Rossi EP Series Operating Instructions Manual
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Rossi EP Series Operating Instructions Manual

Planetary gear reducers and gearmotors
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EP series
Operating instructions
Planetary gear reducers and gearmotors
UTD.175.09.2022.00_EN

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  • Page 1 EP series Operating instructions Planetary gear reducers and gearmotors UTD.175.09.2022.00_EN...
  • Page 2 UTD.175.09.2022.00_EN...
  • Page 3 UTD.175.09.2022.00_EN...
  • Page 4 UTD.175.09.2022.00_EN...
  • Page 5 Index General and safety informations Recycling Safety Use conditions and limits Supply status Name plate Lubricant Painting Protections and packing Lifting, handling and storage Receipt Lifting and handling Storage Installation General Screws and tightening torques Flange mounting Gear reducer mounting with slewing outputs Foot mounting Shaft mounting arrangements Torque arm...
  • Page 6 Motor mounting or replacement Electric motors Hydraulic motors Lubrication Commissioning Cooling unit systems Backstop device Maintenance Mounting positions, oil quantities and tanks Plug positions and types Troubles: causes and corrective actions PB series - Parking brakes Commissioning Maintenance Oil change Seal change Troubles: causes and corrective actions UTD.175.09.2022.00_EN...
  • Page 7 All the people who work with the products presented in this operating instructions must carefully read and apply them rigorously. The products correspond to the technical level reached at the moment the document is printed. Rossi S.p.A. reserves the right to introduce, without notice, the necessary changes to improve effi ciency and safety of its products.
  • Page 8 The operation outside this range, with a minimum of -40 °C and a maximum of +60 °C, must be evaluated in relation to the specifi c operating conditions, duty cycle, type of lubricant, type of seals and cooling/heating system (where possible); please contact Rossi S.p.A. Allowed operational and storage ambient temperature in relation to lubricant type...

  • Page 9: Supply Status

    Every gear reducer is provided with a name plate in anodized aluminium containing main information necessary for a correct identifi cation of the product; the name plate must not be removed and must be kept integral and readable. All name plate data must be specifi ed on eventual spare part orders. Assembled by Rossi Italy Gear reducer size...

  • Page 10: Protections And Packing

    Supply status and product designation Lubricant If not differently stated, gear reducers until size 021A are supplied filled for the specific mounting position involved with synthe- tic PAO oil as indicated in an additional label. Painting Standard painting Internal painting External painting Notes Final color Blue RAL 5010...

  • Page 11: Lifting And Handling

    At receipt verify that the unit corresponds to the one ordered and has not been damaged during the transport, in case of damages, report them immediately to the courier. Avoid commissioning gear reducers, that are even slightly damaged. Report any non-compliance to Rossi S.p.A.. Lifting and handling First make sure that the lifting equipment (e.g.
  • Page 12 • generously grease the sealing, the shafts and the unpainted machined surfaces, if any, and periodically control conservation state of the protective anti rust oil • completely fi ll the gear reducers with lubrication oil For storages longer than 2 years or in aggressive environment or outdoors, consult Rossi S.p.A.. UTD.175.09.2022.00_EN...

  • Page 13: Installation

    Connect thermal probes, if any, to auxiliary safety circuits. Use varistors and/or RC filters to limit voltage peaks due to con tactors. • For accessories not supplied by Rossi pay attention to their correct dimensioning; if necessary consult us. Warning! Bearings life, safe shaft and coupling running depend on precise alignment of the shafts.
  • Page 14 Installation Screws and tightening torques According to the design and size stated on nameplate, use screws and tightening torques as shown in the following tables; at least class 10.9 is necessary but in case of heavy stresses, alternate loads and shocks use class 12.9. Screws of class 12.9 must be equipped (where indicated, e.g.: see following table) with ISO 7089 washers (300 HV min.).
  • Page 15 Installation Tightening torque [N m] size output design l min output design l min output design l min R30b S30b H30b R30c S30c H30c R30d S30d H30d R30e S30e H30e R30f S30f H30f R30g S30g H30g R30h S30h H30h R30i S30i H30i R30j...

  • Page 16: Flange Mounting

    Flange mounting For splined couplings apply proper lubricants. To machine the driven shaft, please refer to the dimensions shown in ch. 4, catalog EP series. Before mounting, pay attention to clean carefully mating surfaces. In presence of external radial loads or torque required M ≥...

  • Page 17: Foot Mounting

    Installation Gear reducer mounting with slewing outputs Installation In case of gear reducers with slewing outputs (output design R-S-H), in order to assure a correct running and an excellent power transfer between gear reducer and machine, the gear reducer requires a rigid connection structure withstanding the radial loads. The position and shape tolerances stated below are to be observed.
  • Page 18 Installation Shaft mounting arrangements When shaft mounted, the gear reducer must be supported both axially and radially (also for mounting positions B5 … B53 see ch. 6) by the shaft end of the driven machine as well as anchored against rotation only by means of a reaction having freedom of axial movement and suffi cient clearance in its couplings to permit minor oscillations –...
  • Page 19 Installation Asymmetrical torque arm with spherical plain bearing (size 030-710) H and M output designs can be considered with rigid shaft fastening. T type outputs are to be considered less rigid as a consequence of splined shaft connection and mounting backlash. H and M outputs are to be preferred only when following conditions are met: •...
  • Page 20 Installation Asymmetrical torque arm foot Here below are the recommended dimensions for the torque arm ground connection brackets. Customized solutions on request. Item Description Connection Rod Foot Screw UNI 5739 Spherical plain bearing GE-UK-2RS Torque Arm Circlip DIN 7435 Size W1 W2 Screw 92,5...
  • Page 21 Installation Dynamic torque arm assembly for system flexibility Torque arm with double fulcrum and torsion bar fixed to the ground, allows the gear reducer to follow the driven shaft move- ments during operation and offers an elastic reaction able to absorb the overloads of moment twisting. The allowed displacement values are shown in the figure, are a function of the quantities and must be checked during accessory selection.
  • Page 22 If the shrink disc is not supplied by us, please carefully follow the manufacturer's instructions When keying the shrink disc supplied by Rossi, follow these instructions: • carefully degrease the surfaces of hollow shaft and shaft end of driven ma- chine to be fi tted •...
  • Page 23 Installation • gradually and uniformly tighten, by means of dynamometric wrench, the screws of shrink disc at torque value shown in the fi g. below, by a continuous sequence (not crossing) using approximately ¼ turns for several passes until ¼ turns can no longer be achieved •...
  • Page 24 120 °. Gradually and uniformly tighten the screws by means of dynamometric wrench. • Lock system are plased and no axial movement must be observed, otherwise check components dimension or contact Rossi S.p.A. before other step.

  • Page 25: Accessories Mounting

    Installation 5.10 Accessories mounting Carefully clean the coupling surfaces, apply locking adhesives (recommended only with torque arm or foot bracket) and assemble the accessory to the gear reducer. Tighten the screws by a dynamometric wrench at values shown in the following tables. Torque arm Code screw...
  • Page 26 Installation Fitting of components to shaft end It is recommended that the bore of parts keyed to cylindrical shaft ends (spigots for splined shaft ends) is machined as indicated in EP ca- talog. Before mounting, clean mating surfaced thoroughly and lubri- cate against seizure and fretting corrosion.
  • Page 27 Installation Splined shaft greasing When pinion is supplied separately from gear reducer, before keying it onto shaft, lubricate the splined shaft with anti-corrosion grease in order to avoid any contact corrosion process. Do this operation at the first commissioning, only. Meshing clearance adjustment In the presence of eccentric centering, the meshing action between pinion and rack is regulated through the rotation of the gear reducer inside its seat on the machine.
  • Page 28 Installation Output Gear reducer shaft end tolerances Suggested mating tolerances UTD.175.09.2022.00_EN...
  • Page 29 Installation Tolerances according to ISO 286 from -0,014 -0,006 -0,002 -0,002 +0,006 +0,008 +0,020 +0,012 +0,031 +0,012 +0,006 +0,010 +0,004 -0,024 -0,016 -0,008 -0,012 -0,006 -0,025 +0,002 +0,014 +0,006 +0,006 +0,002 -0,006 > -0,020 -0,010 -0,004 -0,004 +0,009 +0,012 +0,028 +0,018 +0,040 +0,016...
  • Page 30 When a universal fl ange adapter is used, it must be checked if the total weight of the fl ange+motor and the distance of their center of gravity are compliant with the following diagram. In case of high vibrations or dynamic stress, please contact Rossi S.p.A.. Severe or fatal injury and damage to property may occur.

  • Page 31: Motor Mounting Or Replacement

    Motor mounting or replacement Electric motors Check the mating dimensions for standards IEC 72-1 be sure that the mating surfaces are machined under accuracy rating (IEC 60072-1, UNEL 13501-69; DIN 42955) – for NEMA standards please refer to NEMA C-FACE chart; •...

  • Page 32: Hydraulic Motors

    Motor mounting or replacement Bending moment M and dimension h bmax Code bmax I14×160 I19×200 I24×200 I28×250 I28×250 I38×300 I42×350 I48×350 I28×250 I28×250 I38×300 I42×350 2800 I48×350 I55×400 I60×450 I38×300 133,5 I42×350 I48×350 I55×400 4500 I60×450 I65×550 I75×550 I42×350 I48×350 I55×400 4500 I60×450...
  • Page 33 Rossi S.p.A. declines any responsibility deriving from the use of other lubricants or from the use outside the expected ambient temperature range. The indications on lubricants do not bind Rossi S.p.A. on the quality of the lubricant supplied by each re- spective manufacturer.
  • Page 34 Foresee a phase of rotation at no load (pre-heating) at least up to the attainment of a temperature equal or superior to the minimum indicated in the field of application admitted. Application field not allowed. If necessary contact Rossi S.p.A. Indicative output speed for selection of lubricant viscosity >140...
  • Page 35 Commissioning Carry out an overall check, making particularly sure that the gear reducer is fi lled with lubricant up to level and mounted according to the mounting position stated on name plate. The fi ller plug and breather is supplied disassembled, positioned near its hou- sing.
  • Page 36 Commissioning Plugs For EP series plugs are magnetic. Size of plugs and breather plugs and values of tightening torque are shown below. Filler plugs Breather plugs Ø Tightening torque Ø Tightening torque [N m] [N m] G 1/8 " G 1/4 "...
  • Page 37 Cooling unit systems Integrated water cooling unit The gear reducers, according to the sizes, can be equipped with a water cooling unit. Suggested cooling water specifications are: • low hardeness; • max temperature 20 °C; • minimum flow 3 dm /min (l/min);...
  • Page 38 Cooling unit systems Independent cooling units Independent cooling unit with oil-air heat exchan- Independent cooling unit with oil-water heat ger UR O/A ... exchanger UR O/W ... Pos. Description Basament Electric motor Water Coupling Gear Pump Heat Exchanger Pressure Gauge Costumer shaft Pressure Switch Ouput Filter...
  • Page 39 Cooling unit systems Operational features - UR O/A ... - EP Air Oil Heat Air Oil heat Exchanger features Oil filter type Exchanger motor pump Electric fan side Oil side Motor Power and motor type suction delivery fem. Capacity Designation vol.
  • Page 40 G 1" max delivery sending for 1 hole. G 1 1/4" is the gear reducer oil quantity at correct level, see ch. 6, cat. EP series. Stated values are valid with a kinematic oil d internal diameter of fitting and pipes.

  • Page 41: Maintenance

    Backstop device The presence on gear reducer of backstop device is stated by a specific label indicating the free rotation. This system allows the rotation in one specific direction preventing the counter-rotation when the drive is switched off. The exact direction of free rotation is stated on a specific label on the gear reducer.
  • Page 42 Maintenance Re-greasing procedure for slewing output bearings In case of gear reducers with slewing outputs (output design R-S-H), independently from mounting position, the output bearing presents an independent lubrication with grease. The re-greasing of bearing must be realized with the same oil change intervals. It is advisable to re-grease the bearings and the seals with the same grease the gear reducer was supplied with.
  • Page 43 Mounting positions, oil quantities and tanks 001A ... 021A Mounting positions (Output mounting ... F..., ... A...) V3** * Based on the motor size, the expansion tank is required (see page 6.23). ** Based on the output design, the expansion tank is required (see page 6.27). Reference hole for the identification of the mounting position.
  • Page 44 Mounting positions, oil quantities and tanks 001A ... 021A Mounting positions (Output mounting ... F..., ... A...) V3** V31** V32** V33** B51* * Based on the motor size, the expansion tank is required (see page 6.23). ** Based on the output design, the expansion tank is required (see page 6.27). Reference hole for the identifi cation of the mounting position.
  • Page 45 Mounting positions, oil quantities and tanks 001A ... 021A Mounting positions (Output mounting ... P...) B71* B31* B61* B81* * Based on the motor size, the expansion tank is required (see page 6.23). 1) The drawings show the terminal box in position 0. For different positions of terminal box see page 6.22. Oil quantities B3 ...
  • Page 46 Mounting positions, oil quantities and tanks 001A ... 021A Mounting positions (Output mounting ... F..., ... A...) V3** * Based on the gear reducer size and input type, the expansion tank is required (see page 6.23). ** Based on the output type, the expansion tank is required (see page 6.27). Reference hole for the identification of the mounting position.
  • Page 47 Mounting positions, oil quantities and tanks 001A ... 021A Mounting positions (Output mounting ... F..., ... A...) V3** V31** V32** V33** B51* * Based on the gear reducer size and input type, the expansion tank is required (see page 6.23). ** Based on the output design, the expansion tank is required (see page 6.27).
  • Page 48 Mounting positions, oil quantities and tanks 001A ... 021A Mounting positions (Output mounting ... P...) B31* B71* B61* B81* * Based on the gear reducer size and input type, the expansion tank is required (see page 6.23). Oil quantities B3 ... B8 1,2 1,2 3,8 3,7 3,7 6,2 6,2 1,4 1,4 1,8 1,9 1,8 3,2 3,1 3,1 3,7 3,7 1,5 1,5 3,6 3,6...
  • Page 49 Mounting positions, oil quantities and tanks 022A ... 710A Mounting positions (Output mounting ... F..., ... A...) V3** * Based on the motor size, the expansion tank is required (see page 6.23). ** Based on the output design, the expansion tank is required (see page 6.27). Reference hole for the identification of the mounting position.
  • Page 50 Mounting positions, oil quantities and tanks 022A ... 710A Mounting positions (Output mounting ... F..., ... A...) V3** V31** V32** V33** B51* * Based on the output design, the expansion tank is required (see page 6.27). Reference hole for the identifi cation of the mounting position. 1) The drawings show the terminal box in position 0.
  • Page 51 Mounting positions, oil quantities and tanks 022A ... 710A Mounting positions (Output mounting ... F..., ... A...) V3** ** Based on the output design, the expansion tank is required (see page 6.27) * Based on the gear reducer size and input type, the expansion tank is required (see page 6.23). Reference hole for the identification of the mounting position.
  • Page 52 Mounting positions, oil quantities and tanks 022A ... 710A Mounting positions (Output mounting ... F..., ... A...) V3** V31** V32** V33** B51* * Based on the gear reducer size and input type, the expansion tank is required (see page 6.23). ** Based on the output design, the expansion tank is required (see page 6.27).
  • Page 53 Mounting positions, oil quantities and tanks Note For the oil quantities to be filled into the gear reducers with slewing outputs (output design R-S-H), refer to the quantities stated in the previous tables for gear reducers with F output design. The oil quantities stated are approximative for the provisioning.
  • Page 54 Plug positions and types 001A ... 021A Plug positions and types      Mounting positions B3, B5, B6, B7, B8 B32, B52, B62, B72, B82 B33, B53, B63, B73, B83  022A ... 710A  Plug positions and types ...
  • Page 55 Plug positions and types 001A ... 021A Plug positions and types       Mounting positions  B31, B51, B61, B71, B81 022A ... 710A Plug positions and types      Mounting positions  1) See page 6.23.
  • Page 56 Plug positions and types 001A ... 021A Plug positions and types Mounting positions V1, V11, V12, V13 V5, V51, V52, V53             Mounting positions V3, V31, V32, V33  ...
  • Page 57 Plug positions and types 022A ... 710A Plug positions and types Mounting positions V1, V11, V12, V13      Mounting positions V3, V31, V32, V33      1) See page 6.23. 2) Sizes 030A, 042A and 060A. 3) Size ≥...
  • Page 58 • failure nature and duration; • when and under what conditions the failure happened; • during the warranty period, in order not to loose its validity, do not dissamble nor open the gear reducer without the approval of Rossi. UTD.175.09.2022.00_EN...

  • Page 59: Speed Limits

    Features The parking brakes of PB series are spring applied and hydraulic released multi-disc brakes, to be used in combination with planetary gear reducers of EP series. They are not service brakes and they cannot be used in dynamic conditions.
  • Page 60 PB series - Parking brakes 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 the braking torque.
  • Page 61 PB series - Parking brakes Technical data of PB parking brakes PB10-… 0075 0150 0225 0340 0420 0525 0650 0815 Static braking torque [N m] Bstat Min release pressure [bar] 10,2 15,7 15,4 19,4 20,1 24,9 Release pressure [bar] 14,9 16,1 24,7 24,2...

  • Page 62: How Supplied

    PB series - Parking brakes How supplied Nameplate of PB parking brake Every brake is provided with a name plate in anodized aluminium containing main information necessary for a correct identifi cation of the product; the name plate must not be removed and must be kept integral and readable. All name plate data must be specifi ed on eventual spare part orders.
  • Page 63 PB series - Parking brakes PB10 (001/002/C125/C160) Oil quantities [l] 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 quantities [l] 003A…006A 009A…022A 030A…061A 085A…180A 009A…015A, 022A 030A…043A 085A…125A 0,09 0,06 0,16 UTD.175.09.2022.00_EN...
  • Page 64 PB series - Parking brakes PB30 (003/004/006/C200) Oil quantities [l] 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 quantities [l] 0,48 0,24 0,90 009A…015A 030A…043A 085A…125A 250A, 355A 018A, 021A, 030A 060A…085A 180A, 250A Oil quantity [l] For mounting position B5 the exact oil quantity to be filled in the brake is given by the level.
  • Page 65 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.

  • Page 66: Oil Change

    In this case it is necessary to stop gear reducer / brake and contact Rossi after sale service for repair.
  • Page 67 UTD.175.09.2022.00_EN...
  • Page 68 UTD.175.09.2022.00_EN...
  • Page 69 UTD.175.09.2022.00_EN...
  • Page 70 Rossi, who were duly informed about Customer’s application purposes. In this case all the necessary data required for the selection shall be communicated exactly and in writing by the Customer, stated in the order and confirmed by Rossi. The Customer is always responsible for the safety of product applications. Every care has been taken in the drawing up of the catalog to ensure the accuracy of the information contained in this publication, however Rossi can accept no responsibility for any errors, omissions or outdated data.

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