CLP PG
API GL5
SEW PG
HCE
CLP HC
CLP PG
CLP (CC)
CLP HC
VG 680
CLP PG
Klber-Summit
HySyn FG-32
Klberoil
GEM 1-68
Klberoil
GEM 1-150
Shell Omala Klbersynth

HD 150
EG 4-150

EG 4-460
HD 460
Shell Tivela Klbersynth

S 680
GH 6-680
Shell Omala Klberoil

GEM 1-680
680
Isoflex
Shell Tellus
MT 30 ROT
T 15
Shell Tellus
T 32
Shell Omala
100

HD 150
EG 4-150
2)
Mobil
SHC 624
000 - 0
00
VG 460
3)
Mobilux
EP 004
Glygoyle
Grease 00
SAE 75W90 Mobilube SHC

(~VG 100)
75 W90-LS
VG 460
VG 460
VG 460
VG 32
Shell Alvania
GL 00
Shell Tivela
GL 00
Shell Cassida
Fluid GL 460
Klbersynth
UH1 6-460
Klbersynth
GE 46-1200
Klber SEW
HT-460-5
Klberoil
4UH1-460 N
Klberbio
CA2-460
Klber-Summit
HySyn FG-32

GEM 1-150
100
1)
Mobil
VG 220
S 220
GH 6-220
Glygoyle 30
Mobilgear
627
VG 150
VG 100
Mobil
SHC 634
Mobil
SHC 629
1)
Mobilgear
636
Mobil
D.T.E. 11M
VG 150
VG 460
VG 680
VG 22
VG 15
CLP (CC)
HLP (HM)
Mobil
SHC 624
Mobil
D.T.E. 13M
VG 68-46
VG 32
HLP (HM)
VG 32
Mobilgear
627
VG 150
VG 100
CLP (CC)
CLP HC
Mobil
SHC 629

EG 4-220
HD 220
Aralub
MFL 00
Aral Eural
Gear 460
Aral Degol
BAB 460
Aral Degol
BG 100
Aral Degol
BG 680
Aral Degol
BG 46
Aral Degol
BG 100
Aral Degol
PAS 220
Aral Degol
GS 220

GH 6-220
S 220
Mobil
Glygoyle 30
Mobil
SHC 630
Aral Degol
BG 220

GEM 1-220
220
Mobilgear
630
Mobil
VG 150
VG 220
VG 220
CLP PG
CLP HC
VG 220
ISO,NLGI
CLP(CC)
DIN (ISO)
Oil
BP Energrease
LS-EP 00
BP Energol
GR-XP 100
BP Enersyn
SG-XP 680
BP Energol
GR-XP 680
BP Energol
HLP-HM 15
BP Energol
GR-XP 100
BP Enersyn
SG-XP 220
BP Energol
GR-XP 220
Multifak
EP 000
Multifak
6833 EP 00
Longtime
PD 00
Optileb
GT 460
Optisynt
BS 460
Optiflex A
220
Synlube
CLP 220
Tribol
800/220
Cetus
PAO 46
Optigear
BM 100
Optigear
BM 680
Optigear
32
Optigear
BM 100
Meropa 100
Pinnacle
EP 150
Synlube
CLP 680
Pinnacle
EP 460
Meropa 680
Rando
HDZ 15
Cetus
PAO 46
Rando EP
Ashless 46
Meropa 150
Pinnacle
EP 150
Renolin
CLP 220
Renolin
SF 7 - 041
Renolin
CLP 150
Renolin
CLP 680
Renolin
B 46 HVI
Renolin
CLP 150
Optigear Syn- Renolin Unisyn

thetic A 220
CLP 220
Optiflex A
220
Synlube
CLP 220
Pinnacle
EP 220
Optigear
BM 220
Meropa 220
Tribol
1100/100
Tribol
800/680
Tribol
1100/680
Tribol
1100/68
Tribol
1100/100
Tribol
1510/220
Tribol
800/220
Tribol
1100/220
9
Lubricants
Lubricant table
Lubricant table
01 805 892
Lubricants
Lubricant fill quantities
9.2

The specified fill quantities are recommended values. The precise values vary depending on the number of stages and gear ratio. When filling, it is essential to check the oil
level plug since it indicates the precise oil capacity.
The following tables show guide values for lubricant fill quantities in relation to the
mounting position M1 ... M6.
Helical (R) gear

units
Gear unit
type
R.., R..F
Fill quantity in liters

M1
R07/R07F
0.12
1)
M2
1)
0.20
M3
M4
M5
M6
0.20
0.20
0.20
0.20
R17/R17F
0.25
0.55
0.35
0.55
0.35
0.35
R27/R27F
0.25/0.40
0.70
0.50
0.70
0.50
0.50
R37/R37F
0.30/0.95
0.85
0.95
1.05
0.75
0.95
R47/R47F
0.70/1.50
1.60
1.50
1.65
1.50
1.50
R57/R57F
0.80/1.70
1.90
1.70
2.10
1.70
1.70
R67/R67F
1.10/2.30
2.60/3.50
2.80
3.20
1.80
2.00
R77/R77F
1.20/3.00
3.80/4.10
3.60
4.10
2.50
3.40
R87/R87F
2.30/6.0
6.7/8.2
7.2
7.7
6.3
6.5
R97
4.60/9.8
11.7/14.0
11.7
13.4
11.3
11.7
R107
6.0/13.7
16.3
16.9
19.2
13.2
15.9
R137
10.0/25.0
28.0
29.5
31.5
25.0
25.0
R147
15.4/40.0
46.5
48.0
52.0
39.5
41.0
R167
27.0/70.0
82.0
78.0
88.0
66.0
69.0
Gear unit
type
RF.. / RM..

M11)
M21)
M3
M4
M5
M6
RF07
0.12
0.20
0.20
0.20
0.20
0.20
RF17
0.25
0.55
0.35
0.55
0.35
0.35
RF27
0.25/0.40
0.70
0.50
0.70
0.50
0.50
RF37
0.35/0.95
0.90
0.95
1.05
0.75
0.95
RF47
0.65/1.50
1.60
1.50
1.65
1.50
1.50
RF/RM57
0.80/1.70
1.80
1.70
2.00
1.70
1.70
RF/RM67
1.20/2.50
2.70/3.60
2.70
2.60
1.90
2.10
RF/RM77
1.20/2.60
3.80/4.10
3.30
4.10
2.40
3.00
RF/RM87
2.40/6.0
6.8/7.9
7.1
7.7
6.3
6.4
RF/RM97
5.1/10.2
11.9/14.0
11.2
14.0
11.2
11.8
RF/RM107
6.3/14.9
15.9
17.0
19.2
13.1
15.9
RF/RM137
9.5/25.0
27.0
29.0
32.5
25.0
25.0
RF/RM147
16.4/42.0
47.0
48.0
52.0
42.0
42.0
RF/RM167
26.0/70.0
82.0
78.0
88.0
65.0
71.0
1) The output end gear unit of multi-stage gear units must be filled with the larger oil volume.
77
Lubricants
Helical (RX) gear

units
Gear unit
type
RX..

M1
M2
M3
M4
M5
M6
RX57
0.60
0.80
1.30
1.30
0.90
0.90
RX67
0.80
0.80
1.70
1.90
1.10
1.10
RX77
1.10
1.50
2.60
2.70
1.60
1.60
RX87
1.70
2.50
4.80
4.80
2.90
2.90
RX97
2.10
3.40
7.4
7.0
4.80
4.80
RX107
3.90
5.6
11.6
11.9
7.7
7.7
Gear unit
type
RXF..

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
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
RXF97
2.10
3.70
7.1
6.3
4.80
4.80
RXF107
3.10
5.7
11.2
9.3
7.2
7.2
Parallel shaft
helical (F) gear
units
F.., FA..B, FH..B, FV..B:
Gear unit
type
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
2.60
3.50
2.10
3.50
2.80
2.90
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
40.5
54.5
34.0
61.0
46.3
47.0
F..157
69.0
104.0
63.0
105.0
86.0
78.0
Gear unit
type
M1
M2
M3
M4
M5
M6
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
FF..:
78
Lubricants
FA.., FH.., FV.., FAF.., FHF.., FVF.., FAZ.., FHZ.., FVZ..:

Gear unit
type
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
Helical-bevel (K)
gear units
K.., KA..B, KH..B, KV..B:
Gear unit
type
M1
M2
M3
M4
M5
M6
K..37
0.50
1.00
1.00
1.25
0.95
0.95
K..47
0.80
1.30
1.50
2.00
1.60
1.60
K..57
1.20
2.30
2.50
2.80
2.60
2.40
K..67
1.10
2.40
2.60
3.45
2.60
2.60
K..77
2.20
4.10
4.40
5.8
4.20
4.40
K..87
3.70
8.0
8.7
10.9
8.0
8.0
K..97
7.0
14.0
15.7
20.0
15.7
15.5
K..107
10.0
21.0
25.5
33.5
24.0
24.0
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
Gear unit
type
M1
M2
M3
M4
M5
M6
KF37
0.50
1.10
1.10
1.50
1.00
1.00
KF47
0.80
1.30
1.70
2.20
1.60
1.60
KF57
1.30
2.30
2.70
3.15
2.90
2.70
KF67
1.10
2.40
2.80
3.70
2.70
2.70
KF77
2.10
4.10
4.40
5.9
4.50
4.50
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
KF157
31.0
66.0
69.0
92.0
62.0
62.0
KF..:
79
Lubricants
KA.., KH.., KV.., KAF.., KHF.., KVF.., KAZ.., KHZ.., KVZ..:
Spiroplan (W)
gear units
Gear unit
type
M1
M2
M3
M4
M5
M6
K..37
0.50
1.00
1.00
1.40
1.00
1.00
K..47
0.80
1.30
1.60
2.15
1.60
1.60
K..57
1.30
2.30
2.70
3.15
2.90
2.70
K..67
1.10
2.40
2.70
3.70
2.60
2.60
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
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
K..157
31.0
66.0
67.0
87.0
62.0
62.0
KH167
33.0
95.0
105.0
123.0
85.0
84.0
KH187
53.0
152.0
167.0
200
143.0
143.0
The fill quantity of Spiroplan gear units does not vary, irrespective of their mounting
position:
Gear unit
type
Fill quantity in liters, regardless of mounting position
W..10
0.16
W..20
0.26
W..30
0.50
Helical-worm (S)
gear units
S..:
Gear unit
type
M1
M2
M31)
M4
M5
M6
S37
0.25
0.40
0.50
0.55
0.40
0.40
S47
0.35
0.80
0.70/0.90
1.00
0.80
0.80
S57
.50
1.20
1.00/1.20
1.45
1.30
1.30
S67
1.00
2.00
2.20/3.10
3.10
2.60
2.60
S77
1.90
4.20
3.70/5.4
5.9
4.40
4.40
S87
3.30
8.1
6.9/10.4
11.3
8.4
8.4
S97
6.8
15.0
13.4/18.0
21.8
17.0
17.0
1) The larger gear unit of multi-stage gear units must be filled with the larger oil volume.
SF..:
Gear unit
type
M1
M2
M31)
M4
M5
M6
SF37
0.25
0.40
0.50
0.55
0.40
0.40
SF47
0.40
0.90
0.90/1.05
1.05
1.00
1.00
SF57
0.50
1.20
1.00/1.50
1.55
1.40
1.40
SF67
1.00
2.20
2.30/3.00
3.20
2.70
2.70
SF77
1.90
4.10
3.90/5.8
6.5
4.90
4.90
SF87
3.80
8.0
7.1/10.1
12.0
9.1
9.1
SF97
7.4
15.0
13.8/18.8
22.6
18.0
18.0
80
Lubricants
SA.., SH.., SAF.., SHF.., SAZ.., SHZ..:

Gear unit
type
M1
M2
M31)
M4
M5
M6
S..37
0.25
0.40
0.50
0.50
0.40
0.40
S..47
0.40
0.80
0.70/0.90
1.00
0.80
0.80
S..57
0.50
1.10
1.00/1.50
1.50
1.20
1.20
S..67
1.00
2.00
1.80/2.60
2.90
2.50
2.50
S..77
1.80
3.90
3.60/5.0
5.8
4.50
4.50
S..87
3.80
7.4
6.0/8.7
10.8
8.0
8.0
S..97
7.0
14.0
11.4/16.0
20.5
15.7
15.7
81
Appendix
10
10
Appendix
10.1 Index of changes

The following additions and changes have been made compared to the previous edition
of the "Explosion-Proof Gear Units R..7, F..7, K..7, S..7, SPIROPLAN W" (publication
number: 1055520x, edition 11/2002) operating instructions:
General additions and corrections.
Mechanical
installation
Inspection and
maintenance
82
Installing the gear unit: Data on flatness error

Installing torque arms for mounted gear units: Data on retaining bolts
Mounted gear units with shrink disks: Information on assembly / removal has been
added
AM adapter coupling: Point A
Lubricant change intervals
11
11
Index
A
AD inspection / maintenance 47
AD, mounting on the input shaft assembly
Adapter coupling 36
Adjusting the mounting position 17
AM with backstop 38
Anti-friction bearing greases 75
AQ, installing the coupling adapter 38
AQA, maintenance / inspection
Input and output elements, installation 19

Inspection intervals 45
Inspection of AD adapter 47
Inspection of AM / AQA adapters 47
Installation tolerances 15
Installing couplings 20
Installing input and output elements 19
Installing the AM coupling adapter 36
Installing the AQ coupling adapter 38
Installing the gear unit 16
40
47
K gear units, lubricant fill quantities

Keyway 23
C
Centering shoulder AD../ZR
Change the oil seal 47
40
Lubricant table 74,

Lubricants 74
17
6
F gear units, lubricant fill quantities

Flatness error 16
79
7
8
9
10
11
76
Maintenance / inspection 47
Maintenance intervals 45
Maintenance of AD adapter 47
Maintenance of AM / AQA adapters
Malfunctions 48
AD input shaft assembly 49
AM / AQA / AL adapters 48
Gear units 48
Mechanical installation 15
Motor mounting platform 40
F
78
G
Gear unit inspection 46
Gear unit maintenance 46
Gear unit structure 9
Gear unit venting 18
H
Helical gear units, lubricant fill quantities 77,
helical gear units, structure 9
Helical-bevel gear units, lubricant fill quantities
Helical-bevel gear units, structure 11
Helical-worm gear unit, structure 12
Helical-worm gear units, lubricant fill quantities
36
13
IEC adapter
Lubricant change intervals 45

Lubricant fill quantities 77
Lubricant fill quantities for helical gear units 77, 78
Lubricant fill quantities for helical-bevel gear units 79
Lubricant fill quantities for helical-worm gear units 80
Lubricant fill quantities for parallel shaft helical gear units
78
Lubricant fill quantities for Spiroplan gear units 80
41
Check oil 46
Check oil level 46
Churning losses 51
Couplings, installation 20
Cover with backstop AD../RS 43
Cover with motor mounting platform AD../P
Customer service 48
Extended storage
Backstop RS 38
Breather valve 18
Damp locations
Designated use
78
79
80
14
15
47
Mounted gear units 23, 27, 30

Mounting on the input shaft assembly AD
Mounting position designation 50
Mounting positions
Helical gear units 52, 55
Helical-bevel gear units 60
Helical-worm gear units 65
Parallel shaft helical gear units 57
Spiroplan gear units 71
Mounting torque arms 21
16
17
18
40
19
20
21
22
N
Nameplate 14
NEMA adapter 36
Operating Instructions Gear Units, R..7, F..7, K..7, S..7 Series, SPIROPLAN W
83
11
O
Oil change 46
Open air 17
P
Painting gear units 18
Parallel shaft helical gear unit, structure 10
Parallel shaft helical gear units, lubricant fill quantities
78
R
R gear units, lubricant fill quantities
77
RS backstop
43
RX gear units, lubricant fill quantities
78
S
S gear units, lubricant fill quantities
Safety notes 6
Serial number 14
Shrink disk 27
80
Solid shaft 19
Spiroplan gear units, lubricant fill quantities 80
Spiroplan W gear units, structure 13
Splined hollow shaft 23
Startup 44
Helical, parallel shaft helical and helical-bevel gear
units 44
Helical-worm and Spiroplan W gear units 44
Structure
Helical gear units 9
Helical-bevel gear units 11
Helical-worm gear unit 12
Parallel shaft helical gear unit 10
Spiroplan gear units 13
T
TorqLOC 30
Torque arm for helical-bevel gear units 21
Torque arm for helical-worm gear units 22
Torque arm for Spiroplan W gear units 22
Torque arms for parallel shaft helical gear units
Torque arms, mounting 21
Transportation 7
21
U
Unit designation
14
W
W gear units, lubricant fill quantities
Waste disposal 5
84
80
Operating instructions Gear Units, R..7, F..7, K..7, S..7 Series, SPIROPLAN W
Address List
Address List
Germany
Headquarters
Production
Sales
Bruchsal
SEW-EURODRIVE GmbH & Co KG

Ernst-Blickle-Strae 42
D-76646 Bruchsal
P.O. Box
Postfach 3023 D-76642 Bruchsal
Tel. +49 7251 75-0

Fax +49 7251 75-1970
http://www.sew-eurodrive.de
sew@sew-eurodrive.de
Service
Competence Center
Central
Gear units /
Motors

D-76676 Graben-Neudorf
Tel. +49 7251 75-1710

Fax +49 7251 75-1711
sc-mitte-gm@sew-eurodrive.de
Central
Electronics

D-76646 Bruchsal
Tel. +49 7251 75-1780

Fax +49 7251 75-1769
sc-mitte-e@sew-eurodrive.de
North

Alte Ricklinger Strae 40-42
D-30823 Garbsen (near Hannover)
Tel. +49 5137 8798-30

Fax +49 5137 8798-55
sc-nord@sew-eurodrive.de
East

Dnkritzer Weg 1
D-08393 Meerane (near Zwickau)
Tel. +49 3764 7606-0

Fax +49 3764 7606-30
sc-ost@sew-eurodrive.de
South

Domagkstrae 5
D-85551 Kirchheim (near Mnchen)
Tel. +49 89 909552-10

Fax +49 89 909552-50
sc-sued@sew-eurodrive.de
West

Siemensstrae 1
D-40764 Langenfeld (near Dsseldorf)
Tel. +49 2173 8507-30

Fax +49 2173 8507-55
sc-west@sew-eurodrive.de
Drive Service Hotline / 24 Hour Service
+49 180 5 SEWHELP

+49 180 5 7394357
Additional addresses for service in Germany provided on request!

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

Algeria
Sales
Alger
Rducom
16, rue des Frres Zaghnoun
Bellevue El-Harrach
16200 Alger
Tel. +213 21 8222-84

Fax +213 21 8222-84
Buenos Aires
SEW EURODRIVE ARGENTINA S.A.

Centro Industrial Garin, Lote 35
Ruta Panamericana Km 37,5
1619 Garin
Tel. +54 3327 4572-84

Fax +54 3327 4572-21
sewar@sew-eurodrive.com.ar
Argentina
Assembly
Sales
Service
08/2004
85
Address List
Australia
Assembly
Sales
Service
Melbourne
SEW-EURODRIVE PTY. LTD.

27 Beverage Drive
Tullamarine, Victoria 3043
Tel. +61 3 9933-1000

Fax +61 3 9933-1003
http://www.sew-eurodrive.com.au
enquires@sew-eurodrive.com.au
Sydney

9, Sleigh Place, Wetherill Park
New South Wales, 2164
Tel. +61 2 9725-9900

Fax +61 2 9725-9905
Wien
SEW-EURODRIVE Ges.m.b.H.
Richard-Strauss-Strasse 24
A-1230 Wien
Tel. +43 1 617 55 00-0

Fax +43 1 617 55 00-30
http://sew-eurodrive.at
sew@sew-eurodrive.at
Brssel
CARON-VECTOR S.A.
Avenue Eiffel 5
B-1300 Wavre
Tel. +32 10 231-311

Fax +32 10 231-336
http://www.caron-vector.be
info@caron-vector.be
Sao Paulo
SEW-EURODRIVE Brasil Ltda.

Avenida Amncio Gaiolli, 50
Caixa Postal: 201-07111-970
Guarulhos/SP - Cep.: 07251-250
Tel. +55 11 6489-9133

Fax +55 11 6480-3328
http://www.sew.com.br
sew@sew.com.br
Austria
Assembly
Sales
Service
Belgium
Assembly
Sales
Service
Brazil
Production
Sales
Service
Additional addresses for service in Brazil provided on request!

Bulgaria
Sales
Sofia
BEVER-DRIVE GMBH
Bogdanovetz Str.1
BG-1606 Sofia
Tel. +359 2 9532565

Fax +359 2 9549345
bever@mbox.infotel.bg
Douala
Electro-Services
Rue Drouot Akwa
B.P. 2024
Douala
Tel. +237 4322-99

Fax +237 4277-03
Toronto
SEW-EURODRIVE CO. OF CANADA LTD.

210 Walker Drive
Bramalea, Ontario L6T3W1
Tel. +1 905 791-1553

Fax +1 905 791-2999
http://www.sew-eurodrive.ca
l.reynolds@sew-eurodrive.ca
Vancouver

7188 Honeyman Street
Delta. B.C. V4G 1 E2
Tel. +1 604 946-5535

Fax +1 604 946-2513
b.wake@sew-eurodrive.ca
Montreal

2555 Rue Leger Street
LaSalle, Quebec H8N 2V9
Tel. +1 514 367-1124

Fax +1 514 367-3677
a.peluso@sew-eurodrive.ca
Cameroon
Sales
Canada
Assembly
Sales
Service
Additional addresses for service in Canada provided on request!

Chile
Assembly
Sales
Service
Santiago de
Chile
SEW-EURODRIVE CHILE LTDA.

Las Encinas 1295
Parque Industrial Valle Grande
LAMPA
RCH-Santiago de Chile
P.O. Box
Casilla 23 Correo Quilicura - Santiago - Chile
Tel. +56 2 75770-00

Fax +56 2 75770-01
sewsales@entelchile.net
Tianjin
SEW-EURODRIVE (Tianjin) Co., Ltd.

No. 46, 7th Avenue, TEDA
Tianjin 300457
Tel. +86 22 25322612

Fax +86 22 25322611
victor.zhang@sew-eurodrive.cn
http://www.sew.com.cn
China
Production
Assembly
Sales
Service
86
08/2004
Address List
China
Assembly
Sales
Service
Suzhou
SEW-EURODRIVE (Suzhou) Co., Ltd.

333, Suhong Middle Road
Suzhou Industrial Park
Jiangsu Province, 215021
P. R. China
Tel. +86 512 62581781

Fax +86 512 62581783
suzhou@sew.com.cn
Bogot
SEW-EURODRIVE COLOMBIA LTDA.

Calle 22 No. 132-60
Bodega 6, Manzana B
Santaf de Bogot
Tel. +57 1 54750-50

Fax +57 1 54750-44
sewcol@andinet.com
Zagreb
KOMPEKS d. o. o.
PIT Erddy 4 II
HR 10 000 Zagreb
Tel. +385 1 4613-158

Fax +385 1 4613-158
kompeks@net.hr
Praha
SEW-EURODRIVE CZ S.R.O.
Business Centrum Praha
Lun 591
CZ-16000 Praha 6 - Vokovice
Tel. +420 220121234 + 220121236

Fax +420 220121237
http://www.sew-eurodrive.cz
sew@sew-eurodrive.cz
Kopenhagen
SEW-EURODRIVEA/S
Geminivej 28-30, P.O. Box 100
DK-2670 Greve
Tel. +45 43 9585-00

Fax +45 43 9585-09
http://www.sew-eurodrive.dk
sew@sew-eurodrive.dk
Tallin
ALAS-KUUL AS
Paldiski mnt.125
EE 0006 Tallin
Tel. +372 6593230

Fax +372 6593231
veiko.soots@alas-kuul.ee
Lahti
SEW-EURODRIVE OY
Vesimentie 4
FIN-15860 Hollola 2
Tel. +358 3 589-300

Fax +358 3 7806-211
http://www.sew-eurodrive.fi
sew@sew-eurodrive.fi
Libreville
Electro-Services
B.P. 1889
Libreville
Tel. +241 7340-11

Fax +241 7340-12
Normanton
SEW-EURODRIVE Ltd.
Beckbridge Industrial Estate
P.O. Box No.1
GB-Normanton, West- Yorkshire WF6 1QR
Tel. +44 1924 893-855

Fax +44 1924 893-702
http://www.sew-eurodrive.co.uk
info@sew-eurodrive.co.uk
Athen
Christ. Boznos & Son S.A.

12, Mavromichali Street
P.O. Box 80136, GR-18545 Piraeus
Tel. +30 2 1042 251-34

Fax +30 2 1042 251-59
http://www.boznos.gr
info@boznos.gr
Hong Kong
SEW-EURODRIVE LTD.
Unit No. 801-806, 8th Floor
Hong Leong Industrial Complex
No. 4, Wang Kwong Road
Kowloon, Hong Kong
Tel. +852 2 7960477 + 79604654

Fax +852 2 7959129
sew@sewhk.com
Colombia
Assembly
Sales
Service
Croatia
Sales
Service
Czech Republic
Sales
Denmark
Assembly
Sales
Service
Estonia
Sales
Finland
Assembly
Sales
Service
Gabon
Sales
Great Britain
Assembly
Sales
Service
Greece
Sales
Service
Hong Kong
Assembly
Sales
Service
08/2004
87
Address List
Hungary
Sales
Service
Budapest
SEW-EURODRIVE Kft.
H-1037 Budapest
Kunigunda u. 18
Tel. +36 1 437 06-58

Fax +36 1 437 06-50
office@sew-eurodrive.hu
Assembly
Sales
Service
Baroda
SEW-EURODRIVE India Pvt. Ltd.

Plot No. 4, Gidc
Por Ramangamdi Baroda - 391 243
Gujarat
Tel. +91 265 2831021

Fax +91 265 2831087
mdoffice@seweurodriveindia.com
Technical Offices
Bangalore
SEW-EURODRIVE India Private Limited

308, Prestige Centre Point
7, Edward Road
Bangalore
Tel. +91 80 22266565

Fax +91 80 22266569
sewbangalore@sify.com
Mumbai

312 A, 3rd Floor, Acme Plaza
Andheri Kurla Road, Andheri (E)
Mumbai
Tel. +91 22 28348440

Fax +91 22 28217858
sewmumbai@vsnl.net
Dublin
Alperton Engineering Ltd.

48 Moyle Road
Dublin Industrial Estate
Glasnevin, Dublin 11
Tel. +353 1 830-6277

Fax +353 1 830-6458
Tel-Aviv
Liraz Handasa Ltd.

Ahofer Str 34B / 228
58858 Holon
Tel. +972 3 5599511

Fax +972 3 5599512
lirazhandasa@barak-online.net
Milano
SEW-EURODRIVE di R. Blickle & Co.s.a.s.

Via Bernini,14
I-20020 Solaro (Milano)
Tel. +39 2 96 9801

Fax +39 2 96 799781
sewit@sew-eurodrive.it
Abidjan
SICA
Ste industrielle et commerciale pour lAfrique
165, Bld de Marseille
B.P. 2323, Abidjan 08
Tel. +225 2579-44

Fax +225 2584-36
Toyoda-cho
SEW-EURODRIVE JAPAN CO., LTD

250-1, Shimoman-no,
Toyoda-cho, Iwata gun
Shizuoka prefecture, 438-0818
Tel. +81 538 373811

Fax +81 538 373814
sewjapan@sew-eurodrive.co.jp
Ansan-City
SEW-EURODRIVE KOREA CO., LTD.

B 601-4, Banweol Industrial Estate
Unit 1048-4, Shingil-Dong
Ansan 425-120
Tel. +82 31 492-8051

Fax +82 31 492-8056
master@sew-korea.co.kr
Riga
SIA Alas-Kuul
Katlakalna 11C
LV-1073 Riga
Tel. +371 7139386

Fax +371 7139386
info@alas-kuul.ee
Beirut
Gabriel Acar & Fils sarl

B. P. 80484
Bourj Hammoud, Beirut
Tel. +961 1 4947-86

+961 1 4982-72
+961 3 2745-39
Fax +961 1 4949-71
gacar@beirut.com
India
Ireland
Sales
Service
Israel
Sales
Italy
Assembly
Sales
Service
Ivory Coast
Sales
Japan
Assembly
Sales
Service
Korea
Assembly
Sales
Service
Latvia
Sales
Lebanon
Sales
88
08/2004
Address List
Lithuania
Sales
Alytus
UAB Irseva
Merkines g. 2A
LT-4580 Alytus
Tel. +370 315 79204

Fax +370 315 79688
irmantas.irseva@one.lt
Brssel
CARON-VECTOR S.A.
Avenue Eiffel 5
B-1300 Wavre
Tel. +32 10 231-311

Fax +32 10 231-336
Johore
SEW-EURODRIVE SDN BHD

No. 95, Jalan Seroja 39, Taman Johor Jaya
81000 Johor Bahru, Johor
West Malaysia
Tel. +60 7 3549409

Fax +60 7 3541404
kchtan@pd.jaring.my
Casablanca
S. R. M.
Socit de Ralisations Mcaniques
5, rue Emir Abdelkader
05 Casablanca
Tel. +212 2 6186-69 + 6186-70 + 618671

Fax +212 2 6215-88
srm@marocnet.net.ma
Rotterdam
VECTOR Aandrijftechniek B.V.

Industrieweg 175
NL-3044 AS Rotterdam
Postbus 10085
NL-3004 AB Rotterdam
Tel. +31 10 4463-700

Fax +31 10 4155-552
http://www.vector.nu
info@vector.nu
Auckland
SEW-EURODRIVE NEW ZEALAND LTD.

P.O. Box 58-428
82 Greenmount drive
East Tamaki Auckland
Tel. +64 9 2745627

Fax +64 9 2740165
sales@sew-eurodrive.co.nz
Christchurch

10 Settlers Crescent, Ferrymead
Christchurch
Tel. +64 3 384-6251

Fax +64 3 384-6455
Moss
SEW-EURODRIVE A/S
Solgaard skog 71
N-1599 Moss
Tel. +47 69 241-020

Fax +47 69 241-040
sew@sew-eurodrive.no
Lima
SEW DEL PERU MOTORES REDUCTORES

S.A.C.
Los Calderos, 120-124
Urbanizacion Industrial Vulcano, ATE, Lima
Tel. +51 1 3495280

Fax +51 1 3493002
sewperu@sew-eurodrive.com.pe
Lodz
SEW-EURODRIVE Polska Sp.z.o.o.

ul. Techniczna 5
PL-92-518 Lodz
Tel. +48 42 67710-90

Fax +48 42 67710-99
http://www.sew-eurodrive.pl
sew@sew-eurodrive.pl
Coimbra
SEW-EURODRIVE, LDA.
Apartado 15
P-3050-901 Mealhada
Tel. +351 231 20 9670

Fax +351 231 20 3685
http://www.sew-eurodrive.pt
infosew@sew-eurodrive.pt
Bucuresti
Sialco Trading SRL

str. Madrid nr.4
011785 Bucuresti
Tel. +40 21 230-1328

Fax +40 21 230-7170
sialco@sialco.ro
Luxembourg
Assembly
Sales
Service
Malaysia
Assembly
Sales
Service
Morocco
Sales
Netherlands
Assembly
Sales
Service
New Zealand
Assembly
Sales
Service
Norway
Assembly
Sales
Service
Peru
Assembly
Sales
Service
Poland
Assembly
Sales
Service
Portugal
Assembly
Sales
Service
Romania
Sales
Service
08/2004
89
Address List
Russia
Sales
St. Petersburg
ZAO SEW-EURODRIVE
P.O. Box 263
RUS-195220 St. Petersburg
Tel. +7 812 5357142 +812 5350430

Fax +7 812 5352287
http://www.sew-eurodrive.ru
sew@sew-eurodrive.ru
Dakar
SENEMECA
Mcanique Gnrale
Km 8, Route de Rufisque
B.P. 3251, Dakar
Tel. +221 849 47-70

Fax +221 849 47-71
senemeca@sentoo.sn
Beograd
DIPAR d.o.o.
Kajmakcalanska 54
SCG-11000 Beograd
Tel. +381 11 3046677

Fax +381 11 3809380
dipar@yubc.net
Singapore
SEW-EURODRIVE PTE. LTD.

No 9, Tuas Drive 2
Jurong Industrial Estate
Singapore 638644
Tel. +65 68621701 ... 1705

Fax +65 68612827
sales@sew-eurodrive.com.sg
Sered
SEW-Eurodrive SK s.r.o.
Trnavska 920
SK-926 01 Sered
Tel. +421 31 7891311

Fax +421 31 7891312
sew@sew-eurodrive.sk
Celje
Pakman - Pogonska Tehnika d.o.o.

UI. XIV. divizije 14
SLO 3000 Celje
Tel. +386 3 490 83-20

Fax +386 3 490 83-21
pakman@siol.net
Johannesburg
SEW-EURODRIVE (PROPRIETARY) LIMITED

Eurodrive House
Cnr. Adcock Ingram and Aerodrome Roads
Aeroton Ext. 2
Johannesburg 2013
P.O.Box 90004
Bertsham 2013
Tel. +27 11 248-7000

Fax +27 11 494-3104
dross@sew.co.za
Capetown

Rainbow Park
Cnr. Racecourse & Omuramba Road
Montague Gardens
Cape Town
P.O.Box 36556
Chempet 7442
Cape Town
Tel. +27 21 552-9820

Fax +27 21 552-9830
Telex 576 062
dswanepoel@sew.co.za
Durban

2 Monaceo Place
Pinetown
Durban
P.O. Box 10433, Ashwood 3605
Tel. +27 31 700-3451

Fax +27 31 700-3847
dtait@sew.co.za
Bilbao
SEW-EURODRIVE ESPAA, S.L.

Parque Tecnolgico, Edificio, 302
E-48170 Zamudio (Vizcaya)
Tel. +34 9 4431 84-70

Fax +34 9 4431 84-71
sew.spain@sew-eurodrive.es
Jnkping
SEW-EURODRIVE AB
Gnejsvgen 6-8
S-55303 Jnkping
Box 3100 S-55003 Jnkping
Tel. +46 36 3442-00

Fax +46 36 3442-80
http://www.sew-eurodrive.se
info@sew-eurodrive.se
Senegal
Sales
Serbia and Montenegro

Sales
Singapore
Assembly
Sales
Service
Slovakia
Sales
Slovenia
Sales
Service
South Africa
Assembly
Sales
Service
Spain
Assembly
Sales
Service
Sweden
Assembly
Sales
Service
90
08/2004
Address List
Switzerland
Assembly
Sales
Service
Basel
Alfred lmhof A.G.

Jurastrasse 10
CH-4142 Mnchenstein bei Basel
Tel. +41 61 41717-17

Fax +41 61 41717-00
http://www.imhof-sew.ch
info@imhof-sew.ch
Chon Buri
SEW-EURODRIVE (Thailand) Ltd.

Bangpakong Industrial Park 2
700/456, Moo.7, Tambol Donhuaroh
Muang District
Chon Buri 20000
Tel. +66 38 454281

Fax +66 38 454288
sewthailand@sew-eurodrive.co.th
Tunis
T. M.S. Technic Marketing Service

7, rue Ibn EI Heithem
Z.I. SMMT
2014 Mgrine Erriadh
Tel. +216 1 4340-64 + 1 4320-29

Fax +216 1 4329-76
Istanbul
SEW-EURODRIVE
Hareket Sistemleri Sirketi
Bagdat Cad. Koruma Cikmazi No. 3
TR-34846 Maltepe ISTANBUL
Tel. +90 216 4419163 + 216 4419164 +

216 3838014
Fax +90 216 3055867
sew@sew-eurodrive.com.tr
Production
Assembly
Sales
Service
Greenville
SEW-EURODRIVE INC.
1295 Old Spartanburg Highway
P.O. Box 518
Lyman, S.C. 29365
Tel. +1 864 439-7537

Fax Sales +1 864 439-7830
Fax Manuf. +1 864 439-9948
Fax Ass. +1 864 439-0566
Telex 805 550
http://www.seweurodrive.com
cslyman@seweurodrive.com
Assembly
Sales
Service
San Francisco
SEW-EURODRIVE INC.
30599 San Antonio St.
Hayward, California 94544-7101
Tel. +1 510 487-3560

Fax +1 510 487-6381
cshayward@seweurodrive.com
Philadelphia/PA
SEW-EURODRIVE INC.
Pureland Ind. Complex
2107 High Hill Road, P.O. Box 481
Bridgeport, New Jersey 08014
Tel. +1 856 467-2277

Fax +1 856 845-3179
csbridgeport@seweurodrive.com
Dayton
SEW-EURODRIVE INC.
2001 West Main Street
Troy, Ohio 45373
Tel. +1 937 335-0036

Fax +1 937 440-3799
cstroy@seweurodrive.com
Dallas
SEW-EURODRIVE INC.
3950 Platinum Way
Dallas, Texas 75237
Tel. +1 214 330-4824

Fax +1 214 330-4724
csdallas@seweurodrive.com
Thailand
Assembly
Sales
Service
Tunisia
Sales
Turkey
Assembly
Sales
Service
USA
Additional addresses for service in the USA provided on request!

Venezuela
Assembly
Sales
Service
08/2004
Valencia
SEW-EURODRIVE Venezuela S.A.

Av. Norte Sur No. 3, Galpon 84-319
Zona Industrial Municipal Norte
Valencia, Estado Carabobo
Tel. +58 241 832-9804

Fax +58 241 838-6275
sewventas@cantv.net
sewfinanzas@cantv.net
91
How were driving the world
With people who

think fast and
develop the
future with you.
With a worldwide
service network that is
always close at hand.
With drives and controls

that automatically
improve your productivity.
With uncompromising
quality that reduces the
cost and complexity of
daily operations.
With comprehensive
knowledge in virtually
every branch of
industry today.
SEW-EURODRIVE
Driving the world
With a global presence

that offers responsive
and reliable solutions.
Anywhere.
With innovative
technology that solves
tomorrows problems
today.
With online information

and software updates, via
the Internet, available
around the clock.

P.O. Box 3023 D-76642 Bruchsal / Germany
Phone +49 7251 75-0 Fax +49 7251 75-1970
sew@sew-eurodrive.com
www.sew-eurodrive.com
AC Motors DR/DV/DT/DTE/DVE,
Asynchronous Servo Motors CT/CV
Edition 08/2004
11291613 / EN
A6.C01
Operating Instructions
SEW-EURODRIVE Driving the world
Contents
1 Important Notes................................................................................................. 4
2 Safety Notes ...................................................................................................... 5
3 Motor Design ..................................................................................................... 6
3.1 Basic structure of AC motors .................................................................... 6
3.2 Nameplate, unit designation ..................................................................... 7
4 Mechanical Installation ..................................................................................... 9
4.1 Before you begin ....................................................................................... 9
4.2 Preliminary work........................................................................................ 9
4.3 Installing the motor.................................................................................. 10
4.4 Installation tolerances ............................................................................. 11
5 Electrical Installation ...................................................................................... 12
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
5.5 Special aspects of torque motors and low-speed motors ....................... 13
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
5.10 Connecting DT56 motor...+/BMG............................................................ 16
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
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
7 Malfunctions .................................................................................................... 31
7.1 Motor Malfunctions.................................................................................. 31
7.2 Brake problems ....................................................................................... 32
7.3 Malfunctions during operation with a frequency inverter......................... 32
8 Inspection / Maintenance................................................................................ 33
8.1 Inspection and maintenance intervals..................................................... 33
8.2 Preliminary work for motor and brake maintenance................................ 34
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
8.6 Inspection / maintenance for BMG05-8, BM15-62 brakes ...................... 44
8.7 Inspection / maintenance of the BMG61/122 brake ................................ 49
9 Technical Data ................................................................................................. 52
9.1 Work done, braking torque BMG02......................................................... 52
9.2 Information for ordering a replacement BMG02...................................... 52
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
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
Important Notes
1
1
Important Notes
Safety and
warning notes
Betriebsanleitung
Always follow the safety and warning instructions in these operating instructions!
Electrical hazard
Hazard
Hazardous situation
Possible consequences: Slight or minor injuries.
Harmful situation
Possible consequences: Damage to the drive and the environment.
Tips and useful information.
You must adhere to the operating instructions to ensure:
Trouble-free operation
Fulfillment of any rights to claim under limited warranty
Consequently, read the operating instructions before you start operating the drive!
The operating instructions contain important information about servicing. Therefore,
keep the operating instructions close to the drive.
Waste disposal
Dispose of the following materials in accordance with the regulations in force:
Iron
Aluminum
Copper
Plastic
Electronic components
Operating Instructions AC Motors DR / DV / DT / DTE / DVE / Asynchrounos Servo Motors CT / CV
Safety Notes
Safety Notes
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.
Please also consider the supplementary safety notes in the individual sections of
these operating instructions.
General
information
During and after operation, motors and gearmotors have live and moving parts and their
surfaces may be hot.
All work related to transport, putting into storage, setting up/mounting,
connection, startup, maintenance and repair may only be performed by trained
personnel observing
The corresponding detailed operating instructions and wiring diagrams
The warning and safety signs on the motor/gearmotor
The specific regulations and requirements for the system
The national / regional regulations governing safety and accident prevention
Severe injuries and damage to property may result from
Designated use
Improper use
Incorrect installation or operation
Unauthorized removal of necessary protection covers or the housing
These electric motors are intended for industrial systems. They fulfill the applicable
standards and regulations:
Low voltage directive 73/23/EEC
Technical data and information about the permitted conditions can be found on the
nameplate and in the documentation.
It is essential to observe all the specified information!
Transportation
Inspect the shipment for damage as soon as you receive the delivery. Inform the
shipping company immediately. It may be necessary to preclude startup.
Tighten installed eyebolts. They are only designed for the weight of the
motor/gearmotor; do not attach any additional loads.
The installed lifting eyebolts comply with DIN 580. Observe the loads and regulations specified 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 transportation. In this case, the tension force vector of the slings must not
exceed a 45 angle in accordance with DIN 580.
Use suitable, sufficiently rated handling equipment if necessary. Remove any transportation fixtures prior to startup.
Installation /
assembly
Follow the instructions in the section "Mechanical Installation"!
Inspection /
maintenance
Follow the instructions in the section "Inspection and Maintenance"!
Motor Design
Basic structure of AC motors
3
3
Motor Design
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
possible depending on the motor size and version!
3.1
Basic structure of AC motors

31
44 41
20
1
3
12
11
10
9
106
2
13
107
100
101
103
22
35
32
36
37
42
116
118
117
119
111
16
112
123
135
130
129
134
115
113
131
132
02969AXX
[1] Rotor, cpl.
[31] Key
[107] Oil-flinger ring
[2] Circlip
[32] Circlip
[111] Gasket
[132] Terminal box cover
[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
[10] Circlip
[41] Equalizing ring
[116] Terminal yoke
[11] Grooved ball bearing
[42] Non drive-end

bearing shield
[117] Hex head bolt
[12] Circlip
[44] Grooved ball bearing [118] Lock washer
[13] Hex head screw (tie rod)
[100] Hex nut
[119] Machine screw
[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
Motor Design
3.2
Nameplate
Example: DFV 160 M4 /BM brake motor
03214BXX
Unit designation
Example: DR / DT / DV / DTE / DVE AC (brake) motors
DFV 132M2 / BM /TF / AMA1 / EV1T
Motor option: 5 V TTL incremental
encoder
Motor option: AMB1 plug connector
Motor option: TF thermistor sensor
Motor option: Brake
Size 132M and 2-pole
Flange-mounted motor

01.
3009818304.
0002.
99
Year number end digits of the year of manufacture (2digit)
Sales organization
Motor Design
Nameplate
Example: CT90L4 / BMG / TF / ES1S servo brake motor
CT90L4 BMG TF / ES1S

01.3410069302.0001.00
30.5
10.5
3000
103
345
28
B5
230~
20
7.9
54
F
BGE 1.5
51358BXX
Unit designation
Examples: Servo (brake) motors CT / CV
CFV 132M4 / BM / TF / EV1S
Motor option: Sine/cosine incremental encoder
Motor option: TF thermistor sensor
Motor option: Brake
Size 132M and 4-pole
Flange-mounted motor

01.
3009818304.
0002.
99
Year number end digits of the year of manufacture (2digit)
Sales organization
Before you begin
It is essential to comply with the safety notes in Section 2 during installation!
4.1
Before you begin
The drive may

only be installed
if
The entries on the nameplate of the drive and/or the output voltage of the frequency
inverter match the voltage supply system
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)
No oil, acid, gas, vapors, radiation, etc.
Installation altitude max. 1000 m above sea level
Note the restrictions for encoders
Special versions: Drive configured in accordance with the ambient conditions
4.2
Preliminary work
Motor shaft ends must be thoroughly cleaned of anti-corrosion agents, contamination or
similar (use a commercially available solvent). Do not allow the solvent to penetrate the
bearings or shaft seals this could cause material damage!
Extended storage
of motors
Please note the reduced grease utilization period of the ball bearings after storage
periods exceeding one year.
Check whether the motor has absorbed moisture as a result of being stored for a long
time. Measure the insulation resistance to do this (measuring voltage 500 V).
The insulation resistance ( following figure) varies greatly depending on the

temperature! The motor must be dried if the insulation resistance is not adequate.
[M ]
100
10
0,1
20
40
60
80
[C]
01731AXX
1) Minimum temperature for motors with backstop: 15 C. Note that the temperature range of the gear unit
may also be restricted ( gear unit operating instructions)
Installing the motor
Drying the motor
Heat up the motor
with hot air or
using an isolation transformer

Connect the windings in series ( following figure)
Auxiliary AC voltage supply max. 10 % of the rated voltage with max. 20 % of the
rated current
Transformer
01730AEN
The drying process is finished when the minimum insulation resistance has been
attained.
Check the terminal box to see whether
4.3
The inside is clean and dry
The connections and fixing parts are free from corrosion
The joint seals are OK
The cable glands are sound, otherwise clean or replace them.
Installing the motor

The motor or gearmotor may only be mounted or installed in the specified mounting
position on a level and torsionally rigid support structure which is not subjected to
shocks.
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!).
Do not butt or hammer the shaft end.
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
be drawn in or reused.
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
opened when necessary; open condensation drain holes are not permitted, as
this would invalidate higher classes of enclosure.
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).
Note the following for encoder mounting:
Foot-mounted motors CT/DT71, CT/DT90, CV/DV132M, CV/DV160L must be mounted
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 corresponds 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 dimensions; see Sec. "Dimension Sheet Notes" in the Gearmotors catalog.
10
Installation tolerances
Installation in
damp locations
or in the open
If possible, arrange the terminal box so the cable entries are pointing downwards.
Coat the threads of cable glands and pocket caps with sealant and tighten them well
then coat them again.
Seal the cable entry well.
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!
Restore the anticorrosive coating if necessary.
Check the enclosure.
4.4
Installation tolerances
Shaft end
Flanges
Diameter tolerance in accordance with DIN 748

ISO k6 at 50 mm
ISO m6 at > 50 mm
Center bore in accordance with DIN 332, shape
DR..
Centering shoulder tolerance in accordance with

DIN 42948
ISO j6 at 230 mm
ISO h6 at > 230 mm
11
Electrical Installation
Wiring notes
5
5
It is essential to comply with the safety notes in section 2 during installation!
Switch contacts in utilization category AC-3 to EN 60947-4-1 must be used for
switching the motor and the brake.
Using the wiring

diagrams
5.1
The motor must only ever be connected as shown in the wiring diagram included with
the motor. Do not connect or start up the motor if this wiring diagram is missing.
You can obtain the valid wiring diagram free of charge from SEW-EURODRIVE.
Wiring notes
Comply with the safety notes during installation.
Protecting brake
control systems
against
interference
Do not route brake cables alongside switched-mode power cables, as otherwise there
is a risk of disrupting brake control systems.
Switched-mode power cables include in particular:
Output cables from frequency and servo controllers, converters, soft start units and
brake units
Feeder cables for brake resistors and similar options
Protecting motor
protection
devices against
interference
To protect SEW motor protection devices (temperature sensors TF, winding thermostats
TH) against interference:
Route separately shielded feeder cables together with switched-mode power lines in
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.
12
Improving the grounding (EMC)
5.4
Improving the grounding (EMC)

For improved, low-impedance grounding at high frequencies, we recommend using the
following connections with the DR/DV/DT AC motors:
Sizes DT71 ... DV 132S: [1] M5x10 thread rolling screw and 2 serrated lock washers
to DIN 6798 in the stator housing.
[1]
Sizes DV112M ... DV280: Screw and 2 serrated lock washers in the bore of the eye
bolt.
Thread size of the eye bolt:
DV112 / 132S:
M8
DV132M ... 180L: M12
DV200 ... 280:
M16
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
may be generated when they are switched off. Consequently, SEW-EURODRIVE
recommends using the varistor circuit shown below for protection. The size of the varistors depends, amongst other factors, on the starting frequency note for project planning!
U1
V1
W1
01732CXX
13
Special aspects in switching operation
5
5.6
Special aspects in switching operation

When the motors are used in switching operation, possible interference of the switchgear must be excluded by ensuring suitable wiring. According to EN 60204 (electrical
equipment of machines), motor windings must have interference suppression to protect
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.
5.7
Environmental conditions during operation
Ambient
temperature
The temperature range of -20 C to +40 C must be ensured unless specified otherwise
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
0.8
0.7
1000
Hazardous
radiation
14
2000
3000
4000
Motors must not be subjected to hazardous radiation. Contact SEW-EURODRIVE if

necessary.
Connecting the motor
5.8
Connecting the motor

In case of operation with electronic control units, it is essential to adhere to the
corresponding operating instructions / wiring diagrams!
Connecting the
motor via
terminal boxes
Small connection
accessories
According to the circuit diagram provided
Check the line cross section
Arrange terminal links correctly
Screw connections and protective earth conductors on firmly
In terminal boxes: Check winding connections and tighten them if necessary
Note: In the case of motor sizes DR63 - DV132S, the small connection 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 accordance 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
2 Nm 20 % for M5
1
5
6
1
2
50926AXX
1
2
3
4
5
6
7
8
Terminal stud
Lock washer
Connection disk
Motor terminal lead
Top nut
Washer
External connection
Bottom nut
1
2
3
4
5
6
Terminal stud
Hex nut with flange
Terminal link
Motor connection with Stocko connection
terminal
Connection disk
External connection
The asynchronous servomotors of the CT/CV series are supplied with connected
terminal links according to the nameplate.
15
Preparing motor sizes 56 and 63 knockout
5
5.9
Preparing motor sizes 56 and 63 knockout

Important: Wear safety glasses danger of injury from fragments!
Put on the terminal box cover and screw it into place
Define which cable entries to open
Open the cable entries

with a chisel or similar (hold at an angle)
by a light tap with a hammer
01733AXX
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
Secure the cable screw fittings with the supplied lock nuts
5.10 Connecting DT56 motor...+/BMG

The motor has a star point with three fixed connection points in the winding overhang.
The supply system leads (L1, L2, L3) are connected to a spring cage terminal block [2]
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.
1
3
2
TF TF
04861AXX
16
Single-phase version ET56
5.11
Single-phase version ET56

The ET56 single-phase motor is supplied with a running capacitor that is mounted and
connected:
1~230 V, 50 Hz
CB = 4 F
1~230 V, 60 Hz
CB = 4 F
1~110 V, 60 Hz
CB = 20 F
No full-load startup is possible with the running capacitor alone! The singlephase motor cannot be combined with a TF.
5.12 Connecting the motor using the IS 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
section
Make sure the type of line corresponds to the applicable regulations. The rated currents
are specified on the motor nameplate. The line cross sections that can be used are listed
in the following table.
Without variable terminal link
With variable terminal link
Link cable
Double assignment
(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
17
Connecting the motor using the IS plug connector
Wiring the upper

section of the
plug connection
Loosen the housing cover screws

Remove the housing cover
Remove the screws from the upper section of the plug connector
Remove the upper section of the plug connector from the cover
Strip the insulation off the connection lead

Strip about 9 mm insulation off the connecting leads
Pass the cable through the cable gland
Wiring up as
shown in circuit
diagram DT82,
DT83
Connect the lines as shown in the circuit diagram
Wiring up as
shown in wiring
diagram DT81
For / startup:
Tighten the clamping screws carefully!
Install the plug connector ( Sec. "Installing the plug connector")
Connect with 6 lines

Tighten the clamping screws carefully!
Motor contactors in the switch cabinet
For or 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 ( or )
01734AXX
18
01735AXX
Brake control
system BSR
preparing the
variable terminal
link
For operation:
On the side of the variable terminal link as shown in the following figure: Remove only
the bare metal pin of the marked prong horizontally touch guard!
50429AXX
For operation:
On the side of the variable terminal link as shown in the following figure: Completely
remove two prongs horizontally.
50430AXX
Wiring according to
the DT81 wiring
diagram for or
operation with
double terminal
assignment
At terminal point for double assignment:

Connect the link cable
When operation is as required:

Insert the link cable in the variable terminal link
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.
01738AXX
19
Installing the plug

connector
The housing cover of the IS plug connector can be screwed onto the lower section of
the plug connector depending on the required position of the cable lead. The upper
section of the plug connector shown in the following figure must first be installed in the
housing cover so it will match the position of the lower section of the plug connector:
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
Tighten the cable gland
01739AXX
Mounting position of the upper section of the plug connection in the housing cover
01740AXX
20
Connect the motor using plug connectors AB.., AD.., AM.., AS
5.13 Connect the motor using plug connectors AB.., AD.., AM.., AS
AMA1
ASE1
50956AXX
The installed plug connector systems AB.., AD.., AM.., AC.. and AS.. are based on the
plug connector systems made by Harting.
AB.., AD.., AM..
Han Modular
AC.., AS..
Han 10E / 10ES
The plugs are mounted on the side of the terminal box. They are locked either using two
clamps or one clamp on the terminal box.
UL approval has been granted for the plug connectors.
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
2
1
B
51081AXX
ECO FAST
certified
Drives with ASK1 plug connectors are certified according to the ECOFAST specification
(version 1.1). Switchgear or control units which also have to be certified can be
connected to SEW-EURODRIVE motors using a pre-fabricated system cable or a carrier 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
21
Connecting the motor using ASK1 plug connector
factory fully wired up, including additional features such as a brake rectifier.
Position of the
plug connector
The customer must obtain the system cable pre-fabricated according to the
ECOFAST specification from a specialist retailer.
For installation integrated in the motor according to the ECOFAST specification, 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.
Possible positions of the ASK1 plug connector are "X" (= normal position), "1", "2" or "3".
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
3
1
X
51323AXX
Installing the
carrier plate
22
Unscrew and remove four retaining screws [1] below the terminal box ( Fig. A)
Place the carrier plate [2] against the holes for the retaining screws and install it by
screwing in the four retaining screws [1] ( Fig. B).
Connecting the brake
5.15 Connecting the brake

The brake is released electrically. The brake is applied mechanically when the voltage
is switched off.
Comply with the applicable regulations issued by the relevant employer's liability
insurance association regarding phase failure protection and the associated
circuit/circuit modification!
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
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
Hand lever (for self-reengaging manual brake release)
Setscrew (for locking manual brake release)
Connecting the
brake control
system
After replacing the brake disc, the maximum braking torque is reached only after several cycles.
The DC disk brake is powered from a brake control system with a protection circuit. It is
located in the terminal box / IS lower part or must be installed in the switch cabinet (
Sec. "Wiring notes").
Check the line cross sections - braking currents ( Sec. "Technical Data")
Connect the brake control system according to the wiring diagram supplied with the
brake
For motors in thermal class H, install the brake rectifier in the switch cabinet!
23
Accessory equipment
5.16 Accessory equipment

Connect supplied accessory equipment according to the wiring diagrams included.
TF temperature sensor
Do not apply voltage!
The positive temperature coefficient (PTC) thermistors comply with DIN 44082.
Resistance measurement (measuring instrument with V 2.5 V or I < 1 mA):
Standard measured values: 20...500 , thermal resistance > 4000
Measured values pole-changing with separate winding: 40...1000 ,

Thermal resistance > 4000
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
temperature reaches an excessive level, the thermal protection function must be
effective immediately.
TH winding thermostats
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.
VAC
VDC
Voltage U [V]
250
400
60
24
Current (cos = 1.0)

[A]
2.5
0.75
1.0
1.6
Current (cos = 0.6)

[A]
1.6
0.5
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).
24
Accessory equipment
VR system
24 VDC 20 %
Plug connector
Max. connection cross section 3x1 mm2
Pg7 cable gland with 7 mm inside diamater
The VR forced cooling fan is available for 24 V DC voltage and for 100 ... 240 V AC
voltage.
24V DC +
2
1
50990AXX
The AC voltage type includes a VR forced cooling fan and the UWU51A switch-mode
power supply ( following figure).
Input: 90 ... 265 VAC 6 % / + 10 %, 50/60 Hz
Output: 24 VDC 1 % / + 2 %, 1.3 A
Connection: Terminal screws 0.2 ... 2.5 mm2, separable
Enclosure: IP20; mounted on mounting rail EN 60715TH35 in the switch cabinet
77
38
76
86.5
54411AXX
Refer to the VR wiring diagram for information about connecting the VR forced cooling
fan (order number: 0880 3198)
25
Accessory equipment
Motor size 132M - 280

V system
3 x 400 VAC, 50 Hz
Connection in separate terminal box
Max. connection cross section 4 x 1.5 mm2
Cable gland M16x1.5
Refer to the V wiring diagram for information about connecting the V system (order
number: 0975 8385).
A transformer may be present in the VS system to adapt to a voltage other than the
standard. The VS and V systems are also available for 60 Hz.
Overview of
encoders
Encod
er
For SEW motor
Encoder type
Shaft
Specification
EH1T1)
EH1S2)
EH1R
Supply
5 VDC regulated
DR63...
Encoder
Hollow shaft
24 VDC
ES1R
5 VDC regulated
24 VDC
ES2R
Encoder
5 VDC regulated
-
24 VDC
EV1R
5 VDC regulated
CT/CV71...200
DT/DV71...280
DTE/DVE90...225
24 VDC
A track
NV21
A+B tracks
DT/DV71...132
DTE/DVE90...132S
Proximity sensor
Solid shaft
A track
A+B tracks
NV16
A track
NV26
A+B tracks
AV1Y
AV1H3)
5 VDC TTL/RS-422
24 VDC HTL
NV11
NV12
5 VDC TTL/RS-422
1 Vss sin/cos
Solid shaft
EV1C
NV22
5 VDC TTL/RS-422
24 VDC HTL
1)
EV1S2)
5 VDC TTL/RS-422
1 Vss sin/cos
ES2C
EV1T
5 VDC TTL/RS-422
24 VDC HTL
Spreadshaft
ES2T1)
CV/DV(E)112...132S
5 VDC TTL/RS-422
1 Vss sin/cos
CT/DT/CV/DV71...100
DTE/DVE90...100
ES1C
ES2S2)
5 VDC TTL/RS-422
24 VDC HTL
1)
ES1S2)
5 VDC TTL/RS-422
1 Vss sin/cos
EH1C
ES1T
Signal
CT/CV71...200
DT/DV71...280
DTE/DVE90...225
absolute encoder
HIPERFACE
encoder
Solid shaft
1 pulse/revolution, normally open contact

24 VDC
2 pulses/revolution,
normally open contact
6 pulses/revolution,
normally open contact
15/24 VDC
MSSI interface and 1

Vss sin/cos
12 VDC
RS485 interface and 1

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
26
Accessory equipment
Refer to the following wiring diagrams for information about connecting

ES1./ES2./EV1./EH1. encoders and AV1Y and AV1H absolute encoders:
Encoder
connection
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
Maximum oscillation load for encoder 10 g 100 m/s2 (10 Hz ... 2 kHz)
Shock resistance 100 g 1000 m/s2
When connecting the encoders to the inverters, always follow the operating instructions
for the relevant inverter!
Maximum line length (inverter - encoder):

100 m with a capacitance per unit length 120 nF/km
Core cross section: 0,20 ... 0.5 mm2
Use a shielded cable with twisted pairs of insulated conductors (exception: cable for
HTL sensor) and connect the shield over a large surface area at both ends:
to the encoder in the cable gland or in the encoder plug
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.
27
Startup
Prerequisites for startup
Startup
6.1
Prerequisites for startup

It is essential to comply with the safety notes in Sec. 2 during startup!
Before startup,
make sure that
The drive is undamaged and not blocked
The measures stipulated in the "Preliminary work" section are performed after
extended storage
All connections have been made properly
The direction of rotation of the motor/gearmotor is correct

(motor rotating clockwise: U, V, W to L1, L2, L3)
During startup,
make sure that
All protective covers have been fitted correctly
All motor protection equipment is active and set for the rated motor current
The self-reengaging manual brake release is used in case of hoist drives
There are no other sources of danger present
The motor is running correctly (no overload, no speed fluctuation, no loud noises,
etc.)
The correct braking torque is set according to the specific application ( Sec. "Technical 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.
28
Startup
Altering the blocking direction on motors with a backstop
6.2
10
6
50447AXX
[1] Fan guard

[2] Fan
[3] Hexagon socket head cap
screw
[4] V-ring
Dimension "x"
after installation
[5]
[6]
[7]
[8]
Felt ring
Circlip
Threaded hole
Carrier
Motor
Dimension "x" after installation
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
[9] Wedge element train

[10] Equalizing ring
29
Startup
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.
1. Isolate the motor from the supply, safeguarding it against unintentional powerup.
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
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].
30
Malfunctions
Motor Malfunctions
Malfunctions
7.1
Motor Malfunctions
Problem
Possible cause
Remedy
Motor does not start up
Interruption in connecting harness
Check connections, correct if necessary
Motor does not start or only

with difficulty
Motor does not start in star

connection, only in delta
connection
Brake does not release
Sec. "Brake Problems"
Fuse blown
Replace fuse
Motor protection has tripped
Check motor protection for correct setting, correct error if

necessary.
Motor protection does not switch, error in

control
Check motor protection control, correct error if necessary.
Motor designed for delta connection but

used in star connection
Correct circuit
Voltage and frequency deviate markedly

from setpoint, at least during switch-on
Provide better power supply system; check cross section

of connecting harness
Torque not sufficient in star connection
Switch on directly if delta inrush current is not too great;

otherwise use a larger motor or a special version (contact
SEW)
Contact fault on star delta switch
Rectify fault
Incorrect direction of rotation
Motor connected incorrectly
Swap over two phases
Motor hums and has high

current consumption
Sec. "Brake Problems"
Winding defective
Send motor to specialist workshop for repair
Fuses blow or motor protection trips immediately
Short circuit in line
Rectify short circuit
Short circuit in motor
Lines connected incorrectly
Correct circuit
Ground fault on motor
Overload
Perform power measurement, use larger motor or reduce

load if necessary
Rotor rubbing
Severe speed loss under

load
Motor heats up excessively

(measure temperature)
Excessively loud
Voltage drops
Increase cross section of connecting harness
Overload
Perform power measurement, use larger motor or reduce

load if necessary
Inadequate cooling
Correct cooling air supply or clear cooling air passages,

retrofit forced cooling fan if necessary
Ambient temperature is too high
Adhere to permitted temperature range
Use delta connection for motor rather than

star connection as provided for
Correct circuit
Loose contact in connecting harness (one

phase missing)
Rectify loose contact
Fuse blown
Look for and rectify cause (see above); replace fuse
Supply voltage deviates from rated motor

voltage by more than 5 %. A higher voltage
has a particularly unfavorable effect in
motors with a low-speed winding since in
these, the no-load current is already close
to the rated current even when the voltage
is normal.
Adapt motor to supply voltage
Rated operation type (S1 to S10, DIN

57530) exceeded, e.g. through excessive
starting frequency
Adjust rated operation type of motor to required operating

conditions; if necessary call in a specialist to determine
correct drive
Ball bearing compressed, contaminated or

damaged
Re-align motor, inspect ball bearing ( Sect. "Permitted

ball bearing types"), grease if necessary ( Sect. "Lubricant 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
31
Malfunctions
Brake problems
7
7.2
Brake problems
Problem
Possible cause
Remedy
Incorrect voltage on brake control unit
Apply correct voltage
Brake control unit failed
Install a new brake control system, check internal resistance and insulation of brake coil, check switchgear
Max. permitted working air gap exceeded

because brake lining worn down
Measure and set working air gap
Voltage drop along connecting harness > 10

%
Provide for correct connection voltage; check cable cross

section
Inadequate cooling, brake overheats
Replace type BG brake rectifier with type BGE
Brake coil has interturn fault or short circuit to

exposed conductive part
Replace complete brake and brake control system (specialist workshop), check switchgear
Rectifier defective
Replace the rectifier and brake coil
Working air gap not correct
Brake lining worn down
Replace entire brake disk
Incorrect braking torque
Change the braking torque ( Sect. "Technical Data")

By the type and number of brake springs
BrakeBMG 05: By installing the same brake coil body
design as in brakeBMG 1
BrakeBMG 2: By installing the same brake coil body
design as in brakeBMG 4
BM(G) only: Working air gap so large that setting nuts come into contact
Set the working air gap
Only BR03, BM(G): Manual brake release

device not set correctly
Set the setting nuts correctly
Brake is applied with time

lag
Brake is switched on AC voltage side
Switch on DC and AC voltage sides (e.g. BSR); please

refer to wiring diagram
Noise in the brake area
Gearing wear caused by jolting startup
Check project planning
Pulsating torques due to incorrectly set frequency inverter
Check/correct setting of frequency inverter according to

operating instructions
Motor does not brake
7.3
Malfunctions during operation with a frequency inverter

The symptoms described in the "Motor Malfunctions" section may also occur when the
motor is operated with a frequency inverter. Please refer to the frequency inverter
operating instructions for the significance of the problems which occur and to find
information about rectifying the problems.
Customer service
Please have the following information to hand if you require the assistance of our
customer service:
Data from the nameplate (complete)
Nature and extent of the fault
Time and peripheral circumstances of the fault
Presumed cause
32
Inspection / Maintenance
8.1
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
coil!
Motors can become very hot during operation danger of burns!
Secure hoist drives or lower them (danger of falling).
Isolate the motor and brake from the supply before starting work, safeguarding them
against unintentional power-up!

Unit / unit part
Frequency
What to do?
Inspect the brake

Measure the brake disk thickness
Brake disk, lining
Pressure plate
Carrier / gearing
Pressure rings
If used as a working brake:

At least every 3000 hours of operation1)
Brake BMG02, BR03,

BMG05-8, BM15-62
If used as a holding brake:

Every 2 to 4 years, depending on
operating conditions 1)
Motor
Motor with backstop
Extract the abraded matter.

Inspect the switch elements and
change if necessary (e.g. in case
of burn-out)
Inspect the motor:

Check ball bearings and change
if necessary
Change the oil seal
Clean the cooling air passages
Every 10,000 hours of operation
Tacho-generator
Drive
Varies
(depending on external factors)
Change the low-viscosity grease

in the backstop
Inspection / maintenance as
described in the enclosed operating instructions
Touch up or renew the surface/anticorrosion coating.
1) The periods of wear are affected by many factors and may be short. The machine designer must calculate
the required inspection/maintenance intervals individually in accordance with the project planning documents (e.g. "Drive Planning").
33
Preliminary work for motor and brake maintenance
8
8.2

Isolate the motor and brake from the power supply before starting work,
safeguarding them against unintentional power-up!
Removing the EV1. incremental encoder / AV1H absolute encoder
369
234
703 234 369 251 232
361
361
EV1.
220
EV1.
220
AV1.
AV1.
236
233
251
366
232
550
236 366 233
51322AXX
Removing EV1. / AV1 encoders from motors up to size 225
[220] Encoder
[232] Hexagon socket head cap screw
[233] Coupling
[234] Hex head screw
51324AXX
Removing EV1. / AV1 encoders from motors from size

250 upwards
[236] Adapter flange

[251] Conical spring washer
[361] Protective canopy / fan guard
[366] Hexagon socket head cap screw
[369] Cover plate

[550] Brake
[703] Hex head screw
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.
34
Incremental encoder ES1. Removing / ES2. / EH1.
733
367
220
220
361
367
54196AXX
[220] Encoder
[367] Retaining screw
[361] Protective canopy

[733] Retaining screw for torque arm
Remove the protective canopy [361].
Unscrew the retaining screws [733] for the torque arm.
Open the screw cover at the rear of the encoder [220].
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.
35
Removing the proximity sensor NV1. / NV2.
3.5
01114CXX
Caution! It is essential for the fan wheel to be stationary!
Disconnect plug
Pull off the fan guard including NV1. / NV2. Do not tilt it, in order to avoid damaging
the proximity switch.
If the mounting block has been removed from the fan guard or has come loose, it is
essential to ensure the following during re-assembly:
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).
36
Inspection / maintenance on the motor
8.3
Example: Motor DFT90
11 12
9
6
4
3
15
20
19
18
17
16
14
13
54008AXX
Key
1 Circlip
2 Oil-flinger ring
8 Circlip
16 V-ring
9 Rotor
17 Fan
3 Oil seal
11 Ball bearing
18 Circlip
4 Screw plug
12 Equalizing ring
19 Fan guard
5 Drive end bearing end shield
13 Stator
20 Housing screw
6 Circlip
14 Non drive-end bearing shield
7 Ball bearing
15 Hex head bolt
37
Sequence
Isolate the motor and brake from the supply, safeguarding them against unintentional power-up!
1. Remove the forced cooling fan and encoder, if installed ( Sec. "Preliminary work
for motor and brake maintenance")
2. Remove flange or fan guard [19], fan [17].
3. Remove the hex head bolt [15] from the drive end bearing end shield [5] and the nondrive end bearing end shield [14], release the stator [13] from the drive end bearing
end shield.
4. Motors with BM/BMG brake:
Open the terminal box cover, unfasten the brake cable from the rectifier
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
5. Motors with BMG02, BR03 brake:
Remove the complete brake with the releasing lever (on version with manual
brake release)
6. Visual inspection: Are there traces of gear oil or condensation inside the stator?
If not, continue with 9
If there is condensation, continue with 7
If there is gear oil, have the motor repaired by a specialist workshop
7. If there is moisture inside the stator:
With gearmotors: Remove the motor from the gear unit
With motors without a gear unit: Remove the drive end flange
Remove the rotor [9]
8. Clean the winding, dry it and check it electrically ( Sec. "Preliminary work")
9. Replace the ball bearings [7], [11] (only use authorized ball bearings Sec.
"Permitted ball bearing types")
10.Reseal the stator seat ("Hylomar L Spezial") and grease the V-ring or labyrinth seal
(DR63)
11.Install the motor, brake and accessories
12.Check the gear unit ( gear unit operating instructions)
Lubrication of the
backstop
38
The backstop is supplied with Mobil LBZ low-viscosity grease as a lubricant and
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]
15
15
20
45
80
Inspection / maintenance of the BMG02 brake
8.4
Inspection / maintenance of the BMG02 brake
Measure the
brake disk
thickness, install
a new brake
BMG02
The status of the brake disk is ascertained by measuring the brake disk thickness. Install
a new BMG02 brake once the brake disk thickness reaches the minimum value ( figure below). It is not possible to adjust the working air gap.
d
5 4
50345AXX
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
guard and the fan.
3. Loosen the screws [2] and remove the complete brake with the releasing lever (on
version with manual brake release).
4. Measure the thickness "d" of the brake disk [3]:
Brake
Type
BMG02
Thickness "d" of the brake disk [mm]
Max. braking torque
Maximum
Minimum
[Nm]
5.4
5.6
0.8
1.2
5. Replace the complete brake if the brake disk thickness has reached the
minimum value.
6. Install the complete brake in the motor:
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)
39
Inspection / maintenance of the brake BR03
8
8.5
13
12
14
11
10
16 15
17
18
8
7
12
6
4
5
50067AXX
Key
40
1 Carrier
7 Brake disk
13 Hand lever
2 Clip
8 Pressure plate with stud
14 Releasing lever
3 Circlip
9 Damping plate
15 Sealing washer
4 Friction plate
10 Brake springs
16 Self locking counter nut
5 Screw
11 Brake coil body
17 Conical coil spring
6 Guide ring
12 Screw
18 Sealing element
Inspect brake
BR03, measure
the working air
gap
The working air gap cannot be adjusted and can only be measured by means of the
stroke of the pressure plate when the brake is released.
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:
50066AXX
From the end of the stud on the pressure plate [8] to the brake coil body [11]
5. Release the brake electrically
6. Measure clearance x with the brake released:
From the end of the stud on the pressure plate [8] to the brake coil body [11]
7. The differential corresponds to the working air gap, i.e. the stroke of the pressure
plate [18]:
If the working air gap 0.8 mm, reinstall the conical coil springs [17], releasing
lever [14] and self locking counter nuts [16]
If the working air gap 0.8 mm, install a complete new brake
Use setting nuts to set the floating clearance "s" between the conical coil springs
(pressed flat) and the setting nuts ( following figure)
01111BXX
Brake
Floating clearance s [mm]
BR03
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.
41
8. Reassemble the removed parts. Connect the complete new brake (replaced if the
working air gap 0.8 mm) to the motor ( following figure)
Make sure the gearing of the brake disk engages in the gearing of the carrier and
that the plug on the motor end fits into the socket on the brake end.
50175AXX
Changing the
BR03 braking
torque
The braking torque can be changed in steps ( Sec. "Work done, working air gap,
braking torques of brake BR03, BMG05-8")
by installing different brake springs
by changing the number of brake springs
unintentional power-up!
guard and the fan.
3. Loosen the screws [12] and remove the complete brake with the releasing lever (on
version with manual brake release).
4. Loosen the screws [5] and remove the guide ring [6] with friction plate [4], brake disc
[7], pressure plate [8] and damping plate [9]
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]
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
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!
10.Place the guide ring [6] and friction disk [4] onto the brake disk [7], press down and
install the screws [5].
42
11.Design with manual brake release:

Put on the conical coil springs [17] and releasing lever [14], install the self locking
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)
01111BXX
Brake
BR03
guaranteed.
12.Connect the complete brake back onto the motor ( following figure):
Make sure the gearing of the brake disk engages in the gearing of the carrier and
that the plug on the motor end fits into the socket on the brake end
50175AXX
13.Refit the fan and fan guard, screw the hand lever [10] (on version with manual brake
release)
43
Inspection / maintenance for BMG05-8, BM15-62 brakes
8
8.6
BM(G)05-08 brakes
9
8
6
5
2
22
21
e
10
b
20
19
a
16
17
18
15
14
11
12 13
01955AXX
Key
1
2
3
4
5
6
7
8
9
44
Motor with brake bearing end shield

Carrier
Circlip
Niro disk (BMG only)
Rubber sealing collar
Annular spring
Brake disk
Pressure plate
Damping plate (BMG only)
10a
10b
10c
10e
11
12
13
Stud (3 pcs.)
Counter spring
Pressure ring
Hex nut
Brake spring
Brake coil body
In BMG: Gasket
In BM: V-ring
14 Dowel pin
15
16
17
18
19
20
21
22
Release lever with hand lever

Stud (2 pcs.)
Conical coil spring
Setting nut
Fan
Circlip
Fan guard
Housing screw
BM15-62 brake
10
20
19
17
18
16
15
14
13
12
11
8
7b
7
6
2
5
01956AXX
Key
1
2
3
4
5
6
7
7b
Motor with brake bearing end shield

Carrier
Circlip
Niro disk (BMG only)
Annular spring
Brake disk
Only BM 32, 62:
Brake stationary disk, annular spring,
Brake disk
8
9
10a
10b
10c
10e
11
12
13
Pressure plate
Damping plate (BMG only)
Stud (3 pcs.)
Counter spring
Pressure ring
Hex nut
Brake spring
Brake coil body
In BMG: Gasket
In BM: V-ring
14
15
16
17
18
19
20
21
22
Dowel pin
Release lever with hand lever
Stud (2 pcs.)
Conical coil spring
Setting nut
Fan
Circlip
Fan guard
Housing screw
45
BMG05-8, BM15-62 brakes, set the working air gap

2. Remove the following:
If installed, forced cooling fan, tacho/encoder ( Sec. "Preliminary work for motor
and brake maintenance")
Flange cover or fan guard [21]
3. Push the rubber sealing collar aside [5]
Release the clip to do this, if necessary
4. Measure the brake disc [7], [7b]:
If the brake disk is
9 mm on brake motors up to size 100
10 mm on brake motors up to size 112
Install a new brake disk ( Sec. "Changing the brake disk BMG 05-8, BM 15-62"),
otherwise
5. With BM30-62:
Loosen the setting sleeve [10d] by turning it towards the bearing end shield
6. Measure the working air gap A ( following figure)
(use a feeler gauge and measure at three points offset by 120)
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]
7. Tighten the hexagon nuts [10e]
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
8. With BM30-62:
Tighten the setting sleeves
Against the brake coil body
9. Install the rubber sealing collar back in place and re-install the dismantled parts
01957AXX
46
Changing the BMG05-8, BM15-62 brake discs

When fitting a new brake disk (in BMG05-4 9 mm; in BMG62 10 mm) inspect the
other removed parts as well and install new ones if necessary.
Flange or fan guard [21], circlip [20] and fan [19].
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
[14]
4. Unscrew hexagon nuts [10e], carefully pull off the coil body [12] (brake cable!) and
take out the brake springs [11].
5. Remove the damping cable [9], pressure plate [8] and brake disc [7], [7b], clean the
brake components
6. Install a new brake disk
7. 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 30-62, setting the working air gap", points
5 to 8)
8. 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
BMG05-1
1.5
BMG2-8
BM15-62
guaranteed.
9. Install the rubber sealing collar back in place and re-install the dismantled parts.
Notes
The lockable manual brake release (type HF) is already released if resistance is
encountered when operating the grub screw.
The self-reengaging manual brake release (type HR) can be operated with normal
hand pressure.
Important: In brake motors with self-reengaging manual brake release, the

manual brake release lever must be removed after startup/maintenance! A
bracket is provided for storing the lever on the outside of the motor.
47
Change braking
torque of BMG058, BM15-62
The braking torque can be changed in steps ( Sec. "Technical Data")
by installing different brake springs
by changing the number of brake springs
by changing the brake coil body:

BMG05: if the maximum braking torque is not sufficient for the specific
application, install the brake coil body [12] of brake BMG1 of the same design to
ensure safe braking
BMG2: if the maximum braking torque is not sufficient for the specific application,
install the brake coil body [12] of brake BMG4 of the same design to ensure safe
braking
1. Isolate the motor and brake from the supply, safeguarding them against unintentional power-up
Setting nuts [18], conical coil springs [17], studs [16], release lever [15], dowel pin
[14]
4. Unscrew hex nuts [10e], pull off the coil body [12].
by approx. 50 mm (watch the brake cable!)
5. Change or add brake springs [11]
Position the brake springs symmetrically
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)
01111BXX
Brake
BMG05-1
1.5
BMG2-8
BM15-62
guaranteed.
8. Install the rubber sealing collar back in place and re-install the dismantled parts.
Note
48
Install new setting nuts [18] and hexagon nuts [10e] if the removal procedure is repeated!
Inspection / maintenance of the BMG61/122 brake
8.7

BMG61/122 brakes with encoder mounting are only used as a holding brake.
Maintenance work is only allowed to be performed by SEW-EURODRIVE.
BMG61/122 brakes
8
15
11
21
17
23
25
16 19
10
12
13
14
18
20 22
24
26
27
54318AXX
Key
1
2
3
4
5
6
7
8
9
Brake end shield

Intermediate flange
Hex head bolt
Carrier
Brake disc, complete 1
Annular spring 1
Brake stationary disc
Setting sleeve
10
11
12
13
14
15
16
17
18
Brake disc, complete 2

Stud
Annular spring 2
Brake stationary disc
Magnet, complete
Brake spring
Hex head bolt
V-ring
O-ring
19
20
21
22
23
24
25
26
27
Release lever
Stud
Conical coil spring
Hex nut
Hand lever
Fan
Circlip
Hex head bolt
Fan guard
49
BMG61/122 brake without encoder mounting, set the working air gap
Remove the forced cooling fan, if installed ( Sec. "Preliminary work for motor
Flange cover or fan guard [27]
3. Push the rubber sealing collar aside [5]
Release the clamping strap to do this, if necessary
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]

Until the working air gap is initially 0.25 mm
8. Tighten the setting sleeves [9]
Against the magnet [14]
9. Refit the rubber sealing collar [5] and re-install the dismantled parts
01957AXX
50
BMG 61/122 brake without encoder mounting, change the brake disc
When fitting a new brake disk ( 12 mm), inspect the other removed parts as well and
install new ones if necessary.
Forced cooling fan, if installed ( Sec. "Preliminary work for motor and brake
maintenance")
Hex nuts [16], conical coil springs [21], studs [20], release level [17]
4. Loosen the hex nuts [16], remove the connection cable to the plug connector for the
magnet [14], remove the magnet, and remove the brake springs [15].
5. Remove the complete pressure plate [8], the complete brake disc [10] as well as the
brake stationary disk and complete brake disc [6] for BMG122, clean the brake
components.
6. Install a new brake disk
Sec. "Inspecting brake BMG 61/122, setting the working air gap", points 5 to 8)
8. With manual brake release: Use setting nuts [22] to set the floating clearance "s"
between the conical coil springs [21] (pressed flat) and the setting nuts ( following
figure)
s
01111BXX
s = 2 mm
51
kVA
Technical Data
Work done, braking torque BMG02
P Hz
Technical Data
9.1
Work done, braking torque BMG02

Brake
Type
For motor size
Work done until

maintenance
Thickness of brake
disk [mm]
[106 J]
BMG02
9.2
DT56
ET56
30
max.
min
[Nm]
5.6
5.4
1.2
0.8
Information for ordering a replacement BMG02

Brake
Type
Voltage
Braking torque
[VDC]
[Nm]
0574 319 2
1.2
0574 323 0
0.8
0574 327 3
1.2
0574 331 1
Voltage
Braking torque
Brake part number
[VAC]
[Nm]
24
BMG02/HR
24
230
BMG02
400
460/500
230
BMG02/HR
Brake part number
0.8
BMG02
Brake
Type
400
460/500
52
Braking torque
0.8
0574 320 6
1.2
0574 324 9
0.8
0574 321 4
1.2
0574 325 7
0.8
0574 322 2
1.2
0574 326 5
0.8
0574 328 1
1.2
0574 332 X
0.8
0574 329 X
1.2
0574 333 8
0.8
0574 330 3
1.2
0574 334 6
Technical Data
Work done, working air gap, braking torques of BMG05-8, BR03, BC, Bd
9.3
kVA
P Hz
Work done, working air gap, braking torques of BMG05-8, BR03, BC, Bd
Brake
type
For
motor
size
BR03
63
Work done
until
maintenanc
e
Working air gap

[mm]
Braking torque settings

Braking
torque
Type and no. of brake

springs
Order number of brake

springs
[106 J]
min.1)
max.
[Nm]
standard
red
standard
red
200
0.8
3.2
2.4
1.6
0.8
6
4
3
-
2
6
185 815 7
185 873 4
3
2
-
2
6
4
3
135,017 X
135 018 8
BMG052)
71
80
60
0.25
0.6
5.0
4.0
2.5
1.6
1.2
BMG1
80
60
0.25
0.6
10
7.5
6.0
6
4
3
2
3
135,017 X
135 018 8
3
2
-
2
6
4
3
135 150 8
135 151 6
BMG2
90
100
130
0.25
0.6
20
16
10
6.6
5.0
BMG4
100
130
0.25
0.6
10
30
24
6
4
3
2
3
135 150 8
135 151 6
0.9
75
55
45
37
30
19
12.6
9.5
6
4
3
3
2
-
2
3
2
6
4
3
184 845 3
135 570 8
3)
BMG8
112M
132S
300
0.3
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
a test run.
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.
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.
53
kVA
Technical Data
Work done, working air gap, braking torques of BM15 - 62
P Hz
9.4
Work done, working air gap, braking torques of BM15 - 62
Brake
type
For
motor
size
Work done
until
maintenanc
e
[106 J]
BM15
132M, ML
160M
1000
BM30
160L
180
1500
BM31
200
225
1500
BM322)
180
Working air gap

[mm]
min.1)
0.3
BM622)
200
225
Braking
torque
max.
1.2
1500
0.4
1.2
1500
BMG61
0.3
250
280
BMG1222)
2500
1.2
0.4
Braking torque settings

Type and no. of
springs
Order number of
springs
[Nm]
standard
red
standard
red
150
125
100
75
50
35
25
6
4
3
3
-
2
3
6
4
3
184 486 5
184 487 3
300
250
200
150
125
100
75
50
8
6
4
4
2
-
2
4
4
8
6
4
187 455 1
187 457 8
300
250
200
150
100
4
2
-
4
8
6
4
600
500
400
300
250
200
150
100
8
6
4
4
2
-
2
4
4
8
6
4
187 455 1
187 457 8
600
500
400
300
200
8
6
4
4
-
2
4
8
1200
1000
800
600
400
8
6
4
4
-
2
4
8
186 838 1
186,839 X
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
54
Technical Data
Operating currents
9.5
kVA
P Hz
Operating currents
The current values IH (holding current) specified in the tables are r.m.s. values. Use only
units to measure the r.m.s. values. The inrush current (acceleration current) IB only flows
for a short time (max. 120 ms) when the brake is released or during voltage dips below
70 % of rated voltage. There is no increased inrush current if the BG brake rectifier is
used or if there is a direct DC voltage supply both are only possible with brakes up to
motor size BMG4.
BMG02, BR03
brake
BMG02
BR03
Motor size
56
63
Max. braking torque [Nm]
1.2
3.2
Braking power [W]
25
25
Inrush current ratio IB/IH

Rated voltage VN
VAC
BMG02
BR03
VDC
IH
[AAC]
IG
[ADC]
IH
[AAC]
IG
[ADC]
24
0.72
0.72
24 (23-26)
10
1.5
1.80
42 (40-45)
18
0.81
1.01
48 (46-50)
20
0.72
0.90
53 (51-56)
22
0.64
0.80
60 (57-63)
24
0.57
0.72
67 (64-70)
27
0.50
0.64
73 (71-78)
30
0.45
0.57
85 (79-87)
36
0.40
0.51
92 (88-98)
40
0.35
0.45
110 (99-110)
44
0.31
0.40
120 (111-123)
48
0.28
0.36
133 (124-138)
54
0.25
0.32
147 (139-154)
60
0.22
0.29
160 (155-173)
68
0.20
0.25
184 (174-193)
75
0.17
0.23
208 (194-217)
85
0.16
0.20
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
318 (307-343)
140
0.10
0.13
360 (344-379)
150
0.09
0.11
400 (380-431)
170
0.08
0.10
0.08
0.10
460 (432-500)
190
0.07
0.09
0.07
0.09
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)
55
kVA
Technical Data
Operating currents
P Hz
BMG 05 - BMG 4
brake
Motor size
BMG05
BMG1
BMG2
BMG4
71/80
80
90/100
100
10
20
40
Braking power [W]
32
36
40
50
Rated voltage VN
VAC
VDC
BMG05
IH
[AAC]
24
IG
[ADC]
BMG 1
IH
[AAC]
1.38
IG
[ADC]
BMG 2
IH
[AAC]
1.54
BMG 4
IG
[ADC]
IH
[AAC]
1.77
IG
[ADC]
2.20
24 (23-25)
10
2.0
3.3
2.4
3.7
42 (40-46)
18
1.14
1.74
1.37
1.94
1.46
2.25
1.80
2.80
48 (47-52)
20
1.02
1.55
1.22
1.73
1.30
2.00
1.60
2.50
56 (53-58)
24
0.90
1.38
1.09
1.54
1.16
1.77
1.43
2.20
60 (59-66)
27
0.81
1.23
0.97
1.37
1.03
1.58
1.27
2.00
73 (67-73)
30
0.72
1.10
0.86
1.23
0.92
1.41
1.14
1.76
77 (74-82)
33
0.64
0.98
0.77
1.09
0.82
1.25
1.00
1.57
88 (83-92)
36
0.57
0.87
0.69
0.97
0.73
1.12
0.90
1.40
97 (93-104)
40
0.51
0.78
0.61
0.87
0.65
1.00
0.80
1.25
110 (105-116)
48
0.45
0.69
0.54
0.77
0.58
0.90
0.72
1.11
125 (117-131)
52
0.40
0.62
0.48
0.69
0.52
0.80
0.64
1.00
139 (132-147)
60
0.36
0.55
0.43
0.61
0.46
0.70
0.57
0.88
153 (148-164)
66
0.32
0.49
0.39
0.55
0.41
0.63
0.51
0.79
175 (165-185)
72
0.29
0.44
0.34
0.49
0.37
0.56
0.45
0.70
200 (186-207)
80
0.26
0.39
0.31
0.43
0.33
0.50
0.40
0.62
230 (208-233)
96
0.23
0.35
0.27
0.39
0.29
0.44
0.36
0.56
240 (234-261)
110
0.20
0.31
0.24
0.35
0.26
0.40
0.32
0.50
290 (262-293)
117
0.18
0.28
0.22
0.31
0.23
0.35
0.29
0.44
318 (294-329)
125
0.16
0.25
0.19
0.27
0.21
0.31
0.25
0.39
346 (330-369)
147
0.14
0.22
0.17
0.24
0.18
0.28
0.23
0.35
400 (370-414)
167
0.13
0.20
0.15
0.22
0.16
0.25
0.20
0.31
440 (415-464)
185
0.11
0.17
0.14
0.19
0.15
0.22
0.18
0.28
500 (465-522)
208
0.10
0.15
0.12
0.17
0.13
0.20
0.16
0.25
Key
56
IB
IH
IG
Direct current with direct DC voltage supply
VN
Technical Data
Operating currents
BMG 8 - BM 32/62
brake
kVA
P Hz
BMG8
BM 15
BM30/31; BM32/62
112/ 132S
132M-160M
160L-225
75
150
600
Braking power [W]
65
95
120
6.3
7.5
8.5
BMG8
BM 15
BM 30/31; BM 32/62
VDC
IH
[AAC]
IH
[AAC]
IH
[AAC]
24
2.771)
4.151)
4.001)
42 (40-46)
2.31
3.35
48 (47-52)
2.10
2.95
56 (53-58)
1.84
2.65
60 (59-66)
1.64
2.35
73 (67-73)
1.46
2.10
77 (74-82)
1.30
1.87
88 (83-92)
1.16
1.67
97 (93-104)
1.04
1.49
110 (105-116)
0.93
1.32
1.78
125 (117-131)
0.82
1.18
1.60
139 (132-147)
0.73
1.05
1.43
153 (148-164)
0.66
0.94
1.27
175 (165-185)
0.59
0.84
1.13
200 (186-207)
0.52
0.74
1.00
230 (208-233)
0.46
0.66
0.90
240 (234-261)
0.41
0.59
0.80
290 (262-293)
0.36
0.53
0.71
318 (294-329)
0.33
0.47
0.63
346 (330-369)
0.29
0.42
0.57
400 (370-414)
0.26
0.37
0.50
440 (415-464)
0.24
0.33
0.44
500 (465-522)
0.20
0.30
0.40
Motor size
Rated voltage VN
VAC
1) Direct current in BSG operation
Key
IH
IB
IG
Direct current with direct DC voltage supply
VN
57
kVA
Technical Data
Operating currents
P Hz
BMG61, BMG122
brake
BMG61
Motor size
BMG122
250M...280S

Braking power [W]
600
1200
200
6
Rated voltage VN
BMG61/122
VAC
IH
[AAC]
208 (194-217)
1.50
230 (218-243)
1.35
254 (244-273)
1.20
290 (274-306)
1.10
318 (307-343)
1.00
360 (344-379)
0.85
400 (380-431)
0.75
460 (432-484)
0.65
500 (485-500)
0.60
Key
58
IB
IH
VN
Technical Data
Permitted ball bearing types
9.6
Permitted ball bearing types

Drive-end bearing
(AC motor, brakemotor)
Motor type
DT56
DFR63
DT71 - DT80
DT(E)90 - DV(E)100
DV(E)112 - 132S
DV(E)132M - 160M
DV(E)160L - 180L
DV(E)200 - 225
DV250-280
9.7
Flangemounted motor
6203-2Z-J
6204-2Z-J
6208-2Z-J
Gearmotor
6302-2Z-J
6303-2Z-J
6303-2Z-J
6306-2Z-J
6307-2Z-J
6309-2Z-J-C3
6312-2Z-J-C3
6314-2Z-J-C3
6316-2Z-J-C3
Footmounted
motor
6204-2Z-J
Non drive-end bearing

(foot-mounted, flange-mounted,
gearmotors)
AC motor
Brake motor
6208-2Z-J
6001-2RS-J
6001-2RS-J
6202-2Z-J
6202-2RS-J-C3
6203-2Z-J
6203-2RS-J-C3
6205-2Z-J
6205-2RS-J-C3
6207-2Z-J
6207-2RS-J-C3
6209-2Z-J-C3
6213-2Z-J-C3
6314-2Z-J-C3
6315-2Z-J-C3
Lubricant table for anti-friction bearings of SEW motors

The bearings are 2Z or 2RS closed bearings and cannot be regreased.
Anti-friction bearing in motor
Ambient temperature
Manufacturer
Type
20 C ... +80 C
Esso
Polyrex EM1)
+20 C ... +100 C
Klber
Barrierta L55/22)
40 C ... +60 C
Klber
Asonic GHY722)
1) Mineral lubricant (= mineral-based anti-friction bearing grease)

2) Synthetic lubricant (= synthetic-based anti-friction bearing grease)
59
Appendix
10
10
Appendix
10.1 Index of changes

The following additions and changes have been made since the last edition of the "DR/
DV/DT/DTE/DVE AC Motors, CT/CV Asynchronous Servomotors" operating instructions (publication number: 10567917, Edition 02/2003):
General updates and revisions.
60
Motor design
Nameplate, unit designation: Example has been changed.
Mechanical
installation
Before you start: Ambient temperature.
Electrical
installation
Using wiring diagrams.

Improving the grounding (EMC).
Ambient conditions during operation.
Connecting the motor: Tightening torques.
Connecting the motor via the plug connectors AB.., AD.., AM.., AS.
Optional equipment: VR forced cooling fan.
Inspection /
maintenance
Inspection / maintenance of the BMG61/122 brake.
Operating Instructions DR / DV / DT / DTE / DVE AC Motors / CT / CV Asynchronous Servomotors
Index
10.2 Index
Extended storage of motors .................................. 9
A
Absolute encoder, removal ..................................34
Altering the blocking direction ..............................29
AM........................................................................21
Ambient temperature............................................14
Anti-friction bearings for motors ...........................59
AS ........................................................................21
ASK1 ....................................................................21
AV ........................................................................26
AV1H removal ......................................................34
B
Backstop ........................................................29, 38
Ball bearing types.................................................59
BM02 operating currents......................................55
BM15-62, BMG61/122 .........................................54
BMG02 spare parts ..............................................52
BMG02 work done, braking torque ......................52
BMG05 - BMG4 operating currents......................56
BMG05-8, BC, Bd ................................................53
BMG05-8, BM15-62 brake .............................44, 49
BMG61, BMG122 operating currents...................58
BMG8 - BMG32/62 operating currents.................57
BR03 operating currents ......................................55
Brake connection .................................................23
Brake control system, interference.......................12
Brake maintenance, preliminary work ..................34
Braking torque
BM15-62, BMG61/122...................................54
BMG02 ..........................................................52
BMG05-8, BC, Bd..........................................53
Bremsenanschluss...............................................23
C
Connecting accessory equipment ........................24
Connecting the motor using the IS plug connector ..
17
Connection for encoder........................................27
D
Designated use ......................................................5
DT56 motor connection........................................16
Dust......................................................................14
E
EH ........................................................................26
Electrical installation.............................................12
Encoder................................................................26
Encoder connection .............................................27
Encoder removal ..................................................34
Environmental conditions .....................................14
ES ........................................................................26
ET56 motor connection ........................................17
ET56 single-phase motor .....................................17
EV ........................................................................26
EV1 removal.........................................................34
F
Forced cooling fan............................................... 24
V ................................................................... 26
VR................................................................. 25
VS ................................................................. 24
Frequency inverter .............................................. 12
G
Gas...................................................................... 14
I
Incremental encoder, removal............................. 34
Inspection ............................................................ 33
BMG02 brake................................................ 39
BMG-05-8, BM15-62 brake..................... 44, 49
BR03 brake................................................... 40
Motor............................................................. 37
Inspection intervals ............................................. 33
Installation altitude .............................................. 14
Installation tolerances ......................................... 11
Interference
Brake control system .................................... 12
Motor protection equipment .......................... 12
IS ......................................................................... 17
IS Integrated plug connector ............................... 17
K
Knockout ............................................................. 16
L
Low-speed motors............................................... 13
Lubricant table for anti-friction bearings .............. 59
M
Maintenance............................................ 33, 44, 49
BMG02 brake................................................ 39
BR03 brake................................................... 40
Motor............................................................. 37
Maintenance intervals ......................................... 33
Malfunctions ........................................................ 31
Brake ............................................................ 32
Frequency inverter........................................ 32
Motor............................................................. 31
Mechanical installation .......................................... 9
Motor connection................................................. 15
DT56 ............................................................. 16
ET56 ............................................................. 17
Motor maintenance, preliminary work ................. 34
Motor protection equipment, interference ........... 12
N
Nameplate ............................................................. 7
NV ....................................................................... 26
NV1 removal ....................................................... 36
NV2 removal ....................................................... 36
61
Index
O
Operating currents ...............................................55
BM02, BR03 ..................................................55
BMG05 - BMG4 .............................................56
BMG61, BMG122 ..........................................58
BMG8 - BMG32/62 ........................................57
Operation with Frequency inverter .......................12
Overivew of encoders ..........................................26
Working air gap

BM15-62, BMG61/122 .................................. 54
BMG05-8, BC, Bd ......................................... 53
P
Permitted ball bearing types.................................59
Plug connector
AM .................................................................21
AS..................................................................21
ASK1 .............................................................21
IS ...................................................................17
Proximity sensor, removal....................................36
R
Radiation ..............................................................14
Removal
AV1H .............................................................34
EV1................................................................34
S
Safety and warning notes.......................................4
Safety notes ...........................................................5
Serial number.........................................................7
Single-phase motors ............................................12
Size 56 / 63, preparation for installation...............16
Spare parts BMG02 .............................................52
Startup .................................................................28
Switching operation..............................................14
T
Technical data......................................................52
Temperature sensor TF .......................................24
TF.........................................................................24
TH ........................................................................24
Torque motors......................................................13
Transportation ........................................................5
U
Unit designation .....................................................7
V
V...........................................................................26
Vapors..................................................................14
VR ........................................................................25
VS ........................................................................24
W
Waste disposal.......................................................4
Winding thermostat TH ........................................24
Wiring diagrams ...................................................12
Wiring notes .........................................................12
Work done
BM15-62, BMG61/122...................................54
BMG02 ..........................................................52
BMG05-8, BC, Bd..........................................53
62
Address List
Address List
Germany
Headquarters
Production
Sales
Bruchsal

D-76646 Bruchsal
P.O. Box
Postfach 3023 D-76642 Bruchsal
Tel. +49 7251 75-0

Fax +49 7251 75-1970
http://www.sew-eurodrive.de
sew@sew-eurodrive.de
Service
Competence Center
Central
Gear units /
Motors

D-76676 Graben-Neudorf
Tel. +49 7251 75-1710

Fax +49 7251 75-1711
sc-mitte-gm@sew-eurodrive.de
Central
Electronics

D-76646 Bruchsal
Tel. +49 7251 75-1780

Fax +49 7251 75-1769
sc-mitte-e@sew-eurodrive.de
North

Alte Ricklinger Strae 40-42
D-30823 Garbsen (near Hannover)
Tel. +49 5137 8798-30

Fax +49 5137 8798-55
sc-nord@sew-eurodrive.de
East

Dnkritzer Weg 1
D-08393 Meerane (near Zwickau)
Tel. +49 3764 7606-0

Fax +49 3764 7606-30
sc-ost@sew-eurodrive.de
South

Domagkstrae 5
D-85551 Kirchheim (near Mnchen)
Tel. +49 89 909552-10

Fax +49 89 909552-50
sc-sued@sew-eurodrive.de
West

Siemensstrae 1
D-40764 Langenfeld (near Dsseldorf)
Tel. +49 2173 8507-30

Fax +49 2173 8507-55
sc-west@sew-eurodrive.de
Drive Service Hotline / 24 Hour Service
+49 180 5 SEWHELP

+49 180 5 7394357
Additional addresses for service in Germany provided on request!

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

Algeria
Sales
Alger
Rducom
16, rue des Frres Zaghnoun
Bellevue El-Harrach
16200 Alger
Tel. +213 21 8222-84

Fax +213 21 8222-84
Buenos Aires
SEW EURODRIVE ARGENTINA S.A.

Centro Industrial Garin, Lote 35
Ruta Panamericana Km 37,5
1619 Garin
Tel. +54 3327 4572-84

Fax +54 3327 4572-21
sewar@sew-eurodrive.com.ar
Argentina
Assembly
Sales
Service
10/2004
63
Address List
Australia
Assembly
Sales
Service
Melbourne

27 Beverage Drive
Tullamarine, Victoria 3043
Tel. +61 3 9933-1000

Fax +61 3 9933-1003
http://www.sew-eurodrive.com.au
Sydney

9, Sleigh Place, Wetherill Park
New South Wales, 2164
Tel. +61 2 9725-9900

Fax +61 2 9725-9905
Wien
SEW-EURODRIVE Ges.m.b.H.
Richard-Strauss-Strasse 24
A-1230 Wien
Tel. +43 1 617 55 00-0

Fax +43 1 617 55 00-30
http://sew-eurodrive.at
sew@sew-eurodrive.at
Brssel
CARON-VECTOR S.A.
Avenue Eiffel 5
B-1300 Wavre
Tel. +32 10 231-311

Fax +32 10 231-336
Sao Paulo
SEW-EURODRIVE Brasil Ltda.

Avenida Amncio Gaiolli, 50
Caixa Postal: 201-07111-970
Guarulhos/SP - Cep.: 07251-250
Tel. +55 11 6489-9133

Fax +55 11 6480-3328
http://www.sew.com.br
sew@sew.com.br
Austria
Assembly
Sales
Service
Belgium
Assembly
Sales
Service
Brazil
Production
Sales
Service
Additional addresses for service in Brazil provided on request!

Bulgaria
Sales
Sofia
BEVER-DRIVE GMBH
Bogdanovetz Str.1
BG-1606 Sofia
Tel. +359 2 9532565

Fax +359 2 9549345
bever@mbox.infotel.bg
Douala
Electro-Services
Rue Drouot Akwa
B.P. 2024
Douala
Tel. +237 4322-99

Fax +237 4277-03
Toronto

210 Walker Drive
Bramalea, Ontario L6T3W1
Tel. +1 905 791-1553

Fax +1 905 791-2999
http://www.sew-eurodrive.ca
l.reynolds@sew-eurodrive.ca
Vancouver

7188 Honeyman Street
Delta. B.C. V4G 1 E2
Tel. +1 604 946-5535

Fax +1 604 946-2513
b.wake@sew-eurodrive.ca
Montreal

2555 Rue Leger Street
LaSalle, Quebec H8N 2V9
Tel. +1 514 367-1124

Fax +1 514 367-3677
a.peluso@sew-eurodrive.ca
Cameroon
Sales
Canada
Assembly
Sales
Service
Additional addresses for service in Canada provided on request!

Chile
Assembly
Sales
Service
Santiago de
Chile
SEW-EURODRIVE CHILE LTDA.

Las Encinas 1295
Parque Industrial Valle Grande
LAMPA
RCH-Santiago de Chile
P.O. Box
Casilla 23 Correo Quilicura - Santiago - Chile
Tel. +56 2 75770-00

Fax +56 2 75770-01
sewsales@entelchile.net
Tianjin
SEW-EURODRIVE (Tianjin) Co., Ltd.

No. 46, 7th Avenue, TEDA
Tianjin 300457
Tel. +86 22 25322612

Fax +86 22 25322611
victor.zhang@sew-eurodrive.cn
http://www.sew.com.cn
China
Production
Assembly
Sales
Service
64
10/2004
Address List
China
Assembly
Sales
Service
Suzhou
SEW-EURODRIVE (Suzhou) Co., Ltd.

333, Suhong Middle Road
Suzhou Industrial Park
Jiangsu Province, 215021
P. R. China
Tel. +86 512 62581781

Fax +86 512 62581783
suzhou@sew.com.cn
Bogot
SEW-EURODRIVE COLOMBIA LTDA.

Calle 22 No. 132-60
Bodega 6, Manzana B
Santaf de Bogot
Tel. +57 1 54750-50

Fax +57 1 54750-44
sewcol@andinet.com
Zagreb
KOMPEKS d. o. o.
PIT Erddy 4 II
HR 10 000 Zagreb
Tel. +385 1 4613-158

Fax +385 1 4613-158
kompeks@net.hr
Praha
SEW-EURODRIVE CZ S.R.O.
Business Centrum Praha
Lun 591
CZ-16000 Praha 6 - Vokovice
Tel. +420 220121234 + 220121236

Fax +420 220121237
http://www.sew-eurodrive.cz
sew@sew-eurodrive.cz
Kopenhagen
SEW-EURODRIVEA/S
Geminivej 28-30, P.O. Box 100
DK-2670 Greve
Tel. +45 43 9585-00

Fax +45 43 9585-09
http://www.sew-eurodrive.dk
sew@sew-eurodrive.dk
Tallin
ALAS-KUUL AS
Paldiski mnt.125
EE 0006 Tallin
Tel. +372 6593230

Fax +372 6593231
veiko.soots@alas-kuul.ee
Lahti
SEW-EURODRIVE OY
Vesimentie 4
FIN-15860 Hollola 2
Tel. +358 3 589-300

Fax +358 3 7806-211
http://www.sew-eurodrive.fi
sew@sew-eurodrive.fi
Libreville
Electro-Services
B.P. 1889
Libreville
Tel. +241 7340-11

Fax +241 7340-12
Normanton
SEW-EURODRIVE Ltd.
Beckbridge Industrial Estate
P.O. Box No.1
GB-Normanton, West- Yorkshire WF6 1QR
Tel. +44 1924 893-855

Fax +44 1924 893-702
http://www.sew-eurodrive.co.uk
info@sew-eurodrive.co.uk
Athen
Christ. Boznos & Son S.A.

12, Mavromichali Street
P.O. Box 80136, GR-18545 Piraeus
Tel. +30 2 1042 251-34

Fax +30 2 1042 251-59
http://www.boznos.gr
info@boznos.gr
Hong Kong
SEW-EURODRIVE LTD.
Unit No. 801-806, 8th Floor
Hong Leong Industrial Complex
No. 4, Wang Kwong Road
Kowloon, Hong Kong
Tel. +852 2 7960477 + 79604654

Fax +852 2 7959129
sew@sewhk.com
Colombia
Assembly
Sales
Service
Croatia
Sales
Service
Czech Republic
Sales
Denmark
Assembly
Sales
Service
Estonia
Sales
Finland
Assembly
Sales
Service
Gabon
Sales
Great Britain
Assembly
Sales
Service
Greece
Sales
Service
Hong Kong
Assembly
Sales
Service
10/2004
65
Address List
Hungary
Sales
Service
Budapest
SEW-EURODRIVE Kft.
H-1037 Budapest
Kunigunda u. 18
Tel. +36 1 437 06-58

Fax +36 1 437 06-50
office@sew-eurodrive.hu
Assembly
Sales
Service
Baroda
SEW-EURODRIVE India Pvt. Ltd.

Plot No. 4, Gidc
Por Ramangamdi Baroda - 391 243
Gujarat
Tel. +91 265 2831021

Fax +91 265 2831087
mdoffice@seweurodriveindia.com
Technical Offices
Bangalore

308, Prestige Centre Point
7, Edward Road
Bangalore
Tel. +91 80 22266565

Fax +91 80 22266569
sewbangalore@sify.com
Mumbai

312 A, 3rd Floor, Acme Plaza
Andheri Kurla Road, Andheri (E)
Mumbai
Tel. +91 22 28348440

Fax +91 22 28217858
sewmumbai@vsnl.net
Dublin
Alperton Engineering Ltd.

48 Moyle Road
Dublin Industrial Estate
Glasnevin, Dublin 11
Tel. +353 1 830-6277

Fax +353 1 830-6458
Tel-Aviv
Liraz Handasa Ltd.

Ahofer Str 34B / 228
58858 Holon
Tel. +972 3 5599511

Fax +972 3 5599512
lirazhandasa@barak-online.net
Milano
SEW-EURODRIVE di R. Blickle & Co.s.a.s.

Via Bernini,14
I-20020 Solaro (Milano)
Tel. +39 2 96 9801

Fax +39 2 96 799781
sewit@sew-eurodrive.it
Abidjan
SICA
Ste industrielle et commerciale pour lAfrique
165, Bld de Marseille
B.P. 2323, Abidjan 08
Tel. +225 2579-44

Fax +225 2584-36
Toyoda-cho
SEW-EURODRIVE JAPAN CO., LTD

250-1, Shimoman-no,
Toyoda-cho, Iwata gun
Shizuoka prefecture, 438-0818
Tel. +81 538 373811

Fax +81 538 373814
sewjapan@sew-eurodrive.co.jp
Ansan-City
SEW-EURODRIVE KOREA CO., LTD.

B 601-4, Banweol Industrial Estate
Unit 1048-4, Shingil-Dong
Ansan 425-120
Tel. +82 31 492-8051

Fax +82 31 492-8056
master@sew-korea.co.kr
Riga
SIA Alas-Kuul
Katlakalna 11C
LV-1073 Riga
Tel. +371 7139386

Fax +371 7139386
info@alas-kuul.ee
Beirut
Gabriel Acar & Fils sarl

B. P. 80484
Bourj Hammoud, Beirut
Tel. +961 1 4947-86

+961 1 4982-72
+961 3 2745-39
Fax +961 1 4949-71
gacar@beirut.com
India
Ireland
Sales
Service
Israel
Sales
Italy
Assembly
Sales
Service
Ivory Coast
Sales
Japan
Assembly
Sales
Service
Korea
Assembly
Sales
Service
Latvia
Sales
Lebanon
Sales
66
10/2004
Address List
Lithuania
Sales
Alytus
UAB Irseva
Merkines g. 2A
LT-4580 Alytus
Tel. +370 315 79204

Fax +370 315 79688
irmantas.irseva@one.lt
Brssel
CARON-VECTOR S.A.
Avenue Eiffel 5
B-1300 Wavre
Tel. +32 10 231-311

Fax +32 10 231-336
Johore
SEW-EURODRIVE SDN BHD

No. 95, Jalan Seroja 39, Taman Johor Jaya
81000 Johor Bahru, Johor
West Malaysia
Tel. +60 7 3549409

Fax +60 7 3541404
kchtan@pd.jaring.my
Casablanca
S. R. M.
Socit de Ralisations Mcaniques
5, rue Emir Abdelkader
05 Casablanca
Tel. +212 2 6186-69 + 6186-70 + 618671

Fax +212 2 6215-88
srm@marocnet.net.ma
Rotterdam
VECTOR Aandrijftechniek B.V.

Industrieweg 175
NL-3044 AS Rotterdam
Postbus 10085
NL-3004 AB Rotterdam
Tel. +31 10 4463-700

Fax +31 10 4155-552
http://www.vector.nu
info@vector.nu
Auckland

P.O. Box 58-428
82 Greenmount drive
East Tamaki Auckland
Tel. +64 9 2745627

Fax +64 9 2740165
Christchurch

10 Settlers Crescent, Ferrymead
Christchurch
Tel. +64 3 384-6251

Fax +64 3 384-6455
Moss
SEW-EURODRIVE A/S
Solgaard skog 71
N-1599 Moss
Tel. +47 69 241-020

Fax +47 69 241-040
sew@sew-eurodrive.no
Lima
SEW DEL PERU MOTORES REDUCTORES

S.A.C.
Los Calderos, 120-124
Urbanizacion Industrial Vulcano, ATE, Lima
Tel. +51 1 3495280

Fax +51 1 3493002
sewperu@sew-eurodrive.com.pe
Lodz
SEW-EURODRIVE Polska Sp.z.o.o.

ul. Techniczna 5
PL-92-518 Lodz
Tel. +48 42 67710-90

Fax +48 42 67710-99
http://www.sew-eurodrive.pl
sew@sew-eurodrive.pl
Coimbra
SEW-EURODRIVE, LDA.
Apartado 15
P-3050-901 Mealhada
Tel. +351 231 20 9670

Fax +351 231 20 3685
http://www.sew-eurodrive.pt
infosew@sew-eurodrive.pt
Bucuresti
Sialco Trading SRL

str. Madrid nr.4
011785 Bucuresti
Tel. +40 21 230-1328

Fax +40 21 230-7170
sialco@sialco.ro
Luxembourg
Assembly
Sales
Service
Malaysia
Assembly
Sales
Service
Morocco
Sales
Netherlands
Assembly
Sales
Service
New Zealand
Assembly
Sales
Service
Norway
Assembly
Sales
Service
Peru
Assembly
Sales
Service
Poland
Assembly
Sales
Service
Portugal
Assembly
Sales
Service
Romania
Sales
Service
10/2004
67
Address List
Russia
Sales
St. Petersburg
ZAO SEW-EURODRIVE
P.O. Box 263
RUS-195220 St. Petersburg
Tel. +7 812 5357142 +812 5350430

Fax +7 812 5352287
http://www.sew-eurodrive.ru
sew@sew-eurodrive.ru
Dakar
SENEMECA
Mcanique Gnrale
Km 8, Route de Rufisque
B.P. 3251, Dakar
Tel. +221 849 47-70

Fax +221 849 47-71
senemeca@sentoo.sn
Beograd
DIPAR d.o.o.
Kajmakcalanska 54
SCG-11000 Beograd
Tel. +381 11 3046677

Fax +381 11 3809380
dipar@yubc.net
Singapore
SEW-EURODRIVE PTE. LTD.

No 9, Tuas Drive 2
Jurong Industrial Estate
Singapore 638644
Tel. +65 68621701 ... 1705

Fax +65 68612827
sales@sew-eurodrive.com.sg
Sered
SEW-Eurodrive SK s.r.o.
Trnavska 920
SK-926 01 Sered
Tel. +421 31 7891311

Fax +421 31 7891312
sew@sew-eurodrive.sk
Celje
Pakman - Pogonska Tehnika d.o.o.

UI. XIV. divizije 14
SLO 3000 Celje
Tel. +386 3 490 83-20

Fax +386 3 490 83-21
pakman@siol.net
Johannesburg

Eurodrive House
Cnr. Adcock Ingram and Aerodrome Roads
Aeroton Ext. 2
Johannesburg 2013
P.O.Box 90004
Bertsham 2013
Tel. +27 11 248-7000

Fax +27 11 494-3104
dross@sew.co.za
Capetown

Rainbow Park
Cnr. Racecourse & Omuramba Road
Montague Gardens
Cape Town
P.O.Box 36556
Chempet 7442
Cape Town
Tel. +27 21 552-9820

Fax +27 21 552-9830
Telex 576 062
dswanepoel@sew.co.za
Durban

2 Monaceo Place
Pinetown
Durban
P.O. Box 10433, Ashwood 3605
Tel. +27 31 700-3451

Fax +27 31 700-3847
dtait@sew.co.za
Bilbao
SEW-EURODRIVE ESPAA, S.L.

Parque Tecnolgico, Edificio, 302
E-48170 Zamudio (Vizcaya)
Tel. +34 9 4431 84-70

Fax +34 9 4431 84-71
sew.spain@sew-eurodrive.es
Jnkping
SEW-EURODRIVE AB
Gnejsvgen 6-8
S-55303 Jnkping
Box 3100 S-55003 Jnkping
Tel. +46 36 3442-00

Fax +46 36 3442-80
http://www.sew-eurodrive.se
info@sew-eurodrive.se
Senegal
Sales
Serbia and Montenegro

Sales
Singapore
Assembly
Sales
Service
Slovakia
Sales
Slovenia
Sales
Service
South Africa
Assembly
Sales
Service
Spain
Assembly
Sales
Service
Sweden
Assembly
Sales
Service
68
10/2004
Address List
Switzerland
Assembly
Sales
Service
Basel
Alfred lmhof A.G.

Jurastrasse 10
CH-4142 Mnchenstein bei Basel
Tel. +41 61 41717-17

Fax +41 61 41717-00
http://www.imhof-sew.ch
info@imhof-sew.ch
Chon Buri
SEW-EURODRIVE (Thailand) Ltd.

Bangpakong Industrial Park 2
700/456, Moo.7, Tambol Donhuaroh
Muang District
Chon Buri 20000
Tel. +66 38 454281

Fax +66 38 454288
sewthailand@sew-eurodrive.co.th
Tunis
T. M.S. Technic Marketing Service

7, rue Ibn EI Heithem
Z.I. SMMT
2014 Mgrine Erriadh
Tel. +216 1 4340-64 + 1 4320-29

Fax +216 1 4329-76
Istanbul
SEW-EURODRIVE
Hareket Sistemleri Sirketi
Bagdat Cad. Koruma Cikmazi No. 3
TR-34846 Maltepe ISTANBUL
Tel. +90 216 4419163 + 216 4419164 +

216 3838014
Fax +90 216 3055867
sew@sew-eurodrive.com.tr
Production
Assembly
Sales
Service
Greenville
SEW-EURODRIVE INC.
1295 Old Spartanburg Highway
P.O. Box 518
Lyman, S.C. 29365
Tel. +1 864 439-7537

Fax Sales +1 864 439-7830
Fax Manuf. +1 864 439-9948
Fax Ass. +1 864 439-0566
Telex 805 550
http://www.seweurodrive.com
cslyman@seweurodrive.com
Assembly
Sales
Service
San Francisco
SEW-EURODRIVE INC.
30599 San Antonio St.
Hayward, California 94544-7101
Tel. +1 510 487-3560

Fax +1 510 487-6381
cshayward@seweurodrive.com
Philadelphia/PA
SEW-EURODRIVE INC.
Pureland Ind. Complex
2107 High Hill Road, P.O. Box 481
Bridgeport, New Jersey 08014
Tel. +1 856 467-2277

Fax +1 856 845-3179
csbridgeport@seweurodrive.com
Dayton
SEW-EURODRIVE INC.
2001 West Main Street
Troy, Ohio 45373
Tel. +1 937 335-0036

Fax +1 937 440-3799
cstroy@seweurodrive.com
Dallas
SEW-EURODRIVE INC.
3950 Platinum Way
Dallas, Texas 75237
Tel. +1 214 330-4824

Fax +1 214 330-4724
csdallas@seweurodrive.com
Thailand
Assembly
Sales
Service
Tunisia
Sales
Turkey
Assembly
Sales
Service
USA
Additional addresses for service in the USA provided on request!

Venezuela
Assembly
Sales
Service
10/2004
Valencia
SEW-EURODRIVE Venezuela S.A.

Av. Norte Sur No. 3, Galpon 84-319
Zona Industrial Municipal Norte
Valencia, Estado Carabobo
Tel. +58 241 832-9804

Fax +58 241 838-6275
sewventas@cantv.net
sewfinanzas@cantv.net
69
How were driving the world
With people who

think fast and
develop the
future with you.
With a worldwide
service network that is
always close at hand.
With drives and controls

that automatically
improve your productivity.
With uncompromising
quality that reduces the
cost and complexity of
daily operations.
With comprehensive
knowledge in virtually
every branch of
industry today.
SEW-EURODRIVE
Driving the world
With a global presence

that offers responsive
and reliable solutions.
Anywhere.
With innovative
technology that solves
tomorrows problems
today.
With online information

and software updates, via
the Internet, available
around the clock.

P.O. Box 3023 D-76642 Bruchsal / Germany
Phone +49 7251 75-0 Fax +49 7251 75-1970
sew@sew-eurodrive.com
www.sew-eurodrive.com
900010107
SEW EURODRIVE GmbH & Co KG

Ernst-Blickle-Strae 42, D-76646 Bruchsal
erklrt in alleiniger Verantwortung die Konformitt der folgenden Produkte
declares under sole responsibility conformity of the following products
dclare, sous sa seule responsabilit, que les produits suivants
Elektromotoren der Baureihe:
Electric motors of the series:
Moteurs lectriques des sries :
DT../ DV.. / DR..

DFR.. / DFT.. / DFV.. / DFS.. / DFY..
DAS..
CT.. / CV.. / CMP.. /CFM..
ggf. in Verbindung mit:

poss. in combination with: / le cas chant associs :
Getriebe und Verstellgetriebe der Baureihen:
Gear units and variable speed gear units of the series:
Rducteurs et variateurs mcaniques des sries :
Stirnradgetriebe R...
Helical gear unit R.. / Rducteurs
engrenages cylindriques R..
Flachgetriebe F...
Parallel shaft helical gear unit F.. /
Rducteurs arbres parallles F..
Kegelradgetriebe K...
Helical-bevel gear unit K.. / Rducteurs
couple conique K..
Spiroplan-Getriebe W...
Spiroplan gear unit W.. / Rducteurs
Spiroplan W..
Schneckengetriebe S...
Helical-worm gear unit S.. /
Rducteurs vis sans fin S..
Elektrohngebahnen-Getriebe H...
Overhead trolley system gear unit H.. /
Rducteurs pour convoyeur arien H..
VARIBLOC, VARIMOT
Servo-Kegelradgetriebe BSF..
Helical-bevel servo gear unit BSF../
Rducteurs servo couple conique
BSF..
Servo-Planetengetriebe PS..
Planetary servo gear unit PS.. /
Rducteurs plantaires PS..
mit der
with the / respectent la
Niederspannungsrichtlinie
Low Voltage Directive / Directive Basse Tension
2006/95/EG
2006/95 EC / 2006/95/CE
angewandte harmonisierte Normen:

Applied harmonized standards: / Normes harmonises appliques :
EN 60034-1:2004
EN 60664-1:2003
Asynchronmotoren an sinusfrmigem Netz gelten als elektromagnetisch passive Komponenten, da sie
weder Strungen verursachen noch strungsanfllig sind. Nach Kapitel 2.1 der EMV-Richtlinie (89/336/
EWG) sind sie daher vom Geltungsbereich der Richtlinie ausgeschlossen.Bei Umrichterbetrieb beachten Sie
bitte unbedingt die Hinweise des Herstellers.
Asynchronous motors connected to sinusoidal power supply systems are considered to be electromagnetically
passive components since they neither cause electromagnetic disturbance nor are affected by such disturbance.
According to section 2.1 of the EMC Directive (89/336/EEC), they are thus excluded from the scope of the Directive.
For inverter operation, the instructions of the manufacturer must be observed.
Les moteurs asynchrones raccords sur un rseau de tension alternative sont considrs comme des composants
passifs lectromagntiques car ils ne gnrent pas et ne sont pas sujets des perturbations. Selon les termes du
chapitre 2.1 de la Directive CEM (89/336/CEE), ils nentrent donc pas dans le domaine dapplication de la directive.
En cas de pilotage par variateur lectronique,respecter imprativement les instructions du fabricant.
19.06.07
Operating manual
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Operating manual
11.3 Coupling
Page 37
Operating manual
- blank page -
Page 38
HFB
Wlzlager - Gehusetechnik GmbH
Siemensstr. 33
74722 Buchen
Postfach 12 06
74711 Buchen
Tel.-Nr.
Fax.-Nr.
+49 (0) 62 81 / 52 66-0

+49 (0) 62 81 / 52 66-33
Mounting and operating instructions for flexible couplings
Due to their rotation flexibility the EK-couplings can damp critical rotational vibrations of
the machinery and avoid like this negative effects on it.
Arrangement of the couplings

The flexible couplings are suitable for right- and left-hand side turn. It doesnt matter
how the parts of the couplings are arranged on the shaft ends which have to be
connected.
For vertical arrangement of the shaft part 1 should be placed on its lower end.
Security precautions
The rotating parts, couplings and shafts have to be equipped with a protection device.
The maximum bore diameters indicated in our catalogue have to be respected (not to
be exceeded). The parts of the coupling have to be mounted tightly on the shaft.
When dismounting a B-coupling and assembling it later you have to guarantee that both
parts are mounted in their previous positions.
For the final processing of the bore of pre-bored couplings every part has to be fixed in
turned our cheeks at the outer diameter of the hub.
Assembly of the coupling

The parts of the couplings and the shaft end have to be cleaned before beginning to
mount them. The assembly has to be done very carefully by using special equipment or
heating the relevant part of the coupling. Before heating the rubber elements have to be
dismounted. The parts of the couplings are fixed by screws.
Alignment of the couplings

The couplings lift up deviation of position of the end of the shafts to be connected.
A thorough alignment will increase their life.
Please, find the permissible shaft mismatch in the table below.
Radial shaft mismatch

mismatch
Axial shaft mismatch
Angular shaft
Permissible shaft mismatch in mm

Size
58
radialVr
0,1
axialVa
angularEmaxEmin
68
80
125
140
160
180
200
225
250
280
400
440
480
0,11 0,13
0,15 0,18 0,21
0,24
0,27
0,3
0,34
0,38
0,42
0,47 0,52 0,56 0,65
0,72
0,78
24
24
24
24
24
26
26
26
26
38
38
0,1
0,11 0,13
0,15 0,18 0,21
0,24
0,27
0,3
0,34
0,38
0,42
0,47 0,52 0,56 0,65
24
95
110
24
315
38
350
38
35 510 510
0,72
0,78
Speed and nominal rating

speed
n 1/min
Coupling size
EK 58
EK 68
EK 80
EK 95
EK 110
EK 125
EK 140
EK 160
EK 180
EK 200
EK 225
EK 250
EK 280
EK 315
EK 350
EK 400
EK 440
EK 480
EK 520
10
0.02
0.036
0.063
0.11
0.17
0.25
11
0,022
0,04
0,07
0,12
0,19
0,28
0.38
0.59
0.92
1,4
2,1
2,9
4,1
5,8
8,1
10,5
14
17,5
22
0,42
0,66
1,6
2,3
3,3
4,6
6,4
12
16
19,5
12
0,025
0,044
0,78
0,13
0,21
0,31
0,47
25
0,73
1,2
1,8
2,6
3,7
5,1
7,2
10
13,5
17,5
21,5
28
14
0,028
0,05
0,088
0,15
0,23
0,35
0,53
0,82
1,3
2,9
4,1
16
0,032
0,057
0,1
0,17
0,27
0,4
0,6
0,94
1,5
2,2
3,3
4,7
5,7
8,1
11,5
15
20
24
31
6,5
9,2
13
17
22,5
28
35,5
18
0,036
0,064
0,11
0,19
0,3
0,45
0,68
1,7
2,5
3,8
5,3
20
0,04
0,071
0,13
0,21
0,34
0,5
0,75
1,2
1,8
2,8
4,2
5,9
7,3
10,5
14,5
19,5
25,5
31
40
8,2
11,5
16
21,5
28,5
35
44
22,4
0,045
0,08
0,14
0,23
0,38
0,56
0,84
1,3
2,1
3,1
4,7
6,6
25
0,05
0,089
0,16
0,26
0,42
0,63
0,94
1,5
2,3
3,5
5,2
7,3
9,1
13
18
24
32
39
50
10
14,5
20
35
43
28
0,056
0,1
0,18
0,29
0,47
0,7
1,6
2,6
3,9
5,9
8,2
55
11,5
16
22,5
30
40
49
62
31,5
0,063
0,11
0,2
0,33
0,53
0,79
1,2
1,8
2,9
4,4
6,6
9,2
13
18
25,5
34
45
55
70
35,5
0,071
0,13
0,22
0,37
0,59
0,89
1,3
2,1
3,3
7,4
10,5
14,5
20,5
28,5
38
50
62
79
40
0,08
0,14
0,25
0,42
0,67
1,5
2,3
3,7
5,6
8,4
11,5
16,5
23
32
43
57
69
89
45
0,089
0,16
0,28
0,47
0,75
1,1
1,7
2,6
4,1
6,3
9,4
13
18,5
26
36
49
64
78
100
50
0,099
0,18
0,31
0,52
0,84
1,3
1,9
2,9
4,6
10,5
14,5
20,5
29
40
54
71
87
110
56
0,11
0,2
0,35
0,59
0,94
1,4
2,1
3,3
5,2
7,9
11,5
16,5
23
32
45
60
79
97
125
63
0,13
0,22
0,4
0,66
1,1
1,6
2,4
3,7
5,8
8,8
13
18,5
25,5
36
51
68
89
110
140
71
0,14
0,25
0,45
0,74
1,2
1,8
2,7
4,2
6,5
10
15
21
29
41
57
77
100
125
160
80
0,16
0,28
0,5
0,84
1,3
4,7
7,4
11
16,5
23,5
33
46
65
86
115
140
175
90
0,18
0,32
0,57
0,94
1,5
2,3
3,4
5,3
8,3
12,5
19
26,5
37
52
73
97
125
155
200
100
0,2
0,36
0,63
1,1
1,7
2,5
3,8
5,9
9,2
14
21
29
41
58
81
110
140
175
220
112
0,22
0,4
0,7
1,2
1,9
2,8
4,2
6,6
10,5
15,5
23,5
33
46
65
90
120
160
195
250
125
0,25
0,44
0,78
1,3
2,1
3,1
4,7
7,3
11,5
17,5
26
37
51
72
100
135
175
215
275
140
0,28
0,5
0,88
1,5
2,3
3,5
5,3
8,2
13
19,5
29,5
41
57
81
115
150
200
245
310
160
0,32
0,57
1,7
2,7
9,4
14,5
22,5
34
47
65
92
130
175
225
280
360
180
0,36
0,64
1,1
1,9
4,5
6,8
10,5
16,5
25
38
53
74
105
145
195
255
310
400
200
0,4
0,71
1,3
2,1
3,4
7,5
11,5
18,5
28
42
59
82
115
160
215
285
350
440
224
0,45
0,8
1,4
2,3
3,8
5,6
8,4
13
20,5
31
47
66
91
130
180
240
320
390
500
250
0,5
0,89
1,6
2,6
4,2
6,3
9,4
14,5
23
35
52
73
100
145
200
270
350
430
550
280
0,56
1,8
2,9
4,7
10,5
16,5
26
39
59
82
115
160
225
300
400
490
620
315
0,63
1,1
3,3
5,3
7,9
12
18,5
29
44
76
92
130
180
255
340
450
550
700
355
0,71
1,3
2,2
3,7
5,9
8,9
13,5
21
33
50
74
105
145
205
285
380
500
620
790
400
0,8
1,4
2,5
4,2
6,7
10
15
23,5
37
56
84
115
165
230
320
430
570
700
890
450
0,89
1,6
2,8
4,7
7,5
11,5
17
26,5
41
63
94
130
185
260
360
490
640
700
1000
500
0,99
1,8
3,1
5,2
8,4
12,5
19
29,5
46
70
105
145
205
290
400
540
710
870
1100
560
1,1
3,5
5,9
9,4
14
21
33
52
79
115
165
230
320
450
600
790
970
1250
630
1,3
2,2
6,6
10,5
16
23,5
37
58
88
130
185
260
360
510
680
890
1100
1400
710
1,4
2,5
4,5
7,4
12
18
27
42
65
100
150
210
290
410
570
770
1000
1250
1600
750
1,5
2,7
4,7
7,8
12,5
19
28,5
44
69
105
155
220
310
430
600
810
1050
1300
1650
800
1,6
2,8
8,4
13,5
20
30
47
74
110
165
235
330
460
650
860
1150
1400
1800
900
1,8
3,2
5,7
9,4
15
22,5
34
53
83
125
190
265
370
520
730
970
1250
1550
2000
2100
950
1,9
3,4
9,9
16
24
36
56
87
153
200
280
390
550
770
1000
1350
1650
1000
3,6
6,3
10,5
16,5
25
38
59
92
140
210
290
410
580
810
1100
1400
1750
2000
1120
2,2
11,5
19
28
42
66
105
155
235
330
460
650
900
1200
1600
1950
2500
1250
2,5
4,4
7,8
13
21
31
47
73
115
175
260
370
510
720
1000
1350
1750
2150
2750
1400
2,8
8,8
14,5
23,5
35
53
82
130
195
295
410
570
810
1100
1500
2000
2450
1450
2,9
5,2
9,1
15
24,5
36
55
85
135
205
300
430
590
840
1150
1550
2050
1500
5,3
9,4
15,5
25
37
57
88
140
210
310
440
610
860
1200
1600
2100
1600
3,2
5,7
10
16,5
27
40
60
94
145
225
340
470
650
920
1300
1700
1800
3,6
6,4
11,5
19
30
45
68
105
165
250
380
530
740
1050
1450
2000
7,1
13
21
34
50
75
115
185
280
420
590
810
1050
2240
4,5
14
23,5
38
56
84
130
205
310
470
660
910
2500
8,9
15,5
26
42
63
94
145
230
350
520
730
2800
5,6
10
17,5
29,5
47
70
105
165
260
390
590
3000
10,5
19
31
50
75
115
175
275
420
630
3150
6,3
11
20
33
53
79
120
185
290
440
3550
7,1
12,5
22,5
37
59
89
125
210
330
235
4000
14
25
42
67
100
150
4500
8,9
16
28,5
47
75
115
170
5000
9,9
18
25
52
84
125
12/07

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Operating manual

SMD Cellular wheel sluice

: cement raw meal

Technical data and usage to the intended purpose:

SMD Cellular wheel sluice

SMD FRDERTECHNIK GmbH

Validity, warranty, liability

Transport and storage

Spare parts stocking / Customer service

1.3 EC Declaration of conformity

2 Validity, warranty, liability

2.2 Other valid document

2.3 Field of application and usage to the intended purpose

2.4 Warranty and liability

2.5 Operational preconditions

Danger notice, which if ignored can lead to serious injury or death.

Warning of electrical voltage:

Danger to operating safety of the system:

3.2 Basic safety instructions

3.3 Special instructions

3.4 Organisational measures

3.5 Protective equipment

3.6 Informal safety measures

3.7 Training personnel

3.8 Cellular wheel sluice control

3.9 Safety measures during normal operation

3.10 Risks from electrical energy

3.11 Escape of hazardous gases, vapours and dusts

3.12 Maintenance, servicing and repairs

3.13 Structural changes to the cellular wheel sluice

3.14 Cleaning the Sluice and disposal of wastes

3.15 Noise from the cellular wheel sluice

3.16 Changing the location of the cellular wheel sluice

4 Transport and storage

4.2 Extent of delivery

4.3 Intermediate storage

5.2 Installation informations

5.3 Installation of drive unit

5.4 Installation of speed monitoring

5.5 Elektrical installation

5.6 Protection against contact by hot material conveying

5.7 Tightening torques for boltings

5.8 Checks at the end of installation

6.2 Visual check

6.3 Trial run without material

6.4 Trial run with material

7.2 What to do in the event of faults

Immediately stop the cellular wheel sluice if:

7.2.2 Re-starting after a malfunction

Amount of discharged Amount of feeded material is

No pulses from speed

Material leakage, dust

Shut off the material

Aligne sealing strips ,

Tighten glands or renew

ZRS = Cellular wheel sluice

7.3 Before a longer standstill period

7.4 After a longer standstill period

8.2 Routine maintenance

8.2.2 Routine maintenance and inspeciton list

Pay attention to the safety instructions in these operating instructions!

8.3.1 Drive unit

8.3.2 Chain drive

8.3.4 Replacing rubber sealing