Emerson 3000 User Manual

OtN Series 3000

CAUTION

WARNING

Gearmotors and Reducers

Emerson Industrial Automation

7120 New Bufngton Road

Florence, KY 41042

Application Engineering: 800 626 2093

www.PowerTransmissionSolutions.com

F O R M

9020E

Revised

January 2014

• Read and follow all instructions carefully.

• Disconnect and lock-out power before installation and maintenance. Working on or near energized equipment can result in severe injury or death.

• Avoid contact with energized circuits or rotating parts.

• Be sure shaft key is fully captive before unit is energized.

• Do not operate equipment without guards in place. Exposed equipment can result in severe injury or death.

• Periodic inspections should be performed. Failure to perform proper maintenance can result in premature product failure and personal injury.

• All electrical work should be performed by qualied personnel and compliant with local and national electrical codes.

Thank you for choosing an OtN Series 3000 gearmotor or reducer.

Installation Instructions

Start-Up

• Before operating the reducer or gearmotor, the following must be done:

• If foot or ange mount, install the drive on a rigid and vibration-free surface. If shaft mounted, install the drive onto a rigidly supported drive shaft.

• Remove the protective coating on the shaft and ange. Use solvent if necessary.

• Carefully install coupling, sheaves, sprockets, or pinions on shaft. Mount as close to the shaft shoulder as possible.

• It is preferable to use heat instead of force. Do not hammer on shaft!

• Check shaft alignment when using direct coupling.

• Check shaft parallelism when using belt or chain drive.

CAUTION : Refer to belt manufacturer’s recommendation for belt tension. (Tension should not be applied on chain drives.)

• Check oil level in oil lubricated reducer.

• Install breather plug in the plug hole per recommendations shown on page (5).

Maintenance

To provide safe operation and to avoid problems, it is recommended the reducer or gearmotor be inspected every 50 hours of operating time.

• Check mounting bolts and belt tension (if applicable).

The preventative maintenance list below should be performed every 5000 hours of operating time:

• Check oil level and add oil if necessary.

• Make sure the vent hole in the breather is clean

Browning, Emerson and Emerson Industrial Automation are trademarks of Emerson Electric Co. or one of its affiliated companies. ©2007, 2009, 2010, 2011, 2012, 2014 Emerson Power Transmission, All Rights Reserved. MCIM14001E • Form 9020E • Printed in USA

Combined Reduction

Lubricants

Series 3000 OtN gearing is shipped with one of the following synthetic lubricants per the table below and tted with a magnetic drain. Each reducer is lled according to the mounting position specied when ordered. Refer to unit nameplate and the chart and table on page 4 and 5 for mounting position arrangement for your unit.

In the case of synthetic oil, the lubricant does not require changing but it is recommended that proper oil level be checked periodically.

Standard Synthetic Gear Oil (Non - Food Grade)

No Backstop

Manufacturer

Fuchs* Sintogear

Mobil* Mobilgear

Shell* Omala

-25° F to 125° F

(-30° C to 50° C)

125

SHC 150

S4 GX 150

Standard Synthetic Gear Oil (Food Grade)

No Backstop

Manufacturer

22° F to 125° F

(-20° C to 50° C)

Mobil SHC Cibus 150

CAUTION: Never mix synthetic oil and mineral oil. (1) Never use extreme pressure (EP) oil in a reducer with a backstop.

Acceptable Mineral Oil Lubricants

With Backstop (1)

Manufacturer

Shell Morlina S4 B 700

Mobil SHC 629

-25° F to 125° F

(-30° C to 50° C)

Ambient Range of Installation

-4°F to 14°F

(-20°C to 10°C)

14°F to 122°F (-10°C to 50°C)

No Backstop With Backstop (1)

122°F and Above

(50°C +)

ISO VG 68 ISO VG 100 ISO VG 150 ISO VG 220 ISO VG 150 ISO VG 320

Combined OtN 3000 Gearing

Consists of an OtN primary gear housing and a CbN secondary gear housing. The table below provides the CbN oil volumes in quarts.

OtN

Frame

Size

3245 CbN 30 ** 0.64 ** 0.64 ** 0.64 ** 0.64 ** 0.64 ** 0.64

3365 CbN 31 ** 0.63 ** 1.16 ** 0.90 ** 1.00 ** 1.22 ** 1.48 3475/3476 CbN 31 ** 0.63 ** 1.16 ** 0.90 ** 1.00/1.30 ** 1.22 ** 1.48 3585/3586 CbN 31 ** 0.63 ** 1.16 ** 0.90 ** 1.00/1.30 ** 1.22 ** 1.48 3695/3696 CbN 32 ** 1.00 ** 2.38 ** 1.64 ** 1.85/2.43 ** 2.38 ** 2.85 3705/3706 CbN 32 ** 1.00 ** 2.38 ** 1.64 ** 1.85/2.43 ** 2.38 ** 2.85 3825/3826 CbN 32 ** 1.00 ** 2.38 ** 1.64 ** 1.85/2.43 ** 2.38 ** 2.85

Sec.

Gear

Size

B P H T V W

Prim. Sec. Prim. Sec. Prim. Sec. Prim. Sec. Prim. Sec. Prim. Sec.

** Refer to table on page 5 for the OtN oil volume based on frame size, Mounting Conguration, Mounting Position and Type of Mounting ( i.e. Foot, Flange, etc.) of your unit.

Combined Reduction

Secondary

Mounting Position

Primary

* The following trade names, trademarks and/or registered trademarks are used in this material by Emerson Power Transmission Corporation are NOT owned or controlled by Emerson Power Transmission Corporation and are believed to be owned by the following parties: Fuchs and Sintogear: Fuchs Corporation; Mobil and Mobilgear: Exxonmobil Oil Corporation; Shell and Omala: Shell Petroleum Incorporated.

Emerson Power Transmission Corporation cannot and does not represent or warrant the accuracy of this information.

Plug Location and Oil Volume

S2 Conguration - All mounting styles S1 Conguration - All mounting styles (except foot mounted 33, 34, and 35 – see below)

Mounting Position

Gear

Frame

Design

Plug Type

Size

Level 12 Drain 2 6 2 12 5 2

31 Breather 6 2 8*D 8*G 8 5

B P H T V W

Plug #

Oil Volume

Quarts

0.95

Plug #

Oil Volume

Quarts

1.06

Plug #

Oil Volume

Quarts

0.95

Plug #

Oil Volume

Quarts

0.8

Plug #

Oil Volume

Quarts

1.64

Fill 5 2 12 2 12 5

32 Drain 2 6 2 4 4 2

Double Reduction

Breather 6 2 4 2 8 5

Fill 5 2 4 2 2 5

1.96

Level 4

32 Drain 2 5 2 8 5 8

Breather 6 3 4 3 8 5

0.55

2.06

1.82

1.74

1.5

2.06

1.5

3.12

Fill 5 3 4 2 8 4

33 (A) Drain 2 5 2 4 5 8

Breather 6 4 4 3 4 5

1.16

Level 3

3.7

3.49

2.96

3.96

Fill 5 2 4 2 2 4

34 Drain 2 5 2 4 or 8 5 8

Breather 6 3 4 3 8 5

1.37

Level 3

6.45

5.39

4.65

6.76

Fill 5 2 4 2 8 5

35 Drain 2 5 2 8 5 8

Breather 6 3 5 3 8 5

2.85

Level 3

8.88

5.39

7.72

11.42

Fill 5 2 5 2 8 5

Triple Reduction

36 Drain 2 5 3 4 5 2

Level 5**

Breather 5 10 4 3 11 9

6.08

10**

19.24

4**

14.28

3**

12.9

11**

23.36

Fill 5 10 4 3 11 9

37 Drain 2 5 3 4 5 2

Breather 5 10 4 3 11 9

10.58

Level 5**

10**

4**

20.3

3**

17.97

11***

35.94

Fill 5 2 4 3 11 9

Level 5**

Drain 11 5 3 4 5 2

Breather 5 10 4 3 11 9

10.57

10**

34.87

4**

29.06

3**

22.19

11**

43.32

Fill 5’ 11 4 3 11 9

Plug #

9**

Oil Volume

Quarts*

1.11

2.48

1.4

2.75

3.91

6.61

13.95

25.05

25.36

S1 Congurations 33D,33G,33X for Frames 33,34 and 35. See above for all other mounting.

Gear

Frame

Size

Plug Type

Level 3 Draining 6 2 4 2 5 8 Breather 2 6 3 4 4 5

B P H T V W

Plug#Oil Volume

Quarts

Plug#Oil Volume

Quarts

Plug#Oil Volume

3.7

1.16

Filling 2 5 2 4 2 4

Level 3 Draining 6 2 4 or 8 2 5 8 Breather 2 6 3 5 8 5

6.45

1.37

Filling 2 5 2 5 8 5

Level 3

Adaptor is assembled to position breather location on top when mounted in this position ** This is location for dipstick to check oil level *** This location for dipstick with extension added to check oil level

Draining 6 2 8 2 5 8 Breather 2 6 3 5 8 5

8.88

Filling 2 5 2 5 8 5

2.65

Mounting Position

Quarts

2.96

4.65

7.72

Plug#Oil Volume

Quarts

3.49

5.39

Plug#Oil Volume

Quarts

3.96

6.76

11.42

Quarts

2.75

3.91

6.61

Gearbox Mounting Positions

Foot Mount

Foot Mount with Face or Flange

Flange, Face or Shaft Mount

1. OtN Shaft Mount Reducer Installation

For long service and dependable performance, an OtN shaft mounted gear unit must be properly supported and accurately aligned. The following instructions are a step-by-step guide to meeting these requirements for an OtN 3000 design shaft mounted product. If there is a need to vary or deviate from any of these installation instructions, contact Application Engineering Department at 1-800-626-2093 before completing the installation.

CAUTION: When the driven shaft is smaller than the maximum bushing size for a gear frame, check the driven shaft and key stress per ANSI/AGMA Std. 6001-D97 for the application.

1.1 Reducer and Driven Shaft Preparation

1.1.1 The driven shaft diameter is to be within the commercial tolerances for turned, ground and polished bars. The key and keyseat in the driven shaft are to be in accordance with commercial standards for the size, depth, offset, and parallelism.

1.1.2 The driven shaft on which the gear unit is to be mounted must be straight, clean, and free of burrs.

1.1.3 Rotate the driven shaft on which the gear unit is to be mounted so that the shaft keyseat is in the upward position.

1.1.4 A lifting lug is provided to lift the gear reducer or gearmotor into position.

WARNING! Never lift the gear unit by the input or output shaft. The lifting lug is designed for lifting only the gear reducer or gearmotor. Do not use the lifting lug to lift attached assemblies.

Do not apply grease, oil, or any anti-seize compounds to the taper bore of the reducer, barrel of the bushing, driven shaft or the bushing bore. If any of these substances are applied, equipment failure and personal injury may result.

1.2 Determine Mounting Conguration – Bushed Bore Models

Due to the unique design of OtN bushed shaft mounted product, the reducer may be mounted to the driven shaft in a variety of congurations. The following instructions will help to determine the correct mounting conguration based on the available shaft and key length

1.2.1 Measure the available driven shaft length “H” (in inches) starting with the end of the driven shaft to the rst obstruction or point of interference.

1.2.2 Measure the length of available keyseat “K” in the driven shaft (in inches) starting from the end of the shaft to the end of the useable keyseat.

1.2.3 The following sections 1.3, 1.4, 1.5 show the three standard mounting congurations for the Browning

OtN tapered bushed “33B” gearing. Refer to the following sections in sequence to determine the optimum mounting conguration for your application.

1.2.4 Compare the measured values of H and K of the driven shaft to the tabulated values of H and K. If the measured values for H and K are greater than the tabulated values, the mounting conguration shown in the gure may be used. If the measured values for H and K are less than the tabulated values, proceed to the next gure and repeat this step.

Note: If the measured values for H and K are less than the tabulated values shown in 1-5, contact the Application Engineering Department at 1-800-626-2093.

1.2.5 Tightening torque for bushing components.

Table 1.2.5

33B Taper Bushed Screw Conveyor

EXTERNAL KEY FURNISHED

TYPE 1

BUSHING

TYPE 2

BUSHING

THROUGH KEY FURNISHED

Figure 1-1

BUSHING

FLANGE

EXTERNAL KEY

KEY SHOWN FOR TYPE 2

BUSHING

RING

TYPE 2

BUSHING

Figure 1-2

BUSHING

Gear

Frame

Tapered

Bushing Cap

screws

End Cap

Setscrews

(nylon tipped)

Keeper

Bolts

Size Ft.-Lbs Size In-Lbs Size Ft.-Lbs

31 5/16-18 16 1/4-20 60 - -

32 5/16-18 16 1/4-20 60 1/2-13 99

5/16-18 16 1/4-20 60 1/2-13 99

33A 3/8-16 29 1/4-20 60 - -

34 3/8-16 29 1/4-20 60 5/8-11 200

35 3/8-16 29 1/4-20 60 3/4-10 350

36 3/8-16 29 1/4-20 60 3/4-10 350

37 1/2-13 70 1/4-20 60 1-8 600

38 1/2-13 70 1/4-20 60 1-8 600

This design is replaced by 33A design effective Jan. 2010 for 33B output

1.3 Mounting Conguration with Bushing Outboard of Load

Endcap

Driven

Stabilizer Ring

Shaft

Bushing Ring

Driven Shaft Key

Bushing

Figure 1-3

Table 1-3 Dimensions for Mounting Conguration

with Bushing Outboard of Load

Minimum Shaft

Mounting

Length

Gear

Frame

End cap

Clearance

MC H K

31 0.85 8.23 2.88

32 0.97 9.28 4.38

0.97 9.21 4.38

33A 1.03 11.16 4.63

34 1.03 11.34 4.63

35 1.21 12.23 5.63

36 1.31 16.75 6.13

37 1.44 18.08 7.38

38 1.69 18.43 7.38

This design is replaced by 33A design effective Jan. 2010

1.3.1 On the input shaft side, thread the bushing ring onto the hollow reducer quill until the bushing ring is ush with the end of the reducer quill shaft.

1.3.2 Place the end cap on the driven shaft with the threaded bore facing the end of the shaft. Slide the stabilizer ring on the driven shaft with the small end of the taper toward the end of the shaft.

1.3.3 Install Key(s)

Type 1 Bushing (2 keys):

• Install the external bushing key into the bushing as shown in Figure 1-1 (external bushing key is supplied with the bushing kit)

• Install the driven shaft key (customer supplied) into the driven shaft keyseat. Position the end of the driven shaft key even with the end of the driven shaft. Retain this key to prevent movement.

1.3.4 Install Reducer

Type 1 Bushing

• Mount the reducer on the driven shaft with the bushing ring facing outward toward the end of the driven shaft

Minimum Key

Connection

Length

• Locate the reducer on the driven shaft such that approximately .50 inch of the driven shaft extends out beyond the end of the reducer quill.

• Start the bushing (small end rst) by aligning the keyway in the bushing with the key previously installed in the driven shaft.

• Continue moving the bushing into position and rotate the input of the reducer as required to align the external bushing key with the keyway in the reducer quill.

• Rotate the bushing ring clockwise to align the clearance holes in the bushing with the threaded holes in the bushing ring. (This will require less than 1/2 turn of the bushing ring).

• Install the bushing cap screws and hand tighten. Reposition the reducer until the end of the driven shaft is even with the end of the bushing ring.

• Slide the stabilizer ring into the reducer quill and thread the end cap on hand tight.

• Tighten the bushing cap screws evenly around the bushing ange to the recommended torque as shown Table 1.2.5. See bolt torque specications section.

• Tighten the end cap again until hand tight. Tighten the setscrew in the end cap to the recommended torque from Table 1.2.5.

Type 2 Bushing

• Mount the reducer on the driven shaft with the bushing ring facing outward toward the end of the driven shaft.

• Rotate the input of the reducer as required to align the external bushing key with the keyway in the reducer quill.

• Locate the reducer on the driven shaft such that approximately .50 inch of the driven shaft extends out beyond the end of the reducer quill.

• Start the bushing (small end rst) by aligning the keyway in the bushing with the key previously installed in the driven shaft.

• Rotate the bushing ring clockwise to align the clearance holes in the bushing with the threaded holes in the bushing ring. (This will require less than 1/2 turn of the bushing ring).

• Install the bushing cap screws and hand tighten. Reposition the reducer until the end of the driven shaft is even with the end of the quill.

• Slide the stabilizer ring into the reducer quill and thread the end cap on hand tight.

• Tighten the bushing cap screws evenly around the bushing ange to the recommended torque as shown in Table 1.2.5.

• Tighten the end cap again until hand tight. Tighten the setscrew in the end cap to the recommended torque from Table 1.2.5.

Note: The key length must be sufcient to engage the full length of the bushing. The shaft must engage the full length of the reducer shaft (Refer to “H” in Figure 1-3).

Note: There are three (3) series of bushing keys used in the Type 2 bushing system: rectangular, square and offset. In most cases, the key supplied will be rectangular or offset. Use caution when installing rectangular keys as some may visually appear square. The key should install in the bushing keyway with a sliding type t. The key in the driven shaft keyseat should be retained to prevent movement.

WARNING! The cap screws must thread into the bushing ring and not the bushing. Threaded holes in the bushing are for removal only. If assembled incorrectly, equipment failure and personal injury may result.

1.4 Mounting Conguration with Bushing on Load Side of Reducer and Using Stabilizer Ring

Endcap

Dirt Cover

Stabilizer

Ring

Bushing Ring

Bushing

Driven Shaft

Driven Shaft Keyseat

Figure 1-4

Table 1-4 Dimensions for Mounting Conguration

with Bushing on Load Side of Reducer and Using Stabilizer Ring

Minimum

Gear

Frame

Bolt

Clearance

Shaft

Mounting

Length

MC H K J

31 1.50 9.11 2.88 4.73

32 1.75 10.54 4.38 4.28

1.75 10.47 4.38 4.21

33A 1.88 12.23 4.63 5.83

34 1.88 12.51 4.63 6.01

35 1.88 13.13 5.63 5.62

36 1.88 17.50 6.13 9.49

Minimum

Key

Connection

Length

Max.

Note: Key length must be sufcient to engage the full length of the bushing. The shaft must engage the full length of the bushing.

1.4.2 For Type 2 bushings which require one through key: Install the bushing on the shaft, anged end rst. Align the keyway in the bushing with the keyseat in the shaft and install the shaft key. Position the shaft key ush against the inside ange surface of the bushing. See Figure 1-2 Shaft Key and Bushing Location.

Note: The shaft must be engaged the full length of the bushing.

1.4.3 On the side where the driven shaft enters, thread the bushing ring onto the hollow quill until the bushing ring is ush with the end of the hollow shaft. Rotate the gear unit input to align the keyway in the hollow quill with the bushing/shaft key. Position the reducer on the shaft with the bushing ring toward the bushing.

1.4.4 Slide the stabilizer ring onto the driven shaft with the small end of the taper toward the reducer. Insert the stabilizer ring into the quill.

1.4.5 Thread the end cap and the dirt cover (not used if driven shaft extends beyond the end of the hollow quill) onto the hollow quill until hand tight. Do not tighten the end cap.

1.4.6 Rotate the bushing ring clockwise until the tapped holes align with the drilled holes in the bushing ange. Prior to tightening the cap screws, make sure the bushing key is as close as possible to the inside ange of the bushing as shown in Figure 1-2 and the bushing is positioned on the shaft as required in Figure 1-4. Dimensions for rear mounting conguration with the stabilizer ring.

1.4.7 Install the bushing cap screws and tighten all the cap screws evenly around the bushing ange to the required torque. See bolt torque specications Table 1.2.5.

1.4.8 Tighten the end cap again until hand tight. Tighten the setscrews to the recommended torque. See bolt torque specications Table 1.2.5.

37 2.25 19.76 7.38 10.13

38 2.75 19.05 7.38 7.74

This design is replaced by 33A design effective Jan. 2010

1.4.1 For Type 1 bushings which require an external key and a shaft key: Install the key (supplied with the bushing) in the external keyseat of the bushing as shown in Figure 1-1. Install the shaft key (not supplied) in the shaft keyseat and retain to prevent movement. Install the bushing onto the shaft, anged end rst, align the bushing keyway with the shaft key and position the bushing over the key.

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Emerson 3000 User Manual

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Frequently Asked Questions

User Manual