The Strong Silent Type

Transcription

1 The Strong Silent Type Shaft Mount Speed Reducers

2 SMR-15 Vortex Shaft Mount Reducers Engineering Guide VORTEX 2

3 Shaft Mount Speed Reducers What do you want to do? Understand an Engineering Term Go to Page 7 Select a Reducer Go to Page 9 Order a Part Go to Page 61 Check Dimensions Go to Page 62 Select a Lubricant Go to Page 81 Install a Reducer Go to Page 89 Copyright 2015, Baart Industrial Group. All rights reserved. The contents of this guide are subject to change without notice or obligation. Baart Industrial Group (Baart) has tried to ensure that the information contained in this guide is accurate. Baart makes no warranty or guarantee concerning the accuracy or reliability of the content. Assessing accuracy and reliability of information is the responsibility of the user. Baart shall not be liable for errors contained herein or for any damages in connection with the use of the information contained herein. 1

4 Table of Contents Features Vortex VXT XD Series 4-5 Safety Warnings 6 Unit Identification Nameplate 6 Vortex Versus AGMA Unit Sizes 6 Engineering Terms and Formulas Rotary Motion, Torque and Power 7 Input Speed, Output Speed, and Ratios 7 Efficiency 7 Reducer Ratings and Factors Mechanical Horsepower Ratings 8. Thermal Horsepower Ratings 8. Mechanical and Thermal Service Factors 8 Equivalent Horsepower Ratings [HPEM] [HPET] 8 Design Considerations Overview 9. Life Design Service Life 9 Design Safety Factor 9 Drive Power Prime Mover 9 Oversized Prime Movers 9 Start Up Torque 9 Variable Speed Motor Use 9 Internal Combustion Engine Use 9 Environment Extreme Ambient Temperatures 10 Direct Sunlight 10 Humidity 10 High Altitude 10 Industry Food and Drug Industry 10 People-Conveying Equipment 10 Motion Rotation 11 Reversibility 11 Reversing Service 11 Maximum Speeds 11 Restricting Motion Brake-Equipped Applications 11 Backstops 11 Loads Momentary Overloads 12 Shock Loads 12 High Inertia Loads 12 Overhung Loads 12 Thrust Loads 12 Miscellaneous Exact Ratios 13 Minimum Sheave Diameters 13 Connection Efficiencies 13 Selection Methods Choosing a Method 15 Quick-Selection Method Overview 16 How to Select 16 Example Selection 17 AGMA Application Class Numbers (Table) 18 Reducer Selection for Application Class I 25 Reducer Selection for Application Class II 26 Reducer Selection for Application Class III 27 Horsepower Selection Method Overview 28 How to Select 28 Example Selection 29 Determining Actual Horsepower 31 Torque Selection Method Overview 32 How to Select 32 Example Selection 33 AGMA Mechanical Service Factors Common Application Service Factor Tables 35 Load Classification for Unlisted Applications 42 Internal Combustion Engine Factors 43 Mechanical and Thermal Capacities Capacities by Reducer at Various Output Speeds 44 Equivalent Thermal Horsepower Calculation [HP ET ] Overview 48 Equivalent Thermal Horsepower [HP ET ] Formula 48 Example Calculation 48 Overhung Load Input Shaft 51 Calculating Overhung Load 51 Example Calculation 51 Overhung Load Capacity 54 Output Shaft 55 Calculating Overhung Load 55 Example Calculation 55 Overhung Load Capacity 57 Thrust Load Overview 58 Input Shaft 58 Hollow Shaft 58 Calculating Thrust Loads 58 Shaft and Key Tolerances Input Shaft Tolerances 59 Driven Shaft Tolerances 59 2

5 Metallurgy Reducer Material Specifications 60 Reducer Parts Illustration and Table 61 Dimensions Size VXT2 XD Dimensions 62 Bushings 62 Accessories 63 Size VXT3 XD Dimensions 64. Bushings 64 Accessories 65 Size VXT4 XD Dimensions 66 Bushings 66 Accessories 67 Size VXT5 XD Dimensions 68 Bushings 68 Accessories 69 Size VXT6 XD Dimensions 70 Bushings 70 Accessories 71 Size VXT7 XD Dimensions 72 Bushings 72 Accessories 73 Size VXT8 XD Dimensions 74 Bushings 74 Accessories 75 Size VXT9 XD Dimensions 76 Bushings 76 Accessories 77 Lubrication Lubrication Basics 78 Viscosity Basics 79 Lubrication Selection 81 Recommended Lubricants 82 Lubrication Maintenance 84 Lubricant Fill Volumes 85 Installation Housing Plug Installation 86 Reducer Installation 89 Overview 89 Installation Instructions 89 Removing the Reducer From the Shaft 91 Accessory Installation Backstop Installation 92 Installation Instructions 92 Removal Instructions 93 Cooling Fan Installation 94 Installation Instructions 94 Assembly Dimensions 95 Motor Mount Installation 96 2MMA 7MMA Installation 96 8MMA 9MMA Installation 97 Screw Conveyor Adapter Installation 98 Installation Instructions 98 Adapter Removal 99 Disassembly, Inspection, and Reassembly Reducer Disassembly 100 Disassembly Instructions 100 Component Inspection 101 Oil Seal and Contact Surface Inspection 101 Bearing Inspection 101 Gear and Pinion Inspection 103 Other Components 103 Reducer Reassembly 105 Ordering Parts 105 Reassembly Instructions 105 Long-Term Storage Storage Preparation 109 Returning to Service 109 Interchanges Vortex Ratio 15:1 Interchanges 110 Vortex Ratio 25:1 Interchanges 110 Selection Checklist Checklist Form 111 Page for Additional Notes 112 3

6 4 The Strong Silent Type

7 At Vortex, we build reducers that are strong enough to handle the toughest applications. Our reducers are designed for rugged reliability and smooth running performance. Check out the features that make us better than the competition. When we say Vortex is "The Strong Silent Type", we mean it. Accessories Available accessories include: Twin Tapered Bushing Kit Backstop Assembly Heavy-Duty Motor Mount Screw Conveyor Adapter Kit Torque Arm (included) Ground Gearing Highly efficient helical gears are made from high-grade, case-hardened steel. They are ground, not shaved. The smoother finish transmits more horsepower, runs more quietly, and extends gear life. Pressure Tested Pressure testing identifies leaks assuring that only leak-free units ever leave the factory. Rigid Housing Heavy-duty cast-iron housings withstand the effects of vibration and shock. They feature a corrosion-resistant finish. Premium Quality Bearings Precision bearings run in shouldered housings, allowing perfect gear alignment for smooth operation. Seals Metal-reinforced, spring-loaded, double-lip oil seals ride on shafts with ground seal seats minimizing oil leakage and providing longer seal life. Twin Tapered Bushings Twin tapered bushings allow for easy mounting and removal. This bushing system provides tight and even gripping at both ends of the reducer. Shafts All shafts are one-piece, heat-treated, high-strength alloy steel. The bearing seats are centerless ground for ideal shaft fits and longer bearing life. 5

8 Part # VXT325 Batch # Ratio 25 : 1 Safety Warnings Always install and operate Vortex reducers following our installation and maintenance instructions. Vortex shaft mount reducers are shipped without oil. It is extremely important to add the proper amount of lubricant prior to operating the reducer. Always comply with applicable local and national safety codes for guarding rotating components. Reinstall all safety guards, if removed for maintenance or repair. Before installation, lubrication, or servicing, be sure the starting switch of the equipment is locked out and all external loads have been removed. Vortex speed reducers can normally operate with housing and lubricant temperatures reaching 200 F (93 C). Hot machinery, bearings, and lubricant can cause severe burns. Use extreme caution when servicing. Vortex and its distributors are not responsible for any injury or damage sustained due to improper installation or operation of Vortex reducers. Unit Identification Nameplate When ordering replacement parts or requesting support, please supply the following information from the nameplate: Part number Batch number Illustration A Nameplate Information and Location Part # VXT325 XD Batch # Ratio 25 : 1 Table 1 Vortex vs. AGMA Unit Sizes Vortex AGMA Unit Size Unit Size Nominal Ratio Manufacturing Batch Number V X T X D Product Type Unit Size Nominal Ratio Extreme Duty 6

9 Engineering Terms and Formulas Rotary motion, torque, and power Rotary motion is rotation around a fixed axis. The speed of rotation is measured in revolutions per minute [rpm]. Torque is a force with the capacity to produce rotary motion. Torque is sometimes called a twisting force. Torque causes the rotation of a shaft, or transmits a twisting force to a stationary shaft. Torque is measured in inch-pounds [in-lbs] or foot-pounds [ft-lbs]. In the metric system torque is commonly expressed in Newton-meters [N-m]. Power is the rate of doing work. Power is measured in units called horsepower [hp]. In the metric system power is measured in watts [W]. Mechanical horsepower is used to quantify the output power of motors. This engineering guide uses the terms horsepower and power interchangeably. The relationship between rotational speed, torque, and power is illustrated by the following three formulas: Power [hp] # 63, 025 Rotational speed[rpm] = Torque [in lb] Power [ hp] # 63, 025 Torque [ in lb] = Rotational speed [ rpm] Torque [ in lb] # Rotational speed [ rpm] Power [ hp] = 63, 025 Input speed, output speed, and ratio A reducer s input speed is the speed at which the input shaft rotates. The output speed is the rotational speed of the reducer s output shaft. Both input and output speeds are measured in revolutions per minute [rpm]. The ratio [Ratio] is determined by dividing the input speed by the output speed. The relationship between a reducer s input speed, output speed, and ratio is illustrated by the following three formulas: Input speed [ rpm] Output speed [ rpm] = Ratio Input speed [ rpm] = Output speed [ rpm] # Ratio Input speed [ rpm] Ratio = Output speed [ rpm] Efficiency A speed reducer s efficiency is the percentage [%] of input power that is transmitted as output power. The efficiency of a reducer is dependent on the input speed, type of lubricant, ambient temperature, number of gear meshes, and many other variables. The efficiency a of new reducer will increase after an initial operation period because the gearing undergoes a natural run-in process. The efficiency of a shaft mount reducer is typically 98.5% per gear stage. Therefore, the efficiency of a 2-stage unit is 97%. 25:1 and 15:1 units are 2 stage units. The relationship between a reducer s efficiency, power, and torque is illustrated by the three formulas below: Efficiency [%] = Output power [ hp] Input power [ hp] x 100 Efficiency [%] Output power [ hp] = Input power [ hp] # Efficiency [%] 100 Efficiency [%] Output torque [ in lb] = Input torque [ in lb] # Ratio # Efficiency [%] 100 7

10 Reducer Ratings and Factors Mechanical horsepower rating A reducer s mechanical rating is the maximum torque or horsepower it is capable of transmitting (based on the strength of its components). All Vortex shaft mount reducers can withstand momentary loads of up to 200% of their mechanical rating (100% overload), assuming working conditions that equate to a 1.00 service factor (pages 35-41). Thermal horsepower rating The thermal horsepower rating quantifies the reducer s ability to dissipate heat in a defined environment. If the reducer's input horsepower exceeds the thermal horsepower rating, the lubricant may overheat, resulting in failure. The lubricant temperature of the reducer should not exceed 200 F (93.3 C). Seals, shims and gaskets may be damaged by higher temperatures. Factors that can decrease a thermal rating include: An enclosed space Lack of air flow Dust or other materials providing thermal insulation High ambient temperatures High altitudes Direct sunlight Factors that can increase a thermal rating include: A heat sink Low ambient temperatures A continuous air flow Intermittent or variable load conditions Mechanical and thermal service factors A service factor is a multiplier used to determine the overload capacity at which the reducer can operate without damage. More demanding applications require a higher service factor while for less demanding applications, a lower factor will suffice. Variables such as different types of motors or engines, hours of use, and any shock or vibration present in the application are considered when formulating a mechanical service factor. Thermal service factors consider conditions such as enclosed spaces, extreme ambient temperatures, or high altitudes. See Table 12 (pages 35-41) for a list common applications and service factors. When choosing a service factor, it is recommended that you use the application closest to yours or see page 42 for information on unlisted applications. The mechanical and thermal service factors shown in this catalog have been developed from the experience of manufacturers and users for common applications. Equivalent horsepower ratings [HP EM ] [HP ET ] Before a speed reducer can be selected for any application, both mechanical and thermal equivalent horsepower ratings must be determined. This is done by multiplying the prime mover's nameplate horsepower by the service factor that is determined by the application and conditions. The selected reducer must have a load capacity at least equal to these equivalent horsepower ratings. 8

11 Design Considerations Overview Before using any method to select a reducer, the following design considerations should be reviewed. In many cases, adjustments to the selection or installation process, that arise from this review, can extend the life and capacity of your reducer. Life Design service life Assuming that a reducer is properly installed and maintained, ratings and selection methods are based upon a service life of 10,000 hours. Design safety factor Overdesigning a drive can have an exponential effect on the life of the reducer. If a service life of greater than 10,000 hours is required, a 20% safety factor in selection can double the life of the reducer. Drive Power Prime mover A prime mover is the device that provides power to a reducer. Typical prime movers include: AC and DC motors, internal combustion engines, and hydraulic motors. The type of prime mover used affects the speed reducer s operation. Uniform power sources such as electric motors, run more smoothly than internal combustion engines. Service factors are based on the use of a uniform power source. Oversized prime movers Applications requiring oversized prime movers, for high energy or high peak loads, are not covered by mechanical service factors. If you intend to install an oversized prime mover, consider the use of a fail safe. A mechanical or electrical shear pin can prevent damage to the reducer in the event of an equipment jam. Start up torque Synchronous motors and specific types of induction motors require special considerations. These motors can produce extremely high starting torque. Adjustments to reducer selection may be necessary based on the worst case starting requirements. The use of a soft start or clutching style device may be necessary to prevent damage to the reducer. Variable speed motor use When starting or stalling, variable speed motors are capable of delivering torque loads of three to five times their nameplate ratings. Because of this, careful consideration must be given to the system design and reducer selection process. Shear pins, clutching devices and service factor adjustments may be necessary to ensure the service life of the reducer. Internal combustion engine use Vortex reducers driven by internal combustion engines require an adjustment to their service factor. See page 43 for more information on this adjustment. 9

12 Design Considerations Environment Extreme ambient temperatures If a reducer is expected to run in ambient temperatures above 125ºF, it increases the risk of overheating. Monitor the reducer and, if necessary, use special provisions to keep the case and oil temperature below 200ºF. Fans, cooling tubes, or heat exchangers may be necessary to ensure the service life of the reducer. When a reducer is expected to run in ambient temperatures below -30ºF, it increases the risk of fracturing. Extremely cold conditions can cause the reducer housing to become brittle. Steps should be taken to keep the reducer above -30ºF. The use of an oil sump heater may help. Direct sunlight If a reducer operates in direct sunlight at ambient temperatures over 100 F (38 C), measures must be taken to protect the drive from overheating. This protection can consist of a shade over the reducer or reflective paint on the reducer. If neither of these options are possible, additional cooling may be required. Fans, cooling tubes, or heat exchangers may be necessary. The lubricant temperature should not exceed 200 F (93.3 C). Humidity Humid environments can cause condensation to collect in the reducer housing. This moisture will contaminate the lubricant. Inspect the lubricant often and change the oil per the conditions listed on page 84. High Altitude At high altitudes (above 3,000 feet) the ability of a reducer to dissipate heat is affected. The horsepower selection method (page 28) and the torque selection method (page 32) apply factors to account for use at various altitudes. The quick selection method (page 16) does not mathematically check thermal capacities so it is recommended that you monitor your reducer for signs of overheating. Industry Food and drug industry Vortex lubrication recommendations exclude applications where lubricant may contact processed goods. The customer shall assume responsibility for the selection of a lubricant that conforms to FDA federal regulations. People-conveying equipment People-conveying applications are not approved. The selection, installation, or retrofitting of any Vortex shaft mount reducer on equipment for transporting people is not recommended. This includes all freight and passenger elevators, escalators, moving walkways (horizontal escalators), ski lifts, ski tows, or man-lift platforms of any type. 10

13 Motion Rotation With Vortex shaft mount reducers, the input shaft rotation can be either clockwise or counter-clockwise. Reversibility All Vortex shaft mount reducers are reversible. When torque is applied to the reducer s output shaft the input shaft will rotate. This feature allows for the reducer to function in applications where backdriving is desired. However, If the application requires irreversibility, a suitable brake or backstop should be used. Reversing service Applications involving more than twenty reversals per ten hour period, or reversals with peak torques greater than 200% of normal load, will decrease the service life of the reducer. Maximum speeds The maximum recommended input and output speeds for Vortex reducers are found in Table 2 (right). Restricting Motion Brake-equipped applications There are two types of brake-equipped applications: A Working brake application uses a brake to slow the motion of the system. A Holding brake application uses a brake to hold the system in place after it has stopped. Table 2 Maximum Input and Output Speeds Unit Nominal Maximum Maximum Size Ratio Input RPM Output RPM VXT215 XD 15 1, VXT225 XD 25 1, VXT315 XD 15 2, VXT325 XD 25 2, VXT415 XD 15 2, VXT425 XD 25 2, VXT515 XD 15 1, VXT525 XD 25 2, VXT615 XD 15 1, VXT625 XD 25 2, VXT715 XD 15 1, VXT725 XD 25 1, VXT815 XD 15 1, VXT825 XD 25 1, VXT915 XD 15 1, VXT925 XD 25 1, Using a brake in your drive design may affect the selection of your reducer. If the brake torque rating is higher than the reducer torque capacity, damage may occur. To compare capacities, first convert the equivalent horsepower of the application to equivalent torque using the formula found on page 32. Next, determine the brake torque rating (provided by the manufacturer). Finally, select a speed reducer size based on the higher of the two torque values. Ideally, a brake (working or holding) is installed between the prime mover and the reducer. When a holding brake is thus installed, the brake rating must not exceed 200% of the reducer mechanical horsepower rating. Any application where a brake is installed on the output side of the reducer should be checked to ensure that the torque capacity of the output shaft is not exceeded. When the brake is applied, measures must be taken to decrease the drive power being transmitted to the reducer. Backstops Backstops prevent the backdriving of a reducer. Backstops are a standard accessory for horizontally mounted reducers. See Illustration I (page 85). When using a backstop for your application, do not use oils that contain EP additives as they can decrease or eliminate the cam/sprag action of the device. Do not use backstops on vertically mounted reducers. DO NOT use a backstop as a substitute for a holding brake. Backstops should be engaged fewer than 6 times per 8 hours. There should be at least 1 minute between each engagement. If backstopping operations are more frequent, or the time between operations is less than one minute, the backstop could fail. In such applications, Vortex recommends the use of a brake. 11

14 Design Considerations Loads Momentary overloads Vortex shaft mount reducers are designed to withstand momentary loads of up to 200% capacity (100% overload). Momentary overloads are loads applied to the reducer for a maximum of two seconds. The total number of momentary overloads is generally limited to 10,000 instances over the life of the reducer. Shock loads Since the reducer ratings apply to applications involving uniform loads, the magnitude of any recurrent shock loads should be estimated or determined by the system designer. Recurrent shock loads can be of such a short duration that they may not be reflected in motor amperage readings. In these cases actual loads are usually determined by strain gauging the driven shaft. The customer is responsible for isolating the reducer from any vibratory or transient load induced by the driven equipment. High inertia loads Starting or stopping a high inertia load can cause extreme stress on a reducer. Including a flywheel in the system design or increasing the reducer service factor may ensure the service life of the reducer. Overhung loads An overhung load is a radial force transmitted to a shaft beyond the bearing. Components mounted on the shaft exert this force. This force is shaft bending. The reducer s bearings must be able to support this load without damage. See Illustration B (below). Thrust loads A thrust load is an axial force transmitted in-line with the shaft. This force often occurs in screw conveyor applications, as well as those involving mixers, fans, and blowers. The reducer must be able to support this load without damage. See Illustration B (below). Illustration B Loads and Forces Exerted on a Reducer's input shaft Table 3 Reduction Ratios Unit Size Nominal Ratio Exact Ratio Thrust loads exert axial force Overhung loads exert radial loads Input VXT215 XD VXT225 XD VXT315 XD VXT325 XD VXT415 XD VXT425 XD VXT515 XD VXT525 XD VXT615 XD VXT625 XD VXT715 XD VXT725 XD VXT815 XD VXT825 XD VXT915 XD VXT925 XD

15 Miscellaneous Exact ratios The exact ratios of Vortex shaft mounted speed reducers are found in Table 3 (page 12). Minimum sheave diameters The minimum sheave diameters for NEMA motors and Vortex reducers are found in Tables 4 and 5 (below) Connection efficiency The efficiency of the connection between the prime mover and reducer is important when calculating the overall efficiency of a system. Connection efficiencies are also used in thermal capacity calculations. See Table 5b (below) for types of connections and their efficiencies. Table 4 Minimum Sheave Diameters For NEMA T-Frame 1750 RPM AC Motors Motor NEMA Output Minimum Horsepower Frame Shaft Sheave Size Diameter Diameter (inches) (inches) 1 143T 7/ /2 145T 7/ T 7/ T 1-1/ T 1-1/ /2 213T 1-3/ T 1-3/ T 1-5/ T 1-5/ T 1-7/ T 1-7/ T 2-1/ T 2-1/ T 2-3/ T 2-3/ T 2-7/ T 3-3/ T 3-3/ T 3-3/ Table 5 Minimum Sheave Diameters For Vortex Shaft Mount Reducers Input Minimum Unit Shaft Sheave Size Diameter Diameter (inches) (inches) VXT215 XD 1-1/8 3.0 VXT225 XD 1-1/8 3.0 VXT315 XD 1-1/4 4.0 VXT325 XD 1-1/4 4.0 VXT415 XD 1-7/ VXT425 XD 1-7/ VXT515 XD 1-15/ VXT525 XD 1-15/ VXT615 XD 2-3/ VXT625 XD 2-3/ VXT715 XD 2-7/ VXT725 XD 2-7/ VXT815 XD 2-7/ VXT825 XD 2-7/ VXT915 XD 2-7/ VXT925 XD 2-7/ Table 5b Connection Efficiency Type of Connection Efficiency Direct Coupled 100% Synchronous (Timing) Belt 98% Flat Belt 98% Single or Multiple V-Belt 94% Roller Chain 92% 13

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17 Selection Methods Choosing a method Before selecting a reducer, determine which method is appropriate for your situation. The three methods are: The Quick Selection Method (page 16) The Horsepower Selection Method (page 28) The Torque Selection Method (page 32) The Quick Selection Method is for use with 1750 rpm AC motors up to 150 horsepower. This is the easiest selection method and will ensure that your chosen reducer has adequate capacity. This method uses AGMA application classes, you may not require the capacity of the reducer selected by this method. In order to make a more economical choice you may wish to use another selection method. The Horsepower Selection Method chooses a reducer based on the actual horsepower used by the application. This method is typically used for replacing an existing drive system with a more economical one. Unlike the quick selection method, this method uses AGMA service factors, thermal adjustments, and mathematical equivalents for a more accurate selection. The Torque Selection Method is the most economical reducer selection method. However, this method assumes that you know the output torque required for your application. Like the horsepower selection method, this method uses AGMA service factors, thermal adjustments, and mathematical equivalents for accurate selection. Quick Selection Method Go to Page 16 Horsepower Selection Method Go to Page 28 Torque Selection Method Go to Page 32 15

18 Quick Selection Method Overview Use the Quick Selection Method for applications using 1750 rpm AC motors with ratings up to 150 horsepower. In high altitude applications (above 3,000 feet), reducers and electric motors have an increased risk of overheating. Monitor your reducer for signs of overheating, and take corrective action if required. For any applications involving extreme shock, high-energy loads, or loads which can stall the prime mover, please contact Vortex engineering. How to select Step 1. Determine the Application Class See Table 6 (pages 18 24). Find the type of application and duty cycle that most nearly matches your requirements or see page 42 for information on unlisted applications. Step 2. Step 3. Step 4. Step 5. Determine the Horsepower of the Prime Mover. Determine the Output Speed of the Reducer. Select the Reducer Size and Ratio See Tables 7 to 9 (pages 25 27). The information in these tables is sorted by application class. Locate the table for the Application Class determined in Step 1. Next, select the reducer size and ratio based on the reducer's output speed and input horsepower. In some applications a cooling fan is recommended. When this is not possible, move up one Application Class number to make the selection. If more than one reducer is listed, the most economical ratio is generally listed first. Determine Sheave Ratio Use the formula below to determine the ratio of the driver and driven sheaves. When purchasing sheaves to attain this ratio, be sure that the driven sheave (mounted on the reducer's input shaft) exceeds the minimum pitch diameter listed in Table 5 (page 13). Mount the sheave as close to the reducer as practical. See Table 3 (page 12) for a list of reducer reduction ratios. Sheave ratio = Speed of prime mover [rpm] Reducer output speed [rpm] x Reducer reduction ratio Note the sheave ratio and input horsepower. Refer to a belt drive manufacturer catalog for the selection of sheaves and belts. See Table 5 (page 13) to ensure that your driven sheave selection exceeds the listed pitch diameter. Step 6. Step 7. Step 8. Determine Required Bushings All Vortex shaft mount reducers require bushings. Match the bushing bore size with the driven shaft diameter. Refer to reducer dimensions and data (pages 62 77) for available bushing options. Make sure both the driven shaft and key have adequate load and torque capacities. Check Dimensions See pages for reducer dimensions, weights and part numbers. See Illustration I (page 85) for standard reducer mounting positions. Select Accessories A torque arm assembly is furnished with every Vortex reducer. Optional accessories such as backstops, cooling fans, and motor mounts are ordered separately. 16

19 Selection Example Application A uniformly loaded belt conveyor carrying sand. Operating 16 hours per day, the headshaft has a diameter of 2-7/16 and rotates at 70 rpm. The conveyor needs to be prevented from moving backwards. Selection Step 1. Determine the Application Class In Table 6 (page 18) locate Conveyors General Purpose Uniformly Loaded or Fed for over 10 hours per day. This is a Class II application. Step 2. Step 3. Step 4. Step 5. Determine the Horsepower of the Prime Mover 10 hp 1,750 rpm AC motor. Determine the Output Speed of the Reducer The desired output speed of the reducer is 70 rpm. It is to be mounted directly on the headshaft. Select the Reducer Size and Ratio From Table 8 (page 26) Selection Guide By Input Horsepower For AGMA Application Class II Loads, find the horsepower column and locate 10 hp. Then, find the output RPM column and locate 70 RPM. Two reducer sizes are listed, but the most economical reducer is listed first. A Vortex VXT425 XD is the correct selection. Determine Sheave Ratio Complete the formula to determine the sheave ratio that is required to obtain your desired output speed. See the formula below. From Table 3 (page 12) we see that a VXT 425 XD is a 25:1 reduction ratio. Speed of prime mover [rpm] 1750 Sheave Ratio = = = 1 Reducer output speed [rpm] x Reducer reduction ratio 70 x 25 Step 6. Step 7. Step 8. The formula tells us that our sheaves should be a 1:1 ratio. Note the sheave ratio and input horsepower. Refer to a belt drive manufacturer catalog for the selection of sheaves and belts. See Table 5 (page 13) to ensure that your driven sheave selection exceeds the listed pitch diameter. Determine Required Bushing Per the list of available bushings (page 66), 2-7/16 is the maximum bore available for a Vortex VXT425 XD size reducer, so it will work in this application. Be sure both the driven shaft and key have adequate load and torque capacity. Check appropriate references for your application. Check Dimensions Check the reducer dimensions on page 66. See Illustration I (page 85) for reducer mounting positions. Select Accessories 4BKS backstop to hold conveyor from moving backwards when shut down. 17

20 AGMA Application Class Numbers Table 6 Application Class Numbers for Reducers Driven by Motors or Turbines (Based on ANSI/AGMA 6013 A06, Standard for Industrial Enclosed [Helical] Gear Drives) Class numbers Application Up to 3 hrs 3 to 10 hrs Over 10 hrs per day per day per day Agitators (Mixers) Pure Liquids I I II Liquids and Solids I II II Liquids Variable Density I II II Blowers Centrifugal I I II Lobe I II II Vane I II II Brewing and Distilling Bottling Machinery I I II Brew Kettles Continuous Duty II II II Cookers Continuous Duty II II II Mash Tubs Continuous Duty II II II Scale Hopper Frequent Starts II II II Can Filling Machines I I II Car Dumpers II III III Car Pullers I II II Clarifiers I I II Classifiers I II II Clay Working Machinery Brick Press II III III Briquette Machine II III III Pug Mill I II II Compactors III III III Compressors Centrifugal I I II Lobe I II II Reciprocating, Multi Cylinder II II III Reciprocating, Single Cylinder III III III Conveyors General Purpose Includes: Apron, Assembly, Belt, Bucket, Chain, Flight, Oven and Screw Uniformly Loaded or Fed I I II Heavy Duty Not Uniformly Fed I II II Severe Duty Reciprocating or Shaker II III III Cranes 1 Dry Dock Main Hoist Use Another Selection Method Auxiliary Hoist Use Another Selection Method Boom Hoist Use Another Selection Method Slewing Drive Use Another Selection Method Traction Drive Use Another Selection Method Container Main Hoist Use Another Selection Method Boom Hoist Use Another Selection Method Trolley Drive Gantry Drive Use Another Selection Method Traction Drive Use Another Selection Method 18

21 Table 6 Application Class Numbers for Reducers Driven by Motors or Turbines (Based on ANSI/AGMA 6013 A06, Standard for Industrial Enclosed [Helical] Gear Drives) Class numbers Application Up to 3 hrs 3 to 10 hrs Over 10 hrs per day per day per day Cranes 1 (continued) Mill Duty Main Hoist Auxiliary Bridge Travel Trolley Travel Industrial Duty Main Auxiliary Bridge Travel Use Another Selection Method Use Another Selection Method Use Another Selection Method Use Another Selection Method Use Another Selection Method Use Another Selection Method Use Another Selection Method Trolley Travel Use Another Selection Method Crusher Stone or Ore III III III Dredges Cable Reels II II II Conveyors II II II Cutter Head Drives III III III Pumps III III III Screen Drives III III III Stackers II II II Winches II II II Elevators Bucket I II II Centrifugal Discharge I I II Escalators I I II Freight I II II Gravity Discharge I I II Extruders General II II II Plastics Variable Speed Drive III III III Fixed Speed Drive III III III Rubber Continuous Screw Operation III III III Intermittent Screw Operation III III III Fans Centrifugal I I II Cooling Towers III III III Forced Draft II II II Induced Draft II II II Industrial and Mine II II II Feeders Apron I II II Belt I II II Disc I I II Reciprocating II III III Screw I II II 19

22 AGMA Application Class Numbers 20 Table 6 Application Class Numbers for Reducers Driven by Motors or Turbines (Based on ANSI/AGMA 6013 A06, Standard for Industrial Enclosed [Helical] Gear Drives) Class numbers Application Up to 3 hrs 3 to 10 hrs Over 10 hrs per day per day per day Food Industry Cereal Cooker I I II Dough Mixer II II II Meat Grinders II II II Slicers I II II Generators and Exciters II II II Hammer Mills III III III Hoists Heavy Duty III III III Medium Duty II II II Skip Hoist II II II Laundry Tumblers II II II Laundry Washers II II III Lumber Industry Barkers Spindle Feed II II II Main Drive III III III Conveyors Burner II II II Main or Heavy Duty II II II Main Log III III III Re-Saw, Merry-Go-Round II II II Slab III III III Transfer II II II Chains Floor II II II Green II II III Cut-Off Saws Chain II II III Drag II II III Debarking Drums III III III Feeds Edger II II II Gang II III III Trimmer II II II Log Deck III III III Log Hauls Incline Well Type III III III Log Turning Devices III III III Planer Feed II II II Planer Tilting Hoists II II II Rolls Live Off Bearing Roll Cases III III III Sorting Table II II II Tipple Hoist II II II Transfers Chain II II III Causeway II II III Tray Drives II II II Veneer Lathe Drives II II II

23 Table 6 Application Class Numbers for Reducers Driven by Motors or Turbines (Based on ANSI/AGMA 6013 A06, Standard for Industrial Enclosed [Helical] Gear Drives) Class numbers Application Up to 3 hrs 3 to 10 hrs Over 10 hrs per day per day per day Metal Mills Draw Bench Carriage and Main Drive II II II Runout Table Non-Reversing Group Drives II II II Individual Drives III III III Reversing III III III Slab Pushers II II II Shears III III III Wire Drawing II II II Wire Winding Machine II II II Metal Strip Processing Machinery Bridles II II II Coilers and Uncoilers I I II Edge Trimmers I II II Flatteners II II II Loopers (Accumulators) I I I Pinch Rolls II II II Scrap Choppers II II II Shears III III III Slitters I II II Mills, Rotary Type Ball and Rod Spur Ring Gear III III III Helical Ring Gear II II II Direct Connected III III III Cement Kilns II II II Dryers & Coolers II II II Paper Mills 2 Agitator (Mixer) II II II Agitator for Pure Liquids II II II Barking Drums III III III Barkers Mechanical III III III Beater II II II Breaker Stack II II II Calendar 3 II II II Chipper III III III Chip Feeder II II II Coating Rolls II II II Conveyors Chip, Bark, and Chemical II II II Log (Including Slab) III III III Couch Rolls II II II Cutter III III III Cylinder Molds II II II Dryers 3 Paper Machine II II II Conveyor Type II II II 21

24 AGMA Application Class Numbers Table 6 Application Class Numbers for Reducers Driven by Motors or Turbines (Based on ANSI/AGMA 6013 A06, Standard for Industrial Enclosed [Helical] Gear Drives) Class numbers Application Up to 3 hrs 3 to 10 hrs Over 10 hrs per day per day per day Paper Mills 2 (continued) Embosser II II II Extruder II II II Fourdrinier Rolls (Includes Lump Breaker, Dandy Roll, Wire Turning, and Return Rolls) II II II Jordan II II II Kiln Drive II II II Mt. Hope Roll II II II Paper Rolls II II II Platter II II II Presses Felt and Suction II II II Pulper III III III Pumps Vacuum II II II Reel (Surface Type) II II II Screens Chip II II II Rotary II II II Vibrating III III III Size Press II II II Supercalendar 4 II II II Thickener (AC Motor) II II II Thickener (DC Motor) II II II Washer (AC Motor) II II II Washer (DC Motor) II II II Wind and Unwind Stand I I I Winders (Surface Type) II II II Yankee Dryers 3 II II II Plastics Industry Primary Processing Intensive Internal Mixers Batch Mixers III III III Continuous Mixers II II II Batch Drop Mill 2 Smooth Rolls II II II Continuous Feed, Holding and Blend Mill II II II Calendars II II II Plastics Industry Secondary Processing Blow Molders II II II Coating II II II Film II II II Pipe II II II Pre-Plasticizers II II II Rods II II II Sheet II II II Tubing II II II Pullers Barge Haul II II II Pumps Centrifugal I I II Proportioning II II II 22

25 Table 6 Application Class Numbers for Reducers Driven by Motors or Turbines (Based on ANSI/AGMA 6013 A06, Standard for Industrial Enclosed [Helical] Gear Drives) Class numbers Application Up to 3 hrs 3 to 10 hrs Over 10 hrs per day per day per day Pumps (continued) Reciprocating Single Acting, 3 or more cylinders II II II Double Acting, 2 or more cylinders II II II Rotary Gear Type I I II Lobe I I II Vane I I II Rubber Industry Intensive Internal Mixers Batch Mixers III III III Continuous Mixers II II II Mixing Mill 2 Smooth Rolls II II II 1 or 2 Corrugated Rolls III III III Batch Drop Mill 2 Smooth Rolls II II II Cracker Warmer 2 Rolls, 1 Corrugated Roll III III III Cracker 2 Corrugated Rolls III III III Holding, Feed & Blend Mill 2 Rolls II II II Refiner 2 Rolls II II II Calendars II II II Sand Miller II II II Sewage Disposal Equipment Bar Screens II II II Chemical Feeders II II II Dewatering Screens II II II Scum Breakers II II II Slow or Rapid Mixers II II II Sludge Collectors II II II Thickener II II II Vacuum Filters II II II Screens Air Washing I I II Rotary Stone or Gravel II II II Traveling Water Intake I I I Screw Conveyors Uniformly Loaded or Fed I I II Heavy Duty I II II Sugar Industry Beet Slicer III III III Cane Knives II II II Crushers II II II Mills (Low Speed End) III III III Textile Industry Batchers II II II Calendars II II II Cards II II II Dry Cans II II II 23

26 AGMA Application Class Numbers Table 6 Application Class Numbers for Reducers Driven by Motors or Turbines (Based on ANSI/AGMA 6013 A06, Standard for Industrial Enclosed [Helical] Gear Drives) Class numbers Application Up to 3 hrs 3 to 10 hrs Over 10 hrs per day per day per day Textile Industry (continued) Dyeing Machinery II II II Looms II II II Mangles II II II Nappers II II II Pads II II II Slashers II II II Soapers II II II Spinners II II II Tenter Frames II II II Washers II II II Winders II II II NOTES: 1 Because crane drive applications may require a service factor greater than 2.0, Class Numbers are not applicable. Use the horsepower selection method (page 28) or the torque selection method (page 32) for accurate reducer selection. 2 The class numbers listed in this table for paper mill applications are consistent with those shown in TAPPI (Technical Association of Pulp and Paper Industry) Technical Information Sheet , Service Factors for Gears on Major Equipment in the Paper and Pulp Industry. 3 Class Numbers are for motors with anti-friction bearings only. 4 A Class Number of I may be applied at base speed of a super calendar operating over a speed range of part constant power and part constant torque, where the constant power speed range is greater than 1.5 to 1. A Class Number of II is applicable to super calendars operating at constant torque over the entire spead range or where the constant power speed range is less than 1.5 to 1. 24

27 Horsepower Ratings for Class I Loads Table 7 Selection Guide By Input Horsepower For AGMA Application Class I Loads HP Output Reducer RPM Number 1/2 4 to 6 VXT225 XD 3/4 4 to 5 VXT325 XD 3/4 6 to 8 VXT225 XD 1 4 to 5 VXT425 XD 1 6 to 7 VXT325 XD 1 8 to 12 VXT225 XD 1-1/2 4 VXT525 XD 1-1/2 5-7 VXT425 XD 1-1/ VXT325 XD 1-1/2 13 to 16 VXT225 XD 2 4 to 5 VXT525 XD 2 6 to 11 VXT425 XD 2 12 to 15 VXT325 XD 2 16 to 24 VXT225 XD or VXT215 XD 3 4 to 5 VXT625 XD 3 6 to 9 VXT525 XD 3 10 to 17 VXT425 XD 3 18 to 25 VXT325 XD 3 26 to 45 VXT225 XD or VXT215 XD 5 4 to 5 VXT725 XD 5 6 to 9 VXT625 XD 5 10 to 17 VXT525 XD 5 18 to 24 VXT425 XD or VXT415 XD 5 32 to 45 VXT325 XD or VXT315 XD 5 46 to 74 VXT225 XD or VXT215 XD 5 75 to 92 VXT215 XD 7-1/2 4 to 5 VXT825 XD 7-1/2 6 to 9 VXT725 XD 7-1/2 10 to 15 VXT625 XD 7-1/2 16 to 25 VXT525 XD 7-1/2 26 to 51 VXT425 XD or VXT415 XD 7-1/2 52 to 77 VXT325 XD or VXT315 XD 7-1/2 78 to 85 VXT215 XD or VXT225 XD 7-1/2 86 to 140 VXT215 XD 10 5 VXT925 XD 10 6 to 7 VXT825 XD 10 8 to 13 VXT725 XD to 23 VXT625 XD to 37 VXT525 XD or VXT515 XD to 77 VXT425 XD to VXT415 XD to 85 VXT315 XD or VXT325 XD to 104 VXT315 XD to 140 VXT215 XD 15 5 to 7 VXT925 XD 15 8 to 11 VXT825 XD to 19 VXT725 XD to 37 VXT625 XD or VXT615 XD to 57 VXT525 XD or VXT515 XD to 80 VXT425 XD or VXT415 XD to 109 VXT415 XD to 140 VXT315 XD HP Output Reducer RPM Number 20 6 to 9 VXT925 XD to 15 VXT825 XD to 25 VXT725 XD or VXT715 XD to 53 VXT625 XD or VXT615 XD to 79 VXT525 XD to VXT515 XD to 85 VXT415 XD* or VXT425 XD* to 140 VXT415 XD* 25 8 to 11 VXT925 XD to 21 VXT825 XD to 33 VXT725 XD or VXT715 XD to 69 VXT625 XD or VXT615 XD to 80 VXT515 XD* or VXT525 XD* to 99 VXT515 XD* to 140 VXT415 XD* to 15 VXT925 XD to 25 VXT825 XD or VXT815 XD to 44 VXT725 XD or VXT715 XD to 84 VXT625 XD or VXT615 XD to 125 VXT515 XD* to 19 VXT925 XD or VXT915 XD to 37 VXT825 XD or VXT815 XD to 61 VXT725 XD or VXT715 XD to 79 VXT615 XD* or VXT625 XD* to 111 VXT615 XD* to 125 VXT515 XD* to 27 VXT925 XD or VXT915 XD to 49 VXT825 XD to VXT815 XD to 77 VXT715 XD or VXT725 XD to 125 VXT615 XD* to 33 VXT925 XD* to VXT915 XD* to 60 VXT825 XD* or VXT815 XD* to 70 VXT725 XD* or VXT715 XD* to 120 VXT715 XD* to 44 VXT925 XD* or VXT915 XD* to 70 VXT825 XD* or VXT815 XD* to 78 VXT815 XD* to 120 VXT715 XD* to 69 VXT925 XD* or VXT915 XD* to 120 VXT815 XD* to 70 VXT915 XD* or VXT925 XD* to 90 VXT915 XD* to 123 VXT815 XD* to 120 VXT915 XD* *Cooling fan required 25

28 Horsepower Ratings for Class II Loads Table 8 Selection Guide By Input Horsepower For AGMA Application Class II Loads HP Output Reducer RPM Number 1/3 4 to 6 VXT225 XD 1/2 4 to 5 VXT325 XD 1/2 6 to 8 VXT225 XD 3/4 4 to 5 VXT425 XD 3/4 6 to 7 VXT325 XD 3/4 8 to 12 VXT225 XD 1 5 to 7 VXT425 XD 1 8 to 11 VXT325 XD 1 12 to 16 VXT225 XD 1-1/2 4 to 5 VXT525 XD 1-1/2 6 to 11 VXT425 XD 1-1/2 12 to 17 VXT325 XD 1-1/2 18 to 24 VXT225 XD or VXT215 XD 2 4 to 5 VXT625 XD 2 6 to 9 VXT525 XD 2 10 to 15 VXT425 XD 2 16 to 23 VXT325 XD or VXT315 XD 2 24 to 34 VXT225 XD or VXT215 XD 3 4 to 5 VXT725 XD 3 6 to 8 VXT625 XD 3 9 to 14 VXT525 XD 3 14 to 25 VXT425 XD or VXT415 XD 3 26 to 37 VXT325 XD or VXT315 XD 3 38 to 70 VXT215 XD or VXT225 XD 5 4 to 5 VXT825 XD 5 6 to 9 VXT725 XD 5 10 to 15 VXT625 XD 5 16 to 24 VXT525 XD 5 24 to 49 VXT425 XD or VXT415 XD 5 50 to 69 VXT325 XD or VXT315 XD 5 70 to 85 VXT215 XD or VXT225 XD 5 86 to 136 VXT215 XD 7-1/2 4 to 5 VXT925 XD 7-1/2 6 to 7 VXT825 XD 7-1/2 8 to 13 VXT725 XD 7-1/2 14 to 23 VXT625 XD 7-1/2 24 to 37 VXT525 XD or VXT515 XD 7-1/2 38 to 77 VXT425 XD or VXT415 XD 7-1/2 78 to 85 VXT325 XD or VXT315 XD 7-1/2 86 to 109 VXT315 XD 7-1/2 110 to 140 VXT215 XD 10 4 to 7 VXT925 XD 10 8 to 11 VXT825 XD to 17 VXT725 XD to 37 VXT625 XD or VXT615 XD to 54 VXT525 XD or VXT515 XD to 85 VXT425 XD or VXT415 XD to 99 VXT415 XD to 140 VXT315 XD HP Output Reducer RPM Number 15 8 to 9 VXT925 XD to 17 VXT825 XD to 27 VXT725 XD to 57 VXT625 XD or VXT615 XD to 84 VXT515 XD or VXT525 XD to 140 VXT415 XD to 13 VXT925 XD to 23 VXT825 XD to 39 VXT725 XD or VXT715 XD to 77 VXT625 XD or VXT615 XD to 80 VXT515 XD to VXT525 XD to 110 VXT515 XD to 140 VXT415 XD* to 17 VXT925 XD or VXT915 XD to 31 VXT825 XD or VXT815 XD to 51 VXT725 XD or VXT715 XD to 80 VXT615 XD or VXT625 XD to 99 VXT615 XD to 125 VXT515 XD* to 22 VXT925 XD to 39 VXT825 XD or VXT815 XD to 65 VXT725 XD or VXT715 XD to 78 VXT625 XD or VXT615 XD to 125 VXT615 XD to 31 VXT925 XD or VXT915 XD to 57 VXT825 XD or VXT815 XD to 74 VXT725 XD or VXT715 XD to 80 VXT715 XD to 120 VXT615 XD* to 46 VXT925 XD or VXT915 XD to 71 VXT825 XD to VXT815 XD to 120 VXT715 XD to 50 VXT925 XD to VXT915 XD to 74 VXT825 XD or VXT815 XD to 89 VXT815 XD to 120 VXT715 XD to 73 VXT925 XD or VXT915 XD to 75 VXT825 XD or VXT815 XD to 120 VXT815 XD* to 75 VXT915 XD* or VXT925 XD* to 103 VXT915 XD* to 120 VXT815 XD* to 120 VXT915 XD* *Cooling fan required 26

29 Horsepower Ratings for Class III Loads Table 9 Selection Guide By Input Horsepower For AGMA Application Class III Loads HP Output Reducer RPM Number 1/4 4 to 6 VXT225 XD 1/3 8 to 8 VXT225 XD 1/2 4 to 5 VXT425 XD 1/2 6 to 7 VXT325 XD 1/2 8 to 12 VXT225 XD 3/4 4 VXT525 XD 3/4 5 to 7 VXT425 XD 3/4 8 to 11 VXT325 XD 3/4 12 to 16 VXT225 XD 1 4 to 5 VXT525 XD 1 6 to 9 VXT425 XD 1 10 to 16 VXT325 XD 1 16 to 24 VXT225 XD 1-1/2 4 to 5 VXT625 XD 1-1/2 6 to 9 VXT525 XD 1-1/2 10 to 17 VXT425 XD 1-1/2 18 to 25 VXT325 XD 1-1/2 26 to 34 VXT225 XD or VXT215 XD 2 6 to 7 VXT625 XD 2 8 to 13 VXT525 XD 2 14 to 23 VXT425 XD 2 24 to 38 VXT325 XD or VXT315 XD 2 38 to 58 VXT225 XD or VXT215 XD 3 4 to 5 VXT825 XD 3 6 to 7 VXT725 XD 3 8 to 13 VXT625 XD 3 14 to 20 VXT525 XD 3 21 to 39 VXT425 XD or VXT415 XD 3 40 to 57 VXT325 XD or VXT315 XD 3 58 to 85 VXT215 XD or VXT225 XD 3 86 to 100 VXT215 XD 5 4 to 5 VXT925 XD 5 5 to 7 VXT825 XD 5 8 to 13 VXT725 XD 5 14 to 23 VXT625 XD 5 24 to 37 VXT525 XD or VXT515 XD 5 38 to 73 VXT425 XD or VXT415 XD 5 74 to 85 VXT315 XD or VXT325 XD 5 86 to 105 VXT315 XD to 140 VXT215 XD 7-1/2 5 to 6 VXT925 XD 7-1/2 7 to 11 VXT825 XD 7-1/2 12 to 19 VXT725 XD 7-1/2 20 to 37 VXT625 XD or VXT615 XD 7-1/2 38 to 57 VXT525 XD or VXT515 XD 7-1/2 58 to 85 VXT415 XD or VXT425 XD 7-1/2 86 to 109 VXT415 XD 7-1/2 110 to 140 VXT315 XD HP Output Reducer RPM Number 10 6 to 9 VXT925 XD to 15 VXT825 XD to 25 VXT725 XD or VXT715 XD to 53 VXT625 XD to VXT615 XD to 80 VXT525 XD or VXT515 XD to 140 VXT415 XD to 15 VXT925 XD to 25 VXT825 XD or VXT815 XD to 44 VXT725 XD or VXT715 XD to 84 VXT615 XD or VXT625 XD to 125 VXT515 XD to 19 VXT925 XD or VXT915 XD to 37 VXT825 XD or VXT815 XD to 61 VXT725 XD to VXT715 XD to 70 VXT625 XD to VXT615 XD to 109 VXT615 XD to 125 VXT515 XD to 27 VXT925 XD or VXT915 XD to 49 VXT825 XD or VXT815 XD to 77 VXT715 XD or VXT725 XD to 125 VXT615 XD to 33 VXT925 XD or VXT915 XD to 61 VXT825 XD or VXT815 XD to 70 VXT725 XD or VXT715 XD to 94 VXT715 XD to 125 VXT615 XD to 49 VXT925 XD or VXT915 XD to 58 VXT825 XD or VXT815 XD to 84 VXT815 XD to 90 VXT715 XD to 61 VXT925 XD or VXT915 XD to 74 VXT815 XD to VXT825 XD to 110 VXT815 XD to 120 VXT715 XD* to 74 VXT925 XD to VXT915 XD to 78 VXT915 XD to 115 VXT815 XD to 75 VXT915 XD* or VXT925 XD* to 120 VXT915 XD* *Cooling fan required 27

30 Horsepower Selection Method Overview The Horsepower Selection Method will allow you to choose a reducer based on the horsepower used by your application. This method is typically used for replacing an existing drive system with a more economical one. Because you will be selecting a reducer based on the transmitted power of your prime mover (instead of nameplate horsepower), you may be able to install a more economical reducer. Determine the following information Application: 1. Type belt conveyor, centrifugal pump, etc. 2. Data hours per day of operation, load classification, number of starts, and number of reversals 3. Actual input horsepower (page 31) 4. Required output RPM 5. Ambient conditions temperature, altitude, air flow, etc. Prime Mover: 1. Type electric motor, single or multi-cylinder internal combustion engine, etc. 2. Horsepower and Frame Size 3. RPM 4. Brake type and rating (if used) How to select Step 1. Determine the mechanical service factor See Table 12 (pages 35 41) for a list of common applications. If your application is not listed see page 42. If your prime mover is an internal combustion engine, see page 43 for instructions on adjusting your service factor. Step 2. Calculate the equivalent mechanical horsepower [HP EM ] First, determine actual horsepower (page 31). Next, multiply actual horsepower by the mechanical service factor: Actual horsepower x Mechanical Service Factor = HP EM Step 3. Select the reducer s size and ratio From Table 16 (pages 44 47) under your output speed, locate a horsepower rating at least equal to the calculation of Step 2. Follow the row left to find the recommended reducer size. If your output speed falls between those listed, interpolation or estimation can be used to determine the rating at the required speed. Step 4. Calculate the sheave ratio Use the formula below to determine the ratio of the driver and driven sheaves. When purchasing sheaves to attain this ratio, be sure that the driven sheave (mounted on the reducer's input shaft) exceeds the minimum sheave diameter listed in Table 5 (page 13). Mount the sheave as close to the reducer as practical. Sheave ratio = Speed of prime mover [rpm] Reducer output speed [rpm] x Reducer reduction ratio Note the sheave ratio and input horsepower. Refer to a belt drive manufacturer catalog for the selection of sheaves and belts. See Table 5 (page 13) to ensure that your driven sheave selection exceeds the listed pitch diameter. 28

31 Step 5. Check the reducer thermal capacity First, calculate the allowable HP ET : HP ET = HP T x F T x F D x F H x F V (See pages 48 50) Next, calculate the reducer input power: Input power = Prime mover nameplate horsepower x Connection efficiency Connection efficiencies can be found in Table 5b (page 13). If the reducer input power is less than the HP ET, the reducer is thermally sufficient. Step 6. Step 7. Step 8. Check the overhung load If an overhung load is present, calculate and compare the load to reducer capacity (pages 51 57). Check the thrust load If a thrust load is present, calculate and compare the load to reducer capacity (page 58). Determine Required Bushings All Vortex shaft mount reducers require bushings. Match the bushing bore size with the driven shaft diameter. Refer to reducer dimensions and data (pages 62 77) for available bushing options. Make sure both the driven shaft and key have adequate load carrying capacities. Step 9. Check dimensions Find reducer dimensions on pages Step 10. Determine the accessories required for your application i.e.: backstop, motor mount, shaft cooling fan, v-belt guard, etc. Selection Example Application information Driven Machine: 1. Application description: a uniformly loaded belt conveyor with the reducer mounted on the conveyor s headshaft which is 3-7/16 in diameter 2. Duty cycle: 16 hours per day operating 42 minutes of each hour with 3 starts & stops per hour and no reversals 3. Actual input horsepower: 27.4 hp (page 31) 4. Required output speed: 60 rpm 5. Ambient conditions: 80 F at an elevation of 2,500 feet and installed in a sheltered outdoor space Prime mover 1. Type: AC electric motor 2. Horsepower: 30 hp 286T frame 3. RPM: Brake: none Step 1. Determine the mechanical service factor From Table 12 (page 35)... conveyors general purpose, belt, uniformly loaded or fed, load duration over 10 hours per day. This application requires a 1.25 service factor. Because we are using an electric motor, we don't need to adjust this factor for internal combustion use. Step 2. Calculate the equivalent mechanical horsepower [HP EM ] Actual horsepower = 27.4 hp (page 31). Equivalent mechanical horsepower [HP EM ] = Mechanical service factor x Actual horsepower = 1.25 x 27.4 hp = 34.3 [HP EM ] Step 3. Select the reducer size and ratio From Table 16 (page 44) under output speed 60 find the first input mechanical horsepower rating over 34.3 hp which is hp. Follow the row to the far left column and Vortex catalog number, which in this case is VXT615 XD. Selection example continued on next page 29

32 Horsepower Selection Method Selection example (continued) Step 4. Calculate the sheave ratio Complete the formula below to determine the sheave ratio that is required to obtain your desired output speed. See Table 3 (page 12) to determine your reducer reduction ratio. Speed of prime mover [rpm] 1750 Sheave Ratio = = = 1.94 Reducer output speed [rpm] x Reducer reduction ratio 60 x 15 The formula tells us that our sheaves should have a 1.94:1 ratio. With the sheave ratio and input horsepower noted, select your sheaves and belts from a belt drive manufacturer catalog. See Table 5 (page 13) to ensure that your driven sheave selection exceeds the listed minimum pitch diameter. Step 5. Check the reducer thermal capacity First calculate the allowable HP et: HP ET = Equivalent thermal horsepower = HP T x F T x F D x F H x F V HP t = Catalog input thermal horsepower rating for VXT615 XD (60 rpm) in Table 16 (page 45) = 42.0 F t = Service factor for 80 F ambient temperature in Table 17 (page 50) = 0.92 F d = Thermal service factor for 42 minutes of operating time per hour in Table 18 (page 50) = 1.15 F h = Altitude Adjustment Factor in Table 19 (page 50) = 0.95 Fv = Ambient Air Velocity Correction Factor in Table 20 (page 50) = 1.30 HP et = 42.0 x.92 x 1.15 x.95 x 1.30 = Next calculate the reducer input power. Input power = Prime mover horsepower x Connection efficiency from Table 5b (page 13) = 30 x.94 = 28.2 hp The reducer output power of 28.2 hp is less than the HP ET of hp. The reducer selected is thermally sufficient. Step 6. Step 7. Step 8. Step 9. Check the overhung load There is no need to check the overhung load if the selected sheave is larger than the minimum 6.2 inches shown in Table 5 (page 13), as well as the motor sheave diameter being larger than the 5.2 inch minimum from Table 4 (page 13). Check thrust load This application has no thrust load to calculate. Determine Required Bushing Per the list of available bushings (page 70), 3-7/16 is the maximum bore available for a Vortex VXT615 XD size reducer, so it will work in this application. Be sure both the driven shaft and key have adequate load carrying capacity. Check appropriate references for your application. Check dimensions See page 70 for VXT6 XD dimensions. Consult the manufacturer for prime mover dimensions. Step 10. Determine the accessories required for your application The reducer application requires a backstop. See page 71. Order a 6BKS. 30

33 Determining Actual Horsepower Actual versus nameplate horsepower Nameplate horsepower is the horsepower the motor is capable of producing without being overloaded. Nearly all AC motors have a built in service factor of This means a 10 hp (nameplate) AC motor actually can operate safely at 11.5 hp without overheating. Actual horsepower is the amount of the motor horsepower that is used to move a load in a given application. In many cases the actual horsepower used is much less than the motor nameplate horsepower. Replacing a reducer (in a pre-designed system) by using actual horsepower, rather than nameplate horsepower, could result in the use of a more economical reducer. See the horsepower selection method (page 28). Calculating actual horsepower The actual horsepower used can be determined by measuring the motor terminal ampere load and calculating. For single phase AC motors the formula is: For three phase AC motors the formula is: First, calculate or estimate the motor load and select the appropriate factor. The power factors for typical 3 phase AC motors are found in Table 10 (below). For single phase motor power factors, contact the motor manufacturer. Table 11 (below) shows the relationship between amp draw and horsepower. If the horsepower calculated is higher than the value shown in the chart, the motor is overloaded. Example Calculation Given A 230 volt, 3 phase, 75 hp (nameplate) AC motor with (nameplate) efficiency of 88% is estimated to be 3/4 (75%) loaded. The motor s terminal amp draw, as measured by an amp meter, is 140 amps. Calculate the actual horsepower used HP Transmitted = = HP Transmitted = 56.4 actual horsepower HP Transmitted = HP Transmitted = Amps x Volts x Motor Efficiency x Power Factor x 230 x 0.88 x Table 10 Typical Motor Power Factors* For 3 phase AC Motors Motor Motor Power Factor Horsepower Speed (rpm) 1/2 load 3/4 load Full load ½ * The power factor of an AC motor is the ratio of the real power flowing to the load over the apparent power in the circuit. Real power is measured in watts (W). It is the power drawn by the circuit to perform useful work. Apparent power is measured in volt-amperes (VA). It is the product of RMS (root mean square) voltage and RMS current. In an AC motor the power factor changes with the amount of load that is applied to the motor. Amps x Volts x Motor Efficiency x Power Factor 746 Amps x Volts x Motor Efficiency x Power Factor 432 Table 11 Typical Motor Terminal Amps at Full Load* Horsepower Single Three Phase Phase AC Motors AC Motors ½ ½ ½ * values are for all motor speeds and frequencies at 230 volts 31

34 Torque Selection Method Overview The Torque Selection Method is the best method for selecting the most economical reducer. However, this method assumes that you know the output torque required by your application. Determine the following information Application: 1. Type belt conveyor, centrifugal pump, etc. 2. Data hours per day of operation, load classification, number of starts, and number of reversals 3. Required input torque [in-lbs] 4. Required output RPM 5. Ambient conditions temperature, altitude, air flow, etc. Prime Mover: 1. Type electric motor, single or multi-cylinder internal combustion engine, etc. 2. Horsepower 3. RPM 4. Brake type and rating (if used) How to select Step 1. Determine the mechanical service factor See Table 12 (pages 35 41) for a list of common applications. If your application is not listed see page 42. If your prime mover is an internal combustion engine, see page 43 for instructions on adjusting your service factor. Step 2. Calculate equivalent mechanical torque Equivalent mechanical torque = (Mechanical service factor x Input torque) Step 3. Convert equivalent mechanical torque to equivalent mechanical horsepower [HP EM ] HP EM Step 4. Step 5. Select the reducer s size and ratio From Table 16 (pages 44 47) under your output speed, locate a horsepower rating at least equal to the calculation of Step 3. Follow the row left to find the recommended reducer size. If your output speed falls between those listed, interpolation or estimation can be used to determine the rating at the required speed. Calculate the sheave ratio Use the formula below to determine the ratio of the driver and driven sheaves. When purchasing sheaves to attain this ratio, be sure that the driven sheave (mounted on the reducer's input shaft) exceeds the minimum sheave diameter listed in Table 5 (page 13). Mount the sheave as close to the reducer as practical. Speed of prime mover [rpm] Sheave ratio = Reducer output speed [rpm] x Reducer reduction ratio Note the sheave ratio and input horsepower. Refer to a belt drive manufacturer catalog for the selection of sheaves and belts. See Table 5 (page 13) to ensure that your driven sheave selection exceeds the listed pitch diameter. 32

35 Step 6. Check the reducer thermal capacity First, calculate the allowable HP ET : HP ET = HP T x F T x F D x F H x F V (See pages 48 50). Next, calculate the reducer input power: Input power = Prime mover nameplate horsepower x Connection efficiency Connection efficiencies can be found in Table 5b (page 13). If the reducer input power is less than the HP ET, the reducer is thermally sufficient. Step 7. Check the overhung load If an overhung load is present, calculate the load (pages 51 57). Step 8. Check the thrust load If an thrust load is present, calculate the load (page 58). Step 9. Determine Required Bushing Per the list of available bushings (page 72), 3-7/16 is the maximum bore available for a Vortex VXT615 XD size reducer, so it will work in this application. Be sure both the driven shaft and key have adequate load carrying capacity. Check appropriate references for your application. Step 9. Check dimensions Find a reducer dimensions on pages Step 10. Determine the accessories required for your application i.e.: backstop, motor mount, shaft cooling fan, v-belt guard, etc. Selection Example Application information Driven Machine: 1. Application description: a uniformly loaded belt conveyor with the reducer mounted on the conveyor s head shaft which is 3-7/16 in diameter 2. Duty cycle: 16 hours per day operating 42 minutes of each hour with 3 starts & stops per hour and no reversals 3. Required input torque 987 [in-lbs] 4. Required output speed: 60 rpm 5. Ambient conditions: 80 F at an elevation of 2,500 feet and installed in a sheltered outdoor space Prime mover: 1. Type: AC electric motor 2. Horsepower: 30 hp 286T frame 3. Speed: 1750 rpm 4. Brake: none Step 1. Step 2. Step 3. Determine the mechanical service factor From Table 12 (page 35) conveyors general purpose, belt, uniformly loaded or fed, load duration over 10 hours per day. This application requires a 1.25 service factor. Because we are using an electric motor, we don't need to adjust this factor for internal combustion use. Calculate equivalent mechanical torque Equivalent mechanical torque = (Mechanical service factor x Input torque) = 1.25 x 987 in-lbs = 1,233 in-lbs Convert equivalent mechanical torque to equivalent mechanical horsepower [HPEM] HPEM Step 4. Select the reducer size and ratio From Table 16 (page 44) under output speed 60 find the first input mechanical horsepower rating over 34.3 hp which is hp. Follow the row to the far left column and Vortex catalog number, which in this case is VXT615 XD. Selection example continued on next page. 33

36 Torque Selection Method Selection example (continued) Step 5. Calculate the sheave ratio Complete the formula below to determine the sheave ratio required to obtain your desired output speed. See Table 3 (page 12) to determine your reducer reduction ratio. Speed of prime mover [rpm] 1750 Sheave Ratio = = = 1.94 Reducer output speed [rpm] x Reducer reduction ratio 60 x 15 The formula tells us that our sheaves should be a 1.94:1 ratio. With the sheave ratio and input horsepower noted, select your sheaves and belts from a belt drive manufacturer catalog. See Table 5 (page 13) to ensure that your driven sheave selection exceeds the listed minimum pitch diameter. Step 6. Check the reducer thermal capacity First calculate the allowable HP ET : HP ET = Equivalent thermal horsepower = HP T x F T x F D x F H x F V HP t = Catalog input thermal horsepower rating for VXT615 XD (60 rpm) in Table 16 (page 45) = 42.0 F t = Service factor for 80 F ambient temperature in Table 17 (page 50) = 0.92 F d = Thermal service factor for 42 minutes of operating time per hour in Table 18 (page 50) = 1.15 F h = Altitude Adjustment Factor in Table 19 (page 50) = 0.95 Fv = Ambient Air Velocity Correction Factor in Table 20 (page 50) = 1.30 HP ET = 42 x.92 x 1.15 x.95 x 1.30 = Next calculate the reducer input power. Input power = Prime mover horsepower x Connection efficiency from Table 5b (page 13) = 30 x.94 = 28.2 hp The reducer output power of 28.2 hp is less than the HP ET of hp. The reducer selected is thermally sufficient. Step 7. Step 8. Step 9. Check the overhung load There is no need to check the overhung load if the selected sheave is larger than the minimum 6.2 inches shown in Table 5 (page 13), as well as the motor sheave diameter being larger than the 5.2 inch minimum from Table 4 (page 13). Check the thrust load This application has no thrust load to calculate. Determine Required Bushing Per the list of available bushings (page 70), 3-7/16 is the maximum bore available for a Vortex VXT615 XD size reducer, so it will work in this application. Be sure both the driven shaft and key have adequate load carrying capacity. Check appropriate references for your application. Step 10. Check dimensions See page 70 for VXT6 XD dimensions. Consult the motor manufacturer for prime mover dimensions. Step 11. Determine the accessories required for your application The reducer application requires a backstop. See page 71. Order a 6BKS. 34

37 AGMA Mechanical Service Factors WARNING: Service factors in Table 12 are for enclosed helical gear drives only. Table 12 Service Factors for Reducers Driven by Motors or Turbines (Based on ANSI/AGMA 6013 A06, Standard for Industrial Enclosed [Helical] Gear Drives) Load duration Application Up to 3 hours 3 to 10 hours Over 10 hours per day per day per day 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 Machines 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 Includes: Apron, Assembly, Belt, Bucket, Chain, Flight, Oven and Screw Uniformly Loaded or Fed Heavy Duty Not Uniformly Fed Severe Duty Reciprocating or Shaker Cranes 1 Dry Dock Main Hoist Auxiliary Hoist Boom Hoist

38 AGMA Mechanical Service Factors Table 12 (continued) Service Factors for Reducers Driven by Motors or Turbines (Based on ANSI/AGMA 6013 A06, Standard for Industrial Enclosed [Helical] Gear Drives) Load duration Application Up to 3 hours 3 to 10 hours Over 10 hours per day per day per day Cranes 1 (continued) Dry Dock (continued) Slewing Drive Traction Drive Container Main Hoist Boom Hoist Trolley Drive Gantry Drive Traction Drive Mill Duty Main Hoist Auxiliary Bridge Trolley Travel Industrial Duty Main Auxiliary Bridge Trolley Travel Crusher Stone or Ore Dredges Cable Reels Conveyors Cutter Head Drives Pumps Screen drives Stackers Winches Elevators Bucket Centrifugal Discharge Escalators Not Approved Freight Gravity Discharge Man Lifts Not Approved Passenger Elevators Not Approved Extruders General Plastics Variable Speed Drive Fixed Speed Drive Rubber Continuous Screw Operation Intermittent Screw Operation

39 Table 12 (continued) Service Factors for Reducers Driven by Motors or Turbines (Based on ANSI/AGMA 6013 A06, Standard for Industrial Enclosed [Helical] Gear Drives) Load duration Application Up to 3 hours 3 to 10 hours Over 10 hours per day per day per day 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 Laundry Washers Lumber industry Barkers Spindle Feed Main Drive Conveyors Burner Main or Heavy Duty Main Log Re-Saw, Merry-Go-Round Conveyors Slab Transfer Chains Floor Green Cut Off saws Chain Drag Debarking Drums Feeds Edger Gang

40 AGMA Mechanical Service Factors Table 12 (continued) Service Factors for Reducers Driven by Motors or Turbines (Based on ANSI/AGMA 6013 A06, Standard for Industrial Enclosed [Helical] Gear Drives) Load duration Application Up to 3 hours 3 to 10 hours Over 10 hours per day per day per day Lumber Industry (continued) Feeds (continued) Trimmer Log Deck Log Hauls Incline Well Type Log Turning Devices Planer Feed Planer Tilting Hoists Rolls Live Off Bearing Roll Cases Sorting Table Tipple Hoist Transfers Chain Craneway 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 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 & Coolers Mixers Concrete

41 Table 12 (continued) Service Factors for Reducers Driven by Motors or Turbines (Based on ANSI/AGMA 6013 A06, Standard for Industrial Enclosed [Helical] Gear Drives) Load duration Application Up to 3 hours 3 to 10 hours Over 10 hours per day per day per day Paper Mills 2 Agitator (Mixer) Agitator for Pure Liquids Barking Drums Barkers Mechanical Beater Breaker Stack Calender 3 (Anti-Friction Bearings Only) Chipper Chip Feeder Coating Rolls Conveyors Chip, Bark, Chemical Log (Including Slab) Couch Rolls Cutter Cylinder Molds Dryers 3 (Anti-Friction Bearings Only) Paper Machine Conveyor Type Embosser Extruder Fourdrinier Rolls (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 Calender Thickener (AC Motor) (DC Motor) Washer (AC Motor) (DC Motor) Wind and Unwind Stand Winders (Surface Type) Yankee Dryers 3 (Anti-Friction Bearings Only)

42 AGMA Mechanical Service Factors 40 Table 12 (continued) Service Factors for Reducers Driven by Motors or Turbines (Based on ANSI/AGMA 6013 A06, Standard for Industrial Enclosed [Helical] Gear Drives) Load duration Application Up to 3 hours 3 to 10 hours Over 10 hours per day per day per day Plastics Industry Primary Processing Intensive Internal Mixers Batch Mixers Continuous Mixers Batch Drop Mill 2 Smooth Rolls Continuous Feed, Holding and Blend Mill Compounding Mill Calenders Secondary Processing Blow Molders Coating Film Pipe Pre Plasticizers Rods Sheet Tubing Pullers Barge Haul Pumps Centrifugal Proportioning Reciprocating Single Acting, 3 or More Cylinders Double Acting, 2 or More Cylinders Rotary Gear Type Lobe Vane Rubber Industry Intensive Internal Mixers Batch Mixers Continuous Mixers Mixing Mill 2 Smooth Rolls (if corrugated rolls are used, then use the same service factors that are used for a cracker warmer) Batch Drop Mill 2 Smooth Rolls Cracker warmer 2 rolls; 1 Corrugated Roll Cracker 2 Corrugated Rolls Holding, Feed and Blend Mill 2 Rolls Refiner 2 Rolls Calenders Sand Muller Sewage Disposal Equipment Bar Screens Chemical Feeders

43 Table 12 (continued) Service Factors for Reducers Driven by Motors or Turbines (Based on ANSI/AGMA 6013 A06, Standard for Industrial Enclosed [Helical] Gear Drives) Load duration Application Up to 3 hours 3 to 10 hours Over 10 hours per day per day per day Sewage Disposal Equipment (continued) Dewatering Screens Scum Breakers Slow or Rapid Mixers Sludge Collectors Thickeners Vacuum Filters Screens Air Washing Rotary Stone or Gravel Traveling Water Intake Sugar Industry Beet Slicer Cane Knives Crushers Mills (Low Speed End) Textile Industry Batchers Calenders Cards Dry Cans Dryers Dyeing Machinery Looms Mangles Nappers Pads Slashers Soapers Spinners Tenter Frames Washers Winders NOTES: 1 When selecting a reducer for a crane drive, consider the gear tooth bending strength. See page 60 for more information on Vortex gear materials. 2 Service factors for paper mill applications are applied to the nameplate of the electric drive motor at the motor's rated base speed. 3 Service factors for motors with anti-friction bearings only. Use 1.5 service factor for sleeve bearings. 4 A Service factor of 1.0 may be applied at base speed of a super calendar operating over a speed range of part constant power and part constant torque, where the constant power speed range is greater than 1.5 to 1. A Service Factor of 1.25 is applicable to super calendars operating at constant torque over the entire spead range or where the constant power speed range is less than 1.5 to 1. 41

44 Load Classification For Unlisted Applications Estimating a mechanical service factor If your application is not listed in Tables 6 (pages 18-24) or 12 (pages 35-41), use Tables 13 and 14 (below) to estimate an appropriate service factor. Do this by first determining the following information: Total operating time per day The load classification of your application. Then use Table 13 (right) to determine the mechanical service factor that most closely matches your application conditions. If you are selecting a reducer with the quick selection method (page 16), convert the determined service factor in Table 13 (right) to an application classification number using Table 14 (below). If your prime mover is an internal combustion engine, this service factor must be adjusted. See page 43. Table 13 AGMA Load Classifications and Service Factors for Motors or Turbines (Based On ANSI/AGMA 6013-A06 Standard for Industrial Enclosed [Helical] Gear Drives) LOAD CLASSIFICATION Uniform Moderate Heavy Load Shock Shock Load Load Recurring shock Recurring shock Recurring shock loads are less loads are less loads are less than 100% than 140% than 200% reducer s reducer s reducer s mechanical mechanical mechanical horsepower horsepower horsepower rating rating rating TOTAL SERVICE SERVICE SERVICE OPERATING FACTORS FACTORS FACTORS TIME PER DAY For For For (24-HOURS) Uniform Moderate Heavy Loads Shock Shock Loads Loads less than 3 hours to 10 hours over 10 hours Table 14 The Relationship Between AGMA Application Classification Numbers and AGMA Service Factors (Based On ANSI/AGMA 6013-A06 Standard for Industrial Enclosed [Helical] Gear Drives) AGMA Load Description AGMA Maximum Overload Maximum Overload Application (operating Service Percentage Percentage of the Classification 3 to 10 hours) Factor Prime Mover s Number Horsepower Rating I uniform % 200% II moderate shock % 280% III heavy shock % 400% 42

45 Internal Combustion Engine Factors Overview Applications driven by internal combustion engines do not run as smoothly as those driven by electric motors. Because of this, internal combustion applications require their mechanical service factors to be adjusted. To do this, determine your unadjusted service factor. Table 12 (pages 35-41) lists service factors for common applications. If your application is not listed refer to page 42. Next, in the first column of Table 15 (below), find your service factor. Then, to the right, under the desired prime mover, locate the adjusted service factor. Use this adjusted factor in any equations that use "mechanical service factor". Example From Table 12 (page 35 41), if the prime mover is an electric or hydraulic motor, the service factor for a uniformly loaded belt conveyor in operation over 10 hours per day is In Table 15 (below), locate the 1.25 mechanical service factor. Follow to the right to see the adjusted factors for combustion engines: Single-cylinder: 1.75 service factor Multi-cylinder: 1.50 service factor Table 15 Service Factor Adjustments for Single or Multi-Cylinder Engines (Based On ANSI/AGMA 6013-A06 Standard for Industrial Enclosed [Helical] Gear Drives) Mechanical service factor for Adjusted Adjusted electric and hydraulic motors service factors for service factors for (from Table 8 or 16) single-cylinder engines multi-cylinder engines

46 Horsepower and Torque Capacities Table 16 Mechanical and Thermal Capacities at Various Output Speeds Output Speed (RPM) Vortex Catalog Number VXT 215 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) ,192 6,871 6,646 6,501 6,296 6,170 6,053 5,929 5,825 5,739 5,688 VXT 225 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 7,859 7,390 7,307 7,192 6,871 6,646 6,501 6,296 6,170 6,053 5,929 5,825 5,739 5,688 VXT 315 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) ,243 8,978 8,765 8,579 8,414 8,296 8,157 8,038 7,913 VXT 325 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 12,926 11,406 10,556 9,926 9,502 9,243 8,978 8,765 8,579 8,414 8,296 8,157 8,038 7,913 VXT 415 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) ,034 17,288 16,712 16,320 15,853 15,521 15,224 14,923 14,694 14,518 14,315 VXT 425 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 20,133 18,795 18,495 18,034 17,288 16,712 16,320 15,853 15,521 15,524 14,923 14,694 14,518 14,315 VXT 515 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) ,583 24,535 23,726 23,035 22,499 22,036 21,617 21,241 20,941 20,700 20,521 VXT 525 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 31,665 29,155 27,051 25,583 24,535 23,726 23,035 22,499 22,036 21,596 21,241 20,941 20,700 20,521 VXT 615 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) ,541 43,817 42,921 42,012 40,730 39,865 39,109 38,465 37,747 37,161 36,826 VXT 625 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 48,996 45,940 45,816 45,541 43,817 42,921 42,012 40,730 39,865 39,109 38,465 37,747 37,161 36,826 Purple text indicates the limiting factor. Thermal horsepower capacities are based on the units operating at sea level, with an ambient temperature equal to 68 F. 44

47 Table 16 Mechanical and Thermal Capacities at Various Output Speeds Output Speed (RPM) VXT 215 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 5,619 5,555 5,552 5,557 5,563 5,575 5,580 5,585 5,590 5,594 5,599 5,603 5,608 5,613 VXT 225 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 5,619 5,555 5, VXT 315 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque 7,887 7,924 7,933 7,949 7,955 7,960 7,974 7,980 7,985 7,996 8,002 8,013 8,018 8,028 VXT 325 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque 7,887 7,924 7, VXT 415 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 14,318 14,329 14,349 14,365 14,380 14,401 14,415 14,427 14,445 14,455 14,472 14,487 14,496 14,510 VXT 425 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 14,318 14,329 14, VXT 515 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (in-lbs) 20,404 20,423 20,453 20,477 20,501 20,529 20,557 20,574 20,598 20,625 20, VXT 525 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 20,404 20,423 20, VXT 615 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 36,452 36,485 36,543 36,593 36,648 36,696 36,741 36,783 36,828 36,869 36, VXT 625 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque 36,452 36, Purple text indicates the limiting factor. Thermal horsepower capacities are based on the units operating at sea level, with an ambient temperature equal to 68 F. 45

48 Horsepower and Torque Capacities Table 16 Mechanical and Thermal Capacities at Various Output Speeds Output Speed (RPM) Vortex Catalog Number VXT 715 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) ,755 67,063 64,766 63,181 61,470 60,193 59,059 57,903 56,978 56,207 55,653 VXT 725 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 80,806 74,933 72,506 69,755 67,063 64,766 63,181 61,470 60,193 59,059 57,903 56,978 56,207 55,653 VXT 815 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) , , , ,532 99,840 97,761 95,954 94,087 92,635 91,440 90,463 VXT 825 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 132, , , , , , ,532 99,840 97,761 95,954 94,087 92,635 91,440 90,463 VXT 915 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) , , , , , , , , , , ,858 VXT 925 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 195, , , , , , , , , , , , , ,858 Purple text indicates the limiting factor. Thermal horsepower capacities are based on the units operating at sea level, with an ambient temperature equal to 68 F. 46

49 Table 16 Mechanical and Thermal Capacities at Various Output Speeds Output Speed (RPM) VXT 715 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 55,131 54,495 54,590 54,673 54,748 54,830 54,907 54,977 55,048 55, VXT 725 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 55, VXT 815 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 89,827 89,080 89,238 89,377 89,519 89,662 89,793 89,900 90,043 90, VXT 825 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 89, VXT 915 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 124, , , , , , , , , , VXT 925 XD Input Mechanical Horsepower Input Thermal Horsepower Output Mechanical Horsepower Output Mechanical Torque (In-Lbs) 124, Purple text indicates the limiting factor. Thermal horsepower capacities are based on the units operating at sea level, with an ambient temperature equal to 68 F. 47

50 Thermal Factors and HP ET Calculation Overview Vortex reducer thermal horsepower capacities are based on the unit operating continuously, at sea level, in a large indoor space, with an ambient temperature equal to 68 F, and in mounting position 2. A reducer's thermal rating is affected by ambient conditions, operating time per hour and mounting position. To account for these varying conditions, the equivalent thermal horsepower [HP ET ] of the reducer should be determined. Equivalent thermal horsepower [HP ET ] formula Use the following formula to determine the equivalent thermal horsepower [HP ET ]: HP ET = HP T x F T x F D x F H x F V Where: HP ET = Equivalent thermal horsepower HP t = Catalog thermal horsepower ratings in Table 16 (pages 44 47) F t = Service factor for ambient temperature in Table 17 (page 50) F d = Thermal service factor for operating time per hour in Table 18 (page 50) F h = Altitude Adjustment Factor in Table 19 (page 50) Fv = Ambient Air Velocity Correction Factor in Table 20 (page 50) Example Calculation Application Lumber industry heavy duty burn conveyor operating 16 hours per day Required application horsepower: 22.5 hp Required output speed: 60 rpm Connection efficiency: The prime mover will be connected to the reducer by a v-belt drive. From Table 5b (page 13), we see that a v-belt drive has a connection efficiency of about 94%. Required motor horsepower = = = Required application horsepower ( Reducer efficiency x Connection efficiency ) 22.5 ( 0.97 x 0.94 ) = 24.7 hp Drive selection AC Motor = 25 hp at 1750 rpm Mechanical service factor of 1.50 in Table 12 (page 37) Calculate equivalent mechanical horsepower [HP EM ]: HP EM = Mechanical Service factor x Input horsepower = 1.50 x 25hp = 37.5 HP EM From Table 16 (pages 44 47) under output speed 60 rpm find the first input mechanical horsepower rating over 37.5 hp which is hp. Follow the row to the far left column and Vortex catalog number, which is VXT615 XD. Environment Ambient temperature: 100 F Altitude: 2,500 feet elevation Installed in a large indoor space 48

51 Example Calculation (continued) Step 1. Calculate the allowable HP ET Where: HP ET = HP T x F T x F D x F H x F V HP ET = Equivalent thermal horsepower HP t = Catalog thermal horsepower rating for the correct ratio in Table 16 (pages 44 47) = 42.0 F t = Service factor for ambient temperature in Table 17 (page 50) = 0.77 F d = Thermal service factor for operating time per hour in Table 18 (page 50) = 1.00 F h = Altitude Adjustment Factor in Table 19 (page 50) = 0.95 Fv = Ambient Air Velocity Correction Factor in Table 20 (page 50) = 1.00 HP ET = 42.0 x 0.77 x 1.00 x 0.95 x 1.00 = 30.7 Therefore, the allowable HP ET for a VXT615 XD in this environment is 30.7 horsepower. Step 2. Calculate the reducer input power Input power = Prime mover nameplate horsepower x connection efficiency = 25.0 hp x 0.94 = 23.5 hp Conclusion The reducer input power (23.5 hp) is less than the allowable HP ET (30.7 hp). Therefore, this is a suitable selection. 49

52 Thermal Ratings and Service Factors Table 17 Thermal Service Factor (F t ) Ambient Temperature Correction Ambient Temperature Fahrenheit Celsius Service Factor F t Table 18 Thermal Service Factor (F d ) Operating Time Per Hour Correction Operating Time Per Hour Percent [%] of Each Hour 100% 80% 70% 40% 20% Total Minutes Service Factor F d Table 19 Thermal Service Factor (F h ) Altitude Adjustment Factor Altitude Meters Feet Factor Fv Sea Level Sea Level , ,500 4, ,250 7, ,000 9, ,750 12, ,500 14, ,250 17, Table 20 Thermal Service Factor (F v ) Ambient Air Velocity Correction Factor Ambient Air Velocity (If Known) Meters/Second Miles/Hour Factor Fv Less than 0.5 Less than to to to to Greater than 3.7 Greater than If Ambient Air Velocity is Unknown Factor Fv Small confined space 0.86 Large indoor space 1.00 Sheltered outdoor space 1.30 Unsheltered outdoor space

53 Overhung Load Input Shaft Overview An overhung load is a radial force transmitted to a shaft beyond the bearing. Overhung loads [OHL] occur when a sprocket, gear, or sheave is mounted on the input shaft. An overhung load varies with the type of connection and its distance from the reducer housing. These loads can be reduced by increasing the diameter of the mounted sprocket, gear, or sheave. This increased radius on a pulley reduces the force that is required to create the same turning torque. If the maximum permissible overhung load is exceeded, the sprocket, gear, or sheave should be mounted on a separate shaft, coupled and supported by outboard bearings. A larger diameter sprocket, gear, or sheave is often the least expensive solution. The overhung load formula below is appropriate for applications where starting loads, momentary overloads, and brake capacities do not exceed 200% of reducer rating. Calculate overhung load Calculate the input shaft overhung load using the formula below. Check the calculated load against the overhung capacities listed in Table 24 (page 54). Input mechanical horsepower # 126, 000 # K # L OHL = Input shaft RPM # PD Where: Input mechanical horsepower = the nameplate horsepower of the prime mover. K = Load connection factor from Table 21 (page 52) L = Load location factor from Table 23 (page 53) Input shaft RPM = speed of input shaft rotation PD = pitch diameter of the sprocket, gear, or sheave attached to the shaft (inches) Example Calculation Application Prime mover = 10 hp, 1750 rpm AC motor Output shaft speed = 100 rpm Reducer size selection and service factor = VXT315 XD using a mechanical service factor of 1.25 Sheave ratio: 1.16:1 Motor sheave 7.40 inch pitch diameter Reducer sheave 8.60 inch pitch diameter Two B-section v-belts Center line of sheave overhung load = 2.0 inches from the reducer s housing. Calculate the overhung load on the input shaft Input mechanical horsepower # 126, 000 # K # L OHL = Input shaft RPM # PD Where: Input mechanical horsepower = the nameplate horsepower of the prime mover = 10 hp K = Load connection factor in Table 21 (page 52) is 1.50 L = Load location factor in Table 23 (page 53) is 1.24 PD = pitch diameter of the reducer s sheave is 8.6 inches Input shaft RPM 1,750 AC motor RPM = 1.16 V belt ratio = 1,508 RPM 10 # 126,000 # 1.50 # 1.24 OHL = 1,508 # 8.6 = lbs The actual OHL of lbs. is less than the allowable 580 lbs. in Table 24 (page 54) and is therefore satisfactory. 51

54 Overhung Load Input Shaft Load connection factor [K] The type of connection used affects an overhung load. See Table 21 (below) for load connection factors (K) used in the overhung load calculation (page 51). Load location factor [L] Locate the center line of the load as close to the reducer housing as practical. Do this to minimize the overhung load and increase the bearing life. See Table 23 (page 53) for load location factors (L) used in the overhung load calculation (page 51). Minimum sheave pitch diameters (input shaft) Minimum pitch diameters for input shaft sheaves are listed in Table 22 (below). These minimums are for V-belt drives with the center line of the load applied one shaft diameter (or less) from the reducer housing. For loads applied at a distance greater than the shaft's diameter, multiply the published minimum sheave pitch diameter by the load location factor in Table 23 (page 53). To calculate the minimum pitch diameter for chains or timing belts, multiply minimum sheave pitch diameters by Table 21 Load Connection Factor (K) Type of Connection Factor Sprocket or Timing Belt 1.00 Machined Pinion & Gear 1.25 Synchronous (Timing) Belts 1.30 Single or Multiple V-Belt 1.50 Flat Belt 2.50 Variable Pitch Pulley 3.50 Table 22 Minimum Sheave Pitch Diameters For Reducer Input Shafts Input Minimum Unit Shaft Sheave Size Diameter Pitch Diameter (inches) (inches) VXT215 XD 1-1/8 3.0 VXT225 XD 1-1/8 3.0 VXT315 XD 1-1/4 4.0 VXT325 XD 1-1/4 4.0 VXT415 XD 1-7/ VXT425 XD 1-7/ VXT515 XD 1-15/ VXT525 XD 1-15/ VXT615 XD 2-3/ VXT625 XD 2-3/ VXT715 XD 2-7/ VXT725 XD 2-7/ VXT815 XD 2-7/ VXT825 XD 2-7/ VXT915 XD 2-7/ VXT925 XD 2-7/

55 Illustration C Measuring Distance J On the Input Shaft J Center of Overhung Load Table 23 Input Shaft Load Location Factor (L) for Loads Located at Distance J Distance Unit Size J VXT2 VXT3 VXT4 VXT5 VXT6 VXT7 VXT8 VXT9 (inches) XD XD XD XD XD XD XD XD

56 Overhung Load Capacity Input Shaft Input shaft OHL capacities Input shaft overhung load ratings published in Table 24 (below) are based on normal conditions where: The sheave diameter is less than the minimum listed in Table 22 (page 52) The center line of the load is located no more than one shaft diameter away from the reducer housing. See Table 22 (page 52) for reducer shaft diameters. The input shaft speed does not exceed the maximum listed in Table 2 (page 11). These overhung load capacities are based upon a combination of the most unfavorable conditions. Therefore, it may be possible to exceed these capacities in more favorable conditions. Output RPM Table 24 Input Shaft Overhung Load Capacities (pounds) Unit Size VXT2 VXT3 VXT4 VXT5 VXT6 VXT7 VXT8 VXT9 XD XD XD XD XD XD XD XD 15:1 Ratio Reducers ,190 1,850 2,710 3,670 3,810 3, ,190 1,850 2,710 3,630 3,810 3, ,190 1,840 2,710 3,215 3,810 3, ,190 1,690 2,710 2,950 3,810 3, ,190 1,580 2,545 2,760 3,810 3, ,190 1,495 2,410 2,610 3,810 3, ,190 1,430 2,305 2,495 3,810 3, ,190 1,370 2,210 2,395 3,810 3, ,190 1,325 2,135 2,315 3,855 3, ,190 1,285 2,070 2,240 3,735 3, ,170 1,245 2,010 2,180 3,630 3, ,140 1,215 1,960 2,120 3,535 3, ,115 1,185 1,910 2,070 3,450 3, ,090 1,160 1,870 2,025 3,375 3,315 Output RPM 25:1 Ratio Reducers ,190 1,850 2,710 3,670 3,810 3, ,190 1,785 2,710 3,115 3,810 3, ,190 1,580 2,545 2,760 3,810 3, ,190 1,450 2,335 2,530 3,810 3, ,190 1,355 2,185 2,365 3,810 3, ,190 1,285 2,070 2,240 3,735 3, ,150 1,225 1,975 2,140 3,565 3, ,105 1,175 1,900 2,055 3,425 3, ,065 1,135 1,830 1,985 3,305 3,315 54

57 Overhung Load Output Shaft Overview Typically, there is no overhung load on the hollow shaft when the reducer is shaft mounted. An overhung load will exist at the hollow shaft when the reducer is mounted to a foundation and a sheave, sprocket, or gear is mounted on the stub shaft. Any reducer that is mounted to a foundation should have the OHL checked. If the maximum permissible overhung load is exceeded, the sprocket, gear, or sheave should be coupled and supported by outboard bearings. The overhung load formula below is appropriate for applications where starting loads, momentary overloads, and brake capacities do not exceed 200% of reducer rating. Calculate overhung load Calculate the output shaft overhung load using the formula below. Check the calculated load against the overhung capacities listed in Table 27 (page 57). Where: OHL = Input mechanical horsepower = the nameplate horsepower of the prime mover. K = Load connection factor from Table 21 (page 52) L = Load location factor from Table 26 (page 56) Output shaft RPM = speed of output shaft rotation PD = pitch diameter of the sprocket, gear or sheave attached to the shaft Example Calculation Application Prime mover = 10 hp, 1750 rpm AC motor Output shaft speed = 100 rpm Reducer size selection and service factor = VXT315 XD using a mechanical service factor of pitch diameter 21 tooth 100B21 sprocket mounted on a 2-3/16 diameter stub shaft. Center line of sprocket overhung load is positioned at 4.0 inches from the reducer s housing. Calculate the overhung load Input mechanical horsepower x 126,000 x K x L Output shaft RPM x PD OHL = Input mechanical horsepower x 126,000 x K x L Output shaft RPM x PD Where: Input mechanical horsepower = the prime mover horsepower = 10 hp K = Load connection factor in Table 21 (page 52) for a sprocket drive is 1.00 L = Load location factor for 4 inches from the reducer s housing in Table 26 (page 56) is 1.14 RPM = 100 rpm PD = pitch diameter of the sprocket is 8.4 inches 10 # 126,000 # 1.00 # 1.14 OHL = 100 # 8.4 = 1,710 lbs The actual OHL of 1,710 lbs is less than the allowable 3,492 lbs. in Table 27 (page 57) and is therefore satisfactory. 55

58 Overhung Load Output Shaft Load connection factor [K] The type of connection used affects an overhung load. See Table 21 (page 52) for load connection factors (K) used in the overhung load calculation (page 55). Load location factor [L] Locate the center line of the load as close to the reducer housing as practical. Do this to minimize the overhung load and increase the bearing life. See Table 26 (below) for load location factors (L) used in the overhung load calculation (page 55). Output shaft RPM Review the hollow shaft RPM and make sure it does not exceed the maximum output RPM listed in Table 25 (right). Illustration D Measuring Distance H On the Stub Shaft The reducer is mounted to the foundation and is not supported by the stub shaft H Center of Overhung Load Table 25 Maximum Output Speeds Unit Size Maximum Output RPM VXT215 XD 140 VXT225 XD 85 VXT315 XD 140 VXT325 XD 85 VXT415 XD 140 VXT425 XD 85 VXT515 XD 125 VXT525 XD 80 VXT615 XD 125 VXT625 XD 80 VXT715 XD 120 VXT725 XD 75 VXT815 XD 120 VXT825 XD 75 VXT915 XD 120 VXT925 XD 75 Table 26 Load Location Factor (L) for Load Located at Distance H Distance H (Inches) Load Location Factor L Unit Size VXT2 VXT3 VXT4 VXT5 VXT6 VXT7 VXT8 VXT9 XD XD XD XD XD XD XD XD

59 Overhung Load Capacity Output Shaft Output shaft OHL capacities Output shaft overhung load ratings published in Table 27 (below) are based on normal conditions where: The output shaft is not subject to a thrust load. The center line of the load is located no more than one shaft diameter in length from the reducer oil seal. See Table 26 (page 56) for the factor of other distances. The RPM of the hollow shaft does not exceed the maximum speed in Table 25 (page 56). See page 55 for an example calculation. Table 27 Overhung Load Capacity at Hollow Shaft* (Pounds) Output Speed RPM Unit Shaft Size Size (inches) VXT2 XD 1 7/16 4,027 3,196 2,792 2,537 2,355 2,216 2,014 1,869 1,759 1, /16 3,670 2,913 2,545 2,312 2,146 2,020 1,835 1,704 1,603 1,523 VXT3 XD 1 15/16 7,228 5,871 5,199 4,769 4,460 4,223 3,873 3,623 3,430 3, /16 6,967 5,659 5,011 4,597 4,299 4,070 3,734 3,492 3,306 3,157 VXT4 XD 2 3/16 9,929 8,065 7,141 6,551 6,127 5,801 5,321 4,977 4,712 4, /16 9,618 7,812 6,917 6,345 5,935 5,619 5,154 4,820 4,564 4,358 VXT5 XD 2 7/16 11,390 9,252 8,192 7,515 7,028 6,654 6,104 5,709 5,405 5, /16 10,722 8,709 7,712 7,074 6,616 6,264 5,746 5,374 5,088 4,858 VXT6 XD 2 15/16 16,304 13,243 11,726 10,757 10,060 9,525 8,737 8,171 7, /16 15,473 12,568 11,129 10,209 9,548 9,039 8,292 7,755 7,342 - VXT7 XD 3 7/16 13,860 11,000 9,610 8,731 8,105 7,627 6,930 6,433 6, /16 13,218 10,491 9,165 8,327 7,730 7,274 6,609 6,135 5,773 - VXT8 XD 3 15/16 13,990 11,104 9,700 8,813 8,181 7,699 6,995 6,493 6, /16 13,413 10,646 9,300 8,450 7,844 7,381 6,706 6,226 5,859 - VXT9 XD 4 7/16 18,288 14,516 12,681 11,521 10,695 10,065 9,144 8,489 7, /16 17,563 13,940 12,177 11,064 10,271 9,665 8,781 8,152 7,671 - *Overhung load is at the center line located one shaft diameter from the reducers s output shaft oil seal (L = 1.00 and with no thrust load.) 57

60 Thrust Load Overview A thrust load is an axial force transmitted in-line with the shaft. This force often occurs in screw conveyor applications, as well as those involving mixers, fans, and blowers. The reducer must be able to support this load without damage. Input shaft Input shaft thrust loading (inward or outward along the shaft) occurs very rarely. Refer all applications where a thrust load is applied to the input shaft to Vortex Engineering for evaluation. Hollow shaft Some applications, notably screw conveyor drives, place a thrust load on the hollow shaft. The applied axial thrust loads must be less than or equal to the capacities below. For thrust load capacities on larger reducers, contact Vortex engineering. Calculating Thrust Loads Because thrust loads have a large number of variables, there is no easy formula for calculating the exact load. The customer is responsible for calculating their expected load and checking it against the capacities listed in Table 28 (below). For more support contact Vortex Engineering. Table 28 Hollow Shaft Thrust Load Ratings (pounds) Output RPM : Reducer Size VXT215 XD 1,433 1,433 1,433 1,433 1,355 1,305 VXT315 XD 6,000 6,000 5,370 4,926 4,607 4,453 VXT415 XD 9,500 7,872 6,970 6,394 5,980 5,780 VXT515 XD 9,500 9,435 8,354 7,663 7,167 - VXT615 XD 9,500 9,500 9,500 9,500 9, Output RPM : Reducer Size VXT225 XD 1,433 1,433 1,433 1,433 1,433 VXT325 XD 6,000 5,415 4,730 4,630 4,537 VXT425 XD 8,855 7,028 6,140 6,009 5,889 VXT525 XD 9,500 8,423 7,358 7,202 - VXT625 XD 9,500 9,500 9,500 9,500-58

61 Input Shaft Tolerances Input shaft diameter tolerances The tolerances for Vortex reducer input shaft diameters fall within the standard tolerances for turned and polished shafting. See Table 29 (below) for more specific information. Key and keyway tolerances Keys and keyways are in accordance with ANSI B17.1 for size, depth, offset, lead, and parallelism. Table 29 Input Shaft Diameter Tolerances Shaft Diameter (inches) Maximum Undersize Variation (inches) to to to Driven Shaft Tolerances Driven shaft diameter tolerances The driven shaft is installed through the hollow shaft of the reducer. The driven shaft tolerances should be within the standard tolerances for turned and polished shafting and are found in Table 30 (below). Keyway tolerances Keyways should be in accordance with ANSI B17.1 for size, depth, offset, lead, and parallelism. Table 30 Driven Shaft Diameter Tolerances Shaft Diameter (inches) Maximum Undersize Variation (inches) to to to to Illustration E Reducer Installed on Driven Shaft Input shaft Driven shaft Sheave 59

62 Material Specifications Overview For information regarding the material, hardness or finish of Vortex parts, see Table 31 (below). All material testing was performed by an independant test lab and is subject to change without notice. Illustration F Vortex Shaft Mount Double Reduction Gear Sets First stage reduction pinion and gear set shown in blue. Second stage reduction pinion and gear set shown in purple. Table 31 Material Specifications Part Part Material Hardness Gear Description Number Finish Output Hub 1 AISI 1045 HRC35 40 N/A Input Shaft 2 AISI 4115 HRC56 58 N/A Input Pinion 3 AISI 4115 HRC56 58 AGMA11 Intermediate Gear 4 AISI 4115 HRC54 56 AGMA11 Intermediate Pinion 5 AISI 4115 HRC56 58 AGMA7 (VXT2 XD VXT6 XD) Intermediate Pinion 5 AISI 4115 HRC56 58 AGMA11 (VXT7 XD VXT9 XD) Output Gear 6 AISI 4115 HRC54 56 AGMA7 (VXT2 XD VXT6 XD) Output Gear 6 AISI 4115 HRC54 56 AGMA11 (VXT7 XD VXT9 XD) 60

63 Vortex Shaft Mount Reducer Parts List This drawing does not represent every available reducer style. Different models may have slightly different parts and configurations. 9 8 Illustration G Shaft Mount Speed Reducer Parts Table 32 Shaft Mount Speed Reducer Parts List Part Description Part Description Number Number 1 Intermediate Shaft Bearing 22 Hollow Dowel 2 Intermediate Shaft and Pinion 23 Back Housing Half 3 Intermediate Gear Key 24 Housing Lock Washer 4 Intermediate Gear 25 Housing Nut 5 Intermediate Shaft Bearing 26 Output Hub Bearing 6 Backstop Cover Gasket 27 Output Hub 7 Backstop Cover 28 Output Gear Key 8 Cover Lock Washer 29 Output Gear 9 Cover Bolt 30 Output Hub Bearing Cover Gasket 10 Housing Bolt 31 Input Shaft Bearing 11 Breather Plug 32 Input Shaft Spacer 12 Intermediate Bearing Cover 33 Input Shaft and Pinion 13 Oil Plug 34 Input Shaft Square Key 14 Output Hub Bearing Cover 35 Input Shaft Snap Ring 15 Output Hub Oil Seal 36 Input Shaft Bearing 16 Output Hub Collar 37 Input Shaft Bearing Cover Gasket 17 Output Hub Snap Ring 38 Input Shaft Bearing Cover 18 Bushing 39 Input Shaft Oil Seal 19 Washer 40 Intermediate Bearing Cover Gasket 20 Screw 41 Intermediate Bearing Cover 21 Front Housing Half 61

64 VXT2 XD Dimensions XD Style Speed Reducer (AGMA Size 115) MAXIMUM MINIMUM DISTANCE FOR BUSHING SCREW REMOVAL MINIMUM MAXIMUM Reducer Exact Maximum Weight Unit Ratio Output (pounds) RPM VXT215 XD 14.04: VXT225 XD 23.37: /16 BOLT 3.00 Output Hub Tapered Bushings (Other bushing sizes available by special order) Included Torque Arm Bushing Kit Shaft Keyseat Weight Number Required (pounds) (bore diameter) (inches) XBK2 1-5/16* 5/16 x 5/32 x 6-11/ XBK2 1-3/8* 5/16 x 5/32 x 6-11/ XBK2 1-7/16* 3/8 x 3/16 x 6-11/ XBK2 1-1/2* 3/8 x 3/16 x 6-11/ XBK2 1-5/8* 3/8 x 3/16 x 6-11/ XBK2 1-11/16 3/8 x 3/16 x 6-11/ XBK2 1-3/4 3/8 x 3/16 x 6-11/ XBK2 1-15/16 1/2 x 1/4 x 6-11/ Notes: * Check the driven shaft and key for adequate load capacity. Torque Arm Weight Kit (pounds) Number 2TA 4 62

65 VXT2 XD Accessories Motor Mount MAXIMUM MINIMUM 5/8 x 7.00 STUD REDUCER OUTPUT HUB CENTERLINE 3.38 REDUCER INPUT SHAFT 4.18 Motor Mount NEMA Weight Kit Motor (pounds) Number Frame 2MMA 56T 215T 37 V-Belt Center Distance For NEMA Frame Motors Minimum Maximum Backstop Cooling Fan Repair Kit (bearings, gaskets, shims and seals) Backstop 2BKS Cooling Fan Kit 2CFK Component Replacement Repair Kit 2RK Screw Conveyor Adapter Kits (flange, shaft, and shaft removal kits sold individually) Output Shaft Diameter Options (inches) Screw Conveyor Flange 2SCF Screw Conveyor Drive Shaft 2SCDS 1-1/ /16 3 Screw Conveyor Shaft Removal Wedge 2SCRW 63

66 VXT3 XD Dimensions XD Style Speed Reducer (AGMA Size 203) MAXIMUM MINIMUM DISTANCE FOR BUSHING SCREW REMOVAL MINIMUM MAXIMUM Reducer Exact Maximum Weight Unit Ratio Output (pounds) RPM VXT315 XD 14.87: VXT325 XD 24.75: /16 BOLT 3.00 Output Hub Tapered Bushings (Other bushing sizes available by special order) Included Torque Arm Bushing Kit Shaft Keyseat Weight Number Required (pounds) (bore diameter) (inches) XBK3 1-11/16* 3/16 x 3/16 x 8-1/ XBK3 1-3/4* 3/16 x 3/16 x 8-1/ XBK3 1-7/8* 1/2 x 1/4 x 8-1/ XBK3 1-15/16 1/2 x 1/4 x 8-1/ XBK3 2 1/2 x 1/4 x 8-1/ XBK3 2-3/16 1/2 x 1/4 x 8-1/ Torque Arm Weight Kit (pounds) Number 3TA 7 Notes: * Check the driven shaft and key for adequate load capacity. 64

67 VXT3 XD Accessories Motor Mount MAXIMUM MINIMUM 5/8 x 7.00 STUD REDUCER OUTPUT HUB CENTERLINE 4.25 REDUCER INPUT SHAFT 4.88 Motor Mount NEMA Weight Kit Motor (pounds) Number Frame 3MMA 56T 215T 38 V-Belt Center Distance For NEMA Frame Motors Minimum Maximum Backstop Cooling Fan Repair Kit (bearings, gaskets, shims and seals) Backstop 3BKS Cooling Fan Kit 3CFK Component Replacement Repair Kit 3RK Screw Conveyor Adapter Kits (flange, shaft, and shaft removal kits sold individually) Output Shaft Diameter Options (inches) Screw Conveyor Flange 3SCF Screw Conveyor Drive Shaft 3SCDS 1-1/ /16 3 Screw Conveyor Shaft Removal Wedge 3SCRW 65

68 VXT4 XD Dimensions XD Style Speed Reducer (AGMA Size 207) MAXIMUM MINIMUM DISTANCE FOR BUSHING SCREW REMOVAL MINIMUM MAXIMUM Reducer Exact Maximum Weight Unit Ratio Output (pounds) RPM VXT415 XD 15.13: VXT425 XD 24.38: /2 BOLT HOLES 4.00 Output Hub Tapered Bushings (Other bushing sizes available by special order) Included Torque Arm Bushing Kit Shaft Keyseat Weight Number Required (pounds) (bore diameter) (inches) XBK4 1-15/16* 1/2 x 1/4 x 9-1/ XBK4 2* 1/2 x 1/4 x 9-1/ XBK4 2-1/8* 1/2 x 1/4 x 9-1/ XBK4 2-3/16* 1/2 x 1/4 x 9-1/ XBK4 2-1/4* 1/2 x 1/4 x 9-1/ XBK4 2-7/16 5/8 x 5/16 x 9-1/ Torque Arm Weight Kit (pounds) Number 4TA 10 Notes: * Check the driven shaft and key for adequate load capacity. 66

69 VXT4 XD Accessories Motor Mount MAXIMUM MINIMUM 3/4 x 8.00 STUD REDUCER OUTPUT HUB CENTERLINE 4.63 REDUCER INPUT SHAFT 6.13 Motor Mount NEMA Weight Kit Motor (pounds) Number Frame 4MMA 143T 286T 75 V-Belt Center Distance For NEMA Frame Motors Minimum Maximum Backstop Cooling Fan Repair Kit (bearings, gaskets, shims and seals) Backstop 4BKS Cooling Fan Kit 4CFK Component Replacement Repair Kit 4RK Screw Conveyor Adapter Kits (flange, shaft, and shaft removal kits sold individually) Output Shaft Diameter Options (inches) Screw Conveyor Flange 4SCF Screw Conveyor Drive Shaft 4SCDS 1-1/ / /16 Screw Conveyor Shaft Removal Wedge 4SCRW 67

70 VXT5 XD Dimensions XD Style Speed Reducer (AGMA Size 215) MAXIMUM MINIMUM DISTANCE FOR BUSHING SCREW REMOVAL MINIMUM MAXIMUM Reducer Exact Maximum Weight Unit Ratio Output (pounds) RPM VXT515 XD 15.40: VXT525 XD 25.56: /2 BOLT 4.00 Output Hub Tapered Bushings (Other bushing sizes available by special order) Included Torque Arm Bushing Kit Shaft Keyseat Weight Number Required (pounds) (bore diameter) (inches) XBK5 1-5/16* 1/2 x 1/4 x 9-3/ XBK5 1-3/8* 1/2 x 1/4 x 9-3/8 9.2 XBK5 1-7/16* 5/8 x 5/16 x 9-3/8 8.5 XBK5 1-1/2* 5/8 x 5/16 x 9-3/8 8.5 XBK5 1-5/8* 5/8 x 5/16 x 9-3/8 7.9 XBK5 1-11/16 5/8 x 5/16 x 9-3/8 7.8 Torque Arm Weight Kit (pounds) Number 5TA 11 Notes: * Check the driven shaft and key for adequate load capacity. 68

71 VXT5 XD Accessories Motor Mount MAXIMUM MINIMUM 3/4 x 8.00 STUD REDUCER OUTPUT HUB CENTERLINE 4.13 REDUCER INPUT SHAFT 6.65 Motor Mount NEMA Weight Kit Motor (pounds) Number Frame 5MMA 143T 286T 76 V-Belt Center Distance For NEMA Frame Motors Minimum Maximum Backstop Cooling Fan Repair Kit (bearings, gaskets, shims and seals) Backstop 5BKS Cooling Fan Kit 5CFK Component Replacement Repair Kit 5RK Screw Conveyor Adapter Kits (flange, shaft, and shaft removal kits sold individually) Output Shaft Diameter Options (inches) Screw Conveyor Flange 5SCF Screw Conveyor Drive Shaft 5SCDS 2 2-7/ /16 Screw Conveyor Shaft Removal Wedge 5SCRW 69

72 VXT6 XD Dimensions XD Style Speed Reducer (AGMA Size 307) MAXIMUM MINIMUM DISTANCE FOR BUSHING SCREW REMOVAL MINIMUM MAXIMUM Reducer Exact Maximum Weight Unit Ratio Output (pounds) RPM VXT615 XD 15.33: VXT625 XD 25.14: /8 BOLT 4.75 Output Hub Tapered Bushings (Other bushing sizes available by special order) Included Torque Arm Bushing Kit Shaft Keyseat Weight Number Required (pounds) (bore diameter) (inches) XBK6 2-1/2* 5/8 x 5/16 x 10-11/ XBK6 2-11/16* 3/4 x 3/8 x 10-11/ XBK6 2-7/8* 3/4 x 3/8 x 10-11/ XBK6 2-15/16* 3/4 x 3/8 x 10-11/ XBK6 3* 3/4 x 3/8 x 10-11/ XBK6 3-7/16 7/8 x 7/16 x 10-11/ Torque Arm Weight Kit (pounds) Number 6TA 23 Notes: * Check the driven shaft and key for adequate load capacity. 70

73 VXT6 XD Accessories Motor Mount MAXIMUM MINIMUM 3/4 x 8.00 STUD REDUCER OUTPUT HUB CENTERLINE 4.50 REDUCER INPUT SHAFT 7.31 Motor Mount NEMA Weight Kit Motor (pounds) Number Frame 6MMA 143T 326T 99 V-Belt Center Distance For NEMA Frame Motors Minimum Maximum Backstop Cooling Fan Repair Kit (bearings, gaskets, shims and seals) Backstop 6BKS Cooling Fan Kit 6CFK Component Replacement Repair Kit 6RK Screw Conveyor Adapter Kits (flange, shaft, and shaft removal kits sold individually) Output Shaft Diameter Options (inches) Screw Conveyor Flange 6SCF Screw Conveyor Drive Shaft 6SCDS 1-1/ /16 3 Screw Conveyor Shaft Removal Wedge 6SCRW 71

74 VXT7 XD Dimensions XD Style Speed Reducer (AGMA Size 315) MAXIMUM MINIMUM DISTANCE FOR BUSHING SCREW REMOVAL MINIMUM MAXIMUM Reducer Exact Maximum Weight Unit Ratio Output (pounds) RPM VXT715 XD 15.14: VXT725 XD 25.35: /8 BOLT 4.75 Output Hub Tapered Bushings (Other bushing sizes available by special order) Included Torque Arm Bushing Kit Shaft Keyseat Weight Number Required (pounds) (bore diameter) (inches) XBK7 2-15/16* 3/4 x 3/8 x 11-27/ XBK7 3* 3/4 x 3/8 x 11-27/ XBK7 3-3/16* 3/4 x 3/8 x 11-27/ XBK7 3-15/16 7/8 x 7/16 x 11-27/ XBK7 3-15/16 1 x 1/2 x 11-27/ Torque Arm Weight Kit (pounds) Number 7TA 37 Notes: * Check the driven shaft and key for adequate load capacity. 72

75 VXT7 XD Accessories Motor Mount MAXIMUM MINIMUM 1 x 9.00 STUD REDUCER OUTPUT HUB CENTERLINE 4.75 REDUCER INPUT SHAFT 7.81 Motor Mount NEMA Weight Kit Motor (pounds) Number Frame 7MMA 143T 365T 110 V-Belt Center Distance For NEMA Frame Motors Minimum Maximum Backstop Cooling Fan Repair Kit (bearings, gaskets, shims and seals) Backstop 7BKS Cooling Fan Kit 7CFK Component Replacement Repair Kit 7RK Screw Conveyor Adapter Kits (flange, shaft, and shaft removal kits sold individually) Screw Conveyor Flange Screw Conveyor Drive Shaft Output Shaft Diameter Options (inches) Screw Conveyor Shaft Removal Wedge Not Available Not Available Not Available Not Available 73

76 VXT8 XD Dimensions XD Style Speed Reducer (AGMA Size 407) MAXIMUM 2.06 MINIMUM DISTANCE FOR BUSHING SCREW REMOVAL MINIMUM MAXIMUM 7.00 Reducer Exact Maximum Weight Unit Ratio Output (pounds) RPM 3/4 BOLT VXT815 XD 14.79: VXT825 XD 24.33: Output Hub Tapered Bushings (Other bushing sizes available by special order) Included Torque Arm Bushing Kit Shaft Keyseat Weight Number Required (pounds) (bore diameter) (inches) XBK8 2-15/16* 3/4 x 3/8 x 13-1/ XBK8 3-7/16* 7/8 x 7/16 x 13-1/ XBK8 3-15/16 1 x 1/2 x 13-1/ XBK8 4-3/16 1 x 1/2 x 13-1/ XBK8 4-7/16 1 x 1/2 x 13-1/ Torque Arm Weight Kit (pounds) Number 8TA 37 Notes: * Check the driven shaft and key for adequate load capacity. 74

77 VXT8 XD Accessories Motor Mount MAXIMUM MINIMUM REDUCER OUTPUT HUB CENTERLINE Motor Mount NEMA Weight Kit Motor (pounds) Number Frame 8MMA 213T 365T 119 V-Belt Center Distance For NEMA Frame Motors Minimum Maximum Backstop Cooling Fan Repair Kit (bearings, gaskets, shims and seals) Backstop 8BKS Cooling Fan Kit 8CFK Component Replacement Repair Kit 8RK Screw Conveyor Adapter Kits (flange, shaft, and shaft removal kits sold individually) Screw Conveyor Flange Screw Conveyor Drive Shaft Output Shaft Diameter Options (inches) Screw Conveyor Shaft Removal Wedge Not Available Not Available Not Available Not Available 75

78 VXT9 XD Dimensions XD Style Speed Reducer (AGMA Size 415) MAXIMUM 2.44 MINIMUM DISTANCE FOR BUSHING SCREW REMOVAL MINIMUM MAXIMUM 7.00 Reducer Exact Maximum Weight Unit Ratio Output (pounds) RPM 3/4 BOLT VXT915 XD 15.12: VXT925 XD 25.66: Output Hub Tapered Bushings (Other bushing sizes available by special order) Included Torque Arm Bushing Kit Shaft Keyseat Weight Number Required (pounds) (bore diameter) (inches) XBK9 3-7/16* 7/8 x 7/16 x 12-15/ XBK9 3-15/16* 1 x 1/2 x 12-15/ XBK9 4-7/16 1 x 1/2 x 12-15/ XBK9 4-15/16 1-1/4 x 5/8 x Torque Arm Weight Kit (pounds) Number 9TA 55 Notes: * Check the driven shaft and key for adequate load capacity. 76

79 VXT9 XD Accessories Motor Mount MAXIMUM MINIMUM REDUCER OUTPUT HUB CENTERLINE Motor Mount NEMA Weight Kit Motor (pounds) Number Frame 9MMA 213T 365T 120 V-Belt Center Distance For NEMA Frame Motors Minimum Maximum Backstop Cooling Fan Repair Kit (bearings, gaskets, shims and seals) Backstop 9BKS Cooling Fan Kit 9CFK Component Replacement Repair Kit 9RK Screw Conveyor Adapter Kits (flange, shaft, and shaft removal kits sold individually) Screw Conveyor Flange Screw Conveyor Drive Shaft Output Shaft Diameter Options (inches) Screw Conveyor Shaft Removal Wedge Not Available Not Available Not Available Not Available 77

80 Lubrication Basics The function of lubricant Lubricants in gear applications minimize friction between mating surfaces and transfer heat away from the contact area. Lubricant can also serve as a medium to carry any additives required for special functions. Lubricant installed in a reducer serves not only the gearing, but the bearings and seals. Therefore, when selecting a lubricant, consider the requirements of all associated components. Lubrication classifications Each class of lubricant (listed below) is unique and intended for use in specific applications. Lubricant properties vary depending on the source of their base stocks and the type of additives used. The physical properties of a lubricant are largely determined by the base stock from which it was made. Rust and oxidation inhibited lubricants [R & O] R & O lubricants are formulated with highly refined petroleum-based oils. They contain additives that enhance oxidation stability. These additives provide corrosion protection, and suppress foam. While the superior oxidation stabilities set them apart, their load-carrying capabilities may be less than others. R & O lubricant is typically used in higher speed and lighter load applications. Extreme pressure lubricants [EP] Formulated with refined petroleum or synthetic base oils, EP lubricants contain additives which provide protection against wear and scuffing. These lubricants were developed to protect geared systems operating at high loads and severe impact or reversal conditions. They are generally used in ISO viscosity grades of 150 and above. Sulfur phosphorus EP lubricant is typically used in severe duty applications. Since the EP additives can prevent proper operation of a backstop, do not use EP lubricants in a reducer equipped with a backstop. Compounded lubricants [CP] Compounded gear lubricants are a blend of petroleum base oils with three to ten percent of natural or synthetic fatty oils. These lubricants have high film strength that protects sliding or rubbing components. CP lubricants perform well in worm gear reducers. Synthetic lubricants [S] Polyalphaolefin type synthetic lubricants are best used in extreme ambient or operating temperatures. Synthetic lubricants are generally more expensive than petroleum-based lubricants, but provide extended oil change intervals. Synthetic lubricant performs well in reducers equipped with backstops. Pour point The pour point is the minimum temperature at which a lubricant will pour or flow. Petroleum-based lubricants installed in a speed reducer must have a pour point at least 10 F (5.5 C) below the expected minimum ambient starting temperature. Consult the lubricant manufacturer if using a petroleum-based or synthetic lubricant not listed in Tables 35 and 36 (pages 82 and 83). Cautions and warnings Do not use EP lubricants or lubricants with anti wear additives in reducers equipped with backstops These additives include: sulfur, phosphorus, chlorine, lead derivatives, graphite or molybdenum disulfides. Synthetic lubricants of the polyalphaolefin type are recommended for use in reducers equipped with backstops. Lubricants in food processing applications Many lubricants contain toxic substances and should not be used in the food processing industry. Lubricants which meet USDA H1 classification are suitable for food processing applications. 78

81 Viscosity Basics Viscosity Viscosity (or fluidity) is the most important property of a lubricant. Viscosity is the measure of the lubricant flow rate at a specific temperature. The higher the flow rate, the lower the viscosity. Stating an oil s viscosity is meaningless unless the temperature of the oil is defined. Typically, the viscosity is reported at one of two temperatures, either 104 F (40 C) or 212 F (100 C). The viscosity of a lubricant decreases as temperature increases. The viscosity of a lubricant affects its ability to reduce friction. Generally, the lubricant with the lowest viscosity while still providing protection performs best. If the lubricant viscosity is too high (as in honey), it will require a large amount of energy to move it; if it is too low (as in water), the surfaces will rub and friction will increase. Absolute viscosity (or dynamic viscosity) Internal fluid friction is the resistance to flow of a lubricant. Absolute viscosity is the force required to overcome this friction at a specific temperature. This force is measured in poise [P], centipoise [cp], or using the English system, reyn [µ]. Kinematic viscosity Kinematics refers to the study of the motion of a body without consideration given to its mass. The absolute viscosity divided by the density of the lubricant is called kinematic viscosity. Lubricant kinematic viscosity is resistance to flow and shear due to gravity in other words, how quickly it pours. This force is typically measured in stokes [S] and centistokes [cs]; and in the English system as square inches per second and Saybolt Universal Seconds [SSU]. Water has a low viscosity, of 1-3 cs, and honey has a very high viscosity, usually 2,000-3,000 cs. Viscosity index (VI) Lubricant viscosity is affected by temperature. The Viscosity index (VI) is a numerical representation of the ability of a lubricant to maintain viscosity at higher temperatures. Two different oils could have the same viscosity at a starting temperature, but as the temperature increases the high VI oil would thin less and provide a higher viscosity at operating temperature. VI is measured in Saybolt Universal Seconds (SSU). Flow time is the SSU required for 60 milliliters of product to flow through the orifice of a Saybolt Universal Viscometer. See Illustration H (right). This is calculated based on known viscosities at 100 F (38 C) and 210 F (99 C). OIL BEING TESTED SAYBOLT TUBE Illustration H Saybolt Universal Viscometer TEMPERATURE REGULATOR HEATER THERMOMETER OIL BATH ORIFICE 60 MILLILITERS 79

82 Viscosity Basics Chart 1 Oil Viscosity Equivalency Chart 1. Viscosities can be related horizontally only. 2. Viscosities based on 96 viscosity index single grade oils. 3. SAE 75W, 80W, and 85W grade gear oils specified at low temperature. Equivalent viscosities for 100 F and 200 F are shown. 4. SAE 90, 140, and 250 grade gear oils specified at 100 F. 5. Each ISO viscosity grade number corresponds to the mid-point of viscosity range expressed in centistokes (cs) at 40 C. For example, a lubricant with an ISO grade of 32 has a viscosity within the range of , the mid-point of which is

83 Lubrication Selection Overview Vortex shaft mount reducers are shipped without oil. It is extremely important to add the proper amount of lubricant prior to operating a reducer. For most applications a high-grade petroleum-based rust and oxidation inhibited (R&O) gear oil is suitable. Under severe conditions EP oil can be used. EP lubricants contain friction modifiers that impair the function of backstops. If the reducer is equipped with an internal backstop, do not use an EP lubricant. Selection Step 1. Step 2. Step 3. Determine ambient air temperature For ambient temperatures of 50 F-125 F use Table 33 (below). For temperatures of 15 F-60 F use Table 34 (below) Determine ISO viscosity grade Use the table to determine the recommended viscosity grade based on the size and output speed of your reducer. Select a lubricant Use the ISO viscosity grade to select a lubricant that best suits your application. Make the selection from Table 35 or 36 (pages 82 or 83) Table 33 ISO Viscosity Grade Recommendation for Temperatures of 50 F to 125 F Output VXT2 VXT3 VXT4 VXT5 VXT6 VXT7 VXT8 VXT9 RPM XD XD XD XD XD XD XD XD Assumes auxiliary cooling where recommended in the catalog Table 34 ISO Viscosity Grade Recommendation for Temperatures of 15 F to 60 F Output VXT2 VXT3 VXT4 VXT5 VXT6 VXT7 VXT8 VXT9 RPM XD XD XD XD XD XD XD XD Assumes auxiliary cooling where recommended in the catalog 81

84 Petroleum Speed Reducer Lubricants Table 35 Recommended Petroleum-Based Gear Lubricants Ambient +15 to +60 F +30 to +100 F +50 to +125 F Temperature -9 to 16 C -1 to 38 C 10 to 52 C AGMA Viscosity Grade ISO Viscosity Grade Viscosity 100 F Kinematic Viscosity 40 C MANUFACTURER LUBRICANT LUBRICANT LUBRICANT Amoco Oil Co. Amer. Ind. Oil 150 Amer. Ind. Oil 220 Amer. Ind. Oil 320 Permagear/Amogear EP150 Permogear/Amogear EP 220 Permogear/Amogear EP 320 BP Oil Co. Turbinol T-150 Energol HLP-HD 220 Energear EP 150 Energear EP 220 Energear EP 320 Chevron U.S.A., Inc. Machine Oil AW 150 Machine Oil AW 220 Machine Oil AW 320 Gear Compounds EP 150 Gear Compounds EP 220 Gear Compounds EP 320 Citgo Petroleum Corp. Citgo Pacemaker 150 Citgo Pacemaker 220 Citgo Pacemaker 320 Citgo EP Compound 150 Citgo EP Compound 220 Citgo EP Compound 320 Conoco Inc. Dectol R&O Oil 150 Dectol R&O Oil 220 Dectol R&O Oil 320 Gear Oil 150 Gear Oil 220 Gear Oil 320 Exxon Company, U.S.A. Teresstic 150 Teresstic 220 Teresstic 320 Spartan EP 150 Spartan EP 220 Spartan EP 320 Houghton International, Inc. Hydro Drive HP 750 Hydro Drive HP 1000 MP Gear Oil 150 MP Gear Oil 220 MP Gear Oil 320 Imperial Oil Ltd. Teresso 150 Teresso 220 Teresso 320 Spartan EP 150 Spartan EP 220 Spartan EP 320 Keystone Lubricants KLC 40 KLC-50 Keygear 150 Keygear 220 Keygear 320 Lyondell Petrochemical (ARCO) Duro 150 Duro 220 Duro 320 Pennant NL 150 Pennant NL 220 Pennant NL 320 Mobil Oil Corp. DTE Oil Extra Heavy DTE Oil BB DTE Oil AA Mobilgear 150 Mobilgear 220 Mobilgear 320 Petro-Canada Products Harmony 150 or 150D Harmony 220 Harmony 320 Ultima EP 150 Ultima EP 220 Ultima EP 320 Phillips 66 Co. Magnus Oil 150 Magnus Oil 220 Magnus Oil 320 Philgear 150 Philgear 220 Philgear 320 Shell Oil Co. Morlina 150 Morlina 220 Morlina 320 Omala Oil 150 Omala Oil 220 Omala Oil 320 Shell Canada Limited Tellus 150 Tellus 220 Tellus 320 Omala Oil 150 Omala Oil 220 Omala Oil 320 Texaco Lubricants Regal Oil R&O 150 Regal Oil R&O 220 Regal Oil R&O 320 Meropa 150 Meropa 220 Meropa 320 Unocal 76 (East) Unax RX 150 Unax RX 220 Unax AW 320 Extra Duty NL Gear Lube 150 Extra Duty NG Gear Lube 220 Extra Duty NG Gear Lube 320 Unocal 76 (West) Turbine Oil 150 Turbine Oil 220 Turbine Oil 320 Extra Duty NL Gear Lube 150 Extra Duty NG Gear Lube 220 Extra Duty NG Gear Lube 320 Valvoline Oil Co. Valvoline AW ISO 150 Valvoline AW ISO 220 Valvoline AW ISO 3 AGMA EP 150 AGMA EP 220 AGMA EP 320 Minimum viscosity index of 90. Maximum operating temperature of lubricants is 200 F (93 C). Purple text indicates EP lubricant (contains sulfur-phosphorus). Do not use in drives equipped with an internal backstop. 82

85 Synthetic Speed Reducer Lubricants Table 36 Recommended Synthetic Lubricants Polyalphaolefin Type Ambient 30 to +10 F 15 to +50 F 0 to +80 F +10 to +125 F +20 to +125 F Temperature ( 34 to 12 C) ( 26 to +10 C) ( 18 to +27 C) ( 12 to +52 C)* ( 7 to +52 C) AGMA Viscosity Grade 0S 2S 4S 5S 6S ISO Viscosity Grade Viscosity 40 C Viscosity 100 F MANUFACTURER LUBRICANT LUBRICANT LUBRICANT LUBRICANT LUBRICANT Chevron U.S.A., Inc Clarity Synthetic PM Oil 220 Syn. Gear Lube Tegra 220 Conoco Inc. Syncon R & O 32 Syncon R & O 68 Syncon R & O 220 Syncon EP 68 Syncon EP 150 Syncon EP 220 Syncon EP 320 Dryden Oil Co. Dryden SHL Lubricant 32 Dryden SHL Lubricant 68 Dryden SHL Lubricant 150 Dryden SHL Lubricant 220 Dryden SHL Lubricant 32 Exxon Company, U.S.A. Teresstic SHP 32 Teresstic SHP 68 Teresstic SHP 150 Teresstic SHP 220 Teresstic SHP 220 Spartan Synthetic EP 150 Spartan Synthetic EP 220 Spartan Synthetic EP 320 Mobil Oil Corp. SHC 624 SHC 626 SHC 629 SHC 630 SHC 632 Mobilgear SHC 150 Mobilgear SHC 220 Mobilgear SHC 320 Pennzoil Products Co. Pennzgear SHD 32 Pennzgear SHD 68 Pennzgear SHD 150 Pennzgear SHD 220 Pennzgear SHD 320 Super Maxol S 68 Super Maxol S 150 Super Maxol S 220 Super Maxol S 320 Petro-Canada Products Super Gear Fluid 150EP Super Gear Fluid 220EP Shell Oil Co. Hyperia 220 Hyperia 320 Hyperia S 220 Hyperia S 320 Sun Co. Sunoco Challenge 220 Sunoco Challenge 320 Sunoco Challenge EP 220 Sunoco Challenge EP 320 Texaco Lubricants Co. Pinnacle 32 Pinnacle 68 Pinnacle 150 Pinnacle 220 Pinnacle 320 Pinnacle EP 150 Pinnacle EP 220 Whitmore Manufacturing Co. Decathlon 4EP Decathlon 5EP Decathlon 6EP Minimum viscosity index of 130. Consult lubricant supplier/manufacturer for maximum operating temperature. Purple text indicates EP lubricant (contains sulphur-phosphorus). Do not use in a reducer equipped with an internal backstop. * Reducers NOT equipped with internal backstop may widen the ambient temperature range to -25 to +125 F (-32 to 52 C). Minimum viscosity index of

86 Lubrication Maintenance Lubricant changes Initial operation After an initial operation of 100 hours (about one to two weeks), the oil should be changed. This oil may be filtered and reused. Past the initial break-in period see oil the change recommendations below. Typical change interval for petroleum lubricants Under normal operating conditions, change gear lubricants every six months or 2,500 operating hours, whichever occurs first. If the drive is operated in an area where temperatures vary with the seasons, change the oil viscosity grade to suit the temperature, refer to Tables 33 and 34 (page 81). Typical change interval for synthetic lubricants Synthetic lubricant changes can be extended to 8,000 working hours depending upon operating conditions. Laboratory analysis is recommended for optimum lubricant life and drive performance. Change lubricant viscosity if required by seasonal temperatures. Refer to Tables 33 and 34 (page 81). Oil Change Recommendations At every oil change, drain the reducer, clean the magnetic drain plug, and refill the reducer with new lubricant. Obtain an oil analysis report from your lubricant supplier at regular intervals. The oil should be changed when any of the following conditions exist: 1. Water content is greater than 500 parts per million (ppm), 2. Iron content exceeds 150 ppm, 3. Silicon (dust/dirt) exceeds 25 ppm, 4. Calcium content 50 ppm above normal lubricant amount, 5. Viscosity changes more than 15%. Special Conditions Check the lubricant more frequently when any of the following conditions exist: 1. High operating temperatures caused by heavy intermittent loads, particularly where the temperature of the gear case rises rapidly, then cools, 2. An unusually humid atmosphere or any other condition that would tend to cause condensation on the inside of the gear case which might contaminate the oil, 3. Operating conditions which cause the lubricant to reach temperatures near 200 F (93 C) for extended periods, 4. An extremely dusty or dirty environment. Oil level inspections Reducer oil levels should be inspected often to ensure that the reducer maintains adequate lubrication. One solid oil plug serves as an oil level indicator. This plug is determined by the mounting position of the reducer. See pages Removing this plug will allow you to view and ensure the level of the oil within the reducer. Always inspect the oil level when the reducer is not running. The oil should be cool and lack foam or bubbles before performing an inspection. Non-standard mounting positions may make oil level indicator use difficult. See pages 87 and 88 for more information on angular tilt limits and their effect on oil level indicators. 84

87 Ratio 25 : # Batch VXT325 # Part Lubricant Fill Volumes Table 37 Approximate Volume of Oil Required to Fill a Reducer (Running At 15+ RPM Output in a Standard Mounting Position) Unit Size Position A Position B Position C Position D Position E Position F Quarts Liters Quarts Liters Quarts Liters Quarts Liters Quarts Liters Quarts Liters VXT2 XD VXT3 XD VXT4 XD VXT5 XD VXT6 XD VXT7 XD VXT8 XD VXT9 XD Notes: 1. Oil quantity is approximate. Fill with lubricant until oil reaches the oil level indicator plug. See Illustration J (page 86). 2. Refer to Illustration I (below) for standard mounting positions A, B, C, D, E, and F. 3. Below 15 RPM output speed, additional oil is required to reach the elevated oil level indicator. See Illustration K (page 87). 4. If the reducer position differs from the positions shown below, oil volumes may vary. Consult Vortex engineering. 5. If equipped with a backstop, mounting positions C and D will need more oil than listed above. Backstops do not have rolling elements but must slide on the shaft, therefore the input shaft must stay lubricated. Increase the oil within the reducer until it submerges half of the input shaft. This increased oil quantity may reduce the thermal capacity of the reducer. It is recommended that you monitor the reducer for signs of overheating. Illustration I Standard Mounting Positions Horizontal Mounting Positions: Position A Position B Position C Position D Vertical Mounting Positions: Part # VXT325 Batch # Ratio 25 : 1 Position E Position F 85

88 Housing Plug Installation Overview Vortex reducers are supplied with six solid housing plugs installed. Also included with the reducer is one breather plug and one magnetic drain plug. These plugs are identically sized so as to be interchangeable. See Table 38 (right) for information on housing plug thread specifications. B D P L Breather Magnetic Drain Solid Plug Solid Plug (to function as oil level indicator) Before removing solid plugs for breather or drain plug installation, determine the running position of the reducer. For horizontal mounting positions (A-D), see below. For vertical mounting positions (E and F), skip to page 88. Housing plug installation for horizontal mounting positions Determine the output speed of the reducer If the output speed is: 15 RPM and above, refer to Illustration J (below) Below 15 RPM, refer to Illustration K (page 87) Table 38 Housing Plug Thread Specifications Unit Size VXT2 XD VXT3 XD VXT4 XD VXT5 XD VXT6 XD VXT7 XD VXT8 XD VXT9 XD Determine the mounting position of the reducer Illustrations J (below) and K (page 87) show the standard horizontal mounting positions A, B, C, and D. Reducers with output speeds 15 RPM and above Install the magnetic drain plug in the threaded hole closest to the bottom of the reducer. Install the breather plug in the topmost threaded hole. The lowest threaded hole on the side of the reducer will function as an oil level indicator. Install solid plugs in the remaining threaded holes. See Illustration J (below). Reducers with output speeds of less than 15 RPM Install the magnetic drain plug in the threaded hole closest to the bottom of the reducer. Install the breather plug in the topmost threaded hole. The highest remaining threaded hole on the side of the reducer will function as an oil level indicator. Install solid plugs in the remaining threaded holes. See Illustration K (page 87). Illustration J Plug Locations for Horizontal Mounting Positions (Output Speeds of 15 RPM and Above) Thread Type and Size BSPT-1/4" BSPT-1/4" BSPT-3/8" BSPT-1/2" BSPT-1/2" BSPT-1/2" BSPT-3/4" BSPT-3/4" The BSPT (British Standard Pipe Thread) is not compatible with the NPT (National Pipe Thread) common in the US. [one additional solid plug on opposite side of housing is not shown] P P B front housing half B P B P B P input shaft D Mounting Position A hollow shaft L D Mounting Position B L D Mounting Position C L D Mounting Position D L 86

89 Ratio 25 : # Batch VXT325 # Part Part # VXT325 [one additional solid plug on opposite side of housing is not shown] L P B front housing half Illustration K Plug Locations for Horizontal Mounting Positions (For Output Speeds Under 15 RPM) B L B L B L P input shaft D hollow shaft P D P D P D Mounting Position A Mounting Position B Mounting Position C Mounting Position D Angular tilt limits for horizontal mounting positions Horizontal mounting positions have two types of angular tilt limits to consider: rotational and incline. Because the running position of the reducer is not limited to positions A, B, C, or D, it is sometimes necessary to make special adaptations for checking oil levels. If the mounting position is rotationally tilted more than: ±20 in positions B and D or ±5 in positions A and C or, if the mounting position is incline tilted more than: ±5 in any position additional oil may be required. For output speeds under 15 RPM, ensure that the oil level reaches 50% of the lowest rolling element on the highest bearing. For output speeds above 15 RPM, ensure that the input pinion or output gear is at least 50% submerged in oil. This increased oil quantity may reduce the thermal capacity of the reducer. It is recommended that you monitor the reducer for signs of overheating. To ensure the ability to accurately check the oil level, install the reducer within the tilt limits. Illustration L Maximum Rotational Tilt For Accurate Oil Level Indicator Use -20 Max +20 Max -20 Max +20 Max +5 Max +5 Max -5 Max -5 Max Mounting Position A Mounting Position B Mounting Position C Mounting Position D Illustration M Maximum Incline Tilt For Accurate Oil Level Indicator Use -5 Max Ratio 25 : # Batch VXT325 # Part Ratio 25 : B # atch +5 Max For All Mounting Horizontal Positions 87

90 Ratio 25 : # Batch VXT325 # Part Ratio 25 : # Batch VXT325 # Part Ratio 25 : # Batch VXT325 # Part Ratio 25 : # Batch VXT325 # Part Ratio 25 : # Batch VXT325 # Part Housing Plug Installation Housing plug installation for vertical mounting positions Determine the mounting position of the reducer The preferred mounting positions E and F are shown in Illustration N (below). Reducer output speeds The quantity of the lubricant required and location of plugs for vertically mounted reducers are the same regardless of the output speed. Housing plug installation Install the breather plug in the hole provided in the top face of the housing. Install the magnetic drain plug in the bottom of the housing. The threaded hole in side of the upper half of the housing will function as an oil level indicator. Use solid plugs in the remaining threaded holes of the housing. Angular tilt limits for vertical mounting positions Consider the incline tilt if a unit is mounted vertically. Because the running position of the reducer is not limited to positions E or F, it is sometimes necessary to make special adaptations for checking oil levels. Illustration N Vertical Mounting Positions B L B L P D Mounting Position E P D Mounting Position F If the vertical mounting position is incline tilted more than ±1 the oil indicator plug should not be used to check the oil level. To ensure the ability to accurately check the oil level, install the reducer within the tilt limits. Illustration O Maximum Incline Tilt For Accurate Oil Level Indicator Use +1 Max -1 Max Ratio 25 : # Batch VXT325 # Part -1 Max +1 Max Mounting Position E Mounting Position F 88

91 Reducer Installation Overview A bushing kit is required to mount the reducer on the driven shaft. See pages for information on available bushing kits by reducer size. A bushing kit consists of two tapered bushings, shaft keys, bolts, and washers. The driven shaft must extend through the full length of the reducer. The minimum shaft length, as measured from the end of the shaft to the outer edge of the bushing flange, is given in Table 39 (below). See Illustration P (below). This dimension does not include distance A. Distance A should be added to the minimum shaft length to allow for the removal of the bushings at disassembly. WARNING: Do not apply anti-seize lubricant to bores, tapered surfaces, or bolt threads of bushings; this will void any and all warranties. The use of anti-seize compounds may allow excessive pressure on the output hub and result in damage to the reducer. Installation instructions Step 1. Step 2. Step 3. Step 4. Slide the first bushing, flange end first, onto the driven shaft. Position the bushing no less than distance A from the equipment, as shown in Table 39 (below). This will allow enough room for both the bolts to be threaded into the bushing, and for their removal. If the reducer must be positioned closer to the equipment than distance A, place the bolts, with washers installed, into the unthreaded holes of the bushing flange prior to placing the bushing on the shaft. Maintain at least 1/8 between the bolt heads and the equipment. CAUTION: This type of assembly is not easily removed. Install the key in the driven shaft and bushing. For ease of installation, rotate the driven shaft so that the shaft keyseat is at the top position. Mount the reducer on the driven shaft. Align the shaft key with the hub keyway. Maintain the recommended minimum distance A from the shaft bearing. Install bushing bolts. Insert the bolts, with washers installed, through the unthreaded holes in the bushing flange. Align the bolts with the threaded holes of the output hub collar. Tighten the bolts lightly. (See Steps 5 through 9 on the next page.) Illustration P Minimum Recommended Dimensions Minimum Required Shaft Length Table 39 Minimum Mounting Dimensions Minimum A Unit Required Minimum Size Shaft Clearance Length for Removal VXT2 XD 7-7/16 1-1/4 VXT3 XD 9-3/8 1-1/2 VXT4 XD 10-5/16 1-3/4 VXT5 XD 10-7/8 1-13/16 VXT6 XD 11-3/4 1-13/16 VXT7 XD 13-3/8 2-1/16 VXT8 XD 14-9/16 2-1/16 VXT9 XD 14-3/4 2-7/16 Table 40 Bushing Bolt Information A Unit Fastener Max Torque Size Size In (UNC) Foot-Pounds VXT2 XD 5/ VXT3 XD 3/ VXT4 XD 3/ VXT5 XD 7/ VXT6 XD 7/ VXT7 XD 1/ VXT8 XD 1/ VXT9 XD 5/

92 Reducer Installation Installation instructions (continued) Step 5. Slide the second bushing, tapered end first, onto the driven shaft. Align the bushing keyway with the shaft key. Repeat Step 4 to secure this second bushing. Step 6. Step 7. Step 8. Tighten bushing bolts. Alternately tighten the bolts in the bushing nearest the equipment. Repeat procedure on the outer bushing. See Table 46 (page 108) for recommended torque values. Install sheave on input shaft as close to reducer as practical. See Illustration Q (to the right). Install motor and v-belt drive. When using the torque arm for belt tensioning, the angle between the center line of the input and output shafts should be 90 from the center line of the belt drive. See Illustration R (below). Input Shaft Illustration Q Reducer and Sheave Installation Keep Minimum Clearance For Removal Driven Shaft Step 9. Install the torque arm mounting brackets. The mounting brackets can be installed on any two bolts along the input end of the reducer. Remove the selected housing bolts and position the mounting brackets. Reinstall and tighten the housing bolts. Sheave Keep as close as practical Illustration R Angle of V-Belt Drive Driven Shaft Input Shaft 90 (±20 ) V-Belt Drive May Be Located On Either Side 90

93 Step 10. Step 11. Secure the anchor of the torque arm to a flat and rigid surface. When using the torque arm for belt tensioning, the torque arm should also run at 90º of the center line of the input and output shafts. See Illustration T (below). If necessary, the location can vary ±20. Make sure that the turnbuckle is in an accessible position to allow for belt tensioning. Fill the reducer with oil. Vortex reducers are shipped without oil. Before operating, fill the reducer with the amount of lubricant recommended in Table 37 (page 85). Removing the reducer from the shaft Step 1. Remove bushing bolts. Step 2. Step 3. Step 4. Place the bolts in the threaded holes provided in the bushing flange. Tighten the bolts alternately and evenly until the bushings are free on the shaft. Remove the outboard bushing, the reducer, key(s), and inboard bushing. See Illustration S (right). Illustration S Inboard and Outboard Bushings Outboard Bushing Inboard Bushing Note: If the reducer was installed closer to machinery than recommended (page 89), loosen the inboard bushing bolts until they are clear of the hub collar by 1/8. Place two wedges, at 180 degrees, between the bushing flange and output hub collar. Drive the wedges alternately and evenly until the bushing is free on the shaft. Illustration T Angle of Torque Arm Driven Shaft Input Shaft Torque Arm Mounting Bracket 90 (±20 ) Torque Arm Anchor Torque Arm May Be Located On Either Side 91

94 Backstop Installation Precautions Do not use EP lubricants or lubricants containing additives such as graphite or molybdenum disulphide in a reducer equipped with a backstop. The use of EP lubricant will cause a backstop to fail. Installation instructions Step 1. Remove input power. To prevent injury, turn off, lock out, and tag the power source before beginning the installation of a backstop. Step 2. Remove the backstop cover plate. This plate is directly opposite of the input shaft. See part #7 (page 61) for more information on the plate location. Step 3. Step 4. Step 5. Match the arrow on the backstop to the rotation direction of the input shaft. The input shaft will only rotate in the same direction as the arrow on the installed backstop. The input shaft direction will be the same as the desired output hub direction. Install large snap ring (VXT9 XD only). Place the large snap ring in the inside diameter of the carrier. See Illustration U (below). Insert the backstop. Lightly coat the outside diameter of the backstop with machine oil. This will help when rotating the backstop for the key s installation. Slowly rotate the reducer s input shaft in same direction as arrow on backstop. Without removing the cardboard retainer from the backstop, push backstop onto the input shaft. The retainer will be pushed out automatically as backstop is pressed into the reducer. The retainer can be kept for future use. Do not hammer on the backstop when installing. If necessary, the backstop may be tapped gently. Table 41 Backstop Catalog Numbers Unit Size Backstop Catalog Number Illustration U Snap Ring Installation on VXT9 XD Reducers Bearing VXT2 XD VXT3 XD VXT4 XD VXT5 XD VXT6 XD VXT7 XD VXT8 XD VXT9 XD 2BKS 3BKS 4BKS 5BKS 6BKS 7BKS 8BKS 9BKS Input Shaft (Part #33) Back stop Backstop Cover (Part #7) Large Snap Ring (VXT9 XD Only) 92

95 Step 6. Step 7. Step 8. Step 9. Insert keys. Some backstops require two keys on the input shaft. Some only require one. Line up the keyways between the backstop and the input shaft. Install the key(s). Some backstops have two different key lengths, Use the longer key(s) for the shaft keyseat. Insert the last key between the housing and the backstop outside diameter. Install small snap ring (VXT6 XD only). Place the ring in the groove of the input shaft. See Illustration V (below). Replace the gasket, cover plate, screws, and lock washers. Be sure that the cover plate does not bind the backstop. Ensure backstop lubrication. When the input shaft will be located higher than the output shaft, the oil level within the reducer should be increased. See Table 37, Note 5 (page 85) for more information. If this increased amount of oil is not an option, putting some non-ep grease in the backstop and cover plate will help lubricate the backstop. Removal Instructions Step 1 Remove or block all external loads. Turn off, lock out, and tag the power source. Step 2 Remove backstop cover, part #7 (page 61). Step 3 Step 4 If present, remove snap ring from the end of the input shaft Insert a tool, such as a flat-head screw driver, in the groove around the outside diameter of the backstop. Slowly pry the backstop from the housing while inserting a cardboard retainer into the inside diameter of the backstop to hold the sprags in place. Illustration V Snap Ring Installation on VXT6 XD Reducers Bearing Input Shaft (Part #33) Back stop Backstop Cover (Part #7) Small Snap Ring (VXT6 XD Only) 93

96 Cooling Fan Installation Overview Cooling fans provide an optional, inexpensive way of lowering the oil temperature. This increases the thermal capacity of the reducer. Cooling fans produce free circulation of air at the back of the housing as well as through the front of the unit. The fan blade is designed to produce a radial streamline air flow, which means smaller size fans and more efficient air flow. Installation instructions Step 1. Remove input power. To prevent injury, turn off, lock out, and tag the power source before beginning the installation of a cooling fan. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Examine all parts. Ensure that all parts are free of any foreign materials prior to assembly. Install mounting straps. First, remove every other bolt in the input shaft bearing cover. Set the mounting straps in place and re-install the bolts. Finger tighten. Mount the fan shroud so that it is centered and align the mounting strap bolt holes with those on the shroud. Once properly aligned, remove the shroud and tighten the cover bolts to the values listed in Table 47 (page 108). Set the safety screen. Place the safety screen on the shaft against the mounting straps. Install the fan blade. Place the fan blade on the input shaft, with the fan blade edge at distance C from end of shaft. See Illustration Y and Table 42 (page 95). Install the set screws in the fan blade hub and tighten securely. Mount the fan shroud. Install the bolts through the shroud and safety screen. Install lock washers and tighten the hex nuts. Check clearance. Slowly rotate the input shaft and make sure the fan and shroud do not touch. Illustration W Cooling Fan Assembly Parts Bolt Fan Shroud Fan Blade Lockwasher Hex Nut Set Screw Mounting Strap Safety Screen 94

97 Illustration X Cooling Fan Assembly Dimensions Illustration Y Fan Blade Location Dimension C Fan Blade to End of Shaft B Cooling Fan Assembly Key A Diameter Input Shaft Fan Blade Table 42 Cooling Fan Assembly Dimensions Unit Cooling A B C Size Fan Number Inches Inches Inches VXT3 XD 3CFK VXT4 XD 4CFK VXT5 XD 5CFK VXT6 XD 6CFK VXT7 XD 7CFK VXT8 XD 8CFK VXT9 XD 9CFK

98 Motor Mount Installation Overview Motor mount kits are designed to be installed on the output hub end of the reducer. See Illustration Z (below) and Illustration BB (page 97). If bottom mounting is desired, alterations to the torque arm or mount may be necessary. 2MMA 7MMA installation instructions Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8. Step 9. Step 10. Remove the housing bolts. See Illustration Z (right). Attach motor mount brackets. Align the brackets and install the longer housing bolts supplied with the motor mount kit. Do not fully tighten the housing bolts at this time. Install the bottom motor plate. Set the plate on the motor mount brackets. Secure the bottom motor plate to the mounting brackets with the bolts, nuts, and washers provided. See Illustration AA (bottom right). Torque the housing bolts. See Table 43 (below). Install the adjusting studs. Install the studs through the bottom motor plate and securely tighten the top and bottom nuts. These will not require any further adjustment. See Illustration AA (bottom right). Add one additional nut to each stud. Thread the nuts near the middle of the stud. Install the top motor plate. Slide the plate on the studs. It should rest on the nuts installed in Step 6. Add the remaining nuts. Thread them to secure the top motor plate. Hand tighten these nuts. Mount the motor, the sheaves, and the v-belts. To reduce the overhung load, mount the reducer sheave as close to the reducer housing as is practical. Adjust the nuts and plates. Make adjustments until the v-belts are in proper tension and alignment, then securely tighten all nuts. Adjusting Nuts Illustration Z VXT2 XD VXT7 XD Housing Bolts To Be Removed Remove These Housing Bolts Illustration AA 2MMA 7MMA Motor Mount Adjusting Studs Remove This Housing Bolt If Applicable Top Motor Plate Table 43 Recommended Torque Values For Tightening Housing Bolts Unit Size Torque (lbs.-ft.) VXT2 XD VXT3 XD VXT4 XD VXT5 XD VXT6 XD VXT7 XD VXT8 XD VXT9 XD Bottom Motor Plate Motor Mount Brackets 96

99 8MMA 9MMA installation instructions Step 1. Step 2. Step 3. Remove the housing bolts. See Illustration BB (right). Attach motor mount brackets. Align the brackets and install the longer housing bolts supplied with the motor mount kit. Do not fully tighten the housing bolts at this time. Install the adjusting studs to the motor plate. Thread a nut to the end of each stud. Slide the studs through the motor plate and use a second nut to securely tighten. See Illustration CC (bottom right). Illustration BB VXT8 XD VXT9 XD Housing Bolts To Be Removed Remove These Housing Bolts Step 4. Step 5. Add one additional nut to each stud. Thread the nuts near the middle of the stud. Attach the plate to the brackets. Slide the studs through the holes on the brackets until the nuts, installed in step 4, rest on the brackets. Install the remaining nuts onto the studs to secure the plate to the brackets. Step 6. Torque the housing bolts. See Table 43 (Page 96). Step 7. Step 8. Step 9. Step 10. Install the front motor rail. Lightly tighten the rail to the motor plate. Install the back motor rail. Measure the distance between the mounting holes of the motor. Position the rear motor rail at this distance from the front rail. Lightly tighten the rail to the motor plate. Mount the motor, the sheaves, and the v-belts. To reduce the overhung load, mount the reducer sheave as close to the reducer housing as is practical. Securely tighten the motor rails. Illustration CC 8MMA 9MMA Motor Mount Back Motor Rail Front Motor Rail Step 11. Adjust the nuts and plates. Make adjustments until the v-belts are in proper tension and alignment, then securely tighten all nuts. Adjusting Nuts Adjusting Studs Bottom Motor Plate Motor Mount Brackets 97

100 Screw Conveyor Adapter Installation Overview With a few easy steps, Vortex shaft mount reducers can be converted into screw conveyor drives. Follow the directions below to prepare your speed reducer for screw conveyor applications. Installation instructions Step 1. Step 2. Remove the snap rings, and collars from both sides of the output hub. These parts are not used for screw conveyor applications. Position the screw conveyor flange so that the bolt holes on the smaller end of the adapter align with the threaded bolt holes of the reducer. See Illustration DD (right). Illustration DD Screw Conveyor Flange Installation Conveyor Flange Threaded Bolt Holes Step 3. Install the bolts supplied with the screw conveyor flange kit. Tighten these bolts to the values listed in Table 44 (page 99). Flange Bolts Step 4. Using caution, slide the keyed end of the screw conveyor shaft into the flange. Be careful not to damage the oil seals or seal pack within the flange. Sharp edges of the shaft can damage seals. See Illustration EE (bottom right). Smaller Flange End Step 5. Once the screw conveyor shaft is fully inserted, the keyway will be visible from the opposite side of the reducer. Align the shaft keyway with the output hub keyway. Install the drive key. Step 6. Decide if you require the option of shaft removal. If you need to remove the drive shaft in the future, make sure you have purchased the optional screw conveyor removal wedge. See pages to review reducer accessories. Illustration EE Screw Conveyor Shaft Installation Standard wedge installation Step 7. If you do not intend to remove the shaft from the reducer (recommended), insert the standard wedge into the space between the hollow bore and the screw conveyor shaft. Install the wedge with the smaller end of the taper facing the reducer. See Illustration FF (page 99). Screw Conveyor Drive Shaft Shaft Keyway Removal wedge installation Step 7. To ensure the ability to remove the shaft from the reducer, a screw conveyor removal wedge (sold separately) should be installed into the space between the hollow bore and the screw conveyor shaft. This wedge includes a snap ring installed inside of the bore. Install the wedge with the smaller end of the taper facing the reducer. See Illustration FF (page 99). Installed Conveyor Flange 98

101 Step 8. Step 9. With the wedge now in place, slide the retaining bolt through the lock washer and keeper plate. Tighten the bolt into the end of the drive shaft. Use Table 44 (below) to determine the recommended torque value. The reducer is now ready to attach to your screw conveyor assembly. To ensure proper installation of a conveyor system, refer to directions provided by the screw conveyor manufacturer. Step 10. Return to Step 7 on page 90 to complete your reducer installation. Removal instructions Step 1. Remove the keeper bolt, lock washer, and threaded keeper plate from the drive shaft. Illustration FF Wedge and Retaining Bolt Installation Removal Wedge Snap Ring Step 2. Using snap ring pliers, remove the snap ring from the removal wedge. Step 3. Place the threaded keeper plate inside of the removal wedge and reinstall the snap ring. See illustration GG (below). Keeper Plate Retaining Bolt Step 4. Step 5. Step 6. Step 7. Step 8. Thread the removal bolt into the threads of the keeper plate and begin to tighten. As the large bolt begins to push against the drive shaft, the wedge will be dislodged from the reducer. Pull the drive shaft out of the reducer and flange. The key between the shaft and hub will also come loose. Loosen the bolts that connect the small end of the conveyor flange to the reducer. Remove the flange and bolts. Replace the snap rings and collars to both sides of the output hub. Standard Wedge Table 44 Recommended Adapter Bolt Torque Values [ft.-lbs.] Unit Conveyor Retaining Size Flange Bolt VXT2 XD VXT3 XD VXT4 XD VXT5 XD VXT6 XD Installed Removal Wedge Illustration GG Wedge Removal Threaded Keeper Plate Snap Ring Removal Bolt Table 45 Adapter Bolt Sizes (UNC) Unit Retaining Removal Size Bolt Bolt VXT2 XD 1/2-13 3/4-10 VXT3 XD 5/8-11 7/8-9 VXT4 XD 5/8-11 7/8-9 VXT5 XD 5/8-11 7/8-9 VXT6 XD 5/8-11 7/8-9 99

102 Reducer Disassembly Equipment needed Before disassembling a reducer, be sure to have the following items available: An arbor press A bearing, gear, or wheel puller An induction bearing heater or an industrial oven. Disassembly instructions Step 1. Remove the reducer from the shaft. For instructions on removing the reducer from the driven shaft, see page 91. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8. Step 9. Step 10. Step 11. Step 12. Clean the reducer. Clean all accumulated dirt from the surface of the housing. Drain all oil from the reducer. Set the oil aside for inspection. Remove locking collars, retaining rings, and bushing backup plates. Remove the backstop. See page 93 for removal instructions. Be sure to note the direction of the arrow for future reassembly. If the arrow is no longer visible, a picture can be taken to note the direction of the sprags. Remove all housing bolts. Stand the reducer on a side for bolt removal and housing separation. Remove the two hollow dowel pins. Drive the two hollow dowel pins from the reducer housing. These pins are located in the center bolt holes on each side of the reducer. See part #22 (page 61). Separate the housing halves. Open the halves evenly to prevent damage to internal parts. Initial separation may be aided by using a wedge in the slots along the flat sides of the reducer. Remove the hub and shaft assemblies from the housing. Remove oil seals. A puller and a slide hammer can be used to shock-out an oil seal. See Illustration HH (below). Oil seals are easily damaged during disassembly and should be replaced before reassembly. Remove the bearings. Be careful not to scratch or damage any oil seal contact area during bearing removal. Tapered roller bearing cups will need to be "shocked-out" of the back housing half. Remove the bearing covers on the front housing half to remove front-side bearing cups. See page 102 for more information on bearing removal. Disassemble the output hub (optional). The output hub assembly can be disassembled for gear replacement. If the hub is scratched or grooved, replace it. Illustration HH Oil Seal Removal 100

103 Component Inspection Overview Before beginning an inspection, disassemble and clean all components. The following components are the main concerns in an inspection: The oil seals and their contact surfaces The bearings The pinions and gears Oil seal and contact surface inspection One of the primary causes of reducer failure is insufficient lubricant caused by oil seal failure. The oil seal and the surface where the seal lip makes contact are both critically important. Even new seals will leak if the polished contact surface is damaged. Vortex recommends replacing all seals after disassembly. Because of this, a thorough inspection of the seal itself is not necessary. However, the condition of contact surfaces will play a large role in the life and effectiveness of a new seal. Inspect contact surfaces After disassembly, carefully inspect the seal contact surfaces. If the surface shows any sign of a nick, scratch, groove, or any other defect corrective action should be taken before reassembly. Wear sleeves In many instances a worn or damaged contact surface can be restored by use of a thin wall wear sleeve. Check with your local seal supplier and follow the manufacturer s instructions for installing the wear sleeve. Replacing contact surfaces If the use of a wear sleeve is not practical, the components with damaged contact surfaces should be replaced. See page 105 for more information on ordering replacement parts. Never attempt to repair the shaft or hub contact surface using abrasive materials. Bearing inspection Inspecting the bearings of a reducer can provide information about specific issues the reducer may be experiencing. Bearing failures can cause catastrophic damage to both the reducer and connected machinery. Because of this, Vortex recommends replacing all bearings after disassembly. When tapered roller bearings are replaced, replace both the cup and the cone of the bearing. Each reducer will have six bearings to remove and inspect. See Illustration II (below). Continue to page 102 for more information on bearing removal and inspection. Illustration II Bearings To Remove For Inspection Output Hub Intermediate Shaft Input Shaft 101

104 Component Inspection Bearing inspection (continued) Removing ball bearings (VXT2 XD) Remove ball bearings from shaft assemblies using a bearing or wheel puller. See Illustration JJ (below). As VXT2 size units use ball bearings throughout, there are no bearing cups to remove. Removing tapered roller bearings (VXT3 XD VXT9 XD) Remove bearing cones from shaft assemblies with a bearing or wheel puller. See Illustration JJ (below). Do not press against the rollers or cage of any bearing. The cups should be removed using a slide hammer and a 3-way adjustable puller to shock a bearing cup out of the housing. See Illustration KK (below). Back-side bearing cups (backstop side) are accessible from inside of the reducer. Frontside bearing cups can be removed from the exterior of the housing after removing the bearing cover plates. Check bearing function Lubricate the bearing with light oil before spinning to avoid scoring the working surfaces. Each bearing should turn smoothly and easily. Check for discoloration Discoloration is usually caused by overheating. Inappropriate speeds, loads, or lubricants can all cause a bearing to run too hot. Investigate and correct possible issues before installing any new bearings. Check for pitting Bearings that are exposed to water will often develop pitting. In humid or rapidly changing ambient conditions a reducer is susceptible to water contamination. After replacing the bearings, be sure to check and change the lubricant frequently. See page 84 for information on lubricant changes. General Inspection Check the rolling elements, cages, and races for any other signs of damage. If the bearing has suffered a premature failure, submitting the bearing for professional analysis will help determine the cause of failure. Illustration JJ Bearing Removal Make sure that the puller claw is positioned on the bearing inner ring and does not contact the bearing rollers or cages. Cage Cage Inner Ring Shoulder Roller Illustration KK Back-Side Bearing Cup Removal 102

105 Gear and pinion inspection The condition of gears and pinions are critically important to reducer operation. Each reducer will have two gears and two pinions to inspect. Gears can typically be inspected while still attached to their shaft assemblies. However, in some cases, you may wish to remove a gear for inspection or replacement. When replacing a gear or pinion, the mating pinion or gear should also be replaced. Removing gears from shaft assemblies Use a 3-way cone puller or a 3-way adjustable jaw puller to remove the gears from their shafts. Because of the hollow bore, removing the gear from the output hub will require a special attachment to be made or purchased for the puller. See Illustration LL (below). Illustration LL Hub Gear Removal Attachment needed to remove gear because of the hollow hub bore Attachment threads onto gear puller shaft Inspect gear teeth Inspect all gear and pinion teeth for wear or indications of fatigue. Check for hairline cracks at the root of each tooth. Deformation, pitting, scoring, or spalling are also a concern. Last, check the gear for evidence of misalignment such as uneven tooth wear. Specific types of gear fatigue and their causes are listed on page 104. Damage and repair If a gear shows signs of fatigue, it should be replaced before reassembly. Use caution when removing or replacing gears as seal surfaces are easily scored. If the output gear is damaged, it is recommended that you replace the entire output hub assembly. Other Components Inspect bolts and fasteners Replace any damaged bolts with Grade 5 fasteners. These fasteners have three (3) radial lines on the head. See Illustration MM (Right). Illustration MM Grade 5 Fastener Check housing condition If inspection has revealed any component degradation consistent with overload conditions, both housing halves should be inspected. Check for fine cracks or hairline fractures that indicate casting failure. If the reducer case has been damaged, both housing halves will need replacement. Because of this, a new reducer is often the best option. If the internal parts of the reducer are still in good condition, they can be stored for future use. 103

106 Component Inspection Specific gear and pinion fatigue Gearing distress and failure can be classified into five basic categories: Surface fatigue pitting and spalling Plastic flow Excessive wear Breakage Chipping Initial Pitting Destructive Pitting Initial pitting is caused by areas of high stress due to uneven surfaces on the gear tooth. Initial pitting is no cause for alarm as it can be corrective. Destructive pitting is a type of surface fatigue and is a result of overload conditions. Spalling Spalling is where a large area of surface material has broken away from the gear tooth. It may appear as flaking. If the gearing is hardened correctly, spalling results from overload conditions. Plastic Flow Plastic flow is sometimes referred to as wire edging. It is caused by a hammering shock load on the gear teeth while in motion. Plastic flow is nearly always the result of impact overloading. Excessive Wear Excessive wear (sometimes called destructive wear) is the destruction of the gear tooth shape to the point where the meshing action of the teeth is no longer smooth. This can be caused by excessive loads, contaminated oil, or an oil viscosity that is too light. Breakage Breakage is the ultimate gear failure. It begins with fatigue cracks and with continued operation will progress until the tooth breaks from the rim material. Sometimes a single overload incident can be responsible for this type of failure. Chipping Tooth tip chipping occurs when the tip of the gear tooth breaks away from the lower portion. Chipping may be caused by poor heat treatment, grinding issues during manufacture, or foreign material passing through the gear mesh. 104