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PB manual - Sharpe Mixers

1. Telium VSF 320 Spartan EP 220 Spartan EP 320 Kl bersynth GH 6 220 HL BER LUBRICATION Klubersynth GH 6 320 Kl bersynth UH1 6 460 Glygoyle HE 320 Glygoyle HE 460 Mobilgear SHC XMP 220 Mobil Mobilgear SHC XMP 320 Mobil SHC 630 Mobil SHC 632 DTE FM 460 Alphasyn PG 220 Castrol Alphasyn PG 320 Carter SY 220 Carter SY 320 Carter SY 460 Degol GS 220 Degol GS 320 Degol PAS 220 Synlube CLP 220 Synlube CLP 320 G Grease F Food grade BONFIGLIOLI RIDUTTORI Renoling PG 220 Renoling PG 320 BEE Recommended Permitted 25 8 5 CHECKING EFFICIENCY Remove dust deposits from the gear unit and motor casings e 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 e Check the power absorption and voltage against the nominal values given on the motor s nameplate e Check the wear of linings on the brake motor if used and if necessary adjust the gap e Check for lubricant leaks from the gaskets seals caps and casings Check all bolted couplings for wear deformation or co
2. Oilleakage Excessive lubricant eCheck manual for proper amount lubricant and drain excess s Da maged broken gasket Replace gasket e Loose bolts around eCheck and tighten bolts side plates eSealswom or Replace seals damaged Vent not installed clogged e Replace seals install unclog vent e Shaft vibration e Impeller not immersed in liquid e Fill tank e lmpeller too close to surface e Fill tank or lower impeller see Paragraph B4 Bent mixer shaft Consult factory e Unsta ble mounting platform Reinforce platform Loose or improperly assembled e Assemble securely see Para B4 coupling shaft runout adjacent to coupling should be lt 0 005 e Debrs in coupling Clean and reassemble Damaged gearbox bearings eCheckand replace if necessary e Debris on impeller eClean impeller e Loose or bent impeller blades e Tighten or straighten consult factory e Operating over maximum e Reduce motor speed shaft pm variable speed only BC 7440 11 1098 B 11 PROBLEM Seal leakage POSSIBLE CAUSE eInsufficient incorrect lubrication Wom mechanical seal e Damaged mating ring eSolids in seal gland eScored shaft e Insufficient incorect lubrication eExcessive heat e nc orrect seal position Exc essive shaft runout SOLUTON elubricate properly see Paragraph B7 check for scoring replace if necessaary Replace seal Replace mating ring Flush properly see Paragraph B8 Replace
3. S S NS S 3 3 N R e o SS AAA ER Sch ES IS aa Sex S ER N SS NS IR SE SS TER S x SS SSOO 360 x SS 0 ER QO SS S SS SR 3 AS NY 2 SS S WO Q SS S 2 EXA x EEE 4422 SRR AA 22 LG GE A 4 REGS VLG FREE SEN FS z 7 4 22 D Ae SS N SON ITS N N BOO SS eS ESA N HA OER 5 1 2 Gear units with hollow output shaft To facilitate mounting hollow shaft gear units onto the machine s driven shaft proceed as indicated in the diagram below Also refer to Annex 3 of this Manual for dimension information on customer s shaft KE NN The bolt 1 and spacer 2 are to be supplied by customer BONFIGLIOLI 14 RIDUTTORI 7 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 e 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 e 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
4. B8 15 Start Up Checklist Prior and during start up please check that the following things have been done a Manualhasbeen read and followed b Coupling bolts torqued to specifications C Hold washer tight when applicable d Proper shaft rotation see drawings amp data sheet e Shaft alignment confirmed with hand rotation f Steady bearing installed properly when applicable g Impeller is immersed in liquid h Suffic ient protection for motor if outdoors L Impeller s installed correctly see assembly drawings Gearbox vented k Mounting Impeller bolts tight l All guardsin place m Proper type and amount of lubricant see Section C n Motor chec ked for moisture absorption Resistance less than 3 meg ohms D Wiring correctly installed grounded and insulated p Correct voltage amperage Q start up Motor na meplate F LA F LA measured with amp meter Actualline voltage measured q Exc essive vibration of mixer sup port r Speed limitations set on variable speed controller when applicable LLL LLL D LELLLLLLLLLLLL S Properseallubrication when applicable t Proper seal run in time allowed INSPECTOR DATE BC 7440 9 109 C 0 098 B 9 PRO BLEM e Shaft will not fit into drive or coupling TROUBLE SHOOTING GUIDE POSSIBLE CAUSE Set screws extend into bore eShaft over size proper dia 0 001 0 002 under nominal dia eDamaged shaft e Overs
5. 61806 30x42x7 PAM 80 27 30 44 49 10x19x7 25x40x7 30x40x7 40x55x7 8x16x7 20x32x7 35x37x7 PAM 63 30x42x7 PAM 80 25x42x7 PAM 63 71 VF N Denominazione Description Denomination Benennung Denominaci n 4 Guarnizione cassa Gasket Joint Dichtung Junta 5 Cuscinetto Bearing Roulement Kugellager Rodamiento 6 Cuscinetto Bearing Roulement Kugellager Rodamiento 7 Anello di tenuta Oilseal Joint d etancheite Simmering Reten 57 30 44 49 8 Anello di tenuta Oilseal Joint d tanch it Simmering Ret n 10 Seeger i Circlip i Seeger i Seeger i Seeger i 12 Cappellotto in gomma Rubber cap Capouchon en caoutchouc Gummideckel Sombrerete de caucho 13 Vite a testa esagonale Hexagonal head screw Vis de fixation Schraube Tornillo exagonal 14 Dado alto Nut Ecrou Mutter Tuerca 35 Cuscinetto Bearing Roulement Kugellager Rodamiento 2 Corona elicoidale Wormwheel Couronne Schneckenrad Corona 3 Vite senza fine VVormshaft Vis sans fin Schnecke Vis sin fin N A P 30 44 49 9 Ralla Spacer ring Entretoise Lagerschale Distanciador F FC 11 Seeger Y e Circlip e Seeger e Seeger e Seeger e 15 Motore elettrico Electric motor Moteur lectrique El motor Motor el ctrico 24 Vite senza fine VVormshaft Vis sans fin Schnecke Vis sin fin 28 Cappellotto in gomma Rubber cap Capouchon en caoutchouc Gummideckel Sombrerete de caucho 27 Linguetta Key Clav
6. from the upper most port in the seal housing to the upper port in the lubricant reservoir The retum line runs from the bottom of the reservoirto the lower port in the seal housing Care must be taken not to attach the retum line to the cooling coil inlet or outlet if present which are also in the bottom of the reservoir Referto the reservoir drawing forthe orientation of the inlets and outlets Keep horizontal runsto a minimum B6 8 1 Fill the seal reservoir until liquid level is higherthan upper most plumbing line Recheck level after mixer hasrun a fevv minutes and replenish if necessary Operating liquid must be thin water like since thicker materials will not flow creating heat buildup and premature seal failure Iftank is pressurized maintain 15 30 psi above tank pressure in the lubricant reservoir Thisisaccomplished by either a permanent air line to the top of the reservoir vvith a pressure regulating valve a nitrogen tankor other compatible pressurized medium A back pressure valve may be incorporated to prevent the back flow of tank contents in case of seal failure during a loss of pressure in the supply system A low pressure shut off switch may also be used to shut down the mixer in case of a seal system failure B6 8 2 Many lubrication reservoirs incorporate alarms and other integrated systems which require thorough understanding priorto start up Sharpe Mixers recommends consulting with the mechanical seal l
7. impeller and cause damage to the equipment CAUTION DO NOTSTART MIXER WITH IMPELLER BURIED IN SOLIDS OR WITH LIQUID SO LUTIO N SOLIDI FIED DAMAGE WILL OC CUR B8 8 f impeller is buried in solids prior to starting mixer solids must be dispersed This may be achieved with an air hose a recirculating pump ora large stirring stick if necessary depending on tank Size B8 9 Align flexible motorcoupling on foot mounted motors only to reduce wearof flexible insert of coupling Check parallel alignment by placing a straight edge acrossthe two coupling flanges and measuring the maximum offset at various points around the coupling See Figure B10 1 DO NOTrotate the coupling This dimension must be less than 0 015 Check angular alignment with a mic om eterorcaliper Measure the outside of one flange to the outside of the other at intervals around the coupling See Figure B8 2 Find the maximum and minimum dimensions DO NOTrotate the coupling The difference between the maximum and minimum must not exceed 0 015 Recheck both parallel and angular alignments again Shims ma y be required to adjust propeny B8 10 Shaft seal must be lubric ated flushed during operation of mixer B8 11 When vanable speed drivesare used AC vanable frequency airorhydraulic motors amp mechanical vanable drives run only at speeds set forth on the data sheet and drawings in front of this manual DO NOTRUN ABOVE OR BELOW SPEEDS LISTED ON THE
8. the final steady bearing location will vary depending upon the shaft length and diameter Steady Bearing Positioning Bow in shaft greatly exaggerated for clarity Shaft a xis B5 3 The shaft wear sleeve must be fully engaged with the bearing B5 4 The steady bearing and wear sleeve are wearing partsand should be checked periodically It is recommended that a spare bearing and wear seeve be kept in stock at all times Path of shaft when rotated by hand Shaft axis and final location of centerline of steady bearing for properrotation FIGURE 1 MECHANICAL SEAL PREPARATION amp LUBRICATION B6 1 Mechanical seals are precision ma chined fragile components that are easily damaged by careless handling Any servicing of mechanical seal must be handled ina clean white coat manner Even a fingerprint on the mating seal faces Can cause premature leakage Most premature seal failures are due to lack of lubrication or improper installation Seal manufacturers offer mechanical seal maintenance seminars or seal schools to help service personnel understand seal operation The minimal cost and time required for this education is easily justified when the expense of down time and loss of product which occurs when mechanical seals fail prematurely is considered B6 1 1 Do notallow the mixer to be wired before prepaning the seal foroperation The electn cian may bump start the mixerto check for r
9. 250 HS P IEC HS P IEC VF 250 HS VF 250 P IEC VFR 250 BONFIGLIOLI RIDUTTORI HS P IEC VF permanent lubrication VFR permanent lubrication For VFR units the lubricant charge refers only to the additional helical reduction 35 ANNEX 4 LIFTING oks etc which are certified and adequate for the load When lifting use accessories such as eyebolts snap hooks screw clamps straps ropes ho The weight of the product to be lifted is given in the Sales Catalogue The method of attachment for the products covered by this Manual are detailed below according to the vario us product series sizes and configurations The most suitable type of solution for safely lifting and handling each is indicated below Symbols Lifting method Simbol Manual Through mechanical equipment A B Approximate weight gt 15 Kg Instruction Recommended method for po sitioning Recommended method for handling and positioning Warning The load may be unstable The load may sway or oscillate Solution Slide the lifting ring to align it with the load s centre of gravity as shown in the diagrams below Lock the ropes under the ring with a cable clamp or similar device so as to prevent them sliding and lift the load Observe all precautions regar ding the handling of loads Stabilise the moving
10. 3 BN 100LB 4 1410 20 80 10 78 6 9 5 2 3 2 2 54 22 FD 15 40 12400 14400 58 28 FA 15 40 4400 58 29 BA 100 50 3800 66 32 4 BN 112M 4 1420 27 83 10 78 89 56 2 7 2 5 98 30 FD06S 60 1400 107 40 FA 065 60 2100 107 42 BA 110 75 2000 114 43 5 5 BN 1325 4 1440 36 84 10 80 118 55 2 3 2 2 213 44 FD 56 75 11050 223 57 FA 06 75 1200 223 58 BA 140 150 1200 263 76 7 5 BN 132MA 4 1440 50 85 081 15 7 5 7 2 5 2 4 270 53 FD 06 100 950 280 66 FA 07 100 1000 280 71 BA 140 150 1000 320 85 9 2 BN 132MB 4 1440 61 86 0 81 191 59 2 7 2 5 319 59 FD 07 150 900 342 75 FA 07 150 900 342 77 BA 140 150 900 369 91 11 BN 160MR 4 1440 73 87 0 82 22 3 59 2 7 2 5 360 70 FD 07 150 850 382 86 FA 07 150 850 382 88 15 BN 160L 4 1460 98 89 0 82 29 7 59 2 3 2 1 650 99 FD 08 200 750 725 129 FA08 200 750 710 128 18 5 BN 180M 4 1460 121 89 0 61 370 6 2 2 6 25 790 115 FD 08 250 700 865 145 FA 08 250 700 850 144 22 BN 1800 4 1465 143 89 082 45 6 5 2 5 2 5 11250 135 FD 09 300 400 1450 175 30 BN 200L 4 1465 196 90 083 58 7 1 2 7 2 8 1650 157 FD 09 400 300 1850 197 NDUSTRY PROC
11. 41 1375 1 74 62 0 77 0 761 3 3 1 9 1 7 5 8 5 1 FD 03 3 5 7700 11000 6 9 7 8 FA 03 35 111000 69 7 5 BA 70 8 9700 78 9 0 0 37 BN 71B 411370 26 65 0 77 107 37 2 0 19769 59 FD 03 5 0 6000 9400 8 0 8 6 FA 03 5 0 9400 8 0 83 BA 70 8 8500 8 9 9 8 0 55 BN 71C 4 1380 38 69 0 74 155 4 1 23 2 3 9 1 7 3 FD 53 7 5 4300 8700 10 2 10 FA 03 7 5 8700 10 2 9 7 BA70 8 8000 11 1 112 0 55 BN 80A 4 1390 38 72 0 77 1 43 4 1 23 20 15 82 FD 04 10 14100 8000 16 6 12 1 FA 04 10 8000 16 6 12 0 BA80 18 7400 18 13 5 0 75 BN 80B 4 1400 5 1 75 10 78 1 85 49 2 7 2 5 20 99 FD 04 15 4100 7800 22 13 8 FA 04 15 7800 22 13 7 BA80 18 7400 23 15 2 1 1 BN 80C 4 1400 7 5 75 10 79 2 68 5 1 2 8 25 251113 FD04 15 2600 5300 27 15 2 FA 04 15 5300 27 15 1 BA80 18 5100 28 16 6 1 1 BN 90S 4 1400 7 5 73 0 77 282 46 26 2 2 211122 FD14 15 4800 8000 23 16 4 FA 14 15 8000 23 16 3 BA90 35 6500 28 19 5 1 5 BN90LA 4 1410 102 77 0 77 3 7 5 3 2 8 24 28 13 6 FD05 26 3400 6000 32 19 6 FA 05 26 6000 32 20 3 BA90 35 5400 35 21 1 85 BN90LB 4 1400 126 77 0 78 44 52 2 8 26 30 15 1 FD 05 26 3200 5900 34 21 1 FA 05 26 5900 34 218 BA90 35 15400 37 22 2 2 BN 100LA 4 1410 14 9 78 10 76 54 45 2 2 2 0 40 183 FD15 40 12600 4700 44 25 FA 15 40 4700 44 25 BA100 50 4000 52 29
12. AC Variable Speed Electric motors using an AC variable frequency controller must be wired following the instructions supplied with the controller Many adjustments are often required to the controller and instructions must be read result if speed limitations are not followed B 8 WARNING Ground the mixer motor properly to avoid serious injury to personnel Ground ing needsto be in accordance with the National Electrical Code and consistent with local building codes B 9 Othertypesof motors e g hydraulic must be installed perthe motor manufacturer instructions See data sheet and assembly drawings for possible RPM lockout ranges Operate only at speedsoutlined on those sheets Damage to equip ment or serious injury to personnel can result if speed limita tions are not followed B7 10 Motor lubrication Electric motor bearings are often sealed and need no relubrication When zirc fittings are present relubricate with a No 2 consistency lithium soap base and petroleum com pound Relubricate every 6 monthsto 3 years depending on usage Open and clean drains Add grease until new grease isforced out drain Remove excess grease and replace input plugs Run motor one half hourbefore replacing drain plugs SIART UP amp OPERATION B8 1 WARNING High voltage and rotating parts can cause seriousorfatal injury Loc kout Tagout powerbefore servicing B8 2 Some models may be shipped dry without lubricant and must be
13. BC 7440 13 109 C 0 13 1098 B 13 MAINTENANCE NO TES Description Date By B 14 BC 7440 14 1098 IM Bs DB T GA IM B5 DB 4 62 LB EA LL A a 3 A Eo 7 CIS RT d 4 A C B x E LB EA ADOS 4 nz q u A H K y DB A D BONFIGLIOLI 2 RIDUTTORI M30 LISTA PARTI DI RICAMBIO M30 SPARE PARTS LIST M30 ERSATZTEILLISTE M30 LISTE DES PIECES DETACHEE Th Statore completo Rotore completo Flangia IM B5 IM B14 Ventola Copriventola Scatola coprimorsettiera Guarnizione scatola coprimorsettiera Tappo filettato Morsettiera Vite serraggio flangia Cuscinetto Cuscinetto Anello di compensazione Linguetta Anello di tenuta Anello V ring Disponibile SOLO in kit BONFIGLIOLI RIDUTTORI Stator winding complete Rotor shaft Mounting flange IM B5 IM B14 Fan Fan cover Terminal box lid Terminal box gasket Blank plug Terminal board Bolt Bearing Bearing Compensation ring Key Seal ring V ring HEHH Only available as a complete kit Stator Laufer komplett Flansch IM B5 IM B14 L fter L fterhaube Klemmenkastendeckel Klemmenkastendeckeldichtung Gevvindest psel Klemmenplatte Schraube Kuge
14. DATA SHEET OR ASSEMBLY DRAWING S Specific data on these special drive components are located elsewhere in this manual Section D B 8 B8 12 Keep motorsfree from oil dust dirt water and chemicals Keep airintakes and outlets free from foreign material Electric motors supplied although designed foroutdooruse may be dam aged due to weather A rain hood orother protec tion may be necessary to prolong motor life Consult factory for recommendations B8 13 Regular maintenance isthe best assur ance of trouble free long life mixer operation Inspect and relubricate at regularintervals Fre quency and thoroughness dependson operation nature of service and environment CAUTION Before start up replace OSHA guards provided Seriousinjury may occurif not replaced B8 14 Inthe event of a break down within the warranty period Sharpe Mixers must be notified within 30 days if it isintended that the warranty isto coverthe problem When requesting spare replace ment parts anytime have serial numberand model number off mixer nameplate readily available Do not disassemble components or otherwise modify equipment without prior authorization from Sharpe Mixers or warranty will be voided Note Sharpe Mixers will not accept back chargesforany repair work that hasnot been previously authorized Flexible motor coupling adjustment foot mounted motors only m Calipers FIGURE B8 2 BC 7440 8 1098
15. 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 LA 8 0 MAINTENANCE Maintenance and replacement work must be done by expert maintenance technicians trained in the observance of applicable laws on health and safety at work and the special ambient problems attendant on the installation Before doing any work on the unit the operator must first switch off power to the gear unit and ensure that it is out of service as well as taking all necessary precautions against it be ing accidentally switched on again or its parts moving without warning due to suspended lo ads or similar external factors Furthermore all additional environmental safety precautions must be taken e g elimination of residual gas or dust etc e 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 e Replace worn components with original spare parts only Use the lubricants oil and grease recommended by the Manu
16. Lovver mixer shaft Hange Coupling FIGURE B3 3 B3 5 Remove motorfan guard and tum fan by hand to check that mixer shaft tums freely and alignment istrue Repeat once impellers are in stalled INSTALLING THE MIXER IMPELLER WARNING Alwayslockout power before installing or removing impeller B4 1 Referto mixer assembly and impeller detail drawings for proper impeller rotation position ing and placement B4 2 1 Piece Impellers Slide the impelleron the shaft facing the correct way according to the assembly drawings Impellers without keys setsc rew directly onto shaft When divotsare in the shaft bolt the setscrew directly into divot Forimpellers with keys position the key with pin if present below the impeller Tighten the setscrew securely B4 3 Split Hub Impellers Clamp split hub impellers to shaft If impellers where shipped with shims discard pnorto assembly do not use to assemble on mixer shaft Be sure to maintain 1 4 gap between hubs except 2 blade split which the gap will be shown on the impeller detail drawing to insure correct blade alignment and vibration free operation When torque pinsare present on mixer Shaft clamp so the socket in the hub fits over the Shaft pin Tighten split hub impeller bolts to the following torque ratings Bolt Torque Ratings split impeller bolts only 1 2 bolt 29 ft Ibs 5 8 bolt O 54 ft Ibs 3 4 bolt 96 ft Ibs 7 8 bolt 150 ft Ibs Tab
17. capable of bearing the torsional stresses it produces in operation Make sure not to deform the contact surfaces mounting feet and or flanges by overtightening the bolts Use bolts of quality no lower than 8 8 for mounting the gear unit and for heavy duty installa tions use 10 9 bolts For the tightening torque refer to table AO To prevent bolts from unscre wing apply a thin film of Loctite 510 or 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 BONFIGLIOLI RIDUTTORI 13 5 1 1 Gear units with solid output shaft For mounting external parts do not use hammers or other tools which might damage the gear unit s shafts or bearings Instead proceed as indicated in the diagram below lege L A 7 LR E K TRI LE A Bolt 1 and spacer 2 are to be supplied by customer To minimise the loads on the shaft bearings when mounting transmission elements with asymmetrical hubs the preferred layout is shovvn in diagram A belovv z xx SR 2 P 2 SEITE Cx H 2 Uum AAA x d RE X 2 A 2 SISSIES o 27 0602
18. con nections and installation B 3 Electrical connections must conform to National Electrical code and alllocal regulations Line voltage and wire capacity must match motor rating stamped on motornameplate B 4 Electric motors Single phase If the mixer is supplied with a single phase motor it may be wired by the factory with a ten foot cord and an on off switch If no cord orswitch is provided referto the wiring diagram on the motorforcormect connections Check that the switch is in the off position before plugging the cord into a 110 volt outlet Check for proper rotation Interc hange lines if necessary for proper rotation see assembly drawing B 5 Electric motors 3 phase Motorsrequir ing 3 phase power must be wired according to the wiring diagramson the motor Rotation of the impeller must be according to the assembly drawing and data sheet Interchange lines if necessary for proper rotation B7 6 Electric DC Variable Speed Direct cument variable speed electric motors using an SCR controller must be wired following the instructions supplied with the controller Many adjustments are often required to the SCR controller and instructions must be read carefully before applying power See data sheet and assem biy drawings for possible RPM lockout ranges Oper ate only at speedsoutlined on those sheets Dam age to equipment or serious injury to personnel can result if speed limitations are not followed B7 7 Electric
19. filled with the proper lubricant before start up Referto Section C forthe propertype and amount of lubricant Units shipped With oil will have the gearbox vent hasbeen re placed with a temporary plug for shipment BC 7440 1098 B 7 Vent must be reinstalled prior to start up or damage may occur Check that the oil level is at the proper level see Section C before start up B8 3 Priorto applying power test line resistance to check for possible moisture in the motor Referto Paragraph B1 3 Do not apply power if any resis tance exceedsone to three meg ohms B8 4 Rotate mixer shaft by hand to check shaft straightness and assure that the impeller is free of any obstructions in the tank B8 5 Extended operation of the mixerwhen liquid level isat ornearthe bottom impeller is not recommended B8 6 The impeller rotates in the direction shown in the assembly drawing Opposite rotation may cause overload and inefficient mixing B8 7 Vortexing may occurif liquid level istoo Close to the upperimpeller This will cause aeration ofthe product and excessive vibration of the equip ment When mixing products of dissimilar viscosities and orspecific gravitiesthe lighter or less viscous matenal should be introduced first Gradually add the heavier material or powders into the center of the tank while the agitator is running Neverdump large amounts of powderor solids into the mixing tank This may create clotting or sanding in of
20. groups include A VF27 VF30 VF44 VF49 VF 63 VF72 and VF86 B VF110 VF 130 VF 150 FV 185 no Small and medium size gearboxes belonging to first group are maintenance free being filled with synthetic oil which also allows installation in any mounting positions However in case of V5 and V6 UU O O C UU Technical Service for careful assessment of working conditions Above gearboxes have no filling level and drain piugs being the proper quantity of oil filled from the factory and for life Medium and large size gearboxes belonging to second group require lubrication with oil No lubricant is supplied from factory and they therefore must be filled before use with the proper quantity of oil Quantity shown on catalogue is indicative only For adequate filling refer always to level gauge centerline Above gearboxes are provided with filling level and drain plugs To allow right positioning of plugs kindly specify actual mounting position when ordering whenever different from B3 La lubrification des r ducteurs a vis sans fin est scindee en deux groupes A VF27 VF30 VF49 VF63 VF72 VF86 B VF110 VF130 VF150 VF185 VF210 VF250 Le premier groupe qui comprend des redusteurs de faible it moyenne puissance est prevu avec lubrification permanente c est a dire graissage a vie en permettant installation en toutes les positions de montage sauf pour positions V5 V6 pour lesquelles on devra contacter n
21. la tabla siguiente se indican las cantidades adecuadas Bei Getrieben mit Motoreingangsflansch ist es notwending die erste Untersetzungsstufe vor Benutzung mit Schmiermittel zu versehen N B Nei riduttori forniti con predisposizione per attacco motore e necessario introdurre lubrificante nella precoppia prima del funzionamento Le with lubricant before use The table quantita sono riportate nella tabella sotto below indicates the right quantities of indicata lubricant N B In the gearboxes supplied with motor mounting flange is necessary to fill the primary reduction housing N B Nous ne pouvons pas lubrifier le pr r ducteur de la version motorisable si nous ne livrons pas le moteur il y a donc lieu de le munir d une charge de lubrifiant lors de la mise en service Voir quantit dans le tableau sous indiqu A Lubrificazione a olio sintetico litri Synthetic oil lubrication litres Lubrificazione a olio litri Oil lubrication litres Lubrification a l huile litres Lubrification a Vhuile litres Olschmierung Liter Lubricaci n con aceite sint tico litros Olschmierung Liter Lubricaci n con aceite litros VFR 44 VFR 49 VFR 63 VFR 72 VFR 86 VFR 110 VFR 130 VFR 150 VFR 185 VFR 210 VFR 250 0 050 0 065 0 150 0 320 0 200 0 300 0 500 0 700 1 000 1 200 Le quantit di lubrificante indicate sono The lubricant quantities indicated refer to the relative alle precoppie nella posizione di primary redu
22. load by hand Observe all precautions regar ding the handling of loads The load must not be allowed to sway or oscillate by more than 15 in any direction when being lifted If the oscillation exceeds this limit stop and repeat the lifting operation as instructed 40 BONFIGLIOLI se RIDUTTORI VFR 44 VFR 49 VFR 130 VFR 150 VFR 185 VFR 210 VFR 250 Reccomended solution A for positioning solution B for positioning and handling Ring harness Screw clamp Lift manually om use with harness M vveight x 15 kg Rope and hooks Snap hook en rope A Lift as per diagram A 3 Open harness Eyebolt already fitted with eyelets to gear units VF130 VF250 B Lift as per diagram B Maximum permissible tilt during handling 15 46 BONFIGLIOLI 2 RIDUTTORI BONFIGLIOLI NDUSTRY PROCESS AND AUTOMATION SOLUTIONS lan ricambio Spare parts list Ersatzteiliste Liste des pieces detachees GES BONFIGLIOLI Cuscinetti Bearings Roulements Kugellager Rodamientos 33 32 22 21 7 204 5 28 25 26 1 13 44 6000 10x26x8 16005 25x47x8 6006 35x55x13 16008 40x68x9 608 8x22x7 6200 10x30x9 6301 12x37x12 BAK3903 17x47x14 Anelli di tenuta Oilseals Joint d tanch it Simmerringe Ret n 608 8x22x7 61804 20x32x7 61805 25 37 7 61908 25x42x9 63 71
23. mixer isin operation If mounting to an unstable support mixer loads ma y cause damage to the equipment tank or other hazards CAUTON DO NOTUFT MIXER BY THE SHAFT DO NOT LIFT THE MIXER USING THE LIFTING LUG OF THE MOTOR ALONE USE SLINGS TIG HTENED AROUND THE MIXER DRIVE B2 2 Mixer drives with mounting plates may need to be shimmed for shaft to be vertically aligned and then bolted securely to the mounting structure Flange mounts must have gaskets betvveen flanges before bolting securely for proper sealing VVhen a remote seal is used seal must be concentric and perpendicularto mixer shaft Using lock washers or double nutting the mounting bolts is recommended to prevent bolts from loosening by equipment vibration B2 3 When foot mounted motors are supplied readjust the motor after installation for proper align ment of the flexible coupling see Paragraph B8 9 INSTALLING THE MIXER SHAFT WARNING Always lockout power before installing orremoving mixer shaft B3 1 If the mixer shaft isa two piece design the upper shaft is norma y installed at the factory If not mixers with shaft seals must have the mixer shaft raised through the seal area carefully Some seals will have parts shipped separately from the drive which need to be installed in sequence while installing the mixer shaft Referto the detail drawings in front of the manual If your mixer has a split mechanical seal see data sheet the seal must be
24. motor may be required Consult electrician Change motorleadsper nameplate instructions Check viscosity and specific gravity consult factory eCheck against assembly drawings correct if required Raise impeller Add orchange lubricant see Section C Confirm speed consult factory Clean orimgate sediment e Replace with correct heaters Consult VF drive manufacturer for motor recommendation BC 7440 10 1098 PROBLEM Noisy POSSIBLE CAUSE e Insufficient lubricant e Foreign materal in lubricant e Incorrect lubricant eVVom or faulty bearings or gears eIncorrect coupling alignment Bent broken guards SOLUTON eFill proper amount of lubricant Change lubricant Change to correct lubricant eCheck bearings gears replace if necessary e adjust align coupling e Stra ighten replace guard Bearing failure High temperature product Excessive overhung load eWaterdamage e See all items under Noisy Provide heat shield e Consult factory e Replace bearing check all other parts e Gear failure Excessive loading check amps eLack of orimproper lubrication e Sta rt sto p start loa d ing product burying impeller with solids Foreign material in lubricant e Consult factory e Fill with recommended lubricant or equivalent see Section C Free impellerof any solids at start up pre stir with air hose orpaddle Replace lubricant
25. shaft and seal lubric a te flush seal elubricate properly see Paragraph B8 eLubncate propeny or consult factory a special seal may be required eSee drawings in front of manual for correct position e See Shaft vibration above Note Other trouble shooting guides for special optional equipment will be located in Section D when present B 12 BC 7440 12 1098 A NOTE ON RECOMMENDED SPARE PARTS B9 1 Recommended spare parts are different for individual needs The main factor affecting which parts should be kept asspareson the users shelf is dovvntime allovva ble time period the mixer can be out of service This list shows acceptable downtime and partsto stock asspareswhich under normal circumstances Sharpe Mixers cannot supply in less time Note that the less downtime that isacceptable the more spare parts that will be required to be stocked If this equipment is critical to the plant operation Sharpe Mixers recom mendsthe purchase of a complete agitatorto prevent extended downtime Allowable Recommended parts to stock for repair Typical shipment varies Downtime due to long delivery times 3 weeks Steady bearing bushings wear sleeves 4 weeks stuffing gland throttles bushings side entry mixer shafts special alloy seals special motors 2 weeks Above parts plus gearbox gear sets 4 weeks motors and mechanical seals l weeks Above parts plus gearbox seals bearings 4 weeks gaskets shims motors flex
26. site and is awaiting insta lla tion b mixer has been installed but regularopera tion is delayed c there are long idle periods be tween operating cycles d plant department operation is shut down Store mixer in a clean dry location with circulating air free from wide variations in temperature Electric motors are easily damaged by moisture Store the entire unit off the floor cov ered with plastic and use desicc ants to reduce moisture buildup Do not seal the plastic cover asthis tra ps moisture If the motor shows signs of moisture a bsorption before start up dry the motoroutby applying 10 voltage on two leads if in doubt me asure resistance in windings one to three meg ohms is nomal This will give approximately 50 rated current There are also sprays a valla ble to help dry out motors Relubricate motor before sta rt up vvhen in storage six months or more Storage of mixers over six months must have gear reducers filled completely vvith storage oil Do not install vent plug when in storage Spray oil on exposed lip sealsand unpainted carbon steel parts Rotate motor and gearbox shafts penodically When retuming to service drain storage oil clean with mineral spirits and replace with correct lubricant see SectionC MOUNTING THE DRIVE B2 1 Mounting structure must be stable and strong enough to handle torque bending moment and weight specified on asembly drawing The structure must not flex or vibrate when the
27. 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 e 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 e When commissioning the gear unit the surface temperature must be measured in the same operating conditions as for the final application The surface temperature must be measured at the coupling between the gear unit and motor and at the points which are most shielded from the motor s fan cooling S2 Temperatura IMPORTANT The maximum surface temperature is reached after 3 hours operation at full load The temperature measured in these conditions must not differ AT from the ambient tempe rature by more than the following values AS C 11 C 61 A 10 A 60 F 10 F 60 VF 44 VF 49 VV 63 VV 86 VV 110 Should the temperature differential exceed these values stop the gear unit at once and contact the BONFIGLIOLI RIDUTTORI technical service If the temperature differential is within the above values wait for the gear unit to cool down and then install the temperature indicator supplied vvith the gear unit at the p
28. unit seals and gaskets ing of external seals Replace if aged worn Depending on the temperature reached by the lubricant it should be replaced at the intervals indica ted in table A4 below A4 Oil temperature Hours t C t lt 65 25000 65 lt t lt 80 15000 80 lt t lt 95 12500 For installations in zones 21 and 22 the User must schedule and implement a regular clea ning programme for all surfaces and recesses to avoid build up of dust more than 5 mm in depth Every 1000 h of operation or after 6 months Measure the surface temperature of the coupling between the gear unit and motor at the po ints most shielded from the motor s fan cooling The maximum temperature must not differ AT from the ambient temperature by more than the following values nor may this differential be exceeded during operation A3 C 11 C 61 A 10 A 60 F 10 F 60 VF 44 VF 49 VV 63 VV 86 VV 110 BONFIGLIOLI RIDUTTORI 21 Op 22 LA Check the condition of the temperature indicator previously installed on the gear unit during commissioning Example Q6 86 Sa 739 739 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
29. 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 properties and application range before assembly Regardless of the type of gear unit whenever a seal ring is replaced its lips should be smea red with a thin layer of grease Fluorocarbon gel 880 ITP or equivalent product with similar pro perties and application range before assembly Use only original spare parts for repairs BONFIGLIOLI Hi 20 RIDUTTORI Ber AA x AOS 8 1 ROUTINE MAINTENANCE Keep the gear unit at its maximum efficiency by following the routine maintenance schedule specified by the Manufacturer Good maintenance enables the unit to operate at its maximum performance over a long servi ce life in compliance with safety regulations Frequency Component Type of work Operation Check oil level Maintain or replace compo External seals and gaskets Check for leaks by eye nents as required For gear units with torque arm polymer bushings Replace if no longer fully Check for cracks ageing afectiva Inspect carefully for wear age Gear
30. valve on the drainage line must be installed on the seal to maintain a pressure in the seal housing 15 30 pounds higherthan the tank pressure A filteron the inlet to the seal is recom mended t isalso recommended that a check valve be installed on the inlet line to prevent back flow of tank contents in case of loss of pressure in the flushing line Pay special attention to seal housing temperature during operation Never allovv heat buildup in seal housing Increase flow of flushing vvater to cool the seal Y C heck Valve Y Filter Y a d Pressure Regulator Drain FIGURE 6 3 Double seal with flushing B6 8 DOUBLE MECHANIC AL SEAL WITH NATURAL CONVEC TON LUBRICANTRESERVOIR see Figure 6 4 This design requires a lubricant reservoir usually 2 5 gallon capacity mounted 6 18 above and no more than 3 ft away from the mechanical seal These syste ms are often fumished by Sharpe Mixers mounted on the agitator and fully plumbed to the seal housing Lubricant circulation occurs when the lubricat ing fluid heated by the seal expandsand becomes lighter and rises out of the seal to the top of the lubricant reservoir Once in the reservoirthe fluid cools becoming heavierand retums to the mechani cal seal housing This process may be be aided by cooling coilsin the reservoir Asnatural convection requires low restriction plumbing Sharpe Mixers recommends 1 2 diameter tubing Route the tubing
31. 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 e Assembly is not carried out in a potentially explosive atmosphere oil acid gas vapour or ra diation and that there is no dust deposits thicker than 5 mm on the gear unit During service the gear unit is sufficiently ventilated and that it is not subject to radiation from external heat sources During service the cooling air does not exceed 40 C The oil level drain and vent plugs are all easily accessible All accessories of any type mounted onto the gear unit are ATEX compliant Gear units with hollow shafts with or without shrink disk have been correctly mounted The gear unit is thoroughly cleaned after installation All guards installed to prevent accidental contact between operators and the gear units moving parts or seals are effective BONFIGLIOLI RIDUTTORI 17 O gt LA Measuring the gear
32. ESS AND AUTOMATION SOLUTIONS BONFIGLIOLI BIELIE Use and service manual AE GK BONFIGLIOLI 1 0 GENERAL INFORMATION 2 121 PURPOSE OE THE MANDJAL 30029 0000 e ttt leto oda at sind Guam ini 2 12 EQUIPMENT IDENTIFICATION imet en a beet 3 1 3 GLOSSARY AND TERMINOLOGY su een PU 4 1 4 REQUESTING TECHNICAL ASSISTANCE as 4 1 5 MANUFACTURER S leader see ae ax dun 4 2 0 TECHNICAL INFORMATION 5 2 1 GEAR UNIT DESCRIP TION bu salsa d n s n lal Posts 5 2 2 GONEORMITF TO STANDARDS t ER ee aa SA aaa a dre er aldada IDE OE d 5 2 3 OPERATING LIMITS AND CONDITIONS e e e e em e e e e e e e e rr re e arre 6 3 0 SAFETY INFORMATION 7 3 1 SAFETY STANDARDS za aa re 7 4 0 HANDLING AND TRANSPORT 8 A SW PRC PIN LE een De ee es TEE arala a Steen 8 4 2 HANDEING INS TRUC TIONS udi ades estet ee ma ao uba aa 9 42 Tks Moving package ee dl la a net 9 2 22 Moving Kr Le Ellen EE 9 AS STORAGE 32 021900 am s b DA re a Ba ay ee 10 5 0 INSTALLATION 11 5 1 SINS TALEING THE GEAR UNIT ee 11 5 1 1 Gear units with solid outpnutehaft LL 14 5 1 2 Gear units With hollow output EE 14 513 Gear units witbi shinmnk AIS Kata ala a Yee ess uu 15 51 4 s Shall mounted gear Unis Senes F cest otn CREER 15 5 2 INSTALLING AN IEC STANDARD
33. FLANGED MOTOR e e e e s le e llli 16 6 0 TESTING THE GEAR UNIT 17 7 0 USING THE EQUIPMENT 19 8 0 MAINTENANCE 20 8 1 ROUTINE MAINTENANCE tii ha 21 0 22 LUBRICANTS 0 det s Do a o PAA 23 ds OI CHANGE ss ne l east outed nd Dinde l ks 23 84 RECOMMENDED PERMITTED OUES ca aaa see 24 8 5 CHECKING EFFICIENCY moto cio srta m a o beue a a a cp tC aa an o 26 BC ERAI IOS o m Sd a a a da aaa 26 A DI osa he Misti eta bd ok Bs bad l r S 26 9 0 REPLACING PARTS 27 9 1 TAKING APART OF THE IEC STANDARD FLANGED MOTO 27 9 2 SCRAPPING THE GEAR UNI 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 sss III I RI ee ee he hee ne eh e e en en en ere e enis 32 Bevel helical gear UNIS Selles A VE La ele Da a a esse 33 Shaft mounted gear units Series Fun ec ae re se E a sas 34 Wormrgear units Senes cs h ern ee 35 Worm gear units s ries W 5 502065536 eate Po aaa cua BE epe AAR Ubro NAT Head dunes aa ORAT Nr pete ee 36 Single stage helical gear units sees 36 ANNEX 3 CUSTOMER S SHAFT 37 SERIES Re ee TT E ee el ee De CR 37 6505 o s s os sem et ee s ehe 38 Series VF and TT n da b alo de Bl s la r b 39 ANNEX 4 LIFTING 77 A ANNEX 5 INSTALLING THE MOTOR ON
34. ONAL SAFETY AND HEALTH ACT OF 1970 WE do not warrant or represent that any of SHARPE s products by themselves or in a system or with other equipment will conform to or comply with the provisions of the Occupational Safety and Health Act of 1970 and the standards and regulations thereunder or any other federal state or local law or regulation of the same or similar nature 9 PATENTS SHARPE certifies that to its knovvledge the Mixer does not infringe upon any patents granted to others by the United States of America VVE do not assume any responsibility or liability for any claim of infringement brought against the Buyer its successors assigns customers or users of the Mixer 10 ATTORNEY FEES n the event an arbitration suit or action is brought by any party under this agreement to enforce or interpret any of its terms or in any appeal therefrom it is agreed that the prevailing party shall be entitled to reasonable attorneys fees to be fixed by the arbitrator trial court and or appellate court Buyer shall be responsible for any and all costs of collection incurred by SHARPE in connection herevvith including attorneys fees and costs 11 JURISDICTION VENUE This agreement shall be binding upon the successors and assigns of SHARPE and Buyer and shall be deemed entered into at Seattle VVashington and shall be governed by and construed in accordance with the laws of the State of Washington n the event of litigation between the parties to e
35. OPERATION amp MAINTENANCE MANUAL FOR SHARPE MIXERS LIQUID AGITATON EQUIPMENT I gt READ BEFORE UNPAC KING MIXER 3 II YO UR MIXER HAS BEEN TESTED AND SHAFT STRAIG HTNESS VERIFIED PRIOR TO SHIPMENT CAREFUL HANDLING OF SHAFTPRIOR TO AND DURING INSTALLATION WILL ENSURE PROPER OPERATION THE FOLLOWING CRITERIA MUST BE ADHERED TO IN ORDER TO PREVENTDAMAGE TO EQUIPMENTOR SERIO US IN URY TO OPERATING PERSONNEL WARNING HIGH VOLTAGE AND ROTATING PARTS CAN CAUSE SERIO US OR FATAL INJ URY ONLY EXPERIENC ED PERSONNEL MUST OPERATE OR SERVIC E THIS EQUIPM ENT e NEVER EN TER TANK WITHO UT LO C KING O UT POWER TO MIXER e LO C KO UT POWER PRIOR TO REMOVING ANY GUARDS OR SERVICING ANY PART OF THIS EQUIPMENT INCLUDING INITIAL INSTALLATION AND OR INSPECTION e THIS MANUAL MUST FIRST BE FULLY READ AND UNDERSTO OD PRIOR TO INSTALLATION BY ALL PERSONNEL INSTALLING AND OR OPERATING THIS OR NEAR THIS EQUIPM ENT NEVER USE THIS EQUIPM ENT FOR ANY USE O THER THAN DESC RIBED IN THE ORIGINAL PROPOSAL AND APPLICATION BOX ON THE DATA SHEET e MODIFICATIONS UNAUTHORIZED BY SHARPE MIXERS TO THIS EQUIPMENT MAY DAMAGE EQUIPMENT OR CAUSE SERIO US INJ URY TO PERSONNEL CAUTION e ALWAYS READ THE SERVICE MANUAL THO ROUGHLY BEFORE INSTALLATION AND START UP OPERATION OF MIXER IN AIR IS NOTRECOMM ENDED e ALWAYS FOLLOW MOUNTING RECOMMENDATIONS DESCRIBED IN ORIGINAL PROPOSAL MIXER PLATFORM MUST BE STABLE e EXTENDED OPERATION OF MIXER WHEN LIQUID LEVEL I
36. S ATOR NEAR BOTTOM IMPELLER IS NOTRECOMM ENDED e ALWAYS RO TATE THE SHAFT BY HAND TO VERIFY STRAIG HTNESS PRIOR TO OPERATION IN LIQUID e ALWAYS C HEC K ASSEMBLY DRAWING AND DATA SHEET FOR SPECIAL OPERATING SPEED REQ UIREM ENTS IF USING A VARIABLE SPEED DRIVE e ALWAYS FLUIDIZE SETTLED SO LIDS BEFORE STARTING MIXER e NEVER LIFT MIXER BY SHAFT ANY EXCEPTIONS TO THE ABOVE MUST BE AG REED UPON IN WRITING BY SHARPE MIXERS AND NOTED ON THE ASSEMBLY DRAWING SHARPE MIXERS S 4 P O BOX 3906 SEATTLE WA 98124 z 206 767 5660 FAX 206 767 9170 S CAE 800 237 8815 SERIAL NO SHARPE MIXERS STANDARD TERMS amp CONDITIONS OF SALE In consideration of the mutual promises and agreements contained herein the buyer Buyer and SHARPE MIXERS INC SHARPE or VVE hereby agree to the following terms and conditions provided that the terms and conditions including the price quotations shall only become binding on SHARPE upon the mailing or other transmission of SHARPE s Acknowledgment Form as described in Section 6 Below 1 Warranty We warrant that we shall repair or replace without additional charge or refund the price of the products provided to the Buyer herewith collectively Mixer if the Mixer a is defective in materials or vvorkmanship b fails to provide the process results specified in SHARPE s proposal Proposal or c if no process results are specified in SHARPE s proposa
37. 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 7 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 disassembiy 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 carefuliy read and applied rigorously The information regarding the electric motor that can be found matching the speed reducer is sup plied with the owner s manual relevant to the specific electric motor Failure to adhere to the information provided herein may result in risk to personal health and safety and may incur economic damages This information provided in the original language Italian of the Manufacturer may also be made available in other languages to meet legal and or commercial requirements The documentation 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 manu
38. al The manual reflects the state of the art at the time of commercialisation of the gear unit The Manufacturer reserves the right to modify supplement and improve the manual without the present pu blication being for that reason considered inadequate Particularly significant sections of the manual and important specifications are highlighted by symbols whose meanings are given below SYMBOLS DANGER WARNING This symbol indicates situations of serious danger which if ignored may result in serious risks to the health and safety of personnel CAUTION ATTENTION AN This symbol indicates the need to adopt specific precautions to avoid risks to the health and safety of personnel and possible economic damages IMPORTANT This symbol indicates important technical information The instructions indicated on a yellow background next to these symbols refer exclusively to equipment conforming to the Directive 94 9 EC The operations highlighted by these symbols must be carried out by qualified professionals spe cially trained in the safety requirements for zones characterised by potentially explosive atmo spheres Failure to observe these instructions may result in serious risks to personal and environmental safety BONFIGLIOLI 2 RIDUTTORI 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 R
39. alth 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 l of ATEX Directive 94 9 EC and conform to the following classification Equipment group l Calass Gas 2G Dust 2D Zone Gas 1 Dust 21 Maximum surface temperature temperature class T4 for 2G and 130 C for 2D Some types of gear units given in the catalogue are exceptions to this rule and are marked temperature class T3 for 2G or 160 C for 2G and 2D BONFIGLIOLI E RIDUTTORI 5 Modification of the gearbox configuration or mounting position is only permitted if previously aut horised by the BONFIGLIOLI RIDUTTORI technical service Failure to obtain said authorisation voids the ATEX certification Ambient conditions Ambient temperature min 20 C max 40 C e 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 The nameplate data on the m
40. at thoroughly before start up during operation and aftershutdown iffollowed bya purge Some prod uctsharden to a solid state when exposed to air Glue molasses paint sugarsare examples An effective flush isa dead end lubricator Thiswillkeep out the air Note that this type of flush does not enter the product but only mixes with the product leak age t may also be desirable to purge utilizing a solvent of the liquid being mixed Penodically vent dead end lubricated sealsto clean chamber BC 7440 5 1098 B6 4 Lubrication of mechanical seals is re quired at all times during operation of the mixing equipment The only exception are dry running seals which are cleany stated in the seal description in the data sheet and assembly drawings See specific seal data Section D in this manual for more information on dry running seals B6 5 Lubrication system designs are as varied ascustomersapplications Listed below are some typical application designs Study the seal drawing and description in this manual and circle the lubrica tion system that best describes yourapplication Reservoirs filters rota meters flow and pressure control valvesand gaugesasrequired may be purchased from Sharpe Mixers B6 6 SINGLE EXTERNALLY MOUNTED SEAL This design positions the rotating elements of the seal outboard from the tank contents and islubricated by one of the following means B6 6 1 Sealflushing see Figure B6 1 requir
41. aximum surface temperature refer to measurements made in nor mal ambient and installation conditions Even minimal variations to said conditions e g smaller mounting cabinet could have a significant impact on the build up of heat e Lighting AN 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 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 app
42. cautions must be taken e g elimination of residual gas or dust etc During operation wear only the apparel and safety equipment indicated in the User instructions provided by the Manufacturer or laid down by applicable laws on safety at work Replace worn components with original spare parts Use the lubricants oil and grease recommended by the Manufacturer Do not dump polluting materials into the environment Dispose of all such materials as stipulated by appli cable legislation After replacing lubricants clean the gear unit s surfaces and the walk on surfaces around the work area BONFIGLIOLI RIDUTTORI f 4 3 STORAGE Some recommendations for storing the gear unit are indicated below 1 Do not store the unit in excessively humid conditions or vvhere it is exposed to the vveather do not store outdoors Do not place the gear unit directly on the ground 3 Place the gear unit on a stable base and make sure that it is not subjected to accidental displacement 4 Store the packaged gear unit if allowed in accordance with the instructions on the packaging itself If the gear unit is stored for more than 6 months the following additional precautions must be taken 5 Cover all machined external surfaces with a rustproofing product such as Shell Ensis or equivalent pro duct with similar properties and application range 6 Fillthe unit with lubricating oil SAFETY PRECAUTIONS to be taken when returning t
43. cident prevention at work e incorrect installation disregard or incorrect application of the instructions provided in this manual e incorrect or defective power supply gearmotors e modifications or tampering e 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 e always operate the unit within its operating limits e diligently observe the routine maintenance schedule e only authorise trained operators to inspect and service the unit use only original spare parts the configurations given in the gear unit catalogue are the only ones permitted N do not attempt to use the unit contrary to the instructions supplied the instructions given in this manual do not substitute but summarise the provisions of applicable safety legislation BONFIGLIOLI 2 RIDUTTORI 2 0 TECHNICAL INFORMATION 2 1 GEAR UNIT DESCRIPTION The gear unit has been designed and constructed for integration if required driven by an electric motor into an assembly of interlocking parts or mechanisms as part of a specific application Depending on the requirements of the application the gear unit can be supplied in a variety of executions and configurations It is capable of satisfying a range of specific requirements in the mechanical chemical agricultural and food industries etc BONFIGLIOLI RIDUTTORI supplie
44. ctions is mounting position B3 montaggio B3 N B Please always specify mounting montage B3 anzugeben de montaje B3 N B Specificare sempre la pos di position N B Indiquer toujours la position de N B Bei Bestellung bitte immer die Einbaulage Nota especificar siempre la posici n de montaggio montage angeben montaje Les quantites de lubrifiant indiquees concernet les pre reducteurs en position de Sollte eine andere Einbaulage als B3 ben tigt Las cantidades de lubricante indicadas werden ist dies bei der Bestellung unbedingt corresponden a los prepares en la posici n lubrificanti sintetici possono essere The synthetic lubricants can be used impiegati per temperature ambiente with ambient temperature from 20 C da 20 C a 40 C to 40 C Les lubrificants synthetiques peuvent tre utilises pour des temp ratures ambiantes dans une plage de 20 C a 40 C Synthetische Schmiermittel k nnen in Umgebungstemperaturen von 20 C bis 40 C engesetzt werden Los lubricantes sinteticos pueden ser empleados para temperaturas ambientales entre 20 C y 40 C BONFIGLIOLI RIDUTTORI 28 E molto importante per l installazione del riduttore Assicurarsi che il fissaggio del riduttore sia stabile onde evitare qualsiasi vibrazione nstallare se si prevedono urti sovraccarichi prolungati o possibili bloccaggi giunti idraulici frizioni limitatori di coppia ecc Durante la verniciatura si c
45. cure 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 RIDUTTORI 11 Tightening torque Nm 5 10 Bolt size Bolt class Cap vent thread Tightening torque Nm 1 8 5 1 4 7 3 8 7 1 2 14 3 4 14 1 25 5 Charge the gear unit with oil or top it up with reference to the method in which gear units of the type co vered by this manual are filled in the factory The standard charge of synthetic life time lubricant is as fol lows A1 VF 150 Life time lubrication Life time lubrication with ATEX specified unit only BONFIGLIOLI 2 RIDUTTORI Helical in line gear units C 11 C 21 and C 31 are not equipped with service plugs for direct oil level checks Bevel helical gear units A 10 A 20 and A 30 are not equipped with service plugs for direct oil level checks in mounting positions B6 and B7 only For these types of gear units refer to Annex 1 of this Manual Before installing check the unit as follovvs 1 Place the gear unit in t
46. d 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 maliy require 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 vvith a light solvent before refilling vvith a nevv lubricant 8 3 OIL CHANGE 1 Place an adequate container under the drain plug 2 Remove the filler and drain plugs and allovv 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 dovvn the filler plug after fitting a nevv gasket The gear unit may be supplied vvith or vvithout lubricant as specified by the User The quan AN tity of oil to be filled is specified in the Sales Catalogue This specification is however appro ximate and reference must always be made to the centre of the level plug the placement of which depends on the mounting position specified in the order Lubricants solvents and detergents ar
47. de fixation Schraube Tornillo exagonal FA 44 69 36 Coperchio con flangia FA FA cover Couvercle avec bride FA FA deckel Tapa con brida FA BONFIGLIOLI z RIDUTTORI La lubrificazione dei riduttori a vite senza fine viene divisa in due distinti gruppi A VF27 VF30 VF44 VF49 VF63 VF72 VF86 B VF110 VF130 VF150 VF185 VF210 VF250 Nel primo gruppo che comprende riduttori di bassa e media potenza viene adottata la lubrificazione permanente con olio sintetico e questo ne consente l installazione in tutte le posizioni di montaggio fatta eccezione per le posizioni di montaggio V5 V6 per le quali e necessario valutare le condizioni d impiego con il nostro UFF TECNICO suddetti riduttori sono sprovvisti dei tappi di carico livelli e scarico e non hanno perci necessit di alcuna manutenzione essendo gi dosati nella giusta quantit di olio Nel secondo gruppo che comprende riduttori di media e alta potenza si adottata la lubrificazione ad olio riduttori sono forniti dei tappi di carico livello e scarico olio ed a tal proposito e importante specificare in fase di ordine la posizione di montaggio se diversa dalla B3 I suddetti riduttori sono forniti sprovvisti di lubrificante e sar cura del cliente prima della messa in opera introdurre la giusta quantit di olio Versione Version Version Ausf hrung A Different patterns have been followed depending on size of worm geaboxes Two main
48. e Olio sintetico Synthetic oil Huile synthetique Synthetisches Schmier l Applicazione Application Application Einsatzbereich Schmier ltyp Aplicati n Casa produttrice Manufacturer Fabricant Hersteller Casa productora Riduttori ad ingranaggi e riduttori a vite senza TELIUM OIL VSF 320 AGP izi earboxes and vvorm gearboxes TVELA OILS 0 SHELL d SYNTHESO D220EP KL BERSYNTH GH 6 320 KL BER Reducteurs a engrenages et reducteurs a vis Tipo di olio Type of oil Type d huile Hersteller Tipo de aceite sans fin GLYGOYLE HE 320 MOBIL ALPHASYN PG 320 CASTROL CARTER SY 320 TOTAL Zahnradgetriebe und Schneckengetriebe Reductores de engranajes y reductores de tornillo sinfin Aceite sintetico Riduttori a vite senza fine con limitatore di coppia V orm gearbox with torque limiter Reducteurs a vis sans fin avec limiteur de couple Schneckengetriebe mit Drehmomentbegrenzer Reductores de tornillo sin fin con limitador de par TIVELA OIL S 460 QUANTITA DI LUBRIFICANTE CONTENUTE NELLE THE PRIMARY REDUCTION PRECOPPIE DEI RIDUTTORI OF GEARBOXES SERIES SERIE RVF RVF LUBRICANT QUANTITYOF QUANTITE DE LUBRIFIANT DU F LLMENGEN DER RVF PRE REDUCTEUR SERIE CANTIDAD DE LUBRIFICANTE CONTENIDA EN LOS PRE PARES DE LOS REDUCTORES DE LA SERIE RVF Nota En el caso de los reductores con predisposici n para el montaje al motor se debe introducir el lubricante en el prepar antes de ponerlos en funcionamiento En
49. e figu re belovv If the level is more than 3 mm belovv the overflovv level top up and check the reason for the drop in oil level ENSURE THAT THE ROD IS SNUG AGAINST THE THREAD Helical in line gear units C11 C21 and C31 all mounting positions and bevel helical gear units A10 A20 and A30 in mounting positions B6 and B7 only do not feature a level plug 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 RIDUTTORI 29 VVorm gear units series VF Th A14 HS P IEC P IEC HS P IEC HS P IEC VFR 130 HS P IEC HS P IEC VF 130 VFR 130 HS P IEC HS P IEC VF 130 HS VF 130 P IEC VFR 130 HS P IEC VF 150 HS P IEC VFR 150 VF 150 HS P IEC VFR 150 HS P IEC HS P IEC VF 150 VF 150 HS P IEC VFR 150 HS P IEC VF 185 HS P IEC VFR 185 VF 185 HS P IEC VFR 185 HS P IEC HS P IEC VF 185 HS VF 185 P IEC VFR 185 HS P IEC VF 210 HS P IEC VFR 210 VF 210 HS P IEC HS P IEC VFR 210 HS P IEC VF 210 HS VF 210 P IEC VFR 210 HS P IEC VF 250 HS P IEC VFR 250 VF 250 HS P IEC VFR
50. e toxic harmful to health they may cause irritation in direct contact with the skin they may cause intoxication if inhaled they can be fatal if swallowed Handle them with care using suitable individual safety equipment Do not dump into the environment and dispose of in compliance with applicable legislation If a leak is found identify the cause of the fault repair it and refill with lubricant before opera ting the gear unit BONFIGLIOLI RIDUTTORI 23 8 4 RECOMMENDED PERMITTED OILS OILS AND GREASES COMPATIBLE with Atex certified gear units Greases e Kl ber Asonic GHY 72 e Shell TVX Compound B for bearings Shell Tivela GL 00 alternative for greased gear trains for greased gear trains e Kl berpaste 46 MR 401 e TP Fluorocarbon gel 880 to facilitate coupling of cylindrical parts for greasing contact seals Oils as alternatives to Shell Tivela Oil S 320 Shell Tivela Oil SC320 Aral Degol GS 320 IP Telium Oil VSF 320 o Agip Kluber Klubersynth GH 6 320 Total Carter SY 320 Mobil Glygoyle HE 320 BONFIGLIOLI Hi 24 RIDUTTORI 11 100 10 50 z 0 25 0 5 Tivela S 220 Tivela S 320 Tivela S 460 Donax TX Shell Donax TA Cassida Fluid WG 460 Cassida Fluid HF 46 TVX Compound B Telium VSF 220
51. ear 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 tolerances given in tables A16 A17 A18 A19 A20 and A21 in Annex 3 of this Manual n case of installation outdoors and when fitted with an electric motor protect the latter from direct sun light and the weather by means of guards or a casing Also make sure that the assembly is properly ven tilated Now proceed with the installation as follows 1 2 Th Place the gear unit in the vicinity of the installation area Mount the gear unit and se
52. erlei Wartung Sollte das Getriebe ber l ngere Zeit nicht laufen und in einer Umgebung mit hoher Feuchtigkeit stehen dann empfehlen wir es vollst ndig mit Ol zu f llen Selbstverst ndlich mu wieder auf korrekten Olstand vor erneuter Inbetriebnahme aufgef llt werden N B Um k rzeste Lieferzeiten f r Ersatzteilbe stellungen zu gew hrleisten sind jeweils Type Ausf hrung und Untersetzung des betreffenden Getriebes genau zu spezifieren Generalmente es aconsejable graduar el aumento de la potencia transmitida partiendo de valores minimos y limitando la potencia transmitida 50 7095 de la potencia m xima durante las primeras horas de funcionamiento Los reductores lubricados con aceite sint tico no requiren mantenimiento Cuando el reductor deba permanecer por largo tiempo inactivo en ambiente excesivamente h medo aconsejamos llenarlo totalmente con aceite obviamente el nivel del lubricante deber ser controlado y restablecido al momento de poner nuevamente en funcionamente el grupo N B Con el fin de conseguir una mayor rapidez en la cumplementaci n de los pedidos de recombios rogamos indiquer siempre tipo versi n y relaci n de reducci n del reductor al cual se refieren 30
53. es a line of lubricant usually water plumbed to the seal housing and a line from the seal housing to a drain In this design the seal housing will usually incorporate a lip sealto contain the lubricant in the housing but will not hold pressure within the seal housing There fore a flow restriction and pressure reducing valve must be incorporated in the supply line to the seal An in line filter is also recommended Neverallow pressure to build within the seal housing or you may blowout the lip seal The drainage line must rise above the elevation of the seal housing by a few inchesto guarantee seal will be lubricated without siphoning and must be free flowing to prevent pressure buildup Y Check Valve Filter Y Pressure Regulator Y gt Drain higher Flow Control gt Rotameter Tank Side Single extemal seal with flushing FIGURE B6 1 Tank Side Single extemal seal with lubric ation FIGURE B6 2 B6 6 2 OilCup see Figure B6 2 requiresa light oil orothercompatible lubncating liquid to completely fillthe smallextemalcup Thiscup must be checked periodically If lubricant has drained mechanical seal must be checked for possible leakage B6 7 DOUBLE MEC HANIC AL SEAL WITH THROUGH FLUSHING see Figure 6 3 This system requires a lubricant line plumbed to to the seal usually water and another line from the seal housing to the drain A flow control valve on the inlet and a pressure regulating
54. es are approximations only We will not be liable for or penalized as a result of delays in shipment for any cause including but not limited to delays that are beyond our control Shipments may not be deferred by Buyer beyond the specified shipment date after commencement of manufacture without SHARPE s written consent When shipping is deferred for Buyer s convenience due to lack of shipping instructions failure to complete credit arrangements satisfactory to SHARPE or late delivery of customer supplied material Buyer agrees to pay reasonable storage charges interest and any other expenses incurred by SHARPE due to the delay Orders on which delivery is deferred shall be invoiced upon completion of manufacture and are subject to finance charges of 1 5 per month 4 CHANGES Any changes requested by Buyer and approved by SHARPE with respect to the Mixers shall be subject to adiustments to the delivery schedule and or price of the Mixer as shall be determined by SHARPE in its sole discretion 5 PRICES PAYMENT Price quotations set forth on any Proposals from SHARPE are for informational purposes only and represent an estimate of the prices that vvill be available to Buyer Such price quotations are not binding upon SHARPE until an authorized representative of SHARPE at SHARPE s home office in Seattle VVashington accepts and confirms in vvriting any offer to purchase submitted by the Buyer by vvay of a Contract Acknovvledgment Prices set fort
55. ette Einlegekeil Chaveta at 25 Corona elicoidale Wormwheel Couronne Schneckenrad Corona 26 Linguetta Key Clavette Einlegekeil Chaveta 29 Motore elettrico Electric motor Moteur lectrique El motor Motor el ctrico 30 44 49 1 Cassa integrale Housing vvith integrated flange Carter avec bride Gehause mit flansch Caja con brida integrada 16 Cassa Housing Carter Getriebehause Caja 27 17 Flangia attacco motore Motorflange Bride moteur Motorflansch Brida para motor 49 Gr 63B14 18 Guarnizione flangia Gasket Joint Dichtung Junta 19 Vite atesta esagonale Hexagonal head screw Vis de fixation Schraube Tornillo exagonal 27 30 44 49 20 Coperchio con piedi Foot cover Couvercle avec pied F deckel Tapa con pies N A 30 44 49 21 Vite atesta cava esagonale Socket head screw Vis de fixation Schraube Tornillo exagonal 27 32 Vite atesta esagonale Hexagonal head screw Vis de fixation Schraube Tornillo exagonal 27 30 44 49 23 Coperchio con flangia Flange cover Couvercle avec pied Flanschdeckel Tapa con brida 21 Vite a testa cava esagonale Socket head screw Vis de fixation Schraube Tornillo exagonal F 30 44 49 22 Coperchio pendolare P Cover Couvercle P P Deckel Tapa P 33 Coperchio di chiusura Plain cover Couvercle de fermeture Verschlu sdeckel Tap n 32 Vite a testa esagonale Hexagonal head screvv Vis de fixation Schraube Tornillo exagonal B 30 44 49 22 Coperchio pendolare Side cover Couvercle P P Deckel Tapa P 30 44 49 21 Vite a testa cava esagonale Socket head screw Vis
56. facturer e When working on the gear unit always replace gaskets and seals with new original ones e f a bearing requires replacement it is good practice to also replace the other bearing supporting the same shaft e 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 damage to components due to the use of non original spa re parts and non routine work which modifies the safety requirements without the express prior authorisation of the Manufacturer Refer to the specific spare parts catalogue when ordering spare parts for the gear unit Do not dump polluting liquids worn parts and maintenance waste into the environment Di spose of all such materials as stipulated by applicable legislation Observe the routine inspection and maintenance schedule to ensure suitable operating condi tions and the effective explosion protection of the unit Always apply fresh Loctite 510 paste or equivalent product with similar properties and applica tion range to all disassembled threads Before servicing or repairing internal components allow the gear unit to cool down completely before opening the casing so as to avoid burns from parts which are still hot Make sure on completion of maintenance work that all safety measures and equipment have been applied and reset Clean the gear
57. h on SHARPE s Acknovvledgment Form shall be binding vvith respect to the order described therein provided that orders placed on hold or held over 3 months or more i e avvaiting Buyers approval are subiect to price adiustments Upon approval of Buyer s credit by SHARPE unless stated otherwise on the face hereof in which case such terms shall control terms are net 30 days F O B Seattle VVA Freight Collect provided that if in the sole discretion of SHARPE a the order is for a customized or otherwise unique Mixer or is of a substantial magnitude or for any other reason or b Buyer s credit is not approved or the financial condition of Buyer becomes such that it does not justify continuance of production shipment or delivery on the terms of payment specified we may require full or partial payment in advance or payment upon delivery Prices do not include customs duties or taxes such as sales use excise retailer s occupation or similar taxes and if in connection with this transaction SHARPE is subject to any such customs duties or taxes the same will be added to the purchase price to be paid by Buyer If payment is not made when due Buyer shall pay SHARPE a finance charge of 1 5 per month and ii ALL WARRANTIES PROVIDED BY SHARPE HEREUNDER SHALL IMMEDIATELY BE NULL AND VOID All price lists and discount schedules are subject to change without notice 6 ACCEPTANCE All orders by Buyer are subject to acceptance by SHARPE s au
58. he gear unit to service after storage The output shafts and external surfaces must be thoroughly cleaned of all rustproofing product contaminants and other impurities use a standard commercial solvent Do this outside any explosion hazard area The solvent must not touch the seal rings as this can damage them and render them ineffective If the oil or protective material used during storage is 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 10 RIDUTTORI 5 0 INSTALLATION 5 1 INSTALLING THE GEAR UNIT The entire installation process must be planned based on the general design of the machine The person authorised to do the work must if necessary implement a safety plan to safe guard all persons directly involved and rigorously apply all applicable legislation If a gearmotor is going to be installed please consult the owner s manual of the electric motor on beforehand 1 xo m 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 g
59. he mounting position indicated for the gear unit in question in Annex 1 Wait 10 minutes for the oil level to stabilise inside the gear unit s casing 2 Insert a dipstick through the hole shown in drawing S4 or S5 and measure the distance betwe en the oil level and the exterior of the casing This value must be compared with the values in mm given in Annex 1 tables A7 and A8 depending on the mounting position for the gear unit in question 3 If the measurement gives a higher value than that prescribed top up the oil to the correct level as indicated in the catalogue For all other types of gear unit the oil level must be checked via the oil plug spill type using the tool out of scope for supply described in Annex 1 For the first charge and subsequent top ups only use the recommended oils Installation of gear units classified under Directive 94 9 EC e Category 2D gear units must be installed in compliance with the provisions of standards EN 1127 1 and EN 50281 1 2 The installer must therefore be fully informed and trained for this application The installation technician must be aware of the ATEX class of the installation area as well as the risks associated with the presence of a potentially explosive atmosphere with particular at tention to explosion and fire hazards and thereby adopt the necessary safety precautions All maintenance assembly and disassembly work must be done outside the explosion ha zard area by trai
60. ible couplings 3 days Above parts and or complete gearbox 4 6 weeks gland packing and v belts lday Complete agitator 4 12 weeks Note Shaftsand impellers although not normally wearing parts may be damaged and require repair replacement These parts are long delivery items and should be considered if extended down time isunac ceptable For any downtime all wearing parts are normally recommended spares These include bearings seals gears input couplings and shims gaskets V belts steady bearing bushings and wear sleeves are also recom mended when present Closed tank mixers will often require seal shaft repair replacement if seal problems are encountered Seal shafts are typically 4 week shipment items and should be considered a recommended spare parts item if downtime is critic al NOTE Replacement gearboxes should be purchased through SHARPE MIXERS SHARPE MIXERS incorporates several modificationsto the gearbox casing and intemal partsto make the gearbox suitable foroperation asan agitator drive Purchasing the gerarbox from other suppliers ma y result in incorrect selection and possible gearbox failure WARRANTY For standard terms and conditions of sale including warranty please refer To the inside front cover of this manual Ihe expressed warranty implies that MIXER was purchased through SHARPE MIXERS Warranties for MIXERS purchased through distribu tors must be handled through original distributor
61. installed after the mixer shaft isin place Split seal assembly instructions will be included in Section D Note the type of shaft coupling to the drive on the assembly drawingsand install the shaft by one of the following steps B3 2 Hollow bore drive Remove cover over hollow bore on drive when supplied Remove hold washer and protective wrap on top of mixer shaft Clean machined section of shaft of any rust grit and lubricate lightly with NEVER SEEZ compound Raise mixer shaft from below and through seal Install the Shaft into the drive see Figure B3 1 Be sure key isin place Do not hammer partsin place If keysdo not fit grind to size Before bolting hold washerin place add NEVER SEEZ compound supplied to the top of shaft The top hold bolt must be installed dry and threaded into top of of shaft a distance equal to at least one bolt dia meter Tighten the hold vvasher bolt to the torque ratings listed in table B3 1 using a torque wrench socket combination for best results Rein sta ll the hollow bore cover when supplied B3 3 Split coupling drive Remove split cou pling from drive shaft Raise mixer shaft from belovv and through seal see Paragraph B3 1 Bolt hold vvasher to top of mixer shaft if not already done Install keys on both shafts Do not hammer parts in place If keysdo not fit grind to size Make sure all partsare clean and assemble split coupling halves onto shafts see Figure B3 2 The split cou
62. ixation du r ducteur soit rigide afin d viter les vibrations Installer suivant n cessit par example en cas de chocs de surcharges prolong es ou de blocage possible un coupleur hydraulique un embrayage ou un limiteur de couple etc Pedant les operations de peinture il est conseill de prot ger les joint d tanch it pour viter que la peinture ne las ass che et soit ainsi pr judicable leur bonne tenue Les organes mont s sur les arbres du r ducteur doivent tre al s s aux tol rances ISO H7 pour viter des ammanchements trop serrants qui pourraient endommager le r ducteur lors du montage De m me il est conseill pour le montage et le d montage des m me organes d utiliser un outillage adapt et de se servir du trou tarad existant en bout d arbre Pour les memes raisons ci dessus les organes devant etre cal s sur les arbres de sortie du variateur doivent etre travaill s avec une tol rance ISO F7 Les surfaces de contact doivent tre nettoy es et prot g es contre l oxydation pour viter le blocage des parties La liaison avec l arbre creux du r ducteur tol rance H7 doit normalement s effectuer avec des arbres usin s la tol rance h6 L ou l application l exige il est possible de r eliser un ajustement plus serr H7 J6 Verifier le niveau d huile avant la mise en service fonction de la position de montage Le viscosit de l huile doit
63. ize key SOLUTION Loosen set screws Measure and consult factory Consult factory eGrind key to fit e Mixer vvill not sta rt e incorect wiring eL Loose connections e Blown fuse e Incorrect voltage e Impeller interference eVVater damage to motor eVVrong size heatersin starter eCheck wiring diagram and wire correctly eCheck and tighten connections e Replace fuse e Wire for correct voltage e Free all debrisfor rotation e Service or replace motor consult factory Replace heaters e Mixer vvill not reach correct speed Overload of motor eLoose drive coupling bolts See Mixer will not start eCheck amperage against nameplate data eCheck coupling bolt tension coupling and or shaft maybe damaged if mixer has been run with slip ping coupling eMotor runs hot eAmperage overload e Lovv or high voltage e Product too viscous e Restricted ventilation e Frequent starting and stopping eUnbalanced voltage between phases eIncorrect rotation e Product too viscous e Incorrect rotation or upside down impeller eImpellertoo close to tank floor eLack of improper lubricant elmproper output speed Build up of sediment on tank bottom e Undersized heaters Variable frequency drive incompatible with motor B 10 Wire for correct voltage Check viscosity and specific gravity of product consult fa ctory eClearvents eCheck with factory a special
64. l Mixer fails to provide the process results described in Buyer s written specifications While we warrant that the Mixer is made from the materials specified in the Proposal or its commercial equivalent WE DO NOT GUARANTEE THE MIXER AGAINST CHEMICAL ATTACK OR OTHER DETERIORATION DUE TO EXPOSURE THE FOREGOING WARRANTIES EXTEND ONLY FOR TWELVE 12 MONTHS AFTER FIRST INSTALLATION OF THE MIXER AT BUYER S FACILITY OR FOR EIGHTEEN 18 MONTHS AFTER ITS SHIPMENT FROM SHARPE S FACILITY WHICHEVER PERIOD IS SHORTER ADDITIONALLY SUCH WARRANTIES ARE EXPRESSLY IN L EU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED ORAL OR WRITTEN INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND OF ALL OTHER OBLIGATIONS OR LIABILITIES ON THE PART OF SHARPE THESE WARRANTIES SHALL NOT APPLY TO FAILURES RESULTING FROM A NORMAL WEAR AND TEAR B ACCIDENT NEGLIGENCE ALTERATION ABUSE MISUSE OR USE INCONSISTENT WITH ANY INSTRUCTIONS PROVIDED AS TO STORAGE HANDLING MAINTENANCE LUBRICATION INSTALLATION STARTUP OPERATION AND SAFETY C IMPROPER INSTALLATION AND OR D INACCURATE AND OR INCOMPLETE SPECIFICATIONS DESIGN CONDITIONS OR OTHER DATA FURNISHED BY OR ON BEHALF OF BUYER WE MAKE NO WARRANTY WHATSOEVER WITH RESPECT TO ACCESSORIES OR PARTS NOT SUPPLIED BY SHARPE 2 LIMITATION OF REMEDIES Buyer s remedy for breach of any of the foregoing warranties shall be limited to those set forth in Section 1 above provided WE will not be res
65. le B4 1 B4 4 Othertypes of impellers are Bolted blades in which blades must be securely bolted to the tabs welded to the shaft Welded bladesin which require no special installation work INSTALLING THE STEADY BEARING optional equipment WARNING Alwayslockout power before insta lling or servic ing the steady bearing Neverrun mixer without the steady bearing installed B5 1 This section isfor mixers which include an optional steady bearing to accommodate longer than standard mixer shafts A steady bearing must be installed only afterthe drive assembly and lower mixer shaft have been assembled and firmly bolted in place DO NOT predetemine the bearing location BC 7440 3 1098 B 3 from tank and mixer outline dimension dravv ings The vertical center line of the steady bearing must coincide with the shafts natural axis of rotation to minimize bearing preload see Figure B5 1 Tis axis may not necessarily be atthe center of the tank The mixer shaft must be hand rotated using input shaft coupling or motor fan with a fixture attached to the shaft to mark a line on the tank bottom The center of this inscribed area vvill be the location for the center of the steady bearing B5 2 The steady bearing must be securely installed with its vertical centerline aligned with the axis of rotation of the shaft as described in paragraph B5 1 The amount of lateral movement required to bring the shaft into properalignment with
66. led by an extemal flush of clean liquid through a throttle Flushing pressure needs to be 15 30 psi greaterthan tank pressure B6 3 2 PRECIPITATING LIQUIDS Solids which precipitate out of a liquid do so by reason of either anincrease in concentration orbecause ofa lowering or in some casesa raising of temperature beyond that at which it is proper to operate Illustra tions are caustic soda and calcium hydroxide With ammonium nitrate for example temperature must be controlled atan optimum level in relation to its concentration Ifthe temperature rises above the optimum it will boil and form crystals and conversely if temperature drops it will become saturated and sa lt out B6 3 3 EVAPORATING LIQUIDS Solids can form asa result of heat which promotes eva poration Examples include any of the hot chemical salts the chlorides chlorates sulfates sulfides Cool by flushing or by utilizing water jackets B6 3 4 CONGEALING LIQUIDS Generally speaking these liquids congeal either because of a drop in temperature orasa result of drying out after exposure to air Sugar syrupsfall into both categones A good rule isto keep the fluid moving before congealing cantake place Control with heat and orby flush orpurge Clean liquid flush pressure needs to be 25 psigreaterthan tank pressure Asphaltisa typicalcase ofa liquid which congealsasitcools and thiscan be controlled by heat Some sugar syrupsfallunderthiscategory Be sure to he
67. lications envisaged by the Manufacturer Improper use can result in risks to personal health and safety and economic damages The applications defined by the Manufacturer are those industrial applications for which the gear unit has been developed Keep the gear unit at its maximum efficiency by following the routine maintenance schedule Good mainte nance enables the unit to operate at maximum performance over a long service life in compliance with sa fety regulations When working on the unit in areas which are difficult to access or hazardous ensure that adequate safety precautions have been taken for the operator and others in compliance with the provisions of law on health and safety at work All maintenance inspection and repairs must only be done by an expert maintenance technician fully fami liar with the attendant hazards It is therefore essential to implement operating 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 If the gear unit is to be serviced in a potentially explosive atmosphere the operator must first switch off power to the gear unit and ensure that it is out of service as well as taking all neces sary precautions against it being accidentally switched on again or its parts moving without war ning Furthermore all additional environmental safety pre
68. llager Kugellager Federring Pa feder Dichtring V ring Nur lieferbar als Kit Stator Rotor Bride IM B5 IM B14 Ventilateur Couvre ventilateur Couvercle boite a bornes Joint de la bofte a bornes Bouchon taraude Boite a bornes Vis Roulement Roulement Bague de compensation Clavette Bague d etancheite Bague V ring HHH Disponible seulement en kit 71 IHOLLNGIH 2 I1011914N04 e _ 1 4 P 1500 min1 S1 50 Hz NOTE INFORMATION IS FOR 50 Hz freno c c d c brake freno c a a c brake G S bremse frein c c VV S bremse frein c a Pn n y In Jm MB5 Mb Z Jm IMB5 Mb Z Jm mes Mb gt Jm MB5 Is Ms Ma x 10 x 10 x 107 nas x 107 COS o A In Mn Mn mA Mod 1 h A Mod A Mod A kW min Nm 96 400V kgm Nm NB SB Kgm Nm 1P kgm Rim 1h kgm G 0 06 BN 56A 41 1350 0 42 47 0 62 0 30 26 2 3 2 0 1 5 3 1 0 09 BN 56B 41 1350 0 64 52 0 62 0 40 26 2 5 24 1 5 3 1 0 12 BN 63A 4 1310 0 88 51 0 68 0 50 26 19 1 8 2 0 3 5 FD 02 1 75 1000013000 2 6 52 FA 02 1 75 13000 2 6 5 0 BA 60 5 9000 4 0 5 8 0 18 BN 63B 4 1320 1 30 53 068 0 2 26 22 20 23 39 FD 02 3 5 10000130001 30 5 6 FA 02 3 5 113000 3 0 5 4 BA 60 5 19000 4 3 6 2 0 25 BN 63C 4 1320 1 61 60 0 69 0 87 27 2 1 1 9 3 3 5 1 FD 02 3 5 7800 10000 3 9 6 8 FA 02 3 5 10000 3 9 6 6 BA 60 5 8500 5 3 7 4 0 25 BN 71A
69. ned personnel Check that all accessory components cables joints cable glands cooling units etc comply with the Essential Health and Safety Requirements of the ATEX directives Handle them with extreme care to avoid altering their characteristics Remove the bolts sealing the threaded holes if provided for securing the gear unit Do not da mage the coupling surfaces When assembling gear units with 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 obiect vvith electrical resistance greater than 10 O to the product Install guards to prevent the hazardous accumulation of dust and liquids on the seals of the so lid shafts and to protect them mechanically n case of installation of the gearmotor in a vertically dovvnvvard orientation the electric motor must be equipped with a drip cover The output shaft and any pulleys or other transmission components must be perfectly aligned Only install the gear unit in the motor execution and mounting position specified on the order Shaft mounted gear units can be installed with a tolerance relative to the theoretical plane of installation of 5 If the gear unit is supplied without lubricant it must be installed as such and only filled with lu bricant thereafter Secure the gear unit to a flat vibration free surface
70. nes should be followed The gearbox to be securely bolted to a rigid base to avoid vibrations If shocks extended overloads or jamming is expected hydraulic couplings torque limiters clutches etc should be fitted n case the gearbox is to be painted use adhesive tape to prevent contact of paint with the oil seals Painting of oil seals may lead to premature drying of rubber and result into oil leakage Any gears sprockets or pilleys being fitted to the input or output shafts must have their bores machined to ISO H7 tolerance The shafts are provided with threaded hole to facilitate the use of tierods with backplate and nut to push on tha gear or sprockets being fitted For the same reasons all units keyed onto the variator output shaft must be machined to ISO F7 tolerance In order to avoid oxidation and the possible sezing of the above parts clean mating surface before assembly and apply water repellant grease or similar material Bore of hollow shaft of gearbox has tolerance H7 all shafts being fitted usually are machined to h6 If required for the application an interference fit H7 J6 can be used Before operating the machine check that the lubricant level is correct for the mounting position of the gearbox and the lubricant viscosity is correct for the kind of load Il est important pour l installation du r ducteur de suivre les conseils suivants S assurer que la f
71. nforce any terms of the agreement the parties agree that venue shall be the Superior Court of the State of Washington for King County 9v Document 0051848 05 August 27 1998 OPERATION amp MAINTENANCE INSIRUG TIO NS SIA LR 22 MIXERS TOP ENTRY WITH MEG HANIG AL SEAL TABLE OF CONTENTS SECTION A MIXER DATA SHEET amp DRAWING S SECTION B INITALINSPEC TION RECEIVING AND SIO RAG E nn ae B 1 MOUNING EE En Dn nd B 2 INSIALUNG THE MIXER SHAFT ae nen B 2 INSTALUNG THE MIXER IM PELLER ee ne ae a P ERE RNS B 3 INSTALLING THE STEADY BEARING optional equipment rss B 3 MECHANICAL SEAL PREPARATION amp LUBRICATION 5 B 4 MOTOR CONNECTIONS S LUBRICATION ana un B 7 SARTUP TON EE B 7 TROUBLE SHOOTING G Uli 22 242222222222nnnnnnnanennannennnanannannnnannnnnnnnannannnnnnnnannnsannnnnannannann B 10 RECOMMENDED SPARE PA B 13 WARRANTY ome A A La REA P deng AE B 13 SECTION C SPEED REDUC ER LUBRICRQEEBIDEENDUPUITIEREA VE df ER AO DU AY A C 1 SPEED REDUC ER PAD mode D cm C 3 SECTION D MISCELLANEOUS DEAILS amp INSIRUCTO NS when required Nm fi SECTION B INITIAL INSPEC TION RECEIVING AND STORAGE B1 1 Immediately upon receipt of the equip ment check the crating and conte
72. nts for any dam age that may have occurred in transit Report any damage immediately to the camerand to Sharpe Mixers Check againstthe packing slip to be sure that allpartswere received Report missing itemsto the ca mer and Sharpe Mixers Bl 2 The drive unit impellers and the mixer shaft are normally packed in a separate containers If space allows keep shipping containers for possible future use B1 3 Mechanical Seal receiving and inspec tion Thoroughly review the drawingsin the service manualagainstthe equipment and inspectthe mechanicalsealhousing and partsfor possible damage during shipment Mechanicalsealsare easily damaged by improper handling often unde tected until the tank contents leak through the seal NEVER LIFT MIXER BY THE MIXER SHAFT When lifting the equipment with a lifting strap never allow the strap to come in contact with the mixer shaft me chanical seal housing piping or related compo nents Study carefully the mechanical seal drawing to determine whether seal isa single or double mechanical seal design Double mechanical seals are pressure tested at the factory using air t is recommended that double mechanical seals be BC 7440 1 1098 pressure tested again using airor water pressure pnor to installing the equipment on your tank When using air the seal faces may need to be coated with lubricant to achieve a static seal B1 4 Storage Storage iswhen a mixer has been delivered to the job
73. oint of maximum tem perature Example 57 7399 Atthe same time check for excessive running noise and vibration BONFIGLIOLI 2 RIDUTTORI e 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 vvhich itself com plies vvith the provisions of Directive 94 9 EC f 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 assembiy in cluding the gear unit itself be compliant with the requirements of Directive 94 9 EC 7 0 USING THE EQUIPMENT Before putting the gear unit into service the User must ensure that the plant in which it is installed complies with all applicable directives especially those regarding health and safety at work The gear unit may not be used in areas and environments N e vvith highly corrosive and or abrasive vapours smoke or dust e in direct contact with loose food products
74. onsiglia di proteggere il bordo esterno degli anelli di tenuta per evitare che la vernice ne essicchi la gomma pregiudicando la tenuta del paraolio stesso Gli organi che vanno calettati sugli alberi del riduttore devono essere lavorati con tolleranza ISO H7 per evitare accoppiamenti troppo bloccati che in fase di montaggio potrebbero danneggiare irreparabilmente il riduttore stesso Inoltre per il montaggio e lo smontaggio di tali organi si consiglia l uso di adeguati tiranti ed estrattori utilizzando il foro filettato posto in testa alle estremit degli alberi Per gli stessi motivi di cui sopra gli organi che vanno calettati sugli alberi di uscita del variatore devono essere lavorati con tolleranze ISO F7 Le superfici di contatto dovranno essere pulite e trattate con adeguati protettivi prima del montaggio onde evitare l ossidazione e il conseguente bloccaggio delle parti L accoppiamento all albero cavo del riduttore tolleranza H7 viene normalmente eseguito con perni lavorati con tolleranza h6 Dove il tipo di applicazione lo richieda si pu prevedere un accoppiamento con una leggera interferenza H7 J6 Prima della messa in funzione della macchina accertarsi che la posizione del livello del lubrificante sia conforme alla posizione di montaggio del riduttore e che la viscosit del lubrificante sia adeguata al tipo del carico For the installation of the gearboxes the following guideli
75. otation and ruin the seal in the process Many double mechanical seals have assembly positioning tabs which hold the seal wearsleeve on center in position orcompressthe seal to running height during ship ping and assembly These tabs must be rotated out ofthe way orremoved completely before start up B6 1 2 If the seal has not been installed at the factory Install seal over shaft at time of shaft installa tion in correct position Use a light vegetable oil to aid in installation over shaft Compress seal to height shown in seal detail drawing in front of this manual once shaft installation is complete Split seals must be fully installed after shaft installation is complete See specific seal details elsewhere in this manual B6 1 3 The mechanical seal housing or gland plate will have one or more tapped holes for lubrica tion ventilation and draining which will be plugged from the factory with temporary plastic plugs These plugs must be replaced with the proper flush lube recirculating lines ordead end plugged asdescribed below Paragraph B6 4 B6 1 4 Make sure all valvesare open to insure the sealreceivesa positive flow of liquid at all times Bleed all gasestrapped in the seal cavity before start up orthe cavity may vaporlockand the seal will bum up by running dry Open valves slowly once the lubrication system has been pressurized Open ing inlet valvestoo quickly may cause a water hammer effect that could crack or shatte
76. otre Bureau Technique Les r ducteurs susmentionnes ne n cessitent aucun entretien et sont donc depourvus de bouchons de remplissage de vidange et de niveau ayant re u au montage la quantite de graisse n cessaire Le deuxieme groupe qui comprend des reducteurs de moyenne et forte puissance est prevu avec lubrification l huile Dans ce cas les reducteurs sont livres sans hulle et il appartiendra au client lors de la mise en service de les pourvoir de la quantite d huile necessaire A cette fin ces redusteurs sont munis de bouchons de remplissage de niveau et de vidange Il est necessaire a la commande specifier la version si differente de B3 Version VF 86 B Bez glich der Schmierung sind die Getriebe in zwei Gruppen zu unterteilen A VF27 VF30 VF44 VF49 VF 63 VF72 VF 86 B VF 110 VF 130 VF 150 VF 185 VF210 VF 250 Die unter Pos 1 aufgef hrten getriebe sind auf Lebensdauer durch synt Ol geschmiert Die exakte Olmenge wird bei der Montage eingefullt Die unter Pos 2 aufgef hrten Getriebe werden bei mittleren und schweren _ Einsatzbedingungen mit Ol geschmiert Bei Verwendung von Olschmierung m ssen die Getriebe vor Inbetriebnahme gef llt werden Zu diesem Zweck sind sie mit Einfull und Abla schraube sowie Schauglas versehen Sollte eine andere Einbaulage als B3 ben tigt werden ist dies bei der Bestellung unbedngt anzugeben da sich nachfolgende lmengen nur auf B3 beziehen Sie gel
77. outine maintenance the set of operations required for maintaining the functionality and efficiency of the gear unit These operations are usually scheduled by the Manufacturer who defines the qualifications requi red and tasks in question Non routine maintenance the set of operations required for maintaining the functionality and efficiency of the gear unit These operations are not scheduled by the Manufacturer and must be done by an expert main tenance technician Expert maintenance technician an authorised technician selected by means of having the qualifications skills and mechanical and electrical training to do repairs and non routine maintenance work on the gear unit Overhaul an overhaul consists in the replacement of bearings and or other mechanical components which have worn to such an extent as to compromise the operation of the gear unit The overhaul also includes ve 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 ac
78. pling has one end marked drive on each half This end must face the gearboxforproperalignment Replace split Washercover a E Hold bolt Hold washer optional Mixer drive Output shaft Key Mixer shaft Hollow Bore Drive FIGURE B3 1 Bolt Torque Ratings 5 16 bolt O 10 ft Ibs 3 8 bolt O 25 ft Ibs 7 16 bolt 35 ft Ibs 1 2 bolt O 45 ft Ibs 5 8 bolt O 75 ft Ibs 3 4 bolt O 130 ft Ibs 7 8 bolt O 200 ft Ibs Table B3 1 coupling Be sure gap iseven on both sides of coupling Tighten split coupling bolts to the torque ratings listed in Table B3 1 Tighten from the center out in an opposite diagonal sequence t is critical that shaft alignment be checked closely after insta llation with split couplings Impropertorquing an oversize key or eccentric washers can cause mis alignment and problems during operation See B3 5 BC 7440 2 1098 Mixer drive O E A Output shaft Key U O 9g E Q Hold bolt Hold washer 4 dill Split Mixer coupling Mixer shaft shaft Key Split Coupling Drive FIGURE B3 2 B3 4 Hange coupling optional Clean mating surfa ces of any nicks or grit which may cause misalignment Raise mixer shaft to mate to flange coupling Boltflanges securely together see Figure B3 3 Be sure flanges mount flush Upper mixer shaft
79. ponsible for removal loading installation freight or similar related expenses in connection with any replacement repair or return The determination of which such remedy shall be applicable shall be determined by SHARPE in its sole discretion THE ABOVE STATED REMEDIES ARE SHARPE S ENTIRE AND EXCLUSIVE LIABILITIES AND BUYER S EXCLUSIVE REMEDIES FOR ANY CLAIM FOR DAMAGES IN CONNECTION HEREWITH By way of illustration and not limitation in no event shall we be liable for any direct indirect special or consequential damages or delay whatsoever or loss of use and SHARPE S liability under no circumstance will exceed the contract price for the Mixer for which liability is claimed All claims for breach of any of SHARPE S warranties shall be barred unless Buyer notifies SHARPE in writing within 30 days of discovery of the breach WE shall not be responsible for any repairs performed by third parties unless the extent terms and costs of such repairs are authorized by SHARPE in writing in advance Buyer shall be solely responsible for any agreement that Buyer makes with its customers which is contrary to the foregoing provisions 3 DELIVERY SHIPMENTS Unless otherwise quoted shipments are F O B shipping point Risk of loss and damage to the Mixer shall pass to Buyer upon delivery to the carrier and at such time Buyer shall be solely responsible for the Mixer We will make every effort to ship on the date specified in the contract provided that such dat
80. properties and application range e Tighten down all motor gear unit mounting bolts to their prescribed torque For the tightening torques refer to table AO When the gear unit is mounted to an IEC electric motor proceed as follows e 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 S1 1 Apply Loctite 510 to both the flange surface and spigot 2 Apply Kl berpaste 46MR401 to the input shaft bore and motor shaft 3 Use Loctite 5366 to seal the area of contact between the gear unit and motor taking care to fill in any gaps between the two flanges e g disas sembiy slots e 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 e If the gearbox is of the flanged type the User must take similar precautions to prevent dust de posits forming in the gaps between the flanges or in the vicinity of the couplings BONFIGLIOLI a 16 RIDUTTORI 6 0 TESTING THE GEAR UNIT The gear unit has been factory tested by the Manufacturer Before starting the unit check that The machine incorporating the gear unit complies vvith the provisions of the Machinery Directive 98
81. r the seal faces On high speed above 350 rpm and high temperature applications the mechanical seal housing must be constantly flushed with a cooling lubricant before applying powerto the mixer orheat will quic kly build and destroy the seal Where colder ambient temperatures will cause thickening of the lubricant the seal housing and lubricant lines must be preheated to allow free flowing lubricant to seal before start up Neverallow the seal orlubrication lines to freeze B6 2 Tankliquid level must be filled to at least one prop diameterabove the impeller elevation before starting mixer Mixer must never run when liquid level drops below this point A low liquid alarm or shut off switch is recommended if low liquid levels are likely to occur BC 7440 4 1098 B6 3 SEALING ABRASIVE LIQUIDS Asused here abrasives isa broad tem intended to cover the problem of sealing against slumes congealing liquids crystallizing salts and the like They cause the great est damage to equipment and present diffic ulties for mec hanical seals In general the cure involves flushes purges and temperature controls See mechanical seal lubrication Paragraph B6 4 for more information on lubrication and flushing of mec hanical seals B6 3 1 SUSPENDED SOLIDS Solids which are suspended in liquidsand which are an inherent part Of their structure vvould inc lude starch conta minated or muddy water sand and other slumes This is best hand
82. rfaces but proceed as indicated belovv S3 IMPACT EXTRACTOR Drill and thread the motor shaft fan side Screvv an impact extractor tool into the tap Undo the screvvs fixing the motor to the gear unit Remove the motor by means of the inertial force of the extractor 9 2 SCRAPPING THE GEAR UNIT This must only be done by operators trained in the observance of applicable lavvs on health and safety at vvork Do not dump non biodegradable products lubricants and non ferrous materials rubber PVC resins etc into the environment Dispose of all such materials as stipulated by applicable environmental protection legi slation N Do not attempt to re use parts or components which appear to be in good condition after they have been checked and or replaced by qualified personnel and declared unsuitable for use BONFIGLIOLI RIDUTTORI 27 10 0 TROUBLESHOOTING The following information is intended to serve as an aid in identifying and correcting defects and faults In some cases such problems may be caused by the plant or machine onto which the gear unit is assembled and hence the cause and eventual solution can be found in the Manufacturer s technical documentation for the machine plant in question PROBLEM Bearing temperature too high CAUSE Oil level too low SOLUTION Top up oil level Oil too old Replace oil Defective bearings Contact authorised vvorkshop Operating tempera
83. ricaci n con aceite litros VF 250 Le quantita riportate nella tab A sono quelle introdotte all assembiaggio del riduttore e sono valide per tutte le posizioni di montaggio Le quantita nella tab B sono indicative e sono relative alla posizione di montaggio B3 BONFIGLIOLI RIDUTTORI Mp The quantities shown in table A refer to amounts filled when assembling the gearbox and are valid for all mounting positions The quantities in table B are indicative and relevant to mounting position B3 only 10 7 28 4 PAM 22 6 Les quantit s r per es au tableau A sont celles introduites l assemblage du r ducteur et sont valides pour toutes les positions de montage Les quantit s r per es au tableau B sont indicatives et se rapportent la position de montage B3 Die in Tabelle A angegebenen Mengen sind Montage lf llmengen Sie sind fur alle Einbaulagen g ltig Hingegen die in Tabelle B angegebenen Mengen sind fur Einbaulage B3 g ltig und stellen nur Richtwerte fur die anderen Einbaulagen dar 22 6 Las cantidades indicadas en la tabia A son aquellas relativas al aceite sintetico introducido en el reductor al momento del montaje y son validas para todas las posiciones de instalaci n Las cantidades de la tabia B son aproximadas y corresponden a la posici n de instalacion B3 27 Tipo di lubrificante Type of lubrificant Type de lubrifiant Schmiermittel Tipo de lubricant
84. rrosion and tighten them down fully without overtig htening 8 6 CLEANING Clean all dust and process waste off the gear unit Do not use solvents or other products which are incompa tible with the construction material and do not direct high pressure jets of water at the gear unit 8 7 PAINT COATING In the factory the cast iron casing of 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 VF 44 VF 49 If the gear unit is to be painted tape the nameplate and seal rings to prevent contact with solvent BONFIGLIOLI Hi 26 RIDUTTORI 9 0 REPLACING PARTS e Do not hesitate to replace parts and or components if they are not able to guarantee safe and re liable operation N Never improvise repairs e 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 screvvdrivers or levers to apply force as this can damage the flanges and coupling su
85. rst running hours is also suggested Gearboxes supplied with synthetic oil from factory do not require futher maintenance Should the gearbox be sitting standstill for a long time in a very humid environment we suggest to full it up With oil The proper level must be restored when the gearbox is newly put back into operation N B We kindly ask you to specify always type ratio and version of the gearbox the required spare parts refers to G n ralement il est conseill de graduer dans le temps l augmentation de la puissance transmise en partant des valeurs mini ou lui imposer un limite 50 7096 de la puissance maxi pedant les premi res heures de fonctionnement Les r ducteurs lubrifi s l huile synth tique ne n cessitent aucun entretien Lorsque le r ducteur reste longtemps inutilis dans un milieu tr s humide nous conseillons de le remplir totalement d huile il est vident que le niveau de lubrifiant doit etre r tabli lorsque le groupe sera mis en fonction N B Afin d tre en mesure de livrer rapidement les pi ces de r chenge command es nous vous prions d indiquer le type la version et le rapport du r ducteur auquel elles sont destin es W hrend der Einlaufphase ist es bessen die Abtriebsleistung stufenweise bis zur max Leistung anzuheben oder f r die ersten Stunden auf 50 70 die Maximalleistung zu begrenzen Die mit synthetischem Schmier l arbeitenden Getriebe erfordern kein
86. s a range of accessories and optionals to make their products as versatile as possible For further technical information and descriptions refer to the Sales Catalogue The User is responsible for using the products recommended for installation and maintenance of BONFIGLIOLI gear units in an appropriate manner and in accordance with instructions SAFETY SPECIFICATIONS FOR ATEX SPECIFIED GEAR UNITS e use Of synthetic lubricants only oil and grease e VITON seal rings thread locker on all external bolts vent caps with anti intrusion valve double oil seals on series C gear units and oil seals with dust traps on all other types components and products operable at above the maximum rated operating temperature no metal moving parts external to the gear unit no plastic parts capable of building up electrostatic charge irreversible temperature indicator supplied along with each unit 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 He
87. s piezas El acoplamiento el ele hueco del reductor tolerancia HT debe efectuarse con ejes maquinados con tolerancia h6 Cuando el tipo de aplicai n lo requiera pueden prevers acoplamientos con una ligera interferencia H7 J6 Antes de la puesta en marcha de la m quina comprobar que la posici n del nivel de aceite sea adecuada a la posicion de montaje del reductor y que la viscosidad del lubricante sea idonea para el tipo de carga a soportar BONFIGLIOLI z RIDUTTORI 29 Generalmente e consigliabile guardare nel tempo l aumento della potenza trasmessa partendo da valori minimi oppure porre ad essa un limite 50 70 della potenza massima per le prime ore di funzionamento I riduttori lubrificati con olio sintetico non necessitano di alcuna manutenzione Quando il riduttore resta per lungo tempo inattivo in ambiente con una elevata percentuale di umidita consigliamo di riempirlo totalmente di olio logicamente il livello del lubrificante dovra essere ripristinato quando il gruppo sara messo in funzione N B Al fine di consentire una rapida evasione degli ordini di ricambi vi preghiamo di indicare sempre tipo versione e rapporto di trasmissione del riduttore a cui essi sono riferiti BONFIGLIOLI z RIDUTTORI Whenever putting a band new mit into operation a progressive increase of transmitted power is advisable Alternatively limiting of transmitted power to 50 70 of max rating for the fi
88. ten auch f r die entsprechenden Baureihen RVF ausgenommen Eingangsstirnradstufe und VF VF Respecto de la lubricaci n los reductores de tornillo sin fin son divididos en dos grupos A VF27 VF30 VF44 VF49 VF 63 VF 72 VF 86 B VF 110 VF 130 VF 150 VF 185 VF210 VF 250 En el primer grupo que comprende reductores de baja y media potencia ha sido adoptado el sistema de lubricaci n permanente con aceite sint tico y esto permite que puedan ser instalados en cualquier posici n de montaje con excepci n de las posiciones de montaje V 5 V 6 para las cuales es necesario evaluar las condiciones de empleo con nuestra OFICINA TECNICA Los citados reductores est n desprovistos de los tapones de carga nivel y descarga y por lo tanto no necesitan mantenimiento dado que contienen ya la necesaria cantidad de aceite En el segundo grupo que comprende reductores de media y alta potencia ha sido adoptada la lubricaci n con aceite de recambio Los reductores est n provistos de tapas de carga nivel y descarga aceite y a este respecto al momento de efestuar el pedido es importante especificar la posici n de montaje en caso de ser diferente de B3 Estos reductores son suministrados desprovistos de lubricante por lo que el cliente deber introducir la necesaria cantidad de aceite antes de la puesta en funcionamiento Lubrificazione a olio litri Oil lubrication litres Lubrification a huile litres Olschmierung liter Lub
89. thorized representative at SHARPE s main office provided that any terms or conditions which are additional or different to the terms and conditions set forth herein or which may have been included in any communication between Buyer and SHARPE whether written or oral are hereby objected to by SHARPE and shall not be effective or binding upon SHARPE unless specifically assented to by a duly authorized officer of SHARPE in Writing No waiver alteration or modification of any of the provisions hereof shall be binding on SHARPE unless made in writing and signed by a duly authorized officer of SHARPE Buyer s acceptance of delivery of the Mixer shall constitute full acceptance of all of the terms and conditions set forth herein The failure of either party to enforce any of its rights hereunder shall not constitute a waiver of such rights or of any other rights hereunder The terms and conditions of the Acknowledgment contain the entire agreement of the parties Clerical and typographical errors are subject to correction 7 CANCELLATION CHARGES Orders placed by Buyer may not be canceled without SHARPE s written consent Buyer agrees to indemnify SHARPE against all loss damage or expense incurred due to cancellation including but not limited to the cost of special materials non resalable goods completed or in process labor freight engineering time overhead and profit A minimum charge of 20 will be applied in the event of a cancellation 8 OCCUPATI
90. tre adapt e au type de service Bei der Installation des Getriebes m ssen folgende Anweisuggen unbedingt beachtet werden Das Getriebe mu stabil befestigt werden um Vibrationen zu vermeiden Sollte vorauszusehen sein daB am Antrieb Schl ga l ngere Uberlastun gen oder Blockierungen auftreten k nnen dann Drehmoment begrenzer usw einbauen Bei der Lackierung sollte der AuBen rand der Dichtringe gesch tzt werden um zu vermeiden da der Gummi durch den Lack austrocknet Dies w rde zu mangelnder Dichte f hren Die Einheiten die mit der Abtriebswelle des Getriebes verbunden werden m ssen mit einer Toleranz ISO H7 bearbeitet werden um zu starre Verbindungen zu vermeiden die w hrend der Montage zu irreparablen Sch den am Getriebe f hren k nnen Ferner sollte der Ein und Ausbau dieser Einheiten mit Hilfe geeigneter Zugbolzen und Auszieher an der Gewindebohrung am Ende der Wellen erfolgen Auch die Einheiten die mit der Abtriebswelle des Drehzahlvvandlers verbunden vverden sollten aus obengenannten Gr nden mit einer Toleranz ISO F7 bearbeiten werden Die Kontaktfl chen m ssen vor der Montage sauber sein und mit angemessenen Schutzmitteln behandelt werden damit eine Oxydation und in Folge eine Blockierung der Teile vermieden wird Der Anschlu and die Abtriebs hohlwelle des Getriebes Toleranz H7 erfolgt normalerweise mit Stiften die mit einer Toleranz h6 bearbeitet
91. ture too high Abnormal running noise Oil level too high Oil too old Check oil level Replace oil Impurities in oil Gears damaged Replace oil Contact authorised workshop Bearing axial backlash too high Contact authorised workshop Bearings defective or worn Contact authorised workshop Service load too high Correct service load to nominal values given in Sales Catalogue Impurities in oil Replace oil Abnormal noise at gear unit mounting Mounting bolts loose Tighten down to specified torque Mounting bolts worn Replace bolts Oil leaks Oil level too high Check oil level Casing coupling seals inadequate Contact authorised workshop Gaskets worn Contact authorised workshop Gear unit does not run or runs with difficulty Oil viscosity too high Replace oil see table of recom mended lubricants Oil level too high Check oil level Service load too high Redesign drive for actual service load Output shaft does not turn with motor running 28 Gears damaged Contact authorised workshop BONFIGLIOLI 2 RIDUTTORI ANNEX 1 CHECKING OIL LEVEL ON ATEX SPECIFIED GEAR UNITS Gear units are normally supplied vvith a yellovv oil level plug of the spill type To check the oil level first identify the yellovv level plug Remove the plug and insert a bar of the right size for the hole and of the shape shown in th
92. ubrication system representative for assistance with these complex systems Pressure Nitrogen Check Valve gt x Y Lubrication Reservoir Tank Side Double seal with convection lubrication FIGURE B6 4 BC 7440 6 1098 B6 8 3 A 10 weight oil or otherthin nonc orrosive lubricating liquid is recommended rather than water when the lubrication reservoir is carbon steel NOTE Friction based non setscrew driven seals require a non lubrcating ba mer fluid B6 9 DOUBLE MECHANICAL SEAL WITH POSITIVE HOW LUBRICATION SYSTEM This system uses a pump supplying positive flow to and from the seal These systems often have a cooling system pressure and flow control valves low level alarms and other components which require a thorough understand ing before startup Sharpe Mixers recommends consulting with the mechanical seal lubrication system representative for assistance with these complex systems MOTOR CONNECTIONS amp LUBRIC ATION WARNING High voltage and rotating partscan cause serious or fatal injury Electric machinery can be hazardous Installation operation and mainte nance of electric machinery should be performed by qualified personnel Familia rity with NEMA safety standards National Electrical Code and local building codesare required B 2 Wiring Starting and overload control devices must be matched to motorrating Follow control manufacturers instructions for proper
93. unit f 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 original spare parts Every 5000 h of operation Change the synthetic oil and bearing grease if the gear unit is not life time lubricated Replace all externally accessible seal rings unless this has already been done as a result of problems occurring before the scheduled maintenance deadline Every 5000 h of operation at rated torque The minimum overhaul interval indicated here may increase considerably depending on actual conditions of service see table A5 Overhaul the gear unit unless this has already been done as a result of problems occurring before the specified deadline An overhaul involves the replacement of bearings and or other mechanical components which have worn to such an extent as to compromise the operation of the gear unit AS interval hours Mn2 nominal torque at output shaft M2 required torque at output shaft BONFIGLIOLI 2 RIDUTTORI uM a e gt ES TS ARAS AS 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 use
94. werden Falls erforderlich Kann die Verbindung mit einer leichten Tolleranz H7 J6 erfolgen Vor Inbetriebnahme der Maschine kontrollieren ob das Schmiermittelniveau der Einbauposition des Getriebes entspricht und ob die Schmiermittelviskosit t sich fur die vorgesehene Belastung eignet Para la instalaci n del reductor es muy importante atenerse a las siguientes normas Asegurar un correcto anclaje del reductor a fin de evitar cualquier vibraci n Si se preveen golpes sacudidas sobrecargas prolongadas o posibles blocajes instalar acoplamientos hidr ulicos embragues limitadores de par etc En el pintado debe protegerse el labio exterior del reten de aceite para evitar que la pintura reseque el caucho perjudicando su capacidad de cierre Las piezas que vajan montadas sobre los ejes del reductor deben mecanizarse con una tolerancia ISO H7 a fin de evitar montajes demasiado fuertes que puedan da ar de forma importante el reductor Ademas para el montaje y desmontaje de tales piezas se aconseja el uso de extractores adecuados utilizandose el aquiero roscado situado en la punta de los ejes Por los mismos motivos reci n citados los rganos que deben ser ensamblados en los ejes de salida del variador deben ser maquinadoscon tolerancia ISO F7 Las superficies de contacto deberan estar limpias y protegidas entes del montaje para evitar la oxidacion y el consegulente deterioro de la

PB manual - Sharpe Mixers

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