PP68 Bonfiglioli gearbox manual
Contents
1. nennen 36 ANNEX 3 CUSTOMER S SHAFT 37 SERIES Re alienato a ee DER NS Cala Bai De ia 37 Sees ee ee cee he ura oe Aa aiar 38 Seres VF and Was ae ee ne laici ee 39 ANNEX 4 LIFTING 40 ANNEX 5 INSTALLING THE MOTOR ON TYPE VFR WORM GEAR UNITS 47 ANNEX 6 CALIBRATING THE TORQUE LIMITER SLIP TORQUE 48 Revisions Refer to page 50 for the catalogue revision index Visit www bonfiglioli com to search for catalogues with up to date revisions BONFIGLIOLI i RIDUTTORI 1 0 GENERAL INFORMATION 1 1 PURPOSE OF THE MANUAL This manual has been compiled by the Manufacturer to provide information on the safe transport handling installation maintenance repair disassembly and dismantling of the gear units All purchasing and design criteria is provided in the Sales Catalogue Apart from adhering to establi shed engineering practices the information given in this manual must be carefully read and applied rigorously The information regarding the electric motor that can be found matching the speed reducer is sup plied with the owner s manual relevant to the specific electric motor Failure to adhere to the information provided herein may result in risk to personal health and safety and may incur economic damages This information provided in the original language Italian of the Manufacturer may also be made available in other languages to meet legal and or commercial requirements The documentation m2. Lubricant is not factory filled BONFIGLIOLI 34 RIDUTTORI Worm gear units series VF Th A14 HS P IEC HS P IEC HS P IEC P IEC HS P IEC HS P IEC VFR 130 HS P IEC HS P IEC VF 130 VFR 130 HS P IEC HS P IEC VF 130 HS VF 130 P IEC VFR 130 HS P IEC VF 150 HS P IEC VFR 150 VF 150 HS P IEC VFR 150 HS P IEC HS P IEC VF 150 VF 150 HS P IEC VFR 150 HS P IEC VF 185 HS P IEC VFR 185 VF 185 HS P IEC VFR 185 HS P IEC HS P IEC VF 185 HS VF 185 P IEC VFR 185 HS P IEC VF 210 HS P IEC VFR 210 VF 210 HS P IEC HS P IEC VFR 210 HS P IEC VF 210 HS VF 210 P IEC VFR 210 HS P IEC VF 250 HS P IEC VFR 250 VF 250 HS P IEC VFR 250 HS P IEC HS P IEC VF 250 HS VF 250 P IEC VFR 250 BONFIGLIOLI RIDUTTORI HS P IEC VF permanent lubrication VFR permanent lubrication For VFR units the lubricant charge refers only to the additional helical reduction 35 Worm gear units series W A15 i 7 10 12 15 i 19 24 30 38 45 64 80
3. Mt Nm EJ Mt Nm 5 1 4 Shaft mounted gear units series F Anchoring the torque arm Use the original vibration damping kit to ensure optimal operation of the assembly as it is specifi cally designed and constructed along with the gear unit for operation in explosion hazard areas Failure to use the original accessory on gear units classified under 94 9 EC voids the ATEX certi fication The torque arm shown in the diagram is to be supplied by customer BONFIGLIOLI RIDUTTORI 15 5 2 INSTALLING AN IEC STANDARD FLANGED MOTOR Further to all the precautions indicated above when installing a IEC flange mount electric motor the following precautions must also be observed Do not force the coupling and do not use inappropriate tools during assembly Take care not to damage the flat and or cylindrical coupling surfaces Do not force the shaft with large radial and or thrust loads To facilitate assembly use a lubricating synthetic oil paste such as Kl berpaste 46 MR 401 or equivalent product with similar properties and application range Tighten down all motor gear unit mounting bolts to their prescribed torque For the tightening torques refer to table AO When the gear unit is mounted to an IEC electric motor proceed as follows Apply a layer of sealant Loctite 510 or eq
4. A20 F 90 gt 126 102 h7 38 BONFIGLIOLI i RIDUTTORI Series VF and W UNI 6604 5x5x40 A 6x6x50 A 8x7x20 A 14x9x60 A 14x9x70 A 18x11x80 A 25x14x80 A 28x16x80 A A22 UNI 6604 8x7x35 A 8x7x40 A 8x7x40 A 10x8x40 A 12x8x50 A BONFIGLIOLI RIDUTTORI 39 ANNEX 4 LIFTING oks etc which are certified and adequate for the load When lifting use accessories such as eyebolts snap hooks screw clamps straps ropes ho The weight of the product to be lifted is given in the Sales Catalogue The method of attachment for the products covered by this Manual are detailed below according to the vario us product series sizes and configurations The most suitable type of solution for safely lifting and handling each is indicated below Symbols Lifting method Simbol Manual Through mechanical equipment A B Approximate weight gt 15 Kg Instruction Recommended method for po sitioning Recommended method for handling and positioning Warning The load may be unstable The load may sway or oscillate Solution Slide the lifting ring to align it with the load s centre of gravity as shown in the diagrams below Lock the ropes under the
5. INDUSTRY PROCESS ASA AND AUTOMATION SOLUTIONS BIELIE use and service manual m er E e i e ro PATAS ici gt dense SU O II AO do Ti o a i a GE ATEI GE BONFIGLIOLI 1 0 GENERAL INFORMATION 2 121 PURPOSE OE THE MANUAL 2 e ae e ns e i ut i A at la i d a ate palos 2 12 EQUIPMENT IDENTIFICATION imet ata c ae DU a Cobb a tb Ee tao 3 1 3 SLOSSARY AND TERMINOLOGY ici ea d para ll rear rear 4 1 4 REQUESTING TECHNICAL ASSISTANCE 4 1 5 MANUFACTURER S LIABILITY avec i d e A 4 2 0 TECHNICAL INFORMATION 5 2 1 GEAR UNIT DESCRIP TION 2 e utet ipsa tas i aaa odo dala ela tas Duvet Posts 5 2 2 GONEORMITF TO STANDARDS nus tos D P Due habe t ER ee y A aep Ad IDE OE dn 5 2 3 OPERATING LIMITS AND CONDITIONS sss e e e e em e e e nee e e e e rr re e arre 6 3 0 SAFETY INFORMATION 7 S SAFETY STANDARDS sn ear rari pa ia vii aa a a 7 4 0 HANDLING AND TRANSPORT 8 A ON PACKAGING aicea sate een diari 8 Z2 s FANDEINGJINSTRUGTIONS Ze tis ades estet omes ee tb eee m eR Ete ce et eR e eU 9 42 Tks Moving Packages u nieto E lis dude dl se RAiled n ie tabled talon lle route out ee dort uud 9 2 22 Movingihe edulpIriefib oen ee hot naltul ata ala iau pia aie ie a tat 9 AS STORAGE a ee ee een ans ue Mc a oa a ea i ot i ia 10 5 0 INSTALLATION 11 5 1 SINS TALEING THE GEAR UNIT o mrt oe ee nel uk 11 5 1 1 Gear units with solid output shafi nennen
6. For installations in zones 21 and 22 the User must schedule and implement a regular clea ning programme for all surfaces and recesses to avoid build up of dust more than 5 mm in depth Every 1000 h of operation or after 6 months Measure the surface temperature of the coupling between the gear unit and motor at the po ints most shielded from the motor s fan cooling The maximum temperature must not differ AT from the ambient temperature by more than the following values nor may this differential be exceeded during operation A3 C 11 C 61 A 10 A 60 F 10 F 60 VF 44 VF 49 W 63 W 86 W 110 BONFIGLIOLI RIDUTTORI 21 Op 22 A Check the condition of the temperature indicator previously installed on the gear unit during commissioning Example Q6 a6 739 7300 Limit temperature exceeded Limit temperature NOT exceeded Also check that the temperature is not excessive around the gear units bearings Check the oil levels with reference to the tables and diagrams given in Annexes 1 and 2 Check that there are no signs of lubricant leaks near to the gear unit If any anomalies are found identify their cause repair the unit accordingly and top up the lubricant before putting the gear unit back into service Every 3000 h of operation For gear units with torque arm check that the polymer bushings are not aged or damaged If they are at all compromised replace with
7. 100 i 7 10 15 i 30 40 i 20 25 50 60 80 100 7 10 15 i 30 i 20 23 40 46 56 64 80 100 P80 P132 xix 15 20 xi x 100 Life time lubricated gear units Life time lubricated gear units only in combination with ATEX variants Lubricant is not factory filled Single stage helical gear units series S A16 Life time lubricated gear units Lubricant is not factory filled BONFIGLIOLI Hi 36 RIDUTTORI ANNEX 3 CUSTOMER S SHAFT Series A F S 15 pra 4 U E A17 UNI 6604 8x7x20 A 8x7x20 A 10x8x20 A 8x7x25 A 12x8x30 A 10x8x30 A 14x9x45 A 12x8x50 A 16x10x55 A 14x9x65 A 20x12x70 A 18x11x80 A 22x14x90 A 20x12x110 A 25x14x120 A 22x14x130 A 28x16x160 A 25x14x190 A A18 BONFIGLIOLI RIDUTTORI 37 Series F 15 A19 gt UNI 6604 8x7x20 A 8x7x20 A 10x8x22 A 8x7x22 A 12x8x30 A 10x8x30 A 14x9x45 A 12x8x45 A 16x10x50 A 14x9x50 A 20x12x70 A 18x11x70 A 22x14x75 A 20x12x75 A 25x14x100 A 22x14x100 A 28x16x110 A 25x14x110 A
8. 7 ZY yp QU A SR N SON SSR N N N BOO ER ESA N HA OER 5 1 2 Gear units with hollow output shaft To facilitate mounting hollow shaft gear units onto the machine s driven shaft proceed as indicated in the diagram below Also refer to Annex 3 of this Manual for dimension information on customer s shaft RS AS NN The bolt 1 and spacer 2 are to be supplied by customer BONFIGLIOLI a 14 RIDUTTORI 5 1 3 Gear units with shrink disk Series A and F gear units may be specified with a shrink disk for coupling onto the driven shaft When instal ling a unit of this type proceed as follows 1 Loosen the locking bolts gradually and in sequence and remove the entire shrink disk 2 Clean and carefully degrease the coupling surface between the gear unit s output shaft and the customer shaft Do not use molybdenum bisulphide or any other grease which would affect the friction coeffi cient ofthe coupling surfaces and reduce the performance of the shrink disk 3 Fitthe gear unit onto the machine sliding its output shaft onto the driven shaft 4 Fitthe shrink disk to the gear unit shaft 5 Fully tighten down the shrink disk bolts gradually following a circular sequence using a torque wrench This operation usually must be repeated several times to reach the tightening torque Mt specified in the table below A2
9. R Corrected oil quantities for gear units VF 150 We reserve the right to implement modifications without notice This catalogue cannot be reproduced even partially without prior consent BONFIGLIOLI 50 RIDUTTORI AUSTRALIA BONFIGLIOLI TRANSMISSION Aust Pty Ltd 48 50 Adderley St East Auburn Sydney N S W 2144 Tel 61 2 8748 4400 Fax 61 2 9748 8740 Po Box 6705 Silverwater NSW 1811 www bonfiglioli com au bta1 bonfiglioli com au AUSTRIA BEST MOLL MOTOR GmbH Industriestrasse 8 2000 Stockerau Tel 43 2266 63421 DW Fax 43 6342 180 Tlx 61 32 22 348 Molla www mollmotor at office mollmotor at BELGIUM BEST N V ESCO TRANSMISSION S A Culliganlaan 3 1831 Machelem Diegem Tel 0032 2 7204880 Fax 0032 2 7212827 Tlx 21930 Escopo B www escotrans be info escotrans be BRASIL BEST ATI BRASIL Rua Omlio Monteiro Soares 260 Vila Fanny 81030 000 Tel 41 334 2091 Fax 41 332 8669 www atibrasil com br vendas atibrasil com br CANADA BONFIGLIOLI CANADA INC 2 7941 Jane Street Concord ONTARIO LAK 4L6 Tel 1 905 7384466 Fax 1 905 7389833 www bonfigliolicanada com sales bonfigliolicanada com CHINA BONFIGLIOLI DRIVES SHANGHAI CO LTD No 8 Building Area C1 318 SuHong Road Qingpu Shanghai 201700 Tel 86 21 69225500 Fax 86 21 69225511 www bonfiglioli cn linkn bonfiglioli com FRANCE BONFIGLIOLI TRANSMISSIONS S A 14 Rue Eug ne Pottier BP 19 Zone Industriel
10. STANDARDS Carefully read the instructions given in this manual and those posted directly on the gear unit especially those regarding safety Persons charged with working on the gear unit at any time in its service life must be trained specifically for the purpose with special abilities and experience in this area as well as being equipped with the appropria te tools and individual safety equipment as per Legislative Decree 626 94 Failure to meet these require ments constitutes a risk to personal health and safety Use the gear unit only for the applications envisaged by the Manufacturer Improper use can result in risks to personal health and safety and economic damages The applications defined by the Manufacturer are those industrial applications for which the gear unit has been developed Keep the gear unit at its maximum efficiency by following the routine maintenance schedule Good mainte nance enables the unit to operate at maximum performance over a long service life in compliance with sa fety 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 the provisions of law on health and safety at work All maintenance inspection and repairs must only be done by an expert maintenance technician fully fami liar with the attendant hazards It is therefore essential to implement operating procedu
11. a torque arm make sure that during operation the metal parts which move relative to each other do not come into contact If necessary insert non me tal anti friction elements in compliance with Directive 94 9 EC Do not connect any object with electrical resistance greater than 10 O to the product Install guards to prevent the hazardous accumulation of dust and liquids on the seals of the so lid shafts and to protect them mechanically In case of installation of the gearmotor in a vertically downward orientation the electric motor must be equipped with a drip cover The output shaft and any pulleys or other transmission components must be perfectly aligned Only install the gear unit in the motor execution and mounting position specified on the order Shaft mounted gear units can be installed with a tolerance relative to the theoretical plane of installation of 5 If the gear unit is supplied without lubricant it must be installed as such and only filled with lu bricant thereafter Secure the gear unit to a flat vibration free surface capable of bearing the torsional stresses it produces in operation Make sure not to deform the contact surfaces mounting feet and or flanges by overtightening the bolts Use bolts of quality no lower than 8 8 for mounting the gear unit and for heavy duty installa tions use 10 9 bolts For the tightening torque refer to table AO To prevent bolts from unscre wing apply a thin film of Loctite 510 or equi
12. and environmental safety BONFIGLIOLI i RIDUTTORI 1 2 EQUIPMENT IDENTIFICATION The gear unit bears the following nameplate The nameplate bears all references and indispensable safety instructions The gear unit s identifying code is explained in the Sales Catalogue If the gear unit is supplied complete with electric motor gearmotor all information regarding the motor itself is supplied in the motor manual Nameplate data Gear unit type Product code Month Year of manufacture Mounting position BONFIGLIOLI RIDUTTORI S p A ITALY Gear ratio Nameplate for ATEX specified gear units Gear unit type Gear ratio Product code Ml JO Transmissible torque at n 1400 rpm Nn cO MELO Im our O B O CE Mounting position OS MIO min ECO Month Year of manufacture 9 26 ck il 2D ck fc Maximum drive speed E BONFIGLIOLI LIPPO DI silita Certification Nr Temperature class or maximum surface temperature Maximum surface temperature CE txMark e Environmental limits ambient temperature range between 20 C and 40 C e Maximum surface temperature temperature class T4 for 2G and 130 C for 2D Some types of gear unit shown in the catalogue are exceptions to this rule and are marked temperature class T3 for 2G or 160 C for 2G and 2D e Certifying agency with whom the technical file has been deposited Readability of the nameplate The nameplate and the
13. grounded as per standard EN 50014 The motor power supply corresponds to that prescribed and is within 5 of the rated value The oil level is as prescribed and that there are no leaks from the caps or gaskets The unit does not run noisily or with excessive vibration Before starting up the unit check and ensure that Assembly is not carried out in a potentially explosive atmosphere oil acid gas vapour or ra diation and that there is no dust deposits thicker than 5 mm on the gear unit During service the gear unit is sufficiently ventilated and that it is not subject to radiation from external heat sources During service the cooling air does not exceed 40 C The oil level drain and vent plugs are all easily accessible All accessories of any type mounted onto the gear unit are ATEX compliant Gear units with hollow shafts with or without shrink disk have been correctly mounted The gear unit is thoroughly cleaned after installation All guards installed to prevent accidental contact between operators and the gear units moving parts or seals are effective BONFIGLIOLI a RIDUTTORI 17 OD LA Measuring the gear unit s surface temperature The gear units maximum surface temperature depends on the motor speed gear ratio and motor execution and must never exceed 130 C 160 C if so specified on the nameplate The nameplate specifications regarding the maximum surface temperature refer to m
14. instructions are aimed at ensuring efficient and safe operation of the gear unit The Manufacturer declines all liability for injury and damage to components due to the use of non original spa re parts and non routine work which modifies the safety requirements without the express prior authorisation of the Manufacturer Refer to the specific spare parts catalogue when ordering spare parts for the gear unit Do not dump polluting liquids worn parts and maintenance waste into the environment Di spose of all such materials as stipulated by applicable legislation Observe the routine inspection and maintenance schedule to ensure suitable operating condi tions and the effective explosion protection of the unit Always apply fresh Loctite 510 paste or equivalent product with similar properties and applica tion range to all disassembled threads Before servicing or repairing internal components allow the gear unit to cool down completely before opening the casing so as to avoid burns from parts which are still hot Make sure on completion of maintenance work that all safety measures and equipment have been applied and reset Clean the gear unit thoroughly after maintenance work and repairs On completion of maintenance work tighten all vent filler and level plugs to their specified tor que table AO On completion of any maintenance work all seals must be refitted and sealed as prescribed On gear units with double seal rings t
15. nenne nennen 14 5 1 2 Gear units With hellow euiput shafi s eek ae a tz b o E 14 5 15 Gear units With SMH disk x ooo tate ee Ro oerte Era ee e eod Yee 2009 ea o NEA i 15 51 4 s Shall mounted gear Unis Senes F sro 15 5 2 INSTALLING AN IEC STANDARD FLANGED MOTOR 16 6 0 TESTING THE GEAR UNIT 17 7 0 USING THE EQUIPMENT 19 8 0 MAINTENANCE 20 8 1 ROUTINE MAINTE NA NCE court ta ee ec inc ae lie n 21 8 22 LUBRICANTS te an een et anne E a ee a Sees cen ot 23 Oo Ol CHANGE RENE a aie ee ee aaa ba de SAIL iaia ses 23 8 4 RECOMMENDED PERIVITTED OILS ar e ten aaa see 24 8 5 CHECKING EFFICIENCY ose srta et tee E Ri dida een 26 BC ERAI IOS e ctre aa iat tn Ne SR a dt Re ee EN 26 ea EA S uzata r ul z een rent een asa pad a he E a tt a ut a d at atita aaa ita 26 9 0 REPLACING PARTS 27 9 1 TAKING APART OF THE IEC STANDARD FLANGED MOTOR 27 9 2 SCRAPPING THE GEAR UNIT ae 27 10 0 TROUBLESHOOTING 28 ANNEX 1 CHECKING OIL LEVEL ON ATEX SPECIFIED GEAR UNITS 29 ANNEX 2 LUBRICANT CHARGE QUANTITY 32 Helical in line gear units series C nb hee ne eh e e en en en tnt e enis 32 Bevel helical gearunits senesA ucraini 33 Shaftemounted gear units Series Fun ec ae re se herr 34 Wor Gear UniS SEI ES Vers lied aa Gala B ee Salate ern ee 35 Worm Gear units seles VV en see amie ti p a a Po cua BE ai il Ubro NAT Head dunes EIE ORAT Nr ee 36 Single stage helical gear units series S
16. original spare parts Every 5000 h of operation Change the synthetic oil and bearing grease if the gear unit is not life time lubricated Replace all externally accessible seal rings unless this has already been done as a result of problems occurring before the scheduled maintenance deadline Every 5000 h of operation at rated torque The minimum overhaul interval indicated here may increase considerably depending on actual conditions of service see table A5 Overhaul the gear unit unless this has already been done as a result of problems occurring before the specified deadline An overhaul involves the replacement of bearings and or other mechanical components which have worn to such an extent as to compromise the operation of the gear unit AS Interval hours Mn2 nominal torque at output shaft M required torque at output shaft BONFIGLIOLI 2 RIDUTTORI uM IN DI as AT ES agire LATO TOS 8 2 LUBRICANTS Before putting the gear unit into service check the oil level This must be done with the gear unit in the mo unting position in which it will be used in the application If necessary if or top up the lubricant to the filling mark on the level cap which may be transparent or of the spill type Life time lubricated gear units which are not subject to external contamination do not nor mally require periodic lubricant changes Do not mix oils of different nature or spe
17. ring with a cable clamp or similar device so as to prevent them sliding and lift the load Observe all precautions regar ding the handling of loads Stabilise the moving load by hand Observe all precautions regar ding the handling of loads The load must not be allowed to sway or oscillate by more than 15 in any direction when being lifted If the oscillation exceeds this limit stop and repeat the lifting operation as instructed 40 BONFIGLIOLI xk RIDUTTORI lt A gt lt B gt m AAT Maximum permissible tilt during handling 15 gt A A FA fits BL SI El CD OE Da 9 5 5 gt TO Lo Oo 5 VI D D oe o 2 o o ED lo o El g I2 LJ 3 a o a To x DO o _ 2 38 aE 8 39 D ES yo EZ Oe Se 5 Ox ce xc 358 99 Do co 30 Om Cio gt 9 e Ring harness Rope and hooks 7p 7p DN 0 ci co os Os 41 RIDUTTORI BONFIGLIOLI a A10 A60 A70 A90 M P63 P90 A B P100 P112 A A B A B Reccomended solution A for positioning solution B for positioning and handling D Ring harness Screw clamp M Lift manually Maximum permissible tilt during use with harness weight lt 15 kg handlin
18. the yellow service cap on top of the gear unit until it touches the floor of the casing Mark the level of the upper surface of the casing on the dipstick in this po sition 3 Extract the dipstick and measure the distance X shown in diagram S5 above 4 The value X must be less than the value given in table A8 BONFIGLIOLI RIDUTTORI 31 ANNEX 2 LUBRICANT FILL QUANTITY Helical in line gear units series C A9 B3 B6 B7 B8 V5 V6 BS B51 B53 Vi V3 B5 B51 B53 B52 Vi V3 Life time lubricated gear units L Life time lubricated gear units only in combination with ATEX variants Lubricant is not factory filled BONFIGLIOLI 32 tg RIDUTTORI Bevel helical gear units series A see Annex 1 Life time lubricated gear units Med Lubricant is not factory filled BONFIGLIOLI RIDUTTORI O 00 00 O A A aL 13 Io IS lo lo see Annex 1 33 Shaft mounted gear units series F A12 Life time lubricated gear units
19. FIGLIOLI i RIDUTTORI 2 0 TECHNICAL INFORMATION 2 1 GEAR UNIT DESCRIPTION The gear unit has been designed and constructed for integration if required driven by an electric 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 capable of satisfying a range of specific requirements in the mechanical chemical agricultural and food industries etc BONFIGLIOLI RIDUTTORI supplies a range of accessories and optionals to make their products as versatile as possible For further technical information and descriptions refer to the Sales Catalogue The User is responsible for using the products recommended for installation and maintenance of BONFIGLIOLI gear units in an appropriate manner and in accordance with instructions SAFETY SPECIFICATIONS FOR ATEX SPECIFIED GEAR UNITS e use of synthetic lubricants only oil and grease e VITON seal rings thread locker on all external bolts vent caps with anti intrusion valve double oil seals on series C gear units and oil seals with dust traps on all other types components and products operable at above the maximum rated operating temperature no metal moving parts external to the gear unit no plastic parts capable of building up electrostatic charge irreversible temperature indicator supplied along with each unit
20. IDUTTORI 11 Tightening torque Nm 5 10 Bolt size Bolt class Cap vent thread Tightening torque Nm 1 8 5 1 4 7 3 8 7 1 2 14 3 4 14 1 25 5 Charge the gear unit with oil or top it up with reference to the method in which gear units of the type co vered by this manual are filled in the factory The standard charge of synthetic life time lubricant is as fol lows A1 VF 150 Life time lubrication Life time lubrication with ATEX specified unit only BONFIGLIOLI i RIDUTTORI Helical in line gear units C 11 C 21 and C 31 are not equipped with service plugs for direct oil level checks Bevel helical gear units A 10 A 20 and A 30 are not equipped with service plugs for direct oil level checks in mounting positions B6 and B7 only For these types of gear units refer to Annex 1 of this Manual Before installing check the unit as follows 1 Place the gear unit in the mounting position indicated for the gear unit in question in Annex 1 Wait 10 minutes for the oil level to stabilise inside the gear unit s casing 2 Insert a dipstick through the hole shown in drawing S4 or S5 and measure the distance betwe en the oil level and the exterior of the casing This value must be compared with the values in mm given in Annex 1 tables A7 and A8 depending on the mou
21. P 320 Mobil SHC 630 Mobil SHC 632 DTE FM 460 Castrol Alphasyn PG 220 Alphasyn PG 320 Carter SY 220 Carter SY 320 Carter SY 460 Degol GS 220 Degol GS 320 Degol PAS 220 Synlube CLP 220 Synlube CLP 320 G F Ted Renoling PG 220 Renoling PG 320 Grease Food grade BONFIGLIOLI RIDUTTORI BEE Recommended Permitted 25 8 5 CHECKING EFFICIENCY Remove dust deposits from the gear unit and motor casings Check that noise 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 the nominal values given on the motor s nameplate Check the wear of linings on the brake motor if used and if necessary adjust the gap Check for lubricant leaks from the gaskets seals caps and casings Check all bolted couplings for wear deformation or corrosion and tighten them down fully without overtig htening 8 6 CLEANING Clean all dust and process waste off the gear unit Do not use solvents or other products which are incompa tible with the construction material and do not direct high pressure jets of water at the gear unit 8 7 PAINT COATING In the factory the cast iron casing of t
22. W 110L The device is factory calibrated to a slip torque which coincides with the nominal torque Mn n 1400 for the gear unit in question This is achieved as follows The same operations with exclusion of step 2 allow the User to calibrate the li miter to a torque different to that set in the factory 1 The calibration ring nut is screwed in until the disk springs are loaded to the point that they cannot be tur ned freely by hand 2 Acentre punch is used to make two corresponding reference marks at the same angular position on the ring nut and the protruding section of the output shaft This reference position is the starting point from which all further turns of the ring nut are counted and thus the torque calibration is measured 3 The ring nut is now screwed in by the fractions of a turn which correspond to the nominal torque Mn for the gear unit in question The reference in this case is given by the diagram below which is also to be used for any new settings required over time Torque Nm TUT wee ULC sea a III i i TTT vas ia ni TELE DRESSER TTE RT TITTI e TTI TITTI LTT TIE E TTT TTT TTT L E 0 14 1 2 3 4 1 114 112 134 2 21 4 212 234 3 31 4 31 2 33 4 N of ring nut turns i f A i y f i f 1 N LL NI LLL SS Tt p BONFIGLIOLI Hi 48 RIDUTTORI BONFIGLIOLI x RIDUTTORI 49 INDEX OF REVISIONS
23. aft must be protected by a guard BONFIGLIOLI RIDUTTORI 19 LA 8 0 MAINTENANCE Maintenance and replacement work must be done 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 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 be ing accidentally switched on again or its parts moving without warning due to suspended lo ads or similar external factors Furthermore all additional environmental safety precautions must be taken e g elimination of residual gas or dust etc Before doing any maintenance work activate all safety equipment and if necessary inform persons wor king in the vicinity In particular mark 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 Replace worn components with original spare parts only Use the lubricants oil and grease recommended by the Manufacturer When working on the gear unit always replace gaskets and seals with new original ones f a bearing requires replacement it is good practice to also replace the other bearing supporting the same shaft We recommend replacing the lubricating oil after all maintenance work The above
24. al moving parts of the gear unit If the work environment is corrosive for the gear unit or any of its parts take the special precautions re quired for aggressive environments In this case contact the BONFIGLIOLI RIDUTTORI sales service We recommend applying a protective paste to all couplings between the gear unit motor and other parts Kl berpaste 46 MR 401 or equivalent product with similar properties and application range to ensure optimal coupling and protection against fretting corrosion To ensure effective coupling the driven shafts should be machined to the tolerances given in tables A16 A17 A18 A19 A20 and A21 in Annex 3 of this Manual In case of installation outdoors and when fitted with an electric motor protect the latter from direct sun light and the weather by means of guards or a casing Also make sure that the assembly is properly ven tilated Now proceed with the installation as follows 1 2 Th Place the gear unit in the vicinity of the installation area Mount the gear unit and secure it to the structure at the points provided The gear unit should be secured to the structure through all mounting points on the mount specified feet or flange Locate the closed plug used for transportation usually red and replace it with the vented plug provided Tighten down the mounting bolts and check that the oil plugs are screwed down to the torque given in ta ble AO BONFIGLIOLI R
25. cifications and check that the oil is highly resistant to foaming and is EP rated If the same type of oil as that already in use is not available drain the gear unit completely and flush its inte rior thoroughly with a light solvent before refilling with a new lubricant 8 3 OIL CHANGE 1 Place an adequate container under the drain plug 2 Remove the filler and drain plugs and allow the oil to drain out AN The oil will drain better if it is warm 3 Wait for a few minutes until all the oil has drained out then screw the drain plug back on with a new ga sket 4 Fill the gear unit with the new oil in its actual mounting position to the centre of the level plug 5 Tighten down the filler plug after fitting a new gasket The gear unit may be supplied with or without lubricant as specified by the User The quan AN tity of oil to be filled is specified in the Sales Catalogue This specification is however appro ximate and reference must always be made to the centre of the level plug the placement of which depends on the mounting position specified in the 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 can be fatal if swallowed Handle them with care using suitable individual safety equipment Do not dump into the environment and dispose of in compliance with applicable legislation If a lea
26. d 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 applicable environmental protection legi slation N Do not attempt to 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 for use BONFIGLIOLI RIDUTTORI 27 10 0 TROUBLESHOOTING The following information is intended to serve as an aid in identifying and correcting defects and faults In some cases such problems may be caused by the plant or machine onto which the gear unit is assembled and hence the cause and eventual solution can be found in the Manufacturer s technical documentation for the machine plant in question PROBLEM Bearing temperature too high CAUSE Oil level too low SOLUTION Top up oil level Oil too old Replace oil Defective bearings Contact authorised workshop Operating temperature too high Abnormal running noise Oil level too high Oil too old Check oil level Replace oil Impurities in oil Gears damaged Replace oil Contact authorised workshop Bearing axial backlash too high Contact authorised workshop Bearings defective or worn Contact authorised workshop Service load too high Correct
27. easure ments made in normal ambient and installation conditions Even minimal variations to said conditions e g smaller mounting cabinet could have a significant impact on the build up of heat When commissioning the gear unit the surface temperature must be measured in the same operating conditions as for the final application The surface temperature must be measured at the coupling between the gear unit and motor and at the points which are most shielded from the motor s fan cooling S2 Temperatura IMPORTANT The maximum surface temperature is reached after 3 hours operation at full load The temperature measured in these conditions must not differ AT from the ambient tempe rature by more than the following values A3 C 11 C 61 A 10 A 60 F 10 F 60 VF 44 VF 49 W 63 W 86 W 110 Should the temperature differential exceed these values stop the gear unit at once and contact the BONFIGLIOLI RIDUTTORI technical service If the temperature differential is within the above values wait for the gear unit to cool down and then install the temperature indicator supplied with the gear unit at the point of maximum tem perature Example A 988 7399 Atthe same time check for excessive running noise and vibration BONFIGLIOLI 3 RIDUTTORI Provided all the above checks have been passed and that all other instructions in this manual have been strictly observed an e
28. esales bonfiglioliusa com VENEZUELA BEST MAQUINARIA Y ACCESSORIOS IND C A Calle 3B Edif Comindu Planta Baja Local B La Urbina Caracas 1070 Tel 0058 212 2413570 2425268 2418263 Fax 0058 212 2424552 Tlx 24780 Maica V www maica ve com maica telcel net ve HEADQUARTERS BONFIGLIOLI RIDUTTORI S p A Via Giovanni XXIII 7 A 40012 Lippo di Calderara di Reno Bologna ITALY Tel 39 051 6473111 Fax 39 051 6473126 www bonfiglioli com bonfiglioli bonfiglioli com SPARE PARTS BONFIGLIOLI B R T Via Castagnini 2 4 Z Bargellino 40012 Calderara di Reno Bologna ITALY Tel 39 051 727844 Fax 39 051 727066 www brtbonfiglioliricambi it brt bonfiglioli com INDUSTRY PROCESS AND AUTOMATION SOLUTIONS www bonfiglioli com GS BONFIGLIOLI COD 1261 R3
29. for installations in zones 21 and 22 the User must schedule and implement a regular cleaning programme of all surfaces and recesses to avoid a build up of dust of more than 5 mm in depth to prevent dust build ups in difficult to access areas the units are equipped with a variety of se als in proximity to the couplings of moving parts mounting flanges and external threaded holes 2 2 CONFORMITY TO STANDARDS All gear units or gearmotors when supplied complete with electric motor are designed in compliance with the provisions of all applicable Essential Health and Safety Requirements Machinery Directive 98 37 EC and if requested can be supplied complete with Manufacturer s Declaration Annex IIB as provided by said directive The electric motors of all BONFIGLIOLI RIDUTTORI gearmotors conform to the provisions of Low Voltage Directive 73 23 EEC and Electromagnetic Compatibility Directive 89 336 EEC Furthermore if specified for use in potentially explosive atmospheres the gear units are desi gned and constructed to conform with the Essential Health and Safety Requirements EHSR of Annex Il of ATEX Directive 94 9 EC and conform to the following classification Equipment group Il Calass Gas 2G Dust 2D Zone Gas 1 Dust 21 Maximum surface temperature temperature class T4 for 2G and 130 C for 2D Some types of gear units given in the catalogue are exceptions to this rule and are marked temperature class T3 for 2G
30. g 15 o 7 Lp 2 Rope and hooks ui A Lift as per diagram A x 04 ay ndi d ACEA Y S a a Eyebolt B Lift as per diagram B L Hor AT 42 BONFIGLIOLI x RIDUTTORI M P63 P90 A B P100 P112 Reccomended solution A for positioning solution B for positioning and handling D Ring harness M Lift manually Maximum permissible tilt during Screw clamp weight lt 15 kg handling 15 use with harness T D 2 Rope and hooks x o4 er Lift as per diagram A YEN ua Open harness use with rope oi AF yo with eyelets B Lift as per diagram B BONFIGLIOLI RIDUTTORI 43 Reccomended solution A for positioning Maximum permissible tilt during M Lift manually handling 15 weight lt 15 kg 1 Ring harness A Lift as per diagram A 44 BONFIGLIOLI x RIDUTTORI UM MN N n j E zucm zm Fes j 3 ete 3 er mS al 3 e 9 E a ete J Q O xa Y ja EN E 3 EREI Eal ZERO Da 3 e o e a 9 Neta Neta gr pr WR 63 WR 75 WR 86 WR 110 Reccomended solution A for positioning solution B for positioning and handling 1 Ring harness Screw clamp M Lift manually Maximum permissible t
31. he cavity between the two rings must be packed with synthetic grease Fluorocarbon gel 880 ITP or equivalent product with similar properties and application range before assembly Regardless of the type of gear unit whenever a seal ring is replaced its lips should be smea red with a thin layer of grease Fluorocarbon gel 880 ITP or equivalent product with similar pro perties and application range before assembly Use only original spare parts for repairs BONFIGLIOLI a 20 RIDUTTORI e a e a AA 08 Mu T SS 8 1 ROUTINE MAINTENANCE Keep the gear unit at its maximum efficiency by following the routine maintenance schedule specified by the Manufacturer Good maintenance enables the unit to operate at its maximum performance over a long servi ce life in compliance with safety regulations Frequency Component Type of work Operation Check oil level Maintain or replace compo External seals and gaskets Check for leaks by eye nents as required For gear units with torque arm polymer bushings Replace if no longer fully Check for cracks ageing ee iva Inspect carefully for wear age Gear unit seals and gaskets ing of external seals Replace if aged worn Depending on the temperature reached by the lubricant it should be replaced at the intervals indica ted in table A4 below A4 Oil temperature Hours t C t lt 65 25000 65 lt t lt 80 15000 80 lt t lt 95 12500
32. he gear unit is magnetised and sprayed with polyester heat setting re sin which is then baked on Aluminium casings are not paint coated Table A6 shows in colour the types and gear frame sizes of gear units which are generally painted A6 VF 44 VF 49 If the gear unit is to be painted tape the nameplate and seal rings to prevent contact with solvent BONFIGLIOLI a 26 RIDUTTORI 9 0 REPLACING PARTS Do not hesitate to replace parts and or components if they are not able to guarantee safe and re liable operation N Never improvise repairs The use of non original spare parts not only voids the warranty but can compromise gear unit operation 9 1 TAKING APART OF THE IEC STANDARD FLANGED MOTOR If during operation the coupling area of the motor and gear unit has not rusted significantly it should be possi ble to remove the motor without applying excessive force If on the other hand it proves difficult to remove the motor do not use screwdrivers or levers to apply force as this can damage the flanges and coupling surfaces but proceed as indicated below S3 IMPACT EXTRACTOR Drill and thread the motor shaft fan side Screw an impact extractor tool into the tap Undo the screws fixing the motor to the gear unit Remove the motor by means of the inertial force of the extractor 9 2 SCRAPPING THE GEAR UNIT This must only be done by operators traine
33. he oil level must therefore be checked not as described above but via a hole provided for the purpose in the manner described hereafter BONFIGLIOLI a RIDUTTORI 29 30 LA Helical in line gear units C 11 C 21 C 31 S4 C 112 P63 P71 C 112 P80 P112 C212 P63 P71 HS C212 P80 P112 C 21 3_ P63 P71 C 21 3_ P80 P112 C 31 2_ P63 P112 HS C 31 3_ P63 P112 Values in the table are given in mm To check the oil level proceed as follows 1 Place the gear unit in the mounting position as shown in diagram S4 2 Insert a dipstick through the yellow service cap on top of the gear unit until it touches the floor of the casing Mark the level of the upper surface of the casing on the dipstick in this po sition 3 Extract the dipstick and measure the distance X shown in diagram S4 above 4 The value X must be less than the value given in table A7 BONFIGLIOLI 2 RIDUTTORI a Bevel helical gear units A 10 A 20 and A 30 Mounting positions B6 and B7 N S5 gt A8 A10 P63 P112 A 20_ P63 P112 HS A30 P63 P112 HS Values in the table are given in mm To check the oil level proceed as follows 1 Place the gear unit in the mounting position as shown in diagram S5 2 Insert a dipstick through
34. he pinion 1 should be snug against the bushing 2 5 Lock the assembly with the spacer 4 and washer 5 by tightening down the bolt 6 or for configura tions which have this option fit the stop bushing B1 and tighten down the two grub screws 7 while hol ding it snug against the pinion 1 see figure on the right 6 Lubricate the seal ring lips with a film of grease 7 For type VFR 49 units which are lubricated for life and hence do not have a service plug fill with the quantity of lubricant specified in the corresponding chapter of the catalogue dealing with lubrication of VFR units 8 Hold the motor firmly and holding it in alignment mount it to the flange of the additional helical reduction casing Take the greatest care to avoid denting the pinion or gear wheel teeth 9 With the motor and gear unit flanges in contact fully tighten down the mounting bolts 8 gradually and in a cross wise pattern 10 For units VER 110 to VFR 250 the lubricant must be changed periodically The lubricant charge fil for these gear units is given in the VF catalogue Check that the correct level has been reached via the sight glass with the gear unit in its specified mounting position Top up as ne cessary BONFIGLIOLI RIDUTTORI 47 ANNEX 6 CALIBRATING THE TORQUE LIMITER SLIP TORQUE The torque limiter is an optional device available for worm gear units of the following types VF 44L VF 49L W 63L W 75L W 86L and
35. ilt during use with harness weight lt 15 kg handling 15 Rope and hooks Snap hook i 9 e pl Eyebolt B Lift as per diagram B BONFIGLIOLI RIDUTTORI 45 VFR 44 VFR 49 VFR 130 VFR 150 VFR 185 VFR 210 VFR 250 Reccomended solution A for positioning solution B for positioning and handling Ring harness Screw clamp Lift manually om use with harness M weight lt 15 kg Rope and hooks Snap hook l en sS s rope A Lift as per diagram A 8 Open harness O Eyebolt already fitted l with eyelets to gear units VF130 VF250 B Lift as per diagram B Maximum permissible tilt during handling 15 46 BONFIGLIOLI i RIDUTTORI 1 Thoroughly clean and degrease the motor shaft and pinion 1 and bushing 2 coupling surfaces 2 Check the motor shaft tolerance meets the following specifications Shaft diameter mm Tolerance 11 28 i6 38 48 k6 3 Preheat the bushing 2 and pinion 1 to 80 100 C 4 Quickly fit the bushing 2 key 3 and pinion 1 in succession to the motor shaft When fitting the bushing 2 ensure that the chamfered side is facing the operator To facilitate mounting lightly press on the parts being fitted e g with a tubular drift Make sure that the reaction force in this case is supported at the opposite end of the shaft and not by the fan cover After this procedure t
36. information thereon must be readable at all times and consequently cleaned from time to time Should the nameplate wear and or become damaged so as to affect its readability or that of even one of the items of information thereon the User must request a new nameplate from the Manufacturer quoting the in formation given in this manual and replace the old one BONFIGLIOLI a RIDUTTORI 3 1 3 GLOSSARY AND TERMINOLOGY Some of the frequently occurring terms used in this manual are described below so as to unequivocally defi ne their meaning Routine maintenance the 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 requi red and tasks in question Non routine maintenance the set of operations required for maintaining the functionality and efficiency of the gear unit These operations are not scheduled by the Manufacturer and must be done by an expert main tenance technician Expert maintenance technician an authorised technician selected by means of having the qualifications skills and mechanical and electrical training to do repairs and non routine maintenance work on the gear unit Overhaul an overhaul consists in the replacement of bearings and or other mechanical components which have worn to such an extent as to compromise the operation of the gear unit The overhaul also includes ve
37. is safety and that of all other persons involved 4 2 1 Moving 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 used e g crane or lift truck must have 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 Har ness heavy packages with chains belts and steel ropes after checking that they are capable of sustaining the weight of the load which is generally specified When handling the load keep it level to avoid instability and or tipping 4 2 2 Moving the equipment All the following operations must be done with due care and caution and without sudden mo vements Identify the attachment points for lifting the gear unit Refer to Annex 4 of this manual for this information Prepare the gear unit for lifting by attaching straps hooks shackles etc to its attachment points or alternati vely use a pallet for moving the load If using a crane first lift the gear unit vertically out of its packaging If using a lift truck or pallet truck remove the packaging and fit the truck s forks at the indicated positions First lift the load very slowly to check that it is stable Move the gear unit to the unloading area and lower it gently into position taking care
38. k is found identify the cause of the fault repair it and refill with lubricant before opera ting the gear unit BONFIGLIOLI RIDUTTORI 23 8 4 RECOMMENDED PERMITTED OILS OILS AND GREASES COMPATIBLE with Atex certified gear units Greases e Kl ber Asonic GHY 72 e Shell TVX Compound B for bearings e Shell Tivela GL 00 alternative for greased gear trains for greased gear trains e Kl berpaste 46 MR 401 e ITP Fluorocarbon gel 880 to facilitate coupling of cylindrical parts for greasing contact seals Oils as alternatives to Shell Tivela Oil S 320 Shell Tivela Oil SC320 Aral Degol GS 320 IP Telium Oil VSF 320 o Agip Kluber Klubersynth GH 6 320 Total Carter SY 320 Mobil Glygoyle HE 320 BONFIGLIOLI a 24 RIDUTTORI Tivela S 220 Tivela S 320 Tivela S 460 0 25 0 5 Donax TX Shell Donax TA Cassida Fluid WG 460 Cassida Fluid HF 46 TVX Compound B Telium VSF 220 Telium VSF 320 Spartan EP 220 Spartan EP 320 HLUBER LUBRICATION Klubersynth GH 6 220 Klubersynth GH 6 320 Kl bersynth UH1 6 460 Mobil Glygoyle HE 320 Glygoyle HE 460 Mobilgear SHC XMP 220 Mobilgear SHC XM
39. le de Moimont Il 95670 Marly la Ville Tel 33 1 34474510 Fax 33 1 34688800 www bonfiglioli fr btf bonfiglioli fr GERMANY BONFIGLIOLI GETRIEBE GmbH Hamburger StraBe 18 41540 Dormagen Tel 49 2133 50260 Fax 49 2133 502610 www bonfiglioli de bonfiglioli getriebe bonfiglioli de VECTRON Elektronik GmbH Europark Fichtenhain A 6 47807 Krefeld Tel 49 2151 83960 Fax 49 2151 839699 www vectron net info vectron net GREAT BRITAIN BONFIGLIOLI UK Ltd Unit 3 Colemeadow Road North Moons Moat Redditch Worcestershire B98 9PB Tel 44 1527 65022 Fax 44 1527 61995 www bonfiglioli co uk marwaha bonfiglioli com GREECE BONFIGLIOLI HELLAS S A O T 48A T O 230 C P 570 22 Industrial Area Thessaloniki Tel 4 30 2310 796456 Fax 4 30 2310 795903 www bonfiglioli gr sales bonfiglioli gr HOLLAND BEST ELSTO AANDRIJFTECHNIEK Loosterweg 7 2215 TL Voorhout Tel 31 252 219 123 Fax 31 252 231 660 www elsto nl imfo elsto nl INDUSTRY PROCESS AND AUTOMATION SOLUTIONS Worldwide Bonfiglioli Worldwide amp BEST Partners HUNGARY BEST AGISYS AGITATORS amp TRANSMISSIONS Ltd 2045 T r kb lint T u 2 Hungary Tel 36 23 50 11 50 Fax 36 23 50 11 59 www agisys hu info agisys com INDIA BONFIGLIOLI TRANSMISSIONS PVT Ltd PLOT AC7 AC11 Sidco Industrial Estate Thirumudivakkam Chennai 600 044 Tel 91 0 44 24781035 24781036 24781037 Fax 91 0 44 24780091 24781904 www b
40. lectric motor with ATEX rating equal or greater than that of the gear unit may be installed thus forming a gearmotor which itself com plies with the provisions of Directive 94 9 EC If on the other hand the installation of the motor to the gear unit requires actions other than those prescribed in this Manual and or one or more of the manual s prescriptions has not been satisfied the User shall be responsible for analysing the risks attendant on this particular motor gear unit combination The risk analysis is in any case manda tory if the motor is driven through an inverter Only in this way and subject to certification by the assembler shall the assembly in cluding the gear unit itself be compliant with the requirements of Directive 94 9 EC 7 0 USING THE EQUIPMENT 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 gear unit may not be used in areas and environments AN with highly corrosive and or abrasive vapours smoke or dust e in direct contact with loose food products Danger zones and exposed persons The danger zone of the gear unit is the protrusion of the shaft which constitutes a hazard for exposed persons in direct contact with it crushing cutting trapping In particular when the gear unit is ope rating in automatic mode and in an accessible area the sh
41. nments which are under cover and not humid The material can be stored in suitable conditions for a period of two years under cover at a temperature bet ween 15 C and 50 C ata 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 Wooden crate for miscellaneous products shipped by sea Carton pallet packaging for single products and kits Horizontal packaging Vertical packaging and that it is not damaged or faulty in any way Refer any nonconformity to your BONFIGLIOLI On receipt of the gear unit check that the delivery item corresponds to the purchase order RIDUTTORI dealer Dispose of packaging materials as laid down by the provisions of law BONFIGLIOLI x RIDUTTORI uM IN DI as AT ES agire LATO TOS 4 2 HANDLING INSTRUCTIONS Handle packages as per the Manufacturer s instructions and those marked on the packages themselves Since the weight and shape of 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 safeguard his safety and that of all other persons involved The person authorised to handle the product must take all necessary precautions to safe guard h
42. not to cause sudden oscillations while moving it If the gear unit is coupled to an electric motor do not use the eyebolts on the motor for lifting the entire load unless this is expressly indicated BONFIGLIOLI Hi RIDUTTORI 9 4 3 STORAGE Some recommendations for storing the gear unit are indicated below 1 Do notstore the unit in excessively humid conditions or where it is exposed to the weather do not store outdoors Do not place the gear unit directly on the ground 3 Place the gear unit on a stable base and make sure that it is not subjected to accidental displacement 4 Store the packaged gear unit if allowed in accordance with the instructions on the packaging itself If the gear unit is stored for more than 6 months the following additional precautions must be taken 5 Cover all machined external surfaces with a rustproofing product such as Shell Ensis or equivalent pro duct with similar properties and application range 6 Fill the unit with lubricating oll SAFETY PRECAUTIONS to be taken when returning the gear unit to service after storage The output shafts and external surfaces must be thoroughly cleaned of all rustproofing product contaminants and other impurities use a standard commercial solvent Do this outside any explosion hazard area The solvent must not touch the seal rings as this can damage them and render them ineffective If the oil or protective material used during storage is no
43. nting position for the gear unit in question 3 If the measurement gives a higher value than that prescribed top up the oil to the correct level as indicated in the catalogue For all other types of gear unit the oil level must be checked via the oil plug spill type using the tool out of scope for supply described in Annex 1 For the first charge and subsequent top ups only use the recommended oils Installation of gear units classified under Directive 94 9 EC e Category 2D gear units must be installed in compliance with the provisions of standards EN 1127 1 and EN 50281 1 2 The installer must therefore be fully informed and trained for this application The installation technician must be aware of the ATEX class of the installation area as well as the risks associated with the presence of a potentially explosive atmosphere with particular at tention to explosion and fire hazards and thereby adopt the necessary safety precautions All maintenance assembly and disassembly work must be done outside the explosion ha zard area by trained personnel Check that all accessory components cables joints cable glands cooling units etc comply with the Essential Health and Safety Requirements of the ATEX directives Handle them with extreme care to avoid altering their characteristics Remove the bolts sealing the threaded holes if provided for securing the gear unit Do not da mage the coupling surfaces When assembling gear units with
44. onfiglioli co in bonfig vsnl com NEW ZEALAND BEST SAECO BEARINGS TRANSMISSION 36 Hastie Avenue Mangere Po Box 22256 Otahuhu Auckland Tel 64 9 634 7540 Fax 64 9 634 7552 mark saeco co nz POLAND BEST POLPACK Sp z 0 0 Ul Chrobrego 135 137 87100 Torun Tel 0048 56 6559235 6559236 Fax 0048 56 6559238 www polpack com pl polpack polpack com pl RUSSIA BEST FAM 57 Maly prospekt V O 199048 St Petersburg Tel 7 812 3319333 Fax 7 812 3271454 www fam drive ru fam nm ru SPAIN TECNOTRANS SABRE S A Pol Ind Zona Franca sector C calle F n 6 08040 Barcelona Tel 34 93 4478400 Fax 34 93 3360402 www tecnotrans com tecnotrans tecnotrans com SOUTH AFRICA BONFIGLIOLI POWER TRANSMISSION Pty Ltd 55 Galaxy Avenue Linbro Business Park Sandton Tel 27 11 608 2030 OR Fax 27 11 608 2631 www bonfiglioli co za bonfigsales bonfiglioli co za SWEDEN BONFIGLIOLI SKANDINAVIEN AB Kontorsgatan 234 34 Lomma Tel 46 40 412545 Fax 46 40 414508 www bonfiglioli se info bonfiglioli se THAILAND BEST K P T MACHINERY 1993 CO LTD 259 83 Soi Phiboonves Sukhumvit 71 Rd Phrakanong nur Wattana Bangkok 10110 Tel 0066 2 3913030 7111998 Fax 0066 2 7112852 3811308 3814905 www kpt group com sales kpt group com USA BONFIGLIOLI USA INC 1000 Worldwide Boulevard Hebron KY 41048 Tel 1 859 334 3333 Fax 1 859 334 8888 www bonfiglioliusa com industrialsales bonfiglioliusa com mobil
45. or 160 C for 2G and 2D BONFIGLIOLI E RIDUTTORI 5 Modification of the gearbox configuration or mounting position is only permitted if previously aut horised by the BONFIGLIOLI RIDUTTORI technical service Failure to obtain said authorisation voids the ATEX certification Ambient conditions Ambient temperature min 20 C max 40 C Do notuse the gear unit if not explicitly intended for the purpose in a potentially explosive atmosphere or where the use of explosion proof equipment is specified The nameplate data on the maximum surface temperature refer to measurements made in nor mal ambient and installation conditions Even minimal variations to said conditions e g smaller mounting cabinet could have a significant impact on the build up of heat Lighting If the unit is to be serviced in a poorly lit area use additional lamps and ensure that the work is done in compliance with applicable safety legislation Noise Vibration 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 vibrations produced by the gear unit do not constitute a health risk for personnel Excessive vibration may be the result of a fault and should be immediately reported and eliminated BONFIGLIOLI sE RIDUTTORI 3 0 SAFETY INFORMATION 3 1 SAFETY
46. res which address potential hazards and their prevention for the entire machine The expert maintenance technician must al ways work with extreme caution in full compliance with applicable safety standards If the gear unit is to be serviced in a potentially explosive atmosphere the operator must first switch off power to the gear unit and ensure that it is out of service as well as taking all neces sary precautions against it being accidentally switched on again or its parts moving without war ning Furthermore all additional environmental safety precautions must be taken e g elimination of residual gas or dust etc During operation wear only the apparel and safety equipment indicated in the User instructions provided by the Manufacturer or laid down by applicable laws on safety at work Replace worn components with original spare parts 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 appli cable legislation After replacing lubricants clean the gear unit s surfaces and the walk on surfaces around the work area BONFIGLIOLI a RIDUTTORI T i al en EN ici pio c A a TON lt TT 4 0 HANDLING AND TRANSPORT 4 1 PACKAGING The standard packaging when supplied and unless otherwise agreed is not proofed against rainfall and is intended for shipping by ground and not sea and for enviro
47. rification of the condition of all gear unit components keys seals gaskets vents etc If any such compo nents are damaged they must be replaced and the reason for the damage identified 1 4 REQUESTING TECHNICAL ASSISTANCE For any technical service needs contact the Manufacturer s sales network quoting the information on the units nameplate the approximate hours of service and the type of defect 1 5 MANUFACTURER S LIABILITY The Manufacturer declines all liability for cases of use of the gear unit in violation of local laws on safety and accident prevention at work incorrect installation disregard or incorrect application of the instructions provided in this manual incorrect or defective power supply gearmotors modifications or tampering work done on the unit by unqualified or unsuitable persons The 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 maintenance schedule only authorise trained operators to inspect and service the unit use only original spare parts the configurations given in the gear unit catalogue are the only ones permitted N do not attempt to use the unit contrary to the instructions supplied e the instructions given in this manual do not substitute but summarise the provisions of applicable safety legislation BON
48. service load to nominal values given in Sales Catalogue Impurities in oil Replace oil Abnormal noise at gear unit mounting Mounting bolts loose Tighten down to specified torque Mounting bolts worn Replace bolts Oil leaks Oil level too high Check oil level Casing coupling seals inadequate Contact authorised workshop Gaskets worn Contact authorised workshop Gear unit does not run or runs with difficulty Oil viscosity too high Replace oil see table of recom mended lubricants Oil level too high Check oil level Service load too high Redesign drive for actual service load Output shaft does not turn with motor running 28 Gears damaged Contact authorised workshop BONFIGLIOLI i RIDUTTORI ANNEX 1 CHECKING OIL LEVEL ON ATEX SPECIFIED GEAR UNITS Gear units are normally supplied with a yellow oil level plug of the spill type To check the oil level first identify the yellow level plug Remove the plug and insert a bar of the right size for the hole and of the shape shown in the figu re below If the level is more than 3 mm below the overflow level top up and check the reason for the drop in oil level ENSURE THAT THE ROD IS SNUG AGAINST THE THREAD Helical in line gear units C11 C21 and C31 all mounting positions and bevel helical gear units A10 A20 and A30 in mounting positions B6 and B7 only do not feature a level plug T
49. t compatible with the synthetic oil used during the machine s operation the interior of the unit must be thoroughly cleaned before filling with the operating oil The service life of bearing grease is reduced if the unit is stored for more than 1 year The bearing grease must be synthetic BONFIGLIOLI a 10 RIDUTTORI 5 0 INSTALLATION 5 1 INSTALLING THE GEAR UNIT The entire installation process must be planned based on the general design of the machine The person authorised to do the work must if necessary implement a safety plan to safe guard all persons directly involved and rigorously apply all applicable legislation If a gearmotor is going to be installed please consult the owner s manual of the electric motor on beforehand 1 o xo o Thoroughly clean all packaging materials and protective product residue from the gear unit Pay particu lar attention to the coupling surfaces Check that the data on the nameplate corresponds to that which is specified on the order Ensure that the structure to which the gear unit is to be mounted is sufficiently robust and rigid to support its weight and operating stresses Check that the machine on which the gear unit is to be installed is switched off and cannot be acciden tally switched on again Check that all coupling surfaces are flat Check that the shaft shaft or shaft bore are perfectly aligned for coupling Fit suitable guards to protect against the extern
50. uivalent product with similar properties and applica tion range to the motor gear unit mounting flanges spigot and frontal coupling surfaces as shown in diagram S1 S1 1 Apply Loctite 510 to both the flange surface and spigot 2 Apply Kl berpaste 46MR401 to the input shaft bore and motor shaft 3 Use Loctite 5366 to seal the area of contact between the gear unit and motor taking care to fill in any gaps between the two flanges e g disas sembly slots After mounting the motor apply a layer of sealant Loctite 5366 or equivalent product with simi lar properties and application range around the edges of the flanges so as to close any gaps between their surfaces f the gearbox is of the flanged type the User must take similar precautions to prevent dust de posits forming in the gaps between the flanges or in the vicinity of the couplings BONFIGLIOLI a 16 RIDUTTORI 6 0 TESTING THE GEAR UNIT The gear unit has been factory tested by the Manufacturer Before starting the unit check that The machine incorporating the gear unit complies with the provisions of the Machinery Directive 98 37 EC and any other applicable safety legislation The gear units mounting position in the installation corresponds to that prescribed and indicated on the nameplate The electrical power supply and control systems are suitable and operational as stipulated in standard EN 60204 1 and
51. ust be stored by a person with the correct authority and must always be made availa ble 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 reflects 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 pu blication being for that reason considered inadequate Particularly significant sections of the manual and important specifications are highlighted by symbols whose meanings are given below SYMBOLS DANGER WARNING This symbol indicates situations of serious danger which if ignored may result in serious risks to the health and safety of personnel CAUTION ATTENTION AN This symbol indicates the need to adopt specific precautions to avoid risks to the health and safety of personnel and possible economic damages IMPORTANT This symbol indicates important technical information The instructions indicated on a yellow background next to these symbols refer exclusively to equipment conforming to the ATEX Directive 94 9 EC The operations highlighted by these symbols must be carried out by qualified professionals spe cially trained in the safety requirements for zones characterised by potentially explosive atmo spheres Failure to observe these instructions may result in serious risks to personal
52. valent on threads of all bolts used to assemble the gear unit onto the structure and or to the electric motor Make sure that the radial thrust loads and operating torques do not exceed those specified for the unit The vent caps and oil level caps must be easy to access for inspection Clean the gear unit thoroughly after installation BONFIGLIOLI RIDUTTORI 13 5 1 1 Gear units with solid output shaft For mounting external parts do not use hammers or other tools which might damage the gear unit s shafts or bearings Instead proceed as indicated in the diagram below Jj J T A SEE SEI EN E E LIZA SA Y a Bolt 1 and spacer 2 are to be supplied by customer To minimise the loads on the shaft bearings when mounting transmission elements with asymmetrical hubs the preferred layout is shown in diagram A below CA SSS SR P o EEE SEITE x DES A NL VE CSS F x RE X DUO ED CISA OOOO e A 2 POLIS EEE EEE 27 ID EII 0602 Ta 3 3 RS R Si o SS SS Kx tel AAA ER X EI VR ISS Sex SS ER N SS NS IR xS SS TER gt 38 x gt SS SSOO S x SS 3 S 0 S X S SS SS 3 IR SO S WO S SS S P EXA x DEAR ARANA EEE PIE LISIIIS A SIS ter SRR AA BEI AA A 4 REGS VLG AAA P LIS Le
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