IronHorse Worm Gearbox User Manual, 2nd Edition
Contents
1. 2nd Edition 04 2009 GETTING STARTED In This Chapter Manual Overview cinc AA AA a 1 2 Overview of This Publication 1 2 Who Should Read This Manual 1 2 Technical Support 5 5 5005 HERE nn rien OSES ETT e 1 2 Special Symbols icici 000 nun un eee eee eee ee ee anna an 1 2 lronHorse Worm Gearbox Introduction 1 3 Purpose of Worm Gearboxes ccc cece eee 1 3 Package Contents ocionisrrarar rra ee deee nenn Cees ann 1 3 Part Number Explanation is i ssc 05 0620 sche rar 1 4 Nameplate Information 44444 viet eue en eed eee nn 1 4 lronHorse Worm Gearbox Specifications 1 5 Gearbox Selection Factors 1 9 Service Factors and K Factors usuun 1 9 Chapter 1 Getting Started SS _ _ _ J J _ _ J J Manual Overview O verview of This Publication ThelronH orse Worm Gearbox U ser M anual describes the installation operation and preventative maintenance of IronH orse Worm Gearboxes Who Should Read This M anual T his manual contains important information for people who will install maintain and or Operate any of the IronH orse Worm Gearboxes Technical Support Our technical support group is gla2. T T T Ze ee 2 6 IronH orse Worm Gearbox User M anual 2nd Edition 04 2009 Chapter 2 Installation and Lubrication lronHorse Worm Gearbox Lubrication amp Mounting Orientations Lubricant selection is important to all gearboxes and it is particularly critical for the worm gear type An oil with special characteristics and a relatively high viscosity is required due to Sliding action between the gear teeth where they mesh Aside from improper gearbox selection inadequate lubrication is the greatest factor contributing to premature worm gearbox failures Improper lubrication also causes reduced gearbox performance Lubrication Instructions IronH orse Worm Gearboxes are shipped to you filled with Mobil SH C 634 synthetic oil Oil must be added or partially drained depending upon your mounting orientation as shown in the Lubricant Capacities table Since many oils are not suitable for worm gears it is very important to use the proper lubricant type It is also very important to keep the oil free from oxidation and contamination by water or debris For longer service life the gearbox should be periodically drained preferably while warm and refilled to the proper level with a recommended gear oil N on synthetic oils should be changed every 6 months or 250 hours of operation under normal operating conditions H owever synthetic lubricants have increased resistance to thermal and oxidation degradation
3. WG 206 005 D WG 206 005 H WG 206 005 R WG 206 010 D WG 206 010 H WG 206 010 R WG 206 015 D WG 206 015 H WG 206 015 R WG 206 020 D WG 206 020 H WG 206 020 R mic CD WG 206 040 R WG 206 060 D WG 206 060 H WG 206 060 R 1 Nominal Motor HP is the highest HP 1800 rpm motor to be used with the gearbox under conditions of 1 0 service factor Gearbox input power capacity decreases as motor speed decreases and as service factor increases 2 Output Type D Dual Shaft H Hollow Shaft R Right Hand Shaft 3 The Center Distance is the distance between the centerlines of the input and output shafts serves as the gearbox frame size 4 Overhung Load ratings are for forces perpendicular to the output shaft and located at the shaft midpoint such as from a gear pulley or sprocket with a belt or chain Divide OHL ratings by the applicable OHL K factors shown separately in the Selection Factors tables OHL ratings should also be divided by applicable service factors 5 Thrust Load ratings are for forces along the axis of the output shaft usually encountered in vertical drive applications from agitators mixers fans blowers etc 6 Maximum Mechanical Ratings are limits based on strength and durability of gearbox components applicable when operating time is short and stopped time is greater than or equal to operating time These ratings are applicable for 1 0 service factor loads
4. and may require modification depending upon characteristics of the applicable driven loads Refer to the Service Factors table for more information 7 Maximum Thermal Ratings are limits for gearbox continuous use without overheating 750 0 48 2 o 5 5 5 5 Output Type 2 l 6 IronH orse Worm Gearbox User M anual 2nd Edition 04 2009 Chapter 1 Getting Started IronH orse Worm Gearbox Specifications continued TronHorse Worm Gearbox Specifications Frame Size 237 Maximum Ratings O 1750 rpm Input Thermal 7 Part Number Output RPM 1750 rpm Input Nominal Motor HP 1 1800 rpm NEMA Motor Frame Center Distance 3 in Overhung Load 4 Ib Efficiency Approx Weight Ib Input Power hp Output Power hp Output Torque Ib in Input Power hp Output Power hp Output Torque Ib in Maximum Input Speed rpm 1 Nominal Motor HP is the highest HP 1800 rpm motor to be used with the gearbox under conditions of 1 0 service factor Gearbox input power capacity decreases as motor speed decreases and as service factor increases 2 Output Type D Dual Shaft H Hollow Shaft R Right Hand Shaft 3 The Center Distance is the distance between the centerlines of the input and output shafts serves as the gearbox frame size 4 Overhung Load ratings are for forces
5. 1 350 1 1 2 56C H 93 27 2 83 2 62 499 2 28 2 11 402 WG 175 005 R R 22 WG 175 010 D D 23 WG 175 010 H 10 1 175 1 56C H 88 27 1 57 1 38 515 1 36 1 19 445 WG 175 010 R R 22 WG 175 015 D D 23 WG 175 015 H 15 1 117 3 4 156C H 85 27 1 24 1 06 554 1 13 0 96 506 WG 175 015 R R 22 WG 175 020 D 5 1 75 650 550 53 2500 WG 175 020 H 20 1 88 3 4 560 H 83 27 1 26 1 04 737 0 98 0 81 572 WG 175 020 R R 22 WG 175 040 D D 23 WG 175 040 H 40 1 44 1 3 56C H 62 27 10 79 0 49 714 0 45 0 28 404 WG 175 040 R R 22 WG 175 060 D D 23 WG 175 060 H 60 1 29 1 4 56C H 52 27 0 38 0 20 433 0 35 0 19 404 WG 175 060 R R 22 1 Nominal Motor HP is the highest HP 1800 rpm motor to be used with the gearbox under conditions of 1 0 service factor Gearbox input power capacity decreases as motor speed decreases and as service factor increases 2 Output Type D Dual Shaft H Hollow Shaft R Right Hand Shaft 3 The Center Distance is the distance between the centerlines of the input and output shafts serves as the gearbox frame size 4 Overhung Load ratings are for forces perpendicular to the output shaft and located at the shaft midpoint such as from a gear pulley or sprocket with a belt or chain Divide OHL ratings by the applicable OHL K factors shown separately in the Selection Factors tables OHL ratings should also be divided by ap
6. durability of gearbox components applicable when operating time is short and stopped time is greater than or equal to operating time These ratings are applicable for 1 0 service factor loads and may require modification depending upon characteristics of the applicable driven loads Refer to the Service Factors table for more information 7 Maximum Thermal Ratings are limits for gearbox continuous use without overheating l 8 IronH orse Worm Gearbox User M anual 2nd Edition 04 2009 Gearbox Selection Factors Service Factors and K Factors Service Factors for Selecting Gearboxes when used with electric motors Chapter 1 Getting Started Service Continuity per day Load Characteristics Uniform Moderate Heavy Shock Shock Extreme Shock Occasional 1 2 hour 1 00 1 00 1 00 1 25 Less than 3 hours 1 00 1 00 1 25 1 50 3 10 hours 1 00 1 25 1 50 1 75 Overhung Load K Factors for Various Drive Types More than 10 hours 1 25 1 50 1 75 2 00 Chain amp Sprocket 1 00 Shock results from sudden increases in the torque demand of the load such as sudden stopping restarting and or reversing significantly heavy loads dropped onto a moving conveyor impact loads such as punch press operations Gear 1 25 V belt 1 50 Flat Belt 2 50 Depending upon the load characteristics divide
7. perpendicular to the output shaft and located at the shaft midpoint such as from a gear pulley or sprocket with a belt or chain Divide OHL ratings by the applicable OHL K factors shown separately in the Selection Factors tables OHL ratings should also be divided by applicable service factors 5 Thrust Load ratings are for forces along the axis of the output shaft usually encountered in vertical drive applications from agitators mixers fans blowers etc 6 Maximum Mechanical Ratings are limits based on strength and durability of gearbox components applicable when operating time is short and stopped time is greater than or equal to operating time These ratings are applicable for 1 0 service factor loads and may require modification depending upon characteristics of the applicable driven loads Refer to the Service Factors table for more information 2 0 22 0 x 3 o gt Output Type 2 7 Maximum Thermal Ratings are limits for gearbox continuous use without overheating 04 2009 2nd Edition IronHorse Worm Gearbox User Manual 1 7 Chapter 1 Getting Started a _ co J IronH orse Worm Gearbox Specifications continued Maximum Ratings O 1750 rpm Input The
8. the gearbox HP Overhung Load and Maximum Mechanical Capacity ratings by the applicable service factor 04 2009 2nd Edition Variable Pitch Belt 3 50 Divide gearbox OHL ratings by the applicable OHL K factors uns IronHorse Worm Gearbox User M anual 1 9 THIS PAGE INTENTIONALLY LEFT BLANK INSTALLATION AND LUBRICATION In This Chapter lronHorse Worm Gearbox Installation 2 2 Installation Instructions 0oocococ es 2 2 Vent Plug Installation ss sise ses cu essences sde ann 2 3 Gearbox Dimensions ociosa Ehren 2 4 IronHorse Worm Gearbox Mounting Bases 2 6 Mounting Base Selection and Dimensions 2 6 lronHorse Worm Gearbox Lubrication amp Mounting Orientations 2 7 Lubrication Instructions u a exa rr ea 2 7 Lubrieant Selection y eomsiccce cara rra E As 2 7 Lubricant Capacities amp Mounting Orientations 2 8 Chapter 2 Installation and Lubrication lronHorse Worm Gearbox Installation Read these instructions thoroughly before installing or operating the gearbox Installation Instructions e Leave the protective shaft sleeves in place for safe handling of the gearbox during installation e Add or partially drain oil as needed depending upon the mounting orientation Refer to the lubrication section of this chapter for more information Install
9. PAGE INTENTIONALLY LEFT BLANK Automation IronH orse Worm Gearbox User M anual WG USER M WO 2nd Edition
10. WAUTOMATIONDIRECT IronHorse Worm Gearbox User Manual WG USER M WO 2nd Edition THIS PAGE INTENTIONALLY LEFT BLANK Thank you for purchasing automation equipment from Automationdirect com doing business as AutomationD irect We want your new automation equipment to operate safely Anyone who installs or uses this equipment should read this publication and any other relevant publications before installing or operating the equipment To minimize the risk of potential safety problems you should follow all applicable local and national codes that regulate the installation and operation of your equipment T hese codes vary from area to area and usually change with time It is your responsibility to determine which codes should be followed and to verify that the equipment installation and operation isin compliance with the latest revision of these codes At a minimum you should follow all applicable sections of the N ational Fire Code National Electrical Code and the codes of the N ational Electrical M anufacturer s Association NEM A T here may be local regulatory or government offices that can also help determine which codes and standards are necessary for Safe installation and operation Equipment damage or serious injury to personnel can result from the failure to follow all applicable codes and standards Wedo not guarantee the products described in this publication are suitable for your particular application nor do we ass
11. a RAROS 1 4 Nameplate Information a an darin 1 4 IronHorse Worm Gearbox Specifications 1 5 Gearbox Selection Factors ssssssssssssumcmeonciessstusc esussdstetenu 1 9 Service Factors and K Factors n eee eth cok ee Se ae bene eee o 1 9 Chapter 2 Installation and Lubrication 2 1 IronHorse Worm Gearbox Installation 2 2 Installation Instructions Gucci ron rias 2 2 Vent Plug Installation use ao ce co ia oo 2 3 Gearbox DIMENSIONS SL du dico en ner ec divise 2 4 IronHorse Worm Gearbox Mounting Bases 2 6 Mounting Base Selection and Dimensions 2 6 IronHorse Worm Gearbox Lubrication amp Mounting Orientations 2 7 Lubrication Instructions san a a ra an ee ee de ea ee 2 7 Lubricant Selection airis sea pe a ne a aaa ee ame 2 7 Lubricant Capacities amp Mounting Orientations 2 8 Table of Contents Appendix A Glossary of Terms A 1 Glossary of Gearbox Terms ue een an E Es ce A 2 Appendix B Gearbox Selection B 1 Gearbox Selection Procedure B 2 Gearbox Selection StepS sssaaa kere one oad apace ene ore wean ws B 2 Gearbox Selection Example a ans aaa aaa B 2 ji IronH orse Worm Gearbox User Manual
12. and do not need to be changed as frequently Synthetic lubricant should be changed every 6 000 hours of operation or every two years which ever comes first Lubricant Selection ThelronH orse Worm Gearbox Lubricant Selection table indicates lubricants that are suitable for IronH orse gearboxes operating at various temperatures IronHorserM Worm Gearbox Lubricant Selection 30 to 225 F 40 to 90 F 34 to 107 C 4 4 to 32 2 C Synthetic 7 8 320 460 460 680 SHC634 600W 80 to 125 F 26 7 to 51 7 C 8 EP 680 Recommended supplied with GB cylinder oil Extra Heela Super Cylinder Oil Mobilgear 634 04 2009 2nd Edition synthetic recommendation is exclusively for Mobil SHC 634 Veedol Asreslube 95 Veedol Asreslube 98 Almasol 608 Almasol 609 SPO 288 Valvala J460 Omala 460 Valvala J680 Omala 680 Meropa 460 Meropa 680 WARNING Some lubricants contain non corrosive extreme pressure additives DO NOT USE lubricants that contain sulphur and or chlorine which are corrosive to bronze gears Also some extreme pressure lubricants contain materials that are toxic Avoid the use of these lubricants where harmful effects can occur IronH orse Worm Gearbox User M anual l 2 7 Chapter 2 Installation and Lubrication Lubricant Capacities amp Mounting Orientations WARNING Too much oil will cause overheati
13. d to load speed O verall speed ratio motor speed load speed 1725 20 86 25 about 86 1 3 D etermine pulley ratios at available gearbox ratios Gearbox ratio overall speed ratio pulley ratio Pulley ratio overall speed ratio gearbox ratio For 5 4 gearbex pulley ratio 86 25 5 4425 17 25 pulley size is prohibitively large For 10 1 gearbox pulley ratio 86 25 10 8 63 For 15 1 gearbox pulley ratio 86 25 15 5 75 For 20 1 gearbox pulley ratio 86 25 20 4 31 For 40 1 gearbox pulley ratio 86 25 40 2 16 For 60 1 gearbox pulley ratio 86 25 60 1 44 Pulley ratio conveyor pulley diameter gearbox pulley diameter B 2 IronH orse Worm Gearbox User M anual 2nd Edition 04 2009 Appendix B Gearbox Selection 4 D etermine service factor SF and overhung load factor K from applicable tables SF 1 25 dueto moderate shock loading and 3 10 hours day operation K 1 5 dueto V belt 5 Use specifications table to select gearbox with M ax T hermal Torque rating gt required real torque G earbox required real torque final torque pulley ratio For 10 1 gearbox For 15 1 gearbox For 20 1 gearbox 2700 in lb 8 63 312 86 in lb useWG 175 x or larger 2700 in Ib 5 75 469 57 in lb use WG 175 x or larger 2700 in Ib 4 31 626 45 in lb use WG 206 x or larger 2700 in Ib 2 16 1250 0 in Ib none applicable For 69 1 gearbex 2700 in Ib 1 44 1875 0
14. d to work with you to answer your questions Please call the technical support group if you need technical assistance or visit our web site Our website contains technical and non technical information about our products and our company By telephone 770 844 4200 Mon Fri 9 00 am 6 00 pm ET OntheWeb www automationdirect com Special Symbols When you see the notepad icon in the left hand margin the paragraph to its immediate right will be a special note which presents information that may make your work quicker or more efficient T he word NOTE will mark the beginning of the text W hen you see the exclamation point icon in the left hand margin the paragraph to its immediate right will be a warning T his information could prevent injury loss of property or even death in extreme cases Any warning in this manual should be regarded as critical information that should be read in its entirety The word WARNING in boldface will mark the beginning of the text 1 2 IronH orse Worm Gearbox User M anual 2nd Edition 04 2009 Chapter 1 Getting Started IronHorse Worm Gearbox Introduction Purpose of Worm Gearboxes Gearboxes also known as enclosed gear drives or speed reducers are mechanical drive components that can drive a load at a reduced fixed ratio of the motor speed T he output torque is also increased by the same ratio while the horsepower remains the same less
15. efficiency losses A 10 1 ratio gearbox outputs approximately the same motor output horsepower but motor speed is divided by 10 and motor torque is multiplied by 10 Worm gearboxes contain a worm type gear on the input shaft and a spur type mating gear on the output shaft Worm gearboxes also change the drive direction by 90 degrees Our worm gearboxes are manufactured in an ISO 9001 certified plant by one of the leading and most internationally acclaimed worm gearbox manufacturers in the world today Only the highest quality materials are tested certified and used in the manufacturing process Strict adherence to and compliance with the toughest international and U S testing standards and manufacturing procedures assure you the highest quality products We offer right angle worm gearboxes with right hand and dual both right and left output shafts and with hollow shaft outputs all the way through from one side to the other T hese outputs are perpendicular to the inputs and change the drive direction s by 90 Our gearboxes utilize C face mounting interfaces for C face motors We also offer optional gearbox mounting bases for ease of installation Package C ontents After receiving the IronH orse Worm Gearbox please check for the following e M ake sure the package includes the speed reducer and the vent plug e Inspect the unit to insure it was not damaged during shipment e M ake sure that the part number on the gearbox nameplate is
16. h sides Right hand shaft gearboxes have output shafts only on the right side as viewed looking into the input shaft dimensions B BB L1 S amp N 2nd Edition 04 2009 Chapter 2 Installation and Lubrication Gearbox Dimensions continued H ollow Shaft O utput Gearboxes W G xxx xxx H AB gLC U gt Y V as Als a gt Ih H de f NS T i f Y 2 A e o dl OLB Output Shaft View BE F 2 NES ae BD F Y lt BB gt lt BB gt lt AC gt ty Rear View Left View lt gt W Z Part Number UNC WG 175 xxx H 5 16 18 WG 206 xxx H WG 237 xxx H Chapter 2 Installation and Lubrication lronHorse Worm Gearbox Mounting Bases Mounting Base Selection and Dimensions IronHorser Worm Gearbox Mounting Bases Fits Gearbox Dimensions in Numbers DIET Part Number WG 175 BASE WG 175 xxx x 5 69 7 00 WG 206 BASE WG 206 xxx x 5 91 7 76 WG 237 BASE WG 237 xxx x 6 22 8 50 WG 262 BASE WG 262 xxx x 9 65 4 d1 y 4 02 ort 5 ir LIT t
17. in Ib none applicable 6 Use specs table to select gearbox with M ax Mechanical Torque rating gt required design torque Gearbox required design torque real gearbox torque service factor For 10 1 gearbox 312 86 in 1b 1 25 391 08 in Ib use WG 175 x or larger For 15 1 gearbox 469 57 in 1b 1 25 586 96 in Ib use W G 206 x or larger For 20 1 gearbox 646 45 in 1b 1 25 808 06 in Ib use W G 206 x or larger 7 Use the gearbox overhung load ratings from the specifications table to determine the minimum allowable pulley diameters Select gearbox with O verhung Load rating gt overhung load force Gearbox required OH L rating gearbox real torque K SF gearbox pulley diameter 2 Minimum gearbox pulley diameter T K SF 2 O H L rating Conveyor pulley diameter gearbox pulley diameter pulley ratio For 10 1 WG 175 010 x gearbox Minimum gearbox pulley diameter 312 86 in 1b 1 5 1 25 2 650 Ib 1 8 use 2 Conveyor pulley diameter 2 8 63 172 17 26 pulley size is prohibitively large Determine pulley sizes and OH L for next larger gearbox ratio For 15 1 WG 206 015 x gearbox Minimum gearbox pulley diameter 469 57 in 1b 1 5 1 25 2 700 Ib 2 5 use 2 5 Conveyor pulley diameter 2 5 5 75 14 38 use 14 4 Select W G 206 015 x gearbox 2 5 gearbox pulley and 14 4 conveyor pulley For 20 1 WG 206 020 x gearbox All gearboxe
18. ng and too little oil will result in gear failure Check oil level regularly M ore frequent oil changes are recommended when operating continuously at high temperatures or under conditions of extreme dirt or dust lronHorse Worm Gearbox Lubricant Capacities Gearbox Mounting Orientation A B C D Gearbox Part Number Approx Capacity fl oz WG 175 xxx x 1164 18 74 18 74 17 24 WG 206 xxx x 19 41 2841 2841 26 71 WG 237 xxx x 24 07 35 17 35 17 33 77 WG 262 xxx x 34 55 48 25 48 25 45 85 Gearboxes are shipped filled with oil sufficient for mounting orientation A Oil must be added to gearboxes installed in other mounting orientations Gearbox Mounting Orientations Horizontal Input Shaft Vertical Input Shaft not allowed 2 8 IronH orse Worm Gearbox User M anual Znd Edition 04 2009 GLOSSARY OF TERMS In This Appendix Glossary of Gearbox Terms A 2 Appendix A Glossary of Terms Glossary of Gearbox Terms Axial M ovement Often called endplay The endwise movenent of motor or gear shafts Usually expressed in thousandths of an inch Back Driving Driving the out
19. nted plug is located in a horizontal plane the vent hole must point upward e For all mounting positions where the vented plug is located in a vertical plane the vent hole must point toward the center of the gearbox housing e Failure to properly install the vent plug can lead to pressurization of the gearbox housing as operating temperature rises resulting in leakage at the shaft seals 04 2009 2nd Edition IronH orse Worm Gearbox User M anual l 2 3 Chapter 2 Installation and Lubrication Gearbox Dimensions Solid Shaft O utput G earboxes W G xxx xxx D R gs LC gt Rear View Left View Left side output shafts are present only on dual shaft models WG xxx xxx D Dimensions inches IronHorse Worm Gearboxes Solid Shaft Outputs Part Number gt lt gt W lt Input Shaft View Z UNC WG 175 xxx D R 5 16 18 WG 206 xxx D R WG 237 xxx D R WG 262 005 D R WG 262 010 D R WG 262 015 D R Output Shaft L1 1 1 781 2 09 2 37 5 875 4 5 6 496 0 157 0 433 0 625 Dual shaft output gearboxes have B BB L1 S amp N dimensions on bot
20. oad No IronH orse worm gearbox should be considered self locking Service Factor for gearbox A constant used to modify the M echanical Rating of a gearbox based on the duration of service and characteristics of the driven load Use the Service Factor either as a multiplier to increase the calculated loads or as a divisor to reduce the gearbox M echanical and O verhung Load ratings Service Factor for motors Refers to a motor s ability to handle a load greater than the motor s rated horsepower on a continuous basis Speed Reducer Gearbox Thermal Ratings The power or torque a gearbox can transmit continuously T hese ratings are based upon the gearbox s ability to dissipate the heat caused by friction Thrust Load Forces along the axis of the output shaft usually encountered in vertical drive applications Worm Gear A set of threads similar to a thread screw that advance as they rotate around their axis The advancing threads cause the mating gear to turn and also slide against the gear teeth 04 2009 2nd Edition IronH orse Worm Gearbox User M anual A 3 THIS PAGE INTENTIONALLY LEFT BLANK CEARBOX SELECTION In This Appendix Gearbox Selection Procedure B 2 Gearbox Selection Steps 10 a a AAA B 2 Gearbox Selection Example B 2 Appendix B Gearbox Selection Gearbox Selection Procedure Gearbox Selecti
21. on Steps 1 Determine the torque and speed required for the load 2 Determine the overall speed ratio of motor speed to load speed 3 Determine the gearbox ratio as well as any reduction outside the gearbox pulleys gears etc 4 Determine the applicable service factor and overhung load K factor 5 Determine the gearbox real output torque required and select a gearbox with a higher M aximum Thermal output Torque rating 6 Determinethe gearbox design output torque required torque with service factor applied and select a gearbox with a higher M aximum M echanical O utput Torque rating Gearbox must also meet requirement 5 7 Determine the required sizes of pulleys gears etc and determine the overhung load force Select a gearbox with a higher O verhung Load rating Gearbox must also meet requirements 5 amp 6 8 Confirm that the selected gearbox meets the applicable system requirements 9 Select a compatible motor Gearbox Selection Example Refer to the specifications tables for gearbox specifications service factors and K factors A conveyor will run 10 hours day with moderate shock loading The conveyor will be driven by a V belt and needs to be driven at approximately 20 rom The motor to be used will havea nominal speed of 1800 rpm 1725 rpm actual speed The conveyor will require 2700 in Ib of torque 1 Required torque 2700 in 1b required speed 20 rpm 2 D etermine the overall speed ratio of motor spee
22. pany names may be trademarked and are the sole property of their respective owners AutomationD irect disclaims any proprietary interest in the marks and names of others Copyright 2008 2009 Automationdirect com Incorporated All Rights Reserved No part of this manual shall be copied reproduced or transmitted in any way without the prior written consent of Automationdirect com Incorporated AutomationD irect retains the exclusive rights to all information included in this document DENN ES AMA UA Nous vous remercions d avoir achet l quipement d automatisation de Automationdirect com en faisant des affaires comme AutomationD irect N ous tenons ce que votre nouvel quipement d automatisation fonctionne en toute s curit Toute personne qui installe ou utilise cet quipement doit lire la pr sente publication et toutes les autres publications pertinentes avant de l installer ou de l utiliser Afin de r duire au minimum le risque d ventuels probl mes de s curit vous devez respecter tous les codes locaux et nationaux applicables r gissant l installation et le fonctionnement de votre quipement Ces codes diff rent d une r gion l autre et habituellement voluent au fil du temps II vous incombe de d terminer les codes respecter et de vous assurer que l quipement l installation et le fonctionnement sont conformes aux exigences de la version la plus r cente de ces codes Vous devez tout le moins res
23. pecter toutes les sections applicables du C ode national de pr vention des incendies du Code national de l lectricit et des codes de la N ational Electrical M anufacturer s Association NEM A Des organismes de r glementation ou des services gouvernementaux locaux peuvent galement vous aider d terminer les codes ainsi que les normes respecter pour assurer une installation et un fonctionnement s rs L omission de respecter la totalit des codes et des normes applicables peut entra ner des dommages l quipement ou causer de graves blessures au personnel N ous ne garantissons pas que les produits d crits dans cette publication conviennent votre application particuli re et nous n assumons aucune responsabilit l gard de la conception de l installation ou du fonctionnement de votre produit Nos produits ne sont pas insensibles aux d faillances et ne sont ni con us ni fabriqu s pour l utilisation ou la revente en tant qu quipement de commande en ligne dans des environnements dangereux n cessitant une s curit absolue par exemple l exploitation d installations nucl aires les syst mes de navigation a rienne ou de communication le contr le de la circulation a rienne les quipements de survie ou les syst mes d armes pour lesquels la d faillance du produit peut provoquer la mort des blessures corporelles ou de graves dommages mat riels ou environnementaux activit s risque lev La soci t Automa
24. plicable service factors 5 Thrust Load ratings are for forces along the axis of the output shaft usually encountered in vertical drive applications from agitators mixers fans blowers etc 6 Maximum Mechanical Ratings are limits based on strength and durability of gearbox components applicable when operating time is short and stopped time is greater than or equal to operating time These ratings are applicable for 1 0 service factor loads and may require modification depending upon characteristics of the applicable driven loads Refer to the Service Factors table for more information 7 Maximum Thermal Ratings are limits for gearbox continuous use without overheating 04 2009 2nd Edition IronHorse Worm Gearbox User Manual l 5 Chapter 1 Getting Started H _ ____ __ _ _ _ _ _ _ _ c Q _ IronH orse Worm Gearbox Specifications continued IronHorse Worm Gearbox Specifications Frame Size 206 Maximum Ratings 1750 rpm Input Thermal a D a a o Part Number Output RPM 1750 rpm Input Nominal Motor HP 1 O 1800 rpm NEMA Motor Frame Center Distance 3 in Overhung Load 4 Ib Efficiency Approx Weight Ib Input Power hp Output Power hp Output Torque Ib in Input Power hp Output Power hp Output Torque Ib in Maximum Input Speed rpm N N CD
25. put shaft of a gearbox to increase speed rather than reduce speed Worm gearboxes are not suitable for service to increase speed Backlash Rotational movement of the output shaft clockwise and counter clockwise while holding the input shaft stationary Usually expressed in thousandths of an inch and measured at a specific radius at the output shaft Center Distance A basic measurement or size reference for worm gearboxes T he distance between the centerlines of the input and output shafts Efficiency A ratio of the input power compared to the output power usually expressed as a percentage Flanged Reducer U sually used to refer to a gearbox having provisions for close coupling of a motor either via a hollow quill shaft or flexible coupling M ost often aN EM A C face motor is used Gearbox Also called a Speed Reducer An enclosed set of gears used in mechanical power transmission to reduce speed and increase torque Input Power The power applied to the input shaft of a gearbox T here are separate ratings for M echanical Input Power Thermal Input Power and N ominal M otor H orsepower K Factor Also called an O verhung Load Factor A constant used to modify the overhung load rating of a gearbox based on the type of load applied on the shaft UsetheK factor either to increase the calculated overhung load or to reduce the gearbox overhung load rating Mechanical Ratings The maximum power or torque a gearbox can transmi
26. r backlash at installation and again at regular intervals This should be done by measuring the rotary movement of the output shaft rotating the shaft alternately clockwise and counterclockwise at a suitable radius while holding the input shaft stationary T he gearbox should be replaced when the backlash exceeds four times the measurement taken at installation e Gear drives are rated for 1750 input rpm and Class Service Service Factor 1 0 using M obil SH C 634 synthetic lubricant e Initial operating temperatures may be higher than normal during the break in period of the gear set For maximum life DO NOT ALLOW THE GEARBOX TO OPERATE CONTINUOUSLY ABOVE 225 F at the gear case In the event of overheating check for overloads or high ambient temperatures Keep shafts and vent plugs clean to prevent foreign particles from entering seals or gear housing 2 2 IronH orse Worm Gearbox User M anual 2nd Edition 04 2009 Chapter 2 Installation and Lubrication Vent Plug Installation All IronH orse Worm G earboxes are tested and filled with M obil SH C 634 synthetic lubricant prior to shipment All vent openings are plugged by the manufacturer to prevent the loss of lubricant in shipment T he vent plug is shipped loose in the package with the gearbox and should be installed prior to placing the gearbox in operation e The ventplug must be installed in the uppermost position For all mounting positions where the ve
27. rmal 7 Output RPM 1750 rpm Input Nominal Motor HP 1 O 1800 rpm NEMA Motor Frame Center Distance 3 in Overhung Load 4 Ib Efficiency Approx Weight Ib Input Power hp Output Power hp Output Torque Ib in Input Power hp Output Power hp Output Torque Ib in Maximum Input Speed rpm 23022022 0 9 2 0 E o Output Type 2 1 Nominal Motor HP is the highest HP 1800 rpm motor to be used with the gearbox under conditions of 1 0 service factor Gearbox input power capacity decreases as motor speed decreases and as service factor increases 2 Output Type D Dual Shaft H Hollow Shaft R Right Hand Shaft 3 The Center Distance is the distance between the centerlines of the input and output shafts serves as the gearbox frame size 4 Overhung Load ratings are for forces perpendicular to the output shaft and located at the shaft midpoint such as from a gear pulley or sprocket with a belt or chain Divide OHL ratings by the applicable OHL K factors shown separately in the Selection Factors tables OHL ratings should also be divided by applicable service factors 5 Thrust Load ratings are for forces along the axis of the output shaft usually encountered in vertical drive applications from agitators mixers fans blowers etc 6 Maximum Mechanical Ratings are limits based on strength and
28. s of the same frame size arethe same price yet the smaller ratio gearboxes offer higher efficiency and power characteristics than higher ratio gearboxes Therefore the WG 206 015 x gearbox is preferable over the W G 206 020 x gearbox for this application 04 2009 2nd Edition IronH orse Worm Gearbox User M anual B 3 Appendix B Gearbox Selection TE A on _ _ JJJ _ _______ _ J 8 Check results against original speed and torque requirements a Conveyor speed motor speed gearbox ratio pulley ratio 1725 rpm 15 14 4 2 5 20 rpm b M aximum real torque available at conveyor gearbox thermal torque pulley ratio 673 in 1b 14 4 2 5 3876 in Ib c M aximum design torque available at conveyor gearbox mechanical torque pulley ratio service factor 1002 in 1b 14 4 2 5 1 25 4617 in Ib The speed is correct as required and both maximum torque values are greater than the 2700 in Ib required by the load 9 Select a motor and check torque transmitted to the load From the gearbox spec tables WG 206 015 x efficiency 85 maximum thermal input power 1 40 hp maximum mechanical input power 1 0 SF 2 09 hp maximum mechanical input power 1 25 SF rated max mechanical input power SF 2 09 hp 1 25 1 67 hp maximum allowable motor power 1 40 hp select nominal 1hp motor Selec
29. t 1hp motor and check for adequate torque at the load Torque Power Speed conversion factor 1hp 63 025 in Ib rpm Torque Joad 63 025 in lb pm hp geerbox input hp gearbox efficiency motor rpm gearbox ratio pulley ratio 63 025 1 0 85 1725 15 1 14 4 2 5 26834n 46 insufficient torque at load T his torque value is less than the 2700 in Ib required by the load So select and check the next larger nominal motor size which is 1 1 2 hp Since the 206 frame size 15 ratio gearbox does not meet the required 1 1 2 hp thermal rating choose the W G 237 015 x gearbox Select 1 1 2 hp motor and WG 237 015 x gearbox and check for adequate torque WG 237 015 x gearbox efficiency 84 maximum thermal input power 1 55 hp maximum mechanical input power 1 25 SF 2 64 hp 1 25 2 11 hp maximum allowable motor power 1 55 hp nominal 1 1 2 hp motor gearbox ratio is still 15 1 and OH L rating is increased to 900 Ib so the previous pulley calculations step 7 remain sufficient smaller pulleys can be calculated and selected for this gearbox if desired Torque Power Speed conversion factor 1hp 63 025 in lb rpm Tload 63 025 in Ib rpm hp 1 5hp 84 1725 rpm 15 1 14 4 2 5 3977 in Ib gt 2700 in Ib sufficient torque at load Final gearbox and motor selection 1 1 2 hp motor WG 237 015 x gearbox B 4 IronH orse Worm Gearbox User M anual 2nd Edition 04 2009 THIS
30. t based on the strength and durability of its components Some applications require the gearbox M echanical Ratings to be reduced by a Service Factor Mounting Position The relationship of the input and output shafts of a gearbox relative to horizontal A 2 IronH orse Worm Gearbox User M anual 2nd Edition 04 2009 Appendix A Glossary of Terms Nominal M otor H orsepower The highest horsepower 1800 rpm motor that can be used with the gearbox under 1 0 service factor conditions T his rating decreases as the motor speed decreases and asthe service factor increases Output H orsepower The amount of horsepower available at the output shaft of a gearbox O utput horsepower is always less than the input horsepower due to the efficiency of the gearbox O verhung Load A force applied at right angles to a shaft beyond its outermost bearing This shaft bending load must be supported by the bearing O verhung load ratings are listed for each gearbox size and should not be exceeded Some applications require the gearbox O verhung Load rating to be reduced by aK Factor and or a Service Factor O verhung Load Factor K Factor Prime M over In industry the prime mover is most often an electric motor Occasionally engines hydraulic or air motors are used Special considerations are called for when other than an electric motor is the prime mover Self Locking The inability of a reducer to be driven backwards by its l
31. the same as the part number that you ordered 04 2009 2nd Edition IronH orse Worm Gearbox User M anual l l 3 Chapter 1 Getting Started Part Number Explanation WG 262 060 R Output Type D Dual shaft H Hollow shaft R Right hand shaft Ratio Three digit input for output of 1 Example 060 60 1 ratio Frame Size center distance 175 1 75 206 2 06 237 2 37 262 2 62 Gearbox Type Series Designation WG Worm gear Nameplate Information Gearbox Frame Size center distance A N PEED REDUCER IRONHORSE WAV ALUTOMATIONDIRECT COM CARON EA1175 Mco WG 175 060 R WMECANON 70606827 Gearbox Serial Gearbox Ratio Gearbox M odel PAPE Country of Origin 1 4 IronH orse Worm Gearbox User Manual 2nd Edition 04 2009 Chapter 1 Getting Started lronHorse Worm Gearbox Specifications 1 1 1 DO 1 1 p 53 Maximum Ratings 2 O 1750 rpm Input z Mechanical 6 Thermal Sl er w E SPRS Part Number EN E a S 2la Bela Bis a es Ejla Blo z s 23 SSS e g 2 alles 2 ss 2 El e ses e g Sg l ec ac g o 5 58 lt 3552133 82 s 2 Er 22 Gi gt 2 SS elie Sot 6b 83 LEE FIZ 6 8 815 WG 175 005 D D 23 WG 175 005 H 5
32. the vent plug Refer to the next subsection for more information e Align all shafts accurately since improper alignment can result in premature failure U se flexible couplings to compensate for slight misalignment e For hollow shaft output gearboxes U se anti seize compound when inserting the load shaft into the hollow output shaft It is preferrable to size the load shaft with sufficient length to allow complete insertion through the hollow output shaft of the gearbox This allows equal support of the load shaft by both of the output shaft bearings and permits the use of the output shaft setscrews to lock the two shafts together on both sides of the gearbox At minimum the load shaft should be inserted at least half way into the hollow output shaft and secured with the setscrews on the insertion end of the gearbox e Mount the gearbox to a rigid foundation and use the maximum possible bolt size Periodically inspect the mounting bolts Do NOT mount gearbox vertically with input shaft pointing downward Refer to the lubrication section of this chapter for allowable mounting orientations e Optional gearbox and motor mounting bases are available for ease of mounting and alignment e M ount auxiliary drive components such as sprockets gears and pulleys on the gearbox shaft as close to the housing as possible in order to minimize the effects of overhung loads Avoid force fits that might damage bearings or gears e Check and record gea
33. tionD irect nie toute garantie expresse ou implicite d aptitude l emploi en ce qui a trait aux activit s risque deve Pour des renseignements additionnels touchant la garantie et la s curit veuillez consulter la section M odalit s et conditions de notre documentation Si vous avez des questions au sujet de l installation ou du fonctionnement de cet quipement ou encore si vous avez besoin de renseignements suppl mentaires n h sitez pas nous t l phoner au 770 844 4200 Cette publication s appuie sur l information qui tait disponible au moment de l impression A la soci t AutomationD irect nous nous efforcons constamment d am liorer nos produits et services C est pourquoi nous nous r servons le droit d apporter des modifications aux produits ou aux publications en tout temps sans pr avis ni quelque obligation que ce soit La pr sente publication peut aussi porter sur des caract ristiques susceptibles de ne pas tre offertes dans certaines versions r vis es du produit Marques de commerce La pr sente publication peut contenir des r f rences a des produits fabriqu s ou offerts par d autres entreprises Les d signations des produits et des entreprises peuvent tre des marques de commerce et appartiennent exclusivement a leurs propri taires respectifs AutomationD irect nie tout int r t dans les autres marques et d signations Copyright 2008 2009 Automationdirect com Incorporated Tous droits r serv s N
34. ulle partie de ce manuel ne doit tre copi e reproduite ou transmise de quelque facon que ce soit sans le consentement pr alable crit de la soci t Automationdirect com Incorporated AutomationD irect conserve les droits exclusifs l gard de tous les renseignements contenus dans le pr sent document IRONHORE WORM GEARBOX User MAN WAUTOMATIONDIRECT Please include the M anual Number and the M anual Issue both shown below when communicating with Technical Support regarding this publication Manual Number WG USER M WO Issue 2nd Edition Issue D ate 04 2009 Publication History Issue Date Description of Changes First Edition 06 2008 Original Issue ist Ed Rev A 06 2008 Gearbox mounting orientation Chapter 2 Second Edition 04 2009 Added hollow shaft gearboxes THIS PAGE INTENTIONALLY LEFT BLANK IRONHORSE VORM GEARBOX User MN TABLE OF CONTENTS Chapter 1 Getting Started 1 1 1 Manual Overview seis ie tiv ed cede beers a a A 1 2 Overview of This Publication sra ue eee a decent eee eee A 1 2 Who Should Read This Manual ie ie sise ase 1 2 spa SUpport A es bane nae eas Oh er Er 1 2 Special MODUS au te aan eens Pate ie sree EEE EAL bee RE 1 2 lIronHorse Worm Gearbox Introduction 1 3 Purpose of Worm Gearboxes u ra SS a ee d s aa ENE ee 1 3 Package COT ES area di dde ei een 1 3 Part Number Explanation circ
35. ume any responsibility for your product design installation or Operation O ur products are not fault tolerant and are not designed manufactured or intended for use or resale as on line control equipment in hazardous environments requiring fail safe performance such asin the operation of nuclear facilities aircraft navigation or communication systems air traffic control direct life support machines or weapons systems in which the failure of the product could lead directly to death personal injury or severe physical or environmental damage High Risk Activities AutomationD irect specifically disclaims any expressed or implied warranty of fitness for H igh Risk Activities For additional warranty and safety information see the Terms and Conditions section of our catalog If you have any questions concerning the installation or operation of this equipment or if you need additional information please call us at 770 844 4200 T his publication is based on information that was available at the time it was printed At AutomationD irect we constantly strive to improve our products and services so we reserve the right to make changes to the products and or publications at any time without notice and without any obligation This publication may also discuss features that may not be available in certain revisions of the product This publication may contain references to products produced and or offered by other companies The product and com
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