Operating Manual: For Electric Motor / Gear Motor

Electric motor / gear motor
Operating manual
for electric motor / gear motor
Status : April, 2016
Electric Motor Spur Gear Motor Flat Gear Motor
© Copyright ABM Greiffenberger Antriebstechnik GmbH, Friedenfelser Straße 24, 95615 Marktredwitz, 2013
Table of contents
1. General safety information ................................................................................................................. 4
1.1. General .................................................................................................................................................. 4
1.2. Explanation of symbols .......................................................................................................................... 4
1.3. Personnel ............................................................................................................................................... 4
1.4. Mechanical hazard................................................................................................................................. 5
1.5. Thermal hazard ...................................................................................................................................... 5
1.6. Magnetic hazard .................................................................................................................................... 5
2. General.................................................................................................................................................. 6
2.1. General instructions ............................................................................................................................... 6
2.2. Used terms ............................................................................................................................................ 6
2.3. Modification of the product..................................................................................................................... 6
2.4. Liability and warranty claims .................................................................................................................. 6
2.5. Addresses .............................................................................................................................................. 7
3. Specification ........................................................................................................................................ 8
3.1. Construction of the motor (schematic diagram) .................................................................................... 8
3.2. Name plate ............................................................................................................................................ 9
3.3. Type designation .................................................................................................................................10
3.4. Standards and guidelines ....................................................................................................................11
3.5. CE conformity ......................................................................................................................................12
3.6. Intended use ........................................................................................................................................13
3.7. Optional modules .................................................................................................................................13
4. Preparation of the drives for operation ...........................................................................................14

4.1. Shipment and packaging .....................................................................................................................14
4.2. Transport and storage .........................................................................................................................14
4.3. Mechanical installation .........................................................................................................................15
4.4. Electrical installation ............................................................................................................................19
4.5. Commissioning ....................................................................................................................................20
4.6. Commissioning after longer downtimes ...............................................................................................20
5. Operation ............................................................................................................................................21
5.1. Safety instructions ...............................................................................................................................21
5.2. Error diagnosis and fault removal ........................................................................................................22
6. Maintenance .......................................................................................................................................25
6.1. Safety instructions ...............................................................................................................................25
6.2. Maintenance ........................................................................................................................................26
6.3. Spare parts ..........................................................................................................................................28
7. Decommissioning and disposal .......................................................................................................29

7.1. Decommissioning ................................................................................................................................29
7.2. Recycling and disposal ........................................................................................................................30
8. List of images .....................................................................................................................................31
9. List of tables .......................................................................................................................................31
10. Index....................................................................................................................................................32
Annex .............................................................................................................................................................33
A Constructions ....................................................................................................................................33
A1 Electric motors .....................................................................................................................................33
A2 Spur gear motors .................................................................................................................................36
A3 Flat gear motors ...................................................................................................................................37
B Allowed radial forces .........................................................................................................................38

B1 Electric motors .....................................................................................................................................38
B2 Spur gear motors .................................................................................................................................39
B3 Flat gear motors ...................................................................................................................................41
C Lubrication .........................................................................................................................................42
C1 Lubricant amounts ...............................................................................................................................42
C2 Lubricants ............................................................................................................................................44
D Screw tightening torques..................................................................................................................45
E Safety parameters for rotary encoder .............................................................................................46

1. General safety information

1.1. General
Any work for the transport, storage, installation, commissioning and maintenance may be
carried out with the personal protective equipment required for the work.
1.2. Explanation of symbols

Signal words:
Signal word field with signal word Meaning
DANGER
Indicates a hazard with a high degree of risk
which leads to death or severe injuries if it is not
prevented.
Indicates a hazard with a medium degree of risk,

WARNING which can lead to death or severe injuries if it is
not prevented.
Indicates a hazard with a low degree of risk which

CAUTION can cause minor or moderate injuries if it is not
prevented.
Table 1 : Signal words and their meaning
The safety instructions in this operating manual are structured as follows:
Signal word with illustration
HAZARD
 Actions to prevent the hazard
1.3. Personnel
Any work for the transport, storage, installation, commissioning and maintenance must only be
carried out by qualified specialist personnel. The binding specifications for the qualification of
electrically qualified persons and electrically skilled personnel apply as defined in DIN VDE
0105-100.
4
1.4. Mechanical hazard

Transport, assembly, commissioning and decommissioning, as well as maintenance and
inspection work must only be carried out using the personal protective equipment required for
the respective work, and only by trained specialist personnel while the machine is idle, de-
energised and cooled off.
1.5. Thermal hazard
WARNING
HOT MACHINE PARTS

Hot machine parts can cause burns in case of
skin contact
 Do not touch hot surfaces!
 If possible, the manufacturer of the complete
machine has to provide suitable touch guards!
 Wear the personal protective equipment for
maintenance or troubleshooting work!
 Observe the cool-down times!
Electric mains must not be in contact with hot surfaces.
1.6. Magnetic hazard

When using ABM SINOCHRON® motors, observe the following:
DANGER
MAGNETIC FIELD
Due to the strong magnetic field as well as the
associated high magnetic attractive forces,
hazards to the health especially to persons with
a pacemaker can occur. Severe injuries or death
can be the result.
 Any work on the drive is forbidden for persons
with a pacemaker!
5
2. General
2.1. General instructions
Before working with the drive, carefully read the operating manual. This way, you ensure a risk-
free and smooth function of the drive. The instructions of this operating manual must be
observed.
Special designs can deviate in technical details! This operating manual and all associated
special documentations must be kept in close proximity to the drive.
The reproduction, distribution and utilization of this document as well as the communication of
its contents to others without express authorization is prohibited. Offenders will be held liable for
the payment of damages. All rights reserved in the event of the grant of a patent, utility model or
design.
2.2. Used terms
Term Hereinafter used for

Motor Three-phase motor
Single-phase motor
Gear motor
ABM SINOCHRON® motors
Gear Spur gear
Flat gears
Special gears
Drive Motor or gear motor
Table 2 : Used terms
2.3. Modification of the product

The drive itself must not be changed. Adjacent constructions by the customer must not obstruct
the heat flow by means of convection and heat conduction. A heat input into the drive from the
outside is not allowed.
2.4. Liability and warranty claims

The drive must only be operated in compliance with the specifications in the operating manual.
In case of property and personal damage caused by improper handling or noncompliance with
the safety instructions, any liability and warranty claim expires.
6
2.5. Addresses
Germany
ABM Greiffenberger Antriebstechnik GmbH
Postfach 140 Friedenfelser Str. 24
D - 95614 Marktredwitz D - 95615 Marktredwitz
Phone: +49 9231 67-0

Fax: +49 9231 67-5295
e-mail: sales@abm-drives.com
USA Austria
ABM DRIVES INC. ABM Antriebstechnik GmbH
2000 Ford Circle, Suite E Ortstrasse 18/1/5-7
Milford, Ohio 45150 A - 2331 Vösendorf
Phone: +1 513 5761300 Phone: +43 1 69911620

Fax: +1 513 5764999 Fax: +43 1 699116223
e-mail: abmus@abm-drives.com e-mail: abm-austria@abm-antriebe.de
France P.R. China

ABM Systèmes d'Entraiment S.A.R.L. ABM Drives (Suzhou) Co., Ltd.
40, rue Jean Monet Kuachun Industrial Area Unit 9G,
Melpark Bat. 5 Chun Hui Lu, Weiting Town
F - 68200 Mulhouse VR China - 215122 Suzhou
Phone: +33 3 89334401 Phone: +86 512 - 8717 1081

Fax: +33 3 89334405 Fax: +86 512 - 8717 1084
e-mail: infofr@abm-drives.com
e-mail: infocn@abm-drives.com
Turkey India
ABM Greiffenberger Hareket Sistemleri Ticaret ABM Drives India Private Limited
Limited Şirketi Lunkad Sky Vista, 308 Viman Nagar,
Barbaros Mah. Bezirgan Sok. No:3 Near Dorabji Mall, Opp New Airport Road,
Deluxia Suites A Blok Daire:17 Pune - 411014
Batı Ataşehir-İstanbul, TR 34746
Phone: +91 20 6648 7579
Phone: +90 216 2903525
Fax: +90 216 2903526
E-Mail: abmtr@abm-drives.com
7
3. Specification
3.1. Construction of the motor (schematic diagram)
Deviations are possible depending on the design.
Image 1 : Construction of the motor
[1] Bearing plate A-side [11] Fan
[2] Shaft seal ring [12] Traction screw
[3] Ball bearing shim [13] Locking ring
[4] Grooved ball bearing [14] Fan cowl
[5] Fitting key [15] Hexagon screw
[6] Rotor [16] Terminal board
[7] Stator [17] Seal
[8] Ball bearing [18] Slider
[9] Adjusting washer [19] Terminal box
[10] Bearing plate B-side [20] Cylinder screw
8
3.2. Name plate

Name plate (Example)
Abbreviation Unit Designation
D = three-phase motor
Mot E = single-phase motor
PM = SINOCHRON® motor
Nr Serial number
TNr ABM part number
IKL Insulation class
UT °C Max. allowed ambient temperature
IP Type of protection
Typ ABM type designation
Operating mode
kW Motor rated power
V Motor connection voltage
Hz Frequency motor voltage
Switching type of the motor (Y / delta)
A Rated current of the motor
Cos-Phi of the motor
1/min Rated speed at the motor shaft or gear shaft
TS Nm Braking torque
Brake
V Brake connection voltage

A Rated current of the brake
CB μF Operating capacitor for single-phase motors
CA μF Starting capacitor for single-phase motors
Table 3 : Field description at the name plate
9
3.3. Type designation

This documentation applies to ABM drives with the following type designation (example):
ZFB100 / G200F / 4D132Mc-4

Brake designation Gear designation Motor designation
Type designation brake

See operating manual brake
Type designation gear
Gear type Spur gear Flat gear
G = 2-stage
FG = normal gear
Designation 3G = 3-stage
FGS = special gear
GS = special
1. addition Axle height A = attachment version
2. addition V = reinforced Output torque
3. addition F = flange F = flange version
Type designation motor
3 = die-cast case
Casing key 4 = extruded casing
- = bearing plate motor
D = three-phase motor
Motor type E = single-phase motor
PM = Permanent magnet motor
EK = with operating capacitor
EKK = with operating and starting capacitor
Variants for single-phase ERKK = with relay, operating and starting capacitor
motors EWR = with auxiliary resistance phase and relay
EZKK = with centrifugal switch, operating and starting capacitor
DEK = with Steinmetz circuit
K= flywheel
L= bearing plate motor (without casing)
1. addition B= reinforced coil
G= non-ventilated
F = flange design
2. addition Motor size (peak height) and packet length
3. addition Number of pins
FL: forced ventilated
st
4. addition for 1 addition “G” EL: external ventilation
DL: open-circuit ventilated
Table 4 : type designation ABM drives
10
3.4. Standards and guidelines

The motors comply with the following standards:
Standard Title
IEC / EN 60034-1 Rotating electrical machines - part 1: Rating and
performance
IEC / EN 60034-5 Rotating electrical machines - part 5: Degrees of
protection provided by the integral design of
rotating electrical machines (IP code) -
Classification
IEC / EN 60034-7 Rotating electrical machines - part 7:
Classification of types of construction and
mounting arrangements
IEC / EN 60034-8 Rotating electrical machines - part 8: Terminal
markings and direction of rotation
IEC / EN 60034-9 Rotating electrical machines - part 9: Noise limits
IEC / EN 60034-14 Rotating electrical machines - part 14: Mechanical
vibration of certain machines with shaft heights
56 mm and higher - Measurement, evaluation and
limits of vibration severity
IEC / EN 60204-1 Safety of machinery - Electrical equipment of
machines - part 1: General requirements
Table 5 : Standards
If the products fall within their scope, the following guidelines and directives apply:
Number Abbreviated designation

2006/95/EC Low-Voltage Directive
2009/125/EC Ecodesign Directive
2011/65/EU RoHS directive
Directive EC 640/2009 Implementing directive 2005/32/EC
Directive EC 1907/2006 REACH
Table 6 : Guidelines
Asynchronous motor at sinusoidal mains are considered as electromagnetically passive

components because they neither cause faults nor are they error-prone. According to chapter 1
paragraph 1 section 3 of the EMC directive (2004/108/EC), they are therefore excluded from the
scope of this directive.
11
3.5. CE conformity
12
3.6. Intended use

The drives serve the generation of a rotary movement and are intended for commercial plants.
Ambient conditions Requirement

Ambient temperatures -15° up to +40 °C
Installation height  1000 m above sea level
Humidity Up to 50% (at +40°)
Up to 90% (at room temperature)
Table 7 : Operating conditions according to EN 60034-1 or EN 60204-1
The use in explosive areas is forbidden.
An overload can cause damages to the drive. The maximum shaft load allowed for your gear is
specified in Annex B.
In order to prevent an overheating of the drive, it must be ensured that sufficient space is
available for the unobstructed ventilation. The fan cowls must not be covered. When using
several drives in close proximity, it must be ensured that it is possible to prevent a suction of
warm exhaust air.
The technical data on the name plate must be observed. The documentation must be complied
with. For applications in which the failure of a gear or motor could cause a danger to persons,
corresponding safety precautions must be provided.
The motor is no independently functional machine and it is intended for the integration into
another machine. The commissioning is prohibited until it has been determined that the machine
complies with the regulations of the EC directives.
3.7. Optional modules

If your drive is equipped with a brake, please observe the supplementary operating manual.
This manual will also specify the B10d characteristics pursuant to EN ISO 13849-1.
The safety characteristics for the variant with rotary encoder are specified in Annex E.
13
4. Preparation of the drives for operation

4.1. Shipment and packaging
The motor is delivered with suitable packaging. The outer packaging is taken back.
Incoming control:
- Check the completeness on the basis of the delivery note!
Is the packaging damaged?

- Check the delivery for damages (visual inspection)!
In case of complaints
If the delivery was damaged during transport:
- Contact the forwarding agent immediately!
- Keep the packaging (due to a possible inspection by the forwarding agent, or for the return of
the goods)!
Packaging for the return of the goods

- Pack the motor shockproof.
4.2. Transport and storage

During transport, motors (from size 100) and all gear motors must only be suspended at the
provided lifting eyes. Do not attach additional loads to the motor. Only use suitable lifting
means. Improper execution, unsuitable or damaged devices and tools can cause injuries and/or
property damage.
DANGER
FALLING OBJECTS
In case of improper transport, the drive could
detach from the transport and lifting gear.
Falling objects can cause severe injuries.
 Staying underneath the drive during transport is
forbidden!
 Ensure secure fastening!
14
The following points must be observed for the storage:
 Storage in installation position, protect the drive against falling

 Slightly lubricate blank casing surfaces and shafts
 Store in dry, dust-free rooms
 Temperature without considerable fluctuations between -25°C and +55°C
 Relative humidity less than 60%
 No direct sunlight or UV light
 No aggressive, corrosive materials (contaminated air, ozone, gases, solvents, acids,
lye, salts, radioactivity etc.) in the surroundings
 No shocks and vibrations.
4.3. Mechanical installation

The mechanical connection of the electric motor has to be carried out by a specialist. Only carry
out work at the drive when it is switched off and secured against restart.
Before the installation, check the installation situation. Shearing and crushing points must be
avoided when handling the drive.
Also observe the following when using ABM SINOCHRON® motors:
CAUTION
MAGNETIC FIELD
Due to the magnetic forces, injuries can be
caused by attracted tools
 Hold on to the tools tightly!
 Bring them closer to the motor slowly!
 Wear work gloves!
15
Assembly
The following must be observed during assembly:
 Mount the drive on an even, vibration-free locating surface. All fastening bases and
flanges must rest flush in order to prevent bracings of the motor casing or gear casing.
 Ensure a free cooling air supply. The distance between motor air inlet and walls,
components etc. must be at least 40 mm.
min. 40 mm
Image 2 : Minimum distance from the fan cowl
 The airflow direction is from the B-side towards the A-side. The escaping exhaust air
must not be sucked in again immediately. The air inlets and outlets must be kept free
from dirt.
 Ensure that existing condensate bores are located at the lowest point of the motor.
Protect them against contaminations. If required, remove the plastic sealing plugs (if
available).
 Remove the rust protection coating from the shaft ends. When removing the rust
protection, no solvents may penetrate into the bearings.
 Mount the transmission element to the motor / gearbox drive shaft.
 The cylindrical shaft ends are equipped with a centring device whose thread enables
the fitting of the transmission element. Always use suitable devices for the fitting and
removal. Avoid vibrations and shocks during assembly. In case of a force effect, the
bearings will be damaged.
 Only use elastic couplings. Rigid couplings require a precise alignment of the shafts.
16
 When using transmission elements which cause radial and axial shaft loads during
operation, observe the allowed loads. If not specified in the data sheet, the
specifications are stipulated in Annex B.
DANGER
MOVING PARTS
Rotating parts can cause injuries
 Equip the transmission elements with a safety
device!
 Observe the design guidelines of “DIN EN ISO
12100” and the safety distances pursuant to
“DIN EN ISO 13857”!
 Product-specific characteristics must be observed when selecting add-on components

(fixtures) and for the later use of the complete machine:
Balancing
Only for the assembly of the drive element onto the motor shaft:
Ensure the correct balancing type of the drive element according to the balancing type of the
motor shaft (F- or H-balancing). The shafts are balanced according to DIN ISO 1940-1.
The marking is indicated on the Name plate behind the product number.
Marking Balancing type

F Balanced with full fitting key
H Balanced with half fitting key
Table 8 : Balancing type
Couplings, pulleys, gear wheels etc. must be balanced on an even shaft without fitting key
(other balancing types only after previous agreement).
17
Alignment
In coupling operation, align the shafts axially and radially against each other.
Fit dial gauges.

Measure at four measuring points, which are each offset by 90°, while rotating both coupling
halves at the same time.
Check the alignment at operating temperature.
Axial measurement
 Balance the discrepancy by placing sheet metal plates underneath.
 Do not exceed remaining inaccuracies of 0.03 mm, based on a measuring circle of

200 mm.
Radial measurement
 Balance differences by displacement or by placing sheet metal plates underneath.
 Do not exceed remaining inaccuracies of 0.03 mm, based on a measuring circle of

200 mm.
 Carry out the adjustment of the axial air between the coupling halves according to the
specifications of the coupling manufacturer.
E E
Axial measurement Radial measurement

(angular offset) (angular offset)
Image 3 : Measurement of angular offset
18
4.4. Electrical installation
DANGER
ELECTRIC SHOCK
Electrical parts are energized with hazardous
voltage. When touching these parts you will get
an electric shock. Death or severe injuries are
the result.
 Any work for electrical installations must only be
carried out by qualified specialists!
 Connecting work must only be carried out in de-
energized condition!
 Compare the mains voltage and mains frequency with the data on the rating plate. The
allowed mains voltage fluctuation is +10%.
 Adjust the cross-sections of the connecting cables to the nominal current pursuant to
the regulations.
 Connect and arrange the connection terminals according to the connection plan on the
inside of the terminal box.
 Ensure that all connections including ground wire are tightly screwed.
 In order to avoid a tensile load of the terminals, mount the connection cables strain-
relieved.
 No foreign matters, dirt or humidity may enter the terminal box.
 In order to ensure the type of protection when closing the terminal box, use the original
seals.
 Only use screw connections and locking screws made of insulating material for the
bushing bores at the plastic terminal box.
 Close unused cable entries in a dust- and waterproof manner.
19
4.5. Commissioning
 Before commissioning, ensure that the drive is undamaged and non-choked. Ensure the
proper installation of the safety devices.
 In order to check the rotational direction, switch the properly connected motor in
uncoupled condition “On/Off” for a short time.
 In order to avoid inadmissible switching current and torque jerks, the switching from Y-
to delta start-up may only be effected is the starting current of the Y-step has decayed.
 Connect integrated temperature sensors (PTC thermistor or bimetal temperature

sensor) to the control device. If a continuity test of the temperature sensors is required,
this must be carried out with a measuring bridge (max. 5 V).
 During the test run under maximum load, the gear must be checked for:
4.1.1. Unusual noises such as milling, knocking or grinding noises
4.1.2. Unusual vibrations, oscillations and movements
4.1.3. Generation of steam and smoke
The drive must be shut down and ABM must be contacted if an abnormality was
determined during the aforementioned check tests.
 After the test run, the gear must be checked for leaks.
4.6. Commissioning after longer downtimes

 After longer downtimes (longer than 1 year), check the screw connections and bearings
before the commissioning.
 Ensure that cooling airways, especially the openings of the fan cowls, are free from
contaminations
 Before commissioning, replace the lubricant in the gear.
 Measure the insulation resistance. The maximum discharge current of the coil against
the casing at 1500 V test voltage for the motors in supplied condition is 10 mA. The
measurement must be carried out by a correspondingly qualified employee.
20
5. Operation
5.1. Safety instructions
DANGER
MOVING PARTS
Rotating parts can cause injuries
 Never reach into moving parts and keep foreign
materials away from these parts!
 Safety devices must be provided by the
manufacturer of the complete machine and
must not be removed or put out of operation!
 Observe the safety distance!
During operation, motor surfaces must not be touched. The surfaces at the drives can become
very hot. If required, provide a touch guard!
WARNING
HOT MACHINE PARTS

skin contact
Carry out regular checks during the operation, depending on the operating conditions.
In doing so, pay special attention to:
 Unusual or excessive noise or temperature generation,

 Loose fixing elements,
 The condition of the electric mains,
 Stronger vibrations,
 Changes in the rotational speed,
 Problems with the heat removal due to depositions on the drive system.
In case of faults, contact the maintenance personnel immediately.
21
5.2. Error diagnosis and fault removal
DANGER
ELECTRIC SHOCK
Electric parts
the result.
 Any repair work must only be carried out by
qualified specialists!
 Connecting work must only be carried out in de-
energized condition!
Fault Possible cause Remedy
Motor does not Fuse has blown Replace the fuse

start
Motor protection has tripped Check the motor protection for correct
adjustment, readjust if necessary
Motor protection does not Check the control of the motor

switch, error in the control protection, remove error
Power supply interrupted Check connections, adjust if necessary
Counter torque of the load is Check load and reduce if necessary

too big (check application)
Voltage or frequency Provide better mains conditions; check

deviate severely from the the cross-section of the supply line
target value, at least when
switching on
Coil defective Repair by manufacturer
Rotor streaks Repair by manufacturer
Drive blocked Check components for free movement;

remove foreign materials from the
motor, if necessary
Motor does not Torque in Y-connection not Unless the delta starting current is too
start in Y- sufficient high, switch on directly; otherwise you
connection but in need a larger motor or special
delta connection equipment after consultation
22
Contact error on the Y-delta Remove the error

connection
Blow when Motor coupling defective Replace elastomer gear rim,

switching on
Gear fixture loose Re-tighten the motor and gear fixture

screws
Rubber element defective Replace rubber element
Wrong rotational Motor connected incorrectly Interchange the two phases

direction
Gearbox drive shaft Breakage in the gear Contact ABM-Service

does not rotate
although the motor
is rotating
Motor coupling defective Contact ABM-Service
Shrink disc slips through Contact ABM-Service
Motor hums and Coil defective Repair by manufacturer

has a high power
consumption
Rotor streaks Repair by manufacturer
Running noises Foreign materials inside the Cleaning of the interior, possibly by the
motor manufacturer
Bearing damage Installation of new grooved ball

bearings, possible repair by
manufacturer
Gearing damage Contact ABM-Service
Oil deficiency Contact ABM-Service
Vibrations Remove cause, balance if necessary
Motor gets too hot Motor switched in delta Correct the switching
instead of Y, as intended
Overload of the drive Check load and reduce if necessary
Insufficient cooling air, Ensure free inlet and outlet of the

cooling airways blocked supply air
23
Motor gets too hot Cooling air is preheated Provide fresh air
Ambient temperature too Provide fresh air

high
Heat removal impaired due Clean the surface of the drives

to deposits
Power supply deviates from Provide the correct power supply

the rated motor voltage by
more than 5%. Higher
voltage is particularly
unfavourable for multi-pin
motors because for these
motors, the no-load current
is already close to the
nominal current at a normal
voltage.
Gear gets too Unfavourable installation

Contact ABM-Service
warm conditions
Gear damage Contact ABM-Service
Oil escapes from

Seal defective Contact ABM-Service
the gear or motor
Oil escapes from

Incorrect oil level Oil change
pressure ventilation
Dirty oil Oil change
Table 9 : Error diagnosis
24
6. Maintenance
6.1. Safety instructions
DANGER
ELECTRIC SHOCK
the result.
 Any maintenance work must only be carried out
by qualified specialists!
 Maintenance work must only be carried out if
the system is de-energised and secured against
restart!
WARNING
HOT MACHINE PARTS
skin contact
Please also observe the following when using ABM SINOCHRON® motors:
CAUTION
MAGNETIC FIELD
Due to the magnetic forces, injuries can be
caused by attracted tools
 Hold on to the tools tightly!
 Bring them closer to the motor slowly!
 Wear work gloves!
Please also ensure that no foreign materials reach the inside of the motor during repair work.
25
6.2. Maintenance
WARNING
FUMES
Chemical cleaning agents can be corrosive or
develop hazardous fumes. Breathing
difficulties, irritation or poisoning can be the
result.
 Use the personal protective equipment!
 Observe the warning notices of the cleaning
agent producer!
CAUTION
DUST
When cleaning with compressed air or steam
jet, dirt particles can be raised and inhaled, or
they can reach into the eyes
 Use the personal protective equipment!
 Ensure proper extraction!
Maintenance Maintenance work

intervals
Maintenance work for the machine operator:
Regularly Depending on the dirt, clean the motor regularly along the entire
cooling airway.
Maintenance work for specialist personnel:
Every 3000  Check oil level

operating hours, at
 Visual check for leakages
least every six
months  Check the coupling
 Re-lubricate
 Check the gear for abnormal running noises and / or vibrations
Every 3 years  Oil change (for mineral oil)
Every 5 years  Oil change (for synthetic oil)
Table 10 : Maintenance work
26
Operating hours
Oil bath - continuous temperature

Image 4 : Oil change interval for normal operating conditions
We recommend shortened change intervals in case of particularly difficult operating conditions

such as high humidity, aggressive environment, severe temperature fluctuations, etc.
Our gear motors are delivered ready-to-use. The first lubricant filling ex works lasts for approx.
10,000 operating hours for oil filling, for grease filling approx. 8,000 operating hours.
For quantity and type of the lubricant, please see Annex C. In doing so, observe the instructions
in your data sheet. When changing the lubricant, the gear must be cleaned thoroughly.
DANGER
HOT OIL
In case of contact with hot oil, there is a risk of
scalding
 Open the discharge carefully!
 Wear the personal protective equipment!
Ensure that no dirt reaches the inside of the gear when changing the lubricant. Remove
bypassing oil immediately using an oil binding agent.
27
6.3. Spare parts

We expressly point out that spare and equipment parts, which were not delivered by ABM, were
also not tested and approved by ABM.
The installation and / or use of such products could therefore have a negative impact on the
constructive properties of your drive. The liability of the manufacturer is excluded for damages
arising from the use of non-original spare parts and non-original equipment.
Request a separate spare parts drawing and list for your drive.
28
7. Decommissioning and disposal

7.1. Decommissioning
 First, remove the electrical connections
DANGER
ELECTRIC SHOCK
the result.
 Any electrical work for the decommissioning
must only be carried out by qualified specialists!
 Electrical work must only be carried out if the
system is de-energised and secured against
restart!
 For gear with oil filling: remove the lubricant
 Remove the drive from the machine
 Transport the drive to the work station prepared for the disassembly. Observe the
Instruction in the chapter “Transport”
 Protect the drive and the components against falling when disassembling
DANGER
FALLING OBJECTS
Falling objects can cause severe injuries.
 Ensure secure fastening!
29
7.2. Recycling and disposal

Divide the components into the following category for recycling:
 Electronic scrap
 Iron scrap
 Aluminium
 Non-ferrous metal such as motor coil
 Insulation material, cables
 Permanent magnets (for ABM SINOCHRON® motor)
Divide the auxiliary materials into the following category for recycling:
 Oil
 Grease
 Anticorrosive agents
The permanent magnets must be demagnetised before the disposal. This prevents hazards
which are caused by the permanent magnets during and after the disposal. Permanent magnets
are demagnetized by heating up.
Dispose of the components in compliance with the national and local regulations.
30
8. List of images
Image 1 : Construction of the motor............................................................................................... 8
Image 2 : Minimum distance from the fan cowl ...........................................................................16
Image 3 : Measurement of angular offset ....................................................................................18
Image 4 : Oil change interval for normal operating conditions ....................................................27
Image 5 : Terminal box position, foot design ...............................................................................33
Image 6 : Terminal box position, flange design ...........................................................................33
Image 7 : Constructions electric motors with horizontal shaft arrangement ................................34
Image 8 : Constructions electric motors with vertical shaft arrangement ....................................35
Image 9 : Constructions spur gear motors with horizontal shaft arrangement ............................36
Image 10 : Constructions spur gear motors with vertical shaft arrangement ..............................36
Image 11 : Constructions of flat gear motors ...............................................................................37
Image 12 : Radial force and distance X .......................................................................................41
9. List of tables
Table 1 : Signal words and their meaning ..................................................................................... 4
Table 2 : Used terms ...................................................................................................................... 6
Table 3 : Field description at the name plate ................................................................................. 9
Table 4 : type designation ABM drives ........................................................................................10
Table 5 : Standards ......................................................................................................................11
Table 6 : Guidelines .....................................................................................................................11
Table 7 : Operating conditions according to EN 60034-1 or EN 60204-1 ...................................13
Table 8 : Balancing type ..............................................................................................................17
Table 9 : Error diagnosis ..............................................................................................................24
Table 10 : Maintenance work .......................................................................................................26
Table 11 : Allowed radial forces for electric motors .....................................................................38
Table 12 : Permissible forces for spur gear motors (standard bearing) ......................................39
Table 13 : Permissible forces for spur gear motors (reinforced bearing, up to G225) ................40
Table 14 : Factors for the calculation of the radial force for the flat gear ....................................41
Table 15 : Lubricant amounts for spur gears (1) ..........................................................................42
Table 16 : Lubricant amounts for spur gears (2) ..........................................................................42
Table 17 : Lubricant amounts for flat gears .................................................................................43
Table 18 : Lubricant table ............................................................................................................44
Table 19 : Screw tightening torques in Nm ..................................................................................45
Table 20 : Tightening torques for traction screws of motors in Nm .............................................45
Table 21 : Tightening torques for motors with frame size 160 and 180.......................................45
Table 22 : Safety parameters for rotary encoders .......................................................................46
31
10. Index
A M
Alignment ................................................................... 18 Magnetic field........................................................ 15, 25
Assembly .................................................................... 16 Maintenance ............................................................... 25
Modification................................................................... 6
B
N
Balancing .................................................................... 17
Name plate ................................................................... 9
C
O
Commissioning ........................................................... 20
Conformity ............................................................ 11, 13 Oil change................................................................... 27
Construction ................................................................. 8 Operation .................................................................... 21
D P
Declaration of conformity ............................................ 13 Packaging ................................................................... 14
Decommissioning ....................................................... 29
Disposal ...................................................................... 30
R
E Recycling .................................................................... 30
Error ........................................................................... 22
S
F Safety ........................................................................... 4
Shipment..................................................................... 14
Fastening ............................................ 14, 16, 17, 21, 29 Signal words ................................................................. 4
Fault removal .............................................................. 22 Sinochron.................................................................... 25
Spare parts ................................................................. 28
G Standards ................................................................... 11
Storage ....................................................................... 15
Guidelines................................................................... 11 Surface ....................................................... 5, 21, 25, 26
I T
Installation ............................................................ 15, 19 Terms............................................................................ 6

Insulation resistance ................................................... 20 Transport .................................................................... 14
Intended use ............................................................... 13
V
L
Vibrations .................................................................... 15
Lubricant change ........................................................ 27
W
Warranty ................................................................. 6, 28
32
Annex
A Constructions
A1 Electric motors
The constructions of the ABM electric motors comply with the standardization regulations DIN
EN 60034-7.
Terminal box position:

The illustrations (image A-1 and A-2) show the terminal box position A, B, C and D.
If no specification is made upon order placement, the motor is delivered in terminal box position
A. Terminal box positions B, C and D are delivered upon customer request.
The cable inlet can only be rotated by 90° for terminal boxes made of plastic. It is only partly
possible for aluminium boxes (request).
Foot design:
Example for terminal box position and cable inlet
Image 5 : Terminal box position, foot design
Flange design:
Example for terminal box position and cable inlet
Image 6 : Terminal box position, flange design
33
Constructions with horizontal shaft arrangement
Image 7 : Constructions electric motors with horizontal shaft arrangement
34
Constructions with vertical shaft arrangement
Image 8 : Constructions electric motors with vertical shaft arrangement
35
A2 Spur gear motors

For the constructions of the ABM electric motors, see A1, image 7
Marking: = Oil fill plug
= Oil level check plug
= Oil drain plug
Constructions with horizontal shaft arrangement
Image 9 : Constructions spur gear motors with horizontal shaft arrangement
Constructions with vertical shaft arrangement
Image 10 : Constructions spur gear motors with vertical shaft arrangement
36
A3 Flat gear motors

For the constructions of the ABM electric motors, see A1, image 7
The illustration shows the standard design. The shown constructions are also valid for flange
and journal shaft design.
Image 11 : Constructions of flat gear motors
The oil drain plug is always located at the bottom and corresponds to the installation position of
the gears.
37
B Allowed radial forces

B1 Electric motors
The data refer to the centre of the standard shaft end at the drive side, for operation with 50 Hz
Design size Fr [N]

2-pin 4-pin 6-pin 8-pin
56 230 270 310 -
63 230 300 350 380
71 260 320 370 400
80 350 450 520 560
90 550 750 860 920
100 770 950 1090 1170
112 900 1110 1270 1360
132 1140 1400 - -
160 - 2500 2800 3100
Table 11 : Allowed radial forces for electric motors
38
B2 Spur gear motors

Radial forces refer to the centre of the short shaft end. Valid for 90°. Axial forces traction or
pressure at level towards the output shaft. If radial and axial forces occur simultaneously, please
check back.
For normal bearing:

Motor output in kW
Gear
0.12 0.18 0.25 0.37 0.55 0.75 1.1 1.5
Fr 700 700 700 700 600 500 - -
G71
Fa 500 500 500 500 400 300 - -
Fr 1600 1400 1400 1400 1100 1100 1100 1000
G80
Fa 1000 1000 1000 1000 1000 1000 1000 1000
Fr 3000 3000 3000 2500 2000 2000 1500 1500
G90
Fa 2500 2500 2500 2000 2000 2000 1500 1500
Fr 3000 3000 3000 2800 2000 2000 2000 1500
G100
Fa 2500 2500 2500 2000 2000 2000 1500 1500
Fr 4500 4500 4500 4500 4000 4000 3000 2500
G112
Fa 3500 3500 3500 3500 2500 2500 2000 2000
Fr 8000 8000 8000 8000 7000 7000 6000 5000
G132
Fa 5000 5000 5000 5000 4000 4000 3000 3000
Fr 10000 10000 10000 10000 10000 10000 7500 7000
G160
Fa 7000 7000 7000 7000 7000 7000 5500 4500
Fr 17500 17500 17500 17500 17500 17500 15000 13000
G180
Fa 10000 10000 10000 10000 10000 10000 9000 8000
Gear Motor output in kW
2.2 3.0 4.0 5.5 7.5 11.0 15.0 18.5 22.0
Fr 1000 1000 - - - - - - -
G90
Fa 1000 1000 - - - - - - -
Fr 1500 1000 1000 - - - - - -
G100
Fa 1500 1000 1000 - - - - - -
Fr 2000 2000 1500 1500 - - - - -
G112
Fa 2000 1500 1500 1500 - - - - -
Fr 5000 4000 3500 3000 3000 - - - -
G132
Fa 2500 2000 2000 1500 1500 - - - -
Fr 6000 5000 4000 4000 3000 2000 1500 - -
G160
Fa 3500 3000 2500 2000 1500 1000 1000 - -
Fr 12000 10000 9000 8000 7000 5500 4500 4000 3000
G180
Fa 8000 8000 8000 7000 6000 3000 2500 2000 1500
Table 12 : Permissible forces for spur gear motors (standard bearing)
39
For reinforced bearing (possible from G90):

Motor output in kW
Gear
0.12 0.18 0.25 0.37 0.55 0.75 1.1 1.5
Fr 3000 3000 3000 3000 3000 2500 2500 2500
G90
Fa 3000 3000 3000 3000 3000 2500 2500 2500
Fr 3200 3200 3200 3200 3200 3000 3000 3000
G100
Fa 3000 3000 3000 3000 3000 3000 2500 2500
Fr 6000 6000 6000 6000 5000 5000 4000 4000
G112
Fa 5000 5000 5000 5000 4000 4000 3000 3000
Fr 9000 9000 9000 9000 9000 8000 7000 6000
G132
Fa 7000 7000 7000 7000 7000 7000 6000 5000
Fr 12500 12500 12500 12500 12500 12500 12500 11000
G160
Fa 10000 10000 10000 10000 10000 10000 10000 9000
Fr 24000 24000 24000 24000 24000 24000 22000 20000
G180
Fa 15000 15000 15000 15000 15000 15000 14000 12000
Fr 27000 27000 27000 27000 27000 27000 25000 23000
G200
Fa 18000 18000 18000 18000 18000 18000 16000 14000
Fr 30000 30000 30000 30000 30000 30000 30000 30000
G225
Fa 20000 20000 20000 20000 20000 20000 20000 20000
Gear Motor output in kW
2.2 3.0 4.0 5.5 7.5 11.0 15.0 18.5 22.0
Fr 2500 2000 - - - - - - -
G90
Fa 2500 2000 - - - - - - -
Fr 3000 2500 2000 - - - - - -
G100
Fa 2500 2000 2000 - - - - - -
Fr 3000 3000 3000 3000 - - - - -
G112
Fa 3000 2000 2000 2000 - - - - -
Fr 6000 5000 4000 3500 3000 - - - -
G132
Fa 5000 4000 3000 2500 2500 - - - -
Fr 10000 9000 7000 6000 5000 4000 3000 - -
G160
Fa 8000 7000 5000 5000 4000 3500 3000 - -
Fr 18000 15000 12000 12000 10000 9500 8000 7000 6000
G180
Fa 10000 10000 9000 8000 7000 6000 5000 5000 4000
Fr 21000 17000 14000 13000 12000 11000 10000 9000 8000
G200
Fa 13000 13000 12000 11000 10000 9000 8000 6000 5000
Fr 30000 27000 25000 22000 20000 19000 18000 17000 15000
G225
Fa 20000 17000 15000 12000 10000 9000 8000 7000 5000
Table 13 : Permissible forces for spur gear motors (reinforced bearing, up to G225)
40
B3 Flat gear motors

The permissible radial force is stated based on the nominal service life for normal running
conditions of the hollow shaft bearing according to DIN ISO 281. Fr is dependent on the output
-1
torque T2 [Nm], on the output speed n2 [min ], and on the distance x [mm]. The calculation
applies to the least favourable force application angle and is dependent on the rotational
directions. Fr is applied on the non-motor side.
Image 12 : Radial force and distance X
-1
The calculation of Fr is only valid for n2 > 9 min .
Gear type K1 K2 K3
5
FGA53 6.9 * 10 600 61.5
5
FGA103 9.8 * 10 644,5 68
6
FGA252 / FGA253 2.4 * 10 1259 111.5
6
FGA422 / FGA424.3 2.3 * 10 908 94
6
FGA423 / FGA424.4 2.3 * 10 540 94
6
FGA453 2,3 * 10 908 94
6
FGA952 / FGA954.3 5.9 * 10 900 131.5
6
FGA1353 / FGA1354.3 5.9 * 10 490 131.5
Table 14 : Factors for the calculation of the radial force for the flat gear
41
C Lubrication
C1 Lubricant amounts
Spur gear with horizontal shaft arrangement

Type Construction
Foot B3, B6, B7 Foot B8 Flange B5
Oil filling in cm³ Grease filling in cm³ Oil filling in cm³
Two- Three-stage Two- Three-stage Two- Three-stage Two- Three-stage
stage stage stage stage
Main Pre- Main Pre- Main Pre-
stage stage stage stage stage stage
G 71 100 80 100
G 80 130 100 140
G 90 3 - G90 / 71 200 200 60 160 160 50 180 180 60
G 100 3 - G100 / 71 280 280 100 220 220 80 250 250 100
G 112 3 - G112 / 80 400 400 100 320 320 80 400 400 100
G 132 3 - G132 / 90 600 600 160 480 480 120 550 550 160
G 160 3 - G160 / 100 1000 1000 250 800 800 200 800 800 250
G 180 3 - G180 / 100 1400 1400 250 1100 1100 200 1200 1200 250
G 200 3 - G200 / 132 2100 2100 450 1600 1600 350 1800 1800 450
G 225 3 - G225 / 132 3000 3000 450 2400 2400 350 2500 2500 450
Table 15 : Lubricant amounts for spur gears (1)
Spur gears with vertical shaft arrangement

Construction
Type Foot V5, V6 Flange V1, V3
Grease filling in cm³ Grease filling in cm³
Three-stage Three-stage
Two- Two- Two-
Three-stage Main Pre- Main Pre-
stage stage stage
stage stage stage stage
G 71 100 100
G 80 230 230
G 90 3 - G90 / 71 340 340 100 340 340 100
G 100 3 - G100 / 71 420 420 150 420 420 150
G 112 3 - G112 / 80 800 800 150 800 800 150
G 132 3 - G132 / 90 1000 1000 200 1100 1100 200
G 160 3 - G160 / 100 1600 1600 270 1700 1700 270
G 180 3 - G180 / 100 2100 2100 270 2500 2500 270
G 200 3 - G200 / 132 3200 3200 650 3500 3500 650
G 225 3 - G225 / 132 4800 4800 650 5000 5000 650
Table 16 : Lubricant amounts for spur gears (2)
42
Flat gears
Type Construction
A1 A2 A3 A4 AV1 AV3
Grea Grea Grea Grea Grea Grea
Oil Oil Oil Oil Oil Oil
se se se se se se
FG 103 400 450 400 450 400 450 400 450 400 450 400 450
FG422 900 1100 1000 1200 900 1100 800 1000 900 1100 1100 1300
FG423 900 1100 1000 1200 900 1100 800 1000 900 1100 1100 1300
FG424 900 1100 1000 1200 900 1100 800 1000 900 1100 1100 1300
FG453 900 1100 1000 1200 900 1100 800 1000 900 1100 1100 1300
FG424 / FG424
100 120 100 120 100 120 100 120 100 120 100 120
Primary gear stage
FG952 / FG954 1300 1500 2800 3200 1900 2200 1800 2100 1800 2100 3000 3500
FG1353 / FG1354 1300 1500 2800 3200 1900 2200 1800 2100 2200 2500 2500 2900
FG954 / FG1354
170 200 170 200 170 200 170 200 170 200 170 200
Primary gear stage
Table 17 : Lubricant amounts for flat gears

 Preferred lubricant for FG 103: ISO VG 680 CLP
43
C2 Lubricants
Gear oils
Type Temp.* ISO VG
Degol Energol Alpha Renolin Mobilgear Omala

0…40°C 220
BG 220 GR-XP 220 EP 220 CLP 220 600 XP 220 S2 G 220

CLP
-10…25°C 100
BG 100 GR-XP 100 EP 100 CLP 100 600 XP 100 S2 G 100

0 … 40°C 680
BG 680 GR-XP 680 EP 680 SEW 680 600 XP 680 S2 G 680
Degol Enersyn Alphasyn Renolin Glygoyle Omala S4

-35…80°C 220
GS 220 SG-XP 220 GS 220 PG 220 HE 220 WE 220
PG
Degol Enersyn Alphasyn Renolin Glygoyle Omala S4

-30…80°C 460
GS 460 SG-XP 460 GS 460 PG 460 HE 460 WE 460
Optigear Renolin
Degol Mobil Omala
HC
-30…60°C 220 - Synthetic Unisyn

PAS 220 SHC 630 220 HD
X220 CLP 220
Observe the instructions on the data sheet of your drive!
Getriebefette
Type Temp.* NLGI
Renolit Mobiltemp Aero Shell

min.
-25…60°C 00 FDP 00 - Olit CLS 00

S2 SHC 32 Grease 16
PAO
-30...130°C 00 - EP 00 - - - -
Observe the instructions on the data sheet of your drive!
Table 18 : Lubricant table
*Temp = recommended temperature range – can be surpassed or under passed depending on

the application
Notes:
 CLP : Mineral oil, lubricating oil
 PG : Synthetic oil (polyglycol)
 HC : Synthetic oil l (Lubricant on the basis of poly-alpha-olefin - PAO)
44
D Screw tightening torques

Thread Strength class of screw Terminal board / Terminal board /
connection steel nuts brass nuts
8.8 10.9 12.9
M4 3.2 5 6 1,5 1,5
M5 6.4 9 11 2,4 3
M6 11 16 19 3,75 5
M8 27 39 46 7,5 10
M10 53 78 91
M12 92 135 155
M16 230 335 390
M20 460 660 770
M24 790 1150 1300

Tolerance of all tightening torques = 15%
Delivery status for teminal boards: upper nut tightened with reduced moment
Table 19 : Screw tightening torques in Nm
Tightening torques for traction screws of motors

Thread M4 M5 M6 M8 M10
Tightening torque 1,8 3,8 6,5 16 32
Tolerance of all tightening torques = 15%
Table 20 : Tightening torques for traction screws of motors in Nm
Tightening torques for motors with frame size 160 and 180 (flange
mounting)
Motor frame size 160 180
Tightening torque 25 35
These screws have to be additionally secured with Loctite 243
Table 21 : Tightening torques for motors with frame size 160 and 180
45
E Safety parameters for rotary encoder

Definition of the safety parameter MTTFd:
MTTFd (Mean Time To Dangerous Failure) is a statistical variable and is defined in the standard
EN ISO 13849-1 as “Expected value of the mean time until the dangerous failure”.
This emphasizes that it is a statistical variable, which is an empirically generated value. This
value is not related to a “guaranteed service life” or a “failure-free time”.
Type Company Designation MTTFd [hours]

Sensor
SKF BMB/BMO 166,000,000
bearing
Rotary
Baumer IVO GM400 / 401 722,126
encoder
Hengstler AC 58 1,400,000
Leine Linde RSA 698 1,875,000
ABM HMX 2 1,042,000
ABM HDI 2 - NE - M142 1.226.400
Table 22 : Safety parameters for rotary encoders
46

Operating Manual: For Electric Motor / Gear Motor

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Electric motor / gear motor

Status : April, 2016

Electric Motor Spur Gear Motor Flat Gear Motor

4. Preparation of the drives for operation ...........................................................................................14

7. Decommissioning and disposal .......................................................................................................29

8. List of images .....................................................................................................................................31

9. List of tables .......................................................................................................................................31

B Allowed radial forces .........................................................................................................................38

D Screw tightening torques..................................................................................................................45

E Safety parameters for rotary encoder .............................................................................................46

1. General safety information

1.2. Explanation of symbols

Signal word field with signal word Meaning

Indicates a hazard with a medium degree of risk,

Indicates a hazard with a low degree of risk which

Table 1 : Signal words and their meaning

The safety instructions in this operating manual are structured as follows:

Signal word with illustration

1.4. Mechanical hazard

1.5. Thermal hazard

HOT MACHINE PARTS

Electric mains must not be in contact with hot surfaces.

1.6. Magnetic hazard

2.2. Used terms

Term Hereinafter used for

2.3. Modification of the product

2.4. Liability and warranty claims

Phone: +49 9231 67-0

Phone: +1 513 5761300 Phone: +43 1 69911620

France P.R. China

Phone: +33 3 89334401 Phone: +86 512 - 8717 1081

Image 1 : Construction of the motor

[1] Bearing plate A-side [11] Fan

[2] Shaft seal ring [12] Traction screw

[3] Ball bearing shim [13] Locking ring

[4] Grooved ball bearing [14] Fan cowl

[5] Fitting key [15] Hexagon screw

[6] Rotor [16] Terminal board

[7] Stator [17] Seal

[8] Ball bearing [18] Slider

[9] Adjusting washer [19] Terminal box

[10] Bearing plate B-side [20] Cylinder screw

3.2. Name plate

Abbreviation Unit Designation

V Brake connection voltage

Table 3 : Field description at the name plate

3.3. Type designation

ZFB100 / G200F / 4D132Mc-4

Type designation brake

3.4. Standards and guidelines

Number Abbreviated designation

Asynchronous motor at sinusoidal mains are considered as electromagnetically passive

3.6. Intended use

Ambient conditions Requirement

The use in explosive areas is forbidden.

3.7. Optional modules

4. Preparation of the drives for operation

Is the packaging damaged?

Packaging for the return of the goods

4.2. Transport and storage

The following points must be observed for the storage:

 Storage in installation position, protect the drive against falling

4.3. Mechanical installation