Project Planning

List of application variables 4

4 Project Planning 1
Project planning should be performed for all gear units. The data specified in this catalog
applies only if project planning was completed correctly. It is particularly important for gear 2
units under the following conditions:
• Increased ambient temperatures 3
• Altitudes > 3280 feet (less convection)
• Gear units > size 87 with small ratios (more heat from oil churning) 4
• All helical-worm gear units with small ratios and increased ambient temperature
5
4.1 List of application variables
6
Your application data is required in order to precisely define the correct drive. The
abbreviations used for project planning are summarized in the following table:
7
Designation Meaning Unit
namin Minimum output speed [rpm]
namax Maximum output speed [rpm]
8
Pa at namin Output power at minimum output speed [HP]
Pa at namax Output power at maximum output speed [HP] 9
Ta at namin Output torque at minimum output speed [lb-in]
Ta at namax Output torque at maximum output speed [lb-in] 10
FRa Overhung load on gear unit output shaft [lb]
FAa Axial load on gear unit output shaft [lb] 11
ne Input speed [rpm]
Pm at ne Motor input power [HP] 12
Te at ne Input torque [lb-in]
Te max Maximum input torque [lb-in]
13
FRe Overhung load on input of gear unit [lb]
FAe Axial load on input of gear unit [lb]
14
JLast Mass moment of inertia to be driven [lb-ft2]
R, F, K, S, W Required gear unit type and mounting position
- 15
M1 - M6 (see chapter, "Mounting positions")
IP.. Required degree of protection -
Umg Ambient temperature [°C] 16
[ft above sea
H Installation altitude
level]
Duty type and cyclic duration factor (cdf) or exact load cycle can be
17
S.., ..% cdf -
specified.
Z Starting frequency; alternatively, exact load cycle can be specified [1/h] 18
VBremse Operating voltage of the brake (AT with brake) [V]
TB Required braking torque (AT with brake) [lb-in] 19
TR Slip torque (AR) [lb-in]
Type of the ... Electric motor
motors ... Internal combustion engine - 20
... Hydraulic motor

21

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Gear Units – 2016 41

4 Project Planning
Project planning assistance

4.2 Project planning assistance

SEW-EURODRIVE’s regional engineers will gladly perform project planning for you. In
addition, we offer the information in this catalog and complete documentation covering the
topic of drive engineering. The publication "Project Planning for Drives" provides a
comprehensive collection of the the most important formulas needed for drive calculation,
as well as detailed examples for the most frequently used applications. No doubt, it is a very
valuable tool for project planning!

You may download "Project Planning for Drives" by scanning the bar code below. Or, you
may go to the following link: www.seweurodrive.com/download/pdf/10522913.pdf

The following catalogs are also available from SEW-EURODRIVE for assistance with
project planning:

• DRE.. Gearmotors (IE2 efficiency)

• DRP.. and DRN.. Gearmotors (IE3 efficiency)
• Synchronous servo gearmotors
• X series Industrial Gear Units

You may request a hard copy of these catalogs by calling SEW-EURODRIVE, or download
them from www.seweurodrive.com.

INFORMATION

Online assistance for conveyor, hoisting,

and travel drive applications is available
through SEW-EURODRIVE’s exclusive
PT Pilot® calculator.

Simply enter your drive parameters and

let PT Pilot® do all of the work. Visit
www.ptpilot.com.

42 Gear Units – 2016

 Project Planning
Selection procedure 4
4.3 Selection procedure 1
The following flowchart presents a schematic view of the procedure for planning a project
incorporating a gear unit with a component on the input side. 2

Necessary information regarding the machine to be driven 3

– Technical data and environmental conditions
– Positioning accuracy 4
– Travel cycle calculation

5
Calculation of the application data
– Static, dynamic, and regenerative power
– Speeds 6
– Torques
– Travel diagrams 7

Gear unit selection 8
– Define gear unit size, gear unit ratio and gear unit type
– Check the positioning accuracy
– Check the gear unit torque against the load torque for proper service factor 9

Selecting components on the input side 10
– Specify input type
– Check the axial and radial loads on input 11
– Define input size

12
Options
– Monitoring functions (devices, equipment)
– Brake (for AT only) 13
– Backstop
– Centering shoulder 14
– Motor mounting platform

15
Make sure that all requirements have been met.

16

17

18

19

20

21

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Gear Units – 2016 43

4 Project Planning
Gear efficiency and thermal losses

4.4 Gear efficiency and thermal losses

The efficiency of gear units is mainly determined by the gearing and bearing friction. The
starting efficiency of a gear unit is always less than its efficiency at operating speed. This is
particularly true for helical-worm and SPIROPLAN® right-angle gear units. Gear units are
listed below in order of highest efficiency to lowest efficiency.

R, F, and K The helical (R), parallel shaft (F) and helical-bevel (K) gear units (excluding K19, K29, K39,
K49) contain 100% rolling friction and the highest efficiency. Efficiency depends on the
number of gear stages: 96% (3-stage), 97% (2-stage) and 98% (1-stage).

K..19 - K..49 These right-angle units contain 2-stage hypoid gearing that combines rolling friction with
minor sliding friction. Their efficiency ranges from 90% to 96%, depending on the ratio.
Current sizes include K19, K29, K39, and K49.

W - SPIROPLAN® The SPIROPLAN® gear units (W-series) combine rolling friction with some sliding friction,
similar to hypoid gearing. The sliding friction induces some loss and lower efficiency than R,
F or K gear units, but higher efficiency than a helical-worm (S-series).
The SPIROPLAN® gear units W37 and W47 contain a helical input stage. Therefore, they
have the highest efficiency of the SPIROPLAN® gear units (>90%), dropping only slightly for
larger ratios.
The efficiency depends on the following factors:
• Gear ratio
• Input speed
• Ambient temperature

S-series The helical-worm (S-series) gear units contain a first stage helical gear set and a second
stage worm set. Various degrees of sliding friction occurs in the worm set, depending on the
number of starts on the worm gear. Therefore, these gear units have higher losses and
lower efficiency than other SEW-EURODRIVE gear units. However, they are still
significantly more efficient than single stage worm gear units common in the industry.
The efficiency depends on the following factors:
• Gear ratio (number of starts on worm)
• Input speed
• Ambient temperature

Self-locking Backdriving torques on helical-worm or SPIROPLAN® gear units produce an efficiency of

' = 2 - 1/, which is significantly less than the forward efficiency, . The helical-worm or
SPIROPLAN® gear unit is self-locking if the forward efficiency is   0.5, which may occur on
some higher ratios. Therefore, some SPIROPLAN® gear units are dynamically self-locking.
Contact SEW-EURODRIVE if you wish to make technical use of the braking effect of self-
locking characteristics.

INFORMATION
Note that the self-locking effect of helical-worm and SPIROPLAN® gear units should
not be used as the sole safety function for hoists!

44 Gear Units – 2016

 Project Planning
Gear efficiency and thermal losses 4
Run-in phase When gears are initially manufactured, the tooth flanks of helical-worm and SPIROPLAN® 1
gear units are not 100% smooth. They require a run-in period in order to achieve their
maximum polish. Therefore, there is a greater friction angle and less efficiency during initial
operation. This effect intensifies with higher gear ratios. To determine the startup efficiency, 2
subtract the following values from the listed efficiency:
3
Helical-Worm
Ratio Range  reduction 4
1-start approx. 50 ... 280 approx. 12 %
2-start approx. 20 ... 75 approx. 6 % 5
3-start approx. 20 ... 90 approx. 3 %
5-start approx. 6 ... 25 approx. 3 %
6
6-start approx. 7 ... 25 approx. 2 %

7
®
SPIROPLAN W..
Ratio Range  reduction 8
approx. 30 ... 75 approx. 8 %
approx. 10 ... 30 approx. 5 % 9
approx. 3 ... 10 approx. 3 %

10
The run-in period usually lasts 48 hours. Helical-worm and SPIROPLAN® gear units achieve
their rated efficiency under the following conditions: 11
• The gear unit has completed the run-in period
• The gear unit has reached nominal operating temperature 12
• The gear unit contains the recommended lubricant and fill quantity
• The gear unit is operating in the rated load range 13

14
Thermal losses In certain gear unit mounting positions (see chapter "Mounting Positions"), the first gearing
stage is completely immersed in the lubricant. When the circumferential velocity of the input 15
stage is high, considerable churning losses occur, especially in larger gear units (> size 87),
or with input speeds > 1750 rpm. As a result, the gear unit may have a reduced input HP 16
rating. Substituting synthetic oil and high temperature FKM seals often permits a higher
operating temperature and increases the HP rating.
17
To keep churning losses to a minimum, use gear units in M1 mounting position whenever
possible. For more information on gear units with AD input shaft assembly, see page 63.
18

INFORMATION 19
For thermal limitations, you may visit www.ptpilot.com. PT Pilot® uses average
conduction and convection to figure your thermal limitation. It also provides a complete 20
quotation, including all motor and gear unit options.

21

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Gear Units – 2016 45

4 Project Planning
Service factor and inertia

4.5 Service factor and inertia

Inertia The inertia acceleration factor, IAF, is the ratio between the system (load) inertias and the
acceleration motor inertias. It is an important factor that determines system stability and gear unit service
factor factor. It is calculated at the motor shaft, as follows:

J +J +J
gear apt x
IAF = -------------------------------------------------
J mot + J b + J z

Jx = Inertia of all load components reflected to the motor shaft

Jgear = Inertia of gear unit (ratio dependent)
Japt = Inertia of input adapter (AD, AM, AT, AQ)
Jmot = Inertia of motor without brake
Jb = Inertia of the brake on motor shaft (if applicable)
Jz = Inertia of the cast iron fan on motor (if applicable)

Values for Jmot and Jz are available in the motor section of SEW catalogs. Jb is already
included in the value for Jmot if you select the column for brakemotor. Both Jgear and Japt are
often negligible, especially on smaller gear units.

Jx can be calculated from the application formulas below.

Linear Motion Rotational Motion

(Conveyor, Travel Drive, Hoist) (Turntable, Solid Cylinder)

W T  V max 2 W T  D 2  n t 2
J x = -----------   ----------------  J x = ---------   ------    -------- 
39.5  n m  2  24   n m 

WT = Total weight (lbs)

Vmax = Maximum velocity (feet per minute)
D = Diameter of turntable or cylinder (in)
nt = Turntable speed (rpm)
nm = Motor full-load speed (rpm)

Load There are three load classifications, based upon the inertia acceleration factor:
classification

Load Class Type IAF

(I) Uniform IAF  0.2
(II) Moderate Shock 0.2  IAF  3.0
(III) Heavy Shock 3.0 IAF  10

Contact SEW-EURODRIVE for inertia acceleration factor > 10.

46 Gear Units – 2016

 Project Planning
Service factor and inertia 4
SEW service The load from the driven machine imposes a shock on the gear unit. The degree of shock 1
factor, fB depends upon the load inertia, motor inertia, daily operating time, and starting frequency.
The SEW service factor, fB, considers all of these variables.
2
Since the method for determining the maximum output torque rating can vary among gear
manufacturers, the required SEW service factor applies to SEW gear units. As such, this
service factor may differ from an AGMA service factor, or the service factor from another 3
manufacturer. However, even when fB=1.0, the SEW gear unit contains an extremely high
level of safety and reliability in the fatigue strength range.
4
Service factor is determined from Figure 1 below, using the load classifications I, II, III as
defined on page 46. For proper project planning, the maximum permissible output torque of
the gear unit (as shown in the selection tables within this catalog) must be greater than the 5
load torque multiplied by the SEW service factor, fB, per the following equation.
6

T amax   Ta  fB  7

Ta = load torque 8
Tamax = maximum permissible output torque (from gear unit tables)
9
24* 16* 8*
(III)
10
1.8 1.7 1.6
1.5 11
1.7 1.6 (II)
1.4
1.5 12
fB 1.6 1.3
1.4
1.5 1.2 (I) 13
1.3
1.1
1.4
1.2 14
1.0
1.3 1.1 0.9 15
1.2 1.0 0.8
0 200 400 600 800 1000 1200 1400 16
Z [1/h] **
00656BXX 17
Figure 1: SEW service factor fB

* Daily operating time in hours/day 18

** Frequency, Z, is the sum of all load changes within one hour, which includes all
instances of starting, braking, and speed changes. Example: In one hour, a
2-speed motor starts 50 times, switches from low to high speed 50 times, switches 19
from high to low speed 50 times, and stops 50 times. In this case, Z= 200.
20
fB>1.8 can occur with large inertia acceleration factor (>10), high levels of backlash in the
transmission elements, or a large overhung load. Contact SEW-EURODRIVE. 21

22

Gear Units – 2016 47

4 Project Planning
Service factor and inertia

Example 1 • Inertia acceleration factor = 2.5

• 14 hours/day operation
• 300 load changes/hour
• R, F, or K-series gear unit required

Using the load classification table: when IAF = 2.5 then,

Load class = II.

From Figure 1: Using the column for 16 hr/day (round up 14 hrs/day) and load class II,
fB = 1.5.

Therefore, the R, F, or K gear unit must have torque rating,

Tamax > (load torque x 1.5)

48 Gear Units – 2016

 Project Planning
Service factor and inertia 4
Helical-worm For helical-worm (S-series), two additional service factors, fB1 and fB2, are needed and 1
(S-series) obtained from Figure 2 below. Contact SEW-EURODRIVE if the temperature < -20°C [-4°F].

2
• fB1 = Service factor from ambient temperature
• fB2 = Service factor based upon %ED, which is the amount of time the motor is operating 3
compared to the time that it is resting.

Time under load in min/hr

%ED = ---------------------------------------------------------------------  100 5
60
6

f B1 (I) 7
1.8
(II)
8
1.6
fB2
(III)
9
1.4 1.0

1.2 0.8
10

1.0 °C 0.6 %ED 11

-20 -10 20 30 40 50 0 20 40 60 80 100
00657BXX
Figure 2: Additional service factors fB1 and fB2 12

13
The total service factor for a helical-worm gear unit becomes:

14
f Btotal = f B  f B1  f B2
15

16

17

18

19

20

21

22

Gear Units – 2016 49

4 Project Planning
Service factor and inertia

Example 2 Change example 1 to use a helical-worm gear unit with the additional conditions below.

• Inertia acceleration factor = 2.5 (load class = II

• 14 hours/day operation
• 300 load changes/hour
• Ambient temperature = 40°C
• Time under load = 40 min/hour
• Load Torque = 4200 lb-in
• 29:1 ratio

From Figure 1 using 16 hr/day,

fB = 1.50

Calculate %ED,
ED = 40/60 = 66.7%.

Using Figure 2,
fB1 = 1.40
fB2 = 0.95

The total service factor becomes,

fBtotal = 1.50  1.40  0.95 = 2.0

Therefore, the helical-worm gear unit must have an output torque rating,
Tamax > (4200 lb-in x 2.0)
Tamax > 8400 lb-in

From the S67 gear unit table on page 582, Tamax = 4240 lb-in, which is too low.
Thus, the solution requires an S77, 28.41:1, Tamax = 8750 lb-in, as shown on page 584.

50 Gear Units – 2016

 Project Planning
Axial forces and overhung loads 4
4.6 Axial forces and overhung loads 1

Axial force If there is no overhung load, then an axial force. FA (tension or compression) equal to 50% 2
of the overhung load given in the selection tables is permitted on the output shaft. The 50%
rule applies to the following gear units: 3

• R-series helical gearmotors except R..137... to R..167... 4

• F-series parallel shaft with solid shaft except F97...
• K-series helical-bevel with solid shaft 5
• S-series helical-worm gear units with solid shaft
6
INFORMATION
7
Contact SEW-EURODRIVE for all other types of gear units, a greater axial load, or a
combination of an overhung load and an axial load. 8

Overhung load The type of transmission component that is mounted to the output shaft has a direct impact
10
(OHL) on the overhung load. Some components impart higher forces than others, as shown by the
transmission factor, fZ in the following table.
11
Component Transmission factor fZ Comments
Gears 1.15 < 17 teeth
Chain sprockets 1.40 < 13 teeth
12
Chain sprockets 1.25 < 20 teeth
Narrow V-belt pulleys 1.75 Due to pre-tension 13
Flat belt pulleys 2.50 Due to pre-tension
Timing or toothed belt pulleys 2.00 - 2.50 Due to pre-tension 14
Gear rack pinion, pre-tensioned 2.00 Due to pre-tension
15
The following formula determines the overhung load on the output shaft of a gear unit.
16

17
2T
F R = -----------  f z
d o 18

FR = Overhung load (lbs) 19

T = Load torque (lb-in)
d0 = Diameter of the gear, sprocket, or pulley (in inches) 20
fZ = Transmission factor
21

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Gear Units – 2016 51

4 Project Planning
Axial forces and overhung loads

Permissible OHL The basis for determining the permissible overhung loads is the calculation of the rated
bearing service life L10h of the rolling bearings (according to ISO 281).

The overhung load rating changes for every angle,  and direction of rotation. Since the
rating listed in the catalog is based upon the most unfavorable angle and direction, a higher
overhung load rating is possible when considering your specific angle and rotation. In
addition, even higher loads are permitted if heavy duty bearings are installed on the output
shaft of R, F, and K gear units. Contact SEW-EURODRIVE in such cases. Use the figure
below to specify your angle of force.

The application force, is defined according to the following figure:

X
α α FR

0° FA
0°

63214axx

 = angle of force
FR = Permissible overhung load at distance, x [lbs]
FA = Permissible axial load [lbs]

INFORMATION
The overhung load values (FRa) shown in the rating tables of this catalog refer to a force
applied at the center of a standard-length solid output shaft. These values are also
based upon the most unfavorable application angle,  and direction of rotation.
For OHL values of a hollow shaft gear unit, please consult SEW-EURODRIVE.

INFORMATION
Reduction of overhung loads
• Only 50% of the FRa value specified in the selection tables is permitted in mounting
position M1 with wall attachment on the front face for K and S gear units.
• Helical-bevel gearmotors K167 and K187 in mounting positions M1 to M4: A
maximum of 50% of the overhung load FRa specified in the selection tables in the
case of gear unit mounting other than as shown in the mounting position sheets.
• Foot and flange-mounted helical gearmotors (R..F): A maximum of 50% of the
overhung load FRa specified in the selection tables in the case of torque
transmission via the flange mounting.

52 Gear Units – 2016

 Project Planning
Axial forces and overhung loads 4
OHL conversion Please contact SEW-EURODRIVE to determine the permissible overhung load for an input 1
shaft assembly (ex: R67AD2) when the overhung load force is not located at the center of
the input shaft.
2
When the overhung load force is not applied at the midpoint of the output shaft, the following
formulas should be used to determine two permissible overhung load values - FxL for 3
bearing life, and FxW for shaft strength. The constants in the formulas are listed on the next
page for each gear unit size. 4
The final permissible value, FR, for the overhung load at point, x, is the smaller of the two
values of FxL and FxW. 5

FxL, based on bearing life: 6

a 7
F xL = F Ra  ------------- [lb]
b+x
8

9
FxW, based upon shaft strength:
10

3
 10 - [lb] 11
F xW = c---------------
f+x
12

FRa = Permitted overhung load [lb] at the midpoint (x = I/2) of the output shaft for foot- 13
mounted gear unit. See selection tables.
x = Distance from the shaft shoulder to the point of application [in] 14
a, b, f = Gear unit constants for overhung load conversion [in]
c = Gear unit constant for overhung load conversion [lb-in] 15

Figure 3 shows the overhung load FR not located at the shaft mid-point: 16

x
17
FRa
FRa
FR FR 18
l/2
19
d
d

l x 20
63215axx
Figure 3: Overhung load, FR not located at shaft midpoint 21

22

Gear Units – 2016 53

4 Project Planning
Axial forces and overhung loads

Constants for
overhung load
a b c f d l
conversion Gear unit type
[in] [in] [lb-in] [in] [in] [in]
RX/RXF57 1.71 0.93 1.34 1.35 0.750 1.57
RX/RXF67 2.07 1.08 2.14 1.56 1.000 1.97
RX/RXF77 2.38 1.20 1.73 0 1.250 2.36
RX/RXF87 2.89 1.32 6.81 1.93 1.625 3.15
RX/RXF97 3.41 1.44 12.66 2.12 2.125 3.94
RX/RXF107 4.04 1.67 21.86 2.45 2.375 4.72
R/RF07 2.83 2.05 0.41 0.43 0.750 1.57
R/RF17 3.48 2.70 0.58 0.67 0.750 1.57
R/RF27 4.19 3.21 1.38 0.46 1.000 1.97
R/RF37 4.65 3.66 1.10 0 1.000 1.97
R/RF47 5.39 4.21 2.16 0.59 1.250 2.36
R/RF57 5.81 4.43 3.34 0.71 1.375 2.76
R/RF67 6.63 5.26 2.35 0 1.375 2.76
R/RF77 6.84 5.26 3.51 0 1.625 3.15
R/RF87 8.53 6.56 7.50 0 2.125 3.94
R/RF97 10.06 7.70 10.53 0 2.375 4.72
R/RF107 11.24 8.48 18.23 0 2.875 5.51
R/RF137 13.52 10.18 54.34 1.18 3.625 6.69
R/RF147 15.83 11.69 76.56 1.30 4.375 8.27
R/RF167 17.72 13.58 111.52 0 4.750 8.27
F27 4.31 3.33 1.00 0 1.000 1.97
F37 4.86 3.88 0.95 0 1.000 1.97
F47 6.04 4.86 1.58 0 1.250 2.36
F57 6.72 5.34 4.86 1.26 1.375 2.76
F67 7.14 5.56 3.65 0 1.625 3.15
F77 8.50 6.53 6.97 0 2.000 3.94
F87 10.35 7.99 10.53 0 2.375 4.72
F97 13.78 11.02 18.50 0 2.875 5.51
F107 14.70 11.36 37.44 0 3.625 6.69
F127 17.42 13.29 83.64 0 4.375 8.27
F157 20.16 16.02 92.93 0 4.750 8.27
K37 4.86 3.88 1.25 0 1.000 1.97
K47 6.04 4.86 1.58 0 1.250 2.36
K57 6.68 5.30 6.02 1.22 1.375 2.76
K67 7.14 5.56 3.65 0 1.625 3.15
K77 8.50 6.53 6.81 0 2.000 3.94
K87 9.92 7.56 14.52 0 2.375 4.72
K97 12.56 9.80 24.78 0 2.875 5.51
K107 14.70 11.36 48.94 0 3.325 6.69
K127 17.46 13.33 73.55 0 4.375 8.27
K157 20.04 15.91 104.44 0 4.750 8.27
K167 24.47 19.55 166.39 0 6.250 9.84
K187 28.37 22.07 269.06 0 7.500 12.60
3.34 2.55 0.32 0 0.625 1.57
W10
3.88 3.09 0.39 0 0.750 1.57
W20
4.31 3.52 0.53 0 0.750 1.57
W30
4.77 3.98 0.61 0 0.787 1.57
W37
5.73 4.55 3.74 1.40 1.181 2.36
W47

S37 4.67 3.88 0.53 0 0.750 1.57

S47 5.12 4.13 1.18 0 1.000 1.97
S57 5.91 4.72 1.89 0 1.250 2.36
S67 7.24 5.87 2.69 0 1.375 2.76
S77 8.82 7.05 4.66 0 1.750 3.54
S87 11.08 8.72 14.87 0 2.375 4.72
S97 12.85 10.09 22.48 0 2.875 5.51

d = standard diameter of output shaft [in]

l = standard length of output shaft [in]

Values for gear unit types not listed are available on request.

54 Gear Units – 2016

 Project Planning
AM adapter with IEC/NEMA motor 4
4.7 AM adapter with IEC/NEMA motor 1
Power ratings,
mass moments of
Type (IEC) Type (NEMA) Pm1) [HP] Japt [lb-ft²]
2
inertia
AM63 - 0.33 1.05 x 10-3
AM71 AM56 0.50 1.05 x 10-3 3
-3
AM80 AM143 1.0 4.51 x 10
AM90 AM145 2.0 4.51 x 10-3 4
-3
AM100 AM182 4.0 12.34 x 10
AM112 AM184 5.4 12.34 x 10-3 5
AM132S/M AM213/215 10 45.1 x 10-3
AM132ML - 12.5 45.1 x 10-3 6
AM160 AM254/256 20 216 x 10-3
AM180 AM284/286 30 214 x 10-3
7
AM200 AM324/326 40 413 x 10-3
AM225 AM364/365 60 413 x 10-3
8
AM250 - 75 411 x 10-3
AM280 - 125 1626 x 10-3
9
1) Maximum rated power of the mounted electric motor at 1750 rpm

10
Selecting the
gear unit 11
Determine the gear unit type

From the gear unit selection tables with AM adapter, determine the gear unit size based upon: 12
• the maximum output torque (Tamax)
• gear ratio (i)
13

Check the maximum permissible overhung load value on the output shaft (FRa)
14

Check the maximum permissible input power at the adapter (Pm) using the chart above and/or
the equation below. 15

Is the required gear ratio available with the required adapter size? 16

17

Input power (Pm) The maximum input power (Pm) shown in this catalog corresponds to 1750 rpm. For input 18
at alternate speed speeds other than 1750, use the formula below to calculate the maximum input power.

19
RPM new
P new = P m  -------------------------- 20
1750
21

22

Gear Units – 2016 55

4 Project Planning
AM adapter with IEC/NEMA motor

Backstop If the application requires only one direction of rotation, the AM adapter can be configured
AM../RS with a backstop. Backstops with centrifugal lift-off sprags are used. The advantage of this
design is that above a certain speed (lift-off speed), the sprags move around inside the back-
stop without making contact. Therefore, the backstop is suited for high speeds and operates
maintenance free, wear-free, and without losses.

Dimensions:
The backstop is completely integrated inside the adapter. Therefore, the dimensions are the
same with or without backstop.

Locking torques:
Type Maximum locking Minimum
torque of the backstop lift-off speed
[lb-in] [rpm]
AM80/90/RS,
575 820
AM143/145/RS
AM100/112/RS,
3760 620
AM182/184/RS
AM132/RS,
7525 530
AM213/215/RS
AM160/180/RS,
12830 480
AM254/286/RS
AM200/225/RS,
17260 450
AM324-365/RS
AM250/280/RS 17260 450

56 Gear Units – 2016

 Project Planning
AR adapter with torque limiting coupling 4
4.8 AR adapter with torque limiting coupling 1

If torque limiting is desired for compound gear units (ex: R77R37..), the AR adapter 2
containing a torque limiting coupling should preferably be placed between the two gear units
(ex: R77AR95R37...) rather than placed at the motor. Please contact SEW-EURODRIVE if 3
you intend to use a torque limiting coupling with a compound gear unit.

4
Selecting the If torque limiting is required for a single gear unit (ex:R77), the AR adapter is placed between
gear unit the gear unit and motor. The sizes of the AR adapters correspond to those of the AM
adapters for IEC motors. 5
This means you can select the gear unit using the selection tables for IEC AM adapters.
Then, substitute the unit designation "AM" with "AR" and determine the required slip torque. 6

The slip torque should be about 1.5 times the rated torque of the drive. When determining 7
the slip torque, bear in mind the maximum permissible output torque of the gear unit as well
as the variations in the slip torque of the coupling (+/-20%) which are a feature of the design. 8
When you order a gear unit with adapter and torque limiting coupling, please specify the
required slip torque of the coupling. If you do not specify, it will be set according to the 9
maximum permissible output torque of the gear unit.

10
Slip torque
values
Type Pm1) [HP]
MR2) [lb-in] 11
Option 1 Option 2 Option 3
AR71 .50 9 - 53 54 - 142 - 12
AR80 1.0 9 - 53 54 - 142 -
AR90 2.0 9 - 53 54 - 142 150 - 285
13
AR100 4.0 44 - 115 124 - 708 -
AR112 5.4 44 - 115 124 - 708 -
14
AR132S/M 10 133 - 1150 - -
AR132ML 12.5 133 - 1150 - -
AR160 20 265 - 750 760 - 1770 -
15
AR180 30 265 - 750 760 - 2660 -
1) Maximum rated power of the mounted electric motor at 1750 rpm
16
2) Adjustable slip torque according to cup springs
17

18

19

20

21

22

Gear Units – 2016 57

4 Project Planning
AR adapter with torque limiting coupling

Speed monitor SEW-EURODRIVE recommends monitoring the speed of the coupling using a speed mon-
option /W itor to avoid uncontrolled slippage of the coupling and the associated wear on the friction
ring pads.
The speed of the output end coupling half is detected in a proximity-type method using a
trigger cam and an inductive encoder. The speed monitor compares the pulses with a
defined reference speed. The output relay (NC or NO contact) trips when the speed drops
below the specified speed (overload). The monitor is equipped with a start bypass to
suppress error messages during the startup phase. The start bypass can be set within a time
window of 0.5 to 15 seconds.
Reference speed, start bypass and switching hysterisis can be set on the speed monitor.
The following figure shows the adapter with torque limiting coupling and speed monitor,

[8]
[1] [2] [3] [4] [5] [6] [7]

65931AXX

[1] Trigger cam [5] Cup spring

[2] Encoder (adapter) [6] Slotted nut
[3] Driving disk [7] Friction hub
[4] Friction ring pads [8] Speed monitor

Connection The encoder is connected to the slip monitor using a two or three-core cable (depending on
the encoder type).
• Maximum cable length: 500 m with a line cross section of 1.5 mm2
• Standard supply cable: 3-core / 2 m
• Route the signal lines separately (not in multicore cables) and shield them, if necessary.
• Degree of protection: IP40 (terminals IP20)
• Operating voltage: AC 220 V or DC 24 V
• Maximum switching capability of the output relay: 6 A (AC 250 V)

58 Gear Units – 2016

 Project Planning
AR adapter with torque limiting coupling 4
Terminal 1
assignment
The following figure shows the terminal assignment for /W:
2
1 9
2 10 3
3 11
[7] [6] 4 12 4
5 13 [1]
/W
[4]
6 14 5
7 15
[2]
8 16 6
53653AXX

[1] Relay output [6] Signal 7

[2] Connection voltage AC 230 V (47 to 63 Hz) [7] Encoder
[3] External slip reset [/W] Speed monitor 8
[4] DC 24 V supply voltage
[5] Jumper for synchronous operation monitoring 9

Dimensions The following figure shows the dimensions for /W: 10

11

12

13

14

52250AXX 15

16

17

18

19

20

21

22

Gear Units – 2016 59

4 Project Planning
AD input shaft

4.9 AD input shaft

Selecting the
gear unit
Determine the gear unit type.

Determine the gear unit size based on the
• maximum output torque (Ta max)
• gear ratio (i)
Look in the gear unit selection tables with input shaft assembly AD.
When selecting AD/P, please observe the weight limitation for additional components as shown
on page 62.

Check the maximum overhung load permissible on the output shaft (FRa).

Check the maximum input power permissible on the input of the gear unit (Pe). Observe the
thermal limit rating.

Check the overhung load at the input (FRe). The larger the AD size (ie: AD3 vs. AD2), the higher the
price. So for maximum savings, select the smallest AD size that meets the overhung load rating.

If the case of higher requirements (e.g. larger overhung load on the input shaft), please contact
SEW-EURODRIVE.

Centering The input shaft assembly can be configured with a machined centering shoulder as an option.
shoulder AD../ZR This allows the customer to locate the exact center of the input shaft for proper alignment.

Backstop AD../RS The input shaft assembly can be supplied with a backstop if only one direction of rotation is
permissible. Backstops with centrifugal lift-off sprags are used. The advantage of this design
is that above a certain speed (lift-off speed), the sprags move around inside the backstop
without making contact. Therefore, the backstop is suited for high speeds and operates
maintenance free, wear-free, and without losses.

Dimensions:
The backstop is completely integrated inside the cover. Therefore, there is no difference in
dimensions between an input shaft assembly with or without a backstop (see dimension
sheets in the "Input shaft assembly AD" chapter).

Locking torques:
Type Maximum backstop locking torque Minimum lift-off speed
[lb-in] [rpm]
AD2/RS 575 820
AD3/RS 3760 620
AD4/RS 7525 530
AD5/RS 12830 480
AD6/RS 17260 450
AD7/RS 17260 450
AD8/RS 17260 450

60 Gear Units – 2016

 Project Planning
AD input shaft 4
Motor mounting 1
platform AD.. /P
Available The following table shows the motors that are available for each mounting platform. The 2
combinations highlighted cells show the additional weight (lbs) that is permissible for installed components
(pulley, sprockets, belts, etc).
Motor mounting platform
3
DRS Motor AD2/P AD3/P AD4/P AD5/P AD6/P AD7/P
DRS71S 12 4
DRS71M 12
DRS80S 12
DRS80M 12 25
5
DRS90M 12 25
DRS90L 25 6
DRS100M 25
DRS100L 25
DRS100LC 25
7
DRS112M 25
DRS132S 50 8
DRS132M 50
DRS132MC 50
DRS160S 50 90
9
DRS160M 90
DRS160MC 90 10
DRS180S 90
DRS180M 90
DRS180L 90
11
DRS180LC 90
DRS200L 135 12
DRS225S 135
DRS225M 135
DRS225MC 135
13
DV250 225
DV280 225 14
Combination is available / additional weight for installed components (lb)
15

16

17

18

19

20

21

22

Gear Units – 2016 61

4 Project Planning
AD input shaft

Permissible Permissible weights for installed components (pulley, sprockets, belts, etc).
Weights
Motor mounting platform
DRE Motor AD2/P AD3/P AD4/P AD5/P AD6/P AD7/P
DRE80S 12
DRE80M 12
DRE90M 12 25
DRE90L 12 25
DRE100M 25
DRE100L 25
DRE100LC 25
DRE112M 25
DRE132S 25
DRE132M 50
DRE132MC 50
DRE160S 50 90
DRE160M 90
DRE160MC 90
DRE180S 90
DRE180M 90
DRE180L 90
DRE180LC 90
DRE200L 135
DRE225S 135
DRE225M 135
DVE250 225
DVE280 225

Motor mounting platform

DRP Motor AD2/P AD3/P AD4/P AD5/P AD6/P AD7/P
DRP80M 12
DRP90M 12 25
DRP90L 12 25
DRP100M 25
DRP100L 25
DRP100LC 25
DRP112M 25
DRP132M 50
DRP132MC 50
DRP160S 50 90
DRP160M 50 90
DRP160MC 90
DRP180S 90
DRP180M 90
DRP180L 90
DRP180LC 90
DRP200L 135
DRP225S 135
DRP225M 135
DRP225MC 135

Combination is available / additional weight for installed components (lb)

62 Gear Units – 2016

 Project Planning
AD input shaft 4
Thermal The power values given in the selection tables for gear units with AD input shaft assembly 1
limitations with are based upon mechanical limitations. However, depending on the mounting position, gear
AD input units may become thermally overloaded before they reach the mechanical limit. The column
in the selection tables (as circled below) lists mounting positions that may reduce the input 2
power rating for each ratio.
3
R107 AD... , ne = 1700 rpm 38060 lb-in
i na Tamax Pe FRa FRe Stages  (/R) 4
[ratio] [rpm] [lb-in] [HP] [lb] [lb] Lg Sm [']

50494AUS 5
Please contact SEW-EURODRIVE if the mounting position you require is shown in this
column. By considering the actual operating conditions, SEW-EURODRIVE can calculate 6
the thermal limit rating based upon the specific application. Often, alternate measures are
available (ex: using FKM seals and a synthetic lubricant with higher thermal stability) to 7
increase the thermal rating of the gear unit.

8
The following data is required for recalculation:
9
Gear unit type ... R, S, K, F, or W

Gear unit size ... 37, 47, etc. 10

Input speed ............... rpm
11
Gear ratio, i

Cyclic duration factor, CDF ................. % 12

Ambient temperature ............... °C
13
Load power ............... HP

Environment / convection ... in small, enclosed rooms

... in large rooms, halls
14
... outdoors
15
Installation / conduction ... base made of steel or concrete

16

17
INFORMATION
You may also visit our online selection program at www.ptpilot.com. PT Pilot 18
automatically calculates your oil sump temperature based upon your mounting position
and ambient temperature. When applicable, PT Pilot® adds synthetic oil and FKM seals
for proper protection against heat.
19

20

21

22

Gear Units – 2016 63

4 Project Planning
RM - extended bearing housing

4.10 RM - extended bearing housing

Project Planning You must take account of the higher overhung and axial loads when planning projects with
RM helical gear units with extended bearing hub. Observe the following project planning
procedure. Note that all values are metric.

See next page

for data tables
Permissible axial load from table (N)
Axial loads during operation (N)
Gear-unit constant from data table
Overhung loads during operation (N)
Permissible overhung load (at x=1000 mm) from data table (N)
Permissible overhung load due to flange tensile strength (N)
Permissible overhung load due to bearing life (N)

X Distance between force application

and shaft shoulder (mm)
all other bearing hours upon request
T Output Torque (Nm)

X < 500mm?

X
?

(FR X/FAa )<100 Fa / Ta > 3

?

End of
Project Planning
02457BUS

64 Gear Units – 2016

 Project Planning
RM - extended bearing housing 4
Permissible The permissible overhung loads FRa and axial forces FAa are listed below for various service 1
overhung loads factors fB and nominal bearing service life L10h.
and axial forces
2
fBmin = 1.5; L10h = 10,000 h
Output speed na [rpm] 3
< 16 16-25 26-40 41-60 61-100 101-160 161-250 251-400

RM57
FRa [N] 400 400 400 400 400 405 410 415 4
FAa [N] 18800 15000 11500 9700 7100 5650 4450 3800
FRa [N] 575 575 575 580 575 585 590 600
RM67 5
FAa [N] 19000 18900 15300 11900 9210 7470 5870 5050
FRa [N] 1200 1200 1200 1200 1200 1210 1210 1220
RM77
FAa [N] 22000 22000 19400 15100 11400 9220 7200 6710
6
FRa [N] 1970 1970 1970 1970 1980 1990 2000 2010
RM87
FAa [N] 30000 30000 23600 18000 14300 11000 8940 8030 7
FRa [N] 2980 2980 2980 2990 3010 3050 3060 3080
RM97
FAa [N] 40000 36100 27300 20300 15900 12600 9640 7810 8
FRa [N] 4230 4230 4230 4230 4230 4230 3580 3830
RM107
FAa [N] 48000 41000 30300 23000 18000 13100 9550 9030 9
FRa [N] 8710 8710 8710 8710 7220 5060 3980 6750
RM137
FAa [N] 70000 70000 70000 57600 46900 44000 35600 32400
10
FRa [N] 11100 11100 11100 11100 11100 10600 8640 10800
RM147
FAa [N] 70000 70000 69700 58400 45600 38000 32800 30800
FRa [N] 14600 14600 14600 14600 14600 14700 - -
11
RM167
FAa [N] 70000 70000 70000 60300 45300 36900 - -
12
fBmin = 2.0; L10h = 25,000 h
Output speed na [rpm]
13
< 16 16-25 26-40 41-60 61-100 101-160 161-250 251-400
FRa [N] 410 410 410 410 410 415 415 420 14
RM57
FAa [N] 12100 9600 7350 6050 4300 3350 2600 2200
FRa [N] 590 590 590 595 590 595 600 605 15
RM67
FAa [N] 15800 12000 9580 7330 5580 4460 3460 2930

RM77
FRa [N] 1210 1210 1210 1210 1210 1220 1220 1220 16
FAa [N] 20000 15400 11900 9070 6670 5280 4010 3700
FRa [N] 2000 2000 2000 2000 2000 1720 1690 1710
RM87 17
FAa [N] 24600 19200 14300 10600 8190 6100 5490 4860
FRa [N] 3040 3040 3040 3050 3070 3080 2540 2430
RM97
FAa [N] 28400 22000 16200 11600 8850 6840 5830 4760
18
FRa [N] 4330 4330 4330 4330 4330 3350 2810 2990
RM107
FAa [N] 32300 24800 17800 13000 9780 8170 5950 5620 19
FRa [N] 8850 8850 8850 8830 5660 4020 3200 5240
RM137
FAa [N] 70000 59900 48000 37900 33800 31700 25600 23300 20
FRa [N] 11400 11400 11400 11400 11400 8320 6850 8440
RM147
FAa [N] 70000 60600 45900 39900 33500 27900 24100 22600 21
FRa [N] 15100 15100 15100 15100 15100 13100 - -
RM167
FAa [N] 70000 63500 51600 37800 26800 23600 - -
22

Gear Units – 2016 65

4 Project Planning
RM - extended bearing housing

Conversion The following conversion factors and gear unit constants apply to calculating the permissible
factors and gear overhung load FxL at point x  1000 mm for RM gearmotors:
unit constants
Gear unit type a b cF (fB = 1.5) cF (fB = 2.0) FF
RM57 1047 47 1220600 1260400 277
RM67 1047 47 2047600 2100000 297.5
RM77 1050 50 2512800 2574700 340.5
RM87 1056.5 56.5 4917800 5029000 414
RM97 1061 61 10911600 11124100 481
RM107 1069 69 15367000 15652000 554.5
RM137 1088 88 25291700 25993600 650
RM147 1091 91 30038700 31173900 756
RM167 1089.5 89.5 42096100 43654300 869

Additional weight
of RM gear units
Type Additional weight of RM compared to RF
(compared to the smallest RF flange)
weight [lbs]
RM57 +26
RM67 +35
RM77 +55
RM87 +66
RM97 +113
RM107 +194
RM137 +245
RM147 +369
RM167 +431

66 Gear Units – 2016

 Project Planning
DUO - Oil aging monitor 4
4.11 DUO - Oil aging monitor 1

DUO10A 2
diagnostic unit
DUO10A Technical data
CLP mineral oil. Tmax = 100 °C 3
OIL1
Bio oil Tmax = 100 °C

Preset oil grades OIL2

CLP HC synthetic oil: Tmax = 130 °C 4
CLP PAO oil Tmax = 130 °C
OIL3 CLP PG polyglycol Tmax = 130 °C
5
OIL4 Food grade oil Tmax = 100 °C
1: Early warning (time to next oil change can be set to between 2 and 100 days)
Switch outputs
2: Main alarm (time to oil change 0 days) 6
3: Exceeded temperature Tmax
4: DUO10A is ready for operation
Permitted oil temperature -40 °C to +130 °C 7
Permitted temperature sensor PT1000
EMC IEC1000-4-2/3/4/6
Ambient temperature -25 °C to +70 °C
8
Operating voltage DC 18-28 V
Current consumption for < 90 mA 9
DC 24 V
Protection class III
Degree of protection IP67 (optionally IP69K)
10
Evaluation unit: V2A, EPDM/X, PBT, FPM
Housing materials
Temperature sensor: V4A 11
Evaluation unit: M12 plug connector
Electrical connection
PT1000 temperature sensor: M12 plug connector

Designations and
12
part numbers
Designation Description Part number
13
DUO10A Evaluation unit (basic unit) 1 343 875 1

14

15

16

17

18
DUO10A-PUR-M12-5m 5 m PUR cable with 1 connector 1 343 877 8
DUO10A-PVC-M12-5m 5 m PVC cable with 1 connector 1 343 878 6
DUO10A Angle bracket 1 343 880 8
19
DUO10A D = 34 Mounting clamp 1 343 879 4
20

21

22

Gear Units – 2016 67

4 Project Planning
DUO - Oil aging monitor

Designation Description Part number

W4843 PT1000 PT1000 temperature sensor 1 343 881 6

W4843_4x0.34-2m-PUR 2 m PUR cable for PT10001) 1 343 882 4

W4843_4x0.34-2m-PVC 2 m PVC cable for PT10002) 1 343 883 2
DUO10A Protection cap (for aseptic design, 1 343 902 2
IP69K)

1) PUR cables are particularly suited for use in oil-contaminated environments.

2) PVC cables are particularly suited for use in wet environments.

Mounting on Adapter for mounting the PT1000 temperature sensor in screw plug holes:
standard gear
Complete adapter for PT1000 sensor Part number
units (R, F, K, S)
M10  1 1 343 903 0
M12  1.5 1 343 904 9
M22  1.5 1 343 905 7
M33  2 1 343 906 5
M42  2 1 343 907 3

Mounting base for installing the diagnostic unit at the gear unit with an angle bracket:
Mounting base with sealing ring Part number
M10  1 1 343 441 1
M12  1.5 1 343 827 1
M22  1.5 1 343 829 8
M33  2 1 343 830 1
M42  2 1 343 832 8

68 Gear Units – 2016