BONFIGLIOLI A 10 Installation Use And Service Manual Download Page 1

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NDUSTRY

ROCESS

AND

UTOMATION

OLUTIONS

C, A, F, S, VF, W

A T E X

INCLUDED

Installation,

use and service manual

Summary of Contents for A 10

Page 1: ...INDUSTRY PROCESS AND AUTOMATION SOLUTIONS C A F S VF W A T E X INCLUDED Installation use and service manual ...

Page 2: ......

Page 3: ... 0 TESTING THE GEAR UNIT 17 7 0 USING THE EQUIPMENT 19 8 0 MAINTENANCE 20 8 1 ROUTINE MAINTENANCE 21 8 2 LUBRICANTS 23 8 3 OIL CHANGE 23 8 4 RECOMMENDED PERMITTED OILS 24 8 5 CHECKING EFFICIENCY 26 8 6 CLEANING 26 8 7 PAINT 26 9 0 REPLACING PARTS 27 9 1 TAKING APART OF THE IEC STANDARD FLANGED MOTOR 27 9 2 SCRAPPING THE GEAR UNIT 27 10 0 TROUBLESHOOTING 28 ANNEX 1 CHECKING OIL LEVEL ON ATEX SPECIF...

Page 4: ...must be requested directly from the Manufacturer quoting the code of this manual The manual reflects the state of the art at the time of commercialisation of the gear unit The Manufacturer reserves the right to modify supplement and improve the manual without the present pu blication being for that reason considered inadequate Particularly significant sections of the manual and important specifica...

Page 5: ...ture class or maximum surface temperature Maximum surface temperature CE Mark Environmental limits ambient temperature range between 20 C and 40 C Maximum surface temperature temperature class T4 for 2G and 130 C for 2D Some types of gear unit shown in the catalogue are exceptions to this rule and are marked temperature class T3 for 2G or 160 C for 2G and 2D Certifying agency with whom the technic...

Page 6: ...ts 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 ca...

Page 7: ...rostatic 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...

Page 8: ...nce 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 Modification of the gearbox configuration or mounting position is only permitted if previously aut horised by the BONFIG...

Page 9: ...nd 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 w...

Page 10: ...0 Storage in all other conditions requires specific packaging In order to facilitate handling heavy packages can be loaded on pallets The most frequent types of packaging are shown in the figures below Wooden crate for miscellaneous products shipped by sea Carton pallet packaging for single products and kits On receipt of the gear unit check that the delivery item corresponds to the purchase order...

Page 11: ...the package itself Har ness heavy packages with chains belts and steel ropes after checking that they are capable of sustaining the weight of the load which is generally specified When handling the load keep it level to avoid instability and or tipping 4 2 2 Moving the equipment All the following operations must be done with due care and caution and without sudden mo vements Identify the attachmen...

Page 12: ...nsis or equivalent pro duct with similar properties and application range 6 Fill the unit with lubricating oil SAFETY PRECAUTIONS to be taken when returning the gear unit to service after storage The output shafts and external surfaces must be thoroughly cleaned of all rustproofing product contaminants and other impurities use a standard commercial solvent Do this outside any explosion hazard area...

Page 13: ...k 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 opt...

Page 14: ...F 30 F 40 F 50 F 60 F 70 F 80 F 90 S 10 S 20 S 30 S 40 S 50 VF 27 VF 30 VF 44 VF 49 VF 130 VF 150 VF 185 VF 210 VF 250 W 63 W 75 W 86 W 110 A1 Life time lubrication Life time lubrication with ATEX specified unit only Cap vent thread Pitch Tightening torque Nm 1 8 28 5 1 4 19 7 3 8 19 7 1 2 14 14 3 4 14 14 1 11 25 Bolt size Tightening torque Nm 5 10 Bolt class 8 8 10 9 M4 3 3 8 M5 5 9 8 0 M6 10 3 1...

Page 15: ...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...

Page 16: ...mer To minimise the loads on the shaft bearings when mounting transmission elements with asymmetrical hubs the preferred layout is shown in diagram A below 5 1 2 Gear units with hollow output shaft To facilitate mounting hollow shaft gear units onto the machine s driven shaft proceed as indicated in the diagram below Also refer to Annex 3 of this Manual for dimension information on customer s shaf...

Page 17: ...5 Fully tighten down the shrink disk bolts gradually following a circular sequence using a torque wrench This operation usually must be repeated several times to reach the tightening torque Mt specified in the table below A 10 A 20 A 30 A 41 A 50 A 60 A 70 A 80 A 90 Mt Nm 14 5 14 5 14 5 14 5 35 35 35 69 69 F 10 F 20 F 30 F 40 F 50 F 60 F 70 F 80 F 90 Mt Nm 8 5 14 5 14 5 14 5 14 5 35 35 69 69 A2 Mt...

Page 18: ...EC electric motor proceed as follows Apply a layer of sealant Loctite 510 or equivalent product with similar properties and applica tion range to the motor gear unit mounting flanges spigot and frontal coupling surfaces as shown in diagram S1 S1 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 th...

Page 19: ...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 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 radia...

Page 20: ...easured at the coupling between the gear unit and motor and at the points which are most shielded from the motor s fan cooling S2 IMPORTANT The maximum surface temperature is reached after 3 hours operation at full load The temperature measured in these conditions must not differ DT from the ambient tempe rature by more than the following values Should the temperature differential exceed these val...

Page 21: ...rough an inverter Only in this way and subject to certification by the assembler shall the assembly in cluding the gear unit itself be compliant with the requirements of Directive 94 9 EC 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 ...

Page 22: ...se 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 Obser...

Page 23: ...xternal 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 Oil temperature t C Hours t 65 25000 65 t 80 15000 80 t 95 12500 A4 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 ...

Page 24: ...ynthetic 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 ...

Page 25: ...drain better if it is warm 3 Wait for a few minutes until all the oil has drained out then screw the drain plug back on with a new ga sket 4 Fill the gear unit with the new oil in its actual mounting position to the centre of the level plug 5 Tighten down the filler plug after fitting a new gasket The gear unit may be supplied with or without lubricant as specified by the User The quan tity of oil...

Page 26: ...ear trains Shell Tivela GL 00 alternative for greased gear trains Klüberpaste 46 MR 401 to facilitate coupling of cylindrical parts ITP Fluorocarbon gel 880 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 Klüber Klübersynth GH 6 320 Total Carter SY 320 Mobil Glygoyle HE 320 ...

Page 27: ...elium VSF 320 Spartan EP 220 Spartan EP 320 Klübersynth GH 6 220 Klübersynth GH 6 320 Klübersynth UH1 6 460 F F F F F F F F Glygoyle HE 320 Glygoyle HE 460 Mobilgear SHC XMP 220 Mobilgear SHC XMP 320 Mobil SHC 630 Mobil SHC 632 DTE FM 460 Alphasyn PG 220 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 Renoling PG 220...

Page 28: ...te 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 ...

Page 29: ...e the flanges and coupling surfaces but proceed as indicated below S3 1 Drill and thread the motor shaft fan side 2 Screw an impact extractor tool into the tap 3 Undo the screws fixing the motor to the gear unit 4 Remove the motor by means of the inertial force of the extractor 9 2 SCRAPPING THE GEAR UNIT This must only be done by operators trained in the observance of applicable laws on health an...

Page 30: ...nning noise Gears damaged Contact authorised workshop Bearing axial backlash too high Contact authorised workshop Bearings defective or worn Contact authorised workshop Service load too high Correct service load to nominal values given in Sales Catalogue Impurities in oil Replace oil Abnormal noise at gear unit mounting Mounting bolts loose Tighten down to specified torque Mounting bolts worn Repl...

Page 31: ...nd of the shape shown in the figu re below If the level is more than 3 mm below the overflow level top up and check the reason for the drop in oil level 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 ...

Page 32: ...must be less than the value given in table A7 B3 B6 B7 B8 V5 V6 B5 B51 B53 B52 V1 V3 B5 B51 B53 B52 V1 V3 C 11 2_ P63 P71 70 70 70 70 70 45 70 70 70 70 60 30 70 70 70 70 60 30 C 11 2_ P80 P112 75 75 75 75 75 45 75 75 75 75 70 30 75 75 75 75 70 30 C 21 2_ P63 P71 HS 70 70 70 70 70 40 70 70 70 70 70 45 70 70 70 70 70 45 C 21 2_ P80 P112 75 75 75 75 75 40 75 75 75 75 75 45 75 75 75 75 75 45 C 21 3_ P...

Page 33: ...gram S5 2 Insert a dipstick through the yellow service cap on top of the gear unit until it touches the floor of the casing Mark the level of the upper surface of the casing on the dipstick in this po sition 3 Extract the dipstick and measure the distance X shown in diagram S5 above 4 The value X must be less than the value given in table A8 B6 B7 A 10_ P63 P112 30 30 A 20_ P63 P112 HS 25 25 A 30_...

Page 34: ... 2 1 1 9 2 6 3 2 C 41 4 2 8 2 6 2 8 2 6 3 5 3 9 2 8 2 6 2 8 2 6 3 5 3 9 C 51 2 3 1 3 0 3 1 3 0 4 3 5 0 3 1 3 0 3 1 3 0 4 3 5 0 C 51 3 3 0 2 8 3 1 3 0 4 1 4 9 3 0 2 8 3 1 3 0 4 1 4 9 C 51 4 4 3 4 1 4 4 4 2 5 4 6 1 4 3 4 1 4 4 4 2 5 4 6 1 C 61 2 4 2 4 0 4 2 4 1 6 0 6 7 4 2 4 0 4 2 4 1 6 0 6 7 C 61 3 4 2 4 0 4 2 4 1 6 0 6 7 4 2 4 0 4 2 4 1 6 0 6 7 C 61 4 6 1 5 9 6 1 6 0 7 9 8 6 6 1 5 9 6 1 6 0 7 9 8 ...

Page 35: ... 16 19 14 A 70 3 10 14 10 15 20 14 A 70 4 13 14 10 15 23 14 A 80 3 15 22 15 26 35 22 A 80 4 20 22 15 26 39 22 A 90 3 31 35 37 44 66 39 A 90 4 41 35 37 44 73 39 A10 oil l A11 B3 B6 B7 B8 VA VB A 10 2 0 80 1 2 1 2 1 1 A 20 2 1 2 1 7 1 8 1 5 A 20 3 1 5 1 7 2 4 1 6 A 30 2 1 8 2 3 2 6 2 1 A 30 3 2 3 2 4 3 5 2 3 A 41 2 4 0 4 1 4 1 4 7 5 2 4 4 A 41 3 4 0 4 0 4 0 4 7 6 1 3 9 A 50 2 4 9 8 1 4 7 8 4 11 9 2 ...

Page 36: ...5 11 oil l Life time lubricated gear units Lubricant is not factory filled H1 H2 H3 H4 H5 H6 F 10 2 0 95 0 95 0 95 0 95 0 95 0 95 F 20 2 1 4 1 4 1 4 1 4 1 4 1 4 F 20 3 1 8 1 8 1 8 1 8 1 8 1 8 F 30 2 2 6 2 1 1 5 2 1 2 9 2 1 F 30 3 2 6 2 1 1 5 2 1 2 9 2 1 F 30 4 2 9 2 4 1 7 2 4 3 2 2 4 F 40 2 5 0 3 9 4 0 3 1 5 1 4 0 F 40 3 5 0 3 9 4 0 3 1 5 1 4 0 F 40 4 5 3 4 3 4 3 3 3 5 5 4 4 F 50 2 9 2 6 7 7 6 4 7...

Page 37: ...5 3 6 4 3 3 0 VFR 150 V HS P IEC 1 0 0 80 0 80 0 40 0 60 1 0 VF 150 A F FC FR P HS 9 6 5 5 5 5 5 0 6 7 6 7 VF 150 A F FC FR P P IEC 7 8 5 5 5 5 5 0 6 7 6 7 VFR 150 A F FC FR P HS P IEC 0 60 0 80 0 80 1 0 0 40 1 0 VF 185 N HS P IEC 5 0 5 5 5 5 7 8 6 6 6 8 VFR 185 N HS P IEC 1 0 0 80 0 80 0 60 0 40 1 0 VF 185 V HS P IEC 6 8 5 5 5 5 6 4 7 8 5 4 VFR 185 V HS P IEC 1 0 0 80 0 80 0 40 0 60 1 0 VF 185 A ...

Page 38: ...2 M3 1 5 1 7 1 7 1 9 1 7 1 6 7 i 15 1 5 1 7 1 7 1 9 1 7 1 6 20 i 100 2 7 1 7 1 7 1 9 1 7 1 6 A15 oil l Single stage helical gear units series S P F B3 B6 B7 B8 V5 V6 B5 B51 B52 B53 V1 V3 S 10 1 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 0 30 S 20 1 0 45 0 45 0 45 0 45 0 45 0 45 0 45 0 45 0 45 0 45 0 45 0 45 S 30 1 0 70 0 70 0 70 0 70 0 70 0 70 0 70 0 70 0 70 0 70 0 70 0 70 S 40 1 1 6 1...

Page 39: ... 2 33 8 h9 0 5 1 5 8x7x25 A A 30 47 40 h7 39 158 23 112 30 2 2 43 12 h9 0 5 1 5 12x8x30 A 42 35 h7 34 158 23 112 30 2 2 38 10 h9 0 5 1 5 10x8x30 A A 41 52 45 h7 44 184 28 128 45 2 5 2 5 49 5 14 h9 1 2 14x9x45 A 47 40 h7 39 184 28 128 50 2 5 2 5 43 12 h9 1 2 12x8x50 A A 50 63 55 h7 54 226 37 5 151 55 2 5 2 5 59 16 h9 1 2 16x10x55 A 57 50 h7 49 226 37 5 151 65 2 5 2 5 53 5 14 h9 1 2 14x9x65 A A 60 7...

Page 40: ... 70 2 5 2 5 74 5 20 h9 1 2 0 20x12x70 A 68 60 h7 59 180 38 104 70 2 5 2 5 64 18 h9 1 2 0 18x11x70 A F 70 89 80 h7 79 229 58 113 75 3 3 85 22 h9 2 5 2 5 22x14x75 A 78 70 h7 69 229 58 113 75 3 3 74 5 20 h9 2 5 2 5 20x12x75 A F 80 99 90 h7 89 272 78 116 100 3 3 95 25 h9 2 5 2 5 25x14x100 A 89 80 h7 79 272 78 116 100 3 3 85 22 h9 2 5 2 5 22x14x100 A F 90 111 100 h7 99 333 87 5 158 110 3 3 106 28 h9 2 ...

Page 41: ...2 5 53 5 14 h9 2 5 2 14x9x70 A VF 185 68 60 f7 59 188 63 62 80 2 5 2 5 64 18 h9 2 5 2 18x11x80 A VF 210 99 90 f7 89 258 83 92 80 3 3 95 25 h9 2 5 2 5 25x14x80 A VF 250 121 110 h7 109 318 83 152 80 3 3 116 28 h9 2 5 2 5 28x16x80 A A21 A22 A1 A2 A3 B B1 B2 C D E F G R S UNI 6604 W 63 30 25 24 118 38 42 35 2 2 28 8 h9 1 1 5 8x7x35 A W 75 35 28 27 125 38 49 40 2 2 31 8 h9 1 1 5 8x7x40 A 35 30 29 125 3...

Page 42: ...oximate weight 15 Kg 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 lif...

Page 43: ...fitted to gear units C50 C100 3 Open harness with eyelets 2 Rope and hooks 1 Ring harness Series C A B A B B C41 C51 C41 C51 C41 C51 C41 C51 C41 C51 C41 C51 C41 C51 2 3 1 C41 C51 2 3 1 2 3 A 1 P F U UF M05 M1 M2 M3 M4 M5 C 05 M C 11 M A M M C 21 M A M M C 31 M A M M C 35 A A A C 41 A B A B A B C 51 A B A B A B C 61 A B A A B A B C 70 A B A A B A B C 80 A B A A B A B C 90 A B A A B A B C 100 A B A ...

Page 44: ...AX Maximum permissible tilt during handling 15 3 Open harness with eyelets 2 Rope and hooks 1 Ring harness Lift manually weight 15 kg M Lift as per diagram A A Lift as per diagram B B M05 M1 M2 M3 M4 M5 A 10 M A M M A 20 A B M P63 P90 M A B P100 P112 A 30 A A A A 41 A B A B A B A 50 A B A B A B A 60 B A B A B A 70 B B B A 80 B B B A 90 B B B Reccomended solution A for positioning solution B for po...

Page 45: ...elets 2 Rope and hooks 1 Ring harness Lift manually weight 15 kg M Lift as per diagram A A Lift as per diagram B B M05 M1 M2 M3 M4 M5 F 10 M A B M M F 20 A B M P63 P90 M A B P100 P112 F 30 A A A F 40 A B A B A B F 50 A B A B A B F 60 A B A B A B F 70 A B A B A B F 80 A B A B A B F 90 A B A B A B Reccomended solution A for positioning solution B for positioning and handling ...

Page 46: ... permissible tilt during handling 15 1 5 1 5 MAX 1 Ring harness Lift manually weight 15 kg M Lift as per diagram A A M05 M1 M2 M3 M4 S 10 1 M A M M S 20 1 M A M M S 30 1 M A M M S 40 1 A A A S 50 1 A A A Reccomended solution A for positioning ...

Page 47: ...5 1 5 MAX Lift manually weight 15 kg M Lift as per diagram A A Lift as per diagram B B 3 Open harness with eyelets 2 Rope and hooks 1 Ring harness Eyebolt Snap hook use with rope Screw clamp use with harness W 63 WR 63 M M M W 75 WR 75 A B M M W 86 WR 86 A B M M W 110 WR 110 A B B A B Reccomended solution A for positioning solution B for positioning and handling ...

Page 48: ...ift as per diagram B B Snap hook use with rope Screw clamp use with harness Eyebolt already fitted to gear units VF130 VF250 3 Open harness with eyelets 2 Rope and hooks 1 Ring harness VF 30 M VF 44 VFR 44 VF 49 VFR 49 VF 130 VFR 130 A B A B A B VF 150 VFR 150 VF 185 VFR 185 VF 210 VFR 210 VF 250 VFR 250 Reccomended solution A for positioning solution B for positioning and handling ...

Page 49: ...n fit the stop bushing B1 and tighten down the two grub screws 7 while hol ding it snug against the pinion 1 see figure on the right 6 Lubricate the seal ring lips with a film of grease 7 For type VFR 49 units which are lubricated for life and hence do not have a service plug fill with the quantity of lubricant specified in the corresponding chapter of the catalogue dealing with lubrication of VFR...

Page 50: ...ur ned freely by hand 2 A centre punch is used to make two corresponding reference marks at the same angular position on the ring nut and the protruding section of the output shaft This reference position is the starting point from which all further turns of the ring nut are counted and thus the torque calibration is measured 3 The ring nut is now screwed in by the fractions of a turn which corres...

Page 51: ...49 ...

Page 52: ...50 INDEX OF REVISIONS R We reserve the right to implement modifications without notice This catalogue cannot be reproduced even partially without prior consent R3 ...

Page 53: ... marwaha bonfiglioli com GREECE BONFIGLIOLI HELLAS S A O T 48A T O 230 C P 570 22 Industrial Area Thessaloniki Tel 30 2310 796456 Fax 30 2310 795903 www bonfiglioli gr bonfigr otenet gr HOLLAND ELSTO AANDRIJFTECHNIEK Loosterweg 7 2215 TL Voorhout Tel 31 252 219 123 Fax 31 252 231 660 www elsto nl imfo elsto nl HUNGARY AGISYS AGITATORS TRANSMISSIONS Ltd 2045 Törökbálint Tö u 2 Hungary Tel 36 23 50 ...

Page 54: ...COD 1261 R3 INDUSTRY PROCESS AND AUTOMATION SOLUTIONS w w w b o n f i g l i o l i c o m ...

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