Operating and Maintenance Manual

Hyponic®

07.020.60.002
Hyponic O&M 2019
Contents Safety Precautions
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 • 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
Inspection Upon Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 for correct operation. Retain this manual for future reference.
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 • Pay close attention to the “DANGER” and “CAUTION” warnings regarding safety and proper use.

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transportation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DANGER
Improper handling may result in physical damage, serious personal injury and/or death.
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Standard Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CAUTION
Improper handling may result in physical damage and/or personal injury.
Mounting Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Motor Mounting (Quill Shaft Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Direction of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Matters described in CAUTION may lead to serious danger depending on the situation.
Be sure to observe important matters described herein.
Connecting to the Driven Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Flange or Foot Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Solid Shaft Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Precautions for Mounting Hollow Shaft Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 • Transport, installation, plumbing, wiring, operation, maintenance, and inspections should be performed by trained
Hollow Shaft Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 technicians; otherwise, electric shock, personal injury, fire, or damage to the equipment may result.
• In the case of disassembly, assembly or overhaul of this device, contact the nearest authorized service station.
Keyed Hollow Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 • When using the equipment in conjunction with an explosion proof motor, a technician with electrical expertise
Shrink Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 should supervise the transport, installation, plumbing, wiring, operation, maintenance and inspection of the
equipment; otherwise, explosion, ignition, electrical shock, personal injury, fire or damage to the equipment may
Torque Arm Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 result.
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 • When the unit is to be used in a system for human transport, a protecting device for human safety should be
installed to prevent chances of accidents resulting in personal injury, death, or damage to the equipment due to
Wiring Connections for Standard Motor Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 running out of control or falling.
Wiring Connections for VFD (Inverter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 • When the unit is to be used for an elevator or lifter, install a safety protecting device on the elevator side to prevent
it from falling; otherwise, personal injury, death, or damage to the equipment may result.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Daily Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FB Brake Assembly – Inspection, Adjustment, and Maintenance . . . . . . . . . . . . . . . . . . . . . 20
Brake Models FB-01A1, FB-02A1, and FB-05A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Brake Models FB-1D, FB-2D, FB-1E, FB-1HE, FB-2E and FB-3E . . . . . . . . . . . . . . . . . . . . . . . . . 23
Brake Models FB-5E, FB-8E, FB-10E, and FB-15E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 1
Inspection Upon Delivery Storage
• Unpack the unit after verifying that it is positioned right side up; otherwise, injury may result. If this product is not for immediate use, please note the following points when storing it.
• Verify that the unit received is in fact the one you ordered. Installing the wrong unit may result in
personal injury or equipment damage.
• Do not remove the nameplate. Storage Location
Verify the items listed below upon receiving the product. If a nonconformity or problem is found, please Store the product indoors in a clean, dry location.
contact your nearest agent, distributor, or sales office.
Do not store outdoors. Store in a location that is free of moisture, dust, extreme temperature changes,
1. Does the information on the nameplate conform to what you ordered?
corrosive gases, etc.
2. Was any part broken during transport?
3. Are all bolts and nuts tightened firmly?
4. Were the ordered accessories received?
Storage Time
Lubrication
• The storage time should be within one year.
Hyponic® units are grease-lubricated. They are filled prior to shipment and arrive ready for customer use. It is recom- • If the storage time exceeds one year, adherence to special rust prevention specifications is required. Please consult
mended to overhaul the gearbox after 20,000 hours. with us.
Note: Over-hauling consists of disassembling the unit, replacing the seals and gaskets, cleaning the internal parts and • If for export, adherence to export rust prevention specifications is required. Please consult with us.
then repacking the unit with designated grease.
Standard Rust Prevention Specifications
Standard Low Temperature Food Grade External Rust Prevention:
Rust prevention oil is applied when shipping from the factory. Check rust conditions every six months after
Nihon Koyu BA-11A Nihon Koyu BH-17B Fuchs Cassida SGG 000
shipment. Reapply the rust prevention process, if necessary.

Table 1. Grease Lubrication Levels. Internal Rust Prevention:

Store in an ordinary factory or warehouse in an environment free of moisture, dust, extreme temperature
Size Ratio oz. (g) Size Ratio oz. (g)
changes, corrosive gases, etc.
1120 5 - 60 3.17 (90) 1530 80 - 240 52.9 (1500)
1220 5 - 60 5.64 (160) 1531 40 - 80 52.9 (1500)
1230 80 - 240 7.05 (200) 1540 300 - 1440 52.9 (1500)
Using After Storage
1320 5 - 60 9.17 (260) 1630 80 - 120 68.8 (1950) • Oil seals are affected by temperature, ultraviolet light, and other ambient conditions and can easily degrade. After
long storage periods, inspect before operation, and replace any degraded seals with new seals.
1330 80 - 240 10.9 (310) 1631 150 - 240 68.8 (1950) • At startup, check that there are no unusual noises, vibrations, temperature rises, or other symptoms. For motor with
1340 300 - 1440 16.2 (460) 1632 30 74.1 (2100) brakes, check that brakes work properly. If any abnormalities are found, immediately contact the nearest authorized
service station.
1420 5 - 60 19.8 (560) 1632 40 - 60 68.8 (1950)
1430 80 - 240 26.5 (750) 1633 20 - 25 74.1 (2100)
1440 300 - 1440 31.7 (900) 1633 30 - 40 68.8 (1950)
1520 5 - 60 31.7 (900) 1634 5 - 15 106 (3000)
1521 5 - 25 31.7 (900) 1634 20 - 25 68.8 (1950)
1522 5 - 15 31.7 (900) 1640 300 - 1440 127 (3600)

2 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 3
Transportation • Bolt the motor into place. Refer to the motor operating instructions for proper bolt tightening torque. Important: If
the bolt is tightened when the fitting is not inserted, uneven tightening will result, causing damage to the internal
bearing and other components.
Do not stand directly under a unit suspended by a crane or other lifting mechanism; otherwise, injury or
death may result.
Direction of Rotation
• Exercise ample care so as not to drop the unit. • After wiring the motor as recommended in the Wiring section, the motor shaft rotates to the right as seen from
When a hanging bolt or hole is provided, be sure to use it. After mounting a unit to a machine, do not hoist the the fan cover side. Figure 1 shows the direction of rotation for the output shaft depending on the size and ratio
entire machine using the hanging bolt or hole; otherwise, personal injury or damage to the equipment and/or combination.
lifting device may result. • After corroborating direction of rotation, the gearmotor can be connected to the driven machine. It is
• Before hoisting, refer to the rating plate, crate, outline drawing, catalog, etc. for the weight of the unit. Never hoist recommended to do a test run with no load, and increase load gradually. Observe precautions listed in Table 8 Trial
a unit that exceeds the rating of the crane or other mechanism being used to lift it; otherwise, personal injury or Run Precautions in the Operation section during test run.
damage to the equipment and/or lifting device may result.
• Use an appropriate hanging bolt or hole, and make sure that the eye-bolt and/or nut is not loose before hoisting. Fig. 1 Rotating Direction of the Output Shaft

Installation CCW
CW

CW
CW
Standard Operating Conditions
Ambient temperature: 14°F to 104°F (-10°C to 40°C)
Humidity: 85% or less
Altitude: Lower than 3300 ft (1000 m) above sea level
Atmosphere: Free from corrosive gases, explosive gases or steam. It should also be free from dust and well
Model Counter Clockwise Reduction Ratio (:1) Model Clockwise Reduction Ratio (:1)
ventilated.
1120 5, 7, 10, 12, 15, 20, 25, 30, 40, 50, 60 1120 –
Mounting Angle 1220 5, 7, 10, 12, 15, 20, 25, 30, 40, 50, 60 1220 –
1230 – 1230 80, 100, 120, 150, 200, 240
There is no limit on a mounting angle.
1320 5, 7, 10, 12, 15, 20, 25, 30, 40, 50, 60 1320 –
Do not remove the motor’s eye-bolt. In the rare case that it is removed, insert a bolt or other appropriate material 1330 – 1330 80, 100, 120, 150, 200, 240
into the screw hole to prevent water or other substances from entering the motor through the screw hole. 1340 300, 360, 480, 600, 720, 900, 1200, 1440 1340 –
1420 5, 7, 10, 12, 15, 20, 25, 30, 40, 50, 60 1420 –
1430 – 1430 80, 100, 120, 150, 200, 240
Motor Mounting (Quill Input Shaft) 1440 300, 360, 480, 600, 720, 900, 1200, 1440 1440 –
1520 5, 7, 10, 12, 15, 20, 25, 30, 40, 50, 60 1520 –
Reducer Supplied with Motor (assembled): 1521 5, 7, 10, 12, 15, 20, 25 1521 –
Some units may come from the factory with the motor attached. In this case, no additional preparation is required. 1522 5, 7, 10, 12, 15 1522 –

Customer Supplied Motor or Motor Supplied Separately (disassembled): 1530 – 1530 80, 100, 120, 150, 200, 240
1531 – 1531 40, 50, 60, 80
• Inspect the input shaft hollow bore and the motor shaft for debris or other material that may prevent the insertion
1540 300, 360, 480, 600, 720, 900, 1200, 1440 1540 –
of the motor shaft into the hollow quill input shaft – carefully clean if necessary.
1630 10, 12, 15, 20, 25, 30, 40, 50 1630 60, 80, 100, 120
• To enable easy installation and removal of the motor, apply anti-seize paste to both the reducer hollow bore and the
1631 – 1631 150, 200, 240
motor shaft. 1632 10, 12, 15, 20, 25, 30 1632 40, 50, 60
• Hollow input shaft units for the Food and Beverage Industry have either an o-ring or gasket material (solid or 1633 20, 25 1633 30, 40
liquid) for installation between the motor and reducer. 1634 5, 7, 10, 12, 15 1634 20, 25
• Place the motor key into the motor shaft and carefully insert the motor into the quill high-speed shaft of the 1640 300, 360, 480, 600, 720, 900, 1200, 1440 1640 –
reducer. Do not force the assembly if the shafts are slanted or misaligned or if the key is only partially engaged.
• Ensure that the motor flange bolts are aligned with the through holes of the reducer flange, and also ensure that the
motor is properly aligned with the reducer. Note: Swapping two of the three input power leads of a three-phase induction motor will cause the motor direction to reverse.

4 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 5
Connecting to the Driven Machine Excessively loose chains will cause a jolt upon start-up that may damage the Hyponic® unit and the driven
machine. Excessive tension of V-belts or chain may cause bearing failure.

Flange or Foot Mount

1. Mount the gearmotor on a rigid surface. Fig. 2
2. Ensure there is no restriction for mounting angle.
3. Use hexagon socket head bolts when mounting RNF series (flange-mount type). See Table 2 for bolt sizes.

Table 2. Flange Mount Bolt Size.

Series Frame Size Type Bolt Size

1120 M6

1220, 1230 M8

1320, 1330, 1340 M10

RNFJ(M)
RNFX(M) 1420, 1430, 1440 Through Hole M12 Fig. 3
RNFM 1520, 1521, 1522

1530, 1540 M16

1630, 1631,
M20
1632,1633, 1640

Solid Shaft Type

When mounting connected equipment, do not apply impact or excessive axial or radial load to the shaft. The
bearing could be damaged, or the collar could come off.
Fig. 4
1. Mount the connecting device, such as a coupling, chain, sprocket, gear or V-pulley, on the shaft as close as possible
to the shaft collar as shown in Figure 2. This places the load point between the center of the shaft and the shaft
collar.
2. We recommend using end cap screws or interference fit on the connecting device to avoid possible bearing
damage from excessive force or thrust load that may be applied to the shaft while fitting the connecting device
(Figure 3).
3. When connecting the Hyponic® unit to the driven machine with:
a. V belts, keep parallelism and eccentricity β if the pulleys within 20’ as shown on Figure 4.
b. Couplings, align according to the coupling manufacturer’s recommendation.
c. Chains, sprockets or gears, select a pitch circle diameter at least 3 times the shaft diameter. For chain tension,
please refer to the chain manufacturer recommendation and keep tension angle perpendicular to the shaft.

6 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 7
Hollow Shaft Type Fig. 5

Precautions for Mounting the Hollow Shaft Type

1) Driven Shaft Size

• If the driven shaft dimension is small and there is a space from the hollow shaft, abrasion from fretting tends to
occur. The resulting abrasion powder may get pinched in the oil seal, causing the grease to leak.
• Furthermore, vibrations due to the space may damage the parts inside the drive.
a ......Spacer b ......Thrust Bearing c ......Nut d ......Double end threaded bolt
• If the driven shaft length is short, excessive force is applied on the hollow shaft, possibly causing vibration or The hollow shaft is made according to ISO H8 tolerances. Following installation, ensure that the fitting
grease leak. between the hollow and the driven shaft is tightened correctly. We recommend ISO js6 or k6 as the
• If the effective length of driven shaft is short, the key and the keyway may be damaged. tolerance for the driven shaft.
2) Mounting on the Driven Shaft
• If the hollow shaft end face is hit with a metal hammer or the driven shaft was biting on the hollow shaft when b. Mounting the Hyponic® unit
assembled, the hollow shaft may become deformed and the oil seal contact may become uneven, causing the Be sure to fix the gearmotor onto the driven shaft. Fixing options are shown on Figures 6 and 7.
grease to leak.
• If the case or the oil seal is hit, the damaged or deformed case or oil seal may cause the grease to leak. Fig. 6: Method of fixing in which the product does not move to the machine side.

3) Fixing on the Driven Shaft Stepped Shaft Option Spacer Option Set Screw Option
• If the hollow shaft is not fixed, it may vibrate in the thrust direction due to the vibration from the operation or
from the machine side, possibly causing the oil seal performance to become uneven and the grease to leak.
• The vibration may also damage the parts inside the drive.

4) Torque Arm Retainer

• Fixing the torque arm retainer may prevent the case from following the driven shaft movement, and as a result of
excessive force being applied on the hollow shaft, the grease may leak through the oil seal.
• It may also damage the parts inside the drive.

When using the hollow shaft type, be sure to refer to the mounting procedure on pages 8 to 14.

Fig. 7: Method of fixing in which the product does not move in the opposite direction of the
Keyed Hollow Bore machine.
1. Mount the gearmotor onto the driven shaft that has sufficient rigidity. Spacer and Plate Option End Plate Option
2. Ensure there is no restriction for the mounting angle.
3. Mounting Procedures:
a. Connecting a Driven Shaft

Apply customer-supplied anti-seize grease to the surface of the driven shaft and the inner surface of the
hollow shaft. Slide the Hyponic® unit onto the driven shaft. To make the installation smoother if the fit
is too tight, lightly tap the end of the hollow output shaft with a wooden hammer. Avoid hitting the
casing. To ensure smooth installation of the drive, we recommend the use of a jig shown in Figure. 5.

Inappropriate installation will result in shaft fretting. Fretting will cause shaft wear, jamming,
and misalignment between the gearmotor and driven shaft.

8 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 9
 When installing the gearmotor when flange-mounted, ensure that the gearmotor and the Shrink Disc
shaft of the driven machine are properly aligned so that the gearmotor is free from excessive
force (Figure 8). Before placing unit onto driven shaft, do not apply grease, oil, or anti-seize grease to the entire driven
shaft or to the bore of the shrink disc. Use of these friction-minimizing products will adversely affect the
Fig. 8 ability of the unit to transmit torque.

Bearing unit Bearing unit Bearing unit Degrease these areas 1

Clean and degrease contact surfaces; reducer shaft and bore, and the machine
Hyponic® hollow Hyponic® hollow Hyponic® hollow driven shaft.
shaft model shaft model shaft model
Apply Molykote 321 or an equivalent dry film lubricant to the driven shaft
Correct Incorrect
Incorrect
Poor perpendicularity of driven shaft Poor concentricity of driven
projection opposite from the shrink disc.
center and mounting flange surface shaft and mounting flange
Apply Molykote 321
to this shaft area only For food grade application, use food grade dry film lubricant.

Do not apply any friction minimizing compound to the driven shaft at

or near the shrink disc
d. Removing the Shaft
Do not apply excessive force to the unit and shaft. Using a jig as shown in Figure 9 will facilitate
removal of the shaft. 2
Align the driven shaft with the reducer hollow bore and carefully slide unit onto the driven shaft.

If the fit is tight, strike on the reducer hollow bore with a mallet to assist in the assembly.

Fig. 9 If using a soft non-metallic mallet during installation, strike only against the unit’s steel hollow bore. Do not
strike the reducer housing or oil seal. Damage to the bearings, the housing, and/or the seals may occur.

Note: If the fit is tight, use a jig such as the one shown in Figure 5 to ease assembly. Sumitomo does not supply a
mounting jig. This information is provided for reference only.

Never tighten locking screws before shaft installation. Inner ring may become permanently contracted even
at low tightening torques.

Ensure that all power switches are locked out before installing or removing shrink disc. Wear safety glasses
Note: Customer should supply parts for setting, securing or removing the shaft. and protective clothing at all times

3
Remove any wooden spacers that may have been used during shipping. Lightly lubricate the hub outside diameter
and shrink disc bore.

10 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 11
 4 Removal Instructions
Set the (untightened) shrink disc on the reducer shaft. Following either a clockwise or counterclockwise sequence, loosen all locking screws using approximately ½ turns, until
you can remove the shrink disc from the hub. The shrink disc, hub, and shaft will return to their original clearance fits.
5 Note: Locking screws do not have to be removed completely from the shrink disc.
After confirming the correct position of the hub and shrink discs, hand tighten
three or four equally spaced locking screws and ensure the discs are parallel.
Hand-tighten remaining locking screws. Torque Arm Installation
Standard Face Mount Torque Arm
Mount the torque arm on the driven machine side of the drive casing. Use hexagon socket head bolts
6 for mounting. (See Table 4 for bolt sizes.)
1 2 Using a torque wrench, tighten the screws according to the initial torque listed
3 in Table 3. Tighten in either a clockwise or counter-clock wise sequence, using Table 4. Torque Arm Bolt Sizes.
4 ¼ turns, until you can no longer complete a ¼ turn for any of the screws. This
Model Bolt Size
procedure keeps the discs parallel.
5 1120,1230 M8
6 7 1220, 1330, 1340 M10
7
Continue to tighten the screws for two more passes. This compensates for system 1320, 1430, 1440 M12
induced relaxing of the locking screws.
8 1420, 1530, 1531 M16

Set the torque wrench to the final torque and tighten all locking screws. At this point, no screw should turn; 1520, 1521, 1522, 1630, 1631,
M20
otherwise, set the torque wrench to the initial torque and repeat steps 6 and 7 above. It is not necessary to re- 1632, 1633, 1640
torque after equipment has been in operation.
The torque arm should be mounted to ensure that the contact surface between the drive and shaft are free from
9 excessive forces (Figure 10). Do not attach the torque arm using anti-rotation bolts. For applications that require
For units with a safety cover, reinstall the guard over the shrink disc. frequent starts and stops or frequent reversing, insert a rubber bushing (or spacer) between the torque arm and
securing bolt in order to dampen impact load as shown in (Figure 11).
Do not operate unit until the torque arm has been attached. Refer to
the Torque Arm Installation section in this guide for instructions. Fig. 10 Fig. 11
Torque Arm
Leave some
Spacer clearance

Table 3. Shrink Disc Size and Tightening Torque

Screw Size M5 M6 M8 M10 M12 M16

Flat washer No clearance between torque
Initial Torque 45 109 275 557 929 2327 Bolt or pin
arm and machine
in-lb (Nm) (5.1) (12.3) (31) (63) (105) (263)
Final Torque 43 105 266 531 885 2221
in-lb (Nm) (4.9) (11.8) (30) (60) (100) (251)
Correct Incorrect
Socket Size mm 8 10 13 17 19 24 Adjust clearance according to Excessive force on the torque
movement of machine arm bolt, machine and unit
may cause damage

12 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 13
T-Type Torque Arm Wiring
The Hyponic® T-type torque arm design allows for reversing rotation and can be mounted to accept loads in tension 1. Prior to wiring, refer to the name plate mounted to the motor portion of the Hyponic® unit. Check the power
or compression. Any of the mounting positions shown in Figure 12 are permissible. Table 5 shown below, mentions supply, interconnects, relays, protective starting devices (i.e, Star (Wye) delta - if reduced voltage starting is
the necessary components for a proper operation of the T-type torque arm. required), space heaters, thermal sensors and other accessories.

During the operation, the Hyponic® unit will rotate in the direction opposite to that of the driven shaft. 2. Be aware that long wiring may cause voltage drops.

Tighten both pairs of nuts against the mounting tab so that there is zero clearance between the rubber
bushings and the tab, but you can still rotate the rubber bushings by hand. Do not overtighten, but ensure Wiring Connections for Standard Motor Contactor
that the nuts in each pair are tightened securely against each other so vibration will not cause them to Models FB-01A1 through FB-15E, 230/460V, 60Hz or 575V, 60Hz
loosen. Be sure that the bottom of the mounting angle bracket is secured to a rigid surface.
Fig. 13-a Normal Brake Action, 230V or 575V Brake Fig. 13-b Fast Brake Action, 230V Brake

Fig. 12

Fig. 13-c Normal Brake Action, 460V Brake Fig. 13-d Fast Brake Action, 460V or 575V Brake

Table 5. T-Type Torque Arm Components

Item Quantity

Torque Arm 1 Key:

MC: Motor Contactor
Bolt, Hex Head 2 OLR: Overload or Thermal Relay
VR: Varistor (protective device, refer to Varistor Specification Table 6)
Washer, Lock 2
Nut, Hex, Coarse 2
Bushing, Rubber 3
Washer, T-Type 2

14 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 15
 VFD
Wiring Connections for VFD (Inverter) Table 6. Varistor Specification Table
Models FB-01A1 through FB-15E, 230/460V, 60Hz or 575V, 60Hz Operating Voltage 190-230V 380-460V 575V
Varistor Rated Voltage AC260-300V AC510V AC604V
Fig.14-a Normal Brake Action, 230V or 575V Brake Fig. 14-b Fast Brake Action, 230V Brake
Varistor Voltage 430-470V 820V 1000V
FB-01A1, 02A1, 05A1 Over 0.4W Over 0.4W Over 0.4W
FB-1E, 1D Over 0.6W Over 0.6W Over 0.4W
Rated Watt
FB-1HE, 2E, 2D, 3E Over 1.5W Over 1.5W Over 0.6W
FB-5E, 8E, 10E, 15E Over 1.5W Over 1.5W Over 1.5W

VFD VFD
VFD
Motor Operating Precautions
a. Always ground the motor terminal box or frame.
Fig. 14-c Normal Brake Action, 460V Brake Fig. 14-d Fast Brake Action, 460V or 575V Brake b. Insulation Resistance
Follow instructions supplied with the motor insulation tester. The insulation resistance value will vary depending on
the temperature, humidity, extent of contamination, the servicing period, test running time, as well as the motor out-
put, voltage and type of insulation. Therefore, the insulation resistance (r) cannot be expressed uniformly; however, it
should be equal to or greater than the value listed in Table 7.

Table 7. Insulation Resistance

Motor Voltage Megger Voltage Insulation Resistance (r)

VFD
Low voltage motor (≤ 600V) 500V Higher than 1 M Ω
VFD VFD

Key:
VR: Varistor (protective device, refer to Varistor Specification Table 6)

VFD

16 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 17
Operation Daily Inspection and Maintenance
Once the Hyponic® unit is installed, ensure that the wiring is correct and secure prior to operation. Observe the 1. Inspect the gearmotor daily for each of the items listed in Table 9.
precautions listed in Table 8 during the trial run. Stop running the gearmotor if any abnormalities are detected and 2. If any abnormalities are found during daily inspections, follow the procedures outlined in the Troubleshooting
contact your nearest sales office or distributor. Guide, Table 18 on page 32. If the abnormality is not listed or the recommended procedure does not solve the
problem, contact your nearest sales office or distributor.
3. The Hyponic® unit does not require grease replenishment, but overhauling after 20,000 hours of operation, or 3 -
Table 8. Trial Run Precautions 5 years will extend its life.
Observation Possible Cause
Table 9. Daily Inspection Items
Any abnormal 1. The casing is distorted due to an uneven mounting surface.
noises or 2. The gearmotor is resonant due to insufficient rigidity of the mounting surface. Items Details
vibrations 3. The shaft of the Hyponic® and the driven machine are not aligned.
4. Vibrations of the driven machine are conveyed to the gearmotor. Electric Current Is the electric current higher than the value specified on the nameplate?
5. Rigidity of the driven machine and its shaft is insufficient (hollow shaft type).
6. Excessive force is exerted on the baffle sections of the torque arm (hollow shaft
Noise Is the gearmotor making any unusual sounds?
type).
7. After the Hyponic® unit is flange or foot mounted, undue force is exerted between
the gearmotor and its shaft. Vibration Are there any unusual vibrations of the gear or motor frame?

Surface Temperature Is the surface temperature of the gear case, or motor frame too high or rising
Abnormally high 1. Motor electric current is exceeding the rated value specified on the nameplate.
suddenly? (The temperature rise during operation varies depending on the
temperature of 2. Is voltage applied between THREE motor connections equal to the motor
type of motor. There may be a problem, if the temperature frequently rises
the gear casing nameplate voltage rating ± 10%?
approximately 40°C (104°F) above the ambient temperature.)
or motor frame 3. The ambient temperature around the unit is too high.
surface.
Grease Leakage Is there any grease leaking from the gear assembly?

Mounting Bolts/Torque Arm Are there any loose mounting bolts?

Chains and V-belts Are there any loose chains or V-belts?

Brake Is the brake lining worn out?

Is the air gap within specification?

18 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 19
FB Brake Assembly - Inspection, Adjustment & Maintenance Fig. 15 FB-01A1, FB-02A1, FB-05A1 Models

No. Part Name

FB series brakemotors are designed to be mechanically rugged in design, electrically reliable and efficient in 1 Stationary Core*
operation. To maintain this reliable performance, the brake assembly must be inspected and adjusted periodically.
2 Pressure Spring*
This section of the manual pertains specifically to the brake portion of the Hyponic® unit and provides all the 3 Armature Plate*
necessary information to insure long and trouble-free service. 4 Brake Lining*
5 Brake Shoe*
6 Leaf Spring*
Brake Models FB-01A1, FB-02A1, and FB-05A1
7 Hub*
1. Standard Brakemotor Specifications 8 C-type Retaining Ring
Table 10 lists the standard specifications for Models FB-01A1, FB-02A1, and FB-05A1. 9 Cover
10 Set Screw (TEFC model only)
Table 10. FB-01A1, FB-02A1, and FB-05A1 Standard Specifications
11 V-Ring
Braking Delay Time (sec) Brake Work Capacity
Motor Capacity Standard Brak-
Brake
ing Torque Normal Braking Action
12 Fan (TEFC model only)
Model Fast Braking Allowable Gap Adjust Total
ft - lbs (N - m) Action E0 (J/min) (x 107 J) E1 (x 107 J) 13 Waterproof Cover
HP x 4P kW x 4P Standard Wiring Inverter Wiring[1]
14 Restraining Screw*
FB-01A1 1/8 0.1 0.7 (1.0)
0.15 ~ 0.2 0.08 ~ 0.12 0.015 ~ 0.02 15 Spacer*
FB-02A1 1/8 ~ 1/3 0.1 ~ 0.25 1.4 (2.0) 1080 2.6 6.7 16 Waterproof Seal
17 Solenoid Coil*
FB-05A1 1/4 ~ 1/2 0.2 ~ 0.4 2.9 (4.0) 0.1 ~ 0.15 0.03 ~ 0.07 0.01 ~ 0.015 18 Motor Shaft
19 Fan Side Bearing
Notes: Above table applies to standard brake specification under standard brake torque. Special brakes may perform differently from those shown. Initial
brake torque may be lower than specified brake torque. If this is the case, under light load start and stop the motor to wear-in the braking surface. To improve * These parts are included in a complete brake kit.
performance for positioning accuracy or lifting applications, consider using fast braking action circuit. If the brake is operated at a rate greater than the Allowable
Brake Work Capacity, E0, the brake performance may degrade or become inoperable.
[1] Also applies to wiring where brake is powered separately from the motor leads. b) Operating Principles
The brake is a (fail safe type) spring actuated type brake, which will release the brake mechanism when the solenoid
coil is energized and which will engage when the coil is de-energized.
2. Construction and Operating Principles
a) Construction When power is applied to the unit, the solenoid coil and the electric motor will energize, and the energized coil
Figure 15 illustrates the construction of the brake. The restraining screw (14) fastens the brake shoe (5) and spacer attracts the armature plate (3) against the tension of the pressure spring (2). As a result, the brake lining (4) will
(15) onto the stationary core (1). The armature plate (3) is kept form rotation by the restraining screw (14) but moves disengage, and the motor begins to run.
axially by electromagnetic attraction and the tension of the pressure spring (2). The brake lining (4) is fitted to the hub
(7) which is secured to the motor shaft with a key. The solenoid coil (17) is energized via a rectifier provided within the When the power is disconnected, the solenoid coil and the electric motor is de-energized. This causes the pressure
conduit box. spring (2) to actuate the armature plate (3) which in turn presses the brake lining (4) against the brake shoe (5) and
brings the motor to a quick stop.

3. Inspection
a) At regular intervals, check that:
• the unit is operating normally.
• the brake lining is not excessively worn (or gap G is normal).
• all the mounting screws are securely tightened.

20 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 21
b) Manual brake release procedure Brake Models FB-1D, FB-2D, FB-1E, FB-1HE, FB-2E, and FB-3E
FB-01A1, FB-02A1, and FB-05A1 brakemotors are equipped with a one touch release mechanism. To manually release
1. Standard Brakemotor Specifications
the brake with power to the unit turned off, pull the brake release lever up and out from its holder and push it forward
towards the reducer. Releasing the lever will re-engage the brake. Table 12 lists the standard specifications for Models FB-1D, FB-2D, FB-1E, FB-1HE, FB-2E, FB-3E.

Table 12. Models FB-1D, FB-2D, FB-1E, FB-1HE, FB-2E, FB-3E Standard Specifications

4. Gap Inspection Brake Motor Capacity

Standard Brak- Braking Delay Time (sec) Brake Work Capacity
ing Torque Normal Braking Action Fast Braking Allowable Gap Adjust Total
Model
The brake lining will wear after the unit has been used for a long period of time. Regularly check that gap G (Figure HP x 4P kW x 4P ft - lbs (N - m) Standard Wiring Inverter Wiring[1] Action E0 (J/min) (x 107 J) E1 (x 107 J)
15) is at an acceptable value. If the gap G become too large, the solenoid coil may fail to pull in the armature plate FB-1D 1/2 ~ 3/4 0.4 ~ 0.55 5.8 (7.5) 1620 7.0 33.1
and hence cannot release the brake, resulting in the unit remaining in a continuously braked condition. Follow these 0.2 ~ 0.3 0.1 ~ 0.15 0.01 ~ 0.02
FB-2D 3/4 0.55 11 (15) 2580 6.8 29.5
steps to inspect the brake gap:
FB-1E 1 0.75 5.5 (7.5) 0.25 ~ 0.45 0.15 ~ 0.25 2580 11.6 38.7
a) Remove cover (9).
b) Remove fan (12) by loosening set screw (10) (models FB-02A1 and FB-05A1). FB-1HE 1.5 1.1 8.0 (11) 0.45 ~ 0.65 0.25 ~ 0.35 0.01 ~ 0.03
3360 20.8 46.3
c) Remove waterproof seal (16). FB-2E 2 1.5 11 (15) 0.35 ~ 0.55 0.15 ~ 0.25
d) Insert a gap gage into the space between stationary core (1) and armature plate (3). Measure the gap size at
three appropriate circumferential points. FB-3E 3 2.2 16 (22) 0.75 ~ 0.95 0.4 ~ 0.5 0.02 ~ 0.04 5720 26.3 105.3

e) The gap needs to be adjusted if the values are close to the allowable limit listed in Table 11.
Notes: Above table applies to standard brake specification under standard brake torque. Special brakes may perform differently from those shown. Initial
Table 11. Brake Gap Size brake torque may be lower than specified brake torque. If this is the case, under light load start and stop the motor to wear-in the braking surface. To improve
performance for positioning accuracy or lifting applications, consider using fast braking action circuit. If the brake is operated at a rate greater than the Allowable
Gap value G, in. (mm) Brake Work Capacity, E0, the brake performance may degrade or become inoperable.
Brake Type
Spec. value Allowable limit [1] Also applies to wiring where brake is powered separately from the motor leads.

FB-01A1

FB-02A1 0.008 - 0.014 0.02

(0.20 - 0.35) (0.5) 2. Construction and Operating Principles
FB-05A1 a) Construction
Figure 16 illustrates the construction of the brake. The restraining bolt (16) fastens the brake shoe (8), gap adjusting
shims (17) and spacer (18) onto the stationary core (1). The armature plate (4) is kept from rotation by the restraining
5. Gap Adjustment bolt (16) but moves axially by electromagnetic attraction and the tension of the pressure spring (2). The brake lining
(9) is fitted to the hub (11) which is secured to the motor shaft with a key. The solenoid coil (19) is energized via a
If the brake lining is so heavily worn that gap adjustment is required, follow these steps:
rectifier provided within the terminal box.
a) Remove cover (9).
b) Remove fan (12) by loosening set screw (10) (models FB-02A1 and FB-05A1).
c) Remove waterproof seal (16).
d) Loosen restraining bolts (14), rotate the brake shoe completely counterclockwise, and re-tighten the restraining
bolts (14). After tightening the restraining bolts, measure the gap G to verify that it falls within the specification
value and the allowable limit shown in Table 10. (This procedure reduces the gap approximately 0.012 inch (0.30
mm).)
e) Check for brake performance by turning system power on and off a few times.
f) Reinstall waterproof seal (16) and fan(12).
g) Replace cover (9).

22 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 23
Fig. 16 FB-1D, FB-2D, FB-1E, FB-1HE, FB-2E, and FB-3E Models (E-Series Shown) When the power is disconnected, the solenoid coil and the electric motor are not energized. This causes the pressure
spring (2) to actuate the armature plate (4) which in turn presses the brake lining (9) against the brake shoe (8) and
No. Part Name
brings the motor to a quick stop.
1 Stationary Core*
2 Pressure Spring* 3. Inspection
3 Brake Release Support a) At regular intervals, check that:
4 Armature* • the unit is operating normally.
5 Shifting Pin • the brake lining is not excessively worn (or gap G is normal).
• all the mounting screws are securely tightened.
6 Brake Release Lever
7 Retaining Clip
b) Manual brake release procedure
8 Brake Shoe* FB-1D, FB-2D, FB-1E, FB-1HE, FB-2E and FB-3E brakemotors are equipped with a one touch release mechanism. To
9 Brake Lining* manually release the brake with power to the unit turned off, pull the brake release lever up and out from its holder
10 Leaf Spring*
and push it forward towards the reducer. Releasing the lever will re-engage the brake.

11 Hub*
12 C-type Retaining Ring 4. Gap Inspection
13 Cover The brake lining will wear after the unit has been used for a long period of time. Regularly check that gap G from
14 Retaining Ring time to time (Figure 16) is at an acceptable value. If gap G become too large, the solenoid coil may fail to pull in
the armature plate and hence cannot release the brake, resulting in the unit remaining in a continuously braked
15 Fan
condition. Follow these steps to inspect the brake gap:
16 Restraining Bolt*
17 Gap Adjusting Shims*
a) Remove shifting pin (5) and brake release lever (6).
b) Remove cover (13).
18 Spacer* c) Remove fan (15) by removing retaining ring (14).
19 Solenoid Coil* d) Remove waterproof seal (25).
20 Fan Side Bearing e) Insert a gap gage into the space between the stationary core (1) and armature plate (4). Measure the gap size at
three appropriate circumferential points.
21 Motor Shaft
f) Check for brake performance by turning system power on and off a few times.
22 Attachment Screw g) The gap needs to be adjusted if the values are close to the allowable limit listed in Table 13.
23 V-Ring
24 Waterproof Cover Table 13. Brake Gap Size

25 Waterproof Seal Gap value G, in. (mm)

Brake Type
26 Shock Absorber* Spec. value Allowable limit Gap Adjustment Shim Thickness
* These parts are included in a complete brake kit.
0.012 - 0.016 0.024 0.008 - 0.01
FB-1D, FB-2D
(0.3 - 0.4) (0.6) (0.2 - 0.25)
b) Operating Principles
The brake is a (fail safe type) spring actuated type brake, which will release the brake mechanism when the solenoid 0.01 - 0.014 0.024 0.008 - 0.01
FB-1E
(0.25 - 0.35) (0.6) (0.2 - 0.25)
coil is energized and engages when the coil is de-energized.
0.01 - 0.014 0.029 0.014 - 0.018
FB-1HE, FB-2E
When power is applied to the unit, the solenoid coil and electric motor will become energized, and the energized (0.25 - 0.35) (0.75) (0.35 - 0.45)
coil attracts the armature plate (4) against the tension of the pressure spring (2). As a result, the brake lining (9)
0.01 - 0.014 0.033 0.018 - 0.022
disengages, and the motor starts to run. FB-3E
(0.25 - 0.35) (0.85) (0.45 - 0.55)

24 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 25
5. Gap Adjustment Brake Models FB-5E, FB-8E, FB-10E, and FB-15E
If the brake lining is so heavily worn that gap adjustment is required, follow these steps: 1. Standard Brakemotor Specifications
a) Remove shifting pins (5) and brake release lever (6). Table 15 lists the standard specifications for Models FB-5E, FB-8E, FB-10E, and FB-15E.
b) Remove the cover (13). Remove fan (15) by removing retaining ring (14). Remove V-Ring (23) waterproof seal
Table 15. Models FB-5E, FB-8E, FB-10E, and FB-15E Standard Specifications
(25) and waterproof cover (24).
c) Measure the gap size to confirm the deviation from the specification value. The minimum adjustable setting is Brake Motor Capacity
Standard Brak- Braking Delay Time (sec) Brake Work Capacity
ing Torque Normal Braking Action Fast Braking Allowable Gap Adjust Total
no less than the thickness of the Gap Adjusting Shim shown in Table 13. Model
HP x 4P kW x 4P ft - lbs (N - m) Standard Wiring Inverter Wiring[1] Action E0 (J/min) (x 107 J) E1 (x 107 J)
d) Loosen the restraining bolt (16) and remove parts (16), (8), (17), and (18) as a set. Be careful not to remove only
FB-5E 5 3.7 30 (40) 1.1 ~ 1.3 0.4 ~ 0.5
the bolt (16) and lose the shims (17). 6900 57.4 382.8
e) Decrease the number of shims in use according to the degree of wear (Note: Retain the removed shims for use FB-8E 7.5 5.5 40 (55) 1.0 ~ 1.2 0.3 ~ 0.4
0.02 ~ 0.04
during the brake lining replacement procedure). Reassemble parts (16), (8), (17) and (18) as a set.
FB-10E 10 7.5 59 (80) 1.8 ~ 2.0 0.6 ~ 0.7
f) Once reassembled, check gap G. If the gap size is still too large, adjust the number of shims again. 10800 110.2 551.1
g) After completing the gap adjustment, turn the system power on and off a few times to check the brake FB-15E 15 11 80 (110) 1.6 ~ 1.8 0.5 ~ 0.6
performance. Notes: Above table applies to standard brake specification under standard brake torque. Special brakes may perform differently from those shown. Initial
h) Replace waterproof cover (24), waterproof seal (25), V-Ring (23), fan (15), retaining ring (14), cover (13), shifting brake torque may be lower than specified brake torque. If this is the case, under light load start and stop the motor to wear-in the braking surface. To improve
pins (5), and brake release lever (6). performance for positioning accuracy or lifting applications, consider using fast braking action circuit. If the brake is operated at a rate greater than the Allowable
Brake Work Capacity, E0, the brake performance may degrade or become inoperable.
[1] Also applies to wiring where brake is powered separately from the motor leads.
6. Brake Lining Replacement
Follow these steps to replace the brake lining when its thickness has reached the allowable limit shown in Table 14,
or when sleeve adjustment is no longer an effective means of gap adjustment:

a) Remove shifting pins (5) and brake release lever (6). 2. Construction and Operating Principles
b) Remove the cover (13). Remove fan (15) by retaining ring (14). Remove V-Ring (23) waterproof seal (25) and a) Construction
waterproof cover (24).
Figures 17-a and 17-b illustrate the construction of the brake. Among the brake parts, the stationary core (1),
c) Loosen the restraining bolt (16) and remove parts (16), (17), (18) and (8) as a set.
solenoid coil (20), and stud bolt (19) constitute an integral subassembly unit. The stud bolt (19) keeps the armature
d) Remove the brake lining (9), taking care to prevent the leaf spring (10) from coming off.
plate (4) from rotating, but the plate moves axially by electromagnetic attraction and the tension of the pressure
e) Install the new brake lining, taking care not to damage or remove the leaf spring (10). Ensure that the lining
spring (2). The adjusting washer (18) and spring washer (17) hold the brake shoe (8) against the nut (16) at all times.
moves smoothly along the hub (11).
The brake lining (9) is fit to the hub (11), which is secured to the motor shaft with a key.
f) Replace any gap adjusting shims removed and retained from previous gap adjustments. Then reinstall parts
(16), (17), (18) and (8) as a set.
g) Measure gap G. Readjust if the gap is not within the specification value range.
h) Turn the system power on and off a few times to check the brake performance. If no abnormalities are detected,
replace waterproof cover (24), waterproof seal (25), V-Ring (23), fan (15), retaining ring (14), cover (13), shifting
pins (5) and brake release lever (6).

Table 14. Brake Lining Size

Initial Thickness Allowable Thickness

Brake Type Brake lining dimension
t0, in. (mm) t0, in. (mm)

FB-1D 0.276 (7.0) 0.236 (6.0)

FB-2D, FB-1E 0.347 (8.8) 0.307 (7.8)

FB-1HE, FB-2E, FB-3D 0.354 (9.0) 0.315 (8.0)

FB-3E 0.398 (10.4) 0.331 (8.4)

26 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 27
Fig. 17-a FB-5E and 8E Models Fig. 17-b FB-10E and 15E Models

No. Part Name No. Part Name

1 Stationary Core* 1 Stationary Core*
2 Pressure Spring* 2 Pressure Spring*
3 Brake Release Support 3 Brake Release Support
4 Armature* 4 Armature*
5 Shifting Pin 5 Shifting Pin
6 Brake Release Lever 6 Brake Release Lever
7 Retaining Clip 7 Retaining Clip
8 Brake Shoe* 8 Brake Shoe*
9 Brake Lining* 9 Brake Lining*
10 Leaf Spring* 10 Leaf Spring*
11 Hub* 11 Hub*
12 C-type Retaining Ring 12 C-type Retaining Ring
13 Cover 13 Cover
14 C-type Retaining Ring 14 C-type Retaining Ring
15 Fan 15 Fan
16 Gap Adjusting Nut* 16 Gap Adjusting Nut*
17 Spring Washer 17 Spring Washer
18 Adjusting Washer* 18 Adjusting Washer*
19 Stud Bolt* 19 Stud Bolt*
20 Solenoid Coil* 20 Solenoid Coil*
21 Fan Side Bearing 21 Fan Side Bearing
22 Motor Shaft 22 Motor Shaft
23 Attachment Screw 23 Attachment Screw
24 V-Ring 24 V-Ring
25 Waterproof Cover 25 Waterproof Cover
26 Waterproof Seal 26 Waterproof Seal

* These parts are included in a complete brake kit. * These parts are included in a complete brake kit.

b) Operating Principles
The brake is a (fail-safe type) spring actuated type brake that releases the brake mechanism when the solenoid coil is
energized and engages when the solenoid coil is not energized.

When power is applied to the unit, the solenoid coil and electric motor become energized and the energized
coil attracts the armature plate (4) against the tension of the pressure spring (2). As a result, the brake lining (9)
disengages and the motor starts to run.

28 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 29
When the power is disconnected, the solenoid coil and electric motor are not energized. This causes the pressure 5. Gap Adjustment
spring (2) to actuate the armature plate (4), which in turn presses the brake lining (9) against the brake shoe (8) and If the brake lining is so heavily worn that gap adjustment is required, follow these steps:
brings the motor to a quick stop.
a) Remove shifting pins (5) and brake release lever (6).
3. Inspection b) Remove the cover (13). Remove fan (15) by removing retaining ring (14). Remove V-Ring (24) waterproof seal
(26) and waterproof cover (25).
a) At regular intervals, check that: c) Insert a gap gage into the space between the stationary core (1) and armature plate (4) and rotate the nut (16) at
• the unit is operating normally. the tip of the stud bolt (19) clockwise until the gap measures an appropriate size. If the gap is too large to adjust
• the brake lining is not excessively worn (or gap G is normal). by this procedure, decrease the number of adjusting washers (18) in use. Evenly adjust the three nuts (16) until
• all the mounting screws are securely tightened. the gaps at the three circumferential points are equal and fall within the specification range shown in Table 16.
d) After completing the gap adjustment, turn the system power on and off a few times to check the brake
b) Manual brake release procedure performance.
FB-5E, FB-8E, FB-10E, and FB-15E brakemotors are equipped with a one-touch release mechanism. To manually e) Replace waterproof cover (25), waterproof seal (26), V-Ring (23), fan (15), retaining ring (14), cover (13), shifting
release the brake with power to the unit turned off, pull the brake release lever out from its holder and push it forward pins (5), and brake release lever (6).
toward the reducer. Releasing the lever will re-engage the brake.
6. Brake Lining Replacement
Follow these steps to replace the brake lining when its thickness has reached the allowable limit shown in Table 17,
4. Gap Inspection or when sleeve adjustment is no longer an effective means of gap adjustment:
The brake lining will wear after the unit has been used for a long period of time. Regularly check that gap G (Figures
a) Remove shifting pins (5) and brake release lever (6).
17-a and 17-b) is at an acceptable value. If gap G becomes too large, the solenoid coil may fail to pull in the armature
b) Remove the cover (13). Remove fan (15) by retaining ring (14). Remove V-Ring (24) waterproof seal (26) and
plate, and hence cannot release the brake, resulting in the unit remaining in a continuously braked condition. Follow
waterproof cover (25).
these steps to inspect the brake gap:
c) Remove all three nuts (16)
a) Remove shifting pin (5) and brake release lever (6). d) Remove the brake shoe (8) and take out the brake lining (9).
b) Remove cover (13). e) Fix the leaf spring (10) as shown in Figure 18.
c) Remove fan (15) by removing retaining ring (14). f) Apply a small amount of grease along the spline of the new brake lining (9), taking care not to apply any to the
d) Remove waterproof seal (26). wear surface.
e) Insert a gap gage into the space between the stationary core (1) and armature plate (4). Measure the gap size at g) Fit the new brake lining (9) onto the hub (11) and check that it moves smoothly. Remove any excess grease.
three appropriate circumferential points. h) After reassembling the brake, measure gap G. If the gap is out of the specification range, adjust by rotating the
f) Check for brake performance by turning system power on and off a few times. gap adjusting nut (16).
g) The gap needs to be adjusted if the values are close to the allowable limit listed in Table 16. i) Turn the system power on and off a few times to check the brake performance. If no abnormalities are detected,
replace the fan (15), retaining ring (14) and cover (13).
j) Measure gap G. Readjust if the gap is not within the specification value range.
Table 16. Brake Gap Size k) Turn the system power on and off a few times to check the brake performance. If no abnormalities are detected,
Gap value G, in. (mm) replace waterproof cover (25), waterproof seal (26), V-Ring (24), fan (15), retaining ring (14), cover (13), shifting
Brake Type pins (5) and brake release lever (6).
Spec. value Allowable limit
0.040
FB-5E, FB-8E Table 17. Brake Lining Size
(1.0)
0.014 - 0.017
(0.35 - 0.45) 0.047 Fig. 18 Leaf Spring
FB-10E, FB-15E Brake lining Initial Thickness Allowable Thickness
(1.2) Brake Type
dimension t0, in. (mm) t0, in. (mm)

0.394 0.236
FB-5E, FB-8E
(10.0) (6.0)

FB-10E, FB-15E
0.433 0.276 Leaf Spring
(11.0) (7.0)

30 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 31
Troubleshooting Table 18. Quick Troubleshooting Guide (cont.)

Problem Possible Cause Corrective Action

The Hyponic® unit is running normally when it meets the following criteria:
Starts in either
Three phase is operating as single- Check the power source with a
1) The motor begins to run immediately after the start switch is moved to the ON position. direction when
phase voltmeter.
2) The unit does not make any abnormal sounds during operation. turned by hand
3) The motor stops running within about 0.5 seconds after power to the unit is switched off. Repair by rewinding or replacing stator
Load is Stator coil open
assembly.
disconnected
Table 18. Quick Troubleshooting Guide but motor
doesn’t rotate Power failure Contact the power company.
Doesn’t make
Problem Possible Cause Corrective Action (cont.) any noise Outside the Open connection
Check the source wiring.
Load exceeds the capacity of the Check rated capacity of the Hyponic®; replace motor wire
Overloading
Hyponic® with unit of sufficient capacity or reduce load.
Runs Hot Faulty starter
Replace contact.
Improper Flush out and refill with correct lubricant as contact
Wrong lubricant
lubrication recommeded. Rotates in the Change any two of the three-phase
Connection error
wrong direction source.
Loose Inspect mounting of Hyponic®. Tighten loose
Weak mounting structure
Foundation bolts and/or reinforce mounting structure.
Fuse blows Shorted lead wire Replace.
bolts /
Torque Arm Loose bolts Tighten bolts.
Speed doesn’t
HYPONIC®

Vibration or Faulty starter contact Replace contact.

noise increase
May be due to lack of lubricant Replace unit. Rotates with

MOTOR (cont.)
Failure of the load Overcurrent Rotor and Repair by winding or replacing stator
bearings disconnected, Overheating stator touching assembly.
Check rated capacity of Hyponic®, replace with
Overload but:
unit of sufficient capacity or reduce load. Groans
One phase
Overloading of reducer can cause Replace broken shaft. Check rated capacity of Overcurrent of stator coil Replace the stator winding.
damage Hyponic®. shorted
Motor shaft
Output shaft broken Key missing or sheared off on Makes a high
Replace key. pitched metallic Faulty bearing Replace the bearing.
does not turn input shaft
noise
Motor Refer to Motor section of Troubleshooting
Motor Replace with one having the rated
doesn’t turn Guide. Insufficient switch capacity
Switch capacity.
Faulty switch contact Replace contact. overheats
Overload Drop to the rated load.
Blown fuse Replace. Replace with one having the rated
Rotates Fuse blows Insufficient fuse capacity
Load is capacity.
MOTOR

Makes a One phase wire of the power when the

disconnected Replace.
groaning supply open load is dis-
but motor Overload Drop to the rated load.
sound connected Overheats
doesn’t rotate Repair by rewinding or replacing stator but when
Stator coil open
assembly. the load is Voltage drop Consult with the power company.
Stator and rotor touching due to connected:
Replace the bearing and bracket. Voltage drop Consult with the power company.
bearing housing wear Speed suddenly
drops
Overload Drop to the rated load.

Stops Bearing damaged by overheat Replace the bearing.

32 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 33
Table 18. Quick Troubleshooting Guide (cont.)

Problem Possible Cause Corrective Action

Improper adjustment after

Brake fails to operate Adjust again.
reassembly

Not wired for fast action Wire for fast action.

Foreign matter entrapped in brake lining. Remove foreign matter and take preventive
Brake slips Oil on lining surface action. Wipe lining surface with a dry cloth.
(Braking time is too
long) Worn brake lining Adjust brake gap or replace lining.

Uneven brake gap Adjust evenly.

Excessive load Decrease load or use larger brake.

Faulty electric circuit Check circuit.

Blow fuse Replace fuse.

Only single phase available from three Measure power supply voltage and check for
phase power supply defective circuit.

Protective device has tripped Eliminate cause and reset.

Rotor fails to turn Damaged or burned motor winding Repair or replace.

BRAKE

Rust on brake friction surface Clean brake (lining).

Gap needs adjustment Readjust gap.

Burned bearing Replace.

Replace. Check and troubleshoot load and

Overload
safety device.

Examine inside brakemotor and remove foreign

Foreign material inside the brakemotor.
material.

Damaged bearing Replace.

Abnormal noise Worn brake lining Adjust brake gap or replace lining.

Hub leaf spring is off or damaged Replace.

Burned solenoid coil Replace.

Damaged rectifier Replace.

Voltage drop Raise voltage to rated level.

Trouble under loaded Overload Reduce the load or oversize the brakemotor.
condition
Improper protective device setting Adjust protective device.

34 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 35
36 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 37
Notes Notes

38 Hyponic® Operating and Maintenance Manual www.SumitomoDrive.com Hyponic® Operating and Maintenance Manual 39
Headquarters & Manufacturing

4200 Holland Boulevard

Chesapeake, VA 23323
Tel: 757-485-3355 • 1-800-SMCYCLO
Fax: 757-485-7490

www.sumitomodrive.com
E-mail: sma.service@shi-g.com

After Hours Technical Support

Tel: 1-800-983-1000

www.sumitomodrive.com/Hyponic

World Headquarters
For facilities located in the Americas, please visit
Japan www.sumitomodrive.com/locations
Sumitomo Heavy Industries, Ltd.
Power Transmission & Controls Group
ThinkPark Tower, 1-1, Osaki 2-chome, For worldwide locations, please visit
Shinagawa-ku, Tokyo 141-6025 Japan
Tel: +81-36-737-2511 • Fax: +81-36-866-5160 www.sumitomodrive.com/worldwide

07.020.60.002 Hyponic O&M 2019; Supersedes Manual 07.020.60.001

40 Hyponic® Operating and Maintenance Manual ©2019 Sumitomo Machinery Corporation of America