Caution! - GEA engineering for a better world Documents/Grasso... · 2017-11-10 · Run the drive...

1 Mounting V-belt drive (motor pulley, fly wheel, V-belts and guard)

1.1 General safety instructions, requirements and procedures

General safety instructions

1. Do respect all federal state or local safety regulations during service jobs onthe compressor

2. This service job should be carried out only by those who have been trainedand delegated to do so, and who have read and understood this completeservice instruction

Caution!

Prepare the compressor in accordance with Instruction andMaintenance Manual (IMM), prior to carry out any service job in or onthe compressor

General requirements

Documents

1. Installation and Maintenance Manual (IMM)

General procedure

1. Disconnect the electrical power supply

1.2 Mounting V-belts and guard

Fig.1: Initial situation

Mounting V-belt drive (motor pulley, fly wheel, V-belts and guard)General safety instructions, requirements and procedures

0087528-VBeltDrive-gbr_4 10.11.2017 1

Fig.2: Position motor-plate onto the motor shaft

Fig.3: Position the back-plate onto support brackets on base frame

Fig.4: Tighten back-plate with bolts and nuts

Mounting V-belt drive (motor pulley, fly wheel, V-belts and guard)Mounting V-belts and guard

0087528-VBeltDrive-gbr_42 10.11.2017

Fig.5: Mounting fly-wheel and motor pulley

1 Slide compressor pulley and motor pulley onto the shafts

2 Tighten the compressor pulley (fly-wheel), refer for details Page 5

3 Align and tighten the motor pulley and mount V-belts, refer for details Section 1.3, Page 4.

Fig.6: Tighten the motor-plate to the back-plate with bolts and nuts in the slots of the back plate

Fig.7: Position the front-cover between the support brackets on the base frame

Mounting V-belt drive (motor pulley, fly wheel, V-belts and guard)Mounting V-belts and guard

0087528-VBeltDrive-gbr_4 10.11.2017 3

Fig.8: Tighten the front-cover with bolts and nuts

Fig.9: Attach the inspection-plate on top of the front-plate

1.3 Instruction mounting V-belts

Introduction

Modern V belt drives are designed to transfer max. power/torque with a minimumamount of belts. New types of belt material allow higher loads but on the otherhand also require more accurate tensioning to guarantee highest efficiency.

For the new generation of V-series reciprocating compressors Grasso use:

1. type V-belts; XPBTo ensure that you benefit from a long lasting and high performance drive systemyou have to fully comply with the mounting instructions as written below.

Requirements

1. Common toolbox

2. Groove gauge

3. Belt tension indicator, Figure 11, Page 7

4. Table with required belt tension forces technical data, Page 18

Mounting V-belt drive (motor pulley, fly wheel, V-belts and guard)Instruction mounting V-belts

0087528-VBeltDrive-gbr_44 10.11.2017

Mounting conditions

1. Flywheel and pulley must be free from scores and sharp edges

2. Groove dimensions according relevant standard (groove gauge)

3. Groove(s) free from grease and paint.

4. Grsso V 300 .. 600; The compressor flywheel must be mounted with adistance of X=2 mm from the boss of the crankshaftGrasso V 700 .. V 1800; Start with X=0 mm (after tightening distance X>0mm)

5. Correct alignment of compressor flywheel and motor pulley

6. Very important:

Caution!

Please note that with replacement of the V-belts never V-belts fromdifferent brands and/or different batches are being used at one driveset

X1 2a2b

Fig.10: Detail mounting fly-wheel pulley on crankshaft compressor

1 Crankshaft compressor

2a Grasso V 300 .. 600; Clamping bush, refer to Section 2.1, Page 9

2b Grasso V 700 .. 1800; Clamping set, detachable shaft-hub-connection, refer to instructionSection 2.2, Page 10

X Grasso V 300 .. 600, X=2 mm // Grasso V 700 .. 1800; X=0 mm

Belt installation

1. Check alignment of flywheel and motor pulley

2. ►Good alignment of pulleys is important to avoid belt flank wear. Thediagram in Figure 13, Page 8 show some of the common alignment faults.Pulley misalignment should not exceed 0.5o angularly and 3 mm/mtr. drivecentre distance axially.

3. Check correct mounting of the motor pulley on the drive shaft.

4. ►Pulleys are secured with ”Taper Lock” type bushes and therefore theinstallation leaflet, supplied with every bush, must be consulted.


0087528-VBeltDrive-gbr_4 10.11.2017 5

5. Check correct number of belts to be used. (Product Information, Section 2.3,Page 14)

6. ►Less belts as calculated ►result in excessive wear and shorter lifetime

7. ►More belts as calculated ►higher load on compressor and motor bearingsand possible belt whip

8. ►The drive centre distance should be reduced prior to the installation of thebelts so that they may be fitted without the use of force. Under nocircumstances belts must be pushed into the grooves by mechanical forceotherwise damage of the belts & pulleys can occur.

9. Install the belts to be a snug fit around the pulleys, starting on groove closestto the compressor

10. ►Mount belts as close as possible to compressor housing in order tominimize bearing and shaft load.

11. ►Spin the pulleys manually 3-4 revolutions to bed the belts into the pulleygrooves. Beware of finger entrapment between belts and pulley!

12. Read the required tensioning force (in kgf.) at a deflection of 10 mm atPage 18 and add 10% to compensate for permanent lengthening of thebelt(s) after first tensioning.

You can use one of the following tools to check the belt tension:

1. “Gates” belt tension tester (Refer Figure 11, Page 7), recommended

2. ►Place the belt tension indicator on the top of the belt at the center of thespan and apply a force perpendicular to the belt deflecting it to the pointwhere the lower marker ring is level with the top of an adjacent belt.

3. ►Read the setting force value indicated by the top edge of the upper markerring. Compare this force with the required kgf. value (Refer Page 18) incl.the 10%

4. Quality spring balance, alternative

5. ►Place the spring balance at the center of span and apply a forceperpendicular on the belt (pulling) inwards until the required kgf. (ReferPage 18) incl. the 10% has been reached. The measured deflection relatedto an adjacent belt must be corresponding with 10 mm

Next installation steps:

1. Fit V-belt protection guard

2. Run the drive line at high load for approx. 24 hours

3. Stop compressor, check and if necessary re-tension to correct required forceaccording to Page 18

4. Re-fit V –belt protection guard

5. With a drive that is properly designed for the application there should be nofurther attention during the life of the belts.


0087528-VBeltDrive-gbr_46 10.11.2017

Important remarks

Excessive contamination by oil, certain cutting fluids, water or rubber solvent cancause belt swelling, softening and slipping.Insufficient belt tension, excessive heat and/or chemical fumes can cause radialcracks on top or bottom side.Belt whip is often caused by incorrect tensioning especially on long centre drives.If a slightly higher (or lower) tension does not cure the problem, there may be acritical vibration frequency in the system which requires a redesign.

Caution!

Note: Too much (>10%) over tightening can cause overload (damage)to compressor/motor bearingsAttention: When you design your own driveline be aware that longercenter distances between the driver and the driven component(compressor) increase the introduction of belt whip! Consult yourlocal Grasso supplier if you have any questions or need assistance.

Fig.11: Tension tester, Grasso Code 7340130

Fig.12: Deflection

X Deflection, refer Page 18

CP Compressor pulley

MP Motor pulley

CD Centre distance


0087528-VBeltDrive-gbr_4 10.11.2017 7

Fig.13: Alignment

A Angular misalignment

B Composite misalignment

C Axial misalingment

D Corredt installation - both shafts and pulleys are parallel and in alignment

Mounting V-belt drive (motor pulley, fly wheel, V-belts and guard)

0087528-VBeltDrive-gbr_48 10.11.2017

2 APPENDIX

2.1 Grasso V300 .. 600; MOUNTING FLYWHEEL (0087169)

Introduction

X1


1 Crank shaft

X Grasso V 300 .. 600; Initial X=2 mm

Requirements

1. Common tool box

Fig.15: Flywheel

1. Remove the protective coating from the bore and outside of bush, and bore ofhub. After ensuring that the mating tapered surfaces are completely clean andfree from oil or dirt, insert bush in hub so that the holes line up.

2. Sparingly oil thread and point of grub screws or thread and under head of capscrews. Place screws loosely in holes threaded in hub.

3. Clean shaft and tab the key into the crankshaft keyway.

APPENDIXGrasso V300 .. 600; MOUNTING FLYWHEEL (0087169)

0087528-VBeltDrive-gbr_4 10.11.2017 9

4. Fit the hub and bush to shaft as one unit and locate in position desired,remembering that bush will nip the shaft first and then hub will be slightlydrawn on to the bush.

Fig.16

5. Using a hexagon wrench tighten screws (1) gradually alternately until all arepulled up very tightly.

6. Hammer against large end of bush, using a block or sleeve to preventdamage. This will ensure that the bush is seated squarely in the bore).Screws will now turn a little more. Repeat this alterate hammering and screwtightening once or twice until correct tightening torque.

7. After drive has been running under load for a half or one running hour, stopand check tightness of screws.

8. Fill empty holes with grease to exclude dirt.

2.2 Grasso V 700 .. 1800; MOUNTING FLYWHEEL(0087168)

Introduction

X1


1 Crank shaft

X Grasso V 700 .. 1800; Initial X=0 mm (After tightening the clamping set X will increase slightly)

APPENDIXGrasso V 700 .. 1800; MOUNTING FLYWHEEL(0087168)

0087528-VBeltDrive-gbr_410 10.11.2017

Requirements

1. Common toolbox

Mounting conditions

1. Flywheel and pulley must be free from scores and sharp edges

2. Groove dimensions according relevant standard (groove gauge)

3. Groove(s) free from grease and paint.

4. Start with X=0 mm (after tightening distance X>0 mm)

Caution!

Maximum permissible tolerances h8 shaft /H8 hubContact surfaces with roughness; Rtmax 16 micronError of concentricity; 0.02 - 0.04 mm

Details

Fig.18

A Compressor shaft-end

B Clamping set

C Grooved part of fly wheel

D Non-grooved part of fly wheel

E "Front" mark (do not mount the fly wheel the other way around)

F Pulley "stop breast"


0087528-VBeltDrive-gbr_4 10.11.2017 11

Fig.19

Fig.20

Legend Figure 20, Type DIN 912 12.9 M10 x 60

d x D mm 75 x 115

L1 mm 70

L2 mm 78

B mm 88

Torque Nm 11733

Axial force kN 313

Surface pressure shaft N/mm2 220

Surface pressure hub N/mm2 115

Torque Nm 83

Weight kg 3.3


0087528-VBeltDrive-gbr_412 10.11.2017

Fig.21: Gap in the inside clamping element must be in line with the gap in the outer ring

Assembly

1. Check the shaft and hub position regarding the permitted tolerances h8/H8

2. Carefully clean the hub and shaft contact surfaces

Caution!

Oils and greases with molybdenum sulfide or high-pressure additives,additives of Teflon and silicone as well as slide grease pastes mustnot be used which would considerably reduce the coefficient offriction

3. Lightly unscrew the clamping screws to facilitate the assembly, fix the internaland external ring via the pull-off threads by means of 2-off clamping screws.Insert the clamping set between shaft and hub.

4. Remove the clamping screws used for fixing and screw in the threads of theexternal ring agin. Slightly tighten the clamping screws manually and align theclamping set with hub part. Tighten the clamping screws stepwise and withseveral resolutions evenly crosswise to the tightening torque "Ms" mentionedin the table respectively, 83 Nm. Repeat the process until a 1/4 revolution ofthe screws is no longer possible. Afterwards tighten the clamping screws oneafter another at the tightening torque mentioned over one revolution.

Disassembly

1. Release all clamping screws evenly one after the other and unscrew them

2. Screw the clamping screws into the threads of the internal ring

3. Tighten the clamping screws evenly at 1/4 revolution crosswise. Increase thecompression torque stepwise until external ring and internal ring areseparated

4. Remove the unscrewed clamping set between shaft and hub


0087528-VBeltDrive-gbr_4 10.11.2017 13

2.3 V-BELT SELECTION

Additional information V-belt drive

1. Transmitted power is based on V-belt type XPB

2. V-belt drive has to be mounted according to Grasso instruction sheet

3. In case of local product designed compressor packages, the selection datafrom this chapter must be used.

APPENDIXV-BELT SELECTION

0087528-VBeltDrive-gbr_414 10.11.2017

Tran

smitt

ed P

ower

Gra

sso

V 30

0(T)

.. V

600

(T)

Gra

sso

V 30

0(T)

.. V

600

(T)

Tran

smitt

ed P

ower

(kW

)Q

ty x

V-be

lts

Com

pres

sor s

peed

with

mot

or s

peed

147

5 m

in-1

50

Hz

Com

pres

sor s

peed

with

mot

or s

peed

177

5 m

in-1

60

Hz

656

738

831

937

1054

1171

1328

1475

631

704

789

888

1000

1127

1260

1420

Max

. sha

ft po

wer

com

pres

sor t

otra

nsm

it (k

W),

depe

ndin

g on

num

ber o

f V-b

elts

1xX

PB

2833

3742

4651

4752

2629

3338

4245

4348

2xX

PB

5765

7584

9310

194

104

5158

6775

8589

5310

0

3xX

PB

8598

112

126

139

152

140

156

7788

100

113

127

134

7915

0


0087528-VBeltDrive-gbr_4 10.11.2017 15

Tran

smitt

ed P

ower

Gra

sso

V 70

0(T)

.. V

180

0(T)

Gra

sso

V 70

0(T)

.. V

180

0(T)

Tran

smitt

ed P

ower

(kW

)Q

ty x

V-

belts

Com

pres

sor s

peed

with

mot

or s

peed

147

5 m

in-1

50

Hz

Com

pres

sor s

peed

with

mot

or s

peed

177

5 m

in-1

60

Hz

656

738

831

937

1054

1171

631

704

789

888

1000

1127

Max

. sha

ft po

wer

com

pres

sor t

o tra

nsm

it(k

W),

depe

ndin

g on

num

ber o

f V-b

elts

1xX

PB

2833

3742

4651

2629

3338

4245

2xX

PB

5765

7584

9310

151

5867

7585

89

3xX

PB

8598

112

126

139

152

7788

100

113

127

134

4xX

PB

113

130

149

168

186

202

102

117

134

150

169

179

5xX

PB

142

163

187

211

232

253

128

146

167

188

212

224

6xX

PB

170

195

224

253

279

303

154

175

200

225

254

268


0087528-VBeltDrive-gbr_416 10.11.2017

V-be

lt dr

ive

sele

ctio

n da

ta G

rass

o V

300(

T) ..

V 1

800(

T)

Gra

sso

V 30

0(T)

.. V

180

0(T)

Com

pres

sor s

peed

with

mot

or s

peed

147

5 m

in-1

50

Hz

Com

pres

sor s

peed

with

mot

or s

peed

177

5 m

in-1

60

Hz

65

673

883

193

710

5411

7113

2814

7563

470

478

988

810

0011

2712

6014

20

Dia

met

er m

otor

pul

ley

(mm

)28

031

535

540

045

050

045

050

022

425

028

031

535

540

035

540

0

Dia

met

er fl

y w

heel

(mm

)63

050

063

050

0

Fram

e si

ze m

otor

..(A

1, A

2, e

tc, r

efer

Pag

e 18

)

<= 2

50A

1<=

250

B1

<= 2

50C

1

<= 250)

D1

EF

<= 3

15G

1<=

315

H1

<= 2

50J1

<= 3

15K

1<=

250

L1<=

225

M1

<= 2

50N

1<=

315

P1

<= 3

15Q

1<=

315

R1

> 25

0A

2>

250

B2

> 25

0C

2>

250

D2

EF

= 35

5G

2=

355

H2

> 25

0J2

= 35

5K

2>

250

L2>

225

M2

> 25

0N

2=

355

P2

= 35

5Q

2=

355

R2


0087528-VBeltDrive-gbr_4 10.11.2017 17

Centre distance, length and required force

Dependancies on frame size motor

Frame sizemotor, referPage 17

Lenght V-belts Centre distance

Required force at max. deflexion of 10mm1

V-belts > 1operating hour[kgf]

(New) V-Belts < 1operating hour [kgf]

A1 3350 944 4.9 5.4

A2 3550 1046 5.3 5.8

B1 3550 1021 5.4 5.9

B2 3750 1122 4.8 5.3

C1 3550 992 5.6 6.2

C2 3750 1093 5.0 5.5

D1 3550 959 6.0 6.6

D2 3750 1060 5.4 5.9

E 3750 1023 5.8 6.4

F 3750 985 6.3 6.9

G1 3350 929 7.1 7.8

G2 3550 1020 7.0 7.7

H1 3350 890 8.1 8.9

H2 3550 990 9.0 9.9

J1 3350 983 5.2 5.7

J2 3550 1085 4.8 5.3

K1 3350 965 5.5 6.1

K2 3550 1067 4.9 5.4

L1 3350 944 5.8 6.4

L2 3550 1046 5.1 5.6

M1 3350 919 6.0 6.6

M2 3550 1021 5.4 5.9

N1 3550 992 5.7 6.3

N2 3750 1093 5.3 5.8

P1 3550 959 6.1 6.7

P2 3750 1060 5.9 6.5

Q1 3150 901 6.4 7.0

Q2 3350 1001 6.6 7.3

R1 3150 867 7.8 8.6

R2 3350 967 7.8 8.6

1 Refer to Grasso instruction


0087528-VBeltDrive-gbr_418 10.11.2017

f

Fig.22: Flywheel Grasso V(T)

Flywheel data, refer to Figure 22,

Diameter Remark Dims 500 630 630

Number of grooves 8 8 6

Max. allowed number of V-beltsGrasso V 300(T) .. 600(T) 3 3 -

Grasso V 700(T) .. 1800(T) - - 6

Type of Groove XPB

Mass. approx. kg 54 60 143

Mass moment of inertia kg.m2 1.9 3.9 10.0

a mm 158

b (pitch) mm 19.0

cCentre first groove - flywheel

mm 12.5

dCentre compr. foot - centre first

groove

Grasso V 300(T) .. 600(T) mm 81.5 86 -

Grasso V 700(T) .. 1800(T) mm - - 92.5

eCentre compr. foot - flywheel

Grasso V 300(T) .. 600(T) mm 227 231.5 -

Grasso V 700(T) .. 1800(T) mm - - 238

fFree space between flywheel and

crankcase

Grasso V 300(T) .. 600(T) mm 59 64 -

Grasso V 700(T) .. 1800(T) mm - - 69

APPENDIX

0087528-VBeltDrive-gbr_4 10.11.2017 19

APPENDIX

0087528-VBeltDrive-gbr_420 10.11.2017

Caution! - GEA engineering for a better world Documents/Grasso... · 2017-11-10 · Run the drive...

Documents

Transcript of Caution! - GEA engineering for a better world Documents/Grasso... · 2017-11-10 · Run the drive...