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Rulli Rulmeca
Bulk Handling Motorized Pulleys

Bulk Handling Motorized Pulleys

Product catalog summary

Company Overview
Rulmeca, founded in 1962 and based in Bergamo, Italy, is a prominent manufacturer of conveyor components for the bulk handling industry. The company employs 1,200 people across 22 global locations and serves clients in 85 countries under the brands Rulmeca, Precismeca, and Melco. Their focus is on durable belt conveyor components for industries like mining, cement, and recycling.

Product Description
The Rulmeca Motorized Pulley, initially produced in 1953, is a compact, hermetically sealed conveyor drive unit designed for harsh environments. It features a steel cylindrical shell, precision bearings, and a highly efficient geared motor drive. The unit is oil-filled for lubrication and cooling, ensuring minimal maintenance and high efficiency.

Specifications

Machined mild steel crowned shell.
Electric motor compliant with IEC 34-1 standards.
Class F insulation and IP66/67 protection.
Available in various international voltages.
CE-marked according to European Directives.

Features and Benefits

Space-saving design with enclosed motor and gearbox.
Low maintenance with oil changes every 20,000 hours.
High efficiency with up to 97% energy conversion.
Hermetically sealed to prevent contamination.
Thermal protection and variable frequency control.

Applications
Rulmeca Motorized Pulleys are used in various applications, including cement plants and recycling, offering advantages like reduced installation costs and enhanced safety.

Ordering Information
When ordering, specify application details, motorized pulley options, and any special requirements. Standard specifications include a crowned mild steel shell, IP66/67 sealing, and compatibility with most global voltages. Options for stainless steel execution and additional features are available.

Conclusion
The Rulmeca Motorized Pulley is a reliable and efficient solution for conveyor systems, offering significant advantages in terms of space, safety, and maintenance. Its robust design and high efficiency make it suitable for a wide range of industrial applications.

Specifications and Features:
The document provides detailed specifications for Motorized Pulleys, specifically models 138E and 165E. Both models offer options for total stainless steel construction, re-greasable labyrinth seals, and food-grade oil and grease compliant with FDA and USDA standards. They are designed to be dust explosion-proof according to ATEX 95 standards for Zone 22 applications.

Model 138E:
- Diameter: 138 mm
- Available with black rubber lagging and white smooth rubber lagging (FDA compliant).
- Optional features include single-phase motors, electromagnetic brakes, mechanical backstops, and modifications for vertical mounting.
- Insulation class F is standard, with class H available for higher temperature ranges.
- IP66/67 protection is standard, with options for screened cables and special voltages.

Model 165E:
- Diameter: 165 mm
- Similar features to 138E, with additional options for a machined helical gearbox and a range of power outputs from 0.11kW to 1.5kW.
- Suitable for light agriculture, bulk solids handling, and mobile conveyors.
- Offers a stainless steel version for wash-down applications.

Installation and Usage Recommendations:
- It is crucial to calculate the belt tension (T1+T2) to ensure it does not exceed the maximum radial load specified.
- High belt tensions should be avoided with thick, heavy, or large belts.
- If the specified models cannot handle the required load, a larger diameter pulley should be considered.

Optional Extras and Customization:
- Both models offer a range of optional extras, including special lagging, low noise drives, and various connector types.
- Customization options are available for specific applications, such as magnetic separators and noise-sensitive areas.

Technical and Environmental Considerations:
- The document references additional pages for technical precautions, environmental considerations, and connection diagrams.
- Regular oil changes are recommended every 20,000 operational hours to maintain performance.

Spare Parts and Maintenance:
- A comprehensive list of spare parts is provided, including bearings, seals, connectors, and screws.
- Maintenance instructions emphasize the importance of using the correct parts and following specified procedures to ensure longevity and reliability.

Overview: This document provides detailed specifications and guidelines for selecting and using motorized pulleys, specifically the 220M and 220H models, based on belt tension and radial load requirements. It includes information on standard and optional features, material specifications, and application recommendations.

Specifications:

Standard Features: The motorized pulleys feature a crowned mild steel shell treated with anti-rust wax, powder-coated cast iron bearing housings, and mild steel shafts. They include a shaft sealing system with IP66/67 protection, a compact terminal box, and 3-phase induction motors with thermal protection.
Material Options: Stainless steel options (TS9N and TS10N) and semi-rust-free options (TS11N and TS12N) are available, with varying degrees of re-greasable labyrinth seals and anti-rust treatments.
Electrical Specifications: The pulleys support a wide range of voltages and include motor winding insulation Class F. Special voltages and dual voltage configurations are available upon request.

Application Guidelines:

Belt Tension: It is crucial to calculate the belt tension (T1+T2) and ensure it does not exceed the maximum allowable radial load specified in the catalogue. High belt tensions may require selecting a pulley with a larger diameter.
Duty Classifications: The 220M is suitable for medium-duty applications like mobile crushing and screening, while the 220H is designed for heavy-duty applications requiring low speeds and high torque, such as recycling and bunker discharge conveyors.

Optional Features:

Options include FDA & USDA food-grade oils, dust explosion-proof configurations, and various lagging types for enhanced grip and reduced noise.
Additional features like electromagnetic brakes, mechanical backstops, and special mounting configurations are available.

Technical Considerations:

Environmental and technical precautions are detailed on pages 77-92, with connection diagrams on pages 98-100.
Regular maintenance, such as oil changes every 20,000 operational hours, is recommended to ensure optimal performance.

Specifications:
- The motorized pulleys are designed with a degree of protection IP66/67 according to EN60034-5 standards. They feature compact powder-coated die-cast aluminum terminal boxes for motors up to 4.0 kW and larger ones for motors 5.5 kW and above. The motors are 3-phase induction types with thermal protectors and have a wide voltage range. Motor winding insulation is Class F, and the rotors are dynamically balanced. Oil plugs are magnetized for oil filtration, with oil changes recommended every 20,000 operational hours. The pulleys are intended for horizontal use only, with specific RL dimensions detailed in the document.

Stainless Steel Options:
- TS9N and TS10N models offer stainless steel components, with TS9N including re-greasable labyrinth seals. TS11N and TS12N are semi-rust-free options with mild steel shells treated with anti-rust wax.

Other Options:
- FDA & USDA food-grade oils and greases are available on request. Complete motorized pulleys in acid-resistant stainless steel are also available. Electrical connection options include saltwater-resistant aluminum terminal boxes and stainless steel connectors.

Optional Extras:
- Various optional extras are available, including dust explosion-proof motorized pulleys, special lagging, electromagnetic brakes, and low noise drives. Special voltages and dual voltage connections can be specified.

Technical Precautions and Environmental Considerations:
- Detailed technical precautions and environmental considerations are provided in the document, along with connection diagrams and optional extras.

Spare Parts and Sectional Drawings:
- The document includes a comprehensive list of spare parts and sectional drawings for different models of motorized pulleys, detailing components such as bearings, seals, and connectors.

Overview: The document provides detailed specifications and options for Rulmeca Motorized Pulleys, specifically focusing on the 320L, 320M, 320H, 400L, 400M, and 400H models. These pulleys are designed for various applications, including mobile crushing and screening, with options for light, medium, and heavy-duty use.

Specifications: The motorized pulleys are available in diameters of 320 mm and 400 mm, with different loading performances: L for light-duty, M for medium-duty, and H for heavy-duty. The document emphasizes the importance of selecting the correct pulley based on estimated belt tension and radial load requirements.

Standard Features: The pulleys feature a crowned mild steel shell, bolted powder-coated cast iron bearing housings, mild steel shafts with anti-rust treatment, and a shaft sealing system with IP66/67 protection. They are equipped with 3-phase induction motors, thermal protectors, and dynamically balanced rotors. Oil changes are recommended every 20,000 operational hours.

Options and Customizations: Various options are available, including stainless steel components (TS9N, TS10N), semi-rust-free options (TS11N, TS12N), and food-grade oil and grease. Additional features include electromagnetic brakes, mechanical backstops, and special lagging options. Electrical connection options and environmental considerations are also detailed.

Technical Precautions and Optional Extras: The document provides guidance on technical precautions and optional extras, such as dust explosion-proof pulleys, special voltages, and CSA-approved motors. It also includes connection diagrams and environmental considerations.

Spare Parts and Sectional Drawings: Detailed spare parts lists and sectional drawings are provided for the 400L and 400M models, including bearings, retaining rings, hexagon screws, and other components.

Overview: This document provides a comprehensive guide on motorized pulleys, specifically focusing on the 400H, 500L, 500M, and 500H models. It includes specifications, spare parts lists, sectional drawings, and options for different applications.

Specifications: The motorized pulleys are available in different diameters (400 mm and 500 mm) and are designed for various duty levels: Light-duty (L), Medium-duty (M), and Heavy-duty (H). Key features include a crowned mild steel shell, IP66/67 protection, 3-phase induction motors, and dynamically balanced rotors. The document emphasizes the importance of selecting the correct pulley based on belt tension and radial load requirements.

Spare Parts and Sectional Drawings: Detailed lists of spare parts are provided for each model, including bearings, retaining rings, hexagon screws, and more. Sectional drawings illustrate the assembly and components of the pulleys, aiding in maintenance and repair.

Options and Customizations: The document outlines various options such as semi-rust-free configurations, electromagnetic brakes, and backstop options. Special lagging and custom voltages are available upon request. The document also highlights the availability of dust explosion-proof pulleys for specific applications.

Maintenance and Recommendations: Regular oil changes are recommended every 20,000 operational hours. The document advises on environmental considerations and technical precautions to ensure optimal performance and longevity of the pulleys.

Applications: The motorized pulleys are suitable for a wide range of applications, including grain storage, cement, steel, fertilizer, and heavy mobile crushing and screening. The document emphasizes the reliability and robustness of the pulleys, capable of operating continuously under harsh conditions.

Overview: The document provides detailed specifications and options for Motorized Pulleys designed for heavy-duty applications, specifically the 630H and 800 series. These pulleys are engineered to handle extreme conditions, offering necessary torque and belt pull.

Standard Specifications:

Material and Construction: The pulleys feature a crowned mild steel shell, painted yellow with a minimum layer of 60 µm, and bolted powder-coated cast iron bearing housings and covers.
Protection and Sealing: They include a shaft sealing system with IP66/67 protection (EN60034-5) and a cast iron terminal box.
Motor and Electrical: Equipped with 3-phase induction motors with thermal protectors, motor winding insulation Class F, and dynamically balanced rotors. Voltage options are available upon specification.
Maintenance: Oil changes are recommended every 20,000 operational hours.
Installation: Designed for horizontal use within ±5 degrees.

Semi-Rust-Free Options:

TS11: Features painted mild steel shell and cast iron end housings with stainless steel covers and nitrided shaft sleeves.
TS12: Similar to TS11 but without re-greasable seals.

Optional Extras:

Re-greasable labyrinth seals, black rubber lagging, and white smooth rubber lagging (FDA approved).
External brake shaft, mechanical backstop, and special voltages available on request.

Technical Data: The document includes detailed tables with specifications for different models, including motor power, nominal belt speed, torque, and belt pull. It also provides dimensions and weight for various configurations.

Environmental and Technical Considerations: Additional information on environmental considerations, technical precautions, and connection diagrams is referenced in specific pages.

Conclusion: The document serves as a comprehensive guide for selecting and configuring motorized pulleys for specific heavy-duty applications, emphasizing the importance of matching pulley specifications with application requirements.

Overview: The document provides detailed technical specifications, parts lists, and operational guidelines for RULMECA Motorized Pulleys, specifically focusing on the 1000HD model. It includes information on design, applications, and optional features for various environmental conditions.

Specifications: The Motorized Pulley 1000HD is designed for heavy-duty applications such as mining conveyors and stackers. It features a crowned mild steel shell with ceramic lagging, cast steel bearing houses, and a sealing system with IP66/67 protection. The pulley supports a power range of 160-250 kW and is suitable for extreme conditions.

Parts List: The document lists numerous components such as bearings, retaining rings, screws, washers, gaskets, and keys. It also includes specific parts for the backstop and brake shaft assemblies.

Operational Guidelines: The pulley is designed for tough environments, with features like regreasable labyrinth seals and synthetic oil. It supports various voltages and includes thermal protectors and temperature resistors for motor protection.

Optional Features: Options include different ceramic lagging types, mechanical backstops, external brake shafts, and dust explosion-proof configurations. The document also outlines special requirements for low/high temperatures, dusty environments, and food handling applications.

Applications: The pulley is suitable for use in marine environments, reversible conveyors, and applications requiring frequent start/stops. It is not intended for continuous underwater use or intrinsically safe environments without consultation.

Power Calculation: A formula is provided for calculating the necessary power for bulk handling applications, considering factors like frictional resistance and belt speed.

Standard Loading Conditions:
This section outlines the parameters for conveyor operations, including conveyor length, tonnage rate, belt speed, material lift height, ambient temperature range, initial velocity of material, and the number of belt cleaners and plows. It also lists the frictional coefficients and bulk densities for various materials, which are crucial for calculating conveyor performance.

Operating Conditions:
Details the duty cycle, hours and days of operation, and whether the belt is reversible. Additional comments can be added for specific operational considerations.

Special Loading Conditions:
Includes parameters for hopper feeders, slider beds, sidewall and cleated belts, and tripper design. These specifications are essential for customizing the conveyor system to specific material handling needs.

Technical Precautions for Design, Installation, and Maintenance:
Emphasizes the importance of following safety instructions and standards such as ANSI and ISO for the installation and maintenance of motorized pulleys. It includes guidelines for transport, mounting orientation, electrical installation, and protection against overload and thermal issues.

Installation & Maintenance:
Provides detailed instructions on the transport and handling of pulleys, mounting orientation, bracket installation, and electrical setup. It stresses the importance of using licensed electricians and adhering to national electrical standards to prevent hazards.

Safety and Compliance:
Highlights the need for compliance with safety regulations and standards, including the Williams-Steiger Occupational Safety and Health Act and CEMA standards. It warns against installing motorized pulleys in explosive environments and outlines the necessary precautions for safe operation.

Additional Notes:
The document advises on the use of appropriate mounting brackets, the importance of proper electrical connections, and the need for regular maintenance checks to ensure the longevity and safety of the conveyor system.

Specifications:
ZED Pulley motors are equipped with built-in thermal protectors in each phase, using bi-metallic switches to prevent overheating. The standard permissible current is 2.5 Amps at 230V. These switches must be connected to a normally closed control circuit to maintain warranty validity.

Procedures:
1. Belt Tension: Ensure the conveyor belt is not over-tensioned to prevent slippage. Use anti-slip lagging to minimize radial load.
2. Belt Alignment: Install Motorized Pulleys with the shaft perpendicular to the belt centerline to avoid misalignment and excessive friction.
3. Start-up: Verify nameplate data, electrical connections, and ensure the Pulley is free to rotate before initial start-up.

Norms and Recommendations:
1. Lagging: Available in various patterns and materials, lagging affects heat dissipation. Choose based on application needs.
2. Ambient Temperature: Designed for up to +40°C. Higher temperatures or rubber lagging can impair heat dissipation.
3. Surface Coating: Pulleys are coated for corrosion resistance, with additional painting recommended for aggressive environments.

Key Parameters:
1. Actual vs. Nominal Belt Speed: Actual speed varies with motor characteristics and load. Nominal speeds are based on un-lagged Pulleys.
2. Belt Pull: Calculate required belt pull considering all forces involved in material conveyance.

Limitations:
1. Mechanical Backstops: Used for inclined conveyors, not suitable for reversible applications.
2. Reversing Conveyors: Ensure complete stop before reversing to avoid damage.

Maintenance:
1. Oil and Oil Seal: Regular oil changes are necessary, with specific types and quantities detailed in the manual.
2. Electromagnetic Brake: Ensure control circuits prevent motor and brake from working against each other.

Critical Information:
Exceeding specified radial loads, improper installation, or neglecting maintenance can void the product warranty and lead to equipment failure.

Oil and Seal Maintenance: Regular oil changes are crucial for motorized pulleys. Mineral oils should be changed after 20,000 hours, while synthetic oils last up to 50,000 hours. Magnetic oil plugs need cleaning during each oil change. Oil seals should be replaced every 30,000 hours, with specific procedures depending on the pulley type. Switching oil types requires a thorough cleaning process to avoid compatibility issues.

Labyrinth Seals: These optional seals protect against harsh conditions and require regular greasing, especially in abrasive or wet environments. Proper maintenance is essential to avoid warranty voidance.

Pulley Diameter: The conveyor belt type dictates the minimum pulley diameter to prevent damage. Consultation with a belting supplier is recommended.

Terminal Box: Motorized pulleys come with terminal boxes or power cords. Proper handling and authorized modifications are necessary to maintain warranty.

Frequency Converter: Must be set within 15-65 Hz to maintain constant torque. Avoid resonant frequencies and ensure proper cable screening to comply with EMC directives.

Capacitors for Single Phase Motors: Appropriate capacitors are crucial for motor function. Incorrect capacitors can damage the motor and void the warranty.

General Maintenance: Motorized pulleys are generally maintenance-free but require disconnection from power for any repairs. Safety precautions are critical during maintenance.

After Sales Service: Contact authorized service centers for support. Unauthorized modifications can void the warranty.

Storage: Store pulleys in covered areas, protect from sun, and rotate periodically. Test pulleys stored for over six months before use.

Dust Explosion Proof Pulleys: Ensure proper assembly and sealing to prevent explosions. Use appropriate cable glands.

IP Ratings: Defines protection levels against solid objects and water ingress, crucial for selecting the right equipment for specific environments.

Oil Contents and Specifications:
The document provides detailed information on oil contents for standard motorized pulleys used in horizontal applications. It specifies that the given oil quantities are valid only for standard un-lagged motorized pulleys, and special options may require different amounts. Users are advised to refer to the motor data plate for accurate oil quantities.

Oil Types and Specifications:
Various oil types are listed with their respective specifications, including types like 138E, 165E, 220M, and others, with oil amounts ranging from 1.4 liters to 40 liters. The document emphasizes the importance of using the correct oil type to ensure optimal performance and longevity of the pulleys.

Installation and Application Guidelines:
The document outlines the typical installation angles for different motorized pulleys, ranging from 5° to less than 90°, and highlights the importance of magnetic separations for certain models. It also advises contacting Rulmeca for special designs and oil requirements.

Connection Diagrams:
Detailed connection diagrams for motorized pulleys are provided, including configurations for both AC and DC motors, thermal protectors, and electromagnetic brakes. The diagrams cover various models and power ranges, ensuring proper electrical connections.

Additional Notes:
The document includes notes on the importance of checking star connections before reconnection and provides color codes for wiring, such as red, yellow, black, grey, blue, green, white, and brown. It also mentions the use of synthetic oil to reduce wear, noise, and overheating.

Catalog excerpts

Rulmeca – Moving ahead. Since its foundation in 1962, Rulmeca, headquartered in Bergamo (Almé), Italy, has grown to become one of the world’s leading manufacturers of conveyor rollers/idlers, motorized pulleys, fabricated pulleys and other components for the bulk handling industry. 1,200 employees in twenty-two production and sales companies around the globe serve clients in 85 countries. Today, Rulmeca Group’s global business incorporates the product brands Rulmeca, Precismeca and Melco. All three of them specialize in the supply of long-lasting premium belt conveyor components. Rulmeca Group products are developed and produced to meet the most demanding everyday challenges of all major bulk handling applications: coal and lignite mining, cement, steel, quarries, tunneling, power plant installations, ports, salt and fertilizers, sugar plants, recycling and demolition, crushing and screening. The close partnership with our customers, OEMs, engineering companies and end users has made us one of the most trusted brands in the industry. As a family-owned business with a long-term perspective, our combination of traditional values and openness to innovation continues to be one of our key success factors. This is also seen in our consistent environmental and social responsibility throughout the value chain. We are committed to the continuous improvement of our range, often considered among the best in the market. Our research departments are equipped with state-of-the-art test facilities, where our products are thoroughly examined under extreme conditions. Every day and on all continents, Rulmeca products improve the performance, safety and reliability of systems, equipment and machines within the bulk handling industry. Whatever your materials handling problem might be, talk to us. We have the expertise, the experience – and the products you need.

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General description The Rulmeca Motorized Pulley was first produced in 1953 specifically for use on conveyors belt applications. The aim was to produce a compact, hermetically sealed, highly efficient conveyor drive unit that would be unaffected by dust, water, oil, grease or other harmful substances. A Motorized Pulley that would be quick and simple to install and require virtually no maintenance. These aims were achieved and today the Rulmeca Motorized Pulley is considered to be one of the most reliable, effective and safe conveyor drive systems available throughout the world. The Rulmeca Motorized...

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Sea-dredged aggregates working in wet, salty and aggressive environment! IP66/67 sealing – a MUST – often with re-greasable seals! Recycling application benefiting from IP66/67 sealing systems avoiding internal damage from audio or video cassette tapes and aggressive ambient environments containing air or gas of high Ph-values.

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Purpose-built design The Rulmeca Motorized Pulley has been specifically designed for belt conveyors. Totally enclosed The motor, gearbox and bearings are totally enclosed and sealed inside a steel shell; therefore they are unlikely to fail due to harmful environmental conditions such as water, dust, grit chemicals, grease, oil, etc. Space saving design Because the drive unit and the bearings are mounted inside the Motorized Pulley shell, it takes up much less room than a conventional drive. No need for costly extras like chains, v-belts, couplings, bearings, support structure and special guarding. Safety The...

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Excavator in a US cement application. Two Motorized Pulleys type 800H drive both the incoming & outgoing conveyors. Compact and reliable drive unit using Motorized Pulley type 800H, 75kW at 3.15 m/sec. Both Motorized Pulleys are fitted with brake shaft for connection to external brakes.

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Sectioned model of Motorized Pulley type 220M.

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२ CSAus approved motors? २ Class F (Standard) २ Class H २ Synthetic २ Food grade २ Vertical २ NON-horizontal between 5° - ≤90° २ TS7N २ TS9N २ TS10N २ TS11 २ TS12 २ Anticondensation heater explosion proof – ATEX 95 – Zone 22 २ Parallel shell (cylindrical)

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Motorized Pulley 138E, with machined helical gear box, performs an efficiency, in a compact diameter of 138 mm only. With a min RL of 300 mm and powers ranging from 0.10 to 1.0kW this size of motorized pulley is suitable for most duties requiring such a small diameter - e.g.: • Light agriculture and bulk solids handling conveyors • Mobile or portable conveyors • As a drive unit for brush cleaners etc. Motorized pulley 138E has standard IP66/67 enclosure and is available in complete stainless steel execution for wash down application. For the choice of the Motorized Pulley it is very important...

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Motorized Pulley with Terminal box Motorized Pulley with cable Straight connector Elbow connector Front shaft with cable slot Idler pulley stainless steel version; cylindric option Standard measurements Type / Option Ref.

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Motorized pulley 138E – Ø 138 mm Power kW/HP No. Gear stages of Poles Nominal belt Torque Belt speed at Pull Full Load 50Hz m/sec Nm N Weight in kg for STANDARD width Dimension RL in mm 300 320 Weight in kg for STANDARD width Dimension RL in mm 300 320

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5 Bearing housing complete with geared rim 7 Bearing housing complete 10 Terminal box - bottom part 23 Intermediate pinion shaft 31 Labyrinth seal cover 53.1 Cable seal nipple (cable option) 55 Spacer bushing 64 Needle bearing 65-70 Ball bearing 71 Inner race 93 Elbow or straight connector 115 Oil plug with magnet

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Motorized Pulley 138ESpare Parts List and sectional drawings Pos. Description 204 Rotor complete with pinion 208 Bearing housing with labyrinth

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Motorized Pulley 165E, with machined helical gear box, performs an efficiency, in a compact diameter of 165 mm only. With a min RL of 400 mm and and powers ranging from 0.11kW to 1.5kW this size of motorized pulley is suitable for most duties requiring such a small diameter - e.g.: • Light agriculture and bulk solids handling conveyors • Mobile or portable conveyors • As a drive unit for brush cleaners etc. Motorized pulley 165E has standard IP66/67 enclosure and is available in complete stainless steel execution for wash down application. For the choice of the Motorized Pulley it is very important...

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