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1 tel. +44 (0) fx +44 (0) e.mil points for considertion when shft mounting direct drive ger units. modern hollow bore output hub ger units lend themselves to direct shft mounting on to the driven ppliction shft. right ngle / direct drive / shft mounted / rection rm / brcket electric motor reduction ger unit if instlled correctly this reduces the need for reltively expensive trnsmissions or shft couplings t the low speed / high torque ger unit output nd foundtion or pltform for mounting is normlly not required, gurding is lso minimised. the following points however must be considered to reduce the possibility of of ppliction problems nd increse the mintennce intervls on the ppliction:- shft bering selection; the shft berings must cter for both the rdil rods induced from the ppliction loding nd lso ny overhung lods generted by the ger unit nd motor mss. the ger unit hollow bore is normlly sized to suit the torque being trnsmitted which will be proportionl to the bering lod, typiclly the bering I.D. should be pprox % greter in Ø thn the ger hub for roller nd sphericl roller bering types. the bering selection should however be verified by the relevnt bering supplier! nti-rottion device, (torque rm, rection brcket or bolt etc.); when shft mounting is dopted the ger hub nd ppliction shft become in effect one piece. this mens tht the 2 ppliction shft berings nd 2 ger unit hub berings must be concentric to ensure excessive rdil lods re not generted. the most effective wy to chieve this is by use of device such s torque rm or rection brcket / bolt kit which hs flexible element to llow simple instlltion. this will normlly lso cter for shft oscilltion tht occurs in mny pplictions. the nchor point for the rection device must be robust enough to cope with the reltively lrge rective forces tht cn be generted, especilly during D.O.L. strting where the ger unit torque cn be up to 3 times it's nominl torque rting. the rection device should not hve xil lod exerted on it during instlltion - typiclly this cn occur by incorrect lignment. idelly the nchor point for the rection device should prevent xil movement. shft, key & keywys; it is impertive tht shft keywys / fitted keys re s per ger unit mnufcturers instructions to ensure tht correct instlltion nd in prticulr top fitting keys do not occur. ttched is sheet showing stndrd key nd keywy sizes - refer to mnufctures dt for shft tolernces.

2 tel. +44 (0) fx +44 (0) e.mil xil loction of the ger unit on to the ppliction shft; s virtully no xil loding is generted when shft mounting procedure is dopted it is not common for the ger unit to move xilly. normlly the rection device / nchor point will prevent xil ger movement. if xil loction is required then the shft Ø reduction from berings to ger unit cn be used s locting point for the inside of the ger unit hub to prevent inwrd movement. some ger units hve n internl hub circlip rrngement which cn then be used to fix xil loction. if tht is not present then simple wsher locted ginst the hub t the outside s shown in the following drwings is cceptble. gurding / sfety hub covers; s no trnsmission is required for direct shft mounting then gurding is reduced. the rotting keywy in the output hub however is n issue nd must be covered. some ger unit mnufcturers supply plstic plug in cover - this rottes with the output hub but the keywy is covered. Helth & Sfety Inspectors my not pprove the plstic covers s the method of fixing is not positive nd depends on friction. if this is the cse lrger sttionry hub cover cn normlly be supplied. lubriction; one of the dvntges of shft mounting is the bility to rottionlly locte the drive unit to the most suitble position. the lubricnt should be instlled s per mnufcturers instructions. the pproprite positions for ny sight glss, brether or drin point will lso be shown. if the ctul position is not one of the norml positions shown in the instructions then "pro-rt" fill should be used bsed on quntity - in these positions the sight glss cn not be used for level checking. motor seling nd terminl block position; most motors now re either IP54 or IP55 rted s stndrd mking them suitble for norml outside use. this rting however is only ctive when correct glnds nd cbles re fitted so it is impertive tht cre is tken if storing drive unit outside prior to electricl connection tht moisture ingress cn not occur. the motor terminl box position cn normlly be djusted to fcilitte cble entry nd in our experience when the glnds re locted t the bottom of the terminl box, (s shown on ttched drwing), then moisture ingress on the ppliction is lest likely to occur. method of strting; shft mounting cretes very positive drive on to the ppliction shft with no flexible coupling elements or rubber type trnsmissions present to cushion shock lods on strt up. when motor size is 7.5kw or below, D.O.L. (Direct On Line) strting is not normlly n issue but bove tht ssisted strting is recommended. - consult with technidrive during ger unit selection for dvice on this subject. ger unit removl; fretted corrosion cn occur between the ger unit output hub nd ppliction shft fter period of time. one method of minimising this is to pply liberl coting of high qulity nti-seize compound during instlltion of the ger unit on to the ppliction shft nd ger unit output hub. if nd when ger unit is to be removed nd proves difficult then in our experience it is dvisble to try nd remove the shft key first - this cn be chieved by drilling nd tpping the key in n xil direction nd using threded impct hmmer or similr to drift the key out. this will mke subsequent removl of the ger unit much esier thn with the key instlled.

3 Unit 19, Tullygoonign Industril Estte, 89, Moy Rod, Armgh, Co. Armgh, N. Irelnd,BT61 8DR fx+44 (0) schemtic to show ger unit shft mounting direct shft mounting vi hollow bore is now very common method used to mount ger units on to driven shfts. it reduces the need for reltively expensive couplings or trnsmissions t the low speed / high torque output side of the reducer, foundtion for the drive is not normlly required nd gurding is minimised. when this method is dopted the ger unit hub nd driven shft in effect become one component nd s most ger units hve 2 berings supporting the output hub nd most driven shfts hve 2 locting berings then commonly 4 berings re to be locted on the sme xis. if the ger unit is incorrectly fixed to rigid plne or structure which is not exctly t the correct dimension to enure xis of shft nd xis of bering rottion re the sme then excessive rdil loding cn be generted on either the ger unit or shft berings. most ger unit mnufcturers who offer hollow bore ger units for shft mounting lso offer devices tht prevent rottion of the ger without cusing dditionl bering loding due to mislignment. typiclly these re in the form of:- torque rm rection brcket rector bolt kit most of these hve some form of flexible element which llows connection to rigid plne but still llowing contined movement of the ger unit with regrd to xil, ngulr nd prllel movement of the ger unit reltive to the shft xis. it is difficult to see smll mounts of ngulr mislignment or oscilltion t the shft but when ger unit is fitted with rection device it is common to see quite lot of movement of the ger unit t prts furthest wy from the hub centre. gin it is not uncommon to see 2 identicl ppliction with shft mounted ger units hving rection devices nd for 1 to show no signs of movement nd the other to hve considerble pprent oscilltion of the ger unit.

4 Unit 19, Tullygoonign Industril Estte, 89, Moy Rod, Armgh, Co. Armgh, N. Irelnd,BT61 8DR fx+44 (0) W t2 H/2 tc H t1 H/2 Dk y D ppliction shft Bk D W H t1 t2 y Bk Dk tc shft key key keywy keywy bore & shft & top dimeter width height depth height keywy key clernce

5 Unit 19, Tullygoonign Industril Estte, 89, Moy Rod, Armgh, Co. Armgh, N. Irelnd,BT61 8DR fx+44 (0) detil for shft mounting rrngement with xil loction bolt nd hub cover (Bonfiglioli A series) robust nchor point for rection device - lso provides xil loction shoulder on shft used for xil loction of ger unit hub sfety hub cover A1 A2 A1 B = effective shft length through hub. xil retention wsher nd bolt (s per dimension UR in ctlogue)

6 lubriction recommendtions Unit 19, Tullygoonign Industril Estte, 89, Moy Rod, Armgh, Co. Armgh, N. Irelnd,BT61 8DR fx+44 (0) (Bonfiglioli A series) position B3 / B8 lubricte s per mnufcturers instructions, sight glss for level cn be used. position VA lubricte s per mnufcturers instructions, sight glss for level cn be used. position VB lubricte s per mnufcturers instructions, sight glss for level cn be used. no ctlogue reference lubricte pro-rt between positions, DO NOT use sight glss for level checking.

7 Unit 19, Tullygoonign Industril Estte, 89, Moy Rod, Armgh, Co. Armgh, N. Irelnd,BT61 8DR fx+44 (0) detil for electric motor terminl box position on shft mounted right ngle ger units terminl box orienttion A terminl box locted t side, terminl cover for side ccess, cble glnd loction t bottom. terminl box orienttion B notes :- 1) most electric motors re IP 54 / IP 55 rted mking them suitble for outside pplictions. this rting is only when correct IP rted cbles / glnds re fitted - if the motor is to be left in outside environment nd exposed to the elements prior to correct electricl connection, the motor must be protected ginst moisture ingress. 2) on outside pplictions or res where moisture is present it is recommended tht the terminl box cover nd cble glnds hve dditionl seling vi cot of silicone selnt or similr. 3) on very wet pplictions it is dvisble to fill the terminl box fter correct electricl connection with seler such s Ry-tech Mgic Gel or similr to provide enhnced protection ginst moisture ingress.