Installation, operation, maintenance, and spare parts instructions for Bonfiglioli EVOX-CP series helical gear reducers (including ATEX explosion-proof models)

Installation, operation, maintenance, and spare parts instructions for Bonfiglioli EVOX-CP series helical gear reducers (including ATEX explosion-proof models)

Installation, operation, maintenance, and spare parts manual for Bangfeili EVOX-CP series helical gear reducers (including ATEX explosion-proof models), covering CP07-CP67 machine bases, including standard industrial versions and models that comply with EU ATEX 2014/34/EU potential explosive environments. The manual is aimed at installation personnel, operation and maintenance personnel, and equipment scrap disposal personnel, covering the entire product life cycle operation. The gray background box is the ATEX explosion-proof exclusive clause, which can only be executed by personnel with explosion-proof special qualifications. This manual belongs to the same Bangfeili transmission technology system as the previous C/A/F/S and VF-W series IOMs.

Security Information

Operators must receive specialized training and wear personal protective equipment; All maintenance must be stopped, all power must be cut off, and measures to prevent accidental restarts must be taken.

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.

The noise level of a single machine at a full load distance of 1 meter is less than 85 dB (A), and the overall equipment noise is measured by the equipment integrator in accordance with the Machinery Directive 2006/42/EC.

Key safety prohibitions:

Do not use high-pressure water guns to rinse the gearbox;

It is prohibited to use the gearbox housing as a welding ground, as welding can damage the gears and bearings;

The operating temperature of the shell is high, which poses a risk of burns; Discharge hot oil to prevent burns; The vent plug with pressure relief valve needs to be disassembled after the equipment has cooled down;

There is a risk of reverse operation in models without backstop during power outages; Lifting and hoisting loads must be equipped with power-off brakes;

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

ATEX explosion-proof area maintenance requires cutting off the motor power supply and removing residual explosive gases and dust 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

The ordinary nameplate includes: model, product code, serial number, and country of production; The ATEX explosion-proof nameplate additionally includes: transmission ratio, maximum allowable output torque, installation location, production year and month, maximum input speed, EC-Cert certificate number, temperature rating, Ex explosion-proof identification; Standard ambient temperature -20 ℃~+40 ℃. The nameplate must be kept clear; Ordering spare parts and technical consultation must provide all information on the nameplate.

3.2 Product Description and ATEX Hardware Mandatory Requirements

EVOX-CP helical gear reducer is used in industries such as machinery, chemical, and agriculture, and can be equipped with various accessories. Mandatory hardware conditions for ATEX explosion-proof models:

Only synthetic lubricants and fluororubber seals are allowed;

Apply thread locking adhesive to all external bolts and oil plugs;

Install ventilation plugs with anti intrusion valves; The output shaft adopts dual oil seals;

All components can withstand temperatures higher than the maximum temperature specified on the nameplate for the casing; There is no metal sliding friction pair outside the shell; Plastic parts are anti-static or shielded; Configure irreversible temperature sensors;

21/22 Dust area, users must develop regular shell dust removal plans to prevent dust accumulation.

3.3 Compliance

The regular version complies with the Machinery Directive 2006/42/EC; the supporting motor complies with the Low Voltage Directive and the EMC Electromagnetic Compatibility Directive. ATEX version: Equipment Group II; Category 2G (Gas Zone 1), 2D (Dust Zone 21); The standard temperature level is T4 (gas 135 ℃), dust 135 ℃, and some models are T3 (200 ℃)/dust 160 ℃, according to the nameplate.

3.4 Operating Restrictions

Only used for industrial working conditions specified in the sample; Any changes to the installation location or product configuration must be approved in writing by the manufacturer, otherwise ATEX certification will be invalidated. Prohibit direct contact with loose food materials, strongly corrosive steam dust (without special anti-corrosion options); Narrow installation chambers and surrounding heat sources can alter the heat dissipation conditions and increase the actual temperature of the casing.

3.5 Allowable temperature limit

Parameter 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 gradually increase the load for low-temperature full load startup.

Handling and Storage

4.1 Packaging Specifications

Standard cardboard tray packaging is not waterproof and suitable for land transportation; Customized wooden boxes are required for sea transportation and outdoor storage. The maximum storage time in a sheltered environment is 2 years, with a relative humidity of ≤ 80%. Check the order upon arrival and inspect for transportation damage.

4.2 Handling and Lifting

≤ 15   kg can be manually transported; Lifting equipment is required for weights greater than 15 kg; It is strictly prohibited to use motor lifting rings to lift the entire set of deceleration motors.

The load of the lifting device must be sufficient; The swing angle of lifting shall not exceed ± 15 °; The motor and accessories will change the center of gravity, and it is necessary to increase the lifting points; Rotate the equipment as close to the ground as possible to prevent the lifting equipment from slipping and falling. The manual provides a schematic diagram for the lifting of all CP series machine bases.

4.3 Storage

Prohibited from outdoor storage, cannot be directly placed on the ground, and a tray should be placed at the bottom to avoid temperature difference condensation.

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

If stored for more than 1 year, the lifespan of the synthetic lubricating grease for the bearing will decrease.

Remove the anti rust coating before operation, and solvents are strictly prohibited from contacting the oil seal; If the storage protective oil is incompatible with the operating oil, the tank must be thoroughly flushed.

Installation

The base 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 position; Equipotential grounding of the shell; IEC hot surface warning signs shall be installed on the high-temperature shell.

5.1 Installation of reducer body

All anchor/flange fixing holes must be used; The manual provides complete tightening torque for 8.8, 10.9, and stainless steel bolts; Aluminum shells are not allowed to use bolts higher than grade 8.8; Simultaneously provide tightening torque for oil plug and vent plug.

Solid shafts are prohibited from hammering and assembling transmission components; Asymmetric wheel hubs should be installed according to the recommended method to reduce the cantilever load of bearings.

Special installation requirements for ATEX models: Installation personnel must have explosion-proof qualifications; Unused threaded holes need to be sealed and threaded with locking adhesive; Prohibit connecting objects with a resistance greater than 10 ⁹  Ω; The input speed cannot exceed the nameplate; All bolts and oil plugs are made of Loctite 510; The cantilever load and axial thrust must be verified.

5.2 IEC standard flange motor assembly

Thoroughly remove oil and grease from the mating surface; Sealing of flanges and application of sealant to the joint; Apply anti sticking paste to the motor shaft and gearbox input shaft; Tighten the bolts to the specified torque; ATEX version flange gaps are additionally sealed with sealant to prevent dust accumulation. Forced pressing is prohibited.

5.3 Installation of external transmission components

Moderately heat the wheel hub assembly, but do a good job of oil seal insulation protection; Axial limit must be set; The radial and axial loads of the verification shaft must not exceed the allowable values of the sample.

5.4 AL/AR backstop (one-way check)

Wedge type overrunning clutch; Confirm the correct rotation of the output shaft during operation; The motor is prohibited from rotating in the opposite direction, as it will directly damage the backstop; The allowable torque of the backstop may be lower than the rated torque of the gearbox body.

5.5 Coating and Surface Protection

Standard anti-corrosion grade C2; optional C3/C4 heavy anti-corrosion, provide RAL color code list. During on-site painting, protect the nameplate, oil seal, and machined joint surface, and do not paint the joint surface.

5.6 Lubrication (EVOX-CP Core Features)

EVOX-CP standard factory lifetime lubrication, supports multiple installation positions; The SO option is equipped with an independent oil drain plug.

Special constraint: Equipped with OHA/OHR reinforced output bearings and adopting an upward vertical orientation of the output shaft (or within ± 60 ° range), it is necessary to contact the manufacturer to confirm whether the oil level is suitable.

This machine does not have a traditional oil level observation plug, and uses a matching graduated measuring rod. The gearbox needs to be adjusted to a horizontal state for oil level detection; Oil change must use a 25 μ m filter funnel; It is strictly prohibited to mix different oil products; Oil change requires flushing the casing.

ATEX mandates the use of specified synthetic PAG oils, and the manual lists qualified oils and bearing greases such as Shell, Kl ü ber, Mobil, Total, etc; Provide reference fuel quantities for each machine base (CP07:0.35L~CP67:2.9L).

5.7 Put into operation

Pre operation inspection: The entire machine complies with mechanical instructions and the power supply and grounding are qualified; The oil level is normal and there is no leakage; All protective components have been restored; The thickness of dust accumulation on the casing of ATEX models is ≤ 5mm.

No load test run, confirm no abnormal noise or vibration; After running for 100 hours, tighten all flanges and anchor bolts.

Temperature measurement points: gear reducer motor joint position, worst ventilation housing area; Measure after 3 hours of full load; The temperature rise Δ T is not allowed to exceed 75   K; if it exceeds the temperature limit, the machine will be stopped immediately.

Variable frequency drive ATEX machine: Users must conduct their own risk assessment and issue a self declaration; The frequency converter must limit the maximum input speed to ≤ 1500   min ⁻¹ to prevent overload.

Maintenance and upkeep

Power off and lock before maintenance work, and implement anti misoperation measures; ATEX dust areas 21/22 must be regularly dusted, with a dust thickness not exceeding 5mm; after disassembly and reassembly, all threads must be re coated with Loctite 510, and all seals must be replaced with new ones.

6.1 Operation status check

Monitor noise and vibration, motor current and voltage, housing temperature, seal leakage, and fastener status; Wear inspection of bearings and friction components.

6.2 Routine maintenance cycle

Noise and vibration: every 24 hours;

Sealing leakage: 720   h;

Oil level: 720   h;

Bolt tightening: 2000-4000 hours;

Axis alignment inspection: 9000-18000 hours;

ATEX explosion-proof models: Measure the temperature rise of the casing every 100 hours; Replace the exposed oil seal every 5000 hours; Determine the overhaul cycle based on the load factor.

Lifetime lubrication models only require oil change when the oil is contaminated, contaminated, or mixed with metal debris.

6.3 Oil change operation process

Shutdown for cooling, discharge waste oil, flush the box, and add specified new oil; Apply locking adhesive to the oil plug thread; Dispose of waste oil as hazardous waste.

6.4 Cleaning

Prohibit high-pressure water guns and use a soft cloth to clean the casing.

Disassembly

7.1 Disassembly of IEC flange motor: Do not pry the flange hard; Use an impact extractor; If necessary, thread the motor fan end and use a special tool to separate the motor to avoid damaging the flange stop.

Troubleshooting Table

The manual provides fault diagnosis, covering: high bearing temperature, overheating of the entire machine, loud noise and vibration, oil leakage, difficulty in rotation, and motor output shaft not rotating. Provide the causes and solutions for each fault, and contact an authorized service center for internal gear damage or bearing failure.

Scrap Disposal

The reducer contains cast iron, aluminum alloy, rubber seals, and lubricating oil, which are hazardous waste and should be handed over to authorized recycling agencies in accordance with EU and local environmental regulations; Do not dispose of lubricating oil and seals at will.