Installing EK8./EK9./AK8./AK9./RK8M – Add-on encoder set A-Box-U for connection option in/on terminal box

  1. Force open the knock-out on the stator [16] and remove it.
  2. Slide the grommet [1526] onto the cable end of the cover [619].
    • To make it easier to insert the grommet [1526] into the opened knock-out on the stator [16], prevent the FCI connector from protruding out of the grommet [1526].
    • When the grommet [1526] is inserted into the knock-out, retrieve the FCI connector from the grommet [1526].
    • Pull the thin end of the grommet [1526] through the knock-out first. When doing this, make sure that the cable jacket is not yet located in the grommet [1526].
  3. If the grommet [1526] is properly seated in the knock-out, use a cable lubricant such as Lub-I from 3MTM to pull the cable jacket through the grommet [1526] towards the terminal box [112].
  4. Clean the cone of the encoder [220].
  5. Remove the screw plug [A] of the encoder.
  6. Retrofitting insulation coupling on the encoder mounting adapter: Insert the insulation coupling [1891] into the conical bore of the rotor [1] and tighten the central retaining screw.
    • Tightening torque 2.25 Nm
  7. Use solvent to remove the residual adhesive from the central retaining screw.
  8. For AK8H safety encoders: Wet the central retaining screw that is required in the following step with LOCTITE® 241.
  9. Insert the encoder [220] into the conical bore of the rotor [1] or the coupling [233]/[1891].
  10. To secure the encoder [220] in place, tighten the central retaining screw. Use a tool that is at least 45 mm long for this.
    • Counter-tighten the spanner flat SW27 of the coupling and SW10 of the encoder shaft.
    • Tightening torque 3.3 Nm
    • For safety encoders: Tightening torque 3.3 Nm ± 8%

    NOTICE

    For encoders RK8M, EK8W, AK8H, AK8W, EK9Z and AK8Z on DR2C.. motors, a calibration process must be carried out for flawless operation. See Additional work for the RK8M encoder on the DR2C.. motor and Additional work for EK8W, AK8H, AK8W, EK9Z, and AK8Z encoders on the DR2C.. motor.
    Failure to calibrate results in greater motor losses and reduced torque. In the worst-case scenario, the motor will not run.
  11. To seal the encoder [220], screw in the screw plug [A].
    • Tightening torque 1.8 Nm
  12. For size 132M – 180 with forced cooling fan: Guide the torque bracket [935] over the connection unit [U] and the encoder [220].
  13. For size 132M – 180 with forced cooling fan: When mounting the torque bracket [935], make sure it is aligned centrally to the encoder [220]. Screw in the screw [936] with the spacer bushings [934].
    • Tightening torque 12 Nm
  14. For size 132M – 180 with forced cooling fan: Screw the torque bracket of the encoder [1889] with the screws [232] through the bores of the torque bracket [935].
    • Tightening torque 3.3 Nm
    • For safety encoders: Tightening torque 3.3 Nm ±10%
  15. For safety encoders: Wet the screws that are required in the following step with LOCTITE® 241.
  16. Retrofitting insulation coupling on the encoder mounting adapter: Replace the support ring [1895] with the spacer ring [1895] and screw it securely in place with the new M5×10 screws [1896].
    • Tightening torque 7 Nm
  17. For size 132M – 180 with forced cooling fan: Screw the connection unit [U] with the screws [3188] through the bores of the torque bracket [935].
    • Tightening torque 1 Nm
  18. For size 71 – 180 without forced cooling fan: Mount the fan guard [35] over the encoder [220].
    • Guide the connection unit [U] with the signal cable through the central grille cutout of the fan guard [35] or the central opening of the support ring [1895].
    • Guide the cover [619] with the signal cable through the designated opening of the fan guard [35].
    • For size 71 – 132S: Tightening torque 3.3 Nm
    • For size 132M/L: Tightening torque 12 Nm
    • For size 160 – 180: Tightening torque 29 Nm
  19. For safety encoders: Wet the screws that are required in the following step with LOCTITE® 241.
  20. For size 63 – 132S: Screw the screws [232] through the grille of the fan guard [35] and into the nuts of the torque bracket [1889].
    • Tightening torque 3.3 Nm
  21. For size 132M – 180 without forced cooling fan: Screw the screws [232] through the grille of the fan guard [35] or the central opening of the support ring [1895] and into the nuts of the torque bracket [1889].
    • If you need to turn the encoder [220] in order for the screws to reach the nuts of the torque arm, turn the encoder [220] clockwise.
    • Tightening torque 3.3 Nm
    • For safety encoders: Tightening torque 3.3 Nm ±10%
  22. Without forced cooling fan: Insert the connection unit [U] with the expansion anchors into the corresponding punch-outs on the fan guard’s grille [35] up to the stop.
    • Fully insert and tighten the screws [3200].
    • Tightening torque 1.6 Nm
  23. Without forced cooling fan: Insert the signal cable of the cover [619] into the designated recess of the wear part [3069].
    • Fasten the signal cable into the rectangular cutout of the fan guard [35].
  24. Place the cover [619] onto the connection unit [U].
    • Screw the cover [619] onto the connection unit [U] with the screws [1996].
    • Tightening torque 1 Nm
  25. Make sure that the signal cable of the cover [619] does not form a loop between the fan guard [35] or the torque bracket [935] and the terminal box [112] that can collide with the fan.
  26. For size 80 with brake: Attach the encoder cable [619] to the fan guard [35] using the cable tie [3229].
  27. With forced cooling fan: Insert the signal cable of the encoder [220] into the designated openings in the cable retainer [1900] in such a way that prevents it from colliding with the fan wheel of the forced cooling fan.
  28. For size 71 – 180 without forced cooling fan: Place the safety cover [361] onto the fan guard [35].
    • For size 63 – 132S: Tightening torque 2 Nm
    • For size 132M – 180: Tightening torque 3.5 Nm
  29. With forced cooling fan: Secure the forced cooling fan [170] with the screws [22].
    • For size 71 – 132S: Tightening torque 3.3 Nm
    • For size 132M/L: Tightening torque 12 Nm
    • For size 160 – 180: Tightening torque 29 Nm
  30. For size 71 – 132S with forced cooling fan: Additionally secure the forced cooling fan [170] in place by using the screws [34] and washers [33].
    • Tightening torque 2 Nm
  31. Without forced cooling fan: Secure the safety cover [361] in place by using the screws [34] and washers [33].
    • For size 63 – 132S: Tightening torque 2 Nm
    • For size 132M – 180: Tightening torque 3.5 Nm