ENGINEERING INC

Technical Manual No. M14-1265 Revision 000

NUOVO PIGNONE SPECIFICATION RT2629679

MODEL PG7121EA GAS TURBINE STARTING/TURNING SYSTEM WITH EMERGENCY DC DRIVE

ENGINEERING INC.

410 EAGLEVIEW BOULEVARD SUITE 100

EXTON, PA 19341 TELEPHONE: (610) 458-0153 FACSIMILE: (610) 458-0404

www.koenigengr.com

REVISION SHEET

Revision Revision Date Section Description of Change

000 17-June-2015 ALL Original Issue

Safety The Meaning of Safety Statements

You will f ind various types of safety information on the following pages and on the labels attached to the equipment. This section explains the meaning.

ENGINEERING INC

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Danger Danger means that failure to follow the safety statement will result in serious personal injury, death, or substantial property damage.

Warning Warning means that failure to follow the safety statement could result in serious personal injury, death, or substantial property damage.

Caution Caution means that failure to follow the safety statement may result in minor or moderate personal injury or property damage.

Notice Notice means that failure to follow these instructions could cause damage to the equipment or cause it to operate improperly.

Safety

ENGINEERING INC

The following safety statements relate to the installation, operation and troubleshooting of Koenig Engineering, Inc. Starting and Turning Gear Drive Packages

Notice Make sure you read and understand the installation procedures in this manual before you attempt to install, operate, maintain or troubleshoot the equipment.

Warning The instruction manual should be used for proper installation, operation and maintenance of the equipment. Improperly installing and maintaining these products can result in serious personal injury or property damage. Before attempting installation or maintenance, read and understand this entire manual.

Danger High Voltage There can be line voltage potential at the motor load terminals even with the starter in the off state. This is due to the possible leakage across SCR's. Always disconnect input power before servicing any electrical component.

ENGINEERING INC

Contents and Index Section 1 Starting and Turning System Description Starting System Schematic 14-1265-14 Starting and Turning System Installation Procedure Starting and Turning System Drawing 14-1265 Piping Assembly 14-1265-8 Recommended Spare Parts Section 2 Turning Gear Motor GE Emergency DC Drive Motor GE Section 3 Torque Converter and Gear Box Assembly SSS Duo-Concentric Clutch Output Shaft Bearings Section 4 Turning Gear, Delroyd Worm Gear Emergency Turning Gear Section 5 Motor - Converter Coupling Kop-Flex 353 KD1 Output Coupling Kop-Flex 354 RZ Morse “M” Series Clutch Holding Brake Tol-O-Matic P220 Section 6 Long Term Storage Instructions

KOENIG ENGINEERING, INC.

Technical Manual

TECHNICAL MANUAL NO. M14-1265

SECTION 1

MODEL PG7121EA GAS TURBINESTARTING TURBINE SYSTEM

EMERGENCY DC DRIVE

ENGINEERING INC

MODEL PG7121EA STARTING AND TURNING SYSTEM DESCRIPTION

(Refer to KEI Starting System Schematic)

PURPOSE:

The function of the Starting and Turning System is to initially breakaway the turbine drive train from rest and achieve turning gear operation. The starting motor is then energized in order to accelerate the gas turbine to ignition and assist until self-sustaining speed is attained. The system is designed to automatically engage, accelerate and disengage from the gas turbine shafting. The KEI Starting and Turning System is actually connected to turbine accessory gear, hereafter referred to as the turbine shaft. In addition the starting system may be operated for extended periods for the purpose of fast turbine cool down, HRSG purging or turbine water washing utilizing the main starting motor. For the normal cooldown period, an AC motor driven Turning Gear is provided. An Emergency DC motor driven Turning Gear is provided in the event of loss of AC.

COMPONENT DESCRIPTION:

A. ELECTRIC STARTING MOTOR The prime mover is a 935 KW (1254 HP), 4 POLE, 4000 VAC, 60 Hz motor provided by Nuovo Pignone.

The motor operates at a single speed to produce the necessary horsepower for starting the gas turbine. B. INPUT GEAR/TORQUE CONVERTER ASSEMBLY The input gear/torque converter assembly contains two helical gears, driver and driven, which are supported

by tapered roller bearings. The input shaft is attached to the motor shaft via a limited end float double engagement disc coupling. The driven gear shaft is connected to the torque converter impeller shaft via an internal spline. The input gear train is a step-up ratio type which increases the input speed to the torque converter to match the torque absorption characteristics of the torque converter and to provide optimum output torque for turbine starting.

A torque converter charging pump is provided as part of the assembly. The pump which is mounted to the

input gear boosts oil pressure to the converter from 25 psi, supplied from the turbine lube oil system, to 70/110 PSI, suitable for the converter traction circuit. The torque converter is also equipped with a speed control solenoid valve. The gas turbine is started with the solenoid valve closed (de-energized) and ignition off. The unit accelerates to approximately 1150 RPM for the purpose of purging prior to turbine ignition or for continuous operation for fast cool down, water washing, etc. To attain ignition speed, (432 RPM), the valve is opened (energized). Once ignition is established the valve is closed and the unit accelerates to self-sustaining speed.

After the starting motor is de-energized, a hydraulic brake automatically engages and the driven elements of

the torque converter are brought to rest.

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ENGINEERING INC C. DUO-CONCENTRIC CLUTCH The SSS (Synchro-Self-Shifting) clutch is a positive tooth type overrunning clutch which is self-engaging

when passing through synchronism. The duo-concentric clutch combines the turning gear and starting system clutches. The dual clutch disengages the turbine shaft from the turning gear system when the turbine speed becomes greater than the speed of the turning gear system. Likewise, the clutch disengages the turbine shaft from the starting system when its speed becomes greater than the speed of the starting system.

The clutch is supported by the hollow shaft of the worm gear assembly and the clutch input section is

connected to the torque converter by an internal spline shaft. The output shaft of the clutch is supported by two (2) journal bearings and is connected to the turbine shaft by a disc type flexible coupling.

D. TURNING GEAR SYSTEM The turning gear system consists of a worm gear assembly and an AC electric motor. The turning gear system

provides the torque necessary to breakaway and rotate the turbine shaft prior to the start of the turbine and also to rotate the turbine shaft after shut down to avoid rotor deformation due to thermal gradients. The AC motor driven turning gear provides a continuous output speed of 6 RPM. In the event of loss of AC power an Emergency DC Drive is provided to continue low speed operation until AC power can be restored. The Emergency drive will provide a continuous output speed of .25 RPM. The Emergency Drive gear is fitted with a 3/4 inch (19mm) hex for manual turning input.

LUBRICATION SYSTEM:

The starting system uses the turbine plant lube oil system for its lubricating and working fluid. The oil is provided through an oil header to lubricate the duo-concentric clutch and its support bearings. The torque converter also uses plant lube oil for its working fluid. Lubricating oil is provided through the oil header to the charging pump driven by the Torque Convertor Input Gear. The discharge oil plus all other oil drains from various components are routed back to the plant lube oil drain system. The turning gear lubrication system is a self contained immersion type system independent of the turbine plant lube system. A sight glass is provided to check oil level periodically.

-2-

ENGINEERING INC

MODEL PG7121EA STARTING AND TURNING SYSTEM

INSTALLATION PROCEDURE

(Refer to KEI Starting and Turning System Drawing 14-1265 and KEI Piping System Drawing 14-1265-8)

INSTALLATION PROCEDURES 1. Remove Input and Output Coupling Guards and retain hardware. 2. Install Output Coupling Half onto Accessory Gear shaft. Refer to Section 5 of Instruction Book,

Kop-Flex #354RZ Installation Instruction Form 16-601-1. Note: Accessory Gear Coupling Half, Spacer and Fasteners shipped assembled to unit 3. Install Motor Coupling Half on Motor shaft. Refer to Section 5 of Instruction Book, Kop-Flex #353

KD1 Disc Coupling Installation Instructions Form 22-001. Note: Motor Coupling Half, Spacer and Fasteners shipped assembled to unit. 4. Position Starting System on Accessory Package Support Structure. 5. Align Starting System Output Shaft to Accessory Gear Shaft. Refer to Nuovo Pignone Alignment

Arrangement Drawing and Kop-Flex Installation Instructions for the requirements and procedures. 6. After tightening hold down bolts, repeat alignment check and adjust as required. Dowel Bedplate

(Items 4, 5) to Accessory Package support in two (2) places per Drawing 14-1265, Note 3 and Section “B-B”

7. Reassemble Coupling Halves using Fasteners provided. (Follow referenced Kop-Flex Installation

Instructions for removal of Red Locking Set Screws and Yellow Collapsing Capscrews). 8. Position Starting Motor onto Accessory Package Support Structure and align to Input Gear Torque

Converter Input Shaft. Refer to Nuovo Pignone Alignment Arrangement Drawing and Kop-Flex Installation Instructions for the requirements and procedures.

1

ENGINEERING INC

9. After tighenting motor hold down bolts repeat alignment check and adjust as required. Dowel

motor foot to Accessory Package Support in to (2) places, 180º diametrically opposite. 10. Follow Kop-Flex Installation Instruction for removal of shipping screws. 11. Reinstall Input and Output Coupling Guards. 12. Connect oil supply and drain lines to Turbine Lube Oil System (Ref. Drawing 14-1265-8). 13. Oil for the Turning Gear is self-contained. The unit was shipped with 23.5 gallons of oil in the

reducer. Check for proper oil level through the sight glass and top off with Mobil SHC626 oil. Recommended alternate lubricants are listed in the Turning Gear Section 4.

14. Oil for the Emergency Turning Gear (DC Motor driven) is self-contained. The unit was shipped

with 1.0 gallon of oil in the reducer. Check for proper oil level through the Oil Level Plug and top off with Mobil SHC626 oil.

15. The following Electrical Connections are required:

(Refer to Drawing 14-1265 for locations) a. AC Turning Gear Motor: 460 VAC, 3 Phase, 1750 RPM, 60Hz, 15hp. Refer to

Note 1, below, and Section 2 of Manual for wiring diagram and re-greasing procedures b. Emergency DC Motor Drive: 125 VDC, 1770 RPM, 2 HP. Refer to Notes 1 & 2 below. c. Speed Control Valve Solenoid: 120 Volts DC, .19 AMPS (22.6 Watts)

d. Starting Motor: 4000 VAC, 3 Phrase, 60Hz, 935 KW, (1254 HP) (Not of KEI supply). Refer to

Note 1 below. Note: 1. Confirm correct rotation of Starting Motors. Starting Motor Rotation to be CCW looking at the drive end of Motor Shaft, AC Turning Gear Motor to be CW looking at drive end of Motor Shaft, and DC Turning Gear to be CW looking at drive end of Motor Shaft. Note: 2. DC Motor controls to have appropriate resistance to limit in-rush current to 21 amps during start-up (results in 9 ft-lbs. of motor output torque). Refer to Motor Section (2) for additional information regarding wiring diagram and re-greasing procedures.

2

ENGINEERING INC

INITIAL START-UP PROCEDURE When the turbine is ready to be started, the following procedure is to be followed. 1. Once the Starting System Assembly is installed and prepared for operation, the Turning Gear

should be initially operated manually ensure that breakaway of the turbine is possible without exceeding the torque capability of the Turning Gear.

2. Insert a torque wrench, with 19 mm (or .75 inch) hex drive socket, into the Manual Turning

Provision on the Emergency DC Drive. With the turbine lubrication in operation, rotate the gear input in the CW direction. Once the SSS Clutch is engaged, continue to apply torque to the Turning Gear until turbine shaft breakaway is achieved.

3. Once breakaway is achieved, the Turning Gear is ready for normal operation. 4. Upon initial start-up, the Speed Lower Solenoid to the Torque Converter should be energized to

allow passage for air to escape the Pressure Control Circuit.

CAUTION

BEFORE ATTEMPTING MANUAL OPERATION, AC AND DC TURNING GEAR MOTOR BREAKERS MUST BE DISCONNECTED AND TAGGED IN ORDER TO

PREVENT ACCIDENTAL INJURY.

CAUTION

DO NOT EXCEED 12 FT-LB (16 Nm) OF TORQUE ON THE MANUAL TURNING INPUT. DAMAGE TO THE TURNING GEAR COULD RESULT.

3

MechanicalPressure Measurement

R

Bourdon Tube Pressure GaugesStainless Steel Series, Solid Front CaseType 232.30 - Dry CaseType 233.30 - Liquid-filled Case

WIKA Datasheet 23X.30

Bourdon Tube Pressure Gauge Model 232.30

Applications

With liquid filled case for applications with high dynamic pressure pulsations or vibration

Suitable for corrosive environments and gaseous or liquid media that will not obstruct the pressure system

Process industry: chemical/petrochemical, power stations, mining, on and offshore, environmental tech-nology, mechanical engineering and plant construction

Special Features

Solid-front stainless steel caseExcellent load-cycle stability and shock resistanceAll stainless steel constructionPositive pressure ranges to 20,000 PSI

···

Standard Features

DesignASME B40.100 & EN 837-1

Sizes2½”, 4”, 4½” & 6” (63, 100, 115 and 160 mm) Temperature error

Additional error when temperature changes from reference Accuracy class temperature of 68°F (20°C) ±0.4% for every 18°F (10°C) rising 2½”: ± 2/1/2% of span (ASME B40.100 Grade A) or falling. Percentage of span.4”, 4½” & 6”: ± 1.0% of span (ASME B40.100 Grade 1A)

Weather protectionRanges Weather tight (NEMA 4X / IP65)Vacuum / Compound to 200 psiPressure from 0/15 to 0/15,000 psi - 2½” , 4”, 4½” Pressure connectionPressure from 0/10 to 0/20,000 psi - 6” Material: 316L stainless steelor other equivalent units of pressure or vacuum Lower mount (LM)

Lower back mount (LBM) - 2½” & 4” size onlyWorking pressure 1/4” NPT or 1/2” NPT limited to wrench flat area2½”: Steady: 3/4 full scale Fluctuating: 2/3 full scale Bourdon tube Short time: full scale value Material: 316L stainless steel

1,000 PSI: C-type, 4”, 4½” & 6”: Steady: full scale value 1,500 PSI: helical type Fluctuating: 0.9 x full scale value Short time: 1.3 x full scale value Movement

Stainless steelOperating temperatureAmbient: -40°F to +140°F (-40°C to +60°C) - dry Dial -4°F to +140°F (-20°C to +60°C) - glycerine filled White aluminum with black lettering, 2½” with stop pin -40°F to +140°F (-40°C to +60°C) - silicone filled

PointerMedium: +392°F (+200°C) maximum - dryBlack aluminum, adjustable +212°F (+100°C) maximum - liquid filled

WIKA Datasheet 23X.30 · 10/2011 Page 1 of 2

steve.yemenijian

Text Box

WIKA P/N's 10bar: 52713108 16bar: 52713109

Case304 stainless steel with solid baffle wall and blowout back (safety case)

WindowPolycarbonate (2½”) and Safety Glass (4”, 4½” & 6”)with Buna-N gasket)

Bezel ringStainless steel, bayonet-type

Case fillGlycerine 99.7% - Type 233.30 (LM only)

Optional extras Other pressure connections Monel® wetted parts (Type 26X.30) Front flange, SS (LBM only) Mounting lugs for wall mounting* Silicone or Halocarbon case filling (LM only) Red drag pointer or mark pointer Non-adjustable pointer Safety glass window Custom dial layout Integral alarm contacts or transmitters Other pressure scales available: bar, kPa, MPa, kg/cm² and dual scales

Size

A B C1 E G H J L M N S T W Weight

2.5” mm 63 48 42 17.5 63 18.5 4 3 85 75 2 14 0.44 lb. dry

in 2.48 1.89 1.65 0.69 2.48 0.73 0.16 0.12 3.35 2.95 0.08 1/4” 0.55 0.57 lb. filled

4” mm 101 86 57.5 24 93 30 4.8 3 132 116 2 22 1.43 lb. dry

in 3.98 3.35 2.26 0.94 3.66 1.18 0.19 0.12 5.20 4.57 0.08 1/2” 0.87 2.38 lb. filled

4.5” mm 121 97 59.5 25 X X X X X X X 22 1.43 lb. dry

in 4.76 3.82 2.34 0.99 X - X X X X X 1/2” 0.87 2.38 lb. filled

6” mm 161 116 58 24 - - 5.8 3 196 178 2 22 2.86 lb. dry

in 6.34 4.57 2.28 0.94 - - 0.23 0.12 7.72 7.01 0.08 1/2” 0.87 5.15 lb. filled

1 For 6” LM range 20,000 psi, C dimension changes to 75.5 mm / 2.97 in.2 Weight without optional accessories.

Note: For 2½” size, front flange is a 2-piece design. Hole panel cutout dimension for this option is 66.5 mm.

* Note: When mounting rear lugs, leave 15 mm between the back of the gauge and the mounting surface.

Recommended panel cutout is dimension D + 1 mm

Page 2 of 2 WIKA Datasheet 23X.30 · 10/2011

ROrdering informationPressure gauge model / Nominal size / Scale range / Size of connection / Optional extras requiredSpecifications and dimensions given in this leaflet represent the state of engineering at the time of printing.Modifications may take place and materials specified may be replaced by others without prior notice. WIKA Instrument Corporation

1000 Wiegand BoulevardLawrenceville, GA 30043Tel (770) 513-8200 Toll-free 1-888-WIKA-USAFax (770) 338-5118E-Mail [email protected]

U:\Technical Manuals Draft\M14-1265\14-1265_recsp.doc

RECOMMENDED SPARES MODEL PG7121EA, GT Starting/Turning System w/Emergency DC Drive.

KEI DRAWING 14-1265 SPEC NO. RT2629679

TECHNICAL MANUAL M14-1265

* Qty. Part No. Description Delivery/Price 1 WD7360PRIM Turning Gear Primary Set w/ 8Wk/ARO Seals and Bearings Per WD7360/DDSMBM140-S5 Consists of: 1) LOC. 14, Gear 11-2/3 Ratio 2) LOC 23, Bearing 1) LOC. 52, Shaft Collar 2) LOC. 53, C/R Oil Seal 3) LOC. 54, Shim 3) LOC. 55, Shim 3) LOC. 56, Shim 2) LOC. 73, Hub, Rotex 42 1-1/2 1) LOC. 74, Spider, Rotex 42 98 Duro 1) LOC. 75, Worm 11-2/3 Ratio 1) LOC. 78, Sleeve, Sure Flex 9JE 1) LOC. 79, Hub, Sure Flex 9S 1-5/8 1) LOC. 82, Shaft Collar 1 WD7360SEC Turning Gear Secondary Set w/Seals & Bearings 8 Wk/ARO Per WD7360/DDSMBM140-S5 Consists of: 1) LOC. 4, Gear 24-1/2 Ratio 2) LOC. 6, Bearing 1) LOC. 9, Worm 24-1/2 Ratio 2) LOC. 10, Bearing 1) LOC. 35, Tedeco Breather ¾ NPT 2) LOC. 42, Garlock Oil Seal 3) LOC. 57, Shim 3) LOC. 58, Shim 3) LOC. 59, Shim _____________________________________________________________________________________________ 1 WD66190/GEAR KIT Turning Gear Kit w/Bearings 8 Wk/ARO Per WD6619/VM35-S16 Consists of: 1) LOC. 7, Clutch 6) LOC. 15, Shim 6) LOC. 16, Shim 1) LOC. 21, Oil Seal 2) LOC. 22, Oil Seal 1) LOC. 23, Hub, Lovejoy 1” 1) LOC. 24, Hub, Lovejoy 1-1/8 1) LOC. 25, Lovejoy Spider 1) LOC. 26, Bearing 1) LOC. 27, Tedeco Breather ¾” NPT 1) LOC. 28, Bearing 1) LOC. 50, Worm 24-1/2 Ratio 1) LOC. 51, Gear 24-1/2 Ratio 2) LOC. 52, Bearing 1) LOC. 59, Gear Page 1 of 4



TECHNICAL MANUAL M14-1265*

Qty. Part No. Description Delivery/Price 1 SL17866MNKT SSS Clutch Minor Repair Kit Per 8 Wk/ARO Consists of: 4) Secondary pawl Pin 2) Primary Pawl Stop Pin 1) Bearing (Rigid Ball) 4) Turning Pawl Pin 4) Turning Pawl 4) Starting Secondary Pawl 4) Turning Pawl Spring 8) Secondary Pawl Stop Pin 2) Primary Pawl Pin 1) Bearing (Rigid Ball) 4) Turning Pawl Stop Pin 2) Starting Primary Pawl 2) Primary Pawl Spring _____________________________________________________________________________________________ 1 SL 17866MAJKT SSS Clutch Major Repair Kit 4 Mo/ARO Consists of: Includes Items From Minor Repair Kit Plus: 1) Helical Sliding Component (S) 1) Helical Sliding Component (T) 1) Sec. Ratchet Ring (S) NOTE; IF MINOR KIT HAS BEEN PURCHASED, HELICAL SLIDING COMPONENTS AND RATCHET RING CAN BE ORDERED SEPARATELY. _____________________________________________________________________________________________ 1 SL17866 (Optional) Replacement SSS Clutch Assembly Contact KEI _____________________________________________________________________________________________ 1 CD77685DRIVING Output Coupling Driving Unit 16 Wk/ARO 354 RZ (NOTE; MUST BE SHIPPED AS ASSEMBLED UNIT) Consists of: 1) CC77798, Hub 1) 1123725, Sleeve 1) 1123729, Disc Pack Assembly 8) WA82279, Capscrew 8) WA82245, Lock Nut 8) WA80625, Washer Page 2 of 4



TECHNICAL MANUAL M14-1265*

Qty. Part No. Description Delivery/Price 1 CD77685DRIVEN Output Coupling Driven Unit Per 16 Wk/ARO 354RZ (NOTE: MUST BE SHIPPED AS ASSEMBLED UNIT) Consists of: 1) CC77798, Hub

1) 1123725, Sleeve 1) 1123729, Disc Pack Assembly 8) WA82279, Capscrew 8) WA82245, Lock Nut 8) WA80625, Washer _____________________________________________________________________________________________ 1 CD77685FASTSET Coupling Fastener Set 12Wk/ARO 354RZ Consists of: 01) CX99688, Shim Pack 28) WA82272, Capscrew 28) WA82242, Lock Nut _______ ______________________________________________________________________________________ O P T I O N A L: (ENTIRE COUPLING REPLACEMENT) IN LIEU OF, OR ALONG WITH THE ABOVE COUPLING DRIVING/DRIVEN UNITS, AND FASTENER SET, IS RECOMMENDED FOR

EXTREMELY CRITICAL SERVICE OR WHERE THE COUPLING DESIGN USES NON-STANDARD COMPONENTS AS FOLLOWS:

1 CD77685 Output Shaft Coupling 16 Wk/ARO 354RZ _____________________________________________________________________________________________ 1 1154973 353 KD1 Flex Disc Coupling 16 Wk/ARO (Starting Motor to Torque Converter) _____________________________________________________________________________________________ 1 0939/0638 Output Shaft Bearing Set 4 Wk/ARO Consists of: 1) Journal Bearing 1) Journal/Thrust Bearing Page 3 of 4


KEI DRAWING 14-1265SPEC NO. RT2629679

TECHNICAL MANUAL M14-1265 *

Qty. Part No. Description Delivery/Price 1 AC141265 460 VAC Motor, 15 HP 16 Wk/ARO Non-Sparking (NEC Cl. 1, Div. 2, T3) If maintenance or overhaul is desired in lieu of motor replacement, contact KEI since this motor must be repaired or overhauled as a complete assembly, to maintain certification validity for hazardous environment specified. _____________________________________________________________________________________________________________________ 1 36A167400AA001 Brush Set, 2 HP DC motor 3 Wk/ARO 1 36B467022AB001 Brush Spring Set, 2 HP DC motor 3 Wk/ARO (This item is shipped with the above mentioned Brush Set) _____________________________________________________________________________________________________________________ 1 DC041260 125 VDC Motor, 2 HP, Explosion Proof 16 Wk/ARO If maintenance or overhaul is desired in lieu of motor replacement, contact KEI since this motor must be repaired or overhauled as a complete assembly to maintain certification validity for hazardous environment specified. _____________________________________________________________________________________________________________________ 1 X228816-H Torque Converter Charging Pump w/Mounting Gasket 4 Mo/ARO _____________________________________________________________________________________________ 1 52713108 / 9 Torque Converter Pressure Gauge Set 8 Wk/ARO (Long Term Spare) _____________________________________________________________________________________________ 1 67682 Torque Converter Model 4LUGP-2222 14 Mo/ARO Torque Converter W/Input Gear Box Assy. Torque Converter must be overhauled or replaced as a Complete assembly. Contact KEI for instructions. _____________________________________________________________________________________________ ACCESSORIES: 1 P220SBF07330120 Brake – Package Holding 1 Mo/ARO 1 SS92M4-O-W Brake Control Valve 1 Mo/ARO 1 238914-134D Electrical Solenoid, Torque Converter, 125 VDC 2 Wk/ARO Page 4 of 4


SECTION 2


EMERGENCY DC DRIVE

© Copyright 2010 General Electric Company 2010/11/08

g GE Energy

Motor Installation And Maintenance Instructions

Horizontal AC Small Industrial Motors

NEMA 143 to 5013 Frame

GEI 56128-J

GEI 56128-J

© Copyright 2010 General Electric Company

Table of Contents

I. General Information ................................................................................................................................................. 1 A. How to Properly Use this Instruction Manual .................................................................................. 1 B. Safety Symbols ............................................................................................................................................. 1 C. Safe Motor Operation Information ....................................................................................................... 2 D. Description of Labels and Nameplates ............................................................................................. 3 E. Model and Serial Numbers ....................................................................................................................... 3 F. Relevant Industry Standards ................................................................................................................... 3 II. Receiving ....................................................................................................................................................................... 3 A. Unpacking ....................................................................................................................................................... 3 B. Temporary Storage ..................................................................................................................................... 4 C. Extended Storage ........................................................................................................................................ 4 D. Handling .......................................................................................................................................................... 4 III. Installation .................................................................................................................................................................... 4 A. Location ........................................................................................................................................................... 4 B. Mounting .......................................................................................................................................................... 5 C. Sleeve Bearing Endplay ............................................................................................................................. 7 D. Power Supply and Connections ............................................................................................................ 7 IV. Operation…………………………………………… .................................................................................................................... 8 A. Steps Prior to Starting ................................................................................................................................ 8 B. Initial Start ....................................................................................................................................................... 8 C. Jogging and Repeated Starts ................................................................................................................. 9 V. Maintenance ................................................................................................................................................................ 9 A. General ........................................................................................................................................................... 10 B. General Cleanliness .................................................................................................................................. 10 C. Division 1 Explosion Proof Motors ...................................................................................................... 10 D. Insulation and Windings ......................................................................................................................... 10 E. Vacuum and Compressed Air Cleaning ........................................................................................... 10 F. Cleaning with Water and Detergent .................................................................................................. 11 G. Anti-Friction Bearings and Lubrication ............................................................................................ 11 H. Sleeve Bearings .......................................................................................................................................... 12 VI. Operational Difficulties.......................................................................................................................................... 13 VII. Failure ........................................................................................................................................................................... 15 VIII. Repair ............................................................................................................................................................................ 15 IX. Renewal Parts ........................................................................................................................................................... 15 X. Tightening Torque for SAE Hardware ............................................................................................................. 16 XI. Motor Lubrication Guide ....................................................................................................................................... 20

GEI 56128-J

© Copyright 2010 General Electric Company 1

I. GENERAL INFORMATION

A. How to Properly Use this Instruction Manual This installation and maintenance manual has been written to assist the user with proper procedures when handling, installing, operating and maintaining the equipment. All of the safety warnings and instructions in this book must be followed to prevent injury to personnel. This manual must be kept for future reference during installation, operation and maintenance.

B. Safety Symbols Below is a safety symbol table that identifies the safety symbols that appear in this manual and on the motors.

The use of a lightning bolt within an arrowhead symbol, enclosed in a yellow triangle warns of dangerous electrical voltage that could cause an electric shock to a person.

This symbol identifies a terminal, which is intended for connection to an external grounding conductor for protection against electric shock in case of a fault.

The use of an exclamation point within a yellow triangle indicates to the user that important installation, operating and maintenance instructions must be followed.

The use of a small case “i” enclosed in a square indicates a general note.

The use of wavy lines, enclosed in a yellow triangle, indicates that the motor can be hot and should not be touched without taking proper precautions.

WARNING: Indicates a procedure or condition that, if not strictly observed, could result in personal injuries or death.

This symbol instructs one to read the manufacturer’s instruction manual before installation, operation and maintenance.

CAUTION: Indicates a procedure or condition that, if not strictly observed, could result in minor injuries to personnel.

This symbol indicates the need to wear hearing protection.

GEI 56128-J


C. Safe Motor Operation Information

WARNINGS: High voltage and rotating parts can cause serious or fatal injuries. Qualified

personnel should perform installation, operation and maintenance of electrical machinery. For

equipment covered by this instruction book, it is important to observe safety precautions to protect

personnel from possible injury. Be sure to keep the installation and maintenance information for future reference. All

warnings and cautions must be followed.

Installation

Avoid contact with energized circuits and rotating parts.

Avoid bypassing or rendering inoperative any safeguards or protective devices.

Avoid use of automatic-reset thermal protection where unexpected starting of equipment might be hazardous to

personnel.

Avoid contact with capacitors until safe discharge procedures have been followed.

Be sure the motor shaft key is captive before the motor is energized.

Avoid long exposure in close proximity to machinery with high noise levels.

When the motor is coupled to equipment, ensure that system vibrations are within acceptable limit (per ISO 10816-

1) to avoid failure of the motor.

Use proper protective gear, care and procedures when handling, lifting, installing, operating and maintaining the

motor.

If eyebolts are used for lifting motors, they must be securely tightened, and the direction of the lift must not exceed

a 15° angle from the shank of the eyebolt. Do not use eyebolts in an ambient below 0°F. At temperatures below 0°

F, the eyebolt could fail resulting in injury to personnel and/or damage to equipment. Drop-forged eyebolts per

American Society of Testing Materials A489 or equivalent must be used.

Do not use the motor shaft as a means for lifting.

Do not lift both the motor and driven equipment with the motor lifting means.

Do not stand on or place objects on the motor.

Maintenance

Safe maintenance practices performed by qualified personnel are imperative. Before starting maintenance

procedures, be positive that:

Equipment connected to the shaft will not cause mechanical rotation.

Main motor windings and all accessory devices associated with the work area are disconnected from electrical

power sources.

The motor has been given time to cool. Failure to properly ground the frame of the motor can cause serious injury to personnel. Grounding should be in accordance with National and local Standards and consistent with sound practice. These instructions do not purport to cover all the details in motors nor to provide for every possible contingency to be met in connection with installation, operation or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should be referred to the General Electric Company. This document contains proprietary information of General Electric Company, USA and is furnished to its customer solely to assist that customer in the installation, testing, operating and/or maintenance of the equipment described. This document shall not be reproduced in whole or in part, nor shall its contents be disclosed to any third party without the written approval of GE Energy.

GEI 56128-J


D. Description of Labels and Nameplates Motor rating and identification data are furnished on labels and nameplates. Packing nameplates provide a permanent record of motor characteristics, plant identification and date of manufacture. Below is an example of a label that is attached to the shipping package.

E. Model and Serial Numbers As discussed in section D, every motor that is manufactured by GE Energy has a model and serial number, which are permanently marked on the motor nameplate. When contacting a GE Energy Service Shop or representative, please provide to the model and serial numbers.

Data and information regarding an individual motor model can be obtained from the Data Pack for the motor or through EliteNet or by contacting your local GE Energy representative.

F. Relevant Standards

1. Motors shipped with this installation instruction have been designed and built to the latest revision of the following standards:

a. NEMA MG-1

2. Motors that have the IECEx designation have also been designed to meet the requirements of the

following standards:

a. IEC and/or BS/EN 60079-0 b. IEC and/or BS/EN 60079-15

3. Motors with the CE Mark have also been designed to meet the requirements of the following EU directives:

a. Machinery safety b. Low Voltage c. Electromagnetic Compatibility d. Conformity Assessment

II. RECEIVING Each shipment should be carefully inspected upon arrival. Motor rating and identification data are furnished on a packing label for verification purposes. Any damage should be reported promptly to the carrier and a claim filed. The nearest GE Energy sales office may provide additional guidance.

A. Unpacking If the motor has been exposed to low temperatures, unpack it only after it has reached the temperature of the room in which it will be unpacked. Otherwise the motor windings will be exposed to condensing moisture.

MOD – GE model number KW = Motor power rating RPM = Motor speed at full load VOL – Motor voltage ENCL = Enclosure code FR = Frame size MASS = Motor mass SERIAL = Motor serial number

Figure 1: Packing Label

GEI 56128-J


B. Temporary Storage (Up to 6 Months) If the motor will not be put into service immediately, certain precautions should be taken to protect the motor while in

storage. It is recommended the motor be placed under cover in a clean, dry location.

During storage, windings should be protected from excessive moisture by some safe and reliable method of heating, such as space heaters, to keep the temperature of windings above the temperature of the surrounding air. It is recommended the motor in storage be inspected at periodic intervals, the windings meggered and a log kept of

pertinent data. (Refer to the OPERATION section.) Any significant drop in insulation resistance should be investigated. Precautions are taken by the factory to guard against corrosion. The machined parts are coated to prevent rust during shipment. If the equipment is to be stored, examine the machined parts carefully for rust and moisture and recoat where necessary. Motors with oil-lubricated or oil-mist lubricated bearings are normally operated and tested in the factory with a rust-inhibiting oil in the lubrication system. A rust-inhibiting film remains on critical bearing surfaces during transit and for up to six months in storage. However, when the machine is received, it is recommended that the bearing oil reservoirs on sleeve bearing motors be filled to the proper oil level with a good grade of rust-inhibiting oil. Rotate the shaft of two-bearing machines (10 to 25 revolutions) until the journals are thoroughly coated with oil.

The bearings of grease-lubricated motors are greased at the factory with the grease cavity approximately 50% full. Rotate the shaft of all grease-lubricated motors 10-20 revolutions at two-month intervals.

If the purchaser has specified the machine be packaged for long-term storage, the foregoing recommendations do not apply and the packing should be left intact during the period of storage.

C. Extended Storage (Longer than 6 months) In the event the motor is to be stored longer than six months, please refer to GE instruction manual GEK-97427.

D. Handling

WARNING: Lifting lugs on the motor are designed for handling only the motor. They are not to be used

to lift the motor plus additional equipment such as pumps, compressors or other driven equipment. In

the case of assemblies on a common base, lugs or eyebolts provided on the motor are not to be used to

lift the assembly and base. The assembly should be lifted by a sling around the base or by other lifting means

provided on the base. In the case of unbalanced loads (such as couplings or other attachments), additional slings

or other effective means should be used to prevent tipping.

III. Installation WARNING: Installation should be in accordance with the ‘USA-National Electric Code’ or ‘BS/EN 60204-

1’ and ‘BS/EN 60204-11’ and consistent with sound National and local practices. Coupling, belt and

chain guards should be installed as needed to protect against accidental contact with moving parts.

Motors accessible to personnel should be further guarded by screening, guard rails, etc., to prevent them from

coming in contact with the equipment.

A. Location Install the motor in a well-ventilated area. Make sure there is a minimum clearance of one foot around the motor to allow normal flow of air.

1. Drip-proof motors are intended to be used in a well-ventilated place reasonably free of dirt and moisture.

2. General Purpose enclosed motors can be used where they are exposed to dirt, moisture, and most outdoor conditions.

GEI 56128-J


3. Severe-duty enclosed motors can be used in highly corrosive or excessively moist areas.

4. Zone 2 Hazardous Locations

All motors marked with an IECEx or ATEX designation are suitable for Zone 2 locations. Before the motor is installed in the hazardous location, the marking must be reviewed for the intended location. If the motor marking does not meet the intent of the location do not install or operate the motor. Refer to BS/EN 60079-0 and BS/EN 60079-15. Motor marking for IECEx will have a nameplate with the IECEx logo, IECEx certification number, and IECEx marking codes. An example of the IEC Ex marking is as follows;

Ex nA IIC T3 Gc Where symbol:

a. Ex provides assurance of protection per IEC standards. b. nA indicates non-sparking c. IIC is a code to indicate the type of explosive gas atmosphere. d. T3 is a code for the maximum surface temperature. e. Gc is a code for the motor protection level.

Refer to B/EN 60079-0 and BS/EN 60079-15 for the meaning and understanding of all symbols and codes.

5. Division 1 Explosion-proof motors bearing the Underwriters’ Laboratories label designating the motor’s Class and Group as defined in the National Electrical Code (NEC) are designed for operation in areas classified by local authorities as hazardous in accordance with the NEC.

B. Mounting

1. Mount motors securely on a firm, flat base. Grout-in larger motors, if necessary. Grease lubricated motors can be wall or ceiling mounted with the shaft horizontal. Grease lubricated motors in NEMA 140–320 frame ratings can be wall mounted with the shaft vertical. The standard transition and/or sliding bases are only suitable for floor mounting. For other mounting positions, please refer to your local GE representative.

Oil lubricated sleeving-bearing motors shall always be mounted with the shaft horizontal. The endshield shall be located with the oil ring sight glass in the twelve o’clock position.

WARNING: Remove drain plugs from the frame or end shields of enclosed motors used outdoors or in

other high moisture areas.

2. On motors with dual mounting holes use the holes indicated per Figure 2A and 2B.

GEI 56128-J


Figure 2A: Mounting

Figure 2B: Mounting

GEI 56128-J


3. For base assembly and motor mounting, the mounting bolts must be tightened to prevent changes in alignment and possible damage to the equipment. It is recommended that a washer be used under each nut or bolt head to get a secure hold on the motor feet. As an alternative, flanged nuts or bolts may be used. The recommended tightening torques for medium carbon steel mounting bolts, SAE Grade 5, are listed below in Table 1. For recommended tightening torques of other hardware on the motor see tables 4A, and 4B in the Tightening Torque section of this book.

Table 1

Bolt Size Recommended Torque

in Ft-Lb (N-M)

Inch Metric Minimum Maximum

1/4 (M6) 7 (9) 11 (15) 5/16 (M8) 14 (19) 21 (28) 3/8 (M10) 25 (34) 37 (50) 1/2 (M12) 60 (81) 90 (122) 5/8 (M16) 120 (163) 180 (244) 3/4 (M20) 210 (285) 320 (433)

Note: For low carbon steel bolts, use 50% of the above recommended tightening torques. There are no ID marks on low carbon steel bolts.

4. For direct coupled applications use flexible couplings if possible.

Accurate mechanical lineup is essential for successful operation. Mechanical vibration and roughness in running the motor may be an indication of poor alignment. In general, lineup by straight edge across, and feeler gauges between coupling halves is not sufficiently accurate. It is recommended that the lineup be checked with a dial indictor and checking bars connected to the motor and load-machine shafts. The space between coupling hubs should be maintained as recommended by the coupling manufacturer. Shaft offset should not exceed 0.002”. Angular misalignment should be less than 0.002”.

5. The application of pulleys, sheaves, sprockets, and gears on the motor’s shaft is shown in NEMA Standard

MG1-14.07. The application of the V-belts dimensions for alternating current motors is in MG1-14.42. V-belt sheave pitch diameters should not be less than the values shown in Table 14-1 of NEMA MG-1. Sheave ratios greater than 5:1 and center-to-center distances less than the diameter of the large sheave should be referred to the Company. Make certain that the minimum allowed diameter of the motor pulley and the maximum belt tension are not exceed because an excessive pull may cause bearing trouble and shaft failures. Tighten belts only enough to prevent slippage. Belt speeds should not exceed 5000 feet per minute (25 meters per second). When V-belts are used, sheave ratios greater than 5:1 and center-to-center distances less than the large sheave shall not be used. The dimensions of the belt pulley are to be determined according to the kind of belt, transmission and capacity to be transmitted. Vent holes have to be kept free and required minimum distances are to be observed in order not to obstruct the flow of cooling air. In addition, make sure that the discharged hot air is not re-circulated into the motor.

C. Sleeve Bearing Endplay On sleeve-bearing motors, the feet should be located at a correct distance from the load so that the motor’s rotor is in the approximate mid-point of its endplay. The mid-position of the rotor’s endplay is indicated with a mark on the motor’s shaft. Locate this mark flush with the bearing housing.

D. Power Supply and Connections

1. Nameplate voltage and frequency should agree with the power supply. Motors will operate satisfactorily on line voltage within ±10% of the nameplate value or frequency within ±5%, combined variation not to exceed ±10%.

GEI 56128-J


2. Dual voltage motors can be connected for the desired voltage using instructions on the nameplate or the

connection diagram.

3. Wiring of motor, control, overload protection and grounding should meet the National and Local codes.

4. When mounting conditions permit, the conduit box may be rotated so that the conduit entrance can be made upward, downward, or from either side. For oversize conduit boxes, the mounting height of the motor may have to be increased for accessibility.

WARNING: Motor and control overload protection and grounding should be in accordance with

the USA -National Electric Code’ or ‘BS/EN 60204-1’ and/or ‘BS/EN 60204-11’ and consistent with

sound local practices.

IV. OPERATION

A. Steps Prior to Starting

WARNING: If the motor has been in a damp location, dry it out thoroughly before operating.

Before energizing the motor for the first time or after an extended shut down, it is advisable to

check the insulation resistance, power supply and mechanical freedom of the motor.

In accordance with established standards, the recommended minimum insulation resistance for the stator winding when measured with a 500 volt DC direct indicating ohmmeter with self-contained power supply (megger), shall not be

less than 5 mega-ohms at 40C for a motor rated under 1000 volts, and not less than 100 mega-ohms at 40C for a motor rated over 1000 volts. If the insulation resistance is lower than this value, it is advisable to eliminate the moisture in one of the following ways.

1. Dry the winding in an air-circulating oven with the air surrounding the winding at 110C, +5/-15C until the

part has been above 90C for at least four hours. Then the air temperature may be raised to 150C,

+5C/-15C. Continue to heat until the insulation resistance is constant for a one-half-hour period.

2. Enclose the motor with canvas or similar covering, leave a hole at the top for moisture to escape. Insert heating units or lamps and leave them on until the insulation resistance is constant for a one-half hour period.

3. With the rotor locked mechanically and using approximately 10% of rated voltage, pass a current through

the stator windings. Increase the current gradually until the winding temperature reaches 90C. Do not

exceed this temperature. Maintain a temperature of 90C until the insulation resistance becomes constant for a one-half hour period.

B. Initial Start

WARNING: Be sure the motor is not running and the power supply is disconnected.

1. For sleeve-bearing motors, flush out all sleeve bearings with kerosene to remove any dust or grit which

may have accumulated during storage.

Make sure that the oil plugs are tight and fill the oil wells with the oil recommended in the “Maintenance” section under “Sleeve Bearings” of this book to center of the oil level sight gauges. The oil level should be checked only when the machine is not running.

Do not flush out anti-friction bearings. The bearing grease supplied is sufficient for initial operation.

2. Whenever possible, examine the interior of the motor for loose objects or debris which may have

accumulated and remove any foreign material.

GEI 56128-J


3. If possible, turn the rotor by hand to be sure that it rotates freely.

4. Check all connections with the connection diagram. Check all accessible factory made connections for tightness to make sure none has become loose during shipment.

5. When the driven load is likely to be damaged by the wrong direction of rotation, it is best to uncouple the motor from its load during the initial start and make certain it rotates in the correct direction. If it is necessary to change rotation, interchange any two line leads.

Some motors are designed for unidirectional rotation. Rotation of these motors must be in accordance with the rotation indicated on the motor’s nameplate and the outline furnished with the equipment. Connection plates on the motor have been furnished to assist in obtaining the proper rotation.

6. After inspecting the motor carefully, make the initial start by following the regular sequence of starting operations in the motor starter control instructions.

7. For sleeve-bearing machines, after starting verify that the oil rings are operating properly and that oil is

being fed to the shaft.

The temperature of the sleeve bearings, as measured by bearing temperature detectors, should not

exceed 93C (200F).

At initial start, the rate of rise of the bearing temperature is more indicative of trouble than is total temperature. When starting a machine for the first time, the bearing temperature should be observed for

a minimum of 2 hours. If at any time the rate of temperature rise exceeds 2C/minute, shut down the motor immediately and make an investigation of lineup conditions, and if necessary, the bearing and oil ring assembly.

8. For anti-friction bearings check motor operation under load for an initial period of at least one hour to

observe whether any unusual noise or hot spots develop.

9. In the event of excessive vibration or unusual noise disconnect the motor from the load and check the mounting and alignment.

10. Check the operating current against the nameplate value. Do not exceed the value of nameplate current

multiplied by the motor service factor (if any) under steady continuous load.

11. Space heaters should be de-energized during motor operation.

C. Jogging and Repeated Starts

CAUTION: Repeated starts and/or jogs of induction motors greatly reduce the life of the winding

insulation. The heat produced by each acceleration or jog is much more than that dissipated by the

motor under full load. If it is necessary to repeatedly start or jog a motor, it is advisable to check the

application with the local GE Energy sales office.

V. MAINTENANCE

WARNING: Before initiating maintenance procedures, disconnect all power sources to the motor

and accessories. For motors equipped with surge capacitors, do not handle the capacitors until

they are discharged by a conductor simultaneously touching all terminals

and leads, including earth. This discharge conductor should be insulated for handling. Replace all normal

grounding connections prior to operating.

GEI 56128-J


A. General If the motor is dismantled during maintenance, sealing compounds (if any) shall be removed from machined rabbets (spigots). When reassembling the motor, all machined surfaces forming metal-to-metal joints should be sealed with watertight sealing compound (Tite-Seal, GE Spec. A50CD427A or equivalent). Inspect the motor at regular intervals, depending on service. Keep the motor clean and the ventilation openings clear. In addition to the daily observation of the overall condition, it is recommended that a general inspection routine be set up to check periodically the following items:

1. General cleanliness

2. Insulation and windings

3. Lubrication and bearings

B. General Cleanliness The interior and exterior of the motor should be kept free from dirt, oil and grease and conducting dust. Paper, textile or dusts may build up and block off ventilation. Any of these contaminants can lead to early motor failure.

C. Division 1 Explosion Proof Motors

Division 1 Explosion-proof motors have special features and are manufactured in accordance with UL and carry its label. Therefore, repairs need to be made at a GE Service Shop, which has been authorized to make such repairs.

D. Insulation and Windings To obtain a long life and satisfactory operation of insulated windings, they should be kept clean from dirt, oil, metal particles and other contaminants. A variety of satisfactory and acceptable methods are available for keeping the windings clean. The choice of method will depend greatly on time, availability of equipment and on the insulation system. Vacuum and/or compressed air cleaning with non-metallic hose tips should precede cleaning with water and detergent or with solvents. Tightly adhering dirt will require removal by gentle brushing or wiping.

WARNING: To prevent injury to the eyes and respiratory organs, safety glasses and suitable

ventilation or other protective equipment should be used.

E. Vacuum and Compressed Air Cleaning Compressed air should be used to remove loose dirt and dust from air passages such as air ducts. Suction should be used to remove dirt from the windings and to avoid damaging the coils.

CAUTION: Care must be taken to make sure the air is dry and that air pressure of not more than 21 x

103kg/m2 (30 psi) is used.

WARNING: Operator must not use compressed air to remove dirt or dust from his or her person and

clothing.

GEI 56128-J


F. Cleaning with Water and Detergent

This method is very effective in cleaning windings when used with a low-pressure steam jenny maximum steam flow

30 psi and 90C.

CAUTION: To minimize possible damage to varnish and insulation, a fairly neutral non-conductive type

of detergent such as DuBois Flow should be used. A pint of detergent to 76 liters (20 gallons) of water is

recommended.

If a steam jenny is not available, the cleaning solution may be applied with warm water by a spray gun. After the cleaning operation, the windings should be rinsed with water or low-pressure steam.

Dry the windings. Refer to the Insulation Resistance section in IV A. above, for instructions on how to proceed.

G. Anti-Friction Bearings and Lubrication The grease used as a lubricant in grease-lubricated anti-friction bearings does not lose its lubricating ability suddenly, but over a period of time. For a given bearing construction and assembly, the lubricating ability of a grease over time depends primarily on the type of grease, the size of the bearing, the speed at which the bearing rotates and the severity of operating conditions. As a result, it is not possible to accurately predetermine when new grease must be added. But, good results can be obtained if the general recommendations stated in this manual are followed. The primary function of grease is to supply the essential lubrication oil from the sponge-like reservoir of its soap structure. Grease-lubricated anti-friction bearings consume only a small amount of lubricant. This lubricant must always be present to avoid rapid wear and bearing failure. However, excessive or too frequent lubrication may also damage the motor. Ball bearing motors are adequately lubricated at the factory. Motors with grease fittings should be lubricated in accordance with these instructions to provide maximum bearing life. To obtain optimum results, Exxon Mobil Polyrex EM (General Electric Specification D6A2C23) polyurea grease should be used for lubrication, unless special grease is specified on the motor’s nameplate. See Section XI Lubrication Guide for greasing frequency and recommended quantity of grease. If in doubt, refer to GE Energy.

CAUTION: Failure to use polyurea base (NLGI Grade 2) or known compatible grease could result in

premature bearing failure.

The procedure below must be followed for safe and effective re-greasing. The recommended frequency and quantity of grease is stated in tables 5 and 6.

WARNING: Lubrication maintenance should be performed with the motor stationary and

disconnected from the power source. Extreme caution must be exercised to avoid contact with

rotating parts or electrical wiring if the motor must be lubricated while running. Extreme caution

must be exercised to avoid contact with rotating parts or electrical wiring if the motor must be lubricated while

running. Failure to observe these precautions may result in damage to the equipment, injury to personnel, or both.

1. Run the motor until warm.

2. Stop the motor and disconnect it from the power supply.

3. Clean dirt and debris from around the inlet lubrication fitting and the grease relief plug.

4. Remove the relief plug and clean the opening and relief tube of hardened grease. This may be accomplished with a twisted wire brush or sturdy pipe cleaner.

GEI 56128-J


5. Insert brush into the relief hole. While the motor is still warm, add grease with a hand-operated grease

gun until fresh grease appears on the end of the brush or until grease has been added up to the amount listed in Table 6.

6. Leave the relief plug temporarily off. Start the motor and run for 10 to 20 minutes to expel any excess

grease.

7. Stop the motor. Replace the relief plug.

8. Restart the motor and resume operation.

CAUTION: Failure to observe the foregoing instructions for re-greasing may result in grease leakage

and/or bearing damage. To avoid damage to equipment, bearings and grease must be kept free of dirt.

Because this method of greasing bearings tends to purge the housing of used grease over a period of time, removal of all grease should be required infrequently. A GE Energy Authorized Service Shop can clean the bearing cavity and replace the bearings and grease when the motor is removed from service for maintenance or reconditioning.

NOTE: Warranty may be voided if internal maintenance or repairs are not performed by a GE Energy

Authorized Service Shop

H. Sleeve Bearings

Motors with sleeve bearings have a removable top half bearing housing cover. By removing this cover each bearing and the oil in the reservoir can be inspected without disturbing the line-up. Prior to operation of the motor, both oil reservoirs should be filled to the center of the oil level gage. The oil should be maintained at this level (determined with the motor at stand still). Oil is added through the oil sight gauge hole above each bearing or through the inlet pipe provided.

1. Oil

For motors operating between -10C and 50C, use a good grade of mineral oil having a viscosity of ISO 32. Consult GE Energy sales office regarding special lubricants for unusual operating conditions.

2. Cleaning Sleeve Bearings Sleeve bearings housings are provided with liberal settling chambers into which dust, dirt, and oil sludge collect. The only cleaning necessary is to remove the drain plug from beneath the oil level indicator or bearing housing as the case may be. After draining, seal the threads of the drain plug with an oil sealing compound and refill the oil reservoir. Whenever the motor is disassembled for general cleaning, the bearing housing may be washed out with a suitable solvent. In washing the bearing housing the bearing and bearing housing assembly should be disassembled only to the extent that is absolutely necessary. Dry the bearing lining and shaft with a film of oil before reassembling.

3. Sleeve Bearing Replacement

Extreme care is required in the disassembly of a bearing to prevent nicking or burring of the bearing or

machined surfaces. In addition, the surfaces of the journal and the bearing must be protected from

damage when exposed during the process of disassembly.

Remove all bearing sensors prior to disassembly of the bearing.

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a. The drive end and opposite drive end sleeve bearing may be replaced by the following procedure:

i. For the opposite drive end the fan cover must be removed first. Use the lifting eye on the fan

cover to support and move the fan cover during disassembly. There are 5 socket head cap screws that secure the fan cover. These must be removed.

ii. For Zollern bearings remove the three socket head cap screws on the outer flange of the upper

half of the bearing housing which secure it to the endshield. For RENK bearings remove the cover plate that is bolted to the upper half of the bearing housing and endshield. The name Zollern or RENK will be embossed in the bearing housing.

iii. Remove the four socket head screws that secure the top half of the bearing housing to the

bottom half.

iv. Remove the upper half of the bearing housing.

v. Remove the four socket head screws on the bearing.

vi. Remove the upper half of the bearing.

vii. Jack up the shaft a few mils to remove the weight of the rotor from the lower bearing surface.

viii. Remove the split line screws from the oil ring and remove the split parts.

ix. Rotate the lower half bearing around the shaft and remove.

b. Cleanliness is important when working with bearings. Before reassembling a bearing, all bearing and machine surfaces should be thoroughly cleaned with a suitable solvent. Examine all machined fits for burrs. Remove all oil-sealing compounds from sealing surfaces.

Prior to actual reassembly, the following precautions should be observed:

i. Inspect the bearing housing and related parts for foreign matter. Clean, if necessary.

ii. Inspect the journals and polish them with crocus clothe if any scratches are detected. Do not

allow any metal dust to fall into the housing when polishing the journals.

iii. Spread a thin coat of oil over the journal and bearing surfaces before reassembling.

iv. The sealing surfaces of the bearing should be coated with a sealing compound such as No. 3 Permatex.

v. To replace the bearing, reverse the disassembly procedure.

GEI 56128-J


VI. OPERATIONAL DIFFICULTIES

Some operating difficulties may occur. Common causes are given in Table 2 and should be corrected as soon as possible.

TROUBLESHOOTING CHART

Table 2

Affected Parts Difficulty What to Check

Windings Overheating

Calibration of measuring instrument

Excessive Current

Unbalanced AC current

Improper or restricted ventilation

Excessive ambient temperature

Short circuited coil or windings

Dirty windings

Unbalanced voltage

Bearings Overheating

Calibration of measuring instrument

Worn out or dirty oil *

Rough journal *

Oil rings jammed *

Insufficient Oil *

Misalignment

Excessive end thrust or radial loading

Shaft currents

Excessive or insufficient grease **

Worn out or dirty grease **

Motor Excessive Vibration

Unbalance

Misalignment

Improper or settled foundation

Non-uniform air gap

Rubbing parts

Bent shaft

Unbalanced stator current

Damaged bearing

Winding Insulation Low insulation resistance

or insulation failure

Moisture, dirt, metal particles, oil, or other contaminants on the windings

Wrong voltage

Excessive temperature

Voltage surges

Mechanical damage

Excessive vibration with resultant mechanical damage * Sleeve bearings ** Anti-friction bearings

GEI 56128-J


VII. FAILURE

WARNING: An extreme overload or electrical failure may result in heating or arcing which can

cause the insulation to give off noxious fumes. All power should be removed from the motor

circuit as a precaution even though the circuit has overload protection. Personnel should not

approach the motor until adequate ventilation of the area has purged the air of fumes. When covers of a motor

are removed after a failure, care should be observed to avoid breathing fumes from inside the motor. Preferably,

time should be allowed for the motor to cool before attempting any examination or repair.

WARNING: Water should not be applied to any electrically energized equipment because electric

shock could result in serious or fatal injury. In case of fire, disconnect all power and use a carbon

dioxide extinguisher to quench the flame. Before operating any motor after a suspected failure,

it should be inspected for damage.

VIII. REPAIR If a motor is marked with IECEx or ATEX designation and repairs are required, the motor must be repaired by operators trained in the understanding of BS/EN 60079-1 and BS/EN 60079-15 standards. The motor has been designed to meet the rigid requirements of these standards. Repair or alteration of the motor may result in the motor no longer meeting the requirements of these standards. If major repairs are undertaken (such as rewinding a stator), proper facilities should be made available and suitable precautions observed. Recommended tightening torques for various parts is listed in Tables 4A and 5B below.

WARNING: When burning off old insulation materials or when welding near insulation during

rewinding, adequate ventilation must be provided to avoid exposing personnel to noxious fumes.

Combustion of exhaust must be complete and adequately vented to the outside atmosphere in

compliance with acceptable standards.

Exposure of personnel to air-borne inorganic fibers must be avoided by adequate ventilation or by wetting the

remaining insulation components following the burning of the organic materials.

IX. RENEWAL PARTS The use of only GE Energy renewal parts is recommended. When ordering, specify the model number and the serial number of motor (complete nameplate data is desirable). Specify quantity and describe the part.

For information and service, refer to the nearest GE Energy Sales Office or a GE Energy Authorized Service Shop.

GEI 56128-J


X. TIGHTENING TORQUE FOR SAE HARDWARE

General Notes related to fasteners:

1. Medium carbon steel fasteners per ASTM A449 Type 1. 2. Stainless steel fasteners per ASTM F593. 3. Threaded holes in parts for fasteners are per System 21, ASME/ANSI B1.3

Table 4A: Tightening Torque Range Medium Carbon Steel SAE Hardware Grade 5 (Unless specified in below table)

Screw/Bolt Size Typical Application Torque

(Inch-lbs)

Torque

(N-m)

#10 (Low Carbon Steel) Bearing Cap 15 - 25 1.7 – 2.8

1/4 in (Low Carbon Steel) Bearing Cap 35 - 60 4.0 – 6.8

1/4 in All Parts, except Bearing Cap and

Fan Cover 70 – 96 7.9 – 10.8

1/4 in Grade 8 Fan Cover Mounting 100 - 145 11 – 16

5/16 in Bearing Cap 78 - 120 8.8 – 14

5/16 in All Parts, except Bearing Cap 170 - 250 19 – 28

3/8 (Low Carbon Steel) Conduit Box Cover 180 – 240 20 – 27

3/8 in All Parts, except Conduit Box

Cover 250 – 370 28 – 42

1/2 in All Parts 610 – 920 70 – 100

3/4 in All Parts 2150 – 3200 240 – 360

Table 4B: Tightening Torque Range

Stainless Steel SAE Hardware Property Class 50

Screw/Bolt Size Typical Application Torque

(Inch-lbs)

Torque

(N-m)

#10 Bearing Cap 15 – 25 1.7 – 2.8

1/4 in Bearing Cap 35 – 60 4.0 – 6.8

1/4 in All parts, except Bearing Cap 60 - 75 6.8 – 8.5

5/16 in Bearing Cap 78 – 120 8.8 – 14

5 /16 in All parts, except Bearing Cap 130 – 155 15 – 18

3/8 in All Parts 230 – 275 26 – 31

1/2 in All Parts 550 - 670 62 – 76

5/8 in All parts 1100 – 1340 120 – 150

3/4 in All Parts 2000 - 2360 230 - 270

GEI 56128-J


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GEI 56128-J


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GEI 56128-J


Typical 500 Frame TEFC Construction – Ball Bearing

Typical 500 Frame TEFC Construction – Sleeve Bearing

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GEI 56128-J


XI. Lubrication Guide (Excerpt from: GEK-72836E)

Table 5: Motor Lubrication Guide

Type of Service

Typical Examples HP Range Lubrication Interval (Yrs.) Horizontal Vertical

Easy Valves, door openers, portable floor sanders, motor operating infrequently (one hour per day)

1 – 7.5 10 – 40

50 – 150 200 – 350 400 - 1000

10 7 4 3 1

9 3

1.5 9 months

---

Standard

Machine tools, air-conditioning apparatus, conveyors (one or two shafts), garage compressors, refrigeration machinery, laundry machinery, oil well pumps, water pumps, woodworking machinery

1 – 7.5 10 – 40

50 – 150 200 – 350 400 - 1000

7 4

1.5 1

6 months

3 1

6 months 3 months

---

Severe

Motor for fans, MG- sets, etc., that run 24 hours per day, 365 days per year; coal and mining machinery; motors subject to severe vibration; steel mill machinery

1 – 7.5 10 – 40

50 – 150 200 – 350 400 - 1000

4 1.5

9 months 6 months 3 months

1.5 6 months 3 months

1.5 months ---

Very Severe

Dirty, vibrating applications; where end of shaft is hot (pumps and fans); high ambient temperature

1 – 7.5 10 – 40

50 – 150 200 – 350 400 - 1000

9 months 4 months 4 months 3 months 2 months

6 months 3 months 2 months 1 month

---

Table 6: Number of Grease Gun Pumps

Bearing Size on Motor Nameplate

Number of Pumps Bearing Size on

Motor Nameplate

Number of Pumps

16 Oz. Gun (Approx. 475

mL)

24 Oz. Gun (Approx. 700 mL)


mL)


mL)

6205 5 3 6312 40 27 6206 6 4 6314 50 35 6208 10 7 6315; C 2315 65 45 6210 25 17 6316 60 40 6213 35 23 6318; NU 318 75 50 6220 58 39 6320; NU 320; C 2320 95 65 6309 20 13 6321 153 102 6310 25 17 6324; NU324 246 164

NOTE: A standard 10,000 PSI (69 kPa) 16 ounce (475 mL) grease gun delivers approximately 0.04 oz. (1.18

mL) of grease with each pump, and a 24 oz. (710 mL) gun delivers approximately 0.06 oz. (1.77 mL) of

grease. The number of pumps listed represents approximately 20% of the total grease cavity volume in

end shield.

Wednesday, March 11, 2015

Technical Data Center PO Box 2204 Fort Wayne, IN 46801-2204

Customer: KOENIG ENGINEERING INC 410 EAGLEVIEW BLVD STE 100 EXTON, PA 19341

DataPack Document, Version: v15031799.01

Visit us: www.gemotors.com Page 1 of 6

Inside Sales Representative:

Inside Sales Rep Phone: Alternate Phone: 260-439-2000 Model Number: 5KGS254XAA224F2 Customer Order: No: 24493HF

Sales Order No: 5200016654 Customer Item No: Order Line No: 4.1 Customer Part No:

Instruction Manual: GEI-56128 Outline Drawing: 4002B5825PGP5447 Connection Diagram: GEM2034E-FIG7

Accessory Connection Diagrams

Bearing Thermocouple: None Heater: 3027JE-1 RTD: None Thermistor: None

Thermostat: None Winding Thermocouple: None Bearing RTD: None

Revision History Version Date Comments v15031799.01 03/11/2015 Original Version

Distribution Information Quantity Recipient Quantity Recipient 1 [email protected]

[email protected] E-Mail Distribution

1 Meneses, Tomas [email protected] E-Mail Distribution






Customer Order / Item: 24493HF Sales Order No: 5200016654

Customer Part: None Order Line No: 4.1

MODEL NUMBER: 5KGS254XAA224F2 Estimated Weight: 315 Lbs Outline Drawing: 4002B5825PGP5447 Time Rating: CONT

Connection Diagram: GEM2034E-FIG7 Enclosure: TEFC Instruction Book: GEI-56128 Encl Construction: 841

Design Code: 25BD1220A Ambient Max(°C): 50 Type: KGS Insulation Class: H

Frame: 254TD NEMA Design: A Phases: 3 Nominal Efficiency: 92.4%

Poles: 4 Guaranteed Efficiency: 91.7% Output Power: 15HP 11.2KW KVA Code: H

RPM: 1770 Max KVAR: 4.0 Voltage: 460 Power Factor: 86.0

Hertz: 60 Bearing - DE: 6310ZC3 Amps - FL: 17.7 Bearing - ODE: 6309ZC3

Service Factor: 1.15

Enclosure is Totally Enclosed Fan-Cooled

Stamped Nameplate Notes: EXCEPTION TO IEEE-STD-841-2009: NEMA DESIGN A, FABRICATED CONDUIT BOX DE BRG 50BC03XP3 ODE BRG 45BC03XP3 TEMP CONT HTR LDS H 115V 35W INVERTER DUTY PER NEMA MG1 PART 31 ALTERNATE RATING FOR PWM CONTROL:1.0SF 50C AMBIENT VAR TORQUE RANGE 0-60 HZ ROT CW FACING ODE LEAD/PH SEQUENCE 3-2-1/1-2-3 ROT CCW FACING ODE LEAD/PH SEQUENCE 1-2-3/1-2-3 GE SELF DECLARED CLASS I DIV 2 MOTOR MAX EXPOSED INTERNAL AND EXTERNAL SURFACE TEMPERATURES UNDER USUAL SERVICE CONDITIONS AT 1.00 S.F. DO NOT EXCEED 200 DEG C MAX SPACE HEATER SURFACE TEMPERATURE 160 DEG C NOTE TO MANUFACTURING: STAMP TAG NUMBER AS PER ORACLE STAMP PURCHASE ORDER NUMBER AND DATE OF ORDER 80 DEG C RAISE @1.00 SF SUITABLE FOR 2-COLD OR 1-HOT START 657% LRA, 291% LRT Additional Information:






4P - T EXTN FLOOR MOUNT WITH CONDUIT BOX OPPOSITE STANDARD F2 CONDUIT BOX MOUNTING HTR LEADS EXIT AUXILLARY BOX ON TOP "D" FLANGE AT DE ENDSHIELD AK=11" PAINTED FRAME ID & SHAFT, FAN COVER INSIDE & ODE E/S OUTSIDE ROUTINE AND 5 POINT VIBRATION TESTS INCL IN C/BOX VBXX INPRO SEAL BOTH ENDS BURNDY SERVIT POST ON FRAME ROTATE D.E. E/SHIELD 90 DEG. PER OUTLINE SHAFT RUNOUT LIMIT .001" TIR COPPER WASHER UNDER HEADS OF BEARING CAP BOLTS APPLY TITE-SEAL (A50CD427A) ON BEARING CAP SCREWS, RABBETS, AND PLUG THREADS OIL RESISTANT SLEEVING ON LEADS NEMA 4X CONDUIT BOX WITH TERMINAL BOARD TOP MOUNTED AUXILLARY BOX 30 CU.IN. WITH 1" NPT ENTRY WITH TERMINAL BOARD DE-RATED 240V HEATER FOR OPERATION AT 120V LRT < 300% AND BDT < 230% OF FLT

Model Number: 5KGS254XAA224F2 / Version: v15031799.01 Wednesday, March 11, 2015


Diagrams for Model: 5KGS254XAA224F2

Connection Diagram Heater Connection GEM2034E-FIG7 3027JE-1

Model Number: 5KGS254XAA224F2 / Version: v15031799.01 Wednesday, March 11, 2015


Performance Characteristics 1st Winding 1st Connection Design: 25BD1220A

LOAD % 125.0 115.0 100.0 75.0 50.0 25.0 0.0 % EFF 91.28 91.81 92.40 93.29 93.32 90.85 0.00 % PF 86.58 86.53 86.00 83.25 75.69 54.94 5.16 AMPS 22.21 20.32 17.70 13.56 9.94 7.03 5.60

TORQ(FL)#FT 44.51 TORQ(LR)%FL 290.75 TORQ(BD)%FL 226.42 AMPS(LR) 116.25 PF AT START 0.57

This motor is capable of two cold or one hot start with a maximum connected load inertia of 608.0 Lb-Ft Sq (25.6 Kg-meter Sq) at 100% voltage, where the load torque varies with the square of the speed. Acceleration time with maximum inertia and the above load type is 38 seconds. Safe stall time at 100% voltage is 77 seconds cold, 56 seconds hot. Rotor inertia is 2.73 Lb-Ft Sq (0.115 Kg-meter Sq).

Open Circuit A-C: 0.494 Short Circuit D-C: 0.010 Short Circuit A-C: 0.017 X/R Ratio: 3.646

Stator Slots: 48 Rotor Slots: 40

Model Number: 5KGS254XAA224F2 / Version: v15031799.01 Certified Print Wednesday, March 11, 2015

Page 6 of 6

GEH-4200D(Supplement to GEH-3967)

�GE Industrial Systems

Instructions

Explosion-ProofDirect CurrentMotors and GeneratorsFrames Type CD180AT – CD400AT

GEH-4200D

2

Safety Precautions

High voltage and rotating partscan cause serious or fatal in-jury. The use of electric ma-chinery, like all other utiliza-tions of concentrated powerand rotating equipment, canbe

hazardous. Installation, operation and mainte-nance of electric machinery should be per-formed by qualified personnel, in accordancewith applicable provisions of the National Elec-trical Code and sound local practices.

For equipment covered by this instructionbook, it is important to observe safety precau-tions to protect personnel from possible injury.Among the many considerations, personnelshould be instructed to:

• Avoid contact with energized circuits or ro-tating parts,

• Not by-pass or render inoperative any safe-guards or protection devices,

• Avoid extended exposure in close proximityto machinery with high noise levels, and

• Use proper care and procedures in han-dling, lifting, installing, operating and main-taining the equipment.

Safe maintenance practices with qualified per-sonnel is imperative. Before starting mainte-nance procedures, be positive that:

• Equipment connected to the shaft will notcause mechanical rotation,

• Main machine windings have been discon-nected and secured from all electricalpower sources, (lock out drive), and

• All accessory devices associated with thework area have been de-energized.

If high potential insulation test is required, pro-cedures and precautions outlined in NEMAstandards MG-1 should be followed.

Failure to properly ground the frame of thismachine can cause serious or fatal injury topersonnel. Grounding of the machine frameand structure should be in accordance with theNational Electrical Code and consistent withsound local practices.

These instructions do not purport to cover all of the details or variations in equipment nor to provide for every possiblecontingency to be met in connection with installation, operation or maintenance. Should further information be desiredor should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should bereferred to the General Electric Company.

1989, 1992, 1999 General Electric Company

GEH-4200D

3

Explosion-Proof, Direct CurrentMotors and Generators

Frames Type CD180AT – CD400AT

I. INTRODUCTION

This instruction book is a supplement toGEH-3967, and covers the TypeCD180AT-CD400AT line of explosion-proof DC motors and generators.

Explosion-proof motors and generatorsare designed and constructed to meet therequirements specified by UnderwritersLaboratories for use in hazardous (explo-sive) locations.

These motors are totally enclosed and ca-pable of withstanding explosion pressuresgenerated when hazardous atmosphereenters the enclosure and is ignited. Sincethese motors are not completely air tight,clearance fits and flame paths are carefullycontrolled. This allows for the release ofinternal pressure caused by an explosionand the cooling of escaping gases to atemperature that is below the ignitionpoint of the external atmosphere.

It is a prerequisite in the design of thesemotors that none of the external surfacesexceed 80% of the auto-ignition tem-perature of the gas or vapor that is presentin the hazardous environment. Also, inthe event of an abnormal overload condi-tion, the surrounding atmosphere will notexplode or ignite due to overtemperatureof the machine.

Explosion-proof motors are listed in ac-cordance with their suitability for the envi-ronment in which they are installed.These environments, or hazardous loca-tions, are defined by the National Electri-cal Code (NEC).

GE Industrial Systems provides motorsfor the following defined locations:

A. Class I, Group D

Class I atmospheres contain flam-mable gases or vapors from flamma-ble liquids.

Common Group D environmentsare:

Gasoline, naptha, benzine, pe-troleum, butane, propane, al-cohols, acetone, lacquer sol-vents and natural gas.

B. Class II, Groups E, F and G

Class II atmospheres contain com-bustible dust.

Common environments are:

Group E Metal dustGroup F Carbon black,

coal, coke dustGroup G Grain dust

These classifications are brokendown further into degrees of hazard.There are two degrees of hazard forboth Class I and Class II locations.

Division 1, or normally haz-ardous

Division 2, or hazardous onlyunder abnormal conditions

GEH-4200D

4

GE Industrial Systems explosion-proof DC equipment is suitable forboth divisions.

For a complete list of hazardous en-vironments and auto-ignition tem-peratures, consult the NationalElectrical Code.

C. Operating Temperature Code

Explosion-proof motors have an op-erating temperature code identifica-tion number. This is the maximumexternal temperature determinedduring the normal and overload op-erating temperature test. GE explo-sion-proof motors have a T4A(120°C) operating temperaturecode, except for motors rated 75HP, which have a T4 (135°C) iden-tification number.

Machines supplied with a UL,Class I, Group D, or Class II,Group E, F or G label havebeen manufactured in accor-dance with standards estab-lished by

UL for that service. Mating surfaces are ma-chined to specified tolerances and finishes.Any nicks or burrs in those surfaces may de-stroy the explosion-proof adequacy of the en-closure.

High voltage and rotating partscan cause serious or fatal in-jury. The use of electric ma-chinery, like all other utiliza-tions of concentrated power

and rotating equipment, can be hazardous.Installation, operation and maintenance of elec-tric machinery should be performed by quali-fied personnel. Familiarization with NEMAsafety standards for construction and guide forselection, installation and use of integral HPmotors and generators, the National ElectricalCode, and sound local practices is recom-mended.

D. Handling

Complete motors or generators canbe lifted by using hooks or slings inthe lifting lugs on top of the unit.The lifting lugs are designed tosafely carry the weight of the indi-vidual machine. Do not lift the ma-chine with the shaft extensions.For approximate net weights of theequipment, refer to Table 1.

Motor-generator sets or unitswith heavy attachments such asgear boxes or pumps must NOTbe lifted by using the liftinglugs of the individual ma-chines.

Table 1Approximate Net Weights*

Armature MotorFrame Weight WeightSize Lbs. Kgs. Lbs. Kgs.

CD188AT 25 11 150 68CD189AT 35 16 180 82CD2110AT 63 29 340 155CD288AT 130 59 655 298CD328AT 181 82 920 418CD407AT 395 179 1550 705CD409AT 493 224 1850 841

*Approximate weights for typical motors in eachframe size. Does not include weights of accesso-ries such as tachometers, blowers, heat exchang-ers, etc. For specific weights, refer to certified out-line.

II. INSTALLATION

Installation should be in accordance withthe National Electrical Code and consis-tent with all local codes. Coupling, beltand chain guards should be installed asneeded to protect against accidental con-tact with moving parts. Machines acces-sible to the public should be further

GEH-4200D

5

guarded by screens, guard rails, etc., toprevent personnel from coming into con-tact with the equipment.

A. Location

Motors and generators should beinstalled so that they are readily ac-cessible for routine inspection andmaintenance. They are suitable foruse in ambient temperatures from0°C (32°F) to 40°C (104°F). It isimportant that the surfaces exposedfor ventilation of all machines arenot obstructed in any manner thatmight limit the free passage of air.

The use of electrical equipmentin hazardous locations is re-stricted by the National Electri-cal Code, Article 500. Originalequipment manufacturers and

user customers must read, understand and ap-ply these rules for installation and use of allequipment in such locations and consult localcode inspection and enforcement agencies asnecessary to insure compliance. Motors listedby Underwriters Laboratories, Inc. for use inspecific locations have been designed, testedand approved for use in such locations only.

Sections 501-8 and 502-8 now permit the use oftotally enclosed motors with positive pressureventilation or totally enclosed inert-gas-filledmotors (Class I locations only) when installa-tion and operation conform to certain require-ments.

Motors for Class I locations must have leadssealed at the frame exit and an explosion-proofconduit box. (Refer to Sections 501-4 and 501-5.

Motors for Class II locations must have leadssealed at the frame exit and a dust-ignitionproof conduit box. (Refer to Sections 502-4 and502-5.)

Articles 501-8 and 502-8 of the National Electri-cal Code governing the installation of motors

in Class I and Class II locations assign approvalof the installation to “the authority having ju-risdiction” (see Article 100 – Definitions of theNEC). Therefore, it is the res ponsibility of thecustomer to be familiar with the NEC and thelocal jurisdictional requi rements and to deter-mine that the motor selection (including possi-bly permiss ible alternative ventilation systemsor accessories) is “acceptable to the authorityhaving jurisdiction”.

III. OPERATION

Disconnect power beforetouching any internal part.High voltage may be presenteven when the mac hine is notrotating. If used with a rectified

supply, disconnect all AC line connections topower supply. With other power supplies, dis-connect all DC line and field connections. Alsodisconnect power from auxiliary devices.

Ground the machine properlyto avoid serious injury to per-sonnel. Grounding must be inaccordance with the Nat ionalElectrical Code and consistent

with sound local p ractices. A gr ounding lead,identified by GND, is located in the conduit boxand should be used to attach a ground cable.

Before starting the motor, re-move all unused shaft keys andloose rotating parts to preventthem from flying off.

A. Conduit Box

The conduit box is mounted on athreaded pipe nipple and may be ro-tated to any angle when the back nutis loosened. Retighten the back nutafter the conduit box has been reori-ented.

GEH-4200D

6

B. Overtemperature Protection

All explosion-proof motors are fur-nished with an internally mounted,normally closed thermostat. If, forany reason, the temperature of themotor windings exceeds the allow-able rise, the thermostat will open.

The thermostat leads (marked P1,P2) should be connected in serieswith the motor control circuit sys-tem in the same manner as the“stop” button control. Operation ofthe thermostat due to temperaturerise will turn off the motor and pre-vent excessive and dangerous tem-peratures.

Thermostats automatically re-set after the motor has cooledsomewhat. In order to preventproperty damage or injury topersonnel, the control circuit

should be designed to prevent the automaticstarting of the motor when the thermostat re-sets.

Thermostats may be used in alarm orrelay circuits within rating limitsshown in Table 2.

Table 2Maximum Current Ratings

For Thermostats on DripproofAnd Totally Enclosed Motors

(Normally open or normally closed contacts)

Load125Vac

250Vac

600Vac

30VDC

Do not use above 600 VAC or 30 VDCResistive 5 Amps 2.5 Amps 1 Amp 5 Amps

Induc-tive*

3 Amps 1.5 Amps 0.5 Amps 1.5 Amps

*Suitable for pilot duty only (relay coils).

IV. MAINTENANCE

In the interest of safety, no re-pairs or maintenance should beundertaken which involves dis-assembly other than cover re-moval for brush replacement

(refer to GEH-3967 for brush removal, installa-tion and seating procedures). If disassembly isrequired, this should be done only by a serviceshop which has access to the UL “procedures”(specifications) for that particular product line.Contact your nearest GE Service S hop for as-sistance if such work becomes necessary.

Explosion-proof motors haveexplosion-proof features onlywhen all covers are in place.Covers removed to servicebrushes must be replaced. Use

extreme care to prevent nicks and burrs in thecover and frame threads.

High voltage electric shock maycause serious or fatal injury.Disconnect power beforetouching any internal part.High voltage may be presenteven

when the machine is not rotating. If used with arectified power supply, disconnect all AC lineconnections to power supply. With otherpower supplies, disconnect all DC line and fieldconnections. Also, disconnect power fromauxiliary devices.

Ground the machine properlyto avoid serious injury to per-sonnel. Grounding must be inaccordance with the Nat ionalElectrical Code and consistent

with sound local p ractices.

Replace covers and protectivedevices before operat ing.

GEH-4200D

7

All TEFC explosion-proofframes include a groundingdevice on the external fan.During reassembly, thegrounding device must contactthe shaft to

eliminate the possibility of static accumulationon the fan collar during operation.

A. Bearings (Frames CD180AT)

Double shielded bearings are stan-dard in these frame sizes. Thebearings are lubricated by the bear-ing manufacturer and are not re-greasable. These bearings should bereplaced whenever the motor is dis-assembled for servicing. Endshieldsshould not be removed by unau-thorized personnel.

B. Bearings (Frames CD210AT-CD400AT)

Ball bearing housings are packedwith grease at the factory. Greasingis not required before the motor isput into service. Since the oil in thegrease will ultimately become de-pleted, it is necessary to relubricateball bearing motors periodically, de-pending on size and type of service.(Refer to Table 3.)

For best lubrication results, regreasewith GE grease No. D6A2C5 or anequivalent lithium base ball bearinggrease. Avoid mixing different typesof grease. Lubricate motor at stand-still. Replace the top grease plugwith a lubrication fitting. Make sureit is clean and free from dirt. Re-move lower grease relief plug (reliefpipe on fan cooled motor). Free therelief hole from any hardened grease.Use a hand-operated grease gunonly. Pump in grease until newgrease appears at

lower grease hole. (Inspect pipe oc-casionally on fan cooled motors tocheck for appearance of newgrease.)

After regreasing, allow motor to runabout ten minutes before replacinggrease relief plug (or pipe) to permitexcess grease to drain out. It is rec-ommended that the lubrication fit-ting be replaced with the plug afterregreasing to prevent casual over-greasing.

Table 3Recommended Regreasing Periods

Ball Bearing Only

RelubricationInterval In

Average Hours ofFrame Size RPM Operation

CD2110AT 500 36000CD288AT & 1150 15000CD328AT 1750 10000

3000 5000CD407AT & 500 30000CD409AT 1150 12000

1750 60003000 2500

C. Brushes

Explosion-proof motors haveexplosion-proof features onlywhen all covers are in place.Covers removed to servicebrushes must be replaced. Use

Extreme care to prevent nicks and burrs in thecover and frame threads.

In the interest of safety, no re-pairs or maintenance should beundertaken which involves dis-assembly other than cover re-moval for brush replacement.

(Refer to GEH-3967 for brush removal, installa-tion and seating procedures.) If disassembly isrequired, this should be done only by a serviceshop which has access to the UL “procedures”(specifications ) for that particular product line.Contact your nearest GE Service S hop for as-sistance if such work becomes necessary.

GEH-4200D

8

High voltage and rotating ma-chinery can cause serious orfatal injury. Brushes may notbe touched or replaced whilethe machine is energized or

rotating.

DC motors and generators op-erated for long periods of timeat light loads or in contami-nated atmospheres may besubject to abnormal brush and

commutator wear. This can result in the needfor excessive maintenance and/or commutatordamage. If the application requires operationunder these conditions, GE Industrial Systemswill be pleased to suggest a change in brushgrade or other measures to minimize the prob-lem.

The presence of silicone in DCmotors, particularly totally en-closed constructions, willcause rapid brush wear.Sources of silicone includeoils, RTV compounds, handcreams, mold

release agents, grease and some insulatingvarnishes. These silicone substances must beavoided to insure proper motor performance.

Refer to GEH-3967 for brush removal,installation and seating procedures.

V. ACCESSORY MOUNTING

Explosion-proof motors do not have acommutator end accessory mountingface. Contact GE Industrial Systems forsuitability and availability of accessorymounting options. Accessories and modi-

fications may be added only when they donot affect the explosion-proof features ofthe motor. All accessories must meet orexceed environment class and group re-quirements.

VI. RENEWAL PARTS

Using genuine GE renewal parts assurescontinued high performance and the fullbenefits of the long operating life designedinto your GE motor. (Refer to Table 4 fora complete listing of recommended spareparts and Table 5 for standard brush andbrush spring part numbers.)

Downtime can be minimized by having aprotective stock of parts available for re-placement.

The permanently attached nameplate onyour GE motor displays the model and se-rial number, providing all of the informa-tion needed for ordering. Parts are avail-able directly from authorized GE partsdistributors. Direct electronic access tothe factory database of motor informationand warehouse inventories enables thedistributor to quickly identify part num-bers, delivery times and order status.

Distributor location is available to youat (814) 875-2387 (and toll free outside

Pennsylvania at 1-800-458-0451).

GEH-4200D

9

VII. SPARE PARTS

Table 4Recommended Spare Parts

As insurance against costly downtime, it is strongly recommendedthat spare parts be kept on hand in accordance with the chart below:

Number of Duplicate Motors in ServiceDescription 1 2-4 5-10 11-20 More Than 20

With or Without Electrical Shop FacilitiesComplete Machine - - - 1 2Drive End Ball Bearing 1 1 1 2 3Front End Ball Bearing 1 1 1 2 3Brushes (Sets) 2 4 6 8 10Brushholders (Sets) - 1/2 1/2 1 1Brushholder Springs (Sets) 1/2 1 1 2 2Main Field Coil and Pole - 1 1 2 3Commutating Field Coil andPole

- 1 1 2 3

Armature, Complete* - 1 1 2 2With Electrical Shop FacilitiesShaft** - - - 1 1Armature Rewinding Supplies - 1 1 2 3* If shop facilities are available, the quantity of armatures may be reduced by stocking

the armature parts listed in the second group.** Shaft not replaceable in CD180AT and CD2110AT.

Table 5Standard Brush and Brush Spring Part Numbers

Standard Brush Brush SpringFrame Size Part Number *** Part NumberCD180AT 36A167400AA001 36B467022AB001CD210AT 36A167401AA008 36B467020AA001CD280AT 36A167402AA004 36B467021AA001CD320AT 36A167402AA004 36B467021AA001CD400AT 36A164451AB018 36B465481AD001

*** Brush part numbers are for most applications. Special applications such as papermills,pump motors, diesel-driven generators, and others may require special brush grades.Before ordering brushes, check the part number stamped on the brush to ensure the cor-rect brush replacement.

GE Industrial Systems

Friday, August 05, 2005


Customer: KOENIG ENGINEERING INC 410 EAGLEVIEW BLVD STE 104 EXTON PA 19341


Page 2

g

Customer Order: 11611RN GE Requisition: 66024726 Customer Part: GE Job Number: 050727241

MODEL NUMBER: 5BY552XC808A800

Outline Drawing: 36B549871BB Enclosure Mtg Assem: Connection Diagram: 36A290336AJ Instruction Book: GEH4200

Horsepower: 2 RPM: 1750/2300 Armature Volts: 125 Armature Amps: 13.6

Wound: COMPOUND Type: CD189ATCY Power Supply Code: A

Enclosure: TEFC Insulation Class: F Duty: CONT Ambient Max (°C): 50

Rating Code: 552XA1Z40-04 Field Volts: 125 K(V): .636 Cemf Volts/Radian/Sec WK2: .77 Lb Ft2 K(T): .44 Ft/Amp Year of Manufacture: 2005

Minimum Ambient: 0 C Max Altitude: 3300 Ft. Resistances at 25 Degrees C: Inductance’s:

Shunt Field: 111.0 OHMS Armature Circuit Total: 6.8 mH Saturated Armature: .1953 OHMS Shunt Field: 37 Henries Unsaturated

Commutator Field: .1053 OHMS Shunt Field Data: Shunt Field Current(1): .89 AMPS at Rated Load and 1750 RPM Shunt Field Current(2): .46 AMPS at Rated Load and 2300 RPM

Additional Drawings: Description: None

Additionial Machine Notes: TOTALLY ENCLOSED FAN COOLED- BALL BEARINGS CLASS I GROUP D - EXPLOSION PROOF OP TEMP CODE T4A CONDUIT BOX ON RIGHT HAND SIDE FACING COMMUTAQTOR END STANDARD SHAFT DRIVE END ONLY- WITH FEET WITH: THERMOSTAT- NORMALLY CLOSED, AC RATING- 600V MAX- .5A, 250V-1.5A, OR 125V-3A, DC RATING- 30V MAX- 1.5A. MAXIMUM CURRENT BASED ON INDUCTIVE LOADS UP TO AND INCLUDING NEMA NO. 5 CONTACTOR Marks PO #11611RN

Mod

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Page

3

Marks: PO #11002RN

Model Number: 5BY552XC808A800 Certified Print Wednesday, November 03, 2004

Page 4

Marks: PO #11002RN


SECTION 3


EMERGENCY DC DRIVE

TWIN DISCI N C O R P O R A T E D

OPERATOR’S MANUAL#1022626Model 4-LUGP-2222BOM N67682Torque Converter forGas Turbine Starting UnitDecember, 2005

NOTICE

Twin Disc, Incorporated makes no warranty or guaranty of anykind, expressed, implied or otherwise, with regard to theinformation contained within this manual. Twin Disc,Incorporated has developed this manual through research andtesting of the information contained therein. Twin Disc,Incorporated assumes no responsibility for any errors that mayappear in this manual and shall not be liable under anycircumstances for incidental, consequential or punitive damagesin connection with, or arising out of, the use of this manual. Theinformation contained within this manual is subject to changewithout notice.

3

Twin Disc, Incorporated Table of Contents

Torque Converter Operator’s Manual #1022626

Table of Contents

Introduction ...........................................................4General Information ............................................................................ 4Safety and General Precautions ...................................................... 4Distribution ........................................................................................... 5Inspection Overhaul ............................................................................ 5Replacements and Adjustments ........................................................ 5Warranty ................................................................................................ 5

Description and Specifications ...........................6General.................................................................................................. 6Starting Drive Components ................................................................ 6

Input Gearbox Assembly ............................................................................... 7 Torque Converter ........................................................................................... 7 Output Shaft Group of Parts........................................................................... 8 Valve Assembly ............................................................................................... 8

Operation..............................................................10General................................................................................................ 10Hydraulic System .............................................................................. 10

General ......................................................................................................... 10 Oil Flow .......................................................................................................... 11

Preventative Maintenance ..................................13General................................................................................................ 13

Troubleshooting..................................................14

Engineering Drawings ........................................17List of Engineering Drawings .......................................................... 17

4

Twin Disc, IncorporatedIntroduction

Torque Converter Operators Manual #1022626

Introduction

General Information

This publication contains information on construction features and instructionsfor operating and troubleshooting the 4-LUGP-2222 gearbox/torque converterassembly as supplied by Twin Disc Incorporated for a gas starting driveapplication.

Safety and General Precautions

Proper installation, maintenance, and operation procedures must be followeddue to the possible danger to person(s) or property from accidents that mayresult from the use of machinery. Twin Disc, Inc. will not be responsible forpersonal injury resulting from careless maintenance/working practices.

Inspect as necessary to assure safe operations under prevailing conditions.Proper guards and other safety devices that may be specified in safety codesshould be provided. These devices are neither provided by, nor are they theresponsibility of Twin Disc, Inc.

To prevent accidental starting of the engine when performing routinetransmission maintenance, disconnect the battery cables from thebattery and remove ignition key from the switch.

Most Twin Disc products have provisions for attaching lifting bolts. Theholes provided are always of adequate size and number to safely liftthe Twin Disc product. These lifting points must not be used to lift thecomplete power unit. Lifting excessive loads at these points could causefailure at the lift point (or points) and result in damage or personal injury.

Select lifting eyebolts to obtain maximum thread engagement with boltshoulder tight against housing. Bolts should be near but should notcontact bottom of bolt hole.

5

Twin Disc, Incorporated Introduction

Torque Converter Operators Manual #1022626

Distribution

All personnel responsible for operating and maintaining this product should befamiliar with this publication and have it at their disposal.

Inspection Overhaul

The torque converter must be replaced or overhauled as a complete assembly.Contact Koenig Engineering, Inc. for instructions.

Be sure that the Model Number, Bill of Material Number (BOM) and SerialNumber of the unit are included in the order. These numbers are stamped onthe identification plate attached to the input gearbox housing. Cross sectiondrawings included in this manual may be used to identify location and determinenomenclature of parts but should not be used to ascertain part numbers.

Replacements and Adjustments

Any complaint that the user or ultimate customer may have concerning theproduct must be submitted through the original equipment manufacturer, KoenigEngineering, Inc.

Warranty

Equipment for which this manual was written has a limited warranty. For detailsof the warranty, contact Koenig Engineering, Inc.

6

Twin Disc, IncorporatedDescription and Specifications


Description and Specifications

General

The purpose of the Model 4-LUGP-2222 is to provide a means of transmittingcranking power to a large gas turbine engine. The cranking capability must besufficient to spin the turbine to its self-sustaining speed.

Control of the Twin Disc supplied components of the gas turbine starting unit isintegrated into the control system for the unit. The unit control system is suppliedby the customer.

The letters and numbers in the torque converter model designation indicate thefollowing:

4 = Type 4 torque converter circuit designL = Left hand bladingU = Flanged or universal joint inputG = Gearing—reduction or transferP = Pressure controlled pressure lowering valve22 = Circuit size in inches22 = Major design difference

Starting Drive Components

The Twin Disc supplied components of the gas turbine starting unit consist of astep-up gear ratio gearbox assembly, torque converter, a valve assembly andcertain plumbing. These components are installed as part of a larger systemthat includes a prime mover (electric motor), a turning gear, connectingcouplings and necessary plumbing supplied by Koenig Engineering, Inc.

7

Twin Disc, Incorporated Description and Specifications


Input Gearbox Assembly

The function of the input gearbox assembly is to provide a 1.470:1 step-upgear ratio connection between the output of the prime mover and the input tothe torque converter. This step-up gear ratio converts prime mover output speedto the input speed required for proper operation of the torque converter therebymatching the prime mover to the torque converter. The torque converter providesthe torque multiplication necessary for cranking the gas turbine engine.

Note: Number of input gear teeth = 97 (part number 228066N)Number of output gear teeth = 66 (part number 228065R)

The input gearbox housing consists of front and rear housing halves containingline-bored bearing bores that necessitate the housing be serviced as anassembly. (Housing halves are not serviced separately.) Mating surfaces of thehousing halves are sealed with anaerobic sealant to prevent leakage. Two dowelpins align the housing halves that are secured together with a total of 28 hex-head capscrews. The output side of the input gearbox is attached to the inputend of the torque converter. Twenty-two capscrews secure the input gearboxto the torque converter. An O-ring seal prevents leakage between the gearboxhousing and the torque converter.

The input shaft of the gearbox is connected to the prime mover by a couplingand drives the input gear through a keyed joint. The gearbox output gear is inmesh with, and driven by, the input gear. Power is transmitted to the torqueconverter through the internally splined hub of the output gear that meshes withexternal splines of the torque converter input shaft. Direction of rotation for thetorque converter input shaft is opposite the prime mover direction of rotation.

The input shaft and gear assembly and the output gear are mounted on taperedroller bearings in bearing bores in the input gearbox assembly. Bearingclearances are adjusted by use of shims. Cast iron seal rings in the torqueconverter minimizes transfer of oil from the torque converter into the inputgearbox and vice versa.

Torque Converter

The torque converter is a stationary housing, single stage, type four circuit designincorporating blading for left-hand output rotation (counter-clockwise whenviewed from the prime mover).

Input to the torque converter is through the impeller, which is spline connectedto the input shaft. The input shaft is driven by the output driven gear of the inputgearbox. The turbine wheel transmits torque converter output power through

8

Twin Disc, IncorporatedDescription and Specifications


internal splines in its hub that mesh with external splines of a short output shaftthat is connected with the turning gear. The stator (guide wheel) is attached tothe converter housing. The torque converter housing provides an enclosureand support for the torque converter elements. The housing is secured to thegearbox housing with 22 twelve point capscrews. An O-ring prevents leakagebetween the housing and gearbox housing.

Support for the torque converter input shaft (and the spline connected impeller)is provided by the hub of the output driven gear (in the input gearbox) at itsforward end and by a ball bearing (in the hub of the turbine wheel) at its rearend. The ball bearing outer race is retained in the turbine wheel hub by a bearingretainer and six 12-point capscrews. The split inner race is retained on the rearend of the shaft with a retainer washer and one 3/4-16 UNF x 2-1/4” long hex-head capscrew.

A pair of tapered roller bearings support the turbine wheel hub and forward endof the output shaft from the converter. The end-play of these bearings isadjustable by means of a large retainer nut on the rear of the turbine wheel hub.The nut and washer bear against the inner race of the gear bearing coneassembly.

Output Shaft Group of Parts

The output shaft group of parts consists of the following: two “o” rings (oneseals the converter output housing and the other seals the output shaft to theturbine hub splines within the turbine hub), two back up rings that hold the shaft“o” ring seal in position, a (1/4 x 1 inch) Woodruff key supplied with the shaft,the shaft spline that connects to the load. The customer must provide not over0.06 maximum axial movement through assembly of his mating parts. Also,the customer must provide a gallon per minute return connection to sump fromthe converter output bearing for the lube oil.

Valve AssemblyA valve assembly mounted on the torque converter functions to relieve excessoil pressure, control normal converter pressure and provide a means of loweringconverter pressure to reduce output torque of the converter. The valve assemblyconsists of a valve body containing two valves:

1. A pressure regulating/relief valve2. A pressure lowering valve

9

Twin Disc, Incorporated Description and Specifications


The converter pressure regulating/relief valve functions primarily as a relief valveto relieve excess pressure that may occur in the torque converter inlet line.Regulation of the lube-pilot pressure (X) is accomplished by an orifice in thetorque converter oil inlet.

Torque converter outlet pressure is controlled by an orifice (notch) in the pressurelowering valve that controls oil flow to sump. Action of the pressure loweringvalve is controlled by a solenoid that is energized—de-energized as a part ofthe starting sequence by the starting drive control system. Energizing thesolenoid will lower torque converter outlet pressure. An adjusting screw isprovided to further adjust this pressure to obtain the desired torque converteroutput shaft speed.

10

Twin Disc, IncorporatedOperation


Operation

General

Power from the prime mover is transmitted to the input shaft of theinput gearbox by a coupling. An input gear, which is mounted on akeyless taper on the input shaft, is in mesh with the gearbox outputgear. Input power is transmitted to the output gear through this gearmesh causing the output gear to rotate at 1.470 times input speed,opposite to prime mover direction of rotation. For example, 1000 rpm(input speed) x 1.470 = 1470 rpm (output speed). Internal splines in theoutput gear hub mesh with external splines of the torque converterinput shaft thereby rotating the shaft in output gear direction of rotationand at output gear speed. An externally splined pump drive adapter inthe front end of the output gear hub drives a gear-type pump thatprovides oil pressure and flow to pressurize the torque converter andlubricate the input gearbox and torque converter. The torque converterimpeller is spline connected to the input shaft. Therefore, rotation of theinput shaft causes the impeller to circulate pressurized oil within thetorque converter housing. Power is transmitted by the circulating oil tothe turbine wheel which is spline connected with the output shaft.

Hydraulic System

General

The hydraulic system provides oil pressure and flow to charge andcool the torque converter and to lubricate the input gearbox and torqueconverter. Exterior plumbing (except that between the gearbox/torqueconverter components), the oil reservoir, supply pump and supplyfiltration components are supplied by the customer. There is no sepa-rate cooler needed to cool the converter. The large oil reservoir actsas a heat sink.

Oil for torque converter charge and lubrication of the input gearbox andtorque converter is supplied by a gear-type pump. The pump ismounted on the input gearbox and driven by a pump drive adapter inthe hub of the output (driven) gear. Oil is supplied to the inlet port of thepump by a customer provided pump and external line.

11

Twin Disc, Incorporated Operation


Oil Flow

Pressurized oil from the customer supplied pump outlet port is routedthrough a filter to the inlet of the lube pump and main pump. This isalso supplied to the output bearing lube port on the torque converter.The lube pump outlet is plumbed to supply lube oil to the input gear-box, and into the pilot section of the pressure lowering valve through anorifice. The main pump supplies oil to the pressure relief valve, provid-ing oil for the torque converter circuit. Oil passes through the convertercircuit and exits through the pressure lowering valve to sump. ThreeTwin Disc supplied external lines connect the following:

A lube cover mounted on the front of the input gearbox housing.

Oil entering the lube cover is routed through a filter screen and an orificeinto internal passages in the input gearbox for lubrication of the taperedroller bearings supporting the input shaft and output shaft.

The main pump to the converter regulator/relief valve in the valveassembly.

This provides the oil supply for converter charge.

The pressure relief valve in the valve assembly to the converter inlet..

A solenoid valve is installed in the passage containing pilot pressure. Thesolenoid is controlled electrically by the control system for the gas turbine startingunit.

When the solenoid is de-energized the pilot pressure forces the pressurelowering valve to the bottom of the bore (against spring tension). This positionsthe valves so that normal converter outlet pressure is maintained. In thisconfiguration, normal converter outlet pressure is maintained by the relationshipbetween the orifice in the converter inlet passage and a slot in the pressurelowering valve spool that controls the flow to sump for oil in the converter outletline.

Energizing the solenoid will relieve pilot pressure to sump allowing spring tensionto position the pressure lowering valve against an adjustment screw. Movement

12

Twin Disc, IncorporatedOperation


of the pressure lowering valve to seat against the adjustment screw exposes agreater area of the slot in the valve spool with the passage to sump. This lowersconverter outlet pressure and reduces converter output torque and speed. Anadjusting screw on the pressure lowering valve is used to make minoradjustments to converter outlet pressure to attain the desired output torque andspeed.

De-energizing the solenoid will allow pilot pressure to position the pressurelowering valve the normal operating position and raise converter outlet pressureto its normal value of 90 to 120 psi.

13

Twin Disc, Incorporated Preventative Maintenance


Preventative Maintenance

General

Lubrication

Lubrication is integral with the equipment. No lubrication procedure isrequired beyond the daily check of system oil level.

Overhaul Interval

A complete overhaul of the torque converter is required after 1,000start cycles. Contact Koenig Engineering, Inc. for instructions at leastthree (3) months prior to required overhaul date.

Oil System

The oil supply tank, filtration system, supply pump and external plumb-ing are supplied by the customer. Because a single oil supply tanksupplies oil to all elements of the gas turbine starting unit, the oil se-lected must be suitable for use by all elements of the system. For thisreason a specific recommendation for oil to be used in the input gear-box/torque converter is not provided.

Procedures and intervals for oil level check, filter change, oil change,etc. are established by the customer.

14

Twin Disc, IncorporatedTroubleshooting


Troubleshooting

General

This section of the Operator’s Manual has been prepared to assistpersonnel in diagnosing possible problems and to determine whethersuch problems can be repaired in place or if the unit must be removedfrom service for major repair. Internal failures involving bearings,gears, shafts, seal rings, etc. will require disassembly of the inputgearbox/torque converter and replacement of failed/worn parts. Cer-tain other difficulties may not require such major disassembly andcould be repaired in place. It must always be remembered that theinput gearbox/torque converter is but one part of the total starting unitpackage. Problems with input power or problems in output drivencomponents can sometimes be observed as problems in the gearbox/torque converter; therefore, the entire starting unit package mustalways be considered to properly diagnose/isolate difficulties.

Troubleshooting Chart

The following troubleshooting chart is organized in three columns. Useof the chart will aid in the rapid determination and repair of difficultiesthat may occur.

Table 1. Troubleshooting Chart

Symptom Cause Remedy

1. Overheating 1.1 Faulty temperature gauge.

1.2. Low converter outlet pressure.

1.3. Reduced pump flow

1.4. Converter relief valve opening to sump.

1.1 Replace temperature gauge.

1.2. See Symptom 3.

1.3. Measure pump flow or replace pump.

1.4. Inspect valve, clean and repair.

15

Twin Disc, Incorporated Troubleshooting


Table 2. Troubleshooting Chart (continued)


2. Low torque output.

2.1. Low converter outlet pressure.

2.2. Prime mover does not come up to rated performance.

2.1. See Symptom 3.

2.2. Check prime mover to assure that rated performance is obtained. Performance curves are available from the original equipment manufacturer.

3. Low converter outlet pressure.

3.1. Faulty pressure gauge.

3.2. Converter regulator/relief valve stuck open.

3.3. Solenoid controlled valve on pressure lowering valve leaking pilot pressure to sump.

3.4. Pressure lowering valve spool stuck or binding.

3.5. Worn or defective charging pump.

3.1. Replace pressure gauge.

3.2. Remove and clean valve. Assure that the valve spool moves freely in the valve bore.

3.3.1. Determine if valve is being energized electrically due to malfunction in starting unit control system. If so, repair defect in control system.

3.3.2. If solenoid valve is stuck or binding, replace solenoid valve.

3.4. Disassemble valve. Inspect valve spool and bore in valve body for corrosion, debris, etc. Clean and reassemble.

3.5. Replace charging pump.

16

Twin Disc, IncorporatedTroubleshooting


Table 3. Troubleshooting Chart (continued)


3. Low converter outlet pressure (continued).

3.6. Loss of pressure in converter (seal failure).

3.6. Check gearbox return oil flow from port BK. Flow should not exceed 7 - 14 gpm. Check for excessive oil flow from drain for output housing. Excessive oil flow from either location ind icates seal ring failure. Remove converter and overhaul. Replace defective seal rings.

4. Low lube/pilot pressure.

4.1. Defective pressure gauge.

4.2. Worn or damaged pump assembly.

4.3. Converter regulator/relief valve stuck open.

4.1. Replace gauge.

4.2. Replace pump.

4.3. See 3.2 above.

17

Twin Disc, Incorporated Engineering Drawings


Engineering Drawings

List of Engineering Drawings

The following pages include the engineering drawings that are specific to thismodel. The engineering drawings included are listed below.

Note: Any part numbers listed in the following engineeringdrawings are for reference only. Please refer to your billof material for part numbers specific to your model.

1016571A Torque Converter

1016576 Plumbing Group

225256D Hydraulic Schematic

18

Twin Disc, IncorporatedEngineering Drawings


%

)

Features• Rugged piston construction built to withstand pressure

ratings of 450 to 1500 psi.

• Angle body design for high flows.

• Ideal for high pressure water applications, such as car washes.

• Mountable in any position.

2.19

Pilot OperatedHigh Pressure Solenoid Valves

Brass or Stainless Steel Bodies1/4" to 3/4" NPT

NC2/2SERIES

8223

Solenoid Enclosures

Electrical

Nominal Ambient Temperature Ranges:AC: 32˚F to 125˚F (0˚C to 52˚C) DC: 32˚F to 104˚F (0˚C to 40˚C)Refer to Engineering Section for details.

Approvals:CSA certified. Meets applicable CE directives.Refer to Engineering Section for details.

Construction

Standard: Watertight, Types 1, 2, 3, 3S, 4, and 4X.Optional: Explosionproof and Watertight, Types 3, 3S, 4, 4X, 6, 6P, 7, and 9.

(To order, add prefix “EF” to catalog number.) See Optional Features Section for other available options.

Valve Parts in Contact with Fluids

Body Brass 300 Stainless Steel

Seals and Disc NBR, PA, PTFE PTFE, NBR

Core Tube 305 Stainless Steel

Core and Plugnut 430F Stainless Steel

Core Spring 302 Stainless Steel

Shading Coil Copper Silver

Stem PA (Normally Open)

StandardCoil andClass of

Insulation

Watt Rating and Power Consumption Spare Coil Part Number

DCWatts

AC General Purpose Explosionproof

WattsVA

HoldingVA

Inrush AC DC AC DCF - 10.1 25 50 238610 - 238614 -F 22.6 17.1 40 70 238610 238710 238614 238714

Standard Voltages: 24, 120, 240, 480 volts AC, 60 Hz (or 110, 220 volts AC, 50 Hz). 6, 12, 24, 120, 240 volts DC. Must be specified when ordering. Other voltages available when required.

Brass Version

4qwer

Warehouse

PART# EFHB8223G25V120

Specifications (Metric units)

Specifications (English units)

4SERIES

8223

2.20

Pipe Size (ins.)

Orifice Size (ins.)

Cv Flow

Factor

Operating Pressure Differential (psi) MaximumFluid

Temp. ˚F Brass Body Stainless Steel Body

Watt Rating/Class of Coil

Insulation

Min.

Max. AC Max. DC

Air-InertGas Water

Light Oil@ 300SSU

Air-InertGas Water

Light Oil@ 300SSU AC DC

CatalogNumber

Constr.Ref. No.

CatalogNumber

Constr.Ref. No. AC DC

NORMALLY CLOSED (Closed when de-energized)

1/4 5/16 1.5 10 750 750 750 - - - 200 - 8223G21 1 - - 10.1/F - 1/4 5/16 1.5 10 1500 1500 1500 500 500 500 200 150 8223G25 1 - - 17.1/F 22.6/F 3/8 5/16 1.5 10 750 750 750 400 400 400 200 150 8223G23 1 - - 10.1/F 22.6/F 3/8 5/16 1.5 10 1500 1500 1500 500 500 500 200 150 8223G27 1 - - 17.1/F 22.6/F 1/2 3/8 3.2 25 1500 1500 1500 500 500 500 200 150 8223G3 2 8223G10 4 17.1/F 22.6/F 3/4 3/4 7.8 25 750 750 750 450 450 450 200 150 8223G5 3 8223G12 5 17.1/F 22.6/F

Pipe Size (ins.)

Orifice Size (mm)

Kv FlowFactor(m3/h)

Operating Pressure Differential (bar)Maximum

Fluid Temp. ˚C Brass Body Stainless Steel Body

Watt Rating/Class of CoilInsulation

Min.

Max. AC Max. DC

Air-InertGas Water

Light Oil@ 300SSU

Air-InertGas Water

Light Oil@ 300SSU AC DC

CatalogNumber

Constr.Ref. No.

CatalogNumber

Constr.Ref. No. AC DC

NORMALLY CLOSED (Closed when de-energized)

1/4 8 1.29 0.7 52 52 52 - - - 92 - 8223G21 1 - - 10.1/F -

1/4 8 1.29 0.7 103 103 103 34 34 34 92 65 8223G25 1 - - 17.1/F 22.6/F

3/8 8 1.29 0.7 52 52 52 28 28 28 92 65 8223G23 1 - - 10.1/F 22.6/F

3/8 8 1.29 0.7 103 103 103 34 34 34 92 65 8223G27 1 - - 17.1/F 22.6/F

1/2 10 2.74 1.7 103 103 103 34 34 34 92 65 8223G3 2 8223G10 4 17.1/F 22.6/F

3/4 19 6.69 1.7 52 52 52 31 31 31 92 65 8223G5 3 8223G12 5 17.1/F 22.6/F

Dimensions: inches (mm)

Constr.Ref. No.

H K L P W

1 ins. 3.41 1.91 2.44 2.88 1.95mm 87 49 62 73 50

2 ins. 4.32 2.17 3.03 3.13 1.95mm 110 55 77 80 50

3 ins. 5.03 2.64 3.60 3.61 2.00mm 128 67 91 92 51

4 ins. 4.34 2.15 2.50 3.13 1.95mm 110 55 64 80 50

5 ins. 5.03 2.53 3.53 3.50 3.50mm 128 64 90 89 89

Constr. Refs. 1 - 5

steve.yemenijian

Highlight


Warehouse

Warehouse

Warehouse


Warehouse

Warehouse

ANY CATALOGUE NUMBERS DESCRIBED IN THIS CERTIFICATION RECORD MAY HAVE EITHER ONE OR TWO ZEROS EMBEDDED ANYWHERE BETWEEN FIRST AND LAST CHARACTER OF THE ORIGINAL CATALOGUE NUMBER. THE ZEROS ARE ONLY IN PLACE FOR CLIENTS TRACKING PURPOSES.

Class I, Groups A, B, C and D; Class II, Groups E, F and G; Class III, Encl. 3 or 4, intrinsically safe:

� "ASCO" Solenoid Valves, Series Nos IS8223, IS8262, IS8308, IS8314, IS8316, IS8317, IS8344, IS8345 and IS8408; intrinsically safe when connected to CSA Certified zener barriers, R. Stahl Inc., Model Nos 8901/31-280/085/00, 8901/30-280/085/00, 8901/33-273/000/00, 8901/34-273/000/00, 9001/01-280-085-10, 9001/00-280-085-10, 9001/03-280-000-10 and 9001/04-280-000-10 in accordance with Drawing FV-222-411.

Class I, Groups C and D; Class II, Groups E, F and G; Encl. 3 or 4, intrinsically safe:

� "ASCO" Solenoid Valves, Series Nos IS8223, IS8262, IS8308, IS8314, IS8316, IS8317, IS8344, IS8345 and IS8408; intrinsically safe when connected to CSA Certified zener barriers, R. Stahl Inc., Model Nos 8901/31-280/100/70, 8901/30-280/100/70, 8901/33-273/000/00, 8901/34-273/000/00, 9001/03-280-000-00, 9001/04-280-000-00, 9001/01-280-100-10, 9001/00-280-100-10, 9002/13-280/100-04, 9002/13/280/110/00, 9001/01/252/100/14 and 9001/00-252-100-14 MTL Inc. Measurement Technology, Ltd., Model Nos 787+, 787-, 728+, 728-, 4025, Pepperl & Fuchs, Inc., Model Nos Z129/EX, Z129/EX-CL, Z229/EX, Z229/EX-CL, Z478/EX, Z487/EX, Z479/EX, Elcon Instruments Inc., Model Nos 1871, 1872, MB4/2/16+, MB4/4/16+16+, in accordance with Drawing FV-222-411.

Notes:

1. Intrinsically safe solenoid valves, Series Nos "IS" with prefix "WP" or "WS", are Certified for CSA Encl. 3 or 4.

2. No prefix and prefix "C" or "T" general purpose enclosure, and prefix "U" open frame (no enclosure) are not suitable for Class II or III.

3. Prefix "K" or "KA" screw terminal coil, prefix "L" or "X" leads 18 in or greater and suffix "13790" green grounding conductor.

4. Suffix "MF" general service to -40C, suffix "09376" slow closing construction, suffix "17626" or "17637" epoxy painted construction and suffix "17647" lower MOPD rating for mounting valve in any position.

Class I, Groups A, B, C and D; Class II, Groups E, F and G; Encl Types 3, 3S, 4, 4X, 6 or 6P (as applicable).

� "ASCO RED-HAT II" Solenoid Operated Shutoff and General Purpose Valves, Series Nos EF8030G, EF8040G, EF8210G, EF8215G, EF8220G**, EF8221G, EF8223G, EF8262G, EF8263G**, EF8314G, EF8316G, EF8317G, EF8320G, EF8321G, EF8327G***, EF8342G, EF8344G, EF8345G.

� EFX8210G2 13244, 550V ac or 575V, 60Hz, 6.1W. � EFX8210G22 13244, 575V, 60Hz, 6.1W. � EFX8345G1 13244, 550V, 60Hz, 10.1W.

Certification Record

CUSTOMER CLASS FILE

ASCO 3228-01 013976_0_000

50-60 Hanover Rd, VALVES-For Hazardous Locations

Florham Park

NJ

07932

USA Refer to Class Description for program details

Page 1 of 10

11/20/2009http://directories.csa-international.org/xml_transform.asp?xml=certxml\013976_0_000-3...

� EFX8210G9V 18824, 120V, 60Hz, 6.1W, 110V, 50Hz, 8.1W. � HV-274-060-3, 24V dc, 22.6W. � HV-274-060-4, 120V, 60Hz, 110V, 50Hz, 17.1W. � HV-274-060-8, 24V dc, 9.0W. � "ASCO RED-HAT II" Solenoid Operators, Cat Nos EF8200G1, EF8329G1, -G2, -G3, -G7, -G8 and -G9. All

series and catalogue numbers above are not Certified for Group G when prefixed HT or HB or with M12 size solenoid rated 16.1W or 20.1W ac only. Note: Class I, Groups B, C and D when Prefix JB, JC or JD is used denoting Model EP Junction Box Assembly. *** - May contain the Prefix EV and the following suffixes: G41, G42, G43, G45, G51, G52, G53, G55.

� ASCO RED-HAT II Solenoid Operated Valves and General Purpose Valves, Dual Stage; Models HV270244-1; 120V, 60Hz, 110V, 50Hz, 14.00W; -2; Models HV270244-2; 240V, 60Hz, 220V, 50Hz, 14.00W; Models HV279205-1; 120V, 60Hz, 110V, 50Hz, 14.0W and Models HV279205-2; 240V, 60Hz, 220V, 50Hz, 14.0W.

� "ASCO RED-HATT II" Solenoid Operated Valves and General Purpose Valves, Models EF or EV8327G41, G42, G43, G45, G51, G52, G53, G55. Electrical ratings 24-480V, 50/60Hz, 12.0W ac 6-240V, 11.6W DC.

� "ASCO RED-HATT II" Solenoid Operated Valves and General Purpose Valves, Models EV8327G21, G22, G31, and G32. Electrical ratings 24-480V, 50/60Hz, 12.0W ac 6-240V, 11.6W DC.

Class I, Groups C and D; Class II, Groups E, F and G; Encl Types 3, 3S, 4, 4X, 6 or 6P (as applicable):

� "ASCO" solenoid valves, Bulletin Nos. 8015*, 8025*, EF8030, 8031, EF8037, 8037, 8041, 8044, EF8047, 8047, EF8210, 8211, EF8215***, 8215***, 8217, EF8220**, 8220**, EF8221, 8222**, 8223, 8262, 8263**, EF8264, 8264, EF8266, 8266, EF8267, 8267, 8292, EF8300, 8302, EF8308, 8309, EF8310, 8311, 8314, 8315, 8316, 8317, 8320, 8321, 8323, 8324, EF8340, 8340, EF8342, 8342, 8344, 8345, 8347, 8350*, 8377, 8400, EF8408, 8409, EF8410, 8411.

Note: These "ASCO" solenoids valves meet the requirements for Single Seal marking per ANSI/ISA 12.27.01-2003 standard.

� "ASCO" solenoid valves Cat Nos: � HV106-020, 24 to 480V, 50/60Hz, 6W. � HV106-217, 48V dc, 19.7W � HV106-248-1, 48V dc, 19.7W � HV166-159, with or without suffixes "MO" or "MS", 24 through 480V, 50/60Hz, 9W. � HV206-691, 24 to 480V, 50/60Hz, 11W. � HV168-301, 24 to 480V, 50/60Hz, 11W. � HV206-938, 24V dc, 9.7W. � HV206-939, 24V dc, 9.7W. � HV206-940, 24V dc, 16.8W. � HV206-941, 24V dc, 16.8W. � HV206-942, 24V dc, 11.2W. � HV206-943, 24V dc, 23W. � HV206-944, 24V dc, 35.1W. � HV208-540-1, dual solenoid, 24 to 480V, 50/60Hz, 9W (sol. A) and 6W (sol. B). � HV218-222-1, dual solenoid, 24 to 480V, 50/60Hz, 9W (sol. A) and 6W (sol. B). � HV218-710-1, -2, -3, dual solenoid, 24 to 480V, 50/60Hz, 10.5W (sol. A and B). � HV218-714-1, 120V, 60Hz, 16.7W. � HV222-402-1, 24, 120, 240V, 50/60Hz, 9.95W. � HV222-763-1, 24 to 480V, 50/60Hz, 6W. � HV222-764-1, 24 to 480V, 50/60Hz, 6W. � HV226-700-1, 24 to 240V, 60Hz, 9.95W. � HV226-787-1, 24 to 480V, 60Hz, 15.05W. � HV-256567-1, Dual Solenoid, 24V dc, 15.3W (Solenoid A and B). � HV-262-976-1, 120V, 60Hz, 110V, 50Hz, 14.15W. � HV-262-976-2, 240V, 60Hz, 220V, 50Hz, 14.15W. � HV-270-244-1, 120V, 60Hz, 110V, 50Hz, 14.00W. � HV-270-244-2, 240V, 60Hz, 220V, 50Hz, 14.00W.

Page 2 of 10


� HV279455-1, 220/240V; 50/60Hz; 17.1W. � X8031A7106298, 24-480V, 50/60Hz, 20W. � X8031B57P10898, 120V, 60Hz, 20.9W, intermittent duty. � FBX822012B15131, 24 to 480V ac, 50/60Hz, 16.7W. � HTX8223A1313622, 24V dc, 16.8W. � FTX8262B211V13420, 575V, 60Hz, 10.5W. � 829212 and 829214, 24, 120 and 240V, 60Hz, 110 and 220V, 50Hz, 14.15W. � HBX8302A81VF12275, 24-480V, 50/60Hz, 20W. � X832064V09027, 24-480V, 50/60Hz, 6W. � X8320A10613420, 550V, 60Hz, 15.4W. � X83448313366, 24-480V, 50/60Hz, 6W. � HBX8031A7106298, 24-480V, 50/60Hz, 20W. � FBX8031B1307330, 24-480V, 50/60Hz, 16.7W. � X8211C1213420, 550V, 50/60Hz, 11W. � HTX8211C3313053, 24-480V, 50/60Hz, 10.5W. � DPX8320A4212293, 110/220, 220/440V, 50Hz, 120/240, 240/480V, 60Hz, 16.7W. � FBX8320A4212293, 24-480V, 50/60Hz, 16.7W. � DFX8320A4212513, 110/220, 220, 440V, 50Hz, 120/240, 240/280V, 10.5W. � BX8320A145VMB06136, 6-240V dc, 15.3W. � FBX8320A145VMS06136, 6-240V dc, 15.3W. � FBX8320A149VMS06136, 6-480V dc, 15.3W. � X8320A14510510, 24-480V, 50/60Hz, 9W. � DPX8320B212536, 110/220V, 220/440V, 50Hz and 120/240V, 240/480V, 9W. � HVX166-15910510, 24-480V, 50/60Hz, 9W. � DFX8345E1112225, 120/240V, 60Hz, 11W. � FTX8345E12225, 120V, 60Hz, 11W. � FTX8345E12225, 120V dc, 11.2W. � "ASCO" solenoids, Cat Nos 80033, 80034, 80103, 80104, EF80141, EF80142, 80143, 80144, 80163, 80164,

EF80171, EF80172, 80173, 80174, 82022, 82024, 82026, 82028.

Note: "ASCO" solenoids, Cat Nos 80103 and 80104 meet the requirements for Single Seal marking per ANSI/ISA 12.27.01-2003 standard. marking per ANSI/ISA 12.27.01-2003 standard.

� Cat Nos 202-749-260562 and HV-268-439-1, 120V, 60Hz, 110V, 50Hz, 15.4W; 202-749-260563 and HV-268-439-2, 24V dc, 36.2W.

� "ASCO" solenoid operators, Cat Nos 82002, 8328, suffixes, 2, 4, 6, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40. � Cat Nos HV-180-885-1, HV-180-886-1, 110/120V, 50/60Hz, 16.7W, HV-180-885-2, HV-180-886-2,

220/240V, 50/60Hz, 16.7W, HV-180-885-3, HV-180-886-3, 53V dc Int., 34.6W, HV-180-885-4, HV-180-886-4, 106V dc Int., 34.6W.

Class I, Groups A, B, C and D; Class II, Groups E, F, and G; Encls 3 and 4:

� "ASCO RED-HAT II" Solenoid, Cat Nos EF8016G1, EF8016G2, EF8003G1, EF8003G2, EF8003G9, , EV8003G1, EV8003G2, EV8003G9, EF8007G1, EF8007G2, EV8007G1, EV8007G2, EF8202G1, EF8202G3, EF8202G5 and EF8202G7.

� "ASCO" solenoid Cat No EF80041, rated 24, 110 and 220V ac at 50Hz, and 24, 120, 240V ac at 60Hz, 6.2W max; 6, 12, 24, 100, 110 and 120V dc, 7.0W max.

� "ASCO" Solenoid Cat No EF8004A1, rated 100, 110, 220, 240V ac at 50Hz; and 12, 24, 110, 120 and 240V ac at 60Hz, 6.3W max; 6, 12, 24, 48, 100 and 120V dc, 6.9W max. Note: Class I, Groups B, C & D when Prefix JB, JC or JD is used.

� ASCO Solenoid Valve Cat No. HV287776-001, -002, -003 or -004, rated 12 Vdc with 72" leads, 24Vdc with 72" leads, 12 Vdc with 18" leads or 24 Vdc with 18" lead option, respectively. Class F coil and 4W, 35psi maximum operating pressure differential. Ambient Temperature: -45.6° C to 51.7° C.

� ASCO Solenoid Valve Cat No. HV285926-001, -002, -003 or -004, rated 12 Vdc with 72" leads, 24Vdc with

Page 3 of 10


72" leads, 12 Vdc with 18" leads or 24 Vdc with 18" lead option, respectively. Class H coil and 12.1W, 35psi maximum operating pressure differential. Ambient Temperature: - 40°C to 51.7°C. Temperature Code T4A

Class I; Groups B, C and D; Class II, Groups E, F and G; 25° C Ambient; Enclosure 3, 3S, 4, 4X, 6, 6P, 7 & 9

� Accessory Model EP Junction Box Accessory for use with selected RED HAT II™ solenoids. The prefix is added to Catalogue Numbers as follows:

"JB" – ½ inch – 14 NPT Conduit Connection "JC" – ¾ inch – 14 NPT Conduit Connection "JD" – M20 X 1.5 6H Conduit Connection Note these are factory-installed accessories only.

Class I; Groups C and D; Class II, Groups E, F and G; 25° C to -40° C Ambient; Enclosure 3, 3S, 4, 4X, 6, 6P, 7 & 9

� Accessory Model EP Junction Box Accessory for use with selected RED HAT II™ solenoids. The prefix is added to Catalogue Numbers as follows:

"JB" – ½ inch – 14 NPT Conduit Connection "JC" – ¾ inch – 14 NPT Conduit Connection "JD" – M20 X 1.5 6H Conduit Connection Note these are factory-installed accessories only.

Class I, Groups A, B, C and D; Class II, Groups E and F; Encl Type 3, 3S, 4, 4X, 6 or 6P (as applicable).

� "ASCO RED-HAT II" Solenoid, Cat Nos EFHT8016G1, EFHB8016G2, EFHT8003G1, EFHB8003G2, EFHT8007G1, EFHB8007G2, EFHT8202G1, EFHB8202G3, EFHT8202G5, EFHB8202G7, EVHT8003G1, EVHB8003G2, EVHT8007G1, EVHB8007G2, EF8017G1, EFHT8017G1, EF8017G2, EFHB8017G2, EF8014G1, EFHT8014G1, EF8014G2 and EFHB8014G2. Note: Class I, Groups B, C & D when Prefix JB, JC or JD is used.

Class I, Groups A, B, C and D; Class II Groups E, F and G; Encls 3, 3S, 4, 4X, 6 or 6P (where applicable).

� "ASCO RED-HAT II" Solenoid, Cat Nos EV8003G1, EV8003G2, EV8003G9, EV8003G300, EF8003G300, EVMF8003G300, EFM8003G300, EV8003G301, EF8003G301, EVMF8003G301, EFM8003G301, EF8003G302, EV8003G302, FF8003G303, EV8003G303, EV800G71 and EV8007GT2.

� "ASCO RED-HAT II", Solenoid Valve Series, rated 20.1W max, 24-480V ac, 50 or 60Hz, Cat No EF8030G with suffix 17, 67, 70 and 71, EF8210F with suffix 26, 27, 54, 55, 56, 89, 13, 14, 18, 32, 103 and 104, EF8342G with suffix 1, 3, 701, 703, 20, 22, 720 and 722.

Class I, Groups B, C and D; Class II, Groups E, F and G; Encl. 3 and 4:

� "ASCO" solenoids, Cat Nos 80145, 80146, 80175 and 80176. Class I, Groups C and D; Class II, Groups E, F and G; Encl 3:

� "ASCO" solenoid operators, intermittent duty, Cat No HV-228-873-1, 120V, 60Hz, 128W; Cat No HV-228-873-2, 240V, 60Hz, 128W.

Class I, Groups C and D; Encl 3:

� "ASCO" Solenoid, Cat No HPX8018A508195, 24V dc, 56.5W. � "ASCO" Solenoid, Cat No HV222-732-1, 120V, 60Hz, 41.4W. � "ASCO" Solenoid, Cat No 8018A3, 24 to 480V, 60Hz, 28.2W. � "ASCO" Solenoid, Cat No 8018A4, 24 to 240V dc, 35.1W. *Must include prefix letters "EP" or "EF". **Not

Page 4 of 10


listed for Group G when steam fluid temperatures exceed 120C (240F). ***Cat Nos EF8215A40, -A90, 8215A41, -A91, and -B94 not Certified for Class II, Groups E, F and G.

Notes: 1. Rating (except where otherwise indicated), 600V and less, 50/60Hz, and 500V dc and less, 65W and

less. 2. Prefix and suffix letters and numbers are added to bulletin and catalogue numbers to indicate electrical

and mechanical variations and accessories. 3. Solenoids and solenoid operators are Certified for use only in other equipment where the suitability of

the combination is to be determined by the Canadian Standards Association. 4. Operating pressures, types of fluids and max temperatures are on file with CSA. 5. For valves with minor mechanical variations in addition to standard markings, the markings shall include

the basic bulletin number, together with the CSA Monogram and file number LR 13976. 6. Manual reset valves may include suffix "SW" to denote addition of CSA Certified hazardous locations

switch to indicate closed position of valve. With suffix "SW", valves are not suitable for "Encl. 4" use. 7. Cat No with prefix "CG" also have the designation "CGA 6.5". Cat Nos EF8210G3B, EF8210G75B,

EF8210G76B, EF8210G94B, EF8210G95B, EF8210G105B, EF8210G106B, EF8215G10B, EF8215G20B, EF8215G30B, EF8262G210B, EF8262G232B and EF8263G206B also have the designation "CGA 3.9".

8. Solenoid valves, Cat Nos HV168-301, HV206-691, HV218-174-1, HV222-763-1, HV222-764-1, HV226-700-1, HV256567-1 and HV-262-976-1, -2, are optionally without the green ground wire. In which case, such valves are Certified only for use in other equipment, where the suitability of the final combination is to be determined by CSA or Inspection Authority having jurisdiction.

9. Solenoid valves Cat Nos 829212 and 829214 may have prefix "L" added to denote lead length of more than 18 in. Unless a grounding lead is provided, these solenoid valves are Certified only for use in other equipment, where the suitability of the final combination is to be determined by CSA or the Inspection Authority having jurisdiction.

Class I, Groups A, B, C and D; Class II, Groups E, F and G; Class III; Encl Type 3, 4 or 4X (as applicable):

� "ASCO" General Purpose Solenoid Valves Series aIS8223b, aIS8262320, aIS8314c,aIS8316d, aIS8317e, aIS8344f, aIS8345301; "ASCO" Solenoid Operator Series aIS8003g, intrinsically safe when connected to CSA Certified Zener Barriers R. Stahl Inc., Model Nos 9001/01-280-100-10; 9001/00-280-100-10,9002/13-252-121-04, 9002/13-280-100-04, 9002/13-280-110-00, 9001/01-252-100-14and 9001/00-252-100-14, Measurement Technology Ltd., Model Nos 787+, 787-,728+, 728-, MTL2241, MTL2242, MTL3021, 708 and 707, Pepperl & Fuchs Mfg., (GB)Ltd., Model Nos Z478/EX, Z487/EX and Z479/EX, Elcon Instruments S.R.L. ModelNos 1871, 1872, MB4/2/16+ and MB4/4/4/16+16+ in accordance with ASCO Form NoV6850 or when connected to CSA Certified Zener Barrier rated 28V maximum, 300ohm minimum.

Class I, Groups A, B, C and D:

� "ASCO" General Purpose Solenoid Valves Series UIS8223b, UIS8262320, UIS8314c,UIS8316d, UIS8317e, UIS8344f, UIS8345301; "ASCO" Solenoid Operator Series UIS8003g, intrinsically safe when connected to CSA Certified Zener Barriers R. Stahl Inc., Model Nos 9001/01-280-100-10; 9001/00-280-100-10,9002/13-252-121-04, 9002/13-280-100-04, 9002/13-280-110-00, 9001/01-252-100-14and 9001/00-252-100-14, Measurement Technology Ltd., Model Nos 787+, 787-,728+, 728-, MTL2241, MTL2242, MTL3021, 708 and707, Pepperl & Fuchs Mfg., (GB)Ltd., Model Nos Z478/EX, Z487/EX and Z479/EX, Elcon Instruments S.R.L. ModelNos 1871, 1872, MB4/2/16+ and MB4/4/4/16+16+ in accordance with ASCO Form NoV6850 or when connected to CSA Certified Zener Barrier rated 28V maximum, 300ohm minimum.

Class I, Groups C and D; Class II, Groups E, F and G; Class III, Encl Type 3, 4 or 4X (as applicable):

� "ASCO" General Purpose Solenoid Valves Series aIS8223b, aIS8262320, aIS8314c,aIS8316d, aIS8317e, aIS8344f, aIS8345301; "ASCO" Solenoid Operator Series aIS8003g, intrinsically safe when connected to CSA Certified Zener BarrierMeasurement Technology Ltd., Model No MTL3022 in accordance with ASCO Form

Page 5 of 10


NoV6850.

Class I, Groups C and D:

� "ASCO" General Purpose Solenoid Valves Series UIS8223b, UIS8262320, UIS8314c,UIS8316d, UIS8317e, UIS8344f, UIS8345301; "ASCO" Solenoid Operator Series UIS8003g, intrinsically safe when connected to CSA Certified Zener BarrierMeasurement Technology Ltd., Model No MTL3022 in accordance with ASCO Form NoV6850.

Notes: 1.(a) Prefix "a" in the solenoid valve and/or solenoid operator Cataloguenumbers represents the alpha characters corresponding to the solenoidenclosure types, as follows:

WP": Enclosure Type(s) 3 and 4; "WS": Enclosure Type(s) 3,4 and 4X;

(b)Prefix "U" in the solenoid valve and/or solenoid operator Catalogue numbers designates open type solenoid ( no enclosure configuration ).

2. Suffixes "b", "c", "d", "e" and "f" in the solenoid valve Catalogue numbers represent the following numerical characters (pertinent to valve body construction and process specifications): b = 303 or 323; c = 300 or 301; d = 334, 354, 364 or 374; e = 307 or 388; f = 344, 354, 356, 370, 372, 374, 376, 378, 380 or 382.

3. Suffix "g" in the solenoid operator Catalogue number represents the following numerical characters designating the type of operation:

� 300: 3-way; � 301: 2-way.

4. Solenoid valves are consisting of solenoid operator assembly ( 2-way or 3-way ) combined with the applicable valve bodies/associated wetted parts.

5.(a) Solenoid Operators are Certified as Components only for use in other equipment where suitability of the combination is to be determined by the Authority having jurisdiction;

(b)Solenoid Valves/Operators with open type solenoid ( no enclosure configuration ) are Certified as Components only for installation in the suitable electrical enclosure and the combination is a subject of Acceptance by the Authority having jurisdiction.

Class I, Groups A, B, C and D; Class II, Groups E, F and G; Class III; Encl Type 3, 4 or 4X (as applicable):

� "ASCO" General Purpose Solenoid Valves Series a8223Abc, a8262A320cd, a8314Abc,a8316Abcd, a8317Abc, a8344Abcd, a8345A301c; "ASCO" Solenoid Operator Series a8003Ae, intrinsically safe when connected to CSA Certified Zener Barriers R. Stahl Inc., Model Nos 9001/01-280-100-10; 9001/00-280-100-10,9002/13-252-121-04, 9002/13-280-100-04, 9002/13-280-110-00, 9001/01-252-100-14and 9001/00-252-100-14, Measurement Technology Ltd., Model Nos 787+, 787-,728+, 728-, MTL2241, MTL2242, MTL3021, 708 and 707, Pepperl & Fuchs Mfg., (GB)Ltd., Model Nos Z478/EX, Z487/EX and Z479/EX, Elcon Instruments S.R.L. ModelNos 1871,1872, MB4/2/16+ and MB4/4/4/16+16+ in accordance with ASCO Form NoV6969 or when connected to CSA Certified Zener Barrier rated 28V maximum, 300ohm minimum.

Class I, Groups A, B, C and D:

� "ASCO" General Purpose Solenoid Valves Series f8223Abc, f8262A320cd, f8314Abc,f8316Abcd, f8317Abc, f8344Abcd, f8345A301c; "ASCO" Solenoid Operator Series f8003Ae, intrinsically safe when connected to CSA Certified Zener Barriers R.

Page 6 of 10


Stahl Inc., Model Nos 9001/01-280-100-10; 9001/00-280-100-10,9002/13-252-121-04, 9002/13-280-100-04, 9002/13-280-110-00, 9001/01-252-100-14and 9001/00-252-100-14, Measurement Technology Ltd., Model Nos 787+, 787-,728+, 728-, MTL2241, MTL2242, MTL3021, 708 and 707, Pepperl & Fuchs Mfg., (GB)Ltd., Model Nos Z478/EX, Z487/EX and Z479/EX, Elcon Instruments S.R.L. ModelNos 1871, 1872, MB4/2/16+ and MB4/4/4/16+16+ in accordance with ASCO Form NoV6969 or when connected to CSA Certified Zener Barrier rated 28V maximum, 300ohm minimum.

Class I, Groups C and D; Class II, Groups E, F and G; Class III, Encl Type 3, 4 or 4X (as applicable):

� "ASCO" General Purpose Solenoid Valves Series a8223Abc, a8262A320cd, a8314Abc,a8316Abcd, a8317Abc, a8344Abcd, a8345A301c; "ASCO" Solenoid Operator Seriesa8003Ae, intrinsically safe when connected to CSA Certified Zener BarrierMeasurement Technology Ltd., Model No MTL3022 in accordance with ASCO Form NoV6969.

Class I, Groups C and D:

� "ASCO" General Purpose Solenoid Valves Series f8223Abc, f8262A320cd, f8314Abc, f8316Abcd, f8317Abc, f8344Abcd, f8345A301c; "ASCO" Solenoid Operator Series f8003Ae, intrinsically safe when connected to CSA Certified Zener Barrier Measurement Technology Ltd., Model No MTL3022 in accordance with ASCO Form No V6969.

Class I, Div. 2, Groups A, B, C and D:

� "ASCO" 300 WBEE Solenoid Valves Series a8223Abcd, a8262A320cd, a8314Abcd, a8316Abcd, a8317Abcd, a8344Abcd, a8345A301cd, Non-Incendive when connected with Non-Incendive Field Wiring parameters of Vmax = 30V; Imax = 100mA; Ci = 0; Li = 0. Temp. Code T6, Tamb = 60 ˚C. Encl Type 3, 3S, 4 or 4X.

Notes: 1. (a) Prefix "a" in the solenoid valve and/or solenoid operator Catalogue numbers represents the alpha characters corresponding to the solenoid enclosure types, as follows:

- "WPIS": Enclosure Type(s) 3 and 4; - "WSIS": Enclosure Type(s) 3,4 and 4X; - "WBIS": Enclosure Type(s) 3,4 and 4X; - "WBEE": Enclosure Type(s) 3, 3S, 4, 4X.

(b) Prefix "f" in the solenoid valve and/or solenoid operator Catalogue numbers designates open type solenoid (no enclosure) - configurations "UIS" or "ISSC".

2. Suffixes "b", "c", "d" and "e" in the solenoid valve Catalogue numbers represent the following numerical characters (pertinent to valve body construction and process specifications):

b = Pipe and orifice size : 303 or 323 (8223 only); 300 or 301 (8314 only); 334, 354, 364 or 374 (8316 only); 307 or 308 (8317 only); 344, 354, 356, 370, 372, 374, 376, 378, 380 or 382 (8344 only). 302, 304, 305, 306, 309, 310, 313, 314, 317, 318, 319, 320, 321, 322, 365, 366, 367, 368, 381 or 386. c = General service to -40 C (-40 F) - "MF" designator in the solenoid valve Catalogue number.

d = Mounting bracket and/or manual operator, designator "MB" and/or "MO" or no designator, if no mounting bracket or manual operator.

Page 7 of 10


e = Operation:

- 300: 3-way; - 301: 2-way.

3. Solenoid valves are consisting of solenoid operator assembly ( 2-way or 3-way ) combined with the applicable valve bodies/associated wetted parts.

4. (a) Solenoid Operators are Certified as Components only for use in other equipment where suitability of the combination is to be determined by the Authority having jurisdiction;

(b) Solenoid Valves/Operators with open type solenoid ( no enclosure configuration ) are Certified as Components only for installation in the suitable electrical enclosure and the combination is a subject of Acceptance by the Authority having jurisdiction.

5. Process data:

Medium: air or inert gas; Maximum working pressure: 1035 kPa (150 psig); Maximum fluid temperature: 60 C (140 F).

Ambient Temperature: -40 C to +60 C (-40 F to +140 F).

Class I, Groups C and D; Encl Type 4X:

� "ASCO RED HAT" General Purpose offshore service solenoid valve Cat Nos EF8317501, -511*, EF8320501-505, -511*, -515*, 12 or 24V dc, 2.88W; EF8317502, -512*, 12 or 24V dc, 1.44W. Note: *Solenoid incorporates factory sealed leads.

Class I, Groups A, B, C and D; Class II, Groups E, F and G; Class III, Encl Types 3, 3S, 4, 4X, 6 or 6P (applicable):

� "ASCO RED-HAT" II" General purpose, low power solenoid valves Series Cat Nos, Cat Nos EF or EV, with or without MF, -8223Ge, -8262Gg, -8314Ga, -8316Gb, -8317Gc, -8344Gd, and -8345G301; Solenoid operator Series Cat Nos, Cat Nos EF or EV, with or without MF, -8003Gf. Note: Class I, Groups B, C & D when Prefix JB, JC or JD is used.

Notes: 1. Solenoid valves and solenoid operator are consisting of solenoid coil assembly EF 238714-902 (24V dc)

or -903 (12V dc) and (EV) 274714-902 (24V dc) or -903 (12V dc) 1.4 max, (EFMF 276006-004 (12V dc) or -006 (24V dc) and EVMF 276007-004 (12V dc) or -006 (24V dc), 1.7W max combined with the valve bodies/associated wetted parts as described in the corresponding report.

2. Suffix a = 300 or 301; Suffix b = 334, 354, 356, 364 or 374; Suffix c = 307 or 308; Suffix d = 344, 354, 356, 370, 372, 374, 376, 380 or 382; Suffix e = 303, 310 or 323; Suffix f = 300 (3-way) or 301 (2-way) operation. Suffix g = 320 or 386.

3. Solenoid operators are Certified as components only for use in other equipment where the suitability of the combination is to be determined by the Authority having jurisdiction.

4. Model EP Junction box accessory may be added as shown above by the Prefix option of JB, JC, JD.

Class I, Groups A, B, C, and D; Class II, Groups E, F and G; Types 3, 3S, 4, 4X, 6 or 6P (as applicable):

� "ASCO RED-HAT II" General purpose, low power solenoid valves Series Cat Nos EF8040H (6,7,8);

Page 8 of 10


EF8210H (105B, 106B); EF345H3; EF8353G39.

Ex m IIC T3

� "ASCO RED-HAT ® Next Generation Solenoid" - General purpose, low power solenoid valves Catalogue Numbers - EF8003P001, EF8007P001, EF8202P001, -005, EJ8003K001, J8007K001, EJ8202K001, EJ8202K005, EF8003K001, -002, -009, EF8007K001, EF8202K001, -003, -005, -007; 12 - 240V ac/dc; 50/60Hz for Ac units; rated. -40ºC to max ambient of 75ºC.

Ex m II, T4A (120° C):

� "ASCO RED-HAT Next Generation (47) Solenoid" - Catalogue Numbers – EE8003P001, EE8007P001,

EE8202P001, -005, rated 12-240Volts AC/DC, 50/60 Hz for AC; Rated. -40° C to max ambient of 60° C. � Electrically operated valves "RED HAT" Next Generation (47), two ways valves Series 8030, 8210, 8221,

8262, three way valves, Series 8314, 8316, 8317, 8320, 8321, 8344 and 8345 followed by P and two way or three way and reverse acting type solenoid Series 8003, 8007 and 8202 followed by P, rated 12-24V dc, 24-

99V dc; 100-240V dc, 24-99V ac, 100-240V ac, 50/60Hz, 2 Watts, Class H insulation, 60° C ambient, 150-825 PSI, max

Notes:

1. Models with the prefix "EE".

2. The Temperature Code is T4A (120° C) for the coil type P – "Premium".

Class I, Div 2, Groups A, B, C, and D; Class II, Div 2, Groups F and G; Class III; T4A (120° C); Encl. Types 3, 3S, 4 and 4X:

� "ASCO RED-HAT Next Generation (47) Solenoid" - Catalogue Numbers – EE8003P001, EE8007P001,

EE8202P001, -005, rated 12-240Volts AC/DC, 50/60 Hz for AC; Rated. -40° C to max ambient of 60° C. � Electrically operated valves "RED HAT" Next Generation (47), two ways valves Series 8030, 8210, 8221,

8262, three way valves, Series 8314, 8316, 8317, 8320, 8321, 8344 and 8345 followed by P and two way or three way and reverse acting type solenoid Series 8003, 8007 and 8202 followed by P, rated 12-24V dc, 24-

99V dc; 100-240V dc, 24-99V ac, 100-240V ac, 50/60Hz, 2 Watts, Class H insulation, 60° C ambient 150-825 PSI, max.

Notes:

1. Models with the prefix "EE".

2. The Temperature Code is T4A (120° C) for the coil type P - "Premium".

Class I, Grps. A, B, C and D; Class II, Grps. E, F and G; Temp. Code T3C or T3B; Encl. Types 3, 3S, 4, 4X, 6 or 6P

� Two way normally closed PWM proportional modulating solenoid valves, models HV139068-004, HV139068-005, HV139068-007, HV139068-008, HV139068-009, HV139069-004, HV139074-005 and

HV286528-001; rated 24V dc, 12.8 W; Maximum operating pressure 50 psi, operating ambient –30° C to 70°

C except for model HV286528-001 -30° C or 60° C. � Two way normally closed direct acting solenoid valves, models HV290042-001and HV290042-002; rated

110/220V ac, 50 Hz and 120/240V ac, 60 Hz; Maximum operating pressure 50 psi, operating ambient –13° C

to 131° C.

Class I, Div 1, Groups A, B, C, and D; Class II, Div 1, Groups E, F, G; Class III; Encl. Type 3 and 4

� PART A: Electrically operated valves, Cat No’s EF8262 and EF8263 Revision letter H Normally Closed Safety Shutoff and General Purpose rated 24-240V AC, 50/60Hz 6-240V DC. Max.

Page 9 of 10


ambient temperature 60° C (55° C for DC rated valves). � PART B: ASCO RED HAT II solenoid, Cat No’s EF8016H1, EF8016H2 and EF8003H1,

EF8003H2 rated 24-240V AC, 6-240V DC. Max. ambient temperature 60°C (55° C for DC rated valves).

Notes:

1. All series and Cat. Nos. above are not Certified for Group G when prefixed HT or HB. 2. DC/H Cat. Nos. are Certified only for Class I, Div 1, Groups A, B, C, and D & Class II, Group E. 3. Cat No’s 8263 Revision letter H not Certified for Group G when steam fluid temperature exceeds

120° C. 4. The Temperature Code is as follows:

Class I, Div 2, Groups A, B, C, and D; Class II, Div 2, Groups F and G; Class III; T4A (120° C); Encl. Types 3, 3S, 4 and 4X

Class I, Zone 2, IIC, T4A (120° C)

� PART A: Electrically operated valves, Cat No’s EE8262 and EE8263 Revision letter R Series Normally Closed Safety Shutoff and General Purpose rated 12V DC, 24-99V AC 50/60Hz/DC, 100-240V AC 50/60Hz/DC.

� PART B ASCO RED-HAT Next Generation (47) Solenoid" - Catalogue Numbers –

EE8003R001, rated 12-240Volts AC/DC, 50/60 Hz for AC; Rated. –40° C to max ambient of 60° C.

/mer

Solenoid Class Temperature Temp Code

MXX F 165°C T3B

MXX H 180°C T3A

M6 F 165°C T3B

M6 H 180°C T3A

Next Gen T4A

Copyright © 2009 CSA International. All rights reserved.

Page 10 of 10


GEARS LTDTechnical Manual

for aSize 80T/55T

Duo Concentric Clutch

Manual Number: IB.687Issue No. 3 4-1-02

SSS Gears Ltd. Park Road, Sunbury-on-Thames, Middlesex, TW16 5BL. England.

Tel: +44 (0)1932 780644. Fax: +44 (0)1932 780018

Manual Number IB.687.

GEARS LIMITED

Contents and index

General1.1 The purpose of the clutch1.2 Main clutch components - diagram

Installation of the clutch2.1 Clutch identification2.2 Direction of rotation2.3 Pre-installation actions2.4 Clutch installation

Maintenance of the clutch3.1 Pre-stripping and assembly actions3.2 Match marks3.3 Stripping the clutch3.4 Stripping and assembling the primary pawl mechanism3.5 Stripping and assembling the secondary pawl mechanism3.6 Assembling the clutch

Fault finding4.1 General4.2 The starting drive clutch fails to engage at high speed4.3 The starting drive clutch fails to engage from rest or at low speed4.4 The turning gear clutch fails to engage4.5 The clutch fails to disengage

Parts list5.1 Clutch parts list

Spare parts6.1 Ordering spare parts6.2 Recommended spares

DrawingsClutch assembly drawing - SL.17632 or SL.17866

Principles of operationApplicable principlesBasic SSS clutch principlePrisec pawls

Section 1

Section 2

Section 3

Section 4

Section 5

Section 6

Section 7

Section 8


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The purpose of the clutchThe SSS (synchro-self-shifting) duo concentric clutch is installed between astarting drive, a turning gear drive, and common, associated, driven machinery.

The two functions of the clutch are to: 1. automatically connect the starting driveto a gas turbine so that the gas turbine may be accelerated to self-sustaining speedand 2. provide a simple mechanical means of automatically engaging and disen-gaging the turning gear motor as and when it is required.

It the driven machinery is stationary, the clutch will automatically engage fromrest the moment either the starting drive or the turning gear motor starts to rotate.

If the driven machinery is rotating, driven by the turning gear, the clutch willautomatically engage the moment the speed of the starting drive tends to exceedthat of the driven machinery. The turning gear motor drive will automaticallydisengage and can be shut down independently.

The starting drive will automatically disengage as the driven machinery acceler-ates away, allowing the starting drive to be shut down independently.

It the gas turbine fails to start, the starting drive can be re-accelerated and theclutch will automatically re-engage the moment the speed of the starting drivetends to exceed that of the decelerating gas turbine.

The turning gear motor can be independently started while the main drive is stilloperating so that when the main drive is shut down and the driven machinerydecelerates, the clutch will automatically engage to maintain the driven machin-ery at turning gear speed.

Section 1 General

1.11.1.1

1.1.2

1.1.3

1.1.4

1.1.5

1.1.6

1.1.7


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GeneralSection 1

Main clutch componentsThe full contruction of the clutch is shown on the assembly drawing and comprisesfive main sub assemblies: A turning gear input assembly; A starting drive inputassembly; A turning gear helical sliding assembly; A starting drive helical slidingassembly; A common output assembly.

Diagram showing the sub assemblies and the main component parts

1.21.2.1

1.2.2

Helical sliding component

(turning gear)

Input splined member(turning gear)

Pawls(turning gear)

Output clutch ring(turning & starting)

Secondary pawls(starting drive) Helical sliding

component(starting drive)

Primary pawls(starting drive)

Input shaft(starting drive)


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2.12.1.1

2.22.2.1

2.32.3.1

2.3.2

2.3.4

2.3.5

2.3.6

2.3.7

2.42.4.1

2.4.2

Section 2 Installation of the clutch

Clutch identificationEach clutch is marked with an individual four or five figure serial number precededby the letter ‘R’. The number (illustrated below), is marked on the outside of theclutch and where possible, each individual sub-assembly.

Direction of rotationThe outside diameter of the clutch is marked with an arrow (illustrated below)indicating the direction of rotation.

Pre-installation actionsEnsure that the clutch assembly drawing is available and used throughout theassembly operation.

Ensure that the main plant driving and driven shafts and casing have beeninspected and meet technical specification and tolerance.

Check that any final deburring, cleaning or flushing has been completed.

Read section 3.2 of this manual concerning match-marks.

Remove any red painted transport fittings from the clutch.

Remove the clutch split retaining ring (14) for later assembly.

Clutch installationAlign and fit the clutch into its location in the turning gear worm drive.

Align the flange on the clutch input splined member (3), fit location dowels and boltdown (dowels and bolts not supplied by SSS Gears).

INPUTDIRECTION OF

ROTATION

CLUTCH SERIAL No R * * * * *


GEARS LIMITED

Section 2 Installation of the clutch

Align and fit the clutch split retaining ring (14) and bolt down (29).

Position and secure the turning gear worm drive and housing and check forconcentricity and parallelism.

Locate the flange on the output clutch ring (4) with the spigot on the flange of thedriven machinery. Align the two flanges and bolt together (bolts not supplied bySSS Gears).

Fit the starting drive coupling (not supplied by SSS Gears).

Check the clutch for concentricity and parallelism (see 2.4.10).

Ensure that filtered lubrication oil is supplied to the clutch and refer to theassembly drawing to check the specified flow rate and supply details.

Check for satisfactory operation of the clutch by alternately turning the turninggear input side and the starting drive input side in the direction of rotation toengage and against the direction of rotation to disengage (see 2.2).

2.4.3

2.4.4

2.4.5

2.4.6

2.4.7

2.4.8

2.4.9

2.4.10

Maximum dial indicator reading = 0.03 mm

To check that the input and output shafts are concentic with each other, rotate the dial indicator about the

output shaft using the input shaft as a datum.


GEARS LIMITED

Maintenance of the clutchSection 3

3.13.1.1

3.1.2

3.1.3

3.23.2.1

3.2.2

3.2.3

3.33.3.1

3.3.2

3.3.3

3.3.4

3.3.5

Pre-stripping and assembly actionsEnsure the clutch assembly drawing is available and is used in conjunction withthese instructions.

Remove the clutch using the reverse of the procedure described in Section 2.

Read section 3.2 of this manual as all clutch components are match-marked asillustrated below and care must be taken to ensure correct alignment.

Match-marksThe match-marks for mating holes, flanges, and splines, as illustrated in 3.2.3 areused throughout the clutch. The only exception can be on interface flanges wherebolt/dowel holes may be match-numbered.

Identify individual match-marks before removing each component and take greatcare to re-align them on re-assembly.

Stripping the clutch.Read Section 3.1 and 3.2 of this manual.

Support the clutch on a worksurface with the ring nut (11) on the input shaft-starting (6) end face down.

Remove bolts (48) and lift off the retaining cap (12).

Withdraw the helical sliding component-starting (1) and the output clutch ring (4)as an assembly, complete with the turning gear pawl mechanism and the startingdrive primary and secondary pawl mechanism, gently drawing it through the gearteeth and ratchet rings.

Separate the helical sliding component-starting (1) from the output clutch ring (4).

Bolted or dowelledconnections

Flangedconnections

Splinedconnections

Ø Ø AAAAAAAAAAAA

X XX


GEARS LIMITED

Section 3 Maintenance of the clutch

Withdraw the helical sliding component-turning (2) from the input splinedmember-turning (3).

Remove bolts (47) and tap off the input splined member-turning (3).

Remove bolts (47) and tap off the bearing support ring (27) allowing the bearingretaining cap (9) to drop gently down onto the ring nut (11) for later removal.

Extract the top bearing (19).

Turn the remaining assembly upside down and support.

Remove locking screws (41) and undo the ring nut (11) and remove.

Remove the loose bearing retaining cap (9).

Extract the remaining bearing (20).

Stripping and assembling the starting drive primary pawl mechanismand the turning gear pawl mechanismPlace the output clutch ring (4) on a worksurface with the pawl mechanism faceup.

Remove bolts (28) releasing the pawl carrier (8) from the output clutch ring (4).

Hold the assembly together by hand and turn upside down (if you lift the pawlcarrier straight off, all the pawl pins and pawls will drop out).

Gently ease the output clutch ring (4) off its dowels (32) and separate it from thepawl carrier (8).

The primary pawl pins (18) pawls (36) springs (38) and pawl stop pins (17) can beextracted in turn.

Similarly, the turning gear pawl pins (21) pawls (35) springs (39) and stop pins (22)can also be extracted in turn.

To re-assemble, use the reverse procedure and refer to the assembly drawing andthe diagram in 3.4.8 for correct pawl alignment.

3.3.6

3.3.7

3.3.8

3.3.9

3.3.10

3.3.11

3.3.12

3.3.13

3.4

3.4.1

3.4.2

3.4.3

3.4.4

3.4.5

3.4.6

3.4.7


GEARS LIMITED


Pawls and adjacent surfaces are marked with assembly arrows

Stripping and assembling the starting drive secondary pawlmechanismPlace the helical sliding component-starting (1) on a worksurface with theretaining collar (13) face up.

Remove bolts (31) and lift off the retaining collar (13).

The secondary pawl pins (15) pawls (37) and pawl stop pins (16) can be extractedin turn.

To re-assemble, use the reverse procedure and refer to the assembly drawing andthe diagram in 3.4.8 for correct pawl alignment.

Assembling the clutchPlace the input shaft-starting (6) on a worksurface with the keyed end face up.

Press on the bearing (20) until it is flush against its location shoulder.

Pre-position the bearing retaining cap (9) flush against the bearing.

Position and screw up the notch nut (11) and secure with the locking screws (41).

Turn the assembly upside down and support.

Press on the bearing (19) until it is flush against its location shoulder.

Fit the bearing support ring (27) and press it on to the bearing until it is flush

3.4.8

3.5

3.5.1

3.5.2

3.5.3

3.5.4

3.63.6.1

3.6.2

3.6.3

3.6.4

3.6.5

3.6.6

3.6.7

Pawl carrierPawl


GEARS LIMITED

against its location shoulder. Align it with the pre-fitted bearing retaining cap (9)and bolt the two together (47).

Align and fit the input splined member-turning (3) to the bearing support ring (27)and bolt the two together (47).

Align and fit the helical sliding component-turning (2) to the helical spline on theinput splined member-turning (3)

Align and pre-fit the helical sliding component-starting (1) with the output clutchring (4) complete with the three assembled pawl mechanisms.

Align and fit this assembly onto the spline of the input shaft-starting (6). Gentlyease the assembly into place through the gear teeth and ratchet rings.

Align and fit the retaining cap (12) and bolt down (48).


3.6.8

3.6.9

3.6.10

3.6.11

3.6.12


GEARS LIMITED

Fault findingSection 4

4.14.1.1

4.1.2

4.1.3

4.24.2.1

4.2.2

4.34.3.1

4.3.2

4.44.4.1

4.4.2

4.54.5.1

4.5.2

GeneralThe only faults likely to occur are those caused by operational defects - notably alack of lubricating oil during operation and/or misalignment.

A lack of lubricating oil will result in overheating and damage to the bearings andpossibly the clutch teeth and the pawl and ratchet mechanism.

Misalignment could result in damage to the primary and/or secondary pawl andratchet mechanism such that the clutch will not engage either in the low speedrange or the high speed range.

The starting drive clutch fails to engage at high speedIf the starting drive is able to rotate faster than the turbine, then there is damageto the secondary pawl and ratchet mechanism.

Action: Stop the starting drive immediately to prevent further damage and contactSSS Gears.

The starting drive clutch fails to engage from rest or at low speedIf the starting drive will not rotate the turbine from standstill (but is able to rotateitself) or if, when at low speed, the starting drive is able to rotate faster than theturbine, then there is damage to the primary pawl and ratchet mechanism.

Action: Stop the starting drive immediately to prevent further damage and contactSSS Gears.

The turning gear clutch fails to engageIf the turning gear motor will not rotate the driven machine from standstill (butcan rotate itself) or if, when at low speed, the turning gear motor is able to rotateslightly faster than the driven machinery, then there is damage to the pawl andratchet mechanism.

Action: Stop the drive immediately to prevent further damage and contact SSSGears.

The clutch fails to disengageIf the speed of the starting drive will not reduce below the speed of the turbine whenthe drive is turned off, this indicates that the clutch mechanism is damaged andheld in the engaged position.

Action: Stop turning gear drive, starting drive, and the turbine immediately toprevent further damage and contact SSS Gears.


GEARS LIMITED

Parts listSection 5

Item Description Qty

1 Helical sliding component-starting 12 Helical sliding component-turning 13 Input splined member-turning 14 Output clutch ring 15 Secondary ratchet ring-starting 16 Input shaft-starting 18 Pawl carrier 19 Bearing retaining cap 111 Ring nut 112 Retaining cap 113 Retaining collar 114 Retaining ring 115 Pawl pin-secondary 416 Pawl stop pin-secondary 817 Pawl stop pin-primary 218 Pawl pin-primary 219 Bearing (rigid ball) 120 Bearing (rigid ball) 121 Pawl pin-turning 422 Pawl stop pin-turning 427 Bearing support ring 128 Socket cap screw 3/8"UNF x 1.75" long 429 Socket cap screw 3/8"UNF x 1.25" long 631 Socket cap screw 5/16"UNF x 1/2" long 432 Dowel 233 Location screw 435 Pawl-turning 436 Pawl-starting primary 237 Pawl-starting secondary 438 Pawl spring-primary 239 Pawl spring-turning 441 Locking screw 142 Transportation clamp 143 Hexagon head bolt 5/8"UNF x 2.25" long 244 Nut 5/8" thin 245 Washer 5/8" heavy 447 Socket cap screw 3/8"UNF x 1.5" long 2048 Socket cap screw 5/16"UNF x 1.5" long 4

Clutch parts list5.1


GEARS LIMITED

Section 6 Spare parts

Ordering spare partsFive items of information are required when ordering spare parts from themanufacturers. (1) The quantity required, (2) The item number, (3) The descrip-tion, (4) The drawing number, (5) The clutch serial number.

The clutch serial number (preceded by the letter R) is clearly marked on the outsideof the clutch. The remaining information required can be found either in Section6 of this manual or on the assembly drawing.

Order example: Qantity 4, Item 35, Pawl-turning, Drawing number SL.*****,Serial number (see clutch).

Recommended sparesIt is advised that the following spares are carried as stock.

6.16.1.1

6.1.2

6.1.3

6.26.2.1

Item Description Qty

15 Pawl pin-secondary 416 Pawl stop pin-secondary 817 Pawl stop pin-primary 218 Pawl pin-primary 219 Bearing (rigid ball) 120 Bearing (rigid ball) 121 Pawl pin-turning 422 Pawl stop pin-turning 435 Pawl-turning 436 Pawl-starting primary 237 Pawl-starting secondary 438 Pawl spring-primary 239 Pawl spring-turning 4


GEARS LIMITED

DrawingsSection 7

The clutch assembly drawing is providedin this manual as a bound-in insert.

This manual is suitable for all clutchesbuilt to the assembly drawings listed above.

Clutch assembly drawing - SL.17632 or SL.17866


GEARS LIMITED

Section 8 Principles of operation

Applicable principlesThe SSS clutch incorporates a number of features. As an aid to understandingthese features, the applicable SSS principles of operation are contained in thepages of this section.

These principles are:

Basic SSS clutch principle SSS Principle No. 1a.

Prisec pawls SSS Principle No. 2.

The diagrams used to describe these SSS principles are generic and not descriptiveof any individual SSS Clutch.


GEARS LIMITED

Principles of operationSection 8

Basic SSS clutch principle (SSS Principle No.1a)The initials SSS denote the 'Synchro-Self-Shifting' action of the clutch, wherebythe clutch driving and driven teeth are phased and then automatically shiftedaxially into engagement when rotating at precisely the same speed. The clutchdisengages as soon as the input speed slows down relative to the output speed.

The basic operating principle of the SSS clutch can be compared to the action of anut screwed on to a bolt. If the bolt rotates with the nut free, the nut will rotatewith the bolt. If the nut is prevented from rotating while the bolt continues to turn,the nut will move in a straight line along the bolt.

In an SSS clutch the input shafthas helical splines which corre-spond to the thread of the bolt.Mounted on the helical splinesis a sliding component whichsimulates the nut. The slidingcomponent has external clutchteeth at one end, and externalratchet teeth at the other (seeFigure 1).

When the input shaft rotates,the sliding component rotateswith it until a ratchet toothcontacts the tip of a pawl on theoutput clutch ring to preventrotation of the sliding compo-nent relative to the outputclutch ring, and align the driv-ing and driven clutch teeth (seeFigure 1 and Figure 4).

As the input shaft continues torotate, the sliding componentwill move axially along the heli-cal splines of the input shaftmoving the clutch driving anddriven teeth smoothly into en-gagement.

During this movement, the onlyload taken by the pawl is thatrequired to shift the lightweight

Movement intoengagement

Figure 2: Engaging travel (pawls unloaded)

Input shaft Pawls Output clutch ring

Clutchteeth

Ratchet

Helical sliding component Helical splines

Figure 1: Clutch disengaged


GEARS LIMITED


sliding component along thehelical splines.

As the sliding componentmoves along the input shaft,the pawl passes out of contactwith the ratchet tooth, allow-ing the driving teeth to comeinto flank contact with thedriven teeth and continues theengaging travel (see Figure2).

Driving torque from the inputshaft will only be transmittedwhen the sliding componentcompletes its travel by con-tacting an end stop on theinput shaft, with the clutchteeth fully engaged and thepawls unloaded (see Figure3).

When a nut is screwed againstthe head of a bolt, no externalthrust is produced. Similarlywhen the sliding componentof an SSS clutch reaches itsend stop and the clutch istransmitting driving torque,no external thrust loads areproduced by the helicalsplines.

If the speed of the input shaftis reduced relative to the output shaft, the torque on the helical splines will reverse.This causes the sliding component to return to the disengaged position and theclutch will overrun. At high overrunning speeds, pawl ratcheting is prevented bya combination of centrifugal and hydrodynamic effects acting on the pawls.

The basic SSS clutch can operate continuously engaged or overrunning at maxi-mum speed without wear occurring.

Figure 3: Clutch engaged

As the clutch input overtakes the clutch output,the pawls engage with the ratchet ........

...... and the driving and driven teeth areperfectly aligned for inter-engagement.

Clutchoutput

Clutchinput

Pawl

Ratchet

Figure 4: Clutch teeth alignment


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Prisec pawls - Primary and Secondary (SSS Principle No.2)The purpose of Prisec pawls is to enable the clutch to engage both at low speed andat high speed but prevent sustained ratcheting action of the pawls with the clutchoutput at speed and the clutch input stopped.

Primary pawls operating forlow speed engagement

Helical splinesDriven teeth

Driving teeth

Primary pawlsEngage the clutch in the lowspeed range and have thefollowing features:

Mounted on the clutchoutput.

Spring loaded onto theratchet teeth.

Unbalanced relative topivots to centrifugallyretract when the outputexceeds a prediterminedspeed (usually about500 rpm).

Section A-A

Input shaft

Primarypawls Output

clutch ring

Driventeeth

Helical splines

Secondarypawls

BA

A

B

Oilsupply

Drivingteeth

Oilrim

Prisec pawls(Primary and Secondary)

The secondary pawls areactivated by centrifugal force.

The primary pawls are springloaded inwards and retractedby centrifugal force.


GEARS LIMITED


Secondary pawls operatingfor high speed engagements

Section B-B

Secondary pawlsEngage the clutch in the high speedrange and have the following features:

Mounted on the sliding componentdriven by the clutch output.

Unbalanced relative to pivot to givea centrifugal movement towards theratchet teeth when the input rotates.

Oil immersed ratchet teeth providesa skimming action for the pawls whenthere is a high relative speed betweenthe pawls and the ratchet teethkeeping the pawls out of contactwith the ratchet teeth until the inputspeed approaches the output.

Primary pawlscentrifugally retracted

Secondary pawlsskimming on oil rim

Condition with output at highspeed and input stopped

Prisec pawls

Primary pawls arecentrifugally retractedwhen the clutch outputis at speed.

Rotating oil rimdepresses secondarypawls to preventratcheting whenoverrunning at highspeeds.

Both sets of pawls areinert when the clutchoutput is rotating athigh speed and theinput is at rest or atlow speed.

Warehouse

Warehouse

Warehouse

Warehouse

Warehouse

Warehouse

Warehouse

F/doc/sp/waukesha7eabr

INSTRUCTIONS

FOR

TAPER LAND JOURNAL BEARINGAND

TAPER LAND JOURNAL & THRUST BEARING

I. BEARING DESCRIPTION

The Taper Land Journal Bearing is a split shell, babbited type of bearing. It is an anti-whirl type ofbearing designed for one directon of rotation of the shaft. Oil is supplied to the OD central grooveand is fed to the four (4) axial spreader grooves in the bore through radial feed holes. This oil isdischarged from each end of the bearing.

The two halves are doweled and bolted together and an anti-rotation pin is located in the upper half.

The Taper Land Journal and Thrust Bearing is similar, except it includes taper land thrust typefaces on each end. These also, are designed for one direction of shaft rotation. Oil is fed to thesethrust faces via feed holes from the OD groove.

This bearing also includes a 1/2 inch long circumferential groove in the bore to feed oil from thejournal portion through mating holes in the shaft at this axial location.

II. BEARING INSTALLATION

The bearings are processed with a rust inhibitor prior to shipment which should not be removed untilready for installation. Assembly is made by placing the lower half of the bearing into the housing,setting the shaft in place, then assembling the top half of the bearing with the aid of the joint boltsand dowels. All parts should be coated with the lubricant to be used in the unit at this time. Thebearings are then rotated to place the anti-rotation dowel on top center. This locates the bore grooveproperly.

CAUTION: The Taper Land Journal Bearing is a universal design and can be installed in either clockwise or counter-clockwise systems. The anti-rotation pin can be installed in

either of two positions allowing the bearing to be reversed to suit shaft rotation. Observe direction of rotation arrow clearly marked on bearing OD.

F/doc/sp/waukesha7eabr

I. BEARING OPERATION DATA

1. Design RPM: 3600 Maximum

2. Design Thrust Load: 1300 # Maximum

3. Bearing Oil Requirements: Taper Land Journal: - 1-1/2 GPMTaper Land Journal & Thrust: - 2-3/4 GPM

4. Power Loss: Taper Land Journal: - 3 HorsepowerTaper Land Journal & Thrust: - 5 Horsepower

5. Oil: 145-175 SSU @ 100° F Turbine Oil

6. Inlet Temperature: 145° F Maximum

7. Design Outlet Temperature: 160° F Maximum


SECTION 4


EMERGENCY DC DRIVE

Delroyd Worm Gear 2221 Niagara Falls Blvd. Niagara Falls, NY 14302

Telephone: 716.298.4100 Toll Free: 800.432.0121

Fax: 716.298.4101 Web: www.delroyd.com email: [email protected]

Double Worm Gear Speed Reducers o Installation o Lubrication o Maintenance o Operation o Replacement Parts

DE35 – DE40

DSM35 – DSM200

DV35 – DV200

DE50 – DE140

2

DELROYD APPROVED LUBRICANTS* Compounded Steam Cylinder Oil Manufacturer AGMA #7C AGMA #8C Ashland Oil Inc. Light Cylinder No Product Atlantic Richfield Co. No Product MODOC 175 British Petroleum ENERGOL DCC 460 ENERGOL DCC 680 Chevron Oil Co. Chevron Cyl. Oil W ISO 460 Chevron Cyl. Oil W ISO 680 Citgo Petroleum Corp. CITGO Cyl. Oil 400-5 CITGO Cyl. Oil 680-7 Continental Oil Co. INCA Oil 460 INCA Oil 680 Exxon Company, U.S.A. Cylesstic TK 460 Cylesstic TK 680 Imperial Oil Ltd. (Canada) Cylesso TK 460 Cylesso TK 680 Keystone No Product Keygear K600 Mobil Oil Corp. 600W Super Cylinder Oil 600W Extra Hecla Super Cyl. Oil Phillips Petroleum Co. Hector 460S Hector 630S Shell Oil Company Valvata Oil J 460 Valvata Oil J 680 Texaco Inc. Vanguard Cylinder Oil J 460 Vanguard Cylinder Oil J 680 PAO Synthetic Oil Manufacturer AGMA #7 Synthetic AGMA #8 Synthetic Chevron Oil Co. Hipersyn 460 No Product Klubersynth Gem 4-460N Gem 4-680N Mobil Oil Corp. SHC 634 SHC 636 Petro-Canada Syndro SHB 460 No Product

*Use only Delroyd approved lubricants. Contact the factory prior to using any lubricant not appearing above.

Proper installation of your worm gear speed reducer is essential for efficient, economical operation and long life. The unit is built for proper operation in the mounting position or-dered. Tilted or different mounting positions may require factory installed lubrication provi-sions. Accurate initial alignment to motor and driven machine is required and must be main-tained by use of a rigid foundation that prevents springing. After a few days of operation, the

alignment should be rechecked and foundation bolts should be retightened if necessary. Mount gears, sprockets, or sheaves as close as possible to reduce bearing overhung load. Avoid heavy hammer blows when mounting couplings or sprockets as this may damage bearings or spring shafts. When tight fits are used, the coupling half should be heated in oil at 150°-200°F to expand the bore.

When speed reducers are used as standby equipment, operate them about once a month. Always store reducers indoors in a clean dry location if possible. Standard shop preparation will allow storage under the above conditions for up to six months. Longer storage periods, or outdoor storage requires special preparation at the factory.

INSTALLATION

LUBRICATION

LUBRICANTS NOT RECOMMENDED The following lubricants should never be used for worm gearing: 1. Ordinary motor oils, regardless of viscosity. 2. Automotive rear-end oils. 3. Greases of any kind. They do not flow

sufficiently to provide the necessary cooling.

4. EP Oils. Some suppliers may suggest oils with sulfur-phosphorous additives instead of the cylinder oils specified here. We do not recommend their use.

APPROXIMATE OIL CAPACITY Oil Capacity (Gallons) Type DSM,

DSMB, DSMF Units

Bottom Drive

Vertical

35 .45 .65 40 .67 .94 50 1.0 1.6 60 1.7 2.7 70 2.0 3.1 80 2.6 3.8 90 4.3 6.1 100 4.6 7.9 120 7.3 13.8 140 13.5 20.8 170 22.3 36.4 200 32.6 43.5

Oil Capacity (Gallons) Type DE or DV

Units Bottom Drive

Vertical

35 .50 1.6 40 .68 2.1 50 .76 1.6 60 1.1 2.7 70 1.3 3.1 80 1.9 3.8 90 2.9 6.1 100 3.6 7.9 120 5.0 13.8 140 6.8 20.8 170 - 36.4 200 - 43.5

Proper lubrication is crucial to obtaining the highest possible performance, utmost efficiency and maximum life of your speed reducer. All units are shipped from the factory without oil. Due to the nature of worm gear sliding and rolling action, the lubricants listed in this manual must be used. Suppliers of industrial lubricants, not service stations, should be contacted to supply suitable lubricants to meet the proper AGMA specifications. Units should be filled to the oil level as shown on the drawing with the AGMA (American Gear Manufacturers Association) lubricant listed below. UNIT SIZES 35-60

Ambient Temperature 15°°°°-60°°°°F 50°°°°-125°°°°F AGMA 7 Comp. 7 Comp.

UNIT SIZES 70-200

Ambient Temperature Worm Speed 15°°°°-60°°°°F 50°°°°-125°°°°F Up to 400 RPM 7 Comp. 8 Comp. Above 400 RPM 7 Comp. 7 Comp.

LOW AMBIENT LUBRICANTS

If ambient temperatures below 15°F are expected, a winter lubricant must be selected, since the above AGMA lubricants will solidify and the motion of the gears will channel the solidified oil until no lubricant is present at the gear mesh.

For Ambient Temperature of…

Use AGMA Lubricant…

0°F -10°F -20°F -30°F

6 Synthetic 5 Synthetic 4 Synthetic 3 Synthetic

The lubricant should be changed to the heavier oils when the minimum ambient temperature again goes above 15°F.

OIL CHANGES Check the oil level periodically when the unit is not operating. Add oil if necessary. Drain and flush housing after first 150 hours of operation. Drain oil and flush after every 6 months of normal service or after every 3 months of severe service. GREASE LUBRICATED BEARINGS The low speed shaft bearings are provided with grease fittings on the following units: Sizes DE50 - DE140. Sizes DV30 - DV200 Down Shafts – both bearings; up shafts - top bearing only. Sizes DSM, DSMB, DSMF30 - 200 B & V assemblies. These bearings are packed at the factory with an NLGI approved EP grade 2 grease. This grease is mineral based with a lithium base thickener. Repack with the same grease type at normal oil change intervals. Due to compatibility issues, contact the factory prior to using any other type of grease.

3

GENERAL ASSEMBLY INSTRUCTIONS When a new primary-worm worm gear, or secondary-worm worm gear is installed in your Delroyd reducer, the assembly procedure affects the life expectancy of all rotating parts as well as quietness of operation. The important assembly procedures are the establishment of correct axial end play on primary worm shaft, secondary worm shaft and gear shaft, and proper tooth contact between the primary worm and gear and the secondary worm and gear. INSTRUCTIONS FOR AXIAL END PLAY OF SECONDARY WORM SHAFT Sizes DE35, 40

1. Coat worm threads with Prussian Blue and assemble worm shaft with complete set of tapered roller bearings in worm bearing bore of one-half housing.

2. Assemble shims in circular groove in housing bore next to each worm bearing. 3. Measure axial end play of worm shaft. Adjust shim thickness until end play = .001" to .003".

INSTRUCTIONS FOR AXIAL END PLAY OF GEAR SHAFT Sizes DE35, 40

1. Should gear replacement become necessary, remember when disassembling to keep separate all parts (shims, spacers, bearings) removed from one side of gear from those on the opposite side, and note from which side of housing they were removed. Compare by measuring the hub thickness of the new gear with the hub thickness of the replacement gear. If they are the same within ±.002 reassemble the gear and the shims, spacer and bearing on side "A".

2. Coat gear teeth with red lead and assemble partial gear shaft assembly into proper housing half, side "A" down, after having painted worm threads with Prussian Blue and placed worm assembly into housing half.

3. Rotate worm shaft by hand and observe tooth contact pattern. If contact is low, press off gear, remove appropriate shim from side "A" and save to add at side "B" later. If contact is high take a shim from side "B" and move it to side "A." Remember, shim total must be maintained to effect proper endplay. When proper contact is achieved, assemble remaining shims, spacer and bearing on side "B".

4. Assemble the other half-housing on worm and gear assemblies. 5. Oil seals are installed in shaft openings after tooth contact and axial endplay of .000" to .002" are established.

INSTRUCTIONS FOR AXIAL END PLAY OF PRIMARY WORM SHAFT Sizes 35 thru 140

MAINTENANCE

1. Install primary worm housing into main housing. 2. Install primary worm gear with spacer and fan shims on secondary

worm shaft. 3. Install bearing inner race and roller on primary worm shaft. 4. Install primary worm in primary housing. 5. Install outer bearing race in primary worm shaft housing bore. 6. Install primary worm bearing retainers without oil seal with .020” thick

shim on each retainer. 7. Check axial end play of primary worm shaft. Add or subtract shims

until end play =.003” to .007" for Size 35 to 80 and.006” to .010” for Size 90 to 140.

4

THRUST BEARING SHIMS

INSTRUCTIONS FOR AXIAL END PLAY OF SECONDARY WORM SHAFT Sizes DV, DSM35, 40, 50, 60, 70 DE50, 60, 70

1. Install primary worm housing with spacer and one worm bearing outer race in main housing worm bore with sealant and .020" thick shim.

2. Coat worm threads with Prussian Blue, and install worm shaft in housing, with both worm shaft bearing inner race and roller assemblies.

3. Install one outer race only of gear shaft bearing in gear shaft bearing bore. 4. Coat gear teeth with red lead and install gear shaft assembly complete with both gear shaft bearing inner race

and roller assemblies. 5. Install other worm shaft bearing outer race. 6. Install other gear shaft bearing outer race. 7. Install worm shaft bearing retainer with .020" thickness of shims. 8. Measure axial end play of worm shaft, add or delete shims until end play = .001" to .003" for sizes 35, 40

.002" to .004" for sizes 50, 60, 70 Sizes DV, DSM80, 90, 100, 120 DE80, 90, 100, 120

1. Install radial bearing housing in worm bore. Install primary worm housing. 2. Coat worm threads with Prussian Blue, and install worm shaft complete with both bearing assemblies and

locknuts, in housing bore. Assemble worm shaft assembly from thrust bearing end of housing inserting radial bearing end of shaft first.

3. Install one outer race only of gear shaft bearing in gear shaft bearing bore. 4. Coat gear teeth with red lead and install gear shaft assembly complete with both inner race and roller assemblies

in housing. 5. Install worm shaft thrust bearing retainer complete with shims. 6. Install other gear shaft bearing outer race in housing bore. 7. Axial end play of worm shaft is shimmed for endplay of .002” to .005” at assembly

MAINTENANCE (cont.)

5

INSTRUCTIONS FOR AXIAL END PLAY OF SECONDARY WORM SHAFT (cont.) Sizes DV, DSM140, 170, 200 DE140

1. Install radial bearing housing in worm radial bearing bore with adaptor. Install thrust bearing housing in bearing bore. 2. Coat worm threads with Prussian Blue, and assemble worm shaft complete with both bearing assemblies including locknuts. Insert assembly

from fan end of housing with radial bearing entering housing bore first. 3. Install one outer race only of gear shaft bearing in gear shaft bearing bore. 4. Coat gear teeth with red lead and install gear shaft assembly complete with both gear shaft bearing inner race and roller assemblies. 5. Install worm shaft thrust bearing retainer complete with gasket. 6. Install other gear shaft bearing outer race in housing bore. 7. Axial end play of worm shaft is controlled by worm thrust bearing spacers and is .003" to .008". No adjustment is necessary.

INSTRUCTIONS FOR AXIAL END PLAY OF GEAR SHAFT Sizes DV, DSM35 thru 200 DE50 thru 140

1. Install gear shaft bearing retainers with .020" thickness of shims on each bearing retainer. 2. Measure axial end play of gear shaft. Add or delete shims until axial end play = .000" to .002" for sizes DV35, 40

.003" to .005" for sizes 50 and up 3. Rotate worm shaft by hand and observe tooth contact pattern. Exchange gear shaft bearing retainer shims until correct contact is obtained.

Do not add or delete shims. (See instructions for tooth contact.) 4. Oil seals on shaft openings are installed after axial end play and tooth contact are established.

INSTRUCTIONS FOR AXIAL END PLAY OF PRIMARY WORM SHAFT Sizes 170 & 200

MAINTENANCE (cont.)

1. Install primary worm housing to main housing. 2. Install primary worm gear, shims, spacer, ball bearing and

locknut on secondary worm shaft. 3. Install thrust bearing and radial bearing on primary worm

shaft. 4. Install primary worm shaft with bearings in primary housing

from fan end with radial bearing entering first. 5. Install thrust bearing retainer with gasket. 6. Install radial bearing retainer. 7. Axial end play = .004" to .008". No adjustment necessary.

6

TOOTH CONTACT INSTRUCTIONS Worm gears are produced to allow for deflection and provide entry gap on "entering side" of gear tooth. Contact on the driving face of gear tooth is required on "leaving side" as shown on Fig. 1.

Figure 1

Contact should be checked after worm and gear have been installed with Prussian Blue coating on worm threads, and red lead on gear teeth. Turn worm shaft by hand and observe contact pattern on gear teeth. Interchanging gear shaft bearing retainer shims from one end to other will shift position of contact and move gear to right or left of worm as required. Shims should not be added or deleted after axial end play is established, but may be shifted from one gear shaft bearing retainer to other for adjusting tooth contact pattern. Primary gear contact is adjusted by adding or deleting shims located at primary gear hub on secondary worm shaft. With the contact on "leaving side" of gear tooth, as the worm deflects under load, contact moves toward the center of gear but still maintains some gap for lubricant on "entering side." When assembling worm gear which operates in both directions of rotation, it is necessary to consider both driving faces of gear teeth, and aim at contact as shown in Fig. 2. Note that both faces of gear tooth have a "leaving side" contact relative to corresponding direction of rotation.

Figure 2

GENERAL INSTRUCTIONS FOR DISASSEMBLY 1. Refer to parts drawing. 2. Drain lubricant from unit. 3. Remove shaft keys. 4. Remove fan housing and fan. 5. Match mark housing and covers. 6. Remove worm shaft covers. 7. Disengage worm from mesh with

gear teeth.

8. Remove gear shaft covers. 9. Remove gear shaft assembly. 10. Remove worm. 11. Clean removed parts, and protect

from dirt and moisture. 12. Clean all metal-to-metal, and

shim-to-metal surfaces of old sealing compound.

13. Apply new sealing compound to these surfaces, using silicone RTV sealant. Use gasket cement on gaskets.

14. Obtain new parts required including seals, shims, and gaskets.

All internal and unpainted external surfaces of gear drives have been treated at the factory, prior to shipment, with a rust preventative. The protective life of this rust preventative will vary with temperature fluctuations, atmospheric moisture content, degree of exposure to the elements during storage, and degree of contact with other object. Inspect all machined surfaces and spray or add rust inhibitor to exposed metal surfaces that may have been removed in shipping and handling. To assure that the gear drive will operate satisfactorily at startup, certain precautions must be taken by the customer upon receipt. The expected length of storage and the storage atmosphere dictate the maintenance schedule to be followed. Units must always be stored level on their mounting feet, free of loads or weights on output and input shafts. These instructions apply to the reducer only. If the motor is included in our drive package, motor operating maintenance and storage instructions are included with drawing transmittals and are also attached to the unit. These instructions must be carefully read and followed. Short Term Storage (indoor) If the gear drives are to be stored for a period of 30 days or less, the following should be observed.

1. Store indoors in a clean, dry location with factory packaging intact, and with as nearly as constant temperature as possible. Elevate a minimum of six inches above floor level. Avoid areas that are subject to extremes in temperature, vibrations, and humidity.

Long Term Storage (indoor) If units are to be stored for a period longer than 30 days, the following should be observed.

1. Store in a clean, dry location with unit elevated a minimum of six inches above ground or floor level. Avoid areas that are subject to extremes in temperature, vibrations, and humidity.

2. Remove breather and replace with pipe plug. 3. A vapor-phase rust inhibitor such as Daubert Chemical, Nox-Rust Motorstor VCI-10, or equal, may be added to the recommended oil type in

the amount of 2% of the total sump capacity. Fill the unit to the recommended oil level. Do Not Overfill. 4. The high speed shaft should be rotated slowly by hand, eighty revolutions, at least once every four weeks. 5. Inspect unit periodically and spray or add rust inhibitor as required. 6. Upon startup, the unit may run without changing this oil mixture, provided foaming does not occur. If foaming occurs, drain oil, flush unit and

refill to proper oil level with recommended oil type.

MAINTENANCE (cont.)

STORAGE

7

All units have been shipped from the factory without oil. Make certain that the reducer is filled with oil before starting. See lubrication instructions. Although the unit has been tested under no-load at the factory, it takes additional hours of running to attain highest efficiency. If necessary, full load can be applied immediately, but it is better for the ultimate life of the gear to operate the unit initially at one-half load for 20-30 hours and three-quarters load for 20-30 hours, if possible. During first few minutes of operation, reducer efficiency will be low due to churning of heavy cold oil. On this initial run, oil temperatures will stabilize at a higher level, efficiency will be lower, and gear noise will be greater than after the gear run-in. Successful operation of worm gearing depends on the ability of the bronze gear to conform to the hardened steel worm. Some initial wear and/ or pitting is therefore necessary on the gear tooth to allow the contact to spread across the full face of the gear as shown below:

Once through the run-in period, the oil temperature rise, noise level, wear and pitting will stabilize and your Delroyd Reducer will be operating at peak effi-ciency. At this point, the oil temperature in the gear box if operated continuously should stabilize at a maximum of 100°F above the surrounding air temperature when transmitting catalog thermal rating. For example, if the air temperature is 70°F, the oil temperature in the reducer could be 170°F. The case temperature below the oil level maybe

150°-160°F, so the unit could be very hot to the touch but still be operating normally. Since recommended worm gear lubricants will deteriorate rapidly, require frequent replacement, and may not support gear mesh loads when operating continuously at temperatures above 210°F, the maximum ambient temperature for worm gear reducers when carrying full thermal rating is 100°F. Therefore, to minimize maintenance problems, it is important during operation to:

1. Keep surrounding air temperature as low as possible.

2. Shield reducer from external sources of heat such as furnaces or other machinery.

3. Prevent direct exposure to sunlight unless unit is painted with reflective paints.

4. Allow movement of artificial or natural air drafts.

5. Keep fan operating and fan inlet unobstructed.

6. Keep outside surfaces of gear box housing free of dust and dirt if possible.

Keeping operating oil temperatures as low as possible will also aid in preventing excessive seal replacements, as shown in the sketches.

Lip type oil seals are used on both shafts. The high speed shaft seal has a dust excluding second lip. During initial operation, these seals may heat the shaft considerably and tend to leak slightly until the BUNA-N sealing lip is run-in and properly seated on the shaft. Even after run-in some seepage of oil through the seal is necessary for proper lubrication of the lip. If the unit is subjected to chemicals not compatible with the seal or abrasive dust, it is important to provide guards where possible to prevent accumula-tions at the seal area. To prevent oil leakage, the breather should be checked periodically to be sure it is not clogged and producing pressure build-up inside the reducer. While all Delroyd Reducers are designed for operation in both directions of rotation as speed reducers or with the worm driving the gear, there are some applications where the gear may be required to drive the worm during all or part of its cycle of operation. Examples of this condition, called overdriving, are when the reducer is used as an increaser or when heavy rotating parts, driven by the gear are stopped by switching off the motor which drives the worm. During stopping, the gear may overdrive the worm and, if it does not do this efficiently, there may be excessive load applied to the gear teeth. Therefore, where overdriving exists, efficient backdriving ratios (15:1 or less) should be used and/or the weight of the rotating parts must be limited. In many cases, this stopping load is increased substantially by use of a motor brake. If sufficient inertia exists in the driven machine, the gear load required to overcome the brake torque through an inefficient backdriving gear reducer can be enough to cause damage to the gears. Therefore, brake torque should be limited to 75%-50% of full load motor torque depending on ratio. On the other hand, this inefficient backdriving tendency cannot be depended upon to supply sufficient braking action to stop a machine that might tend to run away with the drive and a brake must be used. Even when stopped, there can be no assurance that any reducer will be self-locking under all conditions of load and vibration so a brake must be used.

OPERATION

DE 9007 REV 4 6/07

Spare / Replacement Parts – Instructions for order parts: Phone factory at 1-800-432-0121 or distributor and request a parts drawing and parts list. Please provide serial number, model number and ratio. Recommended Spare Parts:

o Worm shaft o Worm gear o Worm shaft bearings o Gear shaft bearings o Complete set of shaft oil seals o Complete set of shims and gaskets

For additional information request Catalog #8804, Reducer Ratings and Dimensions Catalog #8805, Gear Sets Ratings and Dimensions

Call for fast personal service on specialized reduction equipment, too!




Straightener Drive 12” Center Distance

Hoist Drive 8” Center Distance, 35” Shaft

Screw Jack 8” Center Distance

Stacker/Reclaimer Wheel Drive 12” Center Distance

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

E E

F F

G G

H H

2/4/2014M.KAISER

C.FREY 2/3/2014

ELECTRONIC ORIGINAL ONLY - NO HARDCOPY ON FILE

OUTLINE FOR DDSMBM140-S5

2300 LBSAPPROX. FINISH

WEIGHT

THIRD ANGLEPROJECTION

DRAWN

CHECKED

TITLE

(EXCEPT DRILLED HOLES)

WD6950REF -

MACH. TOL. NOT OTHERWISE SPEC.1 PL DEC ± .1"2 PL DEC ± .020" 3 PL DEC ± .005"4 PL DEC ± .0005" FRACTIONAL ± 1/32"ANGLES ± 1°DRILLED HOLES -0, +.015BREAK CORNERS .015" ± .005"

FABRICATION TOLERANCES1 PL DEC ± .1

2 PL DEC ± .06

THIS DRAWING CONTAINS INFORMATION PROPRIETARY TO DELROYD WORMGEAR/NUTTALL GEAR; IT IS BEING SUBMITTED IN CONFIDENCE AND IS TO BE

USED SOLELY FOR THE PURPOSE FOR WHICH IT IS FURNISHED AND RETURNEDUPON REQUEST. THIS DRAWING AND SUCH INFORMATION IS NOT TO BE

REPRODUCED, TRANSMITTED, DISCLOSED, OR USED OTHERWISE IN WHOLE ORIN PART WITHOUT THE WRITTEN AUTHORIZATION OF DELROYD WORM

GEAR/NUTTALL GEAR.

SYMBOL

SCALE 1/4

1101291

2221 Niagara Falls Blvd.Niagara Falls, New York 14302

t: 716.298.4100 f: 716.298.4101www.delroyd.com

FIRST ORDER

WD

73

60-

DW

G. N

O.

DW

G. N

O.

SYMBOL

WD

736

0

DELROYD WORM GEARUNIT SIZE------------------------------------DDSMBM140-S5FIRST SALES ORDER-------------------1101291MATERIAL NUMBER----------------------20048932SERVICE HP---------------------------------21.4SERVICE FACTOR-------------------------1.0RATIO------------------------------------------285.8:1RPM IN----------------------------------------1800RPM OUT--------------------------------------6.3ASSEMBLY FIGURE-----------------------AS SHOWNROTATION-----------------------------------AS SHOWNAPPROX WEIGHT WITHOUT OIL-----2,300 LBSAPPROX OIL CAPACITY-----------------18.5 GALS

KOENIG ENGINEERINGFIRST CUSTOMER PO--21712MBQTY----------------------------2CUSTOMER PART #------KE7-1560,61FIRST PROJECT-----------COVE POINT PROJECTS

RATING INFORMATION FOR VM35-S16 INPUTRATIO---------------24-1/2:1 (OVERALL RATIO: 7003:1)HP--------------------1.9SF--------------------1.0INPUT---------------1800OUTPUT------------0.26

3 1/2

6

FOR ADDITIONAL DIMENSIONSON VM35-S16, SEE OUTLINE WD6618

16 3/4

16 5/16

15 3/4 15 3/4

34

66 4

7.5°

7.810n7.820

45°

9 15/16

25/32 DIA - 24 HOLES EQUALLYSPACED ON 21-7/8 DIA B.C.

STRADDLING C/L'S WITHIN ± 1/64VERIFY HOLE POSITION AT ASSEMBLY

3/4 NPTDRAIN PLUGSFAR SIDE

1-1/16 DIA4 HOLES

OIL LEVELSIGHT GLASS

DRAIN

BREATHER& OIL FILL

ADAPTOR AND COUPLING FORCD189ATC FRAME MOTORBY DELROYD. MOTOR SUPPLIED ANDMOUNTED BY KOENIG ENGINEERING.MOTOR SHAFT:1-1/8 DIA WITH 1/4 x 1/8 KEYWAYREDUCER SHAFT:1" DIA WITH 1/4 x 1/8 KEYWAY

n17/32 THRU

(4) HOLES EQUALLY SPACEDON 7-1/4 DIA B.C.

ROTATIO

N

ROTATION

8 7/8

5 3/4 5 3/4

1 3/4

3/4

6 1/4 6 1/4

15

15 5/8 23 3/8

4 1/4

n23 3/4

14

17 1/8

8.123n8.122

0.1600.156

PAINT SYSTEM: 1 COAT OF SHERWINWILLIAMS KEM KROMIK PRIMER

11/16 DIA - 12 HOLES EQUALLYSPACED ON 19-1/8 DIA B.C.

STRADDLING C/L'S

FOR GENERAL ASSY AND PARTS LIST SEE WD7361

ROTATIO

N

10 1/4

2 1/32

17 3/8

6 3/32

1 7/8ROTEX 42-ST CPLNG.1-1/2 DIA BORES

ROTATION

10.26010.258Ø

10.252n10.254

7/8 - 01/16+

2 5/16

6 3/4

9 1/8

1 9/16

5/8

18-HOLES EQ. SPACED(12) .7500-.7508 REAM13/16 DEEP(6) 1/2-20 TAP 1-1/8 FULL THD.ON 11.500 DIA B.C.

3/4 NPT

1" NPT

8.000`.030VERIFY THIS DIM.AFTER ASSEMBLY

20 1/2Ø

13/161/2 NPT

CUSTOMER TOAPPLY RTV

SILICONE SEALANTAT SPLIT

3

7 3/45 1/8

7 1/8Ø

6.5006.501Ø

5 23/32

2.3122.309

1.7501.747

3/8 NPT1" NPT

10 1/4

2

15 1/16

3/4

5/16

4SHAFT EXT

2 1/4

45°

9S

9JESLEEVE

9S

11.002n11.004 14Ø

ADAPTOR AND COUPLING FOR254TD FRAME MOTOR BY DELROYD.MOTOR SUPPLIED AND MOUNTEDBY KOENIG ENGINEERING.MOTOR SHAFT:1-5/8 DIA WITH 3/8 x 3/16 KEYWAYREDUCER SHAFT:1-1/2 DIA WITH 3/8 x 3/16 KEYWAY

ROTATION

n13/16 THRU

(4) HOLES EQUALLY SPACEDON 12 1/2 DIA B.C.

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

A A

B B

C C

D D

E E

F F

G G

H H

2/5/2014M.KAISER

C.FREY 2/5/2014

ELECTRONIC ORIGINAL ONLY - NO HARDCOPY ON FILE

GENERAL ASSEMBLY FOR DDSMBM140-S5

2300 LBSAPPROX. FINISH

WEIGHT

THIRD ANGLEPROJECTION

DRAWN

CHECKED

TITLE

(EXCEPT DRILLED HOLES)

WD6951REF -

MACH. TOL. NOT OTHERWISE SPEC.1 PL DEC ± .1"2 PL DEC ± .020" 3 PL DEC ± .005"4 PL DEC ± .0005" FRACTIONAL ± 1/32"ANGLES ± 1°DRILLED HOLES -0, +.015BREAK CORNERS .015" ± .005"

FABRICATION TOLERANCES1 PL DEC ± .1

2 PL DEC ± .06

THIS DRAWING CONTAINS INFORMATION PROPRIETARY TO DELROYD WORMGEAR/NUTTALL GEAR; IT IS BEING SUBMITTED IN CONFIDENCE AND IS TO BE

USED SOLELY FOR THE PURPOSE FOR WHICH IT IS FURNISHED AND RETURNEDUPON REQUEST. THIS DRAWING AND SUCH INFORMATION IS NOT TO BE

REPRODUCED, TRANSMITTED, DISCLOSED, OR USED OTHERWISE IN WHOLE ORIN PART WITHOUT THE WRITTEN AUTHORIZATION OF DELROYD WORM

GEAR/NUTTALL GEAR.

SYMBOL

SCALE 7/32

1101291

2221 Niagara Falls Blvd.Niagara Falls, New York 14302

t: 716.298.4100 f: 716.298.4101www.delroyd.com

FIRST ORDER

WD

73

61-

DW

G. N

O.

Parts List

QTYDRW. NO.PART NUMBERDESCRIPTIONITEMSP

1WB16035DH124N-24BEARING RETAINER1

1WF5671DH1300N-11X2U/LMACHINED ADAPTOR2

REFWB16034DG47N-28CENTER3

REFWB-7533DR0249NFLANGED RIM4*

1WF5514DH1300N-12x1ADAPTOR5

2 297546BEARING (L860049/010)6*

REFWA-5475DH53NRIM BOLT 7

REF 3011865/8-11 ESNA NUT8

1WB16036DW0249N-16WORM9*

2 315022BEARING (9380/9321)10*

1WA11510DH71MX12BEARING RETAINER11

1WA-10095DH75Mx14BEARING RETAINER12

1WD-7011DH26G-2x12HOUSING13

1WB-17730DG0335G-14GEAR14*

1 HK0.625SQX03.69KEY - 5/8 SQ x 3 11/1615

1WA-9051DH1288M-4THRUST WASHER16

1WA-9089DH1298M-4LOCKING PLATE17

3WB-6712DH1242CSHIM18*

3WB-6712DH1242Cx1SHIM19*

3WB-6712DH1242Cx2SHIM20*

1 774A164H093/4-10 x 1 1/2 HEX BOLT21

Parts List


1WA-9443DH27G-22COVER22

2 315454BEARING (72187C/72487)23*

2WB-10635DH86Gx1BEARING RETAINER24

1WB19049DH1300D-27ADAPTOR25

1 DH1300D-35MOTOR ADAPTOR PLT26

1 WD6619G02VM35-S16 O/L WD661827

3WC-6764DH1255L-14SHIM28*

3WC-6764DH1255L-14x1SHIM29*

3WC-6764DH1255L-14x2SHIM30*

1 DH1204H-40SIGHT GLASS31*

8 774A163H115/8-11 x 1 1/2 HEX BOLT32

36 774A191H155/8 LOCKWASHER33

1 5192A15H101 1/4 x 3/4 REDUCER34

1WA-9356298206BREATHER35*

2WA-11592318165EYEBOLT36

12 774A163H135/8-11 x 1 3/4 HEX BOLT37

12 774A163H215/8-11 x 2 3/4 HEX BOLT38

4 774A174H125/16-18 x 1 SHCS39


6 774A161H073/8-16 x 3/4 HEX BOLT41

2 DH37N-20GARLOCK OIL SEAL42*

Parts List


6WA-8319DH1278L-4SPECIAL STUD 43

6 774A184H075/8-11 HEX NUT44

8WA-8405DH1278G-7SPECIAL STUD 45

8 20207/16 LOCKWASHER46

8 774A184H047/16-14 HEX NUT47

8 A101552H055/16-18 x 1 1/4 HSFCHCS48


8 774A160H145/16-18 x 1 1/4 HEX BOLT50

1 HK0.375SQX02.43KEY - 3/8 SQ x 2 7/1651

1 297325SHAFT COLLAR (24)52

2WC-5878DH37G-1SEAL (C/R 17381)53*

3WC-5876DH1255G-1SHIM54*

3WC-5876DH1255G-1x1SHIM55*

3WC-5876DH1255G-1x2SHIM56*

3 DH1255N-18SHIM57*

3 DH1255N-18x1SHIM58*

3 DH1255N-18x2SHIM59*

4 891A403H061" PIPE PLUG60

5 891A403H053/4 PIPE PLUG61

2 891A403H041/2 PIPE PLUG62

1 891A403H071 1/4 PIPE PLUG63

Parts List


3 891A403H033/8 PIPE PLUG64

2 891A403H011/8 PIPE PLUG65

2 891A403H021/4 PIPE PLUG66

1WB-195891146RATING NAMEPLATE67

4 303263DRIVE SCREW #2 x 3/1668

4 891A401H151/4 x 1 1/2 ROLL PIN69

1WD7080DH4866N-1HOUSING ASSY70


12 774A164H113/4-10 x 1 3/4 HEX BOLT72

2 502150ROTEX 42 - 1 1/2 BORE73*

1 502142ROTEX 42 SPIDER RED 98 DUR74*

1WB17761DW0335G-1x2WORM75*

1WC9017DH1300G-88MOTOR ADAPTER- 254TD76

1 298422TB WOODS 9S - 1 1/2 BORE77*

1 2984249JE SLEEVE78*

1 298402TB WOODS 9S - 1 5/8 BORE79

1 B201514H16KEY - 3/8 SQ x 280

2 503013CAPLUG WW-12X81

1 297384SHAFT COLLAR 1-5/882

1WB20075DR0249N ASSYCENTER/RIM ASSY83

DW

G. N

O.

SYMBOL

WD

736

1

FOR OUTLINE AND OVERALL DIMS. SEE WD7360

PARTS MARKED WITH * ARE RECOMMENDED SPARE PARTS

RATING INFORMATION FOR VM35-S16 INPUTRATIO---------------24-1/2:1 (OVERALL RATIO: 7003:1)HP--------------------1.9SF--------------------1.0INPUT---------------1800OUTPUT------------0.26

KOENIG ENGINEERINGFIRST CUSTOMER PO--21712MBQTY----------------------------2CUSTOMER PART #------KE7-1560,61FIRST PROJECT-----------COVE POINT PROJECTS

DELROYD WORM GEARUNIT SIZE------------------------------------DDSMBM140-S5FIRST SALES ORDER-------------------1101291MATERIAL NUMBER----------------------20048932SERVICE HP---------------------------------21.4SERVICE FACTOR-------------------------1.0RATIO------------------------------------------285.8:1RPM IN----------------------------------------1800RPM OUT--------------------------------------6.3ASSEMBLY FIGURE-----------------------AS SHOWNROTATION-----------------------------------AS SHOWNAPPROX WEIGHT WITHOUT OIL-----2,300 LBSAPPROX OIL CAPACITY-----------------18.5 GALS

69

70

63

3332

11

282930

36 10 67

68

34

35

27

10 12 43 33 44

14 15

22

13

41 40

31

21

17 32 16

20 19 18

AXIAL ENDPLAY.002 - .004L

62

66

5

42

60

3337

575859AXIAL ENDPLAY

.001L - .001T

6

7271 4 83 7

8

57

58

59

1

39

6

60

42

3 60

61

2

62

64

38 33

54 55 56

24 45 46 47

77 80

78

79

82

76 81

5253652375642354

55

56

AXIAL ENDPLAY.006 - .008L

45

46

47

2425

61

73

74

50

49

51

2648

9

THIS BORE AND FACE TO RUNTRUE WITHIN .004 T.I.R.

IMPORTANT ASSEMBLY NOTE:WITH THE OUTPUT BORE VERTICAL, INDICATE THISFACE AND O.D. OF BEARING RETAINER (IT.1) ALL AROUNDWITH THE DIAL INDICATOR MOUNTED ON THE FACE OFCENTER (IT.3). FACE MUST RUN TRUE WITHIN .006 T.I.R.AND O.D. WITHIN .005 T.I.R.

E20 – E40

SM30 – SM200

V30 – V200

E50 – E140




Single Worm Gear Speed Reducers o Installation o Lubrication o Maintenance o Operation o Replacement Parts

2

DELROYD APPROVED LUBRICANTS* Compounded Steam Cylinder Oil Manufacturer AGMA #7C AGMA #8C Ashland Oil Inc. Light Cylinder No Product Atlantic Richfield Co. No Product MODOC 175 British Petroleum ENERGOL DCC 460 ENERGOL DCC 680 Chevron Oil Co. Chevron Cyl. Oil W ISO 460 Chevron Cyl. Oil W ISO 680 Citgo Petroleum Corp. CITGO Cyl. Oil 400-5 CITGO Cyl. Oil 680-7 Continental Oil Co. INCA Oil 460 INCA Oil 680 Exxon Company, U.S.A. Cylesstic TK 460 Cylesstic TK 680 Imperial Oil Ltd. (Canada) Cylesso TK 460 Cylesso TK 680 Keystone No Product Keygear K600 Mobil Oil Corp. 600W Super Cylinder Oil 600W Extra Hecla Super Cyl. Oil Phillips Petroleum Co. Hector 460S Hector 630S Shell Oil Company Valvata Oil J 460 Valvata Oil J 680 Texaco Inc. Vanguard Cylinder Oil J 460 Vanguard Cylinder Oil J 680 PAO Synthetic Oil Manufacturer AGMA #7 Synthetic AGMA #8 Synthetic Chevron Oil Co. Hipersyn 460 No Product Klubersynth Gem 4-460N Gem 4-680N Mobil Oil Corp. SHC 634 SHC 636 Petro-Canada Syndro SHB 460 No Product

*Use only Delroyd approved lubricants. Contact the factory prior to using any lubricant not appearing above.

APPROXIMATE OIL CAPACITY Oil Capacity (Gallons) Type

E or V Units

Bottom Drive

Top Drive

Vertical

20 .15 .29 .34 25 .16 .30 .44 30 .29 .47 .88 35 .38 .57 1.5 40 .56 1.1 2.0 50 .57 .88 1.4 60 .69 1.4 2.3 70 .75 1.9 2.6 80 1.3 2.3 3.2 90 1.8 3.0 5.0 100 2.5 3.9 6.9 120 3.2 5.5 12.0 140 5.0 6.5 19.0 170 - - 32.0 200 - - 37.0

Oil Capacity (Gallons) Type SM, SMB, SMF

Units Bottom Drive

Top Drive

Vertical

30 .25 .36 .30 35 .33 .62 .53 40 .55 .83 .82 50 .87 1.5 1.4 60 1.3 2.3 2.3 70 1.5 3.7 2.6 80 2.0 4.7 3.2 90 3.2 7.0 5.0 100 3.5 10.0 6.9 120 5.5 14.0 12.0 140 11.7 23.0 19.0 170 17.9 35.5 32.0 200 26.1 55.0 37.0

Proper installation of your worm gear speed reducer is essential for efficient, economical operation and long life. The unit is built for proper operation in the mounting position or-dered. Tilted or different mounting positions may require factory installed lubrication provi-sions. Accurate initial alignment to motor and driven machine is required and must be main-tained by use of a rigid foundation that prevents springing. After a few days of operation, the

alignment should be rechecked and foundation bolts should be retightened if necessary. Mount gears, sprockets, or sheaves as close as possible to reduce bearing overhung load. Avoid heavy hammer blows when mounting couplings or sprockets as this may damage bearings or spring shafts. When tight fits are used, the coupling half should be heated in oil at 150°-200°F to expand the bore.

When speed reducers are used as standby equipment, operate them about once a month. Always store reducers indoors in a clean dry location if possible. Standard shop preparation will allow storage under the above conditions for up to six months. Longer storage periods, or outdoor storage requires special preparation at the factory.

Proper lubrication is crucial to obtaining the highest possible performance, utmost efficiency and maximum life of your speed reducer. All units are shipped from the factory without oil. Due to the nature of worm gear sliding and rolling action, the lubricants listed in this manual must be used. Suppliers of industrial lubricants, not service stations, should be contacted to supply suitable lubricants to meet the proper AGMA specifications. Units should be filled to the oil level as shown on the drawing with the AGMA (American Gear Manufacturers Association) lubricant listed below. UNIT SIZES 35-60

UNIT SIZES 70-200

Ambient Temperature Worm Speed 15°°°°-60°°°°F 50°°°°-125°°°°F Up to 400 RPM 7 Comp. 8 Comp. Above 400 RPM 7 Comp. 7 Comp.

LOW AMBIENT LUBRICANTS

Ambient Temperature 15°°°°-60°°°°F 50°°°°-125°°°°F All Speeds 7 Comp. 7 Comp.

If ambient temperatures below 15°F are expected, a lower viscosity synthetic lubricant must be used, since the above AGMA lubricants will solidify and the motion of the gears will channel the solidified oil until no lubricant is present at the gear mesh.

For Ambient Temperature of…

Use AGMA Lubricant…

0°F -10°F -20°F -30°F

6 Synthetic 5 Synthetic 4 Synthetic 3 Synthetic

The lubricant should be changed to the heavier oils when the minimum ambient temperature again goes above 15°F.

INSTALLATION

LUBRICATION

LUBRICANTS NOT RECOMMENDED The following lubricants should never be used for worm gearing: 1. Ordinary motor oils, regardless of viscosity. 2. Automotive rear-end oils. 3. Greases of any kind. They do not flow

sufficiently to provide the necessary cooling.

4. EP Oils. Some suppliers may suggest oils with sulfur-phosphorous additives instead of the cylinder oils specified here. We do not recommend their use.

OIL CHANGES Check the oil level periodically when the unit is not operating. Add oil if necessary. Drain and flush housing after first 150 hours of operation. Drain oil and flush after every 6 months of normal service or after every 3 months of severe service. GREASE LUBRICATED BEARINGS The low speed shaft bearings are provided with grease fittings on the following units: Sizes E50 - E140. Sizes V30 - V200 Down Shafts – both bearings; up shafts - top bearing only. Sizes SM, SMB, SMF30 - 200 B & V assemblies. These bearings are packed at the factory with an NLGI approved EP grade 2 grease. This grease is mineral based with a lithium base thickener. Repack with the same grease type at normal oil change intervals. Due to compatibility issues, contact the factory prior to using any other type of grease.

3

GENERAL ASSEMBLY INSTRUCTIONS When a new worm or gear is installed in your Delroyd Reducer, the assembly procedure affects the life expectancy of all rotating parts as well as quietness of operation. The important assembly procedures for worm gears are establishment of correct axial end play for worm and gear shaft, with proper contact between worm and gear. INSTRUCTIONS FOR AXIAL END PLAY OF WORM SHAFT Sizes E20, 25, 30, 35, 40

1. Coat worm threads with Prussian Blue and assemble worm shaft with complete set of tapered roller bearings in

worm bearing bore of one-half housing. 2. Assemble shims in circular groove in housing bore next to each worm bearing. 3. Measure axial end play of worm shaft. Adjust shim thickness until end play = .003" to .007".

Sizes V & SM30, 35, 40, 50, 60, 7

E50, 60, 70

1. Install outer race of worm shaft bearing at fan end of housing, in housing worm bearing bore. 2. Coat worm threads with Prussian Blue, and install worm shaft in housing, with both worm shaft bearing inner race

and roller assemblies. 3. Install one outer race of gear shaft bearing in gear shaft bearing bore. 4. Coat gear teeth with red lead and install gear shaft assembly complete with both gear shaft bearing inner race

and roller assemblies. 5. Install other worm shaft bearing outer race. 6. Install other gear shaft bearing outer race. 7. Install worm shaft bearing retainers with .020" thickness of shims on each bearing retainer. Measure axial end

play of worm shaft, add or remove shims until end play = .003" to .007" for sizes 30, 35, 40. .006" to .010" for sizes 50, 60, 70.

MAINTENANCE

4

INSTRUCTIONS FOR AXIAL END PLAY OF WORM SHAFT (cont.) Sizes E, V, SM80, 90, 100, 120

1. Coat worm threads with Prussian Blue, and install worm shaft complete with both bearing assemblies and locknuts, in housing bore. Assemble worm shaft assembly from fan end of housing inserting radial bearing end of shaft first.

2. Install one outer race only of gear shaft bearing in gear shaft bearing bore. 3. Coat gear teeth with red lead and install gear shaft assembly complete with both inner race and roller assemblies

in housing. 4. Install worm shaft thrust bearing retainer complete with shims. 5. Install worm shaft radial bearing retainer without shims or gasket. 6. Install other gear shaft bearing outer race in housing bore. 7. Axial end play of worm shaft is shimmed for end play of .002” to .005” at assembly.

Sizes E140, V & SM140, 170, 200

1. Install worm thrust bearing housing in worm thrust bearing bore. 2. Coat worm threads with Prussian Blue, and assemble worm shaft complete with both bearing assemblies

including locknuts. Insert assembly from fan end of housing with radial bearing entering housing bore first. 3. Install one outer race only of gear shaft bearing in gear shaft bearing bore. 4. Coat gear teeth with red lead and install gear shaft assembly complete with both gear shaft bearing inner race

and roller assemblies. 5. Install worm shaft thrust bearing retainer complete with gasket. 6. Install worm radial bearing retainer without shims or gasket. 7. Install other gear shaft bearing outer race in housing bore. 8. Axial end play of worm shaft is controlled by worm thrust bearing spacers and is .003" to .008". No adjustment is

necessary.

MAINTENANCE (cont.)

THRUST BEARING SHIMS

5

INSTRUCTIONS FOR AXIAL END PLAY OF GEAR SHAFT Sizes E20, 25, 30, 35, 40

1. Should gear replacement become necessary, remember when disassembling to keep separate all parts (shims, spacers, bearings) removed from one side of gear from those on the opposite side, and note from which side of housing they were removed. Compare by measuring the hub thickness of the new gear with hub thickness of the replacement gear. If they are the same within ±.002” reassemble the gear and the shims, spacer and bearing on side "A".

2. Coat gear teeth with red lead and assemble partial gear shaft assembly into proper housing half, side "A" down, after having painted worm threads with Prussian blue and placed worm assembly into housing half.

3. Rotate worm shaft by hand and observe tooth contact pattern. If contact is low, press off gear, remove appropriate shim from side "A" and save to add at side "B" later. If contact is high take a shim from side "B" and move it to side "A". Remember, shim total must be maintained to effect proper end play. When proper contact is achieved, assemble remaining shims, spacer and bearing on side "B".

4. Assemble the other half-housing on worm and gear assemblies. 5. Oil seals are installed in shaft openings after tooth contact and axial endplay of .001 " to .003" are established.

Sizes V & SM30 to 200, E50 to 140

1. Install gear shaft bearing retainers with .020" thickness of shims on each bearing retainer. 2. Measure axial end play of gear shaft, Add or delete shims until axial end play is .003" to .005". 3. Rotate worm shaft by hand and observe tooth contact pattern. Exchange gear shaft bearing retainer shims until

correct contact is obtained. Do not add or delete shims. (See instructions for tooth contact.) 4. Oil seals on shaft openings are installed after axial end play and tooth contact are established.

MAINTENANCE (cont.)

6

TOOTH CONTACT INSTRUCTIONS Worm gears are produced to allow for deflection and provide entry gap on "entering side" of gear tooth. Contact on the driving face of gear tooth is required on "leaving side" as shown on Fig. 1.

Figure 1

Contact should be checked after worm and gear have been installed with Prussian Blue coating on worm threads, and red lead on gear teeth. Turn worm shaft by hand and observe contact pattern on gear teeth. Interchanging gear shaft bearing retainer shims from one end to other will shift position of contact and move gear to right or left of worm as required. Shims should not be added or deleted after axial end play is established, but may be shifted from one gear shaft bearing retainer to other for adjusting tooth contact pattern. Primary gear contact is adjusted by adding or deleting shims located at primary gear hub on secondary worm shaft. With the contact on "leaving side" of gear tooth, as the worm deflects under load, contact moves toward the center of gear but still maintains some gap for lubricant on "entering side." When assembling worm gear which operates in both directions of rotation, it is necessary to consider both driving faces of gear teeth, and aim at contact as shown in Fig. 2. Note that both faces of gear tooth have a "leaving side" contact relative to corresponding direction of rotation.

Figure 2

GENERAL INSTRUCTIONS FOR DISASSEMBLY 1. Refer to parts drawing. 2. Drain lubricant from unit. 3. Remove shaft keys. 4. Remove fan housing and fan. 5. Match mark housing and covers. 6. Remove worm shaft covers. 7. Disengage worm from mesh with

gear teeth.

8. Remove gear shaft covers. 9. Remove gear shaft assembly. 10. Remove worm. 11. Clean removed parts, and protect

from dirt and moisture. 12. Clean all metal-to-metal, and

shim-to-metal surfaces of old sealing compound.

13. Apply new sealing compound to these surfaces, using silicone RTV sealant. Use gasket cement on gaskets.

14. Obtain new parts required including seals, shims, and gaskets.

All internal and unpainted external surfaces of gear drives have been treated at the factory, prior to shipment, with a rust preventative. The protective life of this rust preventative will vary with temperature fluctuations, atmospheric moisture content, degree of exposure to the elements during storage, and degree of contact with other object. Inspect all machined surfaces and spray or add rust inhibitor to exposed metal surfaces that may have been removed in shipping and handling. To assure that the gear drive will operate satisfactorily at startup, certain precautions must be taken by the customer upon receipt. The expected length of storage and the storage atmosphere dictate the maintenance schedule to be followed. Units must always be stored level on their mounting feet, free of loads or weights on output and input shafts. These instructions apply to the reducer only. If the motor is included in our drive package, motor operating maintenance and storage instructions are included with drawing transmittals and are also attached to the unit. These instructions must be carefully read and followed. Short Term Storage (indoor) If the gear drives are to be stored for a period of 30 days or less, the following should be observed.

1. Store indoors in a clean, dry location with factory packaging intact, and with as nearly as constant temperature as possible. Elevate a minimum of six inches above floor level. Avoid areas that are subject to extremes in temperature, vibrations, and humidity.

Long Term Storage (indoor) If units are to be stored for a period longer than 30 days, the following should be observed.

1. Store in a clean, dry location with unit elevated a minimum of six inches above ground or floor level. Avoid areas that are subject to extremes in temperature, vibrations, and humidity.

2. Remove breather and replace with pipe plug. 3. A vapor-phase rust inhibitor such as Daubert Chemical, Nox-Rust Motorstor VCI-10, or equal, may be added to the recommended oil type in

the amount of 2% of the total sump capacity. Fill the unit to the recommended oil level. Do Not Overfill. 4. The high speed shaft should be rotated slowly by hand, eighty revolutions, at least once every four weeks. 5. Inspect unit periodically and spray or add rust inhibitor as required. 6. Upon startup, the unit may run without changing this oil mixture, provided foaming does not occur. If foaming occurs, drain oil, flush unit and

refill to proper oil level with recommended oil type.

MAINTENANCE (cont.)

STORAGE

7

All units have been shipped from the factory without oil. Make certain that the reducer is filled with oil before starting. See lubrication instructions. Although the unit has been tested under no-load at the factory, it takes additional hours of running to attain highest efficiency. If necessary, full load can be applied immediately, but it is better for the ultimate life of the gear to operate the unit initially at one-half load for 20-30 hours and three-quarters load for 20-30 hours, if possible. During first few minutes of operation, reducer efficiency will be low due to churning of heavy cold oil. On this initial run, oil temperatures will stabilize at a higher level, efficiency will be lower, and gear noise will be greater than after the gear run-in. Successful operation of worm gearing depends on the ability of the bronze gear to conform to the hardened steel worm. Some initial wear and/ or pitting is therefore necessary on the gear tooth to allow the contact to spread across the full face of the gear as shown below:

Once through the run-in period, the oil temperature rise, noise level, wear and pitting will stabilize and your Delroyd Reducer will be operating at peak effi-ciency. At this point, the oil temperature in the gear box if operated continuously should stabilize at a maximum of 100°F above the surrounding air temperature when transmitting catalog thermal rating. For example, if the air temperature is 70°F, the oil temperature in the reducer could be 170°F. The case temperature below the oil level maybe

150°-160°F, so the unit could be very hot to the touch but still be operating normally. Since recommended worm gear lubricants will deteriorate rapidly, require frequent replacement, and may not support gear mesh loads when operating continuously at temperatures above 210°F, the maximum ambient temperature for worm gear reducers when carrying full thermal rating is 100°F. Therefore, to minimize maintenance problems, it is important during operation to:

1. Keep surrounding air temperature as low as possible.

2. Shield reducer from external sources of heat such as furnaces or other machinery.

3. Prevent direct exposure to sunlight unless unit is painted with reflective paints.

4. Allow movement of artificial or natural air drafts.

5. Keep fan operating and fan inlet unobstructed.

6. Keep outside surfaces of gear box housing free of dust and dirt if possible.

Keeping operating oil temperatures as low as possible will also aid in preventing excessive seal replacements, as shown in the sketches.

Lip type oil seals are used on both shafts. The high speed shaft seal has a dust excluding second lip. During initial operation, these seals may heat the shaft considerably and tend to leak slightly until the BUNA-N sealing lip is run-in and properly seated on the shaft. Even after run-in some seepage of oil through the seal is necessary for proper lubrication of the lip. If the unit is subjected to chemicals not compatible with the seal or abrasive dust, it is important to provide guards where possible to prevent accumula-tions at the seal area. To prevent oil leakage, the breather should be checked periodically to be sure it is not clogged and producing pressure build-up inside the reducer. While all Delroyd Reducers are designed for operation in both directions of rotation as speed reducers or with the worm driving the gear, there are some applications where the gear may be required to drive the worm during all or part of its cycle of operation. Examples of this condition, called overdriving, are when the reducer is used as an increaser or when heavy rotating parts, driven by the gear are stopped by switching off the motor which drives the worm. During stopping, the gear may overdrive the worm and, if it does not do this efficiently, there may be excessive load applied to the gear teeth. Therefore, where overdriving exists, efficient backdriving ratios (15:1 or less) should be used and/or the weight of the rotating parts must be limited. In many cases, this stopping load is increased substantially by use of a motor brake. If sufficient inertia exists in the driven machine, the gear load required to overcome the brake torque through an inefficient backdriving gear reducer can be enough to cause damage to the gears. Therefore, brake torque should be limited to 75%-50% of full load motor torque depending on ratio. On the other hand, this inefficient backdriving tendency cannot be depended upon to supply sufficient braking action to stop a machine that might tend to run away with the drive and a brake must be used. Even when stopped, there can be no assurance that any reducer will be self-locking under all conditions of load and vibration so a brake must be used.

OPERATION

DE 9005 REV 4 6/07

Spare / Replacement Parts – Instructions for order parts: Phone factory at 1-800-432-0121 or distributor and request a parts drawing and parts list. Please provide serial number, model number and ratio. Recommended Spare Parts:

o Worm shaft o Worm gear o Worm shaft bearings o Gear shaft bearings o Complete set of shaft oil seals o Complete set of shims and gaskets

For additional information request Catalog #8804, Reducer Ratings and Dimensions Catalog #8805, Gear Sets Ratings and Dimensions

Call for fast personal service on specialized reduction equipment, too!




Straightener Drive 12” Center Distance

Hoist Drive 8” Center Distance, 35” Shaft

Screw Jack 8” Center Distance

Stacker/Reclaimer Wheel Drive 12” Center Distance

Altra Industrial Motion • The Power of Experience

Boston Gear • Warner Electric • Formsprag Clutch • Stieber Clutch • Marland Clutch • Wichita Clutch • Industrial Clutch

Centric Clutch • Ameridrives Couplings • Nuttall Gear • Delroyd Worm Gear • Kilian Manufacturing

2221 Niagara Falls Blvd. Niagara Falls, NY 14302 t: 716.298.4100 f: 716.298.4101 www.delroyd.com

IOM Clutch/Backstop Supplement (Formsprag) Page 1 of 7 Rev 1, November 18, 2009

Information on Formsprag Clutches and Backstops

This supplement applies to all units that contain an “FSO” type backstop or clutch.

• Externally Mounted Backstops: externally mounted backstops are provided to allow for rotation in one direction only. These backstops are grease lubricated and require periodic maintenance. New backstops are filled grease and are ready for operation. Refer to the information in the following pages for maintenance instructions. When re-greasing, we recommend removing the plug in the outer race to allow old grease to purge out. Failure to remove the plug will cause the grease to purge out through the seals on either end of the clutch, making cleanup very difficult, and in some cases impossible without removing the clutch.

• Internally Mounted Clutches: internally mounted clutches are provided on units with more than one motor. They allow for either motor to drive depending on relative speed. The clutch will overrun when one motor is engaged and will drive when the other is engaged. Rotation of the output shaft is only possible in one direction. Internal clutches are lubricated by the gear reducer oil. No additional maintenance is required. Refer to the reducer IOM manual for maintenance instructions.

CAUTION: Never use EP type greases or oils with clutches or backstops. These lubricants contain slippery additives that will compromise the functionality of the backstop/clutch.

BULLETIN 2219

Installation Instructions

General PurposeOverrunning Clutches

FSO 300 thru 700FSO 750 thru 1027FS 750 thru 1027

23601 Hoover Road - Warren, MI 48089-3994 - 586-758-5000

www.formsprag.com

P-222-10

2 Formsprag Clutch • 800-927-3262 Bulletin 2219

Introduction

FS and FSO models are general purpose ball bearingclutches suitable for overrunning, backstopping andlight duty indexing applications. They featureFormchrome®‚PCE™ sprags and Formsprag’s exclusive“Free-Action” Retainer for longer life and instantengagement.

• Formsprag ball bearing clutches mount on a through-shaft with the inner race driven by a key.

• The O.D. of the outer race is designed as a mounting surface or pilot for attaching the driven member.

• The O.D. of the outer race is ground concentric with the bore to provide for proper alignment and installation.

Failure to follow these instructions may result in product damage,equipment damage, and serious or fatal injury topersonnel.

Pre-installation Check

Before installing, check:

1. Shaft to Bore fit:

Clutch Bore Shaft Fit Guide*

0 to 2 inches dia. Line fit to .002 inches loose



*If a press fit is necessary under special circumstances, do

not exceed .001 inch tight.

In some cases, builders of equipment in which a

Formsprag clutch is used, specify other shaft fit

limits than those listed. In this event, direct

questions concerning fit limits to the equipment

manufacturer.

2. Key and keyseat

Hardness: Use a hardened key, from 30 to 40

Rockwell “C” scale. Use materials AISI 1141,

1045 or 4130

Overrunning & Backstopping

Fit: Break edges of the key before installing, to

prevent any bearing at these points. Install with

a push fit. Be sure the key seats squarely. Do

not use force fit.

Length: The key must be equal to the length of

the inner race for proper engagement.

Indexing

Fit: Fit the key up to .001 inch interference on

Width dimension to prevent loosening in

indexing service. Do no exceed .001 inch tight.

3. Rotation

Check the clutch for the proper rotation in each

application. Turn the inner race to check over-

running direction.

Installation

1. If this FSO clutch is being used as part of a

HSB assembly (High Speed Backstop, which is

finned aluminum housing, mounted to the clutch

for added speed capability and heat dissipa-

tion), please refer to the HSB Installation and

Maintenance bulletin No, 2214 for complete

mounting instructions. This bulletin is available

from our Website www.formsprag.com or

contact Formspag Clutch at 1-800-97-36.

2. Mount the clutch and key on the shaft.

Note: Oil lubricated clutches should be

mounted on horizontal shafts only. For

vertical shaft mountings of oil lubricated

clutches contact Formsprag Clutch.

3. Apply pressure to end face of the clutch inner

race only.

Application of pressure to the outer race could

preload the bearings excessively. For oil lubri-

cated clutches, to simplify mounting, if a .001”

interference fit is required, (this is the tightest

allowable) immerse the clutch in hot, clean oil

(not to exceed 200°F/93°C) for ten to fifteen

minutes before mounting.

4. Secure the clutch in position on the shaft.

Use a lock washer and nut, a flat washer

fastened to the shaft end with a screw, snap

rings, collars, etc. to keep the clutch in position

on the shaft.

3Formsprag Clutch • 800-927-3262 Bulletin 2219

5. Mount attaching parts to the clutch outer race

as required by the application.

If a torque arm is to be mounted to the clutch,

allow .25 inch to .50 inch clearance between

stops and torque arm.

Tapped mounting holes are provided in each

end of the outer race. Center the gear, pulley or

sheave on the outer race. Avoid excessive over-

hung loads.

Check with Formsprag Clutch if the clutch must

support large side loads during overrunning

cycle of operation.

6. All Formsprag clutches are lubricated before

leaving the factory. However, check the

following Lubricant table for the proper lubricant

and fill level for each type application and

ambient operating temperature range. Change

the lubricant or add oil to proper level, if

required.

7. Check for proper installation by overrunning

(free-wheeling) the clutch by hand.

Lubrication

Proper lubrication and lubricant maintenance are the

most important single maintenance factors for long,

effective, trouble-free clutch operation. Read the

following instructions and follow them carefully for

maximum performance and utilization of Formsprag

overrunning clutches. Always recheck oil level in

clutch after installation and before start up.

Oil Lubrication

Use oils selected from the following table according tothe application and ambient temperature existing atthe clutch.

Note: FSO-300 thru 700 and FS-750 thru 1027

clutches are shipped from Formsprag half full

of Mobil DTE Heavy Medium oil.

For applications where the ambient temperatureexceeds +150°F (+65°C) consult Formsprag Clutch.

Do not use lubricants of the EP

type (extreme pressure characteristics) or those

containing slippery additives. For additional lube

information, see Brochure #A-4032.

Temperature Range Recommended OilLubricant

+20°F to +150°F Mobil DTE Heavy Medium

(-7°C to +65°C) Any Automatic Transmission

(Maximum permissible Fluid (high grade only)

ambient temperature) Texaco Regal R&O 68

Shell Turbo Oil 68

Gulf Harmony 68

Amoco Industrial Oil 68

Exxon Teresstic Oil 68

Sunoco Sunvis 931

-10°F to +20°F Chevron Oil 46

(-23°C to -7°C) Chevron GST Oil 931

Mobil Gargoyle Arctic

C Heavy

Texaco Regal R&O Oil 46

Sunoco Sunvis 921

Any Automatic Transmission

Fluid (ATF)

-40°F to +150°F Mobil Jet Oil 2

(-40°C to +65°C) Shell Turbine Oil 500

(Maximum permissible Exxon Turbo Oil 2389

ambient temperature) Standard Esso Turbo

Oil 2389

Military Oils MIL-L-7808

Or MIL –L-23699

Important: Do not mix the oils, they are not compati-

ble. When switching from one brand to

another, drain old oil and flush clutch with

mineral spirits. Do not use Carbon

Tetrachloride before adding new oil.

The use of lubricants in clutchassemblies, other than those shown, can result inimproper sprag engagement. Improper spragengagement may cause personal injury or propertydamage.

Formsprag Clutch is not responsible for anychanges made by the manufacturers in their lubri-cants.

The use of any lubricants, other than those listed inthis manual, will automatically void any warranty.

4 Formsprag Clutch • 800-927-3262 Bulletin 2219

Oil Lubrication Maintenance

1. Check the oil level once a month or every 160

hours of operation, whichever occurs first. For

indexing applications and indexing in excess of

150 strokes a minute, oiling may be required at

shorter intervals and use Models HPI. See

Bulletin 2213.

2. Add oil if necessary to maintain the proper fluid

level.

Overrunning, Backstopping – 1/2 full

Indexing – 7/8 full

3. To assure continued efficiency of operation,

flush clutch every 6 months with mineral spirits.

Do not use Carbon Tetrachloride.

Important: Under severe operating conditions,

such as heavy dust or twenty-four

hours per day operation, flushing

may be required at shorter intervals.

Flushing will remove waxes and gums formed

by vaporization of the oil and assure continued

efficiency of operation. See “Flushing

Procedure” section.

4. Flush with mineral spirits and relubricate before

use if clutch has been out of service or in

storage for six months or more. Use recom-

mended oils only.

In cases of dirty or abrasive environment or

severe operating conditions (24 hours per day),

it is recommended that oil be changed every

month.

5. If the clutch is out of service or in storage for

two years or more, new seals should be

installed before putting clutch into service.

Oil Lubrication – Filling Procedure

Overrunning and Backstopping Applications

1. Rotate the clutch outer race to locate two oil

ports at positions (A) and (B) as shown on illus-

tration for Overrunning.

2. Remove (A) and (B) plugs and add oil through

(A) until oil flows from (B). The clutch will then

be one-half full. Use a pressure can for best

results.

3. Install both plugs and tighten to prevent

leakage. Plugs on some models consist of a

buttonhead screw and leather washer. Be sure

the washer is in place.

Indexing Applications 0 to 149 strokes per minute(150 strokes per minute or more – use Models HPI,see Bulletin 2213).

1. Rotate the clutch outer race to locate two oil

ports at positions (A) and (B) as shown in the

illustration for indexing.

2. Remove (A) and (B) plugs and add oil through

(A) until oil flows from (B). The clutch will then

be 7/8 full. Use a pressure can for best results.

3. Install both plugs and tighten to prevent

leakage.

Flushing Procedure

1. Rotate the clutch outer race to locate one oil

port at lowest point of the outer race.

2. Remove lowest plug and drain clutch of oil.

Remove the top plug to vent for better drainage.

3. Install bottom drain plug and fill clutch com-

pletely full with mineral spirits. Re-install the top

plug.

4. Rotate clutch slowly for several minutes to

break up and dissolve oily residue which may

have formed.

5. Remove lower plug and drain all mineral spirits

from the clutch assembly. Remove top plug to

vent for better drainage.

6. Replace and tighten the lower plug.

7. Relubricate the clutch according to Oil

Lubrication Filling Procedure.

8. Replace top plug, then tighten all plugs to

prevent leakage.

Port-A

Port-B

Port ‘X’Oil Oil

Port ‘X’

Port-B

Note: Models FSO-300 through -600 do not havePort ‘X’. Position as shown without Port ‘X’

Overrunning andBackstopping

Indexing

5Formsprag Clutch • 800-927-3262 Bulletin 2219

Grease Lubrication

Use greases selected from the following table:

Fiske Bros. Lubriplate Low-TempFiske Bros. Aero LubriplateExxon Beacon 325Shell Alvania No. 1Shell Aeroshell No. 7Shell Aeroshell No. 16

Note: FSO 300 thru 700 are packed at the factory

with the Fiske Brothers “Lubricate Low Temp”

and FSO-750 thru FSO-1027 are packed with

Fiske Brothers Aero Lubricate.

• Use no other greases unless a specific recom-

mendation has been made by Formsprag

Clutch.

• If operation at ambient temperatures below

+20°F/-7°C or above +120°F/ + 55°C is

required, consult Formsprag Clutch for special

lubricant recommendations.

• Grease lubrication may be used if:

– The clutch is in accessible for frequent

maintenance.

– Conditions do not permit the type of main

tenance required for oil lubricated clutches.

– The clutch is mounted on a vertical shaft.

– The clutch is operated in the presence of

severe abrasive dust.

• Do not attempt to substitute grease lubrication

in a standard oil lubricated clutch. The use of

grease lubrication in a clutch intended for oil

could cause a malfunction.

• Formsprag Clutch can convert in-service

clutches from oil to grease lubrication. Changes

in internal construction are usually required.

Consult Formsprag Service Department, giving

complete model number.

Grease Lubrication Maintenance

Add Grease

Application Add Grease Under Rugged

Conditions*

Overrunning Every 3 months Every 2 weeks

Backstopping Every 3 months Every 2 weeks

Indexing Once a month Every 2 weeks

* 24 hours per day or operation in severe abrasive dust conditions.

Grease Lubrication Procedure

1. Wipe all grease fittings clean, then pump new

grease into all fittings until clean grease flows

out completely around the seals on both sides

of the clutch.

2. Lubrication should be done with the clutch atnormal operating temperature.

Use Recommended Greases Only

Packaging

Your Formsprag clutch, carefully wrapped in Vapor

Inhibitor type activated paper for corrosion protection

and packed in a shipping box conforming to the

requirements of Rule 41, Uniform Freight

Classification, may be stored for up to two (2) years

and reshipped without added packaging.

Models 300 through 700 are packed in corrugated

board shipping boxes and models 750 thru 1027 in

wooden, style 4 shipping boxes with integral skids.

(See Oil Lubrication Maintenance for information

about clutches which have been stored for extended

periods.) To store in an unprotected area or if original

package is opened, wrap the box with a waterproof

covering.

Clutch Rebuilding Service

Disassembly and repair of

Formsprag clutches in the field is not recom-

mended.

Formsprag clutches are precision devices manufac-

tured under careful controls to meet exacting

standards. When reconditioning is required, clutches

should be returned to Formsprag Clutch, (Purchase

Orders must go directly or through your local Warner

Electric Distributor, or through the Original Equipment

Manufacturer).

These instructions cannot cover all details or varia-

tions in equipment and applications nor provide for

every possible contingency which may be met in

installation, operation or maintenance. Should further

information be needed, contact Formsprag Clutch.

Rotating Equipment

Rotating equipment is potentially dangerous andshould be properly guarded. The user should checkfor all applicable safety codes in his area and providea suitable guard.

For additional technical and dimensional informationon FS/FSO clutches refer to Formsprag OverrunningClutch Catalog P-956 or call800-927-3262

Warranty

Formsprag LLC warrants that it will repair or

replace (whichever in its sole discretion it deems

advisable) any product it manufactured and sold

which proves to be defective in material or

workmanship within a period of one (1) year

from date of original purchase for consumer,

commercial or industrial use. This warranty

extends only to the original purchaser and is not

transferable or assignable without Formsprag

LLC’s prior consent.

This warranty covers normal use and does not

cover damage or defect which results from alter-

ations, accident, neglect, disassembly, or

improper installation, operation, or maintenance.

Formsprag LLC’s obligation under this warranty

is limited to the repair or replacement of the

defective product. In no event shall Formsprag

LLC be liable for consequential, indirect or inci-

dental damages of any kind incurred by reason

of manufacture, sale or use of any defective

product. Formsprag LLC neither assumes nor

authorizes any other person to give any other

warranty or to assume any other obligation or

liability on its behalf.

P-222-10 Bulletin 2219 9/05 Printed in USA

Formsprag Clutch23601 Hoover Road • Warren, MI 48089586-758-5000 • Fax: 586-758-5204


SECTION 5


EMERGENCY DC DRIVE

© Emerson Power Transmission Manufacturing, L. P. 2000. All Rights Reserved.

DEPTH GAUGE

FEELER GAUGES

SPLIT COLLAR

Installation andAlignment InstructionsFORM 22-001AUGUST, 2000

KD1 & KD10 Disc Coupling

Figure 3. Hub Advance vs. Interference Chart

KOP-FLEX, INC., P.O. BOX 1696, BALTIMORE MARYLAND 21203, 410-768-2000KOP-FLEX CANADA, LTD., 19 METEOR DRIVE, REXDALE, ONTARIO, CANADA M9W-1A3, 416-675-7144 Emerson Power Transmission

Figure 1. Measuring Hub Overhang

Figure 2. Using Split Collar to Set Advance

CAUTIONIf assembledincorrectly,equipment failureand personalinjury may result.

Diametral Taper Rate

.000

.010

.020

.030

.040

.050

.060

.070

.0000 .0005 .0010 .0015 .0020 .0025 .0030 .0035 .0040

Interference (in.)

1/2"/ft 5/8"/ft3/4"/ft

1"/ft

1 1/4"/ft

1 1/2"/ft

Ad

va

nce

(in

.)

Because of the possible danger to person(s) or property from accidents which may result from the improper use or unapprovedmodification of the product, this product must be installed, maintained, and operated in accordance with the procedures, standards and engineeringinformation specified in the product brochures and illustrations. To assure safe operation, this product should be inspected in accordance with theinstructions described in this form. Proper guards and other suitable safety devices or procedures as may be desirable, or as may be specified insafety codes, should be installed by the user. Guards and other safety equipment are not provided, nor are they the responsibility of Emerson PowerTransmission.

1.0 General Instructions

Prior to installation, inspect the coupling for any signs of damagethat may have occured during shipment. Check that all parts areon hand and are as ordered.

ONLY BOLTS AND NUTS SUPPLIED BYKOP-FLEX ARE TO BE USED.

Components should be cradled or supported during handling toavoid damage and should be wrapped for protection. Flangesshould be kept free of nicks and burrs.

Read all of the installation instructions and review the procedurebefore the actual coupling installation.

2.0 Installation of Coupling Hubs - Keyed Mounting

2.1 Check the hub bore and shaft for nicks and burrs, dress ifnecessary. Make sure that the bore and shaft are clean.

2.2 For tapered bores, check the fit of the bore to the shaft.

2.3 Keys must be precisely fitted to the keyways in the shaft andhub. Each key should have a tight fit on the sides with a slightclearance on top. To maintain dynamic balance, the keys shouldfill the keyways exactly and not be too short or too long.

2.4 Clean the hub bore and shaft. For straight bores, proceed tostep 2.6. For tapered bores, mount the hub hand-tight on theshaft and lightly rap it with a soft mallet to establish the initialline-to-line fit. This is the START position. With a depth gauge,measure the amount the hub overhangs the shaft end andrecord this value. See Figure 1.

Disconnect all power while adjusting units

2.5 Tapered Bores Only: A recommended method to measure thehub advance is to install a split collar on the shaft, away fromthe hub by the amount of the specified advance. Use feelergauges for accurate spacing. See Figure 2. The amount ofhub advance is dependent upon the desired interference andtaper angle as specified by the machine manufacturer or asgiven on the coupling drawing. See Figure 3.


ADAPTER RINGDISC PACK

BUSHING


Figure 6. KD10 Disc Pack Assembly


WASHER SPLIT DISC PACK

SPLIT DISC PACK


Table 1. Disc Pack Bolt Tightening Torque

2.6 Heat the hub to expand the bore; DO NOT allow the hub tem-perature to exceed 600°F (300°C). DO NOT apply an openflame to any part of the coupling, an oven is recommended.

To avoid the risk of explosion, fire, ordamage to the coupling and equipment,and/or injury to personnel, do not usean open flame or oil bath to expand thehub. If heat is used at any time for in-stallation, DO NOT allow the hub tem-perature to exceed 600°F (300°C).

2.7 Place the hub in the proper position on the shaft. Hold the hubin place as it cools. For tapered bores, verify the hub advance(see Figures 1 and 2) and install the shaft retaining nut. Re-move the split collar from the shaft.

3.0 Initial Assembly

The terminology used to identify parts and the order of assemblymay differ from one coupling style to another. Follow the instruc-tions which match the coupling style being installed.

KD1 - For KD10 skip to 3.5

3.1 Line up the disc pack bushings with the reamed holes in thehub. Lightly tap on the bushings to start them in the reamedholes (See Figure 4).

3.2 Insert three disc pack bolts from the disc pack side, throughthe three bushings that are lightly tapped into the reamed holes.Assemble with lock-nuts and tighten them evenly and in suc-cessive steps until they are tightened to the specified value inTable 1.

3.3 Position the adapter ring over the hub so that the spacer pilotand counterbored holes are on the face opposite the disc pack.(see Figure 4).

3.4 Install the disc pack bolts and nuts with the bolt heads in thering. Torque the fasteners evenly and in successive steps tothe values in Table 1.

KD10 - For KD1 skip to 4.0

3.5 The disc packs are packaged as two halves; one left hand(yellow mark) and one right hand pack (white mark). One lefthalf and one right half must be put together to make one com-plete disc pack. For replacements, slide one half through thegap between the hubs followed by the other half.

3.6 Place the two halves on the hub, press together and reas-semble the complete disc pack (see Figure 5).

3.7 Position the adapter ring over the hub so that the spacer pilotand counterbored holes are on the face opposite the disc pack.(see Figure 6). Make sure to align reamed holes with largerclearance holes in mating part.

3.8 Install the disc pack bolts and nuts with the bolt heads in thering. Torque all disc pack bolts to the values specified in Table 1.

gnilpuoCeziS

)deliOylthgiL(euqroTgninethgiT1DK 01DK

bl-tf m-N bl-tf m-N301 8 01 01 41351 03 04 72 73

402,302 05 07 55 57452,352 57 001 55 57403,303 021 061 511 061453,353 091 062 571 042404,304 092 093 082 083454,354 023 034 082 083

405 — — 024 075455 — — 037 0001406 — — 0201 0041507 — — 0081 0542508 — — 0032 0013509 — — 0032 0013

ADAPTER RINGASSEMBLED

DISC PACK

4.0 Alignment

Note:Exact values and procedures for aligning equipment are nor-mally specified by the equipment manufacturers.

The amounts given below represent values that would pro-vide excellent coupling performance in operation.

Good initial alignment to the minimum possible values willpromote optimum machinery performance and eliminate po-tential operating problems. After securely tightening the foun-dation bolts, the hub separation and alignment should be re-checked and adjusted if necessary.

The coupling alignment should be checked periodically. Evenwhen a coupling is well aligned at installation, subsequentsettling of foundations, shifting of equipment, etc., may causethe alignment to deteriorate.


6.0 Disc Pack Replacement

KD1 - For KD10 Skip to 6.8

6.1 Remove the spacer halves in reverse order as per the appli-cable assembly procedure. Once these are removed work onone hub at a time.

6.2 Loosen and remove all of the disc pack bolts from the halfcoupling.

6.3 Insert the disc pack removal socket into one of the disc packclearance holes as shown in Figure 8 (counter bore first), in-stall the removal capscrew and turn it until it cannot be tight-ened any more.Note: The removal socket is supplied as part of the “parts kit”.


Table 2. Hub Separation

Offset and Angular Misalignment

4.1 Reverse dial indication or optical methods of alignment (suchas laser) are recommended. A cold alignment and a hot check(with corrections if necessary) are required. The hub flangeOD can be used to mount the alignment equipment. The hubflange OD is machined to be concentric to the coupling boreand can be used as the reference diameter.

4.2 The maximum recommended operating misalignment is:

0.10 degrees per disc pack

(0.0035 in/in TIR equivalent parallel offset)Important: Total misalignment is the combination of equipment

parallel offset and angular misalignment.Note that improving the alignment below these values willpromote optimum machinery performance.

Axial Alignment

4.3 Align the hubs until they are at the hub separation used inTable 2, or as shown on the coupling drawing if one is sup-plied.

gnilpuoCeziS

1DK 01DK

dradnatS buHenOdesreveR dradnatS buHenO

desreveR301 49.0 96.1 21.0 65.1351 91.1 05.2 21.0 09.1

402,302 13.1 18.2 21.0 04.2452,352 05.1 91.3 91.0 66.2403,303 57.1 18.3 91.0 11.3453,353 49.1 13.4 52.0 28.3404,304 31.2 96.4 52.0 44.4454,354 31.2 96.4 13.0 07.4

405 — — 13.0 82.5455 — — 13.0 20.6406 — — 13.0 04.6507 — — 83.0 05.7508 — — 83.0 73.8509 — — 05.0 05.9

Table 3. Spacer Bolt Tightening Torque.

5.0 Final Assembly (KD1 and KD10)

5.1 Insert the collapsing bolts into the hub thru holes and threadinto the ring. Draw the rings towards the hub flanges by tight-ening the collapsing bolts. Collapse ONLY ENOUGH to en-able the split spacer to fit between the rings. See Figure 7.

5.2 Insert one of the spacer halves between the two rings. Threadbolts in by hand.

5.3 Repeat for the other spacer half, making sure that the flangeOD groove in the two spacer halves match. IMPORTANT: Re-move the bolts used to collapse the disc pack. Tighten allspacer bolts evenly and in an alternating fashion as specifiedin Table 3.

gnilpuoCeziS

)deliOylthgiL(euqroTgninethgiT1DK 01DK

bl-tf mN bl-tf mN301 8 01 8 11351 8 01 71 32

402,302 03 04 05 07452,352 03 04 05 07403,303 57 001 011 051453,353 57 001 051 002404,304 051 002 072 073454,354 051 002 072 073

405 — — 034 085455 — — 046 078406 — — 046 078507 — — 0211 0051508 — — 0741 0002509 — — 0741 0002

SPLIT SPACERDISC PACK BOLT

HUBCOLLAPSING SCREW

DISC PACK NUTDISC PACK

RING

GROOVE

RINGDISC PACK

COLLAPSING SCREW

DISC PACK NUT

HUB

Figure 7. Hub separation.

CLEARANCE HOLEDISC PACK

BUSHING

REMOVAL SOCKET REMOVAL SCREW

WASHER

Figure 8. Disengaging bushings from flange.

6.4 Repeat step 6.3 on all of the bushings to free the disc packfrom the ring and hub flange.

6.5 Slide the ring and disc pack out of the coupling from betweenthe hubs. Repeat steps 6.3 to 6.4 to remove the second discpack.

6.6 Clean and deburr all the coupling parts.6.7 Install new disc packs per 3.1 to 3.4.

KD10

6.8 Remove the spacer halves in reverse order as per the appli-cable assembly procedure. Once these are removed workon one hub at a time.

6.9 Unbolt the adapter ring and slide it out of the way onto theother hub. Unbolt the disc pack from the hub and pull thewashers off using pliers.

6.10 Split the disc pack into two separate halves. Remove eachdisc pack half through the gap between the hubs.

6.11 Install new disc packs per 3.5 to 3.8.

7.0 Dynamic BalanceBalanced parts will be marked with the letter “B.”. A standard bal-anced coupling will not have match marks. If a coupling is supplied with match marks, it has been specially balanced; the couplingmust be assembled with the match marks in line.

8.0 Finish Boring and KeywaysCoupling hubs are often furnished with a “rough stock bore.” Thisrough bore is not necessarily concentric to other hub diameters.To prepare for boring, set-up and indicate the hub as shown inFigure 9.


9.0 Bore Sizing and Recommended FitThe finish bore size should be based on the actual measured shaftdimension, regardless of whether straight or taper shaft. For keyedshafts, a light interference fit based on a nominal interference rate of0.0005 inch per inch of shaft diameter is suggested, or refer to publishedAGMA standards. Do not exceed an interference fit of 0.001 inch/inchof shaft diameter. If other than a light interference fit is desired, consultthe published AGMA boring and keyway standards.For Straight Bores, the hub diameter should be chucked inthe boring lathe and dial indicated as shown of Figure 9.For Taper Bores, chuck and indicate as shown on Figure 9.Machine the counterbore and SKIM A REFERENCE DIAMETERon the hub body. Then, reverse the hub in the chuck, and indicateusing the reference diameter before final boring. Run-outs should beas near zero as possible. It is essential that the finished bore beconcentric with the two indicating surfaces.

Form 22-001 8/14/00Printed in U.S.A.

KOP-FLEX, INC.EMERSON POWER TRANSMISSIONP. O. Box 1696Baltimore, MD 21203-1696®

Important Safety InstructionsBefore start-up . . . for reasons of safety and to extend shaft coupling life, followthese requirements.

1. Coupling guards protect personnel. ALL COUPLINGS MUST BE COVEREDWITH A GUARD AS PER OSHA REQUIREMENTS.

2. Recheck alignment after all foundation bolts and mechanical connectionsare tightened.

3. Make sure all fasteners are properly installed and tightened.4. Take the time to double check your work.5. Only authorized KOP-FLEX replacement parts are to be used.6. Call Kop-Flex for any clarification or questions.

5 YEAR WARRANTY REGISTRATION CARD

Name (Last, First)

Title:

Company Name:

Location:

Phone:

APPLICATION DATA

Coupling Type:

HP:

RPM:

Application:

Shaft Size(s): Driving: Driven:

Distance Between Shaft Ends

Plant Identification Pump # Motor #

Send Warranty Card To: Attention Marketing DepartmentKop-Flex, Inc.

Mail to: P. O. Box 1696 or Fax to: 410-787-8424Baltimore, MD 21203-1696

Figure 9. Hub boring.

KD10 KD1

10.0 KeywaysKeyways should be cut to give a tight fit on the sides and slightclearance over the key. Keyways should not have sharp cor-ners. Refer to published AGMA standards for specific dimen-sioning of coupling bores and keyways.

11.0 General Recommendations

11.1 KOP-FLEX KD1 and KD10 split spacer style disc couplings aredesigned to operate for extended periods without the need forlubrication or maintenance. Visual inspection of the disc packs issufficient to assess the operational condition of the coupling.

11.2 All machinery should be monitored to detect unusual or chang-ing vibration levels. KOP-FLEX KD1 and KD10 split spacer stylecouplings, under normal operation conditions, have no wearingparts and will retain their original balance quality. Any change invibration levels should be investigated and remedial action shouldbe taken immediately.

CERTIFIED GDM

© Emerson Power Transmission Manufacturing, L. P. or affiliates 2002. All Rights Reserved.

DO NOT TIGHTEN OR LOOSENTHE DISC PACK BOLTS OR NUTS

SHIPPING SCREWS(YELLOW COLLAPSING CAPSCREW)

SHIPPING SCREWS(RED LOCKING SET SCREW)

“RZ” STYLE

“RM” STYLE SHIPPING SCREWS(YELLOW COLLAPSING CAPSCREW)

SHIPPING SCREWS(RED LOCKING SET SCREW)

DO NOT TIGHTEN OR LOOSENTHE DISC PACK BOLTS OR NUTS

HIGH PERFORMANCEDISC COUPLING“RM” and “RZ” STYLE

Installation InstructionsForm 16-601-1RevisedMAY, 2002

KOP-FLEX, INC., P.O. BOX 1696, BALTIMORE MARYLAND 21203, 410-768-2000KOP-FLEX CANADA, LTD., 19 METEOR DRIVE, REXDALE, ONTARIO, CANADA M9W-1A3, 416-675-7144

Emerson Power Transmission

1.0 GENERAL INSTRUCTIONS

The KOP-FLEX High Performance disc coupling is dynamically bal-anced and must be assembled with all parts in the positions speci-fied by the match marks on the coupling.

Each coupling assembly has a unique serial number marked on everymajor component. Make sure that the serial numbers match exactlyon every component used for a complete coupling.

The spacer bolts and nuts are individually weight balanced so thatany nut may be used on any bolt.

ONLY BOLTS AND NUTS SUPPLIED BYKOP-FLEX ARE TO BE USED.

For optimum coupling life, balance quality, and ease of installation,KOP-FLEX High Performance disc couplings are supplied in factorypreassembled units. DO NOT ATTEMPT TO DISASSEMBLE THEHALF COUPLINGS. DO NOT TIGHTEN OR LOOSEN THE DISCPACK BOLTS AND NUTS.

Because of the possible danger to person(s) or property from accidents which may result from the improper use or unapprovedmodification of the product, this product must be installed, maintained, and operated in accordance with the procedures, standards and engineeringinformation specified in the product brochures and illustrations. For safe operation, this product should be inspected in accordance with the instructionsdescribed in this form. Proper guards and other suitable safety devices or procedures as may be desirable, or as may be specified in safety codes, shouldbe installed by the user. Guards and other safety equipment are not provided, nor are they the responsibility of Emerson Power Transmission.

Prior to installation, inspect the coupling for any signs of damageduring shipment. Check that all parts are on hand and are as or-dered.

Components should be cradled or supported during handling to avoiddamage and should be wrapped for protection. Flanges and rabbetsshould be kept free of nicks and burrs.

The preassembled coupling halves are made rigid duringmanufacturing by shipping screws (see figure). The red lockingscrews (setscrews) hold the disc pack in the neutral position. Theyellow collapsing screws (socket head capscrews) lock the halfcoupling assembly in place. DO NOT REMOVE OR LOOSENTHESE SCREWS UNTIL INSTRUCTED.

Read all of the installation instructions and review the procedurebefore the acutal coupling installation.

WARNING!

High voltage and rotating parts may causeserious or fatal injury.

Turn off power to install or service.

Operate with guards in place.

Read and follow all instructions in this manual.

The Emerson logo is a trademark and a service mark of Emerson Electric Co.© Emerson Power Transmission Manufacturing, L. P. or affiliates 2002. All Rights Reserved.

2.0 INSTALLATION OF COUPLING HALVES

Note: The half couplings are preassembled from the factory andlocked in place by the shipping screws, see general section.

KEYED


2.2 For taper bores, check the fit of the bore to the shaft.

2.3 Keys must be precisely fitted to the keyways in the shaft andhub. Each key should have a tight fit on the sides with a slightclearance on top. To maintain dynamic balance, the keysshould fill the keyways exactly and not be too short or toolong.

2.4 Clean the hub bore and shaft. Record the position of the hubon the shaft as the “start” position for advancing taper boredcouplings.

2.5 Heat the entire half coupling to expand the bore; DO NOTallow the coupling temperature to exceed 450 degrees F (230degrees C). DO NOT apply an open flame to the disc packs.An oil bath or oven is recommended.

2.6 Place the half coupling in the proper position on the shaft.For taper bored hubs, the hub must be advanced the correctamount as specified by the machine manufacturer or as givenon the coupling drawing.

2.7 Hold the hub in place as it cools. For taper bores, verify thehub advance and install the shaft retaining nut.

HYDRAULIC

Specific instructions for hydraulic mounting of coupling hubs are givenby the manufacturers of the connected equipment. The following gen-eral instructions on mounting are given for reference. Make surethat the equipment manufacturer’s instructions are supplied and arefollowed.


2.9 Check the fit of the bore to the shaft, at least 85% contact isrequired. Make sure there are no O-rings or backup rings inthe oil seal grooves. DO NOT lap the hub on the shaft toobtain the required contact, use special gauges. Record theposition of the hub on the shaft as the “start” position foradvancing.

2.10 Clean the hub bore and shaft and install the O-rings andbackup rings (if used).

2.11 Place the half coupling on the shaft and install the necessaryhydraulic mounting equipment.

2.12 Place the hub in the “start” position and inject oil to pressur-ize the bore and expand the hub. Check for leaks.

2.13 Push the coupling onto the shaft to the specified advance.Keep the proper pressure in the bore. DO NOT exceed themaximum allowable assembly pressure specified on thecoupling general arrangement drawing or on equipmentmanufacturer’s installation instructions.

2.14 Release the bore pressure slowly and allow some time forthe oil to drain from the bore. Leave the pusher in place tohold the hub in position.

Disconnect all power before adjusting units

2.15 Remove the hub pusher after the bore oil has drained andverify the correct advance of the hub on the shaft. Install theshaft nut (if used) and lock in place.

If sufficient time is not allowed for the oil todrain from the bore, the hub could moveoff the shaft with great force when thepusher is removed. Make sure propersafety procedures are followed.

If heat is used at any time for installa-tion, DO NOT allow the coupling tem-perature to exceed 450 degrees F (230degrees C). DO NOT apply an openflame to to disc packs. An oil bath oroven is recommended.

3.0 SOLO OPERATION

After the half coupling is mounted on the shaft the equipment can besoloed (i.e.., run uncoupled for testing purposes).

3.1 If a moment simulator plate or solo adapter is required, seeForm 16-611 “Moment Simulator and Solo Plate InstallationInstructions.” Note that API 671 specifies the use of plates forsolo operation and also specifies that they are piloted on boththe hub and sleeve.

4.0 ALIGNMENT

Note: Exact values and procedures for aligning equipment are nor-mally specified by the equipment manufacturers.

The amounts given below represent values that would pro-vide excellent coupling performance in operation.

Good initial alignment to the minimum possible values willpromote optimum machinery performance and eliminate po-tential operating problems.

OFFSET AND ANGULAR MISALIGNMENT

4.1 Reverse dial indication or optical methods of alignment arerecommended. A cold alignment and a hot check (with cor-rections if necessary) are required. The sleeve flanges of theassembled halves can be used to mount the alignment equip-ment (the flange outer diameter is machined to be concentricto the coupling bore and can be used as the reference diam-eter). If the shipping screws have been released, the flangeouter diameter concentricity to the bore will have to be ze-roed by adjusting the shipping screws until the runout is mini-mal.

4.2 The maximum recommended operating misalignment is:0.10 degrees per disc pack(0.0035 in/in TIR offset)

Note that improving the alignment below these values willpromote optimum machinery performance.

© Emerson Power Transmission Manufacturing, L. P. or affiliates 2002. All Rights Reserved.

Disconnect all power before adjusting units

4.3 Check the axial position of the coupling halves by measuringthe sleeve flange separation. The correct separation at thecoupling installation is equal to the design flange separationgiven on the coupling drawing plus the installation prestretch.

CALCULATED FLANGE SEPARATION =DESIGN FLANGE-TO-FLANGE DIMENSION + PRESTRETCH

The installation prestretch accommodates thermal growth andinitial axial misalignment.

If the shipping screws have been released, the sleeve flangeface will rest in approximately the neutral position, and mea-surements can be taken from the flange in this condition. Usean average of at least four (4) measurements at 90 degrees.

4.4 Compare the measured flange separation to the calculatedflange separation and adjust the connected equipment ac-cordingly.

4.5 If the correct flange separation cannot be obtained by mov-ing the equipment, the spacer flange shim packs can be usedto adjust for axial position. Two packs are supplied with indi-vidual shims of various thickness; the coupling is designedso that one pack is installed if the measured flange separa-tion is EQUAL to the calculated separation.

4.6 If the measured flange separation is LESS than the calcu-lated value, remove shims from one pack equal to the differ-ence between the measured and calculated values and in-stall the remainder of the shim pack on the spacer (the shimshave a piloted fit with the spacer rabbet). Store the removedshims and the other shim pack for future use.

4.7 If the measured flange separation is MORE than the calcu-lated value, install one complete shim pack on the spacerand install shims form the second pack equal to the differ-ence between the measured and calculated values (placethe shims on both spacer rabbets, DO NOT put all the shimson one rabbet). Store the remaining shims from the secondpack for future use.

4.8 The axial shim adjustment can be represented by:

SHIM ADJUST =MEASURED SEPARATION - CALCULATED SEPARATION

If SHIM ADJUST is zero, place one shim pack on the spacerand store the second shim pack.

If SHIM ADJUST is a negative number, remove shims equalin thickness to SHIM ADJUST form one pack and put theremainder of the pack on the spacer (store the removed shimsand the second pack), see 3.5.

If SHIM ADJUST is a positive number, place one shim packon the spacer and remove shims equal in thickness to SHIMADJUST from the second pack and place them on the otherend of the spacer (store the remainder of the second pack),see 3.6.

DO NOT PUT MORE THAN ONE SHIM PACK ONANY SPACER FLANGE.

5.0 FINAL ASSEMBLY

5.1 Remove the red locking screws and tighten the yellow screws;this collapses the disc pack and pulls the sleeves apart toallow clearance of the spacer rabbets. Tighten the screwsprogressively and in small increments; DO NOT tighten themone at a time.

5.2 Place the coupling spacer with the correct amount of shimbetween the two halves and line up the match marks, makesure the identifying letters or numbers with the match marksare the same.

5.3 Release the collapsing screws; this must be done progres-sively and in small increments. DO NOT loosen them one ata time. Store the yellow collapsing screws for future use.

5.4 Line up the match marks exactly and push the spacer andsleeve flanges together. KOP-FLEX High Performance disccouplings are designed with interference rabbets so they mustbe pressed or lightly tapped together. DO NOT use exces-sive force.

5.5 Install the flange bolts and nut in the direction as shown onthe coupling general arrangement drawing. The proper tight-ening torque is listed on the coupling drawing; they are alsomarked on the coupling flange for reference.

5.6 Recheck the coupling alignment after the machinery hasreached a stable operating temperature and correct if neces-sary.

6.0 REMOVAL

6.1 Remove the spacer bolts and nuts and break the flanges apartusing the jacking screw holes located between the spacerbolt holes.

6.2 Install the yellow collapsing screws in the counterbored clear-ance holes in the sleeve and tighten them to collapse thedisc pack. The collapsing screws must be tightened progres-sively and in small increments; DO NOT tighten them one ata time. This operation will pull the sleeve away from the spacerand allow the rabbets to clear so that the spacer can be re-moved.

6.3 KEYED - Install a puller on the hub using the tapped holesprovided in the hub face; pull the hub off the shaft. DO NOTPULL ON THE SLEEVE OR DISC PACK.

6.4 HYDRAULIC - Install the hydraulic equipment and removethe hub from the shaft, reversing the installation procedure.DO NOT exceed the maximum allowable assembly pressurespecified on the coupling general arrangement drawing, or onequipment manufacturer’s installation instructions.

If heat is used in removing the half couplingfrom the shaft, apply it directly to the hub. DONOT use extreme temperatures. DO NOTapply direct flame to the disc pack.

If direct flame is required to remove the hub,the disc pack MUST be protected with insu-lating wool or flame resistant material.

Excessive heat on the disc pack will destroythe disc coating and reduce the service lifeof the coupling.

© Emerson Power Transmission Manufacturing, L. P. or affiliates 2002. All Rights Reserved. Printed in U.S.A.

KOP-FLEX, INC.Emerson Power TransmissionP. O. Box 1696Baltimore, MD 21203-1696www.emerson-ept.com

Important Safety InstructionsBefore start-up . . . for reasons of safety and to extend shaft coupling life,follow these requirements.

1. Coupling guards protect personnel. ALL COUPLINGS MUST BE COVEREDWITH A GUARD AS PER OSHA REQUIREMENTS.

2. Recheck alignment after all foundation bolts and mechanical connections aretightened.

3. Make sure all fasteners are properly installed and tightened.

4. Take the time to double check your work.

5. Only authorized KOP-FLEX replacement parts are to be used.

6. Call KOP-FLEX for any clarification or questions.

7.0 GENERAL RECOMMENDATIONS

KOP-FLEX High Performance disc couplings are designed to operatefor extended periods without the need for lubrication or maintenance.Visual inspection of the disc packs is sufficient to assess theoperational condition of the coupling.

All high speed machinery should be constantly monitored to detectunusual or changing vibration levels. The KOP-FLEX coupling, undernormal operation conditions, has no wearing parts and will retain itsoriginal balance quality. Any change in vibration levels should beinvestigated and remedial action should be taken immediately.

The serial number of the coupling is marked on every majorcomponent of the coupling. It is required for accurate identificationand is sufficient for ordering an exact duplicate of the coupling or itscomponents.

The self-locking nuts on the spacer bolts shouldbe replaced after they have been assembledand removed from the bolts TEN (10) times.

Only KOP-FLEX FURNISHED REPLACEMENTPARTS ARE ALLOWED FOR USE.

KOP-FLEX High Performance disc couplingsare factory preassembled.

DO NOT TIGHTEN OR LOOSEN THE DISC PACK NUTS.DO NOT ATTEMPT TO DISASSEMBLE THE DISC PACKS.

REPAIR OR REPLACEMENT OF KOP-FLEXHIGH PERFORMANCE DISC COUPLINGS ISRESTRICTED TO KOP-FLEX AUTHORIZEDFACILITIES.

8.0 REFERENCE INSTRUCTION SHEETS

Form 16-602 - “MP”, “MS” Style Installation InstructionsForm 16-611 - “Moment Simulator and Solo Plate InstallationInstructions

Warehouse

Warehouse

Warehouse

Warehouse


SECTION 6


EMERGENCY DC DRIVE

ENGINEERING INC

MODEL PG7121EA. STARTING AND TURNING SYSTEMLONG TERM STORAGE INSTRUCTIONS

(Refer to: Starting and Turning System Drawing)

The unit as it left the factory was prepared for in-transit protection against the elementsand is not intended as protection for long-term storage. In the event the unit cannot beinstalled and placed into service, the unit should be removed from the container in whichit was shipped, but retaining the wood skid on which it came to prevent damage to pipingconnections and machined surface of the base. The unit mounted on its skid is to bestored in a secure, cool, dry, vibration free and clean environment limiting its exposure tothe elements. Tag unit to show date placed in storage or decommissioned and currentstatus relating to storage procedure per the following outline.

INITIALLY AND THEN AT APPROPRIATE INTERVALS, INSPECT THE UNITFOR THE FOLLOWING:

1. Paint deterioration, renew as required.

2. Exposed machined surfaces for coating deterioration and/or rust blush. Renew coating as required with Dow Corning Metal Protective Coating or equivalent. (See Dow Corning Protective Coating Specification Sheet in this section)

3. The Turning Gear Lubrication System is separate from the Starting SystemLubricating System. It comes from the factory with 24 gallons of oil in the housing.Remove breather and completely fill the Turning Gear with the recommendedlubricant immersing the gear completely in oil and maintaining this level. Replacebreather with a plug and place breather in a bag and tag with CAUTION NOTE:“Must Be Drained To Proper Level And Breather Installed Before Operation”.Tie wire bag and tag to unit. For additional information refer to IMO IndustriesDelroyd Division Long Term Storage Instruction found in this section.

4. The Torque Converter and Input Gear Assembly, as well as the Starting SystemOutput Shaft are interconnected by a common lubrication system. If the system is tobe stored excess of four (4) months it is to be preserved for long term storage utilizinga corrosion inhibitive lubricating as oil follows:

a. Referring to Dwg. No. 14-1265-8 Piping Assembly drawing, disconnectTorque Converter Input Gear Vent by removing vent connection R11 andpour three (3) quarts of Non Rust VCI-10 Oil or its equivalent into the gearcasing (product information found in this section). Reconnect the vent line.

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ENGINEERING INC

LONG TERM STORAGE INSTRUCTIONS

b. Refer to Dwg. No. 14-1265-8, Piping Assembly drawing. Disconnect 3/8”tubing at Torque Converter Inlet (Item 3) and pour one (1) quart of Nox RustVCI-10 Oil (product information found in this section). Reconnect the tubing.

When preparing the unit for installation, care should be exercised when removing theblank flanges on the oil supply and drain headers to catch any oil, which may havedrained back to this point.

IF AFTER INSTALLATION AND COMMISSIONING THE UNIT IS TO BEDECOMMISSIONED OR OUT OF SERVICE FOR EXTENDED PERIODS, THEFOLLOWING PROCEDURE SHOULD BE FOLLOWED:

1. Maintain the level of lubricant in the Worm Gear of the Turning Gear Assemblyreducer using the sight gage to periodically check the level.

2. Once a month, energize the power plant lube oil system and, while circulating oil,operate the Turning Gear Unit for a few minutes and every six months operate theunit for two (2) hours. This can be done with the unit main coupling connected ordisconnected from the main power plant. The power plant operating procedures mustbe observed when operating the Turning Gear.

FOR ADDITIONAL INFORMATION REFER TO THE FOLLOWING:

TURNING GEAR SYSTEM

The following IMO Industries, Inc., Delroyd Worm Gear Division engineering documentprovides instruction for long term storage of the Turning Gear and Emergency Gear (Seepage 6 of this section).

Refer to Section 4 of Instruction Manual for specified lubrication feed and drainconnections.

INPUT GEAR/TORQUE CONVERTER ASSEMBLY

Prior to any shaft rotation of this assembly, the main turbine plant lube oil system shouldbe energized to provide oil through the oil header for lubrication.

The assembly should be lubricated and rotated (input and output shaft) at least five (5)revolutions at intervals of every six (6) months.

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ENGINEERING INC

LONG TERM STORAGE INSTRUCTIONS

AC TURNING GEAR MOTOR (GENERAL ELECTRIC ) DC EMERGENCY GEAR MOTOR (GENERAL ELECTRIC) Please refer to Section 2 of Instruction Manual. Manufacturer’s recommendation for storage, withdrawal from service, and maintenance are provided. INPUT/OUTPUT KOP-FLEX COUPLINGS Kop-Flex high of performance couplings are designed to operate for extended periods without the need for lubrication or maintenance. Visual inspection of the disc packs is sufficient to assess the operational condition of the couplings. Prior to commissioning following long term storage, it is recommended the coupling alignments be checked. Even when a coupling is well aligned at installation, subsequent settling of foundation or shifting of equipment etc., may cause the initial alignment to deteriorate. Refer to Section 5 of Instruction Manual for installation and alignment specifications. SSS DUO-CONCENTRIC CLUTCH AND OUTPUT SHAFT ASSEMBLY This assembly should be lubricated and rotated at intervals of every six (6) months. Refer to Section 3 of Instruction Manual for additional information.

CAUTION

PRIOR TO ANY SHAFT ROTATION OF THIS ASSEMBLY, THE MAIN TURBINE PLANT LUBE OIL SYSTEM SHOULD BE ENERGIZED TO PROVIDE OIL THROUGH THE OIL HEADER TO LUBRICATE THE SSS DUO-CONCENTRIC CLUTCH AND ITS SUPPORT BEARINGS.

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Product Information

SpecialtyCoatings

FEATURES• Good corrosion protection in

thin film• Colorless• Non-oily

COMPOSITION• Corrosion-protective coating

Dow Corning®

Metal Protective Coating

Coating prevents corrosion on metal parts in storage, overseasshipments and other high-humidity, long-term exposure

USESDow Corning® Metal Protective Coating is typically used to protect high-value-added metal parts during production, storage and shipment – especiallycomponents exposed to high humidity, salty conditions or corrosiveindustrial environments.

Typical uses for Dow Corning Metal Protective Coating include:

• Manufacturing – machined surfaces, stampings, raw stock, work-in-progress parts and finished products

• Aircraft – corrosion protection• Machine shop and tool room – dies, fixtures, jigs, tools, molds, guides and

ways, and raw ground stock• Maintenance – machine tools, pneumatic tools, spare parts, storage and

product equipment temporarily out of service• Finished products – machined and painted surface protection during

domestic and foreign shipments

DESCRIPTIONDow Corning Metal Protective Coatingis a transparent, dry, wax-like coatingthat protects metal parts from corro-sion. The coating has good inherentlubricating properties and usuallydoes not require removal prior toany subsequent machining, assem-bly or start-up of equipment. Ifnecessary, Dow Corning Metal Pro-tective Coating may be removed bymost common solvents such asmineral spirits or Dow Corning® OSFluids.

Parts protected with Dow CorningMetal Protective Coating may beexamined through the transparentcoating. Additionally, the parts willremain relatively clean since the drycoating will not readily pick up dirt,dust and grit under normalhandling and storage.

HOW TO USEDow Corning Metal ProtectiveCoating is ready to use as supplied.However, for uniform solidsdistribution and coating thickness,the bulk material should be gentlymixed before and during use.Dipping will provide a uniformcoating; however, spraying is oftenthe preferred method ofapplication. For best results, threelight applications are better thanone heavier application. For smallerjobs and touch-up work, Dow CorningMetal Protective Coating may beapplied from an aerosol container.Brushing may also be used. For bestprotection, scratching of the coatingafter application should be avoided.

Surface PreparationSurfaces to be protected withDow Corning Metal ProtectiveCoating must be clean and dry.

1Registered trademark of The Dow ChemicalCompany.

Although the coating will notpermit moisture to penetrate, itdoes not displace moisture alreadyon the metal surface.

Film ThicknessA film thickness suitable for mostrequirements (0.40 mil) can beobtained by dipping at normal roomtemperature. For a thicker film andincreased metal protection,additional dip coatings may berepeated after allowing the first coatto dry. Similar buildup of theprotective film may be achieved byrepeated spray or brushapplications, with intervals fordrying between coats. A thick film,however, may cause the wax to pullaway from corners and metal edges,leaving metal exposed for corrosion.If a thinner film is desired, theliquid material may be diluted byusing a suitable chlorinated solventsuch as Chlorothene®1, which alsoreduces drying time, or by usingmineral spirits.

Removal of FilmIn most cases, Dow Corning MetalProtective Coating does not have tobe removed from coated parts beforethey are machined, assembled orstarted up. However, if removal isdesired, degreasing with commonsolvents such as mineral spirits orDow Corning OS Fluids will normallyremove the coating as will steamcleaning or alkali cleaners.

TYPICAL PROPERTIESThese values are not intended for use in preparing specifications.

Test Unit ResultAs SuppliedAppearance1 Opaque, yellow liquidDensity1 lb/gal 6.8Boiling Point1 °F (°C) 240 (115)Flash Point1 °F (°C) 82 (28)Surface Coverage, film thickness of

0.0001 inch sq ft/gal 21000.0002 inch sq ft/gal 11000.0003 inch sq ft/gal 700

Drying Time,bulk, thin film, one dip minutes 10 to 30aerosol spray, thin film, one pass minutes 10 to 20

Solvent,bulk Mineral spiritsaerosol spray Mineral spirits plus

nonchlorofluorohydro-carbon propellant

As AppliedAppearance Transparent,

non-oily waxSoftening Point °F (°C) 150 (65)Service Temperature Range, estimated °F (°C) -40 to 150 (-40 to 65)Single Dip Film Thickness

at 68°F (19.9°C) mils 0.4Corrosion Resistance, mild steel

5 percent salt spray, dipped from bulk hours 200+5 percent salt spray, aerosol spray hours 72+humidity room cycles 50

Lubrication2 Pass, no stick-slipCoefficient of Friction 0.121Properties for bulk form. Aerosol contains bulk plus nonchlorofluorohydrocarbon propellant.2Faville-LeValley Corp., LFW-4 Press Fit Machine.

Specification Writers: Please obtain a copy of the Dow Corning Sales Specification for thisproduct and use it as a basis for your specifications. It may be obtained from any Dow CorningSales Office, or from Dow Corning Customer Service in Midland, MI. Call (517) 496-6000.

Note: Caustic cleaners should notbe used to remove Dow Corning MetalProtective Coating from aluminumsurfaces.

CautionDow Corning Metal ProtectiveCoating contains mineral spirits. Itshould be used in a well-ventilatedarea, and the precautions normallyfollowed when working with thissolvent should be implemented.Solvents used to dilute this material,as well as metal cleaning or alkalicleaners, should only be used withadequate ventilation. Follow hand-ling precautions on container labels.

USE LIMITATIONSPainted surfaces should be wellcured before Dow Corning MetalProtective Coating is applied. If theintent is to remove Dow CorningMetal Protective Coating from thepainted surface at a later date, onlyone light application should bemade.

This product is neither tested norrepresented as suitable for medicalor pharmaceutical uses.

SHIPPING LIMITATIONSLiquid – DOT classification:flammable liquid.

Aerosol – DOT classification:flammable gas.

STORAGE AND SHELF LIFEWhen properly stored undernormal warehouse conditions,Dow Corning Metal ProtectiveCoating has a shelf life of 60 monthsfrom date of manufacture. To obtainuniform mixture, slight stirring afterstorage is recommended before use.

PACKAGINGDow Corning Metal ProtectiveCoating is supplied in 30-lb (13.6-kg) pails and 375-lb (170-kg)drums, net weight. Dow CorningMetal Protective Coating aerosol issupplied in 10-oz (284-g)containers, net weight.

SAFE HANDLINGINFORMATIONPRODUCT SAFETY INFORMATIONREQUIRED FOR SAFE USE IS NOTINCLUDED. BEFORE HANDLING,READ PRODUCT AND MATERIALSAFETY DATA SHEETS AND CON-TAINER LABELS FOR SAFE USE,PHYSICAL AND HEALTH HAZARDINFORMATION. THE MATERIALSAFETY DATA SHEET IS AVAILABLEFROM YOUR DOW CORNING REP-RESENTATIVE, OR DISTRIBUTOR,OR BY WRITING TO DOW CORNINGCUSTOMER SERVICES, OR BYCALLING (517) 496-6000.

WARRANTY INFORMATION– PLEASE READ CAREFULLYThe information contained hereinis offered in good faith and isbelieved to be accurate. However,because conditions and methods ofuse of our products are beyond ourcontrol, this information should notbe used in substitution for customer’stests to ensure that Dow Corning’sproducts are safe, effective, and fullysatisfactory for the intended end use.

Dow Corning’s sole warranty isthat the product will meet theDow Corning sales specifications ineffect at the time of shipment. Yourexclusive remedy for breach of suchwarranty is limited to refund of pur-chase price or replacement of anyproduct shown to be other than aswarranted. Dow Corning specificallydisclaims any other express orimplied warranty of fitness for aparticular purpose or merchantabil-ity. Unless Dow Corning providesyou with a specific, duly signedendorsement of fitness for use,Dow Corning disclaims liability forany incidental or consequentialdamages. Suggestions of use shallnot be taken as inducements toinfringe any patent.

DAUBERTNOX RUST VCI-1O OIL

NOX RUST VCI-lO Oil is a volatile corrosioninhibitive lubricating oil for use in the preservation offerrous metal parts in enclosed ‘systems.

Having combined the protective properties of apreservative oil with those of volatile corrosioninhibitors, VCI-l0 Oil makes possible long termprotection against rust within what are termed “closed”systems or voids.

PHYSICAL CHARACTERISTICS(Typical Values, Not Specifications)Viscosity @ lOO°F. SUS: 210Pour Point: -10°FFlash Point: 300°FSpecific Gravity: 0.931

Film Thickness @ 77°F: 0.2 milsCoverage: 800 sq ft per galVolatile: 5%Accelerated Corrosion Test, Humidity JAN—H-792,

100% RH § 1209F: 300 HoursVapor Phase Protection,MIL-P-46002A Procedure: Pass

NOX RUST VCI-l0 Oil is intended for use in the pres-ervation of enclosed systems where the volatile compo-nents will provide protection above the oil level. It pro-vides an effective contact preservative oil film. Typicalexamples of “closed” systems in which VCI-l0 Oil isused to protect metal from damaging rust include: fueltanks, storage tanks, cylinders, transmissions, metalcontainers, gear housings, clutch compartments, crankcases, hydraulic and coolant circu1ating systems.

Conventional lubricating or preservative oils slushedor fogged into such systemswill drain away from thevertical metal surfaces in about six months, exposingthe metal to moisture, condensation and corrosion. WhileNOX RUST VCI-l0 OIL also drains away, the vapor-izing rust inhibitors evolving from the product spreadthroughout the void or system and neutralize the corro-sion-causing tendency of the moisture present in theair. VCI-1O OIL, being highly fortified with contactinhibitors, also protects the metal below the oil level.

HOW NOX RUST VCI—10 OIL IS USED

[1] Since drive clutch and steering clutch assembliesare subject to corrosion within their compartments dur-ing shipment and storage, this problem was overcome byfogging three ounces of VCI-i0 to the hydraulic test oil.After testing, an additional three ounces are added.

[2] Corrosion of hydraulic cylinders can cause leak-age. Protection of cylinders and circulating systems isprovided by adding 2% VCI-lO to the hydraulic test oil.After testing, an additional three ounces are added.

[3] To forestall rust which will foul a dieselinjection system, one ounce of VCI—l0 per each 7—1/2gallons (1 cubic foot) capacity is fogged into the fuel tanks.If tank contains oil or gasoline, one ounce of VCI-l0 isadded for each gallon present.

[4] To protect crankshaft, bearings, rocker armsand all surfaces normally lubricated by crankcase oil,1% VCI-1O, by volume, is added to the crankcase oil.

[5] To protect upper cylinder walls and valves indiesel or gasoline engines, eight ounces of VCI10 areintroduced through the air filterand sucked into thecylinders by turning over the motor with ignition off.

[6] For transmissions, 2% VCI-10 is added to thelubricant.

The unusual properties of VCI-10 OIL can be used toadvantage for winter layaway of farm and roadbuilding equipment and for summer storage of schoolbuses, snow plows, etc. It may also be fogged intoshipping cases to protect unpainted auto and truck bodysections during shipments.

NOX RUST VCI-10 OIL can be used full strength insystems with ferrous metals only. Where non-ferrousmetals are present, VCI-10 must be diluted to 2% orless, depending on the metals present.

CAUTION: The data, statements and recommendations set fourth in this product information sheet arebased on testing, research and other development work which has been carefully conducted by us, and webelieve such data, statements and recommendations will serve as reliable guidelines. However, thisproduct is subject to numerable uses under varying conditions over which we have no control, andaccordingly, we do NOT warrant that this product is suitable for any particular use. Users are afvised tothest the product in advance to make certain it is suitable for their particular production conditions andparticular use or uses.

WARRANTY: Daubert Chemical Company, Inc. (“Daubert”) warrants all products manufactured by it tofree from defects in material and workmanship. DAUBERT MAKES NO OTHER WARRANTIESWHETHER EXPRESS OR IMPLIED WITH RESPECT TO SUCH PRODUCTS AND ALL OTHERWARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIEDWARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ANDIMPLIED WARRANTIY ARISING FROM A COURSE OF DEALING OR USAGE OF TRADE AREDISCLAIMED BY DAUBERT. All claims hereunder must be made in writing within30 days afterreceipt of the products at buyer’s plant and prior to further processing the products of combining themwith other materials or products. Daubert’s liability, whether under this warranty of in contract, tort,negligence or otherwise, is limited to the return of the net purchase price paid for any products provendefective or at Daubert’s option to repair or replacement of said products upon their return,transportation prepaid to Daubert. Remedy hereby provided shall be the exclusive and sole remedy ofthe buyer. Under no circumstances shall Daubert be liable for consequential or incidental damages. NoDaubert representative or other person is authorized to change this warranty in any way to assume forDaubert any other liability in connection with the sale or use of its products.

Refer to material safety data sheet for health and safety information.

Daubert Chemical Company Inc.

4700 S. Central Ave. Chicago, IL 60638 (708) 496-7350

ENGINEERING INC

IMO DELROYD SPEED REDUCERSLONG TERM STORAGE INSTRUCTIONS

Problems can start to develop through improper standby and storage of new worm gearreducers awaiting installation or operation. Ambient conditions during long, idle periodswill determine necessary measures.

To avoid rust and deterioration of seals:

1. Replace breathers with pipe plugs, wiring the breathers to the unit to prevent loss.

2. Fill the reducer with recommended lubricant to the proper level and operate once amonth for a few minutes, or completely fill the unit, or use desiccants or vapor phaseinhibitors.

3. Cover the reducer with a tarpaulin or plastic cover, leaving openings underneath forventilation. A heavy, skidded platform with an internally lined wooden box may alsobe required when storage is in highly humidity or seaside areas.

4. Periodically drain any accumulated water from the bottom of the oil reservoir andreplace desiccants or vapor phase inhibitors.

Occasionally an idle reducer undergoes severe vibration from adjacent operatingmachinery. Even if the bearings are subjected to only partial load, vibrations can excluderesidual oil or grease from under bearings rollers or balls and result in false brinelling.

Immediate failure of the bearing is not a result, but once the bearing is put in operationthese pit marks act as stress risers. The fatigue life of the bearing can be reduced to afraction of the calculated design life.

False brinelling can usually be prevented by filling the reducer with oil to cover thebearings completely. This maintains a supply of oil at the contact points of the balls orrollers even under conditions of vibration.

ENGINEERING INC

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