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cap (only up to D 48 mm for overhanging shafts, D 110 mm for
hollow shafts). All internal parts are protected with protective antirust oil.
Unless otherwise agreed in the order, products are adequately packed
as follows: on pallets, protected with a polyethylene film, wound with
adhesive tape and strap (bigger sizes); in carton pallets, wound with
adhesive tape and strap (smaller sizes); in carton boxes wound with
tape (for small dimensions and quantities). If necessary, gear reducers
are conveniently separated by means of antishock foam cells or of filling
cardboard.
Do not stock packed products on top of each other.
4 - Storing
Surroundings should be sufficiently clean, with relative humidity equal
to or less than 50% and free from excessive vibrations (v
to avoid damage to bearings (excessive vibrations should also guarded
during transit, even if within wider range) and ambient storage temperature
should be 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 name plate during transport and storage.
Every six months rotate the shafts to prevent damage to bearings and seal
rings.
Assuming normal environment and the provision of adequate protection
during transit, the unit is suitable for storage not longer than 1 year.
For a 2 year storing period in normal environment or up to 1 year in envi-
ronment with high humidity and temperature and/or environment with high
changes in temperature it is necessary to pay attention also to following
instructions:
– generously grease the seal rings, the shafts and the unpainted machined
surfaces, if any, and periodically check the conservation state of the pro-
tective anti-rust oil;
– for gear reducers and gearmotors supplied without oil: insert anti-
condensation pastilles into the gear reducers to be replaced befo-
re due date and remove them before commissioning (as alterna-
tive completely fill the gear reducers with lubrication oil and
verify the specified level before commissioning).
For storages longer than 2 years, in aggressive environment or
outdoors, consult ROSSI MOTORIDUTTORI.
5 - Installation
5.1 - General
Before the installation, verify that:
– basing on the name plate data and additional literature, if any, the size of
the unit has been chosen to meet the requirements of the application,
that is service factor fs = P
/P
is greater than or equal to fs requested
N1
1
determined basing on instructions given in par. 5.6. At any rate fs is
always to be ≥ 1 (≥ 0,85 for worm gear reducers and gearmotors series
A04):
– input power P
is to be lower than thermal power determined basing on
1
instructions given in par. 5.7.
–
For further information consult ROSSI MOTORIDUTTORI
– Verify the radial and axial loads are to be according to the max admissible
value stated in our technical catalogues. In doubtful cases consult ROSSI
MOTORIDUTTORI;
– There were no damages during transport or storage.
– The motor shaft has not been displaced axially in such a way as to result
in the fan blades touching the fan cover or shield causing possible damage
to one or more bearings.
– Design is suitable to the environment (temperature, atmosphere, etc.).
– Electrical connection (power supply, etc.) corresponds to motor name
plate data.
– Used mounting position corresponds to the one stated in name plate.
– Gear reducers supplied complete with oil contain the correct quantity of
oil for the mounting position specified on the nameplate (see ch. 20) and
filler plug with filter and valve are present (see ch. 6).
– Unpainted surfaces not used for assembly are protected with paint sui-
table for the installation. The paint should be antistatic and not exceed a
thickness of 200
m.
– The category of the machine is suitable to the area where it will
be used. For gearmotors it is necessary to do verifications both regar-
ding gear reducer and motor on the basis of the data of the respec-
tive name plates because their limits of application may be different.
Attention! the name plate data refer only to gear reducer part, when a
motor is assembled to it, the application limits must be deduced from the
combination of the two nameplates, considering the most restrictive ones.
The sensors (e.g. Pt 100) and the thermostats, if any, are sup-
plied apart. For this reason they have to be mounted on the
gear reducer in the mounting position stated in SPT scheme
attached to UT.D 123, following the instructions given in par. 16,
17 and 18.
Connect sensors, if any, to suitable monitoring/control equi-
pment (e.g. Pt 100): see SPT sketch and ch.16, 17, 18.
For equipments suitable for speed variation, utilise a control
system (e.g. encoder connected to a safety system) in order
not to exceed the maximum input speed of 1 500 min
The gear reducer or gearmotor can be installed only if in the environ-
ment there is no potentially explosive atmos phere during the instal-
lation.
Zone
1 (G)
21 (D)
2 (G)
22 (D)
When a motor is assembled to a gear reducer or gearmotor without motor
0,2 mm/s)
eff
verify that it satisfies the minimum safety requirements according to ATEX
94/9/CE, as follows:
1) The equipments suitable for zone 1 are also suitable for zone 2; similarly, the ones suitable
for zone 21 are also suitable for zone 22.
Attention! When lifting and transporting the gear reducer or gearmotor
use through holes or tapped holes of the gear reducer casing; be sure that
load is properly balanced and provide hooks, lifting systems, and cables
of section suitable for the total mass of gear reducer or gearmotor (gear
reducer, motor, oil etc.).
Do not use motor eyebolts when lifting the gearmo-
tors.
When lifting do not add supplementary loads to the gear
reducer or gearmotor mass.
Mount the gear reducer or gearmotor so as not to receive vibrations, if be
sure that the structure on which gear reducer or gearmotor is fitted is plane,
levelled and sufficiently dimensioned in order to assure fitting stability and
vibration absence (vibration speed v
4,5 mm/s for P
forces due to the masses, to the torque, to the radial and axial loads.
Install the unit in such a way that the level plug is accessible for inspec-
tion (where applicable).
For the dimensions of fixing bolts of gear reducer feet and flanges and the
depth of tapped holes consult the ROSSI MOTORIDUTTORI technical cata-
logues: for bolt tightening torques see table 11a.
Carefully select the length of fixing screws when using tapped holes for gear
reducer fitting, in order to assure a sufficient meshing thread length (min
1,5 · D screw) for the correct gear reducer fitting to the machine without
breaking down the threading seat.
Attention! Bearing life and good shaft and coupling running
depend on alignment precision between the shafts. Carefully
align the gear reducer with the motor and the driven machine
(with the aid of shims if need be; for gear reducers size 400
use level tapped holes), interposing flexible couplings whenever possible.
Incorrect alignment may cause breakdown of shafts and/or
bearings (which may cause overheatings) which may represent
heavy danger for people.
Position the gear reducer or gearmotor so as to allow a free
passage of air for cooling both gear reducer and motor (especially at the fan
side of gear reducer and motor).
Avoid: any obstruction to the air flow; heat sources near the gear redu-
cer that might affect the temperature of cooling air and of gear reducer
(by radiation); insufficient air recycle and applications hindering the
steady dissipation of heat. Do not intake heated air.
Mating surfaces (of gear reducer and machine) must be clean
and sufficiently rough to provide a good friction coefficient: remo-
ve by a scraper or solvent the eventual paint of gear reducer
coupling surfaces.
When external loads are present use pins or locking blocks, if necessary.
The bonding connection of gear reducer and eventually his base,
must be carried out through one of the free casing holes:
– remove paint from mating surface;
– use conductors of adequate section according to the regulations in
force, see table 3 of EN 50014 standard, considering as traverse section
area of phase conductors of the installation the one of the motor power
supply cables.
– point out the place used for the earth connection with adequate
.
symbols
Mating surfaces of connections must be clean and protected against corro-
sion and conductors must not be subjected to mechanical stresses.
When fitting gear reducer and machine and/or gear reducer and eventual
flange B5 it is recommended to use locking adhesives such on the faste-
ning screws (also on flange mating surfaces).
Before wiring-up the gearmotor make sure that motor voltage corresponds
to input voltage. If direction of rotation is not as desired, invert two phases
at the terminals of three phase asynchronous motor.
Y- starting should be adopted for no-load starting (or with a very small
load) and for controlled starts, low starting current and limited stresses, if
requested.
If overloads are imposed for long periods or if shocks or danger of jamming are
envisaged, then motor-protection, electronic torque limiters, fluid couplings,
safety couplings, control units or other similar devices should be fitted.
-1
.
Usually protect the motor with a thermal cut-out however, where duty
cycles involve a high number of on-load starts, it is necessary to utilise
thermal probes for motor protection (fitted on the wiring); magnetothermic
UT.D 123 rev. 3
Motor
1)
Thermal probes
II 2G EExe, EExd, EExde
Thermistor
II 2D IP65
o Pt 100
II 3G EExn
—
II 3D IP55 (II 2D IP65
for conductive dust
3,5 mm/s for P
eff
15 kW are acceptable), keeping in mind all transmitted
1
ROSSI
GEARMOTORS
T
surface
To be defined
to zone appli-
cation charac-
teristic
15 kW and v
1
eff
23
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