Bonfiglioli VF-W series ATEX worm gear reducer

Bonfiglioli VF-W series ATEX worm gear reducer

General Information

1.1 Symbols and Units of Measurement

The manual defines the parameter symbols used for all selection calculations:

Load category: (A_n) allows axial thrust load (R_c ) Calculate radial load (R_n ) allows radial load;

Torque power: (M2) The required output torque for the application (M2) rated output torque (M2) Calculate torque (P_ {r1} ) application requires input power (P_ {n1} ) rated input power;

Operating condition coefficient: (f_s ) Usage coefficient (f_ {TP} ) environmental temperature correction coefficient;

Kinematics: Transmission ratio (i=n1/n2 ); Speed n; Intermittent rate I; Number of starts per hour (Z_r ); Dynamic efficiency ( eta-d );

Inertia: (J-c ) Load inertia (J'm ) motor inertia Inertia of the reducer; Quality Acceleration Factor (K=Jc/Jm );

Safety factor: (S=M2/M2); Environmental temperature, working time, and resting time.

1.2 Introduction to ATEX Directive

Definition of Explosive Environment (2014/34/EU): Combustible gases/vapors/mists/dust mixed with air at atmospheric pressure, and flame diffusion after ignition; Potential explosive environment refers to working conditions where explosive mixtures may form under normal conditions.

regional division

Table

Gas area G Dust area D Environmental frequency Hazard level

0 20 Persistent/Long term Existence Permanent

1 21. Occasional potential issues during normal operation

2 22 rarely appears, appearing only briefly and mildly

This series of reducers is suitable for zones 1 and 2 (gas), zones 21 and 22 (dust), and does not support zone 0/20. It cannot be used in Class I mining environments.  

Equipment group

Group I: Underground mines with biogas/combustible dust present, this product is not suitable;

Group II: Other potential explosion sites, products only support Categories 2 and 3 (2G/3G gases; 2D/3D dust);

Protective labels: Ex h Gb, Ex h Db, Ex h Gc, Ex h Dc.

Legal effect: Starting from April 20, 2016, 2014/34/EU replaced the old 94/9/EC; the ATEX directive takes priority over the Machinery Directive 2006/42/EC and specifically deals with explosion risks; Mechanical instructions handle other mechanical safety risks.

Declaration of conformity: Product compliance certificate must strictly follow the user manual, which can be downloaded from the official website; The certificate becomes invalid if the usage conditions are not followed.

1.3 Use, Installation, and Maintenance

Complete storage, handling, and usage instructions can be found in the user installation and maintenance manual; The manual needs to be kept near the equipment; The manufacturer reserves the right to modify the manual.

1.4 Equipment selection

1.4.1 Selection Process

Determine the usage factor (f_s ) based on the load type K (K1 uniform, K2 moderate impact, K3 strong impact), hourly startup frequency, and daily operating hours;

Calculate the required power of the motor shaft: (P_ {r1}= frac {M {r2} cdot n2} {9550 cdot eta-d} ); The efficiency of the worm gear decreases with the increase of the transmission ratio, and the efficiency curve chart is attached to the manual.

1.4.2 Selection of IEC motor flange reducer

Determine the usage coefficient (f_s );

Check if the sample power meter satisfies (Pn_1 ge P_ {r1} times f_s );

Rated power of motor (P_1 ge P_ {r1} );

Verify the safety factor (S= frac {P_ {n1}} {P_1} ge f_s ).

1.4.3 Selection of Solid Input Shaft Reducer

Calculate the torque (M2=M2 times f_s times f_TP ) (f_ {TP} ) is the temperature correction coefficient, and the higher the ambient temperature, the greater the impact and the larger the coefficient;

Ensure rated output torque (M2} ge M2} ).

1.4.4 Verification after selection

The maximum allowable instantaneous peak torque is 200% (M2} ), and a torque limiter is required for exceeding the tolerance;

Radial load: The actual radial load must be less than the allowable radial load of the sample (R_n ); When the load application point is not on the axis centerline, it needs to be converted;

Axial thrust load: Verify that it does not exceed the allowable thrust.

1.4.5 Mandatory operating conditions for ATEX models

Environmental temperature: -20 ℃~+40 ℃;

Installation must be carried out in accordance with the nameplate specifications, and any changes to the installation posture must be approved in writing by the manufacturer; Prohibit arbitrary tilting installation;

The maximum speed of the supporting motor is not allowed to exceed 1500min ⁻¹;

When driving the motor with a frequency converter, the frequency converter cannot exceed the upper limit of 1500rpm, cannot overload the reducer, and the motor itself must be adapted to the frequency conversion working condition;

It is necessary to fully comply with all installation and maintenance requirements in the user manual.

1.4.6 Usage Factor (f_s )

(f_s ) Comprehensive daily running time, hourly startup frequency, impact level K1/K2/K3; Retrieve through charts; Select the K curve for the quality improvement acceleration factor (K=J-c/Jm); Even if the requirements of (f_s ) are met for lifting applications, additional safety considerations are still necessary.

Worm Gear Unit for Potential Explosive Environments

2.1 Structural characteristics of ATEX explosion-proof reducer

Check the oil level with the oil plug; Add long-lasting lubricating oil to the factory according to the ordered installation posture; The V5/V6 installation position and B14 flange version of W110 do not require oil injection at the factory;

Standard configuration fluororubber sealing ring; No plastic components; The nameplate indicates the equipment category and explosion-proof protection type.

Version 2.2 and Installation Location

VF series: versions A, N, V, P, F, FA, U; Installation positions B3/B6/B7/B8/V5/V6, provide installation diagram;

W series: versions U, UF, UFC, FCR; Installation positions B3/B6/B7/B8/V5/V6.

2.3 Order Number Rules

Example of numbering structure: W 75 U D30 60 HS-B3-2D3D-130

Series (W/VF) - Seat Number - Version - Output Shaft Hole - Speed Ratio - Input Configuration (HS Solid Shaft/IEC Flange) - Installation Location - Explosion proof Options Explosion proof Options Description: 

| Options | Applicable Area | Temperature Limit |

| 2D3D-160 | Dust 21/22 Zone | Shell Surface ≤ 160 ℃ | 

| 2D3D-130 | Dust 21/22 Zone | Shell Surface ≤ 130 ℃ | 2G3G-T3 | Gas 1/2 Zone | T3, up to 200 ℃ | 

| 2G3G-T4 | Gas 1/2 Zone | T4, up to 135 ℃|

2.4 Lubrication

Lubricating oil model: SHELL OMALA S4 WE 320 synthetic oil;

Except for W110 special working conditions, pre filled lubricating oil is provided at the factory, and the oil quantity matches the installation position ordered; Sealed oil plugs for transportation must be replaced with vent plugs before on-site operation;

Provide oil filling gauges for each base and installation position of VF30-W110; W110 does not need to be refueled at the factory in V5/V6 and B14 flange states, but needs to be refueled on site.

2.5 Allowable cantilever load (radial&axial)

Radial load: External transmission (sprocket, pulley) generates radial force; The calculated load (R_c ) must be ≤ the allowable cantilever load (R_n ); When the load is not at the midpoint of the axis, the allowable load needs to be converted based on distance; Provide the geometric parameters of a/b for each VF/W machine base.

Axial thrust load

When there is a rated radial load at the same time: (A_ {n1}=0.2 cdot R_ {n1} ) (A_{n2}=0.2 cdot R_{n2})

When there is no radial load, the allowable thrust can reach 50% of the rated cantilever load;

The thrust load is too large, and it is necessary to contact the manufacturer for special verification.

2.6 Performance parameter table of reducer

Provide the performance of all speed ratios for VF30, VF44, VF49, W63, W75, W86, and W110:

(n2 ) Output speed ( eta_2 ) theoretical efficiency ( eta-d ) dynamic efficiency;

(M2) rated output torque (P_ {n1} ) rated input power (R_ {n1} ) allows radial load on the input shaft (R_ {n2} ) allows radial load on the output shaft;

Simultaneously indicate the explosion-proof options available for the corresponding speed ratio (2G3G-T3/T4, 2D3D-130/160).

2.7 Motor adaptation

IEC motor adaptation table: only represents geometric compatibility, selection still needs to follow the selection steps in Chapter 1; List the B5/B14 flange motors that can be adapted to P56~P132 for each machine base.

Non IEC standard motor: HS solid input shaft and customized flange can be configured; Provide selection of input shaft aperture and flange outer diameter. After selection, the power safety factor must be verified, and S must not be less than 0.9.

2.8 Rotational inertia

Provide the rotational inertia of the high-speed end with different IEC flanges and HS solid input shafts at various machine bases and speed ratios, denoted as (J-R ) in units of (10 ^ {-4} text {kg · m} ^ 2 ), for calculating the acceleration factor K.

2.9 External installation dimensions

Complete drawings and dimension tables: VF30/VF44/VF49, W63/W75/W86/W110; Coverage:

IEC flange B5/B14 input flange size;

Output the size of the hollow shaft keyway;

The shaft extension and flange dimensions of the HS solid input shaft version;

All external dimensions of the shell, foundation, and flange in each version.

2.10 Attachment

Plug in output shaft: Each machine base is equipped with a solid output shaft, including shaft diameter, keyway, total length dimension table, and engineering drawings;

VF series interchangeable foot kit KA, KV: foot installation dimensions.

2.11 User made matching shaft (Customer's shaft)

The shaft material requirements for the customer's supporting drive equipment are high alloy steel; Provide recommended dimensions, keyways, chamfers, and tolerances for the mating axis; Suggest adding an axial locking structure.