IronHorse® Worm Gearbox User Manual
Contents
1. 3rd Edition 10 24 2014 IronHorse Worm Gearbox User Manual 5 Chapter 4 Installation and Lubrication Ei 6 IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 GLOSSARY OF TERMS In This Appendix Glossary of Gearbox Terms PENDIX Appendix A Glossary of Terms jg _ Glossary of Gearbox Terms Axial Movement Often called endplay The endwise movement of motor or gear shafts Usually expressed in thousandths of an inch Back Driving Driving the output shaft of a gearbox to increase speed rather than reduce speed Worm gearboxes are not suitable for service to increase speed Backlash Rotational movement of the output shaft clockwise and counter clockwise while holding the input shaft stationary Usually expressed in thousandths of an inch and measured at a specific radius at the output shaft Center Distance A basic measurement or size reference for worm gearboxes The distance between the centerlines of the input and output shafts Efficiency A ratio of the input power compared to the output power usually expressed as a percentage Flanged Reducer Usually used to refer to a gearbox ha2. 4 Overhung Load ratings are for forces perpendicular to the output shaft and located at the shaft midpoint such as from gear pulley or sprocket with a belt or chain Divide OHL ratings by the applicable OHL K factors shown separately in the Selection Factors tables OHL ratings should also be divided by applicable service factors 5 Maximum Mechanical Ratings are limits based on strength and durability of gearbox components applicable when operaling time is short and stopped time is greater than or equal to operating time These ratings are applicable for 1 0 service factor loads and may require modification depending upon characteristics of the applicable driven loads Refer to the Service Factors table for more information 3 H IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 Chapter 3 Aluminum Worm Gearboxes IronHorse Aluminum Worm Gearbox Dimensions G Part Number A c H G La T Output Bore Input Shaft L M WGA 30M xxx H1 WGA 40M xxx H1 WGA 50M xxx H1 WGA 63M xxx H1 3 82 248 3 15 2 24 1 57 1 18 2 89 1 57 4 78 3 07 3 94 2 81 1 97 1 57 3 18 1 97 5 67
3. IronHorse Worm Gearbox Introduction Purpose of Worm Gearboxes Gearboxes also known as enclosed gear drives or speed reducers are mechanical drive components that can control a load at a reduced fixed ratio of the motor speed The output torque is also increased by the same ratio while the horsepower remains the same less efficiency losses For example a 10 1 ratio gearbox outputs approximately the same motor output horsepower but motor speed is divided by 10 and motor torque is multiplied by 10 Worm gearboxes contain a worm type gear on the input shaft and a spur type mating gear on the output shaft Worm gearboxes also change the drive direction by 90 degrees IronHorse worm gearboxes are manufactured in ISO9001 certified plant by one of the leading and most internationally acclaimed gearbox manufacturers in the world today Only the highest quality materials are tested certified and used in the manufacturing process Strict adherence to and compliance with the toughest international and U S testing standards and manufacturing procedures assure you the highest quality products We offer right angle worm gearboxes with aluminum frames and with cast iron frames The output shafts are perpendicular to the inputs and change the drive direction s by 90 Our gearboxes utilize C face mounting interfaces for C face motors Our cast iron gearboxes feature right hand and dual both right and left output shafts and with ho
4. 4 5 Appendix A Glossary of Terms A 1 Glossary of Gearbox Terms A 2 Appendix B Gearbox Selection B 1 Gearbox Selection Procedure B 2 Gearbox Selection Steps B 2 Gearbox Selection Example u u iucundo hoe attentats EMA B 2 ii IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 GETTING STARTED In This Chapter Manual OvervieW isses Coe 66099 104 0 oe doo DENS OU OME 1 2 Overview of This Publication 1 2 Who Should Read This Manual 1 2 Technical Support se 24er 2 du aar rr a a hr d b bd E E E 1 2 Special Symbols kak l n a ala lala arat S A 1 2 IronHorse Worm Gearbox Introduction 1 3 Purpose of Worm Gearboxes 1 3 Package Contents ck sso si 1 3 Part Number Explanation 1 4 Nameplate Information 1 4 Chapter 1 Getting Started _ _ Manual Overview Overview of This Publication The IronHo
5. 2 2 IronHorse Cast Iron Worm Gearbox Specifications 2 3 IronHorse Cast Iron Worm Gearbox Dimensions 2 7 Solid Shaft Output Gearboxes WG xxx xxx D R 2 7 Hollow Bore Output Gearboxes WG xxx xxx H 2 8 IronHorse Cast Iron Worm Gearbox Accessory Mounting Bases 2 9 10 24 2014 3rd Edition IronHorse Worm Gearbox User Manual 1 Table of Contents E Chapter 3 Aluminum Worm Gearboxes 3 1 Gearbox Selection Factors 3 2 Service Factors and K Factors uu ese ere REA e n ra da 3 2 IronHorse Aluminum Worm Gearbox Specifications 3 3 IronHorse Aluminum Worm Gearbox Dimensions 3 5 IronHorse Aluminum Worm Gearbox Accessories 3 6 Chapter 4 Installation and Lubrication 4 1 IronHorse Worm Gearbox Installation 4 2 Installation Instructions 4 2 Vent Plug Installation Cast Iron Gearboxes only 4 3 IronHorse Worm Gearbox Lubrication amp Mounting Orientations 4 4 Lubrication Instructions da d k w n y d Qa 4 4 Lubricant Capacities amp Mounting Orientations
6. 3rd Edition 10 24 2014 Chapter 2 Cast Iron Worm Gearboxes IronHorse Cast Iron Worm Gearbox Accessory Mounting Bases Mounting Base Selection and Dimensions IronHorse Worm Gearbox Mounting Bases Part Number Fits Gearbox Numbers Approx Weight Ib Dimensions in E F WG 175 BASE WG 175 xxx x 4 0 5 69 7 00 WG 206 BASE WG 206 xxx x 4 8 5 91 7 76 WG 237 BASE W6G 237 xxx x 6 2 6 22 8 50 WG 262 BASE 10 24 2014 3rd Edition WG 262 xxx x 4 d1 6 69 9 65 k IronHorse Worm Gearbox User Manual 2 9 Chapter 2 Cast Iron Worm Gearboxes 56 2 1 0 IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 ALUMINUM WoRM GEARBOXES In This Chapter Gearbox Selection Factors 3 2 Service Factors and Factors 3 2 Aluminum Worm Gearbox Specifications 3 3 IronHorse Aluminum Worm Gearbox Dimensions 3 5 5 Aluminum Worm Gearbox Accessories 3 6 Chapter 3 Aluminum Worm Gearboxes Gearbox Selection Factors
7. shaft and located at the shaft midpoint such as from a gear pulley or sprocket with a belt or chain Divide OHL ratings by the applicable OHL K factors shown separately in the Selection Factors tables OHL ratings should also be divided by applicable service factors 5 Thrust Load ratings are for forces along the axis of the output shaft usually encountered in vertical drive applications from agitators mixers fans blowers etc 6 Maximum Mechanical Ratings are limits based on strength and durability of gearbox components applicable when operating time is short and stopped time is greater than or equal to operating time These ratings are applicable for 1 0 service factor loads and may require modification depending upon characteristics of the applicable driven loads Refer to the Service Factors table for more information 7 Maximum Thermal Ratings are limits for gearbox continuous use without overheating 10 24 2014 3rd Edition IronHorse Worm Gearbox User Manual 2 5 Chapter 2 Cast Iron Worm Gearboxes IronHorse Cast Iron Worm Gearbox Specifications continued IronHorse Cast Iron Worm Gearbox Specifications Frame Size 262 Maximum Ratings 1750 rpm Input Mechanical 6 Thermal 7 Output RPM 1750 rpm Input Maximum Input Speed rpm Nominal Motor HP 1800 rpm NEMA Motor Frame Center Distance 3 in Overhung Load Ib Thrust
8. Service Factors and K Factors Service Factors for Selecting Gearboxes when used with electric motors Load Characteristics Service Continuity per day Uniform Moderate Heavy Extreme Shock Shock Shock Occasional 1 2 hour 1 00 1 00 1 00 1 25 Overhung Load K Factors Less than 3 hours 1 00 1 00 1 25 1 50 for Various Drive Types 3 10 hours 1 00 1 25 1 50 175 Chain amp Sprocket 1 00 More than 10 hours 1 25 1 50 1 75 2 00 Gear 1 25 Shock results from sudden increases in the torque demand of the load such as V belt 1 50 sudden stopping restarting and or reversing significantly heavy loads dropped Flat Belt 2 50 onto a moving conveyor impact loads such as punch press operations Variable Pitch Belt 3 50 Depending upon the load characteristics divide the gearbox HP Overhung Load Divide gearbox OHL ratings by and Maximum Mechanical Capacity ratings by the applicable service factor the applicable OHL K factors 3 2 IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 Chapter 3 Aluminum Worm Gearboxes IronHorse Aluminum Worm Gearbox Specifications IronHorse Aluminum Worm Gearbox Specifications Frame Sizes 30 40 50 mm Maximum Ratings 1750 rpm Input Mechanical 5 Part Number Output RPM 1750 rpm Input Nominal
9. Shock results from sudden increases in the torque demand of the load such as V belt 1 50 sudden stopping restarting and or reversing significantly heavy loads dropped Flat Belt 2 50 onto a moving conveyor impact loads such as punch press operations Variable Pitch Belt 3 50 Depending upon the load characteristics divide the gearbox HP Overhung Load Divide gearbox OHL ratings by and Maximum Mechanical Capacity ratings by the applicable service factor the applicable OHL K factors 2 2 IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 Chapter 2 Cast Iron Worm Gearboxes E Kil IronHorse Cast Iron Worm Gearbox Specifications IronHorse Cast Iron Worm Gearbox Specifications Frame Size 175 Maximum Ratings 1750 rpm Input Thermal 7 m n z 5 n 2 o Part Number Output RPM 1750 rpm Input Nominal Motor HP 1800 rpm NEMA Motor Frame Center Distance 3 in Overhung Load Ib Thrust Load 5 Ib Efficiency 96 Approx Weight Ib Input Power hp Output Power hp Output Torque Ib in Input Power hp Output Power hp Output Torque Ib in Maximum Input Speed rpm WG 175 005 D WG 175 005 H WG 175 005 R WG 175 010 D WG 175 010 H WG 175 010 R WG 175 015 D WG 175 015 H WG 175 015 R WG 175 020 D WG 175 020 H WG 175 020 R WG 175 040 D WG 175 040 H WG 175 040 R WG 175 06
10. 3 62 4 72 3 31 2 36 1 97 3 58 2 36 6 87 4 42 5 69 4 00 2 87 2 48 4 06 2 84 WGA 63M xxx H2 145TC 6 87 442 5 69 4 00 2 87 248 4 06 2 84 WGA 75M xxx H1 56C 8 07 4 72 6 77 4 69 3 39 2 95 4 68 3 39 WGA 75M xxx H2 145TC 8 07 4 72 6 77 4 69 3 39 2 95 4 68 3 39 WGA 75M xxx H3 182 4TC 8 07 4 72 6 77 4 69 3 39 2 95 4 68 3 39 See our website www AutomationDirect com for complete Engineering drawings 3rd Edition 10 24 2014 IronHorse Worm Gearbox User Manual 3 5 Chapter 3 Aluminum Worm Gearboxes _ _ IronHorse Aluminum Worm Gearbox Accessories IronHorse Aluminum Worm Gearbox Accessories Part Number Description Typical Photo WGA 30M ACC1 Output flange for aluminum WGA 30M series gearboxes Includes 4 mounting screws WGA 40M ACC1 Output flange for aluminum WGA 40M series gearboxes Includes 4 mounting screws WGA 50M ACC1 Output flange for aluminum WGA 50M series gearboxes Includes 4 mounting screws WGA 63M ACC1 Output flange for aluminum WGA 63M series gearboxes Includes 8 mounting screws WGA 75M ACC1 Output flange for aluminum WGA 75M series gearboxes Includes 8 mounting screws WGA 30M ACC2 Torque arm for aluminum WGA 30M series gearboxes Include
11. WGA 63M 020 H2 WGA 63M 030 H1 WGA 63M 040 H1 WGA 63M 060 H1 WGA 63M 080 H1 WGA 63M 100 H1 WGA 75M 010 H1 10 1 175 56C 604 WGA 75M 010 H2 10 1 175 145TC 604 WGA 75M 010 H3 10 1 175 182 41C 604 WGA 75M 020 H1 20 1 88 56C 759 WGA 75M 020 H2 20 1 88 145TC 759 WGA 75M 030 H1 30 1 58 56C 873 WGA 75M 040 H1 40 1 44 56C 957 WGA 75M 060 H1 60 1 29 56C 1099 1 206 0 78 WGA 75M 080 H1 80 1 22 0 75 56C 1205 0 97 0 56 WGA 75M 100 H1 100 1 18 0 75 56C 1289 52 0 80 0 2 1 Nominal Motor HP is the highest HP 1800 rpm motor to be used with the gearbox under conditions of 1 0 service factor Gearbox input power capacity decreases as motor speed decreases and as service factor increases 2 Output Type Hollow Bore 3 The Center Distance is the distance between the centerlines of the input and output shafts bores serves as the gearbox frame size M 3 16 3 16 1 63 2 04 1 63 176 128 1 26 0 88 0 86 0 51 0 67 0 36 0 57 027 5 44 4 68 5 44 4 68 5 44 4 68 3 14 248 3 14 248 248 179 1 88 1 28 Overhung Load 4 Ib S S Efficiency 96 N wy w h 25 a Input Power hp w w 95 A A gt N N N w co go gt Ov a M M N N
12. Worm gear aluminum frame Nameplate Information WG Cast Iron Gearbox 2 PE EN posee RSE VW AUTOMATIONDIRECT COM MFG NO Mele Ten Gearbox Model Country of Origin Gearbox Serial i Gearbox Frame Size center distance WGA Aluminum Gearbox ALUM INUM Gearbox Type GEAR REDUCER Gearbox Ratio TYPE Gearbox Frame Size RATIO center distance BOX SIZE 30 5 Gearbox Model MODEL 3 Country Origin Gearbox Serial SERIAL gt 1 H IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 CAST IRON WoRM GEARBOXES In This Chapter Gearbox Selection Factors 2 2 Cast Iron Worm Gearbox Specifications 2 3 5 Cast Iron Worm Gearbox Dimensions 2 7 5 Cast Iron Worm Gearbox Accessory Mounting Bases 2 9 Chapter 2 Cast Iron Worm Gearboxes Gearbox Selection Factors Service Factors and K Factors Service Factors for Selecting Gearboxes when used with electric motors E e Load Characteristics Service Continuity per day Uniform Moderate Heavy Extreme Shock Shock Shock Occasional 1 2 hour 1 00 1 00 1 00 1 25 Overhung Load K Factors Less than 3 hours 1 00 1 00 125 1 50 for Various Drive Types 3 10 hours 1 00 1 25 1 50 1 75 Chain amp Sprocket 1 00 More than 10 hours 1 25 1 50 1 75 2 00 Gear 1 25
13. 015 x gearbox 2 5 gearbox pulley and 14 4 conveyor pulley For 20 1 WG 206 020 x gearbox N A All gearboxes of the same frame size are the same price yet the smaller ratio gearboxes offer higher efficiency and power characteristics than higher ratio gearboxes Therefore the WG 206 015 x gearbox is preferable over the WG 206 020 x gearbox for this application For 30 1 WGA 63M 030 H1 gearbox Minimum gearbox pulley diameter 937 50 in Ib 1 5 1 25 2 736 Ib 4 78 use 5 Conveyor pulley diameter 5 2 88 14 40 use 14 4 N A WGA 63M gearbox costs more than WG 206 3rd Edition 10 24 2014 IronHorse Worm Gearbox User Manual B 3 Appendix B Gearbox Selection ih hh Z j w l z l l li i E _ zj j z h222 ZzZnHLLe 8 Check results against original speed and torque requirements a Conveyor speed motor speed gearbox ratio pulley ratio 1725 rpm 15 14 4 2 5 20 rpm b Maximum real torque available at conveyor gearbox thermal torque pulley ratio 673 in Ib 14 4 2 5 3876 in b c Maximum design torque available at conveyor gearbox mechanical torque pulley ratio service factor 1002 inb 14 4 2 5 1 25 4617 in Ib The speed is correct as required and both maximum torque values are greater than the 2700 in lb required by the load 9 Select a motor and check torque transmitted to the loa
14. Load 5 Ib Approx Weight Ib Input Power hp Output Power hp Output Torque Ib in Input Power hp Output Power hp Output Torque Ib in Efficiency 96 WG 262 005 D WG 262 005 H WG 262 005 R WG 262 010 D WG 262 010 H WG 262 010 R WG 262 015 D WG 262 015 H WG 262 015 R WG 262 020 D WG 262 020 H WG 262 020 R WG 262 040 D WG 262 040 H WG 262 040 R WG 262 060 D WG 262 060 H 0 94 WG 262 060 R 1 Nominal Motor HP is the highest HP 1800 rpm motor to be used with the gearbox under conditions of 1 0 service factor Gearbox input power capacity decreases as motor speed decreases and as service factor increases 2 Output Type D Dual Shaft Hollow Bore Right Hand Shaft 3 The Center Distance is the distance between the centerlines of the input and output shafts bores serves as the gearbox frame size s gt gt output Type 4 0verhung Load ratings are for forces perpendicular to the output shaft and located at the shaft midpoint such as from a gear pulley or sprocket with a belt or chain Divide OHL ratings by the applicable OHL K factors shown separately in the Selection Factors lables OHL ratings should also be divided by applicable service factors 5 Thrust Load ratings are for forces along the axis of the output shaft usually encountered in vertical drive applications from agitators mixers fan
15. Motor HP 1 1800 rpm NEMA Motor Frame Center Distance mm Overhung Load Ib Approx Weight Ib Output Torque Ib in Maximum Input Speed rpm Output Type 2 Input Power hp WGA 30M 010 H1 WGA 30M 020 H1 WGA 30M 030 H1 WGA 30M 040 H1 WGA 30M 060 H1 WGA 40M 010 H1 WGA 40M 020 H1 WGA 40M 030 H1 WGA 40M 040 H1 WGA 40M 060 H1 WGA 40M 080 H1 WGA 40M 100 H1 WGA 50M 010 H1 10 1 WGA 50M 020 H1 20 88 WGA 50M 030 H1 30 1 58 0 75 WGA 50M 040 H1 40 44 0 75 WGA 50M 060 H1 60 1 29 0 33 0 46 0 26 WGA 50M 080 H1 80 22 0 33 0 38 0 19 WGA 50M 100 H1 100 1 17 5 0 25 46 0 28 0 13 N gt e Output Power hp S NI amp Efficiency 96 0 16 0 19 0 10 0 12 0 06 1 15 0 95 0 61 048 0 53 0 36 0 39 025 0 25 0 14 0 19 0 10 0 15 0 07 2 06 173 1 13 0 88 0 95 0 67 0 70 0 46 gt gt SN o gt gt be o N 1 Nominal Motor HP is the highest HP 1800 rpm motor to be used with the gearbox under conditions of 1 0 service factor Gearbox input power capacity decreases as motor speed decreases and as service factor increases 2 Output Type Hollow Bore 3 The Center Di
16. WGA 50M series gearboxes EORUM Includes 4 keys 2 spacers and 2 retaining rings Double output shaft 01 125 in for aluminum WGA 63M series gearboxes SCELUS TE Includes 4 keys 2 spacers and 2 retaining rings Double output shaft 01 25 in for aluminum WGA 75M series gearboxes Includes 4 keys 2 spacers and 2 retaining rings WGA 75M ACC4 WGA 30M ACC5 Output cover for aluminum WGA 30M series gearboxes Includes 4 mounting screws 40 5 Output cover for aluminum WGA 40M series gearboxes Includes 4 mounting screws WGA 50M ACCS5 Output cover for aluminum WGA 50M series gearboxes Includes 4 mounting screws WGA 63M ACC5 Output cover for aluminum WGA 63M series gearboxes Includes 4 mounting screws WGA 75M ACC5 Output cover for aluminum WGA 75M series gearboxes Includes 4 mounting screws 3 IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 NSTALLATION AND LUBRICATION In This Chapter Worm Gearbox Installation 4 2 Installation Instructions 4 2 Vent Plug Installation Cast Iron Gearboxes only 4 3 Worm Gearbox Lubrication amp Mounting Orientations 4 4 Lubrication Instructions 4 4 Lubricant Capacities am
17. a rigid foundation and use the maximum possible bolt size Periodically inspect the mounting bolts Do NOT mount gearbox vertically with input shaft pointing downward Refer to the lubrication section of this chapter for allowable mounting orientations Optional gearbox and motor mounting bases are available for ease of mounting and alignment Mount auxiliary drive components such as sprockets gears and pulleys on the gearbox shaft as close to the housing as possible in order to minimize the effects of overhung loads Avoid force fits that might damage bearings or gears Check and record gear backlash at installation and again at regular intervals This should be done by measuring the rotary movement of the output shaft rotating the shaft alternately clockwise and counterclockwise at a suitable radius while holding the input shaft stationary The gearbox should be replaced when the backlash exceeds four times the measurement taken at installation Gear drives are rated for 1750 input rpm and Class I Service Service Factor 1 0 using Mobil 634 synthetic lubricant Initial operating temperatures may be higher than normal during the break in period of the gear set For maximum life DO NOT ALLOW THE GEARBOX TO OPERATE CONTINUOUSLY ABOVE 225 at the gear case In the event of overheating check for overloads or high ambient temperatures Keep shafts and vent plugs clean to prevent foreign particles from entering seals or gear h
18. and or offered by other companies The product and company names may be trademarked and are the sole property of their respective owners AutomationDirect disclaims any proprietary interest in the marks and names of others Copyright 2008 2009 2014 Automationdirect com Incorporated All Rights Reserved No part of this manual shall be copied reproduced or transmitted in any way without the prior written consent of Automationdirect com Incorporated AutomationDirect retains the exclusive rights to all information included in this document 3rd Edition 10 24 2014 IronHorse Worm Gearbox User Manual W 1 AVERTISSEMENT Nous vous remercions d avoir achet l quipement d automatisation de Automationdirect com en faisant des affaires comme AutomationDirect Nous tenons ce que votre nouvel quipement d automatisation fonctionne en toute s curit Toute personne qui installe ou utilise cet quipement doit lire la pr sente publication et toutes les autres publications pertinentes avant de l installer ou de l utiliser de r duire au minimum le risque d ventuels probl mes de s curit vous devez respecter tous les codes locaux et nationaux applicables r gissant l installation et le fonctionnement de votre quipement Ces codes different d une r gion l autre et habituellement voluent au fil du temps Il vous incombe de d terminer les codes respecter et de vous assurer que l quipement
19. are suitable for your particular application nor do we assume any responsibility for your product design installation or operation Our products are not fault tolerant and are not designed manufactured or intended for use or resale as on line control equipment in hazardous environments requiring fail safe performance such as in the operation of nuclear facilities aircraft navigation or communication systems air traffic control direct life support machines or weapons systems in which the failure of the product could lead directly to death personal injury or severe physical or environmental damage High Risk Activities AutomationDirect specifically disclaims any expressed or implied warranty of fitness for High Risk Activities For additional warranty and safety information see the Terms and Conditions section of our catalog If you have any questions concerning the installation or operation of this equipment or if you need additional information please call us at 770 844 4200 This publication is based on information that was available at the time it was printed At AutomationDirect we constantly strive to improve our products and services so we reserve the right to make changes to the products and or publications at any time without notice and without any obligation This publication may also discuss features that may not be available in certain revisions of the product This publication may contain references to products produced
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21. with special characteristics and a relatively high viscosity is required due to sliding action between the gear teeth where they mesh Aside from improper gearbox selection inadequate lubrication is the greatest factor contributing to premature worm gearbox failures Improper lubrication also causes reduced gearbox performance Lubrication Instructions IronHorse Worm Gearboxes are shipped to you filled with Mobil SHC634 synthetic oil Oil must be added or partially drained depending upon your mounting orientation as shown in the Lubricant Capacities table Since many oils are not suitable for worm gears it is very important to use the proper lubricant type Itis also very important to keep the oil free from oxidation and contamination by water or debris For longer service life the gearbox should be periodically drained preferably while warm and refilled to the proper level with a recommended gear oil Non synthetic oils should be changed every 6 months or 250 hours of operation under normal operating conditions However synthetic lubricants have increased resistance to thermal and oxidation degradation and do not need to be changed as frequently Synthetic lubricant should be changed every 6 000 hours of operation or every two years which ever comes first WARNING Some lubricants contain non corrosive extreme pressure additives DO NOT USE lubricants that contain sulphur and or chlorine which are corrosive to bronze gears Also some
22. 0 D WG 175 060 H WG 175 060 R 1 Nominal Motor HP is the highest HP 1800 rpm motor to be used with the gearbox under conditions of 1 0 service factor Gearbox input power capacity decreases as motor speed decreases and as service factor increases 2 Output Type D Dual Shaft Hollow Bore Right Hand Shaft 3 The Center Distance is the distance between the centerlines of the input and output shafts bores serves as the gearbox frame size N o s gt Output Type 2 4 Overhung Load ratings are for forces perpendicular to the output shaft and located at the shaft midpoint such as from a gear pulley or sprocket with a belt or chain Divide OHL ratings by the applicable OHL K factors shown separately in the Selection Factors tables OHL ratings should also be divided by applicable service factors 5 Thrust Load ratings are for forces along the axis of the output shaft usually encountered in vertical drive applications from agitators mixers fans blowers etc 6 Maximum Mechanical Ratings are limits based on strength and durability of gearbox components applicable when operating time is short and stopped time is greater than or equal to operating time These ratings are applicable for 1 0 service factor loads and may require modification depending upon characteristics of the applicable driven loads Refer to the Servi
23. 62 010 D R WG 262 015 D R WG 262 020 D R WG 262 040 D R WG 262 060 D R Dual shaft output gearboxes have B BB L1 S N amp Y dimensions on both sides Right hand shaft gearboxes have output shafts only on the right side as viewed looking into the input shaft 10 24 2014 3rd Edition IronHorse Worm Gearbox User Manual 2 1 Chapter 2 Cast Iron Worm Gearboxes Cast Iron Worm Gearbox Dimensions continued Hollow Bore Output Gearboxes WG xxx xxx H m A gt AB 2x4 Z Y i JIN 1 U ji m O H 7 vi 1 N i d 2 Qs q lo T 1 Y it iH T Output Shaft View BE F 2 EM PN BD F lt gt BB BB AC i ty Rear View Left View e w 7 UNC WG 175 xxx H 5 16 18 WG 206 xxx H WG 237 xxx H WG 262 005 H WG 262 010 H WG 262 015 H WG 262 020 H WG 262 040 H WG 262 060 H Part Number Output Bore T U 1 0 1 4 WG 262 005 H WG 262 010 H WG 262 015 H WG 262 020 H WG 262 040 H WG 262 060 H 2 8 IronHorse Worm Gearbox User Manual
24. Edition 10 24 2014 IRONHORSE Worm GEARBOX USER MANUAL TABLE OF CONTENTS IronHorse Worm Gearbox User Manual Contents WARNING saa ak aa aa a eG al sede l l l l la W 1 Trademarks Mistral see eee a ta et states W 1 AVERTISSEMENT iir kl ki alal xl ki alal xalk RR RR eee a ACA RR a al W 2 Marques de commerce se PERKE a oi W 2 User Manual Publication History H 1 Chapter 1 Getting Started 1 1 Manual Overview E Ea n piece n 1 2 Overview of This Publication 1 2 Who Should Read This Manual 1 2 Technical Support 25 42 sun asqa aa K TEE dy uba 1 2 Special SYMPOISE 22242524 ne see SR ANAM RSENS 1 2 IronHorse Worm Gearbox Introduction 1 3 Purpose of Worm Gearboxes 1 3 Package Contents 55 an am aaa 1 3 Part Number Explanation ER rennes 1 4 Nameplate Information 1 4 Chapter 2 Cast Iron Worm Gearboxes 2 1 Gearbox Selection Factors 2 2 Service Factors and Factors
25. Ib none applicable Aluminum gearboxes do not have thermal ratings use mechanical ratings 6 Use specifications table to select gearbox with Max Mechanical Torque rating required design torque Gearbox required design torque real gearbox torque service factor For 10 1 gearbox 312 86 in Ib 1 25 391 08 in Ib use WG 175 x or larger For 15 1 gearbox 469 57 in Ib 1 25 586 96 in Ib use WG 206 x or larger For 20 1 gearbox 646 45 in Ib 1 25 808 06 in Ib use WG 206 x or larger For 30 1 gearbox 937 50 in Ib 1 25 1178 88 in lb use WGA 63M or larger 7 Use the gearbox overhung load ratings from the specifications table to determine the minimum allowable pulley diameters Select gearbox with Overhung Load rating overhung load force Gearbox required OHL rating gearbox real torque K SF gearbox pulley diameter 2 Minimum gearbox pulley diameter T K SF 2 OHL rating Conveyor pulley diameter gearbox pulley diameter pulley ratio For 10 1 WG 175 010 x gearbox Minimum gearbox pulley diameter 312 86 in Ib 1 5 1 25 2 650 Ib 1 8 use 2 Conveyor pulley diameter 2 8 63 726 17 26 pulley size is prohibitively large Determine pulley sizes and OHL for next larger gearbox ratio For 15 1 WG 206 015 x gearbox Minimum gearbox pulley diameter 469 57 in Ib 1 5 1 25 2 700 Ib 2 5 use 2 5 Conveyor pulley diameter 2 5 5 75 14 38 use 14 4 Select WG 206
26. WAUTOMATIONDIRECT IronHorse Worm Gearbox User Manual IH WG USER M WO 3rd Edition IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 Thank you for purchasing automation equipment from Automationdirect com doing business as AutomationDirect We want your new automation equipment to operate safely Anyone who installs or uses this equipment should read this publication and any other relevant publications before installing or operating the equipment To minimize the risk of potential safety problems you should follow all applicable local and national codes that regulate the installation and operation of your equipment These codes vary from area to area and usually change with time It is your responsibility to determine which codes should be followed and to verify that the equipment installation and operation is in compliance with the latest revision of these codes At a minimum you should follow all applicable sections of the National Fire Code National Electrical Code and the codes of the National Electrical Manufacturer s Association NEMA There may be local regulatory or government offices that can also help determine which codes and standards are necessary for safe installation and operation Equipment damage or serious injury to personnel can result from the failure to follow all applicable codes and standards We do not guarantee the products described in this publication
27. box frame size 9 s gt Output Type 2 4 0verhung Load ratings are for forces perpendicular to the output shaft and located at the shaft midpoint such as from a gear pulley or sprocket with a belt or chain Divide OHL ratings by the applicable OHL K factors shown separately in the Selection Factors tables OHL ratings should also be divided by applicable service factors 5 Thrust Load ratings are for forces along the axis of the output shaft usually encountered in vertical drive applications from agitators mixers fans blowers etc 6 Maximum Mechanical Ratings are limits based on strength and durability of gearbox components applicable when operating time is short and stopped time is greater than or equal to operating time These ratings are applicable for 1 0 service factor loads and may require modification depending upon characteristics of the applicable driven loads Refer to the Service Factors table for more information 7 Maximum Thermal Ratings are limits for gearbox continuous use without overheating 2 H IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 Chapter 2 Cast Iron Worm Gearboxes IronHorse Cast Iron Worm Gearbox Specifications continued IronHorse Cast Iron Worm Gearbox Specifications Frame Size 237 Maximum Ratings 1750 rpm Input Mechanical 6 Th
28. box s ability to dissipate the heat caused by friction Not applicable for aluminum frame gearboxes due to their inherently better ability to dissipate heat Thrust Load Forces along the axis of the output shaft usually encountered in vertical drive applications Worm Gear A set of threads similar to a thread screw that advance as they rotate around their axis The advancing threads cause the mating gear to turn and also slide against the gear teeth 3rd Edition 10 24 2014 IronHorse Worm Gearbox User Manual 3 Appendix A Glossary of Terms j gt A 4 IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 PENDIX GEARBOX SELECTION In This Appendix Gearbox Selection Procedure B 2 Gearbox Selection B 2 Gearbox Selection Example Appendix B Gearbox Selection ga Gearbox Selection Procedure Gearbox Selection Steps 1 Determine the torque and speed required for the load 2 Determine the overall speed ratio of motor speed to load speed 3 Determine the gearbox ratio as well as any reduction outside the gearbox pulleys gears etc 4 Determine the applicable service factor and overhung load K factor 5 Determine the gearbox real output torque requi
29. ce Factors table for more information 7 Maximum Thermal Ratings are limits for gearbox continuous use without overheating 10 24 2014 3rd Edition IronHorse Worm Gearbox User Manual 2 3 Chapter 2 Cast Iron Worm Gearboxes IronHorse Cast Iron Worm Gearbox Specifications continued IronHorse Cast Iron Worm Gearbox Specifications Frame Size 206 Maximum Ratings 1750 rpm Input Mechanical 6 Thermal 7 Part Number Output RPM 1750 rpm Input Nominal Motor HP 1 1800 rpm NEMA Motor Frame Center Distance 3 in Overhung Load Ib Thrust Load 5 Ib Approx Weight Ib Input Power hp Output Power hp Output Torque Ib in Input Power hp Output Power hp Output Torque Ib in Maximum Input Speed rpm Efficiency 96 WG 206 005 D WG 206 005 H WG 206 005 R WG 206 010 D WG 206 010 H WG 206 010 R WG 206 015 D WG 206 015 H WG 206 015 R WG 206 020 D WG 206 020 H WG 206 020 R WG 206 040 D WG 206 040 H WG 206 040 R WG 206 060 D WG 206 060 H WG 206 060 R 1 Nominal Motor HP is the highest HP 1800 rpm motor to be used with the gearbox under conditions of 1 0 service factor Gearbox input power capacity decreases as motor speed decreases and as service factor increases 2 Output Type D Dual Shaft Hollow Bore Right Hand Shaft 3 The Center Distance is the distance between the centerlines of the input and output shafts bores serves as the gear
30. conversion factor 1hp 63 025 in Ib rpm 63 025 in Ib rpm hp 1 5hp 8490 1725 rpm 15 1 14 4 2 5 3977 in lb gt 2700 inb sufficient torque at load Final gearbox and motor selection 1 1 2 hp motor WG 237 015 x gearbox IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 3rd Edition 10 24 214 IronHorse Worm Gearbox User Manual IronHorse Worm Gearbox User Manual IH WG USER M WO 3rd Edition
31. d From the gearbox spec tables WG 206 015 x efficiency 85 maximum thermal input power 1 40 hp maximum mechanical input power e 1 0 SF 2 09 hp maximum mechanical input power e 1 25 SF rated max mechanical input power SE 2 09 hp 1 25 1 67 hp maximum allowable motor power 1 40 hp select nominal 1hp motor Select 1hp motor and check for adequate torque at the load Torque Power Speed conversion factor 1hp 63 025 in Ib rpm Torque Joad 63 025 in lb rpm hp gearbox input hp gearbox efficiency motor rpm gearbox ratio pulley ratio 63 025 1 0 85 1725 15 1 14 4 2 5 2683 4845 insufficient torque at load This torque value is less than the 2700 in lb required by the load So select and check the next larger nominal motor size which is 1 1 2 hp Since the 206 frame size 15 ratio gearbox does not meet the required 1 1 2 hp thermal rating choose the WG 237 015 x gearbox Select 1 1 2 hp motor and WG 237 015 x gearbox and check for adequate torque WG 237 015 x gearbox efficiency 84 maximum thermal input power 1 55 hp maximum mechanical input power 1 25 SF 2 64 hp 1 25 2 11 hp maximum allowable motor power 1 55 hp nominal 1 1 2 hp motor gearbox ratio is still 15 1 and OHL rating is increased to 900 lb so the previous pulley calculations step 7 remain sufficient smaller pulleys can be calculated and selected for this gearbox if desired Torque Power Speed
32. ermal 7 Part Number Output RPM 1750 rpm Input Nominal Motor HP 1 1800 rpm NEMA Motor Frame Center Distance 3 in Overhung Load Ib Thrust Load 5 Ib Approx Weight Ib Input Power hp Output Power hp Output Torque Ib in Input Power hp Output Power hp Output Torque Ib in Maximum Input Speed rpm Efficiency 20 WG 237 005 D WG 237 005 H WG 237 005 R WG 237 010 D WG 237 010 H WG 237 010 R WG 237 015 D WG 237 015 H WG 237 015 R WG 237 020 D WG 237 020 H WG 237 020 R WG 237 040 D WG 237 040 H WG 237 040 R WG 237 060 D WG 237 060 H WG 237 060 R 37 6 38 4 32 4 02 766 36 7 37 6 38 3 47 3 09 1158 36 7 37 6 38 2 64 2 22 1249 36 7 06 1 69 145 1 02 86 0 53 1 37 6 38 2 1195 36 7 37 6 38 1483 0 83 36 7 1 37 6 38 10 149 0 63 36 7 1 Nominal Motor HP is the highest HP 1800 rpm motor to be used with the gearbox under conditions of 1 0 service factor Gearbox input power capacily decreases as molor speed decreases and as service factor increases 2 Output Type D Dual Shaft Hollow Bore Right Hand Shaft 3 The Center Distance is the distance between the centerlines of the input and output shafts bores serves as the gearbox frame size 4 Overhung Load ratings are for forces perpendicular to the
33. extreme pressure lubricants contain materials that are toxic Avoid the use of these lubricants where harmful effects can occur _ IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 Chapter 4 Installation and Lubrication Lubricant Capacities amp Mounting Orientations WARNING Too much oil will cause overheating and too little oil will result in gear failure Check oil level regularly More frequent oil changes are recommended when operating continuously at high temperatures or under conditions of extreme dirt or dust IronHorse Aluminum Worm Gearbox Lubricant Capacities Gearbox Mounting Orientation Gearbox Part Number Approx Capacity fl oz WGA 30M xxx xx 1 69 WGA 40M xxx xx 3 38 WGA 50M xxx xx 5 07 WGA 63M xxx xx 10 14 WGA 75M xxx xx 16 91 IronHorse Cast Iron Worm Gearbox Lubricant Capacities Gearbox Mounting Orientation B c D Gearbox Part Number Approx Capacity fl oz WG 175 xxx x 11 64 18 74 18 74 17 24 WG 206 xxx x 19 41 28 41 28 41 26 71 WG 237 xxx x 24 07 35 17 35 17 33 77 WG 262 xxx x 34 55 48 25 48 25 45 85 Gearboxes are shipped filled with oil sufficient for mounting orientation A Oil must be added to gearboxes installed in other mounting orientations Gearbox Mounting Orientations Horizontal Input Shaft Vertical Input Shaft D not allowed
34. l installation et le fonctionnement sont conformes aux exigences de la version la plus r cente de ces codes Vous devez tout le moins respecter toutes les sections applicables du Code national de pr vention des incendies du Code national de l lectricit et des codes de la National Electrical Manufacturer s Association NEMA Des organismes de r glementation ou des services gouvernementaux locaux peuvent galement vous aider d terminer les codes ainsi que les normes respecter pour assurer une installation et un fonctionnement s rs L omission de respecter la totalit des codes et des normes applicables peut entra ner des dommages l quipement ou causer de graves blessures au personnel Nous ne garantissons pas que les produits d crits dans cette publication conviennent votre application particuli re et nous n assumons aucune responsabilit l gard de la conception de l installation ou du fonctionnement de votre produit Nos produits ne sont pas insensibles aux d faillances et ne sont ni conqus ni fabriqu s pour l utilisation ou la revente en tant qu quipement de commande en ligne dans des environnements dangereux n cessitant une s curit absolue par exemple l exploitation d installations nucl aires les syst mes de navigation a rienne ou de communication le contr le de la circulation a rienne les quipements de survie ou les syst mes d armes pour lesquels la d faillance du produit peut provoquer la
35. llow bore outputs all the way through from one side to the other We also offer optional gearbox mounting bases for ease of installation of these cast iron gearboxes Our aluminum gearboxes feature hollow bore outputs all the way through from one side to the other We also offer optional single and double output shafts output flanges torque arms and output covers Package Contents After receiving the IronHorse Worm Gearbox please check for the following Make sure the package includes the speed reducer and the vent plug Vent plugs not included or required for aluminum gearboxes nspect the unit to insure it was not damaged during shipment Make sure that the part number on the gearbox nameplate is the same as the part number that you ordered 3rd Edition 10 24 2014 IronHorse Worm Gearbox User Manual 1 3 Chapter 1 Getting Started Part Number Explanation WG 175 060 R Output Type ACC Accessory D Dual shaft cast iron frame H Hollow bore cast iron frame H1 Hollow bore 56C face AL frame H2 Hollow bore 145TC face AL frame H3 Hollow bore 182 4TC face AL frame R Right hand shaft cast iron frame Ratio Three digit input for output of 1 Example 060 60 1 ratio Frame Size center distance 30M 30mm 175 1 75 in 40M 40mm 206 2 06 in 50M 50mm 237 2 37 in 63M 63mm 262 2 62 in 75M 75mm Gearbox Type Series Designation WG Worm gear cast iron frame WGA
36. ousing D 2 IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 Chapter 4 Installation and Lubrication Kil Vent Plug Installation Cast Iron Gearboxes only All IronHorse Worm Gearboxes are tested and filled with Mobil SHC634 synthetic lubricant prior to shipment All vent openings are plugged by the manufacturer to prevent the loss of lubricant in shipment The vent plug is shipped loose in the package with cast iron gearboxes and should be installed prior to placing the gearbox in operation The ventplug should be installed in the uppermost position Use of a vent plug not necessary for aluminum gearboxes vent plug not provided For all mounting positions where the vented plug is located in a horizontal plane the vent hole must point upward For all mounting positions where the vented plug is located in a vertical plane the vent hole must point toward the center of the gearbox housing Failure to properly install the vent plug can lead to pressurization of the gearbox housing as operating temperature rises resulting in leakage at the shaft seals 3rd Edition 10 24 2014 IronHorse Worm Gearbox User Manual 1 3 Chapter 4 Installation and Lubrication TE IronHorse Worm Gearbox Lubrication amp Mounting Orientations Lubricant selection is important to all gearboxes and it is particularly critical for the worm gear type An oil
37. p Mounting Orientations 4 5 Chapter 4 Installation and Lubrication hh hn _ 7 z z z z z gt z zzxxxMmmmr a _z_zd______n IronHorse Worm Gearbox Installation Read these instructions thoroughly before installing or operating the gearbox Installation Instructions Leave the protective shaft sleeves in place for safe handling of the gearbox during installation Add or partially drain oil as needed depending upon the mounting orientation Refer to the lubrication section of this chapter for more information Install the vent plug Not required for aluminum gearboxes refer to the next subsection for more information Align all shafts accurately since improper alignment can result in premature failure Use flexible couplings to compensate for slight misalignment For hollow bore output gearboxes Use anti seize compound when inserting the load shaft into the hollow output shaft It is preferrable to size the load shaft with sufficient length to allow complete insertion through the hollow output shaft of the gearbox This allows equal support of the load shaft by both of the output shaft bearings and permits the use of the output shaft setscrews to lock the two shafts together on both sides of the gearbox At minimum the load shaft should be inserted at least half way into the hollow output shaft and secured with the setscrews on the insertion end of the gearbox Mount the gearbox to
38. red and select a gearbox with a higher Maximum Thermal output Torque rating for WG cast iron gearboxes not applicable for WGA aluminum gearboxes 6 Determine the gearbox design output torque required torque with service factor applied and select a gearbox with a higher Maximum Mechanical Output Torque rating Gearbox must also meet requirement 5 7 Determine the required sizes of pulleys gears etc and determine the overhung load force Select a gearbox with a higher Overhung Load rating Gearbox must also meet requirements 5 amp 6 8 Confirm that the selected gearbox meets the applicable system requirements 9 Select a compatible motor Gearbox Selection Example Refer to the specifications tables for gearbox specifications service factors and K factors A conveyor will run 10 hours day with moderate shock loading The conveyor will be driven by a V belt and needs to be driven at approximately 20 rpm The motor to be used will have a nominal speed of 1800 rpm 1725 rpm actual speed The conveyor will require 2700 in b of torque 1 Required torque 2700 in Ib required speed 20 rpm 2 Determine the overall speed ratio of motor speed to load speed Overall speed ratio motor speed load speed 1725 20 86 25 about 86 1 3 Determine pulley ratios at available gearbox ratios Gearbox ratio overall speed ratio pulley ratio Pulley ratio overall speed ratio gearbox ratio For amp i gearbex p
39. rse Worm Gearbox User Manual describes the installation operation and preventative maintenance of IronHorse Worm Gearboxes Who Should Read This Manual This manual contains important information for people who will install maintain and or operate any of the IronHorse Worm Gearboxes Technical Support Our technical support group is glad to work with you to answer your questions Please call the technical support group if you need technical assistance or visit our web site Our website contains technical and non technical information about our products and our company By telephone 770 844 4200 Mon Fri 9 00 am 6 00 pm ET On the Web www automationdirect com Special Symbols When you see the notepad icon in the left hand margin the paragraph to its immediate right will be a special note which presents information that may make your work quicker or more efficient The word NOTE will mark the beginning of the text When you see the exclamation point icon in the left hand margin the paragraph to its immediate right will be a warning This information could prevent injury loss of property or even death in extreme cases Any warning in this manual should be regarded as critical information that should be read in its entirety The word WARNING in boldface will mark the beginning of the text 1 2 IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 Chapter 1 Getting Started
40. s 4 mounting screws WGA 40M ACC2 Torque arm for aluminum WGA 40M series gearboxes Includes 4 mounting screws WGA 50M ACC2 Torque arm for aluminum WGA 50M series gearboxes Includes 4 mounting screws WGA 63M ACC2 Torque arm for aluminum WGA 63M series gearboxes Includes 8 mounting screws WGA 75M ACC2 Torque arm for aluminum WGA 75M series gearboxes Includes 8 mounting screws Single output shaft 00 625 in for aluminum WGA 30M series gearboxes Includes 3 keys 1 spacer and 1 retaining ring Single output shaft 00 75 in for aluminum WGA 40M series gearboxes ECCO Includes 3 keys 1 spacer and 1 retaining ring Single output shaft 01 0 in for aluminum WGA 50M series gearboxes EOM ACC Includes 3 keys 1 spacer and 1 retaining ring Single output shaft 01 125 in for aluminum WGA 63M series gearboxes on Includes 3 keys 1 spacer and 1 retaining ring Single output shaft 01 25 in for aluminum WGA 75M series gearboxes Includes 3 keys 1 spacer and 1 retaining ring WGA 75M ACC3 Double output shaft 00 625 in for aluminum WGA 30M series gearboxes Includes 4 keys 2 spacers and 2 retaining rings Double output shaft 00 75 in for aluminum WGA 40M series gearboxes Includes 4 keys 2 spacers and 2 retaining rings Double output shaft 01 0 in for aluminum
41. s blowers etc 6 Maximum Mechanical Ratings are limits based on strength and durability of gearbox components applicable when operating time is short and stopped time is greater than or equal to operating time These ratings are applicable for 1 0 service factor loads and may require modification depending upon characteristics of the applicable driven loads Refer to the Service Factors table for more information 7 Maximum Thermal Ratings are limits for gearbox continuous use without overheating 2 IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 Chapter 2 Cast Iron Worm Gearboxes IronHorse Cast Iron Worm Gearbox Dimensions Solid Shaft Output Gearboxes WG xxx xxx D R AB 25 X A ICE Output Shaft View lt lt gt lt Y T m B gt w Rear View Left View Input Shaft View Left side output shafts are present only on dual shaft models WG xxx xxx D Part Number i WG 175 xxx D R 5 16 18 WG 206 xxx D R WG 237 xxx D R WG 262 005 D R WG 262 010 D R WG 262 015 D R WG 262 020 D R WG 262 040 D R WG 262 060 D R Part Output Shaft repeated N 5 Xe WG 175 xxx D R 1 781 0 875 2 09 1 2 37 WG 262 005 D R WG 2
42. shaft of a gearbox Output horsepower is always less than the input horsepower due to the efficiency of the gearbox Overhung Load A force applied at right angles to a shaft beyond its outermost bearing This shaft bending load must be supported by the bearing Overhung load ratings are listed for each gearbox size and should not be exceeded Some applications require the gearbox Overhung Load rating to be reduced by a K Factor and or a Service Factor Overhung Load Factor K Factor Prime Mover In industry the prime mover is most often an electric motor Occasionally engines hydraulic or air motors are used Special considerations are called for when other than an electric motor is the prime mover Self Locking The inability of a reducer to be driven backwards by its load No IronHorse worm gearbox should be considered self locking Service Factor for gearbox A constant used to modify the Mechanical Rating of a gearbox based on the duration of service and characteristics of the driven load Use the Service Factor either as a multiplier to increase the calculated loads or as a divisor to reduce the gearbox Mechanical and Overhung Load ratings Service Factor for motors Refers to a motor s ability to handle a load greater than the motor s rated horsepower on a continuous basis Speed Reducer Gearbox Thermal Ratings The power or torque a gearbox can transmit continuously These ratings are based upon the cast iron gear
43. stance is the distance between the centerlines of the input and output shafts bores serves as the gearbox frame size 4 Overhung Load ratings are for forces perpendicular to the output shaft and located at the shaft midpoint such as from a gear pulley or sprocket with a belt or chain Divide OHL ratings by the applicable OHL K factors shown separately in the Selection Factors tables OHL ratings should also be divided by applicable service factors 5 Maximum Mechanical Ratings are limits based on strength and durability of gearbox components applicable when operating time is short and stopped time is greater than or equal to operating time These ratings are applicable for 1 0 service factor loads and may require modification depending upon characteristics of the applicable driven loads Refer to the Service Factors table for more information 3rd Edition 10 24 2014 IronHorse Worm Gearbox User Manual 3 3 Chapter 3 Aluminum Worm Gearboxes IronHorse Aluminum Worm Gearbox Specifications continued IronHorse Aluminum Worm Gearbox Specifications Frame Sizes 63 amp 75 mm Maximum Ratings 1750 rpm Input Mechanical 5 Part Number Output RPM 1750 rpm Input Maximum Input Speed rpm Nominal Motor HP 1800 rpm Output Type 2 Center Distance mm Approx Weight Ib Output Power hp Output Torque Ib in lt NEMA Motor Frame WGA 63M 010 H1 WGA 63M 010 H2 WGA 63M 020 H1
44. tout int r t dans les autres marques et d signations Copyright 2008 2009 2014 Automationdirect com Incorporated Tous droits r serv s Nulle partie de ce manuel ne doit tre copi e reproduite ou transmise de quelque fa on que ce soit sans le consentement pr alable crit de la soci t Automationdirect com Incorporated AutomationDirect conserve les droits exclusifs l gard de tous les renseignements contenus dans le pr sent document W 2 IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 IRoNHonsE WORM GEARBOX USER MANUAL WAUTOMATIONDIRECT Please include the Manual Number and the Manual Issue both shown below when communicating with Technical Support regarding this publication Manual Number IH WG User M WO Issue 3rd Edition Issue Date 10 24 2014 Publication History Issue Date Description of Changes First Edition 06 2008 Original Issue ist Ed RevA 06 2008 Gearbox mounting orientation Chapter 2 Second Edition 04 2009 Added cast iron hollow bore gearboxes Renamed User Manual was WG User M WO Added aluminum gearboxes Third Edition 10 2014 Rearranged chapters Revised output shaft dimensions for cast iron solid shaft gearboxes Chapter 2 3rd Edition 10 24 2014 IronHorse Worm Gearbox User Manual H 1 Publication History ll H 2 IronHorse Worm Gearbox User Manual 3rd
45. ulley ratio 86 25 5 4425 17 25 pulley size is prohibitively large For 10 1 gearbox pulley ratio 86 25 10 8 63 For 15 1 gearbox pulley ratio 86 25 15 5 75 For 20 1 gearbox pulley ratio 86 25 20 4 31 For 30 1 gearbox pulley ratio 86 25 30 2 88 For 40 1 gearbox pulley ratio 86 25 40 2 16 For 60 1 gearbox pulley ratio 86 25 60 1 44 For 80 1 gearbox pulley ratio 86 25 80 1 08 Pulley ratio conveyor pulley diameter gearbox pulley diameter B 2 IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 Appendix B Gearbox Selection 4 Determine service factor SE and overhung load factor from applicable tables SE 1 25 due to moderate shock loading and 3 10 hours day operation K 1 5 due to V belt 5 Use specifications table to select gearbox with Max Thermal Torque rating required real torque Gearbox required real torque final torque pulley ratio For 10 1 gearbox 2700 in Ib 8 63 312 86 in Ib use WG 175 x or larger For 15 1 gearbox 2700 in lb 5 75 469 57 in Ib use WG 175 x or larger For 20 1 gearbox 2700 in Ib 4 31 626 45 in Ib use WG 206 x or larger For 30 1 gearbox 2700 in Ib 2 88 937 50 in Ib use WGA 63M or larger For 40 searbex 2700 in lb 2 16 1250 0 in Ib none applicable For 60 1 searbex 2700 inb 1 44 1875 0 in Ib none applicable For 80 earbex 2700 in lb 1 08 2500 0 in
46. ving provisions for close coupling of a motor either via a hollow quill shaft or flexible coupling Most often a NEMA C face motor is used Gearbox Also called a Speed Reducer An enclosed set of gears used in mechanical power transmission to reduce speed and increase torque Input Power The power applied to the input shaft of a gearbox There are separate ratings for Mechanical Input Power Thermal Input Power and Nominal Motor Horsepower K Factor Also called an Overhung Load Factor A constant used to modify the overhung load rating of a gearbox based on the type of load applied on the shaft Use the K factor either to increase the calculated overhung load or to reduce the gearbox overhung load rating Mechanical Ratings The maximum power or torque a gearbox can transmit based on the strength and durability of its components Some applications require the gearbox Mechanical Ratings to be reduced by a Service Factor Mounting Position The relationship of the input and output shafts of a gearbox relative to horizontal A 2 IronHorse Worm Gearbox User Manual 3rd Edition 10 24 2014 Appendix A Glossary of Terms Nominal Motor Horsepower The highest horsepower 1800 rpm motor that can be used with the gearbox under 1 0 service factor conditions This rating decreases as the motor speed decreases and as the service factor increases Output Horsepower The amount of horsepower available at the output
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