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1. Taper Bushing Sizes M1200 amp M1210 Driven shafts are retained on M1200 amp M1210 drives with a thrust plate and three cap screw arrangement With the driven shaft keyway at the 12 o clock position slide bushing onto the driven shaft flange end first and position the keyway slot over the shaft keyway The bushing may have to be opened slightly to assist in installation Insert a screwdriver into the slot in the bushing and very lightly pry open until the bushing slides onto the shaft Insert the drive key furnished with the bushing into the shaft keyway Installation of Shaft Mounted Drives Sizes M1200 M1210 1 Before lifting the drive into position rotate the high speed shaft until the hollow shaft keyway will be in position to line up with the driven shaft key 2 Lift the drive into position and slide onto the drive shaft taking care that the driven shaft key seats into the hollow shaft keyway DO NOT hammer or use excessive force 3 Align three holes in hollow shaft thrust plate with tapped holes in end of driven shaft Insert fasteners through thrust plate and engage tapped holes in driven shaft one to two turns by hand to ensure that fasteners are not cross threaded 4 Tighten fasteners to the torque vales 10 listed below M24 x 3 640 Nm 470 lb ft for metric based bushing bores 1 250 7UNC 1400 Nm 1060 lb ft for inch based bushing bores 5 Re install low speed shaft cover
2. BP Oil Co Energrese LS EP2 Chevron U S A Inc ndustrial Grease Medium Citgo Petroleum Corp Premium Lithium Grease No 2 Conoco Inc EP Conolith Grease No 2 Exxon Company U S A Unirex N2 E F Houghton amp Co Cosmolube 2 mperial Oil Ltd Unirex N2L endall Refining Co ulti Purpose Lithium Grease L421 Keystone Div Pennwalt Corp Zeniplex 2 Lyondell Petrochemical ARCO Litholine H EP 2 Grease Mobil Oil Corp obilith 22 obil Oil Corp obilith SHC 460 Petro Canada Products ultipurpose EP2 Phillips 66 Co Philube Blue EP Shell Oil Co Alvania Grease 2 Shell Canada Limited Alvania Grease 2 Sun Oil Co Ultra Prestige EP2 Texaco Lubricants Premium RB Grease Unocal 76 East amp West Unoba EP2 Valvoline Oil Co ultilube Lithium EP Grease High performance synthetic alternate CAUTION LUBRICANTS amp INTERNAL BACKSTOPS Do not use lubricants with anti wear additives or lubricant formulations including PTFE Teflon lead derivatives graphite or molybdenum disulfide in drives equipped with backstops Some lubricants in Table 8 may contain several of these additives Synthetic Lubricants Synthetic lubricants of the polyalphaolefin type are recommended for cold climate operation high temperature applications extended temperature range all season operation and or extended lubricant change intervals The proper viscosity grade of synthetic lubricant is given in Table 9 Refer to Table 10 for Synthetic lu
3. 28 8 35 2 61 2 74 8 135 165 198 242 288 352 414 506 Es n ur 134 164 284 347 626 765 918 1122 1335 1632 1919 2346 Manufacturer Lubricant Clarity Synthetic PM Oil 220 m m Chevron U S A Inc p ad Syn Gear Lube Tegra 150 t Syn Gear Lube Tegra 220 Syn Gear Lube Tegra 320 Syn Gear Lube Tegra 460 t Syncon R amp 0 32 Syncon R amp 0 68 iss Syncon R amp 0 220 t Syncon R amp 0 460 t is Pus Syncon EP 150 t Syncon EP 220 t Syncon EP 320 t Syncon EP 460 11 Dryden Oil Co Drydene SHL Lubricant 32 Drydene SHL Lubricant 68 Drydene SHL Lubricant 150 Drydene SHL Lubricant 220 Drydene SHL Lubricant 320 Drydene SHL Lubricant 460 Co Wed Teresstic SHP 32 Teresstic SHP 68 Teresstic SHP 150 Teresstic SHP 220 Teresstic SHP 320 Teresstic SHP 460 D e Spartan Synthetic EP 150 t Spartan Synthetic EP 220 Spartan Synthetic EP 320 Spartan Synthetic EP 460 Mobil 01 Cr SHC 624 SHC 626 SHC 629 SHC 630 SHC 632 SHC 634 et ad Mobilgear SHC 150 Mobilgear SHC 220 Mobilgear SHC 320 Mobilgear SHC 460 Pennzgear SHD 32 Pennzgear SHD 68 Pennzgear SHD 150 Pennzgear SHD 220 Pennzgear SHD 320 Pennzgear SHD 460 Pennziol Products Co Super Maxol S 68 t Super Maxol S 150 t Super Maxol S 220 1 Super Maxol S 320 t Super Maxol S 460 t Petro Canada Products T Super Gear Fluid 150EP t Super Gear Fluid 220EP Super Gear Fluid 320EP Super Gear Fluid 460EP Syndustrial P Oil 32 Phillips 66 Comp
4. ADJUSTING Vr SCREW x 5 CARRIAGE PIN JL LOCKING LII PN LIT PLATE JAM NUT SUPPORT BAR ROD END r RETAINING PIN RING Q ne sg RE SUPPLIED BY tL NUN Z Z CUSTOMER SECTION A N spacer LIFT POINTS FIGURE 4 Rexnord Industries LLC 3001 W Canal St Milwaukee WI 53208 4200 168 050 Telephone 414 342 3131 Fax 414 937 4359 PN 2124650 November 2008 e mail info rexnord com web www rexnord com Supersedes 07 08 Appendix E Falk Drive One Enclosed Gear Drives Sizes M1130 thru M1210 e Type D Series Page 20of 26 REXN RD Electric Fan Installation amp Maintenance Installation The installation and troubleshooting of electric cooling fans are to be carried out by a qualified electrician according to the applicable local state province and federal codes Inspect for any damage that may have occurred during transit Check all bolts screws set screws etc Retighten as required Before installing rotate the blade to be sure it does not rub Adjust if necessary Before installation read the entire manual carefully This guide is pertinent only to electric fans furnished by the Factory and manvfactured by Multifan Inc can be verified from nameplate on the electric fan In the event the electric fan furnished by
5. Falk Drive One Enclosed Gear Drives REXN RD Page 10 of 26 Sizes M1130 thru M1210 e Type D Series TABLE 13 Fastener amp Wrench Sizes DRIVE SIZE TM M1130 M1140 M1150 M1160 M1170 M1180 M1190 M1200 M1210 Diamghar 185mm 205mm 225mm 240mm 260mm 280mm 295mm Bushing 13 8 1 8 9 9 4 10 2 11 0 11 6 Nut 581 644mm 709mm 754mm 817mm 880mm 927mm 22 9 25 4 27 9 29 7 322 34 6 36 5 Bushing Screw Size M8 M8 M8 M8 M8 M8 M8 Hex Size 4mm 4mm 4mm 4mm 4mm 4mm 4mm wad m Inspection Screw Size M12 M12 M12 M12 M12 M12 M12 M12 M12 Cover Wrench Size 19mm 19mm 19mm 19mm 19mm 19mm 19mm 19mm 19mm Screw Size M12 M16 M16 M20 M20 M24 M24 M24 M24 Wrench Size 19mm 24mm 24mm 30mm 30mm 36mm 36mm 36mm 36mm Magnetic Plug Size 3 4 BSPT 3 4 BSPT 3 4 BSPT 3 4 BSPT 1 0 BSPT 1 0 BSPT 1 0 BSPT 1 0 BSPT 1 0 BSPT Drain Plugs Wrench Size 14mm 14mm 14mm 14mm 19mm 19mm 19mm 14mm 14mm Other Plugs Plug Size 3 4 BSPT 3 4 BSPT 3 4 BSPT 3 4 BSPT 1 0 BSPT 1 0 BSPT 1 0 BSPT 1 0 BSPT 1 0 BSPT Hex Size 12mm 12mm 12mm 12mm 17mm 17mm 17mm 17mm 17mm Torque Nut Size M30 M30 M36 M36 M36 M36 M48 M48 M48 Arm Wrench Size 46mm 46mm 55mm 55mm 55mm 55mm 75mm 75mm 75mm Grease Screw Size M6 M8 M6 M8 M6 M8 M6 M8 M6 M8 M8 M8 M8 M8 purge Wrench Size 10 13 10mm 13mm 10mm 13mm 10mm 13mm 10mm 13mm 13mm 13mm 13mm 13mm Shaft Fan Screw Size M8 M8 M8 M8 M8
6. Removal of Shaft Mounted Drives Sizes M1200 amp M1210 1 Remove low speed shaft cover 2 Remove three thrust plate fasteners retaining ring and thrust plate from the hollow shaft 3 Select the backing bolts from the table above and install them into the three threaded holes in the end of the driven shaft The head of the backing bolts provides a working surface for the removal bolts 4 Re insert the thrust plate and retaining ring into the hollow shaft and select the removal bolts from the table above 5 Thread three removal bolts into the thrust plate until they contact the backing bolt heads 6 Tighten the removal bolts equally in stages to the torque indicated in the table above After torquing the bolts as instructed strike the bolts sharpy with a hammer and re torque the bolts if separation of the drive from the driven shaft did not occur Repeat this procedure re torquing the bolts after each blow until separation occurs 7 Prepare drive for lifting by disconnecting the torque arm 8 Slide the drive from the bushing The bushing can be left in place or removed as required If bushing will not slide off the shaft insert a small prybar into the split of the bushing and pry the split open slightly to loosen the bushing and remove from the shaft Shaft Connections WARNING Provide suitable guards in accordance with local and national standards COUPLING CONNECTIONS The performance and life of any cou
7. OIL PUMPS When selecting a lubricant for a gear drive equipped with an oil pump cold temperature oil viscosity is important Lubricant viscosity at start up generally should not exceed 1725 cSt 8 000 SSU When exceeding this viscosity pump cavitation is possible reducing oil circulation and possibly damaging the pump A sump heater may be required or it may be possible to use a lower viscosity oil to minimize pump cavitation Petroleum Based Lubricants refer to the Factory R amp O GEAR LUBRICANTS Table 7 Industrial type petroleum based rust and oxidation inhibited R amp O gear lubricants are the most common and readily available general purpose gear lubricants the sulfur phosphorus type EXTREME PRESSURE EP LUBRICANTS Table 8 For highly loaded gear drives or drives loaded in excess of original estimates industrial type petroleum extreme pressure lubricants are preferred The EP lubricants currently recommended are of WARNING EP LUBRICANTS IN FOOD PROCESSING INDUSTRY EP lubricants may contain toxic substances and should not be used in the food processing industry without the lubricant manufacturers approval Lubricants which meet USDA H1 classification are suitable for food processing applications TABLE 10 Synthetic Lubricants Polyalphaolefin Type vi ei ea i 0s 25 4s 55 6 cee 32 68 150 220 320 460 Viscosity Grade P
8. e mail info rexnord com web www rexnord com Falk Drive One Enclosed Gear Drives Appendix D REXN RD D Series e Sizes M1140 thru M1210 Page 19 of 26 Close Coupling Ensure that adjusting rod locking plate is NOT installed at this time as it will prevent adjustment of the torque arm assembly Assemble anchor bracket to male rod end with a spacer on each side and secure with pin and retaining ring Mount the coupling hubs to the drive high speed shaft and motor shaft Hubs are to be mounted flush with the end of the shafts unless otherwise noted coupling hubs may be furnished with an interference fit Mount the motor to the bell housing Lifting the Alignment Free Drive apply Loctite 242 or equivalent to fastener threads and Lifting points are provided on the corners of the motor end of tighten to proper torque Install high speed coupling per the bell housing see Figure 4 Lift by these and the provisions coupling instructions provided on the drive housing itself to maneuver the drive DO Guards and Covers NOT lift by the motor lifting eye Install bell housing covers top and bottom Install air Mounting the Drive deflectors on the top bottom and both sides of the gear drive The bends of the deflectors are perforated to allow positioning of the deflectors Air deflectors should be positioned approximately 25mm 1 inch from the nearest housing surface by bending deflector towards or away from the drive
9. gauge between the control valve and the exchanger to determine actual flow rate Discharge water to an OPEN DRAIN to prevent back pressure INTERNAL COOLING TUBES Refer to Appendix E for installation operation and maintenance of internal cooling tubes Lubrication Systems SPLASH LUBRICATED DRIVES Standard horizontal shaft type DH amp DB drives are splash lubricated The lubricant is picked up by the revolving elements and distributed to the bearings and gear meshes OIL PUMP LUBRICATED DRIVES Types DV and DX are equipped with an external oil pump to provide oil to the upper bearings and gear meshes The system is composed of an electric motor driven gear pump and an internal distribution network with relief valve set at 30 psi The pump system may be furnished with a 50 or 60Hz 3 phase electrical motors based on the selection Refer to the pump motor nameplate and Table 5 for electrical requirements Wire the motor for correct rotation as indicated by the rotation arrow Optional accessories include an oil filter and flow indicator with switch The flow indicator has a single pole double throw switch rated at 15A 125V 7A 250V maximum Connect the flow indicator switch with the prime mover control circuitry to prevent drive operation without the lubrication system Other types of gear drives may also be equipped with oil pumps for special lubrication considerations or external cooling TABLE 5 Oil Pump Electric
10. 07 08 Appendix D Falk Drive One Enclosed Gear Drives Sizes M1140 thru M1210 e Type D Series Page 18of 26 REXN RD Alignment Free Assembly and Installation Cast Design Introduction The Alignment Free Drive design consists of a shaft mounted gear drive bell housing torque arm motor and coupling When assembled the gear drive bell housing and motor locate off registers resulting in alignment of the shafts Therefore no additional alignment is required for the high speed coupling Assembly Instructions The Bell Housing is fastened to the gear drive s high speed end using capscrews through the four mounting holes on that face with a nut and lock washer see Table 1 for size and torque Apply Loctite 242 or equivalent to mounting fastener threads The bell housing will locate on the bevel head of the gear drive Read instructions provided with high speed coupling prior to assembly TABLE 1 Tightening Torques Tightening Torque DRIVE SIZE Bolt Size Nm Ib ft M1140 M24 780 570 M1150 M24 780 570 M1160 M24 780 570 M1170 M30 1540 1140 M1180 M30 15640 1140 M1190 M36 2720 2000 M1200 M36 2720 2000 M1210 M36 2720 2000 High Speed Shaft Fan High speed shaft fan is standard on all Drive One Alignment Free Drives Fan size and position is dependent on bell housing casting and high speed coupling not drive size Assemble fan to fan hub apply Loctite 242 or equivalent to fastener thr
11. 7 A temperature switch is provided to control oil sump 10 Remove proper condensation plug See Figure 3 below temperature See Figure 2 for proposed wiring There are Do not discard Plug is to be used during cleaning two separate circuits in the temperature switch The low circuit is to operate the electric fan It is recommended the AIR SUPPLY AND TEMPERATURE Sufficient air supply over E BUE the motor must be assured in all circumstances Limits of SET AT AO C operating ambient temperature are 14 F to 113 F 10 C to fan motor be operated by the temperature switch through a FIGURE 3 motor starter relay consult applicable local and national electrical codes The high circuit is provided to operate Mounting Positions either a high temperature alarm or main motor shutdown For Position For Position Nererise A amp B copper or brass Remove Plug 1 Remove Plug 2 fastening materials FIGURE 2 POSITION A POSITION B POSITION C PROPOSED TEMPERATURE SWITCH WIRING DIAGRAM FOR ELECTRIC FANS n Li 2 iii 5 CONTROL VOLTAGE III po FALK PART NO l l 932716 NEMA 4 amp 13 LOW CIRCUIT ON en l ms V START FAN PURPLE 9 MS MOTOR k MOTOR j NOTES HIGH CIRCUIT l l et 45 C YELLOW epus BROW 4 RESTRICTION ON USE Fan blade material is b L
12. END CLEVIS SPACER MALE RETAINING D RING AM NUT SPACER JAM NUT J U 3x ROD END RETAINING XL END SPACER TORQUE RING 3 WH FEMALE prm PIN KR ANCHOR TORQUE RING NS BRACKET ANCHOR ARM PIN A M NJ BRACKET MOUNTING HARDWARE MOUNTING HARDWARE SUPPLIED BY CUSTOMER SUPPLIED BY CUSTOMER FIGURE 3 FIGURE 4 ANCHOR BRACKET RETAINING RING SPACER ROD END ROD END SPACER RETAINI TORQUE ROD END RING um HEAD CORRECT INCORRECT ANCHOR LINK ASSEMBLY LINK ASSEMBLY ROD END HEADS MOUNTING HARDWARE SUPPLIED BY CUSTOMER PARALLEL NOT PARALLEL 168 050 November 2008 PN 2124650 Supersedes 07 08 Rexnord Industries LLC 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info rexnord com web www rexnord com REXN RD Type D Series e Sizes M1130 thru M1210 Falk Drive One Enclosed Gear Drives Appendix C Page 15 of 26 Swing Base Installation Introduction The Drive One Swing Base is a welded steel structure designed to support a motor and a right angle Type DB shaft mounted drive The swing base itself is a length of square cross sectional tubing with plates welded to it for the motor and drive The motor and drive plates are not machined and are supported by gussets for additional strength A torque arm attaches to the tube section near the motor end of the swing base M
13. M8 M8 M12 M12 Shroud Wrench Size 13mm 13mm 13mm 13mm 13mm 13mm 13mm 18mm 18mm Shaft Fan Screw Size M6 M8 M6 M8 M6 M8 M8 M8 M8 M8 M10 M10 Setscrew Hex Size 3mm 4mm 3mm 4mm 3mm 4mm 4mm 4mm 4mm 4mm 5mm 5mm Lubricant Changes GUN through the seal cavity until fresh grease flows out along OIL ANALYSIS REPORT Checking oil condition at regular the shaft Wipe off purged grease Refer to Table 11 for NLGI intervals is recommended In the absence of more specific 2 greases Some of these greases of the IP type and may limits the guidelines listed below may be used to indicate when contain toxic substances not allowed in the food processing to change oil industry A grease that meets the USDA H1 classification is suitable for food processing applications 1 Wat tent i ter th 05 ater content is greater than 500 ppm 0 05 CAUTION Rapid greasing with a power grease gun can force 2 Iron content exceeds 150 ppm grease inward past the seals causing seal leaks 3 Silicon dust dirt exceeds 25 ppm GREASE LUBRICATED BEARINGS TYPES DV AND DX Most vertical low speed shaft drives have a grease lubricated lower low speed bearing Grease bearings during oil changes PETROLEUM LUBRICANTS For normal operating conditions or at intervals of every 6 months or 2500 hours of operation change gear oils every 6 months or 2500 operating hours whichever is less whichever occurs first Change oil more frequently when gear drives o
14. November 2008 e mail info Qrexnord com web www rexnord com Supersedes 07 08 Appendix F Falk Drive One Enclosed Gear Drives Sizes M1130 thru M1210 e Type D Series Page 22of 26 REXN RD Internal Cooling Tubes Installation amp Maintenance Cooling Tube Description The internal cooling tube accessory is a network of finned cooling tubes Factory installed in the base of a drive housing for heat removal The cooling tubes operate submerged in the oil of the drive sump The revolving elements provide the necessary oil flow around the cooling tubes for efficient heat transfer No oil pumps are required The external requirement for the cooling tube system is a clean water hookup supplying a flow rate of 2 gallons 8 liters per minute at a maximum temperature of 90 F 32 C An inlet water temperature of 70 F 21 C is required to obtain the system catalog thermal power rating with a sump oil temperature of 200 F 93 C The number of cooling tubes required varies with drive size type and number of reductions Cooling tubes are connected in series to maintain the optimum water flow velocity in the tubes with the specified water flow rate of 2 to 5 gallons 8 to 19 liters per minute Note A typical Falk PC cooling assembly requires between 2 to 70 gallons 8 to 265 liters of water per minute depending upon PC size and cooling requirements All cooling tube system connections are made outside of the housing to
15. coupling on the high speed shaft of the gear drive per fluid coupling instructions If a shaft fan is required remove every other of the twelve delay fill chamber fasteners Install the fan adapter ring to the fluid coupling using the long socket head cap screws provided Place a mounting post between the delay fill chamber flange and the adapter ring as shown in Figure 1 After all fasteners and mounting posts are installed tighten cap screws to the torque specified in Table 2 Install the six fan segments to the outer bolt circle of the adapter ring see Table 2 for tightening torque FIGURE 1 FAN FAN ADAPTER SEGMENT RING DRIVE LONG MOUNTING CAP SCREW POST Once the fluid coupling is installed the motor adapter plate can be mounted to the bell housing also being located by a register Measurements must be taken to accurately position the motor half of the coupling hub on the motor shaft First TABLE 2 Fan Mounting Tightening Torques Fastener Fastener Tightening Torque Location Size Nm ftelb 1420HFDD M12 80 59 1480HFDD M12 80 59 1584HFDD M14 130 Fan Segment M8 20 15 Fan Hub M6 10 75 For close coupling only measure the distance from the motor mounting face to the end of the motor shaft A Then measure the distance from the motor adapter plate face to the hub on the fluid coupling B Finally measure the distance from the hub flange to the hub end C The desired gap can be fo
16. drive performance Change lube with change in on D ambient temperature if required Refer to Table 9 for synthetic Lol 9 2 1 T lubricant viscosity recommendations ate RELIEF Grease Lubricated Seals Depending on the frequency and FITTING Pug degree of contamination at least every six months or when changing oil in the drive purge contaminated grease from seals by slowly pumping fresh grease WITH A HAND GREASE 168 050 Rexnord Industries LLC 3001 W Canal St Milwaukee WI 53208 4200 November 2008 PN 2124650 Telephone 414 342 3131 Fax 414 937 4359 Supersedes 07 08 e mail info rexnord com web www rexnord com REXN RD Falk Drive One Enclosed Gear Drives Owners Manual Type D Series e Sizes M1130 thru M1210 Page 11 of 26 Stored amp Inactive Gear Drives Each gear drive is protected with a rust preventative that will protect parts against rust for a period of 4 months in an outdoor shelter or 12 months in a dry building after shipment from the Factory If a gear drive is to be stored or is inactive after installation beyond the above periods drain oil from housing and spray all internal parts with a rust preventative oil that is soluble in lubricating oil or add Motorstor vapor phase rust inhibitor at the rate of 1 05 liters per cubic meter one ounce per cubic foot of internal drive space 596 of sump capacity Refer to Table 12 for Motorstor quantities Rotate the shafts several times
17. eliminate the possibility of water leakage into the drive sump Seal rings are used at all connections for ease of disassembly and reassembly The standard cooling tubes are 90 10 copper nickel alloy with aluminum fins Cooling tube connections are cadmium plated mild steel with Buna N seal rings Water connections are 500 14 NPT fittings located at the high speed end The water outlet is located on the high speed end of the drive The water inlet connection is a straight fitting located on the lowest cooling tube in the drive The water outlet connection is a right angle fitting faced up located on the uppermost tube in the drive The cooling tube system connections are selected and located so that the cooling system is always full of water during operation for maximum heat transfer The water inlet and outlet connections may be moved to the opposite end of the drive by removing the water inlet outlet and all loop end fitting assemblies and by reinstalling them on the same tubes at the opposite end of the drive Refer to the Maintenance Instructions on Page 22 and Figures 7 amp 8 on Page 23 for disassembly and reassembly Installation amp Operation 1 Connect the 500 14 NPT straight water inlet fitting to a source of clean fresh water Water must be regulated to a minimum of 2 gallons 8 liters per minute and must not exceed 90 F 32 C 2 Connect the 500 14 NPT right angle water outlet fitting faced up to a
18. mount with torque arm at maximum angle 5 The support to which the clevis bracket is mounted must sustain the load from the torque reaction shown in Table 1 The maximum load reaction through the torque arm occurs when the torque arm is located in the extreme off angle position Use Class 8 8 fasteners to anchor the clevis bracket Refer to Table 2 for fastener size and tightening torque TABLE 2 Tie Rod Clevis Bracket fastener Tightening Torque Fastener Tightening Torque Nm lb ft Size t Steel Foundation Concrete Foundation DRIVE SIZE M1130 M1140 M20 x 2 5 415 305 330 246 M1150 M1160 M24 x 3 0 705 530 570 420 M1170 M1210 M30 X 3 5 1440 1060 1150 850 t Class 8 8 fasteners required 6 Bolt the torque arm to both the clevis bracket and the drive anchor bracket and tighten the bolts until seated against the brackets DO NOT bend the bracket as clearance between the clevis brackets and tie rod is necessary 168 050 November 2008 PN 2124650 Supersedes 07 08 Rexnord Industries LLC 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info rexnord com web www rexnord com Falk Drive One Enclosed Gear Drives Appendix B REXN RD D Series e Sizes M1130 thru M1210 Page 13 of 26 Rod End Adjustable Torque Arm Installation Introduction 3 Mount the anchor bracket or clevis to the drive or The Drive One rod end t
19. of 26 Adjustable Torque Arm Installation Introduction The Drive One adjustable tie rod style torque arm is available for all shaft mounted Drive One sizes parallel shaft DH only It is used to support the drive when mounted in a standard horizontal position refer to the Factory for other positions The torque arm is mounted directly to the drive with an anchor bracket The torque arm requires mounting holes in the driven equipment support structure to provide for clevis bracket attachment The customer is responsible for determining the structural integrity of their support member Mounting It is natural for the drive system to move during operation This movement is due to run out from the driven equipment shaft and gear drive low speed shaft Clearance in the torque arm assembly will accommodate the motion of the drive To allow for the movement the torque arm should be centered at its attachment point on the drive system and also centered in the clevis bracket on the support member Over tightening or failure to center the torque arm in the mounting will restrict the drive s motion and will result in premature failure of the drive or driven equipment The torque arm should be perpendicular to the support structure 2 when looking at the end of the drive see Figure 1 ANCHOR BRACKET 90 2 CLEVIS BRACKET FIGURE 1 Installation 1 Position the drive on the driven equipment shaft such that the tor
20. that the torque arm link is centered in the anchor bracket Ideally the anchor bracket mounting holes should be added to the structure after the drive has 7 If the drive system is not horizontal the rod end been secured to the driven equipment linkage can be adjusted within the limits indicated in rtifi int to level the drive NOTE Do not fasten the torque arm to the support or Certi So leveline give siructureat this fime 8 Verify the torque arm link is centered in the anchor 2 Secure the drive to the driven equipment via the TA bracket and is not restricting motion of the drive Bushing shrink disc or rigid coupling connection 9 Some rod ends may be provided with grease fittings for lubricating Grease rod end at every scheduled maintenance or at least every six months See Table 11 for approved greases Rexnord Industries LLC 3001 W Canal St Milwaukee WI 53208 4200 168 050 Telephone 414 342 3131 Fax 414 937 4359 PN 2124650 November 2008 e mail info rexnord com web www rexnord com Supersedes 07 08 Appendix B Falk Drive One Enclosed Gear Drives REXNRD Page 14 of 26 Sizes M1130 thru M1210 e Type D Series FIGURE 1 FIGURE 2 e MOUNTING HARDWARE I ANCHOR _ PROVIDED as i OA BRACKET TORQUE D ARM PIN A ARM PIN v RETAINING PE T RING ROD
21. the Factory is of a special nature manufactured by an alternate fan manufacturer please contact the Factory for appropriate electric fan installation and maintenance instructions General Safety Information Warning To reduce the risk of fire electric shock or personal injury observe the following 1 Use this electric fan only in the manner intended by the manufacture If you have any questions contact Factory 2 Before servicing or cleaning the fan switch the power off at the service panel and lock out to prevent the power from being switched on accidentally 3 Follow all local electrical and safety codes as well as the National Electrical Code NEC and Occupational Safety and Health Act OSHA 4 Fan motor must be securely and adequately grounded 5 All working parts should be grounded 6 When cleaning electrical equipment always use an approved cleaning agent See CLEANING in NOTES section Page 18 7 For general ventilation and cooling use only DO NOT use if hazardous or explosive materials and vapors are present Guidelines For Installation Before connecting the electric fan check if the information on the fan motor name plate is in accordance with the actual main supply voltage phase and frequency Warning To reduce the risk of fire electric shock or personal injury observe the following 1 Switch off the main power supply and lock out before installing servicing or making connections to th
22. to release the drive from the driven shaft refer to Appendix G for backing and removal bolt sizes user supplied To use remove thrust plate retaining ring and thrust plate install backing bolt and reinstall thrust plate with retaining ring Remove bushing nut retaining ring Install removal bolt in thrust plate and tighten against backing bolt to release drive from driven shaft insert screwdriver in thrust plate key slot to engage hollow shaft keyway to prevent thrust plate rotation while tightening removal bolt Prepare drive for lifting by disconnecting the torque arm Slide the drive from the bushing The bushing can be left in place or removed as required If bushing will not slide off the shaft insert a small prybar into the split of the bushing and pry the split open slightly to loosen the bushing and remove from the shaft 168 050 November 2008 PN 2124650 Supersedes 07 08 Rexnord Industries LLC 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info Qrexnord com web www rexnord com Falk Drive One Enclosed Gear Drives Owners Manual Type D Series e Sizes M1130 thru M1210 Page 5 of 26 Backing Bolt Size amp Max Length M24 x 3x 45 mm 1 250 7UNC x 3 00 inch Bushing Removal Bolt Size amp Max Tightening Torque Size Minimum Length Nm lb ft 190 200 mm M30 x 3 5 x 200 mm 1355 1000 7 50 8 00 inch 1 500 6UNC x 7 50 inch 1125 830
23. 1150 thru M1210 Page 17 of 26 line up For fill angles greater than 90 rotate the fill plug downward until the marks line up When the proper marks are in line fill the fluid coupling with recommended fluid until fluid appears at the lip of the fill hole Close Coupling If the drive requires a shaft fan mount the fan hub on the high speed shaft of the gear drive see Figure 3 See Table 4 for shaft protrusion based on drive size Apply Loctite 242 or equivalent to hub setscrews and tighten into hub Mount the fan adapter ring to the fan hub Install six fan segments to the outer bolt circle on the adapter ring to complete the fan see Table 2 for fastener tightening torque FIGURE 3 FAN ADAPTER PNS DRIVE lt FAN FAN SHAFT HUB SEGMENT PROTRUSION TABLE 4 Fan Hub Location Shaft Protrusion DRIVE SIZE mm Inch M1150 105 4 13 M1160 110 4 33 M1170 115 4 53 M1180 125 4 92 M1190 130 5 12 M1200 178 7 01 M1210 178 7 01 Mount the motor to the motor adapter plate on the bell housing before installing the coupling Once the motor is secured measure the distance D between the end of the motor shaft and the high speed shaft of the drive see Figure 4 Subtract the distance D from the length of the spacer coupling BE Then divide this value in half to find the overhang of each hub Overhang BE D 2 The overhang will be negative this is the amount each hub overhangs the shaft Once t
24. 3A Equivalent Tightening Torque t Required Torque Person s Weight Length of Handle Nm lb ft kg Ibs mm ft M1130 380 280 80 100 180 220 460 610 1 5 2 M1140 450 a 80 100 E 610 915 2 3 M1150 450 332 80 100 180 220 610 915 2 3 M1160 520 384 80 100 180 220 610 915 2 3 M1170 630 465 80 100 180 220 915 1220 3 4 M1180 770 568 80 100 180 220 915 1220 3 4 M1190 900 664 80 100 180 220 1220 1525 4 5 If a torque wrench is not available the torque can be approximated by applying the given weight at the given distance from the nut wrench handle 3 feet from the nut Apply Loctite 243 or equivalent to threads of the setscrew Tighten the setscrew to 10 Nm 90 lb in For drives subjected to vibratory conditions refer to Step c b Optional TA Bushing Nut Tightening When the required tightening torque of the TA Bushing nut can not be measured at the low speed shaft the torque multiplying characteristic of the drive can be utilized Rotating the high speed shaft of the drive while holding the TA Bushing nut stationary will allow a large torque to be reached Fix the TA Bushing nut by securing a spanner chain or pipe wrench to the nut Allow the wrench to contact a surface that will hold the force when tightening WARNING Make sure the wrench will not slip and cause damage or injury Determine the proper rotation of the high speed shaft to achieve tightening of the stationary nut If the dri
25. 4375 00 0007 62349 6 2549 5 4305 5 4375 4 9375 0 0 0 007 5 9856 60056 49305 4 9375 65000 0 0 0 008 7 1590 7 1800 64920 6 5000 180 6 0000 0 0 0007 69106 6 9306 5 9930 6 0000 5 9375 00 0007 68794 6 8994 59305 5 9375 70000 0 0 0 008 78045 78255 6 9920 7 0000 6 9375 00 0008 7 7725 7 7935 6 9295 6 9375 1190 65000 0 0 0 008 7 5539 7 5749 6 4920 6 5000 6 0000 00 0 007 73055 7 3255 5 9930 6 0000 5 9375 00 0 007 7 2743 7 2943 5 9305 5 9375 000 00 00 9 2224 9 2434 7 9920 8 0000 7500 00 0008 8 8478 8 8688 74920 7 5000 mizo 000 00 0008 2224 9 2434 7 9920 8 0000 7500 00 0008 8 8478 amp 8688 7 4920 7 5000 TAPER BUSHING With the driven shaft keyway at the 12 o clock position slide bushing assembly onto the driven shaft gt gt TABLE 2 N Dimension t Minimum Maximum DRIVE SIZE mm Inches mm Inches M1130 285 11 2 340 13 4 M1140 300 11 8 390 15 4 M1150 310 12 2 410 15 7 M1160 330 13 0 450 17 7 M1170 340 13 4 435 17 1 M1180 380 15 0 515 20 3 M1190 395 15 6 545 21 5 M1200 423 16 78 425 16 84 M1210 423 16 78 425 16 84 t The minimum engagement is necessary for full bushing engagement the maximum engagement is only if a thrust plate will be employed to re
26. 7 08 Owners Manual Falk Drive One Enclosed Gear Drives Sizes M1130 thru M1210 e Type D Series Page 2 of 26 structural steel it is recommended that an engineered design be utilized for a pedestal adapter base or bed to provide sufficient rigidity to prevent induced loads from distorting the housing and causing gear misalignment In the absence of an engineered design it is recommended that a base plate with thickness equal to or greater than the thickness of the drive feet be securely bolted to steel supports and extend under the entire drive as illustrated FOUNDATION CONCRETE If a concrete foundation is used allow the concrete to set firmly before bolting down the gear drive For the best type of mounting grout structural steel mounting pads into the mounting base as illustrated rather than grouting the drive directly into the concrete Continuous Plate Motors and other components mounted on motor plates or motor brackets may become misaligned during shipment ALWAYS check alignment after installation Refer to Page 5 for coupling alignment instructions Gear Drive Alignment FOOT MOUNTED DRIVES Align drive with driven equipment by placing broad flat shims under all mounting pads Jack screw holes are provided by mounting feet to facilitate alignment See Table 13 Page 10 for fastener and wrench sizes Start at the low speed shaft end and level across the length and then the width of the
27. 840 130 000 70 0 0 0 160 184 173 184 763 169 840 170 000 M1180 60 0 0 0 160 179 113 179 733 159 840 160 000 50 0 0 0 160 174 113 174733 149 840 150 000 85 0 0 0 160 201 698 202 303 184 815 185 000 M1190 75 0 0 0 160 196 723 197 303 174 840 175 000 70 0 0 0 160 194 223 194 803 169 840 170 000 60 0 0 0 160 189 223 189 803 159 840 160 000 M1200 200 0 0 0 185 226 087 226 732 199 815 200 000 90 0 0 0 185 221 087 221 732 189 815 190 000 m1210 200 0 0 0 185 226 087 226 732 199 815 200 000 90 0 0 0 185 221 087 221 732 189 815 190 000 Shaft Diameter A B pig Tolerance per AGMA 6109 Nominal Min Max Min Max 3 4375 0 0 0 006 3 8580 38770 3 4315 3 4375 Mil30 3 4875 0 0 0 006 37331 3 7521 3 1815 3 1875 2 9375 0 0 0 006 3 6081 3 6271 2 9315 2 9375 4 1875 0 0 0 007 4 6278 4 6478 4 1805 4 1875 m1140 3 9375 00 0 006 45028 4 5218 3 9315 3 9375 3 4375 00 0006 42528 42718 3 4315 3 4375 4 4375 0 0 0 007 5 1450 5 1650 44305 4 4375 1150 4 1875 0 0 0 007 5 0200 5 0400 4 1805 4 1875 3 9375 00 0006 48950 4 9140 3 9315 3 9375 4 9375 0 0 0 007 5 5920 5 6120 4 9305 4 9375 M1160 44375 00 0007 53420 5 3620 44305 44375 5 9375 00 0007 64855 65055 5 9305 5 9375 mii70 5
28. 90 F 32 C MAX TEMP WATER OUTLET DISCHARGE INTO OPEN DRAIN FE ug BALL VALVE AD JUST MAX yama INLET THERMOMETER WATER FLOW WATER FLOW CONTROLLER RATE WITH FLOW CONTROL OPEN WITH SENSOR BULB amp CAPILLARY FLEXIBLE WATER INLET LINE Figure 6 Thermometer The standard thermometer is a bimetallic dial type instrument Cooling Tube Inlet amp Outlet Connection Assemblies WATER OUTLET 500 14NPT Figure 7 Cooling Tube Loop End Connection Assemblies TAPERED SPLIT RING REMOVED FROM NUT o TAPERED SPLIT RING amp NUT REPLACED WITH JAM NUT 6 Figure 8 Drive Housing Wall Cooling Tube Pipe Bushing 1 250 x 7 50 Male Connector Lenz 100 10 12 Special Lenz Elbow Fitting Falk Part 1199037 Union Elbow Lenz 500 10 Female Elbow Lenz 450 10 168 050 November 2008 PN 2124650 Supersedes 07 08 Rexnord Industries LLC 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info rexnord com web www rexnord com Falk Drive One Enclosed Gear Drives Appendix G REXN RD ER Type D Series e Sizes M1130 thru M1190 Page 25of 26 Thrust Plate amp Fastener Usage Thrust plate usage is optional To use remove hollow shaft cover from g
29. ED WITH LOCTITE PIPE JOINT COMPOUND 30557 P N D004945 4B HEX SOCKET PIPE PLUG SEALED WITH LOCTITE PIPE JOINT COMPOUND 30557 P N D004945 5B INSPECTION COVER IF COVER WAS REMOVED APPLY A CONTINOUOUS BEAD OF LOCTITE 515 GASKET ELIMINATOR P N 99409561 DR TO HOUSING INSPECTION COVER BOLTING SURFAC SURE THAT THE BEAD IS LOCATED INSIDE THE BOLT PATTERN AND CIRCLES EACH BOLT HOLE INSTALL INSPECTION COVER AND TIGHTEN FASTENERS TO 85 Nm 63lb ft INVERTED MOUNT INSPECTION COVER DOWN RELOCATE MAGNETIC DRAIN PLUGS BOTH ENDS FROM 1A TO 1B AND SWITCH THE SOCKET HEAD PLUGS FROM 2A TO 2B RELOCATE THE DIPSTICK FROM TO AND SWITCH THE SOCKET HEAD PLUGS FROM 4A TO 4B BE SURE TO LOCATE THE DIPSTICK ON THE OPPOSITE SIDE FROM THE LOW SPEED GEAR TO AVOID INTERFERENCE 168 050 Rexnord Industries LLC 3001 W Canal St Milwaukee WI 53208 4200 November 2008 PN 2124650 Telephone 414 342 3131 Fax 414 937 4359 Supersedes 07 08 e mail info rexnord com web www rexnord com
30. ITH EXPANDED METAL FAN GUARD FIGURE 2 Fluid Coupling The fluid coupling can be installed removed without removing the motor see fluid coupling instructions for procedure Mount the coupling hubs to the drive high speed shaft and the motor shaft Hubs are to be mounted flush with the end of the shafts coupling hubs may be furnished with an interference fit Mount the motor to the bell housing apply Loctite 242 or equivalent fastener threads and tighten to proper torque Install fluid coupling per coupling instructions To fill the fluid coupling to the proper oil level install the small top cover on the bell housing Rotate the fluid coupling such that the fill hole is up and fill with the approximate quantity of oil see coupling instructions for oil type and quantity Rotate the coupling in either direction to align the mark on the perimeter of the fluid coupling with the mark in the center of the cover on the bell housing A container should be placed to catch any excess oil that may spill from the fill hole If oil drains from the fill hole allow all excess to drain to achieve the proper fill level If no oil drains when marks are aligned rotate coupling back and add more oil Repeat process until excess oil drains and proper fill level is achieved 168 050 November 2008 PN 2124650 Supersedes 07 08 Rexnord Industries LLC 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359
31. Morlina 460 Shell Canada Limited Tellus 150 Tellus 220 Tellus 320 fhaa Sun Oil Co Sunvis 9150 Sunvis9220 nee ee Texaco Lubricants Regal Oil R amp O 150 Regal Oil R amp O 220 Regal Oil R amp O 320 Regal Oil R amp O 460 Unocal 76 East Unax RX 150 Unax RX 220 Unax AW 320 Turbine Oil 460 Unocal 76 West Valvoline Oil Co Turbine Oil 150 Valvoline AW ISO 150 Turbine Oil 220 Valvoline AW ISO 220 Turbine Oil 320 Valvoline AW ISO 320 Turbine Oil 460 t Minimum viscosity index of 90 Rexnord Industries 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info rexnord com web www rexnord com 168 050 PN 2124650 November 2008 Supersedes 07 08 Owners Manual e Falk Drive One Enclosed Gear Drives Page 8 of 26 Sizes M1130 thru M1210 e Type D Series TABLE 9 Viscosity Grade Recommendations for Synthetic Lubricants Cold Climates Normal Climates Output 34 to 12 C 26 to 10 C 18 to 27 C 12 to 52 C 7 to 52 C RPM 30 to 10 F 715 to 50 F 0 to 80 F 4 10 to 125 F 4 20 to 125 F ISO VG AGMA ISO VG AGMA ISO VG AGMA 1SO VG AGMA ISO VG AGMA Below 80 32 05 68 25 150 45 320 65 320 65 80 amp Above 32 05 68 25 150 4s 220 5S 320 6S Refer to the Factory for viscosity recommendations when ambient temperatures are below 34 C 30 F or above 52 C 125 F
32. Mount the Alignment Free Drive to the driven equipment per pages 2 and 3 of this manual With Alignment Free drive assembly supported rotate adjusting screw to move torque arm to desired position and to line up with foundation Torque Arm must be perpendicular in both directions 1 adjust screw if Torque Arm not Install locking plate to lock the adjusting screw plate can The carriage adjusting rod brackets and support bar are be installed on either side Remove support from drive and furnished pre assembled from the Factory Assemble the rod secure anchor bracket to foundation Use M24 Class 8 8 1 ends with heads perpendicular to each other 90 as shown in inch Grade 5 or better fasteners with lock and flat washers to Figure 3 Rod end threads must be engaged a minimum of one mount anchor bracket Slots are provided such that torque arm times thread diameter Attach female rod end to carriage with can be mounted perpendicular pin Place a spacer on each side of the rod end Secure pin CAUTION Do NOT adjust torque arm screw after support is with locking plate Carriage may be adjusted from center to removed and torque arm is under any load either far end of the housing to facilitate installation of pin CARRIAGE FEMALE T READED PIN LOCKING SPACER J ROD END GRAD PLATE ANZ T E ac o
33. ORANGE P SA Polypropylene which is unsuitable and or not recommended for OR MAIN MOTOR certain chemicals The following is a partial list of unsuitable CIRCUIT chemicals for guideline purposes I SET 210 F I 100 C e PE Chloro Sulphonic Acid Nitric Acid Chloroform CUSTOMER WIRING MS MOTOR STARTER Mixture of HNO3 HCL Esters 1 2 Dichloroethylene AND COMPONENTS Mixture of HNO3 H25O4 Benzene Trichloroethylene Sulfuric Acid fuming Gasoline Diethyl Ether AC RATING INDUCTIVE LOAD 50 PF Carbon Tetrachloride Toluene Chlorine Liquid DC RATING INDUCTIVE LOAD L R 0 26 Chlorobsnzane Xylene 125 15 250 15 24 5 480 15 125 0 05 250 0 03 CLEANING When cleaning fan both condensation holes MAXIMUM CONTINUOUS CURRENT Figure 3 Items 1 and 2 are to be temporarily plugged If this Reference only is not done guarantee is void When cleaning electrical equipment always use an approved cleaning agent 8 Connect power to the motor using an approved wiring method See Figure 1 for connection diagrams 9 Before starting the fan double check to ensure there are no obstructions that could interfere with proper fan operation and airflow Verify proper fan rotation resulting in air flow directed at the adjacent face of the gear drive Rexnord Industries LLC 3001 W Canal St Milwaukee WI 53208 4200 168 050 Telephone 414 342 3131 Fax 414 937 4359 PN 2124650
34. OTOR PLATE TORQUE ARM DRIVE PLATE CONNECTION LUG TUBE SECTION GUSSET Supporting the Swing Base The torque arm connection lug prevents the swing base from lying flat on the ground therefore a supporting structure is required for mounting the gear drive and motor to the swing base This structure is typically built from wood and is unique to each swing base All gussets have a 19 mm 0 75 inch diameter hole for securing the swing base to the supporting structure STRUCTURE Mounting Gear Drive to Swing Base It is Rexnord s standard procedure to mount the drive to the swing base at the Factory These instructions are to be followed when field mounting of the drive to the swing base is required Use of broad flat shims between the gear drive and mounting plate are recommended to prevent distortion of the housing when the drive is bolted down Jacking screw holes are provided in gear drive housing to aid in fixing the shims Begin at the low speed shaft end and level across the length and then the width of the gear drive Use a feeler gauge to insure that all pads are supported Bolt down the drive to the torque specified in Table 4 Page 6 Mounting Motor and Coupling Alignment Shims are provided for motor mounting Holes must be drilled into the swing base motor plate for mounting of the motor Step blocks are also provided for some small frame motors Use a feeler gauge to ensure that all motor pads are firmly
35. REXN RD Falk Drive One Enclosed Gear Drives Owners Manual Type D Series e Sizes M1130 thru M1210 Page 1 of 26 How to Use This Manual This manual provides detailed instructions on installation and maintenance of parallel shaft Type DH DV and right angle Type DB DX gear drives Use the table of contents below to locate required information CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE FREE SERVICE OF YOUR FALK GEAR DRIVE Table of Contents Installation Instructions 1 5 Shak xe quedo SD Us REPSOL E NS 5 Tightening 6 Lubrication 6 9 Preventive Maintenance 9 10 Stored and Inactive Gear 11 APPENDIX Appendix A Adjustable Torque Arm Installation 12 Appendix B Rod End Adj Torque Arm Installation 13 14 Appendix C Swing Base 15 Appendix D Alignment Free Assembly amp Installation 16 19 Appendix E Electric Fan Installation amp Maintenance 20 21 Appendix F Cooling Tubes Installation amp Maintenance 22 24 Appendix Thrust Plate amp Fastener Usage 25 Appendix Directions For Inverting Drives DH2 amp DB3 26 Introduction Credit for long service and dependable operation of a gear drive is ofte
36. ST DRIVEN SHAFT PLATE BORE BEARING SUPPORT INPUT SHAFT SHEAVE 168 050 November 2008 PN 2124650 Supersedes 07 08 Rexnord Industries LLC 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info rexnord com web www rexnord com REXN RD Falk Drive One Enclosed Gear Drives Owners Manual Type D Series e Sizes M1130 thru M1210 Page 3 of 26 TABLE 1 Driven Shaft Dimensions mm Shaft diameter A B Tolerance 10 Nominal Min Max Min Max 90 0 0 0 140 99 314 99 774 89 860 90 000 M1130 85 0 0 0 140 96 814 97 274 84 860 85 000 80 0 0 0 120 94 334 94 774 79 880 80 000 75 0 0 0 120 91 834 92 274 74 880 75 000 00 0 0 0 140 114 362 114 812 99 860 100 000 M1140 95 0 0 0 140 111 862 112 312 94 860 95 000 90 0 0 0 140 96 550 97 000 89 860 90 000 20 0 0 0 140 134 334 134 784 119 860 120 000 M1150 15 0 0 0 140 131 834 132 284 114 860 115 000 10 0 0 0 140 129 334 129 784 109 860 110 000 35 0 0 0 160 146 674 147 204 134 840 135 000 M1160 30 0 0 0 160 144 314 144 784 129 840 130 000 25 0 0 0 160 141 814 142 284 124 840 125 000 20 0 0 0 160 139 334 139 784 119 860 120 000 50 0 0 0 160 164 193 164 773 149 840 150 000 M1170 40 0 0 0 160 159 193 159 773 139 840 140 000 30 0 0 0 160 154 293 154773 129
37. al Specifications DRIVE SIZE 1150 1190 1130 amp 1140 HP Cycles Hz 50 60 50 60 RPM 1425 1800 1425 1800 Voltage 220 380 440 208 230 460 220 380 440 208 230 460 168 050 November 2008 PN 2124650 Supersedes 07 08 Rexnord Industries LLC 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info rexnord com web www rexnord com REXN RD TABLE 6 Viscosity Grade Recommendations for Petroleum Based R amp O or EP Lubricants Output RPM Output RPM Below 80 Output RPM 80 amp Above Falk Drive One Enclosed Gear Drives Owners Manual Type D Series e Sizes M1130 thru M1210 Page 7 of 26 TABLE 8 Extreme Pressure Lubricants t Maximum Operating Temperature Lubrication Recommendations Carefully follow lubrication instructions on the gear drive nameplate warning tags and installation manuals furnished with the gear drive Lubricants listed in this manual are typical ONLY and should not be construed as exclusive recommendations Industrial type petroleum based rust and oxidation inhibited R amp O gear lubricants or industrial type sulfur phosphorus extreme pressure EP gear lubricants are the recommended lubricants for ambient temperatures of 9 C to 50 C 15 F to 125 F For drives operating outside the above temperature range refer 93 C 200 F Normal Cli
38. al leg of the square LEVEL SQUARE AND PARALLEL DO NOT over tighten belts or chains Adjust chains to manufacturers specifications Adjust belts as follows The ideal tension is the lowest tension at which the belt will not slip under peak load conditions Check the belt tension frequently during the first 24 to 48 hours of run in operation Over tightening belts shortens belt and bearing life Keep belts free from foreign material which may cause slippage Inspect the V belt periodically tighten the belts if they are slipping OUTBOARD BEARING Mount the outboard bearing and gear drive on a common foundation so that they will shift as an assembly if settling should occur Bring the outboard bearing to the correct horizontal position with broad flat shims under the mounting pad Align accurately so that the load is equally divided between the two drive bearings and the outboard bearing Mount a stop bar against the pillow block foot on the load side when large horizontal load components are exerted on the pillow block PINION MOUNTING Mount pinion as close to the drive as possible to avoid undue bearing load and shaft deflection Refer to the Factory for pinion alignment instructions NON FALK COUPLINGS Refer to manvfacturers installation and maintenance instructions BACKSTOPS To prevent damage to backstops due to incorrect motor shaft rotation at start up couplings are NOT assembled when gear drives are furnishe
39. any Syndustrial EP Oil 68 Syndustrial EP 01 Syndustrial EP Oil 220 Syndustrial EP Oil 320 Syndustrial EP Oil 460 1501 Hyperia 220 Hyperia 320 Hyperia 460 Shell Oil Co Hyperia 220 Hyperia S 320 Hyperia S 460 Sini Sunoco Challenge 220 Sunoco Challenge 320 Zes es n Sunoco Challenge EP 220 t Sunoco Challenge EP 320 ig Taco lobiais Pinnacle 32 Pinnacle 68 Pinnacle 150 Pinnacle 220 Pinnacle 320 Pinnacle 460 Pinnacle EP 150 t Pinnacle EP 220 t te Pinnacle EP 460 t Whitmore Mfg Co Decathlon Decathlon 5EP t Decathlon 6EP Decathlon 7EP 76 Lubricants Company 76 Triton Syngear 76 Triton Syngear SEP 76 Triton Syngear 7EP Minimum viscosity index of 130 Consult lubricant supplier manufacturer for maximum operating temperature t Minimum viscosity index of 120 f Extreme Pressure EP lubricant contains sulphur phosphorus 168 050 November 2008 PN 2124650 Supersedes 07 08 Rexnord Industries LLC 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info Qrexnord com web www rexnord com REXN RD Falk Drive One Enclosed Gear Drives Owners Manual Type D Series e Sizes M1130 thru M1210 Page 9 of 26 TABLE 11 Greases for Bearings and Seals 18 to 93 C 0 to 200 F Lubricant Amolith Grease No 2 Manufacturer Amoco Oil Co
40. bricants WARNING SYNTHETIC LUBRICANTS IN FOOD PROCESSING INDUSTRY Synthetic lubricants may contain toxic substances and should not be used in the food processing industry without the lubricant manufacturers approval Lubricants which meet USDA H1 classification are suitable for food processing applications Bearing and Seal Greases All drives and some backstops have grease lubricated seals Some vertical shaft and specially mounted drives have grease lubricated bearings Drives are shipped with NLGI 2 grease in the seal housing cavities unless otherwise specified Refer to Table 11 for grease recommendations GREASE LUBRICATED BEARINGS Vertical shaft drives with drywells have grease lubricated lower low speed bearings These bearings are lubricated at the Factory with an NLGI 2 grease Refer to the preventive maintenance instructions for greasing instructions GREASE LUBRICATED SEALS Drive One drives are furnished with grease purged seals which minimize the entry of contaminants into the drive Drives are shipped with NLGI 2 grease in the seal housing cavities unless otherwise specified If grease could contaminate the product as in the food and drug industries it should be removed A grease that meets USDA H1 classification is suitable for food processing applications Oil Levels TYPES DH amp DB Fill the drive with oil to the level indicated on the oil dipstick Approximate oil capacities are given o
41. by hand Before operating drives which have been stored or inactive must be filled to the proper level with oil meeting the specifications given in this manual Refer to Manual 128 014 for Start up after Storage instructions TABLE 12 Motorstor VCI 10 Add to stored or inactive drives Motorstor Milliliters Per Drive DRIVE SIZE Ounces Per Drive M1130 5 M1140 amp M1150 2 M1160 amp M1170 4 M1180 amp M1190 6 M1200 amp M1210 10 Product of Daubert Chemical Company Chicago IL Periodically inspect stored or inactive gear drives and spray or add rust inhibitor every six months or more often if necessary Indoor dry storage is recommended Gear drives ordered for extended storage can be treated at the Factory with a special preservative and sealed to rust proof parts for periods longer than those cited previously The vented dipstick should be replaced with a plug vented dipstick should be attached to gear drive for future use so that the protective rust inhibiting atmosphere is sealed inside the drive Install vented dipstick when preparing drive for operation Rexnord Industries 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info rexnord com web www rexnord com 168 050 PN 2124650 November 2008 Supersedes 07 08 Appendix A Falk Drive One Enclosed Gear Drives Sizes M1130 thru M1210 e Type D Series Page 12
42. d with backstops After completing electrical connections check motor and gear drive shaft rotations If rotations are correct complete alignment and assembly of coupling Fastener Tightening Torques Use the tightening torque values specified in Table 4 for fastening Falk gear drives motors and accessories to their mounting surtaces with un lubricated fasteners DO NOT use these values for torque locking fasteners or for fastening components with aluminum feet or soft gaskets or vibration dampeners on the mounting surface If the tightening torque exceeds the capacity of the torque wrench use a torque multiplier Use ISO property class 8 8 for metric fasteners See Table 13 for fastener and wrench size TABLE 4 Tightening Torques 5 DO NOT Lubricate Fasteners Metric Fasteners Property Class 8 8 Fastener Metal to Metal Metal to Concrete Sire Nm Ib ft Nm Ib ft M x 7 3 2 2 15 M5 x 8 6 5 5 35 M6 x 1 0 10 8 8 6 M8 x 1 25 24 18 19 14 MIO x 1 5 50 36 39 29 MI2 x 1 75 84 62 68 50 M16 x2 210 156 170 126 M20 x 2 5 415 305 330 246 M24 x3 705 530 570 420 M30 x 3 5 1 440 1060 1150 850 M36 x 4 2520 1860 2030 1500 M42 4 5 4 050 3000 3250 2400 M8x5 6100 4500 4 880 3600 M56 x 5 5 9 850 7300 7 860 5800 Water Cooling WATER COOLED HEAT EXCHANGERS Install a shut off or control valve in the water line to the heat exchanger to regulate the water flow through the exchanger Also install a water flow
43. drive Check with a feeler gauge to make certain that all pads are supported to prevent distortion of housing when drive is bolted down After drive is aligned with driven equipment and bolted down align prime mover to drive input shaft Refer to Page 5 for coupling alignment If equipment is received from the Factory mounted on a JACKING SCREW HOLES DIPSTICK VENT HOLES LIFTING HOLES 2 PER CORNER 16 TOTAL PLI JACKING SCREW HOLES bedplate the components were accurately aligned at the Factory with the bedplate mounted on a large flat assembly plate Shim under the bedplate foot pads until the gear drive is level and all feet are in the same plane Check high speed shaft coupling alignment If the coupling is misaligned the bedplate is shimmed incorrectly Re shim bedplate and recheck high speed coupling alignment If necessary realign motor Leveling Reference Surfaces Shaft Mounted Drives General Shaft mounted drives should never be mounted in a manner that restricts the natural movement of the drive They should be allowed to move freely with the shaft on which it is mounted Shaft mounted drives should always be used in conjunction with a torque reaction arm Refer to appendixes A B or C for torque reaction arm mounting instructions and angular limits The drive may require repositioning on the driven shaft after initial installation to accommodate the location of the foundation ancho
44. e connection of the drive to the shaft and cause the drive to move See Table 13 for nut setscrew and wrench sizes a Preferred Method Use a spanner chain or pipe wrench to tighten the bushing nut to the torque value indicated in Table 3 If the required torque cannot be measured an approximation can be made using Table 3A The full weight should be applied to the wrench handle in a horizontal position For example to achieve the required tightening torque for an M1180 bushing nut a 85 kg person would have to apply all of their weight to a wrench handle 950 mm from the nut a 190 lb person would have to apply all their weight to a Rexnord Industries 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info Qrexnord com web www rexnord com 168 050 PN 2124650 November 2008 Supersedes 07 08 Owners Manual Falk Drive One Enclosed Gear Drives REXN RD Page 4 of 26 Sizes M1130 thru M1210 e Type D Series TABLE 3 Wrench Type and Bushing Nut Tightening Torque DRIVE Wrenches d Nut SIZE ightening Torque Armstrong Tools Williams Nm lb ft M1130 34 313 4748 380 280 M1140 34 313 4748 450 332 M1150 34 313 4748 450 332 M1160 73 237 T 15 2 520 384 M1170 73 237 T 15 2 630 465 M1180 73 237 T 15 2 770 568 M1190 73 237 T 15 2 900 664 These are chain wrenches where standard spanner wrenches are not available TABLE
45. e fan 2 Installation work and electrical wiring must be done by a qualified person s in accordance with all applicable codes and standards including fire rated construction 3 The fan should be securely mounted Recheck the mounting hardware and tighten as necessary 4 The fan motor must always be grounded The installation of a motor protection switch is recommended See Figure 1 for wiring diagrams 5 Mount the motor guard if removed The motor guard must be installed at all times during operation to prevent injury to personnel by rotating fan blade 6 Use liquid tight electrical fittings and conduit FIGURE 1 1 PHASE 220V 50Hz 1 PHASE 240V 50Hz 1 PHASE 110V 60Hz 1 PHASE 220V 60Hz 1 PHASE 240V 60Hz CAPACITOR B 7 e s THERMAL PROTECTION L N L2 SINGLE PHASE THREE PHASE TYPE D 3 PHASE 3 PHASE 220 380V 50Hz 3 PHASE 230 400V 50Hz 3 PHASE 240 415V 50Hz 3 PHASE 220 380V 60Hz 3 PHASE 208 360V 60Hz 3 PHASE 265 460V 60Hz THERMAL LI L2 L3 PROTECTION OPTION L1 L2 L3 168 050 November 2008 PN 2124650 Supersedes 07 08 Rexnord Industries LLC 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info rexnord com web www rexnord com Falk Drive One Enclosed Gear Drives Appendix E REXN RD Type D Series e Sizes M1130 thru M1210 Page 21of 26
46. eads and tighten CAUTION Do not over tighten fasteners into plastic fan as fan may crack Mount the fan hub on the gear drive high speed shaft such that the set screw hole in the hub is towards the end of the shaft Locate the hub axially at the values listed in Table 2 TABLE 2 Fan Hub Location Hub Location Bell Housing COUPLING SIZE Casting Number Inch 1420 0011723 130 5 12 1480 0011724 125 4 92 1584 0011725 115 4 53 1660 0011726 142 5 59 Close Coupling 0011723 130 5 12 Close Coupling 0011725 115 4 53 Casting number located on inside sidewall of bell housing Dimensions listed are from the inside face of the bell housing to the far side of the hub see Figure 1 Apply Loctite 242 or equivalent to threads of the set screw and tighten over key to secure hub in position Fan hub must be installed prior to installing high speed coupling hub POSITON SET SCREW FIGURE 1 Assemble fan shroud mounting rails to bell housing Assemble fan cowling with expanded metal guard to back of fan shroud plates on same fasteners Mount fan shroud assembly to mounting rails The cowling may require to be notched to allow clearance for the bell housing to drive mounting fasteners Rotate fan to ensure clearance reposition fan hub if necessary Split fan guard may be removed or installed without disrupting high speed coupling See Figure 2 MOUNTING RAILS MOUNTING PLATE FAN COWLING W
47. ear drive Slide bushing with shaft key onto driven shaft near final position Shaft Length N 5mm or 0 20 in and slide gear drive onto driven shaft Tighten bushing nut to specified torque Verify location of drive on driven shaft to be within angular limits of the drive torque arm Install thrust plate and thrust plate retaining ring Coat four or five engaging threads of the retention fastener with a low strength thread locking compound and install snug tight Install hollow shaft cover TABLE 1 Metric amp Inch Bore Bushings DRIVE Retention Fastener Backing Bolt t Removal Bolt t Shaft Length N t Keyway L SIZE mm Inch mm Inch mm Inch mm Inch mm Inch M1130 M20x2 5x75 750 10UNCx3 00 M20x2 5x40 750 10x1 50 M24x3x70 M24x3x70 341 13 43 204 11 18 M1140 M24x3x90 000 8UNC x 3 50 M24x3x45 1 00 8x 2 00 M30x3 5x80 M30x 3 5 x 80 386 15 20 319 12 55 M1150 M24x3x90 000 8UNC x 3 50 M24x3x45 1 00 8x 2 00 M30x3 5x80 M30x 3 5 x 80 406 15 98 334 13 15 M1160 M24x3x90 000 8UNC x 3 50 M24x3x45 1 00 8x 2 00 M30x3 5x80 M30x 3 5 x 80 454 17 87 407 16 02 M1170 M30x3 5x 100 1 125 7UNCx 3 75 M30x3 5x 60 1 125 7x2 25 M36x4x90 M36x4x90 436 1717 392 15 44 M1180 M30x3 5x100 1 125 7UNCx 3 75 M30x3 5x 60 1 125 7x2 25 M36x4x90 M36x4x90 503 19 80 450 17 72 M1190 30 3 5 100 1 125 7UNCx 3 75 M30x3 5x 60 1 125 7x2 25 M36x4x90 M36x4x90 549 21 61 502 19 76 Retention fa
48. en equipment so that the distance between shaft ends is equal to the coupling gap Align the shafts by placing a spacer block equal in thickness to required gap between hub faces as shown at right and also at 90 intervals around the hub Check with feelers OFFSET ALIGNMENT Align driving and driven shafts so that a straight edge will rest squarely on both couplings hubs as shown to the right and also at 90 intervals Tighten foundation bolts of the connected equipment and recheck alignment and gap SPROCKETS PULLEYS OR SHEAVES Mount power take offs as close to the gear drive housing as possible to avoid undue bearing load and shaft deflection Steelflex Illustrated Steelflex Illustrated Rexnord Industries 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info rexnord com web www rexnord com 168 050 PN 2124650 November 2008 Supersedes 07 08 Owners Manual Falk Drive One Enclosed Gear Drives Sizes M1130 thru M1210 e Type D Series Page 6 of 26 REXN RD Align the output shaft of the gear drive square and parallel with the driven shaft by placing a straightedge across the face of the sprockets or sheaves as illustrated RIGHT WRONG Check horizontal shaft alignment by r lt gt og placing one leg of a square against Vt the face of the sheave or sprocket GEAR DRIVE WALL with the spirit level on the horizont
49. end of the tapered split ring must face the fitting body 3 Figure 3 Lubricate the rubber seal ring Insert the tube into the fitting body past the rubber seal ring 4 Figure 4 Slide the tapered split ring against the fitting body Lubricate O D of tapered split ring with 2 bearing grease 5 Figure 5 Assemble nut to fitting and tighten hand tight Turn nut with a wrench one turn or until the tapered split ring is flush with the end of the nut TUBE Figure 1 DEBURRED END TAPERED NUT BODY SPLIT RING d Figure 2 RUBBER SEAL RING Figure 3 TEFLON BACK UP RING BODY TAPERED SPLIT RING Figure 4 TIGHTEN NUT UNTIL FLUSH Figure 5 Maintenance Instructions The cooling tube system is designed to be removed from the drive housing without disturbing the drive or its foundation provided sufficient room is available at either end of the housing for tube withdrawal All tube connections are outside the drive and are of the seal ring type for ease of maintenance and reusability Light coatings of sludge or scale will cause a reduction in heat transfer capacity of the system Therefore periodic cleaning of the system may be required to restore the heat transfer capacity The cooling tube system may be cleaned by flushing with commercially available cleaning compounds such as Oakite or Dowell The commercially available cleaning compounds are corrosive and must be used in accordance with their manufact
50. etention fastener with Loctite 222 or equivalent low strength thread locking compound and thread into driven shaft end until snug tight Reinstall shaft cover Removal of Shaft Mounted Drives Sizes M1130 M1190 WARNING Lock out power source and remove all external loads from drive before servicing drive or accessories 1 2 3 4 Drain the lubricant from the drive Remove safety guards and belts if so equipped Remove hollow shaft cover if thrust plate kit is used Removal of motor and motor mount if so equipped Remove backstop if so equipped WARNING Drive must be supported during removal process Use a sling and take up the slack before proceeding 5 Remove the setscrew s on the bushing nut which is located at the output end of the hollow shaft On drives using the thrust plate kit remove the driven shaft retention fastener Use a spanner pipe or chain wrench to loosen the bushing nut Initially the nut will freely rotate counterclockwise approximately 180 as the nut moves from the locked position to the removal position At this point anticipate resistance which indicates unseating of the bushing Continue to rotate the nut until it is free from the hollow shaft If unable to release the drive from the driven shaft with the bushing nut the thrust plate kit using a backing bolt threaded into the driven shaft tapped hole and removal bolt threaded into the thrust plate tapped hole may be used
51. g temperature of lubricants 93 C 200 F AGMA Viscosity Grade 4 5 6 7 ISO Viscosity Grade 150 220 320 460 Viscosity SSU c 100 F 626 765 918 1122 1335 1632 1919 2346 Viscosity cSt 40 C 135 165 198 242 288 352 414 506 Manufacturer Lubricant Lubricant Lubricant Lubricant Amoco Oil Co Amer Ind Oil 150 Amer Ind Oil 220 Amer Ind Oil 320 Amer Ind Oil 460 BP Oil Co ie aes Energol HLP HD 220 Chevron U S A Inc Citgo Petroleum Corp achine Oil AW 150 Citgo Pacemaker 150 achine Oil AW 220 Citgo Pacemaker 220 Machine Oil AW 320 Citgo Pacemaker 320 Citgo Pacemaker 460 Conoco Inc Exxon Company U S A Houghton International Inc Imperial Oil Ltd Dectol R amp O Oil 150 Teresstic 150 Hydro Drive HP 750 Teresso 150 Dectol R amp O Oil 220 Teresstic 220 Hydro Drive HP 1000 Teresso 220 Dectol R amp O Oil 320 Teresstic 320 Dectol R amp O Oil 460 Teresstic 460 Kendall Refining Co Keystone Lubricants Lyondell Petrochemical ARCO Mobil Oil Corp Pennzoil Products company Petro Canada Products Four Seasons AW 150 KLC 40 Duro 150 DTE Oil Extra Heavy Pennzbell AW Oil 150 Premium R amp O 150 Duro 220 DTE Oil BB Pennzbell AW Oil 220 Premium R amp O 220 Pennzbell AW Oil 320 Premium R amp O 320 DTE Oil HH Pennzbell AW Oil 460 Phillips 66 Co agnus Oil 150 agnus Oil 220 Magnus Oil 320 Shell Oil Co Morlina 150 Morlina 220 Morlina 320
52. he overhang is determined install the hubs according to the instructions provided with the coupling Install the spacer sections and verify the gap is correct If not readjust the hub on the motor shaft If the coupling is furnished with an interference fit readjustment will not be possible take extra care in making measurements After the proper gap is set finish installing the coupling per the instructions MOTOR BELL ADAPTER MOTOR PLATE HOUSING OVERHANG OVERHANG FIGURE 4 Lifting the Alignment Free Drive Lifting points are provided on the corners of the motor side of the bell housing see Figure 5 Lift by these and the provisions provided on the drive housing itself to maneuver the drive DO NOT lift by the motor lifting eye LIFT POINTS FIGURE 5 Mounting the Drive Mount the Alignment Free Drive to the driven equipment per Page 3 The torque arm must be located on the TA Bushing nut side hollow shaft or the extension side solid shaft of the drive at the foot as shown in Figure 6 Connect the torque arm to the foundation per the torque arm installation instructions TA BUSHING TORQUE ARM LOCATION AT NUT SIDE OR DRIVE FOOT ON BUSHING EXTENSION SIDE NUT SIDE OR EXTENSION SIDE FIGURE 6 Rexnord Industries 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info rexnord com web www rexnord com 168 050 PN 2124650 November 2008 Supersedes
53. mates Manufacturer Lubricant 9 to 16 C 10 to 52 C 15 to 60 F 50 to 125 F Amoco Oil Co Permagear Amogear EP BP Oil Co Energear EP VE ROME 50 VG Lee Chevron U S A Inc Gear Compounds EP 150 4 320 6 Citgo Petroleum Corp Citgo EP Compound 150 4 220 5 Conoco Inc Gear Oil Exxon Co U S A Spartan EP E F Houghton amp Co MP Gear Oil mperial Oil Ltd Spartan EP endall Refining Co Kendall NS MP Keystone Div Pennwalt Corp Keygear Lyondell Petrochemical ARCO Pennant NL Mobil Oil Corp Mobilgear Petro Canada Products Ultima EP Phillips 66 Co Philgear Shell Oil Co Omala Oil Shell Canada Limited Omala Oil Sun Oil Co Sunep Texaco Lubricants Meropa Valvoline Oil Co AGMA EP to Synthetic Lubricants paragraphs Synthetic lubricants can also be used in normal climates VISCOSITY IMPORTANT The proper grade for R amp O and EP lubricants is found in Table 7 For cold climate conditions refer to Table 9 Page 8 and the Synthetic Lubricant paragraphs t Minimum viscosity index of 90 If a gear drive operates in a typical indoor environment where the ambient temperature is within 21 C to 52 C 70 F to 125 the oil viscosity could be increased one AGMA grade above that shown for the 10 C to 52 C 50 F to 125 F range That is an AGMA Number 6 or 7 could be substituted for a 5 or 6 respectively under these ambient conditions TABLE 7 Petroleum Based R amp Gear Oils t Maximum operatin
54. move the drive from the driven shaft Shaft engagements include 5mm 20 inch clearance at the bushing nut nut end first and position the keyway slot over the shaft keyway The bushing may have to be opened slightly to assist in installation Insert a screwdriver into the slot in the bushing and very lightly pry open until the bushing slides onto the shaft Insert the drive key furnished with the bushing into the shaft keyway On drives using the thrust plate kit slide the bushing assembly onto the driven shaft until final position end of driven shaft open ended keyway Installation of Shaft Mounted Drives Sizes M1130 M1190 1 On drives using the thrust plate kit remove the hollow low speed shaft cover Before lifting the drive into position rotate the high speed shaft until the hollow shaft keyway will be in position to line up with the driven shaft key 2 Lift the drive into position and slide onto the driven shaft taking care that the driven shaft key seats into the hollow shaft keyway DO NOT hammer or use excessive force 3 Thread the bushing nut onto the hollow shaft one to two turns NOTE The bushing nut threads have been coated with an anti seize compound at the Factory This compound should not be removed Before re installing a previously used nut recoat the nut threads only with an anti seize compound WARNING DO NOT apply anti seize or lubricant to bushing or shaft surfaces Use of anti seize may prevent secur
55. n given to the engineers who designed it or the craftsmen who constructed it or the sales engineer who recommended the type and size Ultimate credit belongs to the mechanic on the job who worked to make the foundation rigid and level who accurately aligned the shafts and carefully installed the accessories and who made sure that the drive received regular lubrication The details of this important job are the subject of this manual NAMEPLATE Operate Falk Rexnord gear drives only at power speed and ratio shown on the nameplate Before changing any one of these submit complete nameplate data and new application conditions to Factory for correct oil level parts and application approval DISASSEMBLY AND ASSEMBLY Disassembly amp assembly instructions and parts guides are available from Factory or Rexnord Representatives When requesting information please give complete data from the nameplate on the gear drive Model M O Number Date RPM and Ratio WARNING Consult applicable local and national safety codes for proper guarding of rotating members Lock out power source and remove all external loads from drive before servicing drive or accessories Warranty Rexnord Industries LLC the Company warrants that Drive One gear drives l conform to Company s published specifications and Il are free from defects of material for three years from the date of shipment Company does not warrant any non Company branded pr
56. n open drain Do not pressurize the cooling tube system The turned up water outlet fitting ensures that the system is always full of water during operation 3 Control water flow rate to between 2 and 5 gallons 8 and 19 liters per minute to minimize fouling at low flow rates or tube erosion at high flow rates The water flow rate may be reduced to 1 gallon 4 liters per minute if clean fresh drinking quality water is used and the sump oil temperature can be maintained within the maximum limit of 200 F 93 C 4 For shutdowns at ambient temperatures less than 32 F 0 C drain the cooling tube system by removing the loop end assemblies on the end of the drive opposite the water inlet Refer to Figure 8 on Page 23 for typical assemblies and record location of assemblies for reinstallation purposes 168 050 November 2008 PN 2124650 Supersedes 07 08 Rexnord Industries LLC 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info rexnord com web www rexnord com REXN RD Falk Drive One Enclosed Gear Drives Appendix F Type D Series e Sizes M1130 thru M1210 Page 23of 26 Assembly of Seal Ring Fittings Note For Disassembly of seal ring fittings reverse the steps of the following assembly procedure 1 Figure 1 Deburr tube end to prevent cutting the rubber seal ring during assembly 2 Figure 2 Slide nut and tapered split ring on tube The large
57. n the drive nameplate The inspection cover is sealed with a non hardening chemical gasket eliminator When replacing the inspection cover run a bead of Loctite 515 Gasket Eliminator or equivalent around the perimeter of the inspection opening making sure to circle the fastener holes Product of Henkel Corp Rocky Hill CT DRIVES WITH OIL PUMPS Types DV DX and occasionally other types of gear drives will be equipped with oil pumps for cooling or special lubrication considerations If a drive is equipped with an oil pump fill the drive to the level marked on the dipstick Run the lubrication system for several minutes to fill the system components Verify that the pump is circulating oil properly then recheck oil level If necessary add oil to compensate for filter and or cooler Before starting the gear drive rotate the input shaft to check for obstructions Then start the drive and allow it to run without load for several minutes Shut down and recheck oil level If everything is satisfactory the drive is ready for operation Preventive Maintenance AFTER FIRST WEEK Check alignment of total system and realign where necessary Also tighten all external bolts and lugs where necessary DO NOT readjust the internal gear or Rearing settings in the drive these were permanently set at the Factory See Table 13 for fastener and wrench sizes AFTER FIRST MONTH Proceed as follows 1 Operate drive until old sump
58. odates the motion of the drive To allow for maximum movement the torque arm must be perpendicular to the supports and rod ends centered in the mounting anchor bracket Restricting the drive s motion in any way may result in premature failure 6 Install pin in anchor bracket mounted to supporting of the drive or driven equipment structure with spacers in a similar manner The drive may need to be rotated about the low speed shaft to install second pin If the drive has a backstop it may be necessary to disconnect the backstop to rotate the drive Refer to the backstop instructions for removal create a link A combination of male female rod ends clevis male rod end or turnbuckle male rod ends are required dependent on torque arm style All styles require jam nuts to lock linkage Refer to Figures 1 thru 3 NOTE Rod ends must be assembled such that the relative position of one rod end head to the other is parallel Loosen locknut and adjust if necessary See Figure 4 5 For Standard and Turnbuckle style torque arm install pin through one lug of anchor bracket mounted to drive Position spacer then rod end and finally second spacer on pin Finish positioning pin within anchor bracket Install retaining ring to secure the pin See Figure 1 or 3 For Clevis style torque arm install crowned pin through clevis and drive foot Secure pin with retaining ring See Figure 2 Installaton Position the drive on the driven equipment shaft such
59. oducts or components manufacturer s warranty applies or any defects in damage to or failure of products caused by I dynamic vibrations imposed by the drive system in which such products are installed unless the nature of such vibrations has been defined and accepted in writing by Company as a condition of operation II failure to provide suitable installation environment IIl use for purposes other than those for which designed or other abuse or misuse IV unauthorized attachments modifications or disassembly or V mishandling during shipping Installation Instructions The following instructions apply to standard Falk Type DH DB DV amp DX drives If a drive is furnished with special features refer to the supplementary instructions shipped with the drive WELDING Do not weld on the gear drive or accessories without prior approval from the Factory Welding on the drive may cause distortion of the housing or damage to the bearings and gear teeth Welding without prior approval could void the warranty NOTE Drives equipped with cooling fans may require removal of shroud when installing foundation fasteners EFFECTS OF SOLAR ENERGY If the gear drive operates in the sun at ambient temperatures over 38 C 100 F then special measures should be taken to protect the drive from solar energy This protection can consist of a canopy over the drive or reflective paint on the d
60. oil reaches normal operating temperature Shut down drive and drain immediately 2 Immediately flush drive with an oil of the same type and viscosity grade as the original charge warmed to approximately 38 C 100 F in cold weather by rapidly pouring or pumping a charge equal to 25 100 of the initial fill volume or until clean oil flows through the drain 3 Close the drain and refill the drive to the correct level with new oil of the correct type and viscosity PERIODICALLY 1 Check the oil level of the drive when it is stopped and at ambient temperature Add oil if needed If the oil level is ABOVE the high oil level mark on the dipstick have the oil analyzed for water content Moisture in the oil may indicate that a seal or the heat exchanger is leaking If so replace the defective part immediately and change the oil DO NOT fill above the mark indicated as leakage or undue heating may result 2 Check coupling alignment to make certain that foundation settling has not caused excessive misalignment 3 If drive is equipped with a fan periodically clean accumulated foreign matter from the fan guard and deflector 4 If drive is equipped with a torque arm check for free movement Rexnord Industries 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info rexnord com web www rexnord com 168 050 PN 2124650 November 2008 Supersedes 07 08 Owners Manual
61. ord Industries 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info Qrexnord com web www rexnord com 168 050 PN 2124650 November 2008 Supersedes 07 08 Appendix D Falk Drive One Enclosed Gear Drives Sizes M1150 thru M1210 e Type D Series Page 16 of 26 REXN RD Alignment Free Assembly and Installation Welded Design Introduction The Alignment Free Drive design consists of a shaft mounted drive bell housing motor adapter plate torque arm motor and coupling When assembled the bell housing motor adapter and motor locate off registers resulting in alignment of the motor and gear drive shafts Therefore no additional alignment is required for the high speed coupling Assembly Instructions The bell housing is fastened to the drive s high speed end using cap screws through the four mounting holes on that face see Table 1 for size and torque The bell housing will locate on the bevel head of the drive Read instructions provided with high speed coupling prior to assembly TABLE 1 Tightening Torques DRIVE Bolt Tightening Torque SIZE Size N m lb ft M1150 M24 725 535 M1160 M24 725 535 M1170 M30 1450 1070 M1180 M30 1450 1070 M1190 M36 2530 1866 M1200 M36 2530 1866 M1210 M36 2530 1866 Fluid Coupling Location of the fluid coupling on the high speed shaft of the drive is determined by the provided shaft spacer Install the fluid
62. perate extremely humid chemical or dust laden atmospheres In ss hay DRIVES the Pressure pus these cases R amp O and EP lubricants should be changed every 3 to greasing oe an dia 2 e 4 months or 1500 to 2000 hours If the drive is operated in an area hon f js p n ep ace the pressure reliet plug where the temperatures vary with seasons change oil viscosity grade when MNgure De Ow 4 Viscosity changes more than 1596 to suit temperature Lubricant suppliers can test oil periodically and Refer to Table 11 for NLGI 2 greases Some of these greases recommend economical change intervals are of the EP type and may contain toxic substances not SYNTHETIC LUBRICANTS Synthetic lube change intervals can allowed in the food processing industry A grease that meets the USDA HT classification is suitable for food processing be extended to 8000 10 000 hours depending upon operating applications temperatures and lubricant contamination Change oil more frequently when gear drives operate in extremely humid chemical or dust laden atmospheres In these cases synthetic lubricants zl should be changed every 4 to 6 months or 4000 to 6000 hours I E Laboratory analysis is recommended for optimum lubricant life nid mA and gear
63. pling depends largely upon how well the coupling is installed and serviced Refer to the coupling manufacturer s manual for specific instructions CORRECT METHOD Heat interference fitted hubs pinions sprockets or pulleys to a maximum of 135 C 275 F and slide onto gear drive shaft INCORRECT METHOD DO NOT drive coupling hub pinion sprocket or pulley onto the shaft An endwise blow on the shaft coupling may damage gears and bearings CAUTION DO NOT HAMMER FALK COUPLINGS Except fluid type Detailed installation manuals are available from Factory your local Rexnord Representative or Distributor just provide size and type designations stamped on the coupling For lubricant requirements and a list of typical lubricants meeting Rexnord specifications refer to appropriate coupling service manual FALK FLANGED TYPE RIGID COUPLINGS These are typically used on drives with vertical output shafts The low speed shaft extension ends of the solid vertical shaft drives are drilled and tapped to accommodate coupling keeper plates Tightening torques for fasteners including keeper plate fasteners are listed in Table 4 Page 6 FALK FLUID COUPLINGS Refer to the installation manual furnished with the Falk fluid coupling for installation and startup instructions For Alignment Free Drives refer to Appendix D GAP AND ANGULAR ALIGNMENT If possible after mounting coupling hubs position the driving and driv
64. que arm is perpendicular and centered in the clevis mounted to the supporting structure and at its attachment point on the drive system Ideally the clevis bracket should be added to the structure after the drive has been secured to the driven equipment NOTE Do not fasten the torque to the support structure at this time 2 Secure the drive to the driven equipment via the TA Bushing or rigid coupling connection 3 Check that the torque arm remains perpendicular and centered in the clevis if mounted If the torque arm is not perpendicular and centered reposition the drive on the driven equipment shaft If the clevis bracket is not mounted position and mount at this time ANCHOR BRACKET 7 TORQUE ARM ASSEMBLY Hd OO HIGH SPEED SHAFT FIGURE 2 4 The exact position of the torque arm may vary within the range shown in Figure 2 For torque arm mountings other than shown refer to the Factory If it is necessary to shorten the torque arm assembly cut the excess from either tie rod end on Sizes M1130 through M1190 only TABLE 1 Load Reaction Through Tie Rod DRIVE Load SIZE N lb M1130 42700 9600 M1140 54500 12300 M1150 69500 15600 M1160 92300 20800 M1170 126000 25300 M1180 130000 29200 M1190 160200 36000 M1200 170300 38300 M1210 202900 45600 Load includes moment due to motor and motor
65. r and be within limits specified in appendix A fixed torque arm or appendix B adjustable torque arm The tapered bore hollow shaft is designed for use with a TA taper bushing for mounting the drive on a driven shaft with a straight outside diameter The taper bushing assembly is supplied with a thrust plate kit and retention fastener as standard usage is optional shaft cover must be removed to install thrust plate kit refer to data sheet supplied with the tapered bushing assembly for driven shaft length shaft keyway length and driven shaft tapped hole dimensions if the thrust plate kit with retention fastener is to be used Prior to installing the drive it is a good idea to check the driven shaft for proper dimensions Using Table 1 or 1A find the driven shaft size for the application Verify that dimensions A and B are within the allowable range When dimensions are verified proceed with the installation The minimum and maximum driven shaft engagements dimension N in Figure 1 are shown in Table 2 The minimum engagement is necessary for full bushing engagement and the maximum and specified engagement is provided for use when the thrust plate kit is used for added retention capacity and an auxiliary removal aid bushing nut normally used for both KEEP CLOSE gt j lt N gt FIGURE 1 1 I KEEP CLOSE BUSHING NUT THRU
66. re required Rexnord Industries 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info rexnord com web www rexnord com 168 050 PN 2124650 November 2008 Supersedes 07 08 Appendix F Falk Drive One Enclosed Gear Drives Sizes M1130 thru M1210 e Type D Series Page 24of 26 REXN RD Accessories A sump temperature sensing water flow controller and sump temperature indicator thermometer are available accessories for the internal cooling tube system It is recommended that a thermometer be used with a water flow controller Additional holes in the housing are required for these accessories and should be referred to the Factory at the time of order Water Flow Control Valve A water flow control valve is recommended where the availability or cost of water is at a premium or where automatic water shutoff or constant temperature is desired The standard water flow control valve is an adjustable capillary type temperature sensing flow modulating valve The flow control valve should be installed in series with a ball valve to limit maximum water flow Refer to Figure 6 for recommended plumbing diagram The water flow control valve will control water flow rates to less than 2 gallons 8 liters per minute however the cooling tubes will be subject to increased fouling and may require cleaning at more frequent intervals WATER SUPPLY 2 GPM MIN 8 LITERS PER MIN
67. rive If neither is possible a heat exchanger or other cooling device may be required to prevent the sump temperature from exceeding the allowable maximum MOUNTING POSITION Standard mounting positions for types DH amp DB are with the input and output shafts horizontal and for DV amp DX with the output shafts vertical Allowable mounting angles for standard oil levels are Bridge Slope DH amp DB 0 Up amp 4 Down 1 5 Consult Factory for other angles If a gear drive is ordered for non standard mounting positions refer to the instructions provided with the drive for oil levels and bearing lubrication If it is necessary to mount the gear drive in a different position from which it was ordered refer to Factory for required changes to provide proper lubrication FOUNDATION GENERAL To facilitate oil drainage elevate the gear drive foundation above the surrounding floor level If desired replace the drive oil drain plug with a valve but provide a guard to protect the valve from accidental opening or breakage When an outboard bearing is used mount drive and outboard bearing on a continuous foundation or bedplate and dowel both in place FOUNDATION STEEL When mounting gear drive on Rexnord Industries 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info rexnord com web www rexnord com 168 050 PN 2124650 November 2008 Supersedes 0
68. seated Motor mounting needs to be done in conjunction with coupling alignment to control angular and offset misalignment Refer to the coupling manufacturer s manual for specific instructions Bolt down the motor to the torque specified in Table 4 Page 6 Coupling Guard The coupling guard must be trimmed in order to fit the height and shaft extension requirements Refer to the coupling guard installation manual for instructions on trimming the guard After the guard has been trimmed holes can be drilled in the coupling guard plate on the swing base The guard can then be bolted down to the plate Lifting the Swing Base Assembly After the drive motor and coupling have been mounted to the swing base the completed assembly can be lifted into position for installation on the driven shaft The motor eyebolt and the lifting holes on the drive housing can be used as cable attachment points The motor eyebolt is strongest when the cable pull is vertical To insure that cable pull on the motor eyebolt is vertical use of a spreader bar is recommended See the sketch below To ensure safety chains or a sling should be placed behind the torque arm connection SPREADER BAR VERTICAL CABLE PULL LOCATE SAFETY CHAINS SLING HERE Mounting Swing Base Assembly to Driven Equipment Mount the gear drive to the driven shaft See Page 3 Secure the torque arm to the foundation per the instructions in Appendix A Rexn
69. stener is factory supplied Grade 8 8 metric amp Grade 5 inch t Backing and removal bolts are user supplied Removal bolt Grade 8 8 minimum Shaft length and Keyway L are required when using thrust plate and supplied retention fastener lt N gt RETENTION FASTENER r5 mm 20 INCHES THREADED HOLE ET REMOVAL BOLT AUXILIARY RELEASE SYSTEM USER PROVIDED WHEN REQURED LOOSEN BUSHING NUT AND REMOVE NUT RETAINING RING BEFORE USING ADD FLAT WASHERS AT BACKING BOLT IF NEEDED BACKING BOLT WITH FLAT WASHER S Rexnord Industries LLC 3001 W Canal St Milwaukee WI 53208 4200 168 050 Telephone 414 342 3131 Fax 414 937 4359 PN 2124650 November 2008 e mail info rexnord com web www rexnord com Supersedes 07 08 Appendix Falk Drive One Enclosed Gear Drives BR REXN RD Page 26o0f 26 Sizes M1130 thru M1210 e Type D Series Directions for Inverting Drives DH2 amp DB3 3A DIPSTICK IN HOLE OPPOSITE 5A INSPECTION COVER OF LOW SPEED GEAR LOCATION 2A HEX SOCKET PIPE PLUG 1 EACH END 1A SQUARE HEAD MAGNETIC DRAIN PLUG 4A HEX SOCKET PIPE PLUG 1 EACH END STANDARD MOUNT INSPECTION COVER UP 3B DIPSTICK IN HOLE OPPOSITE LOW SPEED GEAR LOCATION 2B HEX SOCKET PIPE PLUG 1 EACH END SEALED WITH LOCTITE PIPE JOINT COMPOUND 30557 P N D004945 1B SQUARE HEAD MAGNETIC DRAIN PLUG 1 EACH END SEAL
70. und in Table 3 based on coupling size TABLE 3 Coupling Gap Fluid Coupling Tschan Hub Gap Size Size mm Inch 370HFDD 200 6 5 0 256 1420HFDD 230 15 0 295 1480HFDD 260 15 0 295 1584HFDD 300 8 4 0 331 1660HFDD 360 9 0 0 354 Calculate the hub protrusion Protrusion A Gap B C If the calculated protrusion is a negative value the hub overhangs the shaft by that amount Figure 2 MOTOR MOUNTN s PLATE HOUSING SHAFT FIGURE 2 PROTRUSION SPACER gt the hub is correctly located on the motor shaft the motor can be mounted to the motor adapter plate The hubs will be aligned and come together to the proper gap To fill the fluid coupling to the proper oil level align the mark on the perimeter of the fluid coupling with the mark in the center of the inspection window on the bell housing on the side opposite the TA Bushing nut or shaft extension To locate the correct mark on the fluid coupling begin by aligning the fill hole of the fluid coupling with the mark in the inspection window For fill angles less than 90 rotate the fill plug upward until the marks 168 050 November 2008 PN 2124650 Supersedes 07 08 Rexnord Industries LLC 3001 W Canal St Milwaukee WI 53208 4200 Telephone 414 342 3131 Fax 414 937 4359 e mail info rexnord com web www rexnord com REXN RD Falk Drive One Enclosed Gear Drives Appendix D Type D Series e Sizes M
71. urer s recommendations Cleaning may also be accomplished by means of a rod or wire brush Remove the tube end seal ring fittings Figures 7 amp 8 on Page 23 and pass a 500 12 mm diameter rod or wire brush through the tubes to remove the scale Tube 1 0 is 527 13 39 mm After cleaning all tubes reinstall the tube end seal ring fittings The outside of the cooling tubes aluminum fins may be cleaned by removing the tubes from the housing and cleaning with steam or suitable solvent To remove the tubes from the housing remove all seal ring fittings from the tubes Remove the 1 250 11 NPT x 750 14 NPT pipe bushings from one end of the drive A special deep well thin wall socket 1 812 hex by 7 deep may be required to remove and reinstall the pipe bushings CAUTION Take care not to damage cooling tube ends during disassembly cleaning and reassembly Withdraw the tubes from the housing through the 1 250 11 NPT holes using a 375 10 mm diameter rod through the tube as a disassembly and reassembly aid After cleaning reinstall the tubes in the drive Coat pipe bushing threads with thread sealant and reinstall the pipe bushings and tube fittings in the reverse order of disassembly Install the loop end assemblies in the same positions as before disassembly Refer to Column 1 for seal ring fitting assembly procedures Seal ring fittings use standard No 114 625 I D x 812 O D x 094 W Buna N seal rings if replacements a
72. ve is equipped with a backstop verify that the backstop will allow the necessary rotation or remove the backstop Find the torque to apply to the high speed shaft by dividing the tightening torque indicated in Table 3 by the drive s ratio Torque Ratio Apply the calculated torque to the high speed shaft or coupling using a spanner chain or pipe wrench Be careful not to damage the usable length of the high speed shaft Remove the fixed wrench from the TA Bushing nut and reassemble the backstop if necessary WARNING Never use the prime mover to produce the required torque This could result in severe personal injury or damage Apply Loctite 243 or equivalent to threads of setscrew Tighten the setscrew to 10 Nm 90 lb in on the bushing nut For drives subjected to vibratory conditions refer to Step c c Drives Subjected to Vibratory Conditions Extra precautions should be taken for drives subjected to vibratory conditions With the nut of the TA Bushing tightened to the specified torque locate the setscrew hole in the nut of the bushing assembly Using a 6 mm 15 64 inch diameter drill create a dimple in the outside diameter of the bushing flange by drilling through the setscrew hole in the nut Apply Loctite 243 or equivalent to threads of setscrew and tighten into bushing nut d Drives Using Thrust Plate Kit Install thrust plate and thrust plate retaining ring in hollow shaft Coat four to five engaging threads of r
73. ype adjustable torque arm is drive system if not already done Locate the position available for all shaft mounted Drive One sizes both of the anchor bracket to be mounted to the support parallel shaft Type DH and right angle Type DB It is structure Match drill the mounting holes for M20 CI used to support the drive when mounted in a standard 8 8 or 0 75 inch Grade 5 fasteners or better Lock horizontal position other positions may be available washers and flat washers are also required consult Factory The torque arm accessory is suitable NOTE Torque arm must be vertical 1 in both for use on swing bases bedplates or mounted directly to directions after installation the drive Three styles of rod end torque arms are AGE REGSUIIREIS Aeceimiblecro dard compaia Ta available 1 Standard style for swingbase or bedplate mounting 2 Clevis style for mounting directly to the drive foot 3 Turnbuckle style for greater length and adjustment The torque arm requires mounting holes in the driven equipment support structure to provide for attachment The customer is responsible for determining the structural integrity of their support member Mounting It is natural for the drive system to move during operation This movement is due to runout from the driven equipment shaft gear drive low speed shaft and the connection of the two Rod ends containing plain spherical bearings form a link to provide a resilient mounting support that accomm

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