Worm gear reducers RT/MRT

Size : 28, 30, 40, 50, 60, 70, 80, 100, 120, 150, 180

Transmission ratio : „i“ = 5 – 100

Power: 0,06 – 15 kW

Torque: 8 – 2540 Nm

Modern design, proved quality, reliability and the involute gear profile used at the worm gearing guarantee trouble-free service of RT / MRT . . A, series gear unites manufactured by TOS ZNOJMO. The RT/MRT30A to RT/MRT80A gear unit housings, feet and flanges are made of aluminium alloy and are supplied unpainted as standard. The RT/MRT100A to RT/MRT180A gear units housings are of cast iron and are supplied RAL5021 green-blue painted. By request any worm-gear unit can be supplied in stainless steel execution.

Characteristic properties of worm-gear units:

High gear ratio 5 to 100 achieved by one gear unit only
Noise-free operation
High load capacity
Self-locking ability
Reduced weight
Easy integration to the driven machine

Identification of basic design

RT . .	Worm-gear unit with the solid input shaft
MRT . .	Worm-gear unit with an electric motor or with hollow input shaft fitted with a flange for B5 mounted electric motor or B14A mounted motor or B14B mounted motor
MRP . .	Worm-gear unit with spur gear step (i = 3) at the input shaft
MAT . .	MRT worm-gear unit with ATC in-line gearbox at the input shaft ( i = 3,4 and/or i = 6, and/or i = 8
MRT . . x . .	Combination of two worm-gear units to achieve very high gear ratios i = 4,000. Gearbox combinations up to i = 10,000 ratio are available as an option.

Selection

General

The wide range of ratios specified in the catalogue enables to solve any requirements resulting from the operation of various equipment. The following data are necessary to specify a suitable gear unit:

a) input and output speed determining the gear ratio i
b) required torque Mk, or input power P₁

The data given in the tables 8.1 až 8.4, enable easy selection of a suitable gear unit. Should a non-standard unit be required please contact your distributors for the technical support.

Gear Ratio i

Gear ratio is a relation between input speed n₁ [rpm] and output speed n₂ [rpm].

n₁
i = ———————
n₂

Gear ratios from 5 to 100 are used at worm-gear units. The use of squirrel cage asynchronous motors is recommended to drive the equipment as their speed n₁ [rpm] is almost constant even if under load. The following speed can be used for 50 Hz:

2 – pole motor n₁=2800 rpm
4 – pole motor n₁=1400 rpm
6 – pole motor n₁=900 rpm
8 – pole motor n₁=700 rpm

Two-pole motors are usually suitable for short-time operation.. It is, however, possible to use these after consultation with the manufacturer. Their use should be consulted with the manufacturers. When 60 Hz supply frequency is used the increase of the input as well as output speed by 20 % need to be taken into consideration.

Torque M₂

The required torque M_k is determined by the load applied on the gear unit. It can be described as force F applied at certain distance of the arm r.

M_k[Nm] = F[N] x r[m]

The output torque M₂ can be calculated from the following formula:

9550 x P₁[kW] x η[%] x i
M₂[Nm] = —————————————–
100 x n₁[rpm]

The output torque M2 is selected greater than the desired torque. 2 need to be selected at a higher value than the required torque. Output torque related to individual gear ratios is specified in the Gear Unit Selection 8.4.

Input and Output Power P₁ and P₂

Motor input power can be calculated from the general relation between torque M and speed n :

M[Nm] x n[rpm]
P[kW] = —————————-
9550

The efficiency , of a gear unit is given by the ratio of the output power P₂ and the input power P₁, see Table 8.1 to 8.3.

M_krequired [Nm] x n₂[rpm]
P₁[kW] = —————————————————-
9550 x [%]

Service factors

Service Factors

Operation factor S_m

In order to guarantee operation safety at various loads and operation conditions the type of the gearbox (and motor) must be specified through the operation factor S_m. The values of operation factor S_m can be found in Table 6.1 taking the type of load, the average daily operation, the number of starts per hour into consideration. These values are applicable when the gear unit is used in conjunction with an electric motor. Should a brake motor be used the operation factor S_m needs to be multiplied by a coefficient of 1.15. When selecting an actual gear unit the operation factor S_m must be lower than the gear unit service factor S_f or the required output torque M_p must be increased as per the following formula:

M₂ = M_p x S_m

Tab. 6.1 Service Factors

Kind of load	Number of starts per hour	Average daily operation [hr]
Kind of load	Number of starts per hour	<2	2÷8	9÷16	17÷24
Normal shock-free operation, small inertia (fans, gear pumps, assembly lines, conveyer screws, liquid mixers, filling machines and wrapping machines)	<10	0,8	1	1,2	1,3
Light jolts at starting, irregular operation, medium inertia (conveyer belts, hoists, winches, kneading and mixing machines, woodworking machines, printing machines,textile machines)	<10	1,0	1,3	1,5	1,6
	10÷50	1,2	1,4	1,7	1,9
	50÷100	1,3	1,6	2,0	2,1
	100÷200	1,5	1,9	2,3	2,4
Heavy shock irregular operation, high inertia (concrete mixers, suction pumps, compressors, rams, rolling mills, heavy goods conveyer belts, bending machines, presses, machines with irregular load and motion)	<10	1,2	1,5	1,8	2,0
	10÷50	1,4	1,7	2,1	2,2
	50÷100	1,6	2,0	2,3	2,5
	100÷200	1,8	2,3	2,7	2,9

Service factor S_f

Service factor S_f is a ratio between the maximum output torque the gearbox can continuously develop and the actual output torque which can be developed by the selected electric motor.

M_2max
S_f = ————————— [ – ]
M₂

The maximum torque M_2max is established for the operation factor S_m = 1. Service factor values for individual gearbox executions and sizes, the gear ratios and a selection of electric motors are shown in the Table 8.4

Reversibility

Reversibility and parameters

Reversibility

A worm gearing is self-locking if it is not possible to turn the input shaft by turning of the output shaft. The worm gearing is self-locking if the worm helix angle is lower than the friction angle at idle or when the static efficiency of the gearing is lower than 50 %. The gearing is then statically self-locking. Should the worm helix angle be lower than dynamic friction angle or when the dynamic efficiency of the gearing is lower than 50 %, the gearing is dynamically self-locking.

The following relation applies:

= tg / tg(+) or = tg / tg( + arctg( _z))

… efficiency
… worm helix angle
… friction angle ( =arctg(_z))
_z … coefficient of friction in gearing

Static coefficient of friction between gear materials (steel – bronze) is within the range of _z = 0.09 to 0.14 depending on the lubricant used (its age, conditions and temperature) and the roughness of contact surfaces (given by gearing wear). The conforming friction angle is _s = 5° to 8°.

When static self-locking property can be influenced by vibrations or shocks a dynamic coefficient of friction shall be considered. The value of the dynamic coefficient of friction depends on surface roughness, the lubricant used, the load applied and the sliding speed. It ranges within _z = 0.02 and 0.05 for standard load and speed 900 to 1400 rpm. The conforming dynamic friction angle is _d = 1° to 3°.

With respect to the fact that the helix angles are higher than 1,5° at all gear ratios, the 100% self-locking cannot be guaranteed. In cases when the gear unit must be secured against slipping, it is recommended to use electric motors with brakes.

Tab. 16.2. Self-locking Status

γ	Self-locking
>25°	total reversibility
12° – 25°	static reversibility
	reversing rapidly
	dynamic reversibility
8° – 12°	variable and static reversibility
	reversing rapidly when vibrating
	dynamic reversibility
5° – 8°	static self-locking
	reversing when vibrating
	light dynamic self-locking
3° – 5°	static self-locking
	reversing slowly when vibrating
	almost dynamically self-locking
	light dynamic reversibility when vibrating
1° – 3° <1°	static self-locking
	dynamic self-locking
	light dynamic reversibility when vibrating
	full static and dynamic self-locking

Table of actual transfers

	MRT30A			MRT40A			MRT50A
i_N	z₂	z₁	i_R	z₂	z₁	i_R	z₂	z₁	i_R
5	29	6	4,833	26	5	5,2	30	6	5
7,5	30	4	7,5	31	4	7,75	31	4	7,75
10	29	3	9,667	29	3	9,6667	29	3	9,6667
12,5	37	3	12,33	37	3	12,333	38	3	12,667
15	31	2	15,5	29	2	14,5	31	2	15,5
20	39	2	19,5	39	2	19,5	40	2	20
25	25	1	25	51	2	25,5	51	2	25,5
30	30	1	30	30	1	30	30	1	30
40	40	1	40	40	1	40	40	1	40
50	50	1	50	50	1	50	50	1	50
60	60	1	60	60	1	60	60	1	60
70	70	1	70	70	1	70	70	1	70
80	80	1	80	80	1	80	80	1	80
100	100	1	100	100	1	100	100	1	100

Shafl loads

RADIAL AND AXIAL SHAFT LOADS

Worm-gear units are supplied with a hollow output shaft where a solid output shaft can be inserted. The robust housing of the hollow shaft and its bearings enable absorption of high radial forces while its service life is comparable with the other gearbox parts. The values shown in the Table 7.1have been calculated for the input speed of 1400 rpm. The maximum applied load shown 7.1 must not be exceeded. Taper bearings can be used on the output shaft at sizes 40 to 150 if required. A use of different bearings at the gear units need to be consulted with the manufacturers.

Radial Load F_rad

To establish the radial load F_rad the middle of the solid inserted shaft length is considered to be the point where the force is applied (see Fig.7.1). Should the actual radial load be applied on the shaft at a greater length, the maximum load must be reduced. For example only 80 % of the radial load shown in the table is applicable should the force be applied at 75 % of the shaft length. The radial load higher by 25 % can be applied should the force be applicable at 30 % of the shaft length. If a pulley, chain sprocket or gear wheel, etc. is fitted on the output shaft, the radial load can be determined from the following formula:

M₂ x k x 2000
F_rad = ——————————
D

F_rad	=	radial load [N]
M₂	=	output torque [Nm]
D	=	calculated pulley diameter (pitch circle) [mm]
k	=	load factory 1,00 for chain sprockets 1,25 for spur gears wheels 1,50 for pulleys

It means that the shaft radial load can be decreased by the increase of the pulley diameter, if at all possible. Should the radial load be too high or the force be applied on the shaft at a long distance, an external support by bearings must be opted for to the force be applied on the shaft at a long distance, an external support by bearings must be opted for to absorb the additional forces.

Axial load F_ax

Permissible values of axial load F_ax represent approximately 20 % of permissible radial load F_rad.

Table 7.1 - Max. Permissible Radial and Axial Load

			RT/MRT 30A		RT/MRT 40A		RT/MRT 50A		RT/MRT 60A		RT/MRT 70A		RT/MRT 80A		RT/MRT 100A		RT/MRT 120A		RT/MRT 180A		RT/MRT 180A
	i	min^-1	F_ax	F_rad	F_ax	F_rad	F_ax	F_rad	F_ax	F_rad	F_ax	F_rad	F_ax	F_rad	F_ax	F_rad	F_ax	F_rad	F_ax	F_rad	F_ax	F_rad
n₁		1400	20	100	40	200	60	300	70	340	70	360	90	450	130	650	170	850	260	1300	500	1550
n₂	5	280	110	600	150	780	200	980	300	1490	380	1880	450	2180	520	2655	750	3730	1020	5050	1100	5480
n₂	7,5	187	130	660	170	870	220	1100	330	1650	420	2090	500	2490	580	2880	810	4050	1100	5480	1190	5950
n₂	10	140	150	730	190	960	240	1220	360	1810	460	2300	550	2740	630	3170	890	4460	1210	6040	1310	6550
n₂	12,5	112	160	790	210	1030	260	1310	390	1950	490	2470	590	2950	680	3410	960	4800	1300	6510	1410	7060
n₂	15	93	170	840	220	1090	280	1390	420	2080	530	2630	630	3140	730	3630	1020	5110	1380	6920	1500	7510
n₂	20	70	180	920	240	1200	310	1530	460	2280	580	2890	690	3450	800	3990	1120	5610	1520	7610	1650	8260
n₂	25	56	200	990	260	1300	330	1650	490	2460	620	3120	740	3720	860	4300	1210	6050	1640	8200	1780	8890
n₂	30	47	210	1050	270	1370	350	1750	520	2610	660	3300	790	3940	910	4560	1280	6410	1740	8690	1890	9430
n₂	40	35	230	1160	300	1520	390	1930	580	2880	730	3650	870	4350	1010	5030	1410	7070	1920	9590	2080	10400
n₂	50	28	250	1250	330	1630	420	2080	620	3100	790	3930	940	4680	1080	5420	1520	7620	2070	10330	2240	11210
n₂	60	23	270	1330	350	1740	440	2220	660	3310	840	4190	1000	5000	1160	5790	1630	8140	2210	11030	2390	11960
n₂	70	20	280	1380	360	1830	460	2320	680	3480	880	4360	1050	5240	1220	6065	1700	8530	2320	11560	2510	12540
n₂	80	17,5	290	1460	380	1910	490	2430	720	3620	920	4590	1100	5480	1270	6340	1780	8910	2420	12080	2620	13110
n₂	100	14	310	1570	410	2060	520	2620	780	3900	990	4950	1180	5900	1370	6830	1920	9600	2600	13010	2820	14120

Table 7.1 -Max. Permissible Radial and Axial Load for Taper Bearings

			RT/MRT 30A		RT/MRT 40A		RT/MRT 50A		RT/MRT 60A		RT/MRT 70A		RT/MRT 80A		RT/MRT 100A		RT/MRT 120A		RT/MRT 150A		RT/MRT 180A
	i	min^-1	F_ax	F_rad	F_ax	F_rad	F_ax	F_rad	F_ax	F_rad	F_ax	F_rad	F_ax	F_rad	F_ax	F_rad	F_ax	F_rad	F_ax	F_rad	F_ax	F_rad
n₁		1400	20	100	40	200	60	300	70	340	70	360	90	450	130	650	170	850	260	1300	500	1550
n₂	5	280	150	720	340	1690	430	2130	750	3620	830	4200	860	4410	1220	6080	1640	8160	1740	8670	1790	8970
n₂	7,5	187	160	790	370	1850	470	2350	820	4090	920	4620	960	4800	1310	6550	1760	8780	1870	9330	1930	9650
n₂	10	140	170	860	400	2010	510	2570	890	4460	1010	5040	1050	5230	1430	7150	1910	9570	2040	10180	2100	10520
n₂	12,5	112	180	920	430	2150	550	2750	950	4770	1080	5390	1120	5590	1530	7640	2050	10240	2180	10880	2250	11250
n₂	15	93	200	980	460	2280	580	2900	1010	5040	1140	5700	1180	5920	1620	8080	2160	10820	2300	11510	2380	11900
n₂	20	70	210	1060	500	2480	630	3160	1100	5490	1240	6210	1290	6440	1760	8800	2360	11790	2510	12530	2590	12960
n₂	25	56	230	1140	530	2650	680	3380	1170	5870	1330	6640	1380	6890	1880	9410	2520	12600	2680	13400	2770	13850
n₂	30	47	240	1200	560	2790	710	3560	1240	6190	1400	7000	1450	7260	1980	9910	2660	13280	2820	14120	2920	14600
n₂	40	35	260	1310	610	3050	780	3890	1350	6760	1530	7640	1590	7930	2170	10830	2900	14510	3090	15430	3190	15950
n₂	50	28	280	1400	650	3260	830	4160	1450	7230	1630	8170	1700	8480	2320	11580	3100	15510	3300	16490	3410	17050
n₂	60	23	300	1490	690	3460	880	4420	1530	7670	1730	8670	1800	9000	2460	12280	3290	16460	3500	17500	3620	18090
n₂	70	20	310	1550	720	3610	910	4610	1600	8020	1810	9030	1870	9370	2560	12800	3440	17160	3650	18250	3770	18860
n₂	80	17,5	320	1610	750	3760	960	4790	1660	8320	1880	9410	1950	9760	2670	13330	3570	17860	3800	18990	3930	19640
n₂	100	14	350	1730	800	4020	1030	5130	1780	8900	2010	10060	2090	10440	2850	14260	3820	19100	4060	20310	4200	21000

Designation

TYPE IDENTIFICATION DIAGRAM

Tab. 4.1 :Mounting Positions and Design

Nominal power

Nominal Power

In operating conditions with a service factor S_m = 1 the reducers can be maximally loaded with capacities as shown in table 8.1., 22.1., 8.2. – 8.3. These tables show various ingoing revolutions, n₁ [min^-1], the maximum outgoing torques M_2max [Nm] and the accompanying ingoing capacities P₁[kW]. In exceptional cases can be used ingoing otáčky n₁ = 2800 [min^-1], but should be consulted with the manufacturer.

Combination of two worm gear reducers is a precondition for achieving very high ratio under keeping high compactibility. This design allows in the abstract to achieve ratio upto 10 000:1. From practical reasons are used ratios only upto 4 000:1.

Table 8.1. Table of Rated Data RT/MRT

Table 22.1. Table of Rated Data 80 AP

MRT 80AP

Table 8.2. Table of Rated Data MRP

Table 8.3. Table of Rated Data combination RT/MRT

Output power parameters

Performance Data

Selection of a gear unit with electric motor we can make as a Table 8.4. Tables are lined up for a posibility posibility of an ideal gear unit size selection based on a requested electric motor input power. Requested ratio and output speed show appropriate torque M₂ and service factor S_f. These values are in table stated for electric motors of 4 and 6 poles execution.

Table 8.4.1. Table of Performance Data of Gear Units MRT

Table 8.4.2. Table of Performance Data of Gear Units MRP

Table 8.4.3. Table of Performance Data of Combined Gear Units MRT x RT

Dimensional drawings

Measurements for the various basic versions. Worm gear reducers can also be supplied with special measurements.

Accessories

Under the customer request is possible to deliver following accessories:

Output Shaft - single sided

TYPE	A1	A2	C	Dh7	D1	L	L1	L2	F	P	R	DS	M1	M2	Kg
TYPE	A1	A2	C	Dh7	D1	L	L1	L2	F	P	R	DS	DIN 332		I	II
RT – MRT 30A	62	94	2,5	14	20	30	94,5	127	5	20	2,5	20	M5	M5	0,12	0,16
RT – MRT 40A	80	132	10	19	23	40	130	177	6	32	3	25	M6	M6	0,3	0,4
RT – MRT 50A	97	158	5	24	28	50	152	213	8	40	3,5	34	M8	M8	0,55	0,75
RT – MRT 60A	118	185	5	25	30	60	183	250	8	50	3,5	34	M10	M8	0,7	0,9
RT – MRT 70A	119	191	10	28	35	60	189	256	8	50	3,5	34	M10	M8	0,9	1,25
RT – MRT 80A	138	205	5	35	40	60	203	270	10	50	4	45	M12	M8	1,5	2
RT – MRT 100A	150	234	10	40	46	80	240	324	12	70	5	53	M16	M12	2,4	3,2
RT – MRT 120A	170	264	10	45	52	90	270	364	14	80	5	53	M16	M12	3,4	4,6
RT – MRT 150A	218	323	10	55	62	100	328	433	16	90	6	68	M20	M16	6,1	8,1
RT – MRT 180A	262	377	10	60	68	110	382	497	18	100	6	78	M20	M16	8,9	12

Output Shaft - double sided

TYPE	A1	A2	C	Dh7	D1	L	L1	L2	F	P	R	DS	M1	M2	Kg
TYPE	A1	A2	C	Dh7	D1	L	L1	L2	F	P	R	DS	DIN 332		I	II
RT – MRT 30A	61	95,5	2,5	14	20	30	94	128	5	20	2,5	20	M5	M5	0,12	0,16
RT – MRT 40A	80	132	10	19	23	40	125	182	6	32	3	25	M6	M6	0,3	0,4
RT – MRT 50A	97	158	10	24	28	50	152	218	8	40	3,5	34	M8	M8	0,55	0,75
RT – MRT 60A	118	185	5	25	30	60	183	250	8	50	3,5	34	M10	M8	0,7	0,9
RT – MRT 70A	120	191	10	28	35	60	185	261	8	50	3,5	34	M10	M8	0,9	1,25
RT – MRT 80A	138	205	5	35	40	60	203	270	10	50	4	45	M12	M8	1,5	2
RT – MRT 100A	150	242	10	40	46	80	240	332	12	70	5	53	M16	M12	2,4	3,2
RT – MRT 120A	170	272	10	45	52	90	270	372	14	80	5	53	M16	M12	3,4	4,6
RT – MRT 150A	218	330	10	55	62	100	328	440	16	90	6	68	M20	M16	6,1	8,1
RT – MRT 180A	262	377	10	60	68	110	382	497	18	100	6	78	M20	M16	8,9	12

Reaction Arm

TYPE	A	B	C	D	E	F	G	H	J	Weight
TYPE	A	B	C	D	E	F	G	H	J	Kg
RT – MRT 30A	85	40	143	55	65	8	14	7	4	0,22
RT – MRT 40A	100	39	161	50	65	8	14	7	4	0,25
RT – MRT 50A	100	44	170	60	75	10	20	7	4	0,3
RT – MRT 60A	150	53	233	70	85	10	20	9	5	0,57
RT – MRT 70A	200	62,5	295	80	100	14	24	9	6	1,1
RT – MRT 80A	200	77,5	315	110	130	14	24	11	6	1,25
RT – MRT 100A	230	77,5	345	110	130	14	24	11	6	1,35
RT – MRT 120A	260	95	395	130	165	16	26	13	8	2,45
RT – MRT 150A	300	125	480	180	215	16	26	15	8	3,7
RT – MRT 180A	350	150	545	230	265	25	30	17	8	4

Reducer Shaft Sleeves

ID	D1	D2	B1	B2	L
1109 6356	9	11	3	4	20
1409 7156	9	14	3	5	30
1411 7163	11	14	4	5	23
1911 8063	11	19	4	6	40
2411 9063	11	24	4	8	50
1914 8071	14	19	5	6	30
2414 9071	14	24	5	8	50
2814 0071	14	28	5	8	60
2419 9080	19	24	6	8	40
2819 0080	19	28	6	8	60
3819 3280	19	38	6	10	80
2824 0090	24	28	8	8	50
3824 3290	24	38	8	10	80
4224 6090	24	42	8	12	110
3828 3200	28	38	8	10	80
4228 6000	28	42	8	12	110
4238 6032	38	42	10	12	80

Upon requirement of the client is possible to provide gear reducer RT and MRT on the output (or input) with:

a suitable kind of shaft coupling for an aligning of a radial, axial and angular offsets of shafts
slip clutch to limit transmitted torque
eventually overrunning clutch
combination of the flexible coupling with overload clutch
combination of the flexible coupling with overrunning clutch.

Lubricants

Lublicants

RT/MRT gear units are lubricated by running the worm wheel or the worm in oil in combination with oil splashing. Under normal conditions a reliable operation as well as service life and efficiency of the gear units are secured. Gearboxes sizes 30 to 80 can be used at any mounting position. Gearboxes sizes 100 to 180 are suitable for mounting positions as shown in Table 4.1 Mounting Positions and Design due to positioning of the breathe plug. For any other mounting position please contact the manufacturers.

RT/MRT gear units are generally supplied filled for life – ÖMV PG 460EP is a synthetic oil enabling maintenance-free operation. Under normal conditions no oil needs to be changed during service life of the gearboxes. Should a different lubricant be required, e.g. due to more demanding conditions (higher operating temperature, high speed etc.), it must be established that oil additives do not affect bronze and/or oil seals in any way. It is recommended to use synthetic oils which guarantee high service life, stability and dynamic efficiency of the worm gears. When mineral oil is used, it must be changed in certain periods. In case grease is used as lubricant, reduction of heat dissipation, reduction of efficiency and reduced lubrication of all moving parts should be expected causing higher wear of the gear unit. Recommended equivalent lubricants are shown in the Tab. 19.1. The oil quantity per individual type and size of gear units is shown in the Table 19.2.

Table. 19.1 Equivalent Lubricants

Ambient temperature	-10^oC – +50^oC		-30^oC – +100^oC	-40^oC – +120^oC	-10^oC – +60^oC
Lubricant	Mineral oil		Synthetic oil		Synthetic grease
Type of load	normal	high	normal and high		normal and high
OMV	Öle HST 320 EP	Öle HST 460 EP	PG 460 EP	PG 220 EP	Duraplex EP 00
Agip	Blasia 320	Blasia 460	Blasia S	–	–
Aral	Degol BG 320	Degol BG 460	Degol GS 220	Degol PAS 230	Aralub BAB EP
Castrol	Alpha SP 320	Alpha SP 460	Alpha SH 220	–	Alphagel
ESSO	Spartan EP 320	Spartan EP 460	–	–	Grease S420
Kluber	Lamora 320	Lamora 460	Syntheso HT220	Syntheso HT220	Strugtovis P Liquid
Mobil	Mobilgear 632	Mobilgear 634	Glycoil 30	–	Glycoil Grease 00
Shell	Omala EP 320	Omala EP 460	Tivela Oil WB	Omala HD 320	Tivela GL 00
Optimol	Optigear BM 320	Optigear BM 460	Optiflex A 220	–	Longtime PD 00
Total	Carter EP 320	Carter EP 460	–	–	–
Paramo	Paramol CLP 320	Paramol CLP 460	–	–	–

All gear units are supplied filled for life as standard.

Table. 19.2 Lubricant Fill

Type	Oil [l]
(M)RT 30A	0,04
(M)RT 40A	0,13
(M)RT 50A	0,21
(M)RT 60A	0,36
(M)RT 70A	0,46
(M)RT 80A	0,7
(M)RT 100A	1,6
(M)RT 120A	2,2
(M)RT 150A	4
(M)RT 180A	7
MRP 40A	0,13+0,05
MRP 50A	0,21+0,05
MRP 60A	0,36+0,15
MRP 70A	0,46+0,20
MRP 80A	0,70+0,20
MRP 100A	1,6+0,3
MRP 120A	2,2+0,4
MRP 150A	4+0,3
MRP 180A	7,0+0,3

Storage, maintenance

Storage, putting into the operation and maintenance

Storage

If the worm gear boxes are stored for longer periods of time or are not used, It Is necessary to take certain measures. All untreated metals need to be conserved in order to avoid corrosion. The choice of conservation depends on the environmental conditions. Storage should take place In a dust, moisture and vibration free environment to as great an extent as possible. If the reducers are fitted with a filling/ventilation plug, the reducer needs to be completely filled with oil, and the ventilation plug has to be sealed. It is recommended that the reducers are run for a few revolutions once every 3 – 4 months.

Instalation

The following aspects are important when installing a worm gear reducer:

avoid external vibrations and high ambient temperatures
an elastic coupling should be given preference for jolting loads
shafts and couplings must be installed in line and according to the assembly instructions
the worm gear reducer must be mounted on a level (machined) surface. If mounting is carried out directly on to the shaft to be driven, the entire construction process must be carried out in such a way that the reaction torque is sufficiently taken up
all parts to be mounted on to the infeed shaft must be drawn using the tapped hole in the shaft on the reducer shaft in order to prevent damage being caused to the bearings
mounting surtaces of flanges and shafts need to be conserved before assembly in order to prevent oxidization
if oil lubrication is used the reducer must be filled with a quantity of oil as indicated on the type plate, see Tab. 19.2.
if the reducer is not used for longer period of time, the storage instructions must be adhered to
after long term storage with a full oil filling, it is important to adjust the oil quantity and to refit the ventilation plug before putting the unit into operation

Maintenance

Because the worm gear reducers are provided as standard with a syntetic grease lubricant maintenance is not necessary. For worm gear reducers with a mineral oil lubricant it is necessary to change the oil – see Table 12.1. After running in with oil the reducer must be cleaned and given new oil.

Running in

During the period of the first about 400 hours it is recommended that the reducer is not nominally loaded, but that a start is made with 70% for the first hours after which the load can be gradually increased to the nominal load. The rise in temperature is higher during the running in period than afterwards.

Cleaning

Drain the oil at operating temperature. Rinse the worm gear reducer clean.

Filling with oil

Fill the reducer with the definitive oil quantity as indicated on the type plate see Tab. 19.2.

Table 12.1. Lubricating intervals [h]

oil temperature ^oC	type of load	mineral oil	synthetic oil/grease
< 60	continuous interrupted	4000 6000	lifetime
> 60	continuous interrupted	2000 4000	lifetime

Warning:
Synthetic and mineral lubricants can not be mixed together. Mixing the synthetic lubricants of differing manufacturers can also cause problems. If the type or brand of lubricant is changed the reducer must be cleaned out.

Shaft seals

The good running thus the life of shaft seals, is affected in a very remarkable way by the running temperature in the contact area, by potential chemical reactions occuring between the rubber compound and the lubricant, and by the saving status of the seal itself. The replacement of shaft seals becomes necessary when: the seals are damaged and does not work proper way.

Spare parts

1	Housing	13	Input flange
2	FT flange	14	Bearing
3	Oil seal	15	RT worm
4	Bearing	16	Bearing
5	Worm wheel	17	Oil seal
6	NBR cap	18	RT cap
7	Circlip	19	FF flange
8	Circlip	20	Foot
9	Bearing	21	Reaction arm
10	Worm gear	22	Output double-sided shaft – complete
11	Bearing	23	Output double-sided shaft – complete
12	Oil seal

1	Housing	10	Flange
2	Bearing	11	Bearing
3	Oil seal	12	Step gearing housing
4	Spur gear step	13	Worm wheel
5	Circlip	14	Bearing
6	Bearing	15	Circlip
7	Circlip	16	NBR cap
8	Pinion	17	Circlip
9	Oil seal

Bearings and Seals

TYPE	Motor	MRT			RT
TYPE	Motor	Bearing 4	Bearing 7	Oil gasket 2	Bearing 4A	Bearing 7A	Oil gasket 2A
30A	56; 63	HK 2016	6300	20x28x7	6201	6300	12x32x7
30A	56; 63	20x26x16	10x35x11	20x28x7	12x32x10	10x35x11	12x32x7
40A	63	6004	6302	20x35x7	6302	6302	15x26x7
	63	20x42x12	15x42x13	20x35x7	15x42x13	15x42x13	15x26x7
	71	61905	6302	25x35x7
	71	25x42x9	15x42x13	25x35x7
50A	63; 71	6205	6304	25x40x7	30304	30304	17x35x7
	63; 71	25x52x15	20x52x15	25x40x7	20x52x15	20x52x15	17x35x7
	80	61906	6304	30x40x7
		30x47x9	20x52x15	30x40x7
		51107	30304	30x40x7
		35x37x12	20x52x15	30x40x7
60A	71; 80	32006	30205	30x47x7	30206	30205	28×40-7
	71; 80	30x55x17	25x52x15	30x47x7	30x62x16	25x52x13	28×40-7
	90	61907	6304	35x47x7
		35x55x10	25x52x15	35x47x7
		51107	30205	35x47x7
		35x52x12	25x52x15	35x47x7
70A	71; 80	32006	30205	30x47x7	30206	30205	28×40-7
	71; 80	30x55x17	25x52x15	30x47x7	30x62x16	25x52x13	28×40-7
	90	61907	6304	35x47x7
		35x55x10	25x52x15	35x47x7
		51107	30205	35x47x7
		35x52x12	25x52x15	35x47x7
80A	80; 90	30207	30306	35x55x7	30206	30205	30x55x7
	80; 90	35x72x17		35x55x7	30x62x16	25x52x13	30x55x7
	100	32008	30306	40x55x7
	100	40x69x19	30x72x19	40x55x7
100A	80; 90; 100; 112	32208	31307	40x62x12	32208	31307	40x62x8
100A	80; 90; 100; 112	40x80x24,75	35x80x22,75	40x62x12	40x80x24,75	35x80x22,75	40x62x8
120A	80; 90; 100; 112	32208	31307	40x62x12	32208	31307	40x62x8
120A	80; 90; 100; 112	40x80x24,75	35x80x22,75	40x62x12	40x80x24,75	35x80x22,75	40x62x8
150A	100; 112; 132	32211	31309	55x80x10	31309	31309	45x75x8
150A	100; 112; 132	55x100x22,75	45x100x27,75	55x80x10	45x100x27,75	45x100x27,75	45x75x8
180A	112; 132; 160	31312	31312	60x80x10	31312	31312	60x75x9
180A	112; 132; 160	60x130x33,5	60x130x33,5	60x80x10	60x130x33,5	60x130x33,5	60x75x9

TYP	12	12A	11
RT – MRT 30A	6005	7005
RT – MRT 30A	25x47x12	25x47x12	25x40x7
RT – MRT 40A	6006	32006
RT – MRT 40A	30x55x13	30x55x17	30x47x7
RT – MRT 50A	6007	32007
RT – MRT 50A	35x62x14	35x62x18	35x50x7
RT – MRT 60A	6008	32008
RT – MRT 60A	40x68x15	40x68x19	40x55x7
RT – MRT 70A	6009	32009
RT – MRT 70A	45x75x16	45x75x20	45x60x8
RT – MRT 80A	6010	32010
RT – MRT 80A	50x80x16	50x80x20	50x65x8
RT – MRT 100A	6011	32011
RT – MRT 100A	55x90x18	55x90x23	55x72x10
RT – MRT 120A	6013	32013
RT – MRT 120A	65x100x18	65x100x23	65x85x12
RT – MRT 150A	6216	30216
RT – MRT 150A	80x140x26	80x140x28,25	80x100x10
RT – MRT 180A	6218	32218
RT – MRT 180A	90x160x30	90x160x42,5	90x110x12

Electromotors

This paragraph provides basic technical and dimensional data of three-phase squirrel cage asynchronous electric motors with frame sizes 56 to 160 supplied by Siemens. Any further details and/or technical information can be obtained from the manufacturers.

Mounting Positions of Electric Motors:

Terminal box on top as standard – pos. 1

If different terminal box position is required please specify in your order as special requirement.

Technical Data:

Mounting:

– flange mounted IM 3041 (IM B5), IM 3641 FT** (IM B14 FT**)
– foot & flange mounted IM 2081 (IM B35)
– all mounting to IEC 34-7 code I/II

Mounting dimension:

– in compliance with IEC 72 / DIN 42673

Protection:

– IP 55

Table. 25.1: 2 -pole, Synchronous Speed 3000 rpm

Size		Output	Speed	Rated current A	Rated torque	Power factor	Efficiency	Ratio		Inertia	Weight
		kW	rpm	400 V	Nm	cos φ	η %	I_k/In	M_z/M_n	kg×m²	kg
56	2s	0,09	2830	0,26	0,3	0,81	63	3,7	2,0	0,00015	3,0
56	2	0,12	2800	0,32	0,41	0,83	65	3,7	2,1	0,00015	3,0
63	2s	0,18	2820	0,51	0,61	0,82	63	3,7	2,0	0,00018	3,5
63	2	0,25	2830	0,68	0,84	0,82	65	4,0	2,0	0,00023	4,1
71	2s	0,37	2740	1,00	1,3	0,82	66	3,5	2,3	0,00035	5,0
71	2	0,55	2800	1,36	1,9	0,82	71	4,3	2,5	0,00045	6,6
80	2s	0,75	2855	1,73	2,5	0,86	73	5,6	2,3	0,00085	8,2
80	2	1,1	2845	2,4	3,7	0,87	77	6,1	2,6	0,0011	9,9
90S	2	1,5	2860	3,25	5,0	0,85	79	5,5	2,4	0,0015	12,9
90L	2	2,2	2880	4,55	7,3	0,85	82	6,3	2,8	0,0020	15,7
100L	2	3,0	2890	6,1	9,9	0,85	84	6,8	2,8	0,0038	21,5
112M	2	4,0	2905	7,8	13,1	0,86	86	7,2	2,6	0,0055	29
132S	2	5,5	2925	10,3	18	0,89	86,5	5,9	2,0	0,016	40,5
132S	2	7,5	2930	13,8	24,4	0,89	88	6,9	2,3	0,021	48,5
160M	2	11	2940	20,0	36	0,88	89,5	6,5	2,1	0,034	68,5
160M	2	15	2940	26,5	49	0,90	90	6,6	2,2	0,040	76,5
160L	2	18,5	2940	32,5	60	0,91	91	7,0	2,4	0,052	87

Table. 25.2: 4 -pole, Synchronous Speed 1500 rpm

Size		Output	Speed	Rated current A	Rated torque	Power factor	Efficiency	Ratio		Inertia	Weight
		kW	rpm	400 V	Nm	cos φ	η %	I_k/In	M_z/M_n	kg×m²	kg
56	4s	0,06	1350	0,20	0,42	0,77	56	2,6	1,9	0,00027	3,0
56	4	0,09	1350	0,29	0,63	0,77	58	2,6	1,9	0,00027	3,0
63	4s	0,12	1350	0,42	0,84	0,75	55	2,8	1,9	0,0003	3,5
63	4	0,18	1350	0,56	1,3	0,77	60	3,0	1,9	0,0004	4,1
71	4s	0,25	1350	0,76	1,8	0,79	60	3,0	1,9	0,0006	4,8
71	4	0,37	1370	1,03	2,5	0,8	65	3,3	1,9	0,0008	6,0
80	4s	0,55	1395	1,45	3,7	0,82	67	3,9	2,2	0,0015	8,0
80	4	0,75	1395	1,86	5,1	0,81	72	4,2	2,3	0,0018	9,4
90S	4	1,1	1415	2,55	7,4	0,81	77	4,6	2,3	0,0028	12,3
90L	4	1,5	1420	3,4	10,1	0,81	79	5,3	2,4	0,0035	15,6
100L	4s	2,2	1420	4,7	14,8	0,82	82	5,6	2,5	0,0048	21,5
100L	4	3,0	1420	6,4	20,2	0,82	83	5,6	2,7	0,0058	24,5
112M	4	4,0	1440	8,2	26,5	0,83	85	6,0	2,7	0,011	31
132S	4	5,5	1455	11,4	36,1	0,81	86	6,3	2,5	0,018	42,5
132M	4	7,5	1455	15,2	49,2	0,82	87	6,7	2,7	0,024	49
160M	4	11	1460	21,5	72	0,84	88,5	6,2	2,2	0,040	68
160L	4	15	1460	28,5	98,1	0,84	90	6,5	2,6	0,052	93,5

Table. 25.3: 6 -pole, Synchronous Speed 1000 rpm

Size		Output	Speed	Rated current A	Rated torque	Power factor	Efficiency	Ratio		Inertia	Weight
		kW	rpm	400 V	Nm	cos φ	η %	I_k/In	M_z/M_n	kg×m²	kg
63	6	0,09	870	0,47	1,0	0,70	40	2,0	1,8	0,0004	4,1
71	6s	0,18	835	0,62	2,0	0,75	56	2,3	2,1	0,0006	6,3
71	6	0,25	850	0,78	2,8	0,76	61	2,7	2,2	0,0009	6,3
80	6s	0,37	920	1,2	3,8	0,72	62	3,1	1,9	0,0015	7,5
80	6	0,55	910	1,6	5,8	0,74	67	3,4	2,1	0,0018	9,4
90S	6	0,75	915	2,1	7,8	0,76	69	3,7	2,2	0,0028	12,5
90L	6	1,1	915	2,9	11,5	0,77	72	3,8	2,3	0,0035	15,7
100L	6	1,5	925	3,9	15	0,75	74	4,2	2,2	0,0063	24
112M	6	2,2	940	5,2	22	0,78	78	4,6	2,2	0,011	27
132S	6	3,0	950	7,2	30	0,76	79	4,2	1,9	0,015	41
132M	6	4,0	950	9,4	40	0,76	80,5	4,5	2,1	0,019	46
132M	6	5,5	950	12,8	55	0,76	83	5,0	2,3	0,025	54
160M	6	7,5	960	17,0	75	0,74	86	4,6	2,1	0,041	76
160L	6	11	960	24,5	109	0,74	87,5	4,8	2,3	0,049	102

Table. 25.4: 8 -pole, Synchronous Speed 750 rpm

Size		Output	Speed	Rated current A	Rated torque	Power factor	Efficiency	Ratio		Inertia	Weight
		kW	rpm	400 V	Nm	cos φ	η %	I_k/In	M_z/M_n	kg×m²	kg
71	8s	0,09	630	0,36	1,4	0,68	53	2,2	1,9	0,0009	6,3
71	8	0,12	645	0,51	1,8	0,64	53	2,2	2,2	0,0009	6,3
80	8s	0,18	675	0,75	2,5	0,68	51	2,3	1,7	0,0015	7,5
80	8	0,25	680	1,03	3,5	0,64	58	2,6	2	0,0018	9,4
90S	8	0,37	675	1,13	5,2	0,75	63	2,9	1,6	0,0025	10,5
90L	8	0,55	675	1,58	7,8	0,76	66	3,0	1,7	0,0035	13,2
100L	8	0,75	680	2,15	10,5	0,76	66	3,0	1,7	0,0053	20
100L	8	1,1	680	2,9	15,4	0,76	72	3,4	1,9	0,0070	22
112M	8	1,5	705	3,9	20	0,76	74	3,7	1,8	0,013	24
132S	8	2,2	695	5,7	30	0,74	75	3,9	1,9	0,014	41
132M	8	3,0	700	7,6	40	0,74	77	4,1	2,1	0,019	49
160M	8s	4,0	715	10	53	0,72	80	4,5	2,2	0,035	61
160M	8	5,5	710	13	73	0,73	83,5	4,7	2,3	0,043	70
160L	8	7,5	715	17,7	100	0,72	85	5,3	2,7	0,062	91

Table. 25.5 Dimensions of Motors

Size	Flanged motors – dimensions in mm
	Dk6	E	F	G	GD	AC	HF	HG	L	LB	LD	LG	LK
56	9	20	3	7,2	3	116	78,5	101	177	157	69,5	75	32
63	11	23	4	8,5	4	118	78,5	101	202	179	69,5	75	32
71	14	30	5	11	5	139	88,5	111	240	210	63,5	75	32
80	19	40	6	15,5	6	156,5	95,5	120	272,5	232,5	63,5	75	32
90	24	50	8	20	7	173,6	105,5	128	331	281	79	75	32
100	28	60	8	24	7	196	78	129	327,5	312,5	102	120	42
112	28	60	8	24	7	219,5	91	142	393	333	102	120	42
132S	38	80	10	33	8	259	107	164	454	374	128,5	140	42
132M	38	80	10	33	8	259	107	164	454	374	128,5	140	42
160M	42	110	12	37	8	314	127	191	588	478	160,5	165	54
160L	42	110	12	37	8	314	127	191	588	478	160,5	165	54

Size	Flanged motors – dimensions in mm
	Mounting IM B5 flange							Mounting IM B 14FT.. small flange						Mounting IM B 14FT.. bigger
		M	Nj6	P	S	T	LA		M	Nj6	P	S	T		M	Nj6	P	S	T
56	FF100	100	80	120	7	3	8	FT65	65	50	80	M5x16	2,5	FT85	85	70	105	M6x16	2,5
63	FF115	115	95	140	10	3	8	FT75	75	60	90	M5x14	2,5	FT100	100	80	120	M6x16	3
71	FF130	130	110	160	10	3,5	9	FT85	85	70	105	M6x16	2,5	FT115	115	95	140	M8x16	3
80	FF165	165	130	200	12	3,5	10	FT100	100	80	120	M6x16	3	FT130	130	110	160	M8×16	3,5
90	FF165	165	130	200	12	3,5	10	FT115	115	95	140	M8x21	3	FT130	130	110	160	M8×22	3,5
100	FF215	215	180	250	14,5	4	11	FT130	130	110	160	M8×20	3,5	FT165	160	130	200	M10x20	3,5
112	FF215	215	180	250	14,5	4	11	FT130	130	110	160	M8×20	3,5	FT165	160	130	200	M10×20	3,5
132S	FF265	265	230	300	14,5	4	12	FT165	165	130	200	M10×24	3,5	–	–	–	–	–	–
132M	FF265	265	230	300	14,5	4	12	FT165	165	130	200	M10×24	3,5	–	–	–	–	–	–
160M	FF300	300	250	350	18,5	5	13	–	–	–	–	–	–	–	–	–	–	–	–
160L	FF300	300	250	350	18,5	5	13	–	–	–	–	–	–	–	–	–	–	–	–