Varvel RC series Working Instructions & Maintenance Manual Download Page 30

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Working Instructions & Maintenance

Directive 94/9 CE (ATEX)

9.7 Maintenance Servicing

Strict observance of maintenance intervals is recommended to ensure appropriate working conditions and explosion-proof
protection.



According to working conditions:

Elimination of any dust accumulation thicker than 5 mm by means of a vacuum cleaner.



Every 500 working hours or every month:

Visual inspection of oil seals to monitor any lubricant leakage.



Every 3000 working hours or every 6 months:

Inspection of oil seals and replacement if worn-out.



Every 5 years:

Replacement of synthetic oil.

9.8 Materials - Dangerous Zones - Categories

CORRESPONDENCE AMONG MATERIALS, DANGEROUS ZONES AND CATEGORIES

(ACCORDING TO DIRECTIVE 94/9/CE)

MATERIALS

DANGEROUS ZONES

Summary of Contents for RC series

Page 1: ...WORKING INSTRUCTIONS MAINTENANCE ATEX MANUAL RO RN RV RD RT RG RC RS RP XA VR ...

Page 2: ...es Series RS 15 Gearboxes Series RT 16 Torque Limiter Option TLE 17 Torque Limiter Option TLI 18 Variators Series VR 19 Variators Series VS 20 4 INSTALLATION 21 4 1 Tolerances 21 4 2 Precautions 21 4 3 Groundwork 21 4 4 Set up 21 4 5 Pinions Couplings 21 4 6 Torque Arms 21 4 7 Painting 21 5 STARTING 22 5 1 Series RS RT 22 5 2 Series RC RD RP XA VR 22 6 INSPECTIONS AND MAINTENANCE 22 6 1 Intervals ...

Page 3: ...ents 2 2 Prevalent Use Gearboxes and variators referred to in this manual are destined to operate industrial applications and they correspond to standards and regulations where applicable Performances and technical data are available in the unit s nameplate and from the related documentation 2 3 Transport Carefully check the state of the goods at their receipt and immediately notify the possible d...

Page 4: ... 72 Shore D Temperature TPU 20 75 C 4 167 F TPE 30 100 C 22 212 F Motor half coupling Material Aluminium die cast G3 G5 G6 Alloy steel GS8 Dynamic balancing Fitting Clamp G3 G5 G6 Key GS8 Bores IEC 72 N42948 NEMA C y TC Advantages One gearbox only for each reduction ratio Greater flexibility Increased stock rotation Fretting corrosion elimination between key and keyway Zero backlash in gearbox mot...

Page 5: ...wo stage foot mounted helical gearbox type FRC sizes 05 to 30 RC 01 Oil seal 19 Bearing 02 Housing 20 Bearing 03 Key 21 Pinion 04 Output shaft 22 Key 05 Key 23 Gear 06 Bearing 24 Bearing 07 Spacer 26 Bearing 11 Gasket 27 Gear 13 Bearing 29 IEC input cover 15 Pinion 33 Hollow input 16 Key 35 Oil seal 17 Hollow input ...

Page 6: ... a two stage foot mounted helical gearbox type FRD RD 01 Input cover 54 Gear 02A Hollow input IEC 55 Spacer 02B Hollow input G 65 Bearing 04 Pinion 66 Bearing 15 Bearing 67 Bearing 16 Bearing 68 Bearing 20 Oil seal 69 Oil seal 41 Gear 82 Gasket 50 Housing 85 Motor Flange 51 Upper cover 52 Output shaft 53 Pinion ...

Page 7: ...box type FRD RD 01 Input cover 40 Pinion 68 Bearing 02A Hollow input IEC 41 Gear 69 Oil seal 02B Hollow input G 50 Housing 82 Gasket 03 3rd stage shaft 51 Upper cover 85 Motor flange 04 Pinion 52 Output shaft 05 Gear 53 Pinion 15 Bearing 54 Gear 16 Bearing 55 Spacer 17 Bearing 56 Spacer 18 Bearing 65 Bearing 19 Spacer 66 Bearing 20 Oil seal 67 Bearing ...

Page 8: ... backlash planetary gearbox type FRG 01 Screw 13 Sun gear 02 Plug 14 Ring gear body 03 Motor flange 15 Planet gear 04 Screw 16 Needle bearing 05 Input flange 17 Planet shaft 06 Plug 18 Planet carrier 07 Adapter 19 Key 08 Clamp coupling 20 Bearing 09 Bearing 21 Snap ring 10 Input shaft 22 Shim 11 Shim 23 Bearing 12 Spacer 24 Snap ring ...

Page 9: ...1 Screw 13 Sun gear 25 Bearing 02 Plug 14 Ring gear body 26 Snap ring 03 Motor flange 15 Planet gear 27 Shim 04 Screw 16 Needle bearing 28 Bearing 05 Input flange 17 Planet shaft 29 Snap ring 06 Plug 18 Planet carrier 07 Adapter 19 Planet gear 08 Clamp coupling 20 Needle bearing 09 Bearing 21 Planet shaft 10 Input shaft 22 Spacer 11 Shim 23 Planet carrier 12 Spacer 24 Key ...

Page 10: ...e FRN with through hollow output shaft 01 Input flange 13 Bearing 25 Spacer 02 Oil seal 14 Key 26 Bearing 03 Snap ring 15 Pinion 27 Snap ring 04 Bearing 16 Bearing 28 Oil seal 05 Input shaft 17 Snap ring 06 Bearing 18 Oil seal 07 Cover 19 Snap ring 08 Pinion 20 Bearing 09 Oil seal RCA 21 Body 10 Snap ring 22 Key 11 Gear 23 Output shaft 12 Spacer 24 Gear ...

Page 11: ... 01 Motor flange 13 Shaft 25 Snap ring 02 Oil seal 14 Bearing 26 Oil seal 03 Snap ring 15 Snap ring 27 Snap ring 04 Bearing 16 Pinion 28 Bearing 05 Input shaft 17 Oil seal RCA 29 Spacer 06 Bearing 18 Snap ring 30 Gear 07 Pinion 19 Bearing 31 Output shaft 08 Cover 20 Pinion 32 Key 09 Bearing 21 Key 33 Body 10 Gear 22 Bearing 34 Bearing 11 Spacer 23 Spacer 35 Snap ring 12 Key 24 Gear 36 Oil seal ...

Page 12: ... flange 13 Gear 25 Output shaft 02 Oil seal 14 Spacer 26 Body 03 Snap ring 15 Bearing 27 Snap ring 04 Input shaft 16 Cover 28 Bearing 05 Bearing 17 Pinion 29 Pinion 06 Pinion 18 Oil seal RCA 31 Bearing 07 Oil seal RCA 19 Oil seal 32 Spacer 08 Snap ring 20 Snap ring 33 Gear 09 Bearing 21 Bearing 34 Snap ring 10 Key 22 Spacer 35 Bearing 11 Shaft 23 Gear 36 Snap ring 12 Spacer 24 Key 37 Oil seal ...

Page 13: ...flange 13 Bearing 25 Bearing 02 Oil seal 14 Shaft 26 Snap ring 03 Snap ring 15 Key 27 Oil seal 04 Input shaft 16 Bearing 28 Snap ring 05 Bearing 17 Snap ring 29 Bearing 06 Pinion 18 Oil seal RCA 30 Body 07 Oil seal RCA 19 Snap ring 31 Output shaft 08 Pinion 20 Gear 33 Gear 09 Cover 21 Spacer 34 Spacer 10 Bearing 22 Bearing 35 Bearing 11 Spacer 23 Key 36 Snap ring 12 Gear 24 Pinion 37 Oil seal ...

Page 14: ...cture of a one stage helical gearbox type FRP and FXA flange mounting 01 Body 15 Bearing 02 Snap ring 16 Bearing 03 Oil seal 18 Snap ring 04 Output shaft 19 Bearing 05 Key 20 Key 06 Screw 21 Adapter 07 Bearing 24 Snap ring 08 Gear 25 Spacer 10 Motor flange 26 Plug 11 Snap ring 27 Flexible coupling 12 Oil seal 13 Pinion ...

Page 15: ... helical worm are made of a helical one stage gearbox XA mounted as input stage onto a standard worm box RS and the Series RS RS two stage worm of two standard worm boxes RS and an appropriate combination kit 01 Body 84 Oil seal RCA 04 Side cover 125 Snap ring 07 Motor flange 126 Snap ring 31 Worm wheel 50 Worm shaft 60 Bearing 61 Bearing 62 Bearing 63 Bearing 80 Oil seal 81 Oil seal 82 Oil seal ...

Page 16: ...l one stage gearbox XA mounted as input stage onto a standard worm box RT and the Series RT RT two stage worm of two standard worm boxes RT and an appropriate combination kit 01 Housing 82 Oil seal 04 Side cover 84 Oil seal RCA 07 Motor flange 125 Seeger ring 31 Worm wheel 126 Seeger ring 50A Worm shaft IEC 50B Worm shaft G 60 Bearing 61 Bearing 62 Bearing 63 Bearing 80 Oil seal 81 Oil seal ...

Page 17: ...e Limiter TLE is directly fitted into the hollow shaft of already assembled standard gearboxes with out any special tooling 01 Setting torque hand wheel 13 Front washer 02 Belville washer 14 Front friction 03 Spacer 15 Front protection 04 Spacer 16 Front bush 05 Rear protection 17 Key 06 Belville washer 18 Low speed shaft 07 Key 08 Thrust washer 09 Rear friction 10 Rear washer 11 Key 12 Rear bush ...

Page 18: ...ayout shows the general structure of a built in torque limiter type TLI incorporated inside a worm gearbox Series RS or RT 01 Lock nut 81 Oil seal 02 Bellville washer 03 Bush 04 Oil seal 05 Key 06 Spacer 07 Worm wheel 08 Hollow output shaft 10 Cover 60 Bearing 61 Bearing 80 Oil seal RS RT ...

Page 19: ...ntrol shaft lock 28 Bearing 03 Screw 16 Control shaft 29 Snap ring 04 Seal plate 17 Oil seal OR 30 Oil seal 05 Bearing 18 Screw 31 Index scale 06 Spacer 19 Output shaft 32 Snap ring 07 Cone 20 Key 33 Spring 09 Body 21 Bearing 34 Friction ring carrier 10 Cylindrical slide 22 Snap ring 35 Friction ring 11 Oil seal OR 23 Snap ring 39 Cone holder 12 Oil seal OR 24 Oil seal 40 Bellows seal 13 Screw 26 ...

Page 20: ...ral structure of a flange mounted variator without gearbox type 01 Output shaft 02 Planet carrier 03 Sliding bush 04 Adjusting track 05 Ball carrier 06 External mobile track 07 Planet 08 Adjusting box 09 External fixed track 10 Internal fixed track 11 Internal mobile track 12 Belville washer ...

Page 21: ...oes not came in contact with sealing lips of oil seals to avoid any damage and lubricant leakages 4 4 Set up The unit may be connected for clockwise or counter clockwise rotation Stop immediately the unit when unexpected running or noise occurs if the part originating the anomaly is not identified other parts may be damaged with consequent difficulty in going back to the cause 4 5 Pulleys Pinions ...

Page 22: ...tch it is advisable not to run them at maximum load for the first 20 30 hours to allow proper running in For variators run throughout the full speed range at reduced load before the full load is applied The units are delivered already filled with synthetic long life oil no servicing or refilling within the average lifetime of 15 000 hours for operation according to SF1 0 Refer to the Catalogues as...

Page 23: ...very 6 months Oil seal check and replacement if considerably used Every 5 years Replace synthetic oil VARIATORS Series VR only Series VR Variation section dry running and with lifetime grease packed bearings does not require any periodic servicing except ed the friction ring replacement on normal wearing conditions According to working conditions Replace friction ring if considerably used Every 30...

Page 24: ...place the oil seal Loosen screws Tighten the screws Inner overpressure Contact Customer Service Oil seal fitting Defective fitting or fitting lubricant melting No rotation of output shaft Internal connection cut off Contact Customer Service Series VR Friction ring end of life Replace the friction ring at an authorized centre Series VR Contaminated friction ring Clean carefully cone and ring workin...

Page 25: ... 0 70 1 15 0 80 RC330 1 15 1 50 1 15 RC140 0 60 1 15 0 60 RC240 1 15 2 25 2 00 RC340 1 50 3 00 2 25 RC150 1 50 2 25 1 50 RC250 2 25 4 40 4 00 RC350 3 75 6 00 5 00 RC160 3 00 4 40 3 00 RC260 6 00 8 80 8 00 RC360 8 00 10 00 8 80 1c One stage 2c Two stages 3c Three stages l1 B3 B6 B7 B8 B5 l2 V1 V5 l3 V3 V6 RD 2c H V 3c H V RD02 0 20 0 28 RD03 0 30 0 38 RD12 0 50 0 70 RD13 0 50 0 70 RD22 0 80 1 00 RD...

Page 26: ... 80 110 0 10 1 50 100 110 0 20 1 50 100 130 0 20 2 75 100 150 0 20 4 40 l Litres FRS l1 l2 Litres FXA FRS l3 l4 Litres FRS FRS RT RT l TA l1 l2 RT RT l3 l4 28 0 03 63 40 0 04 0 08 0 03 0 03 28 28 40 0 08 63 50 0 04 0 13 0 03 0 08 28 40 50 0 13 63 60 0 04 0 20 0 03 0 13 28 50 60 0 20 71 50 0 06 0 13 0 03 0 20 28 60 70 0 35 71 60 0 06 0 20 0 08 0 35 40 70 85 0 60 71 70 0 06 0 35 0 08 0 60 40 85 110 ...

Page 27: ...1 3 2 2 1 3 2 4 9 4 9 53 5 0 2 8 1 6 2 8 4 0 3 4 62 9 2 5 8 3 8 5 8 8 8 8 8 63 9 0 5 0 2 9 5 0 7 2 6 1 RO RV RO H1 l H2 l H3 l H4 l V1 l V2 l RV H1 l H2 l H3 l H4 l V1 l V2 l 13 0 6 0 6 0 6 0 6 0 7 0 7 13 0 6 0 5 0 4 0 5 0 6 0 6 23 0 9 0 7 0 9 0 7 1 0 1 0 23 0 9 0 6 0 5 0 6 0 7 0 7 33 1 5 1 2 1 4 1 2 1 7 1 7 33 1 5 1 0 0 8 1 0 1 2 1 2 43 2 8 2 0 1 6 2 0 2 5 2 5 43 2 9 1 9 1 2 1 8 2 6 2 6 53 5 1 3 ...

Page 28: ...er bearings with Viton oil seals on input and output shafts et with the adequate oil quantity to assure the design operation 9 2 Prevalent Use VARVEL ATEX gearboxes are identified as components fundamental but without any autonomous function to oper ate units and protection systems for production transport storage measurement control and conversion of energy or the processing of materials which ar...

Page 29: ...led on a metal surface If the motor is earthed electrical continuity is ensured by the adapter between the motor and gearbox that is always of metallic material steel aluminium cast iron It is the final responsibility of the installer to verify the electrical continuity between the engine and gearbox 9 6 ATEX Marking VARVEL Series RD XA RP RS RT RN RO RV conform to design requirements required by ...

Page 30: ...0 working hours or every month Visual inspection of oil seals to monitor any lubricant leakage Every 3000 working hours or every 6 months Inspection of oil seals and replacement if worn out Every 5 years Replacement of synthetic oil 9 8 Materials Dangerous Zones Categories CORRESPONDENCE AMONG MATERIALS DANGEROUS ZONES AND CATEGORIES ACCORDING TO DIRECTIVE 94 9 CE MATERIALS DANGEROUS ZONES CATEGOR...

Page 31: ...Propyl acetate Amyl alcohol Ethyl alcohol Isobutyl alcohol Methyl alcohol n butyl alcohol Acetic anhydride Ciclohexanone Liquefied petroleum gas Natural gas Iso Propane Mono amyl acetate n Butane Cyclohexane Cyclohexanol Decane Heptane Hexane Gasoil Kerosene Naphtha Pentane Oil acetaldehyde Ethylic ether II B Coke gas Water gas 1 3 butadiene Ethyl benzene Ethylene Ethylene oxide Sulphydric acid Is...

Page 32: ...sulla base dei re quisiti delle norme o dei documenti normativi The conformity is under observance of the stand ard documents EN 1127 1 2011 EN 13463 1 2009 EN 13463 5 2011 EN 13463 8 2003 Modo di protezione Type of protection II 2 G D ck T4 T135 C IP66 Tamb 20 55 C I File Tecnici The Technical Files sono stati depositati presso l Organismo Notificato di deposito del fascicolo tecnico were deposit...

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