Hyponic Quick-Start Guide 1 Manual 12.002.61.008
Hyponic Safety Consult the factory if Hyponic products are driven by DC motors, variable frequency AC drives, or speeds other than standard catalog input speeds. Be sure to install and operate Hyponic speed reducers, gearmotors and brakemotors in compliance with applicable local and national safety codes. Appropriate guards for rotating shafts should be used and are available from the factory. When Hyponic speed reducers, gearmotors or brakemotors are a component in a system for human transport, install a secondary safety device in order to minimize the risk of accidents that may result in personal injury, death or equipment damage. Inspection Upon receipt verify that: The information on the nameplate (Figures 1 & 2) matches the specifications of the unit you ordered. The unit was not damaged during shipment. All nuts and bolts are securely tightened. There are no missing parts or accessories. Daily: Check for loose nuts and bolts. On gearmotors, check for obstructions to the cooling fan. Listen for abnormal sounds. Stop the unit and inspect it if you hear any abnormal internal sounds. Check for high temperature and abnormal vibration. Caution: If you suspect the temperature is elevated, be extremely careful when touching the unit! A temperature rise of up to 72 F (40 C) above ambient on the gear case surface is acceptable if the fluctuation is small. However, a rapid rise in temperature may indicate that the lubricant is low. Check for lubricant leaks. 2
Nameplate The nameplate, which is secured to the housing, lists your unit s essential identification information. You will need to give your sales representative or distributor the complete description shown on the nameplate when ordering replacement parts or requesting service. Fig. 1 Gearmotor Nameplate Quick Start Guide Fig. 2 Reducer Nameplate Note: Nameplate style may differ depending on your order specification. Motor Installation Hollow input shaft units for the Food and Beverage industry have either an o-ring or a gasket for installation between the motor and reducer. 1. Installation Instructions a. Make sure that the o-ring is in the o-ring groove, or that the gasket is in place. b. Apply a thin film of the supplied food-grade Kluberpaste to the hollow shaft. Save enough Kluberpaste to coat the Hyponic output shaft (nonshrink disc units). 3
Mounting & Alignment Table 1 Driven Shaft Mounting and Removal Detail (in.) Model min. ød max Bore Size [1] Recommend L LH LG LF L1 L2 L3 1120 0.750 0.751 3.23 2.64 2.01 1.22 2.36 0.16 1.37 1220 1.000 1.001 3.62 2.76 2.13 1.50 2.36 0.28 1.98 1230 1.000 1.001 3.94 3.07 2.44 1.50 2.68 0.28 1.98 1320/30/40 1.250 1.252 4.33 3.46 2.52 1.81 2.80 0.28 2.10 1420/30/40 1.375 1.377 5.43 4.41 3.39 2.05 3.66 0.39 2.32 1520/21/22/ 30/31/40 1.500 1.502 6.14 5.12 3.86 2.28 4.09 0.39 3.49 1630/31/32/ 33/34/40 2.000 2.002 8.82 7.24 5.83 2.99 6.26 0.47 3.53 Model Recomm Model e f g h A2 Bolt Retaining Ring O.D. x I.D. 1120 0.59 #10-32UNF x 0.98 0.75 0.75 x 0.28 1220 0.51 5/16-18UNC x 1.38 1.00 1.00 x 0.39 1230 0.51 5/16-18UNC x 1.57 1.00 1.00 x 0.39 1320/30/40 0.51 5/16-18UNC x 1.77 1.25 1.25 x 0.67 1420/30/40 0.59 3/8-16UNC x 2.17 1.38 1.37 x 0.75 1520/21/22/ 30/31/40 0.55 1/2-13UNC x 2.56 1.50 1.50 x 1.02 1630/31/32/ 33/34/40 1.02 5/8-11UNC x 2.95 2.00 2.17 x 0.98 Note: [1] Dimensions LH, LG, and LF change when bore diameter changes. [2] Parts a k are not supplied by Sumitomo Drive Technologies. 4
ed Shaft Size Recommended Component Size [2] a b c d L4 L5 A1 Nut Thread Thrust Bearing #10-32UNF 0.63 0.20 #10-32UNF #10-32UNF x 5.91 51100 5/16-18UNC 0.79 0.28 5/16-18UNC 5/16-18UNC x 5.91 51100 5/16-18UNC 0.79 0.28 5/16-18UNC 5/16-18UNC x 5.91 51100 5/16-18UNC 0.79 0.28 5/16-18UNC 5/16-18UNC x 5.91 51100 3/8-16UNC 0.98 0.31 3/8-16UNC 3/8-16UNC x 9.45 51201 1/2-13UNC 1.18 0.39 1/2-13UNC 1/2-13UNC 9.45 51202 5/8-11UNC 1.57 0.51 5/8-11UNC 5/8-11UNC x 11.81 51204 ended Component Size [2] i j k Bolt A3 A4 A5 A6 A7 A8 5/16-18UNC x 4.72 0.16 0.64 0.75-0.004-0.012 3/16 5/16-18UNC 0.08 1/2-13UNC x 4.72 028 0.86 1.00-0.004-0.012 1/4 1/2-13UNC 0.08 1/2-13UNC x 4.72 0.28 0.86 1.00-0.004-0.012 1/4 1/2-13UNC 0.08 5/8-16UNC x 5.91 0.51 1.11 1.25-0.004-0.012 1/4 5/8-16UNC 0.12 5/8-16UNC x 7.87 0.51 1.20 1.37-0.004-0.012 5/16 5/8-16UNC 0.20 3/4-10UNC x 7.87 0.63 1.29 1.50-0.004-0.012 3/8 3/4-10UNC 0.20 1-8UNC x 9.45 0.75 1.72 2.00-0.004-0.012 1/2 1-8UNC 0.20 5
Hyponic Mounting and Alignment 1. Mounting the Shaft in the Hollow Bore a. Hollow Input Shaft Models - Before assembling, apply anti-seize (molybdenum disulfide) paste to the surface of a motor shaft and the inner surface of a hollow input shaft. The anti-seize paste is not supplied by the manufacturer. b. Hollow and Solid Output Models (without shrink disc) - Apply antiseize (molybdenum disulfide) paste to the surface of a driven shaft and the inner surface of a hollow shaft. Then insert the Drive into the driven shaft. c. A clearance fit is standard. A tight fit is recommended for severe application. For tight-fit applications, tap the end of the hollow shaft with a rubber mallet to aid insertion into the bore. Using fixtures b e shown in Fig. 3 is also recommended for easy assembly. Fig. 3 Driven Shaft Mounting A2 e b d c See Table 1 Pages 4 & 5 6
Quick Start Guide 2. Securing the Shaft in the Hollow Bore a. Refer to Fig. 4 and Table 1 for details on securing a staged shaft. b. Refer to Fig. 5 and Table 1 for details on securing a straight shaft using a spacer. Fig. 4 Secured by Staged Driven Shaft L2 L1 L3 L4 x L5 DEEP A1 a f ød LF LG LH L g Fig. 5 Secured by Spacer h a See Table 1 Pages 4 & 5 7
Hyponic Mounting & Alignment 3. Shaft Removal using fixtures i k shown in Fig. 6 is recommended for easy removal of the shaft. The shaft should be designed to allow use of these fixtures. Fig 6. Driven Shaft Removal k A8 A3 j i A7 A5 A6 A4 See Table 1 Pages 4 & 5 8
Quick Start Guide 4. Securing the Hyponic Drive to Prevent Movement Away from the Machine Side (Fig. 7, 8).* Stepped Shaft Stepped Shaft Snap ring Spacer End plate Machine side Machine side Fig. 7 Secured by a Spacer and a Snap Ring Fig. 8 Secured by an End Plate *WARNING: Inappropriate installation may result in shaft fretting. Fretting will cause shaft wear, jamming, and misalignment between the drive and Customer s shaft. 9
Hyponic Mounting & Alignment 5. Torque Arm a. Attach the torque arm to Hyponic Drive casing on the machine side with hex socket head cap screws. (Refer to the table below for bolt sizes.) b. Leave some allowance in the section of torque arm so that excessive force will not be applied between Hyponic Drive and the driven shaft. Don t secure the torque arm with the torque arm bolt; otherwise, it may damage the bolt, torque arm, Hyponic Drive or the machine. c. For frequent start/stop operations, or repeated normal/reverse operations, use a rubber bushing between the torque arm and mounting bolt (or spacer) to absorb the shock. Frame Size Bolt Fig. 10 Example of Torque Arm Mounting 1120, 1230 M8 1330, 361 M10 1320, 1430, 461 M12 1420, 1530, 1531 M16 1520, 1521, 1522, 1630 M20 1631, 1632, 1633, 1640 Torque arm Machine side Spacer Keep some allowance Flat washer Special bolt (or pin) No allowance between the torque arm and the machine (Adjust the allowance according to the movement of the machine.) CORRECT 10 (Excessive force on the torque arm bolt, machine and Hyponic may cause damage.) INCORRECT
Quick Start Guide 6. Flange Mounting and Casing Bottom Mounting (optional) Handle with care in order not to apply excessive force to driven shaft or hollow shaft by twisting the Hyponic casing. Fig. 11 Flange Mounting Surface Correct Incorrect Incorrect Bearing unit Bearing unit Bearing unit Hollow shaft type Hollow shaft type Hyponic Drive Hollow shaft type (Poor concentricity of the driven shaft and mounting flange.) (Poor perpendicularity of the driven shaft center and mounting flange surface.) (Excessive force on Hyponic and the bearing unit may cause damage to internal parts.) 11
Hyponic Shrink Disc Installation Important Never tighten locking screws before shaft installation. Inner ring may become permanently contracted even at low tightening torques. Warning Ensure that all power switches are locked out before installing or removing shrink disc. Wear safety glasses and protective clothing at all times. 1. Installation Instructions a. Remove any wooden spacers that may have been used during shipping. b. Lightly lubricate the hub outside diameter and shrink disc bore. c. Critical: Clean any lubricant from the shaft and hub bore before mounting the hub onto the shaft. d. After confirming the correct position of the hub and shrink discs, hand tighten three or four equally spaced locking screws and ensure the discs are parallel. Hand-tighten remaining locking screws. e. Using a torque wrench, tighten the screws according to the initial torque listed in Table 2. Tighten in either a clockwise or counter-clock wise sequence, using ¼ turns. After turning one screw a ¼ turn, tighten in a cross-star pattern and so on, until you can no longer complete a ¼ turn for any of the screws. This procedure keeps the discs parallel. f. Continue to tighten the screws for two more passes. This compensates for system induced relaxing of the locking screws. g. Set the torque wrench to the final torque and tighten all locking screws. At this point, no screw should turn; otherwise, set the torque wrench to the initial torque and repeat steps above. It is not necessary to re-torque after equipment has been in operation. 12
Quick Start Guide Table 2 Locking Screw Torque Screw Size M5 M6 M8 Initial Torque (N m) 5.1 12.3 31 Final Torque (N m) 4.9 11.8 30 Socket Size (mm) 8 10 13 2. Removal Instructions Following either a clockwise or counterclockwise sequence, loosen all locking screws using approximately ½ turns, until you can remove the shrink disc from the hub. The shrink disc, hub, and shaft will return to their original clearance fits. Warning Do not completely remove locking screws before outer collars are disengaged from the inner ring. A sudden release of the outer collars involves high separating forces a nd could result in permanent injury or death. Be certain that outer collars are disengaged from the inner ring before completely removing locking screws. 3. Re-installation of Shrink Discs In relatively clean operating conditions, shrink discs can be re-used without prior cleaning. However, shrink discs used under severe conditions require thorough cleaning and re-lubrication with Kluberpaste UH1 84-201 or the equivalent before re-using. 13
Hyponic Motor Wiring This section details wiring for standard Sumitomo three-phase motors and brakemotors. The motor diagram found inside Sumitomo supplied motor conduit box cover is correct. If using a motor manufactured by a company other than Sumitomo, please refer to that manufacturer s instruction manual for wiring, operating and maintenance details. When wiring motors into the power supply, Sumitomo recommends the use of terminal rings to facilitate the connection. Do not handle the unit when cables are live. Be sure to turn-off the power; otherwise electric shock may result. Connect the power cables to the unit according to the connection diagram shown inside the terminal box or in the maintenance manual; otherwise electric shock or fire may result. Correctly ground the grounding bolt; otherwise electric shock may result. Keep all wiring and electrical parts dry and moisture free. Follow local electrical codes and regulations when wiring; otherwise burning, electrical shock, injury and/or fire may result. The motor is not equipped with an overload device. Sumitomo strongly recommends that another protective device (i.e.: ground fault interrupters, etc.), in addition to an overload device, be installed in order to prevent burning, electric shock, personal injury and/or fire. For Single Phase motors, exercise caution so as to not damage the vinyl cover of the starting capacitor, otherwise shock may result. 14
Quick Start Guide For Brakemotors, do not electrify a brake coil continuously when the motor is stopped otherwise the brake coil may burn and fire may result. For Brakemotors, install the rectifier where the temperature is less than 140 F (60 C). Long wires cause the voltage to drop. Select cables with appropriate diameter so that the voltage drop will be less than 2%. After wiring the motor, check that the terminal box mounting bolts are tight. Motor Wiring Use a molded case circuit breaker for protection against short circuit. Use an overload protection device that protects the unit against voltage surges. 15
Hyponic Start-up Check the following under no load prior to start-up: Ensure that the driven load and the Hyponic reducer or gearmotor are properly secured. Verify the rotation direction. If a reverse direction is required, simply reverse any two power leads. Check the voltage supply and current (line and phase) to verify balancing for a three-phase power source. When power is supplied to the motor, if start-up is abnormally long, is not completed or any abnormal sound is heard, immediately shut-off the power and consult the factory. Measure the current draw. The current measured at full load should not exceed the nameplate rating. 16
Long Term Storage Procedure Preparation for Six Months to One Year Storage Quick Start Guide Hyponic models are filled with grease prior to shipping and do not require additional lubricant during long term storage. At approximately three-month intervals, rotate the input shaft several times to keep all internal components coated with lubricant. The higher the ratio, the more rotations needed for proper lubrication. Consult the factory for storage procedures if you plan to store your unit for longer than one year. Operation After Six Months to One Year Storage Units do not require any special procedures following storage, however, you should follow the steps listed in the Start-up section of this document before operating. Consult the factory before operating units stored for periods longer than one year. 17
Hyponic Notes 18
Quick Start Guide Notes 19
Headquarters & Manufacturing 4200 Holland Boulevard Chesapeake, VA 23323 Tel: +1-757-485-3355 1-800-SMCYCLO Fax: +1-757-485-7490 E-mail: customercare@suminet.com After Hours Technical Support service@suminet.com 1-800-983-1000 Hyponic /hyponic World Headquarters Japan Sumitomo Heavy Industries, Ltd. Power Transmission & Controls Group ThinkPark Tower, 1-1, Osaki 2-chome, Shinagawa-ku, Tokyo 141-6025 Japan Tel: +81-367-37-2511 Fax: +81-368-66-5160 For facilities located in the Americas, please visit /locations For worldwide locations, please visit /worldwide