Installation, operation, and maintenance IOM instructions for Bonfiglioli C/A/F/S series gear reducers (including ATEX explosion-proof versions)

Installation, operation, and maintenance IOM instructions for Bonfiglioli C/A/F/S series gear reducers (including ATEX explosion-proof versions)

Installation, operation, and maintenance IOM manual for Bangfeili C/A/F/S series gear reducers (including ATEX explosion-proof versions), covering helical gear C series, bevel gear helical gear A series, shaft mounted F series, and single-stage S series; It includes both ordinary industrial working conditions and models that meet the potential explosive environment requirements of the EU ATEX 2014/34/EU. The book is 112 pages long and covers the entire life cycle from receiving, storage, installation, lubrication, commissioning, regular maintenance, disassembly, troubleshooting, and disposal. The explosion-proof clauses are specifically highlighted and only personnel with explosion-proof qualifications can perform corresponding operations.

Safety Information

Operators must undergo specialized training and be equipped with personal protective equipment; Maintenance and repair must be carried out by shutting down the machine, cutting off all power, and implementing anti accidental restarts.

Only use the recommended lubricating grease from the original factory; Waste oil and components shall be disposed of in accordance with local environmental regulations, and dumping at will is prohibited.

Whole machine noise: The noise level at 1 meter of full load of a single machine is less than 85dB (A). The noise level of the whole machine equipment is measured by the equipment integrator according to the Machinery Directive 2006/42/EC.

Safety red line:

Do not use high-pressure water to rinse the reducer;

Do not use the gearbox housing as a welding grounding electrode, as welding can damage the gears and bearings;

The operating temperature of the gearbox casing is high, which poses a risk of burns; Discharge hot oil to prevent burns;

A gearbox without a backstop will experience reverse rotation when it loses power; The lifting load must be equipped with a fail safe brake;

In high-altitude installation scenarios, equipment integrators must provide maintenance work platforms; Increase safety chains and restraint protection for high-risk working conditions such as suspension and output shaft facing downwards;

During ATEX area maintenance, the motor power must be cut off and residual explosive gas dust must be removed from the site.

The whole machine integrator needs to incorporate the key requirements of this manual into the whole machine operation manual; Exposed rotating parts must be equipped with protective covers.

Technical Information

3.1 Equipment nameplate identification

Ordinary nameplate: model, product code, production year and month, installation location, transmission ratio, manufacturer. The ATEX explosion-proof nameplate additionally includes: transferable torque, maximum input speed, certificate number, temperature rating, maximum surface temperature of the enclosure, and Ex explosion-proof identification; Standard ambient temperature -20 ℃~+40 ℃.

The nameplate must be kept clear and readable; All technical consultations and spare parts orders must provide nameplate information.

3.2 Product Description and ATEX Explosion proof Hardware Specifications

The C/A/F/S series is used for industrial machinery, chemical, agricultural, and material equipment. ATEX model mandatory hardware configuration:

Only synthetic lubricants and fluororubber seals are allowed;

All external threaded bolts and oil plugs use thread locking adhesive;

Ventilation plug with pressure relief valve; The C-series output shaft adopts dual oil seals, while other series come with dust collection oil seals;

All components of the shell can withstand a surface temperature higher than the maximum specified on the nameplate; There is no metal sliding friction pair on the outside of the shell; Plastic parts must be anti-static or shielded;

A regular shell dust removal plan needs to be developed in the dust area on 21/22 to prevent dust accumulation and temperature rise.

3.3 Compliance

The regular version complies with the Machinery Directive 2006/42/EC; the equipped motor complies with the low voltage and EMC directives. ATEX version: Equipment Group II, Category 2G (Gas Zone 1), 2D (Dust Zone 21); The standard temperature level is T4 (gas, 135 ℃), 135 ℃ (dust), and some models are T3 (200 ℃)/160 ℃ dust. Please refer to the nameplate for accuracy.

3.4 Operating Restrictions

Only allowed for sample specified industrial conditions; Any changes to the installation location or model configuration must be approved in writing by the manufacturer, otherwise ATEX certification will be invalidated. Prohibit direct contact with loose food materials, strong corrosive steam and dust environments (when no special anti-corrosion options are available); Heat dissipation is affected by the installation cavity and surrounding heat sources, which can alter the actual surface temperature of the casing.

3.5 Temperature Limit Parameter Table

Table

Project Synthetic Oil Mineral Oil

Minimum working environment temperature -30 ℃ -10 ℃

Maximum working environment temperature+50 ℃+40 ℃

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

Continuous maximum surface temperature of shell 100 ℃ 100 ℃

Continuous maximum oil temperature of lubricating oil 95 ℃ 95 ℃

Long term operation at 80-95 ℃ is not recommended; It is recommended to slowly increase the load for low-temperature full load startup.

Handling and Storage

4.1 Packaging Specifications

Standard cardboard/pallet packaging is not rainproof and suitable for land transportation; Customized wooden boxes are required for sea transportation and outdoor storage. Standard storage conditions: sheltered environment, humidity ≤ 80%, maximum 2 years. Check the order upon arrival and inspect for transportation damage.

4.2 Handling and Lifting

<15kg can be manually transported; Lifting equipment must be used if the weight is greater than 15kg; It is strictly prohibited to use motor lifting rings to lift the entire set of deceleration motors.

The lifting device must have a sufficient rated load; The swinging angle of the equipment during the lifting process shall not exceed ± 15 °; Provide lifting diagrams for each machine base of C/A/F/S, distinguishing between lifting schemes A and B.

The center of gravity will change with the accessories and motor, and it is necessary to increase the lifting points; The rotating equipment should be operated as close to the ground as possible to prevent the lifting equipment from slipping and falling.

4.3 Storage

Prohibited from outdoor storage, cannot be placed directly on the ground, and padded with pallets; Avoid internal condensation caused by large temperature differences.

Storage>6 months: Apply rust inhibitor to the machined shaft surface; Non lifetime lubrication models require oil injection and replacement of blind plugs for ventilation.

Long TERM STOCK (long-term inventory option): The equipment is packaged in VpCI vapor phase rust proof bags, and the outer packaging is labeled as "can only be opened before installation"; The standard maximum storage time is 2 years; Upon expiration, it must be sent to Bangfeili Service Center for testing, and if it passes the testing, it can be stored for up to 2 years.

Before the long-term inventory models are put into operation: remove the anti rust coating, and the solvent must not come into contact with the oil seal; If the anti rust protective solution is incompatible with the official operating oil, the box must be flushed. The lifespan of synthetic lubricating grease for bearings decreases after being stored for more than one year.

Installation

Check the nameplate before installation; The base structure must have sufficient rigidity; It is recommended to install torque limiters and hydraulic couplings for impact and stall conditions. Recommended ISO H7 tolerance for the inner hole of the output coupling; Apply anti micro corrosion paste to the key connection area. Equipotential grounding of equipment casing; Set high temperature warning signs on the high-temperature shell.

5.1 Installation of reducer body

Installation must use all anchor/flange fixing holes; Provide a complete bolt tightening torque table (8.8/10.9/stainless steel bolts); Aluminum shells are not allowed to use bolts higher than grade 8.8.

The transportation blind plug must be replaced with a vent plug kit (ATEX is a vent plug with a pressure relief valve). The oil plug also has a specified tightening torque.

Solid shaft: Do not hammer the assembled transmission components; Wheel hub installation should reduce the cantilever load on bearings.

Installation of hollow shaft (keyway/spline), shrink disc, and transition sleeve adapter:

Do not apply molybdenum disulfide grease to the mating surface of the shrink disc, as it will reduce friction and cause slippage; Apply anti sticking paste only to non friction cylindrical surfaces;

The contraction plate bolts are gradually tightened diagonally in multiple rounds, and the manual provides the standard torque for each machine base;

Apply sealant to the joint surface of the ATEX version shrink disc cover; Additional axial anti detachment mechanism is added for axial heavy load and output shaft downward working conditions;

Do not remove the protective cover of the shrink disc during operation.

5.2 Torque Arm (Torque Arm)

Axis mounted F series can be equipped with torsion arms; ATEX explosion-proof models must use original shock absorber kits, otherwise the explosion-proof certification will be invalidated; The supporting surface of the torsion arm needs to be quenched and hardened; Increase the breakage protection chain in high-risk working conditions. Provide torque for the torque arm bolt.

5.3 TKL Taconite labyrinth seal options

Selection of high abrasion dust environment; It is necessary to regularly add bearing grease through the oil nozzle.

5.4 Motor assembly

SK input (IEC flange/servo motor): thorough degreasing of flange and shaft mating surfaces; Flange sealant, apply anti seize paste on the shaft; Tighten the bolts with torque. ATEX version has thread locking adhesive on all threads.

SC input (shrink disc connected servo/motor): The motor shaft key needs to be removed; Tighten the shrink disc bolts step by step; Do not apply lubrication on the friction contact surface.

5.5 Installation of external transmission components

Prohibit hammering; The coupling can be heated moderately, but the oil seal insulation protection should be done well; The radial and axial loads of the shaft must be verified and cannot exceed the allowable cantilever load of the sample; Axial limit must be set to prevent the transmission components from shifting.

5.6 AL/AR backstop (one-way check device)

Relying on wedge type overrunning clutch; The allowable torque of the backstop may be lower than the rated torque of the gearbox body; Before putting into operation, confirm that the output shaft can rotate freely. It is strictly prohibited for the motor to rotate in the opposite direction, as it will directly damage the backstop.

5.7 Coating and Protection

Cast iron shell factory grade C2 anti-corrosion RAL7042 gray; Aluminum shell without paint; Optional C3/C4 heavy-duty anti-corrosion coating. When repainting on site, protect the nameplate, oil seal, and sealing surface, and do not spray the joint installation surface.

5.8 Lubrication Chapter (Core Focus)

There are three types of supply: lifetime lubrication models, factory oiled models, and factory non oiled models (requiring on-site oiling, some special installation positions such as B6/B7/V5/V6 default to no oiling); ATEX mandates the use of synthetic oil.

It is strictly prohibited to mix different types of oil products; When changing oil, the casing must be flushed. The machine base without an oil level plug uses a probe to measure the oil level.

Recommended oil list (Shell, Kl ü ber, Mobil, Castrol, Total), distinguishing PAG synthetic oil PAO、 Mineral oil, food grade; ATEX specifies bearing grease and assembly paste.

Long TERM STOCK has two types of protective fluids for long-term inventory models: SLM (compatible with minerals/PAO) and SLP (compatible with PAG polyethylene glycol oil); The operation process can be divided into two types: compatible and incompatible. Incompatibility requires flushing of the container.

A large number of drawings throughout the book: C/A/F/S, all installation positions B3/B6/B7/B8/V5/V6/B5/B51/B52/B53, etc., indicating the positions of oil level plugs, drain plugs, and vent plugs; Refer to the fuel gauge for different installation postures of each machine base.

5.9 Customer side drive shaft requirements

Provide users with self-made dimensions, tolerances, chamfers, and heat treatment requirements for the assembly of hollow shafts/shrink discs.

5.10 Preparation before putting into operation

All installations are completed, the oil level is confirmed, and the vent plug is installed in place; Check the torque of the bolts, ensure that all protections are in place, and conduct a no-load test run.

Key points of ATEX additional mandatory installation clauses:

The installation personnel have explosion-proof qualifications;

The maximum input speed of the motor cannot exceed the nameplate;

It is prohibited to change the installation posture of the order without authorization;

All bolts and oil plugs must be coated with Loctite 510 thread locking adhesive;

Unused threaded holes on flanges must be sealed and glued;

Metal moving contact surfaces should avoid direct dry friction and non-metallic wear reducing components should be added as necessary;

Protect the outer shaft extension to avoid dust accumulation.

Maintenance and upkeep

Operational efficiency inspection: oil temperature, noise, vibration, shell temperature, oil level; Whether the seal leaks; ATEX models require additional inspection of the cleanliness of the casing to prevent dust accumulation.

Regular routine maintenance checklist: oil level, seal leakage, fasteners, vent plugs, Taconite seal grease, check check check; Shorten the cycle under harsh working conditions.

Oil change: Oil must be changed if the oil temperature is high, water contamination occurs, or metal debris is present; Lifetime lubrication models do not require oil change under pollution-free conditions, but once contaminated, oil must be changed.

The specific installation position of the IEC-P200 large machine base requires lubricating grease to be added to the bearings.

Cleaning: Do not use high-pressure water guns; Clean the outer shell with a soft cloth; ATEX dust environment shall be cleaned according to the prescribed period.

Disassembly

Step by step instructions: disassembly of IEC flange motor; Disassembly of hollow keyway output shaft; Disassemble the hollow shaft of the shrink disc; Dismantling of adapter with liner; Disassemble the input motor of SC shrink disc. Tip: Loosening the bolt of the shrink disc requires step-by-step diagonal release and cannot be completely unscrewed at once.

Troubleshooting

The manual contains a built-in fault diagnosis table, which includes possible causes and troubleshooting directions for phenomena such as high oil temperature, oil leakage, abnormal noise, high vibration, insufficient output torque, and failure of the backstop. Common causes: incorrect oil level, forgotten replacement of vent plug, loose bolts, poor alignment, overload, bearing/gear wear, insufficient torque of shrink disc and slipping.

Scrap disposal

The reducer includes cast iron, aluminum alloy, rubber seal, and lubricating oil; Classify and recycle according to EU WEEE and local regulations; Waste oil belongs to hazardous waste and should not be discarded at will.