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Operating Instructions
ABM Helical Geared Motors

2.3.1 Aligning
For coupling operations the shafts must be axially and radially aligned. Dial gauges must be firmly mounted. Measurements must be taken at four measuring points each offset at 90 while the two halves of the coupling are turned simultaneously.

Reversal of direction of rotation:

Type of connecting/ winding Direct connection and changepole motors with separate winding S/D connection and change-pole motors with Dahlander winding Measure Exchange two supply wires on motor terminal board Exchange two supply wires at the feed to the combined earth

Safety Precautions:
Work on the motor or the transmission must only be carried out when these are switched off and secured against power being restored.

2.3.2 Axial measurements

Do not exceed an inaccuracy of 0.03mm with a given measurement diameter of 200mm.

2.3.3 Radial measurement

Do not exceed an inaccuracy of 0.03mm. The axial clearance between the two halves of the coupling (measurement "E") should be set in accordance with the manufacturer's instructions. Check the alignment when the motor is warm.

Please refer to the Notes on Safety and Guarantees

2.2.4 Star/Delta start To prevent unacceptable current surges on change-over and instantaneous surges the change-over from star to delta should only be carried out when the starting current of the delta level has faded.

2.4.5 Motor protection

The usual protective motor switches are not sufficient for motors with a high switching frequency. This type of motor should be ordered with a temperature sensor in the winding and monitored by a release device. To achieve complete thermal protection for the motors a thermal time element must be provided in addition as an overload protection. Fuses by themselves usually only protect the mains supply and not the motor.

1. General Information
1.1 Area of application
These Operating Instructions apply to helical geared motors with totally enclosed fan-cooled rotary current cage rotor motors for low-voltage operations. Motor protection type IP54 and terminal protection box IP55 in compliance with DIN VDE 0530/Part 5, DIN EN 60529. Higher protection types are indicated on the rating plates. The helical geared motors are operated at a height of <= 1000m above mean sea level at a coolant temperature of max. 40C. Exceptions are indicated on the ratings plate.

Axial measurement (angle offset)

Radial measurement (mismatch)

3. Maintenance
3.1 Lubrication
ABM helical geared motors have a LIFETIME LUBRICATION. Refilling is not usually required under normal conditions.

1.2 Transport
Use only the shackles provided for suspending the helical geared motors. Do not install any additional loads. The shackles have been designed to support the weight of the helical geared motors only.

Knocks and blows will damage the bearings. Use only suitable devices to fit and remove the transmission elements.

2.4 Electrical starting

An electrical motor must be installed by an electrician familiar with the relevant VDE regulations. In particular, VDE Regulation 0100 on the installation of heavy current appliances up to 1000V and DIN EN 60204-1, IEC 602041 must be noted. In addition the applicable Regulations of the provisions laid down by the appropriate (German) employers' liability insurance association and the connected switching arrangements must be observed.

1.3 Ventilation
The distance between motor air inlets and walls and components etc. should be 1/4 of the diameter of the air inlet opening, with a minimum distance of 40mm. The air flow is from the opposite side to the drive side. Outflowing air should not be sucked in again directly. Keep the air inlets and outlets free of all obstructions. If the motor is fitted with a upper ventilator hood the air inlet opening must be fitted with a suitable cover to prevent foreign bodies falling in. The cover must not affect ventilation.

Oil Grease

ca.10000 ca.8000

operating hours operating hours

3.2 Lubricant
The amount of oil corresponds to the design. According to the mounting position, please use the required lubrication as per the attached plan of lubrication.

2.4.1 Voltage and switching

Compare the switching details on the rating plates as well as the motor operating voltage and the supply voltage. The permitted supply fluctuations are 5%. Exceptions, such as e.g. multirange voltages, are shown on the rating plates.

3.3 Bearing changes

Bearing changes during the guarantee period require the prior approval of the motor manufacturer.

2.4.2 Connection
Each motor has a connection plan in the inside of the terminal box lid. The cross sections of the connection cables must be adjusted to the rated current values. Connection must be carried out carefully in accordance with the enclosed wiring diagram. Permanent safe connections for all wiring including the earth wire must be guaranteed. To prevent tensile strain on the terminals the connection cables must be installed with strain relief. Care must be taken that the connection box is free of all foreign bodies, dirt and humidity. To guarantee the protection the original seals must be reused when sealing the connection box. Cable entries not in use must be watertight and dust-proof.

1.4 Condensation drain holes

The condensation drain holes must be at the lowest part of the motor following assembly. The holes must be protected from impurities

3.4 Information on storage

The drive motors must be stored in a clean, dry, well ventilated area with a constant temperature and free of vibrations. After a longer idle period (1 year) the bearings must be checked. The insulation resistance of each phase must be measured against the earth for a minute with a hand generator (max. DCV 630V).

1.5 Radio interference suppression

The motors comply as a minimum with the radio interference level N (Normal) in accordance with DIN EN 55014-1, IEC/CISPR 14-1. It is recommended that a local noise voltage measurement be carried out and suitable noise suppression means be installed.

4. Information on repairs
Repair work during the guarantee period requires the prior approval of the motor manufacturer.

2. Installation and starting

2.1 Mechanical starting
The helical geared motors may only be operated in the structural shape as ordered and indicated on the name plate. When using transmission elements with cause radial or axial shaft loads during operations (e.g. pulleys, cog wheels etc.) care must be taken that the maximum permitted loads are not exceeded. The permitted loads are shown in the technical specifications.

4.1 General
2.4.3 Direction of rotation
The helical geared motors are normally suitable for operations in both directions. Before connecting the helical geared motors the phase sequence in the power supply must be determined. The following stator connections are given for each direction of rotation: Connection of L1, L2, L3 Direction seen from power take-off side 2/4-stages 1/3-stages right left left right It is recommended that original spare parts only are used in all repair work.

5. Spare parts
5.1 Ordering spare parts
For spares orders it's absolutely necessary to know the type of drive and number of the drive. Please mention the part number according to the spares drawing.

2.2 Mounting surface

The motors must be fixed to a level, vibration-free surface. The motor feed must be level with the surface to avoid distortion of the gearbox housing. U1, V1, W1 W1, V1, U1

Check for direction of rotation

2.3 Assembly of helical geared motors

If the gear shaft and the machine shaft are directly coupled the shafts must be in alignment with one another.

To check the direction of rotation switch the motor, uncoupled and connected in accordance with the regulations, "On/Off" quickly.

ABM Greiffenberger Antriebstechnik GmbH, D-95614 Marktredwitz, Phone (09231)67-0, Telefax (09231)62252, http://www.abm-antriebe.de

We put ideas into gear Safety information for electrical operating appliances for use in industrial heavy current facilities Operating instructions
This Information Sheet with warnings shall apply in addition to the operating instructions specific to the product and for safety reasons particular attention must be paid to it.

WARNING

DANGER
The electrical machines and/or appliances are operating appliances for use in industrial heavy current facilities. When being operated, the appliances have dangerous live parts, and in some cases moving or rotating parts as well. They can therefore cause serious injury or damage, e.g. if the necessary coverings are removed without cause, if they are operated in an improper manner, if they are incorrectly operated or if they are insufficiently maintained. -

It is assumed that the basic planning work in the facility, as well as all work regarding transport, assembly, installation, starting up, maintenance and repairs will be carried out by qualified personnel and/or checked by the responsible skilled staff. The following must be particularly observed:
Technical data and details as to the permitted application (conditions for the assembly, connection, environment and operations), with are contained, among other places, in the catalogue, in the order documentation, in the operating instructions, on the rating plates and in other product documentation; general assembly and safety regulations; local provisions and requirements specific to the facility; the correct use of tools and lifting and transport devices; the use of personal protective clothing; assembly conditions for appliances delivered in accordance with IPOO (without covering): during operations the required protection against accidental contact must be present and/or dangerous approaches prevented.

It is recommended that the services of the ABM Customer Service Department are used for all servicing.

NOTE: The ABM assembly brochures, witch can be obtained where necessary from the distributors, contain further detailed information on general work, e.g. checking incoming deliveries (transport damage), long-term storage and conservation of machines, checking foundations, fitting couplings, fitting and aligning machines, and installing measures.

Those responsible for safety in the plant must therefore guarantee: that only qualified persons work with the machines and/or appliances; that the operating instructions and other documentation delivered with the machine/appliance are available to such persons at all times and that they are obliged to observe the regulations contained therein; that unqualified persons are forbidden to work at or near the machines/appliances. Qualified persons are persons who, by reason of their training, experience and instructions, as well as their knowledge of the relevant standards, regulations, accident prevention regulations and operating relations have been empowered by the person(s) responsible for plant safety to carry out the necessary work and are able to recognize and avoid possible dangers (definitions for skilled workers - cf. VDE0105 or DIN VDE 0100-300 as well).

WARNING To prevent breakdowns it is necessary that the prescribed maintenance, inspection and revision measures are carried out regularly by experienced servicing staff (see above).
Changes to normal operations (increased power consumption, higher temperatures, increased vibrations, noises etc. or responses from the monitoring equipment) can mean that functions are impaired. To prevent breakdowns, which can directly or indirectly lead to serious injuries or damage, the maintenance staff must be informed without delay.

For the sake of clarity the operating instructions cannot contain all the detailed information on possible model variations, and particularly cannot take into consideration every possible case of installation, operation or maintenance. For this reason the Operating Instructions can basically only contain information which is required for the correct use of the machine or appliance by qualified personnel (see above) in industrial applications. If in special cases more exacting demands are made for the planned utilization of the machine or appliance in non-industrial areas (e.g. child-proof safety devices or similar) these conditions must be fulfilled on assembly by the customer with additional safety devices. If there are any uncertainties regarding this, especially if detailed information specific to the product is lacking, clarification can be obtained from the competent ABM distribution agency. Please quote the machine or appliance type description and manufacturing number.

IF IN DOUBT SWITCH THE APPLIANCE OFF IMMEDIATELY!

Among other things, acquaintance with firstaid measures and the local rescue devices is required. The prohibition on the employment of unqualified personnel in work on heavy current facilities is regulated, for example, in DIN VDE0105 or DIN VDE 0100-300.

It should be pointed out that the contents of the Operating Instructions and product documentation are not part of, and are not intended to amend, any earlier or existing agreement, undertaking or legal relationship. All obligations on the part of ABM result in each case form the Sales Agreement, witch also contains the complete and exclusive guarantee provisions. These contractual guarantee provisions are neither extended nor limited by the contents of these instructions and documentation.

Structural shape in compliance with DIN EN 60034-7, VDE 0530-7, IEC 4-7

Lubricants
When changing the lubricant the transmission must be thoroughly cleaned. The helical gear bearings must be checked and if necessary exchanged for new bearings. Do not mix lubricants. This applies in particular to mineral and synthetic lubricants. When using synthetic lubricants check their tolerance with the conical nipples. Too much lubricant can lead to overheating.

ABM Greiffenberger Antriebstechnik GmbH, D-95614 Marktredwitz, Phone (09231)67-0, Telefax (09231)62252, http://www.abm-antriebe.de