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GEAR BOX INSTRUCTION MANUAL

Messrs.

SM Cyclo de Chile Ltda.

GEAR BOX

技 術 部 2012.09.13 ENGINEERING DEP
技 術 部
2012.09.13
ENGINEERING DEP

WORK No. 12-NAEA01

Date:

Sep.

2012

de Chile Ltda. GEAR BOX 技 術 部 2012.09.13 ENGINEERING DEP WORK No. 12-NAEA01 Date: Sep.
技 術 部 2012.06.01 ENGINEERING DEP
技 術 部 2012.06.01 ENGINEERING DEP
技 術 部 2012.06.01 ENGINEERING DEP
技 術 部 2012.06.01 ENGINEERING DEP
技 術 部 2012.06.01 ENGINEERING DEP
技 術 部 2012.06.01 ENGINEERING DEP

技 術 部

2012.06.01

ENGINEERING DEP

技 術 部 2012.06.01 ENGINEERING DEP

Ⅰ.MESSRS

SM Cyclo de Chile Ltda.

 

Ⅱ.NO. OF ORDER

--

Ⅲ.MANUFACTURERʼs SERIAL NUMBER

12-NAEA01

 

Ⅳ.DATE OF

MANUFACTURE

Sep. 2012

 

Ⅴ.SPECIFICATION

 

1) TYPE

DHB115

 

2) INPUT POWER

2700

HP

3) INPUT SHAFT SPEED

1500

r/min

 

4) OUTPUT SHAFT SPEED

261

r/min

 

5) GEAR RATIO

1 / 5.747

 

6) TORQUE OF OUTPUT SHAFT

--

7) USE CONDITIONS

--

8) LUBRICATION METHOD

FORCED LUBRICATION

 

9) LUBRICATION OIL

JIS K2219 GEAR OIL Gr.2 , ISO VG 220

10) LUBRICATION GREASE

--

11) LUBRICATION OIL Q'TY

APPROX. 430 L

 

12) OIL SEAL

 
 

INPUT SHAFT

TB-17020016 x 1

 
 

OUTPUT SHAFT

TB-27033025 x 1

 

13) BEARING

INPUT SHAFT

22330

C3 x

 

1

,

22326 C3 x 1

INTERMEDIATE SHAFT

22344

x

1

,

23240 x 1 ,

29428 x 2

 

OUTPUT SHAFT

23052

x

1

,

32336DF+KR x 1

14) MASS

APPROX. 8900 kg

( LUBRICATION UNIT: 500 kg )

15) RUST PREVENTIVE OIL

SHELL VSI CIRCULATING OIL 32 APPROX. 15 L

 

16) OTHERS

--

-1-

1. Method of Use.

The method of use and maintenance of this machine is easy and simple. If however, the method of use of this machine should be erroneous, there would be a danger of damaging the machine within a short period of time. Accordingly, if is strongly recommended to pay special attention to the following matters in order to attain perfect maintenance of the machine.

1-1

Installation and coupling.

This speed reduction gear is assembled in such a way that it may have the best possible tooth contact and lubricating condition as it is installed in the standard position. The foundation on which the machine is to be installed should be properly strengthened to eliminate the loosening and vibrations of the machine during its operation. When installing the machine, distortions may sometimes occur due to its own weight of this machine in accordance with the condition of the foundation. Consequently, the foundation bolts should be fastened, when correcting the leveling of the machine by using liners and wedges, and then, the leveling of the machine is confirmed after its fastening. For centering of coupling, measure the deviation on the outside diameter of datum face for centering as well as the deviation on the end face using dial gauge, and ensure that the tolerances of both the deviation of face and of axis are within 5/100 mm.

1-2

Operation

On finishing installation, grease upping must be performed by feeding Grease at necessary points. If circumstance permits it is desirous to perform test run of prime mover being disconnected from mating machine. Upon ascertaining that there is no anomaly, connect the prime mover to the machine.

1) First conduct no-load operation of reduction gear alone. the no-load operation should be continued for more than three hours. The more the time for test run is spent, the more the operation later will become smooth and durability of machine will be increased. The test run should be performed to make certain that the operation can be had without being attended with anomalous power consumption, noise of gear bearing temperature. 2) Next connect the reduction gear with machine to enter upon operation which should be performed in stages. At this phase, pay attention that load must be applied little by little. Under any circumstance avoid applying full load from the beginning.

-2-

3) Checks to be made during or after operation should be made on the following points. Whether or not the bearing is overheated. Whether or not anomalous sound is being emanating. Whether or not the extent of vibration is great. Whether or not the set bolts and foundation bolts and loose. Whether or not the oil level is proper. After checking aforementioned items, full load operation may be Entered upon.

4) Operation of oil pump Start the pump motor three to five minutes before starting operation of the drive motor for the speed reducer.

2. Check and Maintenance

2-1

Standard for Check

1) General During operation, always attend to sound, heating, oil leakage, and vibration. Even while the machine is working trouble –free, regular check should preferable be performed once a year. In performing regular, check wash the machine with clean oil without dismantling gears and bearings, so far as dismantling is not particularly necessary, and check for any anomalous wear or flaws.

2) Reduction gear body

(1)

Gear wheel

 

Machine

Checking

Checking

Checking

Checking

Checked

Item

points

Time

Frequency

 

Anomalous noise

Contact part of gear wheel and Surrounding case

During operation

Ordinary

Gear

Oil feeding

condition

Oil gauge

During operation and suspension

Ordinary

wheel

Tooth contact

Tooth face

During

Every

6

and Wear

suspension

Months

(2)

Bearing

 
 

Checking

Checking

Checking

Checking

Item

Point

Time

Frequency

Bearing

Temperature, Anomalous noise

Pedestal, Surrounding case

During

Daily

operation

-3-

a. Bearing temperature should be less than 80Should the bearing temperature becomes above 90, lubricating

oil tend to deteriorate due to oxidation at high temperature and causes break of oil film in consequence of which seizure may result, and hence the temperature should always be checked. b. When change of temperature is intense it is an indication of some anomaly. When temperature exceeds 80°, stop operation and check lubrication, and also check whether there is foreign

 

matters

caught in the machine.

 

(3)

Oil seal

 

Checking

Checking

Checking

Checking

Item

Point

Time

Frequency

Oil seal

Oil leakage

Sealing part

During

Daily

operation

When oil leaks from oil seal part following causes are Considered, that is, life of oil seal is expired, damage to lip due to bad fitting or insertion, damage to shaft sliding face.

3) Maintenance during suspension of operation In case where machine is cut off from service for long period of

time, cautions must be exercised to prevent ingress of dust and generation of rust. a. More than once monthly, perform operation of machine for about One hour.

b. More than once monthly, check the gear wheel and bearing part, etc. for generation of corrosion through inspection holes of each case and from side cover.

4) Lubricating oil

 

Checking

Checking

Checking

Checking

Item

Points

Time

Frequency

 

Extent of

Oil

During suspension

As

Lubricating

Deterioration

undermentioned

oil

and purity

Checking of

Oil gauge

During operation and suspension

Ordinary

oil level

Perform sampling of lubricant from time to time to have it inspected for its property. Inspection are done by oil maker, so, forward sample of about 1 liter to the maker and receive inspection report and prescription. Since oil containing solid, water content or bubbles as well oil of acidity is harmful to machine, oil should be always kept clean. After the passage of 500 hours after the commencement of the operation of the machine installed, it is advisable to replace the oil with the fresh one without fail. Inspection of oil by

-4-

user should be conducted once per 2,500 hrs running as a rule, or in case where working hour is short perform inspection once in 6 months period. Besides, all problems relating to oil should be handled in accordance with maker’s direction. Caution: Same brand of lubricating oil should be used in continuation. When it has to be changed with other brand by some reason replacement of lubricant should be made after completely extracting old oil. Under no circumstance should mixture of more than two brands be used.

3. Disassembly and Assembly

Perform disassembly and reassembly by referring to the annexed drawings.

3-1 Disassembly

1) When disassembly is conducted, get to work after have a proper understanding of each construction.

2) Parts disassembled should be marked with mating marks for the convenience of reassembly.

3) Parts disassembled should not be stained, and their finished faces should be protected from getting flaws. For this purpose they should not be placed directly on the ground or concrete. Small parts should preferably kept in box so that they may not miss.

4) Parts disassembled should be cleaned enough, and should be coated not collect on them during assembly work.

5) Avoid directly hitching wires on machining part, but apply clothes to hitching wire.

Disassembly order

Remove couplings on prime mover side and on driven machine side.

Remove exterior and interior pipes which hinder the work.

Remove bolts on the case fitting surface.

Draw out respective bearing and gear wheel. (Do not take off gear wheel or bearing from shaft unless it is necessary.)

3-2 Reassembly

Prior to starting assembly, inside of casing, gears, shaft, bearings and all other parts should be well washed with cleaning oil. When bearing is re-used, retainer and other parts should be checked if they are free from bruise. Assembly is accomplished by taking reverse order of steps to the

disassembly. Parts locked should be locked again.

are found defective replace them. Fitting faces of both case and side cover should be coated with

If locking parts

-5-

liquid packing (three bond) to prevent oil leakage. End cover should be fitted with oil seal and seal retainer in advance. (NoteEnsure that oil seal edge and contact surface with the edge is free from damage. Even small flaw may cause oil leakage.) Then coat liquid packing on the end cover and fit it. Lastly mount air breather, oil gauge and drain plug, etc. With these mounted re-assembly is completed.

4. Long term storage point of the unit

Follow the following points, when being kept after shipment without operating one month or more.

1) Keep it in a general factory indoor or a general warehouse without the influences of a rainstorm, humidity, dirt, an intense temperature change, sulfurous acid gas, etc. 2) Check an internal antirust state, spray & pour in "SHELL VSI CIRCULATING OIL 32" (gaseous phase rust preventive oil) by SHOWA SHELL SEKIYU, and seal after that. Avoid the mixed use with other rust preventive oil. Then, the above should work for every half a year. 3) Operate after draining rust preventive oil and changing to recommendation lubricating oil, when starting operation. Don't operate by rust preventive oil. 4) Equivalent of the NP-1 by JIS K 2246 is applied to shaft part at the time of shipment. If an antirust state is checked by viewing and there is a problem, apply an equivalent of the NP-1 by JIS K 2246. 5) The amount of oil supply of "shell VSI circulating oil 32" refer to the amount of rust preventive oil. (1-page principal items table)

-6-

5. SAFETY AND OTHER PRECAUTIONS

The gear unit should be handled, installed and maintained by trained technicians.

Carefully read manual and all accompanying documents before use(installation, operation, maintenance, inspection, etc.) Thoroughly understand the machine, information abut safety, and all precautions for correct operation. Maintain this manual for future reference.

Pay particular attention to the DANGERand CAUTIONwarnings regarding safety and proper use.

:Improper handling may result in damage, serious personal injury and/or death.

! DANGER ! CAUTION
!
DANGER
!
CAUTION

:Improper handling may result in damage and/or personal injury.

! CAUTION
! CAUTION

Matters described in

Be to observe important matters herein.

may lead to serious danger depending on the situation.

!
!

DANGER

General

Transport, installation, plumbing, operation, maintenance, and inspections should be handled by properly trained technicians; otherwise, injury or the machine may result. When the unit is to be used in a system for transport of human beings, a secondary safety device should be installed to minimize chances of accidents resulting in injury, death, or damage to the system. When the unit is to be used for an elevator, install a safety device on the elevator side to prevent it from falling, otherwise, serious injury, death, or the elevator may result.

Installation

Never stand directly under a unit suspended by a crane or other lifting mechanism; otherwise personal injury or death may result.

Operation

Never approach or touch any rotating parts(shaft, etc.)during operation, loose clothing caught in these rotating parts may result in severe injury and/or death.

Daily inspection and maintenance

Never approach or touch any rotating parts(shaft, etc.)when maintaining or inspecting the reducer during operation. Loose clothing coaught in these rotating parts may result severe injury and/or death. Be sure to stop both the driving and driven machines before checking any tooth surfaces, otherwise, you may be caught in the gear engaging section. resulting in severe injury and/or death. Do not operate any units without all(safety)covers in place. Failure to do so may cause injury and/or death.

《Note》

A copy this manual should be sent to the actual user of the gear unit. This manual should be maintained by the user.

-7-

 
!
!

CAUTION

General

The unit should be operated only within its design and performance specifications; otherwise, injury or damage to a system may occur. Keep hands and foreign objects from the internal moving parts of the unit ; otherwise, injury or damage to a system may occur. Damaged units should be taken off-line and not put back in operation until properly repaired. Any modifications or alterations of any kind, to the unit, will void the warranty and all subsequent claims. Do not remove the rating plate.

Inspection upon delivery

unpack the after verifying that it is positioned right side up ; otherwise, injury may result. Verify that the unit received is in fact the one ordered. When a different product is installed, injury or damage to the system may result.

Transport

Exercise ample care not to drop the unit during transport. When a hanging bolt or hole is provided, be sure to use it. after mounting the unit on a system, however, do not hoist the entire system using the hanging bolt or hole. Before hoisting, check the weight with the rating plate, crate, outline drawing, catalog, etc. Never hoist the unit that exceeds the rating of the crane or other mechanism being used to lift it ; otherwise, injury or damage to the unit and/or lifting device may occur.

Installation

Do not place objects that will hinder ventilation around the unit ; otherwise, cooling effect is reduced, and may lead to a possible fire hazard due to excessive heat build-up. Do not step on or hang from the unit ; otherwise, injury may result. Do not touch the key way at the shaft end or on the inside of the unit ; injury may result. When the unit is used in food processing applications vulnerable to oil contamination, install an oil pan or other such device to cope with oil leakage due to failure or limited service life. Otherwise, oil leakage may damage products.

Coupling with other machines

When coupling unit with a load, confirm that the alignment error is within the specified limits shown in the maintenance manual, drawings, catalog, etc.;otherwise, damage to the system may result, due to misalignment. Correctly tighten respective bolts to the specified torque shown in the drawing, catalog, etc. ; otherwise ; scattering fragments may damage the system. When a belt is used for coupling the unit with another machine, check that the belt tension and the parallelism of the pulley are within the specified limits. When the unit is directly coupled with another machine, check that the direct coupling accuracy is within the specified limits ; otherwise, the system may be damaged, due to misalignment. Install appropriate guard devices around rotating parts ; otherwise, injury may result. Remove the key temporarily attached to the output shaft of the unit when the shaft is free-rotating (i.e. not loaded) ;otherwise, injury may result. Confirm the direction of rotation before coupling the unit with its driven machine. Difference in the direction of rotation may cause injury or damage to the system.

Operation

The reducer will get very hot during operation. Do not touch or come in contact in any way with the reducer ; otherwise, you may suffer bums. If the reducer is operating in an abnormal way, stop the unit immediately ; otherwise, injury may result. Do not operate the reducer in a manner the exceeds its rating criteria ; otherwise, injury or damage to the system may result. Do not remove any covers or open the reducer during operation;otherwise, splashing lubricant may cause burns. Do not loosen the oil filler plug during operation ; otherwise, splashing lubricant may cause bums. For a system in which a lubricant motor pump is provided separately, switch on the pump motor prior to switching on the reducer motor. This will enable praper lubrication of the bearings prior to start-up. Failure to do so may damage the unit. When reversing the direction of rotation, first bring the unit to a complete stop, then commence reverse rotation ; otherwise, the system may be damaged. Identify and provide appropriate corective action in a timely fashion for any abnormal operation characteristics according as the maintenance manual. Do not operate the unit until corrective action has been taken.

Daily inspection and maintenance

Change lubricant according to the maintenance manual, and use only those recommended lubricants ; otherwise, the system may be damaged. Do not change the oil during operation or soon after operation has ceased ; otherwise, the hot oil may cause burns.

Disassembly and reassembly

Repair, disassembly, and reassembly should be handled by properly trained technicians ; the system may be damaged.

Disposal

Dispose the reducer and lubricant as general industrial waste.

-8-

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Lovejoy / Sier-Bath

“FSL” Slide Type Coupling

Size FSL 2 thru FSL 7

Introduction

   

Carefully follow the instructions in this manual for optimum performance and trouble free service.

This manual applies to standard “FSL” Slide type couplings. The “FSL” Slide type couplings are recommended for horizontal applications only. For vertical applications please consult with Lovejoy application Engineering.

The “FSL” Slide type coupling is used for applications

galling lubricant. Insure that seals and pipe plugs are in place in the gear sleeve. Lubricate around sleeve gear teeth and seal surface and place over respective shaft

before mounting hubs. Protect shaft on which sleeve will rest during hub installation.

2) Determine the mounting arrangement of the proper mating hubs as illustrated in figure 1. Heat hubs in either an oil bath or oven until bores are larger than shaft diameter. Mount so that the end of each hub is flush with the end of the shaft as illustrated in figure 1. Allow hubs to cool before proceeding.

requiring axial movement between the shaft ends greater than standard. This function must be performed under NO LOAD, STATIC conditions.

 

WARNING: If an oil bath is used, the oil must have a flash point of 350°°°°F or higher. Do not rest hubs on the bottom of the container. Do not use an open flame in a combustible atmosphere or near combustible materials.

Installation & Alignment Instructions

All parts must be clean and free of any foreign materials before attempting assembly, use a non- flammable solvent. All Parts should be examined for any damage during shipping and handling. Measurements should be taken to verify correctness of parts to meet application requirements, such as, hub and shaft fits, shaft separation, etc. Check hubs, shafts and keyways for burrs.

3) Although the shafts may be perfectly aligned at installation they should be realigned after mounting of coupling. Position equipment in the approximate alignment with the approximate “G” dimension found on Chart 1. Align coupling using the instrument method as described below.

1) Install keys in respective shafts. Keys should fit shaft keyseat with a tight fit on the sides and slight clearance over the key. Coat the shafts with an anti-

4) Angular Alignment – Using an inside micrometer, take readings at four points 90°°°° apart. Adjust machines until all four readings are identical. The

Caution: Consult applicable local and national safety codes for proper guarding of rotating coupling. Observe all safety rules when installing or servicing coupling.

difference in maximum and minimum measurements must not exceed the installation angular limits specified in chart 1.

Warning: Lockout starting switch of prime mover and remove all external loads form drive before installing or servicing coupling.

5) Parallel Offset Alignment – The dial indicator method is recommended for this procedure. Attach the dial indicator base to one hub and set the dial indicator needle in contact with the outside diameter of opposite hub. Rotate hub on which the indicator is mounted 360°, taking indicator readings at four points 90°°°° apart. Adjust machines until all four readings are identical. The difference in maximum and minimum measurements must not exceed the installation-offset limits specified in chart 1. Relocate the indicator dial base to the opposite hub and repeat the procedure. Tighten all foundation bolts and repeat step 4 and 5.

 

T ABLE O F C ONTENTS

1

Introduction

1

Installation & Alignment Instructions

2

Maintenance

2

Part Identification

Lovejoy / Sier-Bath

1

Slide Type FSL Coupling instructions

Realign coupling if necessary.

Any parts showing signs of wear or damage should be replaced. These parts are available for purchase by referencing the coupling UPC number, size, type and bolting style. Hub and sleeve should be replaced as half coupling whenever possible.

Warning: Before installing couplings, make certain that foundations of equipment to be connected meet manufacturer’s requirement. Check for “soft foot”. The use of stainless steel shims is recommended.

6) Coat hub teeth and body as well as inside of sleeve with coupling grease. Slide the sleeve onto its respective hub, making sure that the gear teeth mesh properly. Apply light dots of oil to one side of the gasket. Install gasket between the sleeve flanges, align the boltholes and press the side with oil against flange. Place Plate into counter bore of sleeve. Move sleeves together, with lube plugs 90° apart. Install bolts and locknuts, tightening alternately and evenly to recommended torque in chart 1. Remove the two lube plugs in each sleeve and fill coupling with the recommended amount of coupling grease indicated in Chart 1. Replace lube plugs and tighten securely.

Check alignment per steps 4 and 5. If maximum operating misalignment values are exceeded, realign the coupling to the recommended installation values found in chart 1.

Lubrication

Adequate lubrication is essential for satisfactory operation. Lovejoy Coupling Grease is specially formulated for coupling applications to increase coupling life while drastically reducing maintenance cycle time. And it'’ in complete compliance with AGMA 9001 lubrication recommendations.

Maintenance

Unlike bearing or general-purpose grease, coupling grease must withstand the centrifugal forces generated by a spinning coupling. Lovejoy Coupling Grease is designed to resist centrifugal separation, which allows the lubricant to be used for relatively long periods of time.

Other benefits of this product includes; highest pressure and wear protection available, built-in rust and corrosion inhibitors, increased coupling life, reduced maintenance costs, reduced downtime and superior lubrication.

Following an initial break-in period of about 3 million revolutions (80 hr. @ 600 rpm) it is recommended that the coupling be completely flushed and re-lubricated. Thereafter, a regular relubrication schedule should be maintained. If coupling leaks grease, is exposed to extreme temperatures, excessive moisture or frequent reversals, frequent lubrication may be required. For average industrial operating conditions, relubrication every 12 months should suffice with periodic visual inspections to insure that neither the quality nor the supply (due to leakage) of the lubricate has deteriorated to an unacceptable level.

During relubrication cycle or at least yearly, whichever comes first, the coupling should be disassembled and thoroughly cleaned of all grease. Remove and visually inspect all parts; gear teeth for signs of abnormal stress and wear, the seals and gaskets for any cracks or breaks.

One of the secrets to the success of Lovejoy Coupling Grease is the variable consistency throughout the working cycle of the application. The consistency of our grease changes with the operating conditions. Working of the lubricant under actual service conditions causes the grease to become semi-fluid, functionally splash lubricating the wear surfaces of the coupling. As the grease cools, it returns to the original consistency, thereby preventing leakage.

Lovejoy / Sier-Bath

2

Slide Type FSL Coupling instructions

FIGURE 1
FIGURE 1
FIGURE 1 CHART 1 Size F2 F2.5 F3 F3.5 F4 F4.5 F5 F5.5 F6 F7 "G"

CHART 1

CHART 1 Size F2 F2.5 F3 F3.5 F4 F4.5 F5 F5.5 F6 F7 "G" hub Separation
Size F2 F2.5 F3 F3.5 F4 F4.5 F5 F5.5 F6 F7 "G" hub Separation 0.125
Size
F2
F2.5
F3
F3.5
F4
F4.5
F5
F5.5
F6
F7
"G" hub Separation
0.125
0.19
0.19
0.25
0.25
0.312
0.312
0.312
0.312
0.375
"AP" MAX Separation
0.78
0.94
1.03
1.06
1.31
1.69
1.97
2.06
1.47
1.91
Installation
Offset MAX
0.002
0.003
0.003
0.004
0.005
0.005
0.006
0.007
0.008
0.008
Limits
Angular MAX
0.009
0.011
0.013
0.015
0.018
0.02
0.022
0.024
0.026
0.031
Operating
Offset MAX
0.009
0.012
0.014
0.017
0.02
0.02
0.026
0.027
0.032
0.033
Limits
Angular MAX
0.036
0.045
0.052
0.061
0.072
0.081
0.087
0.096
0.105
0.122
Max Speed
5000
4400
4000
3500
3000
2700
2500
2200
2100
2000
Lube capacity
Weight
5.8 oz
10.5 oz
1 lb
1.25 lb
2 lb
3.5 lb
4.5
lb
6.5
lb
7.25 lb
9.25 lb
Volume
3/8 pt
3/4 pt
1-1/8 pt
1-1/2 pt
1-7/8 pt
2 qt
2.5
qt
3.5
qt
1 gal
1-1/4 gal
Tightening Torque
940
1750
1750
2650
2650
2650
3650
3650
3650
4850
in-lb.

Lovejoy / Sier-Bath

3

Slide Type FSL Coupling instructions

Lovejoy Grid Coupling

Lovejoy Grid Coupling

Grid Coupling Installation Instructions

Pre-Assembly Inspection

Hubs, covers and grids come in a variety of sizes and types. First, determine the size and type of components being used. Remove all components from their boxes and packaging. Check maximum RPM values in Table 2 against operating speed.

Inspect all coupling components and remove any protective coatings or lubricants from bores, mating surfaces and fasteners. Clean all parts using a non-flammable solvent. Make sure that shaft, hubs and keyways are clean and smooth.

Assembly Instructions

1. Lightly smear seals with grease. When using vertical covers place

a greased seal on each of the covers and install covers and the

gasket on shafts before mounting hubs. When using horizontal covers, lightly smear seals with grease and place seals on shafts before mounting hubs (and covers, if necessary) on the shafts.

2. When installing coupling hubs onto each shaft, use keys where required. Keys should fit snugly. Seal the keyways to prevent grease leakage.

3. Coupling hub sizes 1020 - 1090 are clearance fit with the shaft and are supplied with set screws. Do not heat the clearance fit hubs. Position the hubs on the shafts to approximately achieve the "G” dimension shown in Table 2. It is usually best to have an equal length of shaft extending into each hub. Tighten the set screws.

Coupling hub sizes 1100 and larger are an interference fit with the shaft and are not supplied with set screws. It is necessary to heat hubs, using a torch, oven, induction heater or an oil bath, to a maximum temperature of 275° F. To avoid overheating the hubs, direct flame towards the bore using a constant motion. If an oil bath is used it must have flash point of at least 350° F. DO NOT rest hubs on the bottom of container or apply heat directly to the teeth.

Heat hubs as specified above. Mount hubs immediately with the hub teeth flush with the shaft end unless otherwise specified. Allow the hubs to cool before proceeding to the next step.

4. Set gap using a spacer bar equal in thickness to the nominal gap specified in Table 2. With the spacer bar inserted to the same depth, measure clearance between the bar and hub face at 90° intervals using feelers. Determine the maximum and minimum dimensions without rotating the coupling, the difference of these two measurements must be less that the Angular value in Table 2.

5. Check the parallel alignment by placing a straight edge across the two coupling hubs, and measuring the maximum offset at various points around the periphery of the coupling without rotating the coupling. If the maximum offset exceed the Parallel value in Table 2, realign the shafts.

6. Tighten all foundation bolts using the tightening torque values specified in Table 1. Repeat steps 5 and 6 and if necessary re-align the coupling.

7. Before inserting the grid segments, thoroughly pack the grooves with specified lubricant. When grids are supplied in two or more

segments assemble so that the cut ends of a segment joint extend

in the same direction. Spread the grid slightly so that it will pass

over the coupling teeth, and tap all the rungs into the respective slots with a soft mallet.

all the rungs into the respective slots with a soft mallet. HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL

HORIZONTAL

into the respective slots with a soft mallet. HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL VERTICAL

HORIZONTAL

respective slots with a soft mallet. HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL VERTICAL VERTICAL VERTICAL

HORIZONTAL

slots with a soft mallet. HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL VERTICAL VERTICAL VERTICAL VERTICAL

HORIZONTAL

with a soft mallet. HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL VERTICAL VERTICAL VERTICAL VERTICAL VERTICAL

HORIZONTAL

with a soft mallet. HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL VERTICAL VERTICAL VERTICAL VERTICAL VERTICAL

VERTICAL

with a soft mallet. HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL VERTICAL VERTICAL VERTICAL VERTICAL VERTICAL

VERTICAL

with a soft mallet. HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL VERTICAL VERTICAL VERTICAL VERTICAL VERTICAL

VERTICAL

with a soft mallet. HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL VERTICAL VERTICAL VERTICAL VERTICAL VERTICAL

VERTICAL

with a soft mallet. HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL HORIZONTAL VERTICAL VERTICAL VERTICAL VERTICAL VERTICAL

VERTICAL

Lovejoy Grid Coupling

Lovejoy Grid Coupling

Grid Coupling Installation Instructions

Assembly Instructions

- Continued

8. Pack the spaces around the grid with lubricant and wipe off the excess, flush with the top of grid. When using vertical covers slide the covers over the hubs to match with each other, positioning the gasket between the two cover halves. Install the fasteners through the cover halves and torque to the specifications in Table 3.

When using horizontal covers position seals on hubs so that they line up with grooves in cover. Position gaskets on lower cover half and assemble covers so that match marks are on the same side. If using the coupling in any position other than horizontal, assemble cover halves with the lug and match mark up, or on the high side. Tighten the fasteners to the torque specified in Table 3.

Make certain all plugs are inserted and secured before operating the equipment.

Note: Install coupling guards per OSHA and ASME 815.1 requirements.

Annual Maintenance

1. To prevent the possibility of unexpected motion, ensure that the power source is isolated before attempting to service the system components.

2. Adequate lubrication is essential to prolong the life of the coupling and obtain trouble free service. It is recommended that the couplings be relubed annually when using the common industrial lubricants shown in our catalog. If using Lovejoy Coupling Grease, lube intervals can be extended. However, a coupling exposed to extreme temperatures, excessive moisture, frequent reversals or grease leakage may require more frequent lubrication.

Remove covers and check lubricant condition, alignment and general condition of grid members and teeth every year. Couplings used in high ambient temperatures (greater than 158º F), at high speeds and/or frequent reversing applications may require more frequent inspection and relubing.

3. If lubricant is required, remove both lube plugs and insert the appropriate lubrication fitting in one of the tapped holes. Fill with the recommended lubricant until excess appears at the opposite lube hole. Replace both lube plugs.

4. For best results, clean coupling of all lubricant and replenish every two years.

Grid Removal

When it is necessary to remove the grid, remove the cover. Use a round rod or screwdriver that fits into the open loop ends of the grid. Using the teeth on the hub as a support, pry the grid out radially in even, gradual stages, proceeding alternately from side to side.

Tightening Torque for Set Screws

Table 1

 

For Inch Screws

 

For Metric Screws

Set Screw

Tightening

Set Screw

Tightening

Coupling

Size Length

Torque

Size

Length

Torque

Size

 

Inch

in-lbs

Nm

mm

in-lbs

Nm

1020

8-32

3 16

13.5-15 1.5-1.7

M5

5

24-26

2.8-3

1030

8-32

3 16

13.5-15 1.5-1.7

M5

5

24-26

2.8-3

1040

10-24

1 4

32-36

3.6-4

M6

6

42-44

4.75-5

1050

10-24

1 4

32-36

3.6-4

M6

6

42-44

4.75-5

1060

10-24

1 4

32-36

3.6-4

M6

6

42-44

4.75-5

1070

1 4-20

5 16

78-87

9-10

M8

8

84-88

9.5-10

1080

1 4-20

5 16

78-87

9-10

M8

8

84-88

9.5-90

1090

5 16-18

3 8

150-165 17-18

M10

10

165-176 19-20

Misalignment and End Float

Table 2

   

Max. Total

Coupling

Vertical Horiz.

G

Misalignment

End

Grease

Size

Speed

Speed

Dim.

Parallel Angular

Float

Weight

RPMRPM

± 10%

Inch

Inch

Inch

oz.

kg

1020

6000

4500

0.13

0.012

0.010

0.210

1.00

0.03

1030

6000

4500

0.13

0.012

0.012

0.198

1.40

0.04

1040

6000

4500

0.13

0.012

0.013

0.211

1.90

0.05

1050

6000

4500

0.13

0.016

0.016

0.212

2.40

0.07

1060

6000

4350

0.13

0.016

0.018

0.258

3.00

0.09

1070

6000

4125

0.13

0.016

0.020

0.259

4.00

0.11

1080

5500

3600

0.13

0.016

0.024

0.288

6.10

0.17

1090

4750

3600

0.13

0.016

0.028

0.286

9.00 . 0.25

1100

4000

2440

0.19

0.020

0.033

0.429

15.00

0.43

1110

3250

2250

0.19

0.020

0.036

0.429

17.60

0.51

1120

3000

2025

0.25

0.022

0.040

0.556

25.60

0.74

1130

2700

1800

0.25

0.022

0.047

0.551

30.00

0.9

1140

2400

1650

0.25

0.022

0.053

0.571

40.00

1.14

Tightening Torque For Cover Fasteners

Table 3

 

Horizontal Cover Fastener

Vertical Cover Fastener

Coupling

 

Tightening

 

Tightening

Size

Size

Torque Values

Size

Torque Values

Inch

Metric

in-lb

Nm

Inch

Metric

in-lb

Nm

1020

1 4-20

M6

100

11

1 4-20

M6

71

8

1030

1 4-20

M6

100

11

1 4-20

M6

71

8

1040

1 4-20

M6

100

11

1 4-20

M6

71

8

1050

5 16-18

M8

195

22

5 16-18

M8

159

18

1060

5 16-18

M8

195

22

5 16-18

M8

159

18

1070

5 16-18

M8

195

22

5 16-18

M8

159

18

1080

5 16-18

M8

195

22

5 16-18

M8

159

18

1090

5 16-18

M8

195

22

5 16-18

M8

159

18

1100

3 8-16

M10

336

28

3 8-16

M10

336

38

1110

3 8-16

M10

336

38

3 8-16

M10

336

38

1120

1 2-13

M12

549

62

3 8-16

M10

336

62

1130

1 2-13

M12

549

62

1 2-13

M12

549

62

1140

1 2-13

M12

549

62

1 2-13

M12

549

62

Notes: 1.

Horizontal covers 1020-1090 are supplied with socket head cap screws, horizontal covers 1100-1140 are supplied with hex head cap screws.

2.

Vertical covers are supplied with hex head cap screws.

 

Lovejoy, Inc. 2655 Wisconsin Ave. Downers Grove, IL 60515 630-852-0500 Fax: 630-852-2120 www.lovejoy-inc.com

Grove, IL 60515 630-852-0500 Fax: 630-852-2120 www.lovejoy-inc.com Where the World Turns for Couplings. 2/02 697904-05585

Where the World Turns for Couplings.

2/02

697904-05585

Features • Peak equivalent, true RMS or true peak output • Temperature signal output •

Features

• Peak equivalent, true RMS or true peak output

• Temperature signal output

• Optional dynamic signal output

• Corrosion resistant

• Hermetic seal

• ESD protection

• Overload protection

• Reverse wiring protection

Benefits

• Choice of output: RMS, equivalent peak, and true peak; permits you to choose the sensor that best fits your industrial requirements

• Provides continuous trending of overall machine vibration

• Can help guide maintenance

The 4-20 mA output of the PC425 Series

is proportional to vibration. An output of 4 mA indicates a level of 0 ips or no vibration present for velocity output models and 0

g for acceleration output models. A full-

scale reading of 20 mA indicates that the maximum range (RMS, Equivalent Peak or True Peak) of the chosen unit, acceleration or velocity, is present.

Optionally, any of the base sensor models can have dynamic signal output. Adding -DA to a model specifies a dynamic acceleration signal output (100 mV/g). Adding -DV to a model specifies a dynamic velocity signal output (100 mV/ips).

The temperature output of the PC425 Series is in terms of degrees kelvin (K), where 0 K

= -273° C. The voltage output at 0° C = 2.73

Volts (273 K). The voltage output at 80° C = 3.53 Volts (353 K).

(273 K). The voltage output at 80° C = 3.53 Volts (353 K). Model PC425 Loop
(273 K). The voltage output at 80° C = 3.53 Volts (353 K). Model PC425 Loop
(273 K). The voltage output at 80° C = 3.53 Volts (353 K). Model PC425 Loop

Model PC425 Loop Powered Sensor (LPS TM ) Side exit, 4-20 mA vibration with temperature output

Output, 4-20 mA

Full scale, 20 mA (±5%) Frequency response:

see Table 1 on back

±10%

10 Hz - 1.0 kHz

5%

±3 dB Repeatability

4 Hz - 2 kHz

Transverse sensitivity, max

see Table 1 on back

Output, temperature

Temperature output sensitivity, ±5°K Temperature measurement range

Output, dynamic

10 mV/K 223 to 358 K (-50 to 85° C)

 

PC425xxx-yy-DA

PC425xxx-yy-DV

Sensitivity (±10%)

100 mV/g

100 mV/ ips

Full scale Frequency response:

20g, peak

1.5 ips @ 1kHz

±3 dB

2.5 Hz - 10 kHz

2.5 Hz - 2.5 kHz

Amplitude nonlinearity, maximum

1%

Resonant frequency, mounted, nominal

21 kHz

Transverse sensitivity, max

5%

Electrical

Power requirements (two wire loop power):

Voltage (between pins A & B)

10 VDC min, 30 VDC max

Loop resistance 1 at 24 VDC, maximum

700Ω

Turn on time, 4-20 mA loop Grounding

30 seconds case isolated, internally shielded

Power requirements (temperature sensor): 4 Voltage source Current

12 to 18 V 0.4 to 5 mA

Environmental

Temperature range

–40 to 85°C

Vibration limit

250 g peak

Shock limit

2,500 g peak

Sealing

hermetic

Physical

Sensing element design Weight Case material Mounting Output connector Mating connector Recommended cabling

PZT ceramic / shear 320 grams 316L stainless steel 1/4 - 28 captive bolt MIL-C-5015 style, 6-pin R19SLI 5 J9T4 / J9T4A /J95

See back for notes.

6-pin R19SLI 5 J9T4 / J9T4A /J95 See back for notes. Sensor connector 6-pin top view

Sensor connector 6-pin top view

/J95 See back for notes. Sensor connector 6-pin top view 98895 Rev.B1 01/10 Due to continued

98895 Rev.B1 01/10

Due to continued research and product development, Wilcoxon Research reserves the right to amend this specification without notice.

Connector pin

Function

J9T4 / J9T4A

J95

Shell

ground

A

loop positive (+)

white

red

B

loop negative (-)

black

black

C

dynamic signal (optional)

n/c

white

D

temperature signal

green

green

E

temperature common

red

yellow

F

not used

n/c

n/c

Notes: 1 maximum loop resistance (RL) can be calculated by:

V DC power - 10 V

RL (max. resistance) =

20 mA

V DC power - 1 0 V RL (max. resistance) = 20 mA 2 Lower resistance

2 Lower resistance is allowed, greater than 10Ω recommended

3 Minimum R L wattage determined by: (0.0004 x R L )

4 The temperature sensor must have a current flow to operate. This current can be provided through constant-current diodes

5 When ordering a 4 conductor cable assembly, use the following format : R19SL1-x-J9T4A-xxx-PC; only available with non-dynamic output units

Table 1: PC425xxx-yy-Dz model number selection

xxx (4-20 mA output type)

-yy (full scale)

-Dz (dynamic output) A

AR = acceleration, RMS AP = acceleration, equivalent peak B ATP = acceleration, true peak C

-05 = 5 g (49 m/sec2) -10 = 10 g (98 m/sec2) -20 = 20 g (196 m/sec2)

-DA = dynamic acceleration

100 mV/g (10.2 mV/ m/sec2) 100 mV/ips (3.94 mV/ mm/sec)

-DV = dynamic velocity

VR = velocity, RMS VP = velocity, equivalent peak B VTP = velocity, true peak C

-05 = 0.5 i.p.s. (12.8 mm/sec) -10 = 1.0 i.p.s. (25.4 mm/sec) -20 = 2.0 i.p.s. (50.8 mm/sec) -30 = 3.0 i.p.s. (76.2 mm/sec) -50 = 5.0 i.p.s. (127 mm/sec)

-DA = dynamic acceleration

100 mV/g (10.2 mV/ m/sec2) 100 mV/ips (3.94 mV/ mm/sec)

-DV = dynamic velocity

A Dynamic output is an option on all models. If dynamic output option is not desired, do not add -DA or -DV to the model number.

B Equivalent peak output is developed based on the true RMS value of vibration. For a pure sine wave, the equivalent peak output is 1.414 times the RMS value.

C True peak output is based on the actual measured peak value using the time waveform and is not based on the RMS calculation.

PPC425xxx-yyC425xxx-yy wiringwiring AA lloopoop ppositiveositive ((+)+) RR LL BB looploop nnegativeegative (-)(-) ++
PPC425xxx-yyC425xxx-yy wiringwiring
AA
lloopoop ppositiveositive ((+)+)
RR LL
BB
looploop nnegativeegative (-)(-)
++ DDCC ppowerower
ssupplyupply
1122 VVDCDC ttoo
-- 3366 VVDCDC
CC
NN/C/C
DD
ttemperatureemperature ssignalignal
Signal measuring
circuitry
PLC/DCS 4-20mA input card
EE
temperaturetemperature ccommonommon
FF
NN/C/C
CCD
+ DC power
12
VDC to
-
18
VDC
+
Temperature DC voltage
-
SeriesPC425
PC425 Series
side exit
exitside
sensorsensor

PPC425xxx-yy-DzC425xxx-yy-Dz wiringwiring

Wilcoxon Research Inc 20511Seneca Meadows Parkway Germantown, MD 20876USA SeriesPC425 PC425 Series exitside side
Wilcoxon Research Inc
20511Seneca Meadows Parkway
Germantown, MD 20876USA
SeriesPC425
PC425 Series
exitside
side exit
sensorsensor

All wire and cable used for installation of the PC425 Series sensor should be shielded. Generally accepted instrumentation wiring practice considers the best way to ground the shield is to connect it at the measurement end of the cable. The shield should not be wired to ground at the sensor end of the cable. The Wilcoxon R19SLI type connector leaves the shield unconnected at the sensor end of the cable.

Tel: 301 330 8811 Fax: 301 330 8873 Email: wilcoxon@meggitt.com

www.meggitt.com

at the sensor end of the cable. Tel: 301 330 8811 Fax: 301 330 8873 Email:
Features • Intrinsic safety rated • Peak equivalent or true RMS • Corrosion resistant •

Features

• Intrinsic safety rated

• Peak equivalent or true RMS

• Corrosion resistant

• Hermetic seal

• ESD protection

• Overload protection

• Reverse wiring protection

Benefits

• Choice of output: RMS, equivalent peak, and true peak; permits you to choose the sensor that best fits your industrial requirements

• Provides continuous trending of overall machine vibration

• Can help guide maintenance

The 4-20 mA output of the PC421 Series is proportional to vibration. An output of 4 mA indicates a level of 0 ips or no vibration present for velocity output models and 0 g for acceleration output models. A full- scale reading of 20 mA indicates that the maximum range (RMS, or peak) of vibration is present.

the maximum range (RMS, or peak) of vibration is present. Model PC421 IS Series Intrinsically safe,side

Model PC421 IS Series Intrinsically safe,side exit, 4-20mA, Loop-powered sensors (LPS)™

Output, 4-20 mA

Full scale, 20 mA (±5%) Frequency response:

see Table 1 on back

±10%

10 Hz - 1.0 kHz

±2%

±3 dB Repeatability

4 Hz - 2 kHz

Transverse sensitivity, max

5%

Electrical

Power requirements (two wire loop power):

Voltage (between pins A & B) Loop resistance 1 at 24 VDC, maximum Turn on time, 4-20 mA loop Grounding

Environmental

12 VDC min, 30 VDC max

600Ω

30 seconds

case isolated, internally

shielded

Temperature range

–40

to 85°C

Vibration limit

250

g peak

Shock limit

2,500

g peak

Sealing

hermetic

Physical

Sensing element design

PZT

ceramic / shear

Weight

320

grams

Case material

316L

stainless steel

Mounting

1/4

- 28 captive bolt

Outut connector

2 pin, MIL-C-5015 style

PC421xxx-yy-Dz

Mating connector Recommended cabling

3 pin, MIL-C-5015 style

R6 type

J9T2A

Connector pin

Function

Shell

ground

A

loop positive (+)

B

loop negative (-)

Notes: 1 maximum loop resistance (RL) can be calculated by:

V DC power - 10 V

RL (max. resistance) =

20 mA

DC supply

RL (max resistance) 2

RL (minimum wattage capability) 3

voltage

20VDC

400.

1/4 watt

24VDC

600.

1/2 watt

26VDC

700.

1/2 watt

2 Lower resistance is allowed, greater than 10recommended

3 Minimum R L wattage determined by: (0.0004 x R L )

4 The following are recommended barrier strips: MTL7087, MTL7187, or MTL787S for Class I, Division 1 locations.

Wilcoxon Research Inc

21 Firstfield Rd Gaithersburg, MD 20878 USA

Tel: 301 330 8811 Fax: 301 330 8873 Email: sensors@wilcoxon.com

301 330 8811 Fax: 301 330 8873 Email: sensors@wilcoxon.com *CSA approval: class I, division 1, groups

*CSA approval: class I, division 1, groups A, B, C, D LCIE approval: EEx ia IIC T3 When installed in accordance with WR drawing 12799

www.meggitt.com

D LCIE approval: EEx ia IIC T3 When installed in accordance with WR drawing 12799 www.meggitt.com

Table 1: PC421xxx-yy-IS model number selection

xxx (4-20 mA output type)

-yy (full scale)

AR = acceleration, RMS AP = acceleration, peak

-05 = 5 g (49 m/sec2) -10 = 10 g (98 m/sec2) -20 = 20 g (196 m/sec2)

VR = velocity, RMS VP = velocity, equivalent peak B

-05 = 0.5 i.p.s. (12.8 mm/sec) -10 = 1.0 i.p.s. (25.4 mm/sec) -20 = 2.0 i.p.s. (50.8 mm/sec) -30 = 3.0 i.p.s. (76.2 mm/sec) -50 = 5.0 i.p.s. (127 mm/sec)

Pin A PLC or DCS +24 Volt supply 4-20mA return Pin B 4 1 system
Pin A
PLC or DCS
+24 Volt supply
4-20mA return
Pin B
4
1
system
+24 volt supply
5 2
4-20 mA return
shield
3
Intermediate
6
Shield
Not
MTL 7000
terminal
connected
R6Q1 or R6W type
connector
(isolated)
MTL 7700
block
(optional)
PC421 Series
Earth
ground

All wire and cable used for installation of the PC421 Series sensor should be shielded. Generally accepted instrumentation wiring practice considers the best way to ground the shield is to connect it at the measurement end of the cable. The shield should not be wired to ground at the sensor end of the cable. Wilcoxon R6W and R6QI type connectors leave the shield unconnected at the sensor end of the cable.