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Installation of the motor and gearmotor*

Summary: This procedure provides important recommendations related to the design and assembly of an electric gearmotor system. As such, it gives recommendations regarding alignment, mechanical fixing, compliance with the protection index (IP), thermal management (ventilation), and concerning the electrical wiring of motor and reducer systems.

1) Preparation and mechanical fixing

  • Support: Ensure that the support is rigid and perfectly flat to avoid any deformation of the motor or reducer housing. The use of spacers or reinforcement plates may be necessary.
  • Tightening: Strictly adhere to the torque values specified by the manufacturer for fixing the motor, reducer, and supports. Apply threadlocker according to recommendations. A recheck of the tightening is required after 50 hours of operation, then periodically.
  • Alignment: Check the coaxiality between the motor and the reducer, as well as the alignment of the couplings. Misalignment is a major source of vibrations, premature wear, and system overheating.
  • Anti-vibration: Use silent blocks if the application requires it, but ensure they do not degrade the system alignment when subjected to nominal load.


2) Environmental protection (IP) and sealing

  • Protection Index (IP): Choose a protection index suited to the usage environment (dust, mud, rain, cleaning). It is essential to protect even connectors considered as 'sealed'.

  • Cable glands and grommets: Preferably orient them downwards to prevent water ingress. Create a service loop (drip loop) to guide moisture away from the enclosure entry.

  • Covers and Screens: Install protections against splashes and stones. Avoid configurations that could create mud or water traps, which may retain moisture and accelerate corrosion.

3) Thermal management (motor, reducer, controller)

  • Dissipation: Install diffusion plates, finned heat sinks, or forced ventilation if the thermal study justifies it. If planned, thermal coupling with the chassis (via thermal paste or film) must be done carefully.
  • Ventilation: Avoid installing the motor or controller in an enclosed space without adequate ventilation. Consider the thermal derating (reduction of allowable power) of the controller and motor related to ambient temperature.
  • Monitoring: During testing, monitor the temperature. The nominal continuous current must not be exceeded. Reduce the load or operating time in case of excessive heating.

4) Transmission and couplings

  • Couplings: Choose elastic or toothed couplings based on allowable alignment tolerances and the torque to be transmitted. Strictly adhere to tightening torques and key adjustments.
  • Chains and Belts: Ensure the tension is correct and that pulleys or sprockets are perfectly aligned. Provide protective covers and apply lubrication according to recommendations.
  • Motor-Wheel: The reducer must be sized to support the total mechanical load. A fail-safe brake is highly recommended to ensure safety when stationary or on a slope.

5) Wiring and connectors

  • Power Wiring: Use crimped lugs with an approved tool and adhere to terminal tightening torques. Protect connections with heat-shrink tubing and route harnesses in protected paths.
  • Signal Wiring: For signals (Hall sensors, encoder, CAN bus), use twisted and shielded pairs. If a CAN bus is used, ensure termination at $120\ \Omega$. Strictly separate power harnesses from logic (signal) harnesses to avoid interference.
  • Identification: Clearly identify polarities, phases, identifiers, and direction of rotation. Keep the technical wiring documentation up to date.

6) Commissioning and testing

  1. Preliminary Inspection: Perform a complete visual inspection to check tightening, alignment, and compliance with the IP rating.
  2. No-Load Test: Start the system with a gradual speed increase. Check for the absence of vibrations or abnormal noises. Use telemetry to monitor current, speed, and temperature.
  3. Light Load Test: Monitor the heating of the motor, reducer, and controller. Watch for the appearance of slips or play in the transmission.
  4. Final Validation: Confirm that the achieved torque and speed meet the specified requirements. Adjust acceleration/deceleration ramps and safety limits, then check the emergency stop function.

7) Maintenance and checkpoints

  • Retightening: A recheck of mechanical and electrical tightening is mandatory after commissioning, then must be scheduled periodically.
  • Cleanliness: Check the condition of filters and air intakes, the cleanliness of cooling fins, and the integrity of seals and cable glands.
  • Monitoring and Maintenance: Monitor oil leaks from the reducer, abnormal noises, and heating points. Establish and follow a strict preventive maintenance plan.

Quick checklist

  • Flat/rigid supports 
  • Tightening torques respected
  • Alignment and couplings checked
  • IP/connectors protected; 
  • Cable glands oriented correctly
  • Thermal dissipation planned; 
  • Temperature tests compliant
  • Power/logical wiring separated
  • Complete identification



*: The technical information presented in this article is provided for guidance only. It does not replace the official manuals of the manufacturers. Before any installation, handling or use, please consult the product documentation and comply with safety instructions. Torque.works cannot be held responsible for inappropriate use or incorrect interpretation of the information provided.