Sumitomo Drive Technologies IB Series User manual

No.ZM2003E-7Maintenance Manual
■Thisproductshouldbehandledbyonlythosewhohavebeentrainedforthework.
Carefullyreadthemaintenancemanualbeforeuse.
■Deliverthismanualtothecustomerwhowillactuallyusetheproduct.
■Thismaintenancemanualshouldbekeptbytheuserforfuturereference.
Planetary Gear Reducer
for Servo Motors
IB Series
P1 Type
PK1 Type
P2 Type
P Type
L Type
《CAUTION》

1
Introduction: Safety Precautions
- Carefully read this maintenance manual and all accompanying documents before use (installation,
operation, maintenance, inspection, etc.). Thoroughly understand the machine, information about
safety, and all precautions for correct operation.
Maintain this manual for future reference.
- Pay particular attention to the "DANGER" and "CAUTION" warnings regarding safety and proper use.
Improper handling may result in physical damage, serious personal injury
and/or death.
Improper handling may result in physical damage and/or personal injury.
Matters described in may lead to serious danger depending on the situation.
Be sure to observe important matters described herein.
DANGER
- Transport, installation, plumbing, wiring, operation, maintenance and inspections should be
handled by properly trained technicians; otherwise, electric shock, injury, re, or damage to
the equipment may result.
- In the case of maintenance with disassembly, please contact the nearest authorized
maintenance shop.
- When the unit is to be used in a system for human transport, a protecting device for human
safety should be installed to prevent accidents resulting in personal injury, death, or damage
to the equipment due to running out of control or falling.
- When the unit is to be used in an elevator or lifter, install a protective device on the elevator
side to prevent it from falling; otherwise, personal injury, death, or damage to the equipment
may result.
CAUTION
Please install loss prevention device such as oil pan to the machine which is
vulnerable to oil especially (machine for food processing and machine for clean
room, and so on) in case oil or grease leaks; otherwise, the product may fail
because of oil leakage.

2
Contents
Contents
Instruction: Safety Precautions …………………………………………………………………… 1
Contents …………………………………………………………………………………………… 2
1. Receiving Inspection …………………………………………………………………………… 3
2. Storage …………………………………………………………………………………………… 5
3. Transport ………………………………………………………………………………………… 6
4. Installation ………………………………………………………………………………………… 7
5. Mounting the Servo Motor ……………………………………………………………………… 8
6. Coupling with Other Machines ………………………………………………………………… 11
7. Operation ………………………………………………………………………………………… 13
8. Daily Inspection and Maintenance ……………………………………………………………… 14
9. Troubleshooting ………………………………………………………………………………… 16
10. Structural Drawing ……………………………………………………………………………… 17
11. Warranty ………………………………………………………………………………………… 22

3
1. Receiving Inspection
CAUTION
- Unpack the unit after verifying that it is positioned correct side up; otherwise, injury may
result.
- Verify that the unit received is the one you ordered. Installing the wrong unit may result in
personal injury or equipment damage.
- Do not remove the nameplate.
Verify the items listed below upon receiving the product. If a nonconformity or problem is found,
contact our nearest agent, distributor, or sales oce.
[1] Does the information on the nameplate conform to what you ordered?
[2] Was any part broken during transport?
[3] Are all bolts and nuts tightened rmly?
1-1 Reading the Nameplates
There are two main types of nameplates: type 1 and type 2. Representative examples are shown below.
Please observe them by type.
When contacting us, please provide [1] Nomenclature and [2] Serial No.
■Nameplate Type 1: P1, PK1, P2, P Type
1-2 Checking Lubrication Method
IB Series is a grease-lubricated unit. Grease is injected into the unit components before shipment so that no
further lubrication is necessary during use.
[1] Nomenclature
[1]
[2]
[2] Serial No.
AP1158G
[1]
[2]
[1] Nomenclature
[2] Serial No.
[1] Nomenclature
[1]
[2]
[2] Serial No.
min
-1
kW
■Nameplate Type 2: L Type
Figure 1-1 Nameplate (type 1)
Figure 1-2 Nameplate (type 2)

4
1. Receiving Inspection
1-3 Nomenclature
Symbol meanings are shown below. Please conrm that the nomenclature matches your order.
A N F X F P120 2R LD 15
Type of Input
X With Motor Flange P1, PK1, P2, P Type
XM With Motor Flange + Motor
J With Motor Flange L Type
JM With Motor Flange + Motor
Backlash
L3 3 min
Specication P1, P2, P Type
LB 6 min
Specication PK1 Type
LC 10 min
Specication P type
LD 15 min
Specication P1, PK1 Type
SVLB 0.5 min
Specication L Type
SV 3 min
Specication
Output Shaft Geometry
N Solid Shaft (Keyless)
W Solid Shaft (With Key)
F Flange Shaft
Note: L type does not have
this symbol.
Motor Flange Code
Various
Note: L type does not have this
symbol.
Special Specication
Blank Standard
Specications
SSpecial
Specication
Reduction Ratio
Actual Reduction Ratio P1, P2, P, L Type
Nominal Ratio PK1 Type
Model Symbol
A IB Series
Output Shaft Direction
N Universal Mounting
Mounting Method
F Flange Mounting
Type/Frame Size
P1 Type PK1 Type P2 Type P Type L Type
P110 PK110 P240 P10 L10
P120 PK120 P250 P15 L20
P130 PK130 P20 L30
P25 L40
P30
P35

5
2. Storage
If this product is not for immediate use, note the following points when storing it.
2-1 Storage Location
Store the unit indoors in a clean and dry location.
Do not store the product outdoors. Store it in a location that is free of moisture, dust, extreme
temperature changes, corrosive gases, etc.
2-2 Storage Time
- Storage period should be less than 1 year.
- Standard rust prevention specications
External rust prevention Rust prevention oil is applied when shipping from the factory. Check the
rust conditions to see if any rust is forming on the machined surface every
six months after shipment. Reapply the rust prevention oil or any other rust
prevention process if necessary.
Internal rust preventionStore the product in a general factory or warehouse in an environment free
of moisture, dust, extreme temperature changes, corrosive gases, etc.
- If the product is for export, or if the storage time is longer than 1 year, adherence to special rust
prevention specications is required. Please consult with us.
- If the storage time is longer than 1 year, run the product for a few minutes under no load once every 2 to
3 months.
2-3 Using after Storage
- Oil seals are affected by temperature, ultraviolet light and other ambient conditions and can easily
degrade. After long storage periods, inspect it before operation, and replace any degraded seals with
new seals.
- When the storage period is 2 years or longer, the oil seals and grease should be replaced before starting
operation.
- At the start of operation, make sure there is no abnormal noise, vibration, heat, etc. If any abnormality is
found, immediately contact the nearest authorized maintenance shop.

6
3. Transport
DANGER
- Do not step under a unit suspended by a crane or other lifting mechanism for transport;
otherwise, injury or death may result.
CAUTION
- When hanging bolts or holes are provided, be sure to use them. After mounting the unit to
a machine, do not hoist the entire machine by using the hanging bolts or holes; otherwise,
personal injury or damage to the equipment and/or lifting device may result due to falling of
the machine or failure of hanging metal tting.
- In the case the product is lifted by using the tapped hole on it, refer to the nameplate,
crate, outline drawing, catalog, etc. for the weight of the unit before hoisting. Never hoist
a unit that exceeds the load capacity of the crane or other mechanism being used to lift it;
otherwise, personal injury or damage to the equipment and/or lifting device may result.
- When the product is lifted, use suitable lifting parts, and conrm that eye bolts and nuts are
not loose.

7
4. Installation
CAUTION
- Do not use the unit for a purpose other than that indicated on the nameplate or in the
manufacturing specications; otherwise, injury or damage to the equipment may result.
- Do not place any object that will hinder ventilation around the reducer. Insufficient
ventilation can cause excessive heat that may result in burns or re.
- Do not step on or hang from the gearmotor or reducer; otherwise injury may result.
- Do not touch the shaft end of the product and inside key ways with bare hands; otherwise,
injury may result.
- Install a loss prevention device such as oil pan to machines particularly vulnerable to oil
especially (machine for food processing, machine for clean room, and so on) in case oil or
grease leaks; otherwise, oil or grease leakage may cause failure of the unit.
4-1 Installation Location
Ambient temperature 0 to 40°C (Start failure may occur depending on the speed and torque of the
motor in use, so consult us if the reducer will be used at about 0°C.)
Ambient humidity P1, PK1, P2, P type: 85%RH or less with no condensation.
L type: 90%RH or less with no condensation.
Altitude 1,000m max.
Ambient atmosphere No corrosive or volatile gases, no steam .
Dust-free, well-ventilated area.
Installation Indoor (area with minimal dust, no contact with water)
-Mounting in conditions other than the above requires adherence to special specifications. Please
consult with us.
- Mount in a location that enables smooth operation, such as inspection and maintenance.
- Mount on a suciently rigid base.
4-2 Installation Angle
There is no limit on a mounting angle.

8
5. Mounting the Servo Motor
5-1 P1, PK1, P2, P Type
The product has a special shaft coupling between the reducer and the motor so that shaft with keyway
or D shaft other than straight shaft can be accommodated.
Attaching the motor in the following steps from (1) to (8): (In the case of a shaft with keyway, remove
the key before assembly).
(1) Wipe rustproong or other oils from the motor shaft surface and the ange surface of the reducer. (see
gure5-1).
(2) Place the reducer on an appropriate working table with the coupling [3] facing straight up.
(3) Remove the plug [1] from the setting hole.
(4) Manually align the components so that the coupling tightening bolt [2] can be tightened from the
setting hole [1].
(5) Insert the motor shaft into the center hole of the coupling [3]. Press the shaft straight into the
coupling, and engage the joint between the motor and the adapter plate [4].
In the case of the motor with the ange plate, set the ange plate [5] between motor and adapter
plate [4].
After tting the spigot of the ange plate [5] and adapter plate [4], insert motor shaft into the center
hole of the coupling [3], press in vertically and t the spigot of the motor and the ange plate [5].
(6) Lock the motor and the adapter plate [4] together by tightening the motor mounting bolt.
(7) Tighten the coupling tightening bolt [2] from the setting hole using a torque wrench. Tighten to the
appropriate torque value shown on Table 5-1 and 5-2.
(8) Reinstall the plug [1] from the setting hole.
Figure 5-1 Part to Clean

9
5. Mounting the Servo Motor
Table 5-1 Bolt Tightening Torque (P1, PK1, P Type) Table 5-2 Bolt Tightening Torque (P2 Type)
Tightening Bolt Tightening
Torque
Coupling Hole
Diameter Tightening Bolt Tightening Torque
Coupling Hole
Diameter
M3 1.67Nm Ø 6-8 M8 35Nm Ø 24-35
M4 3.92Nm Ø 9-14 M10 65Nm Ø 24-42
M5 7.35Nm Ø 16-19 M12 102Nm Ø 35-55
M6 8.83Nm Ø 22-28 M16 253Nm Ø 60
M8 21.6Nm Ø 32-38
Figure 5-2 Assembly Drawing
Adapte plate [4]
Plug/setting hole [1] Coupling [3]
Coupling
tightening
bolt [2]
Motor
mounting
bolt
ange plate [5]
Motor
Motor
mounting
bolt
Plug/setting
hole [1]
Plug/setting
hole [1]
Motor
Torque
wrench
Torque
wrench
Without the ange plate
for a motor
With the ange plate
for a motor

10
5. Mounting the Servo Motor
5-2 L Type
The product has a shaft coupling between the reducer and the motor.
Assemble the motor in the following steps from (1) to (9).
(1) Wipe rustproong or other oils from the motor shaft surface.
(2) Place the reducer on an appropriate working table with the oldham’s coupling facing straight up.
(3) Align the oldham’ coupling boss 1 [5], spacer [4], and oldham’ coupling boss 2 [2] straight and push
in so that the claws of the boss engage suciently.
(4) Remove the plug [3] from the setting hole.
(5) Manually align the components so that the coupling tightening bolt [1] can be tightened from the
setting hole [3].
(6) Insert the motor shaft into the center hole of the oldham’coupling boss 2 [2] . Press the shaft straight
into the coupling, and engage the joint between the motor and the adapter plate [6].
(7) Lock the motor and the adapter plate [6] together by tightening the motor mounting bolt.
(8) Tighten the coupling tightening bolt [1] from the setting hole using a torque wrench. Tighten to the
appropriate torque value shown on Table 5-3.
(9) Reinstall the plug [3] from the setting hole.
Table 5-3 Bolt Tightening Torque (L Type)
Tightening Bolt Tightening Torque Coupling Hole Diameter
M3 1.67Nm CCZ18
M4 3.92Nm CCZ25
M5 7.35Nm CCZ35
M8 19.6Nm CCZ50
M10 33.3Nm CCZ70
M6 8.83Nm FF10
M8 21.6Nm FF15
Figure 5-3 Assembly drawing
Motor
Adapteplate[6]
Motormountingbolt
Coupling
tighteningbolt[1]
Oldham'
couplingboss2[2]
Oldham'
couplingboss1[5]
Plug/setting
hole[3]
Spacer[4]

11
6. Coupling with Other Machines
CAUTION
- Conrm the direction of rotation before coupling with the driven machine. Incorrect rotation
direction may cause personal injury or damage to the equipment.
- When operating the product alone (uncoupled), remove the key that is temporarily attached
to the output shaft; otherwise the key could y o, and injury may result.
- Install a cover or other appropriate protection items over the rotating parts to prevent
human contact; otherwise, injury may result.
- When coupling the product with another machine, check that the centering, the belt
tension and parallelism of the pulleys are within the specified limits. When the unit is
directly coupled with another machine, check that the direct coupling accuracy is within the
specied limits. When a belt is used for coupling the unit with another machine, check the
belt tension. Correctly tighten bolts on the pulley and coupling before operation; otherwise
there is a risk of injury due to scattering the broken pieces or of damage to the products.
6-1 Checking the Rotational Direction
(1) P1, P2, P, L Type
Verify that the rotation direction is the same as that of the input shaft.
(2) PK1 Type
Verify that the rotation direction is the opposite to that of the input shaft.

12
6. Coupling with Other Machines
6-2 Mounting a Connector
- When installing a connector, do not apply impact or excessive axial load to the shaft. The bearing could
be damaged, or the collar could come o.
- Shrinkage t is recommend.
(1)When Using a Coupling
The alignment accuracy (A, B, X) in Figure 6-1 should be no greater than that shown in Table 6-1.
(2) When Using a Chain, Sprocket, or Gear
- When using a chain, attach it so that the chain tension angle is perpendicular to the shaft.
- Refer to the chain catalog or other reference for chain tension.
- The pitch circle diameter of the sprocket and gear shall be three times or more of the shaft diameter.
-The load point of the sprocket or gear should be nearer to the product than to center of the shaft.
(see gure 6-2)
(3) When Using a Timing Belt
-Over-tightening the timing belt will damage the shaft and bearing. Refer to the timing belt catalog or
other reference for timing belt tension.
-Refer to the manufacturer’s catalog for the allowable values of parallelism and eccentricity (β) between
pulleys. (see gure 6-3)
-Have the timing belt load point positioned as close as possible to this unit.
Table 6-1 Flexible Coupling Alignment Errors
Allowable
Dimensional Error
for A
0.1 mm or manufacturer-
specied value
Allowable
Dimensional Error
for B
0.1 mm or manufacturer-
specied value
Dimension for X Manufacturer-specied
value
X
A
X
B
Figure 6-1
Figure 6-2 Figure 6-3
Connectingelement
Thisproduct
Shaft
β
β

13
7. Operation
DANGER
- Do not touch rotating parts (output shaft, etc.) during operation; otherwise, loose clothing
caught in these rotating parts may result in serious injury.
CAUTION
- Do not put ngers or foreign object into the opening of the reducer; otherwise, injury or
damage to the equipment may result.
- The products becomes very hot during operation. Be careful not to touch with hands or
body; otherwise, burns may result.
- If any abnormality occurs during operation, stop operation immediately; otherwise, electric
shock, injury, or re may result.
- Do not operate the products beyond the rated load; otherwise, personal injury or damage to
the equipment may result.
7-1 Items to Check Before Operation
After installation and wiring are completed, check the following items before operating.
- Is the unit properly coupled with the driven machine?
- Are mounting bolts tightened rmly?
- Is the direction of rotation as required?
After conrming these items, operate without a load and gradually apply a load. Check the items shown
in Table 7-1.
7-2 Items to Check During Operation
Table 7-1 Items to Check During Operation
Does abnormal sound or vibration
generate?
-
Isthehousingdeformedbecausetheinstallationsurfaceis
notat?
-Isinsu󱐰cientrigidityoftheinstallationbasegenerating
resonance?
-Istheshaftcenteralignedwiththedrivenmachine?
-Isthevibrationofthedrivenmachinetransmittedtothe
gearmotororreducer?
Is the surface temperature abnormally
high? -Istheambienttemperaturetoohigh?
If any abnormalities are found, immediately stop operation and contact the nearest authorized maintenance
shop.

14
8. Daily Inspection and Maintenance
DANGER
- Do not come close to or touch any rotating parts (output shaft, etc.) during maintenance or
inspection of the unit; otherwise, loose clothing caught in these rotating parts may result in
injury or death.
CAUTION
- Do not put ngers or foreign object into the opening of the reducer; otherwise, injury or
damage to the equipment may result.
- The reducer will become very hot during operation. Do not touch the unit with bare hands;
otherwise, burns may result.
- Identify and provide appropriate corrective action in a timely fashion and according to this
maintenance manual if any abnormal operating characteristics are observed. Do not operate
the unit corrective action has been taken.
- Do not use damaged reducers; otherwise, injury or damage to the equipment may result.
- We can not assume any responsibility for damage or injury as a result of an unauthorized
modication by a customer.
- Dispose of the reducer as general industrial waste.

15
8. Daily Inspection and Maintenance
8-1 Daily Inspection
Be sure to perform daily inspection according to Table 8-1. Lack of inspections is a source of trouble.
Table 8-1 Daily Inspection
Inspection Item Details of Inspection
Noise Is there abnormal sound? Is there sudden change in sound?
Vibration Is vibration abnormally large? Does vibration change suddenly?
Surface temperature Is the surface temperature abnormally high? Does the surface
temperature rise suddenly?
Grease leakage Is there any grease leakage from the gears? Is there any rust on the
sliding surface of the oil seal?
Installation bolts Have any of the installation bolts become loose?
Chain Timing belt Is the chain or timing belt loose?
- If any problems are found in daily inspection, follow“9.Troubleshooting”(P16) to take appropriate actions.
If these actions do not solve the issue, immediately contact the nearest authorized maintenance shop.
8-2 Maintenance of Main Unit
- Oil seals have a lifetime. During long use, natural degradation and frictional wear will reduce eectiveness.
Depending on the operating conditions and ambient environment for this product, the lifetime of seals
greatly varies. Given normal operation, (uniform load, running 10 hours per day, normal temperature)
it is recommended to change them every 1 to 3 years. If the sliding surfaces of oil seals or V-rings show
signs of wear or corrosion, replace them with new ones. Because sliding surfaces for oil seals are made of
carbon steel, take periodic rust prevention measures not to spread rust on them by applying rustproof oil
and so on, if there are exposed surfaces of steel.
8-3 Backlash
The product has been assembled with a preconditioned backlash.
A complete backlash reconditioning would be necessary if the product is disassembled. Never
disassemble the product.

16
9. Troubleshooting
If any abnormal condition occurs, refer to Table 9-1 and promptly take appropriate measures.
If these actions do not solve the issue, immediately contact the nearest authorized maintenance shop.
Table 9-1 Troubleshooting
Condition Possible causes Control
The motor rotates without a load
but the output shaft does not
rotate
Unit damaged due to gear
overloading etc.
Confer with authorized
maintenance shop.
The output shaft turns
without a load
but when load is applied
The speed will not
increase and the motor
is overheating
Overload Reduce the load to the
specication level
It stops
The key is not inserted Insert the key
Bearing is burned Confer with authorized
maintenance shop.
Runs in the reverse direction Control setup error Change the control setup
Excessive temperature rise
Overload Reduce the load to the
specication level
Ambient temperature at the use
location is too high Improve ventilation
Bearing damaged Confer with authorized
maintenance shop.
Reduction gears excessively worn
due to overloading etc.
Confer with authorized
maintenance shop.
Grease leaking
Oil and fat blot or drip from
the seal section of input /
output shaft.
Grease applied to the oil seals
tends to seep out from the seals at
the beginning of use
Wipe the grease o the oil seals
and observe the condition
Leakage of oil or grease
from input or output shaft
section
Oil seal or shaft damaged Confer with authorized
maintenance shop.
Leakage from case or other
mating surfaces Tightening bolt loose Confer with authorized
maintenance shop.
Abnormal noise
Abnormally severe vibration
Dust or foreign objects inside the
bearing, or the bearing is damaged
Confer with authorized
maintenance shop.
Foreign objects stuck between
reduction gears
Confer with authorized
maintenance shop.
Reduction gears damaged Confer with authorized
maintenance shop.
Warping of housing because the
installation surface is not at
Correct the installation surface
to make it completely at or use
liners etc. for adjustment
Resonance due to the installation
surface not being suciently rigid
Reinforce the installation surface
for greater rigidity
Shaft misalignment with the
driven machine Align the shaft centers
Vibration of the driven machine
transmitted to the reducer
Individually operate the products
to check the source of the sound.

17
10. Construction Drawing
10-1 Construction Drawing (P1 Type)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Part Number Description
1 Output shaft
2 Oil seal
3 Main bearing
4 Sun gear of output
5 Planetary gear of output
6 Casing with internal gear
7 Sun gear of input
8 Planetary gear of input
9 Internal gear of input
10 Motor ange bracket
11 Oil seal
12 Input shaft bearing
13 Coupling
14 Adaptor plate
15 Motor (Provided by the user)
Table 10-1 Main Components (P1 Type)
Figure 10-1 P1 Type Double-reduction (example: ANFX-P120N)

18
10. Construction Drawing
10-2 Construction Drawing (PK1 Type)
1235649 10 8 12 1411 13 7 15
16
17
18
19
20
21
22
24
25
23
Part Number Description Part Number Description
1 Output shaft 14 Casing
2 Oil seal 15 Bearing
3 Bearing of output 16 Intermediate Shaft
4 Sun gear of output 17 Spiral bevel gear
5 Planetary gear of output 18 Pinion shaft
6 Casing with internal gear 19 Bearing
7 Sun gear of input 20 Cover
8 Planetary gear of input 21 Oil seal
9 Internal gear of input 22 Input shaft bearing
10 Adaptor 23 Coupling
11 Oil seal 24 Adaptor plate
12 O-ring 25 Motor (Provided by the user)
13 Bearing
Table 10-2 Main Components (PK1 Type)
Figure 10-2 PK1 Type Triple-reduction (example: ANFX-PK120N)