Sumitomo Cyclo BBB5, Operation And Maintenance Manual

Page 1: ...Cyclo BBB5 BevelBuddybox RightAngleSpiralBevelSpeedReducer withCyclo orPlanetaryInput Operation and Maintenance Manual 13 605 60 006 BBB5 O M 2019 ...

Page 2: ...enclature 15 Lubrication Method 16 Recommended Lubricants 17 Lubrication Quantities 18 Oil Quantities 18 Oil Supply Procedures 19 Oil Discharge Procedures 19 Grease Quantities 20 Grease Replenishment and Draining Procedures 21 Grease Replacement 21 Y2 Oil Fill Drain Procedures 22 Motor Wiring 26 Wiring Guidelines 26 Measuring Insulation Resistance 26 Motor Protection 27 Motor Wiring Method 27 Brak...

Page 3: ...all align wire inspect operate and maintain the unit When the unit is to be used in a system for transport of human beings a secondary safety device should be installed to guard against accidents that may result in injury death or damage to the system When the unit is to be used for an elevator install a safety device on the elevator side to prevent it from falling otherwise serious injury death o...

Page 4: ...t distributor or sales office about this product please be prepared to provide the following information from the reducer gearmotor nameplate reducer or gearmotor model number nomenclature reduction ratio serial number Lubrication Inspection Oil lubricated units are shipped without oil unless the customer specified otherwise when the unit was ordered Always fill the unit with the correct type and ...

Page 5: ...1 1 4 0 2 02 1 3 0 25 03 1 2 0 4 05 3 4 0 55 08 1 0 75 1 1 5 1 1 1H 2 1 5 2 3 2 2 3 5 3 7 5 7 5 5 5 8 10 7 5 10 15 11 15 20 15 20 25 18 5 25 30 22 30 40 30 40 50 37 50 60 45 60 75 55 75 Single Reduction 5Z100 5A110 5B120 5C140 5Z105 5A115 5B125 5C145 5Z110 5A120 5B140 5C160 5Z115 5A125 5B145 5C165 5Z120 5A140 5B160 5C170 5Z125 5A145 5B165 5C175 Double Reduction 5Z10DA 5A12DA 5B12DA 5C14DA 5Z12DA 5...

Page 6: ...2 5B12 5Z11 15 89 5A11 5A14 16 00 5B14 5C14 5C17 16 17 5B16 16 26 5C16 18 5Z10 16 80 5Z12 17 12 5A12 5B12 5Z11 17 38 5A11 5A14 17 50 5B14 5C14 5C17 17 68 5B16 17 78 5C16 5B14 5B16 17 78 5C16 BBB with Cyclo Input Nominal BBB Frame Size Exact Ratio Input Ratio Overall Ratio 6 21 All 21 0 7 22 22 4 25 24 5 8 28 28 0 11 35 35 2 39 38 5 13 46 45 5 15 53 52 5 17 60 59 5 21 67 67 2 74 73 5 25 80 80 0 88 ...

Page 7: ...rnal machined surfaces are coated with a suitable NP 19 JIS petroleum base corrosion preventative such as Black Bear Par Al Ketone Houghton RustVeto 342 Daphne Ever Coat No 1 or equivalent Consult Sumitomo for Long Term Storage procedures Storage without factory preparations Ongoing maintenance during storage period Operation After Storage Before operating the unit after an extended storage period...

Page 8: ...ial unit modifications may be required Units manufactured according to customer specified application requirements i e outdoor modifications high temperature modifications are designed to operate within the specified environment Install the unit so inspection and or maintenance procedures may be easily performed Install all units with a torque arm or similar means to limit housing rotation NOTE To...

Page 9: ...nti seize compound to the driven shaft surface and inside the reducer keyed hollow bore 2 Align the driven shaft with the reducer gearmotor bore and carefully slide unit onto the driven shaft to desired location If the fit is tight strike on the keyed hollow bore with a wooden or hard rubber mallet to assist in the assembly If using a mallet during installation strike only against the unit s steel...

Page 10: ... Refer toTorque Arm Installation section in this manual for instructions CAUTION The Cyclo BBB5 must be externally supported prior to insertion of driven shaft into hollow bore External support MUST be maintained until all shrink disc socket head cap screws have been tightened to the appropriate operational torque Bore and Shaft Tolerance Specifications Refer to the certified outline drawing or Cy...

Page 11: ...ize Model Typical Bolt Bolt Torque lb ft Nm 5Z TAS 3071 45x55 8 x M6X25 ISO JIS grade 10 9 9 12 5A TAS 3071 55x68 10 x M6x25 ISO JIS grade 10 9 9 12 5B TAS 3071 65x80 7 x M8x30 ISO JIS grade 12 9 26 34 5C TAS 3071 75x100 12 x M8x35 ISO JIS grade 12 9 26 34 Table 2 Shrink Disc Bolt Tightening Torques 3 Set the untightened shrink disc on the reducer shaft For 3 piece design shrink disc make sure tha...

Page 12: ...cket Bolt Size 1 Torque lb ft N m 5Z 8 x M8 17 19 24 26 5A 8 x M10 34 38 46 51 5B 8 x M12 59 65 80 88 5C 8 x M16 152 167 206 227 Note 1 Bolt ISO JIS Class 8 8 Torque Arm Bracket Bracket Mounting Bolt s Torque Arm Introduction A torque arm is a device used to prevent counter rotation of the shaft mounted reducer gearmotor during operation The torque arm must be mounted in tension when torque arm mo...

Page 13: ... has not been over tightened Compressed bushings will not allow the bushings to properly absorb the loads of the shaft mounted gearbox This can lead to premature failure MountingAngleBracketmustbesecuredtothemachinestructure Rubber Bushing Washer When installed bolt must be parallel to this surface Mounting Structure or Angle Bracket Customer Supplied Washer Rubber Bushings Nuts Customer Supplied ...

Page 14: ...e the safety cover and the shaft retaining device from the driven shaft 3 Apply a liquid penetrant to the shaft where it contacts the keyed hollow bore Allow time for the liquid to penetrate between the shaft and the wall of the keyed hollow bore 4 Once the penetrant has settled adequately carefully remove the Cyclo BBB5 from the driven shaft If shaft removal is difficult a jig such as the one sho...

Page 15: ...ut the entire removal process Do not raise the unit too high Shaft binding may occur 2 If required remove the safety cover and apply liquid penetrant to the shrink disc bolts and shaft bore allowing adequate time for proper penetration Loosen the locking bolts on the shrink disc Complete bolt removal should not be required Tapping the shrink disc flanges with a wooden or hard rubber mallet may be ...

Page 16: ... before start up The Bevel Gear portion of models built for the Y4 mounting configuration requires filling with gear oil before start up Refer to the Lubrication Method section for details For the Cyclo BBB5 built for the Y4 mounting configuration the Cyclo and the bevel gear portions must be filled with lubricant separately and maintained separately Lubricant does not flow from one portion to the...

Page 17: ...or Y4 Configuration Mounting Configuration Unit Size Lubrication Method Bevel Gear Size Cyclo Size 5Z 5A 100 105 110 115 120 125 10DA 12DA 12DB Cyclo Portion Maintenance Free Grease 1 Bevel Gear Portion Oil 5A 5C 140 145 160 165 170 175 12DA 12DB 14DA 14DB 14DC 16DA Cyclo Portion Grease 2 Bevel Gear Portion Oil Notes 1 Maintenance Free Grease the input Cyclo portion is grease lubricated as standar...

Page 18: ...pecified lubrication method refer to the Lubrication Method section for details Table 11 Cyclo Portion Approved Greases Ambient Temp F C Overall Reduction Ratio All Unit Sizes 14 122 F 10º 50ºC 11 1 through 18 1 Shell Gadus S2 V220 NLGI 00 19 1 and higher ExxonMobil Unirex N2 grease Cyclo portions have unique operating characteristics that require specific lubricant properties Please consult Sumit...

Page 19: ...3 07 11 62 1 53 5 78 1 69 6 39 5C17 1 72 6 52 3 20 12 13 1 64 6 22 1 80 6 83 Table 13 Double Reduction Approximate Oil Quantity Units U S liquid gallon liter Note Output Bevel Gear Portion Input Cyclo Bevel Gear Unit Size Mounting Configuration Output Input 5Z10DA 0 24 0 89 0 42 1 60 0 18 0 70 Grease 0 24 0 91 0 26 1 00 5Z12DA 0 24 0 89 0 47 1 78 0 29 1 10 0 29 1 10 5Z12DB 0 26 0 99 0 47 1 78 0 29...

Page 20: ...N o t e U n i t s s u p p l i e d w i t h M o b i l S H C G e a r H i S h o c k 1 5 0 m a y d o u b l e t h e o i l c h a n g e i n t e r v a l s ...

Page 21: ...4DA First Input 0 88 25 Second 15 9 450 5C14DB First Input 2 12 60 Second 15 9 450 5C14DC First Input 4 24 120 Second 15 9 450 5C16DA First Input 2 12 60 Second 26 5 750 Grease Quantities Grease quantities listed in this section are for the Cyclo portion of the reducer gearmotor The Bevel Gear portion is always oil lubricated unless otherwise specified at time of order entry Refer to the Oil Quant...

Page 22: ...e lubrication models excluding maintenance free models 1 Remove the grease discharge plug from the outside cover 2 Add grease with a grease gun from the grease nipple in the inside cover section or motor connection cover 3 Insert the grease discharge plug Add grease while manually rotating the input shaft to ensure proper uniform circulation Add grease slowly to prevent internal air pressure and p...

Page 23: ...Y2 mounting motor up configuration Images contained within the document show a single reduction input stage however the process remains the same for double and triple reduction product offerings Oil Fill Process CAUTIONARY NOTE Use only those lubricating oils approved by Sumitomo Drive Technologies for use in the Cyclo Bevel Buddybox Use the appropriate grade of lubricating oil based on ambient op...

Page 24: ...e oil to drain from the cup into the reducer 5 The input portion is considered full when the oil level stabilizes in the middle of the oil sight gauge Check gauge carefully Oil film from fill procedure can distort view Be sure to check the oil level after a few minutes of operation Stop equipment and check gauge as shown in step 5 Adjust oil level as required 6 Once the input portion of the unit i...

Page 25: ...ion after oil fill is complete 2 Carefully remove the unit air breather assembly and put aside for reinsertion after oil fill process is complete Allow used oil to freely flow into an approved lubricant container Once the unit is completely drained of oil reinstall the drain plug and tighten Refer to torque tightening values in Table 19 Table 19 Plug sizes and tightening torque values Plug Sizes T...

Page 26: ... liter 5B12 1 37 5 17 5B14 1 46 5 52 5B16 1 63 6 17 5C14 2 84 10 7 5C16 3 07 11 6 5C17 3 20 12 1 Bevel Gear Unit Size Y2 Configuration Oil Quantity gallon liter 5Z10DA 0 18 0 68 5Z12DA 0 18 0 70 5Z12DB 0 18 0 70 5A12DA 0 22 0 83 5A12DB 0 22 0 83 5B12DA 0 42 1 60 5B12DB 0 42 1 60 Bevel Gear Unit Size Y2 Configuration Oil Quantity gallon liter 5B14DA 0 42 1 60 5B14DB 0 42 1 60 5C14DA 0 93 3 53 5C14D...

Page 27: ...les to the unit according to the connection diagram shown inside the terminal box or in the maintenance manual otherwise electric shock or fire may result Correctly ground the grounding bolt otherwise electric shock may result Keep all wiring and electrical parts dry and moisture free Follow local electrical codes and regulations when wiring otherwise burning electrical shock injury and or fire ma...

Page 28: ... type Motor Protection Use a molded case circuit breaker for protection against short circuit Use an overload protection device that protects the unit against voltage surges Motor HP kW x P Standard AF Motor EP NA Motor Non CSA CSA Non CSA CSA UL CSA CE 1 8 0 1 x 4 WYE WYE WYE WYE 1 4 0 2 x 4 1 3 0 25 x 4 1 2 0 4 x 4 3 4 0 55 x 4 1 0 75 x 4 WYE 1 5 1 1 x 4 2 1 5 x 4 3 2 2 x 4 5 3 7 x 4 DELTA 7 5 5...

Page 29: ...ot always agree with that on the motor In such cases connection diagram found inside the conduit box of the motor should be used 1 Based on motor power determine if motor is WYE or DELTA type 2 Wire the motor to the power source using the correct connection type Operating Voltage 190 230V 380 460V 575V Varistor Rated Voltage Varistor Voltage AC260 300V 430 470V AC510V 820V AC604V 1000V Rated Watts...

Page 30: ... the motor may be wired using one of the following these methods Models FB 01A through FB 15B FB 15E Figure 10 Normal Brake Action 230V 575V Figure 12 Normal Brake Action 460V Figure 11 Fast Brake Action 230V Figure 13 Fast Brake Action 460V 575V MC Electromagnetic Relay MCB Magnetic Circuit Breaker OLR Overload or Thermal Relay VR Varistor protective device 1 Note 1 Refer to Varistor Specificatio...

Page 31: ...0V Figure 16 Normal Brake Action 460V 575V Brake Figure 18 FB 20 and FB 30 Brake Wiring 480VAC or less Figure 19 FB 20 and FB 30 Brake Wiring 575VAC Figure 15 Fast Brake Action 230V Brake Figure 17 Fast Brake Action 460V 575V Brake MC Electromagnetic Relay MCB Magnetic Circuit Breaker OLR Overload or Thermal Relay VR Varistor protective device 1 Note 1 Refer to Varistor Specifications Table Motor ...

Page 32: ...ormal Brake Action 380V Motor 220V Brake Separated Figure22 NormalBrakeAction 380VMotor 220VBrake Tapped Figure 25 Fast Brake Action 380V Motor 220V Brake Separated Figure 23 Fast Brake Action 380V Motor 220V Brake Tapped Figure 21 Fast Brake Action 220V Motor 220V Brake MC Electromagnetic Relay MCB Magnetic Circuit Breaker OLR Overload or Thermal Relay VR Varistor protective device 1 Note 1 Refer...

Page 33: ...x P Brake Model Motor Voltage Brake Voltage 1 8 0 1 x 4 FB 01A 220 380V 50Hz 220V 50Hz 1 4 0 2 x 4 FB 02A 1 3 0 25 x 4 1 2 0 4 x 4 FB 05A 3 4 0 55 x 4 FB 1D FB 1E 1 0 75 x 4 1 5 1 1 x 4 FB 2D FB 1HE FB 2E 2 1 5 x 4 3 2 2 x 4 FB 3D FB 3E 4 3 x 4 FB 5B FB 4E FB 5E 5 3 7 x 4 7 5 5 5 x 4 FB 8B FB 8E 380V 50Hz 380V 50Hz 10 7 5 x 4 FB 10B FB 10E 15 11 x 4 FB 15B FB 15E Table 26 Standard CE Motor Motor B...

Page 34: ... 7 5 x 4 FB 15B 15B1 15E 15 11 x 4 FB 20 20 15 x 4 FB 30 25 18 5 x 4 30 22 x 4 40 30 x 4 Brake Type Motor HP kW x P 220V Rectifier 380V Rectifier Model Number Part Number Model Number Part Number FB 01A 1 8 0 1 x 4 10F 2FB2 MP983WW 01 Consult Factory Consult Factory FB 02A 1 4 0 2 x 4 1 3 0 25 x 4 FB 05A 1 2 0 4 x 4 FB 1D 1E 3 4 0 55 x 4 1 0 75 x 4 FB 2D 1HE 2E 1 5 1 1 x 4 2 1 5 x 4 FB 3D 3E 3 2 2...

Page 35: ...pacer 9 Cycloid Discs 10 Cyclo Eccentric Cam Assembly 11 Spacer 12 Snap Ring 2 3 21 7 8 9 10 11 12 14 13 15 17 24 16 5 4 1 6 18 19 20 22 23 Number Description 13 Cyclo High Speed End Shield 14 Eccentric Key 15 High Speed Shaft Oil Seal Collar 16 High Speed Shaft Oil Seal 17 High Speed Shaft 18 High Speed Shaft B Bearing 19 Cycloid Disc Spacer 20 Retaining Bolts 21 Lock Washers 22 End Plate 23 Pin ...

Page 36: ...11G AX2806G AX2543G AX2761G CJ244LG CK322LG for5Z CJ701LG for5A CJ703LG for5B 13 14 4 1 931BB612 004G AP8706G CJ554LG AP8705G 16 18 5 1 931BB612 005G AP8714G CJ585LG AP8713G 5A140 5A145 5B140 5B145 5C140 5C145 11 3 1 931BB614 003G AP8717G CJ586LG AP8716G AX2807G AX2763G AX2544G CJ588LG CJ702LG for5A CJ704LG for5B CJ706LG for5C 13 14 4 1 931BB614 004G AP8708G CJ555LG AP8707G 16 18 5 1 931BB614 005G...

Page 37: ...5 163 179 51 D78686 189 207 59 D78687 227 249 71 D78688 278 305 87 D78689 364 104 See Note 1 364 417 119 See Note 1 424 121 See Note 1 Bevel Pin Carrier Reduction Kit Input Kit Unit Size Reduction Ratio Part Numbers Overall Cyclo Input Kit Reduction Kit 5A12 5B12 Bevel Pin Carrier Bevel Pin Carrier 5A120 5A125 5B120 5B125 19 21 6 D78623 D78690 CJ691LG CJ693LG 22 25 7 See Note 1 26 28 8 D78691 35 3...

Page 38: ...8741 93 102 29 D78742 112 123 35 D78743 138 151 43 D78744 163 179 51 D78745 189 207 59 D78746 227 249 71 D78747 278 305 87 D78748 364 104 See Note 1 364 417 119 See Note 1 424 121 See Note 1 Table 33 Cyclo Reduction Component Part Numbers Ratios 19 1 continued Unit Size Reduction Ratio Part Numbers Overall Cyclo Input Kit Reduction Kit Bevel Pin Carrier 5Z100 5Z105 5A100 5A105 19 21 6 D78504 D7852...

Page 39: ...2916 32308 32011 6302RSH2 6302Z D 80 x 105 x 13 S 50 x 68 x 9 S 20 x 35 x 7 5A120 5A125 32013 6304 6305Z D 32 x 52 x 8 5A140 5A145 30215 6305R 6306 D 38 x 58 x 11 5B120 5B125 32020 32018 32310 32013 6304 6305Z D 90 x 115 x 13 S 60 x 75 x 9 D 32 x 52 x 8 5B140 5B145 30215 6305R 6306 D 38 x 58 x 11 5B160 5B165 30217 6307R 6308 D 55x78 x 12 5C140 5C145 32022 32020 32312 30215 6305R 6306 D 100 x 125 x...

Page 40: ... count of the bevel gearset is provided for vibration analysis purposes To determine the bevel tooth count identify the Cyclo BBB5 nominal ratio and corresponding bevel ratio from Table 36 Then reference Table 37 to identify the actual number of bevel gear and pinion teeth Cyclo BBB5 Nominal Ratio Bevel Ratio Cyclo Input Ratio 80 3 2 25 88 3 5 25 93 3 2 29 102 3 5 29 112 3 2 35 123 3 5 35 138 3 2 ...

Page 41: ...rs should be conducted by experienced personal to prevent damage to components or persons Cyclo Portion General Disassembly 1 Before starting the disassembly process Sumitomo recommends draining and properly disposing of all lubrication 2 Carefully remove the entire Cyclo BBB5 from the driven shaft by following the instructions outlined in the Removal From Driven Shaft section of this manual Cyclo...

Page 42: ... bolts from the Cyclo ring gear housing shown in horizontal position for clarity 5 Carefully separate the bevel gear housing assembly from the Cyclo portion to gain access to the Cyclo reduction components 6 Remove the slow speed rollers Additionally check the pins on the pin carrier to see if any of the rollers have adhered to them 7 Remove the snap ring the ball bearing and the spacer from the h...

Page 43: ... Bearing Key Cycloid Disc 8 Using both hands carefully remove the top Cycloid disc 9 For Cyclo units supplied with a spacer remove the Cycloidal disc spacer 10 Remove the eccentric bearing from the high speed shaft 11 Using both hands carefully remove the remaining Cycloid disc 42 Operation Maintenance Manual Cyclo BBB5 ...

Page 44: ...Ring Gear Housing Spacer High Speed Shaft Bearing 12 Remove the ring gear housing 13 Remove the spacer and the snap ring from the high speed end shield 14 Remove the high speed shaft along with its associated bearing from the high speed end shield Operation Maintenance Manual 43 Cyclo BBB5 ...

Page 45: ... housing on the Cyclo high speed end shield or the motor flange and insert the ring gear housing pins and rollers if they had been removed during the disassembly process Rotate each of the pins and rollers by hand to assure that they freely move rotate If the Cyclo portion of the Cyclo BBB5 is grease lubricated liberally apply grease to the ring gear pins and rollers before they are inserted into ...

Page 46: ...fied in Grease Quantities section of this manual or fill to 80 of the space around the reduction mechanism and bearings of single reduction units and 50 of the space around the reduction mechanism of both the first and second stage of double reduction units If the Cyclo portion of the Cyclo BBB5 unit is oil lubricated do not add any grease during the reassembly process 6 When reassembling the Cycl...

Page 47: ...ush the reducer and fill with the correct type and quantity of lubricant Load exceeds capacity of reducer Check the rated capacity of the reducer Replace with unit of sufficient capacity or reduce the driven load Insufficient lubricant Insufficient lubricant Check lubricant level and adjust to recommended level Damaged Cyclo pins and rollers Load exceeds capacity of reducer Disassemble Cyclo porti...

Page 48: ... and rewire short Speed does not increase Faulty starter contact Replace or adjust starter contact Makes a groaning sound Overcurrent Overheating due to Rotor and Stator touching Repair by rewinding or replacing stator assembly Overcurrent due to one phase of Stator Coil shorted Replace the stator winding Makes a highpitched metallic noise Faulty bearing Replace the bearing Rotates when the load i...

Page 49: ...48 Operation Maintenance Manual Cyclo BBB5 Cyclo BBB5 Notes CYCLO 6000 Gearmotors 5 26 Technical Information Cyclo 6000 Series Notes ...

Page 50: ... Sumitomo Machinery Corporation of America Printed in USA www sumitomodrive com BBB5 For facilities located in the Americas please visit www sumitomodrive com locations For worldwide locations please visit www sumitomodrive com worldwide Headquarters Manufacturing 4200HollandBoulevard Chesapeake VA23323 Tel 757 485 3355 1 800 SMCYCLO Fax 757 485 7490 www sumitomodrive com E mail sma service shi g ...