Description
FA Series — Flange-Output Double Worm Gear Reducer
The FA Series takes the proven double-stage WP worm gear train and packages the output behind a square machined flange, allowing the reducer to bolt directly onto pumps, fans, clarifier rakes, and any driven machine with a mating flange interface. This close-coupled arrangement eliminates the base plate, flexible coupling, and alignment ritual that a foot-mounted output demands, saving both capital cost and ongoing maintenance hours. Five frame combinations (WP40–70 through WP155–250) with ratios from 200:1 to 900:1 deliver output torques up to 6,050 N·m. Dual self-locking worm stages hold the output in position when the motor stops, and the foot-mounted input connects to the motor through a coupling or belt for maximum layout flexibility.
Where Flange Output Adds Value
Pump and Fan Drives
Vertical and horizontal centrifugal pumps from Sulzer, KSB, and Grundfos, as well as large industrial fans from Howden and TLT-Turbo, use flange-mounted inputs on their drive pedestals. The FA bolts directly to these flanges, creating a rigid, self-aligning connection that transmits torque without radial offset. This is mechanically superior to a foot-mounted reducer with a flexible coupling, particularly where vibration and misalignment cause premature coupling wear. Frame combinations WP80–135 and WP120–175 cover the power and torque range most medium-duty industrial gearbox pump applications require.
Clarifier and Thickener Rakes
Water- and wastewater-treatment clarifiers use slow-speed rake drives to sweep settled sludge toward the discharge cone. An FA at 600:1 or 900:1 produces the 1–3 r/min output these rakes need, and the flange connects directly to the centre-column drive housing. The self-locking worm gearbox property holds the rake stationary during maintenance, preventing free rotation under the weight of sludge on the blades.
Square-flange output and foot-mounted input layout
Technical Data
All values measured at 1,500 r/min input under continuous duty. The FA uses the same WP-platform gear pairs, bearings, and alloys as the entire double-stage range. Output flange bolt circles follow IEC/GB standards and are noted in the frame-specific dimension sheet. contact us with your frame combo for full drawings.
| Frame Combo | Motor (kW) | Ratios | Torque at 300:1 (N·m) | Peak Torque (N·m) |
|---|---|---|---|---|
| WP40–70 | 0.12 – 0.48 | 200:1 – 900:1 | 88 | 250 |
| WP60–100 | 0.37 – 0.95 | 200:1 – 900:1 | 276 | 500 |
| WP80–135 | 1.5 – 2.5 | 200:1 – 900:1 | 880 | 1,400 |
| WP120–175 | 2.2 – 5.09 | 200:1 – 900:1 | 2,340 | 3,050 |
| WP155–250 | 5.5 – 11.71 | 200:1 – 900:1 | 4,087 | 6,050 |
Construction Highlights
The FA pairs a first-stage and second-stage grey cast-iron housing, with the second-stage output face machined to a square-flange profile rather than the foot-pad layout used on the EA. The flange face is surface-ground to a flatness tolerance of 0.05 mm, ensuring flush mating with the driven machine bracket. All internal components — worm shafts, bronze wheels, tapered roller bearings, and NBR shaft seals — are identical to the EA, EDA, and EO variants, maintaining full parts interchangeability within the speed reducer gearbox platform. The input side is a bare shaft with keyway, supported on tapered roller bearings, accepting a coupling, pulley, or chain sprocket.
Components and Spare Parts
Every major component inside this reducer is available as an individual spare part, so a worn gear set or leaking seal never means replacing the entire unit. Our spare-parts inventory covers the full WP-platform range and ships from our Condell Park, NSW warehouse. The FA shares its full internal parts catalogue with the EA, EDA, and EO double-stage models. Each stage draws from the same worm-pair, bearing, and seal inventory as the corresponding single-stage frame size.
Worm Shaft
Case-hardened 20CrMnTi alloy steel, thread-ground to Ra 0.8 μm finish
Worm Wheel
Centrifugally cast ZCuSn10Pb1 tin-bronze, hobbed full-depth involute profile
Bearings
Tapered roller bearings handling combined radial and axial loads on both shafts
Seal & Gasket Kit
Double-lipped NBR oil seals, housing gaskets, breather plugs, and O-rings
Individual components available for order: worm shaft, bronze wheel, bearings, and seal kits
Oil and Service Schedule
Fill both stages with ISO VG 220–320 EP mineral gear oil for ambient temperatures up to 40 °C. Synthetic ISO VG 220 (Mobil SHC 630, Shell Omala S4 GX 220) is recommended for continuous duty above six hours. First oil change at 100 hours; thereafter every 2,000 hours or annually. When the flange output faces downward (e.g. on a vertical pump), verify the second-stage oil level covers the entire worm-wheel tooth zone to prevent dry-running the upper teeth.
Customer Reviews
The flange output was the deciding factor. We bolted the FA directly to our vertical pump housing without any adapter plate. Alignment was spot-on out of the box. Twelve months in, zero issues.
Nathan Price
Lead Engineer, Pump Manufacturer
Reliable performance on our clarifier rake drive. The flange-mount arrangement keeps the reducer close-coupled to the drive pinion, which reduced vibration compared with our old foot-mounted setup.
Karen Hughes
Maintenance Planner, Municipal Water
We spec the FA for bucket-elevator head drives on several projects. The flange interface eliminates the coupling and two bearing housings, cutting installation time by roughly 40 percent.
Steve Kim
Applications Engineer, Material Handling
Ever-Power Australia — Your Local Supplier
We stock FA frame combinations and all matching spare parts at our Condell Park, NSW facility. ISO 9001-certified, factory-tested, and backed by Sydney-based engineering support. We also supply FGV035 compact aluminium worm gearbox for light-duty OEM equipment drives. Call +61 2 9708 3322 or email [email protected] for pricing and lead times.
Final inspection and export packing
