Benzlers BS 40 Installation & Maintenance Download Page 6

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INFORMATION

1.6 Marking

Gear units with -marking are especially selected for use as a component of an industrial system operating in a

potentially explosive atmosphere.

Provided they are correctly installed in accordance with these instructions (gear units only) they comply with the EU

directive 94/9/EC (ATEX 100a).

The units must be selected for use in potentially explosive atmospheres classified as Group II Cat 2 (zones 1 & 21)

or Group II Cat 3 (zones 2 & 22).

Motors, couplings, or any other equipment fitted to the gear unit must also comply with this directive.

If the gear unit is supplied as a geared motor package it is important to check that the nameplates of the gear unit and the

motor (or any other equipment fitted) corresponds with the classification of the potentially explosive atmosphere in which

the unit is to be installed.

1.6.1 Understanding EU Directive 94/9/EC (ATEX 100a) Markings.

The product will be typically marked as shown:

Summary of Contents for BS 40

Page 1: ...Series BS Installation Maintenance ...

Page 2: ...2 ...

Page 3: ...11 3 3 Approved lubricants 11 4 MOTOR CONNECTIONS 12 5 STARTING UP 12 5 1 Prior to starting up 12 5 2 Running in 12 6 OPERATION 13 6 1 Noise 13 6 2 General Safety 13 6 3 Initial start up for gear units operating in a potentially explosive atmosphere 13 7 MAINTENANCE 1 14 7 1 Prior to any maintenance operations 14 7 2 Oil plugs Ventilator 14 7 3 Maintaining lubrication 14 7 4 Bearings 16 7 5 Oil Se...

Page 4: ...ily if subjected to full load immediately after installation However optimum performance is best achieved by a process of gradual load increments up to the full value over the first 50 hours or so of their working life During these early stages of running sensible temperature may occur over many hours until the unit has reached its highest efficiency The gear unit must not be used until the machin...

Page 5: ...rk under adverse conditions for example in hot dusty or damp premises must be fitted with appropriate protection The circulation of air around the gear unit must not be obstructed however 1 4 Reading the Nameplate 1 4 1 Unit Identification When requesting further information or service support quote the following information from the nameplate Unit type Model No Order Number Year of Manufacture 1 ...

Page 6: ...losive atmospheres classified as Group II Cat 2 zones 1 21 or Group II Cat 3 zones 2 22 Motors couplings or any other equipment fitted to the gear unit must also comply with this directive If the gear unit is supplied as a geared motor package it is important to check that the nameplates of the gear unit and the motor or any other equipment fitted corresponds with the classification of the potenti...

Page 7: ... the gear unit 2 Check that the gear unit and the motor name plate matches the requirements of the machine the unit is to be installed into 3 Thoroughly clean the gearbox mounting surfaces that are to be used and the shafts of paint and anti corrosion agents using a commercially available solvent Ensure solvent does not make contact with the oil seals 2 3 Fitting of components to either the unit i...

Page 8: ...lign unit See Appendix 1 Note It is important to ensure when aligning unit on baseplate that all machined mounting points are supported over their full area If steel packings are used these should be placed either side of the foundation bolt as close as possible During final bolting ensure the unit or baseplate is not distorted as this would cause strains in the gear case resulting in errors of al...

Page 9: ...nting The gear housing for BS40 BS71 with a vertical secondary shaft will have separate feet When fitting the angle feet for BS40 BS71 locking washers DIN 6797 must be fitted to the bolts between the gear housing and the angle feet When tightened the gear housing should be pressed against the mating surface of the feet 2 5 2 Flange Mounting When installing with a secondary flange you must ensure t...

Page 10: ...r to start up NOTE If the unit has been damaged in transit do not use 2 Check name plate of unit corresponds with the sites potentially explosive atmosphere classification 4 Check ambient temperature falls within lubricant grade recommendations 5 Make sure no potentially explosive atmosphere exists during installation 6 Make sure that gear unit is sufficiently ventilated with no external heat inpu...

Page 11: ...lubricants are specially suited to worm gears During normal operation the lubricant will never require replacement Ambient temperature range 30 C 3 2 Ventilator Clean and secure the ventilator in the correct location for the required mounting position See Appendix 4 3 3 Approved lubricants 3 3 1 Oils Mobil SHC 634 ...

Page 12: ...e coupling guards covers etc are dust tight or are designed in such way that a build up of dust deposits cannot form when the unit is used in Zone 21 and Zone 22 classification areas 4 Remove any safety devices fitted to prevent machine rotation 5 Units fitted with backstop ensure motor is correctly wired for free direction of rotation Caution Any deviation from normal operating conditions increas...

Page 13: ... in the product safety page at the front of this booklet See chapter 1 Information Advice is also given on sensible precautions which need to be taken to avoid injury or damage Please read 6 3 Initial start up for gear units operating in a potentially explosive atmosphere After 3 hours of operation check the gear unit surface temperature This temperature should not exceed 110 degrees If temperatur...

Page 14: ...ved 2 Place a container below the oil drain plug to be removed Note It is recommended that the oil should be slightly warm 40 50 C when drained Cooler oil will be more difficult to drain correctly 3 Top ups or refills should be done where possible through the ventilator position 4 Remember to refit all plugs and torque tighten to Table M1 below Table M1 5 Clean away any oil spillage 7 3 Maintainin...

Page 15: ...ct quantity of lubricant in accordance with the renewal period of Table M2 See Appendix 4 for correct oil quantity Following factors should be used to determine the frequency at which oil changes are carried out a Oil temperature unit operating under load b Type of oil c Environment humidity dust etc d Operating conditions shock loading etc At elevated temperatures the effective life of the oil is...

Page 16: ...ver 0 mm output shaft sealing ring 3 5 mm inside the gear house Before mounting the seal lip must be greased by a grease of Lithium type NLGI class 1 2 7 6 Cleaning With the drive stationary periodically clean any dirt or dust from the gear unit and the electric motor cooling fins and fan guard to aid cooling Ensure that the build up of dirt or dust does not exceed 5 mm maximum Unit Input Shaft Re...

Page 17: ...m output end oil seal a Defective gasket on gear unit cover b Defective gasket c Gear unit not ventilated a Retighten screws on gear unit cover and observe gear unit If oil still leaks contact your local sales office b Contact your local sales office for more details c Vent the gear unit See Appendix 4 Mounting position Oil leaking from the ventilator a Gear unit over filled with oil b Gear unit i...

Page 18: ...ft equal to the diameter of the coupling flanges and from this the difference in the relative heights of the feet of the motor or other connected machine can be found by proportion Similarly the difference between the reading 2 and 4 gives the amount of sideways adjustment necessary to correct any errors of alignment in the horizontal plane Generally however the coupling faces will not be absolute...

Page 19: ...int position and a final check made with the unit at operating temperature The permitted eccentricity error which can be accommodated in addition to that of the angularity error is as follows Table 6 SPECIAL NOTE CONCERNING RIGID COUPLINGS In lining up elements involving rigid couplings it is important that no attempt is made to correct errors of alignment or eccentricity greater than those above ...

Page 20: ...20 APPENDIX 2 Alternative Shaft Fixing Methods ...

Page 21: ...not exceed 20 The torque arm must be positioned so that it is loaded in tension i e in the direction of torque reaction which is opposite to the direction of shaft rotation as shown above For reversing applications two torque arms must be fitted in opposite mounting positions Gear units must be locked axially when mounted in position and supported by the low speed sleeve for a minimum of 90 of the...

Page 22: ... the motor nameplate data and that they are connected as indicated on the nameplate The correct sizing of the cables to electrical regulations is essential To change the direction of rotation of the electric motor one of the three main line terminals should be changed with the other Connect the earth conductors to the marked earth terminals Note This instruction only applies to Benzlers and Radico...

Page 23: ...y and have no oil level plug See Table 7 and Table 8 Unit Quantity liter BS40 0 20 BS50 0 25 BS63 0 40 BS71 0 75 Unit Quantity liter BS40 0 25 BS50 0 35 BS 63 0 55 BS 71 0 75 Table 7 Lubricant quantity liters Single units BS40 BS71 Applicable for all mounting positions Table 8 Lubricant quantity liters Double units BS40 BS71 Applicable for all mounting positions ...

Page 24: ...24 APPENDIX 4 Ventilator Position for BS40 BS71 ...

Page 25: ...25 APPENDIX 5 ...

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