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Instruction Manual Safe Operation

1. eReference In case of coupling via chain 6 should be within 2 of the roller chain pitch and 6 should be within 1 2 Attaching Chains V Belts Gears etc 1 The center of the shaft of the reducer and that of the other equipment should be parallel 2 The tension of Chains of V Belts must be perpendicular to the center of the shaft 3 Excessive tensioning of the chain or V belt may result in damage to the bearings of the shaft 4 If the chain is too loose or slack shock loading will occur when the drive shaft starts rotation This can result in damage to the reducer and or the equipment Therefore adjust the tension of the chain properly Proper Installation e he tension of V belt and chain are properly set e The pulley and sprocket are properly positioned on the gearmotor shaft The chain V belt is as close to the gearmotor output shaft bearing as possible This minimizes overhung load and promotes longer bearing life Improper Installation e The Chain is too loose e The sprocket is applied to the shaft improperly The chain or V belt is set too far from the gearmotor output shaft bearing This may lead to excessive overhung load OHL and shortens bearing life 6 3 Attaching Detaching a Driven Shaft to from F or F3 Type Hollow Shaft eAttaching a Driven Shaft to the Reducer Hollow Shaft 1 Apply an extreme pressure agent such as molybdenum disulfide on the surface of driven shaft and the bore o
2. The earth terminal lead wire or lug is properly grounded Note When using a water resistant IP 65 motor in the circumstance where water may be persistently present during operation it is recommended to use ground fault circuit interrupter for safety 2 Check these issues during the initial test run 1 Confirm the direction of rotation for 1 2 seconds by starting the motor in the unloaded condition If you find improper rotational direction change the wiring 2 Test run the gearmotor with the machine in an unloaded condition When no defect is observed add load gradually and eventually start operation under the full load 3 Check these issues during operation 1 Confirm there is no abnormal noise and or vibration Stop operation of the gearmotor immediately if abnormal noise or vibration occurs Failure to observe this warning may cause physical injury and or damage to the equipment 2 Confirm if the surface temperature of the gear case and motor frame does not exceed 176F 80 C Do not touch the surface of the gearmotor with your bare hands Failure to observe this warning may cause a burn injury 21 8 Inspection and Adjustment eWhen inspecting and or adjusting the machine while it is in operation do not touch rotating parts such as a shaft Failure to observe this warning may cause physical injury eDo not attempt to disassemble the gearmotor while it is in operation Lubricant may blow out and cause a bu
3. Induction motor LI i E L4 he LI sA mE 7 k r n4 Lf 444 i 1 3 1 MEE n i E jw d lm1d Lj uil M lt 735 in Ib M lt 825 in Ib M lt 300 in Ib C in Length from reducer flange to center of motor W Ib Weight of the motor in lbs 1 The limit of vibration that a gear reducer can withstand is 0 5G If the vibration is greater than 0 5G or if the motor mass limit is above the M limitation the casing of the reducer and or the reducer flange may be damaged The motor may fall off the reducer and cause injury of damage the equipment The motor should be supported by a separate device supplied by the user for safety 2 Before using other manufacturer s motors with our reducer you should carefully read this Instruction Manual and understand the contents The failures of a reducer caused by poor installation will not be warranted 11 5 Direction of Rotation G3 Series 1 8 Hp 14 Hp 2 Hp 1 Hp 2 Hp 3 Hp 60 1 to 200 1 Counter Direction 40 1 to 200 1 Counter Direction H2 Series 1 8Hp 1 Hp 5 1 6 0 1 amp 600 1 15001 1 8Hp 1 Hp 80 1 450 1 Hp 1HP 5 1 60 1 amp 300 1 15001 5 Hp 1 Hp 80 1 240 1 2Hp 3Hp 5 1 3 0 1 2 Hp 3 Hp 40 1 240 1 F Series 1 8Hp 4 Hp Hp 1 Hp 5 1 6 0 1 amp 300 1 45 0 1 1 8Hp Hp Hp 1 Hp 80 1 240 1 2Hp 3Hp 5 1 30 1 2 Hp 3Hp 40 1 240 1 12 F3 Series 1 8 Hp 5 1 60 1and 300 1 150 0 1 V4 Hp 5 1 60 1and 300
4. Law These Standard terms and Conditions of Sale shall be interpreted in accordance with the Laws of the State of New Jersey Severability If any of the terms and Conditions shown here are determined to be invalid illegal or unenforceable the remainder of these Terms and Conditions shall remain in full force and effect 29 If you have any questions or concerns about our product please contact the dealer or distributor from who purchased or contact the sales office of Brother International Corporation BROTHER INTERNATIONAL CORPORATION 100 Somerset Corporate Boulevard Bridgewater NJ 08808 Phone 866 523 6283 Fax 908 575 3743 E mail gearmotors brother com www brother com 2009Mid Ver 1
5. Recommended Dimensions of the Shaft from the Shoulder Inch Dimension Bore Metric Dimension Bore Bore Shaft Inch Dimension Bore Shaft Metric Dimension Diameter O D Key Diameter D Inch in in in in in in Metric mm mm mm mm mm 0 7500 9 99 0 945 3 125 1 500 0 1875 0 1875 1 4 20x0 50 20 20h 24 30 M6X12 0 0 0 0008 l l i j Pu d 1 0000 in 1 6875 Lm 1969 5375 3 375 0 3750 0 3750 a e 16x0 75 45 h M10X20 40 0 0 0010 i i i 7 1 9375 cM 2465 5375 3 938 0 5000 0 5000 7 16 14x1 0 50 h M12X24 40 0 0 0010 i 7 2 0000 in Note Refer to the product catalog for Dimensions L and P Flange surface Shoulder L3 L2 Figure 6 Recommended Dimensions of the Driven Shaft Designing your Own Shaft The usable key length L3 should be greater than 1 5X the diameter of the driven shaft The Key should be engaged with at least half of the length L1 The minimum length of shaft engaged inside the bore is approximately L L1 L1 P 2 For dimensions L and P refer to the product catalog the www or request a drawing from Brother or your Brother distributor The recommended dimension L2 is not essential If your application requires a different length or if you prefer a different method of securing the shaft it may be acceptable for your application 10 Removing the Shaft from the Hollow Bore Avoid applying excessive force to the casing
6. Spring 2 6 Nut 7 Key 8 Hexagon socket head bolt 8 Brake cover O ring 11 Brake cover Setscrew amp Gap Gap g Data water resistant IP 65 Motors Three Phase Motor Horsepower 1 8 Hp Motor 14 Hp Hp 1 Hp Allowable Gap g mm less than 0 8 1 Field 2 Armature 3 Friction Disk 4 Spring 1 5 Spring 2 6 Nut Key 8 Hexagon socket head bolt 8 Brake cover 0 O ring 7 Brake cover fixing screw 42 Oil seal 13 V seal 14 Fan 15 Hexagon socket head locking screw 18 Fan cover 47 Fan cover fixing screw g Gap Proper Gap g V4 Hp Hp less than 0 7 0 30 0 1 1 Hp less than 0 9 0 30 0 1 25 4 Warning Label A warning label is attached to a gearmotor equipped with a brake that has a manual release lever If the label peels off or becames hard to read contact Brother or your brother distributor for a replacement label 5 Grease Oil seal and O Ring 1 All of our gearmotors employ grease lubrication They are filled with a determined quantity of lubricant before shipping from our factory 2 Replacement or refill of the lubricant is not necessary However replacing it once every 10 000 hours may help prolong the life of the reducer If you need to replace the lubricant be sure to use factory authorized grease and consider using our facility in the USA 3 Our machines are protected from grease leakage by an oil s
7. any way been tampered with or altered by anyone other than an authorized representative of Brother 5 Expenses incurred by the Purchaser in an attempt to repair or rework an allegedly defective product 6 Product damaged in shipment or otherwise without the fault of Brother eS Returns No product will be accepted for return unless authorized in writing with a returned merchandise authorization RMA number assigned Any returned goods must be returned with transportation charges prepaid Regulatory Laws and or Standards It is the Purchaser s obligation to install and operate all Brother gearmotor products in conformance with all applicable national or local laws and safety codes Patents Brother represents that its gearmotors are designed and manufactured such that they do not infringe on any United States Patent s and that Brother will at its expense defend any claim charging such infringement and will save Purchaser harmless from any adverse judgments resulting there from Purchaser agrees to give Brother prompt written notice of any claim of infringement and to turn over to Brother the complete control of any litigation involving such claims including the right to settle such claims This indemnity does not apply to Products which are incorporated by the Purchaser into Products which are changed to infringe a Patent or to Product which is used by Purchaser in performance of a method or process which is charged to infringe a Patent
8. of the earth wire should be AWG16 1 25mm minimum for 1 Hp 2 Hp or 3 Hp motors The earth wire should be longer than the lead wire of the power source of the motor Wiring a Gearmotor For standard gearmotors the wiring described below is recommended The direction of rotation referenced is as viewed from the back of the motor Counter clockwise is the forward direction for 3 phase motors Clockwise is the forward direction for single phase motors Three Phase Motors 1 8 Hp 4 Hp 1 2Hp 1 Hp 2 Hp 3 Hp 208 230V 460V 15 Single Phase Motors 1 8 Hp Permanent Split Capacitor Type 115V 220 230V Capacitor C used with PSC Type Motor e1 8 Hp single phase motors are permanent split capacitor PSC type motors The starting torque of a PSC motor is 80 85 ePSC motors use a capacitor that remains in the circuit permanently The capacitor needs to be mounted separately by the User eBe careful not to substitute an intermittent duty starting capacitor for use with a PSC motor Consult brother if you are unsure A4 eThe capacitor Voltage is 2X that of the Motor Voltage because the 115V 220V 24 uFd voltage across the capacitor terminals will become nearly 2X that of the input voltage Single Phase Motors 14 Hp Hp Capacitor Start type U black Vired dila X blue Motor gt Xblue Motor i wed N TN A an SOUNOS JaMwog te 16 Wiring a Gearmoto
9. rotating bore If you cannot secure the safety cover supplied please prepare a cover yourself Failure to cover the exposed rotating bore may result in damage to the equipment or injury Driven shaft without a shoulder Fixing the driven shaft between the pilicws E7777 7 7L E F x X DR I aui pei BuneuuoA in unt a Hn Iu aria 4 BN P MEM Ss N Figure 4 Fixing by spacer and snap ring Spacer positioning spacer bolt and snap ring are not supplied by Brother Note The positioning spacer should not have a tight fit It should have a loose fit and be concentric such that it does not interfere with the D of the bore as it rotates Excessive tightness or inaccuracy of the spacer s diameter may be a cause of rubbing interference with the bore The positioning spacer is usefull when the resulting position of the driven shaft is not known In case the length of the driven shaft is precisely known the positioning spacer is not necessary A properly applied positioning spacer does promotes easier removal of the shaft from the bore eRecommended Size for Securing Parts Inch E Bore BM D Bore Bore Bore D I D O D I D mm Internal External mm Internal External in in in E ES PI 0 7500 7500 114 20x0 75 20X0 75 A22 20x1 25 EN T3 028 28 0425 125 wexe Mex30 L type snap nng Figure 5 Recommended Size of Securing Parts
10. 1 000m max Environment Standard Type Well ventilated free from vapor and dust IP 65 Type Well ventilated free from vapor Note In a hazardous environment where any explosive and flammable gases exist use an explosion proof motor Installation Location Indoors 2 Direction of Installation This product can be installed in any direction and any angle due to a grease lubrication system 4 3 Method for Installation Tightening Torque for Torque Arm a Mounting a foot or flange type with a shaft Fixing Hole Metric Tightening Fixing Tightening eSecure the product with four bolts on a flat and Metric Bolt Torque N Hole Torque machined surface free from vibration mm eRoughness of the mounting surface should be less than 0 3mm b Mounting a hollow bore shaft mount type eThe driven shaft should be large enough and supported such that it can handle the weight of the gearmotor or reducer eForces other than the turning or reactive force should not be imposed on the torque arm eFor frequent start stops or forward reverse secure the torque arm with bolts to keep it axially secure 4 Ventilation Around the Gearmotor Any Reducer Type Applies eae T G3 H2 F or F3 Minimum Dimension A for Proper Ventilation Horno wor Phase 3 Phase 3 Phase Motor Motor The 1 Hp 2Hp and 3 Hp are not available in 1 Phase Note The dimension A is the space required for ventilation and for easy removal of t
11. 1 1200 1 V5 Hp 5 1 60 1and 300 60 0 1 1Hp 5 1 60 and 30 0 1 1 8 Hp Hp Hp 1 Hp 2 Hp 80 1 240 1 2Hp 3Hp 5 1 6 0 1 3 Hp 80 1 120 1 6 Wiring 1 Direct Connection lt DANGER eWhen connecting power to the machine follow the instructions shown on the connection diagram in the terminal box or in this Instruction Manual Failure to observe this warning may cause electric shock or fire e o not bend pull or tuck motor cables or lead wires forcibly Failure to observe this warning may cause electric shock eBe sure to ground the earth terminal lead wire or lug Failure to observe this warning may cause electric shock eBe sure to use the power source specified on the name plate Failure to observe this warning may cause the motor to burnout and or fire eAvoid exposing the power rectifier or capacitor to water Failure to observe this warning may cause electric shock damage to the equipment or fire 13 N CAUTION e1 8 Hp single phase motors have a thermal protector is built in If you suspect the thermal protector has tripped switch off the power to the gearmotor and or the machine before attempting any inspection e 1 8 Hp single phase motors trip temperature is 120 C 5 C Reset temperature under 105 C The gearmotor will be hot if the thermal has tripped Do not touch it with your bare hand as this will cause a burn injury e Do not touch the terminals or un insulated wire connections when inspectin
12. GTR MID GEARMOTORS 1 8 Hp 1 4 Hp 1 2Hp m 1 Hp m 2 Hp 3 Hp Instruction Manual oafe Operation e The Gearmotor should be operated by a skilled and qualified person The contents of this Instruction Manual should be carefully read and understood before operating this product eThis Instruction Manual should be accessible to the person who operates this product eThis Instruction Manual should be kept in a convenient place for the operator s easy reference Manufacturer Brother International Corporation Address 100 Somerset Corporate Blvd Bridgewater NJ 08807 TEL 866 523 6283 FAX 908 575 3743 E MAIL gearmotors brother com WEB www brother com Thank you for your purchasing this product Potential injuries and or damage caused by mishandling equipment are classified into two categories Danger and Caution The definitions of the classifications are given below with the corresponding graphic symbols O Mishandling the equipment may result in a dangerous situation and Danger may lead to serious or fatal injury to personnel AN Mishandling the equipment may result in a dangerous situation and CAUTION may lead to medium to light injury or damage to the equipment Please be aware that even items marked with CAUTION may cause fatal accidents Therefore be sure to follow the instruction for every item described is very important 4 DANGER eUse an explosion proof motor when any explosive or flammable gases a
13. The above diagrams are not suitable 5 Cautions for Operation with an Inverter VFD 1 Compared to operation using a general power source higher temperature rise noise and vibration may be observed when using an inverter 2 Low speed low frequency operation naturally reduces the cooling effect of the fan This may cause abnormal temperature rise Please use caution and check to if the surface temperature remains below allowable levels 176F 80C 3 When driving a gearmotor equipped with a brake the brake may malfunction due to voltage drop caused by normal operation of the inverter VFD if the rectifier is powered by the output side of the inverter VFD To avoid this it is imperative to bypass the inverter when wiring the brake See the special wiring diagrams for use with inverters VFd in this manual 4 When using a 460V inverter VFD it is recommended that a suitable filter or reactor be used to suppress excessive repetitive voltage spikes caused by the normal operation of a 460V inverter VFD Failure to take this precaution may result in premature burn out of the motor and breakdown of the motor insulation Please consult the inverter manufacturer for the proper size of the filter or reactor as it depends on the inverter parameter settings length of wire etc 5 When using a 460V inverter with a brake do not tap the motor windings to power the rectifier T8 T5 T9 T6 Due to voltage drop caused by normal operation of t
14. and or the hollow shaft Smooth detachment can be obtained by using a jig as shown in the figure below The convexity part is for the fixing part of the spacer Key Te Disk Snap ring i Cross section of the spacer Bolt By tightening the bolt output shaft comes out Figure 7 Jig for Removing the Shaft Spacer w tap disk bolt and snap ring are not supplied by Brother Attaching a Motor to a NEMA 56C Reducer eAttaching Procedure Attaching 1 Confirm the key is securely inserted in the key slot of the motor input shaft flange T pem 2 Align the keyway of the motor with the keyway of the reducer input bore Ir ill r ff Y Gently insert the shaft into the reducer bore JEH E i i 3 Confirm the motor shaft is securely inserted with the key fully engaged pinion ae E Jj 4 Secure the motor to the reducer using 4 flange bolts bolts not provided by Brother eCautions when Attaching the Motor 1 Wipe off any rust and dust and apply and anti seizing agent to the motor shaft 2 When inserting the motor shaft do not hit the motor or reducer with a hammer nor forcibly insert the motor shaft 3 Take advantage of the tightening force of the bolts to fully insert the shaft if required Failure to observe this warning may cause damage to the bearing and or abnormal noise 4 Observe the motor weight limit guidelines shown in the Table eMotor Mass Limit Guideline
15. eal and or o ring While our sealing is highly reliable it is recommended to protect the machine with an oil pan for safety Grease leakage may be observed when machine is in trouble or at the end of a long life 4 The life of oil seal will vary according to the condition of use Therefore replacement under severe conditions may be needed within 10 000 hours of use If you need to replace the oil seal be sure to use a factory authorized part Repair service from the factory is available as well 9 Troubleshooting 1 Trouble Shoting a Gearmotor no brake Failure of Power Supply Check the Power Source Bad Wire Connections Check the Electric Circuit Failed Contact Switch Repair Replace the Relay Motor Does Not Run in the Disconnected Stator Coil Repair at Auth Facility Unloaded Condition 3 phase Motor Running 1 phase Check the Terminal Voltage Capacitor Not Connected 1 8 Hp 1 Phase Connect the Capacitor Governor Switch Malfunction Repair at Auth Facility Broken Gear Shaft Bearing Repair at Auth Facility Voltage Drop Check the Length of Wire Motor Does Not Run in the n Worn Out Gear Repair at Auth Facility Loaded Condition Overload Tripped Reduce the Load Overload Tripped Reduce the Load High Frequency of Starts Stops Reduce the Freq of Starts Stops Abnormal Temperature Damage to Bearings Repair at Auth Facility Overvoltage or Undervoltage Check the Voltage Defective Bearing or Worn Out Gear Repair at Auth Facility Abnornal No
16. erature Thermometer Less then 176F 80C No lubricant leaking from the casing joints rotor Grease Leakage Visual fan extension terminal box lead wire grommet cord exit or output shaft seal 2 Periodic Inspections In case of operating 8 hours a day Check tension loose or tight and adjust to proper tension More than 1MOhm when insulation resistors is 500V TS 1 Year or Check if the gap is within the allowable limit Refer to Page rake Ga E 171 5 Million Cycles 21 Adjust as instructed Check the thickness of the friction disk Replace if the disk is Brake Friction Disk less than 1 5 mm Consult Brother or your brother dealer for a replacement friction disk When any abnormality is found during the daily inspection take proper measures to correct the situation 3 Brake Gap g Adjustment for a Brake Equipped Gearmotor gt DANGER 1 When adjusting the gap disconnect the motor from the power source Failure to observe this warning may cause physical injury 2 After inspection and adjustment of the gap be sure to confirm the brake functions properly Failure to observe this warning may cause an accident or allow the machine to run out of control 3 After inspection and adjustment of the gap do not operate the motor with the fan cover or brake cover open Failure to observe this warning may cause physical injury Note Brake Gap g Adjustment After operation for an extended period of time the fr
17. f the hollow shaft to avoid seizing 2 If the load is uniform low impact a loose fit is recommended for the tolerance of driven shaft 3 If a shock load or heavy radial load will be applied to the shaft the fit should be tighter 4 If the fit is tight tap on the end of the hollow drive shaft gently with a plastic or wooden hammer Do not to hit the gear casing 5 If the fit is extremely tight smooth insertion can be achieved if you prepare a jig shown in the figure below 6 The length of the driven shaft and the fixing key should be positioned within the space where the bore tolerance is tight The key should not be seated in the central relief area where the bore is larger Key eee i Hallow shalt i aa Deven Shat V e i i pe 4 ALN 2 Mut Output shaft can be inserted A ft d by tightening the nut SS ay E p Figure 1 Spacer nut bolt key and jig parts are not supplied by Brother eConnecting Reducer with Driven Shaft Dri kh Figure 2 Fixing by spacer and snap ring Spacer nut bolt key and jig parts are not supplied by Brother Note Excessive tightening of the bolt may cause the deformation of the snap ring Fixing the driven shaft between the plows LPA Dumas o pou Figure 3 Fixing by End plate End plate and bolt parts are not supplied by Brother A plastic bore cover is supplied with each FS F2S or F3S type unit to cover the exposed
18. g the insulation resistance Failure to observe this warning may cause electric shock eWires should be connected properly using the specified electrical standard or safety code Failure to observe this warning may cause electric shock fire or physical injury eThree phase motors are not equipped with thermal protective devices Other protective devices such as a circuit breaker fuse or thermal relay are recommended If CE is required a thermal relay certified for use in Europe should be used The thermal set value should be the same as the current value specified in the name plate Failure to observe this warning may cause damage to the equipment electric shock fire or physical injury eWhen operating a gearmotor not connected to a load remove the key from the output shaft Failure to observe this warning may cause physical injury eCheck the direction of rotation before connecting the gearmotor to the machine s load Rotation in the wrong direction may cause physical injury and or damage to the equipment e f a 460V class inverter is used to drive the motor use a control filter or a reactor with the inverter Breakdown of motor insulation due to repetitive and or extreme voltage spikes caused by normal operation of the inverter may cause damage to the equipment or fire e1 8 Hp single phase motors use a continuous running type capacitor Do not substitute a starting capacitor intended for intermittent duty use A starting type capacitor w
19. he fan or brake cover and adjustment of the brake gap g for brake equipped gearmotors Gearmotors should be mounted to allow ventilation and free air flow around the entire motor diameter Good ventilation prolongs product life 4 Connecting With Other Equipment N CAUTION eWhen connecting the gearmotor to a load with a chain or belt make sure of the shaft parallel alignment is precise Make sure the belt chain tension is properly adjusted and pulleys or sprockets are parallel eWhen direct coupling make sure the concentric alignment of shafts is precise eBefore operation make sure the set screws for the sprockets pulleys or coupling are securely tightened Failure to observe this warning may cause serious injury and or damage to the equipment eSafety guards should be furnished around rotating parts and securely in place before starting the equipment e Do not over tension chain or belts Damage to the gearmotor may occur due to excessive overhung load e Avoid excessively rigid direct couplings as damage may occur to the bearings due to high overhung load 1 Direct Connection Connect the reducer to the other equipment precisely so that the center of the shaft of both machines will be fully aligned eThe displacements and 0 should be minimized as much as possible eThe displacements 6 and 9 differ according to the type of coupling They should be within the allowable value defined by the respective manufacturer
20. he inverter VFD power from tapping the coil wires is not reliable and will result in brake failure The rectifier A200 D90 must be powered with a separate 200 230V 1 phase source Alternatively if the input power source is 115V please consult brother for the purchase of a rectifier that accepts 115VAC and has an output of 90VDC Ref P N A100 D90 rectifier The A200 D90 A100 D45 rectifier is not suitable for 115V power 19 Wiring a Brake Equipped Gearmotor with an Inverter VFD EE 208 230V 460V 460 5 To O 220 230V Note p e un zi z 3 ge 220 230V d o Note white black blue SER blue G ae P m blue Brake Jia ble Brake sums OC Note If the Alternate input power is 115V please purchase an A100 D90 rectifier and substitute it for the A200 D90 The required voltage to the brake coil is 90VDC 7 Operation e Do not operate the gearmotor with the terminal box cover opened Failure to observe this warning may cause electric shock e Do not approach or touch rotating parts such as a shaft while the machine is running Failure to observe this warning may cause physical injury e f power loss occurs switch off the power supply to the machine Unexpected recovery of electric service may cause a sudden start of the gearmotor and cause physical injury and or damage to the equipment 20 e The gearmotor may become hot during
21. iction Desk d Fan cover setting boit Spring B Setcrew amp Spring B Bush Spring g Gap Spring2 g Gap Castellated Nut Castellated Nut Set Screw 2 is only for 1 phase motors Gap g Data Standard Motors Motor Horsepower Type Allowable Gap g Proper Gap g Three Phase Single Phase mm mm 1 8 Hp Hp 1 18 Hp 4 Hp less than 2 3 1 9 0 0 4 2 Hp 3 Hp less than 1 0 0 4 0 1 24 Water resistant IP 65 Motor Procedure for Brake Gap g Adjustment D Remove the fan cover in the case of a fan cooled model Then remove the fan Then remove the brake cover In the case of a 1 8 Hp non vented unit no fan start by removing the brake cover Lift the tooth of the castellated nut from the securing slot 3 Press down on the friction disk and tighten the castellated nut by hand until it is firmly locked Loosen the castellated nut 1009 1809 Confirm the gap g is within the acceptable range using a gauge 5 Press the tooth of the castellated nut into the nearest slot on the friction disk Install the brake cover Check if there is any damage in the o ring of the brake cover before installation If damage exists replace it with new one Note Do not allow grease or dust to adhere to the friction disc Failure to observe this warning will cause a decrease in braking performance Motor 1 8 Hp T Field 2 Armature 3 Friction Disk 4 Spring 1 5
22. iction disk of the brake wears and the gap g increases When the gap clearance becomes too large the armature cannot function and the brake will become ineffective or fail Continuous usage of a brake when the gap is out of specification causes excessive temperature rise in the brake coil and will lead to coil failure For safe operation the brake gap should be inspected every 12 months or 1 1 5 Million cycles 23 Standard Motor Procedure for Brake Gap g Adjustment Remove fan cover in the case of a or the brake cover Lift the tooth of the castellated nut from the securing slot Also loosen the set screw for single phase motors 3 Press down the friction disk and tighten the castellated nut by hand until it is firmly locked Loosen the castellated nut 1009 1809 Confirm the gap g is within the acceptable range using a gauge Press the tooth of the castellated nut into the nearest slot on the friction disk For single phase motors secure setscrew as well 6 Install the fan cover Note Do not allow grease or dust to adhere to the friction disc Failure to observe this warning will cause a decrease in braking performance Motor 1 8 Hp 4 Hp Hp 1 Hp Motor 2 Hp 3 Hp 90 o li e a Bracket wih fied C Key Feld C Key Spring Pin Fan cover Spring Pin C Hex socket head cap screw E Amature Fan cover setting bolt E Amature Fan cover E Fan Friction Desk iD Bush C FanlFr
23. ill fail when used with a permanent split capacitor motor Use of a starting capacitor may cause damage to the equipment or failure of the capacitor For replacement capacitors please consult Brother or your Brother Distributor eDo not damage the vinyl coating of the capacitor Damage may cause electric shock eVoltage drop in the wiring should be kept above 296 Excessive length of wiring may cause a severe voltage drop Voltage drop reduces starting capacity and may result in the load not starting eWhen reversing either a three phase or a single phase gearmotor be sure to fully stop rotation before starting in the reverse direction Failure to completely stop before reversing may cause physical injury and or damage to the equipment e Reversing a 1 8 Hp single phase PSC motor without completely stopping first may result in the motor not reversing and running in the same direction This may cause physical injury and or damage to the equipment eWhen using a gearmotor with a brake do not energize the brake coil continuously while the motor is not running The brake coil of totally enclosed fan cooled motors may rely on the motor fan for cooling Continuous operation without the effect of the fan may cause the brake coil to burn out and or fire eTotally enclosed non ventilated brake equipped motors do not rely on the fan for cooling However continuously energizing the coil without motor operation may still cause damage e f a gearmotor with a bra
24. ise Intermittent Noise damaged Gear or Foreign Repair at Auth Facility Substance in the Gearbox Worn Out Gear or Bearing Repair at Auth Facility Excessive Vibration Improper Installation or Loose Bolts Tighten the Bolts Loose Bolts Nuts or Screws Tighten the Bolts Nuts or Screws Grease Leakage Damaged Oil seal Repair at Auth Facility 26 2 Trouble Shooting a Gearmotor with a Brake Incorrect Wiring Check the Wiring Brake Does Not Work Damaged Switch or Rectifier Replace Repair l a Remove Foreign Substance and or Clean Foreign Substance or Oil on Friction Disk off the Oil Hold Torque Inadequate Friction Disk Worn out l l Replace the Friction Disk Brake Takes Too Long to Activate Thickness Less than 0 8 mm 1 32 in Excessive Load Inertia Reduce the Load Inertia AC Switching Used Change to DC Switching Wiring Incorrect Correct the Wiring Adjust the Brake Gap or Replace Friction Motor Does Not Run Motor Brake Gap g Too Large isk Overheats Trips Thermal l Rectifier Failed Replace the Rectifier Abnormal Brake Noise Brake Coils Disconnected or Shorted Replace the Coil Damaged Contact Switch Repair or Replace the Switch l l i Reduce the Brake Frequency l High Frequency of Braking Stops Min Excessive Temperature Fewer Stops Min Excessive Load or Load Inertia Reduce the Load or Load Inertia 3 Parts for Replacement Repair Contact Brother or your Brother distributor for the replacement brake parts P
25. ke is used as a lift or hoist DC Switching wiring should be used Failure to use DC Switching may result in the lift or hoist falling and causing damage to the equipment or physical injury 14 Special Notes About Wiring 1 The brake rectifier A100 D90 or A200 D90 contains diodes Improper wiring may cause a fatal short circuit and damage or destroy the rectifier Special care should be used when wiring 2 The brake circuit relay for AC Switching should be an electro magnetic switch with the capacity greater than 6A AC200V 3 The brake circuit relay for DC Switching should be an electro magnetic switch with a capacity of 1A DC110V 4 If a noncontact relay is used an electromagnetic switch with a rated voltage of AC240V is recommended The capacity to switch half wave rectification is required 5 The direction of rotation of the output shaft varies according to the reduction ratio of the gear head Be sure to confirm the gear ratio and the direction of rotation before wiring and starting 6 The voltage between the capacitor terminals of a single phase motor will become nearly twice that of the power source of the motor Therefore be sure to insulate wires at the terminals for safety Special Notes About Grounding Ground should be connected to the provided ground terminal lead wire or lug The cross section of the earth wire should be AWG18 0 8 7mm minimum for 1 8 Hp Hp or Hp motors The cross section
26. lease note that we will not warrant any defect caused by improper replacement or repair completed by the user 10 Disposal CAUTION Gearmotors and lubricant should be disposed as general industrial waste 27 11 UL CSA CE 1 UL CSA Information Hp Range Voltage UL Standard UL File No Phase 115 60 Hz UL2111 220V 60 Hz Overheating Protection for Motors E153713 230V 60 Hz Includes standards for UL1004 1 8 Hp Single Phase 115 60 Hz 1 4Hp 5 Hp UL1004 220V 60 Hz E172017 Single Phase Standard for Safety Electric Motors 230V 60 Hz UL 1004 1 4Hp 3 Hp 208 230 460V E172017 Standard for Safety Electric Motors Brother Gearmotors have the UL Component Recognition mark on the nameplate Brother gearmotors have the cUL Component Recognition for Canada mark on the nameplate 2 CE Information Hp Range Voltage Standards Phase 115 60 Hz m 1 8Hp 1 2 Hp E EC Directive 73 23 EEC Single Phase Low Voltage Directive 230V 60 Hz EN Standard EN60034 1 1 8 3 Hp 208 230V 460V Regulations on Motors in General Three Phase Brother Gearmotors have the CE mark on the nameplate Please consult Brother for Technical File Information or a Formal Declaration of Conformity 28 12 Warranty Warranty All Brother gearmotor products are warranted against defects in materials and workmanship for a period of 2 years from the date of our shipment This constitutes Brother s only warranty in connection
27. observe this warning may cause electric shock physical injury and or damage to the equipment eDo not insert your fingers or any other object into the terminal box lead wire exit fan cover or any other aperture of the gearmotor Failure to observe this warning may result in electric shock physical injury fire and or damage to the equipment eDo not use a damaged gearmotor Failure to observe this warning may result in physical injury and or fire e o not remove the nameplate e The manufacturer will not warrant and will not be responsible for any product modified or repaired by the user Contents 1 Check When Unpacking P 3 7 Operation P 20 2 Transportation P 3 8 Inspection and Adjustment P 22 3 Installation P 4 9 Trouble Shooting P 26 4 Connecting with Other Equipment P 5 10 Disposal P 27 5 Direction of Rotation P 12 11 UL CSA CE P 28 6 Wiring P 13 12 Warranty P 29 1 Check When Unpacking When unpacking the carton please check the following items If you have any problems or questions please contact the dealer from which the product was purchased or Brother International Corp sales office N CAUTION Check whether the product is the product you ordered Installing the wrong gearmotor on your equipment may cause physical injury and or damage to the equipment 1 The ordered product s the contents of the box or crate and the rating indicated on the nameplate are correct Type Reduction Ratio RPM Horsepower or Watt
28. operation Do not touch it with your bare hands Failure to observe this warning may cause burn injury eWhen a gearmotor is running abnormal stop it immediately Failure to observe this warning may cause electric shock physical injury or fire e Do not overload a gearmotor Failure to observe this warning may cause physical injury and or damage to the equipment Do not touch any current carrying part of the capacitor used for a single phase motor until it has been discharged completely Failure to observe this warning may cause electric shock eWhen reversing the direction of a single phase motor it must come to a complete rest before starting rotation in the opposite direction If a single phase motor does not come to a complete stop before reversing the direction of rotation may not change Failure to stop the motor completely before reversing may cause physical injury or damage to the machine Do not stop or stall a motor forcibly It may cause damage to the machine elf a 1 8 Hp single phase permanent split capacitor PSC motor is stalled forcibly the motor may spontaneously rotate in the opposite direction This may cause damage to the equipment or physical injury 1 Check these issues before turning the power switch on 1 Wiring and connections are done properly to required codes 2 Fuses and thermal relays of proper capacity are used 3 Installation and the connection with the machine is properly done 4
29. r with a Brake 1 If a gearmotor is used in an application requiring fast brake response such as a lift or hoist DC Switching should be used 2 Asurge suppressor is recommended if DC Switching is required Varistor Voltage 423 517V 3 The brake coil voltage for a three phase motor 208 230V 460V or a single phase motor 220 230V is DC90V 4 The brake coil voltage of a 1 8 Hp single phase 115V model is DC45V 5 The required input voltage to the yellow and white wires of the rectifier A200 D90 A100 D45 for single phase 115V motors is single phase 115VAC The voltage output to the brake is DC45V 6 The required input voltage to the yellow and white wires of the rectifier A200 D90 A100 D45 for three phase motors 208 230V 460V or for single phase 220 230V motors is single phase 220 230VAC The voltage output to the brake is DC90V 7 If AC switching is used the electro magnetic switch used in the brake circuit should have a capacity greater than 6A AC200V 8 If DC Switching is used the electro magnetic switch should have a capacity of 1A DC110V in order to shield the inductive load 9 If a noncontact relay is used an electro magnetic switch with a rated voltage of AC240V is recommended The capacity to switch half wave rectification is required 10 The rectifier unit contains diodes Improper wiring may cause fatal short circuiting and failure of the rectifier Special care should be taken when wi
30. re present Failure to observe this warning may cause explosion spark fire electric shock physical injury and or damage to the equipment ePeople in charge of transportation installation wiring operation maintenance and inspection of the equipment should have sufficient knowledge and technical skill to install electrical and mechanical products Failure to observe this warning may cause explosion spark fire electric shock physical injury and or damage to the equipment eDo not repair or wire the equipment with the electric power on Cut the power before working on this product Failure to observe this warning may cause electric shock e f the equipment incorporating this gearmotor is used in a system for human transport furnish it with sufficient protective devices for safety and follow any and all local or national codes Failure to observe this warning may cause physical injury death and or damage to the equipment e f the equipment is to be used to drive an elevator be sure to furnish it with safety devices to prevent the elevator from accidentally falling Failure to observe this warning may cause physical injury and or damage to the equipment eBe sure not to get water or oil grease into the brake unit Failure to observe this warning may cause brake failure by decreasing brake holding torque N CAUTION eDo not use this gearmotor under conditions other than specified on the nameplate or product specifications Failure to
31. ring 11 When operating the machine with inverter refer to the Cautions for operation with an inverter on page 19 12 When wiring for 460V no inverter VFD the 220 230V AC voltage to power the rectifier can be tapped off the motor coil Please see the wiring diagrams for details Caution do not tap the coil voltage to power a brake coil if an inverter VFD is used Brake Lag Time sec Motor Type Type Three Phase 208 230 460V Three Phase 208 230 460V Single Phase 115V 220 230V 1 8Hp 4 Hp Hp 1 Hp 2 Hp 3 Hp 1 8 Hp 4 Hp 2 Hp 1 DC Switching 0 005 0 015 0 005 0 02 0 005 0 015 2 AC Switching A 0 03 0 10 0 05 0 15 0 03 0 10 3 AC Switching B 0 10 0 20 0 20 0 40 0 10 0 20 17 Brake Equipped Single Phase Motor 1 8 Hp Permanent Split Capacitor Type DEM 115V _220 230V SUIYIMS Od V sSurqojyAS JV li The blue to blue amp Z00 D90 in the reciis A100 D45 SE 4 gj3 SE short tm Dsus OV ea un S 6 E z E V SurgojytaS JV Eu TIT TI The blue to blue A200 D90 in the rectifier iiia corresponds tp the a RE SE l short circuit g SumrqoyagS OV Cs a 18 Brake Equipped Three Phase 1 8 Hp 4 Hp 2 Hp 1 Hp 2 Hp 3 Hp SUIYIMS Od gt ea un s z 3 ga E g Surqoj3IAS DV Note If an inverter VFD is used the brake rectifier cannot be powered using the output side of the inverter Please see the special inverter VFD wiring diagrams
32. rn injury Opening the motor may cause electric shock e f the gearmotor is enclosed inside the equipment and you need to inspect it be sure to immobilize the gearmotor drive shaft and the machine drive shaft prior to inspection Also confirm the equipment is sufficiently cooled down before attempting any inspection eDuring any inspection please have support personnel outside the machine to watch safety conditions If lubricant has spilled it can be very slippery please use caution Failure to observe this warning may cause physical injury eDo not operate the equipment with safety guards off Failure to observe this warning may cause physical injury Inspection and Maintenance of Brake Parts eDo not operate the equipment with the manual release lever of a brake disengaged Failure to observe this warning may cause damage to the equipment physical injury or death eBefore starting the equipment make sure the brake is functioning properly Turn the switch on and off and listen for the click of the brake Failure to observe this warning may cause malfunction of the machine loss of brake function resulting in damage to the equipment physical injury or death e Do not operate the equipment without the fan cover or brake cover installed after inspection and adjustment of brake gap Failure to observe this warning may cause wind in and physical injury e o not release the brake while the equipment is operating Failure to observe thi
33. rom the top 3 Installation Proper installation of a product will ensure reliable service and maximum life N CAUTION eDo not place any flammable object near the gearmotor Failure to observe this warning may cause fire eDo not allow interference with the ventilation of the gearmotor Be sure to observe the spacing requirements for adequate air flow around the gearmotor In the case of a fan cooled model do not block the vent holes on the fan cover Failure to observe this warning may result in abnormal overheating and or injury or fire eDo not step on a gearmotor Do not use a gearmotor as a grip to hoist yourself onto a machine Failure to observe this warning may cause physical injury eDo not touch the edge of the shaft of the gearmotor or the key groove of the bore with your bare hands Failure to Observe this warning may cause physical injury e Food machine regulations may prohibit the possibility of oil or grease getting into the food area If this is the case please use a drip pan to prevent lubrication from getting into the food area Alternatively please request that appropriate food grade lubricants are applied e eaking oil may cause products to fail eVibration resulting from improper installation of the gearmotor or from other sources should be under 0 5G 1 Proper location for installation Ambient Temperature 14 to 104F 1 O C to 4 0 C Ambient Humidity 85 max Altitude Sea level to 3280 feet
34. s Voltage Frequency etc 2 No accidental damage to the product during transportation has occurred 3 Screws or nuts are not loose 4 In case of a brake equipped gearmotor be sure the rectifier is enclosed 5 In case of a 1 8 Hp single phase motor be sure the capacitor is enclosed 6 In case of F or F3 series hollow bore shaft mount type be sure the bore safety cap is enclosed 2 Transportation 4 DANGER When a product is lifted for transportation be careful If a product is dropped and lands on any part of your body it may cause serious injury N CAUTION eAvoid dropping products during transport When an eyebolt or eyeplate is provided on a gearmotor or reducer confirm it is secure before using it After installing the gearmotor or reducer in the equipment do not hoist the entire machine using the eyebolt or eyeplate Failure to observe this warning may cause physical injury and or damage to the equipment eBefore lifting the product confirm it s weight using the packing box product catalog or by weighing it Use a lifting device that has enough capacity to handle the weight of the gearmotor Failure to observe this warning may cause physical injury or damage the equipment e f the product is packed in a wooden crate please do not use a forklift to lift it from the bottom The crate is not designed for use with a forklift in that manner If using a forklift please use a belt to lift the wooden box f
35. s warning may cause the machine to run out of control damage the equipment and result in physical injury or death eWhen measuring the insulation resistance do not touch the terminals Failure to observe this warning may cause electric shock eThe surface of a gearmotor may be very hot Do not touch it with your bare hands Failure to observe this warning may cause burn injury eWhen abnormal operation is observed diagnose the fault according to the instruction manual Do not operate the machine until the cause of the fault is found and proper measures are taken to correct the matter eWhen measuring the insulation resistance of an explosion proof type motor confirm that there is no gas vapor or other explosive substance around the unit Failure to observe this warning may cause an explosion or ignition eRepairing disassembling and reassembling of the equipment should be done only by an experienced technician Failure to observe this warning may cause electric shock physical injury or fire e mproper disassembly of the gearmotor voids the warranty 22 1 Daily Inspection Following items should be inspected every few days Inspection Item Method Details of inspection Load Current Compare it to the full load current on nameplate Human Ear No abnormal rumbling grinding clicking or Noise Detection Rod ticking sound Touch Vibration No abnormal vibration on gear case or motor please wear a protective gloves Surface Temp
36. with this sale and is in lieu of all other warranties expressed or implied written or oral There are no implied warranties of merchantability or fitness for a particular purpose that apply to this sale If performance guarantees are requested they should be requested in writing Full consideration will be given to such requests when complete details of the proposed application are included Limitation of Remedy Brother will repair or replace at brother s option F O B Brother s factory freight prepaid any brother gearmotor proved defective in materials or workmanship if immediate written notice of claim is made to Brother by Purchaser within 2 years from the date of shipment It is agreed that such repair or replacement is the exclusive remedy available from Brother Under no circumstances shall Brother be liable to anyone for any special incidental or consequential damages whether the result of negligence or otherwise Warranty Exclusions The Warranty of Brother gearmotor products does not cover and Brother makes no warranty with respect to 1 Failures not reported in writing to Brother within the warranty period of 2 years after the date of shipment Failures or damages due to miss application abuse improper installation or abnormal conditions of temperature humidity dirt or corrosive matter Failures due to operation either intentional or otherwise above rated capacities or in an otherwise improper manner 4 Product which has in

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