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Habasit Rossi A Series Operating Instructions Manual

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ATEX Operating Instructions

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  • Page 1 A, E, G, H, EP series ATEX Operating Instructions...

  • Page 2: Table Of Contents

    Content 1 - General safety information .............................4 1.1 - Residual risks ..................................4 1.2 - Recycling ....................................4 1.3 - Safety .......................................4 2 - Operating instructions and limits of use ......................6 2.1 - Use ......................................6 2.2 - Special conditions for a safe use .............................6 3 - Product identification ............................8 3.1 - A series - Worm gear reducers and gearmotors ......................
  • Page 3 9 - Motor assembly and disassembly ........................56 9.1 - General ....................................56 9.2 - Gearmotors with motor keyed onto hollow high speed of gear reducer ............. 56 9.3 - Gearmotors with helical pinion keyed directly on motor shaft end .....................57 10 - Cooling systems ..............................

  • Page 4: General Safety Information

    Operating instructions gear reducers and gearmotors complying with ATEX 2014/34/EU A series Worm gear reducers and gearmotors E series Coaxial gear reducers and gearmotors G series Helical and bevel helical gear reducers and gearmotors (sizes 40 ... 401) H series Helical and bevel helical gear reducers (sizes 4000 ... 8001) EP series Planetary gear reducers and gearmotors 1 - General safety information This chapter provides information about handling, installation and maintenance of the gear reducers and...
  • Page 5 − rotation or loosening of the gear reducer from shaft end of driven machine following to accidental breakage of the reaction arrangement; − the accidental breakage of shaft end of driven machine. If deviations from normal operation occur (temperature increase, unusual noise, etc) immediately switch off the machine.

  • Page 6: Operating Instructions And Limits Of Use

    2 - Application conditions and use limits 2.1 - Use foreseen The gearboxes and gearmotors of the A, E, G, H, EP series are intended to be used, in accordance with the data on the plate, in environments where during normal activities it is possible or probable the formation of an explosive atmosphere consisting of a mixture of air and flammable substances in the form of gases, vapors, mists (G) or air and combustible dusts (D).
  • Page 7 This page is intentionally left blank. UTD.123.2019-10.00_EN...

  • Page 8: Product Identification

    3 - Product identification 3.1 - A series - Worm gear reducers and gearmotors U O 2 A – 50 U O 3 A - 24 × 200 – 25 MOUNTING POSITION (see page 15) TRANSMISSION RATIO IEC MOTOR MATING DIMENSIONS Ød ×...

  • Page 9: E Series - Coaxial Gear Reducers And Gearmotors

    3.2 - E series - Coaxial gear reducers and gearmotors 50 U C 2 A – 29.3 B3 MR 3I 50 U C 2 A - 19 × 200 – 22.7 V5 MOUNTING POSITION (see page 16) TRANSMISSION RATIO IEC MOTOR MATING DIMENSIONS Ød ×...

  • Page 10: G Series - Helical And Bevel Helical Gear Reducers And Gearmotors

    2 - Designazione Codice di designazione 3.3 - G series - Helical and bevel helical gear reducers and gearmotors 2I 320 U P 2 D - 10,3 MR C2I 200 U O 2 V - 48 × 350 - 35,3 V5 MOUNTING POSITION (see page 17) TRANSMISSION RATIO...

  • Page 11: H Series - Helical And Bevel Helical Gear Reducers

    3.4 - H series - Helical and bevel helical gear reducers C2I 5600 U O 1 A 25.4 B3 MOUNTING POSITION (see page 18) TRANSMISSION RATIO DESIGN standard others MODEL SHAFT POSITIONS helical bevel helical MOUNTING universal SIZE 4000 … 8001 TRAIN OF GEARS Parallel shaft 2 cylindrical gear pairs...

  • Page 12: Ep Series - In-Line And Right Angle Shaft Gear Reducers And Gearmotors

    3.5 - EP series - In-line and bevel gear reducers and gearmotors Designation Gear red. size and transm. ratio 3EL 018A 61,3Y TRANSMISSION RATIO TYPE standard transmission ratio transmission ratio not to catalog TRANSMISSION RATIO REDUCTION STAGES COMPOSITION standard stage composition stage composition not to catalog SIZE 001 ...
  • Page 13 Brake Exit Input C100M1 F10d I38×300 B5 ,... PB10 - 0340 UH SA1 ACCESSORIES ,SW... ,SB... ,WF... ,SC... Stop washer Splined Wheel flange Splined bar bushing BRAKING TORQUE ,TA... ,SD... ,FB... ,R... torque arm shrink disc foot bracket pinion gear BRAKE TYPE PB10, PB30, PB90 others...

  • Page 14: General Product Description

    4 - General product description 4.1 - General Every gear reducer is provided with a name plate in anodised aluminium containing main technical information relevant to operating and constructive specifications and defining, according to contractual agreements (see fig. ,below), the application limits; the name plate must not be removed and must be kept integral and readable. All name plate data must be specified on eventual spare part orders.

  • Page 15: Nominal Data

    4.3 - Nominal data Low speed shaft nominal torque M - Low speed shaft radiall load F A series E series G series H -series Size V, IV, 2IV 2I, 3I I, 2I, 3I, 4I, CI, ICI, C2I, C3I 2I, 3I, 4I, CI, C2I, C3I riduttore [N m] [N m]...
  • Page 16 Nominal data and performance of EP series: Size Train of gears - Coaxial [N m], M [N m] 2max [N] (C ...), F [N] (S ...) 3.55 ... 7.1 12.5 ... 50 50 ... 250 180 ... 3550 001A 1 600, 1 900 17 000, 20 000 002A 2 240, 2 650...
  • Page 17 Size Trai of gears - Bevel helical [N m], M [N m] 2max [N] (C ...), F [N] (S ...) 9 ... 31.5 31.5 ... 200 160 ... 2240 001A 1 600, 1 900 17 000, 20 000 002A 2 240, 2 650 20 000, 23 600 003A 3 150, 3 750...
  • Page 18 Size Train of gears - Coaxial [N m], M [N m] 2max [N] (C ...), F [N] (S ...) 18 ... 31.5 63 ... 250 250 ... 1 800 125A 125 000, 200 000 250 000, 280 000 180A 180 000, 280 000 355 000, 375 000 250A 265 000, 400 000...
  • Page 19 Size Trai of gears - Bevel helical [N m], M [N m] 2max [N] (C ...), F [N] (S ...) 10 ... 25 45 ... 160 160 ... 1 250 125A 125 000, 200 000 250 000, 280 000 180A 180 000, 280 000 355 000, 375 000 250A...

  • Page 20: Nameplate

    4.4 - Nameplate Every gear reducer is provided with a name plate in anodised aluminium containing main technical information relevant to operating and constructive specifications and defining, according to contractual agreements (see fig. ,below), the application limits; the name plate must not be removed and must be kept integral and readable.

  • Page 21: How Supplied

    Attention! For the mass stated on name plate remind that: – it does not consider the lubricant mass; – it is the maximum one for the gear reducer size, therefore the actual one can be lower as it depends from train of gears and transmission ratio;...

  • Page 22: Painting

    5.3 - Painting Gear reducers in ATEX design are externally protected with electrically conductive enamel with surface resistivity < 10 Ω; grey color RAL 7040. In order not to affect the protection coat of external paint, avoid damages to it both from a mechanical (ex. scratch), chemical (ex.

  • Page 23: Lifting, Handling And Storage

    6 – Lifting, handling and storage 6.1 - Lifting and handling Make sure that the lifting equipment (e.g.: crane, hook, eye bolt, straps, etc.) is suitable for the dimensions and total weight of gear reducer or gearmotor (gear reducer, motor, oil, etc.); refer to Rossi technical catalog, if need be.

  • Page 24: Storing

    6.2 - Storing The ambient must be sufficiently clean, dry (relative humidity < 50%), free from excessive vibrations (v < 0,2 mm/s) to avoid damage to bearings (excessive vibrations should als guarded during transmt, even if within wider range) and at a temperature of 0 ÷ +40 °C: peaks of 10 °C above and below are acceptable. The gear reducers filled with oil must be positioned according to the mounting position stated on order and on name plate during storage.

  • Page 25: Installation

    7 – Installation 7.1 - Maintenance and cleaning General safety precautions Maintenance on gear reducers and gearmotors series A, E, G, H, EP, must be performed only by expert personnel, whose training has included all the necessary instructions on the equipment protection methods, on the installation methods, on the relevant laws and regulations and on the general principles of classification of places with danger of explosions (see IEC/EN 60079-17 "Explosive atmospheres - Part 17: verification and maintenance of electrical installations"...
  • Page 26 Install the unit in such a Tab. 7.1 - Minimum safety requirements for ATEX motor way that the level plug is Zone Motor Thermal probes accessible inspection surface (where applicable). 1 (G) II 2G Ex e, Ex d, Ex de Thermistors To be defined or Pt100...

  • Page 27: Initial Inspection To Be Executed By Skilled Staff

    7.3 - Initial inspection by qualified personnel Before commissioning, the equipment must be subjected to the initial detailed inspection to ensure that the chosen protection and installation methods are suitable. In this regard, see the standard IEC / EN 60079-17 "Explosive atmospheres - Part 17: verification and maintenance of electrical installations", in particular Annex B "knowledge, skills and competences of the responsible personnel, technical personnel with executive functions and operating staff".

  • Page 28: Tightening Torques For Fastening Bolts (Feet, Flange, Accessories) And For Plugs

    7.4 - Tightening torques for fastening bolts (feet, flange, accessories) and for plugs Unless otherwise stated, usually it is sufficient to use screws in class 8.8; Before tightening the bolt be sure that the eventual centering of flanges are inserted properly- Before tightening the bolt be sure that the eventual centering of flanges are inserted properly The bolts are to be diagonally tightened with the maximum tightening torque.
  • Page 29 EP series Size 001A ... 021A Tab. 7.4.3 - Tightening torque for fastening bolts, feet and flanges Performance Size (e.g.: C038M1 F10a) C... F... K... F... K... F... C... P... S... F... Z... F... Z... F... S... P... H... A... M...
  • Page 30 EP series Slewing Drives ightening torque for fastening bolts Tab. 7.4.7 - T output output output size l min l min l min design design design R30b S30b H30b R30c S30c H30c R30d S30d H30d R30e S30e H30e R30f S30f H30f R30g S30g...

  • Page 31: Flange Mounting

    7.5 - Flange mounting Carefully select the length of fixing screws when using tapped holes (B14) for gear reducer fitting, in order to assure a sufficient meshing thread length (minimum length 1,5 · D screw), for the correct gear reducer fitting to the machine without breaking down the threading seat.

  • Page 32: Foot Mounting

    7.6 - Foot mounting A series Tab. 7.6.1 Gear red. Worm size UNI 5737-88 × l M6 × 25 M8 × 35 M8 × 40 63, 64 M10 × 50 80, 81 M12 × 60 M14 × 55 125, 126 M16 ×...
  • Page 33 Gear reducer mounting for slewing drives In the case of slewing drives (output design R-S-H), to ensure a correct operation and an excellent power transmission between gear reducer and machine, the gear reducer requires a rigid connection structure Installation resistent to radial loads. The shape and position tolerances stated below must be followed. To ensure proper functioning and optimum transfer of power between the gear reducer and the driven gear, the gear reducer requires a rigid connection construction that is resistant to torsion.

  • Page 34: Shaft Mounting

    7.7 - Shaft mounting Important! When shaft mounted, the gear reducer must be supported both axially and radially (also for mounting positions B3 ... B8 in the case of A, E, G H series and mounting positions B5 and B53 for EP) by the machine shaft end, as well as anchored against rotation only, by means of a reaction having freedom of axial movement and sufficient clearance in its couplings to permit minor oscillations always in evidence without provoking dangerous overloading on the gear reducer.
  • Page 35 System with rigid or flexible torque arm If the direction of rotation is opposite to that given in the fig. rotate the rigid torque arm by 180° (unnecessary operation in case of flexible torque arm). System with torque arm (A, E, G, H series) According to dimensions, some mounting positions of the motor flange torque arm could not be possible.

  • Page 36: Hollow Low Speed Shaft Mounting

    System with torque arm EP series Symmetrical torque arm is provided as standard option (,TA - up to size 085A); if you need a one sided torque arm, it must comply with the dimensions shown below. Tab. 7.7.1 Size [mm] [mm] [mm] [mm]...

  • Page 37: Gear Reducer Assembly And Disassembly

    Tab. 7.8.1 - Hollow low speed shaft Hole Parallel key Keyway × × Ø H7 H9 hub N9 shaft shaft 21,8 × × × × 27,3 × × 31.2 32,7 × × 35.3 × × × × 40,7 1)4) × ×...

  • Page 38: Axial Fastening Of Gear Reducer

    7.10 - Gear reducer axial fastening For the axial fastening Screw Helical and bevel helical Parallel shaft Screw 32 ... 50 size 40, 50 MR 3I 40, 50 63 ... 161 it is possible to adopt the system per fig. 7.10.1 and 7.10.2.

  • Page 39: Mounting Of Hollow Low Speed Shaft With Shrink Disc G, H Series

    7.12 - Mounting of hollow low speed shaft with shrink disc G, H series Shrink disc machine opposite side Shrink disc machine side Shrink disc Shrink disc Shrink disc machine side machine opposite side machine side (sizes 125) (sizes 140) (sizes 140) Fig.
  • Page 40 Attention! Verify that machine shaft end has dimensions, tolerances and roughness as per fig. 7.12.1 ... 7.12.3 and table 7.12.1; the respect of these prescriptions guarantees the correct running of the shrink disc and is an integrating part of ATEX protection system. Pre-arrange a proper protection of the shrink disc against the accidental contact and against the dust;...

  • Page 41: Ep Series

    EP series For installation in case of hollow shaft and shrink disc, follow the statements of EP series - Operating instructions. Attention! Verify that the shaft end have dimensions, tolerances and roughness as stated in the figure and in the table stated here following; the consideration of following prescriptions ensures the correct running of shrink disc, and is an integrating part of ATEX protection system.
  • Page 42 Tab. 7.12.2 Tab. 7.12.3 Size screws Quantity T... tightening Size screws Quantity T... tightening [N m] [N m] 125A 001A 180A 002A 250A 003A 004A 355A 006A 500A 009A 710A 012A 015A 018A 021A 030A 042A 060A 085A Removing Do not completely remove fastening screws before locking rings are disengaged. Risk of serious injury!!! Clean off any rusty areas.

  • Page 43: Fitting Of Components To Low And High Speed Shaft Ends

    7.13 - Fitting of components to low and high speed shaft ends High speed shaft Standard low speed Solid low speed shaft end shaft end Gear reducer shaft end Machine shaft Tab. 7.13.1 - Low and high speed shaft ends Shaft end Parallel key Keyway...
  • Page 44 Incorrect Correct Generally, it is recommended to machine the hole of parts keyed onto shaft end, tolerance H7. For high speed shaft end with D > 55mm tolerance can be G7, progided that load is uniform and light. For low speed shaft with D < 180 tolerance must be K7, provided that load is not uniform and light. Before mounting, thoroughly clean mating surfaces and lubricate against seizure and fretting corrosion.

  • Page 45: Backstop Device

    7.14 - Backstop device A, E, G, H series The presence on gear reducer of backstop device is stated by the arrow near the low speed shaft, indicating the free rotation. Provide a protection system where a backstop device breaking could cause personal injury or property damage.

  • Page 46: Verification Of Service Factor Fs Required By The Application

    7.15 - Verification of service factor fs required by the application Service factor fs takes into account the different running conditions (type of load, running time, frequency of starting, other considerations) which must be referred to when performing calculations of gear reducer selection and verification.
  • Page 47 Tab. 7.15.2 - Service factor fs based on nature of load and of frequency of starting Nature of load of driven machine Ref. Description Frequency of starting z [starts/h] A series E, G series H series – – EP series Uniform 1.06 1.12...

  • Page 48: Thermal Power Verification Pt [Kw] Of Gear Reducer

    7.16 - Thermal power verification Pt [kW] of gear reducer The nominal thermal power Pt of gear reducer, stated in the following tables, is that which can be applied at the gear reducer input, without exceeding 95 °C approximately oil temperature when operating in following running conditions: –...
  • Page 49 Tab. 7.16.1b - Nominal thermal power Pt of A series worm worm Size 32 Size 40 1 400 0.82 0.67 0.44 1.14 0.93 0.84 0.77 0.6 0.55 0.49 1 120 0.61 1.04 0.84 0.76 0.69 0.55 0.49 0.45 0.94 0.76 0.7 0.64 0.5 0.46 0.87 0.7 0.63 0.58 0.45 0.41...
  • Page 50 Tab. 7.16.1c - Nominal thermal power Pt of EP series Train of gears Gear reducer size 20 °C 40 °C 20 °C 40 °C 20 °C 40 °C 20 °C 40 °C 20 °C 40 °C 20 °C 40 °C 20 °C 40 °C 001A...
  • Page 51 Tab. 7.16.3 - Thermal factor ft according to ambient temperature and Tab. 7.16.4 - Thermal factor ft according service to altitude of installation Altitude a.s.l. Maximum Continuous Intermittent load duty ambient duty S3 ... S6 temperature Cyclic duration factor [%] °C for 60 min running 0.71...
  • Page 52 Tab. 7.16.7 - Thermal factor ft according to mounting position where ft = 1 is not specified Train of Mounting gears position Size A series B6, B7 MR V Size E series 100, 101 125, 126 R 2I MR 2I V5 0.85 0.85 ...

  • Page 53: Lubrication

    8 - Lubrication 8.1 - General Gear reducers and gearmotors must be lubricated with polyglycol or polyalphaolephines based synthetic oil depending on the series; they are supplied FILLED WITH OIL OR WITHOUT OIL according to type and size (see ch. 8.2). The gear pairs are oil-bath lubricated, the bearings are either oil bathed or splashed or lubricated «for life»...

  • Page 54: Lubrication Tables

    8.2 - Lubrication tables Table 8.2a - How supplied and plugs (identification through specific lubrication nameplate) A series E, G series EP series A series E, G, H series EP series size size size 021A size size size 022A COMPLETE of SYNTHETIC OIL WITHOUT OIL (except different statement on lubrication name plate) ISO VG 320...

  • Page 55: Extruder Support Lubrication (Helical And Bevel Helical, Sizes 100

    Grease-lubricated bearings: Lubrication is «for life» assuming uniform load and pollution-free environment. Replace the grease every year with running up to 12 h/d and every 6 months with running of 12 ÷ 24 h/d; in these occasions re- lubricate the backstop device with grease SHELL Alvania RL2. Bearing should be filled with ESSO Gadus S2 V100 bearing-grease for ball bearings, KLÜBER STABURAGS NBU 8 EP for roller bearings.

  • Page 56: Motor Assembly And Disassembly

    9 - Motor assembly and disassembly 9.1 - General Attention. Verify that motor: – respects the application limits (P , etc.) stated on nameplate of gear reducer on which it is 1max 1max mounted (gearmotor without motor), – it has ATEX protection specifications equal to or higher than the gear reducer ones on which it is mounted (gearmotor without motor) –...

  • Page 57: Gearmotors With Helical Pinion Keyed Directly On Motor Shaft End

    9.3 - Gearmotors with helical pinion keyed directly on motor shaft end Worm gearmotors MR IV, MR 2IV (A series) Coaxial gearmotors MR 2I, MR 3I (E series) Helical gearmotors MR 3I 40 ... 125, MR 4I (G series) Bevel helical gearmotors MR ICI, MR C3I (G series) –...

  • Page 58: Cooling Systems

    10 - Cooling systems 10.1 - Fan cooling If there is fan on the gear reducer verify that there is sufficient space allowing for adequate circulation of cooling air also after fitting coupling protection . If a coupling protection is fitted (drilled case or wire netting), smooth, the coupling hub, if necessary.

  • Page 59: Integrated Water Cooling Unit (Ep Series)

    Attention! Do not tamper with the eventual stop plate in order to keep the pipes locked; in particular keep the pipe locked while tightening the nut of connection pipe. Unless specific indications given on the documentation attached to present instructions, water fed into the system must: –...

  • Page 60: Accessories

    11 - Accessories IMPORTANT. Rossi has the right to supply interchangeable probes such as functional technical specifi cations and connections, but with slightly modifi ed case dimensions. The probes (temperature probe, level probe) are an integrating part of safety system and must be connected to control devices of category to ISO 13849-1.

  • Page 61: Resistance Thermometers (Oil Or Bearings)

    11.2 - Oil or bearing resistance thermometers Bearing Connection Resistance Fixed connection Sliding connection 4 threads type without bulb bulb bulb (optional) not possible Ex_d ATEX II 2G, 2D 4 terminal ceramic base Ex_d IIC T6 see specific documentation Ex_ia ATEX II 2G, 2D Ex_ia IIC T6 TMT82 transmitter...
  • Page 62 Installation and maintenance Fit the coupling with sliding probe into the appropriate threaded hole of the gear reducer (for the position refer to SPT scheme attached to present operating instructions) by using a spanner key 24, loosen the hexagon using a 19 mm spanner and slide the probe of the thermometer in (up to the point of contact when the temperature of a bearing is to be measured) so that the head of the thermometer is closer to gear reducer.
  • Page 63 11.3 - Oil thermostat Thermostat TRI120 II 2 G Ex d IIB T6 IP65 II 2 D Ex d IIB T85 °C IP65 Features It is a thermostat for oil with following features: - Internal temperature regulator, manually set by operator - Body: aluminium alloy - Liquid dilatation probe in cylindrical sump made of tropicalized brass - Cable entry Ø...

  • Page 64: Tca 2Ba Thermostat

    TCA 2BA Thermostat II 2 G Ex d IIC T6 IP65 II 2 D Ex d IIC T85 °C IP65 It is a thermostat for oil with following features: – Scale: the instrument is fitted as standard with an approximate scale of the set point indication; –...

  • Page 65: Oil Level Switch With Float

    11.4 - Oil level switch with float II 1 G Ex d IIC T6 II 2 G Ex d IIC T6 It is a level control device with reed contacts in a supporting stem moved by the magnetic field activated by the magnets included in the float. The float and the supporting stem are included in a hollow column of not magnetic material connected to the gear reducer casing through communicating vessels.

  • Page 66: Pressure Switch With Flameproof Enclosure Ex D

    11.5 - Pressure switch with flameproof enclosure Ex d II 2G Ex db IIC T4 Gb II 2D Ex tb IIIC T135 Db IP66 ATTENTION: In presence of brake PB series and application of ATEX 2G, 2D and 3G, 3D, the pressure switch is always necessary as a safety device.
  • Page 67 Pressure switch mounting position VERTICAL (standard) Cable entry 1/4"G x12 Brake Release Port fig. 11.5.1 1/4"G x12 Brake Release Port HORIZONTAL (optional) Cable entry fig. 11.5.2 A design. Brake of PB series B. Pressure switch. C. Connection KIT UTD.123.2019-10.00_EN...

  • Page 68: Flow Gauge Bfs-20

    11.6 - Flow gauge BFS-20 II 1 G Ex ia IIB T100°C IP6X II 1 D Ex ia IIIB T100°C IP6X It's a capacity control device. The measurement is executed through a piston movement equipped with loaded spring, free to flow inside a cylindrical pipe. The piston movement depends from device calibrating and from its minimum and maximum setup capacity.

  • Page 69: Commissioning

    12 - Commissionning 12.1 - General Carry out a general check, making particularly sure that the gear reducer is filled with synthetic oil in the correct quantity (up to level), with the proper viscosity and one of the brands recommended in table 8.2, and that it is installed in the mounting position stated on nameplate.

  • Page 70: Measurement Of Surface Temperature

    12.3 - Measurement of surface temperature Measure by a thermometer the surface temperature of gear reducer close to the high speed shaft (gear reducer) or at the coupling surface between motor and gear reducer (gearmotors) in the position which is most protected from air circulation.
  • Page 71 Maintenance procedures to be adopted: – LOTO (Lockout/Tagout): è necessario adottare la procedura di disconnessione della macchina (segregazione elettrica e meccanica). – HOT Works: hot fitting of components (ex. to the shaft end) can absolutely only be made in certified safe areas.

  • Page 72: Oil Change

    13.2 - Oil change Execute the oil change with machine at rest and cold gear reducer. Pre-arrange a proper tank system for the drain oil, unscrew the drain plug and the filler plug to facilitate the drain; make sure that all oil has been drained, inclining the gear reducer of removing any residual parts with a suction pump;...

  • Page 73: Seal Rings

    13.4 - Seal rings Seal rings duration depends on several factors such as dragging speed, temperature, ambient conditions, etc.; as a rough guide it can vary from 1 600 to 12 500 h; in any case replace them every 5 years. In general, however, replace the seal rings in case of dismounting or of periodical check;...

  • Page 74: Gear Reducer Troubles: Causes And Corrective Actions

    13.8 - Gear reducer troubles: causes and corrective actions Trouble Possible causes Corrective actions Excessive oil temperature Inadequate lubrication: Check: – excessive of insufficient oil quantity – oil level (gear reducer at rest) or quantity (see ch. 15 ... 20) –...

  • Page 75: Atex Checks And Verifications

    14 - ATEX checks and verifications Attention. Do all checks and verifications listed below, at first commissioning and during normal running. These checks are integrating parts of the device protection system and have to be carefully executed. 14.1 - Table of main installation checks and operations Operation / Check Reference Has the consignment been damaged during shipping (dented shafts, strained oil seals,...

  • Page 76: Table Of Commissioning Checks And Operations

    14.2 - Table of commissioning checks and operations Object Check On starting After 24 h and after one week (category 2 and 3) (category 2) A Oil leaks (oil seals, Visual check Keep under control for the first 4 h: Temporary check joining surfaces, plugs, etc.)

  • Page 77: Table Of Checks And Operations Frequency During Normal Running

    14.3 - Table of inspections to be made during the normal operation (to be made after checks listed on table 14.2) Object Inspections in absence of oil Inspections in presence of oil Ref. temperature probe temperature probe A Oil leaks (oil seals, joining every six months for category 3G, every three months surfaces, plugs, etc.)

  • Page 78: A Series - Mounting Positions, Oil Quantity And Position Of Plugs

    15 - Mounting positions, oil quantity and position of plugs For inclined mounting positions, when "spec." is stated on nameplate in IM field, refer to the attached specific documentation. 15.1 - Oil (quantity) levels for worm GEAR REDUCERS and GEARMOTORS sizes 32 ... 81 (A series), supplied FILLED with OIL Before commissioning, use a dipstick and check that the vertical distance X [mm] between plug shoulder and oil level corresponds to the value stated in the table 13.1.1.

  • Page 79: Mounting Positions And Plug Position For Worm Gear Reducers And Gearmotors Sizes

    15.2 - Mounting positions and plug position for worm GEAR REDUCERS and GEARMOTORS sizes 100 ... 250 (A series), supplied WITHOUT OIL Verify oil level through the level plug which is placed in the position indicated the following figures. For mounting position B7 the level is stated on the dipstick mounted on the filler plug.
  • Page 80 MR V 100 ... 250 Oil filler plug  size  200 ( n > 710 min ● Oil level plug bearing lubrication pump ■ Oil drain plug Bearing greased. ** Both low speed shaft bearings greased. MR IV 100 ... 250 size ...

  • Page 81: E Series - Mounting Positions, Oil Quantity And Position Of Plugs

    16 - E series - Mounting positions, oil quantity and position of plugs For inclined mounting positions, when "spec." is stated on nameplate in IM field, refer to the attached specific documentation. 16.1 - Oil level (quantity) for coaxial GEAR REDUCERS and GEARMOTORS sizes 50 ... 81 (E series) supplied FILLED WITH OIL Before commissioning of the units verify that the dimensions X [mm] between the plug shoulder and oil level corresponds to the value stated in table 14.1, using a dipstick.

  • Page 82: Mounting Positions And Plug Positions For Coaxial Gear Reducers And Gearmotors Sizes

    16.2 - Mounting positions and plug positions for coaxial GEAR REDUCERS and GEARMOTORS sizes 100 ... 180 (E series), supplied WITHOUT OIL Verify oil level through the level plug which is placed in the position indicated the following figures. For mounting position B7 the level is stated on the dipstick mounted on the filler plug.

  • Page 83: G Series - Mounting Positions, Oil Levels, Plug Positions

    17 - G series - Mounting positions, oil quantity and position of plugs For inclined mounting positions, when "spec." is stated on nameplate in IM field, refer to the attached specific documentation. 17.1 - Oil levels (quantity) for helical and bevel helical GEAR REDUCERS AND GEARMOTORS sizes 40 ...
  • Page 84 Tab. 15.1.1 - Oil level (dimension X) and oil quantity for gear reducers and gearmotors G series sizes 40 ... 81 HELICAL Train of gears Mounting position Oil level (dimension x ) [mm] and quantity [l] Size B3, B8 B6, V5, B3, B8 B7, V5, B3, B8...

  • Page 85: Mounting Position And Plug Positions For Helical And Bevel Helical Gear Reducers And Gearmotors

    17.2 - Mounting position and plug positions for helical and bevel helical GEAR REDUCERS and GEARMOTORS sizes 100 ... 360 (G series), supplied WITHOUT OIL Verify oil level through the level plug which is placed in the position indicated the following figures. For mounting position B7 the level is stated on the dipstick mounted on the filler plug.
  • Page 86 R 3I 100, 125 Oil filler plug ( not in view)  Oil level plug ( not in view)  Upper bearings greased (in mounting position V5 also high speed shaft bearing Oil drain plug ( not in view)  is greased) R 3I 140 ...
  • Page 87 R ICI 100 ... 200 * The 2 upper bearings are greased. High speed shaft upper bearing is greased. Oil filler plug ( not in view)  Oil level plug ( not in view) *** For mounting position B7 (design ...D) the upper bearings of bevel pinion are ...
  • Page 88 MR 2I 140 ... 360 Possible bearing lubrication pump; when it is not present or there are no ducts, the upper bearings are greased. Possible high oil splash: for the corrective factor ft of nominal thermal power see ch. 7.16. Oil filler plug ( not in view) ...
  • Page 89 MR CI 100 * The 2 upper bearings are greased. Oil filler plug ( not in view)  Oil level plug ( not in view) ** For mounting positions B6, B7 (design ...D) the upper bearings of bevel  Oil drain plug ( not in view) pinion are greased.
  • Page 90 MR C2I 140 ... 360 UO2H UO2Hsin UO2R UO2Rsin Possible bearing lubrication pump; when it is not present or there are no ducts, the upper bearings are greased. Possible high oil splash: for the corrective factor ft of nominal thermal power see ch.

  • Page 91: H Series - Mounting Positions, Oil Levels, Plug Positions

    18 - H series - Mounting positions, oil quantity and position of plugs For oil levels and position of plugs see attached SPT sketch Before commissioning, check lubricant level. R 2I 4000 ... 8001 Possible high oil splash: for the corrective factor ft of nominal thermal power Pt see ch.
  • Page 92 R CI 4000 ... 8001 Possible high oil splash: for the corrective factor ft of nominal thermal power Pt see ch. 7.16. 1) Mounting position B3 may be identified from the position of the screw-heads as arrowed. The same applies for V5 and V6 with double extension or hollow low speed shaft.

  • Page 93: Ep Series - Mounting Positions, Oil Levels And Tanks

    19 – EP series - Mounting positions, oil quantity and tanks Oil filling Pay attention to the correct position of the oil level plug (see cat. EP). For mounting positions with input side in vertical position, during the oil filling it is very important to always open the plug located up to the level air to escape in order to reach the correct level.
  • Page 94 Size 001A ... 021A Mounting positions (Output design ... F..., ... A...) For further information see cat. EP series * Based on the motor size, the expansion tank is required . ** Based on the output design, the expansion tank is required . Reference hole for the identification of the mounting position.
  • Page 95 Size 001A ... 021A Mounting positions (Output design ... F..., ... A...) For further information see cat. EP series * Based on the motor size, the expansion tank is required. ** Based on the output design, the expansion tank is required. Reference hole for the identification of the mounting position.
  • Page 96 Size 001A ... 021A Mounting positions (Output design ... P...) For further information see cat. EP series * Based on the motor size, the expansion tank is required. 1) The drawings show the terminal box in position 0. Oil quantity [l] B3 ...
  • Page 97 Size 001A ... 021A Mounting positions Output design ... F..., ... A...) For further information see cat. EP series * Based on the gear reducer size, the expansion tank is required. ** Based on the output design, the expansion tank is required. Foro di riferimento per l'individuazione della forma costruttiva.
  • Page 98 Size 001A ... 021A Mounting positions (Output design ... F..., ... A...) For further information see cat. EP series * Based on the gear reducer size, the expansion tank is required. ** Based on the output design, the expansion tank is required. Reference hole for the identification of the mounting position.
  • Page 99 Size 001A ... 021A Mounting positions (Output design ... P...) For further information see cat. EP series * Based on the gear reducer size, the expansion tank is required. Oil quantities [l] B3 ... B8 6.2 6.2 B33 ... B83 6.2 6.2 B31 ...
  • Page 100 Size 022A ... 710A Mounting positions Output design ... F..., ... A...) * Based on the motor size, the expansion tank is required. ** Based on the output design, the expansion tank is required. Reference hole for the identification of the mounting position. 1) The drawings show the terminal box in position 0.
  • Page 101 Size 022A ... 710A Mounting positions (Output design ... F..., ... A...) For further information see cat. EP series ** Based on the output design, the expansion tank is required. Reference hole for the identification of the mounting position. 1) The drawings show the terminal box in position 0. Oil quantities [l] V3 ...
  • Page 102 Size 022A ... 710A Mounting positions (Output design ... F..., ... A...) For further information see cat. EP series ** Based on gear reducer size and on output design, the expansion tank is required. ** Based on the output design, the expansion tank is required. Reference hole for the identification of the mounting position Oil quantities [l] 10.7...
  • Page 103 Size 022A ... 710A Mounting positions (Output design ... F..., ... A...) For further information see cat. EP series * Based on the gear reducer size, the expansion tank is required. ** Based on the output design, the expansion tank is required. Reference hole for the identification of the mounting position.

  • Page 104: Plug Positions And Types (Ep Series)

    20 – Plug position and types (EP series)  Size 001A ... 021A     Mounting positions B3, B5, B6, B7, B8 B32, B52, B62, B72, B82 B33, B53, B63, B73, B83  Size 022A ... 710A  ...
  • Page 105 Size 001A ... 021A        Mounting positions B31, B51, B61, B71, B81 Size 022A ... 710A      Mounting positions  1§) For more information see cat. EP series. 2) Only for 2EB train of gears. 3) Only for size 022A.
  • Page 106 Size 001A ... 021A Mounting positions V1, V11, V12, V13 V5, V51, V52, V53             Mounting positions V3, V31, V32, V33 V6, V61, V62, V63     ...
  • Page 107 Size 022A ... 710A Mounting positions V1, V11, V12, V13      Mounting positions V3, V31, V32, V33      1) For more information see cat. EP series. 2) Sizes 030A, 042A e 060A. 3) Size 085A.

  • Page 108: Appendix

    Appendice Parking brake PB series General specifications The parking brakes of PB series are spring applied and hydraulic released multi-disci brakes (steel discs alternating with discs with sintered bronze coating), to be used in combination with planetary gear reducers of EP series. They are not service brakes and cannot be used in dynamic conditions.
  • Page 109 Functioning of PB parking brakes Brake closed When no pressure is applied to the brake (0 bar) springs (1) apply a force to the piston (2) which lock the discs (3) and produce a nominal braking torque equivalent to M Bstat Brake opened Above the pressure of 0 bar, the piston begins to compress the springs and the brake progressively reduces...
  • Page 110 Technical data of PB parking brakes PB10-… 0075 0150 0225 0340 0420 0525 0650 0815 Static braking torque [N m] Bstat Min opening pressure [bar] 10.2 15.7 15.4 19.4 20.1 24.9 Opening pressure [bar] 14.9 16.1 24.7 24.2 30.4 31.6 39.1 Max opening pressure [bar]...

  • Page 111: How Supplied

    How supplied Nameplate of PB parking brakes Every gear reducer is provided with a name plate in anodized aluminium containing main informations necessary for a correct identification of the product; the name plate must not be removed and must be kept integral and readable.
  • Page 112 Mounting position and oil quantities PB10 (001/002/C125/C160) Oil quantity 001A, 002A 001A…006A 001A…022A 001A…061A 001A…006A 001A…022A 001A…061A 0.09 0.06 0.16 PB10 (003/004/006/C200) Oil quantity 003A…006A 009A…022A 030A…061A 085A…180A 009A…015A, 022A 030A…043A 085A…125A 0.09 0.06 0.16 UTD.123.2019-10.00_EN...
  • Page 113 Mounting position and oil quantities PB30 (003/004/006/C200) Oil quantity 003A…006A 009A…022A 030A…061A 085A…180A 009A…015A, 022A 030A…043A 085A…125A 0.36 0.18 0.67 PB90 (009/012/015/C250) Oil quantity 009A…015A 030A…043A 085A…125A 250A, 355A 018A, 021A, 030A 060A…085A 180A, 250A 0.48 0.24 0.90 Oil quantities [l] For mounting position B5 the exact oil quantity ghe gear reducer is to be filled with is definitely given by the level.
  • Page 114 Commissioning An inadequate commissioning can damage the gear reducer, the brake and compromise the correct operation of the application. Do not disassemble and do not modify any brake component in order not to compromise the correct operation of gear reducer / brake. Before commissioning verify that: −...
  • Page 115 Maintenance All maintenance activities must be executed in safe conditions. At machine rest, verify at regular intervals (more or less frequently according to environment and use): a) all external surfaces are clean and air passages to gear reducer and brake are free, in order that cooling remains fully effective.
  • Page 116 Troubles: causes and corrective actions If deviations from normal operation occur, refer to the following table. If deviations persist, consult Rossi. Trouble Possible cause Corrective action Oil leakage from seals Seal stiffening due to long lasting Clean the area and check the leakage storage after some hours of running Seal damage or wear...
  • Page 117 Dichiariazione UE di Conformità Rossi S.p.A. Via Emilia Ovest, 915/A EU Declaration of Conformity 41123 Modena – ITALY www.rossi-group.com Rossi S.p.A., in qualità di fabbricante del prodotto Rossi S.p.A., as the manufacturer of the product stabilito nella Comunità (produttore), dichiaa sotto la established in the Community (producer), declares nostra esclusiva responsabilità...
  • Page 118 UTD.123.2019-10.00_EN...
  • Page 119 UTD.123.2019-10.00_EN...
  • Page 120 Rossi S.p.A. Via Emilia Ovest 915/A 41123 Modena - Italy Phone +39 059 33 02 88 info@rossi.com UTD.123.2019.10.00_EN www.rossi.com © Rossi S.p.A. Rossi reserves the right to make any modification whenever to this publication contents. The information given in this document only contains general descriptions and/or performance features which may not always specifically reflect those described.

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