BONFIGLIOLI VF 44, VF 150, VF 49, VF 210, VF 185 Installation, Operation And Maintenance Manual
...
VF, W series
Installation, Operation
and Maintenance Manual
INCLUDED
USER
MANUAL
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
1 - GENERAL INFORMATION ................................................................................................................ 2
1.1 - PURPOSE OF THIS MANUAL ....................................................................................................................2
1.2 - GLOSSARY, TERMS AND SYMBOLS ........................................................................................................2
1.3 - REQUESTING TECHNICAL ASSISTANCE ................................................................................................3
1.4 - MANUFACTURER’S LIABILITY .................................................................................................................3
1.5 - SUPPLEMENTARY INFORMATION............................................................................................................3
2 - SAFETY INFORMATION ................................................................................................................... 4
2.1 - SAFETY STANDARDS ................................................................................................................................4
3 - TECHNICAL INFORMATION ............................................................................................................ 7
3.1 - EQUIPMENT IDENTIFICATION ................................................................................................................7
3.2 - DESCRIPTION OF THE EQUIPMENT ......................................................................................................8
3.3 - CONFORMITY ...........................................................................................................................................8
3.4 - OPERATING LIMITS AND CONDITIONS .................................................................................................9
3.5 - ALLOWED TEMPERATURE LIMITS ......................................................................................................10
4 - HANDLING AND TRANSPORT ...................................................................................................... 11
4.1 - PACKAGING SPECIFICATIONS ...............................................................................................................11
4.2 - HANDLING INSTRUCTIONS ....................................................................................................................12
4.3 - STORAGE ..................................................................................................................................................16
5 - INSTALLATION ...............................................................................................................................17
5.1 - INSTALLING THE GEARBOX ...................................................................................................................17
5.2 - ANCHORING THE TORQUE ARM ............................................................................................................21
5.3 - INSTALLING AN ELECTRIC MOTOR WITH AN IEC STANDARD FLANGE ...........................................21
5.4 - INSTALLING MOTORS ON VFR WORM GEARBOXES ..........................................................................22
5.5 - INSTRUCTIONS FOR THE ASSEMBLING OF THE LIMIT-SWITCH DEVICE (RVS)
ONTO GEARBOX ......................................................................................................................................23
5.6 - CALIBRATING THE TORQUE LIMITER SLIPPING TORQUE .................................................................25
5.7 - INSTALLING CONNECTING ELEMENTS ................................................................................................25
5.8 - PAINTING AND SURFACE PROTECTION ...............................................................................................26
5.9 - LUBRICATION ...........................................................................................................................................27
5.10 - PREPARING CUSTOMER SHAFTS .........................................................................................................50
5.11 - PUTTING THE GEARBOX INTO SERVICE ..............................................................................................51
General information
For the installer
6 - MAINTENANCE ............................................................................................................................... 54
6.1 - CHECKING OPERATIONAL EFFICIENCY ...............................................................................................55
6.2 - ROUTINE MAINTENANCE ........................................................................................................................56
6.3 - OIL CHANGES ..........................................................................................................................................58
6.4 - CLEANING .................................................................................................................................................59
7 - REMOVAL ........................................................................................................................................ 60
7.1 - REMOVING A MOTOR WITH AN IEC STANDARD FLANGE ..................................................................60
7.2 - REMOVING A GEARBOX WITH HOLLOW OUTPUT SHAFT WITH KEYWAY .......................................61
8 - TROUBLESHOOTING ..................................................................................................................... 62
9 - DISPOSING OF THE GEARBOX .................................................................................................... 63
Revisions
The revision list for this manual is given on page . The most recent version of this manual is available from www.bonglioli.com.
IOM Manual VF-W_ATEXgb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
64
For the user
For the
disposer
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1 GENERAL INFORMATION
1.1 PURPOSE OF THIS MANUAL
This manual has been prepared by the manufacturer in order to provide information regarding the safe
transport, handling, installation, maintenance, repair, disassembly and disposal of the gearbox/gearmotor.
All necessary purchasing and design information is provided in the sales catalogue. Follow good
engineering practices, read the information in this manual thoroughly and apply it rigorously.
Information on any electric motor coupled to the gearbox must be obtained directly from the
motor’s own installation, operation and maintenance manual.
Failure to observe the information provided in this manual may result in risks to personal health
and safety, as well as damage to equipment.
This information is originally provided in the manufacturer’s own language (Italian), but may be made
available in other languages to meet legal and commercial requirements.
This manual, along with all other relevant documentation, must be stored by personnel appointed
to do so, in a suitable location, and in such a way that it is always available in good condition for
consultation. In case of loss or damage, request a replacement directly from the manufacturer,
quoting the code of this manual.
This manual reects the conditions prevalent at at the time the gearbox was introduced.
The manufacturer reserves the right to modify, supplement and improve this manual in future, without this
present revision being considered inadequate for that reason.
1.2 GLOSSARY, TERMS AND SYMBOLS
of the most frequently used terms in this manual are explained below to dene their meaning clearly.
Some
Scheduled maintenance: a set of operations required for maintaining the functionality and efciency
of the gearbox. These operations are usually scheduled by the manufacturer, who also establishes the
competences and procedures required.
Unscheduled maintenance: a set of operations required for restoring the functionality and efciency
of the gearbox. These operations are not scheduled maintenance operations. In order to maintain the
proper functioning and safety of the gearbox/gearmotor, we recommend that users have unscheduled
maintenance performed by the manufacturer or by an authorised, specialist service centre. Contact the
manufacturer’s technical assistance service. Failure to comply with this requirement during the warranty
period automatically invalidates the warranty.
Expert maintenance technician: an authorised technician who has the necessary qualications, skills
and mechanical and electrical training to perform scheduled maintenance on the gearbox.
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SYMBOLS:
Particularly signicant sections of the manual and important specications are highlighted by symbols
whose meanings are given below.
DANGER - WARNING
This symbol indicates situations of danger which, if ignored, may result in risks to personal health
and safety.
CAUTION - ATTENTION
This symbol indicates the need to adopt specic precautions to avoid personal injury as well as
damage to equipment.
IMPORTANT
This symbol indicates important technical information.
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
Instructions given in rectangles with a grey background, accompanied by the symbols ,
alongside or above,
refer only to equipment that conforms to the “ATEX” Directive 2014/34/EU.
Instructions marked in this way must only be performed by professionally qualied operators
who are specially trained in the safety precautions required for working in potentially explosive
atmospheres.
Failure to observe these instructions may result in serious safety and environmental risks.
1.3 REQUESTING TECHNICAL ASSISTANCE
For any technical service needs, contact the Manufacturer’s sales network (www.bonglioli.com) quoting
the information indicated on the unit’s name plate, the approximate hours of service, the duty cycle and the
type of defect.
1.4 MANUFACTURER’S LIABILITY
The Manufacturer declines all liability in the event of:
• use of the gearbox/gearmotor in contravention of local occupational health and safety legislation
• incorrect installation, disregard of or incorrect application of the instructions provided in this manual
• electrical power supply defects (for gearmotors and/or gearboxes with electrical devices)
• modications or tampering
• work done on the gearbox by unqualied or unsuitable personnel
The functionality
and safety of the gearbox also depends on the scrupulous application of the instructions
given in this manual, in particular:
• Always operate the gearbox within its operating limits.
• Diligently observe the maintenance schedule.
• Ensure that only trained operators are authorised to inspect and service the gearbox.
• the congurations given in the gearbox catalogue are the only permitted ones
• do not attempt to use the unit in any other way
• the instructions given in this manual do not substitute but rather supplement the provisions of
established safety legislation.
1.5 SUPPLEMENTARY INFORMATION
Additional
information about the gearboxes described in this manual can be obtained from the sales
catalogues, available on the website www.bonglioli.com:
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2 SAFETY INFORMATION
2.1 SAFETY STANDARDS
Read thoroughly the instructions given in this manual and those printed directly on the gearbox,
especially those regarding safety.
●
Personnel appointed to work on the gearbox at any time during its service lifetime must be trained
specically for the purpose, must possess the necessary skills and experience, and must also be
equipped with and trained to work with the appropriate tools and personal protection equipment required
by the safety legislation applicable in the place where the gearbox/gearmotor is installed. Failure to meet
these requirements constitutes a risk to personal health and safety.
●
Keep the gearbox at its maximum efciency by scrupulously following the maintenance schedule. Proper
maintenance ensures maximum performance, extended service life and continued compliance with
safety regulations.
●
When working on the gearbox in areas that are difcult to access or hazardous, ensure that adequate
safety precautions have been taken for yourself and others in compliance with applicable legislation on
occupational health and safety.
●
All maintenance, inspection and repairs must only be carried out by an expert maintenance technician
fully familiar with the attendant hazards. It is therefore essential to implement operating procedures which
address potential hazards and their prevention for the entire machine in which the gearbox is installed.
Expert maintenance technicians must always work with caution and in observance of applicable safety
standards.
●
When working on the gearbox, wear the clothing and personal protective equipment specied in the
manufacturer’s instructions or required by the safety legislation applicable in the place where the gearbox
is installed.
●
Use only the lubricants (oil and grease) recommended by the manufacturer.
●
Do not dump polluting materials into the environment. Dispose of all such materials as stipulated by
applicable legislation.
●
After changing lubricants, clean the gearbox and the walk-on surfaces around the work area.
●
If the gearbox has to be serviced in a poorly lit area, use additional lamps and ensure that the work is
done in compliance with all applicable safety legislation.
●
During functional testing at the manufacturer’s premises, the acoustic pressure measured under full load
at a distance of 1 m from the gearbox and at 1.6 m above ground level, without vibration, was less than
85 dB(A). The gearbox is a component. The constructor of the plant or machine in which the gearbox is
installed must therefore measure the level of noise emitted by the complete machine as required by the
Machinery Directive 2006/42/EC. The vibrations produced by the gearbox do not constitute a health risk
for personnel. Excessive vibration may be the result of a fault, and should be immediately reported and
eliminated.
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If a gearbox must be serviced in a potentially explosive atmosphere, the service engineer must
rst switch off power to its motor to ensure that it is out of service, and must take all necessary
precautions against it being accidentally switched on again and against connected parts moving
without warning.
All additional environmental safety precautions must also be taken (e.g. elimination of residual gas
or dust, etc).
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
Unless they have backstop devices, gearboxes may reverse direction. If there is any risk of
uncontrolled movement occurring in the event of a power failure (for example in load lifting
applications), measures must be put in place to prevent such movement occurring (for example by
using motors with brakes that engage automatically if the power fails).
If the gearbox is installed in a position that cannot be reached from the oor, the constructor of the
plant or machine in which it is installed must provide, as necessary, suitable means for accessing
a position from which the gearbox can be serviced.
The user is responsible for using the products recommended for the installation and maintenance
of the gearbox in an appropriate manner and in accordance with the Manufacturer’s instructions.
Before putting the gearbox into service, the user must ensure that the plant in which it is installed
complies with all applicable directives, especially those regarding health and safety at work.
The constructor of the plant or machine in which the gearbox/gearmotor is installed must protect all
rotating parts to prevent personnel coming into accidental contact and incurring a risk of crushing,
cutting or entanglement, especially if the gearbox operates automatically and in an accessible area.
●
Do not use high pressure jets of water to clean gearboxes unless they are EP versions with a seal ring
and reinforced shield.
●
Only perform work on the gearbox when it is at a standstill.
●
Protect the electric motor against accidental startup (e.g. by padlocking the main power switch or
removing the power fuses). For this purpose, also afx a notice to the motor indicating that work is in
progress on the gearbox.
●
Do not perform welding work on the gearbox. Do not use the gearbox as an earthing post for welding
operations because this could damage or destroy parts of the gear teeth and bearings.
●
Switch off the motor immediately if any changes are noticed in the normal functioning of the gearbox,
such as an abnormal increase in operating temperature or abnormal running noise.
●
If the gearbox is to be installed in a plant or machine, the constructor of the said plant or machine
is required to include the prescriptions, instructions and descriptions contained in this manual in the
operating manual for the plant or machine.
●
If the gearbox is installed in situations that are particularly hazardous to personal safety, or that could
cause serious damage to equipment, or that involve high inertial loads, vibrations, etc., such as:
- suspended installations
- motors supported exclusively by the gearbox
- output shaft with shrink disc oriented downwards
suitable safety devices, such as harnesses, safety chains and restraining systems, etc. must be
installed.
Depending on operating conditions, the outer surfaces of the gearbox may reach very high
temperatures. Risk of burns!
When draining spent oil as part of an oil change, always bear in mind that hot oil can cause serious
burns!
If the gearbox is equipped with a vent plug that incorporates a pressure relief valve, wait for the
oil in the gearbox to cool before removing the plug, and beware of possible jets of oil during
transport, lifting, installation, adjustment, operation, cleaning, maintenance, repair, dismantling
and scrapping.
Wait for the gearbox to cool before inspecting it.
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IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
3 TECHNICAL INFORMATION
3.1 EQUIPMENT IDENTIFICATION
The gearbox bears the following identifying nameplate. The nameplate provides essential information and
specications for correct and safe use. The designation of the gearbox is explained in the sales catalogue.
If the gearbox is supplied tted with a motor (gearmotor), all information regarding the motor itself is
provided in the motor’s own manual.
Nameplate information
Gearbox type
Product code
Month / Year of manufacture
Mounting position
Gear ratio
Nameplate data for ATEX-specied
gearboxes
N
Name of manufacturer
Gearbox type
Gear ratio
Product code
Transmissible torque [Nm] at n
Mounting position
Month / Year of manufacture
Maximum drive speed
Deposited certicate no.
Temperature class, or
maximum surface temperature
= 1400 rpm
1
Maximum surface temperature
Name of manufacturer
CE - Ex Mark
●
Environmental limits (ambient temperature range: - 20°C to + 40°C).
● T
emperature class: T4 for 2G and 135°C for 2D. Some types of gearbox, as specied in
the catalogue, are exceptions to this rule and are marked temperature class: T3 for 2G or
160°C for 2D.
●
Notied body with whom the technical le has been deposited.
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Legibility of the nameplate
The nameplate and the information thereon must be legible at all times. The nameplate should therefore
be cleaned from time to time.
Always quote the identifying data on the nameplate in all correspondence with the manufacturer,
when ordering spare parts, requesting information or arranging technical assistance.
3.2 DESCRIPTION OF THE EQUIPMENT
This
gearbox has been designed and made for integration in an assembly of rigidly interconnected parts
or mechanisms conceived to perform a specic application in which power may be provided by an electric
motor.
Depending on the requirements of the application, the gearbox can be supplied in a variety of versions and
congurations.
The gearbox is designed to satisfy specic requirements in the mechanical, chemical, agricultural and food
industries, etc.
The manufacturer offers a range of accessories and optional variants to make gearboxes as versatile as
possible. For further technical information and descriptions, refer to the relevant catalogue.
The user is responsible for using the products recommended for the installation and maintenance of the
gearbox in an appropriate manner and in accordance with the manufacturer’s instructions.
SAFETY SPECIFICATIONS FOR ATEX-COMPLIANT GEARBOXES
• Use only synthetic lubricants (oil and grease).
• Use only uoroelastomer seals.
• Apply thread lock to all external bolts and plugs.
• Fit vent plugs with anti-intrusion valves.
• Fit oil seals with dust trap to the output shaft.
• Ensure that all components and products can resist temperatures above the maximum rated operating
temperature.
• Ensure that there are no metal parts in sliding contact outside the gearbox.
• Ensure that plastic parts cannot accumulate an electrostatic charge, or are shielded if they can.
• Install irreversible heat sensors.
• Installations in zones 21 and 22 require the user to draft and implement a regular cleaning schedule for
all surfaces and recesses to avoid the build-up of dust.
• To prevent dust building up in difcult to access areas, sealing devices, mounting anges and external
threads must be provided at all mobile couplings.
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3.3 CONFORMITY
All gearboxes or
gearmotors (when supplied with motor) are designed as state of the art devices in
compliance with the provisions of applicable Essential Health and Safety Requirements.
All gearmotor motors conform to the provisions of the Low Voltage Directive 2006/95/EC and the
Electromagnetic Compatibility Directive 2004/108/EC.
If specied for use in potentially explosive atmospheres, gearboxes must also be designed and constructed
to conform with the Essential Health and Safety Requirements (EHSR) of Annex II of the ATEX Directive
2014/34/EU and must conform to the following classication:
●
Equipment group: II.
●
Category: Gas 2G – Dust 2D.
●
Zone: Gas 1 – Dust 21.
●
Temperature class: T4 for 2G and 135°C for 2D.
●
Some types of gearbox, as specied in this catalogue, are exceptions to this rule and are marked
temperature class T3 for 2G or 160°C for 2D.
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
3.4 OPERATING LIMITS AND CONDITIONS
The applications permitted by the Manufacturer are the industrial applications for which the gearbox
has been designed.
Changes to the gearbox version or mounting position are only permitted if previously authorised by the
manufacturer’s technical assistance service.
Failure to obtain this authorisation invalidates the ATEX certication.
Refer to chapter “ALLOWED TEMPERATURE LIMITS” for the optimum ambient conditions.
The gearbox may not be used in areas and environments:
●
with highly corrosive/abrasive vapours, smoke or dust
●
In direct contact with loose food products.
Do not use the gearbox/gearmotor, if not explicitly intended for the purpose, in a potentially
explosive atmosphere or where the use of explosion-proof equipment is specied.
The maximum surface temperature specied on the nameplate refers to measurements made in
normal ambient and installation conditions.
Even minimal variations in these conditions (e.g. smaller mounting compartments, proximity of
external equipment to the gear unit that generates heat and not provided by the manufacturer) may
have a signicant effect on heat dissipation.
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3.5 ALLOWED TEMPERATURE LIMITS
t
a
tau
min
-30°C -10°C
t
au Max
+50°C +40°C
t
as min
-40°C -10°C
t
as Max
+50°C +50°C
t
s
t
s min
-25°C -10°C
t
sc min
-10°C -5°C
t
s Max
+100°C +100°C (@)
t
o
t
o Max
+95°C +95°C (@)
Description / Condition
Maximum oil temperature during continuous operation
Oil temperature
Value (*)
Synthetic
Oil
Mineral
Oil
Surface temperature
Minimum gearbox surface temperature starting with partial load (#)
Minimum gearbox surface temperature starting with full load
Maximum casing surface temperature during continuous operation
(measured next to the gearbox input)
Ambient temperature
Minimum operating ambient temperature
Maximum operating ambient temperature
Minimum storage ambient temperature
Maximum storage ambient temperature
Symbols
(*) =
For further information about minimum and maximum values of different oil viscosity refer to the table “Se-
lection of the optimal oil viscosity” on the catalog available on www.bon glioli.com
(@) = Continuous operation it is not advised if ts and to range is 80°C to 95 °C.
(#) = For full load start-up it is recommended to ramp-up and provide for greater absorption of the motor.
If needed, contact Bon glioli Technical Service.
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IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
4 HANDLING AND TRANSPORT
Personnel authorised to handle packages must take all necessary precautions to safeguard their
own safety and that of all other persons involved.
4.1 PACKAGING SPECIFICATIONS
Unless otherwise agreed, standard packaging, if supplied, is not rainproof. This type of packaging is
intended for shipping by ground and not by sea, and for storage in areas which are under cover and
not humid. The material can be stored in suitable conditions for a period of two years under cover at
a temperature within the limits speci ed in the chapter “ALLOWED TEMPERATURE LIMITS” and at a
relative humidity not in excess of 80%. Storage in all other conditions requires speci c packaging.
In order to facilitate handling, heavy packages can be loaded on pallets.
The most frequent types of packaging are shown in the gures below.
Standard carton pallet packaging.
Horizontal packaging
Special wooden crates.
Vertical packaging
On receipt of the gearbox, make sure the delivery corresponds to the purchase order and that it is
not damaged or faulty in any way. Report any problems to the Manufacturer’s sales network.
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Dispose of packaging materials as stipulated by applicable legislation.
4.2 HANDLING INSTRUCTIONS
Handle packages according to the instructions provided by the manufacturer on the packages
themselves, if present. If the weight and shape of the packages makes manual handling unfeasible,
use special equipment to avoid damage and injury. Personnel authorised to use lifting and moving
equipment must be trained and experienced in the operations required in order to avoid risks to
themselves and other persons.
4.2.1
Moving the packages
●
Prepare a suitable, delimited area with a level oor or surface for unloading the packages.
●
Prepare the equipment required for handling the package. The lifting and handling equipment (e.g. crane
or lift truck) must be of adequate capacity for the weight and size of the load, taking into account its
attachment points and centre of gravity. If required, this information is indicated on the package itself.
Harness heavy packages with chains, belts and steel ropes after checking that they are suitable for the
weight of the load, which is always specied.
●
When handling the load keep it level horizontally to avoid tipping and instability.
4.2.2 Moving the equipment
All the following operations must be carried out with the greatest care and attention to avoid sudden
movements during the handling of the gearbox.
When lifting the gearbox, only use accessories such as eyebolts, shackles, safety hooks, straps,
ropes and hooks, etc. that are fully certied and adequate for the load to be lifted.
Do not use eyebolts on the motor to lift gearmotors.
Miscellaneous accessories (e.g. connecting anges, etc.) and/or motors coupled to the gearbox
may signicantly alter the centre of gravity and impair stability. Use an additional lifting point in
such cases, if necessary.
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During lifting operations, the load must not be allowed to swing beyond an arc of ± 15°.
If greater swinging movements occur during movement, stop and repeat the operations for the
lifting system adopted.
To rotate the gearbox, use the same attachment points used to lift it and proceed as instructed for
lifting. Rotate the gearbox as near as possible to a supporting surface. Pay special attention to
the location of the centre of gravity to prevent the load from becoming unbalanced as it is being
rotated. Lifting gear must be attached in such a way that it cannot slip off or move, as this could
cause the load to fall. This is especially important if the gearbox is being rotated using slings or
ropes, since these are particularly prone to slipping off their attachment points.
When manually lifting small size gearboxes (weighing less than 15 kg), always wear suitable
clothing as well as gloves and safety footwear.
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
●
Identify the attachment points for lifting the gearbox, as shown in the drawings.
●
Prepare the gearbox for lifting by attaching straps, hooks, etc. to its attachment points, or alternatively
use a pallet for moving the load. When using a crane, rst lift the gearbox vertically out of its packaging.
●
If using a fork lift or pallet truck, remove the packaging and insert the forks at the positions provided.
●
Lift the load very slowly and to a limited height above the ground, and check that it is stable.
●
Move the gearbox to the unloading area and lower it gently into position, taking care not to cause sudden
oscillations while moving it.
The following pages illustrate in detail the different lifting methods to be adopted for the gearbox series,
sizes and congurations described in this manual. The most suitable solution for the safe lifting and moving
of each product is shown.
Legend:
Type of lifting Manual With mechanical lifting equipment
Symbol M A B
Approx. weight ≤ 15 kg > 15 kg
Requirement —
Recommended method for
positioning
Warning — The load may be unstable
Slide the lifting ring to align it with
the load’s centre of gravity as
shown in the diagrams below.
Solution —
Lock the ropes below the ring with
a cable clamp or similar device to
prevent them from sliding, then lift
the load.
Observe all precautions regarding
the handling of loads.
Recommended method for
moving and positioning
The load may sway or
oscillate
Stabilise the moving load
by hand.
Observe all precautions
regarding the handling of
loads.
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VF Series
Strap and ring
Rope and hooks
Open strap
and eye-bolts
VF 27
VF 30
VF 44 VFR 44
VF 49 VFR 49
VF 130 VFR 130
VF 150 VFR 150
VF 185 VFR 185
VF 210 VFR 210
VF 250 VFR 250
Shackle
(for use with strap)
Safety hook
(for use with rope)
Eye-bolt (already present
on
VF130...VF250
M
A - B B A - B
Lift manually
(weight ≤ 15 kg)
Lift according
to drawing A
Lift according
gearboxes)
to drawing B
Maximum tilt permitted during
movement: 15°
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IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
W Series
Strap and ring
Rope and hooks
Open strap
and eye-bolts
W 63 WR 63 M
W 75 WR 75
W 86 WR 86
W 110 WR 110
Shackle
(for use with strap)
Safety hook
(for use with rope)
Eye-bolt
IOM Manual VF-W_ATEXgb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
A - B
B A - B
Lift manually
(weight ≤ 15 kg)
Lift according
to drawing A
Lift according
to drawing B
M
Maximum tilt permitted during
movement: 15°
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4.3 STORAGE
Place the gearbox/gearmotor on a stable base and make sure that there is no risk of it moving or
falling off.
The following recommendations should be followed when storing the gearbox/gearmotor.
1. Do not store the unit in excessively humid conditions or where it is exposed to the weather (i.e. outdoors).
2. Avoid excessive variations in temperature as this can cause condensation inside the gearbox and its
accessories.
3. Do not place the gearbox directly on the ground.
4. Store the packaged gearbox (if allowed) in accordance with the instructions on the packaging itself.
If the gearbox/gearmotor is stored temporarily outdoors it must be protected to ensure that humidity
and foreign matters cannot penetrate to the interior.
If the gearbox is to be stored for more than 6 months, the following additional precautions must be taken.
5. Coat all external machined surfaces with a protective anti-corrosion product such as Shell Ensis SX (or
a product with similar properties and application range). Check the surfaces regularly and re-apply the
protective coating as necessary.
6. Fill the gearbox with lubricating oil and replace any vent plugs with blind plugs. This operation does not
apply to gearboxes that are lubricated for life (see the “LUBRICATION” section).
PRECAUTIONS TO BE TAKEN WHEN PREPARING GEARBOXES FOR SERVICE AFTER STORAGE.
Thoroughly clean the output shaft and external surfaces to remove all rustproong products, contaminants
and other impurities (using a standard commercial solvent). Do this outside the explosion hazard area.
Do not allow solvent to come into contact with seal rings as this may damage them and cause them to leak.
If the oil or protective product used during storage is not compatible with the synthetic oil required for
service, clean out the inside of the gearbox thoroughly before lling with the service oil.
Storage for periods of over 1 year reduces the service life of bearing grease. Bearing grease must be
synthetic.
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IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
5 INSTALLATION
5.1 INSTALLING THE GEARBOX
All phases of installation and maintenance must be taken into consideration from the machine
design stage. Design personnel must, if necessary, implement a safety plan to protect the health
and safety of all persons directly involved and to ensure the rigorous application of all relevant
legislation.
It is essential for impact and stress to be avoided during the installation process.
Before installing a gearmotor, also refer to the instructions contained in the installation and user manual
for the electric motor.
Before installing the gearbox:
1. Drain out the oil used for storage if it is not the same as the oil used for normal functioning, and ush
the inside of the gearbox out thoroughly (see the “LUBRICATION” section in this manual).
2. Carefully remove all packaging and protective coatings from the gearbox suitable solvents. Take
special care when cleaning mating surfaces. Avoid getting solvents on the shaft seal rings.
3. Check that the data on the nameplate correspond to those specied in the order.
4. Ensure that the structure in which the gearbox is to be mounted is sufciently robust and rigid to support
its weight and operating forces. If normal service is likely to involve impacts, extended overloads or
possible seizures, t the necessary hydraulic couplings, clutches, torque limiters, etc..
5. Check that the machine in which the gearbox is to be installed is switched off and cannot be accidentally
started up.
6. Check that all coupling surfaces are at.
7. Check that the shaft/shaft or shaft/ bore are perfectly aligned for coupling.
8. Fit suitable guards to prevent accidental contact with rotating parts outside the gearbox.
9. If the work environment is corrosive for the gearbox or any of its parts, follow the special precautions
required for aggressive environments. Contact the manufacturer’s technical assistance service for
further details.
10. We recommend applying a protective paste such as Klüberpaste 46 MR 401 (or a product with
similar properties and application range) to all key type couplings to ensure optimal coupling
and protection against fretting corrosion. Clean all friction couplings thoroughly but do not
apply any protective pastes to them.
11. Thoroughly clean all other contact surfaces (feet, anges, etc.) and apply a suitable protective product
to them to prevent oxidation.
12. Mechanical organs keyed on to the solid gearbox output shafts must be machined to an ISO H7
tolerance to prevent couplings from seizing and to prevent irreparable damage to the gearbox during
installation. To ensure effective coupling, driven shafts should be machined to the tolerances specied
in the “PREPARING CUSTOMER SHAFTS” section in this manual.
13. In outdoor installations, protect the gearbox and its motor from direct sunlight and inclement weather
by means of canopies or covers. Make sure that the assembly is properly ventilated.
14. Make sure that the casing of the gearbox is connected to the equipotential protection (earth/ground)
circuit of the machine in which it is installed.
15. Evaluate whether accessible surfaces may exceed the temperature limits established in EN ISO
13732-1 on the basis of the gearbox conditions of use and ambient temperatures; if these limits can
be easily reached or exceeded, the surfaces in question must be protected to prevent contact (by
means of guards and/or lagging). Wherever impossible, signs bearing symbol 5041 of IEC standard
60417 “Warning! Hot surfaces” must be displayed in such a way that they are clearly visible to
machine operators (bearing in mind the position and orientation of the gearbox). Refer to chapter
“ALLOWED TEMPERATURE LIMITS” for further details.
Symbol 5041 of IEC standard 60417 “Risk of burns! Hot Parts”
IOM Manual VF-W_ATEXgb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
17 / 64
Proceed as follows to install the gearbox.
16. Place the gearbox in the vicinity of the installation area.
17. Mount the gearbox and secure it to the structure at the xing points provided. Secure the gearbox to the
structure using all the xing points on the relevant mounting (foot or ange).
18. Locate the blind service plug tted for shipping and replace it with the vent plug included in the supply
(if relevant). Refer to the plug diagram in the “LUBRICATION” section of this manual.
19. Tighten the xing bolts to the torque values given in the following table.
(tab 1)
Fixing bolt tightening torque [Nm]
Bolt size
Bolt class Stainless steel
8.8 10.9
+5% /-10% +5% /-5%
M2.5 0.75 — —
M3 1.34 — —
M4 3 4.5 2.1
M5 5.9 8.9 4.2
M6 10.3 15.3 7.3
M8 25.5 37 18
M10 50 73 35
M12 87.3 127 61
M14 138.3 201 150
M16 210.9 314 —
M18 306 435 —
M20 432 615 —
M22 592 843 —
M24 744 1060 —
M27 1100 1570 —
M30 1500 2130 —
M33 1850 2600 —
M36 2350 3300 —
M39x3 3200 4500 —
M42x3 4050 5700 —
18 / 64
In general, 8.8 grade bolts are sufcient for correct installation. Under particularly harsh operating
conditions, grade 10.9 bolts can also be used.
If grade 10.9 bolts are used, make sure that the structure in which they are tted is of adequate strength.
Do not use bolts graded higher than 8.8 to install gearboxes with mounting elements (casing, ange or foot)
made from aluminium.
20. Fill the gearbox with oil or top up as necessary, as instructed in the “LUBRICATION” section in this
manual.
21. Check that all service plugs are tightened to the torque values given in the following table.
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
(tab 2)
Tightening torque [Nm]
Plug/vent thread Pitch (threads per inch)
Plugs with non-metallic
gasket
Plugs with aluminum
or copper gasket
+5%/-5%
1/8” 28 5 10
1/4” 19 7 10
3/8” 19 7 20
1/2” 14 14 30
3/4” 14 14 40
1” 11 25 40
M14x2 2 [mm] 20 —
Installing ATEX-specied gearboxes
• Category 2D gearboxes must be installed in compliance with the provisions of standards EN 1127-1, EN
61241-14 and EN 61241-17. Installation technicians must be fully qualied to work in potentially explosive
atmospheres.
• Installation technicians must be aware of the ATEX classication of the installation area, must understand
the risks associated with potentially explosive atmospheres with particular reference to explosion and re
hazards, and must adopt all necessary safety precautions.
• All maintenance, assembly and disassembly work must be done by specialist personnel outside the
explosion hazard area.
• Check that all accessory components (cables, joints, cable clamps, heat exchangers, etc.) also comply
with the requirements of the ATEX directive. Handle all components with extreme care to avoid altering
their characteristics.
• Remove the sealing bolts from the threaded holes needed to install the gearbox. Take care not to damage
the mating surfaces.
• When installing gearboxes with reaction arms, make sure that no sliding movement is generated between
metallic parts when the gearbox is functioning. If necessary, t non-metallic anti-friction elements
conforming to Directive 2014/34/EU between moving metal parts.
• Do not connect any object with an electrical resistance greater than 10
9
Ω to the gearbox.
• Install guards to prevent hazardous accumulations of dust and liquids at the seals of protruding shafts and
to protect them mechanically.
• The gearbox input speed (or the speed of the motor coupled to it) must not exceed n
=1500 min-1.
1
• When installing a gearmotor with the electric motor arranged vertically with its shaft facing down, the
motor must be covered by a protective canopy.
• The output shaft and any pulleys or other transmission components must be perfectly aligned.
• Only install the gearbox with the motor version and in the mounting position specied in the order. Shaft-
mounted gearboxes can be installed with a tolerance of ± 5° to the theoretical plane of installation.
• If the gearbox is supplied without lubricant it must be installed as it is and only lled with lubricant on
completion of installation.
• Secure the gearbox to a at, vibration-free surface capable of bearing the torsional stresses it produces in
service. Take care not to deform mating surfaces, mounting feet or anges by over-tightening xing bolts.
• Use bolts graded no lower than 8.8 for mounting the gearbox. For heavy duty installations 10.9 grade
bolts can be used. Do not use bolts graded higher than 8.8 to install gearboxes with mounting elements
(casing, ange or foot) made from aluminium. See the “INSTALLING THE GEARBOX” section in this
manual for tightening torque values. To stop mounting bolts becoming loose, apply Loctite 510 (or a
product with similar properties and application range) to the threads of all bolts securing the gearbox to
the machine structure and to the electric motor, also apply it to the threads of all the oil plugs (even on
those eventually removed for oil level check, before their relocation).
• Make sure that overhung and thrust loads and operating torques do not exceed those for which the
gearbox is specied.
• Make sure that the vent plugs and oil level plugs are easy to access for inspection.
• Clean the gearbox thoroughly after installation.
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5.1.1 Gearboxes with solid shafts (input and output)
Do not use hammers or other tools which might damage the gearbox shafts or bearings to t
external parts. Proceed as shown below, following the recommendations given in the “INSTALLING
CONNECTING ELEMENTS” section in this manual:
Bolt (1) and spacer (2) shown above are not included in the supply.
To minimise the loads on the shaft bearings, when mounting transmission mechanisms with asymmetrical
hubs use the con guration shown in diagram (A) below:
1
2
(A)
5.1.2 Gearboxes with hollow output shaft and keyway or with splined hollow output shaft
Proceed as shown in the following diagram to couple gearboxes with a hollow output shaft to solid machine
shafts. See also the “PREPARING CUSTOMER SHAFTS” section in this manual.
20 / 64
The tie bolt (1) and spacer (2) are not included in the consignment.
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
5.2 ANCHORING THE TORQUE ARM
For shaft-mounted solutions, on request, the gearbox can be equipped with a torque arm.
This device comes complete with an anti-vibration bush (included in the supply except with VF 30, VF 44
and VF 49 gearboxes) and is speci cally designed and sized for the purpose. As such it offers the best
possible guarantee of correct functioning for the assembly.
The machine shaft must be able to support the gearbox radially and axially. The torque arm must
t without stress.
The torque bolt must be tted on the side of the gearbox next to the driven machine. Supporting
surfaces should be hardened and tempered (minimum hardness 58 HRC, with case hardening to a
minimum depth of 0.6 mm), smoothed and ground if possible. Nitriding is an alternative treatment
that guarantees a base material capable of resisting compression and scoring.
If safety is at risk and/or maximum reliability is required, install suitable devices to stop the gearbox
rotating or breaking free if the torque arm or machine shaft should break.
5.3 INSTALLING AN ELECTRIC MOTOR WITH AN IEC STANDARD FLANGE
• Thoroughly clean and degrease all the mating surfaces between the motor and the gearbox (shafts and
anges).
• Do not force the surfaces together or use inappropriate tools to couple them. Take care not to damage the
at and/or cylindrical mating surfaces.
• Do not strain the coupling shafts with large thrust or overhung loads.
• To facilitate assembly, use a synthetic oil-based lubricating paste such as Klüberpaste 46 MR 401 (or a
product with similar properties and application range).
• Tighten all the motor/gearbox xing bolts to their prescribed torques. See the “INSTALLING THE
GEARBOX” section in this manual for tightening torque values.
The O-rings on the screws through the anges of P(IEC) version VF and W gearboxes have been
tted only to prevent the screws from falling out during transport.
These O-rings must be removed before the gearboxes are coupled to their motors.
When the gearbox is to be coupled to a standard electric motor conforming to IEC 60072-1, proceed as
follows.
• Apply a layer of sealant such as Loctite 510 (or a product with similar properties and application range)
to the motor/gearbox coupling anges, to the alignment ring and the frontal mating surfaces as shown in
the gure below.
1. Apply Loctite 510 to the at surface of the ange and to the alignment ring.
2. Apply Klüberpaste 46MR401 to the inside of the gearbox input shaft and to the motor shaft.
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21 / 64
3. Seal the join between the gearbox
and the motor with Loctite 5366,
taking care to ll any gaps between
the two anges (e.g. recesses for
decoupling the units).
• With the motor coupled to the gearbox, apply a lm of sealant such as Loctite 5366 (or a product with
similar properties and application range) around the edges of the anges to seal any gaps between their
surfaces.
• If the output shaft is also equipped with a ange, the user must take similar precautions to prevent dust
accumulating in the gaps between the anges or in the vicinity of moving couplings.
5.4 INSTALLING MOTORS ON VFR WORM GEARBOXES
22 / 64
1) Thoroughly clean and degrease the motor shaft and mating surfaces of the pinion (1) and bushing (2).
2) Check the motor shaft tolerance meets the following spec cations:
(tab 3)
Shaft bore - Ø [mm] Tolerance
11…28 j6
38…48 k6
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
3) Preheat the bushing (2) and pinion (1) to 80-100°C.
4) Quickly t to the motor shaft, in succession: the bushing (2), key (3) and pinion (1). When tting the
bushing (2), ensure that the side with the chamfer for the seal ring is facing you. To facilitate mounting,
lightly press on the parts being tted (e.g. with a tubular drift). Make sure that the reaction force in
this case is supported by the opposite end of the shaft, and not by the fan cover. At the end of this
procedure the pinion (1) should be snug against the bushing (2).
5) Secure the assembly axially with the spacer (4) and washer (5) and tighten the bolt (6) to the specied
torque. Alternatively, for congurations which have this option, t the stop bushing (B1) and hold it
snug against the pinion (1) while tightening the two grub screws (7). See the gure at the right.
6) Lubricate the seal ring lips with a lm of grease.
7) For type VFR 49 gearboxes, which are lubricated for life and hence do not have a service plug, ll with
the quantity of lubricant specied in the lubrication chapter of the VFR catalogue.
8) Grip the motor rmly and, holding it in alignment, mount it to the ange of the rst reduction stage. Take
the greatest care to avoid denting the pinion or gear wheel teeth.
9) With the motor and gearbox anges in contact, fully tighten down the xing bolts (8), proceeding
gradually and in a cross-wise pattern.
10) Lubricant must be changed periodically on VFR 130 to VFR 250 gearboxes. For these gearboxes the
lubricant charge is given in the “LUBRICATION” section of this manual. Check that the correct level
has been reached via the sight glass, with the gearbox in its specied mounting position. Top up as
necessary.
5.5 INSTRUCTIONS FOR THE ASSEMBLING OF THE LIMIT-SWITCH DEVICE (RVS) ONTO GEARBOX
5
4 2
4
6
5
7
1
10
9
3
8
1. Make sure that the limit-switch device (10), as well as the mounting kit for the specic gearbox, is
available in the required conguration.
2. Start assembling the components of the mounting kit rst. Insert the dowel pin (1) and keys (2) into their
sites. Then slide shaft (3) into the hollow shaft of the gearbox. The position of the dowel pin (1) will dene
the side the limit-switch (10) ts onto.
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23 / 64
3. Retain shaft axially inserting the washers (4) rst and then snap rings (5) into their groves.
4. Fit connecting ange (6) onto the gearbox and lock it with the two bolts (7).
5. Mount limit-switch (10) onto connecting ange (6) and secure it with the two socket head bolts (8). Whilst
performing this, make sure that the dowel pin (1) is located in the grove machined into the bush trailing
the entire limit-switch device.
6. Finally insert the dust proof contact seal (9) carefully into its site. See gure for reference.
5.5.1 Setting of the limit-switch device (RVS)
Disconnect power to the electric motor before working on the limit switch device.
The device must only be installed and calibrated by specialist personnel, according to these
instructions and any other instructions provided with it or separately from it. All standards
applicable in the country or region of installation must also be respected.
The micro switches carry the letters (A) or (B) which refer to the direction of rotation of the drive shaft.
To set the “open” and “close” positions of the equipment, rst install the gearmotor onto the framework.
Allow the drive pinion to mesh with the relative rack.
Thereafter, remove the lid from the top and follow the procedure, as described below:
24 / 64
1. Drive the gearmotor until either one of the two end positions is reached. Disconnect power. While
performing this, observe which direction the shaft is rotating, whether (A) or (B). Refer to raised arrows
on side of the housing.
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
2. Loosen the pair of nylon wheels in relation to the micro switch which corresponds to the direction of
rotation previously observed (carrying the letter A in the example alongside). Use the 1.5 mm Allen key
supplied with the device.
Set the two grooves side by side and rotate both wheels manually until the roller of the switch snaps into
the grooves and a click can be heard. Then lock both the wheels in that position by screwing down the
respective grub screws.
To set the other end position, drive the gearmotor in the opposite direction until that end position is
reached. Follow same procedure described above, operating on the correspondent micro-switch. At the
end, close the lid and lock it with the 4 nos. socket head screws.
N.B. With reference to the revolutions of the output shaft, the limit switch range is 0 – 43 turns.
5.6 CALIBRATING THE TORQUE LIMITER SLIPPING TORQUE
A preliminary slip torque setting is conducted at the factory. Reference is made to torque rating Mn
[n
=1400] of the captioned VF or W gear unit.
1
Here below the operations performer at the factory for the initial adjustment are listed. Same steps, with the
exception of step (2), must be followed when a different torque setting is required.
1. Ring nut is tightened until spring washers are sufciently loaded that manual rotation is hardly possible.
2. By means of an engraver marks are made, in identical (angular) position, on both the ring nut and the
hollow shaft. Setting will then be referred to as the zero-point for the consequent slip torque adjustment,
through turning of the ring nut.
3. Ring nut is then turned of the number of turns, or fraction of, corresponding to nominal torque rating
Mn
of the captioned gear unit. In this case the diagram shown here under refers as to the proportion
2
between number of turns and transmissible torque. Same diagram comes handy for customised torque
adjustments, should these be required with time.
Torque [Nm]
2
N. of ring nut turns
5.7 INSTALLING CONNECTING ELEMENTS
Use the utmost caution when installing the various components, to ensure that no damage is caused to the
gearbox and its parts, such as oil seals and mating surfaces, or internal parts such as gears and bearings.
Make sure that you have access to suitable lifting equipment to perform the installation operations
correctly.
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25 / 64
When installing external transmission parts do not use hammers or other unsuitable tools, to avoid
the risk of damaging the gearbox shafts or supports.
When installing connecting elements it is advisable to preheat them slightly. Take the following precautions
when doing so:
Adopt protection against contact with hot parts: risk of burns!
Protect the oil seals from damage and accidental overheating to avoid impairing their functionality
(use a heat shield to protect against radiated heat).
The connecting or transmission elements must not transmit static or dynamic external loads to the
shafts unless said loads have been calculated at the time of gearbox selection.
If the element to be coupled to the shaft is not xed axially by the interference of the coupling, utilise
suitable retaining components to prevent axial movement of the element in question on the shaft.
5.8 PAINTING AND SURFACE PROTECTION
Gearboxes
when no specic protection class is requested, if equipped with cast-iron housing are supplied
with the housing painted in factory (GREY RAL 7042). The painted (ferrous) surfaces are protected to at
least corrosivity class C2 (UNI EN ISO 12944-2). Aluminium casings are not painted.
In the following table, the types and sizes of gearboxes that are painted are shown in grey.
(tab 4)
VF 27 VF 30 VF 44 VF 49 VF 130 VF 150 VF 185 VF 210 VF 250
W 63 W 75 W 86 W 110
Through dedicated options (C3, C4) may be requested specic painting treatments for improved resistance to atmospheric corrosion, obtained by painting the complete gearbox and available in various colours.
Gearboxes of EP series may be request with a painting treatment highly resistant to the corrosion and
suitable for incidental food contact, approved by FDA and NSF (depending on colour).
If the gearbox has to be painted, protect the nameplate and seal rings against contact with paint
and solvent.
Do not paint the mating surfaces that will be used for the nal installation (foot or anges). If mating
surfaces are painted, carefully check that the gearbox is rigidly mounted and that its shafts are
correctly aligned on completion of the installation.
Contact the manufacturer’s technical assistance service before painting any control devices tted
to the gearbox.
26 / 64
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
5.9 LUBRICATION
Gearboxes can be supplied with or without lubricant, as shown in table 5, or as speci ed by the
customer.
On gearboxes with an oil level plug, check the oil level before starting up the gearbox. As with lling, this
operation must be done with the gearbox in the mounting position in which it will be used in the application.
If necessary, ll or top up the lubricant to the half way point in the level window, to the reference notch on
the dipstick, or until it starts to ow out of the plug hole.
The charts on the following pages show the position of the service plugs.
The lubricant utilised must be new and uncontaminated and can be poured in through the ller hole or from
the inspection cover opening using a ller lter with 25 µm mesh, ensuring that the relative gasket is re tted
without damaging it or reapplying the sealant to provide a perfectly oil-tight t.
Gearboxes that are lubricated for life and not subject to external contamination do not normally
require periodic lubricant changes. The following table identi es the gearboxes that are supplied
with synthetic “for life” lubricant.
(tab 5)
VF 27 VF 30 VF 44 VF 49 VF 130 VF 150 VF 185 VF 210 VF 250
W 63 W 75 W 86 W 110
Lubricated for life.
Lubricated for life (unless speci ed with the SO option)
Lubrication for life only with LO and ATEX options speci ed. The applicability of the LO
option is described in the table below.
LO
Mounting Position
B3 B6 B7 B8 V5 V6
W 110 U-UF-UFC X X X X
In the ATEX version, in addition to mounting positions V5 and V6, all W110
worm gears with motor fl ange type B14 are supplied without lubricant.
Gearboxes normally supplied without lubricant, and supplied with synthetic oil only if the LO option
is speci ed. The applicability of the LO option is described in the table below.
LO
Mounting Position
B3 B6 B7 B8 V5 V6
VF 130 A-N-P-F-FC X X X X
VF 130 V X X X X
VF 130 FR X X
VF 150 A-N-P-F-FC X X X X
VF 150 V X X X X
VF 150 FR X X
VF 185 A-N-P-F-FC X X X X
VF 185 V X X X X
VF 185 FR X X
VF 210 A-N-P X X
VF 210 V X X
VF 250 A-N-P X X
VF 250 V X X
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Do not mix oils of different makes or specications. Make sure also that the oil is highly resistant
B3 - B6 - B7 - B8 - V5 V6
WR 63...WR 86
OMALA S4 WE 320 GADUS S5 V142W 00
VFR 44...VFR 250
WR 110
OMALA S4 WE 320
W 63...W 110
VF 44...VF 250
OMALA S4 WE 320
W 63...W 110
VF 44...VF 49
OMALA S4 WE 460
mounting position
Helical
reduction
Worm gear unit
Worm gear unit
c/w torque
limiter
to foaming and is EP (Extreme Pressure) rated.
If you do not have the same type of oil, completely drain the gearbox and ush it out thoroughly with the
new oil to remove all traces of the old oil and any contaminants from inside the casing before lling the
gearbox with the new oil.
Oil level can be checked by removing the oil level check plug and checking that the oil spills from the
bottom edge of the hole.
Only use recommended oils to ll and top up the gearbox.
5.9.1 Recommended / permitted lubricants
When using a lubricant other than the recommended SHELL
lubricant, be sure it is a synthetic lubricant
with equivalent viscosity and composition and added with adequate anti-foaming agents.
Lubricants for ATEX-specied gearboxes
28 / 64
Greases:
• Klüber Asonic GHY 72 (for bearings)
• Klüber Klüberquiet BQ 72-72 (for bearings)
• Klüberpaste 46 MR 401 (for easy engagement of cylindrical couplings)
• ITP Fluorocarbon gel 880 (for lubricating sliding seals)
Oils (alternatives to Shell Omala S4 WE 320 - standard supply):
• Shell: Tivela Oil S320
• Klüber: Klübersynth GH 6 320
• Total: Carter SY 320
• Mobil: Glygoyle 320
• Castrol Alphasyn PG 320
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
5.9.1.1 Synthetic oils and minaral oils with EP (Extreme Pressure) additives
Omala S2 G
Omala S4 GX
Omala S4 WE
Blasia
Blasia S
Blasia SX
Klübersynth GH 6
Klübersynth UH1 6
Klüberoil GEM1
Klübersynth GEM2
Mobil Glygoyle
Mobil SHC 600
Mobilgear 600 XP
Carter SY
Alphasyn PG 320
Mobil Glygoyle (USDA H1)
[#]
VF - W
VFR - WR
VFL - WL
VF_EP
W_EP
Food grade.
F
─
─
─
─
─
─
─
─
─
─
─
─
─
─
─
─
─
─
─
─
F
F
─
─
─
F
─
─
─
─
─
─
─
─
─
─
─
─
─
─
─
F
─
F
─
─
─
─
─
F
─
─
Recommended use.
Permitted use. The manufacturer cannot guarantee the quality or suitability of lubricants. Characteristics
*
must be veri ed directly with the manufacturer of the chosen lubricant (or ask Bon glioli Technical
Service for oil certi cation).
Nevastane SY
F
F
─
F
PolyAlkylene Glycol (PAG) synthetic oil (API group V)
PolyAlphaOle n (PAO) synthetic oil (API group IV)
Mineral oil with EP additives
# = Exclusive use of PAG, oil viscosity suggested: 320.
Contact Bon glioli Technical Service for different needs.
5.9.2 Quantity of lubricant
The quantities of lubricant specied in the tables are purely indicative.
Gearboxes with level plugs correctly located for the mounting position must be lled to the mid
point of the sight glass, or to the reference notch on the dipstick, or until oil starts to ow out of the
plug hole, depending on the type of level plug.
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29 / 64
In the case of gearboxes normally supplied lubricated for life (see table 5), but supplied without lubricant
and with no level plug, consult the manufacturer’s technical assistance service.
5.9.2.1 Wormgears, Serie VF:
VF 27 N - A - V - F HS - P(IEC)
VF 30 N - A - V - F - P - U HS - P(IEC)
VF 44 N - A - V - F - FA - P - U HS - P(IEC)
VFR 44 N - A - V - F - FA - P - U P(IEC)
VF 49 N - A - V - F - FA - P - U HS - P(IEC)
VFR 49 N - A - V - F - FA - P - U HS - P(IEC)
VF 130 N HS - P(IEC) 2.3 2.5 2.5 3.0 3.2 3.4
VFR 130 N HS - P(IEC) 0.70 0.50 0.50 0.40 0.40 0.50
VF 130 V HS - P(IEC) 3.4 2.5 2.5 3.1 3.0 2.5
VFR 130 V HS - P(IEC) 0.50 0.50 0.50 0.40 0.40 0.70
VF 130 A - F - FC - FR - P HS - P(IEC) 46 ≤ i ≤ 100 3.9 2.5 2.5 2.3 3.3 3.3
VF 130 A - F - FC - FR - P P(IEC) 7 ≤ i ≤ 40 3.0 2.5 2.5 2.3 3.3 3.3
VFR 130 A - F - FC - FR - P HS - P(IEC) 0.40 0.50 0.50 0.70 0.40 0.50
W/VF 63/130 A - F - FC - FR - P HS - P(IEC) - S 3.9 2.5 2.5 2.3 3.3 3.3
VF 150 N HS - P(IEC) 3.0 3.5 3.5 4.3 3.8 4.0
VFR 150 N HS - P(IEC) 1.0 0.80 0.80 0.60 0.40 1.0
VF 150 V HS - P(IEC) 4.0 3.5 3.5 3.6 4.3 3.0
VFR 150 V HS - P(IEC) 1.0 0.80 0.80 0.40 0.60 1.0
VF 150 A - F - FC - FR - P HS - P(IEC) 46 ≤ i ≤ 100 4.5 3.5 3.5 3.0 3.9 3.9
VF 150 A - F - FC - FR - P P(IEC) 7 ≤ i ≤ 40 4.3 3.5 3.5 3.0 3.9 3.9
VFR 150 A - F - FC - FR - P HS - P(IEC) 0.60 0.80 0.80 1.0 0.40 1.0
W/VF 86/150 A - F - FC - FR - P HS - P(IEC) - S 4.5 3.5 3.5 3.0 3.9 3.9
VF 185 N HS - P(IEC) 5.0 5.5 5.5 7.8 6.6 6.8
VFR 185 N HS - P(IEC) 1.0 0.80 0.80 0.60 0.40 1.0
VF 185 V HS - P(IEC) 6.8 5.5 5.5 6.4 7.8 5.4
VFR 185 V HS - P(IEC) 1.0 0.80 0.80 0.40 0.60 1.0
VF 185 A - F - FC - FR - P HS 9.6 5.5 5.5 5.0 6.7 6.7
VF 185 A - F - FC - FR - P P(IEC) 7.8 5.5 5.5 5.0 6.7 6.7
VFR 185 A - F - FC - FR - P HS - P(IEC) 0.60 0.80 0.80 1.0 0.40 1.0
W/VF 86/185 A - F - FC - FR - P HS - P(IEC) - S 9.6 5.5 5.5 5.0 6.7 6.7
VF 210 N HS - P(IEC) 7.5 9.5 9.5 7.3 9.2 9.0
VFR 210 N HS - P(IEC) 1.3 1.1 1.1 0.80 0.70 1.3
VF 210 V HS - P(IEC) 8.9 9.5 9.5 7.3 11 8.0
VFR 210 V HS - P(IEC) 1.3 1.1 1.1 0.60 0.90 1.3
VF 210 A - P HS 15 9.5 9.5 7.5 9.4 8.9
VF 210 A - P P(IEC) 11 9.5 9.5 7.5 9.4 8.9
VFR 210 A - P HS - P(IEC) 0.80 1.1 1.1 1.3 0.70 1.3
VF/VF 130/210 A - P HS - P(IEC) 15 9.5 9.5 7.5 9.4 8.9
VF 250 N HS - P(IEC) 11 17 17 11 17 17
VFR 250 N HS - P(IEC) 1.3 1.1 1.1 0.80 0.70 1.3
VF 250 V HS - P(IEC) 17 17 17 11 23 11
VFR 250 V HS - P(IEC) 1.3 1.1 1.1 0.60 0.90 1.3
VF 250 A - P HS 28 17 17 11 18 17
VF 250 A - P P(IEC) 23 17 17 11 18 17
VFR 250 A - P HS - P(IEC) 0.80 1.1 1.1 1.3 0.70 1.3
VF/VF 130/250 A - P HS - P(IEC) 28 17 17 11 18 17
B3 B6 B7 B8 V5 V6
Consult the manufacturer’s technical
assistance service.
30 / 64
Gearboxes normally supplied lubricated for life.
Gearboxes normally supplied without lubricant.
For VFR units the lubricant charge refers only to the additional helical reduction.
For the combined gearboxes, quantity of lubricant required in the secondary gearbox (the one bolting onto
the driven machine).
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
5.9.2.2 Wormgears, Serie W:
i = 7, 10, 12, 15
W 63
i = 19, 24, 30, 38, 45, 64, 80, 100
i = 7, 10, 15
W 75
i = 30, 40
i = 20, 25, 50, 60, 80, 100
i = 7, 10, 15
W 86
i = 30
i = 20, 23, 40, 46, 56 ,64, 80, 100
i = 7, 10, 15 1.6 1.7 1.7 1.9 1.9 1.8
W 110
i = 20, 23, 30, 40, 46, 56 ,64, 80, 100 2.8* 1.7 1.7 1.9 1.9 1.8
R
B3 B6 B7 B8 V5 V6
B3, B6, B7,
B8, V5
V6
Consult the manufacturer’s technical assistance service.
B3 B6 B7 B8 V5 V6
B3, B6, B7,
B8, V5, V6
0.40
* quantity of lubricant required for all WR and VF/W versions
Gearboxes normally supplied lubricated for life.
Gearboxes normally supplied without lubricant.
For WR units the lubricant charge refers only to the additional helical reduction.
ATEX versions of VF and W Series gearboxes are supplied with lubricant, with the exceptions shown in table
5. Oil quantities are therefore not specied for these gearboxes. If necessary, contact the manufacturer’s
technical assistance service for details.
Before installing the gearbox and putting it into service, always check the oil level as instructed in the
“SCHEDULED MAINTENANCE” section of this manual.
The following table list the quantities of lubricant required for ATEX version of W Series gearboxes supplied
without lubricant (see table 5).
The quantities of lubricant specied in the table are purely indicative.
In this case too, before installing the gearbox and putting it into service, check the oil level as
instructed in the “SCHEDULED MAINTENANCE” section of this manual.
ATEX version of the W Series worm gearbox, supplied without lubricant:
W 110
B3 B6 B7 B8 V5 V6
B14
B5 1.9 1.8
i = 7, 10, 15 1.6 1.7 1.7 1.9 1.9 1.8
i = 20, 23, 30, 40, 46, 56 ,64, 80, 100 2.8 1.7 1.7 1.9 1.9 1.8
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5.9.3 Mounting positions and service plugs
Legend:
Vent / ller plug
5.9.3.1 Wormgears, Serie VF:
VF 27 _ ... VF 49 _ VFR 44 _ , VFR 49 _
B3
A
B6
B3
N
B7 V5
B8
B7 V5
B8
V6
V6B6
Level plug
Drain plug
HS S - P (IEC)
Plug in sight
Plug not in sight
V
P
F
U
B3
B3
B3
B3
B6
B7 V5
B8
B7 V5
B8
B7 V5
B8
B7 V5
B8
V6B6
V6B6
V6B6
V6
32 / 64
Base mounting position. Gearboxes are plated only for base mounting position (B3). They can
nevertheless also be installed in any of the derived positions (B6, B7, B8, V5, V6). Mounting
position may not be changed after installation.
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
HS P (IEC)
VF 30 A ... VF 49 A
B3
B6
B7
B8
V5
V6
VF 49 VF 49
B3
B6
B7
B8
V5
VF 30 N ... VF 49 N
HS P (IEC)
VF 49 VF 49
V6
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B3
VF 30 V ... VF 49 V
B6
B7
B8
HS P (IEC)
V5
V6
B3
B6
B7
VF 49 VF 49
VF 30 P ... VF 49 P
HS P (IEC)
VF 49 (*) VF 49 (*)
34 / 64
B8
V5
V6
(*) On both sides
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
HS P (IEC)
VF 30 F/FA ... VF 49 F/FA
B3
B6
B7
B8
V5
V6
VF 49
VF 49
B3
B6
B7
B8
V5
VF 30 U ... VF 49 U
HS P (IEC)
VF 49
VF 49
V6
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VF 130 A ... VF 250 A VFR 130 A ... VFR 250 A
HS P (IEC)
B3
VF, VF/VF,
W/VF
VF 130-150 (46 ≤ i ≤ 100)
VF/VF, W/VF
B6
B7
B8
V5
V6
36 / 64
Service plugs for the _R (pre-stage) section only are shown in section 5.9.3.3 of this manual.
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
VF 130 N ... VF 250 N VFR 130 N ... VFR 250 N
HS P (IEC)
B3
B6
B7
B8
V5
V6
Service plugs for the _R (pre-stage) section only are shown in section 5.9.3.3 of this manual.
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VF 130 V ... VF 250 V VFR 130 V ... VFR 250 V
HS P (IEC)
B3
B6
B7
B8
V5
V6
38 / 64
Service plugs for the _R (pre-stage) section only are shown in section 5.9.3.3 of this manual.
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
VF 130 P ... VF 250 P VFR 130 P ... VFR 250 P
HS P (IEC)
B3
VF, VF/VF,
W/VF
VF 130-150 (46 ≤ i ≤ 100)
VF/VF, W/VF
B6
B7
B8
V5
V6
Service plugs for the _R (pre-stage) section only are shown in section 5.9.3.3 of this manual.
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HS P (IEC)
VF 130 F ... VF 185 F VFR 130 F ... VFR 185 F
B3
VF, VF/VF,
W/VF
VF 130-150 (46 ≤ i ≤ 100)
VF/VF, W/VF
B6
B7
B8
V5
V6
40 / 64
Service plugs for the _R (pre-stage) section only are shown in section 5.9.3.3 of this manual.
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
5.9.3.2 Wormgears, Serie W:
W 63 U ... W 86 U WR 63 U ... WR 86 U
HS S - P (IEC)
B3
B6
B7
B8
V5
V6
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W 63 UF/UFC ... W 86 UF/UFC WR 63 UF/UFC ... WR 86 UF/UFC
HS S - P (IEC)
B3
B6
B7
B8
V5
V6
42 / 64
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
HS P (IEC)
W 63 U ... W 86 U W 63 UF/UFC ... W 86 UF/UFC
B3
B6
B7
B8
V5
V6
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HS S - P (IEC)
W 110 U WR 110 U
B3
B6
B7
B8
V5
V6
44 / 64
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
W 110 UF/UFC WR 110 UF/UFC
HS P (IEC)
B3
B6
B7
_S - _P (IEC)
B8
V5
V6
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B3
B6
B7
W 110 U W 110 UF/UFC
HS P (IEC)
B8
V5
V6
46 / 64
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
VFR 130 ... VFR 250 A/N
5.9.3.3 Worm gearboxes with helical pre-stage: VFR
A N
HS P (IEC) HS P (IEC)
B3
B6
B7
B8
V5
V6
Service plugs for the _VF (main reduction) section only are shown in section 5.9.3.1 of this manual.
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B3
B6
B7
VFR 130 ... VFR 250 V/P
V P
HS P (IEC) HS P (IEC)
B8
V5
V6
48 / 64
Service plugs for the _VF (main reduction) section only are shown in section 5.9.3.1 of this manual.
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
B3
B6
B7
VFR 130 ... VFR 250 F/FC/FR
FRFCF
HS P (IEC)
B8
V5
V6
Service plugs for the _VF (main reduction) section only are shown in section 5.9.3.1 of this manual.
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5.10 PREPARING CUSTOMER SHAFTS
Make the driven shaft to be coupled to the gearbox’s output shaft from a good quality steel, respecting the
dimensions given in the table. A device such as that illustrated below should also be installed to secure the
shaft axially. Take care to verify and dimension the various components to suit the needs of the application.
5.10.1 Wormgears, Serie VF:
Ø N2
DIN 332-DR
VF 30
VF 44
VF 49
VF 130
VF 150
VF 185
VF 210
VF 250
Ø N1
VF 30-VF 44
A1 A2 A3 B B1 B2 C D E F G R S N N1 N2 H H1
UNI 6604 UNI 5739
≥ 19 14 f7 13 53 18.5 16 40 6.5 6.5 16 5 h9 0.5 1.5 5x5x40 A
≥ 23 18 f7 17 62 22.5 17 50 6 6 20.5 6 h9 0.5 1.5 6x6x50 A
≥ 30 25 f7 24 80 20.5 39 20 2 2 28 8 h9 1 1.5 8x7x20 A
≥ 52 45 f7 44 163 50.5 62 60 2.5 2.5 49.5 14 h9 2.5 2 14x9x60 A
≥ 57 50 f7 49 173 53 67 70 2.5 2.5 53.5 14 h9 2.5 2 14x9x70 A
≥ 68 60 f7 59 188 63 62 80 2.5 2.5 64 18 h9 2.5 2 18x11x80 A
≥ 99 90 f7 89 258 83 92 80 3 3 95 25 h9 2.5 2.5 25x14x80 A
≥ 121 110 h7 109 318 83 152 80 3 3 11 6 28 h9 2.5 2.5 28x16x80 A
22 14 d9 5.5 4 2.5 M5x16
27 18 d9 6.5 4.5 3 M6x20
35 25 d9 9 7 5.5 M8x25
60 45 d9 14 8.5 7 M12x35
65 50 d9 18 10 8.5 M16x45
75 60 d9 22 10 8.5 M20x50
105 90 d9 26 22 20.5 M24x70
125 110 d9 26 22 20.5 M24x70
Ø N
50 / 64
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
5.10.2 Wormgears, Serie W:
Ø L2
DIN 332-DR
A1 A2 A3 B B1 B2 C D E F G R S L L1 L2 H H1
≥ 30 25 f7 24 118 38 42 35 2 2 28 8 h9 1 1.5 8x7x35 A 35 25 d9 9 7 5.5 M8x25
W 63
≥ 35 28 f7 27 125 38 49 40 2 2 31 8 h9 1 1.5 8x7x40 A 40 28 d9 11 8.5 7 M10x30
W 75
≥ 35 30 f7 29 125 38 49 40 2 2 33 8 h9 1 1.5 8x7x40 A 40 30 d9 11 8.5 7 M10x30
≥ 42 35 f7 34 138 43 52 40 2 2 38 10 h9 1.5 1.5 10x8x40 A 45 35 d9 11 8.5 7 M10x30
W 86
W 110
≥ 48 42 f7 41 153 43 67 50 2 2 45 12 h9 1.5 2 12x8x50 A 55 42 d9 14 8.5 7 M12x35
5.11 PUTTING THE GEARBOX INTO SERVICE
The gearbox has been tested in the factory by the manufacturer.
Before starting it up, make sure:
●
That the machine or part of the machine in which the the gearbox/gearmotor is to be installed has
been declared to conform to the requirements of the Machinery Directive 2006/42/EC and to any other
relevant and applicable safety standards.
●
That the gearbox mounting position in the installation corresponds to that prescribed and indicated on
the nameplate. This requirement does not apply to gearbox sizes from 27 to 49, unless they are ATEX-
compliant (where applicable).
●
It is expressly forbidden to install the gearbox at an angle without having consulted and obtained
authorisation from the manufacturer’s technical service. A tolerance of ± 5° with respect to the theoretical
plane of installation is permitted only for shaft mounted installations. This requirement does not apply to
gearbox sizes from 27 to 49, unless they are ATEX-compliant (where applicable).
●
That the electrical power supply is suitable and operational as prescribed in EN 60204-1 and is correct
grounded.
●
That the rating of the power supply to the motor and any installed electrical devices corresponds to that
prescribed and is within ±10% of the rated value.
●
That the oil level in the gearbox/gearmotor and any lubricated accessories is as required and that there
are no leaks from any plugs, seals or pipes.
●
That any parts and/or accessories disconnected for transport purposes have been reconnected.
●
That any of original guards removed for transport purposes have been retted.
Ø L1
UNI 6604 UNI 5739
Ø L
On startup of the gearbox/gearmotor:
●
Check that there are no unusual noises and/or vibrations.
●
After the rst 100 hours of operation, check the tightening torque of all bolt couplings:
- machine side anges
- motor anges
- supports
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Before putting the gearbox into service, make sure that:
●
Assembly will not be carried out in a potentially explosive atmosphere (oil, acid, gas, vapour, radiation)
and that dust deposits on the gearbox do not exceed 5 mm in depth.
●
Clean the gearbox thoroughly after installation.
●
The oil level, drain and vent plugs are all easily accessible.
●
All guards designed to prevent accidental contact between operators and rotating parts, and all oil seals,
are fully ef cient.
●
Gearboxes with hollow shafts have been correctly mounted.
●
All types of accessory installed on the gearbox are ATEX speci ed and have been installed in accordance
with ATEX requirements.
During service make sure that:
●
The gearbox is suf ciently ventilated and that it is not subject to radiation from external heat sources.
●
The temperature of the cooling air does not exceed 40°C.
Measuring the gearbox surface temperature
• The gearbox maximum surface temperature depends on motor speed, transmission ratio and motor
version, but must never exceed the value stated on the nameplate.
• The maximum surface temperature speci ed on the nameplate refers to measurements made in normal
ambient and correct installation conditions. Even minimal variations in these conditions (e.g. smaller
mounting compartments) may have a signi cant effect on heat dissipation.
• When putting the gearbox into service, the surface temperature must be measured in the same conditions
as those in which the gearbox will operate. The surface temperature must be measured at the coupling
between the gearbox and motor, and at the points which are most shielded from the forced ventilation
provided by the motor fan.
Temperature
measurement area
52 / 64
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
IMPORTANT:
The maximum surface temperature is reached after 3 hours operation at full load. Temperature
measured in this way must not differ (ΔT) from ambient temperature by more than the following
values:
(tab 6)
ΔT [K]
VF 44, VF 49 75
W 63 ... W 86 75
W 110 90
If the temperature differential exceeds this value, stop the gearbox at once and contact the
manufacturer’s technical assistance service.
• If the temperature differential lies within the above value, wait for the gearbox to cool down and then
install the heat sensor included in the supply at the point of maximum temperature.
Example:
• Check that the gearbox functions normally (no unusual vibrations and/or noise).
●
Provided all the above checks have been completed positively, and provided all the instructions
in this manual have been strictly observed, an electric motor with ATEX rating equal to or higher
than that of the gearbox may be installed to form a gearmotor that complies with the provisions
of Directive 2014/34/EU.
●
If, on the other hand, the motor and gearbox have been coupled in a way other than that prescribed
in this manual, or if one or more of the instructions provided in this manual has been ignored, the
user must perform a risk assessment specic to the motor-gearbox coupling.
●
Risk assessment is mandatory if the motor is to be powered by an inverter. Only if this is done
and self-certication issued by the assembler will the complete assembly in which the gearbox is
installed conform to the requirements of Directive 2014/34/EU. The inverter control system must
not allow the motor to exceed the gearbox maximum input speed (n
=1500 min-1) or to generate
1
overloads under any circumstances.
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6 MAINTENANCE
Maintenance and replacement work must be carried out by expert maintenance technicians trained
in the observance of applicable laws on health and safety at work and the special ambient problems
attendant on the installation. In order to maintain the proper functioning and safety of the gearbox/
gearmotor, we recommend that users have non-routine maintenance performed by the Manufacturer
or an authorised, specialist service centre. Contact the manufacturer’s sales network. Failure to
comply with this requirement during the warranty period automatically invalidates the warranty.
Never improvise repairs.
Before doing any work on the unit, the operator must rst switch off power to the gearbox and ensure
that it is out of service, as well as taking all necessary precautions against it being accidentally
switched on again or its parts moving without warning (due to suspended loads or similar external
factors).
Furthermore, all additional environmental safety precautions must be taken (e.g. elimination of
residual gas or dust, etc.).
• Disconnect power to the machine in which the gearbox is installed before commencing any maintenance
work, and secure all switches in the OFF position. All persons performing maintenance must secure the
disconnecting switches for themselves, using personal devices (e.g. padlocks) the keys of which they
must keep with them for the duration of the work.
• Ensure surfaces have cooled before commencing work. If necessary, wear anti-burn safety gloves when
working on gearboxes. Refer to chapter “ALLOWED TEMPERATURE LIMITS” for further details.
• Before commencing any maintenance work, activate all the safety devices provided and, if necessary,
inform persons working in the vicinity. Cordon off the area around the gearbox and prevent access to any
equipment which, if activated, might be the cause of unexpected health and safety hazards.
• Replace worn components with original spare parts.
• Use only recommended lubricants (oil and grease).
• When working on the gearbox, always replace all gaskets and seals with original new ones.
• If a bearing requires replacement, it is good practice to replace the other bearing on the same shaft as
well.
• Change the oil after completing maintenance work.
• If, during work, there is any risk of coming into contact with oils and greases, respect the safety precautions
provided on the manufacturer’s data sheets and use all items of personal protective equipment specied
therein.
54 / 64
If the gearbox is not going to be used for a prolonged period following installation or run-in, it must be
run at least once a month. If this is not possible, the gearbox must be protected against corrosion with a
suitable rust inhibitor, or completely lled with new oil of the type normally utilised for operating duty. (See
the “STORAGE” section in this manual.)
The above instructions are aimed at ensuring the efcient and safe operation of the gearbox.
The manufacturer declines all liability for injury to persons or damage to components due to the use of
non-original spare parts or non-routine work that compromises safety requirements without express prior
authorisation. Refer to the specic spare parts catalogue when ordering spare parts for the gearbox.
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
Do not disperse contaminant liquids, worn parts and maintenance residues in the environment.
Dispose of all such substances in strict compliance with applicable statutory legislation.
• Respect scheduled inspection and maintenance intervals to ensure the correct functioning of the gearbox
and the effectiveness of the explosion protection.
• Allow the gearbox to cool down completely before servicing or repairing internal components in order to
avoid burns from hot internal parts.
• On completion of maintenance work, make sure that all safety devices have been applied and reset.
• Clean the gearbox thoroughly after maintenance or repair.
• On completion of maintenance, tighten all vent, ller and level plugs to the torque values specied in the
“INSTALLING THE GEARBOX” section of this manual.
• Apply fresh Loctite 510 paste (or a product with similar properties and application range) to all
disassembled threads (bolts and plugs).
• On completion of any maintenance work, renew all seals and re-apply sealing compound as specied.
On gearboxes with double seal rings, the space between the two rings must be packed with synthetic
grease such as Fluorocarbon 880 ITP gel (or a product with similar properties and application range).
• Regardless of the type of gearbox, whenever a seal ring is replaced, its lips should be smeared with a thin
layer of grease such as Fluorocarbon 880 ITP gel (or a product with similar properties and application
range) before it is tted.
• Use only original spare parts for repairs.
6.1 CHECKING OPERATIONAL EFFICIENCY
●
Periodically remove any dust from the gearbox and motor casings.
●
Check that the noise generated at constant load does not vary. Excessive vibration or noise can indicate
wear of the gear train or failure of a bearing.
●
Check power absorption and voltage against the nominal values given on the motor’s nameplate.
●
On brake motors, check the friction surfaces and friction material for wear and adjust the gap if necessary.
●
Check for lubricant leaks from the gaskets/seals, plugs, casings and pipes.
●
Check that temperature does not rise above normal operating levels (refer to chapter “ALLOWED
TEMPERATURE LIMITS”) unless this is justied by a corresponding increase in the applied load,
rotation speed, ambient temperature or other factor. If temperature rises, stop the gearbox immediately
and identify the cause of the fault.
●
Check all bolt couplings for wear, deformation and corrosion and tighten the bolts correctly, without
exceeding the torque values specied in the “INSTALLING THE GEARBOX” section in this manual.
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6.2 ROUTINE MAINTENANCE
Respect the manufacturer’s routine maintenance schedule to keep the gearbox at peak efciency.
Good maintenance ensures maximum gearbox performance, extended service life and continued
compliance with safety regulations.
List of routine checks
We recommend keeping a checklist of inspections so that any changes in individual control parameters can
be identied rapidly and easily.
The times indicated in the following tables vary signicantly in relation to the conditions of use of
the gearbox and must be construed as valid in the absence of other types of problems.
Depending on the temperature reached by the lubricant, it should be replaced at the intervals indicated in
the table below.
(tab 7)
Interval replacement [h]
Average oil opera-
ting temperature
mineral oil
synthetic oil
[C°]
EP(*)
PAO
PAG
< 65 25000
t
o
< 80 15000
65 < t
o
< 95 12500
80 < t
o
not required
not required
not required
not required
not required
not required
(*) = Replacement within 1 year
(tab 8)
Inspection parameter Frequency
First oil change after putting into service (excluding gearboxes that are
lubricated “for life”)
300 h
Subsequent oil changes see the above table
Noise, vibration 24 h
External condition of gearbox (fouling, oil deposits) 170 h ... 720 h
Oil leaks, external seals and gaskets 720 h
Oil level 720 h
Tightness of xing bolts, connecting anges and torque transmission
components
2000 h ... 4000 h
Regrease bearings and seals (where required) 2000 h ... 4000 h
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Condition of torque arm polymer bushes (aging, cracking) 3000 h
Condition of oil in gearbox (possible presence of contaminants,
especially water)
2000 h ... 9000 h
Alignment of gearbox shafts with respect to coupled machine shafts 9000 h ... 18000 h
Cleanliness of electric motor fan and fan cowling (if present) and cleanliness
of gearbox body
IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
at each oil change
For installations in zones 21 and 22, the user must schedule and implement a regular cleaning
programme for all surfaces and recesses to avoid dust build-ups of more than 5 mm in depth.
Every 100 hours of operation or every 2 weeks:
• Measure the surface temperature at the coupling between the gearbox and motor, and at the points most
shielded from the forced ventilation provided by the motor’s fan. Maximum surface temperature measured
at these points must not exceed ambient temperature by more than 75 K (ΔT) (90 K in the case of the
W 110 gearbox), and this temperature differential must not have been exceeded in service. Check the
condition of the heat sensor installed previously.
Example:
Limit temperature exceeded Limit temperature NOT exceeded
Also check that high temperatures are not being generated at the gearbox bearings.
Every 1000 hours of operation or every 6 months:
• Check the oil level according to the tables provided in the “LUBRICATION” section of this manual and
according to the gure below.
• Check that there are no signs of lubricant leaks near the gearbox.
• If any anomalies are found, identify their cause, make the necessary repairs, and top up the
lubricant level before putting the gearbox back into service.
Every 3000 hours of operation:
• On gearboxes with reaction arms, check that the polymer bushes are not aged or damaged. If the bushes
show any sign of fatigue or damage, replace them with original spare parts.
Every 5000 hours of operation:
• Change the synthetic oil and bearing grease if the gearbox is not lubricated for life.
• Replace all externally accessible seal rings unless this has already been done as a result of problems
occurring before the scheduled maintenance was due.
Every 5000 hours of operation at rated torque
(The minimum overhaul interval specied here may increase considerably, depending on actual service
cycles. See the table below).
• General overhaul of the gearbox, if not performed earlier as a result of malfunctioning (Overhaul consists
of the replacement of all bearings and/or other mechanical components showing signs of wear that might
compromise the functioning of the gearbox).
(tab 9)
M
n2
M
r2
Interval (hours)
1.0 5000
1.25 10000
1.5 17000
1.75 27000
2.0 40000
M
= Rated torque at output shaft
n2
M
= Required torque at output shaft
n2
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Gearboxes are normally tted with yellow oil level plugs. Level plugs may be of the spill type or may require
a dipstick (not supplied) to be inserted. In other cases, yellow level plugs have dipsticks incorporated.
To check the oil level using a spill type level plug, rst identify the yellow level plug. Remove the plug and
insert into the hole a rod of suitable size and of the shape shown in the gure.
If the level is more than 3 mm below the spill level, top up and check the reason for the drop in oil level.
N.B. Make sure that the
dipstick rests rmly on the
edge of the threaded hole.
If the level plug has a dipstick incorporated, simply identify it by its yellow colour, remove it, and check that
the level lies between the MIN. and MAX. markings.
If the level lies outside these marks, restore the correct level and identify the causes of the incorrect level.
The correct method for checking oil level by inserting a rod (not supplied) through the yellow level plug is
described on the following pages.
6.3 OIL CHANGES
1. Place a suitable container under the drain plug.
2. Remove the ller and drain plugs and allow the oil to drain out.
3. Wait for a few minutes to ensure all the oil has drained out. Thoroughly clean the drain plug magnet (if
tted), t a new seal and re t the drain plug.
4. With the gearbox installed in its nal mounting position, ll it with oil to the mid point of the sight glass, or
to the reference notch on the dipstick, or until oil starts to ow out of the level hole.
5. Fit a new seal, replace and tighten the ller plug.
Apply Loctite 510 (or a product with similar properties and application range) on the thread of plugs.
See the “LUBRICATION” section in this manual for details of the quantity of oil required. Speci ed
quantities are only approximate. Gearboxes must be lled to the mid point of the sight glass, or to
the reference notch on the dipstick, or until oil starts to ow out of the oil level hole, according to
the mounting position speci ed on order.
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IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
Lubricants, solvents and detergents are toxic/harmful to health:
- they may cause irritation in direct contact with the skin
- they may cause intoxication if inhaled
- they may be fatal if swallowed.
Handle them with care using suitable personal protection equipment. Do not dump them into the
environment and dispose of in accordance with applicable legislation.
If a leak is found, identify the cause of the fault and repair it before topping up the lubricant and
operating the unit.
6.4 CLEANING
o clean dust, dirt and process residues off the gearbox, do not use solvents or other products that might
T
be incompatible with the materials from which it is made. Do not use high pressure jets of water to clean
gearboxes unless they are EP versions with a seal ring and reinforced shield.
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7 REMOVAL
7.1 REMOVING A MOTOR WITH AN IEC STANDARD FLANGE
If the mobile coupling between the motor and the gearbox has not rusted badly during service, it should be
possible to remove the motor without applying excessive force once the screws coupling it to the gearbox
have been removed.
If it proves difcult to remove the motor, do not use screwdrivers or levers to apply force as this may
damage the anges and mating surfaces. Proceed as illustrated below instead.
Drill and thread (as necessary)
Impact extractor
1. Drill and thread the fan end of the drive shaft if it is not already threaded.
2. Screw in an impact extractor.
3. Undo the bolts xing the motor to the gearbox.
4. Use the impact extractor to detach the motor.
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IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
7.2 REMOVING A GEARBOX WITH HOLLOW OUTPUT SHAFT WITH KEYWAY
1
●
Remove the device that secures the gear unit axially.
The machine’s shaft can be extracted directly in-situ using a hydraulic device, or by using the device
shown in the gure below:
3
4
6
5
1. Machine shaft
2. Hollow shaft
3. Threaded rod (not supplied)
4. Bolts (not supplied)
5. Thrust ring (not supplied)
6. Torque plate (not supplied)
2
During the extraction process observe the maximum thrust values specied in the table below and
take care to avoid knocks or misalignment.
(tab 10)
Maximum
thrust force
[N]
VF 27 VF 30 VF 44 VF 49 W 63 W 75 W 86 W 110
300 850 1250 1700 2500 3100 3500 4000
VF 130 VF 130 FR VF 150 VF 150 FR VF 185 VF 185 FR VF 210 VF 250
6900 12500 8000 17500 9750 19000 17250 26000
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8 TROUBLESHOOTING
The following information is intended to serve as an aid in locating and eliminating defects and faults. In
some cases, such problems may be caused by the plant or machine to which the gearbox is assembled
and hence, the cause and remedy will be described in the Manufacturer’s technical documentation for the
machine/plant in question.
If any components fail or require replacement as a result of levels of wear likely to compromise the
functioning of the gearbox, contact the Manufacturer’s sales network.
(tab 11)
FAULT CAUSE REMEDY
Oil level too low. Top up oil level.
Bearing temperature too high.
Operating temperature too high.
Oil too old. Change oil.
Bearings faulty. Contact authorised workshop.
Oil level too high. Check oil level.
Oil too old. Change oil.
Oil contaminated. Change oil.
Gears damaged. Contact authorised workshop.
Excessive axial play in bearings. Contact authorised workshop.
Abnormal running noise.
Abnormal noise at gearbox
mounting.
Oil leaks.
Gearbox does not run or runs with
difculty.
Output shaft does not turn with
motor running.
Bearings faulty or worn. Contact authorised workshop.
Excessive load applied.
Oil contaminated. Change oil.
Mounting bolts loose. Tighten bolts to specied torque.
Mounting bolts worn. Replace mounting bolts.
Oil level too high. Check oil level.
Casing/coupling seals inadequate. Contact authorised workshop.
Gaskets worn. Contact authorised workshop.
Oil viscosity too high.
Oil level too high. Check oil level.
Excessive load applied.
Gears damaged. Contact authorised workshop.
Bring external loads into conformity with
rated values specied in sales catalogue.
Change oil (see recommended lubricant
table).
Redesign transmission system to suit
actual load.
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IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
9 DISPOSING OF THE GEARBOX
Make sure that the gearbox cannot function accidentally while it is being taken out of service.
The gearbox/gearmotor must be disposed of in compliance with environmental legislation, and the various
materials used in its manufacture must be delivered to an authorised disposal/recycling centre.
The gearbox must only be taken out of service by operators trained in the observance of applicable
laws on health and safety at work.
Do not dump non-biodegradable products, lubricants and non-ferrous materials (rubber, PVC,
resins, etc.) into the environment. Dispose of all such materials as stipulated by current environment
protection laws.
Do not re-use parts or components which appear to be in good condition after they have been
checked and/or replaced by qualied personnel and declared unsuitable for use.
IOM Manual VF-W_ATEXgb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
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INDEX OF REVISIONS (R)
BR_IOM_VF-W_ATX_ENG_R03_0
10
Added chapter “ALLOWED TEMPERATURE LIMITS”
We reserve the right to modify the information given herein without prior notication.
This manual may not be reproduced, even partially, without express authorisation.
This edition cancels and replaces all previous editions and revisions.
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IOM Manual VF-W_ATEX_gb - Translation of original instructions in Italian - Rev 03_0 - 30/09/16
We have a relentless commitment to excellence, innovation &
sustainability. Our team creates, distributes and services worldclass power transmission & drive solutions to keep the world in
motion.
HEADQUARTERS
Bonfiglioli Riduttori S.p.A.
Via Giovanni XXIII, 7/A
40012 Lippo di Calderara di Reno
Bologna (Italy)
tel: +39 051 647 3111
fax: +39 051 647 3126
bonfiglioli@bonfiglioli.com
www.bonfiglioli.com
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