Belt Drive & Bearing Systems Driving Energy Responsibility

Don Sullivan Belt Drives Sr. Product Manager

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Belt Drive & Bearing System Driving Energy Responsibility Agenda Topics

Belt Drives and Ventilation Components of a Belt Drive System Why Belt Drives Exist How Belt Drives Work Belt Constructions Energy Hogs Belt Drive Design Bearing Maintenance

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Belt Drive Introduction

A V-Belt drive is used to: Reduce or increase speed between a motor and a piece of equipment or machinery. Increase or decrease torque Using a V-Belt Drive Is far more economical than buying a motor to run at the speed required by the driven equipment V-Belt Drives are used everywhere: Mining, Conveyors, Crushers, HVAC/R, Etc. A V-Belt Drive Consists of: Sheaves (Pulleys) + Belt and sometimes bushings Driver (Motor) Driven (Blower)

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Belt Drives used in HVAC

Ventilators to Rooftop HVAC

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Belt Drives used in a typical Downblast Ventilation Unit

Fixed Pitch Variable Pitch

Sheave

Sheave

Mounted Bearings

Fan Shaft

Electric Motor
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Belt Drives used in a typical Roof Top Unit

Fixed Pitch Variable Pitch

Sheave

Sheave

Typical Commercial Roof Top Unit

BX Belt

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Why Belt Drives are used in HVAC

Efficient (up to 98%) Adjustability of Speed Economical Quiet & Smooth Running Readily Available Rugged & Versatile Multiplies Torque

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Sheaves Use 3 Principles of Basic Machines They give us a Mechanical Advantage There are 6 Basic Machines Lever Belt Drives use 3 Wheel & Axle Pulley Inclined Plane Wedge Screw
15 lbs. Driver (Motor) Driven (Blower)

5 lbs. 4 to 12 Sheave = 3X Torque Belt Drives Multiply Torque Creating a Mechanical Advantage
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Wedge Principle of a V-Belt Drive

They give us a mechanical advantage There are 6 Basic Machines Lever Wheel & Axle Pulley Inclined Plane Wedge Screw
Wedging Action

Belt Tension forces Belt (Wedge) into Sheave Groove

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V-Belt and Sheave Designs and the use the Principle of the Wedge

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REFERENCE GUIDE Form 8932 ~~~~~~~~~~~~~~~~~~~~~~~~~~

Belt Types

V-Belt Cross Sections [--------------- FHP----------------] FHP (Fractional Horsepower) 2L, 3L, 4L, 5L [---------- Classical --------------] CLASSICAL A, B, C, D [-------------- 358--------------------] 358 DEEP GROOVE 3V, 5V, 8V

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Horsepower Comparison by Construction Type Wrapped vs. Notched (Raw Edge)

BX

Wrapped to Cogged (+27%)

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Energy Efficiency for Different Belt Types

The industry normally uses the following ratings for estimates. Wrapped V-belts = 90% to 95% Notched Raw Edge V-belts = 95% to 98% Synchronous = 95% to 98%

A recent review by eSource of five studies in which V-belts were replaced with cogged V-belts reported savings of between 0.4 and 10 percent with a median savings of 4.1 percent. At the 4.1 percent savings level, the payback from energy savings alone ranged from 1 to 5 months. Example: A typical 100 HP motor operating at 12 hours per day, costs more than $35,000 in electricity (0.10/kWhr) per year to run. A 4.1% efficiency gain in belt drives translates into a $1,400/year electricity savings.

358 High Horsepower Gripbelts and Gripnotch ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

5VX

Deeper Groove. More Belt surface area in contact with Sheave.

BX

5VX has a steeper angle than B which provides greater Company Confidential Internal Use Only wedging action
Not For Publication

Horsepower Comparison by Cross Section BX vs. 5VX

BX

5VX

BX section to 5VX (+49% Horsepower)

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Electrical Energy Consumption by End-use

Other 10% Other 6% Cooking 6% Heating 20% Laundry appliances 7% Home electronics 7% Water heating 9% Kitchen appliances 27% HVAC 31%

Lighting 9%

Lighting (including street) 32%

Pumps 6%
Refrigeration 7%

Office equipment 8% Cooling 15%

Residential 37%

Residential

Commercial 34%

Commercial

Source: Curbing Global Energy Demand Growth: The Energy Productivity Opportunity, McKinsey Global Institute, May 2007

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Energy Hogs

Improper Belt Tensioning Worn Sheave Grooves Unmatched Set of Belts Misalignment

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Energy loss from Belt slip

(result of poor tensioning)

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General Rules for Proper Belt Tensioning

1. Ideal tension is the lowest tension at which the belt will not slip under peak load conditions. 2. Check tension frequently during the first 24 - 48 hours of operation. 3. Over tensioning shortens belt and bearing life. 4. Keep belts free from foreign material which may cause slip. 5. Make V-drive inspection on a periodic basis. Tension when slipping. Never apply belt dressing as this will damage the belt and cause early failure.

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Energy Loss from Worn Sheaves

Sheave Groove Wear

Check for groove wear 1/32 Worn sheaves cause more load on the end cords and more rapid failure
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Belt should never ride in bottom of groove

Energy Savings from Belt Matching

RMA*
Standard Length Designation 26 31 35 38 42 46 51 55 60 68 75 80 81 Standard Datum Lengths Cross Section A,AX B,BX C,CX D 27.3 32.3 36.3 38.8 39.3 39.8 43.3 47.3 52.3 56.3 61.3 69.3 76.3 81.3 43.8 47.8 52.8 56.8 61.8 69.8 76.8 82.8 Permissible Deviation from Std. Datum Lgth +0.6 -0.6 +0.6 -0.6 +0.6 -0.6 +0.7 -0.7 +0.7 -0.7 +0.7 -0.7 +0.7 -0.7 +0.7 -0.7 +0.7 -0.7 +0.7 -0.7 +0.7 -0.7 +0.7 -0.7 +0.7 -0.7 Matching Limits for One Set 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.15 0.30 0.30 0.30 0.30 Matching Matching Limits for Limits for Code 1 Machine 0.15 0.10 0.15 0.10 0.15 0.10 0.15 0.10 0.15 0.15 0.15 0.15 0.15 0.24 0.24 0.24 0.24 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10

53.9 62.9 70.9 77.9 83.9

* RMA = Rubber Manufacturers of America (also ANSI Standard)

Tips for Saving Energy with Belt Drives

(Hunting down Hogzillas)

Improper Belt Tensioning

Use Tension Checkers

Worn Sheave Grooves

Check Sheaves with Groove Gauges Replace Sheaves with every 5-7 belts

Unmatched Set of Belts Use Code 1 or Machine Matched Sets Misalignment

Check Alignment using a Straightedge

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Use the Browning Groove Gage to Check for Groove Wear

Sheaves should be replaced with every 5th to 7th Belt

Replace Sheaves

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Bearing Function
Supports a shaft and its associated load Allows rotation of shaft Minimizes frictional losses

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Bearing FAILURE MODES

* 43% Lubrication - Re-Lube Frequency, Environmental Concerns * 27% Improper Mounting - Improper Installation Procedure and Specifications * 21% Misapplication - Brinnelling, Electric Arcing, Submerged in liquid * 9% Fatigue - End of Bearing Life, Overloaded

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Bearing Lubrication
Re-lubrication Schedule

Re-lubrication Amount

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Automatic Bearing Lubricators

OPERATING PRINCIPLES Utilizes Nitrogen (N2) Gas Generated Through the Use of an Electrolyte and Electrical Energy Utilizing a Self-contained Microprocessor that has a 1-12 Month Variable Dispensing Rate
This computerized dispensing method ensures accurate and reliable lubricant delivery.

USES Use Lubricators Where:

Bearing Access Is Limited or Difficult Applications Are Not Inspected Frequently The Ambient Setting Is Damp or Corrosive Excessive Contamination Is Present Downtime Losses Are High & Output Is Critical Maintenance Costs Must Be Minimized

Gas Generated

Programmable

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Conclusion Its hard to please everyone but.. Your customers want to save money on energy You want to save time on maintenance and keep your customer happy V-Belt Drive efficiency can reach up to 98% when properly installed and maintained. What to do:
Use raw edge notched belts Tension them correctly Replace worn sheaves Lubricate bearings (make life easy and do it automatically)

SAVE ENERGY = $AVE MONEY

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