Bonfiglioli HDP/HDO series gear unit IOM installation, operation and maintenance instructions

Bonfiglioli HDP/HDO series gear unit IOM installation, operation and maintenance instructions

The complete IOM manual for Bangfeili HDP and HDO heavy-duty industrial gearboxes (including ATEX explosion-proof models) covers safety, identification, storage and transportation, installation, full set of options, lubrication, commissioning, maintenance, disassembly, troubleshooting, and disposal; The gray highlighted area is specifically designed for ATEX 2014/34/EU explosion-proof equipment. Explosion proof related operations must be carried out by certified professionals in explosive environments. Violation will directly result in the invalidation of the explosion-proof certificate.

Technical Information

Equipment Identification - Nameplate

Ordinary nameplate: model, option, product code, batch, speed ratio i, rated output torque Mn2, installation position, input rated power, oil injection amount, weight, remarks.

ATEX explosion-proof nameplate: add Ex identification, temperature rating, ambient temperature, EC-Cert certificate number, radial/axial load parameters; The nameplate must be kept clear and readable.

All communication and spare parts procurement with the manufacturer must provide all information on the nameplate.

Equipment Description

HDP/HDO heavy-duty gearbox is used for industrial equipment such as machinery, chemical industry, agriculture, etc; Rich options can be configured.   ✅  Mandatory hardware requirements for ATEX explosion-proof models

Only synthetic lubricating oil (oil/grease) is allowed;

Fluoroelastomer seals;

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

Ventilation plug with anti intrusion valve and dust-proof lip oil seal;

Metal sliding friction pairs are not allowed externally; Plastic parts must be anti-static or shielded;

Install irreversible temperature sensors;

21/22 Dust area: Users must develop a regular cleaning plan to prevent dust accumulation.

Compliance

Ordinary gearboxes meet mechanical instructions; The supporting motor meets low voltage and EMC instructions.

ATEX model: Group II equipment; 2G gas/2D dust; Suitable for gas zone 1 and dust zone 21; Temperature level T4 (maximum 135 ℃ for gas), maximum 135 ℃ for dust 2D.

Use of boundary conditions

Only allow samples to be designated for industrial use; Changing the installation posture and product version requires written permission from the manufacturer, otherwise the ATEX certificate will be invalidated.

Do not come into direct contact with bulk food materials; Salt spray and corrosive gas environments require regular inspections for corrosion.

Outdoor installation must be shaded and rainproof, while ensuring ventilation and heat dissipation; A sealed cabinet will change the heat dissipation conditions and increase the oil temperature of the shell.

Equipped with MCR/MOP cooling/forced lubrication unit: Environment -10~+50 ℃; The maximum oil pressure of the system is 10 bar; Start with a minimum viscosity of 1500 cSt.

Temperature Limit Table

Parameter synthetic oil mineral oil

Minimum working environment -30 ℃ -10 ℃

Maximum working environment+50 ℃+40 ℃

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

The maximum continuous surface temperature of the shell is 100 ℃

Maximum continuous oil temperature 95 ℃ 95 ℃

Long term continuous operation at 80-95 ℃ is not recommended; It is recommended to start at full load and increase the load for operation.

Handling, Transportation, and Storage

Packaging

Standard cardboard tray packaging is suitable for indoor land transportation, not rainproof, and cannot be directly shipped by sea; Indoor storage for up to 2 years, humidity ≤ 80%; Customized wooden boxes are required for sea transportation and outdoor use; Check the goods for any damage upon receipt.

Handling and Lifting

Lifting equipment is required for a weight greater than 15 kg; It is prohibited to use motor lifting lugs to lift the entire gear motor; Only the lifting ring of the gearbox body can be used.

The maximum swing angle for lifting is ± 15 °; Do not use shaft end threads or external pipelines as lifting points.

HDP/HDO provide corresponding lifting point diagrams for different installation postures B3/B6/B7/V5; When carrying a motor, the center of gravity needs to be offset and additional suspension points need to be added.

Storage Requirements

Prohibit outdoor high humidity, use pallets, and do not directly land on the ground; Avoid internal condensation caused by large temperature differences.

Storage<6 months: Fill oil according to the nameplate oil level; Drive the vehicle for at least 1 hour every 4 weeks.

Storage>6 months: Apply rust inhibitor to the machined shaft extension; Fill the box with oil and replace the vent plug with a blind plug; Regularly rotate the input and output shafts to protect the bearing oil seal. Remove the rust inhibitor before operation, and the solvent must not come into contact with the oil seal as it may damage 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 Storage Options (SL)

BBOX paper or wooden box packaging, with the box printed with "OPEN ONLY BEFORE THE INSTALLATION" and internal VpCI vapor phase rust proof bag;

The longest storage period is 2 years; Upon expiration, it must be tested by Bangfeili Service Center, and if qualified, it can be stored for another 2 years; Unpacking can only be done before installation and operation.

Installation

Plan during the whole machine design phase before installation; Power off and lock the equipment before homework; The base/flange must have sufficient rigidity; It is recommended to configure hydraulic couplings and torque limiters for impact and locked rotor conditions.

Installation of gearbox body

Before operation: Drain the stored oil (flush the box if incompatible); Remove all anti rust coatings; Check the nameplate parameters; Base rigidity; Axis alignment; Install protective covers on exposed rotating parts; The whole machine is reliably grounded; Attach high temperature warning signs on high temperature surfaces.

The transport blind oil plug must be replaced with a supply vent plug; Bolts and oil plugs should be tightened strictly according to the torque specified in the manual, and a complete torque table for 8.8/10.9 grade bolts should be provided.

Installation of three types of output shafts: 1) Solid output shaft: Do not strike with a hammer; The recommended assembly method is used for wheel hub installation to avoid applying excessive cantilever loads to the bearings. 2) Hollow output shaft with key: An axial anti detachment device must be added to prevent separation from the equipment shaft. 3) Shrink disc hollow output shaft:

Thoroughly remove oil and grease from the mating surface; It is strictly prohibited to apply molybdenum disulfide grease, as reduced friction can cause locking failure;

Tighten diagonally in multiple steps to the specified torque; Disassemble and use top threaded holes;

Apply Loctite 5366 sealant to the joint surface of the ATEX version shrink disc protective cover; Apply Loctite 510 to the bolt threads.

Special mandatory requirements for ATEX installation: Construction must be carried out by personnel with explosion-proof qualifications; Unused threaded holes must be sealed with plugs; Install the torsion arm to avoid sliding friction between metals; The input speed cannot exceed the nameplate; The bolt grade shall not be lower than 8.8, and 10.9 shall be used for heavy loads; Apply thread locking adhesive to all oil plug bolts; The shaft coupling is perfectly aligned.

IEC standard flange motor assembly

Thoroughly remove oil and grease from the flange mating surface, and prohibit molybdenum disulfide; Apply Loctite 510 to the flange and locating ring; Apply anti micro motion corrosion paste Kl ü berpast46 MR401 to the motor shaft; Sealing of flange gap with Loctite 5366; Tighten the bolts with torque.

External transmission components (couplings, pulleys)

Do not strike; Allow moderate heating of the wheel hub and ensure proper oil seal insulation protection; It is necessary to verify the allowable radial/axial load of the shaft; Axial limit must be set.

Detailed explanation of all optional attachments

Auxiliary cooling and heating system

Shaft driven fan FANL/FANR/FANLR/FAN/FANJ: Input shaft drives the fan to dissipate heat; The heat dissipation effect significantly decreases when the input speed is less than 900rpm; The fan cover cannot be removed; Keep the grille clean.

Independent cooling unit

MCRW (Oil Water Cooling): Built in electric pump, 60 μ m filter, oil-water heat exchanger, pressure switch, temperature control, water circuit solenoid valve; Provide flow and power parameters for various models; Inlet water temperature ≤ 20 ℃, maximum water pressure 10bar; Low temperature shutdown requires emptying the water circuit to prevent freezing and cracking.

MCRA (oil air cooling): oil pump+air-cooled radiator; Pressure switch, temperature control; Reserve a ventilation space of ≥ 1m around the radiator.

SR built-in water-cooled coil: integrated inside the box; Maximum water pressure of 8 bar, distinguishing the minimum water flow rate of the machine base; It is recommended to install a temperature control valve and only allow cooling water to flow in at 70 ℃; Low temperature emptying water circuit antifreeze.

HE oil heater: used in low-temperature environment, 220VAC; Default temperature control is 25 ± 5 ℃; The heating element must be completely immersed in oil before it can be powered on; Cannot be heated continuously for a long time to prevent oil carbonization; The low temperature of the forced lubrication system pipeline also requires heat tracing.

Lubrication System

Splash oil bath lubrication: most standard configurations; High/low-speed boundary conditions need to be evaluated.

Oil lubrication: Some V5/B6 attitude high position bearings use regular grease replenishment cycles.

OP mechanical driven forced lubrication pump; MOP motor driven oil pump:

MOP is an independent motor oil pump, equipped with a 60 μ m filter and a minimum pressure switch (alarm threshold of 0.5 bar);

The oil pump must be started and run for a few minutes before the gearbox can be started; Delayed shutdown of oil pump after shutdown;

Provide power and current parameters of MOP oil pump motors for the full range of HDP/HDO.

Reversing device A-CW/A-CCW

Centrifugal wedge block one-way locking; Prevent load reversal; The operating speed must be greater than the minimum disengagement speed n1min to ensure centrifugal disengagement of the wedge block, otherwise it will wear and damage quickly; Order specifying free rotation direction CW/CCW; You can contact the manufacturer to modify the rotation direction.

Other attachments

F... L/F... R fixed flange, FM sleeve flange: provide bolt torque for each machine base flange;

Sealing VS, DS, DVS, TK: Fluororubber oil seal, labyrinth seal TK for high dust;

TG bimetallic temperature control switch sensor, OLG oil level sensor;

DW dry well seal: prevents oil from leaking outward along the axis;

TA torsion arm: capable of withstanding counter torque;

Painting and other accessories.

Coating

Pay attention to protecting the sealing surface of the factory coating; On site painting should cover the oil seal lip.

Lubrication Chapter

Distinguish between EP extreme pressure mineral oil and synthetic oil; ATEX can only use synthetic oil;

Long term storage of anti rust liquid in SL does not equal working oil, and it should be emptied and flushed before operation;

List of compatible lubricants; Oil filling gauges for each installation posture; Tightening torque for various specifications of oil plugs and vent plugs; DBF breathing filter with desiccant.

User made axis

Provide design recommendations for fitting tolerances, materials, key slots, and anti micro corrosion treatment.

Preparation for gearbox operation

The gearbox cannot be powered on separately and must be integrated into a complete machine that meets mechanical instructions;

Check the installation posture and oil level; The ventilation plug is unobstructed; The wiring of the cooling unit is correct; Complete grounding; Complete protective cover;

MCR independent cooling unit is debugged separately.

Maintenance

Before maintaining all operations: cut off all power and lock the equipment; The high-temperature box is fully cooled; Clearing flammable and explosive media in explosion-proof areas; Only original spare parts are allowed; Replace the gasket every time it is disassembled and installed; Apply thread sealant to the threads according to regulations; Apply lubricating grease to the lip of the oil seal assembly.

Routine inspection: oil level, leakage, noise, vibration, shell temperature; Check the ventilation plug;

Routine maintenance cycle: distinguish between intermittent and continuous working conditions;

Maintenance of independent cooling unit MCRW/MCRA: replacement of filter element; Heat sink/coil descaling; Check the pressure switch and temperature control; Waterway descaling and antifreeze;

Oil level inspection method; Oil change operation steps;

B3/B6 Attitude Input End Bearing Lubricating Grease Regulations;

The box should be cleaned and high-pressure water flushing is prohibited.

Disassembly

Disassembly steps for hollow output shaft with key;

Dismantling of shrink disc hollow shaft: Gradually loosen the shrink disc bolts diagonally, use the top screw hole to exit the gearbox, and prohibit violent tapping.

Troubleshooting

Gearbox body failure: abnormal noise, overheating, oil leakage, vibration, insufficient torque; 8.2 Independent cooling unit failure: oil pump not starting, pressure alarm, insufficient cooling; The manual provides information on possible causes and corresponding solutions.

Scrap Disposal

Dismantling and scrapping of gearbox; Waste oil, rubber parts, and metal components should be classified and disposed of according to local environmental regulations, and direct discharge of pollutants into the environment is prohibited.