BONFIGLIOLI C Series Installation Use And Service Manual
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BONFIGLIOLI C Series Installation Use And Service Manual

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I
P
NDUSTRY
ROCESS
A
S
AND
UTOMATION
OLUTIONS
Installation,
C, A, F, S, VF, W
A T E X
INCLUDED
use and service manual

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Summary of Contents for BONFIGLIOLI C Series

  • Page 1 NDUSTRY ROCESS UTOMATION OLUTIONS Installation, use and service manual C, A, F, S, VF, W A T E X INCLUDED...

  • Page 3: Table Of Contents

    ANNEX 5 - INSTALLING THE MOTOR ON TYPE VFR WORM GEAR UNITS ANNEX 6 - CALIBRATING THE TORQUE LIMITER SLIP TORQUE Revisions Refer to page 50 for the catalogue revision index. Visit www.bonfiglioli.com to search for catalogues with up-to-date revisions.

  • Page 4: General Information

    1.0 - GENERAL INFORMATION 1.1 - PURPOSE OF THE MANUAL This manual has been compiled by the Manufacturer to provide information on the safe transport, handling, installation, maintenance, repair, disassembly and dismantling of the gear units. All purchasing and design criteria is provided in the Sales Catalogue. Apart from adhering to establi- shed engineering practices, the information given in this manual must be carefully read and applied rigorously.

  • Page 5: Equipment Identification

    1.2 - EQUIPMENT IDENTIFICATION The gear unit bears the following nameplate. The nameplate bears all references and indispensable safety instructions. The gear unit’s identifying code is explained in the Sales Catalogue. If the gear unit is supplied complete with electric motor (gearmotor), all information regarding the motor itself is supplied in the motor manual.

  • Page 6: Glossary And Terminology

    1.3 - GLOSSARY AND TERMINOLOGY Some of the frequently occurring terms used in this manual are described below so as to unequivocally defi- ne their meaning. Routine maintenance: the set of operations required for maintaining the functionality and efficiency of the gear unit.

  • Page 7: Technical Information

    It is capable of satisfying a range of specific requirements in the mechanical, chemical, agricultural and food industries, etc. BONFIGLIOLI RIDUTTORI supplies a range of accessories and optionals to make their products as versatile as possible. For further technical information and descriptions, refer to the Sales Catalogue.

  • Page 8: Operating Limits And Conditions

    2.3 - OPERATING LIMITS AND CONDITIONS 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 •...

  • Page 9: Safety Information

    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).

  • Page 10: Handling And Transport

    Vertical packaging On receipt of the gear unit, check that the delivery item corresponds to the purchase order and that it is not damaged or faulty in any way. Refer any nonconformity to your BONFIGLIOLI RIDUTTORI dealer. Dispose of packaging materials as laid down by the provisions of law.

  • Page 11: Handling Instructions

    4.2 - HANDLING INSTRUCTIONS Handle packages as per the Manufacturer’s instructions and those marked on the packages themselves. Since the weight and shape of packages may make manual handling unfeasible, special equipment must be used to avoid damage and injury. Persons authorised for this purpose must be trained and experienced in the work in question to safeguard his safety and that of all other persons involved.

  • Page 12: Storage

    4.3 - STORAGE Some recommendations for storing the gear unit are indicated below. 1. Do not store the unit in excessively humid conditions or where it is exposed to the weather (do not store outdoors). 2. Do not place the gear unit directly on the ground. 3.

  • Page 13: Installation

    8. 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. 9. We recommend applying a protective paste to all couplings between the gear unit/motor and other parts (Klüberpaste 46 MR 401 or equivalent product with similar properties and application range) to ensure...
  • Page 14 (A0) Tightening torque [Nm] +5% /-10% Bolt size Bolt class 10.9 10.3 13.0 25.5 87.3 138.3 210.9 1100 1400 1500 1850 Cap/vent thread Pitch Tightening torque [Nm] 1/8" 1/4" 3/8" 1/2" 3/4" 1" 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.
  • Page 15 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.

  • Page 16: Gear Units With Solid Output Shaft

    5.1.1 - Gear units with solid output shaft For mounting external parts do not use hammers or other tools which might damage the gear unit’s shafts or bearings. Instead, proceed as indicated in the diagram below: Bolt (1) and spacer (2) are to be supplied by customer. To minimise the loads on the shaft bearings, when mounting transmission elements with asymmetrical hubs, the preferred layout is shown in diagram (A) below: 5.1.2 - Gear units with hollow output shaft...

  • Page 17: Gear Units With Shrink Disk

    5.1.3 - Gear units with shrink disk Series A and F gear units may be specified with a shrink disk for coupling onto the driven shaft. When instal- ling a unit of this type, proceed as follows: 1. Loosen the locking bolts gradually and in sequence and remove the entire shrink disk. 2.

  • Page 18: Installing An Iec-Standard Flanged Motor

    5.2 - INSTALLING AN IEC-STANDARD FLANGED MOTOR Further to all the precautions indicated above, when installing a IEC-flange mount electric motor the following precautions must also be observed: • Do not force the coupling and do not use inappropriate tools during assembly. Take care not to damage the flat and/or cylindrical coupling surfaces.

  • Page 19: Testing The Gear Unit

    6.0 - TESTING THE GEAR UNIT The gear unit has been factory tested by the Manufacturer. Before starting the unit, check that: • The machine incorporating the gear unit complies with the provisions of the “Machinery Directive” 98/37/EC and any other applicable safety legislation. •...
  • Page 20 W 110 Should the temperature differential exceed these values, stop the gear unit at once and contact the BONFIGLIOLI RIDUTTORI technical service. • If the temperature differential is within the above values, wait for the gear unit to cool down and then install the temperature indicator supplied with the gear unit at the point of maximum tem- perature.

  • Page 21: Using The Equipment

    • Provided all the above checks have been passed and that all other instructions in this manual have been strictly observed, an electric motor with ATEX rating equal or greater than that of the gear unit may be installed, thus forming a gearmotor which itself com- plies with the provisions of Directive 94/9/EC.

  • Page 22: Maintenance

    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).

  • Page 23: Routine Maintenance

    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...
  • Page 24 Check the condition of the temperature indicator previously installed on the gear unit during commissioning. Example: 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. •...

  • Page 25: Lubricants

    8.2 - LUBRICANTS Before putting the gear unit into service, check the oil level. This must be done with the gear unit in the mo- unting position in which it will be used in the application. If necessary, if or top up the lubricant to the filling mark on the level cap which may be transparent or of the spill type.

  • Page 26: Recommended/Permitted Oils

    8.4 - RECOMMENDED/PERMITTED OILS OILS AND GREASES COMPATIBLE with Atex-certified gear units Greases: • Klüber Asonic GHY 72 (for bearings) • Shell TVX Compound B (for greased gear trains) • Shell Tivela GL 00 (alternative for greased gear trains) • Klüberpaste 46 MR 401 (to facilitate coupling of cylindrical parts) •...
  • Page 27 VF_L VF-EP 11…100 10…50 10…90 70...90 10…60 W-EP 0.25-0.5 1…10 0.25…10 Tivela S 220 Tivela S 320 Tivela S 460 Donax TX Donax TA Cassida Fluid WG 460 Cassida Fluid HF 46 TVX Compound B Telium VSF 220 Telium VSF 320 Spartan EP 220 Spartan EP 320 Klübersynth GH 6 220...

  • Page 28: Checking Efficiency

    8.5 - CHECKING EFFICIENCY • Remove dust deposits from the gear unit and motor casings. • Check that noise at constant load does not vary. Excessive vibration or noise can indicate wear of the gear train or failure of a bearing. •...

  • Page 29: Replacing Parts

    9.0 - REPLACING PARTS • Do not hesitate to replace parts and/or components if they are not able to guarantee safe and re- liable operation. • Never improvise repairs. • The use of non-original spare parts not only voids the warranty but can compromise gear unit operation.

  • Page 30: Troubleshooting

    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.

  • Page 31: Annex 1 - Checking Oil Level On Atex-Specified Gear Units

    ANNEX 1 - CHECKING OIL LEVEL ON ATEX-SPECIFIED GEAR UNITS Gear units are normally supplied with a yellow oil level plug of the spill type. To check the oil level, first identify the yellow level plug. Remove the plug and insert a bar of the right size for the hole and of the shape shown in the figu- re below.
  • Page 32 Helical in-line gear units C 11, C 21, C 31 (S4) (A7) U-UF B3 B6 B7 B8 V5 V6 B5 B51 B53 B52 V1 V3 B5 B51 B53 B52 V1 V3 C 11 2_ P63-P71 70 70 70 45 C 11 2_ P80…P112 75 75 75 45 C 21 2_ P63-P71, HS...
  • Page 33 Bevel helical gear units A 10, A 20 and A 30 - Mounting positions B6 and B7 (S5) (A8) A 10_ P63...P112 A 20_ P63...P112, HS A 30_ P63...P112, HS Values in the table are given in mm To check the oil level, proceed as follows: 1.

  • Page 34: Annex 2 - Lubricant Charge Quantity

    ANNEX 2 - LUBRICANT FILL QUANTITY Helical in-line gear units, series C: (A9) U - UF B51 B53 B52 B51 B53 B52 C 05 2 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 0.35 C 11 2 0.45 0.45 0.45 0.45 0.50 0.60 0.40 0.40 0.50 0.50 0.50 0.60 0.40 0.40 0.50 0.50 0.50 0.60 C 21 2 0.80 0.80 0.80 0.80 0.85...

  • Page 35: Bevel Helical Gear Units, Series A

    Bevel helical gear units, series A: (A10) A 10 2 A 20 2 A 20 3 A 30 2 A 30 3 A 41 2 A 41 3 A 50 2 A 50 3 A 50 4 A 60 2 A 60 3 A 60 4 A 70 3...

  • Page 36: Shaft-Mounted Gear Units, Series F

    Shaft-mounted gear units, series F: (A12) F 10 2 0.95 0.95 0.95 0.95 0.95 0.95 F 20 2 F 20 3 F 30 2 F 30 3 F 30 4 F 40 2 F 40 3 F 40 4 F 50 2 F 50 3 F 50 4 F 60 3...

  • Page 37: Worm Gear Units, Series V

    Worm gear units, series VF: (A14) VF 27 N - A - V - F HS - P(IEC) 0.025 0.025 0.025 0.025 0.025 0.025 VF 30 N - A - V - F - P HS - P(IEC) 0.045 0.045 0.045 0.045 0.045...

  • Page 38: Worm Gear Units, Series W

    Worm gear units, series W: (A15) i = 7, 10, 12, 15 0.31 0.31 0.31 0.31 0.31 0.31 W 63 0.15 i = 19, 24, 30, 38, 45, 64, 80, 100 0.38 0.38 0.38 0.38 0.38 0.38 i = 7, 10, 15 0.48 0.48 0.48...

  • Page 39: Annex 3 - Customer's Shaft

    ANNEX 3 - CUSTOMER'S SHAFT Series A (A17) UNI 6604 ³ 35 30 h7 8 h9 8x7x20 A A 10 ³ 30 25 h7 8 h9 8x7x20 A ³ 42 35 h7 10 h9 10x8x20 A A 20 ³ 35 30 h7 8 h9 8x7x25 A...

  • Page 40: Series F

    Series F (A19) UNI 6604 ³ 35 30 h7 15.5 8 h9 8x7x20 A F 10 ³ 30 25 h7 15.5 8 h9 8x7x20 A ³ 42 35 h7 10 h9 10x8x22 A F 20 ³ 35 30 h7 8 h9 8x7x22 A ³...

  • Page 41: Series Vf And W

    Series VF and W (A21) UNI 6604 ³ 19 VF 30 14 f7 18.5 5 h9 5x5x40 A ³ 23 VF 44 18 f7 22.5 20.5 6 h9 6x6x50 A ³ 30 VF 49 25 f7 20.5 8 h9 8x7x20 A ³...

  • Page 42: Annex 4 - Lifting

    ANNEX 4 - LIFTING When lifting, use accessories such as eyebolts, snap hooks, screw clamps, straps, ropes, ho- oks etc. which are certified and adequate for the load. 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.
  • Page 43 Series C C41-C51 C41-C51 C41-C51 C41-C51 C41-C51 C41-C51 C41-C51 C41-C51 C 05 — — — — — — C 11 — — C 21 — — C 31 — — C 35 — — C 41 A - B — A - B A - B C 51...
  • Page 44 Series A 1 2 3 1 2 3 1 2 3 A10...A60 A10...A60 A10...A60 1 2 3 1 2 3 1 2 3 A10...A60 A10...A60 A10...A60 A70...A90 A70...A90 A70...A90 A 10 — — M (P63...P90) A 20 A - B —...
  • Page 45 Series F F 10 A - B — — M (P63...P90) F 20 A - B — — A - B (P100...P112) F 30 — — F 40 A - B — A - B A - B F 50 —...
  • Page 46 Series S S 10 1 — S 20 1 — S 30 1 — S 40 1 S 50 1 Reccomended: solution A for positioning. Maximum permissible tilt during handling: 15° Lift manually (weight £ 15 kg) 1 Ring harness Lift as per diagram A...
  • Page 47 Series W W 63 WR 63 W 75 WR 75 A - B W 86 WR 86 A - B W 110 WR 110 A - B A - B Reccomended: solution A for positioning; solution B for positioning and handling. Screw clamp Lift manually Maximum permissible tilt during...
  • Page 48 Series VF VF 30 VF 44 VFR 44 VF 49 VFR 49 VF 130 VFR 130 VF 150 VFR 150 VF 185 VFR 185 A - B A - B A - B VF 210 VFR 210 VF 250 VFR 250 Reccomended: solution A for positioning;...

  • Page 49: Annex 5 - Installing The Motor On Type Vfr Worm Gear Units

    ANNEX 5 - INSTALLING THE MOTOR ON TYPE VFR WORM GEAR UNITS 1) Thoroughly clean and degrease the motor shaft and pinion (1) and bushing (2) coupling surfaces. 2) Check the motor shaft tolerance meets the following specifications: Shaft diameter - Æ [mm] Tolerance 11 - 28 38 - 48...

  • Page 50: Annex 6 - Calibrating The Torque Limiter Slip Torque

    ANNEX 6 - CALIBRATING THE TORQUE LIMITER SLIP TORQUE The torque limiter is an optional device available for worm gear units of the following types: VF 44L, VF 49L, W 63L, W 75L, W 86L and W 110L. The device is factory calibrated to a slip torque which coincides with the nominal torque Mn = 1400] for the gear unit in question.
  • Page 52 INDEX OF REVISIONS (R) We reserve the right to implement modifications without notice. This catalogue cannot be reproduced, even partially, without prior consent.
  • Page 53 NDUSTRY ROCESS UTOMATION OLUTIONS Worldwide Bonfiglioli Worldwide & BEST Partners AUSTRALIA HUNGARY BONFIGLIOLI TRANSMISSION (Aust) Pty Ltd. AGISYS AGITATORS & TRANSMISSIONS Ltd 48-50 Adderley St. (East) - Auburn (Sydney) N.S.W. 2144 2045 Törökbálint, Tö u.2. Hungary Tel. (+61) 2 8748 4400 - Fax (+61) 2 9748 8740 Tel.
  • Page 54 NDUSTRY ROCESS UTOMATION OLUTIONS w w w . b o n f i g l i o l i . c o m COD. 1261 R3...

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