Home

HDP serie

Contents

1. 13 64 IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 Bonfiglioli Riduttori 43 STORAGE Place the gear unit gearmotor on stable base and make sure that there is no risk of it moving or falling off The following recommendations should be followed when storing the gear unit gearmotor 1 Do not store the unit in excessively humid conditions or where it is exposed to the weather i e outdoors 2 Avoid excessive variations in temperature as this can cause condensation inside the gear unit and its accessories 3 Do not place the gear unit directly on the ground 4 Store the packaged gear unit if allowed in accordance with the instructions on the packaging itself If the gear unit gearmotor is stored temporarily outdoors it must be protected to ensure that humidity and foreign matters cannot penetrate to the interior If gear units and accessories are to be stored for periods under 6 months if required fill them with oil to the right level see the LUBRICATION section in this manual and run them at regular intervals at least once every 4 weeks for at least 1 hour following all the requirements given in this manual If
2. 60 2 HDP 702 C Filler plug with air vent T Blank plug L Level plug No plug present S Drain plug L Overflow level plug Bonfiglioli 42164 IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 pong C Filler plug with air vent T Blank plug L Level plug No plug present S Drain plug L Overflow level plug 7 T 57 Bonfiglioli T EU Riduttori IOM Manual HDP_gb Translation of original instructions in Italian Rev 0 27 07 11 43164 ep por rs wo s zs n so 0 gt nor 02 s o s n n so s sos orsa as vo n ze er sso es HDP 100 3 110 3 HDP 1203 Excluding D
3. 63 Revisions The revision list for this manual is given on page 64 The most recent versions of this manual are available at www bonfiglioli com 2 64 IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 Bonfiglioli Riduttori 1 1 1 2 GENERAL INFORMATION PURPOSE OF THIS MANUAL This Manufacturer s manual provides information regarding the safe transport handling installation maintenance repair disassembly and disposal of the gear unit gearmotor All purchasing and design information is given in the sales catalogue As well as adhering to good engineering practices read the information in this manual carefully and apply it rigorously Information about the motor used with the gear unit must be obtained directly from the motor s own installation operation and maintenance manual Failure to observe the information provided herein may result in risk to personal health and safety as well as damage to equipment This information provided in the Manufacturer s original language Italian may also be made available in other languages to meet legal and commercial requirements The documentation must be stored by a person charged to do so in a suitable location so as to be always available in good condition for consultation In case of loss or damage replacement documentation must be requested directly from the Manufacturer quoting the code of this manual The manual ref
4. In the presence of accessories optional variants it is strictly forbidden to use any accessory for any purpose other than that specified in the contract of supply fill any accessory with lubricants other than those recommended permitted use any accessory as a support or mounting surface use any accessory as an attachment point for the handling or transport of the gear unit gearmotor modify any accessory in any way loosen and or remove any component pipe fitting flange control device etc while the system is functioning and or under pressure fail to respect the requirements affixed to any accessory and or to the gear unit gearmotor or remove cover or render illegible any labels start up any accessory without any relevant guards in place and functional start up any accessory if damaged All work on any accessory must be performed by qualified personnel who have a thorough knowledge of the instructions and technical specifications for the product and who are authorised to perform such work by the safety supervisor It is the responsibility of the manufacturer or assembler of the machine in which these gear units are incorporated to ensure the safety of that machine as a whole and its conformity to all relevant end product directives Parts of accessories may be electrically live or in motion The removal of electrical or mechanical guards improper use or inadequate maintenance may therefore lead to serious
5. 6 MAINTENANCE uu e 51 6 1 CHECKING OPERATIONAL EFFIGCIENQGY 2 U u nenen ennenen 52 6 2 ROUTINE MAINTENANCE coni sea aia rarai 52 6 2 1 MAINTENANCE OF AUTONOMOUS COOLING UNITS optional variant MCRW MCRA u l ieiuno eranc te oki nne 54 6 3 CHECKING THE OIL LEVEL 6 4 lt OIL CHANGES ERR 6 5 GLEANING lll ULU US III S asas assia ak sss aandae i nri OST aadis esada akain isandaan 56 dde l M eed 57 7 1 REMOVAL OF MOTOR WITH IEC STANDARD FLANGE optional variant AD E E US u u EEE au 57 7 2 DISASSEMBLING A GEAR UNIT EQUIPPED WITH HOLLOW OUTPUT SHAFT WITH KEYWAY RENS 58 7 3 DISASSEMBLING A GEAR UNIT EQUIPPED WITH HOLLOW OUTPUT SHAFT AND SHRINK DISC COUPLING 8 TROUBLESHOOTING For the user For the disposer 9 1 Gear units 5nd reote cessa sa sabre aac CE ane ESSEN ENTRE a TUBE E AST OE 8 2 Autonomous control units u u uu LLULLU cuv oan sas as wass as asi CEU cR a a RR Rada cR rev ARNAR DRE Y RR RR Rcg 61 9 DISPOSING OF THE GEAR UNIT kenn annua sans aane
6. 32 5 4 6 SEALS AND GASKETS optional variant VS DS DVS 33 5 4 7 SENSORS optional variant TG OLG 33 2 5 4 8 DRYWELL optional variant DW UU II tnnt 35 5 5 4 9 ANCHORING OF TORQUE ARM optional variant TA eese 35 5 4 10 lt OTHER ACCESSORIES ccc scccccssacsssssssessscesessnscesascaescsesserscacenesrsensesccescashuoasaausaeounouasesacssesensansdacceuones 37 5 5 qu 37 5 6 LUBRICATION m O 38 5 6 1 PolyAlkylene Glycol PAG synthetic oils nenen 39 5 6 2 PolyAlphaOlefin PAO synthetic oils U enne nnne 40 5 6 3 Mineral oil with EP Extreme Pressure additives eese 40 5 6 4 Compatible greases 41 5 6 5 Quantity Of lubricant I U u 41 5 6 6 5 PIUGS e 42 5 7 PREPARING CUSTOMER SHAFTS I uuu 47 5 8 STARTING UP THE GEAR UNIT II II a aa usa 5 8 1 Starting up autonomous control units MCRW MCRA Bonfiglioli IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 1 64 INSTALLATION OPERATION AND MAINTENANCE MANUAL
7. painted with an epoxy primer and then externally finished with a coat of epoxy enamel The total thickness of the paint is 130 180 um If the gear unit is to be painted protect the nameplate and seal rings against contact with solvent Bonfiglioli Riduttori IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 37164 LUBRICATION Before operating the gear unit check the oil level As with filling this operation must be done with the gear unit in the mounting position in which it will be used in the application If necessary fill or top up the lubricant to the half way point in the level window to the reference notch on the dipstick or until it starts to flow out of the plug hole The lubricant utilised must be new and uncontaminated and can be poured in through the filler hole or from the inspection cover opening using a filler filter with 25 um mesh ensuring that the relative gasket is refitted without damaging it or reapplying the sealant to provide a perfectly oil tight fit The oil level must never be below the minimum mark and must be checked periodically with the gear unit at a standstill after allowing it to cool for a short period Do not mix oils of different makes or specifications and check that the oil is highly resistant to foaming and is EP Extreme Pressure rated If you do not have the same type of oil completely drain the gear unit and flush it out thoroughly
8. blue Power supply 28 V AC Degree of protection IP 65 Threaded fitting GAS 1 2 M 5 4 7 3 Minimum pressure switch The minimum pressure switch used with forced lubrication see optional variants OP MOP MCRW MCRA and refer to the AUXILIARY THERMAL DEVICES and LUBRICATION SYSTEM sections in this manual provides an alarm signal if pressure in the lubrication system falls below the minimum permissible value of 0 5 bar The output of the pressure switch must be bypassed for a brief period approx 30 seconds immediately after start up while the oil starts to circulate Do not modify the pressure switch trip setting with the adjuster screw at the top of the device Electrical connections and or cabling to user points are the responsibility of the Customer and must be completed prior to start up Contact type SPDT changeover contact Common NC Normally closed NO Normally open Ground Terminal faston 6 3x0 8 The position of the contacts is purely indicative Contact current rating 5 A resistive 240 V AC 2 A resistive 24 V DC Degree of protection IP 65 with connector fitted Bonfiglioli 34 64 IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 pong 5 4 8 DRYWELL optional variant DW The drywell device prevents oil leaking from the gear unit s output shaft seals into the driven machine It consists of a grease filled chamb
9. f the unit is to be serviced in a poorly lit area use additional lamps and ensure that the work is done in compliance with the safety requirements of established legislation During operational testing at the Manufacturer s premises the acoustic pressure measured under full load at a distance of 1 m from the unit and 1 6 m above ground level without vibration was less than 85 dB A The gear unit is a quasi machine The constructor of the plant or machine in which the gear unit is installed must therefore measure the level of noise emitted by the machine as required by the Machinery Directive 200 42 EC The vibrations produced by the gear unit do not constitute a health risk for personnel Excessive vibration may be the result of a fault which should be immediately reported and eliminated Unless they have backstop devices gear units may reverse direction If there is any risk of uncontrolled movement occurring in the event of a power failure for example in load lifting applications measures must be put in place to prevent such movement occurring for example by using motors with brakes that engage automatically if the power fails If the gear unit is installed in a position that cannot be reached from the floor the constructor of the plant or machine in which it is installed must provide as necessary suitable means for accessing a position from which the gear unit can be serviced Bonfiglioli Riduttori IOM Manual HDP_gb
10. 2 Bonfiglioli Riduttori HDP serie Installation Operation and Maintenance Manual GD Bonfiglioli ontrol and gre INSTALLATION OPERATION AND MAINTENANCE MANUAL 1 GENERAL INFORMATIQN riore oro one eevee caved cca a een 3 1 1 PURPOSE OF THIS MANUALLA I 3 1 2 GEOSSARY TERMS AND SYNBOLS u u uu ertt etna u u 3 1 3 REQUESTING TECHNICAL ASSISTANCE sese ereenn 4 1 4 MANUFACTURER S LIABILITY 1 5 SUPPLEMENTARY INFORMATION 4 2 SAFETY INFORMATION rhon uuu tenant v bna d aa anh ara dana aeu iran 5 2 1 5 STANDAR DIlm 5 3 TECHNICAL INFORMATION 8 3 1 EQUIPMENT IDENTIFICATION 8 3 2 DESCRIPTION OF THE EQUIPMENT U U 8 3 3 CONFORMITY 9 3 4 OPERATING LIMITS AND CONDITIONS esee u uu u 9 4 HANDLING AND TRANSPORT 10 4 1 PACKAGING SPECIFICATIONS eese nennen nnne uuu 10
11. 280 230 1 12 0 65 CRA 34 1 55 CLF IP55 57280 1447 B35 CUS 265 460 60 18 300 1 10 0 63 BN 100LA 4 230 400 Logn 230 1 12 0 65 ajo MCRA 51 IP55 CLF 55 37280 112 1 12 aan 265460 60 25 51 300 1 10 0 63 1 For different mains frequencies contact the Manufacturer s Technical Service 2 Nominal flow rate may vary as a function of oil type and functioning temperature 24164 Bonfiglioli IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 Riduttori 5 4 1 2 3 Installing autonomous control units MCRW MCRA Check that the actual mains power mounting and service conditions correspond to those declared on the name plates of the components and or specified in this manual Electric motors must rotate in the direction shown on the components Make sure that all electrical power cables are big enough to carry the current draw and suitable for the installation conditions Inadequate cables can cause overheating and or voltage drops Information about the pump s motor must be obtained directly from the motor s own sales catalogue or installation operation and maintenance manual For all other devices see the SENSORS section in this manual Wiring and connections must permit a functioning logic suited to the functionalities of the control unit as described in the following section MCRW Connections to the solenoi
12. 320 460 Alphasyn PG 220 Alphasyn PG 320 Q TOTAL E Recommended use Permitted use The Manufacturer cannot guarantee the quality or suitability of lubricants Characteristics must be verified directly with the manufacturer of the chosen lubricant Bonfiglioli Riduttori IOM Manual b Translation of original instructions in Italian Rev 0 27 07 11 5 6 2 PolyAlphaOlefin PAO synthetic oils 5 6 3 HDP 60 HDP 160 Omala S4 GX 220 Omala S4 GX 320 Kl bersynth GEM2 150 220 320 460 SHC XMP 220 320 Mobigear SHC 630 692 SHC 630 632 Mobil SHC Cibus 320 460 USDA H1 Degol PAS 220 l Recommended use F Food grade Permitted use The Manufacturer cannot guarantee the quality or suitability of lubricants Characteristics must be verified directly with the manufacturer of the chosen lubricant Mineral oil with EP Extreme Pressure additives HDP 60 HDP 160 Omala S2 G 220 320 460 Blasia 220 320 460 Kl beroil GEM1 220 320 460 Mobil XMP 220 320 Mobil 600 XP 220 320 Permitted use The Manufacturer cannot guarantee the quality or suitability of lubricants Characteristics must be verified directly with the manufacturer of the chosen lubricant Refer to the individual sales catalogue for lubricant viscosity 40 64 Bonfiglioli Manual gb Translation of original instructio
13. 4 2 HANDEING INSTRUCTIONS ie pete pases aa ss cauaa 11 4 21 Moving the DacKagges n nnnc nte ene rient dete 11 4 2 2 Moving equipment U u uu u u u LULU resnas sss massae Pana 11 4 3 STORAGE S SINSTAEPATION inician tete etie atre erui gah cued ree IE 15 5 1 INSTALLING THE GEAR nner 15 5 1 1 Gear units with solid output shafts U u eene enen ennenen nenen 17 5 1 2 Gear units with hollow output shafts with keyway I nennen nnne 18 5 1 3 Gear units with shrink disc 5 2 INSTALLING A MOTOR WITH AN IEC STANDARD FLANGE optional variant AD GL GR 19 5 3 INSTALLING CONNECTING ELEMENTS 20 5 4 ACCESSORIES AND OPTIONAL 21 5 4 1 AUXILIARY COOLING HEATING SYSTEMS optional variant FANL FANR FANLR MCRW MCRA SR 21 General information 5 4 2 LUBRICATION SYSTEM optional variant OP OP1 OP2 MOP 28 5 4 3 BACKSTOP DEVICE optional variant CW A CCW eee ereer 30 5 4 4 GEAR UNIT WITH FIXING FLANGE optional variant F L 31 5 4 5 GEAR UNIT WITH SLEEVE FLANGE optional variant
14. Translation of original instructions in Italian Rev 0 27 07 11 5 64 The user is responsible for using the products recommended for the installation and maintenance of the gear unit in an appropriate manner and in accordance with the Manufacturer s instructions Before putting the gear unit into service the user must ensure that the plant in which it is installed complies with all applicable directives especially those regarding health and safety at work The constructor of the plant or machine in which the gear unit gearmotor is installed must protect all rotating parts to prevent persons coming into accidental contact and incurring a risk of crushing cutting or entanglement especially if the gear unit operates automatically and in an accessible area Do not use high pressure jets of water to clean the unit All work must be performed exclusively with the gear unit at a standstill The motor must be protected against accidental startup e g by padlocking the main power switch removing the power fuses For this purpose also affix a notice to the motor indicating that work is in progress on the gear unit Do not perform welding work on the gear unit The gear unit cannot be used as an earthing post for welding operations because this could damage or destroy parts of the gear teeth and bearings The motor must be disconnected immediately if any alterations in the normal operation of the gear unit are noted when it
15. gear unit is equipped with an autonomous control unit also follow the instructions given below during start up Unless stated otherwise the requirements and specifications given below are valid even if non standard control devices have been supplied with the gear unit instead of the standard ones described in this manual Perform regular checks during functioning to identify any malfunctions or problems as early as possible Under operating conditions take care to avoid all contact including accidental contact with the surfaces of the heat exchanger which can reach high temperatures Case 1 Functionality cooling with oil water heat exchanger MCRW once the gear unit has started and the oil has reached a temperature of 60 the control thermostat must give the signal to start the electric pump and open the water supply solenoid valve when oil temperature reaches 90 the maximum temperature thermostat must activate an alarm and stop the gear unit as soon as possible Bonfiglioli Riduttori IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 49 64 Cooling with heat exchanger MCRA once the gear unit has started start the control unit in compliance with the requirements of the OPERATING LIMITS AND CONDITIONS section in this manual to avoid the fan running continuously even when not needed its motor can be controlled to run over a range of tempe
16. in the table below tab 13 Lubrication interval h t C Synthetic oil Mineral oil Oil temperature 65 lt t lt 80 15000 4000 80 lt t lt 95 12500 2000 Bonfiglioli 52164 IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 tab 14 Frequency Inspection parameter 300 h first oil change after commissioning see table subsequent oil changes oil temperature bearing temperature 170h 720h gear unit external conditions fouling oil deposits 24h 24h 24h 24h 720h oil leaks external seals and gaskets 2200 h vent filter 2000 h 4000 h check tightness of the fixing bolts connecting flanges and drive transmission components 2000 h 4000 h check the elastic elements in all joints for wear 3000 h check cup springs for wear and adjust the torque arm 3000 h condition of torque arm polymer bushes aging cracking 2000 h 9000 h condition of gear unit oil possible presence of contaminants especially water 720h oil filter contamination indicator 2000 h 4000 h regrease the Drywell device bearings and seals where required 9000 h 18000 h internal cleanliness of the cooling coil and water oil heat exchanger possible presence of deposits 9000 h 18000 h alignment of gear unit shafts with respect to coupled machine shafts at every general internal functioning conditions of gear unit lubrication devices and or oil change oil coolin
17. injury or damage Bonfiglioli e CEN Riduttori IOM Manual _ Translation of original instructions in Italian Rev 0 27 07 11 7164 3 3 1 3 2 TECHNICAL INFORMATION EQUIPMENT IDENTIFICATION The gear unit bears the following identifying name plate The name plate provides all references and indispensable instructions for safe use The gear unit s identifying code is explained in the sales catalogue If the gear unit is supplied fitted with a motor gearmotor all information regarding the motor itself is supplied in the motor s own manual Name plate information Gear unit type Optional variants Product code ________ option diio LL Month Year of manufacture Transmission ratio Rated torque at output shaft mount 1400 rpm ________ Mounting position Rated power at input shaft Approximate quantity of lubricant Weight Notes Name of Manufacturer Readability of the name plate The name plate and the information thereon must be kept readable The plate should therefore be cleaned from time to time Should the name plate wear and or become damaged so as to compromise its readability or that of even one of the items of information thereon the user must request a new name plate from the Manufacturer quoting the information given in this manual to replace the old one DESCRIPTION OF THE
18. is running such as an abnormal increase in operating temperature or abnormal running noise f the gear unit is to be installed in a plant or machine the manufacturer of said plant or machine is required to include the prescriptions instructions and descriptions contained in this manual in its own operating manual f the gear unit is installed in situations that are particularly hazardous to personal safety or that could cause serious damage to equipment or that involve high inertial loads vibrations etc such as suspended installations motors supported exclusively by the gear unit low speed shaft with shrink disc oriented downwards install suitable safety devices such as harnesses safety chains and restraining systems etc Depending on the operating conditions the outer surfaces of the gear unit may reach very high temperatures Serious burns hazard When draining out spent oil at the time of an oil change beware of the risk of serious burns caused by hot oil In the presence of a vent plug with relief valve wait for the oil in the gear unit to cool before opening the plug and pay attention to possible jets of oil during transportation lifting installation adjustment operation cleaning maintenance repair dismantling and scrapping Wait for the gear unit to cool before inspecting it Bonfiglioli 6 64 IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11
19. maintenance schedule only authorise trained operators to inspect and service the unit the configurations given in the gear unit catalogue are the only permitted ones do not attempt to use the unit in any other way the instructions given in this manual do not substitute but rather supplement the provisions of established safety legislation SUPPLEMENTARY INFORMATION Additional information about the gear units described in this manual can be obtained from the sales catalogues available on the website www bonfiglioli com HDP Series parallel shaft gear units Code 1920 Bonfiglioli IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 Riduttori 21 SAFETY INFORMATION SAFETY STANDARDS Carefully read the instructions given in this manual and those printed directly on the gear unit especially those regarding safety Use the gear unit only for the applications specified by the Manufacturer Improper use can result in risks to personal health and safety and damage to equipment Persons charged with working on the gear unit at any time during its service life must be trained specifically for the purpose must possess the necessary specific skills and experience and must also be equipped with and trained to work with the appropriate tools and individual safety equipment as required by the safety legislation applicable in the place where the gear unit gearmotor is inst
20. of forced lubrication if the circuit components such as the connecting pipelines and pump etc are exposed to freezing temperatures they too must be equipped with a heating system to ensure correct oil circulation following startup 5 4 2 LUBRICATION SYSTEM The gear unit s internal parts are usually lubricated with a mixed oil bath and oil splash system In some configurations certain bearings may be grease lubricated and equipped with Nilos seal rings A forced lubrication system can be supplied on request 5 4 2 1 Splash lubrication In gear units with oil splash lubrication the rotation of the gears splashes the lubricant and distributes it to the gear teeth and bearings even in positions above the oil level To guarantee effective lubrication the oil must be sufficiently fluid i e its viscosity must allow it to flow freely while simultaneously maintaining suitable characteristics to support high gear meshing loads In particular special care must be taken in the following conditions and suitable cooling heating systems provided as required applications involving oil temperatures in excess of 95 C starting in situations in which the minimum ambient temperature is less than 10 C higher than the oil s drop point gear unit operation in ambient temperatures below 0 C or above 50 C 5 4 2 2 Forced lubrication The gear unit is equipped with a volumetric pump when forced lubrication of gears and or bearings is required The oi
21. of the extractor Bonfiglioli Riduttori IOM Manual 9 Translation of original instructions in Italian Rev 0 27 07 11 57 64 7 2 DISASSEMBLING A GEAR UNIT EQUIPPED WITH HOLLOW OUTPUT SHAFT WITH KEYWAY Remove the device that secures the gear unit axially The machine s shaft can be extracted directly in situ using a hydraulic device or by using the device shown in the figure below 2 7 6 Dm p qe eu il h w Lo 9 er 1 Machine shaft 2 Hollow output shaft 3 Key not supplied 4 Threaded rod not supplied 5 Bolts not supplied 6 Thrust ring not supplied 7 Torque plate not supplied During the extraction process observe the maximum thrust values specified in the table below and take care to avoid knocks or misalignment tab 15 bud HDP ped pu HDP HDP HDP HDP HDP HDP HDP 100 110 120 130 140 150 160 70 Maximum thrust force 25000 25000 40000 59000 59000 59000 76000 122000 122000 122000 122000 N Bonfiglioli 58 64 IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 pong 1 Bolts not supplied 2 Thrust ring not supplied 3 Circlip not supplied 7 3 DISASSEMBLING A GEAR UNIT EQUIPPED WITH HOLLOW OUTPUT SHAFT AND SHRINK DISC COUPLING Unscrew the fixing bolts gradually one at a time and then remove the sh
22. outer cage around Contact the Manufacturer s Technical Service for information on how to proceed if you wish to change the direction of the backstop device GEAR UNIT WITH FIXING FLANGE optional variant F L F R Thoroughly clean and degrease the flange of the gear unit and the area of the machine to which it is to be coupled Safe torque transmission depends largely on the correct execution of this procedure Do not use solvents or dirty rags to degrease mating surfaces Do not apply any type of grease as this would significantly lower the friction coefficient in the contact area and therefore impair the functionality of the coupling Tighten the bolts fully down working in a crosswise sequence and applying the maximum tightening torque shown in the table below using a torque wrench Thread Screw Nut Tightening torque UNI 5737 UNI 5588 tab 7 Class 10 9 Class 10 1060 Nm Class 10 9 Class 10 1060 Nm HDP 140 HDP150 Contact the Manufacturer s Technical Service HDP 160 Bonfiglioli Riduttori IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 31 64 If the gear unit is installed in situations that are particularly hazardous to personal safety install suitable safety devices such as harnesses safety chains and restraining systems etc 5 4 5 GEAR UNIT WITH SLEEVE FLANGE optional variant FM f Li w Thorough
23. permitted by the Manufacturer are the industrial applications for which the gear unit has been designed Ambient conditions e The permitted ambient temperature range for these gear units is between 20 C and 50 C In ambient temperatures between 20 C and 10 C the gear unit must only be operated normally after the machine has been properly and gradually warmed up or after initial no load operation Load may only be applied to the gear unit s output shaft once the unit s temperature has risen to 10 C or higher The gear unit may not be used in areas and environments with highly corrosive abrasive vapours smoke or dust n direct contact with loose food products Do not use the gear unit gearmotor if not explicitly intended for the purpose in a potentially explosive atmosphere or where the use of explosion proof equipment is specified The following conditions must be borne in mind if the gear unit is equipped with auxiliary cooling units MCRW and MCRA or forced lubrication pumps MOP and OP e permissible ambient temperature 10 C to 50 C e maximum oil pressure 10 bar minimum start up temperature whatever temperature guarantees a minimum oil viscosity of 1500 cSt generally within the range of 5 C to 25 C depending on the type of oil used For precise temperature values refer to the relevant sales catalogue and or product data sheet of the lubricant manufacturer Irrespective of the d
24. prevents reverse movement caused by the load applied to the output shaft The device consists of a free wheel with centrifugal shoes In certain cases the torque transmittable by the backstop device can be limiting with respect to the torque transmitted by the gear unit Consult the sales catalogue for detailed information on this subject Before commissioning the unit ensure that the output shaft can be freely turned in the required direction of travel without having to apply excessive force To avoid damaging the backstop device or the gear train it is essential to prevent the motor from rotating in the wrong direction Under continuous operating conditions it is advisable to maintain a neutral rotation speed greater than that specified in the catalogue in order to ensure the effective centrifugal release of all the shoes and avoid unnecessary wear For further details contact the Manufacturer s Technical Service 30 64 Bonfiglioli IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 Riduttori 5 4 4 The backstop device is keyed to the end of the input shaft opposite the drive side in such a way that it is accessible for inspection and maintenance The device shares the gear unit s own lubrication system The direction of the backstop device can be reversed by turning the device s
25. s ow ws sse mos es X HOP 10 vos 9 ww p L2 M 3 3 M1 UNI 5739 HOP sos ns _ 8 206 zoe ve To facilitate disassembly provide a machine shaft with a hole through which an anti corrosion fluid can be injected 2 or a machine shaft with provision for fitting a bush at the cylindrical guide section opposite the shrink disc 1 In the presence of external thrust loads vibration safety problems requirements for enhanced reliability or unfavourable mounting positions e g V5 mounting positions output shaft directed downwards install suitable devices to secure the shaft in an axial direction and prevent accidental decoupling 48 64 Bonfiglioli IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 Riduttori 5 8 STARTING UP THE GEAR UNIT The gear unit has been factory tested by the Manufacturer Before starting the unit make sure that the machine or part of the machine in which the the gear unit gearmotor is to be installed has been declared to conform to the requirements of the Machinery Directive 2006 42 EC and to any other relevant and applicable safety standards that the gear unit s mounting position in the installation corresponds to that prescribed and indicated on the name plate that the electrical power supply is suitable and
26. the motor Before installing the gear unit 1 Drain out the oil used for storage if it is not the same as the oil used for normal functioning and flush the inside of the gear unit out thoroughly see the LUBRICATION section in this manual 2 Carefully remove all packaging and protective product residues from the gear unit using suitable solvents Take special care over the mating surfaces but avoid getting solvents on the shaft seal rings Check that the data on the name plate correspond to those specified in the order 4 Ensure that the structure in which the gear unit is to be mounted is sufficiently robust and rigid to support its weight and operating stresses 5 Checkthatthe machine in which the gear unitis to be installed is switched off and cannot be accidentally started up 6 Check that all coupling surfaces are flat 7 Check that shaft shaft or shaft bore are perfectly aligned for coupling 8 9 Fit suitable guards to prevent accidental contact with the gear unit s external moving parts If the work environment is corrosive for the gear unit or any of its parts follow the special precautions required for aggressive environments Contact the Manufacturer s sales network for further details 10 We recommend applying a protective paste to all key type couplings Kl berpaste 46 MR 401 or a product with similar properties and application range to ensure optimal coupling and protection against fretting corr
27. thermostat 6 water shut off solenoid valve 7 Bonfiglioli 22164 IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 pong Technical specifications MCRW Frequency of power supply 50 60 Hz 1 tab 3 Control unit BN 71B 6 IP55 MORES CLF B35 CUS Description Tm Tm Duc For different mains frequencies contact Manufacturer s Technical Service S Nominal flow rate may vary as a function of oil type and functioning temperature Filter with element in metal mesh Electric pump Air oil heat exchanger solenoid valve Oil flow Water flow rate Fittings GAS de 3 8 F 3 8 M e 1 2 F 1 2 M B T i Y connection 2 A l min ea ore fe Essen eo oss 5 en 1 woo v EIE EIE CIE 60 um l min Fittings BSP T i 265 460 230 400 265 460 5 4 1 2 2 Control units with heat exchanger 1 Electric pump with by pass circuit 2 Filter with blockage indicator and by pass valve 3 Air oil heat exchanger with control thermostat 4 Minimum pressure switch only with forced lubrication 5 Maximum temperature thermostat Bonfiglioli Riduttori IOM Manual HDP_gb Translation of original instructions in Italian Rev 0 27 07 11 23164 Design and functional characteristics MCRA MCRA cooling units are
28. with the new oil to remove all traces of the old oil and any contaminants from inside the casing before filling the unit with the new oil To facilitate flushing pre heat the oil of the viscosity specified for functioning or use an oil of the same type but of lower viscosity contact the lubricant manufacturer for further information Adopt protection against contact with hot parts risk of burns In the case of gear units equipped with forced lubrication the oil circuit must also be filled In this case the unit must be run for a short period and then stopped before rechecking the oil level Lubricants solvents and detergents are toxic harmful to health they may cause irritation in direct contact with the skin they may cause intoxication if inhaled they may be fatal if swallowed Handle them with care using suitable personal protection equipment Do not dump them into the environment and dispose of in accordance with applicable legislation 38 64 Bonfiglioli IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 Riduttori 5 6 1 Food grade PolyAlkylene Glycol PAG synthetic oils HDP 60 HDP 160 54 220 54 320 54 320 OmaaSAWE460 54 OmaaSAWE460 460 EO A S 220 BasaS320 S 320 Kl bersynth GH 6 220 y ROPA GH 6 320 Kl bersynth UH1 6 320 UH1 6 320 LUBRICATION Mobil Glygoyle HE 220
29. CITOR yellow green THERMOSTAT ELECTRIC FAN Single phase __ CONNECTOR 230 V single phase MCRA21 MCRA34 51 Three phase power supply gray black 1 yellow green ELECTRIC FAN three phase 1234156 TERMINAL BOARD 230 400 V three phase To ensure an adequate air flow and good thermal efficiency install the heat exchanger with at least 1 m of free space around it In the case of indoor installations and installations in restricted spaces make sure that there is sufficient ventilation and or air recycling to prevent overheating For more general information on installation refer to the INSTALLING THE GEAR UNIT section in this manual 5 4 1 3 Cooling coil optional variant SR The cooling coil designed for integration in a cooling circuit created by the customer is installed inside the gear unit sump and is not removable For optimal efficiency the cooling circuit supply must comply with the following specifications max pressure 8 bar min flow rate 5 l min for HDP 60 HDP 90 min flow rate 10 l min 100 140 max water temperature 20 Cooling water can circulate through the coil in either direction If the cooling water is very hard the use of a water softener is recommended To avoid excessive energy consumption it is good practice to equip the cooling circuit with a thermostatic valve that admits coolant only when the
30. EQUIPMENT The gear unit has been designed and constructed for integration driven by motor into an assembly of interlocking parts or mechanisms as part of a specific application Depending on the requirements of the application the gear unit can be supplied in a variety of executions and configurations It is designed to satisfy a range of specific requirements in the mechanical chemical agricultural and food industries etc The Manufacturer supplies a range of accessories and optional variants to make these gear units as versatile as possible For further technical information and descriptions refer to the corresponding sales catalogue and the OPTIONAL ACCESSORIES AND VARIANTS section in this manual The user is responsible for using the products recommended for the installation and maintenance of the gear unit in an appropriate manner and in accordance with the Manufacturer s instructions 8 64 Bonfiglioli IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 Riduttori 3 3 3 4 CONFORMITY All gear units or gearmotors when supplied with motor are designed as state of the art devices and in compliance with the provisions of applicable Essential Health and Safety Requirements All gearmotor motors conform to the provisions of the Low Voltage Directive 2006 95 EC and the Electromagnetic Compatibility Directive 2004 108 EC OPERATING LIMITS AND CONDITIONS The applications
31. W Bonfiglioli 44 1 64 IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 LJ D H C or 202 2 e m 1 wor 102 210 so s so 130 3 140 3 C Filler plug with air vent T Blank plug L Level plug No plug present S Drain plug L Overflow level plug Excluding DW Bonfiglioli m EON Riduttori IOM Manual HDP_gb Translation of original instructions in Italian Rev 0 27 07 11 45 64 bens s rs e n vor 102 wr s oe o ro e HDP 150 3 HDP 160 3 5 Bonfiglioli 46 64 IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 Excluding DW 5 7 PREPARING CUSTOMER SHAFTS Make the driven shaft to be coupled to the gear unit s output shaft from a good quality steel respecting the dimensions given in the table A device such as that illustr
32. a minimum temperature thermostat to switch them on and off Unless otherwise agreed or required this thermostat is set at 25 5 C see the SENSORS section in this manual Examples of situations requiring oil heating include operation at temperatures below 0 C starting of gear units featuring oil bath and splash lubrication if the minimum ambient temperature is not at least 10 C higher than the oil drop point start up of gear units with forced lubrication if oil viscosity exceeds 1500 cSt Depending on the lubricant used kinematic viscosity is generally between 220 and 460 cSt and maximum permissible viscosity occurs at ambient temperatures between approximately 5 and 25 For precise temperature values refer to the relevant sales catalogue and or product data sheet of the lubricant manufacturer The heating elements are installed directly in the gear unit casing below the level of the oil The gear unit must therefore be completely drained before the elements can be removed The standard power supply voltage is 220 V AC Consumption varies according to size configuration For more detailed information and to ensure correct product selection contact the Manufacturer s Technical Service The electrical circuit connected to the thermostat must be configured so that the heating element s is are switched on to heat the oil at temperatures below the minimum threshold the heating element s is are switched off when th
33. afts Do not use hammers or other tools which might damage the gear unit s shafts or bearings to mount external parts Proceed as shown below following the recommendations of the INSTALLING CONNECTING ELEMENTS section in this manual Bolt 1 and spacer 2 shown above are not included in the supply To minimise the loads on the shaft bearings when mounting transmission mechanisms with asymmetrical hubs use the configuration shown in diagram A below Bonfiglioli _ ERR Riduttori IOM Manual HDP_ gb Translation of original instructions in Italian Rev 0 27 07 11 17 64 5 1 2 Gear units with hollow output shafts with keyway To facilitate mounting hollow shaft gear units to the machine s cylindrical shaft proceed as indicated in the following diagram See also the PREPARING CUSTOMER SHAFTS section in this manual AS 2 The tie bolt 1 and spacer 2 are not included in the consignment Alternative method The tie bolt 1 spacer 2 and circlip 3 are not included in the supply Install suitable devices to secure the hollow shaft to the machine shaft in an axial direction and prevent accidental decoupling 5 1 3 Gear units with shrink disc Certain gear units may be equipped with a shrink disc for coupling the hollow output shaft to the driven shaft When installing a gear unit of this type proceed as follows 1 Unscrew the locking bolts gra
34. alled Failure to meet these requirements constitutes a risk to personal health and safety Keep the gear unit at its maximum efficiency by following the routine maintenance schedule Good maintenance ensures the units maximum performance extended service life and continued compliance with safety regulations When working on the unit in areas which are difficult to access or hazardous ensure that adequate safety precautions have been taken for the operator and others in compliance with established legislation on health and safety at work All maintenance inspection and repairs must only be carried out by an expert maintenance technician fully familiar with the attendant hazards It is therefore essential to implement operating procedures which address potential hazards and their prevention for the entire machine The expert maintenance technician must always work with caution in observance of applicable safety standards During operation wear only the apparel and safety equipment indicated in the User Instructions provided by the Manufacturer or stipulated by the safety legislation applicable in the place where the gear unit is installed Use the lubricants oil and grease recommended by the Manufacturer Do not dump polluting materials into the environment Dispose of all such materials as stipulated by current legislation After replacing lubricants clean the gear unit s surfaces and the walk on surfaces around the work area
35. ance with applicable legislation Pay the maximum attention when using hazardous chemical detergents and take all the necessary precautions to ensure they are disposed of in compliance with the law Before re starting the gear unit or the control unit fill the gear unit and any relevant accessories with oil to the correct level Never run the control unit without the necessary guards in place Always replace the guards before starting the unit 54 64 Bonfiglioli IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 Riduttori 6 3 6 4 CHECKING THE OIL LEVEL Cil level sight glass To check the correct level of oil refer to the mid point of the sight glass or to the marks on the dipstick If the oil level is lower than the lower edge of the sight glass or the dipstick minimum mark replenish the oil and locate the cause for the fall in level Overflow level plug Gear units equipped with certain options e g Drywell device may also be equipped with a yellow plug for use as an overflow level check To check the oil level first identify the yellow level cap on the gear unit Remove the plug and insert a bar of the right size in the hole and of the shape shown in the figure If the level is more than 3 mm below the spill level top up and check the reason for the drop in oil level 3mm 1 N B Make sure that the dipstick rests firmly on the edge of the threaded hol
36. anings are given below DANGER WARNING This symbol indicates situations of danger which if ignored may result in risks to personal health and safety CAUTION ATTENTION This symbol indicates the need to adopt specific precautions to avoid personal injury as well as damage to equipment IMPORTANT This symbol indicates important technical information Bonfiglioli Riduttori IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 3 64 1 4 1 5 REQUESTING TECHNICAL ASSISTANCE For any technical service needs contact the Manufacturer s sales network www bonfiglioli com quoting the information indicated on the unit s name plate the approximate hours of service the duty cycle and the type of defect MANUFACTURER S LIABILITY The Manufacturer declines all liability in the event of use of the gear unit gearmotor in contravention of local safety at work legislation incorrect installation disregard or incorrect application of the instructions provided in this manual electrical power supply defects for gearmotors and or gear units with electrical devices modifications or tampering work done on the unit by unqualified or unsuitable persons The functionality and safety of the gear unit also depends on scrupulous observance of the instructions given in this manual in particular always operate the unit within its operating limits diligently observe the routine
37. ated below should also be installed to secure the shaft axially Take care to verify and dimension the various components to suit the needs of the application S Y SS UNI 6604 EH 745 nes 129 139 5 5 5 1111 2 ves rone eas 5 0 138 svo 400 so avo ve Not included in the supply HDP 60 UNI 7437 G1 UNI 5739 HDP 70 s mors ws HDP 90 130 110 d9 13 5 M24x60 more to toss s 22060 HDP 100 120x4 120 d9 12 M24x70 morte mow sw wee 130x4 130 d9 105 26 M2 12 M24x70 mrn es 108 s 25 wm 12 HOP 120 moa wooo ws HOP 130 18 0 2 0 4 mra 2106 Tans we wo 33 wine Bonfiglioli m EON Riduttori IOM Manual HDP_gb Translation of original instructions in Italian Rev 0 27 07 11 47 1 64 412 O11 OL fi 1 2 M EA 290 7217 7056 25 4 gt 90 727 69 7096 2 5 25 preme vs unes boim 575 use mes 59 worm 2188 1695 17096 99 boim 5228 2055 21098 559 2 12 3 Not included in the supply Q UNI 7437 L L1 mrs o om
38. available in various sizes each with a different flow rate and cooling capacity Oil is sucked directly from the gear unit casing and circulated through an external closed circuit by the electric pump 1 which has a by pass valve calibrated at 6 bar to avoid overpressure in the system Before returning to the gear unit the oil passes through the filter with blockage indicator and by pass valve 2 which eliminates any suspended solid particles and guarantees a more reliable and long lasting transmission 60 micron metal mesh filter element the air oil heat exchanger unit aluminium radiator electric fan and control thermostat 3 dimensioned to remove the excess heat generated by the gear unit The following control devices are provided to ensure the correct functioning of the accessory and to save energy minimum pressure switch 4 maximum temperature thermostat 5 adjustable control thermostat on the heat exchanger 3 Technical specifications MCRA Frequency of power supply 50 60 Hz 1 tab 4 Control Electric pump Air oil heat exchanger Filter with unit element in metal mesh Description i Fittings GAS MCRA IP55 CLF IP 44 1 230 F F Scis asno o os wr s 5 C 9 IP55 CLF IP44 1 230 ral eo foes 155 T BN 800 4 230 400 1 1 21 3 230 0 0 61 0 35 CRA 21 IP55 CLF IP 54 TF T F 3 4 B35 CUS 265 460 260 0 74 0 43 120 160 18 0 61 0 BN 90LA 4 230 400 3
39. ctionality of the coupling Do not force the coupling and do not use inappropriate tools during assembly Take care not to damage the flat cylindrical coupling surfaces Do not force the rotary coupling mechanisms with large thrust and or overhung loads To facilitate assembly use a synthetic oil lubricating paste such as Kl berpaste 46 MR 401 or other product with similar properties and application range Tighten down all motor gear unit mounting bolts to their prescribed torques See the INSTALLING THE GEAR UNIT section in this manual for details of tightening torque values Bonfiglioli Riduttori IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 19 64 5 3 If the gear unit is installed in situations that are particularly hazardous to personal safety install suitable safety devices such as harnesses safety chains and restraining systems etc INSTALLING CONNECTING ELEMENTS Use the utmost caution when installing the various components to ensure that no damage is caused to the gear unit and its parts such as oil seals and mating surfaces or internal parts such as gears and bearings Make sure that you have access to suitable lifting equipment to perform the installation operations correctly When installing external transmission parts do not use hammers or other unsuitable tools to avoid the risk of damaging the gear unit shafts or supports When instal
40. d valve must respect the following specifications Connection type three pole connector type DIN 43650 Contact type NC normally closed Power V Hz 220 240 50 240 60 Consumption 9 W DC Degree of protection IP 65 with connector fitted To ensure maximum efficiency provide a water supply system that corresponds to the following specifications max pressure 10 bar maximum water delivery temperature 20 C minimum flow rate according to the table in the previous section and make the connections to the water supply circuit so that water enters the heat exchanger via the solenoid valve and the fitting furthest away from the oil circulation pipes and leaves the heat exchanger through the fitting nearest to them If the cooling water is very hard the use of a water softener is recommended In the case of freezing temperatures or long periods of disuse to avoid possible damage the cooling water should be drained from the circuit and compressed air blown through the empty circuit to eliminate all residual moisture MCRA Connections to the electric fan of the air oil heat exchanger must respect the following specifications MCRAS Single phase power supply black yellow green THERMOSTAT ELECTRIC FAN single phase CONNECTOR 230 V single phase Bonfiglioli Riduttori IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 25 64 9 Single phase power supply black CAPA
41. dually one at a time and remove the entire shrink disc 2 Clean and carefully degrease the coupling surface between the gear unit s output shaft and the machine shaft Do not use molybdenum disulphide or any other grease which could reduce the friction of the mating surfaces and affect the performance of the shrink disc Adopt one of the following techniques to facilitate subsequent disassembly at the cylindrical guide section opposite the shrink disc Use a protective paste Kl berpaste 46 MR 401 or other product with similar properties and application range Design the machine shaft as suggested in the PREPARING CUSTOMER SHAFTS section in this manual to accept a self lubricating cylindrical bushing or with a hole for the injection of an anti corrosion liquid Bonfiglioli 18 64 IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 pong 5 2 3 Fit the gear unit to the machine and couple its output shaft to the driven shaft 4 Fit the shrink disc to the gear unit shaft 5 Fully tighten down the shrink disc bolts gradually one at a time in a clockwise sequence using a torque wrench This operation usually has to be repeated several times to reach the tightening torque Mt specified in the table below tab 2 60 70 80 90 3100 110 120 130 140 150 160 wei 95 127 127 aso 250 250 20 Torque the shrink d
42. e OIL CHANGES 1 Place a suitable container under the drain plug 2 Remove the filler and drain plugs and allow the oil to drain out 3 Wait for a few minutes to ensure all the oil has drained out and then refit the drain plug after renewing the seal and cleaning the drain plug magnet if fitted carefully 4 With the gear unit installed in its final mounting position fill it with oil to the mid point of the sight glass to the reference notch on the dipstick or until oil starts to flow out of the plug hole 5 Tighten down the filler plug after changing its seal See the LUBRICATION section in this manual for details of the quantity of oil required Specified quantities are only approximate Gear units must be filled to the mid point of the sight glass or to the reference notch on the dipstick or until oil starts to flow out of the plug hole according to the mounting position specified on order Lubricants solvents and detergents are toxic harmful to health they may cause irritation in direct contact with the skin they may cause intoxication if inhaled they may be fatal if swallowed Handle them with care using suitable personal protection equipment Do not dump them into the environment and dispose of in accordance with applicable legislation Bonfiglioli Riduttori IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 55 64 6 5 If a leak is found identif
43. e control thermostat is functioning correctly No or insufficient oil circulation Contact authorised workshop No or insufficient oil circulation Electric pump damaged or worn By pass circuit valve damaged or worn Pressure switch damaged or incorrectly calibrated Check oil level Check the used lubricant Check that all components are correctly secured and sealed Check that the electric pump is functioning correctly Check that the filter is clean Contact authorised workshop Suction pipe blocked Check that the pipe is clean Operating temperature too high See relevant section Oil too viscous Delivery pipes or components blocked Electric fan damaged or worn Check the used lubricant Wait for the gear unit to reach its normal operating temperature Check that the pipes are clean Check that the filter is clean Check that the heat exchanger is clean Check that the electric fan is functioning correctly Check that the heat exchanger is clean Fittings loose Check correct tightness Damaged seals Check correct tightness Contact authorised workshop Filter seals damaged Check correct tightness Replace the filter element Leaks in heat exchanger Contact authorised workshop Bonfiglioli Riduttori IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 61 64 FAULT CAUSE REMEDY Check the condition of the water heat exchanger Check t
44. e machine shaft must be able to support the gear unit radially and axially The torque arm must fit without stress The torque bolt must be fitted on the side of the gear unit next to the driven machine Supporting surfaces should be hardened and tempered minimum hardness 58 HRC with case hardening to a minimum depth of 0 6 mm smooth and ground if possible Nitriding is an alternative treatment that guarantees a sufficiently resistant base material capable of resisting the compression and scoring of the surface If safety is at risk and or maximum reliability is required install suitable devices to stop the gear unit rotating or breaking free if the torque arm or machine shaft should break Bonfiglioli Riduttori IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 35 64 tab 11 G mm 100 110 120 130 140 Free height RE Height under load mm mm HDP 150 HDP 160 150 160 Lo Free height mm L4 Height under l
45. e made by the customer prior to the startup of the gear unit The electrical contacts of the minimum pressure switch supply an alarm signal when pressure in the lubrication system falls below the minimum permissible value 0 5 bar see the SENSORS section in this manual If an alarm occurs stop the gear unit as soon as possible and locate the cause of the problem The lubrication system must be started up before the gear unit is started Do not start up the gear unit until the electric pump has been functioning for a few minutes The electric pump must always run along with the gear unit and must only be switched off after the gear unit has effectively stopped Check that the actual mains power mounting and service conditions correspond to those declared on the name plates of the components and or specified in this manual Electric motors must rotate in the direction shown on the components Make sure that all electrical power cables are big enough to carry the current draw and suitable for the installation conditions Inadequate cables can cause overheating and or voltage drops Information about the pump s electric motor must be obtained directly from the electric motor s own sales catalogue or installation operation and maintenance manual For all other devices see the SENSORS section in this manual BACKSTOP DEVICE optional variant A CW A CCW The backstop device ensures that the gear unit only turns in one direction and
46. e nominal values given on the motor s nameplate Checkthe wear ofthe friction surfaces and braking gasket on the brake motors if fitted and if necessary adjust the gap Check for lubricant leaks from the gaskets seals plugs casings and pipes Check that temperature does not rise over normal operating levels unless this is not justified by a corresponding increase in the applied load the rotation speed ambient temperature or any other factor If it does the gear unit must be stopped immediately and the cause of the fault identified Check all bolted couplings for wear deformation and corrosion and tighten them correctly without exceeding the values specified in the INSTALLING THE GEAR UNIT section in this manual 6 2 ROUTINE MAINTENANCE Keep the gear unit at its maximum efficiency by following the Manufacturer s routine maintenance schedule Good maintenance ensures the unit s maximum performance extended service life and continued compliance with safety regulations List of routine checks We recommend keeping a checklist of inspections so that any changes in individual control parameters can be identified rapidly and easily The times indicated in the following tables vary significantly in relation to the conditions of use of the gear unit and must be construed as valid in the absence of other types of problems Depending on the temperature reached by the lubricant it should be replaced at the intervals indicated
47. e oil temperature reaches the upper threshold Contact the Manufacturer s Technical Service to determine the ideal temperature thresholds These may coincide with other thresholds and in any case need to be determined on the basis of the application and the type of lubricant used All electrical connections to be made by the customer prior to the startup of the gear unit The heater must remain disconnected during periods in which the gear unit is not in use the heater must be switched on before the gear unit is started only when it is completely immersed in the oil and only for the time required for the oil to reach its minimum specified temperature The use of the heater for longer periods than specified can result in carbonisation of the oil molecules impairing lubrication performance and producing residues that are harmful to the gear unit and its components Bonfiglioli Riduttori IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 27 64 Unless stated otherwise the requirements and specifications given above valid even if non standard control devices have been supplied with the gear unit instead of the standard ones described in this manual If the normal heater s is are insufficient to heat the oil to the minimum temperature required for startup or operation or if shorter warm up times are required consult the Manufacturer s Technical Service In the presence
48. e sales catalogue for information on the availability of the cooling devices for the different sizes of gear unit and for other technical specifications and dimensions 5 4 1 2 1 Control units with oil water heat exchanger MCRW 1 Electric pump with by pass circuit 2 Filter with blockage indicator and by pass valve 3 Water oil heat exchanger 4 Minimum pressure switch only with forced lubrication 5 Maximum temperature thermostat 6 Control thermostat 7 Solenoid valve Design and functional characteristics MCRW MCRW control units are available in various sizes each with a different flow rate and cooling capacity Oil is sucked directly from the gear unit casing and circulated through an external closed circuit by the electric pump 1 which has a by pass valve calibrated at 6 bar to avoid overpressure in the system Before returning to the gear unit the oil passes through the filter with blockage indicator and by pass valve 2 which eliminates any suspended solid particles and guarantees a more reliable and long lasting transmission 60 micron metal mesh filter element the copper tube bundle water oil heat exchanger 3 which removes the excess heat generated by the gear unit To ensure the proper functioning of the auxiliary cooling system and to save energy and coolant the following control devices are provided minimum pressure switch 4 maximum temperature thermostat 5 control
49. egree of protection specified outdoor installations must be protected against direct sunlight inclement weather and infiltration by water and foreign bodies without however compromising effective gear unit ventilation Bonfiglioli Riduttori IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 9 64 4 HANDLING AND TRANSPORT The person authorised to handle the product must take all necessary precautions to safeguard his own safety and that of all other persons involved 4 1 PACKAGING SPECIFICATIONS The standard packaging if supplied and unless otherwise agreed is not rainproof and is intended for shipping by ground and not by sea and for storage in areas which are under cover and not humid The material must be stored under cover in temperatures between 15 C and 50 C at a relative humidity not in excess of 80 Storage in all other conditions requires specific packaging In order to facilitate handling heavy packages can be loaded on pallets The most frequent types of packaging are shown in the figures below Standard carton pallet packaging for single products and kits Horizontal packaging Vertical packaging Wooden crates for miscellaneous products and shipments by sea On receipt of the gear unit make sure the delivery corresponds to the purchase order and that it is not damaged or faulty in any way Report any problems to the Manufacturer s sa
50. er that stops oil leaks and provides the necessary lubrication for the shaft s bottom bearing At the intervals specified in the Operating and Maintenance table inject about 40 grams of grease for rolling contact bearings through the grease nipples tab 9 Quantity of grease kg Optional variant DW HDP HDP HDP HDP HDP HDP HDP HDP 60 70 80 90 100 130 140 160 0 100 0 150 0 250 0 350 Contact the Manufacturer s Technical Service Topping up 0 030 0 030 0 040 0 040 The gear unit is supplied with no grease in the output shaft s bottom bearing All work must be performed exclusively with the gear unit at a standstill The motor must be protected against accidental startup e g by padlocking the main power switch or removing the power fuses For this purpose also affix a notice to the motor indicating that work is in progress on the gear unit The gear unit must always be drained of oil before it is moved to avoid oil overflowing into the grease chamber ANCHORING OF TORQUE ARM optional variant TA For shaft mounted solutions the gear unit can be equipped with a torque arm on request Depending on circumstances this type of device may be equipped either with an anti vibration bushing or a cup spring damper included in the supply Because it is designed and sized specifically for the purpose this type of device provides the best possible guarantee for the correct operation of the assembly Th
51. ersonal protective equipment specified therein If the gear unit is not used for a prolonged period following installation or run in it must be run at least once a month If this is not possible the gear unit must be protected against corrosion with a suitable rust inhibitor or completely filled with new oil of the type normally utilised for operating duty See the STORAGE section in this manual The above instructions are aimed at ensuring efficient and safe operation of the gear unit The Manufacturer declines all liability for injury to persons and damage to components due to the use of non original spare parts and non routine work which modify the safety requirements without the manufacturer s express prior authorisation Refer to the specific spare parts catalogue when ordering spare parts for the gear unit Bonfiglioli Riduttori IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 51 64 Do not disperse contaminant liquids worn parts and maintenance residues in the environment Dispose of all such substances in strict compliance with applicable statutory legislation 6 1 CHECKING OPERATIONAL EFFICIENCY Periodically remove any dust from the gear unit and motor casings Check that the noise generated at constant load does not vary Excessive vibration or noise can indicate wear of the gear train or failure of a bearing Check the power absorption and voltage against th
52. further details 90 C 5 C setting of optional variant MCRA see the Autonomous control units section in this manual for further details Depending on configuration thermostats may be installed on board the gear unit or supplied separately If supplied separately remove the blind plug fitted for transport purposes and fit the thermostat in its place Electrical connections and or cabling to user points are the responsibility of the Customer and must be completed prior to start up Contact type NC normally closed Contact current rating 5 A resistive 240 V AC 5 A resistive 24 V DC Degree of protection IP 65 with connector fitted Threaded fitting GAS 1 2 M 5 4 7 2 Oil level sensor optional variant OLG A sensor for the remote monitoring of lubricant safety level can also be installed on request If the sensor is supplied separately remove the clearly identified blind plug fitted for transport purposes and fit the sensor in its place The device functions when the gear unit is idle When the gear unit is running the oil level sensor must be bypassed Bonfiglioli Riduttori IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 33 64 Electrical connections and or cabling to user points are the responsibility of the Customer and must be completed prior to start up Contact type NC normally closed in air brown black OUT
53. g devices and control devices at el condition of gear tooth flanks oil change at every oil change cleanliness of fan fan cowl and gear unit casing Bonfiglioli m EON Riduttori IOM Manual HDP_gb Translation of original instructions in Italian Rev 0 27 07 11 53 64 6 2 1 MAINTENANCE OF AUTONOMOUS COOLING UNITS optional variants MCRW MCRA If the gear unit is equipped with an autonomous control unit also follow the instructions given below Before commencing any cleaning and or maintenance activate all necessary safety devices to prevent the accidental start up of the gear unit and control unit wait for the gear unit and all parts of the control unit to cool down drain the gear unit or lower the oil level so that no oil flows out during work to replace components In particular perform the following periodical checks check the blockage indicator always when the oil is hot and clean or replace the filter element with another of the same characteristics if the pressure gauge depending on the type installed displays a pressure above 6 bar or 1 5 bar above the value displayed with a new filter element or isin the red area the cross section of water passages MCRW to check that they are free from sediment and or blockages that might impair the efficiency of the auxiliary cooling system If necessary clean the circuit by flushing with a suitable chemical agent checking wi
54. gear unit oil reaches a temperature max of 70 C In the case of freezing temperatures or long periods of disuse to avoid possible damage the cooling water should be drained from the circuit and compressed air blown through the empty circuit to eliminate all residual moisture 26 64 IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 Bonfiglioli 5 4 1 4 Before starting the gear unit ensure that all the connections have been made properly It is also advisable to check the cross section of water passages periodically to ensure that they are free from sediment and or obstructions that could impair the efficiency of the external cooling system If necessary clean the circuit by flushing with a suitable chemical agent checking with the manufacturer of the cleaning agent that it is compatible with the construction material of the coil The intervals at which to check the condition of the cooling system depend on the characteristics of the cooling water used see the ROUTINE MAINTENANCE section in this manual Pay the maximum attention when using hazardous chemical detergents and take all the necessary precautions to ensure they are disposed of in compliance with the law Oil heater optional variant HE In significantly low ambient temperatures increased viscosity can prevent correct oil flow In such conditions the gear unit can be equipped with one or more electrical heating elements and
55. he customer prior to the startup of the gear unit The electrical contacts of the minimum pressure switch supply an alarm signal when pressure in the lubrication system falls below the minimum permissible value 0 5 bar see the SENSORS section in this manual If an alarm occurs stop the gear unit as soon as possible and locate the cause of the problem 5 4 2 4 Forced lubrication with electric pump optional variant MOP This system comprises an electric pump with a separate power supply a coarse mesh filter a minimum pressure switch and any necessary connecting pipelines To ensure a good lubricant flow rate make sure that the power supply to the pump motor conforms to the requirements on the motor name plate and to the requirements given in the following tables unless specified otherwise tab 5 HDP V5 MOP without DW Mains frequency 50 Hz 60 Hz 230A 400Y 265A 460Y Size Description Pn In 400V Pn In 460 V kW A kW A HDP 60 HDP 80 HDP 100 HDP 110 BN 71A 6 IP55 CLF B34 CUS 0 18 0 67 0 21 HDP 120 HDP 130 HDP 150 tab 6 HDP V5 MOP DW Mains frequency 50 Hz 60 Hz 230A 400Y 265A 460Y Size Description Pn In 400V Pn In 460 V kW A kW A HDP 60 HDP 100 HDP 160 Contact the Manufacturer s Technical Service Bonfiglioli Riduttori IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 29 64 All electrical connections to b
56. he water supply circuit Heat exchanger damaged or fittings Water leaks MCRW Oil too old or high level of impurities Replace oil Electric pump damaged or worn Contact authorised workshop Check that the pipes are clean Check that the heat exchanger is clean Check the condition of internal Unusual wear of gear unit components components gears bearings etc Filters frequently become clogged with metal particles Pipes or components blocked Bonfiglioli 62 64 IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 Rong 9 DISPOSING OF THE GEAR UNIT Make sure that the gear unit cannot function accidentally while it is being taken out of service The gear unit gearmotor must be disposed of in compliance with environmental legislation and the various materials used in its manufacture must be delivered to an authorised disposal recycling centre The gear unit must only be taken out of service by operators trained in the observance of applicable laws on health and safety at work Do not dump non biodegradable products lubricants and non ferrous materials rubber PVC resins etc into the environment Dispose of all such materials as stipulated by current environment protection laws Do not re use parts or components which appear to be in good condition after they have been checked and or replaced by qualified personnel and declared unsuitable fo
57. herwise set the said thermostat to switch on the electric fan at a temperature of 60 C whenever possible when oil temperature reaches 90 the maximum temperature thermostat must activate an alarm and stop the gear unit as soon as possible when pressure falls below 0 5 bar the minimum pressure switch must activate an alarm and stop the gear unit as soon as possible 50 64 Bonfiglioli IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 Riduttori Maintenance and replacement work must be carried out by expert maintenance technicians trained in the observance of applicable laws on health and safety at work and the special ambient problems attendant on the installation In order to maintain the proper functioning and safety of the gear unit gearmotor we recommend that users have non routine maintenance performed by the Manufacturer or an authorised specialist service centre Contact the manufacturer s sales network Failure to comply with this requirement during the warranty period automatically invalidates the warranty Never improvise repairs Before doing any work on the unit the operator must first switch off power to the gear unit and ensure that it is out of service as well as taking all necessary precautions against it being accidentally switched on again or its parts moving without warning due to suspended loads or similar external factors Furtherm
58. isc as prescribed to assure axial fixing of the transmission in the absence of external loads E HDP HDP HDP HDP HDP HDP HDP The shrink disc coupling must not be disassembled nor lubricated before being reinstalled Disassemble and clean the shrink plate only when it is fouled When cleaning and or during maintenance lubricate only the sliding surfaces of the shrink disc using solid lubricant with friction value of 0 04 such as Kl ber Molykombin UMFT 1 or an equivalent product having the same characteristics and durability of performance Never run the gear unit when the shrink disc protective guard is not fitted In the presence of external thrust loads vibration safety problems requirements for enhanced reliability or unfavourable mounting positions e g output shaft directed downwards install suitable devices to secure the shaft in an axial direction and prevent accidental decoupling INSTALLING A MOTOR WITH AN IEC STANDARD FLANGE optional variant AD GL GR Thoroughly clean and degrease the flange of the gear unit and the area of the machine to which it is to be coupled The correct execution of this procedure is essential for safe torque transmission Do not use solvents or dirty rags to degrease mating surfaces Do not use molybdenum disulphide or any other type of grease as this would significantly lower the friction coefficient in the contact area and therefore impair the fun
59. l pump can be driven mechanically off one of the shafts of the gear unit or connected to a motor fixed to the gear unit casing If forced lubrication is installed pay special attention to the maximum permissible viscosity 1500 cSt especially at the time of plant startup Depending on the lubricant used kinematic viscosity is generally between 220 and 460 cSt and maximum permissible viscosity occurs at ambient temperatures between approximately 5 C and 25 C For precise temperature values refer to the relevant sales catalogue and or product data sheet of the lubricant manufacturer If this value is not reached under normal conditions the oil must be preheated The plant can be equipped with suitable devices to ensure correct operation and to monitor the main functional parameters For further information refer to the SENSORS section in this manual 5 4 2 3 Forced lubrication with pump optional variants OP OP1 OP2 OP This system comprises a reversible pump keyed directly to a gear unit shaft a coarse mesh filter a minimum pressure switch and any necessary connecting pipelines 28164 IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 Sonnen To ensure an optimum supply of lubricant a constant rotation speed must be maintained at a value that is as close as possible to the rotation speed for which the pump is designed see sales catalogue All electrical connections are to be made by t
60. lects the state of the art at the time of commercialisation of the gear unit The Manufacturer reserves the right to modify supplement and improve the manual without the present publication being for that reason considered inadequate GLOSSARY TERMS AND SYMBOLS Some of the frequently occurring terms used in this manual are explained below to unequivocally define their meaning Routine maintenance a set of operations required for maintaining the functionality and efficiency of the gear unit These operations are usually scheduled by the Manufacturer who defines the qualifications and tasks in question Non routine maintenance a set of operations required for restoring the functionality and efficiency of the gear unit These operations are not routine maintenance operations In order to maintain the proper functioning and safety of the gear unit gearmotor we recommend that users have non routine maintenance performed by the manufacturer or an authorised specialist service centre Contact the manufacturer s sales network Failure to comply with this requirement during the warranty period automatically invalidates the warranty Expert maintenance technician an authorised technician selected from those having the qualifications Skills and mechanical and electrical training to do routine maintenance work on the gear unit SYMBOLS Particularly significant sections of the manual and important specifications are highlighted by symbols whose me
61. les network Bonfiglioli 10 64 IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 4 2 4 2 1 4 2 2 Dispose of packaging materials as stipulated by applicable legislation HANDLING INSTRUCTIONS Handle packages as per the Manufacturer s instructions on the packages themselves if present Since the weight and shape of the packages may make manual handling unfeasible special equipment must be used to avoid damage and injury Persons authorised for this purpose must be trained and experienced in the work in question to avoid risks to themselves and other persons Moving the packages Prepare a suitable delimited area with a level floor or surface for unloading the packages Prepare the equipment required for handling the package The lifting and handling equipment e g crane or lift truck must be of adequate capacity for the weight and size of the load taking into account its attachment points and centre of gravity If required this information is indicated on the package itself Harness heavy packages with chains belts and steel ropes after checking that they are suitable for the weight of the load which is always specified e When handling the load keep it level horizontally to avoid tipping and instability Moving the equipment the following operations must be carried out with care and caution and without sudden movements When lifting use accessories
62. ling connecting elements it is advisable to preheat them slightly Take the following precautions when doing so Adopt protection against contact with hot parts risk of burns Protect the oil seals from damage and accidental overheating to avoid impairing their functionality use a heat shield to protect against radiated heat The connecting or transmission elements must not transmit static or dynamic external loads to the shafts unless said loads have been calculated at the time of gear unit selection If the element to be coupled to the shaft is not fixed axially by the interference of the coupling utilise suitable retaining components to prevent axial movement of the element in question on the shaft 20 64 Bonfiglioli IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 Riduttori 5 4 5 4 1 5 4 1 1 ACCESSORIES AND OPTIONAL VARIANTS AUXILIARY COOLING HEATING SYSTEMS Forced ventilation optional variants FANL FANR FANLR A fan is keyed to the gear unit input shaft and protected against accidental contact by a guard Never run the gear unit when the fan guard is not fitted After each maintenance intervention refit the guards before restarting the gear unit The fan draws in air through the grille in the protective guard and conveys it to the gear unit casing thereby dissipating a quantity of heat that depends on the rotation speed The effectiveness of f
63. ly clean and degrease the flange of the gear unit and the area of the machine to which it is to be coupled Safe torque transmission depends largely on the correct execution of this procedure Do not use solvents or dirty rags to degrease mating surfaces Do not apply any type of grease as this would significantly lower the friction coefficient in the contact area and therefore impair the functionality of the coupling Tighten the bolts fully down working in a crosswise sequence and applying the maximum tightening torque shown in the table below using a torque wrench Thread Screw Nut Tightening torque UNI 5737 UNI 5588 men wos meea wa mea vo ww EIN tab 8 Class 10 9 Class 10 1060 Nm HDP 130 Class 10 9 Class 10 2130 Nm HDP 140 Class 10 9 Class 10 2130 Nm Contact the Manufacturer s Technical Service HDP 160 If the gear unit is installed in situations that are particularly hazardous to personal safety install suitable safety devices such as harnesses safety chains and restraining systems etc Bonfiglioli 32 64 IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 pong 5 4 6 5 4 7 5 4 7 1 SEALS AND GASKETS optional variants VS DS DVS TK The gear units can be supplied with alternative seal systems on request Contact seals single or double DS nitrile rubber compound seal ri
64. ngs single VS or double DS Viton compound seal rings Taconite TK seals are recommended for environments characterised by the presence of abrasive dust or powders Taconite seals incorporate a combination of sealing rings labyrinths and grease chambers At the intervals specified in the ROUTINE MAINTENANCE section in this manual inject about 30 grams of grease for rolling contact bearings through the grease nipples All work must be performed exclusively with the gear unit at standstill The motor must be protected against accidental startup e g by padlocking the main power switch or removing the power fuses For this purpose also affix a notice to the motor indicating that work is in progress on the gear unit SENSORS Bimetal thermostat optional variant TG Non adjustable thermostats are preset to a fixed switching temperature The actual temperature depends on the thermostat s function and the accessory with which it is used as shown below 90 C 5 C optional variant TG in this case the thermostat trips when the lubricant reaches its maximum permissible temperature If an alarm occurs stop the gear unit as soon as possible and locate the cause of the problem 25 5 C setting of optional variant HE see the Oil heater section in this manual for further details 60 C 5 C e 90 C 5 C settings of optional variant MCRW see the Autonomous control units section in this manual for
65. ns in Italian Rev 0 27 07 11 Riduttori 5 6 4 Compatible greases Staburags NBU 8 EP for bearings Kl berpaste 46 MR 401 to facilitate the coupling of cylindrical parts ITP Fluorocarbon gel 880 to grease contact seals Kl ber Petamo GHY 133 N for Taconite seals 5 6 5 Quantity of lubricant The quantity of lubricant specified in the following tables is purely indicative Gear units must be filled to the mid point of the sight glass or to the reference notch on the dipstick or until oil starts to flow out of the plug hole according to the mounting position specified on order tab 10 on d 0 602 _ 602 _ 2 60 3 LI 3 HDP LI 2 HDP DIM 3 HDP DIM 2 HDP LI 3 HDP LI 2 70 56 58 HDP 100 4 34 HDP 110 2 27 61 49 51 HDP 110 4 HDP 120 2 35 83 64 68 1203 HDP 1203 3 45 96 74 79 HDP 120 4 HDP oa 2 57 154 119 128 86 181 140 150 HOP 1303 130 4 HDP 140 2 76 163 126 115 191 147 135 HDP 140 4 88 HDP rete 2 109 HP 1803 150 4 HDP 160 2 160 3 160 3 3 160 4 Bonfiglioli m EON Riduttori IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 41164 5 6 6 Service plugs The following charts identify the position of the various service plugs
66. oad mm 204 3 204 3 f Deflection Lo L4 mm 36 64 IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 Bonfiglioli Riduttori 5 4 10 5 5 To ensure the necessary preload the user must adjust the torque arm before the gear unit is started up in line with gap G shown in the table In spring sets friction and spring height change over time After the initial running in period and then at regular intervals check for wear and the adjustment setting G To improve drive conditions reduce friction and extend the working life of the cup springs lubricate the sliding paths with grease a paste with molybdenum disulphide additives lubricating paints or other solid lubricants OTHER ACCESSORIES For any special accessories installed on the gear unit in accordance with contractual specifications refer to the instructions supplied by the manufacturer of the accessories in question or to any accompanying manuals Such components may require special maintenance and or lubrication PAINTWORK HDP gear units in sizes 60 to 90 are externally and internally painted in oven hardened epoxy resin and polyester powder paint that provides an excellent level of protection against corrosion and is suitable for outdoor installations The colour is RAL 7042 grey Total thickness on the outside of the gear unit is 60 80 um HDP gear unit sizes 100 to 160 on the other hand are internally and externally spray
67. on as follows 15 Place the gear unit in the vicinity of the installation area 16 Mount the gear unit and secure it to the structure at the points provided The gear unit should be secured to the structure using all the fixing points on the mounting provided feet or flange 17 Locate the closed oil plug used during shipping and replace it with the vent plug supplied in the shipment if required 18 Tighten down the mounting bolts and check that the service plugs are screwed down to the torque values given in the following table tab 1 Bolt torque Nm 5 10 Bolt class Bolt size Thread Pitch Tightening torque Nm Plug Vent threads per inch 5 10 Bonfiglioli 16 64 IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 Riduttori After having tightened the fixing bolts check the alignment of the shafts again Alignment must checked again and if necessary corrected after a few days of operation In the presence of high external loads in particularly dangerous mounting positions and in mounting positions other than B3 use Class 10 9 fixing bolts 19 Fill the gear unit with oil or top up as necessary as instructed in the LUBRICATION section in this manual If the gear unit is equipped with a fan or an auxiliary cooling unit with an oil air heat exchanger leave enough room to ensure adequate air circulation 5 1 1 Gear units with solid output sh
68. operational as prescribed in EN 60204 1 and is grounded as per EN 60079 that the rating of the power supply to the motor and any installed electrical devices corresponds to that prescribed and is within 1096 of the rated value that the oil level in the gear unit gearmotor and any lubricated installed accessories is as required and that there are no leaks from any plugs seals or pipes that any connections to parts and or accessories disconnected for transport purposes have been reconnected that any of the Manufacturer s guards that might have been removed have been refitted that there are no unusual noises and or vibrations when the gear unit gearmotor is started up After the first 100 hours of operation check the tightening torque of all screw couplings shrink discs motor flanges machine flanges supports In the presence of optional accessories it is also necessary to check that all the operations required for their correct functioning have been carried out as described in the relative sections and or manuals When the gear unit is started for the first time allow it to run at slow speed and at zero load for some time If no irregular operation is noted during this period the load and speed can be gradually increased to the rated operating conditions over a reasonable period of time during which the gear unit must be monitored closely Starting up autonomous control units MCRW MCRA If the
69. orced ventilation falls off dramatically at rotation speeds below n4 900min if it proves necessary to increase the thermal capacity of the gear unit under such conditions an auxiliary cooling device should be installed if dirt builds up on the blades of the fan or blocks the protective grille over the fan Clean regularly as instructed in the MAINTENANCE section in this manual 8 FANL FANR FANLR HDP100 HDP160 When installing a gear unit equipped with a forced air cooling fan it is essential to allow ample space around the unit to ensure sufficient air circulation for cooling purposes 5 4 1 2 Autonomous control units optional variants MCRW MCRA Autonomous cooling units are specially designed to cool gear unit lubricant They come installed on board the gear units mounted on special plates and connected to the relevant unions by rigid pipes and or flexible hoses also included in the supply Electrical connections and or cabling to user points are the responsibility of the Customer and must be completed prior to start up Bonfiglioli Riduttori IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 21 64 Refer to th
70. ore all additional environmental safety precautions must be taken e g elimination of residual gas or dust etc Before commencing any maintenance work power to the machine in which gear units are installed must be disconnected and the switches secured in OFF position All persons performing maintenance must secure the disconnecting switches for themselves using personal devices e g padlocks the keys of which they must keep with them for the duration of the work e f the temperature of accessible surfaces exceeds the limits established by EN ISO 13732 1 65 C for occasional brief contact with exposed metal wait for the said surfaces to cool before commencing work If necessary wear anti burn safety gloves when working on gear units Before doing any maintenance work activate all the safety devices provided and if necessary inform persons working in the vicinity Cordon off the area around the unit and prevent access to any equipment which if activated might be the cause of unexpected health and safety hazards Use the lubricants oil and grease recommended by the Manufacturer When working on the gear unit always replace gaskets and seals with original spare parts We recommend replacing the lubricating oil after all maintenance work f during work there is any risk of coming into contact with oils and greases respect the safety precautions provided on the manufacturer s data sheets and use any items of p
71. osion Clean all friction couplings thoroughly but do not apply any protective pastes 11 To ensure effective coupling the driven shafts should be machined to the tolerances specified in the PREPARING CUSTOMER SHAFTS section in this manual 12 In the case of outdoor installations protect the gear unit and any motor from direct sunlight and inclement weather by means of guards or a casing Also make sure that the assembly is properly ventilated 13 Make sure that the casing of the gear unit is connected to the earth circuit of the machine in which it is installed 14 Evaluate whether accessible surfaces may exceed the temperature limits established in EN ISO 13732 1 on the basis of the gear unit s conditions of use and ambient temperatures If the temperature of accessible surfaces exceeds the limits established by EN ISO 13732 1 65 C for occasional brief contact with exposed metal the surfaces in question must be protected to prevent contact by means of guards and or lagging Wherever impossible signs bearing symbol 5041 of IEC standard 60417 Warning Hot surfaces must be displayed in such a way that they are clearly visible to machine operators bearing in mind the position and orientation of the gear unit Symbol 5041 of IEC standard 60417 Risk of burns Hot Parts Bonfiglioli m EON Riduttori IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 15 64 Proceed with the installati
72. r use Bonfiglioli Riduttori IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 63 64 INDEX OF REVISIONS R 1661 We reserve the right to modify the information given herein without prior notification This manual may not be reproduced even partially without express authorisation This edition cancels and replaces all previous editions and revisions Bonfiglioli 64 64 IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 5 Bonfiglioli power control and green solutions Bonfiglioli has been designing and developing innovative and reliable power transmission and control solutions for industry mobile machinery and renewable energy applications since 1956 Bonfiglioli Riduttori S p A tel 39 051 647 3111 Via Giovanni XXIII 7 A 39 051 647 3126 40012 Lippo di Calderara di Reno bonfiglioli bonfiglioli com Bologna Italy www bonfiglioli com
73. ratures by a thermostat in the heat exchanger Unless instructed otherwise set the said thermostat to switch on the electric fan at a temperature of 60 C whenever possible when oil temperature reaches 90 the maximum temperature thermostat must activate an alarm and stop the gear unit as soon as possible Case 2 Functionality cooling and forced lubrication of internal components startthe control unitin compliance with the requirements of the OPERATING LIMITS AND CONDITIONS section in this manual do not start up the gear unit until the control unit has been functioning for a few minutes The control unit s electric pump must always run along with the gear unit and must only be switched off after the gear unit has effectively stopped Autonomous control units with oil water heat exchanger MCRW once the oil has reached a temperature of 60 the control thermostat must give the signal to open the water supply solenoid valve when oil temperature reaches 90 the maximum temperature thermostat must activate an alarm and stop the gear unit as soon as possible when pressure falls below 0 5 bar the minimum pressure switch must activate an alarm and stop the gear unit as soon as possible Autonomous control units with oil air heat exchanger MCRA to avoid the fan running continuously even when not needed its motor can be controlled to run over a range of temperatures by a thermostat in the heat exchanger Unless instructed ot
74. rink disc coupling Extract the machine shaft as instructed in the section DISASSEMBLING A GEAR UNIT WITH HOLLOW OUTPUT SHAFT WITH KEYWAY Bonfiglioli e CEN Riduttori IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 59 64 8 TROUBLESHOOTING The following information is intended to serve as an aid in locating and eliminating defects and faults In Some cases such problems may be caused by the plant or machine to which the gear unit is assembled and hence the cause and remedy will be described in the Manufacturer s technical documentation for the machine plant in question If any components fail or require replacement as a result of levels of wear likely to compromise the functioning of the gear unit contact the Manufacturer s sales network 8 1 Gear units Bearing axial backlash too high Contact authorised workshop Abnormal running noise Bearings defective or worn Contact authorised workshop Correct load to rated values given in Excessive load applied sales catalogue Contaminant in oil Replace oil Mounting bolts loose Tighten bolts to specified torque Mounting bolts worn Replace bolts Oil level too high Check oil level Oil leaks Casing coupling seals inadequate Contact authorised workshop Replace oil see recommended lubricant table Gear unit does not run or runs with difficulty Oil level too high Check oil level Excessi
75. such as eyebolts screw clamps snap hooks straps ropes hooks etc which are certified and adequate for the load in question The weight of the unit to be handled is specified on the name plate and or in the relative sales catalogue Do not use eyebolts on the motor to lift gearmotors unless specifically instructed to do so During lifting operations the load must not be allowed to swing beyond an arc of 15 If greater swinging movements occur during the procedure stop and repeat the operations required for the type of lifting system adopted To rotate the gear unit use the same attachment points used to lift it and proceed as instructed for lifting Rotate the gear unit as closely as possible to a supporting surface Pay special attention to the location of the centre of gravity to prevent the load from becoming unbalanced as it is being rotated Lifting gear must be attached in such a way that it cannot slip off or move as this could cause the load to fall This is especially important if the gear unit is being rotated using slings or ropes since these are particularly prone to slipping off their attachment points Bonfiglioli Riduttori IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 11 64 dentify the attachment points for lifting the gear unit as shown in the drawings Prepare the gear unit for lifting by attaching straps hooks etc to its attachment points or al
76. ternatively use a pallet for moving the load If using a crane first lift the gear unit vertically out of its packaging f using a lift truck or pallet truck remove the packaging and insert the truck s forks at the positions provided First lift the load very slowly to only a limited height above the ground and check that the load is stable Move the gear unitto the unloading area and lower it gently into position taking care not to cause sudden oscillations while moving it Do not use the shaft end threads or external pipes as lifting points Take care not to damage any lubrication or cooling system accessories when lifting moving or positioning the gear unit Ob OQ lo o o EE Miscellaneous accessories e g connecting flanges etc and or motors coupled to the gear unit may significantly alter the centre of gravity thereby impairing the stability of the gear unit In such cases it may be necessary to use an additional anchor point Bonfiglioli 12 64 IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11
77. th the manufacturer that the cleaning agent is compatible with the construction material of the heat exchanger The interval for checking the condition of the heat exchanger and any maintenance work depends on the characteristics of the cooling water used Any defects in the heat exchanger water supply circuit can be identified by observing the condition of the lubrication oil in the gear unit which will display a high degree of foaming if it has become contaminated with water the condition of the radiator MCRA to verify that it is free from sediment and or blockages that might impair the efficiency of the heat exchange process if necessary blow the fins clean with compressed air max pressure 6 bar taking care to direct the air jet parallel to the fins to avoid damaging them and protecting any electrical components Only if absolutely necessary spray a detergent product compatible with the material from which the heat exchanger is made before blowing clean The interval for checking the condition of the heat exchanger and any maintenance work depends on the characteristics of the installation environment Lubricants solvents and detergents are toxic harmful to health they may cause irritation in direct contact with the skin they may cause intoxication if inhaled they may be fatal if swallowed Handle them with care using suitable personal protection equipment Do not dump them into the environment and dispose of in accord
78. the unit is to be stored for more than 6 months the following additional precautions must be taken 5 Coat all external machined surfaces with a protective anti corrosion product such as Shell Ensis Fluid SX Tectyl 506 EH or other product with similar properties and application range Check the surfaces regularly and re apply the coating as necessary 6 Fill the gear unit with lubricating oil and replace the vent plugs with blind plugs 7 Periodically rotate the gear unit s input and output shafts through a few turns to avoid damage to bearings and seals At the end of the storage period replace the vent plugs before starting up gear units To store gear units gearmotors with a drywell sealing device and for specific needs and types of storage consult the Manufacturer s Technical Service Bonfiglioli 14 64 IOM Manual HDP gb Translation of original instructions in Italian Rev 0 27 07 11 pong 5 INSTALLATION 5 4 INSTALLING THE GEAR UNIT All phases of installation and maintenance must be planned to suit the overall design of the machine The person authorised to do the work must if necessary implement a safety plan to protect the health and safety of all persons directly involved and apply all applicable legislation It is essential for impact and strain to be avoided during the installation process Before installing a gearmotor also refer to the instructions contained in the installation and user manual for
79. ve load applied Redesign drive for actual load required Abnormal noise at gear unit mounting Oil viscosity too high Output shaft does not turn with Gears damaged Contact authorised workshop motor running Bonfiglioli 60 64 IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 sinu 8 2 Autonomous control units MCRW MCRA FAULT CAUSE REMEDY Operating temperature too high Bearing temperature too high Unusual noise during functioning in general caused by no or insufficient pressure in the circuit Unusual noise during functioning in general caused by excess pressure in the circuit Abnormal running noise air oil heat exchanger Oil leaks or excessive oil consumption No or insufficient oil circulation Water oil heat exchanger not working correctly MCRW Air oil heat exchanger not working correctly MCRA Check the speed and direction of rotation of the electric pump Check that the filter is clean Check that the control thermostat is functioning correctly Check that the pressure switch is functioning correctly Check the water supply circuit Check that the solenoid valve is functioning correctly Check that the heat exchanger is clean Check that the control thermostat is functioning correctly Check the speed and direction of rotation of the electric fan Check that the heat exchanger is clean Check that th
80. y the cause of the fault and repair it before topping up the lubricant and operating the unit CLEANING To clean dust dirt and process residues off the gear unit do not use solvents or other products that might be incompatible with the materials from which it is made and do not direct high pressure jets of water on to the gear unit 56 64 Le RO Bonfiglioli IOM Manual gb Translation of original instructions in Italian Rev 0 27 07 11 Riduttori 7 REMOVAL 7 1 REMOVAL OF MOTOR WITH IEC STANDARD FLANGE optional variant AD If during operation the mobile coupling between the motor and gear unit has not rusted significantly it should be possible to remove the motor without applying excessive force once the screws coupling it to the gear unit have been removed If the motor proves particularly difficult to remove take all necessary precautions and avoid using Screwdrivers or levers which might damage the flanges and mating surfaces If the motor shaft has a threaded hole proceed as instructed below Impact extractor 1 Screw the end of an impact extractor into the threaded hole of the motor shaft fan side 2 Undo the bolts fixing the motor to the gear unit 3 Detach the motor by means of the inertial force

Download Pdf Manuals

Related Search

Related Contents

Samsung YP-U6AB Керівництво користувача  Technical guide circuit breaker diagnosis  Manual WS10 - NOVUS Produtos Eletrônicos  Alcatel-Lucent OpenTouch™ Session Border Controler – R2.x  Mayenne : redevance incitative mode d`emploi  Secure Computing SSL Scanner User's Manual  dds bruyere  Tristar LF-4701 humidifier  Argument+bulletin-Journée CPCT 2014  Betriebsanleitung TPS V1.1  

Copyright © All rights reserved. Failed to retrieve file