Table of Contents
Topic
PowerGrip GT2 and Poly Chain GT2 Belt Drive Advantages 1. Energy Efficiency 2. Energy Savings 3. Maintenance Savings Total Drive Cost Considerations HVAC Drive Design Considerations 1. HVAC Equipment Inspection 2. HVAC Start Up Load Characteristics A. Full Load Start Up B. Controlled Start Up 3. Drive System Noise A. Noise Generation B. Designing PowerGrip GT2 and Poly Chain GT2 Belt Drives for Reduced Noise 4. Fan Speed Considerations 5. Belt Pull Considerations 6. Installation A. Alignment B. Tension Summary Appendix Design Flex II Energy Savings Report Design Flex II PowerGrip GT2 Drive Detail Report Design Flex II V-belt Drive Detail Report Energy Survey Data Plots Annual Energy Dollar Savings Using PowerGrip GT2 and Poly Chain GT2 Belt Drives High Speed Drive Survey and Energy Savings Worksheet
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1 1 2 3 6 8 8 13 13 13 14 14 14 15 16 17 17 18 19 20 21 22 23 24 29 30
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V-belt slip occurs when installation tension is insufficient to transmit a load. Slip can also occur if sheaves are worn, allowing improper fit of the belt in the sheave groove. Belt slip is the difference in rotational movement of the belt compared to the rotational movement of the sheave. Belt creep is the slight incremental elongation of the belt due to increasing belt tension as the belt travels from the entry point on the slack side of the driveN sheave or sprocket to the tight side exit point on the driveN sheave or sprocket. Belt creep is typically responsible for approximately 0 .5% loss in driveN sheave or sprocket speed (RPM). Since V-belts generally have a much thicker cross section than PowerGrip GT2 and Poly Chain GT2 belts, more energy is used to bend the belt around the sheave. Also, V-belts operate through a wedging action with the sheave, thus generating heat caused by friction between the belt sidewall and the groove surface. There is more heat lost through this wedging action than from the minimal friction generated as a PowerGrip GT2 or Poly Chain GT2 belt tooth enters and exits the sprocket grooves. V-belt drives, especially if poorly maintained, will slip. PowerGrip GT2 and Poly Chain GT2 belts operate with positive tooth/groove engagement and do not slip. The V-belt drive, therefore, will show a decrease in driveN speed (rpm) and the PowerGrip GT2 or Poly Chain GT2 belt drive will not. This loss of driveN fan speed results in a drop in the volume of air being moved by the fan. This air volume reduction can result in occupant discomfort, health issues, or production losses. For example, rehabilitation facilities or infection control units in hospitals are required to meet a minimum of air changes per hour. Poorly maintained Vbelt drives may not consistently meet minimum air change requirements.
Efficiency can be defined by the following formulas: Efficiency = HPout/HPin or Efficiency = (TORQUEout x RPMout)/(TORQUEin x RPMin) As these equations show, energy losses in belt drives can be separated into two categories, torque and speed loss. Torque loss results from the energy required to bend the belt around the sprocket or sheave. Energy lost as heat (due to friction) also causes torque loss. Speed losses are the result of belt slip and creep. Synchronous belts cannot slip because of the positive tooth/groove engagement. All belt types will experience belt creep, although synchronous belts typically have very minimal creep due to their greater resistance to elongation.
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97.8% PowerGrip GT2 /Poly Chain GT2 Belt Drive 100 90 80 94% V-Belt Drive
With this information, the annual energy cost and energy savings can be calculated using Equations 1 and 2.
Equation 1
70 60 50
Annual Energy Costs = Motor HP x Hrs/Year Operation x .746 x Cost/KWH Motor Efficiency Equation 2 Annual Energy Savings = Energy Cost x Efficiency Increase
To calculate the payback period for the PowerGrip GT2 or Poly Chain GT2 belt drive, divide the annual energy savings into the cost of the new drive (Equation 3).
This method of determining payback does not account for a V-belt drive needing to be replaced, regardless of whether or not a changeover is made. If this situation occurs, then the difference in drive cost (PowerGrip GT2 or Poly Chain GT2 drive cost minus the V-belt drive cost) may be used instead of the PowerGrip GT2 or Poly Chain GT2 belt drive cost. The payback period in this case is much shorter.
KW
Existing V-Belt Drive dR: 2/5V9.00 dN: 2/5V12.50 Belt: 2 each, 5VX1180 CD: 42.08" dN RPM: 1256
PowerGrip GT2 Belt Drive dR: P80-8MGT-30 dN: P112-8MGT-30 Belt: 3048-8MGT-30 CD: 44.85" dN RPM: 1250 RPM
The V-belt drive price is $265.85, and the PowerGrip GT2 belt drive price is $342.83. Assume a 5% increase in efficiency over V-belts. From Equation 1, Annual energy cost = 40 HP x 8736 hrs x .746 x .10 = $29,290.14 .89 Annual energy savings = $29,290.14 x .05 = $1464.51 Payback period = $342.83 = .23 years, or 3 months. $1464.51 Figure 3 shows the estimated annual energy cost for both the PowerGrip GT2/Poly Chain GT2 and V-belt drives. The difference between the two is the $1464.51 annual energy savings made possible by using a PowerGrip GT2 or Poly Chain GT2 belt drive.
7.5
15
25
40
60
100
Motor Horsepower
Figure 4
3 Maintenance Savings While PowerGrip GT2 and Poly Chain GT2 belt drives are more efficient than V-belt drives, the potential savings in maintenance costs can also be very significant. The minimal elongation characteristics of PowerGrip GT2 and Poly Chain GT2 belts virtually eliminate maintenance time and costs. Less attention from maintenance personnel translates to additional savings in productivity for the end user. As discussed, proper V-belt tension maintenance is essential to minimize slip and maximize V-belt efficiency. However, few drives are maintained at a level that keeps the optimum tension in the belt. Over time, the tension in a V-belt decays. If not properly retensioned, a V-belt will slip and the belt drive efficiency will be reduced. 3
1464. 27825. PowerGrip GT2 Poly Chain GT2 27825. Competitive V-Belt
Energy Used for Both V-belts and Synch. Belts Additional Energy Used by V-belts
Figure 3 www.gates.com/pt
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Competitive V-Belt
Installation
Figure 5 Note that these maintenance costs assume that both belt drives are replaced once per year. Actual customer experience has shown that PowerGrip GT2 and Poly Chain GT2 belt drives typically outperform competitive V-belt drives on HVAC applications. This means that the actual maintenance cost for V-belt drives is going to be even greater over the lives of both types of belt drives, as the V-belts will have to be replaced more frequently. For example, if the PowerGrip GT2 or Poly Chain GT2 belt drive ran for 2 years on the fan drive, and the competitive V-belt drive ran for 1 year, the cost comparison over the length of the PowerGrip GT2 or Poly Chain GT2 belt drives operation would be:
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Competitive V-Belt
Installation
Figure 6
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Total Drive Cost Example The example drives being considered are shown below. Existing V-Belt Drive dR: 2/5V9.00 dN: 2/5V12.50 Belt: 2 each, 5VX1180 CD: 42.08" dN RPM: 1256 PowerGrip GT2 Belt Drive dR: P80-8MGT-30 dN: P112-8MGT-30 Belt: 3048-8MGT-30 CD: 44.85" dN RPM: 1250 RPM
Competitive V-Belt
Maintenance Cost
Initial Cost
Figure 7 The difference in initial component costs is an additional $76.98 for the PowerGrip GT2 belt drive. The difference in maintenance costs is an additional $400 for the V-belt drive. The difference in energy costs is an additional $1464.51 for the V-belt drive. The sum of these additional costs are shown in Figure 8. The difference in the additional costs is the savings provided by the PowerGrip GT2 belt drive. For this example, the savings amount to $1787.53.
The initial drive component cost is $265.85 for the V-belt drive, and $342.83 for the PowerGrip GT2 belt drive. As calculated in the energy savings portion of this example, the total annual energy cost for the V-belt drive is $29,290.14. The total annual energy cost for the PowerGrip GT2 belt drive is $27,825.63. As approximated in the maintenance savings portion of this example, the total first year maintenance cost for the V-belt drive is $560. The total first year maintenance cost for the PowerGrip GT2 belt drive is $160. The V-belt drive's total cost for the first year is $30,115.99 ($265.85 + $29,290.14 + $560.00). The PowerGrip GT2 belt drive's total cost for the first year is $28,328.46 ($342.83 + $27,825.63 + 160.00).
PowerGrip GT2 Additional Energy Cost Additional Maintenance Cost Additional Initial Drive Cost
Competitive V-Belt
Dollars ($)
PowerGrip GT2 Additional Energy Cost Additional Maintenance Cost Additional Initial Drive Cost
Competitive V-Belt
Figure 9
Note that costs incurred due to additional maintenance or downtime have not been shown in any of the cost comparisons. Any additional costs (lost productivity) should be added to the Competitive V-belt cost for a total cost comparison.
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1 HVAC Equipment Inspection Many air handling units have structures that are not always particularly rigid. With V-belt drives, this is not a major concern. PowerGrip GT2 and Poly Chain GT2 belt drives are sensitive to fluctuations in the center distance that can be caused by an inadequate structure. This lack of rigidity is critical under start up conditions, when an AC motor can be required to pro-
Figure 10
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Figure 11
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Figure 12
Figure 12 shows a drive that has the motor mounted on a cantilevered motor mount. This can sometimes be a poor choice for an unreinforced conversion. Cantilevered mounting systems may not be rigid enough to prevent center distance collapse. It is important that cantilevered systems be checked for system rigidity before converting to a PowerGrip GT2 or Poly Chain GT2 belt drive. Reinforcement will usually be sufficient to strengthen the structure for conversion to PowerGrip GT2 or Poly Chain GT2 belt drives.
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Figure 13
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Figure 14
Figure 15
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Figure 16
2 HVAC Start Up Load Characteristics A. Full Load Start Up Start up loads can be a significant concern when evaluating potential drives for conversion to PowerGrip GT2 or Poly Chain GT2 belts. PowerGrip GT2 and Poly Chain GT2 belt drives will transmit all of the start up torque, where V-belts may slip if the load is excessive. Due to the inertia of the fan, start up loads can potentially be 150% to 200% of the normal operating load. This is obviously much more of a concern when the drive will be operating on a system that frequently cycles on and off. Drives that run continuously will only see the start up load intermittently, so are not as sensitive to the combination of high start up loads and weak structures. It is important that the start up load be considered when evaluating a drive. If the structure is weak, a high start up load will further adversely effect the PowerGrip GT2 or Poly Chain GT2 belt drive's performance by allowing center distance collapse. This reduction in center distance results in an under tensioned belt which may wear prematurely from being undertensioned, or even worse, premature failure from
ratcheting. If an electrician or properly trained technician is available, an ammeter can be used to compare the start up amperage to the steady operation amperage. If the amperage is 1 1/2 to 2 times the steady state amperage, the structure should be carefully inspected to insure that it is robust enough to prevent center distance collapse upon start up. With the drive shut off and safely locked out, the structural rigidity can be checked by pushing the two belt spans inward toward each other and looking for any relative movement in the structure (see Figure 10).
B. Controlled Start Up If the air handling unit has a soft start or variable frequency (AC Inverter) control, the start up condition is ideal for any belt drive. The fan will be ramped up to speed slowly, with a corresponding increase in load as the speed increases. Units with a soft start or AC Inverter are ideal candidates for conversion to PowerGrip GT2 and Poly Chain GT2 belt drives. Since the start up loads are low and gradually applied, a structure that might otherwise be too weak for a PowerGrip GT2 or Poly Chain GT2 belt drive if unrein13
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3 Drive System Noise A. Noise Generation Drive system noise can come from many components. Nearly all moving parts in a system are capable of making noise - including bearings, motors, and belts. Potential noise from other components should be considered when trying to solve a noise problem. Bearings that are undersized, poorly lubricated, worn or misaligned may cause noise. Rotating components can create air movement that can generate noise. A weak structural design could flex under load and cause belt misalignment which will increase tooth interference and possibly create noise. PowerGrip GT2 and Poly Chain GT2 belt drives, like any other power transmission drive system, are capable of high noise levels. All synchronous belts generate noise as the belt teeth enter and exit the sprocket grooves with slight interference. Since the belt noise will tend to increase as the interference increases, the more accurate the tensioning and alignment, the less tendency the drive will have to make noise. Testing has shown that the GT tooth profile has minimal interference and excellent noise characteristics. B. Designing PowerGrip GT2 and Poly Chain GT2 Belt Drives for Reduced Noise Many different factors affect belt drive noise. The guidelines shown below have been developed that will aid in designing and selecting quieter drives.
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4 Fan Speed Considerations Air handling units are unique in industry in that a small change in the RPM at the driveN shaft can dramatically affect the application. The volume of air being transmitted is sensitive to changes in the driveN fan speed. The amount of power required is also related to the driveN fan speed. In order to utilize the PowerGrip GT2 and Poly Chain GT2 belt drive energy efficency advantages, it is very important that the belt drive be designed to achieve the desired driveN speed. All conversions to PowerGrip GT2 or Poly Chain GT2 belt drives from existing V-belt drives should have the design speed ratio based on a measured (tached) driveN shaft RPM, and not calculated from the V-belt speed ratio (using the sheave diameters). The horsepower requirement for fans varies with the cube of the RPM. That is, a small change in the fan RPM makes a much larger difference in the actual horsepower (and amperage) required. The relationship is shown in equation 4. Equation 4 HP1/HP2 = (RPM1/RPM2)3 Where: HP1 HP2 RPM1 RPM2 = Initial Horsepower = New Horsepower @ New Fan RPM = Initial Fan RPM = New Fan RPM
Power Usage Example A 50 HP motor is driving a fan. The existing drive has the following components:
Horsepower
Motor: 3/5V8.0 50 HP, 1750 RPM Fan: 3/5V14.0 Theoretical Fan RPM: 995 RPM Belts: 3/5VX1180 Center Distance: 41.61"
50
A Poly Chain GT2 drive is chosen that replaces the Vbelt drive with the ratio based on the theoretical V-belt speed ratio. In this example, it is assumed that the driveN fan shaft speed was not measured. The Poly Chain GT2 drive that was chosen is shown below.
Figure 18 Due to the failure to measure the actual fan shaft speed, the horsepower requirement has increased to 58.3 HP. The horsepower and energy requirement has increased 16.6%. It is very important that any replacement PowerGrip GT2 or Poly Chain GT2 belt drive be designed for the proper, measured fan RPM (using a contact or strobe tachometer) not a theoretical fan RPM that is calculated using a nameplate motor RPM and the existing V-belt sheave diameters. In this example, instead of saving money by converting to a synchronous belt drive, the operating energy cost will be increased due to the replacement drive being improperly designed. Increasing the driveN fan speed will also increase air flow. This increased flow can sometimes produce unexpected and undesirable results in a facility or environment.
Motor: 14mm pitch, 36 grooves (6.316 Pitch Dia.) Fan: 14mm pitch, 63 grooves (11.053 Pitch Dia.) Belt: 14mm pitch, 2800mm Pitch length, 37mm wide Center Distance: 41.41" Fan Speed: 1000 RPM
From a power transmission standpoint the replacement drive is acceptable. However, by not physically measuring the fan shaft speed, the motor horsepower requirement will be substantially increased since the Poly Chain GT2 belt drive was designed to run at a faster driveN RPM, and will always operate at that speed since it is a positive, no slip drive. For this example, assume that the V-belt drive's actual fan shaft RPM was 950 RPM (due to slippage). The actual horsepower requirement can be calculated using Equation 4.
5 Belt Pull Considerations Since PowerGrip GT2 and Poly Chain GT2 belts are high capacity power transmission products, it is very easy to reduce the overall size of a belt drive when converting from V-belts. If shaft length is limited, a width reduction can be an advantage. However, care must be taken when selecting sprocket diameters. Belt pull (and the resulting bearing load) is directly proportional to the diameter of the sheaves or sprockets in the drive. The larger the diameter, the lower the belt pull. Since diameters can be reduced when using PowerGrip GT2 or Poly Chain GT2, it is important to consider the sheave diameters of the existing V-belt drive. If there is any concern about the rigidity of the structure, it is important that the sprockets which are chosen be approximately the same size (or larger) than
50/HP2 = (950/1000)3
HP2 = 58.3 HP
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Figure 19
PowerGrip GT2 and Poly Chain GT2 belts are made with high modulus tensile members which provide length stability over the belt life. Because of this low stretch characteristic, misalignment does not allow equal load distribution across all of the belt's tensile cords. In a misaligned drive, the load is being carried by only a small portion of the belt's tensile cords, resulting in reduced belt longevity.
Figure 21
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Figure 22 If a belt is overtensioned, the belt will wear in the land area (area between the belt teeth). This can result in premature belt failure. Overtensioning can also damage bearings, shafts, and other drive components. See Figure 23. Both undertensioning and overtensioning can result in shortened belt life. It is important that the proper initial static tension values be used when installing the belt. These values can be calculated by using the proper Gates design catalog, the Gates Design Flex II design program, or by consulting your local Gates representative. Belt static installation tension can be accurately measured using a variety of tools available from Gates. 18 Gates Corporation Figure 24 www.gates.com/pt
Summary
PowerGrip GT2 and Poly Chain GT2 belt drives offer several significant advantages compared to competitive V-belt drives on HVAC applications. These advantages include: An average of 5% energy savings compared to V-belt drives Maintenance costs virtually eliminated Dramatically reduced total belt drive costs over the life of the belt drives. With proper design procedures and verification of the HVAC unit's structural integrity, PowerGrip GT2 and Poly Chain GT2 belt drives provide a dramatic combination of advantages: energy savings, maintenance savings, and performance.
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Appendix
Documents in the Appendix include the following:
Design Flex II Energy Savings Report The Design Flex II Energy Savings report is a hardcopy of the information available in the Design Flex II design program. Design Flex II is available for download at www.gates.com. Note that in this example report on page 21, list prices are shown and the payback period for conversion from a 5VX V-belt drive to a PowerGrip GT2 belt drive range is 2 months.
To obtain an estimate for the total energy savings at a facility, add up the individual estimated savings for all of the drives to be converted.
Example: The cost per Kilowatt Hour at a facility is $.10. All of the drives run 24 hours per day, year round. The facility is converting five 50 HP units, two 20 HP units, and ten 10 HP units to PowerGrip GT2 belt drives. Using the Savings table, the 50 HP unit savings is $1,815; the 20 HP unit savings is $760 and the 10 HP unit savings is $394. The total estimated savings for the facility is the per unit savings multiplied by the number of units, summed for all of the different size units. Total estimated savings: 5(1815) + 2 (760) + 10 (394) = $14,500
Design Flex II PowerGripGT2 Drive Detail Report The PowerGrip GT2 Drive Detail Report on page 22 shows the PowerGrip GT2 belt drive used in the savings examples throughout the manual.
Design Flex II V-belt Drive Detail Report The V-belt Drive Detail Report on page 23 shows the V-belt drive used in the savings examples throughout the manual.
High Speed Drive Survey and Energy Savings Worksheet The High Speed Worksheet on page 30 can be used to record the necessary data when surveying V-belt drives for conversion to PowerGrip GT2 or Poly Chain GT2 belt drive systems. The Drive Information section will help the drive designer select components that are appropriate for the application's special characteristics.
Energy Survey Data Plots Energy survey plots on pages 24-28 are provided as additional examples of data showing documented PowerGrip GT2 and Poly Chain GT2 belt drive energy savings.
Annual Energy Dollar Savings Using PowerGrip GT2 and Poly Chain GT2 Belt Drives The Annual Energy Dollar Savings table on page 29 can be used to quickly estimate annual dollar savings for drives which have been converted from V-belt drives to PowerGrip GT2 or Poly Chain GT2 belt drives.
Example: If the cost per Kilowatt Hour is $.12 on a 50 HP motor running 24 hours per day, the annual dollar savings would be $2,177.
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Appendix
Design Flex II Energy Savings Report
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Appendix
Design Flex II PowerGrip GT2 Drive Detail Report
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Appendix
Design Flex II V-belt Drive Detail Report
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Appendix
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Appendix
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Appendix
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Appendix
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Appendix
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Appendix
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$15 $24 $35 $47 $68 $90 $110 $131 $174 $216 $259 $320 $426 $527 $632 $1,265 $1,518 $253 $1,054 $1,265 $211 $853 $1,023 $171 $639 $767 $128 $639 $853 $1,054 $1,265 $517 $621 $103 $517 $431 $517 $86 $431 $349 $418 $70 $349 $697 $862 $1,034 $1,279 $1,705 $2,108 $2,530 $262 $314 $52 $262 $523 $220 $264 $44 $220 $441 $180 $217 $36 $180 $361 $137 $164 $27 $137 $274 $329 $433 $529 $628 $837 $1,034 $1,241 $1,535 $2,046 $2,530 $3,036 $93 $112 $19 $93 $187 $224 $70 $84 $14 $70 $140 $168 $30 $39 $58 $76 $93 $110 $147 $182 $218 $269 $359 $444 $533 $48 $57 $10 $48 $96 $115 $20 $29 $35 $6 $29 $59 $71 $12 $62 $101 $148 $197 $288 $380 $464 $551 $734 $908 $1,089 $1,346 $1,795 $2,220 $2,664 $124 $202 $295 $394 $577 $760 $928 $1,101 $1,469 $1,815 $2,178 $2,693 $3,591 $4,440 $5,327 $149 $242 $354 $472 $692 $912 $1,114 $1,322 $1,762 $2,178 $2,614 $3,232 $4,309 $5,327 $6,393
Annual Energy Dollar Savings Using PowerGrip GT2 and Poly Chain GT2 Belt Drives
40 Hrs./Week (2080 hrs./year) 80 Hrs./Week (4160 hrs./year) 24 Hrs./Day (8760 hrs./year) Avg. Motor Motor HP Eff. $0.01/KWH $0.05/KWH $0.10/KWH $0.12/KWH $0.01/KWH $0.05/KWH $0.10/KWH $0.12/KWH $0.01/KWH $0.05/KWH $0.10/KWH $0.12/KWH
79%
$3
81%
$5
7.5
83%
$7
10
83%
$9
15
85%
$14
20
86%
$18
25
88%
$22
30
89%
$26
40
89%
$35
50
90%
$43
60
90%
$52
75
91%
$64
100
91%
$85
125
92%
$105
150
92%
$126
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Appendix
High Speed Drive Survey HIGH SPEED DRIVE SURVEY and Energy Savings Worksheet
AND ENERGY SAVINGS WORKSHEET
Customer r Information
Distributor: Customer:
DriveR R Information
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Drive e Identification n (location, , number, , etc.) n of f DriveN N Equipment: Description Manufacturer r of f DriveN N Equipment:
Motor r Nameplate e Data Rated Horsepower = Rated Voltage = Measured Amps = Actual Motor Load = Start Up Load: % Motor Rating at Startup Rated RPM = Rated Amps = Measured Voltage = Output Speed: AC Inverter? Constant Yes No Motor Type: Motor Frame Size : Measured Speed (Tach/Strobe) = Variable Soft Start? Yes No AC DC
Yes No
No
Hours/Day =
Weeks/Year =
Special l Requirements:
Space Limitations: Maximum DriveR Dia. = Maximum DriveR Width = Guard Description: Environmental Conditions: Temperature Range = Oil Mist Oil Splash Belt Conductivity Required Moisture Abrasives Maximim DriveN Dia = Maximum DriveN Width =
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