Table of Contents - Motorized Pulleys & Belt Conveyor Rollers · tle frictional torque loss. The Motorized Pulley is filled with oil, which acts as a lubricant and coolant. Heat is

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Rulmeca Motorized Pulley Cut-away View and Summary of Key Benefits................................................................................coverRulmeca Motorized Pulleys Application Photos........................................................................................................................ coverRulmeca FAA GmbH Manufacturing Facility Photos ............................................................................. .................................. coverTable of Contents ................................................................................................................................................................... .. 1Rulmeca Motorized Pulleys - Introduction..................................................................................................................................... 2Features and Benefits of Rulmeca Motorized Pulleys ............................................................................................................. 3Rulmeca Motorized Pulleys - General Description ....................................................................................................................... 4

• Motorized Pulley Highlight: “Mounting Orientations” ............................................................................................................. 5• Motorized Pulley Highlight: “Dual Drive Concept” ................................................................................................................. 6

Ordering Information ....................................................................................................................................................................... 7Model 138E (5.45” diameter) specifications ............................................................................................................................. 8-13Model 165E (6.49” diameter) specifications ............................................................................................................................. 14-19Model 220M & 220H (8.50” diameter) specifications .............................................................................................................. 20-28

• Motorized Pulley Highlight: “Compact Drives” ....................................................................................................................... 29Model 320L, 320M & 320H (12.64” diameter) specifications.................................................................................................. 30-38

• Motorized Pulley Highlight: “Tail Drives” ................................................................................................................................ 39Model 400L, 400M & 400H (15.91” diameter) specifications.................................................................................................. 40-48

• Motorized Pulley Highlight: “Hopper Feeder Drives” ......................................................................................................... 49Model 500L, 500M & 500H (19.72” diameter) specifications.................................................................................................. 50-58

• Motorized Pulley Highlight: “Bucket Wheel Excavators & Reclaimers”................................................................................ 59Model 630M & 630H (24.80” diameter) specifications ............................................................................................................ 60-63Model 800M & 800H (31.50” diameter) specifications ............................................................................................................ 64-67Part Lists & Sectional Drawings - 500H, 630M, 630H, 800M & 800H......................................................................................... 68-69

• Motorized Pulley Highlight: “Mechanical Backstops” ............................................................................................................ 70• Motorized Pulley Highlight: “Internal and External Brakes” .................................................................................................. 71

Special Environmental Conditions.................................................................................................................................................. 72-73Bulk Handling Engineering Principles............................................................................................................................................ 74Application Worksheet .................................................................................................................................................................... 75Technical Precautions for Design, Installation and Maintenance................................................................................................. 76-86

• Motorized Pulley Highlight: “Variable Frequency Drives”...................................................................................................... 87International Protection - IP ratings................................................................................................................................................ 88

• Motorized Pulley Highlight: “Lagging Options” ...................................................................................................................... 89Oil Quantities and Oil Types........................................................................................................................................................... 90-91Electrical Connection Diagrams - 138E - 800H........................................................................................................................92-100

Summary of Optional Extras .......................................................................................................................................................... coverInternational Directory..................................................................................................................................................................... cover

Table of Contents


The Rulmeca Motorized Pulleys present-ed in this catalogue have a long historyto tell. It goes back to the 1950’s, whenthe product was developed in Germanyand Denmark.

Eventually, through a merging processthe German Förder und AntriebstechnikAschersleben GmbH and the DanishJohn Kirkegaard Maskinfabrik A/Sbecame partners in the Interroll Group.

From the early 1990’s the manufacturingof all Interroll’s BULK Motorized Pulleyswere centralized in Aschersleben, Ger-many.

In July 2003 Rulli Rulmeca S.p.A. pur-chased the production facility in Ascher-sleben, Germany, where Motorized Pul-leys have been developed and producedfor almost half a century, along with theentire BULK Business Unit.

Today this plant, renamed RulmecaFAA GmbH, will continue the JOKI tradition for quality and reliability underthe Rulmeca brand.

Thanks to this long history Rulmeca is avery experienced manufacturer of BULKMotorized Pulleys, offering the world’slargest product range.

www.rulmecacorp.comwww.precismeca.ab.ca

Rulmeca Motorized Pulleys: a new name with deep roots

Purpose-built designThe Rulmeca Motorized Pulley has beenspecifically designed for belt conveyors.

Hermetically SealedThe motor, gearbox and bearings arehermetically sealed inside a steel shell.Therefore they are unlikely to fail due toharmful environmental conditions suchas water, dust, grit, chemicals, grease,oil, etc.

Space saving designBecause the drive unit and the bearingsare mounted inside the Motorized Pulleyshell, it requires much less room than anexposed drive. No need for costly extraslike chains, v-belts, couplings, bearings,support structure and special guarding.

SafetyThe Rulmeca Motorized Pulley is one ofthe safest drives available because themotor is completely enclosed and theexternal shafts are always stationary.The only moving external parts are theMotorized Pulley shell and bearing hous-ings.

Low purchasing and installation costThe Rulmeca Motorized Pulley is quiteoften less expensive than exposeddrives because it has fewer parts. There-fore less conveyor design time and partspurchasing costs. It is also much quickerand easier to install - certainly less thana quarter of the time taken to fit anexposed system.

Low maintenance costThe end user also benefits from the Rul-meca Motorized Pulley, because itrequires no maintenance other than therecommended oil change every 10,000operating hours and oil seal change

Features and Benefits of Rulmeca Motorized Pulleysevery 30,000 operating hours. In otherwords, almost 5 years between oilchanges based on an 8-hour/day work-ing week. Synthetic oil can be specifiedto extend the oil service life up to 30,000operating hours.

EfficiencyThe Rulmeca Motorized Pulley usuallyhas a much higher efficiency from elec-trical motor to shell (Pulley face) thanexposed drives, because it has fewerfrictional losses. Therefore, efficienciesof up to 97% can be achieved.

CleanlinessBecause the Rulmeca Motorized Pulleyis hermetically sealed it cannot contami-nate any conveying materials such asfood, electrical components, plastics andother materials that must be kept per-fectly clean during handling.

Aesthetic appearanceIf installed correctly the Rulmeca Motor-ized Pulley always looks good. Due to itscompact size and smooth lines, theMotorized Pulley is out of sight, because itis hidden within the conveyor frame.

Thermal protectionAll three phase Rulmeca Motorized Pul-leys are protected by our thermal protec-tion switches. These heat-sensitiveswitches are built into the motor wind-ings to protect the motor from overheat-ing. The thermal protectors must be con-nected to a normally closed control cir-cuit in order to protect the motor.

Weight saving and distributionThe Rulmeca Motorized Pulley is oftenlighter than exposed drives. It is possi-ble to reduce the weight and cost of theconveyor structure, because the convey-

or drive weight is evenly distributed with-in the conveyor frame.

Variable frequency drive All Rulmeca Motorized Pulleys with 3phase motors are easily controlled byvariable frequency drives working in the12 Hz to 66 Hz frequency range. SeeTechnical Precautions in the catalogue.

Fewer parts A Rulmeca Motorized Pulley consists ofthe Motorized Pulley and two fixingbrackets! Exposed drives can require upto eight or more separate components,most of which have to be purchasedfrom different suppliers or custom manu-factured.

Low noiseThanks to the totally sealed enclosureand high quality gears the RulmecaMotorized Pulley runs almost at a whis-per – a very important fact in today’smodern factory environments.

The Rulmeca Motorized Pulley – theideal drive unit for conveyors “Fit itand forget it!”



The Rulmeca Motorized Pulley was firstproduced in 1953 specifically for use onconveyor belt applications.

Until recently it was known as the JOKIMotorized Pulley or JOKI drum motor.

The objective was to produce a compact,hermetically sealed, highly efficient con-veyor drive unit that would be unaffectedby dust, water, oil, grease or other harm-ful substances. A Motorized Pulley thatwould be quick and simple to install andrequire virtually no maintenance.

The Rulmeca Motorized Pulley achievedthis objective and today is considered tobe one of the most reliable, effective andsafe conveyor drive systems availablethroughout the world.

The Rulmeca Motorized Pulley is a high-ly efficient geared motor drive, which ishermetically sealed within a steel cylin-drical shell.

The shell, which is normally crowned toensure belt tracking, is fitted with bearinghousings incorporating precision bear-ings and double lipped oils seals androtates on a pair of fixed shafts.

The motor stator is fixed to the shaftsand the motor winding cables passthrough one of the shafts, eliminating theneed for slip rings and brushes.

General DescriptionThe squirrel cage induction motor, man-ufactured in steel laminate, is machinedconcentric to high tolerances anddesigned to give 200% starting torque for3 phase versions.

The rotor pinion is coupled directly to thegearbox.

The gearbox transmits torque to the shellthrough a geared rim and allows very lit-tle frictional torque loss.

The Motorized Pulley is filled with oil,which acts as a lubricant and coolant.Heat is dissipated through the shell andconveyor belt.

All vital parts are CNC machined.

The Rulmeca Motorized Pulley is sup-plied as standard with:• Machined mild steel crowned shell.• Electric motor manufactured in accor-

dance with IEC 34-1 (EN60034-1),(VDE 0530).

• Class F insulation according to IEC 34-1 (EN60034-1), (VDE 0530).

• Most international voltages. • Standard voltages supplied with +/-

10% tolerance in accordance with IEC38.

• Factory oil filled and tested.• Degree of protect ion IP66/67

(EN60034-5).

Rulmeca Motorized Pulleys are manu-factured according to the Council Direc-tives of the European Communities.

The CE-marking is according to Direc-tive 73/23/EEC relating to electricalequipment and according to Directive89/336EEC relating to electrical magnet-ic compatibility and amendments.


Head Pulley Drive (Above Horizontal Mounting Surface)Typical “head pulley drive position” on sinter conveyor at Chicago area steelmill. Two bolts secure each mounting bracket to top of the horizontal struc-tural surface. This model 630M (24.8” diameter) 30 HP Motorized Pulleydrives the 48” wide belt at 384 FPM. Note that two cables enter terminal boxthrough separate fittings. Power cable connects pulley’s motor to460V/3ph/60 Hz plant supply and control cable connects pulley’s internalthermal protection switches to 115V/1ph/60 Hz normally-closed control cir-cuit. Note that this 2,000 lb Motorized Pulley is fitted with lifting lugs. Photoalso shows jacking screw used to facilitate pulley alignment.

Technical Precaution: Always mount motorized pulley with “UP” directionoriented according to installation instructions (see page 82.)

Center Pulley Drive (On Fixed Vertical Mounting Surface)Photo shows one of two 150 HP Rulmeca Motorized Pulleys in “center driveposition” on two mile long overland conveyor at Lafarge’s Mountsorrel Quar-ry. Transferring granite on the 48” wide belt at various rates up to 2,000TPH, the two Motorized Pulleys are driven by synchronized ABB variablefrequency drives. Two bolts (with locking nuts) secure each mounting brack-et to side of the vertical structural surface. The two drives are mountedbeneath the conveyor belt, 50 feet apart and have an automatic belt take-upsystem operating between them. The Motorized Pulley’s compactness sim-plified the 2006 system upgrade.

Tail Pulley Drive (On Movable Vertical Mounting Surface)TAKRAF mobile crusher uses model 630M 50 HP Rulmeca Motorized Pul-ley in “tail drive position” to move limestone on 100 foot long cantilevereddischarge conveyor at German limestone quarry. Choosing tail rather thanhead drive position enabled designers to avoid suspending the 2,000 lb con-veyor drive unit at the tip of the cantilever. Compact Motorized Pulley easi-ly fit within the expanding bracket-type jacking screw belt take-up.

Technical Precaution: When mounting a motorized pulley in a screw take-up always make sure that pulley centerline is perpendicular to belt center-line to avoid overstressing internal bearings. Also make sure to provide a“festoon loop” in the power cord so that Motorized Pulley will have enoughtravel distance to accommodate normal belt stretch.

Center Pulley Drive (Below Horizontal Mounting Surface)Located in “center drive position” beneath bucket wheel reclaimer boomconveyor at Lake Superior taconite ship loading facility, model 800H 120 HPMotorized Pulley drives boom conveyor belt at 768 FPM. Two bolts (withlocking nuts) secure each mounting bracket to bottom of the horizontalstructural surface. Note two jib keys used to transfer drive torque from shaftto mounting bracket. The 54” wide boom conveyor transfers taconite pelletsfrom boom tip receiving chute to the cantilevered tail conveyor.

Technical Precaution: Always mount motorized pulleys so that 100% of beltforce presses against shoulder or base of mounting brackets (see page 82-83.)

Motorized PulleyMounting Orientations


Motorized PulleysDual Drive Concept

Bucket Wheel Reclaimer for taconite pelletsLocated in “center drive position” beneath a 4,000 TPH bucket wheelreclaimer tail conveyor at Lake Superior taconite ship loading facility, twomodel 800H 120 HP Motorized Pulleys drive discharge belt at 768 FPM.Since the 2004 reclaimer upgrade, each Motorized Pulley is powered by460V/3ph/60 Hz directly by the on-board diesel electric generator. Motorsynchronization was not necessary on either this reclaimer or its two sistermachines at the terminal.

Technical Precaution: Always mount motorized pulley with “UP” directionoriented according to installation instructions.

Suspended Construction Conveyor for wet concreteOne of four 150 foot long “dual drive” conveyors suspended from construc-tion cranes to pour wet concrete during Sesam River Dam construction inSoutheast Asia. During the five year project each conveyor was driven atthe head and tail by a model 800H 50 HP Rulmeca Motorized Pulley.

Overland Conveyor for graniteOne of two 150 HP Rulmeca Motorized Pulleys on two mile long overlandconveyor at Lafarge’s Mountsorrel Quarry in “center drive position.” The twoMotorized Pulleys are driven by synchronized ABB variable frequencydrives (VFDs), transferring granite on the 48” wide belt at various rates upto 2,000 TPH. The VFDs: (1.) provide a “soft start” feature, (2.) enable thetwo drives to “talk” and keep rotor speeds synchronized, and (3.) conservepower by linking to load sensors and optimizing belt speed according tomeasured conveyor throughput.

Technical Precaution: When using a VFD always restrict frequencies tobetween 12 Hz to 66 Hz and install a filter on the VFD output if it is locatedmore than 30 feet from the Motorized Pulley (see page 86.)

Reversing Shuttle Conveyor for crushed graniteOne of two 31.5” diameter 50 HP Motorized Pulleys, one on north end andone on south end, driving reversing shuttle conveyor at Lafarge’s Mountsor-rel granite quarry since 1998. Photo shows stone discharging from 600FPM belt at 2,500 TPH. Changing from a “single drive” to a “dual drive”arrangement can reduce slack-side belt tension (T2) to 20%. This willreduce maximum belt tension (T1) and can significantly extend conveyor beltlife because it provides 360 degrees of belt wrap around pulleys (180degrees per Motorized Pulley), without the use of “dirty side” snub pulleys.

Technical Precaution: When using Motorized Pulleys in reversing applica-tion, always bring conveyor to complete stop before starting belt in oppositedirection (see page 84-85.)


ORDERING* INFORMATIONMotorized Pulleys

Belt Speed (fpm)

1012141824303848607696

120150192240300384480600768960

1064

Lagging Material

black rubber, diamond patternblack rubber, smooth patternwhite rubber, smooth patternred ceramic bonded to pulley shellgreen ceramic vulcanized into rubber

Lagging Bond

cold bondedhot vulcanized

Lagging Thickness

1/8 inch1/4 inch5/16 inch3/8 inch1/2 inch

Type of Oil

standardsyntheticfood grade

Motor Insulation

class F (standard)class H

Type of Crown

center crowntrapezoidal crownno crown

Mounting Brackets

standard paintnickel platednone

Type of Holdback

mech. backstop, clockwisemech. backstop, counterclockwiseinternal brakeexternal brake shaft

Type of Seals

standardregreasable

Material & Surface Finish

mild steel, standard painttotal stainless steelsemi-rust free

Other Special Options

vertical mountnon-horizontal mountCSA approved motordust explosion proof (per ATEX 95,Zone 22)

Diameter(in)

5.456.498.50

12.6415.9119.7224.8031.50

Voltage

208v230v380v460v575v

Phase &Frequency

3ph/60Hz3ph/50Hz1ph/60Hz1ph/50Hz

RollerLength (in)

11.8112.6013.7815.7517.7219.6921.6523.6225.5927.5629.5331.5033.4635.4337.4039.3741.3443.3145.2847.2449.2151.1853.1555.1257.0959.0661.0262.9964.9666.9368.9070.8772.8374.8076.7778.74Other

_______

Power (HP)

0.130.150.250.330.500.751.01.52.03.04.05.57.5101520253040506175

100122150180

Termination (select one)

standard box, standard paintstandard box, food grade paintstandard box, unpainted compact box, unpaintedcompact box. stainless steelpower cord, elbow connectorpower cord, stan. straight connectorpower cord, SS straight connector

Power Cord (if applicable)

4 ft, standard insulation4 ft, screened10 ft, standard insulation10 ft, screened

Contact Person ____________________________ Date ______________ Ref # ________________Company __________________________________________________________________________ Address ___________________________________________________________________________Phone _______________________ Fax ______________________ Email _____________________

Quantity _____ Motorized Pulley(s)Quantity _____ Idler Pulley(s)Special Comments: ___________________________________________________________________________________________________________________________________________

* Note that this form displays all powers, speeds, and options available from Rulmeca. Some combinations are unavailable (e.g.100 HP is not available in 12.64” diameter.) For interactive ordering sheet go to www.rulmecacorp.com.

Documents

Table of Contents - Motorized Pulleys & Belt Conveyor Rollers · tle frictional torque loss. The Motorized Pulley is filled with oil, which acts as a lubricant and coolant. Heat is