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SERVICE & PARTS MANUAL
FOR
T30 TERMINATOR
10200 JACKBORO HWY., FORT WORTH, TX 76135
PH: (817) 237-7700 FAX: (817)237-2777
WEBSITE: WWW.ACEWORLDCOMPANIES.COM
REGISTERED ISO 9001 COMPANY
Revised 25 Oct 2010
TABLE OF CONTENTS
SECTION 1 Introduction
Handling
Prolonged Storage
SECTION 2 Installation
General
Bridge Requirements
Pre-Operation Check
Preliminary Testing
Wire Rope Reeving
SECTION 3 Lubrication Instructions
Lubrication System
Type of Lubricant
Low Temperature Operation
Grease Lubrication of Bearings
Oil Seals
Oil Changes
Factory Applied Rust Preventative
SECTION 4 Operation Instructions
Start-Up Procedure
Operational Checks
SECTION 5 Troubleshooting
Troubleshooting Chart
SECTION 6 Preventive Maintenance
General
Scheduled Maintenance
Daily
Weekly
Monthly
Two Month Intervals
Six Month or 2500 Hour Intervals
Extended Shutdown Periods
Lubricants
Oil Service Life Guidelines
SECTION 7 Hoist Reducer Disassembly and Assembly Procedures
INTRODUCTION
This manual contains general installation, operating, maintenance and troubleshooting instructions for the Gearbox’s. These gearboxes are rugged, high quality designed in accordance with standards of the American Gear
Manufacturers Association to give many years of trouble-free service. However, optimum performance can be expected only if the procedures in this manual are followed. Should questions arise that are not covered in this guide, additional information may be obtained by contacting Ace World Companies service department.
All inquiries should be accompanied by the following information, which can be obtained from the gearbox nameplate:
Gearbox size and Type
All Orders for renewal parts or replacement parts should include description and part number shown on the parts list supplied in this manual (see section 7).
NOTE
Adequate installation, maintenance, and safety instructions must be given by the User to personnel directly responsible for the operation of the gearbox. In addition, the procedures set forth in the operating instructions must be followed carefully.
HANDLING
When handling the gearbox, care must be taken to avoid supporting or lifting in a manner that would place excess stress on parts that are not designed to support the unit’s weight.
Never drag the gearbox. This will mar the machined mounting surfaces and may overstress housing.
Use only lifts that are adequately maintained and that possesses sufficient load carrying capacity for the particular application. Secure and balance the load properly to prevent shifting during suspension.
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When attaching slings to the gearbox, attention must be given to the behavior of the sling under load. Do not attach a sling in a manner which will damage any exterior components mounted on the gearbox.
PROLONGED STORAGE
When gearbox is shipped from factory it is filled to cover all gears to prevent rust from forming. At time of installation oil is drained and refilled to the proper level which is determined by the sight gauge as to when it is to its proper level.
When prolonged storage is necessary it should be in-doors and preferably in a dry free area having a relatively constant temperature.
When outdoor storage is unavoidable, gearbox should be raised off the ground on skids and covered with a tarp or equivalent covering.
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INSTALLATION
DESCRIPTION PAGE
General 7
7
Lubrication 7
7
Preliminary Testing
Reeving
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GENERAL:
Hoists are tested before being shipped from the factory. To place hoist in service, set on bridge and connect to electrical service.
WARNING
Before attempting installation of hoist/trolley, the main power switch must be locked in the open position.
Perform pre-operation checks and tests before placing in service.
The successful operation of the hoist depends upon a properly installed bridge. The bridge should be checked for adequacy of the following:
Size of trolley rail (trolley wheels are arranged to operate on a specific rail size.
Trolley rails are to be solidly fastened to the supporting girder.
The rails shall be straight, parallel, level and at the same elevation. The distance
(gage) center to center of bridge rails as well as the rail elevation shall be within a tolerance of plus or minus 1/8” (.32cm).
Rail joints must be smooth and held in tight alignment by properly fitted rail joint bars so that ends are held tightly with no crack or opening.
The bridge should be designed in accordance with specifications outlined by the
Crane Manufacturer Association of America for the maximum wheel loads involved.
Size and placement of trolley end stops or bumpers should be checked to insure that they are of the proper height and width to fully contact the trolley wheels and also placed so as to stop the trolley with sufficient clearance between any portion of the trolley and the building.
The trolley is grounded
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LUBRICATION:
All hoists are completely lubricated at the factory.
WARNING
Before energizing the hoist, and prior to running any motion, be certain that you have read this manual in its entirety and you are familiar with your hoist.
Check the main switch serving the runway conductors and also the main disconnect switch on the bridge. Lock both switches in the open position (power off).
Check trolley wheels
Check all connections for tightness of bolts, inclusion of lock washers or other type fasteners, to insure correct material as been used. This check must be made for all connections, mechanical, structural and electrical including both field and factory made connections.
Check to insure that all shipping supports, tie downs, brackets or other items which were used only for shipping or storage purposes are removed from the trolley.
Check alignment of trolley collectors
Check electrical wiring fro conformance to the wiring diagram.
Check all gear cases for oil level, and check all other parts for lubrication.
Check to be certain that the trolley and bridge is clear and free of all obstructions.
Prior to the start of these tests, make a last minute check to see that loose parts, such as tools, covers, excess hardware, nuts, bolts, etc., have been picked up and safely stored.
Only qualified personal (electricians, etc,) be used for testing unit.
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CAUTION
Verify that the trolley furnished has the same voltage, frequency, and phase as the bridge power supply.
Place all master control switches in the OFF position. If trolley is pendant push button operated, check that all buttons are in the OFF (fully released) position. Open power circuit knife switches of each control panel. If the panels are not so equipped, then remove fuses in the motor circuit.
Hoist Test: a) Test is made prior to reeving the hoist. If your hoist was reeved at the factory then lower the load block manually to a position 8 to 10 feet below the trolley. This can be done by manually releasing the motor brake; some effort will be required to rotate the motor shaft. b) Close the mainline disconnect switch serving the runway conductors. c) Using a voltmeter, check all legs of the power leads at the mainline disconnect switch, located on the crane. Determine that power being supplied is of the correct voltage. d) Close the mainline disconnect switch after checking to see that fuses are is place. e) Energize the mainline contactor by depressing the START button. Deenergize by depressing the STOP button. The action of the contractor in closing and opening the circuit is operating leave circuit with mainline contactor energized. f) At the hoist control panel, check all legs of the power leads. Determine that power is being supplied at the correct voltage. g) Check out reversing contactor and accelerating contactor sequencing.
Operate the hoist push button on the pendant control, step by step in both directions. At each step, check contactor sequence with sequence shown on panel wiring diagram for proper operation. h) Open mainline disconnect switch and replace fuses in the hoist motor circuit of the hoist panel.
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i) Close mainline disconnect switch and reset mainline contactor by pressing the START button. j) Jog the hoist master switch or push button in the UP direction, Check to insure that the drum is rotating in a direction which would raise the load block. (Refer to reeving instructions), to determine drum direction for rising).
If direction is wrong, correct by interchanging any two leads at motor conduit box. Be certain main disconnect switch is open (power off)
when making this correction.
k) Operate the hoist several revolutions of the drum in both direction, observing that the motor brake releases properly, and that the gear train and bearings operate without binding. l) After the hoist is reeved and before placing trolley in service, a confirming load test is recommended under the direction of an appointed qualified person.
Hoist Limit Switch Test: (no load)
After the hoist is completely reeved, the upper and lower (if so equipped) limit switches must be checked for proper operation and safe stopping distance. a) Set upper and lower limits of load block. b) Slowly raise the load block. Observe the relationship of the load block to the underside of the trolley. The hoist limit switch should stop the upward travel of the load block with a few inches.
WARNING
Do not contact or strike trolley frame with load block. If hoist motion is not interrupted by limit switch, stop hoist by depressing the STOP button.
c) If the limit switch does not stop the load block, or if stopping distance exceeds several inches check electrical circuit against wiring diagram, determine cause and correct. Also check brake torque adjustment. d) Repeat test increasing the speed until test ifs performed at full speed.
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WARNING
Distance required to stop the load block after tripping the limit switch increases with speed. Be certain that the limit switch trips soon enough so that the load block will not contact the trolley frame or other obstruction in stopping.
e) If trolley is equipped with a lower limit switch, check switch rip setting by lowering load block until motor stops. With load block in extreme low position, two full wraps of rope must be on the drum. a) At the trolley control panel, check all legs of the power leads. Determine that power is being supplied at the correct voltage. b) Check reversing contactor and accelerating contactor sequencing by operation of the trolley push button on the pendant control in both directions.
Check sequence with panel wiring diagram to determine proper operation. c) Open mainline disconnect switch and replace fuses in the trolley motor circuit of the trolley panel. d) Close mainline disconnect switch and reset mainline contactor by pressing the START button.
CAUTION
When operating the trolley motion, place load block in high position and watch out for overhead or side interferences between the building and the crane.
e) Jog trolley master switch in the forward direction (be sure trolley is free to move in either direction). If direction of trolley is incorrect, reverse lead as described under Hoist Test above. f) Operate the trolley slowly across the entire bridge and slowly contact the end stops. Check contact of bumpers or wheels to end stops. Operate several times back and forth across the bridge avoiding contact with end stops, working the unit up to full speed. Observe that the gear train and bearings operate without binding and that the trolley travels across the bridge without skewing.
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LUBRICATION INSTRUCTIONS
LUBRICATION
Lubrication is accomplished by the splash system. The oil level is set high enough to partially submerge all gears, and in some cases, the bearings. In some cases splash feed lubrication fills oil pockets at bearings on all shafts and thereby maintains a reservoir of oil at these points.
TYPE OF LUBRICANT
Use CHEVRON MEROPA ISO 220 or equal.
If ambient temperatures drop below 35
0
F, gearbox oil must be changed to ISO
150 MINERAL GEAR OIL.
If ambient temperatures remain BELOW 0
0
F, an oil heater will have to be installed.
OIL SEALS
Oil seals require a small amount of lubricant to prevent frictional heat and subsequent destruction when the shaft is rotating. Oil seals often permit a slight seepage of oil along the sealing surfaces. This seepage is required to minimize seal friction and heat.
OIL CHANGES
After the initial six (6) months of operation, the original oil should be changed.
Very often, due to the wearing-in process, small metal particles will appear in the oil; this is not abnormal. Fill the housing to the indicated level with straight mineral flushing oil which must not contain additives. Start gearbox and bring up to operating speed (preferably without load) and then stop. Drain flushing oil and fill with recommended operating lubricant to proper level.
Unusual environmental or load conditions may necessitate replacement of oil as frequently as one (1) or two (2) month intervals as determined by field inspection.
Special attentions must be given to the inspection of lubricants when following conditions exist: a) High operation temperatures resulting from heavy intermittent loads, causing the temperature of the gear housing to rise rapidly and then cool. b) Ambient temperature conditions which may cause sweating on the inside wall of the gear housing, contaminating the oil and forming sludge.
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Precautions must be taken to prevent any foreign matter from entering the gearbox housing. Dust, dirt, moisture and chemical fumes form a sludge which is detrimental to proper and adequate lubrication. Ace World Companies must be advised before manufacture of gearbox when environmental conditions are anticipated.
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OPERATION
DESCRIPTION PAGE
8
8
8
8
8
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3-6 Operating the Controls (No Load)
3-7 Operating the Controls (With Load)
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3-1 GENERAL
a) The importance of safe handling of overhead hoisting cannot be overstated. The operator should be aware at all time that he is in control of a powerful machine, which if used carelessly, can do a great deal of damage. Correct usage is fundamental to reliable operation and minimum maintenance costs of the trolley.
One measuring stick of a good operator is his smoothness of operation. Jumpy of jerky trolley movement, flying starts, quick reversals and sudden stops are the trade marks of the carless operator. b) Equally important to the safe operation of the trolley is frequent and systematic inspection and maintenance. Mandatory requirements on a national level are detailed in OSHA Part 1910.179. The user should become familiar with those regulations, along with any other state or local codes.
a) Safe and efficient trolley operation requires skill, extreme care, good judgment, alertness, concentration, knowledge of and rigid adherence to proven safety rules and practices. No person should be permitted to operate a trolley:
1) Who is not qualified or has handicaps that could adversely affect such operation.
2) Who has not been properly instructed?
3) Who has not been informed and does not have thorough knowledge of all applicable safe operating practices, including those in this book as well as rigging equipment and practices. b) The user is also referred to American National Standard ANSI B30.2.0 Section 2-
3.1 for qualification and conduct of operators. Additionally, the user should become familiar with National, State or Local safety codes which may apply.
WARNING
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Equipment covered herein is not designed or suitable as power source for lifting or lowering persons.
Safe operation of an overhead hoist is the operator’s responsibility. Listed below are some basic rules that can make an operator aware of dangerous practices to avoid and precautions to take for his own safety and the safety of others. Observance of these rules in addition to frequent examinations and periodic inspection of the equipment may save injury to personnel and damage to equipment.
a) DO
1) Read ANSI B30.2.0 Safety Standard for Overhead and Gantry Cranes.
2) Be familiar with hoist operating controls, procedures and warnings.
3) Make sure lock block travel is in the same directions as shown on controls.
4) Make sure hoist limit switches function properly.
5) Maintain firm footing when operating hoist.
6) Make sure that load slings or other approved single attachments are properly sized and seated in the load block saddle.
7) Make sure that the lock block latch, if used, is closed and not supporting any part of the load.
8) Make sure that load is free to move and will clear all obstructions.
9) Take up slack carefully, check load balance, lift a few inches and check load holding action before continuing.
10) Avoid swinging of load or load hook.
11) Make sure that all persons stay clear of the suspended load.
12) Warn personnel of and approaching load.
13) Protect wire rope from weld spatter or other damaging.
14) Promptly report any malfunction, unusual performance, or damage of the hoist.
15) Use common sense and best judgment whenever operating a hoist.
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16) Inspect hoist regularly, replace damaged or worn parts, and keep appropriate records of maintenance.
17) Use the hoist manufacturer’s recommended parts when repairing a hoist.
18) Use hook latches wherever possible.
19) Apply lubricant to the wire rope as recommended by the hoist manufacturer.
b) DO NOT
1) Lift more than rated load.
2) Use the hoist load limiting device to measure the load.
3)
Operate damaged hoist or hoist that is not working correctly.
4)
Operate the host with twisted, kinked, damaged or worn wire ripe.
5)
Lift a load unless wire rope is properly seated in its grooves.
6)
Use load rope as sling or wrap rope around the load.
7)
Lift a load if any binding prevents equal loading on all load supporting ropes.
8)
Apply the load to the tip of the hook.
9)
Operate unless load is centered under host.
10)
Allow your attention to be diverted from operating the hoist.
11)
12)
Operate the hoist beyond limits of load rope travel.
Use limit switches as routine operating stops unless recommended. They are emergency devices only.
13)
Use hoist to lift, support or transport people.
14)
15)
Lift loads over people.
Leave a suspended load unattended unless specific precautions have been taken.
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16)
Allow sharp contact between two hoist or between host and obstructions
17)
Allow personnel not physically fit or properly qualified to operate the hoist.
18)
19)
Allow the rope or hook to be used as a ground for welding.
Allow the rope or hook to be touched by a live wilding electrode.
20)
21)
Remove or obscure the warnings on the hoist.
Adjust or repair a hoist unless qualified to perform hoist maintenance.
22)
Attempt to lengthen the load rope or repair damaged load rope.
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With forearm vertical, and forefinger pointing up, move hand in small horizontal circle.
With arm extended downward, forefinger pointing down, move hand in a small horizontal circle.
Arm extended forward, hand open and slightly raised, make pushing motion in direction of travel.
Hold up one finger for block marked ”1” and two finger for block marked “2”.
Palm up, fingers closed, thumb pointing in direction of motion, jerk hand horizontally.
Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal.
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Arm extended, palm down,hold position rigidly.
Arm extended, palm down, move hand rapidly right and left.
Crane operator spreads both hands apart – palms up.
The operator should locate and be familiar with the operation of the runway mainline disconnect switch and for this exercise lock switch in the OPEN (power off) position.
The operator should now manipulate the various push buttons to get the “feel” and determine that they do not bind or stick in any position. The operator should become familiar with the location of the buttons or switches for their respective motions, as well as the “START” and “STOP” buttons which operate the mainline contactor. The
“STOP” buttons should be used in any emergency since it will shut off power to all motions.
WARNING
If a push button binds or sticks in any position or does not return to the OFF position – do not turn power on – determine the cause of malfunction and correct before operating trolley.
3-6.1 Close the mainline disconnect switch. Press the START button. The trolley is now under power and ready to operate. For descriptive purposes assume the trolley is push button controlled with three speed points. Be certain the area is clear of all obstructions and people.
3-6.2 Hoist motion. Depress the “Down” push button to the first speed point.
Observe that the load block is moving down slowly.
If the load block does not start down, depress the push button to the second speed point to start the load block in motion, and then back off to the first speed point. This
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may occur if the hoist is new or has been idle for a period of time. If the load block still does not move on the first speed point after an initial break-in period, the hoist secondary resistance can be modified. This should be done only after consultation with ACE WORLD COMPANIES electrical department.
With the load block moving downward, push to the 2 nd
and finally to the 3 rd
(full speed) point of control observing the increase in speed as the button is depressed. With no load on the load block the speed change may be detectable only by the use of a tachometer.
Release push button and observe distance required to stop load block. The load block may be lowered until two full wraps of cable remain on the drum. Never lower load block below this position.
In the same manner, depress the “UP” push button to the first speed point, then to the
2 nd
speed point and finally to the 3 rd
(full speed point. Release push button and observe stopping distance. During this practice be certain to stop the load block several feet below the bottom of the trolley.
At the beginning of each shift the operator must check the hoist upper limit switch with no load. Extreme care must be exercised to avoid accidental damage in the event the switch does not operate. Raise the load block by slow inching. Carefully observe the relationship of the load block and the bottom of the trolley frame. The hoist upper limit switch, when working properly, should cause the host upward motion to stop.
WARNING
Do not contact or strike trolley frame, drum or upper block with load block. If hoist motion is not interrupted by limit switch, stop hoist. Do not attempt further operation. Report condition to proper supervisor for correction.
Repeat upper limit switch test described above several times, each time increasing the hoist speed until switch is tested at full speed. Do not use this upper limit switch as an operating control.
3-6.3 Trolley motion. The operator must develop complete familiarity with response of the trolley motion and direction relative to position of the controls. As with the hoist, the operator should become familiar with each speed point working to full speed ONLY after stopping from each speed point. This practice should continue ling enough so that direction speeds, stopping, distance, hook swing control, etc., become “second nature” to the operator’s judgment and reflexes.
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The exact same procedures apply with load as given in Para. 3-6 for no load. Start operation using a light load of 10 to 15 percent full load graduating to approximately
50% load and then to full load in three load steps. This will give the operator a feel for control response throughout the load range. The most important effect of a changing load with which the operator must become familiar is the variation of stopping distance required.
Motor torque in the first speed point is limited to approximately 50 percent and therefore the hoist will not raise or lower loads exceeding approximately 50 percent of the rated load while on the first speed point.
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OPERATING INSTRUCTIONS
A B
A
Fig. 3-1, Fig. 3-2
PRELIMINARY CHECKS
When starting up any new equipment, it is best to proceed cautiously. Even though the installation instructions are followed, the existence of errors or omissions is always possible. Before initial start-up, perform the following procedures: a) Before start-up, check the gearbox to be sure it is filled to the proper oil level with the correct type, grade, and amount of oil specified (Fig 3-1(A). b) Have required electrical connections been made, gearboxes equipped with an electric motor or control devices must be wired and checked for proper operation (Fig 3-1(B) and Fig 3-2(A).
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A B
A
Fig. 3-3 Fig. 3-4 c) Check all mounting bolts for proper torque (Fig 3-3(A). d) Check all external bolts, screw, accessories and other mounted equipment to ensure they have not loosened during shipment or handling (Fig 3-3(B).
A B
Fig. 3-5, e) Are all couplings, pinions, or other drive components installed on shaft extensions with keys and fasteners in place? (Fig 3-4(A) and Fig 3-5(A). f) Check drive motor and make sure it will drive the gearbox unit input shaft in the correct direction (Fig 3-5(B).
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START-UP PROCEDURE
The gearbox unit has been test run at the factory; however, during initial start-up, perform the following recommended procedures: a) Electrical motor starting must be arranged to start gearbox slowly to avoid severe impact loads. Across the line starting of motors must be applied with caution to prevent instantaneous gear loads greatly in excess of rating. b) If the gearbox is equipped with heaters c) Starting gearbox slowly and under as light a load as possible. d) Check for oil leaks.
OPERATIONAL CHECKS
a) As the gearbox is brought up to normal operating speed, it must be checked constantly for unusual sounds, excessive vibration, excessive heat or oil leakage. If any of these problems develop, the gearbox must be stopped immediately and the cause determined and corrected. b) After start-up the gearbox should be operated until temperatures stabilize.
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FIG
TROUBLESHOOTING
TROUBLSHOOTING CHART
PROBABLE CAUSE
a) Gearbox overloaded.
OVERHEATING
CORRECTIVE ACTION
a) Reduce loading or replace with gearbox of sufficient capacity. c) Recommended oil level exceeded or low. d) Breathers dirty or obstructed.
c) Check oil level indicator and add or drain oil. e) Improper grade of oil.
d) Breathers dirty or obstructed.
Clean breathers insolvent.
e) Drain, flush and fill with proper grade of oil. f) Oil oxidized or dirty f) Drain, flush and fill with clean oil.
Clean or replace oil filter.
Refer to lube chart.
FIG
SHAFT FAILURE
PROBABLE CAUSE
a) Gearbox overloaded. b) Couplings improperly aligned. c) Improper couplings installed. f) Torsional or lateral vibrations.
CORRECTIVE ACTION
a) Reduce loading.
Consult Ace World Companies b) Consult Ace World Companies c) Remove couplings and replace with proper type and size. f) Consult Ace World Companies.
BEARING FAILURE
PROBABLE CAUSE
a) Gearbox overloaded. b) Bearings improperly lubricated.
CORRECTIVE ACTION
a) Reduce loading or replace with
gear drive of sufficient capacity. b) Check oil level indicator and add
or drain oil.
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FIG
FIG
PROBABLE CAUSE
a) Recommended oil level exceeded. b) Breather dirty or obstructed. c) Oil drain obstructed. d) Oil seals defective. e) Drain plug, fittings, and connections leaking. f) Housing and caps leaking.
OIL LEAKAGE
CORRECTIVE ACTION
a) Check oil level indicator and drain excess oil. b) Clear breather of obstruction.
Clean breathers in solvent. c) Check that drain is clean and allow free flow. d) Replace oil seals. Consult Ace World Companies e) Disconnect, apply pipe sealant, and tighten. f) Tighten screw and bolts.
PROBABLE CAUSE
a) Gearbox overloaded. b) Recommended oil level exceeded or low. c) Improper grade oil. d) Oil oxidized or dirty. e) Gears misaligned.
GEAR WEAR
CORRECTIVE ACTION
a) Reducing loading and/or consult Ace World Companies. b) Check oil level indicator and add or drain oil. c) Drain, flush and fill with proper grade of oil.
See lube Chart. d) Drain, flush and fill with clean oil. See lube chart. e) Check gear teeth contact pattern and if tooth contact
is inadequate check condition and alignment of bearings.
consult Ace World Companies.
FIG
UNUSUAL OR INCREASING NOISE AND/OR VIBRATION
PROBABLE CAUSE
a) Gearbox overloaded.
CORRECTIVE ACTION
a) Reduce loading and/or consult Ace World Companies.
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PREVENTIVE MAINTENANCE
GENERAL
The preventive maintenance instructions are presented as scheduled procedures and provide the information necessary for prolonging the life of the gearbox and for the prevention and detection of gearbox failures before actual failure takes place. The majority of gearbox failures can be attributed to improper lubrication, misapplication and misalignment.
Improper lubrication is a prime cause of gear failures. Too frequently, units are started up without a lubricant. Conversely, the unit sometimes has a larger volume of oil than is specified in the mistaken belief that better lubrication is obtained. A higher volume of oil usually results in more of the input power going into churning of the oil, creating excessive temperatures with detrimental results to gears and bearings. Insufficient lubrication causes the same results.
Gear failure due to overload is a broad and varied area of misapplication of the gear train. The nature of load (input torque, output torque, duration of operating cycle, chocks, speed, acceleration, braking, frequent starts and stops, etc.) determines the gear unit size and other design criteria. If there is any question that the actual service conditions may be more severe than originally anticipated, consult Ace World Companies before start-up. Often there are remedies that can be suggested before the gearbox is damaged by overload, but none are effective after severe damage.
The hoist should be analyzed while the gearbox is under a full load condition to determine that the hoist is not overloaded and thus putting out more than rated torque. If it is determined that overload does exist, the unit should be stopped and steps taken to either remove the overload or contact Ace World Companies to determine suitability of the gearbox under observed conditions.
SCHEDULED MAINTENANCE
DAILY:
The gearbox must be routinely inspected for unusual sounds or visible oil leaks. If either occurs, the gearbox must be stopped immediately, and the cause determined and corrected.
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After the first 100 hours of operation, all external housing and mounting bolts should be torque to make certain they have not loosened. Check all piping connections and tighten if necessary.
WEEKLY
Check oil level and add oil if necessary.
Check the alignment of the gearbox with connected machinery after initially operating for 4 weeks under load. a) Are all mounting bolts torque to correct tightness? b) Is all housing and cap bolts torque to correct tightness. c) Is gearbox correctly alignment with other equipment. d) Is any excessive torque or overhung loads placed on gearbox.
TWO MONTHLY INTERVALS
Check oil for contamination.
SIX MONTH OR 2500 HOUR INTERVALS
Change oil in gearbox.
EXTENDED SHUTDOWN PERIODS
If it becomes necessary to shut down for a period longer than 25 weeks, the gearbox must be operated for at least 15 minutes during each week that it is idle.
This periodic operation will keep the gears and bearings coated with oil and will prevent rust due to condensation of moisture resulting from temperature changes.
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HOIST REDUCER
ASSEMBLY AND DISASSEMBLY PROCEDURES
ASSEMBLY PROCEDURES
CAUTION
Assembly should only be done by qualified personnel experienced with this type of machinery. Before starting work they should review the service manual and familiarize themselves with the assembly, parts list, and drawings. All safety precautions must be observed. Personal injury or equipment damage could result if these precautions are not observed.
TIPS FOR ASSEMBLY
Hoist of sufficient capacity to handle the parts must be available in the area where the unit will be assembled.
Slings should be used when handling machined parts. Clean up the area around the gearbox before assembly to keep parts clean. Sufficient space should be available to lay parts out in proper order for assembly.
Move gearbox to a clean prepared area for assembly when possible. Before starting assembly, carefully review assembly, parts lists, and drawings. Inspect the gearbox.
GEARBOX ASSEMBLY, (Drum Output Shaft) Page 2 of 5
GEARBOX ASSEMBLY, (Drum Pinion & Shaft) Page 3 of 5
GEARBOX ASSEMBLY, (Motor Pinion & Shaft) Page 4 of 5
GEARBOX ASSEMBLY, (Lid, Breather, Sight Gauge and Plug) Page 5 0f 5
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17
14
13
2
3
5
8
19
20
7
6
9
10
21
22
4
1
11
18
12
16
15
Fig. 6-1, Gearbox Assembly, (Drum Output Shaft)
1. Move Gearbox Housing (1) on a clean table for assembly.
2. Lower (2) Drum Gear in housing (1).
3. Insert (3) Keystock on (4) Output Shaft.
4. Align (4) Output Shaft with (2) Drum Gear in housing and slide through Drum Gear until it stops.
5. Install (5) Bearing on (4) Output Shaft.
6. Install (6) Seal in (8) Capsule.
7. Install (7) Shim on (8) Capsule.
8. Install (8) Capsule to (1) Housing.
9 Secure (8) Capsule to Housing (1) with (9) Soc.Hd. Cpscw and (10) Lockwasher.
10. Install (11) Drum Gear Spacer onto (4) Output Shaft.
11. Install (12) Bearing onto (4) Output Shaft.
12. Install (13) Shim onto (14) Capsule.
13. Install (14) Capsule onto (1) Housing.
14. Secure (14) Capsule to (1) Housing with (15) Soc Hd Cpscw and (16) Lockwasher.
15. Install (17) Bearing into (14) Capsule.
16. Install (18) Snap Ring onto (4) Output Shaft.
17. Install (19) Flex Hub onto (4) Output Shaft and (3) Keyway.
18. Install (20) Sleeve onto (19) Flex Hub.
19. Use (21) (22) to attach Sleeve to Drum.
Page 2 of 5
19
20
22
25
26
28
21
23
24
31
30
29
1
27
Fig. 6-2, Gearbox Assembly, (Drum Pinion & Shaft)
1. Lower (19) Motor Gear into (1) Housing.
2. Insert (20) Keystock on (21) Drum Pinion Shaft.
3. Insert (21) Drum Pinion Shaft____________________________
4. Insert (22) Bearing into (24) Capsule.
5. Install (23) Shim onto (24) Capsule.
6. Install (24) Capsule onto (1) Housing.
7. Secure (24) Capsule onto (1) Housing with (25) Soc. Hd. Cpscw and (26) Lockwasher.
8. Install (27) Bearing into (28) Capsule.
9. Install (29) Shim onto (28) Capsule.
10. Install (28) Capsule onto (1) Housing.
11. Secure (28) Capsule to (1) Housing with (30) Soc Hd Cpscw and (31) Lockwasher.
Page 3 of 5
37
34
35
36
38
33
41
40
1
32
42
39
Fig. 6-3, Gearbox Assembly, (Motor Pinion & Shaft)
1. Install (32) Motor Pinion & Shaft into (1) Housing.
2. Insert (33) Bearing into (34) Brake Adaptor/Capsule.
3. Insert (34) Brake Adaptor/Capsule onto (1) Housing.
4. Secure (34) Brake Adaptor/Capsule onto (1) Housing with (35) Soc. Hd. Cpscw & (36)
Lockwasher.
5. Install (37) Seal into (34) Brake Adaptor/Capsule.
6. Install (38) Bearing into (39) Brake Adaptor/Capsule.
7. Secure (39) Capsule onto (1) Housing
8. Secure (39) Capsule onto (1) Housing with (40) Soc. Hd. Cpscw and (41) Lockwasher.
9. Install (42) Seal into (39) Brake Adaptor/Capsule.
Page 4 of 5
44
45
43
49
48
47
1
46
Fig. 6-4, Gearbox Assembly, (Lid, Breather, Sight Gauge and Plug)
1. Set (43) Lid on top of (1) Housing (Match Lid Holes with Housing Holes).
(Before setting lid on housing put Silicone Sealant around holes and edge of lid)
2. Secure (43) Lid to (1) Housing with (44) Soc Hd Cpscw and (45) Lockwasher.
3. Install (46) Drain Plug into (1) Housing.
4. Install (47) Sight Gauge into (1) Housing.
5. Install (48) Pipe Elbow into (1) Housing.
6. Install (49) Breather onto (48) Pipe Elbow.
DISASSEMBLY PROCEDURES
To disassemble gearbox proceed as follows:
Hoists of sufficient capacity to handle the parts must be available in the area where the unit will be disassembled.
Slings should be used when handling machined parts. Clean up the area around the gearbox before disassembly to keep parts clean. Sufficient space should be available to lay parts out in proper order for assembly. Remember that parts are usually disassembled in reverse order of assembly. Provide wooden blocks or skids for storing machined parts to prevent damage to machined parts.
Page 5 of 5
ILLUSTRATED PARTS MANUAL
FOR
T-30 TERMINATOR
TABLE OF CONTENTS
FIGURE 1 - Structure Assembly
FIGURE 2 - Wheel and Drive Axle Assembly
FIGURE 3 - Wheel and Idler Axle Assembly
FIGURE 4 - Hoist Drum Assembly up to 20 Ton
FIGURE 4A - Hoist Drum Assembly 25 Ton
FIGURE 5 - Geared Limit Switch Installation
FIGURE 6 - Hoist Brake & Encoder Installation
FIGURE 7 - Hoist Motor & Reducer Installation
FIGURE 8 - Hoist Reducer Assembly
FIGURE 9 - Upper Limit Switch Installation
FIGURE 10 - 5 – 25 Ton Load Block Assemblies
FIGURE 11 - 5 – 25 Ton Top Sheave Assemblies
FIGURE 12 - Trolley Drive Installation
FIGURE 13 - Reeving Drawings
7
3
FIG. 1, STRUCTURE ASSEMBLY
10
11
12
2
6
13
2
4
5
8
9
1
8
9
10
11
12
13
ITEM QTY
1 1 GEARBOX HOUSING
2
3
DESCRIPTION
2 TROLLEY WHEEL MODULE
1 TROLLEY TAIL BEARING SIDE PLATE
4
5
6
7
1
12
12
12
TOP SHEAVE POCKET
BOLT, HX HD, 1”‐8 X 3 1/2" LG. A325
FLATWASHER, 1” (HARDENED)
NUT, HVY HX, 1”‐8 A325
4 BOLT, HX HD, 1/2"‐13 X 1 1/4" LG
4 LOCKWASHER, 1/2"
4 SPACER, 1/2 Sch. 40 Pipe ‐9‐1/2” Lg
4 ROD, Threaded, 1/2‐13 x 12 3/4" Lg.
8 NUT, Nyloc, Hex Hd, 1/2‐13
4 BUMPER, Size 80
6’ GAGE 8’ GAGE 10’ GAGE
ITEM 2 401898‐0000 401899‐0000 401900‐0000
PART NUMBER
100893‐0000
SEE TABLE
100916‐0000
401907‐0000
105604‐00
105605‐00
104037‐00
100404‐00
100612‐00
105032‐00
102545‐00
FIGURE 2, WHEEL AND DRIVE AXLE ASSEMBLY
3
2
4
6
7
8
11
1
12
9
4
3
5
DESCRIPTION
3 2 100048-00 Bearing
6
7
8
1
6
6
See chart below Axle, Drive
100416-00 Bolt, H x Hd, 5/8-11 x 1 1/4
100614-00 Washer, Lock, 5/8
10 1 100021-00 Fitting,
11 1 100019-00 Fitting,
12 2 102187-00 Seal
ITEM
6’ gage 8’ gage 10’ gage
6 100979-0000 100980-0000 100983-0000
5
10
FIGURE 3, WHEEL AND IDLER AXLE ASSEMBLY
5
1
2
4
3
9
6
8
7
DESCRIPTION
2 2 100048-00 Bearing
5
6
7
1
6
6
See chart below Axle, Idler
100416-00 Bolt, H x Hd, 5/8-11 x 1 1/4
100614-00 Washer, Lock 5/8
10 2 102187-00 Seal
ITEM
6’ gage 8’ gage 10’ gage
5 100981-0000 100982-0000 100984-0000
FIG. 4, HOIST DRUM ASSEMBLY UP TO 20 TON
1A
2
3
1
1B
1C
4
5
1D
1 1 See chart below Drum Assembly
1A 1 105077-00 RING,
DESCRIPTION
1C
1D
4
4
100612-00
100408-00
WASHER, Lock, 1/2
BOLT, Hx Hd, 1/2–13 x 2” Lg
2 1 105657-00 BEARING
4
5
4
4
100614-00
100125-00
WASHER, Lock, 5/8
BOLT, Hx Hd, 5/8-11 x 1-1/2” Lg
ITEM 6’ Gage 8’ Gage
1 200185-0000
10’ Gage
200187-0000
FIG. 4A, HOIST DRUM ASSEMBLY 25 TON
1A
2
3
1
1B
1C
4
5
1D
1 1 See chart below Drum Assembly
1A 1 105077-00 RING,
DESCRIPTION
1C
1D
4
4
100612-00
100408-00
WASHER, Lock, 1/2
BOLT, Hx Hd, 1/2–13 x 2” Lg
2 1 105657-00 BEARING
4
5
4
4
100614-00
100125-00
WASHER, Lock, 5/8
BOLT, Hx Hd, 5/8-11 x 1-1/2” Lg
ITEM 6’ Gage 8’ Gage
1 109321-0000
10’ Gage
200205-0000
FIG. 5, GEAR LIMIT SWITCH INSTALLATION
1
3
2
4
11 10
9
6
7
8
ITEM QTY PART NUMBER
1
2
3
1
1
1
100627‐00
104354‐00
FLATWASHER, 1/2
NUT, Hx Hd, 1/2‐20
STUD, 1/2 x 2 1/4 Lg
4
4A
4B
5
6
7
1
1
1
1
2
2
100026‐00
106233‐00
100722‐00
106218‐0000
102416‐00
101737‐00
DESCRIPTION
COUPLING, Lovjoy, Half, 1/2" ID
COUPLING, Lovjoy, Half
COUPLING, Bushing
SWITCH, Limit
SCREW, #12‐24 x 2” Lg.
LOCKWASHER, #12
8
9
10
11
2
1
2
2
104570‐00 NUT, Hx, #12‐24
106221‐00 MOUNT BRACKET, Gear Switch
100007‐00 BOLT, Hx Hd., 1/4‐20 x 3/4 Lg.
100609‐00 LOCKWASHER, 1/4
5
Motor Trouble-Shooting Chart
Caution:
1. Disconnect power to the motor before performing service or maintenance.
2. Discharge all capacitors before servicing motor.
3. Always keep hands and clothing away from moving parts.
4. Be sure required safety guards are in place before starting equipment.
Problem:
Motor fails to start upon initial installation.
Motor has been running, then fails to start.
Motor runs but dies down.
Like Causes:
Motor is miswired.
Motor damaged and rotor is striking stator.
Fan guard bent and contacting fan.
Fuse or circuit breaker tripped.
Stator is shorted or went to ground. Motor will make a humming noise and the circuit breaker or fuse will trip.
Motor overloaded or load jammed.
Capacitor (on single phase motor) may have failed.
Starting switch has failed.
Voltage drop.
Load increased.
Motor takes too long to accelerate.
Defective capacitor
Faulty stationary switch.
Bad bearings.
Voltage too low.
Motor runs in the wrong direction.
Motor overload protector continually trips.
Incorrect wiring.
Load too high.
Ambient temperature too high.
Protector may be defective.
Winding shorted or grounded.
What To Do:
Verify motor is wired correctly.
May be able to reassemble; otherwise, motor should be replaced.
Replace fan guard.
Replace fuse or reset the breaker.
Disassemble motor and inspect windings and internal connections.
A blown stator will show a burn mark. Motor must be replaced or the stator rewound.
Inspect to see that the load is free. Verify amp draw of motor versus nameplate rating.
First discharge capacitor. To check capacitor, set volt-ohm meter to
RX100 scale and touch its probes to capacitor terminals. If capacitor is OK, needle will jump to zero ohms, and drift back to high. Steady zero ohms indicates a short circuit; steady high ohms indicates an open circuit.
Disassemble motor and inspect both the centrifugal and stationary switches. The weights of the centrifugal switch should move in and out freely. Make sure that the switch is not loose on the shaft.
Inspect contacts and connections on the stationary switch.
Replace switch if the contacts are burned or pitted.
If voltage is less than 10% of the motor’s rating contact power company or check if some other equipment is taking power away from the motor.
Verify the load has not changed. Verify equipment hasn’t got tighter. If fan application verify the air flow hasn’t changed.
Test capacitor per previous instructions.
Inspect switch contacts and connections. Verify that switch reeds have some spring in them.
Noisy or rough feeling bearings should be replaced.
Make sure that the voltage is within 10% of the motor’s nameplate rating. If not, contact power company or check if some other equipment is taking power away from the motor.
Rewire motor according to wiring schematic provided.
Verify that the load is not jammed. If motor is a replacement, verify that the rating is the same as the old motor. If previous motor was a special design, a stock motor may not be able to duplicate the performance. Remove the load from the motor and inspect the amp draw of the motor unloaded. It should be less than the full load rating stamped on the nameplate.
Verify that the motor is getting enough air for proper cooling. Most motors are designed to run in an ambient temperature of less than
40°C. (Note: A properly operating motor may be hot to the touch.)
Replace the motor’s protector with a new one of the same rating.
Inspect stator for defects, or loose or cut wires that may cause it to go to ground.
Motor Trouble-Shooting Chart
10/13/00 (continued)
Problem:
Motor vibrates.
Bearings continuously fail.
The motor, at start up, makes a loud rubbing or grinding noise.
Start capacitors continuously fail.
Run capacitor fail.
Like Causes:
Motor misaligned to load.
Load out of balance.
(Direct drive application.)
Motor bearings defective.
Rotor out of balance.
Motor may have too much endplay.
Winding may be defective.
Load to motor may be excessive or unbalanced.
High ambient temperature.
Rotor may be striking stator.
What To Do:
Realign load.
Remove motor from load and inspect motor by itself. Verify that motor shaft is not bent. Rule of thumb is .001" runout per every inch of shaft length.
Test motor by itself. If bearings are bad, you will hear noise or feel roughness. Replace bearings. Add oil if a sleeve of bearing.
Add grease if bearings have grease fittings.
Inspect motor by itself with no load attached. If it feels rough and vibrates but the bearings are good, it may be that the rotor was improperly balanced at the factory. Rotor must be replaced or rebalanced.
With the motor disconnected from power turned shaft. It should move but with some resistance. If the shaft moves in and out too freely, this may indicate a preload problem and the bearings may need additional shimming.
Test winding for shorted or open circuits. The amps may also be high. Replace motor or have stator rewound.
Besides checking load, also inspect drive belt tension to ensure it’s not too tight may be too high. An unbalanced load will also cause the bearings to fail.
If the motor is used in a high ambient, a different type of bearing grease may be required. You may need to consult the factory or a bearing distributor.
Ensure that motor was not damaged in shipment. Frame damage may not be repairable. If you cannot see physical damage, inspect the motor’s rotor and stator for strike marks. If signs of rubbing are present, the motor should be replaced. Sometimes simply disassembling and reassembling motor eliminates rubbing.
Endbells are also sometimes knocked out of alignment during transportation.
The motor is not coming up to speed quickly enough.
The motor is being cycled too frequently.
Voltage to motor is too low.
Motor may not be sized properly. Verify how long the motor takes to come up to speed, Most single phase capacitor start motors should come up to speed within three seconds. Otherwise the capacitors may fail.
Verify duty cycle. Capacitor manufacturers recommend no more than 20, three-second starts per hour. Install capacitor with higher voltage rating, or add bleed resistor to the capacitor.
Verify that voltage to the motor is within 10% of the nameplate value. If the motor is rated 208-230V, the deviation must be calculated from 230V.
Replace switch.
Starting switch may be defective, preventing the motor from coming out of start winding.
Ambient temperature too high.
Possible power surge to motor, caused by lightning strike or other high transient voltage.
Verify that ambient does not exceed motor’s nameplate value.
If a common problem, install surge protector.
Bulletin 2400 10/00
Lubrication Instructions
For Ball Bearing Motors
Lubrication
This motor is supplied with pre-lubrication ball bearings. No lubrication required before start up.
Relubrication Intervals
The following intervals are suggested as a guide:
SUGGESTED RELUBRICATION INTERVALS
HOURS OF SERVICE PER YEAR
5,000
Continuous Normal Applications
Season Service Motor
Idle 6 Months or More
Continuous High Ambients
Dirty or Moist Locations
High Vibrations
Where Shaft End is Hot (Pumps-Fans)
H.P. RANGE
Sub Fractional to 7 1/2
10 to 40
50-200
Sub Fractional to 7 1/2
10 to 40
50 to 200
All
Sub Fractional to 40
50 to 200
RELUBE INTERVAL
5 Years
3 Years
1 Year
2 Years
1 Year
9 Months
1 Year
(Beginning of Season)
6 Months
3 Months
Lubrication
Use high quality ball bearing lubricant. Use consistency of lubricant suitable for class of insulation stamped on nameplate as follows:
INSULATION
CLASS
B & F
F & H
LUBRICATION CONSISTENCY
CONSISTENCY
TYPE
TYPICAL
LUBRICATION
Medium Polyurea
Shell Dolium R and/or
Chevron SR1 2
FRAME
TYPE
Sub Fractional to 447T
All
Procedure
If motor is equipped with Alemite fitting, clean tip of fitting and apply grease gun. Use 1 to 2 full strokes on motors in NEMA 215T frame and smaller. Use 2 to 3 strokes on NEMA 254T thru NEMA 365 T frame. Use 3 to 4 strokes on NEMA 404T frames and larger. On motors having drain plugs, remove drain plug and operate motor for 20 minutes before replacing drain plug.
On motors equipped with slotted head grease screw, remove screw and apply grease tube to hole. Insert 2 to
3 inch length of grease string into each hole on motors in NEMA 215T frame and smaller. Insert 3 to 5 inch length on larger motors. For motors having drain plug and operate motor for 20 minutes before replacing drain plug.
CAUTION:
Keep lubricant clean. Lubricate motors at standstill. remove and replace drain plugs at standstill. Do not mix petroleum lubricant and silicone lubricant in motor bearings.
300-088.02
Installation Maintenance Instructions
AC Induction Motors
Installation
After unpacking, check for damage. Be sure that shaft rotates freely. Before making electrical power connections, check for proper grounding of motor and application. All electrical contacts and connections must be properly insulated and enclosed. Couplings, belts, chains or other mounted devices must be in proper alignment, balance and secure to insure safe motor operation.
Electrical Wiring
Prior to connecting to the power line, check nameplate for proper voltage and rotation connection. This motor should be installed in compliance with the National Electrical Code and any other applicable codes. Voltage at motor not to exceed + or -10% of nameplate. Authorized person should make all electrical connections.
Mounting
This motor should be securely mounted to the application. Sufficient ventilation area should be provided to insure proper operation.
25
25
30
30
40
10
15
15
20
20
40
50
50
60
60
75
75
H.P.
1 1/2
1 1/2
2
2
3
3
5
5
7 1/2
7 1/2
10
H.P.
1 1/2
2
3
5
7 1/2
RECOMMENDED COPPER WIRE & TRANSFORMER SIZE
SINGLE PHASE MOTORS - 230 VOLTS
TRANSFORMER
KVA
100
DISTANCE - MOTOR TO TRANSF. IN FT.
150 200 300
3
3
5
7 1/2
10
10
10
8
6
6
8
8
8
4
4
8
8
6
4
3
6
6
4
2
1
500
4
4
2
0
0
460
230
460
230
460
230
460
230
460
230
VOLTS
230
460
230
460
230
460
230
460
230
460
230
460
230
460
230
460
230
460
THREE PHASE MOTORS - 230 & 460 VOLTS
TRANSFORMER
KVA
3
3
3
3
5
5
7
1/2
7 1/2
10
10
15
15
20
20
Consult
Local
Power
Company
DISTANCE - MOTOR TO TRANSF. IN FT.
100
150 200 300 500
12
12
12
12
12
12
12
12
12
12
12
10
10
12
8
12
12
12
10
12
12
10
12
12
8
12
12
6
10 12
10
12
8
12
6
12
4
12
4
10
2
8
2
8
1
6
1
4
1
4
0
4
8
12
6
12
4
12
4
10
2
8
2
8
1
6
0
6
0
4
00
2
000
2
8
12
6
12
4
12
4
10
2
8
2
6
1
6
00
4
00
2
000
2
0000
0
6
10
4
10
4
10
2
8
1
6
0
6
00
4
0000
2
0000
2
250
0
300
00
4
8
2
8
1
8
0
6
000
4
000
4
0000
2
300
0
300
0
500
00
500
000
M F 2 C R o t a r y L i m i t S w i t c h
Conformity to Community Directives
Conformity to Standards
Ambient temperature
Protection degree
Insulation category
Cable entry
Homologations
*UL – (c) UL limit switches available on request.
T
ECHNICAL
S
PECIFICATIONS
73/23/CEE 93/68/CEE
EN 60204-1 EN60947-1 EN 60947-5-1
EN 60529 EN 50013 IEC 536
Storage -40 °C / +70 °C
Operational -25 °C / +70 °C
IP 65
Class II
Cable clamp PG 9
CE - UL - (c)UL*
T
ECHNICAL
S
PECIFICATIONS OF THE
S
WITCHES
Utilisation category
Rated operational current
Rated operational voltage
Rated thermal current
Rated insulation voltage
Mechanical life
Terminal referencing
Connections
Homologations
AC 15
3 A
250 V
10 A
300 V ~
1 x 10 6 operations
According to EN 50013
6.3 mm Faston taps
CE - UL - (c)UL
O
VERALL
D
IMENSIONS
3
4
M F 2 C R o t a r y L i m i t S w i t c h
42
41
31
32
33
34
35
40
39
38
37
36
D
ETAILED
D
RAWING
19
20
23
28
27
24
25
26
21
22
29
18
13
14
15
16
17
1
2
3
4
5
6
7
8
9
10
11
12
31
30
M F 2 C R o t a r y L i m i t S w i t c h
7
8
25
30
32
35
37
41
D
RAWING
C
ODE
PRSL0040XX
PRSL7140PI
PRSL7141PI
PRSL7142PI
PRSL7143PI
PRSL7144PI
PRSL6600PI
PRSL6601PI
PRSL6602PI
PRSL6603PI
PRSL6604PI
PRSL6605PI
PRSL6606PI
PRSL6607PI
PRSL6608PI
PRSL6609PI
PRSL6611PI
PRSL6612PI
PRSL6613PI
PRSL6614PI
PRSL6615PI
PRSL0919PI
PRSL0920PI
PRTO0063PE
PRTO0075PE
PRSL6701PI
PRSL0911PI
PRSL0912PI
PRSL0913PI
PRSL0914PI
PRSL0915PI
PRSL0916PI
PRSL0917PI
PRSL0918PI
D
ESCRIPTION
Snap action switch
Pointed cam
Sector cam
10 point cam
Circular cam
180° cam
Lateral gear wheel Z 36
Lateral gear wheel Z 38
Lateral gear wheel Z 40
Lateral gear wheel Z 42
Lateral gear wheel Z 44
Lateral gear wheel Z 46
Lateral gear wheel Z 48
Lateral gear wheel Z 50
Lateral gear wheel Z 52
Lateral gear wheel Z 54
Lateral gear wheel Z 56
Lateral gear wheel Z 58
Lateral gear wheel Z 60
Lateral gear wheel Z 62
Lateral gear wheel Z 64
Male coupling + pin (31)
Female coupling + pin (31)
Single-thread worm shaft
Flexible shaft
Central gear wheel Z 50
Pinion gear M10 Z12 + pin (42)
Pinion gear M12 Z10 + pin (42)
Pinion gear M14 Z10 + pin (42)
Pinion gear M16 Z10 + pin (42)
Pinion gear M20 Z8 + pin (42)
Pinion gear M5 Z12 + pin (42)
Pinion gear M6 Z11 + pin (42)
Pinion gear M8 Z12 + pin (42)
5
M F 2 C R o t a r y L i m i t S w i t c h
6
REVOLUTION RATIO
1:15
1:25
1:50
1:75
1:100
1:150
2 switches
PF0901 0015 0003
PF0901 0025 0005
PF0901 0050 0005
PF0901 0075 0004
PF0901 0100 0005
PF0901 0150 0003
S
TANDARD
L
IMIT
S
WITCHES
CODE
3 switches
PF0901 0015 0004
PF0901 0025 0006
PF0901 0050 0012
PF0901 0075 0005
PF0901 0100 0007
PF0901 0150 0004
Standard limit switches are equipped with 2 or 3 snap action switches and with pointed cams PRSL7140PI.
Other patterns and revolution ratios are available on request. Maximum revolution ratio 1:150.
U
SE AND
M
AINTENANCE
I
NSTRUCTIONS
The MF2C rotary limit switch is an electromechanical device for low voltage control circuits (EN 60947-1, EN 60947-5-1) to be used as electrical equipment on machines (EN 60204-1) in compliance with the fundamental requirements of the Low Voltage Directive 73/23/CEE and of the Machine
Directive 89/392/CEE.
The limit switch is designed for industrial use and also for use under particularly severe climatic conditions (operational temperature from
–25 °C to +70 °C, suitable for use in tropical environment). The equipment is not suitable for use in environments with potentially explosive atmosphere, corrosive agents or a high percentage of sodium chloride (saline fog).
Oils, acids or solvents may damage the equipment. Use the fixing holes on the base (29) to mount the limit switch. The use of special couplings (30, 32), flexible shafts or special driving systems (not supplied) are recommended for eliminating any misalignment between the limit switch shaft (35) and the reduction gear shaft to which it is connected. After loosening the central screw (04) use the screws (09, 12, 13) to adjust the operating point of the cams (08); once the cams are adjusted, tighten the central screw (04).
The switches (07) are designed for auxiliary control of contactors or electromagnetic loads (utilisation category AC-15 according to EN 60947-5-1).
The switches (07) have positive opening operation contacts (EN 60947-5-1).
Do not connect more than one phase to each switch (07). Do not oil or grease the control elements (08) or the switches (07). For easy wiring, the set of cams-switches (22) may be removed by loosening the screws (18) on the lower fixing plate; do not loosen the screws on the upper part of the set of cams-switches (01) in order not to take apart the switches; after wiring is completed, the set of cams-switches (22) must be properly fixed and screwed, paying attention to the coupling of the hexagonal plastic bushes (14, 39).
The installation of the limit switch shall be carried out by an expert and trained personnel. Wiring shall be properly done according to the current instructions.
Prior to the installation and the maintenance of the limit switch, the main power of the machinery shall be turned off.
Steps for the proper installation of the limit switch
• loosen the fixing screw (19) and remove the cover (20)
• connect the limit switch shaft (35) to the reduction gear shaft; to avoid any misalignment between the two shafts the use of couplings (30, 32), flexible shafts or special driving systems is recommended
• fix the limit switch firmly in place to prevent abnormal vibrations of the equipment during operation; use only the fixing holes on the base (29) to fix the equipment
• insert the cable into the limit switch through the cable clamp (27)
• strip the cable to a length suitable for wiring the switches (07)
• tape the stripped part of the cable
• clamp the wire into the cable clamp (27)
• connect all the switches (07) according to the contact scheme printed on the switches (use 6.3 mm Faston taps)
• adjust the operating point of the cams (08); for proper adjustment, loosen the central screw (04) of the cam set, adjust the operating point of each single cam (08) by turning its screw (09, 12, 13) (the numbers on the screws refer to the cams counting from bottom to top), then tighten the central screw (04)
• close the limit switch checking the proper positioning of the rubber (21) in the cover (20)
Periodic maintenance steps
• check the proper tightening of the screws (19) and cover (20)
• check the proper tightening of the central screw (04) holding the cams
• check the wiring conditions (in particular where wires clamp into the switch)
• check the proper positioning of the front (33) and rear (28) bush covers
• check the conditions of the rubber (21) fit between the cover (20) and the base (29) and check the tightening of the cable clamp (27) around the cable
• check that the limit switch enclosure (20, 29) is not broken
• check the alignment between the limit switch shaft (35) and the reduction gear shaft
• check that the limit switch is properly fixed
In case any component of the limit switch is modified, the validity of the markings and the guarantee on the equipment are annulled. Should any component need replacement, use original spare parts only.
TER declines all responsibility for damages caused by the improper use or installation of the equipment.
M F 2 C R o t a r y L i m i t S w i t c h
Request form for non standard limit switches
Cams
1
PRSL7140PI
2
PRSL7141PI
3
PRSL7142PI
4
PRSL7143PI
5
PRSL7144PI
Cover
Standard shaft Flexible shaft
Cams
Pinion gears
1
PRSL0911PI M10 Z12
2
PRSL0912PI M12 Z10
3
PRSL0913PI M14 Z10
4
PRSL0914PI M16 Z10
5
PRSL0915PI M20 Z8
6
PRSL0916PI M5 Z12
7
PRSL0917PI M6 Z11
8
PRSL0918PI M8 Z12
Instructions
• Mark the box corresponding to the components required.
• Write the number corresponding to the cams required and to the pinion
gear when required.
• Write the revolution ratio required.
Cams
Pinion gear
Revolution ratio
Remarks_____________________________________________________________________________________________________________
____________________________________________________________________________________________________________________
____________________________________________________________________________________________________________________
____________________________________________________________________________________________________________________
4
1
FIGURE 6, HOIST BRAKE & ENCODER INSTALLATION T30
3
2
1
2
3
4
1
1
6
1
202317-00
717339-00 Encoder
DESCRIPTION
Hoist Brake Installation
105396-00 BOLT, Hx Hd, 3/8-16 x 1-1/4” Lg
100974-0000 Spacer
*
*Fluid level in picture above is correct for standard motor RPM's.
Please see the following page of correspondence for correct fluid levels of motors operating at higher than normal RPM's (2700-3600 RPM's).
Friction Products & Power Transmissions for Industry
April 26, 2011
Ace World Companies
10200 Jacksboro Hwy
Fort Worth, TX 76135
Subject: Electro Shear Oil Levels for 2700 – 3600 RPM’s
AWC, thank you for your interest in oil level parameters in applications operating at higher rpm’s than your standard 1800 RPM’s. The operation of Electro Shear brakes incorporates the oil shear technology – which allows for shearing of the oil to generate torque , as well as the cooling and lubrication of discs , which allows any heat build up to dissipate through the cast aluminum housing.
The following has been the standard oil levels for the brakes we have furnished you, using your standard 1800 RPM’s:
Electro Shear Model 8725 w/ full disc stack: oil level is 1.5 “ above the centerline.
Electro Shear Model 8727 w/ full disc stack: oil level is @ centerline.
Based upon our ‘typical application history ‘the following oil levels should be maintained when running 2700 – 3600 RPM’s:
Electro Shear Model 8725 w/ full disc stack: oil level should be @ 1.5 “ below centerline.
Electro Shear Model 8727 w/ full disc stack: oil level should be @ 1.5 “ below centerline.
Electro Shear Brake temperatures are a key measuring point of operation: Temperatures should not exceed 200 degrees F; with an optimum high temperature of 180 degrees F.
Cordially,
Midwest Brake
2 6 2 5 5 G r o e s b e c k H i g h w a y
W a r r e n Mi c h i g a n 4 8 0 8 9
5 8 6 7 7 5 - 3 0 0 0
F a x : 5 8 6 7 7 5 - 3 0 4 0
w w w . m i d we s t b r a k e . c o m
s a l e s @ m i d we s t b r a k e . c o m
*
*incorrect fluid level. see the preceding page of correspondence.
Kübler by TURCK
Incremental Encoders
3.5" (T8.A020) Large Bore Incremental Hollow Shaft Encoder Part Number Key
Flange
1 = Face mount
2 = Short anti-rotational spring
3 = Long anti-rotational spring
5 = Tether arm (long)
Bore Dimensions
1 =
∅42 mm
2 =
∅38 mm
3 =
∅28 mm
4 =
∅1.0”
5 =
∅25 mm
6 =
∅24 mm
A =
∅30 mm
B =
∅40 mm
C =
∅20 mm
D =
∅1/2“
T8. A020. X X X X.
XXXX PXX XX
Special Connector Wiring Formats
See page F5
Special Output Signal Formats
See page A7
Pulse Rate (PPR)
See below
Connection Type
1 = Radial cable (PVC, 1 meter)
2 = Radial 12-pin, M23 (multifast
®
)
D = Radial MS, 10-pin
(MS 3102R18-1P)
E = Radial 8-pin, M12 (eurofast
®
)
K = Radial MS, 7-pin (MS 3102R165-1P)
Input/Output Circuit
1 = 5 VDC / TTL (26C31)
3 = 10-30 VDC / Push-Pull (IC-WE)
4 = 10-30 VDC / TTL (26C31) w/5 VDC regulator
8 = 5 VDC / 1 Vpp Sine Wave
9 = 10-30 VDC / 1 Vpp Sine Wave
A = 5-30 VDC / Line Driver (7272)
B = 5-30 VDC / Open Collector (7273)
E = 5-30 VDC, 7272 (TTL)
3.5" (T8.A02H) Vector Motor Incremental Hollow Shaft Encoder Part Number Key
T8. A02H. X X X X.
XXXX PXX X X
Flange
1 = Face mount
2 = Short anti-rotational spring
3 = Long anti-rotational spring
5 = Tether arm (long)
6 = 4.5 inch C-face tether
Bore Dimension
1 =
∅42 mm
2 =
∅38 mm
3 =
∅28 mm
†
†
4 =
∅1.0”
5 =
∅25 mm
6 =
∅24 mm
†
A =
∅30 mm
B =
∅40 mm
†
C =
∅20 mm
D =
∅1/2“
†
E =
∅5/8“
†
F =
∅3/4“
†
G =
∅1-1/8“
†
N =
∅1-1/4“
†
P = 32 mm-***
Input / Output Circuit
1 = 5 VDC / TTL (26C31)
3 = 10-30 VDC / Push-Pull (IC-WE)
4 = 10-30 VDC / TTL (26C31)
8 = 5 VDC / 1 Vpp Sine Wave
9 = 10-30 VDC / 1 Vpp Sine Wave
A = 5-30 VDC / Line Driver (7272)
B = 5-30 VDC / Open Collector (7273)
D = 5-30 VDC / TTL (26C31)
E = 5-30 VDC / TTL Line Driver (7272)
Special Connector Wiring Format
0 = Standard wiring
Other = See page F5
Special Insert Options
B = Isolation insert included**
A = Isolation insert not included
Special Output Signal Formats
See page A7
Pulse Rate (PPR)
See below
Connection Type
1 = Radial cable (PVC, 1 meter)
2 = Radial 12-pin, M23 (multifast)
D = Radial MS, 10-pin
(MS 3102R18-1P)
E = Radial 8-pin, M12 (eurofast)
K = Radial MS, 7-pin
(MS 3102R165-1P)
** Includes plastic hub inserts for electrical isolation.
† Bores available with isolation inserts.
*** This bore size only available as an isolation insert.
Pulse Rates (PPR):
50, 100, 360, 512, 600, 1000, 1024, 1500, 2000, 2048, 2500, 4096, 5000.
F2
TURCK Inc. 3000 Campus Drive Minneapolis, MN 55441 Application Support: 1-800-544-7769 Fax: (763) 553-0708 www.turck.com
Kübler by TURCK
Incremental Encoders
3.5" (T8.A02H) Vector Motor Incremental Specifications
Mechanical:
Protection Rating . . . . . . . . . . . . . IP 64
Speed . . . . . . . . . . . . . . . . . . . 6000 RPM for continuous duty cycle
Operating Temperature . . . . . . . . . -20°C to +85°C (-4°F to +177°F) to 3600 RPM
. . . . . . . . . . . . . . . . . . . . . .
-20°C to +75°C (-4°F to +167°F) to 6000 RPM
Shock/Vibration . . . . . . . . . . . . . 2000 m/s
2
, (6 ms) per DIN-IEC 68-2-27 / 100 m/s
2
(10-2000 Hz) per IEC 68-2-6
Humidity . . . . . . . . . . . . . . . . . 98% relative humidity without condensing
Housing/Shaft . . . . . . . . . . . . . . Aluminum, with epoxy powder coat / 316 stainless
Starting Torque. . . . . . . . . . . . . . 28.32 oz.in. (<0.2 Nm)
Hub Bore Tolerance . . . . . . . . . . . H7
Electrical:
Input/Output . . . . . . . . . . . . . . . . . . . . . 5 VDC/TTL (26C31). . . . . . . . . . . . . 5-30 VDC/Line Driver (7272)
Power Consumption . . . . . . . . . . . . . . . . . 90 mA . . . . . . . . . . . . . . . . . . . 100 mA
Short-circuit Protection (DIN-IEC 68-2-27) . . . . . Yes
1)
. . . . . . . . . . . . . . . . . . . . . Yes
Reverse Polarity Protection . . . . . . . . . . . . . No . . . . . . . . . . . . . . . . . . . . . Yes
Operating Frequency (max.) . . . . . . . . . . . . . 300 kHz. . . . . . . . . . . . . . . . . . . 300 kHz
Permissible Load per Channel . . . . . . . . . . . . ±20 mA . . . . . . . . . . . . . . . . . . ±20 mA
Signal Level High (min.) . . . . . . . . . . . . . . . 2.5 V . . . . . . . . . . . . . . . . . . . . +V -2 V
Signal Level Low (max.) . . . . . . . . . . . . . . . 0.5 V . . . . . . . . . . . . . . . . . . . . 0.5 V
Input/Output . . . . . . . . . . . . . . . . . . . . . 5-30 VDC/Open Collector (7273) . . . . . 10-30 VDC/Push-Pull (IC-WE)
Power Consumption . . . . . . . . . . . . . . . . . 150 mA . . . . . . . . . . . . . . . . . . . 150 mA
Short-circuit Protection (DIN-IEC 68-2-27) . . . . . Yes . . . . . . . . . . . . . . . . . . . . . Yes
Reverse Polarity Protection . . . . . . . . . . . . . No . . . . . . . . . . . . . . . . . . . . . Yes
Operating Frequency (max.) . . . . . . . . . . . . . 300 kHz . . . . . . . . . . . . . . . . . . . 300 kHz
Permissible Load per Channel . . . . . . . . . . . . 20 mA sink @ 30 VDC . . . . . . . . . . . ±30 mA
Signal Level High (min.) . . . . . . . . . . . . . . . 2.5 V . . . . . . . . . . . . . . . . . . . . +V -3 V
Signal Level Low (max.) . . . . . . . . . . . . . . . 0.5 V . . . . . . . . . . . . . . . . . . . . 2.5 V
Input/Output . . . . . . . . . . . . . . . . . . . . . 10-30 VDC/TTL (26C31) . . . . 5 VDC/SIN/COS . . . . 10-30 VDC/SIN/COS
Power Consumption . . . . . . . . . . . . . . . . . 90 mA. . . . . . . . . . . . . . 110 mA . . . . . . . . . 110 mA
Short-circuit Protection (DIN-IEC 68-2-27) . . . . . Yes
1)
. . . . . . . . . . . . . . . Yes . . . . . . . . . . . Yes
Reverse Polarity Protection . . . . . . . . . . . . . Yes . . . . . . . . . . . . . . . No. . . . . . . . . . . . Yes
Operating Frequency (max.) . . . . . . . . . . . . . 300 kHz . . . . . . . . . . . . 180 kHz . . . . . . . . . 180 kHz
Permissible Load per Channel . . . . . . . . . . . . ±20 mA. . . . . . . . . . . . . N/A . . . . . . . . . . . N/A
Signal Level High (min.) . . . . . . . . . . . . . . . 2.5 V . . . . . . . . . . . . . . 1 VSS (±20%) . . . . . . 1 VSS (±20%)
Signal Level Low (max.) . . . . . . . . . . . . . . . 0.5 V . . . . . . . . . . . . . . 0.1-1.2 V . . . . . . . . 0.1-1.2 V
1)
Only one channel at a time:
(when +V = 5 VDC, short-circuit to common, or +V is permitted)
(when +V = 10-30 VDC, short-circuit to common is permitted)
F4
TURCK Inc. 3000 Campus Drive Minneapolis, MN 55441 Application Support: 1-800-544-7769 Fax: (763) 553-0708 www.turck.com
Industrial
Automation
3.5" (T8.A02X) Incremental Encoder Wiring Configurations
Cable direction for right angle M12 cordset is parallel to Hollow Shaft.
Standard Wiring / Pin Configuration
Output
M23 multifast
®
MS 7- pin
MS 10-pin
M12 eurofast
®
Cable
Case Ground Common +V A
Coupling Nut 10 12 5
G
J
Coupling Nut
Shield / Drain
F
F
1
WH
D
D
A
A
A
6
-
G
B
8
B
B
B
1
-
H
Z
3
C
C
Z
4
I
-
-
-
-
-
2 3 4 5 6 7 8 -
BN GN YE GY PK BU RD BK VT
-
-
-
-
Special Connector Pin Configuration
Connection Type Case Ground Common
07 M12 eurofast Coupling Nut 7
02 MS 7-pin G F
06 MS 10-pin G F
+V
2
D
D
A
1
A
A
A
3
C
H
B
4
B
B
B
5
E
I
Z
6
-
C
Z
8
-
J
Male Encoder View
M12 Pinout
Mating Cordset
E-RKC 8T-264-*
M23 Pinout (12-Pin)
E-CKS 12-931-*
Male Encoder View
MS Pinout (7-Pin)
Mating Cordset
E-MK 7-930-*
MS Pinout (10-Pin)
E-MK 10-931-*
TURCK Inc. 3000 Campus Drive Minneapolis, MN 55441 Application Support: 1-800-544-7769 Fax: (763) 553-0708 www.turck.com
F5
Kübler by TURCK
Incremental Encoders
3.5" (T8.A020) Incremental Hollow Shaft Encoder Dimensions
T8.A020 with Flange
1 = Face Mount
2 = Short Anti-rotation Spring
3 = Long Anti-rotation Spring
5 = Tether Arm (long)
Dimension for Radial Connector - Inches (mm)
DIM
A
B
Cable
1.181 (30.0)
- - - -
M12
Connection Style
M23 MS (7-pin) MS (10-pin)
1.181 (30.0) 1.181 (30.0) 1.457 (37.0) 1.457 (37.0)
4.705 (119.5) 4.961 (126.0) 5.079 (129.0) 5.394 (137.0)
F6
TURCK Inc. 3000 Campus Drive Minneapolis, MN 55441 Application Support: 1-800-544-7769 Fax: (763) 553-0708 www.turck.com
Industrial
Automation
3.5" (T8.A02H) Incremental Hollow Shaft Encoder Dimensions
T8.A02H with Flange
1 = Face Mount
2 = Short Anti-rotation Spring
3 = Long Anti-rotation Spring
5 = Tether Arm (long)
Mating Shaft Requirements
Type of Flange Axial End Play
Type 2 (Anti-rotational spring short) max. ±1 mm
Type 3 (Anti-rotational spring long) max. ±1 mm
Type 5 (Tether arm long)
Type 6 (C-face tether) max. ±0.5 mm max. ±0.5 mm
Radial Runout Angular Offset max. ±0.3 mm max. ±2° max. ±0.3 mm max. ±2° max. ±0.3 mm max. ±0.3 mm max. ±2° max. ±2°
The A02H encoder is used for AC Vector motor and general industrial applications. For AC Vector motor applications, the encoder should be electrically isolated from the motor chassis to minimize encoder bearing currents and ground noise. An isolation insert for the hub is provided with the encoder by specifying B0 in the "special insert option" decode. When ordering isolation inserts separately, choose option A0 with a bore diameter of 38 mm.
For general industrial applications, isolation is not required and the decode for "special insert options" can be left blank.
Part Number
8.0010.4070.0000
8.0010.4090.0000
8.0010.4050.0000
8.0010.4014.0000
8.0010.4060.0000
8.0010.4011.0000
8.0010.4012.0000
8.0010.4016.0000
8.0010.4015.0000
Isolation Inserts
Inner Dimension Outer Dimension
15.875 mm (5/8")
19.05 mm (3/4")
25.4 mm (1")
28.58 mm (1-1/8")
38 mm
38 mm
38 mm
38 mm
31.75 mm (1-1/4")
20 mm
25 mm
30 mm
32 mm
38 mm
38 mm
38 mm
38 mm
38 mm
TURCK Inc. 3000 Campus Drive Minneapolis, MN 55441 Application Support: 1-800-544-7769 Fax: (763) 553-0708 www.turck.com
F7
Kübler by TURCK
Incremental Encoders
Flex Brackets (T8.A02X)
Part Number
8.0010.4E00.0000
Description
Tether arm (long) for A020 and A02H
(3) M4x5 mm screws
8.0010.4L00.0000
Tether arm (long) for A020 and A02H
8.0010.4M00.0000
8.0010.4T00.0000
Tether arm (long) for A020
4.5" C-Face Tether for A02H
(3) M4x5 mm screws
(1) 1/4-20 x 1/0" bolt
(3) 1/4-20 nuts
(3) M4x5 mm screws
(1) 3/8-16 x 1/0" bolt
(3) 3/8-16 nuts
(3) M4x5 mm screws
(1) 3/8-16 x 1/0" bolt
(3) 3/8-16 nuts
Includes
(1) Nylon step washer
(1) Nylon mating washer
(1) Nylon step washer
(1) Nylon mating washer
(1) Nylon step washer
(1) Nylon mating washer
8.0010.4E ..
8.0010.4L ..
8.0010.4M ..
8.0010.4T ..
F8
TURCK Inc. 3000 Campus Drive Minneapolis, MN 55441 Application Support: 1-800-544-7769 Fax: (763) 553-0708 www.turck.com
1
FIGURE 7, HOIST MOTOR & REDUCER ASSEMBLY T30
4
2B
2A
2
3
6
5
9
7
8
1
2 1 100806-00 Coupling
2A 1 105597-00 Spider
2B 1 105594-00 Coupling
DESCRIPTION
Hoist Gearbox Assembly
4 1 106778-0000 Spacer
5 1 See
6
7
8
9
1
4
4
1
See Table
100407-00
100612-00
101694-00
Motor
Cap screw, 1/2 -13 x 2” Lg
Lock washer, 1/2"
Keyway, 3/8” x 1 ½” Lg
ITEM 5
TABLE
6’, 8’ and 10’ GAGE
100903-0000 ITEM 6 10 HP 202356-00
15 203956-00
20 202359-00
25 202357-00
30 202358-00
FIG.8 REDUCER PARTS LIST
DESCRIPTION
1 1 100893-0000
2
3
4
2
2
1
100906-0000
100908-0000
5 1 100909-0000
6 1 100899-0000
7
8
1
1
100912-0000
SEE TABLE
9
10
11
1
1
1
SEE TABLE
100911-0000
100915-0000
18
19
20
21
22
12
13
1
1
100894-0000
100910-0000
14 2 100703-00
15 1 100975-00
16
17
1
2
100795-00
100963-00
2
1
1
1
2
100964-00
105087-0000
105602-00
101694-00
100965-00
23 1 100023-00
24 1 100008-00
25
26
27
28
1
8
8
8
100009-00
100380-00
100614-00
100374-00
T30HP2, BRAKE ADAPTOR/CAPSULES
CAPSULE, CLOSED
T30HP2, ADAPTOR, MOTOR
T30HP2, OUTPUT SHAFT, SINGLE
T30HP2, DRUM PINION & SHFT
T30HP2, DRUM GEAR
T30HP2, MOTOR GEAR
T30HP2, MTR PINION & SHAFT
T30HP2 GEARBOX LID, 1/4" THK.
SPACER, T30 DRUM GEAR
SNAP RING, EX, SH-177
BEARINGS, 32209, SKF
BEARINGS, 6308 2RS C3, DOUBLE SEAL
SQUARE, 3/4" 4140 ANNEALED
KEYSTOCK, 1/2" SQ.
KEYSTOCK, 3/8" SQ
SEAL, CR 15142, NITRILE
SEAL, 31173, 3-1/8" SHAFT
PLUG 3/4 NPT MALE PLUG
SCREW, SHCS, 5/8"-11 X 1 1/2"
WASHER, LOCK, 5/8"
SCREW, SHCS, 1/2"-13 X 1 1/2"
WASHER, LOCK, 1/2"
SCREW, SHCS, 3/8"-16 X 1 1/4" GR5
34
35
36
37
38
39
29
30
8
6
100612-00
100369-00
31 6 100611-00
32 8 100090-00
33 16 101624-00
16
2
2
1
1
1
100610-00
32209SHIM
22216SHIM
3/4STELBOW90
100010-00
105707-00
SCREW, SHCS, 1/2"-13 X 2" GR5
SCREW, SHCS, 5/16"-18 X 3/4" GR5
WASHER, LOCK, 5/16"
SHIM SET, 32209 CAPSULE, .003/.005/.010
SHIM SET, 22216 CAPSULE, .003/.005/.010
ELBOW, ST, 3/4 X 90
0
BREATHER, 3/4 NPT
KEYSTOCK, SQ 7/8" X 3-3/8" 4140HT
RATIOS
ITEM
8 100931-0000 100923-0000
9 100930-0000 100922-0000
FIG. 9, UPPER LIMIT SWITCH INSTALLATION T30
1
7
2
3
4
8
6
5
1
2
3
1
4
4
101135-00
100391-00
100611-00
DESCRIPTION
SWITCH, Limit
BOLT, Hx Hd., 5/16-18 x 3/4” Lg
WASHER, Lock, 3/8”
6 2 101112-00 CLIP, Cable, 1/8
7 1 101110-00 CABLE,
8 1 100016-00 PIN, Cotter, 1/8 x 1-1/2” Lg.
FIGURE 10, 5 & 7.5 TON LOADBLOCK ASSEMBLY, 200191‐0000
1
3
6
7
5
16
14
18
19
8
17
16
13
20
11
12
4
15
21
9
1 1 104373-0000 Skirt/Shroud
2 1 100956-0000 Side Plates (Pair)
3 1 100898-0000 Pin
4 2 100097-0000 Keeper
5 2 100890-0000 Sheave,
6 2 100897-0000 Spacer
7 3 100896-0000 Spacer
8 1 100972-0000 Trunion
9 1 104911-0000 Hook
10 4 104354-00 Bolt, H x Hd, 1/2”-20 x 7 1/2 “
11 4 104356-00 Nut, Slotted, 1/2-20
12 4 1/2
13
14
4
4
100110-00
100611-00
Bolt, H x Hd, 3/8-16 x 3/4"
Washer, Lock, 3/8”
15 2 101614-00 Bearing
16 2 104374-00 Ring,
17 1 100699-00 Bearing
18 1 100601-00 Nut,
19 1 100652-00 Pin,
20 4 104357-00 Pin, Cotter, 1/8 x 1 1/2
21 1 100021-00 Fitting,
DESCRIPTION
2
10
FIGURE 10, 10 TON LOADBLOCK ASSEMBLY, 200192‐0000
1
3
16
13
14
2
16
6
5
7
15
21
4
20
11
12
18
17
8
19
9
2 1 100956-0000 Side Plates (Pair)
DESCRIPTION
2
10
10
11
12
13
14
4
4
4
4
4
104354-00
104356-00
100612-00
100110-00
100611-00
Bolt, H x Hd, 1/2”-20 x 7 1/2 “
Nut, Slotted, 1/2-20
Washer, Lock 1/2
Bolt, H x Hd, 3/8-16 x 3/4"
Washer, Lock, 3/8”
15 3 101614-00 Bearing
16 2 104374-00 Ring,
17 1 100699-00 Bearing
18 1 100598-00 Nut,
19 1 100650-00 Pin,
20 4 104357-00 Pin, Cotter, 1/8 x 1 1/2
21 1 100021-00 Fitting,
FIGURE 10, 15 TON LOADBLOCK ASSEMBLY, 200193‐0000
3
1
5
15
14
17
21
6
13
20
11
2
4
12
DESCRIPTION
1 1 104373-0000 Skirt/Shroud
2 1 100956-0000 Side Plates (Pair)
3 1 100898-0000 Pin
4 2 100097-0000 Keeper
6 5 100897-0000 Spacer
8 1 100972-0000 Trunion
9 1 104911-0000 Hook
10 4 104354-00 Bolt, H x Hd, 1/2”-20 x 10 1/2 “
11
12
13
14
4
4
4
4
104356-00
100612-00
100110-00
100611-00
Nut, Slotted, 1/2-20
Washer, Lock 1/2
Bolt, H x Hd, 3/8-16 x 3/4"
Washer, Lock, 3/8”
15 4 101614-00 Bearing
16 2 104374-00 Ring,
17 1 100699-00 Bearing
18 1 100598-00 Nut,
19 1 100650-00 Pin,
20 4 104537-00 Pin, Cotter, 1/8 x 1 1/2
21 1 100021-00 Fitting,
8
9
16
18
2
10
19
FIGURE 10, 20 TON LOADBLOCK ASSEMBLY, 200194‐0000
5
6 3
1
16
16
15
14
13
4
2
18
17
8
20
11
12
2 1 100954-0000 Side Plates (Pair)
DESCRIPTION
9
21
19
7
2
10
10
11
12
13
4
4
4
4
104355-00
104356-00
100612-00
100110-00
Bolt, H x Hd, 1/2”-20 x 10 1/2 “
Nut, Slotted, 1/2-20
Washer, Lock 1/2
Bolt, H x Hd, 3/8-16 x 3/4"
14 4 100611-00 Washer, Lock, 3/8”
15 6 101614-00 Bearing
16 2 104374-00 Ring,
17 1 100700-00 Bearing
18 1 100601-00 Nut, Bearing (Hook)
19 1 100652-00 Pin,
20 4 104537-00 Pin, Cotter, 1/8 x 1 1/2
21 1 100021-00 Fitting,
12
13
14
20
11
4
FIGURE 10, 25 TON LOADBLOCK ASSEMBLY, 200195‐0000
3
1
16
6
5
15
16
18
17
2
9
7
8
19
21
2
DESCRIPTION
2 1 100954-0000 Side Plates (Pair)
10
11
12
13
14
4
4
4
4
4
104355-00
104356-00
100612-00
100110-00
100611-00
Bolt, H x Hd, 1/2”-20 x 10 1/2 “
Nut, Slotted, 1/2-20
Washer, Lock 1/2
Bolt, H x Hd, 3/8-16 x 3/4"
Washer, Lock, 3/8”
15 6 101614-00 Bearing
16 2 104374-00 Ring,
17 1 100700-00 Bearing
18 1 100601-00 Nut,
19 1 100652-00 Pin,
20 4 104537-00 Pin, Cotter, 1/8 x 1 1/2
21 1 100021-00 Fitting,
FIGURE 11, 5 ‐ 7.5 TON TOP SHEAVE ASSEMBLY, 401912‐0000
11
9
8
10
12
7
6
7
1
2
3
4
4
5
1 1 104828-0000
3 2 104370-00 SPACER
DESCRIPTION
IDLER SHEAVE POCKET
7 2 101210-00 SPACER
8 1 102456-0000 PIN, Idler Sheave
10 2 100110-00 3/8 -16 X 3/4 Lg Hex Bolt
11 2 100611-00 3/8
12 1 100021-00 GREASE FITTING, 1/8 NPT
FIGURE 11, 10 TON UPPER SHEAVE ASSEMBLY, 401913‐0000
6
4
4
2
3
4
2
5
5
5
4
1
3 2 101614-00 BEARING
3
5
4
DESCRIPTION
6
4
FIGURE 11, 15 TON UPPER SHEAVE ASSEMBLY, 401914‐0000
6
5
4
2
2
5
2
3
1
3
3
5
6
3 3 101614-00 BEARING
DESCRIPTION
FIGURE 11, 20 TON UPPER SHEAVE ASSEMBLY, 401916‐0000
6
4
2
5
2
3
2
2
3
2
3
3
3
5
5
1
5
4
6
DESCRIPTION
3 5 101614-00 BEARING
FIGURE 11, 25 TON UPPER SHEAVE ASSEMBLY, 401917‐0000
4
2
3
3
3
4
2
3
2
3
2
4
5
4
2
4
2
1
4
3 6 101614-00 BEARING
DESCRIPTION
4
3
5
FIGURE 12, TROLLEY DRIVE INSTALLATION
ITEM QTY PART NUMBER
1 1 203476‐00
1
2
3
4
1
1
2
1
203477‐00
109664‐0000
419241‐0B
100412‐00
5
6
7
4
2
2
100627‐00
100586‐00
100405‐00
DESCRIPTION
Brake, Motor, Reducer combination for 80 FPM
Brake, Motor, Reducer combination for 120 FPM
Torque Arm Bracket
Bushing, Torque Arm
Bolt, ½‐13 x 4” Gr. 5
Washer, Flat ½
Nut, ½ ‐ 13
Bolt, ½ ‐ 13 x 1.50” Gr. 5
Quantities above double for 25 Ton capacity
UNICASE
®
Shaft Mount Gearboxes
Installation and Maintenance Instructions
Retain These Safety Instructions For Future Use
BIM 1020
USA
CDN
INSPECTION OF UNIT
Thoroughly inspect the equipment for any shipping and handling damage before accepting shipment from the freight company. If any of the goods called for in the bill of lading or express receipt are damaged or the quantity is short, do not accept until the freight or express agent makes an appropriate notation on your freight bill or express receipt. If any concealed loss or damage is discovered later, notify your freight carrier or express agent at once and request him to make an inspection. We will be very happy to assist you in collecting claims for loss or damage during shipment; however, this willingness on our part does not remove the transportation company’s responsibility in reimbursing you for collection of claims or replacement of material. Claims for loss or damage in shipment must not be deducted from the NORD Gear invoice, nor should payment of the NORD Gear invoice be withheld awaiting adjustment of such claims, as the carrier guarantees safe delivery.
If considerable damage has been incurred and the situation is urgent, contact the nearest NORD Gear Sales Office for assistance. Please keep a written record of all communications.
RECORD NAMEPLATE DATA
Locate the gear reducer nameplate and record all nameplate data for future reference.
SK ________________________________________________________ S/N _________________________________
RATIO ______________ MAX TORQUE ____________________ RPM ______________ MTG. POS ______________
PROPER STORAGE UNTIL INSTALLED
Keep unit in a dry, temperature controlled area. If stored other than said, long term storage methods must be applied to the unit including complete fill with lubricant. Protect machined surfaces and rotate shafts periodically. Prior to putting unit into service, drain lubricant and refill to proper level as determined by the mounting position.
STORAGE
PROPER HANDLING OF THE UNIT
Exercise care to prevent damage to the unit when moving. Lift onIy at designed Iifting points. Do not attach other machinery and lift by the unit lifting points. The lifting points are to be used to lift the unit only. Insure that adequate safety measures are taken to protect personneI during transportation. Protect the mounting surface from damage.
BIM 1020/2005/03 Page 1 of 12 www.nord.com
INSTALLATION OF UNIT
To ensure Iong service and dependabIe performance, an encIosed gear drive must be rigidIy supported and the shafts accurateIy aIigned.
The foIIowing describes the minimum precautions required to accompIish this end.
FOUNDATION
The responsibiIity for the design and construction of the foundation Iies with the user. The foundation must be adequate to withstand normaI operating Ioads and possibIe overIoads whiIe maintaining aIignment to attached system components under such Ioads.
MOUNTING POSITION
UnIess a unit is specificaIIy ordered for incIined mounting, the foundation must be IeveI and fIat. The Iubrication system may not operate properIy if the unit is not mounted in the position for which it is designed. It may be desirabIe to eIevate the foundation to faciIitate oiI drainage.
> ∅ 50 ≤ ∅ 80 = +0.000/-0.019
> ∅ 80 ≤ ∅ 120 = +0.000/-0.022
> ∅ 120 ≤ ∅ 180 = +0.000/-0.025
Inch
≤ ∅ 0.750 = +0.0000/-0.0004
> ∅ 0.750 ≤ ∅ 1.125 = +0.0000/-0.0005
> ∅ 1.125 ≤ ∅ 2.000 = +0.0000/-0.0006
> ∅ 2.000 ≤ ∅ 3.000 = +0.0000/-0.0007
> ∅ 3.000 ≤ ∅ 4.750 = +0.0000/-0.0008
> ∅ 4.750 ≤ ∅ 7.000 = +0.0000/-0.0010
Shaft finish to be 125 micro inches or smoother.
CONCRETE FOUNDATION
Customer shaft diameter toIerance with Shrink Disc fit f6
(Iooser fit)
Metric (mm)
If a concrete foundation is used, steeI mounting pads and boIts of sufficient size to distribute the stress into the concrete shouId be grouted into the foundation.
STEEL FOUNDATION
If a structuraI steeI foundation is used (i.e. wide fIange beams or channeIs), a base pIate or soIe pIate of suitabIe thickness shouId be used and shouId extend under the entire unit.
FOOT MOUNTED UNITS
Use shims under the feet of the unit to aIign the output shaft to the driven equipment. Make sure that aII feet are supported so that the housing wiII not distort when it is boIted down. Improper shimming wiII reduce the Iife of the unit and may cause faiIure.
DoweI pins may be instaIIed to prevent misaIignment and ensure proper reaIignment if removed for service.
≤ ∅ 18 = -0.016/-0.024
> ∅ 18 ≤ ∅ 30 = -0.020/-0.029
> ∅ 30 ≤ ∅ 50 = -0.025/-0.036
> ∅ 50 ≤ ∅ 80 = -0.030/-0.043
> ∅ 80 ≤ ∅ 120 = -0.036/-0.051
> ∅ 120 ≤ ∅ 180 = -0.043/-0.061
Inch
≤ ∅ 0.750 = -0.0006/-0.0011
> ∅ 0.750 ≤ ∅ 1.125 = -0.0008/-0.0013
> ∅ 1.125 ≤ ∅ 2.000 = -0.0010/-0.0016
> ∅ 2.000 ≤ ∅ 3.000 = -0.0012/-0.0019
> ∅ 3.000 ≤ ∅ 4.750 = -0.0014/-0.0023
> ∅ 4.750 ≤ ∅ 7.000 = -0.0017/-0.0027
Shaft finish to be 125 micro inches or smoother
FLANGE MOUNTED UNITS
SHAFT MOUNTED UNITS
Shaft mounted drives should be mounted as close to the driven
If a structuraI steeI foundation is used (i.e. wide fIange beams or channeIs), a base pIate or soIe pIate of suitabIe thickness shouId equipment bearing support as possible to minimize bearing loads due to overhung load. Design of the joint connection between the be used and shouId extend under the entire unit. If a buIk head pIate is used it shouId be of proper strength to minimize buckIing torque reaction arm and the foundation is the user’s responsibility. distortions.
HoIIow Shaft Diameter toIerance
Metric (mm)
FIange PiIot ‘AK’ or ‘AK1’ toIerance
Metric (mm)
Inch
≤ ∅ 18 = +0.018/-0.000
> ∅ 18 ≤ ∅ 30 = +0.021/-0.000
> ∅ 30 ≤ ∅ 50 = +0.025/-0.000
> ∅ 50 ≤ ∅ 80 = +0.030/-0.000
> ∅ 80 ≤ ∅ 120 = +0.035/-0.000
> ∅ 120 ≤ ∅ 180 = +0.040/-0.000
≤ ∅ 4.375 = +0.0010 / -0.0000
> ∅ 4.375 = +0.0015 / -0.0000
Customer shaft diameter toIerances with keyed hoIIow shafts
Metric (mm)
≤ ∅ 18 = +0.000/-0.011
> ∅ 18 ≤ ∅ 30 = +0.000/-0.013
> ∅ 30 ≤ ∅ 50 = +0.000/-0.016
> ∅ 50 ≤ ∅ 80 = +0.000/-0.019
> ∅ 80 ≤ ∅ 120 = +0.000/-0.022
> ∅ 120 ≤ ∅ 180 = +0.000/-0.025
Inch
≤ ∅ 1.500 = +0.000/-0.002
> ∅ 1.500 ≤ ∅ 2.500 = +0.000/-0.003
> ∅ 2.500 ≤ ∅ 7.000 = +0.000/-0.004
Shaft finish to be 125 micro inches or smoother.
Customer shaft diameter toIerance with Shrink Disc fit h6
Metric (mm)
Inch
> ∅ 50 ≤ ∅ 80 = +0.012/-0.007
> ∅ 80 ≤ ∅ 120 = +0.013/-0.009
> ∅ 120 ≤ ∅ 180 = +0.014/-0.011
> ∅ 180 ≤ ∅ 230 = +0.016/-0.013
> ∅ 230 ≤ ∅ 315 = +0.000-0.032
> ∅ 315 ≤ ∅ 400 = +0.000/-0.036
> ∅ 400 ≤ ∅ 500 = +0.000/-0.040
> ∅ 1.969 ≤ ∅ 3.150 = +0.005/-0.0003
> ∅ 3.150 ≤ ∅ 4.724 = +0.005/-0.0004
> ∅ 4.724 ≤ ∅ 7.087 = +0.006/-0.0004
> ∅ 7.087 ≤ ∅ 9.055 = +0.006/-0.0005
> ∅ 9.055 ≤ ∅ 12.402 = +0.000/-0.0013
> ∅ 12.402 ≤ ∅ 15.748 = +0.000/-0.0014
> ∅ 15.748 ≤ ∅ 19.685 = +0.000/-0.0016
BOLT STRENGTH
BoIt size, strength and quantity shouId be verified to insure proper torque reaction capacity whatever the mounting arrangement.
LUBRICATE SHAFTS
Both the hollow shaft and the driven shaft should be liberally lubricated before assembly. The unit must slide freely onto the driven shaft. Do not hammer or force the unit into place. For shrink disc, follow instructions below.
≤ ∅ 18 = +0.000/-0.011
> ∅ 18 ≤ ∅ 30 = +0.000/-0.013
> ∅ 30 ≤ ∅ 50 = +0.000/-0.016
BIM 1020/2005/03 Page 2 of 12 www.nord.com
AXIAL RETENTION
Each drive shaft must be retained in place relative to the gear reducer. Or each gear reducer must be retained in place relative to the drive shaft. Either way NORD recommends the use of shaft shoulders, locking collars or FIXING ELEMENTS to axially retain the shaft or gear reducer in position.
SET SCREWS
If set screws are used for axial retention, they should be tightened evenly. Flats may be filed on the driven shaft and a threadlocking adhesive used for more position retention.
SNAP RING RETENTION
Placing external snap rings on drive shafts must be performed with caution. The groove, which the snap ring fits into, may weaken the drive shaft causing premature failure. NORD does not recommend this type of shaft retention.
THRUST PLATE
In applications, which are subject to high vibratory loads, a thrust plate will provide greater resistance to axial movement. Follow the manufacturer’s recommendations for assembly.
SHRINK DISC
If a shrink disc is used to secure a reducer hollow shaft to the driven shaft, follow this assembly procedure. Start with the shrink disc mounted onto the extension of the hollow shaft disc locking bolts loosened.
1. Clean reducer bore and mating solid shaft to be free of any lubricants or dirt.
2. Slide reducer onto the solid shaft until it is about half way through.
3. Lubricate the remaining portion of the solid shaft with a #2 grease or similar lubricant. This part will be located under the bronze bushing. Do not install grease under the
shrink disc gripping area. Finish installing the solid shaft into the reducer hollow bore.
4. Finger tighten all shrink disc bolts. Now, moving a circular pattern, tighten each shrink disc locking bolt 1/4 to 1/2 turn.
Do not use criss cross pattern. Continue tightening in the same circular direction with 1/4 or 1/2 turn increments until all bolts reach the specified bolt tightening torque. Bolt tightening torque is shown on the shrink disc label for the particular unit.
5. Run unit for 24 hours, then retighten shrink disc locking bolts to the proper bolt torque as indicated above.
TORQUE REACTION ARM
On the shaft mount ‘Clincher’, torque is reacted through the integral torque tab, which is part of the casting. Commonly,
NORD’s optional RUBBER BUFFER bushings are installed on each side of the integral torque tab to dampen torque shocks and allow for mis-alignment received from the machinery during operation.
Torque arm connection fabrications should always be mounted perpendicular to a line through the output shaft center and the point at attachment of the torque arm to the unit housing. In this position the minimum load on the attachment structure arm will be experienced. The attachment structure must be rigid and may not deflect under any load. Doing so will place extra loads on the output bearings of the reducer.
PRIME MOVER MOUNTING
AIign the prime mover to the reducer-input shaft using shims under the feet. Make sure that the feet are supported. DoweI the prime mover to its foundation.
SHAFT CONNECTIONS
When connecting shafts to either the input or output of the reducer, consider the foIIowing instructions.
FITS
CIearance or interference fits for coupIing hubs shouId be in accordance with ANSI/AGMA 9002-A86 or as follows.
BIM 1020/2005/03
Output and Input shaft Diameter toIerance
Inch
≤ ∅ 18 = +0.012/+0.001
> ∅ 18 ≤ ∅ 30 = +0.015/+0.002
> ∅ 30 ≤ ∅ 50 = +0.018/+0.002
> ∅ 50 ≤ ∅ 80 = +0.030/+0.011
> ∅ 80 ≤ ∅ 120 = +0.035/+0.013
> ∅ 120 ≤ ∅ 180 = +0.040/+0.015
≤ ∅ 1.750 = +0.0000/-0.0005
> ∅ 1.750 = +0.0000/-0.0010
Output and Input shaft DriII and tap shaft end
Metric (mm)
≤ ∅ 16 = M5
> ∅ 16 ≤ ∅ 21 = M6
> ∅ 21 ≤ ∅ 24 = M8
> ∅ 24 ≤ ∅ 30 = M10
> ∅ 30 ≤ ∅ 38 = M12
> ∅ 38 ≤ ∅ 50 = M16
> ∅ 50 ≤ ∅ 85 = M20
> ∅ 85 ≤ ∅ 130 = M24
Inch
≤ ∅ 0.438 = #10-24 x 0.4 deep
> ∅ 0.438 ≤ ∅ 0.813 = 1/4-20 x 0.6 deep
> ∅ 0.813 ≤ ∅ 0.938 = 5/16-18 x 0.7 deep
> ∅ 0.938 ≤ ∅ 1.125 = 3/8-16 x 0.9 deep
> ∅ 1.125 ≤ ∅ 1.375 = 1/2-13 x 1.1 deep
> ∅ 1.375 ≤ ∅ 1.875 = 5/8-11 x 1.4 deep
> ∅ 1.875 ≤ ∅ 3.250 = 3/4-10 x 1.7 deep
> ∅ 3.250 = 1-8 x 2.2 deep
Outboard pinion and sprocket fits shouId be as recommended by the pin sprockets with interference fits shouId be heated according to the manufacturer’s recommendations, generaIIy
250
°F to 300°F, (120°C to 150° C) before assembIing to the shaft.
LOCATION
CoupIing hubs shouId be mounted fIush with the shaft ends, unIess specificaIIy ordered for overhung mounting. Pinions, sprockets and sheaves shouId be mounted as cIose as possibIe to the unit housing to minimize bearing Ioads and shaft defIections.
Page 3 of 12 www.nord.com
COUPLING ALIGNMENT
Shaft coupIings shouId be instaIIed according to the coupIing manufacturer’s recommendations for gap, anguIar and paraIIeI aIignment. In many instaIIations, it is necessary to aIIow for thermaI and mechanicaI shaft movement when determining shaft aIignment. The coupIing manufacturer’s recommendations shouId be foIIowed.
AXIAL DISPLACEMENT
The gap between shaft ends shouId be the same as the specified coupIing gap unIess overhung mounting of the coupIing hub is specified. The coupIing gap and shaft gap must be sufficient to accommodate any anticipated thermaI or mechanicaI axiaI movement.
ANGULAR ALIGNMENT
Insert a spacer or shim stock equaI to the required coupIing gap between the coupIing hub faces and measure the cIearance using feeIer gauges. Repeat this at the same depth at 90-degree intervaIs to determine the amount of anguIar misaIignment.
PARALLEL ALIGNMENT
Mount a diaI indicator to one coupIing hub, and rotate this hub, sweeping the outside diameter of the other hub. The paraIIeI misaIignment is equaI to one-haIf of the totaI indicator reading.
Another method is to rest a straight edge squareIy on the outside diameter of the hubs at 90-degree intervaIs and measure any gaps with feeIer gauges. The maximum gap measurement is the paraIIeI misaIignment.
CHECKING ALIGNMENT
After both anguIar and paraIIeI aIignments are within specified
Iimits, tighten aII foundation boIts secureIy and repeat the above procedure to check aIignment. If any of the specified Iimits for aIignment are exceeded, reaIign the coupIing.
SPROCKET OR SHEAVE ALIGNMENT
AIign the sheaves or sprockets square and paraIIeI by pIacing a straight edge across their faces. AIignment of bushed sheaves and sprockets shouId be checked after bushings have been tightened. Check horizontaI shaft aIignment by pIacing a IeveI verticaIIy against the face of the sheave or sprocket. Adjust beIt or chain tension per the manufacturer’s specified procedure.
OUTBOARD PINION ALIGNMENT
AIign the pinion by adjusting the gear tooth cIearance according to the manufacturer’s recommendations and checking for acceptabIe outboard pinion tooth contact. The foundation boIts may have to be Ioosened and the unit moved sIightIy to obtain this contact. When the unit is moved to correct tooth contact, the prime mover shouId be reaIigned.
RECHECK ALIGNMENT
After a period of operation, recheck aIignment and adjust as required.
1. Properly install unit on a rigid foundation
• adequateIy supported
• secureIy boIted into pIace
•
IeveIed so as not to distort the gear case
2. Properly install couplings suitabIe for the application and connected equipment.
3. Ensure accurate aIignment with other equipment.
4. Furnish and install adequate machinery guards as needed to protect operating personneI and as required by the appIicabIe standards of the OccupationaI Safety and HeaIth
Administration (OSHA), and by other appIicabIe safety reguIations;
5. Ensure that driving equipment is running in the correct direction before coupling to reducers with backstops
(designed to operate onIy in a specific direction) or machinery designed to operate only in one direction.
BIM 1020/2005/03
CHANGES IN PERFORMANCE SPECIFICATIONS
Owner has the responsibiIity to consult with NORD GEAR if such items such as applied Ioads, operating speeds or other operating conditions have changed.
WARNING:
LOCK OUT POWER before any maintenance is performed.
Make absolutely sure that no voltage is applied while work is being done on the gearbox.
START-UP
1. Ensure that switches, aIarms, heaters, coolers and other safety and protection devices are instaIIed and operational for their intended purpose.
2. Verify that the installed mounting position is the same as the nametag mounting position. If not, adjust the oil level accordingly and relocate the vent plug, fill plug and drain plug according to the mounting position. See following.
AUTOVENT PLUG
The Autovent plug is brass in color and will be located at the highest point on the gearbox. It operates like a check-valve to allow the reducer to relieve internal pressure while preventing lubricant contamination during cooling. A spring presses a ball or plunger against a machined orifice until pressure exceeds 2 psi.
Above 2 psi the air is allowed to escape depressurizing the gearcase. When internal pressure drops below 2 psi, the autovent re-seals closing the unit to the outside environment.
After shutdown, the reducer cools along with the air inside the reducer. The unit will temporarily maintain a slight vacuum until normalization occurs. NORD Gear supplies an Autovent as a standard feature. inside the gearbox (Max. pressure 2 psi).
Page 4 of 12
The Autovent releases built-up air pressure from www.nord.com
FILL LEVEL & DRAIN PLUGS
The drain plugs are metric socket head cap screws. They will be located at the lowest part of the gearbox for ease of draining. The fill level plug is a hex head cap screw. It will be located between the Autovent and drain plug. Both types of plugs will have gaskets included to prevent oil from leaking.
Two types of plugs for maintenance
LUBRICANT
AII NORD reducers are shipped from the factory properIy fiIIed with Iubricant and all plugs are installed according to the mounting position given on the reducer nametag. Acceptable oil fill level is within ½ inch of the bottom of the fill plug threads.
OPERATION AND MAINTENANCE CHECKLIST
1. Operate the equipment as it was intended to be operated
2. Do not overIoad.
3. Run at correct speed.
4. Maintain Iubricant in good condition and at proper IeveI.
5. Dispose of used Iubricant in accordance with appIicabIe
Iaws and reguIations.
6.
AppIy proper maintenance to attached equipment at prescribed intervaIs recommended by the manufacturer.
7. Perform periodic maintenance of the gear drive as recommended by NORD.
MOUNTING POSITIONS
These charts detail the mounting positions for horizontal and vertical mounting. The Autovent, oil fill plug and drain plug are indicated on each mounting position picture. The factory set mounting position and plug locations match that shown on the gearbox nametag. For mounting orientations other than shown consult NORD Gear.
Horizontal position
SK 6282 - SK 11282
SK 6382 - SK 12382
SK 6282 - SK 11282
SK 6382 - SK 12382
SK 1282 - SK 5282
SK 6382 - SK 12382
H 1
SK 1282 - SK 5282
H 2
Vertical position
SK 1282 - SK 5282
SK 2382 - SK 5382
H 3
SK 2382 - SK 5382
H 4
H 5 * H 6
Symbols: Vent plug Oil level Drain plug
*
Mounting position H5 with lubricant expansion unit recommended
SK0182NB & SK1382NB have no vent or drain plugs. They are filled with synthetic oil so the units are
“Lubed for Life”.
BIM 1020/2005/03 Page 5 of 12 www.nord.com
MAINTENANCE
Mineral lubricant should be changed every 10,000 service hours or after two years. For synthetic oils, the lube should be changed every
20,000 service hours or after four years. In case of extreme operating (e.g. high humidity, aggressive environment or large temperature variations), shorter intervals between changes are recommended.
OIL SPECIFICATIONS
NORD supplies aII reducers fiIIed with oiI from the factory. Consult the sticker adjacent to the fill plug to determine the type of lubricant installed at the factory. Standard lubricant is ISO VG220 mineral-based oil. However, some units have special lubricants designed to operate in certain environments or to extend the service life of the lubricant. If in doubt about which lubricant is needed, contact NORD Gear.
STANDARD OIL – ISO VG220
Ambient Temperature
20 to 104
°F (-5 to 40°C)
TYPICAL OILS
FormuIation
MineraI
Viscosity
ISO NLGI
Formulation
Service
Temperature
Range
Shell
Castrol
VG 460
VG 320
VG 220
VG 150
&
VG 100
VG 68
VG 32
Conventional
Mineral
Synthetic
PAO
Conventional
Mineral
Synthetic
PAO
Conventional
Mineral
Synthetic
PAO
Conventional
Mineral
Synthetic
PAO
Conventional
Mineral
Synthetic
PAO
Synthetic
PAO
20
°C to +50°C
68F to +122
°F
-30
°C to +80°C
-22
°F to +176°F
0
°C to +30°C
32
°F to +86°F
-35
°C to +80°C
-31
°F to +176°F
-5
°C to +40°C
+20
°F to +104°F
-34
°C to +80°C
-30
°F to +176°F
-15
°C to +25°C
5
°F to +77°F
-37
°C to +10°C
-35
°F to +50°F
-15
°C to +25°C
5
°F to +77F
-40
°C to +10°C
-40
°F to +50F
-40
°C to +10°C
-40
°F to +50°F
Mobilgear
634
Mobil
SHC 634
Mobilgear
632
Mobil
SHC 632
Mobilgear
630
Mobil
SHC 630
Mobilgear
629
Mobil
SHC 629
Mobilgear
626
Mobil
SHC 626
Mobil
SHC 624
PAO = Poly Alpha Olefin
SPECIAL PURPOSE LUBRICANTS
Ambient Temperature FormuIation
20 to 104
°F (-5 to 40°C)
20 to 104
°F (-5 to 40°C)
5 to 125
°F (-20 to 50°C)
-30 to 140
°F (-35 to 60°C)
-30 to 140
°F (-35 to 60°C)
Food Grade Oil - Synthetic
Food Grade Oil - Synthetic
FIuid Grease
FIuid Grease - Synthetic
FIuid Grease - Synthetic
STANDARD BEARING GREASE – NLGI 2EP Lithium
Ambient Temperature
-20 to 140
°F (-30 to 60°C)
OPTIONAL BEARING GREASES
Ambient Temperature
-40 to 230
°F (-40 to 110°C)
-40 to 230
°F (-40 to 110°C)
FormuIation
MineraI
FormuIation
Food Grade - Synthetic
Omala
460
Omala
460 HD
Omala
320
Omala
320 HD
Omala
220
Omala
220 HD
Omala
100
Omala
150 HD
Omala
68
N/A
Isolube
EP 460
Isolube
EP 460
Isolube
EP 220
Isolube
EP 150
Isolube
EP 68
Manufacturer
Chevron
OilJAX
MobiI
MobiI
SheII
7EP
6EP
5EP
4EP
2EP
Manufacturer
LubripIate
Klüberoil
GEM 1-460
Klübersynth
EG 4-460
Klüberoil
GEM 1-320
Klübersynth
EG 4-320
Klüberoil
GEM 1-220
Klübersynth
EG 4-220
Klüberoil
GEM 1-150
Klübersynth
EG 4-150
Klüberoil
GEM 1-68
Oil Brand Name
FM ISO 220
MagnapIate 85W140-FG
MobiIux EP023
MobiIith SHC 007
Albida LC
SFL1
Energol
GR-XP 460
N/A
Energol
GR-XP 320
N/A
Energol
GR-XP 220
N/A
Energol
GR-XP 100
Grease Brand Name
Tribol
1100/460
Tribol
1510/460
Tribol
1100/320
Tribol
1100/220
Tribol
1510/220
Tribol
1100/100
N/A N/A
Energol
GR-XP 68
Tribol
1510/320
Tribol
1100/68
N/A N/A
BIM 1020/2005/03 Page 6 of 12 www.nord.com
LUBRICANT CAPACITY
Each reducer has the oil level and oil quantity adjusted according to the mounting position shown in the tables. When replacing the oil, consult the tables below to determine the proper amount of oil to be installed according to the reducer size and mounting position. Note that this is approximate and the final level will be adjusted when the reducer is installed. Acceptable oil fill level is within ½ inch of the bottom of the fill plug threads.
LUBRICATION CAPACITY - SHAFT MOUNT 'CLINCHER' GEARBOXES
MOUNTING POSITION MOUNTING POSITION
Horizontal Vertical
H1 H2 H3 H4 H5 H6
SK 0182NB quarts 0.42 0.63 0.53 0.53 0.58 0.58
liters 0.40 0.60 0.50 0.50 0.55 0.55
SK0282NB quarts 0.74 0.85 0.95 0.95 1.16 1.06
liters 0.70 0.80 0.90 0.90 1.10 1.00
SK 1282
quarts 0.95 0.95 1.00 1.00 1.27 1.37
liters 0.90 0.90 0.95 0.95 1.20 1.30
SK 2282
quarts 1.74 2.01 1.90 1.90 2.11 2.54
liters 1.65 1.90 1.80 1.80 2.00 2.40
SK 3282
quarts 3.33 3.44 3.33 3.33 4.33 4.33
liters 3.15 3.25 3.15 3.15 4.10 4.10
SK 4282
quarts 4.97 5.02 4.97 4.97 5.71 6.45
liters 4.70 4.75 4.70 4.70 5.40 6.10
SK 5282
quarts 7.93 7.93 7.61 7.61 9.30 9.30
liters 7.50 7.50 7.20 7.20 8.80 8.80
SK 6282
quarts 18.0 12.7 14.8 10.6 18.5 14.8
liters 17.0 12.0 14.0 10.0 17.5 14.0
SK 7282
quarts 26.4 21.1 22.2 16.9 28.5 22.2
liters 25 20 21 16 27 21
SK 8282
quarts 39.1 31.7 32.8 32.8 43.3 34.9
liters 37 30 31 31 41 33
SK 9282
quarts 78.2 58.1 62.4 72.9 76.1 74.0
liters 74 55 59 69 72 70
SK 10282 quarts 95 42 87 63 95 95 liters 90 40 82 60 90 90
Horizontal Vertical
H1 H2 H3 H4 H5 H6
SK 1382NB quarts 1.37 1.48 2.01 2.11 2.22 2.43 liters 1.30 1.40 1.90 2.00 2.10 2.30
SK 2382
quarts 1.80 2.01 1.59 1.59 3.28 2.75 liters 1.70 1.90 1.50 1.50 3.10 2.60
SK 3382
quarts 4.33 3.49 3.49 3.49 5.92 4.33 liters 4.10 3.30 3.30 3.30 5.60 4.10
SK 4382
quarts 6.24 5.18 5.18 5.18 8.77 7.19 liters 5.90 4.90 4.90 4.90 8.30 6.80
SK 5382
quarts 13.21 7.08 8.77 8.77 14.80 12.68
liters 12.50 6.70 8.30 8.30 14.00 12.00
SK 6382
quarts 17.4 10.1 13.2 14.8 19.0 13.7
SK 7382
quarts 23.3 16.9 20.1 24.3 26.4 21.1 liters 22 16 19 23 25 20
SK 8382
quarts 35.9 26.4 31.7 37.0 40.2 33.8 liters 34 25 30 35 38 32
SK 9382
quarts 77.2 47.6 63.4 68.7 78.2 74.0 liters 73 45 60 65 74 70
SK 10382 quarts 90 77 85 85 93 93 liters 85 73 80 80 88 88
SK 11382 quarts 169 148 143 164 222 164 liters 160 140 135 155 210 155
SK 12382 quarts 169 148 143 164 222 164 liters 160 140 135 155 210 155
SK 11282 quarts 174 153 148 106 206 169 liters 165 145 140 100 195 160
Note: Filling quantities are approximate figures. Oil level must be checked according to oil level plug after final installtion.
Acceptable oil fill level is within 1/2 inch of the bottom of the fill plug threads. For mounting angles not shown, consult factory.
BIM 1020/2005/03 Page 7 of 12 www.nord.com
PROBLEM WITH THE REDUCER
Overloading
Runs Hot
Improper lubrication
Runs Noisy
Output Shaft
Does Not Turn
Loose foundation bolts
Worn RV Disc
Failure of Bearings
Insufficient Lubricant
Internal parts are broken
Worn Seals
Oil Leakage
TROUBLE SHOOTING
POSSIBLE CAUSES
Load exceeds the capacity of the reducer
Insufficient lubrication
Excessive lubrication
Wrong lubrication
Weak mounting structure
Loose hold down bolts
Overloading unit may result in damage to disc
May be due to lack of lubricant
Overload
Level of lubricant in the reducer not properly maintained.
Overloading of reducer can cause damage.
Key missing or sheared off on input shaft.
Coupling loose or disconnected.
Caused by dirt or grit entering seal.
Overfilled reducer.
Autovent clogged.
Improper mounting position, such as wall or ceiling mount of horizontal reducer.
SUGGESTED REMEDY
Check rated capacity of reducer, replace with unit of sufficient capacity or reduce load
Check lubricant level and adjust up to recommended levels
Check lubricant level and adjust down to recommended levels
Flush out and refill with correct lubricant as recommended
Inspect mounting of reducer. Tighten loose bolts and/ or reinforce mounting and structure
Tighten bolts
Disassemble and replace disc. Recheck rated capacity of reducer.
Replace bearing. Clean and flush reducer and fill with recommended lubricant.
Check rated capacity of reducer.
Check lubricant level and adjust to factory recommended level.
Replace broken parts. Check rated capacity of reducer.
Replace key.
Properly align reducer and coupling.
Tighten coupling.
Replace seals. Autovent may be clogged.
Replace or clean.
Check lubricant level and adjust to recommended level.
Clean or replace, being sure to prevent any dirt from falling into the reducer.
Check mounting position. Name tag & verify with mounting chart in manual.
BIM 1020/2005/03 Page 12 of 12 www.nord.com
Motor Brakes
Installation and Maintenance Instructions
BIM 1090
USA
CDN
Retain These Safety Instructions for Future Use
Safety Notice
This equipment contains high voltage! Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt installation, operation and maintenance of electrical equipment.
Be sure that you are completely familiar with NEMA publication
MG-2, safety standards for construction and guide for selection, installation and use of electric motors and generators, the
National Electric Code and local codes and practices. Unsafe installation or use can cause conditions that lead to serious or fatal injury.
WARNING:
LOCK OUT POWER BEFORE ANY MAINTENANCE IS
PERFORMED. MAKE ABSOLUTELY SURE THAT NO
VOLTAGE IS APPLIED WHILE WORK IS BEING DONE
ON THE GEARBOX. READ SAFETY INSTRUCTIONS
PRIOR TO ANY WORK DONE ON THE MOTOR.
TABLE OF CONTENTS
General Description – Brakes & Rectifiers……………….. 2
Rectifier Part Numbers and Ratings…………………….… 2
Technical Data – Precima Brakes………………………… 3
Maintenance – Precima Brakes…………………………… 4
Parts List – Precima Brakes……………………………….. 5
Brake Pad Replacement – Precima Brakes……………… 6
Maintenance – Mayr Brakes (10-20Nm) …………………. 7
Maintenance – Mayr Brakes (400-800Nm)…………….…. 8
Hand Release Air Gap Setting – Precima & Mayr....……. 9
Brake Torque Adjustment………………………………….. 9
Connection Diagrams – 60Hz……………………………… 10
Connection Diagrams – 50Hz ……………………………... 11
Trouble Shooting…………………………………………….. 11
This instruction manual is not intended to include a comprehensive listing of all details for all procedures required for installation, operation and maintenance. This manual describes general guidelines that apply to most of the motor products shipped by NORD Gear. If you have a question about a procedure or are uncertain about any detail, DO NOT PROCEED.
Please contact your NORD distributor for more information or clarification
.
DANGER:
THE USER IS RESPONSIBLE FOR CONFORMING TO
THE NATIONAL ELECTRIC CODE AND ALL OTHER
APPLICABLE LOCAL CODES. WIRING PRACTICES,
GROUNDING DISCONNECTS AND OVERCURRENT
PROTECTION, ARE OF PARTICULAR IMPORTANCE.
FAILURE TO OBSERVE THESE PRECAUTIONS COULD
RESULT IN SERVERE BODILY INJURY OR LOSS OF
LIFE.
BIM 1090/2008/02 Page 1 of 12 www.nord.com
GENERAL DESCRIPTION
BRAKES
General
NORD brakes are “spring set”. When power is removed from the brake, the brake will automatically set to hold the load. NORD brakes are DC voltage brakes and in most instances are supplied with a motor mounted brake rectifier for easy connections to AC power. AC power is taken directly from the power line or from the terminal block of the motor and converted to DC by the supplied rectifier in the terminal box. If the motor is connected to a
frequency inverter, soft start, or is a two-speed motor, the AC power must be supplied to the brake rectifier separately from the motor power.
When the brake is de-energized (Power Off), the braking springs exert a force against the anchor plate, which prevents the brake rotor from rotating. When the brake coil is energized (Power On), a magnetic field builds and pulls the anchor plate across the air gap to the brake casing, which frees the brake rotor and allows the motor shaft to rotate.
NORD Gear typically use brakes manufactured by Precima and
Mayr. The Mayr brake is used mainly on the 20Nm and some of the 400-1200Nm sizes. For questions regarding brake manufacturer, please contact NORD Gear.
Standard Rectifiers
As standard, NORD integral gearmotors with a DC brake include a rectifier mounted in the motor terminal box to supply DC power to the brake. The rectifier can be wired for switching either the
AC power source or the DC voltage supply (output). Wiring the
DC switching gives the fastest reaction (de-energize – brake engage – stopping) time. If AC switching is used, the source power can be attached to the motor brake terminals. Tapping into the motor terminals gives the slowest de-energize time (stopping), due to the collapsing time of the motor magnetic field.
Terminals
1 & 2
3 & 4
Brake system connection AC voltage
Switch contact or jumper (for DC switching)
5 & 6 Connection brake coil
RECTIFIERS
General
The DC power required to energize the brake is not available in most applications. AC power is available in all applications since it is required to power the motor. The rectifier converts the available AC voltage to the DC voltage needed to power the brake.
Features
• Individual power supply for each motor.
•
Compact size; mounted inside motor terminal box.
• Multiple voltage options
•
Solid state bridge rectifier
•
Integral protection against transient voltage spikes
• Half wave rectifier:
DC voltage is 45% of the applied AC voltage
•
Full wave rectifier:
DC voltage is 90% of the applied AC voltage
RECTIFIER PART NUMBERS & RATINGS
Special Function Rectifiers & Current Sensing Relays
NORD offers special function rectifiers (Option FR) which provide improved brake performance. Refer to “BIM 1095 FR Brake
Rectifier” for more information.
Another way of improving brake performance is using NORD’s current sensing relay (Option IR). It requires no external wiring and screws into the spare side hole of the conduit box. Refer to
“BIM 1092 IR Relay” for more information.
Part #
19141000
19141010
19141020
Color
Black
Yellow
Grey
Style
Full-wave
Half-wave
Half-wave
Input Voltage
110-230 VAC ± 10%
230-480 VAC ± 10%
500-575 VAC ± 10%
Output Current
2A
2A
2A
Temp
-10°C to 80°C
-10°C to 80°C
-10°C to 80°C
BIM 1090/2008/02
Cautions
•
Brake torque - The brake torque is measured with a mean friction radius of the brake pad surface with a circumferential speed of 1m/sec (197 fpm).
•
Brake torque tolerance - For different applications and operating conditions, brake torque can vary from +40/-20% compared to the rated brake torque.
•
Hoisting (lifting/lowering) applications - must have the brake wired for fast response (DC-switching)
•
Initial operation & wear-in period - In new condition, the brake will have a reduced torque of up to 30%. In order to achieve full rated brake torque, a short run-in period is required. The run in time will vary depending on system loads.
Page 2 of 12 www.nord.com
TECHNICAL DATA – PRECIMA BRAKES
Brake Size 5 - Tb = 5 Nm, 3.7 lb-ft max torque
NORD p/n
Half-Wave Full-Wave Pc Vc Ic Rc
[V
AC
] [A
AC
] [V
AC
] [A
AC
] [ W ] [V
DC
] [A
DC
]
[ Ω ]
19010212
19010912 230 0.09
115 0.19
19011902 400 0.05
200 0.11
19011912 460 0.05
230 0.10
19012212 500 0.04
250 0.08
19012512 575 0.04
277 0.08
22
22
22
22
21
22
24
105
180
205
225
250
0.92
0.21
0.12
0.11
0.09
0.09
26
500
1475
1900
2450
2850
Brake Size 20 - Tb = 20 Nm, 15 lb-ft max torque
NORD p/n
Half-Wave Full-Wave Pc Vc Ic Rc
[V
AC
] [A
AC
] [V
AC
] [A
AC
]
[ W ]
[V
DC
] [A
DC
] [ Ω ]
19030224
19030924 230 0.16
115 0.32
19031904 400 0.09
200 0.19
19031924 460 0.09
230 0.19
19032224 500 0.08
250 0.15
19032524 575 0.07
277 0.14
36
38
38
43
38
38
24
105
180
205
225
250
1.50
0.36
0.21
0.21
0.17
0.15
16
292
857
976
1323
1666
Brake Size 60 - Tb = 60 Nm, 44 lb-ft max torque
NORD p/n
Half-Wave Full-Wave Pc Vc Ic Rc
[V
AC
] [A
AC
] [V
AC
] [A
AC
]
[ W ]
[V
DC
] [A
DC
] [ Ω ]
19050252
19050952 230 0.27
115 0.54
19051902 400 0.14
200 0.27
19051952 460 0.13
230 0.25
19052252 500 0.10
250 0.20
19052552 575 0.09
277 0.17
52
63
54
57
50
48
24
105
2.18
0.60
11
174
180
0.30
602
205
0.28
740
225
0.22
1004
250
0.19
1300
Brake Size 150 - Tb = 150 Nm, 110 lb-ft max torque
NORD p/n
Half-Wave Full-Wave Pc Vc Ic Rc
[V
AC
] [A
AC
] [V
AC
] [A
AC
]
[ W ]
[V
DC
] [A
DC
] [ Ω ]
19070252
19070952 230 0.39
115 0.79
19071902 400 0.18
200 0.36
19071952 460 0.15
230 0.31
19072252 500 0.15
250 0.30
19072552 575 0.14
277 0.27
77
92
73
70
76
76
24
225
250
3.20
0.34
0.30
7.5
105
0.88
120
180
0.40
445
205
0.34
600
670
825
Brake Size 400 - Tb = 400 Nm, 300 lb-ft max torque
NORD p/n
Half-Wave Full-Wave Pc Vc Ic Rc
[V
AC
] [A
AC
] [V
AC
] [A
AC
]
[ W ]
[V
DC
] [A
DC
] [ Ω ]
19092254 127
19092954 230 0.56
115 1.13
131
19093904 400 0.33
200 0.67
135
19093954 460 0.31
230 0.61
141
19093964 500 0.26
250 0.51
130
24
5.28
4.54
105
1.25
82.6
180
0.74
241
205
0.68
303
225
0.57
389
Brake Size 10 - Tb = 10 Nm, 7.5 lb-ft max torque
NORD p/n
Half-Wave Full-Wave Pc Vc Ic Rc
[V
AC
] [A
AC
] [V
AC
] [A
AC
] [ W ] [V
DC
] [A
DC
]
[ Ω ]
19020222
19020922 230 0.14
115 0.29
19021902 400 0.07
200 0.14
19021922 460 0.06
230 0.12
19022222 500 0.06
250 0.12
19022522 575 0.05
277 0.10
28
33
29
26
30
27
24
105
180
205
225
250
1.17
0.32
0.16
0.13
0.13
0.11
20.6
332
1100
1620
1700
2323
Brake Size 40 - Tb = 40 Nm, 30 lb-ft max torque
NORD p/n
Half-Wave Full-Wave Pc Vc Ic Rc
[V
AC
] [A
AC
] [V
AC
] [A
AC
]
[ W ]
[V
DC
] [A
DC
] [ Ω ]
19040232
19040932 230 0.21
115 0.41
19041902 400 0.11
200 0.23
19041922 460 0.11
230 0.22
19042232 500 0.09
250 0.18
19042532 575 0.08
277 0.16
41
49
45
50
44
44
24
105
180
205
225
250
1.69
0.46
0.25
0.24
0.20
0.18
14.2
226
723
840
1150
1425
Brake Size 100 - Tb = 100 Nm, 74 lb-ft max torque
NORD p/n
Half-Wave Full-Wave Pc Vc Ic Rc
[V
AC
] [A
AC
] [V
AC
] [A
AC
]
[ W ]
[V
DC
] [A
DC
] [ Ω ]
19060252
19060952 230 0.40
115 0.79
19061902 400 0.21
200 0.41
19061952 460 0.20
230 0.40
19062252 500 0.16
250 0.32
19062552 575 0.14
277 0.28
80
92
83
91
79
79
24
105
3.33
0.88
7
120
180
0.46
390
205
0.44
464
225
0.35
643
250
0.31
795
Brake Size 250 - Tb = 250 Nm, 185 lb-ft max torque
NORD p/n
Half-Wave Full-Wave Pc Vc Ic Rc
[V
AC
] [A
AC
] [V
AC
] [A
AC
]
[ W ]
[V
DC
] [A
DC
] [ Ω ]
19080252 101
19080952 230 0.51
115 1.03
120
19081902 400 0.27
200 0.54
108
19081952 460 0.24
230 0.49
111
19082252 500 0.20
250 0.40
100
19081962 575 0.17
277 0.34
95
24
225
250
4.21
0.44
0.38
5.7
105
1.14
92
180
0.60
300
205
0.54
380
507
655
Brake Size 800 - Tb = 800 Nm, 600 lb-ft max torque
NORD p/n
Half-Wave Full-Wave Pc Vc Ic Rc
[V
AC
] [A
AC
] [V
AC
] [A
AC
]
[ W ]
[V
DC
] [A
DC
] [ Ω ]
19094254 152
19094954 230 0.85
115 1.70
197
19095904 400 0.47
200 0.95
191
19095954 460 0.44
230 0.87
201
24
6.32
3.79
105
1.89
54.8
180
1.05
170
205
0.97
213
Tb
Half-Wave [V
AC
]
Full-Wave [V
AC
]
Half-Wave [A
AC
]
=
=
=
Brake torque max
Voltage AC with half-wave rectifier (range -30% to +10%)
Voltage AC with full-wave rectifier (range -30% to +10%)
= Current AC to half-wave rectifier
Full-Wave [A
AC
]
= Current AC to full-wave rectifier
Pc
Vc
Ic
Rc
=
=
=
=
Power
Voltage DC (-30% to +10%)
Current DC
Resistance
Tolerance of the listed resistance figures ± 5%
Coil data at 20°C
*Precima 20Nm brake by special order only! NORD’s standard 20Nm brake is manufactured by Mayr which needs no air gap adjustment. See page 9 for Mayr information.
BIM 1090/2008/02 Page 3 of 12 www.nord.com
MAINTENANCE – PRECIMA BRAKES
General
In order to get maximum life out of the brake, the air gap must be set properly and checked at regular intervals. As the brake wears and decreases in thickness, the air gap will increase. If the air gap is too large, the brake coil may not have enough magnetic force to pull the metal armature disc across the gap and the brake rotor will drag. Refer to the table below for maximum air gap allowance and minimum brake pad thickness.
Brake Air Gap Adjustment:
When a complete brake motor is supplied by NORD, the air gap is already set at the factory. If the brake is ordered as a part, the air gap must be set at the time of assembly. All brake air gap adjustments must be made with the brake assembled onto the motor and power off
(Brake Engaged). If the brake has an optional hand release (Option HL), refer to page 9 for additional instructions.
While checking the air gap, measure the gap around the socket head cap screws as shown in the picture below.
•
Loosen the socket head cap screw that attaches the brake to the motor B-endbell.
•
Depending if the air gap needs to be increased/decreased, turn the adjusting nut accordingly. A quarter or half turn is usually sufficient for adjusting purposes.
•
After adjusting the nut, tighten the socket head cap screw back onto the brake.
•
Measure the air gap for spacing - Repeat process to achieve recommended setting.
Size
Rated
Torque lb-ft [Nm]
Power of
Brake Coil
W
Air Gap
Setting in [mm]
Max Air Gap
Before
Re-Adjustment in [mm]
Minimum
Rotor
(Brake Pad)
Thickness in [mm]
5
10
20
40
60
100
150
250
3.75 [5]
7.5 [10]
16 [20]
30 [40]
44 [60]
75 [100]
110 [150]
188 [250]
22
28
34
42
50
64
76
100
0.008 [0.2]
0.008 [0.2]
0.012 [0.3]
0.012 [0.3]
0.012 [0.3]
0.016 [0.4]
0.016 [0.4]
0.019 [0.5]
0.031 [0.8]
0.031 [0.8]
0.031 [0.8]
0.035 [0.9]
0.039 [1.0]
0.043 [1.1]
0.043 [1.1]
0.047 [1.2]
0.177 [4.5]
0.217 [5.5]
0.301 [7.6]
0.374 [9.5]
0.453 [11.5]
0.492 [12.5]
0.571 [14.5]
0.650 [16.5]
Rubber Dust Boot (Option SR)
The optional rubber dust boot protects the brake from dusty/sandy debris from reaching the brake pad. However, it also keeps the brake dust from getting out. Regular maintenance must be done to the brake to remove the brake dust. The amount of brake dust accumulated will vary with the brake size and application.
BIM 1090/2008/02 Page 4 of 12 www.nord.com
PARTS LIST – PRECIMA BRAKES
* *
*
Normal Design, Enclosure IP55 with following options:
RG – Stainless Steel Disc (Item 990)
SR – Dust Boot-includes Option RG (Item 992)
HL – Hand Release (Item 937)
932
936
937
938
939
940
946
971
990
991
Non-drive endshield
Brake coil
Manual brake lever – optional
Brake hub
Fan
Fan cover
Fixing screw
O-ring - optional
Friction plate - optional
Setting bolt
Optional Brake with optional IP66 enclosure
992
993
994
995
996
997
998
999
Dust protection ring
1)
Brake disc
Anchor plate
Spring
Adjustable ring **
Bushing/seal - optional
V-ring - optional
– optional
Pressure plate adjustment**
1)
Not available for 400N, and 800 Nm.
** Only for brakes that are 5 Nm to 40 Nm
BIM 1090/2008/02 Page 5 of 12 www.nord.com
BRAKE PAD REPLACEMENT – PRECIMA BRAKES
LIST OF TOOLS
Following are a list of tools to remove the brake:
• Screw drivers – Philips & Flat (to remove the fan cover)
•
External snap ring pliers (to remove fan retaining snap ring)
• Large screw drive or a small pry bar (to pop off the fan)
•
Metric sockets & T-handles and open-end wrenches
IMPORTANT
Ensure that the reducer load is supported. Removal of the brake will let the load free fall, which may cause injury.
Disconnect the power from the motor.
PROCEDURE
When the brake pad is worn to the minimum thickness as shown in the chart on page 5, the pad should be replaced to maintain the proper operation. To replace the pad:
• Remove the 4 bolts to remove the fan cover
•
If the brake has a hand release, this can be removed by unscrewing.
•
Remove the fan cover and note the position of the hand release slot if applicable.
• Remove the snap ring holding the cooling fan.
•
Carefully remove the cooling fan, key and second snap ring.
•
If the brake is equipped with a dust boot, remove it.
•
Remove the 3 socket head cap screws holding the brake coil to the motor end-bell.
•
Remove the brake coil, noting the hand release and power cable locations.
• The brake pad will now slide off the hub holding it on the shaft.
•
Clean the brake, install the pad and reassemble.
NOTE: Upon reassembly, the brake air gap setting must be checked and adjusted if needed, as noted in MAINTENANCE.
PRECIMA BRAKE REPLACEMENT PARTS
BRAKE SIZE
BRAKE DISC (PAD)
[ITEM 993]
HANDLE
[ITEM 937]
5 NM
10NM
20NM
40NM
40NM
1)
2)
3)
60NM
100NM
150NM
250NM
19120042
19120082
19120162
19120322
19120402
19120602
19120802
19121502
19122402
19150042
19150082
19150162
19150322
19150322
19150602
19150802
19151502
19152402
400NM
800NM
Call Factory
Call Factory
Call Factory
Call Factory
1) Alternate-Special order only. Standard brake is by Mayr – see page 7.
2) 90 and 100 frame motors with spline style hub.
3) 112 frame motor with hex style hub
STAINLESS DISC
[ITEM 990]
19130042
19130082
19130162
19130322
19130322
19130602
19130802
19131502
19132500
Call Factory
Call Factory
DUST BOOT
[ITEM 992]
19110042
19110082
19110162
19110402
19110402
19110602
19110802
19111502
19112502
Call Factory
Call Factory
BIM 1090/2008/02 Page 6 of 12 www.nord.com
MAINTENANCE – MAYR BRAKES (10 - 20Nm)
1.
Gear hub
2.
Coil carrier complete with coil (7)
3.
Rotor
5.
Armature disc
6.
Helical spring (torque)
7.
Coil
8.
Fixing screw
9.
Friction disc
10. Helical spring (hand release)
11. Threaded bolt
12. Lever
13. Washer
14. Hexagon nut
15. Hand release bar
16.
Shoulder screw
This style brake needs very little maintenance while it is in operation.
The air gap does not need to be adjusted. It is pre-set at the factory and is self adjusting for the life of the brake rotor pad. When the brake is not operation properly, the rotor pad may need to be replaced. The brake coil will have to be removed to check the brake pad thickness.
Size
Rated torque Power of Brake Coil
* Fixing scr
Inspection dimension ew (8)
Minimum Rotor Thickness
(brake pad)
10
20
7.4 lb-ft / 10 Nm
16 lb-ft / 20 Nm
BRAKE PAD REPLACEMENT
LIST OF TOOLS
Following are a list of tools to remove the brake:
• Screw drivers – Philips & Flat (to remove the fan cover)
•
External snap ring pliers (to remove fan retaining snap ring)
33 Watts
43 Watts
0.20” / 5.2 mm
0.27” / 6.8 mm
• Large screw drive or a small pry bar (to pop off the fan)
•
Metric sockets & T-handles and open-end wrenches
IMPORTANT
Ensure that the reducer load is supported. Removal of the brake will let the load free fall, which may cause injury.
Disconnect the power from the motor.
PROCEDURE
•
Remove the 4 bolts to remove the fan cover.
• If the brake has a hand release, it can be removed by unscrewing it.
•
Remove the fan cover and note the position of the hand release slot if applicable.
• Remove the snap ring holding the cooling fan in place.
•
Carefully remove the fan, key and second snap ring.
•
Remove the 3 socket head cap screws holding the brake coil to the motor endbell.
• Remove the brake coil, noting the hand release and power cable locations.
•
The brake pad will now slide off the hub holding it on the shaft.
• Clean the brake coil, replace the pad, and reassemble.
NOTE: The air gap is self adjusting and can not be measured with the brake assembled. To check the proper operation, apply pressure to the hand release lever and turn the motor by hand to check for free rotation.
MAYR BRAKE REPLACEMENT PARTS
Complete Brake Part Number
(Includes Brake Disc)
BRAKE
SIZE
24VDC 105VDC 180VDC 205VDC 250VDC
10NM N/A N/A N/A 19021934
20NM 19030224 19030924 19031904 19031924
1)
N/A
19032524
1) Standard NORD brake
BRAKE DISC (PAD)
[ITEM 3]
19120084
19120164
HANDLE
[ITEM 15]
19150074
19150164
STAINLESS DISC
[ITEM 9]
N/A
19130164
BIM 1090/2008/02 Page 7 of 12 www.nord.com
MAINTENANCE - MAYR BRAKES (400 - 800Nm)
1.
Gear hub
2.
Coil body complete with coil (9) and guide bushes (7)
5. Armature disc
7.
Guide bush
8.
Friction lining
9.
Coil
10. Anchor Plate
11. Helical spring
13. Fixing screw
14. Set screw
28. Spring washer
31. Threaded distance ring open
35. Rotor with friction linings (8)
58. Lock washer
59. Locking screw
60.
Spring washer
This style brake may need the air gap adjusted or have the pad replaced.
Both procedures are listed below.
Brake Size Rated Torque Power of Brake Coil
400
800
300 lb-ft / 400 Nm
600 lb-ft / 800 Nm
134 Watts
196 Watts
LIST OF TOOLS
Following are a list of tools to remove the brake:
• Screw drivers – Philips & Flat (to remove the fan cover)
•
External snap ring pliers (to remove fan retaining snap ring)
Minimum Rotor Thickness
(Brake pad)
0.53” / 13.5 mm
0.79” / 20 mm
Air Gap Setting
0.015” / 0.4 mm
0.020” / 0.5 mm
• Large screw drive or a small pry bar (to pop off the fan)
•
Metric sockets & T-handles and open-end wrenches
IMPORTANT
Ensure that the reducer load is supported. Removal of the brake will let the load free fall, which may cause injury.
Disconnect the power from the motor.
PROCEDURE FOR CHECKING AND ADJUSTING THE AIR GAP
•
Remove the 4 bolts to remove the fan cover.
• Remove the fan cover.
•
Remove a plug from the threaded distance ring (31) and measure the air gap with a feeler gauge. If the distance is larger than
0.012”/0.3mm over the nominal setting listed in the table, the air gap should be adjusted.
• Loosen the fixing screws (13)
•
Loosen the locking screw (59) and lock washer (60).
•
Turn the threaded distance ring counterclockwise to decrease the air gap. One graduation on the stamped scale corresponds with
.004”/0.1mm.
•
Tighten the fixing and clamp screws and recheck the air gap.
• If the air gap is within specifications, reassemble the fan cover.
PROCEDURE FOR REPLACING THE BRAKE ROTOR PAD
•
Remove fan cover and snap ring.
• Carefully remove the fan, key and second snap ring.
•
Remove the 3 socket head cap screws holding the brake coil to the motor endbell.
• Remove the brake coil.
•
The brake pad will now slide off the hub holding it on the shaft.
•
Clean the brake coil, replace the pad, and reassemble.
NOTE: Check the air gap per the above procedure.
MAYR BRAKE REPLACEMENT PARTS
BRAKE SIZE
400NM
800NM
BRAKE DISC (PAD)
19124004
Call Factory
HANDLE
19154002
Call Factory
BIM 1090/2008/02 Page 8 of 12 www.nord.com
HAND RELEASE BRAKE AIR GAP SETTING
When a complete brake motor is supplied by NORD, the brake air gap and hand release lever spacing are already set from the factory. Only the brake air gap will need to be adjusted for maintenance (Precima Brakes). Refer to the brake air gap setting on page 4. Thread adhesive is applied to the hand release adjusting bolt so it will not lose the setting. The spacing for the hand release can be checked only with the brake assembled onto the brake B-endbell. If the spacing needs to be adjusted, remove the brake from the motor B-endbell and the adjusting bolt will be accessible. Refer to Figure 1. *20Nm Mayr brake air gaps do not need adjustment.
If the brake is sent by itself from the factory, the brake air gap and hand release lever spacing must be set. If the air gap is set less than recommended, the brake will lose holding force prematurely. If very little air gap is set, the brake will not engage. Setting the brake air gap must be done with the brake removed from the motor. The “new” brake air gap value will be the sum of the brake air gap value and the hand release spacing value. After the gap has been set, assemble the brake onto the motor and measure both the brake air gap and hand release spacing with a feeler gauge. Refer to Figure 2.
BRAKE SIZE
y
5
0.040”
1 mm
10
0.040”
1 mm
20*
0.040”
1 mm
40
0.040”
1 mm
60
0.040”
1 mm
100
0.047”
1.2 mm
150
0.047”
1.2 mm
250
0.059”
1.5 mm
* Mayr Brake Hand Release: Tighten hand lever bolts snug and then back off by 2 turns.
ADJUSTING BRAKE TORQUE
The table below shows the rated torque of brakes as springs are removed (7, 5 or 3 springs). The springs are placed in such a way where there are three centers and four outer springs. The four outer springs are the ones that are removed for decreasing the torque. When decreasing the torque, remove springs opposite of each other to prevent uneven brake wear.
TORQUE ADJUSTMENT SPECIFICATIONS
Ring Nut Torque Adjustment
Brake
Size
Rated Torque
(full torque) lb-ft [Nm]
Rated Torque lb-ft [Nm]
Rated Torque lb-ft [Nm]
Torque Reduction
Per Click
Lb-ft [Nm]
Minimum Brake
Torque Available lb-ft [Nm]
5
10
20
20
1)
2)
40
60
100
150
7-springs
3.7 [5]
7.4 [10]
15 [20]
15 [20]
30 [40]
44 [60]
74 [100]
111 [150]
8-springs
5-springs
2.6 [3.5]
5.18 [7.0]
N/A
10.3 [14]
20.72 [28]
32 [43]
52 [70]
79 [106]
6-springs
3-springs
1.5 [2.0]
3 [4.0]
N/A
6 [8]
12.58 [17]
19 [25]
31 [41]
48 [65]
4-springs
250
400
184 [250]
295 [400]
138 [186]
221 [298]
92 [124]
148 [200]
800 600 [800] 442 [596] 296 [400]
1) Standard Stock MAYR Brake 2) Special Order PRECIMA Brake
0.15 [0.2]
0.15 [0.2]
0.81 [1.1]
0.22 [0.3]
0.74 [1.0]
0.9 [1.2]
1.8 [2.4]
7.5 [10.0]
3.6 [4.8]
8.5 [11.4]
Does not include a ring nut
Does not include a ring nut
Does not include a ring nut
Does not include a ring nut
Does not include a ring nut
Does not include a ring nut
400
0.059”
1.5 mm
BIM 1090/2008/02 Page 9 of 12 www.nord.com
CONNECTION DIAGRAMS
BIM 1090/2008/02
The external contacts shown for the brake operation must be rated for inductive loads and/or IEC class AC3 contacts.
Page 10 of 12 www.nord.com
CONNECTION DIAGRAMS (Cont.)
BIM 1090/2008/02
The external contacts shown for the brake operation must be rated for
inductive loads and/or IEC class AC3 contacts.
Page 11 of 12 www.nord.com
CONNECTION DIAGRAMS (Cont.)
TROUBLESHOOTING
FAULTS
Brake doesn’t release
Brake release is delayed
Brake does not engage
Brake engagement is delayed
CAUSE
Air gap too large
Brake not receiving electrical power
Failed rectifier
Brake is getting too warm
Voltage to brake coil too small
Rectifier supply voltage from inverter
Air gap too large
Voltage to brake coil too small
Voltage to coil too large
Hand release is adjusted incorrectly
Anchor plate mechanically blocked
Voltage to coil too large
Brake is switched to AC side
REMEDY
Check air gap and adjust
Check electrical connection
Replace rectifier
Use fast response (FR) rectifier
Check connection voltage of brake coil
Rectifier voltage must be from separate source. (Inverter output voltage varies)
Check air gap and adjust
Check connection voltage of brake coil
Check connection voltages of brake windings
Adjust to correct air gap
Remove mechanical blockage
Check connection voltage of brake windings
Use DC switching
BIM 1090/2008/02 Page 12 of 12 www.nord.com
MOTORS
Standard efficiency, 1.15 Service factor
Inverter duty, TEFC
Synchronous speed 1800rpm @ 60Hz, 4-pole
Voltages: 230/460 & 332/575 – 60Hz, Three-phase
Continuos Duty, 40°C Ambient, up to 3300ft Elevation
Class B temperature rise, Class F insulation
/ 6 0 H z
Frame
Size
HP kW n n
Full
Load
Full-load current I
230V 460V n
575V
I a
/I n
63S/4
63L/4
71S/4
71L/4
80S/4
80L/4 **
90S/4 **
90L/4 **
100L/4 **
100L/40 **
132S/4 **
132M/4 **
160M/4 *
160L/4 *
180M/4 *
180L/4 *
200L/4 *
225S/4 *
225M/4 *
250M/4 *
280S/4 *
280M/4 *
315S/4 *
315M/40 *
0.16
0.12
18.5
22
30
37
45
55
75
rpm
1700
A
0.88
A
0.44
A
0.35
0.25
0.18
1680 1.12
0.56
0.45
300
0.33
0.25
1710 1.56
0.78
0.62
0.50
0.37
1720 1.90
0.95
0.76
400
0.75
0.55
1710 2.70
1.35
1.0
0.75
1650 3.65
1.83
1.5
2.0
3.0
5.0
7.5
10
15
20
25
30
40
50
60
75
100
125
150
1.1
1.5
2.2
3.7
5.5
7.5
11
15 1760
90 1775 290
110
1660
1660
1700
1725
1730
1730
1760
1750
1755
1755
1755
1760
1760
1770
1775
4.83
6.33
9.04
15.2
19.8
25.7
36.8
49
60
71
91
124
143
170
223
345
200 150 1775 445
2.42
3.17
4.52
7.62
9.91
12.9
18.4
24.5
30.0
35.5
45
62
71
85
111
145
173
223
* - Underwriter Laboratories Recognition - pending
** - Carries the CE mark
1.08
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
%
300
340
400
280
320
340
350
510
380
440
820
800
740
800
580
670
700
700
670
650
750
750
Abbreviations
n
I n n
I a
/I n
T n
T a
/T n
T k
/T n pf
Full-load speed
-
-
-
-
-
-
Full-load current
Locked-rotor current ratio (percentage)
Full-load torque
Locked-rotor torque ratio
Break-down torque ratio
Power factor
Eff.
J m
Nominal efficiency
Motor inertia
Code
Letter
K
J
H
J
D
G
C
E
H
D
D
D
H
G
H
G
G
G
H
H
F
H
H
H
T n
75.9
111
183
273
364
537
716
900
lb-in
5.93
9.38
12.3
18.3
27.6
38.2
57.0
1080
1440
1800
2150
2690
3560
4440
5330
7100
2.2
2.7
2.2
2.7
2.8
2.8
2.6
2.9
2.7
2.3
2.3
2.2
2.0
2.1
2.6
2.5
2.6
2.2
2.8
2.6
2.6
2.6
3.1
3.2
T a
/T n
T k
/T n pf Eff.
J m
Inertia
% lb-ft
2
3.5
0.66
52 0.00499
2.5
0.72
57 0.00665
3.0
0.64
63 0.0133
2.7
0.69
71
2.3
0.71
72
2.2
0.64
70
2.5
0.68
73
0.0173
0.0304
0.0623
0.0887
2.4
0.70
74
2.5
0.70
75
3.1
0.75
81
2.6
0.71
85
3.0
0.73
87
3.3
0.85
89
3.3
0.86
89
3.0
0.87
89
0.1182
0.1699
0.2831
0.8796
1.197
1.187
1.661
3.085
3.3
0.87
90
2.6
0.89
92
2.2
0.83
91
2.8
0.86
91
2.6
0.89
90
2.6
0.87
91
2.6
0.86
91
3.1
0.87
90
3.2
0.86
93
3.560
10.68
13.29
16.85
19.93
37.02
42.71
80.68
125.8
Data subject to change without notice
www.nord.com
5/00
6
6
FIGURE 13
REEVING DRAWINGS
2 PD
3 PD
4 PD
6 PD
7 PD
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