TM
Operations & Maintenance Manual
42" Skid Belt Feeder Plant Owner's Manual
S/N: M6804ERC17F
OWNER’S MANUAL
Introduction
Your equipment purchase has been designed and manufactured by ELRUS Aggregate Systems Inc.
All components used are of the highest quality available at the time of manufacture.
Our workmanship has set a standard of excellence, in the custom manufacturing field.
This information is based on the knowledge and experience of highly qualified people at our company and
field service.
We strongly recommend that all personnel directly involved with this equipment be familiar with this manual.
This manual contains vital information essential for proper and safe operation of the equipment. Failure to
follow instructions and warnings contained in this manual can cause severe personal injury or death.
The information contained in this manual is not to be considered all-inclusive for every application. Questions
regarding “specific uses” of this equipment should be directed to ELRUS Inc. Anyone who uses this
equipment for any purpose other than its intended use assumes the risk of any danger in doing so.
--NOTICE—
Elrus Aggregate Systems does not warrant the completeness or accuracy of any information contained in this manual and
may make changes thereto at any time at its sole discretion without notice.
Identifying the Equipment
Due to constant improvements, when ordering parts or service information, please refer to the
Equipment’s aluminum identification plate for model type and serial number.
Manual Properties
One hard copy of this manual, CD, and Parts Catalog will be provided for all new
equipment. It is very important to keep one copy with the equipment at all times.
Illustrations shown in this manual are based on ELRUS typical equipment and components
as a “reference” only and may differ from model type purchased. This document has been
standardized to suit all ELRUS models.
When ordering a replacement copy of this manual, always specify the serial number.
1
OWNER’S MANUAL
Parts identification and Replacement
When ordering replacement parts, it is necessary to include the model number or serial
number of the unit with your order. Please be as exact as possible in describing the part
to your ELRUS support team.
This information together with the Parts List Drawing item number and Part Numbers
ensures that the factory will furnish the exact parts required. Order only genuine parts, they
are specially designed for your equipment, provide better performance, and are easily
procured from ELRUS Equipment.
Provide Shipping Instructions: Company Name, complete shipping address. State
whether freight, express, parcel, or other handling is desired. Confirm telephone orders in
writing.
Inspection of parts when received is very important. Shortages or damage should be
noted by the carrier agent at the time the parts are accepted. Shipper’s responsibility ceases
upon delivery of shipment to customer in good order. Claims for damage or loss are subject
to the terms and conditions as noted on your invoice.
Parts and Service
Contact the nearest ELRUS Company, Service Centre, or Factory Representative,
or head office directly:
ELRUS Aggregate Systems Inc.
Head Office and Manufacturing Facilities
4409 Glenmore Trail S.E.
Calgary, Alberta T2C 2R8
Canada
Email Parts: parts@elrus.com
Phone: 888 535-7877
403 279-7741 including after hours
Leduc, Ab. Branch
Surrey, B.C. Branch
Saskatoon, Sk. Branch
Email Parts: edmonton@elrus.com
Email Parts: bc@elrus.com
Email Parts: Saskatoon@elrus.com
Phone: 877 484-3303
780 980-5600 including after hours
Cambridge, Ont. Branch
Email Parts: ontario@elrus.com
Phone: 866 795-1188
519 624-6500 including after hours
Phone: 877 788-8499
Phone: 306 227-2588
604 888-8499 including after hours
Winnipeg, MB. Branch
Email Parts: Winnipeg@elrus.com
Phone: 855 588-5588
204 888-5588 including after hours
2
OWNER’S MANUAL
Preparing the Portable Plant for Transport
In some cases, due to the weight of the plant and the forward extension of the under-screen, or discharge conveyor,
you will need either a long-wheelbase tractor or a standard tractor with a jeep to transport the plant.
Before the plant is moved, prepare the plant for transport. Make sure all conveyors are empty. Clean any rock
material buildup off all the equipment.
Disconnect plumbing and electrical hookups, as necessary, wrap cables on cable wraps and tie to prevent
unraveling, to ensure the plant can be transported without damage to equipment. Stow the fittings, bolts
and loose parts in a tool box or in marked boxes. Remove and stow the ladder. Check oil level in wheel
hubs. Check tires, brakes, and lights before transport.
Later ELRUS portable plants are equipped with boomers to secure forward and rear extending conveyors preventing
hinged conveyors from bouncing and inflicting damage. Ensure boomers are secure prior to moving plant.
The plant is NOT equipped with MAXI Brakes. Make sure the plant wheels are
blocked before hooking or unhooking tractor or jeep.
Position the tractor or Tractor/Jeep under the Chassis, back under slowly making sure the tractor has enough
distance without hitting any part of the plant and lock the kingpin.
Connect the tractor’s electrical cable and air hoses to the chassis. Make sure the chassis brakes are locked.
Raise the landing jacks completely, stow blocks securely. Check the chassis lights and brakes before rolling.
Make sure the tractor has enough clearance to turn without hitting any part of the plant.
3
OWNER’S MANUAL
Specifics for transporting certain types of equipment
(In addition to all other information in this section)
Portable Screen plants
•
•
•
•
Lower the Screen for Transport (In Pit and Highway)
(If Necessary) remove and re-locate the height positioning pins from both telescoping legs on the overheadconveyor supports and lower the overhead conveyor to assist with travel height issues.
Center cross conveyors (or fold where equipped) to the centre of the chassis and secure to prevent over
width.
Ensure all conveyors are empty. Clean any rock material buildup off all the equipment.
Portable Jaw Plants
•
•
•
•
•
•
Should the hopper have to be removed, chain the VGF to the plant chassis to reduce bounce when
transporting.
Fold down crusher platform hand rails and secure bolts.
lock antiluce clips on hinged guards
Check that shim kit is secure, Grease gun, screw stand and jack.
Lower discharge conveyor to within travel height in your area and secure with boomer.
Ensure all conveyors are empty. Clean any rock material buildup off all the equipment.
Portable Cone Plants
•
•
•
•
Notice: Always lower & block the cone head before transporting the crusher (In Pit and Highway). Serious
damage to the vital cone parts could result if the cone head is not blocked properly. Install the shipping blocks
in the crusher’s cone head.
Secure access ladder and tool box, lock antiluce clips on hinged guards, secure oil tank doors.
Lower Feed and Discharge conveyors to within travel height in your area and secure with boomers.
Ensure all conveyors are empty. Clean any rock material buildup off all the equipment.
Transport Height and weight restrictions in some locales may require some disassembly of the plant. If
weight reduction is necessary, the crusher upper section or other components may have to be removed.
Check the route, clearances and local ordinances before moving the plant. Special permits or special
routing may be required for travel.
Ensure all equipment is properly secured to truck bed before transport.
Observe speed or other special limits for transport (such as travel only during certain hours) set by each Province
or State. Exceeding the limits may cause damage to the plant or its components, delay transport, or cause a road
hazard.
Take extra precautions when crossing an abrupt change in road elevation, such as a railroad crossing, to avoid
“high-centering” the truck frame. High-centering can damage undercarriage accessories.
Observe all bridge overhead clearances heights.
KNOW YOUR CHASSIS HEIGHT!
Please Drive Safely.
4
OWNER’S MANUAL
General Safety
This section is intended to provide you with general guidance regarding the safe operation
and maintenance of your ELRUS equipment. The information is designed to supplement
the information contained in the operation and maintenance manuals for the specific
equipment. You should always review those manuals before operating or maintaining any
equipment. If you do not have the manuals, contact ELRUS to obtain a replacement copy.
Hazard identification
Warning signs
General Danger
Read Carefully
Dangerous Voltage
Risk of Crushing
Important Information
Failure to read this manual and follow the instructions and warnings
could cause severe personal injury, death or substantial property
damage!
Equipment is designed with safety of all personnel in mind. Do not
change, modify or eliminate guards, covers and shields installed around
moving parts.
5
OWNER’S MANUAL
Equipment Decals
The following decals may be in various locations on your equipment.
Always ensure Hard Hats and or Eye Protection and or Ear Protection are worn in these
vicinities.
Exercise caution when near this area of the equipment.
Lockout and test all energy sources before attempting any maintenance.
Possible entanglement hazard in this area of the equipment.
6
OWNER’S MANUAL
Do not remove guard while machine is in operation.
Drive guards must be installed before unit is started.
Observe Hard Hat areas at all times.
Personnel
All work on the equipment is to be carried out by trained personnel only. Technical
documentation provided by ELRUS covers operation, maintenance, and
troubleshooting on the equipment itself only. It does not cover operations procedures
associated with the operating company or other equipment or routines at the site.
It is the responsibility of the Site Management to assign responsibility for:
•
Establishing their Own on-site operating procedures.
•
The production equipment and the work area around the
equipment.
•
Compliance with National, Regional, and Local safety regulations.
•
Checking that all safety devices are fully operational.
•
All personnel around the equipment.
Elrus Aggregate Systems declines all responsibility for damage or injury resulting
from non-compliance with the instructions in this manual including non-compliance
with national, regional and local safety regulations.
7
OWNER’S MANUAL
This Manual has recommendations for:
Personal Protection Equipment (PPE)
ELRUS recommends that all personnel working in the vicinity of the equipment
always wear approved personal protective equipment. Actual requirements will
be defined in the Operator’s Practice and Procedures policies.
Required PPE is likely to consist of:
•
•
•
•
•
•
Ear Protection
Safety Hard Hat
Eye Protection
Protective Gloves
Safety Boots
Mask or breathing apparatus
Machine Guarding
Do not remove machine guards. Make sure all guards are in place, secure, and
functioning prior to and during operating the equipment.
Electrical Safety
Only qualified Electrical Technicians are permitted to perform electrical operations
on the equipment.
All personnel must regard all electrical devices as “Live” until device is proven to be
dead by proper testing procedure.
Replace, repair, and periodically check all cables prior to starting the equipment.
Ensure all electrical cabinets are locked.
Welding Information
Only qualified Welding Technicians are permitted to perform welding operations on
the equipment.
Toxic Gasses
Inhalation of welding fumes can be dangerous to health. Always follow
instructions provided by the welding equipment supplier.
8
OWNER’S MANUAL
Lifting Equipment
1.
Lift from designated lift points.
2.
Do not exceed crane lift capacity.
3.
Use proper slings/lifting devices. Use spreader bars when necessary.
4.
Do not walk or stand under loads hanging from a crane.
5.
Use ropes or poles to steady and maneuver and stay clear of suspended
loads. Do not use hands and feet.
6.
When a sling is applied to a sharp edge of a load, the edge or the sling must
be protected to prevent damage to the sling.
7.
Inspect chains, wire ropes, slings, lifting eyes for wear and damage. Replace
damaged lifting equipment.
8.
Use caution when operating a crane near power lines.
Start up
1.
Familiarize all equipment operators with safety and operation instructions
before starting the equipment.
2.
Do not operate equipment unless all guards are properly installed.
3.
Store hazardous materials in restricted access areas and mark accordingly.
4.
Make sure enough ventilation is present to safely run engines. Do not start an
engine without properly vented exhaust.
5.
No smoking near flammable fuels or solvents.
6.
Avoid electrical and static sparks and open flame when handling fuels, battery
electrolytes, hydraulic fluids or coolants.
7.
Check for leaks in tanks with flashlights. Never use open flame!
8.
Know location of fire extinguishers.
9.
Be alert around pressurized systems, hydraulic, air, high-pressure gases and
oils.
10.
Keep equipment clean and free of grease and dirt.
11.
Always look around equipment before start-up to make sure no one is near
moving parts. Use warning alarms to alert personnel of equipment start-up.
9
OWNER’S MANUAL
Operation
1.
Stand clear of material discharge and feed areas at all times. Material can be
ejected suddenly and unexpectedly from discharge and feed areas.
2.
Do not attempt to remove jammed product or other blockage from running
equipment. Shut off power and lockout equipment before attempting to
remove the blockage.
3.
Maintain a safe distance from equipment during operation at all times.
4.
Do not clean up spilled material while the equipment is running. Tools and
personnel may get entangled in the running equipment.
5.
Keep general work area clean and free of debris. Avoid stone or other
material build-up on walkways, platforms, ladders and under conveyors.
6.
Do not overload walkways. They are intended for personnel, not equipment.
Maintenance
1.
Establish a positive lockout or tag-out of the power source before performing
lubrication, maintenance, repair or adjustments to prevent start-up by other
people. NEVER lubricate the equipment when it is in motion. Failure to follow
proper lockout and tag-out procedures could result in serious injury or death!
Double check Power is OFF!!
2.
Secure parts as necessary to prevent unexpected motion while performing
maintenance or repairs.
3.
Do not attempt to remove jammed product or other blockage from running
equipment. Power must be shut off and locked out while doing so.
4.
Replace guards and covers after adjustment or maintenance of equipment.
5.
After performing maintenance, ensure that tools and parts are cleaned up
before equipment start up.
10
OWNER’S MANUAL
Personal Safety /Equipment
1.
Wear adequate hearing protection devices where noise level is above
acceptable limits.
2.
Wear adequate breathing masks when dust and fumes are present.
3.
Wear eye protection to prevent flying particles from entering eyes.
4.
Hardhats are necessary protection.
5.
Wear clothing that fits SNUGLY. Loose-fitting clothing should never be worn
on the job site.
6.
Never work around crushing and screening equipment while wearing a
necktie, scarf, etc.
7.
Mount and dismount the equipment using only steps, ladders, handrails and
walkways.
8.
To reduce the risk of fires, do not refuel the equipment with the engine
running. All sparks and open flames must be kept at a minimum of 50 feet
away from the equipment when refueling.
9.
Be aware of your actions and the actions of other people and equipment on
the job site at all times.
Conveyors
1.
To prevent wind damage to elevated conveyors, lower the conveyor fully
when not in use.
2.
Lower conveyors fully for in-pit transport.
3.
On conveyors with Gravity take-ups, support the weight of the gravity take-up
before installing or repairing the belt.
4.
For conveyors with Grease Take-ups, Keep clear of vent tube when opening
bleed valve to retract take up.
5.
Keep clear of head and tail pulleys and rollers while conveyor is in operation.
6.
Do not overload the conveyor belt – excess material will fall off an overloaded
conveyor belt.
7.
Do not ride the conveyor belt.
11
OWNER’S MANUAL
Vibratory Equipment (Screens and Vibrating Grizzly Feeders)
1.
Pinch point hazard: Keep clear of the vibrating equipment including the
springs.
2.
Screen cloth edges are sharp. Use care when installing and handling.
Jaw Crushers
1.
Stand clear of the jaw feed opening during operation. Material can eject
unexpectedly from the feed opening.
2.
Pinch point hazard: Keep hand and fingers clear of shims when adjusting the
crusher. Use a pry bar to install and remove shims.
3.
Use extreme caution when removing tramp iron from the crusher. Never
reach into or enter the crushing chamber in this situation. Stored energy in the
jaw could cause the item to eject unexpectedly with tremendous energy.
Pressurized Systems (Air, Hydraulic)
1.
Do not perform maintenance on pressurized system components without
relieving all the pressure in the system.
2.
Do not operate pressurized systems with worn or damaged hoses, valves or
fittings. Replace defective components before pressurizing the system.
3.
Hydraulic fluid under pressure can penetrate the skin and cause serious injury
or even death. However, fluid leaks under pressure may not always be
visible. Do not check for leaks with your hand.
Dumping Grizzlies
1.
A falling rock hazard exists with a dumping grizzly, keep clear of the grizzly.
12
OWNER’S MANUAL
Equipment Setup
Elrus’ portable plants provide several convenient features to help you quickly set up
and tear down for transport to a new site.
1.
Prepare site properly for plant setup.
Refer to your site plan or contact your Elrus Representative for guidance in
determining the best location and required clearances for your equipment.
Prepare the operating site for level, spacious, and stable foundation
conditions, particularly in those areas that need cribbing and stabilizing.
Level the area where you want the plant to operate. Be sure the soil is firm and
solidly compacted to stand the weight and vibration of the equipment. Use
crushed rock, if needed, to establish a firm base.
2.
Crib and Stabilize the Chassis.
The support (blocking) legs for the chassis frame that are furnished by Elrus
must be used effectively.
Be sure the footpads rest on a firm surface of the proper height to match
related equipment, such as radial pivoting conveyors. You will need timbers
under the bearing surface on soft ground. Place the footpads under the plant
legs, including any front folding legs. When the plant is properly supported,
remove the dolly or haul the tractor from the kingpin. Securely chock (block)
tires any time equipment is to remain “parked” for extended periods of time.
Because of the distribution of equipment and product weight during operation,
cribbing under the 5th-wheel cross member provides stability and reduces
vibration.
13
OWNER’S MANUAL
Level the plant
Keep the plant level at all times during operation. Maintaining a level plant is
critical to proper operation of the crusher, screen, and conveyors keeping
stress to a minimum on components.
Level the chassis frame lengthwise and crosswise, using a 4ft carpenter’s
level.
Install Ladder, Handrails, and Other Plant mounted equipment
Install the Ladder (where applicable). Normally the ladder is fixed to the plant
for transport and operation.
14
OWNER’S MANUAL
ELRUS has included appropriate handrails in each plant’s design for safety
and convenience. Do not remove factory installed handrails.
Where Applicable, Remove cone head blocks from the crushing chamber.
Refer to your CONE Owner/Operators Manual for the removal instructions.
Additional Set-up Notes
1.
Changing the configuration or adding equipment to your system may create
hazards, which require additional guards to comply with OSHA or MSHA
regulations.
Guards may not meet all local codes; customer is responsible to have
guarding inspected.
2.
Any modifications to be made to the original design of the equipment must be
approved by qualified Personnel.
3.
Ground all electrical components in accordance with local and national
electrical codes.
4.
Protect electrical cables and fuel lines from traffic (dozers, trucks, loaders and
other vehicles).
5.
Report unsafe conditions or machinery to your supervisor.
6.
Save your back, use leg muscles for lifting.
7.
Keep work area clean & neat.
8.
Install and secure all walkways, handrails, guards and ladders prior to
operation.
15
Owner’s Manual
Maintenance
ELRUS BELT-FEEDER
BELT ADJUSTMENT
BELT TENSION
By tightening the take-up screws on either sliding pulley, tension is applied.
Enough tension must be applied in order to prevent belt slippage on the head
pulley. Too much tension can weaken the belt and shorten its life expectancy.
If the conveyor is to be shut down for a considerable length of time, the belt
tension should be slackened. This eliminates the possibility of undue strain placed
upon the equipment caused by belt shrinkage.
TRAINING THE BELT
A properly adjusted conveyor belt should run straight and true down the Center
Line of the idlers, permitting the belt to run to one side and rub on an obstruction
will seriously damage the belt.
Improper tracking of the belt can be due to any one or combination of the following
factors:
1.
Pulley(s) not mounted level and square to the conveyor Center Line cause
the belt to run off the slack side.
2.
Belt not troughing sufficiently to give adequate contact with the middle roller
of the troughing idlers.
3.
Carrying idlers not squared to the conveyor Center Line.
4.
Belt not straight.
5.
Belt splice not square.
6.
Belt not loaded centrally. An offset load causes the empty side to run off.
Redesign of the transfer point is the only solution.
7.
Belt dragging against stationary obstructions.
8.
Belt exposed to wind.
Owner’s Manual
Maintenance
If the belt is running off at the head pulley, check the pulley’s alignment with a large
steel square and adjust accordingly.
If the belt is running off at the tail pulley, tighten the take-up screw on the side on
which the belt overhangs the tail pulley.
The troughing idlers can be turned if the belt is still misaligned. For example; if the
belt is running to the left of the Center line (when looking in the direction of travel),
the idlers in question must be slewed out of center such that the left side is
advanced and the right side is brought back. Start by adjusting the idler over which
the belt travels just before it runs out of line. If required, adjust further back.
Visualize the belt as being a plant rolling on a flat roller. Conveyor belt responds in
the same manner. Point the idler in the direction in which you want the belt to go.
Always start on the return belt at the head pulley following the direction of travel.
After having centered the return belt the top is starting at the tail pulley and
proceeding in the direction of travel.
An untrue splice can be readily identified as the belt runs off only when the splice
appears. Cutting and re-splicing the belt is the only method by which this situation
can be remedied.
OPERATING PRECAUTIONS
1.
Ensure that the conveyor is level crosswise. Otherwise, material will not ride
the center of the belt causing misalignment.
2.
Keep the belt plow at the tail pulley properly adjusted in order to prevent
material from accumulating on the pulley and becoming trapped between
the pulley and the belt. Material caked to pulleys and idlers will cause the
conveyor belt to run out of line. Always keep the area in the vicinity of the
tail pulley free of debris.
3.
Inspect conveyor belts at least once a week. This will eliminate the
possibility of a shut down due to torn belts (or broken fasteners). Tighten or
replace loose fasteners.
Always repair a damaged belt at once. If a torn belt is encountered, repair it by
installing Flexco type fasteners at 3” to 6” centers along the tear. Lengthwise
and crosswise repairs may be carried out using this method. Strive to retain the
original belt shape when installing fasteners as shortening or buckling of only a
portion of the belt width can cause a serious misalignment problem.
4.
Inspect transfer points on a regular basis. A rock wedged between the back
of a hopper and the belt cover. Allowing material to build up on hopper sides
and chutes will reduce production.
5.
Establish a definite lubrication and inspection program.
6.
Initiate a preventative maintenance program to ensure the longevity of the
plant.
OWNER’S MANUAL
GENERAL PREVENTIVE MAINTENANCE SECTION
Before attempting to operate any equipment, the operator is strongly
recommended to familiarize himself with the contents of this manual.
Always refer to the service and maintenance section of this manual
before starting any type of maintenance for Bearings, Conveyors, etc.
and to ensure proper amounts and types of lubrication used.
On an on-going basis, always examine your equipment for breaks or
worn areas.
•
Check the blocking platforms of the plant at least twice a week for
possible slippage or cracks due to plant vibration.
•
On a weekly basis, the entire plant must be checked for any loose
bolts and general signs of wear.
•
Unusual sounds should be noted. They may indicate a loose bolt, a
damaged bearing, structural interference etc.
•
Where fitted with labrynth seals, ensure that lubricant is escaping
from the seals on bearing housings indicating that the unit has been
properly lubricated (see lubrication instructions).
LUBRICATION
Oil
On all equipment, Check all lube levels and ensure that sufficient oil has
been installed each day (where necessary) before start-up or after 8 hours of
operation.
The oil condition should be regularly visually checked for any signs of
property break-down, leakage etc. and immediate action should be taken to
remedy any failures.
Drain oil soon after operations have ceased and while the oil is still warm.
ELRUS recommends that periodic laboratory oil analysis be performed to
determine bearing conditions.
OWNER’S MANUAL
Hydraulics
The hydraulic pump reservoir must be checked periodically to make sure the
proper amount of oil is in the reservoir. Care must be taken that no dirt or
foreign material enters the reservoir when refilling with hydraulic fluid. Use
only clean automatic transmission fluid in this unit.
Oil filters should be changed for the first time after five (5) Hours of operation,
and subsequent changes after approximately one hundred (100) Hours of
operation.
Periodically, inspect hydraulic and electrical lines for wear
due to vibration and rubbing on components.
Chassis
Trailer Axles:
Check oil level in wheel hub and inspect wheel for leaks every 1000 miles or
twice a year.
Check brake adjustment and repack wheel bearings (grease application)
every 15,000 miles or minimum of twice a year.
Check lining wear and estimate reline time. Inspect camshaft spider bushing
and camshaft support bracket bushing for any signs of wear and lubricate
brake actuating components every 25,000 to 30,000 miles or twice a year.
Replace wheel bearing lubricating oil (if applicable). Check brake air
chambers and slack adjusters. Inspect brake rollers, roller shafts, anchor pins
and bushings and replace if necessary.
Conveyors
Special care must be exercised to keep the return rollers and snub pulleys
clean. Buildup of material on this equipment has a destructive effect upon
belt training with the result that the belt may run against the structure and
damage itself. It is advisable wherever possible that return idlers be
suspended sufficiently below the structure so that any miss-alignment or dirty
idlers can be easily seen.
Keeping the return rolls and snubs clean requires that the belt be clean when
it enters the return run. Failure to keep the return idlers clean can result in the
roller bearings becoming dirty and ultimately failing.
A L T R A
I N D U S T R I A L
M O T I O N
Installation & Maintenance of
V-Belt Drives
®
Contents
1
2
3
4
5
6
®
V-Drive Inspection and
Maintenance Procedures
1
®
2
®
3
®
Belt Selection
4
®
Classical
Belt Section
Minimum*
Pitch Diameter
Narrow
Belt Section
Minimum
Sheave Diameter
5
®
6
®
Safety Tips
7
®
Drive Installation
8
®
Tapered
Bushing
Size & Thread
of Cap Screw
Ft.-Lbs.
To Apply With
Torque Wrench
9
®
10
®
For Installation (Subtract)
Belt
Length
3VX
&
3V
3V
Banded
5VX
&
5V
5V
Banded
For take-up (Add)
8VX
&
8V
8V
Banded
For Installation (Subtract)
Belt
Length
Designation
AX
&
AP
BX
&
BP
BX
& BP
Banded
CX
&
CP
CX
& CP
Banded
All
Cross Sections
For take-up (Add)
DX
&
DP
DX
& DP
Banded
All
Cross Sections
11
®
Tensioning V-Belt Drives
12
®
13
®
Drive Ratio
Small Sheave
Belt
Section
Speed
Range
Dia.
1.0
1.5
2.0
4.0 &
over
D—d
C
14
Arc
Contact
Degree
Factor
Ac
K
D—d
C
Arc
Contact
Degree
Factor
Ac
K
®
NARROW BAND
Ts
Per
Strand
(lbs.)
CLASSICAL BAND
CLASSICAL COG BAND
CROSS SECTION
5V
8V
BP
CP
3V
DP
5V1700
& under
5V1800
& over
8V1700
& under
8V1800
& over
BP144
& under
Over
BP144
CP144
& under
Over
CP144
BX
All
Sizes
CX
All
Sizes
DX
All
Sizes
17
®
Trouble Shooting V-Belts
18
®
19
®
20
®
21
OWNER’S MANUAL
RECOMMENDED ELRUS LUBES
Jan. 27, 1999
Application
Texaco
Esso
Petro-Canada
Jaw-Oil-All Season
Jaw-Oil-Summer
Jaw-Oil-Winter
Multigear 80W90
Meropa 150
Meropa 68
GX 80W90
Spartan EP 150
Spartan EP 68
Gearlube 80W90
Ultima EP 150
Ultima EP 68
Multifak HD 00
Jaw LabyrinthGrease-All Season (1)
Dynagear
Multi-purpose Low
Temp.
Jaw Labyrinth-GreaseSummer (1)
Jaw Labyrinth-GreaseWinter (1)
Multifak EP 0
Dynagear
Multi-purpose EP-1
Multifak HD 00
Dynagear
Multi-purpose Low
Temp.
Inclined Screen-Grease
Multifak EP 2
VGF-Oil-All Season
VGF-Oil-Summer
VGF-Oil-Winter
Multigear 80W90
Meropa 150
Meropa 68
GX 80W90
Spartan EP 150
Spartan EP 68
Gearlube 80W90
Ultima EP 150
Ultima EP 68
Hydraulic Oil-All Season
Hydraulic Oil-All Season
ATF Dexron III
Ursa SuperPlus
10W
ATF Dexron III
XD3 SAE 10W
Dexron III
Super Plus 10
Sandvik Spider
Grease
Unirex EP 2
Multi–purpose EP 2
Refer to manufacturer’s operating manual
Sandvik Hydroset Oil
Refer to manufacturer’s operating manual
Sandvik Main Lube Oil
Sandvik Main Lube-Winter
Refer to manufacturer’s operating manual
Refer to manufacturer’s operating manual
Browning Reducers
Rando HD220
NOTE: As of January 1999, lithium base greases are replacing sodium base greases for
the jaw labyrinth seals. These greases are not compatible, and bearings must be
completely purged of the sodium base grease when switching over to the lithium base
grease.
OWNER’S MANUAL
HYDRAULIC MAINTENANCE GUIDE MANUAL
The hydraulic system designed for your plant is a sensitive and expensive item of
equipment, but provided that it is well maintained, it will give many years of service.
The condition of the hydraulic oil is of great importance in insuring the longevity of
the various components within the system. Refer to the table of ELRUS lubricants
for the recommended hydraulic oil.
OIL FILTERS
These should be changed for the first time after five (5) Hrs. of operation, and the
next change after approximately one hundred (100) Hrs. of operation.
Subsequent filter changes should take place between 100 and 250 hours of
operation, however the visual indicator built in the filter housing will indicate (by
changing colour from green to red) when an oil change is necessary. Read the
instructions on the filter canister.
The change procedure should take place only after the canister and area have
been wiped (or blown) clean of all dirt and dust. Care must be taken to avoid dust
and dirt from entering the components during a filter change.
BREATHER ELEMENT
Mounted on top of the oil tank, this element should be checked at the same
intervals as the filter and changed when necessary. Care must be taken when
changing the element to prevent dust and dirt from entering the tank.
RELIEF VALVES
The pressure relief valves are factory set and are not to be tampered with.
OWNER’S MANUAL
OIL FAILURE
There are a number of causes of oil failure, the most common of which are;
•
•
Overheating, which breaks down certain properties of the oil causing a
deterioration of lubricating potential.
Contamination, such as water, which will cause lubrication failure, and dirt
particles, which could act as a grinding compound or cause valves etc. to stick
and jam.
The oil condition should be regularly visually checked for any signs of property
break down, leakage etc. and immediate action should be taken to remedy any
failures.
Hose condition should be visually checked and care should be taken to avoid
hoses rubbing on metal edges, possibly causing hose failure.
Temperature and pressure gauges should also be checked to determine that oil
conditions are within limits.
CONVEYOR BELT
INSTALLATION
AND MAINTENANCE
Owner’s Manual
Belting
TABLE OF CONTENTS
PAGE
Receiving and unpacking
P.3
Handling the roll
P.3
Storage
P.3
Installation
P.4
Belt training
P.5
Factors affecting the training of a belt
P.6
Carrying Idlers
P.6
Return Idlers
P.8
The belt itself
P.8
Sequence of training operations
P.9
Cleaning
P.10
Loading
P.12
Pulley lagging
P.15
Types of lagging
P.15
Trouble shooting
P.18
Trouble shooting solutions
P.19 to P.21
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Belting
RECEIVING THE ROLL
Upon delivery check the factory packaging for damage, punctures, etc. Make any appropriate claim
against the carrier at that time.
HANDLING THE ROLL
Factory packaging is designed to protect your conveyor belt during normal shipping and handling.
When a belt arrives, be careful unloading it. Don't drop it or handle it roughly. This could break the
packaging and cause the belt to telescope. Once a belt telescopes, it's almost impossible to re-roll.
Try not to roll it, but if you must, roll in the direction the belt is wound. Rolling a belt in the opposite
direction can cause it to loosen and telescope.
The best way to move a belt is to slip a sturdy hoisting bar through the center core. Then, lift it with a
sling or with strong cables. Be careful that these hoist cables don't damage the outer wraps at the
belt edges. Protect the edges with special "spreader bars:' or short wooden planks. (Fig. 1) Never
apply a sling around the circumference of a roll of belting...it isn't safe!
You can also move a belt safely by laying the roll flat on a skid and hoisting the skid with a forklift.
Just be sure the forks on the lift don't come in contact with the belt itself.
STORAGE
When storing a new conveyor belt, leave it hoisted or stand it upright, preferably on a dry surface (do
not lay the roll on its side.) A wooden skid is best. Block it safely so it can't accidentally roll.
Extreme temperature variations can have an adverse effect on a belt over long periods of time. The
ideal storage range is between 50 deg. F. and 70 deg. F.
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Long exposure at temperatures even slightly below 40 deg. F. can harden or stiffen the compounds.
If installed on a conveyor in this stiffened state, the belt may not train well until it adjusts or "warms
up" to the system. Neoprene, for example, is especially sensitive to low temperatures and should
never be stored at less than 40 deg. F. Stiffened neoprene belting is different than other
constructions. It won't loosen up until it's had a lengthy exposure to relatively mild temperatures.
Temperatures over 90 deg. F. have an adverse effect, too, and should be avoided.
Sunlight and ozone can also deteriorate any exposed rubber over time. Store your belt out of the
direct sunlight whenever possible. Electrical generators or welders can sometimes generate ozone. It
is best to store your belt some distance away from this type of equipment.
In general, it's wise to keep any unused belt stored in its protective factory packaging until it's ready
for installation.
Used belt should be thoroughly cleaned and dried prior to storage.
A dry place out of direct sunlight is preferred for storage, excessive temperature variations or
extremes being avoided. Belts should not be stored in excessively wet places or in areas where oils,
gasoline, paint materials, acids, and chemicals, are also stored or used. Motor-control rooms, welding
shops, and other places where ozone is generated should likewise be avoided. A belt should not be
permitted to rest on a concrete floor. If it is necessary to lay a belt on the floor, use a pallet or cradle.
Belts which are not endless should be stored in rolls. Once thoroughly cleaned and dried, it is good
practice to dust a belt with tire talc or to insert kraft paper between the layers when rolling it up. Care
should be taken not to roll a belt too tightly be sure the interior diameter of the roll is sufficiently large
to avoid any possible carcass damage or warping. The belt should be rolled evenly to avoid
telescoping and warping. Excessive flexing or sharp bends of any sort are to be avoided. Rolls
should not be stood on edge or leaned against a wall.
Small endless belts may be hung up on a dowel or peg for storage. It is advisable to rotate the belt
occasionally to avoid a constant flex or bend at one point. Larger endless belts may be stored flat,
doubling them over as necessary it is advisable when doubling a belt over to be sure that the edges
of the belt are in line to avoid any warping. As above, it is good practice to rotate and re-pile the belt
occasionally to avoid constant flexing or bending at any point. Bends should be made as large as
possible to avoid cracking the carcass.
INSTALLATION
Once the roll of belting has been transported to the point of installation it should be mounted on a
suitable shaft for unrolling and threading onto the conveyor. Conveyor belting is normally rolled at the
factory with the carrying side out. Consequently, in mounting the roll the belt must lead off the top of
the roll if it is being pulled onto the troughing or carrying idlers but off the bottom of the roll if it is
being pulled onto the return idlers. (Fig. 2) illustrates suitable methods of mounting and stringing belt
for each case.
In some cases, such as in mines where head room does not permit maneuvering a roll, the belt may
have to be pulled off the roll and reefed (Fig. 3). Extreme care should be exercised to see that the
loops have large bends to avoid kinking or placing undue strain on the belt. No weight should ever be
placed on the belt when it is in this position. Another method of handling belting under such
conditions is to lay the roll on a turn-table with a vertical spindle.
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Owner’s Manual
Belting
TRAINING THE BELT
Training the belt is a process of adjusting idlers, pulleys and loading conditions in a manner which will
correct any tendency of the belt to run other than centrally.
When all portions of a belt run off through a part of the conveyor length the cause is probably in the
alignment or leveling of the conveyor structures, idlers or pulleys in that area.
If one or more portions of the belt run off at all points along the conveyor the cause is more likely in
the belt itself, in the splices, or in the loading of the belt. When the belt is loaded off-center the center
of gravity of the load tends to find the center of the troughing idlers, thus leading the belt off on its
lightly loaded edge (See Fig. 4.).
These are the basic rules for diagnosis of belt running ills. Combinations of these things sometimes
produce cases that do not appear clear-cut as to cause but if a sufficient number of belt revolutions is
observed the running pattern will become clear and the cause disclosed. The usual cases when a
pattern does not emerge are those of erratic running which may be found on an unloaded belt that
does not trough well, a loaded belt which is not receiving its load uniformly centered, or a belt that is
not tensioned tight enough to allow the pulley crown to perform properly.
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Belting
FACTORS AFFECTING THE TRAINING OF A BELT
Pulleys and Snubs
Relatively little steering effect is obtained from the crown of conveyor pulleys. Crown is most effective
when there is a long unsupported span of betting, (approximately 10 feet) approaching the pulley.
Lengthening the unsupported span beyond 10 feet does not seem to increase the effectiveness of
the crown. Diminishing the length of the unsupported span on the other hand, does diminish the
effectiveness of the crown. As this may not be possible on the conveyor carrying side, head pulley
crowning may be relatively ineffective and therefore would not be worth the lateral mat-distribution of
tension it produces in the belt.
Tail pulleys may have such an unsupported span of belt approaching them and crowning may help
except when they are at points of high belt tension, The greatest advantage here is that the crown, in
some degree, assists in centering the belt as it passes beneath the loading point which is necessary
for good loading. Takeup pulleys are sometimes crowned to take care of any slight mis-alignment
which occurs in the takeup carriage as it shifts position. Recommendations to a standard pulley
crown of 1/16" per foot of pulley face. This results in an increase in pulley diameter at a point 12 "
from the edge of the pulley of 1/8" above the edge diameter. A crown of 1/8" per foot should be
considered maximum.
It is further recommended that the crown not be carried beyond a point 18 " in from the edge of the
pulley. If the pulley width is greater than 36 " it is recommended that a trapezoidal pulley be used. In
other words, that pulley will have a flat face in its center equivalent to the amount that the pulley width
exceeds 36”.
All pulleys should be level and with their axis at 90 deg. to the intended path of the belt. They should
be kept that way and not shifted as a means of training with the exception that snub pulleys may have
their axis shifted when other means of training have provided insufficient correction. Pulleys with their
axis at other than 90 deg. to the belt path will lead the belt in the direction of the edge of the belt
which first contacts the mis-aligned pulley. When pulleys are not level the belt tends to run to the low
side. This is contrary to the old "rule of thumb" statement that a belt runs to the "high" side of the
pulley. When combinations of these two occur, the one having the stronger influence will become
evident in the belt performance.
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Belting
Carrying Idlers
Training the belt with the troughing idlers is accomplished in two ways. Shifting the idler axis with
respect to the path of the belt, commonly known as "knocking idlers:' is effective where the entire belt
runs to one side along some portion of the conveyor. The belt can be centered by "knocking" ahead
(in the direction of belt travel) the end of the idler to which the belt runs, like using handlebars to steer
a bicycle. When you shift the idler as you would the handlebars, the belt will move in the same
direction the bike would. (The belt most always tries to steer to the side of the idler it touches
first.)(See Fig. 5) Shifting idlers in this way should be spread over some length of the conveyor
preceding the region of the trouble. (The movement of one idler generally has its greatest training
effect in an area about 15' to 25' downstream of the idler.) It will be recognized that a belt might be
made to run straight with half the idlers "knocked" one way and half the other, but this would be at the
expense of increased rolling friction between belt and idlers. For this reason all idlers should initially
be squared with the path of the belt and only the minimum shifting of idlers used as a training means.
If the belt is over-corrected by shifting idlers it should be restored by moving back the same idlers, not
by shifting additional idlers in the other direction.
Obviously such idler shifting is effective for only one direction of belt travel. If the belt is reversed, a
shifted idler, corrective in one direction, is mis-directive in the other. Hence reversing belts should
have all idlers squared up and left that way. Any correction required can be provided with self-aligning
idlers designed for reversing operation. (Not all self-aligners are of this type, as some work in one
direction only.).
Tilting the troughing idler forward (not over two degrees) in the direction of belt travel produces a selfaligning effect. The idlers may be tilted in this manner by shimming the rear leg of the idler stand.
Here again this method is not satisfactory where belts may be reversing. This method is illustrated in
Fig. 6.
This method has an advantage over "knocking idlers" in that it will correct for movement of the belt to
either side of the idler, hence is useful for training erratic belts. It has the disadvantage of
encouraging accelerated pulley cover wear due to increased friction on the troughing rolls. It should
therefore be used as sparingly as possible--especially on the higher angle troughing idlers.
Special, self-aligning troughing idlers are also available to assist in training the belt. (Fig. 7) Selfaligning, or training idlers, are available for both the carrying and return runs. There are various types,
but they all operate on this basis: if the belt moves toward one side, the idler mechanism exerts a
force that gently returns the belt back toward the center.
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Owner’s Manual
Belting
Most self aligning idlers work best when the belt is dry. Wetness greatly reduces the co-efficient of
friction between the belt and the idlers. Where the belt must operate in wet conditions, it's best to use
self-aligning idlers with attached side-guide rolls. These are known as "positive-acting" trainers
They're the most effective and the ones most commonly used.
When mounting a self-aligning idler, the center roll should be elevated 1/2 " to 3/4 " higher than the
center rolls of the adjacent idlers. This is to keep the belt cradled firmly in the training profile and
activating properly. (Several idler manufacturers pre-build this feature into the training idler
structure.).
Self aligning idlers are especially useful near the head and tail pulleys since these are the loading
and discharge areas where the belt should always run on center. Substituting one or two self-aligning
idlers at approximately 15 and 30-foot intervals ahead of each pulley will help guide the belt properly.
The most effective location for any self-aligning idler will vary with conditions such as belt width,
speed, and tension. As a rule, it isn't good practice to locate self-aligning idlers in either concave or
convex curves.
Often, material hauling designers will designate self-aligning idlers on long-center conveyors to insure
good belt control. In these applications, return trainers are often specified at 200-ft intervals. When
called for, carrying trainers are usually designated on 400-ft. spacing.
Self-aligning idlers are not intended to continually alter the belt movement. Continuous activity will
over-work the trainers and quickly reduce their longevity. In such instances, the source of the training
problem will have to be corrected by more permanent procedures.
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Belting
Return Idlers
Return idlers, being flat, provide no self-aligning influence as in the case of tilted troughing idlers.
However: by shifting their axis (knocking). with respect to the path of the belt, the return roll can be
used to provide a constant corrective effect in one direction. As in the case of troughing rolls, the end
of the roll toward which the belt is shifting should be moved longitudinally in the direction of return belt
travel to provide correction. (Fig. 5).
Self-aligning return rolls should also be used. These are pivoted about a central pin. Pivoting of the
roll about this pin results from an off-center belt and the idler roll axis becomes shifted with respect to
the path of the belt in a self-correcting action. (Fig. 8) Some return idlers are made with two rolls
forming a 10 deg. to 20 deg. V-trough which is effective in helping to train the return run.
A further aid to centering the belt as it approaches the tail pulley may be had by slightly advancing
and raising the alternate ends of the return rolls nearest the tail pulley (Fig. 9).
The Belt Itself
A belt, having extreme lateral stiffness relative to its width, will be more difficult to train due to its lack
of contact with the center roll of the carrying idler. Recognition of this fact enables the user to take
extra precaution and, if necessary, load the belt during training to improve its steer-ability.
Observation of trough-ability design limitations will normally avoid this trouble. (Fig. 11) Some new
belts may' tend to run off to one side, in a certain portion or portions of their length, because of
temporary lateral mal-distributions of tension. Operation of the belt under tension corrects this
condition in practically all cases. Use of self-aligning idlers will aid in making the correction.
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Owner’s Manual
Belting
SEQUENCE OF TRAINING OPERATIONS
Initial installation of conveyor equipment should ensure good alignment of all pulleys, troughing and
return idlers, i.e., they should be placed at right angles to the direction of belt travel, leveled and
centered on a straight line. First movement of the belt should be slow and intermittent so that any
tendency of the belt to run off may be quickly observed and the belt stopped before damage occurs.
When the conveyor is a long center installation, men should be stationed at frequent intervals to
observe the action of the belt. They should be provided with an effective method of communication so
as to report their observations and, if necessary, cause the belt to be stopped.
Initial movement of the belt will provide indication of where corrections of the types described are
required. The first corrections must be those at points where the belt is in danger of being damaged.
Once the belt is clear of all danger points, a sequence of training operations can be followed.
The best procedure to use in starting the training sequence is probably to start with the return run and
work toward the tail pulley. Use the following steps: 1). Move from idler to idler in the direction of belt
travel. 2). Shift only one idler at a time (shifting subsequent idlers may cause overcorrection). 3).
Make slight adjustments rather than extreme ones. 4). Wait for at least 3 belt revolutions before
making further adjustments. 5). Try never to adjust pulleys for belt training... pulleys should be kept
square to belt travel, and only altered when all other training resources fail. 6). Remember...apply the
"handlebar" principle to each of these idlers. This assures early centering of the belt on the tail pulley
so that it can be centrally loaded.
If the empty belt troughs readily, so that its running tendencies are not erratic, the training can and
should be completed. Should the belt tend toward stiffness and erratic running, getting some load
onto the belt as soon as the return run has been straightened up and the belt centered on the tail
pulley will help hold the top run down.
Normally, the belt can be trained properly onto the tail pulley by manipulation of return idlers and with
the assistance of self-aligning return rolls. Seldom is any adjustment of snub or tail pulley necessary
but the snub can be used as a supplementary training means.
Training of the top run, with the belt empty, is usually no problem if the belt troughs readily. In this
case self-aligners on top are not required except as insurance against damage in the region
approaching the head pulley. There, two self-aligners, placed approximately 15 and 30 feet preceding
the pulley, will help re-center the belt if it is ever forced off due to some temporary disturbance.
It should not be necessary to use the head pulley for training purposes if it has been aligned properly
Likewise, adjusting the snub following the head pulley should not be required as a training means. It
is relatively ineffective as a training device due to the strong influence of the head pulley.
The takeup carriage has a strong influence on the running of the belt at that point and, due to its
movement as belt length changes, is subject to mis-alignment. A vertical takeup carriage, hanging in
a festoon of belt, must be guided in its travel so that the pulley shaft remains horizontal.
A horizontal takeup carriage is subject to mis-alignment due to loose track gauge fouled rails, or even
jumping off the track V-shaped rails help hold the carriage tight and, with the apex upward. are selfcleaning. Hold down rails above the wheels with sufficient clearance so that they do riot touch under
normal operation will help prevent jumping off the track. (Fig 12).
With the empty belt trained satisfactorily, good operation with load is usually assured. Disturbances
which appear with load are usually due to off-center loading or to accumulation of material from the
load on snub pulleys and return idlers.
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Owner’s Manual
Belting
When equipment is known to be properly aligned, training action should be taken slowly and in small
steps because the belt requires some time to respond to corrective measures. It should begin at
some point preceding that where run-off occurs and then gradually proceed forward, in the direction
of belt travel. until the run-off condition has been corrected.
Under some conditions of operation where the conveyor is not level, is extremely short or too wide to
be affected by permissible crowning, belts with a special guide strip have been used. This V-guide
strip runs loosely in grooved pulley and idler rolls. Guide strips are not recommended or necessary
for the long conveyors, but may be essential in tracking short/wide conveyor belts.
CLEANING
Special care must be exercised to keep the return rolls and snub pulleys clean. Buildup of material on
this equipment has a destructive effect upon training with the result that the belt may run against the
structure and damage itself. It is advisable wherever possible that return idlers be suspended
sufficiently below the structure so that any mis-alignment or dirty idlers can be easily seen.
Keeping the return rolls and snubs clean requires that the belt be clean when it enters the return run.
Scraping is the most common method of doing this.
Rubber scrapers can be made by clamping rubber slabs 1/2 " to 1 "thick (not old belting) between two
metal or wooden bars. Extend the rubber about twice its thickness beyond the bars and suspend the
mechanism with a counter-weight to provide pressure against the belt. (Fig 13). Replace the rubber
when it wears down near the bars. Two or three such scrapers can be used in succession.
The most common steel scraper is a series of diagonally set blades mounted on the end of a leaf
spring to maintain pressure against the belt. These will scrape sticky materials which rubber scrapers
may ride over. (Fig. 14).
Washing the belt with a water spray before wiping with a rubber scraper will do a good cleaning job
on almost any material, including iron ores and mixed concrete.
Dry materials can be cleaned off the belt with rotating bristle or rubber vane brushes, driven at fairly
high surface speed (usually three to five times the belt speed). (Fig. 15). They wear rapidly, require
considerable maintenance and are likely to fill up solid if used with wet and sticky materials.
It is preferable to clean just after the head pulley and before the snub. An exception to this involves
sticky material. It often requires scraping on the head pulley.
In some cases the best possible cleaning is insufficient and steps must be taken to compensate for
the effect of a dirty belt. Snub pulleys can be kept from building up by the use of soft rubber lagging
or by scraping directly against the pulley. Diagonal grooving will distort and discharge accumulations
on these pulleys. Rubber disc or spiral type return rolls prevent build-up on themselves and thus save
a training problem (Fig. 16&17).
The only cleaning required on the pulley side is removal of material, principally lumps, which may fall
or bounce onto the return run, and be carried between the belt and tail pulley if not removed.(Fig. 20).
Rubber faced plows immediately in front of the tail pulley are used fur this purpose. (Fig. 18 &
19)They are usually held against the belt by gravity and set at an angle to the direction of belt travel.
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Belting
LOADING
Receiving material off center will cause the belt to move sideways after loading as the center of the
load seeks the lowest point in the troughing idlers. This can be corrected by proper chute
arrangement provided, of course, that the belt is centered as it enters the loading point.
The loading point of any conveyor is nearly always the critical point-the life determining point of the
belt. Here the conveyor receives its major abrasion, and practically all of its impact. The "ideal
condition" is to have the material pass from chute to belt at almost the same speed and direction of
travel as the belt with a minimum amount of impact. (A difference of 5-10' per minute is required for
good "take-away:').
The subject of chute design and arrangement is too broad to be discussed in detail here. In lieu of
such discussion, the following suggestions are offered.
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Belting
The width of the receiving end of the loading chute should be great enough to accept material lying
on the extreme edge of the preceding belt or feeder, and its position determined by the trajectory of
the material coming into it. At no place should the chute be less than twice the size of the largest
lumps, if fines are present, and 3 1/2 times the size of lumps, if uniform. The discharge width of the
chute thus determined should not exceed about 2/3 of the receiving belts width. (fig. 21).
The slope of the chute is determined by the nature of the material, its entering velocity and length of
the chute. This value varies with each particular installation, but about 35 deg. has been found
satisfactory for most dry industrial materials such as coal and rock.
An attempt to approach the above "ideal condition" should be made continually by adjusting the chute
arrangement. Optimum loading and transferring through chutes still requires considerable
experimental adjustment in the field.
Skirt boards should be used to further center and settle the load as it leaves the loading point. The
steel structure of the chute and skirts never should be placed closer to the surface of the belt than 1".
This distance to be made increasing in the direction of belt travel to free any material trapped
between the belt surface and the skirt. (Fig. 22) Skirt boards are usually 4 or 5 times the belt width in
length, but may vary considerably due to belt speed, type of material and lump size. Sample skirt
board arrangements are shown in Fig. 23.
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Impact of material being loaded on the belt is often the cause of severe cuts and gouges. The degree
of impact can be lessened to some extent by providing a cushion in the form of rubber covered disc
type or semi-pneumatic idlers which also tend to prevent material from crowding under the skirt
boards at the instant of impact.(Fig. 24). The use of a "Grizzly” a slightly fanned row of bars, at the
bottom of the transfer chute reduces wear on the belt It distributes the impact of large lumps by
allowing the fines to fall onto the belt first which act as a cushion. The fan shape of the "Grizzly” in the
direction of travel prevents jamming of the lumps. (Fig. 25) .
A "V-slot” cut in the bottom of the chute is another very satisfactory method of allowing fines to fall on
the belt before the lumps and thereby reduce belt wear at this point. (Fig. 26).
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Belting
PULLEY LAGGING
Lagging is recommended for drive pulleys for the following reasons:
1.
Improved co-efficient of friction. This permits a belt to be driven by lower slack side
tension and sometimes results in lower total tension.
2.
Reduction of slippage due to wet conditions if grooved lagging is used.
3.
Increased life for pulley and pulley cover of bolt.
Other pulleys in the system, especially those contacting the carrying side of the belt, are often lagged
to prevent build-up of material. Grooving improves cleaning action on the lagging and the belt.
Types of Lagging:
1.
Bolted lagging is usually fabric reinforced; the fabric being necessary to give proper boltholding. This type has no inner cover. Where no growing is intended 1/8 " top cover is the
proper minimum, but if the lagging is to be grooved a minimum of 1/4 " top cover must be
used.
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Owner’s Manual
Bolted lapping is usually applied in two or more circumferential strips, applied under tension with the
points in the different strips staggered around the pulley.(On flat-faced pulleys one strip the width of
the pulley may be used.).
For open end pulleys 5/16" or 3/8" diameter flat head elevator bolts with nuts may be used. Alternate
methods include slotted bolts with tapped holes or self tapping screws for use in welded steel pulleys.
It is necessary that the bolt heads be sunk below the level of the surrounding lagging to prevent
damage to the belt as it passes over the pulley. This may be accomplished by counter-sinking the
holes in the pulley or, where the lagging cover is greater than about 1/8” it is possible to sink the
heads merely by tightening the bolts.
Ends of the strips should be bolted in a dovetail joint as shown in Fig. 27. In addition, bolts should be
used in rows running across the face and around the circumference of the pulleys no further than 10 "
apart in either direction. Edges of all strips should be bolted down. It is recommended that all
exposed fabric edges be cemented to keep out moisture.
2.
Vulcanized lagging is a sheet of rubber, usually 1/2 " thick, bonded directly to the metal. No
fabric is used because no bolt-holding reinforcement is needed. It is much longer wearing, has better
and more uniform adhesion to the pulley and eliminates the hazard of serious belt damage to a loose
bolt.
This type of lagging can be applied in two different ways:
Spiral method--generally used for lower tension applications. A 4 " wide strip is recommended for
ease of handling. (Fig. 28) The length of the strip may be calculated by the formula:
CXW
L =---------------- + C
4
In application by the sheet wrap method, a beveled lateral splice is recommended. (Fig 29) The tie
gum side should contact the beveled leading edge for maximum adhesion at the splice.
3. Grooved lagging should be used on drive pulleys if they are liable to be wet. The grooves break
the film of moisture between the belt and lagging thereby eliminating slippage. Either bolted or
vulcanized lagging can be furnished with grooves. Either type can be grooved in the field with a
tire-groover if there is sufficient rubber to prevent cutting into the fabric carcass or metal pulley.
Herringbone grooving 3/16" deep and wide spaced (1”) apart is recommended. (Fig. 30)
4.
A modified type of bolted pulley lagging is also available which features replaceable
rubber pads that slip into metal guides bolted or welded to the pulley. (Fig. 31)
16
Owner’s Manual
Belting
17
Belting
Owner’s Manual
TROUBLE SHOOTING
PROBLEM/CAUSE
SEE PAGES 19-21
FOR SOLUTIONS
A.
Belt runs off at tail pulley
(39-10-1-19-31)
B.
Belt runs to one side for long distance or entire length
of conveyor
(39-8-5-1-2-3)
Particular section of belt runs to one side at all points
on conveyor
(6-7-46)
D.
Belt runs off at head pulley
(33-10-1-3)
E.
Conveyor runs to one side at given point on structure
(5-4-1-2-3-44)
F.
Belt runs true when empty, crooked when loaded
(8-51-52)
G.
Belt slips
(34-33-31-10-4-30)
H.
Belt slips on starting
(34-31-33-30-42-43)
I.
Excessive belt stretch
(12-35-32-43)
J.
Grooving, gouging or stripping of top cover
(13-14-15-16-53)
K.
Excessive top cover wear, uniform around belt
(19-20-10-8-36)
L.
Severe pulley cover wear
(4-9-10-17-11-27)
M.
Longitudinal grooving or cracking of bottom cover
(4-10-9-33-36)
N.
Covers harden or crack
(23-37)
O.
Cover swells in spots or streaks
(21)
P.
Belt breaks at or behind fasteners; fasteners pull out
(24-22-48-30-47-49)
Q.
Vulcanized splice separation
(38-30-12-17-25)
R.
Excessive edge wear. broken edges
(8-10-40-7-50-38)
S.
Transverse breaks at belt edge
(18-25-26)
T.
Short breaks in carcass parallel to belt edge, star breaks in
carcass.
(16-17)
U.
Ply separation.
(29-30-23)
V.
Carcass fatigue at idler junction.*
W.
Cover blisters or sand blisters.
C.
18
Owner’s Manual
Belting
X.
Belt Cupping--Old belt (was OK when new)
*The idler junction is the gap between the functioning surfaces of the center roll and one of side rolls
of the idler (See Fig. 32). This gap poses a potential hazard for the belt by providing a narrow space
in which the belt can settle, experiencing highly detrimental flex and possible exposure to oil or
grease from the idler bearings (See Fig. 33). When slipping of the belt into the idler junction is the
cause of belt damage, it is called idler junction failure. The idler junction gap should be less than .4 "
or twice belt thickness-whichever is less.
CONVEYOR SYSTEM PROBLEMS/CAUSES AND THEIR SOLUTIONS
1.
Idlers or pulleys out-of square with center line of belt: readjust idlers in affected area.
2.
Conveyor frame or structure crooked: straighten in affected area.
3.
Idler stands not centered on belt: readjust idlers in affected area.
4.
Sticking idlers: free idlers and improve maintenance and lubrication.
5.
Buildup of material on idlers: remove accumulation; improve maintenance. Install
scrapers or other cleaning devices.
6.
Belt not joined squarely: remove affected splice and re-splice.
7.
Bowed belt: for new belt this condition should disappear during break-in; in rare instances
belt must be straightened or replaced; check storage and handling of belt rolls.
8.
Off-center loading or poor loading: adjust chute to place load on center of belt: discharge
material in direction of belt travel at or near belt speed.
9.
Slippage on drive pulley: increase tension thru screw takeup or add counterweight; lag
drive pulley; Increase arc of contact.
10.
Material spillage and buildup: improve loading and transfer conditions; install cleaning
devices: improve maintenance.
11.
Bolt heads protruding above lagging: tighten bolts; replace lagging; use vulcanized-on
lagging.
12.
Tension too high: increase speed, same tonnage: reduce tonnage, same speed; reduce
friction with better maintenance and replacement of damaged idlers; decrease tension by
increasing are of contact or go to lagged pulley: reduce CWT to minimum amount.
19
Owner’s Manual
Belting
13.
Skirt boards improperly adjusted or of wrong material: adjust skirt board supports to
minimum 1" between metal and belt with gap increasing in direction of belt travel; use skirt
board rubber(not old belt).
14.
Load jams in chute: redesign chute for proper angle and width.
15.
Material hanging up in or under chute: improve loading to reduce spillage; install baffles;
widen chute.
16.
Impact of material on belt: reduce impact by improving chute design: install impact idlers.
17.
Material trapped between belt and pulley. install plows or scrapers on return run ahead of
tail pulley.
18.
Belt edges folding up on structure: same corrections as for 1, 2, 3; install limit switches;
provide more clearance.
19.
Dirty, stuck, or misaligned return rolls: remove accumulations; install cleaning devices:
self-cleaning return rolls; improve maintenance and lubrication.
20.
Cover quality too low. Replace with belt of heavier cover gauge or higher quality rubber or
other elastomer.
21.
Spilled oil or grease: over-lubrication of idlers: improve housekeeping; reduce quantity of
grease used; check grease seals.
22.
Wrong type of fastener, fasteners too tight or too loose: use proper fasteners and splice
technique; set up schedule for regular fastener inspection.
23.
Heat or chemical damage: use belt designed for specific condition.
24.
Fastener plates too long for pulley size: replace with smaller fasteners; increase pulley
size.
25.
Improper transition between troughed belt and terminal pulleys: adjust transition.
26.
Severe convex (hump) Vertical curve: decrease idler spacing in curve: increase curve
radius.
27.
Excessive forward tilt of trough rolls: reduce forward tilt of idlers to no more than 20 from
vertical.
28.
Excess gap between idler rolls: replace idlers; replace with heavier belt.
29.
Insufficient transverse stiffness: replace with the proper belt.
30.
Pulleys too small: use larger diameter pulleys.
31.
Counterweight too light: add counterweight or increase screw take-up tension to Value
determined from calculations.
32.
Counterweight too heavy: lighten counterweight to value required by calculations.
33.
Pulley lagging worn: replace pulley lagging.
use
20
Owner’s Manual
Belting
34.
Insufficient traction between belt and pulley: lag drive pulley; increase belt wrap; install belt
cleaning devices.
35.
System underbelted: recalculate belt tensions and select proper belt.
36.
Excessive sag between idlers causing load to work and shuffle on belt as it passes over
idlers: increase tension if unnecessarily low; reduce idler spacing.
37.
Improper storage or handling.
38.
Belt improperly spliced: re-splice using proper method as recommended by Elrus.
39.
Belt running off-center around the tail pulley and through the loading area: install training
idlers on the return run prior to tail pulley.
40.
Belt hitting structure: install training idlers on carrying and return run.
41.
Improper belt installation causing apparent excessive belt stretch: pull belt through
counterweight with a tension equal to at least empty running tension: run belt in with
mechanical fasteners.
42.
Improper initial positioning of counterweight in its carriage causing apparent excessive belt
stretch: check with Elrus for recommended initial position.
43.
Insufficient counterweight travel: consult Elrus for recommended minimum distances.
44.
Structure not level: level structure in affected area.
45.
Cover cuts or very small cover punctures allow fines to work under cover and cut cover
away from carcass: make spot repair with vulcanizer or self-curing repair material.
46.
Worn edge: "press" edge.
47.
Interference from belt scrapers: adjust belt scrapers.
48.
Tension too high for fasteners: use vulcanized splice.
49.
Belt carcass to light: select stronger carcass.
50.
Belt misalignment: see training recommendations.
51.
Variations in nature and formation of load: use notched chute to keep load peak in exact
center of belt.
52.
Belt not making good contact with all idlers: adjust height so all idlers contact belt.
53.
Sharp edges of material or tramp iron coming in contact with cover: use jingle bars,
impact idlers, magnetic removal equipment.
21
A
B
C
D
E
F
24
8
8
6
3
10
7
5
1
24
9
7
7
27
29
3A
8
6
11
6
12
28
4
5
4
42” F eed er C artridg e P arts list
27
5
3
3
#
1
2
3
3A
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
23
24
24
25
26
27
28
29
26
2
13
25
DWG. NO.
REV
TYPICAL FEEDER
42" CARTRIDGE
14
N/A
N/A
4050075
6100041
4050070
6100099
4850005
4071 LB
1
8/28/2009
PLOTTED
1:12
SCALE
1 OF 1
SHEET
M00 42in CARTRIDGE-1-
--
CHECK
WEIGHT (LBS)
PART NO.
KCM
DRAWN
8/26/2009
DATE
15
Motor 10hp / 1800rpm
Torspec 10hp Vari-motor (option)
Pil Blk Bearing 2 15/16”
#2 Take-up
Bearing Pil Blk 1 15/16 NTN
Roller Snubber RTN 6”x42”
140 Roller Chain
4550150
4550063
4550131
5300312
4050093
4100153
4100063
6100038
6100080
6100030
5300190
N/A
5300438
4100144
Head Pulley MD18XTB45 x 44 LG.
Pil Blk Bearing 3 7/16” S2000R
Bushing XTB45 3 7/16”
Bushing J 3 7/16”
Sprocket 140 A 45, C/W J Hub
Head Shaft 307 - 42 - 56
42” Impact Shaft
Return Roller S/C 5” x 42” SUPER
Tail Shaft 215-42-0 60"
Tail Pulley MD 14XT35 x 44
Bushing XTB35 2 15/16”
Belt Scraper Rubber 1” x 4” Spec.
42” 3 PLY Belting
Flashing Rubber 1/2” x 4”
6100034
4850401
Sprocket 140 A 15, C/W E Hub
Sprocket 140 A 17 (Torspec Opt.)
1
PART #
4350216
2
DESCRIPTION
Reducer Eurodrive K97AD3
A
B
C
D
E
F
A
B
C
D
E
F
2
18
1
8
8
14
8
9
7
7
10
7
11
12
13
6
6
3
20
5
5
P
T
15
4
4
B
A
16
17
3
3
16
17
18
20
1
2
3
7
8
9
10
11
12
13
14
15
ITEM #
2
2
1
PART #
4450013
4450409
N/A
4450100
4450073
4450004
4450054
4450196
4450110
4450258
4450246
6400006
6400004
6400022
6400008
6400008
6400022
6400022
4450281
4450222
6400028
4450228
--
CHECK
670 LB
WEIGHT (LBS)
DWG. NO.
1
3/15/2011
PLOTTED
REV
1:12
SCALE
1 OF 1
SHEET
SEE NOTE15HP PUMP PKG-1 -
PART NO.
15HP PUMP PAK W/10GAL HYD TANK
SCHEMATIC
KCM
DRAWN
8/25/2009
DATE
PART# 6400065 (WITH 460V CFACE MOTOR)
PART# 6400066 (WITH 575V CFACE MOTOR)
NOTE
DESCRIPTION
BREATHER
10 GAL. HYDRAULIC TANK
15 HP / 1800 RPM C-FACE MOTOR
FILTER BASE (spin-on post)
OIL FILTER
C-FACE BELL ADAPTOR
L110 7/8” X 1 5/8” LOVEJOY COUPLER
18 G.P.M. PUMP
PRESSURE GUAGE 0-3000 P.S.I.
RELIEF VALVE RL-75
1 1/4” GATE VALVE
42” FEEDER GRIZZLY CYLINDER LONG 4”
36” FEEDER GRIZZLY MED 4”
2054 JAWPLANT 5” MINI GRIZZLY CYL HD
2236 JAWPLANT 5” MINI GRIZZLY CYL
2442 JAWPLANT 5” MINI GRIZZLY CYL
3042 JAWPLANT 5” MINI GRIZZLY CYL HD
3054 JAWPLANT 5” MINI GRIZZLY CYL HD
1/2” YUKEN VALVE
YUKEN VALVE SUB PLATE
HYDRAULIC MOTOR PUMP BASE
CHECK VALVE
A
B
C
D
E
F
5777
FEEDER 42" SKID CUSTOM BASE
Item #
01
07 OR 10 *
StockCode
StockDescription
QTY REQ'D
4450162
4450222
OIL 10W
SUBPLATE YUKEN 1/2"
40
1
4450281
VALVE YUKEN 1/2"
1
4450342
4550150
4600146
4600147
COUPLING L-110 1-3/8" X 1-1/8"
RUBBER SCRAPER 1" X 4" BLACK
TORSPEC 10HP/460V VARI-MOTOR
TORSPEC ENCLOSURE W/BOARD
1
4
1
1
4850005
4850010
4850401
CHAIN ROLLER 140
CHAIN LINK CONNECTING 140
SPROCKET 140 A 17 C/W E HUB
12
2
1
6400065
PUMP PACKAGE 15HP 460V HYD
1
4350322
4100006
REDUCER EURODRIVE K97AM215 105
BUSHING E 2 7/8"
1
1
* - please verify part before ordering
5777F
FEEDER 42" GRIZZLY
Item #
StockCode
6050008
6050013
* - please verify part before ordering
StockDescription
PIN HINGE - GRIZZLY PIN
BUSHING TRACK 8M2619
QTY REQ'D
4
4
5777H
FEEDER 42" CARTRIDGE
Item #
StockCode
04
05
05
06 OR 16 *
06 OR 16 *
08
15
21
23
24
4100063
6100030
6100037
6100048
6100099
5300312
4050186
4050187
4100144
4100153
6100080
5300438
6100041
4050070
5300190
* - please verify part before ordering
StockDescription
BUSHING J 3 7/16"
ROLLER,SHAFT IMP 42" C/W DNUTS
SPROCKET 140 A 45 C/W "J" HUB
TUBES INNER/OUTER TAKE UP #5
ROLLER SNUBBER 6" DIA. FOR 42"
PULLEY HEAD MD 18XTB45 X 44 LG
BEARING PIL BLK 2 15/16" USRB
BEARING PIL BLK 3 7/16" USRB
BUSHING XTB35 2 15/16"
BUSHING XTB45 3 7/16"
SHAFT HEAD 307-42-56 65"
PULLEY TAIL MD 14XT35 X 44
TAKE UP #2 PILLOW BLOCK
BEARING PIL BLK 1 15/16" NTN
ROLLER RTN S/C 5" X 42" SUPER
QTY REQ'D
1
25
1
2
1
1
2
2
2
2
1
1
2
52
1
Number 5
99?05 NTN Bearing Unit Grease – Technical Specifications
NTN Bearing Unit grease is a lithium soap based product for normal industrial lubrication. It
contains a high viscosity base oil and is fortified with extreme pressure and anti-wear additives to protect bearings against wear. It provides excellent lubrication over a wide operating range in NTN Bearing units.
NTN Bearing Unit grease is designed to provide excellent lubrication under conditions of
high or low speed, moderately wet and dusty conditions. The grease makes an excellent
selection for the lubrication of bearing units used in agricultural machinery.
FEATURES:
?
?
?
?
Wide operating range
Minimize wear
Prevent rust & corrosion
Good mechanical stability & water resistance
TYPICAL PROPERTIES
Appearance
Smooth, green grease
NLGI Grade
2
Dropping Point, o C
200
Base Oil Viscosity @ 40o C, cSt
150
Base Oil Pour Point, o C
-12
-40 to 150
Operating Range, o C
RELUBRICATION FREQUENCIES*
Environtmental
Conditions
Operating temperatures
o
C
o
F
Relubrication frequency
Hours
Period
Normal, low
speed
-15 to +80
+5 to +176
1 550 to 3 000
6 to 12 mos.
Normal
-15 to +80
+5 to +176
1 000 to 2 000
3 to 6 mos.
Normal
+80 to +100
+176 to +212
500 to 700
1 month
Very dusty
-15 to +100
+5 to +212
100 to 500
1 wk. to 1 mo.
Exposed to water
splashes
-15 to +100
+5 to +212
30 to 100
1 day to 1 wk.
*For high and low temperature bearing units (HT2D1 and CT1D1 suffixes), consult NTN for re-lubrication interval.
NTN Bearing Corporation of Canada Ltd. reserves the right to change specifications as our technology progresses. We are not
responsible for misuse and/or misapplication of our products.
11. Lubrication
11.1
Lubrication of rolling bearings
The purpose of bearing lubrication is to prevent direct metallic
contact between the various rolling and sliding elements. This
is accomplished through the formation of a thin oil (or grease)
film on the contact surfaces. However, for rolling bearings,
lubrication has the following advantages.
(1)
(2)
(3)
(4)
(5)
Friction and wear reduction
Friction heat dissipation
Prolonged bearing life
Prevention of rust
Protection against harmful elements
In order to achieve the above effects, the most effective
lubrication method for the operating conditions must be
selected. Also, a good quality, reliable lubricant must be
selected. In addition, an effectively designed sealing system
prevents the intrusion of damaging elements (dust, water, etc.)
into the bearing interior, removes dust and other impurities
from the lubricant, and prevents the lubricant from leaking from
the bearing.
Almost all rolling bearings use either grease or oil lubrication
methods, but in some special applications, a solid lubricant
such as molybdenum disulfide or graphite may be used.
11.2
Grease lubrication
Grease type lubricants are relatively easy to handle and require
only the simplest sealing devices—for these reasons, grease
is the most widely used lubricant for rolling bearings.
11.2.1 Type and characteristics of grease
Lubricating grease are composed of either a mineral oil base
or a synthetic oil base. To this base a thickener and other
additives are added. The properties of all greases are mainly
determined by the kind of base oil used by the combination of
thickening agent and various additives.
Standard greases and their characteristics are listed in Table
11.1. As performance characteristics of even the same type of
grease will vary widely from brand to brand, it is best to check
the manufacturers’ data when selecting a grease.
Table 11.1 Types and characteristics of greases
Name of grease
Lithium grease
Sodium grease
(Fiber grease)
Calcium grease
(Cup grease)
Thickener
Li soap
Na soap
Ca soap
Base oil
Mineral oil
Diester oil
Silicone oil
Mineral oil
Minera oil
Dropping point °C
170~190
170~190
200~250
150~180
80~90
Applicable Temperature range °C
–30~+130
–50~+130
–50~+160
–20~+130
–20~+70
Mechanical
properties
Excellent
Good
Good
Excellent or Good
Good or Impossible
Pressure resistance
Good
Good
Impossible
Good
Good or Impossible
Water resistance
Good
The widest range
of application
Applications
Grease generally
used in roller
bearings
Good
Excellent in low
temperature and
wear characteriststics
Good or Impossible
Good
Suitable for high
and low temperatures
Good
Some of the grease
is emulsified
when mixed in water
Excellent in water
resistance, but inferior in heat resistance
Unsuitable for
heavy load use
because of low oil
film strength
Relatively excellent
high temperature
resistance
A-79
Low speed and
heavy load use
Technical Data
11.2.2 Base oil
Natural mineral oil or synthetic oils such as diester oil, silicone
oil and fluorocarbon oil are used as grease base oils.
example, a sodium based grease is generally poor in water
resistance properties, while greases with bentone, poly-urea
and other non-metallic soaps as the thickening agent are
generally superior in high temperature properties.
Mainly, the properties of any grease is determined by the
properties of the base oil. Generally, greases with a low
viscosity base oil are best suited for low temperatures and
high speeds; while greases made from high viscosity base
oils are best suited for heavy loads.
11.2.3
11.2.4
Additives
Various additives are added to greases to improve various
properties and efficiency. For example, there are anti-oxidents,
high-pressure additives (EP additives), rust preventives, and
anti-corrosives.
Thickening agents
Thickening agents are compounded with base oils to maintain
the semi-solid state of the grease. Thickening agents consist
of two types of bases, metallic soaps and non-soaps. Metallic
soap thickeners include: lithium, sodium, calcium, etc.
For bearing subject to heavy loads and/or shock loads, a grease
containing high-pressure additives should be used. For
comparatively high operating temperatures or in applications
where the grease cannot be replenished for long periods, a
grease with an oxidation stabilizer is best to use.
Non-soap base thickeners are divided into two groups;
inorganic (silica gel, bentonite, etc.) and organic (poly-urea,
fluorocarbon, etc.)
11.2.5
The various special characteristics of a grease, such as limiting
temperature range, mechanical stability, water resistance, etc.
depend largely on the type of thickening agent is used. For
Calcium compound grease
(Complex grease)
Consistency
The consistency of a grease, i.e. the stiffness and liquidity, is
expressed by a numerical index.
Sodium grease
Aluminum grease
Non-soap based grease
(Non-soap grease)
Ca compound soap
Ca+Na soap
Ca+Li soap
Al soap
Mineral oil
Mineral oil
Mineral oil
Mineral oil
Synthetic oil
200~280
150~180
70~90
250 or more
250 or more
Bentone, Silica gel, Urea,
Carbon Black
–20~+150
–20~+120
–10~+80
–10~+130
–50~+200
Good
Excellent or Good
Good or Impossible
Good
Good
Good
Excellent or Good
Good
Good
Good
Good
Good or Impossible
Good
Good
Good
Some of the grease
Excellent in pressure
containing extreme
resistance and mechanical
pressures additives are
stability
suitable for heavy load use
Suitable for bearings which
For general roller bearings receive vibrations
Excellent in stickiness
(adhesiveness)
These can be applied to the range from
low to high temperatures. Excellent
characteristics are obtained in heat and
Suitable for bearings which by suitably arranging the thickening
receive vibrations
agents and base oils
Grease for general roller bearings.
A-80
The NLGI values for this index indicate the relative softness of
the grease; the larger the number, the stiffer the grease. The
consistency of a grease is determined by the amount of
thickening agent used and the viscosity of the base oil. For the
lubrication of rolling bearings, greases with the NLGI
consistency numbers of 1,2, and 3 are used.
Where speeds are high and temperature rises need to be kept
to a minimum, a reduced amount of grease should be used.
Excessive amount of grease cause temperature rise which in
turn causes the grease to soften and may allow leakage. With
excessive grease fills oxidation and deterioration may cause
lubricating efficiency to be lowered.
General relationships between consistency and application of
grease are shown in Table 11.2.
11.2.8
Replenishment
Applications
As the lubricating efficiency of grease declines with the passage
of time, fresh grease must be re-supplied at proper intervals.
The replenishment time interval depends on the type of
bearing, dimensions, bearing’s rotating speed, bearing
temperature, and type of grease.
355 ~ 385
For centralized greasing use
An easy reference chart for calculating grease replenishment
intervals is shown in Fig. 11.1
1
310 ~ 340
For centralized greasing use
2
265 ~ 295
For general use and sealed
bearing use
3
220 ~ 250
For general and high
temperature use
4
175 ~ 205
For special use
Table 11.2 Consistency of grease
NLGI
Consistency No.
JIS (ASTM)
Worked
penetration
0
11.2.6 Mixing of greases
When greases of different kinds are mixed together, the
consistency of the greases will change (usually softer), the
operating temperature range will be lowered, and other
changes in characteristics will occur. As a general rule, greases
with different bases oil, and greases with different thickener
agents should never be mixed.
This chart indicates the replenishment interval for standard
rolling bearing grease when used under normal operating
conditions.
As operating temperatures increase, the grease re-supply
interval should be shortened accordingly.
Generally, for every 10°C increase in bearing temperature
above 80°C, the relubrication period is reduced by exponent
“1/1.5”.
(Example)
Find the grease relubrication time limit for deep groove ball
bearing 6206, with a radial load of 2.0 kN operating at 3,600 r/
min.
Cr/Pr=19.5/2.0 kN=9.8, from Fig. 9.1 the adjusted load, fL, is
0.96.
Also, greases of different brands should not be mixed because
of the different additives they contain.
From the bearing tables, the allowable speed for bearing 6206
is 11,000 r/min and the numbers of revolutions permissible at
a radial load of 2.0 kN are
However, if different greases must be mixed, at least greases
with the same base oil and thickening agent should be selected.
But even when greases of the same base oil and thickening
agent are mixed, the quality of the grease may still change
due to the difference in additives.
therefore,
For this reason, changes in consistency and other qualities
should be checked before being applied.
11.2.7
Amount of grease
The amount of grease used in any given situation will depend
on many factors relating to the size and shape of the housing,
space limitations, bearing’s rotating speed and type of grease
used.
As a general rule, housings and bearings should be only filled
from 30% to 60% of their capacities.
no = 0.96 × 11000 = 10560 r/min LLLLL A
no 10560
=
= 2.93LLLLLLLLLLL B
3600
n
Using the chart in Fig. 11.1, find the point corresponding to
bore diameter d=30 (from bearing table) on the vertical line for
radial ball bearings. Draw a straight horizontal line to vertical
line I. Then, draw a straight line from that point (A in example)
to the point on line II which corresponds to the no/n value
(2.93 in example). The point, C, where this line intersects
vertical line III indicates the relubrication interval h. In this case
the life of the grease is approximately 5,500 hours.
A-81
Technical Data
no/n
II
20.0
15.0
400
300
200
Bearing bore d, mm
Relubrication interval, h
III
I
20 000
10.0
9.0
8.0
7.0
6.0
10 000
5.0
30 000
100
50
40
30
20
10
7
A
C
500
300
200
Radial ball bearings
100
200
100
50
30
20
10
50
30
20
5 000
4 000
500
3 000
300
200
2 000
4.0
3.0
B
2.0
100
50
30
20
1 000
1.5
500
400
Thrust ball bearings
300
Cylindrical roller bearings
1.0
Tapered roller bearings
Spherical roller bearings
0.9
0.8
no = factor ƒL × limiting speed for grease see Fig. 9.1 and bearing tables
n = actual rotational speed, r/min
0.7
Fig. 11.1 Diagram for relubrication interval of greasing
11.3
Oil lubrication
Generally, oil lubrication is better suited for high speed and
high temperature applications than grease lubrication. Oil
lubrication is especially effective for those application requiring
the bearing generated heat (or heat applied to the bearing
from other sources) to be carried away from the bearing and
dissipated to the outside.
11.3.1 Oil lubrication methods
1)
Oil bath
Oil lubrication is the most commonly used method for
low to moderate speed applications. However, the
most important aspect of this lubrication method is oil
quantity control.
For most horizontal shaft applications, the oil level is
normally maintained at approximately the center of the
lowest rolling elements when the bearing is at rest.
With this method, it is important that the housing
design does not permit wide fluctuations in the oil
level, and that an oil gauge be fitted to allow easy
A-82
inspection of the oil level with the bearing at rest or in
motion (Fig. 11.2).
Fig. 11.2 Oil bath lubrication
For vertical shafts at low speeds, the oil level should
be up to 50% to 80% submergence of the rolling
elements. However, for high speeds or for bearings
used in pairs or multiple rows, other lubrication
methods, such as drip lubrication or circulation
lubrication, should be used (see below).
2)
Oil splash
In this method the bearing is not directly submerged in
the oil, but instead, an impeller or similar device is
mounted on the shaft and the impeller picks up the oil
and sprays it onto the bearing. This splash method of
lubrication can be utilized for considerably high
speeds.
As shown in the vertical shaft example in Fig. 11.3, a
tapered rotor is attached to the shaft just below the
bearing. The lower end of this rotor is submerged in
the oil, and as the rotor rotates, the oil climbs up the
surface of the rotor and is thrown as spray onto the
bearing.
Fig. 11.4 Drip lubrication
Fig. 11.3 Oil spray lubrication
3)
Drip lubrication
Used for comparatively high speeds and for light to
medium load applications. an oiler is mounted on the
housing above the bearing and allows oil to drip down
on the bearing, striking the rotating parts, turning the
oil to mist (Fig. 11.4). Another method allows only
small amounts of oil to pass through the bearing at a
time. The amount of oil used varies with the type of
bearing and its dimensions, but, in most cases, the
rate is a few drops per minute.
4)
Circulating lubrication
Used for bearing cooling applications or for automatic
oil supply systems in which the oil supply is centrally
located.
The principal advantage of this method is that oil
cooling devices and filters to maintain oil purity can be
installed within the system.
Fig. 11.5 Circulating lubrication (Horizontal shaft)
With this method however, it is important that the
circulating oil definitely be evacuated from the bearing
chamber after it has passed through the bearing. For
this reason, the oil inlets and outlets must be provided
on opposite sides of the bearing, the drain port must
be as large as possible, or the oil must be forcibly
evacuated from the chamber (Fig. 11.5). Fig. 11.6
illustrates a circulating lubrication method for vertical
shafts using screw threads.
5)
A-83
Disc lubrication
In this method, a partially submerged disc rotates at
high speed pulling the oil up by centrifugal force to an
oil reservoir located in the upper part of the housing.
The oil then drains down through the bearing. Disc
lubrication is only effective for high speed operations,
such as supercharger or blower bearing lubrication
(Fig. 11.7).
Technical Data
A fresh lubricating oil is constantly being sent to the
bearing, there is no oil deterioration, and with the
cooling effect of the compressed air, bearing
temperature rise can be kept to a minimum. The
quantity of oil required to lubricate the bearing is also
very small, and this infinitesimal amount of oil fed to
the bearing does not pollute the surrounding
environment.
Note: This air-oil lubrication unit is now available from
NTN.
Reservoir (Level switch)
Mist separator
Oil
Air
Solenoid valve
Air filter Pressure
switch
Fig. 11.6 Circulating lubrication (Vertical shaft)
T
Air oil line
Timer
Air
Nozzle
Fig. 11.9 Air-Oil lubrication supply system
8)
Fig. 11.7 Disc lubrication
6)
Oil mist lubrication
Using pressurized air, the lubrication oil is atomized
before it passes through the bearing. This method is
especially suited for high speed lubrication due to the
very low lubricant resistance. As shown in Fig. 11.8,
one lubricating device can lubricate several bearings
at one time. Also, oil consumption is very low.
Oil jet lubrication
This method lubricates the bearing by injecting the
lubricating oil under pressure directly into the side of
the bearing. This is the most reliable lubricating
system for severe (high temperature, high speed, etc.)
operating conditions.
This is used for lubricating the main bearings of jet
engines and gas turbines, and all types of high speed
equipment. This system can be used in practice for dn
values up to approximately 2.5 × 106.
Usually the oil lubricant is injected into the bearing by
a nozzle adjacent to the bearing, however in some
applications, oil holes are provided in the shaft, and
the oil is injected into the bearing by centrifugal force
as the shaft rotates.
Fig. 11.8 Oil mist lubrication
7)
Air-oil lubrication
With the air-oil lubrication system, an exact measured
minimum required amount of lubricating oil is fed to
each bearing at correct intervals. As shown in Fig.
11.9, this measured amount of oil is continuously sent
under pressure to the nozzle.
A-84
Fig. 11.10 Oil jet lubrication
11.3.2
Lubricating oil
Under normal operating conditions, spindle oil, machine oil,
turbine oil and other minerals are widely used for the lubrication
of rolling bearings. However, for temperatures above 150°C or
below –30°C, synthetic oils such as diester, silicone and
fluorosilicone are used.
For lubricating oils, viscosity of the oil is one of the most
important properties and determines the oil’s lubricating
efficiency. If the viscosity is too low, the oil film will not be
sufficiently formed, and it will damage the load carrying surface
of the bearing. On the other hand, if the viscosity is too high,
the viscosity resistance will also be high and cause temperature
increases and friction loss. In general, for higher speed, a lower
viscosity oil should be used, and for heavy loads, a higher
viscosity oil should be used.
It shows which oil would have the appropriate viscosity at a
given temperature. For lubricating oil viscosity selection
standards relating to bearing operating conditions, see Table
11.4.
Table 11.3 Minimum viscosity of lubricating oil for
bearings
In regard to operating temperature and bearing lubrication,
Table 11.3 lists the minimum required viscosity for various
bearings. Fig. 11.11 is a lubricating oil viscosity-temperature
comparison chart is used in the selection of lubricating oil.
Bearing type
Dynamic viscosity
mm2/s
Ball bearings, cylindrical roller
bearings, needle roller bearings
13
Spherical roller bearings, tapered
roller bearings, thrust needle roller
bearings
20
Spherical roller thrust bearings
30
3000
2000
1:ISOVG320
2:ISOVG150
3:ISOVG68
4:ISOVG46
5:ISOVG32
6:ISOVG22
7:ISOVG15
1000
500
300
200
Viscosity
mm2/s
100
50
30
20
15
1
2
10
8
6
5
6
4
3
4
5
7
3
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100 110 120 130 140 150 160
Temperature °C
Fig. 11.11 Relation between viscosity and temperature
A-85
Technical Data
Table 11.4 Selection standards for lubricating oils
Operating temperature
of bearings
°C
Viscosity grade of lubricating oil
dn–value
Heavy or
Impact load
Bearing type
Ordinary load
22 32
46
All type
–30 to 0
Up to the allowable
revolution
Up to 15,000
46 68
100
All type
0 to 60
15,000 to 80,000
32 46
68
All type
80,000 to 150,000
22 32
32
Except thrust ball bearings
22 32
Single row radial ball bearings,
cylindrical roller bearings
150,000 to 500,000
60 to 100
10
Up to 15,000
150
220
All type
15,000 to 80,000
100
150
All type
80,000 to 150,000
68
100 150
Except thrust ball bearings
68
Single row radial ball bearings,
cylindrical roller bearings
150,000 to 500,000
32
100 to 150
0 to 60
320
Up to the allowable
revolution
46
60 to 100
Notes:
11.3.3
All type
68
Spherical roller bearings
150
1. In case of oil drip or circulating lubrication
2. In case the usage conditions’ range is not listed in this table, please refer to NTN.
Oil quality
Table 11.5 Factor K
In forced oil lubrication systems, the heat radiated away by
housing and surrounding parts plus the heat carried away by
the lubricating oil is approximately equal to the amount of heat
generated by the bearing and other sources.
Temperature rise, °C
K
10
15
20
25
1.5
1
0.75
0.6
For standard housing applications, the quantity of oil required
can be found by formula (11.1).
Q = K • q LLLLLLLLLLLLL(11.1)
where,
Q : Quantity of oil for one bearing cm3/min
K : Allowable oil temperature rise factor (Table 11.5)
q : Minimum oil quantity cm3/min (From chart)
Because the amount of heat radiated will vary according to
the shape of the housing, for actual operation it is advisable
that the quantity of oil calculated by formula (11.1) be multiplied
by a factor of 1.5 to 2.0. Then, the amount of oil can be adjusted
to correspond to the actual machine operating conditions. If it
is assumed for calculation purposes that no heat is radiated
by the housing and that all bearing heat is carried away by the
oil, then the value for shaft diameter, d, (second vertical line
from right in Fig. 11.12) becomes zero, regardless of the actual
shaft diameter.
A-86
(Example)
For tapered roller bearing 30220U mounted on a flywheel shaft
with a radial load of 9.5 kN, operating at 1,800 rpm; what is the
amount of lubricating oil required to keep the bearing
temperature rise below 15°C?
d=100 mm, dn=100×1,800=18×104 mm r/min
from Fig. 11.12, q=180 cm3/min.
Assume the bearing temperature is approximately equal to
the outlet oil temperature, from Table 11.5, since K =1,
Q=1×180=180 cm3/min.
dn , ×
104
mm
/min
1
2
3
4
5
6
8
10
Needle roller bearings
Spherical roller bearings
Tapered roller bearings
Angular contact ball bearings
Deep groove ball bearings
Cylindrical roller bearings
Basic oil
d Pr
Loa kgf
quantity q
0
0
kN
30 0 00
cm2/min
300 20 0
200
00
10 0
100
Shaft diameter d
0
100
7 00
mm
70
200
0
6 00
160
0
60
4 00
300
140
40
0
3 00
400
30
100
0
80
2 00
500
60
20
0
40
1 50
20
600
15
0
0
1 00
700
10
800
8
800
600
6
15
4
20
30
40
2
400
200
900
1 000
1 100
1 200
Fig. 11.12 Guidance for oil quantity
11.3.4 Relubrication interval
The interval of oil change depend on operating conditions, oil
quantity, and type of oil used. A general standard for oil bath
lubrication is that if the operating temperature is below 50°C,
the oil should be replaced once a year. For higher operating
temperatures, 80°C to 100°C for example, the oil should be
replaced at least every three months.
In critical applications, it is advisable that the lubricating
efficiency and oil deterioration be checked at regular intervals
in order to determine when the oil should be replaced.
A-87
V.J.Pamensky Canada Inc.
September 6, 2002
GENERAL and Long Term STORAGE , COMMISSIONING (STARTUP), SERVICE
and maintenance of WEG electric motors
Scope:
The following instructions will ensure that all motors about to enter service are given extra special attention before they are
commissioned and put into service. Failure to follow these guidelines could result in the motors failing on or shortly after
start-up and/or having a premature bearing problem.
These instruction must be read in conjunction with WEG’s “Installation and Maintenance Instructions for Electric Motors #:
0280.1388". These instructions are not, however, a guarantee in itself. It is the responsibility of those personnel working
on the motors to practice safe and good working practices and to follow all local electrical codes and by-laws.
Storage:
Motors in storage, or stored for long periods of time, inside/outside, must be protected from direct exposure to the
elements, and therefore they must be covered by a plastic wrap/tarpaulin , DO NOT SHRINK WRAP THE MOTORS, they
must still be able to breath and not retain any moisture build-up within the wrapping. .
->
->
->
->
Inspection:
'
'
Start-Up:
As per the WEG I +M manual:
Motors must be stored in a dry place, free of dust, vibration, gases, corrosives environments and must be at a constant
temperature.
If the motors are stored for more than 2 years, before startup, the bearing must be changed or the lubrication must be
cleaned out and replaced with fresh grease.
We recommend that the motor shaft are rotated (by hand) at least once a month.
If the motors have space heaters they should be energized.
Inspection prior to storage:
All motors with roller bearings should have the shaft locking device installed correctly over the shaft.
Ensure that all the motors are completely covered with the plastic wrap/tarpaulin such that the motor is protected from direct
exposure to the elements.
Instructions/Inspections prior to Start-Up:
Do not energize the motor before proceeding
with the following:-
'
Remove the plastic wrap from the motors.
'
'
'
Remove the shaft locking device on those motors which have the devices installed.
Visually inspect the motors for any damage or abnormalities.
Ensure that there are no obstructions, nests or small animals in the fan cover which could obstruct the fan and possibly reduce
airflow or the mechanical rotation of the motor.
Rotate the shaft by hand which will help determine if there are any obstructions to the rotor, the rotor must be free and easily
rotatable.
It is very important to identify that the motor being connected, and energized is the correct motor, below you will
find an overview of a typical WEG motor nameplate.
'
'
Identification:
Sample Nameplate:
A.
B.
.
D.
www Some important Nameplate items to note:
C.
V.j.pAMENSKY CANADA INC.
64 Samor Rd. Toronto on. M6a 1J7
tel: (416)781-4617 Fax: (416)781-4352 E-Mail: mikei@pamensky.com
1
V.J.Pamensky Canada Inc.
September 6, 2002
GENERAL and Long Term STORAGE , COMMISSIONING (STARTUP), SERVICE
and maintenance of WEG electric motors
'
A. The Header which includes the WEG logo and certification of the motor:
CSA Safety logo, CSA Efficiency
Verification logo, UL logo and the Area classification, all with their file numbers. In this particular nameplate you can see
the WEG 3 Phase TEFC has Division 2 certification (This is not for Division 1 - XP motors).
'
B. The Body, which identifies the motor, items to note: Frame size, HP, RPM, Voltage, Full Load Current, Enclosure,
Service Factor, Hz, Insulation class, Temperature rise, Degree of Protection, Duty cycle.
C. Also in the body there is the
motor connection diagram. This is VERY important, if the motor is incorrectly connected it will fail prematurely. This
nameplate shows that the motor is a DELTA Run, note the Voltage/Current directly under this diagram, however, this motor is
suitable to be started with, Full Voltage, Auto Transformer, WYE/DELTA and Electronic Soft starters.
'
D. Below the body there is another section with some mechanical characteristics. Drive End bearing and Non Drive End
bearing, Type of grease, Lubrication interval in hours, Quantity of grease for lubrication and motor weight.
Bearings and Grease
'
'
'
General
WEG have standardized on the Esso grease - Polyrex EM (Polyurea), which is a wide temperature range grease for use in anti
friction bearings with generators and electric motors, specifically formulated for the Canadian climate.
We strongly recommend that you use this grease or at least an equal grease with similar qualities. DO NOT MIX GREASES mixing different types of grease can lead to serious lubrication problems.
All WEG motors from frame 254/6T to 586/7T have grease fittings which include the alemite (zerk) grease nipple and a
relief port. Smaller frames have ZZ (Double shelved) bearings.
Greasing/Inspection
'
'
'
'
'
All WEG motor are greased at the factory. Due to shipping, storage and natural movement from manufacturing to actual
startup, grease can and does get displaced from the bearing. It is imperative that the technician commissioning the system
grease the motor/bearings if the storage is shorter than 2 years.
Also rotate the shaft by hand to move the grease in the bearing. Remember, this motor could have sat for some time and the
grease beneath the balls/rollers has been displaced by the weight of the rotor and there could be metal to metal contact.
On those motors with ZZ bearings, the grease has been contained within the bearing and by rotating the shaft the grease will
cover the complete bearing.
Using a regular grease gun, pump the amount of grease (or more) noted on the nameplate into the Drive End and Non Drive
End bearing while the shaft continues to be rotated.
Starting the motor without ensuring that the bearings are correctly greased will result in a premature bearing
failure.
Insulation Resistance test (As per IEEE Standard #: 43, April 1950)
.
WARNING:
Failure to do an Insulation Resistance test of the windings prior to startup could result in a winding
failure at startup.
'
The Insulation Resistance test will check the integrity of the windings after any storage period. Insulation Resistance - Rm
- is obtained from the formula. (Low Voltage motors)
RM = kv + 1
Where:
Rm
=
kv
=
Minimum recommended Insulation Resistance in MS
(RM @ 40°C is in effect 1MS per 1000v plus 1MS)
Rated machine potential (voltage) in kilovolts
DO NOT ATTEMPT TO ENERGIZE THE MOTOR IF THE Rm IS BELOW THIS VALUE.
'
In the event that the Rm is below the minimum level corrective action must be taken, that being, the windings must be dried.
'
Drying the windings will mean, in practical terms, that it will be necessary to take some form of heat and position it around
the motor and leave it there until the Rm increases to an acceptable level. Alternatively, which could be quicker, take
portable heaters, open up the terminal box and direct the heated air into the motor.
Only once the Rm, Insulation Resistance, level has increase above the required minimum level can the motor be energized.
'
NOTE:
You have now taken care of 2 important items that can cause the motor to fail on or shortly after startup.
General maintenance
'
Under normal operating conditions please follow the instructions in the WEG “Installation and Maintenance Instructions for
Electric Motors” number 0280.1388 or 260.01/0995.
V.j.pAMENSKY CANADA INC.
64 Samor Rd. Toronto on. M6a 1J7
tel: (416)781-4617 Fax: (416)781-4352 E-Mail: mikei@pamensky.com
2
INSTALLATION AND
MAINTENANCE
INSTRUCTIONS FOR
ELECTRIC MOTORS
Frames 143/5T - 586/7T
READ CAREFULLY THIS MANUAL BEFORE
INSTALLING THE MOTOR.
RECEIVING CHECK
9 Check if any damage has occured during transportation.
9 Check nameplate data.
9 Remove shaft locking device (if any) before operating the
motor.
9 Turn the shaft with the hand to make sure if it is turning freely.
HANDLING AND TRANSPORTATION
1 - General
MOTORS MUST NOT BE LIFTED BY THE SHAFT,
BUT BY THE EYE BOLTS WHICH ARE PROPERLY
DESIGNED TO SUPPORT THE MOTOR WEIGHT.
Lifting devices, when supplied, are designed only to support
the motor. If the motor has two lifting devices then a double
chain must be used to lift it.
Lifting and lowering must be done gently without any
shocks, otherwise the bearings can get damaged.
DURING TRANSPORTATION, MOTORS FITTED
WITH ROLLER OR ANGULAR CONTACT
BEARINGS ARE PROTECTED AGAINST BEARING
DAMAGES WITH A SHAFT LOCKING DEVICE.
THIS LOCKING DEVICE MUST BE USED ON ANY
FURTHER TRANSPORT OF THE MOTOR, EVEN
WHEN THIS MEANS TO UNCOPULE THE MOTOR
FROM THE DRIVEN MACHINE.
STORAGE
If motors are not immediately installed, they must be stored
in dry places, free of dust, vibrations, gases, corrosive smokes,
under constant temperature and in normal position free from
other objects.
In case the motors are stored for more than two years, the
bearings must be changed or the lubrication grease must be
totally replaced after cleaning.
Single phase motors when kept in stock for 2 years or more
must have their capacitors replaced (if any).
We recommend to turn the shaft (by hands) at least once a
month, and to measure the insulation resistance before
installing it, in cases of motors stored for more than 6 months
or when subject to high humidity areas.
If motor is fitted with space heaters, these should be
switched on.
Insulation Resistance Check
Measure the insulation resistance before operating the
motor and/or when there is any sign of humidity in the winding.
The resistance measured at 25°C (77oF) must be:
Ri > (20 x U) / (1000 + 2P) [Mohm] (measured with a
MEGGER at 500 V d.c.); where U = voltage (V); P = power
(kW).
If the insulation resistance is less than 2 megaohms, the
winding must be dried according to the following:
9 Warm it up inside an oven at a minimum temperature of
80°C (176oF) increasing 5°C (41oF) every hour until 105°C
(221oF), remaining under this temperature for at least one hour.
Check if the stator insulation resistance remains constant within
the accepted values. If not, stator must be reimpregnated.
INSTALLATION
1 - Safety
All personnel involved with electrical installations, either
handling, lifting, operation or maintenance must be well
informed and up-to-dated concerning the safety standard and
principles that govern the work and carefully follow them.
We strongly recommend that these jobs are carried out by
qualified personnel.
MAKE SURE THAT THE ELECTRIC MOTORS ARE
SWITCHED OFF BEFORE STARTING ANY
MAINTENANCE SERVICE.
Motors must be protected against accidental starts.
When performing any maintenance service, disconnect the
motor from the power supply. Make sure all accessories have
been switched off and disconnected.
Do not change the regulation of the protecting devices to
avoid damaging.
LEAD CONNECTION IN SULATION INSIDE THE
TERMINAL BOX MUST BE DONE WITH AN
INSULATING MATERIAL COMPATIBLE WITH
MOTOR THERMAL CLASS WHICH IS SHOWN
ON THE MOTOR NAMEPLATE.
2 - Operating Conditions
Electric motors, in general, are designed for operation at
an altitude of 1000m above sea level for an ambient
temperature between 25°C (77°F) and 40°C (104°F). Any
variation is stated on the nameplate.
COMPARE THE CURRENT, VOLTAGE,
FREQUENCY, SPEED, OUTPUT AND OTHER
VALUES DEMANDED BY THE APPLICATION WITH
THE DATA GIVEN ON THE NAMEPLATE.
Motors supplied for hazardous locations must be
installed in areas that comply with that specified on the motor
nameplate.
KEEP AIR INLET AND OUTLET FREE AND CLEAN.
THE AIR BLOWN OUT BY THE MOTOR SHALL
NOT ENTER AGAIN. THE DISTANCE BETWEEN
THE AIR INLET AND THE WALL MUST BE
AROUND ¼ OF THE INLET OPENING DIAMETER.
3 - Foundation
Motors provided with feet must be installed on though
foundations to avoid excessive vibrations.
The purchaser is fully responsible for the foundation.
Metal parts must be painted to avoid corrosion.
The foundation must be uniform and sufficiently tough to
support any short circuit strengths. It must be designed in
such a way to stop any vibration originated from resonance.
4 - Drain Holes
Make sure the drains are placed in the lower part of the
motor when the mounting configuration differs from that
specified on the motor purchase order.
5 - Balancing
WEG MOTORS ARE DYNAMICALLY
BALANCED, WITH HALF KEY AT NO LOAD
AND UNCOUPLED.
Transmission elements such as pulleys, couplings, etc must
be dynamically balanced with half key before installation. Use
always appropriate tools for installation and removal.
6 - Alignment
ALIGN THE SHAFT ENDS AND USE FLEXIBLE
COUPLING, WHENEVER POSSIBLE.
Ensure that the motor mounting devices do not allow
modifications on the alignment and further damages to the
bearings.
When assembling a half-coupling, be sure to use suitable
equipment and tools to protect the bearings.
Suitable assembly of half-coupling: check that clearance Y
is less than 0.05mm and that the difference X1 to X2 is less
than 0.05m as well.
Note: The“X” dimension must be at least 3mm.
7 - Belt Drive
When using pulley or belt coupling the following must be
observed:
9 Belts must be tighten just enough to avoid slippage when
running, according to the specifications stated on the belt
supplier recommendation.
W ARNING:
Excessive tension on the pulleys
will damage the bearings and lead to
a probable shaft rupture.
8 - Connection
WARNING
ARNING: Voltage may be connected at standstill inside the
terminal box for heating elements or direct winding heating.
WARNING
ARNING: The capacitor on single-phase motors can retain
a charge which appears across the motor terminals, even when
the motor has reached standstill.
A WRONG CONNECTION CAN BURN THE
MOTOR.
Voltage and connection are indicated on the nameplate.
The acceptable voltage variation is ± 10%, the acceptable
frequency variation is ± 5% and the total acceptable variation
is ± 10%.
9 - Starting Methods
The motor is rather started through direct starting. All Weg
motors must be connected as shown on the motor nameplate,
failure to follow the motor nameplate could lead to motor failure.
In case this is not possible, use compatible methods to the
motor load and voltage.
9 3 lead single voltage and 9 lead dual voltage motors can be
started as follows:
Full Voltage Direct On Line.
Auto-Transformer Starting.
Electronic Soft-Starting.
VFD Starting - subject to verification and application analysis.
9 6 lead single voltage motors and 12 lead dual voltage motors
can be connected as follows:
Full Voltage Direct On Line.
WYE/DELTA Starting.
Auto-Transformer Starting.
Electronic Soft-Starting.
VFD Starting - subject to verification and application analysis.
The rotation direction is clockwise if the motor is viewed
from DE side and if the phases are connected according to
the sequence L1, L2, L3.
To change the rotation direction, interchange two of the
connecting leads.
THE CONNECTION TO THE POWER SUPPLY
MUST BE DONE BY QUALIFIED PERSONNEL
AND WITH FULL ATTENTION TO ASSURE A SAFE
AND PERMANENT CONNECTION. AFTER
CONNECTING THE MOTOR, CHECK FOR ANY
STRANGE BODY INSIDE THE TERMINAL BOX.
THE CABLE INLETS NOT IN USE MUST BE
CLOSED.
Make sure to use the correct cable dimension, based on
the rated current stamped on the motor nameplate.
BEFORE ENERGIZING THE TERMINALS, CHECK
IF THE EARTHING IS MADE ACCORDING TO THE
ACTUAL STANDARDS. THIS IS ESSENTIAL
AGAINST ACCIDENT RISKS.
When the motor is supplied with protective or monitor
temperature device such as thermostats, thermistors, thermal
protector, etc, connect their terminals to the corresponding
devices on the control panel.
10- Start-Up
THE KEY MUST BE FASTENED OR REMOVED
BEFORE STARTING THE MOTOR.
a) The motor must start and operate smoothly. In case this
does not occur, turn it off and check the connections and the
mounting before starting it again.
b) If there is excessive vibration, check if the fastening
screws are correctly fastened. Check also if the vibration comes
from a neighbour machine. Periodical vibration checks must
be done.
c) Run the motor under rated load for a short period of
time and compare if the running current is equal to that
stamped on the nameplate.
MAINTENANCE
WARNING:
SAFETY CHECK LIST.
1 - General Inspection
Check the motor periodically.
Keep the motor clean and assure free air flow.
Check the seals or V Ring and replace them, if required.
Check the connections as well as supporting screws.
Check the bearings and observe:
Any excessive noise, bearing temperature and grease
condition.
9 When a changing, under normal conditions, is detected,
check the motor and replace the required parts.
The frequency of the inspections depends on the motor
type and on the application conditions.
9
9
9
9
9
LUBRICATION
FOLLOW THE REGREASING INTERVALS. THIS IS
FUNDAMENTAL FOR PROPER MOTOR
OPERATION.
1 - Machines without Grease Nipples
Motors up to frame 324/6T are normally fitted without grease
nipples. In these cases the regreasing shall be done at the
preventive maintenance job observing the following aspects:
9 Disassemble carefully the motors.
9 Take all the grease out.
9 Wash the bearing with querosene or diesel.
9 Regrease the bearing immediately.
2 - Machines Fitted with Grease Nipples
It is strongly recommended to grease the machine while
running. This allows the grease renewal in the bearing housing.
When this is not possible due to turning parts by the grease
device (pulleys, bushing, etc) that offer some risk to the
physical integrity of the operator, proceed as follows:
9 Clean the area near to the grease nipple.
9 Put approximately half of the total grease and run the motor
for 1 minute at full speed. Then turn off the motor and pump
the rest of the grease.
9 The injection of all the grease with the motor in standstill
can make the grease penetrate into the motor, through the
inner seal of the bearing housing.
When regreasing, use only special bearing grease with the
following properties:
Amount of
grease (g)
13
18
21
27
27
27
27
27
21
27
34
45
45
45
60
Frame
254/6T
284/6T
324/6T
364/5T
404/5TS
444/5TS
504/5TS
586/7TS
324/5T
364/5T
404/5T
444/5T
447/5T
504/5T
586/7T
9800
3600
3600
3600
3600
3600
9800
11500
15700
3600
rpm
1500
rpm
1200
rpm
1000
rpm
900
rpm
9700
9700
9700
9700
9700
20000
20000
20000
11600
11600
11600
11600
11600
20000
20000
20000
14200
14200
14200
14200
14200
20000
20000
20000
16400
16400
16400
16400
16400
20000
20000
20000
17300
17300
17300
17300
17300
20000
20000
20000
Relubrication intervals in hours - ball bearings
1800
rpm
19700
19700
19700
19700
19700
20000
20000
20000
750
rpm
11900
3300
4700
4700
4700
6000
9700
20000
4400
6000
6000
6000
7600
11600
20000
5900
7600
7600
7600
9500
14200
20000
7800
9800
9800
9800
11600
16400
20000
10700
12200
12200
12200
13800
17300
20000
11500
13700
13700
13700
15500
19700
20000
Relubrication intervals in hours - cylindrical roller bearings
4500
4500
4500
4500
4500
11900
13700
18100
3000
rpm
11500
13700
13700
13700
15500
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
720
rpm
13400
15700
15700
15700
17800
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
600
rpm
17300
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
500
rpm
RELUBRICATION INTERVALS RECOMMENDED - POLYREX® EM GREASE (ESSO/EXXON)
WARNING:
The table above is specifically intended for relubrication
with Polyrex® EM grease and bearing absolute operating
temperature of:
9 70oC (158oF) for 254/6T to 324/6T frame motors;
9 85oC (185oF) for 364/5T to 586/7T frame motors.
For every 15oC (59oF) above these limits, relubrication
interval must be reduced by half.
Shielded bearing (ZZ) are lubricated for berings life as long
as they operate under normal ambient conditions and
temperature of 70°C(158oF ).
WE RECOMMEND TO USE BALL BEARINGS FOR
MOTORS DIRECTLY COUPLED TO THE LOAD.
WARNING:
EXCESS OF GREASE CAN CAUSE BEARING
OVERHEATING RESULTING IN COMPLETE
DAMAGE.
Compatibility of P
olyrex® EM grease
Polyrex
with other types of grease:
Containing polyurea thickener and mineral oil, the Polyrex®
EM grease is compatible with other types of grease that
contain:
9 Lithium base or complex of lithium or polyurea and highly
refined mineral oil;
9 Inhibitor additive against corrosion, rust and anti-oxidant
additive.
Notes:
9 Although Polyrex® EM is compatible with the types of grease
given above, we do no recommend to mix it with any other
greases.
9 If you intend to use a type of grease different than those
recommended above, first contact WEG.
9 On applications (with high or low temperatures, speed
variation, etc), the type of grease and relubrication interval
are given on an additicional nameplate attached to the motor.
9 Vertical mounted motors must have the relubrication intervals
reduced by half.
THE USE OF STANDARD MOTORS IN SPECIFIC
AREAS OR SPECIAL APPLICATIONS MUST BE
DONE BY CONSULT TO THE GREASE
MANUFACTURER OR WEG.
ASSEMBLY AND DISASSEMBLY
Disassembly and assembly must be done by qualified
personnel using only suitable tools and appropriated methods.
The stator grips must be applied over the side face of the inner
ring to be disassembled or over and adjacent part.
It is essential that the bearings disassembly and assembly
be done under cleanning conditions to ensure good operation
and to avoid damages. New bearings shall only be taken out
from their cases when assembling them.
Before installing a new bearing it is required to check the
shaft fitting for any sharp edge or strike signals.
For bearing assembly, warm their inner parts with suitable
equipment - inductive process - or use suitable tools.
SPARE PARTS
When ordering spare parts, please specify the full type
designation and product code as stated on the motor
nameplate.
Please also inform the motor serial number stated on the
nameplate.
MOTORS FOR HAZARDOUS LOCATIONS
Besides the recommendations given previously, these ones
must be also followed:
THE SPECIFICATION OF THE MOTOR
INSTALLATION PLACE IS FOR CUSTOMER’S
RESPONSIBILITY, WHO WILL ALSO DETERMINE
THE ENVIRONMENT CHARACTERISTICS.
Motors for hazardous locations are manufactured according
to specific standards for such environments and they are
certified by worldwide certifying entities.
1 - Installation
The complete installation must follow procedures given by
the local legislation in effect.
THE INSTALLATION OF HAZARDOUS LOCATION
MOTORS MUST BE CARRIED OUT BY SKILLED
PEOPLE, AND THE THERMAL PROTECTION
MUST BE ALWAYS INSTALLED, EITHER INSIDE
OR OUTSIDE THE MOTOR, OPERATING AT THE
RATED CURRENT.
2 - Maintenance
Maintenance must be carried out by repair shops authorized
by WEG.
Repair shops and people without WEG’s authorization who
will perform any service or hazardous location motors will be
fully responsible for such service as well as for any
consequential damage.
ANY ELECTRICAL OR MECHANICAL
MODIFICATION MADE ON HAZARDOUS
LOCATION MOTORS WILL VOID THE
CERTIFICATION.
When performing maintenance, installation or relubrication,
follow these instructions:
9 Check if all components are free of edges, knocks or dirt.
9 Make sure all parts are in perfect conditions.
9 Lubricate the surfaces of the endshield fittings with protective
oil to make the assembly easier.
9 Use only rubber hammer to fit the parts.
9 Check for correct bolts tightening.
9 Use clearance calibrator for correct T-box fitting (smaller
than 0.05mm).
DO NOT REUSE DAMAGED OR WORN PARTS.
REPLACE THEM BY NEW ONES SUPPLIED BY
THE FACTORY.
MOTORS DRIVEN BY VFD
Applications using VFD´s without filter can affect motor
performance as follows:
9 Lower efficiency.
9 Higher vibration.
9 Higher noise level.
9 Higher rated current.
9 Higher temperature rise.
9 Reduced motor insulation.
9 Reduced bearing life.
1 - Standard Motors
9 Voltages lower than 440V do not require filter.
9 Voltages equal or higher than 440V or lower than 575V
require filter for motor power supply cables longer than 20
meters.
9 Voltages equal or higher than 575V require filter for any size
of power supply cables.
IF SUCH RECOMMENDATIONS ARE NOT
FOLLOWED ACCORDINGLY, MOTOR WARRANTY
WILL BE VOID.
2 - Inverter Duty Motors
9 Check power supply voltage of the forced cooling set.
9 Filters are not required.
WARRANTY TERMS
SERIES AND ENGINEERING PRODUCTS
WEG warrants its products against defects in workmanship
and materials for 18 months from the invoice date issued by the
factory, authorized distributor or agent limited to 24 months from
manufacturing date independent of installation date as long as
the following items are fulfilled accordingly:
- Proper transportation, handling and storage;
- Correct installation based on the specified ambient conditions
and free of corrosive gases;
- Operation under motor capacity limits;
- Observation of the periodical maintenance services;
- Repair and/or replacement effected only by personnel duly
authorized in writing by WEG;
- The failed product be available to the supplier and/or repair shop
for a required period to detect the cause of the failure and
corresponding repair;
- Immediate notice by the purchaser about failures occured and
that these are accepted by WEG as manufacturing defects.
This warranty does not include disassembly services at the
urchaser facilities, transportation costs with product, tickets,
accomodation and meals for technical personnel when requested
by the customer. The warranty service will be only carried out at
WEG Authorized Repair Shops or at WEG´s facilities.
Components whose useful life, under normal use, is shorter
than the warranty period are not covered by these warranty terms.
The repair and/or replacement of parts or components, when
effected by WEG and/or any WEG Authorized Repair Shop, will not
give warranty extension.
This constitutes WEG´s only warranty in connection with this
sale and the company will have no obligation or liability whatsoever
to people, third parties, other equipment or installations, including
without limitation, any claims for consequential damages or labor
costs.
Gear Units
R..7, F..7, K..7, S..7 Series, Spiroplan® W
Edition
04/2000
07/2002
Operating Instructions
1055 2715 / EN
SEW-EURODRIVE
Inhaltsverzeichnis
I
1
Important Notes................................................................................................. 4
2
Safety Notes ...................................................................................................... 5
3
Gear Unit Structure ........................................................................................... 7
3.1 Basic structure of helical gear units .......................................................... 7
3.2 Basic structure of parallel shaft helical gear units..................................... 8
3.3 Basic structure of helical-bevel gear units ................................................ 9
3.4 Basic structure of helical-worm gear units .............................................. 10
3.5 Basic structure of SPIROPLAN® gear units............................................ 11
4
Mechanical Installation................................................................................... 12
4.1 Required tools / resources ...................................................................... 12
4.2 Before you begin..................................................................................... 12
4.3 Preliminary work ..................................................................................... 12
4.4 Installing the gear unit............................................................................. 13
4.5 Gear units with solid shafts ..................................................................... 15
4.6 Installing torque arms for shaft-mounted gear units................................ 17
4.7 Assembly/removal of shaft-mounted gear units with keyway
or splined hollow shaft ............................................................................ 19
4.8 Assembly/removal of shaft-mounted gear units with shrink disk ............ 23
4.9 Mounting the coupling of adapter AM ..................................................... 25
4.10 Mounting the coupling of adapter AQ ..................................................... 27
4.11 Mounting on input shaft assembly AD .................................................... 28
5
Startup.............................................................................................................. 30
5.1 Startup of helical-worm and Spiroplan® W gear units............................. 30
5.2 Startup of helical, parallel shaft helical and helical-bevel gear units....... 30
6
Inspection and Maintenance .......................................................................... 31
6.1 Inspection and maintenance intervals..................................................... 31
6.2 Lubricant change intervals ...................................................................... 31
6.3 Inspection and maintenance of the gear unit .......................................... 32
7
Malfunctions .................................................................................................... 33
7.1 Gear unit malfunctions ............................................................................ 33
8
Mounting Positions......................................................................................... 34
8.1 General information about mounting positions ....................................... 34
8.2 Key to the mounting position sheets ....................................................... 35
8.3 Mounting positions of R helical gear units .............................................. 36
8.4 Mounting positions of RX helical gear units ............................................ 39
8.5 Mounting positions of parallel shaft helical gear units............................. 41
8.6 Mounting positions of helical-bevel gear units ........................................ 44
8.7 Mounting positions of helical-worm gear units ........................................ 49
8.8 Mounting positions of Spiroplan® W gear units ...................................... 55
9
Lubricants........................................................................................................ 58
10
Index................................................................................................................. 65
10.1 Index of changes..................................................................................... 65
10.2 Index ....................................................................................................... 66
0
M1 … M6
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan®W Gear Units
3
1
Important Notes
1
Important Notes
Safety and warning instructions
Always follow the safety and warning instructions contained in this publication!
Electrical hazard
Possible consequences: Severe or fatal injuries.
Hazard
Possible consequences: Severe or fatal injuries.
Hazardous situation
Possible consequences: Slight or minor injuries.
Harmful situation
Possible consequences: Damage to the drive and the environment.
Tips and useful information.
A requirement of fault-free operation and fulfillment of any rights to claim under guarantee is that you adhere to the information in the operating instructions. Consequently,
read the operating instructions before you start operating the gear unit!
The operating instructions contain important information about servicing; as a result,
they should be kept in the vicinity of the gear unit.
Waste disposal
4
•
Adjust the lubricant fill volumes and position of the breather valve accordingly
in case you change the mounting position (see Sec. 'Lubricants' and 'Mounting
Positions').
•
Please follow the instructions in Sec. 'Mechanical Installation' / 'Installing the
gear unit'!
Please follow the current instructions:
•
Dispose of housing parts, gears, shafts and anti-friction bearings of the gear units as
scrap steel. The same applies to gray cast iron castings unless there are separate
collection arrangements.
•
Some worm gears are made of non-ferrous metals and must be disposed of accordingly.
•
Collect waste oil and dispose of it correctly.
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Safety Notes
2
2
Safety Notes
Preliminary
remarks
The following safety notes are principally concerned with the use of gear units. If using
geared motors, please also refer to the safety notes for motors in the corresponding
operating instructions.
Please also take account of the supplementary safety notes in the individual sections of these operating instructions.
General information
During and after operation, geared motors, gear units and motors have live and moving
parts and their surfaces may be hot.
All work related to transport, putting into storage, setting up/mounting, connection, startup, maintenance and repair should only be performed by trained personnel observing
•
the corresponding detailed operating instructions booklet(s) and wiring diagrams,
•
the warning and safety signs on the gear unit/geared motor,
•
the specific regulations and requirements for the system and
•
national/regional regulations governing safety and the prevention of accidents.
Severe injuries and damage to property may result from
Designated use
•
incorrect use,
•
incorrect installation or operation,
•
removal of required protective covers or the housing when this is not permitted.
These geared motors/gear units are intended for industrial systems. They correspond
to the applicable standards and regulations.
The technical data and the information about permitted conditions are to be found on the
nameplate and in the documentation.
It is essential that you observe all specified information!
Transportation
Inspect the delivery for any damage in transit as soon as you receive the delivery.
Inform the shipping company immediately. It may be necessary to preclude startup.
Tighten screwed in transport lugs firmly. They are only designed for the weight of the
geared motor/gear unit; do not attach any additional loads.
The installed lifting eyebolts are in accordance with DIN 580. The loads and regulations specified in that document must always be observed. If the geared motor
is equipped with two suspension eye lugs or lifting eyebolts, then both of the suspension eye lugs should be used for transport. In this case, the tension force vector of the slings must not exceed a 45° angle in accordance with DIN 580.
Use suitable, sufficiently rated handling equipment if necessary. Remove any transportation fixtures prior to startup.
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
5
2
Safety Notes
Extended storage of gear units
Gear units of the 'extended storage' type have
•
an oil fill suitable for the mounting position so the unit is ready to run (mineral oil CLP
and synthetic oil CLPHC). You must still check the oil level before startup (see Sec.
'Inspection and Maintenance' / 'Inspection and maintenance').
•
a higher oil level in some cases (synthetic oil CLP PG). Correct the oil level before
startup (see Sec. 'Inspection and Maintenance' / 'Inspection and maintenance').
Comply with the storage conditions specified in the following table for extended storage:
Packaging1)
Climate zone
Temperate
(Europe, USA,
Canada, China
and Russia,
excluding tropical zones)
Tropical (Asia,
Africa, Central
and South America, Australia,
New Zealand
excluding temperate zones)
Storage location
Storage time
Packed in containers, with
desiccant and moisture
indicator sealed in the plastic film.
With roof, protected against rain and snow, no
shock loads.
Max. 3 years with regular
checks on the packaging and
moisture indicator (rel. atmospheric humidity < 50 %).
Open
With roof, enclosed, at constant temperature and
atmospheric humidity (5 °C < ϑ < 60 °C, < 50 %
relative atmospheric humidity).
No sudden temperature fluctuations and controlled ventilation with filter (free from dirt and
dust). No aggressive vapors and no shock loads.
2 years or more given regular
inspections. Check for cleanliness and mechanical damage as part of the inspection.
Check the corrosion protection is intact.
Packed in containers, with
desiccant and moisture
indicator sealed in the plastic film.
Protected against insect
damage and mildew by
chemical treatment.
With roof, protected against rain, no shock loads.
Max. 3 years with regular
checks on the packaging and
moisture indicator (rel. atmospheric humidity < 50 %).
Open
With roof, enclosed, at constant temperature and
atmospheric humidity (5 °C < ϑ < 60 °C, < 50 %
relative atmospheric humidity).
No sudden temperature fluctuations and controlled ventilation with filter (free from dirt and
dust). No aggressive vapors and no shock loads.
Protection against insect damage.
2 years or more given regular
inspections. Check for cleanliness and mechanical damage as part of the inspection.
Check the corrosion protection is intact.
1) Packaging must be performed by an experienced company using the packaging materials which have been expressly qualified for the
particular application.
Installation/
mounting
Comply with the instructions in Sec. 'Installation' and Sec. 'Assembly/removal'!
Startup/operation
Check the direction of rotation is correct in decoupled status (also listen out for unusual
grinding noises as the shaft rotates).
Secure the shaft keys for test mode without drive components. Do not render monitoring
and protection equipment inoperative even for test mode.
Switch off the geared motor if in doubt whenever changes occur in relation to normal operation (e.g. increased temperature, noise, vibration). Determine the cause; contact
SEW if necessary.
Inspection and
maintenance
6
Follow the instructions in Sec. 'Inspection and Maintenance'!
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
3
Gear Unit Structure
3
Gear Unit Structure
The following illustrations are intended to explain the general structure. Their purpose is
only to make it easier to assign components to the spare parts lists. Discrepancies are
possible depending on the gear unit size and version!
3.1
Basic structure of helical gear units
59
20
24
101
2
45
100
515
516 47
517
59
43
41
1
102
3
42
6
181
25
88
22
11
12
9
17
19
8
521
522
523
7
59
31
32
34
30
4
5
131
506
39 507
508
37
03438AXX
Figure 1: Basic structure of helical gear units
Key
1
Pinion
19 Key
42
Anti-friction bearing
507
Shim
2
Gear
20 Breather valve
43
Key
508
Shim
3
Pinion shaft
22 Gearcase
45
Anti-friction bearing
515
Shim
4
Gear
24 Lifting eyebolt
47
Circlip
516
Shim
5
Pinion shaft
25 Anti-friction bearing
59
Screw plug
517
Shim
6
Gear
30 Anti-friction bearing
88
Circlip
521
Shim
7
Output shaft
31 Key
100
Gearcase cover
522
Shim
8
Key
32 Distance piece
101
Hex head screw
523
Shim
9
Oil seal
34 Anti-friction bearing
102
Seal
11 Anti-friction bearing
37 Anti-friction bearing
131
Closing cap
12 Circlip
39 Circlip
181
Closing cap
17 Distance piece
41 Circlip
506
Shim
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
7
3
Gear Unit Structure
3.2
Basic structure of parallel shaft helical gear units
2
181
41
20
45
43
515
516 42
517
22
59
1
3
161
30
4
32
59
31
131
506
507 39
508
37
5
183
165
160
19
91
92
93
94
102
521 88
25 522
523
100
101
7
59
17
81
9 11
6
14
16
05676AXX
Figure 2: Basic structure of parallel shaft helical gear units
Key
8
1
Pinion
22
Gearcase
91
Circlip
506 Shim
2
Gear
25
Anti-friction bearing
92
Washer
507 Shim
3
Pinion shaft
30
Anti-friction bearing
93
Lock washer
508 Shim
4
Gear
31
Key
94
Hex head screw
515 Shim
5
Pinion shaft
32
Distance piece
100 Gearcase cover
516 Shim
6
Gear
37
Anti-friction bearing
101 Hex head screw
517 Shim
7
Hollow shaft
39
Circlip
102 Seal
521 Shim
9
Oil seal
41
Circlip
131 Closing cap
522 Shim
11 Anti-friction bearing
42
Anti-friction bearing
160 Closing plug
523 Shim
14 Hex head screw
43
Key
161 Closing cap
16 Output flange
45
Anti-friction bearing
165 Closing plug
17 Distance piece
59
Screw plug
181 Closing cap
19 Key
81
O-ring
183 Oil seal
20 Breather valve
88
Circlip
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
3
Gear Unit Structure
3.3
Basic structure of helical-bevel gear units
100
102
536
3 43 537
538
20
533
534
535
22
45
59
2
114
113
101
42
59
119
(116)
523
89 59
522 88
521
19
8
84
25
1
59
7
6
9
12
11
83
59
17
161
132
133
542
30 543
544
135
31
5
131
39
4
37
506
507
137 508
05675AXX
Figure 3: Basic structure of helical-bevel gear units
Key
1
Pinion
25 Anti-friction bearing
102 Adhesive and sealant
522 Shim
2
Gear
30 Anti-friction bearing
113 Slotted round nut
523 Shim
3
Pinion shaft
31 Key
114 Multi-tang washer
533 Shim
4
Gear
37 Anti-friction bearing
116 Thread lock
534 Shim
5
Pinion shaft
39 Circlip
119 Distance piece
535 Shim
6
Gear
42 Anti-friction bearing
131 Closing cap
536 Shim
7
Output shaft
43 Key
132 Circlip
537 Shim
8
Key
45 Anti-friction bearing
133 Spacer
538 Shim
9
Oil seal
59 Screw plug
135 Nilos ring
542 Shim
11 Anti-friction bearing
83 Nilos ring
161 Closing cap
543 Shim
12 Circlip
84 Nilos ring
506 Shim
544 Shim
17 Distance piece
88 Circlip
507 Shim
19 Key
89 Closing cap
508 Shim
20 Breather valve
100 Gearcase cover
521 Shim
22 Gearcase
101 Hex head screw
521 Shim
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
9
3
Gear Unit Structure
3.4
Basic structure of helical-worm gear units
101
59
20
100
131
39
137
506
507
102
37
5
43
30
2
61
22
59
1
19
89
25
523
522
521
88
59
7
6
11
520
12 519
518
9
50884AXX
Figure 4: Basic structure of helical-worm gear units
Key
10
1
Pinion
20
Breather valve
88
Circlip
518
Shim
2
Gear
22
Gearcase
89
Closing cap
519
Shim
5
Worm
25
Anti-friction bearing
100 Gearcase cover
520
Shim
6
Worm gear wheel
30
Anti-friction bearing
101 Hex head screw
521
Shim
7
Output shaft
37
Anti-friction bearing
102 Rubber seal
522
Shim
9
Oil seal
39
Circlip
131 Closing cap
523
Shim
11
Anti-friction bearing
43
Key
137 Spacer
12
Circlip
59
Screw plug
506 Shim
19
Key
61
Circlip
507 Shim
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
3
Gear Unit Structure
3.5
Basic structure of SPIROPLAN® gear units
100
101
102
65
71
66 143
68
72
1
22
89
25
88
521
522
523
6
19
250
251
17
8
7
11
12
518
519
520
9
05674AXX
Figure 5: Basic structure of SPIROPLAN® gear units
Key
1
Pinion
19 Key
88
Circlip
251
Circlip
6
Gear
22 Gearcase
89
Closing cap
518
Shim
7
Output shaft
25 Anti-friction bearing
100
Gearcase cover
519
Shim
8
Key
65 Oil seal
101
Hex head screw
520
Shim
9
Oil seal
66 Anti-friction bearing
102
Seal
521
Shim
11
Anti-friction bearing
71 Spacer
132
Circlip
522
Shim
12
Circlip
72 Circlip
183
Oil seal
523
Shim
17
Distance piece
143 Spacer
250
Circlip
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
11
4
Mechanical Installation
4
Mechanical Installation
4.1
Required tools / resources
•
Set of spanners
•
Torque wrench (for shrink disks, AQH motor adapter, input shaft assembly with centering shoulder)
•
Mounting device
•
Shims and distance rings if necessary
•
Fastening devices for input and output elements
•
Lubricant (e.g. NOCO® Fluid)
•
Bolt locking compound (for input shaft assembly with centering shoulder), e.g. Loctite
243
Installation tolerances
4.2
Shaft end
Flanges
Diametric tolerance in accordance with DIN 748
• ISO k6 for solid shafts with ∅ ≤ 50 mm
• ISO m6 for solid shafts with ∅ > 50 mm
• ISO H7 for hollow shafts
• Center hole in accordance with DIN 332, shape
DR..
Centering shoulder tolerance in accordance with
DIN 42948
• ISO j6 with b1 ≤ 230 mm
• ISO h6 with b1 > 230 mm
Before you begin
The drive may
only be installed
if
•
the entries on the nameplate of the geared motor match the voltage supply system,
•
the drive is undamaged (no damage caused by transportion or storage) and
•
it is certain that the following requirements have been met:
– with standard gear units:
ambient temperature according to the lubricant table in Sec. 'Lubricants' (see
standard), no oil, acid, gas, vapors, radiation, etc.
– with special designs:
drive configured in accordance with the ambient conditions
– with helical-worm / Spiroplan® W gear units:
no large external mass moments of inertia which could exert a retrodriving load
on the gear unit
[at η’ (retrodriving) = 2 - 1/η < 0.5 self-locking]
4.3
Preliminary work
The output shafts and flange surfaces must be thoroughly cleaned of anti-corrosion
agents, contamination or such like (use a commercially available solvent). Do not let the
solvent come into contact with the sealing lips of the oil seals since it could damage the
material!
12
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Mechanical Installation
4.4
4
Installing the gear unit
The gear unit or geared motor may only be mounted or installed in the specified mounting position (Spiroplan® gear units are not dependent on the mounting position) on a level1, vibration damping and torsionally rigid support structure. Do not tighten the housing
legs and mounting flanges against one another and comply with the permitted overhung
and axial loads!
Always use bolts of quality 8.8 for mounting geared motors.
Bolts of quality 10.9 must be used for fastening the flange to the customer unit in order
to transmit the rated torque specified in the catalog in case of the following flangemounted helical geared motors (RF..) and foot/flange-mounted helical geared motors
(R..F):
•
RF37, R37F with flange ∅ 120 mm
•
RF47, R47F with flange ∅ 140 mm
•
RF57, R57F with flange ∅ 160 mm
The oil level plug and drain screws as well as the breather valves must be freely
accessible!
At the same time, also check that the oil fill is as specified for the mounting position (see
Sec. 'Lubricants' / 'Lubricant fill quantities' or refer to the information on the nameplate).
The gear units are filled with the required oil volume at the factory. There may be slight
deviations at the oil level plug as a result of the mounting position, which are permitted
within the manufacturing tolerances. Adjust the lubricant fill volumes and the position of the breather valve accordingly in case you change the mounting position.
Please contact our customer service if you change the mounting position of K gear units
to M5 or M6 or between M5 and M6.
Please contact customer service if you change the mounting position of size S47...S97
S gear units to mounting position M2.
Use plastic inserts (2 – 3 mm thick) if there is a risk of electrochemical corrosion between
the gear unit and the driven machine (connection between different metals such as cast
iron and high-grade steel)! Also fit the bolts with plastic washers! Ground the housing
additionally – use the grounding bolts on the motor.
Installation in
damp areas or in
the open
Drives are supplied in corrosion-resistant versions for use in damp areas or in the open.
Any damage to the paint work (e.g. on the breather valve) must be repaired.
1. Maximum permitted flatness error for flange mounting (approximate values with reference to DIN ISO
1101): with → flange 120...600 mm max. error 0.2...0.5 mm
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
13
4
Mechanical Installation
Gear unit venting
No breather plug is required for the following gear units:
•
R07 in mounting positions M1, M2, M3, M5 and M6
•
R17, R27 and F27 in mounting positions M1, M3, M5 and M6
•
Spiroplan® W gear units
All other gear units are delivered by SEW-EURODRIVE ready for the respective mounting position with the breather valve fitted and activated.
Exception:
Gear units for extended storage, with pivoting mounting positions and for mounting at
an angle are delivered with a screw plug on the vent hole. Prior to startup, the customer
must replace the highest screw plug by the supplied breather valve on each individual
gear unit
Activating the
breather valve
•
With geared motors for extended storage, with pivoting mounting positions and for
mounting at an angle, the supplied breather valve is located in the terminal box of
the motor.
•
With gear head units requiring venting on the input end, a breather valve is supplied
in a plastic bag.
•
Enclosed gear units are delivered without a breather valve.
As a rule, the breather valve is already activated at the factory. If this is not the
case, remove the transportation fixture from the breather valve before starting up
the gear unit!
1. Breather valve with
transportation fixture
2. Remove the transportation fixture
02053BXX
Painting the gear
unit
14
02054BXX
3. Breather valve activated
02055BXX
If all or some of the drive surface is to be painted over, make sure that you carefully mask
over the breather valve and the oil seals. Remove the strips of tape after completing the
paint job.
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Mechanical Installation
4.5
4
Gear units with solid shafts
Installing input
and output elements
The following illustration shows an example of a mounting device for installing couplings
or hubs on gear unit or motor shaft ends. It may be possible to dispense with the thrust
bearing on the mounting device.
1) Gear shaft end
2) Thrust bearing
3) Coupling hub
03371BXX
The following illustration shows the correct mounting arrangement B of a gear or chain
sprocket for avoiding impermissibly high overhung loads.
1 = Hub
A = Unfavorable
B = Correct
03369BXX
•
Only use a mounting device for installing input and output elements. Use the center
bore and the thread on the shaft end for positioning purposes.
•
Never drive belt pulleys, couplings, pinions, etc. onto the shaft end by hitting
them with a hammer (damage to bearings, housing and the shaft!).
•
In the case of belt pulleys, make sure the belt is tensioned correctly (in accordance with the manufacturer’s instructions).
•
Power transmission elements should be balanced after fitting and must not give rise
to any impermissible radial or axial forces (see the 'Geared Motors' catalog for permitted values).
Note:
Mounting is easier if you first apply lubricant to the output element or heat it up briefly
(to 80 – 100 °C).
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
15
4
Mechanical Installation
Mounting of couplings
Couplings must be mounted and balanced according to the information provided by the
coupling manufacturer:
a) Maximum and minimum clearance
b) Axial misalignment
c) Angular misalignment
a)
b)
c)
03356AXX
Figure 6: Clearance and misalignment for clutch mounting
Input and output elements such as belt pulleys, couplings, etc. must be equipped
with touch guards!
16
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Mechanical Installation
4.6
4
Installing torque arms for shaft-mounted gear units
Do not place torque arms under strain during installation!
Parallel shaft helical gear units
01029BXX
Figure 7: Torque arm for parallel shaft helical
gear units
Helical-bevel gear
units
•
Bushing with bearings on both ends → (1)
•
Install connection end B as a mirror image of A
01030CXX
Figure 8: Torque arm for helical-bevel gear units
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
17
4
Mechanical Installation
Helical-worm
gear units
•
Bushing with bearings on both ends → (1)
01031CXX
Figure 9: Torque arm for helical-worm gear units
•
Bushing with bearings on both ends → (1)
45°
SPIROPLAN® W
gear units
(1)
Figure 10: Torque arm for SPIROPLAN® W gear units
18
02050CXX
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Mechanical Installation
4.7
4
Assembly/removal of shaft-mounted gear units with keyway or splined hollow
shaft
Please also refer to the design notes in the Geared Motors catalog concerning configuration of the customer shaft!
Installation notes
1. Apply NOCO® fluid.
®
O
C
O I
N U
L
F
®
O
C
O I
N U
L
F
02042BXX
2. Distribute the NOCO® fluid carefully.
02043AXX
3. Install the shaft and secure it axially.
(mounting is facilitated by using a mounting device).
3A: Mounting with standard scope of supply
1
2
1
3
4
2
3
4
6
A
Short retaining screw
(standard scope of supply)
Lock washer
Washer
Circlip
Customer shaft
6
03361BXX
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
19
4
Mechanical Installation
3B: Mounting with SEW-EURODRIVE assembly/removal kit (→ page 22)
– Customer shaft with contact shoulder
1
2
3
1 Retaining screw
2 Lock washer
3 Washer
4 Circlip
6 Customer shaft with contact
shoulder
4
B
6
03362BXX
3C: Mounting with SEW-EURODRIVE assembly/removal kit (→ page 22)
– Customer shaft without contact shoulder
1
23
1
2
3
4
5
6
4
5
C
Retaining screw
Lock washer
Washer
Circlip
Distance piece
Customer shaft without
contact shoulder
6
03363AXX
4. Tighten the retaining screw to the appropriate torque (see table).
Bolt
Tightening torque
[Nm]
M5
5
M6
8
M10/12
20
M16
40
M30
80
M24
200
03364AXX
Note:
To avoid contact corrosion, we recommend that the customer shaft should additionally
be recessed between the two contact surfaces!
20
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Mechanical Installation
Information about
removal
4
This description only applies if the gear unit was mounted using the SEW-EURODRIVE
assembly/removal kit (→ page 22 and the description above, points 3B or 3C).
1. Loosen the retaining screw 1.
2. Remove parts 2 to 4 and, if fitted, distance piece 5.
1
2
3
1
2
3
4
5
6
4
5
Retaining screw
Lock washer
Washer
Circlip
Distance piece
Customer shaft
6
03366AXX
3. Insert the forcing disk 8 and the fixed nut 7 from the SEW-EURODRIVE assembly/
removal kit between the customer shaft 6 and the circlip 4.
4. Re-insert the circlip 4.
5. Screw the retaining screw 1 back in. Now you can force the gear unit off the shaft by
tightening the screw.
1
1
4
6
7
8
4
7
8
Retaining screw
Circlip
Customer shaft
Fixed nut
Forcing disk
6
03367AXX
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
21
4
Mechanical Installation
SEW assembly/
removal kit
The SEW-EURODRIVE assembly/removal kit can be ordered by quoting the specified
part number.
1
7
7
8
1
03394CXX
Figure 11: SEW-EURODRIVE assembly/removal kit
1
7
8
Retaining screw
Fixed nut for removal
Forcing disk
DH7
[mm]
M1)
C4
[mm]
C5
[mm]
C6
[mm]
U-0.5
[mm]
T -0.5
[mm]
D3-0.5
[mm]
L4
[mm]
Assembly/
removal kit part
number
WA..10
16
M5
5
5
12
4.5
18
15.7
50
643 712 5
WA..20
18
M6
5
6
13.5
5.5
20.5
17.7
25
643 682 X
WA..20, WA..30, SA..37
20
M6
5
6
15.5
5.5
22.5
19.7
25
643 683 8
FA..27, SA..47
25
M10
5
10
20
7.5
28
24.7
35
643 684 6
FA..37, KA..37, SA..47, SA..57
30
M10
5
10
25
7.5
33
29.7
35
643 685 4
FA..47, KA..47, SA..57
35
M12
5
12
29
9.5
38
34.7
45
643 686 2
FA..57, KA..57, FA..67, KA..67, SA..67
40
M16
5
12
34
11.5
41.9
39.7
50
643 687 0
SA..67
45
M16
5
12
38.5
13.5
48.5
44.7
50
643 688 9
FA..77, KA..77, SA..77
50
M16
5
12
43.5
13.5
53.5
49.7
50
643 689 7
FA..87, KA..87, SA..77, SA..87
60
M20
5
16
56
17.5
64
59.7
60
643 690 0
FA..97, KA..97, SA..87, SA..97
70
M20
5
16
65.5
19.5
74.5
69.7
60
643 691 9
Type
FA..107, KA..107, SA..97
90
M24
5
20
80
24.5
95
89.7
70
643 692 7
FA..127, KA..127
100
M24
5
20
89
27.5
106
99.7
70
643 693 5
FA..157, KA..157
120
M24
5
20
107
31
127
119.7
70
643 694 3
1) Retaining screw
22
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
4
Mechanical Installation
4.8
Assembly/removal of shaft-mounted gear units with shrink disk
Installation notes
•
Do not tighten the locking screws unless the shaft is installed since the hollow shaft
could become deformed!
1. Carefully degrease the hollow shaft bore
and the input shaft.
01815AXX
3. Apply NOCO® fluid to the input shaft1) in
the area of the bushing.
2. Hollow shaft/input shaft after degreasing.
01816AXX
4. Install the shaft, making sure that the
locking collars of the shrink disk are
equally spaced2).
®
01817AXX
1)
2)
01818AXX
Make sure that the clamping area of the shrink disk is free from grease!
As a result, never apply NOCO® fluid directly to the bushing. The paste may get
into the clamping area of the shrink disk when the input shaft is installed.
After assembly, grease the outside of the hollow shaft in the area of the shrink disk.
This is in order to prevent corrosion.
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
23
4
Mechanical Installation
5. Tighten the locking screws by working clockwise several times from one screw to the
next (not in opposite sequence). See the table for tightening torques.
01819AXX
Gear unit type
Bolt
Nm
FH27
SH37
M5
5
FH37...77
SH47...77
M6
12
KH87/97
FH87/97
SH87/97
M8
30
KH107
FH107
M10
59
KH127/157
FH127
M12
100
KH37...77
max.1)
60°
1) Maximum tightening angle per cycle
Notes on removal
of the shrink disk
1. Unscrew the locking screws evenly one after the other. Each locking screw may only
be unscrewed by about one quarter turn in the initial cycle to avoid tilting and jamming of the locking collars. Do not fully unscrew the locking screws!
2. Remove the shaft or pull the hub off the shaft. (It is first necessary to remove any rust
which may have formed between the hub and the end of the shaft.)
3. Pull the shrink disk off the hub.
Important!
Risk of injury if the shrink disk is not removed correctly!
Cleaning and
lubricating the
shrink disk
There is no need to disassemble and re-grease the removed shrink disks before they
are installed once again.
The shrink disk only needs to be cleaned and re-greased if it is contaminated.
Use one of the following solid lubricants for the tapered surfaces:
Lubricant (Mo S2)
Sold as
Molykote 321 (lube coat)
Molykote spray (powder spray)
Molykote G Rapid
Aemasol MO 19P
AemasolDIO-sétral 57 N (lube coat)
Spray
Spray
Spray or paste
Spray or paste
Spray
Grease the locking screws with a multipurpose grease such as Molykote BR 2 or similar.
24
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Mechanical Installation
4.9
4
Mounting the coupling of adapter AM
IEC adapter
AM63...225 /
NEMA adapter
AM56...365
*
1
= NEMA adapter only
= Motor shaft
04469AXX
1. Clean the motor shaft and flange surfaces of the motor and the adapter.
2. IEC adapter: Remove the key from the motor shaft and replace it with the supplied
key (484).
NEMA adapter: Remove the key from the motor shaft, push the distance piece (491)
onto the motor shaft and insert the supplied key (484).
3. Heat the coupling half (479) to approx. 80 – 100 °C, push the coupling half onto the
motor shaft.
IEC adapter: Insert up to the stop against the motor shaft collar.
NEMA adapter: Insert up to the stop against the distance piece.
4. Use the setscrew (481) to secure the key and coupling half on the motor shaft.
5. Mount the motor on the adapter. When doing this, make sure the coupling claws of
the adapter shaft engage in the plastic cam ring.
Note: To avoid contact corrosion, we recommend applying NOCO® fluid to the motor
shaft before mounting the coupling half.
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
25
4
Mechanical Installation
IEC adapter
AM250/AM280
1
2
= Motor shaft
= Setscrew
02047CXX
1. Clean the motor shaft and flange surfaces of the motor and the adapter.
2. Remove the key from the motor shaft and insert the supplied key (size AM280 only).
3. Heat the coupling half (479) to 80°C – 100°C) and push it onto the motor shaft
(A = 139 mm).
4. Secure the coupling half with a setscrew and check its position (clearance 'A').
5. Mount the motor on the adapter. When doing this, make sure the claws of both coupling halves engage in the plastic cam ring.
Note: To avoid contact corrosion, we recommend applying NOCO® fluid to the motor
shaft before mounting the coupling half.
26
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
4
Mechanical Installation
4.10
Mounting the coupling of adapter AQ
AQA
AQH
479
479
491
1
2
3
1
AQA = With keyway
AQH = Without keyway
1
2
3
A
Motor shaft
Setscrew
Bolt
A
02702CXX
1. Clean the motor shaft and flange surfaces of the motor and the adapter.
2. Type AQH:
Push distance piece (491) onto the motor shaft.
3. Type AQH:
conical connection.
Unscrew the bolts of the coupling half (479) and loosen the
4. Heat the coupling half (80 °C 100 °C) and push it onto the motor shaft.
Type AQH: Insert up to the stop against the distance piece (491).
Type AQA: Insert up to clearance 'A' (see table).
5. Type AQH: Tighten the bolts on the coupling half (work round several times tightening the bolts evenly one after the other) until all bolts reach the tightening torque TA
specified in the table.
Type AQA: Use a setscrew to secure the coupling half.
6. Check the position of the coupling half (clearance 'A', see table).
Fit the motor onto the adapter, making sure that the claws of the two coupling halves
engage in one another. The force which must be applied when joining the two coupling halves is dissipated after final assembly, so there is no risk of any axial load
being applied to adjacent bearings.
Setting dimensions, tightening
torques
Type
Coupling size
AQA /AQH 80 /1/2/3
AQA /AQH 100 /1/2
AQA /AQH 100 /3/4
Clearance 'A'
[mm]
AQA /AQH 140 /1/2
AQA /AQH 140 /3
AQA /AQH 190 /1/2
AQA /AQH 190 /3
Tightening torque TA1)
[Nm]
M4
3
M5
6
M5
6
M6
10
44.5
39
19/24
53
AQA /AQH 115 /1/2
AQA /AQH 115 /3
Bolts DIN 9121)
62
62
24/28
28/38
38/45
62
74.5
76.5
100
1) only type without keyway (AQH)
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
27
4
Mechanical Installation
4.11
Mounting on input shaft assembly AD
Please refer to Sec. 'Installing input and output shafts' concerning the mounting of input
elements.
Cover with motor
mounting platform AD../P
Mounting the motor and adjusting the motor mounting platform
1
2
3
4
5
Motor mounting platform
Stud bolt (only AD6/P / AD7/P)
Support (only AD6/P / AD7/P)
Nut
Threaded column
03519BXX
1. Set the motor mounting platform to the required mounting position by evenly tightening the adjusting nuts. It may be necessary to remove the lifting eyebolt from helical
gear units in order to achieve the lowest adjustment position. Touch up any damage
to the paint work.
2. Align the motor on the motor mounting platform (shaft ends must be in alignment)
and secure it.
3. Mount the input elements on the input shaft end and the motor shaft. Line them up
with one another. Correct the motor position again if necessary.
4. Put on traction elements (V-belt, chain, etc.) and apply a preload by evenly adjusting
the motor mounting platform. Do not stress the motor mounting platform and the columns against one another when doing this.
5. Tighten the threaded columns using the nuts which are not used for adjustment.
Only AD6/P and
AD7/P:
28
Unscrew the nuts on the stud bolts before adjustment to allow the stud bolts to move
axially in the support without restriction. Do not tighten the nuts until the final adjustment
position has been achieved. Do not adjust the motor mounting platform using the support.
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
4
Mechanical Installation
Type with centering shoulder AD../
ZR
Mounting applications on the input shaft assembly with centering shoulder
1. Provide retaining bolts of a suitable length for the application. The length l of the new
bolts is calculated as follows:
l=t+a
t Screw-in depth (see table)
a Thickness of the application
s Retaining thread (see table)
02725CXX
Round down the calculated bolt length to the next smaller standard length.
2. Remove the retaining bolts from the centering shoulder.
3. Clean the contact surface and the centering shoulder.
4. Clean the threads of the new bolts and apply a bolt locking compound (e.g. Loctite
243) to the first few threads.
5. Position the application against the centering shoulder and tighten the retaining bolts
to the specified tightening torque TA (see table).
Cover with backstop AD../RS
Type
Screw-in depth
t
Retaining thread
s
Tightening torque
TA [Nm]
AD2/ZR
AD3/ZR
25.5
M8
25
31.5
M10
48
AD4/ZR
36
M12
86
AD5/ZR
44
M12
86
AD6/ZR
48.5
M16
210
AD7/ZR
49
M20
410
AD8/ZR
42
M12
86
Check the direction of rotation of the drive before installation and startup. Please inform
the SEW-EURODRIVE customer service if the direction of rotation is incorrect.
The backstop is maintenance-free in operation and does not require any further maintenance work.
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
29
I
5
Startup
0
5
Startup
5.1
Startup of helical-worm and Spiroplan® W gear units
Please note: The direction of rotation of the output shaft in series S..7 helical-worm gear
units has been changed from CW to CCW; this is different from the S..2 series. Change
direction of rotation: Swap over two motor feeder cables.
Running-in
period
5.2
Spiroplan® and helical-worm gear units require a running-in period of at least 24 hours
before reaching their maximum efficiency. A separate running-in period applies for each
direction of rotation if the gear unit is operated in both directions of rotation. The table
shows the average power reduction during the running-in period.
Spiroplan®
Worm
No. of
starts
Power reduction
i range
Power reduction
i range
1 start
approx. 12 %
approx. 50 280
approx. 15 %
approx. 40 75
2 start
approx. 6 %
approx. 20 75
approx. 10 %
approx. 20 30
3 start
approx. 3 %
approx. 20 90
approx. 8 %
approx. 15
4 start
-
-
approx. 8 %
approx. 10
5 start
approx. 3 %
approx. 6 25
approx. 5 %
approx. 8
6 start
approx. 2 %
approx. 7 25
-
-
Startup of helical, parallel shaft helical and helical-bevel gear units
No special startup instructions are required for helical, parallel shaft helical and helicalbevel gear units provided the gear units have been installed in accordance with Sec.
'Mechanical Installation'.
30
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
6
Inspection and Maintenance
6
Inspection and Maintenance
6.1
Inspection and maintenance intervals
Frequency
What to do
•
Every 3000 machine hours, at least every 6 months
•
Check the oil
•
Depending on the operating conditions (see illustration
below), at the latest every 3 years
•
Change mineral oil
•
Renew the anti-friction bearing grease
Depending on the operating conditions (see illustration
below), at the latest every 5 years
•
Change synthetic oil
•
Renew the anti-friction bearing grease
•
6.2
®
•
R07, R17, R27, F27 and Spiroplan gear units have lubrication for life and are therefore maintenancefree
•
Varying (depending on external factors)
•
Touch up or renew the surface/anticorrosion coating
Lubricant change intervals
Change the oil more frequently when using special designs subject to more severe/aggressive environmental conditions!
04640AXX
Figure 12: Oil change intervals for standard gear units under normal environmental conditions.
(1) Operating hours
(2) Sustained oil bath temperature
•Average value per oil type at 70 °C
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
31
6
Inspection and Maintenance
6.3
Inspection and maintenance of the gear unit
Do not mix synthetic lubricants with each other and do not mix synthetic with mineral lubricants!
Mineral oil is the standard lubricant.
The position of the oil level plug and oil drain plug as well as the breather valve
depends on the mounting position. Refer to the diagrams of the mounting positions.
Checking the oil
level
1. De-energize the geared motor and secure it to prevent it from being switched
back on inadvertently!
Wait until the gear unit has cooled down – Danger of burns!
2. Refer to Sec. 'Installing the gear unit' when changing the mounting position!
3. For gear units with oil level plug: Remove the oil level plug, check the fill level and
correct if necessary. Reinstall the oil level plug.
Check the oil
1. De-energize the geared motor and secure it to prevent it from being switched
back on inadvertently!
Wait until the gear unit has cooled down – Danger of burns!
2. Remove some oil from the oil drain plug
3. Check the oil consistency
– Viscosity
– If you see that the oil is heavily contaminated, we recommend you change the oil
even if it is outside the service intervals specified in
'Inspection and maintenance periods'
4. For gear units with oil level plug: Remove the oil level plug, check the fill level and
correct if necessary. Reinstall oil level plug.
Changing the oil
Only change the oil when the gear unit is at operating temperature.
1. De-energize the geared motor and secure it to prevent it from being switched
back on inadvertently!
Wait until the gear unit has cooled down – Danger of burns!
Note: The gear unit must still be warm since the high viscosity of cold oil will
make it harder to drain the oil completely.
2. Place a container underneath the oil drain plug.
3. Remove the oil level plug, breather plug/breather valve and oil drain plug.
4. Drain all the oil.
5. Reinstall the oil drain plug.
6. Pour in new oil of the same type through the vent hole (if changing the oil type, please
contact our customer service first)
– Fill in the amount of oil in accordance with the mounting position (see Sec. 'Lubricant fill quantities') or as stated on the nameplate.
– Check the oil level plug
7. Reinstall the oil level plug
8. Reinstall the breather plug/breather valve
32
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Malfunctions
7
Malfunctions
7.1
Gear unit malfunctions
Fault
Possible cause
Remedy
Unusual, regular running
noise
A
B
A
Unusual, irregular running
noise
Foreign bodies in the oil
•
Oil leaking1)
• from the gear cover
plate
• from the motor flange
• from the motor oil seal
• from the gear unit
flange
• from the output end oil
seal
A
Rubber seal on the gear cover plate leaking
Seal defective
Gear unit not vented
A
Oil emerging from breather
valve
A
B
Too much oil
Drive used with the wrong mounting position
Frequent cold starts (oil foams) and/or
high oil level
A
Meshing/grinding noise: Bearing damage
Knocking noise: Irregularity in the gearing
B
•
B
C
C
Output shaft does not turn
although the motor is running or the input shaft is
rotated
Connection between shaft and hub in gear unit
interrupted
B
C
B
7
Check the oil (see Sec. 'Inspection and Maintenance'), change bearings
Contact customer service
Check the oil (see Sec. 'Inspection and Maintenance')
Stop the drive, contact customer service
Tighten the bolts on the gear cover plate and
observe the gear unit. Oil still leaking: Contact customer service
Contact customer service
Vent the gear unit (see Sec. 'Mounting Positions')
Correct the oil level (see Sec. 'Inspection and
Maintenance')
Mount the breather valve correctly (see Sec.
'Mounting Positions') and correct the oil level (see
Sec. 'Lubricants')
Send in the gear unit/geared motor for repair
1) It is normal for small amounts of oil/grease to emerge from the oil seal during the running-in phase - (24 hour running time, see also
DIN 3761).
Customer service
Please provide the following information when contacting customer service:
• Nameplate data (complete)
• Nature and extent of the fault
• Time and peripheral circumstances of the fault
• Presumed cause
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
33
8
Mounting Positions
M1 … M6
8
Mounting Positions
8.1
General information about mounting positions
Mounting position designation
SEW differentiates between six mounting positions M1...M6 for gear units. The following figure shows the
spatial orientation of the gear unit in mounting positions M1...M6.
M6
M6
M1
M1
M2
M2
M5
M5
M4
M4
R..
M3
M3
M6
M6
M1
M2
M2
M1
M5
M5
M4
M4
F..
M3
M3
M6
M1
M1
M6
M2
M5
M5
M2
M4
M4
M3
Figure 13: Depiction of mounting positions M1 M6
34
K..
W..
S..
M3
03203AXX
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Mounting Positions
8.2
M1 … M6
8
Key to the mounting position sheets
Spiroplan® geared motors do not change with their mounting position. However, mounting positions M1 to M6 are also shown for Spiroplan® geared motors to assist you in
working with this documentation.
Important: No breather valves or oil level checking and drain plugs can be fitted on
Spiroplan® geared motors.
Symbols used
The following table shows which symbols are used in the mounting position sheets and
what they mean:
Symbol
Meaning
Breather valve
Oil level plug
Oil drain plug
Churning losses
Increased churning losses may arise in some mounting positions. Please contact SEWEURODRIVE in case of the following combinations:
Mounting position
M2, M4
Gear unit type
R
F
M2, M3, M4, M5, M6
K
S
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Gear unit size
Input speed
[1/min]
97 ... 107
> 2500
> 107
>1500
97 ... 107
> 2500
> 107
> 1500
77 ... 107
> 2500
> 107
> 1500
77 ... 97
> 2500
35
8
M1 … M6
8.3
Mounting Positions
Mounting positions of R helical gear units
R07-R167
* → page 35
36
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Mounting Positions
M1 … M6
8
RF07-RF167
* → page 35
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
37
8
M1 … M6
Mounting Positions
R07F-R87F
* → page 35
Important: Please refer to the
Overhung and axial loads'.
38
information in the 'Geared Motors' catalog, Sec. 'Project Planning for Gear Units/
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Mounting Positions
8.4
M1 … M6
8
Mounting positions of RX helical gear units
RX57-RX107
* → page 35
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
39
8
M1 … M6
Mounting Positions
RXF57-RXF107
* → page 35
40
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Mounting Positions
8.5
M1 … M6
8
Mounting positions of parallel shaft helical gear units
F/FA..B/FH27B-157B, FV27B-107B
* → page 35
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
41
8
M1 … M6
Mounting Positions
FF/FAF/FHF/FAZ/FHZ27-157, FVF/FVZ27-107
* → page 35
42
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Mounting Positions
M1 … M6
8
FA/FH27-157, FV27-107
* → page 35
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
43
8
M1 … M6
8.6
Mounting Positions
Mounting positions of helical-bevel gear units
K/KA..B/KH37B-157B, KV37B-107B
* → page 35
Important: Please refer to the
Overhung and axial loads'.
44
information in the 'Geared Motors' catalog, Sec. 'Project Planning for Gear Units/
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Mounting Positions
M1 … M6
8
K167-187, KH167B-187B
* → page 35
Important: Please refer to the
Overhung and axial loads'.
information in the 'Geared Motors' catalog, Sec. 'Project Planning for Gear Units/
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
45
8
M1 … M6
Mounting Positions
KF/KAF/KHF/KAZ/KHZ37-157, KVF/KVZ37-107
* → page 35
46
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Mounting Positions
M1 … M6
8
KA/KH37-157, KV37-107
* → page 35
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
47
8
M1 … M6
Mounting Positions
KH167-187
* → page 35
48
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Mounting Positions
8.7
M1 … M6
8
Mounting positions of helical-worm gear units
S37
Important: Please refer to the
Overhung and axial loads'.
information in the 'Geared Motors' catalog, Sec. 'Project Planning for Gear Units/
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
49
8
M1 … M6
Mounting Positions
S47-S97
* → page 35
Important: Please refer to the
Overhung and axial loads'.
50
information in the 'Geared Motors' catalog, Sec. 'Project Planning for Gear Units/
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Mounting Positions
M1 … M6
8
SF/SAF/SHF37
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
51
8
M1 … M6
Mounting Positions
SF/SAF/SHF/SAZ/SHZ47-97
* → page 35
52
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Mounting Positions
M1 … M6
8
SA/SH37
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
53
8
M1 … M6
Mounting Positions
SA/SH47-97
* → page 35
54
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Mounting Positions
8.8
M1 … M6
8
Mounting positions of Spiroplan® W gear units
W10-30
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
55
8
M1 … M6
Mounting Positions
WF/WAF10-30
56
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Mounting Positions
M1 … M6
8
WA10-30
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
57
9
Lubricants
9
Lubricants
General information
Unless a special arrangement is made, SEW-EURODRIVE supplies the drives with a
lubricant fill specifically for the gear unit and mounting position. The decisive factor is the
mounting position (M1...M6, → Sec. 'Mounting Positions and Important Order Information') specified when ordering the drive. You must adapt the lubricant fill to any subsequent changes made to the mounting position (→ Lubricant fill quantities).
Lubricant table
The lubricant table on the following page shows the permitted lubricants for SEW-EURODRIVE gear units. Please note the following key to the lubricant table.
Key to the lubricant
table
Abbreviations used, meaning of shading and notes:
CLP
= Mineral oil
CLP PG
= Polyglycol (W gear units, conforms to USDA-H1)
CLP HC
= Synthetic hydrocarbons
E
= Ester oil (water pollution danger category WGK 1)
HCE
= Synthetic hydrocarbons + ester oil (USDA - H1 certification)
HLP
= Hydraulic oil
= Synthetic lubricant (= synthetic-based anti-friction bearing grease)
= Mineral lubricant (= mineral-based anti-friction bearing grease)
1)
Helical-worm gear units with PG oil: Please contact SEW
2)
Special lubricant for Spiroplan® gear units only
3)
Recommendation: Select SEW fB ≥ 1.2
4)
Note critical starting behavior at low temperatures!
5)
Low-viscosity grease
6)
Ambient temperature
Lubricant for the foodstuffs industry (food industry oil)
Biodegradable oil (lubricant for use in agriculture, forestry and water resources)
Oil
Anti-friction bearing greases
The anti-friction bearings in gear units and motors are given a factory-fill with the greases listed below. SEW-EURODRIVE recommends regreasing anti-friction bearings with
a grease fill at the same time as changing the oil.
Anti-friction bearing in
gear unit
Anti-friction bearing in
motor
Ambient temperature
Manufacturer
Type
-30 °C +60 °C
Mobil
Mobilux EP 2
Mobiltemp SHC 100
-40 °C +80 °C
Mobil
-25 °C +80 °C
Esso
Unirex N3
-25 °C +60 °C
Shell
Alvania R3
+80 °C +100 °C
Klüber
Barrierta L55/2
-45 °C -25 °C
Shell
Aero Shell Grease 16
-30 °C +40 °C
Aral
Aral Eural Grease EP 2
-20 °C +40 °C
Klüber
Klüberbio M32-82
Special greases for anti-friction bearings in gear units:
Oil
The following grease quantities are required:
58
•
For fast-running bearings (motor and gear unit input end): Fill the cavities between
the rolling elements one third full with grease.
•
For slow-running bearings (in gear units and gear unit output end): Fill the cavities
between the rolling elements two thirds full with grease.
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
R32
R302
W...(HW...)
R...,K...(HK...),
F...,S...(HS...)
S...(HS...)
F...
K...(HK...)
R...
4)
4)
4)
4)
4)
4)
4)
4)
4)
-20
+40
+40
-15
+80
+40
+60
+40
+10
+40
Standard
-25
-20
-40
0
Standard
-20
-30
-40
+20
-25
+10
+80
+80
+60
+40
+10
0
Standard
-20
+10
+10
+25
+40
-20
-40
-30
-20
-40
-40
-30
-20
-40
-40
-25
+40
+50 +100
0
Standard
-10
°C -50
6)
Oil
5)
DIN 51 818
CLP PG
API GL5
SEW PG
E
HCE
CLP HC
CLP PG
CLP (CC)
CLP HC
VG 680
CLP PG
2)
Mobil
SHC 624
Mobil
Glygoyle 30
000 - 0
00
VG 460
3)
Mobilux
EP 004
Glygoyle
Grease 00
SAE 75W90 Mobilube SHC
(~VG 100)
75 W90-LS
VG 460
VG 460
VG 460
VG 32
VG 220
Mobilgear
627
VG 150
VG 100
Mobil
SHC 634
Mobil Glygoyle
HE 680
Mobil
SHC 629
1)
1)
Mobilgear
636
Mobil
D.T.E. 11M
VG 150
VG 460
VG 680
VG 22
VG 15
CLP (CC)
HLP (HM)
Mobil
SHC 624
Mobil
D.T.E. 13M
VG 68-46
VG 32
HLP (HM)
VG 32
Mobilgear
627
VG 150
VG 100
CLP (CC)
CLP HC
Mobil
SHC 629
Klüber-Summit
HySyn FG-32
Klüberoil
GEM 1-68
Shell Alvania
GL 00
Klübersynth
UH1 6-460
Shell Tivela Klübersynth
Compound A GE 46-1200
Klüber SEW
HT-460-5
Klüberoil
4UH1-460
Klüberbio
CA2-460
Klüber-Summit
HySyn FG-32
Klübersynth
GH 6-220
Shell Omala Klüberoil
GEM 1-150
100
Klübersynth
EG 4-150
Shell Omala Klübersynth
EG 4-460
460 HD
Klübersynth
GH 6-680
Shell Omala Klüberoil
GEM 1-680
680
Shell Cassida
Fluid GL 460
Tribol
1100/100
Aralub
MFL 00
Aral Eural
Gear 460
Aral Degol
BAB 460
Aral Degol
BG 100
Aral Degol
BG 680
Aral Degol
BG 46
BP Energrease
LS-EP 00
BP Energol
GR-XP 100
BP Enersyn
SG-XP 680
BP Energol
GR-XP 680
BP Energol
HLP-HM 10
Tribol
800/220
Tribol
1100/100
Tribol
800/680
Tribol
1100/680
Tribol
1100/68
Multifak
EP 000
Multifak
6833 EP 00
Cetus
PAO 46
Synlube
CLP 220
Meropa 100
Pinnacle
EP 150
Synlube
CLP 680
Pinnacle
EP 460
Meropa 680
Rando
HDZ 15
Cetus
PAO 46
Rando EP
Ashless 46
Meropa 150
BP Energol
GR-XP 100
Renolin
CLP 220
Longtime
PD 00
Optileb
GT 460
Optisynt
BS 460
Optiflex A
220
Optigear
BM 100
Optigear
BM 680
Optigear
32
Optigear
BM 100
Renolin
SF 7 - 041
Renolin
CLP 150
Renolin
CLP 680
Renolin
B 46 HVI
Renolin
CLP 150
Optigear Syn- Renolin Unisyn
thetic A 220
CLP 220
Optiflex A
220
Synlube
CLP 220
Pinnacle
EP 220
Optigear
BM 220
Meropa 220
Klüberoil
GEM 1-150
Aral Degol
BG 100
Tribol
1510/220
Tribol
800/220
Tribol
1100/220
Pinnacle
EP 150
Isoflex
Shell Tellus
MT 30 ROT
T 15
Shell Tellus
T 32
Shell Omala
100
Aral Degol
PAS 220
BP Enersyn
SG-XP 220
BP Energol
GR-XP 220
Klübersynth
EG 4-150
Shell Omala Klübersynth
EG 4-220
220 HD
Aral Degol
GS 220
Shell Tivela Klübersynth
Mobil
GH 6-220
WB
Glygolyle 30
Mobil
SHC 630
Aral Degol
BG 220
Shell Omala Klüberoil
GEM 1-220
220
Mobilgear
630
Mobil®
VG 150
VG 220
VG 220
CLP PG
CLP HC
VG 220
ISO,NLGI
CLP(CC)
DIN (ISO)
Oil
Lubricants
9
Lubricant table
01 805 792
50258AXX
59
9
Lubricants
Lubricant fill
quantities
The specified fill quantities are recommended values. The precise values vary depending on the stages and gear ratio. When filling, it is essential to check the oil level plug
since it indicates the precise oil capacity.
The following tables show recommended values for lubricant fill quantities depending on
the mounting position M1...M6.
Helical (R) gear
units
Gear unit
type
R.., R..F
M11)
M21)
Fill quantity in liters
M3
M4
M5
M6
R07/R07F
0.12
0.20
0.20
0.20
0.20
0.20
R17/R17F
0.25
0.55
0.35
0.55
0.35
0.35
R27/R27F
0.25/0.40
0.70
0.50
0.70
0.50
0.50
R37/R37F
0.30/0.95
0.85
0.95
1.05
0.75
0.95
R47/R47F
0.70/1.50
1.60
1.50
1.65
1.50
1.50
R57/R57F
0.80/1.70
1.90
1.70
2.1
1.70
1.70
R67/R67F
1.10/2.3
2.6/3.5
2.8
3.2
1.80
2.0
R77/R77F
1.20/3.0
3.8/4.1
3.6
4.1
2.5
3.4
R87/R87F
2.3/6.0
6.7/8.2
7.2
7.7
6.3
6.5
R97
4.6/9.8
11.7/14.0
11.7
13.4
11.3
11.7
R107
6.0/13.7
16.3
16.9
19.2
13.2
15.9
R137
10.0/25.0
28.0
29.5
31.5
25.0
25.0
R147
15.4/40.0
46.5
48.0
52
39.5
41.0
R167
27.0/70
82
78
88
66
69
Gear unit
type
RF..
Fill quantity in liters
M11)
M21)
M3
M4
M5
M6
RF07
0.12
0.20
0.20
0.20
0.20
0.20
RF17
0.25
0.55
0.35
0.55
0.35
0.35
RF27
0.25/0.40
0.70
0.50
0.70
0.50
0.50
RF37
0.35/0.95
0.90
0.95
1.05
0.75
0.95
RF47
0.65/1.50
1.60
1.50
1.65
1.50
1.50
RF/RM57
0.80/1.70
1.80
1.70
2.0
1.70
1.70
RF/RM67
1.20/2.5
2.7/3.6
2.7
3.1
1.90
2.1
RF/RM77
1.20/2.6
3.8/4.1
3.3
4.1
2.4
3.0
RF/RM87
2.4/6.0
6.8/7.9
7.1
7.7
6.3
6.4
RF/RM97
5.1/10.2
11.9/14.0
11.2
14.0
11.2
11.8
RF/RM107
6.3/14.9
15.9
17.0
19.2
13.1
15.9
RF/RM137
9.5/25.0
27.0
29.0
32.5
25.0
25.0
RF/RM147
16.4/42.0
47.0
48.0
52
42.0
42.0
RF/RM167
26.0/70
82
78
88
65
71
1) The output end gear unit of multi-stage gear units must be filled with the larger oil volume.
60
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
9
Lubricants
Helical (RX) gear
units
Gear unit
type
RX..
Fill quantity in liters
M1
M2
M3
M4
M5
M6
RX57
0.60
0.80
1.30
1.30
0.90
0.90
RX67
0.80
0.80
1.70
1.90
1.10
1.10
RX77
1.10
1.50
2.6
2.7
1.60
1.60
RX87
1.70
2.5
4.8
4.8
2.9
2.9
RX97
2.1
3.4
7.4
7.0
4.8
4.8
RX107
3.9
5.6
11.6
11.9
7.7
7.7
Gear unit
type
RXF..
Fill quantity in liters
M1
M2
M3
M4
M5
M6
RXF57
0.50
0.80
1.10
1.10
0.70
0.70
RXF67
0.70
0.80
1.50
1.40
1.00
1.00
RXF77
0.90
1.30
2.4
1.80
1.60
1.60
RXF87
1.60
2.0
4.9
4.0
2.9
2.9
RXF97
2.1
3.7
7.1
6.3
4.8
4.8
RXF107
3.1
5.7
11.2
9.3
7.2
7.2
Parallel shaft helical (F) gear units
F.., FA..B, FH..B, FV..B:
Fill quantity in liters
Gear unit
type
M1
M2
M3
M4
M5
M6
F..27
0.60
0.80
0.70
0.70
0.60
0.60
F..37
0.95
1.25
0.70
1.25
1.00
1.10
F..47
1.50
1.80
1.10
1.90
1.50
1.70
F..57
2.6
3.5
2.1
3.5
2.8
2.9
F..67
2.7
3.8
1.9
3.8
2.9
3.2
F..77
5.9
7.3
4.3
8.0
6.0
6.3
F..87
10.8
13.0
7.7
13.8
10.8
11.0
F..97
18.5
22.5
12.6
25.2
18.5
20.0
F..107
24.5
32.0
19.5
37.5
27.0
27.0
F..127
40.5
55
34.0
61
46.5
47.0
F..157
69
104
63
105
86
78
Gear unit
type
M1
M2
M3
M4
M5
M6
FF27
0.60
0.80
0.70
0.70
0.60
0.60
FF37
1.00
1.25
0.70
1.30
1.00
1.10
FF47
1.60
1.85
1.10
1.90
1.50
1.70
FF57
2.8
3.5
2.1
3.7
2.9
3.0
FF67
2.7
3.8
1.90
3.8
2.9
3.2
FF..:
Fill quantity in liters
FF77
5.9
7.3
4.3
8.1
6.0
6.3
FF87
10.8
13.2
7.8
14.1
11.0
11.2
FF97
19.0
22.5
12.6
25.5
18.9
20.5
FF107
25.5
32.0
19.5
38.5
27.5
28.0
FF127
41.5
56
34.0
63
46.5
49.0
FF157
72
105
64
106
87
79
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
61
9
Lubricants
FA.., FH.., FV.., FAF.., FHF.., FVF.., FAZ.., FHZ.., FVZ..:
Fill quantity in liters
Gear unit
type
M1
M2
M3
M4
M5
M6
F..27
0.60
0.80
0.70
0.70
0.60
0.60
F..37
0.95
1.25
0.70
1.25
1.00
1.10
F..47
1.50
1.80
1.10
1.90
1.50
1.70
F..57
2.7
3.5
2.1
3.4
2.9
3.0
F..67
2.7
3.8
1.90
3.8
2.9
3.2
F..77
5.9
7.3
4.3
8.0
6.0
6.3
F..87
10.8
13.0
7.7
13.8
10.8
11.0
F..97
18.5
22.5
12.6
25.0
18.5
20.0
F..107
24.5
32.0
19.5
37.5
27.0
27.0
F..127
39.0
55
34.0
61
45.0
46.5
F..157
68
103
62
104
85
77
Helical-bevel (K)
gear units
K.., KA..B, KH..B, KV..B:
Fill quantity in liters
Gear unit
type
M1
M2
M3
M4
M5
M6
K..37
0.50
1.00
1.00
1.30
0.95
0.95
K..47
0.80
1.30
1.50
2.0
1.60
1.60
K..57
1.20
2.3
2.5
3.0
2.6
2.4
K..67
1.10
2.4
2.6
3.4
2.6
2.6
K..77
2.2
4.1
4.4
5.9
4.2
4.4
K..87
3.7
8.0
8.7
10.9
8.0
8.0
K..97
7.0
14.0
15.7
20.0
15.7
15.5
K..107
10.0
21.0
25.5
33.5
24.0
24.0
K..127
21.0
41.5
44.0
54
40.0
41.0
K..157
31.0
62
65
90
58
62
K..167
33.0
95
105
123
85
84
K..187
53
152
167
200
143
143
Gear unit
type
M1
M2
M3
M4
M5
M6
KF37
0.50
1.10
1.10
1.50
1.00
1.00
KF47
0.80
1.30
1.70
2.2
1.60
1.60
KF57
1.30
2.3
2.7
3.2
2.9
2.7
KF67
1.10
2.4
2.8
3.6
2.7
2.7
KF77
2.1
4.1
4.4
6.0
4.5
4.5
KF87
3.7
8.2
9.0
11.9
8.4
8.4
KF97
7.0
14.7
17.3
21.5
15.7
16.5
KF107
10.0
22.0
26.0
35.0
25.0
25.0
KF127
21.0
41.5
46.0
55
41.0
41.0
KF157
31.0
66
69
92
62
62
KF..:
62
Fill quantity in liters
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
9
Lubricants
KA.., KH.., KV.., KAF.., KHF.., KVF.., KAZ.., KHZ.., KVZ..:
Spiroplan® (W)
gear units
Fill quantity in liters
Gear unit
type
M1
M2
M3
M4
M5
M6
K..37
0.50
1.00
1.00
1.40
1.00
1.00
K..47
0.80
1.30
1.60
2.1
1.60
1.60
K..57
1.30
2.3
2.7
3.2
2.9
2.7
K..67
1.10
2.4
2.7
3.6
2.6
2.6
K..77
2.1
4.1
4.6
6.0
4.4
4.4
K..87
3.7
8.2
8.8
11.1
8.0
8.0
K..97
7.0
14.7
15.7
20.0
15.7
15.7
K..107
10.0
20.5
24.0
32.0
24.0
24.0
K..127
21.0
41.5
43.0
52
40.0
40.0
K..157
31.0
66
67
87
62
62
KH167
33.0
95
105
123
85
84
KH187
53
152
167
200
143
143
The fill quantity of Spiroplan® gear units does not vary with their mounting position:
Gear unit
type
Fill quantity in liters, regardless of mounting position
W..10
0.16
W..20
0.26
W..30
0.50
Helical-worm (S)
gear units
S..:
Fill quantity in liters
Gear unit
type
M1
M2
M31)
M4
M5
M6
S37
0.25
0.40
0.50
0.55
0.40
0.40
S47
0.35
0.80
0.70/0.90
1.00
0.80
0.80
S57
0.50
1.20
1.00/1.20
1.45
1.30
1.30
S67
1.00
2.0
2.2/3.1
3.1
2.6
2.6
S77
1.90
4.2
3.7/5.4
5.9
4.4
4.4
S87
3.3
8.1
6.9/10.4
11.3
8.4
8.4
S97
6.8
15.0
13.4/18.0
21.8
17.0
17.0
1) The large gear unit of multi-stage gear units must be filled with the larger oil volume.
SF..:
Fill quantity in liters
Gear unit
type
M1
M2
M31)
M4
M5
M6
SF37
0.25
0.40
0.50
0.55
0.40
0.40
SF47
0.40
0.90
0.90/1.10
1.05
1.00
1.00
SF57
0.50
1.20
1.00/1.50
1.55
1.40
1.40
SF67
1.00
2.2
2.3/3.0
3.2
2.7
2.7
SF77
1.90
4.1
3.9/5.8
6.5
4.9
4.9
SF87
3.8
8.0
7.1/10.1
12.0
9.1
9.1
SF97
7.4
15.0
13.8/18.8
22.6
18.0
18.0
1) The large gear unit of multi-stage gear units must be filled with the larger oil volume.
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
63
9
Lubricants
SA.., SH.., SAF.., SHF.., SAZ.., SHZ..:
Fill quantity in liters
Gear unit
type
M1
M2
M31)
M4
M5
M6
S..37
0.25
0.40
0.50
0.50
0.40
0.40
S..47
0.40
0.80
0.70/0.90
1.00
0.80
0.80
S..57
0.50
1.10
1.00/1.50
1.50
1.20
1.20
S..67
1.00
2.0
1.80/2.6
2.9
2.5
2.5
S..77
1.80
3.9
3.6/5.0
5.8
4.5
4.5
S..87
3.8
7.4
6.0/8.7
10.8
8.0
8.0
S..97
7.0
14.0
11.4/16.0
20.5
15.7
15.7
1) The large gear unit of multi-stage gear units must be filled with the larger oil volume.
64
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan® W Gear Units
Index
10
10
Index
10.1 Index of changes
The following additions and changes have been made to the previous edition of the Gear
Units operating instructions (publication number: 1050 3005, edition 05/2001):
General
information
•
The R07 series has been adopted into the operating instructions.
Sec. Safety Notes
•
A summary table has been added dealing with the conditions for extended storage
of gear units in the various climate zones.
Sec. Mounting
Positions
•
All mounting position sheets have been revised. The mounting position sheets for
Spiroplan® gear units have been added. The comparison between old and new
mounting positions has been deleted.
Sec. Lubricants
•
The lubricant table has been completely revised. The lubricant fill quantities have
been updated and supplemented by the values for the R07 series.
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan®W Gear Units
65
Index
10.2 Index
A
S
Anti-friction bearing greases
58
Startup 30
Structure of helical gear units 7
Structure of helical-bevel gear units 9
Structure of helical-worm gear units 10
Structure of parallel shaft helical gear units
Structure of Spiroplan® gear units 11
C
Changing the oil 32
Check the oil 32
Checking the oil level
Churning losses 35
32
8
E
Extended storage of gear units
6
G
Gear unit malfunctions
Gear unit venting 14
33
I
Inspection intervals 31
Installation tolerances 12
Installing input and output elements
Installing the gear unit 13
Installing torque arms 17
15
L
Lubricant change intervals 31
Lubricant fill quantities for helical gear units 60
Lubricant fill quantities for helical-bevel gear units 62
Lubricant fill quantities for helical-worm gear units 63
Lubricant fill quantities for parallel shaft helical gear units
61
Lubricant fill quantities for Spiroplan® gear units 63
Lubricant table 59
Lubricants 58
M
Maintenance intervals 31
Mechanical installation 12
Mounting coupling adapter AM 25
Mounting coupling adapter AQ 27
Mounting couplings 16
Mounting on input shaft assembly AD 28
Mounting position designation 34
Mounting positions of helical gear units 36
Mounting positions of helical-bevel gear units 44
Mounting positions of helical-worm gear units 49
Mounting positions of parallel shaft helical gear units 41
Mounting positions of Spiroplan® gear units 55
Mounting shaft mounted gear units with a keyway 19
Mounting shaft mounted gear units with a shrink disk 23
P
Painting gear units
66
14
Operating Instructions – R..7, F..7, K..7, S..7, Spiroplan®W Gear Units
Address List
Address List
Germany
Headquarters
Production
Sales
Service
Bruchsal
SEW-EURODRIVE GmbH & Co
Ernst-Blickle-Straße 42
D-76646 Bruchsal
P.O. Box
Postfach 3023 · D-76642 Bruchsal
Tel. +49 (0) 72 51 / 75-0
Fax +49 (0) 72 51 / 75-19 70
http://www.sew-eurodrive.de
sew@sew-eurodrive.de
Service Electronics:
Tel. +49 (0) 1 71 / 7 21 07 91
Service Gear Units and Motors:
Tel. +49 (0) 1 72 / 7 60 13 77
Assembly
Service
Garbsen
(near Hannover)
SEW-EURODRIVE GmbH & Co
Alte Ricklinger Straße 40-42
D-30823 Garbsen
P.O. Box
Postfach 110453 · D-30804 Garbsen
Tel. +49 (0) 51 37 / 87 98-30
Fax +49 (0) 51 37 / 87 98-55
scm-garbsen@sew-eurodrive.de
Kirchheim
(near München)
SEW-EURODRIVE GmbH & Co
Domagkstraße 5
D-85551 Kirchheim
Tel. +49 (0) 89 / 90 95 52-10
Fax +49 (0) 89 / 90 95 52-50
scm-kirchheim@sew-eurodrive.de
Langenfeld
(near Düsseldorf)
SEW-EURODRIVE GmbH & Co
Siemensstraße 1
D-40764 Langenfeld
Tel. +49 (0) 21 73 / 85 07-30
Fax +49 (0) 21 73 / 85 07-55
scm-langenfeld@sew-eurodrive.de
Meerane
(near Zwickau)
SEW-EURODRIVE GmbH & Co
Dänkritzer Weg 1
D-08393 Meerane
Tel. +49 (0) 37 64 / 76 06-0
Fax +49 (0) 37 64 / 76 06-30
scm-meerane@sew-eurodrive.de
Additional addresses for service in Germany provided on request!
France
Production
Sales
Service
Haguenau
SEW-USOCOME
48-54, route de Soufflenheim
B. P. 185
F-67506 Haguenau Cedex
Tel. +33 (0) 3 88 73 67 00
Fax +33 (0) 3 88 73 66 00
http://www.usocome.com
sew@usocome.com
Assembly
Sales
Service
Bordeaux
SEW-USOCOME
Parc d’activités de Magellan
62, avenue de Magellan - B. P. 182
F-33607 Pessac Cedex
Tel. +33 (0) 5 57 26 39 00
Fax +33 (0) 5 57 26 39 09
Lyon
SEW-USOCOME
Parc d’Affaires Roosevelt
Rue Jacques Tati
F-69120 Vaulx en Velin
Tel. +33 (0) 4 72 15 37 00
Fax + 33 (0) 4 72 15 37 15
Paris
SEW-USOCOME
Zone industrielle
2, rue Denis Papin
F-77390 Verneuil I’Etang
Tel. +33 (0) 1 64 42 40 80
Fax +33 (0) 1 64 42 40 88
Additional addresses for service in France provided on request!
Argentina
Assembly
Sales
Service
Buenos Aires
SEW EURODRIVE ARGENTINA S.A.
Centro Industrial Garin, Lote 35
Ruta Panamericana Km 37,5
1619 Garin
Tel. +54 (0) 33 27 45 72 84
Fax +54 (0) 33 27 45 72 21
sewar@sew-eurodrive.com.ar
Melbourne
SEW-EURODRIVE PTY. LTD.
27 Beverage Drive
Tullamarine, Victoria 3043
Tel. +61 (0) 3 99 33 10 00
Fax +61 (0) 3 99 33 10 03
http://www.sew-eurodrive.com.au
enquires@sew-eurodrive.com.au
Sydney
SEW-EURODRIVE PTY. LTD.
9, Sleigh Place, Wetherill Park
New South Wales, 2164
Tel. +61 (0) 2 97 25 99 00
Fax +61 (0) 2 97 25 99 05
enquires@sew-eurodirve.com.au
Wien
SEW-EURODRIVE Ges.m.b.H.
Richard-Strauss-Strasse 24
A-1230 Wien
Tel. +43 (0) 16 17 55 00-0
Fax +43 (0) 16 17 55 00-30
http://sew-eurodrive.at
sew@sew-eurodrive.at
Australia
Assembly
Sales
Service
Austria
Assembly
Sales
Service
08/2002
Address List
Belgium
Assembly
Sales
Service
Brüssel
CARON-VECTOR S.A.
Avenue Eiffel 5
B-1300 Wavre
Tel. +32 (0) 10 23 13 11
Fax +32 (0) 10 2313 36
http://www.caron-vector.be
info@caron-vector.be
Sao Paulo
SEW-EURODRIVE Brasil Ltda.
Avenida Amâncio Gaiolli, 50
Caixa Postal: 201-07111-970
Guarulhos - Cep.: 07251-250
Tel. +55 (0) 11 64 89 90 00
Fax +55 (0) 11 64 89 90 09
http://www.sew.com.br
filial.sp@sew.com.br
Brazil
Production
Sales
Service
Additional addresses for service in Brazil provided on request!
Bulgaria
Sales
Sofia
BEVER-DRIVE GMBH
Bogdanovetz Str.1
BG-1606 Sofia
Tel. +359 (0) 9 29 53 25 65
Fax +359 (0) 9 29 54 93 45
bever@mbox.infotel.bg
Toronto
SEW-EURODRIVE CO. OF CANADA LTD.
210 Walker Drive
Bramalea, Ontario L6T3W1
Tel. +1 (0) 905 7 91-15 53
Fax +1 (0) 905 7 91-29 99
http://www.sew-eurodrive.ca
l.reynolds@sew-eurodrive.ca
Vancouver
SEW-EURODRIVE CO. OF CANADA LTD.
7188 Honeyman Street
Delta. B.C. V4G 1 E2
Tel. +1 (0) 604 9 46-55 35
Fax +1 (0) 604 946-2513
b.wake@sew-eurodrive.ca
Montreal
SEW-EURODRIVE CO. OF CANADA LTD.
2555 Rue Leger Street
LaSalle, Quebec H8N 2V9
Tel. +1 (0) 514 3 67-11 24
Fax +1 (0) 514 3 67-36 77
a.peluso@sew-eurodrive.ca
Canada
Assembly
Sales
Service
Additional addresses for service in Canada provided on request!
Chile
Assembly
Sales
Service
Santiago de
Chile
SEW-EURODRIVE CHILE LTDA.
Las Encinas 1295
Parque Industrial Valle Grande
LAMPA
RCH-Santiago de Chile
P.O. Box
Casilla 23 Correro Quilicura - Santiago - Chile
Tel. +56 (0) 26 23 82 03 + 6 23 81 63
Fax +56 (0) 26 23 81 79
sewsales@entelchile.net
Tianjin
SEW-EURODRIVE (Tianjin) Co., Ltd.
No. 46, 7th Avenue, TEDA
Tianjin 300457
Tel. +86 (0) 22 25 32 26 12
Fax +86 (0) 22 25 32 26 11
http://www.sew.com.cn
Bogotá
SEW-EURODRIVE COLOMBIA LTDA.
Calle 22 No. 132-60
Bodega 6, Manzana B
Santafé de Bogotá
Tel. +57 (0) 5715 47 50 50
Fax +57 (0) 5715 47 50 44
sewcol@andinet.com
Zagreb
KOMPEKS d. o. o.
PIT Erdödy 4 II
HR 10 000 Zagreb
Tel. +385 (0) 14 61 31 58
Fax +385 (0) 14 61 31 58
kompeks@net.hr
Praha
SEW-EURODRIVE CZ S.R.O.
Business Centrum Praha
Luná 591
CZ-16000 Praha 6 - Vokovice
Tel. +420 (0) 2 20 12 12 34 +
2 20 12 12 36
Fax +420 (0) 2 20 12 12 37
http://www.sew-eurodrive.cz
sew@sew-eurodrive.cz
China
Production
Assembly
Sales
Service
Colombia
Assembly
Sales
Service
Croatia
Sales
Service
Czech Republic
Sales
08/2002
Address List
Denmark
Assembly
Sales
Service
Kopenhagen
SEW-EURODRIVEA/S
Geminivej 28-30, P.O. Box 100
DK-2670 Greve
Tel. +45 (0) 43 95 8500
Fax +45 (0) 43 95 8509
http://www.sew-eurodrive.dk
sew@sew-eurodrive.dk
Tallin
ALAS-KUUL AS
Paldiski mnt.125
EE 0006 Tallin
Tel. +372 (0) 6 59 32 30
Fax +372 (0) 6 59 32 31
Lahti
SEW-EURODRIVE OY
Vesimäentie 4
FIN-15860 Hollola 2
Tel. +358 (0) 3 589 300
Fax +358 (0) 3 780 6211
http://www.sew-eurodrive.fi
sew@sew-eurodrive.fi
Normanton
SEW-EURODRIVE Ltd.
Beckbridge Industrial Estate
P.O. Box No.1
GB-Normanton, West- Yorkshire WF6 1QR
Tel. +44 (0) 19 24 89 38 55
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SEW-EURODRIVE GmbH & Co · P.O. Box 3023 · D-76642 Bruchsal/Germany · Phone +49-7251-75-0
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INSTALLATION AND SETTING UP MANUAL
5001TCP SPEED CONTROLLER
WARNING
Disconnect all incoming power before working on this equipment.
Follow power lockout procedures.
Use extreme caution around electrical equipment.
Do not touch the circuit board while power is applied.
TORSPEC International Inc.
40 Claireville Drive, Etobicoke
(Toronto), Ontario, Canada M9W 5T9
Phone: (416) 213-1026
Fax: (416) 213-0821
E-mail: Sales@torspec.com
TORSPEC International (USA) Inc.
13507-C East Boundary Road
Midlothian (Richmond), VA U.S.A. 23112
Phone: (804) 744-5521
Fax: (804) 744-9131
E-mail: Torspecusa@aol.com
Web-Site: www.torspec.com
Manufacturers & Suppliers of World Class Quality Variable Speed Drives & Controls
TABLE OF CONTENTS
SYSTEM DESCRIPTION ................................................................................................ 3
SCHEMATIC SYSTEM DESCRIPTION .......................................................................... 3
CONSTRUCTION ........................................................................................................... 4
CONTROLLER PHYSICAL DETAILS ............................................................................. 4
SPECIFICATIONS .......................................................................................................... 4
Inputs........................................................................................................................... 4
Outputs ........................................................................................................................ 4
Abbreviations............................................................................................................... 4
PERFORMANCE ............................................................................................................ 5
WARNINGS .................................................................................................................... 7
ADDITIONAL FACILITIES............................................................................................... 7
INSTALLATION............................................................................................................... 8
JUMPER SETTINGS……………………………………………………………………………9
SETTING UP................................................................................................................. 10
5001TCP SCHEMATIC DRAWING............................................................................... 11
5001TCP DIMENSIONAL LAYOUT DRAWING FOR SPEED CONTROL BOARD ...... 12
5001TCP DRIVE INTERCONNECTION DRAWING ..................................................... 13
5001 TERMINAL STRIP CONNECTION DRAWING .................................................... 14
5001 VARIABLE SPEED DRIVE INTERCONNECTION COMPARISON BETWEEN A
5001TCP AND THE 1165/1265P, 1266P AND THE 1268P.......................................... 15
5001 TROUBLESHOOTING GUIDE ............................................................................. 16
5001 TROUBLESHOOTING GUIDE PAGE 2 ............................................................... 17
5001 TROUBLESHOOTING GUIDE PAGE 3 ............................................................... 18
Revised JULY 2002
5001TCP Installation Manual
Page 2 of 18
SYSTEM DESCRIPTION
The 5001TCP drive panel is a solid-state controller, which has been well proven in the
industry and is used to control speed on the TORSPEC drive. The 13 pre-set controls
have been factory adjusted to give a nominal performance so the system may operate
satisfactory without adjustment. However, instructions are provided so the optimum
performance may be obtained with further fine-tuning. The function of these controls
will be described later.
SCHEMATIC SYSTEM DESCRIPTION
The TORSPEC drive coil is driven from a full wave thyristor output stage, which
incorporates current feedback. This output stage is driven from an error voltage via a
pre-amplifier employing operational amplifiers, which as variable gain, integral and
differential action. In addition, there are two optical couplers between the power, output
stage and the control circuitry to provide isolation.
The error voltage is the difference between a reference voltage and a feedback voltage,
which is proportional to the TORSPEC drives output shaft speed. Thus, variable speed
control is achieved by varying the reference voltage. To minimize errors the reference
is derived from a voltage regulator, while the feedback voltage is produced from the
frequency developed by a sinusoidal tachogenerator and via a digital-to-analog
converter.
Revised JULY 2002
5001TCP Installation Manual
Page 3 of 18
CONSTRUCTION
All of the components are mounted on the front of a double-sided epoxy glass printed
circuit card, each component identified by a component code. The board is a hybrid
construction of through hole and surface mount components for high reliability and
serviceability. Termination is through a quick connect terminal strip with captive screws
and retractable wire pressure plates.
CONTROLLER PHYSICAL DETAILS
Size 8.06" long x 6.188" high x 1.125: deep
Permissible temperature is 1-160ºF local ambient around the controller providing the
160ºF local ambient is equivalent to 122ºF outside ambient when the controller is
mounted in a small NEMA 12 enclosure.
SPECIFICATIONS
Inputs
Supply Voltage:
Supply Frequency:
Tach Signal Frequency:
Tach Signal Voltage:
110 - 120VAC, 220 - 240VAC ± 6%
50 to 60 HZ
12 to 720 HZ
Proportional to tach frequency
30 to 60V at 700 HZ
Is controlled by P4 on the board or by an
external 2K pot across terminals A5, A6,
and A7
Torque Limit:
Outputs
Maximum Nominal Output:
Maximum Current:
Reference Signal Load:
Speed Output Signal:
Speed Output Frequency:
Speed Output Signal:
90 VDC (160 VDC optional)
5 ADC (8 amp optional)
16 MADC (625 ohm)
0-10 VDC
0.2 HZ/RPM square wave, 12 VDC
Amplitude
4 to 20 MA
Abbreviations
ADC = Amps direct current
HZ = Hertz
VAC = Volts alternating current
AAC = Amps alternating current
MADC = Milli-amps direct current
VDC = Volts direct current
Revised JULY 2002
5001TCP Installation Manual
Page 4 of 18
PERFORMANCE
1. Speed control range is down to 60 RPM, or as dictated by the drive selected, see
drive technical data sheet for speed range.
2. Response to supply variation - 1% for 6% fluctuation.
3. Regulation is defined as the ability of the system to maintain a set speed when the
applied load is decreased or increased. The regulation accuracy is a function of the
setting of regulation, integral, and differential control pots. These are set at the
factory to give a good performance against most normal applications. With a factory
setting of 90 Volt output to the coil, a change of 1 V would give a speed change of
0.085% at 3300 RPM. Where tighter regulation is required, the control can be
further adjusted in the field against actual dynamic conditions.
4. Speed stability ± 1 RPM over the speed range.
5. Linearity of speed against reference signal is less that 0.5% error of maximum
speed.
6. Linearity of speed against speed control potentiometer rotation is dependent upon
the type and make of potentiometer supplied. However, typical figures are:
a) Single turn pot
Sensitivity
Resolution
Linearity
b) 10 Turn Pot
Sensitivity
Resolution
Linearity
2 Pole
4 Pole
2 Pole
4 Pole
± 4%
9 RPM per degree rotation
4.5 RPM per degree rotation
5 RPM per degree rotation
2.5 RPM per degree rotation
2 Pole
4 Pole
2 Pole
4 Pole
± 0.25%
0.67 RPM per degree rotation
0.33 RPM per degree rotation
0.6 RPM per degree rotation
0.3 RPM per degree rotation
7. Repeatability is the ability of the system to return to the original set speed after this
speed has been changed. The system will revert to within ± 1 RPM providing load,
temperature and supply voltage remains constant.
8. Long term drift due to tachogenerator temperature change - since the feedback
signal is digital, there is no drift.
Revised JULY 2002
5001TCP Installation Manual
Page 5 of 18
9. Reference voltage at terminal A10 and A12 is 10 VDC ± 5%, stability 0.05% for a
12% supply change.
10. Supply transient protection is provided by an input filter and a surge suppressor.
11. Factory preset controls, the 13 internal board mounted pots have the following
functions:
P1 - Minimum speed pot, factory set for zero output speed. Clockwise rotation will
increase minimum speed. Interactive with max speed pot. Adjustment range is 0 55%.
P2 - Maximum speed pot, factory set at 1500/3000 RPM.
reduces set speed. Adjustment range is 30 - 100%
Counter-clockwise
P3 - Acceleration, factory set fully clockwise for fastest acceleration.
P4 - Internal torque, factory set fully clockwise for maximum torque, range of setting
is 0 to 100%. External resistance of 2K can be added between terminals A5, A6, &
A7 for remote adjustment.
P5 - Set for 4 MADC output proportional to zero speed.
P6 - Set maximum 20 MADC output signal proportional to 100% speed
P7 - Calibration for 0 to 10 VDC meter output at terminals A13, A12, proportional to
0 to 100% speed.
P8 - Differential control increases response of the system to speed or load changes.
Factory set at 1/3 clockwise. Clockwise rotation improves stability and minimizes
overshoot and undershoot. CCW increases increases speed change with load
change, increases min/max speed settings.
P9 - Regulation, factory preset at 1/3 clockwise. Counter-clockwise rotation
improves regulation. Interactive with P1, P2, P8, and P10, these controls should be
re-adjusted.
P10 - Integral control smoothes response of system to speed/load changes. Factory
preset at 1/3 clockwise. Clockwise rotation reduces system response and improves
stability. Affects min/max speed settings.
P11 - Current feedback, factory set fully counter-clockwise. Range is from 1 to 5
AMP. For 1 AMP coil set fully clockwise, for 2 AMP set midway, for 5 AMP set fully
counter-clockwise.
P12 - Current gain, factory set fully clockwise. Set counter-clockwise for 2 AMP
coils and at factory setting for 4 AMP coils. Note: If set in the counter-clockwise
position, speed run away may be seen. Reset to clockwise to rectify.
Revised JULY 2002
5001TCP Installation Manual
Page 6 of 18
P13 - Current rate, factory set fully clockwise for slowest response to load change.
Controls P8, P9, P10, P12, and P13 should be adjusted under actual load conditions
to obtain the best possible performance, all three are used to compensate for drastic
or cyclic load changes.
12. Input Signals
0 to 10 VDC at terminals A11 and A12. (Max 12 VDC)
4-20 MADC at A12 ( - ) and A16 ( + ) (jumper between A11 and A16)
Supply-to-control circuit isolation is provided on the control board.
WARNINGS
1. Provision must be made, at an external point, to isolate the supply voltage from the
drive controller and motor.
2. Be sure the supply voltage, frequency and amperage are compatible.
3. The enclosure that the controller is to be fitted into must be grounded.
4. The neutral must be connected to terminal N only when 120 (110) VAC is used as
the supply voltage. For 240 (220) VAC connect neutral to A1.
5. The supply to the controller must be interlocked with the motor starter in such
a way as to prevent the control board from being powered up if the motor is
not operating.
6. Please contact our service department if you experience any difficulties that are not
covered in this manual.
ADDITIONAL FACILITIES
a) Transducer Inputs
For 0 - 10 VDC, connect ( - ) to A12 and ( + ) to A11
For 4 - 20 MADC, connect ( - ) to A12 and ( + ) to A16
The negative signal line may be grounded.
b) Terminal A15 is an input for external reference signal such as synchronization, it
bypasses the acceleration circuit.
Revised JULY 2002
5001TCP Installation Manual
Page 7 of 18
c) Terminal A19 and A12 provide a square wave output signal for use with a digital
meter. The frequency is .2 HZ/RPM. A meter with a time base of 1 second will read
frequency directly where as a time base of 5 seconds will read RPM. The signal is
fed from one source of 5 kilohms.
d) When A14 is connected to A10 by means of an isolated contact, it provides an
inhabit function that not only stops the controller output, but also resets the
acceleration circuit.
e) If your application requires more than 5 Amps @ 90 VDC, the board can easily setup
for a maximum of 8 AMPS @ 160 VDC. The board will have to be wired for 240
VAC supply, place the double jumper JP1 in the 240V position and the single jumper
JP2 in the 120V position. Depending on the load you may have to increase the size
of the fuse rating to a maximum of 10 AMPS for the time delay fuses or 15 AMPS for
fast blow fuses.
Be sure only JP2 is in the 120V position, otherwise damage to the board will
result.
INSTALLATION
Each control has thirteen pots, which have been factory set to give a nominal
performance, so in most cases the control may be installed and operated without further
adjustment. However, optimum performance can be achieved with further calibration to
match the control with the dynamic characteristics of the load. See page 6 for more
details.
If the reference signal and tach feedback wires are run in the same cableway as
current-carrying conductors then shielded cable should be used. Please note that only
one end of the shield wire is to be grounded; the other end should float.
Connect the system as per the attached connection drawing, ensuring the correct
terminals are being used. It is important the connection of the drive tach and coil are
correct or damage to the drive will result. A8 and A9 are for the tach, while A3 and A4
are for the coil. At the drive the smaller wires are from the tach, the larger wires are
from the main coil.
Check the supply voltage and place jumpers JP1, JP2 in the corresponding position.
This determines whether the board is operating on 120 or 240V. The board is marked
as to the correct position.
The 2 pole/4 pole switch, SW2, should be down for the 2 pole (3000/3600-RPM motor)
position and up for the 4 pole (1500/1800) position for the 100, 132, 160, 180 and
225TCD DC clutches. For use with the 280TCD and 305TCD, the position needs to be
set in the 2-pole position.
Revised JULY 2002
5001TCP Installation Manual
Page 8 of 18
SW 1 is for selecting the acceleration time, down for 10 seconds range and up for 100
seconds range. The time is adjusted within the range by P3.
JP3 provides for a quicker deceleration time (left position for quicker deceleration.)
The current feedback must be set to match the drive's main coil amperage. This figure
is stamped on the drive's nameplate or the factory can advise. Set the current feedback
pot (P11) as follows:
-
for 1 AMP or less, set full clockwise
for 1 to 2 AMP, set midway
for 2 to 5 AMP, set fully counter-clockwise
Before engaging the drive, ensure the rotation is correct by starting only the AC motor
and noting the direction of the fan's rotation. The output direction of the drive will be the
same. The direction can be changed by changing phase polarity of any two of the three
motor leads. Ensure power is OFF before attempting this.
The green LED when lit indicates there is an output from the controller to the TORSPEC
drive.
5001TCP JUMPER SETTINGS
The 5001TCP can be set up for 120 or 240VAC input. These input voltages, long with jumpers
JP1 and JP2 set in the proper locations, can give the user different voltages on the output.
Jumpers can be set as follows to achieve desired output voltages.
JP1 JP2
JP1 JP2
120VAC In
90VDC Out
120VAC In
45VDC Out
Revised JULY 2002
JP1 JP2
240VAC In
90VDCout
5001TCP Installation Manual
JP1 JP2
240VAC In
180VDC Out
Page 9 of 18
SETTING UP
All controls are factory preset and the system can be installed and operated with minor
adjustments. Optimum performance can be achieved with further fine-tuning.
Apply power to the motor and verify rotation. Power up the control panel and adjust P1
for zero output volts. Turn RV1 (main speed pot) to maximum and set P2 to match the
drives maximum rated speed. As P1 and P2 are inter-active, a repeat of the above may
be necessary.
If adjustments of P8, P9 and P10 are made, then P1 and P2 must be reset.
To calibrate the speed indicator, the drive should be set for maximum speed and P7
trim pot adjusted to provide the desired reading on the meter scale for full speed. For
digital meters, use the meter's offset pot to set 000 at zero speed and the meter's range
pot to set the desired reading at maximum speed, this reading can be 100% or the
desired engineered units, the top and bottom settings may have to be repeated for the
desired result. As an alternate, the 5001TCP 4-20mA output signal and board mounted
trim pots, P5 and P6 can be used.
With completion of these steps the drive is fully operational.
POT
P1
PARAMETER
Min. speed
FACTORY SET
Set @0
ADJUSTMENT
CW to increase min. speed
P2
Max. speed
CW to increase drive speed
P3
Acceleration
Set for 1500/3000
RPM
Full CW
P4
P5
Torque limit
4MA set
P6
20MA set
P7
Meter Cal.
P8
Differential
Full CW
Set for 4ma meter
reading @0 speed
Set for 20MA reading
@ max. speed
Set for 10VDC
reading @ max.
speed
1/3 CW
P9
Regulation
1/3 CW
P10
Integral
1/3 CW
P11
P12
Current Feedback
Current Gain
CCW
CW
Set to match coil amps
Set to reduce speed drop on
load increase
P13
Current Rate
CW
Determines the speed that the
control reacts to load change
EFFECT
Interactive with
P2
Interactive with
P1
CCW to increase acceleration
time
CCW to limit drive torque
CW to increase output
CW to increase output
CW to increase output
CW to increase drive speed
CW to decrease speed change
with load
CW to smooth response to
load change
Affects
min/max speed
setting
Affects P1, P2,
P8, P10
Affects
min/max speed
settings
Affects
min/max speed
setting
*CW = Clockwise rotation CCW = Counter-clockwise rotationRevised JULY 2002
5001TCP Installation Manual
Page 10 of 18
5001TCP SCHEMATIC DRAWING
Revised JULY 2002
5001TCP Installation Manual
Page 11 of 18
5001TCP DIMENSIONAL LAYOUT DRAWING
FOR SPEED CONTROL BOARD
Revised JULY 2002
5001TCP Installation Manual
Page 12 of 18
5001TCP DRIVE INTERCONNECTION DRAWING
Revised JULY 2002
5001TCP Installation Manual
Page 13 of 18
5001 TERMINAL STRIP CONNECTION DRAWING
Revised JULY 2002
5001TCP Installation Manual
Page 14 of 18
5001 VARIABLE SPEED DRIVE INTERCONNECTION COMPARISON
BETWEEN A 5001TCP AND THE 1165/1265P, 1266P AND THE 1268P
Revised JULY 2002
5001TCP Installation Manual
Page 15 of 18
5001 TROUBLESHOOTING GUIDE
Revised JULY 2002
5001TCP Installation Manual
Page 16 of 18
5001 TROUBLESHOOTING GUIDE PAGE 2
Revised JULY 2002
5001TCP Installation Manual
Page 17 of 18
5001 TROUBLESHOOTING GUIDE PAGE 3
Revised JULY 2002
5001TCP Installation Manual
Page 18 of 18
VARIABLE SPEED DRIVE
INSTALLATION AND MAINTENANCE INSTRUCTIONS
TORSPEC MODEL 160TCD-NEMA
WARNING
Disconnect all incoming power before working on this equipment.
Follow power lockout procedures.
Use extreme caution around electrical equipment.
Do not touch the circuit board while power is applied.
International Inc.
40 Claireville Drive, Etobicoke
(Toronto), Ontario, Canada M9W 5T9
Phone: (416) 213-1026
Fax: (416) 213-0821
E-mail: Sales@torspec.com
International (USA) Inc.
13507-C East Boundary Road
Midlothian (Richmond), VA U.S.A. 23112
Phone: (804) 744-5521
Fax: (804) 744-9131
E-mail: Torspecusa@aol.com
Web-Site: www.torspec.com
Manufacturers & Suppliers of World Class Quality Variable Speed Drives & Controls
TORSPEC MODEL 160TCD-NEMA DISMANTLING INSTRUCTIONS
CAUTION - BE SURE TO DISCONNECT POWER AND FOLLOW LOCK--OUT PROCEDURES AS
SPECIFIED BY LAW BEFORE OPENING ANY TERMINAL BOXES OR TOUCHING ANY WIRING.
D1: Open terminal box and disconnect drive wires. EXTREME CAUTION should be exercised with
the small wires going to the tach generator, as they can be easily broken.
Hint: (Look for broken wires, or poor connections.)
D2: Remove four bolts holding output assembly to main casing. Remove output assembly while
feeding wires through the hole, once the wires are free, the output assembly can be completely
removed.
Hint: (Look for physical damage, remove any build up of foreign material on polewheel which
could cause binding. Binding will cause the drive to run at full speed when the motor is started
even if the clutch is turned off.)
D3: The polewheel is removed by removing the bolt in the center that is attaching it to the output
shaft and inserting a larger 16mm bolt to push it off.
D4: The coil is held in place by a circlip at the back and silicone sealant at the front. After removing
the circlip it is necessary to use a thin blade to break the sealant between the coil form and the
front of the output assembly. Care must be used, the former is breakable.
Hint: (Look for physical damage, signs of overheating, coil should be 20 to 40 ohms depending
on size. Low resistance will cause the control fuses to blow, too high will result in poor
performance.)
D5: To separate the coil and tach wires cut the waxed string and carefully slide the rubber tube off.
If the tach is being replaced, a string or small wire tied to the old tach wires before removing can
be used to assist in pulling in the new wires.
Hint: (Look for broken wires, tach should be 220 ohms, a bad tach will cause the drive to run at
full speed when the controller is energized.)
D6: Remove the tach cover plate and tach stator mounting plate with tach stator. The tach armature
is held in place by a setscrew and can be pulled off. Be sure not to damage the magnetic
strip.
Hint: (Look for broken magnetic strip, this will give the same symptoms as a bad tach.)
D7: Remove the shaft out of the assembly from the input shaft side by pressing on the output side of
the shaft.
D8: The rear bearing and front bearing race that is still on the shaft can now be removed. The front
outer bearing race can also be removed from the stator body.
D9: Remove the motor adapter flange from the main casing. Remove the 6 cap head screws holding
the torque tube assembly to the hub on the motor shaft. Two grub screws hold the hub on the
shaft, be sure to remove these grub screws completely as one is counter sunk into the shaft.
Hint: (Look for pitting and/or lifting of the copper lining on the torque tube, this is what transmits
the power and damage here will cause the drive to be short of power)
TORSPEC MODEL 160TCD-N
JULY 2002
TORSPEC MODEL 160TCD-NEMA ASSEMBLY INSTRUCTIONS
USE A THREAD LOCKING COMPOUND ON ALL BOLTS
A1: If the motor is being replaced it will be necessary to dimple the shaft in the same location as the
original motor. This location is critical for proper alignment. Use an anti-seize compound on
the shaft. Mount the torque tube hub with one of the grub screws in the dimple
A2: Mount the motor adapter flange onto the motor flange with the flat on the bottom. Mount the
torque tube on the hub. Bolt the motor assembly onto the main casing.
A3: Mount the pre-greased rear bearing onto the shaft by pressing on the outer and inner race with a
press, do not hammer. Press the front outer bearing into the stator body and the inner race on
to the shaft with the press. Insert the shaft assembly into the output assembly from the rear side
by pressing on the inner and outer rear bearings. Install rear bearing retaining plate onto stator
body.
A4: Mount the armature onto the shaft. Feed the tach wires through the hole in the output assembly
and slide the tach stator plate over the shaft and bolt to the output assembly. Be sure not to
pinch the tach wires.
A5: Apply silicone rubber to the front of the main coil and push the coil onto the output assembly.
Install the coil circlip. Push the tach wires, then the coil wires into the rubber sleeving. Tie off
with a piece of waxed string.
A6: Bolt the polewheel onto the shaft ensuring the spring pins are in place and the polewheel
completely seats.
A7: Insert the output assembly into the casing while feeding the wires through the hole. Bolt into
place on main casing.
TORSPEC MODEL 160TCD-N
JULY 2002
TORSPEC 160TCD-N PARTS LIST
PART
NO.
4007N
4050N
4106N
4107N
4113N
4115N
4120N
4324N
4001
4002
4004
4009
4016
4017
4018
4019
4020
4022
4024
4028
4030
4038
4060
4063
4066
4069
4073
4079
4084
4087
4089
4097K
4173
4184
4189
4302
4303
4500
4501
4502
4503
4504
9005
9006
9008
9014
9021
9034
9035
9035
9039
9305
9306
DESCRIPTION
OUTPUT SHAFT NEMA 213/215T 1-3/8" CODE S2
KEYSTOCK NEMA 215T 5/16" SQ.X2 3/8" CODES S2, F2
MOTOR ADAPTER 213/215/254/256TC FIXED BY 4-M16X40 HEX HEAD BOLT CODE D2
ROTOR HUB 213/215TC 1 3/8" FIXED BY 1-M8X10 CUP POINT GRUB SCREW, 1-M8X10 CONE POINT GRUB
SCREW CODE D2
ROTOR HUB 254/256TC 1 5/8" FIXED BY 1-M8X10 CUP POINT GRUB SCREW, 1-M8X10 CONE POINT GRUB
SCREW CODE D2
OUTPUT FLANGE 213/215TC FIXED BY 4-M12X50 SOCKET HD CAP CODE F2
NEMA MOTOR SEE MOTOR NAMEPLATE FOR DETAILS FIXED BY 4-1/2"X 1 3/8" SOCKET HD. CAP
INPUT ASSY. NEMA CODE K2
CASING
STATOR BODY ASSY. FIXED BY 4-M12X40 SOCKET HD. CAP
TACH COVER 4-M5X35 SOCKET HD. CAP AND 4 FLAT WASHERS
TACH GENERATOR MOUNTING PLATE
GRILLES SMALL INLET FIXED BY 4-M6X10 PAN HD. SLOTTED
GRILLES LARGE OUTLET FIXED BY 6-M6X10 PAN HD. SLOTTED
GREASE BAFFLE
BEARING SPACER
NILOS RING 6308JV
BEARING FRONT NU308
BEARING REAR RETAINING PLATE FIXED BY 4-M5X16 SOCKET HD. CAP
OIL SEAL 40X52X8 STD. & CODE F1
COIL RETAINING RING
OIL SEAL 40X55X8 CODE F2
STD. COIL FOR 4/15HP, 2/25HP FIXED BY PART NO. 4030
STD. COIL FOR 4/7.5HP, 4/10HP, 2/15HP, 2/20 FIXED BY PART NO 4030
HP COIL FOR 4/15HP, 2/25HP FIXED BY PART NO. 4030 CODES H10, H20, N1, N2
HP COIL FOR 4/7.5HP, 4/10HP, 2/15HP, 2/20HP FIXED BY PART NO. 4030 CODES H10, H20, N1, N2
TORQUE TUBE/ROTOR ASSY. 4 POLE FIXED BY 6-M6X30 SOCKET HD. CAP
POLEWHEEL STD. FIXED BY 1-M12X40 HEX. HD. CAP, 1-M12 FLAT WASHER, 2-M8X24 SLOTTED SPRING PINS
TORQUE TUBE /ROTOR ASSY. FAN DRIVE FIXED BY 6-M6X30 SOCKET HD. CAP SAME AS 4073
POLEWHEEL REDUCED FIXED BY 1-M12X40 HEX. HD. CAP, 1-M12 FLAT WASHER, 2-M8X24 SLOTTED SPRING
PINS CODE R
TORQUE TUBE/ROTOR ASSY. 2 POLE FIXED BY 6-M6X30 SOCKET HD. CAP
POLEWHEEL REDUCED C/W AXIAL BLADES FIXED BY 1-M12X40 HEX. HD. CAP, 1-M12 FLAT WASHER, 2-M8X24
SLOTTED SPRING PINS CODE R
TORQUE TUBE NICKEL PLATED/ROTOR ASSY. 4 POLE FIXED BY 6-M6X30 SOCKET HD. CAP SAME AS 4073
TORQUE TUBE NICKEL PLATED/ROTOR ASSY. FAN DRIVE FIXED BY 6-M6X30 SOCKET HD. CAP SAME AS 4073
TORQUE TUBE NICKEL PLATED/ROTOR ASSY. 2 POLE FIXED BY 6-M6X30 SOCKET HD. CAP SAME AS 4089
TOTALLY ENCLOSED COVERS LEFT HAND FIXED BY 5-M6X16 SOCKET HD. CAP CODES T1, T2
TOTALLY ENCLOSED COVERS RIGHT HAND FIXED BY 5-M6X16 SOCKET HD. CAP CODES T1, T2
TACH ARMATURE FIXED BY 1-M5X8 CUP POINT GRUB SCREW
HOSEPROOF COVERS SMALL INLET FIXED BY 4-M6X40 SOCKET HD. CAP CODES N1, N2
BAFFLES FOR PART NO. 4501 CODES N1, N2
HOSEPROOF COVERS LARGE OUTLET FIXED BY 4-M6X40 SOCKET HD. CAP CODES N1, N2
BAFFLES FOR PART NO. 4503 CODES N1, N2
TERMINAL BOX FIXED BY 4-M5X60 STUD, 4-M5 RUBBER WASHERS, 4-M5 FLAT WASHERS, 4-M5 LOCKNUT
TERMINAL BOX LID
TACH GENERATOR ASSY. FIXED BY 4-M4X16 SOCKET HD. CAP, 4-M4 FLAT WASHERS
TERMINAL BOX GASKET X3 FOR CODES H10, H20, N1, N2, T1, T2
BEARING REAR 6308Z
EYEBOLT M12
PLASTIC PLUG 1-#12 CODES T1, H10, N1
PLASTIC PLUG 2- #12 CODES T1, T2
NAMEPLATE FIXED BY 4-6X1/4 TAPPING SCREWS
TERMIANAL BLOCK 4 WAY FIXED BY 1-M5X12 SOCKET HD. CAP
TERMINAL BLOCK 6 WAY FIXED BY 1-M5X12 SOCKET HD. CAP CODES B? Y?
TORSPEC MODEL 160TCD-N
JULY 2002
TORSPEC MODEL 160TCD-N PARTS DIAGRAM
TORSPEC MODEL 160TCD-N
JULY 2002
DRIVE FEET MOUNTING PROCEDURE
F1:
Push slotted Shims under the Coupling lowest mounting feet and moderately tighten the Bolts
F2:
Align the unit. Insert Feeler Gauges under the remaining feet during the alignment process to
level the unit.
F3:
Replace feeler gauges with equal thickness of slotted Shims. Use a few thick shims rather than
a large number of thin shims.
F4:
Alternately tighten Bolts.
F5:
Recheck alignment and change shims as required.
F6:
Push slotted Shims under AC Motor mounting feet and moderately tighten the bolts.
Note:
-The decision to mount (bolt) the Motor feet should be based on the application dynamics. (I.e.
vibration/support). It is not always necessary to mount the motor feet and is specifically motor
size related.
-When Drives are purchased on base, base must also be leveled and secured.
Warning:
Failure to properly mount and level drive unit my result in distortion to the drive
housing, torque tube, mechanical failure, misalignment, and premature bearing wear.
TORSPEC MODEL 160TCD-N
JULY 2002
WARRANTY TERMS AND CONDITIONS
ELRUS warrants new equipment (the "Equipment") sold by it to a Customer to be free from defects in
material and workmanship. This warranty is subject to the following terms and conditions:
1. In the absence of a written agreement to the contrary, the warranty for Equipment is as follows:
•
•
•
•
•
Chassis and ELRUS walking beam suspension only ‐ 5 Years or 10,000 hours (whichever
comes first) after date of commissioning or start of operation. Warranty will commence at 6
months after delivery of machine to customer if commissioning or start of operation has not
occurred:
ELRUS manufactured components (jaws, screens, VGF's and ELRUS manufactured parts that
comprise the Equipment, excluding chassis & suspension) ‐ 12 Months or 2,000 Hours
(whichever comes first) after date of commissioning or start of operation;
Major supplied components and equipment (Non‐ELRUS) ‐ (Sandvik, McLanahan, Superior,
etc.) ‐ as per original equipment manufacturer’s warranty, copies available upon request
and supplied with Equipment manual;
Minor components (Non‐ELRUS) ‐ Gear reducers, electric motors, conveyor components ‐ as
per manufacturer’s warranty, details supplied with Equipment manual;
Electrical generators, diesel motors and electrical switch gear (Non‐ELRUS) ‐ as per original
equipment manufacturer’s warranty, ELRUS does not offer any supplemental or modified
coverage of these items.
2. ELRUS is not responsible for parts which are subject to normal wear and tear or are designed to
be replaced or renewed as part of the routine maintenance of the Equipment, which include but
are not limited to the following: hand rails, guards, v‐belts, conveyor belts, tires, brakes, paint,
hydraulic hose, and hinges and pins. No warranty is provided for defects arising as the result of
unsuitable or improper use, faulty installation or commissioning by the Customer or third
parties, or faulty or negligent treatment; this also applies to the consequences of improper
modifications or repair work carried out by the Customer or third parties without the consent of
ELRUS.
3. ELRUS reserves the right to make design changes at any time and is not obligated to notify
Customer, or make or implement any changes to Equipment previously sold to Customer.
4. ELRUS will only consider warranty claims made within 30 days of discovery of defect by
Customer. Evident defects must be reported by the Customer in writing to ELRUS promptly after
receipt of the Equipment. All claims must be submitted to ELRUS via fax, electronic mail or in
person with an ELRUS representative. All warranty claims are processed, approved and managed
in the ELRUS Calgary head office by authorized personnel, who shall have final discretion in the
resolution of a warranty issue. In the case of a justified and timely complaint about a defect,
ELRUS will at its discretion (during normal working hours and through an ELRUS repair shop or
other shop approved by ELRUS) provide (at ELRUS' choice) new, remanufactured or ELRUS‐
approved repaired parts or assembled components, as well as reasonable and customary labour,
needed to correct the defect. Parts or components replaced under this warranty shall become
the property of ELRUS.
{W:/DOCS/3186.001/08/00313200.DOCX / 2}
5. ELRUS does not make any warranties for any contingent, incidental or consequential damages,
including but not limited to any loss of time, any damages to goods being produced, or any
other costs or expenses of any other kind or nature resulting from a breakage, breakdown or
malfunctioning of any Equipment sold to the Customer by ELRUS.
6. Due to the variable nature of feed materials and operating conditions, ELRUS makes no
performance guarantees on Equipment unless otherwise stated in quotations or other written
correspondence.
7. ELRUS' obligation under this warranty only applies if the Equipment is properly maintained and
is operated in accordance with ELRUS' instructions as per the operator’s manual and other
official written correspondence.
8. The warranty of a replaced or repaired part expires at the same time as the original warranty of
the supplied Equipment.
9. While ELRUS does its utmost to anticipate and comply with all Federal, Provincial, State,
Municipal or local regulations, Customer acknowledges that the Equipment may or may not
comply with all Federal, Provincial, State, Municipal and local regulations and it is the
Customer's responsibility to ensure compliance.
10. Customer shall be responsible for: providing proof of date of commissioning or start of
operation; all costs associated with transporting the Equipment to and from the place of
business of an ELRUS repair shop or other shop approved by ELRUS; parts shipping charges in
excess of those that are usual and customary; giving timely notice of a warrantable failure and
promptly making the product available for repair; and performance of the required maintenance
(including use of proper fuel, oil, lubricants and coolant) and items replaced due to normal wear
and tear.
11. NEITHER THE FOREGOING EXPRESS WARRANTY NOR ANY OTHER WARRANTY BY ELRUS, EXPRESS
OR IMPLIED, IS APPLICABLE TO ANY ITEM ELRUS SELLS, WHICH IS WARRANTED DIRECTLY TO THE
USER BY ITS MANUFACTURER. THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE. REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE
PROVISION OF MATERIAL AND SERVICES, AS SPECIFIED HEREIN. ELRUS EXCLUDES ALL LIABILITY
FOR OR ARISING FROM ANY NEGLIGENCE ON ITS PART OR ON THE PART OF ANY OF ITS
EMPLOYEES, AGENTS OR REPRESENTATIVES IN RESPECT OF THE MANUFACTURE OR SUPPLY OF
GOODS OR THE PROVISION OF SERVICES RELATING TO THE GOODS.
{W:/DOCS/3186.001/08/00313200.DOCX / 2}
Parts • Sales • Service
Surrey, BC
19066 95A Ave Surrey, B.C.
PH: (604) 888-8499 TF: (877) 788-8499
FX: (604) 513-2452 EM: bc@elrus.com
Cambridge, ON
170 Turnbull Ct. Cambridge, ON N1T 1J2
PH: (519) 624-6500 TF: (866) 795-1188
FX: (519) 624-6505 EM: ontario@elrus.com
Edmonton, AB
8401 39 St Leduc, AB T5S 1J6
PH: (780) 484-3378 TF: (877) 484-3303
FX (780) 489-3041 EM: edmonton@elrus.com
Winnipeg, MB
Hiwy 101 & Sturgeon Rd. N Winnipeg, MB.
PH: (204) 888-5588 TF: (855) 588-5588
FX: (204) 888-4740 EM: winnipeg@elrus.com
TM
Head Office & Manufacturing Facility - 4409 Glenmore Trail SE Calgary, AB T2C 2R8
PH: (403) 279-7741 TF: (888) 535-7877 FX: (403) 236-5151 Email: info@elrus.com
www.elrus.com