UNI EN ISO 9001:2008 UNI EN ISO 14001:2004 BS OHSAS 18001:2007 DIRECTIVE 94/9/EC (ATEX) CERTIFIED MANAGEMENT SYSTEM

Transcription

1 INCH RD

2 CERTIFIED Technology Made in Italy Since 1955 Varvel has been making speed reducers and variators for light industry applications. Reliable partner in power transmission equipment offers also customized solutions always according to a socially responsible company values. Modularity and flexibility lead Varvel products by a unique kit form, common to all gearbox series. This feature allows distributors an easier job to set up required products in few minutes. EN UNI EN ISO 9001:2008 UNI EN ISO 14001:2004 BS OHSAS 18001:2007 DIRECTIVE 94/9/EC (ATEX) MANAGEMENT SYSTEM

3 RD Helical Gearboxes - two and three stages - foot- and flangemount CONTENTS Product description Symbols and formulas... 3 Modular system Flexible coupling G... 6 Flexible coupling selection... 7 NEMA Flanges and flexible coupling... 8 IEC Flanges and flexible coupling... 9 VARsize Electronic catalogue - 3D models Product designation Input arrangements Mounting positions Service factors External loads Component kits and Direction of rotation Selection tables RD RD RD RD RD RD RD Dimensions RD RD RD RD RD RD RD General information Conversion factors Abstract of Operation and Maintenance Instructions... 40

4 Product description Multipurpose housing Foot & Foot/Flange Mountings One housing for 2- & 3-stages Housing & Covers Aluminium die cast (5 sizes) Cast iron (2 sizes) Input NEMA and IEC motor adapters and Universal elastic coupling Gearing Alloy steel Case hardened Profile ground or shaved Oil seals Nitrile Butadiene Rubber -NBR as standard; Viton and Silicon on request Bearings Ball or roller types according to sizes and technical requirements Output Solid shafts imperial and metric Lubrication Synthetic long-life oil Grade ISO VG 320 No oil plugs In-house filling The helical gearboxes Series RD feature a one-piece cast housing complete with inner support to accommodate 2 or 3 gear stages into the same casing. Manufactured to latest ISO engineering design specifications the housing is checked by computer-aided structural analysis for deflection and stress distribution. Significant strains caused by the effects of torque and external loads do not deflect the monolithic ribwork of the housing, which significantly improves the integrity of the sealed surfaces. The helical gearboxes, Series RD are manufactured in B3 base mounted configuration; they can be easily converted to B5 flange mounting by fitting of the appropriate additional adaptor flange onto the footed body. Single-setup machining on state-of-the-art CNC production lines, the most recent calculation techniques and process controls give superior operational reliability, maximum output torques, high overhung and thrust load capacity, and long working life-time. NEMA and IEC motors are mounted by easily fitting interchangeable bolted flanges and flexible couplings The flexible coupling, built-in inside the gearbox body, does not affect dimensional length increase of the gearbox

5 Symbols and formulas Symbol Description Formula D [in] Transmission element PCD F r [lb] Application overhung load (external OHL) F r1 [lb] Catalogue input overhung load (gearbox input OHL) F r2 [lb] Catalogue output overhung load (gearbox output OHL) F r2b(x) [lb] Permissible OHL at position 'X' on output shaft, bearing lifetime condition F r2s(x) [lb] Permissible OHL same as F r2b(x), shaft bending and torsional stress condition SF i n Service factor Nominal reduction ratio M2 FS M(app) i r Actual reduction ratio J 1 [ft 2 -lb] Gearbox moment of inertia at input shaft J 2 [ft 2 -lb] Application moment of inertia J m [ft 2 -lb] Motor moment of inertia k (a) Mass acceleration factor k (t) Transmission element factor Lub H/V [qt] Lubricant [qt]: H = horizontal mounting / V = vertical mounting M 2 [in-lb] Gearbox maximunm output torque 1800 P1 M2 n2 M (app) [in-lb] Application torque n 1 [RPM] Gearbox iinput speed n 2 [RPM] Gearbox output speed P 1 [HP] Gearbox input 60Hz M2 n2 P W [lb] Weight: mounting B3-H & average reduction ratio η Efficiency: stage units stage units - 3 -

6 Modular system - 4 -

7 Modular system - 5 -

8 Flexible coupling G A) Reducer-side coupling hub Material: steel alloy Input shaft built-in Two bearing set Unchanged casing dimensions B) Spider External tooth connection Material: Thermoplastic Elastomer Hytrel TPE - Polyester (white) IXEF TPA - Plyarilamide (black) Hardness TPE 72 Shore D TPA 90 Shore D Temperature TPE -22 / +212 F (-30 / +100 C) TPA -22 / +275 F (-30 / +135 C) C) Motor-side coupling hub Material: Aluminium (G3, G5, G6) die cast Alloy steel (GS8) Alloy steel (GS3, GS5, GS6) on demand Dynamic balancing Fitting: Clamp (G3, G5, G6) Key (GS3, GS5, GS6, GS8) Bores: NEMA C / TC IEC 72 / N42948 Advantages: One gearbox only for each reduction ratio Greater flexibility Increased stock rotation Elimination of fretting corrosion in key/keyway coupling Zero backlash in gearbox/motor connection Allowed angular misalignment 1 max High torsional rigidity High vibration damping Input flanges: Material: Aluminium up to NEMA 180TC and IEC112 Cast iron from NEMA 210TC and IEC

9 Flexible coupling selection Coupling Size IEC NEMA Kit Code RD Size Mt [Nm] Mt 1 [Nm] Mt 2 [Nm] A [mm] B [mm] D1 [mm D 2 [mm / inch] Coupling ID# G3 IEC NEMA KG3.009/X KG3.011/X KG3.014/X KG3.N42/X KG3.N48/X /8" 1/2" N42 3N48 G5 IEC NEMA KG5.009/X KG5.011/X KG5.014/X KG5.019/X KG5.024/X KG5.N48/X KG5.N56/X KG5.N140/X /2" 5/8" 7/8" N48 5N56 5N140 G6 IEC NEMA KG6.014/X KG6.019/X KG6.024/X KG6.028/X KG6.N56/X KG6.N140/X KG6.N180/X /8" 7/8" 1-1/8" N56 6N140 6N180 GS8 IEC * KGS8.19/X * KGS8.24/X * KGS8.28/X * KGS8.38/X * KGS8.42/X * KGS8.48/X NEMA * KGS8.N056/X * KGS8.N140/X * KGS8.N180/X * KGS8.N210/X /8" 7/8" 1-1/8" 1-3/8" 8N56 8N140 8N180 8N210../X - Code of coupling with new IXEF black-spider Mt - Screw locking torque Mt 1 - Transmissible torque with key Mt 2 - Transmissible torque without key * - Coupling GS8: steel and key fit - 7 -

10 NEMA flanges and flexible couplings RD Size Flange Size NEMA Frame Flange Kit Code Type Coupling Kit Code RD 02 RD 03 FM C 56 C 42 C 48 C K N48 K N56 K N48 K N48 G5 ø 1/2 G5 ø 5/8 G3 ø 3/8 G3 ø 1/2 KG5.N48/X KG5.N56/X KG3.N42/X KG3.N48/X RD C 140 TC K N56 K N56 G5 ø 5/8 G5 ø 7/8 KG5.N56/X KG5.N140/X FM 50 RD C K N56 G5 ø 5/8 KG5.N56/X RD 22 RD 23 FM C 140 C 180 C 56 C 140 C K N56 K N56 K N180 K N56 K N56 G6 ø 5/8 G6 ø 7/8 G6 ø 1-1/8 G5 ø 5/8 G5 ø 7/8 KG6.N56/X KG6.N140/X KG6.N180/X KG5.N56/X KG5.N140/X RD 32 RD 33 FM C 140 TC 180 TC 56 C 140 TC K N56 K N56 K N180 K N56 K N56 G6 ø 5/8 G6 ø 7/8 G6 ø 1-1/8 G6 ø 5/8 G6 ø 7/8 KG6.N56/X KG6.N140/X KG6.N180/X KG6.N56/X KG6.N140/X RD 42 RD 43 FM C 140 TC 180 TC 56 C 140 TC 180 TC K N56 K N56 K N180 K N56 K N56 K N180 G6 ø 5/8 G6 ø 7/8 G6 ø 1-1/8 G6 ø 5/8 G6 ø 7/8 G6 ø 1-1/8 KG6.N56/X KG6.N140/X KG6.N180/X KG6.N56/X KG6.N140/X KG6.N180/X RD 52 RD 53 FM C 140 TC 180 TC 210 TC 56 C 140 TC 180 TC 210 TC K N56 K N56 K N180 K N180 K N56 K N56 K N180 K N180 * GS8 ø 5/8 * GS8 ø 7/8 * GS8 ø 1-1/8 * GS8 ø 1-3/8 * GS8 ø 5/8 * GS8 ø 7/8 * GS8 ø1-1/8 * GS8 ø 1-3/8 KGS8.N56/X KGS8.N140/X KGS8.N180/X KGS8.N210/X KGS8.N56/X KGS8.N140/X KGS8.N180/X KGS8.N210/X RD 62 RD 63 FM C 140 TC 180 TC 210 TC 56 C 140 TC 180 TC 210 TC K N56 K N56 K N180 K N180 K N56 K N56 K N180 K N180 * GS8 ø 5/8 * GS8 ø 7/8 * GS8 ø 1-1/8 * GS8 ø 1-3/8 * GS8 ø 5/8 * GS8 ø 7/8 * GS8 ø 1-1/8 * GS8 ø 1-3/8 KGS8.N56/X KGS8.N140/X KGS8.N180/X KGS8.N210/X KGS8.N56/X KGS8.N140/X KGS8.N180/X KGS8.N210/X../X - Code of coupling with new IXEF black-spider * - Coupling GS8: steel and key fit - 8 -

11 IEC flanges and flexible couplings RD Size RD 02 RD 03 RD 12 RD 13 RD 22 RD 23 RD 32 RD 33 RD 42 RD 43 RD 52 Flange Size FM 40 FM 50 FM 70 FM 70 FM 85 FM 130 & FM 150 RD 53 FM 130 RD 62 RD 63 FM 130 & FM 150 FM 130 & FM 150 IEC Frame IEC56 IEC63 IEC71 IEC80 IEC56 IEC63 IEC71 IEC56 IEC63 IEC71 IEC80 IEC90 IEC56 IEC63 IEC71 IEC71 IEC80 IEC90 IEC 100/112 IEC63 IEC71 IEC80 IEC90 IEC71 IEC80 IEC90 * IEC 100/112 IEC71 IEC80 IEC90 ** IEC 100/112 IEC 80 IEC 90 IEC 100/112 IEC 132 IEC 160 IEC 180 IEC 80 IEC 90 IEC 100/112 IEC 80 IEC 90 IEC 100/112 IEC 132 IEC 160 IEC 180 IEC 80 IEC 90 IEC 100/112 IEC 132 * - IEC100/112: not for RD33 ** - IEC112: not for RD43 *** - Coupling GS8: steel and key fit../x - Code of coupling with new IXEF black-spider Kit Code Coupling Flange B5 Flange B14 Type Kit Code K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K G5 ø09 G5 ø11 G5 ø14 G5 ø19 G3 ø09 G3 ø11 G3 ø14 G5 ø09 G5 ø11 G5 ø14 G5 ø19 G5 ø24 G5 ø09 G5 ø11 G5 ø14 G6 ø14 G6 ø19 G6 ø24 G6 ø28 G5 ø11 G5 ø14 G5 ø19 G5 ø24 G6 ø14 G6 ø19 G6 ø24 G6 ø28 G6 ø14 G6 ø19 G6 ø24 G6 ø28 *** GS8 ø19 *** GS8 ø24 *** GS8 ø28 *** GS8 ø38 *** GS8 ø42 *** GS8 ø48 *** GS8 ø19 *** GS8 ø24 *** GS8 ø28 *** GS8 ø19 *** GS8 ø24 *** GS8 ø28 *** GS8 ø38 *** GS8 ø42 *** GS8 ø48 *** GS8 ø19 *** GS8 ø24 *** GS8 ø28 *** GS8 ø38 KG5.009/X KG5.011/X KG5.014/X KG5.019/X KG3.009/X KG3.011/X KG3.014/X KG5.009/X KG5.011/X KG5.014/X KG5.019/X KG5.024/X KG5.009/X KG5.011/X KG5.014/X KG6.014/X KG6.019/X KG6.024/X KG6.028/X KG5.011/X KG5.014/X KG5.019/X KG5.024/X KG6.014/X KG6.019/X KG6.024/X KG6.028/X KG6.014/X KG6.019/X KG6.024/X KG6.028/X KGS8.019/X KGS8.024/X KGS8.028/X KGS8.038/X KGS8.042/X KGS8.048/X KGS8.019/X KGS8.024/X KGS8.028/X KGS8.019/X KGS8.024/X KGS8.028/X KGS8.038/X KGS8.042/X KGS8.048/X KGS8.019/X KGS8.024/X KGS8.028/X KGS8.038/X - 9 -

12 VARsize Electronic catalogue - 3D-models Modularity and flexibility have been leading the design of Varvel products since The gearbox-kit concept was carried out allowing anyone to assemble the unit in a few minutes with standard tooling. This feature provides the highest flexibility to Varvel s distributors and resellers who - thanks to a limited kit selection - are able to immediately configure the required product. VARSIZE selection programme, available from our site allows a friendly sizing of Varvel product range. 2D/3D Drawings A guided selection allows 2D/3D models to be downloaded for the most popular CAD systems. Guided selection This service returns a list of applicable product configurations upon a given sequence of application parameters (power, output torque, rpm, service factor etc.); a PDF data sheet featuring performance data and dimensional drawings is generated for each configuration, as well as the 3D model and 2D drawings

13 Example: FRD32/B3-H N56 AU35 Product designation F RD 52 B3-H N56 AU DFU Type RD - Helical gearbox Mounting position B3 - Foot mounting B5 - Flange mounting Page 5 Output flange [mm] Input type Size Reduction ratio 1: Motor adapter Output shaft dia. a) b) a) b) NEMA RD size in M - motorized unit F - with motor flange S - without motor flange nil - solid input shaft N42 RD N48 RD N56 RD N140 RD N180 RD N210 RD RD a) - 2-stages b) - 3-stages

14 Input arrangements NEMA INPUT FRD NEMA G3 48 G5 G3 56 G5 - - G5 G5 G6 G5 G6 G6 G6 G6 GS8 GS8 GS8 GS G5 - - G6 G5 G6 G6 G6 G6 GS8 GS8 GS8 GS G6 - - G6 - - G6 G6 GS8 GS8 GS8 GS GS8 GS8 GS8 GS8 G3, G5, G6 = Elastic coupling 'G' input, aluminium die cast type GS8 = Elastic coupling 'G' input, steel type IEC INPUT FRD IEC = IEC with G-Coupling (standard) = IEC with quill input (on demand)

15 Mounting positions B3 Foot mounting H2 H1 V6 V5 H4 H3 B5 Flange mounting H2 H1 V6 V5 H4 H3-13 -

16 Service factors SERVICE FACTOR of the gearbox Serevice factor is the ratio between M 2 gearbox maximum output torque and M (app) application torque, and it must be bigger than the related Application factor listed below. Service factor SF1.0 is meant as typical of 8 hours/day operation, with uniform load, starts/ stops lower than 60 per hour and ambient temperature between 60 and 95 F. Application Agitators (mixers) Pure liquids Liquids and solids Liquids - variable density Blowers Centrifugal Lobe Vane Brewing and distilling Bottling machinery Brew kettles - continuous duty Cookers - continuous duty Mash tubs - continuous duty Scale hopper - frequent starts Can filling machine Car dumpers Car pullers Clarifiers Classifiers Clay working machinery Brick press Briquette machine Pug mill Compactors Compressors Centrifugal Lobe Reciprocating, multi-cylinder Reciprocating, single-cylinder Conveyors - General purpose Uniformly loaded or fed - Heavy duty Not uniformly fed - Reciprocating or shaker Crusher Stone or ore Dredges Cable reels. Conveyors Cutter head drives Pumps Screen drives Stackers Winches Load duration (hrs/day) Load duration (hrs/day) Application < > 10 < > 10 Elevators Bucket Centrifugal discharge Escalators Freight Gravity discharge Extruders General Plastics Variable speed drive Fixed speed drive Rubber Continuous screw operation Intermittent screw operation Fans Centrifugal Cooling towers Forced draft Induced draft Industrial and mine Feeders Apron Belt Disc Reciprocating Screw Food industry Cereal cooker Dough mixer Meat grinders Slicers Generators and exciters Hammer mills Hoists Heavy duty Medium duty Skip hoist Laundry Tumblers Washers Lumber industry Barkers Spindle feed Main drive Conveyors Burner Main or heavy duty Main log Re-saw, merry-go-round

17 Service factors Application Load duration (hrs/day) Load duration (hrs/day) Application < > 10 < > 10 Conveyors Slab Transfer Chains Floor Green Cut-off saws Chain Drag Debarking drums Feeds Edger Gang Trimmer Log deck Log hauls - incline - well type Log turning devices Planer feed Planer tilting hoists Rolls -live-off bearings - roll cases Sorting table Tipple hoist Transfers Chain Crane way Tray drives Veneer lathe drives Metal mills Draw bench carriage and main drive Runout table Non-reversing Group drives Individual drives Reversing Slab pushers Shears Wire drawing machine Wire winding machine Metal strip processing machinery Bridles Coilers and uncoilers Edge trimmers Flatteners Loopers (accumulators) Pinch rolls Scrap choppers Shears Slitters Mills, rotary type Ball and rod Spur ring gear Helical ring gear Direct connected Cement kilns Dryers and coolers Mixers Concrete Paper mills Agitator (mixer) Agitator for pure liquors Barking drums Barkers -mechanical Beater Breaker stack Calendar Chipper Chip feeder Coating rolls Conveyors Chip, bark, chemical Log (including slab) Couch rolls Cutter Cylinder molds Dryers Paper machine Conveyor type Embosser. Extruder Fourdrinier rolls (includes lump breaker, dandy roll, wire turning, and return rolls) Jordan Kiln drive Mt Hope roll Paper rolls Platter Presses - felt and suction Pulper Pumps - vacuum Reel (surface type) Screens Chip Rotary Vibrating Size press Super calendar Thickener (AC motor) Washer (DC motor) (AC motor) (DC motor) Wind and unwind stand Winders (surface type) Yankee dryers Plastics industry Primary processing Intensive internal mixers Batch mixers Continuous mixers Batch drop mill - two smooth rolls Continuous feed, holding and blend mill Compounding mill Calendars

18 Service factors Application Load duration (hrs/day) Load duration (hrs/day) Application < > 10 < > 10 Plastics industry Secondary processing Blow molders Coating Film Pipe Pre-plasticizers Rods Sheet Tubing Pullers -barge haul Pumps Centrifugal Proportioning Reciprocating Single acting, three or more cylinders Double acting, two or more cylinders Rotary Gear type Lobe Vane Rubber industry Intensive internal mixers Batch mixers Continuous mixers Mixing mill - two smooth rolls (if corrugated rolls are used, then use the same selection factors that are used for a cracker warmer). Batch drop mill - two smooth rolls Cracker warmer - two rolls; one corrugated roll Cracker - two corrugated rolls. Holding, feed and blend mill - two rolls Refiner - two rolls Calendars Sand muller Sewage disposal equipment Bar screens Chemical feeders Dewatering screens Scum breakers Slow or rapid mixers Sludge collectors Thickeners Vacuum filters Screens Air washing Rotary - stone or gravel Travelling water intake Sugar industry Beet slicer Cane knives Crushers Mills (low speed end) Textile industry Batchers Calendars Cards Dry cans Dryers Dyeing machinery Looms Mangles Nappers Pads Slashers Soapers Spinners Tenter frames Washers Winders This application guide is given by way of an example and therefore, may not include all the possible cases. Should the application not be referable to any of the listed cases, the table below gives two service factors - one referred to both load type and work duration, and another one to starts and stops number of the duty cycle - of which the product is the gearbox oversizing coefficient in order to have a torque good enough to perform the required work. Application: Conveyor RPM - uniform load - 24 hrs/day F 1 =1.4; 60 start/stops per hour F 2 = 1.0; Required torque 1000 x 1.4 x 1.0 = 1400 in-lb Gearbox to select FRD22 1/20 (84 RPM) 1683 in-lb (gearbox service factor SF1.7 = 1683 in-lb : 1000 in-lb) SERVICE FACTOR SF = F 1 F 2 F 1 a b c F 2 d = Load & time factor = Uniform load = Variable load = Shock load = Running factor = Start/stops per hour F 1 a b c F 2 d 3-4 hrs hrs hrs

19 External loads OHL - OVERHUNG LOADS - OUTPUT [lb] Overhung (radial) loads must be checked withf r2 rating factor given in the selection tables. Each transmission element fitted on the gearbox output shaft gives its own transmission element factor k (t) according to the following table. - Application OHL k (t) Transmission Element 1.15 Gear - Tooth No. < Chain sprocket - Tooth No. < 13 Chain sprocket - Tooth No. < 20 Chain sprocket - Tooth No. > V-belt pulley Toothed belt pulley 2 M Fr D 2 k (t) D - Catalogue OHL at mid shaft Fr2 Fr Catalogue value to be greater than application OHL RD a [inch] a [mm] F r2 a - OHL offset from gearbox centre * or ** values as appropriate to be greater than application OHL RD * F F r2b(x) r2b(x) Fr F r2 c x b F r2 x a [inch] b [inch] c [inch] ** Fr Fr 2s(x) 2s(x) Fr Fr 2 a x AXIAL LOADS - OUTPUT Axial load values are assumed to be as 20% of OHL, either on tensile and compressive stress, and besides OHL itself. F a2 F r2 0.2 F r2 F a2-17 -

20 Component kits and Direction of rotation Two-stage gearbox - RD 2 A NEMA or IEC motor adapter B - 2-stage input cover with T3 gear C - Housing with T4, T5, T6 gears D - Output flange Three-stage gearbox - RD 3 A - NEMA or IEC motor adapter B - 3-stage input cover with T1, T 2, T3 gears C - Housing with T4, T5, T6 gears D - Output flange

21 RD02 & RD03 Helical Gearboxes RD 1800 RPM Selection 440 in-lb i n nominal i r actual n 2 M 2 P 1 F r1 F r2 J NEMA frames [RPM] [in-lb] [HP] [lb] [lb] [lb x ft 2 ] RD02 2s 2, G5 G5 3, G5 G5 4, G5 G5 5, G5 G5 6, , , , , , , , , G5 G5 G5 G5 G5 G5 G5 G5 G5 G5 G5 G5 G5 G5 G5 G5 G5 G5 G5 G5 RD03 3s 2s & 3s G3, G G5 G G3 G G3 G G3 G G3 G G3 G G3 G G3 G G3 G G3 G G3 G G3 G G3 G3 - Number of reduction stages - Recommended input in-line coupling drive - Elastic coupling 'G type' input RD Lub. H Lub. V Weight US qt litres US qt litres lb kg

22 Selection RD12 & RD RPM 885 in-lb i n nominal i r actual n 2 M 2 P 1 F r1 F r2 J NEMA frames [RPM] [in-lb] [HP] [lb] [lb] [lb x ft 2 ] RD12 2s G5 G G5 G G5 G G5 G G5 G G5 G G5 G G5 G G5 G G5 G G5 G G5 G G5 G G5 G G5 G5 RD13 3s 2s & 3s G5 RD G G G G G G G G G G G G G5 - Number of reduction stages - Recommended input in-line coupling drive - Elastic coupling 'G type' input Lub. H Lub. V Weight US qt litres US qt litres lb kg

23 RD22 & RD23 Helical Gearboxes RD 1800 RPM Selection 1770 in-lb i n nominal i r actual n 2 M 2 P 1 F r1 F r2 J NEMA frames [RPM] [in-lb] [HP] [lb] [lb] [lb x ft 2 ] RD22 2s G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G6 RD23 3s 2s & 3s G5, G6 RD G6 G6 G G6 G G6 G G6 G G G G G5 G G5 G G G G G G G G G G G G5 - Number of reduction stages - Recommended input in-line coupling drive - Elastic coupling 'G type' input Lub. H Lub. V Weight US qt litres US qt litres lb kg

24 Selection RD32 & RD RPM 3720 in-lb i n nominal i r actual n 2 M 2 P 1 F r1 F r2 J NEMA frames [RPM] [in-lb] [HP] [lb] [lb] [lb x ft 2 ] RD32 2s G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G6 RD33 3s 2s & 3s G6 RD G6 G6 G G6 G G6 G G6 G G6 G G6 G G6 G G6 G G G G G G G G G6 - Number of reduction stages - Elastic coupling 'G type' input Lub. H Lub. V Weight US qt litres US qt litres lb kg

25 RD42 & RD43 Helical Gearboxes RD 1800 RPM Selection 6200 in-lb i n nominal i r actual n 2 M 2 P 1 F r1 F r2 J NEMA frames [RPM] [in-lb] [HP] [lb] [lb] [lb x ft 2 ] RD42 2s G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G6 G G6 G G6 G G6 G6 RD43 3s G6 G G6 G G6 G G6 G G6 G G6 G G6 G G6 G G G G G G6 2s & 3s G6 RD - Number of reduction stages - Elastic coupling 'G type' input Lub. H Lub. V Weight US qt litres US qt litres lb kg

26 Selection RD52 & RD RPM 11,500 in-lb i n nominal i r actual n 2 M 2 P 1 F r1 F r2 J NEMA frames [RPM] [in-lb] [HP] [lb] [lb] [lb x ft 2 ] RD52 2s , ,027 GS8 GS8 GS8 GS , ,531 GS8 GS8 GS8 GS , ,206 GS8 GS8 GS8 GS , ,064 GS8 GS8 GS8 GS , ,680 GS8 GS8 GS8 GS , ,673 GS8 GS8 GS8 GS , ,212 GS8 GS8 GS8 GS , ,759 GS8 GS8 GS8 GS , ,266 GS8 GS8 GS8 GS , ,021 GS8 GS8 GS8 GS , ,156 GS8 GS8 GS8 GS , ,657 GS8 GS8 GS8 GS , ,664 GS8 GS8 GS , ,043 GS8 GS , ,372 GS8 GS8 RD53 3s , ,786 GS8 GS8 GS , ,760 GS8 GS8 GS , ,504 GS8 GS8 GS , ,290 GS8 GS8 GS , ,804 GS8 GS , ,163 GS8 GS , ,924 GS8 GS , ,469 GS8 GS , ,221 GS8 GS , ,292 GS , ,506 GS , ,221 GS , ,055 GS8 2s & 3s GS8 RD - Number of reduction stages - Elastic coupling 'G type' input Lub. H Lub. V Weight US qt litres US qt litres lb kg

27 RD62 & RD63 Helical Gearboxes RD 1800 RPM Selection 20,350 in-lb i n nominal i r actual n 2 M 2 P 1 F r1 F r2 J NEMA frames [RPM] [in-lb] [HP] [lb] [lb] [lb x ft 2 ] RD62 2s GS8 GS8 GS8 GS GS8 GS8 GS8 GS GS8 GS8 GS8 GS GS8 GS8 GS8 GS GS8 GS8 GS8 GS GS8 GS8 GS8 GS GS8 GS8 GS8 GS GS8 GS8 GS8 GS GS8 GS8 GS8 GS GS8 GS8 GS8 GS GS8 GS8 GS8 GS GS8 GS8 GS8 GS GS8 GS8 GS8 GS GS8 GS8 GS8 GS GS8 GS8 GS8 GS8 RD63 3s GS8 GS8 GS8 GS GS8 GS8 GS8 GS GS8 GS8 GS8 GS GS8 GS8 GS8 GS GS8 GS8 GS GS8 GS8 GS GS8 GS8 GS GS8 GS8 GS GS8 GS GS8 GS GS8 GS GS8 GS GS8 GS8 2s & 3s GS8 RD - Number of reduction stages - Elastic coupling 'G type' input Lub. H Lub. V Weight US qt litres US qt litres lb kg

28 Dimensions RD02 & RD03 Foot mounting FRD B3 Output shaft AU RD B3 Gearbox flange input A AC B BA BB BC CB D DA DB E EA EB ø F VB VC FRD Note: CB: max. length with the biggest input flange AB, BD, C, P: according to specific motor manufacturer dimensions Output shaft R U ø h6 V VA KEY TAP AU / 16 x 3 / 16 x 1 1 / 16 1 / 4-20 x 0.63 Standard imperial AU 17 AU x 5 x 25 6 x 6 x 30 M6 x 16 M6 x16 Standard metric Gearbox shaft input AJ' AK' ø g6 BF CA RD02 RD03 RD02 RD03 DC R' U' ø h6 V' VA' VD KEY' TAP' RD x 4 x 15 M5 x 12.5 Dimensions are inch / mm

29 RD02 & RD03 Flange mounting Helical Gearboxes RD Dimensions FRD B3 / B5 Output shaft AU see opposite page OUTPUT FLANGES Built-in flange Bolted flange DFU Gear-case A AC B BA BB BC CB D DA DB E EA EB ø F VB VC FRD Note: CB: max. length with the biggest input flange AB, BD, C, P: according to specific motor manufacturer dimensions Output flange AJ AK AW BD H thread / bore Built-in flange g M6 x 14 (7x) Gearbox housing with built-in flange DFU h ø 0.28 (4x) ø 7 (4x) DFU h ø 0.35 (4x) ø 9 (4x) Bolted flange DFU h ø 0.35 (4x) ø 9 (4x) Dimensions are inch / mm

30 Dimensions RD12 & RD13 Foot mounting FRD B3 Output shaft AU RD B3 Gearbox flange input A AC B BA BB BC CB D DA DB E EA EB ø F VB VC FRD Note: CB: max. length with the biggest input flange AB, BD, C, P: according to specific motor manufacturer dimensions Output shaft R U ø h6 V VA KEY TAP AU / 16 x 3 / 16 x 1 1 / 16 1 / 4-20 x 0.63 Standard imperial AU x 6 x 30 M6 x 16 Standard metric AU x 7 x 40 M6 x 16 Gearbox shaft input AJ' AK' ø g6 BF CA RD12 RD13 RD12 RD13 DC R' U' ø h6 V' VA' VD KEY' TAP' RD x 5 x 25 M6 x 12 Dimensions are inch / mm

31 RD12 & RD13 Flange Mounting Helical Gearboxes RD Dimensions FRD B3 / B5 Output shaft AU see opposite page OUTPUT FLANGES Built-in flange Bolted flange DFU Gear-case A AC B BA BB BC CB D DA DB E EA EB ø F VB VC FRD Note: CB: max. length with the biggest input flange AB, BD, C, P: according to specific motor manufacturer dimensions Output flange AJ AK AW BD H thread / bore Built-in flange g M6 x 14 (7x) Gearbox housing with built-in flange DFU h ø 0.28 (4x) ø 7 (4x) DFU h ø 0.35 (4x) ø 9 (4x) Bolted flange DFU h ø 0.35 (4x) ø 9 (4x) Dimensions are inch / mm

32 Dimensions RD22 & RD23 Foot mounting FRD B3 Output shaft AU RD B3 Gearbox flange input A AC B BA BB BC CB D DA DB E EA EB ø F VB VC FRD Note: CB: max. length with the biggest input flange AB, BD, C, P: according to specific motor manufacturer dimensions Output shaft R U ø h6 V VA KEY TAP AU / 4 x 1 / 4 x 1 5 / 16 3 / 8-16 x 0.87 Standard imperial AU 25 AU x 7 x 35 8 x 7 x 40 M10 x 22 M10 x 22 Standard metric Gearbox shaft input AJ' AK' ø g6 BF RD22 RD23 CA RD22 RD23 DC R' U' ø h6 V' VA' VD KEY' TAP' RD x 5 x 30 M8 x 10 Dimensions are inch / mm

33 RD22 & RD23 Flange mounting Helical Gearboxes RD Dimensions FRD B3 / B5 Output shaft AU see opposite page OUTPUT FLANGES Built-in flange Bolted flange DFU Gear-case A AC B BA BB BC CB D DA DB E EA EB ø F VB VC FRD Note: CB: max. length with the biggest input flange AB, BD, C, P: according to specific motor manufacturer dimensions Output flange AJ AK AW BD H thread / bore Built-in flange g M6 x 10 (8x) Gearbox housing with built-in flange DFU h ø 0.35 (4x) ø 9 (4x) DFU h ø 0.35 (4x) ø 9 (4x) Bolted flange DFU h ø 0.43 (4x) ø 11 (4x) Dimensions are inch / mm

34 Dimensions RD32 & RD33 Foot mounting FRD B3 Output shaft AU RD B3 Gearbox flange input A AC B BA BB BC CB D DA DB E EA EB ø F VB VC FRD Note: CB: max. length with the biggest input flange AB, BD, C, P: according to specific motor manufacturer dimensions Output shaft R U ø h6 V VA KEY TAP AU / 4 x 1 / 4 x 1 1 / 16 1 / 2-13 x 1.12 Standard imperial AU 30 AU x 7 x x 8 x 50 M10 x 22 M10 x 22 Standard metric Gearbox shaft input AJ' AK' ø g6 BF RD32 RD33 CA RD32 RD33 DC R' U' ø h6 V' VA' VD KEY' TAP' RD x 7 x 40 M8 x 15 Dimensions are inch / mm

35 RD32 & RD33 Flange mounting Helical Gearboxes RD Dimensions FRD B3 / B5 Output shaft AU see opposite page OUTPUT FLANGES Built-in flange Bolted flange DFU Gear-case A AC B BA BB BC CB D DA DB E EA EB ø F VB VC FRD Note: CB: max. length with the biggest input flange AB, BD, C, P: according to specific motor manufacturer dimensions Output flange AJ AK AW BD H thread / bore Built-in flange g M8 x 18 (8x) Gearbox housing with built-in flange DFU h ø 0.35 (4x) ø 9 (4x) DFU h ø 0.43 (4x) ø 11 (4x) Bolted flange DFU h ø 0.51 (4x) ø 13 (4x) Dimensions are inch / mm

36 Dimensions RD42 & RD43 Foot mounting FRD B3 Output shaft AU RD B3 Gearbox flange input A AC B BA BB BC CB D DA DB E EA EB ø F VB VC FRD Note: CB: max. length with the biggest input flange AB, BD, C, P: according to specific motor manufacturer dimensions Output shaft R U ø h6 V VA KEY TAP AU / 16 x 5 / 16 x 1 13 / 16 1 / 2-13 x 1.12 Standard imperial AU 35 AU x 8 x x 8 x 60 M12 x 28 M12 x 28 Standard metric Gearbox shaft input AJ' AK' ø g6 BF RD42 RD43 CA RD42 RD43 DC R' U' ø h6 V' VA' VD KEY' TAP' RD x 7 x 50 M8 x 16 Dimensions are inch / mm

37 RD42 & RD43 Flange mounting Helical Gearboxes RD Dimensions FRD B3 / B5 Output shaft AU see opposite page OUTPUT FLANGES Built-in flange Bolted flange DFU Gear-case A AC B BA BB BC CB D DA DB E EA EB ø F VB VC FRD Note: CB: max. length with the biggest input flange AB, BD, C, P: according to specific motor manufacturer dimensions Output flange AJ AK AW BD H thread / bore Built-in flange g M8 x 18 (8x) Gearbox housing with built-in flange DFU h ø 0.43 (4x) ø 11 (4x) DFU h ø 0.53 (4x) ø 13.5 (4x) Bolted flange DFU h ø 0.66 (4x) ø 17 (4x) Dimensions are inch / mm

38 Dimensions RD52 & RD53 Foot mounting FRD B3 Output shaft AU RD B3 Gearbox flange input A AC B BA BB BC CB D DA DB E EA EB ø F VB VC FRD Note: CB: max. length with the biggest input flange AB, BD, C, P: according to specific motor manufacturer dimensions Output shaft R U ø h6 V VA KEY TAP AU AU ⅜ x ⅜ x 2 ¼ ½ x ½ x 2 ⅝ ⅝ - 11 x 1.38 ¾ - 10 x 1.61 Standard imperial AU x 8 x 60 M12 x 28 Standard metric AU x 9 x 90 M16 x 36 Gearbox shaft input AJ' AK' ø g6 BF CA RD52 RD53 DC R' U' ø h6 V' VA' VD KEY' TAP' RD x 8 x 60 M12 x 28 Dimensions are inch / mm

39 RD52 & RD53 Flange mounting Helical Gearboxes RD Dimensions FRD B3 / B5 Output shaft AU see opposite page OUTPUT FLANGES Built-in flange Bolted flange DFU Gear-case A AC B BA BB BC CB D DA DB E EA EB ø F VB VC FRD Note: CB: max. length with the biggest input flange AB, BD, C, P: according to specific motor manufacturer dimensions Output flange AJ AK AW BD H thread / bore Built-in flange M10 x 25 (8x) Gearbox housing with built-in flange DFU ø 0.53 (4x) ø 13.5 (4x) DFU ø 0.69 (4x) ø 17.5 (4x) Bolted flange DFU ø 0.69 (4x) ø 17.5 (4x) Dimensions are inch / mm

40 Dimensions RD62 & RD63 Foot mounting FRD B3 Output shaft AU RD B3 Gearbox flange input A AC B BA BB BC CB D DA DB E EA EB ø F VB VC FRD Note: CB: max. length with the biggest input flange AB, BD, C, P: according to specific motor manufacturer dimensions Output shaft R U ø h6 V VA KEY TAP AU AU ½ x ½ x 2 ⅝ ⅝ x ⅝ x 3 ⅝ ¾ - 10 x 1.61 Standard imperial AU 50 AU x 9 x x 11 x 110 M16 x 38 M20 x 42 Standard metric Gearbox shaft input AJ' AK' ø g6 BF CA RD62 CA RD63 DC R' U' ø h6 V' VA' VD KEY' TAP' RD x 9 x 80 M16 x 36 Dimensions are inch / mm

41 RD62 & RD63 Flange mounting Helical Gearboxes RD Dimensions FRD B3 / B5 Output shaft AU see opposite page OUTPUT FLANGES Built-in flange Bolted flange DFU Gear-case A AC B BA BB BC CB D DA DB E EA EB ø F VB VC FRD Note: CB: max. length with the biggest input flange AB, BD, C, P: according to specific motor manufacturer dimensions Output flange AJ AK AW BD H thread / bore Built-in flange M10 x 25 (8x) Gearbox housing with built-in flange DFU ø 0.53 (4x) ø 13.5 (4x) DFU ø 0.69 (4x) ø 17.5 (4x) Bolted flange DFU ø 0.69 (4x) ø 17.5 (4x) Dimensions are inch / mm

42 Conversion factors - Operation and Maintenance Instructions Imperial CONVERSIONS Metric 1 lb = 4.45 N 1 lb = kg 1 oz = kg HP (60Hz) = kw (50Hz) HP (50 Hz) = kw (50 Hz) HP = in-lb RPM : (63025 x eff.) 1 in-lb = Nm 1 ft-lb = Nm ft-lb = 108 k HP eff. ratio in-lb = 9 k HP eff. ratio = 8000 k HP eff. o/p speed (where k = motor pole #, i.e. 2, 4, 6, 8) Mass & Force 1 N = lb 1 kg = lb 1 kg = oz Power kw (50 Hz) = HP (60 Hz) kw (50 Hz) = HP (50 Hz) kw = Nm RPM : (9550 eff.) Torque 1 Nm = in-lb 1 Nm = ft-lb Nm = 9550 kw eff. : RPM 1 qt (US) = litre Volume 1 litre = qt (US) Abstract of Operation and Maintenance Instructions (download the complete manual from Variators and reduction gearboxes are not part of application field of article1(2) Machinery Directive and they must not be put into service until the machinery into which they are to be incorporated, has been declared in conformity with the provision of article 4(2), annex II(B) of Machinery Directive 2006/42/EC. Installation Check the unit to be installed is properly selected to perform the required function and its mounting position complies with the order. The nameplate reports such information. Check mounting stability to ensure the unit runs without vibrations or overloads. Running The unit may be connected for clockwise or counterclockwise rotation. The unit must be stopped as soon as defective running or unexpected noise occur, remove the faulty part or return the unit to the factory for inspection. If the faulty part is not replaced, other parts can also be affected, causing more severe damage and making the identification of initial cause more difficult. Maintenance Although the units are no-load run tested in the factory before despatch, it is recommended not to run them at maximum load for the first operation hours to allow the proper running in. The gearboxes are delivered already filled with long-life synthetic oil and, in case of replacement or topping, do not mix with mineral lubricants. Handling When hoisting, use relevant housing locations or eyebolts if provided, or foot or flange holes. Never hoist on any moving part. Painting Carefully protect oil seals, coupling faces and shafts when units are re-painted. Long-term storage For storage longer than three months, apply antioxidants onto shafts and machined surfaces, and protective grease on oil seal lips. Product s Environmental Management In conformity with ISO 14001Environmental Certification, we recommend the following to dispose of our products: - scraped components of the units to be delivered to authorized centres for metal object collection; - oils and lubricants drained from the units to be delivered to Exhausted Oil Unions; - packages (pallets, carton boxes, paper, plastic, etc.) to lead into regeneration/recycling circuits as far as possible, by delivering separate waste classes to authorized companies. Directive 94/9/EC - ATEX Directive involves either electrical machines and every apparatus and control devices to be used in potentially explosive atmosphere, to be installed within the European Community Territory. VARVEL products specially asked for ATEX are manufactured according to Directive 1994/9/EC and they are qualified for installation in potentially explosive environment. C-RD Ed rev00 INCH-NA

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