Installation, Operation, and Maintenance of Bonfiglioli 300-300M Series ATEX Reducer

Installation, Operation, and Maintenance of Bonfiglioli 300-300M Series ATEX Reducer

The ATEX explosion-proof version IOM manual for Bangfeili 300/300M series planetary gearboxes covers safety, transportation and storage, installation and commissioning, lubrication, operation, maintenance, fault handling, and appendices; This series can be equipped with motors/hydraulic motors, suitable for potential explosive hazardous environments, ATEX certification: Class II equipment, 2G gas zone 1, 2D dust zone 21; Temperature level T4 (maximum gas temperature of 135 ℃), maximum dust temperature of 135 ℃.

Technical information

2.1 ATEX Explosion proof Version Structure Requirements

Selection requires a higher safety service factor;

Only synthetic lubricating grease is allowed to be used;

Fluororubber seals; Equipped with spring anti intrusion ventilation plug; Aluminum gasket oil plug; Equipped with dust-proof lip oil seal;

No exposed moving metal parts; It is not allowed to accumulate static electricity on plastic parts;

Dust application in Zone 21/22: The surface must be cleaned regularly, and the thickness of dust accumulation must not exceed 5mm.

2.2 Compliance Statement

The equipment meets ATEX 2014/34/EU standards; The supporting motor meets the requirements of low voltage and EMC electromagnetic compatibility directives. Equipment Group II; Category 2G (gas)/2D (dust), suitable for Gas Zone 1 and Dust Zone 21.

2.3 Operating boundary conditions

It is not allowed to change the motor configuration or installation orientation without the manufacturer's written approval, otherwise the explosion-proof function will be ineffective;

The surface temperature of the nameplate is based on the standard installation environment; The installation of a closed cabinet will change the heat dissipation and surface temperature.

2.4 Temperature Limit Table

Project Synthetic Oil Model Mineral Oil Model

Operating environment temperature -30 ℃~+50 ℃ -10 ℃~+40 ℃

Storage environment temperature -40 ℃~+50 ℃ -10 ℃~+50 ℃

Continuous maximum surface temperature of shell 100 ℃ 100 ℃

Maximum oil temperature 95 ℃ 95 ℃

It is not recommended to operate continuously for a long time within the oil temperature range of 80-95 ℃; It is recommended to perform a speed ramp soft start when starting at full load.

Security Information

All operators must receive specialized training and be equipped with labor protection; Only allowed for industrial use designated by the manufacturer;

Professional technicians are required for maintenance and repair; Before working in explosive hazardous areas, power must be cut off, locked to prevent accidental start-up, and combustible gases/dust must be eliminated from the site;

Only original spare parts and recommended lubrication from the factory are allowed; Waste oil and waste shall be disposed of in accordance with environmental regulations.

Handling, transportation, and storage

4.1 Packaging

Standard packaging is suitable for land transportation and not rainproof; Wooden crate packaging is required for sea/air transportation; The storage limit is 2 years under unopened conditions, with an environmental humidity of ≤ 80% and indoor shelter from rain. Verify the order upon receipt and inspect for any damages.

4.2 Lifting and Handling

Mechanical lifting is required for weights greater than 15 kg; The maximum allowable inclination for lifting is 15 °, and if the swing exceeds the tolerance, it must be lifted again;

The large machine base (317-325, 317M-318M) comes with lifting rings; Prohibit the use of motor lifting rings to hoist the entire machine;

The manual provides lifting diagrams for various installation forms, including horizontal and vertical.

4.3 Storage

Prohibit outdoor storage; The equipment pad is elevated and cannot directly touch the ground;

Storage>6 months: Apply rust inhibitor to the exposed processing surface; Add anti rust oil inside the box; Drain the rust proof oil and clean before putting it into use; Solvent cleaning should not come into contact with the oil seal, as it may cause damage to the seal;

If stored for more than 1 year, the lifespan of the bearing grease will decrease, and synthetic grease must be used.

Long Term Stock Options

Special VCI vapor phase rust prevention packaging, with box markings indicating that it can only be opened before installation;

Storage environment -10 ℃~+40 ℃, dry and avoid light; Maximum storage time of 2 years; Upon expiration, it needs to be sent to Bangfeili Service Center for testing, and after passing the inspection, it can be stored for up to 2 years; Unboxing is prohibited before expiration.

Installation

5.1 General points for installation of reducer body

Clean all anti rust protective layers; Check the nameplate parameters; The installation base must have sufficient rigidity; Cut off power before homework to prevent accidental startup;

Axis axis alignment accuracy must meet the standard; Exposed rotating parts must be equipped with protection; Contact the manufacturer for protection solutions in corrosive environments;

It is recommended to use anti micro dynamic corrosion lubricant Kl ü berpaste 46 MR 401 for the mating surface; Outdoor use should be well shaded, rainproof, and ventilated;

Factory transportation sealing plugs must be replaced with matching ventilation plugs on site.

There are three forms of installation: flange installation, foot installation, and hollow shaft (expansion disc) installation; The manual provides complete bolt specifications, strength grades, and tightening torque tables for each machine base, including flange bolts, foot bolts, and expansion plate bolts.

Flange installation: Specify the tolerance of the stop and the tolerance of the form and position; Deformation limit of output shaft under high radial load conditions; Provide installation and disassembly steps for FDK/FZP axial locking half ring structure.

Foot installation: The flatness of the base is ≤ 0.2 mm/100 mm.

Installation of hollow shaft expansion disc:

There are two bolt tightening processes for small machine bases (300-313) and large machine bases (314-325); Prohibit the use of molybdenum disulfide grease to reduce the friction of the expansion disk;

Do not completely unscrew the bolts during disassembly to prevent them from popping open; Large scale models are equipped with pressure oil disassembly ports.

Solid shaft installation accessories: hammering is prohibited; The pulleys must be kept parallel, and the tension of the belt should not be too high to damage the bearings; The spline shaft must use a matching stop end plate.

Models without motor supply: Before disassembling the protective cover, the reducer must be placed vertically to prevent internal parts from scattering.

5.2 Motor Installation (IEC Motor)

Assembly is prohibited from hard tapping, and the mating surface should be coated with paste;

ATEX requirement: The explosion-proof rating of the supporting motor should be ≥ the explosion-proof rating of the reducer;

The frequency converter drives the entire machine, and users need to complete the risk assessment themselves. The responsibility for explosion-proof compliance of the entire machine is assigned to the installation formula.

5.3 Hydraulic Motor Installation

Two sealing forms: O-ring sealing and motor built-in sealing; Bolt ≥ 8.8 grade; Provide hydraulic schematics for open and closed circuits; Specification for T-connection of oil drain port; Multiple motors connected in series must be connected to a drainage pipeline; Recommended hydraulic oil ISO VG46; Filtering level NAS 1638 Class9.

5.4 Hydraulic Brakes

Built in multiple hydraulic brakes share gear oil with the gearbox; Provide the full range of braking torque and minimum release pressure (maximum not exceeding 320 bar); The dynamic braking torque will fluctuate by -5% to+15%.

5.5 Lubrication

ATEX explosion-proof models can only use synthetic lubricants; Select oil products based on industrial equipment/mobile devices and environmental temperature;

Long term inventory versions are divided into SLM (compatible with mineral oil rust inhibitor) and SLP (compatible with polyethylene glycol PAG oil rust inhibitor);

Rust inhibitor is compatible with operating oil: directly add working oil and replace the vent plug;

Incompatible rust inhibitor: The rust inhibitor must be drained, rinsed, and then filled with formal lubricating oil.

List of all plug thread specifications and tightening torque.

Equipment commissioning test

This reducer belongs to the category of "partially completed machinery" and cannot be put into operation separately. It must be integrated into the entire machine and meet the requirements of the Machinery Directive 2006/42/EC before it can be allowed to operate.

Pre startup inspection items:

The installation position is consistent with the nameplate; The parameters of the power supply and hydraulic system meet the standards; The oil level is correct; No leakage; The ventilation plug is unobstructed;

Explosion proof environment: Dust accumulation thickness<5mm; Good ventilation, no external heat source for baking; All accessories are fully ATEX certified; All safety measures are in place; No abnormal noise or vibration.

Equipment usage

Prohibited use scenarios: strong corrosive and abrasive gases and dust; Direct contact with bulk food. The protruding part of the rotating shaft is a dangerous area for compression and shearing, and a protective cover must be installed at the accessible position for personnel.

Maintenance and upkeep

Power off and lock before maintenance work; Clearing hazardous media from explosive environments;

Original factory spare parts are required; It is recommended to replace all seals and gaskets directly during disassembly and assembly; It is recommended to replace the bearings in pairs on the same axis; Replace the lubricating oil after the repair is completed; Apply thread sealant again after disassembling and reassembling the threads;

Wait for the entire machine to cool down sufficiently before opening the cover for maintenance to prevent burns; Apply fluorine lubricating grease to the lip of the oil seal during assembly; After maintenance, all plugs should be tightened to the specified torque;

Maintenance includes: routine maintenance, oil change, operational efficiency check, and cleaning; Component replacement; Motor disassembly; Equipment scrapping and dismantling.

Troubleshooting

Troubleshooting chapter: Symptoms, causes, and solutions for malfunctions such as abnormal noise, oil leakage, overheating, and insufficient torque.