"service manual"
Contents
1. DO EUM QE D rd H E i LE AA Bi Ap PB A SB AT BID leo LP M05 M1 M2 M3 M4 M5 C 05 M Su Mu pe ee C 11 M A ES M M C 21 M A M M C 31 M A M M C 35 A A A C 41 A B A B A B C 51 A B A B A C 61 A B A A B A B C 70 A B A A B A B C 80 A B A A B A B C 90 A B A A B A B C 100 A B A A B A B Ring hamess eedem M Vimeo Maximum permissible tit during o Rope and hooks O este A Lift as per diagram A FRE id O Open harness Eyebol already fied ES imasperdiagame F 24 KIS 7 BONFIGLIOLI RIDUTTORI 41 _ Tai IT RN A10 A60 A10 A60 A10 A60 E E A10 A602. 1000 900 W110 800 700 700 Nm g 600 Z 9 500 g P 400 Miao 300 370 Nm W75 270 Nm 200 W63 160 Nm 100 95 Nm VF49 a SONG VF44 O 14 12 34 1 114 112 134 2 214 212 234 3 314 31 2 334 N of ring nut turns BONFIGLIOLI a 48 RIDUTTORI a BONFIGLIOLI RIDUTTORI 49 A VZ XN INDEX OF REVISIONS R R4 12 15 Addition of new sizes A 05 A 35 and A 55 Les 38 as N oun 42 We reserve the right to implement modifications without notice This catalogue cannot be reproduced even partially without prior consent BONFIGLIOLI 50 COD 1261 R4 EM RIDUTTORI INDUSTRY PROCESS AND AUTOMATION SOLUTIONS www bonfiglioli com amp D BONFIGLIOLI
3. fm er VF 30 VF 44 VFR 44 M VF 49 VFR 49 VF 130 VFR 130 VF 150 VFR 150 VF 185 VFR 185 A B A B A B VF 210 VFR 210 VF 250 VFR 250 Reccomended solution A for positioning solution B for positioning and handling Ring harness Rope and hooks Open harness with eyelets E Screw clamp use with harness Snap hook use with rope Eyebolt already fitted to gear units VF130 VF250 M Lift manually weight lt 15 kg A Lift as per diagram A B Lift as per diagram B Maximum permissible tilt during handling 15 46 BONFIGLIOLI e RIDUTTORI _ LT TC VOZ ANNEX 5 INSTALLING THE MOTOR ON TYPE VFR WORM GEAR UNITS M 2 6 2 3 EE 5 3 1 A 1 8 8 Thoroughly clean and degrease the motor shaft and pinion 1 and bushing 2 coupling surfaces Check the motor shaft tolerance meets the following specifications Shaft diameter O mm Tolerance 11 28 jo 38 48 k6 Preheat the bushing 2 and pinion 1 to 80 100 C 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 facili
4. 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 ob 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 hd RIDUTTORI 17 O gt 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 measure 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 con
5. 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 b RIDUTTORI 7 NH za E I Ec I XN 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 environments 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 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 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
6. oy BONFIGLIOLI INDUSTRY PROCESS AND AUTOMATION SOLUTIONS eke Ekileya use and service manual PATE Gi BONFIGLIOLI 1 0 GENERAL INFORMATION 2 1 1 5 BURPOSE OF THE MANUALE 2 ar ort Lat ina BNE a e d e Ba olivi ici dre INT 2 1 2 EQUIPMENT IDENTIFICATION 3 1 3 GLOSSARY AND TERM IN O O GY 5 deli eei ende aaa t e an ste etd 4 1 4 REQUESTING TECHNICAL ASSISTANCE 4 1 5 MANUFACTURERS HABIL 2 ettet utl eb tei ieu 4 2 0 TECHNICAL INFORMATION 5 215 GEAR UNIT DESCRIPTION S et ett sr t t ke wh t e S 5 2 2 CONFORMITY TO STANDARDS 5 2 3 OPERATING LIMITS AND CONDITIONS es e e ess eee ee es le e e e e es e ee e e e eerie 6 3 0 SAFETY INFORMATION 7 3 1 SAFETY STANDARDS emet ee EN E ana S AULUS ma er 7 4 0 HANDLING AND TRANSPORT 8 2 15 PACKAGING rt A ade iulm elect Meet decus er puce uu E LA A Hunde 8 2 2 HANDLING INSTRUCTIONS 2 2 2 lata deren NADA DOS 9 4 2 1 Moving packages su tm eb aee ets Pd e e i ul ou 9 4 2 2 Moving the equipment 25 cr eese st e A adt A RR RE Ne Res E T P pe CET TEES 9 43 STORAGE nl S RR P PRE a 10 5 0 INSTALLATION 11 5 1 INSTALLING THE GEAR UNIT it rhe a En RE ok ed debet Tatas tes 11 5 1 1 Gear units with solid output shaft sss II e ee e mese nenne 14 5 1 2 Gear units with hollow output shaft sss IR e meme mese e nee 14 5 1 3 Gear units With shrink d
7. A70 A90 A10 A60 A70 A90 A10 A60 A70 A90 A05 A 10 M P63 P90 A B P100 P112 A 20 A 30 A A 35 A A 41 A 50 A 55 A 60 A 70 A 80 U U U UJ A 90 Reccomended solution A for positioning solution B for positioning and handling Ring harness Rope and hooks Open harness with eyelets Screw clamp Lift manually use with harness weight lt 15 kg M A Lift as per diagram A Eyebolt Snap hook use with rope B Lift as per diagram B Maximum permissible tilt during handling 15 E I M Pri O ho 42 BONFIGLIOLI RIDUTTORI Ne M E Mec ai Ld MO5 M1 M2 M3 M4 M5 F 10 M A B M M M P63 P90 F 20 A B A B M P100 P112 F 30 A A A F 40 A B A B A B F 50 A B A B A B F 60 A B A B A B F 70 A B A B A B F 80 A B A B A B F 90 A B A B A B Reccomended solution A for positioning solution B for positioning and handling Ring harness Lift manually Screw clamp M weight lt 15
8. O gt 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 MAX 3mm MIN ENSURE THAT THE ROD IS SNUG AGAINST THE THREAD RAW memo yas 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 The oil level must therefore be checked not as described above but via a hole provided for the purpose in the manner described hereafter BONFIGLIOLI 2 RIDUTTORI 29 ES O gt Helical in line gear units C 11 C 21 C 31 S4 A7 gt JT juar B3 B6 B7 B8 V5 V6 B5 B51 B53 B52 V1 V3 B5 B51 B53 B52 V1 V3 C 11 2_ P63 P71 70 70 70 70 70 45 70 70 70 70 60 30 70 70 70 70 60 30 C 11 2_ P80 P112 75 75 75 75 75 45 75 75 75 75 70 30 75 75 75 75 70 30 C 21 2_ P63 P71 HS 70 70 70 70 70 40 70 70 70 70 70 45 70 70 70 70 70 45
9. WS ESA ES 21 24 ka Wy 58 ESA A 2 C 353 1 14 ESA 1 8 20 2s 1 14 su dcm 2 28 C354 283 2 23 2 27 ORT 28 21 28 2a 27 ESE C412 BY 20 Zal 12 27 ESTA Di 2 Bal id 27 se C413 Fail ORE ae 2S ee za TS 2al 12 25 amp 2 C414 2 8 2 6 2 8 26 3 5 3 9 2 8 26 2 8 26 3 5 3 9 C512 3 1 3 0 3 1 3 0 4 3 50 3 1 3 0 3 1 3 0 4 3 5 0 C513 3 0 2 8 3 1 3 0 4 1 4 9 3 0 2 8 3 1 3 0 4 1 4 9 C514 43 41 44 42 54 6 1 43 41 44 42 5 4 6 1 C612 4 2 40 42 4 1 6 0 6 7 4 2 4 0 4 2 4 1 6 0 6 7 C 613 42 4 0 42 4 1 60 6 7 42 4 0 4 2 4 1 6 0 6 7 C614 6 1 5 9 6 1 6 0 7 9 8 6 6 1 5 9 6 1 6 0 7 9 8 6 C702 6 5 85 85 7 5 11 7 5 6 5 8 5 85 7 5 11 7 5 C703 6 5 85 85 7 5 11 7 5 6 5 8 5 85 7 5 11 7 5 C704 6 5 85 85 7 5 11 8 0 6 5 8 5 85 7 5 11 7 5 C 802 11 14 14 13 18 13 11 14 14 13 18 13 C 803 11 14 14 13 18 13 11 14 14 13 18 13 C804 11 14 14 13 18 13 11 14 14 13 18 13 c 90 2 19 25 25 22 31 22 19 25 25 22 31 22 C 903 19 25 25 22 31 22 19 25 25 22 31
10. 22 C 904 19 25 25 22 31 22 19 25 25 22 31 22 C 100 2 27 37 37 33 45 33 27 37 37 33 45 33 C 1003 27 37 37 33 45 33 27 37 37 33 45 33 C 1004 27 37 37 33 45 33 27 37 37 33 45 33 Life time lubricated gear units Life time lubricated gear units only in combination with ATEX variants Lubricant is not factory filled 52 Gica Bevel helical gear units series A A10 mu B3 B6 B7 B8 VA VB A052 0 50 0 50 0 50 0 50 0 50 0 50 A102 1 4 1 4 14 1 4 1 4 1 4 A202 2 3 23 2 3 23 2 3 2 3 A203 2 6 2 6 2 6 26 2 6 2 6 A302 3 2 32 3 2 32 3 2 3 2 A303 3 6 3 6 3 6 3 6 3 6 3 6 A352 2 8 3 2 3 2 3 2 3 9 2 7 A353 35 3 8 3 8 3 6 4 9 3 3 A412 3 8 31 3 0 4 0 53 33 A 413 4 6 3 9 3 8 4 8 6 1 4 0 A502 4 9 8 1 4 7 8 4 11 9 2 A503 5 1 8 1 4 7 8 4 11 92 A504 6 3 8 2 5 3 8 3 13 9 1 A552 3 2 6 2 6 1 7 0 8 5 8 0 A553 3 8 6 8 6 5 7 7 9 2 8 2 A554 5 2 9 2 9 0 8 8 10 6 8 7 A 602 6 8 8 1 12 15 18 15 A 603 6 8 8 1 12 15 18 15 A 60 4 7 2 11 7 4 16 19 14 A703 10 14 10 15 20 14 A704 13 14 10 15 23 14 A 803 15 22 15 26 35 22 A804 20 22 15 26 39 22 A903 31 35 37 44 66 39 A904 41 35 37 44 73 39 En A102 0 80 1 2 1 2 1 1 A202 12 1 7 1 8 1 5 A 203 1 5 E F 1 7 2 4 1 6 A302 1
11. 3 3 3 5 5 44 F502 9 7 7 2 8 1 5 2 9 7 7 6 F 503 9 7 7 2 8 1 5 2 9 7 7 6 F504 9 7 74 8 1 5 1 9 9 7 4 F603 14 11 7 9 11 15 11 F604 15 12 8 0 11 15 11 Life time lubricated gear units Lubricant is not factory filled BONFIGLIOLI Ht 34 RIDUTTORI Worm gear units series VF A14 0 B3 B6 B7 B8 V5 V6 VF 27 N A V F HS P IEC 0 025 0 025 0 025 0 025 0 025 0 025 VF 30 N A V F P HS P IEC 0 045 0 045 0 045 0 045 0 045 0 045 VF 44 N A V F FA P HS P IEC 0 075 0 075 0 075 0 075 0 075 0 075 VFR 44 N A V F FA P P IEC 0 050 0 050 0 050 0 050 0 050 0 050 VF 49 N A V F FA P HS P IEC 0 12 0 12 0 12 0 12 0 12 0 12 VFR 49 N A V F FA P HS P IEC 0 065 0 065 0 065 0 065 0 065 0 065 VF 130 N HS P IEC 2 3 2 5 2 5 3 0 3 2 3 4 VFR 130 N HS P IEC 0 70 0 50 0 50 0 40 0 40 0 50 VF 130 V HS P IEC 3 4 2 5 2 5 3 1 3 0 2 5 VFR 130 V HS P IEC 0 50 0 50 0 50 0 40 0 40 0 70 VF 130 A F FC FR P HS 3 9 2 5 2 5 2 3 3 3 3 3 VF 130 A F FC FR P P IEC 3 0 2 5 2 5 2 3 3 3 3 3 VFR 130 A F FC FR P HS P IEC 0 40 0 50 0 50 0 70 0 40 0 50 VF 150 N HS P IEC 3 0 3 5 3 5 4 3 3 8 4 0 VFR 150 N HS P IEC 1 0 0 80 0 80 0 60 0 40 1 0 VF 150 V HS P IEC 4 0 3 5 3 5 3 6 4 3 3 0 VFR 150 V HS P IEC 1 0 0 80 0 80 0 4
12. gear units classified under 94 9 EC voids the ATEX certi fication Mt Nm F 10 10 F 20 10 F 30 20 F 40 20 F 50 50 F 60 50 The torque arm shown in the diagram is to be supplied by customer BONFIGLIOLI 2 RIDUTTORI _ TT nn Rn 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 A0 When the gear unit is mounted to an IEC electric motor proceed as follows Apply a layer of sealant Loctite 510 or equivalent 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 ST 1 Apply Loctite 510 to both the flange surface and spigot 2 Apply Kluberpaste 46MR401 to the input shaft bore and motor shaft 3 Use L
13. 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 Z RIDUTTORI _ LT TC Q 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 his safety and that of all other persons involved 4 2 1 Moving packages e Prepare a suitable delimited area with a level floor or surface for unloading the packages e 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 spe
14. not factory filled 36 BONFIGLIOLI 2 RIDUTTORI ANNEX 3 CUSTOMER S SHAFT Series A F UH_ A17 A1 A2 A3 B B1 B2 o D E F G R S gt UNI 6604 A 05 230 25h7 24 102 21 62 20 2 2 28 8 h9 0 5 1 5 8x7x20 A 235 30h7 29 118 16 87 20 2 2 33 8h9 05 1 5 8x7x20 A n2 230 25h7 24 118 16 87 20 2 2 28 8h9 05 1 5 8x7x20 A 242 35h7 34 138 20 98 20 2 2 38 10h9 0 5 1 5 10x8x20 A A gt 35 30h7 29 138 20 98 25 2 2 33 8h9 05 1 5 8x7x25 A 247 40h7 39 158 23 112 30 2 2 43 12h9 05 1 5 12x8x30 A AU 242 35h7 34 158 23 112 30 2 2 38 10h9 0 5 1 5 10x8x30 A AGE 247 40h7 39 175 33 109 40 2 2 43 10h9 1 1 5 12x8x40 A 242 35h7 34 175 33 109 40 2 2 38 10h9 1 1 5 10x8x40 A 252 45h7 44 184 28 128 45 2 5 25 495 14n9 1 2 14x9x45 A M 247 40h7 39 184 28 128 50 2 5 2 5 43 12h9 1 2 12x8x50 A gt 63 55h7 54 226 37 5 151 55 2 5 2 5 59 16h9 1 2 16x10x55 A AS 257 50h7 49 226 37 5 151 65 2 5 25 535 1ang 1 2 14x9x65 A 270 60h7 59 226 37 5 151 65 2 5 2 5 59 16h9 2 2 18x11x65 A A33 gt 60 50h7 49 226 375 151 75 2 5 25 535 14h9 2 2 14x9x75 A 2o 278 70h7 69 248 48 152 70 2 5 25 745 20h59 2 5 2 20x12x70 A 268 60n7 59 248 48 152 80 2 5 2 5 64 18h9 25 2 18x11x80 A 289 80
15. 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 e 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 A5 Mn2 Interval hours Mr2 1 0 5000 1 25 10000 1 5 17000 1 75 27000 2 0 40000 Mn2 nominal torque at output shaft Me required torque at output shaft 22 BONFIGLIOLI 2 RIDUTTORI _ LT TC E 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 re
16. 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 ep 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 ZN with highly corrosive and or abrasive vapours smoke or dust 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 shaft must be protected by a guard BONFIGLIOLI RIDUTTORI 19 ER 8 0 MAINTENANCE in the observance of applicable laws on health
17. 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 O gt Installation of gear units classified under Directive 94 9 EC 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 w
18. 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 the 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 C05 C11 C 21 A05 A10 A 20 F 10 F 20 F 30 S 10 S 20 S 30 KAI VF 27 VF 30 VF 44 W63 W75 W86 If the gear unit is to be painted tape the nameplate and seal rings to prevent contact with solvent BONFIGLIOLI M 26 RIDUTTORI m 200 i 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 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 i
19. 0 Mobil Glygoyle 320 Glygoyle 460 Mobilgear SHC XMP 220 Mobilgear SHC XMP 320 Mobil SHC 630 Mobil SHC 632 Glygoyle 460 UH1 ECastrol Alphasyn PG 220 Alphasyn PG 320 9 TOTAL Carter SY 220 Carter SY 320 Carter SY 460 Nevastane SY 460 Degol GS 220 Degol GS 320 Degol PAS 220 va TEXACO Synlube CLP 220 Synlube CLP 320 Renoling PG 220 Renoling PG 320 G Grease F Food grade BEI Recommended Permitted BONFIGLIOLI Z RIDUTTORI 25 gt IQ i II L i RN 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
20. 0 0 60 1 0 VF 150 A F FC FR P HS 4 5 3 5 3 5 3 0 3 9 3 9 VF 150 A F FC FR P P IEC 4 3 3 5 3 5 3 0 3 9 3 9 VFR 150 A F FC FR P HS P IEC 0 60 0 80 0 80 1 0 0 40 1 0 VF 185 N HS P IEC 5 0 5 5 5 5 7 8 6 6 6 8 VFR 185 N HS P IEC 1 0 0 80 0 80 0 60 0 40 1 0 VF 185 V HS P IEC 6 8 5 5 5 5 6 4 7 8 54 VFR 185 V HS P IEC 1 0 0 80 0 80 0 40 0 60 1 0 VF 185 A F FC FR P HS 9 6 5 5 5 5 5 0 6 7 6 7 VF 185 A F FC FR P P IEC 7 8 5 5 5 5 5 0 6 7 6 7 VFR 185 A F FC FR P HS P IEC 0 60 0 80 0 80 1 0 0 40 1 0 VF 210 N HS P IEC 7 5 9 5 9 5 7 3 9 2 9 0 VFR 210 N HS P IEC 1 3 1 1 1 1 0 80 0 70 1 3 VF 210 V HS P IEC 8 9 9 5 9 5 7 3 11 8 0 VFR 210 V HS P IEC 1 3 1 1 1 1 0 60 0 90 1 3 VF 210 A F FC FR P HS 15 9 5 9 5 7 5 9 4 8 9 VF 210 A F FC FR P P IEC 11 9 5 9 5 7 5 9 4 8 9 VFR 210 A F FC FR P HS P IEC 0 80 1 1 1 1 1 3 0 70 1 3 VF 250 N HS P IEC 11 17 17 11 17 17 VFR 250 N HS P IEC 1 3 1 1 1 1 0 80 0 70 1 3 VF 250 V HS P IEC 17 17 17 11 23 11 VFR 250 V HS P IEC 1 3 1 1 1 1 0 60 0 90 1 3 VF 250 A F FC FR P HS 28 17 17 11 18 17 VF 250 A F FC FR P P IEC 23 17 17 11 18 17 VFR 250 A F FC FR P HS P IEC 0 80 1 1 1 1 1 3 0 70 1 3 VF permanent lubrication VFR permanent lubrication For VFR units the lubricant charge refers only to the additional helical reduction T a BONFIGLIOLI RIDUTTORI 35 Worm gear units series W A15 U de i 7 10 12 15 0 31 0 31 0 31 0 31 0 31 0 31 W 63 0 15
21. 0h7 39 104 28 48 30 2 2 43 12h9 0 5 1 5 12x8x30 A 242 35h7 34 104 28 48 30 2 2 38 10h9 0 5 1 5 10x8x30 A F 40 252 45h7 44 118 27 5 63 45 2 5 2 5 49 5 14 h9 1 2 0 14x9x45 A 247 40h7 39 118 27 5 63 45 2 5 2 5 43 12 h9 1 2 0 12x8x45 A F 50 263 55h7 54 139 33 73 50 2 5 2 5 59 16 h9 1 2 0 16x10x50 A 257 50h7 49 139 33 73 50 2 5 2 5 53 5 14 h9 1 2 0 14x9x50 A F 60 278 70h7 69 180 38 104 70 2 5 2 5 74 5 20 h9 1 2 0 20x12x70A 268 60 h7 59 180 38 104 70 2 5 2 5 64 18 h9 1 2 0 18x11x70 A F70 289 80h7 79 229 58 113 75 3 3 85 22h9 2 5 2 5 22x14x75 A 278 70h7 69 229 58 113 75 3 3 74 5 20h9 2 5 2 5 20x12x75 A F 80 299 90 h7 89 272 78 116 100 3 3 95 25h9 2 5 2 5 25x14x100 A 289 80h7 79 272 78 116 100 3 3 85 22h9 2 5 2 5 22x14x100 A F 90 gt 111 1100 h7 99 333 87 5 158 110 3 3 106 28h9 2 5 2 5 28x16x110 A 299 90h7 89 333 87 5 158 110 3 3 95 25h9 2 5 2 5 25x14x110 A B S 15 S i A20 A1 A2 A3 A4 B B1 B2 R S F10 gt 36 27 h7 24 25 h6 138 34 70 0 5 1 5 F 20 gt 42 32 h7 29 30 h6 160 38 84 0 5 1 5 F 30 gt 50 38 h7 35 36 h6 155 40 73 1 2 F 40 gt 58 44 h7 41 42 h6 177 46 5 82 1 2 F 50 gt 68 54 h7 51 52 g6 201 48 91 1 2 F 60 gt 84 67 h7 64 65 g6 248 53 133 1 5 2 F 70 2104 82 h7 79 80 g6 308 78 140 2 5 2 5 F 80 gt 114 92 h7 89 90 g6 365 88 177 2 5 2 5 F 90 gt 126 102 h7 99 100 g6 429 5 98 221 5 2 5 2 5 BONFIGLIOLI 38 RIDUTTORI Series VF and W A21 A1 A2 A3 B B1 B2 C D E F G R S 3 UNI
22. 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 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 A3 AT C C 11 C 61 75 A 10 A 60 75 F 10 F 60 75 VF 44 VF 49 75 W 63 W 86 75 W 110 90 BONFIGLIOLI 2 RIDUTTORI 21 ES O gt Check the condition of the temperature indicator previously installed on the gear unit during commissioning Example p 96 7300 7300 Limit temperature exceeded Limit temperature NOT exceeded Also check that the temperature is not excessive around the gear unit s 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
23. 6604 VF 30 219 14f7 13 53 18 5 16 40 6 5 6 5 16 5h9 0 5 1 5 5x5x40 A VF 44 223 18f7 17 62 22 5 17 50 6 6 20 5 6h9 0 5 1 5 6x6x50 A VF 49 gt 30 25f7 24 80 20 5 39 20 2 2 28 8 h9 1 1 5 8x7x20 A VF 130 252 45f7 44 163 50 5 62 60 2 5 2 5 49 5 14h9 2 5 2 14x9x60 A VF 150 257 50f7 49 173 53 67 70 2 5 2 5 53 5 14h9 2 5 2 14x9x70 A VF 185 gt 68 60f7 59 188 63 62 80 2 5 2 5 64 18h9 2 5 2 18x11x80 A VF 210 gt 99 90f7 89 258 83 92 80 3 3 95 25 h9 2 5 2 5 25x14x80 A VF 250 2 121 110 h7 109 318 83 152 80 3 3 116 28h9 2 5 2 5 28x16x80 A A22 A1 A2 A3 B B1 B2 c D E F G R S UNI 6604 W 63 230 25f7 24 118 38 42 35 28 8 h9 1 1 5 8x7x35 A 235 28f7 27 125 38 49 40 31 8 h9 1 1 5 8x7x40 A W 75 235 30f7 29 125 38 49 40 33 8 h9 1 1 5 8x7x40 A N IN N N N NM NM ND W 86 242 35f7 34 138 43 52 40 38 10h9 1 5 1 5 10x8x40 A W 110 248 42f7 41 153 43 67 50 2 5 2 5 45 12h9 1 5 2 12x8x50 A BONFIGLIOLI a RIDUTTORI 39 _ IE LL LA IE nn Rn 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 th
24. 8 9 9 2 3 26 24 A 303 DE x i 24 3 5 2 3 A412 4 0 4 1 4 1 4 7 52 44 A413 4 0 4 0 4 0 4 7 6 1 3 9 A 502 4 9 8 1 4 7 8 4 11 9 2 A 50 3 5 1 8 1 47 8 4 11 9 2 A504 6 3 8 2 5 3 8 3 13 9 1 A602 6 8 8 1 12 15 18 15 A603 6 8 8 1 12 15 18 15 A604 7 2 11 74 16 19 14 Life time lubricated gear units Lubricant is not factory filled T a BONFIGLIOLI RIDUTTORI 33 Shaft mounted gear units series F A12 pa a 1 F 102 0 95 0 95 0 95 0 95 0 95 0 95 F 202 1 4 1 4 1 4 1 4 1 4 1 4 F203 1 8 1 8 1 8 1 8 1 8 1 8 F 302 2 6 2 1 ES 21 2 9 al F303 2 6 2 1 ES 2 1 2 9 21 F 304 2 9 2 4 1 7 2 4 3 2 2 4 F 402 5 0 3 9 4 0 3 1 5 1 4 0 F 403 5 0 3 9 4 0 3 1 5 1 4 0 F404 5 3 4 3 4 3 3 3 5 5 4 4 F 502 9 2 6 7 7 6 4 7 9 2 6 7 F503 9 2 6 7 7 6 4 7 9 2 6 7 F504 9 7 7 4 8 1 5 1 9 9 7 4 F603 14 10 7 4 10 14 10 F604 15 12 8 0 11 15 11 F703 23 20 9 7 16 24 19 F704 23 20 9 7 16 27 19 F 803 40 34 16 29 42 31 F804 40 34 16 29 48 31 F 903 71 59 32 49 76 55 F904 71 59 32 49 86 55 A13 di Cy F102 1 2 1 3 0 70 0 80 0 80 11 11 F 202 2 0 1 7 0 90 418 1 2 1 7 F 20 3 2 3 1 8 1 2 1 5 1 8 1 8 ZN F 302 2 6 2 6 1 5 1 1 2 5 2 6 F 30 3 2 5 2 5 1 5 1 6 2 4 2 5 F304 3 0 2 7 1 9 2 0 3 3 2 Ex F 40 2 5 5 4 4 4 5 3 6 5 6 4 9 F403 515 4 4 4 5 3 6 5 6 4 9 F404 5 3 4 3 4
25. C 21 2_ P80 P112 75 75 75 75 75 40 75 75 75 75 75 45 75 75 75 75 75 45 C 21 3_ P63 P71 50 50 50 50 50 30 50 50 50 50 50 30 50 50 50 50 50 30 C 21 3_ P80 P112 55 55 55 55 55 30 55 55 55 55 55 30 55 55 55 55 55 30 C312 P63 P112 HS 65 65 65 65 60 60 65 65 65 65 55 55 65 65 65 65 55 55 C313 P63 P112 55 55 55 55 55 55 55 55 55 55 155 55 55 55 55 55 55 55 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 30 T a BONFIGLIOLI RIDUTTORI I XN Bevel helical gear units A 10 A 20 and A 30 Mounting positions B6 and B7 S5 LA 3 Nar N A Z NS NS A 7 wel O gt A8 B6 B7 A10 P63 P112 30 30 A 20_ P63 P112 HS 25 25 A30 P63 P112 HS 30 30 Values in the table are given in mm To check the oil level procee
26. Even minimal variations to said conditions e g smaller mounting cabinet could have a significant impact on the build up of heat Lighting A 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 2 RIDUTTORI m LI 3 0 SAFETY INFORMATION 3 1 SAFETY 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 an
27. OLI a RIDUTTORI 47 _ IE LL LA IE nn Rn 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 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 A centre 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
28. ON Bearing temperature too high Oil level too low Top up oil level Oil too old Replace oil Defective bearings Contact authorised workshop Operating temperature too high Oil level too high Check oil level Oil too old Replace oil Impurities in oil Replace oil Abnormal running noise Gears damaged Contact authorised workshop Bearing axial backlash too high Contact authorised workshop Bearings defective or worn Contact authorised workshop Service load too high Correct 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 Gears damaged Contact authorised workshop 28 BONFIGLIOLI 2 RIDUTTORI _ LI ML Q Dis ANNEX 1 CHECKING OIL LEVEL ON ATEX SPECIFIED GEAR UNITS
29. 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 Ex no plastic parts capable of building up electrostatic charge irreversible temperature indicator supplied along with each unit 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 Direct
30. and safety at work and the special ambient Maintenance and replacement work must be done by expert maintenance technicians trained 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 e When working on the gear unit always replace gaskets and seals with new original ones If 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 gear unit The Manufacturer declines all liability for injury and da
31. cified e 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 e 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 e e e Move the gear unit to the unloading area and lower it gently into position taking care 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 2 RIDUTTORI 9 ES 4 3 STORAGE Some recommendations for storing the gear unit are indicated below 1 Do not store the unit in excessively humid conditions or where it is exposed to the weather do not store outdoors 2 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 Stor
32. d as follows 1 Place the gear unit in the mounting position as shown in diagram S5 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 S5 above 4 The value X must be less than the value given in table A8 BONFIGLIOLI RIDUTTORI 31 ES ANNEX 2 LUBRICANT FILL QUANTITY Helical in line gear units series C A9 ei A F U UF B3 B6 B7 B8 V5 V6 B5 B51 B53 B52 V1 V3 B5 B51 B53 B52 Vi V3 C052 0 35 0 35 0 35 0 35 0 35 0 35 0 35 0 35 0 35 0 35 0 35 0 35 C112 0 45 0 45 0 45 0 45 0 50 0 60 0 40 0 40 0 50 0 50 0 50 0 60 0 40 0 40 0 50 0 50 0 50 0 60 C212 0 80 0 80 0 80 0 80 0 85 1 1 0 75 0 75 0 75 0 75 0 80 1 0 0 75 0 75 0 75 0 75 0 80 1 0 C213 12 42 442 3 2 dev sh 12 12 12 12 dus JA ELO 1 2 12 2 se dd C312 de pod p xb 14 15 Jm Js p S 18 13 10 15 18 18 13 ESA 15 15 C 313 16 1 6 16 1 6 1 8 18 1 6 1 6 1 6 1 6 1 818 1 6 16 16 1 6 1 8 1 8 C 352 145
33. d 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 procedures 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 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 N If the gear unit is to be serviced in a potentially explosive atmosphere the operator must first residual gas or dust etc
34. ditions 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 i bi Temperature i measurement re 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 AT C C 11 C 61 75 A 10 A 60 75 F 10 F 60 75 VF 44 VF 49 75 W 63 W 86 75 W 110 90 Should the temperature differential exceed these values stop the gear unit at once and contact the BONFIGLIOLI RIDUTTORI technical service e 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 5 n66 7300 e At the same time check for excessive running noise and vibration BONFIGLIOLI 2 RIDUTTORI _ LI ML Rn Provided all the above checks have been passed and that all other instructions in this manual have been strictly observed an electric 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
35. e 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 Manual Through mechanical equipment Simbol M A B Approximate weight lt 15 Kg gt 15 Kg Recommended method for po Recommended method for InetueNon sitioning handling and positioning Warning The load may be unstable The load may sway or oscillate Slide the lifting ring to align it with the load s centre of gravity as shown in the diagrams below SET Cade Lock the ropes under the ring i STO ME CSR Solution 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 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 2 RIDUTTORI
36. e 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 oil 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 O gt If the oil or protective material used during storage is not 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 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 direct
37. environment and dispose of in compliance with applicable legislation If a leak is found identify the cause of the fault repair it and refill with lubricant before opera ting the gear unit BONFIGLIOLI RIDUTTORI 23 ES 8 4 RECOMMENDED PERMITTED OILS OILS AND GREASES COMPATIBLE with Atex certified gear units Greases e Kl ber Asonic GHY 72 for bearings e Shell TVX Compound B for greased gear trains Shell Tivela GL 00 alternative for greased gear trains Kl berpaste 46 MR 401 to facilitate coupling of cylindrical parts N ITP Fluorocarbon gel 880 for greasing contact seals Oils as alternatives to Shell Tivela Oil S 320 e Shell Tivela Oil SC320 Aral Degol GS 320 e IP Telium Oil VSF 320 o Agip e Kl ber Kl bersynth GH 6 320 e Total Carter SY 320 e Mobil Glygoyle HE 320 BONFIGLIOLI pa 24 RIDUTTORI c S F 11 100 10 50 10 90 Shell Tivela S 220 Tivela S 320 Tivela S 460 A 05 60 70 90 VF VER WR VF_L W_L VF EP W EP 0 25 0 5 VR 0 25 10 Donax TX Donax TA Cassida Fluid WG 460 Cassida Fluid HF 46 Tivela GL 00 ii Blasia S 220 Blasia S 320 O Spartan EP 220 Spartan EP 320 Kl bersynth GH 6 220 Kl bersynth GH 6 320 Kl bersynth UH1 6 46
38. es 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 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 2 RIDUTTORI Um Lm A0 Tightening torque Nm 5 10 Holtslze Bolt class 8 8 10 9 M4 3 3 8 M5 5 9 8 0 M6 10 3 13 0 M8 25 5 32 M10 50 64 M12 87 3 110 M14 138 3 180 M16 210 9 275 M18 306 390 M20 432 540 M22 592 720 M24 744 930 M27 1100 1400 M30 1500 1850 Cap vent thread Pitch Tightening torque Nm 1 8 28 5 1 4 19 7 3 8 19 7 1 2 14 14 3 4 14 14 1 11 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
39. f 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 Certifying agency with whom the technical file has been deposited Readability of the nameplate The nameplate and the 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 RIDUTTORI 3 _ IE LL LA IE nn Rn 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 elect
40. h7 79 303 58 187 90 3 3 85 22h9 2 5 2 5 22x14x90 A ATO 278 70h7 69 303 58 187 110 3 3 745 20h9 2 5 2 5 20x12x110 A fo gt 99 90h7 89 358 78 202 120 3 3 95 25h9 2 5 2 5 25x14x120 A gt 89 son 79 358 78 202 130 3 3 85 22h9 25 2 5 22x14x130 A T ME 111 100h7 99 408 78 252 160 3 3 106 28h9 2 5 2 5 28x16x160 A gt 99 90h7 89 408 78 252 190 3 3 95 25h9 2 5 2 5 25x14x190 A B S 15 US i A18 A1 A2 A3 A4 B B1 B2 R S A 10 242 32 h7 29 30 h6 147 5 34 77 5 0 5 1 5 A 20 248 37 h7 34 35 h6 170 40 89 0 5 1 5 A 30 254 42 h7 39 40 h6 191 5 48 95 5 0 5 1 5 A35 254 42 h7 39 40 h6 208 5 48 112 5 0 5 1 5 A41 gt 60 47h7 44 45 h6 222 53 117 1 2 A 50 gt 72 57 h7 54 55 g6 264 46 156 1 2 A55 2 72 62 h7 59 60 g6 266 46 158 2 5 2 A 60 2 90 72 h7 69 70 g6 293 48 178 2 5 2 5 A 70 gt 104 82 h7 79 80 g6 352 5 90 172 5 2 5 2 5 A 80 2114 92 h7 89 90 g6 416 100 216 2 5 2 5 A 90 gt 126 102 h7 99 100 g6 469 78 321 2 5 2 5 aug 37 Series F F H de A19 A1 A2 A3 B B1 B2 C D E F G R S SS UNI 6604 F 10 235 30h7 29 79 15 5 48 20 2 2 33 8 h9 0 5 1 5 8x7x20 A 230 25h7 24 79 15 5 48 20 2 2 28 8 h9 0 5 1 5 8x7x20 A F 20 242 35h7 34 99 18 63 22 2 2 38 10h9 0 5 1 5 10x8x22 A 235 30 h7 29 99 18 63 22 2 2 33 8 h9 0 5 1 5 8x7x22 A F 30 247 4
41. i 19 24 30 38 45 64 80 100 0 38 0 38 0 38 0 38 0 38 0 38 i 7 7 10 15 0 48 0 48 0 48 0 48 0 48 0 48 W 75 i 30 40 0 52 0 52 0 52 0 52 0 52 0 52 0 25 i 20 25 50 60 80 100 0 56 0 56 0 56 0 56 0 56 0 56 i 7 10 15 0 64 0 64 0 64 0 64 0 64 0 64 W 86 i 30 0 73 0 73 0 73 0 73 0 73 0 73 0 25 i 20 23 40 46 56 64 80 100 0 90 0 90 0 90 0 90 0 90 0 90 B6 B B 6 R B P80 P132 ST 1 7 1 9 1 7 1 6 M2 M3 1 7 1 7 1 9 1 7 1 6 W 110 0 40 7 lt i lt 15 1 7 17 1 9 1 7 1 6 i 20 lt i x 100 117 1 7 1 9 1 7 1 6 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 u P F B3 B6 B7 B8 V5 V6 B5 B51 B52 B53 Vi v3 S 101 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 S 20 1 0 45 0 45 045 0 45 0 45 0 45 0 45 0 45 0 45 045 0 45 0 45 S 30 1 0 70 0 70 0 70 0 70 0 70 0 70 0 70 0 70 0 70 0 70 0 70 0 70 S 40 1 1 6 1 6 1 6 1 6 1 6 1 6 1 6 1 6 1 6 1 6 1 6 1 6 S 50 1 1 7 2 2 2 2 3 0 3 0 2 0 1 7 1 7 1 7 1 7 3 0 2 0 Life time lubricated gear units Lubricant is
42. in film of Loctite 510 or equivalent 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 Po BONFIGLIOLI RIDUTTORI 13 _ IE LL LA IE _ V A TN 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 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 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 Ss B E The bolt 1 and spacer 2 are to be supplied by customer BONFIGLIOLI a 14 RIDUTTORI 5 1 3 Gear units with shrink disk S Rn Series A and F gear units may be specified with a shrink disk for coupling onto the driven shaft When instal ling a uni
43. isk re ene a de AR en e pa chasse 15 5 1 4 Shaft mounted gear units series Foo eee e ese eese mese eene 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 4 ROUTINE MAINTENANCE E e aee eei Ve 21 8 2 LUBRICANTS S As rettet ettet tette Ufer a esee S mad ea T o tad e ped 23 8 3 OILS CHANGE tet Ete sob ele a aca da ld dn e halte ie e af se eet ebay t Set 23 8 4 RECOMMENDED PERMITTED OILS IR e eR RII ese e e e le ele e e p p e ee cui 24 8 5 CHECKING EFFICIENCY Toorn ento Eee nn a E ect de e Scanned ER RUE 26 8 9 CLEANING iii a tgo cote SLE e A en emo eo eet Lose edis foto cara ea Ss na 26 8T PAINT ae tese iena M ES Su C E EMEND EN 26 9 0 REPLACING PARTS 27 9 1 TAKING APART OF THE IEC STANDARD FLANGED MOTOR 27 9 2 SGRAPPING THE GEAR UNIT i oe c e E S t t etus 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 eee ee ee Re ee ee I m n ne Rem e mem Re ee Re re rer e neni 32 Bevel helical gear units series A o eoo ere San doe oa pate eerta t Ege queer ela 33 Shaft mounted gear units series Fo enn a n e es sena 34 Worm gear units series V criniera s t RU IS ER ERAS Ret 35 Worm gear units series W gle dale odjek 1 ode ae me gola rr i iii ete
44. ith 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 Q 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 e f 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 A0 To prevent bolts from unscre wing apply a th
45. ive 94 9 EC and conform to the following classification ZN Equipment group II Calass Gas 2G Dust 2D Ex Zone Gas 1 Dust 21 e 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 or 160 C for 2G and 2D BONFIGLIOLI 2 RIDUTTORI 5 _ gt LS prts NE Rn 2 3 OPERATING LIMITS AND CONDITIONS A 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 Operation of gear units is permitted at ambient temperatures between 20 C and 40 C However for temperatures between 20 C and 10 C unit may only start up after it has been progressi vely and evenly pre heated or otherwise initially operated unloaded Load may then be connected to the output shaft when the gear unit has reached the temperature of 10 C or higher Do not use 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 IN The nameplate data on the maximum surface temperature refer to measurements made in nor mal ambient and installation conditions
46. kg use with harness BR A Lift as per diagram A Snap hook use with rope 9 M ie de B Lift as per diagram B Maximum permissible tilt during handling 15 o J Te p x Allen wh a aad TT zv LR BONFIGLIOLI xt RIDUTTORI 43 IED il 4E M05 M1 M2 M3 M4 S 10 1 M A M M S 20 1 M A M M S 30 1 M A M M S 40 1 A A A S 50 1 A A A Reccomended solution A for positioning M Lift manually weight lt 15 kg Ring harness A Lift as per diagram A Maximum permissible tilt during handling 15 44 BONFIGLIOLI 2 RIDUTTORI 9 W 63 WR 63 M M W 75 WR 75 A B M M W 86 WR 86 A B M M W 110 WR 110 A B B A B Reccomended solution A for positioning solution B for positioning and handling ln i M pulus Ed kg aie N 2 Rope and hooks sei A Lift as per diagram A MA Eyebolt B Lift as per diagram B BONFIGLIOLI 2 RIDUTTORI 45
47. ly 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 OO Oe cogi 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 external 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 toleranc
48. mage 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 the cavity between the two rings must be packed with synthetic grease Fluorocarbon gel 880 ITP or equivalent product with similar
49. ndicated below S3 BORE AND TAP IMPACT EXTRACTOR 1 Drill and thread the motor shaft fan side 2 Screw an impact extractor tool into the tap 3 Undo the screws fixing the motor to the gear unit 4 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 trained in the observance of applicable laws on health and safety at work Do not dump non biodegradable products lubricants and non ferrous materials rubber PVC resins etc into the environment Dispose of all such materials as stipulated by 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 _ IE LL LA IE nn Rn 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 CAUSE SOLUTI
50. octite 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 16 BONFIGLIOLI 2 RIDUTTORI Mm LI 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 unit s 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 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
51. 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 Useonly original spare parts for repairs ob BONFIGLIOLI ha 20 RIDUTTORI 8 1 ROUTINE MAINTENANCE _ LI ML Q Dis 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 1000 h External seals and gaskets Check oil level Maintain or replace compo Check for leaks by eye nents as required 3000 h For gear units with torque Check for cracks ageing Replace if no longer fully arm polymer bushings effective 5000 h Gear unit seals and gaskets Inspect carefully for Wealiage Replace if aged worn ing of external seals 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 depth O gt Every 1000 h of operation or after
52. quire periodic lubricant changes Do not mix oils of different nature or specifications 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 N 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 N 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 AN 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
53. r eee 36 Single stage helical gear units series S ee e I Ie e ee ee e ne n le rele eens 36 ANNEX 3 CUSTOMER S SHAFT 37 Kis xw crm 37 Seres Fin SRE cco erede ete HE E UMANE II NEM lea 38 Series VF and Wi ds tra ss Re hace Ron tq ei I EP dui uet e e m EM eR tios eM de 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 2 RIDUTTORI EI 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 Manufact
54. rical 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 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 unit s 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 par
55. se instructions may result in serious risks to personal and environmental safety IMPORTANT This symbol indicates important technical information BONFIGLIOLI 2 RIDUTTORI _ LI ML Q 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 TYPE Gear unit type CODE Product code Month Year of manufacture MOUNT o POS Mounting position BONFIGLIOLI RIDUTTORI S p A ITALY Gear ratio Nameplate for ATEX specified gear units Gear unit type Gear ratio Product code Transmissible torque at nj 1400 rpm Nm Mounting position Month Year of manufacture Maximum drive speed BONFIGLIOLI HPPODI em Y POU ae Certification Nr Temperature class or maximum surface temperature Maximum surface temperature CE amp Mark e Environmental limits ambient temperature range between 20 C and 40 C Maximum surface temperature temperature class T4 for 2G and 130 C for 2D Some types o
56. t 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 of the 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 gt Fit the 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 m A05 A10 A20 A30 A35 A41 A50 A55 A60 A70 A80 A 90 Mt Nm 14 5 14 5 14 5 14 5 14 5 14 5 35 35 35 35 69 69 m N F40 F20 F30 F40 F50 F60 F70 F80 F 90 Mt Nm 8 5 14 5 14 5 14 5 14 5 35 35 69 69 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
57. tate 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 the pinion 1 should be snug against the bushing 2 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 Lubricate the seal ring lips with a film of grease 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 VER units 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 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 VFR 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 le BONFIGLI
58. this manual are filled in the factory The standard charge of synthetic life time lubricant is as fol lows A1 C05 C11 C 21 C 31 C35 C41 C 51 C 61 C70 C80 C90 C100 A05 A10 A20 A30 A35 A41 A50 A55 A60 A70 A80 A90 F 10 F 20 F 30 F 40 F 50 F 60 F 70 F 80 F 90 S 10 S 20 S 30 S 40 S 50 VF 27 VF 30 VF 44 VF 49 VF 130 VF 150 VF 185 VF 210 VF 250 W63 W75 W86 W110 Life time lubrication Life time lubrication with ATEX specified unit only 12 BONFIGLIOLI 2 RIDUTTORI ES ep 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 85 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 mounting position for the gear unit in
59. ts do not attempt to use the unit contrary to the instructions supplied the instructions given in this manual do not substitute but summarise the provisions of applicable safety legislation the configurations given in the gear unit catalogue are the only ones permitted BONFIGLIOLI 2 RIDUTTORI m LI 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 use of synthetic lubricants only oil and grease e VITON seal rings thread locker on all external bolts vent caps with anti intrusion valve N double oil seals on series C gear units
60. urer may also be made available in other languages to meet legal and or commercial requirements The documentation must 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 This symbol indicates the need to adopt specific precautions to avoid risks to the health and safety of personnel and possible economic damages 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 the
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