Airlocks Manual

OPERATION, INSTALLATION, & MAINTENANCE MANUAL forAircon Flex-air AN Airlocks Aircon Corporation P.O. Box 80446 2873 Chelsea Avenue Memphis, TN 38108-0446 Telephone: (901) 452-0230 FAX: (901) 452-0750 AIRCON CORPORATION2INTRODUCTIONThe Aircon "Flex-Air" valve was designed for use as airlocks, pneumatic feeders on conveying systems, or as product metering devices. Available in eight sizes, the valves can maintain an air seal at pressures or vacuums up to 17" WG (water gage). A precision fabricated valve, the "Flex-Air" features a one-piece, full pocket, double wiper design. This design makes it possible to create the best air seal with flexible edge rotors. Aircon "Flex-Air" Valves are ideal for use in industries such as woodworking, metalworking, grain, paper and many more. AIRCON CORPORATION3OPERATING PRINCIPLE A rotary valve (or airlock) offers a means of conveying solid material between two devices of unequal pressures. An airlock may be also be used between either a positive or negative pressured device and the atmosphere. Forming sealed barriers against the inside of the valve body, the six sets of dual wipers are able to resist leakage up to pressure differences of 17" WG. Airlock blades turn at low speeds between 18 and 22 RPM (revolutions per minute), requiring either gear reducers or chains and sprockets for their operation. Forming pockets of displacement between wipers, airlocks are able to meter product in a continuous and consistent manner. AIRCON CORPORATION4OPERATING INSTRUCTIONS RECEIVINGAircon Flex-Air Airlocks are quality manufactured and tested prior to shipment. Upon receipt of order, the customer should check for any possible damage that may have occurred during shipping. The carrier is responsible for any damage incurred in transit. All damage reports must be made with the carrier upon receipt of order. INSTALLATIONAirlocks will be shipped complete with motor and gear reducer (or chains and sprockets) mounted. If a desired rotation is required, this can be achieved with a short ON/OFF operating cycle and a visual check of shaft rotation. See the rotation arrow on the end plate for proper rotation. OPERATING REQUIREMENTS All motors required for Aircon airlocks are three-phase TEFC (Totally Enclosed Fan Cooled) operating at 1800 nominal RPM, requiring a voltage supply of 230 or 460 VAC (volts of alternating current) at 60 hertz. START-UP CHECKLIST 1. Reducer securely mounted to adaptor plate. 2. Top flange of airlock firmly bolted to flange above it. AIRCON CORPORATION5ROUTINE MAINTENANCE Monthly Lubricate shaft flange bearings. Quarterly (every three months) 1. Check internal wipers of airlock for signs of wear. 2. Check gear oil level in reducer AIRCON CORPORATION6SAFETYBefore conducting any maintenance procedures on the airlock, please observe the following safety precautions: 1. Turn off, disconnect, and lock out power to airlock motor and to all fans within the system, and lock out all electrical disconnects for all associated and auxiliary equipment. This includes any level indicator with moving parts in a hopper above the airlock, and especially any type of conveyor located below the airlock. 2. Do not touch the outer surface of the motor housing until the motor has been turned off and allowed to cool for at least twenty minutes. AIRCON CORPORATION7STANDARD FEATURES OF AIRCON FLEX-AIR AIRLOCKS 1. Flexible-edge rotors of 4-ply Transmission Belting. 2. Lifting lugs to facilitate moving. 3. Chain-driven sprockets complete with hand guard. 4. One coat of rust-inhibitive primer, and one coat of Aircon Machine Gray enamel paint. OPTIONAL FEATURES OF AIRCON FLEX-AIR AIRLOCKS 1. Explosion proof motors, NEMA 9, class II, groups E, F, & G. 2. Flexible edge rotors of E.P.D.M., polyurethane, or silicone. 3. Larger shaft sizes and thicker blades for heavy-duty applications. 4. Paint per customer specifications. AIRCON CORPORATION8AN ROUND and SQUARE AIRLOCKS SUGGESTED SPARE PARTS LIST MODEL QTY. DESCRIPTION AN-8 (1) Std. duty 4-bolt flg. 1 7/16" dia. bearing (6) 9 ½" x 13 ¾” x 4-ply trans. belting wipers (8) 1 7/16" ID x 2 ¼"OD x ¼" Neoprene spacers AN-10 (1) Std. duty 4-bolt flg. 1 7/16" dia. bearing (6) 12" x 17" x 4-ply trans. belting wipers (8) 1 7/16" ID x 2 ½"OD x ¼" Neoprene spacers AN-12 (1) Std. duty 4-bolt flg. 1 11/16" dia. bearing (6) 13 ½" x 20 ½" x 4-ply trans. belting wipers (8) 1 11/16" ID x 2 ½"OD x ¼" Neoprene spacers AN-16 (1) Std. duty 4-bolt flg. 1 15/16" dia. bearing (6) 17 ½" x 28 ¼" x 4-ply trans. belting wipers (8) 1 15/16"ID x 2 ¾" OD x ¼" Neoprene spacers AN-20 (1) Std. duty 4-bolt flg. 2 3/16" dia. bearing (6) 21 ½" x 36 ½" x 4-ply trans. belting wipers (8) 2 3/16" ID x 3 ¼"OD x ¼" Neoprene spacers AN-24 (1) Std. duty 4-bolt flg. 2 3/16" dia. bearing (6) 25 ½" x 42 ½" x 4-ply trans. belting wipers (8) 2 3/16" ID x 3 ¼"OD x ¼" Neoprene spacers AN-30 (1) Std. duty 4-bolt flg. 2 15/16" dia. bearing (6) 31 ½" x 54 ½" x 4-ply trans. belting wipers (8) 2 15/16" ID x 3 ¼"OD x ¼" Neoprene spacers NOTES: All wipers are 4-ply trans belting and spacers 60 durometer neoprene. Six (6) wipers constitute one complete set. ANS SQUARE EXTENDED SHAFT AIRLOCK SUGGESTED SPARE PARTS LIST AIRCON CORPORATION9MODEL QTY. DESCRIPTION ANS-8-E (1) Std. duty 4-bolt flg. 1 7/16" dia. bearing (6) 9 ½" x 13 ¾” x 4-ply trans. belting wipers (8) 1 7/16" ID x 2 ¼"OD x ¼" Neoprene spacers ANS-10-E (1) Std. duty 4-bolt flg. 1 7/16" dia. bearing (6) 12" x 17" x 4-ply trans. belting wipers (8) 1 7/16" ID x 2 ½"OD x ¼" Neoprene spacers ANS-12-E (1) Std. duty 4-bolt flg. 1 11/16" dia. bearing (6) 13 ½" x 20 ½" x 4-ply trans. belting wipers (8) 1 11/16" ID x 2 ½"OD x ¼" Neoprene spacers ANS-16-E (1) Std. duty 4-bolt flg. 1 15/16" dia. bearing (6) 17 ½" x 28 ¼" x 4-ply trans. belting wipers (8) 1 15/16"ID x 2 ¾" OD x ¼" Neoprene spacers NOTES: All wipers are 4-ply trans belting and spacers 60 durometer neoprene. Six (6) wipers constitute one complete set. Aircon CorporationP.O. Box 80446 • Memphis, Tennessee 38108(901) 452-0230 • FAX (901) 452-0564E-mail: sales@aircon-corporation.comWebsite: www.aircon-corporation.comFlex-Tip “AN” Square AirlocksEFFECTIVE:January 1, 2002SUPERSEDES: January 1, 2000Information on this page for quotation purposes only, not for construction unless certified. Data subject to change without notice. All dimensions are in inches unless noted. NOTE: All bolt holes are 7/16” diameter • * AN-8 Has only 8 holes equally spacedQty. Shaft Motor Capacity Shipping Wt.Model # A B C D E F G H Bolts Dia. (HP) (CF/REV) RPM (lbs.)ANS-8 8 1/8” 4 15/16” * 0” 36 1/4” 20 1/8” 9 1/8” 17 1/4” 10 3/8” 8 1 7/16” 1/2 0.64 21.1 244ANS-10 10 1/8” 4” 4” 40 1/2” 23 1/8” 10 5/8” 20” 11 7/8” 12 1 7/16” 3/4 1.34 19.9 320ANS-12 12 1/8” 4 1/2” 4 7/8” 45 1/2” 27” 12 5/8” 22 1/2” 13 1/4” 12 1 11/16” 1 2.46 18.6 430ANS-16 16 1/8” 6” 5 3/4” 55 3/4” 35” 16 1/2” 26 1/2” 15 3/8” 12 1 15/16” 2 6.20 17.4 690GHTOP VIEWSIDE VIEW INLET & OUTLET FLANGEDAEFB C BCHAIN & GUARDFLANGED INLETGEAR BOXMOTORAAircon CorporationP.O. Box 80446 • Memphis, Tennessee 38108(901) 452-0230 • FAX (901) 452-0564E-mail: sales@aircon-corporation.comWebsite: www.aircon-corporation.comEFFECTIVE:January 1, 2002SUPERSEDES: January 1, 2000Information on this page for quotation purposes only, not for construction unless certified. Data subject to change without notice. All dimensions are in inches unless noted.Flex-Tip “AN” Round AirlocksNOTE: All bolt holes are 7/16” diameter, except AN-8 (3/8” diameter)Qty. Shaft Motor Capacity Shipping Wt.Model # A B C D E F G H Bolts Dia. (HP) (CF/REV) RPM (lbs.)AN-8 8 1/8” 9 9/16” 10 3/8” 36 1/4” 20 1/8” 9 1/8” 17 1/4” 10 3/8” 6 1 7/16” 1/2 0.64 21.1 244AN-10 10 1/8” 11 13/16” 12 7/8” 40 1/2” 23 1/8” 10 5/8” 20” 11 7/8” 6 1 7/16” 3/4 1.34 19.9 320AN-12 12 1/8” 14” 15 1/8” 45 1/2” 27” 12 5/8” 22 1/2” 13 1/4” 8 1 11/16” 1 2.46 18.6 430AN-16 16 1/8” 18” 19 1/8” 55 3/4” 35” 16 1/2” 26 1/2” 15 3/8” 8 1 15/16” 2 6.20 17.4 690AN-20 20 1/8” 21 3/4” 23 1/8” 68 1/4” 43 1/2” 20 3/4” 31 3/8” 17 7/8” 12 2 3/16” 3 12.6 17.4 1070AN-24 24 1/8” 25 7/8” 27 1/8” 74 3/8” 49 1/2” 23 3/4” 35 3/8” 19 7/8” 12 2 3/16” 3 21.0 17.4 1215AN-30 30 1/8” 32 3/8” 34 1/8” 86 1/4” 63 1/2” 29 3/4” 44 3/8” 24 7/8” 16 2 15/16” 5 43.0 15.5 2155INLET & OUTLET FLANGEABCGHTOP VIEWSIDE VIEWDAEFCHAIN & GUARDFLANGED INLETGEAR BOXMOTORPage 1 of 111/21/2007http://img.directindustry.com/pdf/repository_di/15926/27064_8b.jpg2000RA?WORM GEAR REDUCERINSTALLATION AND MAINTENANCE MANUALOctober 17, 2005Irvine, California (800) 654-6220Indianapolis, Indiana (800) 866-7973Hamilton, Ontario (800) 809-0330e-mail: sales@sterlingelectric.comwww.sterlingelectric.com116752 Armstrong Avenue, Irvine, CA 926067973 Allison Avenue, Indianapolis, IN 46268799 Rennie St., Hamilton, Ontario L8H7L4Website: www.sterlingelectric.com(800) 654-6220 FAX (949) 474-0543(800) 866-7973 FAX (317) 872-0907(800) 809-0330 FAX (905) 547-2381email:sales@sterlingelectric.com2000RA WORM GEAR REDUCER INSTRUCTION MANUALSELECTION INFORMATIONRead ALL instructions prior to operating reducer. Improper maintenance or operation may cause injury to personnel or reducer failure.Written authorization from Sterling Electric is required to operate or use reducers in man lift or people moving devices.Check to make certain application does not exceed the allowable load capacities published in the current catalog.Buyer shall be solely responsible for determining the adequacy of the product for any and all uses to which buyer shall apply the product. The application by buyer shall not be subject to any implied warranty of fitness for a particular purpose. Information contained in this manual is considered correct at the time of publication and is subject to change without notice.SAFETY ALERTWARNING: For safety, purchaser or user should provide protective guards over all shaft extensions and any moving apparatus mounted thereon. The user is responsible for checking all applicable safety codes in his area and providing suitable guards. Failure to do so may result in bodily injury and/or damage to equipment.WARNING: Hot oil or reducers can cause severe burns. Use extreme care when removing lubrication plugs and vents.WARNING: Make certain that the power supply is disconnected before attempting to service or remove any components. Lock out the power supply and tag it to prevent unexpected application of power.WARNING: Reducers are not to be considered fail safe or self-locking devices. If these features are required, a properly sized, independent holding device should be utilized.WARNING: Any brakes that are used in conjunction with a reducer must be sized or positioned in such a way as to not subject the reducer to loads beyond the catalog rating.CAUTION: Test run unit to verify operation. If the unit tested is a prototype, that unit must be of current production.CAUTION: If the speed reducer cannot be located in a clear and dry area with access to adequate cooling air supply, then precautions must be taken to avoid the ingestion of contaminants such as water and the reduction in cooling ability due to exterior contaminants. Reducers located in confined spaces may require forced air-cooling.2IMPORTANT INFORMATIONIn the event of the resale of any of the goods, in whatever form, Resellers/Buyers will include the following language in a conspicuous place and in a conspicuous manner in a written agreement covering such sale:The manufacturer makes no warranty or representations, expressed or implied, by operation of law or otherwise, as to the merchantability or fitness for a particular purpose of the good sold hereunder. Buyer acknowledges that it alone has determined that the goods purchased hereunder will suitably meet the requirements of their intended use. In no event will manufacturer be liable for consequential, incidental or other damages. Resellers/Buyers agree to also include this entire document including the warnings above in a conspicuous place and in a conspicuous manner in writing to instruct users on the safe usage of the product.This instruction manual should be read together with all other printed information such as catalogs, supplied by Sterling Electric.GENERAL OPERATION1. Run the motor, which drives the reducer, and check the direction of reducer output rotation. Consult motor nameplates for instructions to reverse the direction of rotation.2. Attaching the load: On direct-coupled installations, check shaft and coupling alignment between speed reducer and loading mechanism. On chain/sprocket and belt/pulley installation, locate the sprocket or pulley as close to the oil seal as possible to minimize overhung load. Check to verify that the overhung load does not exceed specifications published in the catalog.3. High momentum loads: If coasting to a stop is undesirable, a braking mechanism should be provided to the speed reducer output or the driven mechanism. CAUTION: The system of connected rotating parts must be free from critical speed, torsional or other type vibration, no matter how induced. The responsibility for this system analysis lies with the purchaser of the speed reducer.RUN-IN PERIODThe maximum efficiency of worm reducers is obtained after a “Run-In” period. The length of time required will depend on the load applied and may be two to four hours at rated load and will be considerably longer at lighter loads. Overloading will not decrease the “Run-In” time but will cause severe wear and damage to the unit. During “Run-In”, higher than normal motor current and temperatures along with lower efficiency and output torque can be expected.SELF-LOCKING ABILITYUnder no condition should Sterling Electric, Inc. worm gear reducers be considered to hold a load at rest. The statement is made to cover the broad spectrum of variables effecting self-locking characteristics of a particular gear set in a particular application. Theoretically, a worm gear will not back drive if the friction angle is greater than the worm lead angle. However, the actual surface finish and lubrication may reduce this significantly. More important, vibration may cause motion at the point of mesh with further reduction in friction angle. No guarantee should be made and the customer should be advised that if these features are required, a properly sized, independent holding device, such as a brake, should be utilized in order to maintain a 3safe working environment. Sterling Electric, Inc. cannot accept liability for any damage to personnel or property that may occur from the application of worm gear reducers in which the self-locking ability is utilized to hold a load.INSTALLATION1. Mount the unit to a rigid flat surface using grade 5 or higher fasteners. The mounting fasteners should be the largest standard size that will fit in the base mounting hole. Shim as required under flange or base feet that do not lie flat against the mounting surface.2. For shipment, pipe plugs are installed in the unit and a vent plug is packed separately. After mounting the unit in position, remove the appropriate pipe plug and install the vent plug in the location shown in the chart under LUBRICATION. On double reduction units both the primary and the secondary must be vented. Failure to vent the unit can cause premature seal wear or loss of seal and oil. These conditions are not covered by warranty. Check for correct oil level. Contact the factory for level and vent recommendations on non-standard mounting positions.3. Connect motor to speed reducer.WARNING: Depending upon gear geometry and operating conditions worm gear reducers may or may not backdrive. Special consideration should be given to high inertia loads connected to the output shaft. Consult the factory for further details.CAUTION: DO NOT CHANGE MOUNTING POSITIONS WITHOUT CONTACTING FACTORY. Altering the mounting position may require special lubrication provisions that must be factory installed.CAUTION: Do not operate the reducer without making sure it contains the correct amount of oil. Do not overfill or underfill with oil, or injury to personnel, reducer or other equipment may result.CAUTION: A unit cannot be used as an integral part of a machine superstructure which would impose additional loads on the unit other than those imposed by the torque being transmitted either through a shaft-mounted arrangement, and any shaft mounted power transmitting device. (e.g. sprockets, pulleys, couplings)CAUTION: For safe operation and to maintain the unit warranty, when changing a factory installed fastener for any reason, it becomes the responsibility of the person making the change to properly account for fastener grade, thread engagement, load, tightening torque and the means of torque retention.4LUBRICATIONCAUTION: On ALL quill style input units, cast iron and stainless, single and double reduction, with a motor mounted vertical shaft up on the input will require a double input seal arrangement to prevent leakage. Consult factory.RECOMMENDED LUBRICATION OILSManufacturer 30? F to 100? F Ambient TemperatureAGMA #7 (ISO 460)30? F to 125? F Ambient TemperatureAGMA #8 (ISO 680)Amoco Oil Co. Worm Gear Oil Cylinder Oil #680Chevron USA, Inc. Cylinder Oil #460X Cylinder Oil #680XExxon CO. USA Cylesstik TK-460 Cylesstik TK-680Gulf Oil Co. Senate 460 Senate 680DMobil Oil Co. 600 W Super Cylinder Extra Hecla SuperShell Oil Co. Valvata Oil J460 Valvata Oil J680Sun Oil Co. Gear Oil 7C Gear Oil 8CTexaco Honor Cylinder Oil 650T Cylinder OilUnion Oil of CA Steaval A Worm Gear Lube 140Note: Some gear lubricants contain EP additives that can be corrosive to gear bronze. Avoid lubricants that are compounded with sulfur and/or chlorine. For temperature ranges not shown, contact factory. For lubrication requirements of helical reducers of helical/worm combinations, contact factory.OIL CAPACITIES (FLUID OUNCE)UNIT SIZEMounting Position 2133 2154 2175 2206 2238 2262 2300 2325 2425 2525Worm Over 6 11 12 18 22 33 55 60 100 178Worm Under 11 18 20 28 31 54 74 108 140 303Vertical Output 10 17 17 26 29 51 67 91 105 220Vertical Input 7 14 16 22 25 44 60 81 116 24016 floz = 1 pint2 pints = 1 quart4 quarts = 1 US gallonSYNTHETIC LUBRICANTSAll standard reducers ordered from the factory are shipped with Mobil SHC 634 or equal synthetic oil. Double reduction units have separate oil sumps and must be filled and checked independently. Synthetic lubricants provide the potential for numerous benefits including wider STANDARD SPEED REDUCER MOUNTING POSITIONS VENT, LEVEL, AND DRAIN PLUG LOCATIONS5operating temperature range and increased interval between changes. Use of synthetics can cause problems if they are not compatible with the seals or conventional lubes they replace. The synthetic lubrication provided with the reducer is good for ambient temperature ranges of –10? F to 105? F and is compatible with standard compounded oil. For synthetic oil used in helical reducers of helical/worm combinations, contact factory. Prior to startup, verify that the oil is at the level shown on the drawings above. If the ambient temperature will be outside the range for the lubricant installed at the factory, drain and refill the reducer with the proper viscosity lubricant prior to use. Consult the chart above or the factory for alternate lubricants.Change Intervals: Standard compounded lubricants should be changed every six months or 2500 operating hours, whichever comes first. Synthetic lubricants should be changed every two years or 6000 hours, whichever comes first.CAUTION: Oil should be changed more often if reducer is used in a severe environment. (i.e. dusty, humid)CAUTION: In the Food and Drug Industry (including animal food), consult the lubrication supplier for recommendation of lubricants which are acceptable to the Food and Drug Administration and/or other authoritative bodies having jurisdiction.SPECIAL LUBRICATION REQUIREMENTS – SIZES 2175 & LARGERUnits shipped from the factory are assembled to properly lubricate all internal components based on a specific assumed horizontal mounting orientation, worm over. If a size 2175 or larger unit will be mounted in a different orientation, or run with sustained input speeds less than 900 RPM, it should be specified with the order. The unit can then be modified to assure proper lubrication.The maximum input HP rating as shown in the published Rating Tables is based on a stabilized oil bath temperature not exceeding 200º F for normal ambient temperatures. Higher oil bath temperatures or continued operation in excess of rated input HP will tend to shorten the useful life of a lubricant. For high ambient temperatures in excess of 100º F, special lubricants or de-rating of the Gearmotor may be required. Consult the Factory or Local Office with complete application engineering data if this occurs.MAINTENANCEYour Sterling Electric reducer has been tested and adjusted at the factory. Dismantling or replacement of components must be done by Sterling Electric to maintain the warranty.Frequently check the oil level of the reducer. If oil level is low, (refer to reducer vent and level position chart) add proper lubrication through the filler plug until it comes out the oil level plug.Inspect vent plug often to insure it is clean and operating.CAUTION: Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for proper operation.Seals: The Sterling Electric line of speed reducers utilizes premium quality Viton? seals which are the state-of-the-art in sealing technology. Seals are, however, a wear item and eventually need to be replaced. Seal kits are available and contain all the necessary seals, O-rings, and shims for a given reducer size based on style. Refer to the parts list for available kits. Replacement of the seals can be easily accomplished by following the steps below:61. Remove the worn seal without damaging the shaft surface or the seal bore. This can be done by drilling a .062 diameter hole in the seal casing (being careful not to drill into the bearing behind the seal). Screw a #10 sheet metal screw into the hole and pry out the seal.2. Clean the seal bore of sealant.3. Before installing the new seal, use electrical tape to cover any keyways on the shaft to prevent seal lip damage.4. Grease the seal lips with bearing grease and apply a sealant to the seal bore.5. Slide the seal into the shaft being careful not to fold the inner lip over on any shaft steps.6. Press the seal into its bore with a sleeve that presses on the seal casing, being careful to keep the seal square in its bore.CLASS OF SERVICEAll capacity ratings are based on American Gear Manufacturers Association (AGMA) Standards. Load conditions must be within cataloged ratings published in the current Sterling Electric Catalog (available upon request).LONG-TERM STORAGE (6 MONTHS UP)Units must be stored indoors, in a dry, warm temperature.Completely fill the unit with oil.Rotate the input shaft so that the output shaft rotates at least one revolution per month.Completely cover the input and output shaft with grease.At the time of start up, drain the storage oil, install the breather, and fill to the proper oil level with correct lubricant for the operating condition.WARRANTY (LIMITED)The warranty will cover all of the parts in the gearmotor or reducer unit for 12 months from the date of shipment.The warranty is only for parts and labor. In no event shall our liability exceed the original price of the unit, nor does it cover cost of on site repair, installation, or freight.Contact the service department for a complete explanation as to the full warranty policies and conditions of sale. All dimensions designs and specifications are subject to change without notice.72000RA SEAL AND BEARING SIZESInput Quill or Solid Shaft BearingsUnit Bearing Part Number and SizeSize Series OD (mm) ID (mm) Width (mm) Sterling P/N2133 6203 40 17 12 400-0004-62154 6304 52 20 15 400-0020-82175 6304 52 20 15 400-0020-82206 6305 62 25 17 400-0495-52238 6305 62 25 17 400-0495-52262 6306 72 30 19 400-0022-42300 6306 72 30 19 400-0022-42325 Solid 30306 72 30 20.75 400-0496-4Quill 5306 72 30 30.2 400-0497-32425† Solid 30208 80 40 19.75 400-0502-8Quill 30208 80 40 19.75 400-0502-82525‡ Solid 30309 100 45 27.25 400-0508-2Quill 30309 100 45 27.25 400-0508-2† For input speeds greater than 2400RPM or use with mechanical variable speed drives, 7208 angular contact bearings are used.‡ For input speeds greater than 2400RPM or use with mechanical variable speed drives, 7309 angular contact bearings are used.Solid Shaft Output BearingsUnit Bearing Part Number and SizeSize Series OD (mm) ID (mm) Width (mm) Sterling P/N2133 30204 47 20 15.25 400-0498-22154 30204 47 20 15.25 400-0498-22175 30205 52 25 16.25 400-0499-12206 30206 62 30 17.25 400-0500-02238 30206 62 30 17.25 400-0500-02262 30207 72 35 18.25 400-0501-92300 30207 72 35 18.25 400-0501-92325 30208 80 40 19.75 400-0502-82425 32210 90 50 24.75 400-0509-12525 32211 100 55 26.75 400-0510-0Hollow Shaft Output BearingsUnit Bearing Part Number and SizeSize Series OD (mm) ID (mm) Width (mm) Sterling P/N2133 32005 47 25 15 400-0511-92154 32006 55 30 17 400-0512-82175 32008 68 40 19 400-0503-72206 32010 80 50 20 400-0505-52238 32011 90 55 23 400-0513-72262 32011 90 55 23 400-0513-72300 32014 110 70 25 400-0514-62325 32014 110 70 25 400-0514-62425 30214 125 70 26.25 400-0535-52525¢ 32022 170 110 38 400-0532-8Solid Shaft Input Seals*Unit Seal Part Number and SizeSize Shaft (mm) Bore (mm) Width (mm) Sterling P/N2133 17 30 7 404-0285-52154 20 35 7 404-0286-42175 20 35 7 404-0286-42206 22 40 7 404-0287-32238 22 40 7 404-0287-32262 25 40 7 404-0288-22300 25 40 7 404-0288-22325 25 40 7 404-0288-22425 35 55 8 404-0294-62525§ 45 60 8 404-0295-5*SEALS ARE AVAILABLE IN KITS ONLY. SEE PAGE 98Quill Style Input Seals*Unit Seal Part Number and SizeSize NEMA Input Shaft (mm) Bore (mm) Width (mm) Sterling P/N2133 56C 25 35 7 404-0289-12154 56C 30 40 7 404-0290-02175 56C 30 40 7 404-0290-0140TC 35 45 7 404-0331-92206 56C 30 50 7 404-0291-9140TC 35 50 8 404-0292-82238 56C 30 50 7 404-0291-9140TC 35 50 8 404-0292-8180TC 45 60 8 404-0295-52262 56C/140TC 35 55 8 404-0294-6180TC 45 60 8 404-0295-556C/140TC 35 55 8 404-0294-62300 180TC 45 60 8 404-0295-5210TC 55 70 8 404-0235-556C/140TC 35 55 8 404-0294-62325 180TC 45 60 8 404-0295-5210TC 55 70 8 404-0235-52425 56C/140TC 45 60 8 404-0295-5180TC/210TC 55 80 8 404-0297-32525 56C/140TC 45 60 8 404-0295-5180TC/210TC 55 80 8 404-0297-3Solid Shaft Output Seals*Unit Seal Part Number and SizeSize Shaft (mm) Bore (mm) Width (mm) Sterling P/N2133 20 35 7 404-0286-42154 20 35 7 404-0286-42175 25 40 7 404-0288-22206 30 50 7 404-0291-92238 30 50 7 404-0291-92262 35 55 8 404-0294-62300 35 55 8 404-0294-62325 40 62 7 404-0293-72425 50 65 8 404-0296-42525 55 80 8 404-0297-3Hollow Shaft Output Seals*Unit Seal Part Number and SizeSize Shaft (mm) Bore (mm) Width (mm) Sterling P/N2133 25 35 7 404-0289-12154 30 40 7 404-0290-02175 40 62 7 404-0293-72206 50 65 8 404-0296-42238 55 80 8 404-0297-32262 55 80 8 404-0297-32300 70 100 10 404-0298-22325 70 100 10 404-0298-22425 70 100 10 404-0298-22525¥ 110 130 12 404-0344-6*SEALS ARE AVAILABLE IN KITS ONLY. SEE PAGE 9.¢ EARLY STYLE UNITS HAVE 32024 TAPERED ROLLER BEARINGS (P/N 400-0527-3). CONTACT FACTORY WITH UNIT SERIAL NUMBER BEFORE ORDERING HOLLOW OUTPUT BEARINGS TO CONFIRM SIZE.§ EARLY STYLE UNITS HAVE 45X62X8 SIZE SOLID INPUT SEALS (P/N 404-0345-5). CONTACT FACTORY WITH UNIT SERIAL NUMBER BEFORE ORDERING SEALS TO CONFIRM SIZE.¥ EARLY STYLE UNITS HAVE 120X150X12 SIZE HOLLOW OUTPUT SEALS (P/N 404-0337-3). CONTACT FACTORY WITH UNIT SERIAL NUMBER BEFORE ORDERING SEALS TO CONFIRM SIZE.9 Parts List - Single ReductionItem No.Description Qty Item No.Description Qty1 Housing 1 110 Hollow Output Shaft Cover 22 Solid Input Worm Shaft 1 111 Hollow Output Shaft Seal 23 Single Solid Output Shaft 1 112 Hollow Shaft Output Bearing 23a Double Solid Output Shaft 1 113 Hollow Output Shaft 14 Solid Output Worm Gear 1 114 Hollow Output Worm Gear 15 DE Solid Shaft Input Cover 1 115 Key 16 ODE Input Shaft Cover (2154 and Larger) 1 116 Set Screw 67 DE Solid Shaft Output Cover 1 117 Torque Arm 18 ODE Solid Output Shaft Cover 1 118 Bolt 29 Solid Shaft Input Bearing 2 120 Quill Style Input Flange 110 Input Oil Seal 1 121 Flange Input Oil Seal 111 Solid Shaft Output Bearing 2 122 Quill Style Input Worm Shaft 112 Output Oil Seal 1 123 Retaining Ring (Housing) 113 Input O-Ring 2 124 Quill Style Input Bearing 114 Output O-Ring 2 125 Retaining Ring (Shaft) 115 Key 1 126 Seal End Plug (2133 Only) 116 Key 1 127 Socket Head Cap Screw 417 Key 1 128 Bolt 118 NPT Plug 4 129 Washer 119 Internal Baffle (Splash Guard) 120 Bolt 8 135 Output Flange 121 Bolt 8 136 Socket Head Cap Screw 422 Output Shim Gasket AR* 140 C-Face Input Flange 123 Horizontal Base 1 141 Socket Head Cap Screw 424 Bolt 4 142 Bore Coupling Half 125 Breather Plug 1 143 Coupling Insert 126 Bearing Shim AR* 144 Bore Coupling Half 127 Input Shim Gasket AR** AR= As RequiredNotes:1. Shims are used as required.2. Qty (2) of Item #123, Retaining Ring is required on unit size 2133 with Item #126, Seal End Plug.3. Qty (2) of Item # 5, DE Solid Output Shaft Cover is required in when using Item #3a, Double Output Shaft.4. Qty (12) of Item #21, Bolt is required on unit size 2262 to 2525.5. Qty (6) of Item #131, Socket Head Cap Screw is required in unit size 2262 to 2525.6. Qty (2) of item #124, Quill Style Input Bearing is required on unit size 2425 to 2525.Seal KitsWhen rebuilding or refurbishing a unit, it is recommended that a seal kit be installed as it contains all necessary seals and O-rings for a given reducer style. If any internal parts are to be replaced other than bearings, it will be necessary to adjust the bearing pre-load by measuring and installing shims. Shims are available from the factory.Unit Size BR Seal Kit No. BQ Seal Kit No. HR Seal Kit No. HQ Seal Kit No.2133 2133BRSKIT 2133BQSKIT 2133HRSKIT 2133HQSKIT2154 2154BRSKIT 2154BQSKIT 2154HRSKIT 2154HQSKIT2175 2175BRSKIT 2175BQSKIT 2175HRSKIT 2175HQSKIT2206 2206BRSKIT 2206BQSKIT 2206HRSKIT 2206HQSKIT2238 2238BRSKIT 2238BQSKIT 2238HRSKIT 2238HQSKIT2262 2262BRSKIT 2262BQSKIT 2262HRSKIT 2262HQSKIT2300 2300BRSKIT 2300BQSKIT 2300HRSKIT 2300HQSKIT2325 2325BRSKIT 2325BQSKIT 2325HRSKIT 2325HQSKIT2425 Contact Factory2525 Contact FactoryNOTE: FOR DOUBLE END SOLID SHAFT OUTPUT, AN EXTRA OUTPUT SEAL IS REQUIRED (NOT INCLUDED). REFER TO PAGE 8 FOR SIZE AND PART NUMBER BASED ON FRAME SIZE AND STYLE.10Parts List – Double Reduction (Worm / Worm)Item No.Description Qty Item No.Description Qty1 Housing (Primary or Secondary) 1 122 Quill Style Input Worm Shaft 14 Solid Output Worm Gear 1 123 Retaining Ring (Housing) 16 ODE Input Shaft Cover 1 124 Quill Style Input Bearing 18 ODE Solid Output Shaft Cover 1 125 Retaining Ring (Shaft) 111 Solid Shaft Output Bearing 212 Output Oil Seal 1 200 Double Reduction Adapter 113 Input O-Ring 1 201 Dbl Reduction Primary Unit Output Shaft 114 Output O-Ring 2 202 Key 115 Key 1 203 Bolt 419 Internal Baffle (Splash Guard) 120 Bolt 421 Bolt 422 Output Shim Gasket AR*26 Bearing Shim AR** AR= As RequiredNotes:1. Shims are used as required.2. The primary gearbox in the ratio combination is considered the input or motor end reducer.3. The secondary gearbox in the ratio combination is considered the output or load end reducer.Seal KitsWhen Ordering seal kits for double reduction units, refer to the information for the single reduction units on the previous page. Double reduction units will take two seal kits, one for the primary and one for the secondary. The primary unit will take either the BR or BQ seal kit depending on the input configuration. The secondary unit will take either a BQ or HQ seal kit depending on the output configuration. All outputs for the primary units are solid shaft. All inputs for the secondary units are quill style.Worm / Worm Ratio Combinations2154DW 2175DW 2206DW 2238DW 2262DW 2300DW 2325DW 2425DW 2525DWTotal P S P S P S P S P S P S P S P S P SRatio 2133 2154 2133 2175 2133 2206 2133 2238 2133 2262 2154 2300 2154 2325 2206 2425 2262 252575:1 5 15 5 15 5 15 5 15 5 15 5 15 5 15 5 15 5 15100:1 5 20 5 20 5 20 5 20 5 20 5 20 5 20 5 20 5 20150:1 10 15 10 15 10 15 10 15 10 15 10 15 10 15 10 15 10 15200:1 10 20 10 20 10 20 10 20 10 20 10 20 10 20 10 20 10 20250:1 10 25 10 25 10 25 10 25 10 25 10 25 10 25 10 25 10 25300:1 10 30 10 30 10 30 10 30 10 30 10 30 10 30 10 30 10 30400:1 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20500:1 25 20 25 20 25 20 25 20 25 20 25 20 25 20 25 20 25 20600:1 20 30 20 30 20 30 20 30 20 30 20 30 20 30 20 30 20 30750:1 25 30 25 30 25 30 25 30 25 30 25 30 25 30 25 30 25 30900:1 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 301000:1 50 20 50 20 50 20 50 20 50 20 50 20 50 20 50 20 50 201200:1 40 30 40 30 40 30 40 30 40 30 40 30 40 30 40 30 40 301500:1 50 30 50 30 50 30 50 30 50 30 50 30 50 30 50 30 50 301800:1 60 30 60 30 60 30 60 30 60 30 60 30 60 30 60 30 60 302400:1 60 40 60 40 60 40 60 40 60 40 60 40 60 40 60 40 60 403000:1 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60 503600:1 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60 60P = Primary (Input) unit.S = Secondary (output) unitNote: Actual ratio combination supplied by factory may vary from above depending on application and manufacturing requirements. When ordering replacement parts, provide complete serial number and part number.11Basic Single Reduction Unit12Hollow Output Shaft Unit 13Quill Style Input14Double Reduction Style (Worm/ Worm)15Double Reduction with Helical Primary(Ratio Multiplier)Helical / Worm Ratio Combinations2175HW 2206HW 2238HW 2262HW 2300HW 2325HW 2425HW 2525HWTotal P S P S P S P S P S P S P S P SRatio 2 2175 2 2206 2 2238 2 2262 2 2300 2 2325 3 2425 3 252510:1 2 5 2 5 2 5 2 5 2 5 2 5 2 5 2 520:1 2 10 2 10 2 10 2 10 2 10 2 10 2 10 2 1025:1 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 530:1 2 15 3 10 3 10 3 10 3 10 3 10 3 10 2 1540:1 4 10 4 10 4 10 4 10 4 10 4 10 4 10 2 2045:1 3 15 3 15 3 15 3 15 3 15 3 15 3 15 3 1550:1 5 10 5 10 5 10 5 10 5 10 5 10 5 10 2 2560:1 4 15 4 15 4 15 3 20 4 15 4 15 4 15 4 1575:1 5 15 5 15 5 15 5 15 5 15 5 15 5 15 5 1580:1 4 20 4 20 4 20 4 20 4 20 4 20 4 20 4 20100:1 4 25 4 25 4 25 4 25 4 25 4 25 4 25 4 25125:1 5 25 5 25 5 25 5 25 5 25 5 25 5 25 5 25150:1 5 30 5 30 5 30 5 30 5 30 5 30 5 30 5 30200:1 5 40 5 40 5 40 5 40 5 40 5 40 5 40 5 40250:1 5 50 5 50 5 50 5 50 5 50 5 50 5 50 5 50300:1 5 60 5 60 5 60 5 60 5 60 5 60 5 60 5 60P = Primary (Input) unit.S = Secondary (output) unitNote: Actual ratio combination supplied by factory may vary from above depending on application and manufacturing requirements. When ordering replacement parts, provide complete serial number and part number.LUBRICATION (HELICAL PRIMARY ONLY)All standard helical ratio multipliers ordered from the factory are shipped with standard compounded lubricant and is good for ambient temperature ranges of 30? F to 104? F. Double reduction units have separate oil sumps and must be filled and checked independently. Use of synthetics can cause problems if they are not compatible with the seals or conventional lubes they replace. Prior to startup, verify that the oil is at the level shown on the drawing below. If the ambient temperature will be outside the range for the lubricant installed at the factory, drain and refill the reducer with the proper viscosity lubricant prior to use.VENT PLUG LOCATIONBefore putting the unit into operation, substitute the vent plug for the solid plug at the position desired. Arrows indicate the recommended vent plug locations.16OIL & WEIGHT SPECIFICATIONSOil Type AGMA #4 SAE 40 Weight ISO 150Oil Capacity 7/8 PintSEAL AND BEARING SIZESInput BearingUnit Bearing Part Number and SizeSize Series OD (mm) ID (mm) Width (mm) Sterling P/N2 6204 47 20 15.25 400-0005-43 6204 47 20 15.25 400-0005-4ODE Output BearingUnit Bearing Part Number and SizeSize Series OD (mm) ID (mm) Width (mm) Sterling P/N2 6205 47 20 15.25 400-0006-23 6205 47 20 15.25 400-0006-2DE Output BearingsUnit Bearing Part Number and SizeSize Series OD (mm) ID (mm) Width (mm) Sterling P/N2 6205 47 20 15.25 400-0006-23 (180TC Output) 6206 47 20 15.25 400-0008-93 (210TC Output) 6007 52 25 16.25 400-0367-3Input SealUnit Bearing Part Number and SizeSize Shaft (mm) Bore (mm) Width (mm) Sterling P/N2 35 45 7 404-0331-93 40 60 7 404-0352-8Output SealUnit Bearing Part Number and SizeSize Shaft (mm) Bore (mm) Width (mm) Sterling P/N2 25 40 7 404-0288-23 (180TC Output) 30 50 8 404-0291-93 (210TC Output) 35 50 8 404-0292-8Parts List – Helical Primary OnlyItem No.Description Qty Item No.Description Qty1 Gear Case Housing 1 13 Input Oil Seal 12 Gear Case Cover 1 14 NPT Plug 43 Quill Style Input Flange 1 15 ODE Output Bearing 14 Seal End Plug 1 16 Key 15 Retaining Ring (Shaft) 1 17 Output Shaft 16 Gasket 1 18 Gear 17 Input Bearing 1 19 DE Output Bearing 18 Retaining Ring (Housing) 1 20 Dowel Pin 29 Quill Input Shaft with Pinion 1 21 Output Oil Seal 110 Hex Head Bolt 5 22 Output Key 111 Hex Head Bolt (Motor Mounting) 4 23 Long Socket Head Cap Screw 212 Socket Head Cap Screw 4Notes:7. Item #23 required on Size 3 Ratio Multiplier only.17SIZE 2 PARTSSIZE 3 PARTS Aircon Flex-Air AN Airlock Manual Introduction Operating Principle Operating Instructions Routine Maintenance Safety Standard & Optional Features Suggested Square Parts List Flex-Tip "AN" Round Airlocks Data Sheet Flex-Tip "AN" Square Airlocks Data Sheet Sterling Electric, Inc. Worm Gear Reducer Browning Ball Bearings