INSTALLATION AND MAINTENANCE INSTRUCTIONS
PLANETARY GEAR REDUCERS AND GEARMOTORS
UT. D 114 rev. 0
04-03/1 4000 1 GB
Index
1 - General safety instructions
2 - Operating conditions
3 - How supplied
3.1 - Receipt
3.2 -Name plate
3:3 - Painting
3.4 - Protections and packing
4 - Storing
5 – Installation
5.1 - General
5.2- Directions of rotation
5.3 - Fitting of components to shaft ends
5.4 - Shaft-mounting
5.5 - Hollow shaft with shrink disc
5.6 - independent cooling unit
6 – Lubrication
6.1 - General
6.2 - Bearings with independent lubrication, motor bearings
7 - Commissioning
8 Maintenance
8.1 - General
8.2 - Seal rings
8.3 - Motor replacement
9 -Troubles: causes and corrective actions
The paragraphs marked with present symbol contain dispositions to be strictly respected in order to assure personal safety and to avoid any heavy damages to the machine or to the system (e.g.: works on live parts, on lifting machines, etc.); the responsible for the installation or maintenance must scrupulously follow all instructions contained in present handbook.
1 - General safety instructions
Planetary gear reducers and gearmotors present dangerous parts because they can be:
- live;
- at temperature higher 50 ℃;
- rotating during the operation;
An incorrect installation, an improper use, the removing or disconnection of protection devices, the lack of inspections and maintenance, improper connections may cause severe personal injury or property damage. Therefore the component must be moved, installed, commissioned, handled, controlled, serviced and repaired exclusively by responsible qualified personnel (definition to EC 364).
It is recommended to pay attention to all instructions of present handbook, all instructions relevant to the system, all existing safety laws and standards concerning correct installation.
Components in non-standard design or with special executions or with constructive variations may differ in the details from the ones described here following and may require additional information.
For any clarification and/or additional information consult ROSSI MOTORIDUTTPORI and specify all name plate data.
Gear reducers and gearmotors of present handbook are normally suitable for installations in industrial areas: additional protection measures, if necessary for different employs, must be adopted and assured by the person responsible for the installation.
IMPORTANT the components supplied by ROSSI MOTORIDUTTORI must be incorporated into machinery and should not be commissioned before the machinery in which the components have been incorporated conforms to:
- Machinery directive 98/37/EEC;
- Electromagnetic compatibility (EMC) directive 89/336/EEC and subsequent updatings.
For the installation, use and maintenance of the electric motor (standard, brake or non-standard motor) or of the possible motor-variator and/or the electric supply device (frequency converter, soft-start, etc.) consult the attached specific documentation. If necessary, require it.
When operating on gear reducer (gearmotor) or on components connected to it the machine must be at rest: disconnect motor (including auxiliary equipments) from power supply, gear reducer from load, be sure that safety systems .are on against any accidental starling and, if necessary, pre-arrange mechanical locking devices (to be removed before commissioning).
If deviations from normal operation occur (temperature increase, unusual noise, etc.) immediately switch off the machine.
The products relevant to this handbook correspond to the technical level reached at the moment the handbook is printed. ROSSI MOTORIDUTTORI reserves the right to introduce, without notice, the necessary changes for the increase of product performances.
2 - Operating conditions
Gear reducers are designed for industrial applications according to name plate data, at ambient temperature 0 ÷ +40 ℃ (with peaks at -10 ℃ and +50 ℃), maximum altitude 1 000 m.
Not allowed running conditions: application in aggressive environments having explosion danger, etc. ambient conditions must comply with specifications stated on name plate.
3 - How supplied
3.1 - Receipt
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 and gearmotors, that are even if slightly damaged.
3.2 -Name plate
Every gear reducer presents a name plate in anodised aluminium containing main technical information relevant to operating and constructive specifications and defining, according to contractual agreements, the application limits (see fig. 1); 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.
3.3 -Painting
Products are painted with synthetic paint appropriate for resistance to normal industrial environments and suitable for the application of further coats of synthetic paint; colour blue RAL 5010 DIN 1843.
Internal protection in synthetic paint appropriate for resistance to mineral oils or to polyalphaolefines synthetic oils.
3.4 - Protections 'and packing
Overhanging free shaft ends and hollow shafts are treated With protective anti-rust long life oil and protected with a plastic (polyethylene) cap (only up to D ≤48 mm for overhanging shafts, D ≤ 110 mm for hollow shafts). All internal parts are protected with protective anti-rust oil.
Designation (see table on the right)
Non-standard executions
Gearmotor output speed
Gear reducer nominal power
Two months and year of manufacture
Mounting position (when differing from IM B3 or B5)
Gearmotor service factor
Transmission ratio
? Flange – motor shaft
Designation
Machine
Train of gears
Size
Design
Product
R.MR
R.MR
2E, 3E, 4E
CE, C2E, C3E
200….696
200….696 FC…
FO…
Coaxial
Right angle shaft
Fig. 1 (for more information, see ROSSI MOTORIOUTLORI technical catalogues; consult us).
Unless otherwise agreed in the order, products are adequately packed: on pallet, protected with a polyethylene film, wound with adhesive tape and strap (bigger sizes); in carton pallet, 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 anti-shock foam cells or of filling cardboard.
Do not stock packed products on top of each other.
4 - Storing
Surroundings should be sufficiently clean, dry end free from excessive vibrations (veft ≤ 0,2 mm/s) to avoid damage to bearings excessive vibration should also guarded during transit, even if in wider range) and ambient storage temperature should be 0÷+40 ℃: peaks of 10 ℃ above and below are acceptable.
Every six months rotate the shafts (some revolutions are sufficient) to prevent damage to bearings and seal rings.Every six months rotate the shafts (some revolutions are sufficient) to prevent damage to bearings and seal rings.
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