Operation Manual

Stailess steel planetary gear unit AG2800-+HDVxxx

for synchronous servo motors AM8800 (stainless steel)

1.32017-07-26

Version:Date:

Table of content

Stailess steel planetary gear unitAG2800-+HDVxxx

3Version: 1.3

Table of content1 Foreword .................................................................................................................................................... 5

1.1 Notes on the documentation.............................................................................................................. 51.2 Documentation issue status .............................................................................................................. 61.3 Intended use ..................................................................................................................................... 6

2 Safety.......................................................................................................................................................... 72.1 Safety instructions ............................................................................................................................. 72.2 Special safety instructions ................................................................................................................. 8

3 Guidelines and Standards ...................................................................................................................... 10

4 Handling ................................................................................................................................................... 114.1 Transport ......................................................................................................................................... 114.2 Packaging........................................................................................................................................ 114.3 Storage ............................................................................................................................................ 114.4 Maintenance / Cleaning................................................................................................................... 12

4.4.1 Maintenance schedule.....................................................................................................  124.4.2 Maintenance tasks...........................................................................................................  124.4.3 Commissioning after maintenance ..................................................................................  144.4.4 Cleaning agents and cleaning procedures .....................................................................  15

4.5 Disposal ........................................................................................................................................... 17

5 Product overview..................................................................................................................................... 185.1 AG2800 scope of delivery ............................................................................................................... 185.2 AG2800 name plate......................................................................................................................... 185.3 Type key .......................................................................................................................................... 19

6 Technical description.............................................................................................................................. 206.1 Gear unit configuration .................................................................................................................... 206.2 Overview of gear components......................................................................................................... 206.3 General technical data..................................................................................................................... 20

6.3.1 Weight..............................................................................................................................  20

7 Mechanical installation ........................................................................................................................... 217.1 Important notes................................................................................................................................ 217.2 Mounting the motor on the gear unit................................................................................................ 227.3 Mounting the gear unit at the machine ............................................................................................ 23

8 Technical data.......................................................................................................................................... 258.1 HDV015 ........................................................................................................................................... 25

8.1.1 Dimensional drawing HDV015.........................................................................................  268.2 HDV025 ........................................................................................................................................... 27

8.2.1 Dimensional drawing HDV025.........................................................................................  288.3 HDV035 ........................................................................................................................................... 29

8.3.1 Dimensional drawing HDV035.........................................................................................  30

9 Commissioning........................................................................................................................................ 319.1 Important notes................................................................................................................................ 319.2 Guide for commissioning the gear units .......................................................................................... 329.3 Troubleshooting............................................................................................................................... 33

Table of content

Stailess steel planetary gear unitAG2800-+HDVxxx

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10 Decommissioning.................................................................................................................................... 34

11 Support and Service................................................................................................................................ 35

Foreword

Stailess steel planetary gear unitAG2800-+HDVxxx

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1 Foreword

1.1 Notes on the documentationThis description is only intended for the use of trained specialists in control and automation engineering whoare familiar with the applicable national standards.It is essential that the documentation and the following notes and explanations are followed when installingand commissioning the components. It is the duty of the technical personnel to use the documentation published at the respective time of eachinstallation and commissioning.

The responsible staff must ensure that the application or use of the products described satisfy all therequirements for safety, including all the relevant laws, regulations, guidelines and standards.

Disclaimer

The documentation has been prepared with care. The products described are, however, constantly underdevelopment.We reserve the right to revise and change the documentation at any time and without prior announcement.No claims for the modification of products that have already been supplied may be made on the basis of thedata, diagrams and descriptions in this documentation.

Trademarks

Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE®, XFC® and XTS® are registeredtrademarks of and licensed by Beckhoff Automation GmbH.Other designations used in this publication may be trademarks whose use by third parties for their ownpurposes could violate the rights of the owners.

Patent Pending

The EtherCAT Technology is covered, including but not limited to the following patent applications andpatents:EP1590927, EP1789857, DE102004044764, DE102007017835with corresponding applications or registrations in various other countries.

The TwinCAT Technology is covered, including but not limited to the following patent applications andpatents:EP0851348, US6167425 with corresponding applications or registrations in various other countries.

EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,Germany

Copyright

© Beckhoff Automation GmbH & Co. KG, Germany.The reproduction, distribution and utilization of this document as well as the communication of its contents toothers without express authorization are prohibited.Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of apatent, utility model or design.

Foreword

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1.2 Documentation issue statusVersion Comment1.3 Chapter update:

Disposal 4.5, Guide for commissioning of the gears 9.21.2 Chapter update:

1.0 Foreword; 3.0 Safety1.1 Chapter update:

9.11.0 First edition

1.3 Intended useThe gear unit is used for transforming torques and speeds. It is suitable for all industrial applications that arenot covered by Article 2 of EC Directive 2002/95/EC (restriction of the use of certain hazardous substancesin electrical and electronic equipment).

The gear unit must not be operated in potentially explosive atmospheres. In food processing applications,the gear unit may only be used beside or below the food area.

The gear unit is intended for mounting on motors that:

• match type B5 (if different, please contact our service department);• have a radial and axial run-out tolerance of at least "N" according to DIN 42955;• have a smooth shaft.

NOTEDamage from improper useAny use exceeding the maximum permissible speeds, torques and temperature is considered improper andis therefore not permitted.

Safety

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2 Safety

2.1 Safety instructions

Safety regulations

Please note the following safety instructions and explanations!Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,commissioning etc.

Exclusion of liability

All the components are supplied in particular hardware and software configurations appropriate for theapplication. Modifications to hardware or software configurations other than those described in thedocumentation are not permitted, and nullify the liability of Beckhoff Automation GmbH & Co. KG.

Personnel qualification

This description is only intended for trained specialists in control, automation and drive engineering who arefamiliar with the applicable national standards.

Description of symbols

In this documentation the following symbols are used with an accompanying safety instruction or note. Thesafety instructions must be read carefully and followed without fail!

DANGERSerious risk of injury!Failure to follow the safety instructions associated with this symbol directly endangers the life and health ofpersons.

WARNINGRisk of injury!Failure to follow the safety instructions associated with this symbol endangers the life and health of per-sons.

CAUTIONPersonal injuries!Failure to follow the safety instructions associated with this symbol can lead to injuries to persons.

NOTEDamage to the environment or devicesFailure to follow the instructions associated with this symbol can lead to damage to the environment orequipment.

Tip or pointerThis symbol indicates information that contributes to better understanding.

UL pointerThis symbol indicates important information about the UL-compliant.

Safety

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2.2 Special safety instructionsThe safety instructions are designed to avert danger and must be followed during installation,commissioning, production, troubleshooting, maintenance and trial or test assemblies.

The gear units of the AG2800 series are not designed for stand-alone operation and are always installed in amachine or system. After installation the additional documentation and safety instructions provided by themachine manufacturer must be read and followed.

CAUTIONPersonal injuries• Carefully read this manual before using the gear unit thoroughly, paying particular attention to the safety

instructions. In the event of any uncertainties please notify your sales office immediately and refrain fromworking on the gear unit.

• Only trained, qualified personnel with good knowledge of drive technology may work on this gear unit.• If a gear unit is installed in a machine it must not be commissioned until proof of compliance of the ma-

chine with the latest version of the EC Machinery Directive has been provided. This includes all relevantharmonized standards and regulations required for implementation of this Directive in national legisla-tion.

WARNINGSerious risk of injury through hot surfaces!• The surface temperature may exceed 90 °C, resulting in a risk of burns.• Avoid touching the housing during or shortly after operation.• Allow the gear unit to cool down for at least 20 minutes after switching off.• Use a thermometer to check whether the surface has cooled down sufficiently.

WARNINGObjects flung out by rotating components can cause serious injuries.• Remove any items and tools in the vicinity of the gear unit before starting up the unit.• Remove/secure the feather key (if present), if the gear unit is operated without attachments on the out-

put/drive side.

WARNINGRotating components on the gear unit can pull in parts of the body and cause serious in-jury or death.• When the gear unit is running, keep sufficient distance to rotating machine parts.• During assembly and maintenance work, secure the machine against restarting and unintentional move-

ments (such as uncontrolled lowering of lifting axes).

WARNINGA damaged gear unit can lead to accidents with risk of injury.• Do not operate a gear unit that has been overloaded due to incorrect operation or a machine crash.• Replace affected gear units, even if no external damage is visible.

NOTELoose or overloaded screw connections can damage the gear unit.• Install and check all screw connections for which tightening torques are specified, using a calibrated

torque wrench.

Safety

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WARNINGLubricants are flammable.• Do not use a water jet for extinguishing flames.• Suitable extinguishing media are powder, foam, water spray or carbon dioxide.• Follow the safety instructions of the lubricant manufacturer.

CAUTIONSolvents and lubricants can cause skin irritations.• Avoid direct skin contact.

NOTESolvents and lubricants can pollute soil and water.• Cleaning solvents and lubricants must be used and disposed of properly.

Guidelines and Standards

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3 Guidelines and StandardsIn addition to the safety instructions mentioned in this manual, the general statutory and other rules andregulations for the prevention of accidents (e.g. personal protective equipment) and for environmentalprotection must be followed.

CAUTIONPersonal injuries!The gear units are not products under the terms of the EC Machinery Directive. Operation of the gear units in machines or systems is only permitted once the machine or system manufac-turers has provided evidence of CE conformity of the complete machine or system.

EHEDG certification!The gear units of the AG2800 series are certified according to Type EL – Class I of the EuropeanHygienic Engineering & Design Group (EHEDG).

Handling

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4 Handling

4.1 Transport• No special mode of transport is prescribed for the gear unit.• Only by qualified personnel• Only in the manufacturer's original packaging• Avoid hard shocks.• If the packaging is damaged check the gear unit and any accessories for visible damage. Inform the

transport company and, if necessary, the manufacturer.

WARNINGSuspended loads may fall and cause serious injury or death.• Never stand under suspended loads.• Secure the gear unit with suitable fastenings (e.g. straps) prior to transport.

NOTEHard impacts, e.g. due to falling or dropping, may damage the gear unit.• Use only lifting gear and load handling devices with sufficient load-bearing capacity.• Do not exceed the permitted lifting weight.• Set the gear unit down slowly.

4.2 Packaging• Recyclable cardboard with inserts• Dispose of the packaging materials at designated disposal sites.

Observe the relevant national disposal regulations

4.3 Storage• The gear units must not be stored outdoors. The storage space must be adequately ventilated and dry.• The gear units may only be stored in the original recyclable manufacturer's packaging.• The gear units may only be stored in a horizontal position.• Storage temperature: 0 °C to +40 °C in the original packaging• Storage time: 2 years max.

Possible damage to the gear unit sealsIf the gear units are stored at temperature ranges above 40°C or subjected to direct sunlight or ul-traviolet light, the gear unit seals may become damaged. Storage temperatures of up to +35°C arepermitted for a maximum of 2 weeks. However, please note that even short-term storage at suchtemperatures will result in premature ageing of the seals. Therefore, please check the seals beforecommissioning the gear unit.

Handling

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4.4 Maintenance / Cleaning

4.4.1 Maintenance scheduleMaintenance tasks During commis-

sioningFor the firsttime, after 500operating hoursor 3 months

Every 3 months Annually

Visual inspection x x x -Check the tightening torques x x - xLubrication x - x x

4.4.2 Maintenance tasks

4.4.2.1 Visual inspection• Check the entire gear unit for external damage.• Check the entire gear unit for leaks.

◦ In the installation position, check that no foreign media (e.g. oil) accumulate on the drive andoutput shaft.

• Check the entire gear unit for corrosion.

Further information regarding maintenance!For further information regarding maintenance of bearings or wearing parts please contact theBeckhoff applications department.

4.4.2.2 Check the tightening torques• Check the tightening torque of the fastening screws on the gear housing.

◦ The tightening torque values can be found in chapter 7 "Mechanical installation [} 21]".• Check the tightening torque of the set screws on the motor mounting.

◦ The tightening torque values can be found in chapter 7 "Mechanical installation [} 21]".

Handling

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4.4.2.3 Lubrication

CAUTIONDamage to the gear unit due to overheating of the componentsInadequate lubrication of the components may lead to damage to the gear unit due to overheating.• Calculate the usable life of the lubricant used• Relubricate all relevant components as required

4.4.2.3.1 Calculating the usable life of the lubricant

To calculate the usable life of your lubricant, proceed as follows:

• Measure the temperature at the center of the housing in maximum operating state. The gear unit hasreached thermal steady state when the temperature increase no longer exceeds 2 °C per hour.

CAUTIONDamage to the gear box due to exceeding of the maximum permitted temperatureIf the maximum permitted temperature for the gear unit is exceeded, the gear unit may become damageddue to overheating.• Ensure correct and adequate cooling, positioning and installation of the gear unit, in order to avoid ex-

ceeding the maximum permitted temperature.• Switch off the machine / system as soon as the limit value is reached and the maximum temperature is

exceeded.

• Add 10 °C to the measured temperature.• Now determine the usable life of the lubricant based on the table below.

Handling

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4.4.2.3.2 Notes on the lubricant used

Lubricant usedAll gear units are lubricated for life at the factory with a lithium soap grease based on mineral oil ora food-grade synthetic lubricating oil (oil type CLP PG) (see name plate). All bearings are lubricatedfor life at the factory.

Further information on the lubricants is available directly from the manufacturer:

Lubricants for the food industry (NSF-H1 registered)Klüber Lubrication München KG, Munich

Phone: + 49 89 7876-0

www.klueber.com

• Klübersynth UH1 6-220; NSF H1 registration number: 124438• Klübersynth UH1 6-150; NSF H1 registration number: 124437• Klübersynth UH1 6-100; NSF H1 registration number: 137872

4.4.3 Commissioning after maintenance• Clean the gear unit externally.• Attach all safety devices.• Perform a test run before releasing the gear unit again for operation.

Handling

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4.4.4 Cleaning agents and cleaning procedures

4.4.4.1 Important notes

Cleaning the gear unit!During operation, the pumping action of the gear unit can result in cleaning agent entering the inside of the gear unit. The gear unit may only be cleaned at standstill!

Unsuitable cleaning agents may cause corrosion!The gear unit may only be cleaned with commercial cleaning agents. The cleaning agents may befat-dissolving but must be non-aggressive! An overview of suitable cleaning agents can be found insection "Overview of materials [} 16]".

Damage to seals!Cleaning the gear unit with a high-pressure water jet or a permanent present medium may damagethe gear seals.• Use a water jet with a maximum pressure of 28 bar.• Removal media from the seal within 30 minutes.

Residue-free cleaningRoughened surfaces cannot be cleaned without residues!• Avoid scratching the gear unit or damaging the surface. It may no longer be possible to guaran-

tee the effect of the HD design! Bacteria or similar matter may attach themselves to the surface!

Handling

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4.4.4.2 Overview of materials

This section contains a list of cleaning materials. During cleaning, the gear unit may be subjected to thesubstances listed below, in concentrations of up to 3%.

Overview of permitted cleaning materials:

Medium Chemical formulaAcetyl chloride CH3COCIAluminum chloride AICI3-6H2OAmmonium chloride NH4CIAntimony trichloride SbCl3Barium chloride BaCl2-2H2OChlorine (including chlorine water, chloride of lime andchlorobenzene)

Cl2

Chlorosulfuric acid HSO3ClHydrogen chloride gas HCIChromic acid CrO3

Iron(III) chloride FeCl3Hydrogen fluoride HFCarnallite KCIMgCl2-6H2OAqua regia HCL + HNO3

Magnesium chloride MgCl2-6H2OMonochloroacetic acid CH2CICOOHSodium chloride (common salt) NaClSodium hydroxide NaOHSodium peroxide Na2O2

Sulfuric acid H2SO4

Tartaric acid COOH(CHOH)2COOHTin II (IV) chloride SnCl2-2H2O(SnCl4)

Overview of non-permitted cleaning materials:

The substances listed below may not be used for cleaning the gear unit!

Medium Chemical formulaAniline hydrochloride C6H5NH2HCIBromine Br2

Sodium hypochlorite (bleaching solution) NaCIOMercury (II) chloride HgCl2Hydrochloric acid HCI

Handling

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4.5 DisposalNational regulationsObserve the relevant national disposal regulations.

Supplementary information on replacing the adapter plate and disassembly and disposal of the gear unit isavailable from our service department:

• The device should be disposed of by a certified disposal company. Addresses can be obtained fromour service department.

• Metal parts can be sent for metal recycling.

In accordance with the WEEE 2012/19/EU Directives we take old devices and accessories back forprofessional disposal, provided the transport costs are taken over by the sender. Send the devices with thenote “For disposal” to:

Beckhoff Automation GmbH & Co. KGHülshorstweg 2033415 Verl

Product overview

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5 Product overview

5.1 AG2800 scope of delivery• Check the completeness of the delivery against the delivery note.• Missing parts or damage should be reported immediately in writing to the carrier, the insurance

company and / or Beckhoff Automation.

5.2 AG2800 name plate

Item number Explanation1 Note referring to hygienic design or the gear unit2 Type key3 Transmission ratio4 Date of manufacture5 Lubricant note6 Country of manufacture7 Serial number of the gear unit

Product overview

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5.3 Type keyAG2800 -+ HDV015S - MF1 - 4 - AM88xx ExplanationAG2800 Gear unit series

◦ AG2800 = HDV planetary gear unitHDV Gear type

◦ HDV = Standard015 Size

◦ 0115025035

S Lubrication◦ S = Standard

M Gear unit variant◦ M = Motor-mounted gear unit

F Gear unit version◦ F = Standard

1 No. of stages◦ 1 = single-stage

2 = two-stage4 Ratio

◦ See documentationAM88xx Motor size

◦ 015 = AM883x025 = AM884x035 = AM885x

Technical description

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6 Technical description

6.1 Gear unit configurationGear units of the AG2800-HDV series are single- or multi-stage, low-backlash planetary gear units. The gearunit series is manufactured as version "M" (motor mounting) and can be used in any installation position. Theoutput shaft bearing is designed for high breakdown torques and high axial forces. Motor centering via thesleeve with bearing prevents radial distortion of the motor. The gear unit can be adapted to different motortypes using an adapter flange and a spacer sleeve. The gear units are manufactured to the ISO 9001 qualitystandard and lubricated for life.

6.2 Overview of gear componentsTechnical drawing Pos. Gear components

A Gear housingB Output shaftC Shaft seal at the outputD O-ring sealE Adapter flange

6.3 General technical dataThe maximum permissible speeds and torques can be found in our catalog or on our website athttp://www.beckhoff.de.

6.3.1 WeightThe table below shows the gear unit weights with a standard adapter flange. If a different adapter flange isused, the weight of the gear unit may differ by up to 10%.

Gear size HDV 015 025 0351–stage (in kg) 3.2 5.2 13.62–stage (in kg) 3.8 6.5 16.6

Mechanical installation

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7 Mechanical installation

7.1 Important notes CAUTION

Damage to persons and devicesObserve the general and special safety instructions.

The gear unit can be used in any gear unit.

NOTEAssembly sequenceAlways follow the assembly sequence described below in order to avoid damage.

The fastening screws are not included and must be provided by the customer. Pertinent information can befound in the individual assembly steps.

NOTECompressed air may damage gear unit seals.Do not use compressed air for cleaning the gear unit.

NOTEIn rare cases, leaks ("sweating") may occur at the drive in gear units with grease lubrica-tion (see name plate).• To avoid "sweating", we recommend sealing the areas between

ð adapter plate and drive housing (gear unit) and

ð adapter plate and motor

ð with a surface seal adhesive (e.g. Loctite® 573 or 574).

ð For further information please contact our customer service.

Clean the following components with a clean, lint-free cloth and a grease-dissolving, non-aggressivecleaning agent. Further information can be found in chapter "Cleaning agents and cleaning procedures[} 15]":

• all surfaces in contact with adjacent components• Centering• the motor shaft• the internal diameter of the socket• the spacer sleeve inside and outside

In addition, check the contact surfaces for damage and foreign particles.

Mechanical installation

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7.2 Mounting the motor on the gear unitThe standard scope of supply of a AG2800-HDV series gear unit does not include a motor.

If a motor is to be mounted on the gear unit it must:• be a B5 type• have a radial and axial run-out tolerance according to DIN EN 50347• and have a smooth shaft.

For mounting a gear unit on a motor, we recommend Beckhoff servomotors of theAM8800 series.

If a motor is included in the scope of supply, it is already mounted on delivery. No further installationis required.

NOTEObserve the safety instructions!Follow the information and safety instructions when mounting the gear unit on motor. Special safety instruc-tions can be found in chapter 3.2 "Special safety instructions [} 8]" of this documentation.

Instructions for mounting the motor on the gear unit

• Clean all components to ensure they are grease-free and check the motor and gear unit for damageprior to assembly.

• Mount the motor in vertical direction, if possible.If the motor shaft has a feather key, remove it.Insert a half wedge, if recommended by themanufacturer.• Remove the screw plug (item A) from the mounting

hole in the adapter flange (item B).• Turn the sleeve (item C) until the set screw (item

H) is accessible via the mounting hole.• Place the seal between the motor (item D) and the

adapter flange (item B).• Push the motor shaft into the socket of the gear

unit.

The maximum permitted axial loads must not be exceeded. The motor shaft must slide easily. If this is notthe case, the set screw should be loosened further.The slot in the spacer sleeve must be aligned with the groove (if present) in the motor shaft and the markinghole (item M).There must be no gap between the motor (item D) and the adapter flange (item B).

Mechanical installation

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Technical drawing Pos. NameC SleeveH Set screwJ Spacer sleeveK Grooved motor shaftL Smooth motor shaftM Marking hole

• Coat the four screws (items F) with a threadlocker (e.g. Loctite® 243).

• Mount the motor (item D) with the four screws (items F) at the adapter flange (item B).• Tighten the set screw (item H) in the sleeve (item C).• Screw in the screw plug (item A) of the adapter flange (item B).• The screw sizes and specified tightening torques can be found in the following table.

Width across flats [mm] 10 13 17Tightening torque [Nm] 3 5 5.5

Gear size AG2800-HDV Internal sleeve dia.[mm]

Width across flats of theset screw (item B) [mm]

Tightening torque [Nm] Max. axial force [N]

015 14 4 14 80025 19 5 23 100035 24 6 45 150

7.3 Mounting the gear unit at the machine• The gear housing has four threaded holes (items

A) for connection with your machine.Thoroughly clean the output shaft, the centeringdevices and the contact surfaces.• Coat the four screws (items C) with a threadlocker

(e. g. Loctite® 243).• Attach the gear unit to the machine with the four

mounting screws through the screw holes.

Ensure that the machine surface is as smooth as possible.Mount the gear unit such that the screw plug points downwards.Use screw head seals (items B) and O-rings (items I and J) for sealing.

Fittings on the output side

The gear unit may be damaged by distortion!Distortion may occur during installation of the gear unit, resulting in damage to the gear unit.• Mount gearwheels and toothed belt pulleys on the output shaft without using force.• Never use a reaming or hitting action for mounting!• Only use suitable tools for the installation!• Ensure that the static axial forces permitted for the output bearings are not exceeded.

• Seal possible clearances during mounting on the output side.

Mechanical installation

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Ensure that the surfaces of the mounting parts are as smooth as possible.

Only use screw head seals and O-rings for sealing purposes.

Gear size AG2800-HDV Pitch circle Ø [mm] Screw size / strengthclass

Tightening torque [Nm]

015 62 M5 / Ax-80 4.91025 80 M6 / Ax-80 8.42035 108 M10 / Ax-80 40.0

Technical data

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8 Technical data

8.1 HDV015Size 015Transmission ratio i 1-stage 4 / 5 / 7 / 10

2-stage 16 / 20 / 25 / 35 / 50 / 70 / 100Max. acceleration torque(max. 1000 cycles per hour)

T2B Nm i = 4 / 5 / 7 / 16 / 20 / 25 / 35 / 50 / 70 32i = 10 / 100 29

Rated torque at output(at n1N)

T2N Nm i = 4 / 5 / 7 / 16 / 20 / 25 / 35 / 50 / 70 16i = 10 / 100 15

EMERGENCY OFF torque(1000 x permitted during gear unit ser-vice life)

T2emerg. Nm 75

Permitted mean drive speed(at T2N and 20 °C ambient temp.)

n1N min-1 1-stage 30002-stage 3700

Max. drive speed n1Max min-1 6000Max. torsional backlash jt arcmin 1-stage ≤ 10

2-stage ≤ 15Max. axial force(relative to shaft/flange center output)

F2AMax N 500 / 1000a)

Max. radial force(relative to shaft center at 100 min-1)

F2RMax N 350 / 1600a)

Efficiency at full load η % 1-stage ＞972-stage ＞95

Bearing life Lh h 20000Running noise(at n1 = 3000 min-1 without load)

LPA dB(A) ≤ 60

Max. permitted housing temperature °C 90Ambient temperature °C -25 to +40Lubrication Lubricated for life H1Housing surface electropolishedDirection of rotation Input and output side in the same direc-

tionProtection class IP 69 Kb)

Mass moment of inertia(relative to the drive)

0.17

Bore diameter of the clamping hub Ø 14

a)reinforced bearingsb)at 30 bar, ref. DIN 40050-9

Technical data

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8.1.1 Dimensional drawing HDV015

Technical data

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8.2 HDV025Size 025Transmission ratio i 1-stage 4 / 5 / 7 / 10

2-stage 16 / 20 / 25 / 35 / 50 / 70 / 100Max. acceleration torque(max. 1000 cycles per hour)

T2B Nm i = 4 / 5 / 7 / 16 / 20 / 25 / 35 / 50 / 70 80i = 10 / 100 72

Rated torque at output(at n1N)

T2N Nm i = 4 / 5 / 7 / 16 / 20 / 25 / 35 / 50 / 70 40i = 10 / 100 35

EMERGENCY OFF torque(1000 x permitted during gear unit ser-vice life)

T2emerg. Nm 190

Permitted mean drive speed(at T2N and 20 °C ambient temp.)

n1N min-1 1-stage 27002-stage 3400

Max. drive speed n1Max min-1 6000Max. torsional backlash jt arcmin 1-stage ≤ 10

2-stage ≤ 15Max. axial force(relative to shaft/flange center output)

F2AMax N 500 / 1500a)

Max. radial force(relative to shaft center at 100 min-1)

F2RMax N 350 / 2500a)

Efficiency at full load η % 1-stage ＞972-stage ＞95

Bearing life Lh h 20000Running noise(at n1 = 3000 min-1 without load)

LPA dB(A) ≤ 63

Max. permitted housing temperature °C 90Ambient temperature °C -25 to +40Lubrication Lubricated for life H1Housing surface electropolishedDirection of rotation Input and output side in the same direc-

tionProtection class IP 69 Kb)

Mass moment of inertia(relative to the drive)

0.54

Bore diameter of the clamping hub Ø 19

a)reinforced bearingsb)at 30 bar, ref. DIN 40050-9

Technical data

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8.2.1 Dimensional drawing HDV025

Technical data

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8.3 HDV035Size 035Transmission ratio i 1-stage 4 / 5 / 7 / 10

2-stage 16 / 20 / 25 / 35 / 50 / 70 / 100Max. acceleration torque(max. 1000 cycles per hour)

T2B Nm i = 4 / 5 / 7 / 16 / 20 / 25 / 35 / 50 / 70 200i = 10 / 100 180

Rated torque at output(at n1N)

T2N Nm i = 4 / 5 / 7 / 16 / 20 / 25 / 35 / 50 / 70 100i = 10 / 100 90

EMERGENCY OFF torque(1000 x permitted during gear unit ser-vice life)

T2emerg. Nm 480

Permitted mean drive speed(at T2N and 20 °C ambient temp.)

n1N min-1 1-stage 20002-stage 2600

Max. drive speed n1Max min-1 4800Max. torsional backlash jt arcmin 1-stage ≤ 10

2-stage ≤ 15Max. axial force(relative to shaft/flange center output)

F2AMax N 1700 / 3000a)

Max. radial force(relative to shaft center at 100 min-1)

F2RMax N 1200 / 4250a)

Efficiency at full load η % 1-stage ＞972-stage ＞95

Bearing life Lh h 20000Running noise(at n1 = 3000 min-1 without load)

LPA dB(A) ≤ 60

Max. permitted housing temperature °C 90Ambient temperature °C -25 to +40Lubrication Lubricated for life H1Housing surface electropolishedDirection of rotation Input and output side in the same direc-

tionProtection class IP 69 Kb)

Mass moment of inertia(relative to the drive)

1.8

Bore diameter of the clamping hub Ø 24

a)reinforced bearingsb)at 30 bar, ref. DIN 40050-9

Technical data

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8.3.1 Dimensional drawing HDV035

Commissioning

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9 Commissioning

9.1 Important notes CAUTION

Damage to persons and devices• Read up on the general and special safety instructions before starting the work.

NOTEImproper operation may result in damage to the gear unit.• Please ensure that

ð the ambient temperature is not below -15 °C and not above +40 °C, and

ð the operating temperature does not exceed +90 °C.• Avoid icing, which can damage the seals.• For other operating conditions please contact our customer service.• Do not exceed the operational limit values for the gear unit• Only use the gear unit in a clean, dust-free and dry environment.

DANGERSerious risk of injury!• Only specialist personnel with extensive knowledge in the areas of electrical engineering / drive technol-

ogy are allowed to install and commission the equipment.• Check that all live connection points are protected against accidental contact. Dangerous voltages can

occur, up to 875 VDC.• Due to the DC link capacitors, the DC link contacts "ZK+ and ZK- (DC+ and DC-)" and "RB+ and RB-"

may be subject to dangerous voltages exceeding 875 VDC, even after the servo drive was disconnectedfrom the mains supply. Wait 5 minutes for the AX5101 - AX5125 and AX520x; 15 minutes for theAX5140/AX5160/AX5172; 30 minutes for the AX5190/AX5191; 45 minutes for the AX5192/AX5193 afterdisconnecting, and measure the voltage at the DC links "ZK+ and ZK- (DC+ and DC-)". The device issafe once the voltage has fallen below 50 V.

• The surface temperature of the motor can exceed 100 °C in operation. Check (measure) the tempera-ture of the motor. Wait until the motor has cooled down below 40 °C before touching it.

• Make sure that, even if the drive starts to move unintentionally, no danger can result for personnel ormachinery.

NOTEOverloading of the gear!With motor / gear combinations can in case of failure (mechanical blockage of the power train) due to highratio, the gear will be overloaded.To prevent this, make sure that the motor rated torque and the motor peak torque is limited in theservo drive.Example:• Motor rated torque / motor peak torque: 1 Nm / 5 Nm• Gear rated torque / gear peak torque: 15 Nm / 24 Nm• Gear ratio: i = 10• The motor rated torque is not limited. The motor peak torque is limited to 2,4 Nm.

Commissioning

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9.2 Guide for commissioning the gear unitsThe procedure for commissioning is described as an example.A different method may be appropriate or necessary, depending on the application of the equipment.

• Check the assembly and alignment of the motor and the gear unit.• Check the drive components such as clutch, gear unit, belt pulley and gear unit for correct seating and

setting (observe the permissible radial and axial forces).• Check the wiring and connections at the motor, servo drive and gear unit. Check that the earthing is

correct.• Test the function of the holding brake, if used. (Apply 24VDC, the brake must release).• Check whether the rotor of the motor revolves freely (release the brake, if necessary). Listen out for

grinding noises from the motor and the gear unit.• Check that all the required measures against accidental contact with live and moving parts have been

carried out.• Carry out any further checks which are specifically required for your system.• Now commission the drive according to the commissioning instructions for the servo drive.• In multi-axis systems, individually commission each drive unit (servo drive/motor(s)).• During the installation and commissioning look out for chips or similar contaminants that may penetrate

into the gear unit. Keep the work area clean and protect the gear unit from foreign objects. Penetrationof dirt reduces the service life of the gear unit.

Destruction of the gear unit due to maximal engine torque!Before commissioning, check that your configured max. engine torque does not destroy the gearunit. For further information, please refer to chapter 9.1: "Important notes [} 31]".

Commissioning

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9.3 TroubleshootingNOTE

Changed operating behaviorA change in operating behavior may indicate existing damage of the gear unit or result in damage to thegear unit.• Do not recommission the gear unit until the fault has been rectified.

CAUTIONPersonal injuriesTroubleshooting may only be performed by trained personnel.

Error Possible cause RemedyIncreased operating temperature The gear unit is not suitable for the

purpose.Check the technical data.

Motor heats up the gear unit. Check the wiring of the motor.Ensure adequate cooling.Change the motor.

Ambient temperature too high. Ensure adequate cooling.Increased operating noises Distorted motor mounting Contact our service department.

Bearing damageGear tooth damageToothed belt tension too high

Lubricant loss Lubricant quantity too high Wipe off the leaking lubricant andcontinue to monitor the gear unit.Lubricant discharge should stopafter a short time.

Leaks Contact our service department.

Decommissioning

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10 Decommissioning CAUTION

Damage to persons and devices• Read up on the general and special safety instructions before starting the work.

Support and Service

Stailess steel planetary gear unitAG2800-+HDVxxx

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11 Support and ServiceBeckhoff and their partners around the world offer comprehensive support and service, making available fastand competent assistance with all questions related to Beckhoff products and system solutions.

Beckhoff's branch offices and representatives

Please contact your Beckhoff branch office or representative for local support and service on Beckhoffproducts!

The addresses of Beckhoff's branch offices and representatives round the world can be found on her internetpages:http://www.beckhoff.com

You will also find further documentation for Beckhoff components there.

Beckhoff Headquarters

Beckhoff Automation GmbH & Co. KG

Huelshorstweg 2033415 VerlGermany

Phone: +49(0)5246/963-0Fax: +49(0)5246/963-198e-mail: info@beckhoff.com

Beckhoff Support

Support offers you comprehensive technical assistance, helping you not only with the application ofindividual Beckhoff products, but also with other, wide-ranging services:

• support• design, programming and commissioning of complex automation systems• and extensive training program for Beckhoff system components

Hotline: +49(0)5246/963-157Fax: +49(0)5246/963-9157e-mail: support@beckhoff.com

Beckhoff Service

The Beckhoff Service Center supports you in all matters of after-sales service:

• on-site service• repair service• spare parts service• hotline service

Hotline: +49(0)5246/963-460Fax: +49(0)5246/963-479e-mail: service@beckhoff.com