1 Mounting V-belt drive (motor pulley, fly wheel, V-belts and guard)

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Cameron Blankenship
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1 Mounting V-belt drive (motor pulley, fly wheel, V-belts and guard) General safety instructions, requirements and procedures 1 Mounting V-belt drive (motor pulley, fly wheel, V-belts and guard) 1.1 General safety instructions, requirements and procedures General safety instructions 1. Do respect all federal state or local safety regulations during service jobs on the compressor 2. This service job should be carried out only by those who have been trained and delegated to do so, and who have read and understood this complete service instruction Caution! Prepare the compressor in accordance with Instruction and Maintenance Manual (IMM), prior to carry out any service job in or on the compressor General requirements Documents 1. Installation and Maintenance Manual (IMM) General procedure 1. Disconnect the electrical power supply 1.2 Mounting V-belts and guard Fig.1: Initial situation

2 Mounting V-belt drive (motor pulley, fly wheel, V-belts and guard) Mounting V-belts and guard Fig.2: Position motor-plate onto the motor shaft Fig.3: Position the back-plate onto support brackets on base frame Fig.4: Tighten back-plate with bolts and nuts

3 Mounting V-belt drive (motor pulley, fly wheel, V-belts and guard) Mounting V-belts and guard Fig.5: Mounting fly-wheel and motor pulley 1 Slide compressor pulley and motor pulley onto the shafts 2 Tighten the compressor pulley (fly-wheel), refer for details Page 5 3 Align and tighten the motor pulley and mount V-belts, refer for details Section 1.3, Page 4. Fig.6: Tighten the motor-plate to the back-plate with bolts and nuts in the slots of the back plate Fig.7: Position the front-cover between the support brackets on the base frame

4 Mounting V-belt drive (motor pulley, fly wheel, V-belts and guard) Instruction mounting V-belts Fig.8: Tighten the front-cover with bolts and nuts Fig.9: Attach the inspection-plate on top of the front-plate 1.3 Instruction mounting V-belts Introduction Modern V belt drives are designed to transfer max. power/torque with a minimum amount of belts. New types of belt material allow higher loads but on the other hand also require more accurate tensioning to guarantee highest efficiency. For the new generation of V-series reciprocating compressors Grasso use: 1. type V-belts; XPB To ensure that you benefit from a long lasting and high performance drive system you have to fully comply with the mounting instructions as written below. Requirements 1. Common toolbox 2. Groove gauge 3. Belt tension indicator, Figure 11, Page 7 4. Table with required belt tension forces technical data, Page

5 Mounting V-belt drive (motor pulley, fly wheel, V-belts and guard) Instruction mounting V-belts Mounting conditions 1. Flywheel and pulley must be free from scores and sharp edges 2. Groove dimensions according relevant standard (groove gauge) 3. Groove(s) free from grease and paint. 4. Grsso V ; The compressor flywheel must be mounted with a distance of X=2 mm from the boss of the crankshaft Grasso V V 1800; Start with X=0 mm (after tightening distance X>0 mm) 5. Correct alignment of compressor flywheel and motor pulley 6. Very important: Caution! Please note that with replacement of the V-belts never V-belts from different brands and/or different batches are being used at one drive set 1 2b X 2a Fig.10: Detail mounting fly-wheel pulley on crankshaft compressor 1 Crankshaft compressor 2a Grasso V ; Clamping bush, refer to Section 2.1, Page 9 2b X Grasso V ; Clamping set, detachable shaft-hub-connection, refer to instruction Section 2.2, Page 10 Grasso V , X=2 mm // Grasso V ; X=0 mm Belt installation 1. Check alignment of flywheel and motor pulley 2. Good alignment of pulleys is important to avoid belt flank wear. The diagram in Figure 13, Page 8 show some of the common alignment faults. Pulley misalignment should not exceed 0.5 o angularly and 3 mm/mtr. drive centre distance axially. 3. Check correct mounting of the motor pulley on the drive shaft. 4. Pulleys are secured with Taper Lock type bushes and therefore the installation leaflet, supplied with every bush, must be consulted

6 Mounting V-belt drive (motor pulley, fly wheel, V-belts and guard) Instruction mounting V-belts 5. Check correct number of belts to be used. (Product Information, Section 2.3, Page 14) 6. Less belts as calculated result in excessive wear and shorter lifetime 7. More belts as calculated higher load on compressor and motor bearings and possible belt whip 8. The drive centre distance should be reduced prior to the installation of the belts so that they may be fitted without the use of force. Under no circumstances belts must be pushed into the grooves by mechanical force otherwise damage of the belts & pulleys can occur. 9. Install the belts to be a snug fit around the pulleys, starting on groove closest to the compressor 10. Mount belts as close as possible to compressor housing in order to minimize bearing and shaft load. 11. Spin the pulleys manually 3-4 revolutions to bed the belts into the pulley grooves. Beware of finger entrapment between belts and pulley! 12. Read the required tensioning force (in kgf.) at a deflection of 10 mm at Page 18 and add 10% to compensate for permanent lengthening of the belt(s) after first tensioning. You can use one of the following tools to check the belt tension: 1. Gates belt tension tester (Refer Figure 11, Page 7), recommended 2. Place the belt tension indicator on the top of the belt at the center of the span and apply a force perpendicular to the belt deflecting it to the point where the lower marker ring is level with the top of an adjacent belt. 3. Read the setting force value indicated by the top edge of the upper marker ring. Compare this force with the required kgf. value (Refer Page 18) incl. the 10% 4. Quality spring balance, alternative 5. Place the spring balance at the center of span and apply a force perpendicular on the belt (pulling) inwards until the required kgf. (Refer Page 18) incl. the 10% has been reached. The measured deflection related to an adjacent belt must be corresponding with 10 mm Next installation steps: 1. Fit V-belt protection guard 2. Run the drive line at high load for approx. 24 hours 3. Stop compressor, check and if necessary re-tension to correct required force according to Page Re-fit V belt protection guard 5. With a drive that is properly designed for the application there should be no further attention during the life of the belts

Mounting V-belt drive (motor pulley, fly wheel, V-belts and guard) Instruction mounting V-belts Important remarks Excessive contamination by oil, certain cutting fluids, water or rubber solvent can

7 Mounting V-belt drive (motor pulley, fly wheel, V-belts and guard) Instruction mounting V-belts Important remarks Excessive contamination by oil, certain cutting fluids, water or rubber solvent can cause belt swelling, softening and slipping. Insufficient belt tension, excessive heat and/or chemical fumes can cause radial cracks on top or bottom side. Belt whip is often caused by incorrect tensioning especially on long centre drives. If a slightly higher (or lower) tension does not cure the problem, there may be a critical vibration frequency in the system which requires a redesign. Caution! Note: Too much (>10%) over tightening can cause overload (damage) to compressor/motor bearings Attention: When you design your own driveline be aware that longer center distances between the driver and the driven component (compressor) increase the introduction of belt whip! Consult your local Grasso supplier if you have any questions or need assistance. Fig.11: Tension tester, Grasso Code Fig.12: Deflection X Deflection, refer Page 18 CP Compressor pulley MP Motor pulley CD Centre distance

8 Mounting V-belt drive (motor pulley, fly wheel, V-belts and guard) Fig.13: A B C D Alignment Angular misalignment Composite misalignment Axial misalingment Corredt installation - both shafts and pulleys are parallel and in alignment

Grasso V300.. 600; MOUNTING FLYWHEEL (0087169) 2 APPENDIX 2.1 Grasso V300.. 600; MOUNTING FLYWHEEL (0087169) Introduction 1 X Fig.

9 Grasso V ; MOUNTING FLYWHEEL ( ) 2 APPENDIX 2.1 Grasso V ; MOUNTING FLYWHEEL ( ) Introduction 1 X Fig.14: Detail mounting fly-wheel pulley on crankshaft compressor 1 Crank shaft X Grasso V ; Initial X=2 mm Requirements 1. Common tool box Fig.15: Flywheel 1. Remove the protective coating from the bore and outside of bush, and bore of hub. After ensuring that the mating tapered surfaces are completely clean and free from oil or dirt, insert bush in hub so that the holes line up. 2. Sparingly oil thread and point of grub screws or thread and under head of cap screws. Place screws loosely in holes threaded in hub. 3. Clean shaft and tab the key into the crankshaft keyway

Grasso V 700.. 1800; MOUNTING FLYWHEEL(0087168) 4.

10 Grasso V ; MOUNTING FLYWHEEL( ) 4. Fit the hub and bush to shaft as one unit and locate in position desired, remembering that bush will nip the shaft first and then hub will be slightly drawn on to the bush. Fig Using a hexagon wrench tighten screws (1) gradually alternately until all are pulled up very tightly. 6. Hammer against large end of bush, using a block or sleeve to prevent damage. This will ensure that the bush is seated squarely in the bore). Screws will now turn a little more. Repeat this alterate hammering and screw tightening once or twice until correct tightening torque. 7. After drive has been running under load for a half or one running hour, stop and check tightness of screws. 8. Fill empty holes with grease to exclude dirt. 2.2 Grasso V ; MOUNTING FLYWHEEL( ) Introduction 1 X Fig.17: Detail mounting fly-wheel pulley on crankshaft compressor 1 Crank shaft X Grasso V ; Initial X=0 mm (After tightening the clamping set X will increase slightly)

11 Grasso V ; MOUNTING FLYWHEEL( ) Requirements 1. Common toolbox Mounting conditions 1. Flywheel and pulley must be free from scores and sharp edges 2. Groove dimensions according relevant standard (groove gauge) 3. Groove(s) free from grease and paint. 4. Start with X=0 mm (after tightening distance X>0 mm) Caution! Maximum permissible tolerances h8 shaft /H8 hub Contact surfaces with roughness; Rt max 16 micron Error of concentricity; mm Details Fig.18 A B C D E F Compressor shaft-end Clamping set Grooved part of fly wheel Non-grooved part of fly wheel "Front" mark (do not mount the fly wheel the other way around) Pulley "stop breast"

Grasso V 700.. 1800; MOUNTING FLYWHEEL(0087168) Fig.19 Fig.20 Legend Figure 20, Page 12 Type DIN 912 12.

12 Grasso V ; MOUNTING FLYWHEEL( ) Fig.19 Fig.20 Legend Figure 20, Page 12 Type DIN M10 x 60 d x D mm 75 x 115 L1 mm 70 L2 mm 78 B mm 88 Torque Nm Axial force kn 313 Surface pressure shaft N/mm Surface pressure hub N/mm Torque Nm 83 Weight kg

Grasso V 700.. 1800; MOUNTING FLYWHEEL(0087168) Fig.21: Gap in the inside clamping element must be in line with the gap in the outer ring Assembly 1.

13 Grasso V ; MOUNTING FLYWHEEL( ) Fig.21: Gap in the inside clamping element must be in line with the gap in the outer ring Assembly 1. Check the shaft and hub position regarding the permitted tolerances h8/h8 2. Carefully clean the hub and shaft contact surfaces Caution! Oils and greases with molybdenum sulfide or high-pressure additives, additives of Teflon and silicone as well as slide grease pastes must not be used which would considerably reduce the coefficient of friction 3. Lightly unscrew the clamping screws to facilitate the assembly, fix the internal and external ring via the pull-off threads by means of 2-off clamping screws. Insert the clamping set between shaft and hub. 4. Remove the clamping screws used for fixing and screw in the threads of the external ring agin. Slightly tighten the clamping screws manually and align the clamping set with hub part. Tighten the clamping screws stepwise and with several resolutions evenly crosswise to the tightening torque "Ms" mentioned in the table respectively, 83 Nm. Repeat the process until a 1/4 revolution of the screws is no longer possible. Afterwards tighten the clamping screws one after another at the tightening torque mentioned over one revolution. Disassembly 1. Release all clamping screws evenly one after the other and unscrew them 2. Screw the clamping screws into the threads of the internal ring 3. Tighten the clamping screws evenly at 1/4 revolution crosswise. Increase the compression torque stepwise until external ring and internal ring are separated 4. Remove the unscrewed clamping set between shaft and hub

14 V-BELT SELECTION 2.3 V-BELT SELECTION Additional information V-belt drive 1. Transmitted power is based on V-belt type XPB 2. V-belt drive has to be mounted according to Grasso instruction sheet 3. In case of local product designed compressor packages, the selection data from this chapter must be used

15 V-BELT SELECTION Transmitted Power Grasso V 300(T).. V 600(T) Grasso V 300(T).. V 600(T) Transmitted Power (kw) Qty x V-belts Compressor speed with motor speed 1475 min Hz Compressor speed with motor speed 1775 min Hz Max. shaft power compressor to transmit (kw), depending on number of V-belts 1xXPB xXPB xXPB

16 V-BELT SELECTION Transmitted Power Grasso V 700(T).. V 1800(T) Grasso V 700(T).. V 1800(T) Transmitted Power (kw) Qty x V- belts Compressor speed with motor speed 1475 min Hz Compressor speed with motor speed 1775 min Hz xXPB xXPB Max. shaft power compressor to transmit (kw), depending on number of V-belts 3xXPB xXPB xXPB xXPB

17 V-BELT SELECTION V-belt drive selection data Grasso V 300(T).. V 1800(T) Compressor speed Grasso V 300(T).. V 1800(T) with motor speed 1475 min Hz Compressor speed with motor speed 1775 min Hz Diameter motor pulley (mm) Diameter fly wheel (mm) Frame size motor.. (A1, A2, etc, refer Page 18) <= 250 A1 > 250 A2 <= 250 B1 > 250 B2 <= 250 C1 > 250 C2 <= 250) D1 > 250 D2 E F E F <= 315 G1 = 355 G2 <= 315 H1 = 355 H2 <= 250 J1 > 250 J2 <= 315 K1 = 355 K2 <= 250 L1 > 250 L2 <= 225 M1 > 225 M2 <= 250 N1 > 250 N2 <= 315 P1 = 355 P2 <= 315 Q1 = 355 Q2 <= 315 R1 = 355 R

18 V-BELT SELECTION Centre distance, length and required force Dependancies on frame size motor Frame size motor, refer Page 17 Lenght V-belts Centre distance Required force at max. deflexion of 10 mm 1 V-belts > 1 operating hour [kgf] A A B B C C D D E F G G H H J J K K L L M M N N P P Q Q R R (New) V-Belts < 1 operating hour [kgf] 1 Refer to Grasso instruction

19 f Fig.22: Flywheel Grasso V(T) Flywheel data, refer to Figure 22, Page 19 Diameter Remark Dims Number of grooves Max. allowed number of V-belts Grasso V 300(T).. 600(T) Grasso V 700(T) (T) Type of Groove XPB Mass. approx. kg Mass moment of inertia kg.m a mm 158 b (pitch) mm 19.0 c Centre first groove - flywheel d Centre compr. foot - centre first groove e Centre compr. foot - flywheel f Free space between flywheel and crankcase mm 12.5 Grasso V 300(T).. 600(T) mm Grasso V 700(T) (T) mm Grasso V 300(T).. 600(T) mm Grasso V 700(T) (T) mm Grasso V 300(T).. 600(T) mm Grasso V 700(T) (T) mm

For advanced drive technology CLAMPEX. Shaft-Hub-Connection. KTR Precision Joints CLAMPEX

For advanced drive technology CLAMPEX. Shaft-Hub-Connection. KTR Precision Joints CLAMPEX technology CLAMPEX Shaft-Hub-Connection CLAMPEX KTR Precision Joints 07 technology Table of contents Page Brief information 09 Selection and calculation -5 CLAMPEX -Selection Shaft diameter = d 0 10 0