vs2153-103-a-801_4 (1)

Total Sheet 151

Vendor’s name :

:

Company 's name : JGCS Consortium

:

Plant Location : Nghi Son, Vietnam

Project name : NSRP Complex Project

P / Order No. :

Equipment/Material name :

Item number :

Document title :

PROJECT (JOB No.: 0-6495-20)DOCUMENT CLASS:ISSUE PURPOSE:RESULT CODE: A, B, R, FNEXT STATUS: FA, FR, FI, FC, ABRESUBMISSION DATE:RESPONSIBLE DEPT./PERSON:Review Date:

SERIAL

801

2015.07.06 Y.N.SONG H.J.CHO




2015.01.21 Y.N.SONG H.LEE

DATE PREP'D CHK'D

2 FOR CONSTRUCTION M.G.HA

PurchaserDOC. No.

ORIG. PURCHASE ORDER NO. REV.

V S2153-103-A- 4

3 FOR CONSTRUCTION M.G.HA

4 AS BUILT M.G.HA

Approval or review hereunder shall not be construed to relieve Vendor/ Subcontractor of hisresponsibilities and liability under the Contract

110-AC-001

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

XAB

( )( )( )( )( )

A: Approved without Comment; B: Approved with Minor CommentR: Not Approved; F: Not Subject to Review

AIR COOLED HEAT EXCHANGER

KOREA HEAT EXCHANGER

Nghi Son Refinery and Petrochemical LLC.

SK Engineering & Construction Co., Ltd.

0-6495-PS2153-103-A-100

REVISION DESCRIPTION APP'D

1 FOR CONSTRUCTION C.W.SONG

0 FOR APPROVAL M.G.HA

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107447

A

107447

Mech./Y.C.Ko

107447

July.10,2015

107447

107447

Y.C.Ko

107447

July.10, 2015

SECTION DOCUMENT TITLE REMARKS

1.0 PRIOR TO ERECTION

1.1 SHOP UNIT RUN-IN PROCEDURE PAGE 4

INSTALLATION, OPERATION AND MAINTENANCE MANUAL INDEX

1.2 PROTECTION OF UNASSEMBLED PARTS. PAGE 6

1.3 STORAGE INSTRUCTION FOR ASSEMBLED UNITS PAGE 9

2.0 ERECTION AND ASSEMBLY

2.1 INSTRUCTION FOR BUNDLE HANDLING PAGE 13

2.2 ERECTION PROCEDURE PAGE 16

3.0 LUBRICATION (AT STANDSTILL & FOR OPERATION) PAGE 20

4.0 CHECK UP FIELD ENGINEER FOR PLANT START-UP PAGE 23

5.0 START-UP AND SHUT-DOWN INSTRUCTIONS PAGE 25

6.0 MAINTENANCE AND ROUTINE CHECKING PAGE 29

7.0 SPARE PART LIST PAGE 34

8.0 SPECIAL TOOL LIST PAGE 36

9.0 INSTRUCTION MANUAL

9.1 MANUAL FOR FAN PAGE 41

9.2 MANUAL FOR MOTOR PAGE 88

9 3 MANUAL FOR BELT PAGE 1119.3 MANUAL FOR BELT PAGE 111

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SECTION 1.0 PRIOR TO ERECTION

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SECTION 1.1 SHOP UNIT RUN-IN PROCEDURE

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1.1 Shop unit run-in procedure 1.1.1 Set fan pitch to design angle

1.1.2 Check fan tip clearance

1.1.3 Align and level speed reducer and motor

1.1.4 Install and align belts.

1.1.5 Make sure that the bearings are filled with the proper amount type of lubricant.

1.1.6 Rotate fan by hand to see that shaft and motor turn freely.

1.1.7 Make electrical hook-up.

1.1.8 Bump for rotation check of fan.

1.1.9 Then turn on, allow fan to reach half speed, turn off, allow to coast while checking for unusual noises.

(Blade sticking, motor noises blade sticking, motor noise, etc.)

1.1.10 If all is in order, start fan.

1.1.11 Check amperage, voltage and record same.

1.1.12 Allow to run thirty (30) minutes.

* Reference document No. VS2153-110-A-613 (Shop run test procedure)

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rjkim

입력 텍스트

(See page 109)

rjkim

입력 텍스트

(See page 19)

SECTION 1.2 PROTECTION OF UNASSEMBLED PARTS

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1.2 Protection of unassembled parts

1.2.1 Bearings

a) All bearings must be kept in a dry and well-ventilated storage area until ready for installation.

1.2.2 Motors

a) All motors must be stored in a dry, dust-free, low-vibration and well-ventilated area until ready for installation.

b) Shafts must be rotated every thirty days.

c) Keep machined surface of shaft covered with a heavy coating of grease.

1.2.3 Shafts

a) All shafts must be adequately protected from corrosion and physical damage. .

b) Keep all machined surfaces covered with a heavy coating of grease.

c) Shaft which is kept in stock must have their shaft turned periodically, at least once a month, in order to

renew the grease on the bearing races.

1.2.4 Belts

a) All belts must be stored in a dry and well-ventilated area until ready for installation.

(Preferably not more than 30 days prior to start-up.)

b) Keep all machined surfaces covered with a heavy coating of grease

1.2.5 Pulley

a) Pulleys must be stored in a dry and well-ventilated area with adequate corrosion protection for all machined

surfaces. (We suggest an application of clear plastic or lacquer to all machined grooves.)

1.2.6 Fan Blades

a) All fan blades should be left in their containers until ready for assembly.

b) All containers should be kept in an area where any physical damage can be avoided.

1.2.7 Fan hub

a) Hubs should be left on their shipping pallets until ready for use.

b) Hubs should be kept in an area where physical damage can be avoided.

c) Adequate corrosion protection should be provided for all machined surfaces.

1.2.8 Instruments (Vibration transmitter, Actuator, E/P positioner and etc.)

a) Instruments must be kept in a dry and well-ventilated area until ready for Installation.

1.2.9 Tube Bundles

a) Bundles should be stored in a level position off the ground with adequate protection from such elements as

mud, rain, etc.

b) Fin tubes must be covered preferably with plywood

c) All exposed nozzles must be covered

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d) Care should be exercised to prevent any physical damage to the bundles

1.2.10 Fan guard, Fan ring, Plenum chamber, Machinery mount, etc

a) All structural members should be stored in an area where any physical damage can be avoided.

1.2.11 Hardware

a) All small items such as nuts, bolts, lock washers, etc. should be stored in a dry and well-ventilated area until

ready for use.

1.2.12 Junction box

a) Junction box must be kept in a dry and well-ventilated area until ready for Installation.

1.2.13 Louver control unit

a) All parts should be stored in an area where any physical damage can be avoided

b) All small items such as nuts, bolts, lock washers, etc. should be stored in a dry and well-ventilated area

until ready for use

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SECTION 1.3 STORAGE INSTRUCTION FOR ASSEMBLED UNITS

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1.3 Storage of instruction for assembled units

Units should be placed preferably over hardstand on wooden shore. If units are to be stored in open field, the ground should be treated with herbicides to prevent growth of vegetation, which may enter and foul finned tube surface. Shoring should be level so that unit is not placed in twisted attitude and thereby prevent damaging the alignment of the mechanical equipment. For maximum protection of units, the 3/8" marine plywood may be placed over the fan opening. Special attention should be given to the following. 1.3.1 Tube Bundles

a) For a storage period up to 45 days, bundles should be thoroughly drained and hard board covers taped over nozzle openings.

b) For storage periods longer than 45 days, carbon steel bundles should be thoroughly drained, nozzle openings sealed with gasketed blinds and bundles purged, and pressurized with nitrogen to 5 psig. The exposed ends of carbon steel tubes between aluminum fins and tube sheets should be coated with epoxy to prevent external corrosion.

c) Stainless steel bundles should be hydrostatically tested with de-mineralized water or tap water if the chlorine content is low and flushed with air to eliminate moisture inside. The nozzles should then be sealed with gasketed blinds and pressurized as in step 2.

1.3.2 Mechanical

a) During assembly in our shop, grease lines are filled and connected to bearings, which are also charged with grease with allowing the grease to accumulate in bearing cavities for moisture proofing. Lightweight plastic sheeting will be taped tightly to the shaft just above the bearing to prevent accumulation of condensation or rainwater. The plastic sheeting will be taped in such a manner as to permit shaft rotation and should be left in place until equipment is placed in operation.

b) Motors be wrapped with light plastic sheeting to prevent entry of rainwater into bearing and motor cavities. Sheeting be tightly taped to prevent removal by wind during transportation and yet loose enough to permit shaft rotation. The plastic cover should be left in place during storage and until the unit is put into operation. If units are to be stored for more than 45 days, motors should be removed and stored in a weatherproof area.

c) Belts will be loosely installed at time of shipment and should remain so during storage period to prevent warpage of the shaft or setting of the belts. If units are to be stored for more than 45 days, belts should be removed and stored in a weatherproof area.

d) If units are to be stored more than 45 days, sheaves should be protected preferably with a lacquer or plastic coating applied to the grooves to prevent corrosion. Exposed machine surfaces should be lightly coated with a rust preventative. If units have gear drives, gears should be filled with recommended lubricant to mitigate interior corrosion.

1.3.3 Inspection And Maintenance During Storage

a) Motor shafts and fan shafts should be rotated several revolutions every thirty(30) days. This is to prevent pitting of bearings or bearing races which may occur when lubricant drains away from contacting parts.

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1.3.4 Steps To Be Taken Prior To Startup

a) After units are installed, prior to startup, especially after extended period of storage, grease lines should be disconnected at the bearing hosing and old grease purged from lines. Lines should then be refilled, reconnected to bearing housing and old grease purged from bearing housing. Exhaust plugs should be removed from motor housings and new grease applied until old contaminated grease is removed and new grease appears at exhaust port. Motors should be started and operated 5-10 minutes before exhaust plug is tightened.

(Caution : Be sure exhaust plug is removed prior to grease charge).

b) The same protection procedure of rotating motor shafts and fan shafts as practiced during

storage must be followed even after installation until the unit is put into operation.

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SECTION 2.0 ERECTION AND ASSEMBLY

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SECTION 2.1 INSTRUCTION FOR BUNDLE HANDLING

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2.1 Instruction for bundle handling

2.1.1 Loading and Unloading

Bundle should be handled with shackle and wire sling when they are loaded.

These bundles are consisted of fragile aluminum fin tubes. Please Fig.1 for the lifting method.

2.1.2 Transportation

Bundles should be transported one bundle at a time. Never stack two or more bundles even if they may

be small in size. Please consult Fig.2.

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2.1.3 Lifting and Moving

Bundles should be lifted and moved a crane. Never use forklift to lift are move bundles.

No Forklift. Absolutely No.

2.1.4 Bundle Protection

One should not walk on the bundle top. If walking on the bundle is unavoidable during installation, the

bundle should be protected by covering with plywood of thickness large than or equal to 12mm thick. If

the plywood alone appears to be insufficient, place pipes underneath the ply wood with proper space.

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SECTION 2.2 ERECTION PROCEDURE

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2.2 Erection and Assembly procedure

These instructions are to be used in conjunction with the following :

(Reference document No. VS2153-110-A-800, Erection procedure)

2.2.1 Setting of base plate

a) Set the base plate on the beam for foundation to secure the correct axis.

b) After the aligning of frame work, weld the liner and base plate to the beam for foundation.

2.2.2 Foundation check

a) A base elevation level is marked on the beam for foundation in reference to the bench mark.

b) Check the level of the setting plate by using a Y-Level, and measure the distance between axis.

2.2.3 Installation of steel structure and plenum chamber

a) Necessary scaffolds shall be provided around steel structures.

b) Lift the main column up by a crane and install it on the beam for foundation by fastening the anchor bolts,

when columns are installed attention the correct orientation and parts number.

c) Assemble plenum chamber on the ground.

d) After all columns are installed, install the plenum chamber by a crane. Plenum chamber should be set in

proper position specified in reference dwg.

e) Install each braces with set plates.

f) Each member shall not be tightened strongly on this stage, because it is necessary to adjust dimension later

g) Mount header stages, hand rails and ladders.

h) After the frame work was provisionally assembled, main columns and plenum chambers are checked for the

perpendicularity, horizontality and diagonal difference by using a transit or plumb bob and measure.

Limitation : Perpendicularity of column : 1mm/m

Horizontality of top of chamber : ±2 mm

Diagonal difference of top of column

If there are columns or plenum chambers for which perpendicularity, Horizontality or diagonal difference are

out of the standard, make level adjustment by means of the shim liner and correction of inclination of columns

with hipperers and chain blocks

2.2.4 Installation of floor plates, fan ring and fan guard

a) Fan ring and fan guard with beam of driving parts shall be assembled on the ground.

b) After the fan ring is assembled on the ground, check the roundness of fan ring, if tolerance is out of limit,

distortion of fan ring shall be corrected by using a hipperers, chain blocks and jack.

c) Fan ring and fan guard with driving parts shall be lifted by a crane and temporarily lay them on the scaffold.

d) Install floor plate with bracket.

e) After plenum chamber is finished fan ring with fan guard shall be lifted by a crane and installed to floor plates

from the underside.

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f) After the frame work, check the tightening torque of high strength bolts by using a torque wrench.

2.2.5 Assembling of driving parts

a) The driving parts such as, motor, shaft and bearing unit with bracket, sprocket and belt shall be assembled

one by one in accordance with driving part assembly drawings. Detail assembled procedure of fan shall be

referred to the separated sheets.

b) Check of roundness

Before finishing of fixing fan bracket and fan ring, measure eight point along the circumference to fan ring

radius from center of fan shaft, and check the perpendicularity of fan shaft, if tolerance is within limit,

driving parts shall be fixed.

c) Tensioning method of belt.

In order to tension a drive properly, the following may be followed

I. Push the tension meter to the mid point of the span between the two sprockets.

II. When both point are touched to the belt, read a graduation of the tension meter.

III. Range of deflection forces show in "DEFLECTION & DEFLECTION FORCE TABLE."

d) Sprockets alignment.

I. Misalignment of drive results in unequal tension and edge wear. Consequently, sprocket alignment

should be proved with a straight edge and shafts checked to assure parallelism. On longer center

distance drives because of the belt's tendency to run against one flange of the driven sprocket – it is

often advisable to off-set the driven pulley slightly to compensate.

II. It is important that the frame supporting the sprockets be rigid at all times. A non-rigid frame causes

sprockets misalignment in operation.

e) Mounting Grease Piping

I. Grease piping should be field bent for the purpose of accurate fitting.

II. Alien substance such as sand, rubbish and dust in the grease piping should be thoroughly removed.

III. If the forming of grease pipe was performed by flame, some scale will be made in the pipe.

IV. These scale should be thoroughly removed by acid cleaning or other methods.

f) Installation of Vibration transmitter (Accelerometer)

I. Accelerometer should be assembled on mounting hole of bottom bearing housing with mounting stud bolt.

g) Installation of Louver and instruments (actuator w/positioner) for auto-louver

I. Put the louver on top of the bundle one by one.

II. Fixing the louver to bundle frame with bolt.

III. Connecting the torque bar to link with arm connector shown as in detail A and detail B.

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IV. Put actuator w/positioned on the bracket for actuator and fixing actuator with bolt.

V. Connecting the stem of actuator with the arm of torque bar shown as in detail C

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SECTION 3.0 LUBRICATION(AT STANDSTILL & AT RUNNING)

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3.0 Lubrication

3.1 At running (For operation)

a) Before lubricating, clean the grease nipple and immediate vicinity thoroughly.

b) Remove grease outlet plug.

c) Inject the specified amount of grease into the bearing.

d) Running for 1~2 hours to ensure that all excess grease is forced out of the bearing.

e) Close the grease outlet plug..

3.2 At a standstill

a) Before lubricating, clean the grease nipple and immediate vicinity thoroughly.

b) In this case use only half the quantity of grease and then runt the motor for a few minutes at full speed.

c) When the motor has stopped, apply the rest of the specified amount of grease to the bearing.

d) After 1~2 running hours close the grease outlet plug.

Note.

1. Lubrication of motors shall be followed with maintenance manual for motor.

2. Grease Injection Points

1) For Fan’s Shaft (Top & Bottom)

2) For Motor (Driver End & Non-Driver End)

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NSRP Complex ProjectEmployer Doc. No.

Title: Lubrication ScheduleContractor Doc. No.

REV. 1V S2153 103 A 703

Lubrication Schedule

Title: Lubrication Schedule V-S2153-103-A-703

B G H K L

Interval of Oil Exchange orA li ti

Oil Flushing for Oil Console Unit

J

int

LUBRICANT RECOMMENDED LUBRICANT LUBRICANT QUANTITY

Kinematic Viscosity

A C D E F I

Interval till 1stExchange

RegularInterval at 2nd

and LaterExchange

Initial Quantityto Fill

Times of OilFlushing

OperationTotal Quantity @40°C @100°C

Flash Point Prelubed Sealed by Mfgr.

Notes andAttachmentsISO Visc. Grade

or NLGI Grd.

Initial Quantity to Fill

Application

Estimated Use(Compensate losses)

Oil Flushing for Oil Console Unit

P.O. No.

OT

RE

QU

IRE

D

OIL

GR

EA

SE

Manufacturer Trade Name

Equipment Tag No.

Manufacturername(and Model

name) ofEquipment or

Driver

Description of Each FillingPoint of Equipment orDriver for Lubrication

otal

no.

of f

illin

g po

i

Pour or DropPoint

Liters for OIL /Grams for GREASE

Unit Hours HoursLiters or

Grams/YearUnit Liters/Time Times Liters cSt cSt °C °C Y N Y N

ABBMOTOR D.E

10 X SHELL GADUS S2 V100 NLGZ2 23 12024 12024 N/A N/A N/A 100 11 180 N/A Y N

NOT

ABBO O

BRG(6313/C3)10 X SHELL GADUS S2 V100 NLGZ2 23 g 12024 12024 N/A N/A N/A 100 11 180 N/A Y N

ABBMOTOR N.D.EBRG(6312/C3)

10 X SHELL GADUS S2 V100 NLGZ2 20 g 13032 13032 N/A N/A N/A 100 11 180 N/A Y N

TYFAN SHAFT TOP


110-AC-001

TYBRG(UC314)


NSKFAN SHAFT BOTTOM

BRG(22316K)10 X SHELL GADUS S2 V100 NLGZ2 150 g 8640 8640 N/A N/A N/A 100 11 180 N/A Y N

INSTRUCTIONSCOLUMN K NOTES AND ATTACHMENTS – Detailed lubrication requirements

A List each tag no., manufacturer name (and Model name) and each FIILLING POINT for lubrication such as bearings,・・・・・・・・・. About each FILLING POINT, in the case of twobearings in one equipment, those shall be listed individually into the coupling side and the anti-coupling side.

NLGI GRADE IN COLUMN D MEANS VISCOSITY GRADE OF LUBRICANT.

B

C

D

Units of measure: LUBRICANT QUANTITY (COLUMN E) IS FOR EACH FILLING POINT OF DRIVER BEARING OR SHAFT BEARING.

1 Total no. of filling point covered by each lubricant part shall be described.

A separate line entry is required for each different lubricant type. Place check mark to indicate lubricant type.

Provide complete nomenclature for proper identification of lubricant characteristics. Alternate lubricants should be listed by referencing them to Column “K”.

E

Units of measure:

2

LUBRICANT QUANTITY (COLUMN E) IS FOR EACH FILLING POINT OF DRIVER BEARING OR SHAFT BEARING.

Oil Volume for "L" (liters); Grease Weight for "g" (grams); Time h (hours).

Initial Qty. to fill : Indicate holding capacity of unit.

Interval of Oil Exchange or Application : Based on normal operations. Special break-in Requirements shall be listed in Column “K”.

Estimated use : Write “0” if consumption is negligible

F

G

H

Pour point for oil, dropping point for grease

3

LUBRICATION OF ACTUATOR OR LOUVER IS NOT REQUIRED.

Column may be used for other than flash point if properly identified.

Estimated use : Write 0 if consumption is negligible.

Show viscosity at both temperature listed.

I

J Check “Y (means ; yes)” if equipment is factory sealed and requires no field lubrication.

4

K

Provide additional details and explanations when required by referencing notes in Section ”K”,

e g additives/ thickeners required FLUSHING requirements special conditions break-in procedures common lube system details to identify attachments to list lubricants etc

Check “Y (means ; yes)” if equipment is pre-lubed and requires no initial lubrication at site.

L

e.g. additives/ thickeners required. FLUSHING requirements, special conditions, break-in procedures, common lube system details, to identify attachments, to list lubricants, etc.

5 Provide P.O. No.

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SECTION 4.0 CHECK UP FIELD ENGINEER FOR PLANT START-UP

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4.0 Check up field engineer for plant start-up

4.1 Duties of The Field Engineer

The field engineer is an experienced mechanical technician who can ensure that fin-fan units properly prepared for startup and continuous plant operation. His responsibility is to instruct, to advise and to inspect, (not perform) the assembly operations prescribed in installation instructions. The field engineer's duties include. :

a) Inspect for proper assembly, alignment, fit-up, and tightness of fasteners for structural parts, including columns and braces, fan housing, mechanical mounts, personnel guards, louvers, walkway, and ladders.

b) Before starting fan drives, check rotating components for proper assembly and alignment of all

mechanical parts ; inspect drive shaft bearings, couplings, and speed reducers for lubrication; check fans for proper blade setting; confirm that vibration switches are mounted and connected, ready to energize; inspect HTD-belt drive for belt tension; and check all louvers manually or automatically operated, from fully open to fully closed positions to ensure freedom of movement.

c) Actuate fan drive and then inspect the unit for excessive noise, run-out, excessive heating or vibration

of any part; check motor loadings (it may be necessary to adjust blade angle by trial and error to required motor load); check correct direction of rotation, confirm the sensitivity setting of vibration cut-off switch; recheck louvers through full operational range with fans on.

d) Make sure to remove of shipping clips between header and tube bundle frames, and also confirm that

any piping does not restrict freedom of header to float with process temperature changes.

e) Instruct plant operating personnel on installation and maintenance procedures, safety precautions, and startup sequence (including the time that process fluid is introduced to the exchanger), and also provide information on availability and stocking of spare parts.

4.2 Before Calling The Field Engineer Since the function of the field engineer is to instruct, advise, and inspect, it is important that the equipment be

completely installed and ready to operate before he is called. The following operations are to be completed prior to his arrival.

a) Install and assemble all items in accordance with installation instructions.

b) Install and check electrical system, including vibration cut-off switch. Or applicable utility system,

if other than electric motor drive.

c) Fill all lubrication systems

d) Align all mechanical equipments and then bump (briefly) the fan start switch to check the fan rotation

(Clockwise, facing air stream).

e) Install belts and adjust tension correctly.

f) Install and check control equipments, including auto-variable hubs, louvers, steam coils, actuators, and

valve positioners. Connect all air operated equipments to supply lines and check any leaks.

g) Set fan blade at recommended pitch angle (See certified fan specification sheets).

h) Install personnel guards and remove all construction equipments from the unit.

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SECTION 5.0 START-UP AND SHUT-DOWN INSTRUCTIONS

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5.0 Start-up and shut-down instructions

5.1 Machinery

a) Prior to startup

I. General

i. Check bearings for lubrication. Line from remote grease fittings should be loosened at the

bearing housing and then flushed with grease from the fitting end. Line should then be

reattached to the bearing housing and grease applied until it appears at seal lip. This

procedure will insure that the line is full and free of moisture and debris.

ii. Check that the hub is properly leveled. If the drive shaft is not truly vertical, it causes the hub to

be cocked, and creates difficulty to accurately adjust blade angles. An eccentric rotation of fan

can also cause serious vibration problems. If the fan drive is operational, operate the unit

without the blades installed. If there exist misalignment, vibration or unbalance in the system, it

will be more easily identified and corrected at this time.

iii. Rotate fan by hand to see if shaft, speed reducer, and driver turn freely.

iv. Check adequate fan blade tip clearance. The allowable clearance is 5mm MIN. and 15mm

MAX. To measure the clearance, move all blades past a fixed point on the inside of the fan

ring to select a blade which gives the smallest clearance. Then move the blade through 360

degrees to locate the point of minimum clearance. Set minimum clearance by adjusting fan

ring segments if it is eccentric. Repeat to check maximum clearance.

v. Energize the fan drive fan blade orientation. If r momentarily to check proper direction of rotation

and leading edge is down and trailing edge up, the direction of rotation should be clockwise as

one views looking into the discharge stream.

vi. If the starting torque causes to trip vibration switch, adjust its sensitivity.

II. HTD-belt drive units

i. Check HTD-belt tension in accordance with the "Industrial belt and drive preventive maintenance”.

b) Startup

I. General

i. Start fan driver and then check the driver as outlined in manufacturer's instructions.

ii. Check the unit carefully for any excessive vibration.

II. Belt drive units

i. Run fan for several hours ; check carefully driver and bearings for abnormal heating. (Consult

manufacturer's instructions for maximum allowable start-up and operating temperatures). During

this period, check driver-output power and adjust fan blade pitch to the load driver if necessary.

ii. Tighten HTD-belts as required in accordance with "Industrial belt and drive preventive

maintenance ". (Belts may continue to stretch during the first 30 days of operating requiring re-

tensioning).

5.2 Tube Bundles

a) Prior to introducing hot fluid including steam purge.

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I. Must remove bolts to tie the floating header to side frames. The floating header is bolted to side

frames for transportation.

II. Must remove all covers and tie downs (If applicable).

b) Introduction of process fluid

I. All tube bundles have been hydrostatically tested to 150％ of maximum allowable pressure new and

cold at the manufacturer's shops. To verify that no damage has been done during shipment and/or

erection, it is good practice to hydrostatically test the entire system, including piping, heat exchangers,

pumps, ect., prior to start-up.

II. In general, the start-up procedure should be conducted in a manner that minimizes thermal shock of

the heat exchanger bundles, and prevents over cooling of critical services during periods of low

ambient temperature and low heat load.

III. Special precautions should be observed during starting up units for there move of heat from process

streams of the following types.

i. High viscosity fluids.

Fluids with pour points above the prevailing air temperature. In many cases, the AFC units

serving such streams will be specially equipped with one or more of the following devices

to assist in the prevention of start-up and operating problems.

ii. Louvers

- Manually operated(N/A)

- Automatically operated (N/A)

iii. Auto-variable pitch fan (If applied)

iv. Variable speed motor (If applied)

For units with these special devices, the start-up problems are considerably lessened.

Prior to admitting the process fluid, close the louvers, start steam through the steam coil and

then slowly admit the process fluid until normal flow through the unit is obtained. Gradually

open the louvers, stop the flow of heating steam and start the auto- variable pitch fans at

zero-fluid pitch. (Minimum air flow is usually obtained at 15 psi. instrument pressure). Watch

carefully the process fluid outlet temperature during the period, and if the danger of

excessive cooling seems likely, start the flow of heating steam. Generally, however, the

outlet fluid temperature will still be well above design, and the process of gradual increase in

heat removal can be continued. Gradually increase the flow of air until the desired process

fluid outlet temperature is attained. For units without louvers, steam coils, etc., admit the

process stream to the exchanger rapidly to prevent excessive cooling of the first liquid to

reach the cold tubes. Care must be exercised, however, to prevent undue shock from a

"hammering" effect. When normal flow is attained, start fans at a reduced pitch and then

gradually increase fan pitch until the desired fluid outlet temperature is reached.

IV. Maximum "fan-off" temperature at fan should not exceed 176 . If exceeded, reduce temperature

to a maximum of 121 ∼132 prior to energizing fans.

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5.2 Shut-down

a) Turn off fans.

b) Close inlet valves.

c) Close outlet valves.

d) Open all bundle drain.

e) While bundle is the still hot, stream out with 148.9 Or higher steam( But must be below ignition point

of the tube fluid). Extreme caution should be exercised when isolating bundles for winter operation

during periods of low ambient.

f) All header drain plugs should be removed and all moisture residues purged from bundle with

compressed air.

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SECTION 6.0 MAINTENANCE AND ROUTINE CHECKING

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6.0 Maintenance and Routine Checking 6.1 Maintenance and Routine checking (Instruction for maintenance of equipment)

6.1.1 Mechanical equipments lubrication.

Refer to section 3.0 Lubrication

6.1.2 Drive belt tension check

Refer to section 10.3 Manual for Belt.

6.2 Procedure for Maintenance of Fin tubes (Instruction for tube cleaning)

6.2.1 Interior cleaning of Fin-tubes

The methods used for the cleaning of the inside of air-cooler tubes are the same as for conventional shell-and-tube heat-exchangers.

1. Mechanical cleaning

This method consists of drills or wire brushes fitted to long rods which are rotated by a compressed air motor. This method is normally completed with a water rinse or a blowing out. It is not an advised method for the removal of tarry deposits.

2. Chemical cleaning

This method consists in circulating a hot chemical solution through the tubes. Such solutions contain inhibitors against tube wall corrosion. It is recommended to contact a specialist and to supply him with a sample of the fouling deposit, in order to best choose the chemical solution. Each tube-bundle has to be fitted with inlet and outlet pipe fittings (1 1/2” to 3”) to facilities the passage of the solution. A circulating pump and a topping-up and tank should also be available. This method is becoming well known in process plants because it reduces downtime and avoids disassembling the unit. It offers no advantage at all with blocked tubes.

3. High-pressure flushing equipment The use of these units (or “Hydrojets”) has become widespread in the U.S.A. and Europe during recent years. The

tube cleaning can be accomplished by means of a portable HP pump. Generally speaking, such pumps have a capacity of 25 gm with discharge pressures as high as 620 DAN/cm2. The sprinkler head is fitted at the end of a long tube, similar to that used for mechanical cleaning, and it is introduced into each tube individually. The best pressure is found by trial an error. Generally speaking, the softer the deposit, the lower water pressure needs to be. For example, an amine heat- exchanger can be cleaned with a water pressure of around 140 DAN/cm2. A scale deposit left by carbonated water requires a higher pressure ranging about 410 to 620 DAN/cm2. Here again, it should be emphasized that this is not suitable for blocked tubes. These have to be mechanically cleaned.

6.2.2 Outside cleaning of Fin-tubes

General The fouling of the extended heat-transfer or fin surfaces depends on the location of the unit, the king of process, the ground Conditions, foliage or other environmental factors (presence of other factories in the area)

The best known sorts of fouling are as follows :

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A. Dirt or dust It accumulates over fins and between fins. Sometimes, it collects as a fine powder and after being wetted it forms a crusty deposit. Or alternatively, with oil, it can produce a mixture having the consistency of putty. B. Lint, polar seeds, down of cotton wool (or American polar) etc. C. Insects D. Mixtures of dust with oil and corrosive substances

6.2.3 Cleaning methods Generally speaking, only the two or three lower fin-tube rows will be found to be fouled. This indicates that the cleaning should be undertaken from the top downwards with the fan at standstill and shut-off valves closed. A preliminary examination should first be made to determine which type of cleaning would be best. A. Air nozzle An air jet from a nozzle, under a pressure of 2.2 DAN/cm2, should normally remove dust powder and dry insects. One should ensure that the air jet is always within the plane of the fins to avoid bending them over. The nozzle usually consists of a 1” pipe, 7’ or 10’ long, flattened at the end to form a tip about 1 1/4” across. The air is supplied via a hose, a control valve and a pressure gage. B. Water nozzle A cold water jet, under a pressure of 2.2 DAN/cm2, normally allows the removal of agglomerated dust and other impurities. A fire hose with a 1” round-nosed jet should be satisfactory. As above, the jet should always lie within the fin plane, to avoid bending them over. C. Hot water or steam jet If the consistency of the fouling is such as to resist both the cold water and the air jet, an atomized spray of hot water or steam should be sufficient to clean the fins. The steam nozzle can be made in the same manner as the air nozzle. Hot water can be obtained by means of a proportioning/mixing device fitted at the inlet of the steam nozzle.

D. Chemical cleaning Normally, in 75% of cases, methods A, B and C will enable the fins to be cleaned. Nevertheless there are times when composition of the fouling is either chemical or organic. It is then necessary to consult a specialized chemical cleaning firm. With regard to chemical cleaning, great care should be taken. The cleaning fluid should be consistent with the fin material. The chemical cleaning specialist is familiar with these problems and is capable of supplying the proper cleaning solution.

6.2.4 Removal procedure for sheet plugs of air-cooler tube bundle In order to :

-. Change a leaking gasket -. Perform an internal checking of the headers and finned tubes -. Perform an internal cleaning of the tube bundles -. Plug a leaking tube 1. Removal of the sheet plugs These must be removed compulsory with and hexagonal spanner corresponding to the plug to be removed. The plugs will be loosened adding to the hexagonal spanner an extension tube(do not use in any case a pneumatic or

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electric bolting machine). After loosening, unscrew the plug by hand with hexagonal spanner without extension, or with the fingers. If manual operations is difficult, make a longitudinal hole in the plug to the outer diameter of the plug thread (6 to 7mm on the diameter, or 3 to 3.5mm on the radius). The drilling will be done after locating and marking with a taper the centre of the plug head. A preliminary hole of 5 to 6mm will be drilled in the longitudinal centre line of the plug, then the diameter will be widened either by changing the drill, or by using a cone-shaped reamer adapted to the required nominal diameter. The plug will then be unscrewed manually using the hexagonal spanner with an extension tube if necessary. The plug will shrink on its diameter and this will reduce the damage on the thread. The plug sheet will be tapped again manually with a finished tap. 2. Installation of the plugs after repairing New plugs and gaskets will be used for the reinstallation. The gaskets will be placed in their facing. They can be kept in place with a thin layer of grease. If this is not harmful for the process environment. The plugs will be installed and screwed manually or with the spanner until they are positioned on the gaskets. They will be tightened with the hexagonal spanner and the extension tube to a moderate degrees. The flattening of the soft iron gaskets will ensure the tightness between the plug and the header.

3. This procedure is the only that may be used for aircoolers which have already been operated. It is absolutely forbidden to use a pneumatic or electric bolting machine, as the damages involved by this method can harmful for the headers.

6.3.1 Instructions for remedying plug tube-bundle leakage observed on start-up or during operation.

The tube-bundle units will be delivered perfectly leak-proof after being subjected to tightness tests. However, should any leak be found (which may occur where tube-bundle units have been stored for a long period of time) proceed as follows :

A. Leakage at head front plug -. First reduce pressure, then slowly tighten the leaky plug and pressurize again. If seal is not perfect, repeat this operation.

-. If seal is still not perfect, change the solid ring gasket and also the plug if worn or damaged. Check that the ring gasket fits exactly into the spot facing provided for it in the header front plate.

NEVER RE-USE A WORN OR COLLAPSED GASKET. B. Leakage at tube sheet hole expand tube joint -. Remove plug in way of leaky tube. -. Roll in the tube a little further. -. Replace plug after changing the ring gasket taking the precautions detailed above. -. Re-pressurise. Repeat this procedure if seal is not perfect. C. Leakage resulting from crack in a faulty tube In such case, both ends of the faulty tube must be blocked. Proceed as follows : -. Remove header front plugs in way of the faulty tube. -. Cut through the tube at one end, a few millimeters from the tube sheet before the start of the finned section of the

tube, using an inner tube cutter. -. This is a must to prevent the tubes acting as a tie-rod between the two box headers.

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-. Using the special mandrel provided by the manufacturer, insert a taper plug into each end of the leaky tube. -. Gently hammer in the taper plugs. -. Replace header front plugs fitted with new ring gaskets as instructed under A.

8.3.2 Instruction for replacement of damaged finned tubes (Partial re-tubing of an air cooler plug bundle) Note : Upper tubes which interfere with proper operation to be replaced, too.

Operations Required equipment

1. Upper baffle plates to be dismantled Socket wrench in accordance with size of bolts, or cutter if sheets are secured by rivets.

2. Header plugs to be dismantled and Hexagonal socket wrench in accordance with diameter steel gaskets to be removed. of plug. 3. Tubes to be cut off in way of tube sheet Inner tube-cutter corresponding to diameter and thickness

outside the header. of tubes + set of blades.

4. Tubes for removal to be taken away Crane for burden lifting 5. Tube ends remaining in tube sheet to be Hammer + tube-expeller + cleaning brush removed and grooves to be cleaned.

6. New tubes to be set to position. Tube-expeller + hammer. 7. Tubes to be expanded inside tube sheet. Expanding machine + associated equipment

(filter and lubricator, expander, cutting tools, rollers)

8. Plug sheet to be tapped. Tap + wrench 9. Header to be closed. New gaskets to be fitted. Hexagonal socket wrench. Defective plugs to be changed 10. Hydraulic or pneumatic test to be performed, Conventional testing equipment. according to equipment specifications 11. Baffle plates to be assembled. Bolted sheets : socket wrench.

Riveted sheets : riveting machine + rivets or possible replacement by bolts.

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SECTION 7.0 SPARE PART LISTFOR CONSTRUCTION & PRE-COMMISSIONING

(WILL BE INCLUDED, LATER)

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SPIR No. : VS2153-103-A-750 Revision No. : 1 Date : 2015/03/06 Sheet No. 1 of 1Equip. PO No.: PS2153-103-A-100 Spare PO No. : Price Validity : N/A Currency : USDEquip. PO title : AIR COOLED HEAT EXCHANGER Address : 502-1 Osikdo-dong, Gunsan, Jeonbuk, Korea 573-540Vendor Name : KOREA HEAT EXCAHNGERS IND.CO., LTD. Phone / FAX : 82-63-441-5538/82-63-464-5443 Email address: [email protected] Interchangeability MatrixLineNo Tag No. / Item No. Equipment Description Vendor Name Vendor Model Name Vendor Serial No. 1 2 3 4 5 6

1 110-AC-001 LP STEAM VENT CONDENSER KHE N/A 110-AC-001 5

Total equipment items installed: 5 0 0 0 0 0

Parts per equipment model

LineNo Vendor Part No. Part Description Original Manufacturer

Name Original Manufacturer Part No. Spare PartsCatalogue ID

Assembly/Cross-sectionalDrawing No. Position No. Unit of

measurementDelivery LeadTime (weeks)

Unit price(UDS, Ex-

Works)

Unit Weight(kg)

Net Weight(kg)

Gross Weight(kg)

Measurements(m x m x m)

RecommendedQ'ty by Vendor

RecommendedQ'ty by

Contractor

Q'ty to beOrdered

Total partsinstalled 1 2 3 4 5 6

1 1416-P-001 PLUG BOLT (SA105, 1-3/8*25L) VISION METAL N/A N/A VS2153-103-A-090 8-1 EA N/A N/A N/A 420 4200 8402 1416-PG-001 PLUG GASKET (SOFT-IRON, 1-3/8*25L) JEIL E&S N/A N/A VS2153-103-A-090 8-2 EA N/A N/A N/A 420 4200 840

3 1416-G-001

GASKET for BLIND FLANGE, SPIRAL WOUND WITH GRAPHITEFILLER,304 S.S WINDING WITH 304 S.S INNER RING AND 304 S.SOUTER RING AS PER ASME B16.20.(t4.5*1-1/2" ASME #150 RF) JEIL E&S N/A N/A VS2153-103-A-090 7-7 EA N/A N/A N/A 20 20

4

4 1416-G-002

GASKET for BLIND FLANGE, SPIRAL WOUND WITH GRAPHITEFILLER,304 S.S WINDING WITH 304 S.S INNER RING AND 304 S.SOUTER RING AS PER ASME B16.20.(t4.5*2" ASME #150 RF) JEIL E&S N/A N/A VS2153-103-A-090 7-1,5 EA N/A N/A N/A 20 20

4

5 1416-S-001 STUDBOLT & NUTS for Vent,Drain (SA193-B7/SA194-2H, 1/2- JEIL E&S N/A N/A VS2153-103-A-090 7-8 SET N/A N/A N/A 20 80 166 1416-S-002 STUDBOLT & NUTS for N.C Vent (SA193-B7/SA194-2H, 5/8- JEIL E&S N/A N/A VS2153-103-A-090 7-1,6 SET N/A N/A N/A 10 80 167 1416-H-001 M20x75L_HEX B/2N/2PW(UPPER COLUMN TO TOP BEAM) SKB N/A N/A VS2153-103-A-230 UC01~UC06 SET N/A N/A N/A 6 120 248 1416-H-002 M20x75L_HEX B/2N/2PW(UPPER COLUMN TO MIDDLE BEAM) SKB N/A N/A VS2153-103-A-230 MB01,02 SET N/A N/A N/A 6 120 249 1416-H-003 M20x75L_HEX B/2N/2PW(BEAM TO BEAM) SKB N/A N/A VS2153-103-A-230 TB01,02,04,05 SET N/A N/A N/A 8 150 30

10 1416-H-004 M20x75L_HEX B/2N/2PW(POST TO BEAM) SKB N/A N/A VS2153-103-A-230 PO01 SET N/A N/A N/A 8 160 32

11 1416-H-005M20x75L_HEX B/2N/2PW(HORIZONTAL BRACE (TOP BEAM TO TOPBEAM)) SKB N/A N/A VS2153-103-A-230 HB01 SET N/A N/A N/A 8 160

32

12 1416-H-006M20x75L_HEX B/2N/2PW(HORIZONTAL BRACE (MIDDLE BEAM TOMACHINERY MOUNT)) SKB N/A N/A VS2153-103-A-230 HB02 SET N/A N/A N/A 8 160

32

13 1416-H-007 M20x80L_HEX B/N/2PW(FOR LIFTING LUG) SKB N/A N/A VS2153-103-A-230 LF01 SET N/A N/A N/A 6 120 24

14 1416-H-008M20x65L_HEX B/N/PW/SQ.W(9tx50x50xI.D23)(TOP BEAM TO BUNDLEFRAME) SKB N/A N/A VS2153-103-A-230 TB03 SET N/A N/A N/A 5 80

16

15 1416-H-009 M20x100L_HEX B/2N/2PW(FOR BASE PLATE) SKB N/A N/A VS2153-103-A-230 LC01~LC03 SET N/A N/A N/A 6 120 24

16 1416-H-010 M20x75L_HEX B/2N/2PW(LOWER COLUMN TO UPPER COLUMN) SKB N/A N/A VS2153-103-A-230 LC01~LC03 SET N/A N/A N/A 6 12024

17 1416-H-011 M20x75L_HEX B/2N/2PW(UPPER COLUMN TO PLATFORM SUPPORT) SKB N/A N/A VS2153-103-A-230 PS01,02 SET N/A N/A N/A 3 5511

18 1416-H-012 M20x75L_HEX B/2N/2PW(VERTICAL BRACE (SHORT SPAN)) SKB N/A N/A VS2153-103-A-230 VB01 SET N/A N/A N/A 9 180 3619 1416-H-013 M20x75L_HEX B/2N/2PW(VERTICAL BRACE (LONG SPAN)) SKB N/A N/A VS2153-103-A-230 VB02 SET N/A N/A N/A 6 120 24

20 1416-H-014 M20x75L_HEX B/2N/2PW(VERTICAL BRACE (PLATFORM SUPPORT)) SKB N/A N/A VS2153-103-A-230 VB03 SET N/A N/A N/A 5 10521

Two Years' Operation and Maintenance Spares

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SECTION 8.0 SPECIAL TOOL LIST

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Special Tool List

Project : NSRP(UTILITY) Project

Supplier : Korea Heat Exchanger Ind. Co., Ltd.

Item no. : 110-AC-001

No.

Name Dimension Sketch & Type Material No. of Required

Remarks Work/

set Spare/

set Total/ set

1 Torque Wrench w/ sockets

Maker Standard

1 1 For

Header Plug\

2 Digital Inclinometer

170

50

Maker Standard

1 1 For Fan

3 Torque Wrench w/ sockets ABOUT 630

Maker Standard

1 1 For Fan

4 Belt Tensioner (Analog type)

Maker Standard

1 1 For

HTD Belt

Detail information is on next page.

Korea Heat Exchanger Ind. Co., Ltd.

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No.

Name Picture Maker Model


TORQUEWORLD RNL200-IN

2 Digital Inclinometer

DIGITAL SPIRIT LEVEL

Absolute electronic

level position 400mm


TORQUEWORLD RLN600

4 Belt Tensioner (Analog type)

GATES 7401-0076

-END-

Korea Heat Exchanger Ind. Co., Ltd.

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Special Tools List

Document No.: VS2153-103-A-752 Revision No. : 2 Date : 2015/04/28

Equip. PO No.: PS2153-103-A-100 Sheet No. 1 of 1

Equip. PO title : AIR COOLED HEAT EXCHANGER Address : 502-1 Osikdo-dong, Gunsan, Jeonbuk, Korea 573-540

Vendor Name : KOREA HEAT EXCAHNGERS IND.CO., LTD. Phone / FAX : 82-63-441-5538/82-63-464-5443 Email address: [email protected]

Line

NoTag No. / Item No. Equipment Description Vendor Name Vendor Model Name Vendor Serial No. 1 2 3 4 5 6

1 110-AC-001 LP STEAM VENT CONDENSER KHE 110-AC-001 110-AC-001 5

Total equipment items installed: 5 0 0 0 0 0

Special Tools requird per model

Line

NoVendor Part No. Part Description Original Manufacturer Name

Original

Manufacturer Part

No.

Drawing No.Unit of

measurement1 2 3 4 5 6

1 RNL200-IN TORQUE WRENCH W/ SOCKETS (FOR HEADER PLUG) TORQUEWORLD RNL200-IN N/A N/A SET 1 N/A

2 AELP400MM DIGITAL INCLINOMETER (FOR FAN) DIGITAL SPIRIT LEVEL AELP400MM N/A N/A SET 1 N/A

3 RLN600 TORQUE WRENCH W/ SOCKETS (FOR FAN) TORQUEWORLD RLN600 N/A N/A SET 1 N/A

4 7401-0076 BELT TENSIONER OF ANALOG TYPE (FOR HTD BELT) GATES 7401-0076 N/A N/A SET 1 N/A

* NOTE : ACTUAL PICTURES ARE INDICATED ON NEXT PAGE.

Q'ty of

Special Tools

to be supplied

Spare Parts

Catalogue ID

(to be filled out by

purchaser)

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mailto:[email protected]

SECTION 9.0 INSTRUCTION MANUAL

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SECTION 9.1 MANUAL FOR FAN

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Installation Manual,

Fan Maintenance and Operation

Fan Series B-BR

B-BR Series – V 3.1 – EN December 2013

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COFIMCO axial fans for the world COFIMCO B-BR Series

It is recommended that you carefully read all content of this manual, before proceeding with fan installation.

IMPORTANT: for systems containing more than one fan, carry out equipment setting of a single fan and after proper fan operation is identified (as described in this manual), continue setting up all the other fans.

ATTENTION : COFIMCO B-BR fan series hub and blades are patented components.

The contents of this manual may not be copied, reproduced or printed without written permission from COFIMCO S. r.l. , which is determined to protect itself from contra actions by all law abiding means.

Copyright © 2009 - COFIMCO S.r.l., Pombia (NO), ITALY

All rights reserved.

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Manufacturer Declaration The manufacturer:

COFIMCO S.r.l. via A. Gramsci 62, 28050 Pombia (NO) ITALIA

States:

Each axial fan is considered and constructed to be incorporated into a machine or to be assembled with other machinery to form a machine as requested by 2006/42/EC norm.

It also states:

a fan may not be considered operational until the system containing the same fan or the system above mentioned fan is about to become a part of is declared compliant with 2006/42/EC standard and with current national regulations. The fan must also be mentioned in the conformity declaration .

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GENERAL TERMS AND CONDITIONS OF SALE

I. GENERAL NOTICE

The following general terms and conditions of sale (hereinafter also the “T&Cs”) shall apply to and regulate any purchase order, contract or agreement (hereinafter the “Contract”) resulting between Cofimco s.r.l. ("Cofimco") and any person, whether legal or natural, who orders or purchases or is offered products/equipment from/by Cofimco (hereinafter “Buyer” and, together with Cofimco, the “Parties” or, singularly, the “Party”) and constitute the complete and final agreement between the Parties.

II. TERMS OF PAYMENT

Unless otherwise stated in Cofimco’s order acknowledgment, payment shall become due pro rata as shipments are made and, namely, each payment will be due and payable at the time of the delivery of the equipment to the F.A.S. point specified in the Contract, it being understood that Seller may retain the equipment until payment is made. If Buyer delays shipment, date of readiness for shipment shall be deemed to be the date of shipment for payment purposes. If Cofimco’s manufacturing is delayed by Buyer, Buyer shall pay that portion of the purchase price which is equal to the percentage of completion; the balance shall be payable in accordance with the terms as stated above.

III. TITLE AND RISK OF LOSS

Title to the equipment to be supplied hereunder shall pass to Buyer upon full payment or upon delivery to the F.A.S. point specified in the Contract, whichever occurs last. Notwithstanding the foregoing, risk of loss or damage to the equipment shall remain with Cofimco until delivery of the equipment to the F.A.S. point. If Buyer is unable to take delivery when the equipment is ready for shipment, the equipment will be stored at Buyer’s expense and risk of loss shall immediately pass to Buyer.

IV. PROPRIETARY INFORMATION

All documents, drawings or writings ("Information") of any kind or in any form provided to Buyer by Cofimco are and shall remain the property of Cofimco. Buyer acknowledges that the Information may contain trademarked, copyrighted or otherwise proprietary and/or confidential concepts, ideas and data, all of which is and shall remain owned solely by Cofimco. In light of these acknowledgements, Buyer agrees to keep confidential and treat all information as if Buyer itself held a confidential and proprietary interest in the Information; to obtain Cofimco`s written permission prior to any disclosure or distribution of the Information to third parties and/or prior to the incorporation of the Information into any database, network or other computerized system; and to properly identify and attribute Cofimco`s proprietary interest in the Information including all appropriate trademark and/or copyright notices, whenever Information is disclosed or distributed pursuant to this Section. Buyer shall promptly return any Information to Cofimco upon request and Buyer and its agents shall abide by all nondisclosure terms and other reasonable provisions required by Cofimco as a condition of visiting any Cofimco facility. Except to the extent that the

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Information may be relied upon by Buyer to use and operate the equipment for its intended purpose(s), nothing in this agreement shall be construed as an implicit or explicit license by Cofimco to Buyer to make, use, research and develop, sell, copy, disclose, distribute, or otherwise benefit from the proprietary or confidential nature of the Information. The rights and obligations of this Section ("Proprietary lnformation") shall survive the cancellation, completion or any other termination of this Contract for a period of three (3) years after the date of said event.

V. WARRANTY

Unless expressly agreed otherwise, in writing in Cofimco’s order acknowledgment, Cofimco warrants that the equipment delivered hereunder will be free from defects in workmanship and material for a period of one (1) year from the date of initial startup or eighteen (18) months from the date of shipment, whichever occurs first.

In case of proved mechanical breakage or defects, Cofimco shall, at its expense, repair or replace, at the F.A.S. point specified in the Contract, the defective (portion of any) equipment, or, alternatively, Cofimco may, at its sole discretion, refund to Buyer the price paid for the defective item(s). For the foregoing remedy to apply, the following conditions shall be met: (i) the defect must occur and be discovered during the warranty period as set forth above, (ii) the use of defective equipment must be promptly discontinued by Buyer, (iii) Buyer must return the defective equipment to Cofimco and (iv) Buyer must give Cofimco written notification within thirty (30) days after Buyer's discovery of the defect, provided that any alleged or purported lack of fitness of the equipment or services supplied hereunder consequential upon the failure by Buyer to supply accurate, complete and reliable information regarding its needs and the technical and performance specifications and requirements of the equipment shall not constitute a defect hereunder. In any event, this warranty and remedy shall apply only subject to the further essential condition that Buyer properly unloads, stores, handles, maintains and installs the equipment, protects the equipment from damaging agents, and operates the equipment in a normal and proper manner within proper hosting premises, plant or facilities, in accordance with all due and appropriate standard procedures, in compliance with any applicable installation, maintenance and operations manual(s) for Cofimco fans and all instructions, recommendations and indications given by Cofimco at any stage, and not in excess of any applicable rating limitations, design specifications or technical, operating and dimensional requirements prescribed by the applicable documentation and drawings. Cofimco makes no warranty whatsoever regarding resistance of materials to corrosion or erosion. The sole liability of Cofimco and the exclusive remedy of Buyer, whether arising under contract, tort (including negligence), strict liability or otherwise, arising out of defects in the services or equipment supplied hereunder, shall be the remedies set forth above. In addition, Cofimco shall obtain for Buyer the warranties and guarantees provided by the manufacturers of equipment provided by others, but Cofimco shall have no further liability or responsibility for any equipment supplied by others. Buyer shall take any and all reasonable actions to mitigate any losses, damages or costs arising out of or in connection with the supply of equipment by Cofimco, this agreement and the Contract and any possible liability of Cofimco shall be limited and reduced accordingly and shall in no event include any losses, damages or costs which could have been prevented, avoided or mitigated by prompt, appropriate and diligent action by Buyer or by giving prompt notice to Cofimco.

Unless expressly agreed otherwise in writing in Cofimco’s order acknowledgment, Buyer and Cofimco agree that, in consideration of the express warranties above, all other warranties and guarantees, whether express or implied, whether arising under law, equity or custom of trade, including warranties of merchantability and fitness for a particular purpose, are excluded from these T&C and the Contract.

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VI. FORCE MAJEURE AND DELAY IN PERFORMANCE

Except for the payment of monies due hereunder or as otherwise set forth, neither party shall be held liable for any expense, loss, damage, failure to perform, delay in performing, or for any possible mechanical breakage or defect resulting from delay or prevention of performance caused by a Force Majeure Event or other circumstances outside Cofimco’s control such as, without limitation, hostilities, restraint of rulers or peoples, revolution, civil commotion, strike, shortages of labor, energy, fuel, machinery or materials, technical or yield failures, epidemic, accident, fire, flood, wind, earthquake, explosion, blockade or embargo, lack or failure of transportation facilities, actions of the other party, failure of the other party to perform required or necessary actions, delays in performance by the other party, or any law, proclamation, regulation or ordinance, demand or requirement of any government or governmental agency having or claiming to have jurisdiction over the work, the materials purchased for the work, or the Parties hereto, or any other cause, whether similar or dissimilar to those enumerated above, beyond the reasonable control of the Party affected. Accordingly, Buyer shall not have any claim against Cofimco in respect of nonperformance, erroneous performance or delay in performance. In the event Cofimco is delayed by reason of any of the foregoing, the time for performance and delivery shall be extended by a period of time equal to the period of delay, and the Contract price shall be increased to compensate the affected party for the increased cost of performance hereunder.

VII. TAXES

The prices for equipment are exclusive of any present or future state, municipal or other sales or use tax or any other present or future excise tax upon, measured by the gross receipts for any transaction hereunder or any allocated portion thereof, or by the gross value of the equipment, or of any present or future property tax or similar charge with respect to the equipment. If Cofimco is required by applicable law or regulation to pay or collect any such tax or taxes on account of the equipment, then such amount of tax and any penalties and interest thereon shall be reimbursed to Cofimco by Buyer.

VIII. TEST OF EQUIPMENT

Any performance test of equipment shall be made in accordance with procedures to be agreed upon in writing between Cofimco and Buyer. Cofimco shall be notified of and may witness any such test. All such tests shall be conducted within the warranty period. Buyer shall obtain Cofimco's written permission prior to any disclosure to a third party concerning the nature or results of such tests.

IX. CANCELLATION

Buyer may cancel orders entered on Cofimco's books only after Cofimco consents thereto and Buyer agrees to pay Cofimco for all costs incurred by Cofimco, all costs to cancel orders by Cofimco for performance, and a reasonable amount for Cofimco's profit.

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X. LIMITATION OF LIABILITY

Notwithstanding any other provision to the contrary of these T&Cs, the Contract or at law, neither Cofimco nor its subcontractors shall be held liable to Buyer or any third party for, without limitation, loss of anticipated profits, loss of business reputation or opportunity, loss by reason of plant or other facility shutdown (therein including missing or reduced production), nonoperation or increased expense of operation, service interruptions, cost of purchased or replacement power, claims of customers, loss of use of capital or revenue, cost of money, or for any special, indirect, incidental and/or consequential loss or damage of any nature whatsoever arising at any time from any cause whatsoever in connection with the Contract.

Accordingly, regardless of whether Cofimco has been advised of the possibility of such damages, under no circumstance shall Cofimco be liable for any losses, liabilities, claims, damages and/or expenses howsoever arising as a result of any action or omission by Cofimco under or in connection with the Contract whether under contract, tort (including gross negligence), strict liability or otherwise, except exclusively in the event they are the direct and immediate consequence of willful misconduct or gross negligence by Cofimco resulting in the material breach of essential duties under these T&Cs finally established by a court or arbitral panel of competent jurisdiction after due process of law.

In all cases, any liability of Cofimco arising out of or in connection with these T&Cs or the Contract shall not extend to any damages payable by Buyer to any third parties and shall be limited to such losses, liabilities, claims, damages and/or expenses which had been foreseeable at the time of the execution of the Contract, taking into account the circumstances of which Cofimco was aware at such time; moreover, in no event shall the total liability of Cofimco arising out of the supply of equipment or services hereunder - whether under contract, tort, strict liability or otherwise and regardless of the form of action - exceed the price of the purchase order under which the services or equipment giving rise to liability are provided.

Cofimco’s liability under these T&Cs and within the limits set forth herein, shall be exclusive and in lieu of any provisions, conditions and warranties implied by law, equitable principles or rules and/or custom of trade (including implied warranties of fitness for purpose and merchantability). Accordingly, to the maximum extent permitted and regardless of whether Cofimco has been advised of the possibility of any such loss or damage, Buyer waives any remedies and reliefs provided by the applicable law arising out of, or in connection with, any possible loss of (anticipated) profits and/or any other loss or damage other than as expressly specified under this Article X.

XI. REFUNDS, KICKBACKS, ILLEGAL PAYMENTS

Buyer is prohibited from paying any company funds to any director, officer, employee, or other agent of Cofimco or from otherwise making any payments from the funds that would be illegal under any applicable laws.

XII. GOVERNING LAW

These T&Cs, the Contract and all contractual and non-contractual disputes arising out of, or in connection therewith and with the supply of the equipment or services by Cofimco to Buyer, shall be governed by, and shall be construed solely in accordance with, the substantive laws of the Republic of Italy.

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XIII. JURISDICTION

Unless otherwise stated in Cofimco’s order acknowledgment, each Party agrees for the benefit of the other Party that the court of Milan, Italy, shall have exclusive jurisdiction to hear and determine any suit, action or proceedings, and to settle any disputes, which may arise out of or in connection with these T&Cs, the Contract or the supply of the equipment or services by Cofimco to Buyer and for such purposes, irrevocably submits to the exclusive jurisdiction of such court.

XIV. ENTIRE AGREEMENT CLAUSE

Together with Cofimco’s order acknowledgement, these T&Cs, irrespective of whether they are or will be attached or referred to by other Contract documents, constitute the only general terms and conditions of sale by Cofimco, and purchase by Buyer, of the equipment to be delivered or services to be rendered hereunder. Accordingly, except as provided for under Article XV below, these T&Cs shall supersede all communications, negotiations, arrangements and agreements, whether oral or written, between the Parties with respect to the subject matter of the Contract and, particularly, shall override any terms and conditions stated in any order or acknowledgement or any other document or communication issued, supplied or sent by Buyer.

Cofimco shall not be bound by any terms and conditions stated in Buyer’s purchase orders, acknowledgements forms or in any other document(s) or correspondence which vary, limit or add to these T&Cs, which shall prevail notwithstanding the diverging, conflicting or additional terms and conditions that may appear on any of the aforementioned documents unless not expressly incorporated herein. Moreover, it is expressly agreed that if Buyer issues a purchase order or other documents for the supply of the equipment or the services provided under these T&Cs, such document will be deemed to be for Buyer’s internal use only, and these T&Cs shall supersede any provision therein. Notice of objection is hereby given to any additional or different terms and conditions and Buyer accepts it.

Finally and in any event, subject to Article XV below acceptance by Buyer of the equipment or the services under the Contract will amount to and be deemed to all effects as an unconditional and final acceptance and approval by Buyer of these T&Cs.

XV. AMENDMENTS TO THE T&Cs

Any amendment or addition to these T&Cs may only be made in writing and shall bear the signatures of the duly authorized representatives of each Party.

SPECIFIC APPROVAL

For purposes of Articles 1341 and 1342 of the Italian Civil Code, Articles V, VI, X, XII, XIII, XIV of the General Terms and Conditions of Sale are hereby expressly and specifically agreed upon and approved by the Buyer.

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Table of Contents

Warr anty………………………………………………………………………………………… 12

1 General Information……………………………………………………..…………………… 13

1.1 B-BR Series COFIMCO fan description ..………...………………………..………... 13

1.2 Fan serial number description ..…………………………………...…………………. 14

1.3 Balancing ..…………………….……………………………………………………... 15

1.4 Delivery and storage ……………………………………...…………………………. 15

2 Set-up………………………………………………………………………………………….. 17

2.1 Transport procedure …………………………………………………………………. 17

2.2 Lift procedure ………………………………………………………………………... 18

2.3 Installation required tools……………………………………….……………………. 19

2.4 Blade axis tilt ………………………………………………………............................ 20

2.5 Fan rotation and flow direction …………………………..………………...………... 21

2.6 COFIMCO rotor and B-BR series hub installation procedures ……………..………. 22

2.6.1 Hub installation on shaft …………………………………………………… 22

2.6.2 Blade installation and spin fine tuning …………………………………….. 25

2.6.3 Installing the anti-recirculation disk ...……………..………………………. 28

3 Start-up instructions ………………………………………………………………………… 29

3.1 Operations implemented before start-up ………………………………..................... 29

3.2 Operations implemented after start-up ……………………………………................. 33

3.3 Profile exterior appearance …………………….......…………………………..……. 34

4 Maintenance preventive actions …………………………………………………………….. 36

4.1 Maintenance and operation …………………………………………………….......... 36

4.2 Temperature limits …………………………………………………………………… 38

4.3 Possible vibration causes …………………………………………………………….. 38

Hub removal ……………………………………………………………………………………. 40

Trouble Shooting ……………….………………………………………………………………. 42

Component list………………………………………………………………………..……......... 44

Contact ………………………………………………………………………………………….. 46

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Figure list

Figure 1.1: Fan installation type ……….……………………………..………..………………… 13

Figure 1.2: Identification label format ……………...…..……………...………..………………. 14

Figure 1.3: label sample …………………………………....…………….……………………… 14

Figure 2.1: blade lift……………………………..……………………………………………….. 18

Figure 2.2: torque wrench ……..………………………………………………………………… 19

Figure 2.3: spirit level ……..……….............................................................................................. 19

Figure 2.4: blade axis layout …………………………………………………………………….. 20

Figure 2.5: lade clockwise rotation………………………………………...…………………….. 21

Figure 2.6: cylindrical slot hub installation ………………………………………...……………. 22

Figure 2.7: guided hub installation ………………………………………………………………. 24

Figure 2.8: blade installation………………………………………………...…………………… 25

Figure 2.9: blade turn coordinator positioning……………………………………........................ 26

Figure 2.10: inclinometer correct positioning………………………………..…………...……… 26

Figure 2.11: Installing the anti-recirculation disk........................................................................... 28

Figure 3.1: Schematic reduction in diameter of the fan ................................................................. 31

Figure 3.2: Alignment of blocks …………………...………..………….……………….…….... 31

Figure 3.3: vibration control positioning diagrams ……………………………………………… 33

Figure 3.4: resin rich area ……………………………………………………………………….. 34

Figure 3.5: resin rich area (real section)………………………………………………………….. 34

Figure 3.6: resin rich ……………………………………………...……………………………... 35

Figure 3.7: aluminium superficial scratches.…………......……………...………………………. 35

Figure A.1: Hub removal …………………………………………………………..…….……… 40

Figure C.1 assembly part detail…………………………………..……………………..……….. 45

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Table list

Table 2.2: tightening torque of guiding slot screws …………………...………......…..………… 24

Table 2.2: tightening torque of blocks-hub ...…………………...………................…..………… 27

Table 2.3: screw types for different hubs ...................................................................................... 27

Table 2.4: tightening torque of fixing screws to those of the anti-recirculation disk ……............ 28

Table 3.1: minimum allowed distance between the blade tip and the nearest surface (δ) ....... 30

Table 3.2: tightening torque of screws, blocks-flexible elements .................................................. 32

Table 4.1: limit temperatures ……………………………………....………………...………….. 38

Table C.1: parts list ………………………………...………………………………..……...…… 44

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Warranty

COFIMCO S. r.l. ensures that labour and all materials used in fan construction are of high-quality.

However, in case of mechanical failure of our fans within the first year of operation or 18 months from factory shipment date, if our inspectors have noticed breakages due to material or workmanship defects, the fan will be repaired or replaced with an identical or equivalent fan , according to our exclusive and unquestionable verdict, at our expense. Possible repairs or replacements will be conducted at our establishment and do not include transport and workmanship costs.

Any warranty given by COFIMCO S. r.l. ceases, if the fan has been tampered with or if breakage is caused by incorrect manoeuvres or installation. Expenses for repairs conducted without COFIMCO S. r.l. approval will not be recognized.

In no case COFIMCO S. r.l. may be held responsible for consequential or incidental damage of any type, resulting from construction, sale, installation or use of its product.

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Chapter 1

General information

1.1 B-BR Series COFIMCO fan description

B-BR Series COFIMCO fan with variable rotation from standstill is a truly ingenious fan due to its simplicity.

The hub consists of a single steel block to be installed directly on the shaft.

The blades consists of an aero-dynamic aluminium or fibreglass airfoil, bolted to a flexible plate.

The flexible plate of the blade is provided, at the base, of blocks and bolts that allow its anchoring to the hub.

Figure 1.1: fan installation type

B-BR Series COFIMCO fans are available in two different configurations (see figure 1.1 only as an example)

• B type: fans supported by the drive shaft

• BR type: fans suspended from the drive shaft

B Type BR Type

AIR-FLOW DIRECTION AIR-FLOW DIRECTION

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1.2 Fan serial number description

All COFIMCO fans have a label positioned on the hub making them easy to identify.

Label structure is described in figure 1.2; a label example is given in figure 1.3.

F/T Fan type: fan type is given by a label containing the following: XXX XX XX XXY XXY

Hub dimensions

Hub type

Section material: N: Aluminium L: Flap aluminium F: Fibre-glass

Profile type

Fan blade number

Fan diameter in mm

Sometimes, after the acronym referring to the hub, the letters R and/or T can be reported, representing the reverse direction mode of installation. It also means that the blades are respectively equipped with a special tip plug.

C/R COFIMCO manufacture order reference number. P.O. Client acquisition number

I Manufacturing order item number A° Blade tilt angle

Figure 1.2: identification label format

COFIMCO S.R.L. - ITALY

Via A. Gramsci, 62 - 28050 POMBIA (NO)

F/T

C/R

P.O.

I

A°

BLADE PAT. N° 4618313

HUB PAT. N° 4715784

4267/05/24L/B3T

12345/678

PO123456

E-1234

10.5

Figure 1.3: 4267/05/24L/B3T label example

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The exemplified label (img. 1.3) refers to a 4267 mm diameter fan, equipped with 5 blades, each having a 24L profile (aluminium), blades with special caps at the tip and hub B3. 12345/678 manufacturing order, PO123456 customer purchase order number, E1234 manufacturing order internal number , 10.5° blade pitch angle. ATTENTION : the label shown here is only an example and does not correspond in any way to label data identifying any purchased fan. ATTENTION : data presented by the identification label must always be forwarded to COFIMCO when spare parts are requested.

1.3 Balancing

Unless otherwise requested, all COFIMCO fans are balanced as shown below:

• Fan dynamic balancing, with equilibrium degree G = 6.3 in accordance with ISO 1940/1, in this case the fan will be shipped already assembled.

• Static or dynamic balancing of the hub and static balancing of blades, such as to correspond, after assembly, at a degree G = 6.3 according to ISO 1940/1, when the fan is shipped disassembled. In this case the blades have the same static moment and, therefore, can be positioned in the hub in any order. The blades of the same item can be interchanged.

1.4 Delivery and storage

As soon as the COFIMCO fan is delivered, it is important that a thorough inspection is conducted in order to identify possible damage caused during transport. In this case, submit a complaint to the transport company and mark the related bill of lading. Immediately after fan delivery, check the perfect correspondence between ordered components and delivered components. In case goods do not comply with order, contact COFIMCO within two weeks from delivery.

Removed fan from its packaging only for installation. If the fan is not installed immediately, storage requirements will be as following:

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Short storage period

For a short storage period fan package may be stored in an open area characterized as:

• Covered.

• With good drainage.

• Sufficient placement area bearing capacity.

• Suitable for forklift, truck, crane use.

• Vegetation free.

• Protected from flooding.

• With adequate access roust.

Long storage period

In case of a long storage period, fan package will be preferably stored in an indoor area characterized as following:

• Covered.

• Enclosed on all sides.

• Asphalt or concrete pavement with adequate bearing capacity.

• Suitable for forklift and truck use.

• Parasite free (mice, insects, etc.).

• Protected from flooding.

• With adequate access roust.

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Chapter 2

Set-up

This manual refers to B-BR Series COMFIMCO fan set-up. Set-up conditions may not always be the same.

2.1 Transport procedure

The following rules should be respected during fan and varnished component handling, assembly and maintenance:

• Avoid hub stacking one above other; if necessary, place a separating element (wood, rubber, plastic, etc.) between discs.

• Direct contact between fan and any metallic instrument is strictly forbidden: chains, hooks, etc.

• Store hubs on a non-abrading surface.

• Avoid hub roll or glide during transport.

• Avoid hub exposure to temperatures above 80 °C (176 °F).

• In order to avoid paint damaging do not heat painted surfaces using flames.

• Avoid striking the casing with any object.

• In case a painted surface is damaged, carry out paint repair procedures as soon as possible (see contract applicable touch up procedure) in order to avoid production decline with possible rust appearance and premature deterioration of unprotected parts. In case above mentioned procedure is necessary but is not carried out, the warranty is declared void.

• Possible damage due to transport must be immediately reported to COFIMCO in order to assess whether such damage may or may not affect blade structural safety or aerodynamic performance.

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2.2 Lift procedure

The following rules must be respected during lift:

• Once removed from its package, fan movement must be minimal in order to avoid fan and, especially, paint damage.

• Direct contact between fan and any metallic instrument is strictly forbidden: chains, hooks, etc.

• Fully assembled fan must be elevated using at least three lifting points placed at equal distances between them.

• Elevating devices must be adapted to fan being lifted weight and dimensions.

• General and system's lifting regulations must always be respected.

• Blades must always be lifted in an horizontal profile position as shown in figure 2.1.

Figure 2.1: blade lift

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2.3 Installation required tools

Fan set-up requires the following tools:

• Torque wrench (figure 2.2) used for calibrated torque bolt tightening.

• Spirit level (figure 2.3) used to give the blade profile tilt needed to achieve desired performance according to procedures described in this chapter. Spirit level's precision must be at least ±0.5°(maximum admissible deviation).

Figure 2.2: torque wrench

Figure 2.3: spirit level

If requested, COFIMCO is able to provide assembly necessary tools.

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2.4 Blade axis tilt

B-BR Series COFIMCO fan rotor blade axis are in respect to the normal rotation axis plane, a small angle, aimed toward air flow direction (see figure 2.4). Above mentioned angle presence, the centrifugal force generates a bending torque opposite to the one generated by traction, considerably reducing blade stress. Therefore, when setting-up the blades, the arisen necessity, when mentioned angle is present at the time of installation, is to check that the blade axis will rotate towards the air flow direction.

Figure 2.4: blade axis layout

ATTENTION: in case the precone angle is installed incorrectly, or rather the blades are tilted towards air flow direction, loads stressing the blades considerably increase and may exceed design limits.

For this reason, in case the same cone is incorrectly set-up, the warranty is considered void.

Air -flow

Rotation axis Rotation plane

Blade axis tilt. Traction Centrifugal force torque

Traction torque Centrifugal force

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2.5 Fan rotation and flow direction

Fan rotation direction is correct when air flow moves from the part with greater curvature (back) to the lower curvature (belly). In the example of figure 2.5 it has a clockwise rotation, seen from the side receiving the flow; upon request, COFIMCO provides fans with counter-clockwise rotation.

Figure 2.5 blade clockwise rotation

ATTENTION: excessive obstacle closeness may generate a significant aerodynamic load disturbance for any blade, resulting in turbulence, whirlpools, major tiring loads and vibrations, depending on obstacle dimensions and distance.

Flow direction

Rotation axis

Clockwise rotation Blade axis

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2.6 COFIMCO rotor and B-BR series hub installation procedures

ATT ENTION: after making sure that electrical contacts have been removed and that the engine may not in any way be started inadvertently, it is allowed to proceed with assembly as follows:

NOTE: Elements present in the part list (see attachment C) are invoked in the text by corresponding number insertion between square brackets.

2.6.1 Crankshaft hub installation

COFIMCO provides two hub types:

1) Cylindrical slot hub: attached directly to the drive shaft, for the procedure see figure 2.6 .

Figure 2.6: Cylindrical slot hub installation

19 15

1 16

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Coat the shaft with a thin layer of grease. If provided, install the spacer ring [16] by inserting it in the shaft supporting the fan until it comes into contact with its edge.

Push the hub [1] onto the motor shaft until it comes into contact with the shoulder, with the shaft itself, or with the spacer ring if any. Make sure that the hub is mounted as in figure 2.5, that is with the faces inclined downward.

The shaft on which the rotor is mounted on must remain inside hub slot at least 2mm when the hub/spacer ring is operational (a 5mm distance is recommended), so vertical fan sliding is inhibited when fan fastening plate screw [19] is tightened.

Put the washer [15] to the hub and tighten the screw [19] to the shaft, as shown in figure 2.6.

NOTE: the washer [15] and the screw [19] are not supplied by COFIMCO.

ATTENTION: do not start the fan with central screw incorrectly tightened.

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2) Socket hub: in order to anchor refer to figure 2.7.

ATTENTION: the fan shaft must not be completely lubricated.

Figure 2.7: socket hub installation

Insert socket [17] in the drive shaft to desired anchor position; drive shaft extremity should not find itself inside the socket.

Install the hub [1] onto the guiding slot so as the two component's holes correspond.

Make sure that the hub is mounted as in figure 2.7, that is with the faces inclined downward.

Once component positioning has been verified, tighten guiding slot screws using tightening torques defined in table 2.1 paying attention to guiding slot type.

Cup type Tightening Torque

N m Lb ft

P2

Q1 and Q2

R1 and R2

S1 and S2

21

39

39

95

16

29

29

70

Table 2.1: guided bolt tightening torque [18] .

ATT ENTION: do not start the fan with guiding screws incorrectly tightened.

1

18 17

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2.6.2 Blade installation and pitch fine tuning .

When installing the blades follow the instructions described below and referring to figure 2.8.

CAUTION : before start installing the blades to the hub, clean all mating surfaces.

ATTENTION : if the system is equipped with dynamically balanced fan shipped disassembled, mount it observing the marking on blades/hub.

Figure 2.8: blade installation

1. Install the blade to the hub through the fasteners (hexagon socket screws [9] [11], washers [10] [12]) as shown in figure 2.8. The screws must be tightened so as to allow the rotation of the blades for subsequent adjustment of fitting. It is also recommended the application of an adhesive to secure the thread of the bolts, an adhesive such as Loctite 270 or equivalent.

ATTENTION : during assembly and when tightening the fixing bolts of the blade to the hub, hold the blades raised (so they are not affected by their own weight).

2. Use the inclinometer (figure 2.3) to give blades the tilt angle.

Place the inclinometer on the upper blade side 5 mm away from profile extremity perpendicular to blade axis as shown in figure 2.9.

21

22

23

12

11

9

10

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Figure 2.9: blade turn coordinator

In case the profile is very wide, therefore the instrument length is insufficient, rest a rigid bar of adequate length onto the blade so both profile points are reached and rest the instrument on top of it. See figure 2.10 for correct measuring position.

Figure 2.10: inclinometer correct positioning

Rotate the blades around their own axis until the tilt angle is reached (A°), angle described by the identification label. Maximum allowed tolerance is ±0.5°.

3. Tighten the screws [9] and [11] (using the torque wrench).

Screw tightening torques depend on utility class: use torques from table 2.3.

The type of screw depends on the type of hub, see table 2.2.

NOTE: the hub type is indicated on the identification label while bolt class is indicated by screw head.

ATTENTION : during operation and when the screws fixing the blade to the hub are tightened , hold the blades elevated (so they are not affected by their own weight).

ATTENTION : the stainless steel bolts (class A2/A4) will be manually tightened without the use of automatic/high velocity screwdrivers in order to avoid screw seizing.

Correct positioning Correct positioning Incorrect positioning

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Hub type Screw [9] Screw [11]

B1

B3

B6

M14

M16

M20

M12

M14

M20

Table 2.2: type of screws for different hubs (screws [9] and [11] standard)

Bolt Type

Tightening Torque

Class 8.8 A2/A4-70 A2/A4-80

N m Lb ft N m Lb ft N m Lb ft

M12

M14

M16

M20

75

119

179

350

56

88

132

258

-

125

194

400

-

92

143

295

64

101

151

295

47

75

112

218

Table 2.3: blocks-hub tightening torque (screws [9] and [11] standard)

Repeat above described operations for each blade. Before initiating new blade tilt adjustment, rotate the fan until the new blade reaches previous blade coupling adjustment position. By doing so, possible small variations due to eventual rotation axis verticality imperfections are compensated.

ATTENTION: in case of a multiple fan system, before proceeding with tilt angle adjustment, angle described by the identification label placed on all blades, adjust the angle for one fan and follow chapter 3 instructions.

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2.6.3 Installing the anti-recirculation disk

To install the anti-recirculation disk follow the procedure here below described, making reference to figure 2.11.

NOTE: The hub B1 is not equipped with anti-recirculation disk.

(a) B3 hub configuration (b) B6 hub configuration

Figure 2.11: installing the anti-recirculation disk

1. Position the spacer of the anti-recirculation disk [8A] (in the case of B3 hub) or [8B] (in the case of B6 hub) against the hub [1] B3 or B6, respectively.

2. Place the anti-recirculation disk [2] above the spacer.

3. Tighten the anti-recirculation disk to the hub using the proper screw M8 [13] and washer [14], applying the torques given in table 2.4.

NOTE: the hub type is indicated on the identification label while bolt class is indicated by screw head.

Bolt type

Tightening Torque

Class 8.8 - dry A2/A4-70 - dry

N m Lb ft N m Lb ft

M8 – B3 hub

M8 – B6 hub

25

27

18

20

21

21

15

15

Table 2.4: tightening torque of fixing screws to those of the anti-recirculation disk [13]

8B

1 1

8A

2 2 14

13

14

13

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Chapter 3

3 Start-up instructions

3.1 Operations implemented before start-up

1. Before operating the fan make sure that all the fixing blocks are anchored to the hub, in the case of backlash check the tightening torque of the screws [9] [11].

2. Check if the blade axis respect the tilt angle defined by the data sheet (see paragraph 2.4).

3. Proceed to the measurement of the deflection of the blades when stationary (static, δs) and in motion (dynamic, δd), based on the data sheet supplied with the product.

In the case in which the static deflection is greater than the dynamic one, manually rotate the fan for a full turn and check that the distance between the lowest point of the tip of the blade and the nearest surface (δ) is greater than the distance given in table 3.1 (δmin) for the diameter of the fan in question.

If the static deflection is lower than the dynamic one , manually rotate the fan to a full turn and check that the distance between the lowest point of the blade tip and the nearest surface (δ) satisfies the following relationship:

≥ + −

(Where is found in Table 3.1)

ATT ENTION: the distance between the lowest point of the blade tip and the nearest surface (δ) is valid for wind speeds up to 45 m/s.

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Hub type Fan Diameter (mm)

from to

B1 0 4000 150

B1 with 24L profile

0

3048

3047

4267

150

200

B3 0

4000

3999

4881

150

200

B3 with TD profile

0 5486 200

B6 0

5491

5490

6200

200

250

Table 3.1: minimum allowed distance between the blade tip and the nearest surface ()

4. Turn the fan to check that the gap between blade tip and ferrule is included in design ratio x/D, where x is the distance between blade tip and ferrule and D is fan diameter. The distance between blade tip and ferrule must be measured along blade axis.

ATTENTION : the minimum distance between the blade tip and the ferrule must take into account the difference between the static deflection and the dynamic deflection, in particular, if the static deflection is greater than the dynamic one, the blade must be raised with respect to the static deflection by a level equal to (δs - δd). In case the static deflection of the blade is lower than the dynamic one, the blade must be lowered with respect to the static deflection by a level equal to (δs - δd). The static and dynamic deflections are given in the data sheet of the fan.

In the case where the distance between the blade tip and the ferrule is not the one expected, the diameter of the fan can be modified by acting on the fixing blocks [22] and [23] between the blade and the hub, removing the tightening bolts [21] clamping and reassembling the fixing blocks [22] and [23] in reverse, as shown in figure 3.1.

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Figure 3.1: Schematic reduction in diameter of the fan

ATTENTION: in the case of unscrewing of the bolts [21], for the change in diameter of the fan, the bolts must be tightened again with the tightening torques given in Table 3.2, solely using hand tools; that is, it prohibited to use automatic tools of any kind.

ATTENTION: the change in diameter must be of equal entity on all the blades and the alignment of the blocks must take place on the same plane, as shown in Figure 3.2.

NOTE: data on the type of fasteners are marked on the screw head.

ATTENTION : the stainless steel bolts (class A2/A4) must be tightened, without using automatic/high speed screwdrivers (but manually tightened) in order to avoid screw seizing.

Figure 3.2: alignment of blocks

Flexible Element

21 21

21 21

Flexible Element

22

23

22

22 22 21

23

21

Blocks side surface

Block with slot

22

23

21

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Bolt Type (Block)

Tightening Torque

Class 8.8 - dry

Class 10.9 - dry A2/A4-80

- with grease

N m Lb ft N m Lb ft N m Lb ft

M10 (B1)

M10 (B1) with 24L

M12 (B3)

M16 (B6)

‒

_

‒

242

‒

_

‒

179

74

69 (with grease)

125

296

55

51 (with grease)

92

218

‒

_

‒

175

‒

_

‒

129

Table 3.2: torque screws [21], blocks-flexible element (standard screws)

ATTENTION: stainless steel screws (A2/A4-70 and A2/A4-80) use of the lubricant.

5. In case a painted surface is damaged (during transport, set-up, tilt angle adjustment, screw constant tightening or other reasons), carry out paint repair operations as soon as possible (see touch up procedure applicable to the contract) In case above mentioned procedure is necessary but is not carried out, the warranty is declared void.

6. Possible damage due to set-up must be immediately reported to COFIMCO in order to assess whether such damage may or may not affect blade structural safety or aerodynamic performance.

7. Remove all equipment from fan surrounding area.

8. Power on the fan for a few seconds and then shut it off. During the shut off phase check if blade rotation is correct as described in paragraph 2.5.

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3.2 Operations implemented after start-up

1. Check motor suction, if excessive, gradually reduce blade incidence angle until desired suction is reached. If motor suction is lower than provided, increase blade incidence angle until desired suction is reached; update the incidence angle on all system fans.

NOTE: a few angle deviation from design angle is considered normal.

ATTENTION : power absorption is inversely proportional to ambient air temperature.

2. Check that fan vibration level, measured according to fan shaft bearing assembly, in positions indicated by figure 3.1, do not exceed amplitudes of 7mm/s RMS (overall).

ATTENTION : for vibrations contained in 7-12 mm/s RMS (overall) range, the fan may remain operational for the time necessary for problem solving.

ATTENTION : this vibration limit is valid for translational vibrations, or rather constant direction vibrations along the fan-motor-transmission reference axis (invalid in case of rotational vibrations, in case these vibrations are excessive, contact COFIMCO).

ATTENTION : for whole structure admissible vibration level refer to structure developer. Refer to international standards such as ISO-10816-1 directive.

Figure 3.3: vibration control positioning schematics

3. After 50-75 hours of rotor operation check tightening of bolts fastening the blade [9] and [11].

PAC

CT

ACC

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3.3 Profile exterior appearance

ATTENTION : the fibreglass reinforced profiles (FRP) used in COFIMCO blades are obtained through pultrusion procedures. Because of the intrinsic process nature, during production small formations of reinforcement layer may form (figure 3.4) filled with resin ( resin rich area ). The same resin, once hardened, becomes fragile causing superficial irregularities (mostly on the leading edge) as shown in figures 3.5 and 3.6 even on blades that have never been operational. Above mentioned irregularities are not considered defects and, heaving only an aesthetic value, do not compromise in any way blade structural characteristics. In fact, these irregularities are analysed in the supply chapter and are subjected to acceptance standards defined during design phases.

The "resin rich" may be observed rather a long time after production (for example after transport) and in some cases after a few operation hours.

Figure 3.4: resin rich area

Figure 3.5: resin rich area (real section)

Normal

Resin rich Resin rich area = only aesthetic, non structural

Blade surfaces: textile and resin

Longitudinal fibres (glass) and resin

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Figure 3.6: resin rich

NOTE: The reinforced fibreglass (FRP) is sensitive to UV rays, causing a profile progressive discolouration with the passing of time (until it stabilizes), it does not induce blade mechanical property variation and is considered normal.

ATTENTION : aluminium profiles may have superficial scratches that do not compromise blade integrity and structural characteristics in any way. These scratches are aesthetic and are not covered by warranty.

Figure 3.7: aluminium superficial scratches

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Chapter 4

Maintenance Preventive Measures

4.1 Maintenance and operation

A. Check periodically fan general condition. The inspection interval depends on the fan's operation conditions, in normal conditions the inspection is recommender to be conducted once every 6 months. During these inspections check:

• bolt tightness; • possible corrosion; • blade coupling and profile general status;

If necessary, clean blades to avoid dirt accumulation that could induce improper operation.

ATTENTION : when cleaning the blades do not use high pressure air jets in order to avoid painted and/or fibreglass part damage.

NOTE (in case fibreglass profiles are present): due to blade FPR component manufacturing process, surface imperfections may be contained in the same components but they do not influence the blade's structural integrity. Any blade is individually controlled during assembly, transport and packaging, thus presenting a conformity warranty once the product is released.

B. Ice formation on moving fan elements must absolutely be avoided.

Ice presence on non operating fan blades must be removed before rotor start-up, avoiding blade damage.

Snow accumulation on a non operating fan must periodically be removed depending on snow accumulation abundance.

In order to avoid constant blade snow cleaning, when fan operation is stopped for long periods of time in particularly snowing areas, blade rotation until they reach a vertical position is recommended.

ATTENTION : before moving the blades in a vertical position check if obstacles block the blade's path.

C. In case of a two speed motor system, before switching to the low speed, stop the motor for the time required for the fan to reach a speed lower than the operating speed, then power on the fan.

D. In case a fan is provided with tow way operation, power down the fan before changing rotation direction.

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E. Inspect periodically the varnished parts in order to promptly stop the beginning of any corrosion. Particularly, in the cooling towers, the blade edge connection (tip) wear protection is subjected to intense wear, when it is not made out of stainless steel; it is advised to check protection every six months. Damaged protections must immediately be reconditioned, mainly those on the leading edge of the blades.

ATTENTION : painted parts and protective treatments are subject to wear, independent of fan operation. Inspections and possible reconditioning are, therefore, appropriate when necessary. In case a painted surface is damaged, carry out paint repair procedures as soon as possible (see contract applicable touch up procedure) in order to avoid production decline with possible rust appearance and premature deterioration of unprotected parts. Periodic inspection absence renders the paint warranty void.

F. In case of lack of fan operation for long time periods, start-up the equipment (once every three months) for a few minutes in order to drain possible water / condensate accumulated inside of the blades that could produce excessive corrosion of any particular components.

G. Check that fan vibration level, measured according to fan shaft bearing assembly, in positions indicated by figure 3.1, do not exceed amplitudes of 7mm/s RMS (overall). In case the limit is surpassed, shut down the fan and search for the excessive vibration cause referring to paragraph 4.3 (possible cause of vibration).

NOTE: the vibration level is a good indicator for the system's condition, thus carrying out frequent inspections is considered appropriate. If the fan is provided with tools for rapid and automatic vibration detection, it's recommended to carry out such inspections once a month, otherwise it is advisable to conduct a vibration check every time the fan periodic inspection is carried out.

Reading recording is recommended to be carried out each time so comparison with previous readings is made possible (is always performed in the same locations, which can be identified through paint signs or other). During vibration measurements, conduct the usual safety measures and in particular do not approach a running fan, but place the transducer (accelerometer) near the non-operational fan and perform measurements at a distance.

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4.2 Temperature Limits

B Series COFIMCO fans are designed to operate with the following temperatures:

Minimum - 40 °C (-40 °F) with standard materials

Maximum

For aluminium blades: + 105 °C (+ 221 °F) For fibreglass blades (FRP): + 80 °C (+ 176 °F) operational fan + 105 °C (+ 221 °F) non operational fan

Table 4.1: limit temperatures

4.3 Possible vibration causes

The cause of fan vibrations may vary. Below are listed the most common:

A. Imbalance of one or more blades: this causes vibrations in the rotor plane of rotation, with a frequency equal to the number of fan revolutions and with linear amplitude dependent on the amount of imbalance and the square of the speed of rotation.

B. Average blade pitch angle are not between ±0.5° tolerance: this causes vibrations outside the plane of rotation at a frequency equal to the number of fan revolutions, and amplitude depending on the square value of the speed of rotation.

C. Excessive blade closeness to the obstacles (periodicals aerodynamic disturbances): this causes vibrations outside the plane of rotation, with a frequency equal to the product between the number of blades and the number of laps, the amplitude depends on aerodynamic noise extent.

D. Resonance between one possible forces acting upon the fan is one (or more) way that the fan supporting structure vibrates.

Main vibration generating forces usually have the following frequencies:

• fan lap number;

• product between fan lap number and fan blade number;

• product between fan lap number and number of supports able to generate aerodynamic interference (if placed symmetrical to the axis), the value of this force is inversely proportional to obstacle distance to the blades.

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E. Vibrations transmitted from the structure that the fan is installed on: the frequency of such vibrations depends on the frequency of external forces and on structure resonance frequencies.

F. Blade resonance with one possible forcing: in the vast majority of cases, the vibration is manifested outside of the plane of rotation.

G. Drive shaft misalignment: in the vast majority of cases, the vibration is manifested outside of the plane of rotation.

H. Blade and/or speed reducer mounting bolt loosening: fan behaviour in these conditions is unpredictable because it depends on loosening extent and location.

I. Slow shaft bearing wear: it produces vibrations within the plane of rotation with a frequency equal to the number of fan turns.

J. The fan or support structure's nuts and bolts are loosened: in this case it's necessary to tighten bolts.

K. Blade drain slots are clogged: in this case unclogging is necessary to remove obstructions from drain slots.

L. Incorrect assembly of the blades into the hub : it is required to reassemble the hub properly, as described in paragraph 2.6.

ATTENTION : Fan' vibration amplitude depends on fan support stiffness. Not critical vibrations for a fan supported by a sufficiently rigid structure, are amplified and can become dangerous for the integrity of the impeller, if the fan support is too flexible. In addition, support flexibility causes a blade resonance frequency variation.

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Appendix A

Hub removal

ATTENTION: Before removing the hub must make sure that the motor's power supply is disconnected and also make sure that the motor will not become operational inadvertently.

Hub removal may be carried out with the blades still attached or with detached blades.

ATTENTION : during removal, the fan must be harnessed in order to avoid a fall.

Hub removal may be carried out in a simple manner by using a hub puller B, described in figure A.1, not supplied with the fan.

For removal follow the following procedure referring to figures A.1.

(a) extractor (b) hub removal

Figure A.1: hub removal diagram

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1. Remove the screw anchoring the hub to the shaft [19].

2. Insert a circular plate [A], see Figure A.1, to prevent crankshaft head damage. Plate dimensions depend on the hole (must have a diameter slightly smaller than the hole and a thickness of at least 5 mm).

3. Insert the extractor into the hub up to its end stroke, see Figure A.1 (b).

4. Insert the screw [W] until touching circular plate; remove the entire hub by tightening the screw [W] until the hub is fully raised from the shaft.

5. Once the extraction is completed remove the extractor and tighten once again the screw [19] using the correct tightening torque.

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Appendix B

Troubleshooting

TROUBLESHOOTING

Problem Possible cause Possible Solution

Low volumetric flow rate Low power consumption

System jam. Clean the whole system.

Air flow blocked by obstacles.

Check the obstacle's total effective area and fan inlet shape with regard to the original. Dry-cooler's required minimum free inlet area height must be equal to at least one fan diameter ; this height must be larger than in the case of multiple units in a row.

Static pressure higher than specified.

Increase blade tilt (up to 3 degrees after having consulted the datasheet).

Blade tilt angle decreased due to blade rotation (for example if the bolt tightening torque has not been respected)

Correct blade angle and refer to the instruction manual for correct bolt tightening torque.

Temperature higher than design temperature.

Increase blade tilt (up to 3 degrees after having consulted the datasheet).

High power absorption

Temperature inferior to design temperature.

Lower blade tilt angle. (up to 3 degrees after having consulted the datasheet).

Static pressure lower than design pressure.

Lower blade tilt angle. (up to 3 degrees after having consulted the datasheet).

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Problem Possible cause Possible Solution

The rotor rubs against the ferrule (fan casing)

Fan and/or support structure nuts and bolts is loose.

Tighten all bolts.

Impeller is not centred. Tip clearance to small.

Centre the impeller. Increase fan casing diameter.

Scratches or small damage … Contact COFIMCO Fine cracks on blade surface

… Contact COFIMCO

High vibration level

One or more blades are unbalanced.

Contact COFIMCO

Blade average pitch angle not included in ± 0.5 °tolerance.

Adjust blade angle.

Excessive blade closeness to obstacles (periodical aerodynamic disturbances).

Contact COFIMCO

Resonance between one possible forces acting upon the fan is one (or more) way that the fan supporting structure vibrates.

Contact COFIMCO

Vibrations transmitted from the fan support structure.

Contact COFIMCO

Resonance of the blades with one possible climatic forcing.

Contact COFIMCO

Drive shaft misalignment. Realign the shaft. Output shaft bearing wear. Contact supplier. Fan and/or support structure nuts and bolts is loose.

Tighten bolts with the correct tightening torque.

Blade drain slots are clogged. Remove obstructions from drain slots.

For any problem, please contact COFIMCO specifying purchase order number indicated on the tag attached on the hub.

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Appendix C

Component list

ATTENTION : the part list refers to a standard B-BR series fan, for special applications refer to the documentation supplied with the fan.

PART LIST

ITEM DESCRIPTION ITEM DESCRIPTION

1 HUB 14 WASHER

2 ANTI-RECIRCULATION DISK (IF

PROVIDED) 15 WASHER

7 BLADE 16 SPACER (IF PROVIDED)

8A ANTI-RECIRCULATION DISK SPACER

(IF PROVIDED) 17 CONICAL BUSH (IF PROVIDED)

8B ANTI-RECIRCULATION DISK SPACER

(IF PROVIDED) 18 GUIDING SLOT SCREW (IF PROVIDED)

9 SCREW 19 SCREW (NOT SUPPLIED BY COFIMCO)

10 WASHER 20 FLEXIBLE ELEMENT

11 SCREW 21 SCREW

12 WASHER 22 UPPER BLOCK

13 SCREW 23 LOWER BLOCK

B-BR SERIES FAN COMPONENTS

Table C.1: part list (see figure C.1)

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Figure C.1 assembly part detail

17

16 12

11

23

22

9

10

8A

19

15 21

2 14

13

8B

20 7

1

18

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Contact

COFIMCO S.r.l.

Via A. Gramsci, 62 28050 Pombia (NO) ITALY

Tel. +39 0321/968311 - FAX. +39 0321/958992

Hudson Products Corporation

9660 Grunwald Road Beasley, TX 77417 USA Phone: +1 281 396 8285 - Fax: +1 281 396 8388

Cofimco Fan (Changshu) Co., Ltd.

Jinjiang Industrial Park Huangpujiang Road Changshu Southeast Economic

Development Zone Changshu P.R.CHINA Phone +86-512 5235 8930 - Fax +86-512 5235 8929

Cofimco International Trading Co.,Ltd.

Room 1803, No.3 Building Kai Xuan Hua Yuan, 111 Zhong Cao Road

Shanghai 200030 P.R.CHINA Phone +86-2164-686460 - Fax +86-2164-686460

Cofimco Industrial Fans India Pvt. Ltd .

Survey Nos. 15/2A & 15/2B Mel Ayanambakkam Main Road

Rajiv Nagar, Chennai – 600 095 Tamil Nadu, INDIA Phone +91- 4465510390

[email protected] http://www.cofimco.com

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Low voltage Motors for explosive atmospheresInstallation, operation, maintenance and safety manual

Installation, operation, maintenance and safety manual ............................................................................................. EN 3

Montage-, Betriebs-, Wartungs- und Sicherheitsanleitung ....................................................................................... DE 21

Manuel d’installation, d’exploitation, de maintenance et de sécurité ........................................................................ FR 41

Manual de instalación, funcionamiento, mantenimiento y seguridad ........................................................................ ES 61

Manuale d’installazione, funzionamento e manutenzione ........................................................................................... IT 81

Manual de instalação, operação, manutenção e segurança ................................................................................... PT 119

More languages – see web site www.abb.com/motors&generators > Motors > Document library

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rjkim

입력 텍스트

2 – EN ABB Motors and Generators | Low voltage Ex motor manual 06-2012 90/151

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입력 텍스트

Selected Motor type / Frame : M3GP / 255

Low voltage Motors for explosive atmospheres 06-2012 | ABB Motors and Generators EN – 3

Low voltage Motors for explosive atmospheres

Installation, operation, maintenance and safety manual

Table of Contents Page

Low voltage Motors for explosive atmospheres ................................................................................3

1. Introduction .....................................................................................................................................51.1 Declaration of Conformity ...........................................................................................................5

1.2 Validity .....................................................................................................................................5

1.3 Conformity .................................................................................................................................5

1.4 Preliminary Checks .....................................................................................................................6

2. Handling .....................................................................................................................................62.1 Reception check ........................................................................................................................6

2.2 Transportation and storage .......................................................................................................6

2.3 Lifting .....................................................................................................................................7

2.4 Motor weight ..............................................................................................................................7

3. Installation and commissioning ......................................................................................................73.1 General .....................................................................................................................................7

3.2 Insulation resistance check ........................................................................................................7

3.3 Foundation .................................................................................................................................8

3.4 Balancing and fitting coupling halves and pulleys .......................................................................8

3.5 Mounting and alignment of the motor .........................................................................................8

3.6 Slide rails and belt drives ............................................................................................................8

3.7 Motors with drain plugs for condensation ...................................................................................9

3.8 Cabling and electrical connections .............................................................................................9

3.8.1 Flameproof motors.........................................................................................................9

3.8.2 Dust ignition protection motors Ex tD/Ex t ....................................................................10

3.8.3 Connections for different starting methods ...................................................................10

3.8.4 Connections of auxiliaries .............................................................................................10

3.9 Terminals and direction of rotation ............................................................................................10

3.10 Protection against overload and stalling ...................................................................................10

4. Operation ...................................................................................................................................114.1 Use ...................................................................................................................................11

4.2 Cooling ...................................................................................................................................11

4.3 Safety considerations ...............................................................................................................11

4.3.1 Group IIC and Group III ................................................................................................11

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4 – EN ABB Motors and Generators | Low voltage Motors for explosive atmospheres 06-2012

5. Motors for explosive atmospheres and variable speed operation ............................................125.1 Introduction ..............................................................................................................................12

5.2 Main requirements according to EN and IEC standards ............................................................12

5.3 Winding insulation ....................................................................................................................12

5.3.1 Phase to phase voltages ..............................................................................................12

5.3.2 Phase to ground voltages ............................................................................................12

5.3.3 Selection of winding insulation for ACS800 and ACS550-converters ...........................13

5.3.4 Selection of winding insulation with all other converters ...............................................13

5.4 Thermal protection of windings ................................................................................................13

5.5 Bearing currents .......................................................................................................................13

5.5.1 Elimination of bearing currents with ABB ACS800 and ABB ACS550 converters .........13

5.5.2 Elimination of bearing currents with all other converters ...............................................13

5.6 Cabling, grounding and EMC ...................................................................................................13

5.7 Operating speed ......................................................................................................................14

5.8 Dimensioning the motor for variable speed application .............................................................14

5.8.1 General ........................................................................................................................14

5.8.2 Dimensioning with ABB ACS800 converters with DTC control .....................................14

5.8.3 Dimensioning with ABB ACS550 converters ................................................................14

5.8.4 Dimensioning with other voltage source PWM-type converters ....................................14

5.8.5 Short time overloads ....................................................................................................14

5.9 Rating plates ............................................................................................................................14

5.9.1 Content of standard VSD plate ....................................................................................15 5.9.2 Content of customer specific VSD plates .....................................................................15

5.10 Commissioning the variable speed application .........................................................................15

5.10.1 Programming ABB ACS800 and ACS550 converters based on standard VSD plate ....15

5.10.2 Programming ABB ACS800 and ACS550 converters based on customer specific VSD plate .........................................................................16

6. Maintenance ...................................................................................................................................166.1 General inspection ...................................................................................................................16

6.1.1 Standby motors ..........................................................................................................17

6.2 Lubrication ...............................................................................................................................17

6.2.1 Motors with permanently greased bearings ..................................................................17

6.2.2 Motors with regreasable bearings ................................................................................17

6.2.3 Lubrication intervals and amounts ...............................................................................18

6.2.4 Lubricants ....................................................................................................................19

7. After Sales support ........................................................................................................................207.1 Spare parts ..............................................................................................................................20

7.2 Dismantling, re-assembly and rewinding...................................................................................20

7.3 Bearings ..................................................................................................................................20

7.4 Gaskets and sealings ...............................................................................................................20

8. Environmental requirements. Noise levels ..................................................................................20

9. Troubleshooting..............................................................................................................................21

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1. Introduction NOTE!These instructions must be followed to ensure safe and proper installation, operation and maintenance of the motor. They should be brought to the attention of anyone who installs, operates or maintains the motor or associated equipment. Ignoring these instructions may invalidate all applicable warranties.

WARNINGMotors for explosive atmospheres are specially designed to comply with official regulations concern-ing the risk of explosion. The reliability of these motors may be impaired if they are used improperly, badly connected, or altered in any way no matter how minor.

Standards relating to the connection and use of electrical apparatus in hazardous areas must be taken into consideration, especially the national standards for installation in the country where the motors are being used. Only trained personnel familiar with these standards should handle this type of apparatus.

1.1 Declaration of ConformityAll ABB motors with a CE-mark on the rating plate comply with the ATEX Directive 94/9/EC.

1.2 Validity These instructions are valid for the following ABB electrical motor types, when used in explosive atmospheres.

Non-sparking Ex nA series M2A*/M3A*, sizes 71 to 280 series M2GP, sizes 71 to 250 series M2B*/M3B*/M3G*, sizes 71 to 450

Increased safety Ex e series M2A*/M3A*, sizes 90 to 280 series M2B*/M3H*, sizes 80 to 400

Flameproof enclosure Ex d, Ex de series M2J*/M3J*, M2K*/M3K*, sizes 80 to 400, M3KP/JP 450

Dust ignition protection (DIP, Ex tD, Ex t ) series M2V*, M2A*/M3A*, sizes 71 to 280

series M2B*/M3B*/M3G*, sizes 71 to 450 series M2GP, sizes 71 to 250

(Additional information may be required by ABB when deciding on the suitability of certain motor types used in special applications or with special design modifications.)

These instructions are valid for motors installed and stored in ambient temperatures above – 20°C and below +40°C. Note that the motor range in question is suitable for this whole range. In ambient temperatures exceeding these limits, please contact ABB.

1.3 ConformityAs well as conforming to the standards relating to me-chanical and electrical characteristics, motors designed for explosive atmospheres must also conform to one or more of the following European or IEC-standards for the protec-tion type in question:

IEC/EN 60079-0 IEC/EN 60079-1

IEC/EN 60079-7

IEC/EN 60079-15

Equipment - General requirements Equipment protection by flameproof enclosures ”d“Equipment protection by increased safety ”e“ Equipment protection by type of protection ”n”

IEC/EN 60079-31

IEC/EN 61241-14

IEC/EN 60079-14

IEC/EN 60079-17

IEC/EN 60079-19

IEC 60050-426

IEC/EN 60079-10

IEC 60079-10-1

IEC 60079-10-2

EN 61241-0

EN 61241-1IEC/EN 61241-10

Equipment dust ignition protection by enclosure “t”Selection and installation of Ex tD (DIP) equipmentElectrical installations design, selection and erectionElectrical installations inspections and maintenanceEquipment repair, overhaul and reclamationEquipment for explosive atmospheresClassification of hazardous area (gas areas)Classification of areas – Explosive gas atmospheresClassification of areas – Combustible dust atmospheresElectrical apparatus for use in the presence of combustible dustProtection by enclosure ‘tD’Classification of area where combustible dusts are or may be present

Note: The very latest revisions of standards, which are not cited hereby, will introduce a “protection level” and thus change the marking of the motors. Some new require-ments are also added to several protection types.

ABB LV motors (valid only for Group II of Directive 94/9/EC) can be installed in areas corresponding to the follow-ing markings:

Zone Equipment protection levels (EPLs)

Category Protection type

1 'Gb' 2G Ex d/Ex de/Ex e2 'Gb' or 'Gc' 2G or 3G Ex d/Ex de/Ex e/Ex nA21 'Db' 2D Ex tD A21/Ex t22 'Db' or 'Dc' 2D or 3D Ex tD A21, A22/Ex t

According to the EN 500XX series, certified motors have EEx markings instead of Ex.'Gb'

Atmosphere; G – explosive atmosphere caused by gasesD – explosive atmosphere caused by combustible dust

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1.4 Preliminary ChecksUsers should check all information quoted in the standard technical information in conjunction with data concerning standards on explosion-proofing, such as:

a) Gas groupIndustry Location

gas/vapourPermitted equipment group

Example of gas

Explosive atmospheres other than mines

IIA II, IIA, IIB or IIC Propane

IIB II, IIB or IIC Ethylene

IIC II or IIC Hydrogen/Acetylene

b) Dust groupDust subdivision

Permitted equipment group

Type of dust

IIIA IIIA, IIIB or IIIC Combustible flyings

IIIB IIIB or IIIC Non-conductive dust

IIIC IIIC Conductive dust

c) Marking temperatureTemperature class T1 T2 T3 T4 T5 T6 T125°C T150°C

Max. temperature °C 450 300 200 135 100 85 125 150

Max. temperature rise of surface K at 40°C

400 250 155 90 55 40 80 105

The max. temperature rise of surface is considered to be the surface inside the motor (rotor) for temperature classes T1, T2 and T3 and the outer surface of the motor (frame and/or end shields) for other temperature classes.

It should be noted that the motors are certified and classi-fied according to their group. This is determined by refer-ence to the ambient gas or dust atmosphere and by the marking temperature, calculated as a function of the ambient temperature of 40°C.

If the motor is to be installed in ambient temperatures higher than 40°C or at altitudes higher than 1000 meters, please consult ABB for eventual new rating data and test reports at the required ambient temperature.

The ambient temperature must not be less than -20°C. If lower temperatures are expected, please consult ABB.

2. Handling

2.1 Reception checkImmediately upon receipt check the motor for external damage (e.g. shaft-ends,flanges and painted surfaces) and if found, inform the forwarding agent without delay.

Check all rating plate data, especially voltage, winding connection (star or delta), category, type of protection and temperature class. The type of bearing is specified on the rating plate of all motors except the smallest frame sizes.

In case of a variable speed drive application check the maximum loadability allowed according to frequency stamped on the motor’s second rating plate.

2.2 Transportation and storage The motor should always be stored indoors (above –20°C), in dry, vibration free and dust free conditions. During transportation, shocks, falls and humidity should be avoided. In other conditions, please contact ABB.

Unprotected machined surfaces (shaft-ends and flanges) should be treated against corrosion.

It is recommended that shafts are rotated periodically by hand to prevent grease migration.

Anti-condensation heaters, if fitted, are recommended to avoid water condensing in the motor.

The motor must not be subject to any external vibrations exceeding 0.5 mm/s at standstill so as to avoid causing damage to the bearings.

Motors fitted with cylindrical-roller and/or angular contact bearings must be fitted with locking devices during trans-port.

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2.3 LiftingAll ABB motors above 25 kg are equipped with lifting lugs or eyebolts.

Only the main lifting lugs or eyebolts of the motor should be used for lifting the motor. They must not be used to lift the motor when it is attached to other equipment.

Lifting lugs for auxiliaries (e.g. brakes, separate cooling fans) or terminal boxes must not be used for lifting the motor.

Motors with the same frame may have a different center of gravity because of different output, mounting arrange-ments and auxiliary equipment.

Damaged lifting lugs must not be used. Check that eyebolts or integrated lifting lugs are undamaged before lifting.

Lifting eyebolts must be tightened before lifting. If needed, the position of the eyebolt can be adjusted using suitable washers as spacers.

Ensure that proper lifting equipment is used and that the sizes of the hooks are suitable for the lifting lugs.

Care must be taken not to damage auxiliary equipment and cables connected to the motor.

Specific lifting instructions are available from ABB.

2.4 Motor weightThe total motor weight may vary within the same frame size (center height) depending on different output, mount-ing arrangement and auxiliaries.

The following table shows the estimated maximum weights for motors in their basic versions as a function of frame material.

The actual weight of all ABB’s motors, except the smallest frame sizes (56 and 63) is shown on the rating plate.

FrameSize

AluminumMax. weight kg

Cast iron Max. weight kg

FlameproofMax. weight kg

71 8 13 -

80 13 30 39

90 21 44 53

100 30 65 72

112 36 72 81

132 63 105 114

160 110 255 255

180 160 304 304

200 220 310 350

225 295 400 450

250 370 550 550

280 405 800 800

315 - 1300 1300

355 - 2500 2500

400 - 3500 3500

450 - 4600 4800

If the motor is equipped with a brake and/or separate fan, contact ABB for the weight.

3. Installation and commissioning

WARNINGDisconnect and lock out before working on the motor or the driven equipment. Ensure no explosive atmosphere is present while the work is in progress.

3.1 GeneralAll rating plate values relating to certification must be carefully checked to ensure that the motor protection, atmosphere and zone are compatible.

Standards EN 1127-1 (Explosion prevention and protec-tion), EN 60079-14 (Electrical installations design, selec-tion and erection in explosive atmospheres) and EN 60079-17 (Electrical apparatus for explosive gas atmos-pheres. Inspection and maintenance of electrical installa-tions in hazardous areas (other than mines)) and EN 61241-14 (Electrical apparatus for use in the presence of combustible dust. Selection and installation) must be respected. Special attention should be paid to dust ignition temperature and the thickness of the dust layer in relation to the motor’s temperature marking.

Remove transport locking if employed. Turn shaft by hand to check free rotation if possible.

Motors equipped with roller bearings: Running the motor with no radial force applied to the shaft may damage the roller bearing.

Motors equipped with angular contact bearing: Running the motor with no axial force applied in the right direction in relation to the shaft may damage the angular contact bearing.

WARNINGFor Ex d and Ex de motors with angular contact bearings the axial force must not by any means change direction, because the flameproof gaps around the shaft change dimensions and may even cause contact!

The type of bearing is specified on the rating plate.

Motors equipped with regreasing nipples: When starting the motor for the first time, or after long storage, apply the specified quantity of grease.

For details, see section “6.2.2 Motors with regreasing nipples”.

When fitted in a vertical position with the shaft pointing downwards, the motor must have a protective cover to prevent foreign objects and fluid from falling into the ventilation openings. This task can also be achieved by a separate cover not fixed to the motor. In this case the motor must have a warning label.

3.2 Insulation resistance checkMeasure insulation resistance before commissioning and when winding dampness is suspected.

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WARNINGDisconnect and lock out before working on the motor or the driven equipment. Ensure no explosive atmosphere is present while executing insulation resistance check procedures.

Insulation resistance, corrected to 25°C, must exceed the reference value, i.e. 100 MΩ (measured with 500 or 1000 V DC). The insulation resistance value is halved for each 20°C rise in ambient temperature.

WARNINGThe motor frame must be grounded and the wind-ings should be discharged against the frame immedi-ately after each measurement to avoid risk of electri-cal shock.

If the reference resistance value is not attained, the wind-ing is too damp and must be oven dried. The oven tem-perature should be 90°C for 12-16 hours followed by 105°C for 6-8 hours.

Drain hole plugs, if fitted, must be removed and closing valves, if fitted, must be opened during heating. After heating, make sure the plugs are refitted. Even if the drain plugs are fitted, it is recommended to disassemble the end shields and terminal box covers for the drying process.

Windings drenched in seawater normally need to be rewound.

3.3 FoundationThe end user has full responsibility for preparation of the foundation.

Metal foundations should be painted to avoid corrosion.

Foundations must be even, see figure below, and suffi-ciently rigid to withstand possible short circuit forces. They must be designed and dimensioned to avoid the transfer of vibration to the motor and vibration caused by reso-nance.

Ruler

Foot location

Note! Height difference shall not exceed ± 0,1 mm referred to any other motor foot

Foot location

3.4 Balancing and fitting coupling halves and pulleys

As standard, balancing of the motor has been carried out using half key.

When balancing with full key, the shaft is marked with YEL-LOW tape, with the text “Balanced with full key”.

In case of balancing without key, the shaft is marked with BLUE tape, with the text “Balanced without key”.

Coupling halves or pulleys must be balanced after machin-ing the keyways. Balancing must be done in accordance with the balancing method specified for the motor.

Coupling halves and pulleys must be fitted on the shaft by using suitable equipment and tools which do not damage the bearings and seals.

Never fit a coupling half or pulley by hammering or by removing it using a lever pressed against the body of the motor.

3.5 Mounting and alignment of the motor

Ensure that there is enough space for free airflow around the motor. Minimum requirements for free space behind the motor fan cover can be found in the product catalog or from the dimension drawings available from the Web: see www.abb.com/motors&generators.

Correct alignment is essential to avoid bearing, vibration and possible shaft failures.

Mount the motor on the foundation using the appropriate bolts or studs and place shim plates between the founda-tion and the feet.

Align the motor using appropriate methods.

If applicable, drill locating holes and fix the locating pins into position.

Mounting accuracy of coupling half: check that clearance b is less than 0.05 mm and that the difference a1 to a2 is also less than 0.05 mm. See Figure 3.

Re-check the alignment after final tightening of the bolts or studs.

Do not exceed permissible loading values for bearings as stated in the product catalogs.

3.6 Slide rails and belt drivesFasten the motor to the slide rails as shown in Figure 2.

Place the slide rails horizontally on the same level.

Check that the motor shaft is parallel to the drive shaft.

Belts must be tensioned according to the instructions of the supplier of the driven equipment. However, do not exceed the maximum belt forces (i.e. radial bearing loading) stated in the relevant product catalogs.

WARNINGExcessive belt tension will damage bearings and can cause shaft breakage. For Ex d and Ex de-motors excessive belt tension may even cause danger by eventual mutual contact of the flamepath parts.

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3.7 Motors with drain plugs for condensation

Check that drain holes and plugs face downwards.

Non-sparking & Increased safety motorsMotors with sealable plastic drain plugs are delivered with these in the closed position in aluminum motors and in the open position in cast iron motors. In clean environments, open the drain plugs before operating the motor. In very dusty environments, all drain holes should be closed.

Flameproof motorsDrain plugs, if requested, are located at the lower part of the end shields in order to allow condensation to escape from the motor. Turn the knurled head of the plug to check free operation.

Dust Ignition Protection MotorsThe drain holes must be closed on all dust ignition protec-tion motors.

3.8 Cabling and electrical connections

The terminal box on standard single speed motors nor-mally contains six winding terminals and at least one earth terminal.

In addition to the main winding and earthing terminals, the terminal box may also contain connections for thermistors, heating elements or other auxiliary devices.

Suitable cable lugs must be used for the connection of all main cables. Cables for auxiliaries may be connected into their terminal blocks as such.

Motors are intended for fixed installation only. If not other-wise specified, cable entry threads are metric. The protec-tion class and the IP-class of the cable gland must be at least the same as those of the terminal boxes.

Ensure only certified cable glands for increased safety and flameproof motors are used. For non-sparking motors, cable glands must comply with IEC/EN 60079-0. For Ex tD/Ex t motors, cable glands must comply with IEC/EN 60079-0 and IEC/EN 60079-31.

NOTE!Cables should be mechanically protected and clamped close to the terminal box to fulfill the appropriate re-quirements for IEC/EN 60079-0 and local installation standards (e.g. NFC 15100).

Unused cable entries must be closed with blanking elements according to the protection and IP class of the terminal box.

The degree of protection and diameter are specified in the documents relating to the cable gland.

WARNINGUse appropriate cable glands and seals in the cable entries according to the protection type and the type and diameter of the cable.

Earthing must be carried out according to local regulations before the machine is connected to the supply voltage.

The earth terminal on the frame has to be connected to PE (protective earth) with a cable as shown in Table 5 of IEC/EN 60034-1:

Minimum cross-sectional area for protective conductorsCross-sectional area of phase conductors of the installation, S, mm2

Minimum cross-sectional area of the corresponding protective conductor, SP, mm2

4610162535507095120150185240300400

4610162525253550707095120150185

In addition, earthing or bonding connection facilities on the outside of electrical apparatus must provide effective connection of a conductor with a cross-sectional area of at least 4 mm2.

The cable connection between the network and motor terminals must meet the requirements stated in the national standards for installation or in the standard EN 60204-1 according to the rated current indicated on the rating plate.

Ensure that the motor protection corresponds to the envi-ronment and weather conditions; for example, make sure that water cannot enter the motor or the terminal boxes.

The seals of the terminal boxes (other than Ex d) must be placed correctly in the slots provided, to ensure the correct IP class. A leak could lead to penetration of dust or water, creating a risk of flashover to live elements.

3.8.1 Flameproof motorsThere are two different types of protection for the terminal box:

– Ex d for M3JP-motors– Ex de for M3KP-motors

Ex d-motors; M3JPCertain cable glands are approved for a maximum amount of free space in the terminal box. The amount of free space for the motor range is listed below.

Motor typeM3JP

Pole number

Terminal box type

Threaded holes

Terminal boxfree volume

80 - 90 2 - 8 25 1xM25 1.0 dm3

100 - 132 2 - 8 25 2xM32 1.0 dm3

160 - 180 2 - 8 63 2xM40 4.0 dm3

200 - 250 2 - 8 160 2xM50 10.5 dm3

280 2 - 8 210 2xM63 24 dm3

315 2 - 8 370 2xM75 24 dm3

355 2 - 8 750 2xM75 79 dm3

400 - 450 2 - 8 750 2xM75 79 dm3

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Auxiliary cable entries

80 - 132 2 - 8 1xM20 –

160 - 450 2 - 8 2xM20 –

When closing the terminal box cover ensure that no dust has settled on the surface gaps. Clean and grease the sur-face with non-hardening contacting grease.

WARNINGDo not open the motor or the terminal box while the motor is still warm and energized when an explosive atmosphere is present.

Ex de-motors; M2KA/M3KPThe letter ‘e’ or ‘box Ex e’ is shown on the terminal box cover.

Ensure that assembly of the terminal connection is carried out precisely in the order described in the connection instructions, which are found inside the terminal box.

The creepage distance and clearance must conform to IEC/ EN 60079-7.

3.8.2 Dust ignition protection motors Ex tD/Ex t

The motors have the terminal box fitted on the top with cable entry possible from both sides as standard. A full description is contained in the product catalogs.

Pay special attention to the sealing of the terminal box and cables to prevent the access of combustible dust into the terminal box. It is important to check that the external seals are in good condition and well placed because they can be damaged or moved during handling.

When closing the terminal box cover, ensure that no dust has settled on the surface gaps and check that the seal is in good condition – if not, it must be replaced with one with the same material properties.

WARNINGDo not open the motor or the terminal box while the motor is still warm and energized when an explosive atmosphere is present.

3.8.3 Connections for different starting methods

The terminal box on standard single speed motors nor-mally contains six winding terminals and at least one earth terminal. This enables the use of DOL- or Y/D –starting. See Figure 1.

For two-speed and special motors, the supply connection must follow the instructions inside the terminal box or in the motor manual.

The voltage and connection are stamped on the rating plate.

Direct-on-line starting (DOL):Y or D winding connections may be used.

For example, 690 VY, 400 VD indicates Y-connection for 690 V and D-connection for 400 V.

Star/Delta starting (Y/D):The supply voltage must be equal to the rated voltage of the motor when using a D-connection.

Remove all connection links from the terminal block.

For increased safety motors, both direct-on-line and star-delta starting of motors are allowed. In case of star-delta starting, only Ex-approved equipment is allowed.

Other starting methods and severe starting conditions:In case other starting methods are used, such as a soft starter, or if starting conditions are particularly difficult, please consult ABB first.

3.8.4 Connections of auxiliariesIf a motor is equipped with thermistors or other RTDs (Pt100, thermal relays, etc.) and auxiliary devices, it is recommended they be used and connected by appropri-ate means. For certain protection types, it is mandatory to use thermal protection. More detailed information can be found in the documents delivered with the motor. Connec-tion diagrams for auxiliary elements and connection parts can be found inside the terminal box.

The maximum measuring voltage for the thermistors is 2.5 V. The maximum measuring current for Pt100 is 5 mA. Using a higher measuring voltage or current may cause errors in readings or a damaged temperature detector.

The insulation of thermal sensors fulfills the basic insulation requirement.

3.9 Terminals and direction of rotation

The shaft rotates clockwise when viewing the shaft face at the motor drive end, and the line phase sequence - L1, L2, L3 - is connected to the terminals as shown in Figure 1.

To alter the direction of rotation, interchange any two connections on the supply cables.

If the motor has a unidirectional fan, ensure that it rotates in the same direction as the arrow marked on the motor.

3.10 Protection against overload and stalling

All hazardous area motors must be protected against overloads, see IEC/EN 60079-14 and IEC 61241-14.

For increased safety motors (Ex e) the maximum tripping time for protective devices must not be longer than the time tE shown on the motor rating plate.

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4. Operation

4.1 UseThe motors are designed for the following conditions unless otherwise stated on the rating plate.

– Normal ambient temperature limits are -20°C to +40°C.– Maximum altitude 1000 m above sea level.– Tolerance for the supply voltage is ±5% and for frequen-

cy ±2% according to EN / IEC 60034-1, paragraph 7.3, Zone A.

The motor must only be used in applications it is intended for. The rated nominal values and operational conditions are shown on the motor rating plates. In addition, all requirements of this manual and other related instructions and standards must be followed.

If these limits are exceeded, the motor data and construc-tion data must be checked. Please contact ABB for further information.

Particular attention must be paid to corrosive atmospheres when using flameproof motors; ensure that the paint protection is suitable for the ambient conditions as corro-sion can damage the explosion-proof enclosure.

WARNINGIgnoring any instructions or maintenance of the apparatus may jeopardize safety and thus prevent the use of the machine in hazardous areas.

4.2 CoolingCheck that the motor has sufficient airflow. Ensure that no nearby objects or direct sunshine radiate additional heat to the motor.

For flange mounted motors (e.g. B5, B35, V1), make sure that the construction allows sufficient air flow on the outer surface of the flange.

4.3 Safety considerationsThe motor is intended for installation and use by qualified personnel, familiar with health and safety requirements and national legislation.

Safety equipment necessary for the prevention of acci-dents at the installation and operating site must be pro-vided in accordance with local regulations.

WARNINGEmergency stop controls must be equipped with restart lockouts. After emergency stop a new start command can take effect only after the restart lockout has been intentionally reset.

Points to observe1. Do not step on the motor.2. The temperature of the outer casing of the motor may

be hot to the touch during normal operation and espe-cially after shut-down.

3. Some special motor applications require special instruc-tions (e.g. using frequency converter supplies).

4. Be aware of rotating parts of the motor.5. Do not open terminal boxes while energized.

4.3.1 Group IIC and Group IIIMotors in Group IIC and Group III are certified according to EN60079-0 (2006 or 2009) or IEC60079-0 (edition 5).

WARNING In order to minimize the risk of hazards caused by electrostatic charges, clean the motor only with a wet rag or by non-frictional means.

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In the case of other voltage source PWM converters with a minimum switching frequency of 3 kHz or higher, the preliminary dimensioning instructions provided in Chapter 5.8.3 in this manual can be used. The final values must be verified by combined tests..

Dust ignition protection motors DIP, Ex tDThe motor must be dimensioned so that the maximum outer surface temperature of the motor is limited accord-ing to the temperature class (e.g. T125ºC). For more information on a temperature class lower than 125°C, please contact ABB.

ABB Ex tD motors (125°C) have been type tested with ACS800 converters utilizing DTC control as well as with ABB ACS550 converters, and these combinations can be selected using the dimensioning instructions provided in Chapter 5.8.2.

In the case of other voltage source converters with pulse width modulation type of control (PWM), combined tests are usually needed to confirm the correct thermal perform-ance of the motor. These tests can be avoided if DIP-mo-tors are equipped with thermal sensors intended for control of the surface temperatures. Such motors have the following additional markings on the rating plate: - “PTC” with the tripping temperature and “DIN 44081/82”.

In the case of voltage source PWM converters with a minimum switching frequency of 3 kHz or higher, instruc-tions provided in Chapter 5.8.3 can be used for preliminary dimensioning.

5.3 Winding insulation

5.3.1 Phase to phase voltagesThe maximum allowed phase to phase voltage peaks in the motor terminal as a function of the rise time of the pulse can be seen in Figure 4.

The highest curve “ABB Special Insulation” applies to motors with a special winding insulation for frequency converter supply, variant code 405.

The “ABB Standard Insulation” applies to all other motors covered by this manual.

5.3.2 Phase to ground voltagesThe allowed phase to ground voltage peaks at motor terminals are:

Standard Insulation 1300 V peak

Special Insulation 1800 V peak

5. Motors for explosive atmospheres and variable speed operation

5.1 IntroductionThis part of the manual provides additional instructions for motors used in hazardous areas in frequency converter supply.

Additional information may be required by ABB to decide on the suitability for some machine types used in special applications or with special design modifications.

5.2 Main requirements according to EN and IEC standards

Flameproof motors Ex d, Ex deThe motor must be dimensioned so that the maximum outer surface temperature of the motor is limited accord-ing to the temperature class (T4, T5, etc.). In most cases this requires either type tests, or control of the outer surface temperature of the motor.

Most ABB flameproof motors for temperature class T4 have been type tested with ABB ACS800 converters utilizing Direct Torque Control (DTC) as well as with ABB ACS550 converters. These combinations can be selected using the dimensioning instructions provided in Chapter 5.8.2.

In case of other voltage source converters with pulse width modulation type of control (PWM), combined tests are usually needed to confirm the correct thermal performance of the motor. These tests can be avoided if flameproof motors are equipped with thermal sensors intended for the control of surface temperatures. Such motors have the following additional markings on the rating plate: - “PTC” with the tripping temperature and “DIN 44081/82”.

In the case of voltage source PWM converters with a minimum switching frequency of 3 kHz or higher, instruc-tions provided in Chapter 5.8.3 can be used for preliminary dimensioning.

For more information on T5 and T6 temperature class flameproof motors used with variable speed drives, please contact ABB.

Increased safety motors Ex eABB does not recommend the use of random wound low voltage increased safety motors with variable speed drives. This manual does not cover these motors in variable speed drives.

Non-sparking motors Ex nAThe combination of motor and converter must be tested as a unit or dimensioned through calculation.

ABB non-sparking cast iron motors have been type tested with ABB ACS800 converters utilizing DTC control as well as with ABB ACS550 converters, and these combinations can be selected using the dimensioning instructions provided in Chapter 5.8.2.

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5.3.3 Selection of winding insulation for ACS800 and ACS550-converters

In the case of ABB ACS800 single drives with a diode supply unit or ABB ACS550-converters, the selection of winding insulation and filters can be made according to table below:

Nominal supply voltage UN of the converter Winding insulation and filters requiredUN ≤ 500 V ABB Standard insulationUN ≤ 600 V ABB Standard insulation + dU/dt filters

ORABB Special insulation (variant code 405)

UN ≤ 690 V ABB Special insulation (variant code 405)AND dU/dt-filters at converter output

For more information on resistor braking and converters with controlled supply units, please contact ABB.

5.3.4 Selection of winding insulation with all other converters

The voltage stresses must be limited below accepted limits. Please contact the system designer to ensure the safety of the application. The influence of possible filters must be taken into account while dimensioning the motor.

5.4 Thermal protection of windings

All cast iron ABB Ex motors are equipped with PTC thermistors to prevent the winding temperatures from exceeding the thermal limits of the insulation materials used (usually Insulation Class B or F).

NOTE!If not otherwise indicated on the rating plate, these thermistors do not prevent motor surface temperatures exceeding the limit values of their temperature classes (T4, T5, etc.).

ATEX-countries: The thermistors must be connected to a thermistor circuit relay functioning independently and that is dedicated to reliably trip off the supply to the motor according to the requirements of the “Essential Health and Safety Require-ments” in Annex II, item 1.5.1 of the ATEX Directive 94/9/EC.

Non-ATEX countries: It is recommended that the thermistors are connected to a thermistor circuit relay functioning independently and that is dedicated to reliably trip off the supply to the motor.

NOTE!According to the local installation rules, it may also be possible to connect the thermistors to equipment other than a thermistor relay; for example, to the control inputs of a frequency converter.

5.5 Bearing currentsBearing voltages and currents must be avoided in all variable speed applications to ensure the reliability and safety of the application. For this purpose insulated bearings or bearing constructions, common mode filters and suitable cabling and grounding methods (see chapter 5.6) must be used.

5.5.1 Elimination of bearing currents with ABB ACS800 and ABB ACS550 converters

In the case of the ABB ACS800 and ACS550 frequency converter with a diode supply unit (uncontrolled DC voltage), the following methods must be used to avoid harmful bearing currents in the motors:

Frame size 250 and smaller No actions needed280 – 315 Insulated non-drive end bearing355 – 450 Insulated non-drive end bearing

ANDCommon mode filter at the converter

ABB uses insulated bearings which have aluminum oxide coated inner and/or outer bores or ceramic rolling ele-ments. Aluminum oxide coatings are also treated with a sealant to prevent dirt and humidity penetrating into the porous coating. For the exact type of bearing insulation, see the motor’s rating plate. Changing the bearing type or insulation method without ABB’s permission is prohibited.

5.5.2 Elimination of bearing currents with all other converters

The user is responsible for protecting the motor and driven equipment from harmful bearing currents. Instructions described in Chapter 5.5.1 can be followed, but their effectiveness cannot be guaranteed in all cases.

5.6 Cabling, grounding and EMCTo provide proper grounding and to ensure compliance with any applicable EMC requirements, motors above 30 kW must be cabled using shielded symmetrical cables and EMC glands, i.e. cable glands providing 360° bonding. Also for smaller motors symmetrical and shielded cables are highly recommended. Make the 360° grounding arrangement at all the cable entries as described in the instructions for the glands. Twist the cable shields into bundles and connect to the nearest ground terminal/busbar inside the terminal box, converter cabinet, etc.

NOTE!Proper cable glands providing 360° bonding must be used at all termination points, e.g. at the motor, con-verter, possible safety switch, etc.

For motors of frame size IEC 280 and upward, additional potential equalization between the motor frame and the driven equipment is needed, unless both are mounted on a common steel base. In this case, the high frequency

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conductivity of the connection provided by the steel base should be checked by, for example, measuring the poten-tial difference between the components.

More information about grounding and cabling of variable speed drives can be found in the manual “Grounding and cabling of the drive system” (Code: 3AFY 61201998) and material on fulfilling the EMC requirements can be found on respective converter manuals.

5.7 Operating speedFor speeds higher than the nominal speed stated on the motor’s rating plate, ensure that either the highest permis-sible rotational speed of the motor or the critical speed of the whole application is not exceeded.

5.8 Dimensioning the motor for variable speed application

5.8.1 GeneralIn the case of ABB ACS800 converters with DTC control and ACS550 converters, the dimensioning can be done by using the loadability curves shown in paragraph 5.8.2 and 5.8.3 or by using ABB’s DriveSize dimensioning program. The tool is downloadable from the ABB website (www.abb.com/motors&drives). The loadability curves are based on nominal supply voltage.

5.8.2 Dimensioning with ABB ACS800 converters with DTC control

The loadability curves (or load capacity curves) presented in Figures 5 and 6 show the maximum allowed continuous output torque of the motors as a function of supply frequency. The output torque is given as a percentage of the nominal torque of the motor.

NOTE!The maximum speed of the motor must not be exceeded even if the loadability curves are given up to 100 Hz.

For dimensioning motors and protection types other than those mentioned in Figures 5 and 6, please contact ABB.

5.8.3 Dimensioning with ABB ACS550 converters

The loadability curves (or load capacity curves) presented in Figures 7 and 8 show the maximum allowed continuous output torque of the motors as a function of supply frequency. The output torque is given as a percentage of the nominal torque of the motor.

Note A. The loadability curves in Figures 7 and 8 are based on 4 kHz switching frequency.

Note B. For constant torque applications the lowest allowed continuous operating frequency is 15 Hz.

Note C. For quadratic torque applications lowest continu-ous operating frequency is 5 Hz.

NOTE!The maximum speed of the motor must not be exceeded even if the loadability curves are given up to 100 Hz.

For dimensioning motors and protection types other than those mentioned in Figures 7 and 8, please contact ABB.

5.8.4 Dimensioning with other voltage source PWM-type converters

Preliminary dimensioning can be done by using the guideline loadability curves shown in figures 7 and 8. These guideline curves assume a minimum switching frequency of 3 kHz. To ensure safety, the combination must either be tested or thermal sensors intended for control of the surface temperatures must be used.

NOTE!The actual thermal loadability of a motor may be lower than shown by guideline curves.

5.8.5 Short time overloadsABB flameproof motors usually provide a possibility for short time overloading. For exact values, please see the motor’s rating plate or contact ABB.

Overloadability is specified by three factors:

I OL Maximum short time current T OL The length of allowed overload periodT COOL Cooling time required after each overload period. During the cooling period motor current and torque must stay below the limit of allowed continuous loadability.

5.9 Rating platesHazardous area motors intended for variable speed operation must have two rating plates; the standard name plate for DOL operation required for all motors, figure 9, and the VSD plate. There are two different versions of VSD rating plates available; the standard VSD plate shown in figure 10 and the customer specific VSD plate, figure 11. The values on the rating plates shown in above mentioned figures are for example only!

A VSD plate is mandatory for variable speed operation and must contain the necessary data to define the allowed duty range in variable speed operation. The following parameters at least must be shown on the rating plates for motors intended for variable speed operation in explosive atmospheres:

– Duty type– Type of load (constant or quadratic)– Type of converter and minimum switching frequency– Power or torque limitation – Speed or frequency limitation

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5.9.1 Content of standard VSD plateThe standard VSD plate, Figure 10, contains following information:

Supply voltage or voltage range (VALID FOR) and supply frequency (FWP) of the drive

• Motor type• Minimum switching frequency for PWM converters

(MIN. SWITCHING FREQ. FOR PWM CONV.)• Limits for short time overloads (I OL, T OL, T COOL )

see chapter 5.8.5• Allowed load torque for DTC controlled ACS800

converters (DTC-CONTROL). The load torque is provided as percent of the nominal torque of the motor.

• Allowed load torque for PWM controlled ACS550 converters (PWM-CONTROL). The load torque is provided as percent of the nominal torque of the motor. See also chapter 5.8.3.

The standard VSD plate requires calculation by the cus-tomer to convert the generic data into motor specific data. The hazardous motor catalogue will be required to convert the frequency limits to speed limits, and the toque limits into current limits. Customer specific plates can be re-quested from ABB if preferred.

5.9.2 Content of customer specific VSD plates

Customer specific VSD plates, Figure 11, contain applica-tion and motor specific data for variable speed application as follows:

• Motor type• Motor serial number• Frequency converter type (FC Type)• Switching frequency (Switc.freq.)• Field weakening or nominal point of the motor (F.W.P.)• List of specific duty points• Type of load (CONSTANT TORQUE, QUADRATIC

TORQUE, etc)• Speed range• If the motor is equipped with thermal sensors suitable

for direct thermal control, a text “PTC xxx C DIN44081/-82”. Where “xxx” denotes the tripping temperature of the sensors.

In customer specific VSD plates the values are for the specific motor and application and the duty point values can on most cases be used for programming converters protective functions as such.

5.10 Commissioning the variable speed application

Commissioning the variable speed application must be done according to the instructions provided in this manual, on the respective frequency converter manuals and local laws and regulations. The requirements and limitations set by the application must also be taken into account.

All parameters needed for setting the converter must be taken from the motor rating plates. The most often needed parameters are:

– Motor nominal voltage– Motor nominal current– Motor nominal frequency– Motor nominal speed– Motor nominal power

These parameters shall be taken from a single line of the standard rating plate fixed on the motor, see Figure 9 for an example.

Note: In case of missing or inaccurate information, do not operate the motor before ensuring correct settings!

ABB recommends using all the suitable protective features provided by the converter to improve the safety of the application. Converters usually provide features such as (names and availability of features depend on the model of the converter):

– Minimum speed– Maximum speed– Stall protection– Acceleration and deceleration times– Maximum current– Maximum power– Maximum torque– User load curve

WARNINGThese features are merely extras and do not replace the safety functions required by the standards.

5.10.1 Programming ABB ACS800 and ACS550 converters based on standard VSD plateCheck that the standard VSD plate is valid for the applica-tion in question i.e. that the supply network corresponds to the data of “VALID FOR” and “FWP”.

Check that the requirements set for the converter are met (Type and control type of the converter, as well as the switching frequency)

Check that the load complies with allowed loading for the converter in use.

Feed in the basic start-up data. The basic start-up data (parameter group 99) needed in both converters shall be taken from a single line of the standard rating plate (See Figure 9 as an example). Detailed instructions are available on the manuals of respective frequency converter. The selected line of the standard rating plate must comply with the data of “VALID FOR” and “FWP”, as well as to the rating of the supply network.

In case of ACS800 converters with DTC control, also the following settings must be made:

99.08 Motor Control Mode = DTC95.04 EX/SIN REQUEST = EX95.05 ENA INC SW FREQ = YES

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In case of ACS550 converters, the following settings must also be made:

2606 SWITCHING FREQ = 4 kHz or higher2607 SWITCH FREQ CTRL = 0 (OFF)

In addition to the above mentioned mandatory settings, it is strongly recommended to utilize all the suitable protec-tive functions of the converter. The necessary data must be taken from the standard VSD plate and converted to suitable format.

5.10.2 Programming ABB ACS800 and ACS550 converters based on customer specific VSD plateCheck that the customer specific VSD plate is valid for the application in question i.e. that the supply network corre-sponds to the data of “F.W.P.”.

Check that the requirements set for the converter are met (“FC Type” and “Switc.freq.”)

Check that the load complies with allowed loading.

Feed in the basic start-up data. The basic start-up data (parameter group 99) needed in both converters shall be taken from a single line of the standard rating plate (See Figure 9 as an example). Detailed instructions are available on the manuals of respective frequency converter. The selected line of the standard rating plate must comply with the data of “F.W.P.”, as well as to the rating of the supply network.

In case of ACS800 converters with DTC control, the following settings must also be made:

99.08 Motor Control Mode = DTC95.04 EX/SIN REQUEST = EX95.05 ENA INC SW FREQ = YES

In case of ACS550 converters, also the following settings must be done

2606 SWITCHING FREQ = 4 kHz or higher2607 SWITCH FREQ CTRL = 0 (OFF)

In addition to abovementioned mandatory settings, it is strongly recommended to utilize all the suitable protective functions of the converter. The necessary data must be taken from the standard VSD plate and converted to suitable format.

6. MaintenanceWARNINGVoltage may be connected at standstill inside the terminal box for heating elements or direct winding heating.

WARNINGStandards IEC/EN 60079-17 and -19 relating to repair and maintenance of electrical apparatus in hazardous areas must be taken into consideration. Only competent personnel acquainted with these standards should handle this type of apparatus.

Depending on the nature of the work in question, dis-connect and lock out before working on motor or driven equipment. Ensure no explosive gas or dust is present while work is in progress.

6.1 General inspection1. For inspection and maintenance use standards IEC/EN

60079-17, especially tables 1-4 as a guideline.

2. Inspect the motor at regular intervals. The frequency of checks depends on, for example, the humidity level of the ambient air and on the local weather conditions. This can initially be determined experimentally and must then be strictly adhered to.

3. Keep the motor clean and ensure free ventilation airflow. If the motor is used in a dusty environment, the ventila-tion system must be regularly checked and cleaned. For Ex tD/Ex t motors, respect the environment specifica-tions stated in standard IEC/EN 61241-14

4. Check the condition of shaft seals (e.g. V-ring or radial seal) and replace if necessary. For Ex tD/Ex t motors carry out detailed inspection according to IEC/EN 60079-17 table 4 with recom-mended interval of 2 years or 8000h.

5. Check the condition of connections and mounting and assembly bolts.

6. Check the condition of the bearings by listening for any unusual noise, vibration measurement, bearing tempera-ture, inspection of spent grease or SPM bearing moni-toring. Pay special attention to bearings when their calculated rated life time is coming to an end.

When signs of wear are noticed, dismantle the motor, check the parts and replace if necessary. When bearings are changed, replacement bearings must be of the same type as those originally fitted. The shaft seals must be replaced with seals of the same quality and characteristics as the originals when changing bearings.

For flameproof motors, periodically turn the knurled head of the drain plug, if equipped, in order to prevent jamming. This operation must be done when the motor is at stand-still. The frequency of checks depends on the humidity level of the ambient air, and on the local weather condi-tions. This can initially be determined experimentally and must then be strictly adhered to.

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In the case of the IP 55 motor and when the motor has been delivered with a plug closed, it is advisable to peri-odically open the drain plugs in order to ensure that the way out for condensation is not blocked and allows condensation to escape from the motor. This operation must be done when the motor is at a standstill and has been made safe to work on.

6.1.1 Standby motorsIf the motor is in standby for a longer period of time on a ship or in other vibrating environments the following measures have to be taken:

1.The shaft must be rotated regularly every 2 weeks (to be reported) by means of start-up of the system. In case a start-up is not possible, due to any reason, the shaft must be turned by hand in order to achieve a different position at least once a week. Vibrations caused by other vessel's equipment will cause bearing pitting which should be minimized by regular operation / hand turning.

2.The bearing must be greased while rotating the shaft every year (to be reported). If the motor has been provided with a roller bearing at the driven end the transport lock must be removed before rotating the shaft. The transport locking must be remounted in case of transportation.

3. All vibrations must be avoided to prevent a bearing from failing. Additionally, all instructions in the motor instruc-tion manual for commissioning and maintenance must be followed. The warranty will not cover the winding and bearing damages if these instructions have not been followed.

6.2 LubricationWARNINGBeware of all rotating parts.

WARNINGGrease can cause skin irritation and eye inflamma-tion. Follow all safety precautions specified by the manufacturer of the grease.

Bearing types are specified in the respective product catalogs and on the rating plate of all motors except smaller frame sizes.

Reliability is a vital issue for bearing lubrication intervals. ABB uses the L1-principle (i.e. that 99% of the motors are certain to make the life time) for lubrication.

6.2.1 Motors with permanently greased bearings

Bearings are usually permanently greased bearings of 1Z, 2Z, 2RS or equivalent types.

As a guide, adequate lubrication for sizes up to 250 can be achieved for the following duration, according to L1. For duties with higher ambient temperatures please contact ABB. The informative formula to change the L1 values roughly to L10 values: L10 = 2.7 x L1.

Duty hours for permanently greased bearings at ambient temperatures of 25 and 40°C are:

Frame size PolesDuty hours at 25°C

Duty hours at 40°C

71 2 67 000 42 000

71 4-8 100 000 56 000

80-90 2 100 000 65 000

80-90 4-8 100 000 96 000

100-112 2 89 000 56 000

100-112 4-8 100 000 89 000

132 2 67 000 42 000

132 4-8 100 000 77 000

160 2 60 000 38 000

160 4-8 100 000 74 000

180 2 55 000 34 000

180 4-8 100 000 70 000

200 2 41 000 25 000

200 4-8 95 000 60 000

225 2 36 000 23 000

225 4-8 88 000 56 000

250 2 31 000 20 000

250 4-8 80 000 50 000

Data is valid up to 60 Hz.

These values are valid for permitted load values given in the product catalog. Depending on application and load conditions, see the applicable product catalog or contact ABB.

Operation hours for vertical motors are half of the above values.

6.2.2 Motors with regreasable bearingsLubrication information plate and general lubrication adviceIf the machine is equipped with a lubrication information plate, follow the given values.

On the lubrication information plate, greasing intervals regarding mounting, ambient temperature and rotational speed are defined.

During the first start or after a bearing lubrication a tempo-rary temperature rise may appear, approximately 10 to 20 hours.

Some motors may be equipped with a collector for old grease. Follow the special instructions given for the equipment.

After regreasing a DIP/ Ex tD/ Ex t-motor, clean the motor end shields so they are free of any dust.

A. Manual lubrication

Regreasing while the motor is running– Remove grease outlet plug or open closing valve if fitted.– Be sure that the lubrication channel is open– Inject the specified amount of grease into the bearing.– Let the motor run for 1-2 hours to ensure that all excess

grease is forced out of the bearing. Close the grease outlet plug or closing valve if fitted.

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Regreasing while the motor is at a standstillRegrease motors while running. If it is not possible to regrease the bearings while the motors are running, lubrication can be carried out while the machine is at a standstill. – In this case use only half the quantity of grease and then

run the motor for a few minutes at full speed. – When the motor has stopped, apply the rest of the

specified amount of grease to the bearing.– After 1-2 running hours close the grease outlet plug or

closing valve if fitted.

B. Automatic lubricationThe grease outlet plug must be removed permanently with automatic lubrication or open the closing valve if fitted.

ABB recommends only the use of electromechanical systems.

The amount of grease per lubrication interval stated in the table should be multiplied by three if a central lubrication system is used. In case of a smaller automatic regrease unit (one or two cartridges per motor) the normal amount of grease is valid.

When 2-pole motors are automatically regreased, the notes concerning lubricant recommendations for 2-pole motors in the Lubricants chapter should be followed.

The used grease should be suitable for automatic lubrica-tion. Automatic lubrication system deliverer and the grease manufacturer’s recommendations should check.

Calculation example for the amount of grease for automatic lubrication systemCentral lubrication system: Motor IEC M3_P 315_ 4-pole in 50Hz network, relubrication interval according to Table is 7600 h/55g (DE) and 7600 h/40g (NDE):

(DE) RLI = 55g/7600h*3*24 = 0,52 g/day(NDE) RLI = 40g/7600*3*24 = 0,38 g/day

Calculation example for the amount of grease for single automation lubrication unit (cartridge)(DE) RLI = 55g/7600h*24 = 0,17 g/day(NDE) RLI = 40g/7600*24 = 0,13 g/day

RLI = Relubricaion interval, DE = Drive end, NDE = Non drive end

6.2.3 Lubrication intervals and amountsLubrication intervals for vertical machines are half of the values shown in the table below.

The lubrication intervals are based on a bearing operating temperature of 80°C (ambient temperature +25°). Note! An increase in the ambient temperature raises the tem-perature of the bearings correspondingly. The values should be halved for a 15°C increase in bearing tempera-ture and may be doubled for a 15°C decrease in bearing temperature.

Higher speed operation, e.g. in frequency converter applications, or lower speed with heavy load will require shorter lubrication intervals.

WARNINGThe maximum operating temperature of the grease and bearings, +110°C, must not be exceeded.

The designed maximum speed of the motor must not be exceeded.

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Framesize

Amountof greaseg/DE-bearing

Amount of greaseg/NDE-bearing

3600r/min

3000r/min

1800r/min

1500r/min

1000r/min

500-900r/min

Ball bearings Lubrication intervals in duty hours

160 13 13 7100 8900 14300 16300 20500 21600

180 15 15 6100 7800 13100 15100 19400 20500

200 20 15 4300 5900 11000 13000 17300 18400

225 23 20 3600 5100 10100 12000 16400 17500

250 30 23 2400 3700 8500 10400 14700 15800

280 35 35 1900 3200 – – – –

280 40 40 – – 7800 9600 13900 15000

315 35 35 1900 3200 – – – –

315 55 40 – – 5900 7600 11800 12900

355 35 35 1900 3200 – – – –

355 70 40 – – 4000 5600 9600 10700

400 40 40 1500 2700 – – – –

400 85 55 – – 3200 4700 8600 9700

450 40 40 1500 2700 – – – –

450 95 70 – – 2500 3900 7700 8700

Roller bearings Lubrication intervals in duty hours

160 13 13 3600 4500 7200 8100 10300 10800

180 15 15 3000 3900 6600 7500 9700 10200

200 20 15 2100 3000 5500 6500 8600 9200

225 23 20 1800 1600 5100 6000 8200 8700

250 30 23 1200 1900 4200 5200 7300 7900

280 35 35 900 1600 – – – –

280 40 40 – – 4000 5300 7000 8500

315 35 35 900 1600 – – – –

315 55 40 – – 2900 3800 5900 6500

355 35 35 900 1600 – – – –

355 70 40 – – 2000 2800 4800 5400

400 40 40 – 1300 – – – –

400 85 55 – – 1600 2400 4300 4800

450 40 40 – 1300 – – – –

450 95 70 – – 1300 2000 3800 4400

6.2.4 Lubricants

WARNINGDo not mix different types of grease. Incompatible lubricants may cause bearing damage.

When regreasing, use only special ball bearing grease with the following properties:

– good quality grease with lithium complex soap and with mineral- or PAO-oil

– base oil viscosity 100-160 cST at 40°C– consistency NLGI grade 1.5 - 3 *)– temperature range -30°C - +140°C, continuously.

*) For vertical mounted motors or in hot conditions a stiffer end of scale is recommended.

The above mentioned grease specification is valid if the ambient temperature is above -30°C or below +55°C, and the bearing temperature is below 110°C; otherwise consult ABB regarding suitable grease.

Grease with the correct properties is available from all the major lubricant manufacturers.

Admixtures are recommended, but a written guarantee

must be obtained from the lubricant manufacturer, espe-cially concerning EP admixtures, that the admixtures will not damage bearings or the properties of lubricants at the operating temperature range.

WARNINGLubricants containing EP admixtures are not recom-mended in high bearing temperatures in frame sizes 280 to 450.

The following high performance greases can be used:

– Mobil Unirex N2 or N3 (lithium complex base)– Mobil Mobilith SHC 100 (lithium complex base)– Shell Gadus S5 V 100 2 (lithium complex base)– Klüber Klüberplex BEM 41-132 (special lithium base)– FAG Arcanol TEMP110 (lithium complex base)- Lubcon Turmogrease L 802 EP PLUS

(special lithium base)- Total Multiplex S2 A (lithium complex base)

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NOTE!Always use high speed grease for high speed 2-pole machines where the speed factor is higher than 480,000 (calculated as Dm x n where Dm = average bearing diameter, mm; n = rotational speed, r/min).

The following greases can be used for high speed cast iron motors but not mixed with lithium complex greases:

– Klüber Klüber quiet BQH 72-102 (polyurea base)– Lubcon Turmogrease PU703 (polyurea base)

If other lubricants are used;

Check with the manufacturer that the qualities correspond to those of the above mentioned lubricants. The lubrica-tion interval are based on the listed high performance greases above. Using other greases can reduce the interval.

If the compatibility of the lubricant is uncertain, contact ABB.

7. After Sales support

7.1 Spare partsSpare parts must be original parts or approved by ABB unless otherwise stated.

Requirements in standard IEC 60079-19 must be fol-lowed.

When ordering spare parts, the motor serial number, full type designation and product code, as stated on the rating plate, must be specified.

7.2 Dismantling, re-assembly and rewinding

Follow the instructions given in standard IEC 60079-19 regarding dismantling, re-assembly and rewinding. Any operation must be undertaken by the manufacturer, i.e. ABB, or by an ABB authorized repair partner.

No manufacturing alterations are permitted on the parts that make up the explosion-proof enclosure and the parts that ensure dust-tight protection. Also ensure that the ventilation is never obstructed.

Rewinding must always be carried out by an ABB author-ized repair partner.

When re-assembling the end shield or terminal box to the frame of flameproof motors, check that the spigots are free of paint and dirt with only a thin layer of special non-hardening grease. Also check that the fixing bolts are of the same strength as the original ones or at least of the same strength as indicated on the frame. In the case of DIP/Ex tD/Ex t- motors, when re-assembling the end shields on the frame special sealing grease or sealing compound must be reapplied to the spigots. This should be the same type as originally applied to the motor for this kind of protection.

7.3 BearingsSpecial care should be taken with the bearings.

These must be removed using pullers and fitted by heating or using special tools for the purpose.

Bearing replacement is described in detail in a separate instruction leaflet available from the ABB Sales Office. Special recommendations apply when changing the bearings of DIP/Ex tD/Ex t-motors (as the seals should be changed at the same time).

Any directions placed on the motor, such as labels, must be followed. The bearing types indicated on the rating plate must not be changed.

NOTE!Any repair by the end user, unless expressly approved by the manufacturer, releases the manufacturer from his responsibility to conformity.

7.4 Gaskets and sealingsTerminal boxes others than Ex d –boxes are equipped with tested and approved sealings. If to be replaced, they must be replaced by original spare parts.

8. Environmental requirements. Noise levels.Most of ABB’s motors have a sound pressure level not exceeding 82 dB(A) (± 3 dB) at 50 Hz.

Values for specific machines can be found in the relevant product catalogs. At 60 Hz sinusoidal supply the values are approximately 4 dB(A) higher compared to 50 Hz values in the product catalogs.

For sound pressure levels at frequency converter supply, please contact ABB.

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9. TroubleshootingThese instructions do not cover all details or variations in equipment nor provide for every possible condition to be met in connection with installation, operation or maintenance. Should additional information be required, please contact the nearest ABB Sales Office.

Motor troubleshooting chartYour motor service and any troubleshooting must be handled by qualified persons who have the proper tools and equipment.

TROUBLE CAUSE WHAT TO DO

Motor fails to start Blown fuses Replace fuses with proper type and rating.

Overload trips Check and reset overload in starter.

Improper power supply Check to see that power supplied agrees with motor rating plate and load factor.

Improper line connections Check connections against diagram supplied with motor.

Open circuit in winding or control switch

Indicated by humming sound when switch is closed. Check for loose wiring connections. Also ensure that all control contacts are closing.

Mechanical failure Check to see if motor and drive turn freely. Check bearings and lubrication.

Short circuited stator Poor stator coil connection

Indicated by blown fuses. Motor must be rewound. Remove end shields and locate fault.

Rotor defective Look for broken bars or end rings.

Motor may be overloaded Reduce load.

Motor stalls One phase may be open Check lines for open phase.

Wrong application Change type or size. Consult equipment supplier.

Overload Reduce load.

Low voltage Ensure the rating plate voltage is maintained. Check connection.

Open circuit Fuses blown, check overload relay, stator and push buttons.

Motor runs and then dies down

Power failure Check for loose connections to line, to fuses and to control.

Motor does not accelerate up to nominal speed

Incorrect application Consult equipment supplier for proper type.

Voltage too low at motor terminals because of line drop

Use higher voltage or transformer terminals or reduce load. Check connections. Check conductors for proper size.

Starting load too high Check the motor’s starts against “no load”.

Broken rotor bars or loose rotor Look for cracks near the rings. A new rotor may be required, as repairs are usually temporary.

Open primary circuit Locate fault with testing device and repair.

Motor takes too long to accelerate and/or draws high current

Excessive load Reduce load.

Low voltage during start Check for high resistance. Make sure that an adequate cable size is used.

Defective squirrel cage rotor Replace with new rotor.

Applied voltage too low Correct power supply.

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TROUBLE CAUSE WHAT TO DO

Wrong rotation direction

Wrong sequence of phases Reverse connections at motor or at switchboard.

Motor overheats while running

Overload Reduce load.

Frame or ventilation openings may be full of dirt and prevent proper ventilation of motor

Open vent holes and check for a continuous stream of air from the motor.

Motor may have one phase open Check to make sure that all leads and cables are well connected.

Grounded coil Motor must be rewound.

Unbalanced terminal voltage Check for faulty leads, connections and transformers.

Motor vibrates Motor misaligned Realign.

Weak support Strengthen base.

Coupling out of balance Balance coupling.

Driven equipment unbalanced Rebalance driven equipment.

Defective bearings Replace bearings.

Bearings not in line Repair motor.

Balancing weights shifted Rebalance rotor.

Contradiction between balancing of rotor and coupling (half key – full key)

Rebalance coupling or rotor.

Polyphase motor running single phase

Check for open circuit.

Excessive end play Adjust bearing or add shim.

Scraping noise Fan rubbing end shield or fan cover Correct fan mounting.

Loose on bedplate Tighten holding bolts.

Noisy operation Air gap not uniform Check and correct end shield fits or bearing fits.

Rotor unbalance Rebalance rotor.

Hot bearings Bent or sprung shaft Straighten or replace shaft.

Excessive belt pull Decrease belt tension.

Pulleys too far away from shaft shoulder

Move pulley closer to motor bearing.

Pulley diameter too small Use larger pulleys.

Misalignment Correct by realignment of the drive.

Insufficient grease Maintain proper quality and amount of grease in bearing.

Deterioration of grease or lubricant contaminated

Remove old grease, wash bearings thoroughly in kerosene and replace with new grease.

Excess lubricant Reduce quantity of grease, bearing should not be more than half full.

Overloaded bearing Check alignment, side and end thrust.

Broken ball or rough races Replace bearing, clean housing thoroughly first.

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SECTION 9.3 MANUAL FOR BELT

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Drive the Technology

E2/20099

ED 2005

YOUR DISTRIBUTOR:

Design ManualIndustrial Synchronous Belts

PowerGrip® GT3 • PowerGrip® HTD® • PowerGrip®

Gates D

esign Manual • Ind

ustrial Synchronous B

elts • E2/20099 E

D 2005

NEWPowerGrip® GT3

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CONTENTS PAGE SECTION

INTRODUCTION 1• Gates synchronous belts 2• PowerGrip® GT3 design features 4• PowerGrip® GT3 belts 6• PowerGrip® HTD® belts 8• PowerGrip® classical synchronous belts 10• Tools 12• Belt sizes 13

DRIVE CALCULATION GUIDE 2• Belt drive selection procedure 21

1. Determine the service factor 212. Calculate the design power 213. Determine the belt pitch 234. Select the pulley combination,

belt length and centre distance 255. Select the belt width 26

• Belt drive selection example 27

CENTRE DISTANCE TABLES 3• PowerGrip® HTD® and PowerGrip® GT3 belts 28• PowerGrip® classical synchronous belts 87

POWER RATING TABLES 4• PowerGrip® GT3 belts 128• PowerGrip® HTD® belts 133• PowerGrip® classical synchronous belts 138

PULLEY INFORMATION 5• Preferred pulley ranges 148• Pulley tolerances 156

ENGINEERING DATA 6• Engineering data 157

1. Pulley diameter - speed 1572. Use of flanged pulleys 1573. Fixed (non-adjustable) centres 1574. Idlers 1575. Operating environment 1576. Installation and tensioning allowances 1577. Belt installation and drive alignment 1588. Belt storage and handling 1589. Efficiency 158

10. Installation tension 15911. Belt tolerances 15912. Check belt tension by use of Gates Sonic tension meter 160

APPENDIX 7• Useful information 162

1. Formulae 1622. Units of measurement 1623. Abbreviation table 1624. Conversion table 162

• Support 163

DRIVE DESIGN MANUAL FORPOWERGRIP® GT3, POWERGRIP® HTD® &POWERGRIP® SYNCHRONOUS BELTS

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POWERGRIP® HTD®

POWERGRIP®

INTRODUCTION

DRIVE DESIGN MANUAL FORPOWERGRIP® GT3, POWERGRIP® HTD®

AND POWERGRIP® BELTS - ALL IN ONE

This combined PowerGrip® design manual provides engineers and designerswith information on the range and scope of PowerGrip® GT3, PowerGrip® HTD®

and classical PowerGrip® belt drives, together with full details of belt lengths,centre distances, power ratings and pulley ranges.All information necessary to design the most appropriate synchronous belt driveto power your machines is provided in this manual. No need to consult variousdesign manuals: this manual guides you through the complete drive selectionprocedure.

1

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POWERGRIP® GT3

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GATES SYNCHRONOUS BELTS:THE DESIGNER’S CHOICE

Today Gates PowerGrip® conventional belt drives take theirplace in industry as a highly efficient proven medium for

mechanical power transmission. PowerGrip® belts with classicaltrapezoidal teeth have been adopted as standard equipment for awide range of industrial applications.

Improvements in materials and tooth design technologylead to the development of the PowerGrip® HTD® belt

(High Torque Drive). The curvilinear HTD® tooth geometryeliminates stress concentration at tooth roots and allows higherpower capacity and longer life compared to the classical timingbelt.

In 1946, Gates developed the first synchronous belt to synchronise the needle and bobbin movement ofthe Singer sewing machine. Through a programme of continuous innovation, research and developmentof high quality products Gates has acquired and maintained a leadership position in power transmissiontechnology ever since. Gates offers designers and engineers a premium range of synchronous beltsmeeting industry’s requirements.

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Gates’ latest development in synchronousrubber belts is PowerGrip® GT3.

The PowerGrip® GT3 product range is a major leapin synchronous rubber belt technology. Through theuse of a highly advanced combination of materials,this new synchronous belt transmits up to 30% morepower than previous generation belts.

PowerGrip® GT3 is available in 2MGT, 3MGT, 5MGT,8MGT and 14MGT pitches.

The small 2MGT, 3MGT and 5MGT pitches are idealfor compact drives on hand tools, business machines,domestic appliances, high precision servomotordrives and multiaxis applications.The larger 8MGT and 14MGT pitches are the optimumchoice for high performance drives in the machinetool, paper and textile industries where durability andlow maintenance are required.

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POWERGRIP® GT3 DESIGN FEATURES

Continuous innovative product design enables Gates to answer industry’s increasing power driverequirements.

DRIVE PACKAGE COMPARISON

Drive conditionDriver: - 7.5 kW motor

- 1460 rpmDriven: - pump

- speed ratio of approx. 1.5:1- service factor 1.7

Driven56 grooves

Driver38 grooves

POWER RATING COMPARISON POWERGRIP®, POWERGRIP® HTD® ANDPOWERGRIP® GT3

PowerGrip® PowerGrip® HTD® PowerGrip® GT3

4.5

4

3.5

3

2.5

2

1.5

1

0.5

0

PowerGrip® GT31200-8MGT-20

PowerGrip® HTD®

1200-8M-50

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POWERGRIP® GT3 DESIGN FEATURES

The precise GT tooth form coupled with the new construction provides substantial performance improvementcompared with former constructions. Thanks to this special tooth shape PowerGrip® GT3 belts providesignificant noise reduction, high tooth jump resistance and positioning accuracy.The following charts highlight these improvements.

NOISE

Test method:microphone placed 60 mm from centre of mid span.

TOOTH JUMP RESISTANCE

Improvements over PowerGrip® 8M

Similar diameter pulleys

180

160

140

120

80

60

Torque (N

m)

Installed span tension (N)

POSITIONING ACCURACY

Steps

Error

Time

Application Motion transfer

Belt 90 teethWidth 9 mmPulleys 20/20 groovesSpeed 330 rpmStatic tension 14 NMotor 200 steps/cycle

0.06

0.04

0

(mm)

3M HTD®3MGT PGGT3

0.024

0.006

Competitor’s premiumlow noise belt

PowerGrip® GT3

6000

5500

5000

4500

4000

3500 3000

2500

1000

500250100

90

80

70

60

50

1500

2000

100

200

Noise value comparison Gates PowerGrip® GT3 versuscompetitor’s premium low noise belt

24 30 42 54 73 95 117 141 189 264

8MGT PowerGrip® GT3

8M PowerGrip® HTD®

Test pulleys: 28 groove 8MOverall noise: 50 to 100 dB(A)Test speed: 250 to 6000 rpm

750

1250

1750

2250

5750

4250

4750

4250

3750 2750

3250

0.02

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POWERGRIP® GT3 BELT COMPONENTS AND BENEFITS

FEATURES- Technologically advanced compound with fibreglass tensile cord, elastomeric teeth and backing

and nylon facing.- Elastomeric backing protects the cords from environmental pollution and frictional wear.- Helically wound tensile member gives enormous strength, flex life and elongation resistance.- Low friction nylon facing protects the tooth surfaces against wear.- Precision-formed and accurately spaced elastomeric teeth.- Silicone-free.

BENEFITS- Substantially increased power ratings: up to 30% more than previous constructions.- Compact, light-weight and cost-effective drives.- Improved tooth jump resistance.- High capacity belt with reduced noise levels.- No lubrication needed.

By the use of a technologically advanced compound,PowerGrip® GT3 synchronous belts transmit up to 30% morepower than previous generation belts. They allow the designof more compact drives with higher power capacity, whichincreases space utilisation and cost effectiveness.They are a perfect replacement for HTD® and GT typedrives.

PowerGrip® GT3 is available in five pitches, small 2MGT,3MGT and 5MGT as well as large 8MGT and 14MGTpitches and covers the widest range of industrial applica-tions.

PowerGrip® GT3 8MGT and 14MGT pitches are standard staticconductive to ISO 9563 and can be used in hazardous explosiveareas. Certificates delivered on request.

PowerGrip® GT3 is supplied in a silicone-free construction.For paint processes, Gates can supply, on demand, thePowerGrip® GT3 8MGT and 14MGT in a paint and varnishcompatible construction. As contamination risks areexcluded, it is the ideal belt for paint processes in theautomotive industry.

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PULLEY DIMENSIONSThe three principal dimensions of a pulley are- pitch;- number of grooves;- belt width.

On the pulley, pitch is the distance between groove centres and is measured on thepulley’s pitch circle. The pitch circle of the pulley coincides with the pitch line of thebelt engaging with it. The pulley’s pitch diameter is always greater than its outsidediameter.

PowerGrip® GT3 8MGT and 14MGT pitch belts operate on PowerGrip® HTD® pulleys,which are made in 8 mm and 14 mm pitches. PowerGrip® GT3 2MGT, 3MGT and5MGT pitch belts must be run on pulleys of the same design, so pulleys for thesebelt pitches are made in 2 mm, 3 mm and 5 mm. Standard pulley diameters forPowerGrip® GT3 belts are listed on page 148. These tables list the number of grooves,the flange diameter and the outside diameter. On these pages you will also find thebelt and pulley widths. Using these tables, you will have all the information to completethe pulley ordering code.

Example HTD®: P56-14M-40P56 ...... Pulley designation (P) and number of grooves (56)14M ..... Pitch 14 mm40 ........ Belt width (mm)

Example GT : 3MR-18S-153MR .... Pitch 3 mm18S ...... Number of grooves (18)15 ........ Belt width (mm)

POWERGRIP® GT3 BELTDIMENSIONS

The three principal dimensions of aPowerGrip® GT3 belt are- pitch;- pitch length;- width.

Belt pitch is the distance in millimetresbetween two adjacent tooth centres asmeasured on the pitch line of the belt.Belt pitch length is the total length(circumference) in millimetres asmeasured along the pitch line. Thetheoretical pitch line of a PowerGrip® GT3belt lies within the tensile member.Gates PowerGrip® GT3 belts aremade in 2 mm, 3 mm, 5 mm, 8 mm and14 mm pitches.

REFERENCE DIMENSIONSPitch T Bmm mm mm

2MGT 2.00 0.71 1.523MGT 3.00 1.12 2.415MGT 5.00 1.92 3.818MGT 8.00 3.40 5.60

14MGT 14.00 5.82 9.91

POWERGRIP® GT3 SYSTEM SPECIFICATIONS

Gates PowerGrip® GT3 belt sizes arelisted on pages 13-14. These tables listthe pitch lengths in mm and the numberof teeth. On these pages you will alsofind the standard widths. Using thesetables, you will have all the informationto complete the PowerGrip® GT3 orderingcode.

Example: PGGT3 1040-8MGT-20PGGT3 ... PowerGrip® GT31040 ....... Pitch length (mm)8MGT ..... Pitch 8 mm20 ........... Belt width (mm)

Pitch (circular pitch)

Belt pitch line

Pitch circle

Outside

diameterPitch

diameter

Pitch

T

B

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TOOLS

Features

- Stores weight, width and span constants for up to twenty different systems.- New auto gain adjustment function cancels out background noise automatically.- Shuts off automatically after five minutes of inactivity, making it an energy-saving device.- Measurement range: 10 Hz to 5000 Hz.- Flexible sensor (cord sensor and inductive sensor available on request).- H 160 mm x D 26 mm x W 59 mm.

Optional accessories

Cord sensorThe cord sensor is recommended for measuring tensions at a distance from the tension meter.Inductive sensorThe inductive sensor is recommended for measurement of steel corded belts particularly in noisy or windyenvironments.Sonic tension meter calibrator – model U-305-OS1This special calibrator (oscillator) is available for the frequency test of the 507C. This oscillator generates five typesof oscillations (sine wave): 25, 90, 500, 2000 and 4000 Hz. It features a frequency accuracy of 0.1% or even lower.

Gates 507C sonic tension meter

Proper belt installation is essential for optimum performance of V- andsynchronous belt drives. Gates’ 507C sonic tension meter allows a simpleand accurate tension measurement by analysing sound waves (naturalfrequencies) from the belt through the sensor. It processes the input signalsand gives an accurate digital display of tension. This tester is compact,computerised and stores data for repetitive use measuring belt tensionaccurately time after time. Gates’ sonic tension tester is supplied with ahandy instruction manual (E/20136). See also page 160 for more informationon how to check belt tension.

Gates laser alignment device LASER AT-1The LASER AT-1 identifies parallel as well as angular misalignmentbetween the pulleys and is suitable for pulley diameters of 60 mmand larger. Mounted in a few seconds, the laser line projected onthe targets allows you to quickly ascertain and correct misalign-ment. It is so light it can be mounted on non-magnetic pulleys withthe double sided adhesive tape and used on both horizontal andvertical shaft installations.For more information please see leaflet E2/20121.

WarningGates’ sonic tension meter 507C and laser alignment device LASER AT-1 are not certified foruse in explosion risk areas.

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POWERGRIP® GT3 BELT SIZES

2MGT Pitch: 2 mm

74-2MGT 74 3776-2MGT 76 3880-2MGT 80 4090-2MGT 90 45100-2MGT 100 50112-2MGT 112 56124-2MGT 124 62130-2MGT 130 65132-2MGT 132 66134-2MGT 134 67140-2MGT 140 70142-2MGT 142 71152-2MGT 152 76158-2MGT 158 79164-2MGT 164 82168-2MGT 168 84172-2MGT 172 86178-2MGT 178 89180-2MGT 180 90184-2MGT 184 92186-2MGT 186 93192-2MGT 192 96194-2MGT 194 97202-2MGT 202 101208-2MGT 208 104210-2MGT 210 105212-2MGT 212 106216-2MGT 216 108220-2MGT 220 110224-2MGT 224 112232-2MGT 232 116240-2MGT 240 120242-2MGT 242 121250-2MGT 250 125252-2MGT 252 126264-2MGT 264 132274-2MGT 274 137280-2MGT 280 140284-2MGT 284 142286-2MGT 286 143288-2MGT 288 144304-2MGT 304 152310-2MGT 310 155318-2MGT 318 159320-2MGT 320 160322-2MGT 322 161330-2MGT 330 165332-2MGT 332 166336-2MGT 336 168342-2MGT 342 171356-2MGT 356 178364-2MGT 364 182

Length and Pitch Numberpitch length ofdesignation mm teeth

370-2MGT 370 185380-2MGT 380 190386-2MGT 386 193392-2MGT 392 196400-2MGT 400 200406-2MGT 406 203412-2MGT 412 206420-2MGT 420 210428-2MGT 428 214430-2MGT 430 215436-2MGT 436 218466-2MGT 466 233474-2MGT 474 237480-2MGT 480 240488-2MGT 488 244502-2MGT 502 251516-2MGT 516 258534-2MGT 534 267544-2MGT 544 272576-2MGT 576 288580-2MGT 580 290600-2MGT 600 300660-2MGT 660 330690-2MGT 690 345816-2MGT 816 408930-2MGT 930 4651032-2MGT 1032 5161164-2MGT 1164 5821386-2MGT 1386 6931700-2MGT 1700 8501830-2MGT 1830 915



Available in widths of 3 mm, 6 mm and9 mm.

105-3MGT 105 35120-3MGT 120 40135-3MGT 135 45144-3MGT 144 48150-3MGT 150 50165-3MGT 165 55174-3MGT 174 58180-3MGT 180 60186-3MGT 186 62192-3MGT 192 64195-3MGT 195 65201-3MGT 201 67

3MGT Pitch: 3 mm


204-3MGT 204 68210-3MGT 210 70216-3MGT 216 72225-3MGT 225 75231-3MGT 231 77234-3MGT 234 78240-3MGT 240 80243-3MGT 243 81246-3MGT 246 82252-3MGT 252 84255-3MGT 255 85267-3MGT 267 89270-3MGT 270 90276-3MGT 276 92282-3MGT 282 94285-3MGT 285 95288-3MGT 288 96294-3MGT 294 98300-3MGT 300 100303-3MGT 303 101309-3MGT 309 103312-3MGT 312 104324-3MGT 324 108330-3MGT 330 110339-3MGT 339 113354-3MGT 354 118357-3MGT 357 119360-3MGT 360 120363-3MGT 363 121375-3MGT 375 125384-3MGT 384 128387-3MGT 387 129390-3MGT 390 130393-3MGT 393 131399-3MGT 399 133408-3MGT 408 136420-3MGT 420 140426-3MGT 426 142450-3MGT 450 150456-3MGT 456 152480-3MGT 480 160483-3MGT 483 161489-3MGT 489 163495-3MGT 495 165501-3MGT 501 167510-3MGT 510 170513-3MGT 513 171522-3MGT 522 174537-3MGT 537 179540-3MGT 540 180552-3MGT 552 184561-3MGT 561 187

2MGT Pitch: 2 mm 3MGT Pitch: 3 mm

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POWERGRIP® GT3 BELT SIZES

Preferred sizes are printed in bold.


5MGT Pitch: 5 mm 8MGT Pitch: 8 mm



200-5MGT 200 40225-5MGT 225 45250-5MGT 250 50265-5MGT 265 53275-5MGT 275 55280-5MGT 280 56285-5MGT 285 57300-5MGT 300 60325-5MGT 325 65330-5MGT 330 66340-5MGT 340 68350-5MGT 350 70360-5MGT 360 72375-5MGT 375 75400-5MGT 400 80410-5MGT 410 82415-5MGT 415 83425-5MGT 425 85450-5MGT 450 90460-5MGT 460 92475-5MGT 475 95490-5MGT 490 98500-5MGT 500 100510-5MGT 510 102525-5MGT 525 105530-5MGT 530 106540-5MGT 540 108550-5MGT 550 110600-5MGT 600 120625-5MGT 625 125

5MGT Pitch: 5 mm


3MGT Pitch: 3 mm

564-3MGT 564 188570-3MGT 570 190582-3MGT 582 194588-3MGT 588 196600-3MGT 600 200621-3MGT 621 207630-3MGT 630 210657-3MGT 657 219750-3MGT 750 250840-3MGT 840 280849-3MGT 849 283897-3MGT 897 2991587-3MGT 1587 5291692-3MGT 1692 564

Available in widths of 6 mm,9 mm and 15 mm.

384-8MGT 384 48480-8MGT 480 60560-8MGT 560 70600-8MGT 600 75640-8MGT 640 80720-8MGT 720 90800-8MGT 800 100840-8MGT 840 105880-8MGT 880 110920-8MGT 920 115960-8MGT 960 1201040-8MGT 1040 1301064-8MGT 1064 1331080-8MGT 1080 1351120-8MGT 1120 1401160-8MGT 1160 1451200-8MGT 1200 1501280-8MGT 1280 1601440-8MGT 1440 1801512-8MGT 1512 1891584-8MGT 1584 1981600-8MGT 1600 2001760-8MGT 1760 2201800-8MGT 1800 2252000-8MGT 2000 2502400-8MGT 2400 300

8MGT Pitch: 8 mm


650-5MGT 650 130665-5MGT 665 133700-5MGT 700 140750-5MGT 750 150775-5MGT 775 155800-5MGT 800 160850-5MGT 850 170860-5MGT 860 172900-5MGT 900 180950-5MGT 950 190980-5MGT 980 1961000-5MGT 1000 2001050-5MGT 1050 2101150-5MGT 1150 2301270-5MGT 1270 2541500-5MGT 1500 3002100-5MGT 2100 4202440-5MGT 2440 488

Available in widths of 9 mm, 15 mmand 25 mm.

966-14MGT 966 691190-14MGT 1190 851400-14MGT 1400 1001610-14MGT 1610 1151750-14MGT 1750 1251778-14MGT 1778 1271890-14MGT 1890 1352100-14MGT 2100 1502310-14MGT 2310 1652450-14MGT 2450 1752590-14MGT 2590 1852800-14MGT 2800 2003150-14MGT 3150 2253360-14MGT 3360 2403500-14MGT 3500 2503850-14MGT 3850 2754326-14MGT 4326 3094578-14MGT 4578 3274956-14MGT 4956 3545320-14MGT 5320 3805740-14MGT 5740 4106160-14MGT 6160 4406860-14MGT 6860 490

14MGT Pitch: 14 mm


2600-8MGT 2600 3252800-8MGT 2800 3503048-8MGT 3048 3813280-8MGT 3280 4103600-8MGT 3600 4504400-8MGT 4400 550

Available in widths of 20 mm, 30 mm,50 mm and 85 mm.

Available in widths of 40 mm, 55 mm,85 mm, 115 mm and 170 mm.

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BELT DRIVE SELECTION PROCEDURE

Before designing a synchronous belt drive, you need to determine andtabulate the following drive requirements:1. Power requirement and type of driveN machine2. The rpm of the driveR machine3. The rpm of the driveN machine4. The approximate centre distance for the drive5. Hours per day operation.

To select a Gates PowerGrip® GT3, PowerGrip® HTD® or PowerGrip® beltdrive, you need to complete the following steps:

STEP 1

DETERMINE THE SERVICE FACTOR

Service life of a belt drive depends on the specific use and function. By selectingthe appropriate service life for a drive and designing it accordingly, you will obtainthe most economical drive for your specific application. If the drive conditions areunknown, then the following classification guide will assist in the selection of theappropriate service factor.For an idler, add 0.2 to the basic service factor. For intermittent or seasonal operation,deduct 0.2 from the basic service factor.For speed-up drives, add to the basic service factor an additional factor as given inthe table.

Speed-up Additionalratio range factor

1 to 1.24 none1.25 to 1.74 0.11.75 to 2.49 0.22.50 to 3.49 0.3

3.50 and over 0.4

Additional service factors are required for unusual conditions such as load reversal,heavy shock, plugged motor stop, electric brake. These should be determined by aGates transmission specialist.Any change in the service factor affects the entire calculation. For the majority ofdrive applications, the service factors here are adequate. It must be recognised,however, that these factors are not a substitute for judgement. You may find itpractical to adjust the service factor to conform with your knowledge of the driveconditions and their severity.

STEP 2

CALCULATE THE DESIGN POWER

Design power = service factor x power requirement

A. To calculate the design power it is necessary to determine the service factor forthe drive. Using the service factor chart on page 22, determine the type of driveRmachine.

B. Using the service factor chart, determine the service factor for the driveN machineand the type of operational service.

C. Multiply the power requirement of the drive by the service factor you have selected.This gives you the design power for use in designing the drive.

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Display equipment. Dispensing equipment.Instrumentation. Measuring equipment.Medical equipment. Office equipment.Projection equipment.

Appliances. Sweepers. Sewing machines.Screens: oven, drum, conical. Woodworkingequipment (light): band saws, drills, lathes.

Agitators for liquids. Conveyors: belt, lightpackage. Drill presses. Lathes. Saws.Laundry machinery.Woodworking equipment (heavy): circularsaws, jointers, planers.

Agitators for semi-liquids. Centrifugalcompressors. Conveyor belt: ore, coal,sand. Dough mixers. Line shafts.Machine tools: grinders, shapers, boringmills, milling machines.Paper machinery (except pulpers): presses,punches, shears. Printing machinery.Pumps: centrifugal, gear. Screens:revolving, vibratory.

Brick machinery (except pug mills).Conveyors: apron, pan, bucket, elevator.Extractors. Washers. Fans. Centrifugalblowers. Generators and exciters. Hoists.Rubber calender. Mills. Extruders.

Centrifuges. Screw conveyors. Hammermills. Paper pulpers. Textile machinery.

Blowers: positive displacement. Mine fans.Pulverisers.

Reciprocating compressors. Crushers:gyratory, jaw, roll.Mills: ball, rod, pebble, etc.Pumps: reciprocating.Saw mill equipment.


SERVICE FACTOR CHART

DRIVE N MACHINE

The driveN machines listed below arerepresentative samples only. Select adriveN machine whose loadcharacteristics most closelyapproximate those of the machinebeing considered.

AC motors: high torque, high slip,repulsion induction, single phase,series wound, slip ring.DC motors: series wound, compoundwound, servo motors.Engines: single cylinder internalcombustion. Line shafts. Clutches.

AC motors: normal torque, squirrelcage, synchronous, split phase, invertercontrolled.DC motors: shunt wound, steppermotors.Engines: multiple cylinder internalcombustion.

DRIVE R

Intermittent Normal Continuous Intermittent Normal Continuousservice service service service service service

3-8 hours 8-16 hours 16-24 hours 3-8 hours 8-16 hours 16-24 hoursdaily or daily daily daily or daily daily

seasonal seasonal

1.0 1.2 1.4 1.2 1.4 1.6

1.1 1.3 1.5 1.3 1.5 1.7

1.2 1.4 1.6 1.6 1.8 2.0

1.3 1.5 1.7 1.6 1.8 2.0

1.5 1.7 1.9 1.9 2.1 2.3

1.7 1.9 2.1 2.1 2.3 2.5

1.4 1.6 1.8 1.8 2.0 2.2

1.6 1.8 2.0 2.0 2.2 2.4

These service factors are adequate for most belt drive applications. Note that service factors cannot be substituted for good engineering judgement.Service factors may be adjusted based upon an understanding of the severity of actual drive operating conditions.

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STEP 3

DETERMINE THE BELT PITCH

A. Go to the belt pitch selection guides below or on the following page. Locate the design power along the bottom of one of thebelt pitch selection guides. Read up to the rpm of the faster shaft (smaller pulley). The belt pitch indicated in the areasurrounding the point of intersection is the one you should use for your design. If the point of intersection falls outside of thearea, contact your local Gates representative. If the point falls very near the line between adjacent pitches a good drive canlikely be designed using either belt pitch.

B. Design the drives using both belt pitches and select the drive best meeting your size requirements or the most economicaldrive.

POWERGRIP® GT3 2MGT, 3MGT & 5MGT BELT PITCH SELECTION GUIDE

2MGT 3MGT 5MGT

Design power (kW)

rpm

of f

aste

r sh

aft

POWERGRIP® GT3 8MGT & 14MGT BELT PITCH SELECTION GUIDE

Design power (kW)

rpm

of f

aste

r sh

aft

10000

1000

100

10100 1000

10000

1000

100

100.01 0.1 1 10 100

10

8MGT 14MGT

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MXL XL L H XH XXH


POWERGRIP® HTD® BELT PITCH SELECTION GUIDE

0

0

0

0

3M 5M 8M 14M 20M

POWERGRIP® CLASSICAL TIMING BELT PITCH SELECTION GUIDE

rpm

of f

aste

r sh

aft

rpm

of f

aste

r sh

aft

Design power (kW)

Design power (kW)

10000

1000

100

100.1 1 10 100 1000

10000

1000

100.1 1 10 100 10000.01

0.01

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This method will give sufficient accuracy for drives having aspeed ratio of 3:1 or less. If the ratio is greater than 3:1 then acorrection will be necessary.

If there is limited room for centre distance adjustment

Establish the belt length in millimetres as previously outlined.Calculate the centre distance using the following formula:

Pulley centre distance

Where K = 4L - 6.28 (D + d)D = pitch circle diameter large pulley (mm)d = pitch circle diameter small pulley (mm)L = belt length (mm)

Fixed centre applications

For applications where no centre distance adjustment ispossible, contact Gates’ application engineers.

Exact values may be calculated from the following:

1. Belt length (L)


Locate the correct centre distance table for the belt youselected (pages 28-127).

For standard and non-standard motor speeds:

A. Calculate the speed ratio by dividing the rpm of the fastershaft by the rpm of the slower shaft. In the centre distancetables, refer to the column headed speed ratio. Locate thespeed ratio nearest to your requirements.

B. For the speed ratio selected, note the number of groovesand the pitch diameter of each pulley. If there are severalcombinations close to your requirements, you may want toconsider more than one combination in your drive selection.

C. Reading further to the right on the same line, locate andrecord the centre distance nearest to your requirements.The belt length code is given at the top of that column inmm. Note these values.

Alternative method to establish the belt length/centredistance

The nomograph on page 26 provides a quick, effective methodfor determining the nominal centre distance and belt length ofa drive and converting these nominal values into design values.The values of belt length and centre distance obtained usingthis nomograph are approximate and only intended for use inapplications where reasonable centre distance adjustment ispossible.The nomograph is based on the number of pitches rather thanon actual diameters and lengths.

Hence:

Pulley sizeN = number of grooves in large pulleyn = number of grooves in small pulley

Belt length

Centre distance

To establish required belt length

a. Calculate the values N + n and Nc.b. Place a straight edge across the nomograph connecting

these two points.c. Read off the Nb value and multiply it by the pitch to give the

nominal belt length in mm.d. Select the nearest suitable belt length using the size listings

on pages 13-20 .e. Convert this belt length to pitches and re-apply this value

to the nomograph to obtain the actual centre distance (Nc).

K + K2 - 32 (D - d)2

16C =

STEP 4

SELECT THE PULLEY COMBINATION,BELT LENGTH AND CENTRE DISTANCE

D - d2C

Where ß = 2 cos )(-1

C = (D - d) + 1 - (D - d)2

π ( ß180) L -

2( )1

2 sin ßbelt lengthpitch

Nb = (number of pitches)

centre distancepitch

Nc = (number of pitches)

L = 2C sin (1 -ß + π

(D + d) + ß

(D - d)2 2 180 )

2. Centre distance (C)

N - n1.114 x Nc

Corrected centre distance = Nc -

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A. The tables on pages 128-147 show the power ratings foreach belt which, when combined with the width factors, willgive the rating for each belt width. The left hand columnlists the rpm of the smaller pulley. The stock pulleys arelisted across the top of the columns and are designated bythe number of grooves and the pitch diameter. By readingdown the first column to the speed of your faster shaft andacross the line to the column headed by your smaller pulley,the power rating can be determined for any stock belt width.

IMPORTANTThe tables on pages 128-147 provide power ratings that arebased on a minimum of six teeth in mesh. If less than six teethare in mesh the power rating should be multiplied by theapproximate teeth in mesh factor from the following table.

Use the following formula to establish the number of teeth inmesh:

STEP 5

SELECT THE BELT WIDTHTeeth in mesh factor

Teeth in mesh ≥6 5 4 3 2

Factor 1 0.8 0.6 0.4 0.2

B. Select a stock belt width and determine the power rating asoutlined in Step 5A. If the power rating is equal to or exceedsthe design power found in Step 2, that belt width can beused. If not, move on to the next stock belt width and repeatthis step. If the widest stock belt width for the pitch selectedis still not acceptable, you may want to consider larger pulleydiameters or a larger pitch belt if possible.

C. Where there are several pulley combinations which meetyour drive requirements, the following rules of thumb mayinfluence your choice.a. The larger the pulley diameter, the narrower the belt.b. Larger diameter pulleys typically reduce bearing and shaft

loads.

DESIGN NOMOGRAPH

Where N = number of grooves in large pulleyn = number of grooves in small pulleyNb = belt length in number of pitchesNc = centre distance in number of pitches

400

350

300

250

200

150

100

50

N+n

400

350

300

250

200

150

100

50

500

450

Nb

30

40

50

60

70

80

90

100

110

120

130

140

150

Nc

Teeth in mesh (T.I.M.) = n 0.5 -(N - n)

18.85 x Nc

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BELT DRIVE SELECTION EXAMPLE

A centrifugal blower is to be driven by an AC Motor.Drive requirements and characteristics are as follows:

Driver machineType: AC motor- normal torquePower: 740 WattsSpeed: 2850 rpmShaft diameter: 19 mm

Driven machineType: Centrifugal blowerPower: 600 Watts (absorbed)Speed: 6800 rpmShaft diameter: 12 mm

Drive conditionsSmooth uniform loadOperating 8 hrs/day, 5 days/week

Drive design limitationMaximum driving pulley diameter = 75 mmShaft centres = 70 mm ± 5 mmIdler: not requested

STEP 1

DETERMINE THE SERVICE FACTORFrom the service factor chart select the service factors whichare applicable to the drive.Basic service factor = 1.5In this case additional factors must be added:Speed up factor:it is a speed increasing drive ratio: 6800

2850

Additional factor = 0.2Resultant service factor = 1.5 + 0.2

= 1.7

STEP 2

CALCULATE THE DESIGN POWERa) Determine speed ratioDriver speed = 2850 rpmDriven speed = 6800 rpmSpeed ratio = 2.39 (speed increase)

b) Design powerMultiply the drive absorbed power by the service factor:600W x 1.7 = 1020W

STEP 3

DETERMINE THE BELT PITCHRefer to the belt pitch selection guides on pages 23-24. Usethe design power of 1020W and the small pulley speed of6800 rpm. The chart will show that these conditions give anintercept inside the 3MGT power envelope. Therefore a 3MGTdrive is required.

STEP 4

SELECT THE PULLEY COMBINATION,BELT LENGTH AND CENTRE DISTANCEa) Select pulleysCheck size limitation (see page 148).Driven pulley max. dia. = 75 mm hence max.Stock pulley = 3MR - 72S

Driven pulley shaft dia. = 12 mm hence min.Driven pulley = 3MR - 30S

Bearing these limitations in mind, the stock pulley combinationto give the speed ratio of 2.4 : 1 is 3MR - 72S : 3MR - 30S

b) Select belt lengthRequired centres = 70 ± 5 mmReferring to centre distance table page 48, the most suitablewill be the belt 300 - 3MGT which will give centres of70.63 mm when combined with the above pulley selection.

Hence the pulley/belt combinations required will be:pulleys: 3MR - 72S, 3MR - 30Sbelt: 300 - 3MGT

STEP 5

SELECT BELT WIDTHSelection is always based on the smallest pulley, i.e. 3MR -30S running at 6840 rpm.

Refer to the 3MGT power ratings table on page 129 and notethe ratings for the 30 groove pulley for 6000 and 8000 rpm.

Interpolate these ratings for a speed of 6840 rpm (i.e. 1920W).

This value is for a width of 6 mm.Multiply by the width factor:

Width Factor Watts6 mm 0.62 11909 mm 1 1920

15 mm 1.89 3629

Teeth in mesh factorSee page 26. Calculated value is 14 teeth in mesh. As thisfigure is greater than 5, the factor is 1. Hence the power ratingis not changed.

Our design power requirement is 1020W, hence a belt width of6 mm will be required.

The selected drive will therefore be:

Driver pulley: 3MR - 72S - 6Driven pulley: 3MR - 30S - 6Belt: 300 - 3MGT - 6

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1.00 28 28 287.0 399.0 504.0 609.0 679.0 693.0 749.0 854.0 959.01.00 29 29 280.0 392.0 497.0 602.0 672.0 686.0 742.0 847.0 952.01.00 30 30 273.0 385.0 490.0 595.0 665.0 679.0 735.0 840.0 945.01.00 32 32 259.0 371.0 476.0 581.0 651.0 665.0 721.0 826.0 931.01.00 34 34 245.0 357.0 462.0 567.0 637.0 651.0 707.0 812.0 917.01.00 36 36 231.0 343.0 448.0 553.0 623.0 637.0 693.0 798.0 903.01.00 38 38 217.0 329.0 434.0 539.0 609.0 623.0 679.0 784.0 889.01.00 40 40 203.0 315.0 420.0 525.0 595.0 609.0 665.0 770.0 875.01.00 44 44 287.0 392.0 497.0 567.0 581.0 637.0 742.0 847.01.00 48 48 259.0 364.0 469.0 539.0 553.0 609.0 714.0 819.01.00 56 56 308.0 413.0 483.0 497.0 553.0 658.0 763.01.00 64 64 357.0 427.0 441.0 497.0 602.0 707.01.03 29 30 276.5 388.5 493.5 598.5 668.5 682.5 738.5 843.5 948.51.04 28 29 283.5 395.5 500.5 605.5 675.5 689.5 745.5 850.5 955.51.05 38 40 210.0 322.0 427.0 532.0 602.0 616.0 672.0 777.0 882.01.06 32 34 252.0 364.0 469.0 574.0 644.0 658.0 714.0 819.0 924.01.06 34 36 238.0 350.0 455.0 560.0 630.0 644.0 700.0 805.0 910.01.06 36 38 224.0 336.0 441.0 546.0 616.0 630.0 686.0 791.0 896.01.07 28 30 280.0 392.0 497.0 602.0 672.0 686.0 742.0 847.0 952.01.07 30 32 266.0 378.0 483.0 588.0 658.0 672.0 728.0 833.0 938.01.09 44 48 272.9 377.9 482.9 552.9 566.9 622.9 727.9 833.01.10 29 32 269.4 381.4 486.5 591.5 661.5 675.5 731.5 836.5 941.51.10 40 44 300.9 405.9 510.9 580.9 594.9 650.9 755.9 861.01.11 36 40 216.8 328.9 433.9 538.9 608.9 622.9 678.9 783.9 889.01.12 34 38 230.8 342.9 447.9 552.9 622.9 636.9 692.9 798.0 903.01.13 30 34 258.8 370.9 475.9 580.9 650.9 664.9 720.9 826.0 931.01.13 32 36 244.8 356.9 461.9 566.9 636.9 650.9 706.9 812.0 917.01.13 64 72 328.5 398.6 412.6 468.7 573.7 678.81.14 28 32 272.9 384.9 489.9 594.9 664.9 678.9 734.9 840.0 945.01.14 56 64 384.6 454.7 468.7 524.7 629.7 734.81.16 38 44 307.7 412.8 517.8 587.8 601.9 657.9 762.9 867.91.17 29 34 262.3 374.3 479.4 584.4 654.4 668.4 724.4 829.4 934.41.17 48 56 335.5 440.6 510.7 524.7 580.7 685.8 790.81.18 34 40 223.6 335.7 440.8 545.8 615.9 629.9 685.9 790.9 895.91.19 32 38 237.6 349.7 454.8 559.8 629.9 643.9 699.9 804.9 909.91.20 30 36 251.6 363.8 468.8 573.8 643.9 657.9 713.9 818.9 923.91.20 40 48 286.4 391.6 496.7 566.7 580.7 636.8 741.8 846.81.21 28 34 265.7 377.8 482.8 587.8 657.9 671.9 727.9 832.9 937.91.22 36 44 202.2 314.5 419.6 524.7 594.7 608.7 664.8 769.8 874.81.24 29 36 255.0 367.2 472.2 577.3 647.3 661.3 717.3 822.4 927.41.25 32 40 230.3 342.5 447.6 552.7 622.7 636.8 692.8 797.8 902.81.25 64 80 369.3 383.3 439.6 544.8 650.01.26 38 48 293.2 398.4 503.5 573.6 587.6 643.6 748.7 853.71.27 30 38 244.3 356.6 461.7 566.7 636.8 650.8 706.8 811.8 916.81.27 44 56 243.5 349.0 454.2 524.3 538.3 594.4 699.5 804.61.29 28 36 258.4 370.6 475.7 580.7 650.8 664.8 720.8 825.8 930.81.29 34 44 208.8 321.2 426.4 531.5 601.6 615.6 671.6 776.7 881.71.29 56 72 355.2 425.5 439.6 495.7 600.9 706.11.31 29 38 247.7 359.9 465.1 570.1 640.2 654.2 710.2 815.3 920.31.33 30 40 237.0 349.3 454.5 559.6 629.6 643.6 699.6 804.7 909.71.33 36 48 299.8 405.1 510.3 580.4 594.4 650.5 755.5 860.6

Speed Number of Theoretical centre distance in mmratio grooves

DriveR DriveNBelt length code designation in mm

966 1190 1400 1610 1750 1778 1890 2100 2310

CENTRE DISTANCE TABLES 14M & 14MGT

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1029.0 1099.0 1204.0 1379.0 1554.0 1729.0 1967.0 2093.0 28 28 1.001022.0 1092.0 1197.0 1372.0 1547.0 1722.0 1960.0 2086.0 29 29 1.001015.0 1085.0 1190.0 1365.0 1540.0 1715.0 1953.0 2079.0 30 30 1.001001.0 1071.0 1176.0 1351.0 1526.0 1701.0 1939.0 2065.0 32 32 1.00

987.0 1057.0 1162.0 1337.0 1512.0 1687.0 1925.0 2051.0 34 34 1.00973.0 1043.0 1148.0 1323.0 1498.0 1673.0 1911.0 2037.0 36 36 1.00959.0 1029.0 1134.0 1309.0 1484.0 1659.0 1897.0 2023.0 38 38 1.00945.0 1015.0 1120.0 1295.0 1470.0 1645.0 1883.0 2009.0 40 40 1.00917.0 987.0 1092.0 1267.0 1442.0 1617.0 1855.0 1981.0 44 44 1.00889.0 959.0 1064.0 1239.0 1414.0 1589.0 1827.0 1953.0 48 48 1.00833.0 903.0 1008.0 1183.0 1358.0 1533.0 1771.0 1897.0 56 56 1.00777.0 847.0 952.0 1127.0 1302.0 1477.0 1715.0 1841.0 64 64 1.00

1018.5 1088.5 1193.5 1368.5 1543.5 1718.5 1956.5 2082.5 30 29 1.031025.5 1095.5 1200.5 1375.5 1550.5 1725.5 1963.5 2089.5 29 28 1.04

952.0 1022.0 1127.0 1302.0 1477.0 1652.0 1890.0 2016.0 40 38 1.05994.0 1064.0 1169.0 1344.0 1519.0 1694.0 1932.0 2058.0 34 32 1.06980.0 1050.0 1155.0 1330.0 1505.0 1680.0 1918.0 2044.0 36 34 1.06966.0 1036.0 1141.0 1316.0 1491.0 1666.0 1904.0 2030.0 38 36 1.06

1022.0 1092.0 1197.0 1372.0 1547.0 1722.0 1960.0 2086.0 30 28 1.071008.0 1078.0 1183.0 1358.0 1533.0 1708.0 1946.0 2072.0 32 30 1.07

903.0 973.0 1078.0 1253.0 1428.0 1603.0 1841.0 1967.0 48 44 1.091011.5 1081.5 1186.5 1361.5 1536.5 1711.5 1949.5 2075.5 32 29 1.10

931.0 1001.0 1106.0 1281.0 1456.0 1631.0 1869.0 1995.0 44 40 1.10959.0 1029.0 1134.0 1309.0 1484.0 1659.0 1897.0 2023.0 40 36 1.11973.0 1043.0 1148.0 1323.0 1498.0 1673.0 1911.0 2037.0 38 34 1.13

1001.0 1071.0 1176.0 1351.0 1526.0 1701.0 1939.0 2065.0 34 30 1.13987.0 1057.0 1162.0 1337.0 1512.0 1687.0 1925.0 2051.0 36 32 1.13748.8 818.8 923.8 1098.9 1273.9 1448.9 1686.9 1812.9 72 64 1.13

1015.0 1085.0 1190.0 1365.0 1540.0 1715.0 1953.0 2079.0 32 28 1.14804.8 874.8 979.8 1154.9 1329.9 1504.9 1742.9 1868.9 64 56 1.14937.9 1007.9 1112.9 1287.9 1462.9 1637.9 1876.0 2002.0 44 38 1.16

1004.4 1074.4 1179.4 1354.5 1529.5 1704.5 1942.5 2068.5 34 29 1.17860.8 930.8 1035.8 1210.9 1385.9 1560.9 1798.9 1924.9 56 48 1.17965.9 1035.9 1140.9 1315.9 1490.9 1665.9 1904.0 2030.0 40 34 1.18979.9 1049.9 1154.9 1329.9 1504.9 1679.9 1918.0 2044.0 38 32 1.19993.9 1063.9 1168.9 1343.9 1518.9 1693.9 1932.0 2058.0 36 30 1.20916.8 986.8 1091.9 1266.9 1441.9 1616.9 1854.9 1980.9 48 40 1.20

1007.9 1077.9 1182.9 1357.9 1532.9 1707.9 1946.0 2072.0 34 28 1.21944.8 1014.8 1119.9 1294.9 1469.9 1644.9 1882.9 2008.9 44 36 1.22997.4 1067.4 1172.4 1347.4 1522.4 1697.4 1935.4 2061.4 36 29 1.24972.8 1042.8 1147.9 1322.9 1497.9 1672.9 1910.9 2036.9 40 32 1.25720.1 790.2 895.3 1070.4 1245.5 1420.6 1658.6 1784.6 80 64 1.25923.7 993.8 1098.8 1273.8 1448.8 1623.8 1861.9 1987.9 48 38 1.26986.8 1056.8 1161.9 1336.9 1511.9 1686.9 1924.9 2050.9 38 30 1.27874.6 944.6 1049.7 1224.7 1399.7 1574.8 1812.8 1938.8 56 44 1.27

1000.8 1070.9 1175.9 1350.9 1525.9 1700.9 1938.9 2064.9 36 28 1.29951.7 1021.8 1126.8 1301.8 1476.8 1651.8 1889.9 2015.9 44 34 1.29776.2 846.2 951.3 1126.4 1301.5 1476.6 1714.6 1840.7 72 56 1.29990.3 1060.3 1165.3 1340.3 1515.4 1690.4 1928.4 2054.4 38 29 1.31979.7 1049.8 1154.8 1329.8 1504.8 1679.9 1917.9 2043.9 40 30 1.33930.6 1000.6 1105.7 1280.7 1455.8 1630.8 1868.8 1994.8 48 36 1.33

Theoretical centre distance in mm Number of Speedgrooves ratio

Belt length code designation in mmDriveN DriveR

2450 2590 2800 3150 3500 3850 4326 4578


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1.33 48 64 305.9 411.5 481.7 495.7 551.8 657.0 762.21.36 28 38 251.0 363.3 468.5 573.6 643.6 657.6 713.7 818.7 923.71.38 29 40 240.2 352.6 457.8 563.0 633.0 647.0 703.1 808.1 913.21.38 32 44 215.3 327.9 433.2 538.3 608.4 622.4 678.5 783.5 888.61.40 40 56 256.5 362.2 467.6 537.8 551.8 608.0 713.1 818.21.41 34 48 306.4 411.8 517.1 587.2 601.2 657.3 762.4 867.41.41 64 90 401.8 507.7 613.31.43 28 40 243.5 356.0 461.2 566.4 636.4 650.5 706.5 811.6 916.61.43 56 80 324.6 395.4 409.5 465.9 571.5 676.91.45 44 64 318.9 424.7 495.0 509.0 565.2 670.5 775.71.47 30 44 221.8 334.5 439.9 545.1 629.6 629.2 685.3 790.4 895.51.47 38 56 262.9 368.8 474.3 544.5 558.6 614.7 719.9 825.01.50 32 48 199.8 313.0 418.5 523.8 593.9 608.0 664.0 769.2 874.31.50 48 72 381.2 451.8 465.9 522.3 627.7 733.01.52 29 44 225.0 337.8 443.2 548.5 618.6 632.6 688.7 793.8 898.91.56 36 56 269.3 375.4 480.9 551.2 565.2 621.4 726.6 831.81.57 28 44 228.2 341.1 446.6 551.8 622.0 636.0 692.1 797.2 902.31.60 30 48 206.1 319.5 425.1 530.5 600.7 614.7 670.8 776.0 881.11.60 40 64 331.7 437.7 508.2 522.3 578.5 683.9 789.21.61 56 90 370.2 427.3 533.6 639.51.64 44 72 287.2 394.1 464.8 478.9 535.4 641.0 746.41.65 34 56 275.6 381.8 487.5 557.8 571.9 628.1 733.4 838.61.66 29 48 209.2 322.7 428.4 533.8 604.0 618.0 674.2 779.3 884.51.67 48 80 349.7 420.9 435.5 491.2 597.7 703.41.68 38 64 230.7 338.0 444.2 514.7 528.8 585.1 690.6 795.91.71 28 48 212.3 325.9 431.7 537.2 607.4 621.4 677.5 782.7 887.91.75 32 56 281.9 388.3 494.1 564.5 578.5 634.7 740.1 845.31.75 64 112 420.3 528.11.78 36 64 344.3 450.7 521.3 535.4 591.7 697.2 802.61.80 40 72 299.5 406.7 477.7 491.8 548.4 654.1 759.71.82 44 80 362.1 433.6 447.8 504.6 610.7 716.51.87 30 56 288.2 394.7 500.6 571.1 585.1 641.4 746.8 852.01.88 34 64 242.7 350.6 457.1 527.8 541.9 598.3 703.8 809.21.88 48 90 380.4 394.9 452.3 559.2 665.41.89 38 72 305.6 413.0 484.1 498.2 554.8 660.7 766.31.93 29 56 291.3 397.9 503.9 574.3 588.4 644.7 750.1 855.42.00 28 56 294.4 401.1 507.2 577.6 591.7 648.0 753.4 858.72.00 32 64 248.7 356.9 463.5 534.2 548.4 604.8 710.4 815.92.00 36 72 311.6 419.3 490.4 504.6 561.3 667.2 772.82.00 40 80 374.3 446.1 460.3 517.3 623.6 729.52.00 56 112 444.4 552.92.05 44 90 319.4 392.5 407.0 464.6 571.8 678.22.11 38 80 270.7 380.4 452.3 466.6 523.6 630.0 736.02.12 34 72 317.6 425.5 496.8 511.0 567.7 673.7 779.42.13 30 64 254.6 363.1 469.9 540.7 554.8 611.3 717.0 822.52.21 29 64 257.6 366.2 473.1 543.9 558.0 614.5 720.3 825.82.22 36 80 276.4 386.5 458.5 472.8 529.9 636.4 742.52.25 32 72 323.6 431.8 503.1 517.3 574.1 680.2 785.92.25 40 90 331.1 404.6 419.1 476.9 584.3 691.02.25 64 1442.29 28 64 260.6 369.3 476.2 547.1 561.3 617.8 723.5 829.1



966 1190 1400 1610 1750 1778 1890 2100 2310


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832.2 902.3 1007.4 1182.5 1357.5 1532.6 1770.6 1896.7 64 48 1.33993.8 1063.8 1168.8 1343.8 1518.8 1693.9 1931.9 2057.9 38 28 1.36983.2 1053.2 1158.2 1333.3 1508.3 1683.3 1921.3 2047.4 40 29 1.38958.6 1028.7 1133.7 1308.7 1483.8 1658.8 1896.8 2022.8 44 32 1.38888.3 958.3 1063.4 1238.5 1413.6 1588.6 1826.7 1952.7 56 40 1.40937.5 1007.5 1112.6 1287.6 1462.7 1637.7 1875.7 2001.8 48 34 1.41683.5 753.8 859.0 1034.4 1209.6 1384.8 1623.0 1749.0 90 64 1.41986.6 1056.7 1161.7 1336.7 1511.8 1686.8 1924.8 2050.8 40 28 1.43747.1 817.2 922.4 1097.7 1272.9 1448.0 1686.2 1812.2 80 56 1.43845.8 915.9 1021.0 1196.2 1371.3 1546.4 1784.4 1910.5 64 44 1.45965.5 1035.5 1140.6 1315.6 1490.7 1665.7 1903.7 2029.8 44 30 1.47895.1 965.2 1070.2 1245.4 1420.4 1595.5 1833.6 1959.6 56 38 1.47944.3 1014.4 1119.4 1294.5 1469.6 1644.6 1882.7 2008.7 48 32 1.50803.2 873.4 978.5 1153.8 1328.9 1504.0 1742.2 1868.2 72 48 1.50968.9 1039.0 1144.0 1319.1 1494.1 1669.2 1907.2 2033.2 44 29 1.52901.9 972.0 1077.1 1252.2 1427.3 1602.4 1840.5 1966.5 56 36 1.56972.3 1042.4 1147.4 1322.5 1497.6 1672.6 1910.7 2036.7 44 28 1.57951.2 1021.2 1126.3 1301.4 1476.5 1651.5 1889.6 2015.6 48 30 1.60859.3 929.5 1034.6 1209.8 1385.0 1560.1 1798.2 1924.3 64 40 1.60710.0 780.3 885.8 1061.3 1236.7 1412.0 1650.3 1776.4 90 56 1.61816.6 886.8 992.0 1167.3 1342.6 1517.7 1755.9 1882.0 72 44 1.64908.7 978.8 1083.9 1259.0 1434.2 1609.3 1847.3 1973.4 56 34 1.65954.6 1024.6 1129.7 1304.8 1479.9 1655.0 1893.0 2019.1 48 29 1.66773.7 844.0 949.3 1124.7 1300.0 1475.3 1713.5 1839.6 80 48 1.67866.1 936.2 1041.4 1216.6 1391.8 1566.9 1805.1 1931.1 64 38 1.68958.0 1028.0 1133.1 1308.2 1483.3 1658.4 1896.5 2022.5 48 28 1.71915.4 985.5 1090.7 1265.9 1441.0 1616.1 1854.2 1980.3 56 32 1.75599.4 670.5 776.6 953.0 1128.9 1304.6 1543.3 1669.6 112 64 1.75872.8 942.9 1048.1 1223.4 1398.6 1573.8 1811.9 1938.0 64 36 1.78829.9 900.2 1005.5 1180.8 1356.1 1531.3 1769.6 1895.7 72 40 1.80786.9 857.2 962.7 1138.2 1313.6 1488.8 1727.1 1853.3 80 44 1.82922.2 992.3 1097.5 1272.7 1447.8 1623.0 1861.1 1987.2 56 30 1.87879.5 949.6 1054.9 1230.2 1405.4 1580.6 1818.8 1944.9 64 34 1.88736.0 806.6 912.2 1088.0 1263.5 1439.0 1677.4 1803.6 90 48 1.88836.6 906.8 1012.2 1187.6 1362.9 1538.1 1776.4 1902.5 72 38 1.89925.5 995.7 1100.9 1276.1 1451.3 1626.4 1864.5 1990.6 56 29 1.93928.9 999.1 1104.2 1279.5 1454.7 1629.8 1868.0 1994.0 56 28 2.00886.1 956.3 1061.6 1236.9 1412.2 1587.4 1825.6 1951.7 64 32 2.00843.2 913.5 1018.8 1194.3 1369.7 1544.9 1783.2 1909.3 72 36 2.00800.0 870.4 975.9 1151.5 1327.0 1502.4 1740.7 1866.9 80 40 2.00624.5 695.8 802.3 979.0 1155.3 1331.1 1570.0 1696.4 112 56 2.00749.0 819.6 925.3 1101.2 1276.9 1452.4 1690.9 1817.1 90 44 2.05806.6 877.0 982.5 1158.2 1333.7 1509.1 1747.5 1873.7 80 38 2.11849.8 920.1 1025.5 1201.0 1376.4 1551.7 1790.0 1916.1 72 34 2.12892.8 963.0 1068.3 1243.7 1419.0 1594.2 1832.4 1958.5 64 30 2.13896.1 966.4 1071.7 1247.1 1422.4 1597.6 1835.8 1961.9 64 29 2.21813.1 883.6 989.1 1164.9 1340.4 1515.8 1754.3 1880.4 80 36 2.22856.4 926.7 1032.1 1207.7 1383.1 1558.5 1796.8 1922.9 72 32 2.25761.8 832.5 938.4 1114.4 1290.2 1465.8 1704.4 1830.6 90 40 2.25

537.1 647.3 827.7 1006.2 1183.6 1423.8 1550.7 144 64 2.25899.4 969.7 1075.0 1250.4 1425.7 1601.0 1839.3 1965.4 64 28 2.29



2450 2590 2800 3150 3500 3850 4326 4578


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3

78

2.33 48 112 468.1 577.32.35 34 80 282.2 392.5 464.6 479.0 536.2 642.8 749.02.37 38 90 336.9 410.5 425.1 483.0 590.6 697.42.40 30 72 329.6 438.0 509.4 523.6 580.4 686.6 792.52.48 29 72 332.6 441.1 512.5 526.8 583.6 689.8 795.72.50 32 80 287.9 398.6 470.8 485.2 542.4 649.2 755.42.50 36 90 342.6 416`.5 431.1 489.1 596.8 703.72.55 44 112 367.3 479.9 589.42.57 28 72 335.6 444.1 515.7 529.9 586.8 693.1 799.02.57 56 1442.65 34 90 348.4 422.4 437.1 495.2 603.0 710.02.67 30 80 293.6 404.6 476.9 491.3 548.6 655.5 761.82.76 29 80 296.4 407.6 480.0 494.4 551.8 658.7 765.02.80 40 112 378.5 491.6 601.52.81 32 90 354.1 428.4 443.0 501.2 609.2 716.32.86 28 80 299.3 410.5 483.0 497.4 554.9 661.8 768.22.95 38 112 384.0 497.4 607.53.00 30 90 359.9 434.3 448.9 507.3 615.4 722.63.00 48 1443.00 64 1923.10 29 90 362.7 437.2 451.9 510.3 618.5 725.73.11 36 112 389.6 503.2 613.53.21 28 90 365.6 440.1 454.9 513.3 621.6 728.93.27 44 144 439.23.29 34 112 331.3 395.1 509.0 619.53.43 56 1923.50 32 112 336.6 400.6 514.8 625.43.60 40 144 449.93.73 30 112 341.9 406.2 520.6 631.43.79 38 144 455.23.86 29 112 344.6 408.9 523.5 634.34.00 28 112 347.2 411.7 526.4 637.34.00 36 144 460.64.00 48 1924.24 34 144 465.94.36 44 1924.50 32 144 471.24.80 40 1924.80 30 144 476.54.97 29 144 479.25.05 38 1925.14 28 144 481.95.33 36 1925.65 34 1926.00 32 1926.40 30 1926.62 29 1926.86 28 192



966 1190 1400 1610 1750 1778 1890 2100 2310


14mm

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649.3 720.8 827.7 1004.9 1181.4 1357.5 1596.6 1723.1 112 48 2.12819.6 890.1 995.7 1171.5 1347.1 1522.5 1761.0 1887.2 80 34 2.35768.2 839.0 944.9 1121.0 1296.8 1472.4 1711.1 1837.3 90 38 2.37862.9 933.3 1038.8 1214.4 1389.8 1565.2 1803.6 1929.7 72 30 2.40866.2 936.6 1042.1 1217.7 1393.2 1568.6 1807.0 1933.1 72 29 2.48826.1 896.6 1002.3 1178.1 1353.8 1529.3 1767.8 1894.0 80 32 2.50774.6 845.4 951.4 1127.6 1303.4 1479.1 1717.8 1844.1 90 36 2.50661.6 733.3 840.3 1017.7 1194.4 1370.6 1609.9 1736.4 112 44 2.55869.5 939.9 1045.4 1221.1 1396.6 1571.9 1810.3 1936.5 72 28 2.57484.8 560.3 671.1 852.3 1031.3 1209.1 1449.7 1576.8 144 56 2.57781.0 851.8 957.9 1134.1 1310.1 1485.8 1724.5 1850.8 90 34 2.65832.5 903.1 1008.8 1184.8 1360.4 1536.0 1774.5 1900.7 80 30 2.67835.8 906.4 1012.1 1188.1 1363.8 1539.3 1777.9 1904.1 80 29 2.76673.8 745.7 852.9 1030.5 1207.3 1383.7 1623.1 1749.6 112 40 2.80787.4 858.3 964.3 1140.7 1316.7 1492.4 1731.2 1857.5 90 32 2.81839.0 909.6 1015.4 1191.4 1367.1 1542.6 1781.2 1907.5 80 28 2.86679.9 751.8 859.1 1036.9 1213.8 1390.2 1629.7 1756.3 112 38 2.95793.7 864.6 970.8 1147.2 1323.2 1499.0 1737.9 1864.2 90 30 3.00507.2 583.3 694.8 876.8 1056.3 1234.4 1475.5 1602.7 144 48 3.00

611.2 802.8 987.5 1233.9 1363.1 192 64 3.00796.9 867.8 974.0 1150.5 1326.5 1502.3 1741.2 1867.6 90 29 3.10686.0 758.0 865.4 1043.2 1220.2 1396.7 1636.2 1762.9 112 36 3.11800.0 871.0 977.2 1153.7 1329.8 1505.7 1744.5 1870.9 90 28 3.21518.3 594.8 706.6 888.9 1068.7 1247.0 1488.3 1615.6 144 44 3.27692.1 764.1 871.6 1049.6 1226.7 1403.2 1642.8 1769.5 112 34 3.29

633.0 825.7 1011.2 1258.3 1387.8 192 56 3.43698.1 770.3 877.8 1055.9 1233.1 1409.7 1649.4 1776.0 112 32 3.50529.4 606.1 718.3 901.0 1081.1 1259.6 1501.1 1628.5 144 40 3.60704.2 776.4 884.1 1062.2 1239.5 1416.2 1655.9 1782.6 112 30 3.73535.0 611.8 724.1 907.1 1087.2 1265.9 1507.5 1634.9 144 38 3.79707.2 779.5 887.2 1065.4 1242.7 1419.4 1659.2 1785.9 112 29 3.86

1068.6 1245.9 1422.7 1662.5 1789.2 112 28 4.00540.5 617.5 730.0 913.1 1093.4 1272.2 1513.8 1641.3 144 36 4.00

654.7 848.6 1034.8 1282.7 1412.4 192 48 4.00546.0 623.1 735.8 919.1 1099.6 1278.4 1520.2 1647.7 144 34 4.24

665.5 860.0 1046.6 1294.8 1424.7 192 44 4.36551.5 628.8 741.6 925.1 1105.7 1284.7 1526.6 1654.1 144 32 4.50

676.3 871.3 1058.3 1306.9 1436.9 192 40 4.80557.0 634.4 747.4 931.1 1111.9 1290.9 1532.9 1660.5 144 30 4.80559.8 637.3 750.3 934.1 1114.9 1294.0 1536.1 1663.7 144 29 4.97

681.7 877.0 1064.2 1312.9 1443.0 192 38 5.05562.5 640.1 753.2 937.1 1118.0 1297.2 1539.2 1666.9 144 28 5.14

687.0 882.6 1070.0 1318.9 1449.1 192 36 5.33692.4 888.3 1075.9 1324.9 1455.2 192 34 5.65697.8 893.9 1081.7 1331.0 1461.3 192 32 6.00703.1 899.6 1087.5 1337.0 1467.4 192 30 6.40705.8 902.4 1090.4 1340.0 1470.4 192 29 6.62708.5 905.2 1093.3 1343.0 1473.5 192 28 6.86



2450 2590 2800 3150 3500 3850 4326 4578


14mm

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10 1.22 1.50 1.78 2.05 2.32 2.85 3.37 3.88 4.38 4.87 5.60 5.84 7.73 8.87 9.7740 4.08 5.04 5.99 6.92 7.83 9.62 11.37 13.09 14.77 16.42 18.86 19.66 25.91 29.69 32.6560 5.76 7.14 8.49 9.81 11.11 13.66 16.14 18.57 20.95 23.29 26.74 27.87 36.67 41.98 46.15

100 8.86 11.01 13.10 15.16 17.18 21.13 24.97 28.72 32.40 36.00 41.30 43.03 56.52 64.63 70.97200 15.70 19.59 23.39 27.10 30.74 37.83 44.70 51.40 57.94 64.34 73.72 76.80 100.54 114.75 125.82300 21.78 27.27 32.61 37.82 42.92 52.85 62.46 71.79 80.90 89.80 102.81 107.06 139.85 159.39 174.58400 27.37 34.35 41.13 47.75 54.22 66.79 78.93 90.71 102.18 113.37 129.72 135.05 176.09 200.47 219.39500 32.59 40.99 49.14 57.09 64.85 79.91 94.44 108.52 122.21 135.55 155.01 161.36 210.06 238.91 261.26600 37.52 47.28 56.75 65.96 74.96 92.40 109.19 125.45 141.24 156.62 179.01 186.31 242.21 275.24 300.78800 46.68 59.02 70.98 82.60 93.93 115.84 136.89 157.23 176.95 196.11 223.96 233.02 302.19 342.88 374.25

1000 55.11 69.89 84.18 98.06 111.57 137.66 162.68 186.81 210.15 232.81 265.67 276.35 357.61 405.21 441.811200 62.95 80.05 96.57 112.58 128.16 158.19 186.95 214.62 241.36 267.28 304.80 316.97 409.38 463.31 504.671400 70.30 89.63 108.27 126.33 143.87 177.65 209.95 240.98 270.92 299.90 341.78 355.36 458.12 517.87 563.591600 77.24 98.70 119.39 139.40 158.84 196.20 231.86 266.08 299.05 330.93 376.92 391.81 504.26 569.40 619.141800 83.81 107.34 130.00 151.90 173.14 213.94 252.82 290.09 325.95 360.57 410.45 426.58 548.11 618.28 671.722000 90.06 115.59 140.15 163.87 186.86 230.97 272.95 313.12 351.73 388.97 442.55 459.86 589.93 664.78 721.662400 101.71 131.08 159.27 186.47 212.78 263.16 310.98 356.63 400.41 442.54 502.98 522.47 668.23 751.55 814.582800 112.39 145.39 177.03 207.50 236.94 293.20 346.47 397.21 445.76 492.37 559.08 580.54 740.36 831.10 899.413200 122.23 158.71 193.62 227.20 259.60 321.40 379.78 435.27 488.25 539.00 611.46 634.72 807.17 904.40 977.243600 131.35 171.14 209.19 245.72 280.95 347.99 411.19 471.13 528.23 582.83 660.57 685.48 869.27 972.17 1048.844000 139.81 182.80 223.84 263.21 301.12 373.15 440.90 505.01 565.97 624.14 706.75 733.17 927.16 1034.96 1114.835000 158.54 209.03 257.07 303.02 347.14 430.64 508.76 582.31 651.89 717.94 811.14 840.78 1055.75 1172.78 1258.106000 174.33 231.72 286.18 338.12 387.85 481.61 568.88 650.63 727.56 800.20 902.01 934.20 1164.42 1286.76 1374.168000 198.93 268.72 334.58 397.07 456.59 567.96 670.56 765.65 854.17 936.78 1050.77 1086.32 1331.95 1454.14 1536.22

10000 216.14 296.83 372.58 444.08 511.84 637.65 752.30 857.36 953.93 1042.83 1163.16 1200.03 1442.62 1550.91 1615.2112000 227.43 317.80 402.21 481.48 556.20 693.82 817.78 929.90 1031.45 1123.39 1244.74 1281.04 1502.85 1583.38 1616.9814000 233.79 332.82 424.84 510.79 591.39 738.53 869.35 985.91 1089.63 1181.53 1298.83 1332.72 1515.93 1554.21 1543.33

2MGT POWER RATINGS - WATTS

Number of grooves in small pulley10 12 14 16 18 22 26 30 34 38 44 46 62 72 80

Pulley pitch diameter in mm6.37 7.64 8.91 10.19 11.46 14.01 16.55 19.10 21.65 24.19 28.01 29.28 39.47 45.84 50.93

Belt width correction factors

Belt width (mm) 3 6 9 12

Width factors 0.30 0.62 1.00 1.45

Bold figures refer to standard widths.

Power ratings are based on a minimum of six teeth in mesh.If you have less than this, you have to make an adjustment - see page 26.

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Number of grooves in small pulley16 18 22 26 30 34 38 44 52 56 62 72 80

Pulley pitch diameter in mm15.28 17.19 21.01 24.83 28.65 32.47 36.29 42.02 49.66 53.48 59.21 68.75 76.39

20 7 8 10 12 14 16 18 21 25 26 29 34 3840 12 14 18 22 26 29 33 39 46 49 55 63 7060 17 20 26 31 37 42 48 55 66 71 78 91 101

100 27 32 41 49 58 66 75 87 103 111 123 143 158200 49 57 74 90 106 122 137 160 190 205 227 262 291300 69 81 105 128 151 173 195 228 270 291 322 373 413400 88 103 134 164 193 222 250 292 347 374 413 479 530

500 105 124 162 198 234 268 303 354 420 452 501 579 641 600 122 145 188 231 273 314 354 413 491 529 585 677 749700 139 164 214 263 310 357 403 471 559 603 667 772 854800 155 183 239 294 347 400 451 527 626 675 747 864 956900 170 202 264 324 383 441 498 582 692 745 825 954 1055

1000 185 220 288 354 419 482 545 636 756 814 901 1042 11531200 214 255 334 411 487 561 634 741 880 948 1049 1214 13421400 242 288 379 467 553 638 721 842 1001 1078 1193 1379 15251450 248 296 390 481 569 656 742 867 1030 1110 1228 1420 15701600 268 320 422 521 617 712 805 941 1117 1204 1332 1540 17021750 288 344 453 560 664 766 866 1013 1203 1296 1433 1657 18311800 294 351 464 573 680 784 886 1036 1231 1326 1467 1695 18742000 319 382 504 624 740 854 966 1130 1342 1446 1599 1847 20412400 366 440 583 722 858 990 1120 1310 1556 1676 1853 2139 23622800 411 495 658 816 970 1121 1268 1483 1761 1897 2096 2419 26683200 454 547 730 906 1078 1246 1410 1650 1959 2109 2330 2685 29603600 495 598 799 994 1183 1367 1548 1810 2149 2313 2554 2941 32394000 534 647 866 1078 1284 1485 1681 1966 2332 2510 2770 3186 35056000 709 866 1171 1465 1749 2024 2290 2675 3163 3396 3733 4262 46538000 858 1056 1438 1805 2156 2495 2820 3284 3861 4131 4514 5090 5493

10000 985 1221 1674 2106 2516 2907 3279 3801 4431 4717 510912000 1096 1366 1884 2371 2831 3264 3670 4226 487014000 1191 1493 2068 2605 3104 3567 3992 4557


Belt width (mm) 3 6 9 12 15 20 25

Width factors 0.30 0.62 1.00 1.45 1.89 2.64 3.38


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20 12 14 17 19 21 24 28 33 37 42 46 55 64 73 8240 22 27 31 36 40 45 54 62 71 80 88 105 122 139 15560 32 38 45 52 58 65 77 90 103 115 128 153 177 201 225

100 50 60 71 81 92 102 123 144 164 184 204 244 283 322 361 200 90 111 131 151 171 190 230 269 307 346 384 459 534 608 681

300 127 157 186 215 244 273 330 387 443 499 554 664 772 879 985 400 162 201 239 277 315 352 427 501 574 647 719 861 1002 1142 1280500 195 243 290 337 383 429 521 611 701 790 879 1054 1226 1397 1567600 227 283 339 394 449 504 612 719 825 931 1035 1242 1446 1648 1847700 258 322 387 450 514 577 701 825 947 1068 1188 1426 1661 1893 2123800 288 361 433 505 577 648 789 928 1066 1203 1339 1608 1873 2135 2394

1000 345 434 524 612 700 787 960 1131 1300 1468 1634 1963 2288 2608 29251200 399 505 611 715 819 922 1126 1328 1527 1725 1922 2309 2692 3069 34421400 451 574 695 815 934 1053 1288 1520 1750 1977 2203 2648 3087 3520 39471450 464 590 715 840 963 1085 1328 1567 1805 2039 2272 2732 3185 3631 40711600 502 640 777 912 1047 1181 1446 1708 1967 2224 2478 2980 3474 3961 44411750 538 688 837 984 1130 1275 1563 1847 2128 2406 2682 3225 3760 4286 48051800 550 704 856 1008 1158 1307 1602 1893 2181 2466 2749 3306 3854 4394 49252000 597 767 934 1101 1266 1430 1754 2075 2391 2705 3015 3627 4227 4818 53992400 688 887 1085 1282 1476 1669 2052 2429 2802 3170 3534 4251 4954 5644 63192800 773 1003 1231 1456 1680 1902 2340 2773 3200 3622 4038 4857 5657 6439 72033200 855 1114 1371 1625 1877 2127 2621 3108 3587 4061 4528 5444 6336 7205 80513600 933 1221 1506 1789 2069 2346 2894 3433 3965 4488 5003 6012 6992 7941 88614000 1008 1325 1638 1948 2255 2560 3161 3751 4332 4904 5466 6563 7624 8648 96335000 1182 1569 1951 2328 2702 3071 3799 4512 5210 5895 6565 7862 9099 102746000 1341 1795 2243 2685 3121 3552 4399 5226 6032 6817 7581 9043 104148000 1618 2199 2770 3333 3886 4430 5491 6514 7499 8444 9348

10000 1845 2544 3228 3898 4554 5195 6432 7607 8716 9756 1072112000 2026 2831 3617 4381 5123 5843 7214 848714000 2160 3062 3934 4777 5588 6367 7821

Number of grooves in small pulley18 20 22 24 26 28 32 36 40 44 48 56 64 72 80

Pulley pitch diameter in mm28.65 31.83 35.01 38.20 41.38 44.56 50.93 57.30 63.66 70.03 76.39 89.13 101.86 114.59 127.32


Belt width (mm) 6 9 12 15 20 25 30

Width factors 0.62 1.00 1.45 1.89 2.64 3.38 4.13


rpmof

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GT3

139/151

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8MGT POWER RATINGS - KILOWATTS

10 0.06 0.07 0.08 0.08 0.09 0.10 0.11 0.12 0.13 0.13 0.15 0.17 0.20 0.23 0.26 0.2920 0.11 0.13 0.15 0.16 0.18 0.19 0.21 0.23 0.24 0.26 0.29 0.32 0.38 0.45 0.51 0.5750 0.27 0.30 0.34 0.38 0.42 0.46 0.50 0.54 0.57 0.61 0.69 0.76 0.91 1.06 1.21 1.35

100 0.50 0.58 0.65 0.73 0.80 0.88 0.95 1.02 1.10 1.17 1.32 1.46 1.75 2.03 2.32 2.60200 0.95 1.10 1.24 1.38 1.53 1.67 1.81 1.95 2.10 2.24 2.52 2.80 3.35 3.90 4.45 5.00300 1.38 1.59 1.80 2.01 2.22 2.43 2.64 2.85 3.06 3.26 3.68 4.09 4.90 5.71 6.51 7.31

400 1.79 2.07 2.34 2.62 2.90 3.17 3.45 3.72 3.99 4.26 4.81 5.34 6.41 7.47 8.53 9.57500 2.19 2.53 2.88 3.22 3.56 3.90 4.24 4.58 4.91 5.25 5.91 6.58 7.90 9.21 10.50 11.79600 2.58 2.99 3.40 3.81 4.21 4.61 5.02 5.42 5.82 6.21 7.01 7.80 9.36 10.91 12.45 13.98720 3.04 3.53 4.01 4.50 4.98 5.46 5.93 6.41 6.88 7.36 8.30 9.23 11.09 12.93 14.76 16.57800 3.35 3.88 4.42 4.95 5.48 6.01 6.54 7.06 7.59 8.11 9.15 10.18 12.23 14.26 16.27 18.27

1000 4.09 4.75 5.41 6.07 6.73 7.38 8.03 8.68 9.32 9.97 11.25 12.52 15.04 17.54 20.01 22.461200 4.82 5.60 6.39 7.17 7.95 8.72 9.49 10.26 11.03 11.79 13.31 14.81 17.80 20.75 23.68 26.571460 5.74 6.69 7.63 8.57 9.50 10.43 11.36 12.28 13.20 14.11 15.93 17.74 21.32 24.85 28.34 31.781600 6.23 7.26 8.29 9.31 10.33 11.34 12.35 13.35 14.35 15.35 17.33 19.29 23.18 27.02 30.80 34.541800 6.92 8.07 9.22 10.36 11.49 12.62 13.75 14.87 15.98 17.09 19.30 21.49 25.81 30.07 34.27 38.402000 7.59 8.87 10.13 11.39 12.64 13.89 15.13 16.36 17.59 18.81 21.24 23.65 28.40 33.08 37.67 42.182400 8.92 10.43 11.93 13.42 14.90 16.37 17.84 19.30 20.75 22.19 25.05 27.88 33.46 38.93 44.27 49.492800 10.22 11.96 13.69 15.40 17.11 18.80 20.49 22.16 23.83 25.48 28.76 32.00 38.36 44.56 50.59 56.442920 10.60 12.41 14.20 15.99 17.76 19.52 21.27 23.01 24.74 26.45 29.86 33.21 39.80 46.21 52.43 58.453500 12.42 14.55 16.67 18.77 20.85 22.92 24.98 27.02 29.04 31.05 35.02 38.93 46.54 53.884000 13.94 16.34 18.73 21.10 23.45 25.77 28.08 30.37 32.63 34.88 39.30 43.65 52.064500 15.42 18.09 20.74 23.37 25.97 28.54 31.09 33.61 36.10 38.57 43.42 48.165000 16.86 19.79 22.70 25.57 28.42 31.23 34.00 36.75 39.46 42.13 47.37 52.465500 18.26 21.45 24.60 27.72 30.79 33.83 36.82 39.77 42.68 45.55 51.14

Number of grooves in small pulley22 24 26 28 30 32 34 36 38 40 44 48 56 64 72 80

Pulley pitch diameter in mm56.02 61.12 66.21 71.30 76.39 81.49 86.58 91.67 96.77 101.86 112.05 122.23 142.60 162.97 183.35 203.72

rpmof

fastershaft


Belt width (mm) 20 30 50 85

Width factors 1.00 1.57 2.73 4.75


Belt length correction factors

Belt length (mm) 384-600 640-880 960-1200 1280-1760 1800-4400

Length factors 0.8 0.9 1.0 1.1 1.2


Power ratings refer to standard products only. For special constructions, please contact Gates.

GT3

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14MGT POWER RATINGS - KILOWATTS

10 0.45 0.50 0.53 0.57 0.61 0.65 0.68 0.76 0.84 0.98 1.12 1.27 1.41 20 0.86 0.92 1.00 1.08 1.14 1.22 1.29 1.43 1.57 1.85 2.12 2.40 2.6660 2.31 2.51 2.71 2.90 3.10 3.30 3.49 3.88 4.26 5.02 5.78 6.51 7.25

100 3.64 3.96 4.28 4.60 4.91 5.21 5.53 6.15 6.75 7.96 9.15 10.33 11.50200 6.74 7.34 7.93 8.53 9.11 9.69 10.27 11.43 12.56 14.83 17.05 19.24 21.41

300 9.63 10.48 11.34 12.20 13.04 13.88 14.72 16.38 18.02 21.26 24.45 27.60 30.71400 12.38 13.50 14.60 15.70 16.80 17.89 18.96 21.11 23.23 27.42 31.54 35.60 39.59

500 15.03 16.39 17.74 19.09 20.42 21.75 23.07 25.67 28.26 33.36 38.37 43.30 48.15600 17.59 19.20 20.79 22.36 23.94 25.50 27.04 30.12 33.14 39.13 44.99 50.75 56.42720 20.58 22.46 24.33 26.19 28.04 29.87 31.68 35.29 38.84 45.84 52.70 59.41 66.01800 22.53 24.60 26.64 28.68 30.70 32.71 34.71 38.65 42.55 50.20 57.70 65.03 72.22

1000 27.25 29.77 32.25 34.73 37.18 39.62 42.03 46.82 51.52 60.76 69.77 78.54 87.091200 31.79 34.74 37.65 40.55 43.42 46.27 49.08 54.66 60.14 70.86 81.26 91.32 101.081460 37.47 40.95 44.41 47.82 51.21 54.55 57.87 64.42 70.83 83.31 95.34 106.87 117.921600 40.43 44.19 47.92 51.60 55.25 58.86 62.44 69.48 76.36 89.73 102.52 114.72 126.321800 44.54 48.70 52.80 56.87 60.87 64.85 68.76 76.47 83.99 98.51 112.28 125.292000 48.54 53.08 57.54 61.96 66.32 70.62 74.87 83.20 91.30 106.83 121.442400 56.19 61.42 66.58 71.67 76.66 81.58 86.42 95.84 104.94 122.122800 63.39 69.28 75.05 80.72 86.27 91.73 97.06 107.38 117.232920 65.46 71.53 77.48 83.31 89.02 94.61 100.07 110.62 120.643500 74.95 81.81 88.50 95.01 101.33 107.47 113.424000 82.38 89.80 96.99 103.934500 89.10 96.95

Number of grooves in small pulley28 30 32 34 36 38 40 44 48 56 64 72 80

Pulley pitch diameter in mm124.78 133.69 142.60 151.52 160.43 169.34 178.25 196.08 213.90 249.55 285.21 320.86 356.51

rpmof

fastershaft



Belt width (mm) 40 55 85 115 170

Width factors 1 1.5 2.5 3.5 5.32


Belt length correction factors

Belt length (mm) 966-1190 1400-1610 1778-1890 2100-2450 2590-3360 3500-6860

Length factors 0.8 0.9 0.95 1.0 1.05 1.1

Power ratings refer to standard products only. For special constructions, please contact Gates.

GT2

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PREFERRED PULLEY RANGES

POWERGRIP® GT3

Number Outsideof diameter

grooves (mm)

12 7.1315 9.0420 12.2230 18.5936 22.4148 30.0460 37.6872 45.32

Pulley references initalics are mainly“made-to-order”designs.

2MR

Number Outside Flange Maximum bore - (mm) System widths - (mm)of diameter diameter Standard belt width (mm) Standard belt width (mm)

grooves (mm) (mm) 6 9 15 6 9 15

10 8.79 13 3.5 3.5 3.5 17.5 17.5 2612 10.70 15 5.0 5.0 5.0 17.5 17.5 2614 12.61 16 6.0 6.0 6.0 17.5 17.5 2615 13.56 17.5 7.0 7.0 7.0 17.5 17.5 2616 14.52 18 5.5 5.5 5.5 20.6 20.6 2618 16.43 19.5 6.5 6.5 6.5 20.6 20.6 2620 18.34 23 8.0 8.0 8.0 20.6 20.6 2621 19.29 25 9.0 9.0 9.0 20.6 20.6 2622 20.25 25 9.0 9.0 9.0 20.6 20.6 2624 22.16 25 9.0 9.0 9.0 20.6 20.6 2626 24.07 28 10.0 10.0 10.0 20.6 20.6 2628 25.98 32 11.0 11.0 11.0 20.6 20.6 2630 27.89 32 12.5 12.5 12.5 20.6 20.6 2632 29.80 36 13.5 13.5 13.5 20.6 20.6 2636 33.62 38 15.0 15.0 15.0 22.2 22.2 3040 37.44 42 16.5 16.5 16.5 22.2 22.2 3044 41.26 48 20.0 20.0 20.0 22.2 22.2 3048 45.08 20.0 20.0 20.0 22.2 22.2 3060 56.54 20.0 20.0 20.0 22.2 22.2 3072 67.99 20.0 20.0 20.0 22.2 22.2 30

3MR

Number Outside Flange Maximum bore - (mm) System widths - (mm)of diameter diameter Standard belt width (mm) Standard belt width (mm)

grooves (mm) (mm) 9 15 25 9 15 25

14 21.14 25 9.0 9.0 9.0 20.0 26.0 36.015 22.73 28 10.0 10.0 10.0 20.0 26.0 36.016 24.32 28 10.5 10.5 10.5 20.0 26.0 36.018 27.51 32 12.5 12.5 12.5 20.0 26.0 36.020 30.69 36 13.5 13.5 13.5 22.5 26.0 36.021 32.28 38 14.0 14.0 14.0 22.5 26.0 38.022 33.87 38 15.0 15.0 15.0 22.5 26.0 38.024 37.06 42 16.0 16.0 16.0 22.5 28.0 38.026 40.24 44 18.0 18.0 18.0 22.5 28.0 38.028 43.42 48 18.0 18.0 18.0 22.5 28.0 38.030 46.60 51 21.0 21.0 21.0 22.5 28.0 38.032 49.79 54 23.0 23.0 23.0 22.5 28.0 38.036 56.16 60 23.0 23.0 23.0 22.5 28.0 38.040 62.52 71 23.0 23.0 23.0 22.5 28.0 38.044 68.89 23.0 23.0 23.0 25.5 30.0 40.048 75.25 23.0 23.0 23.0 25.5 30.0 40.060 94.35 28.0 30.0 30.0 25.5 30.0 40.072 113.45 28.0 30.0 30.0 25.5 30.0 40.0

5MR

NOTE: PowerGrip® GT3 8MGT and 14MGT belts are designed to run in standard PowerGrip® HTD® pulleys.

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BORE DIAMETER

B DB (mm)mm + -

≤ 25 0.025 0.0026-50 0.038 0.0051-75 0.050 0.0076 + 0.063 0.00

OUTSIDE DIAMETER

OD DOD (mm)mm + -

≤ 25.40 0.05 0.0025.50-51.00 0.07 0.0051.10-102.00 0.10 0.00102.10-178.00 0.12 0.00178.10-305.00 0.15 0.00305.10-508.00 0.17 0.00508.10 + 0.20 0.00

PITCH ACCURACY

OD DP DP90°mm mm mm

≤ 25.40 ± 0.025 ± 0.06425.50-51.00 ± 0.025 ± 0.08951.10-102.00 ± 0.025 ± 0.114102.10-178.00 ± 0.025 ± 0.127178.10-305.00 ± 0.025 ± 0.152305.10-508.00 ± 0.025 ± 0.165508.10 + ± 0.025 ± 0.191

ECCENTRICITYAllowable amount from pulley bore tooutside diameter (OD) is shown below.

Outside Total eccentricitydiameter (indicator reading)(OD) mm mm

up to 203 0.1over 203 0.005 per 10 mm of ø

(may not exceed thetolerance on

face diameter)

PARALLELISMBore of pulley to be perpendicular tovertical faces of pulley within 0.01 mmper 10 mm of radius with a maximumof 0.51 mm T.l.R.

PITCH ACCURACYThe table on this page shows the pitchaccuracy tolerance (∆P).

HELIX ANGLEGrooves should be parallel to the axis ofthe bore within 0.01 mm per 10 mm.

DRAFTThe maximum permissible draft is0.01 mm per 10 mm of face width, but itmust not exceed the outside diametertolerance.

PULLEY TOLERANCES

Pitch U.R.D.(mm)

2 mm 0.203 mm 0.325 mm 0.538 mm 0.89

14 mm 1.6520 mm 2.54

A: Concentric measurementB: Perpendicular measurement

PULLEY TOLERANCE BAND

A

B

PULLEY* BORE/FACE DIAMETER TOLERANCE SPECIFICATIONSGates recommends that pulleys are precision made to close tolerances. Inaccurate manufacture or reboring may result in poordrive performance. Permissible tolerances for bore (B) (∆B) and for outside diameter (OD) (∆OD) are shown in the tables on thispage. Working surfaces should be free from surface defects and be to 3.2 µm or better.

U.R

.D. 0.05

0.05

0.050.05

0.05

0.05

0.050.05 0.05

0.05

* 8M and 14M HTD® pulleys are suitable for PowerGrip® GT3 belts.

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ENGINEERING DATA

1. PULLEY DIAMETER - SPEED

Blanks in the lower right-hand portions of the power ratingtables occur because pulley rim speed exceeds40 m/s. Centrifugal forces developed beyond this speed mayprohibit the use of stock grey cast iron pulleys. For rim speedsexceeding 40 m/s, contact your Gates sales representative forrecommendations.

2. USE OF FLANGED PULLEYS

Flanges are needed in order to keep the belt on the pulley. Dueto tracking characteristics, even on the best aligned drives,belts will ride off the edge of the pulleys. Flanges will preventthis belt ride-off.

On all drives using stock or made-to-order pulleys, the followingconditions should be considered when selecting flangedpulleys:

1. On all two-pulley drives, the minimum flanging requirementsare two flanges on one pulley or one flange on each pulleyon opposite sides.

2. On drives where the centre distance is more than eight timesthe diameter of the small pulley, special care has to be takenwhen setting up the drive. Always make sure the belt runscorrectly on both pulleys. In some cases it might benecessary that both pulleys are flanged on both sides. (Seepoint 7 “Belt installation and drive alignment” on page 158).

3. On drives with more than two pulleys, the minimum flangingrequirements are two flanges on every other pulley or oneflange on every pulley — alternating sides around thesystem.

On made-to-order pulleys, flanges must be securely fastened,by using mechanical fasteners, welding, shrink-fit or otherequivalent methods.

3. FIXED (NON-ADJUSTABLE)CENTRES

Consult Gates’ application engineers.

4. IDLERS

Use of idlers should be restricted to those cases in which theyare functionally necessary. Idlers usually are used to applytension when centres are not adjustable.

Idlers should be located on the slack side of the belt drive.For inside idlers, grooved pulleys are recommended up to40 grooves. On larger diameters, flat, uncrowned idlers maybe used. Inside idler diameters should not be smaller than thesmallest loaded pulley in the system.

Outside or backside idlers should be flat and uncrowned;flanges are not recommended. Diameters should generally notbe smaller than the smallest loaded pulley in the system.

Slack side spring loaded idlers can be used, as long as care istaken to avoid resonant vibration conditions and load reversals.

Table No. 2Additional centre distance allowancefor installation over flanged pulleys

Belt type One pulley Both pulleysflanged (mm) flanged (mm)

3MGT, 3M, XL 8 14

5MGT, 5M, L 14 19

8MGT, 8M, H 22 33

14MGT, 14M, XH 36 58

20M, XXH 47 78

Table No. 1Centre distance allowance for installation and tensioning(mm)

Belt Standard Tensioninginstallation allowance allowance

(flanged pulleys (any drive)removed

for installation)

1000 mm and under 1.8 0.8

over 1000 mm to 1780 mm 2.8 0.8

over 1780 mm to 2540 mm 3.3 1.0

over 2540 mm to 3300 mm 4.1 1.0

over 3300 mm to 4600 mm 5.3 1.3

5. OPERATING ENVIRONMENT

TemperatureGates PowerGrip® GT3, PowerGrip® HTD® and PowerGrip® beltperformance is generally unaffected in ambient temperatureenvironments between -25°C and +100°C. In cases wherebelts are constantly running at or above these temperatureextremes, contact Gates’ application engineers.

Aircraft drivesGates belts should not be used on aircraft or aircraft relatedapplications.

6. INSTALLATION AND TENSIONINGALLOWANCES

The information on centre distance allows for the installationof the belt without damage and then to tension it correctly.The standard installation allowance is the minimum decreasein centre distance required to install a belt when flanged pulleysare removed from their shafts for belt installation. Standardinstallation allowances are shown in the table below. Thistable also lists the minimum increase in centre distancerequired to ensure that a belt can be properly tensioned.

If a belt is to be installed over flanged pulleys without removingthem, the additional centre distance allowance for installationshown in the second table must be added to the first tabledata.

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ENGINEERING DATA

7. BELT INSTALLATIONAND DRIVE ALIGNMENT

If you cannot adjust the centre distance to install the beltaccording to the two tables on page 157, you need to changethe idler position so that the belt can be slipped easily onto thedrive. When installing a belt, never force it over the flange. Thiswill damage the belt tensile member.

Synchronous belt performance may be affected bymisalignment, which can result in inconsistent belt wear andpremature failure.

There are two types of misalignment: parallel and angular.Parallel misalignment is where the driveR and driveN shaftsare parallel, but the two pulleys lie in different planes. Whenthe two shafts are not parallel, the drive is angularly misaligned.

A fleeting angle is the angle at which the belt enters and exitsthe pulley, and equals the sum of the parallel and angularmisalignments.

Misalignment of all positive belt drives should not exceed1/4° or 5 mm per metre of centre distance. Misalignment shouldbe checked with a good straight edge.The straight edge should be applied from driveR to driveN andfrom driveN to driveR so that the effect of parallel and angularmisalignment is taken into account.

Drive misalignment can also cause belt tracking problems.However, some degree of belt tracking is normal and won’taffect performance.

8. BELT STORAGE AND HANDLING

For storage, the belt should be protected from moisture, oil,temperature extremes, direct sunlight and high ozoneenvironments. The belt should be stored in its original package,avoiding any sharp bends or crimping which will damage thebelt.

9. EFFICIENCY

When properly designed and applied, Gates synchronous beltsare up to 98% efficient and above, thanks to the positive, no-slip characteristics.

Synchronous belt drive efficiency can be calculated as follows:

When examining the loss of energy, it is necessary to considerbelt losses in terms of shaft torque and shaft speed. Torquelosses are created due to bending stress and friction.

Chain drives running unlubricated generate significant heatbuild-up due to increased friction in the roller joints. Evenproperly lubricated chains running at higher speeds tend tothrow off the oil due to centrifugal forces, making it difficult tomaintain proper lubrication at the load-bearing surfaces.Consequently, chain drives are typically only 92-98% efficient.

The belt drive is only part of the total system. Motors shouldbe properly sized for the application. They must have sufficientcapacity to meet the power needs, yet overdesigned motorswill lead to electrical insufficiencies. DriveN machines also mayhave inherent inefficiencies which are not a factor in evaluatingdrive efficiency.CL

CL

Parallel misalignment

Angular misalignment

Fleeting angle

Fleeting angle

DN rpm x DN Torque% efficiency = x 100

DR rpm x DR Torque

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11. BELT TOLERANCES

Synchronous belt width tolerances

Belt width tolerances in mm

Belt width Belt lengths Belt lengths Belt lengthsmm 0-838 mm 839-1676 mm 1677+ mm

3-11 +0.4 +0.4

-0.8 -0.8

12-38 +0.8 +0.8 +0.8

-0.8 -1.2 -1.2

39-51 +0.8 +1.2 +1.2

-1.2 -1.2 -1.6

52-64 +1.2 +1.2 +1.6

-1.2 -1.6 -1.6

65-76 +1.2 +1.6 +1.6

-1.6 -1.6 -2.0

77-102 +1.6 +1.6 +2.0

-1.6 -2.0 -2.0

102-178 +2.4 +2.4 +2.4

-2.4 -2.8 -3.2

178+ +4.8

-6.4

ENGINEERING DATA

10. INSTALLATION TENSION

Gates’ synchronous belts operate by positive meshing and donot require high installation tension.

However, if optimum belt performance is to be achieved, beltsshould be installed at an installation tension level suitable forthe particular duty envisaged.

The required tension level will be between the maximum andminimum values (see formulae below). As a general guide, thelower level will be applicable to lightly loaded, smooth runningdrives, whereas drives subjected to high shock loads and/orfrequent starts will be tensioned at the higher level.

A. Recommended maximum installation tension

Tst = 600 P

v

Where: Tst = static tension (N)P = power (kW)

B. Recommended deflectingforces

1. For maximum installationtension

P x 60F = (N)

v

2. For minimum installationtension

P x 25F = (N)

v

The higher level of deflecting forceshould be applied where shockloads are expected. The lower valuemay be used for smooth runningdrives.

3. Belt deflection

Sbelt deflection = (mm)

50

Note:Pitch x N x rpm

v =60 000

WhereP = transmitted power (kW)F = deflecting forcev = belt speed (m/s)S = belt span length (mm)N = number of grooves in driveRrpm = rpm of driveR

Synchronous belt centre distance tolerances

Belt centre distance tolerances in mm

Belt length PowerGrip®/ PowerGrip® GT3 mm PowerGrip® HTD®

127-254 ±0.20 ±0.20

255-381 ±0.23 ±0.23

382-508 ±0.25 ±0.23

509-762 ±0.30 ±0.27

763-1016 ±0.33 ±0.30

1017-1270 ±0.38 ±0.32

1271-1524 ±0.41 ±0.36

1525-1778 ±0.43 ±0.39

1779 (±0.43) ±0.42

(±0.025 mm (±0.025 mm

per 254 mm) per 250 mm)

t

D

d

F

S50

S

ImportantIf belts need to be removed and replaced, the tension prior toremoval has to be measured and applied for re-installation.

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ENGINEERING DATA

12. CHECK BELT TENSION BY USE OFGATES SONIC TENSION METER

The general procedure to check belt tension is as follows.

A. Measure at the centre of the span (t) the force required todeflect the belt on the drive 2 mm per 100 mm span lengthfrom its normal position.

B. If the measured force is less than the minimumrecommended deflection force, the belts should betightened.

C. New belts can be tensioned until the deflection force perbelt is as close as possible to the maximum recommendeddeflection force.

D. To facilitate tension measuring Gates has developed theSonic tension meter.

Sonic tension meterThe sonic tension meter measures tension by analysing thesound waves which the belt produces when strummed. A beltvibrates at a particular frequency based on its tension, massand span length. The tension tester transforms this frequencyin a tension value.

The hand-held tension tester, running on batteries, is suppliedwith two types of sensors (rigid and flexible), either of which isquickly attached to meet a specific need.

1. Enter belt unit weight (provided with operating instructions),width and span on the keypad. These data remain in themeter even after shut-off.

2. Hold the small sensor up to the belt span and strum the beltslightly to make it vibrate.

3. Press the “measure” button. The computer processes thevariations in sound pressure emanating from the belt span.The belt tension values are displayed on the panel inNewtons. If desired, the belt span frequencies can bedisplayed directly in Hz.

For more detailed information, e.g. suitability of the tensionmeter for different belt product lines, please contact your Gatesrepresentative.

For more details on the use of the Gates’ sonic tension meter,please consult Gates’ sonic tension meter manual (E/20136).

WarningGates Sonic tension meter is not certified for use in explosionrisk areas.

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ENGINEERING DATA

Conventional tension testersUnlike the Sonic tension meter, Gates’ conventional tensiontesters measure deflection force. The Single tension testermeasures up to ± 120 N and the Double tension tester up to± 300 N. Both testers consist of a calibrated spring with twoscales: one to measure the deflection and another to measurethe applied force.

The reading of these scales can be done as follows.

1. Measure the span length (t).

2. The calculated deflection (span/50) should be positionedwith the lower ring on the distance scale. The upper ringshould be on the zero position of the deflection force scale.

3. Put the tension tester perpendicular to the span and in themiddle of the span. Exercise enough pressure to the tensiontester to deflect the belt by the amount indicated by thelower ring. A straight edge, laid across the pulleys, canhelp accuracy of reading.

4. The upper ring will slide up the upper scale and indicatesthe deflection force. Read at the bottom edge of the ring.When you use the Double Tension Tester you can read thevalues just underneath the rings and calculate the sum ofboth values. This value has to be compared with thecalculated min./max. forces (see formulae on installationtension, page 159).

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USEFUL INFORMATION

ß = wrap angleC = centre distance (mm)D = pitch circle diameter of large pulley (mm)d = pitch circle diameter of small pulley (mm)DN = driven pulleyDR = driver pulleyF = force (N)i = speed ratioL = belt length (mm)N = number of grooves of large pulleyn = number of grooves of small pulleyNb = belt length in number of pitchesNc = centre distance in number of pitchesp = pitchP = transmitted power (kW)R = speed of large pulley (rpm)r = speed of small pulley (rpm)S = belt span length (mm)T = torque (Nm)T.I.M. = teeth in meshT.I.R. = total indicator readingU.R.D. = upper reference depthv = belt speed (m/s)

1. FORMULAE 3. ABBREVIATION TABLE

kW = kilowattsNm = newton metreN = newtonJ = joules = secondmm = millimetrem/s = metre/secondkg = kilogrammeg/m = gramme/metre

2. UNITS OF MEASUREMENT

1 lbf = 0.454 kgf1 lbf = 4.448 N1 kgf = 9.807 N1 lbf in = 0.113 Nm1 ft = 0.3048 m1 in = 25.4 mm1 ft2 = 0.093 m2

1 in2 = 645.16 mm2

1 ft3 = 0.028 m3

1 in3 = 16.387 mm3

1 oz = 28.35 g1 lb = 0.454 kg1 lmp. ton = 1.016 tonne1 lmp. gal = 4.546 litres1 lmp. pint = 0.568 litre1 radian = 57.296 degrees1 degree = 0.0175 radian1 horsepower = 0.746 kW

4. CONVERSION TABLE

PITCH DIAMETER

d = N x pπ

SPEED RATIO

WRAP ANGLE

TEETH IN MESH

TIM = n ß360

or TIM = n 0.5 - (N - n)18.85 x Nc[ ]

BELT LENGTH

CENTRE DISTANCE

APPROXIMATE BELT LENGTH

L = 2C + π (D + d) + (D - d)2

2 4C

ß = 2 cos-1 D - d2C

[ ]

i = r = N = DR n d

C = 1 L - π (D + d) + 1 - ß (D - d) 2 sin ß 2 180

for i = 1 ß = 180°, sin ß = 1, for D = d C = 1 (L - π D)2 2

[ ) x(2

( )

L = 2C sin ß + π (D + d) + 1 - ß (D - d)2 2 180

for i = 1 ß=180°, sin ß = 1, for D = d L = 2C + π D2

[ ])(

( )

]

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SUPPORT

DESIGNFLEX CALCULATION SOFTWAREYou may calculate your own application by means of one of Gates’design manuals or by using DesignFlex, a Windows-based multilingualsoftware program. The program is available on CD-ROM (E/20098), butcan also be downloaded from Gates’ website at www.gates.com/europe.The program offers a step-by-step drive calculation procedure for bothV-belts and synchronous belts based on the criteria and/or limitationsspecified by the user.DesignFlex runs under Windows 95, 98, 2000, NT or Millennium, requires aPentium 133 processor or higher and an 800 x 600 screen resolution orhigher. A minimum of 32 MB RAM is recommended for satisfactorycalculation speed.

GATES’ APPLICATION ENGINEERS AT YOURSERVICEIf your application cannot be designed with the aid of Gates’ design manualsor the DesignFlex software, you can always contact Gates’ applicationengineers. They are at your service to solve even the most difficult drivedesign problem.

Gates’ application engineers now use DESIGN IQ a very powerful softwareprogram allowing them to calculate multiple pulley drives for the most diversecomplex duty cycles. For more information on this brandnew softwarepossibilities please contact your Gates representative.

ELECTRONIC PRICE LISTGates’ electronic price list for industrial Power Transmission products is availableon CD-ROM and enables the user to easily select any product from the powertransmission range by product number, bar code, description, type, profile anddimension. A full colour photograph and a drawing of the belt profiles completethe information.The information on the CD-ROM is available in six languages.

GATES LITERATUREPlease consult our web site at www.gates.com/europe/pti for specific and updated information on other Gates industrialbelt products and our list of available literature. Industrial Power Transmission brochures and leaflets can be downloadedfrom the site. Distributors may link up with the Gates European site thus supplying visitors with updated information on theEuropean Gates organisation.

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ADDRESSES

FRANCEGates S.A.S.111, rue Francis GarnierB.P. 37F - 58027 Nevers - CedexTl : (33) 3 / 86 71 75 00Fx : (33) 3 / 86 36 62 47

GERMANYGates GmbH AachenEisenbahnweg 50D - 52068 AachenTl : (49) 241 / 5108-0Fx : (49) 241 / 5108-297

OPERATIONS

POLANDGates Polska Sp.z o.o.Ul. Jaworzyµska 301P - 59-220 LegnicaTl : (48) 76 / 855 10 00Fx : (48) 76 / 855 10 01

UKGatesPower Transmission LtdTinwald Downs RoadHeathhall - DumfriesDG1 1TSTl : (44) 1387 / 24 20 00Fx : (44) 1387 / 24 20 10

BELGIUMGates Europe nvDr. Carlierlaan 30B - 9320 ErembodegemTl : (32) 53 / 76 27 11Fx : (32) 53 / 76 27 13

FRANCEGates France S.A.R.L.B.P. 37Zone IndustrielleF - 95380 LouvresTl : (33) 1 / 34 47 41 41Fx : (33) 1 / 34 72 60 54

GERMANYGates GmbH LangenfeldHaus Gravener Straße 191-193D - 40764 LangenfeldTl : (49) 2173 / 795-0Fx : (49) 2173 / 795-150

ITALYGates S.R.L.Via Senigallia 18(Int. 2 - Blocco A - Edificio 1)I - 20161 Milano MITl : (39) 02 / 662 16 21Fx : (39) 02 / 645 86 36

SPAINGates PT Spain S.A.Polígono IndustrialLes MallolesE - 08660 Balsareny(Barcelona)Tl : (34) 93 / 877 70 00Fx : (34) 93 / 877 70 39

SALES ANDMARKETING FACILITIES

www.gates.com/europe/[email protected]

All Gates’ European Power Transmission Operations are ISO 9001 and ISO 14001 registered.

The manufacturers reserve the right to amend details where necessary. © Gates Europe nv 2005 Printed in Belgium - 01/05.

ImportantEvery effort has been made to ensure the accuracy and comprehensiveness of the information included in thiscatalogue. However Gates cannot be held responsible for errors or omissions and for alterations occurred afterrelease for printing; or if Gates products are used in special or exceptional circumstances without prior consultationwith and clearance from a Gates representative.

This issue is released January 2005 and supersedes all previous versions of Gates synchronous belt drive designmanual. If your drive design manual is more than 2 years old, please consult a Gates representative to checkwhether you have the latest version.

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