Sumitomo Bevel BUDDYBOX 4 Series, LH Series, Bevel BUDDYBOX 5 Series, Helical BUDDYBOX, Bevel BUDDYBOX 3 Series Maintenance Manual

...

Trained technicians should handle, install, and maintain the gearmotor and reducer. Make sure to read the maintenance manual carefully before use. A copy of this maintenance manual should be given to the actual user. Actual user should always keep this manual at hand.

BUDDYBOX

Right-angle : Bevel BUDDYBOX

Parallel : Helical BUDDYBOX

No.CM2020E-2

Maintenance Manual

CAUTION

Matters described in may lead to serious danger depending on the situation. Be sure to observe important matters described herein.

DANGER

 Properly trained technician with knowledge should transport, install, plumb, wire, operate, maintain, and inspect

the unit. Otherwise, electric shock, injury, fire, or damage to the equipment may occur.

 For explosion proof motor: Properly trained technician with knowledge should transport, install, plumb, wire,

operate, maintain, and inspect the unit. The technician should have knowledge on each explosion proof structure, electric facility, related law, principles and functions. Otherwise, electric shock, injury, fire, or damage to the equipment may occur.

 Use a secondary safety device on the unit when using for passenger transportation. Otherwise, accident may

occur resulting in injury or death and equipment damage by overdrive and drop.

 Use a secondary safety device on the unit when using for elevators. Otherwise, accident may occur resulting in

injury or death and equipment damage by drop of the car.

(

Safety precautions

)

 Read this maintenance manual and all accompanying documents thoroughly before use. Understand the machine,

information on safety, and all precautions for correct operation.

 Make sure you understand all of the knowledge on the unit and precautions on safety. Always keep this manual handy

after reading this manual.

 There are two levels of safety precaution in this catalog, "DANGER" and "CAUTION."

DANGER

CAUTION

: Incorrect handling of the unit may cause physical damage, serious personal injury,

and/or death.

: Incorrect handling of the unit may cause physical damage and/or personal injury.

Classification

Common specifications

Gearmotor Reducer

Symbol

COMMON

(How to Use the Maintenance Manual)

 This maintenance manual is common for both gearmotor and reducer. The symbols shown below are in the upper right hand

corner of each page to show classification. Read the necessary pages. Symbols identify distinctions between gearmotors

and reducers, even on COMMON pages.

• Refer to the brake maintenance manual (Cat. No.MM0202E) for the handling of gearmotors with brake .

CONTENTS

1. Inspection Upon Delivery............................................................................................................. 3

2. Storage ....................................................................................................................................... 8

3. Transportation ............................................................................................................................ 8

4. Installation .................................................................................................................................. 9

5. Coupling with Other Machines ................................................................................................. 10

6. Wiring ................................................................................................................... 19

7. Operation ................................................................................................................................. 22

8. Daily Inspection and Maintenance ........................................................................................... 23

9. Troubleshooting ....................................................................................................................... 35

10. Construction Drawing ............................................................................................................. 37

11. Warranty ................................................................................................................................. 42

COMMON

1. Inspection Upon Delivery

CAUTION

 Make sure that the unit is positioned right side up before unpacking. Otherwise, injury may occur.

 Make sure that the unit agrees with your order. Injury or damage to the equipment may occur by using the

incorrect product.

 Do not remove the nameplate from the unit.

Make sure of the following when this product arrives.

1. Do the items shown on nameplate agree with the order?

2. Was there no damage during transportation?

3. Are all bolts and nuts tightened firmly?

Consult our agent, distributor, or sales office for any defect or questions.

1-1) Inspection of the Nameplate

Gearmotor

Fig. 1 Nameplate of Gearmotor

Reducer

Fig. 2 Nameplate of Reducer

1-2) Inspection of Lubrication Method

Make sure of the lubrication method by referring to section "8-2. Lubrication Method" on page 24.

• Oil lubrication models are shipped with out oil. Always supply the unit with recommended oil before operation.

• Oil supply for two places is necessary for some models for output side and input side, (such as

combination of BUDDYBOX and CYCLO).

COMMON

Nameplate of Gear Nameplate of Motor

• Let us know the (1) Nomenclature of gearmotor or reducer, (2) reduction ratio, and (3) serial number when

consulting us.

RATIO

INPUT kW

r/min

SERIAL NO.

OUTPUT TORQUE

SERVICE FACTOR

MODEL

•

JAPAN

1 Type of gearmotor (Refer to page 4.) 2 Reduction ratio ･ Service factor ･ Allowable input capacity and speed [r/min] ･ Allowable output torque 3 Serial No.

Motor capacity

Characteristics of motor

Motor efficiency

IE code

Power factor

Brake current value (for the motor with a brake)

4 Motor nomenclature

5 Type of brake (for the motor with brake)

Serial No.

Brake torque (for the motor with brake)

1 Type of reducer (Refer to page 4.) 2 Reduction ratio ･ Service factor ･ Allowable input capacity speed [r/min] ･ Allowable output torque 3 Serial No.

MODEL RATIO SERVICE FACTOR INPUT kW OUTPUT TORQUE SERIAL NO.

JAPAN

r/min

•

1-3) Inspection of Nomenclature of Gearmotor or Reducer

Nomenclature shows following information. Make sure it agrees with your order.

LM104

145 AV B 46

Model

Bevel Buddybox

Helical Buddybox

Mounting style

Y Hollow shaft

Coupling method with driver

Motor

Without With

Type of input

Gearmotor

Blank

Reducer

(Both - end shaft type)

Nominal

reduction ratio

Brake

B With brake

Blank Without brake

Mounting position

Refer to Table 1 and Table 2 on page 5-6.

Motor capacity of gearmotor

4 - pole

Capacity

Symbol

01 02

(HP)

0.1

(1/8)

0.2

(1/4)

0.25 (1/3)

0.4

(1/2)

0.55 (3/4)

0.75 (1)

1.1

(1.5)

1.5 (2)

2.2 (3)

3.0 (4)

3.7 (5)

5.5

(7.5)

7.5

(10)

(15)

18.5 (25)

(30)

(40)

(50)

(60)

(75)

JJM

With input flange

(With coupling base)

XXM

With input flange

(High - speed shaft

hollow coupling)

HY Y1

Output shaft direction

H Horizontal

V Vertical

indicates 0 or 5, depending on the combination of reduction ratio.

COMMON

Suffix

With 3-phase motor for inverter-drive (AF motor)

SV With servo motor

With high-efficiency 3-phase motor

TL With Torque limiter

With premium efficiency 3-phase motor

With premium efficiency 3-phase motor for inverter-drive

Blank With 3-phase motor

  

 



Symbol of mounting position / Position of terminal-box / Position of oil filler and draiin / Rotation direction of output shaft (Bevel BUDDYBOX)

COMMON

Rotation direction of output shaft Oil filler plug Oil level (Oli gauge) Oil drain plug

1-a Hollow shaft

Table

LH M- - 1

LH M- - 2

LH M- - 3

Table 1-b Hollow shaft

Ratio

19-305

Down

LV M- - 5

Down

LHYM- -Y2

Down

LVYM- -Y5

Ratio 11-18

Down

364-7228

LH M- - 4

Ratio

19-305

Ratio 11-18

364-7228

Down

LHYM- -Y1

Down

LHYM- -Y4

Ratio

19-305

Ratio

11-18

364-7228

Ratio

19-305

Ratio

11-18

364-7228

CCW

Down

LV M- - 6

Down

LHYM- -Y3

LVYM- -Y6

Down

Ratio

19-305

Ratio 11-18

364-7228

Ratio

19-305

Ratio 11-18

364-7228

Down

Table 1-c Hollw shaft

LHYM- -Y2

Down

LVYM- -Y5

Down

CCW

"3" Series "4" Series "5" Series

1. " " indicates frame size.

Note:

LHYM- -Y1

Down

LHYM- -Y4

Down

2. " " indicates the direction of motor lead wire.

3. The rotation direction of output shaft is case of the motor rotates "cw" looking from fan-cover side. Be careful for end of frame size with "DA", "DB" or "DC" and with reduction ratio 11-18. Rotation direction of the output shaft is opposite from the above.

LHYM- -Y3

Down

LVYM- -Y6

Down

Symbol of mounting position / Position of terminal-box / Position of oil filler and draiin / Rotation direction of output shaft (Helical BUDDYBOX)

COMMON

Rotation direction of output shaft Oil filler plug Oil level (Oli gauge) Oil drain plug

Table

2-a Hollow shaft

EHYM

- -Y3

EHYM

- -Y2EHYM- -Y1

CCW

Down

CCW

Down

Table 2-b Hollow shaft Flange

EHYM

- -F1

CCW

EHYM

Down

- -F4

CCW

EVYM

EHYM

EVYM

Down

- -Y5

Down

- -F2

Down

- -F5

CCW

Down

EVYM- -Y6EHYM- -Y4

Down

EHYM- -F3

Down

EVYM- -F6

CCW

1. " " indicates frame size.

Note:

Down

CCW

Down

CCW

Down

2. " " indicates the direction of motor lead wire.

1-4) Motor Nomenclature

Nomenclature shows following information. Make sure it agrees with your order.

• Refer to related manual for units with servo motor or DC motor.

COMMON

H With Foot

Blank Flange type

HTC EX

Mounting method

T Totally enclosed

Type of casing

C Ordinary cage type

K Special cage type

Rotor

Blank

Inverter driven (AF Motor)

Commercial power driven

Driving power

Increased safety explosion-proof (Indoor)

Protection method

Increased safety explosion-proof (Outdoor)

C Explosion-proof (Indoor)

CX Explosion-proof (Outdoor)

X Nonexplosion-proof (Outdoor)

Blank Indoor

E Without fan (Self-cooling)

Cooling method

F With Self-ventilating fan (External fan)

B With Separate ventilation fan

Blank

IEC Efficiency Standards

P Premium efficiency motor

Other types of motors

Standards •Regulations

COMMON

Note the following on storing gearmotor or reducer, when not using the unit right away.

2-1) Storage location

Store the unit indoors in a clean dry place.

• Avoid storage outdoors or in places with humidity, dust, sudden temperature changes or corrosive gas.

2-2) Storage period

1. Do not store the unit for more than 6 months.

2. Consult us when the storing the unit for more than 6 months. Special rustproof specification is necessary.

3. Consult us when exporting the unit. Special rustproof specification in necessary.

2-3) Use after storage

1. Make sure that there are no deterioration in non-metal parts, such as oil seal and oil supply plug, before operating after

extended period of storage. Non-metal parts may deteriorate easily by the effect of ambient condition, such as

temperature and ultraviolet rays. Replace the deteriorated parts with new parts.

2. Make sure that there is no abnormal noise, vibration, or temperature rise when starting. Make sure that the brake

functions normally when for types with brake. Consult our distributor or sales office immediately if any abnormality is

found.

2. Storage

3. Transportation

DANGER

 Do not stand below the unit when it is lifted. Injury or death may result.

CAUTION

 Be careful not to let the unit drop or fall when moving the unit. Always use the metal hanging piece for gear or

motor with it. But do not hang the unit using the metal hanging piece after mounting with application machine.

Otherwise, it may cause personal injury or damage to the equipment and/or damage to the equipment.

 Make sure of the mass of gearmotor or reducer by looking at the nameplate, packaging, drawing, catalog, etc.,

before lifting. Do not lift the gearmotor or reducer, which are heavier than the rated weight of the lifting equipment.

Otherwise, it may cause injury or damage to the equipment and lifting device.

COMMON

4. Installation

DANGER

 Use explosion-protection type motor in explosive environment. Do not use the standard unit in explosive

environment. Otherwise, it may cause explosion, ignition, electric shock, injury, fire, or damage to the equipment.

 Use the sufficient motor for explosion-protection motor matching the hazardous location (where explosive gas or

steam exists).

 Inverter itself is not explosion-protection type for flameproof type motor. Always set the unit where there is no

explosive gas. Otherwise, explosion, ignition, electric shock, injury, fire, or damage of the equipment may occur.

CAUTION

 Do not use gearmotor or reducer for specifications other than the one shown on the nameplate or manufacturing

specification document. Otherwise, injury or damage of the equipment may occur.

 Do not place any combustible object around the gearmotor. Otherwise, fire may occur.

 Do not place any object that may prevent ventilation around the gearmotor or reducer. Otherwise, it may lead to

burn or fire by abnormal temperature caused by the decreased cooling effect.

 Do not step on or hang from the gearmotor and reducer. Otherwise, it may cause injury.

 Do not touch the shaft end, internal keyway, or edge of motor cooling fin with bare hands. Otherwise, it may

cause injury.

 Install and oil pan or other device to prevent damage for extremely oil-sensitive applications, such as food

production machine. Otherwise, it may cause defective products by oil leakage when failure occurs or at the end

of lifetime.

4-1) Place of installation

Ambient temperature: -10~40°C

Ambient humidity: 85% or less

Altitude: 1,000m or lower

Atmosphere: There should be no corrosive or explosive gas or steam.

The location should be free of dust and well-ventilated.

Location: Indoor (location free of dust without water splash)

• Consult us when operating under conditions other than the above. Special specification is necessary.

• Units made according to certain specification, such as for outdoor or for explosion protection, may be used under

specified mounting environment.

• Install the unit in location where various procedures can be carried out easily, such as inspection and maintenance.

• Install the unit to a sufficiently rigid base.

4-2) Angle of installation

Install the unit horizontally. Consult us for sloped installation.

Do not use the unit made for given slope for other slopes.

Standard shaft direction for outdoor type gearmotor is horizontal. Consult us for other shaft directions.

• Do not remove the eye-bolt on the motor. When the eye-bolt is removed for any reason, place a bolt in the tapped

hole temporarily. Waterproof treatment is necessary to prevent water entering the motor.

4-3) Under Severe Load Condition

For operation with severe vibration and frequent startup, it is recommended to tighten bolt with at least class 8.8 (by

standard JIS B-1051).

EHYM

EHY

Series

[Y3]

Fig. 4 Rotational Direction of Output Shaft for Helical BUDDYBOX

Relationship of rotational direction of input shaft and output shaft is as shown by the arrow in Fig. 3 and 4.

Note: • Models with reduction ratio 11 & 18 and reducers with "DA," "DB," and "DC," at the end are different from the above. Rotational direction of

output shaft is opposite from the above figure when the motor shaft and reducer type input is clockwise

• Figure above is the rotational direction for mounting style "Y1." Refer to Table 2 on page 6 or catalog for other mounting styles.

LHYM

LHY

Series

[Y1]

Fig. 3 Rotational Direction of Output Shaft for Bevel BUDDYBOX

Note: • Models with reduction ratio 11 & 18 and reducers with "DA," "DB," and "DC," at the end are different from the above. Rotational direction of

output shaft is opposite from the above figure when the motor shaft and reducer type input is clockwise

• Figure above is the rotational direction for mounting style "Y1." Refer to Table 1 on page 5 or catalog for other mounting styles.

COMMON

5. Coupling with Other Machines

CAUTION

 Make sure of the rotation direction of the application machine before coupling. Difference in rotation direction may

cause injury or damage to the equipment.

 Remove the temporary key on the output shaft when operating the gearmotor or reducer unit alone. Otherwise, it

may cause injury.

 Place a cover to prevent touching the rotating parts. Otherwise, it may cause injury.

 Be careful of the center alignment, belt tension, and parallelism of the pulleys when coupling the gearmotor or

reducer to the load. Make sure of the coupling accuracy for applications with direct connections. Adjust the belt

tension correctly for applications with belt. Make sure to tighten the bolt for pulley, and coupling before operation.

Failure to do so may result in damage of equipment or injury by broken pieces.

Gearmotor

5-1) Confirmation of direction of rotation

Fig. 3 and 4 indicates rotational direction of output shaft when wired following Fig. 25 on page 21.

• Motor shaft turns in clockwise looking from the anti-load side. This direction is as shown by the arrow in Fig. 3 and 4.

• Exchange connection R and T in Fig. 25 on page 21 with each other when rotating in the opposite direction.

Reducer

Fig. 6

Fig. 7

COMMON

5-2) Installation of coupling

• Do not apply shock or excess axial load to the shaft when attaching the coupling. It may cause bearing damage or collar

may fall off.

• We recommend attachment by shrink fitting.

(1) When Using Coupling

Adjust the dimensions in Fig. 5 (A, B, and X) within the tolerance shown in Table 3.

(2) When Using with Chain Sprocket and Gear

• Make the tension angle of the chain perpendicular to the shaft.

• Refer to your catalog and other materials on chain for correct tension.

• Use sprocket and gears with pitch diameter at least three times of shaft diameter.

• Make the load point of sprocket and gear closer than the shaft center to the gearmotor or reducer side

(Refer to Fig. 6).

(3) When Using with V-belt

• Too much tension on v-belt will damage the shaft and bearing. Refer to your catalog and other materials on v-belt

for correct tension.

• Make the parallelism and eccentricity (b) between two pulleys 20' or smaller (Refer to Fig. 7.)

• Use the matched set with same circumferential length when using multiple v-belts.

Tolerance for A

dimension

0.1mm or maker’s specification

Tolerance for B

dimension

0.1mm or maker’s specification

X dimension Maker’s specification

Table 3

Centering Accuracy of Flexible Coupling

Fig. 5

Shaft

Gear

5-3) Coupling hollow shaft type with other machines

(1) Attachment and Removal of Hollow shaft and Driven Shaft

(a) Attachment to Driven Shaft

Apply molybdenum disulfide grease to the surface of driven shaft and inner diameter of hollow shaft. Insert the

gearmotor or reducer to driven shaft.

Pound the end surface of hollow shaft lightly with a wooden hammer when the fitting is tight.

Do not pound casing and oil seal for this purpose. Jigs as shown in Fig. 8 can help smooth insertion when the fitting is

especially tight.

(a) .......... Retaining ring

(b) .......... Spacer

(d) .......... Nut

(e) .......... Bolt

Fig.8 Coupling jig

Hollow shaft conforms to JIS H8.

Make the fitting between hollow shaft and driven shaft when there is shock load or when the radial load is large. (js6 or

k6 of JIS standard is recommended for driven shaft.)

(b) Uncoupling from driven shaft

Make sure there is no excess force between casing and hollow shaft. Jig as shown in Fig. 9 can help smooth removal.

Prepare jig and parts for attachment, fixing, and removal by yourself.

(f) ............Spacer

(g) .......... Upper bolt

(h) .......... Disc

(i) ........... Retaining ring

Fig.9 Uncoupling jig

COMMON

(2) How to attach of torque arm (option)

 Attention of attachment

1 Attach torque arm to the application machine side of the reducer. 2 Attach retainer parts of torque arm (refer Fig.11) to release extra force between the reducer and the driven shaft.

(Retainer is to be supplied by customer.)

3 Never lock the torque arm completely with locking bolts and such. 4 Attach shock-absorbing material between torque arm and attachment bolt (or spacer). 5 Use bolt which meets JIS standard of screw strength ranking by 10.9 or above. 6 Bolts must be made to lock when a torque arm is used. (The method to lock is to use U-nut or spring washer, or to

supply adhesive for locking screw, etc.)

Note: As shock-absorbing material, rubber bushes and spring washers are prepared.

By use and operating condition, different shock-absorbing materials are recommended.

• In the case of one direction operation : Spring washers or rubber bushes

• In the case of start-stop operation : Spring washers

Attachment type torque arm (option) Banjo type torque arm (option)

Fig.10 Example of using torque arm

Fig.11 Example of retainer (for attachment type torque arm)

COMMON

Retainer parts of torque arm

Part of is to be supplied by customer.

+ 33 hidden pages

Sumitomo Bevel BUDDYBOX 4 Series, LH Series, Bevel BUDDYBOX 5 Series, Helical BUDDYBOX, Bevel BUDDYBOX 3 Series Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual