Manual

Contract Number: 200733
Recipient: Attention: MAURO RAIMUNDO DA SILVA

LARGO RESOURCES
FAZENDA PATRICIO, S/N, POVOADO DE PORTO ALEGRE
MARACAS - BAHIA, BRASIL
TEL: 55 73 3047 0500
Subject: Transmittal of Field Installation, Operation, and Maintenance Manuals
Quantitiy: Hard Cover 3 Electronic 1
Reference:
Equipment: style C conveyor
Location: BRAZIL
Customer PO: 201697
Proposal 11621-R4
Enclosed are the hard cover and electronic versions of the Rexnord Field Service Manuals for the
furnished equipment as required by this contract. The manuals include installation, operation, and
maintenance instructions as well as drawings and other applicable information.
The manuals are designed and supplied to help in the installation of the equipment in the field, and are
valuable assets for the operation and maintenance personnel. Please make certain that the proper
people receive copies.
Any comments you might have regarding the content of the manual are always appreciated.
Best Regards
Name EMY GARCIA DELGADO

Title PROJECT MANAGER
Phone 414 643 2187
email emy.garciadelgado@rexnord.com
EQUIPMENT SERVICE MANUAL
REXNORD CONTRACT NUMBER: 200733
EQUIPMENT LOCATION: BRAZIL
EQUIPMENT: style C conveyor
PURCHASE ORDER NUMBER: 201697
REXNORD PROPOSAL NUMBER: 11621-R4
INCLUDED DRAWINGS:
UNIT 01: GA 200733-01-01SH T1THROUGH
200733-01-EE SH1 THROUGH T7
GA SH4
DRIVE 200733-01-80-100
HEAD SHAFT 200733-01-10-100
TAIL SHAFT 200733-01-12-100
INQUIRIES RELATIVE TO THIS EQUIPMENT SHOULD BE DIRECTED TO YOUR NEAREST REXNORD LOCATION.
REXNORD INDUSTRIAL CHAIN AND CONVEYOR

4800 WEST MITCHELL STREET
MILWAUKEE, WISCONSIN 53214
414-643-3200
THE INFORMATION AND DESCRIPTIVE LITERATURE CONTAINED HEREIN HAS BEEN PREPARED FOR
REXNORD EQUIPMENT FURNISHED IN REFERENCE TO THE CUSTOMER PURCHASE ORDER
Erection Services
Data Sheet No.
3536 E - 1
Page
CONVEYING EQUIPMENT OPERATION 1 of 1

Issued
SERVICE MANUAL July 91

Supersedes
October 85
Product
ERECTION SERVICES Introduction
Various field erection services are available to you. If you are interested, we
can furnish supervision of erection, erection inspection only, or inspection
service. As you can readily understand, the finest equipment available will
not do the job unless it is installed properly.
Supervision of This permits you to furnish your own manpower, tools, payroll, insurance,
Erection etc., with the assurance of a competent man to supervise the work and assure
you of a job properly erected. This type of work is done on a per diem basis
as outlined in paragraph 13 of our material proposal. If it is to be handled on
a contract basis, there would be a time limit included.
Erection Inspection With this service, you can handle complete erection and avail yourself of our
specialist for a final check of erection and initial operation. Payment would
be on a per diem basis as outlined in paragraph 13 of our material proposal.
!
Inspection Service This covers such matters as trouble-shooting and correction of difficulties
after initial or extended operation and inspection for repairs and replacement
purposes.
Since many of our customers are availing themselves of this service, our
servicemen are in the field much of the time. Therefore, please allow
sufficient time for us to schedule a man to coincide with your needs.
The following information should be sent to:
Rexnord Industries, LLC

Conveying Equipment Operation
P.O. Box 2022
Milwaukee, WI 53201
Attention: Manager of Services
Your Order #: Rexnord Order #:
Firm Name:
Your Name: Title:
Type of Service Required:
Copyright Date:
Rexnord 1992
Data Sheet No.
3536 E - 2
Page

Issued

Supersedes
April 82
Product
ERECTION SERVICES General Information
Assembly of Unit The material furnished on this order will be assembled as indicated on
Rexnord Corp. general arrangement drawings.
The drawings were prepared specifically for this equipment.
If additional copies are required, refer to the lead sheet of your service
manual for the correct mailing address.
Mail to the attention of the Engineering Services Department.
If storage at the site is necessary prior to erection, standard procedure should
be followed, for example:
• Material should be blocked off the ground in a manner to prevent
distortion of structural members, and to avoid accumulation of rain
water and/or snow.
• Electric motors, reducers and related electrical equipment, with shaft
! assemblies, chain and other machinery components should be blocked
off the ground and covered to prevent contact with foreign material.
Shipping Copies of packing lists are attached to the shipment and sent to personnel as
specified in instructions of your purchase order.
It is the responsibility of personnel at the installation site to obtain a copy of
this list.
As the material is unloaded, a careful check should be made against the
packing list.
Damaged material is to be reported to the carrier company and Rexnord
Corp. immediately to insure proper substantiation for claims and
adjustments.
It is your responsibility to file claims as Rexnord Corp. has no authority to
allow claims.
Workmanship This manual is intended only as an aid for the installation, operation and
maintenance of Rexnord Corp. equipment.
It is further based on the assumption that only qualified workmen will
perform the service work, utilizing good workmanship and practices at all
times.
AVOID ACC ID ENT S.

! WARNING
A LL EQUIPME NT M UST BE “L OC KED O UT”
E LECT RICAL LY BEF ORE A NY M AINTE NAN CE O R
Copyright WO RK OF A NY KIND IS P ERFO RM ED O N THE
Rexnord 1992 E QUIPM EN T.
Data Sheet No.
3536 E - 2
Page

Issued

Supersedes
April 82
Product
Standard construction for fabricated steel allows for tolerance in lengths and
hole locations.
Minor misfits are considered a normal part of erection work.
The accumulation of the tolerances in foundations, grades, setting of anchor
bolts, etc. created the necessity to use drift pins, reamers, and gas cutting and
welding equipment.
Dimensional tolerance must be compensated for in fit-up.
When new units are tied into existing units, it can be expected that a major
amount of fit-up is required.
The accumulated tolerances are already built into the existing equipment,
making the job of tie-in and alignment a matter of detail fit-up.
Copyright
Rexnord 1992
Data Sheet No.
3536 E - 3
Page

Issued

Supersedes
April 82
Product
Equipment Warranty Rexnord warrants that its products will be of good merchantable quality, free
from defects in material and workmanship and will possess the
characteristics represented in writing by Rexnord. In addition, Rexnord
certifies that the products will comply with those OSHA Standards in effect
at the date of acceptance of the Order by Rexnord that relate solely to
physical characteristics of the products and not to those relative to which
compliance can and/or does involve circumstances of use of the products.
Claim for breach of the above warranty must be made within eighteen (18)
months from the date of delivery to the Original User or twelve (12) months
from the date of readiness for operation, whichever is sooner; however, with
respect to any item not manufactured by Rexnord, the warranty shall be
limited to that extended to Rexnord by the supplier. Upon satisfactory proof
of claim, Rexnord will, within a reasonable time, make any necessary
repairs, additions or corrections, or, at the option of Rexnord replace
defective parts free of charge. Purchaser’s charges for correcting defects or
!
making additions will not be allowed, nor will Rexnord accept products
returned for credit unless the return or correction is authorized by Rexnord in
writing. The foregoing is in lieu of all other warranties, express or implied,
including any warranties that extend beyond the description of the product.
This warranty statement sets forth the extent of the liability of Rexnord for
breach of any warranty or deficiency in connection with the sale of use of the
products.
For all warranty replacement parts, shipment is F.O.B. shipping point,
freight prepaid at the lowest commercial rate. Freight must be prepaid by
Purchaser when returning allegedly defective parts to Rexnord for
inspection.
Preparation of Site Before the actual erection of the equipment is begun, a thorough inspection
of the site is necessary.
Rexnord Corp. assumes no responsibility for site preparation.
It is recommended that the site be cleared of all excess material to allow for
free and easy movement by the erectors and equipment they are utilizing.
All foundation anchor bolts and other steelwork embedded in concrete must
be checked for cleanliness, accuracy of location, and alignment.
Constant referral to general arrangement drawing(s) and anchor bolt layout
drawing(s), and diligent use of a ruler, surveyor’s transit, etc., will insure
accuracy when the equipment is erected.
It is understood that, in the event of error in location of embedded steelwork
or anchor bolts, they will be correctly positioned by the party or parties
Copyright responsible before erection of the equipment proceeds.
Rexnord 1992
Data Sheet No.
3536 E - 3
Page

Issued

Supersedes
April 82
Product
Remarks These instructions do not purport to cover all details or variations in

equipment nor to provide for every possible contingency to be met in
connection with installation, operation or maintenance.
Should further information be desired or should particular problems arise
which are not covered sufficiently for the purchaser’s purpose, the matter
should be referred to Rexnord Corp.
Copyright
Rexnord 1992
Data Sheet No.
3536 E - 4
Page

Issued

Supersedes
April 82
Product
Mark Numbers for Material on this order has been assigned a series of mark numbers to help
Field Identification you identify the parts as they are received and erected. These mark numbers
are indicated on the general arrangement drawings which are a part of this
manual. Further identification is shown on each piece and/or sub-assembly
as noted below.
This marking system is intended to provide a cross-reference between the
general arrangement drawing(s) [erection drawings(s)] and piece parts. For
example, the mark number identification system enables you to take a piece
part and establish on which general arrangement drawing it is shown, and
also where it is located on the drawing. Conversely, you can use the mark
numbers that are shown on the general arrangement drawings to identify all
of the piece parts that are needed for a piece of equipment.
Examples
Example ofofStructural
Structural Piece
Piece Identification G2785-5-2 Unit -5 Numbers such as 325630, 103-595, or CA3240
!
may be used instead of 503-80200 example.*
MK 100-5-31
or The mark number identifies a specific piece or
assembly shown on the fabricated drawing.
503-80200-80
Table (A):
Structural Identification Number Code
G2785-5-2 General Arrangement Drawing Number.
The “G2785” is the order number and the “5-2” are the drawing suffix
numbers. The general arrangement drawing number consists of both the
order number and the suffixes.
Unit - 5 Rex Unit Number.
The unit number refers to a complete piece of equipment, such as a
bucket elevator or a conveyor. Since the unit number is also shown on the
general drawings, it will help you to tie together all the drawings and piece
parts for a specific piece of equipment.
* MK-100 Mark Number.
- 5-31 Fabrication Drawing Suffix Numbers.
(G2785-5-2 with the “G2785” omitted.)
* 503-80200 Fabrication Drawing Number.
-80 Mark Number.
* Structural pieces will be marked with one of these two numbering systems.
On the general arrangement drawing, you will find this piece identified as
MK100-5-31 or 503-80200-80. An arrow is drawn to the exact location of
the piece or sub-assembly on the general arrangement drawing.
Where there is a large quantity of identical pieces, such as angles, tracks or
channels, only a representative number of pieces in each bundle will be
Copyright marked. At least one marked piece from each bundle should be saved until
Rexnord 1992 the last of the bundle has been erected. Otherwise, the remaining pieces not
marked cannot be identified.
Data Sheet No.
3536 E - 4
Page

Issued

Supersedes
April 82
Product
When material is shipped direct from our vendors, pieces may be marked
similarly to above example for easy identification.
Examples of Shafting Machinery shafting will be stamped on one end with Rex order number,
Identification mark number and shafting assembly drawing number.
Table (B):
Shafting Identification Number Code
G3186 Rex Order Number.
G3186-4-19 Shafting Assembly Drawing No. (the “4” identifies the unit number).
200 Mark number.
G3186 Rex Order Number.
635-40057 Shafting Assembly Drawing Number.
80 Mark number.
All miscellaneous loose items such as bolts, nuts, washers, etc. are identified
as “Field Material” in addition to our regular marking. This material will be
packaged individually according to fabrication drawing numbers.
When a number of “Field Material” packages are required to complete your
order, the packages are collectively shipped in one or more larger containers.
These containers will be identified as Box #1, Box #2, etc., and the contents
of each outlined on our packing list.
Any special markings which you requested have been added to our regular
method of identification
Copyright
Rexnord 1992
Safety Instructions
Storage Instructions
Conveyor
Bearing Manual
INSTALLATION INSTRUCTIONS
Link-Belt® Split Housed Series 6600, 6800, & 6900 (pg 1-5)
Mounted Roller Bearings Series 7600, 7800, & 7900 (pg 6-8)
Bearing Mounting Procedure
WARNING: These instructions should be read entirely and followed 9. Force grease in one side of the bearing until it comes out the other
carefully before attempting to install or remove Link-Belt split housed roller side all the way around. Fill grease reservoir on both sides to the
bearings. Failure to do so can result in improper installation which could cause bottom of the shaft. See LUBRICATION INFORMATION on page 2 for
bearing performance problems as well as serious personal injury. more information.
10. For oil lubricated bearings, apply non-hardening gasket compound to
ADAPTER MOUNTED UNITS (6600, 6800, & 6900)
cap surfaces which contact the base (Not needed for grease
1. Inspect shaft size (see shaft tolerance table, Page 2. Table 3). Shaft must
lubrication). Tighten cap nuts or bolts securely. Bolts should be fully
be to correct size. Clean shaft and mounting surface as needed.
tightened with a torque wrench to values in Table 2 on page 2. Where
2. Position housing base onto mounting surface. Snug down mounting bolts.
bearings are to be periodically removed, use 75% of these values.
3. Slide on seal, adapter assembly, bearing, and second seal onto the shaft in
Use oil only on the bolt threads.
the correct order. If “B” felt seals are used, hold until step 8.
11. With the mounting bolts snug, check the alignment and freedom of
4. Locate the bearing and sleeve snugly on the shaft in the desired position.
rotation. “B” seals: Visually check the clearance between the shaft
Fixed bearings are located with the bearing face opposite the locknut up
and the bore of the seal. This clearance is small and can be visually
against the housing shoulder. Expansion bearings are usually centered in
checked for uniformity all the way around the seal. “R” or “H” seals:
the housing seat between the shoulders to allow for shaft expansion or
Measure the distance between the outside diameter of the seal and the
contraction. A shaft with a pair of bearings normally has one fixed and one
diameter of the housing counterbore in three places. Be sure that
expansion pillow block. The fixed unit is usually located adjacent to the
each measurement is taken 90 degrees from the previous
drive. The fixed bearing takes any thrust loads. In locating, take into
measurement. All three measurements should be uniform to insure
account that tightening correctly will move the bearing further up the
proper alignment. See Figure 4. Align by shimming or shifting as
tapered sleeve. Do not tighten locknut beyond finger tight at this time.
necessary. Use large area shims to avoid distorting the housing and
5. Measure the initial built in clearance across the top of both sets of rollers
pinching the bearing. Appropriate use of stop bars against faces or
as shown in Figure 1. It must be possible to remove shim by pulling
ends of feet opposite the direction of load or vibration to avoid shifting
straight out.
of the housing is recommended. Dowel pins can be equally effective if
6. Using a spanner wrench, tighten the locknut until snug (Figure 2). Hold the
properly used. This is especially important where loads are not directly
adapter sleeve from turning until firmly seated. Using a soft steel bar and a
down through the base. Finally, tighten or torque mounting bolts
hammer, drive against the face of the locknut as shown to relieve the
securely. Up to SAE Grade 5 mounting bolts can be used, properly
thread pressure (Figure 3). Retighten the locknut and repeat until the
torqued, to mount cast iron housings (See table 2A on page 2). Up to
correct adjustment specified in CLEARANCE REDUCTION TABLE (Table
SAE Grade 8 mounting bolts can be used, properly torqued, to mount
1) is achieved.
cast steel housings (see table 2B on page 2).
Table 1: CLEARANCE REDUTION TABLE (All values in inches)C3 Bearing
Radial Clearance
Pillow Block Range Unmounted
Final Operating
Reduction ADDITIONAL INSTALLATION COMMENTS
Clearance 1. Cap and base are machined as matched unit and are not
Clearance
Min Max interchangeable. The machined split line on base is marked and
From To Min Max Min Max
should be matched to corresponding cap.
6823 6828 .0024 .0031 .0012 .0021 .0010 .0012 2. If outer rings become misaligned, do not force back into position.
6831 6835 .0030 .0037 .0014 .0025 .0012 .0016 Instead, carefully work back by turning and sliding.
6839 6843 .0037 .0047 .0017 .0031 .0016 .0020 3. For installation of D5 see page 4. For installation of D8 Sealing
6847 6856 .0043 .0055 .0019 .0037 .0018 .0024 arrangements see page 5
6859 6867 .0053 .0067 .0025 .0047 .0020 .0028
6871 6880 .0063 .0079 .0028 .0053 .0026 .0035
6883 6887 .0071 .0091 .0032 .0061 .0030 .0039
6895 68104 .0079 .0102 .0036 .0071 .0031 .0043
68111 68115 .0087 .0114 .0036 .0079 .0035 .0051
68120 68128 .0098 .0126 .0043 .0087 .0039 .0055
66135 66144 .0106 .0138 .0047 .0095 .0043 .0059
66151 68168 .0118 .0154 .0051 .0107 .0047 .0067
66175 66176 .0130 .0169 .0055 .0118 .0051 .0075
6923 6927 .0024 .0031 .0012 .0021 .0010 .0012
6931 6935 .0030 .0037 .0014 .0025 .0012 .0016
6936 6943 .0037 .0047 .0017 .0031 .0016 .0020
6947 SAF307 .0043 .0055 .0019 .0037 .0018 .0024
315 403 .0053 .0067 .0025 .0047 .0020 .0028 Figure 1) Measuring Initial Clearance Figure 2) Tighten Until Snug
407 500 .0063 .0079 .0028 .0053 .0026 .0035
503 507 .0071 .0091 .0032 .0061 .0030 .0039
SAF22634 515 .0079 .0102 .0036 .0071 .0031 .0043
7. Bend a tang of lockwasher into slot of locknut. If tang does not line up,
tight locknut until closest tang lines up.
8. If felt seal halves are not fastened to the cap with adhesive this should be
done. Dry the seal grooves in both sides of the cap to remove oil and
preservative. Apply a good quality rubber cement evenly to both the seal
O.D. and the housing seal bore. Do not get adhesive on the felt. When
adhesive dries to slight tackiness, install the seal halves in the cap. Install
the other halves in the base before the shaft is in place, then wet the felts
with oil. The shaft holds seals in place for complete drying. Do not operate
until adhesive is set. Figure 3) With a soft steel bar, Figure 4) Checking Alignment
tap on face of locknut
For Tech Support, Phone: 317-273-5781 10-11-12

Rexnord Industries Corp.
For Tech Support, Email: Page 1 of 8
Bearing Group BR3-004
Bearing.tech.support@rexnord.com
Link-Belt® Split Housed Mounted INSTALLTION INSTRUCTIONS
Roller Bearings Series 6600, 6800, & 6900
Table 2A: Recommended Housing Cap Bolt Tightening Torque Table 2B: Recommended Housing Cap Bolt Tightening Torque
Cast Iron Housing Cast Steel Housing
Tightening Tightening Torque (lb-ft)
Series Tightening Series
Torque (lb- Series 6800 Series 6600 Load Directed Load Directed
6800/6600 Torque (lb-ft) 6900/SAF22600
ft) into Base into Cap
6823-6840 45-50 6923-6932 45-50 6839-6840 - 50-65 80-110
6841-6852 90-100 6933-6944 90-100 6841-6848 - 100-130 160-220
6853-6868 160-180 6945-6948 160-180 6853-6864 - 170-230 300-400
6869-6872 280-330 22618 90-100 6869-6872 - 280-370 490-650
6873-68104 400-430 22620-22622 160-180 6873-6880 - 410-550 730-970
68105-68115 630-700 22624-22626 160-180 6883-68104 - 580-780 1030-1370
68117-68128 800-890 22628-22630 220-250 68105-68116 66129-66144 820-1100 1450-1940
66129-66144 630-700 22632 320-350 68117-68128 66B151-66168 1430-1900 2530-3370
66145-66168 800-890 22634 450-500 66169-66176 1400-1550 2530-3370
66169-66176 1400-1500 - -
Table 3: Recommended Shaft Tolerance
SHAFT TOLERANCE TABLE – INCHES
Commercial RECOMMENDED SHAFT
Nominal Shaft
Shaft Tolerance* TOLERANCES*
sizes
(inches) (Cold Finished
Press Fit
Steel, Low Adapter Mounting
Mounting Grease lubrication is recommended wherever
Over Incl. Carbon)
conditions in Table 4 exist. For conditions which are
1 7/16 2 +.000 -.003 +.000 -.003 not completely covered in Table 4 consult Rexnord
2 1/16 4 +.000 -.004 +.000 -.004 Consult Bearing Division. A reputable lubricant manufacturer
4 1/16 6 +.000 -.005 +.000 -.005 Rexnord should be consulted to confirm the lubricant selection
6 1/16 13 +.000 -.006 +.000 -.006 and application.
*Recommended shaft tolerances are generally satisfactory for loads up to 15% of C (see load Relubrication After Running – Relubrication of units in
ratings in catalog). High load applications will require a press fit to the shaft.
service should be through the fitting or hole in the center of
Table 4: GREASE LUBRICATION INFORMATION the unit when bearings with lube holes and grooves are
used as normally supplied. The amount of grease used
LUBRICATION TABLE (HORIZONTAL SHAFT APPLICATION) should be enough to purge old grease from the bearing
RECOMMENDED NUMBER OF MONTHS BEWEEN only (not the entire pillow block) and form a cushion of
6800/6600 RELUBRICATION* (BASED ON 24/7 OPERATION)
To Relubricate grease adjacent to the bearing face.
Series Units Relube Interval
Shaft size in Inches High Speed Operation – Consult Table 4 for a guide to
6 Months 4 Months 2 Months 1 Month correct greases and frequency of relubrication. High speed
1 7/16 – 1 1/2 0.15 oz. 2400 3600 5000 5500
1 11/16 – 1 3/4 0.15 oz. 2200 3300 4500 5000 bearings will not operate satisfactory when packed full of
1 15/16 – 2 0.20 oz. 2200 3000 4000 4500 grease. As relubrication will eventually fill the housing
2 3/16 – 2 1/4 0.40 oz. 1700 2500 3400 3800 cavities, it may be necessary to remove the cap
2 7/16 – 2 1/2 0.40 oz. 1450 2200 3000 2400
2 11/16 – 2 3/4 0.45 oz. 1350 2000 2800 2300
periodically, clean out the old lubricant and repack with the
2 15/16 – 3 0.60 oz. 1300 1900 2600 3000 original amount.
3 3/16 – 3 1/4 0.85 oz. 1200 1800 2400 2700
3 7/16 – 3 1/2 1.15 oz. 1100 1650 2200 2300
3 11/16 – 4 1.60 oz. 1000 1500 1950 2100
4 3/16 – 4 1/4 2.15 oz. 900 1350 1850 1900
4 7/16 – 4 1/2 2.80 oz. 840 1250 1700 1800
4 15/16 – 5 3.20 oz. 780 1150 1600 1700 * Additional bearing protection or special sealing may be
5 3/16 – 5 1/4 4.00 oz. 730 1100 1500 1600
5 7/16 – 5 1/2 5.10 oz. 680 1000 1400 1500 required. Consult Rexnord Bearing Division.
5 15/16 – 6 6.10 oz. 640 970 1300 1400 ** Suggested starting interval for maintenance program.
6 7/16 – 6 1/2 6.40 oz. 610 910 1200 1300 Check grease condition for oiliness and dirt and adjust
6 15/16 – 7 7.70 oz. 570 860 1100 1200 greasing frequency accordingly. Watch operating
7 3 /16 – 7 1/4 11.70 oz. 550 820 1000 1100
7 1/2 – 8 13.40 oz. 500 750 900 1000 temperatures. Sudden rises may show need for grease or
Shaft Speed in RPM indicate over lubrication on higher speed applications.
Clean and Repack Interval 5 Years 3 Years 2 Years 1 Year Rexnord Bearing Division, cannot be held responsible for
performance of individual batches of grease. Changes in
LUBRICATION TABLE (HORIZONTAL SHAFT APPLICATION) lubricant specifications, performance, and lubricant
RECOMMENDED NUMBER OF MONTHS BEWEEN
RELUBRICATION* (BASED ON 24/7 OPERATION) guarantees are the responsibility of the lubricant
6900/SAF22600 To Relubricate
Shaft size in Inches Units Relube Interval manufacturer.
6 Months 4 Months 2 Months 1 Month
1 7/16 – 1 1/2 0.35 oz. 1325 2100 3150 4200
1 11/16 – 1 3/4 0.55 oz. 1200 1900 2850 3800
- Operating temperature limited to -40 to +225°F
1 15/16 – 2 0.65 oz. 1075 1800 2700 3600 - “Dirty,” Corrosive or Wet environments require more
2 3/16 – 2 1/4 0.95 oz. 925 1500 2250 3000 frequent re-lube
2 7/16 – 2 1/2 1.30 oz. 800 1300 1950 2600 - D8 seal limit is 1500 surface feet per minute
2 11/16 – 2 3/4 1.60 oz. 750 1250 1875 2500
2 15/16 – 3 1.80 oz. 700 1150 1725 2300 - B felt seal limit is 800 surface feet per minute
3 3/16 – 3 1/4 2.15 oz. 650 1100 1650 2200 - Reduce lubrication intervals by half for vertical shaft
3 7/16 – 3 1/2 3.10 oz. 600 1000 1500 2000 applications
3 11/16 – 4 4.15 oz. 550 900 1350 1800
4 3/16 – 4 1/4 5.80 oz. 500 800 1200 1600
4 7/16 – 4 1/2 6.70 oz. 450 750 1125 1500
4 15/16 – 5 8.45 oz. 425 700 1050 1400
5 3/16 – 5 1/4 11.00 oz. 400 650 975 1300
5 7/16 – 5 1/2 13.00 oz. 375 625 950 1250
5 15/16- 6 15.50 oz. 350 575 850 1150
Shaft Speed in RPM
Clean and Repack Interval 5 Years 3 Years 2 Years 1 Year
Roller Bearings Series 6600, 6800, & 6900
Oil Lubrication
Oil Cup or Oil Bath Lubrication – Oil cups can be applied for use as a self-contained oil bath system. Oil bath lubrication is not recommended for speeds
above the catalog oil speed limits, where excessive oil churning or misting occurs, or where there is air flow across the housing, which will pull oil out through
the seals due to different pressures.
Oil levels are controlled by sight gages, oil cups, etc. These should be used in conjunction with a vent or breather cap. Proper static oil levels are shown in
Table 5. Cups or sight gages should be carefully marked.
Circulating Oil Lubrication (See page 8) – Oil circulation systems can be used under a wider variety, or under more extreme operating conditions than any
other lubrication method. They are especially valuable for high speed and high temperature service to provide better lubrication and cooler operation.
A complete circulation system includes the use of pressure pump, a heat exchanger (or a method of cooling oil), an adequate sump, a filter to remove
particles over 20 micron in size and safety devices such as pressure and temperature warning devices and filter bypasses. It is also best to tap oversize
drain holes in the housing or to provide a suction pump to positively remove oil from the housing. Oil should be removed from both sides of the housing, but
where speeds are not high one side may be sufficient.
Oil Viscosity – The required viscosity for good lubrication depends on starting temperatures, operating temperatures, and speed. The recommended
viscosity level for bearings operating within catalog speed limits is between 100 and 150 Saybolt seconds (SSU) at operating temperature for oil exit
temperature on circulating systems. Slow speed heavily loaded bearings require much higher viscosities. Consult Rexnord Bearing Division.
Where starting temperatures are very low compared to operating temperatures, heaters may be necessary to provide oil flow in the lines or to provide
adequate lubrication at start-up.
Maintenance and Lubrication:
Oil cup or oil bath systems require close attention because of the limited amount of oil in the system. Frequent changing of oil is necessary in these
systems to avoid lubricant breakdown. Oil circulating systems, properly equipped with safety devices, require minimum attention after they are once
satisfactorily adjusted. Frequency of changing the oil in the system depends upon the severity of the operation and size of the reservoir. Also, summer and
winter grades of oil may be required, to stay within the recommended viscosity limits for good lubrication.
Table 5 – Static Oil Level
L L L
A D A D A D
Block Number High Low Block Number High Low Block Number High Low
Inches Inches Inches
4 4
6823, 6824 2 1/4 7/16 1 9/32 1 3/8 6887 6 11/16 1 15/32 21/32 6935 3 1/2 3/4 2 1/32 2 5/32
1 4 2
6827, 6828 2 1/2 9/16 1 3/8 15/32 6895, 6896 7 1/16 1 1/8 4 3/4 15/16 6939, 6940 4 3/4 11/32 2 1/2
1 4 2
6831, 6832 2 3/4 9/16 17/32 1 5/8 68103 7 1/2 1 1/8 31/32 5 9/32 6943 4 1/4 7/8 15/32 2 5/8
1 1 2 2
6835, 6836 3 1/2 27/32 15/16 68111, 68112 7 7/8 1 1/4 5 1/4 5 7/16 6947 4 1/2 7/8 23/32 13/16
2 2
6839 3 1/4 5/8 2 1/32 2 1/4 68115 8 1/4 1 3/8 5 9/16 5 3/4 22618 4 3/4 1 3/32 25/32 31/32
6
6843 3 1/2 3/4 2 3/16 2 9/32 68120-68128 9 1/2 2 1/2 6 5/32 11/32 22620 5 1/4 1 3 1/8 3 5/16
2 5 3 3
6847, 6848 3 3/4 13/16 2 3/16 15/32 66135-66144 8 1/4 1 3/8 15/16 6 1/8 22622 6 1 1/4 15/32 21/32
2 66B151, 6 3 3
6851 4 3/4 15/32 2 5/8 66B152 9 1/2 1 1/2 15/16 7 1/8 22624 6 5/16 1 3/16 25/32 31/32
2 2 6
6855, 6856 4 1/2 7/8 25/32 15/16 66159, 66160 9 1/2 1 1/2 15/16 7 1/8 22626 6 11/16 1 1/16 4 3/32 4 9/32
6
6859-6864 4 15/16 7/8 3 1/16 3 7/32 66167, 66168 9 1/2 1 1/2 15/16 7 1/8 22628 7 1/16 1 3/16 4 3/8 4 9/16
7 7 4
6867 5 1/4 1 3 5/16 3 1/2 66175, 66176 12 2 7/8 17/32 23/32 22630 7 1/2 1 3/16 11/16 4 7/8
1 4
6871, 6872 6 1 1/4 3 9/16 3 3/4 6923, 6924 2 3/4 11/16 1 7/16 17/32 22632 7 7/8 1 5/16 31/32 5 5/32
1 1
6879, 6880 6 1 1/16 3 7/8 4 1/16 6927 3 9/16 19/32 11/16
BEARING DIVISION
4 1 1
6883 6 5/16 1 1/16 4 5/32 11/32 6931, 6932 3 1/4 13/16 23/32 13/16

Roller Bearings D5 Seal Arrangement
PENTAC D-5 SEALING SYSTEM ADDITIONAL INSTALLATION COMMENTS

1. Before installing the bearing, slide 1st rubber PenTac Seal on shaft. 1. PenTac Seal is made of nitrile rubber and can be cleaned with
If hard to do so, coat shaft and seal bore with a thin layer of oil. If oil certain solvents. Some solvents can cause damage to the seal. For
is used, the shaft must be wiped clean. questions on a specific solvent, contact Rexnord.
2. Pack the grease cavity of the rubber seal with grease using a flexible 2. When sliding seal onto shaft, use light impact blows on the heel on
putty knife. See Figure 5 for reference. the seal. Do not impact the seal lip.
3. Assembly bearing referring to ADAPTER MOUNTED UNITS page 1- 3. If the bearing will experience extreme temperatures (>170°F) due to
2. environment and system conditions, the “Push In” distance of 1mm
4. Slide on second rubber PenTac seal. Repeat steps 1 and 2. should be used regardless of shaft speed.
5. Slowly push each seal so the lip rests lightly against the housing. 4. If seal is pushed in too far, place a screwdriver between seal lip and
You can be sure by seeing a slight flex in the lip seal. housing. While maintaining pressure against the housing, rotate
6. Use a marker and mark the shaft right behind the heel of the seal. handle upward.
Refer to figure 6.
7. Push the seal in by distance given in Table 6 (figure 7).
Table 6: DISTANCE TO PUSH SEAL INWARD

Push in Distance 1 Push in Distance
Shaft Size
mm 2 mm
1 7/16- 1 ½”,
5300 > RPM > 2700 < 2700 RPM
40mm
1 11/16 – 1 ¾”,
5000 > RPM > 2400 < 2400 RPM
45mm
1 15/16 – 2”,
4500 > RPM > 2300 < 2300 RPM
50mm
2 3/16”, 60mm 3800 > RPM > 2200 < 2200 RPM
2 7/16”, 65mm 3400 > RPM > 2000 < 2000 RPM
2 11/16”, 70mm 3200 > RPM > 1800 < 1800 RPM
2 15/16 – 3”,
3000 > RPM > 1700 < 1700 RPM
75mm
3 3/16”, 80mm 2600 > RPM > 1500 < 1500 RPM
3 7/16 – 3 ½”,
2200 > RPM > 1500 < 1500 RPM
90mm
3 11/16 – 4”,
2000 > RPM > 1300 < 1300 RPM
100mm
4 3/16”, 110mm 1900 > RPM > 1200 < 1200 RPM
4 7/16 – 4 ½”,
1800 > RPM > 1150 < 1150 RPM
115mm Figure 6: Complete assembly of D-5 PenTac showing reference line
4 15/16 – 5”, drawn on the shaft.
1700 > RPM > 1000 < 1000 RPM
125mm
5 3/16”, 135mm 1600 > RPM > 950 < 950 RPM
5 7/16”,140mm 1500 > RPM > 950 < 950 RPM
5 15/16 – 6”,
1300 > RPM > 850 < 850 RPM
150mm
6 7/16”, 160mm 1300 > RPM > 800 < 800 RPM
6 15/16” – 7”,
1200 > RPM > 750 < 750 RPM
170mm
7 3/16”, 180mm 1100 > RPM > 700 < 700 RPM
7 ½ - 8”, 200mm 1000 > RPM > 650 < 650 RPM
8 7/16 – 9”,
1000 > RPM > 550 < 550 RPM
220mm
9 7/16 – 10 ½”,
850 > RPM > 500 < 500 RPM
260mm
Seal Figure 5:
Lip Cross section
of rubber
PenTac seal
member
Grease Cavity
Figure 7: Installed “Push In” distance shown at the final installed

position of the PenTac Seal.
Heel
Lip
Roller Bearings D8 Seal Arrangement
D8 (or D9) TACONITE SEALING SYSTEM ADDITIONAL INSTALLATION COMMENTS

1. Before installing the bearing, slide 1st Seal Carrier on shaft. 1. D8 and D9 Sealing systems require a specially machined groove in
2. Assembly bearing referring to ADAPTER MOUNTED UNITS page 1- the housings. The taconite seals cannot be used with a standard
2. Slide on 2nd seal carrier. LER ring housing groove.
3. Seal carrier internal cavities should be fully packed with grease 2. As a starting point, a factor of 0.5 times the shaft diameter gives the
before assembly on shaft. approximate cubic inch volume of grease to flush one seal assembly.
4. The packing ring in the seal carrier O.D. groove should be positioned
in the middle to outboard half of the groove.
5. The seal carriers must be rotated so that the carrier anti rotation
tang fits into the slot provided in the housing base interior side
wall.
Figure 8

Link-Belt® Split Housed Series 7600, 7800, & 7900
Mounted Roller Bearings
Direct Shaft Mount Units (7600, 7800, 7900) 10. With the mounting bolts snug, check the alignment and freedom of
1. Inspect shaft size. Clean shaft and mounting surface as needed. rotation. “B” seals: Visually check the clearance between the shaft
2. Position housing base onto mounting surface. Snug down mounting and the bore of the seal. This clearance is small and can be visually
bolts. checked for uniformity all the way around the seal. “R” or “H”
3. Slide on first seal. If “B” felt seals are used, hold until step 8. seals: Measure the distance between the outside diameter of the
4. Mount all inboard items on shaft. Coat shaft bearing seat with a seal and the diameter of the housing counterbore in three places.
mixture of white lead and oil or suitable solid lubricant. Start bearing Be sure that each measurement is taken 90 degrees from the
squarely on shaft. Apply pressure to the inner ring only. A soft steel previous measurement. All three measurements should be uniform
tube or pipe having an O.D. no larger than the inner ring shoulder to insure proper alignment. See Figure 9. Align by shimming or
may be used to press or tap the bearing into position. Bearings may shifting as necessary. Use large area shims to avoid distorting the
be shrink fitted on the shaft by heating evenly in oil to 250°F max. housing and pinching the bearing. Appropriate use of stop bars
Slip the thoroughly heated bearing onto the shaft and hold in position against faces or ends of feet opposite the direction of load or
until it cools and shrinks on the shaft. vibration to avoid shifting of the housing is recommended. Dowel
5. Install and tighten locknut and lockwasher or other holding device pins can be equally effective if properly used. This is especially
securely. A lockwasher tang must be bent over into a notch in the important where loads are not directly down through the base.
locknut or lockwire heads of capscrews holding the lock plate. Finally, tighten or torque mounting bolts securely. Up to SAE Grade
6. Check for freedom of rotation to ensure operating clearance has not 5 mounting bolts can be used, properly torqued, to mount cast iron
been removed by shaft fit. housings (see table 7A). Up to SAE Grade 8 mounting bolts can be
7. Force grease in one side of the bearing until it comes out the other used, properly torqued, to mount cast steel housings (see table 7B).
side all the way around. Fill grease reservoir on both sides to the
bottom of the shaft. See LUBRICATION INFORMATION on page 7,
Table 8, for more information. ADDITIONAL INSTALLATION COMMENTS
8. If felt seal halves are not fastened to the cap with adhesive this 1. Cap and base are machined as matched unit and are not
should be done. Dry the seal grooves in both sides of the cap to interchangeable. The machined split line on base is marked and
remove oil and preservative. Apply a good quality rubber cement should be matched to corresponding cap.
evenly to both the seal O.D. and the housing seal bore. Do not get 2. If outer rings become misaligned, do not force back into position.
adhesive on the felt. When adhesive dries to slight tackiness, install Instead, carefully work back by turning and sliding.
the seal halves in the cap. Install the other halves in the base before
the shaft is in place, then wet the felts with oil. The shaft holds seals
in place for complete drying. Do not operate until adhesive is set.
9. For oil lubricated bearings, apply non-hardening gasket compound to
cap surfaces which contact the base (Not needed for grease
lubrication).
Table 7A: Recommended Housing Cap Bolt Tightening Torque Table 7B: Recommended Housing Cap Bolt Tightening Torque
Cast Iron Housing Cast Steel Housing**

Tightening Torque (lb-ft)
Tightening Series
Series 7800 Series 7600 Series 7900 Series 7800 Load Directed Load Directed
Torque (lb-ft) 7600
into Base into Cap**
7875 - 7945-7955 45-50 7875 - 50-65 80-110
7880-7890 - 7965-7980 90-100 7880-7885 - 100-130 160-220
78100-78130 - 7985-22322 160-180 7890-78110 - 170-230 300-400
78140-78180 - 22324-22330 400-440 78120-78130 - 280-370 490-650
78190-78200 76240 22332-22334 630-700 78140 - 410-550 730-970
78220 76280 - 800-890 78150-78180 76240 580-780 1030-1370
- 76300 - 1400-1550 78190-78200 76280 820-1100 1450-1940
78220 76300 1430-1900 2530-3370
- - 1400-1550 2530-3370
** Replace spring lockwasher with plain washer.
Figure 9:
Checking
Alignment

Link-Belt® Split Housed Series 7600, 7800, & 7900
Mounted Roller Bearings
LUBRICATION INFORMATION Table 8
LUBRICATION TABLE (HORIZONTAL SHAFT APPLICATION) Grease lubrication is recommended wherever

RECOMMENDED NUMBER OF MONTHS BEWEEN conditions in Table 8 exist. For conditions which are
7800/7600 To Relubricate
RELUBRICATION* (BASED ON 24/7 OPERATION) not completely covered in Table 8 consult Rexnord
Series Units Relube Interval Bearings Division. A reputable lubricant manufacturer
Shaft size
6 Months 4 Months 2 Months 1 Month should be consulted to confirm the lubricant selection
75 mm 0.40 oz. 1450 2200 3000 3400 and application.
80 mm 0.45 oz. 1350 2000 2800 3200
85 mm 0.60 oz. 1300 1900 2600 3000
Relubrication After Running – Relubrication of units in
90 mm 0.85 oz. 1200 1800 2400 2700 service should be through the fitting or hole in the center of
100 mm 1.15 oz. 1100 1650 2200 2300 the unit when bearings with lube holes and grooves are
110 mm 1.60 oz. 1000 1500 1950 2100
120 mm 2.15 oz. 900 1350 1850 1900
used as normally supplied. The amount of grease used
130 mm 2.80 oz. 840 1250 1700 1800 should be enough to purge old grease from the bearing
140 mm 3.20 oz. 780 1150 1600 1700 only (not the entire pillow block) and form a cushion of
150 mm 4.00 oz. 730 1100 1500 1600 grease adjacent to the bearing face.
160 mm 5.10 oz. 680 1000 1400 1500
170 mm 6.10 oz. 640 970 1300 1400 High Speed Operation – Consult Table 8 for a guide to
180 mm 6.40 oz. 610 910 1200 1300 correct greases and frequency of relubrication. High speed
190 mm 7.70 oz 570 860 1100 1200 bearings will not operate satisfactory when packed full of
200 mm 11.70 oz. 550 820 1000 1100 grease. As relubrication will eventually fill the housing
220 mm 13.40 oz. 500 750 900 1000
Shaft Speed in RPM cavities, it may be necessary to remove the cap
Clean and Repack Interval 5 Years 3 Years 2 Years 1 Year periodically, clean out the old lubricant and repack with the
original amount.
* Additional bearing protection or special sealing may be

LUBRICATION TABLE (HORIZONTAL SHAFT APPLICATION) required. Consult Rexnord Bearing Division.
RECOMMENDED NUMBER OF MONTHS BEWEEN ** Suggested starting interval for maintenance program.
RELUBRICATION* (BASED ON 24/7 OPERATION) Check grease condition for oiliness and dirt and adjust
7900/SAF22300 To Relubricate
Shaft size in Inches Units Relube Interval greasing frequency accordingly. Watch operating
6 Months 4 Months 2 Months 1 Month temperatures. Sudden rises may show need for grease or
45 mm 0.35 oz. 1325 2100 3150 4200 indicate over lubrication on higher speed applications.
50 mm 0.55 oz. 1200 1900 2850 3800
55 mm 0.65 oz. 1075 1800 2700 3600 Rexnord Bearing Division, cannot be held responsible for
60 mm 0.95 oz. 925 1500 2250 3000 performance of individual batches of grease. Changes in
70 mm 1.30 oz. 800 1300 1950 2600 lubricant specifications, performance, and lubricant
80 mm 1.60 oz. 750 1250 1875 2500
85 mm 1.80 oz. 700 1150 1725 2300 guarantees are the responsibility of the lubricant
90 mm 2.15 oz. 650 1100 1650 2200 manufacturer.
100 mm 3.10 oz. 600 1000 1500 2000
110 mm 4.15 oz. 550 900 1350 1800
120 mm 5.80 oz. 500 800 1200 1600 - Operating temperature limited to -40 to +225°F
130 mm 6.70 oz. 450 750 1125 1500
140 mm 8.45 oz. 425 700 1050 1400
- “Dirty,” Corrosive or Wet environments require more
150 mm 11.00 oz. 400 650 975 1300 frequent re-lube
160 mm 13.00 oz. 375 625 950 1250 - D8 seal limit is 1500 surface feet per minute
170 mm 15.50 oz. 350 575 850 1150 - B felt seal limit is 800 surface feet per minute
Shaft Speed in RPM
Clean and Repack Interval 5 Years 3 Years 2 Years 1 Year
- Reduce lubrication intervals by half for vertical shaft
applications

Link-Belt Split Housed ®
Series 6600, 6800, & 6900
Mounted Roller Bearings Series 7600, 7800, & 7900
CIRCULATING OIL LUBRICATION INFORMATION

Circulating Oil Lubrication– Oil circulation systems can be used under a wider variety, or under more extreme operating conditions than any other
lubrication method. They are especially valuable for high speed and high temperature service to provide better lubrication and cooler operation.
A complete circulation system includes the use of pressure pump, a heat exchanger (or a method of cooling oil), an adequate sump, a filter to remove
particles over 20 micron in size and safety devices such as pressure and temperature warning devices and filter bypasses. It is also best to tap oversize
drain holes in the housing or to provide a suction pump to positively remove oil from the housing. Oil should be removed from both sides of the housing, but
where speeds are not high one side may be sufficient. See Figure 10 for Schematic.
Oil Viscosity – The required viscosity for good lubrication depends on starting temperatures, operating temperatures, and speed. The recommended
viscosity level for bearings operating within catalog speed limits is between 100 and 150 Saybolt seconds (SSU) at operating temperature for oil exit
temperature on circulating systems. Slow speed heavily loaded bearings require much higher viscosities. Consult Rexnord Bearing Division.
Where starting temperatures are very low compared to operating temperatures, heaters may be necessary to provide oil flow in the lines or to provide
adequate lubrication at start-up.
Maintenance and Lubrication:
Oil cup or oil bath systems require close attention because of the limited amount of oil in the system. Frequent changing of oil is necessary in these
systems to avoid lubricant breakdown. Oil circulating systems, properly equipped with safety devices, require minimum attention after they are once
satisfactorily adjusted. Frequency of changing the oil in the system depends upon the severity of the operation and size of the reservoir. Also, summer and
winter grades of oil may be required, to stay within the recommended viscosity limits for good lubrication.
Figure 10
A. IT IS EXPRESLY AGREED THAT THE FOLLOWING WARRANTY IS GIVEN IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESSLY IMPLIED OF STATUTORY. INCLUDING THOSE OF
MERCHANTABILITY AND FITNESS FOR A PATICULAR PURPOSE, AND OF ANY OTHER OBLIGATION OR LIABILITY ON OR PART OF ANY KIND OR NATURE WHATSOEVER.
No representative of ours has any authority to waive, alter, vary, or add to the terms hereof without prior approval in writing, to our customer, signed by an officer of our company. It is expressly agreed that the
entire warranty given to the customer is embodied in this writing. This writing constitutes the final expression of the parties agreement with respect to warranties, and that it is a complete and exclusive
statement of the terms of the warranty.
We warrant to our customers that all Products manufactured by us will be free from defects in material and workmanship at the time of shipment to our customer for a period of one (1) year from the date of
shipment. All warranty claims must be submitted to us within ten days of discovery of defects within the warranty period, or shall be deemed waived. As to Products or parts thereof that are proven to have
been defective at the time of shipment, and that were not damaged in shipment, the sole and exclusive remedy shall be repair or replacement of the defective parts or repayment of the proportionate purchase
price for such Products or part, at our option. Replacement parts shall be shipped free of charge f.o.b. from our factory.
This warranty shall not apply to any Product which has been subject to misuse; misapplication, neglect (including but not limited to improper maintenance and storage); accident, improper installation,
modification (including but not limited to use of unauthorized parts or attachments), adjustment, repair or lubrication. Misuse also includes, without implied limitation, deterioration in the Product or part caused
by chemical reaction, wear caused by the presence of abrasive materials, and improper lubrication. Identifiable items manufactured by others but installed in or affixed to our Products are not warranted by use
but, bear only those warranties, express or implied, given by the manufacturer of that item, if any. Responsibility for system design to insure proper use and application of Link-Belt Products within their
published specifications and ratings rests solely with customer. This includes without implied limitation analysis of loads created by torsional vibrations within the entire system regardless of how induced.
B. It is expressly agreed that our liability for any damage arising out of or related to this transaction, or the use of our Products, whether in contract or in tort, is limited to the repair or replacement of the
Products, or the parts thereof by use, or to a refund of the proportionate purchase price. We will not be liable for any other injury, loss, damage, or expense, whether direct or consequential, including but not
limited to use, income, profit, production, or increased cost of operation, or spoilage of or damage to material, arising in connection with the sale, installation, use of, inability to use, or the replacement of, or late
delivery of, our Products.

Locking Assembly Head
INSTALLATION AND REMOVAL INSTRUCTIONS FOR 7. Reset torque wrench to specified torque (MA) and check all locking screws.
B-LOC™ LOCKING ASSEMBLY SERIES B106 & B103 No screw should turn at this point, otherwise repeat Step 6 for 1 or 2 more
passes. It is not necessary to re-check tightening torque after equipment has
Thank you for purchasing a B-LOC™ Keyless Frictional Locking Device. been in operation.
B-LOC™ keyless connectors provide a high capacity, zero-backlash
shaft/hub or coupling connection by means of a mechanical interference NOTE: The torque capacity of these units can be increased by approximately 25% by
fit. Please follow these INSTALLATION AND REMOVAL INSTRUCTIONS thoroughly cleaning the shaft and Locking Assembly bore of any lubricant. In
carefully to ensure proper performance of this B-LOC™ unit. applications subject to extreme corrosion, the slits in all collars should be
sealed with a suitable caulking compund or equivalent. Likewise, push-off
EWARNING E threads should be protected from corrosion.
When installing or removing B-LOC™ products, always adhere to the following INSTALLATION OF B-LOC LOCKING
safety standards: ASSEMBLIES OVER SHAFT KEYWAYS
1. Be sure that all power switches are locked out before installing or removing
The Locking Assembly should be positioned so that slits in Locking Assembly
B-LOC™ products.
collars that contact the shaft are located approximately opposite the keyway.
2. Eye protection is required when installing or removing B-LOC™ products
In addition, a locking screw should be centered directly over the keyway.
- please wear safety glasses and protective clothing.
When tightening locking screws, it is important to follow the installation
INSTALLATION procedure outlined above, which specifies equal 1/4 turns of each locking
(Refer to Figure 1) screw. Failure to follow these instructions could result in excessive tightening
B-LOC™ Series B103 and B106 Locking Assemblies are supplied lightly oiled and of the screw over the keyway, possibly causing permanent deformation of the
ready for installation. They are self-centering and fit straight-thru hub bores. Note that Locking Assembly collars. Even after 1/4 turns can no longer be achieved, it
Series B103 units permit axial hub movement during installation. In contrast, the is important to continue to use equal turning angles for every screw until the
extended flange on Series B106 units results in an axially fixed hub position during specified tightening torque is reached.
assembly. When reinstalling a used unit, make sure that all slits are aligned. The
frictional torque capacity of these devices is based on a coefficient of friction of 0.12 for
lightly oiled screw, taper, shaft and bore contact areas.
REMOVAL
(Refer to Figure 2)
Prior to initiating the following removal procedure, check to ensure that

no torque or thrust loads are acting on the Locking Assembly, shaft or
any mounted components.
IMPORTANT! Make sure ends of locking screws used for removal are ground flat
and are slightly chamfered to prevent damage to screw and collar threads during
push-off.
1. Check to ensure that axial

movement of collars - necessary
for release of connection - is not
restricted. Likewise, ensure that
push-off threads are in good
condition.
2. Relax all locking screws by

Figure 1 approx. four (4) complete turns
and transfer screws to all push-
off threads located in flange of
collar Item 1.
Therefore, it is important not to use Molybdenum Disulfide (e.g., Molykote, Never- 3. Release connection by evenly
Seeze or similar lubricants) in any Locking Assembly installation. tightening all push-off screws
(not exceeding 1/4 turns) in a
1. Make sure that locking screw, taper, shaft and bore contact areas are diametrically opposite
clean and lightly oiled and that all collar slits are aligned. sequence.
2. Loosen all locking screws by a minimum of four (4) turns and transfer at
least three (3) screws into push-off threads in order to keep Parts 1 and 2
separated during assembly (see Figure 2). Figure 2
3. After inserting Locking Assembly into hub bore, relocate locking screws
LOCKING SCREW SIZES AND SPECIFIED TIGHTENING TORQUE MA
used for separating Parts 1 and 2.
Tightening
4. Hand tighten locking screws and confirm that collar Item 1 is parallel and Hex Key
Torque Screw Size
in full contact with face of part to be attached to shaft. Metric Series Inch Series MA Size (mm)
(ft-lbs)
5. Use torque wrench and set it approximately 5% higher than specified
B106 B103
tightening torque MA. Tighten locking screws in either a clockwise or
counterclockwise sequence (it is not necessary to tighten in a diametrically 20 x 47 to 40 x 65 3/4 to 1-1/2 12 10 M 6 5
opposite pattern), using only 1/4 (i.e., 90°) turns for several passes until 1/ 45 x 75 to 65 x 95 1-5/8 to 2-9/16 30 25 M 8 6
4 turns can no longer be achieved. 70 x 110 to 95 x 135 2-11/16 to 3-3/4 60 50 M 10 8
100 x 145 to 120 x 165 3-15/16 to 4-3/4105 90 M 12 10
6. Continue to apply overtorque for 1 to 2 more passes. This is required to 130 x 180 to 200 x 260 4-15/16 to 8 166 135 M 14 12
compensate for a system-related relaxation of locking screws since 220 x 285 to 260 x 325 257 219 M 16 14
tightening of a given screw will always relax adjacent screws. Without 280 x 355 to 300 x 375 350 290 M 18 14
overtorquing, an infinite number of passes would be needed to reach 320 x 405 to 340 x 425 500 420 M 20 17
specified tightening torque. 360 x 455 to 400 x 495 675 560 M 22 17
B-LOC Corporation 26 Gilbert Street Monroe, NY 10950 For technical assistance, please call 1-800-865-7756
Motors
INSTALLATION, OPERATION AND
MAINTENANCE INSTRUCTION
MANUAL FOR INDUCTION
MOTORS
Frame sizes 143/5T to 586/7 (02 - 21)
MANUAL DE INSTALACION,
OPERACION Y MANTENIMIENTO
PARA MOTORES DE INDUCCION
Carcasas 143/5t hasta 586/7 (23 - 43)
THIS MANUAL IS INTENDED TO SUPPLY
, IMPORTANT TOPICS THAT MUST BE FOLLOWED

DURING TRANSPORTATION, INSTALLATION,
OPERATION AND MAINTENANCE OF WEG
MOTORS. THEREFORE, WE RECOMMEND
READING CAREFULLY THIS MANUAL BEFORE
INSTALLING AND OPERATING THE MOTOR.
TO ENSURE PHYSICAL INTEGRITY TO THE
OPERATION AND MATERIAL PROTECTION, ALL
INFORMATION INCLUDED IN THIS MANUAL MUST
BE STRICTLY FOLLOWED.
INDEX
1. HANDLING AND TRANSPORTATION 3
2. RECEIVING INSPECTION 3
3. STORAGE 4
4. INSTALLATION 6
4.1 - Safety 6
4.2 - Operating Conditions 7
4.3 - Foundation 7
4.4 - Drain Holes 8
4.5 - Balance 8
4.6 - Alignment 8
4.7 - Couplings 10
4.8 - Electrical Connection 10
4.9 - Starting Methods 11
4.10 - Protection Device 12
4.11 - Start-Up 12
5. MAINTENANCE 13
5.1 - Lubrication 13
5.1.1 - Machines without Grease Nipples 14
5.1.2 - Machines Fitted with Grease Fitting 14
5.1.3 - Compatibility of MOBIL Polirex EM 16
grease with other types of grease
5.2 - Assembly and Disassembly 16
6. SPARE PARTS 17
7. VARIABLE FREQUENCY DRIVE MOTORS 17
7.1 - Standard Motors 17
7.2 - Inverter Duty Motors 18
7.3 - Bearing Insulation 18
8. ADDITIONAL INSTRUCTIONS 19
8.1 - Hazardous Area Motors 19
8.1.1 - General 19
8.1.2 - Installation 19
8.1.3 - Checking and maintenance 20
8.1.4 - Explosion Proof Motor Repairs 20
2
9. WARRANTY TERMS 21
1 - HANDLING AND TRANSPORTATION
MOTORS MUST NOT BE LIFTED BY THE SHAFT,
, BUT BY THE EYEBOLTS SPECIFIC FOR SUCH

PURPOSE
Lifting devices, when supplied, are designed only to support
the motor. If the motor has two lifting devices then a double
chain must be used to lift it.
Lifting and lowering must be done gently without any shocks,
to avoid bearing damaged.
DURING TRANSPORTATION, MOTORS FITTED

WITH ROLLER OR ANGULAR CONTACT BEA-
, RINGS ARE PROTECTED AGAINST BEARING

DAMAGES WITH A SHAFT LOCKING DEVICE
THIS LOCKING DEVICE MUST BE USED ON ANY

FURTHER MOTOR TRANSPORTATION, EVEN
, WHEN THIS MEANS TO UNCOUPLE THE MOTOR
FROM THE DRIVEN MACHINE
2. RECEIVING INSPECTION
When receiving the motor, check if any damage has occurred

during transportation.
If anything has been noticed, notify immediately the carrier,

the insurance company and WEG.
Failure in giving notice to the carrier, to the insurance company
and to WEG may result in loosing product warranty.
Do not remove the existing protecting grease from the shaft

end, nor the stoppers or plugs that close the terminal box holes,
if any. These protection items must be kept in place until the
final installation has been concluded.
After being removed from the package, a complete visual
inspection on the motor should be made:
9 Check if any damage has occurred during transportation.

9 Check nameplate data.
9 Rotate shaft with the hand to make sure it is turning freely.
9 Make sure the motor was not exposed to excessive dirt and
moisture during transportation and storage. 3
3 - STORAGE
If motors are not immediately installed, they must be stored
in dry areas, free of dust, vibrations, gases, corrosive smokes,
under constant temperature and in normal position free from
other materials.
Motor storage temperature must remain between 41ºF (5ºC) to

140ºF (60ºC), with relative humidity not exceeding 50%.
If motors are stored for more than two years, bearings must
be replaced or the lubrication grease must be totally removed
after cleaning.
Single-phase motors when kept in stock for 2 years or more

must have their capacitors replaced (if any).
WEG recommends to rotate the shaft (by hands) at least once

a month, and to measure the insulation resistance before ins-
talling it, if motors are stored for more than 6 months or when
subject to high humidity areas.
If motor is fitted with space heaters, it is recommended to

switch them on during storage period if the relative humidity
exceeds 50%.
If motor remains in stock for a long period without having
the space heaters switched-on or when installed but not in
operation, moisture/water inside the motor may condense.
On these cases, water must be drained by removing the drain
plugs. When drainage is done, switch-on the space heaters and
make sure the motor is completely dry, then reinstall the drain
plugs to ensure proper Degree of Protection (see figure 1).
The space heaters should NEVER be energized while motor

is running.
Picture 1
4
Insulation Resistance Checking
Disconnect motor from power supply before making any

insulation resistance measurement.
To avoid electric discharge risks, discharge the terminals right
after performing the measurement.
Measure the insulation resistance before operating the motor

and/or when there is any sign of moisture in the winding.
The resistance measured at 77ºF (25ºC) must be:
Ri ≥ (20 x U) / (1000 + 2P) [MΩ]

(measured with a MEGGER at 500 V d.c.)
where U = voltage (V); P = power (kW).
If the insulation resistance detected is less than 5 mega ohms,

the winding must be dried according to the following procedure:
Warm it up in an oven at a minimum temperature of 176ºF (80ºC)
increasing 41ºF (5ºC) every hour until reaching 105ºC (221ºF),
remaining under this temperature for at least one hour.
Check if the stator insulation resistance remains constant

within accepted values. If not, stator must be reimpregnated.
If necessary, replace bearings and seals.
Note:
1) All drains (if any) must be removed while drying.
2 - Measured the insulation resistance in ambient temperature.
If different than 25ºC it should be corrected using the following
formula:
R(25°C) = [( K+25 ) / ( K + Ta )] . R(Ta)
Where:
R(25°C) insulation resistance related to 25ºC ambient
temperature
K constant value 234.5 for copper
Ta ambient temperature where the resistance was
measured
R(Ta) resistance value measured in ambient temperature Ta
5
4. INSTALLATION
4.1 - Safety
All personnel involved with electrical installations, either han-

dling, lifting, operation, start up, maintenance or repair must be
well informed and updated concerning safety standards and
principles that govern the work and carefully follow them.
For practical reasons, it is not possible to include in this Manual

detailed information that covers all constructive variables, nor
covering all possible assembly, operation or maintenance
alternatives.
For this reason, the present Manual only includes required
information that allows qualified and trained personnel to
carry out the work.
If you still have further doubts about this, specially in reference

to specific product information, WEG is willing to provide
such information via its network of authorized service agents
and/or distributors.
In order to allow WEG to provide prompt service, within tech-
nical standards, the motor serial number that is available on
the identification nameplate should be supplied.
Use always appropriate tools for installation and removal.
, MAKE SURE THAT ELECTRIC MOTORS ARE SWITCHED

OFF BEFORE STARTING ANY MAINTENANCE SERVICE
All rotating parts such as pulleys, couplings, outside fans, shaft,

etc. must be protected against accidental contact.
Motors must be protected against unexpected starts.
When performing any maintenance service, disconnect the
motor from the power supply. Make sure all accessories have
been switched off and disconnected.
In order to prevent from penetrating dust and/or water into the
terminal box, cable glands or threaded pipe in the lead holes
passage must be installed. They must be of equal or higher
IP rating than the motor.
LEAD CONNECTION INSULATION INSIDE THE
, TERMINAL BOX MUST BE DONE WITH AN

INSULATING MATERIAL COMPATIBLE WITH MOTOR
THERMAL CLASS WHICH IS SHOWN ON THE MOTOR
NAMEPLATE
If installation and safety instructions are not followed
6
accordingly, warranty may be void.
4.2 - Operating Conditions
In general electric motors are designed for operation up to an

altitude of 1000m above sea level for an ambient temperature
ranging from -4ºF (-20ºC) to 104ºF (40ºC). Any variation is
stated on the nameplate.
The recommended installation distance between air inlet from
the motor and the wall should be at least ¼ of the air inlet
diameter. A person should have enough room to carry out
cleaning services.
Machines that are cooled with ambient air, air inlet screens
must be cleaned at regular intervals so as to ensure free air
circulation.
Warm air can not return to the motor.
9 For vertically mounted motors with air inlet on top, the air
opening must be protected by a proper cover so as to avoid
dropping of foreign materials on the motors.
9Considering that direct sun heat causes increase in
temperature, externally installed motors should be always
protected against weathering.
COMPARE THE CURRENT, VOLTAGE, FREQUENCY,

, SPEED, OUTPUT AND OTHER VALUES REQUIRED
BY THE APPLICATION WITH MOTOR NAMEPLATE
INFORMATION
ODP MOTORS – Open motors (IP21, IP23) are machines
designed for operation in clean, dry areas, with enough air
circulation for proper cooling. These motors should never be
used in areas with flammable materials. Open motors may
cause sparks and release cast particles under any eventual
insulation failure (short-circuit).
TEFC MOTORS – Totally enclosed motors are machines
suitable to operate in areas with moisture, dirt and/or corrosive
materials either in enclosed or open environments.
4.3 - Foundation
Motors provided with feet must be installed on solid

foundations to avoid excessive vibrations.
All motors must be fully fixed and aligned.
The purchaser is fully responsible for the foundation.
Metal parts must be painted to avoid corrosion.
The foundation must be uniform and sufficiently strong to

support any shock. It must be designed in such a way to
stop any vibration originated from resonance.
Note: Considering that rotation direction is important for

correct operation, then check it carefully before connecting
motor to the load. 7
4.4 - Drain Holes
Make sure drains are placed at the lower motor position when
the mounting configuration differs from that specified on the
motor purchase order.
4.5 – Balance
,
WHEN SPECIAL BALANCE IS REQUIRED,
CONTACT THE FACTORY
All motors are dynamically balanced at the factory with half

key.
Transmission elements such as pulleys, couplings etc must be

dynamically balanced with half key before installation.
Always use appropriate tools for installation and removal.
4.6 – Alignment
, ALIGN THE SHAFT ENDS AND USE FLEXIBLE

COUPLING, WHENEVER POSSIBLE
Make sure that the motor mounting devices do not allow

modifications on the alignment and further damages to the
bearings.
When assembling a half-coupling, make sure to use suitable
equipment and tools to protect the bearings.
Suitable assembly of half-coupling:
Specially in cases of direct couplings, motor shaft must be
aligned axially and radially with the driven machine shaft.
Incorrect alignment can lead to bearing damage, vibrations or

even cause shaft rupture.
Correct alignment can be ensured with the use of dial gauges,
as shown in figures 4.6.1, 4.6.2 and 4.6.3.
If considering a complete shaft turn, misalignment should not

exceed 0.05 mm.
8
Fig. 4.6.1 - Axial reading (parallelism)
Fig. 4.6.2 – Radial reading (concentricity)
Fig. 4.6.3 – Axial and radial reading combined
The axial alignment (“E” dimension) between half couplings

should be performed in accordance with manufacturer’s
recommendations.
If required, WEG can offer its personnel duly trained as well

as a laser equipment to make motor and driven machine
alignment/leveling.
Expansion effect of the components may change the alignment/

leveling conditions during performance.
9
4.7 – Couplings
When using pulley or belt drive (coupling), follow the ins-

truction given below:
Remove shaft-locking device (if any) before installing the

motor.
Belts must be tighten just enough to avoid slippage when

running, according to the specifications stated on the belt
supplier recommendation.
To make the installation of the pulley on the shaft easier, it

is recommended to heat up the pulley at 176ºF (80°C) and
have it mounted at hot, using suitable tools.
To avoid bearing and shaft end damage, mounting and dis-

mounting of pulleys must be made with suitable tools.
While mounting and dismounting a pulley, never make pres-

sure or knocks on the bearings.
Always use flexible couplings; rigid couplings require special

bearing arrangement as well as axial and radial alignment
of the shafts.
WARNING:
EXCESSIVE BELT/CHAIN TENSION WILL DAMAGE
THE BEARINGS AND LEAD TO A PROBABLE
SHAFT RUPTURE
The couplings used must be suitable to withstand radial and
axial vibrations during operation. Special care must be taken
to avoid that the allowable load and speed limits given in the
catalog are not exceeded.
4.8 – Electrical Connection
Make sure the motor is connected to the correct power

supply.
The cable gauges and the protection devices must be desig-
ned based on motor rated current.
a Voltage may be connected at motor standstill

inside the terminal box for heating elements
or direct winding heating
WARNING
The capacitor on single-phase motors can
a retain a charge which appears across the motor

terminals, even when the motor has reached
standstill condition. So, avoid touching them at
WARNING such condition
10
A WRONG CONNECTION CAN
, BURN OUT THE MOTOR.
Voltage and connection are indicated on the motor

nameplate.
The acceptable voltage variation is ±10%;
the acceptable frequency variation is ±5% and the total
acceptable variation for voltage and frequency is ± 10%.
Note: For rated voltage range (Tru Metric Line), the acceptable
variation is ± 5% according to IEC 60034-1.
4.9 - Starting Methods
The motor is rather started through direct starting. In case

this is not possible, use compatible start methods to the
motor load and voltage.
When applying reduced voltage-starting method, remember
that the starting torque will also reduce.
3 3 leads single voltage and 9 leads dual voltage motors can

be started as follows:
- Full Voltage Direct online
- Auto-Transformer starting
- Electronic Soft-Starting
- VFD Starting – subject to verification and application
analisys.
- Series - Parallel starting (only for 9 leads)
3 6 leads single and dual voltage motors and 12 leads dual

voltage motors can be connected as follows:
- Full Voltage Direct online
- WYE/DELTA starting
- Auto-Transformer starting
- Electronic Soft-Starting
- VFD Starting – subject to verification and application
analisys.
- Series - Parallel starting (only for 12 leads)
Rotation direction is clockwise when motor is viewed from

Drive Endshields side and if the phases are connected
according to sequence L1, L2, L3. This sequence and power
system must be positive.
To change the rotation direction, reverse two of the

connecting leads.
Note: For single-phase motors connections, please check
the motor nameplate.
11
THE CONNECTION TO THE POWER SUPPLY
MUST BE DONE BY QUALIFIED PERSONNEL
, AND WITH FULL ATTENTION TO ASSURE SAFE

AND PERMANENT CONNECTION. AFTER
CONNECTING THE MOTOR, CHECK FOR ANY
STRANGE BODY INSIDE THE TERMINAL BOX. THE
CABLE INLETS NOT IN USE MUST BE CLOSED.
Make sure to use correct cable gauge, based on the rated

current stamped on the motor nameplate.
BEFORE ENERGIZING THE TERMINALS, CHECK IF
, THE GROUNDING IS MADE ACCORDING TO THE

APPLICABLE STANDARDS. THIS IS ESSENTIAL TO
AVOID ACCIDENTS.
4.10 – Protection Device
When the motor is supplied with protective or monitor tem-

perature device such as thermostats, thermistors, thermal
protector etc, connect their terminals to the corresponding
devices on the control panel. If this procedure is not followed
accordingly, warranty will be void.
Do not change protection devices settings as they may not
operate.
Protection Device Diagram
Overtemperature Overtemperature
Protected motor Protected motor
with thermistors with thermostats
L1 L2 L3 P1 P2
L1 L2 L3 P1 P2
Stop switch
RATED CURRENT
VOLTAGE(V) (A)
3x 3x 110-120 3.00
220-240 1.50
RELEASE DEVICE 440-480 0.75
THERMISTORS LEADS
THERMOSTATS LEADS 550-600 0.60
4.11 - Start-Up
IF THE MOTOR IS RUN BARE SHAFT, THE
12
, KEY MUST BE FASTENED OR REMOVED
BEFORE STARTING.
a) The motor must start and operate smoothly. In case this
does not occur, turn it off and check all connections and the
mounting before starting it again.
b) In case there is excessive vibration, check if the fixing

screws are correctly fastened.
Check also if the vibration comes from a neighbor machine.
Periodical vibration check must be done.
c) Run the motor under rated load for a short period of time
and compare if the running current is in accordance to the
nameplate current.
5 . MAINTENANCE
Any service on electric machines should only be carried out

when it is completely stopped and all phases disconnected
from the power supply.
WARNING:
,
General Inspection
SAFETY CHECK LIST
9 Check motor periodically.

9 Keep motor clean and ensure free air flow.
9 Check seals and replace them, if required.
9 Check connections as well as supporting screws.
9 Check bearing condition and pay attention to: Any
excessive noise, vibration, bearing temperature and grease
condition.
9 When a change, under normal conditions is detected,
check the motor and replace required parts.
DO NOT REUSE DAMAGED OR WORN PARTS.
, REPLACE THEM BY NEW ONES SUPPLIED BY THE

FACTORY
Periodical inspection depends on motor type and on
application conditions.
5.1 – Lubrication
,
FOLLOW REGREASING INTERVALS. THIS IS
FUNDAMENTAL FOR PROPER MOTOR OPERATION
13
5.1.1 - Machines without Grease Nipples
Motors up to frame size 215T are normally fitted without

grease fittings. In these cases the regreasing shall be done
during preventive maintenance service paying attention to
the following aspects:
9 Take motor apart carefully.

9 Take all the grease out.
9 Wash the bearing with kerosene or diesel.
9 Dry the bearings
9 Regrease the bearing immediately.
5.1.2 - Motors Fitted with Grease Fitting
It is strongly recommended to grease the machine while run-

ning. This allows the grease renewal in the bearing housing.
When this is not possible due to rotating parts by the grease
device (pulleys, bushing, etc) that offer some risk to physical
integrity of the operator, proceed as follows:
9 Clean the area near the grease nipple.

9 Put approximately half of the total grease and run the motor
for 1 minute at full speed.
Then turn off the motor and pump in the rest of the grease.
9 The injection of all the grease with the motor in standstill
can make the grease penetrate into the motor, through the
bearing housing inner seal.
Inspections intervals depend on motor type and on application
conditions.
USE ONLY MANUAL GREASE GUN FOR

, LUBRICATION
14
RECOMMENDED RELUBRICATION INTERVALS – POLYREX EM GREASE
(MOBIL)
Note:
The table above is specifically intended for relubrification with
MOBIL Polyrex EM grease and bearing absolute operating
temperature of:
9 70ºC (158ºF) for 254/6T to 324/6T frame size motors
9 85ºC (185ºF) for 364/5T to 586/7T frame size motors
For every 15ºC (59ºF) above these limits, relubrification
intervals must be reduced by half. Shielded bearing (ZZ)
are lubricated for bearing life as long are they operate under
conditions and temperature of 70ºC (158ºF).
9 Relubrication periods given above are for those cases
applying MOBIL Polyrex® EM grease.
9 When motors are used on the vertical position, their relu-
brication interval is reduced by half if compared to horizontal
position motors.
9 On applications with high or low temperatures, speed varia-
tion etc., the type of grease and relubrication intervals is given
on an additional nameplate attached to the motor.
15
WE RECOMMENDED TO USE BALL
, BEARINGS FOR MOTORS DIRECTLY

COUPLED TO THE LOAD
WARNING:
, EXCESS OF GREASE CAN CAUSE BEARING

OVERHEATING RESULTING IN COMPLETE DAMAGE.
5.1.3 - Compatibility of MOBIL Polirex EM grease with other

types of grease
Containing polyurea thickener and mineral oil, the MOBIL

Polyrex EM grease is compatible with other types of grease
that contain:
9 Lithium base or complex of lithium or polyurea and highly

refined mineral oil.
9 Inhibitor additive against corrosion, rust and anti-oxidant
additive.
Note:
9 Although MOBIL Polyrex EM is compatible with the types of
grease given above, we do not recommend mixing it with any
other types of grease.
9 If you intend to use a type of grease different than those
recommended above, first contact WEG.
BEFORE USING STANDARD MOTORS IN SPECIFIC
, AREAS OR ON SPECIAL APPLICATIONS, FIRST

CONTACT THE GREASE MANUFACTURER OR WEG
5.2 - Assembly and Disassembly
Disassembly and assembly must be done by qualified

personnel using only suitable tools and appropriate
methods.
The bearing extractor grips must be applied over the
side face of the inner ring to be disassembled or over an
adjacent part.
It is essential to assemble bearings under clean condi-
tions to ensure good operation and to avoid damages. New
bearings shall only be taken out from their packages when
assembling them.
Before installing a new bearing it is required to check
the shaft fitting for any sharp edge or strike signals.
For bearing assembly warm their inner parts with suitable
16
equipment – inductive process – or use suitable tools.
6. SPARE PARTS
When ordering spare parts, please specify the full type designa-
tion and product code as stated on the motor nameplate. Please
also inform the motor serial number stated on the nameplate.
7 - VARIABLE FREQUENCY DRIVE MOTORS
7.1 - Standard Motors Line
Motors with voltages up to 575V do not require filters if follow

the criteria bellow:
Note:
1) Motors with nameplate
showing voltage 380-415V
/ 660-690V - 50Hz and 440-
480V - 60Hz, and fed by VFD
on voltage 660-690V - 50Hz
or 480V - 60Hz require
filters.
2) Motors in frame sizes
504/5T and 586/7T* when
uded with VFD’s, require
insulated bearings.
* Other frame sizes, under

request.
IF SUCH RECOMMENDATIONS AND CRITERIA
, ARE NOT FOLLOWED ACCORDINGLY, MOTOR

WARRANTY WILL BE VOID
17
7.2 - Inverter Duty Motors Line
Motors with voltages above 575V and equal or below 690V and
fed by VFD do not require filters when following the criteria
below:
3 Check power supply voltage of the forced cooling set.
IF SUCH RECOMMENDATIONS AND CRITERIA
, ARE NOT FOLLOWED ACCORDINGLY, MOTOR

WARRANTY WILL BE VOID
7.3– Bearing insulation
Inverter Duty Motors line in frame sizes 504/5T and 586/7T*

are supplied with ground system between the shaft and frame
on Drive Endshield. Also, on request can be supplied with
18
insulated bearings.
For other lines, in frame sizes 504/5T and 586/7T* when used
with VFD’s it is required ground system between the shaft and
frame or insulated bearings.
(*) Other frame sizes, under request.
8 - ADDITIONAL INSTRUCTIONS
8.1 - Hazardous Area Motors
8.1.1 General
Besides the recommendations given above, these recommen-

dations must be also followed.
Motors for hazardous area are manufactured according to
specific Standards for such environments.
Motors supplied for hazardous area (classified areas) must
be installed in areas that comply with those specified on the
motor nameplate.
Notes:
- Motors of Division I are also suitable for Division 2.
- Motors of a given class of temperature are suitable also for
combustible environments of a greater class of temperature
(example, T4 motors are suitable for environments of class
T3, T2, T1).
8.1.2 Installation
A complete installation must follow procedures given by local
legislation in effect.
THE INSTALLATION OF HAZARDOUS AREA

, MOTORS MUST BE CARRIED OUT BY SKILLED
PEOPLE
THE SPECIFICATION OF THE MOTOR INSTALLA-
,
TION SITE IS FOR CUSTOMER’S RESPON-
SIBILITY, WHO WILL ALSO DETERMINE THE
ENVIRONMENT CHARACTERISTICS
When cable entrance is made by a cable gland, this must be
suitable to the unit and to the type of cable; the cable gland
has to be assembled, completely screwed in order to get the
necessary pressure on the sealing rings, so as to:
- Avoid transmission of mechanical vibrations to the motor
terminals.
- Guarantee mechanical protection “IP” to the terminal box.
19
8.1.3 Checking and Maintenance
Maintenance must be carried out by repair shops authorized
and accredited by WEG.
Repair shops and people without WEG’s authorization

who will perform any service on hazardous area motors
will be fully responsible for such service as well as for any
consequential damage.
When performing maintenance, installation or relubrication,
follow these instructions:
9 Electric connections must be correctly locked to avoid re-

sistance-increases, with consequent contact overheating.
9 Insulation air-distance and surface-distance between con-
ductors, required by the Standards, must be respected.
9 All screws, used to assemble parts motor and terminal
box, must be completely screwed.
9 Seals and components replacement for cable entrance
would be made using spare parts, supplied from the
manufacturer, in order to guarantee the original type of
protection.
9 Explosion Proof motors joint surfaces have not to be
machined and it is not allowed to insert, between them, any
kind of seals, not foreseen or supplied by the manufacturer.
Joint surfaces have just to be cleaned and, in order to avoid
corrosion or water penetration; they can be oiled by means
of a thin coat of silicon grease.
9 Check if all components are free of edges, knocks or
dirt.
9 Make sure all parts are in perfect conditions.
9 Lubricate the surfaces of the endshield fittings with pro-
tective oil to make the assembly easier.
9 Use only rubber hammer to fit the parts.
9 Check the correct bolts fastening.
9 Use clearance calibrator for correct connection terminal
box fitting (less than 0.05mm).
8.1.4 Explosion Proof Motor Repairs
Repairing of Explosion Proof motors can only be performed

by authorized companies. Please get in contact with nearest
WEG office/distributor.
20
9. WARRANTY TERMS
WEG warrants its products against defects in workmanship and

materials for eighteen (18) months from the invoice date issued by
the factory, authorized distributor or agent limited to twenty four
(24) months from manufacturing date independent of installation
date as long as the following items are fulfilled accordingly:
- Proper transportation, handling and storage;
- Correct installation based on the specified ambient environmental
conditions;
- Operation under motor capacity limits;
- Observation of the periodical maintenance services;
- Repair and/or replacement effected only by personnel duly
authorized in writing by WEG;
- The failed product be available to the supplier and/or repair
shop for a required period to detect the cause of the failure and
corresponding repair;
- Immediate notice by the purchaser about failures occurred and
that these are accepted by WEG as manufacturing defects.
This warranty does not include disassembly services at the
purchaser facilities, transportation costs with product, tickets,
accommodation and meals for technical personnel when
requested by the customer.
The warranty service will be only carried out at WEG Authorized
Repair Shops or at WEG’s facilities.
Components whose useful life, under normal use, is shorter than
the warranty period are not covered by these warranty terms.
The repair and/or replacement of parts or components, when
affected by WEG and/or any WEG Authorized Repair Shop, will
not give warranty extension.
This constitutes WEG’s only warranty in connection with this sale
and the company will have no obligation or liability whatsoever to
people, third parties, other equipment or installations, including
without limitation, any claims for consequential damages or
labor costs.
21
LA INTENCION DE ESTE MANUAL ES PROVEER
INFORMACIONES IMPORTANTES QUE DEBEN SER
SEGUIDAS DURANTE TRANSPORTE, INSTALACION,
OPERACION Y MANTENIMIENTO DE LOS MOTORES
WEG. ENTONCES, RECOMENDAMOS LEER ATENTA-
, MENTE ESTE MANUAL ANTES DE LA INSTALACION Y

OPERACION DEL MOTOR.
PARA ASEGURAR INTEGRIDAD FISICA DE LA
OPERACION Y PROTECCION MATERIAL, TODA LA
INFORMACION INCLUIDA EN ESTE MANUAL DEBERA
SER EXTREMAMENTE SEGUIDA
INDICE
1. MANEJO Y TRANSPORTE 24
2. VERIFICACION EN LA RECEPCION 24
3. ALMACENAMIENTO 25
4. INSTALACION 27
4.1 - Seguridad 28
4.2 - Condiciones de operación 28
4.3 - Fundaciones del motor 29
4.4 - Agujeros de Drenaje 29
4.5 - Balanceo 29
4.6 - Alineación 31
4.7 - Acoplamientos 31
4.8 - Conexión eléctrica 32
4.9 - Métodos de arranque 32
4.10 - Dispositivo de protección 33
4.11 - Puesta en Marcha 34
5. MANTENIMIENTO 34
5.1 - Lubricación 34
5.1.1 - Motores sin grasera 35
5.1.2 - Motores con grasera 35
5.1.3 - Compatibilidad de la grasa MOBIL Polirex
EM con otros tipos de grasa 37
5.2 - DESMONTAJE Y MONTAJE 37
6. PARTES Y PIEZAS - REPUESTOS 38
7. MOTORES PARA USO CON CONVERTIDOR DE
FRECUENCIA 38
7.1 - Motores Standard 38
7.2 - Motores Inverter Duty 39
7.3 - Aislamiento de rodamientos 39
8. INFORMACIONES ADICIONALES 40
8.1 - Motores para Áreas de Riesgo 40
8.1.1 - General 40
8.1.2 - Instalación 40
8.1.3 - Chequeo y Mantenimiento 41
8.1.4 - Reparos en Motores a Prueba de Explosión 42
22 9. TERMINOS DE GARANTIA 43
1 – MANEJO Y TRANSPORTE
LOS MOTORES NO DEBEN SER IZADOS POR EL
, EJE, UTILIZE LOS CANCAMOS DE SUSPENSION,

ESPECIFICOS PARA ESTE PROPOSITO
Equipamientos de alzamiento, cuando suministrados, son

proyectados solamente para la sustentación del motor.
Si el motor por su diseño constructivo tiene dos cáncamos de
suspensión, use dispositivos que permitan el izamiento por
ambos elementos al mismo tiempo.
El izamiento así como el descenso del motor deben ser realiza-
dos en forma suave, sin golpes, caso contrario los rodamientos
pueden sufrir daños.
LOS MOTORES CON RODAMIENTOS DE RODILLOS O
, DE CONTACTO ANGULAR ESTAN PROTEGIDOS,

DURANTE EL TRANSPORTE, CONTRA DAÑOS POR
MEDIO DE UN DISPOSITIVO DE BLOQUEO DEL EJE
LOS DISPOSITIVOS DE BLOQUEO DEBEN SER

UTILIZADOS SIEMPRE QUE SE TRANSPORTE EL
, MOTOR, AUNQUE ESTO IMPLIQUE TENERLO

QUE DESACOPLAR NUEVAMENTE DE LA
MAQUINA ACCIONADA
2. VERIFICACION EN LA RECEPCION
En la recepción del motor, verifique si ocurrieron daños durante

el transporte.
En el caso de verificar cualquier daño, avisar inmediatamente la

transportadora, la compañía aseguradora y WEG. No avisar la
transportadora, la compañía aseguradora y WEG puede resulta
en la pérdida de la garantía del producto.
No remueva la grasa de protección de la punta de eje, tampoco

los tapones que cierran los agujeros de la caja de conexiones,
caso existir. Estos ítems de protección deben ser mantenidos
hasta que la instalación completa sea concluida. Después de la
remoción de su embalaje, una completa inspección visual debe
ser hecha en el motor:
9Verifique si ocurrieron daños durante el transporte.
9Verifique los datos de la tarjeta de identificación.
9 Gire el eje con la mano para verificar si está girando
libremente.
9Asegurar que el motor no tenga sido expuesto a polvo o
humedad durante el transporte a almacenamiento.
23
3. ALMACENAMIENTO
Si los motores no fueran inmediatamente instalados, deben

ser almacenados en un local seco, libre de polvo, vibraciones,
gases y vapores corrosivos; dotado de temperatura uniforme,
colocándolos en posición normal y sin apoyar sobre ellos
otros objetos.
La temperatura de almacenaje de los motores debe quedar

entre 41°F (5°C) y 140°F (60°C), con humedad relativa no
excediendo a 50%.
En el caso de motores con más de dos años de almacenaje,
se debe proceder al cambio de rodamientos o a la substitución
total de la grasa lubricante después de la limpieza de los
mismos.
En los motores monofásicos almacenados durante dos años
o más, se debe además cambiar los capacitores (cuando
existan).
WEG recomienda girar el eje del motor (manualmente) al

menos una vez al mes y medir la resistencia del aislamiento
antes de instalarlo, en caso de motores almacenados más
de 6 meses o cuando están sometidos a ambientes con alta
humedad.
Caso el motor dispone de resistencias de calentamiento, estas
deberán ser conectadas durante el periodo de almacenaje caso
la humedad relativa exceder 50%.
Caso el motor permanecer almacenado por un largo periodo sin
tener las resistencias de calentamiento conectadas o cuando
están instaladas pero no en operación, humedad/agua en la
parta interna del motor pueden condensar. En estos casos,
la agua debe ser drenada removiendo los drenos (tapones)
roscados. Después del drenaje hecho, conecte las resistencias
de calentamiento y asegure que el motor este completamente
seco, entonces reinstale los tapones (drenos) para asegurar
el grado de protección correcto. (Vea figura 1).
Las resistencias de calentamiento nunca deben ser energi-
zadas mientras el motor este operando.
24 Figura 1
Medición de la resistencia del aislamiento
Desconectar el motor de la red de energía antes de hacer

cualquier medición de la resistencia del aislamiento.
Para evitar riesgo de descarga eléctrica, descargue los
terminales después de la medición.
Mida la resistencia del aislamiento antes de poner el motor

en servicio y/o cuando haya indicios de humedad en el
bobinado.
La resistencia, medida a 25ºC (77ºF), debe ser:
Ri ≥ (20 x U) / (1000 + 2P) [MΩ]

(Medido con MEGGER a 500 V c.c.);
Donde U = tensión (V); P = potencia (kW).
Si la resistencia del aislamiento medida es inferior a 2 MΩ, el

bobinado deberá ser secado de acuerdo con lo que sigue:
Calentar el estator bobinado en un horno partiendo de una
temperatura de 80ºC (176ºF) y elevando 5ºC (41ºF) por hora
hasta llegar a los 105ºC (221ºF); esta última temperatura debe
permanecer durante un período mínimo de una hora.
Medir se la resistencia del aislamiento del bobinado
permanece constante y con valores dentro de los mínimos
recomendados; caso contrario, se deberá proceder a una
nueva impregnación del estator bobinado. Caso necesario,
cambiar los rodamientos y retenedores.
Nota:
1) Los agujeros de drenaje (cuando existan) deben ser
retirados durante el secado.
2) La resistencia de aislamiento debe ser medida en
temperatura ambiente. Caso sea diferente de 25°C debe ser
corregida utilizando la siguiente formula:
R(25°C) = [( K+25 ) / ( K + Ta )] . R(Ta)
Donde:
R(25°C) resistencia del aislamiento relativa a 25°C temperatura
ambiente
K valor constante 234.5 para el cobre
Ta temperatura ambiente donde la resistencia fue medida
R(Ta) valor de la resistencia medida en temperatura
ambiente Ta
25
4. INSTALACION
4.1 - Seguridad
Los profesionales que trabajan en instalaciones eléctricas, sea

en el manejo, montaje, operación, puesta en marcha o en el
mantenimiento, deberán estar permanentemente informados y
actualizados sobre las normas y requisitos vigentes en materia
de seguridad y cuidadosamente ponerlas en práctica.
Por motivos prácticos, no es posible incluir en este Manual

información detallada de todas las variables constructivas,
tampoco todas las posibilidades de montaje, operación o
alternativas de mantenimiento.
Debido a esto, este Manual solamente incluye la información
requerida que recomienda que estos servicios sean efectuados
solamente por personal calificado y entrenado.
Caso Ud. aun tenga alguna duda a este respecto, especial-
mente respecto a información especifica del producto, WEG
suministrará esta información a través de su red de servicio
autorizado y/o distribuidores.
Para permitir que WEG tenga un pronto servicio, dentro de las
normas técnicas, el número de serie del motor que se encuentra
en la tarjeta de identificación debe ser informado.
Utilice siempre herramientas apropiadas para la instalación
y desmontaje.
VERIFIQUE QUE LOS MOTORES ELECTRICOS
, ESTEN DESCONECTADOS ANTES DE INICIAR

CUALQUIER TRABAJO DE MANTENIMIENTO
Todas las partes girantes, tales como poleas, acoplamien-

tos, ventiladores externos, eje, etc., deben estar protegidos
contra toques accidentales.
Los motores deben estar protegidos contra arranques
accidentales.
Al realizar servicios de mantenimiento en el motor, des-
conecte la red de alimentación. Verifique si todos los
accesorios fueron desconectados de la red de alimentación
y desligados.
Para impedir la penetración de polvo o agua en el interior

de la caja de conexión, es necesario instalar prensa cables
o electroductores roscados en las salidas de los cables. Los
mismos deben tener grado IP igual o mayor que el motor.
EL AISLAMIENTO DE LOS CABLES, ADENTRO DE
, LA CAJA DE CONEXIONES DEL MOTOR, DEBEN

SER HECHOS CON MATERIALES COMPATIBLES
CON LA CLASE TERMICA DEL MOTOR QUE ESTA
MOSTRADA EN LA TARJETA DE IDENTIFICACION
26
Se las instrucciones de instalación y seguridad no son seguidas
correctamente, se puede perder la garantía.
4.2 - Condiciones de Operación
Los motores eléctricos, en general, son diseñados para

instalación y operación a una altitud hasta 1000m sobre el
nivel del mar con temperaturas ambientes de -20ºC (-4ºF) a
40ºC (104ºF).
Variaciones respecto a los valores mencionados deben estar
indicadas en la tarjeta de identificación.
La distancia de instalación recomendada entre las entradas de

aire del motor y la pared no debe ser inferior ¼ del diámetro de
la entrada de aire. Una persona debe tener espacio suficiente
para mantener servicios de limpieza.
Máquinas que son enfriadas a través del aire ambiente, deben
limpiar las entradas de aire en intervalos regulares para
asegurar la libre circulación de aire.
Aire caliente no puede retornar al motor.
Para motores montados en la vertical con las entradas de aire al
topo, las entradas de aire deben ser protegidas con sombrerete
para evitar la caída de cuerpos extraños en el motor.
- Considerando que el calor directo del sol causa aumento
de temperatura, los motores instalados externamente deben
siempre ser protegidos contra la intemperie.
COMPARE LOS VALORES DE CORRIENTE, TEN-
, SION, FRECUENCIA, VELOCIDAD, POTENCIA Y

OTROS VALORES EXIGIDOS POR LA APLICA-
CION, CON LOS DATOS CONTENIDOS EN LA
TARJETA DE IDENTIFICACION
Motores ODP – Motores abiertos (IP21, IP23, etc.): Son motores

para uso en locales limpios, secos, con circulación de aire
suficiente para su refrigeración. Este tipo de motor no debe
ser utilizado en la presencia de materiales inflamables o com-
bustibles. Motores abiertos pueden emitir llama/chispa o metal
fundido en una eventual falla del aislamiento (cortocircuito).
Motores TCVE – (Totalmente Cerrado Ventilación Externa): Son
motores aptos a trabajar en áreas con humedad polvo y materia-
les corrosivos, en ambientes cerrados y también abiertos.
4.3 - Cimentación del motor

Los motores con pies (patas) deberán ser instalados sobre
apoyos rígidos para evitar excesivas vibraciones.
Todos los motores deben ser apropiadamente fijados y
alineados.
El cliente es totalmente responsable de estos apoyos.
Las partes metálicas deberán estar pintadas para evitar la
corrosión. 27
La base debe ser uniforme y lo suficientemente robusta para
soportar fuertes choques. Debe ser diseñada de manera que impida
las vibraciones originadas por resonancias.
Nota: Considerando que el sentido de rotación es importante para

un funcionamiento correcto, verificar el sentido de rotación antes
de acoplar la carga al motor.
4.4 - Agujeros de drenaje
Asegúrese que los agujeros de drenaje del motor se sitúen en su

parte inferior, cuando la forma de montaje del motor difiera de la
especificada en la compra del mismo.
4.5 – Balanceo
BALANCEOS ESPECIALES DEBEN SER
, SOLICITADOS PREVIAMENTE A LA
FABRICA
Los motores WEG son balanceados dinámicamente en la planta
con “Media Cuña”
Los elementos de transmisión, tales como, poleas, acoplamientos,

etc., deben ser balanceados dinámicamente con “media cuña”
antes de ser instalados.
Utilice siempre herramientas apropiadas tanto en la instalación
como en el desacople de los motores.
4.6 – Alineación
ALINEAR LAS PUNTAS DEL EJE, Y
, UTILICE SIEMPRE QUE FUERA POSIBLE

ACOPLAMIENTOS FLEXIBLES
Cerciórese de que los dispositivos de montaje del motor no
permitan alteraciones en la alineación y otros daños en los
rodamientos.
Cuando se proceda el montaje del acoplamiento deben ser usados
los medios adecuados y las herramientas necesarias para no
dañar los rodamientos.
Montaje correcto del acoplamiento:
Especialmente en los casos donde se utiliza acoplamiento directo,
el eje debe ser alineado axialmente y radialmente con el eje de la
máquina accionada.
Una alineación incorrecta puede dañar el rodamiento, vibraciones
y hasta provocar ruptura del eje.
Una alineación correcta puede ser asegurada con el uso de
calibradores, de acuerdo con las figuras 4.6.1, 4.6.2 y 4.6.3.
Considerando un giro completo del eje, la desalineación no debe
exceder 0.05mm.
28
Fig. 4.6.1 – Lectura Axial (en paralelo)
Fig. 4.6.2 – Lectura radial (concentricidad)
Fig. 4.6.3 – Lectura Axial y Radial combinado
La alineación axial (dimensión “E”) entre mitad de acoplamientos

deben ser ejecutados de acuerdo con las especificaciones del
fabricante.
Bajo consulta, WEG puede ofrecer su personal entrenado y

también equipamiento láser para hacer la alineación/nivelación
del motor y de la máquina accionada.
La expansión de los componentes puede cambiar las condiciones

de alineación/nivelación durante el desempeño.
29
4.7 – Acoplamientos
Cuando se utilice un acoplamiento por medio de correas y

poleas, se debe seguir las informaciones abajo:
- Remover el dispositivo de bloqueo del eje (caso existir)

antes de instalar el motor.
- Las correas deben ser estiradas apenas lo suficiente como
para evitar deslizamiento en el funcionamiento, de acuerdo con
las recomendaciones del fabricante de las correas.
- Para facilitar la instalación de la polea en el eje, se recomien-
da calentar la polea hasta 176°F (80°C) y montar aún caliente,
utilizando herramientas apropiadas.
- Para evitar daños en los rodamientos y punta del eje, el
montaje y desmontaje de las poleas debe ser hecho con
herramientas apropiadas.
- Mientras el montaje y desmontaje de una polea, nunca haga
presión o golpes en los rodamientos.
- Siempre utilice acoplamientos flexibles, acoplamientos rígi-
dos requieren rodamientos especiales, bien como alineación
axial y radial de los ejes.
ATENCION:
UNA EXCESIVA TENSIÓN EN LAS CORREAS
DAÑARÁ LOS RODAMIENTOS Y HASTA PUEDE
PROVOCAR LA RUPTURA DEL EJE.
Los acoplamientos utilizados deben soportar vibraciones
radiales y axiales durante la operación. Deben ser tomados
cuidados especiales para evitar que no sean excedidas las
cargas permitidas y limites de velocidad de catálogo.
4.8 – Conexión eléctrica
Se debe asegurar que el motor sea conectado correcta-

mente en la red de transmisión.
Los diámetros de los cables y los dispositivos de protec-
ción deben ser diseñados de acuerdo con la corriente
nominal del motor.
Con el motor parado, puede existir energía

a eléctrica en el interior de la caja de conexio-
nes, para las resistencias de calentamiento o
PELIGRO inclusive para el bobinado.
Los capacitores de los motores monofásicos
a pueden retener energía eléctrica, mismo con

el motor parado. no tocar los capacitores y los
PELIGRO
terminales del motor sin verificar que no exista
30
tensión en los mismos.
, TODA CONEXION EFECTUADA DE FORMA
INCORRECTA PUEDE QUEMAR EL MOTOR
La tensión y forma de conexión están indicadas en la tarjeta de

identificación del motor.
La variación aceptable de tensión es de ±10%,
La variación aceptable en la frecuencia es de +3 y –5% y la varia-
ción total aceptable de la tensión y frecuencia es de ±10%.
Nota: Para rango de tensión nominal (Línea Tru Metric), la varia-
ción aceptable es ± 5% de acuerdo con la IEC60034-1.
4.9 - Sistema de arranque
Es preferible que el motor arranque en forma directa. En el

caso de que esto no sea posible, utilizar métodos de arran-
que alternativos que sean compatibles con la carga y tensión
del motor.
Cuando aplicar el sistema de arranque con tensión reducida,

acuerde que el par de arranque también reducirá.
9 Los motores 3 cables tensión única y 9 cables doble tensión

pueden ser arrancados como sigue:
- Arranque directo a plena tensión
- Arranque con auto transformador
- Arrancador Suave (Soft-Starter)
- Arranque con Convertidor de frecuencia – bajo verificación y
análisis de aplicación.
- Arranque Serie-Paralelo (solamente para 9 cables)
9 Los motores 6 cables tensión única y doble y 12 cables doble

tensión pueden ser conectados como sigue:
- Arranque directo a plena tensión
- Arranque estrella-triangulo
- Arranque con auto transformador
- Arrancador Suave (Soft-Starter)
- Arranque con Convertidor de frecuencia – bajo verificación y
análisis de aplicación.
- Arranque Serie- Paralelo (solamente para 12 cables)
El sentido de giro es el horario, mirando el motor desde el extre-

mo del eje y conectando las fases en la secuencia L1, L2 y L3.
Esta secuencia y la alimentación deben ser positivas.
Para cambiar el sentido de giro, invertir dos de los cables de

alimentación.
Nota: Para motores con conexión monofásica, favor verificar la
tarjeta de identificación del motor.
31
LA CONEXION A LA RED DE ALIMENTACION
ELECTRICA DEBE SER EFECTUADA POR
PERSONAL CALIFICADO CON MUCHA ATENCION
PARA ASEGURAR UN CONTACTO SEGURO Y
, PERMANENTE. DESPUES DE HABER CONECTADO

EL MOTOR, VERIFIQUE QUE NINGUN CUERPO
EXTRAÑO PERMANEZCA EN EL INTERIOR DE LA
CAJA DE CONEXIONES. TODA ENTRADA DE CABLES
A LA CAJA QUE NO ESTE SIENDO UTILIZADA, DEBE
SER CERRADA
Asegúrese de utilizar el diámetro correcto para el cable

de alimentación, tomando como base la corriente nominal
indicada en la tarjeta de identificación del motor.
ANTES DE CONECTAR EL MOTOR, VERIFIQUE
, QUE LA PUESTA A TIERRA FUE REALIZADA

DE ACUERDO CON LAS NORMAS VIGENTES.
ESTE DETALLE ES FUNDAMENTAL PARA EVITAR
ACCIDENTES
4.10 – Dispositivos de protección
Cuando el motor es suministrado con dispositivos de protección

o monitoreo de temperatura, tales como, termostatos, termis-
tores, protectores térmicos, etc., conecte sus terminales a los
dispositivos correspondientes en el panel de control. Caso
este procedimiento no sea seguido correctamente, puede
invalidar la garantía.
No altere el reglaje de los dispositivos de protección, porque
los mismos pueden se tornar inoperantes.
Diagrama del Dispositivo de Protección
Motor termicamente
protegido con Motor termicamente
termostatos protegido con
termistores
L1 L2 L3 P1 P2
L1 L2 L3 P1 P2
Clave de Parada
TENSIÓN CORRIENTE
NOMINAL(V) (A)
3x 110-120 3.00
3x
220-240 1.50
440-480 0.75 CABLES DE DISPOSITIVO DE
CABLES DE 550-600 0.60 LOS TERMISTORES PROTECCIÓN
LOS TERMOSTATOS
32
4.11 – Puesta en Marcha (Start-Up)
LA CUÑA DEBE ESTAR COMPLETAMENTE
, ASEGURADA O POR EL CONTRARIO RETIRADA

ANTES DE PONER EN MARCHA EL MOTOR
a) El motor debe arrancar y funcionar de manera suave. En el

caso de que esto no ocurra, desconecte el motor y verifique
nuevamente el sistema de montaje y de conexiones antes
de nueva puesta en marcha.
b) En el caso de vibraciones excesivas, verifique se los

tornillos de fijación están sueltos o se la vibración es
originada por máquinas adyacentes. Se debe hacer una
verificación periódica de la vibración.
c) Mantener el motor en marcha bajo carga nominal durante

un pequeño periodo de tiempo y comparar la corriente
de operación con la corriente informada en la tarjeta de
identificación.
5 - MANTENIMIENTO
Cualquier servicio realizado en máquinas eléctricas

solamente debe ser hecho cuando las mismas estén
completamente paradas y todas las fases desconectadas
de la red de transmisión.
PELIGRO:
, CONTROL DE SEGURIDAD (CHECK LIST).
Inspección General
9 Inspeccionar el motor periódicamente.
9 Mantener limpio el motor y asegurar libre flujo de aire.
9 Verifique los vedamientos (sellos) y efectúe la sustitución
en caso que sea necesario.
9 Verifique el ajuste de las conexiones del motor así como
los tornillos de sustentación.
9 Verifique el estado de los rodamientos siempre obser-
vando: aparición de fuertes ruidos, vibraciones, temperatura
excesiva y condiciones de la grasa.
9 Cuando se detecte un cambio en las condiciones de
trabajo normales del motor, analice el motor y reemplace
las piezas requeridas.
, NO REUTILIZAR PIEZAS DAÑADAS O CON DESGASTE.

SUBSTITUIR POR NUEVAS, ORIGINALES DE FABRICA
La frecuencia adecuada para realizar las inspecciones
dependerá del tipo de motor y de las condiciones de
aplicación. 33
5.1 – Lubricación
PROCEDER DE ACUERDO CON LOS INTERVALOS
, DE REENGRASE RECOMENDADOS. ESTO ES VITAL

PARA LA OPERACION DEL MOTOR
5.1.1 - Motores sin grasera

Los motores hasta la carcasa 215T normalmente no llevan
grasera. En estos casos el reengrase deberá ser efectuado
conforme al plan de mantenimiento preventivo existente,
teniendo en cuenta los siguientes aspectos:
3 Desarmar cuidadosamente los motores.

3 Retirar toda la grasa.
3 Lavar los rodamientos con querosina o gasolina.
3 Secar los rodamientos
3 Reengrasar el rodamiento inmediatamente.
5.1.2 - Motores con grasera

Se recomienda efectuar el reengrase durante el funcionamiento
del motor, de modo que permita la renovación de la grasa
en el alojamiento del rodamiento. Si esto no fuera posible
debido a la presencia de piezas giratorias cerca de la entrada
de grasa (poleas, acoplamientos, etc.) que puedan poner
en riesgo la integridad física del operador, se procede de la
siguiente manera:
3 Limpiar las proximidades del agujero de la grasera.

3 Inyectar aproximadamente la mitad de la cantidad total
de grasa estimada y poner en marcha el motor durante 1
minuto aproximadamente en rotación nominal. Desconectar
nuevamente el motor y colocar la grasa restante.
3 La inyección de toda la grasa con el motor parado puede
llevar a la penetración de parte del lubricante al interior del
motor, a través del agujero de paso de eje en las tapas de
rodamientos interiores.
La frecuencia adecuada para realizar las inspecciones

dependerá del tipo de motor y de las condiciones de
aplicación.
, PARA LUBRICACION, USE EXCLUSIVAMENTE

PISTOLA ENGRASADORA MANUAL
34
INTERVALOS DE RELUBRICACION – GRASA POLIREX EM (MOBIL)
AVISO:
Las tablas arriba son recomendadas específicamente para
relubricación con grasa Polyrex® EM (Mobil) y temperaturas
absolutas de operación del rodamiento de:
9 70ºC (158ºF) para motores carcasas 254/6T hasta 324/6T.
9 85ºC (185ºF) para motores carcasas 364/5T hasta 586/7T.
Para cada 15ºC (59ºF) arriba de ese límite, los intervalos de

lubricación deben ser reducidos a la mitad. Los rodamientos
sellados (ZZ) son lubricados para una determinada vida útil,
una vez operando bajo condiciones de temperatura de 70ºC
(158ºF).
9 Los periodos de relubricación informados arriba son para
los casos de aplicación con grasa Polyrex EM (Mobil)
9 Motores montados de forma vertical deben tener su inter-
valo de relubricación reducido a la mitad cuando comparados
con motores en la posición horizontal.
9 Para aplicaciones con altas o bajas temperaturas, variación
de velocidad, etc. el tipo de grasa e intervalos de relubricación
son informados en una tarjeta de identificación adicional fijada
al motor. 35
RECOMENDAMOS EL USO DE RODAMIENTOS
, DE ESFERAS PARA MOTORES ACOPLADOS

DIRECTAMENTE A LA CARGA
PELIGRO:
,
GRASA EN EXCESO PUEDE PROVOCAR
SOBRECALENTAMIENTO DE LOS RODAMIENTOS,
RESULTANDO UN DAÑO TOTAL
5.1.3 – Compatibilidad de la grasa Polirex EM (Mobil) con
otros tipos de grasa:
Conteniendo espesante polyurea y aceite mineral, la grasa
Polyrex® EM (Mobil) es compatible con otros tipos de grasa
las cuales contengan:
9 Base de litio o complejo de litio o polyurea y aceite mineral
altamente refinado.
9 Aditivo inhibidor contra corrosión, herrumbre y aditivos
antioxidantes.
Notas:
9 Aunque la grasa Polyrex® EM (Mobil) sea compatible con los
tipos de grasa mencionados arriba, no recomendamos la mezcla
con cualquier tipo de grasa.
9 Si Ud. necesita utilizar otro tipo de grasa diferente de las
recomendadas arriba, primeramente contacte con WEG.
LA UTILIZACION DE MOTORES NORMALES EN
, LOCALES Y/O APLICACIONES ESPECIALES DEBE

ESTAR PRECEDIDA DE UNA CONSULTA AL
FABRICANTE DE GRASAS Y/O A WEG
5.2 - Desmontaje Y Montaje
9 El desmontaje y montaje del motor deberá ser hecho por

personal calificado, utilizando solamente herramientas y
métodos adecuados.
9 Las garras del extractor de rodamientos deberán estar
aplicadas sobre la pista interna o sobre la tapa interior.
9 Es esencial que el montaje de los rodamientos sea ejecutado
en condiciones de rigurosa limpieza, para asegurar un buen
funcionamiento y evitar daños. En el caso de colocar rodamientos
nuevos, éstos deberán ser retirados de su embalaje solamente
en el momento previo de su montaje al motor.
9 Antes de instalar un rodamiento nuevo, es necesario verificar
si el alojamiento del mismo en el eje se encuentra exento de
rebabas o señales de golpes.
9 Para montaje del rodamiento caliente sus partes internas con
equipamiento apropiado – por inducción – o utilice herramientas
36
apropiadas.
6. PARTES Y PIEZAS (REPUESTOS)
Al solicitar piezas para reposición, es conveniente indicar la

designación completa del motor, así como el código del mismo
que aparece marcado en la tarjeta de identificación.
Favor informar también el número de serie del motor de la
tarjeta de identificación.
7 – MOTORES PARA USO CON CONVERTIDOR DE FRECUENCI
7.1 – Línea de motores Standard
Motores con tensiones hasta 575V y accionados por
Convertidor de Frecuencia no requieren filtros cuando
adoptados los criterios a seguir:
Notas:
1) Trajeta de identificación
mostrando tensión
380-415V / 660-690V
- 50Hz y 440-460V -
60Hz y alimentados por
convertidor en tensión
660-690V - 50Hz o 480V
Informado por el fabricante del convertidor.
- 60Hz requiere el uso

de filtros.
2) Motores en las carcasas
504/5T y 586/7T* cuando
usados con convertidor,
necesitan uso de
rodamientos aislados.
* Otros tamaños de
carcasas, bajo consulta.
(*)
EL NO CUMPLIMIENTO DE ESTAS
, RECOMENDACIONES Y CRITERIOS CAUSA LA

PERDIDA DE GARANTIA DEL MOTOR
37
7.2 – Motores Inverter Duty
Motores con tensiones superiores a 575V e igual o menor

que 690V y alimentados por convertidor de frecuencia no
necesitan filtros caso sigan las especificaciones abajo:
9 Observar tensión de
alimentación del conjunto
ventilación forzada.
Informado por el fabricante del convertidor.
EL NO CUMPLIMIENTO
DE ESTAS
, RECOMENDACIONES
Y CRITERIOS CAUSA LA
PERDIDA DE GARANTIA
DEL MOTOR
(*)
7.3– Aislamiento del rodamiento
Los motores Inverter Duty en las carcasas 504/5T y 586/7T* son

suministrados con sistema de puesta a tierra entre el eje y la
carcasa en el lado delantero. También, bajo pedido puede ser
suministrado con rodamientos aislados.
Para otras líneas, en las carcasas 504/5T y 586/7T* cuando

usados con convertidor de frecuencia es necesario sistema de
puesta a tierra entre el eje y la carcasa o rodamientos aislados.
38
* Otros tamaños de carcasas, bajo consulta.
8 – INSTRUCCIONES ADICIONALES
8.1 – Motores Para Areas de Riesgo
8.1.1 General
Además de las recomendaciones arriba, las siguientes también

deben ser observadas:
Motores para áreas de riesgo son fabricados de acuerdo con
normas específicas para estos ambientes.
Motores suministrados para áreas de riesgo (áreas clasificadas)
deben ser instalados en área que estén de acuerdo con las
especificadas en la tarjeta de identificación del motor.
Notas:
9 Motores División I son también adecuados para la División
II
9 Motores de una especificada clase de temperatura son tam-
bién adecuados para ambientes con combustible de una clase
de temperatura mayor (ejemplo, motores T4 son adecuados
para ambientes de clase T3, T2, T1).
8.1.2 Instalación
La instalación debe seguir procedimientos elaborados por la

legislación local vigente.
LA INSTALACION DE MOTORES PARA AMBIENTES
, PELIGROSOS DEBE SER EJECUTADA POR PERSO-

NAL ESPECIALIZADO
LA ESPECIFICACION DEL LOCAL DE INSTALA-

CION ES DE RESPONSABILIDAD DEL CLIENTE,
, QUE TAMBIEN DETERMINARA LAS CARACTE-
RISTICAS AMBIENTALES
Cuando se utiliza el prensa cables en la entrada de los cables,
lo mismo debe ser apropiado para el motor y para el tipo de
terminal, el prensa cables debe ser montado, completamente
apretado de manera a adquirir la presión necesaria arriba de
los anillos de vedamiento, bien como:
9 Evitar la transmisión de vibraciones mecánicas para los
terminales del motor.
9 Garantizar la protección mecánica “IP” para la caja de
conexiones.
39
8.1.3 Chequeo y Mantenimiento
El mantenimiento debe ser ejecutado por talleres técnicos

autorizados y acreditados por WEG.
Talleres y personal sin autorización que realicen reparación

en los motores para ambientes peligrosos, serán totalmente
responsables por el trabajo ejecutado y los daños ocurridos
en su servicio.
En la ejecución del mantenimiento, instalación y relubricación,

se deben seguir las siguientes orientaciones:
9 Las conexiones deben estar correctamente cerradas

para evitar elevación de resistencia, consecuentemente
sobrecalentamiento del contacto
9 Aislamiento distancia-aire y distancia-superficie entre
los conductores, requeridos por las normas, deben ser
respectados
9 Todos tornillos utilizados en el montaje de las partes
del motor y caja de conexión, deben ser completamente
apretados
9 Vedamientos y repuestos para entrada de los cables serán
hechos utilizando materiales suministrados por el fabricante,
de manera a garantizar el tipo de protección original
3 Las superficies de encaje de los motores a prueba de

explosión no deben ser mecanizadas y no es permitido
utilizar entre ellas ningún tipo de vedamiento, no descrito
o suministrado por el fabricante. Los encajes deben ser
solamente limpios y para evitar corrosión o penetración de
agua, los encajes pueden ser engrasados con una fina manta
de grasa de silicona.
3 Verificar si los componentes están exentos de rebabas,
golpes y suciedad.
3 Observar si las piezas están en perfectas condiciones.
3 Lubricar superficialmente las guías de las tapas con aceite
protector para facilitar el montaje.
3 Utilizar solamente martillo de material blando en la
colocación de las piezas.
3 Verificar si todos los tornillos están bien apretados.
3 Utilizar sonda calibrada para verificar asiento de la caja de
conexiones (menor de 0,05mm).
40
8.1.4 Reparos De Motores A Prueba De Explosión
El reparo de repuestos, directamente involucrados en la

protección contra riesgo de una explosión, debe ser realizado
sin cualquier modificación al diseño original del motor.
Después del reparo, estos repuestos deben ser chequeados

y cuando concluido, el taller de asistencia técnica debe hacer
una declaración de todas las operaciones realizadas en el
motor específico.
Para maiores informaciones, en México favor comunicarse a:
41
9. TERMINOS DE GARANTIA
WEG ofrece garantía contra defectos de fabricación o de

materiales para sus productos, por un período de 18 meses,
contados a partir de la fecha de la emisión de la factura por parte
de fábrica o del distribuidor/revendedor, teniendo como límite 24
meses de la fecha de fabricación independiente de la fecha de
instalación del motor, siempre y cuando hayan sido satisfechos
los siguientes requisitos:
- Transporte, manoseo y almacenamiento adecuados;
- Instalación correcta y en condiciones ambientales específicas
y sin presencia de gases corrosivos;
- Operación dentro de los límites de la capacidad del motor;
- Realización periódica del debido mantenimiento preventivo;
- Realización de reparaciones y/o modificaciones al producto
original efectuada solo por los agentes autorizados de la Red
de Asistencia Técnica WEG;
- Entregar el producto al proveedor en el caso de ocurrir una falla
con reclamación de garantía en un período mínimo suficiente
para identificar la causa de la anomalía y su conveniente
reparación;
- Dar aviso inmediato a WEG, por parte del cliente, de los defectos
detectados y que los mismos sean posteriormente analizados por
WEG como causados por defectos de fabricación.
La garantía no incluye los servicios de desmontaje del motor en
las instalaciones del cliente, costos de transporte del producto
y gastos de traslado, alojamiento y alimentación del personal de
Asistencia Técnica cuando sean solicitados por el cliente.
Los servicios en garantía serán prestados exclusivamente en
talleres de Asistencia Técnica Autorizada WEG o en la propia
fábrica.
Se excluyen de esta garantía los componentes cuya vida útil,
en uso normal, sea inferior al período de garantía otorgado por
WEG las reparaciones o substituciones de piezas o productos, a
criterio de WEG o su Asistencia Técnica Autorizada, no prorrogará
el plazo de garantía original.
La presente garantía se limita al producto entregado, no siendo
responsable WEG por daños a personas, a terceros, a otros
equipos e instalaciones, utilidades que se dejen de obtener o
cualquier otro daño emergente o consecuente.
42
50000705
WEG Equipamentos Elétricos S.A.

International Division
Av. Prefeito Waldemar Grubba, 3000
89256-900 - Jaraguá do Sul - SC - Brazil
Phone: 55 (47) 3276-4002 - Fax: 55 (47) 3276-4060
www.weg.net
Loss of Motion
Instruction Manual February 2004
milltronics
MFA 4P
Safety Guidelines
Warning notices must be observed to ensure personal safety as well as that of others, and to
protect the product and the connected equipment. These warning notices are accompanied
by a clarification of the level of caution to be observed.
Qualified Personnel
This device/system may only be set up and operated in conjunction with this manual.
Qualified personnel are only authorized to install and operate this equipment in accordance
with established safety practices and standards.
Warning: This product can only function properly and safely if it is correctly transported,
stored, installed, set up, operated, and maintained.
Note: Always use product in accordance with specifications.
Copyright Siemens Milltronics Process Disclaimer of Liability

Instruments Inc. 2004. All Rights Reserved
This document is available in bound version and in While we have verified the contents of
electronic version. We encourage users to this manual for agreement with the
purchase authorized bound manuals, or to view instrumentation described, variations
electronic versions as designed and authored by remain possible. Thus we cannot
Siemens Milltronics Process Instruments Inc. guarantee full agreement. The
Siemens Milltronics Process Instruments Inc. will contents of this manual are regularly
not be responsible for the contents of partial or reviewed and corrections are included
whole reproductions of either bound or electronic in subsequent editions. We welcome
versions. all suggestions for improvement.
Technical data subject to change.
MILLTRONICS®is a registered trademark of Siemens Milltronics Process Instruments Inc.
Contact SMPI Technical Publications at the following address:
Technical Publications
Siemens Milltronics Process Instruments Inc.
1954 Technology Drive, P.O. Box 4225
Peterborough, Ontario, Canada, K9J 7B1
Email: techpubs@siemens-milltronics.com
For the library of SMPI instruction manuals, visit our Web site: www.siemens-milltronics.com
© Siemens Milltronics Process Instruments Inc. 2004

Table of Contents
Table of Contents
Milltronics MFA 4p ............................................................................................................. 1
Safety Notes .............................................................................................................................................1
The Manual ...............................................................................................................................................1
Specifications ...................................................................................................................... 2
Installation ........................................................................................................................... 4
Milltronics MFA 4p ........................................................................................................................4
Probe ................................................................................................................................................4
Wiring ...............................................................................................................................................4
Dimensions ...............................................................................................................................................5
MFA 4p .............................................................................................................................................5
Layout .........................................................................................................................................................7
Interconnection ...................................................................................................................8
MSP-1, 3, or 9 Probe with RMA (remote mounted pre-amplifier) ...............................................8
MSP-12 Probe with IMA (internally mounted pre-amplifier) ........................................................8
XPP-5 with IMA (internally mounted pre-amplifier) .......................................................................9
Connection to power: ...........................................................................................................................10
Wiring .................................................................................................................................. 11
MFA 4p Wiring for Automatic Start Delay ......................................................................................11
Operating Principles ........................................................................................................ 12
MFA 4p .....................................................................................................................................................12
Probe ........................................................................................................................................................12
Pre-Amplifier (IMA and RMA) ............................................................................................................13
MFA 4p Operation .................................................................................................................................13
Calibration ..............................................................................................................................................14
Underspeed ..................................................................................................................................14
Overspeed ....................................................................................................................................15
Signal Generator Interface .................................................................................................................16
Probes ................................................................................................................................. 17
Mini Sensing Probe MSP-1 .................................................................................................................17
High Temperature Probe MSP-3 ........................................................................................................17
Stainless Steel Probe MSP-9 ..............................................................................................................18
Mounting Details .........................................................................................................................18
Standard Probe MSP-12 .....................................................................................................................19
Hazardous Locations XPP-5 ................................................................................................................20
Interconnection Diagram for the XPP-5 .................................................................................21
Mounting Details ...................................................................................................................................22
Applications .......................................................................................................................23
Bucket Elevators ...................................................................................................................................23
Shafts .......................................................................................................................................................24
i
Belt Conveyors .......................................................................................................................................24
Screw Conveyors ...................................................................................................................................24
Table of Contents Non-Ferrous Window .........................................................................................................................25
Bucket Elevator ......................................................................................................................................25
Rotating Shaft of Rotary Feeder ........................................................................................................26
Drive Sprocket on Rotary Feeder ......................................................................................................26
Screw Conveyor Flights .......................................................................................................................27
End Bearing on Screw Conveyor ......................................................................................................27
Troubleshooting ................................................................................................................28
Maintenance ......................................................................................................................29
ii
Milltronics MFA 4p
Milltronics MFA 4p is a highly sensitive, single setpoint motion sensor alarm unit, used
with MSP and XPP probes. The probe detects an increase or decrease in the speed of
rotating, reciprocating, or conveying equipment and sends the information to the MFA 4p.
The MFA 4p works with a pre-amplifier which can be internal to the motion sensing
probe, or remote from the motion sensing probe.
Pulses generated from the probe are continually compared to the adjustable setpoint. If
the pulse rate is lower than the setpoint, the alarm relays operating in a faiI-safe mode
will de-energize, indicating failure. The relays will not energize until the pulse rate
increases above the setpoint.
Speicifcaions
Safety Notes
Special attention must be paid to warnings and notes highlighted from the rest of the text
by grey boxes.
WARNING means that failure to observe the necessary precautions

can result in death, serious injury, and/or considerable material
damage.
Note: means important information about the product or that part of the operating
manual.
The Manual
This instruction manual covers the installation, operation and maintenance of the
Milltronics MFA 4p. It is essential that this manual be referred to for proper installation
and operation of your unit. Adhering to the installation and operating procedures will
insure a quick, trouble free installation and allow for the maximum accuracy and
reliability of your motion sensing alarm unit and probes.
If you have any questions, comments, or suggestions about the manual contents, please
email us at techpubs@siemens-milltronics.com.
For the complete library of Siemens Milltronics manuals,
go to www.siemens-milltronics.com.
7ML19985FM01 MFA 4p - INSTRUCTION MANUAL Page 1

Specifications
Safety
Note: The Milltronics MFA 4p (Motion Failure Alarm) is to be used only in the manner
outlined in this manual, otherwise protection provided by the equipment may be
impaired.
Power
Specifications
• 100/115/200/ 230 V AC ±15%, 50/60 Hz, 15 VA
Output
• 2 relays with Form C (S.P.D.T.) fail-safe contacts (relays operate in unison)
Resistive Rating:
• 8 A @ 250 V AC
Repeatability
• ± 1%
Temperature coefficient (setpoint variance)

• 0.018%/ °C (0.01% / °F)
Setpoint adjustment range

• 2 to 3,000 ppm (pulses per minute): standard model
• 0.15 to 15 ppm: slow speed version
Dynamic range
• 0 to 7,200 ppm
Page 2 MFA 4p - INSTRUCTION MANUAL 7ML19985FM01

Weight
• polycarbonate enclosure: 1.5 kg (3.3 lb.)
• mild steel or stainless steel enclosure: 4.3 kg (9.5 lbs.)
Approvals1
• CE, CSA(C/US), FM
• EMC performance available on request
Environmental
• location: Indoor/outdoor
• altitude: 2000 m max.
• ambient temperature: –20 oC to 50 oC (–4 oF to 122 oF)
• relative humidity: suitable for outdoor (Type 4X / NEMA 4X / IP65)*
• installation category: II
• pollution degree: 4
*Type 4/ NEMA 4 /IP65 with mild steel enclosure
Installation
Related Equipment Ambient Temperature Range Approx wt.
RMA –40 °C to 60 °C (–40 °F to 140 °F ) 2.3 kg (5 lb)
MSP-12 –40 °C to 60 °C (–40 °F to 140 °F ) 1.4 kg (3 lb)
XPP-5 –40 °C to 60 °C (–40 °F to 140 °F ) 1.8 kg (4 lb)
1.
EMC performance available upon request.

Installation
Milltronics MFA 4p
The MFA 4p (and RMA if applicable) must be mounted in a non-hazardous area that is
clean, dry, vibration-free, within the ambient temperature range, and non-corrosive to the
electronics or its enclosure. The door should be accessible for viewing and to allow
calibration of the MFA 4p.
Note: Do not mount MFA 4p in direct sunlight.
Probe
The probe should be mounted onto a vibration free structure using the mounting flange.
The gap between probe and target should be large enough to prevent the target from
damaging the probe. The probe environment must be within the probe's ambient
temperature range and non-corrosive to the probe's body. Refer to Applications drawings
on page 23.
The probe design detects a changing magnetic field, typically caused by a ferromagnetic
target disturbing the probe's magnetic field. Extremely strong magnetic fields (like those
produced by the 30A/m requirements of 1EC 60004-8, Power Frequency Magnetic Field
Immunity test) will be detected and will result in loss of functionality.
Installation
Functionality loss indicators:

• alarm conditions by relay trip
• false pulse readings in LED1
Consider the probe location carefully before installation. Avoid strong magnetic fields
(50/60 Hz) from nearby power transformers, heater elements, or large industrial motors,
because these can affect the probe’s performance.
Wiring
Where possible, the probe components should be interconnected via flexible conduit.
This allows for easier removal or adjustment of the probe and mounting flange assembly.
Note: Installation shall only be performed by qualified personnel and in accordance

with local governing regulations.

Dimensions
MFA 4p
Type 4X / NEMA 4X / IP65 Polycarbonate Enclosure
160 mm
(6.325")
6 mm
15mm 82 mm
131 mm (0.25")
(0.59") (3.225")
(5.138")
240 mm
(9.455")
228 mm
(8.975")
Installation
mounting holes lid screws
4.3 mm (0.170")
dia. 4 places Suitable location for conduit entrance
Notes:
• Non-metallic enclosure does not provide grounding between conduit
connections: use grounding type bushings and jumpers.
• Use only approved, suitable size hubs for watertight application.

Type 4 / NEMA 4 / IP65 Painted Steel Enclosure &
Type 4X / NEMA 4X / IP65 Stainless Steel Enclosure
203 mm
(8.0”)
19 mm
152 mm (0.75”)
(6.0”)
273 mm
254 mm
(10.75”)
(10.0”)
Installation
178 mm
19 mm
(7.0”)
(0.75”)
8 mm
(0.31”)
227 mm
(8.94”)
21 mm
(0.83”)
102 mm
(4.0”)
suitable location for

Conduit Entrance
(customer specified)
Notes:
• Painted steel enclosure does not provide grounding between conduit
connections: use grounding type bushings and jumpers.
• Use only approved, suitable size hubs for watertight application.

Layout
MFA 4p Circuit Board
PULSES PER MINUTE START DELAY

15 30
P1 P2
20 40
9 21
R42
X1 R11 10 50
X10 R10 Q4
X100 R9
0 60 D7
0 30
SW2 SECONDS C38
PPM D6 R43
R16 R28 C40
D1 C6C13
R15 R17
C5
R12 C52
C2 R3 R1 CW D27 D28 C17 D22
R13 C41
R4 P3
IC1 R2
R6 C18
C1 C4 C3 R14
R7 D26 D25 D23 D21 D24
R5
START
DELAY Q1
CAL
CW
PPM
P4
C16
UNDERSPEED
IC5
R45
OVERSPEED C15
SW3
IC4
R40 C12 C11 Q7 Q8

IC3
R38 T2
R39 R26 R27
SW1
230V 200V
R18 C7 IC2 OFF
RL1 RL2
LED1 R8 R25 C9
R24
C8
Q3 Q2 R20
R29 R21
D4 Q10
Q9 SW1
D2
R41 Q11 Q5 R19
R23 R30
R31 R34 R33 C10
R35 R22 100V
R37 115V
LED2 R36
D5 Q6
S1
Interconnection
1 2 3 4 5 6 7 8 R32 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
NO NC NO NC L2/N L1
PROBE
RL1 RL2 INPUT
RELAYS SHOWN IN
DE-ENERGIZED POSITION
250 V 8 AMP
SN

Interconnection
MSP-1, 3, or 9 Probe with RMA (remote mounted

pre-amplifier)
1
NO
RL1
2
250 V
RELAYS SHOWN IN
NC
3
8 AMP
4
MFA 4p
NO
RL2
5
RMA
NC
6
TB1 TB2
3 GND 3 7
7
BLK
2 2
WHT 8
PROBE
1 1
INPUT
8
SHIELD
9
9
10
10
L2/N
11
11
L1
12
12
Maximum cable length from probe to RMA is 30 m / 100 ft of shielded cable, 18 ga. wire.
See table on page 9 for cable lengths from RMA to main group.
MSP-12 Probe with IMA (internally mounted pre-

amplifier) 1
1
NO
RL1
2
250 V
RELAYS SHOWN IN
NC
Interconnection
3
8 AMP
4
NO
RL2
MFA 4p
NC
BLK 7
7
RED
8
PROBE
INPUT
9
9
9
10
10
L2/N
11
11
L1
12
12
Wire can be run in conduit common to motor supply or control wiring. Connection to
probe leads can be made under probe cap. See table on page 9 for lengths from probe at
MFA 4p.

XPP-5 with IMA (internally mounted pre-amplifier)
1
NO
RL1
2
250 V
RELAYS SHOWN IN
NC
3
8 AMP
4
NO
RL2
5
NC
MFA 4p
6
WHT 7
7
BLK
GRN 8
PROBE
INPUT
8
9
9
10
10
L2/N
11
11
L1
12
12
XPP-5 cable must be run in dedicated, approved metal conduit, boxes and fittings and to
procedures in accordance with all governing regulations. See table below for lengths
from probe at MFA 4p.
Note: Refer to Interconnection Diagram for the XPP-5 (drawing number 23650131) on
page 21.
Cable length from RMA or IMA to MFA 4p
Wire Length in
Length in feet
gauge metres
22 AWG 2500 760
(0.34 mm2)
18 AWG 5000 1520
(0.75 mm2)
12 AWG 25000 7600
(4 mm2)
Interconnection

Connection to power:
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
NO NC NO NC L2/N L1
PROBE
RL1 RL2 INPUT
RELAYS SHOWN IN
250 V 8 AMP
• Terminal 10 must be connected to reliable ground.
• The equipment must be protected by a 15A fuse or circuit breaker in the building
installation.
• A circuit breaker or switch in the building installation, marked as the disconnect

switch, shall be in close proximity to the equipment and within easy reach of the
operator.
• AC input circuit, relay circuits, min. 14 AWG copper wire
• Recommended torque on terminal clamping screws, 7 in.lbs. max.
WARNING: All field wiring must have insulation suitable for at least
250 V.
Wiring
Page 10 MFA 4p – INSTRUCTION MANUAL 7ML19985FM01

Wiring
MFA 4p Wiring for Automatic Start Delay

L 115/230V AC 50/60 HZ L/N
STOP START
M
SEE NOTE 3 TB-1 CONTACTOR
1/4 2/5
12 TB-1 11
MFA 4p M1
L MFA 4p N
G 10
SEE NOTE 2
OR
STOP START
M
HOLD UNTIL UP TO SPEED
SEE NOTE 3 CONTACTOR
TB-1
1/4 2/5
MFA 4p M1
12 TB-1 11
L MFA 4p N
G 10
Notes:
1. Interlocks and Safety Pull Switches are not shown.
2. If START is initiated by programmable logic controller, closure time may be too
brief to allow MFA 4p contact to latch. In this case, program a timer contact
into the circuit.
3. CSA requires an 8A or less fuse to protect contacts. For 240 V AC, protect the
contacts with a 1500 VA transformer as well.
Should the Time Delay feature on start-up not be required, power should be applied
continuously from a separate source and the potentiometer turned to zero. This is usually
necessary for automatic up-stream start up of conveying devices after the down-stream
drive has reached its operation speed.
Wiring

Operating Principles
MFA 4p
Milltronics MFA 4p is a highly sensitive, single setpoint motion sensor alarm unit, used
with MSP and XPP probes. The probe detects an increase or decrease in the speed of
rotating, reciprocating, or conveying equipment and sends the information to the MFA 4p.
The MFA 4p works with a pre-amplifier which can be internal to the motion sensing
probe, or remote from the motion sensing probe.
Pulses generated from the probe are continually compared to the adjustable setpoint. If
the pulse rate is lower than the setpoint, the alarm relays operating in a faiI-safe mode
will de-energize, indicating failure. The relays will not energize until the pulse rate
increases above the setpoint.
Probe
The Milltronics probes work on the principle of Faraday’s Laws of Electromagnetic
Induction. When a ferromagnetic object enters the probe’s permanent magnetic field, it
distorts the flux causing it to cut the coil windings and generate a voltage. This voltage is
proportional to the strength of the magnet and the number of wire turns in the coil
(constant in the Milltronics probes) and the speed at which the ferrous target passes
through the flux. The generated voltage is also inversely proportional to the square of the
distance between the target and the probe.
The relationship between speed and gap of a standard probe:
(25.4 mm = 1 inch and 305 mm = 1 foot)

Wiring
FIG. A. FIG. B FIG C

50 x 25 x 50 mm 50 x 50 x 25 mm 50 x 25 x 25 mm
(2”x 1”x 2”) (2”x 2”x 1”) (2”x 1”x 1”)
ferrous block ferrous block ferrous block

The resultant line indicates the threshold tolerance of the accompanying MFA 4p
electronics. For example, in FIG. A, a 100 mm (4") gap requires a minimum velocity of
about 10 m / minute (35 ft / minute): with a velocity of 0.61 m / minute (2 ft / minute), a
maximum gap of 31 mm (1.25") is possible.
Note: 25.4 mm = 1 inch and 0.305 m = 1 foot
The graph was plotted from tests using four ferrous blocks set equidistantly on a
406 mm (16") diameter circle on a non-ferrous disc.
The physical shape of the ferrous target generally becomes important at low velocities or
large gaps. At these points, tests indicate that a cubic shape gives the best results due to
the sudden change it causes in the magnetic field.
An increase in block size beyond 50 x 50 x 25 mm (2" X 2" X 1") is generally not as effective
as minimizing the gap, except at very low velocities.
The Milltronics Mini Sensing Probe, MSP-1

• The MSP-1 is approximately one-quarter the size of the standard probe with about
one-eighth the sensitivity.
• Divide all operating values by 0.125 to obtain the specifications of the MSP-1.
For example, with a gap of 12 mm (0.5"), the minimum velocity is approximately
60 m / min. (200 ft / min.), and with a velocity of 0.6 m / min. (2 ft / min. )
a maximum gap of 0.125" (3 mm) is possible.
Milltronics manufactures probes to suit a wide variety of environments: low temperature,
high temperature, corrosive, and Class I, II and III applications.
Pre-Amplifier (IMA and RMA)

The pre-amplifier accepts the voltage pulses generated by the probe and converts them
into noise-immune current pulses. Current levels are 12 mA low and 45 mA high. The pre-
amplifier comes internally mounted in the probe, or in an enclosure for remote mounting.
Internally mounted pre-amplifiers are called IMAs. Remote mounted pre-amplifiers are
called RMAs.
MFA 4p Operation
The MFA 4p provides a short circuit protected, +24 V DC unregulated supply to the pre-
amp. In the event that the interconnecting wiring is shorted, output current from the
MFA 4p is automatically limited and the on-board alarm relays are de-energized to
indicate failure.
The output current pulses from the pre-amp are super-imposed onto the dc current
supply. These are monitored by Probe LED 1, which is illuminated at the rate of the
Wiring
incoming pulses and is useful for positioning the probe.

The rate at which the pulses are received by the MFA 4p is compared to a setpoint
reference signal from the time base generator.

Although two pulses within range are required to energize the relays, as long as the
frequency of the incoming pulses exceeds the setpoint frequency (or is less than that of
the setpoint in the case of overspeed detection), the MFA 4p keeps the alarm relays
energized. The reference generator is frequency adjustable by the pulses per minute
(ppm) switch and potentiometer.
The alarm relays will de-energize after two time constants of the setpoint when the
frequency of the incoming pulses falls below that of the setpoint (or exceeds that of the
setpoint in the case of overspeed detection). The relay status is indicated by Relay LED 2,
which is illuminated when the relays are energized (normal).
The MFA 4p has a 0 to 60 second time delay feature, allowing the monitored device to
accelerate to normal running speed before monitoring begins.
This feature is activated when power is applied to the MFA 4p in parallel with the motor
starter contact coil. The time delay circuit simulates normal operating conditions for the
amount of time as set by the Start Delay potentiometer, keeping the alarm relays
energized. If the monitored device does not reach normal speed before the set time
period, the relays will de-energize giving an alarm condition. This feature is not applicable
in the overspeed detection mode.
Calibration
The probe and pre-amplifier require no calibration.
Connect the probe, pre-amp, and MFA 4p as shown in the Interconnection diagrams on
pages 8 and 9. Connect the MFA 4p to power as shown in the Power Connection diagram
on page 10, and if applicable, as shown for Automatic Start Delay on page 11.
Note: To help the calibration procedure, short N.O. contacts of relays to prevent
motor shut-down (terminals 1 to 2 and/or 4 to 5). This allows the system to run
uninterrupted until an operating setpoint is established.
MFA 4p (Refer to MFA 4p Circuit Board layout on page 7.)

1. Operate monitored equipment at its normal operating speed.
2. Confirm that Probe LED 1 is pulsing at a regular frequency.
3. Set Start Delay fully counter-clockwise (CCW) to 0 seconds.
Underspeed
1. Set switch SW3 to Underspeed.
2. Set pulses per minute (ppm) switch SW2 to X 100 position.
3. Turn ppm potentiometer fully clockwise (CW) to 30.
4. Determine incoming pulse rate by slowly turning ppm potentiometer CCW until relay
Wiring
LED 2 goes on. As the MFA 4p requires 2 pulses within range before energizing
relays, low ppm applications (e.g. 2 ppm) may require stepping of potentiometer at
appropriate time intervals.

5. If no response is obtained when you set the ppm potentiometer to 3 (below this
stability suffers), reset potentiometer fully CW, set switch SW2 to X 10 and then X 1
if required, and repeat step 4.
6. When Relay LED 2 goes on, indicating the incoming pulse rate, turn potentiometer
CCW slightly past this point to obtain an operating setpoint that allows for normal
fluctuations due to load and voltage variations. For 50% of full speed, set
potentiometer (and SW2 if required) to halfway between incoming pulse rate of
normal speed and 0 ppm.
7. Set Start Delay by adjusting potentiometer so that equipment being monitored can
attain normal operating speed before LED 2 can turn off.
Overspeed
1. Set switch SW3 to Overspeed.
2. Set ppm switch SW2 to X 1 position.
3. Set ppm potentiometer fully CCW to 0.
4. Determine incoming pulse rate by slowly turning ppm potentiometer CW until
Relay LED 2 goes on. Because the MFA 4p requires 2 pulses within range before
energizing relays, low ppm applications (e.g. 2 ppm) may require stepping of
potentiometer at appropriate time intervals.
5. If no response is obtained when you set the ppm potentiometer to 3, (below this
stability suffers), re-set potentiometer fully CCW and set switch SW2 to X 10, and
then X 1 if required, and repeat step 4.
6. When Relay LED 2 goes on, indicating the incoming pulse rate, turn potentiometer
CW slightly past this point to obtain an operating setpoint that allows for normal
fluctuations due to load and voltage variations.
Remember:
If N.O. contacts were shorted as described in final note of calibration
preamble, remove them now as calibration is complete.
Wiring

Signal Generator Interface
Probes The following circuit may be used for calibrating or for troubleshooting the MFA 4p.
470 to 620 ohm to MFA 4p

10K ohm 2N4401 2W TB1
1/4 W
signal generator 8
7
Circuit substitutes operating probe and pre-amp.
Set signal generator for:
6 V p-p sine 0V
6V p-p square OV
3V p square OV

Probes
Probes
Mini Sensing Probe MSP-1
89
(5. mm
50
”)
1" UNF
25 1/2" NPT or
m
(1” m PG16, TAPPED
) BOTH SIDES
3/4" NPT
102 mm
(4”)
51
m
(2” m
)
89
(3. mm
50
”)
MO 165 m 5”)
UN m 37 RS
TIN (6. (4. TE
G
CE
50
”) m m
C EN
NT 111 ING
ER T m
S UN 0m )
MO 14 .50”
(5
8 mm ø (0.312”)
4 HOLES
• CPVC body comes with 2 CPVC locknuts

• 180 cm (6 ft.) of Belden 8760 supplied potted in probe
• Remote mounted pre-amp in NEMA 4 cast aluminum enclosure.
High Temperature Probe MSP-3

2" NPSL
60 MOUNTING FLANGE
(2. mm
37
5”)
LOCKNUT 89
(5. mm
50
PROBE BODY ”)
GASKET
1/2" NPT
or PG16,TAPPED
BOTH SIDES
12
7 102 mm
(5” mm (4”)
) 86
18 (3. mm
7 37
(7. mm 5”)
37
5”)
MO 165 m
UN m 5”) RS
TIN (6. 37
CAP c/w 1/2" NPT G 50
”) (4. NT
E
CONDUIT ENTRANCE
CE
NT 1 mm CE
11 TIN G
ER m
S UN 0m )
MO 14 .50”
(5
8 mm ø (0.312”)
4 HOLES
• Cast aluminum body comes with cast aluminum cap and zinc flange, zinc plated
locknut, and silicone rubber gasket
• See page 22 for Flange and Mounting Details
• Pre-amp is mounted in a NEMA 4 cast aluminum enclosure

Stainless Steel Probe MSP-9
86 mm ø 22 mm ø (0.875”)
(3.375”) 2 PLACES
Probes
51
(2” mm GASKET
) CLAMPS
4 PLACES
111 mm
(4.375”)
17
8
(7” mm
)
15 ) S
MO 17 2m (4” ER
CAP c/w UN 1m (6” m m NT
TIN m (6 ) 2m CE
22 mm ø HOLE . 10 G m
(0.875”) 19
1
G
CE 75”) TIN 2m
(7. mm NT UN 15 (6”)
50 ER MO
”) S
8 mm ø (0.312”)
4 PLACES
Mounting Details
6 mm (0.25") diameter four holes equally
spaced on a 114 mm (4.5") BCD
102mm
(4”)
95 mm (3.75") diameter
Probe clearance hole
102 mm
(4")
probe flange panel
• For high temperature and corrosion resistance applications

• 304 stainless steel body comes with stainless steel clamp and silicone gasket
• 1.5 m (5 ft.) Belden 83321 Teflon£1 cable potted in probe
• Pre-amp is mounted in an enamel painted steel Hammond 1414N4E enclosure
1.
Teflon is a registered trademark of E.I. du Pont de Nemours and Company

Standard Probe MSP-12
2" NPSL
Probes
MOUNTING
FLANGE
6
(2. 0 mm
37
5”) LOCKNUT
PROBE BODY
GASKET
12
7m
(5” m
)
86
(3. mm
18 37
5”)
(7. 7 mm
37
5”)
CAP c/w
½" NPT or PG16
CONDUIT ENTRANCE
• Phenolic body comes with die-cast aluminum cap and zinc flange, zinc plated
locknut, and neoprene gasket
• See page 22 for Flange and Mounting Details
• Pre-amp is potted in the probe body and comes with two 127 mm (5") long hook-up
wires

Hazardous Locations XPP-5
143 mm
¾ “ NPT (5.63”)
9.4 mm
(0.37”)
Probes
cable
SOW-18-3
41.2 mm
(1.62")
probe body
(potted aluminum nameplate
junction box)
probe body
(potted phenolic
housing)
171.5 mm
(6.75”)
2" NSPL nominal
locknut
mounting flange
• C.S.A Approved for:

Class I, Div.1, Gr. A, B, C & D
Class II, Div 1, Gr. E, F & G
Class III
• phenolic/aluminum body with die-cast flange and zinc-plated locknut
• see page 22 for mounting details, and pages 9 and 21 for interconnection
information.
• pre-amp and cable potted in the probe’s body

Interconnection Diagram for the XPP-5
Probes
NON - HAZARDOUS LOCATION HAZARDOUS LOCATION
CLASS I, DIV 1, GROUPS A,B,C,D
CLASS II, DIV 1, GROUPS E,F,G
METAL CONDUIT
MILLTRONICS CERTIFIED CERTIFIED

CONTROLLER CONDUIT CONDUIT
SEAL SEAL
FITTING FITTING
XPP-5
JUNCTION BOX
CLASS I & II
METAL CONDUIT
CERTIFIED CERTIFIED
MILLTRONICS
CONDUIT CONDUIT
CONTROLLER
SEAL SEAL
FITTING FITTING
XPP-5
NOTES :
1) THE XPP-5 CABLE MUST BE TERMINATED IN AN AREA EXTERNAL
TO HAZARDOUS LOCATIONS, CLASS I, DIV 1, GR. A,B,C,D & CLASS II, DIV 1, GR. E,F,G.
2) A SEAL SHALL BE INSTALLED WITHIN 50 mm OF THE XPP-5 CONDUIT HUB
FOR CLASS I, DIV. 1 HAZARDOUS LOCATION ONLY.
3) INSTALLATION SHALL BE DONE IN ACCORDANCE WITH

CANADIAN ELECTRICAL CODE PART 1 REQUIREMENTS.
4) DO NOT EXPOSE THE XPP-5 TO DIRECT SUNLIGHT, OTHERWISE

PROVIDE SUN SHIELD.
REVISED HOUSING THREADS JULY
2 RWG SN
5) STATIC HAZARD, DO NOT RUB WITH DRY CLOTH. PER ECN #00-000-0-0070
REVISED CABLE AND TERMINAL CONNECTOR
11/00
APRIL
1 PER ECN #00-000-0-0037
RWG SN 18/00
MARCH
0 FOR CONSTRUCTION RWG SN 27/00
N. T. S.
B. GRAY
XPP-5 2365013102
R. CLOSS INTERCONNECTION DIAGRAM 1=1 23650131 2
S. NGUYEN 1 1

Mounting Details
6 mm (0.25”) dia.
hole for ¼ -20 nut
and bolt
or drill and tap,
four holes on
114 mm (4.5“) BCD 6 mm (0.25”) dia. hole for
¼ -20 bolt on 114 mm (4.5”)
BCD, four places
95 mm (3.75”) dia.
probe clearance
hole
133 mm
(5.25”) O.D.
Applications
2” NSPL
25mm
(1”)
Mounting Flange
APPLICABLE TO ALL PROBES
EXCEPT MSP-1 AND MSP-9

Applications
Bucket Elevators
down leg
probe (see
Figure A)
probe (see
Figure A)
knee and
Applications
housing
102 mm (4")
preferred work floor

location for
chain and
sprocket
drive
elevators.
For chain and sprocket drive Preferred location for belt-driven elevators
elevators, place the probe so that with ferrous bucket spacing greater than
the gap between the bucket and the 76 mm (3"), and non-ferrous buckets with
probe does not exceed 102 mm (4"). ferrous bolts.
To prevent damage to the probe from
For ferrous buckets with spacings less than
eccentric bucket motion, ensure that
76 mm (3") locate probe on the front of the leg.
the gap is not less than 12.5 mm
(0.5") in the worst condition.
Figure A
elevator mounting
wall flange and For elevators with ferrous walls,
locknut cut 88 mm to 95 mm (3.5" to 3.75")
hole in the elevator wall. Any
probe
position from A to C may be used
to maintain the gap.
95 mm
(3.75")
A B C
7ML19985FM01 MFA 4p – INSTRUCTION MANUAL Page 23

Shafts
probe
probe
key in keyway
shaft
102 mm (4”) dia. min.
added paddle shaft
safety shield not shown
These methods are viable if the speed is such that the blades or key will provide the
number of pulses required at a minimum velocity of 1.5 m / minute (5 ft. / minute). In
Applications
applications where exposed moving parts are required, safety shields and precautions
should be applied.
Where conditions prevent the sensing of buckets, a belt pulley or paddle mounted on an
exposed shaft end, preferably the tail pulley, may be used.
Belt Conveyors
50 x 50 x 25 mm (2” X 2”
X 1") ferrous blocks or
spoked wheel
probe
probe
Potential for damage in each application governs the minimum gap allowable. Maximum
gap for operation is 102 mm (4"), optimum 25 mm to 50 mm (1" to 2").
Screw Conveyors
The probe should be located at the idler end Arrows indicate permissible place-
(usually feed end) ment range of the probe
A ferrous mass added behind the flight of a screw conveyor, where it passes the probe
aids Borderline Operation. This mass must be added for all non-ferrous screws.

Non-Ferrous Window
6 mm ø (0.25”) CONVEYOR
CLEARANCE HOUSING
4 HOLES 12.7 mm MAX.
115 mm
(0.5”)
64 mm ø (3.5”) (4.52”)
CLEARANCE PROBE AND
HOLE MOUNTING FLANGE
WINDOW
C 153 mm SQ.
115 mm (6”)
C (4.52”)
70 mm
BRACKET
140 mm SQ. (2.75”)
(5.5”) WELD
Applications
179 mm SQ. BASE PLATE
(7”)
MINIMUM RECOMMENDED DIMENSIONS SHOWN
For screw conveyor with trough over 3.1 mm (0.125") thick or for high temperature
applications. The dimensions shown for the base, window, and bracket are the minimum
recommended with tolerances of ± 0.8 mm (0.031"). Use 305, 310, or 316 stainless steel,
brass, or aluminum.
The probe may not touch the window if temperatures are in excess of 60 °C (140 °F) when
using the low temperature probes or 260 °C (500 °F) when using the high temperature
probes.
Bucket Elevator

Rotating Shaft of Rotary Feeder
Applications
Drive Sprocket on Rotary Feeder

Screw Conveyor Flights
Troubleshooting
End Bearing on Screw Conveyor

Troubleshooting
LED LED term 7/8 term 1/2 term 4/5
C8
1 2 (note 1) relay 1 out relay 2 out
normal pulsing on 24 V 27 V closed closed
alarm pulsing off 24 V 27 V open open
probe reversed on off 20 V 27 V open open
polarity
probe wiring off off 27 V 27 V open open
open circuit
probe wiring off off 0V 27 V open open
short circuit
relay defective pulsing on 24 V 27 V open open
Notes::
• Voltage levels are dc, nominal values, and may appear to be pulsing, coincidental
with LED 1.
• If diagnosis does not solve the malfunction, the probe, pre-amp or MFA 4p may be
Troubleshootiing
defective.
• If no spare circuit boards or probes are available for interchanging, the MFA 4p may
be tested as follows in order to determine which section is defective:
a. To find out if the MFA 4p is defective:
i. Disconnect the pre-amp.
ii. Set ppm switch SW2 to X 1 position and turn potentiometer to 15.
iii. Connect one Iead of a 530 ohm, 1 watt resistor to terminal 7 and then
momentarily contact terminal 8 at a rate of once per second. If the MFA 4p is
functional, the relays will energize after two puIses and de-energize
approximately 8 seconds after last pulse.
b.To find out if the RMA is defective:
i. Disconnect pre-amp from the MFA 4p. Attach probe across terminals
TB1 1/2 and a 24Vdc (floating) power supply across terminals TB2 3/2,
according to the RMA Interconnectiondiagram on page 8.
ii. Run equipment to be monitored at normal operating speed or pass a ferrous
object in front of and as close to probe as possible at a continuous rate.
iii. With an oscilloscope, look for approximately 6V peak to peak pulses or
alternating hi/lo levels across ground and link 3. Or with an amp meter
connected in series between the RMA and the 24Vdc power supply, Iook for
hi/lo levels of approximately 12mA/40mA alternating at the rate of the
passing ferrous objects.

c.To find out if the probe is defective (non-IMA type only; i.e. MSP-1 , MSP-3, and
MSP-9 ):
i. Disconnect probe from pre-amp.
ii. Connect an ohmmeter across the black and white leads.
iii. Nominal probe impedances are as follows
MSP-1 115 ohms
MSP- 3 and MSP- 9 750 ohms
If impedance deviates substantially from these values, an open or short circuit condition
is indicated.
Maintenance
The Motion Failure Alarm MFA 4p requires no maintenance: however, we recommend a
program of periodic checks.
If it is necessary to clean the enclosure and circuit boards:
1. First, make sure the power is disconnected at the main breaker.
2. Use a vacuum cleaner and a clean, dry paint brush.
3. Check all electrical contacts for corrosion and arcing.
It is a good idea to periodically check the face of the probe: it should be free of material
build-up, corrosion or deformation.

Index O
Operating Principles 12
Operation 13
A Output 2
Ambient Temperature Range 3 Overspeed 15
Index
Applications 23 P
Automatic Start Delay 11 Power 2
B Pre-Amplifier (IMA and RMA) 13
Belt Conveyors 24 Probe
Bucket Elevator 25 operating principle 12
Bucket Elevators 23 Probes
C diagrams and details 17
Cable length 9 Mounting Details 22
Calibration 14 R
D Repeatability 2
Dimensions Resistive Rating 2
MFA 4p 5 Rotating Shaft of Rotary Feeder 26
Drive Sprocket on Rotary Feeder 26 S
Dynamic range 2 Screw Conveyor Flights 27
E Screw Conveyors 24
End Bearing on Screw Conveyor 27 Setpoint adjustment range 2
I Shafts 24
Installation 4 Signal Generator Interface 16
Interconnection 8 Specifications 2
Interconnection Diagram for the XPP-5 21 T
L Temperature coefficient 2
Layout Troubleshooting 28
MFA 4p circuit board 7 U
M Underspeed 14
MFA 4p W
circuit board layout 7 Wiring 11
operating principles 12 X
Operation 13 XPP-5
MSP-1 Mini Sensing Probe dimensions 20
dimensions 17 interconnection 9
specifications 13 interconnection diagram 21
MSP-1, 3, or 9 Probe specifications 3
interconnection 8
MSP-12 Probe with IMA
dimensions 19
interconnection 8
MSP-3 High Temperature Probe
dimensions 17
specifications 3
MSP-9 stainless steel probe
dimensions 18
specifications 3
N
Non-Ferrous Window 25

www.siemens-milltronics.com
Siemens Milltronics Process Instruments Inc. Siemens Milltronics Process Instruments Inc. 2004
1954Technology Drive, P.O. Box 4225 Subject to change without prior notice
Peterborough, ON, Canada K9J 7B1
Tel: (705) 745-2431 Fax: (705) 741-0466 Rev. 1.1
Email: techpubs@siemens-milltronics.com
*7ml19985FM01*
Printed in Canada
Falk™ Fluid Couplings • Installation & Maintenance Instructions
Sizes 185 thru 420 & 1420 • Types HF41 & 42 (Page 1 of 6)
How to Use This Manual ORANGE LABEL PERIMETER

FASTENERS
This manual applies to standard Falk Types HF41 & 42 couplings. FUSIBLE
FILL PLUG
Sizes 185 thru 370 utilize a QD type sheave (by purchaser). 392°F(200°C)
The sheave adapter is furnished and assembled at the Factory. (DRAIN PLUG ON
FACE FOR
The collet, sheave fasteners, draw bolt and washers are SIZE 320) SHEAVE
furnished unassembled. FASTENERS
Sizes 420 and 1420 utilize an integral sheave that is
manufactured and assembled at the Factory.
Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . Pages 1
Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 1-2 SHEAVE (OUTPUT)
ADAPTER
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 2-4
COLLET
Orifice Plugs (1420HFD only) . . . . . . . . . . . . . . . . . . . Page 5 (INPUT)
Fusible Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5 DELAY FILL
CHAMBER
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 5
Startup and Trouble Shooting . . . . . . . . . . . . . . . . . . . Page 6
FUSIBLE
Fluid Coupling Data Record . . . . . . . . . . . . . . . . . . . . Page 6 DRAIN
(FILL PLUG FOR
SIZE 320) PLUG
CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS 284°F (140°C) COLLET
Figure 1
MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE DRAW BOLT
FREE SERVICE.
Identification:
Coupling size and M.O. Number (Mfg Order Number) are
Introduction stamped on the perimeter of the coupling. Where Rexnord has
Type HF fluid couplings are designed for horizontal and level been provided application data (HP, speed, start factor, driven
operation. Refer to the Factory for coupling operation other equipment), the coupling will also include an orange label on the
than horizontal. The Type HF41 coupling is designed for perimeter, indicating the approximate fill quantity in fluid ounces,
mounting on the driving shaft and the Type HF42 coupling is and the correct fill angle. Provide coupling size and M.O. number
designed for mounting on the driven shaft. Internal when ordering spare parts.
construction of these couplings are different and their
mounting positions are NOT interchangeable.
Each fluid coupling is shipped from the Factory with an angle Keep Records for Future Reference
finder (P/N 1224653). Simply place the angle finder on the filler Future maintenance of the fluid coupling can be greatly
plug boss and rotate the coupling to the required fill angle as simplified by keeping good records. It is strongly suggested
instructed in the “Fill Fluid Coupling” section of these instructions. that the Fluid Coupling Data Record, Table 6, be completed
and stored in the maintenance files.
Maximize Performance & Life

The performance and life of couplings depend largely upon Fluids
how you install and maintain them. Before installing couplings, The following specifications and fluids listed in Table 1 apply to
make certain that foundations of equipment to be connected Falk fluid couplings. Refer to the Factory for use of fire resistant
meet manufacturers’ requirements. Check for soft foot. The fluids. NOTE: Fluids listed are typical products ONLY and should
use of stainless steel shims is recommended. not be construed as exclusive recommendations.
WARNING: Lock out power source and remove external loads ISO Viscosity Grade, Petroleum Oils (R & O) . . . . . 46
from drive before servicing drive or accessories. ISO Viscosity Grade, Synthetic Oils . . . . . . . . . . 32
WARNING: When opening the drain plug, filler plug, or Viscosity at 104°F(40°C) — 46 cSt (215 SSU)
metering orifice access plug of a warm or hot fluid coupling, Viscosity Index — Equal to or greater than 95.
place a rag over the drain or filler plug hole and loosen the plug Pour Point — Must be 5°F(3°C) lower than minimum
slowly to relieve any internal pressure. starting temperature.
WARNING: Consult applicable local and national safety codes Flash Point — 400°F(204°C) when using 140°C and/or
for proper guarding of rotating members. Guard must not 180°C fusible plugs.
restrict free flow of air, but the portion of the guard in line with Flash Point — 425°F (218°C) when using 200°C fusible
fusible plugs must be solid construction. plugs at both fill and drain holes.
CAUTION: DO NOT PAINT fluid coupling. Painting will Specific Gravity — 0.87
reduce fluid coupling thermal heat dissipation characteristics. Antioxidant and Anti-foaming Additives
CAUTION: DO NOT spray water on a hot fluid coupling, as
this may result in cracking of aluminum components.
Rexnord Industries, LLC, Coupling Group 528-410

5555 S. Moorland Rd., New Berlin, WI 53151-7953 USA Telephone: 262-796-4060 June 2006
Fax: 262-796-4064 e-mail: info@rexnord.com web: www.rexnord.com Supersedes 11-04
Installation & Maintenance Instructions • Falk™ Fluid Couplings
(Page 2 of 6) Types HF41 & 42 • Sizes 185 thru 420 & 1420
TABLE 1 — Fluids & Operating Temperatures WRENCH

FLATS
Petroleum Oils (R & O)
For Ambient Temperatures 20°F to 125°F (-6°C to 52°C)
Manufacturer Fluid
Amoco Oil Company American Industrial Oil 46
BP Oil Company Turbinol T-46
Chevron Products Company Hydraulic Oil AW 46
Exxon Company, USA Teresstic 46
Mobil Oil Corporation Mobil Fluid 424
Petro-Canada Products Harmony 46
Shell Oil Company Turbo T 46 Figure 2
Texaco Lubricants Company Rando Oil HD 46
76 Lubricants Company 76 Unax AW 46 Installation
Petroleum Oils (R & O) Only standard mechanics tools, torque wrenches, feeler gauges,
For Ambient Temperatures -20°F to 125°F (-28°C to 52°C) straight edges and a bevel protractor with spirit level or Angle
Manufacturer Fluid Finder (P/N 1224653) are required to install Falk fluid couplings.
Amoco Oil Company American Industrial Oil 46
Mobil Oil Corporation Mobilfluid 424
Synthetic Oils and Synthetic Transmission Fluids
1. Install Sheave
For Ambient Temperatures -40°F to 125°F (-40°C to 52°C) A. Check taper bore in sheave and taper fit on sheave
Manufacturer Fluid adapter for nicks or burrs.
Conoco Incorporated Syncon R&O 32 B. Clean surfaces with a non-flammable solvent.
Exxon Company, USA Teresstic SHP 32 C. Assemble sheave with furnished fasteners and lock
Mobil Oil Corporation SHC 624
Texaco Lubricants Company Pinnacle 32 washers, Figure 3. Tighten fasteners evenly to torque
specified in Table 2.
Mobil Oil Corp. Synthetic ATF
Chevron Synthetic All Weather THF
Citgo Transgard Fluid 250
2. Check Collet & Cut Off Key
Automatic Transmission Fluids (Dexron or Mercon Oils, etc.)
For Ambient Temperatures GreaterThan -40°F to 125°F (-40°C to 52°C) A. Lock out starting switch of prime mover.
NOTICE: Can only be used with two 140°C fusible plugs B. Check shaft, collet bore and taper fits for nicks and burrs.
Mobil Multi-purpose ATF C. Clean surfaces with a non-flammable solvent.
Texaco (Havoline) Mercon/Dexron-III or ATF
Citgo Transgard ATF,Type F D. For maximum collet shaft engagement, cut off key per
the following instructions:
Annual Maintenance Type HF41 — Cut motor shaft key to length specified in
An annual check of the coupling and fluid is recommended. For Table 2. NOTE: Maximum bore collets require customer
extreme or unusual operating conditions, or when the coupling is furnished rectangular keys. Dimensions for rectangular keys
subjected to overheating, check the coupling and fluid more are listed in Table 2.
frequently. Overheated fluid which becomes dark in color and Type HF42 — Assemble collet on driven shaft for
gives off a burnt odor must be changed. Fluid suppliers can test maximum engagement without key. Measure length of
coupling fluid samples periodically and recommend economical straight part of collet shaft keyway that is available and
change intervals based on the rate of degradation. Continuous cut key to that length.
operating temperature must not exceed 212°F (100°C).
Lifting
Install sheave as instructed in Step 1 and sling between coupling
and sheave using a complete wrap as shown in Figure 2.
CAUTION: Depending upon sheave size the balance will
change. Ensure proper balance before lifting.
Key Installation Tips

l
Do not exceed specified tightening torques for fusible
plugs at fill and drain holes (Step 6D). Excessive
tightening may strip aluminum threads.
l
Avoid excessive tensioning of V-Belts.
l
Carefully follow the instructions in this manual.
Figure 3
528-410 Rexnord Industries, LLC, Coupling Group

June 2006 5555 Moorland Rd., New Berlin, WI 53151-7953 USA Telephone: 262-796-4060
Supersedes 11-04 Fax: 262-796-4064 e-mail: info@rexnord.com web: www.rexnord.com
C. Insert collet draw bolt with locking and flat washers

through hole in input shaft and thread into tapped hole
TABLE 2 — Collet/Sheave/Removal Bolt/ in collet (Figure 4).
Collet Key Information
(Dimensions – Inches) D. Hold input shaft using wrench flats illustrated in Figure
5, and tighten fastener to torque specified in Table 2.
Torque (lb-ft) Removal Collet Key – Type HF41
Cplg. Collet Bolt SE Motor Key Size
Size Sheave UNC (Min.)
Draw Shaft
Fasteners Dia x Lght Width Height Length
Bolt Size
1/2-13 .875 .187 .187 .875
185 5-6 9 2.00 .187
x 4.00 1.125 H .250 1.125
3/4-10 1.125 .250 .250 1.125
235 18-20 15 2.50
x 5.00 1.375 H .312 .250 1.250
1.125 .250 .250 1.125
7/8-9 1.375 .312 .312 1.375
270 32-35 30 2.50 .375 .375
x 3.75 1.625 1.625
1.875 H .500 .375 2.000
1.375 .312 .312 1.375
7/8-9 1.625 .375 .375 1.625
320 65-80 60 3.12 .500 .500
TORQUE
x 6.00 1.875 2.000 WRENCH
2.125 H .500 .375 2.000
1.625 .375 .375 1.625
1.875 .500 .500 2.000 Figure 5
370 130-145 60 1-8 3.75
x 6.50 2.125 .500 .500 2.000
2.375 H .625 .437 2.500
1.875 .500 .500 2.000
420 2.125 .500 .500 2.000
& 200-220 1 1/8-7 2.375 .625 .625 2.500
28 x 9.50 4.38
1420 2.875 .750 .750 3.000
3.375 H .875 .625 4.500
H Customer furnished rectangular key required with maximum bore collet.
3. Install Collet & Fluid Coupling

NOTE: Make certain belts will pass over coupling. If not,
place them on sheave before assembling.
A. Install cut off key in shaft keyway and slide collet on
shaft for maximum engagement. Minimum shaft
engagement (Dimension SE) is listed in Table 2.
B. Support fluid coupling weight and slide coupling onto
collet taper, being sure proper alignment and engagement
is obtained (Figure 4). Be sure collet and key have not
moved axially as this could cause the key to ride up the
shaft keyway end ramp and cause runout and vibration.
Continue to support fluid coupling through steps C & D.
Figure 6
4. Sheave Connection
A. Mount couplings and sheaves as close to drive or
motor housing as possible to avoid undue bearing
load or shaft deflection.
INSERT
DRAW BOLT CAUTION: Rotate sheave by hand to assure there is
Figure 4 enough clearance between sheave fasteners and driving
or driven equipment, Figure 6.

B. Align sheaves square and parallel by placing a straight C. Slowly rotate fluid coupling until the required fill angle
edge across the face of the sheaves, Figure 7. is achieved, Figure 9. Fluid must appear at the lip of
the hole. Add or drain fluid until level is correct. Figure
10 shows fill angle example.
D. Reinstall fill plug with seal ring and tighten to required
torque: Sizes 185-270, 22 lb-ft; Sizes 320-420 and
1420, 33 lb-ft. DO NOT EXCEED SPECIFIED
SQUARE AND TIGHTENING TORQUE, as aluminum threads may
PARALLEL
Figure 7 strip.
C. Use matched belt sets to prevent belt whip and to

provide uniform tension. Adjust belt tension. The ideal
tension is the lowest tension at which the belt will not
slip under peak load conditions. Check the belt tension
frequently during the first 24 to 48 hours of run-in
operation. Over tightening belts will shorten belt and
bearing life. Avoid excessive tightening of the belts.
Keep belts free from foreign material which may cause Figure 9
slippage. Inspect the V-belt drive periodically;
re-tension the belts if they are slipping.
0°
5. Fill Fluid Coupling
E
0°
° GL
50 N
0° 0°
F A
A. Rotate fluid coupling until fill plug is on top and remove 50° GL
E
O ILL
AN0°
F
the fill plug. Both fill and drain plugs have metric L L
FI F 10
threads. Either plug may be used to fill coupling except O
for Size 320 which must use plug nearest sheave.
B. Fill with the required amount of fluid. Fill information is HIGH
found on the orange label that is affixed to the coupling LEVEL 100°
OF FILL LOW LEVEL
perimeter. Where no orange label is present, refer to OF FILL
fluid coupling Selection Guide 521-110 for fill data.
Fluid must meet the specifications listed in Table 1.
Do not remove orange fluid fill label that is affixed to the Figure 10
coupling perimeter. In cases where no orange label is
affixed, a blank label is furnished. Fill out the blank
orange label once proper fill data has been determined,
then affix that label to the coupling.
C. Before reinstalling fill plug, check fill angle as described
in the following step. Also, heed fill plug tightening
instructions, Step 6D.
6. Check Fill Angle

A. Refer to orange label described in the previous step for
required fill angle.
B. Use either an angle finder or a bevel protractor with
spirit level set for the required fill angle, and place it on
flat boss of filler hole as shown in Figure 8.
FILL ANGLE
Figure 8

7. Size 1420HFD (orifice plugs) 8. Fusible Plugs

The Size 1420HFD fluid couplings contain three orifice plugs A. Fusible plugs in the fill or drain holes have solder cores that
(metric threaded) located near the outer part of the casing. They melt at the temperatures shown in Figure 1, Page 1. One
are located behind three metric hex socket seal plugs (see Figure extra 284°F (140°C) plug is furnished with each coupling.
11). The function of these orifice plugs is to meter the fluid exiting B. If solder in fusible plug melts due to overheating
from the delay fill chamber into the working circuit of the fluid
from stalling or overloading, refer to Table 5, Page
coupling. These plugs are initially drilled with a 2.5mm hole (Size
6 and correct the cause of overheating.
1420) which results in acceptable starting times for most
applications. Should your application require increased or reduced CAUTION: DO NOT replace fusible plugs with solid
starting times, refer to Table 3 below for other orifice hole sizes and plugs. Use of solid plugs can result in coupling failure
their estimated effect on starting time. These estimates are based on from overheating unless used in conjunction with a
the change in flow rate for the fluid to exit the delay fill chamber. proximity sensor cutout switch. Refer to Factory for
recommendation.
CAUTION: Increasing the starting time can result in overheating
the fluid coupling and discharging fluid via the fusible plugs. C. Replace fusible plugs as instructed in Step 6D. DO NOT
EXCEED SPECIFIED TIGHTENING TORQUES, as
Refer to Table 4 for orifice and seal plug sizes, tightening
aluminum threads may strip.
torques, and required hex “Allen” wrench sizes. DO NOT
EXCEED SPECIFIED TIGHTENING TORQUES, as aluminum D. Refill coupling with clean fluid as instructed in Steps 5 & 6.
threads may strip. Use an anti-seize compound such as
Loctite™AntiSeize Thread Compound #767 or equivalent on
orifice plugs to assist in future removal. 9. Coupling Removal
A. Lock out starting switch of prime mover.
B. Remove belts and support coupling with a sling as
ORIFICE PLUG
shown in Figure 2.
C. Loosen collet draw bolt until washers are free and
SEAL WASHER
complete one more turn. Sharply strike the bolt head to
break loose taper fit. If reasonable number of strikes are
unsuccessful, go to Step C. Notice: Use of Step C is
commonly required to remove size 420 & 1420 fluid
couplings. Excessive striking may damage shaft bearings.
SEAL
D. If Step B does not work; remove collet draw bolt and
PLUG refer to Table 2 for “Removal Bolt” dimensions. Insert
removal bolt and tighten. Strike bolt sharply with
hammer to break loose taper fit, Figure 12.
Figure 11
TABLE 3 — Fluid Coupling Starting Times

Estimated Starting Time - % of Original
Orifice Hole Diameter
1420HFD
3/64" (0.0469) 440
1/16" (0.0625) 250
5/64" (0.0781) 160
3/32" (0.0937) 110
2.5 mm (0.0984) 100
7/64" (0.1094) 80
1/8" (0.1250) 60
3.5 mm (0.1380) 50
5/32" (0.1562) 40
3/16" (0.1875) 30
TABLE 4 — Orifice Plug/Seal Plug/

Seal Washer Sizes
Orifice Plug Seal Plug
DIN906 DIN908 Seal Washer
CPLG DIN 7603
SIZE Thread Hex Key Tightening Thread Hex Key Tightening Type “A”
Torque Torque Copper
Size Size Size Size
Ft-lb Ft-lb
Figure 12
1420 1/8R BSPT 5 mm 7 18 x 1.5 mm 10 mm 33 18 x 22 x 1.5 mm

TABLE 5 — Startup & Trouble Shooting

Problem Possible Cause Solution
Drive motor defective or Check motor connection, speed, amperage
incorrectly connected. draw and power draw.
Driven machine jammed. Check driven machine and remove jam.
Power consumption exceeds coupling H
Driven shaft fails to reach specified speed. capacity at specified fill angle.
Coupling over or under filled. Re-check fill angle per Step 6.
Correct source of leakage and re-check fill
Coupling leaking.
angle per Step 6.
1420HFD Only — Orifice plug hole plugged Clean orifice plug hole or use larger hole.
Coupling under filled. Re-check fill angle per Step 6.
Enlarge orifice hole size (See Table 3 for
1420HFD Only — Orifice plug hole too estimated start time reduction) or clean
small or plugged.
plugged hole.
Fusible plugs melt. Correct source of leakage and re-check fill
Coupling leaking.
angle per Step 6.
Driven machine jammed. Check driven machine and remove jam.
Power consumption exceeds coupling H
capacity at specified fill angle.
Re-install fluid coupling and collet per Step
Fluid coupling runout due to improper
assembly of collet and fluid coupling. 3. Check fluid coupling shaft for runout
near wrench flats.
Incorrect coupling or belt alignment. Re-align per instructions in service manual.
Coupling vibration exceeds acceptable limits.
Bent motor shaft. Replace motor.
Loose foundation, coupling or adapter fasteners. Check and tighten fasteners accordingly.
Return fluid coupling to Falk for bearing
Damaged fluid coupling bearing. replacement.
H Increase fluid fill by decreasing fill angle in 5° increments to a minimum of 50°. If drive shaft still does not reach specified speed, refer to the Factory.
TABLE 6 — Fluid Coupling Data Record (Installer – Fill out data below. Keep in coupling maintenance file)
Equipment Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor/Brake Hp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . @. . . . . . . . . . . Input RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Coupling Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fill Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Degrees. Fill Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fl. Oz.

Fluid Used (Mfg & Fluid Designation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Falk Master Order Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Date Installed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shaft Mounted Planetgear™ Speed Reducer • Owners Manual
Type SMP • Size Orion (Page 1 of 20)
TABLE OF CONTENTS
Section I — Introduction
Basic Operation and Design.............................. 2
Sectional View and Component Identification.... 2
Nameplate Information....................................... 3
Section II — Installation
Handing of Speed Reducer............................... 4
Speed Reducer Mounting.................................. 4
Motor Mounting.................................................. 5
Installing Top Motor Mount Plate........................ 5
Sprockets or Sheaves......................................... 5
Installing Motor................................................... 6
C-Face Motor Installation................................... 6
Section III — Lubrication
Lubricant Selection Process............................... 7
Lubricant Analysis and Changes....................... 8
Stored and Inactive Gear Drives...................... 10
Food Grade Lubricants.................................... 11 Section VII — Storage Procedures
Food Grade Lubrication Selection Process...... 11 Spare Parts Storage......................................... 16
Food Grade Lubricant Analysis and Changes....11 Stored and Inactive Speed Reducers.............. 16
Stored and Inactive Gear Drives...................... 12 Long Term Storage........................................... 16
Section IV — Start-Up Section VIII — Troubleshooting
Pre Start-up Checklist...................................... 13 Excessive Temperature.................................... 17
Initial Start-up................................................... 13 Bearing Damage.............................................. 17
Prime Mover...................................................... 13 Bearing Noise................................................... 17
Speed Reducer Rotation.................................. 13 Leakage............................................................ 18
Start-up............................................................ 13 Damage of Fasteners...................................... 18
Post Start-up Checklist..................................... 13
Section IX — Tables
Section V — Maintenance Tables 1 thru 6.................................................. 19
Filling Speed Reducer with Oil......................... 14
Draining Oil from Speed Reducer.................... 14 Section X — Maintenance Log
Adding Grease to Speed Reducer Seals......... 14 Maintenance Log.............................................. 20
Section VI — Disassembly and Assembly

Instructions
Required Equipment........................................ 15
Removal of Shrink Disc.................................... 15
Speed Reducer Removal................................. 15
Reinstallation of Shrink Disc............................. 15
Rexnord, 3001 W. Canal St., Milwaukee, WI 53208-4200 158-310

Telephone: 513-455-5030 Fax: 414-937-4359 March 2015
www.rexnord.com Supersedes 05-14
Owners Manual • Shaft Mounted Planetgear™ Speed Reducer
(Page 2 of 20) Type SMP • Size Orion
Section I — Introduction
The following instructions apply to the standard catalog All gearing has been made of a high grade alloy steel
offering of the Orion Shaft-Mount, Planetgear™ Speed and case hardened for maximum life. Three to four points
Reducer mounted in a horizontal position. To assure long of contact, with a minimum of six to eight gear teeth
life and performance of the Planetgear speed reducer, the engaged allow for a smooth transmission of power during
following practices should be followed. normal operation and under extreme spike loads. Self
contained input and output shaft assemblies use a double
row of tapered roller bearings mounted to a steel alloy
1.1 BASIC OPERATION AND DESIGN shaft to provide high overhung and thrust load capacity.
The Planetgear speed reducer is a concentric shaft This feature also keeps all external shaft forces isolated
speed reducer that uses a simple planetary design, which from the gearing. Included in both shaft assemblies are
utilizes a sun gear as the input, a ring gear as the fixed two seals with a grease purgeable cavity between them.
element, and a planetary carrier as the output. Power is This design prevents contamination from entering the
transmitted from the speed reducer input shaft, through a gear reducer under extreme conditions. The input shaft
splined connection to the input gear (sun gear) of the first assembly also has the ability to add a backstop option to
reduction. The input gear drives the planet gears, which eliminate drive counter rotation when the input driver is
in turn drive the planetary carrier assembly. This carrier shut off.
assembly is then connected to the next reduction sun gear
or to the output shaft through a splined connection. Each
carrier represents a single reduction. The speed reducer 1.2 SECTIONAL VIEW AND COMPONENT
output shaft rotates in the same direction as the input shaft, IDENTIFICATION
regardless of the number of reductions. See Figure 1.2 for
a detailed representation.
Figure 1.2 Sectional View of a Planetgear Speed Reducer
158-310 Rexnord, 3001 W. Canal St., Milwaukee, WI 53208-4200

March 2015 Telephone: 513-455-5030 Fax: 414-937-4359
Supersedes 05-14 www.rexnord.com
NAMEPLATE INFORMATION Operation of the speed reducer shall not differ from
the application data warranted on the nameplate. Any
Note location of serial number and model number on
deviations from this data requires the submission of new
nameplate. When contacting the factory, have the serial
application information, along with all nameplate data to
number available, as this unique number fully describes
the factory or service center for approval. All data changes
the reducer and allows for the most efficient and accurate
require a revised nameplate.
exchange of information. Reference Figure 1.3 for
nameplate illustration.
REXNORD INDUSTRIES, LLC

Planetgear SMP
TM
Speed Reducers WWW.REXNORD.COM

REDUCER ONLY MOTORIZED REDUCER
MODEL NO.
MOTOR HP DATE
MAX. TORQUE OUT LB. IN.
SERIAL NO.
SERVICE HP SERVICE CLASS OIL CAP. APPROX. U.S. GAL.
CUST. PO. ORION TITAN THRU HERCULES
SERVICE FACTOR AMBIENT TEMPERATURES AMBIENT TEMPERATURES
SIZE 15°F TO 60°F 50°F TO 125°F 15°F TO 60°F 50°F TO 125°F
OUTPUT RPM OUTPUT RPM
(-9°C TO 16°C) (10°C TO 52°C) (-9°C TO 16°C) (10°C TO 52°C)
RPM IN ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA
BELOW 10 150 EP 4 EP 320 EP 6 EP BELOW 10 220 5 320 6
10 AND ABOVE 150 EP 4 EP 220 EP 5 EP 10 AND ABOVE 100 3 150 4
RATIO IMPORTANT:
FILL TO THE LEVEL INDICATED WITH A PREMIUM QUALITY INDUSTRIAL TYPE PETROLEUM BASED GEAR LUBRICANT CONTAINING
RPM OUT OXIDATION, RUST AND FOAM INHIBITORS. ORION SMP UNITS REQUIRE EXTREME PRESSURE LUBRICANT
(SULFUR- PHOSPHORUS TYPE). FOR DETAILED LUBRICATION INSTRUCTIONS, SEE LUBRICATION BULLETIN.
UNDER NORMAL CONDITIONS, THE LUBRICANT SHOULD BE CHANGED EVERY 2500 HOURS OR EVERY SIX MONTHS
P/N 1886026801 WHICHEVER COMES FIRST.
Figure 1.3 Reducer Nameplate

Section II — Installation
WELDING — Do not weld on the gear drive or accessories 2.2 REDUCER MOUNTING
without prior approval from the Factory. Welding on the
drive may cause distortion of the housing or damage to the Orion
bearings and gear teeth. Welding without prior approval
could void the warranty. Prior to installing the drive, verify the driven shaft for proper
dimensions. Dimensions are found in Table 6, Page 15.
EFFECTS OF SOLAR ENERGY — Special measures Verify that dimension SA1 is within the allowable range.
should be taken to protect drives operating in direct sunlight When dimensions are verified, proceed with the installation.
at ambient temperatures over 100°F (38°C). This protection
can consist of a canopy over the drive or reflective paint on 1. Insert torque arm mounting pins in torque arm on
the drive. If neither is possible, a heat exchanger or other speed reducer; reference Figure 2.2a.
cooling device may be required to prevent the reducer
sump temperature from exceeding the allowable maximum GEAR DRIVE TORQUE ARM
WITH BUSHING (OPTIONAL)
oil temperature of 200°F (93°C).
2.1 HANDLING OF SPEED REDUCER

Remove top motor mount plate. Using lifting chains of
ample strength, hook through the lifting holes located on
the input side top motor mount bracket, and through the
lifting holes located on the torque arm, reference Figure
2.1a. For speed reducer component weights, reference
Table 1 (Page 18). In order to prevent shifting during
TORQUE ARM
suspension, make sure the speed reducer is properly MOUNTING PIN
secured and balanced. (CUSTOMER SUPPLIED)
WARNING: To avoid personal injury or product damage,

never attempt to lift the speed reducer using any method
other than the one stated above in Section 2.1 “Handling Figure 2.2a Insertion of Torque Arm Pins in Torque Arm
of Speed Reducer”.
2. Installation Of Shrink Disc:
INPUT SIDE Important: Never tighten locking screws before shaft is
TOP MOTOR inside the hub, otherwise plastic deformation of the hub
LIFTING HOLE MOUNT BRACKET LIFTING HOLE projection may occur.
a. Remove shipping spacers and screws, if used,
TORQUE ARM
provided for protection during transportation.
b. Check if supplied locking screw threads, screw
head bearing area and the tapers of the inner
rings are lubricated. If not, lubricate them with a
molybdenum disulfide grease such as Molykote Gn
Paste.
c. Slide Shrink Disc over the output shaft. The outer
surface of the output shaft can be greased. NOTE:
The output shaft bore and the shaft that the speed
Figure 2.1a Speed Reducer Handling reducer will be mounted to SHOULD NOT be
greased. Reference Figure 2.2b.
SD1 RAD.
SC1 SB1
SHRINK DISC
GEAR DRIVE
OUTPUT SHAFT
OUTPUT SHAFT BORE
45°
SHAFT
SA1
Figure 2.1b Driven Shaft Detail
DO NOT GREASE SHAFT AND

OUTPUT SHAFT BORE
Figure 2.2b Placement of Shrink Disc onto Output Shaft

d. Degrease output shaft bore and shaft seat. Lift 2. Attach the third nut loosely onto each cap screw to hold
speed reducer; reference Section 2.1. Align output the mounting plate/caps crew assembly onto mounting
shaft/shrink disc with the driven shaft. brackets; reference Figure2.3.1b.
e. Insert shaft or slide output shaft over the shaft until MOUNTING PLATE
fully seated. STAMPED PART No.
f. Take any three or four locking screws equally

spaced and snug them up to establish a parallel or
perpendicular position of Shrink Disc collars relative MOTOR MOUNT
BRACKET
to output shaft shoulder. This will properly seat the FIRST NUT
collars on the taper of the inner ring and avoid SECOND NUT
cocking of the collars.
THIRD NUT
g. Using a torque wrench, tighten all locking screws
gradually and all the way around in either clockwise
or counterclockwise sequence (not in diametrically
INPUT SHAFT
opposite sequence).
h. Tighten locking screws to 185 ft-lb of torque.
3. Align mounting holes of mounting pins to the mounting
holes of the torque arm bracket.
4. Tighten the bolts with washers, shimming if necessary.
Reference Table 2 (Page 18) for recommended bolt
torques. Reference Figure 2.2c.
TORQUE ARM REDUCER

BRACKET Figure 2.3.1b
BOLTS/WASHERS
2.3.2 SPROCKETS OR SHEAVES

Prior to installing sprockets or sheaves, review the
manufacturer’s requirements for chain or belt tension and
TORQUE ARM
MOUNTING PIN
required alignment. When mounting the sprocket or sheave
to the shaft, locate it as close as possible to the speed
reducer. This will minimize the overhung load and prolong
SPEED REDUCER bearing life.
Figure 2.2c Mounting of torque Arm Pins to Torque Arm Bracket When using a Planetgear motor mount accessory, the
belt tension can be changed by varying the height of the
2.3 MOTOR MOUNTING motor mount plate. This can be done by adjusting the four
WARNING: When the Rexnord Planetgear speed reducer threaded support bolts. Reference Figure 2.3.2.
is connected to a motor or driven equipment through NOTE: Mount sheaves and belts as close to the speed
the use of couplings, sprockets, gears, or belt drives, all reducer as possible to avoid undue overhung loading on
rotating parts must be properly guarded with guarding that the bearings.
conforms to OSHA requirements to prevent personal injury
or property damage.
MOTOR
2.3.1 INSTALLING TOP MOTOR MOUNT PLATE
1. Place top motor mounting plate/cap screw assembly
onto the mounting brackets so that the part number THREADED
on the plate is towards the output end of the speed SUPPORT
BOLTS
reducer; reference Figure 2.3.1a.
MOUNTING
PLATE
GUARD
FIRST NUT
SECOND NUT TAPERED REDUCER

SOCKET HEAD
CAP SCREW Figure 2.3.2 Planetgear Top Motor Mount
Figure 2.3.1a

2.3.3 INSTALLING MOTOR C-FACE COUPLING
1. Loosely attach motor to mounting holes drilled in the top SETSCREWS

motor mounting plate using Grade 5 or equivalent bolts. REDUCER
INPUT GEAR
2. Check sheave alignment:
Sheave alignment should be checked by placing a
straight edge or tight cord across the sheave faces so
that it touches all four points of contact as illustrated in
Figure 2.3.3. Ordinarily, a misalignment of more than
one-half of one degree (one-eighth inch in one foot) will
adversely affect belt life. Improper sheave alignment DOUBLE
LIPPED
produces uneven wear on one side of the belt, causes SEAL
the belt to roll over in the sheave or throws all the load
0.500/0.625
on one side of the belt, stretching or breaking the cords HOLD DIMENSION WHEN
on that side. MOUNTING INPUT COUPING
TO MOTOR SHAFT
3. Tighten motor bolts. Reference Table 2 (Page 18) for
recommended bolt torques. Figure 2.3.4a
CONTACT POINTS 3. Tighten the coupling setscrews; one located over the key
and the other located at 90° (degrees). After tightening
the setscrews, the gap between the motor face and the
coupling should be measured again to insure that the
tolerance has been maintained. If the tolerance is not
within the specification, loosen the setscrews and repeat
steps 2 and 3.
SQUARE AND 4. Mount the motor with coupling to the reducer. Align the
PARALLEL internal spline end of the coupling with the external
spline end of the reducer input gear.
Figure 2.3.3 Alignment CAUTION: Be careful not to roll the seal when installing
or removing the coupling and motor. This could result in oil
2.3.4 C-FACE MOTOR INSTALLATION leakage during operation.
1. Mount the reducer C-face coupling onto the motor 5. Align the mounting holes of the motor with the mounting
shaft with the appropriate size key. The motor shaft holes of the reducer and fasten, reference Table 2,
to coupling fit should be snug and may require light Page 18, for recommended bolt torques.
tapping (NOTE: Warming up the coupling and applying
an Anti-seize compound to the motor shaft is helpful).
NOTE: A loose fit coupling should be avoided and a
heavy fit could damage motor bearings if the coupling
is pressed onto the motor shaft with extreme force.
CAUTION: Never turn down the motor shaft diameter
to allow for easy coupling installation, as this will cause
coupling movement and wear during operation.
2. For quintuple reductions locate the C-face coupling
0.500 to 0.625 inches from the motor face (Hint:
Standard 1/2” to 5/8” keystock is helpful for this
purpose). Refer to the illustration in Figure 2.3.4a.

Section III — Lubrication
INTRODUCTION VISCOSITY (IMPORTANT)

Carefully follow instructions on the drive nameplate, The proper viscosity grade for petroleum-based lubricants
warning tags and installation manuals furnished with the is found in Table 3. For synthetic lubricant viscosity
drive. Failure to follow instructions will void warranty. grades, refer to Table 4 and the “Synthetic Lubricants”
Lubricants listed in this manual are typical products paragraphs.
ONLY and should not be construed as exclusive Viscosity grade is determined by ambient air temperature
recommendations. Industrial type extreme pressure (EP) in the immediate vicinity of the gear drive. Lubricant
or industrial type micropitting resistant gear lubricants are selections must have a pour point at least 10°F
the required gear lubricants. They can be formulated using (5.5°C) below the expected minimum ambient starting
petroleum or synthetic base stocks. temperature.
Summary of allowable lubricant types by unit size can be
found in Table 1.
LUBRICANT TYPES
The section on food grade lubricants provides guidance
in selecting lubricants for applications needing this class PETROLEUM-BASED LUBRICANTS (TABLES 5A &
of lubricants. Food grade lubricants are formulated using 5B) — Industrial type petroleum-based extreme pressure
petroleum or different types of synthetic base stocks. (EP) lubricants are the most common and readily available
general purpose gear lubricants.
WARNING: Failure to use extreme pressure or micropitting
resistant type lubricants in Planetgear Orion SMP size units SYNTHETIC-BASED LUBRICANTS (TABLES 6A & 6B) —
will void warranty. Synthetic lubricants of the polyalphaolefin (PAO) type are
recommended for cold climate operation, high temperature
Table 1 — S
ummary of Allowable applications, extended temperature range (all season)
Lubricant Types for Planetgear operation and/or extended lubricant change intervals. The
SMP units s proper viscosity grade of lubricants is given in Table 4.
Usable temperature ranges can sometimes be widened if
Unit Size Allowable Lubricant Types specific application conditions are known.
Orion Extreme Pressure, Micropitting Resistant WARNING: Polyalkylene glycol (PAG) based synthetic
Titan Rust & Oxidation Inhibited, Extreme Pressure, lubricants cannot be used in Planetgear units.
Micropitting Resistant
EXTREME PRESSURE (EP) LUBRICANTS (TABLES 5A
Jupiter Rust & Oxidation Inhibited, Extreme Pressure, & 6A) — EP lubricants are manufactured from petroleum or
Micropitting Resistant synthetic base lubricants. Anti-scuff is another term used
Gemini Rust & Oxidation Inhibited, Extreme Pressure, to describe EP lubricants.
Micropitting Resistant MICROPITTING RESISTANT LUBRICANTS (TABLES
Hercules Rust & Oxidation Inhibited, Extreme Pressure, 5B & 6B) — Micropitting resistant lubricants are specially
Micropitting Resistant developed for surface hardened gearing commonly used
s Follow recommendations found in the Lubrication Section of this manual in modern industrial gear drives. These lubricants contain
additives to resist formation of micropitting and other
conventional forms of gear wear. Generally these lubricants
LUBRICANT SELECTION PROCESS are available in limited number of viscosity grades.
1. Refer to Tables 3 and 4 for proper lubricant viscosity WARNING: LUBRICANTS IN FOOD PROCESSING
grade based on ambient temperature range. INDUSTRY — Generally, conventional gear lubricants are
2. Refer to Table 2 for summary of lubricant types. classified as H2 by NSF (National Sanitation Foundation)
3. Using proper lubricant table and viscosity grade, since they contain harmful substances and should not
select desired lubricant manufacturer and name. be used in the food processing industry. Lubricants
registered as H1 by NSF are suitable for food processing
4. Refer to nameplate for approximate oil capacity to applications.
purchase.
CLIMATE CONDITIONS — Ambient temperature in
immediate vicinity of gear drive is very important for
Table 2 — S
ummary of Lubricant Type determining viscosity grade. Table 3 provides viscosity
and Greases grade selections for petroleum-based lubricants. See
Petroleum-Based Table 4 for synthetic lubricants.
Extreme Pressure (EP) Micropitting Resistant
See Table 5A See Table 5B
Synthetic Lubricant, Polyalphaolefin Type (PAO)
OIL LEVELS
From the nameplate determine the quantity of oil
Extreme Pressure (EP) Micropitting Resistant
See Table 6A See Table 6B needed. Fill reducer to the oil fill plug as described in the
Maintenance section (Section V) of this manual.
Conventional Grease
See Table 7 NOTE: Quantities are approximate. Always fill drive to the
specified level.
Food Grade Lubricant & Grease
See Page 11

absence of more specific limits, the guidelines listed below

TABLE 3 — V
iscosity Grade may be used to indicate when to change petroleum or
Recommendation For polyalphaolefin type synthetic lubricants:
Petroleum-Based Lubricants
1. Water content is greater than 500 ppm (parts per
AMBIENT TEMPERATURES million) (0.05%).
Output +15° to +60°F +50° to +125°F 2. Iron content exceeds 150 ppm.
Speed (-10° to +15°C) (+10° to +50°C)
3. Silicon (dust/dirt) exceeds 25 ppm, above reference
ISO-VG AGMA ISO-VG AGMA sample from new oil container.
RPM 4. Copper content exceeds 75 ppm.
Below 10 150 4 320 6
5. TAN (Total Acid Number) 50% increase above
10 RPM reference sample from new oil container.
And Above 150 4 220 5
6. Viscosity changes more than ±15%.
7. Solid particle contamination code exceeds 25/22/18
for particle sizes ≥4/≥6/≥14 microns, respectively per
LUBRICANT ANALYSIS AND CHANGES ISO 4406.
OIL ANALYSIS REPORT — Checking oil conditions at Laboratory analysis is recommended for optimum lubricant
regular intervals is recommended. Analyze oil samples life and gear drive performance. Oil samples should be
approximately every 1,000 hours for petroleum lubricants taken from the oil level hole, not the drain hole.
or every 3,000 hours for synthetic lubricants. In the
Table 4 — Viscosity Grade Recommendation For Synthethic Lubricants

Cold Climates Normal Climates
Ambient
Temperature -30° to +10°F -15° to +50°F 0° to +80°F +10° to +125°F
Range (-34° to -12°C) (-26° to +10°C) (-18° to +27°C) (-12° to +52°C)
ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA
Below 10 RPM 32 0 68 2 150 4 320 6
10 RPM &
Above 32 0 68 2 150 4 220 5
Table 5A — P
etroleum Based EP (Extreme Pressure) Lubricantss
Maximum Operating Temperature of Lubricants 200°F (93°C)
ISO Viscosity Grade 150 220 320
AGMA Viscosity Grade 4 5 6
Viscosity cSt @ 40°C n 135-165 198-242 288-352
Viscosity SSU @ 100°F 626-765 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name Lubricant Name
Castrol Industrial Lubricants Alpha SP 150 Alpha SP 220 Alpha SP 320
Chevron/Texaco/Caltex Meropa 150 Meropa 220 Meropa 320

Ultra Gear 150 Ultra Gear 220 Ultra Gear 320
Citgo Petroleum Corp. EP Compound 150 EP Compound 220 EP Compound 320
Exxon Mobil / Esso Mobilgear 600 XP 150 Mobilgear 600 XP 220 Mobilgear 600 XP 320
Fuchs Lubricants Company --- GearMaster CLP Oils 220 ---
Kluber Lubrication Kluberoil GEM 1 N 150 --- ---
Petro-Canada Lubricants Enduratex EP 150 Enduratex EP 220 Enduratex EP 320
Phillips 66/Conoco / 76 Lubricants /
Kendall Extra Duty Gear Oil 150 Extra Duty Gear Oil 220 Extra Duty Gear Oil 320
Shell Oil Co. Omala S2 G 150 Omala S2 G 220 Omala S2 G 320

Total Lubricants USA / Keystone Div.
Penwalt Corp. Carter EP 150 Carter EP 220 Carter EP 320
s Minimum viscosity index of 90.

n Kinematic viscosity in units of mm2/s is equivalent to cSt (centistokes).

Table 5B — P
etroleum Based Micropitting Resistant Lubricantss
Viscosity cSt @ 40°Cn 135-165 198-242 288-352
Viscosity SSU @ 100°F 626-765 918-1122 1335-1632
Kluber Lubrication --- Kluberoil GEM 1 N 220 Kluberoil GEM 1 N 320
s Minimum viscosity index of 90.
Table 6A — Synthetic PAO (Polyalphaolephin) EP (Extreme Pressure) Lubricantss

ISO Viscosity Grade 32 68 150 220 320
AGMA Viscosity Grade 0 2 4 5 6
Viscosity cSt @ 40°C n 28.8-35.2 61.2-74.8 135-165 198-242 288-352
Viscosity SSU @ 100°F 134-164 284-347 626-765 918-1122 1335-1632
Manufacturer Lubricant Name Lubricant Name Lubricant Name Lubricant Name Lubricant Name
Castrol Industrial ---
--- Alphasyn EP 150 Alphasyn EP 220 Alphasyn EP 320
Lubricants Castrol Isolube EP 68 Castrol Isolube EP 150 Castrol Isolube EP 220 Castrol Isolube EP 320
Chevron/Texaco/Caltex --- --- Tegra Synthetic Gear Lubricant 150 Tegra Synthetic Gear Lubricant 220 Tegra Synthetic Gear Lubricant 320
Citgo Petroleum Corp. --- CITGEAR Synthetic EP Gear 68 CITGEAR Synthetic EP Gear 150 CITGEAR Synthetic EP Gear 220 CITGEAR Synthetic EP Gear 320
Exxon Mobil/ Esso --- --- Mobil SHC Gear 150 Mobil SHC Gear 220 Mobil SHC Gear 320
Fuchs Lubricants --- --- --- Renolin Unisyn CLP 220 Renolin Unisyn CLP 320
Company
Kluber Lubrication --- --- Klubersynth EG 4 150 Klubersynth EG 4 220 Klubersynth EG 4 320
Petro-Canada Lubricants --- --- Enduratex Synthetic EP 150 Enduratex Synthetic EP 220 Enduratex Synthetic EP 320
Phillips 66/Conoco/76 --- --- Syncon EP Plus Gear Oil 150 Syncon EP Plus Gear Oil 220 Syncon EP Plus Gear Oil 320
Lubricants /Kendall
Shell Oil Co. --- Omala S4 GX 68 Omala S4 GX 150 Omala S4 GX 220 Omala S4 GX 320
Whitmore Manufacturing --- --- Decathlon HD 150 Decathlon HD 220 Decathlon HD 320
Company
s Minimum viscosity index of 130. Consult lubricant supplier/manufacturer for maximum operating temperature.
Table 6B — Synthetic PAO (Polyalphaolephin) Micropitting Resistant Lubricantss

Viscosity cSt @ 40°C n 28.8-35.2 61.2-74.8 135-165 198-242 288-352
Viscosity SSU @ 100°F 134-164 284-347 626-765 918-1122 1335-1632
Chevron/Texaco/Caltex --- --- --- --- Pinnacle WM 320
Exxon Mobil/Esso --- --- --- --- Mobil SHC Gear 320 WT
Kluber Lubrication --- --- Klubersynth GEM 4 N 150 Klubersynth GEM 4 N 220 Klubersynth GEM 4 N 320
Petro-Canada Lubricants --- --- --- --- Harnex 320
Phillips 66/Conoco/76 --- --- --- --- Syncon WTL 320
Lubricants/Kendall
Whitmore Manufacturing --- --- Decathlon F 150 Decathlon F 220 Decathlon F 320
Company
s Minimum viscosity index of 130. Consult lubricant supplier/manufacturer for maximum operating temperature.

PETROLEUM LUBRICANTS — In the absence of oil

analysis, change gear oils every 6 months or 2,500 Table 7 — Conventional Grease s for
operating hours, whichever occurs first. Change oil more Grease Purged Seals
frequently when gear drives operate in extremely humid, 0°F to +200°F (-18°C to +93°C)
chemical or dust laden atmospheres. In these cases, Manufacturer Grease Name
lubricants should be changed every 3 to 4 months or
1,500 to 2,000 hours. If the drive is operated in an area Chevron/Texaco/Caltex Multifak EP 2
where temperatures vary with the seasons, change the Citgo Petroleum Corp. Lithoplex RT 2
oil viscosity grade to suit the temperature, refer to Table Premium Lithium EP 2
3. Generally lubricant suppliers can test oil from the ExxonMobil/Esso Mobilux EP 2
drive periodically and recommend economical change
schedules. Petro-Canada Lubricants Precision General Purpose EP2
SYNTHETIC LUBRICANTS — In the absence of oil Phillips 66/ Conoco/ 76 Lubricants/ Multiplex Red
Kendall
analysis, synthetic lube change intervals can be extended
to 8,000 hours depending upon operating temperatures. Shell Oil Co. Gadus S2 V100 - 2
Laboratory analysis is recommended for optimum lubricant Total Lubricants USA / Keystone Div. Multis 2 or Multis EP 2
life and drive performance. Change lube with change in Penwalt Corp.
ambient temperature, if required. Refer to Table 4. s Not suitable for food grade applications.
Grease application or re-lubrication should be done at temperatures above 20°F
(-7°C). If grease must be applied below 20°F (-7°C) consult lubricant supplier for
GREASE PURGED SEALS recommendations.
All drives are furnished with grease purged seals which

minimize the entry of contaminants and abrasive dusts into
the drive. Drives are shipped with NLGI #2 grade grease in STORED & INACTIVE GEAR DRIVES
the seal housing cavities unless otherwise specified. Refer to Section VII (Storage Procedures) for details on
Whenever changing oil in the drive, purge the seals stored & inactive gear drives.
with one of the NLGI #2 grade greases listed in Table 7.
Depending upon the degree of contamination, periodically
(at least every six months), purge contaminated grease
from seals by slowly pumping fresh bearing grease through
the seal, WITH HAND GREASE GUN, until fresh grease
flows out along the shaft. Wipe off purged grease.
CAUTION: Rapid regreasing with a power grease gun can
force grease inward past the seals and plug the oil drain
back system causing leaks.
WARNING: Greases in Table 7 contain harmful substances
and are not allowed in the food processing industry. If
grease could contaminate the product, as in the food and
drug industries, the grease originally supplied with gear
drive must be removed and replaced with a grease listed
in Table 13. Simply purging grease with a grease gun will
not remove all grease and cross-contamination will likely
occur. Grease registered as H1 by NSF, (National Sanitation
Foundation) is suitable for food processing applications.

FOOD GRADE LUBRICANTS TABLE 9 — Viscosity Grade

Guidance for selecting petroleum-based and synthetic- Recommendation For Food
based food grade lubricants are shown below in Table 8. Grade Petroleum-Based
For general lubrication guidelines, refer to the first part of Lubricants
the “Lubrication Recommendation” section. AMBIENT TEMPERATURES
Output +15° to +60°F +50° to +125°F
FOOD GRADE LUBRICANT SELECTION Speed (-10° to +15°C) (+10° to +50°C)
PROCESS ISO-VG AGMA ISO-VG AGMA
1. Refer to Tables 9 and 10 for proper lubricant viscosity RPM
grade based on ambient temperature range. Below 10 150 4 320 6
2. Refer to Table 8 for summary of lubricant types. 10 RPM
And Above 150 4 220 5
3. Using proper lubricant table and viscosity grade,
select desired lubricant manufacturer and name.
4. Refer to nameplate for approximate oil capacity to
purchase.
LUBRICANT ANALYSIS AND CHANGES
OIL ANALYSIS REPORT (FOOD GRADE) — Checking oil
Table 8 — S
ummary of Food Grade conditions at regular intervals is recommended. Analyze oil
Lubricants and Greases samples approximately every 1,000 hours for food grade
Petroleum-Based
petroleum lubricants or every 3,000 hours for food grade
Extreme Pressure (EP) synthetic lubricants. In the absence of more specific limits,
See Table 11 the guidelines listed below may be used to indicate when
to change petroleum or polyalphaolefin type food grade
Synthetic Lubricant, Polyalphaolefin Type (PAO) lubricants:
Extreme Pressure (EP)
See Table 12 1. Water content is greater than 500 ppm (parts per
million) (0.05%).
Food Grade Grease
See Table 13 2. Iron content exceeds 150 ppm.
3. Silicon (dust/dirt) exceeds 25 ppm, above reference
sample from new oil container.
FOOD GRADE LUBRICANTS (TABLES 11, 12, & 13) —
Food grade lubricants are a class of lubricants registered 4. Copper content exceeds 75 ppm.
as H1 by NSF (National Sanitation Foundation). They 5. TAN (Total Acid Number) 50% increase above
contain base stock and additives which comply with Food reference sample from new oil container.
and Drug Administration Title 21 CFR 178.3570 regulations 6. Viscosity changes more than ±15%.
for lubricants with incidental food contact. Base stock can
be petroleum oil or different types of synthetic lubricant. 7. Solid particle contamination code exceeds 25/22/18
for particle sizes ≥4/≥6/≥14 microns, respectively per
Food grade lubricants are not the same as biodegradable ISO 4406.
or environmentally friendly lubricants.
Laboratory analysis is recommended for optimum lubricant
Rust and corrosion inhibitors used to protect gear life and gear drive performance. Oil samples should be
drives during shipment are not qualified as food grade taken from the oil level hole, not the drain hole.
fluids. Flush out inhibitor oil before filling with food grade
lubricant. PETROLEUM LUBRICANTS (FOOD GRADE) — In the
absence of oil analysis, change gear oils every 6 months
Tables 11, 12, and 13 list food grade lubricants that have or 2,500 operating hours, whichever occurs first. Change
performance properties meeting Rexnord specifications. oil more frequently when gear drives operate in extremely
They are not exclusive recommendations but serve as a humid, chemical, or dust laden atmospheres. In these
guide for making proper lubricant selections. cases, lubricants should be changed every 3 to 4 months
CLIMATE CONDITIONS — Ambient temperature in or 1,500 to 2,000 hours. If the drive is operated in an area
immediate vicinity of gear drive is very important for where temperatures vary with the seasons, change the oil
determining viscosity grade. Table 9 provides viscosity viscosity grade to suit the temperature, refer to Table 9.
grade selections for petroleum-based lubricants. See Lubricant suppliers can test oil from the drive periodically
Table 10 for synthetic lubricants. and recommend economical change schedules.
Table 10 — V
iscosity Grade Recommendation For Food Grade Synthethic Lubricants
Cold Climates Normal Climates
Ambient
Temperature -30° to +10°F -15° to +50°F 0° to +80°F +10° to +125°F
Range (-34° to -12°C) (-26° to +10°C) (-18° to +27°C) (-12° to +52°C)
ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA ISO-VG AGMA
Below 10 RPM 32 0 68 2 150 4 320 6
10 RPM &
Above 32 0 68 2 150 4 220 5

Table 11 — F
ood Grade Petroleum-Based EP (Extreme Pressure) Type Lubricants —
NSF (National Sanitation Foundation) H1 Registered
Viscosity cSt @ 40°C n 135-165 198-242 288-352
Viscosity SSU @ 100°F 626-765 918-1122 1335-1632
Petro-Canada Purity FG EP 150 Purity FG EP 220 Purity FG EP 320
Total Lubricants USA, Inc. Nevastane EP 150 Nevastane EP 220 Nevastane EP 320
Table 12 — F
ood Grade Synthetic EP (Extreme Pressure) PAO (Polyalphaolefin) Type
Lubricants — NSF (National Sanitation Foundation) H1 Registered
Viscosity cSt @ 40°Cn 28.8-35.2 61.2-74.8 135-165 198-242 288-352
Viscosity SSU @ 100°F 134-164 284-347 626-765 918-1122 1335-1632
Petro-Canada --- --- --- Purity FG Synthetic EP 220 ---
n Kinematic viscosity in units of mm /s is equivalent to cSt (centistokes).
2
SYNTHETIC LUBRICANTS (FOOD GRADE) — In Table 13 — Food Grade Grease for

the absence of oil analysis, synthetic lube change Grease Purged Seals
intervals can be extended to 8,000 hours depending NSF (National Sanitation
upon operating temperatures. Laboratory analysis is Foundation) H1 Registered
recommended for optimum lubricant life and drive
0° to +200°F (-18° to +93°C)
performance. Change lube with change in ambient
temperature, if required. Refer to Table 10. Manufacturer Grease Name
Bel-Ray Company, Inc. No-Tox HD Grease 2
GREASE PURGED SEALS Chevron USA, Inc.
(Texaco/Caltex) Chevron FM ALC EP 2
All drives are furnished with grease purged seals which
minimize the entry of contaminants and abrasive dusts into Exxon Mobil Mobil SHC Polyrex 462
the drive. Drives are shipped with NLGI #2 grade grease in
Kluber Lubrication Klubersynth UH1 14-222
the seal housing cavities unless otherwise specified.
Whenever changing oil in the drive, purge the seals with Lubriplate Lubriplate FGL-2
one of the NLGI #2 grade greases listed in Table 13. Total Lubricants USA, Inc. Nevastane HT/AW 2
Depending upon the degree of contamination, periodically Petro-Canada Purity FG
(at least every six months), purge the contaminated
grease from seals by slowly pumping fresh bearing grease Phillips 66/Conoco/76
Lubricants/Kendall Food Machinery Grease 2
through the seal, WITH HAND GREASE GUN, until fresh
grease flows out along the shaft. Wipe off purged grease. Grease application or re-lubrication should be done at temperatures above 20°F
(-7°C). If grease must be applied below 20°F (-7°C) consult lubricant supplier for
CAUTION: Rapid regreasing with a power grease gun can recommendations.
force grease inward past the seals and plug the oil drain
back system causing leaks. STORED & INACTIVE GEAR DRIVES
Greases in Table 7 contain harmful substances not
See Storage Procedures (Section VII).
allowed in the food processing industry. If grease
could contaminate the product, as in the food and drug WARNING: Rust preventative oil or vapor-phase inhibitors
industries, the grease originally supplied with gear drive are not H1 registered with the NSF (National Sanitation
must be removed and replaced with grease listed in Table Foundation) as suitable for food processing applications.
13. Simply purging grease with grease gun will not remove When Food Grade Lubricants are to be used, it is the end
all grease and cross-contamination will likely occur. Grease users responsibility to properly flush and prepare the drive
registered as H1 by NSF, (National Sanitation Foundation) for Food Grade service. Contact the lubricant manufacturer
is suitable for food processing applications. for specific information and flushing procedures.

Section IV — Start-Up
WARNING: Never operate the speed reducer at speeds 4.2.1 PRIME MOVER
and/or loads that exceed the limits specified on the
nameplate. Exceeding these limits may result in personal The prime mover should be set up to maximize the amount
injury or machinery damage. Check to insure that all of time necessary to get to the rated speed. This will avoid
rotating equipment is properly guarded according to any instantaneous gear loads that could exceed the rating
OSHA standards. of the speed reducer or other components.
CAUTION: All speed reducers are shipped without oil
but may have been treated with a rust preventative oil. A 4.2.2 SPEED REDUCER ROTATION
vapor phase inhibitor may also be added. Be sure to fill the
speed reducer to the proper level prior to start-up. The input and output shafts of the speed reducer will
rotate in the same direction.
WARNING: These corrosion inhibitors are not H1
registered with the NSF (National Sanitation Foundation)
as suitable for food processing applications. When Food 4.2.3 START-UP
Grade Lubricants are to be used it is the end users
responsibility to properly flush and prepare the drive for Start the speed reducer under as light a load as possible.
Food Grade service. Contact the lubricant manufacturer for As the speed reducer is brought up to normal operating
specific information and flushing procedures. speed, check for unusual noises, excessive vibration,
or excessive heat and oil leakage. If any of these
CAUTION: When starting up new equipment, proceed conditions exist, shut down the speed reducer immediately
cautiously. and determine the cause of the problem. Refer to
Troubleshooting (Section 8.0) for assistance.
4.1 PRE-START-UP CHECKLIST
1. Has the speed reducer been filled with the proper oil 4.3 POST START-UP CHECKLIST
type and to the correct oil level? 1. After approximately forty hours of use, check all
2. Are all mounting bolts high strength (Grade 5) and mounting bolts and tighten as required. Note: Always
tightened according to torque specifications in Table 2 recheck alignment after tightening.
(Page 18)? 2. The oil used in the initial start-up of a new speed
3. Are speed reducer input shaft and motor shaft sheaves reducer should be completely drained and replaced
correctly mounted with full engagement and keys in after 500 hours of use. A thorough cleaning of the
place? gear case using a flushing oil should be performed to
4. Are belts at correct tension? remove any foreign matter during the first oil change.
5. Are sheave connections properly aligned and fastened? 3. Check tension if using belts during the first 24-48 hours
of run-in operation.
6. Have all pipe plugs (oil fill, oil level, and oil drain) been
inserted and properly tightened?
7. Have all electrical connections been made?
8. Does the motor shaft rotate in the proper direction?
9. Are all guards in place and properly secured?
4.2 INITIAL START-UP

It is recommended that all Planetgear speed reducers
be run-in for a period of time before introduction to full
service. This will allow the gearing to mate properly prior to
being exposed to any high load conditions. The following
procedure is recommended for initial start-up.

Section V — Maintenance
WARNING: DO NOT PERFORM ANY MAINTENANCE 5.2 DRAINING OIL FROM SPEED
PROCEDURES WHILE SPEED REDUCER IS IN REDUCER
OPERATION. DOING SO MAY RESULT IN PERSONAL
INJURY OR PROPERTY DAMAGE. TO INSURE SAFETY CAUTION: Care should be taken when removing the
DURING MAINTENANCE, ACTIVATE ALL ELECTRICAL vent plug. If vent has been clogged, the possibility of
AND/OR MECHANICAL LOCKOUTS. pressurized air inside the Speed Reducer may exist. Once
threads are free to hand rotate, place a heavy cloth over
the vent plug and rotate counterclockwise until removed.
5.1 FILLING SPEED REDUCER WITH OIL CAUTION: Oil may be hot. Do not drain until oil is at
ambient or a safe temperature.
1. Chose correct oil type; reference Section 3.0.
2. Determine correct oil quantity; reference Nameplate. 1. Clean external surfaces to avoid contaminants from
entering speed reducer when plugs are removed.
3. Remove oil fill plug (vent plug) and one of the two oil
level plugs; reference Figure 5.1. 2. Remove oil fill plug (vent plug) for ventilation; reference
Figure 5.1.
4. Fill speed reducer at oil fill port.
3. With the proper size oil drain pan (reference oil quantity
5. Speed Reducer oil capacity is reached when oil starts on nameplate) in place, remove one of the drain plugs.
to pour out of the bottom of the level port. Allow several
minutes for oil to settle, then recheck oil level. Add oil if 4. After oil is removed, replace oil drain plug, sealing it in
necessary. the process using thread sealant.
5. Reference Section 5.1 for filling speed reducer with oil.
NOTE: Oil should be checked or added when speed
reducer is at ambient temperature 5.3 ADDING GREASE TO SPEED REDUCE
CAUTION: Underfilling speed reducer may cause product SEALS
damage. Overfilling speed reducer may cause excessive
1. Clean grease inserts, reference Figure 5.1 for location.
oil temperatures.
2. Refer to the Lubrication section to determine the correct
6. Replace oil level plug, sealing it in the process using grease for the application. Attach grease gun to grease
thread sealant. insert and pump grease into seal carrier.
7. Replace oil fill plug (vent plug). 3. Stop greasing when a sufficient amount of grease
8. Start up speed reducer under a no load condition. Run purges out of seal carrier next to shaft.
speed reducer for a few minutes. 4. Clean purged grease from speed reducer.
9. Stop speed reducer and recheck oil at the oil level port.
If necessary, add oil.
OIL FILL/VENT
VENT PLUG GREASE INSERT
FOR OUTPUT SEALS
TYP. (4)
GREASE INSERT
FOR INPUT SEALS
OIL LEVEL/
SIGHT PLUG
TYP. (2)
OIL DRAIN PORT
Figure 5.1

Section VI — Disassembly and Assembly Instructions
For assembly drawings for the Orion Shaft-Mount speed SPEED REDUCER REMOVAL
reducer, please see the assembly drawings included in A. Loosen all shrink disc tightening bolts uniformly, one
the documentation that accompanies the speed reducer. by one in a continuous sequence, about a quarter
This is a guide for disassembly, parts replacement, and turn per round.
reassembly. Note: If only replacing seals, they are housed B. Shrink disc should be able to move after bolts have
in the seal carriers which can be removed from the speed been loosened.
reducer. To expedite service, when ordering parts or
requesting information, supply the following information: C. Utilize ‘hydraulic advantage’ by accessing ports
model number, speed reducer size, ratio, serial number, (1/8-27 NPT) located on hollow shaft face, and on
HP, motor RPM, and the build date from the speed reducer outer diameter of hollow shaft (Figure 5.2)
nameplate. No ratio change should be made without first Important: Do Not use any force on drive housing to
consulting a Planetgear representative. All bearings and remove unit
seals used on standard Planetgear speed reducers are
listed in Table 3 and Table 4 (Page15).
GREASE OR HYDRAULIC FLUID
(ENERPAC OR SIMILAR PUMP)
REQUIRED EQUIPMENT
Standard mechanic’s tools: arbor press or hydraulic press, SHRINK DISC
torque wrench, dial indicator with magnetic base, and
CARRIER/SHAFT
hoist. SUB ASSEMBLY
CUSTOMER-SUPPLIED
CAUTION: Always take the necessary safety precautions FITTING
when working with an arbor press, hydraulic press or with
any hand tools.
WARNING: DO NOT PERFORM ANY MAINTENANCE
PROCEDURES WHILE REDUCER IS IN OPERATION.
DOING SO MAY RESULT IN PERSONAL INJURY OR CUSTOMER’S
PROPERTY DAMAGE. TO INSURE SAFETY DURING SHAFT
MAINTENANCE, ACTIVATE ALL ELECTRICAL AND/OR
MECHANICAL LOCKOUTS.
REMOVAL OF SHRINK DISC:

A. Gradually release locking screws all the way around. HYDRAULIC
Initially each screw should be released about a CYLINDER EFFECT
quarter of a turn only. Thus tilting and jamming of
the collar will be avoided. DO NOT remove screws
completely at this time otherwise collar may spring
off. Figure 5.2
B. Any rust formed adjacent to hub must be removed
first. Once the screws are loose, remove shaft or
pull output shaft from hollow bore.
REINSTALLATION OF SHRINK DISC:
Upon removal of component, disassemble Shrink Disc.
Clean and inspect all parts. Reinstall following the
installation procedure beginning with Step “b” of the
appropriate section.

Section VII — Storage Procedures
7.1 SPARE PARTS STORAGE 7.3 LONG TERM STORAGE

1. On receipt of spare parts, unpack and spray or dip the Speed Reducer can be ordered from the factory for long
parts in a rust preventative such as Mobilarma 524, or term storage. Field preparation for long-term storage is
equivalent. described in Section 7.2-1.
2. Place parts on a wood pallet in a dry place. Cover WARNING: The rust preventative oil from the factory
loosely with plastic, DO NOT wrap or store parts in and Nox-Rust VCI-10* are not H1 registered with the
news print as it is corrosive. NSF (National Sanitation Foundation) as suitable for food
3. Re-spray parts every six months. Spray parts every processing applications. When Food Grade Lubricants are
three months if high humidity exists. to be used, it is the end users responsibility to properly
flush and prepare the drive for Food Grade service.
4. If rust develops, remove rust with a medium grit emery Contact the lubricant manufacturer for specific information
cloth and re-spray with rust preventative. and flushing procedures.
5. When ready to install parts, make sure all parts rotate
freely. Clean all grime from the parts before installation. *Product of the Daubert Chemical Company, Chicago, Illinois.
7.2 STORED AND INACTIVE SPEED

REDUCERS
1. Preparation For Storage
A. If a speed reducer is to be stored or is inactive after
installation, fill the speed reducer with the correct
type and amount of lubricant. For drives that have
oil installed, add Nox-Rust VCI-10* vaper-phase
rust inhibitor at the rate of 2% of sump capacity. For
drives without oil, add Nox-Rust VCI-10 vapor-phase
rust inhibitor at the rate of one ounce per cubic foot
of internal drive space. Seal the speed reducer
completely; replace the vent plug with a solid pipe
plug to keep rust inhibiting atmosphere sealed in-
side.
B. After approximately three months, rotate the
input shaft such that the output shaft rotates a full
360°(degrees). This will insure that all internal parts
will remain coated and will also keep the bearings
from becoming lacquered. Noncompliance with this
procedure may cause bearing damage during start-
up.
C. Every six months inspect the stored or inactive
speed reducer and add rust inhibitor if necessary.
Dry, indoor storage is recommended.
WARNING: Nox-Rust VCI-10* is not H1 registered with the
NSF(National Sanitation Foundation) as suitable for food
processing applications. When Food Grade Lubricants are
to be used, it is the end users responsibility to properly
flush and prepare the drive for Food Grade service.
Contact the lubricant manufacturer for specific information
and flushing procedures.
2. Preparation For Start-up
Rotate shafts until the bearings move freely. This is to
assure that the bearings have not become lacquered.
Speed reducer may be operated without draining the
lubricant described in Section 7.2-A.

Section VIII — Troubleshooting

This troubleshooting guide addresses questions that may be encountered in regards to Planetgear speed reducers.
Excessive Temperature (More Than 200°F (93°C))

Possible Causes: Possible Solutions:
zz Compare actual reducer load with rated load on the nameplate. If the HP or torque is greater, or the speed
Overload is slower than stated on the nameplate, the reducer is probably overloaded. Contact a Rexnord Planetgear
Representative; may require a speed change or a larger unit.
zz Inspect bearings for excessive wear or discoloration due to heat. If either is present, replace the bearings.
Tight or Defective Bearings Refer to Section 6.0 for replacing bearings.
zz Provide ventilation for the reducer.

Excessive Ambient Temperature zz Paint white if reducer is in direct sun light.
zz If conditions are extreme, contact a Rexnord Planetgear Representative for assistance.
zz Make sure lubricant is correct for reducer. A mistake frequently made is to use automotive oil. This is incorrect
and will frequently cause the reducer to overheat.
Improper Oil, Oil Level, Old, or zz Check the oil level in the reducer. Too much as well as too little oil can cause the reducer to overheat.
Contaminated Oil zz Check to see that oil has not lost its lubricating property. If oil viscosity is too low, this will result in high oil
temperatures.
Plugged Shroud zz Make sure area immediately in front of fan shroud is clear.
zz Reduce input speed to reduce oil temperature. If reducer input speed is above the stated value on the
Overspeed nameplate, this would raise oil temperature due to increase in internal windage.
zz Remove and clean vent plug.

Restricted Vent Plug zz Replace vent plug.
Bearing Damage
Improper Adjustment zz Adjust bearing to proper axial bearing clearance as instructed in Section 6.0.
Lack Of Lubrication, Improper zz Replace damaged bearings as instructed in Section 6.0. Note: Check hub and shaft for potential damage or
Lubrication, Old, or Contaminated Oil heat distress.
zz Reduce overhung load. Move the sprocket or sheave closer to the bearings or increase the diameter of both
Excessive Overhung Load the driven and the driver.
Bearing Noise
Defective Bearing zz Inspect and replace bearings if necessary. Reference Section 6.0.
Improper Bearing Adjustment zz Adjust bearing endplay. Reference Section 6.0.
Wrong or Insufficient zz Make sure that enough oil of the correct grade is used. Reference Section 3.0.
Lubrication

Leakage
Damaged or Worn Seals zz Replace seals. Reference Section 6.0.
Bearings Out of Adjustment zz Reset bearings. Reference Section 6.0.
Excessive Temperature, zz Isolate reducer from source of extreme temperature.
Causing Brittle Seals zz Install high temperature seals.
Abrasive or Corrosive zz Isolate reducer seal area from environment.
Atmosphere zz Re-grease frequently.
zz Remove and clean vent plug.
Restricted Vent Plug zz Replace vent plug.
zz Make sure fasteners are torqued correctly. Reference Table 2.
Split-Line Leakage zz Remove suspect hub. Visually inspect mating surfaces for rises or dings. File smooth (do not allow file
shavings to enter gearing or bearings) apply gasket eliminator and replace hub.
Damage Of Fasteners
Failure of Fasteners zz For highly vibratory environments, loctite fasteners and torque, or use studs and double nut.
Fastener Loosening zz Make sure the correct grade of fasteners is used. All reducer fasteners should be Grade 5 or equivalent.
zz Check length of fastener.

Section IX — Tables
TABLE 1 — Orion Shaft-Mount Speed

Reducer — Average Weights
(lb)
Reducer †
Reducer Only with Top Motor Mount
1092 1182
†† Does not include motor weight.
TABLE 2 — Torque Requirements H

For Dry Fasteners (Inch)
SAE Diameter 1/4 5/16 3/8 7/16 1/2 1/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2
General
Purpose Torque (ft lb) 6 12 21 34 52 75 104 178 184 265 380 530 700 930
Grade 2
High Strength Torque (ft lb) 9 18 33 53 80 116 160 285 460 690 850 1200 1570 2080
Grade 5
Allow Steel Torque (ft lb) 13 26 47 74 114 164 225 400 650 970 1370 1940 2540 3370
Grade 8
For Dry Fasteners (Metric)
Grade Nominal
Diameter M5 M6 M7 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30
Standard Pitch
808 Torque (Nm) 6.15 10.5 17.5 26 51 89 141 215 295 420 570 725 1070 1450
10.9 Torque (Nm) 8.65 15 25 36 72 125 198 305 420 590 800 1020 1510 2050
12.9 Torque (Nm) 10.4 18 29 43 87 150 240 365 500 710 960 1220 1810 2450
H The torques shown produce a clamp load of 80% of proof load. They assume clean, dry threads with a torque coefficient of 0.2, and a coefficient of
friction of 0.14.
Plated threads need only 3/4 torque shown.
Well lubricated threads need only 1/2 torque shown.
Source: Rexnord Engineering Specification: GES8-19, 04/10/79.
TABLE 3 — Bearings for Orion Shaft-Mount Speed Reducer

(All bearings are “Timken” unless noted otherwise)
Input Sub-Assembly Bearings Output Sub-Assembly Bearings
Inboard Cup/Cone Outboard Cup/Cone Inboard Cup/Cone Output Cup/Cone
362A/368A 3720/3780 LL641110/LL641149 67820/67885
TABLE 4 — Seals for Orion Shaft-Mount Speed Reducer

(All seals are “Chicago Rawhide” unless noted otherwise)
Input Sub-Assembly Seals Output Sub-Assembly Seals
Inboard Outboard Inboard Outboard
CR-24898 CR-24910 180 x 210 x 15 AS 180 x 210 x 15 C
TABLE 5 — Seals and Bearing for Orion Heavy Duty Shaft-Mount Speed Reducer
(All seals are “Chicago Rawhide”, bearings are “Timken” unless noted otherwise)
Input Sub-Assembly Seals Input Sub-Assembly Bearings
Inboard Outboard Inboard Cup/Cone Output Cup/Cone
CR-29866 CR-29871 HM911210/HM911242 78551/78215C
TABLE 6 — Driven Shaft Dimensions

SA1 (h6)
Series SB1 SC1 SD1
Nominal + -
mm 135 135 134.98 155 2.8 1.5
Orion inch 5.315 5.315 5.314 6.102 0.11 0.06

Section X — Maintenance Log
Speed Reducer Serial Number
Date Installed
DATE MAINTENANCE PERFORMED

Drawings
REXNORD CORPORATION Conveying Equipment Division
Rexnord Project Number Unit No. Drawing No. Released by Date
200733 1 200733-01-80 KEM 06/16/15
Customer LARGO RESOURCES PROPOSAL NO. P.O. NO. Engineer: Page
VANADIO DE MARACAS, BRAZIL 11621-R4 MJR / LR 1 of 1
Additional Notes:
VENDOR NOTE: MUST PROVIDE NAME OF MOTOR MANUFACTURER & MOTOR SPECS.
ADD TOTAL WEIGHT OF REDUCER ASSY TO CERTIFIED DRAWINGS.
Within 2 weeks of receipt of order, furnish the following product data:
PLEASE SUBMIT APPROVAL DRAWING INCLUDING DIMENSIONS PRIOR TO
Send PDF or TIF file (preferred) or paper copies of the following to Purchasing
MANUFACTURE AND WITHIN 2 WEEKS OF RECEIPT OF ORDER.
(1) Copy of Data and Certified Dimension Sheets.
(1) Copy of Installation, Operating, Maintenance, and Lubrication Instructions.
(1) Copy of Recommended Spare Parts List.
.
REXNORD, GEAR PRODUCTS, ORIONSMP4-A, SHAFTMOUNT REDUCER; ACTUAL RATIO: 209.86:1, MECHANICAL HP 40.1, FINAL OUTPUT SPEED = 8.34 RPM, ROTATION CW
WHEN VIEWING HOLLOW SHAFT.
ACCESSORIES & OPTIONS:
-- TOP MOTOR MOUNT TO ACCOMMODATE A 20 HP, 256T FRAME MOTOR, (MOTOR FURNISHED & MOUNTED BY FALK).
-- AIRMAX BREATHER, 1:1 V-BELT /SHEAVE PKG AND BELT GUARD WITH MESH BOTTOM TO PREVENT MATERIAL BUILD-UP.
-- BELT GUARD
-- HOLLOW OUTPUT SHAFT WITH SHRINK DISC STANDARD BORE FOR 5.315” DIAMETER.
-- 270HFN41 FLUID COUPLING BETWEEN MOTOR AND REDUCER WITH GUARDING
-- SPLIT GUARD OVER SHRINK DISK WITH ENTRANCE HOLE TO FIT OVER 5.315 DIA SHAFT.
-- STANDARD LENGTH TORQUE ARM, 34” CENTER TO CENTER WITH BUSHING (2.52” I.D.),
WHEN VIEWING OPEN END OF HOLLOW SHAFT
-- INTEGRAL BACKSTOP
-- PREPARE REDUCER FOR LONG TERM STORAGE.
TAGGING:
REXNORD PART NO: 200733-01-80-100
1 Appendix
Reliable, Innovative, Comprehensive. Mining Solutions.
Control & Signal Solutions:

Signal Switch Quick Selector Chart
Series
Feature
AFU AFC AFK AFS AFM
Remote Signaling • • • • •
Audible Signaling x x • x •
Visible Signaling x x • x x
Magnetic Motor Control • x x x x
Heavy-duty 600 VAC Max • x x x x
Heavy-duty 125 VAC Max x • • • •

Water Shedding Cover x x • • •
Water Shedding Enclosure • • x x x
• Feature available x Feature not available
Alignment, Control & Signal Solutions

Crouse-Hinds belt alignment, control and signal devices for mining are
designed to be a safe, rugged, worry-free answer to your productivity needs.
Durable materials, innovative design and a focus on safety let you concentrate
on other parts of your plant while your conveyor system stays running.
• Visual & Directional • Multiple Conduit

Indicators Entry Points
Quick and easy Provide flexibility in
identification to get you retro-fit or new build
safely running again applications
• Multiple Material
Options
Tough, durable
enclosures designed to
stand up to your needs
Belt Control Switch Application

Single-end units are used at the ends of the conveyor system and spaced maximum 30 meters (100 ft) between switches.
Double-end units are used along the conveyor and spaced maximum 30 meters (100 ft) from each side of unit. Double-end
units contain two red painted indicator arms on each side for actuating indication.
1
Engineered to perform in
the harshest environments
Conveyor Belt Alignment Switch Application

15Amp, 600VAC switch with two normally open
and two normally closed contact arrangements.
The operating arm actuates the normally closed
contacts within a 7º to 15º travel of the arm
(for signaling) and actuates the normally open
contacts (for shut-off) within 23º to 31º of the
arm’s vertical position.
Over-travel protection of 85º prevents severe
run-off damage to switch mechanism. The spring
loaded operating arm returns the switch to normal
position when belt interference is removed.
Conveyor belt alignment switches are installed
on both sides of conveyor system and spaced
maximum 90 meters (300ft) from each side of unit.
2
Reliable, Innovative, Comprehensive. Mining Solutions.
AFU & AFUX Conveyor Belt Control Switch

APPLICATIONS: CERTIFICATIONS AND COMPLIANCES: STANDARD FINISHES:
AFU and AFUX conveyor control switches are AFU Series • Feraloy iron alloy – electrogalvanized and
used: aluminum acrylic paint
• NEC/CEC:
• As emergency or normal “STOP” switch Class II, Division 1, Groups E, F, G • Steel – electrogalvanized with chromate finish
for conveyor lines, cranes, unloaders, bulk Class II, Division 2, Groups F, G (red acrylic paint on indicating arm)
handling systems and similar equipment Class III
• Bronze – natural
• In steel mills, mining and ore and coal handling • Encl. 3, 5
operations, automotive and other assembly
• NEMA: 3, 4, 9EFG
lines, warehouses, loading docks and various ELECTRICAL RATING:
process industry facilities • IP66
• Control circuit switch – 15 AMP, 600 VAC max.
• In the control circuit of magnetic motor starters • UL Standard: 698
to shut down motor-driven conveyors or other • CSA Standard: 22.2 No. 30
machinery when switch is actuated OPTIONS:
AFU series complies with requirements for use in AFUX Series

Description Suffix
Class II areas having combustible dusts that may • NEC:
or may not be electrically conductive. Class I, Division 1 & 2, Groups C, D
Finish: Corro-free™ epoxy powder
AFU series are also gasketed for use in Class II, Division 1, Groups E, F, G S752
coat – for coating outside only.
hosedown areas even when combustible dusts Class II, Division 2, Groups F, G
are present. Class III
AFUX series complies with requirements for use • NEMA: 3, 7CD, 9EFG
in NEC Class I areas which are hazardous due • IP65
to the presence of flammable vapors or gases.
AFUX series also complies with requirements for • UL Standard: 698
use in NEC Class I areas which are hazardous • cUL
due to the presence of flammable vapors or
gases. AFUX series also complies with NEC
requirements for use in Class II hazardous areas, STANDARD MATERIALS: AFU0333-50 Single end left
or for use in NEC hazardous areas classified ®
• Enclosure – Feraloy iron alloy
simultaneously as Class I and Class II.
• Plunger – stainless steel
• Loop – bronze
FEATURES:
• Indicating arm – steel
• Furnished with one or two end units,
each containing 2-NO and 2-NC contact
arrangements. ORDERING INFORMATION:
AFU0333-66 Double end
• Precision switches provide maintained contact Maximum Weight of
(switches have a snap action mechanism). Unsupported Line
• Enclosure has three 1” conduit hubs – two for or Cable Without Contact Arrangements With 2-NO, 2-NC
horizontal through feed and one at the bottom. Actuating Switch† Total Operating in Each End Unit
Cast mounting lugs on 1-½” centers permit Description (lbs) Force Required (lbs) Cat# Cat#
attachment to the web of a standard 3” angle Single end left 15 25 AFU0333 50 AFUX0333 50
iron. Single end left 25 50 AFU0333 60 AFUX0333 60
• In installation, the actuating line or cable is Single end right 15 25 AFU0333 05 AFUX0333 05
connected from a fixed point to the loop on
the end unit. A pull on the line of the required Single end right 25 50 AFU0333 06 AFUX0333 06
operating force and with a total movement of Double end 15 25 AFU0333 55 AFUX0333 55
½” actuates the plunger, opens the switch and Double end 25 50 AFU0333 66 AFUX0333 66
trips the red painted indicating arm forward,
† A galvanzed steel aircraft cable, supported every 10’ is recommended
which locks the plunger in the actuated (switch
open) position. Returning the indicating arm
DIMENSIONS (IN INCHES*):
to its normal position resets the mechanism.
A typical installation would include single end
switch units at each end of the conveyor with
double end switch units between.
• Depending on the size and length of line,
supports at properly spaced intervals may
be necessary to ensure that the line or cable
weight alone will not actuate switch.
3 *Dimensions are approximate, not for construction purposes.

2 Appendix

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Contract Number: 200733

Recipient: Attention: MAURO RAIMUNDO DA SILVA

Subject: Transmittal of Field Installation, Operation, and Maintenance Manuals

Quantitiy: Hard Cover 3 Electronic 1

Name EMY GARCIA DELGADO

REXNORD INDUSTRIAL CHAIN AND CONVEYOR

CONVEYING EQUIPMENT OPERATION 1 of 1

SERVICE MANUAL July 91

Rexnord Industries, LLC

Your Order #: Rexnord Order #:

Your Name: Title:

Type of Service Required:

CONVEYING EQUIPMENT OPERATION 1 of 2

SERVICE MANUAL July 91

AVOID ACC ID ENT S.

CONVEYING EQUIPMENT OPERATION 2 of 2

SERVICE MANUAL July 91

CONVEYING EQUIPMENT OPERATION 1 of 2

SERVICE MANUAL July 91

CONVEYING EQUIPMENT OPERATION 2 of 2

SERVICE MANUAL July 91

Remarks These instructions do not purport to cover all details or variations in

CONVEYING EQUIPMENT OPERATION 1 of 2

SERVICE MANUAL July 91

CONVEYING EQUIPMENT OPERATION 2 of 2

SERVICE MANUAL July 91

200 Mark number.

G3186 Rex Order Number.

635-40057 Shafting Assembly Drawing Number.

For Tech Support, Phone: 317-273-5781 10-11-12

For Tech Support, Phone: 317-273-5781 10-11-12

PENTAC D-5 SEALING SYSTEM ADDITIONAL INSTALLATION COMMENTS

Table 6: DISTANCE TO PUSH SEAL INWARD

Figure 7: Installed “Push In” distance shown at the final installed

D8 (or D9) TACONITE SEALING SYSTEM ADDITIONAL INSTALLATION COMMENTS

For Tech Support, Phone: 317-273-5781 10-11-12

Cast Iron Housing Cast Steel Housing**

For Tech Support, Phone: 317-273-5781 10-11-12

LUBRICATION INFORMATION Table 8

LUBRICATION TABLE (HORIZONTAL SHAFT APPLICATION) Grease lubrication is recommended wherever

* Additional bearing protection or special sealing may be

For Tech Support, Phone: 317-273-5781 10-11-12

CIRCULATING OIL LUBRICATION INFORMATION

For Tech Support, Phone: 317-273-5781 10-11-12

Prior to initiating the following removal procedure, check to ensure that

1. Check to ensure that axial

2. Relax all locking screws by

, IMPORTANT TOPICS THAT MUST BE FOLLOWED

MOTORS MUST NOT BE LIFTED BY THE SHAFT,

, BUT BY THE EYEBOLTS SPECIFIC FOR SUCH

DURING TRANSPORTATION, MOTORS FITTED

, RINGS ARE PROTECTED AGAINST BEARING

THIS LOCKING DEVICE MUST BE USED ON ANY

When receiving the motor, check if any damage has occurred

If anything has been noticed, notify immediately the carrier,

Do not remove the existing protecting grease from the shaft

9 Check if any damage has occurred during transportation.

Motor storage temperature must remain between 41ºF (5ºC) to

Single-phase motors when kept in stock for 2 years or more

WEG recommends to rotate the shaft (by hands) at least once

If motor is fitted with space heaters, it is recommended to

The space heaters should NEVER be energized while motor

Disconnect motor from power supply before making any