Poly Chain GT 2 and PowerGrip GT2 Belt Drives for HVAC

High Performance for Critical Applications

The Driving Force in Power Transmission

DRIVE DESIGN MANUAL

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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High Performance Belt Drives for Critical HVAC Applications

High Performance Belt Drives for Critical HVAC Applications
Industrial, office, hotel, rehabilitation, and hospital facilities use a wide variety of belt driven air handling equipment. HVAC (Heating, Ventilation, Air Conditioning) systems can range from fractional horsepower to several hundred horsepower. The diversity of drive sizes is matched only by the different types of units and their uses. The majority of units provided by the OEM use V-belt drives for power transmission. While V-belt drives are widely used on HVAC systems, PowerGrip GT2 and Poly Chain GT2 belt drives offer a number of advantages. This publication will explain the advantages of PowerGrip GT2 and Poly Chain GT2 belt drives in critical HVAC applications, as well as discussing drive design and selection procedures unique to air moving applications.

PowerGrip GT2 and Poly Chain GT2 Belt Drive Advantages

1 Energy Efficiency One of the advantages of PowerGrip GT 2 and Poly Chain GT2 belt drives is their high efficiency. Efficiency of any power transmission system is a measure of the power loss associated with the motor, the bearings and the belt drive. Any loss of power is a loss of money. By minimizing the losses in the system, the cost of operating the drive is minimized. Starting with the passage of the U.S. Energy Policy Act (1992), higher efficiency motors are being used more often by Original Equipment Manufacturers (OEMs) to reduce power loss. The U.S. Energy Policy Act (and its subsequent revisions) is aimed at increasing the efficiency standards for all types of appliances and equipment (including electric motors). However, even a high efficiency motor's advantages can be under-utilized if the most efficient belt drive alternative is not chosen. PowerGrip GT2 and Poly Chain GT2 belt drives are more energy efficient than V-belt drives, providing a cost effective method of improving the overall system efficiency. Energy costs continue to rise. PowerGrip GT2 and Poly Chain GT2 belts can provide significant energy savings on HVAC applications.

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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PowerGrip GT2 and Poly Chain GT2 Belt Drive Advantages

Even though properly maintained V-belts drives can run as high as 95-98% efficient at the time of installation, this will deteriorate as much as 5% during operation. Poorly maintained V-belt drives may be up to 10% less efficient. PowerGrip GT2 and Poly Chain GT2 belt drives remain at an energy efficiency of approximately 98% over the life of the belt. Figure 1 illustrates the efficiency relationship of V-belt and PowerGrip GT2/Poly Chain GT2 belt drives. A simple calculation will provide an estimate of the cost of operating the drive annually, as well as the annual energy savings. To estimate the energy saved by converting from V-belts to PowerGrip GT2 or Poly Chain GT2 belts, the following information is necessary. Motor HP Motor efficiency Hours per year of operation Energy Cost per KWH (Kilowatt Hour)

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

Increasing DriveN Torque

Figure 1 2 Energy Savings On average, a PowerGrip GT2 or Poly Chain GT2 belt drive is 5% more efficient than a V-belt drive. This increased energy efficiency directly corresponds to energy cost savings. A conversion to a PowerGrip GT2 or Poly Chain GT2 belt drive is an easy, cost effective method to reduce air handling unit operating costs. Figure 2 shows an example of a documented energy savings of 7.9% on an air handling unit at a large hospital.

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).

Equation 3 Payback Period = New Drive Cost Annual Energy Savings

Hospital Energy Savings Study AH-3

29 28 27 26 25 24 7.9% Energy Savings 23 22 30 120 210 300 390 480 570 660 750 840 930 020 110 200 1 1 1

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

V-belt [8.87 KW-hrs]

Time Poly Chain GT [8.22 KW-hrs]

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PowerGrip GT2 and Poly Chain GT2 Belt Drive Advantages

Energy Savings Example Consider the following example of energy savings calculations. The drive parameters are as follows: Motor - 40 HP, 1750 RPM, 89% efficient Hours used - 24 hrs/day, 7 days/week, 52 weeks/year Energy cost - $0.10/kwh The Gates Design Flex II belt drive selection computer program calculates estimated energy savings of synchronous belt drives. After a PowerGrip GT2 or Poly Chain GT2 belt drive has been selected using the Design Flex II program, it is a simple matter to use the program to calculate both annual energy savings and payback period. Design Flex II is available for download at www.Gates.com. The Annual Dollar Savings using PowerGrip GT2 and Poly Chain GT2 Belt Drives chart, which is located in the Appendix, shows annual energy dollar savings when using PowerGrip GT2 or Poly Chain GT2 belt drives to replace V-belt drives for some typical motor sizes, energy costs, and operating durations. By adding the savings of all the motors of different horsepowers, the user can estimate the total facility annual energy savings resulting from converting to PowerGrip GT2 or Poly ChainGT2 belt drives. Figure 4 graphically demonstrates the possible average annual savings per drive, assuming a continuous operation and a $0.10 per Kilowatt Hour energy cost.

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.

Average Annual Dollar Savings

PowerGrip GT2 and Poly Chain GT2 Belt Drives

Annual Dollar Savings

$6,000 $4,000 $2,000 $0

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

Annual Energy Cost Comparison

29500 29000 28500 28000 27500 27000

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

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PowerGrip GT2 and Poly Chain GT2 Belt Drive Advantages

PowerGrip GT2 and Poly Chain GT2 belts require minimal retensioning because of their high modulus, low stretch tensile cords. As an example, a 100" long V-belt would require approximately 1 1/2" to 2 1/2" of center distance take up over the life of the belt. By comparison, a PowerGrip GT2 or Poly Chain GT2 belt would only require .04" of center distance take up over its life. Total maintenance costs include the time charged for installing new belt drive components, as well as costs incurred for belt retensioning and replacement. Downtime costs can be incurred if a facilitys manufacturing process is impacted by maintenance downtime. PowerGrip GT2 and Poly Chain GT2 belt drives require virtually no maintenance once properly installed. For optimum performance, V-belt drives should be run in for 24 hours and then retensioned. V-belt tension checks and retensioning procedures at 3 month intervals are not unusual for well maintained drives. This additional maintenance adds costs that are eliminated by using PowerGrip GT2 and Poly Chain GT2 belt drives. Assume the drives are well maintained, four times per year. At $40 per hour per maintenance technician, the cost to retension the drive is $80 ($40 per hour x 2 technicians x 1 hour). Over the course of 1 year, the tension check/ retensioning procedure will be performed 4 times. The annual cost will then be 4 x $80, or $320. Totaling the 1st year maintenance costs for both system types: PowerGripGT2/Poly Chain GT2 Belt Drives 1st year maintenance costs: $160 (Initial installation labor cost) Competitive V-belt Drives 1st year maintenance costs: $560 (Initial installation labor cost plus maintenance costs = $160 + $80 + $320)

Figure 5 graphically illustrates the difference in 1st year maintenance costs.

1st Year Maintenance Cost Comparison

Maintenance Savings Example Continuing the 40 HP air handling unit example, consider the different maintenance costs incurred in 1 year comparing PowerGrip GT2/Poly Chain GT to Vbelts. For these calculations, maintenance costs are approximated at $40 per hour per skilled maintenance technician. Most jobs typically use 2 maintenance technicians working in teams. Both the PowerGrip GT2/Poly Chain GT2 and Vbelt drives will require approximately the same amount of time to install. A typical drive takes approximately 2 hours to install. At $40 per hour per maintenance technician, the cost to install both types of drives is $160 ($40 per hour x 2 technicians x 2 hours). Once the PowerGrip GT2/Poly Chain GT2 belt drive is installed, no further maintenance is typically required until the belt is replaced. No further maintenance means that no additional cost is incurred ($0). The 24 hour run in/retension procedure for the V-belt drive uses the same 2 maintenance technicians for another hour. At $40 per hour per maintenance technician, the cost to retension the drive is $80 ($40 per hour x 2 technicians x 1 hour).
Installation and Maintenance Costs ($)
600 500 400 300 200 100 0

PowerGrip GT2 Poly Chain GT2 Retension

Competitive V-Belt

Run In and Retension

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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PowerGrip GT2 and Poly Chain GT2 Belt Drive Advantages

Totaling the two year maintenance costs for both system types: PowerGrip GT2 Belt Drives Two year maintenance costs: $160 (Initial installation labor cost) Competitive V-belt Drives Two year maintenance costs: $1120 (Initial installation labor cost plus maintenance costs for 2 years = $160 + $80 + $320 + $160 + $80 + $320) The two year maintenance cost comparison is shown in Figure 6.

Two Year Maintenance Cost Comparison

Installation and Maintenance Costs ($)
1200 1000 800 600 400 200 0

PowerGrip GT2 Poly Chain GT2 Retension

Competitive V-Belt

Run In and Retension

Installation

Figure 6

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Total Drive Cost Considerations

The previous sections have discussed the energy and maintenance savings that are possible when using PowerGrip GT2 and Poly Chain GT2 belt drives. While energy and maintenance savings are significant, the total cost of a belt drive system is the most important factor for an end user. Total cost includes the initial drive cost, energy costs, and maintenance costs. The initial drive cost is easily obtained for both V-belt and PowerGrip GT2/Poly Chain GT2 belt drives. The annual energy costs can be calculated using Equation 1. Maintenance costs can be approximated as discussed in the Maintenance section above. The 40 HP drive conversion example is continued below. This example follows through the energy and maintenance costs calculated so far, and adds initial drive cost to arrive at the total 1st year drive cost. If both drives are replaced once per year, the PowerGripGT2 belt drive saves $1787.53 compared to the V-belt drive. Figure 7 graphically shows the 1st year total drive costs.

Total Drive Cost Comparison - 1st Year

35,000 30,000

1st Year Total Drive Costs ($)

25,000 20,000 15,000 10,000 5,000

0

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

PowerGrip GT2 Poly Chain GT2 Energy Cost

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.

Additional Cost Comparison - 1st Year

Dollars ($)

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).

2,000 1,500 1,000 500

0

PowerGrip GT2 Additional Energy Cost Additional Maintenance Cost Additional Initial Drive Cost

Competitive V-Belt

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Total Drive Cost Considerations

Note that these total additional cost comparisons 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 higher over the lives of both types of belt drives, as they will have to be installed more frequently. In this instance, the drive cost would be higher for the competitive V-belt drive. 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: Totaling the two year costs for both system types: PowerGrip GT2 Belt Drive Two year component costs: $342.83 ($5.01 more than V-belt drive) Two year maintenance costs: $160 (Initial installation labor cost) Two year energy costs: $55,651.26 Competitive V-belt Drives Two year component costs: $337.81 (1 set of sheaves, 2 sets of belts) Two year maintenance costs: $1120 (Initial installation labor cost) ($960 more than PowerGrip GT2 belt drive) Two year energy costs: $58,580.28 ($2929.02 more than PowerGrip GT2 belt drive) The two year additional cost comparison is shown in Figure 9.

Additional Cost Comparison - 2 Year

5,000

Dollars ($)

4,000 3,000 2,000 1,000

0

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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HVAC Drive Design Considerations

While HVAC applications are an excellent choice for conversion to PowerGrip GT2 or Poly Chain GT2 belt drives, care must be taken to insure that the HVAC unit is a good candidate for conversion. Air handling equipment is usually designed by the OEM to accommodate V-belt drives. Some easy to follow guidelines are listed below to aid in recognizing good (or bad) conversion candidates. vide 150 to 200% of its rated capacity. V-belts would tend to slip, acting like a clutch under these conditions. This effectively "clips" the peak torque at start up. However, PowerGrip GT2 and Poly Chain GT2 belts cannot slip, and must transmit the higher start up torque. Under these conditions, the drive center distance may collapse if the structure is not sufficiently rigid. With the drive shut off and safely locked out, a simple method to use when inspecting potential drive conversions is to grab the two belt spans and push them together while observing the motor. If any relative movement of the motor or center distance is noticed, the drive will most likely have a structure that is insufficient for a simple conversion. The structure would need to be reinforced to obtain the maximum performance from a PowerGrip GT2 or Poly Chain GT2 belt drive.

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 shows an example of checking for structural rigidity.

Figure 10

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HVAC Drive Design Considerations

The best conversion candidates have motors that are mounted solidly on bracketry that is part of the fan's mounting system. Figure 11 shows an example of a good candidate for conversion. Note that the motor and fan are both solidly mounted to the concrete pad.

Figure 11

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HVAC Drive Design Considerations

The air handler shown in Figure 12 has the total system (including both the motor and fan) mounted on vibration isolation springs. It is important to note that the entire unit is mounted on the same vibration isolation springs. If the motor and fan were mounted independently on their own vibration isolation springs, the center distance would vary under operation. The varying center distance would result in premature belt wear and failure. If a unit has the motor and fan mounted independently on vibration isolation springs, it should not be converted to a PowerGrip GT2 or Poly Chain GT2 belt drive. Systems using this type of motor mount cannot be reinforced. If the motor and fan were mounted independently on separate vibration isolation springs, the entire structural system would need to be redesigned in order to use a PowerGrip GT2 or Poly Chain GT2 belt drive.

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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HVAC Drive Design Considerations

A frequently used configuration has the motor and fan mounted vertically relative to each other. Figure 13 shows a system that has the motor mounted directly to the structural members for the fan mounting system. This is a good conversion candidate. This type of mounting system is typically rigid enough that reinforcement is not necessary.

Figure 13

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HVAC Drive Design Considerations

On the other hand, note that in Figures 14 and 15, the motor is mounted externally on the sheet metal box enclosing the fan unit. This type of mounting system is typically not very rigid. Check the systems structural integrity by performing the system rigidity test shown in Figure 10. Carefully inspect the inside of the sheet metal case for any internal reinforcing structural members. If no structural members are present, reinforcement is usually required to convert this type of drive to synchronous belts. Reinforcement can be as simple as angle iron placed in a location that will support the motor mounts more rigidly.

Figure 14

Figure 15

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HVAC Drive Design Considerations

Double screw motor bases are ideal for use with PowerGrip GT2 and Poly Chain GT2 belt drives because adjustment and alignment are easier and more positive. Single screw motor bases can result in misalignment at the motor that can reduce the overall belt drive performance. Figure 16 illustrates a typical double screw motor base.

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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HVAC Drive Design Considerations

forced is now very likely a good candidate for conversion. A thorough visual inspection of the current belt drive on the unit at start up is recommended. If no unusual belt span vibration is observed, a PowerGrip GT2 or Poly Chain GT2 belt drive can usually be used without reinforcing the unit's structure. Adding a soft start to the system is often a cost effective method of reducing start up loads and center distance collapse. Adding a variable frequency control (AC Inverter) not only reduces start up loads, but also allows for fine tuning of the final driveN fan speed. This fine tuning capability makes balancing the HVAC system much easier and accurate, as well as eliminating the need for expensive variable pitch V-belt sheaves. Belt Speed Noise generally increases with belt speed. Reduce belt speed by designing with smaller sprocket diameters. Be careful to follow NEMA minimum diameter requirements for sprockets which will be installed on AC electric motors. Belt Tension Noise tends to increase with increasing dynamic belt tension. Reduce dynamic belt tensions by designing with larger sprocket diameters. A balance must be achieved on diameters to take advantage of reduced belt speeds and reduced tensions. Belt Width Belt noise tends to increase with belt width. Both PowerGrip GT2 and Poly Chain GT2 are good choices for synchronous belt drive conversions when noise is a concern. Belt widths can be reduced as much as 50% to 75% when using PowerGrip GT2 or Poly Chain GT2, due to the belt's high horsepower capacities. Do not overdesign and use a wider belt than necessary. Noise Barriers and Absorbers Sometimes, even properly aligned and tensioned belt drives may be too noisy for a work environment. When this occurs, steps can be taken to modify the drive guard to reduce the noise level. Noise barriers are used to block and reflect noise. Noise barriers do not absorb or deaden the noise; they block the noise and generally reflect most of the noise back towards its point of origin. Good noise barriers are dense, and should not vibrate. A sheet metal belt guard is a noise barrier. The more complete the enclosure is, the more effective it is as a noise barrier. Noise barrier belt guards can be as sophisticated as a completely enclosed case, or as simple as sheet metal covering the front of the guard to prevent direct sound transmission. Noise absorbers are used to reduce noise reflections and to dissipate noise energy. Noise absorbers should be used in combination with a noise barrier. Noise absorbers are commonly referred to as acoustic insulation. Acoustic insulation (the noise absorber) is used inside of belt guards (the noise barrier) where necessary. A large variety of acoustic insulation manufacturers are available to provide different products for the appropriate situation. A combination of noise barrier (solid belt guard) and noise absorber (acoustic insulation) will provide the largest reduction in belt drive noise. While the noise reduction cannot be predicted, field experience has

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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HVAC Drive Design Considerations

shown that noise levels have been reduced by 10 to 20 dBA when using complete belt guards with acoustic insulation. Fan Speed Horsepower Requirement Example As an example, consider a drive that has the driveN fan speed increased from 1100 RPM to 1125 RPM. The fan load at 1100 RPM is 25 HP. To calculate the new horsepower requirement, use Equation 4. (25/HP2) = (1100/1125)3 HP2 = 26.7 HP Note that the fan speed has only increased 2.3% (1125/1000 X100% = 2.3%), but the horsepower requirement has been increased by 7%. Obviously, great care must be taken when selecting drive components to insure that the proper fan speed is selected. A belt drive design that increases the fan speed will result in higher operating energy costs. When replacing a V-belt drive, a PowerGrip GT2 or Poly Chain GT2 belt drive should not be designed based on the V-belt sheave diameters. This is because the actual driveN fan speed will likely be slower than the theoretical V-belt sheave speed ratio would indicate. This is due to slippage of the V-belt drive. Whenever possible, the RPM of the fan shaft should be measured. This can be done by either using a mechanical contact tachometer or a strobe tachometer as shown in Figure 17.

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

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HVAC Drive Design Considerations

As an example, consider the following example where V-belt slippage was not considered by the designer. This example illustrates how poor design procedures can result in an increase in power usage. Figure 18 graphically illustrates the consequences of improperly designing a PowerGrip GT2 or Poly Chain GT2 belt drive by basing the speed ratio on the V-belt sheave diameters.

Power Usage Example A 50 HP motor is driving a fan. The existing drive has the following components:
Horsepower

Comparison of HP Requirements Varying with Fan speed

58.3
60 55 50
45

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

995 RPM Ideal

1000 RPM Actual

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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HVAC Drive Design Considerations

the V-belt sheave diameters. This will keep the belt pull roughly equal to the existing V-belt drive, and will minimize the possibility of structural problems. It is important to remember that small differences in diameters can make a large difference in belt pull. For example, if a V-belt drive has a 10" driveR diameter sheave, and is replaced by an 8" diameter sprocket, that is a 20% reduction in diameter (and a corresponding 20% INCREASE in belt pull). While 2" may not seem like much of a diameter reduction, the 20% increase in belt pull could potentially be very significant to both the structural rigidity and the unit's bearing performance. Figure 20 6 Installation A. Alignment Proper drive alignment is critical for optimum belt performance. PowerGrip GT2 and Poly Chain GT2 belts are more sensitive to misalignment than V-belts, and should not be used on drives where misalignment is inherent in the system. Misalignment leads to inconsistent belt wear and premature tensile failure due to unequal tensile member loading. See Figure 19. Parallel misalignment occurs when the driveR and driveN shafts are parallel, but the sprockets lie in different planes. When the shafts are not parallel, the drive is angularly misaligned. A fleeting angle is the angle at which the belt enters and exits the sprocket, and equals the sum of the parallel and angular misalignments. Sprocket misalignment will result in reduced belt life. The total misalignment of synchronous belt drives should not exceed 1/4O or 1/16" per foot of center distance. Misalignment should be checked with a good straightedge tool. The tool should be applied from driveR to driveN and from driveN to driveR so that the effect of parallel and angular misalignment is taken into account. Alignment can be checked with tools as simple as a piece of string or straightedge, or as sophisticated as the Gates EZ Align precision laser alignment device shown in Figure 21. There are two types of misalignment: parallel and angular (Figure 20).

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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HVAC Drive Design Considerations

Drive misalignment can also cause belt tracking problems. However, some degree of belt tracking is normal and won't affect performance. Optimum operation of the drive will be with the belt only contacting one flange in the system. The worst case is the contacting of flanges on opposite sides of the sprockets in the system. This traps the belt between the flanges and can force the belt into undesirable parallel misalignment. Improper installation of the bushing can result in the bushing/sprocket assembly being "cocked" on the shaft. This leads to angular misalignment. It is important to follow the installation instructions that are included with the bushing. B. Tension Proper belt installation tension is important to the optimum performance and longevity of the belt. The two extremes of improper tensioning are under and overtensioning. When a belt is undertensioned, it will prematurely wear the belt teeth, and possibly even ratchet (jump teeth) under heavy start up loads, shock loads, or structural flexing. See Figure 22. Figure 23 A common method is to use the force deflection method, measuring the recommended deflection force using the Gates Pencil Type Tension Tester (Product Number 7401-0076). Larger drives with higher recommended static tensions may require the use of the Double Barrel Tension Tester (Product Number 74010075) or the Gates Sonic Tension Meter (Product Number 7420-0507). The Sonic Tension Meter measures belt static tension by measuring span vibration frequency. The Sonic Tension Meter provides an easy measurement method for large drives which would require deflection forces larger than can be measured with either the Pencil Type or Double Barrel Tension Tester. The Sonic Tension Meter is shown in Figure 24.

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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Design Flex II Energy Savings Report

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Appendix
Design Flex II PowerGrip GT2 Drive Detail Report

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Design Flex II V-belt Drive Detail Report

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Energy Survey Data Plots

Appendix

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Energy Survey Data Plots

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Energy Survey Data Plots

Appendix

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Energy Survey Data Plots

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Energy Survey Data Plots

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

The Driving Force in Power Transmission

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

Existing Drive e Information

Drive Type: Current Drive Service Life = DriveR Sprocket/Sheave = DriveN Sprocket/Sheave = Driven RPM= Center Distance = Type of Center Distance Adjustment: Idler used: Motor Mount: Yes No Inside No No Days/Week = Backside Motor Mounted on Sheet Metal? Floating/Pivot Base? Yes V-Belt Synchronous Belt Belt Type/Size and Manufacturer = (teeth/OD) (teeth/OD) DriveR Shaft Diameter = DriveN Shaft Diameter =

Measured DriveN Speed (Strobe/Tach) =

Double Screw Base? Yes Adequate Structure? Yes

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 =

Energy y Savings s Information Energy Cost per KW-Hour: Hours of Operation:

Hours per Day

Days per Week

Weeks per Year

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