General Description 1. Unit Designations & Ordering 2. Design Features 3-4. Explanation and use of Ratings and Service Factors 6-9

Transcription

1 Series H CAT.00000

2 CONTENTS 9709 General Description 1 Unit Designations & Ordering 2 Design Features 3-4 Shaft Sealing Arrangements 5 Explanation and use of Ratings and Service Factors 6-9 Selection Procedure Exact s Lubrication ounting Versions 18 shaft Options 19 bore Options 20 Series X Couplings 21 REDUCER Overhung & Axial Loads on Shafts oments of Inertia Ratings - Input Power / Torque Dimension Sheets - Reducers Customer shaft and Shrink Disk Details Cooling Coil Connections 109 Holdbacks 110 Torque Arm 111 OTORISED Dimension Sheets - Geared otors Shipping Specification

3 GENERAL DESCRIPTION 9606 Radicon Series H Series H gear units are available in in-line and right angle versions in single, double, triple and quadruple reduction gear stages having a maximum power capacity exceeding 8300 kw. The modular design and construction of the Series H offers many engineering and performance benefits including a high degree of interchangeability of parts and sub assemblies. This in turn provides considerable economies of production whilst maintaining the highest standard of component integrity The Range Includes 11 sizes of units with a ratio coverage of 1.22:1 to 130:1. Series H gear units are fully metric. Shaft extensions are to BS 4506 : 1970 (1991)-ISOR775. shaft bores are to BS EN : 1993, ISO : 1988 Pulling down bolt holes are to BS EN : 1992, ISO R273, medium fit series. * H * H 2 S * H 3 S/F Single reduction Foot mounted parallel shafts Double reduction Shaft mounted parallel shafts Triple reduction Foot/Shaft mounted parallel shafts Design Features Include Profile ground helical gears High level of surface finish for quiet running Units can be offered in horizontal mounting positions or alternatively vertical mounting Specially designed units are available for cooling tower applications or heavy duty stirrer applications. All units are also available with hollow bore for output shaft mounting. bores can be connected by shrink disc. * B * B 3 S Double reduction Foot mounted right angle shafts Triple reduction Shaft mounted right angle shafts As improvements in design are being made continually this specification is not to be regarded as binding in detail and drawings and capacities are subject to alteration without notice. Certified drawings will be sent on request. * Typical unit designations 1

4 UNIT DESIGNATIONS & ORDERING * EXAPLE OF TYPE B TYPE OF GEARS H - HELICAL GEARS ONLY 5,6, THROUGH B - HELICAL & BEVEL HELICAL GEARS 2 - NO OF REDUCTIONS 1 THROUGH TYPE OF UNIT - REDUCER UNIT 3 - UNIT VERSION - FOOT OUNTED - OTORISED S SF - SHAFT OUNTED - FOOT/SHAFT OUNTED INFORATION REQUIRED WHEN ORDERING UNITS PRIE OVER - Type - electric motor or engine, for example 4 cylinder internal combustion engine - Power rating in kw - speed. if variable, indicate speed range and frequency of variation - Dimensions of prime mover - Are bedplate and/or couplings required DRIVEN ACHINE - Type, for example, stirrer, cooling tower, fan, etc - Power rating in kw - - Service - hours per day, running time in any hour, details of reversals if applicable, type of loading, ambient temperature etc GEAR UNIT - Type, for example, VB3 - Size, for example, Shaft handing. Refer to dimension pages and quote reference - Direction of rotation (For units with right angle shafts refer to handling diagrams on dimension pages) SHAFT CONNECTIONS - Couplings. Quote shaft diameters with tolerances or coupling bores - Details of overhung loads, including diameter and type of pulley, sprocket or pinion, axial thrust loads and bending moments applied to the outputshafts ANY ADDITIONAL INFORATION * THIS PAGE AY BE PHOTOCOPIED ALLOWING THE CUSTOER TO ENTER THEIR ORDER 2

5 DESIGN FEATURES 9606 Shaft ounted Units Shaft mounted units are of two designs, the first of which is mounted on the driven machine shaft extension and connected to the foundation by torque arm, supplied as an optional extra. Additionally, the foot/shaft design is available for mounting on a baseplate with motor and coupling, the complete assembly being mounted on the driven machine shaft extension and connected to the foundation by a torque arm. All gear units are fitted with a 'shrink disc' device to provide positive clamping on the driven machine shaft extension. It is positioned on the input side of the gear unit. otorised Gear Units Gear units of double and triple reduction types are available as standard assemblies comprising British Standard metric flanged motors direct mounted on gearcase input shaft housings by adaptors. otor and gear unit shafts are connected by flexible couplings. Baseplates Standard baseplates can be supplied for units with parallel or right angle shafts. Assemblies comprise gear units and foot mounted motors correctly aligned in manufacture and connected by David Brown flexible couplings. Coupling guards are fitted. Baseplates for right angle shaft gear units are designed for use with either foot or shaft mounted arrangements, and provision is made for attaching torque arms where required. Designs provide ample stiffness to prevent distortion under load. Full details are available from David Brown. Holdbacks Holdbacks can be fitted to all Series H gear units, with the exception of H1 single reduction type, where required to operate in non-reversing drives. They are located on helical pinion shafts and have adequate capacities to deal with full rated torques. Lubrication is provided automatically from the oil in the gear unit. Changing the direction of locking rotation is a simple operation. Preservation / Protection Series H gear units are despatched without oil. Prior to despatch they are test run with a rust preventative oil giving adequate protection to internal parts for a period of six months covering normal transport in the UK and overseas and covered storage. Shaft extensions and hollow output shafts are protected with a rust inhibitor which is proof against sea water and suitable for under-cover storage up to 12 months. Note: Where gear units are to operate in abnormal conditions, or where they are to stand for long periods without running, eg in plant installation, David Brown must be notified so that suitable protective arrangements can be made. Series H Gear Units are fully metric Shaft extensions are to BS 4506 : 1970 (1991), ISO R775 shaft bores are to BS EN : 1993, ISO : 1988 Holding down bolt holes are to BS EN : 1992, ISO R273, medium fit series 3

6 DESIGN FEATURES 9707 Gears High quality alloy case hardening materials provide long life wear resistance and fatigue strength. Profile ground single helical gears and spiral bevel gears lapped in pairs ensure high standards of accuracy, surface finish and quiet running characteristics. Helical gears are fitted in parallel shaft units with shafts at right angles incorporate spiral bevel and helical gears. Bearings Roller bearings are used throughout. Gearcases Gearcases are of rigid cast iron construction with modern styling. Casings are split in the horizontal plane. Inspection covers are provided for viewing gear contacts. Oil level dipsticks, ventilators and drain plugs are fitted. Gearcase Finish Internal and external surfaces are painted with linear epoxy primer. External surfaces are finished with a styrenated modified alkyd with aluminium, blue hammer finish. These paints are resistant to dilute acids and alkalis, oils and solvents, sea water and temperatures up to 140 o C. External Dimensions Centre distances are chosen from ISO preferred number series. Shaft extensions and hollow wheelshaft bores are to ISO metric standards. Fasteners are metric. Lubrication Lubrication in most instances is by the transfer of oil by gears dipping in the sumps of gear unit bases. Where high pitch line speeds could cause churning of the lubricant, case baffles are fitted as indicated on rating tables. Spray lubrication is necessary where shown and complete systems can be supplied when required. The unit oil grade and change period will be stamped on the nameplate. The change period will be 6 months for mineral oil based lubricants and 18 months for synthetic oil based lubricants. These figures assume a sump temperature of 110 o C. Oil change periods can be extended for lower sump temperatures see installation and maintenance leaflet. Units are provided with combined dipsticks and ventilators, and drain plugs. Cooling Depending on the application standard gear units are cooled by:- Normal heat dissipation by convection from external surfaces. Fans fitted to high speed or intermediate shafts. Cooling water coil fitted in gear unit base. Fan and cooling coil. Separate oil cooler incorporated in forced lubrication system. As improvements in design are being made continually this specification is not to be regarded as binding in detail and drawings and capacities are subject to alteration without notice. Certified drawings will be sent on request. 4

7 SHAFT SEALING ARRANGEENTS 9706 SHAFT SEALING ARRANGEENTS OF HORIZONTAL OUNTED GEAR UNITS Oil seal lip Labyrinth and Oil seal Labyrinth and Flinger Labyrinth, Flinger and Oil seal Type H1 H2 H3 B2 B3 Shaft Input Ouput Input Ouput Input Ouput Input Ouput Input Ouput Unit Size < Oil lip seal > < Labyrinth and Flinger > < Labyrinth, Flinger and Oil seal > < Oil lip seal > <- - - Labyrinth and Flinger - - -> < Labyrinth and Oil seal > < Oil lip seal > < Labyrinth and Oil seal > < Oil lip seal > <- - - Labyrinth and Flinger - - -> < Labyrinth and Oil seal > < Oil lip seal > < Labyrinth and Oil seal > An additional oil seal, felt seal or grease lubricated seal, may be necessary for certain applications, Please refer to David Brown Radicon. 5

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9 EXPLANATION AND USE OF RATINGS AND ASSOCIATED RATING FACTORS Basic Ratings The catalogue mechanical and thermal rating capacity of the Series H gear units are based on a standard set of service operating conditions. The conditions are: i) The unit operates at a uniform absorbed power for 10 hours per day and with no more than one unidirectional start per hour at twice the absorbed power at input shaft to the gear unit. ii) It operates in a large indoor space at an ambient temperature of 20 o C with ambient air velocity of 1.4m/sec. iii) The sump bulk oil temperature is 110 o C when transmitting the power associated with the thermal capacity limit. iv) The air density is that at sea level v) When cooling fans are fitted it is assumed two are fitted to the H1 and H2 units and one to all other units vi) When cooling water coils are fitted the cooling water is supplied at 20 o C and the flow rate is as follows: a) Sizes inclusive 5.7 litres/min b) Sizes inclusive 9.1 litres/min vii) When a forced lubrication system is required the thermal rating given is for a unit where the oil is taken from sump sprayed onto the teeth and bearings and drains back into the sump. When the service conditions vary from those above factors are provided to enable the ratings to be modified to reflect the service operating conditions. Therefore selection of the gear unit is made by comparing the required power capacity (P R ) with the unit basic rating P mechanical, P T thermal both suitably factored for the service operating conditions. 2.0 Gear Unit Selection 2.1 Select Gearbox Type i) Parallel shaft (helical) or ii) Right angled drive (bevel/helical) Either of which can be foot or shaft mounted (the shaft mounted unit can be with or without a foot mounting) 2.2 Calculate the Gear Unit Gear unit ratio = Input 2.3 Gear Unit Required Power (P R ) Calculation of the gear unit required power (P R ) firstly requires determination of the type of drive which is classified as: i) Uniform ii) oderate shock or iii) Heavy shock This is obtained from table 2 page 7 Knowledge of the type of drive allows determination of the mechanical service factor F this is obtained from table 1 below. However if the overloads associated with the type of drive can be calculated or accurately assessed, actual loads should be used instead of F. It maybe that an industry standard has been set for the particular application, hence F should be set to that value N B Applications where high inertia loads are involved eg crane travel drives, slewing motions etc unit selection should be referred to David Brown Applications Engineers. The gear unit required power (P R ) is given by Required power P R = Pa x Fm (kw) Where Pa is the required absorbed power (kw) Table 1. echanical Service Factor (Fm) Prime mover Electric motor, steam turbine or hydraulic motor ulti-cylinder internal combustion engine Single cylinder internal combustion engine Duration of servicehrs per day Load classification-driven machine Uniform oderate Shock Heavy Shock Under to Over Under to Over Under to Over

10 9606 EXPLANATION AND USE OF RATINGS AND ASSOCIATED RATING FACTORS Table 2. Load Classification by Applications U H = Uniform load = oderate shock load = Heavy shock load = Refer to David Brown Driven achine Agitators 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 Cane knifes Car dumpers Car pullers Clarifiers Classifiers Clay working machinery brick press briquette machine clay working machinery pug mill Compressors centrifugal lobe reciprocating multi-cylinder single cylinder Conveyors-uniformly loaded or fed apron assembly belt bucket chain flight oven screw Conveyors-heavy duty not uniformly fed apron assembly belt bucket chain flight live roll oven reciprocating screw shaker type of load U U U U U U U U H U H H U H U U U U U U U U H H Driven achine type of Driven achine type of Driven achine load load U H H H H H H U U U U U U U U H U U H H U U H H H H H H 7 Cranes main hoists bridge travel trolley travel Crusher ore stone sugar Dredges cable reels conveyors cutter head drives jig drives manoeuvring winches pumps screen drive stackers utility winches Dry dock cranes main hoist auxiliary hoist boom, luffing rotating, swing or slew tracking, drive wheels Elevators bucket-uniform load bucket-heavy load bucket-continuous centrifugal discharge escalators freight gravity discharge man lifts passenger Fans centrifugal cooling towers induced draft forced draft induced draft large, mine, etc large, industrial light, small diameter Feeders apron belt disc reciprocating screw Food industry beef slicer cereal cooker dough mixer meat grinders Generators-not welding Hammer mills Hoists heavy duty medium duty skip hoist Laundry washers reversing Laundry tumblers Line shafts driving processing equipment light other line shafts Lumber industry barkers-hydraulicmechanical burner conveyor chain saw and drag saw chain transfer craneway transfer de-barking drum edger feed gang feed green chain live rolls log deck log haul-incline log haul-well type log turning device main log conveyor off bearing rolls planer feed chains planer floor chains planer tilting hoist re-saw merry-go-round conveyor roll cases slab conveyor small waste conveyor-belt small waste conveyor-chain sorting table tipple hoist conveyor tipple hoist drive transfer conveyors transfer rolls tray drive trimmer feed waste conveyor achine tools bending roll punch press-gear driven notching press- belt driven plate planers tapping machine other machine tools main drives auxiliary drives etal mills draw bench carriage and main drive pinch, dryer and scrubber rolls-reversing slitters table conveyors non-reversing group drives individual drives reversing wire drawing and flattening machine wire winding machine ill-rotary type ball cement kilns dryers and coolers kilns, other than cement pebble rod plain wedge bar tumbling barrels ixers concrete mixers -continuous concrete mixers -intermittent constant density variable density Oil industry chillers oil well pumping paraffin filter press rotary kilns Paper mills agitators, (mixers) barker-auxiliarieshydraulic barker-mechanical barking drum beater and pulper bleacher calenders calenders-super converting machine, except cutters, platers conveyors couch cutters-plates cylinders dryers felt stretcher felt whipper jordans H H H H H H U H H H U H H H H H H H H H U H H U H U H H log haul presses pulp machine reel stock chest suction roll washers and thickeners winders Printing presses Pullers barge haul Pumps centrifugal proportioning reciprocating single acting; 3 or more cylinders double acting; 2 or more cylinders single acting; 1 or 2 cylinders double acting; single cylinder rotary gear type lobe, vane Rubber and plastics industries crackers laboratory equipment mixed mills refiners rubber calenders rubber mill-2 on line rubber mill-3 on line sheeter tire building machines tire and tube press openers tubers and strainers warming mills Sand muller Sewage disposal equipment bar screens chemical feeders collectors dewatering screws scum breakers slow or rapid mixers thickeners vacuum filters Screens air washing rotary-stone or gravel travelling water intake Slab pushers Steering gear Stokers Sugar industry cane knives crushers mills Textile industry batchers calenders cards dry cans dryers dyeing machinery knitting machines looms mangles nappers pads range drives slashers soapers spinners tenter frames washers winders Windlass type of load H H U U U H H U U U U U U

11 EXPLANATION AND USE OF RATINGS AND ASSOCIATED RATING FACTORS 2.4 Selection of Gear Unit Size Knowledge of the type of unit (Section 2.1) and the required power (section 2.3) allows selection of the size of gear unit required from the appropriate gear unit rating table pages 29 to Adjustment of echanical Rating for the Service Operating Conditions Adjustment for duration of running has been done via the mechanical service factor Fm. The other adjustment required is for the number of starts or if unit is reversing, this factor Fs is obtained from table 3. Table 3. Number of Starts Factor (Fs) Start / Stops per hour (1) Up to 1 Note: (1) Intermediate values are obtained by linear interpolation 2.6 Unit Capacity The unit capacity (Pc) for the given service operating conditions is given by Pc = Pm x Fs (kw) For the unit to be acceptable mechanically Unidirectional Reversing Pc > P R 3.0 Check Having selected a gear unit which is acceptable mechanically for the application it is now necessary to ensure that the unit has adequate thermal capacity. 3.1 Basic Rating Capacity The thermal capacity of the unit without additional cooling is given together with the mechanical ratings pages 29 to 88. The thermal capacity with the following additional cooling i) fitted (s) ii) fitted with a cooling water coil (with a water supply temperature of 20 o C) iii) fitted (s) and cooling water coil are given separately, also see pages 29 to 88 for each type of gear unit. For units which need forced lubrication the thermal rating capacity are given for units where the oil is taken from the unit sump and sprayed onto the gears and returned to the sump. 3.2 Adjustment of Basic Capacity (P T ) for the Operating Service Conditions The basic thermal rating (P T ) for the unit selected in section 2.0 above is compared, after adjustment for the operating service conditions, with the absorbed power Pa (NB the mechanical service factor Fm is not included). The thermal capacity for the operating service conditions (P TC ) is obtained as follows P TC = P T x Fa x Fd x Fv x Fh (kw) where F a = the ambient temperature adjustment factor (table 4 page 9) Fd = the intermittent duty factor (table 5 page 9) Fv = the ambient air velocity correction factor (table 6 page 9) Fh = the altitude correction factor (table 7 page 9) For the unit to be acceptable thermally then P TC > Pa 8

12 9709 Table 4. Ambient Temperature Adjustment Factor (Fa) (1) Unit Type s Covered EXPLANATION AND USE OF RATINGS AND ASSOCIATED RATING FACTORS Ambient Temperature o C Cooling Type From To Including H No additional cooling H No additional cooling Fan(s) or cooling coil H No additional cooling B No additional cooling H No additional cooling Fan(s) or cooling coil H No additional cooling Fan(s) or cooling coil H No additional cooling Fan(s) or cooling coil B No additional cooling Fan(s) or cooling coil B No additional cooling Fan(s) or cooling coil H Fan(s) or cooling coil Fan(s) and cooling coil H Fan(s) or cooling coil Fan(s) and cooling coil H No additional cooling Fan(s) or cooling coil Fan(s) and cooling coil B Fan(s) or cooling coil Fan(s) and cooling coil B No additional cooling Fan(s) or cooling coil Fan(s) and cooling coil H Fan(s) and cooling coil H Fan(s) and cooling coil H No additional cooling Fan(s) or cooling coil Fan(s) and cooling coil B Fan(s) and cooling coil B No additional cooling Fan(s) or cooling coil Fan(s) and cooling coil Table 5. Intermittent Duty Factor (Fd) (1) Number of % Running time per hour Reductions Table 6. Ambient Air Velocity Correction Factor (Fv) Table 7. Altitude Adjustment Factor (Fh) (1) Air Velocity Vv m/sec Factor Fv Operating Area If Vv is not known use this value for Fv Altitude (m) Factor Fh Fv = 0.1 Vv Small confined 0.86 space > < 6 Fv = 0.2 Vv Large indoor 1.0 space > 2 - < 6 Fv = 0.17 Vv Sheltered outdoor 1.3 space >2 Fv = 0.17 Vv Outdoor space 1.5 (max Fv = 1.92) Sea Level Note: (1) Intermediate values are obtained by linear interpolation 9

13 SELECTION PROCEDURE 9707 EXAPLE 1 A foot mounted parallel shaft speed reducer is to be direct coupled to a 750 kw, 1450 rev/min motor. The output shaft is to rotate at 350 rev/min and is coupled to a large centrifugal pump which absorbs 725 kw on 24 hours/day service. The unit is to operate in a large indoor space with an ambient temperature of 30 o C situated 1000 meters above sea level. 1 Gearbox type 1.1 Parallel shaft type is specified - type H 1.2 = 1450 = 4.14, type H1 (single reduction) echanical capacity 2.1 From table 2 page 7 the application is uniform load 2.2 From table 1 page 6 the mechanical service factor Fm = From table 3 page 8 running 24 hours per day Fs = Given the absorbed power Pa = 725 kw and Fm = The required mechanical capacity P R is P R = Pa x Fm = 725 x 1.25 P R = 906 kw 2.5 From the H rev/min rating table page 32 a H1-280 ratio 4.13 is adequate for the duty ie P c = P x F s P c = 1120 x 1.0 P R < Pc 3 capacity 3.1 The thermal capacity (P TC ) required at the above operating conditions requires the basic thermal rating P T to be modified by the following factors 3.1:1 Ambient temperature factor The unit operates in an ambient temperature of 30 o C hence on examination of the thermal rating P T page 34 and if the H1-280 is selected then additional cooling by the way of fan or cooling water coil is required. In either case the ambient temperature factor Fa = 0.83 (table 4 page 9) the unit will therefore require a cooling water coil to be fitted. 3.1:2 Intermittent duty factor Fd The unit operates 24 hours per day therefore Fd = 1.0 (table 5 page 9). 3.1:3 Ambient air velocity factor (Fv) All that is known is that the unit operates in a large indoor space therefore Fv = 1.0 (table 6 page 9). 3.1:4 Altitude correction factor (Fh) The unit is to operate at an altitude of 1000m therefore from table 7 page 9 Fh = capacity of unit (P TC ) P TC = P T x Fa x Fd x Fv x Fh = 1070 x 0.83 x 1.0 x 1.0 x 0.93 P TC = 826 kw P TC > 725 the H1-280 fitted with a cooling coil will be adequate thermally for the application. 4 Check exact ratio is satisfactory see page 13 5 Order a gear unit type H1-280 fitted with a cooling water coil. EXAPLE 2 A shaft mounted gear unit with right angle shafts is required to drive a uniformly loaded belt conveyor running 24 hours/ day at 77 rev/min. The unit must have feet for the attachment of a motor mounting baseplate. The motor is 75 kw at 1450 rev/min and the absorbed power at the conveyor headshaft is 65 kw. The ambient temperature on site which is a large indoor area is 20 o C and situated at 300 metres above sea level. 1 Gearbox type 1.1 Foot/shaft mounted unit with right angle shafts. 1.2 = 1450 = 18.8, type B2SF or B3SF could be used whichever is the more 77 economical choice. 2 echanical capacity 2.1 From table 2 page 7 the application is uniform load 2.2 From table 1 page 6 the mechanical service factor Fm = From table 3 page 8 running 24 hours per day Fs = Given the absorbed power Pa = 65 kw. The power requirement of the unit P R is P R = 65 x 1.25 P R = 81 kw 10

14 SELECTION PROCEDURE From the B rev/min rating table page 69 a B2SF-225 is adequate for the duty ie P c = P x F s P c = 93.2 kw Pc > P R 3 capacity 3.1 The thermal capacity (P TC ) required at the above operating conditions requires the basic thermal rating P T to be modified by the following factors 3.1:1 Ambient temperature factor Fa Ambient temperature factor Fa = 1.0 (ambient temperature 20 o C) (table 4 page 9). 3.1:2 Intermittent duty factor Fd The unit operates 24 hours per day therefore Fd = 1.0 (table 5 page 9). 3.1:3 Ambient air velocity factor (Fv) All that is known is that the unit operates in a large indoor space therefore FV = 1.0 (table 6 page 9). 3.1:4 Altitude correction factor (Fh) The unit is to operate at an altitude of 300m above sea level. Using linear interpolation Fh = (table 7 page 9). 3.2 capacity of unit (P TC ) P TC = P T x Pa x Pd x Pv x Ph = 74.2 x 1.0 x 1.0 x 1.0 x P TC = 72.8 k P TC > 65 kw a B2SF-225 with no additional cooling is adequate for the application. 4 Check exact ratio is satisfactory see page 14 5 Order a gear unit type B2SF-225 with no additional cooling. EXAPLE 3 A gearbox operating at sea level is required to transmit power continuously from a horizontal foot mounted motor to a cooling tower fan, which is to be mounted directly on the output shaft and above the gearbox. The motor power is 110 kw at 1450 rev/min and the fan speed is 191 rev/min. the maximum ambient temperature is 25 o C. The fan imparts an axial thrust of 14 kn to the gearbox output shaft. It is necessary to have added clearance for the fan, so a CT type is preferred. The cooling tower fan has been calculated to create an ambient air velocity flow of 4.7 m/sec over the gear unit. 1 Gearbox type 1.1 Right angle shafts - type VB 1.2 = 1450 = 7.59, type VB2 CT (double reduction) echanical capacity 2.1 For cooling tower applications a mechanical service factor of Fm = 2.0 is usually used. 2.2 No absorbed power Pa is given the selection is based on the motor power. 2.3 The unit is running continuously therefore Fs = The required power (PR) is therefore P R = 110 x 2.0 P R = 220 kw 2.5 From the B rev/min rating table page 68 a VB2-225CT ratio 7.59:1 is adequate for the duty ie P c = P x F s P c = 263 x 1.0 Pc > P R 3 capacity 3.1 The following thermal service factors are required to adjust for the operating conditions. 3.1:1 Ambient temperature factor Fa The unit is operating in an ambient temperature of 25 o C Fa = unfanned by linear interpolation (table 4 page 9) 3.1:2 Intermittent duty factor Fd The unit operates 24 hours per day therefore Fd = 1.0 (table 5 page 9). 3.1:3 Ambient air velocity factor (Fv) It has been calculated the ambient air flow velocity (Vv) over the gear unit will be 4.7 m/sec Fv = 0.2 x Vv = 0.2 x Fv = 1.66 (table 6 page 9). 3.1:4 Altitude correction factor (Fh) The unit is to operate at sea level therefore Fh = 1.0 (table 7 page 9). 11

15 SELECTION PROCEDURE 3.2 capacity of unit (P TC ) P TC = P T x Fa x Fd x Fv x Fh = 82.2 x x 1.0 x 1.66 x 1.0 P TC = 119 kw The VB2-225 CT with no additional cooling is adequate for the application ie P TC > 110 kw 4 From table 6 given on page 24 a permissible axial thrust of 16.2 kn can be accommodated by the output shaft. Hence the selected unit is satisfactory. 5 Check exact ratio is satisfactory see page Order a gear unit type VB2-225 CT exact ratio 7.76 with no additional cooling. EXAPLE 4 A gearbox with right-angle shafts is required to transmit 190 kw absorbed power from a 200 kw 1450 rev/min motor to a stirrer shaft at 55 rev/min starting once per day. The shaft is to be rigidly coupled to the gearbox output shaft and entirely supported by the gearbox bearings. The radial force at the paddle is 44 kn and it acts at a point 2.3 metres below the gearbox base. The paddle produces an upward axial thrust of 32 kn. The specified mechanical service factor is 2.0. The unit is to operate in a large indoor area at an ambient temperature of 20 o C and the factory situated 800 metres above sea level. 1 Gearbox type 1.1 Right angle shaft type VB. 1.2 = 1450 = 26.36, type VB3 (triple reduction) 55 2 echanical check 2.1 The mechanical service factor Fm = The absorbed power Pa is 190 kw 2.3 The power required P R is P R = 190 x P R = 380 kw The unit is started less frequently than once per hour therefore Fs = From the B rev/min rating table see page 80 a B3-400 nominal ratio 25.6:1 is adequate for the duty (Fs = 1.0) ie P c = Pm x F s = 485 x 1.0 P c = 485 kw Pc > P R 3 check 3.1 service factors The following thermal service factors are required to adjust for the service operating conditions. 3.1:1 Ambient temperature is 20 o C therefore Fa = 1.0 (table 4 page 9) 3.1:2 No information is available regarding duration of operation therefore Fd is set equal to :3 No ambient air velocity is given therefore Fv for a large indoor area is 1.0 (table 6 page 9) 3.1:4 The gear unit is to operate at an altitude of 800 metres above sea level. By linear interpolation Fh = (table 7 page 9) 3.2 Gear unit required thermal capacity (P TC ) P T for unit 515 kw (page 82) P TC = P T x Fa x Fd x Fv x Fh = 515 x 1.0 x 1.0 x 1.0 x P TC = 487 kw P TC > 190 kw As indicated in the rating table the thermal rating is based on the unit having spray lubrication with the oil pumped from the sump and returned to the sump ie no external lubrication system. 4 Bending moment check 4.1 The applied bending moment = 2.3 x 44 = KN. 4.2 From table 10 on page 26 the allowable bending moment limited by shaft stress is 93 KN. for the standard unit and 143 KN. for the Heavy Duty Stirrer. 4.3 From table 11 on page 26 the allowable bending moment limited by bearing life at 45 rev/min 156 KN. for the SA type 5 Axial thrust capacity check 5.1 From table 7 page 25 the thrust limit for the cover bolts is 99 KN 5.2 From table 8 page 25 allowable thrust upwards limited by bearing life at 45 rev/min is 127 KN 6 Check that the exact ratio is satisfactory page 13 and Order a gear unit type VB3-400 SA exact ratio cooling and internal spray lubrication

16 EXACT RATIOS 9606 Single Reduction Units Types H1 UNIT SIZE Double Reduction Units Types H2, H2S, H2SF, VH2, VH2SA, VH2CT UNIT SIZE Triple Reduction Units Types H3, H3S, H3SF, VH3, VH3SA, VH3CT UNIT SIZE

17 EXACT RATIOS 9606 Double Reduction Units Types B2, B2S, B2SF, VB2, VB2SA, VB2CT UNIT SIZE Triple Reduction Units Types B3, B3S, B3SF, VB3, VB3SA, VB3CT UNIT SIZE

18 LUBRICATION 0007 All Series H units are despatched without oil and therefore filled by the client. The David Brown Radicon grade and type of oil will be stamped on the nameplate in accordance with either of the types of oil from tables 3 or 4. The oil change period will be as stated in the lubrication section of Design Features page 4. The approximate quantity of oil required is given in Table 1, but the unit should always be filled to the level marked on the dipstick. Warning: Do not overfill the unit as this can cause leakage and overheating. Where possible run the unit without load for a short time to circulate the lubricant thoroughly, then stop the unit and recheck the oil level after allowing the unit to stand for 10 minutes and if necessary top up to the correct mark on the dipstick. In addition where bearings are grease packed, the greases approved are given in table 2. TABLE 1 LUBRICANT QUANTITY (Litres) Unit UNIT SIZE Type H H H2SF H2S VH VH2SA VH2CT H H3SF H3S VH VH3SA VH3CT B B2SF B2S VB VB2SA VB2CT B B3SF B3S VB VB3SA VB3CT TABLE 2 APPROVED BEARING GREASES SUPPLIER DESIGNATION ALLOWABLE OPERATING TEPERATURE RANGE O C ABOVE TO BP Oil International Limited Energrease LS-EP Caltex ultifak EP Castrol International LX Grease Spheerol AP Spheerol EPL Fuchs Lubricants Renolit EP Klüber Lubrication Klüberlub BE obil Oil Company Limited obilgrease XHP obilith SHC Omega anufacturing Division Omega Optimol Ölwerke GmbH Longtime PD Shell Oils Albida RL Alvania EP B Nerita HV Texaco Limited ultifak All Purpose EP Notes: 1) All the above greases are NLGI grade 2. 2) Refer to David Brown Radicon Application Engineers if the unit is operating in an ambient temperature outside the range of -30 o C to 50 o C. 15

19 APPROVED LUBRICATION TABLE 3 APPROVED LUBRICANTS Type E ineral oil containing industrial EP additives. These have a high load carrying capacity SUPPLIER LUBRICANT RANGE See notes page 17 5E DAVID BROWN GRADE NUBERS 6E 7E ABIENT TEPERATURE RANGE o C -5 to 25 0 to to 50 Batoyle Freedom Group Remus b 220 (-2) 320 (-2) 460 (-2) Boxer Services / illers Oils Indus b,e 220 (-10) 320 (-10) 460 (-10) BP Oil International Limited Energol GR-XF b,c,e 220 (-16) 320 (-13) 460 (-1) Energol GR-XP b,e 220 (-15) 320 (-10) 460 (-7) Caltex eropa b 220 (-4) 320 (-4) 460 (-4) RP Borate EP Lubricant b 220 (-7) 320 (-4) 460 (-7) Carl Bechem GmbH Berugear GS B b 220 (-20) 320 (-13) 460 (-10) Staroil G b 220 (-13) 320 (-13) 460 (-10) Castrol International Alpha ax b,c,e 220 (-19) 320 (-13) 460 (-10) Alpha SP b,e 220 (-16) 320 (-16) 460 (-1) Chevron Lubricants Gear Comp EP (USA ver) b 220 (-16) 320 (-13) 460 (-10) Gear CompEP (Eastern ver) b 220 (-13) 320 (-13) 460 (-13) Ultra Gear b 220 (-10) 320 (-7) 460 (-7) Eko-Elda Abee Eko Gearlub b 220 (-13) 320 (-10) 460 (-1) Engen Petroleum Limited Gengear b 220 (-13) 320 (-10) 460 (-1) Esso Spartan EP b,c 220 (-16) 320 (-13) 460 (-7) Esso/Exxon Spartan EP b,h 220 (-12) 320 (-12) 460 (-4) Fuchs Lubricants Powergear b P/Gear (-16) 460 (-4) Renogear V b 220EP (-13) 320EP (-4) 460EP (-4) Renogear WE b 220 (-7) 320 (-4) 400 (-4) Renolin CLPF Super b,d,e 6 (-13) 8 (-10) 10 (-10) Klüber Lubrication Klüberoil GE1 b 220 (-5) 320 (-5) 460 (-5) Kuwait Petroleum International Q8 Goya b 220 (-16) 320 (-13) 460 (-10) Lubrication Engineers Inc Almasol Vari-Purpose Gear b 607 (-18) 605 (-13) 608 (-10) obil Oil Company Limited obil gear 600 Series b 630 (-13) 632 (-13) 634 (-1) obil gear XP b,c 220 (-19) 320 (-13) 460 (-7) Omega anufacturing Division Omega 690 b,e 85w/140 (-15) Optimol Ölwerke GmbH Optigear B b 220 (-11) 320 (-10) 460 (-7) Optigear b 220 (-18) 320 (-9) 460 (-7) Pertamina (Indonesia) asri b,e 220 (-4) 320 (-4) 460 (-4) Petro-Canada Ultima EP b,e 220 (-22) 320 (-16) 460 (-10) Rocol Sapphire Hi-Torque b,e 220 (-13) 320 (-13) 460 (-13) Sasol Oil (Pty) Limited Cobalt b,e 220 (-4) 320 (-1) 460 (-4) Hemat b,e 220 (-10) 320 (-7) 460 (-4) Saudi Arabian Lubr. Oil Co. Gear Lube EP b,e EP220 (-1) EP320 (0) EP460 (0) Shell Oils Omala b 220 (-4) 320 (-4) 460 (-4) Omala F b,c 220 (-13) 320 (-10) 460 (-4) Texaco Limited eropa b 220 (-16) 320 (-16) 460 (-10) eropa W b, c 220 (-19) 320 (-16) 460 (-11) Total Carter EP b 220 (-7) 320 (-7) 460 (-4) Carter VP/CS b 220 (-16) 320 (-13) 460 (-7) Tribol GmbH olub-alloy Gear Oil b,d 90 (-18) 690 (-16) 140 (-13) Tribol 1100 b 220 (-20) 320 (-18) 460 (-16) 0007 DANGER Numbers in brackets indicate recommended minimum operating temperature in o C. THE UNIT UST NOT RUN BELOW THIS TEPERATURE. 16

20 APPROVED LUBRICATION 0007 TABLE 4 APPROVED LUBRICANTS Type H Polyalphaolefin based synthetic lubricants with Anti-Wear or EP additives. These have a medium to high load carrying capacity. SUPPLIER LUBRICANT RANGE See notes page 17 5H DAVID BROWN GRADE NUBERS 6H 7H ABIENT TEPERATURE RANGE o C -10 to 30 0 to to 50 Batoyle Freedom Group Titan b 220 (-31) 320 (-28) Boxer Services / illers Oils Silkgear b 220 (-35) 320 (-35) 460 (-35) BP Oil International Limited Enersyn EPX b,e 320 (-28) Caltex Pinnacle EP b 220 (-43) 320 (-43) 460 (-37) Carl Bechem GmbH Berusynth GP b 220 (-38) 320 (-35) 460 (-32) Castrol International Alphasyn EP b,c 220 (-37) 320 (-31) 460 (-31) Alphasyn T b 220 (-31) 320 (-28) 460 (-28) Chevron Lubricants Tegra b 220 (-46) 320 (-33) 460 (-31) Esso/Exxon Spartan Synthetic EP b,e 220 (-46) 320 (-43) 460 (-40) Fuchs Lubricants Renogear SG b 220 (-32) 320 (-30) Klüber Lubrication Klübersynth GE 4 b 220 (-35) 320 (-35) 460 (-30) Kuwait Petroleum International Q8 EL Greco b 220 (-22) 320 (-19) 460 (-16) Lubrication Engineers Inc Synolec Gear Lubricant b 9920 (-40) obil Oil Company Limited obilgear SHC b 220 (-40) 320 (-37) 460 (-32) obilgear SHC XP b,c 220 (-40) 320 (-33) 460 (-31) Optimol Ölwerke GmbH Optigear Synthetic A b 220 (-31) 320 (-31) Petro-Canada Super Gear Fluid b,e 220 (-43) 320 (-37) 460 (-37) Shell Oils Omala HD b,c 220 (-43) 320 (-40) 460 (-37) Texaco Limited Pinnacle EP b 220 (-43) 320 (-43) 460 (-37) Pinnacle W b,c 220 (-43) 320 (-40) Total Carter SP b 220 (-34) 320 (-31) 460 (-28) Tribol GmbH Tribol 1510 b 220 (-36) 320 (-33) 460 (-28) NOTES: b) These lubricants should not be used in units fitted with trailing sprag or holdback devices without prior agreement with the manufacturer; the additives, or the base fluids may modify the coefficient of friction which these devices depend on. c) These lubricants have been tested for micro-pitting (FZG Type C), test results are available. d) These oils contains solid lubricants (eg OS 2 or graphite) and must NOT be used in units fitted with any type of hold-back device which relies on friction for its operation. e) These lubricants contain additives which may adversely affect silvered or white metal components; consult oil supplier. h) inimum operating temperatures of these lubricants are based on worst case values, lower operating temperatures may be available, please check with local stockist. DANGER Numbers in brackets indicate recommended minimum operating temperature in o C. THE UNIT UST NOT RUN BELOW THIS TEPERATURE. 17

21 OUNTING VERSIONS Single Reduction - Parallel Shafts 9606 H1 Foot ounted Double Reduction - Parallel Shafts H2 Foot ounted H2S Shaft ounted H2SF Foot/Shaft ounted Triple Reduction - Parallel Shafts H3 Foot ounted H3S Shaft ounted H3SF Foot/Shaft ounted Double Reduction - Right Angle Shafts B2 Foot ounted B2S Shaft ounted B2SF Foot/Shaft ounted Triple Reduction - Right Angle Shafts B3 Foot ounted B3S Shaft ounted B3SF Foot/Shaft ounted Double Reduction - Parallel Shafts VH2 Standard Units VH2 SA Heavy Duty Stirrer Drives VH2 CT Cooling Tower Drives Triple Reduction - Parallel Shafts VH3 Standard Units VH3 SA Heavy Duty Stirrer Drives VH3 CT Cooling Tower Drives Double Reduction - Right Angle Shafts VB2 Standard Units VB2 SA Heavy Duty Stirrer Drives VB2CT Cooling Tower Drives Triple Reduction - Right Angle Shafts VB3 Standard Units VB3 SA Heavy Duty Stirrer Drives 18 VB3 CT Cooling Tower Drives

22 OUTPUTSHAFT OPTIONS 9512 OUTPUTSHAFT OPTIONS SIZE OF UNIT TYPE OF OUTPUTSHAFT 140 Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard DIENSIONS IN (American Shaft in Inches) A B C D E øf American * American * American * American * American * American * American * American * * American shaft has an open ended keyway, therefore no 'C' dimension is required 19

23 OUTPUTBORE OPTIONS 9709 OUTPUTBORE OPTIONS Sizes 140 and 160 only All sizes except 140 and 160 SIZE TYPE OF DIENSIONS IN (American Bore in Inches) OF UNIT OUTPUTBORE G H J K N P Q 140 Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard American American American American American American American American