Sew Eurodrive MOVIGEAR Operating Instructions

Drive Technology \ Drive Automation \ System Integration \ Services

Operating Instructions

Mechatronic Drive System

MOVIGEAR® DSC-B

Direct SBus Communication

Edition 04/2010

16889215 / EN

SEW-EURODRIVE—Driving the world

1	.........................................................................................Important Information		6
	1.1	How to use the operating instructions.........................................................	6
	1.2	Structure of the safety notes .......................................................................	6
	1.3	Rights to claim under limited warranty ........................................................	7
	1.4	Exclusion of liability.....................................................................................	7
	1.5	Copyright notice ..........................................................................................	7

2	Safety Notes ........................................................................................................		8
	2.1	General .......................................................................................................	8
	2.2	Target group ...............................................................................................	8
	2.3	Designated use ...........................................................................................	9
	2.4	Transportation and storage.........................................................................	9
	2.5	Installation.................................................................................................	10
	2.6	Electrical connection .................................................................................	10
	2.7	Safe disconnection....................................................................................	10
	2.8	Operation ..................................................................................................	11

3	Unit Design ........................................................................................................		12
	3.1	MOVIGEAR® drive unit.............................................................................	12
	3.2	Shaft variants ............................................................................................	13
	3.3	Housing mounting .....................................................................................	14
	3.4	Position of the cable entry.........................................................................	15
	3.5	Sample nameplate and type designation of drive unit ..............................	16
	3.6	MOVIGEAR® electronics ..........................................................................	17
	3.7	Application options....................................................................................	19
	3.8	Sample nameplate and type designation for electronics ..........................	21
	3.9	MOVIGEAR® with optional package for wet areas ...................................	23

4	Mechanical Installation.....................................................................................		24
	4.1	Installation notes .......................................................................................	24
	4.2	Required tools and resources ...................................................................	24
	4.3	Installation prerequisites ...........................................................................	25
	4.4	Installing MOVIGEAR® .............................................................................	26
	4.5	Application options....................................................................................	29
	4.6	Shaft-mounted gear unit with keyway .......................................................	31
	4.7	Shaft-mounted gear unit with TorqLOC®
		(customer shaft without contact shoulder) ................................................	35

4.8Shaft-mounted gear unit with TorqLOC®

	(customer shaft with contact shoulder) .....................................................	40
4.9	Installing the protective cover ...................................................................	45
4.10	Torque arm ...............................................................................................	46
4.11	Tightening torques ....................................................................................	47
4.12	MOVIGEAR® with optional package for wet areas ...................................	50

Operating Instructions – MOVIGEAR® DSC-B			3

5						........................................................................................Electrical Installation		55
						5.1	Installation planning considering EMC aspects ........................................	55
						5.2	Installation instructions..............................................................................	56
						5.3	Installation topology (example) .................................................................	64
						5.4	Terminal assignment.................................................................................	65
						5.5	Connection of MOVIGEAR® .....................................................................	67
						5.6	Cable routing and cable shielding.............................................................	68
						5.7	Plug connectors ........................................................................................	75
						5.8	Optional plug connector assignment.........................................................	78
						5.9	Application options....................................................................................	91

6	Startup................................................................................................................		93
	6.1	Startup notes.............................................................................................	93
	6.2	Description of the DIP switches ................................................................	94
	6.3	Startup of the MOVIGEAR® drive units ....................................................	98
	6.4	Startup of application option GIO13A .....................................................	101
	6.5	Deactivating DynaStop® for startup ........................................................	104
7	Operation of MOVITOOLS® MotionStudio ....................................................		105
	7.1	About MOVITOOLS® MotionStudio ........................................................	105
	7.2	First steps ...............................................................................................	106
	7.3	Connection mode....................................................................................	108
	7.4	Executing functions with the units...........................................................	110
8	Parameters.......................................................................................................		111
	8.1	Overview of parameters for command pcb .............................................	111
	8.2	Overview of parameters for application options......................................	113
	8.3	Overview of power section parameters...................................................	115
	8.4	Description of command pcb parameters ...............................................	128
	8.5	Description of application option parameters..........................................	130
	8.6	Description of power section parameters................................................	134
9	Operation .........................................................................................................		162
	9.1	Manual mode with MOVITOOLS® MotionStudio ....................................	162
	9.2	Local mode (only in conjunction with optional plug connector)...............	166
	9.3	DynaStop® ..............................................................................................	167
	9.4	Deactivating DynaStop® .........................................................................	168
10	Service .............................................................................................................		171
	10.1	Malfunctions of the mechanical MOVIGEAR® drive ...............................	171
	10.2	Evaluating error messages .....................................................................	172
	10.3	Switch-off responsess.............................................................................	173
	10.4	Resetting error messages.......................................................................	173
	10.5	Description of status and operating indicators ........................................	174
	10.6	Unit replacement.....................................................................................	179
	10.7	SEW-EURODRIVE Service ....................................................................	180
	10.8	Extended storage....................................................................................	181
	10.9	Disposal ..................................................................................................	182

4			Operating Instructions – MOVIGEAR® DSC-B

..........................................................................11 Inspection and Maintenance			183
11.1	Determining the operating hours.............................................................		183
11.2	Inspection and maintenance intervals.....................................................		184
11.3	Lubricant change intervals ......................................................................		185
11.4	Inspection and maintenance work on the MOVIGEAR® drive ................		186

12 Technical Data and Dimension Sheets .........................................................		190
12.1	Technical data of MOVIGEAR® ..............................................................	190
12.2	Technical data of application options......................................................	193
12.3	Integrated braking resistor BW1 .............................................................	195
12.4	Deceleration torques DynaStop® ............................................................	196
12.5	Torque characteristics.............................................................................	197
12.6	Surface protection...................................................................................	205
12.7	Package for applications in wet areas ....................................................	207
12.8	Screw connections..................................................................................	211
12.9	Connection cables ..................................................................................	212
12.10	Mounting positions ..................................................................................	216
12.11	Lubricants ...............................................................................................	218
12.12	Design notes for gear units with hollow shaft and key ............................	221
12.13	Dimension drawings................................................................................	223
13 EC Declaration of Conformity ....................................................................		231
14 Address List ....................................................................................................		232
Index	.................................................................................................................	242

Operating Instructions – MOVIGEAR® DSC-B			5

	1	Important Information
		How to use the operating instructions

1 Important Information

1.1How to use the operating instructions

The operating instructions are an integral part of the product and contain important information for operation and service. The operating instructions are written for all employees who assemble, install, startup, and service this product.

The operating instructions must be legible and accessible at all times. Make sure that staff responsible for the plant and its operation, as well as persons who work independently on the unit, have read the operating instructions carefully and understood them. If you are unclear about any of the information in this documentation, or if you require further information, contact SEW-EURODRIVE.

1.2Structure of the safety notes

The safety notes in these operating instructions are designed as follows:

Pictogram			SIGNAL WORD

Type and source of danger.

Possible consequence(s) if disregarded.

•Measure(s) to prevent the danger.

Pictogram			Signal word			Meaning	Consequences if
							disregarded
Example:					DANGER	Imminent danger	Severe or fatal injuries
General danger					WARNING	Possible dangerous situation	Severe or fatal injuries
Specific danger,					CAUTION	Possible dangerous situation	Minor injuries
e.g. electric shock					NOTICE	Possible damage to property	Damage to the drive system or its
							environment

INFORMA- Useful information or tip. TION Simplifies the handling of the

drive system.

6			Operating Instructions – MOVIGEAR® DSC-B

Important Information

Rights to claim under limited warranty

1.3Rights to claim under limited warranty

A requirement of fault-free operation and fulfillment of any rights to claim under limited warranty is that you adhere to the information in the operating instructions. Therefore, read the operating instructions before you start working with the unit.

Make sure that the operating instructions are available to persons responsible for the plant and its operation, as well as to person who work independently on the unit. You must also ensure that the documentation is legible.

1.4Exclusion of liability

You must comply with the information contained in the operating instructions to ensure safe operation of MOVIGEAR® and to achieve the specified product and performance features. SEW-EURODRIVE does not assume liability for injury to persons or damage to equipment or property resulting from non-observance of these operating instructions. In such cases, any liability for defects is excluded.

1.5Copyright notice

©2010 – SEW-EURODRIVE. All rights reserved.

Copyright law prohibits the unauthorized duplication, modification, distribution, and use of this document, in whole or in part.

Operating Instructions – MOVIGEAR® DSC-B

1

7

	2	Safety Notes
		General

2 Safety Notes

The following basic safety notes must be read carefully to prevent injury to persons and damage to property. The operator must ensure that the basic safety notes are read and observed. Ensure that persons responsible for the system and its operation, as well as persons who work independently on the unit, have read through the operating instructions carefully and understood them. If you are unclear about any of the information in this documentation, please contact SEW-EURODRIVE.

2.1General

Never install or start up damaged products. Submit a complaint to the shipping company immediately in the event of damage.

During operation, MOVIGEAR® drive units can have live, bare and movable or rotating parts as well as hot surfaces, depending on their enclosure.

Removing covers without authorization, improper use as well as incorrect installation or operation may result in severe injuries to persons or damage to property.

Refer to the documentation for additional information.

2.2Target group

Only qualified electricians are authorized to install, startup or service the units or correct unit faults (observing IEC 60364 or CENELEC HD 384 or DIN VDE 0100 and IEC 60664 or DIN VDE 0110 as well as national accident prevention guidelines).

Qualified personnel in the context of these basic safety notes are: All persons familiar with installation, assembly, startup and operation of the product who possess the necessary qualifications.

Any activities regarding transportation, storage, operation, and disposal must be carried out by persons who have been instructed appropriately.

8			Operating Instructions – MOVIGEAR® DSC-B

	Safety Notes	2
	Designated use

2.3Designated use

MOVIGEAR® drive units are components intended for installation in electrical systems or machines.

In case of installation in machines, startup of the MOVIGEAR® drive units (i.e. start of designated operation) is prohibited until it is determined that the machine meets the requirements stipulated in the EC Directive 2006/42/EC (machine directive).

Startup (i.e. the start of designated use) is only permitted under observance of the EMC (2004/108/EC) directive.

MOVIGEAR® drive units comply with the regulations of the Low Voltage Directive 2006/ 95/EC. The standards given in the declaration of conformity are applied to the MOVIGEAR® drive units.

You must observe the technical data and information on the connection requirements as provided on the nameplate and in the documentation.

2.3.1Safety functions

The MOVIGEAR® drive units may not perform safety functions unless these functions are described and expressly permitted.

2.3.2Hoist applications

MOVIGEAR® drive units must not be used for hoist applications.

MOVIGEAR® drive units may only be used for inclining tracks after the operator has performed a risk assessment. For further information, consult the information in the documentation.

2.4Transportation and storage

You must observe the notes in the documentation regarding transportation, storage and proper handling. Use suitable, sufficiently rated handling equipment (e.g. rope guides) if required. Do not attach any additional loads. Observe climatic conditions in accordance with the documentation.

The following figure shows the eyebolt of MOVIGEAR®:

2770620811

Operating Instructions – MOVIGEAR® DSC-B			9

	2	Safety Notes
		Installation

2.5Installation

The units must be installed and cooled according to the regulations and specifications in the corresponding documentation.

Protect the MOVIGEAR® drive units from improper strain.

The following applications are prohibited unless the unit is explicitly designed for such use:

•Use in potentially explosive atmospheres.

•Use in areas exposed to harmful oils, acids, gases, vapors, dust, radiation, etc.

•Use in non-stationary applications that are subject to mechanical vibration and shock loads as stated in the documentation for MOVIGEAR® drive units.

Important: MOVIGEAR® drive units and corresponding mount-on parts must not protrude into footways.

2.6Electrical connection

Working on live parts of MOVIGEAR® drive units is not permitted.

The drive is operated as a generator due to the kinetic energy of the plant/machine. Secure the output shaft against rotation before you open the wiring compartment.

Electrical installation is to be carried out in compliance with pertinent regulations (e.g. cable cross sections, fusing, protective conductor connection). For any additional information, refer to the applicable documentation.

You will find notes on EMC-compliant installation, such as shielding, grounding, arrangement of filters and routing of lines, in the documentation of the MOVIGEAR® drive units. The manufacturer of the system or machine is responsible for maintaining the limits established by EMC legislation.

Protective measures and protection devices must comply with the regulations in force (e.g. EN 60204-1 or EN 61800-5-1).

2.7Safe disconnection

MOVIGEAR® drive units meet all requirements for safe disconnection of power and electronic connections in accordance with EN 61800-5-1. All connected circuits must satisfy the requirements for safe disconnection as well.

10			Operating Instructions – MOVIGEAR® DSC-B

Safety Notes

Operation

2.8Operation

Systems with integrated MOVIGEAR® drive units must be equipped with additional monitoring and protection devices according to the applicable safety guidelines, such as the law governing technical equipment, accident prevention regulations, etc. Additional protective measures may be necessary for applications with increased potential risk. Changes to the MOVIGEAR® drive units using the operating software are permitted.

Do not touch live components and power connections immediately after separation of the MOVIGEAR® drive units from the supply voltage because some capacitors might still be charged. Wait at least 10 minutes after the supply voltage has been switched off.

The connection boxes must be closed and screwed on before the supply voltages are connected to MOVIGEAR®.

The unit may still be live and connected to the supply, even if the operation LEDs and other display elements are no longer illuminated.

Mechanical blocking or internal safety functions of the unit can cause a motor standstill. Eliminating the cause of the problem or performing a reset may result in the drive restarting automatically. If, for safety reasons, this is not permitted for the driven machine, disconnect the unit from the supply system before correcting the error.

Caution: Danger of burns: The surface temperatures of the MOVIGEAR® drive units can be more than 60 °C during operation.

Operating Instructions – MOVIGEAR® DSC-B

2

11

	3	Unit Design
		MOVIGEAR® drive unit

3 Unit Design

3.1MOVIGEAR® drive unit

MOVIGEAR® drive units are made up of 3 core components: gear unit, motor and drive electronics. These 3 core components are included in one cast aluminum housing (see following figure).

MGF..4

[1]

[2]

[3]

[4]

MGF..2

[1]

[2]

[3]

[4]

[5]

MGF..4/ET

[1]

[2]

[3]

[4]

[5]

[1]MOVIGEAR® electronics cover

[2]Connection ring for cable glands

[3]Gear unit cover

[4]Output shaft version (pictured here: hollow shaft with keyway)

[5]Grounding screws

[5]

2363886987

12			Operating Instructions – MOVIGEAR® DSC-B

	Unit Design	3
	Shaft variants

3.2Shaft variants

MOVIGEAR® is available with the following shaft variants:

3.2.1MOVIGEAR® with hollow shaft and keyway (MGFA..)

The following figure shows a MOVIGEAR® unit with hollow shaft and keyway:

2690820619

3.2.2MOVIGEAR® with TorqLOC® hollow-shaft mounting system (MGFT..)

The following figure shows a MOVIGEAR® unit with TorqLOC® hollow shaft mounting system

2690822539

Operating Instructions – MOVIGEAR® DSC-B			13

	3	Unit Design
		Housing mounting

3.3Housing mounting

3.3.1Torque arm (MGF.T)

The following figure shows the torque arm for MGF.T:

2690826379

3.3.2Housing with threads (MGF.S)

The following figure shows the housing type with threads for mounting a torque arm. This type does not include a centering shoulder, which means it is not suitable for direct installation to the machine:

2690824459

14			Operating Instructions – MOVIGEAR® DSC-B

	Unit Design	3
	Position of the cable entry

3.4Position of the cable entry

The following cable entries are possible for MOVIGEAR®:

•Position X + 2

–X: 2 x M25 x 1.5 + 1 x M16 x 1.5 + 1 x M16 x 1.5 1)

–2: 2 x M25 x 1.5 + 1 x M16 x 1.5 + 1 x M16 x 1.5 1)

•Position X + 2 + 3

–X: 2 x M25 x 1.5 + 1 x M16 x 1.5 + 1 x M16 x 1.5 1)

–2: 2 x M25 x 1.5 + 1 x M16 x 1.5 + 1 x M16 x 1.5 1)

–3: 2 x M25 x 1.5 + 2 x M16 x 1.5

•Position X + 3

–X: 2 x M25 x 1.5 + 1 x M16 x 1.5 + 1 x M16 x 1.5 1)

–3: 2 x M25 x 1.5 + 2 x M16 x 1.5

•Position 2 + 3

–2: 2 x M25 x 1.5 + 1 x M16 x 1.5 + 1 x M16 x 1.5 1)

–3: 2 x M25 x 1.5 + 2 x M16 x 1.5

3.4.1Overview

The following figure shows the possible cable entries:

2

X

3

2

X

3

3

2

X

2690896779

1) 1 x M16 x 1.5 reserved for pressure compensation fitting in connection with the package for wet areas

Operating Instructions – MOVIGEAR® DSC-B			15

	3	Unit Design
		Sample nameplate and type designation of drive unit

3.5Sample nameplate and type designation of drive unit

3.5.1Nameplate

The following figure gives an example of a MOVIGEAR® nameplate. For the structure of the type designation, refer to chapter "Type designation".

76646 Bruchsal/Germany

	MGFAT2-DSM-DSC-B/DSP				Ma pk	220	Nm
[1]	01.1233697403.0001.08		IP	65	MA	143	Nm
	IM M1,M2,M5,M6		f N	50...60	Hz	cos	0,99
	i 37,24	°C -25 ... +40	UN	380...500 V		A	1,52
	3~ EN61800	TENV M.L.	nA	5,4...53,7 r/min		n R 1/10
			kg	16.000		13356887
	CLP HC 220 Synth.Öl/0,55l				Made in Germany

2368165003

[1] Unique serial number

Bar code:

The bar code on the nameplate (code 39) according to ISO/IEC 16388 represents the unique serial number (with period as separator).

3.5.2Type designation

The following table shows the type designation of MOVIGEAR®:

M G F A S 2 – D S M – DSC – B / DSP

MOVIGEAR® option

DSP =		Electrodynamic
		deceleration function DynaStop®
ECR =		Extended control range
ET	=	Extended torque
IV	=	Plug connector

MOVIGEAR® version

MOVIGEAR® installation technology

DSC = Direct SBus Communication

Motor type

Size
2 =		Torque class 200 Nm
4 =		Torque class 400 Nm
Housing mounting
T	=	Drive with torque arm
S	=	Housing with threads for
		mounting a torque arm
Shaft variant
A	=	Shaft-mounted gear unit
		(hollow shaft with keyway)
T	=	TorqLOC® hollow shaft mounting system
Gear unit type
F	=	Parallel-shaft helical gear unit
Product series
MG		= MOVIGEAR®

16			Operating Instructions – MOVIGEAR® DSC-B

	Unit Design	3
	MOVIGEAR® electronics

3.6MOVIGEAR® electronics

3.6.1MOVIGEAR® electronics cover (inside) and connection box

The following figure shows the connection box and the bottom side of the MOVIGEAR® electronics cover:

[1]

[2]

[3]

[4]

[5]

[6]

[7]

[8]	[9]	[10]	[9]	[11]	[9]	[9]	[8]	[12]	[13]
									2389455499

[1]DIP switch S1 for bus termination, see following detailed view

[2]Nameplate of drive unit, see following detailed view

[1]
[2]	OFF
OFF	S1
S1	ON
ON

2490703499

[3]SBus connection

[4]Connection ring

[5]Plug connector connection unit for MOVIGEAR® electronics cover

[6]MOVIGEAR® electronics cover

[7]Electronics cover nameplate

[8]Cable glands

[9]Screw for PE connection

[10]Supply system connection L1, L2, L3

[11]Electronics terminal strips

[12]DIP switches S2/1 – S2/4

[13]DIP switches S1/1 – S1/4

Operating Instructions – MOVIGEAR® DSC-B			17

	3	Unit Design
		MOVIGEAR® electronics

3.6.2MOVIGEAR® electronics cover (outside)

The following figure shows possible types of the MOVIGEAR® electronics cover:

MOVIGEAR® electronics cover	MOVIGEAR® electronics cover
without application slot	with application slot
	and application cover
[1]	[1] [2] [3] [4]

NET

RUN

DRIVE

2367948939

[1] LED displays	[1] Assembly/disassembly handle
	[2] Retaining screws (4x)
	[3] Application cover
	[4] LED displays

18			Operating Instructions – MOVIGEAR® DSC-B

	Unit Design	3
	Application options

3.7Application options

3.7.1GIO12A application option

The following figure shows the GIO12A application option:

[1]

[2]

[3]

NET

RUN

DRIVE

2368100235

[1]Assembly/disassembly handle

[2]Retaining screws (4x)

[3]M12 plug connector for digital I/Os

The following figure shows the position of the GIO12A nameplate:

[1]

2701486347

[1] Nameplate

Operating Instructions – MOVIGEAR® DSC-B			19

	3	Unit Design
		Application options

3.7.2GIO13A application option

The following figure shows the GIO13A application option:

[1]

[2]

[3]

NET

RUN

DRIVE

2585028875

[1]Assembly/disassembly handle

[2]Retaining screws (4x)

[3]M12 plug connector for digital/analog I/Os

The following figure shows the DIP switches S1 to S3 of the GIO13A application option:

S1

S2

S3

<![if ! IE]> <![endif]>1	<![if ! IE]> <![endif]>ON
<![if ! IE]> <![endif]>3 2
<![if ! IE]> <![endif]>4
<![if ! IE]> <![endif]>1	<![if ! IE]> <![endif]>ON
<![if ! IE]> <![endif]>3 2
<![if ! IE]> <![endif]>4
<![if ! IE]> <![endif]>1	<![if ! IE]> <![endif]>ON
<![if ! IE]> <![endif]>3 2
<![if ! IE]> <![endif]>4

<![if ! IE]> <![endif]>1	<![if ! IE]> <![endif]>ON
<![if ! IE]> <![endif]>3 2
<![if ! IE]> <![endif]>4
<![if ! IE]> <![endif]>1	<![if ! IE]> <![endif]>ON
<![if ! IE]> <![endif]>3 2
<![if ! IE]> <![endif]>4
<![if ! IE]> <![endif]>1	<![if ! IE]> <![endif]>ON
<![if ! IE]> <![endif]>3 2
<![if ! IE]> <![endif]>4

[1]

2736188299

[1] Nameplate

20			Operating Instructions – MOVIGEAR® DSC-B

	Unit Design	3
	Sample nameplate and type designation for electronics

3.8Sample nameplate and type designation for electronics

3.8.1Nameplate

The following figure gives an example of a MOVIGEAR® nameplate. For the structure of the type designation, refer to chapter "Type designation".

[1]				[2]

[3]

2585099787

[1]Nameplate of connection unit

[2]Nameplate of application option

[3]Electronics cover nameplate

3.8.2Type designation of electronics cover

The following table shows the type designation of the electronics cover:

M G x 4 – 5 0 3 – DSC – B – 00 – A / ET

Electronics cover option

ET = Extended torque

Electronics cover variant

A = With application slot

Variant

00 = Standard

MOVIGEAR®

Version

MOVIGEAR® installation technology

DSC = Direct SBus Communication

Connection type

3 = 3-phase

Supply voltage

50 = AC 380 – 500 V

Size

2 = Torque class 200 Nm

4 = Torque class 400 Nm

Product series

MG = MOVIGEAR®

Operating Instructions – MOVIGEAR® DSC-B			21

	3	Unit Design
		Sample nameplate and type designation for electronics

3.8.3Type designation of connection unit

The following table shows the type designation of the connection unit:

M G x B – DSC / DSP

Connection unit option

DSP = Electrodynamic

deceleration function DynaStop®

MOVIGEAR® installation technology

DSC = Direct SBus Communication

MOVIGEAR®

Version

Product series

MG = MOVIGEAR®

3.8.4Type designation of application options

The following table shows the unit designation for the available application options:

G IO 1 2 A

Version

Variant

2 = 4 digital inputs + 2 digital outputs

3 = 4 digital inputs

(2 inputs can be used as primary frequency input) + 1 digital output

+ 1 analog input + 1 analog output

Version

Functionality

IO = Digital inputs/outputs

Product series

G = Option for MOVIGEAR®

22			Operating Instructions – MOVIGEAR® DSC-B

	Unit Design	3
	MOVIGEAR® with optional package for wet areas

3.9MOVIGEAR® with optional package for wet areas

3.9.1Properties

The following figure shows the additional features of MOVIGEAR® drive units with optional package for wet areas:

B

[1]

[2]

B

[3]

A

[11]

[4]

[5]

A

[6]

[10]

[9]

[8]

[7]

[12]

2368838155

3.9.2Legend

All illustrations regarding MOVIGEAR® drive units with optional package for wet areas are displayed with a shading (= HP200 surface protection) in this publication

[1]Mounting screws for electronics cover made of stainless steel

[2]Connection ring only possible with cable outlet "at the bottom" or "on the side":

–In connection with mounting position M1 and M2: 2 + 3, 2 + X, X + 3, 2 + X + 3

–In connection with mounting position M4: 2 + X

–In connection with mounting position M5: X + 3

–In connection with mounting position M6: 2 + 3

[3]Screw plugs made of stainless steel installed at the factory

[4]HP200 surface protection, see chapter "Technical data and dimension sheets"

[5]Oil screw plug made of stainless steel (hexagon)

[6]Additional cover opposite the output side

[7]Mounting screws for gear unit housing made of stainless steel

[8]Breather valve mounted and activated according to mounting position, see chapter "Technical data and dimension sheets"

[9]FKM oil seal (Viton)

[10]Output shaft made of stainless steel (can be deselected)

[11]Pre-installed pressure compensation fitting (M16) with mounting positions M5, M6

[12]Pre-installed pressure compensation fitting (M16) with mounting position M1, M2, M4, M4

Optional plug connectors (see chapter "Electrical installation") are available in connection with the package for wet areas.

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	4	Mechanical Installation
		Installation notes

4 Mechanical Installation

4.1Installation notes

INFORMATION

Comply with the safety notes during installation.

CAUTION

Improper installation/disassembly of MOVIGEAR® and mount-on components.

Risk of injury.

•Note the information about installation and disassembly in this chapter.

•Before releasing shaft connections, make sure that there are no active torsional moments present (tensions within the system).

DANGER

Risk of crushing if the drive starts up unintentionally and danger of electrical voltage.

Dangerous voltages may still be present for up to 10 minutes after disconnection from the power supply.

Severe or fatal injuries.

•Completely disconnect the MOVIGEAR® drive unit from the power supply and provide for suitable external measures to secure against unintentional reconnection!

•Secure the output shaft against rotation.

•Then wait for at least 10 minutes

4.2Required tools and resources

•Set of wrenches

•Torque wrench

•Mounting device

•Compensation elements (shims and spacing rings), if necessary

•Mounting materials for output components

•Lubricant (e.g. NOCO® fluid)

•Standard parts are not included in the delivery

4.2.1Installation tolerances for shaft ends

Diameter tolerance in accordance with DIN 748:

•ISO H7 for hollow shafts

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Mechanical Installation

Installation prerequisites

4.3Installation prerequisites

Check that the following conditions have been met:

•The entries on the nameplate of the MOVIGEAR® unit match the voltage supply system.

•The drive is undamaged (no damage caused by transportation or storage)

•Ambient temperature according to the operating instructions, nameplate and lubricant table in chapter "Technical data and dimension sheets / Lubricants".

•The drive must not be assembled in the following ambient conditions:

–Potentially-explosive atmosphere

–Oils

–Acids

–Gases

–Vapors

–Radiation

•For special designs: The drive is designed in accordance with the actual ambient conditions.

•You must clean the output shafts and flange surfaces thoroughly to ensure they are free of anti-corrosion agents, contamination or the like. Use conventional solvents. Do not expose the sealing lips of the oil seals to the solvent – damage to the material.

•When the drive is installed in abrasive ambient conditions, protect the output end oil seals against wear.

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25

	4	Mechanical Installation
		Installing MOVIGEAR®

4.4Installing MOVIGEAR®

•Clean the output shafts thoroughly to ensure they are free of anti-corrosion agents (use a commercially available solvent). Do not expose the bearings and sealing rings to the solvent – damage to the material!

•Carefully align the MOVIGEAR® unit and the driven machine to avoid placing any unacceptable strain on the motor shafts (observe permissible overhung loads).

•Do not butt or hammer the shaft end.

•Ensure that cooling air supply is unobstructed and that air discharged by other units does not influence cooling.

•Use suitable cable glands for the supply leads (use reducing adapters if necessary).

•Seal the cable entry well.

•Clean the sealing faces of the MOVIGEAR® cover well before reassembling the unit.

•Restore the corrosion protection if necessary.

•Check the validity of the degree of protection using the information in the operating instructions and the data on the nameplate.

•When changing the mounting position: Adjust position of breather valve. Observe chapter "Technical data and dimension sheets / Mounting positions".

4.4.1Minimum installation clearance of electronics cover

Note the minimum installation clearance (see following figure) required to remove the MOVIGEAR® electronics cover. For detailed dimension drawings, see chapter "Technical data and dimension sheets".

100

2350097419

NOTICE

The degree of protection specified in the technical data only applies if the MOVIGEAR® electronics cover is properly installed.

When the MOVIGEAR® electronics cover is removed from the connection box, it might be damaged by humidity, dust or foreign particles.

•Protect the MOVIGEAR® electronics cover when it is removed from the connection box.

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	Mechanical Installation	4
	Installing MOVIGEAR®

4.4.2Minimum installation clearance of application options

Note the minimum installation clearance (see following figure) required to install and remove the application options.

200

2350130571

4.4.3Installation in damp locations or in the open

Drives are supplied in corrosion-resistant versions for use in damp areas or in the open. Repair any damage to the paint work if necessary.

For variants with HP200 surface treatment, observe the notes in chapter "MOVIGEAR® with optional package for wet areas".

4.4.4Painting MOVIGEAR®

NOTICE

Breather valves and oil seals may be damaged during painting or re-painting.

Potential damage to property.

•The surface of the drive must be clean and free from grease.

•Thoroughly cover the breather valves and the sealing lip of the oil seals with strips prior to the painting process.

•Remove the strips after the process.

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	4	Mechanical Installation
		Installing MOVIGEAR®

4.4.5MOVIGEAR® gear unit venting

MOVIGEAR® with installed breather valve

MOVIGEAR® with separately included breather valve

Activating the breather valve

SEW-EURODRIVE delivers all MOVIGEAR® drive units ordered for a specific mounting position with a breather valve that is activated and installed according to the mounting position.

MOVIGEAR® drive units with optional "package for wet areas" are generally delivered with the activated breather valve installed corresponding to the respective mounting position.

MOVIGEAR® drive units ordered for a universal mounting position are delivered by SEW-EURODRIVE with a separately included breather valve.

In this case, the breather valve is delivered in the hollow shaft of the drive unit. Before startup, you must replace the highest oil screw plug with the provided breather valve.

After installing the breather valve, you must activate it as follows. For designs with the breather valve screwed in: Check whether the breather valve is activated. If not, you have to remove the transport fixture of the breather valve prior before you start up the drive unit!

1. Breather valve with transport fixture

2350149003

2. Remove transport fixture

2350216203

3. Activated breather valve

2350269835

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	Mechanical Installation	4
	Application options

4.5Application options

WARNING

The surface temperatures of the MOVIGEAR® and the application options can be very high during operation.

Danger of burns.

•Do not touch the MOVIGEAR® drive and application options until they have cooled down sufficiently.

4.5.1Removing the application cover

MOVIGEAR® drives with application slot in the electronics cover are delivered with an application cover as standard.

You have to remove the application cover in order to install an application option: 1. Loosen the 4 retaining screws.

4 x

NET RUN DRIVE

2350325003

2. Remove the application cover.

NET

RUN

DRIVE

2350345355

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	4	Mechanical Installation
		Application options

4.5.2Installing application options

NOTICE

The degree of protection specified in the technical data only applies if the GIO13A application option is properly installed.

In a disassembled state, the option can be damaged by moisture, dust, or foreign objects entering through the openings for the DIP switches.

•Protect the GIO13A application option in a disassembled state.

1.You have to remove the application cover or, depending on the design, the paint protector in order to install an application option:

2.Insert the option into the application slot.

NET

NET

RUN

DRIVE

2350364555

3.Secure the option with the 4 retaining screws. The permitted tightening torque for the retaining screws is 1.2 - 1.4 Nm.

4 x

NET

RUN

DRIVE

2350383755

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