Installation, use and service manual
Contents
1. V10F 2 V 10U VR 10 n Oil Donax TA 2000 3000 hrs V3F V5 5 F_ 1 0 V3U_ VR3 V5 5U VR5 5 1 3 I Oil Donax TA 2000 3000 hrs VD3F VD 5 5F 2 8 VD3U VRD3U 30 I VD 5 5U VRD5 5U_ 3 VD 10 F VD 10 U VRD 10 j n Oil Donax TA 2000 3000 hrs Oil Donax TA 2000 3000 hrs BONFIGLIOLI RIDUTTORI 17 8 3 REPLACING THE OIL Speed variators V1 to V10 1 Place an adequate container under the drain plug 2 Remove the filler drain and level caps and allow the oil to drain out N The oil will drain better if it is warm 3 Wait a few minutes until all the oil has drained out and then screw back on the drain cap only after first fitting it with a new gasket 4 Orient the speed variator in its final position and fill with oil Pour the oil slowly to ensure even filling Stop filling when the oil is flush with the level cap Screw on the level cap after first fitting a new gasket2. and hooks etc which are certified and adequate for the load in question The weight of the product to be lifted is given in the Sales Catalogue Identify the attachment points for lifting the speed variator Refer to the diagram below for this information Prepare the speed variator for lifting by attaching straps hooks and screw clamps etc to its attachment points or alternatively use a pallet for moving the load If using a crane first lift the speed variator verti cally out of its packaging If using a lift truck or pallet truck remove the packaging and insert the truck s forks at the indicated points First lift the load very slowly to check that it is stable Move the speed variator to the unloading area and lower it gently into position taking care not to cause sudden oscillations while moving it If the speed variator is coupled to an electric motor do not use the eye bolts on the motor for lifting the entire load unless this is expressly indicated BONFIGLIOLI 5 RIDUTTORI 7 IMOLLNGIY 11011913 e Maximum permissible tilt during handling V VR 0 25 INPUT V VR 0 25 0 5 V1 V2 VR1 VR2 VR 3 VR 5 5 Equipment not supplied D Ring harness INPUT O 2 Rope and hooks 3 Open harness V VR 0 25 0 5 VR 1 VR 5
3. RO We reserve the right to implement modifications without notice This catalogue cannot be reproduced even partially without prior consent BONFIGLIOLI a 22 RIDUTTORI GD BONFIGLIOLI PER INFORMAZIONI 24 ORE 365 GIORNI NUMERO VERDE 800 442288 SEDE CENTRALE 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 8 bonfiglioli com SALES DEPARTMENT INDUSTRIAL SOLUTIONS 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 bonfiglioli bonfiglioli com SALES DEPARTMENT MOBILE SOLUTIONS BONFIGLIOLI RIDUTTORI S p A Via Enrico Mattei 12 2 1 Villa Selva 47100 Forli ITALY Tel 39 0543 789111 Fax 39 0543 789242 0543 789245 trasmital bonfiglioli com UFFICI VENDITE ITALIA ITALY SALES OFFICES PARMA Largo Luca Ganzi 9 E Tel 0521 987275 Fax 0521 987368 DEPOSITI IN ITALIA STOCK HOUSES IN ITALY ASSAGO MILANO Via Idiomi ang Donizetti Tel 02 48844710 02 4883395 Fax 02 48844750 02 4883874 TORINO Corso Susa 242 Palazzo Prisma 88 10098 Rivoli Tel 011 9585116 Fax 011 9587503 PADOVA IX Strada 1 Zona Industriale Tel 049 8070911 Fax 049 8074033 049 8073883 MILANO Via Idiomi ang Donize
4. Before operating the speed variator check the oil level through the sight glass if fitted This must be done with the speed variator in the mounting position in which it will be installed If necessary refill or top up the lu bricant Speed variators type V 0 25 and V 0 5 are factory filled with long life synthetic lubricant Shell Donax TX and do not have service plugs Speed variators which are not subject to external contamination do not normally require periodic lubricant changes If a top up or complete lubricant change is necessary strictly observe the quantities given in the tables below Do not mix oils of different types Changes and top ups must always be done with the same type of lubricant If the same type of oil as that already in use is not available drain the speed variator casing completely and flush the interior thoroughly with a light solvent before refilling with a new lubricant Shell Donax TX indicative features Density ISO 3675 0 852 Kg dm Kinematic viscosity 40 C ISO 3104 34 cst Kinematic viscosity 100 C ISO 3104 7 4 cst Viscosity index ISO 2909 196 Flash point ISO 2592 198 C Pour point ISO 3016 48 C Speed variators V1 to V10 are supplied already charged with mineral oil Shell Donax TA Changes and top ups must always be done with a compatible type of lubricant Do not in any case mix mineral and synthetic oils Shell Donax TA indicative
5. INDUSTRY PROCESS AND AUTOMATION SOLUTIONS ee BONFIGLIOLI eE use and service manual BONFIGLIOLI 1 0 GENERAL INFORMATION 2 1 1 PURPOSE OE THE MANUAL e mu p od GER S EP EUR PO apu a 2 1 2 IDENTIFICATION OF THE SPEED VARIATOR el hee en es nl nl n in sd el en nein 3 1 3 GEOSSARY AND TERMINOLOGY 2 telo lU I A seen t ae a aqu 3 1 4 REQUESTING TECHNICAL 5 3 1 5 MANUFACTURER S LIABILITY III I ee em ee el hls el el n i ee ep rl esi se tenet eee es 4 2 0 TECHNICAL INFORMATION 4 2 1 DESCRIPTION OF THE SPEED VARIATOR sssssssssssssssssse seem s ee hee es nn n s es ee e e ne ne en nnns 4 2 2 OPERATING LIMITS AND CONDITIONS Ie II III e he hen el ne n s sl es ee e e nn sn nenne 4 3 0 SAFETY INFORMATION 5 4 0 HANDLING AND TRANSPORT 6 TAA PACKAGING cor o pU RSE SERM A EUN MAR LL Lu dodo UM IE 6 42 HANDLING INSTRUCTIONS coco t imt te mans Td ta et o ettet Aud atas 7 42 1 Moving the packages ee een nennen lea Sax a eel ERR eee eU UP Nu Se aa 7 4 2 2 Moving the equipment ooo I III I I ene e ee e Das e ehe e ri isi e esi i i i i i isi een 7 A3 STORAGE a SSE Eas ute ee 9 5 0 INSTALLING THE SPEED VARIATOR 10 5 1 MOUNTING THE TRANSMISSION COMPONENT
6. use of the speed variator in violation of local legislation on safety and accident prevention at work incorrect installation and disregard or incorrect application of the instructions provided in this manual incorrect or defective power supply motorised speed variators modifications or tampering work done on the unit by unqualified or unsuitable persons The safe use of the speed variator also depends on scrupulous observance of the instructions given in this manual In particular always operate the speed variator 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 2 0 TECHNICAL INFORMATION 2 1 DESCRIPTION OF THE SPEED VARIATOR The speed variator has been designed and constructed for integration driven if required by an electric mo tor into an assembly of interlocking parts or mechanisms as part of a specific application Depending on the requirements of the application the speed variator can be supplied in a variety of motor 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 r
7. Italy Tel 051 727844 Fax 051 727066 brtO bonfiglioli com www brtbonfiglioliricambi it Shell Bonfiglioli Riduttori recommends SHELL lubricants COD 1271 RO INDUSTRY PROCESS AND AUTOMATION SOLUTIONS www bonfiglioli com GH BONFIGLIOLI
8. 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 Otecnotrans 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 2 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 mobilesales 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 Distribuzione esclusiva ricambi Bonfiglioli Spare parts Bonfiglioli IDIRIN Bonfiglioli Riduttori sceglie lubrificanti SHELL Via Castagnini 2 4 2 1 Bargellino 40012 Calderara di Reno BO
9. 0 TESTING THE SPEED VARIATOR The speed variator has been factory tested by the Manufacturer Before starting the unit check that the machine incorporating the speed variator complies with the provisions of Machine Directive 98 37 EC and any other applicable safety laws the speed variator s mounting position in the installation corresponds to that prescribed and indicated on the nameplate the electrical power supply is suitable and operational as specified by standard EN 60204 1 and is groun ded as per standard EN 50014 the power supply rating 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 vent plug is correctly installed and that its hole is not obstructed by dust or other foreign bodies the unit does not run noisily or with excessive vibration For initial running in period of 150 200 hours due to settling of the moving parts it is normal for the operating temperature to be higher than that experienced thereafter 12 BONFIGLIOLI 5 RIDUTTORI 7 0 USING THE SPEED VARIATOR Before putting the speed variator into service the user must ensure that the plant in which it is installed com plies with all applicable directives especially those regarding health and safety at work During operation avoid frequent starts of the motor as these can reduce the un
10. 5 0 INSTALLING THE SPEED VARIATOR The entire installation process must be planned based on the general design of the machi N ne The person authorised to do the work must if necessary set out a safety plan to protect the health and safety of all persons directly involved and apply all applicable legislation Carefully remove all packaging and protective product residue from the speed variator Pay particular at tention to the coupling surfaces Check that the data on the nameplate correspond to those specified in the order Ensure that the structure to which the speed variator is to be mounted is sufficiently robust and rigid to support its weight and operating stresses Make sure that the machine on which the speed variator is to be installed is switched off and cannot be accidentally 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 speed variator s external moving parts and the risk of burns from its hot surfaces If the work environment is corrosive for the speed variator or any of its parts take the special precautions required for aggressive environments In this case contact the BONFIGLIOLI RIDUTTORI sales service We recommend applying a protective paste to all couplings between the speed variator motor and other parts Kl berpaste 46 MR 401 or a product with similar properties and appl
11. 5 with eyelets Screw clamp use with harness INPUT 6 Snap hook use with rope iO VR 1 VR 5 5 V VR 10 Eyebolt V VR 0 25 0 5 The load must not be allowed to swing up or down by more than 15 when being lifted If swinging exceeds this angle stop and repeat the lifting operation stabilising the load by hand N If the mass being lifted shows signs of instability stop the operation and slide the lifting ring to align it with the load s centre of gravity then lock the ropes below the ring with a clamp or similar device so as to prevent them sliding and lift the load 4 3 STORAGE Some recommendations for storing the speed variator are described below 1 Do not store the unit in excessively humid conditions or exposed to the weather do not store outdoors 2 Do not place the speed variator directly on the ground 3 Place the variator on a stable base and make sure that it is not subject to accidental displacement 4 Store the packaged variator if allowed in accordance with the instructions on the packaging itself If the unit is to be 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 other product with similar properties and application range 6 Fill the unit with lubricating oil BONFIGLIOLI s RIDUTTORI
12. all such materials as stipulated by established environmental legislation Do not re use parts or components which appear to be in good condition after they have been checked or replaced by qualified personnel and declared unsuitable for use BONFIGLIOLI RIDUTTORI 19 9 2 REMOVING THE ELECTRIC MOTOR If during operation the coupling between the motor and speed variator has not fret corroded significantly it sho uld be possible 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 may damage the flanges and coupling surfaces but proceed as shown below A3 DRILL AND TAP IMPACT EXTRACTOR 1 Drill and thread the motor shaft fan side 2 Screw an impact extractor tool into the bore 3 Undo the bolts fixing the motor to the speed variator 4 Detach the motor by means of the inertial force of the extractor BONFIGLIOLI 20 RIDUTTORI 10 0 TROUBLESHOOTING The following information is intended to serve as an aid in identifying and eliminating defects and faults In some cases such problems may be caused by the plant or machine to which the speed variator is assem bled and hence the cause and eventual solution will be found in the Manufacturer s technical documentation for th
13. and continue filling to its midline point 5 Tighten down the filler cap after changing its gasket The speed variator may be supplied with or without lubricant as requested by the user The quantity of charge oil required is specified in the Sales Catalogue Note however that this quantity is approximate only and the unit must in any case be filled to the midline point of the level cap 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 individual safety equipment Do not dump them into the en vironment and dispose of in observance of applicable legislation If leak is found identify the cause of the fault and repair it before topping up the lubricant and operating the speed variator 8 4 RECOMMENDED LUBRICANTS V R 0 25 0 5 1 10 0 25 10 Legend Donax TX R R Recommended Donax TA R F Food grade sron Cassida Fluid HF 46 F F G Grease TVX Compound B G BONFIGLIOLI 18 RIDUTTORI 8 5 CHECKING EFFICIENCY Remove dust deposits from the speed variator and motor casings Check that the noise generated at constant load does not vary Excessive vibration or noise may indicate wear of the satellite discs or failure of a bearing Check the power absor
14. constitutes a risk to personal health and safety Use the speed variator only for the applications envisaged by the Manufacturer Improper use can result in risks to personal health and safety and economic damages The applications permitted by the Manufacturer are the industrial applications for which the V series speed variators have been developed Keep the speed variator at its maximum efficiency by following the routine maintenance schedule Good maintenance ensures the unit s maximum performance an extended service life and continued complian ce 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 applicable laws 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 ad dress 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 laws on health and safety at work Replace worn components with original spare parts Use the lubricants oil and grease re
15. 8 23 32 M10 46 64 M12 80 110 M14 125 180 M16 195 275 M18 270 390 M20 385 540 5 1 MOUNTING THE TRANSMISSION COMPONENTS ONTO THE SHAFT When mounting external parts do not use hammers or other tools which might damage the speed variator s shafts or bearings Instead proceed as illustrated in the diagram below Bolt 1 and spacer 2 are not included in the consignment To minimize the loads on the shaft bearings when mounting transmission mechanisms with asymmetrical hubs use the configuration shown in diagram A below BONFIGLIOLI 5 RIDUTTORI 11 5 2 INSTALLING THE ELECTRIC MOTOR Further to all the precautions indicated above when installing an electric motor standardised to IEC 72 1 requi rements the following precautions must also be observed e 6 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 radial or thrust loads To facilitate assembly use a lubricating synthetic oil paste such as Kl berpaste 46 MR 401 or other pro duct with similar properties and application range Tighten down all motor variator mounting bolts to their prescribed torques For the tightening torques refer to chart A1 above For speed variators with a differential unit VD only use electric motors featuring an oil seal on the shaft
16. 9 V0 5U_ VR0 5_ 0 15 I 0 32 1 VD 0 5U_ VRD0 5 0 30 TE Oil Donax TX for life Oil Donax TA 2000 3000 hrs V 0 25 F 0 14 0 30 V0 5 0 18 0 40 V0 25U_ VR0 25_ 0 12 0 25 10 V0 5U_7VR05_ 0 15 I 0 32 l VD 0 5U_ VRD0 5 0 30 0 35 Oil Donax TX for life Oil Donax TA 2000 3000 hrs V 0 25 F 0 14 0 30 V0 5F 0 18 0 40 V0 25U VRO0 25 0 12 0 25 9 V0 5U 7 VRO 5 0 15 I 0 32 l VD 0 5 U_ VRD 0 5 0 30 035 Oil Donax TX for life Oil Donax TA 2000 3000 hrs V 0 25 F 0 14 0 30 V0 5F 0 18 0 40 V0 25U_ VR0 25_ 0 12 0 25 0 V0 5U_7VR05_ 0 15 I 0 32 l VD 0 5U_ VRD0 5 0 30 0 35 Oil Donax TX for life Oil Donax TA 2000 3000 hrs V 0 25 F 0 28 0 58 m V0 5F 0 30 0 78 V0 25U VR0 25 022 I 0 40 ll V0 5U 7 VR 0 5_ 0 27 0 54 e Oil Donax TX for life Oil Donax TA 2000 3000 hrs VD 0 5 U_ VRD 0 5 0 70 VD1U VRD1 1 00 9 VD 2 U_ VRD 2 1 5 Oil Donax TX for life l IIP Oil Donax TA for life E 0 14 amp v1F 0 30 0 18 v2F 0 40 _ VR0 25_ 0 12 ll KO V1U_ VR1_ 0 25 I 0 5_ 0 15 7 V2U_ VR2_ 0 32 Oil Donax TX for life ud Oil Donax TA 2000 3000 hrs VD 0 5 U_ VRD 0 5 0 40 4 ma VD1U VRD1 0 50 9 VD2U VRD2 0 70 E Oil Donax TX for life NO O Oil Donax TA for life BONFIGLIOLI 16 RIDUTTORI V3F V55F_ 0 70 V10F aa V10U_ VR10 V3U_IVR3 9 U 1 0 on ATE 1 V
17. ANDLING INSTRUCTIONS Handle packages as per the Manufacturer s instructions and those indicated on the packages themselves 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 Q The person authorised to handle the product must take all necessary precautions to safe guard his safety and that of all other persons involved 4 2 1 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 attac hment 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 When handling the load keep it level to avoid tipping and instability 4 2 2 Moving the equipment All the following operations must be carried out with care and caution and without sudden movements N When lifting use accessories such as eyebolts screw clamps snap hooks straps ropes
18. D 5 5F 13 0 VD 10 U_ VRD 10 U_ VD3U_ VRD3U_ Oil Donax TA 2000 3000 hrs VD 5 5 U VRD 5 5U_ 1 6 Oil Donax TA 2000 3000 hrs V10F in V 10U VR 10 V3U VR3 Yu E V 5 5U VR 5 5 VD3F VD 10 F 20 l VD 5 5F 13 N VD 10 U_ VRD 10 U_ VD 3 U VRD3U Oil Donax TA 2000 3000 hrs VD 5 5 U VRD 5 5U_ 1 6 Oil Donax TA 2000 3000 hrs V3F V5 5F_ 0 90 V 10 F T V10U VR 10 I i V3U VR3 U 1 0 yastlvess e m VD 5 5F 1 3 Il VD 10 U_ VRD 10U VD3U VRD3U Oil Donax TA 2000 3000 hrs VD5 5U VRD5 5U_ 1 6 Oil Donax TA 2000 3000 hrs IV3F V5 5F_ 1 0 V10F 25 j V 10U VR 10 iV3U VR3 T 1 3 VD 10 F 5 5F 1 6 VD 10 U_ VRD 10U VD 3 U_ VRD 3 U_ Oil Donax TA 2000 3000 hrs VD5 5U VRD5 5uU 19 Oil Donax TA 2000 3000 hrs V3F VS5F_ 2 1 V10F V10U VR 10 V3U_ VR3 20 Il I V 5 5 U VR 5 5 7 Oil Donax TA 2000 3000 hrs Oil Donax TA 2000 3000 hrs A VD 3 F_ E SH a a VD 10 F VD 5 5 F y VD 10 U_ VRD 10 85 T VD3U VRD3U g VD 5 5U VRD5 5U Oil Donax TA 2000 3000 hrs Oil Donax TA 2000 3000 hrs
19. S ONTO THE 11 5 2 INSTALLING THE ELECTRIC MOTOR Z n a u ua e hee es el nee e Ea ep e i na nes eee 12 6 0 TESTING THE SPEED VARIATOR 12 7 0 USING THE SPEED VARIATOR 13 8 0 MAINTENANCE 13 9 15 ROUTINE MAINTENANGE x eR utt ee oon deer eet dit Pet CO god 14 9 2 LUBRICATION SARE eo propediem c bt bL be Et ca 15 8 3 REPLACING THE OIL Speed Variators V1 to V10 IRR e eee ee nne 18 8 4 RECOMMENDED F BRICAN TS tns nt be net an elle se IS pe ege 18 9 5 CHECKING EFEIGIENGY tte etr be tette et etre Deere ese rte e idee ese edite e Pede eser eevee 19 8 6 CLEANING R MUS 19 9 1 PAINT COATING e n er SOR e et cda d eta ced k dde c dd e e oh a s das dado te er e 19 9 0 REPLACING PARTS 19 9 1 DECOMISSIONING THE SPEED VARIATOR I em I eee ee em el ne en hne es el hne ne reines 19 9 2 REMOVING THE ELECTRIC MOTORA esee ehe he mes re ne nes nn rn a C suu s 20 10 0 TROUBLESHOOTING 21 Revisions Refer to page 22 for the catalogue revision index Visit www bonfiglioli com to search for catalogues with up to date revisions BONFIGLIOLI Ei RIDUTTORI 1 1 0 GENERAL INFORMATION 1 1 PURPOSE OF THE MANUAL This Manufacturer s manual provides information about the safe transport handling installation maintenan ce repair disassembly and dismantling of the speed variator All purc
20. commended 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 speed variator s surfaces and walk on surfaces around the work area BONFIGLIOLI 5 RIDUTTORI 5 4 0 HANDLING AND TRANSPORT 4 1 PACKAGING The standard packaging if supplied and unless otherwise agreed is not proofed against rainfall and is in tended for shipping by ground and not sea and for storage in areas which are under cover and not humid The material can be stored in suitable conditions for a period of two years under cover in temperatures bet ween 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 Wooden crates for miscellaneous products shipped by sea Carton pallet packaging for single products and kits Horizontal packaging Vertical packaging On receipt of the speed variator make sure the delivery corresponds to the purchase order N and that it is not damaged or faulty in any way Report any nonconformity to your BONFIGLIOLI RIDUTTORI reseller Dispose of packaging materials as stipulated by applicable legislation BONFIGLIOLI 6 RIDUTTORI 4 2 H
21. dicates the need to adopt specific precautions to avoid personal injury and damages IMPORTANT This symbol indicates important technical information gt P P P BONFIGLIOLI 2 RIDUTTORI 1 2 IDENTIFICATION OF THE SPEED VARIATOR The variator is fitted with the nameplate shown below It indicates all references and indispensable instruc tions for the safe use of the speed variator The product identification code is explained in the Sales Catalo gue in more detail If the speed variator is supplied with integral electric motor motorised variator all information regarding the motor itself is supplied in the motor manual Nameplate data TYPE Identification of the variator CODE Product code Month Year of manufacture MOUNT POS BONFIGLIOLI RIDUTTORI S p A Mounting position ITALY Speed variation range Readability of the nameplate The nameplate and the information thereon must be kept readable and consequently must be cleaned from time to time Should the nameplate wear 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 nameplate from the Manufacturer quoting the information given in this manual to replace the old one 1 3 GLOSSARY AND TERMINOLOGY Some of the frequently occurring terms used in this manual are described below to unequivocally define their meanin
22. e machine plant in question PROBLEM CAUSE SOLUTION Bearing temperature too high Oil level too low Top up oil level Oil spent Replace oil Defective bearings Contact authorised workshop Operating temperature too high Oil level too high Check oil level Oil spent Replace oil Contaminant in oil Replace oil Abnormal running noise Satellite discs damaged Contact authorised workshop Bearing axial backlash too high Contact authorised workshop Bearings defective or worn Contact authorised workshop Excessive load is applied Correct load to rated values given in Sales Catalogue Contaminant in oil Replace oil Abnormal noise at variator mounting Mounting bolts loose Tighten bolts to specified torque Mounting bolts worn Replace bolts Oil leaks Oil level too high Check oil level Casing coupling seal inadequate Contact authorised workshop Gaskets worn Contact authorised workshop Speed variator does nat run or runs with difficulty Oil viscosity too high Replace oil see recommended lubricant chart Oil level too high Check oil level Excessive load is applied Redesign drive for actual load required Output shaft does not turn with motor running Satellite discs damaged Contact authorised workshop BONFIGLIOLI 5 RIDUTTORI 21 INDEX OF REVISIONS R
23. esponsible for using the products recommended for installation and maintenance of BONFIGLIOLI speed variators in an appropriate manner and in accordance with instructions 2 2 OPERATING LIMITS AND CONDITIONS Ambient conditions Ambient temperature min 20 C max 50 C Do not use the speed variator if not explicitly intended for the purpose in a potentially explosive atmo sphere or where the use of explosion proof equipment is specified 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 echo was less than 85 dB A The vibrations produced by the speed variator do not constitute a health risk for personnel Excessive vibra tion may be the result of a fault which should be immediately reported and eliminated BONFIGLIOLI 4 RIDUTTORI 3 0 SAFETY INFORMATION Carefully read the instructions given in this manual and those indicated on the product itself especially re garding safety Persons charged with working on the speed variator at any time during its service life must be trained spe cifically for the purpose and possess the special skills and experience in the area as well as being equip ped with and knowledgeable in the use of the appropriate tools and individual safety equipment as per Legislative Decree 626 94 Failure to meet these requirements
24. features Density ISO 3675 0 873 Kg dm Kinematic viscosity 40 C ISO 3104 37 3 cst Kinematic viscosity 100 C ISO 3104 7 0 cst Viscosity index ISO 2909 151 Flash point ISO 2592 196 C Pour point ISO 3016 42 C The helical reduction gear pair on VR variators is lubricated with long life grease Shell TVX Compound B Speed variators fitted with a differential unit VD are factory filled with lubricant only if supplied with an elec tric motor Otherwise the speed variator is supplied unlubricated and the customer is responsible for filling it prior to putting the unit into service In this case the motor shaft must be fitted with an oil seal and the mounting flange must be oil tight BONFIGLIOLI 5 RIDUTTORI ES Breather plug 8 Filer plug Drain plug E Level plug A 3 90 elbow V 0 25 F 0 14 0 30 V0 5F 0 18 0 40 V0 25U_ VR0 25_ 0 12 0 25
25. g Routine maintenance the set of operations required for maintaining the functionality and efficiency of the speed variator These operations are usually scheduled by the Manufacturer who defines the qualifications and tasks in question Non routine maintenance the set of operations required for maintaining the functionality and efficiency of the speed variator These operations are not scheduled by the Manufacturer and must be carried out by an expert maintenance technician Expert maintenance technician an authorised technician selected from those having the qualifications skills and mechanical and electrical training to carry out repairs and non routine maintenance work on the speed variator Overhaul an overhaul consists of the replacement of bearings and or other mechanical components which have worn to such an extent as to compromise the operation of the speed variator An overhaul also includes checking the condition of all variator components keys seals gaskets vents etc If any such components 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 indicated on the unit s nameplate the approximate hours of service and the type of defect BONFIGLIOLI 5 RIDUTTORI 3 1 5 MANUFACTURER S LIABILITY The Manufacturer declines all liability in the event of
26. getriebe 9 bonfiglioli de BONFIGLIOLI WORLDWIDE amp BEST PARTNERS VECTRON Elektronik GmbH Europark Fichtenhain A 6 47807 Krefeld Tel 49 2151 83960 Fax 49 2151 839699 www vectron net info 9 vectron net GREECE BONFIGLIOLI HELLAS S A O T 48A T O 230 C P 570 22 Industrial Area Thessaloniki Tel 30 2310 796456 Fax 30 2310 795903 www bonfiglioli gr bonfigr otenet gr HOLLAND ZF BEST ELSTO AANDRIJFTECHNIEK Loosterweg 7 2215 TL Voorhout Tel 31 252 219 123 Fax 31 252 231 660 www elsto nl imfo elsto nl HUNGARY SBEST 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 9 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 bonfiglioli co in bonfig O vsnl com NEW ZEALAND ZF 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 2 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
27. hasing and design information is given in the Sales Catalogue Besides adhering to establi shed engineering practices the information given in this manual must be read carefully and rigoro usly applied Failure to observe the information provided herein may result in risk to personal health and safety as well as economic damages This information provided in the Manufacturer s original language Italian may also be made available in ot her 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 This manual reflects the state of the art at the time of commercialisation of the speed variator 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 danger which if ignored may result in serious injury to the operator DANGER WARNING This symbol indicates the presence of hot surfaces which may burn the operator CAUTION ATTENTION This symbol in
28. iator at its maximum efficiency by following the routine maintenance AN schedule specified by the Manufacturer Good maintenance ensures the unit s maximum performance extended service life and continued compliance with safety regulations Speed variators V0 25 and V0 5 These units are factory charged with long life synthetic lubricant Shell Donax TX and do not have service plugs Speed variators which are not subject to external contamination do not normally require periodic lubri cant changes Speed variators V1 to V10 It is advisable to change the lubricant after approx 300 hours of operation having first carefully and thoro ughly cleaned the interior of the unit with a suitable detergent Depending on the temperature reached by the lubricant it should be replaced at the intervals indicated in the table below A2 Oil temperature Oil change frequency t C h 65 lt t lt 80 4000 80 lt 1 lt 95 2000 Interval Part Type of check Action 4 Top up lubricant 1000 h Oil seals and gaskets cheek Stoll os Service or replace compo Visual check for leaks nents as required In addition to the operations specified after 1000 h Oil seals and gaskets Inspect carefully for wear ageing of oil seals Replace components if 4000 h and gaskets aged worn ARE Check for excessive noise or Transmission parts vibration BONFIGLIOLI 14 RIDUTTORI 8 2 LUBRICATION
29. ication range to ensure opti mal coupling and protection against fretting corrosion In case of outdoor installations fitted with an electric motor protect the latter from direct sunlight and the weather by means of guards or a casing Make sure that the assembly is properly ventilated The variator s speed settings must only be set with the unit powered up and operating Ope rating the handwheel or the remote speed controls while the variator is stationary can irre versibly damage its internal components Now proceed with the installation as follows 1 2 Place the speed variator in the vicinity of the installation area Mount the speed variator and secure it to the structure at the points provided The speed variator should be secured to the structure at all mounting points bores on the mount provided feet or flange Identify the closed oil plug used during shipping usually red and replace it with the vent plug provided in the shipment Refer to the charts in the Speed variator lubrication chapter Tighten down the mounting bolts and check that the service caps are screwed down to the torques given in the table below A1 10 BONFIGLIOLI 5 RIDUTTORI A1 Bolt torque cap vent Pitch Torque Nm thread Nm Bee Bolt class 118 28 5 8 8 10 9 u 19 T 3 8 19 7 M4 2 7 3 8 4 2 14 14 M5 5 5 8 0 3 4 14 14 M6 9 5 13 0 4 11 25 M
30. it s service life Starts should not exceed 8 to 10 per minute Using the speed variator at a drive speed n lt 300 rpm is inadvisable as this may lead to irregular operation of the unit The speed variator may reach high temperatures even under no load or with reduced load Therefore do not touch with bare hands The speed variator may not be used in areas and environments A with highly corrosive abrasive vapours smoke or dust in direct contact with loose food products Danger zones and exposed persons N The variator s danger zone 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 variator is operating in automatic mode and in an accessible area the shaft must be protected by a guard 8 0 MAINTENANCE Maintenance and replacement work must be carried out by expert maintenance technicians N 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 speed va riator s motor and ensure that it is out of service as well as taking all necessary precau tions against it being accidentally switched on again or its parts moving without warning N due to suspended loads or similar external factors Furthermore all additional environmental safety
31. precautions must be taken e g elimination of residual gas or dust etc Before doing any maintenance work activate all the safety devices provided and if necessary inform per sons working 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 Use the lubricants oil and grease recommended by the Manufacturer When working on the speed variator always replace the 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 instructions are aimed at ensuring efficient and safe operation of the speed variator 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 modifies the safety requirements without the manufactu rer s express prior authorisation Refer to the specific spare parts catalogue when ordering spare parts for the speed variator Do not dump polluting liquids worn parts and maintenance waste into the environment Dispose of all such materials as specified by applicable law BONFIGLIOLI 5 RIDUTTORI 8 1 ROUTINE MAINTENANCE Keep the speed var
32. ption and voltage against the nominal values given on the motor s nameplate Check for lubricant leaks from the gaskets seals caps and casings Check all bolted couplings for wear deformation and corrosion and tighten them down fully without over tightening 8 6 CLEANING Remove all dust and process waste from the speed variator Do not use solvents or other products which are incompatible with the construction material and do not direct high pressure jets of water at the speed variator 8 7 PAINT COATING V 0 25 speed variators feature an aluminium casing and are not paint coated V 0 5 to V 10 variators have cast iron casings which are coated with polyester heat setting resin which is then baked on If the speed variator is to be paint coated protect the nameplate and seal rings against con tact with the solvent 9 0 REPLACING PARTS Do not hesitate to replace parts and 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 variator operation 9 1 DECOMISSIONING THE SPEED VARIATOR The speed variator 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
33. tti 20094 Assago Milano Tel 0245716930 Fax 0245712745 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 P o Box 6705 Silverwater NSW 1811 www bonfiglioli com au bta1 bonfiglioli com au BELGIUM BEST N V ESCO TRANSMISSION S A Culliganlaan 3 1831 Machelem Diegem Tel 0032 2 7204880 Fax 0032 2 7212827 Tix 21930 Escopo B www escotrans be info escotrans be CANADA BONFIGLIOLI CANADA INC 2 7941 Jane Street Concord ONTARIO L4K 4L6 Tel 1 905 7384466 Fax 1 905 7389833 www bonfigliolicanada com sales O bonfigliolicanada com CHINA BONFIGLIOLI DRIVES SHANGHAI CO LTD No 8 Building Area C1 318 SuHong Road Qingpu Shanghai 201700 Tel 86 21 59228800 Fax 86 21 59228811 www bonfiglioli cn linkn 9 bonfiglioli com 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 FRANCE BONFIGLIOLI TRANSMISSIONS S A 14 Rue Eug ne Pottier BP 19 Zone Industrielle de Moimont II 95670 Marly la Ville Tel 33 1 34474510 Fax 33 1 34688800 www bonfiglioli fr btf bonfiglioli fr GERMANY BONFIGLIOLI GETRIEBE GmbH Hamburger Stra e 18 41540 Dormagen Tel 49 2133 50260 Fax 49 2133 502610 www bonfiglioli de bonfiglioli
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