BONFIGLIOLI VF Series Installation, Operation And Maintenance Manual
  1. Manuals
  2. Brands
  3. BONFIGLIOLI Manuals
  4. Engine
  5. VF Series
  6. Installation, operation and maintenance manual
BONFIGLIOLI VF Series Installation, Operation And Maintenance Manual

BONFIGLIOLI VF Series Installation, Operation And Maintenance Manual

Hide thumbs Also See for VF Series:
Table of Contents

Advertisement

Quick Links

VF, W series
Installation, Operation
and Maintenance Manual
USER
MANUAL
INCLUDED

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the VF Series and is the answer not in the manual?

Questions and answers

Related Manuals for BONFIGLIOLI VF Series

Summary of Contents for BONFIGLIOLI VF Series

  • Page 1 VF, W series Installation, Operation and Maintenance Manual USER MANUAL INCLUDED...

  • Page 3: Table Of Contents

    Revisions The revision list for this manual is given on page . The most recent version of this manual is available from www.bonfiglioli.com. 1 / 64 IOM Manual VF-W_ATEXgb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...

  • Page 4: General Information

    1 GENERAL INFORMATION PURPOSE OF THIS MANUAL This manual has been prepared by the manufacturer in order to provide information regarding the safe transport, handling, installation, maintenance, repair, disassembly and disposal of the gearbox/gearmotor. All necessary purchasing and design information is provided in the sales catalogue. Follow good engineering practices, read the information in this manual thoroughly and apply it rigorously.

  • Page 5: Requesting Technical Assistance

    Failure to observe these instructions may result in serious safety and environmental risks. REQUESTING TECHNICAL ASSISTANCE For any technical service needs, contact the Manufacturer’s sales network (www.bonfiglioli.com) quoting the information indicated on the unit’s name plate, the approximate hours of service, the duty cycle and the type of defect.

  • Page 6: Safety Information

    2 SAFETY INFORMATION SAFETY STANDARDS Read thoroughly the instructions given in this manual and those printed directly on the gearbox, especially those regarding safety. Personnel appointed to work on the gearbox at any time during its service lifetime must be trained ●...
  • Page 7 Unless they have backstop devices, gearboxes may reverse direction. If there is any risk of uncontrolled movement occurring in the event of a power failure (for example in load lifting applications), measures must be put in place to prevent such movement occurring (for example by using motors with brakes that engage automatically if the power fails).
  • Page 8 6 / 64 IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...

  • Page 9: Technical Information

    3 TECHNICAL INFORMATION EQUIPMENT IDENTIFICATION The gearbox bears the following identifying nameplate. The nameplate provides essential information and specifications for correct and safe use. The designation of the gearbox is explained in the sales catalogue. If the gearbox is supplied fitted with a motor (gearmotor), all information regarding the motor itself is provided in the motor’s own manual.

  • Page 10: Description Of The Equipment

    Legibility of the nameplate The nameplate and the information thereon must be legible at all times. The nameplate should therefore be cleaned from time to time. Always quote the identifying data on the nameplate in all correspondence with the manufacturer, when ordering spare parts, requesting information or arranging technical assistance.

  • Page 11: Operating Limits And Conditions

    OPERATING LIMITS AND CONDITIONS The applications permitted by the Manufacturer are the industrial applications for which the gearbox has been designed. Changes to the gearbox version or mounting position are only permitted if previously authorised by the manufacturer’s technical assistance service. Failure to obtain this authorisation invalidates the ATEX certification.

  • Page 12: Allowed Temperature Limits

    ALLOWED TEMPERATURE LIMITS Value (*) Symbols Description / Condition Synthetic Mineral Ambient temperature -30°C -10°C Minimum operating ambient temperature au min Maximum operating ambient temperature +50°C +40°C au Max -40°C -10°C Minimum storage ambient temperature as min Maximum storage ambient temperature +50°C +50°C as Max...

  • Page 13: Handling And Transport

    4 HANDLING AND TRANSPORT Personnel authorised to handle packages must take all necessary precautions to safeguard their own safety and that of all other persons involved. PACKAGING SPECIFICATIONS Unless otherwise agreed, standard packaging, if supplied, is not rainproof. This type of packaging is intended for shipping by ground and not by sea, and for storage in areas which are under cover and not humid.

  • Page 14: Handling Instructions

    Dispose of packaging materials as stipulated by applicable legislation. HANDLING INSTRUCTIONS Handle packages according to the instructions provided by the manufacturer on the packages themselves, if present. If the weight and shape of the packages makes manual handling unfeasible, use special equipment to avoid damage and injury. Personnel authorised to use lifting and moving equipment must be trained and experienced in the operations required in order to avoid risks to themselves and other persons.
  • Page 15 Identify the attachment points for lifting the gearbox, as shown in the drawings. ● Prepare the gearbox for lifting by attaching straps, hooks, etc. to its attachment points, or alternatively ● use a pallet for moving the load. When using a crane, first lift the gearbox vertically out of its packaging. If using a fork lift or pallet truck, remove the packaging and insert the forks at the positions provided.
  • Page 16 VF Series VF 27 VF 30 VF 44 VFR 44 VF 49 VFR 49 VF 130 VFR 130 VF 150 VFR 150 A - B A - B VF 185 VFR 185 VF 210 VFR 210 VF 250 VFR 250...
  • Page 17 W Series W 63 WR 63 W 75 WR 75 A - B W 86 WR 86 A - B W 110 WR 110 Shackle Lift manually Maximum tilt permitted during Strap and ring movement: 15° (for use with strap) (weight ≤...

  • Page 18: Storage

    STORAGE Place the gearbox/gearmotor on a stable base and make sure that there is no risk of it moving or falling off. The following recommendations should be followed when storing the gearbox/gearmotor. 1. Do not store the unit in excessively humid conditions or where it is exposed to the weather (i.e. outdoors). 2.

  • Page 19: Installation

    5 INSTALLATION INSTALLING THE GEARBOX All phases of installation and maintenance must be taken into consideration from the machine design stage. Design personnel must, if necessary, implement a safety plan to protect the health and safety of all persons directly involved and to ensure the rigorous application of all relevant legislation.
  • Page 20 Proceed as follows to install the gearbox. 16. Place the gearbox in the vicinity of the installation area. 17. Mount the gearbox and secure it to the structure at the fixing points provided. Secure the gearbox to the structure using all the fixing points on the relevant mounting (foot or flange). 18.
  • Page 21 (tab 2) Tightening torque [Nm] Plugs with non-metallic Plugs with aluminum Plug/vent thread Pitch (threads per inch) gasket or copper gasket +5%/-5% 1/8” 1/4” 3/8” 1/2” 3/4” 1” M14x2 2 [mm] — Installing ATEX-specified gearboxes • Category 2D gearboxes must be installed in compliance with the provisions of standards EN 1127-1, EN 61241-14 and EN 61241-17.
  • Page 22 5.1.1 Gearboxes with solid shafts (input and output) Do not use hammers or other tools which might damage the gearbox shafts or bearings to fi t external parts. Proceed as shown below, following the recommendations given in the “INSTALLING CONNECTING ELEMENTS” section in this manual: Bolt (1) and spacer (2) shown above are not included in the supply.

  • Page 23: Anchoring The Torque Arm

    ANCHORING THE TORQUE ARM For shaft-mounted solutions, on request, the gearbox can be equipped with a torque arm. This device comes complete with an anti-vibration bush (included in the supply except with VF 30, VF 44 and VF 49 gearboxes) and is specifi cally designed and sized for the purpose. As such it offers the best possible guarantee of correct functioning for the assembly.

  • Page 24: Installing Motors On Vfr Worm Gearboxes

    3. Seal the join between the gearbox and the motor with Loctite 5366, taking care to fi ll any gaps between the two fl anges (e.g. recesses for decoupling the units). • With the motor coupled to the gearbox, apply a fi lm of sealant such as Loctite 5366 (or a product with similar properties and application range) around the edges of the fl anges to seal any gaps between their surfaces.

  • Page 25: Instructions For The Assembling Of The Limit-Switch Device (Rvs) Onto Gearbox

    Preheat the bushing (2) and pinion (1) to 80-100°C. Quickly fit to the motor shaft, in succession: the bushing (2), key (3) and pinion (1). When fitting the bushing (2), ensure that the side with the chamfer for the seal ring is facing you. To facilitate mounting, lightly press on the parts being fitted (e.g.
  • Page 26 3. Retain shaft axially inserting the washers (4) first and then snap rings (5) into their groves. 4. Fit connecting flange (6) onto the gearbox and lock it with the two bolts (7). 5. Mount limit-switch (10) onto connecting flange (6) and secure it with the two socket head bolts (8). Whilst performing this, make sure that the dowel pin (1) is located in the grove machined into the bush trailing the entire limit-switch device.

  • Page 27: Calibrating The Torque Limiter Slipping Torque

    2. Loosen the pair of nylon wheels in relation to the micro switch which corresponds to the direction of rotation previously observed (carrying the letter A in the example alongside). Use the 1.5 mm Allen key supplied with the device. Set the two grooves side by side and rotate both wheels manually until the roller of the switch snaps into the grooves and a click can be heard.

  • Page 28: Painting And Surface Protection

    When installing external transmission parts do not use hammers or other unsuitable tools, to avoid the risk of damaging the gearbox shafts or supports. When installing connecting elements it is advisable to preheat them slightly. Take the following precautions when doing so: Adopt protection against contact with hot parts: risk of burns! Protect the oil seals from damage and accidental overheating to avoid impairing their functionality (use a heat shield to protect against radiated heat).

  • Page 29: Lubrication

    LUBRICATION Gearboxes can be supplied with or without lubricant, as shown in table 5, or as specifi ed by the customer. On gearboxes with an oil level plug, check the oil level before starting up the gearbox. As with fi lling, this operation must be done with the gearbox in the mounting position in which it will be used in the application.
  • Page 30 Do not mix oils of different makes or specifications. Make sure also that the oil is highly resistant to foaming and is EP (Extreme Pressure) rated. If you do not have the same type of oil, completely drain the gearbox and flush it out thoroughly with the new oil to remove all traces of the old oil and any contaminants from inside the casing before filling the gearbox with the new oil.
  • Page 31 5.9.1.1 Synthetic oils and minaral oils with EP (Extreme Pressure) additives VF - W [#] ─ ─ ─ ─ ─ ─ ─ ─ VFR - WR ─ ─ ─ ─ ─ ─ ─ ─ VFL - WL ─ ─ ─ ─...
  • Page 32 In the case of gearboxes normally supplied lubricated for life (see table 5), but supplied without lubricant and with no level plug, consult the manufacturer’s technical assistance service. 5.9.2.1 Wormgears, Serie VF: VF 27 N - A - V - F HS - P(IEC) VF 30 N - A - V - F - P - U...
  • Page 33 5.9.2.2 Wormgears, Serie W: B3, B6, B7, B8, V5 i = 7, 10, 12, 15 W 63 i = 19, 24, 30, 38, 45, 64, 80, 100 i = 7, 10, 15 W 75 i = 30, 40 Consult the manufacturer’s technical assistance service. i = 20, 25, 50, 60, 80, 100 i = 7, 10, 15 W 86...
  • Page 34 5.9.3 Mounting positions and service plugs Legend: Vent / filler plug Level plug Plug in sight Drain plug Plug not in sight 5.9.3.1 Wormgears, Serie VF: VF 27 _ ... VF 49 _ VFR 44 _ , VFR 49 _ S - P (IEC) Base mounting position.
  • Page 35 VF 30 A ... VF 49 A P (IEC) VF 49 VF 49 VF 30 N ... VF 49 N P (IEC) VF 49 VF 49 33 / 64 IOM Manual VF-W_ATEXgb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...
  • Page 36 VF 30 V ... VF 49 V P (IEC) VF 49 VF 49 VF 30 P ... VF 49 P P (IEC) VF 49 (*) VF 49 (*) (*) On both sides 34 / 64 IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...
  • Page 37 VF 30 F/FA ... VF 49 F/FA P (IEC) VF 49 VF 49 VF 30 U ... VF 49 U P (IEC) VF 49 VF 49 35 / 64 IOM Manual VF-W_ATEXgb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...
  • Page 38 VF 130 A ... VF 250 A VFR 130 A ... VFR 250 A P (IEC) VF 130-150 (46 ≤ i ≤ 100) VF, VF/VF, VF/VF, W/VF W/VF Service plugs for the _R (pre-stage) section only are shown in section 5.9.3.3 of this manual. 36 / 64 IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...
  • Page 39 VF 130 N ... VF 250 N VFR 130 N ... VFR 250 N P (IEC) Service plugs for the _R (pre-stage) section only are shown in section 5.9.3.3 of this manual. 37 / 64 IOM Manual VF-W_ATEXgb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...
  • Page 40 VF 130 V ... VF 250 V VFR 130 V ... VFR 250 V P (IEC) Service plugs for the _R (pre-stage) section only are shown in section 5.9.3.3 of this manual. 38 / 64 IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...
  • Page 41 VF 130 P ... VF 250 P VFR 130 P ... VFR 250 P P (IEC) VF, VF/VF, W/VF VF 130-150 (46 ≤ i ≤ 100) VF/VF, W/VF Service plugs for the _R (pre-stage) section only are shown in section 5.9.3.3 of this manual. 39 / 64 IOM Manual VF-W_ATEXgb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...
  • Page 42 VF 130 F ... VF 185 F VFR 130 F ... VFR 185 F P (IEC) VF, VF/VF, VF 130-150 (46 ≤ i ≤ 100) W/VF VF/VF, W/VF Service plugs for the _R (pre-stage) section only are shown in section 5.9.3.3 of this manual. 40 / 64 IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...
  • Page 43 5.9.3.2 Wormgears, Serie W: W 63 U ... W 86 U WR 63 U ... WR 86 U S - P (IEC) 41 / 64 IOM Manual VF-W_ATEXgb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...
  • Page 44 W 63 UF/UFC ... W 86 UF/UFC WR 63 UF/UFC ... WR 86 UF/UFC S - P (IEC) 42 / 64 IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...
  • Page 45 W 63 U ... W 86 U W 63 UF/UFC ... W 86 UF/UFC P (IEC) 43 / 64 IOM Manual VF-W_ATEXgb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...
  • Page 46 W 110 U WR 110 U S - P (IEC) 44 / 64 IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...
  • Page 47 W 110 UF/UFC WR 110 UF/UFC _S - _P (IEC) P (IEC) 45 / 64 IOM Manual VF-W_ATEXgb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...
  • Page 48 W 110 U W 110 UF/UFC P (IEC) 46 / 64 IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...
  • Page 49 5.9.3.3 Worm gearboxes with helical pre-stage: VFR VFR 130 ... VFR 250 A/N P (IEC) P (IEC) Service plugs for the _VF (main reduction) section only are shown in section 5.9.3.1 of this manual. 47 / 64 IOM Manual VF-W_ATEXgb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...
  • Page 50 VFR 130 ... VFR 250 V/P P (IEC) P (IEC) Service plugs for the _VF (main reduction) section only are shown in section 5.9.3.1 of this manual. 48 / 64 IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...
  • Page 51 VFR 130 ... VFR 250 F/FC/FR P (IEC) Service plugs for the _VF (main reduction) section only are shown in section 5.9.3.1 of this manual. 49 / 64 IOM Manual VF-W_ATEXgb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...

  • Page 52: Preparing Customer Shafts

    5.10 PREPARING CUSTOMER SHAFTS Make the driven shaft to be coupled to the gearbox’s output shaft from a good quality steel, respecting the dimensions given in the table. A device such as that illustrated below should also be installed to secure the shaft axially.

  • Page 53: Putting The Gearbox Into Service

    5.10.2 Wormgears, Serie W: DIN 332-DR B1 B2 L2 H UNI 6604 UNI 5739 ≥ 30 25 f7 118 38 8 h9 1 1.5 8x7x35 A 25 d9 M8x25 W 63 ≥ 35 28 f7 125 38 8 h9 1 1.5 8x7x40 A 28 d9 11 8.5 M10x30 W 75...
  • Page 54 Before putting the gearbox into service, make sure that: Assembly will not be carried out in a potentially explosive atmosphere (oil, acid, gas, vapour, radiation) ● and that dust deposits on the gearbox do not exceed 5 mm in depth. Clean the gearbox thoroughly after installation.
  • Page 55 IMPORTANT: The maximum surface temperature is reached after 3 hours operation at full load. Temperature measured in this way must not differ (ΔT) from ambient temperature by more than the following values: (tab 6) ΔT [K] VF 44, VF 49 W 63 ...

  • Page 56: Maintenance

    6 MAINTENANCE Maintenance and replacement work must be carried out by expert maintenance technicians trained in the observance of applicable laws on health and safety at work and the special ambient problems attendant on the installation. In order to maintain the proper functioning and safety of the gearbox/ gearmotor, we recommend that users have non-routine maintenance performed by the Manufacturer or an authorised, specialist service centre.

  • Page 57: Checking Operational Efficiency

    Do not disperse contaminant liquids, worn parts and maintenance residues in the environment. Dispose of all such substances in strict compliance with applicable statutory legislation. • Respect scheduled inspection and maintenance intervals to ensure the correct functioning of the gearbox and the effectiveness of the explosion protection.

  • Page 58: Routine Maintenance

    ROUTINE MAINTENANCE Respect the manufacturer’s routine maintenance schedule to keep the gearbox at peak efficiency. Good maintenance ensures maximum gearbox performance, extended service life and continued compliance with safety regulations. List of routine checks We recommend keeping a checklist of inspections so that any changes in individual control parameters can be identified rapidly and easily.
  • Page 59 For installations in zones 21 and 22, the user must schedule and implement a regular cleaning programme for all surfaces and recesses to avoid dust build-ups of more than 5 mm in depth. Every 100 hours of operation or every 2 weeks: •...

  • Page 60: Oil Changes

    Gearboxes are normally fi tted with yellow oil level plugs. Level plugs may be of the spill type or may require a dipstick (not supplied) to be inserted. In other cases, yellow level plugs have dipsticks incorporated. To check the oil level using a spill type level plug, fi rst identify the yellow level plug. Remove the plug and insert into the hole a rod of suitable size and of the shape shown in the fi gure.

  • Page 61: Cleaning

    Lubricants, solvents and detergents are toxic/harmful to health: - they may cause irritation in direct contact with the skin - they may cause intoxication if inhaled - they may be fatal if swallowed. Handle them with care using suitable personal protection equipment. Do not dump them into the environment and dispose of in accordance with applicable legislation.

  • Page 62: Removal

    7 REMOVAL REMOVING A MOTOR WITH AN IEC STANDARD FLANGE If the mobile coupling between the motor and the gearbox has not rusted badly during service, it should be possible to remove the motor without applying excessive force once the screws coupling it to the gearbox have been removed.

  • Page 63: Removing A Gearbox With Hollow Output Shaft With Keyway

    REMOVING A GEARBOX WITH HOLLOW OUTPUT SHAFT WITH KEYWAY Remove the device that secures the gear unit axially. ● The machine’s shaft can be extracted directly in-situ using a hydraulic device, or by using the device shown in the figure below: 1.

  • Page 64: Troubleshooting

    8 TROUBLESHOOTING The following information is intended to serve as an aid in locating and eliminating defects and faults. In some cases, such problems may be caused by the plant or machine to which the gearbox is assembled and hence, the cause and remedy will be described in the Manufacturer’s technical documentation for the machine/plant in question.

  • Page 65: Disposing Of The Gearbox

    9 DISPOSING OF THE GEARBOX Make sure that the gearbox cannot function accidentally while it is being taken out of service. The gearbox/gearmotor must be disposed of in compliance with environmental legislation, and the various materials used in its manufacture must be delivered to an authorised disposal/recycling centre. The gearbox must only be taken out of service by operators trained in the observance of applicable laws on health and safety at work.
  • Page 66 INDEX OF REVISIONS (R) BR_IOM_VF-W_ATX_ENG_R03_0 Added chapter “ALLOWED TEMPERATURE LIMITS” We reserve the right to modify the information given herein without prior notification. This manual may not be reproduced, even partially, without express authorisation. This edition cancels and replaces all previous editions and revisions. 64 / 64 IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16...
  • Page 68 Our team creates, distributes and services world- class power transmission & drive solutions to keep the world in motion. HEADQUARTERS Bonfiglioli Riduttori S.p.A. Via Giovanni XXIII, 7/A 40012 Lippo di Calderara di Reno Bologna (Italy) tel: +39 051 647 3111 fax: +39 051 647 3126 bonfiglioli@bonfiglioli.com...

This manual is also suitable for:

W seriesVf 30Vf 130Vf 44Vf 150Vf 49 ... Show all

Table of Contents

Save PDF