15
Rossi
Operating instructions − UTD.045.06-2013.00_TR_EN
TR
EN
Contents
1 - General safety instructions
15
2 - Operating conditions
15
3 - How supplied
15
3.1 - Receipt
15
3.2 - Name plate
15
3.3 - Painting
15
3.4 - Protections and packing
15
4 - Storing
16
5 - Installation
16
5.1 - General
16
5.2 - Fitting of components to shaft ends
17
5.3 - Shaft-mounting
17
5.4 - Hollow low speed shaft
17
5.5 - Backstop device
20
5.6 - Shrink disc
20
6 - Lubrication
20
6.1 - General
20
6.2 - Lubrication table
18
6.3 - Extruder support lubrication
20
Operating instructions gear reducers and gearmotors
7 - Cooling system
20
7.1 - Cooling by fan
20
7.2 - Water cooling by coil
20
7.3 - Independent cooling unit
20
8 - Commissioning
21
9 - Maintenance
21
9.1 - General
21
9.2 - Coil
21
9.3 - Seal rings
21
9.4 - IEC motor mounting and dismounting
21
9.5 - Servo motor mounting and dismounting
22
9.6 - Bearings
23
9.7 - Metal filler plug with filter and valve
23
10 - Sound levels
23
Painting table
24
Table of tightening torques for axial fastening
bolts and shrink disc
24
Table of tightening torques for fastening bots (foot,
flange, hub clamps and flexible half-coupling bolts)
24
Table of tightening torques for plugs
24
Gear reducer troubles: causes and
corrective actions
25
Recycling
(keeping in mind the instructions in force):
– the elements of housing, gear pairs, shafts and bearings of gear
reducer must be transformed into steel scraps. The elements in
grey cast iron will be subjected to the same treatment if
there is no particular instruction;
– the worm wheels are made in bronze and must be treated
adequately;
– exhausted oils must be recycled and treated according to the
instructions.
The paragraphs marked with present symbol contain
dispositions to be strictly respected in order to assure
personal
safety
and to avoid any
heavy damages
to
the machine or to the system (e.g.: works on live parts, on
lifting machines, etc.); the responsible for the installation or mainte-
nance must scrupulously
follow all instructions contained in
present handbook.
1 - General safety instructions
Gear reducers and gearmotors present dangerous parts because
they may be:
– live;
– at temperature higher than +50 °C;
– rotating during the operation;
– possibly noisy (sound levels > 85 dB(A)).
An incorrect installation, an improper use, the removing or discon-
nection of protection devices, the lack of inspections and maintenan-
ce, improper connections may cause severe personal injury or pro-
perty damage. Therefore the component must be moved, installed,
commissioned, handled, controlled, serviced and repaired
exclusi-
vely by responsible qualified personnel
(definition to IEC 364).
It is recommended to pay attention to all instructions of present
handbook, all instructions relevant to the system, all existing safety
laws and standards concerning correct installation.
Attention!
Components in non-standard design or with constructi-
ve variations may differ in the details from the ones described here
following and may require additional information.
Attention!
For the installation, use and maintenance of the electric
motor (standard, brake or non-standard motor) and/or the electric
supply device (frequency converter, soft-start, etc.) and accessories, if
any (flow indicators, independent cooling unit, thermostat, ecc) con-
sult the attached specific documentation. If necessary, require it.
Attention!
For any clarification and/or additional information con-
sult Rossi and specify all name plate data.
Gear reducers and gearmotors of present handbook are normally
suitable for installations in industrial areas:
additional protection
measures,
if necessary for different employs, must be adopted
and assured by the person responsible for the installation.
IMPORTANT: the components supplied by Rossi must be incorpo-
rated into machinery and
should not be commissioned before
the machinery in which the components have been incor-
porated conforms to:
–
Machinery directive 2006/42/EC and subsequent upda-
tings; in particular, possible safety guards for shaft ends
not being used and for eventually accessible fan cover
passages (or other) are the Buyer’s responsibility;
–
«Electromagnetic compatibility (EMC)» directive 2004/108/
EC and subsequent updatings.
When operating on gear reducer (gearmotor) or on components
connected to it
the machine must be at rest:
disconnect motor
(including auxiliary equipments) from power supply, gear reducer
from load, be sure that safety systems are on against any accidental
starting and, if necessary, pre-arrange mechanical locking devices
(to be removed before commissioning).
If deviations from normal operation occur (temperature increase,
unusual noise, etc.) immediately switch off the machine.
The products relevant to this handbook correspond to the technical
level reached at the moment the handbook is printed. Rossi reser-
ves the right to introduce, without notice, the necessary changes
for the increase of product performances.
2 - Operating conditions
Gear reducers are designed for industrial applications according to
name plate data, at ambient temperature 0
4
+40 °C (with peaks at
-10 °C and +50 °C), maximum altitude 1 000 m.
Not allowed running conditions: application in aggressive envi-
ronments having explosion danger, etc. Ambient conditions must
comply with specifications stated on name plate.
3 - How supplied
3.1 - Receipt
At receipt verify that the unit corresponds to the one ordered and
has not been damaged during the transport, in case of damages,
report them immediately to the courier.
Avoid commissioning gear reducers and gearmotors, that are even
if slightly damaged.
3.2 - Name plate
Every gear reducer presents a name plate in anodised aluminium
containing main technical information relevant to operating and
constructive specifications and defining, according to contractual
agreements, the application limits (see fig. 1); the name plate must
not be removed and must be kept integral and readable. All name
plate data must be specified on eventual spare part orders.
3.3 - Painting
Products are painted according to the painting table shown on page 24.
Before adding further coats of paint (use dual-compound paints only),
properly protect the seal rings (which must neither be damaged nor
painted), degrease and sand the gear reducer (or gearmotor) surfaces.
3.4 - Protections and packing
Overhanging free shaft ends and hollow shafts are treated with protec-
tive anti-rust long life oil and protected with a plastic (polyethylene)
cap (only up to D
≤
48 mm for overhanging shafts, D
≤
10 mm for
hollow shafts). All internal parts are protected with protective anti-rust oil.