Table of Contents F1

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PRODUCT FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F2 TO F3 APPLICATION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F4, TO F5 HORSEPOWER RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F6 TO F12 THERMAL HORSEPOWER RATIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F13 ACTUAL RATIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F14 RATIO COMBINATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F15 OVERHUNG LOAD CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F16 TO F17 THRUST LOAD RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F18 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F19 TO F26 DETAILS OF DRYWELL CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F27

F

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F2 Worm Gear Reducers

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Application Information F3

See Page F27 for details on drywell construction for vertical reducers

F

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F4 Reducer Application Information RATING TABLES Foote-Jones reducers are designed in accordance with applicable AGMA stands. Over 100 years of experience and tens of thousands of units successfully operating in the field attest to the high industrial quality of Foote-Jones gear drives. Horsepower values listed are at input, torque values at output, and efficiences are shown. When the desired input speed falls between two catalog speeds, interpolate to determine unit rating. SERVICE FACTORS The published reducer ratings in this manual allow for infrequent 200% momentary overloads and starting loads. For more severe operating conditions, consult the AGMA application service factor tables on Pages F6 and F7. If the maximum applied power exceeds 3 times the catalog rating of the unit, divide the maximum power by 3, and with the result select a reducer with equal or greater rating. Vibratory and impact loads are not covered in the service factor table and are not covered in the warranty. Where brakes are used with prime movers, the brake torque may govern the reducer selection as it usually exceeds normal motor torque. Also see section K. THERMAL RATINGS The thermal horsepower rating is the reducer’s ability to transmit an actual load continuously without overheating. Normal operating temperature for a gear drive may be considered to be 100° F (55° C) rise over ambient, to a maximum of 200°F (93°C) oil sump temperature. In many cases the operating temperature may be lower, because gear ratio and loading affect the amount of friction and heat. A suitable temperature gauge should be used to determine overheating as normal operating temperature feels hot to the touch. When a reducer operates in sunlight, a canopy should be arranged to shade the unit so that solar energy does not cause the oil sump temperature to rise above 200°F (93°C). Overheating can cause deterioration of the lubricant and severe damage to the reducer. On applications where the cooling fan must be eliminated, consult factory for thermal rating of reducer without fan. OVERHUNG LOADS Overhung load and thrust capacities listed in this manual are based on the least favorable combined conditions of gear load, and direction of external radial load. If combined overhung and thrust loads are applied simultaneously, consult factory giving complete application details. Effective overhung load varies with the type of overhung member. Service factors must be applied to the actual load values using K factors and load location factors (LLF) for correct application. LLF-Load location factors are listed on Page F17. The center of the overhung load should be located as close to the shaft seal as possible to get the maximum bearing life.

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Formula for calculating Overhung Load OHL =

HP* x 63000 x K x LLF RPM x Pitch Radius

*Output HP = Motor HP x Reducer Efficiency Overhung Member Sprocket Spur Pinion V-Belt Sheave Flat Belt Pulley

K Factor 1.00 1.25 1.50 2.50

The calculated equivalent overhung load should not exceed the overhung load values included in the rating tables. If the overhung load on either the input or output shaft should exceed the listed permissible values, either: (a) increase the pitch radius of the overhung drive member; or (b) use a larger reducer; or (c) provide an outboard bearing. Overhung load ratings as shown in the tables are based on the load being applied at the midpoint of the keyway on a standard shaft extension. Careful analysis of the application is important in selecting the reducer size. Foote-Jones Hypower Reducers are designed for 5000 hours minimum L10 bearing life (25000 average hours). Overhung load capacities are calculated at the least favorable combination of rating, speed, rotation, and direction of applied load. If one or more of the above conditions is favorable, the L10 life and overhung load rating will increase. Additional bearing life may be expected of the full catalogued reducer rating is not used. In this case, to determine the absolute minimum L10 bearing life, divide the reducer rating by the transmitted horsepower to find the service factor and read the L10 life from the chart below. Service Factor 1.0 1.1 1.25 1.4 1.5 1.6

L10 Bearing Life 5000 6868 10512 15331 19291 24000

Service Factor 1.75 1.86 2.0 2.11 2.25 2.46

L10 Bearing Life 32232 40000 50281 60000 74428 100000

THRUST LOADS Some applications have external thrust loads imposed on the reducer bearings (see Page F18 for the thrust load capacities). Consult the factory for applications where both thrust loads and overhung loads are applied simultaneously. MOUNTING POSITION All gear reducers are designed to operate with the base mounted horizontally unless specified otherwise. Refer all other special mountings to your Foote-Jones Sales Representative. Modifications to the lubrication system and seals may be required.

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Reducer Application Information F5 EFFICIENCIES Since power transmission by worm gearing is accomplished by the worm thread rubbing on the worm gear tooth, worm gear drives are generally less efficient than helical gearing that transmits power by rolling action. Worm gear efficiency can be approximated as follows: Efficiency = 100 -

Ratio 2

Actual efficiencies are shown in the rating tables.

This treatment will provide adequate protection for normal periods during installation. It is recommended the units be protected during storage, and periodic inspection is recommended and retreatment applied, if necessary. Long Term Storage — for more detailed storage instructions, refer to the Maintenance Manual. LUBRICATION The satisfactory operation of Hypower Worm Gear Reducers is dependent on correct lubrication and treatment in full consideration of ambient conditions.

Higher worm lead angles and pitch line velocities result in higher efficiences. In some cases the efficiences of worm gearing and helical gearing can be extremely advantageous. Efficiency alone should not be the measure of gear selection

Ambient Temperature Range

OPERATIONAL CONSIDERATIONS

AGMA Lubricant # ASTM Viscosity Grade ISO Viscosity Grade Viscosity mm2/s Range @ cst 104°F SSU (40°C)

Foote-Jones reducers will perform satisfactorily for the rating specified on the Foote-Jones certified print and nameplate providing each is properly installed and operated within the speed and torque limits and other load and environmental conditions for which it was sold, and maintained in accordance with the Foote-Jones Maintenance Manuals. It is imperative that the drive SYSTEM be free from critical speeds, torsional and lateral vibratory loads within the operating speeds, torsional and lateral and lateral vibratory loads within the operating speed range, no matter how induced. Responsibility for the system analysis rests with the Buyer. Foote-Jones terms and conditions of sale shall supersede any catalog or sales bulletin data and will prevail in any dispute. ENVIRONMENT The standard reducer is designed to operate in a protected location with reasonable ventilation, free from temperature extremes (below —10°F or above 100°F for significant periods) or severe dust, toxic, explosive, or other unusual environments. Modifications such as special seals, heaters, heat exchangers, etc., could be required for these unusual conditions. Consult your Foote-Jones Sales Representative.

14° to 50° (-10° to +10°C) Normal Service 7

Heavy Duty Service

Compounded

7EP

50° to 122°F (10° to 50°C) Normal Heavy Duty Service Service 8 Compounded 8EP

S2150/C460

S3150/C680

460

680

414 to 506

612 to 748

1919 to 2346

2837 to 3467

LOW TEMPERATURE OPERATION CAUTION

When temperatures are below 14 degrees Fahrenheit (-10°C), please refer to the factory for recommendations giving ambient temperature expected and operating cycle. GREASE LUBRICATION - VERTICAL REDUCER

SAFETY

Grease lubricate the upper and lower output shaft bearings once a month at the grease fitting. A good grade of antifriction bearing grease or its equivalent should be used. It should have neutral and channeling characteristics with a consistency of NLGI #2. It should not be subject to excessive bleeding or deterioration.

It is the purchaser’s responsibility to determine the applicable local and national safety codes related to speed reducers for the specific installation involved. Shaft guarding and noise level requirements particularly should be checked, and any requirements involving the reducer clearly specified.

WARNING In the food (including animal food) and drug industry, consult the petroleum supplier for recommendation of lubricants which are acceptable to the Food and Drug Administration and/or other authoritative bodies having jurisdiction.

Applications involving transportation of people, such as passenger or freight elevators, man lifts, escalators, ski lifts or ski tows must be referred to the factory with full application data.

For more information on lubrication, refer to maintenance manual.

STORAGE All units are coated with a rust-inhibiting oil during the shop test, and shaft extensions are coated with a dry-film preservative.

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F6 Horsepower Ratings

RATINGS IN SHADED AREAS EXCEED THERMAL RATINGS. REFER TO PAGE F13 FOR THERMAL LIMITATIONS.

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Horsepower Ratings F7

RATINGS IN SHADED AREAS EXCEED THERMAL RATINGS. REFER TO PAGE F13 FOR THERMAL LIMITATIONS.

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F8 Horsepower Ratings

RATINGS IN SHADED AREAS EXCEED THERMAL RATINGS. REFER TO PAGE F13 FOR THERMAL LIMITATIONS.

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Horsepower Ratings F9

F RATINGS IN SHADED AREAS EXCEED THERMAL RATINGS. REFER TO PAGE F13 FOR THERMAL LIMITATIONS.

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F10 Horsepower Ratings

RATINGS IN SHADED AREAS EXCEED THERMAL RATINGS. REFER TO PAGE F13 FOR THERMAL LIMITATIONS.

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Horsepower Ratings F11

F

RATINGS IN SHADED AREAS EXCEED THERMAL RATINGS. REFER TO PAGE F13 FOR THERMAL LIMITATIONS.

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F12 Horsepower Ratings

RATINGS IN SHADED AREAS EXCEED THERMAL RATINGS. REFER TO PAGE F13 FOR THERMAL LIMITATIONS.

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Thermal Horsepower Ratings F13

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F14 Actual Ratios

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Ratio Combinations F15

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F16 Overhung Load Capacities - Output Shaft

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Overhung Load Capacities - Input Shaft F17

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F18 Thrust Load Ratings

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Horizontal Gear Reducer Dimensions F19

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F20 Horizontal Gear Reducer Dimensions

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Vertical Gear Reducer Dimensions F21

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F22 Horizontal Gear Reducer Dimensions

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Vertical Gear Reducer Dimensions F23

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F24 Vertical Gear Reducer Dimensions

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Horizontal Gear Reducer Dimensions F25

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F26 Vertical Gear Reducer Dimensions

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Dry Well Construction Type V-Vertical Gear Reducers F27 TYPES V, HV AND DV

The Vertical configuration of HYPOWER worm gear units, sizes 40 through 120, has a dry well construction to provide positive protection against leakage down the output shaft.

F Notice that the low speed bearing retainer (A) extends upward from the bottom of the reducer housing into the disc-shaped center plate of the worm gear (B). This retainer and the housing wall (C) form the oil reservoir for the reducer. The worm bearings and the gear mesh are properly lubricated from this oil reservior.

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The lower worm gear shaft bearing (D) is not lubricated by the oil bath, but by grease lubrication supplied from an external grease fitting (E). By doing so, the worm gear shaft is not subjected to a pressure head of liquid lubricant and the possibility of leaking down this shaft is eliminated.

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F28 Notes

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