99150 Series Electric Rolling Motor

99150 Series Electric Rolling Motor
99150 Series Electric Rolling Motor
For 1/2” – 1-1/2” (12.7mm – 38.1mm) Tube O.D.
Tube & Pipe Cleaners
Tube Testers
Tube Plugs
Tube Removal
Tube Installation
Operating and Maintenance Instructions
WARNING: Read these instructions before using this tool.
www.elliott-tool.com
Table of Contents
Introduction........................................................................................................... 4
Safety Instructions................................................................................................. 5
Setup..................................................................................................................... 7
Troubleshooting Electric Rolling Motors............................................................... 9
Care & Maintenance............................................................................................ 10
Brush Replacement............................................................................................. 11
99150 Series Parts Diagram................................................................................ 12
99150 Series Parts List....................................................................................... 13
Technical Information.......................................................................................... 14
99150 Series 3
Introduction
Thank you for purchasing this Elliott product. More than 100 years of experience have been employed in
the design and manufacture of this tool, representing the highest standard of quality, value and durability.
Elliott tools have proven themselves in thousands of hours of trouble free field operation.
If this is your first Elliott purchase, welcome to our company; our products are our ambassadors. If this is
a repeat purchase, you can rest assured that the same value you have received in the past will continue
with all of your purchases, now and in the future.
The Elliott 99150 Series Electric Rolling Motor is be used with the Elliott Model ELC110220 Electronic
Torque Controller to expand tubes in the following types of equipment:
Heat Exchangers
Condensers
Chillers
Evaporators
Air Conditioners
If you have any questions regarding this product, manual or operating instructions,
please call Elliott at +1 800 332 0447 toll free (USA only) or +1 937 253 6133, or fax us at +1 937 253 9189
for immediate service.
4 99150 Series
Safety Instructions
1. Read all safety and operating instructions contained in this manual prior to use of the tool. Failure
to follow all instructions listed below may result in electrical shock, fire and/or serious injury.
2. Do not operate this tool while under the influence of drugs or alcohol.
3. Do not operate this tool in an explosive atmosphere, such as in the presence of flammable liquids, gases or dust.
4. Check the motor, cable and plug prior to every use of the tool. Repair or replace any defective
parts prior to use of the tool.
5. Do not use motor in wet conditions.
6. Use only extension cords and plugs approved for outdoor use when working outdoors.
7. Use appropriate safety equipment (i.e. safety glasses, ear plugs, dust masks, etc.) when using
this tool.
8. Ensure that long hair or loose fitting clothes are secure prior to use of the tool.
9. Do not use motor without the additional handle.
10.Never apply the motor to an unsecured work piece.
11.Power cable should be located to the rear of the motor during operation, away from the rotating
spindle.
12.Always hold the motor with both hands and maintain a safe stance during use.
13.Stay clear of any objects that may interfere with the operator’s ability to maintain control of the
motor as it reaches maximum torque.
14.Always disconnect the motor from the power source prior to performing any maintenance or
repairs.
Protection
To avoid damage to the tool and/or possible injury to the operator:
Do not continue to run the motor after the motor has reached its maximum torque.
Do not operate the motor beyond the maximum amperage rating shown on the name plate.
Use only original replacement parts from the motor manufacturer.
99150 Series 5
6 99150 Series
Setup
Side Handle
ONLY OPERATE THE MOTOR WITH THE SIDE HANDLE INSTALLED!
Assemble the side handle to the motor housing just behind the drive spindle. Rotate the side handle to
a position suitable for the operator. Secure the assembly in place by turning the handle to tighten the
clamping collar.
Speed Selection
DO NOT ATTEMPT TO CHANGE THE SPEED WHILE THE MOTOR IS RUNNING!
This motor is equipped with a mechanical two-speed gearbox. To select high speed, press in on the
selector switch and slide the switch in the direction of the double arrows (>>). To select low speed,
press in on the selector switch and slide the switch in the direction of the single arrow (<). If the switch
will not slide completely, rotate the spindle slightly by hand while still pressing in on the switch until the
gearbox engages and the switch slides the full distance.
Operating this motor in the high speed selection will yield faster RPMs for higher productivity and less
torque than the low speed selection.
If the motor is running in the high speed selection and the torque controller is set at it’s highest limit
setting and the tubes are being under-expanded, switch the motor to the low speed selection and
rerun the torque controller setup.
Connect to Torque Controller
To get full use of the auto-reverse and torque shut-off features, this motor must be used with the Elliott
Model ELC110220 Electronic Torque Controller. Connect the 7-pin connector on the motor cord to
the 7-pin socket on the torque controller. The controller will automatically detect whether the motor
is 110V or 220V and whether the motor is auto-reversing or manual reversing. (Note: The operating
voltage must correspond with the voltage indicated on the motor’s name plate. 99150-110 motors
designed for 110V can be used with 120V as well. 99150-220 motors designed for 220V can be used
with 240V as well.
99150 Series 7
Setup
Electric motors are designed to operate within
a specific amperage range. Operating above the
maximum specified amperage rating will result in
damage to the motor.
When operating the motor in conjunction with Elliott’s ELC110220 Torque Controller the following maximum
settings must be followed:
Model
Single Phase
Voltage
Maximum
Amperage
Maximum
ELC110220 Setting
99150-110-7P
99150-220-7P
110
220
10.0
5.0
500
250
If using an extension cord, avoid excessive lengths
and/or undersized wire gauge cords. The ELC110220
is designed to operate at a minimum voltage of 100
VAC. The use of an undersized extension cord can
create a voltage drop that may adversely affect the
operation of the ELC110220. An extension cord that
is hot to the touch is most likely undersized and
should be replaced with the next larger size wire.
Grounded power cords have plugs with three prongs and require a three wire extension cord. Double insulated
power cords have plugs with two prongs and can use either two or three wire extension cords. As the distance
from the supply outlet increases, you must use a heavier gauge extension cord. Using extension cords with
inadequately sized wire causes a serious drop in voltage, resulting in loss of power. Refer to the chart below
to determine the required minimum wire size.
Recommended Minimum Wire Gauge for Extension Cords
Nameplate
Amperes
0.0 - 5.0
8.1 - 12.0
8 99150 Series
Extension Cord Length
25’ (7.6m)
50’ (15.2m)
75’ (22.8m)
100’ (30.5m)
150’ (45.7m)
200’ (61.0m)
16
14
16
14
16
12
14
10
12
-
12
-
Troubleshooting Electric Rolling Motors
Symptom
Motor won’t run.
Motor will not shut off at
controller setting.
Motor runs hot.
Motor will not
auto-reverse.
Possible Causes
Solution
Loose plug connections.
Ensure all plug connections are
secure.
Motor voltage doesn’t match power
source voltage.
Ensure that motor voltage matches
the voltage of the power source.
Torque controller is in “Auto” or
“Assisted” mode & is waiting for
additional input.
Check the torque controller dialog
screen & enter info required.
Limit setting on the torque controller is
set too high.
Recalculate or reduce limit setting.
Torque required exceeds motor
capacity.
Set motor speed (if 2-speed) to lower
speed or switch to larger motor.
Motor set at low speed setting
(2-speed motors only).
Set motor to high speed setting.
Motor is too large for application.
Switch to a smaller motor.
Defective trigger switch.
Replace the trigger switch.
Defective motor.
Have the motor serviced by an
authorized repair specialist.
Motor is operating at or above
its max. amperage rating.
Set motor speed (if 2-speed) to lower
speed or switch to larger motor.
Ambient temperature are high.
See Care & Maintenance
on page 10.
Defective motor.
Have the motor serviced by an
authorized repair specialist.
Loose plug connection.
Ensure plug connection to torque
controller is secure.
99150 Series 9
Care & Maintenance
Environments with high ambient temperatures require closer attention to care and use. In order to
achieve optimal motor performance consider the following:
• Clean Power–The use of a reliable, consistent power supply will help minimize voltage fluctuations
that can be harmful to the motor.
• Ambient Temperature–As the ambient temperature rises, so does the need for cooling. When used
in high ambient temperature conditions, operators should run the motor under no load for 10 to 15
seconds periodically during the shift to enable ambient air to pass through the motor and cool the
internal parts. Frequency and duration of cooling periods are dependent on the ambient temperature. If using in conjunction with Elliott ELC110220, this practice will not adversely affect the performance of the controller.
• Cooling Motors–In the event that conditions are so extreme that the cooling recommendation above
is not sufficient, operators should consider implementing a multiple motor system where motors
are run for a short period of time then allowed to rest while a secondary motor is put into service.
Alternating motors in this manner will allow the motor to cool and avoid damage due to overheating.
• Internal Operation Temperature–The operating temperature of the internal components must not
reach 284 degrees Fahrenheit (140 degrees Celsius).
To ensure years of reliable operation, follow these simple care and maintenance suggestions:
• Keep the motor clean and free of dirt and other contaminants.
• Do not allow contaminants inside the motor housing.
• When the brush lengths are .25” (6.35mm) or less, brushes need to be replaced. (See instructions
below.) Brushes should be replaced by a maintenance technician. They must be run in by a 20 minute idle run of the tool. Also, the condition of the commutator must be checked. In case of irregular
coloring of the individual blades and surface crashes, send the tool to an authorized service center.
Environmental Protection
Raw Material Recycling instead of Waste Disposal
The components that make up this tool, as well as its packaging, are made of recyclable materials and
should be disposed of in accordance with local rules and regulations.
10 99150 Series
Brush Replacement
When To Replace The Carbon Brushes:
When the brush lengths are .25” (6.35mm) or less, brushes need to be replaced. Brushes are fieldserviceable components and should be replaced by a maintenance technician.
1.
2.
3.
4.
5.
6.
7.
8.
Disconnect motor from any power source.
Remove (3) side screws (Item 7) and (4) long screws (Item 10) from the D-handle (Item 4).
Lift up the flat spring to remove the carbon brush (Item 15) from the brush holder (Item 14).
Remove the screw & lock washer holding the wire terminal attached to the carbon brush & detach the carbon brush from the holder.
Attach the wire terminal of the new carbon brush with the screw and lock washer. (IMPORTANT:
Ensure that the wire lead on the carbon brush terminal is under the contact washer (Item 24).
Lift up the flat spring & insert the new carbon brush into the brush holder and release the flat
spring to hold the carbon brush in place.
Repeat steps 2 thru 5 for replacing the carbon brush on the other side of the rotor complete (Item
12).
Replace the D-handle sides and (3) screws.
99150 Series 11
99150 Series Parts Diagram
Ersatzteilliste
EHB 16/2.4 S R/L
22
34
35
21
31
43
44
36
41
42
36
30
37
40
38
39
37
6
33
10
48
2a
26
1I 1
4
1
29
3
27
47
2I
2a
32
45
12
13
8
9
2
3
4
3
4
18
11
46
8
7
6
5
5
6
5
21
23
22
1
25
2
7
1I
4
8
4
11
3
2I
24
1
10
28
14
15
06/11
12 99150 Series
20
19
16
10
11
7
L
R
17
10
Änderungen vorbehalten
99150 Series Parts List
Item
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Part Number
99150-110CC
99150-220CC
40-80600110
40-80500010
40-7122H261
40-83000004
40-80600130
40-80600126
40-80201272
40-85000020
40-80201270
40-80201267
40-7122K100
40-7122H100
40-83000036
40-80410011
40-80201196
40-80700013
40-80201180
40-80201385
40-80900088
40-80201266
40-80900017
40-80201333
40-80410032
40-80201320
40-7122H183
40-7122H184
Description
Connection Cable (110V)
Connection Cable (220V)
Reverser
Condenser
D-Handle
Cable Grommet
Switch (110V)
Switch (220V)
Screw HC 4.2x22
Locking Flange
Screw HC 4.2x13
Screw HC 4.8x45
Rotor Complete (110V)
Rotor Complete (220V)
O-Ring
Bearing
Carbon Brush Holder
Carbon Brush
Screw ZM4x12
Spring Disk 34
Motor Housing
Screw C 3.9x60
Air Guidance Ring
Safety Ring
Ball Bearing
Safety Ring
Pigtail 1
Pigtail 2
Qty
1
1
1
1
1
1
1
1
3
1
2
4
1
1
1
1
2
2
4
4
1
2
1
2
2
1
1
1
Item
No.
Part Number
26 40-82000056
27 40-80201284
40-7122K150
28
40-7122H150
29 40-71223400
30 40-71540545
31 40-71223520
32 40-7122H420
33 40-80410112
34 40-80200502
35 40-77225430
36 40-80410010
37 40-80420110
38 40-71223440
39 40-71223460
40 40-80200602
41 40-7122A470
42 40-71323500
43 40-7122A610
44 40-80200582
45 40-80600306
46 40-80600243
47 40-7132A695
48 40-7122H585
Description
Gear Box Seal
Screw HC 4.8x50
Stator Complete (110V)
Stator Complete (220V)
Gear Box Housing
Gear Changer Complete
Coupling Belt Complete
Work Spindle
Ball Bearing
Washer
Spindle Wheel
Ball Bearing
Needle Sleeve
Gear Block
Gear Block Shaft
Locking Spring
Intermediate Wheel
Two Pinion Shaft
Transmission Bearing
Notched Pin
Spacer
Interconnecting Wire
Side Handle Complete
Intermediate Ring
Qty
1
4
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
2
1
1
99150 Series 13
Technical Information
Rated Voltage:
Rated Power Input (Watts):
Frequency:
Max. Amperage:
ELC110220 Limit Setting:
Free Speed (No Load):
Max. Torque (Ft.-Lbs. / N*m):
Protection Class:
Degree of Protection:
Interference Suppression:
110V / 120V (99150-110)
220V / 240V (99150-220)
1100
50 – 60 Hz
10A (110V)
5A (220V)
500 (110V)
250 (220V)
760 (Low Gear) / 1250 (High Gear)
8 / 10.8 @ 690 RPM (High Gear)
12 / 16.3 @ 290 RPM (Low Gear)
II (Double Insulation)
IP 20
as per DIN VDE 0875, EN 55014
All rights of changes due to technical development reserved.
Dimensions (without toolbox):
Length (Inches / mm):
Width (Inches / mm):
Height (Inches / mm):
Weight (Lbs. / Kg):
18 / 457.2
8 / 203.2 (w/ Side Handle)
5.5 / 139.7
9.3 / 4.2
Dimensions (with toolbox):
Length (Inches / mm):
Width (Inches / mm):
Height (Inches / mm):
Weight (Lbs. / Kg):
20 / 508
10.5 / 266.7
10 / 254
11.3 / 5.1
Noise Emission:
Noise emission figures are based on DIN 45 649, part 2, DIN 45 635, part 21, and DIN EN 27 574 (ISO
7574).
- noise level (LWAc) (94+3) dB re 1 pW
working place-related emission figure (LpA) 84 dB per DIN 45635 – 21 – KL 2
- noise level (LWA) 88 dB re 1 pW
working place-related emission figure (LpA, cyc) 79 dB per DIN 45635.
14 99150 Series
Contact Us
Elliott Tool offers a complete line of precision
tube tools to meet your needs. Contact us or
your local support.
Elliott Tool Technologies, Ltd.
1760 Tuttle Avenue
Dayton, Ohio 45403-3428
Phone: +1 937 253 6133 • +1 800 332 0447
Fax: +1 937 253 9189
www.elliott-tool.com
Printed in the USA
© 08/2016 Elliott Tool Technologies, Ltd.
TM-106
Locally Supported By:
www.elliott-tool.com/support
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