GEA Ariete Homogenizer 3075
#15439
Instructions Manual
Translation of the original instructions
Revision:
00
Use and maintenance instructions
REV.
DESCRIPTION
DATE
SIGN
10/04/2020
ANC
00
First issue
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IMAGES DISCLAIMER
All pictures shown are for illustration purposes only. The actual machine may vary due to
enhancements.
The reproduction and the distribution of contents and images, whether in the original or
amended form, without the prior written permission of GEA are forbidden in any kind of
form.
All rights reserved.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. any reproduction, even partial, is prohibited.
COVER02_REV.4
Use and maintenance instructions
FOREWORD
Dear Customer,
we wish to thank you for selecting our product and ensure you our best assistance in order
to enable you to make the most of your machine.
Also, we remind you that a good understanding of the contents of this manual - through
careful reading of all sections - is essential for the correct, safe use and operation of the
machine you have purchased.
No one should operate or perform maintenance on this machine without first having read
and understood the following Instructions for Use & Maintenance.
For any further support or information, you may contact us at the below listed address.
Yours faithfully,
GEA Mechanical Equipment Italia S.p.A.
Via A. M. da Erba Edoari 29, 43123 Parma - Italia
Tel. +39 0521 965411
Fax +39 0521 242819
gea.com/contact
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
0C00SE7C
0.1
Use and maintenance instructions
CONTENTS - SECTIONS
1.
2.
3.
4.
5.
6.
7.
Technical Specifications
General Information
Machine Operation and Use
Maintenance
List of Spare Parts
Wiring Diagrams
Documentation about Suppliers and Components
How to use the manual
This manual is made of separate sections as indicated in the list of CONTENTS.
Each section is divided into chapters and paragraphs, and pages are numbered separately in each
section. A specific list of contents is given at the beginning of each section.
The pictures and tables referred to in the text are numbered inside each section.
Before installing the machine you must be thoroughly familiar with the information given in Section
2, Chapter 2.8 and, in particular, paragraph 2.8.5.
NOTE:
Following the last update of the technical material, two names will now be used in the manual to
indicate the machine model: a trade name and a technical name.
The trade name appears in a key position on the cover page.
The technical name, which coincides with the previous nomenclature used until now, will also be
used inside the manual.
Example
Trade name: GEA Ariete Homogenizer 3110
Technical name: NS3110H
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
0C00SE7C
0.2
Use and maintenance instructions
SECTION 1
TECHNICAL SPECIFICATIONS
1.0. MACHINE DESCRIPTION
1.1. TECHNICAL DATA
1.2. FLOW-SHEET
1.3. FLOW-SHEET LEGEND (SPEC 102)
1.4. INSTALLATION DRAWING
1.5. CONSUMPTION SPECIFICATION
1.6. OPERATION SEQUENCE
1.7. DECLARATION OF CE CONFORMITY
1.8. FINAL TEST DATA REPORT ( MP10M20 )
1.9. AIRBORNE NOISE EMISSIONS
1.10. LUBRICANT (TT-0038)
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
1C001E7C
1.1
Use and maintenance instructions
1.0 Machine description
1.0.1 General description
This GEA Mechanical Equipment Italia S.p.A. homogenizer consists of a positive-displacement piston
pump, equipped with automatic suction and delivery spring-operated valves, and a homogenizing
section connected to it in which the product undergoes a high-pressure micronization process to
reduce the size of the particles suspended in the fluid and achieve homogeneous dimensional
distribution.
This process can be applied to a large range of products, with various viscosity, and makes it possible
to obtain greater product stability through particle dispersion and micronization, depending on the
pressure applied.
As regards the specific configuration of the machine, model, technical data, accessories and optional
features, please refer to the TECHNICAL SPECIFICATIONS enclosed in chapter 1.1 of this manual.
ATTENTION
The machine must not be used for uses other than those indicated in chapter 2 of this manual.
The manufacturer shall not be liable for personal injury or damages caused by improper use
of the machine.
1.0.2
Operation principle
The machine’s operation principle is shown in the diagram below.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
1C001E7C
1.0.1
Use and maintenance instructions
1.0.3
Main machine components
The main components of the machine are shown in the figures below, for a “Homogenizer” machine
(standard and optional versions).
4
B
3
1
10
2
11
A
Fig. A
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
1C001E7C
1.0.2
5
Use and maintenance instructions
12
13
C
6
F
9
FIG. B
Components of homogenizer machine
Standard version= 1-2-3-4-5-10-11-6-9-12-13
Optional version = A-B-C-F
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
1C001E7C
1.0.3
Use and maintenance instructions
Legend Figures A and B Machine components (Homogenizer machine)
Standard units
1)
Compression head
2)
Homogenizing unit –stage 1
3)
Head pressure gauge
4)
Head safety valve
5)
Manifold unit
6)
Lubrication system
7)
Water system (*)
8)
Pneumatic system (*)
9)
Transmission body
Notes
Option for NS2006 / NS3006
Option for NS2006 / NS3006
10) Motor drive
11) Cover panels
12) Control panel
13) On-machine electrical system
Optional units
A
Homogenizing unit –stage 2
B
Pressure gauge -stage 2
C
Suction pressure gauge
D
Delivery pressure gauge (*)
E
Delivery safety valve (*)
F
Suction buffer unit
G
Delivery buffer unit (*)
H
Partial aseptic system (*)
I
Full aseptic system (*)
NOTE: The asterisk (*) indicates components in standard and optional versions that are not
shown in figures A and B.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
1C001E7C
1.0.4
01/10/2005 - Rev. 2.2
GEA Niro Soavi S.p.A.
GEA NIRO SOAVI MACHINE TECHNICAL
DATASHEET
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
TT-0120C
GENERAL SPECIFICATIONS
Type of Machine
Model
Version
Serial Number
Execution
Special Features
Revision Index
Date
HOMOGENIZER
NS3075H
ARIETE
15439
ASEPTIC
PARTIAL ASEPTIC EXEC.NOT STER.
0
24/02/20
WORKING CONDITIONS
Product
MAX Viscosity
MAX Working Pressure
Flow Rate Type
MIN Flow Rate
MAX Flow Rate
MIN Feed Pressure
MAX Backpressure
MAX Product Temperature
MAX CIP / SIP Temperature
Ambient Conditions
COCONUT MILK
500 cP
250 bar
V F = Fixed; V = Variable; M = Multi
2400 L/h @ 14,9 Hz
8000 L/h @ 49,6 Hz
4-5 bar
5 bar
90 °C
140 °C
40°C MAX; R.H. 40%; 1000 m above sea level
TECH FEATURES - COMPRESSION HEAD
Type
Material
No. of Plungers
Plunger Material
Plunger Diameter
Plunger Stroke
Pumping Valve Type
Pumping Valve Material
Pumping Valve Seat Material
Overpressure Valve Type
Overpressure Valve Setpoint
Packing Material
Gaskets Material
Overpress. Valve Type / IN LINE
Overpr. Valve Setpoint / IN LINE
MONOBLOCK
SAF2205
3
AISI316 + CR - C
65 mm
80 mm
PVP40
STELLITE GR.20
STELLITE GR.20
NSSRLV
300
PEEK+KV+PEEK+SS
EPDM
/
/ bar
PAGE 1 / 2
01/10/2005 - Rev. 2.2
GEA Niro Soavi S.p.A.
GEA NIRO SOAVI MACHINE TECHNICAL
DATASHEET
4
4.1
4.2
4.3
4.4
4.5
5
5.1
5.2
5.3
5.4
6
6.1
6.2
6.3
6.4
7
7.1
7.2
7.3
7.4
7.5
7.6
7.7
8
8.1
8.2
8.3
9
9.1
9.2
9.3
9.4
9.5
TT-0120C
TECH FEATURES - CONNECTIONS & ACCESSORIES
Connection INLET
Connection OUTLET
Pulsation Dampener INLET
Pulsation Dampener OUTLET
Feeding Pump
3" TRICLAMP
3" TRICLAMP
/
/
/
TECH FEATURES - PRESSURE GAUGES
Pressure Gauge Inlet
Pressure Gauge Compr. Head
Pressure Gauge second Stage
Pressure Gauge Outlet
/
MANOM. D100 0-400 BAR
/
/
TECH FEATURES - HOMOGENIZING VALVES
No. of Stages
Type of Control
Homogenizing Valve Type
Homogenizing Valve Material
2
PNEUMATIC
NVHC01 3G ASE
C9M
TECH FEATURES - DRIVE END
RPM Crankshaft MIN
RPM Crankshaft MAX
Stroke
Drive Type
Gearbox Speed Reduction Ratio
Main Motor (frame/type)
Main Motor Power
52
174
80 mm
GEAR REDUCER RI180
5,07
280SMB/4P
75,0 kW
TECH FEATURES - LUBRICATION
Type
Lubricating System
Oil Cooling System
FORCED
FP GR1-6,3 (L6)
BPHE
TECH FEATURES - ELECTRICAL SUPPLY
No. of Phases - MAIN
Voltage - MAIN
Frequency - MAIN
Voltage - AUX
Frequency - AUX
3
380 V
50 Hz
24VDC V
/ Hz
PAGE 2 / 2
Niro-Soavi S.p.A.
LEGEND
TO CONCEPT FLOW SHEET
via M. da Erba Edoari, 29/A
43100 PARMA (ITALY)
PHONE : +39.0521.965411 - FAX : +39.0521.242819
1.
INSTRUMENT SYMBOLS
REV.
0
MACHINERY AND EQUIPMENT
LOCAL
AUTOMATIC ACTUATOR FOR REMOTE
CONTROL, GENERAL
IN MAIN PANEL
LIMIT VALUE
H: HIGH OR OPEN
L: LOW OR CLOSED
____________________
DATE
____________________
SIG.
Page 1 of 2
5.
SPEC - 102 C
MANUAL ACTUATOR NOT FOR REMOTE
CONTROL
H
AUTOMATIC ACTUATOR WITH INTEGRATED
MANUAL CONTROL FACILITY
DIAPHRAGM ACTUATOR
T
POINT OF MEASUREMENT
WITHOUT INSTRUMENTATION
SOLENOID ACTUATOR
PISTON ACTUATOR
2.
PROCESS LINES
ELECTRIC AC MOTOR
PRIMARY FLOW LINE, GENERAL
ADJUSTABLE SPEED CONTROL
SECONDARY FLOW LINE, GENERAL
MECHANICAL CONNECTION
COMPRESSOR OR VACUUM PUMP,
GENERAL
SUPPLY LIMIT MARKER
FAN
PUMP FOR LIQUIDS GENERAL
3.
INSTRUMENT SIGNAL LINES
CENTRIFUGAL PUMP
GENERAL
ELECTRICAL
HIGH PRESSURE PUMP
PNEUMATIC
1-STEP HOMOGENIZER
HYDRAULIC
2-STEP HOMOGENIZER
CAPILLARY
FILTER, GENERAL
HEAT EXCHANGER WITHOUT CROSS
FLOW e.g. ELECTRIC HEATER
4.
.
FLOW LINE ABBREVIATIONS
AS
CIP
CS
CWS
ES
GS
NS
OS
SS
WS
R
AIR SUPPLY
CLEANING IN PLACE
CONDENSATE SUPPLY
CHILLED WATER SUPPLY
ELECTRIC SUPPLY
GAS SUPPLY
NITROGEN SUPPLY
OIL SUPPLY
STEAM SUPPLY
WATER SUPPLY
RETURN
LIGHT SOURCE
VALVE CLOSES (FC)
VALVE OPENS (FO)
VALVE RETAINS POSITION
FAIL-OPEN INDICATION FOR A 3-WAY VALVE
LEGEND
TO CONCEPT FLOW SHEETS
Niro-Soavi S.p.A.
Specialty Products
Division
via M. da Erba Edoari, 29/A
43100 PARMA (ITALY)
PHONE : +39.0521.965411 - FAX : +39.0521.242819
6.
SPEC - 102 C
29/01/2003
____________________
DATE
REV.
0
ALB
____________________
SIG.
Page 2 of 2
LETTER CODE FOR IDENTIFICATION OF INSTRUMENT FUNCTIONS
FIRST LETTER
SUCCEEDING LETTER (1)
MEASURED OR INITIATING VARIABLE
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
DISPLAY OR OUTPUT FUNCTION
ALARM
DISPLAY OF STATE
CONTROLLING
DENSITY
ALL ELECTRICAL VARIABLES
FLOW RATE
GAUGING, POSITION OR LENGTH
HAND (MANUALLY INITIATED) OPERATED
(2)
(4)
DIFFERENCE
(5)
SENSING ELEMENT
RATIO
INDICATING
(3)
SCAN
TIME OR PROGRAMMED TIME
LEVEL
MOISTURE OR HUMIDITY
USER'S CHOICE
USER'S CHOICE
PRESSURE OR VACUUM
QUALITY
NUCLEAR RADIATION
SPEED OR FREQUENCY
TEMPERATURE
MULTIVARIABLE
VISCOSITY
WEIGHT OR FORCE
UNSPECIFIED
VIBRATION
EXAMPLE :
1)
2)
3)
4)
MODIFIER
PDIRC
USER'S CHOICE
(5)
(5)
INTEGRATE OR TOTALIZE
TEST-POINT CONNECTION
INTEGRATING OR SUMMATING
RECORDING
SWITCHING
TRANSMITTING
MULTIFUNCTION UNIT
VALVE, DAMPER, ACTU, ELEMENT
(2)
UNCLASSIFIED FUNCTIONS
COMPUTING RELAY, RELAY
EMERG. / SAFETY ACTING
DIFFERENTIAL PRESSURE INDICATION, RECORDING AND CONTROL
FIRST LETTER P, MODIFIER D, SUCCEEDING LETTERS I,R,C
NORMAL SEQUENCE OF SUCCEEDING LETTERS : B.I.R.C.T.Q.S.Z.A.
SIGNAL TYPE : ON/OFF
SIGNAL TYPE : CONTINUOUS
SIGNAL TYPE : NORMALLY CONTINUOUS. IF ON-OFF, S IS ADDED
5) A NOTE SPECIFIES THE MEASURED PROPERTY. E.g. FOR LETTER E, I, U, P OR F
(2)
2005
1520
260
1470
1530
45
2
280
F1
225
1020
F2
1
225
230
7
8
170+K
835
1
1590+K
1420
490
1080
4
220
3
6
LEAVE AT LEAST 1m FROM EACH SIDE OF THE MACHINE
OVERALL DIMENSIONS (mm)
ITEM
REV. NUMBER
K = ± 30 mm
DESCRIPTION
1
2
PRODUCT INLET
PRODUCT OUTLET
3
4
5
6
7
8
WATER INLET
WATER DISCHARGE
OIL CONDENSATE DISCHARGE
AIR INLET
ELECTRICAL CABLES INLET
CONDENSATE INLET
CONNECTION
3" Triclamp
3" Triclamp
G. 1/2" (BSP, MALE)
G. 1" (BSP, MALE, TO DRAIN)
INSIDE THE MACHINE
G. 1/2" (BSP, MALE)
HOLE
G. 1/2" (BSP, MALE)
WEIGHT : Kg.2800 (F1=1870KG F2=930KG)
REVISION DESCRIPTION
DRAWING_CREATION
00
A4O
DESCRIPTION
NS3075_ID_15439
DESIGNER
2
1
DIMENSIONI E PESI A SOLO SCOPO INDICATIVO
PLEASE CONSIDER THE DIMENSIONS AND WEIGHTS SHOWN AS INDICATIVE
ANP
REVISION DESIGNER
ANP
APPROVED
SCALE
EMISSION DATE
24/02/2020
REVISION DATE
24/02/2020
APPROVAL DATE
1:30
SH. 1 OF 1
GEA Niro Soavi
DRAWING
GEA Mechanical Equipment Italia S.p.A.
via da Erba Edoari, 29 43123 Parma (ITALY)
PHONE:++39.0521.965411 - FAX:++39.0521.242819
NS3075_ID_15439
This drawing is property of GEA Mechanical Equipment Italia S.p.A.I, which will guard its rights by law terms.
SPECIFICA CONSUMI
GEA Niro Soavi
TT-0141
GEA Mechanical Equipment Italia S.p.A.
via M. da Erba Edoari, 29 43123 Parma (ITALY)
UTILITY SPECIFICATION
PHONE : +39.0521.965411 - FAX : +39.0521.242819
NS3075H
MODELLO MACCHINA
MACHINE MODEL
15439
MS
11/03/2020
0
N° DI SERIE
SERIAL No.
SIG.
SIG.
DATA
DATE
REV.
REV.
-
CONSUMI
Fluido
Liquid
Rich.
Required
CONSUMPTION
PRESSIONE
PRESSURE
TEMPERATURA
TEMPERATURE
Bar
PISTONI
CONDENSA STERILE
PISTONS
STERILE CONDENSATE
Min
Max
Min
Max
2
4
15
60
60
80
/
/
/
/
/
2
3
10
25
90
/
/
/
/
/
6
10
SI
YES
ACQUA
WATER
l/h
Max
GEAR BOX
OIL EXCHANGER
°C
Min
RIDUTTORE
SCAMBIATORE OLIO
CONSUMI
CONSUMPTION
SI
YES
SCAMB. CONDENSA
CONDENSATE EXCHANGER
/
Note: max. durezza < 15°fH, max. dimensioni particelle 60 micron
Note: max. hardness < 15°fH, max. particle size = 60 microns, filtred water
SI
YES
ARIA COMPRESSA
COMPRESSED AIR
0
Note : max. dimensioni particelle < 15 μm, max. concentrazione particelle < 8 mg/m3, max. termperatura di condesazione < 3°C, max. contenuto olio < 5 mg/m3 ( Rif. ISO 8573 )
Note: max. particel size < 15 μm, max. particel concentration < 8 mg/m3, max. presure dew point < 3°C, max. oil concentration < 5 mg/m3 (Ref. ISO8573)
Bar
PROD. CONDENSA
°C
/
CONDENSATE PROD.
/
/
kg/h
/
/
/
V
Hz
24
DC
Il Cliente dovrà installare un riduttore al punto di attacco del vapore per adattare la pressione alle esigenze della macchina
The customer must install a pressure reducer at the steam inlet connection to adapt the pressure to the machine's requirements
COMPENSAT. PULS.
PULSATION DAMPER
valore di pressione sul tubo di alimentazione del prodotto
pressure value is referred to the inlet feeding pipe
kW
50
65
0,091
0,62
50
AXIAL
50
4
F
da
E
r
b
a
P
A
R
M
A
A
X
:
S
.p
.A
.
E
d
o
ar
i,
(
I
T
A
L
Y
)
+
39.052
15439_TT0141_00_00_C.pdf
29/A
1.2428
19
1/1
NO
B14
NO
82,5
137,0 1041
NO
1,71
A
NO
0,75
A
TERMISTORI
Connection
Collegamento
Marca
Brand
Tensione
Voltage
Frequenza
Frequency
Poli
Poles
Potenza
Rated Output
Corrente
Current
Corr. spunto
Start. current
Fatt. potenza
Power factor
Efficienza
Efficiency
Forma
Frame
Grand.
Size
Protezione
Protection
Rulli / Edm
R. bearings / Edm
AXIAL
3 x
380
WEG
-
50
4
VIP
v
ia
M
.
4310
0
11
0,84
kW
Quadro Elettrico
Switchboard
NO
NO
1.9654
B3
50
STELLA
STAR
+
39.052
95,6
0,19
9572-0127-022
N
ir
o
S
oa
v
i
:
0,87
4
3 x
380
FORNITO
SUPPLIED
%
50
STELLA
STAR
IEC
Cosφ
75
VIP WEG
M-VMP
MOTORS
4
9562-1206-283 IEC-CENELEC
M-PO
Aux. Voltage
50
3 x
380
IEC
125
Hz
STELLA
STAR
9572-0027-025
TRIANGOLO
DELTA
-
TENS. AUSILIARIA
V
3 x
380
9562-0323-515 IEC-CENELEC
M-VM
P
H
O
N
E
Standards
Norme
Code
Codice
TAG
TAG
MOTORI
M-O
A
THERMISTORS
380
3x
Electrical supply
Hz
280S/M
V
ELETTRICITA'
GEA Niro Soavi
15/06/2017 – Rev. 7
Machine Functional Diagram
GEA Mechanical Equipment Italia S.p.A.
via M. da Erba Edoari, 29 43123 Parma (ITALY)
TT-0134
PHONE : +39.0521.965411 - FAX : +39.0521.242819
MACHINE START
SQ-W / SQ-C
contact closed
MACHINE STOP
B
No
SP-I
contact closed
Start M-VM, M.VMP, M-PO,
M-POP
Local
No
Flow alarm lamp
cont. open after
15 sec
Yes
Light on Low Feeding
Pressure alarm lamp
No
Yes
Remote
Local/Remote
Yes Light on Low Water /Cond.
No
Yes
Deactivate YV-A, YV-A1LR,
YV-A2LR
cont. open after
15 sec
activate YV-W, YV-C, YV-S
A
Set manuals regulator of
st nd
1 ,2 stage to 0 Bar
Set YU-1, YU-2 to 0Bar
(4mA)
Deactivate pneumatic
switches of 1st,2nd stages
Deactivate YV-A, YV-A1 YVA2 (note 1)
CIP
cont. open
after 3 sec
Light ON SLRV-PO
open lamp
Yes
No
Yes
Reduce the
pressure to the
nominal value in
order to close the
valve
(Note 7)
Cut Off the Main supply to
MAIN & AUX MOTORS
No
Stop M-VM, M.VMP, M-PO,
M-POP
Start M-O (note 3)
M-O stopped (note 5)
No
Emergency contact
open
Stop M-O (note 4)
M-O at maximum
speed (note 5)
SIP
activate YV-A after 15
seconds
No
Yes
Working Mode?
Production
Inductive Sensor
SE-OP closed?
SP-O, SP-OP
contact closed
Deactivate YV-W, YV-C,
YV-S
Activate SLRVPO pressure?
Yes
MACHINE IS
STOPPED
Yes
No
Cabinet Ventilation
Fault
cont. open after
15 sec
Yes
Light on Low Oil Pressure
alarm lamp
No
Yes Light on Cabinet Vent. Fault
alarm lamp
Activate YV-AOP
No
No
Inductive Sensor
SE-OP open?
Homo/Pump?
Light ON malfunctioning
SLRV-PO warning lamp
Thermal prot.
contact open
Yes
Pump
Yes Light on Electrical protection
lamp alarm
No
B
Homo
Local/Remote
Remote
See Note 1
REFER TO DOC
TT- 0134/PID
No
SP-A
contact closed
No
Light on Air Pressure
warning lamp
OPTIONS LEGEND:
Yes
Local
activate 2nd st.
pressure?
(note6)
Remote ON/OFF
control only?
Yes
Yes
ST-O, ST-C
contact closed
wait 15 sec. from M-O
start
activate pneumatic
switch of 2nd st.
No
No
Light on High Oil temp./
High Condensate temp.
warning lamp
No
Light on Low Oil Level
warning lamp
Yes
set pres. using 2nd st.
manual regulator
Yes
wait 15 sec. from M-O
start
activate 2nd st.
pressure? (note2)
SL_LO
contact closed
activate YV-A2
No
Adjust 2nd stage pressure, if
required, using manual reg.
Yes
SP-O, Oil Pressure Switch
SP-OP, Oil Pistons Pressure Switch
SP-A, Air Pressure Switch
SP-I, Inlet Feeding Pressure Switch
SQ-W, Water Flow Switch
SQ-C, Condensate Flow Switch
ST-O, Oil Thermostat
ST-C, Condensate Thermostat
SL-LO, Low Oil Level Switch
YV-W, Water Solenoid Valve
YV-C, Condensate Solenoid Valve
YV-S, Steam Solenoid Valve
YV-BY, Feeding Pump Bypass Valve
YV-A1LR, 1st stage Air LOC/REM
Valve
1st stage Pressure
reached?
A
No
No
wait 15 sec.
Some functions are related to optional features of the machine. Consider only what is related to
installed devices or options.
Yes
activate 1st stage
pressure?
No
Yes
wait 15 sec. from M-O
start
activate pneumatic
switch of 1st st.
set pres. using 1st st.
manual regulator
st
activate 1 stage
pressure?
No
NOTES:
1)
Yes
activate YV-A1
st
Adjust 1 stage pressure, if
required, using manual reg.
2)
3)
4)
5)
6)
7)
Activate the REMOTE pressure control referring to the LOCAL/REMOTE options (CF17 or
CF14) included with the machine.
consider this block if the 2nd stage is installed with the remote control and and it's required.
with variable capacity, close the digital RUN contact to the frequency converter.
with variable capacity, open the digital RUN contact to the frequency converter.
SIP/CIP procedure may change according to the plant specific requirement.
consider this block if the 2nd stage is installed and it's required.
The necessary actions to reduce the pressure are under customer responsibility
YV-A2LR, 2nd stage Air LOC/REM
Valve
YV-A, General Air Solenoid Valve
YV-A1, 1st stage Air ON/OFF Valve
YV-A2, 2nd stage Air ON/OFF Valve
YU-1, 1st stage Proportional Valve
YU-2, 2nd stage Proportional Valve
M-O, Main motor
M-PO, Oil pump motor
M-VM, Machine Fan motor
M-VMP, Additional Fan motor on
the main motor
M-POP, Oil pistons pump motor
SE-OP, SLRV opening sensor
SLRV-PO, Pneumatic Safety Valve
page 1/1
05/07/2012 – Rev. 0
REMOTE ANALOG
PRESSURE CONTROL
Functional Diagram
GEA Niro Soavi
GEA Mechanical Equipment Italia S.p.A.
via M. da Erba Edoari, 29 43123 Parma (ITALY)
TT- 0134/PID
PHONE : +39.0521.965411 - FAX : +39.0521.242819
FROM
TT-0134
STARTING 2nd STAGE
ON PROCEDURE
activate YV-A2
TURN ON 2nd stage PID
controller setting parameter
as follow:
I = 0.1sec
P = 10%
D=0
RAMP = 3%/sec
NO
Is 2nd stage pressure
over 30% of Setpoint?
YES
STARTING 1st STAGE
ON PROCEDURE
activate YV-A1
SET YU-1 signal to 12mA (note 1)
NO
Is 1st stage pressure
over 50% of Setpoint?
YES
TURN ON 1st stage PID
controller setting parameter
as follow:
I = 0.1sec
P = 10%
D=0
BACK TO
TT-0134
note 1 : Commissioning eng. to set YU‐1/2 ranges to actual normal operating pressure +10%
note 2 : Apply the Power Supply (24VDC) to the to the Proportional Valve only when is required the pressure
regulation function.
page 1/1
EC - Declaration of conformity for machines
in accordance with EC Machinery Directive 2006/42 /EC, Annex II 1. A
Manufacturer:
GEA Mechanical Equipment Italia S.p.A.
Via A.M. Da Erba Edoari 29
43123 PARMA - ITALY
We, as manufacturer, declare in sole responsibility that the machinery
Name:
HOMOGENIZER
Model:
GEA Ariete Homogenizer 3075
Type:
Serial number:
15439
complies to all relevant provisions of this and the following directives:
Relevant EC
Regulations:
2006/42/CE
2014/30/UE
2014/35/UE
Applied harmonized
EN ISO 12100:2010
standards, in particular: EN ISO 13849-1:2008
EN 60204-1:2006
Other applied
standards and
technical
specifications:
Remarks:
(EG)1935/2004
(EG)2023/2006
We also declare that the special technical documentation for this machine has been created in
accordance with Annex VII, Part A and we obligate to provide these upon reasoned request
from the individual national authorities by data transfer.
Authorized person for compiling and handing
over technical documentation:
GEA Mechanical Equipment Italia S.p.A.
FABRIZIO MICCOLI
Via A.M. Da Erba Edoari 29
43123 PARMA - ITALY
Parma, 10/04/2020
FABRIZIO MICCOLI
Managing Director
MP10M50
0,00
50,00
100,00
150,00
200,00
250,00
300,00
0,0
RPGM - Mechanical Manager
RSAQ - Quality Assurance Manager
Serial number 15439
MACHINE TEST REPORT
Max Current (A)= 133,89
Pressure (Bar)- scale 1
Hours
0,4
0,8
da RPR
Frequency (Hz)- scale 1
Appr.
Max Frequency (Hz)= 48,30
0,6
Rev. 02
1,0
0,00
1000,00
2000,00
3000,00
4000,00
5000,00
6000,00
7000,00
8000,00
9000,00
5/5/2020
Max Capacity (l/h)= 8009,00
Capacity (l/h)- scale 2
data 10.04.07
Emesso da RSAQ data 10.04.07
Data collaudo – Test Date
Max Pressure (Bar)= 250,00
Current (A)- scale 1
0,2
Grafico relativo alla Corrente, Frequenza, Pressione, Portata rilevate
Inlet Pressure(Bar)x10- scale 1
0,1
NIRO SOAVI
Max. Inlet Press. (Bar)= 4,55
scale 1
MP10M20
scale 2
Use and maintenance instructions
1.9. AIRBORNE NOISE EMISSIONS
1.9.1
SOUND PRESSURE LEVEL
Machine model
Sound pressure level dB(A)
NS3075
78 dB(A) ± 2 dB(A)
The table gives A-weighted sound pressure level measured at 1 m from the surface of the
machine and 1.6 m. from the ground, in front of the machine.
The above values are calculated on the basis of measurements made on machines that are
technically comparable and representative of the machine herein described.
This manual is the property of GEA Niro Soavi. Any reproduction, even in part, is prohibited.
1C091E0C
1.9
GEA Niro Soavi
GEA Mechanical Equipment S.p.A.
TT-0038-C
GEA Niro Soavi
LUBRICANT
12/04/2017
22
DATA
REV.
LAS
SIG.
WARNING
FOR TRANSPORT SAFETY REASONS THE MACHINE IS SUPPLIED WITHOUT LUBRICATING OIL.
BEFORE ANY OPERATION FILL UP THE MACHINE WITH OIL ACCORDING TO THE
"INSTRUCTIONS FOR USE & MAINTENANCE".
LUBRICATING OIL
ISO L-HM; ISO VG 150; DIN 51524-2-HLP
BRAND
TYPE
Class:
BRAND
Agip
Oso 150
Klüber
Klüber
Klüberoil
GEM1-150N
Gulf
IP
Hydrus Oil 150
Amoco
Energol HLPHM 150
DTE 10 EXCEL
150
BP
Mobil
TYPE
Klübersynth
GEM4-150N
Harmony 150
AW
American
industrial oil 150
Total
Azolla ZS 150
Fina
Hyidran 150
Chevron
AIO ISO 150
Api
Cis 150
Castrol
Hyspin AWS
150
Kuwait Petr. Int.
Q8 haidn 150
Mobil
Vacuoline 528
ELF
Olna DS 150
ARAL
Degol CL 150T
Lubriplate
HO-3
MORLINA Oil
150
Rando oil HD
150
Shell
Texaco
LUBRICATION PLANT CAPACITY (litres) *
MACHINE MODEL
ONE 7TS
ONE11TS-ONE15TS
ONE 37TF
ONE 75TF
NS 2006
NS 3006
NS 3011 - NS 3015
NS 3018 - NS 3024
NS 3030
NS 3037
NS 3045
NS 3055 - NS 3075
NS 3090 - NS 3110
NS 5132 - NS 5180
NS 5250 - NS 5355
NS 6200
NS 8315
FORCED
/
/
28
30
3
4,5
14
14
14
28
30
30
38
55
95
75
105
TYPE OF LUBRIFICATION
SPLASH
2,5
9
1,5
3
* APPROXIMATE
Sheet 1 of 2
TT-0038-C_Rev_22.xlsx
GEA Mechanical Equipment S.p.A.
GEA Niro Soavi
FOOD GRADE
LUBRICANT
TT-0038-C
12/04/2017
22
DATA
REV.
LAS
SIG.
WARNING
FOR TRANSPORT SAFETY REASONS THE MACHINE IS SUPPLIED WITHOUT LUBRICATING OIL.
BEFORE ANY OPERATION FILL UP THE MACHINE WITH OIL ACCORDING TO THE
"INSTRUCTIONS FOR USE & MAINTENANCE".
LUBRICATING OIL
NSF (Class H1)
Class:
BRAND
TYPE
Shell
Cassida GL220
Fuchs
Rivolta Geralyn SF220
Klüber
Klüberoil 4 UH1-220 N
Mobil
Mobil SHC Cibus 220
Molyduval
Syntholube A 220 LM
Lubriplate
SFGO Ultra 220
LUBRICATION PLANT CAPACITY (litres) *
TYPE OF LUBRIFICATION
MACHINE MODEL
ONE 7TS
ONE11TS-ONE15TS
ONE 37TF
ONE 75TF
NS 2006
NS 3006
NS 3011 - NS 3015
NS 3018 - NS 3024
NS 3030
NS 3037
NS 3045
NS 3055 - NS 3075
NS 3090 - NS 3110
NS 5132 - NS 5180
NS 5250 - NS 5355
NS 6200
NS 8315
FORCED
SPLASH
/
/
28
30
3
4,5
14
14
14
28
30
30
38
55
95
75
105
2,5
9
1,5
3
* APPROXIMATE
Sheet 2 of 2
TT-0038-C_Rev_22.xlsx
GEA Mechanical Equipment S.p.A.
GEA Niro Soavi
PNEUMATIC PLANT
OIL
TT-0164-C
01/03/2012
0
DATE
REV.
TAG
SIG.
RACCOMENDED OIL
Class:
ISO VG 32 DIN 51524-2-HLP
TYPE
MAKE
AGIP
OSO 32
IP
HYDRUS OIL 32
SHELL
TELLUS V 32
MOBIL
DTE LIGHT
BP
ENERGOL HLP 32
CHEVRON
EP HYDR. OIL 32
CASTROL
HYSPIN AWS 32
ESSO/EXXON
NUTO H 32
TEXACO
RANDO OIL HP 32
GULF
HARMONY 32 AW
AMOCO
AMERICAN INDUSTRIAL OIL 32
TOTAL
AZOLLA ZS 32
FINA
HYIDRAN 32
API
CIS 32
KUWAIT PETR. INT.
Q8 HAIDN 32
ELF
OLNA DS 31
FOOD GRADE OIL
Class:
FOOD GRADE OIL
TYPE
MARQUE
AGIP ROCOL
FOODLUBE HI POWER 32
SHELL
CASSIDA HF32
FUCHS
GERALYN AW32
OIL QUANTITY
NUMBER OF HOMOGENIZING
STAGE
QUANTITY (l)
1
1,5
2
3
Sheet 1 of 1
TT-0164-C.xlsx
Use and maintenance instructions
SECTION 2
2.1. SAFETY AND ACCIDENT PREVENTION
2.1.1 APPLICATIONS, INTENDED USE
2.1.2 INTENDED USE, IMPROPER USE AND PERMITTED USE
2.1.3 WORK ZONES, CONTROL ZONES, DANGER ZONES
2.1.4 RISKS, HAZARDS AND RESIDUAL RISKS IN THE ENVIRONMENT
2.1.4.1 GENERAL SAFETY
2.1.4.2 RESIDUAL RISKS AND DANGERS
2.1.5 SAFETY DEVICES ADOPTED
2.1.5.1 OVERPRESSURE VALVE
2.1.5.3 EMERGENCY PUSHBUTTON
2.1.5.4 PROTECTIVE PANEL ON HEAD
2.1.5.5 MACHINE PANELS
2.1.6 SAFETY SIGNS
2.2. CE MARK AND ISO 9000 CERTIFICATION
2.3. IDENTIFICATION OF THE MACHINE
2.4. GUARANTEE
2.4.1 SCOPE OF THE GUARANTEE
2.4.2 DURATION OF THE GUARANTEE
2.4.3 APPLICATION OF THE GUARANTEE
2.4.4 EXCLUSIONS AND LIMITATIONS
2.4.5 HOW TO RETURN THE DEFECTIVE MATERIAL
2.5. HANDLING
2.6. RECEIVING AND CHECKING THE MACHINE
2.7. STORAGE
2.7.1 STORAGE BEFORE INSTALLATION
2.7.2 STORAGE FOR PERIODS LONGER THAN 3 MONTHS
2.8. INSTALLATION
2.8.1 POSITIONING
2.8.2 ACCESS TO THE INSIDE OF THE MACHINE
2.8.3 MACHINE LEVELING
2.8.4 CONNECTION TO UTILITIES AND PRODUCT LINE
2.8.5 INSTALLATION
2.8.6 POSITIONING THE ELECTRIC EQUIPMENT
2.8.7 ELECTRICAL CONNECTIONS
2.8.8 DIRECTION OF ROTATION OF ELECTRIC MOTORS
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1
Use and maintenance instructions
2.9. SPECIAL NOTES
2.9.1 CONTROL BOARD TO BE PROVIDED BY THE CUSTOMER
2.9.2 ELECTRIC MOTOR SUPPLIED BY THE CUSTOMER
2.10. NOTES ON MACHINE TEST
2.11. CLEANING THE MACHINE
2.12. DEMOLITION AND DISPOSAL
2.12.1 DEFINITION OF WASTE
2.12.1.1 SPECIAL WASTE
2.12.1.2 TOXIC-HARMFUL WASTE
2.12.2 TEMPORARY STORAGE
2.12.3 CHARACTERISTICS OF THE CONTAINERS
2.12.4 REQUIRED REGISTRATION
2.12.5 DISPOSAL
2.13. OPTIONS
2.13.1 SECOND STAGE HOMOGENIZING VALVE
2.13.2 ASEPTIC EXECUTION
2.13.2.1 STERILIZING THE MACHINE
2.13.2.2 REGULATING THE FLOW OF COOLING WATER
2.13.2.3 DESCALING AND WASHING
2.13.3 PARTIAL HOMOGENIZING SYSTEM
2.13.3.1 HOW THE BYPASS SYSTEM WORKS
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.2
Use and maintenance instructions
2.1. Safety and accident prevention
2.1.1 Applications, intended use
This GEA Mechanical Equipment Italia S.p.A. homogenizer consists of a positive-displacement piston
pump, equipped with automatic suction and delivery spring-operated valves, and a homogenizing
section connected to it in which the product undergoes a high-pressure micronization process to
reduce the size of the particles suspended in the fluid and achieve homogeneous dimensional
distribution.
This process can be applied to a large range of products, with various viscosity, and makes it possible
to obtain greater product stability through particle dispersion and micronization, depending on the
pressure applied.
The GEA Mechanical Equipment Italia S.p.A. pump consists of a piston positive-displacement pump,
equipped with automatic suction and delivery spring-operated valves, whose function is to transfer
fluid by increasing head.
As regards the specific configuration of the machine, model, technical data, accessories and optional
features, please refer to the TECHNICAL SPECIFICATIONS enclosed in chapter 1 of this manual.
2.1.2 Intended use, improper use and permitted use
It is not permitted to use the machine for a purpose other than those indicated in chapter 2.1.1.
In particular it is not permitted to treat different products or to use the machine with performance values
(especially flow rate and pressure) other than those defined in the TECHNICAL SPECIFICATIONS
enclosed in chapter 1 of this manual
IMPORTANT
Any use other than the one for which the machine was designed and described in this manual,
shall be considered nonconforming and shall relieve GEA Mechanical Equipment Italia S.p.A.
of all responsibility.
ATTENTION
The machine is not designed for use in explosive environments.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1.1
Use and maintenance instructions
2.1.3 Work zones, control zones, danger zones
To enable correct understanding of the topics dealt with in this paragraph, the following definitions
are provided:
“Work zones” :
these are the areas where operators can stand during startup and during normal operation.
From these areas they will be able to rapidly intervene in case of need or emergency, always within
the limits of one’s duties and in compliance with intervention procedures.
The work zones are located around the system in the areas where access is allowed during operation.
“Control zones” :
these are the areas where operators can perform system control and adjustment operations, on the
special control panels.
“Danger zones” :
any area inside or around the machine where the presence of an exposed person creates a risk for
the health and safety of this person.
The danger zones are located around the system.
”Exposed person” :
any person that is wholly or partly inside a danger zone.
“Operator” :
a person in charge of installing, operating, adjusting, servicing, cleaning, repairing or transporting
the system.
ATTENTION:
Under normal working conditions, machine control or operation must take place only in the
area designed for its operation.
The control and operation zones are shown in the figure on the following page.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1.2
Use and maintenance instructions
Control and work zones (a)
Fig. 2.1.3.A
The following points provide some important precautions that relate to the above indications.
ATTENTION
Before starting the work process, an operator must be perfectly familiar with:
• position, function and use of all electric and pneumatic controls
• position, function and use of all safety devices
• the characteristics of the machine
• this manual and how to use it
The operator must also:
• have received adequate training provided on site by the manufacturer’s technicians or an
authorized support service centre
• have
performed
machine
operation
trials
under
the
guidance
of
GEA Mechanical Equipment Italia S.p.A. technicians
NOTE for operator
The operator is required to instruct any aid personnel used during the production cycle
regarding precise duties and compliance with the regulations that require suitable clothing
as shown in the following pages.
ATTENTION - CLOTHING
The operators in charge of operating and servicing the machine must wear work clothes
(with tight fitting sleeves), personal protection devices (gloves, glasses, safety boots) in
conformity with current laws and safety regulations.
The following figures show the personal protection gear recommended for personnel in charge of
maintenance who need to access danger zones.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1.3
Use and maintenance instructions
Wear safety boots
Fig. 2.1.3.b
Wear protective gloves
Fig. 2.1.3.c
ATTENTION
Suitable protective gloves must be work in areas with possible high temperature, in particular
in process zones (compression head, homogenizing valves, pipes).
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1.4
Use and maintenance instructions
Overalls must be in perfect condition
Fig. 2.1.3.d
No large objects protruding from pockets
Fig. 2.1.3.e
Do not wear jewellery
Fig. 2.1.3.f
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1.5
Use and maintenance instructions
Muffs or ear plugs must be worn
Fig. 2.1.3.g
No access by personnel not working in the area
Fig. 2.1.3.h
ATTENTION
The work area must NEVER be cluttered with tools or other objects that could cause hindrance.
Nothing must interfere with the free movement of operators.
In case of emergency, personnel in charge must be able to quickly access the line unhindered.
It is the operators’ duty to ensure that these indications are complied with and report any
failure to do so.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1.6
Use and maintenance instructions
ATTENTION
Personnel not working in the area must not stand in the work zone during machine operation.
Maintenance technicians can work around and inside the machine only after the machine
has been set to “maintenance mode”.
To set machine to maintenance mode, follow the detailed instructions indicated in chapter 4.3.1.3 in
this manual.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1.7
Use and maintenance instructions
2.1.4 Risks, hazards and residual risks in the environment
2.1.4.1 General safety
Compulsory information and training
This manual does not describe general safety aspects that should already be in place in the factory
to comply with the requirements for workplace safety.
However it is important to go over the main points to ensure that these are overlooked in the manual
and in the factory’s safety plan.
ATTENTION
“Protection from risks starts with information and training of workers”.
Instructing workers
The Employer shall arrange for each worker to receive adequate instruction on:
• safety and health risks connected with the company’s activity in general
• measures and protection/prevention activities adopted
• specific risks to which workers are exposed in relation with the work performed, safety regulations
and company rules
• procedures regarding first aid, fire prevention and evacuation plans
Training workers
The employer will ensure that operators and maintenance technicians receive adequate safety and
health training particularly with respect to issues concerning their role and specific duties.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1.8
Use and maintenance instructions
2.1.4.2 Residual risks and dangers
The residual risks present in the machine are listed below:
•
Noise level (personal protection devices, such as plugs or muffs, must be worn)
• Risk of scalding from contact with hot machine parts (protective gloves and
adequate clothing must be worn)
•
Risk of injury caused by moving parts (the machine must be used exclusively
with all of the guards in place and correctly fixed, for maintenance follow the
indications given in chapter 4)
•
Electrocution hazard due to the presence of live parts (these parts are signalled
by an electrical hazard sticker)
•
•
Trip hazard (only for models with access step for maintenance of processing area)
•
Residual risk resulting from the inability to supervise the work area (this residual risk is managed
by indicating the areas involved, chapter 2, and, for maintenance operation, by means of signs
affixed onto the machine and the requirements described in chapter 4)
•
Risk of becoming trapped inside the machine (refers to maintenance technician, for models
NS3037 and higher models)
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1.9
Use and maintenance instructions
2.1.5 Safety devices adopted
The machine is equipped with safety devices that prevent it from reaching critical conditions that
would lead to sudden failure and hazard for users.
Intrinsic safety is ensured by accurate design and sizing allowing large safety margins, considering
the high pressure levels that can be reached as a result of incorrect operation by users or problems
in the line where the machine is installed.
The presence of an overpressure valve on the compression head, suitable electric protection on the
main motor, emergency pushbutton and protective panel on the head, are the main safety devices
present on the machine: these devices are described in the following paragraphs.
2.1.5.1 Overpressure valve
The
pressure
limiting
valve
(1)
has
been
designed
and
constructed
by
GEA Mechanical Equipment Italia S.p.A. for the protecting the machine in case of overpressure
inside the compression head as a result of the machine’s pumping action.
ATTENTION
The safety valve is used for machine protection; pipes downstream of the machine are only
protected by a valve that may be installed in the line.
The safety valve offers the following advantages:
• reduced maintenance
• it closes automatically in case of overpressure release, allowing production to be resumed
immediately
• it enables precise calibration and exact repeatability of interventio
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1.10
Use and maintenance instructions
Location of overpressure valve
Fig. 2.1.5.1.a
Operation
The valve has a ball which is kept in place by a spring; this spring will allow the valve to open
whenever the calibration value set during the final testing is exceeded.
Spring preloading must never be changed to avoid modifying the valve opening value, as this would
affect the safety conditions designed by GEA Mechanical Equipment Italia S.p.A.i and invalidate the
guarantee; for this reason the preload adjustment nut is sealed.
If the calibration value is reached the valve opens automatically and discharges product via the outlet
pipe;
Once the overpressure valve has closed, it is possible to increase the homogenizing pressure again
up to the desired working value, unless the condition that triggered the valve has damaged it to an
extent that it will cause immediate stopping.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1.11
Use and maintenance instructions
ATTENTION
The discharge pipe MUST ALWAYS be directed downwards, to prevent hazards for operators;
the Purchaser is responsible for providing a suitable product collection sump connected to
drainage.
ATTENTION
The discharged product must be disposed of properly, in compliance with current regulations
in force in the country where the machine is installed.
ATTENTION
Triggering of the overpressure valve can cause damage to the safety valve seal with
consequent reduction of the opening value set during the calibration phase. It might therefore
prove necessary to replace the seat and ball after a number of opening events, in order to
restore the original operating conditions.
Washing
Washing of the zone in contact with the product (with closed overpressure valve) normally takes
place during the machine washing phase (C.I.P.).
ATTENTION
After triggering of the valve due to the calibration pressure having been exceeded, the valve
MUST ALWAYS be removed from its position and cleaned manually.
ATTENTION
Do not disassemble the valve body and do not remove the plastic cap. It is prohibited to
change the safety valve set value; doing so will invalidate the guarantee and affect protection
of the machine, of its components and of operators.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1.12
Use and maintenance instructions
2.1.5.2 Protection devices on main motor
The machine is equipped with electrical protection devices to suit motor power, starting system and
operating conditions: they use thermal magnetic switches, fast fuses or automatic switches against
short circuits, automatic switches or inverter for protection against overheating.
2.1.5.3 Emergency pushbutton
An emergency pushbutton (1), highlighted by the specific colour required by current regulations, is
located on the front panel of the machine.
If pressed, this button stops the machine instantly if dangerous situations arise, such as: operating
problems, unusual noise level, possibility of breakage.
Emergency pushbutton
Fig. 2.1.5.3.a
In case of danger you can also use the master switch (2) located on the switchboard as an emergency
shutdown device, as shown in the figure below.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1.13
Use and maintenance instructions
Master switch
Fig. 2.1.5.3.b
ATTENTION
The position of the machine and its connection with the product line must leave sufficient
space to enable rapid, unhindered access to the emergency pushbutton.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1.14
Use and maintenance instructions
2.1.5.4 Protective panel on head
The compression head (1) is fitted with an additional panel to protect personnel from the possible
projection of machine parts and from the high temperature that may be reached by the head.
Compression head panel
Fig. 2.1.5.4.a
ATTENTION
Do not enable machine use if the guard is not in place and correctly fixed.
The guards must never be removed during machine operation.
2.1.5.5 Machine panels
The machine is fitted with cover panels (1) made of satin-finish steel sheet which enables:
• protection of internal machine components from dirt, water or product soiling
• external cleaning
• protection of operators from moving parts, live parts or high temperatures which could be a risk
for the safety of personnel, in compliance with CE regulations and safety standards in force in
the country where the machine is installed.
ATTENTION
The machine must be operated EXCLUSIVELY with panels or guards completely closed, to
prevent the danger of operator injury, therefore it is prohibited to open the above protection
devices during machine operation.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1.15
Use and maintenance instructions
The panels can be removed during maintenance and/or installation procedures.
The side panels have handles (2) and locks with special key to access the inside of the machine,
during maintenance procedures.
ATTENTION
Ensure that ALL the panels are closed and blocked before starting the machine, to prevent
accidents; in handling the panels you should always use the handles provided. Depending
on the size and weight of the panels, two people might be needed to remove and fit back the
panels.
ATTENTION
Before removing the protection panels the operators in charge of installation and maintenance
must set the machine to maintenance mode by following the detailed instructions provided in
chapter 4.3.1.3 in this manual.
Cover panels
Fig. 2.1.5.5.A
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1.16
Use and maintenance instructions
2.1.6 Safety signs
A set of danger signs are affixed onto the machine to call the attention of operators and exposed
persons.
IMPORTANT
The warning signs and compulsory action signs on the machine play an important safety
function; operators and maintenance technicians are required to comply with the indications
on these signs.
The safety signs on the machine have been applied as indicated in the figure on the next page.
ATTENTION
It is prohibited to remove warning signs and compulsory action signs that perform a safety
function.
Failure to comply with this requirement will invalidate the guarantee and transfer all liability
to the purchaser. The user is required to restore any signs that might be accidentally removed
or that are dislodged from their position.
Position of some safety signs present on the machine
Fig. 2.1.6.a
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1.17
Use and maintenance instructions
PROHIBITION SIGN
• No access to personnel not working in this
area.
DANGER SIGN
• Presence of live parts
COMPULSORY ACTION SIGN
• Hearing protection muffs must be worn
DANGER SIGN
• Danger of burning or scalding due to possible
high temperature of machine front
DANGER SIGN
• Danger of burning or scalding due to the
high temperature released by hot surfaces
(homogenizing units)
DANGER SIGN
• Danger of injury caused by moving parts
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.1.18
Use and maintenance instructions
2.2. CE mark and ISO 9001 certification
The machine has been designed and built in accordance with EEC standards on the safety of
equipment (2006/42/CE).
GEA Mechanical Equipment Italia S.p.A. guarantees that this machine complies with the abovementioned standard by marking the front of the machine with “CE” as shown in figure 2.2.1 here
below, on the front part of the machine.
In Section 1 – TECHNICAL SPECIFICATIONS we have attached the Declaration of Conformity CE
of the machine.
Figure 2.2.1
In addition to this, GEA Mechanical Equipment Italia S.p.A. is certified according to UNI EN ISO
9001 for design, manufacturing and servicing of homogenisers and high pressure pumps, therefore
your machine has been enginnereed and produced according to approved quality procedures.
See figure 2.2.2 for the UNI EN ISO 9001 Quality System Certificate.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.2.1
Use and maintenance instructions
Certificate
Standard
ISO 9001:2015
Certificate Registr. No.
01 100 1600162/58
Certificate Holder:
GEA Mechanical Equipment Italia S.p.a.
Via A. M. Da Erba Edoari 29
43123 Parma PR
Italy
Scope:
Development, manufacture and service
of homogenisers and high pressure pumps
® TÜV, TUEV and TUV are registered trademarks. Utilisation and application requires prior approval.
Proof has been furnished by means of an audit that the
requirements of ISO 9001:2015 are met.
Validity:
The certificate is valid in conjunction with the main certificate
from 2019-06-28 until 2022-06-27.
2019-07-01
TÜV Rheinland Cert GmbH
Am Grauen Stein · 51105 Köln
www.tuv.com
Figure 2.2.2
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.2.2
Use and maintenance instructions
2.3. Identification of the machine
The machine is identified by the name plate (fig.2.2.1) located on the front panel (or on the pulley
protection panel, for the Hercules versions without casing), which includes:
- the manufacturer’s name
- model and type
- serial number.
The serial number is also punched on the compression head.
This number should always be quoted in any correspondence addressed to
GEA Mechanical Equipment Italia S.p.A.’s Customer Service in order to identify the machine properly.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.3.1
Use and maintenance instructions
2.4. Guarantee
If not specified otherwise in the order confirmation, the terms and conditions of guarantee are as
follows:
2.4.1 Scope of the guarantee
GEA Mechanical Equipment Italia S.p.A. guarantees the good quality and workmanship of its
products and shall - during the specified guarantee period - repair or replace free of charge any
part whose failure or premature wear and tear are the result of poor quality of materials, defective
workmanship or assembling.
The guarantee shall not apply to those parts whose failure or wear and tear are due to:
• operator’s negligence in checking the levels of the fluids, cleaning the filters, providing the correct
utility lines or improper feeding; insufficient infeed pressure in the machine;
• use of the machine with operating values exceeding the ones specified in the contract, especially
with respect to maximum pressure, flow, product treated, operating and washingtemperatures,
feed pressure, specifications of required utilities.
• use of inappropriate tools for the ordinary or extraordinary maintenance;
• failure to perform or incorrect maintenance;
• alterations or modifications carried out - whether directly or indirectly - without the specific
authorization in writing by GEA Mechanical Equipment Italia S.p.A.;
• failure to comply with the INSTRUCTIONS FOR USE & MAINTENANCE.
• incorrect machine use, incorrect operating procedures and conditions
• incorrect machine installation or incorrect layout of feed line
• use of unsuitable components upstream or downstream the machine, and in particular use of
inadequate feed pump.
For this reason, we strongly recommend that the instructions contained in this Manual are understood
and followed, as a pre-condition for the correct and safe use of the machine.
Using the machine and reading the INSTRUCTIONS FOR USE AND MAINTENANCE imply integral
acceptance of Warranty conditions.
For further information about application of the Warranty, see General Terms of Sale.
2.4.2 Duration of the guarantee
The guarantee shall last for 12 MONTHS from the date of delivery of the machine, unless otherwise
specified in the Order Confirmation.
Such period shall remain unchanged even in the event that spare parts replacements or repairs are
carried out during the 12-month period.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.4.1
Use and maintenance instructions
2.4.3 Application of the guarantee
As a condition of the applied warranty, any parts claimed to be defective by the customer shall be
provided to GEA Mechanical Equipment Italia S.p.A. to establish the cause.
The cost of shipping of materials shall always be charged to the customer.
Any work required for replacement/repair under guarantee shall be executed - at
GEA Mechanical Equipment Italia S.p.A.’s option, on the manufacturer’s premises, on thirds’ party
or directly on the spot.
The cost of shipping materials to the customer’s presmises shall always be charged to the customer,
especially in the case of urgent and specials shipments of material or spare parts.
For any work carried out locally, the customer shall provide and pay for the necessary utilities,
extraordinary equipment, auxiliary personnel that may be required and the costs of travel, board and
accomodation of GEA Mechanical Equipment Italia S.p.A.’s technicians.
2.4.4 Exclusions and limitations
The guarantee shall not cover the materials and parts subject to normal wear and tear such as,
but not limited to, all the gaskets used in the machine, v-belts, plunger seals and relevant packing
and support washers, safety valve seat, filters, etc., As well as those parts whose life can not be
estimated beforehand - such as lamps, fuses, plungers - together with any coating, delivery valve
and their seats, homogenizing valve, pressure gauges.
For the components and accessories bought from independent vendors, the guarantee shall be the
one granted to GEA Mechanical Equipment Italia S.p.A. by such vendors.
2.4.5 How to return the defective material
Before returning to GEA Mechanical Equipment Italia S.p.A. any part for which a replacement/
repair under guarantee is claimed, the necessary approval shall be ontained from
GEA Mechanical Equipment Italia S.p.A.’s Customer Service.
All parts shall be properly packed to avoid any damage in transit, and accompanied by:
• reference to the purchase order number;
• machine serial number;
• code number of the part;
• accurate description of the defect and the circumstances which caused it.
All parts approved to be under guarantee are delivered ex works; replaced parts are the property of
GEA Mechanical Equipment Italia S.p.A. and shall be returned ex works.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.4.2
Use and maintenance instructions
2.5. Handling
CAUTION
These instructions shall be made available to the personnel involved in the handling and
installation of the machine.
The machine is sent to the Customer usually packed in a properly sized wooden crate and wrapped
in plastic film for additional protection, unless otherwise specified in the Order Confirmation.
The wooden crate allows the machine to be handled with a fork lift or crane, and appropriate marks
are provided on the crate at the points for running steel cables or belts for lifting (figure 2.5.1).
Figure 2.5.1
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.5.1
Use and maintenance instructions
Concerning the dimensions and weight of the machine, see the “Installation Drawing” shown in
Section 1 – TECHNICAL SPECIFICATIONS, in order to use the proper lifting equipment.
The weight given is merely indicative and should be used only to select the correct handling and
transport means.
Please note that the center of gravity of the machine lies towards the compression head (front part).
When handling unpacked machines use fork lifts (unless otherwise specified in the handling
instructions) and make sure that the compression head lies on the operator’s side. Forks should
be adequately spaced and sized so as to accomodate the entire base of the frame (figure 2.5.2) to
prevent damage to the machine frame or panels.
Side panels can be removed during transport to prevent damage; the front part of the bodywork,
under the compression head, has not been constructed to support the weight of the machine. Do not
use this part as a lifting point as this could result in damage.
G
G
Figure 2.5.2
CAUTION
In order to ensure a balanced handling of the machine and avoid damage to the machine
itself or hazards for the personnel, all movements should be carried out VERY SLOWLY by
authorized operators, who must wear suitable protection devices and comply with safety
regulations.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.5.2
Use and maintenance instructions
WARNING
Before handling the machine, make sure that the route to be followed and the intended place
of installation are clear of any obstacle.
WARNING
Operators are required to read these instructions before handling the machine; all
personnel involved in handling of the machine must be acquainted with transport and
handling regulations, as well as with regular safety standards.
WARNING
Use only tested hoisting devices approved to support the machine’s weight, as indicated in
the dimension drawing in Section 1 – TECHNICAL SPECIFICATIONS.
Do not under any circumstances leave suspended loads and never stand below suspended
load
WARNING
The floor on which the machine is to be placed must withstand to at least 150% of the machine’s
weight indicated in the “Installation Drawing” in Section 1 – TECHNICAL SPECIFICATIONS.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.5.3
Use and maintenance instructions
2.6. Receiving and checking the machine
Unless specified otherwise in the Order Confirmation, once the machine has left the Manufacturer’s
premises, any damage shall be under the responsibility of the carrier - whether an independent one
or a Customer’s employee.
Therefore, when receiving the machine, the following should be checked:
• contents of the packing against the Packing List;
• integrity of the packing, so that any evident damage can be immediately reported to the carrier;
• any damage suffered by the machine as a result of improper transport by the carrier.
In
order
to
minimize
the
amount
of
inconvenience
for
the
Customer,
GEA Mechanical Equipment Italia S.p.A. Shipping Department is always available to assist with
clarifications, evaluation of any damages, and any other action required to restore the machine to its
proper and safe conditions.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.6.1
Use and maintenance instructions
2.7. Storage
2.7.1 Storage before installation
During the time preceding installation, the machine and its apparatus should be conveniently stored
in closed, clean premises to avoid deterioration and preserve its efficiency.
If no storage place can be provided other than outdoor, a waterproof cover should be provided to
prevent contact with dust, humidity, rain, etc.
Special attention should be given to electric control boards and electronic equipment, which are
easily affected by humidity and low temperature.
If separate from the machine, they should be stored indoors and provided with special humidity
absorbers.
WARNING
Storage temperature should not be less than -5°C and more than +55°C; humidity should be
less than 95%, with no-condensate. Vibrations should be avoided as much as possible.
2.7.2 Storage for periods longer than 3 months
If the machine is expected to remain stored for over three months before installation, provide a
closed storage place protected from bad weather, dust or corrosive releases, as described before.
Observe the above precautions for electric components.
In addition YOU MUST:
• loosen the tension of V-Belts using the appropriate tighteners (sees Section 3 - MAINTENANCE);
• disassemble the plungers and seal packings (see Section 3 - MAINTENANCE)
WARNING
Pistons and seal packings should be reassembled, and belts tensioned at the time of machine
installation.
WARNING
In case the machine plungers are chrome coated, or are using a tungsten carbide detonated
coating (see Section 1 – TECHNICAL SPECIFICATIONS), they must be disassembled together
with the packings if the machine is in storage more than ONE month.
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2C001E17C
2.7.1
Use and maintenance instructions
2.8. Installation
2.8.1 Positioning
Correct positioning of the machine in the production line enables optimal operation and easy
accessibility for the required ordinary maintenance procedures.
For this reason, a clearance area must be allowed around the machine for the activities of maintenance
personnel; the area will depend on the size of the machine. See figure below. This clearance area
must also enable staff to quickly leave the area surrounding the machine in case of accidents.
The front part of the machine and the head require maintenance regularly.
We recommend leaving a suitable space in the front area to enable complete removal of the head
and, on the sides, if the main motor needs to be removed using hoisting means (bridge crane or
fork-lift truck).
It is important to keep the machine away from heat sources that could interfere with the necessary
cooling process, and ensure that no objects are obstructing the flow of air.
Water drainage points should also be available to prevent flooding that could affect the machine.
In particular a drainage sump is needed in the safety valve discharge area.
Lastly, it is necessary to prevent water ingress through the ventilation openings of the machine.
ATTENTION
The floor supporting the machine must be able to withstand at least 150% of its weight, as
indicated in the “Installation drawing”.
Fig. 2.8.1.a
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.8.1
Use and maintenance instructions
2.8.2 Access to the inside of the machine
The machine is provided with a satin-finish stainless steel fairing for:
•
•
•
protection of the internal components from dirt, water or fouling with product;
easy cleaning of the external parts;
operator’s protection from moving, under voltage or hot parts which may be hazardous for the
personnel, in compliance with EC standards and CE mark requirements, and safety regulations
in force in the country where the machine is installed.
CAUTION
to avoid any danger of injuries to the operators, the machine should be operated ONLY with
the panneling in place or protections completely closed.
Panels may be removed to allow maintenance and/or installation work to be carried out.
Side panels are fitted with handles and special key locks to access the inside of the machine.
CAUTION
To prevent accidents, ensure that ALL retainers are locked before starting the machine; to
remove or replace panels always use the handles provided. Depending on the size of the
panels, two persons might be needed to remove or instal the panels.
CAUTION
Before removing the protection panels, the installation/ maintenance personnel should cut
off the power input to the machine by locking the appropriate power switch with a padlock.
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2C001E17C
2.8.2
Use and maintenance instructions
2.8.3 Machine leveling
To ensure a smooth, vibration free operation, the machine should be properly leveled and its legs
should rest evenly on the floor.
To this effect, the machine is supplied with adjustable legs and rubber pad (figure 2.8.1, item 1); in
some cases, with fixed legs which do not require to be adjusted or with pivoting wheels which have
to be locked before operating the machine).
For the leveling, proceed as follows:
• lift the machine and place the pads under the legs;
• lower the machine until the legs sit firmly on the blocks;
• adjust height from floor by tightening or loosening the adjustable legs, then check the levelling
with respect to the machined surface of the head;
• make sure that the machine’s weight is divided among all legs;
• lock the legs using the appropriate lock ring (figure 2.8.1, item 2).
In some cases, due to vibrations, the machine may move and consequently cause stress to the
piping; if you wish to avoid this, the leg pads can be secured by steel rings fixed to the floor.
2
1
Figure 2.8.1
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.8.3
Use and maintenance instructions
2.8.4 Connection to utilities and product line
The type, dimension and position of the connectors normally used to connect the machine to the
production line are specified in the dimension drawing in Section 1 – TECHNICAL SPECIFICATIONS.
The machine also includes (section 1 – TECHNICAL SPECIFICATIONS):
• water connection for lubrication of packs and cooling (max. hardness 8 °dH / 15 °fH;
recommended chloride value < 25 mg/liter, max 200 mg/liter
• water drain pipe;
• (possible) connection for compressed air (for homogenizers provided with air-operated control
system);
• (possible) connection for steam (for aseptic versions)
• condensate drain from lubrication system;
• discharge grid for cooling air.
For the specific requirements of each machine, type of connections and fluid specifications, please
refer to Section 1 – TECHNICAL SPECIFICATIONS.
As far as the utility connections, we recommend providing on/off solenoid valves designed to open
at the machine start (if not already included in the machine) to be placed at the machine’s utilities
inlet ports.
In particular, the manual valves of the lubrication water circuit should remain always open, in a
position which allows controlling an adequate flow of water for lubrication or production of enough
condensate (for the aseptic version).
Keep in mind that excessive lubrication water can lead to flooding of the sump where water is
collected, with the risk of water going into the drive section and polluting the lubrication oil; for this
reason it is important to regularly drain any condensate or water that may be found in the lubrication
circuit, as described in Section 4 - MAINTENANCE.
WARNING
In the case of components made of Tungsten Carbide material, during washing or production,
the use of reverse osmosis purified water, demineralized microfiltered water, Water for
Injection is not recommended.
Its aggressive action would lead to chemical etching of the material in question, drastically
reducing its duration and putting the correct homogenizing operation of the machine at risk.
WARNING
For the machines provided with aseptic system, the Customer shall be responsible to install
a steam pressure reducer to protect the aseptic system and ensure operators’ safety. Fluid
specifications are shown in Section 1 – TECHNICAL SPECIFICATIONS.
In case a pipe is used for the water drainage, when calculating the required diameter and slopes,
remember that water is discharged by gravity and not by pressure. Provide an adequate degree of
slope in the system to avoid water to accumulate in the sump.
WARNING
For the disposal of waste water or cooling water, refer to the specific regulations in force
locally. No traces of lubrication oil or product residues are allowed in the effluents disposed.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.8.4
Use and maintenance instructions
Cooling air is discharged through grids, situated on the top of the machine, controlled by a fan of
suitable size for free discharge (not for all models).
In case the discharged air needs to be conveyed via ducts, please contact
GEA Mechanical Equipment Italia S.p.A.’s Technical Office for details.
WARNING
No device designed to throttle, whether totally or in part, the delivery pipe, is allowed to be
installed downstream the machine, as this may cause risk of excessive pressure in the pipes
and compression head.
In fact, the machine has been designed to withstand output counterpressures not bigger
than those indicated in the Technical Specifications, Section 10 but, as this is a positivedisplacement pump it can create dangerous overpressure which can burst the pipes
downstream the machine when the outlet is closed for the liquid flow.
WARNING
For safety reasons we recommend you ALWAYS install a safety valve downstream the machine
to protect the line and users. You should also ensure that all the valves used downstream the
machine are NORMALLY OPEN valves, so that they will not close in case of accidental stops or
emergency power down, or power failures. The machine has been designed to have a certain
level of inertia, so it will go on pumping even after the main motor has been disconnected.
Figure 2.8.2
ATTENTION
If there are specific requirements of purity or a maximum permissible level of contamination
of the treated product, it is necessary downstream of the homogenizing unit/pump to install
a suitable system or filtering or removing potential contaminants.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.8.5
Use and maintenance instructions
2.8.5 Installation
These guidelines are provided to ensure correct machine installation and operation and guarantee
long life to the machine and its components while preventing situations of danger for operators.
•
For high-pressure positive displacement pumps and homogenizers, infeed pressure must
ALWAYS be kept over a minimum level for correct operation without cavitation conditions
which could damage the machine. The minimum values indicated in Section 1 – TECHNICAL
SPECIFICATIONS must be observed strictly; in any case, depending on the process temperature
and viscosity characteristics, it is necessary to ensure that infeed pressure is constant and
sufficient to prevent cavitation and underfeeding of the machine.
For
further
information
or
special
requirements
ALWAYS
contact
GEA Mechanical Equipment Italia S.p.A..
•
to feed the machine use an infeed pump with delivery 1.2 times greater than the rated flow in
case of machines with 3 or more pistons, and 1.5 times in case of machines with 1 or 2 pistons.
Pump delivery must be calculated at least over the minimum pressure required for feeding.
•
If a positive displacement pump (lobe, single screw, etc.) or diaphragm pump is used , a suitable
by-pass pipe regulated by a modulating valve on the infeed pump, and/or an adequate speed
regulating system for the infeed pump, to ensure correct machine feeding
•
if the products treated vary greatly in terms of viscosity, or if a positive-displacement pump must
be used for viscous products and washing water, you must use a pump speed adjustment system
regulated by infeed pressure to ensure that machine feeding is correct under all conditions,
including during transitory production stages.
•
installation of the two homogenizers or piston pumps in series can only be carried out provided
a few changes are made, such as providing speed variation of both machines controlled by an
an infeed pressure adjustment loop and installation of a by-pass system; for information in this
respect please contact GEA Mechanical Equipment Italia S.p.A..
•
it is necessary to use a feeding pump for each single machine; do not install two or more machines
in parallel with one single feeding pump to prevent dangerour pulsation interferences
•
the feeding line between the feed pump and the homogenizer or piston pump must be direct,
possibly without bends, and with a size equal to or greater than the size of the homogenizer/
piston pump, without section variations, to prevent loss of load; the radius of curves must be
as large as possible to prevent loss of load especially in the infeed stage and to avoid noise
problems at delivery.
•
we recommend you install a pressure gauge near the area where product is fed into the
homogenizer / piston pump in order to check infeed pressure; this pressure gauge can be
supplied as an optional by GEA Mechanical Equipment Italia S.p.A. and can be standard, with
minimum contact or with continuous analog signal for remote control.
•
if filters need to be installed on the feeding line, you must allow a clear area at least 3 times the
size of the pipe used; you also need to install a pressure gauge downstream the filter to check
actual infeed pressure and prevent filter clogging and danger of cavitation of the machine. For
cleaning purposes we recommend installing parallel filters to be used alternatingly.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.8.6
Use and maintenance instructions
•
every homogenizer or piston pump is characterized by pulsating operation: for this reason,
depending on the kind of system and machine flow, we recommend you install a pulsation damper
both for suction and delivery (providing up to 20 bar maximum counterpressure on the line.
•
the pulsation damper is always recommended for flow rates exceeding 5000÷6000 l/h; on the suction
end, it must be installed as close as possible to the machine inlet, while on the delivery end it must be
installed on a horizontal pipe at a distance of minimum 1 meter from adjacent bends. For technical
details about size and installation please contact GEA Mechanical Equipment Italia S.p.A.
•
if the feed pump is connected to a tank, ensure that no air is sucked in by the suction inlet through
the creation of vortices by fitting suitable internal barriers to divert the flow; the feeding pump
must have a net positive suction head at all times
•
we recommend you install a suitable safety valve downstream the homogenizer or piston pump
in order to protect the system from possible overpressure caused by inexperience or incorrect
operation procedures downstream the machine; the safety valve fitted in the machine, even
where a piston pump is used, will protect the machine, but not the system to which it is connected,
in case of dangerous overpressure.
•
Never use the machine to fully drain the feeding tank, to avoid product suddenly running out
during operation under pressure, but provide at least one level sensor to remove pressure (in the
case of a homogenizer) and stop the machine before the product being fed runs out.
•
the product treated must contain no air or gas, to prevent cavitation problems in the machine. If
the product contains air because it is very viscous or due to previous processing phases, you
need to remove the air using appropriate deaeration equipment.
•
the pulsation damper must be installed in a vertical position; do not install the damper so that
the flow enters the damper directly, otherwise the damper will fill up too quickly and become less
effective as no air will be left at the top.
•
if processing temperature exceeds 90 °C, it is absolutely necessary to increase feeding pressure
due to increased steam pressure which can lead to cavitation. Feeding pressure should therefore
be increased by 1 bar for each 5 °C of temperature increase above 90 °C added to the minimum
feeding pressure specified in Section 1 - TECHNICAL SPECIFICATIONS.This value must be
doubled in case of products with a viscosity value greater than 500 cP. For special products and
special process temperatures contact GEA Mechanical Equipment Italia S.p.A.
•
the machine is fitted with automatic pumping spring valves; the load is defined according to the
type of valve and the characteristics of the product. This means that if the machine has been
stopped or is inactive, and the feeding line is open and under pressure, you are able to check
the flow of product through the machine. To make sure there is no product flowing through the
machine when the machine is inactive, the user must provide a cutoff valve for the feeding line
upstream the machine.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.8.7
Use and maintenance instructions
2.8.6 Positioning the electric equipment
Our machines are supplied in the standard version without electric power board; this will be designed
and constructed according to the specifications of the machine as an optional; in any case the
machine is fitted with a terminal box which houses all the connections of the electric devices installed
in the machine, excluding the motors.
Where the electric board is supplied, and as a general recommendation, the cabinet containing the
electric control and power equipment - if not built in the machine - should be placed as far as possible
in clean, dry, ventilated premises which should be free from vapour, suspended dust or corrosive
release. Before ordering the machine, the Customer should make sure that the intended place of
installation is suitable to protect the equipment from any aggression.
Besides, it should be ascertained that no heat sources are present in the vicinity to avoid local
overheating and ensure that all electric equipment can be cooled down efficiently.
When forced ventilation is provided, any air vent should remain unobstructed. If it has been established
that the ambient air is not suitable for proper ventilation, an air duct should be provided, in addition
to selecting a control board suitable for the particular operating conditions existing locally.
For the type, overall size, weight and installation requirements of the control board,
see Section 1
TECHNICAL SPECIFICATIONS (if the board has been supplied by
GEA Mechanical Equipment Italia S.p.A.).
2.8.7 Electrical connections
The power line to the control board should be of appropriate type according to the length, type of
routing, ambient temperature, nature of the load, and always in accordance with the provisions
of the local regulations on this matter. If no specific agreements have been made in writing with
GEA Mechanical Equipment Italia S.p.A., the user shall be responsible for establishing the features
of the power line and earthing conductor up to the terminal board of the machine, as well as selecting
appropriate protection devices against short-circuits and contact voltage. Where the electric board
is supplied by GEA Mechanical Equipment Italia S.p.A. we will provide a list of cables with size
calculated assuming a length of 50 meters, closed conduit with three-pole cables and 40 °C ambient
temperature.
As far as the power details of the machine and wiring diagrams, reference should be made to the
electric specifications and diagrams shown in Section 1 - TECHNICAL SPECIFICATIONS and in
Section 6 – WIRING DIAGRAM.
CAUTION
The indications given concerning the wiring refer to standard laying and environmental
conditions; the values shown are purely indicative, therefore they should ALWAYS be crosschecked by the user depending on the actual operating conditions.
The electric connections between machine and electric power board and between electric power
board and power mains must be made by the Customer who is also responsible for checking that
they have been properly executed and that they comply with the wiring diagram, before the machine
is started up.
GEA Mechanical Equipment Italia S.p.A. shall not be liable for injury to people or damage to objects
caused by incorrect connection of electric equipment; all electric connection must be checked by
authorized personnel.
If in doubt please contact GEA Mechanical Equipment Italia S.p.A..
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2C001E17C
2.8.8
Use and maintenance instructions
2.8.8 Direction of rotation of electric motors
At the time of wiring, make sure that all motors rotate in the correct direction:
CAUTION
To check the direction of rotation, the motors should be operated ONLY by impulses.
When performing these operations, follow strictly the safety rules and stay away from any
moving part inside the machine.
Remove only the panels on the LEFT HAND SIDE of the machine.
Before starting the machine, make sure that the protection panels on the RIGHT HAND SIDE
(drive) of the machine are in place.
•
•
•
•
main motor: the correct direction of rotation is shown by the arrow on the flywheel; it is
COUNTERCLOCKWISE for machines with FORCED LUBRICATION and gear reducer);
COUNTERCLOCKWISE for machines with splash lubrication (see Section 1 - TECHNICAL
SPECIFICATIONS), unless otherwise specified by the direction of the arrows on the machine
(flywheel and/or motor)
oil pump motor (only for machines with motor-driven lubrication pump): follow the direction of the
arrow printed on the pump body. In case of mistake, the low pressure in the circuit triggers the
pressure switch, which prevents the machine operation;;
electric fan of main motor (only for machines designed for variable speed): follow the direction
indicated by the arrow;
electric fan of machine body: follow the direction indicated by the arrow.
Auxiliary motors may be installed depending on the type of machine: verify the actual installation with
reference to the technical sheet and the wiring diagrams, Section 1 -TECHNICAL SPECIFICATIONS.
If the direction of rotation is not correct, reverse any of the two phases of the supply cord.
CAUTION
Before starting the motors ensure that ONLY installation personnel are present in the vicinity,
and that NOBODY is in contact with the machine.
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2C001E17C
2.8.9
Use and maintenance instructions
2.9. Special notes
2.9.1 Control board to be provided by the customer
If the electric power and control board (optional) is not supplied with the machine,
GEA Mechanical Equipment Italia S.p.A. will include a Technical Sheet (Section 1 - TECHNICAL
SPECIFICATIONS) showing the electrical requirements of the machine, together with an operation
sequence to enable the Customer to establish the elements of the control board and the operating
features of the required protection devices for a correct execution and the selection of appropriate
control and protection devices.
CAUTION
GEA Mechanical Equipment Italia S.p.A. shall not be held liable for damages caused to either
persons or the machine due to mistakes made in the design and/or execution of the control
board.
CAUTION
The control board should be built in accordance with the local operational and safety
regulations in force.
2.9.2
Electric motor supplied by the customer
The electric motor shall be made in accordance with the general specifications laid down by
GEA Mechanical Equipment Italia S.p.A. as to POWER, NUMBER OF POLES, SIZE, SERVICE
(Section 1 - TECHNICAL SPECIFICATIONS).
The motor shall be placed either on the supporting plate and secured by bolts in the holes provided
(or made at the time of installation) taking care that the motive pulley is in line with the flywheel.
For information on installation and tensioning of V-belts see Section 3 - MAINTENANCE.
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2C001E17C
2.9.1
Use and maintenance instructions
2.10. Notes on machine test
Before shipment all of our machines are accurately tested by qualified personnel through operational
tests which simulate the normal working conditions.
Through the operational tests - run with cold water - it is possible to verify the actual performance
of the machine against the design data, the calibration of safety, control and check devices, the
conditions of any seals, as well as the noise and vibration-free operation of the machine and the
parameters introduced in any programmable instruments or equipment that might be used.
To test the conditions of operation of the machine (flow rate with the maximum operating pressure
allowed, noise level, electric absorption) the machine is run with water at a temperature of approximately
20 °C, so it is possible to verify the deviation of the machine’s actual flow rate compared to the rated
value ± 5% with product.
However, at the time of start-up, after the machine has been installed in the production line, a final
test of the conditions of operation is required.
Upon request of the Customer, GEA Mechanical Equipment Italia S.p.A. can dispatch an engineer
for the first machine start-up in order to check that the wiring has been executed correctly and that
the machine has been properly installed, besides providing any additional information or instruction
to the operators and service personnel with reference to this Manual.
CAUTION
Should the Customer decide not to ask for the attendance of our engineer at the time of
the start-up, GEA Mechanical Equipment Italia S.p.A. shall not be liable for damages to
persons or property caused by failure to observe the instructions provided in this Manual
(INSTRUCTIONS FOR USE AND MAINTENANCE).
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.10.1
Use and maintenance instructions
2.11 Cleaning The Machine
The machine is supplied with external paneling in glazed stainless steel plate (ARIETE version)
which is easy to clean with water.
Washing prevents the deposit of product residuals on the machine: wash the bodywork with running
water from time to time, paying particular attention to the compression head and the sump.
If required you may use a cloth and any standard mild detergent.
To prevent water from entering the machine, place a suitable covering over the ventilation hole; do
not wet the electric panel or the control panel.
The HERCULES industrial version is supplied without external paneling, but only with protection
panels to cover moving parts: in this case make sure you do not wet unnecessarily the electrical
components of the machine.
WARNING
Before washing with running water, make sure that power has been cut off by means of the
sectioning switch of the supply line that should be locked with appropriate padlock.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.11.1
Use and maintenance instructions
2.12. Demolition and disposal
2.12.1 Definition of waste
Waste means any substance and object deriving from human activity or natural cycles, which is
abandoned or destined to be abandoned.
2.12.1.1 Special waste
The following can be considered special waste:
• Residues deriving from industrial processes, agricultural, artisan, commercial and service-related
activity which, because of its quality or quantity, cannot be included in municipal wastei
• Deteriorated, obsolete machinery and equipment
• Motor vehicles and discarded parts
2.12.1.2 Toxic-harmful waste
Toxic and harmful waste means all waste containing or contaminated by the substances indicated in
the annex to DPR 915/82, as amended, implementing the directives 75/442/EEC, 76/403/EEC and
768/319/EEC and/or the laws or regulations of the Country in which the machine is installed.
In particular, the classification of waste is now regulated by the environmental consolidation law
D.Lgs 152/06, as amended, and pursuant to European Regulation no. 1357/2014 harmonizing
the hazardous properties with the new labelling for hazardous substances governed by European
Regulation no. 1272/2008
Fig. 2.12.1.2
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.12.1
Use and maintenance instructions
2.12.2 Temporary storage
Temporary storage of toxic and harmful waste is allowed prior to planned disposal by means of
treatment and/or final storage. In any case environment protection laws in force in the user’s country
must be complied with.
2.12.3 Characteristics of the containers
All fixed and movable containers destined to contain toxic and harmful waste must have adequate
resistance characteristics depending on the chemical-physical properties and the hazardousness of
the waste contained.
All containers holding dangerous or harmful products or substances must bear indications and signs
designed to reveal the nature of their content.
2.12.4 Required registration
For the disposal of used oil, we recommend the use of in/out registers for special waste or toxicharmful waste deriving from machine processes.
2.12.5 Disposal
Any refuse materials product must be disposed of in accordance with the laws in force in the country
where the system is installed.
The substances produced during maintenance or machine demolition procedures are :
• used lubricants;
• recovery materials (coating, electric cables, etc.);
• plastic and rubber materials (pipes, gaskets, etc.);
• metals (head and transmissions components, frame, panels, pipes, bearings, gears, etc.);
• electric and electronic components.
Any polluting product must be disposed of in compliance with the provisions contained in the laws of
the country where the machine is installed.
Pursuant to directives 2002/95/CE (RoHS) and 2002/96/CE (RAEE)relating to disposal, it is
compulsory to ensure that the products subject to these directives are recycles using the best
technology available for treatment, reuse and recycling to safeguard the health of people and the
environment.
The purchaser, i.e. owner of the GEA Mechanical Equipment Italia S.p.A. product, is required to
comply with the obligations laid down by the above mentioned directives.
In particular, it should be noted that:
a) it is prohibited to dispose of RAEE waste as municipal waste; this waste must be disposed of
through the separate collection facilities provided by public or private authorities;
b) potential effects exist for the environment and human health due to the presence of dangerous
substances in the electrical and electronic equipment or due to improper use of the equipment
of part of it.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.12.2
Use and maintenance instructions
2.13. Option
2.13.1 Second stage homogenizing valve
As an option, a second homogenizing stage can be installed on GEA Mechanical Equipment Italia S.p.A.
Homogenizers in series with the first stage valve.
In this way it is possible to reduce the increase of viscosity produced by the treatment of the product,
in case it contains colloidal or thickening substances.
Although the micronization effects obtained with the 1 stage are unaffected, the 2nd homogenizing
stage reduces the product viscosity and allows the distributing of the pressure drop.
Moreover, it is possible to avoid the clustering of micronized particles, due to the homogenizing
effect.
The application of the 2nd stage should be decided on the basis of specific considerations concerning
the type of product.
As a general rule, the second stage pressure is usually applied as 1/10 to 1/5 of the maximum
homogenizing pressure, according to the processed product requirements.
The formula which relates the homogenizing pressures in a two stage system (see figure 2.13.1) is
the following:
Ptot = P1 = P2 + dP
where:
Ptot = P1
is the total pressure measured on the compression head, equivalent to the 1st stage
pressure
P2 is the pressure applied to the 2nd stage
dP = P1 - P2 is the pressure difference between the 1st and the 2nd stage, applied in the
passage through the 1st stage valve.
Do not hesitate to contact GEA Mechanical Equipment Italia S.p.A. for advice and clarifications.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.13.1
Use and maintenance instructions
P2
dP
P tot=P1
Figure 2.13.1
2.13.2 Aseptic execution
Whenever a sterile plant and product needs to be ensured, an aseptic version of the
GEA Mechanical Equipment Italia S.p.A. machine is available.
This can be achieved by running sterile condensate through the plungers in the seal section and
through the seal of the homogenizing valve shaft using appropriate sterile chambers to avoid
contamination from outside sources.
Condensate is produced by steam condensation at a temperature of 140 °C through water run in a
heat exchanger.
The cooling water should be clean and preferably softened to avoid scaling deposits in the exchanger.
Water hardness must be under 8 °dH / 15 °fH, with recommended chloride value < 25 mg/liter and
in no case greater than 200 mg/liter.
The required flow rate and water temperature values are indicated in the consumption tables, Section
1 – TECHNICAL SPECIFICATIONS.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.13.2
Use and maintenance instructions
2.13.2.1 Sterilizing the machine
Before starting up the machine following an extended period of standstill - or at first start-up - we
recommend sterilizing the areas to be maintained aseptic with live steam (max temperature 140
°C at 2.6 bar) and with the machine stopped: to do so, open the steam on/off tap without sending
any water to the exchanger. After sterilizing cool down the system by flowing the sterile condensate
obtained from steam condensation through the aseptic circuit.
This operation should be performed with the machine stopped to avoid damaging irreparably the
seal packings of the plungers.
ATTENTION
If the machine relies on a supply system with a bypass circuit (feed pump and modulating
valve), refer to the sterilization procedures described in the feed pump manual.
• The Control Logic Requires The Feed Pump To Stop In The Sterilization Phase.
• Before restarting in the production phase, reckon on a machine cooling time long enough
to cool the system (t<40°c or three hours).
The machine’s product circuit can be sterilized using live steam or pressurized water, with a maximum
temperature of 140 °C and for maximum 30 minutes. To avoid damaging the seal packings of the
plungers and thus reduce their life, we recommend that you stop the machine before sterilizing it or
that you alternate 1 minute operation phases with 10 minute stops (in case of fixed flow rate/speed
machines), or with the lowest speed possible in case of operation with frequency converter.
During the sterilizing phase the alarm for “ HIGH CONDENSATE TEMPERATURE” may go on: you
may either exclude it or just switch it off
2.13.2.2 Regulating the flow of cooling water
During operation, the cooling water on/off valve (whether manual or solenoid) should remain open.
An additional manual valve on the outlet of the exchanger has been provided to control the water
flow and obtain sterile condensate at a temperature of 40 to 50 °C. This has the extra advantage of
helping reduce any waste of softened water.
2.13.2.3 Descaling and washing
The use of water – even when softened - for steam condensation inevitably produces some deposits
of lime in the exchanger.
Whenever a reduced exchange power is noticed - evidenced by an insufficiently cooled condensation
- a descaling of the aseptic system is required.
It is impossible to predict the frequency of this operation, since the formation of lime deposits depends
largely on the hardness of the water available.
For more details on maintenance operations, see Section 4 - MAINTENANCE.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.13.3
Use and maintenance instructions
2.13.3 Partial homogenizing system
GEA Mechanical Equipment Italia S.p.A. homogenizers can have installed, as an option, a partial
homogenizing system, to homogenize only a part of the total flow which is then mixed with the
remaining non homogenized part in a special mixing chamber (see figure 2.13.2).
The homogenized part is normally around 30% of the total capacity of the system.
A typical application is the homogenization of fresh milk where only the fat part (milk cream) coming
directly from the centrifuge is homogenized then mixed downstream of the homogenizing valve to
get fresh milk with standardized fat content.
The system includes, in addition to the homogenizing valve, a special mixing chamber featuring the
recombination of the two portions using the high speed turbulence of the flow, plus a by-pass system
with pneumatic valve and check valve (see figure 2.13.3) to feed the machine properly during the
centrifuge desludging phase and avoid underfeeding at the homogenizer inlet.
A typical scheme of partial homogenizing system is shown in figure 2.13.4.
Figure 2.13.2
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
2C001E17C
2.13.4
Use and maintenance instructions
2.13.3.1 How the bypass system works
To make the by-pass circuit work properly, it is necessary to open and close the pneumatic butterfly
valve (position A, figure 2.13.3) with a signal coming from the centrifuge.
This valve must be closed during normal operation, opened during desludging phase and cleaning
of the equipment.
A
Figure 2.13.3
Follow the instructions below for the correct operation of the system:
• Open the pneumatic butterfly valve few seconds before the desludging phase of the centrifuge;the
single-acting check valve installed prevents the product to be homogenized from flowing through
the by-pass even when the butterfly valve is open
• Close the pneumatic butterfly valve few seconds after the desludging phase of the centrifuge has
been completed;
• Keep downstream the homogenizer a minimum backpressure of 1÷2 bar, to allow the back
flow of the homogenized product into the suction manifold through the by-pass, when opened.
Thus it is necessary to avoid a free discharge into an open vessel or tank without pressure; if
the backpressure generated by the downstream plant is not enough to make the system work
properly, it will be necessary to install a suitable adjustable backpressure valve necessary to
install a suitable adjustable backpressure valve
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2C001E17C
2.13.5
Use and maintenance instructions
WARNING
To ensure the complete and proper cleaning of the by-pass circuit, it is necessary to keep
the pneumatic butterfly valve (pos. A, figure 2.13.3) during the cleaning phase. Moreover, the
backpressure downstream the homogenizer must always be higher than the suction side
pressure.
Fig. 2.13.4
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2C001E17C
2.13.6
Use and maintenance instructions
SECTION 3
OPERATION & USE OF THE MACHINE - INDEX
3.1. Generals
3.2. Checks before start-up
3.3. Start-up procedure
3.3.1 Operator’s position
3.3.2 Control panel
3.3.3 Start-up
3.4. Operation and adjustment
3.4.1 Homogenizing pressure adjustment – 1 stage
3.4.2 Homogenizing pressure adjustment - 2 stages
3.4.3 Remote pneumatic control (optional)
3.5. Machine stop
3.5.1 Emergency stop
3.6. Cleaning
3.7. Safety devices
3.7.1 Overpressure valve
3.7.1.1 Operation
3.7.1.2 Cleaning
3.7.2 Protections on main motor
3.7.3 Emergency push-button
3.7.4 Compression head guard
3.8.
Troubleshooting
3.9.
Special features of non standard machines
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3C001E14C
3.1
Use and maintenance instructions
3.1. Generals
The GEA Mechanical Equipment Italia S.p.A. Homogenizer consists of a positive-displacement
piston pump provided with automatic valves with suction and delivery spring , connected to a
homogenizing section where the product undergoes the process of high-pressure micronization to
reduce the size of the solid particles suspended in the fluids and achieve homogenous dimensional
distribution.
This process can be applied to a wide range of products with variable viscosity, and it allows to obtain
more stable suspensions through micronization and dissipation of solid particles, depending on the
level of pressure applied.
To find out about the specific configuretion of the machine, model, technical data, accessories and
optionals, see Section 1 - TECHNICAL SPECIFICATIONS.
WARNING
For safety during transport, the machine is supplied WITHOUT LUBRICATION OIL inside the
drive section.
Before carrying out any operation fill with oil as described in Section 4 –MAINTENANCE,
paragraph 4.9 LUBRICATION.
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3C001E14C
3.1.1
Use and maintenance instructions
3.2. Checks before start-up
WARNING
The operating temperature of the machine must be between +5°C and +40°C; maximum
humidity 90%; maximume altitude 1000 m. For operating conditions outside these value
limits a special version must be used.
WARNING
Any operation involving the removal of the machine panelling should be performed with the
MACHINE STOPPED AND ISOLATED from the power line by locking the isolator switch with
a padlock, so that nobody can accidentally give power to the machine.
Since the GEA Mechanical Equipment Italia S.p.A. homogenizer has been designed to reach high
pressures, good practice is to take certain precautions to avoid injuries/damage to persons, the plant
or the machine itself.
These instructions refer to the first startup or after period during which the machine is not in constant
use.
For correct and safe use of the machine we recommend that you carry out the periodical check
required depending on the type of machine use, to ensure the machine is in perfect condition and
prevent possible problems, if any; it is also a good practice to check from time to time that the
machine is being operated in accordance with the prescription of the manual.
Specific indications concerning normal start are given in chapter 3.3.
•
•
Check the connections with utilities and product line. Refer to Section 1 – TECHNICAL
SPECIFICATIONS for their specifications and location.
Check that the pipes upstream and downstream the machine are clean and free from
scaling or welding residues which may damage the machine seriously.
CAUTION
Do not use the machine to dispose of any impurities found in the piping up- and downstream
the machine
•
•
•
•
•
•
•
Check the V-belt drive assembly. For the correct tensioning and alignment of belts refer to Section
4 - MAINTENANCE.
Verify the level of lubrication oil through the sightglass: this should be covered with oil by 3/4 or
reach the level shown on the special visual indicator. When checking the oil level, the machine
should be stopped, because normally the start-up causes the level to lower as it fills the circuits.
If topping-up is needed, use only the oil types indicated in Section 4 - MAINTENANCE.
For machines equipped with gear reducer, check the level of lubrication oil through the inspection
hole provided on the reducer. If topping-up is needed, use only the oil type indicated in Section
4 -- MAINTENANCE.
Make sure that the high pressure flanges, unions and nuts in the compression head are properly
tightened to the values shown in the “Tightening torque” table, Section 4 - MAINTENANCE
Verify that plungers are tight and that seal packings are in place, if they have been removed
during storage or after standstill of over 3 months.
Check the direction of rotation of motors as described in Section 2 - GENERALS, chapter 2.8.8
Make sure that all protection panels are in place and securely fixed.
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3.2.1
Use and maintenance instructions
CAUTION
Failure to observe the last recommendation here above may - in case of machine starting result in a severe risk of injury for anyone standing near moving parts.
•
•
•
Make sure that the homogenizing pressure controls (figure 3.2.1) (air-operated switch A and
reducer B) are either completely loosened or on the OFF position, and that any manual controls
are fully loosened (fig.3.2.2).
Verify that all safety and protection devices are in perfect operating condition.
Make sure that any valves and parts of the system downstream the homogenizer are open to
prevent overpressure in pipes when the homogenizer is started.
C
D
A
B
FIGURE 3.2.1
+
-
FIGURE 3.2.2
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3.2.2
Use and maintenance instructions
3.3. Start-up procedure
3.3.1
Operator’s position
To ensure the safe use of the machine during start-up and adjustment operations, we recommend
that the operator should stand as indicated in figure 3.3.1.
The control panel - configurated according to the Customer’s requirements - is on the left hand side
of the machine front; an EMERGENCY STOP PUSH-BUTTON is always fitted on each machine.
ATTENTION
Adequate free space must be provided in front of the machine under any circumstances in
order to allow immediate access to the emergency push-button and any start/stop or setting
devices.
FIGURE 3.3.1
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3.3.1
Use and maintenance instructions
3.3.2
Control panel
The control panel is located on the front left side of the machine (in the Ariete version with paneling).
There is a single panel for all the different languages which shows the symbols and instruments used
to control the machine (see fig. 3.3.2):
• Emergency Stop push-button to halt the machine instantly in case of emergency
• On/Off push-button (indicated by the symbols I/O); general alarm light (with ! symbol). These controls
are available only if the electric board has been supplied by GEA Mechanical Equipment Italia S.p.A..
• Pneumatic controls for adjustment of the homogenizing pressure (1st and 2nd stage) consisting
in an air-operated control to switch pressure ON and OFF and a pneumatic regulator to increase
or reduce pressure (shown on a measuring scale).
• Pressure gauges for controlling pressure of air sent to the pneumatic head in order to reach
homogenizing pressure.
• Pressure gauge for controlling pressure of drive lubrication oil, identified by a relevant symbol.
FIGURE 3.3.2
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3.3.2
Use and maintenance instructions
3.3.3
Start-up
WARNING
The lubrication oil indicated in the specifications is suitable for operating temperatures
between +5°C ed i +40°C: DO NOT START the machine if ambient temperature is lower than
+5°C to avoid damage to the lubrication system.
Check with GEA Mechanical Equipment Italia S.p.A. Customer Service for the type of lubricant
suitable for the specific local conditions.
ATTENTION
If ambient temperature is lower than +5°C, do not start the machine before checking the
conditions of the plunger water lubrication system and any water heat exchanger.
Once all preliminary checks have been completed, the machine can be started following the
procedure below.
•
Open all on/off valves on utility lines (water, air, steam) and regulate the flow rates if necessary)
ATTENTION
The machine must NEVER be started without water for plunger lubrication, otherwise serious
damage could be caused to the seal packings and plungers; with ceramic plungers, this
incorrect procedure may cause plungers failure because of thermal shock. For further details
on thermal shock problems with ceramic plungers see Section 4 - MAINTENANCE.
WARNING
An excess of cooling water can lead to flooding of the sump or excessive water splashing
on guiding pistons, with the risk of water going into the drive section. Then check the flow
of water and regulate it if needed according to the flow rate indicated in TT-0141 in Section
1 - TECHNICAL SPECIFICATIONS. The lubrication circuit should be regularly drained to drain
out any water that might have gone inside the oil.
•
Feed the machine with product at the required flow rate and pressures as indicated in Section
1 – TECHNICAL SPECIFICATIONS.
WARNING
Feeding pressures lower than the limits given will cause CAVITATION in the machine,
recognized by the typical noise produced by the head, which will seriously damage the
whole machine. GEA Mechanical Equipment Italia S.p.A. shall not be libale for breakages,
malfunctions or damage to the machine caused by CAVITATION even if this occurs during
the 12 month guarantee period.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
3C001E14C
3.3.3
Use and maintenance instructions
•
•
Give power using the main switch on the electric power board.
Press the start push-button. In case the control board has been supplied by
GEA Mechanical Equipment Italia S.p.A., this operation allows to start the machine according to
the correct sequence, depending on the type of machine and optionals provided:
- opening of any utility solenoid valve (optional)
- start of the oil motor-driven pump (if this type has been provided)
- start of electric fans (if provided)
- start of main motor
In case the control board is supplied by the Customer, the correct operating sequence is provided
(see Section 1 – TECHNICAL SPECIFICATIONS), and should be observed strictly.
To identify the machine configuration refer to Section 1 – TECHNICAL SPECIFICATIONS.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
3C001E14C
3.3.4
Use and maintenance instructions
3.4. Operation and adjustment
Once the machine has been started, before increasing the homogenizing pressure, check that the
machine itself is operating normally, with a particular attention paid to the feed pressure, establishing
it is stable and within limits as prescribed in Section 1 – TECHNICAL SPECIFICATIONS.
Then it is possible to operate the control devices in order to increase the homogenizing pressure up
to the desired process value.
If your machine is equipped with a second stage homogenizing valve, refer to paragraph 3.4.2.
3.4.1
Homogenizing pressure adjustment – 1 stage
This type of adjustment, through an air-operated cylinder, controls the position of the homogenizing
valve to establish the homogenizing pressure.
On the machine front panel (see figure 3.4.1) it is located a pneumatic switch (A) and a pressure
regulator (B).
Adjustment operations consist of:
• make sure that pressure reducer (B) is fully backed off, counterclockwise
• set the pneumatic switch to ON position;
• rotate the reducer knob clockwise until the desired homogenizing pressure is obtained, by reading
the reached value on the pressure gauge.
CAUTION
To allow a slow, gradual pressure increase, the pneumatic adjustment system has been
designed to ensure a certain inertia.
Operate the pressure regulator slowly while checking the actual homogenizing pressure
increase until the operating value has been reached.
WARNING
check the increase of air pressure on the pneumatic head using the pressure gauge installed
on the panel control; this makes it possible to have a slow increase of homogenizing pressure.
It is also possible to use the air pressure gauge to refer to if the head pressure gauge is not
working correctly.
Once the homogenizing pressure has been set to the desired value, lock the reducer knob (B) by
pressing it.
If the set pressure is the one used normally during production, the homogenizing pressure can
be applied or released by operating ONLY the pneumatic selector (A), with the reducer left on the
adjustment position.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
3C001E14C
3.4.1
Use and maintenance instructions
CAUTION
this procedure is allowed ONLY for machines with operating pressure up to 250 bar, to prevent
overstressing the machine and avoid too rapid an increase of pressure as this could cause
the safety valve to open.
2
C
D
1
A
B
FIGURE 3.4.1
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
3C001E14C
3.4.2
Use and maintenance instructions
3.4.2
Homogenizing pressure adjustment - 2 stages
To adjust the pressure, follow the same steps as for the single-stage machine.
In order to adjust the pressure, please read carefully what is written in paragraph 3.4.1, and in
specific all warnings.
In machines in which the 1st stage pressure works up to 450 bar, the 2nd stage pressure can reach
a maximum of 1/5 of the 1st stage pressure.
In machines in which the 1st stage pressure works at over 450 bar, the 2nd stage pressure can reach
a maximum of 1/10 of the 1st stage pressure
WARNING
The intended homogenizing pressure value must be set FIRST on the second stage, THEN on
the first stage to reach the total desired pressure.
A different operating sequence may result in SERIOUS RISK because the machine may
inadvertently and suddenly reach higher pressure values than those for which the machine
is designed.
Adjustment operations consist of (see figure 3.4.1):
• make sure the pneumatic regulator ( B , D ) is completely backed off counterclockwise
• set the 2nd stage pneumatic switch (C) to ON position;
• rotate the 2nd stage reducer knob (D) until the desired homogenizing pressure is obtained, by
reading the reached value on the pressure gauge.
• set the 1st stage pneumatic switch (A) to ON position;
• rotate the 1st stage reducer knob (B) until the desired homogenizing pressure is obtained, by
reading the reached value on the pressure gauge.
WARNING
check the air pressure increase on the pneumatic adjuster using the air pressure gauge
located on the control panel; this allows a slow rise of the pressure. It is also possible to use
this air gauge as a reference for the homogenizing pressure in case the main gauge on the
compression block is not working properly as a temporary solution to be able to work with
the machine.
Once the homogenizing pressure has been set to the desired value, block the reducer knob (B and
D) by pressing it.
If the set pressure is the one used normally during production, the homogenizing pressure can be
applied or released by operating ONLY the pneumatic selector (A and C), with the reducer left on the
adjustment position
WARNING
To allow a slow, gradual pressure increase, the pneumatic adjustment system has been
designed to ensure a certain inertia.
Operate the pressure regulator slowly while checking the actual homogenizing pressure
increase until the operating value has been reached.
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3C001E14C
3.4.3
Use and maintenance instructions
WARNING
To release homogenizing pressure in a two-stage system you need to reverse the procedure
used to give pressure.
Therefore first release pressure from the 1st stage and then from the 2nd stage.
3.4.3
Remote pneumatic control (optional)
The pneumatic control for adjustment of homogenizing pressure can be designed as a remote
system using a proportional solenoid valve actuated by a 4÷20 mA signal; the type of system used
depends on the configuration selected by the Customer.
The method for adjusting homogenizing pressure is the same as the one described for standard
pneumatic systems in paragraphs 3.4.1 and 3.4.2.
The supervision and control system (installed by the Customer) must send an electric regulation
signal to the proportional valves, with suitable ramp time and graduality.
CAUTION
Even with remote control, if the system has two stage the intended pressure value should be
set FIRST on the second stage, THEN on the first stage to reach the total desired pressure.
A different operative sequence may result in SERIOUS RISK because the machine may
inadvertently reach higher pressure values than those designed for the machine.
It is important to send the signal gradually over approximately 30 seconds/1 minute to avoid a
sudden increase of homogenizing pressure which could cause the overpressure valve located on
the compression head to open.
The remote control system via proportional solenoid valve uses also an ON/OFF solenoid valve
for switching pressure on and off; this can be installed as an optional even with the manual control
system instead of the pneumatic switch (see paragraphs 3.4.1 e 3.4.2).
Another optional available is the automatic pressure control system, actuated by a regulation loop
which can also mount, as an optional, a pressure gauge with 4÷20 mA analog outpu. Using this
system it is possible to set an operating pressure value which will be kept constant even if the
operating conditions of the machine or of the product change (e.g. variations in flow rate.
Fpr further information about operating and control features please contact
GEA Mechanical Equipment Italia S.p.A..
Machines fitted with remote system for control of the homogenizing pressure can also be equipped,
upon request by the Customer, with local repetition of remote controls for operation during servicing.
The use of the local system is described in paragraphs 3.4.1 and 3.4.2.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
3C001E14C
3.4.4
Use and maintenance instructions
3.5. Machine stop
To stop the machine, follow these steps:
• release the homogenizing pressure by operating either the pneumatic switch to the OFF position,
or the remote control electric valve (or proportional valve) via an appropriate electric signal;
• press the stop push-button (if available on the machine’s control panel) or give a
stop signal via the control system. For machines with electric board supplied by
GEA Mechanical Equipment Italia S.p.A. this operation makes it possible to stop any auxiliary
electric motors and the main motor by following the correct sequence given in Section 1 TECHNICAL SPECIFICATIONS for Customers who wish to make their own board if it has not
been supplied by GEA Mechanical Equipment Italia S.p.A.;
• cut off power using the main switch.
3.5.1
Emergency stop
In case of dangerous situations or serious machine failure, the operation can be immediately halted
by pressing the emergency push-button located on the front panel (figure 3.5.1)
After you have done that, release pressure following the procedure described before.
WARNING
Before resuming the machine operation, elimitate the condition which led to the emergency
stop.
WARNING
By resetting the emergency push-button to its normal status, the machine is not started
automatically, but it is enabled to start operating through the normal startup procedure.
FIGURE 3.5.1
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3C001E14C
3.5.1
Use and maintenance instructions
3.6. Cleaning
A thouroug of the machine will maintain the sanitary or aseptic conditions as necessary to avoid
harmful deterioration or contamination of the product handled.
When designing the machine, special care has been given to the parts in contact with the product to
make them easily cleanable (C.I.P.) and to avoid recesses where the product may stagnate.
However, the following recommendations should be followed to ensure hygiene:
• to avoid the formation of a product film on the inner surfaces and product deposit, the machine
should be cleaned IMMEDIATELY after production. Do not allow the product to rest inside the
machine, and do not let the empty machine stand still without rinsing it;
• make sure that any residue of chemical solution used for cleaning is completely removed by
rinsing the machine thoroughly;
• if the cleaning solutions involve the use of concentrated products or powders, first prepare the
solutions separately in order to avoid any undissolved clods or solid particles.
Cleaning should be performed in a closed cycle (C.I.P.) while the machine is running at homogenizing
pressure equal to zero (for homogenizers).
This allows avoiding energy waste and damage to the homogenizing valve.
WARNING
In the case of components made of Tungsten Carbide material, during washing or production,
the use of reverse osmosis purified water, demineralized microfiltered water, Water for
Injection is not recommended.
Its aggressive action would lead to chemical etching of the material in question, drastically
reducing its duration and putting the correct homogenizing operation of the machine at risk.
WARNING
For the machines with variable or double capacity, the cleaning should be performed at the
maximum speed admitted, however not exceeding the maximum operating capacity by more
than 20% (see Section 1 – TECHNICAL SPECIFICATIONS).
WARNING
The products used for cleaning and rinsing of the equipment should contain only the
substances specified in Table 3.6.A.
The presence of CHLORINE and IODINE ions - including simple traces - is very harmful to
the materials used in the construction of the machine, as it may lead to stress corrosion
phenomena which may cause the compression block failure in a short time and unpredictably.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
3C001E14C
3.6.1
Use and maintenance instructions
P R O D UCT
max concentr. (%)
max temp. (°C)
Caustic Soda (NaOH)
3
90
Nitric Acid (HNO3)
1
70
Phosphoric Acid (H3PO4)
3
85
Hot Water
-
90
Hot Pressurized Water / Steam
-
140
TABLE 3.6.A
CAUTION
Dispose of the cleaning solution and washing fluids as prescribed by the laws in force locally.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
3C001E14C
3.6.2
Use and maintenance instructions
3.7. Safety devices
GEA Mechanical Equipment Italia S.p.A. machines are provided with safety devices to prevent
reaching critical conditions which may cause sudden breakage of the machine and hazards for the
personnel.
In addition the machines are designed with ample safety margins, in consideration of high pressures
which may be reached as a result of improper operations by the user or failures of the line in which
the machine has been included.
The following safety devices have been incorporated: overpressure valve on the compression head,
electric protections on the main motor (if the machine includes a control board), an emergency pushbutton and a guard to protect the head, as described here below.
3.7.1
Overpressure valve
The pressure relief valve has been designed by GEA Mechanical Equipment Italia S.p.A. to protect
the machine from the possibility of overpressure which might be producted inside the compression
head as a consequence of the pumping action of the machine.
CAUTION
The safety valve is used to protect the machine; piping downstream the machine can be
protected only if a valve is fitted on the line.
ATTENTION
the valve protects only the pressurized chamber on which it is installed.
It features the following advantages:
• reduced maintenance
• designed to “3-A” Standards, suitable for C.I.P.
• it closes automatically in case the overpressure is released to allow the immediate resuming of
production
• accurate calibration and repeatable actuation
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
3C001E14C
3.7.1
Use and maintenance instructions
3.7.1.1 Operation
The valve consists of a ball maintained in place in its seat by a spring, which allows it to open when
the calibration set point is exceeded.
The spring loading should not be changed as this would modify the valve opening value and cause the
immediate forfeiture of the safety conditions established by GEA Mechanical Equipment Italia S.p.A.
and the guarantee. Therefore a seal has been applied to the spring load adjustment nut.
In the event the calibration setting is exceeded, the valve opens automatically and lets the product
flow out of the discharge pipe; it closes again when pressure reduces below the opening value. This
can be achieved by adjusting the pressure regulating device until the valve is closing, or reducing
the pump speed in case of high pressure pumps.
Once the valve has closed again, normal operating pressure can be re-established, provided the
machine has not been damaged and the cause of overpressure has been addressed.
ATTENTION
The discharge pipe must ALWAYS be directed downwards to avoid harming the operator; the
Customer shall be responsible to install a funnel to collect the outcoming product and carry
it to the drainage system
ATTENTION
Dispose of any waste fluids as prescribed by the laws in force locally.
ATTENTION
the valve seat of the overpressure relief valve is damaged to some extent each time the valve
blows. This will lower the pressure setpoint of the safety valve. Therefore it is necessary to
replace seat and ball to recover the original setpoint conditions.
3.7.1.2 Cleaning
The part in contact with the product is normally cleaned during the machine washing (C.I.P.).
CAUTION
it is ALWAYS necessary to disassemble the valve from the compression head and clean it
manually, especially the valve seat and the discharge pipe, after any overpressure relief valve
discharge.
For disassembling and maintenance, please refer to Section 4 - MAINTENANCE.
CAUTION
Do not disassemble the valve body and do not remove the plastic cap. Changes to the safety
valve setting are not allowed and shall invalidate the guarantee and affect protection of the
machine, of its components and of the operators, unless a written authorization has been
obtained from GEA Mechanical Equipment Italia S.p.A..
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
3C001E14C
3.7.2
Use and maintenance instructions
3.7.2
Protections on main motor
If the machine is supplied by GEA Mechanical Equipment Italia S.p.A. complete with electric power
board, this includes the electric protections suitable for the main motor power and amps, type of
starting device and conditions of operation. These protections consist of magnetic and thermal cutout
switches, quick fuses or automatic switches for short-circuits, automatic switches or the frequency
converter itself for protection against overheating.
For the specific case see Section 1 – TECHNICAL SPECIFICATIONS.
3.7.3
Emergency push-button
On the front panel of the machine there is installed an emergency stop push-button (figure 3.5.1) of
the colour prescribed by the safety standards in force.
This device allows the operator to stop the machine immediately in case of hazardous situations for
the personnel or the machine itself (abnormal operation, unusual noise, risk of failures).
For the stop procedure and relevant notes see paragraph 3.5.
In the event that the machine is supplied complete with the electric power board, the main switch can
be used for emergency stops as well.
WARNING
When positioning the machine and making the connections with the production line, allow
enough space to reach the emergency stop push-button of the machine quickly and without
obstacles.
3.7.4
Compression head guard
The compression head is provided with an additional guard to protect the operator from any projection
of machine parts, from high temperatures possibly reached by the head and from any injury caused
by protruding, sharp parts.
WARNING
The machine should not be used if the guard is not correctly secured in place.
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3C001E14C
3.7.3
Use and maintenance instructions
3.8. Troubleshooting
This chapter lists the most frequent problems which are likely to be encountered during the machine
operation, their possible causes and remedies in order to restore normal working conditions.
If the failure persists, or does not appear among those listed below, our Service Department will be
pleased to give you the advice and means required to achieve the best possible results.
TROUBLE
1. The machine does not run
2. There is no product flow
POSSIBLE CAUSE
REMEDY
• main motor does not start
• check the electrical wiring, fuses,
automatic switches
• the drive belts are broken or
loose
• replace or tighten the belts
• no feed flow or pressure to
the machine inlet
• feed properly the machine (see Section
1 – TECHNICAL SPECIFICATIONS)
• feeding piping clogged or
closed
• clean properly the pipeline and filters
• bypass valve (if any) opened • close the bypass valve
3. Reduced flow rate
• not enough feeding
• feed properly the machine
• not correct operation (wear)
of suction/delivery valves
• clean or remove particles between
valve and seat (see Section 4 MAINTENANCE)
• verify the wear conditions of the
seating surface of the valves and if
needed replace
• slipping belts
• provide correct belts tension
(Section 4 - MAINTENANCE)
• low main motor speed
• verify the correct motor speed (Section
1 – TECHNICAL SPECIFICATIONS)
• leakage on plunger packings • replace
(Section 4 - MAINTENANCE)
• air into the product
• eliminate air
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3C001E14C
3.8.1
Use and maintenance instructions
TROUBLE
POSSIBLE CAUSE
REMEDY
3. Reduced flow rate
• broken valve springs
• replace
(Section 4 - MAINTENANCE)
4. Noisy compression head
• broken springs
• replace
(Section 4 - MAINTENANCE)
• not enough or too high
feeding pressure
• feed properly the machine
• worn out pumping valves
• replace
(Section 4 - MAINTENANCE)
• pumping valves not working
properly
• verify the valve cleaning and wear
• air into the product
• eliminate air
• wear of bearings
• check, lubricate/grease and eventually
replace the bearings
• loose plungers
• tighten
(Section 4 - MAINTENANCE)
5. Noisy drive end
• not enough feeding pressure • feed properly the machine
6. Noisy belt drive
• slipping belts
• provide correct belts tension (Section
4 - MAINTENANCE)
7.Vibrations of the machine
• the machine is not properly
supported by all feet
• check the machine level adjusting the
feet height
• not enough feeding pressure • feed properly the machine (see Section
1 – TECHNICAL SPECIFICATIONS)
• pulsations at suction and / or • install suitable pulsation
delivery
damper (contact
GEA Mechanical Equipment Italia S.p.A.)
8.No cooling water on plungers • valve on water plant closed
• water filter clogged
• open the plant
• disassemble and clean
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3C001E14C
3.8.2
Use and maintenance instructions
TROUBLE
POSSIBLE CAUSE
8.No cooling water on plungers • no pressure in the water
circuit
9. Pulsating delivery pressure
10.Total lack of homogenizing
pressure
REMEDY
• check the required water supply
conditions at Section 1–TECHNICAL
SPECIFICATIONS
• not enough feeding pressure • feed properly the machine
• damaged or worn out
pumping valves
• replace (Section 4 - MAINTENANCE)
• pump valves not suitable for
the product
• Contact
GEA Mechanical Equipment Italia S.p.A.
• valves springs not suitable
for the product
• Contact
GEA Mechanical Equipment Italia S.p.A.
• Unsteady backpressure
• Adjust the backpressure
• Not enough flow
• See trouble point 3
• Damaged homogenizing
valve
• Check, clean or replace (Section 4 MAINTENANCE)
• No air pressure in pneumatic • Check the pneumatic circuit and the air
circuit
supply (Section 4 - MAINTENANCE)
• Defective pneumatic
actuator
11. Homogenizing pressure
not reached
• Replace
• Not enough feeding pressure • Feed properly the machine
• Blocked homogenizing valve • Disassemble and clean (Section 4 –
MAINTENANCE)
• Worn out homogenizing
valve
• Replace (Section 4 – MAINTENANCE)
• Faulty pressure gauge
• Replace (Section 4 – MAINTENANCE)
• Damaged homogenizing
valve shaft
• Replace (Section 4 – MAINTENANCE)
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3C001E14C
3.8.3
Use and maintenance instructions
TROUBLE
12.Fluctuating homogenizing
pressure
13. Noisy homogenizing valve
POSSIBLE CAUSE
REMEDY
• Air or bubbles in the product
• Remove air or bubbles
• Air into the compression
head
• Release pressure, then apply pressure
again
• Not enough or unsteady
feeding pressure
• Feed properly the machine
• Not correct operation of the
pumping valves
• Check, clean or replace (Section 4 –
MAINTENANCE)
• Not correct operation of
the homogenizing valve
dampening device
• Check the pneumatic plant and
dampening device (Section 4 –
MAINTENANCE)
• Pumping valves not suitable
for the product
• Contact
GEA Mechanical Equipment Italia S.p.A.
• Unsteady backpressure
• Adjust the backpressure
• Worn out homogenizing
valve
• Replace (Section 4 - MAINTENANCE)
• No oil or air pressure into the • Check and restore correct
dampening device
operating conditions (Section 4 –
MAINTENANCE)
• Resonance in the plant
• Modify the backpressure; install
pulsation damper dowstream; move
away the existing damper; contact
GEA Mechanical Equipment Italia S.p.A.
14.Oil level drops quickly
• Leakage in the lubricating
circuit
• Check the plant and look for leakage,
replace gaskets, tighten joints, replace
the oil cooler
15.White foam in the
lubricating oil
• Water into the oil
• Stop the machine for at least 1 hour
and drain water from lowest point
(Section 4 – MAINTENANCE)
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3C001E14C
3.8.4
Use and maintenance instructions
TROUBLE
15.White foam in the
lubricating oil
16. Oil overheats and darkens
17.No oil flow and pressure
18.Not enough oil pressure
and intervention of pressure
switch
19. Main motor
overload
POSSIBLE CAUSE
REMEDY
• Water in the oil because of
broken oil cooler
• Pressure check the oil cooler and
replace
• Excess of water on the
plungers
• Adjust the water flow to reduce
splashing and sump flooding
• Machine overload
• Eliminate overload
• Faulty oil cooler or lack of
cooling water
• Check the oil cooler and the water flow
• Worn out bearings
• Contact
GEA Mechanical Equipment Italia S.p.A.
• Wrong oil pump rotation
• Change the direction of rotation of
the oil pump (Section 2 – GENARAL
INFORMATION)
• Failure of the oil pump
• Contact
GEA Mechanical Equipment Italia S.p.A.
• Leakage on the lubricating
circuit
• Check the oil circuit, replace gaskets
and tighten joints
• Low oil level
• Restore correct oil level.
• Worn out sliding bearings or
crankshaft
• Contact
GEA Mechanical Equipment Italia S.p.A.
• Faulty pressure switch
• Check the pressure switch
and in case replace; contact
GEA Mechanical Equipment Italia S.p.A.
• Leaking oil cooler
• Check and replace; contact
GEA Mechanical Equipment Italia S.p.A.
• Too high homogenizing
pressure
• Reduce to nominal value
• Wear on drive end
• Check wear and contact
GEA Mechanical Equipment Italia S.p.A.
• Too high belts tension
• Check belts tension
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
3C001E14C
3.8.5
Use and maintenance instructions
TROUBLE
POSSIBLE CAUSE
REMEDY
19. Excessive absorption of
the electric motor
• Faulty main motor
• Check main motor; in case replace
20.Oil leakage in the water
sump
• Leakage from crossheads
seals
•
• Scratched crosshead
extensions
• Replace gaskets (Section 4 –
MAINTENANCE)
•
• Replace (contact
GEA Mechanical Equipment Italia S.p.A.)
21. Safety relief valve leakage
• The safety relief valve seat
is worn
• Replace the safety relief valve seat
22. Safety relief valve frequent • Overpressure
openings
• Verify machine operation and feeding
system
• Cavitation
• Verify machine operation and feeding
system
• Loss of safety relief valve
calibration
• Please contact
GEA Mechanical Equipment Italia S.p.A.
customer service for safety relief valve
re-calibration
23. Safety relief valve sensor
signals that safety valve is
open, but there is no product
discharge
(for machines with NSSLRVPO safety relief valve)
• The safety valve inductive
sensor has lost the factory
setting
• Set the inductive sensor
24. Safety relief valve sensor
signals that safety valve is
closed, but there is product
discharge
(for machines with NSSLRVPO safety relief valve)
• The safety valve inductive
sensor has lost the factory
setting
• Set the inductive sensor
• The inductive sensor has
broken
• Replace the inductive sensor
• The union cable is damaged
• Replace the cable
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3C001E14C
3.8.6
Use and maintenance instructions
3.9. Special features of non standard machines
Blank page
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3C090E3C
3.9.1
Use and maintenance instructions
Section 4
Maintenance - index
4.1 General maintenance information
4.1.1 General information
4.1.2 Instructions for correct maintenance
4.1.3 Safety, precautions and maintenance procedures
4.2 Ordinary maintenance
4.3. Tighening bolts and studs
4.4. Compression head
4.5. Homogenizing group
4.6. Overpressure valve and pressure gauge
4.7. Transmission
4.8. Power end - crankcase
4.9. Lubrication
4.10. Pneumatic plant
4.11. Aseptic plant
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
4C00SE7C
4.1
Use and maintenance instructions
4.1. General information
4.1.1 General information’
4.1.1.1 Definition of personnel duties.
Maintenance operations must be performed in accordance with the following areas of competence.
The manufacturer shall not be liable if the following indications are not complied with.
Duties of person in charge of operating the machine (operator)
An operator is authorized only to the use of controls and instruments in the panel and on the control
board.
Any other procedure on mechanical or electrical equipment is prohibited.
In particular, operators are not allowed to:
remove mechanical components and access internal parts
open electrical boards and access the equipment installed inside them
remove the safety devices protecting live parts on the machine, such as for example: terminal strip
covers of junction boxes, etc.
All these operations must be performed by maintenance technicians and electricians.
Duties of electrician and maintenance technician
This is a suitably trained and experience technician in charge of machine maintenance and eletrical
system maintenance. He is responsible for keeping the key that enables access to live parts.
The maintenance technician must reset all safety devices and guards and will also perform machine
repair jobs within the limits and with the methods indicated by the manual.
ATTENTION
Any new components replacing faulty parts must have the same technical characteristics
and performance; in case of safety components, they must be certified and belong to the
same class as the original being replaced.
The new components must be set to the same values that had been used for the components
replaced.
Any changes applied to the machine and all complex repair jobs must previously be agreed with our
TECHNICAL SUPPORT SERVICE.
The manufacturer shall not be liable if the following indications are not complied with.
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4C010E7C
4.1.1
Use and maintenance instructions
4.1.2
Instructions for correct maintenance
4.1.2.1 For adequate maintenance operations:
Use only original spare parts and tools suited for the purpose and in good condition.
Respect the frequency intervals indicated in the maintenance manual for preventive and periodic
maintenance; the interval (indicated as time or work cycles) between maintenance procedures is
intended as the maximum and should not be exceeded. This interval can be shortened if needed .
Corrective preventive maintenance is based on constant attention and continuous monitoring of the
machine. Promptly check any anomalies such as excessive noise, overheating, leaking of fluids, etc.
and apply the required remedy.
If in doubt, contact the manufacturer.
To perform maintenance operations correctly, please refer to the attached documents, such as:
1) – Functional diagrams for electrical equipment and auxiliary equipment, with indications on power
connections.
2) – List of possible failures and solutions suggested (chapter 8 in this manual).
4.1.2.2 Maintenance plan
From a construction point of view, the operations regard mechanical and electrical parts.
For practical reasons, the operations are grouped according to time criteria and complexity. Therefore
every operation or group of operations may deal with mechanical or electrical aspects.
Ordinary maintenance is divided into two categories:
• scheduled ordinary (or preventive) maintenance.
• ordinary maintenance in response to a specific condition.
Scheduled ordinary maintenance (also referred to as periodic or preventive) includes inspections,
checks and operations designed to prevent shutdowns and failure through a systematic control
program:
• machine lubrication
• condition of wear parts
Ordinary maintenance in response to a specific condition regards machine components that are
not subject to periodic checks and whose wear cannot be estimated beforehand. These need to be
checked or replaced when their condition requires it.
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4C010E7C
4.1.2
Use and maintenance instructions
ATTENTION
All of the actions must be performed by qualified technicians after setting the machine to
maintenance mode, i.e. MACHINE OFF and master switch PADLOCKED in the OPEN POSITION,
for the safety of personnel.
ATTENTION
Do not allow machine use, access to inside parts and maintenance by members of personnel
who are not familiar with the indications contained in this manual and ensure that the manual
is available to all operators.
ATTENTION
The only operations allowed are those described in these INSTRUCTIONS; for any extraordinary
operations please contact our Technical Support Service.
The following paragraphs list the procedures, divided by category.
These are followed by the descriptions and illustrations of the procedures, with safety precautions.
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4C010E7C
4.1.3
Use and maintenance instructions
4.1.3
Safety, precautions and maintenance procedures
4.1.3.1 General safety information
Machine and operator safety depends also on the correct and regular performance of maintenance
procedures in accordance with the indications provided herein.
Ordinary and extraordinary maintenance procedures must be performed exclusively by qualified
technical staff in accordance with the criteria indicated in the introduction of this instruction manual.
ATTENTION
- RISK OF ELECTROCUTION by direct contact with switchboard and power supply cable. It
is prohibited to open the switchboard when the system is powered;
- AFTER EVERY MAINTENANCE PROCEDURE FIT BACK AND RESET ALL GUARDS AND
PROTECTION DEVICES that have been removed or switched off during the procedure.
ATTENTION
All maintenance procedures must be carried out in accordance with the instructions given in
4.1.3.3 “setting machine to maintenance mode”.
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4C010E7C
4.1.4
Use and maintenance instructions
4.1.3.2 Safety symbols
The following symbols indicate the precautions that MUST be complied with during maintenance
operations.
Prohibitions
No access to unauthorized
persons
No naked flames
Do not lubricate, repair or adjust while
machine on
Do not remove safety
devices
No smoking
Do not use water to put
fires out
Types of inspections and procedures
Visual inspection.
Lubrication with oil.
Hearing inspection.
Lubrication with grease.
Procedure with tools.
Personal protection devices
Protective helmet must be worn
at all times.
Overalls must be worn.
Protective gloves must be worn.
Mufflers must be worn.
Protective glasses must be
worn.
Protective mask must
be used.
Safety boots must be worn.
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4C010E7C
4.1.5
Use and maintenance instructions
4.1.3.3 Setting machine for maintenance
Before performing any maintenance procedure, the machine must be disconnected from the power
supply line using the necessary precautions to prevent accidental starting and the risk of electrocution.
Before proceeding with any operation on the machine, the electrician and maintenance technician
must wear adequate personal protection devices.
ATTENTION
If the switchboard is not supplied by GEA Mechanical Equipment Italia S.p.A., refer to the
manufacturer’s instructions for information on this procedure.
Procedure for setting machine to maintenance mode
A qualified technician is in charge of this procedure which includes the following steps:
• The master switch on the electrical cabinet must be set to “0” (OPEN), and blocked in that
position with a padlock.
• The padlock key is removed and kept by the maintenance technician in charge until the procedure
has been completed.
Fig. 4.1.3.3.a
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4C010E7C
4.1.6
Use and maintenance instructions
•
The emergency pushbutton located in the control pushbutton panelm must be pressed as shown
in the figure.
Fig. 4.1.3.3.b
•
If the type of maintenance needed requires the side panels to be removed, use the special key
provided. If the panels are large or very heavy, two people are needed to remove the panels.
ATTENTION
Do not restart the machine before closing the panels and checking that closing and locking
parts are efficient.
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4C010E7C
4.1.7
Use and maintenance instructions
4.2. Ordinary maintenance operations
Here below are the tables showing the periodical maintenance required by the machine to operate
efficiently and safely.
Values shown refer to a normal use of the machine; heavy-duty conditions or particularly abrasive/
aggressive products may reduce sensibly the life of some parts, which should therefore be checked
more frequently.
In case of machine malfunction or abnormal noise, we suggest you try to identify the components
which seem to produce the noise and check whether they have been correctly assembled and
tightened or whether they might be worn and in need of replacement.
In particular, machines operatine on very high pressure (over 600 bar) require frequent servicing
to replace gaskets, plunger seals, delivery valves, valve seats and springs, homogenizing valves,
depending on the type of product used – see the Table of Periodical Maintenance for high pressure
machines – in addition to regular checks.
All the operations listed here below are described with detailed procedures in the following paragraphs.
Execute carefully all the checks prescribed in these tables and note scrupulously the DATE,
MACHINE HOURS, OPERATOR in the Tables for the checks to be performed every 1500 HOURS
- 6 MONTHS and every 3000 HOURS - 12 NONTHS. In this way the machine will be maintained
in the best conditions of running and safety, and a track will be kept of the maintenance operations
actually completed.
WARNING
The Periodical Maintenance tables shown below refer to normal operating conditions and
in any case provide merely an indication as to the average life of a component and not a
guarantee of minimum component life.
Special conditions such as high operating pressure, high temperature, steam sterilization
and frequent washing, incorrect operating procedures, can substantially affect the life of the
machine and of its components and therefore the intervals suggested for maintenance of compression head components may vary significantly.
As additional tool for ordinary maintenance of the machine, please refer to the form “checklist
for machine inspection” at Section 5 – SPARE PARTS LIST.
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4C010E7C
4.2.1
Use and maintenance instructions
Periodical maintenance table – generic for all machines
When
After first start-up
Every day
Once a week - 40
hrs
When
(hrs)
Action required
Machine hrs
• Check belt tensioning
• replace lubrication oil
• replace lubrication filter
200
500
500
• check oil level and top up and if needed
• visual check for leaks in seals and gaskets
•
•
•
•
•
•
visual check of plunger gaskets
drain condensate from lubrication system
check tightening of nuts and plungers
check drive
check belt tensioning
check tightening of drive elements and
reducer support
Action required
Mach. hrs
Operator
• change lubrication oil
• clean/replace filters (lubrication
system, pneumatic system, water
system)
• check drive belt wear, tensioning and
1500 and
if required replace
every
• check wear of plungers and if
1500 hrs
required replace
• check pressurization of pneumatic
system and oil level
• check oil level in gear reducer
• check / replace springs and pumping
3000 and
valves
every
• check / replace homogenizing valve
3000 hrs
every
5000 hrs
• replace lubrication oil in gear reducer
(mineral oil)
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4C010E7C
4.2.2
Date
Use and maintenance instructions
When
(hrs)
Action required
Mach. hrs
4500
• change lubrication oil
• clean/replace filters (lubrication
system, pneumatic system, water
system)
• check drive belt wear, tensioning and
if required replace
• check wear of plungers and if
required replace
• check pressurization of pneumatic
system and oil level
6000
• check / replace springs and pumping
valves
• check / replace homogenizing valve
7500
• change lubrication oil
• clean/replace filters (lubrication
system, pneumatic system, water
system)
• check drive belt wear, tensioning and
if required replace
• check wear of plungers and if
required replace
• check pressurization of pneumatic
system and oil level
9000
• check / replace springs and pumping
valves
• check / replace homogenizing valve
10500
• change lubrication oil
• clean/replace filters (lubrication
system, pneumatic system, water
system)
• check drive belt wear, tensioning and
if required replace
• check wear of plungers and if
required replace
• check pressurization of pneumatic
system and oil level
12000
• check / replace springs and pumping
valves
• check / replace homogenizing valve
Operator
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4C010E7C
4.2.3
Date
Use and maintenance instructions
When
(hrs)
Action required
Mach. hrs
13500
• change lubrication oil
• clean/replace filters (lubrication
system, pneumatic system, water
system)
• check drive belt wear, tensioning and
if required replace
• check wear of plungers and if
required replace
• check pressurization of pneumatic
system and oil level
15000
• check / replace springs and pumping
valves
• check / replace homogenizing valve
Operator
Date
Periodical maintenance table for high-pressure machines (over 600 bar)
When
Every 50 hrs
Every 100 hrs
Every 200 hrs
Action required
• visual check for leaks in packings and head
gaskets
• check tightening of nuts in all high-pressure
head elements
• check packings and head gaskets and if
required replace
• check pumping valve seats and if required
replace
• check ball valves and if required replace
• check springs and if required replace
• check homogenizing and if required replace
• check oil-air operated system for vibration
damping in homogenizing valve
• check cooling water piping, check water flow
• tighten nuts in high-pressure head using
dynamometric wrench
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4C010E7C
4.2.4
Machine hrs
Use and maintenance instructions
ORDINARY MAINTENANCE LOG
When
(hrs)
Mach.
hrs
Action required
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4C010E7C
4.2.5
Operator
Date
Use and maintenance instructions
4.3. Tightening nuts and studs
All the studs used in the compression head are subject to vibrating stress so, in addition to being
made of special, highly resistant material with an accurate processing cycle, they require specific
tightening in accordance with the values shown in Table 4.3.1.
It is also necessary to frequently check screwn and nuts to make sure that they do not become loose.
GEA Mechanical Equipment Italia S.p.A. supplies a Maintenance box with the wrenches needed for
the nuts fitted on their machines; we suggest you use a dynamometric wrench (not included) to
check tightening torques as specified in the table below.
Stud size
Tightening torque (n*m)
Tightening torque (lb.*Ft.)
M8
8 ÷10
6 ÷8
M 10
15 ÷ 20
11 ÷ 15
M 12
25 ÷ 30
19 ÷22
M 16
60 ÷ 70
44 ÷52
M 20
120 ÷ 140
89 ÷104
M 24
210 ÷ 230
155 ÷ 170
M24x2
235 ÷ 260
174 ÷ 192
M 27
310 ÷ 340
229 ÷251
M27x2
350 ÷ 390
258 ÷ 288
M 30
410 ÷ 450
304 ÷ 332
M 33
560 ÷ 600
413 ÷ 445
M33x2
635 ÷ 680
469 ÷ 502
M39
880 ÷ 960
650 ÷709
Table 4.3.1
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4C010E7C
4.3.1
Use and maintenance instructions
ATTENTION
The head maintenance operations require disassembling the parts which are secured by
studs and nuts.
When tightening them, refer to the torque values shown in Table 4.3.1 to avoid imposing
abnormal stress and undermining their strentgh.
WARNING
For safety reasons it is strictly forbidden to replace studs in the high-pressure head with nonoriginal spare parts, which might not be able to stand the stress applied resulting in severe
risk of injury!
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4C010E7C
4.3.2
Use and maintenance instructions
4.4. Compression head (monoblock)
ATTENTION
The compression head maintenance operations require to remove the head guard, unscrewing
the side screws.
The machine should not be used if the guard is not correctly secured in place.
ATTENTION
The head maintenance operations require disassembling the parts which are secured by stud
bolts and nuts.
When tightening them, refer to the torque values shown in Table 4.3.1 to avoid imposing
abnormal or excessive stress and undermining their strentgh.
Before proceeding with the description of maintenance operations on the compression head, it is
necessary to remind that the high pressure sealing between the components of the high pressure
area (main block, flanges) are made using O-Rings of various rubber materials, sometimes with
additional antiextrusion rings. These gaskets are suitable for food contact and can resist to the
temperatures which can be reached with the machine during normal operation or cleaning.
As an option, it is possible to have installed FDA certified and approved material gaskets.
As a good maintenance practice, we suggest to replace the gaskets every time the parts of the
machine are disassembled for maintenance or inspection, in addition to what is required because of
leaking or damaged gaskets.
Gaskets should be greased with food-grade vaseline and assembled with non-sharp tools which
might damage them; in any case remember that forced or incorrect assembling might undermine the
gasket life and effectiveness.
To identify and place the gaskets correctly, refer to the drawings provided herein for the disassembling
of compression head and its components, and in specific at Section 5 – SPARE PARTS CATALOG,
where are available the drawings and the list of parts effectively installed on the machine.
4.4.1
Pumping plungers
Plungers are subject to normal wear and tear; however, wear may be accelerated by certain
conditions of use, such as:
• not enough or no lubrication water;
• washing with unsuitable solutions;
• misalignment caused by fixing with guide piston become loose.
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4C041E6C
4.4.1
Use and maintenance instructions
Pumping plungers are available in different materials, which are suggested by
GEA Mechanical Equipment Italia S.p.A. according to the experience on different products and
various applications.
The available materials are:
• stainless steel with hard chrome coating
• stainless steel with tungsten carbide detonated coating
• solid ceramic.
Chrome-coated plungers and tungsten carbide detonated coated plungers should be replaced when
scratched or flaking on the surface because, in these conditions, they can not guarantee an effective
seal of packings and cause a short lifetime of the same.
Normally, ceramic plungers are not subject to surface wear, however they need replacement in case
of breakage due to a thermal shock, mechanical shock or misalignment.
ATTENTION
if the machine is equipped with ceramic plungers, it it necessary to follow special precautions
of use in order to avoid damage because of thermal shock. Please find listed below some
specific information on ceramic plungers handling:
• thermal shock is due to quick change in temperature, for the fluid in contact with the
plunger, above approx 70 °C
• it is absolutely necessary to avoid to run the plungers dry, without water lubrication, even
for a limited period of time; because of friction, the local temperature raise on the plunger
surface may cause breakage for thermal shock when cold water is opened at a later stage
• it is necessary to avoid any quick change from hot to cold liquid inside the compression
block and product path, where the plunger moves back and forward
• the cooling water temperature must be in the specified range (+10÷+25 °C or +40÷+60 °C
in case of aseptic version). See Section 1 – TECHNICAL SPECIFICATIONS
• the temperature gradient must be not more than 70 °C in 15 minutes (approx 5 °C per
minute).
ATTENTION
check periodically and regularly that the plungers are properly tightened, either with direct
thread connection or with clamp, in order to avoid they can get loos or out of the clamp
during the operation of the machine.
The use of unsuitable cleaning agents or wrong concentrations and temperatures may cause
corrosion of coatings on plungers, therefore causing a shorter packings lifetime than usual.
The damage pof plungers’ coating because of corrosion is not covered by any warranty from
GEA Mechanical Equipment Italia S.p.A..
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4C041E6C
4.4.2
Use and maintenance instructions
4.4.1.1 Disassembling
ATTENTION
disassembling of plungers may cause the damage of the gaskets (plungers packings):
check the gaskets and in case replace before reassembling plungers and compression head
components (see paragraph 4.4.2). Before proceeding with disassembling of the parts, check
availability of spare parts.
Disassembling procedure may slightly differ according to the type an material of the plungers,
according to the different fixing system.
Pumping plungers can be:
FIGURE 4.4.1
•
•
connected directly with thread to the crosshead extension (standard configuration for stainless
steel chrome coated plungers): in this case loose the plunger using appropriate wrench, on the
end part of the plunger (see figure 4.4.1)
connected with clamp (B) (standard configuration for solid ceramic or stainless steel tungsten
carbide detonated plungers): in this case (see figure 4.4.2) loose the clamp screws (A) and move
the plunger away from the crosshead extension (C). To easily open the clamp, it is possible to
use one of the screws in the center hole to enlarge the clamp opening.
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4C041E6C
4.4.3
Use and maintenance instructions
FIGURE 4.4.2
Proceed disassembling the front flanges (see figure 4.4.3):
• loose nuts (A) and remove the front flanges (B); gasket (C) usually remains in position on the
flange
• remove the spacer cage (D);
• remove the valve stop cover (H) if this prevents from easy extraction of the plunger
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4C041E6C
4.4.4
Use and maintenance instructions
FIGURE 4.4.3
To remove the plungers, use the extracting tool supplied in the maintenance box (figure 4.4.4): if
present, use the special groove in the front end of the plunger, otherwise clamp the plunger on its
outside end and pull it out (figure 4.4.5).
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4C041E6C
4.4.5
Use and maintenance instructions
C
B
FIGURE 4.4.4
FIGURE 4.4.5
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4C041E6C
4.4.6
Use and maintenance instructions
4.4.1.2 Assembling
ATTENTION
solid ceramic plungers don’t have a specifica direction of assembly (both faces are the same),
while tungsten carbide detonated plungers may have a specific direction of installation; in
this case the center hole must be placed towards the clamp side (figure 4.4.2, item B) and the
extension (figure 4.4.2, item C), NOT towards the product side.
•
•
Put the plunger inside the block cylinder, and fix it into the standard operating position tightening
the thread on the crosshead extension
In case of use of clamp system, put the plunger completely flat against the crosshead extension,
and the clamp completely against the change of diameter on the crosshead extension, then
tighten the clamp with proper screws (see figure 4.4.2, pos. A), using a tightening torque of 7÷8
N*m
ATTENTION
During assembly check carefully that plunger and clamp are properly assembled and fixed in
the correct position, and there is not interference durino the reciprocating movement of the
pistons. We suggest to turn by hand the pulley bifore starting the machine in order to verify
the correct alternate movement of the pumping plungers.
•
•
•
•
•
check that the position of the packing is correct (figure 4.4.3, item F)
place valve cap back on (H), if it has been removed
insert the spacer (D), press the valve cap (H see. Figure 4.4.9 or 4.4.10) to overcome spring
resistance (a screwdrive can sometimes be needed))
assemble the flange (B)with the gasket (C)
tighten the nuts (A) as specified in chapter 4.3, Table 4.3.1
WARNING
the packing spacer (D) can be hard to mount if the valve cap has not been mounted correctly
or if it does not move freely in its seat. Make sure it is not blocked or press it down with a
suitable tool (e.g. curved diagonal pliers) while the spacer is being inserted.
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4C041E6C
4.4.7
Use and maintenance instructions
ATTENTION
tighten the nuts and bolts in cross, according to the shown pattern in figure 4.4.6.
FIGURE 4.4.6
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4C041E6C
4.4.8
Use and maintenance instructions
4.4.2
Plunger seals
The lifetime of these parts is dependent on the following factors:
• conditions of plungers surface;
• process temperature;
• type of product;
• machine underfeeding (not enough feeding pressure, see Section 1 – TECHNICAL
SPECIFICATIONS for reference);
• worn parts (washers, spacers) in contact with the seals.
Some of these factors - such as the peeling off of coatings on plungers and the machine underfeeding
- are likely to lead to an early deterioration of the seals.
Replacement is required when product leakage is noticed in the water sump; however, if the machine
is fed correctly, the processing cycle can be completed without risk of contamination of the product
itself.
For the replacement procedure it is necessary to disassemble the pumping plungers, see paragraph
4.4.1.
To avoid situations where production has to be stopped due to leaking plunger gaskets, we suggest
you schedule preventive replacement on the basis of their expected average lifetime.
WARNING
Before you begin with maintenance and gasket replacement make sure all the necessary
spare parts and tools are available.
To increase the life of packings special anti-extrusion and support rings can be used (figure 4.4.14
items Z, W); these rings are made of high-performance plastic. Normally two rings are used on each
plunger: one (W) is placed before the packing (F) on the side which is pressed against the front of the
machine, and one (Z) is placed immediately after the packing (F), before the bronze packing washer
(G); in some configurations washer (G) is not present.
These rings are also considered wearing parts and should be replaced regularly to maintain perfect
coupling with plunger, preferably when changing the packings or when they are showing signs of
wear in the inner diameter.
Refer to figure 4.4.14 and general drawing in sections 5 – SPARE PARTS CATALOGUE.
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4C041E6C
4.4.9
Use and maintenance instructions
FIGURE 4.4.14
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
4C041E6C
4.4.10
Use and maintenance instructions
4.4.2.1 Disassembling
After having removed the plungers, use the supplied packing extractor to remove the packings from
its place (figure 4.4.3, pos. F) and the packing washer (G), accordino to what shown in figure 4.4.7:
• insert the packing extractor tool (A) into the cylinder
• turn the handle to expand its end
• pull out together the packing washer (D) and packing (C).
C
D
A
FIGURE 4.4.7
WARNING
some special versions use additional anti-extrusion rings in the seal packing. Refer to specific
drawings in Section 5 - SPARE PARTS CATALOGUE or to figure 4.4.14.
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4C041E6C
4.4.11
Use and maintenance instructions
4.4.2.2 Assembling
To install the plunger gaskets (packings) first of all you need to assemble the plungers as described
in paragraph 4.4.1.
After you have done that, follow the steps below and refer to figure 4.4.8:
• put the plunger fully backwards
• insert the packing washer (A)
• insert the packing (B) as a SINGLE PIECE, using greasing or lubricating product (food grade if
required)
• put the packing in place using the provided inserting tool (C) and some hammering with plastic
head hammer
• make sure no air is trapped between the packings rings and take care not to damage the packing
or pull it out of shape during assembly.
C
B
A
FIGURE 4.4.8
Complete the assembly of the compression head parts as decribed at paragraph 4.4.1.
WARNING
check direction of packing: the tip of the “V” on the rings must point towards the back of the
head (see detail in figure 4.4.7).
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4C041E6C
4.4.12
Use and maintenance instructions
4.4.3
Suction and delivery valves
The good conditions of suction and delivery valves are essential for a trouble-free operation of the
machine; an impaired seal of the valves would cause leakage and product backflow, resulting in
pressure and flow instability.
Generally, the valve assembly consists of a shutter, spring, valve cap and seat.
Depending on the type of product handled, the shutter may vary in design; even though it has
generally a long life, because manufactured with heavy-duty materials, it may need replacement
when then seal surface is cut or dented.
The spring tends to lose gradually the original elasticity and, for this reason, it should be replaced
approximately every 3000 hours of operation, unless broken earlier generally because of the machine
is not fed correctly.
For the replacement procedure of the valve assembly see here below; check in Section 1 –
TECHNICAL SPECIFICATIONS the type of valve installed.
4.4.3.1 Disassembling
The disassembly procedure requires access to inner parts of the head as required for disassembling
the plungers and packings (paragraphs 4.4.1 e 4.4.2)
First remove the front flanges (figure 4.4.3):
• loosen the nuts (A) and rimove the front flanges (B); the gasket (C) is normally left in position on
the flange
• loosen the nuts (N) and remove the upper flanges (O); the gasket (P) is normally left in position
on the flange
• remove the spacer (D) from the plunger cylinder
• for delivery side valves, from the upper side of the block extract the valve cover (H) with spring
(J) and valve (L), figures 4.4.9 or 4.4.10;
• with suction valves proceed likewise through the boring of the plunger cylinder, which first needs
to be moved back to the inner dead center.
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4C041E6C
4.4.13
Use and maintenance instructions
4.4.3.2 Reassembling
Once replacement has been completed, reassemble the valves using the tools provided:
• insert the valve (L) and the valve cover (H) with spring (J), according to figures 4.4.9 or 4.4.10;
• insert the spacer (D) into the cylinder and reassemble the flanges, then tighten nuts crosswise
as described on chapter 4.3.
FIGURE 4.4.9
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4C041E6C
4.4.14
Use and maintenance instructions
With ball type valves (PVB), see figure 4.4.10, the valve cover is slightly different and provides a
guide for the ball’s movement.
FIGURE 4.4.10
WARNING
when tightening the head nuts observe the tightening torques shown in chapter 4.3, Table
4.3.1; use a torque wrench (not provided).
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
4C041E6C
4.4.15
Use and maintenance instructions
4.4.4
Valve seats
Valve seats (figure 4.4.11 pos. H and G) are of removable type, inserted into the compression block;
they are made from a particularly hard material to ensure wear resistance and longer life.
Possible light marking by pricks on seat surface does not affect the valve sealing and functionality.
The lifetime of the seats is normally longer than the one of the valves, and depends on the
characteristics of the product and on the working conditions of the machine.
In case of particularly abrasive products, seats can be refurbished or replaced when necessary;
proceed to replacement following the procedure and using the tools described here below.
4.4.4.1 Disassembling
WARNING
The tools used for removing the valve seats are NOT included in the maintenance box.
Tightening of the head nuts must be made using the torque values indicated in chapter 4.3,
Table 4.3.1.; use a torque wrench (not supplied).
To remove the seats you need to have the rights tools (these can be supplied by
GEA Mechanical Equipment Italia S.p.A. upon request) to be able to follow the steps described
below:
G
H
FIGURE 4.4.11
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4C041E6C
4.4.16
Use and maintenance instructions
•
•
•
•
•
•
procede with disassembling of valve groups (see paragraph 4.4.3);
remove the suction manifold
put the pumping plunger fully backwards (inner dead center)
remove first the suction valve seat (H), then the delivery side seat (G)
use a rod made of a soft material, such as bronze or aluminium, to be inserted in the head under
the suction valve; the diameter of the bar must be as large as possible, and to make it fit well
with the seat the support can be made with a conical shape to match the bottom part of the seat
strike the bar with a hammer until the seat has been removed
If this procedure is not sufficient to extract the valve seats a traction system with a threaded bar can
be used.
To follow this procedure (see figure 4.4.12) it is necessary to have:
• a threaded bar (A) made of high-resistance steel with the maximum diameter allowed by the
bores of the valve seats (H)
• a bronze or aluminium pad (D) positioned under the seat, with the bore for the threaded bar nuts
(B)with washer (C)
• a pad (E) to be laid against the pressure gauge flange (F) used to provide thickness
• once the threaded rod is properly in tension using suitable torque on the nuts it is possibile to
hammer the lower part of the threaded rod (using a plastic hammer or a piece of wood to avoid
the damage of the thread, to remove the seats
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4C041E6C
4.4.17
Use and maintenance instructions
A
E
F
H
H
D
C
B
FIGURE 4.4.12
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4C041E6C
4.4.18
Use and maintenance instructions
4.4.4.2 Assembling
•
•
•
•
FIRST install the suction valve seat, THEN the delivery valve seat;
put the seat (H) in place (see figure 4.4.13);
using a suitable rod (A), see figure 4.4.13, lock the seat in its position with hammer
repeat the same procedure for the delivery side valve seat
The definitive blocking of the valve seat in its working position is made durino the operation of the
machine because of the pressare.
Proceed wit reassembling of valve groups as described at paragraph 4.4.3
A
H
FIGURE 4.4.13
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4C041E6C
4.4.19
Use and maintenance instructions
4.5. Homogenizing group
ATTENTION
before start up and after every nanovalve® maintenance, it’s necessary to execute the
procedure for valve allignment, as explaned in instruction manual paragraph 4.5.4.
4.5.1
Homogenizing valve nanovalve®
The NANOVALVE ® homogenizing assembly (optional) (ITALIA patent 1.282.765, EPO patent
97107416.6, USA patent 5.887.971) has been designed by GEA Mechanical Equipment Italia S.p.A.
to create a valve with improved homogenizing efficiency with compared to traditional homogenizing
valve.
Like the standard type, this valve consists of three parts (figure 4.5.1):
H2
H1
H3
FIGURE 4.5.1
•
•
•
passage head (H3)
impact head (H1)
impact ring (H2).
Homogenization takes place when the product passes between the opposing surfaces of the two
heads H1 and H3 at extremely high speed and is completed by the impact with the outer ring.
The action of high-pressure fluid dynamics effects taking place inside the homogenizing valve is
complex; in general the micronization of the particles contained in the liquid phase can be described
as a combination of turbulence, shear, localized cavitation and impact.
The three parts of the homogenizing valve, made with very hard material to resist abrasion, are
normally subject to wear at a rate which depends on the type of product treated; therefore, various
effects resulting from wear or damage can be noticed on their surface. Therefore, various effects
resulting from wear or damage can be noticed on their surface:
• radial grooves developing from the internal diameter on the working surface of the passage head
(H3);
• small craters next to the external diameter of the impact head (H1);
• craters and wear next to the internal diameter of the impact ring (H2).
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4C052E7C
4.5.1
Use and maintenance instructions
Worn valves lead to gradual decrease of the homogenizing effect: in addition, when wear reaches a
certain level, it becomes impossible to reach the required homogenizing pressure.
At that point it is therefore necessary to replace the valve components (impact head, impact ring,
passage head).
To maintain high homogenizing efficiency, we suggest you replace the impact ring (H2) when the
groove caused by wear is approximately 1 mm deep.
As for the impact head (B), the NANOVALVE ® designs makes it possible to use this element TWICE
by simply turning it around: see instructions in paragraph 4.5.2.
The working surface of the passage head (H3) can be refurbished to remove maximum 0.5 mm from
the original element.
When the effect of wear on the elements described above seems excessive, it may be
connected with the use of material that is not suitable to the product handled: contact
GEA Mechanical Equipment Italia S.p.A.’s Customer Service for explanations and solutions.
ATTENTION
the impact head and the passage head are manufactured from a material whose hardness is
suitable to withstand the abrasive action of the product handled for a long time.
Whenever wear signs appear that may jeopardize the homogenizing efficiency, working
surfaces can be rectified: this can be done either at GEA Mechanical Equipment Italia S.p.A.
or at properly equipped workshops.
ATTENTION
the guidelines given above refer to normal operating conditions and provide suggestions for
ordinary and preventive maintenance.
It is important to bear in mind that wear of components of the homogenizing valve is NORMAL
and it will depend on the kind of action taking place inside the valve.
If the valve deteriorates too quickly, contact GEA Mechanical Equipment Italia S.p.A. for
explanations and alternative solutions.
ATTENTION
Maximum service pressure for pneumatic plant and pneumatic actuators is 1 MPa (10 bar).
WARNING
In the case of components made of Tungsten Carbide material, during washing or production,
the use of reverse osmosis purified water, demineralized microfiltered water, Water for
Injection is not recommended.
Its aggressive action would lead to chemical etching of the material in question, drastically
reducing its duration and putting the correct homogenizing operation of the machine at risk.
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4C052E7C
4.5.2
Use and maintenance instructions
4.5.2
Homogenizing group nanovalve ®
When carrying out maintenance work refer to the figure here below.
FIGURE 4.5.2
DISASSEMBLY (figure 4.5.2)
•
•
loosen retaining screws (A) on the bottom flange (B), then loosen the screw on the spring guide
(C) and pull everything out, including the springs (D);
loosen the retaining screws on the homogenizing block (E) and disconnect the pipe for pneumatic
control of the plunger.
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4C052E7C
4.5.3
Use and maintenance instructions
ATTENTION
the homogenizing assembly block is quite heavy!
When removing, handling and positioning the block use both hands to prevent injury and
wear suitable personal protection devices.
•
•
•
remove the top homogenizing chamber (F) together with the pneumatic cylinder (G); you can
lever on the two blocks and use the lifting handles supplied in the maintenance box;
remove the impact head assembly (H) and then the impact ring (J) and passage head (L);
if necessary, loosen the stud nuts (M) and pull out the bottom homogenizing chamber (N).
ASSEMBLY (figure 4.5.2)
ATTENTION
before reassembly make sure you clean all the element and remove any product residue.
ATTENTION
for easier assembly of the gaskets we suggest you grease them with a food-grade lubricant.
•
•
•
•
•
•
•
•
mount the O-Ring (P) and the passage head (L);
mount the O-Ring (R - S) on the guide plunger of the impact head, then the anti-extrusion rings
(T - V);
grease the gaskets with food-grade vaseline to facilitate assembly;
grease the gaskets with food-grade vaseline to facilitate assembly;
insert the impact head assembly in the bottom homogenizing chamber until the surface of the
impact head(H) has come into contact with the passage head (L);
position the impact ring (J);
mount the O-Ring (W) on the top homogenizing chamber (food-grade vaseline can be used to
hold it in position);
mount the top homogenizing chamber (F) complete with pneumatic cylinder (G);
ATTENTION
Assembly must be carried out with care to prevent damaging the gaskets!
•
•
tighten the nuts diagonally (E);
mount the bottom flange (B) with the spring guide screw (C) and Belleville washers (D);
ATTENTION
Belleville washers must be mounted one opposite the other (one by one), unless otherwise
specified.
•
•
tighten the screws (A);
connect the pneumatic cylinder with the control pipe.
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4C052E7C
4.5.4
Use and maintenance instructions
4.5.3
Impact head assembly
When the impact head needs to be replaced, for instance due to wear, this element can be separated
from the two top and bottom guide plungers according to the instructions given below.
FIGURE 4.5.3
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4C052E7C
4.5.5
Use and maintenance instructions
Disassembly (figure 4.5.3)
•
•
•
insert the two screws in the bottom part of the plunger so that the assembly may be blocked in
the vice;
loosen the screw (X) using an Allen wrench;
separate the three pieces (K, H, Y).
Assembly (figure 4.5.3)
•
•
•
keep the bottom plunger (K) blocked in the vice;
replace or turn around the impact head (H), then put the assembly back together after replacing
and correctly positioning the O-Ring (Q, Z);
tighten the assembly with the screw (X).
•
.
ATTENTION
Tightening torque: SCREW M20=200 Nm; SCREW M27=500 Nm.
ATTENTION
Do not replace the middle retaining screw! Use only ORIGINAL parts.
4.5.4
Nanovalve ® alignment
As explained above, NanoValve® is a high-efficiency homogenizing assembly which works with a
minimum distance between the passage head (H3) and the impact head (H1).
For this reason if the alignment of the parts made during assembly is not perfect it might not be
possible to reach the required operating pressure.
To avoid this problem, below we give the procedure for valve ALIGNMENT
• with the machine NOT IN OPERATION, loosen the 4 bottom screws (E) of the valve assembly,
without removing them, and loosen the screws (A) of the flange (B)
• connect the pneumatic cylinder (G) the compressed air pipe and apply pressure as if to close the
valve
• this way the impact head (H1) and the passage head (H3) come into contact and are aligned
• maintaining air pressure on the pneumatic head, tighten the 4 screws (E) one after the other
diagonally, in order to close the bottom and top parts of the homogenizing chamber (F, N)
• remove compressed air
• tighten the bottom flange (B) with the four screws (A)
• verify that the impact head assembly (H) can move freely by giving and releasing pressure to the
pneumatic head and checking the movement of the middle bolt.
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4C052E7C
4.5.6
Use and maintenance instructions
4.5.5
Aseptic nanovalve ® assembly
The maintenance procedure (assembly and disassembly of components) for the aseptic assembly is
not different from the standard version.
The only difference is in the pipes used for aseptic condensate, which have to be disassembled and
reassembled for maintenance, and the double O-ring on the guide plunger of the impact head.
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4C052E7C
4.5.7
Use and maintenance instructions
4.6. Overpressure valve and pressure gauge
4.6.1
Overpressure valve
The pressure relief valve (see SECTION 3 - Paragraph 3.7.1) is usually installed on the compression
head or on the high-pressure delivery line to protect the machine and operators from accidental
overpressure which can create risk of danger.
Maintenance (see figure 4.6.1) is limited to checking and possibly replacing the gaskets (G) and (H),
the ball (E) and valve seat (F); in some versions an anti-extrusion ring is fitted between the seat and
the O-ring gasket (G) to protect the O-ring.
To remove the valve from its operating position you have to loosen the nuts (A) then remove the
complete valve body (B) and its flange (C); these two parts can be separed once the two-part ring
(D) is removed from its position.
Then remove the O-ring (H), the seat (F) housing the ball (E) and the O-ring (G).
Make sure you do not misplace the ball (E), as the valve cannot work without it; we recommend you
always keep a spare seat and ball in case you need to replace them.
Valve maintenance does NOT require replacing the spring.
Carefully clean the seat (F) from any product residues but take care not to damage the sealing area.
If the sealing area between the seat (F) and the ball (E) is damaged or worn, there can be product
leaks and the valve can be triggered at a pressure value lower than the valve setting; we therefore
recommend you replace the seat and ball.
Steps to be followed for assembly:
• Insert the gasket (G) into its housing in the flange or head; food-grade Vaseline or other suitable
lubricants should be used for easier assembly
• prepare the seat (F) for assembly, place the ball (E) and O-ring gasket (H) inside it
• insert the valve body (B), the flange (C) and place the two semi-rings (D) to hold the flange in
position
• insert the seat (F) prepared on the valve body, and keep it in position with your fingers while you
insert the whole valve on the flange housing (or, in some versions, directly on the head)
• insert the flange (C) on the studs and screw the nuts (A) by hand, so as to correctly lock the valve
by inserting the seat (F) on the O-ring gasket (G)
• when the valve is in a stable position, before tightening the nuts (A), place the discharge pipe in
the correct position. For safety reasons the discharge pipe must always be kept open and turned
downwards.
• tighten the nuts (A) fully.
For futher information on operation of the overpressure valve see paragraph 3.7.1.
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4C061E5C
4.6.1
Use and maintenance instructions
WARNING
it is absolutely FORBIDDEN to modify the overpressure valve setpoint and break the seal,
unless with written authorization by GEA Mechanical Equipment Italia S.p.A..
In case of modification of the valve setpoint without authorization, the warranty on the machine
is immediately void, and moreover this may cause ranger for the safety of the personnel
using the machine, as the overpressure relief valve is a fundamental safety device for the
machine accordino to the CE safety regulations.
WARNING
It is absolutely FORBIDDEN to close the discharge pipe of the overpressure valve with a
valve. The valve discharge must always be unobstructed and turned downwards.
FIGURE 4.6.1
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4C061E5C
4.6.2
Use and maintenance instructions
4.6.2
Pressure gauge
The pressure gauge installed on the machine is a component of fundamental importance as it makes
it possible to measure the machine’s operating pressure and thus keep its operation under control.
With a faulty pressure gauge the required working pressure cannot be maintained, so we recommend
you keep a spare pressure gauge in stock in case a replacement is needed.
The type of pressure gauge installed can vary depending on the machine model or if optional
configurations are used.
The standard pressure gauge is analog with Bourdon spring and sanitary baffle separator especially
designed by GEA Mechanical Equipment Italia S.p.A.; it is also equipped with a separator used to
filter the normal pulsations of the plunger machine to allow steady readings of operating pressure.
Never separate the pressure gauge from its separator.
Other versions of pressure gauges or pressure measuring devices are available as alternatives:
• analog pressure gauge with signal transmitter: with 4÷20 mA output for remote transmission of
pressure signal
• pressure transducer: this is a sensor which gives an electric signal to be amplified in order to
obtain a 4÷20 mA output of the pressure signal
• digital pressure gauge with built-in display: this transducer has a display to directly indicate the
pressure value measured. Powered by internal battery.
The pressure gauge normally requires no maintenance, however we recommend a periodical check
to:
• verify the condition of the diaphragm which comes into contact with the product; if it is punctured
or damaged the pressure gauge must be replaced
• for analog pressure gauges, check the level of glycerine inside the dial; if necessary fill the dial
up to ¾ with 99.5% pure glycerine
• replace the gasket between the pressure gauge and the head
For instruments provided with electric equipment refer to the wiring diagram, which also indicates the
setting range of the instrument.
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4C061E5C
4.6.3
Use and maintenance instructions
Refer to figure 4.6.2: to disassemble the pressure gauge (or pressure gauge with transmitter, or
pressure transducer) you need to loosen the nuts (G) and pull out the pressure gauge complete with
flange (F).
The pressure gauge (A) and flange (F) can be separated once the semi-rings (D) have been removed.
Figure 4.6.3 shows the analog configuration for disassembling the pressure transducer.
FIGURE 4.6.2
Steps to be followed for assembly (figure 4.6.2 or 4.6.3):
• insert the gasket (E) on the pressure gauge rod (used only to protect from dirt)
• insert the gasket (G) inside its housing in the flange or head; food-grade Vaseline or other
suitable lubricants should be used for easier assembly
• insert the anti-extrusion ring (C), if used, on the manometer; this ring is used in high-pressure
versions from 600 bar upwards
• insert the flange (F) on the pressare gauge body (A) and fit the two semi-rings (D) to hold the
flange in position
• insert the pressure gauge prepared in this way into its housing, and place the flange (F) on the
studs (H)
• screw the nuts on (G) by hand before tightening them fully.
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4C061E5C
4.6.4
Use and maintenance instructions
FIGURE 4.6.3
In high-pressure versions, equipped with transducer (T) or digital pressure gauge (M) (see figure
4.6.4), a threaded locking ring (D) is used.
FIGURE 4.6.4
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4C061E5C
4.6.5
Use and maintenance instructions
For disassembly, unscrew the ring (D) and pull the instrument out; remove also the gasket (B) and
anti-extrusion rings (A, C) from their housing.
For assembly follow these steps (figure 4.6.4):
• fit anti-extrusion ring (C), gasket (B) and anti-extrusion ring (A) onto the end of the pressure
gauge (M) or transducer (T); food-grade Vaseline or other suitable lubricants should be used for
easier assembly
• fit the pressure gauge (M) or transducer (T) into its housing; with digital pressure gauges make
sure you do not force the element using the head of the instrument to prevent breakages
• tighten the locking ring (D) fully
The digital pressure gauge (M) will switch automatically after a few minutes if no pressure is measured,
to preserve the internal battery.
To start the pressure gauge simply press the front ZERO/ON push-button; keep this button pressed
for a few seconds to reset the instrument to ZERO if the reading given is NEGATIVE.
If the display reads “BATT” it means that the battery is down and needs to be replaced.
Disassemble the pressure gauge and, on a dry surface, remove the rear screws to lift off the
cover on the battery housing. The battery used is a long life 9V lithium battery, size PP3; in special
circumstances a standard 9V alkaline battery may be used.
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4C061E5C
4.6.6
Use and maintenance instructions
4.7. Trasmission (g-fx system)
The machine is equipped with a drive system consisting in:
• fixed-mounted parallel-axle reduction gear, fitted on the machine’s crankshaft and secured to the
drive body by a connection flange;
• V-belts drive and pulleys between main motor and gearbox.
ATTENTION
All jobs must however be assigned to qualified technicians and always require maintenance
shutdown of the machine, that is with the MACHINE STOPPED and the power line circuit
breaker LOCKED (with a padlock) IN THE OPEN POSITION for the safety of staff.
The elements of the drive system usually require only a visual inspection, carried out with the machine
not in operation, to check for possibile lubrication oil leaks and, more importantly, for loosening of
nuts, bolts, belt tensioning components and reduction gear support parts.
Excessive movement of drive components, due to loosening of locking elements caused by vibrations,
can result in slack couplings and consequent breakage of elements during machine operation.
ATTENTION
It is important to regularly check tightening of nuts and bolts in the belt tensioning system
and reduction gear support system. Abnormal vibrations due to incorrect machine operation
or cavitation conditions can cause these components to loosen and damage the drive system.
Instructions for maintenance of drive components are given below.
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4C079E3C
4.7.1
Use and maintenance instructions
4.7.1
Reduction gear
The reduction gear does not require special maintenance precautions; you only need to check the
level of lubricating oil through the inspection hole in the casing.
It is good maintenance practice to protect the seal rings with waterproofing lubricating grease, and
to protect the locking system on the shaft from the effects of oxidation which would make it difficult
to disassemble the reduction gear, if necessary.
For reduction gears equipped with cooling coil inside the casing for artificial refrigeration, the water
circuit needs to be drained off completely if room temperature drops below +4 °C.
For further information and instructions for disassembling the reduction gear from the machine refer
to the reduction gear manual, included in Section 6 – INFORMATION ABOUT SUPPLIERS.
FIGURE 4.7.1.1
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4C079E3C
4.7.2
Use and maintenance instructions
LUBRICATION OIL
Only use oil of the type indicated in TT-0162, attached to section 1 of this manual.
OIL CHANGE INTERVALS
The oil must be changed every 5000 hours if using MINERAL OIL or 20000 hours if using SYNTHETIC
OIL.
OIL QUANTITY FOR REDUCTION GEAR
The quantity of oil for the gear reducer depend by the model of machine as specified in TT-0162,
attached to section 1 of this manual.
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4C079E3C
4.7.3
Use and maintenance instructions
4.7.2 Installing the belts
ATTENTION
All jobs must however be assigned to qualified technicians and always require maintenance
shutdown of the machine, that is with the MACHINE STOPPED and the power line circuit
breaker LOCKED (with a padlock) IN THE OPEN POSITION for the safety of staff.
INSPECTION OF THE PULLEYS
Worn pulleys significantly reduce the life of belts, which can touch the bottom of the groove causing
slipping which provokes wear and superficial burning.
If the sides of the groove are hollow, the contact between the sides of the belt and the pulley is not
uniform, and the lower part of the pulley causes wear of the lower edge of the belt, causing it to break
prematurely.
Thus, it is necessary to check the state of wear of the pulleys and remove any rust, grease or oil that
may be present.
ALIGNMENT CHECK
Correct alignment is essential to ensure long-life of the drive belts.
This operation must be carried out during assembly by skilled personnel: it is important to check
alignment by placing a metal ruler on the 2 pulleys (fig.4.7.2.1).
FIGURE 4.7.2.1
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4C079E3C
4.7.4
Use and maintenance instructions
If necessary alignment can be corrected by loosening the retaining bolts of the conic bush and
slightly move the driven pulley (by a few mm.) to reach optimal position then lock the bushing.
SELECTION OF BELTS
Use at the same time belts of the same make, of the same type and of the same lot, since there may
be differences both in size and in performance.
Moreover, it is essential not to use new belts with others that have already been used, because of a
different extension, adjustment to the grooves of the pulleys, and differences in performance, which
would considerably affect the duration of the drive train.
In order to ensure correct operation and avoid premature breaking, the belts must be stored without
any noticeable bends and must not be exposed to temperatures that are too high or too low, or to a
high degree of humidity.
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4C079E3C
4.7.5
Use and maintenance instructions
DESCRIPTION OF G-FX DRIVE SYSTEM
The drive unit is composed of the motor (1), driving pulley (2), belts (3), flywheel (4), reduction gear
unit (5).
The motor is secured to the frame by a belt tensioning chassis (10). The chassis is equipped with
a micro-regulating system for belt tensioning and pulley alignment, composed of an adjusting and
positioning screw (6) in figure 4.7.2.3.
The adjusting screw (6) is accessible by dismantling the window (7) located on the rear panel (8) of
the homogenizer.
The reduction gear unit is secured to the drive body by G-FX flange
at position (11).
The gearbox hollow shaft is fixed to the crankshaft by means of the locking system indicated in figure
4.7.2.4 pos. 12.
FIGURE 4.7.2.2
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4C079E3C
4.7.6
Use and maintenance instructions
FIGURA 4.7.2.3
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4C079E3C
4.7.7
Use and maintenance instructions
ASSEMBLY OF THE BELTS
The drive belts should be assembled and tensioned in the following sequence:
• Remove the rear window (7)
• Turn the adjusting screw (6) so as to move the motor closer to the reduction unit, decreasing the
centre distance between the pulleys (2, 4)
• Install the drive belts
• Using the adjusting screw (6) move the motor to tension the belts
• Check the pulley positioning and alignment. To tension the belts correctly, see paragraph 4.7.3.
During installation belts must never be forced with a tool into the pulley’s grooves to avoid the risk of
damage thus reducing the life of the drive.
To make this operation easier, simply reduce the distance between the pulleys.
Fit the belts into the grooves and rotate the pulley to facilitate insertion and prevent damage.
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4C079E3C
4.7.8
Use and maintenance instructions
4.7.3 Stretching the belts
ATTENTION
All inspection and maintenance operations must be carried out by qualified technicians
and only when the machine is in maintenance status, that is, with the MACHINE NOT IN
OPERATION; the power mains switch must be LOCKED IN THE OFF POSITION (with a padlock)
for the safety of personnel. The procedure for placing the machine in maintenance status is
described in chapter 4.1.3.3 of this manual.
ATTENTION
The V-belt transmission may create danger of crushing or entrapment. Use always the
necessary fixed protections and in case remove them only after having checked the machine
to be completely stopped in any moving part..
The ideal stretch is the lowest at which the belts do not slip under maximum load.
During the first 24-48 hours of running-in, check the stretch frequently; remember that excessive
stretch reduces the life of the belts and of the bearings that support the drive.
Arrange for the stretch to be tightened as soon as any slipping occurs.
Belt slipping can cause overheating and create hazard particularly if the machine is designed for
operation in danger zones (explosion-proof version).
The following are two methods to identify the correct degree of stretching of the belts; the first, which
is easier, can be used when a new train of belts is installed, or after loosening them completely; the
second allows stretch to be checked even during normal operations of servicing and control. The
procedures of the operations are described in paragraph 4.7.2.
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4C079E3C
4.7.9
Use and maintenance instructions
BELTS TENSIONING – FIRST METHOD
Before stretching the belts assembled on the pulleys, trace two fine marks across the back of one
belt and measure the distance between them; they should be as far from each other as possible but
must remain on the straight-line of the belt. Stretch the belts gradually after having them rotate for
approx. 1 minute in successive stages; at each stage, tighten the belts so that the distance between
the two marks has a percentage increase as shown in table 4.7.3.1, considering the case of medium
diameter pulleys.
Type of transmission
Not constant Torque
- one small size pulley
0,8%
- short shaft center distance
- medium or big size pulleys
1%
- medium or big shaft center distance
TABLE 4.7.3.1
BELTS TENSIONING – SECOND METHOD
Measure the length of the free section “t” (figure 4.7.3.1) and apply to its half-point a force P
perpendicular to the belt, that causes a deformation of 1.6 mm every 100 mm. of free length:
F=1,6 x T/100 (mm)
The intensity of the force, in Newton, should be in the interval of values shown in table 4.7.3.2; ; it is
measured by means of a special dynamometer which is not supplied.
In order to calculate the peripheral speed value it is sufficient to use the formula:
V = 0,052 x n x d x r
(m/s)
where n is the number of revolutions per minute of the crankshaft as indicated in SECTION 1 –
TECHNICAL SPECIFICATIONS, and d is the diameter of the flywheel indicated in metres; r gear
reduction ratio; 0.052 is a constant, the result of converting from r.p.m. to rad/sec
It is important to remember that at the first stretching, the correct value is 1.3 times the maximum
value shown in table 4.7.3.2, so as to compensate the natural extension and initial settling of the
belts.
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4C079E3C
4.7.10
Use and maintenance instructions
FIGURE 4.7.3.2
Tipo / Type
SPZ
SPA
SPB
SPC
D (mm)
Forza / Force P (Newton)
V = 0÷10 m/s
V = 10÷20 m/s
V = 20÷30 m/s
67÷95
12 – 18
10 – 16
8 - 14
> 95
19 – 26
17 – 24
15 – 22
100÷140
22 – 32
18 – 26
15 – 22
> 141
33 – 48
27 – 40
23 – 34
160÷265
38 – 56
32 – 50
28 – 42
> 266
57 – 72
51 – 64
43 – 58
224÷355
72 – 102
60 – 90
50 – 80
> 356
103 – 132
91 – 120
81 - 110
TABLE 4.7.3.3
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4C079E3C
4.7.11
Use and maintenance instructions
4.7.4 Maintenance of belts
The belt drive is an efficient, reliable means for power transmission.
The following are some simple instructions to ensure reliability and long life of the system.
LOOK AND LISTEN
This allows you to easily identify the defects to be corrected:
- Visual check if any oil or grease is present on the belts, since this may cause premature deterioration;
excess oil on the supports and bearings may cause the belts to be dirtied, while a lack may cause
increased friction and subsequent burning of the belts due to overload.
- Listening to the noise during transmission.
If there is any screeching when the motor accelerates or during operation at full load, this means that
there is insufficent stretch of the belts.
Once the correct stretch has been restored, if the noise persists try to identify any overload in
transmission (due to wear, seizure, insufficient lubrication...).
The presence of a regular squeaking, similar to that of a bearing that is insufficiently lubricated, does
not cause any damage to the transmission and may be caused by the presence of dirt.
Do not try to eliminate this noise by oiling the belts.
DIRT AND FOREIGN MATERIALS
Dirt and dust may accelerate wear of the belts and pulleys and obstruct a good traction.
It is necessary to regularly clean the drive system and prevent any foreign material from being
trapped between the belts and pulleys.
OVERLOADS
Any overload shortens the life of the belts.
Check that operation is taking place under the initial project conditions, and that no overloads occur
due to wear or slipping and superficial burning.
PROTECTIONS
The drive should always be protected by a suitable guard, which not only protects the operators but
also protects the parts from dust or dirt and contact with foreign objects which may cause serious
damage to the system.
BREAKING AND CRACKS
Check the condition of the belts, and see if there are any cuts or cracks, that are a sign of excessive
wear and the need to replace the part.
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4C079E3C
4.7.12
Use and maintenance instructions
TENSIONING
Check and maintain the correct stretch of the belts, to prevent irregular vibrations.
EXPOSURE TO HEAT
Check that the belts are not exposed to sources of heat; an exposure to temperatures greater than
60°C will shorten their life.
WEAK
Check the condition of the sides of the belt: an anomalous wear may cause slipping or excessive
wear of the grooves of the pulleys.
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4C079E3C
4.7.13
Use and maintenance instructions
4.7.5
Assembling and disassembling of pulleys
Drive pulleys are usually mounted both on the input shaft of the reduction gear and on the motor
shaft using a “Taper-Lock” conical bushings.
With reference to figure 4.7.5.1, the procedure for disassembly is the following:
FIGURE 4.7.5.1
•
•
•
loosen retaining screws A
use one of the screws in bore B to force the bush open
extract the bush and pulley from the shaft.
Assembly procedure:
• clean bush and shaft thoroughly
• insert “Taper-Lock” bush into pulley
• partially insert threaded screws into bores (A)
• mount the pulley on the shaft
• align the pulleys
• tighten screws A fully
If the motor pulley is not fitted with a “Taper-Lock” bush, to install or remove the pulley use a suitable
pulley extractor and threaded rod to mount the pulley on the shaft, using the threaded bore on the
end of it.
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4C079E3C
4.7.14
Use and maintenance instructions
4.8. Power end - crankcase
The reciprocating linear motion of the plungers is created by an oversized and sturdy crank mechanism
(crankshaft, connecting rod, crosshead).
The system is illustrated in the general exploded view (figure 4.8.1) below.
FIGURE 4.8.1
The type of construction, the high-quality materials used and the careful assembly by highly-qualified
personnel are a guarantee of excellent reliability and durability.
Correct lubrication is fundamental for the life of the drive body and of its components, so it is absolutely
necessary to comply with the instructions given in terms of recommended change frequency (Chapter
4.2), filter cleaning, level and type of lubricant used (Chpater 4.9).
Under normal conditions the power end does not require servicing. Should you notice abnormal
noise levels, irregular machine operation or low pressure of lubrication oil triggering the pressare
switch, contact GEA Mechanical Equipment Italia S.p.A.’s Customer Service to request technical
service.
Under normal working conditions and without specific faults, it is recommended to check the sleeve
bearings (W) and crank pin bearings (S), the wrist pin (O) and its bearing on the conrod (R) at least
every approx 10.000 hours of operation, and to check the roller bearings (B) of the crankshaft at
least every 20.000 hours of operation.
Such kind of maintenance requires skilled personnel, therefore it is recommended to contact
GEA Mechanical Equipment Italia S.p.A. Customer Service for advice and support.
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4C081E6C
4.8.1
Use and maintenance instructions
The only ordinary maintenance operation required is replacement of guide plunger gaskets, in case
of lubrication oil leaks inside the sump.
If the surface of the crosshead extension is badly scratched, it is necessary to replace the complet
guide pistons.
Such kind of maintenance requires skilled personnel, therefore it is recommended to contact
GEA Mechanical Equipment Italia S.p.A. Customer Service for advice and support.
WARNING
All inspection and maintenance operations must be carried out with the MACHINE NOT
IN OPERATION; the power mains switch must be LOCKED IN THE OFF POSITION (with a
padlock) for the safety of personnel.
WARNING
Lubricating oils are extremely harmful to environment and should be disposed of correctly
in suitable disposable, in accordance with the local regulations, to avoid environment and
water pollution.
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4C081E6C
4.8.2
Use and maintenance instructions
4.8.1 Replacing guide plunger gaskets
Before removing the flanges you need to drain out, at least partially, the oil inside the body to prevent
accidental spillage.
Refer to figure 4.8.2 for the assembly and disassembly procedures described below.
FIGURE 4.8.2
DISASSEMBLY
• remove the plunger following the procedure described in Charter 4.4
• loosen the screws (K) and extract the flange (M) from the guide plunger (Q)
• remove the scraping ring (L) and the seal gasket (J).
ASSEMBLY
• fit the scraping ring (L) and gasket (J) inside the flange (M), in the seat.
• check and clean the plunger stem, if the surface is badly scored or the chrome plate damages
the whole plunger must be replaced. The guide plunger stem cannot be supplied separately as
spare part
• insert the complete O-Ring flange (H) onto the guide plunger (Q) as far as the edge. During
assembly take care not to damage the sealing lip of the gaskets; use lubrication grease for easier
assembly
• tighten the screws (K).
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4C081E6C
4.8.3
Use and maintenance instructions
In some models a rubber bellows is installed to protect the guide plunger stem. In this case the
bellows (Z) must be removed to replace the gaskets, and then inserted onto the guide plunger stem
(Q) and snapped on locked against the flange (M) in the seat provided.
FIGURE 4.8.3
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4C081E6C
4.8.4
Use and maintenance instructions
4.9. Lubrication
Proper machine lubrication is required to guarantee its correct operation.
For this reason it is absolutely necessari to follow directions for oil change intervals (see Charter 4.2),
the cleaning or replacement of filters, check of oil level and use of specified lubricating oil.
The lubrication system can be either FORCED or SPLASH, depending on the machine model; see
Section 1 – TECHNICAL SPECIFICATIONS to find out type of lubrication used.
For top-ups and oil changes use ONLY one of the oils indicated in document TT-0038, attached to
section 1 of this manual; the same table indicates the capacity of the lubrication plant for the various
models according to the type of lubrication.
ATTENTION:
The lubrication oil is suitable for operating temperatures ranging from 5°C and +40°C: please
contanct GEA Mechanical Equipment Italia S.p.A. Customer Service to obtain the type of
lubricant suitable for any specific conditions found locally.
ATTENTION:
Used oils are extremely harmful to environment and should be disposed of correctly, in
accordance with the local regulations.
ATTENTION:
All inspection and maintenance operations must be carried out with the MACHINE NOT
IN OPERATION; the power mains switch must be LOCKED IN THE OFF POSITION (with a
padlock) for the safety of personnel.
It is important to periodically ensure there is no foam in the oil as this is a sign that air is being
incorporated due to cavitation in the oil pump or to bad sealing of the lubrication circuit. You also
need to check for a whitish water/oil emulsion which is caused by inefficient drainage of condensate
or water infiltrations inside the body (faulty water/oil exchanger or worn guide plunger gaskets).
Any type of oil used should have the following specifications:
Suitable for hydraulic circuits, of mineral origin, viscosity ISO VG 150 (150 cSt at 40°C) with nonfoaming, antioxidative additives, etc.
The list of recommended oils, including food-grade oils, is given in document TT-0038 attached to
Section 1 of this manual.
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4C091E12C
4.9.1
Use and maintenance instructions
4.9.1 Foorced lubrication with motor-driven pump
Forced lubrication is by means of a lubrication unit (CONTROL UNIT) with separate electric motor,
which makes it possibile to have adeguate flow of lubrication oil and pressure even when the rotation
speed of the crankshaft is low (variable load machine).
The oil circuit inside the drive body is made with rigid or flexible pipes and keeps oil under pressure to
lubricate the crankshaft main bearings, connecting rod bushings and connecting rod pins, to censure
reliable machine operation and durability of contact surfaces in the crank mechanism.
The machine is equipped with a pressure gauge on the front panel for continuous control of lubrication
pressure and a safety pressure switch set to 3 bar to stop the machine if lubrication pressure is
insufficient.
The lubrication system diagram is shown in Section 5 – SPARE PARTS CATALOGUE, while figure
4.9.1 gives an exploded view of the lubrication unit.
The lubrication control unit is made up of the sub-components shown in figure 4.9.1:
• electric motor
• joint between pump and motor (G)
• body (C) with by-pass valve (F)
• gear pump (D)
• tank (A)
• intake filter (B)
The intake filter is fitted inside the tank, so to be able to remove it you need to remove the whole
control unit assembly.
Before removing the control unit, oil needs to be drained out of the body.
The filter must be cleaned or replaced every time the oil is changed according to the indications
given in the PERIODICAL MAINTENANCE TABLES.
ATTENTION:
The by-pass valve (F) MUST NOT BE DISASSEMBLED from the body (C). For adjustment of
lubrication pressure see the instructions given below.
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4C091E12C
4.9.2
Use and maintenance instructions
G
F
C
D
B
A - tank
B - intake filter
C - body
D - gear pump
F - bypass valve
G - joint between pump and
motor
A
Fig. 4.9.1
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4C091E12C
4.9.3
Use and maintenance instructions
OIL LEVEL CHECK
The oil level needs to be checked every day, before the machine is started; the oil should reach the
level indicated on the sightglass located or inside the machine on the crankcase or on the machine
front panel. The oil level must be checked with the machine stopped for at least 1 hour.
See for reference figure 4.9.2.
Fig. 4.9.2
The start of the machine is causing the oil to flow into and fill the lubricating circuit, then it is normal
to observe a lowering of the oil level on the sightglass during the operation of the machine.
If oil drops below the required level top it up through the orange filler located inside the machine on
the body cover.
To reach the fill you need to remove the side panel of the machine.
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4C091E12C
4.9.4
Use and maintenance instructions
PRESSURE CHECK
The pressure gauge located on the front panel is used to measure the pressure in the lubricating
circuit.
During the final machine test optimal lubrication pressure is calibrated under steady operating
conditions; this value is largely affected by oil viscosity and temperature so when the machine is
started pressure is usually high and then tends to decrease and become stable as the machine
warms up with operation.
If pressure drops too low at high temperatures this may be due to problems with the cooling system
of the water/oil exchanger (where used) connected with scaling or very high water temperature.
The water temperature must conform with the values given in Section 1 –TECHNICAL
SPECIFICATIONS.
The pressure in the lubrication circuit can be adjusted via the by-pass valve (F) in the lubrication unit
body (C) (figure 4.9.3):
A
C
F
A - tank
B - intake filter
F - bypass valve
Fig. 4.9.3
•
•
•
•
DO NOT REMOVE THE VALVE FROM THE BODY
Loosen the lock nut and turn the Allen screw (Allen spanner) to reach the correct pressure value
Turn the screw CLOCKWISE to increase pressure and COUNTERCLOCKWISE to reduce it
Tighten the lock nut.
Adjustments must be made at high temperatures, with a value of approximately 5÷6 bar.
ATTENTION:
If the pressure level is too high the circuit may be damaged, particularly during cold starts: oil
viscosity problems can lead to damage in the delivery oil filter and motor overload triggering
the electric protection devices. When adjusting pressure you need to take into account
ambient conditions and the temperature of cooling water.
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4C091E12C
4.9.5
Use and maintenance instructions
OIL CHANGE
The frequency of oil change intervals is given in the “Tables for Regular Servicing” at Chapter 4.2.
Only use oil of the type indicated in TT-0038, attached to section 1 of this manual.
To change the oil (see figure 4.9.1):
• prepare a collection tray of sufficient capacity to contain the quantity of oil contained in the
machine according to TT-0038, attached to section 1 of this manual
• open the filling tap on the crankase cover
• open the drain valve and the plug (J) and let the oil drain out.
• once the oil has drained out completely, close the tap and the plug (J), and pour in the new oil
through the filler plug
• check the oil level through the sightglass.
ATTENTION:
Used oils are extremely harmful to environment and should be disposed of correctly, in
accordance with the local regulations.
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4C091E12C
4.9.6
Use and maintenance instructions
VAPOUR CONDENSATE DISCHARGE
Inside the crankase it is possible to have condensation of vapours depending on the characteristics
of the ambient where the machine is working in, therefore it is necessary to remove regularly the
condensate to avoid any mixing with lubricating oil.
The frequency of the discharge depends on the amount of condensate formed in the drive unit
(which depends on the working temperature, relative humidity, frequency of starting and stopping the
system); however, refer to the “Tables for Regular Servicing”, chapter 4.2.
The condensate drain can be done when the machine is stopped for at least 4 hours.
To drain the condensate:
• Prepare a basin for collection and open the drain valve at the bottom of the lubricating unit
• Water is heavier than oil, therefore it is collected at the bottom of the oil tank; once the oil starts
to pour out, close again the drain valve
• Check the oil level again and, if necessary, top it up through the filler plug
Presence of water into the oil may be caused by cooling water entering trough the crosshead seals;
it is recommended to check the surface of crosshead extensions for scratches, and to replace
the crosshead seals in case of oil leakage or oil into the water, according to what is mentioned in
paragraph 4.8.1.
OIL FILTERS CHANGE
Oil filters change is extremely important to guarantee proper and reliable operation of the lubricating
system.
It is therefore necessary to replace or cleand the oil filters each change of oil as recommended on
the periodical maintenance indications.
The delivery side filter is of “spin-on” disposable cartridge type; the suction side filter is of metallic
mesh and is placet inside the tank (figure 4.9.1, item B).
If the intake filter is of the type “with disposable cartridge”, it should be replaced as often as indicated
in the “Table for Regular Servicing”, paragraph 4.2.
The filter is equipped with an internal by-pass valve: this opens when the pressure drop due to
clogging exceeds a preset level, bypassing the filtering element.
To replace the filter cartridge it is necessary to empty the complete lubricating circuit:
• Remove the spin-on filter cartridge with suitable too (not supplied)
• Install the new filter cartridge after having lubricated with oil the gasket
The intake filter housed inside the oil tank does not have a built-in by-pass. If the filter clogs up the
pressare drop through the filter will increase leading to cavitation of the gear pump and pressure
switch action. Cleaning frequency is given in the “Table of Periodical Maintenance”, Chapter 4.2.
To clean the metal mesh intake filter (figure 4.9.1, item B):
• remove the oil tank as previously explained
• disconnect the tank (A) from the body (C) by loosening the retaining screws and removing the
filter (B) from the tank
• unscrew the filter (B) off the end of the suction pipe
• put it in a container with petrol or solvent for about 30 minutes;
• clean it with compressed air blown opposite to the filtering direction (i.e. from the inside towards
the outside).
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4C091E12C
4.9.7
Use and maintenance instructions
ATTENTION:
Carry out the operations with utmost caution, wearing suitable protection for the body and
the eyes against any petrol splashes; wear a filtering mask and do not inhale the vapour; if
there is any contact with the eyes, wash abundantly with water and consult a doctor.
OIL COOLER MAINTENANCE
The machine is equipped with a water / oil cooler which is not requiring usually any maintenance.
In case of use of hard water, it is possible to have problems with clogging of the cooler because of
calcium carbonates deposits, which is reducing the heat transfer efficiency.
It is therefore necessary to replace the oil cooler if it is not able to reduce anymore the oil temperature
(usually the temperature difference between oil inlet and outlet is in the range of 5 to 10 °C); in case
the oil cooler is made of stainless steel (optional) it is possible to clean it with suitable cleaning
solution to scale the tubing
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4C091E12C
4.9.8
Use and maintenance instructions
4.10. Pneumatic plant
Machines provided with pneumatic control system of the homogenizing pressure are supplied with
specific hydraulic dampening system of the homogenizing valve.
The force required to close the homogenizing valve and consequently achieve the homogenizing
pressure is applied through a pneumatic actuator using compressed air on its upper part; the lower
part of the actuator is connected with the pressurized oil dampening system.
The dampening system is not installed on the machine when the pneumatic valve installed is type
NanoValve®.
The pneumatic actuator does not require any periodical maintenance but it is recommended to
protect it from extreme temperatures (which may damage the gaskets) and corrosive fluids, as its
body is made with Aluminium alloys and not in stainless steel.
In case the pneumatic actuator is not working properly we recommed its replacement; it’s anyway
available upon request to GEA Mechanical Equipment Italia S.p.A. Spare Parts Dept. the complete
gaskets spare kit.
The pneumatic plant can be configured in various versions, according to the options installed;
on figure 4.10.1 it is shown a basic version for single stage homogenizer with manual pneumatic
adjustment of the homogenizing pressure installed on the machine front panel.
The scheme of the plant actually installed on the machine is given in Section 5 – SPARE PARTS
CATALOG with components list; you can also check the Flow-sheet (P&ID) given in Section 1 –
TECHNICAL SPECIFICATIONS.
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4C101E9C
4.10.1
Use and maintenance instructions
FIGURE 4.10.1
The components present on the circuit according to the scheme presented in figure 4.10.1 are:
• Inlet air pre-treatment unit (A) with pressure gauge (B);
• One pneumatic switch (C) (or as option a solenoid valve) to give pressure to the actuator (G);
• One manual pressure regulator (D) (or as option a proportional valve for remote controls;
• Throttle valves (E, H) to achieve a stable operation of the pneumatic system and to adjust the
speed of the raise of the homogenizing pressure by throttling the oil backflow;
• A pressure gauge (F) installed on the machine front panel, indicating the pressure effectively
supplied to the pneumatic actuator;
• A damper tank (K) for oil and pressurized air.
The effect of dampening of the vibrations induced on the homogenizing valve by the normal
reciprocating movement of the plungers is granted by a suitable air/oil damper vessel (K) which is
connected to the lower part of the pneumatic actuator of the homogenizing group.
This damper tank is preloaded with compressed air, pressure 0,5 bar.
The gauge (L) allows to check the pressure in the tank, and ina case of need it is possibile to use the
quick connection (M) to restore the correct pressure inside the tank.
If the pneumatic dampening system is checked on a regular basis for correct preload pressure
and oil level, it is possible to avoid problems of valve vibrations and resonance, which may cause
reduction of homogenizing efficiency and can be dangerous for the machine itself.
Ordinary maintenance operations are listed below:
• Check regularly the oil level inside the damper tank through the sightglass
• Check regularly into the damper tank the correct pressure value: must be 0,5 bar with machine
stopped
• In case refilling of oil is required, close the valve (J) and open slowly the upper filling plug (there
is pressure inside); once the pressure is gone, fill the necessary oil quantity. The specifications
of the suitable oil are listed on table 4.10.2
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4C101E9C
4.10.2
Use and maintenance instructions
WARNING
the damper tank containing oil is under pressure; open carefuly and slowly to allow air
pressure go down and avoid danger for personnel.
Close the upper plug and connect a compressed air source to the quick connection (M) to restore the
pressure of 0,5 bar inside the damper tank
Open the valve (J) and check if the air pressure is still at the set value of 0,5 bar.
Pressure inside the camper tank cannot be higher than 0,6 bar when the machine is
stopped.
Oil into this circuit does not require any change but only refilling in case the level is low.
If during the above mentioned procedures of filling up, or during the homogenizing valve maintenance
some air bubbles are present into the plastic pipes, it is possible to eliminate the same by application
and release of the pressure to the actuator through the pneumatic switch (C), with machine stopped
and with the manual pressure regulator set to allow some air to go through (not at zero).
The presence of air bubbles, anyway, cannot prevent the system to work properly, even if the
dampening effect may be sometimes reduced.
The adjustment of the throttle valve (E, H) allows to regulate the speed of the homogenizing pressare
raise.
Usually the setting of this valve is made during the machine test, in order to avoid a sudden raise of
the homogenizing pressure which may cause the opening of the overpressure relief valve.
Before making any modification to the setting, please tae note of the original setting on the scale in
order to recover the original setpoint in case of need.
As general information the closing of the valve (H) is slowing down the pressure raise, its opening is
making it faster.
WARNING
Used oils are extremely harmful to environment and should be disposed of correctly, in
accordance with the local regulations.
Only use oil of the type indicated in TT-0164, attached to section 1 of this manual.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
4C101E9C
4.10.3
Use and maintenance instructions
4.10.1 Pneumatic plant with local manual adjustment
The pneumatic plant for local and manual pressure adjustment allows to adjust the homogenizing
pressure from the machine front panel through a pneumatic regulator and pneumatic switch.
No maintenance is required on these components, and in case of evident malfunctioning replacement
of faulty parts is recommended.
4.10.2 Pneumatic plant with remote pressure adjustment
The pneumatic plant with remote pressure adjustment is using a proportional valve (or I/P converter)
to adjust the homogenizing pressure (figure 4.10.2.1). This proportional valve requires a suitable
ramp signal on a 4÷20 mA scale; the signal must be isolated and amplified, with electrical connection
to the proportional valve according to the following diagram shown in figure 4.10.2.2.
FIGURE 4.10.2.1
It is anyway always recommended to follow the indications in the specific wiring diagram supplied
in the manual, which is showing also the numbering of terminals on the terminal board for proper
connection.
In case of malfunctioning of the system, it is possible to follow the below listed indications:
• Wrong connection: make sure the wiring is made according to the supplied diagram
• Not enough air pressure supply (required minimum 7,5 bar air pressure)
• Moisture or oil into the supplied air, which is necessary to eliminate
• Not enough power in the signal coming from valve pilot source (especially if directly connected to
a PLC output): it is necessary to install a suitable signal amplifier.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
4C101E9C
4.10.4
Use and maintenance instructions
FIGURE 4.10.2.2
The proportional valve is tested and calibrated during the machine test run. The setting is related
to the range of pneumatic signal output related to the electrical signal input; in case of need it is
possible to modify the factory settings by following the procedure described below and also indicated
in the specific valve manual in Section 7 – SUPPLIERS CATALOGUE.
The proportional valve is installed inside the machine cabinet, on left hand side, and it is possible to
access to it by removing the left side panel of the machine.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
4C101E9C
4.10.5
Use and maintenance instructions
The proportional valve is normally in LOCKED state. By touching one of the control keys on the top
part of the valve (figure 4.10.2.1) the display will show “LOC” message.
Making reference to figure 4.10.2.3:
FIGURE 4.10.2.3
•
•
•
•
Unlock the valve pressing the UNLOCK button for at least 2 seconds, “LOC” will blink on display
Press the SET button to have F_1 indication shown on display, which corresponds to the output
air pressure equivalent to 4 mA input signal – USUALLY THIS VALUE MUST BE 0,00
Press the SET button to have F_2 indication shown on display, which corresponds to the output
air pressure equivalent to 20 mA input signal
Using arrow UP and DOWN buttons, modify the air pressure value (example 4,50) in bar units
which is required to drive the homogenizing valve, equivalent to the max input signal (20 mA)
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
4C101E9C
4.10.6
Use and maintenance instructions
ATTENTION
Before changing the factory setting of the valve, take note of the actual setting for future
reference. The set value must be approx 0,5 bar higher than required air pressure used to
achieve the required homogenizing pressure. Such value can be checked during machine
running on the air pressure gauge installed on the front panel of the machine.
•
To lock the valve settings (the valve is locked automatically the first time the voltage supply is
switched OFF and ON), press the LOCK button for at least 2 seconds; in this way the indication
“UNL” is blinking on the display, and it is possibile to lock the valve by pressing the SET button
Usually it is not required to have any maintenance on these components, and in case of faulty
operation their replacement is recommended
ATTENTION
Maximum service pressure for pneumatic plant and pneumatic actuators is 1 MPa (10 bar).
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
4C101E9C
4.10.7
Use and maintenance instructions
4.11. Aseptic Plant
Machines in aseptic version are equipped with a circuit for the distribution of sterile condensate used
to flush the plunger aseptic chambers and the steam of the homogenizing valve in order to prevent
external contamination.
The distribution circuit and its components do not usually require maintenance; if a heat exchanger
for the produciton of sterile condensate is included we recommend you periodically clean it to remove
scaling which forms due to hard cooling water.
Scaling reduces the efficiency of the exchanger and consequently reduces the quantity of water
required for steam condensation.
Cooling water should be softened to achieve a maximum hardness of 8 °dH / 15 °fH.
WARNING
The sterile system is crossed by live steam at 140 °C: avoid touching the piping and surfaces
before they have cooled down completely (approx. 30 minutes) to avoid burns; operate the
sterile plant only when wearing gloves and protective clothing.
CLEANING THE HEAT EXCHANGER
Cleaning operations are carried out when the exchanger is isolated from the rest of the system using
the supplied valves and circulating a descaling solution into the cooling water side of the exchanger,
at the concentration and temperature indicated by the suppliers (e.g. caustic soda NaOH solution at
3% and 80°C, or 2% nitric acid HNO3 at 50°C).
The heat exchanger and related tubing is made from stainless steel.
Use products that are suitable for use with stainless steel grade AISI 304 and never use substances
containing SALT (NaCl) and SULPHURIC ACID (H2SO4).
After each chemical cleaning, rinse the system with large amount of clean water.
WARNING
Avoid contact with descaling products, and follow the instructions supplied by manufacturers
concerning handling and what to do in case of accidents.
WARNING
Prepare the collection of water and cleaning products for disposal in compliance with
regulations currently in force.
The aseptic system is equipped with valves for adjusting the flow of condensate to the various
point of use (item N, figure 4.11.1); these valves are calibrated during the final machine test so we
recommend you do not change these settings.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
4C111E6C
4.11.1
Use and maintenance instructions
FIGURE 4.11.1
These valves (N) can be used to adjust the backpressure inside the exchanger (E), measured by the
pressure gauge (K); to ensure proper operation of the exchanger it should be set to 1÷2 bar.
Valves (C) are used to adjust the flow of cooling water so that the temperature of the condensate
flow is approximately 40÷60 °C.
ASEPTIC CHAMBERS
The aseptic chambers of the plungers only require replacement of the gaskets.
To avoid contamination, make sure you accurately clean and sterilize the aseptic chambers whenever
there are product leaks from the packings.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
4C111E6C
4.11.2
Use and maintenance instructions
With reference to figure 4.11.2, the parts that need to be replaced are gaskets (P) and (S) and any
guide rings (T, U).
To remove the gaskets you need to disassemble the plungers and remove any sealing elastic rings
not shown in the drawing; refer to the exploded view in SECTION 5 – SPARE PARTS CATALOGUE.
FIGURE 4.11.2
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
4C111E6C
4.11.3
Use and maintenance instructions
SECTION 5
Spare Parts Catalogue - Index
5.1. How to use the spare parts catalogue
5.2. How to order spare parts
5.3. Recommended spare parts
5.4. Maintenance box
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
5C001E6C
5.1
Use and maintenance instructions
5.1. How to use the spare parts catalogue
To ensure that effective operation and quality characteristics are maintained only original spare parts
must be used on GEA Mechanical Equipment Italia S.p.A. machines.
The use of non original spare parts shall instantly invalidate the guarantee.
This catalogue has information on how to order spare parts, selecting the parts in the attached tables
and their code number in the relative tables.
5.2. How to order spare parts
Spare parts can be ordered directly from GEA Mechanical Equipment Italia S.p.A., Service
Department, or through your local GEA Mechanical Equipment Italia S.p.A. agent or Authorized
Dealer, who can provide useful advice and forward your request immediately.
When placing an order please specify:
• SERIAL NUMBER of the machine
• spare part code number
• if necessary, a brief description of the component for easier identification
• if applicable, the item number on the assembly drawing in the SPARE PARTS CATALOGUE
• the means of transport or dispatch requested; if this is not specified
GEA Mechanical Equipment Italia S.p.A. will arrange suitable transport at their discretion
• whether urgent, as this may affect cost
• exact address and name of contact person
To order spare parts or request quotations for spare parts, copy the standard form below and send
it by fax.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
5C001E6C
5.2
Use and maintenance instructions
GEA Mechanical Equipment Italia S.p.A.
ORIGINAL SPARE PARTS INQUIRY FORM
To:
Fax No.
From:
Name:
Reply Fax No.
e-mail:
Model:
Serial No.
¨ URGENT
¨ QUOTATION
Part CODE
Qty
¨ ORDER No.
Description
Shipping Specs.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
5C001E6C
5.3
Use and maintenance instructions
5.3. Recommended spare parts
In order to limit the number of shutdowns during production, and the time required for maintenance of
the machine, we recommend you stock a set of spare parts to replace elements which are normally
subject to wear.
The number of spare parts to be stocked will depend on production needs and on how important it is
to avoid long shutdowns due to unavailable spare parts.
In specific, in case of homogenizing valves, the replacement at due time allows to keep the
homogenizing efficiency and consequently the quality of the processed product.
GEA Mechanical Equipment Italia S.p.A. cannot guarantee that a given spare part will be in stock
either at their central warehouse or at the Dealer’s due to problems with material availability or to
special requirements for dispatch.
Please note that shipment is no guarantee of successful delivery and that delays may occurr due
to customs problems or miscarriage.
In any case GEA Mechanical Equipment Italia S.p.A. shall not be responsible for delays occurring
due to the shipment of spare parts.
The following is a list of spare parts which, in our experience, is important to have in stock:
• a complete set of gaskets, two sets in case of VHP high-pressure compression blocks
• two sets of packings, including packing washers and anti-extrusion rings
• one or two plungers, if ceramic plungers are used
• a homogenizing valve set for each stage (for homogenizers)
• a set of balls and valve seats, for VHP high-pressure heads
• a set of seats and pumping valves, if the machine is used with abrasive products
• a set of pumping valve springs
• a pressure gauge for the compression block
• seat and ball for overpressure relief valve
• oil filters
• a set of guide plunger gaskets
• crankshaft oil guard
In addition to the ordinary maintenance operations described in Section 4 - MAINTENANCE, below
you will find a table with checklist for machine inspection that you can use to check which spare parts
are needed before performing ordinary maintenance on the machine.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
5C001E6C
5.4
Use and maintenance instructions
GEA Mechanical Equipment Italia S.p.A.
CHECKLIST FOR MACHINE INSPECTION
Machine Type :
Working Hours :
Serial Number :
Date :
Checked Replaced
Checked Replaced
1
Compression head
34 Transmission
2
Suction Valves
35 Main motor
3
Suction Springs
36 Auxiliary motors
4
Suction valve seats
37 Gear box
5
Delivery Valves
38 Gear box tightening kit
6
Delivery Springs
39 Gear box oil level
7
Delivery valve seats
40 Belts
8
Gaskets
41 Pulley
9
Plungers
42 Water plant
10 Plunger Packings
43 Water filter
11 Overpressure cleaning/seat
44 Water solenoid valve
12 Homogenizing group
45 Water drain check
13 Passage head 1°st
46
14 Impact ring 1°st
47 Lubrication plant
15 Impact head 1°st
48 Lubrication unit
16 Gaskets 1°st
49 Pump driven by crankshaft
17 Passage head 2°st
50 Heat exchanger (oil/water)
18 Impact ring 2°st
51 Suction oil filter
19 Impact head 2°st
52 Delivery oil filter
20 Gaskets 2°st
53 Condensate discharge
21
54 Gaskets
22
55 Oil level
23
56 Oil piping check
57 Pneumatic plant
24 Transmission body
58 Dampening system check
25 Crankshaft
59 Air filter/Pressure regulator
26 Conrods
60 Accessories
27 Guide pistons
61 Tightening of the nuts
28 Conrod bronze bearings
62 Tightening of plungers
29 Main bronze bearings
63 Pressure gauges
30 Pins
64 Aseptic plant
31 Bearings
65 Steam heat exchanger
32 Gaskets
66 Steam valve
33 Oil splash guards
67 Aseptic chambers gaskets
Notes:
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
5C001E6C
5.5
Use and maintenance instructions
5.4. Maintenance box
The machine is supplied complete with a set of spanners and tools to be used during ordinary
maintenance; they include special tools for installing or removing plungers and packings, where
required.
The set of spanners DOES NOT INCLUDE a Torque Wrench, which is recommended for correct
tightening of nuts and studs to the torque values given in Section 4 - MAINTENANCE.
The maintenance box includes a basic set of spare gaskets.
Please find attached a list of the tools supplied for ordinary maintenance.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
5C001E6C
5.6
Maintenance box
Maintenance box - Mitgeliefertes werkzeug - Herramientas suministradas en la caja de mantenimiento - Liste des outils et des pièces de rechange livrées avec la trousse
d’entretien
Item
-
Part Code
Qty
9538-1213-000
9538-1217-000
9538-1219-000
9538-1224-000
9538-1230-000
9538-1236-000
9538-1241-000
9538-1308-000
9538-1003-000
9538-1612-000
9538-1612-000
9538-1312-000
9538-1314-000
9538-1317-000
9538-1319-000
9538-1445-000
9512-0628-000
9533-5015-000
9512-7452-000
9538-1558-000
9510-4613-000
9536-9112-060
9512-4934-000
9537-0112-040
9538-1419-000
9538-8003-000
9533-5229-000
9531-4085-591
9531-4098-591
9534-1792-659
9513-2558-000
9514-0608-030
9531-4069-591
9531-4213-591
9531-4226-591
9531-4087-591
9531-4049-591
9531-4024-591
9531-4189-591
9531-4191-591
9531-3027-591
9531-4017-591
9531-4011-591
9531-4188-595
9531-3031-591
9531-4071-591
9531-4571-405
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
3
6
3
6
4
4
2
2
2
2
2
2
2
2
1
2
1
2
3
2
5C041E3_15439
Unit Descrizione
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
Description
Beschreibung
Descripción
Description
CHIAVE
WRENCH
GABELSCHLUSSEL
LLAVE
CLEF
CHIAVE
WRENCH
GABELSCHLUSSEL
LLAVE
CLEF
CHIAVE
WRENCH
GABELSCHLUSSEL
LLAVE
CLEF
CHIAVE
WRENCH
GABELSCHLUSSEL
LLAVE
CLEF
CHIAVE
WRENCH
GABELSCHLUSSEL
LLAVE
CLEF
CHIAVE
WRENCH
GABELSCHLUSSEL
LLAVE
CLEF
CHIAVE
WRENCH
GABELSCHLUSSEL
LLAVE
CLEF
CHIAVE
WRENCH
GABELSCHLUSSEL
LLAVE
CLEF
PINZA CURVA
PINCERS
ZANGE
PINZAS
PINCE
LEVA GOMME
PRY BAR
HEBEL
PRY BAR
BARRE D'EXTRACTION
LEVA GOMME
PRY BAR
HEBEL
PRY BAR
BARRE D'EXTRACTION
CHIAVE
WRENCH
GABELSCHLUSSEL
LLAVE
CLEF
CHIAVE
WRENCH
GABELSCHLUSSEL
LLAVE
CLEF
CHIAVE
WRENCH
GABELSCHLUSSEL
LLAVE
CLEF
CHIAVE
WRENCH
GABELSCHLUSSEL
LLAVE
CLEF
CHIAVE
WRENCH
GABELSCHLUESSEL
LLAVE
CLEF
MANICO
HANDLEGRIP
GRIFF
MANGO
MANCHE
VENTOSA
SUCTION CUP
SAUGKOPF
VENTOSA
VENTOUSE
ESTRATTORE PISTONE
PLUNGER EXTRACTOR
KOLBENAUSZIHER
EXTRACTOR PARA PISTON
EXTRACTEUR DE PISTON
ESPANSORE
EXPANDER
EXPANDER
EXPANSOR
EXPANSEUR
MANICO
HANDLEGRIP
GRIFF
MANGO
MANCHE
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
INTRODUTTORE PACCHETTO
PACKING INTRODUCER
PACKUNGINFUHRE
ÚTIL EMPLAZAMIENTO EMPAQUETADURAS
INTRODUCTEUR DE GARNITURE
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
CHIAVE
WRENCH
GABELSCHLUESSEL
LLAVE
CLEF
ATTREZZO
TOOL
WERKZEUG
HERRAMIENTA
OUTILLAGE
CHIAVE UNIFAST
UNIFAST KEY
UNIFAST KEIL
LLAVE UNIFAST
CLEF UNIFAST
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
PACCHETTO
PACKING
PACKUNG
EMPAQUETADURA
GARNITURE DE PISTON
RONDELLA
WASHER
UNTERLEGSCHEIBE
ARENDELA
RONDELLE
RONDELLA
WASHER
UNTERLEGSCHEIBE
ARENDELA
RONDELLE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
GUARNIZIONE
GASKET
DICHTUNG
JUNTA
JOINT
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
GUARNIZIONE
GASKET
DICHTUNG
JUNTA
JOINT
1/2
GEA Mechanical Equipment / GEA Niro Soavi
Maintenance box
Maintenance box - Mitgeliefertes werkzeug - Herramientas suministradas en la caja de mantenimiento - Liste des outils et des pièces de rechange livrées avec la trousse
d’entretien
Item
-
Part Code
9531-4026-591
9531-4041-591
9512-9226-010
9535-5651-591
9531-4069-591
5C041E3_15439
Qty
1
1
6
3
4
Unit Descrizione
PC
PC
PC
PC
PC
O-RING
O-RING
MOLLA
GUARNIZIONE
O-RING
Description
Beschreibung
Descripción
Description
O-RING
O-RING
SPRING
GASKET
O-RING
O-RING
O-RING
FEDER
DICHTUNG
O-RING
JUNTA TÓRICA
JUNTA TÓRICA
MUELLE
JUNTA
JUNTA TÓRICA
JOINT TORIQUE
JOINT TORIQUE
RESSORT
JOINT
JOINT TORIQUE
2/2
GEA Mechanical Equipment / GEA Niro Soavi
Use and maintenance instructions
5.5. Spare parts list and assembly drawings
You will find attached assembly drawings and a list of components and spare parts.
The first code of each spare parts list indicates the assembly drawing which the components refer
to.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
5C050E4C
5.1
Spare parts list
Compression head - Kompressionkopf - Cabezal de compresión - Tete de compression
Item
0010
0020
0030
0040
0050
0060
0070
0080
0090
0100
0110
0140
0150
0160
0170
0180
0190
0200
0210
0220
0230
0240
0250
Part Code
Qty
9512-9113-270
9513-3938-000
9591-2001-315
9591-2001-345
9511-8069-000
9537-6011-000
9531-4085-591
9512-9216-000
9512-9215-000
9511-8069-000
9537-6011-000
9512-5540-000
9537-6013-000
9512-2408-000
9537-6014-000
9512-9214-000
9531-4098-591
9512-9222-120
9534-1792-659
9513-2558-000
9513-5284-000
9591-3116-541
9591-7116-512
1
1
3
3
4
4
3
1
2
8
8
4
4
12
12
3
3
3
3
6
3
3
3
GEA Mechanical Equipment Italia S.p.A
Unit Descrizione
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
ASSIEME
Description
Beschreibung
Descripción
Description
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
TESTATA
COMPRESSION HEAD
ZYLINDERBLOCK
CABEZAL DE COMPRESIÓN
BLOC DE COMPRESSION
ASSIEME
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
ASSIEME
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
PRIGIONIERO
STUD
STIFTSCHRAUBE
PRISIONERO
GOUJON
DADO
NUT
MUTTER
TUERCA
ECROU
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
FLANGIA
FLANGE
FLANSCH
BRIDA
BRIDE
FLANGIA
FLANGE
FLANSCH
BRIDA
BRIDE
PRIGIONIERO
STUD
STIFTSCHRAUBE
PRISIONERO
GOUJON
DADO
NUT
MUTTER
TUERCA
ECROU
PRIGIONIERO
STUD
STIFTSCHRAUBE
PRISIONERO
GOUJON
DADO
NUT
MUTTER
TUERCA
ECROU
PRIGIONIERO
STUD
STIFTSCHRAUBE
PRISIONERO
GOUJON
DADO
NUT
MUTTER
TUERCA
ECROU
FLANGIA
FLANGE
FLANSCH
BRIDA
BRIDE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
DISTANZIERE
SPACER
DISTANZSTUECK
DISTANCIADOR
ENTRETOISE
PACCHETTO
PACKING
PACKUNG
EMPAQUETADURA
GARNITURE DE PISTON
RONDELLA
WASHER
UNTERLEGSCHEIBE
ARENDELA
RONDELLE
RONDELLA
WASHER
UNTERLEGSCHEIBE
ARENDELA
RONDELLE
ASSIEME
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
ASSIEME
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
1 / 18
COMPRESSION HEAD
5C051E3_15439
Spare parts list
Suction valve group - Saugventil Baugruppe - Grupo válvula aspiración - Ensemble clapets d'aspiration
Item Part Code
Qty
0010
0020
0030
0040
0050
3
3
3
3
3
9512-9112-000
9511-8640-000
9512-9280-000
9512-9226-010
9512-9218-010
GEA Mechanical Equipment Italia S.p.A
Unit Descrizione
PC
PC
PC
PC
PC
Description
Beschreibung
Descripción
Description
ASSIEME
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
SEDE VALVOLA
VALVE SEAT
VENTILSITZ
ASIENTO VALVULA
SIEGE DE SOUPAPE
VALVOLA
VALVE
VENTIL
VALVULA
SOUPAPE - VANNE
MOLLA
SPRING
FEDER
MUELLE
RESSORT
COPERCHIO VALVOLA
VALVE COVER
VENTILKAPPE
TAPA PARA VALVULA
CAPUCHON DE SOUPAPE
2 / 18
SUCTION VALVE GR.
5C051E3_15439
Spare parts list
Delivery valve group - Druckventil Baugruppe - Grupo válvula salida - Ensemble clapets de refoulement
Item Part Code
Qty
0010
0020
0030
0040
0050
3
3
3
3
3
9512-9112-000
9511-8640-000
9512-9280-000
9512-9226-010
9512-9218-010
GEA Mechanical Equipment Italia S.p.A
Unit Descrizione
PC
PC
PC
PC
PC
Description
Beschreibung
Descripción
Description
ASSIEME
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
SEDE VALVOLA
VALVE SEAT
VENTILSITZ
ASIENTO VALVULA
SIEGE DE SOUPAPE
VALVOLA
VALVE
VENTIL
VALVULA
SOUPAPE - VANNE
MOLLA
SPRING
FEDER
MUELLE
RESSORT
COPERCHIO VALVOLA
VALVE COVER
VENTILKAPPE
TAPA PARA VALVULA
CAPUCHON DE SOUPAPE
3 / 18
DELIVERY VALVE GR.
5C051E3_15439
Spare parts list
Plunger group - Kolbengruppe - Grupo piston - Ensemble piston pompant
Item Part Code
Qty
0010
0020
0030
0040
0050
3
3
3
3
6
9512-8496-000
9513-7371-290
9512-9182-000
9513-0019-000
9536-9108-025
GEA Mechanical Equipment Italia S.p.A
Unit Descrizione
PC
PC
PC
PC
PC
Description
Beschreibung
Descripción
Description
ASSIEME
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
PISTONE
PLUNGER
KOLBEN
PISTON
PISTON
MORSETTO
CLAMP
KLEMME
ABRAZADERA
MORS
PROLUNGA
EXTENSION
VERLAENGERUNG
PROLONGADOR
PROLONGATEUR
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
4 / 18
PLUNGER GR.
5C051E3_15439
Spare parts list
Aseptic chamber - Aseptikkammer - Cámara Aséptica - Chambre aseptique
Item Part Code
Qty
0010
0020
0040
0060
0070
0080
3
3
3
3
12
6
9512-0204-140
9513-4217-090
9535-5651-591
9531-4098-591
9536-9110-030
9539-9015-000
GEA Mechanical Equipment Italia S.p.A
Unit Descrizione
PC
PC
PC
PC
PC
PC
Description
Beschreibung
Descripción
Description
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
CAMERA ASETTICA
ASEPTIC CHAMBER
ASEPTIKKAMMER
CÁMARA ASÉPTICA
CHAMBRE ASEPTIQUE
GUARNIZIONE
GASKET
DICHTUNG
JUNTA
JOINT
ASSIEME
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
SPINA
PIN
STIFT
CLAVIJA
CHEVILLE
5 / 18
ASEPTIC CHAMBER
5C051E3_15439
Spare parts list
Pressure gauge - Manometer - Gr. Manómetro - Ensemble manometre
Item Part Code
Qty
0010
0020
0030
0040
0050
0060
0070
0080
0090
1
1
1
1
1
1
2
2
0
9512-4219-000
9533-1010-000
9510-0036-000
9512-3102-000
9531-3031-591
9531-3027-591
9511-7400-000
9537-6006-000
9519-9999-999
GEA Mechanical Equipment Italia S.p.A
Unit Descrizione
PC
PC
PC
PC
PC
PC
PC
PC
PC
ASSIEME
Description
Beschreibung
Descripción
Description
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
MANOMETRO
PRESSURE GAUGE
MANOMETER
MANOMETRO
MANOMÈTRE
RONDELLA
WASHER
UNTERLEGSCHEIBE
ARENDELA
RONDELLE
FLANGIA
FLANGE
FLANSCH
BRIDA
BRIDE
GUARNIZIONE
GASKET
DICHTUNG
JUNTA
JOINT
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
PRIGIONIERO
STUD
STIFTSCHRAUBE
PRISIONERO
GOUJON
DADO
NUT
MUTTER
TUERCA
ECROU
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
6 / 18
PRESSURE GAUGE
5C051E3_15439
Spare parts list
Manifold group - Einlassrohr - Gr. Colector - Collecteur
Item Part Code
Qty
0010
0020
0030
0040
0050
0060
0070
0080
0090
0100
0110
0120
1
1
3
1
1
1
12
0
0
0
0
0
9513-4197-030
9513-0313-000
9531-4071-591
9532-7154-000
9531-4571-405
9533-5130-000
9536-9112-035
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
GEA Mechanical Equipment Italia S.p.A
Unit Descrizione
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
Description
Beschreibung
Descripción
Description
ASSIEME
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
COLLETTORE
MANIFOLD
EINLASSROHR
COLECTOR
COLLECTEUR
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
TRONCHETTO
FERRULE
ANSCHLUSS-STUTZEN
TENAZAS
INTERRUPTEUR
GUARNIZIONE
GASKET
DICHTUNG
JUNTA
JOINT
MORSETTO
CLAMP
KLEMME
ABRAZADERA
MORS
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
7 / 18
MANIFOLD GR.
5C051E3_15439
Spare parts list
Outlet flange group - Auslassflansch baugruppe - Gr. Brida de salida - Bride de refoulement
Item Part Code
Qty
0010 9513-4204-110
0020 9513-7233-000
0030 9531-4026-591
0040 9532-7154-000
0050 9531-4571-405
0060 9533-5130-000
0070 9536-9116-035
0080 9513-3271-000
0090 9531-4041-591
0100 9536-9220-040
0110 9519-9999-999
0120 9519-9999-999
1
1
1
1
1
1
2
1
1
4
0
0
GEA Mechanical Equipment Italia S.p.A
Unit Descrizione
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
ASSIEME
Description
Beschreibung
Descripción
Description
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
BRIDE
FLANGIA
FLANGE
FLANSCH
BRIDA
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
TRONCHETTO
FERRULE
ANSCHLUSS-STUTZEN
TENAZAS
INTERRUPTEUR
GUARNIZIONE
GASKET
DICHTUNG
JUNTA
JOINT
MORSETTO
CLAMP
KLEMME
ABRAZADERA
MORS
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
DISTANZIERE
SPACER
DISTANZSTUECK
DISTANCIADOR
ENTRETOISE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
8 / 18
OUTLET FLANGE GR.
5C051E3_15439
Spare parts list
Relief valve - Druckbegrenzungsventil - Gr. Válvula de seguridad - Vanne de securite
Item Part Code
Qty
0010 9512-4720-000
0020 9531-3027-591
0030 9512-3695-000
0040 9531-9044-010
0050 9531-4017-591
0060 9510-0036-000
0070 9512-6123-030
0080 9512-3102-000
0090 9514-1952-000
0100 9537-6006-000
0110 9511-7400-000
0120 9519-9999-999
0130 9536-9106-015
0140 9531-4011-591
0150 9512-4713-000
0160 9512-4714-000
0170 9512-4712-000
0180 9512-4716-000
0190 9512-4943-000
0200 9531-4188-595
0210 9512-6615-000
0220 9512-4711-000
0240 9512-4943-000
0250 9533-5043-000
0260 9531-3031-591
0270 9519-9999-999
0280 9519-9999-999
0290 9519-9999-999
1
1
1
1
1
1
1
1
1
2
2
0
6
2
1
1
1
1
1
1
1
1
1
1
1
0
0
0
GEA Mechanical Equipment Italia S.p.A
Unit Descrizione
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
ASSIEME
Description
Beschreibung
Descripción
Description
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
SEDE VALVOLA
VALVE SEAT
VENTILSITZ
ASIENTO VALVULA
SIEGE DE SOUPAPE
SFERA
BALL
KUGEL
BOLA
SPHERE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
RONDELLA
WASHER
UNTERLEGSCHEIBE
ARENDELA
RONDELLE
ALBERINO
PUSHROD
WELLE
EJE
ARBRE
FLANGIA
FLANGE
FLANSCH
BRIDA
BRIDE
CORPO
BODY
GEHAEUSE
CUERPO
CORPS
DADO
NUT
MUTTER
TUERCA
ECROU
PRIGIONIERO
STUD
STIFTSCHRAUBE
PRISIONERO
GOUJON
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
RONDELLA
WASHER
UNTERLEGSCHEIBE
ARENDELA
RONDELLE
BRONZINA
BRONZE BUSHING
BRONZELAGER
COJINETE DE BRONCE
COUSSINET EN BRONZE
CONTENITORE MOLLA
SPRING HOUSING
FEDERGEHAEUSE
ALOJAMIENTO MUELLE
CONTENEUR RESSORT
MOLLA
SPRING
FEDER
MUELLE
RESSORT
DADO
NUT
MUTTER
TUERCA
ECROU
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
COPERCHIO VALVOLA
VALVE COVER
VENTILKAPPE
TAPA PARA VALVULA
CAPUCHON DE SOUPAPE
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
DADO
NUT
MUTTER
TUERCA
ECROU
PIOMBO
SEAL
PIOMBO
PLOMO
PLOMB
GUARNIZIONE
GASKET
DICHTUNG
JUNTA
JOINT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
9 / 18
RELIEF VALVE
5C051E3_15439
Spare parts list
1st Stage homogenizing group - Homogenisierventil baugruppe 1s - GR. Homogeneización 1 etapa - Gr. Homogeneisant 1er etage
Item Part Code
Qty
0010 9513-7123-150
0020 9513-7484-000
0030 9513-7448-000
0040 9513-7282-000
0050 9514-0507-200
0060 9514-1286-000
0070 9514-1288-000
0080 9514-1287-000
0090 9513-7286-090
0100 9514-1291-000
0110 9512-9972-000
0120 9537-6006-000
0130 9512-9965-130
0140 9512-9968-130
0150 9512-9967-130
0160 9513-8567-000
0170 9536-9116-110
0180 9536-9216-100
0190 9536-9108-020
0200 9532-7221-000
0210 9532-6751-000
0220 9514-0608-030
0230 9531-4069-591
0240 9531-4069-591
0250 9514-0608-030
0260 9531-4213-591
0270 9531-4226-591
0280 9531-4087-591
0290 9531-4049-591
0300 9531-4024-591
0310 9531-4189-591
0320 9531-4191-591
0330 9533-9068-000
0340 9539-9015-000
0350 9537-4720-070
0360 9531-4069-591
0370 9531-4069-591
0380 9533-5240-000
0390 9536-9206-025
0400 9532-6488-000
0410 9532-6721-000
0420 9531-7054-000
0430 9532-6762-000
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
16
2
1
1
1
4
4
2
2
2
4
GEA Mechanical Equipment Italia S.p.A
Unit Descrizione
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
Description
Beschreibung
Descripción
Description
ASSIEME
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
CAMERA OMOGENEIZZANTE
HOMOGENIZING CHAMBER
HOMOGENISIERKAMMER
CÁMARA DE HOMOGENEIZACIÓN
CHAMBRE HOMOGÉNÉISANTE
CAMERA OMOGENEIZZANTE
HOMOGENIZING CHAMBER
HOMOGENISIERKAMMER
CÁMARA DE HOMOGENEIZACIÓN
CHAMBRE HOMOGÉNÉISANTE
FLANGIA
FLANGE
FLANSCH
BRIDA
BRIDE
PISTONE
PLUNGER
KOLBEN
PISTON
PISTON
PISTONE
PLUNGER
KOLBEN
PISTON
PISTON
PISTONE
PLUNGER
KOLBEN
PISTON
PISTON
PISTONE
PLUNGER
KOLBEN
PISTON
PISTON
GUIDA
GUIDE
FUEHRUNG
GUIA
GUIDE
PROLUNGA
EXTENSION
VERLAENGERUNG
PROLONGADOR
PROLONGATEUR
PRIGIONIERO
STUD
STIFTSCHRAUBE
PRISIONERO
GOUJON
DADO
NUT
MUTTER
TUERCA
ECROU
TESTINA D'URTO
IMPACT HEAD
PRALLKOPF
CABEZA DE CHOQUE
TÊTE DE CHOC
TESTINA DI PASSAGGIO
PASSAGE HEAD
PRALLPLATTE
CABEZA DE PASO
TÊTE DE PASSAGE
ANELLO D'URTO
IMPACT RING
PRALLRING
ANILLO DE CHOQUE
ANNEAU DE CHOC
CILINDRO PNEUMATICO
PNEUMATIC ACTUATOR
PNEUMATIKZYLINDER
CILINDRO NEUMATICO
CYLINDRE PNEUMATIQUE
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
RIDUZIONE
REDUCTION
REDUZIERUNG
REDUCION
RÉDUCTION
SILENZIATORE
ACTUATOR
SCHALLDAMPER
SILENCIADOR
SILENCIEUX
RONDELLA
WASHER
UNTERLEGSCHEIBE
ARENDELA
RONDELLE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
RONDELLA
WASHER
UNTERLEGSCHEIBE
ARENDELA
RONDELLE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
MOLLA
SPRING
FEDER
MUELLE
RESSORT
SPINA
PIN
STIFT
CLAVIJA
CHEVILLE
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
TAPPO
O-RING
STOPFEN
TAPON
BOUCHON
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
TAPPO
PLUG
STOPFEN
TAPON
BOUCHON
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
RACCORDO
CONNECTION
ANSCHLUSS
RACOR
RACCORD
RACCORDO
CONNECTION
ANSCHLUSS
RACOR
RACCORD
MANIGLIA
HANDLE
GRIFF
MANGO
POIGNEE
TAPPO
PLUG
STOPFEN
TAPON
BOUCHON
10 / 18
1ST STAGE HOMOGENIZING GR.
5C051E3_15439
Spare parts list
2nd Stage homogenizing group - Homogenisierventil baugruppe 2s - GR. Homogeneización 2 etapa - Gr. Homogeneisant 2eme etage
Item Part Code
Qty
0010 9513-7123-150
0020 9513-7484-000
0030 9513-7448-000
0040 9513-7282-000
0050 9514-0507-200
0060 9514-1286-000
0070 9514-1288-000
0080 9514-1287-000
0090 9513-7286-090
0100 9514-1293-000
0110 9512-9972-000
0120 9537-6006-000
0130 9512-9965-130
0140 9512-9968-130
0150 9512-9967-130
0160 9533-5162-030
0170 9536-9210-065
0180 9536-9116-110
0190 9536-9108-020
0200 9532-7221-000
0210 9532-6751-000
0220 9514-0608-030
0230 9531-4069-591
0240 9531-4069-591
0250 9514-0608-030
0260 9531-4213-591
0270 9531-4226-591
0280 9531-4087-591
0290 9531-4049-591
0300 9531-4024-591
0310 9531-4189-591
0320 9531-4191-591
0330 9533-9068-000
0340 9539-9015-000
0350 9537-4720-070
0360 9531-4069-591
0370 9531-4069-591
0380 9531-1695-000
0390 9536-9206-025
0400 9532-6488-000
0410 9532-6721-000
0420 9531-7054-000
0430 9532-6762-000
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
4
4
4
1
1
1
1
1
1
1
1
1
1
1
1
1
16
2
1
1
1
4
4
2
2
2
4
GEA Mechanical Equipment Italia S.p.A
Unit Descrizione
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
Description
Beschreibung
Descripción
Description
ASSIEME
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
CAMERA OMOGENEIZZANTE
HOMOGENIZING CHAMBER
HOMOGENISIERKAMMER
CÁMARA DE HOMOGENEIZACIÓN
CHAMBRE HOMOGÉNÉISANTE
CAMERA OMOGENEIZZANTE
HOMOGENIZING CHAMBER
HOMOGENISIERKAMMER
CÁMARA DE HOMOGENEIZACIÓN
CHAMBRE HOMOGÉNÉISANTE
FLANGIA
FLANGE
FLANSCH
BRIDA
BRIDE
PISTONE
PLUNGER
KOLBEN
PISTON
PISTON
PISTONE
PLUNGER
KOLBEN
PISTON
PISTON
PISTONE
PLUNGER
KOLBEN
PISTON
PISTON
PISTONE
PLUNGER
KOLBEN
PISTON
PISTON
GUIDA
GUIDE
FUEHRUNG
GUIA
GUIDE
PROLUNGA
EXTENSION
VERLAENGERUNG
PROLONGADOR
PROLONGATEUR
PRIGIONIERO
STUD
STIFTSCHRAUBE
PRISIONERO
GOUJON
DADO
NUT
MUTTER
TUERCA
ECROU
TESTINA D'URTO
IMPACT HEAD
PRALLKOPF
CABEZA DE CHOQUE
TÊTE DE CHOC
TESTINA DI PASSAGGIO
PASSAGE HEAD
PRALLPLATTE
CABEZA DE PASO
TÊTE DE PASSAGE
ANELLO D'URTO
IMPACT RING
PRALLRING
ANILLO DE CHOQUE
ANNEAU DE CHOC
CILINDRO PNEUMATICO
PNEUMATIC ACTUATOR
PNEUMATIKZYLINDER
CILINDRO NEUMATICO
CYLINDRE PNEUMATIQUE
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
RIDUZIONE
REDUCTION
REDUZIERUNG
REDUCION
RÉDUCTION
SILENZIATORE
ACTUATOR
SCHALLDAMPER
SILENCIADOR
SILENCIEUX
RONDELLA
WASHER
UNTERLEGSCHEIBE
ARENDELA
RONDELLE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
RONDELLA
WASHER
UNTERLEGSCHEIBE
ARENDELA
RONDELLE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
MOLLA
SPRING
FEDER
MUELLE
RESSORT
SPINA
PIN
STIFT
CLAVIJA
CHEVILLE
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
TAPPO
O-RING
STOPFEN
TAPON
BOUCHON
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
TAPPO
PLUG
STOPFEN
TAPON
BOUCHON
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
RACCORDO
CONNECTION
ANSCHLUSS
RACOR
RACCORD
RACCORDO
CONNECTION
ANSCHLUSS
RACOR
RACCORD
MANIGLIA
HANDLE
GRIFF
MANGO
POIGNEE
TAPPO
PLUG
STOPFEN
TAPON
BOUCHON
11 / 18
2ND STAGE HOMOGENIZING GR.
5C051E3_15439
Spare parts list
Transmission body - Antriebsgehause baugruppe - Gr. Cuerpo transmisión - Carter de transmission
Item Part Code
Qty
0010 9514-3046-000
0020 9513-1814-000
0030 9514-2874-000
0040 9532-2101-000
0050 9513-3647-000
0060 9537-0316-035
0070 9531-4145-533
0080 9514-2872-000
0090 9531-8356-585
0100 9511-3286-000
0110 9538-1894-000
0150 9511-6728-000
0160 9532-5015-000
0170 9510-3498-000
0180 9511-3847-090
0190 9511-3150-000
0200 9513-3959-000
0210 9531-6136-516
0220 9531-4146-533
0230 9536-9110-025
0240 9513-3775-000
0250 9539-9017-000
0260 9510-1114-030
0270 9536-3005-576
0280 9537-0112-025
0290 9511-2031-000
0300 9537-0410-016
0310 9537-0120-040
0360 9531-6135-516
0370 9537-0316-070
0380 9531-4227-533
1
1
1
2
1
8
2
1
1
2
1
3
3
6
3
3
3
3
3
12
3
2
1
3
14
1
8
4
3
8
1
-
9537-9063-000
9531-2921-000
9537-0320-070
9511-2388-000
9537-9100-150
9532-6001-000
9531-2175-000
9537-9100-050
9537-9100-190
9512-1076-000
9531-2179-000
GEA Mechanical Equipment Italia S.p.A
1
1
4
4
1
1
1
1
1
1
1
Unit Descrizione
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
ASSIEME
Description
Beschreibung
Descripción
Description
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
CORPS DE TRANSMISSION
CORPO DI TRASMISSIONE
TRANSMISSION BODY
ANTRIEBSGEHAEUSE
CUERPO DE TRANSMISIÓN
ALBERO A GOMITI
CRANKSHAFT
KURBELWELLE
CIGÜEÑAL
VILEBREQUIN
CUSCINETTO
BEARING
LAGER
COJINETE
ROULEMENT
SUPPORTO
SUPPORT
LAGER
SOPORTE
SUPPORT
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
FLANGIA
FLANGE
FLANSCH
BRIDA
BRIDE
GUARNIZIONE
GASKET
DICHTUNG
JUNTA
JOINT
BRONZINA
BRONZE BUSHING
BRONZELAGER
COJINETE DE BRONCE
COUSSINET EN BRONZE
LINGUETTA
KEY
PASSFEDER
LENGUETA
CLAVETTE
PISTONE DI GUIDA
CROSS-HEAD
KREUZKOPF
PISTÓN GUÍA
GUIDE PISTON
SPINOTTO
WHRIST PIN
KOLBENBOLZEN
CLAVIJA
AXE
RONDELLA
WASHER
UNTERLEGSCHEIBE
ARENDELA
RONDELLE
BIELLA
CONROD
PLEUEL
BIELA
BIELLE
BRONZINA
BRONZE BUSHING
BRONZELAGER
COJINETE DE BRONCE
COUSSINET EN BRONZE
FLANGIA
FLANGE
FLANSCH
BRIDA
BRIDE
ANELLO RASCHIATORE
ROD SCRAPER
ABSTREIFER
ANILLO RASCADOR
JOINT RACLEUR
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
SOFFIETTO
BELLOWS
PNEUGEBLASE
FUELLE
SOUFFLET
SPINA
PIN
STIFT
CLAVIJA
CHEVILLE
COPERCHIO
COVER
ABDECKUNG
TAPA
COUVERCLE
GUARNIZIONE
GASKET
DICHTUNG
JUNTA
JOINT
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
COPERCHIO
COVER
ABDECKUNG
TAPA
COUVERCLE
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
GUARNIZIONE
GASKET
DICHTUNG
JUNTA
JOINT
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
A COMPLETAMENTO:
IN ADDITION:
ZUR ERGAENZUNG:
PARA COMPLETAMIENTO
POUR COMPLETE:
TUBO
PIPE
ROHR
TUBO
TUBE - CONDUITE
TAPPO
PLUG
STOPFEN
TAPON
BOUCHON
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
BUSSOLA
BUSHING
BUCHSE
MANGUITO
FOURREAU
TUBO
PIPE
ROHR
TUBO
TUBE - CONDUITE
PORTAGOMMA
HOSE COUPLING
SCHLAUCHKUPPLUNG
ACOPLAMIENTO GOMA
PORTE CAOUTCHOUC
FASCETTA
HOSE CLAMP
ROHR CLEMME
ABRAZADERA
BANDEAU
TUBO
PIPE
ROHR
TUBO
TUBE - CONDUITE
TUBO
PIPE
ROHR
TUBO
TUBE - CONDUITE
RACCORDO
CONNECTION
ANSCHLUSS
RACOR
RACCORD
FASCETTA
HOSE CLAMP
ROHR CLEMME
ABRAZADERA
BANDEAU
12 / 18
TRANSMISSION BODY
5C051E3_15439
Spare parts list
Drive end - Antrieb - Gr. Motorización - Ensemble de Motorisation
Item Part Code
Qty
0010
0020
0030
0070
0080
0090
0100
0110
0120
0130
0150
0160
0170
0180
0190
0200
1
1
1
1
1
4
1
1
0
17
8
1
4
8
8
1
9513-6393-030
9569-0000-001
9533-4086-000
9536-1625-000
9536-1638-000
9534-0012-580
9536-1641-000
9536-1672-000
9519-9999-999
9535-3016-000
9537-0616-048
9533-4096-210
9537-0120-035
9537-6006-000
9536-8018-000
9533-4096-180
GEA Mechanical Equipment Italia S.p.A
Unit Descrizione
PC
PC
PC
PC
PC
PC
PC
PC
PC
L
PC
PC
PC
PC
PC
PC
ASSIEME
Description
Beschreibung
Descripción
Description
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
MOTORE
MOTOR
MOTOR
MOTOR
MOTEUR
RIDUTTORE
GEARBOX
ZAHNRADGETRIEBE
REDUCTOR
RÉDUCTEUR
PULEGGIA
PULLEY
SCHEIBE
POLEA
POULIE
BUSSOLA CONICA
TAPER BUSHING
BUCHSE KONISCH
MANGUITO CÓNICO
FOURREAU CONIQUE
CINGHIA
BELT
RIEMEN
CORREA
COURROIE
PULEGGIA
PULLEY
SCHEIBE
POLEA
POULIE
BUSSOLA CONICA
TAPER BUSHING
BUCHSE KONISCH
MANGUITO CÓNICO
FOURREAU CONIQUE
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
OLIO
OIL
OEL
ACEITE
HUILE
PRIGIONIERO
STUD
STIFTSCHRAUBE
PRISIONERO
GOUJON
SLITTA MOTORE
MOTOR SLIDE
MOTORSCHLITTEN
CORREDERA DE MOTOR
CHARIOT MOTEUR
VITE
SCREW
SCHRAUBE
TORNILLO
VIS
DADO
NUT
MUTTER
TUERCA
ECROU
RONDELLA
WASHER
UNTERLEGSCHEIBE
ARENDELA
RONDELLE
BUSSOLA
BUSHING
BUCHSE
MANGUITO
FOURREAU
13 / 18
DRIVE END
5C051E3_15439
Spare parts list
Pneumatic plant - Pneumatiksystem - Planta Neumática - Circuit pneumatique
Item Part Code
Qty
0010
0020
0040
0050
0080
0090
0100
0110
0120
0130
0160
0170
0190
1
1
1
1
0
0
2
2
2
2
0
0
0
9513-5480-000
9532-6162-000
9533-9286-000
9533-1003-000
9519-9999-999
9519-9999-999
9532-6932-620
9532-6932-270
9535-8104-280
9533-1049-000
9519-9999-999
9519-9999-999
9519-9999-999
GEA Mechanical Equipment Italia S.p.A
Unit Descrizione
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
Description
Beschreibung
Descripción
Description
ASSIEME
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
NIPPLO
THREAD
NIPPEL
NIPLE
NIPPLE
FILTRO
FILTER
FILTER
FILTRO
FILTRE
MANOMETRO
PRESSURE GAUGE
MANOMETER
MANOMETRO
MANOMÈTRE
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
INTERRUTTORE PNEUMATICO
PNEUMATIC SWITCH
PNEUMATIKSCHALTER
INTERRUPTOR NEUMÁTICO
INTERRUPTEUR PNEUMATIQUE
RIDUTTORE PRESSIONE
PRESSURE REDUCER
DRUCKREDUZIERER
REDUCTOR DE PRESION
RÉDUCTEUR DE PRESSION
DOSATORE
FLOW BATCHER
FLOSSDOSIERANLAGE
DOSIFICADOR
DOSEUR
MANOMETRO
PRESSURE GAUGE
MANOMETER
MANOMETRO
MANOMÈTRE
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
14 / 18
PNEUMATIC PLANT
5C051E3_15439
Spare parts list
Aseptic plant - Aseptiksystem - Planta Aséptica - Circuit aseptique
Item Part Code
Qty
0010
0020
0030
0090
0130
0150
0170
0180
0190
0200
0210
0220
0230
0240
0250
0260
0270
0280
0290
0300
0340
0510
0520
1
1
1
1
1
1
1
1
1
1
1
4
4
4
3
3
1
1
1
1
1
1
1
9513-5949-010
9532-6162-000
9550-0000-491
9550-0000-073
9532-6045-000
9532-6381-000
9533-1050-000
9532-6723-000
9532-6724-000
9513-2760-000
N.A.
9535-8053-000
9532-6323-000
9532-6488-000
9532-6490-000
9532-6721-000
9532-6488-000
9532-6488-000
9532-6488-000
9532-6721-000
9538-8051-000
9514-7607-000
9550-0001-147
GEA Mechanical Equipment Italia S.p.A
Unit Descrizione
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
ASSIEME
Description
Beschreibung
Descripción
Description
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
NIPPLO
THREAD
NIPPEL
NIPLE
NIPPLE
ADATTATORE
ADAPTER
ADAPTER
ADAPTADOR
ADAPTATEUR
ELETTROVALVOLA
ELECTROVALVE
MAGNETVENTIL
ELECTROVALVULA
ÉLECTROVANNE
VALVOLA
VALVE
VENTIL
VALVULA
SOUPAPE - VANNE
RACCORDO A T
TEE CONNECTION
T-STUECK
CONEXIÓN TIPO T
RACCORD EN T
MANOMETRO
PRESSURE GAUGE
MANOMETER
MANOMETRO
MANOMÈTRE
RACCORDO
CONNECTION
ANSCHLUSS
RACOR
RACCORD
RACCORDO
CONNECTION
ANSCHLUSS
RACOR
RACCORD
DISTRIBUTORE CONDENSA
CONDENSATE DISTRIBUTOR
CONDENSAT VERTILLER
DISTRIBUIDOR CONDENSADOS
DISTRIBUTEUR DE CONDENSATS
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
VALVOLA
VALVE
VENTIL
VALVULA
SOUPAPE - VANNE
RIDUZIONE
REDUCTION
REDUZIERUNG
REDUCION
RÉDUCTION
RACCORDO
CONNECTION
ANSCHLUSS
RACOR
RACCORD
RACCORDO
CONNECTION
ANSCHLUSS
RACOR
RACCORD
RACCORDO
CONNECTION
ANSCHLUSS
RACOR
RACCORD
RACCORDO
CONNECTION
ANSCHLUSS
RACOR
RACCORD
RACCORDO
CONNECTION
ANSCHLUSS
RACOR
RACCORD
RACCORDO
CONNECTION
ANSCHLUSS
RACOR
RACCORD
RACCORDO
CONNECTION
ANSCHLUSS
RACOR
RACCORD
TUBO
PIPE
ROHR
TUBO
TUBE - CONDUITE
SUPPORTO
SUPPORT
LAGER
SOPORTE
SUPPORT
TUBO
PIPE
ROHR
TUBO
TUBE - CONDUITE
15 / 18
ASEPTIC PLANT
5C051E3_15439
Spare parts list
Lubrication plant - Schmiersystem - Planta Lubricación - Circuit de lubrification
Item Part Code
0010
0020
0030
0040
0050
0060
0070
0080
0100
0110
0120
0190
0200
0210
0220
0230
0240
0245
0250
0255
0290
Qty
9513-3377-140
1
9532-6932-320
1
9569-0000-001
1
9532-3009-000
1
9533-6101-000
1
9533-1047-000
1
9533-8100-110
1
9531-7073-200
1
9531-7013-000
1
9535-8012-000
1
9532-6904-000
1
9537-9060-000
1
9519-9999-999
0
9532-6001-000
2
9533-5167-000
1
9513-6396-000
1
9519-9999-999
0
A COMPLET. PER LIV1
9532-6670-000
2
A COMPLETAMENTO:1
9538-8055-000
1
GEA Mechanical Equipment Italia S.p.A
Unit Descrizione
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
ASSIEME
Description
Beschreibung
Descripción
Description
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
CENTRALINA
LUBRICATION UNIT
ZENTRALSCHMIERUNG
CENTRAL DE LUBRICACIÓN
CENTRALE DE LUBRIFICATION
MOTORE
MOTOR
MOTOR
MOTOR
MOTEUR
FILTRO
FILTER
FILTER
FILTRO
FILTRE
SCAMBIATORE
HEAT EXCHANGER
WAERMETAUSCHER
INTERCAMBIADOR
EXCHANGEUR DE CHALEUR
MANOMETRO
PRESSURE GAUGE
MANOMETER
MANOMETRO
MANOMÈTRE
PRESSOSTATO
PRESSURE SWITCH
DRUCKWAECHTER
PRESOSTATO
PRESSOSTAT
TAPPO
PLUG
STOPFEN
TAPON
BOUCHON
LIVELLO OLIO
OIL LEVEL
OELSTAND-ANZEIGE
NIVEL DE ACEITE
NIVEAU D'HUILE
RUBINETTO
BALL TAP
HAHN
VÁLVULA DE BOLA
ROBINET
TAPPO
PLUG
STOPFEN
TAPON
BOUCHON
TUBO
PIPE
ROHR
TUBO
TUBE - CONDUITE
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
PORTAGOMMA
HOSE COUPLING
SCHLAUCHKUPPLUNG
ACOPLAMIENTO GOMA
PORTE CAOUTCHOUC
VALVOLA STROZZATORE
THROTTLE VALVE
REDUZIERVENTIL
EXTRANGULADOR
VANNE D'ÉTRANGLEMENT
SUPPORTO
SUPPORT
LAGER
SOPORTE
SUPPORT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
POUR COMPLETE
A COMPLETAMENTO
IN ADDITION
ZUR ERGAENZUNG
PARA COMPLETAMIENTO
MANICOTTO
SLEEVE
KUPPLUNG
MANGUITO
MANCHON
A COMPLETAMENTO
IN ADDITION
ZUR ERGAENZUNG
PARA COMPLETAMIENTO
POUR COMPLETE
ADATTATORE
ADAPTER
ADAPTER
ADAPTADOR
ADAPTATEUR
16 / 18
LUBRICATION PLANT
5C051E3_15439
GEA Niro Soavi
GEA Niro Soavi
1
08/07/2015 - Rev. 4.0
Description
Code
Lubricating Unit TP3
TT - 0100
Type
NSOA Code
FP-GR1-6,3 (L6)
9532-6932-320 (Motor Type IEC)
1.1 Description
Lubricating unit with gear type oil pump (displacement 6,3 cm3/rev), adjustable bypass valve to regulate
the operating pressure, suction side filter and oil tank, volume 6 L. The unit is prearranged for electric
motor installation, including adapter flange and two-parts elastic joint.
1.2 Technical Data
Gear Pump Displacement
Motor RPM @ 50 Hz
Motor RPM @ 60 Hz
Motor Type IEC
Oil Tank Volume
Suction Filter Type
Max Working Pressure
Oil Type
1.3 Performances
Data
6,3
1500
1800
0,75
6
90
15
Unit
Note
3
cm /rev
rpm
rpm
kW Frame 80 B14 4 poles
l
micron
bar
ISO VG 150
Note
Data
Unit
Nominal Flow @ 50 Hz
9,5
l/min
Nominal Flow @ 60 Hz
11,3
l/min
STD Pressure @ 35°C
6
bar higher value allowed at cold start
1.4 List of Components - drawing 9514-1878-000 (NS3030-3037-NS3075-NS3110-ONE37-ONE75)
Description
Description
Part code
Item
Part code
Item
Filter kit
Moto Flange
9532-6932-400
A
9532-6932-470
F
Suction filter 3/4"G mesh 90
Motor flange (IEC size 80 B14) 16
11
Coupling 3/4"G-3/8"G
10
Copper washer 3/8"G
9
Body Kit
9532-6932-410
B
Oring
Body TP3A
1
5
Supporting bracket
28
Overpressure valve
Tank
14+2
9532-6932-480
G
Tank Lt. 6 1"G
15
By-Pass
9532-6932-420
C
Overpressure valve
Plug kit
14
9532-6932-490
H
PLUG "P1" 3/4 - 16UNF
3
PLUG
4
Joint
9532-6932-450
D
Motor/Pump joint
PLUG TCEI DIN 908 G1/4 OR
18-19-32
6
PLUG
7
PLUG TCEI 1/2+PLUG F.1
12-13
Main pump kit 9532-6932-460
E
Pump OT100 P65 D/N16 B2
COUPLING+EXTENSION
31
21-22-23
Discharge manifold kit
PLUG G1/4+COUPLING 1/4
26-30-25
24-27
Motor /Pump joint
18-19-32
Screw kit
9532-6932-500
I
Screw TCEI M6X45
8
33-29-17-20
SCREW TCEIM8+M10+M8
file: TT-0100.xls - TT-0100
page 1/1
Spare parts list
Water plant - Kuhlwassersystem - Planta de agua - Circuit d'eau
Item Part Code
Qty
0010
0020
0021
0040
0050
0060
0070
0080
0090
0100
0110
0120
0140
0150
0160
0170
0180
0190
0200
0210
0220
0230
0240
0250
0260
0270
0280
0290
0300
0310
0320
0330
0340
0350
0360
0370
0380
1
1
0
0
1
1
0
0
0
0
0
1
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
9513-3601-010
9550-0000-491
9519-9999-999
9519-9999-999
9533-7202-000
9535-8010-000
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
9532-6502-000
9519-9999-999
9532-6162-000
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
9538-8054-000
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
9519-9999-999
GEA Mechanical Equipment Italia S.p.A
Unit Descrizione
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
ASSIEME
Description
Beschreibung
Descripción
Description
ASSEMBLY DRAWING
BAUGRUPPEN ZEICHNUNG
DESPIECE
DESSIN D'ENSEMBLE
ADATTATORE
ADAPTER
ADAPTER
ADAPTADOR
ADAPTATEUR
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
ELETTROVALVOLA
ELECTROVALVE
MAGNETVENTIL
ELECTROVALVULA
ÉLECTROVANNE
RUBINETTO
BALL TAP
HAHN
VÁLVULA DE BOLA
ROBINET
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
NIPPLO
THREAD
NIPPEL
NIPLE
NIPPLE
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
NIPPLO
THREAD
NIPPEL
NIPLE
NIPPLE
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
ADATTATORE
ADAPTER
ADAPTER
ADAPTADOR
ADAPTATEUR
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
CODICE NON PRESENTE
N.A.
NICHT BESTEHENDER KODE
CÒDIGO NO PRESENTE
CODE ABSENT
17 / 18
WATER PLANT
5C051E3_15439
Spare parts list
Extra spare parts - Zusatliche ersatzteile - Lista de ricambios añadidos - Liste des pièces détachées additionnelles
Item Part Code
-
9531-4085-591
9531-4098-591
9534-1792-659
9513-2558-000
9514-0608-030
9531-4069-591
9531-4213-591
9531-4226-591
9531-4087-591
9531-4049-591
9531-4024-591
9531-4189-591
9531-4191-591
9531-3027-591
9531-4017-591
9531-4011-591
9531-4188-595
9531-3031-591
9531-4071-591
9531-4571-405
9531-4026-591
9531-4041-591
9512-9226-010
9535-5651-591
9531-6136-516
9531-4146-533
9531-6135-516
9532-3002-000
9532-6932-470
9512-3695-000
9531-9044-010
9531-4069-591
Qty
6
12
6
12
8
8
4
4
4
4
4
4
4
4
2
4
2
4
6
4
2
2
6
6
3
3
3
1
1
1
1
8
GEA Mechanical Equipment Italia S.p.A
Unit Descrizione
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
PC
O-RING
Description
Beschreibung
Descripción
Description
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
PACCHETTO
PACKING
PACKUNG
EMPAQUETADURA
GARNITURE DE PISTON
RONDELLA
WASHER
UNTERLEGSCHEIBE
ARENDELA
RONDELLE
RONDELLA
WASHER
UNTERLEGSCHEIBE
ARENDELA
RONDELLE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
GUARNIZIONE
GASKET
DICHTUNG
JUNTA
JOINT
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
GUARNIZIONE
GASKET
DICHTUNG
JUNTA
JOINT
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
MOLLA
SPRING
FEDER
MUELLE
RESSORT
GUARNIZIONE
GASKET
DICHTUNG
JUNTA
JOINT
ANELLO RASCHIATORE
ROD SCRAPER
ABSTREIFER
ANILLO RASCADOR
JOINT RACLEUR
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
GUARNIZIONE
GASKET
DICHTUNG
JUNTA
JOINT
CARTUCCIA FILTRO
FILTER CARTRIDGE
FILTEREINSATZ
CARTUCHO FILTRO
CARTOUCHE FILTRANTE
CARTUCCIA FILTRO
FILTER CARTRIDGE
FILTEREINSATZ
CARTUCHO FILTRO
CARTOUCHE FILTRANTE
SEDE VALVOLA
VALVE SEAT
VENTILSITZ
ASIENTO VALVULA
SIEGE DE SOUPAPE
SFERA
BALL
KUGEL
BOLA
SPHERE
O-RING
O-RING
O-RING
JUNTA TÓRICA
JOINT TORIQUE
18 / 18
EXTRA SPARE PARTS
5C051E3_15439
Use and maintenance instructions
SECTION 6
ELECTRICAL DIAGRAMS - INDEX
6.1. Electrical diagrams
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
6C001E5C
6.1
Use and maintenance instructions
6.1. Electrical diagrams
In the following pages it is possibile to find the wiring diagrams of the electrical devices installed
onboard the machine, or as an alternative, the complete electrical diagram of the Electric Power
Board if the same or its engineering is supplied by GEA Mechanical Equipment Italia S.p.A..
We recommend to check carefully the wiring diagrams to proceed with correct connection of the
machinhe and its components.
The wiring of the machine and its components must be done by qualified personnel who must be
able to understand properly the supplied electrical documentation and wiring diagrams.
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
6C001E5C
6.2
Electrical list
Electrical list - Elektrische - Lista parte eléctrica - Liste de pièces électrique
Item
Part Code
Qty
-
9562-1206-283
9562-0323-515
1
1
GEA Mechanical Equipment Italia S.p.A
Unit Descrizione
PC
PC
Description
Beschreibung
Descripción
Description
MOTORE
MOTOR
MOTOR
MOTOR
MOTEUR
MOTORE
MOTOR
MOTOR
MOTOR
MOTEUR
1/1
ELECTRICAL LIST
6C011E3_15439
Use and maintenance instructions
Section 7
Suppliers catalogue - index
7.1. Sub-suppliers and components catalogue
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
7C001E5C
7.1
Use and maintenance instructions
7.1. Sub-suppliers and components catalogue
We have included copies of the suppliers’ catalogues and of components installed in the machine.
In addition to the maintenance guidelines provided in this USE AND MAINTENANCE MANUAL, you
should refer to the specific instructions of any installed components
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
7C001E5C
7.2
GEA Niro Soavi
LIST OF SUB-SUPPLIERS COMPONENTS
Ref.
7.01.1
7.01.2
7.01.3
7.01.4
7.01.5
Part Code
9562-1206-283
9562-0323-515
9533-1010-000
9533-4086-000
9532-6932-320
Description
Description
MOTORE
MOTORE
MANOMETRO
RIDUTTORE
MOTOR
MOTOR
PRESSURE GAUGE
GEARBOX
LUBRICATION UNIT
CENTRALINA
7C011E0_C_15439
1 of 1
GEA Niro Soavi
Ref.
Part Code
Description
Description
7.01.1
9562-1206-283
MOTORE
MOTOR
7.01.1
GEA Niro Soavi
Ref.
Part Code
Description
Description
7.01.2
9562-0323-515
MOTORE
MOTOR
7.01.2
INSTALLATIONANDMAINTENANCEINSTRUCTIONS
FORELECTRICMOTORS
ENGLISH
INSTRUCCIONESPARAL AINSTALACIÓNY
MANTENIMIENTODE MOTORESELÉCTRIC OS
ESPAÑOL
BETRIEBS- UNDWARTUNGSANLEITUNGEN
FÜRELEKTROMOTOREN
DEUTSCH
INSTRUCTIONSPOURINSTALLATIONET
MANUTENTIONDE MOTEURSÉLECTRIQUES
FRANÇAIS
ISTRUZIONID’USO EMANUTENZIONE
PERMOTORIELETTRICI
ITALI ANO
INSTALLATIONS-OGVEDLIGEHOLDELSESVEJLEDNING
FORELEKTRISKEMOTORER
DANSK
INSTALLATIONS-OCHUNDERHÅLLSINSTRUKTIONER
FÖRELEKTRISKAMOTORER
SVENSKA
0280.1400
PYCCKNÑ
BETRIEBS-UND WARTUNGSANLEITUNGEN
FÜRELEKTROMOTOREN
19-2 6
INSTRUCTIONSPOURINSTALLATIONET
MANUTENTIONDEMOTEURSÉLECTRIQUES
27-3 4
ISTRUZIONID’USOEMANUTENZIONE
PERMOTORI ELETTRICI
English
43-4 8
INSTALLATIONS- OCH
UNDERHÅLLSINSTRUKTIONER
FÖRELEKTRISKAMOTORER
49-5 4
Svenska
55-6 1
Dansk
INSTALLATIONS-OG
VEDLIGEHOLDELSESVEJLEDNINGFOR
ELEKTRISKEMOTORER
Pyccknñ
35-4 2
Español
11-1 8
Deutsch
INSTRUCCIONESPARALAINSTALACIÓNY
MANTENIMIENTODE MOTORESELÉCTRICOS
Français
5-10
Italiano
INSTALLATIONAND MAINTENANCE
INSTRUCTIONSFORELECTRICMOTORS
In case the motors are stored for more than
two years, the bearings must be replaced or the
lubrication grease must be totally removed after
cleaning.
Single phase motors when kept in stock
for 2 years or more must have their capacitors
replaced (if any).
We recommend to turn the shaft (by hands)
at least once a month, and to measure the
insulation resistance before installing it, in cases
of motors stored for more than 6 months or when
subject to high humidity areas.
If motor is fitted with space heaters, these
should be switched on.
READ C AREFULLY THIS MANUAL
BEFORE INSTALLING THE MOTOR
RECEIVINGCHECK
Check if any damage has occured during
transportation.
Check nameplate data.
Remove shaft locking device (if any) before
operating the motor.
Turn the shaft with the hand to make sure it
is turning freely.
HANDLINGANDTRANSPORTATION
1 - General
Insulation Resistance Check
MOTORS MUST NOT BE LIFTED BY
THE SHAF T, BUT BY THE EYEBOLTS
Measure the insulation resistance before
operating the motor and/or when there is any
sign of humidity in the winding.
Lifting devices, when supplied, are
designed only to support the motor. If the motor
has two lifting devices then a double chain must
be used to lift it.
Lifting and lowering must be done gently
without any shocks, otherwise the bearings can
get damaged.
The resistance measured at 25ºC must be:
Ri  (20 x U) / (1000 + 2P) [M ]
(measured with a MEGGER at 500 V d.c.)
where U = voltage (V); P = power (kW).
If the insulation resistance is less than 2
megaohms, the winding must be dried
according to the following:
Warm it up inside an oven at a minimum
temperature of 80ºC increasing 5ºC every hour
until 105ºC, remaining under this temperature
for at least one hour.
Check if the stator insulation resistance
remains constant within the accepted values. If
not, stator must be reimpregnated.
DURING TRANSPORTATION,
MOTORS FITTED WITH ROLLER OR
ANGULAR CONT ACT BEARINGS
ARE PROTECTED AGAINST
BEARING DAMAGES WITH A
SHAFT LOCKING DEVICE.
THIS LOCKING DEVICE MUST BE
USED ON ANY FURTHER MOTOR
TRANSPORTATION, EVEN WHEN
THIS MEANS TO UNCOUPLE
THE MOTOR FROM THE DRIVEN
MACHINE.
INSTALLATION
STORAGE
1 - Safety
If motors are not immediately installed,
they must be stored in dry places, free of
dust, vibrations, gases, corrosive smokes,
under constant temperature and in normal
position free from other objects.
Motor storage temperature must remain
between 5ºC to 60ºC, with relative humidity not
exceeding 50%.
All personnel involved with electrical
installations, either handling, lifting, operation
or maintenance must be well informed and
updated concerning safety standards and
principles that govern the work and carefully
follow them.
We strongly recommend that these jobs
are carried out by qualified personnel.
5
ENGLISH
ENGLISH
designed in such a way to stop any vibration
originated from resonance.
MAKE SURE THAT ELECTRIC
MOTORS ARE SWITCHED OFF
BEFORE STARTING ANY
MAINTENANCE SERVICE.
4 - Drain Holes
Motors must be protected against accidental starts.
When performing any maintenance
service, disconnect the motor from the power
supply. Make sure all accessories have been
switched off and disconnected.
In order to prevent from penetrating dust
and/or water into the te rminal box, cable glands
or threaded pipe in the lead holes must be
installed.
Do not change the regulation of the
protecting devices to avoid damaging.
Make sure the drains are placed in the
lower part of the motor when the mounting
configuration differs from that specified on the
motor purchase order.
5 - Balancing
WEG MOTORS ARE D YNAMIC ALLY
BALANCED WITH HALF KEY, AT NO
LOAD AND UNCOUPLED.
Transmission elements such as pulleys,
couplings, etc must be dynamically balanced
with half key before installation.
Use always appropriate tools for installation and
removal.
2 - Operating Conditions
Electric motors, in general, are designed
for operation at an altitude of 1000m above sea
level for an ambient temperature between 0ºC
and 40ºC. Any variation is stated on the
nameplate.
6 - Alignment
ALIGN THE SHAFT ENDS AND
USE FLEXIBLE COUPLING,
WHENEVER POSSIBLE.
COMPARE THE CURRENT, VOL TAGE,
FREQUENCY, SPEED, OUTPUT AND
OTHER VALUES DEMANDED BY THE
APPLICATION WITH THE DATA GIVEN
ON THE NAMEPLATE.
Ensure that the motor mounting devices
do not allow modifications on the alignment and
further damages to the bearings.
When assembling a half-coupling, be sure
to use suitable equipment and tools to protect
the bearings.
Suitable assembly of half-coupling:
Check that clearance Y is less than
0.05 mm and that the difference X1 to X2 is less
than 0.05 mm, as well.
Motors supplied for hazardous locations
must be installed in areas that comply with that
specified on the motor nameplate.
KEEP AIR INLET AND OUTLET FREE
AND CLEAN. THE AIR BLOWN OUT
BY THE MOTOR SHALL NOT ENTER
AGAIN. THE DISTANCE BETWEEN
THE AIR INLET AND THE WALL
MUST BE AROUND ¼ OF THE
INLET OPENING DIAMETER.
3 - Foundation
Note: Dimension X1 and X2 must be
3mm minimum
Figure and alignment tolerances
Motors provided with feet must be installed
on solid foundations to avoid excessive
vibrations.
The purchaser is fully responsible for the
foundation.
Metal parts must be painted to avoid
corrosion.
The foundation must be uniform and sufficiently tough to support any schock. It must be
7 - Belt Drive
When using pulley or belt coupling, the
following must be observed:
Belts must be tighten just enough to avoid
slippage when running, according to the
6
Make sure to use the correct cable
dimension, based on the rated current stamped
on the motor nameplate.
WARNING:
Excessive tension on the pulleys will
damage the bearings and lead to a
probable shaft rupture.
BEFORE ENERGIZING THE
TERMINALS, CHECK IF THE
GROUNDING IS MADE
ACCORDING TO THE CURRENT
STANDARDS. THIS IS ESSENTIAL
AGAINST ACCIDENT RISKS.
8 - Connection
When the motor is supplied with
protective or monitor temperature device such
as thermostats, thermistors, termal protector, etc,
connect their terminals to the corresponding
devices on the control panel.
WARNING:
Voltage may be connected at standstill
inside the terminal box for heating elements or
direct winding heating.
WARNING:
The capacitor on single-phase motors
can retain a charge which appears across the
motor terminals, even when the motor has
reached standstill.
10 - Start-Up
THE KEY MUST BE FASTENED OR
REMOVED BEFORE STARTING THE
MOTOR.
a) The motor must start and operate
smoothly. In case this does not occur, turn it off
and check the connections and the mounting
before starting it again.
b) If there is excessive vibration, check if
the fasteni ng screws are correctly fastened.
Check also if the vibration comes from a
neighbour machine. Periodical vibration checks
must be done.
c) Run the motor under rated load for a
short period of time and compare if the running
current is equal to that stamped on the
nameplate.
A WRONG CONNECTION CAN
BURN THE MOTOR.
Voltage and connection are indicated on
the nameplate. The acceptable voltage
variation is ±10%; the acceptable frequency
variation is ±5% and the total acceptable
variation is ± 10%.
9 - Starting Methods
The motor is rather started through direct
starting. In case this is not possible, use
compatible methods to the motor load and
voltage.
The rotation direction is clockwise if the
motor is viewed from DE side and if the
phases are connected according to the
sequence L1, L2, L3.
To change the rotation direction, interchange two of the connecting leads.
MAINTENANCE
WARNING:
SAFETY CHECK LIST
1 - General Inspection
Check the motor periodically.
Keep the motor clean and a ssure free air flow.
Check the seals or V Ring and replace them, if
required.
Check the connections as well as supporting
screws.
Check the bearings and observe: Any excessive
noise, vibration, bearing temperature and grease
condition.
When a change, under normal conditions, is
detected, check the motor and replace the
required parts.
THE CONNECTION TO THE POWER
SUPPLY MUST BE DONE B Y
QUALIFIED PERSONNEL AND WITH
FULL ATTENTION TO ASSURE A SAFE
AND PERMANENT CONNECTION.
AFTER CONNECTING THE MOTOR,
CHECK FOR ANY STRANGE BODY
INSIDE THE TERMINAL BOX. THE
CABLE INLETS NOT IN USE MUST BE
CLOSED.
7
ENGLISH
specifications stated on the belt supplier
recommendation.
2 - Machines Fitted with Grease Nipples
The frequency of the inspections depends
on the motor type and on the application
conditions.
It is strongly recommended to grease the
machine while running. This allows the grease
renewal in the bea ring housing. When this is
not possible due to turning parts by the grease
device (pulleys, bushing, etc) that offer some
risk to the physical integrity of the operator,
proceed as follows:
Clean the area near the grease nipple.
Put approximately half of the total grease and
run the motor for 1 minute at full speed.
Then turn off the motor and insert the rest of the
grease.
The injection of all the grease with the motor in
standstill can make the grease penetrate into the
motor, through the inner seal of the bearing
housing.
LUBRICATION
FOLLOW THE REGREASING
INTERVALS. THIS IS FUNDAMENTAL
FOR PROPER MOTOR OPERATION.
1 - Machines without Grease Nipples
Motors up to frame 200 are normally fitted
without grease nipples. In these cases the
regreasing shall be done at the preventive
maintena nce job observing the following
aspects:
Disassemble carefully the motors.
Take all the grease out.
Wash the bearing with querosene or diesel.
Regrease the bearing immediately.
FOR LUBRICATION USE ONLY
MANUAL GREASE GUN.
RELUBRICATION INTERVALS
TABLE 1 - BALL BEARINGS - Series 62/63
Relubrication intervals (running hours – horizontal position)
II pol e
IV pole
VI pol e
VIII pol e
X pole
XII pol e
Grea se
Serie 62
Bearing
6209
6211
6212
60Hz
18400
14200
12100
50Hz
20000
16500
14400
60Hz
20000
20000
20000
50Hz
20000
20000
20000
60Hz
20000
20000
20000
Bearing
6309
6311
6312
6314
6316
6319
6322
60Hz
15700
11500
9800
3600
-
50Hz
18100
13700
11900
4500
-
60Hz
20000
20000
20000
9700
8500
7000
5100
50Hz
20000
20000
20000
11600
10400
9000
7200
60Hz
20000
20000
20000
14200
12800
11000
9200
50Hz
60Hz
20000
20000
20000
20000
20000
20000
Serie 63
50Hz
60Hz
20000
20000
20000
20000
20000
20000
16400
17300
14900
15900
13000
14000
10800
11800
50Hz
20000
20000
20000
60Hz
20000
20000
20000
50Hz
20000
20000
20000
60Hz
20000
20000
20000
50Hz
20000
20000
20000
(g)
9
11
13
50Hz
20000
20000
20000
19700
18700
17400
15100
60Hz
20000
20000
20000
19700
18700
17400
15100
50Hz
20000
20000
20000
20000
20000
18600
15500
60Hz
20000
20000
20000
20000
20000
18600
15500
50Hz
20000
20000
20000
20000
20000
20000
19300
(g)
13
18
21
27
34
45
60
TABLE 2 - ROLLER BEARINGS - Series NU 3
Relubrication intervals (running hours – horizontal position)
II pol e
Bearing
NU 309
NU 311
NU 312
NU 314
NU 316
NU 319
NU 322
NU 324
60Hz
9800
6400
5100
1600
-
50Hz
13300
9200
7600
2500
-
IV pole
60Hz
20000
19100
17200
7100
6000
4700
3300
2400
50Hz
20000
20000
20000
8900
7600
6000
4400
3500
VI pol e
60Hz
20000
20000
20000
11000
9500
7600
5900
5000
VIII pol e
50Hz
20000
20000
20000
13100
11600
9800
7800
6600
60Hz
20000
20000
20000
15100
13800
12200
10700
10000
8
50Hz
20000
20000
20000
16900
15500
13700
11500
10200
X pole
60Hz
20000
20000
20000
16900
15500
13700
11500
10200
50Hz
20000
20000
20000
19300
17800
15700
13400
12100
XII pol e
60Hz
20000
20000
20000
19300
17800
15700
13400
12100
50Hz
20000
20000
20000
20000
20000
20000
17300
15000
Grea se
(g)
13
18
21
27
34
45
60
72
The stator grips must be applied over the
side face of the inner ring to be disassembled or
over an adjacent part.
It is essential that bearings assembly be
done under cleanning conditions to ensure
good operation and to avoid damages. New
bearings shall only be taken out from their cases
when assembling them.
Before installing a new bearing it is
required to check the shaft fitting for any sharp
edge or strike signals.
For bearing assembly warm their inner
parts withsuitable equipment - inductive pocess
- or use suitable tools.
SPAREPARTS
When ordering spare parts, please specify
the full type designation and product code as
stated on the motor nameplate. Please also
inform the motor serial number stated on the
nameplate.
WE RECOMENDED TO USE BALL
BEARINGS FOR MOTORS DIRECTLY
COUPLED TO THE LOAD.
WARNING:
EXCESS OF GREACE CAN CAUSE
BEARNING OVERHEATING
RESULTING IN COMPLETE
DAMARGE.
MOTORS FOR HAZARDOUS
LOCATIONS
Besides the recommendations given
previously, these ones must be also followed:
THE SPECIFIC ATION OF THE MOTOR
INSTALLATION PLACE IS FOR
CUSTOMER’S RESPONSIBILITY,
WHO WILL ALSO DETERMINE THE
ENVIRONMENT CHARACTERISTICS.
Compat ibilit y of Polyre x ® EM grease
with other type s of greas e:
Containing polyurea thickener and mineral
oil, the Polyrex ® EM grease is compatible with
other types of grease that contain:
Lithium base or complex of lithium or polyurea
and highly refined mineral oil.
Inhibitor additive against corrosion, rust and
anti-oxidant additive.
Motors for hazardous locations are
manufactured according to specific standards
for such environments and they are certified by
worldwide certifying entities.
Note s:
Although Polyrex ® EM is compatible with types
of grease given above, we do not recommended
to mix it with any other greases.
 If you intend to use a type of grease different
than those recommended above , first contact
WEG.
On applications (with high or low temperatures,
speed variation, etc), the type of grease and
relubrification interval are given on an additional
nameplate attached to the motor.
1 - Installation
The complete installation must follow
procedures given by the local legislation in effect.
THE INSTALLATION OF HAZARDOUS
LOCATION MOTORS MUST BE
CARRIED OUT BY SKILLED PEOPLE,
AND THE THERMAL PROTECTION
MUST BE ALWAYS INST ALLED,
EITHER INSIDE OR OUTSIDE THE
MOTOR, OPERATING AT THE RATED
CURRENT.
THE USE OF ST ANDARD MOTORS
IN SPECIFIC AREAS OR SPECIAL
APPLICATIONS MUST BE DONE BY
CONSULT TO THE GREASE
MANUFACTURER OR WEG
2 - Maintenance
Maintenance must be carried out by repair
shops authorized by WEG.
Repair shops and people without Weg’s
authorization who will perform any service on
hazardous location motors will be fully
responsible for such service as well as for any
consequential damage.
DISASSEMBLYANDASSEMBLY
Disassembly and assembly must be done
by qualified personnel using only suitable tools
and appropriated methods.
9
ENGLISH
Note:
The ZZ bearings from 6201 to 6307 do not
require relubrication as its life time is about
20,000 hours.
Tables 1 and 2 are intended for the lubrication
period under bearing temperature of 70°C (for
bearings up to 6312 and NU 312) and
temperature of 85°C (for bearings 6314 and NU
314 and larger).
 For each 15°C of temperature rise, the
relubricat ion period is reduced by half.
The relubrication periods given above are
for those cases applying Polyrex ® EM grease.
 When motors are used on the vertical
position, their relubrication interval is reduced
by half if compared to horizontal position
motors.
Lower efficiency.
Higher vibration.
Higher noise level.
Higher rated current.
 Higher temperature rise.
Reduced motor insulation.
Reduced bearing life.
ANY ELECTRICAL OR MECHANICAL
MODIFICATION MADE ON
HAZARDOUS L OC ATION MOTORS
WILL VOID THE CERTIFIC ATION.
When
performing
maintena nce,
instal lation or relubricat ion, fo llow these
instructions:
1- Standard Motors
Check if all components are free of edges,
knocks or dirt.
Make sure all parts are in perfect conditions.
Lubricate the surfaces of the endshield fittings
with protective oil to make the assembly easier.
Use only rubber hammer to fit the parts.
Check for correct bolts tightening.
Use clearance cali brator for correct T-box fitting
(smaller than 0.05mm).
Voltages lower than 440V do not require filter.
Voltages equal or higher than 440V or lower
than 57 5V require filter for motor power supply
cables longer than 20 meters.
Voltages equal or higher than 575V require
filter for any size of power supply cables.
IF SUCH RECOMMENDATIONS ARE
NOT FOLLOWED ACCORDINGLY,
MOTOR WARRANTY WILL BE VOID.
DO NOT REUSE DAMAGED OR
WORN PARTS. REPLACE THEM BY
NEW ONES SUPPLIED BY THE
FACTORY.
2- Inverter Duty Motors:
MOTORS DRIVEN BY VFD
Check power supply voltage of the forced
cooling set.
Filters are not required.
Applications using VFD´s without filter
can affect motor performance as follows:
WARRANTYTERMS
Weg warrants its products against defects in
workmanship and materials for twelve (12)
months from the invoice date issued by the
factory, authorized distributor or agent limited
to eighteen (18) months from manufacturingdate
independent of installation date as long as the
following items are fulfilled accordingly:
-
-
-
This warranty does not include disassembly
services at the purchaser facilities,
transporta tion costs with product, tickets,
accomodation and meals for technical personnel
when requested by the customer.
The warranty service will be only carried out at
Weg Authorized Repair Shops or at Weg’s
facilities.
Proper transportation, handling and storage;
Correct installation based on the specified
ambient conditions and free of corrosive
gases;
Operation under motor capacity limits;
Observation of the periodical maintenance
services;
Repair and/or replacement effected only by
personnel duly authorized in writing by Weg;
The failed product be available to the supplier
and/or repair shop for a required period to
detect the cause of the failure and
corresponding repair;
Immediate notice by the purchaser about
failures accured and that these are accepted
by Weg as manufacturing defects.
Components whose useful life, under normal
use, is shorter than the warranty period are not
covered by these warranty terms.
The repair and/or replacement of parts or
components, when effected by Weg and/or any
Weg Authorized Repair Shop, will not give
warranty extension.
This constitutes Weg’s only warranty in
connection with this sale and the company will
have no obligation or liability whatsoever to
people, third parties, other equipment or
installations, including without limitation, any
claims for consequential damages or labor costs.
10
ESPAÑOL
Si los motores no fueran inmediatamente
instalados, deben ser almacenados en un local
seco, libre de polvo, vibraciones, gases y
vapores corrosivos; dotado de temperatura
uniforme, colocándolos en posición normal y
sin apoyar sobre ellos otros objetos.
La temperatura de almacenaje de los
motores debe quedar entre 5ºC y 60ºC, con
humedad relativa no excediendo a 50%.
En el caso de motores con más de dos
años de almacenaje, se debe proceder al cambio
de rodamientos o a la substitución total de la
grasa lubricante después de la limpieza de los
mismos.
VERIFICACIÓN EN LARECEPCIÓN
 Verifique si ocurrieron daños durante el
transporte.
Verifique los datos de la placa de características.
 Retire el dispositivo de bloqueo del eje
(cuando exista), antes de poner el motor en
funcionamiento.
Gire el eje con la mano para verificar si está
girando libremente.
MANIPULACIÓN Y TRANSPORTE
1 - General
En
los
motores
monofásicos
almacenados durante dos años o más, se debe
además cambiar los condensadores (cuando
existan).
LOS MOTORES NO DEBEN SER
IZADOS POR EL EJE, USE PARA ELLO
LOS CÁNCAMOS DE SUSPENSIÓN,
YA QUE LOS MISMOS ESTÁN
DISEÑADOS SOLAMENTE PARA
SOPORTAR EL PESO DEL MOTOR.
Recomendamos girar el eje del motor (con
la mano) al menos una vez al mes y medir la
resistencia del aislamiento antes de instalarlo,
en caso de motores almacenados durante más
de 6 meses o cuando están sometidos a
ambientes con alta humedad.
Si el motor por su diseño constructivo
tiene dos cáncamos de suspensión, use
dispositivos que permitan el izaje por ambos
elementos al mismo tiempo.
Si el motor dispone de resistencias de
calefacción, estas deberán ser conectadas.
El izaje así como el descenso del motor
deben ser realizados en forma suave, sin golpes,
caso contrario los rodamientos pueden sufrir
daños.
Medición de la resistencia del aislamiento
Mida la resistencia del aislamiento antes
de poner el motor en servicio y/o cuando haya
indicios de humedad en el bobinado.
LOS MOTORES CON
RODAMIENTOS DE RODILLOS O
DE CONT ACTO ANGULAR ESTÁN
PROTEGIDOS, DURANTE EL
TRANSPORTE, CONTRA DAÑOS
POR MEDIO DE UN DISPOSITIVO
DE BLOQUEO.
La resistencia, medida a 25ºC, debe ser:
Ri  (20 x U) / (1000 + 2P) [M ]
(medido con MEGGER a 500 V c.c.);
donde U = tensión (V); P = potencia (kW).
Si la resistencia del aislamiento medida
es inferior a 2 Mohm, el bobinado deberá ser
secado de acuerdo con lo que sigue:
LOS DISPOSITIVOS DE BLOQUEO
DEBEN SER USADOS SIEMPRE
QUE SE TRANSPORTE EL MOTOR,
AUNQUE ESTO IMPLIQUE EN
TENERLO QUE DESACOPLAR
NUEVAMENTE DE LA MÁQUINA
ACCIONADA.
Calentar el estat or bobinado en un horno
partiendo de una temperatura de 80ºC y
elevando 5ºC por hora hasta llegar a los 105ºC;
11
ESPAÑOL
ALMACENAMIENTO
LEA ATENTAMENTE ESTE MANUAL
ANTES DE INICIAR LA
INSTALACIÓN DEL MOTOR.
esta última temperatura debe permanecer
durante un período mínimo de una hora.
Medir nuevamente la resistencia del
aislamiento del bobinado para comprobar si es
constante y con valores dentro de los mínimos
recomendados; caso contrario, se deberá
proceder a una nueva impregnación del estator
bobinado.
COMPARE LA CORRIENTE,
TENSIÓN, FRECUENCIA,
VELOCIDAD, POTENCIA Y OTROS
VALORES EXIGIDOS POR LA
APLIC ACIÓN, CON L OS DATOS
CONTENIDOS EN LA PLACA DE
IDENTIFICACIÓN.
Motores para áreas clasificadas deberán
ser instalados en lugares de conformidad con
la identificación en la placa del motor.
INSTALACIÓN
1 - Seguridad
MANTENER LA ENTRADA Y SALIDA
DE AIRE DEL MOTOR SIEMPRE
LIMPIAS. EL AIRE EXPELIDO POR
EL MOTOR NO DEBE SER
ASPIRADO NUEVAMENTE. LA
DISTANCIA ENTRE LA ENTRADA
DE AIRE DEL MOTOR Y LA PARED,
NO DEBE SER INFERIOR A ¼ DEL
DIÁMETRO DE LA ABERTURA DE
LA ENTRADA DE AIRE QUE POSEE
DICHO MOTOR.
Los profesionales que trabajan en
instalaciones eléctricas, sea en el montaje, en la
operación o en el mantenimiento, deberán estar
permanentemente informados y actualizados
sobre las normas y requisitos vigentes en materia
de seguridad y cuidadosamente ponerlas en
práctica.
Se recomienda que éstos servicios sean
efectuados por personal cualificado.
3 - Fundaciones del motor
VERIFIQUE QUE LOS MOTORES
ELÉCTRICOS ESTÉN
DESCONECTADOS ANTES DE
INICIAR CUALQUIER TRABAJO DE
MANTENIMIENTO.
Los motores con patas deberán ser
instalados sobre apoyos rígidos para evit ar
excesivas vibraciones.
El comprador es totalmente responsable
de estos apoyos.
Los motores deben estar protegidos
contra arranques accidentales.
Las partes metálicas deberán estar
pintadas para evitar la corrosión.
Al realizar servicios de mantenimiento
sobre el motor, desconecte la red de alimentación.
Verifique si todos los accesorios fueron
desconectados.
La base debe ser uniforme y lo
suficientemente robusta para soportar fuertes
choques. Debe ser diseñada de manera que
impida las vibraciones originadas por
resonancias.
Para impedir la penetración de polvo y/o
agua en el interior de la caja de conexiones, es
necesario instalar prensaestopas o tapones
roscados en la salida de los cables de conexión.
4 - Agujeros de drenaje
No modifique el ajuste de los dispositivos
de protección, para evitar daños.
Asegúrese que los agujeros de drenaje
del motor se sitúen en su parte inferior, cuando
la forma de montaje del motor difiera de la
especificada en la compra del mismo.
2 - Condiciones de Operación
Las máquinas eléctricas, en general, están
diseñadas para operación a una altitud hasta
1000m sobre el nivel del mar con temperaturas
ambientes de 0º a 40ºC. Variaciones respecto a
los valores mencionados deben estar indicados
en la placa de características.
5 - Equilibrado
LOS MOTORES WEG SON
EQUILIBRADOS DINÁMICAMENTE
CON “MEDIA CHAVETA”, EN V ACÍO
Y DESACOPLADOS.
12
Los elementos de tra nsmisión, tales como,
poleas, acoplamientos, etc., precisan ser
equilibrados dinámicamente con “media
chaveta” antes de ser instalados. Utilice siempre
herramientas apropiadas tanto en la instalación
como en el desacople de los motores.
PELIGRO:
Aún con el motor detenido, puede existir
energia eléctrica en el interior de la caja de
conexiones debido a la presencia de resistencias
calefactoras o en el mismo bobinado en el caso
de que éste sea usado como elemento de
calefacción de reposo.
6 - Alineación
ALINEAR LAS P UNTAS DE EJE Y
UTILICE SIEMPRE QUE FUERA
POSIBLE ACOPLAMIENTOS
FLEXIBLES.
PELIGRO:
Los condensadores de los motores
monofásicos pueden tener energia eléctrica, la
misma estará presente en los terminales del
motor aún cuando el motor estuviere detenido.
Certifiquese de que los dispositivos de
montaje del motor no permitan alteraciones en
la alineación y futuros daños en los rodamientos.
TODA CONEXIÓN EFECTUADA DE
FORMA INCORRECTA P UEDE
QUEMAR EL MOTOR.
Cuando se proceda al montaje de una
mitad del acoplamiento, deben ser usados los
medios adecuados y las herramientas necesarias
para no dañar los rodamientos.
La tensión y forma de conexión están
indicadas en la placa de características. La
variación aceptable de tensión es de ±10%,
la variación admitida en la frecuencia es de ±5%
y la variación simultánea total de ambas es de
±10%.
Montaje correcto de la mitad del
acoplamiento:compruebe que la distancia y sea
inferior a 0,05 mm y que la diferencia de X1 a X2
también sea menor que 0,05mm.
9 - Sistema de arranque
Es preferible que el motor arranque en
forma directa, en el caso de que esto no sea
posible, utilizar métodos alternativos que sean
compatibles con la carga y tensión del motor.
El sentido de giro es el horario, mirando
el motor desde el extremo del eje y conectando
las fases en la secuencia L1, L2 y L3.
Para cambiar el sentido de giro, invertir
dos de los tres cables de alimentación.
Obs.: X1 y X2 deberan ser inferiores a 3mm
Figura y tolerancias para la alineación
LA CONEXIÓN DE LOS CABLES DE
ALIMENTACIÓN ELÉCTRIC A DEBE
SER EFECTUADA POR PERSONAL
CUALIFICADO CON MUCHA
ATENCIÓN PARA ASEGURAR UN
CONTACTO SEGURO Y
PERMANENTE.
DESPUÉS DE HABER CONECT ADO
EL MOTOR, VERIFIQUE QUE
NINGÚN CUERPO EXTRAÑO
PERMANEZCA EN EL INTERIOR DE
LA CAJA DE CONEXIONES. TODA
ENTRADA DE CABLES A LA CAJA
QUE NO ESTÉ SIENDO UTILIZADA,
DEBE SER CERRADA.
7 - Poleas
Cuando se utilice un acoplamiento por
medio de correas y poleas, se debe observar:
Las correas deben ser tensadasapenas lo
suficiente como para evitar deslizamento en el
funcionamiento, de acuerdo con las
recomendaciones del fabricante de las correas.
ATENC IÓN:
Una excesiva tensión en las correas dañará
los rodamientos y hasta puede provocar la
rotura del eje.
13
ESPAÑOL
8 - Conexión
1 - Inspección General
Asegúrese de utilizar el diámetro correcto
para el cable de alimenta ción, tomando como
base la corriente nominal indicada en la placa
de características del motor.
Inspeccionar el motor periódicamente.
Mantener limpio el motor y asegurar libre flujo
de aire.
 Verifique el sello o V Ring y efectúe la
sustitución caso sea necesario.
Verifique el ajuste de las conexiones del motor
 Verifique el estado de los rodamientos
teniendo en cuenta: aparición de fuertes ruidos,
vibraciones, temperatura excesiva y condiciones
de la grasa.
 Cuando se detecte un cambio en las
condiciones de trabajo normales del motor,
analice el motor y reemplaze las piezas
requeridas.
La frecuencia adecuada para realizar las
inspecciones dependerá del tipo de motor y de
las condiciones de aelicación.
ANTES DE CONECTAR EL MOTOR,
VERIFIQUE QUE LA CONEXIÓN A
TIERRA FUE REALIZADA DE
ACUERDO CON LAS NORMAS
VIGENTES. ESTE DET ALLE ES
FUNDAMENTAL P ARA EVITAR
ACCIDENTES.
Cuando el motor esté equipado con
dispositiv os de protección o control de
temperatura como termostatos, termistores,
protectores térmicos, etc., conecte sus
respectivos terminales al panel de control que le
corresponda.
LUBRICACIÓN
10 - Puesta en Marcha Inicial (Start-Up)
PROCEDA DE ACUERDO CON
LOS INTERVALOS DE REENGRASE
RECOMENDADOS. ESTO ES VITAL
PARA LA OPERACIÓN DEL MOTOR.
LA CHAVETA DEBE ESTAR
COMPLETAMENTE ASEGURADA O
POR EL CONTRARIO RETIRADA
ANTES DE PONER EN MARCHA EL
MOTOR.
1 - Motor es sin engra sador
a) El motor debe arrancar y funcionar de
manera suave. En el caso de que esto no ocurra,
desconecte el motor y verifique nuevamente el
sistema de montaje y de conexiones antes de
nueva puesta en marcha
b) Si se perciben vibraciones excesivas,
verifique el sistema de fijación del motor a la base
así como el acoplamiento motor-máquina.
Puede ocurrir también que la vibración sea
originada por máquinas adyacentes se
recomienda hacer controles periódicos de las
vibraciones.
c) Dejar en marcha el motor bajo carga
nominal durante un pequeño periodo de tiempo
y comparar la corriente de operación con la placa
de características del motor.
Los motores hasta la carcaza IEC 200
normalmente no llevan engrasador. En éstos
casos el reengrase deberá ser efectuado
conforme al plan de mantenimiento preventivo
existente, tenien do en cuenta los siguientes
aspectos:
Desarmar cuidadosamente los motores.
Retirar toda la grasa.
Lavar los rodamientos con keroseno o gasóleo.
Reengrasar el rodamiento inmediatamente.
2 - Motores con engrasador
Es aconsejable efectuar el reengrase
durante el funcionamiento del motor, de modo
que permita la renovación de la grasa en el
alojamiento del rodamiento. Si esto no fuera
posible debido a la presencia de piezas
giratorias cerca de la entrada de grasa (poleas,
acoplamientos, etc.) que puedan poner en
riesgo la integridad física del operador, se
procede de la siguiente manera:
MANTENIMIENTO
PELIGRO:
CONTROL DE SEGURIDAD
(CHECK LIST)
14
 Limpiar las proximidades del orificio del
engrasador.
Inyectar aproximadamente la mitad de la
cantidad total de grasa estimada y poner en
marcha el motor durante 1 minuto
aproximadamente en rotación nominal
Desconectar nuevamente e l motor y colocar la
grasa restante.
La inyección de toda la grasa con el motor
parado puede llevar a la penetración de parte
del lubricante al interior del motor, a través del
orificio de pasaje de eje en las tapas de
rodamientos interiores.
ESPAÑOL
PARA LA L UBRICATIÓN, USE
EXCLUSIVAMENTE PISTOLA
ENGRASADORA MANUAL.
INTERVALOS DE RELUBRICACION
TABLA 1 - RODAMIENTOS DE ESFERAS - Series 62/63
Intervalo de relubricación (horas de operación - posición horizontal)
II pol os
IV polos
VI pol os
VIII po los
X polos
XII po los
Grasa
Serie 62
6209
6211
60Hz
18400
14200
50Hz
20000
16500
60Hz
20000
20000
50Hz
20000
20000
60Hz
20000
20000
50Hz
20000
20000
60Hz
20000
20000
50Hz
20000
20000
60Hz
20000
20000
50Hz
20000
20000
60Hz
20000
20000
50Hz
20000
20000
(g)
9
11
6212
12100
14400
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
13
50Hz
20000
20000
20000
19700
18700
60Hz
20000
20000
20000
19700
18700
50Hz
20000
20000
20000
20000
20000
60Hz
20000
20000
20000
20000
20000
50Hz
20000
20000
20000
20000
20000
(g)
13
18
21
27
34
17400
15100
17400
15100
18600
15500
18600
15500
20000
19300
45
60
Rodamiento
6309
6311
6312
6314
6316
60Hz
15700
11500
9800
3600
-
50Hz
18100
13700
11900
4500
-
60Hz
20000
20000
20000
9700
8500
50Hz
20000
20000
20000
11600
10400
60Hz
20000
20000
20000
14200
12800
Serie 63
50Hz
60Hz
20000
20000
20000
20000
20000
20000
16400
17300
14900
15900
6319
6322
-
-
7000
5100
9000
7200
11000
9200
13000
10800
Rodamiento
14000
11800
TABLA 2 - RODAMIENTOS DE ROLLOS - Serie NU 3
Intervalo de relubricación (horas de operación - posición horizontal)
Rodamiento
NU
NU
NU
NU
NU
NU
NU
NU
309
311
312
314
316
319
322
324
II pol os
60Hz
50Hz
9800
13300
6400
9200
5100
7600
1600
2500
-
IV polos
60Hz
50Hz
20000
20000
19100
20000
17200
20000
7100
8900
6000
7600
4700
6000
3300
4400
2400
3500
VI pol os
60Hz
50Hz
20000
20000
20000
20000
20000
20000
11000
13100
9500
11600
7600
9800
5900
7800
5000
6600
VIII po los
60Hz
50Hz
20000
20000
20000
20000
20000
20000
15100
16900
13800
15500
12200
13700
10700
11500
10000
10200
Observa ción:
X polos
60Hz
50Hz
20000
20000
20000
20000
20000
20000
16900
19300
15500
17800
13700
15700
11500
13400
10200
12100
XII po los
60Hz
50Hz
20000
20000
20000
20000
20000
20000
19300
20000
17800
20000
15700
20000
13400
17300
12100
15000
Grasa
(g)
13
18
21
27
34
45
60
72
NU 314 y mayores).
Para cada 15°C de elevación, el periodo de
relubricación se reduce a la mitad.
 Los periodos presentados en las tablas
anteriores, son para el uso de grasa Polyrex ®
EM.
Motores instalados en la posición vertical
deben tene r periodo de relubricación reducido
por la mitad.
Los rodamientos ZZ que van del 6201 hasta
el 6307 no necesitan ser relubricados, una vez
que la vida útil de estos rodamientos es
aproximadamente de 20.000 horas.
Las tablas 1 y 2 se destinan al periodo de
relubricación para temperatura de cojinete de
70°C (para rodamientos hasta 6312 y NU 312)
y temperatura de 85°C (para rodamientos 6314,
15
Es esencial que el montaje de los
rodamientos sea ejecutado en condiciones de
rigurosa limpieza, para asegurar el buen
funcionamiento y evitar daños. En el caso de
colocar rodamientos nuevos, éstos deberán
ser retirados de su embalaje solamente en el
momento previo de su montaje al motor.
Antes de la colocación de un rodamiento
nuevo, es necesario verificar si el alojamiento
del mismo en el eje se encuentra exento de
rebarbas o señales de golpes.
Para el montaje de los rodamientos
calentar la pista inte rna de los mismos utilizando
máquinas adecuadas (proceso inductivo de
calentamiento ), o en su defecto utilizar
herramientas apropiadas.
RECOMENDAMOS EL USO DE
ROLAMIENTOS DE ESFERAS PARA
MOTORES ACOPLADOS
DIRECTAMENTE A LA CARGA.
GRASA EN EXCESO PUEDE
PROVOVAR SOBREC ALENTAMIENTO
DE LOS RODAMIENTOS,
RESULTANDO DE DANOS
COMPLETOS.
Compatibilidad de la grasa Polyrex ®
EM con otros tipos de grasa:
Conteniendo espesante polyureia y aceite
mineral, la grasa Polyrex ® EM es compatible con
otros tipos de grasa las cuales contengan:
Base de litio o complejo de litio o polyureia y
aceite mineral altamente refinado.
Aditivo inhibidor contra corrosión, herrumbre
y aditivos antioxidantes.
PARTESYPIEZAS- REPUESTOS
Al solicitar piezas para reposición, es
conveniente indicar la designación completa del
motor, así como el código del mismo que
aparecen marcados en la placa de características.
Rogamos informen también el número
de serie indicado en la placa de características.
Nota s:
Aunque la grasa Polyrex ® EM sea compatible
con lis tipos de grasa mencionados arriba, no
recomendamos la mezcla con cualquier tipo de
grasa.
 Si Ud. necesita utilizar otro tipo de grasa
distinta de las recomendables arriba,
primeramente se contacte con Weg.
 Para aplicaciones en elevada o baja
temperatura ambiente, variación de velocidad,
etc, el tipo de grasa y el intervalo de lubrificación
son dados en una placa adicional fijada al motor.
MOTORESPARAAMBIENTES
PELIGROSOS
Además de las recomendaciones
anteriores se deben tener en cuenta las
siguientes:
LA UTILIZACIÓN DE MOTORES
NORMALES EN LOCALES Y/O
APLICACIONES ESPECIALES
DEBE ESTAR PRECEDIDA DE UNA
CONSULTA AL F ABRICANTE DE
GRASAS Y/O A WEG.
LA ESPECIFICACIÓN DEL LOCAL
PARA LA INSTALACIÓN DEL MOTOR
ES DE RESPONSABILIDAD DEL
USUARIO, QUE DETERMINARÁ LAS
CARACTERÍSTICAS DE LA
ATMOSFERA AMBIENTE.
DESMONTAJE YMONTAJE
Los motores para ambientes peligrosos
son fabricados conforme normas específicas
para estos ambientes, siendo certificados por
organismos acreditados.
El desmontaje y montaje del motor deberá
ser efectuado por personal cualificado,
utilizando solo herramientas y métodos
adecuados.
Las garras del extractor deberán estar
aplicadas sobre la pista interna del rodamiento
o sobre la tapa de rodamiento interior al intentar
extraer el rodamiento.
1 - Instalación
La
instalación
debe
seguir
procedimentos elaborados por la legislación
vigente en el lugar.
16
MOTORES ACCIONADOS POR
CONVERTIDORDEFRECUENCIA
LA INSTALACIÓN DE MOTORES
PARA AMBIENTES PELIGROSOS
DEBE SER EJECUTADA POR
PERSONAL ESPECIALIZADO Y LA
PROTECCIÓN TÉRMICA DEBERÁ
SIEMPRE SER INSTALADA, SEA
ESTA INTRINSEC A AL MOTOR O
EXTERNA AL MISMO, OPERANDO
CON CORRIENTE NOMINAL.
Rendimiento menor.
 Vibración mayor.
 Ruido mayor.
Corriente nominal mayor.
 Elevación de temperatura mayor.
 Vida util del aislamiento menor.
 Vida util de los rodamientos menor.
2 - Mantenimiento
El mantenimiento debe ser ejecutado por
talleres tecnicos autorizados y acreditados por
Weg Motores.
Talleres y personal sin autorización que
realicen reparación en los motores para
ambientes peligrosos, serán totalmente
responsables por el trabajo ejecutado y los
daños ocurridos en su servicio.
1- Motores normales.
Para tensión menor a 440V no hay necesidad
de utilizar filtros.
 Para tensión mayor o igual a 440V y menor a
575V, debe ser utilizado filtro para cables de
alimentación de motor mayores a 20 metros.
Para tensión igual o superior a 575V debe ser
utilizado filtro para cualquier largo de cable.
CUALQUIER MODIFICACIÓN
ELÉCTRICA O MECÁNICA EN LOS
MOTORES PARA AMBIENTES
PELIGROSOS ACARREARÁ LA
PÉRDIDA DE LA CERTIFICACIÓN
DE LOS MISMOS
EL NO CUMPLIMIENTO DE ESTAS
ORIENTACIONES CAUSA LA
PÉRDIDA DE GARANTÍA DEL
MOTOR.
En la ejecución del mantenimiento,
instalación y relubricación, se deben seguir las
siguientes orientaciones:
2- Motores Inverter Duty
Observar tensión de alimentación del conjunto
ventilación forzada.
No necesita instalación de filtros.
Verificar si los componentes están exentos de
rebabas, golpes y suciedad.
Observar si las piezas están en perfectas
condicione s.
Lubricar superficialmente los encastres de las
tapas con aceite protector para facilitar el montaje.
Utilizar solamente martillo de material blando
en la colocación de las piezas.
 Verificar si todos los tornillos están bien
apretados.
Utilizar sonda calibrada para verificar asiento
de la caja de conexiones (menor de 0,05 mm).
NO RECUPERAR PIEZAS
DAÑADAS O CON DESGASTE.
SUSTITUIR POR NUEVAS,
ORIGINALES DE FÁBRICA.
17
ESPAÑOL
Instalaciones con Convertidores de
Frecuencia sin filtro pueden modificar las
siguientes características de funcionamiento
del motor:
GARANTIA
Weg ofrece garantía contra defectos de
fabricación o de materiales para sus productos,
por un período de 12 meses, contados a partir
de la fecha de la emisión de la factura por parte
de fábrica o del distribuidor/revendedor,
teniendo como límite 18 meses de la fecha de
fabricación independiente de la fecha de
instalación del motor, siempre y cuando hayan
sido satisfechos los siguientes requisitos:
comprador, de los defectos detec tados y que
los mismos sean posteriormente analizados
por Weg como causados por defectos de
fabricación.
La garantía no incluye los servicios de
desmontaje del motor en las instalaciones del
comprador, costos de transporte del producto
y gastos de traslado, alojamiento y alimentación
del personal de Asistencia Técnica cuando
sean solicitados por el cliente.
• transporte, manipulación y almacenamiento
adecuados;
• instalación correcta y en condiciones
ambientales específicas y sin presencia de
gases corrosivos;
• operación dentro de los límites de la
capacidad del motor;
• realización periódica del debido
mantenimiento preventivo;
• realización
de
reparaciones
y/o
modificaciones al producto original efectuada
solo por los agentes autorizados de la Red de
Asistencia Técnica Weg;
• entregar el producto al proveédor en el caso
de ocurrir un fallo con reclamación de garantía
en un período mínimo suficiente como para
identificar la causa de la anomalia y su
conveniente reparación;
• dar aviso inmediato a Weg, por parte del
Los servicios en garantía serán prestados
exclusivamente en talleres de Asistencia
Técnica Autorizada Weg o en la propia fábrica.
Se excluyen de esta garantía los componentes
cuya vida útil, en uso normal, sea inferior al
período de garantía otorgado por Weg . Las
reparaciones o substituciones de piezas o
productos, a criterio de Weg o su Asistencia
Técnica Autorizada, no prorrogará el plazo de
garantía original.
La presente garantía se limita al producto
entregado, no siendo responsable Weg por
daños a personas, a terceros, a otros equipos
e instalaciones, lucros cesantes o cualquier
otro daño emergente o consecuente.
18
DEUTSCH
VOR MONTAGE DES MOTORS,
BITTEN WIR SIE DIESE
BETRIEBSANLEITUNG MIT ALLER
SORGFALT DURCHZULESEN!
Motoren, die nicht sofort nach Lieferung
installier t werden, sind in geschlossenen,
trockenen Räumen, frei von Staub, Gasen,
korrosiven Dämpfen und Schwingungen, bei
gleichmäßiger Temperatur und in normaler
Montageposi-tion zu lagern. Es dürfen keine
anderen Teile gegen den Motor gestellt werden.
Die Temperatur für das Largen von
Motren muss zwischen 5ºC und 60ºC, mit einer
Luftfeuchtigkeit nicht übes 50% fiegen.
Werden Motoren länger als als zwei Jahre
gelagert werden, müssen vor Inbetriebnahme
die Kugellager gewechselt werden, oder nach
entfernen des alten Fettes neu geschmiert
werden.
Bei Einphasenmotoren, die länger als zwei
Jahre gelagert werden, müssen die
Kondensatoren vor Inbetriebnahme gewechselt
werden.
Werden Motoren länger als 6 Monate in
Räumen mit hoher Feuchtigkeit gelagert,
empfehlen wir die Welle des Motors mindestens
einmal pro Monat von Hand zu drehen und vor
Inbetriebnahme den Isolationaswiderstand zu
messen.
Ist der Motor mit Stillstandsheiz ung
versehen, ist es empfehlenswert diese ständig
eingeschaltet zu lassen.
EINGANSPRÜFUNG
Unmittelbar nach dem Empfang ist der Motor
auf äußerliche Transportbeschädi-gungen zu
untersuchen.
Die auf dem Leistungschild angegebenen
Daten prüfen.
 Wenn vorhanden,Tranportsicherung vor
Inbetriebnahme entfernen.
Motorwelle muß von Hand frei drehbar sein.
HANDHABUNG UND TRANSPORT
1 - Allgemein
MOTOREN DÜRFEN NIEMALS AN
DER WELLE, SONDERN NUR AN
DIE DAFÜR VORGESEHENE
RINGSCHRAUBE GEHOBEN
WERDEN.
Hebevorrichtungen, wenn vorgesehen,
haben allein den Zweck den Motor zu heben. Ist
der Motor mit zwei Hebevorrichtungen
versehen, muß zum Transport eine Kette durch
diese Hebeösen gezogen werden.
Prüfung des Isolationswiderstandes
Anheben und Ablegen der Motoren muß
vorsichtig ohne Aufschlag gemacht werden, da
sonst die Kugellager beschädigt weden können.
Vor erstmaliger Inbetriebnahme und/oder
bei Feststellung von Feuchtigkeit an den
Wicklungen, muß der Isolationswider-stand der
Wicklungen ermittelt werden.
MOTOREN MIT
ZYLINDERROLLENLAGERN
BZW.SCHRÄGKUGELLA GERN
HABEN EINE
LÄUFERHALTEVORRICHTUNG, UM
TRANSPORTSCHÄDEN AN DEN
LAGERN ZU VERMEIDEN.
Der Widerstand bei 25ºC gemessen,
beträgt:
Ri  (20 x U) / (1000 + 2P) [M ]
(gemessen mit einem Widerstandsmeß-gerät
bei 500 Vdc); wo: U = Spannung (V); P =
Leistung (kW).
DIE TRANSPORTSICHERUNGEN
ODER
LÄUFERFESTSTELLVORRICHTUNGEN
NÜSSEN IMMER BEIM
TRANSPORT DES MOTORS
VERWENDET WERDEN, AUCH
WENN DIES DIE ABKUPPLUNG
DER ANGETRIEBENEN MASCHINE
ERFORDERT.
Liegt der gemessene Isolationswiderstand der Wicklung unter 2 MW, muß sie nach
der unten angegebenen Methode getrocknet
werden:
Den Motor in eine m Trockenschrank
mit einer Temperatur von 80ºC lagern.Die
Temperatur jede Stunde um 5ºC bis auf 105ºC
19
DEUTSCH
LAGERUNG
Motoren für gefährdeten Zonen dür-fen
nur in Gebieten eingebaut werden, wenn die
Angaben des Leistungsschildes dieser Zone
entsprechen.
erhöhen. Den Motor mindestens eine Stunde
bei dieser Temperatur halten.
Überprüfen, ob der Isolationswiderstand der Wicklung sich konstant verhält und
dem Mindestwiderstand entspricht. Wenn nicht,
eine neue Tränkung des Ständers vornehmen.
BEI MASCHINEN MIT KÜHLUNG
DURCH UMGEBUNGSL UFT, MUß
DIE KÜHLLUFT UNGEHINDERT
ZU- UND ABSTRÖMEN KÖNNEN.
DIE WARNE VOM MOTOR ABGEGEBEN LUFT DARF NICHT
WIEDER VOM LÜFFTER
ANGESAUGT WERDEN. DER
ABSTAND ZWISCHEN DEN LUFTEINTRITTSÖFFNUNGEN DES
MOTORS UND DER WAND SOLL
UNGEFÄHR ¼ DES
DURCHMESSERS DER LUFTEINTRITTSÖFFNUNG ENTSPRECHEN.
INSTALLATION
1 - Wartung und Installation
Der elektrische Anschluß und die
Motorschutzvorrichtungen müssen nach den
örtlichen Vorschriften ausgeführt werden. Installation, Inbetriebnahme, Wartung und
Reparaturen dürfen nur von qualifiziertem
Fachpersonal durchgeführt werden.
BEVOR WARTUNGSARBEITEN
GEMACHT WERDEN, VERGE
WISSERN SIE SICH BITTE, DAß
DER MOTOR VOM NETZ
GETRENNT IST.
3 - Fundament
Motoren mit Füßen müssen auf einem
festen Fundament aufgebaut werden um
Schwingungen zu vermeiden.
Die Motoren müssen gegen zufälliges
Eisnchalten geschützt sein.
Der Käufer trägt die Verantwortung für die
Vorbereitung des Maschinenfun-damentes.
Bei Wartungsarbeiten darauf achten, daß
Zusatzgeräte,
wie
Kondensatoren,
Frequenzumwandler oder ähnliches vom Netz
getrennt und entladen sind.
Stahlstrukturen sollten einen korrosionsschützenden Anstrich erhalten.
Um das Eindringen von Staub oder
Wasser in den Innern des Klemmen-kastens zu
verhindern, müssen die Öffnungen mit
Kabelverschraubung oder Genwinderohr
geschlossen werden.
4 - Entwässerungsöffnungen
Falls die Bauform des Motors nicht der
Standa rddausführung entspricht, ist zu
gewährleisten, daß alle Entwässerungsöffnungen nach unten gerichtet sind.
2 - Betriebsbedingungen
5 - Auswuchten
Elektrische
Motore
können
normalerweise bis zu einer Höhe von 1000 m
über den Meeresspiegel und einer
Umgebungstemperat ur bis höchstens 40ºC
ohne Leistungsreduktion eingebaut werden.
Abweichung sind auf dem Leistungschild
angegeben.
DIE WEG MOTOREN SIND
WERKSEITIG DYNAMISCH MIT
HALBER PASFEDER OHNE LAST,
ABGEK UPPELT A USGEWUCHTET.
Die Antriebselemente, wie Riemenscheiben, Kupplungen, usw. müssen
dynamisch mit halber Passfeder vor dem Einbau
ausgewuchtet Werden. Zum Auf-und Abziehen
der Antriebselemente immer dafür geeignete
Werkzeuge verwenden.
DIE STROM-, SPANNUNGS,
FREQUENZ-, UMDREHUNGS-,
LEISTUNGSWERTE, USW., DIE ZUM
BETRIEB ERFORDERLICH SIND,
MIT DEN DATEN DES LEISTUNGSSCHILDES VERGLEICHEN.
20
6 - Ausrichten
8 - Anschluß
WARNUNG:
Auch beim Stillstand des Motors können
gefährliche Spannungen im Klemmenkasten für
die Versorgung vom Heizelementen oder für
eine direkte Wicklungsbeheizung anliegen.
DIE WELLENENDEN GEGENSEITIG
AUSRICHTEN. WENN MÖGLICH
FEXIBLE KUPPLUNGEN
VERWENDEN.
Vor Inbewtriebnahme vergewissern, daß
Paralelität der Wellen gewährleitet ist.
Beim Auf- und Abziehen von Riemenscheiben, Kupplungen, usw. geeignete
Werkzeuge zur Vermeidung von Lagerschäden
benutzen.
FALSCHER ANSCHLUß KANN DIE
WICKLUNG DES MOTORS
ZERSTÖREN.
Bei Montage von Kupplungshälften
sicherstellen, daß der Luftspalt Y kleiner als
-0,05 mm und der Unterschied von X1 bis X2
kleiner als 0,05 mm ist.
Netz- und Anschlüsspannung laut
Leistunschild
beachten.
Spannungsschwankungen von ±10%, Frequenzschwankungen von ±5% und Schwankungen
der Summe der beiden von ±10% sind zulässig.
9 - Motorschaltungen
Motore sollten bevorzugt direkt
eingeschaltet we rden. Falls dies nicht möglich
ist,
sollten
geeignete
Lastund
Spannungsschaltungen gewählt werden.
Der Anschluß der Phasen in der
Reihenfolge L1, L2, L3 ergibt Rechtslauf, auf die
Kupllung gesehen.
Der Drehsinn kann durch Vertauschen
zweier beliebiger Kabel geändert werden.
Bemerkung: Maß X1 und X2 muß
min. 3mm sein
Ausrichtungstoleranz
7 - Riemenscheiben
UM EINE SICHERE VERBINDUNG
ZU GEWÄHRLEISTEN, SOLL DER
ANSCHLUß VON QUALIFIZIERTEM
FACHPERSONAL
DURCHGEFÜHRT WERDEN. NACH
DEM ANSCHLUß MUß
ÜBERPRÜFT WERDEN, OB NICHT
FREMDKÖRPER IM
ANSCHLUßKASTEN VERGESSEN
WURDEN. NICHT BENUTZTE
KABELEINGÄNGE MÜSSEN
VERSCHLOSSEN SEIN.
Wenn die Übertragung über Scheiben
und Riemen erfolgt, muß beachtet werden:
Daß die Riemen nur so viel gespannt sind,
daß sie während des Betriebes nicht schlupfen;
maximal zulässige Riemenspannung, den
entsprechenden Katalogen entnehmen.
ACHT UNG:
Übermäßiges Spannen der
Antriebsriemen hat Beschädigung der
Lager und Bruch der Welle
zur Folge !
Anschlußkabel entesprechend dem
Leistungsschild angegebener Stromstärke
auswählen.
21
DEUTSCH
WARNUNG:
Bei Einphasenmotoren, kann die Restladung des Kondensators auch beim
Stillstanddes Motors eine elektrische Spannung
über die Motorklemmen zur Folge haben.
1 - Allgem eine Überpr üfung
VOR DEM EINSCHALTEN DES
MOTORS, DIE ERDUNG PRÜFEN
UND SICHER-STELLEN, DAß SIE
VORSCHRIFTSMÄßIG
AUSGEFÜHRT WURDE.
GEEIGNETE ERDUNG IST
WICHTIG UM UNFÄLLE ZU
VERMEIDEN.
Überprüfen Sie den Motor in regel-mäßigen
Abständen.
Halten Sie den Motor sauber und sorgen Sie
für eine freie Kühllufzuführung und Abführung.
 Überprüfen Sie den Zustand der
Wellendichtungen (z. B. - V-Ring) und ersetzen
Sie sie , wenn nötig.
 Überprufen Sie den Zustand aller
Verbindungen und Verbindungselemente (z. B.
Schrauben).
 Überprüfen Sie den Zustand der
Lager auf ungewöhnliche Geräusche,
Lagertemperat urerhögung und Zustand des
Schmierfettes.
Im Falle von Zustandsveränderungen ist der
Motor zu zerlegen, die Bauteile zu untersuchen
und ggf. zu erneuern.
Diese Überprüfungsintervalle hängen
vom Motortyp und von den Arbeits - und
Umweltsbedingungen ab.
Wenn der Motor mit Schutzeinrichtungen, wie Temperaturfühler, Thermostate,
Thermistore, thermische Schutzeinrichtungen,
usw. ausgerüstet ist, sind die entsprechenden
Anschlüsse zu machen um die größte Sicherheit
zu gewährleisten.
10 - Einschalten
BEVOR DER MOTOR
EINGESCHALTEN WIRD,
PASSFEDER SICHERN ODER
ENTFERNEN.
SCHMIERUNG
UM EINEN SICHEREN BETRIEB
DES MOTORS ZU
GEWÄHRLEISTEN, SIND DIE
VORGESEHENEN
SCHMIERFRISTEN DER
KUGELLAGER EINZUHALTEN.
a) Der Motor muß ruhig laufen. Falls dies
nicht der Fall ist, Motor abschalten und Montage
und Anschlüsse vor einem neuen Einschalten
überprüfen.
1 - Motoren ohne Nachmiereinrichtung
b) Treten zu hohe Schwingungen auf,
überprüfen, ob die Befestigungsschrau-ben
angezogen sind, oder bestimmen, ob die
Schwingungen von angekuppelten Maschinen
übertragen werden.
Bis Achshöhe 200 sind die Motoren in der
Regel ohne Nachschmiervorrichtung gebaut.
Diese Motoren müssen wie folgt nach dem
Wartungspaln nachgeschmiert werden:
Motor sorgfältig zerlegen.
Altes Schmierfett entfernen.
 Lager
mit geeignetem
Waschmittel
auswaschen und mit Druckluft ausblasen.
Lager sofor wieder mit neuem Fett füllen.
c) Während einer kurzer Zeit die
Maschine mit Nennlast betreiben und den
Betriebsstrom mit dem des Leistungs-schildes
vergleichen.
2 - Motoren mit Nachmiervorrichtung
Um einen einwandfreiem Fettwechsel im
Innern des Lagers zu gewährleisten, wird
empfohlen den Motor während des Laufes
nachzuschmieren. Falls dies wegen drehender
Teile (Riemenscheiben, Kupplungen, usw.) in
der Nähe des Schmiernipples nicht möglich ist,
WARTUNG
WARNUNG:
SICHERHEITS - CHECK LIST
22
Das Einpressen des ganzen vorge-sehenen
Fettes mit einem mal kann das Eindringen des
Fettes im Innern des Motors verursachen.
soll folgendermaßen vorgegangen werden:
Schmiernippel und Schmiernippelumgebung
reinigen.
Ungefähr die Hälfte Menge des vorgesehenen
Fettes einpressen und den Motor während eine
Minute bei Nenn-drehzahl betreiben; den Motor
ausschal-ten und das restliche Fett einpressen.
ZUR NACHMIERUG NUR
HANDFERRPRESSEN
VERWENDEN
NACHSCHMIERINTERVALLER
TABELLE 1 - KUGELLAGER - Serie 62/63
Nachschmierintervall e (Betriebsstunden – horizontale Aufstellung)
IV polig
VI polig
VIII poli g
X polig
XII pol ig
Fettmenge
Lager
6209
60Hz
18400
50Hz
20000
60Hz
20000
50Hz
20000
60Hz
20000
Serie 62
50Hz
60Hz
20000
20000
6211
6212
14200
12100
16500
14400
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
11
13
Lager
6309
60Hz
15700
50Hz
18100
60Hz
20000
50Hz
20000
60Hz
20000
Serie 63
50Hz
60Hz
20000
20000
50Hz
20000
60Hz
20000
50Hz
20000
60Hz
20000
50Hz
20000
(g)
13
6311
6312
6314
6316
6319
11500
9800
3600
-
13700
11900
4500
-
20000
20000
9700
8500
7000
20000
20000
11600
10400
9000
20000
20000
14200
12800
11000
20000
20000
16400
14900
13000
20000
20000
17300
15900
14000
20000
20000
19700
18700
17400
20000
20000
19700
18700
17400
20000
20000
20000
20000
18600
20000
20000
20000
20000
18600
20000
20000
20000
20000
20000
18
21
27
34
45
6322
-
-
5100
7200
9200
10800
11800
15100
15100
15500
15500
19300
60
50Hz
20000
60Hz
20000
50Hz
20000
60Hz
20000
50Hz
20000
(g)
9
TABELLE 2 - ROLLENLAGER - Serie NU 3
Nachschmierintervall e (Betriebsstunden – horizontale Aufstellung)
II polig
Lager
NU 309
NU 311
NU 312
NU 314
NU 316
NU 319
NU 322
NU 324
60Hz
9800
6400
5100
1600
-
50Hz
13300
9200
7600
2500
-
IV polig
60Hz
20000
19100
17200
7100
6000
4700
3300
2400
50Hz
20000
20000
20000
8900
7600
6000
4400
3500
VI polig
60Hz
20000
20000
20000
11000
9500
7600
5900
5000
50Hz
20000
20000
20000
13100
11600
9800
7800
6600
VIII poli g
60Hz
20000
20000
20000
15100
13800
12200
10700
10000
50Hz
20000
20000
20000
16900
15500
13700
11500
10200
X polig
60Hz
20000
20000
20000
16900
15500
13700
11500
10200
50Hz
20000
20000
20000
19300
17800
15700
13400
12100
XII pol ig
60Hz
20000
20000
20000
19300
17800
15700
13400
12100
50Hz
20000
20000
20000
20000
20000
20000
17300
15000
Fettmenge
(g)
13
18
21
27
34
45
60
72
 Für jede Temperaturerhöhung von 15 0 C
reduziert sich der Nachmierintervall wiederum
um die Hälfte.
Die oben angegebenen Schmierintervalle
beziehen nur für den Einsatz von Polyrex ® Fette.
Bei Motoren der vertikalen Bauform reduziert
sich der Nachschmierintervall um die Hälfte im
Vergleich zu den Motoren der horizontalen
Bauform.
Bemerkung:
ZZ Kugellager von 6201 bis 6307 brauchen
nicht nachgeschmiert werden. Sie haben eine
Lebensadauerschmierung über 20.000
Betriebsstunden.
 Tabelle 1 und Tabelle 2 geben
Nachmierintervalle an für Lagertemperaturen
bis zu 70 0C (für Lager bis 6312 und NU 312)
und Temperaturen bis 85 0C (für Lager 6314
und NU 314 und größer).
23
DEUTSCH
II polig
Vorrichtungen werwenden, die auf die
Seitenfläche des abzuziehenden Innen-deckel
oder auf ein Nebenteil drücken müssen.
Um einen sicheren Betrieb zu gewährleisten und spätere Schäden zu vermei-den, is
es wichting, daß der Wechsel von Kugellagern
mit großer Sorgfalt und Sauberkeit
vorgenommen wird. Neue Kugellager sollen erst
kurz vor dem Einbau ausgepackt werden.
Vor dem Einbau neuer Kugellager
sicherstellen, daß Lagersitz gratfrei und ohne
Schlagmarken ist.
Zum aufziehen sollte das Lager im Ölbad
oder induktiv erhitzt werden. Niemals mit harten
Gegeständen auf das Lager schlagen.
WIR EMPFEHLEN KUGELLAGER
FÜR DIREKT GEKUPPELTE
MOTOREN.
ACHTUNG
ÜBERSCHUSS AN SCHMIERFETT
KANN LAGERÜBERHITZUNG
VERURSACHEN UND DAS LAGER
VOLLSTÄNDIG ZERSTÖREN.
Vertr äglich keit von Polyr ex ® E M
Schmierfe tt mit ande ren Fett en:
Polyrex ® EM enthält Verdickung auf
Polyuhrethanbasis und Mineralöl. Es ist daher
kompatibel mit anderen Schmierfetten , die
folgende Komponenten enthalten:
Lithium-Basis oder Zusammensetzungen aus
Lithium oder Polyuhrethan und hoch-raffiniertes
Mineralöl.
Additive gegen Korrosion, Rost und Additive
gegen Oxidation.
ERSATZTEILE
Bei der Bestellung von Ersatzteilen sollte
die vollständige Typenbezeichnung des Motors
(Leistungschild) angegeben werden.
Wenn der Motor mit einer Seriennummer
gekennzeichne t ist, so ist diese ebenfalls
anzugeben.
Anmerkun g:
 Obwohl Polyrex ® EM kompatibel ist mit
Schmierfetten wie oben beschrieben, empfehlen
wir es nicht mit anderen Fetten zu mischen .
Wenn Sie beabsichtigen andere Schmierfette
als die oben empfohlenen einzusetzen, fragen
Sie bitte bei WEG nach.
 Für Anwendungen mit hohen oder tiefen
Temperaturen, Drehzahlwechseln, etc., wird der
Typ des Schmierfettes und die Nachschmierfrist
auf einen zusätzli chen Typenschild am Motor
ausgewiesen.
MOTORENFÜR
EXPLOSIONSGEFÄHRDETE
BEREICHE
Ausser
den
oben
genannten
Empfehlungen is noch folgendes zu beachten:
DIE EINORDUNG DER
AUFSTELLUNGS-RÄUME NACH
VORKOMMENDEN
EXPLOSIONSFÄHIGEN
GEMISCHEN IST
VERANTWORTLICHKEIT DES
KUNDES.
BEI DER ANWENDUNG VON
STANDARDMOTOREN IN
SONDERUMGEBUNGEN ODER
SONDERANWENDUNGEN,
BITTEN WIR SIE SICH VON WEG
BERATEN ZU LASSEN.
Motoren für explosionsgefährdet e
Bereiche werden nach bestimmten Normen
hergestellt und von Prüfgesellschaften für diese
Bereiche Breiche bescheinigt.
DEMONTAGEUND MONTAGE
Demontage und Montage soll nur von
Fachpersonal, unter Verwendung von
geeigneten Werkzeugen und Methoden,
durchgeführt werden.
Zum Abziehen von Kugellagern,
Abdrückscharauben
bzw.
geeignete
1 -Aufstellung
Die Aufstellung muss unter Berücksichtung der lokalen Gesetzen vorge-nommen
werden.
24
DIE AUFSTELLUNG DER
MOTOREN IN
EXPLOSIONSGEFÄHRDETEN
BEREICHEN MUSS VON
QUALIFIZIERTEM PERSSONAL
VORGENOMMEN WERDEN. DIE
MOTOREN, WENN BEI
NENNSTROM BETRIEBEN,
MÜSSEN IMMER MIT
ENTSPRECHENDEM
THERMOSCHUTZ VERSEHEN
SEIN.DIESE SCHUTZEINRICHTUNG KANN BESTANDTEIL
DES MOTORS SEIN ODER
ÄUSSERLICH ANGEBAUT
WERDEN.
NICHT VERSUCHEN
BESCHÄDIGTE TEILE ZU
REPARIEREN. BESCHÄDIGTE
TEILE MÜSSEN GEGEN NEUE
VOM WERK HERGESTELLTE
TEILE ERSETZT WERDEN.
Wird der Motor über Fequenzumrichter ohne
Filter
betrieben,
können
folgende
Motoreigenschaften negativ beeinflusst werden:
Wirkungsgrad.
Schwingung.
Geräuschpegel.
Nennstrom.
Übertemperatur.
Lebensdauer der Isolation.
Lebendauer der Wälzlager.
2 - Wartung
Die Wartung sollte nur von geschultem
Fachpersonal oder WEG-Servicedienst
ausgeführt werden.
Wird die Reparatur dieser Motoren in nicht
zugelassenen Werkstätten von nicht
genehmeigtem Service-Personal durchge-führt,
trägt der Kunde alleinige Verantwor-tung für alle
Schaden, die durch diese Arbeit verursacht
werden können.
1 - Normmotoren
Bei Betriebsspannungen unter 440V, braucht
kein Filter eingesetzt werden
Bei Betriebsspannungen gleich oder höher
als 440V, aber niedriger als 575V, müssen, wenn
die Kabel zwischen Motor und Umrichter
länger als 20 m sind, Filter eingesetzt werden.
Bei Betriebsspannungen gleich oder höher
als 575V, müssen immer, unab-gesehen von
der Kabellänge, Filter eingesetzt werden.
JEDE ELEKTRISCHE ODER
MECHANI-SCHE ÄNDERUNG
DER MOTOREN FÜR
EXPLOSIOSGEFÄHRDETE
BEREICHE ERKLÄRT DIE
BESCHEINIGUNG DIESER
MOTOREN UNGÜLTIG.
Bei der Auftellung, Wartung und
Nachschmierung muß folgendes beachtet
werden:
Sicherstellen, dass die Bauteile frei von Grat,
Schmutz oder Schlagmarken sind.
Besichtigen, ob die Bauteile einwand-freiem
Betriebszustand aufweisen.
Die Zusammenbauflächen der Lagerschilder
einölen um den Einbau zu erleichtern.
Zur Montage nur Gummihammer verwenden
 Sicherstellen, dass alle Schrauben fest
engezogen sind.
 Zur
Messung
des
Spieles
des
Klemmenkastensitzes eine Lehre benutzen
(kleiner als 0,05mm).
DIE NICHTEINHALTUNG DIESER
EMPFEHLUNGEN FÜHRT ZUR
AUFHEBUNG DER GARANTIE.
2 - Motoren für Umrichterbetrieb (Inverter
Duty)
Bei Motoren für Umrichterbetrieb, die
Betrieb sspannung des Motors für die
auferzwungene Kühlung beobachten.
Motoren
diese Reihen erfordern keinen
Einsatz von Filter Filter.
25
DEUTSCH
MOTORENÜBER
FREQUENZUMRICHTERBETRIEBEN
GEWÄHRLEISTUNGEN
Die Gewährleistungsfrist der WEG- Produkte
beträgt 12 Monate fü r Material-mängel,
Konstruktion oder Ausführung. Sie Beginnt mit
dem Rechnungsdatum des Herstellers oder
Verteiler/Verkäufer und endet spätestens 18
Monate nach dem Herstell ungsdatum,unter
Berücksich-tigung und Einhaltung folgender
Bedingungen:
verbundenen Kosten ein, wie Transport des
• sofortige Benachrichtigung des Kunden
über die aufgetretenen Fehler, die später von
WEG als Herstellungsfehler bestätigt werden
müssen.
Produktes,
Reise-,
und
Aufenthaltskosten
des
Kundendienstpersonals, sowie die Kosten für den Ein- und
Ausbau
beim
Besteller.
Die
Kundendienstleistungen
während der
Gewährleistu ngsfrist werden allein in WEG
Kundendienstwerkstätten oder im Werk des
Herstellers vorgenommen.
• geeigneter Transport, Handhabung und
Lagerung;
• Korrekte Aufstellung unter vorgeschriebenen Umgebungsbedingungen, ohne die
anwesenheit von aggressiven Mitteln;
• Betrieb unter Berücksichtigung der Daten
des Leistungschildes;
• Ausführung der vorbeugenden Wartung in
vorgesehenen Zeitabständen;
• Ausführung von Reparaturen / Ände-rungen
nur durch WEG-Service-Personal;
• Das fehlerhafte Produkt während einer
Mindestzeitspanne zur Reparatur zur
Verfügung stellen, um während dieser Zeit die
Ursache des aufgetretenen Problems
festzustellen und die entsprechende
Reparatur ausführen zu können;
Von
dieser
Gewährleistung
sind
ausgeschlossen die Bauteile, deren
Lebensdauer unter normalem Einsatz kürzer
ist als die vorgesehene Gewährleistungsfrist.
Eine während der Garantiezeit aus geführte
Reparatur oder Ersatzteill eistung verlängert
die Garantiezeit nicht.
Diese Gewährleistung beschränkt sich allein
auf das gelieferte Produkt. WEG trägt keine
Haftung für
Personenver-letzung,oder
Schaden an andere Einrichtungen/Geräten,
Gewinnverlust oder irgendwelche sich
ergebende Folgenschäden.
Die Gewährleistung schließt nicht die damit
26
FRANÇAIS
STOCKAGE
LIRE ATTENTIVEMENT CET TE
NOTICE AVANT D’INSTALLER LE
MOTEUR.
Les moteurs qui ne sont pas directement
installés doivent être stockés dans un endroit
sec, à l’abri des poussières, des vibrations, des
fumées et vapeurs corrosives, des variations de
température, et en position normale, séparés des
autres objets.
CONTROLE A LA RECEPTION
Vérifier que le moteur n’a subi aucun dommage
pendant le transport.
Vérifier les données de la plaque signalétique.
Enlever le dispositif de blocage de I’axe (s’il y
en a un) avant de faire tourner le moteur.
Faire tourner l’arbre à la main pour s’assurer
qu’il tourne librement.
La température de stockage des moteurs
doit rester parmi 5ºC et 60ºC, avec l’humidité
pas excédant 50%.
MANUTENTION ET TRANSPORT
1 - Généralités
Nous recommandons de faire tourner
l’arbre, à la main, au moins une fois par mois, et,
avant install ation, de mesurer la résistance
d’isolation des moteurs stockés depuis plus de
6 mois, ou dans des zones à forte humidité.
UN MOTEUR NE DOIT JAMAIS
ÊTRE SOULEVÉ PAR SON ARBRE,
MAIS PAR LES OEILLETS DE
LEVAGE, QUI SONT CALCULÉS
POUR EN SUPPORTER LE POIDS.
Si le moteur est muni de résistances de
réchauffage, celles-ci devraient être mises en
service.
Les accessoires de levage, s’il y en a, sont
calculés pour supporter uniquement le poids
du moteur. S’il y en a deux, il faut utiliser une
chaîne double pour soulever le moteur.
Vérification de la résistance d’isolement
Les mouvements de levée et de pose
doivent être fait s en douceur, sans aucun choc,
sinon les roulements pourraient être
endommagés.
II faut mesurer la résistance d’isolement
avant de mettre le moteur en service, et / ou si
l’on suspecte que les enroulements soient
humides.
PENDANT LE TRANSPORT, LES
ROULEMENTS DES MOTEURS À
ROULEMENTS À ROULEAUX OU À
CONTACT ANGULAIRE SONT
PROTÉGÉS PAR UN DISPOSITIF DE
BLOCAGE DE I’AXE.
La résistance, mesurée à 25ºC doit être:
Ri  (20 x U) / (1000 + 2P) [M ]
(mesuré avec un MEGGER à 500 V CC);
ou U = tension (en V); P = puissance (en kW).
Si la résistance d’isolement est inférieure
à 2 Mohms, les enroulements doivent être séchés
en chauffant le moteur dans une étuve, à un
minimum de 80ºC, augmentant de 5ºC toutes
les heures jusque 105ºC, et restant à cette
température pour au moins 1 heure.
CE DISPOSITIF DE BLOCAGE DOIT
ÊTRE UTILISÉ LORS DE TOUT
TRANSPORT
ULTÉRIEUR
DU
MOTEUR, MÊME SI CECI IMPLIQUE
LE
DÉMONT AGE
DE
SON
ACCOUPLEMENT
AVEC
LA
MACHINE ENTRAÎNÉE.
Vérifier que la résistance d’isolement reste
27
FRANÇAIS
Si un moteur est conservé en stockage
pour plus de deux ans, les roulements doivent
être remplacés, ou la graisse complètement
éliminée et nettoyée.
Pour les moteurs monophasés, après
deux ans de stockage il faut remplacer les
condensateurs (s’il y en a).
constante et conforme aux valeurs prévues. Si
non, l’imprégnation du stator doit être refaite.
Les moteurs fournis pour installation en
zone à risques ne peuvent être installés que dans
des zones dont les caractéristiques
correspondent à celles définies sur la plaque
signalétique.
INSTALLATION
1 - Sécurité
VEILLER À GARDER LES ORIFICES
D’ENTRÉE ET DE SORTIE D’AIR
BIEN DÉGAGÉS ET PROPRES. L’AIR
EXTRAIT DU MOTEUR NE DEVRAIT
PAS SE MÉLANGER À L’AIR
ENTRANT. LA DISTANCE ENTRE
L’ENTRÉE D’AIR ET LA PAROI NE
DEVRAIT PAS ÊTRE INFÉRIEURE À
¼ DU DIAMÈTRE DE L’ORIFICE
D’ENTRÉE D’AIR.
Tout le personnel qui installe des
systèmes électriques (y compris manutention,
levage), en utilise ou en assure la maintenance
doit être bien au courant des normes et règles
de sécurité applicables, et doit les respecter
soigneusement.
Nous recommandons de réserver ces
activités à du personnel dûment qualifié.
3 - Fondation
S’ASSURER DE CE QUE
L’ALIMENTATION DES MOTEURS
ÉLECTRIQUES SOIT COUPÉE
AVANT TOUTE OPÉRATION DE
MAINTENANCE, ET PROTÉGÉE
CONTRE T OUTE MISE SOUS
TENSION ACCIDENTELLE.
Les moteurs munis de pattes doivent être
installés sur une fondation rigide pour éviter les
vibrations excessives.
L’acheteur est ent ièrement responsable de
cette fondation.
Déconnecter le moteur de son alimentation, et vérifier que tous les accessoires, soient
également mis à l’arrêt et déconnectés.
Pour éviter toute pénétrat ion de poussière
et / ou d’eau dans la boîte à bornes, munir les
orifices d’entrée des conducteurs de presseétoupes ou de tubes filetés.
Les pièces métalliques doivent être peintes
pour les protéger de la corrosion.
La fondation doit être plane et
suffisamment résistante pour supporter tout
effort de chocs elle doit être conçue pour amortir
toute vibration qui serait due à mise en
résonnance.
Pour éviter tout dommage, ne pas
modifier la régulation des dispositifs de
protection.
4 - Orifices de drainage
Si la configuration d’installati on est
différente de celle prévue à la commande,
s’assurer, dans la configuration envisagée, de
ce que les orifices de drainage des condensats
se trouvent bien à la partie inférieure.
2 - Conditions de service
Sauf autre indication sur la plaque
signalétique, les moteurs sont en général
calculés pour être utilisés à une altitude d’au
maximum 1000 m au dessus du niveau de la
mer, à des températures ambiantes comprises
entre 0 et 40ºC.
5 - Equilibrage
LES MOTEURS WEG FONT I’OBJET
D’UN ÉQUILIBRAGE DYNAMIQUE,
AVEC DEMI-CLAVETTE, À VIDE ET
SANS ACCOUPLEMENT.
VÉRIFIER LA CONFORMITÉ DES
CARACTÉRISTIQUES DE
TENSION, INTENSITÉ,
FRÉQUENCE, VITESSE,
PUISSANCE, ETC. DU MOTEUR,
INDIQUÉES SUR LA PLAQUE
SIGNALÉTIQUE, AUX VALEURS
PRÉVUES À LA COMMANDE.
Les éléments de transmission, tels que les
poulies, accouplements, etc.; doivent faire I’objet
d’un équilibrage dynamique avec demi-clavette,
avant installa tion. Toujours utiliser un outillage
approprié pour le montage et le démontage.
28
6 - Alignement
ATTENTION:
Le
condensateur
d’un
moteur
monophasé peut conserver une charge
résiduelle, qui apparaît aux bornes du moteur,
même après l’arrêt.
ALIGNER LES BOUTS D’ARBRE ET
UTILISER DES ACCOUPLEMENTS
FLEXIBLES CHAQUE FOIS QUE
C’EST POSSIBLE.
S’assurer de ce que les fixations du moteur
ne permettent pas d’altérations de l’alignement,
qui pourraient être cause de dommages aux
équipements.
UN RACCORDEMENT ERRONÉ
PEUT GRILLER LE MOTEUR!
La tension et le mode de connexion sont
indiqués sur la plaque signalétique. Les
variations maximum acceptables sont de 10%
pour la tension, de 5% pour la fréquence, et de
10% pour le total des deux.
Lors
du
montage
d’un
demiaccouplement, veiller à utiliser un outillage
approprié pour protéger les roulements.
Montage
correct
d’un
demiaccouplement: vérifier que le jeu Y soit inférieur
à 0,05 mm, et que la différence X1 - X2 soit
également inférieure à 0,05 mm.
De préférence, démarrer le moteur en
direct. Si ce n’est pas possible, employer une
méthode compatible avec la charge et la tension
du moteur.
Le sens de rotation est le sens horlogique,
lorsque le moteur est vu du côté de
I’accouplement et si la séquence de connexion
des phases est L1, L2, L3.
Pour changer le sens de rotation,
intervert ir deux des trois conducteurs
d’alimentation.
Note: L’ecarts X1 et X2 doit être d’un
minimum de 3mm
Figure, dessin et tolérances d’alignement
7 - Transmission par courroie
En cas de transmission par poulie et
courroie, il faut tendre la courroie juste assez
pour éviter le glissement en fonctionnement,
conformément
aux
spécifications
du
fournisseur.
LE RACCORDEMENT AU RÉSEAU
D’ALIMENTATION DOIT ÊTRE
EFFECTUÉ PAR DU PERSONNEL
COMPÉTENT, EN VEILLANT À
ASSURER UNE CONNEXION SÛRE
ET DURABLE. APRÈS
RACCORDEMENT DU MOTEUR,
VÉRIFIER QU’IL NE RESTE AUCUN
CORPS ÉTRANGER DANS LA
BOÎTE À CONNEXIONS,
ET VEILLER À FERMER LES
ENTRÉES DE CÂBLE NON
UTILISÉES.
ATTEN TION :
Une tension excessive peut
endommager les roulements et conduire à
la rupture de l’arbre.
8 - Raccordement électrique
ATTENTION:
Même lorsque le moteur est à l’arrêt,
certaines bornes de la boîte à connexions
peuvent rester sous tension, pour l’alimentation
de résistances de réchauffage, ou pour le
chauffage direct des enroulements.
Veiller à utiliser les dimensions de câbles
correctes, correspondant aux intensités
indiquées sur la plaque signalétique.
29
FRANÇAIS
9 - Méthode de démarrage
Si, en fonctionnement normal, une variation
est décelée, vérifier le moteur et remplacer les
pièces qui devraient l’être.
AVANT DE METTRE LES BORNES
SOUS TENSION, VÉRIFIER QUE LA
MISE À LA TERRE SOIT FAITE
CONFORMÉMENT AUX NORMES
APPLICABLES. CECI EST ESSENTIEL
POUR LA PROTECTION CONTRE
LES RISQUES D’ACCIDENT.
La périodicité des vérifications est
fonction du type de moteur et des conditions de
service.
LUBRIFICATION
Si le moteur est muni de dispositifs de
protection thermique, ou de surveillance de la
température, tels que thermostats, thermistors,
etc., veiller à raccorder ceux-ciaux appareils
correspondants du tableau de commande.
RESPECTER LA PÉRIODICITÉ DE
GRAISSAGE, CELLE-CI EST
FONDAMENTALE POUR LE BON
FONCTIONNEMENT DU MOTEUR.
10 - Démarrage
1 - Moteurs sans graisseurs
LA CLAVETTE DOIT ÊTRE BIEN
FIXÉE, OU ENLEVÉE, AVANT TOUT
DÉMARRAGE DU MOTEUR.
Les moteurs jusqu’au type 200 ne
comportent normalement pas de graisseur. Dans
ce cas, le graissage se fait, lors de la maintenance
préventive, de la façon suivante:
a) Le moteur doit démarrer et fonctionner
de façon régulière. Si ce n’est pas le cas, I’arrêter
et vérifier les connexions et le montage avant de
le démarrer à nouveau.
Démonter précautionneusement le moteur.
Enlever toute la graisse.
Nettoyer le roulement avec du kérosène ou du
diesel.
 Directement renouveler le graissage du
roulement.
b) En cas de vibration excessive, vérifier
que les fixations soient correctement serrées.
Vérifier également si les vibrations ne
proviennent pas d’une machine voisine. Un
contrôle périodique des vibrations doit être
effectué.
2 - Moteurs avec graisseurs
II est fortement conseillé d’effectuer le
graissage pendant le fonctionnement, pour
assurer la répartition de la graisse dans le carter
de palier. Si ce n’est pas possible, à cause de
pièces en rotation trop proches des graisseurs
(poulies, etc.), qui risqueraie nt de blesser
l’opérateur, procéder comme suit:
c) Faire fonctionner le moteur à sa charge
nominale pendant une courte durée, et vérifier
que le courant correspond à celui indiqué à la
plaque signalétique.
MAINTENANCE
Nettoyer la zone a utour du graisseur.
Injecter environ la moitié de la quantité de
graisse et faire tourner le moteur pendant une
minute à pleine vitesse; puis l’arrêter et injecter le
restant de la quantité de graisse.
L’injection de la quantité tota le de graisse en
une fois quand le moteur est à I’arrêt, risquerait
de faire pénétrer la graisse dans le moteur, au
travers du joint d’étanchéité intérieur du
roulement.
ATTENTION:
LISTE DE SECURITÉ
1 - Vérification générale
Vérifier régulièrement le moteur.
 Le garder propre et assurer une bonne
ventilation.
Vérifier les joints d’étanchéité des “V Ring”, les
remplacer si nécessaire.
Vérifier l’état des connexions et des fixations.
 Vérifier
les
roulementes,
et
plus
particulièrement leur température, leur graissage
et l’absence de bruit excessif.
POUR L UBRIFIC ATION SI DOIT
USER SEULEMENT UN
COMPRESSEUR A GRAISE
MANUAL.
30
PERIODICITÉ DU GRAISSAGE
TABLE 1 - ROULEMENTS À BILLES - Série 62/63
Periodicité du graissage (heures de travail - position horizontale)
Pole IV
Pole VI
Pole
Série 62
50Hz
60Hz
20000
20000
20000
20000
20000
20000
Série 63
Palier
6209
6211
6212
60Hz
18400
14200
12100
50Hz
20000
16500
14400
60Hz
20000
20000
20000
50Hz
20000
20000
20000
60Hz
20000
20000
20000
Palier
6309
6311
6312
6314
6316
6319
60Hz
15700
11500
9800
3600
-
50Hz
18100
13700
11900
4500
-
60Hz
20000
20000
20000
9700
8500
7000
50Hz
20000
20000
20000
11600
10400
9000
60Hz
20000
20000
20000
14200
12800
11000
50Hz
20000
20000
20000
16400
14900
13000
6322
-
-
5100
7200
9200
10800
VIII
Pole X
Pole XII
Graisse
50Hz
20000
20000
20000
60Hz
20000
20000
20000
50Hz
20000
20000
20000
60Hz
20000
20000
20000
50Hz
20000
20000
20000
(g)
9
11
13
60Hz
20000
20000
20000
17300
15900
14000
50Hz
20000
20000
20000
19700
18700
17400
60Hz
20000
20000
20000
19700
18700
17400
50Hz
20000
20000
20000
20000
20000
18600
60Hz
20000
20000
20000
20000
20000
18600
50Hz
20000
20000
20000
20000
20000
20000
(g)
13
18
21
27
34
45
11800
15100
15100
15500
15500
19300
60
TABLE 2 - ROULEMENTS À ROULEAUX - Série NU 3
Periodicité du graissage (heures de travai - position horizontale)
Palier
NU 309
Pole II
60Hz
50Hz
9800
13300
Pole IV
60Hz
50Hz
20000
20000
Pole VI
60Hz
50Hz
20000
20000
Pole VIII
60Hz
50Hz
20000
20000
Pole X
60Hz
50Hz
20000
20000
Pole XII
60Hz
50Hz
20000 20000
NU
NU
NU
NU
NU
6400
5100
1600
-
9200
7600
2500
-
19100
17200
7100
6000
4700
20000
20000
8900
7600
6000
20000
20000
11000
9500
7600
20000
20000
13100
11600
9800
20000
20000
15100
13800
12200
20000
20000
16900
15500
13700
20000
20000
16900
15500
13700
20000
20000
19300
17800
15700
20000
20000
19300
17800
15700
20000
20000
20000
20000
20000
18
21
27
34
45
-
-
3300
2400
4400
3500
5900
5000
7800
6600
10700
10000
11500
10200
11500
10200
13400
12100
13400
12100
17300
15000
60
72
311
312
314
316
319
NU 322
NU 324
Note:
Graisse
(g)
13
verticale, leur intervalle de regraissage est réduit
a la moitié si comparé aux moteurs utilisés en
position horizontale.
Les paliers ZZ de 6201 jusqu’à 6307 n’exigent
pas de regraissage car leur vie utile est autour
de 20,000 heures.
Les tables 1 et 2 sont de stinés pour le temps
de graissage sous une temperature du palier
de 70°C (pour paliers jusqu’à 6312 e t NU 312)
et température de 85°C (pour les paliers 6314
et les NU 314 e t plus grand).
Pour chaque augmentation de 15°C de la
temperature du pali er, le temps de regraissage
est réduit a la moitié.
Les termps de regraissages données cidessus sont pour les cas qui s’appliquent la
graisse Polyrex ® EM.
Quand les moteurs sont utilisés en position
NOUS RECOMMANDONS
L’UTILISATION DES ROULEMENTS
A BILLES POUR LES MOTEURS
MONTES EN ACCOUPLEMENT
DIRECT.
ATTENTION :
UN EXCES DE GRAISSE PEUT
CAUSER DES DOMMAGES
IRREMEDIABLES AU ROULEMENT
DUS A UNE SURCHAUFFE.
31
FRANÇAIS
Pole II
Pour monter un roulement, chauffer sa
partie interne avec l’équipement adéquat
(procédé inductif) ou utiliser l’outil adéquat.
Compta bilité de la grais se Polyre x ®
EM avec les autres graisses :
La graisse Polyrex ® EM contient du
polyurea et l’huile minérale qui la rend
compatible avec les graisses contenant :
Lithium, composé de lithium ou polyurea et
huile minérale hautement raffinée.
 Additif anti-corrosion, anti-rouille et antioxydant.
PIECESDERECHANGE
Lors de la commande de pièces de
rechange, veuillez veiller à spécifier la
désignation complète de type et le code de
produit, de même que le numéro de série du
moteur, tels qu’indiqués sur la plaque
signalétique.
Notes :
 Bien que la graisse Polyrex ® EM soit
compatible avec les graisses mentionnées cidessus, nous déconseillons le mélange avec
d’autres graisses.
Avant toute utilisation d’une autre graisse que
celle préconisée, nous vous prions de contacter
WEG.
 Les applications en hautes ou basses
températures, variation de vitesse, etc…, le type
de graisse et l’intervalle de lubrification seront
indiqués sur une plaque signalétique
additionnelle fixée sur le moteur.
MOTEURS POUR ZONES A RISQUES
Veiller à respecter les recommandations
suivantes, en plus de celles indiquées
précédemment:
LA DÉFINITION DE L’ENDROIT
OÙ INSTALLER LE MOTEUR, DE
MÊME QUE LA DÉTERMINATION
DES CARACTÉRISTIQUES DE
L’ENVIRONNEMENT, SONT DU
DOMAINE DE RESPONSABILITÉ
DU CLIENT.
TOUJOURS CONSULTER LE
FABRICANT DES LUBRIFIANTS OU
WEG, EN C AS D’UTILISATION DE
MOTEURS STANDARDS DANS DES
ZONES SPÉCIALES OU POUR DES
UTILISATIONS PARTICULIÈRES.
Les moteurs pour zones à risques sont
fabriqués suivant les normes spécifiques à ces
environnements, et sont certifiés par des
organisations de certification internationales.
DEMONTAGE ET MONTAGE
Le démontage et le remontage doivent être
effectués selon procédure appropriée, par du
personnel qualifié, utilisant I’outillage
convenable.
1 - Installation
L’installation doit se faire en con formité
avec la réglementation locale applicable.
L’extracteur doit être appliqué sur la face
latérale de I’anneau intérieur à démonter, ou sur
une pièce adjacente.
L’INSTALLATION DE MOTEURS
POUR ZONES À RISQUES NE
DOIT ÊTRE EFFECT UÉE QUE PAR
DU PERSONNEL COMPÉTENT, ET
LA PROTECTION THERMIQUE
DOIT TOUJOURS ÊTRE
INSTALLÉE, QUE CE SOIT
EXTERNE OU INTERNE AU
MOTEUR, POUR FONCTIONNER
À L’INTENSITÉ NOMINALE.
II est essentiel que le démontage et le
remontage des roulements soient faits dans un
environnement propre, pour assurer un bon
fonctionnement et éviter toute avarie. Les
nouveaux roulements ne seront extraits de leur
emballage qu’au moment de les monter.
Avant d’installer un nouveau roulement,
il faut vérifier l’absense d’arêtes vives ou de traces
de coups sur I’arbre.
32
Hausse de la température.
Isolation du moteur réduite.
Durée de vie des roulements réduite.
2 - Maintenance
La maintenance doit être assurée par un
atelier de réparation agréé par Weg.
1 - Moteurs standards
Un atelier ou du personnel non agréé par
Weg, qui effectue toute intervention de maintenance sur un moteur pour zones à risques, sera
pleinement responsable de cette intervention et
de tout dommage qui en résulterait.
Tensions inférieures à 440 V n’exige pas
de filtre.
Tensions équivalentes ou supérieure à 440 V
ou inférieures à 575 V exigent un filtre pour des
cables d’alimentation en puissance du moteur
plus long que 20 mètres.
Tensions équivalentes ou plus élevées que
575 V exigent un filtre pour toute dimension de
cables d’alimentation.
TOUTE MODIFIC ATION
ÉLECTRIQUE OU MÉCANIQUE
D’UN MOTEUR POUR ZONES À
RISQUES INVALIDE SA
CERTIFICATION.
Lors de toute intervention de
maintenance, installation, graissage, respecter
les consignes suivantes:
2 - Nouvelle série de Moteurs adaptés au
convertisseur
Vérifier que tous les composants sont propres,
exempts d’arêtes ou coups.
Vérifier que toutes les pièces sont en état parfait.
 Graisser les surfaces des garnitures de
protection avec une huile de protection pour
faciliter l’assemblage.
N’utiliser que des marteaux en caoutchouc
pour assembler les pièces.
Vérifier le serrage correct des écrous.
 Utiliser une jauge pour vérifier le jeu de
l’assemblage de la boîte à bornes (moins de
0,05 mm).
Contrôler la tension fournie par l’ensemble
de refroidissement forcé.
 Filtres ne sont pas demandés.
NE PAS RÉUTILISER DE PIÈCES
ENDOMMAGÉES OU USÉES. LES
REMPLACER PAR DES PIÈCES
NEUVES D’ORIGINE.
MOTEURSENTRAINESPAR
CONVERTISSEURDEFREQUENCE
Applications comportant l’utilisation d’un
convertisseur de fréquence sans filtre peut
affecter les performances de la manière
suivante:
Rendement moins élévé.
Vibration plus élevée.
Niveau de bruit plus élevé.
Courant nominal plus élevé.
33
FRANÇAIS
SI DE TELLES
RECOMMANDATIONS NE SONT
PAS SUIVIES, LA GARANTIE DU
MOTEUR S’ANNULE.
CONDITIONSDEGARANTIE
Weg garantit ses produits contre tout défaut
de matériaux et de main d’oeuvre pour douze
(12) mois à partir de la date de la facture émise
par l’usine, le distributeur autorisé ou l’agent,
avec une limite de dix-huit (18) mois après la
date de fabrication, indépendamment de la
date d’installation, pour autant que les
conditions suivantes soient satisfaites:
Cette garantie n’inclut pas le démontage dans
les installations de l’acheteur, ni les coûts de
transport, les frais de logement et subsistance
du personnel technique si requis par le client.
Le service de la garantie ne sera assuré que
dans des Ateliers Agréés Weg ou dans les
usines de Weg.
Les composants dont la vie utile, en usage
normal, est inférieure à la durée de la garantie,
ne sont pas couverts par les termes de la
présente garantie.
• Transport, manutent ion et stockage
appropriés;
• Installation correcte sur base des conditions
d’ambiance spécifiées, et absence de vapeurs
corrosives;
• Fonctionnement dans les limites d’utilisation;
• Respect de la périodicité des interventions
de maintenance;
• Réparation et / ou remplacement effectués
seulement par du personnel dûment autorisé
par écrit par Weg;
• Le produit defaillant sera mis à disposition du
fournisseur et / ou de l’atelier de réparation le
temps nécessaire pour déterminer la cause
de la défaillance et la réparation
correspondante;
• Information immédiate par l’acheteur de toute
défaillance survenue, et que celle-ci soit
acceptée par Weg comme défaut de
fabrication.
La réparation et / ou le remplacement de
pièces ou composants, effectués par Weg et
/ ou tout Atelier Agréé Weg, ne donne pas lieu
à extension de la garantie.
Ceci constitue la seule garantie de Weg pour
cette vente, et la société n’est en rien liée ou
obligée en quoi que ce soit vis-à-vis de
personnes,
tierces
parties,
autres
équipements ou installations, y compris, sans
aucune limitation, toute réclamation pour
dommages conséquents ou coûts de
production.
34
ITALIANO
IMMAGAZZINAGGIO
SI PREGA DI LEGGERE CON
AT TENZIONE QUESTO MANU ALE
PRIMA D’INIZIARE
I’INSTALLAZIONE.
Se i motori non sono installat i
immediatamente, devono essere immagazzinati
in luogo asciutto, privo di polvere, di vibrazioni,
di gas, di fumi corrosivi, con temperat ura
uniforme, mettendoli in posizione normale e
senza accostarli con altri oggetti.
La temperatura di stoccaggio dei motori
dovrà rimanere tra 5ºC e 60ºC, con una umidità
relativa non oltre 50%.
Nel caso di motori con più di 2 anni di
magazzinaggio, si devono cambiare i cuscinetti
o sostituire tutto il grasso dopo la pulizia.
Nei motori monofasi in magazzino da 2
anni si devono cambiare i condensatori
(quando provvisti).
CONTROLLO DI RICEVIMENTO
Verificare se il motore non ha subito danni
durante il trasporto.
Verificare i dati di targhetta.
 Rimuovere il dispositivo di bloccaggio
dell’albero usato per il trasporto (quando il
caso), prima di far partire il motore.
Girare l’albero per verificare se lo stesso è libero.
MANEGGIAMENTO E TRASPORTO
I MOTORI NON DEVONO ESSERE
SOLLEVATI PER L’ALBERO, MA PER
GLI ANELLI DI SOLLEVAMENTO,
CHE SONO PROGET TATI PER IL
PESO DEL MOTORE.
Controllo della resistenza d’isolamento
Dispositivi di sollevamento, quando
forniti, servono appena per alzare il motore. Se
il motore è provvisto di due dispositivi di
sollevamento, si deve usare una catena doppia.
Misurare la resistenza d’isolamento prima
della messa in servizio del motore e/o quando si
sospetti l’esistenza di umidità nell’avvolgimento.
II sollevamento e deposito deve essere
dolce, senza urti, perchè altrimenti i cuscinetti
possono essere danneggiati.
La resistenza, misurata a 25ºC, deve
essere:
Ri  (20 x U) / (1000 + 2P) [M ]
(misurato con MEGGER a 500 V.c.c.);
dove U = tensione (V); P = potenza (kW).
MOTORI CON CUSCINETTI A RULLI
O CONTATTO ANGOLARE SONO
PROTETTI DURANTE IL
TRASPORTO, PER EVITARE DANNI,
MEDIANTE UN DISPOSITIVO DI
BLOCCAGGIO.
Se la resistenza d’isolamento è inferiore a
2 megaohms, l’avvolgimento deve essere
essicato come segue:
Riscaldare in forno alla temperat ura
minima di 80ºC, aumentando di 5ºC adogni ora,
fino a 105ºC. A questa temperatura deve rimanere
per una durata minima di una ora.
I DISPOSITIVI DI BLOCCAGGIO
DEVONO ESSERE USATI PER
QUALSIASI ALTRO TRASPORTO
DEL MOTORE, ANCHE SE QUESTO
ESIGA CHE LO STESSO SIA DI
NUOVO DISACCOPPIATO DALLA
MACCHINA AZIONATA.
Verificare se la resistenza d’isolamento
dello statore rimane costante ed entro i valori
35
ITALIANO
Si raccomanda che l’albero dei motori sia
girato a mano almeno una volta al mese e che la
resistenza d’isolamento sia misurata prima della
installa zione, nel caso che i motori siano in
magazzino da più di 6 mesi o immagazzinati in
condizioni d’umidità sfavorevoli.
Se il motore è provvisto di scaldiglie,
queste devono di preferenza essere alimentate.
1 - Generale
minimi raccommandati, contrariamente si dovrà
fare una nuova impregnazione dello statore.
I Motori per ambienti a rischio dovranno
essere installa ti in aree in conformità con la
identificazione sulla targhetta del motore.
INSTALLAZIONE
MANTENERE I’ENTRATA E L’USCITA
DEL MOTORE SEMPRE P ULITA.
L’ARIA CONVOGLIATA VERSO IL
MOTORE NON DOVRÀ ESSERE
ASPIRATA DI NUOVO DALLA
VENTOLA. LA DISTANZA TRA
I’ENTRATA DI ARIA DEL MOTORE E
LA PARETE DEVE ESSERE ALMENO
DI ¼ DEL DIAMETRO DELLA
APERTURA DELLA ENTRATA D’ARIA .
1 - Sicurezza
II personale che lavora con installazioni
elett riche, sia nel montaggio, che nelle
operazioni o manutenzione, dovrà essere
continuamente informato ed aggiornato al
riguardo delle norme di sicurezza che il servizio
richiede con I’obbligo che dette norme vengano
scrupolosamente seguite.
Si raccomanda che tali servizi siano
sempre fatti da personale qualificato.
3 - Fondazione
ACCERTARSI SEMPRE CHE I
MOTORI ELETTRICI SIANO
DISINSERITI PRIMA D’INIZIARE
QUALSIASI LAVORO DI
MANUTENZIONE.
I motori con piedi dovranno essere
installa ti sopra fondazioni rigide per evitare
eccessiva vibrazione.
L’acquirente ha la piena responsabilità per
la preparazione della fondazione.
I motori devono essere protetti contro
avviamenti accidentali.
Le parti metalliche delle stesse devono
essere verniciate per evitare la corrosione.
Quando
occorrono
servizi
di
manutenzione del motore, disinserire tutta la rete
d’alimentazione. Verificare che tutti gli accessori
siano stati scollegati e disinnestati.
Le fondazioni dovranno essere in piano
e sufficientemente rigide per sopportare eventuali
sollecitazioni da urti. Devono essere
dimensionate in modo da evitare vibrazioni
dovute alle risonanze.
Per evitare la penetrazione di polvere e/o
acqua nell’interno della morsettiera è necessario
istallare pressa cavi o elettrocondoti filettati nella
uscita dei cavi collegamento.
4 - Fori di scarico condensa
Non alterare la taratura dei dispositivi di
protezione, perchè gli stessi potrebbero
diventare non operanti.
Controllare che i fori di scarico condensa
siano situati nella parte inferiore quando il
montaggio è diverso da quello specificato nella
ordinazione del motore.
2 - Condizioni di operazione
5 - Bilanciamento
Le macchine elettriche in genere sono
indicate per la installazione e servizi ad altitudine
fino a 1000m sopra il livello del mare, con una
temperatura ambiente da 0ºC a 40ºC. Variazioni
sono definite sulla targhetta.
I MOTORI WEG SONO BILANCIATI
DINAMICAMENTE CON “MEZZA
CHIAVETTA”A VUOTO E
DISACCOPPIATI.
COMPARARE I VALORI DI
CORRENTE, TENSIONE,
FREQUENZA, ROTAZIONE,
POTENZA, ETC, RICHIESTI PER LA
APPLICAZIONE, CON I DATI
CONTENUTI SULLA TARGHETTA
DEL MOTORE.
Gli elementi di trasmissione, come per
esempio, pulegge, giunti, etc devono essere
bilanciati dinamicamente con “mezza
chiavetta”prima che essi siano installati.
Usare sempre utensili adeguati nella installazione
e smontaggio.
36
8 - Collegamento
6 - Allineamento
AVVERTENZA
Con il motore fermo si può avere tensione
all’interno della scatola morsetti utilizzata per
alimentare le scaldiglie o direttamente
l’avvolgiment o per tener lo in temperat ura. a
motore fermo.
ALLINEARE LE ESTREMITÀ
DELL’ALBERO OD USARE UN
ACCOPPIAMENTO FLESSIBILE
SEMPRE CHE QUESTO SIA
POSSIBILE.
AVVERTENZA:
Nei motori monofasi i terminali dei
condensatori possono essere in tensione anche.
Controllare che i dispositivi di montaggio
del motore non comportino alterazioni
nell’allineamento
e
conseguenti
danneggiamenti nell‘ equipaggiamento.
Nel montaggio della puleggia si devono
usare mezzi adeguati ed utensili necessari per
non danneggiare i cuscinetti.
II COLLEGAMENTO FATTO IN MODO
NON ADEGUATO PUÒ BRUCIARE IL
MOTORE.
Montaggio corretto della puleggia:
assicurarsi che il gioco sia inferiore allo 0,05mm
e che la differenza da X1 a X2 sia inferiore allo
0,05mm
La tensione ed il collegamento sono
indicati sulla targhetta. La tolleranza accettabile
di tensione è del ±10% la tolleranza accettabile
per la freqüenza è del ±5% e la tolleranza
accettabile nella somma di ambedue è del ±10%.
Di preferenza il motore deve partire con
avviamento diretto. Nel caso che non sia
possibile, usare metodi compatibili con il carico
e la tensione del motore.
II senso di rotazione è orario visto dal lato
comando, collegando le fasi nella sequenza L1,
L2, L3.
Nota: Le misure X1 e X2 deve avere al
minimo 3mm
Figura e tolleranze del allineamento
(in nero)
Per invertire il senso di rotazione
scambiare tra loro i collegamenti di due terminali
qualsiasi.
7 - Azionamento con cinghie
II COLLEGAMENTO DEI TERMINALI
DELLA RETE DOVRÀ ES SERE F ATTA
DA UNA PERSONA QUALIFIC ATA E
CON MOLTA ATTENZIONE PER
GARANTIRE UN CONTATTO
SICURO E PERMANENTE. DOPO IL
COLLEGAMENTO DEL MOTORE SI
VERIFICHI CHE NESSUN
OGGETTO STRANO SIA STATO
LASCIATO ALL INTERNO DELLA
MORSETTIERA. LE ENTRATE DEI
TERMINALI CHE NON VENGONO
USATE DOVRANNO ES SERE
CHIUSE.
Quando è usato un accoppiamento a
mezzo pulegge e cinghie si deve verificare:
Le cinghie devono avere la tensione
appena sufficiente per evitare lo slittamento nel
funzionamento, seguendo i limiti del manuale
del produttore delle cinghie.
ATTE NZION E
Un’eccessiva tensione delle cinghie
danneggerà i cuscinetti e potrà anche
causare una rottura dell’albero.
37
ITALIANO
9 - Metodo D’Avviamento
Controllare le condizioni delle connessioni e
dei bulloni di fissaggio e fondazione.
 Controllar e le condizioni dei cuscinetti
prestando attenzione: ad eventuali rumori forti,
vibrazioni, temperatura dei cuscinetti e
condizioni del grasso.
Quando si rilevino condizioni anomale nel
funzionamento, si devono controllare le parti e,
se necessario, sostituirle.
Assicurarsi di utilizzare la sezione
adeguata per i cavi d alimentazione del motore
alla rete, in base alla corrente nominale riportata
sulla targhetta dello stesso.
PRIMA DI ALIMENT ARE I TERMINALI,
VERIFICARE CHE LA MESSA A
TERRA SIA STATA F ATTA IN
ACCORDO CON LE NORME
VIGENTI. QUESTO È ESSENZIALE
CONTRO IL RISCHIO D INCIDENTI.
La frequenza delle ispezioni dipende dal
tipo del motore e dalle condizioni locali di
utilizzo.
Quando il motore è provvisto di
dispositivi di protezione di temperatura come:
termostati, termistori, protettori termici etc,
collegare i loro corrispondenti terminali nel
dispositivo adeguato per ottenere il corretto
funzionament o.
LUBRIFICAZIONE
10 - Messa in marcia
VERIFICARE GLI INTERVALLI DI
LUBRIFICAZIONE DEI CUSCINETTI.
QUESTO È VIT ALE PER LI BUON
FUNZIONAMENTO DEL MOTORE.
LA CHIAVETTA DEVE ESSERE
COMPLETAMENTE FIS SA O TOLTA
PRIMA DI ATTACC ARE IL MOTORE
ALLA RETE.
a) II motore deve partire e funzionare in
modo regolare. In caso contrario fermare il
motore e verificare di nuovo il montaggio ed i
giunti prima del nuovo avviamento.
1 - Motori non provvisti di ingrassatori
I motori fino alla grandeza 200 sono
normalmente forniti con cuscinetti ad
ingrassaggio permanent e. In questo caso il
reingrassaggio dovrà essere effetuato durante
la manutenzione periodica, controllando i
seguenti aspetti:
b) Se si è verificata una vibrazione
eccessiva, controllare se le viti di fissaggio sono
allentate o se la vibrazione è proveniente da
macchine adiacenti.
Smontare con attenzione i motori.
Togliere tutto il grasso.
Pulire i cuscinetti con cherosene o gasolio.
Rilubrificare i cuscinetti immediatamente.
c) Adoperare il motore sotto carico
nominale per un certo periodo di tempo e
comparare la corrente d’esercizio con quella
della targhetta.
2 - Motori provvisti di ingrassatori
MANUTENZIONE
Si raccomanda di fare la rilubrificazione
del motore quando è in funzione, per permettere
la penetrazione ed il ricambio del grasso
nell’alloggiamento del cuscinetto. Se questo
non fosse possibile a causa della presenza
di’parti in movimento prossime al dispositivo
d’ingrassaggio(pulegge, giunti etc) che
possono essere un rischio per l’integrità fisica
dell’operatore, procedere come segue:
AVVERTENZA:
CHECK LIST DI SICUREZZA
1 - Ispezione generale
Ispezionare il motore periodicamente.
Mantenere il motore pulito e assicurare una
buona ventilazione prodotta dalla ventola.
Controllare le condizioni di anelli di tenuta o
V-ring e cambiarli se necessario.
Pulire I’ orifizio dell’ingrassatore.
Iniettare più o meno la metà della quantità totale
38
stimata di grasso e far girare il motore per un(1)
minuto circa a piena rotazione.
Fermare il motore per iniettare il restante
grasso.
Con la iniezione di tutto il grasso a motore
fermo può succedere che parte del grasso.
PER LA LUBRIFICAZIONE USARE
ESCLUSIVAMENTELA PISTOLA
D’INGRASSAGGIO.
INTERVALI LUBRICAZIONE
TABELLA 1 - CUSCINETTI A SFERE - Serie 62/63
Intervalli lubricazione (ore di lavoro-posizione orizzontale)
Polo IV
Polo VI
Polo VIII
Serie 62
50Hz
60Hz
50Hz
20000
20000
20000
20000
20000
20000
6209
6211
60Hz
18400
14200
50Hz
20000
16500
60Hz
20000
20000
50Hz
20000
20000
60Hz
20000
20000
6212
12100
14400
20000
20000
20000
20000
20000
Serie 63
Cuscinetto
6309
60Hz
15700
50Hz
18100
60Hz
20000
50Hz
20000
60Hz
20000
50Hz
20000
6311
6312
6314
6316
6319
6322
11500
9800
3600
-
13700
11900
4500
-
20000
20000
9700
8500
7000
5100
20000
20000
11600
10400
9000
7200
20000
20000
14200
12800
11000
9200
20000
20000
16400
14900
13000
10800
Cuscinetto
Polo X
Polo XII
Grasso
60Hz
20000
20000
50Hz
20000
20000
60Hz
20000
20000
50Hz
20000
20000
(g)
9
11
20000
20000
20000
20000
20000
13
60Hz
20000
50Hz
20000
60Hz
20000
50Hz
20000
60Hz
20000
50Hz
20000
(g)
13
20000
20000
17300
15900
14000
11800
20000
20000
19700
18700
17400
15100
20000
20000
19700
18700
17400
15100
20000
20000
20000
20000
18600
15500
20000
20000
20000
20000
18600
15500
20000
20000
20000
20000
20000
1930O
18
21
27
34
45
60
XII
50Hz
20000
20000
20000
20000
20000
20000
17300
15000
Grasso
(g)
13
18
21
27
34
45
60
72
TABELLA 2 - CUSCINETTI A RULLI - Serie NU 3
Intervalli lubricazione (ore di lavoro-posizione orizzontale)
Cuscinetto
NU
NU
NU
NU
NU
NU
NU
NU
309
311
312
314
316
319
322
324
Polo
60Hz
9800
6400
5100
1600
-
II
50Hz
13300
9200
7600
2500
-
Polo
60Hz
20000
19100
17200
7100
6000
4700
3300
2400
IV
50Hz
20000
20000
20000
8900
7600
6000
4400
3500
Polo
60Hz
20000
20000
20000
11000
9500
7600
5900
5000
VI
50Hz
20000
20000
20000
13100
11600
9800
7800
6600
Polo
60Hz
20000
20000
20000
15100
13800
12200
10700
10000
VIII
50Hz
20000
20000
20000
16900
15500
13700
11500
10200
Polo X
60Hz
50Hz
20000
20000
20000
20000
20000
20000
16900
19300
15500
17800
13700
15700
11500
13400
10200
12100
Polo
60Hz
20000
20000
20000
19300
17800
15700
13400
12100
Per ogni 15°C di aumento su la temperatura,
il periodo del reingrassaggio è ridotto a metà.
I periodi di reingrassaggio dati sopra sono
per quelli casi dove applicano il grasso
Polyrex ® EM.
 Quando i motori sono utilizz ati in la
posizione verticale, loro intervallo di
reingrassaggio è ridotto a met à se comparò a
motori della posizione orizzontali.
Nota:
I cuscinetti ZZ da 6201 a 6307 non richiedono
reingrassaggio poirché il suo tempo di vita
utile è circa di 20,000 ore.
I Tabelle 1 e 2 sono intesi per il periodo de
ingrassaggio sotto la temperatura del
cuscinetto di 70°C (per cunscinetti su a 6312 e
NU 312) e la temperatura di 85°C (per cuscinetti
6314 e NU 314 e più grande).
39
ITALIANO
Polo II
applicati sulla faccia laterale dell’anello interno
che deve essere smontato, o ad un pezzo
adiacente.
È essenziale che il montaggio dei
cuscinetti sia fatt o in condizioni di completa
pulizia, per avere un buon funzionamento ed
evitare danneggiamenti. I cuscin etti nuovi
dovranno essere tolti dall’imballaggio nel
momento del montaggio.
Prima del montaggio d’un cuscinetto
nuovo, sarà necessario controllare che la sede
dell’albero sia senza sbavature o segni di colpi.
Per il montaggio dei cuscinetti riscaldare
la pista interna degli stessi con macchina
specifica a processo induttivo od utilizza re
utensile adeguato.
RACCOMANDIAMO L’USO DEI
CUSCINETTI A SFERE NEI MOTORI
AD ACCOPPIAMENTO DIRETTO AL
CARICO.
AT TENZIONE!
UN ECCESSO DI GRASSO PUO’
PROVOCARE
SOVRARISCALDAMENTO DEL
CUSCINETTO E CONSEGUENTE
C0MPLETO DANNEGGIAMENTO.
Compa tibil ita’ del grasso “Polyr ex ®
EM” con altr i tipi di grasso:
Il grasso Polyrex ® EM, in virtu’ del
contenuto di indurente poliurea e di olio
minerale, e’ compatibile con altri tipi di grasso
contenenti:
Una base di litio o una miscela di lito-poliurea
e un olio minerale raffinato.
Un additivo inibitore della corrosione, della
ruggine e un additivo antiossidante.
PARTI DI RICAMBIO
Nell’ordinare le parti di ricambio per un
motore indicare i dati completi del motore con
codice del prodotto, come stampigliati sulla
targhetta del motore stesso.
Sulla targhetta c’è il numero di serie del
motore, questo dovrà essere comunicato nella
richiesta delle parti di ricambio.
Note:
Anche se il grasso “Polirex ® EM” e’ compatibile
con i tipi di grasso sopraindicati, non
raccomandiamo di mescolarlo con altri tipi di
grasso.
Prima d’impiegare grassi diversi da quelli
raccomandati, si prega di contattare Weg.
Nelle applicazioni speciali (con alte o basse
temperature, con variazi oni di velocita’ ecc...) Gli
intervalli di rilubrificazione sono riportati nella
targhetta aggiuntiva, applicata sul motore.
MOTORI DA UTILIZZARSI IN
LUOGHIPERICOLOSI
Oltre alle raccomandazioni fatte in
precedenza, si aggiungano le seguenti:
LE SPECIFICHE DEL LUOGO DI
INSTALLAZIONE DEI MOTORI È DI
RESPONSABILITÀ DEI CLIENTI,
CHE DECIDERANNO ANCHE LE
CARATTERISTICHE
DELL’AMBIENTE.
L’USO DI MOTORI IN AREE
SPECIALI O APPLICAZIONI
SPECIALI DEVE ESSERE
PRECEDUTO D’ UNA RICHIESTA AL
FORNITORE DEL GRASSO O ALLA
WEG.
I motori destinati ad ambienti pericolosi
sono fabbricati secondo standard specifici per
questi luoghi e sono garantiti da certificazioni
valide in tutto il mondo.
SMONTAGGIO E MONTAGGIO
1 - Installazione
Lo smontaggio e montaggio dovrà essere
fatto da personale qualificato, utilizzando solo
utensili e metodi adeguati.
I ganci dell’estrattore dovranno essere
L’installazione completa deve seguire le
regolamentazioni previste dalla legislazione
locale vigente.
40
MOTORI ALIMENTATI CON
INVERTER
L’INSTALLAZIONE DEI MOTORI IN
AMBIENTI PERICOLOSI DEVE
ESSERE EFFET TUATA DA
PERSONALE ESPERTO E LA
PROTEZIONE TERMICA DEVE
ESSERE SEMPRE INSTALLATA SIA
ALL’INTERNO CHE ALL’ESTERNO
DEL MOTORE FUNZIONANTE A
CORRENTE ADEGUATA.
Le installazioni con convertitori di
frequenza senza filtro possono modificare le
prestazioni del motore come segue:
Minore rendimento.
Maggiori vibrazioni.
Maggiore rumore.
Maggiore corrente nominale.
Maggiore temperatura.
Minore durata dell’isolamento.
Minore durata dei cuscinetti.
2 - Assistenza
L’assistenza deve essere affettuata da
officine per riparazioni autorizzate dalla WEG.
Le officine di assistenza e le persone non
autorizzate dalla WEG che effettueranno
riparazioni ai motori in ambienti pericolosi
dovranno assumersi la piena responsabilità per
questo servizio e ogni eventuale danno
provocato.
Per tensioni minori di 440 V non è necessario
installare il filtro.
Per tensioni uguali o maggiori di 440 V e
minori di 575 V è necessario installare il filtro se
i cavi di collegamento del motore sono lunghi
più di 20 metri.
Per tensioni maggiori di 575 V è necessario
installare il filtro qualunque sia la lunghezza dei
cavi di collegamento.
QUALSIASI MODIFICA ELETTRICA
O MECC ANICA APPORTATA (AI
MOTORI) IN QUESTI LUOGHI A
RISCHIO RENDERÀ NULLA LA
GARANZIA.
LA MANCATA OSSERVANZA DELLE
SUDDETTE RACCOMANDAZIONI
COMPORTA IL DECADIMENTO
DELLA GARANZIA.
Durante le operazioni di assistenza,
installazi one o lubrificazione, si seguano le
segenti norme:
Controllare che tutti i componenti siano privi
di parti affilate, deformate o sporche.
Assicurarsi che tutte le parti siano in ottime
condizioni.
Lubrificare le superfici degli scudi di fissaggio
con olio protettivo per facilitare l’assemblaggio.
Usare esclusivamente martelli di gomma per
inserire le parti.
Controllare el corretto serraggio delle viti.
 Usare uno spessimetro per un corretto
fissaggio della scatola a T (meno di 0,05 mm).
2 - Motori per inverter
Controllare l’alimentazione del
servoventilatore.
 I filtri non sono necessari.
NON RIUTILIZZARE LE PARTI
DANNEGGIATE O CONSUMATE.
SOSTITUIRLE CON PARTI NUOVE
FORNITE DALLA DITTA.
41
ITALIANO
1 - Motori standard
GARANZIA
La WEG offre per i suoi prodotti garanzia per i
difetti riguardanti la fabbricazione o i materiali,
per un periodo di 12 mesi, che decorrono dalla
data della fattura emessa dalla fabbrica o dal
distributore / rivenditore, limitatamente a 18
mesi
dalla
data di
fabbricazione,
indipendentemente dalla data di installazione
e a patto che siano soddisfatti i seguenti
requisiti:
• Che vi sia stata la denunzia immediata, da
parte dell’acquirente, dei difetti presenti e che
la WEG li abbia riconosciuti in seguito come
diffeti di fabbricazione.
La garanzia non include i servizi di smontaggio
delle installazioni dell’acquirente, i costi di
trasporto del prodotto e le spese di trasferta, di
vito e alloggio del personale dell’Assistenza
Tecnica quando è richiesta dal cliente. I servizi
in garanzia saranno prestati esclusivamente
presso officine di Assistenza Tecnica
autorizzate dalla WEG o nel proprio
stabilimento.
• Che il trasporto, il trattamento e
I’immagazzinaggio siano stati adeguati;
• Che I’installazione sia stata corretta e sia stata
effettuata in condizioni ambientali idonee e
senza la presenza di agenti aggressivi;
• Che ogni operazione sia stata svolta entro i
limiti delle proprie competenze;
• Che siano stati realizzati periodicamente i
necessari interventi di manutenzione
preventiva;
• Che le riparazioni e/o modifiche siano state
effettuate solamente da persone autorizzate
per iscritto dalla WEG;
• Che nel caso di una anomalia il prodotto sia
stato reso disponibile al fornitore per il periodo
minimo necessario per I’identificazione della
causa della stessa anomalia e per la
realizzazione della dovuta riparazione;
Sono esclusi da questa garanzia i componenti
la cui vita media di utilizzo, in condizioni
normali d’uso, sia minore del periodo di
garanzia. La riparazione e/o la sostituzione di
pezzi o prodotti, di competenza della WEG
durante il periodo di garanzia, non prorogherà
il periodo di garanzia originario.
La presente garanzia è limitata al prodotto
fornito e la WEG non è responsabile per i danni
a persone, a terzi, ad altre attrezzature o
installazioni, per il lucro cessante o qualunque
altro danno emergente o conseguente.
42
DANSK
mellem 5ºC and 60ºC, med en relativ
luftfugtighed der ikke overstiger 50%.
For motorer, der har været lagret i mere
end to år, skal lejerne udskiftes eller tømmes for
smørefedt og renses grundigt.
Enfasede motorer skal desuden have
fornyet kondensatorerne (hvis sådanne er
monteret).
LÆS DENNE MANUAL GRUNDIGT
FØR INSTALLATION AF MOTOREN.
CHECKVEDMODTAGELSEN
Fjern låseanordningen på akselen før motoren
idriftsættes.
Drej akselen manuelt for at sikre at den drejer
frit.
Fjern aksel låseanordning (hvis en sådan
findes) før idriftsættelse af motoren.
Drej akslen med hånden for at sikre at den
roterer frit.
Det anbefales at dreje akselen manuelt
mindst en gang om måneden og at måle
isolationsmodstanden på motorer, der har
været lagret mere end 6 måneder eller har været
udsat for fugt.
HÅNDTERING OG TRANSPORT
Motorer med stilstandsvarme skal have
denne tilsluttet.
1 - Generelt
MOTOREN MÅ IKKE LØFTES VED
AKSELEN, MEN KUN I ØJEBOLTEN,
SOM ER DIMENSIONERET I
FORHOLD TIL MOTORENS VÆGT.
Kontrol af isolationsmodstand
Mål isolationsmodstanden inden drift af
motoren eller hvis der er tegn på fugt i viklingen.
Løfteanordningerne er kun beregnet til
al løfte motoren. Hvis motoren er udstyret
med to øjebolte, skal der benyttes en dobbelt
kæde til loftet.
Modstanden målt ved 25 grader C skal
være:
Ri  (20 x U) / (1000 + 2P) [M ]
(målt med en MEGGER ved 500 V);
U = spænding (V); P = effekt (kW).
Løft og sænkning skal foretages med
forsigtighed og uden rystelser, da lejerne
ellers kan beskadiges.
MOTORER UDSTYRET MED RULLE
ELLER VINKELKONTAKTLEJER ER
BESKYTT TET MOD
TRANSPORTSKADER VED EN
AKSEL LÅSEANORDNING.
Varm den op i en ovn til 80 grader C og
forhøj temperaturen med 5 grader hver time til
105 grader, hvor den skal stå mindst en time.
Kontroller at stator isolationsmodstanden
er konstant indenfor de tilladte væ rdier. Hvis ikke,
skal statoren imprægneres om.
DENNE ANORDNING SKAL
BENYTTES VED ENHVER
TRANSPORT AF MOTOREN, SELVOM
DETTE NØDVENDIGGØR
ADSKILLELSE AF MOTOR OG
MASKINE.
INSTALLATION
1 - Sikkerhed
OPBEVARING
Personale der arbejder med elektriske
installa tioner, håndte ring, drift
eller
vedligeholdelse skal instruereres grundigt om
sikkerhedsnormer og principper på området og
det anbefales, at kun kvalificerede teknikere
beskæftiges med disse opgaver.
Motorer, som ikke tages i brug straks, skal
opbevare s tørt, støvfrit, ikke udsætt es for
vibrationer, gasser, ætsende eller korroderende
luftarter og ved konstant temperatur.
Motorenes lager temperatur skal ligge
43
DANSK
Hvis isolationsmodstanden viser sig at
være mindre end 2Mohm, skal viklingen tørres
på følgende måde:
4 - Drænhuller
MAN SKAL SIKRE SIG, AT MOTOREN
ER SPANDINGSLOS, FØR
VEDLIGEHOLDESESARBEJDER
PÅBEGYNDES.
Dræn skal være placeret lavest på
motoren, hvis montageformen afviger fra
indkøbsordrens specifikation.
Der skal tages forholdsregler, så
utilsigtede starter ikke kan forekomme.
5 - Afvejning
WEG MOTORER ER DYNAMISK
AFBALANCERET MED HALV NOT,
UDEN LAST OG UKOBLET.
Ved enhver form for service afbrydes
strømforsyningen fra motoren og alt tilbehør skal
frakobles og afbrydes.
Trasmissionselementer, såsom remskiver,
koblinger etc. skal dynamisk afbalanceres med
halv not inden installation. Anvend alt id korrekt
værktøj.
Der må ikke ændres på indstillingen af
beskyttelsesudstyret.
2 - Driftsforhold
6 - Opretning
Generelt er el-motorer konstrueret til drift
i en højde af 1000 meter over havet og for en
omgivelsestemperatur mellem 0 og 40 Grader
C. Eventuell e afvigelser fremgår af motorens
typeskilt.beskyttelsesudstyret.
OPRET AKSELENDERNE OG
ANVENDE FL EXIBEL KOBLING, NÅR
DETTE ER MULIGT.
Tilbehør for motormontagen må ikke
muliggøre modifikationer af opretningen til
skade for lejerne.
SAMMENLIGN DEN STRØM,
SPÆNDING, FREKVENS,
OMDREJNINGSTAL, EFFEKT OG
ANDRE VÆRDIER, DER ER
NØDVENDIGE FOR DEN
RESPEKTIVE ANVENDELSE, MED
DE PÅ TYPESKILTET ANFØRTE DATA.
Ved samling af halvkoblinger skal der
benyttes de rigtige udstyr og værktøjer, så lejerne
ikke lider overlast.
Motorer leveret til aggressive miljøer skal
installeres i overensstemmelse med det på
typeskiltet specificerede.
Korrekt samling af halvkoblinger:
Kontroller at sløret er mindre end 0.05 mm og at
forskellen mellem X1 og X2 ligeledes er mindre
end 0.05 mm.
HOLD IND-OG UDGANG FOR LUFT
FRI OG REN. UDGANGSLUFTEN FRA
MOTOREN MÅ IKKE RE-CIRKULERE
I MOTOREN. AFSTANDEN MELLEM
LUFTINDGANG OG VÆG SKAL
MINIMUM VÆRE 1/4 AF
INDGANGSÅBNINGENS DIAMETER.
Bemærk: Dimensioner X1 i X2 skal minimum
ucere 3mm.
Figur og opretnings tolerancer
3 - Fundament
Motorer forsynet med fødder skal
installeres på et solidt fundament for at
forebygge unødige vibrationer.
Fundamentet skal være jævn og
tilstrækkelig hå rd udformet for at forebygge
unødige mekaniske vibrationer.
Køber har det fulde ansvar for
fundamentet.
Metaldelene skal males for at undgå
korrosion.
7 - Remtræk
Når der anvendes remskiver eller
remkoblinger skal følgende bemærkes.
Remmene skal strammes netop
tilstrækkeligt, så slip ved drift undgås, i henhold
til de af remtræk - leverandøren specificerede
anbefalinger.
44
INDEN TILSLUTNING TIL NETTET
KONTROLLER AT JORDING ER
FORETAGET EF TER GÆLDENDE
NORMER. DETTE ER NØDVENDIGT
FOR AT UNDGÅ UHELD.
ADVARSEL :
En for hård stramning af remtrækket vil
beskadige lejerne og sandsynligvis føre til
et akselbrud
8 - Tilslutning
Hvis motoren er leveret med temperatur
beskyttelses eller styringsanordning, såsom
termostat, termistor, termisk beskyttelse etc., skal
disses terminaler forbindes til de tilsvarende på
kontrolpanelet.
ADVARSEL:
Ved stilstand kan spænding tilsluttes i
klemkassen til varmeelementer eller direkte
viklingsvarme.
10 - Start
ADVARSEL:
Kondensatoren i en-fasede motorer kan
holde ladningen, der forekommer over
motorterminalerne, selv efter motorstilstand.
KILEN SKAL SPÆNDES ELLER
FJERNES INDEN MOTOREN
STARTES.
a) Motoren skal starte og køre ubesværet.
Hvis dette ikke er tilfældet, skal den afbrydes og
tilslutningerne og montagen kontrolleres inden
den startes igen.
EN FORKERT TILSLUTNING KAN
AFBRÆNDE MOTOREN.
Spænding og forbindelsesdiagram er
angivet på motorens typeskilt. Acceptable
spændingsvariation er +/- 5% og den totale
acceptable variation +/- 10%.
b) Hvis der forekommer unormale
vibrationer,
skal
fastgørelsesboltene
kontrolleres. Desuden bør det konstateres, om
vibrationerne eventuelt kan hidrøre fra en anden
nærstående motor.
9 - Startmetoder
c) Lad motoren køre med den nominelle
last i en kort periode og sammenlign, om
strømmen svarer til den på motorskiltet anførte.
Motoren startes almindeligvis ved direkte
start. Skulle dette ikke være muligt, skal metoder
forenelige med motorlast og spænding
anvendes.
Omdrejningsretning er med uret set fra
drivenden (DE), forudsat faserne er forbundet i
fasefølge L1, L2, L3.
VEDLIGEHOLDELSE
1 - Generelt eftersyn
For at ændre omdrejningsretningen skal
to af lederne ombyttes.
Efterse motoren regelmæssigt.
Motoren skal holdes ren og en fri, uhindret
luftstrøm skal sikres.
 Kontroller pakningerne eller V-ringen og
udskift disse hvis nødvendigt.
Kontrollér tilslutninger og fastgørelser.
Kontrollér lejer og bemærk eventuel fremmed
stoj, lejetemperatur og smøringstilstand.
Hvis unormale forhold afsløres, skal motoren
gennemgås og dele om nødvendigt udskiftes.
FORBINDELSE TIL
KRAFTFORSYNINGEN SKAL
UDFØRES AF KVALIFICERET
PERSONALE OG
MED OMHU FOR AT OPNÅ EN
SIKKER OG
PERMANENT TILSLUTNING. EFTER
TILSLUTNING AF MOTOREN SKAL
KLEMKASSEN KONTROLLERES OG
EVENTUELLE UBENYTTEDE
KABELINDGANGE SKAL LUKKES.
SMØRING
Kablerne skal være i de korrekte
dimensioner, baseret på den nominelle strøm
stemplet på motorskiltet.
FØLG NØJE INTERVALLERNE FOR
EFTERSMØRING. DETTE ER
AFGØRENDE FOR DRIFTEN.
45
DANSK
ADVARSEL:
SIKKERHEDSKONTROLLISTE.
huset. Er smørenipplen ikke let tilgængelig, sker
udskiftning af smørefedt på følgende måde:
1 - Motorer uden smørenippler
Motorer til størrelse 200 er normalt uden
smørenippler. Eftersmøring af disse skal foretage
ved de normale vedligeholdelseseftersyn:
Fjern generende genstande.
Sprøjt det halve af fedtmængden ind i lejet og
lad motoren køre et minut ved fuld hastighed.
Afbryd motoren og påfyld resten at
fedtmængden.
 Indsprøjtning af hele fedtmængden i en
stilleståen de motor kan medføre, at smørefedtet
siver ind i selve motoren gennem den indre
tætning.
Adskil motoren omhyggeligt.
Fjern al smørefedt.
Vask lejet i petroleum eller dieselolie.
Nyt smørefedt tilsættes.
2 - Motorer med smørenippler
VED SMØRING, ANVEND KUN
MANUEL SMØREPISTOL.
Det anbefales, at motoren smøres under
drift. På denne måde fornys smørefedtet i leje
EFTERSMØRINGSINTERVALLER
TABEL 1 - KUGLELEJER - Serie 62/63
Eftersmøringsintervalle r (driftstimer - horisontal montage)
II
IV
VI
VI II
X
XI I
Fedtmængde
Serie 62
Lejer
6209
6211
6212
60Hz
18400
14200
12100
50Hz
20000
16500
14400
60Hz
20000
20000
20000
50Hz
20000
20000
20000
60Hz
20000
20000
20000
50Hz
60Hz
20000
20000
20000
20000
20000
20000
Serie 63
50Hz
20000
20000
20000
60Hz
20000
20000
20000
50Hz
20000
20000
20000
60Hz
20000
20000
20000
50Hz
20000
20000
20000
(g)
9
11
13
Lejer
6309
6311
60Hz
15700
11500
50Hz
18100
13700
60Hz
20000
20000
50Hz
20000
20000
60Hz
20000
20000
50Hz
20000
20000
60Hz
20000
20000
50Hz
20000
20000
60Hz
20000
20000
50Hz
20000
20000
60Hz
20000
20000
50Hz
20000
20000
(g)
13
18
6312
6314
6316
6319
6322
9800
3600
-
11900
4500
-
20000
9700
8500
7000
5100
20000
11600
10400
9000
7200
20000
14200
12800
11000
9200
20000
16400
14900
13000
10800
20000
17300
15900
14000
11800
20000
19700
18700
17400
15100
20000
19700
18700
17400
15100
20000
20000
20000
18600
15500
20000
20000
20000
18600
15500
20000
20000
20000
20000
19300
21
27
34
45
60
TABEL 2 - RULLELEJER - Serie NU 3
Eftersmøringsintervalle r (driftstimer - horisontal montage)
II
Lejer
NU 309
NU 311
NU 312
NU 314
NU 316
NU 319
NU 322
NU 324
60Hz
9800
6400
5100
1600
-
IV
50Hz
13300
9200
7600
2500
-
60Hz
20000
19100
17200
7100
6000
4700
3300
2400
VI
50Hz
20000
20000
20000
8900
7600
6000
4400
3500
60Hz
20000
20000
20000
11000
9500
7600
5900
5000
VI II
50Hz
20000
20000
20000
13100
11600
9800
7800
6600
60Hz
20000
20000
20000
15100
13800
12200
10700
10000
50Hz
20000
20000
20000
16900
15500
13700
11500
10200
X
60Hz
20000
20000
20000
16900
15500
13700
11500
10200
XI I
50Hz
20000
20000
20000
19300
17800
15700
13400
12100
60Hz
20000
20000
20000
19300
17800
15700
13400
12100
Fedtmængde
50Hz
20000
20000
20000
20000
20000
20000
17300
15000
(g)
13
18
21
27
34
45
60
72
Tabellerne 1 og 2 er smøringsperioder ved
lejetemperatur på 70ºC (lejer op til 6312 og NU
312) og temperatur på 85ºC (lejer 6314 og NU
314 og større).
Bemærk:
ZZ lejerne fra 6201 til 6307 kræver ingen
eftersmøring, da deres levetid er omkring
20.000timer.
46
For hver 15ºC temperaturstigning halveres
eftersmøringsperioden.
 Eftersmøringsperioderne nævnt ovenfor
omhandler Polyrex ® EM Grease.
For vertikalt monterede motorer halveres
eftersmøringsinter-va llerne sammenlignet
med horisontalt opstillede motorer.
Inden montagen af nye lejer skal akselen
efterses for skarpe kanter eller anden form for
beskadigelser.
RESERVEDELE
Ved bestilling af reservedele bedes den
fulde typebetegnelse og produkt-kode som
anført på motorskiltet opgivet.
Desuden bedes motorens serie-nummer,
som ligeledes er anført på motorskiltet, opgivet.
ADVARSEL OVERSKUD AF FEDT KAN
FORAARSAGE OVEROPHEDNING AF
LEJET MED TOTAL-SKADE TIL
FOELGE.
MOTORERTILEKSPLOSIONSFARLIGE
OMRÅDER
®
Pol yrex E M s m o e r e m i d l e t s
foreneligh ed med andre fedtt yper:
Foruden de allerede givne vejledninger
skal følgende iagttages:
®
Polyrex
EM indeholder polyurea
fortykningsmiddel og mineralolie og er derfor
compatibelt med andre fedttyper indeholdende:
Lithium eller en sammensaetning med lithium
eller polyurea og mineralolie.
 Tilsaetni ngsstof mod corrosion, rust og
oxidering.
STEDET FOR INSTALLATION AF
EN MOTOR ER KUNDENS
ANSVAR, DENNE SKAL VURDERE
INSTALLATIONSFORHOLDENE.
Motorer til eksplosionsfarlige områder er
fremstillet efter specifikke standarder for sådanne
områder, og de er certificeret af globalt
anerkendte klassifikationsselskaber.
Bema erk:
1. Installation
®
Selvom Polyrex EM er foreneligt med de
naevnte fedttyper, kan det ikke anbefales at blande
med andre typer.
 Har De til hensigt at anvende andre fedttyper
end de anbefa-lede, så kontakt foerst WEG.
Ved anvendelsesomraader (med hoeje eller
lave temperaturer, varierende hastigheder etc.)
angives fedttype og efter-smoeringsinterval paa
en separat maerkeplade paa motoren.
MOTORER I EKSPLOSIONSFARLIGE
OMRÅDER SKAL INSTALLERES AF
FAGFOLK OG DEN TERMISKE
BESK YTTELSE SKAL ALTID
MONTERES, ENTEN I SELVE
MOTOREN ELLER SEPARAT, FOR
DRIFT VED DEN NOMINELLE
STRØM.
VED ANVENDELSE AF STANDARD
MOTORER I SPECIELLE OMRÅDER
ELLER TIL SPECIELLE FORMÅL
SKAL ENTEN OLIELEVERANDØREN
ELLER WEG KONTAKTES.
2. Vedligeholdelse
Vedligeholdelse skal foretages af WEG
- autoriserede værksteder.
Ikke WEG - autoriserede værksteder
eller andre, der foretager enhver service på
motorer til eksplosionsfarlige områder vil
blive holdt ansvarlig for sådan service og for
enhver følgeskade.
DEMONTAGEOGMONTAGE
Demontage og montage skal udføres af
kvalificeret personale og kun egnede værktøjer
må anvendes.
Fastspændelse af stator foretages på den
indre rings sideflade eller på en tilsluttende del.
Det er vigtigt at en demontage/montage af
lejer foretages under rene forhold for at sikre en
god drift og undgå beskadigelser. Nye lejer skal
først tages ud af emballagen ved montering.
CERTIFICERINGEN BORTFALDER,
HVIS DER FORETAGES ELEKTRISKE
ELLER MEKANISKE
MODIFIKATIONER PÅ EN MOTOR TIL
EKSPLOSIONSFARLIGT OMRÅDE.
47
DANSK
Den Komplette installation skal følge de
procedurer.
Højere støjniveau.
Højere nominel strøm.
Reduceret motorisolation.
Nedsat leje-levetid.
Følg disse instrukser ved vedligeholdelse
installation eller smøring:
Kontroller at alle konponenter er under grater,
stød eller snavs.
Kontroller at alle delle er i perfekt stand.
Smør overfladerne på endeskjoldets fittings
med beskyttende olie for at gøre montage lettere.
Benyt kun gummihammer til montage af dele.
Kontroller bolte for korrekt stramning.
Benyt kalibrator for korrekt slør ved klemkassemontage(mindre end 0,05 mm).
1- Standard motorer
For spændinger under 400 V kræves ikke
filter.
For spændinger på over 440 V og indtil 575 V
er filter nødvendigt for motorforsyningskabler
på mere end 20 meter.
Spændinger på eller over 575 V kæver filter for
alle forsyningskabel-dimensioner.
GENANVEND IKKE BESKADIGEDE
ELLER SLIDTE DELE. UDSKIFT
SÅDANNE MED NYE ORIGINALDELE FRA WEG.
HVIS DISSE PUNKTER IKKE
FØLGES NØJE, BORTFALDER
MOTORGARANTIEN.
MOTORERMED
FREKVENSOMFORMER
Anvendelse af frekvensomformere uden
filter kan influere således på motorfunktionen:
Lavere virkningsgrad.
Højere vibrationer.
2- Frekvensomformermotorer:
Kontroller kraftforsyning til den forcerede
kølingsventilat or.
Filtre er ikke nødvendige.
GARANTI
WEG garanterer sine produkter imod
fabrikations - og materialefejl i 12 måneder
regnet fra fabrikens faktureringstado,
autoriseret distributør eller agent begrænset
til 18 måneder fra fabrikationsdato, uafhængigt
af dato for installation, forudsat følgende er
opfyldt:
opståede fejl og at disse af WEG godkendes
som fabrikationsfejl.
Garantien omfatter ikke demontage hos køber,
transportomkost ninger, rejseudgifter fo r
teknikere, logi og fortæring. Garanti-se rvice
udføres kun af værksteder med WEG’s
autorisation eller i WEG’s egne v irksomheder.
• Forsvarlig transport, håndtering og
oplagring;
• Korrekt installation baseret på de
specificerede
ydre
forhold,
uden
korroderende gasser;
• Drift indenfor motorens kapacitet;
• Under hensyntagen til de periodiske
vedligeholdelsese ftersyn;
• Reparationer og/eller udskiftninger foretaget
af teknikere med skriftlig autorisation fra WEG;
• En defekt motor eller dele stilles til
leverandørens rådighed for konstatering af
fejlårsag;
• Omgående advisering fra køber om
Komponenter, hvis levetid normalt er kortere
end garantiperioden er ikke omfattet af
garantien. Reparation og/eller udskiftining af
dele eller komponenter udført af WEG og/eller
WEG autoriseret værksted, medfører ikke
forlængelse af garantien.
Dette angiver WEG’s garanti i forbindelse med
salget og selskabet har in gen forpligtelse eller
ansvar overfor personer, trediepart, andet
udstyr eller installationer og enhver fordring
for følgeudgifter eller arbejdsomkostninger er
WEG uvedkommende.
48
SWEDISH
Om motorerna lagras mer än 2 år måste
antingen lagren bytas ut eller smörjfettet
avlägsnas totalt efter rengöring.
LÄS IGENOM INSTRUKTIONERNA
INNAN NI INSTALLERAR MOTORN.
MOTTAGNINGSKONTROLL
På enfas motorer som lagras i 2 år eller
längre måste kondensatorerna bytas ut.
 Kontrollera om något har skadats under
transporten.
Kontrollera informationen på märkskylten.
Avlägsna transportlåsningen (om det finns
någon) innan motorn tas i bruk.
Vrid axeln för hand för att kontrollera att den
rör sig fritt.
Om motorerna lagras mer än 6 månader
eller om motorerna lagras på ett fuktigt ställe
rekommenderar vi att man vrider axeln, för hand,
minst en gång i månaden och
mäter
isolationsresistansen innan installation.
HANTERING OCH TRANSPORT
Om
motorn
installeras
med
stillestå ndsuppvärmning skall den vara
ansluten.
1. Allmänt
Isolationsresistansk ontroll
MOTORERNA SKALL INTE LYFTAS I
AXELN UTAN I LYFTÖGL ORNA SOM
ÄR KONSTRUERADE FÖR ATT
KLARA MOTORNS VIKT.
Mät isolationsresistansen innan Ni
använder motorn och/eller vid minsta tecken på
fukt i lindningen.
Lyftöglorna är enbart till för att stödja
motorn. Om motorn har två skall två kedjor
användas för att lyfta motorn.
Mätningen genomförd vid 25 o C skall vara:
Ri > (20 x U) / (1000 + 2P) [Mohm]
(mät med en MEGGER vid 500 V c.c);
U = Volt (V); P = Effekt (kW).
Höjning och sänkning måste ske försiktigt
utan slag och stötar för att inte skada lagren.
Om isolationsresistansen är mindre än 2
megaohm måste lindningen torkas enligt
följande:
UNDER TRANSPORT ÄR MOTORER
FÖRSEDDA MED RULL- ELLER
VINKELKONTAKTLAGER , UTRUSTADE
MED TRANSPORTLÅSNING FÖR ATT
FÖRHINDRA SKADA PÅ LAGREN.
Värm upp den i en ugn vi minimum 80 oC
öka temperaturen 5 oC varje timma upp till 105 oC,
behåll denna temperatur i minst en timma.
TRANSPORTLÅSNINGEN MÅSTE
ANVÄNDAS VID ALL TRANSPORT AV
MOTORN, ÄVEN VID URKOPPLING
FRÅN DEN ENHETEN SOM DRIVS
AV MOTORN.
INSTALLATION
LAGRING
1. Säkerhet
Om motorerna inte instal leras direkt,
måste de förvaras i ett torrt utrymme fritt från
damm, vibratione r, gaser, korrosionspåverkan
och vid konstant temperatur och i normal
position och skilt från andra föremål.
Lagringstemperatur för motorn skall vara
mellan 5ºC och 60ºC, och den relativa
fuktigheten får ej överstiga 50%.
All personal som berörs av elektrisk
installation, vad gäller hante ring, lyft, drift eller
underhåll måste vara väl informerad om säkerhet
och övriga rutiner som berör arbetet och följa
dessa noggrant.
Detta arbete får endast utföras av behörig
personal.
49
SVENSKA
Kontrollera att sta torns isolationsresistans
förblir konstant inom accepterade värden, om
inte måste statorn impregneras igen.
Fundamentet måste vara jämt och
tillräckligt hårt för att kunna stå emot eventuella
stötar. Det måste vara konstruerat så att det
förhindrar vibratione r
som eventuellt
uppkommer pga resonans.
KONTROLLERA ATT ELEKTRISKA
MOTORER ÄR FRÅNKOPPLADE
INNAN UNDERHÅLLSSERVICE
PÅBÖRJAS.
Motorer måste skyddas mot ofrivilliga
starter.
4. Dräneringshål
Bryt strömmen innan underhållsservice
påbörjas. Se till att alla tillbehör är avstängda
och bortkopplade.
Försäkra Er om att dräneringshålen är
placerade i den nedre delen av motorn om
monteringen skiljer sig från vad som sagts i
inköpshandlingarna.
För att undvika att damm och/eller
vatte n kommer in i kopplingsboxen,
bör
förskruvningar
installeras
i
kabelgenomföringen.
Förändringar
skyddsutrustninge n.
får
ej
göras
5. Balansering
WEG MOTORER ÄR DYNAMISK
BALANSERADE MED HALV KIL
UTAN LAST OCH URKOPPLAD.
på
Transmissionsdelar såsom remskiva,
kopplingar etc måste vara dynamiskt balanserade
med halv kil innan installation. Använd alltid
lämpliga verktyg vid installation och
borttagande.
2. Användningsvillkor
Elektriska motorer är i allmänhet
konstruerade för att användas <1000 m över
havet vid en temperatur mellan 0 oC och 40 oC.
Varje avvikelse från detta finns noterat på
märkskylten.
6. Inställning
STÄLL IN AXELÄNDAN OCH
ANVÄND OM MÖJLIGT EN
FLEXIBEL KOPPLING.
JÄMFÖR STRÖMSTYRKA,
SPÄNNING, FREKVENS, HASTIGHET,
ANGIVEN EFFEKT OCH ANDRA
VÄRDEN.
Se till att motorns monteringsanordning
inte ändrar inställningen och dessutom inte
skadar lagren.
Motorer som levererats för riskfyllda
utrymmen skall installeras i ett utrymme som
överensstämmer med specifikationen på
motorns märkskylt.
Vid montering av en halv-koppling,
använd alltid rätt ut rustning och verktyg för att
skydda lagren.
SE TILL ATT L UFTINTAG OCH
LUFTUTSLÄPP ÄR RENA OCH FRIA.
UTSLÄPPSLUFTEN SKALL INTE GÅ
IN I MOTORN IGEN. AVSTÅNDET
MELLAN L UFTINTAG OCH VÄGGEN
MÅSTE VARA CA 1/4 AV
DIAMETERN PÅ L UFTINTAGET.
Lämplig montering av halv-koppling:
Kontrollera att Y är mindre än 0,05 mm och att
även skillnaden mellan X1 och X2 är mindre än
0,05 mm.
3. Fundament
Motorer försedda med fött er skall
installeras på ett fast fundament för att undvika
för stor vibration.
OBS: Dimensionen mellan X1 Och X2 skall
vara 3 mm minimum.
Köparen har fullt ansvar för fundament.
7. Remdrift
Metalldelar måste målas för att undvika
korrosion.
Vid användning av remskiva eller
remkoppling måste följande iakttagas:
50
Om
motorn
är
försedd
med
temperaturvakter eller givare som termostater,
termistorer mm koppla in dessa i motsvarande
kontrollpanel.
Remmen måste spännas tillräckligt för att
undvika slirning när den används, enligt
specifikationen från leverantören.
VARNING:
Överdriven dragning av remskivan
skadar lagren och kan leda till axelbrott.
10. Uppstart
KILEN SKALL FÄSTAS ELLER
AVLÄGSNAS INNAN MOTORN
STARTAS.
8. Koppling
VARNING:
Vid stillastå ende
kan spänning
varainkopplad
kopplingslådan
för
värmeelement
eller
för
direkt
lindningsuppvärmning.
a) Motorn måste starta och arbeta jämnt,
om detta inte sker skall starten avbrytas och
anslutningarna och kopplingarna kontrolleras
före omstart..
b) Om det förekommer onormala
vibrationer kontrollera att skruvarna är korrekt
åtdragna. Kontrollera också om vibrationerna
kommer från en närstående maskin.
Vibrationskontroller måste göras med jämna
mellanrum.
VARNING:
Kondensatorn på enfas motorer kan
innehålla laddning, som förekommer över
motorplinten, även efter avstängning.
EN FELAKTIG KOPPLING KAN
MEDFÖRA ATT MOTORN BRÄNNER.
c) Kör motorn med maximal belastning
en kort stund och kontrollera att/om
strömtillförseln överensstämmer med det som
är angivet på märkplåten.
Spänning och koppling anges på
märkskylten.
Högsta tillåtna variation i spänningen är
+/- 10% Högsta tillåtna i frekvensvariation är
+/-5%.
UNDERHÅLL
VARNING!
UNDERHÅLL
SÄKERHETSKONTROLLISTA.
9. Start metoder
Kontrollera motorn med jämna mellanrum.
Håll motorn ren och se till att luftintag inte
hindras.
Kontrollera packningar eller v-ringar och byt
ut dessa vid behov.
Kontrollera kopplingar såväl so m skruvar.
Kontrollera lagren och observera eventuella
ovanliga ljud, vibrationer, lagrens temperatur
och smörjmedlets kondition.
 När en förändring, under normala
förhållanden, upptäcks, kontrollera motorn och
byt even tuellt nödvändiga delar.
Hur ofta man behöver göra dessa inspektioner
beror
på
motortyp
och
på
användningsförhållandet.
INSTALLATION F ÅR ENDAST SKE AV
BEHÖRIG PERSONAL. SE TILL
ATT
INGA FRÄMMANDE FÖREMÅL
FÖREKOMMER I KOPPLINGSLÅDAN
EFTER ANSLUTNING.
KABELINGÅNGARNA SOM INTE
ANVÄNDS MÅSTE TILLSLUTAS.
Använd alltid rätt kabeldimension enligt
strömmen på märkskylten.
SMÖRJNING
INNAN SPÄNNINGEN SLÄPPS PÅ
KONTROLLERA ATT JORDNINGEN ÄR
KORREKT, DET TA ÄR VÄSENTLIGT
FÖR ATT UNDVIKA OLYCKOR.
FÖLJ NOGA INTERVALLERNA FÖR
EF TERSMÖRJNING. DET TA ÄR
AVGÖRANDE FÖR DRIFTEN.
51
SVENSKA
1. Allmän inspektion
Motorn startas helst genom direktstart.
Om detta inte är möjligt, skall metoder förenliga
med motorlast och spänning användas.
Motorn roterar medsols, sedd mot Dändan och nätets fasföljd är L1, L2, L3.
Om motsatt rotat ionsriktning önskas,
växlas två av ledningarna som är anslutna till
motor.
under drift. På detta vis förnyas smörjfettet i
lagerhusen. Är smörjnippeln inte tillgänglig sker
smörjning på följande sätt:
Avlägsna ev kåpor.
Tillsätt ca hälften av smörjfettet som behövs
och kör motorn med full hastighet ca 1 minut.
Stäng av motor och tillsätt resten av smörjfettet.
 Insprutningen av hela fettmängden i en
stillastående motor kan medföra att smörjfettet
kommer in i själva motorns inre tätning.
1. Motorer utan smörjnipplar
Motorer upp till storlek 200 tillve rkas
normalt utan smörjnipplar. Dessa skall
eftersmörjas i samband med underhåll och på
följande sätt:
Montera ner motorn försiktigt.
Avlägsna allt gammalt fett.
Tvätta lagren med bensin eller dieselolja.
Nytt smörjfett tillsättes.
2. Motorer med smörjnipplar
VID SMÖRJNING ANVÄND ENDAST
MANUELL SMÖRJPISTOL
Det är tillrådligt att smörja motorerna
SMÖRJ INTE RVAL LER
TABELL 1 - KULLAGER - Serie 62/63
Smörjinterval l (drifttimmar - horisontellt montage)
II-po l
IV-p ol
VI-po l
VIII-p ol
Serie 62
50Hz
60Hz
X-po l
XII-po l
Fettmängd
Lager
60Hz
50Hz
60Hz
50Hz
60Hz
50Hz
60Hz
50Hz
60Hz
50Hz
(g)
6209
6211
6212
18400
14200
12100
20000
16500
14400
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
Serie 63
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
9
11
13
Lager
6309
6311
60Hz
15700
11500
50Hz
18100
13700
60Hz
20000
20000
50Hz
20000
20000
60Hz
20000
20000
50Hz
20000
20000
60Hz
20000
20000
50Hz
20000
20000
60Hz
20000
20000
50Hz
20000
20000
60Hz
20000
20000
50Hz
20000
20000
(g)
13
18
6312
6314
6316
6319
6322
9800
3600
-
11900
4500
-
20000
9700
8500
7000
5100
20000
11600
10400
9000
7200
20000
14200
12800
11000
9200
20000
16400
14900
13000
10800
20000
17300
15900
14000
11800
20000
19700
18700
17400
15100
20000
19700
18700
17400
15100
20000
20000
20000
18600
15500
20000
20000
20000
18600
15500
20000
20000
20000
20000
19300
21
27
34
45
60
TABELL 2 - RULLAGER - Serie NU 3
Smörjinterval l (drifttimmar - horisontellt montage)
Lager
NU 309
NU 311
NU 312
NU 314
NU 316
NU 319
NU 322
NU 324
60Hz
9800
6400
5100
1600
-
II-po l
50Hz
13300
9200
7600
2500
-
IV-p
60Hz
20000
19100
17200
7100
6000
4700
3300
2400
ol
50Hz
20000
20000
20000
8900
7600
6000
4400
3500
VI-po l
60Hz
50Hz
20000
20000
20000
20000
20000
20000
11000
13100
9500
11600
7600
9800
5900
7800
5000
6600
VIII-p ol
60Hz
50Hz
20000
20000
20000
20000
20000
20000
15100
16900
13800
15500
12200
13700
10700
11500
10000
10200
X-po l
60Hz
50Hz
20000
20000
20000
20000
20000
20000
16900
19300
15500
17800
13700
15700
11500
13400
10200
12100
XII-po l
60Hz
50Hz
20000 20000
20000 20000
20000 20000
19300 20000
17800 20000
15700 20000
13400 17300
12100 15000
Fettmängd
(g)
13
18
21
27
34
45
60
72
För varje 15°C temperat urstegring, kortas
smörjintervallet ned till hälften.
Ovan angivna smörjintervall gäller i de fall
Polyrex ® EM fett används.
 När motorer används vertikalt monterade
kortas smörjintervallet ned till hälften jämfört
med angivna tider i tabeller ovan.
Anmärkni ngar:
 ZZ-lager från 6201 till 6307 behöver ej
återinfettas eftersom deras livslängd är ca 20.000
timmar.
Smörjintervall enligt Tabell 1 och 2 gäller vid
lagertemperaturer upp till 70°C (för lager upp
till 6312 och NU312) respektive 85°C (för lager
6314 och NU314 eller större).
52
RESERVDELAR
VI REKOMMENDERAR
ANVÄNDANDE AV KULLAGER FÖR
MOTORER SOM ÄR
DIREKTKOPPLADE TILL LASTEN.
Vid beställning av reservdelar se till att ha
rätt typbeteckning och produktkod. Dessa står
angivna på märkskylten.
VARNING:
FÖR STOR MÄNGD FETT KAN
ORSAKA ÖVERHETTNING I
LAGREN OCH DÅRMED
FÖRSTÖRA DEM HELT.
Uppge även motorn serienummer som
anges på märkskylten.
MOTORERFÖRRISKFYLLDA
MILJÖER
Polyre x ® EM fett är kompatibelt med
andra fett
Förutom den tidigare givna vägledningen
skall följande iakttagas:
Polyrex ® EM innehåller polyuretan
förtjockningsmedel och mineral olja och är
kompatibelt med andra fett som innehåller:
Lithiumbaserade eller lithium – polyuretan –
och mineraloljeblandningar med tillsatser som
hämmar korrosion, rost & oxidering
STÄLLET FÖR INSTALLATIONEN AV
EN MOTOR ÄR KUNDENS
ANSVAR, DENNE ANSVARAR ÄVEN
FÖR MILJÖN DÄR MOTORN SKALL
INSTALLERAS.
Noteringar:
Även om Polyrex ® EM är kompatibelt med
andra fett enligt ovan re kommenderar vi åndock
Er att inte blanda med andra fett.
Om du har för avsikt att använda andra fett än
de vi ovan rekommenderat, kontakta Weg först.
 Vid speciella applikationer (hög eller lag
temperatur, höga varvtal mm) när motorn är
specialbeställd anges typ av fett och smörjintervall
på motorns märkskylt.
Motorer för riskfyllda miljöer tillverkas
enligt specifik standard för sådana områden och
är certifierade av respektive internationel la
klassningssällskap.
1. Installation
Den kompletta installationen skall ske efter
lokala förskrifter.
INSTALLATIONEN AV MOTORER I
EXPLOSIONSFARLIGA MILJÖER
SKALL SKE AV BEHÖRIG PERSONAL
OCH DET T ERMISKA SKYDDET
SKALL MONTERAS ANTINGEN I
SJÄLVA MOTORN ELLER SEPARAT .
VID ANVÄNDANDE AV
STANDARDMOTORER I SPECIELLA
OMRÅDEN ELLER TILL SPECIELLA
APPLIKATIONER SKALL ANTINGEN
OLJELEVERANTÖREN ELLER WEG
KONTAKTAS.
2. Underhåll
DEMONTERING OCH MONTERING
Demontering och montering skall endast
utföras av kvalificerad personal och endast
lämpliga verktyg och metoder användas.
Ej WEG-auktoriserade verkstäder och
andra som företar någon service på motorer i
riskfyllda miljöer ansvarar för sådan service och
alla eventuella skador.
Statorn skall monteras mot den inre ringen
i skölden.
Det är viktigt att en demontering/
montering av lagren sker under rena
förhållanden för att säkra en god drift och för att
undvika skador. Nya lager skall tas ut ur sitt
emballage först när de skall monteras.
CERTIFIERINGEN SLOPAS OM
DET SKER ELEKTRISKA ELLER
MEKANISKA MODIFIERINGAR PÅ
EN MOTOR LOKALISERAD I EN
RISKFYLLT MILJÖ.
Innan montering av nya lager, kontrollera
att det inte finns några skarpa kanter eller annan
skada på axeln.
Följ dessa instruktioner vid underhåll, installation eller smörjning:
Vid lagermontering, värm de inre delarna
med lämplig utrustning och använd lämpliga
verktyg.
Kontrollera att alla komponenter inte har vassa
kanter, deformation och smuts.
53
SVENSKA
Underhåll måste ske av verkstäder
auktoriserade av WEG.
Högre märksström.
Ökad temperaturstegring.
Minskad motor isolation.
Minskad lagerlivslängd.
Kontrollera att alla delar är i perfekt kondition.
Smörj ytan på sköldlagrets fästen med olja för
att göra montaget lättare.
 Använd endast gummi hammare vid
montering av delarna.
Kontrollera bultarna för korrekt åtdragning.
Montera kopplingslådan noggrannt, glappet
ska vara (mindre än 0,05 mm).
1. Standard motorer
Om spänningen är under 460V krävs inga filter.
Om spänningen är mellan 460V eller lägre än
575V krävs filter om anslutningskabeln är längre
än 20 meter.
Om spänningen är lika med eller högre är 575V
krävs filter oavsett längden på kabeln.
ÅTERANVÄND INTE SKADADE
ELLER SLITNA DELAR. BYT UT
DESSA MOT NYA ORIGINALDELAR.
MOTORER DRIVNA AV
FREKVENSOMRIKTARE
OM REK OMMENDATIONERNA INTE
FÖLJS, GÄLLER INTE GARANTIN.
Användandet av frekvsomr utan
utgångsfilter kan påverka motorns prestande
som följer:
Lägreeffektivitet.
Högre vibrationer.
Högre ljudnivå.
2. IDM Motorer (Inverter Duty Motors)
Kontrollera spänningen till den forcerade
kylningen.
Utgångs filter behövs inte.
GARANTI
WEG garanterar sina produkter mot
fabrikations- och materialfel i 12 månader från
fabrikens
fakturadatum.
Auktoriserad
återförsäljare eller agent begränsas till 18
månader från tillverkningsdatum, oberoende
på installationsdatum och under förutsättning
att följande är uppfyllt:
Garantin omfattar inte demontering hos
köparen, transportkostnader, resekostnader
och uppehälle för teknikern. Garanti-se rvice
utförs endast hos av WEG auktoriserad verkstad
eller i WEG egna verkstäder.
Komponenter, vilkas normala livslän gd, vid
normalt bruk, är kortare än garantitiden omfattas
inte av garantin.
• Korrekt transport, hantering och lagring
• Riktig installat ion baserad på de
specificerade yttre förhållanden och utan
frätande gaser.
• Drift inom motorns kapacitet
• Regelbunden underhållsservice utförs
• Reparation och/eller utbytande av delar utförs
av tekniker med skriftlig auktorisation av WEG.
• En defekt motor eller delar därav skall finnas
tillgänglig
för leverantören och/eller
verkstaden så att arten på felet kan konstateras
och motorn repareras
• Köparen skall så snart ett fel uppstår kontakta
WEG för att få felet godkänt som ett
fabrikationsfel
Reparationer och/eller utbyte av delar som
utförs av WEG och/eller av WEG auktoriserade
verkstad, medför inte förlängning av
garantitiden.
Detta anger WEGs garanti i samband med
försäljningen och företaget har ingen
skyldighet gentemot personer, tredje part,
annan utrustning eller installationer. Alla andra
fordringar eller krav på ersättning tillbakavisas.
54
PYCCKNÑ
PYCCKNÑ
55
56
57
PYCCKNÑ
58
1500
1200
1000
900
(
160
180
200
225
250
280*
280
315*
315
355
13
18
21
27
27
27
34
27
45
27
15700
11500
9800
3600
3600
3600
18100
13700
11900
4500
4500
4500
3600
4500
2400
4500
200
225
250
280
315
355
21
27
27
34
60
60
9800
3600
3600
3600
720
600
500
)
20000
20000
20000
9700
9700
20000
20000
20000
11600
11600
20000
20000
2000
14200
14200
20000
20000
20000
16400
16400
20000
20000
20000
17300
17300
20000
20000
20000
19700
19700
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
20000
8500
10400
12800
14900
15900
18700
20000
20000
20000
7000
9000
11000
13000
14000
17400
17400
20000
20000
20000
9700
9700
8500
5100
5100
20000
11600
11600
10400
7200
7200
20000
14200
14200
12800
9200
9200
20000
16400
16400
14900
10800
10800
20000
17300
17300
15900
11800
11800
20000
19700
19700
18700
15100
15100
20000
20000
20000
18700
15100
15100
20000
20000
20000
20000
15500
15500
20000
20000
20000
20000
19000
19000
20000
)
PYCCKNÑ
(
11900
4500
4500
3500
750
59
60
61
PYCCKNÑ
WEG EXPORTAD ORA S.A.
AV. PREF. WALDEMAR GRUBBA, 3000
89256-900 JARAGUÁ DO SUL, SC - BRAZIL
PHONE (55) (47) 372-4002
FAX (55) (47) 372-4060
http:/ /www.weg.com.br
FOR FURTHER INFORMATION PLEASE CONTACT YOUR NEAREST WEG SALES OFFICE
GEA Niro Soavi
Ref.
Part Code
Description
Description
7.01.3
9533-1010-000
MANOMETRO
PRESSURE GAUGE
7.01.3
Mechanical
Pressure Measurement
Bourdon Tube Pressure Gauges
Stainless Steel, Safety Pattern Version
Model 232.30/233.30, without/with Liquid Filling
WIKA Data Sheet PM 02.04
k
Applications
T Increased safety requirements
T With liquid filled case for applications with high dynamic
pressure pulsations or vibrations
T Suitable for corrosive environments and gaseous or
liquid media that will not obstruct the pressure system
T Process industry: chemical/petro-chemical, power
stations, mining, on- and offshore, environmental technology, mechanical engineering and plant construction
Special Features
T Safety pressure gauge with solid baffle wall designed in
compliance with operational safety requirements of
EN 837-1, BS 1780 and ASME B 40.1
T Excellent load-cycle stability and shock resistance
T All stainless steel construction
T Scale ranges up to 0 … 1600 bar
Bourdon Tube Pressure Gauge Model 232.30
Description
Design
EN 837-1
Nominal size
63, 100 and 160 mm
Accuracy class
63 mm:
1.6
100, 160 mm: 1.0
Scale ranges
63 mm: 0 ... 1 to 0 ... 1000 bar
100 mm: 0 ... 0.6 to 0 ... 1000 bar
160 mm: 0 ... 0.6 to 0 ... 1600 bar
or other equivalent units of pressure or vacuum
Working pressure
63 mm:
Steady:
Fluctuating:
Short time:
100, 160 mm: Steady:
Fluctuating:
Short time:
full scale value
0.9 x full scale value
1.1 x full scale value
full scale value
0.9 x full scale value
1.3 x full scale value
Operating Temperature
Ambient: -40 ... +60 °C without liquid filling
-20 ... +60 °C gauges with glycerine filling
Medium: +200 °C maximum without liquid filling
+100 °C maximum with liquid filling
Temperature effect
When temperature of the pressure element deviates from
reference temperature (+20 °C):
max. ±0.4 %/10 K of true scale value
Ingress protection
IP 65 per EN 60 529 / IEC 529
Page 1 of 2
WIKA Data Sheet PM 02.04 · 01/2004
Stainless steel series
model 232.50
High pressure series
model 222.30
For UHP applications, safety pressure gauges model 232.35
see data sheet PM 02.02
see data sheet PM 02.09
see data sheet PM 02.11
Standard features
Optional extras
Pressure connection
Material: stainless steel 316L
Lower mount (LM) or lower back mount (LBM) 1)
63 mm:
G ¼ B (male), 14 mm flats
100, 160 mm: G ½ B (male), 22 mm flats (160 mm only
lower mount)
T
T
T
T
T
T
T
T
Pressure element
Material: stainless steel 316L
< 100 bar: C-type
≥ 100 bar: helical type
Other pressure connections
Monel pressure system (model 262.30)
Pressure system stainless steel 1.4571
3-hole panel mounting flange, stainless steel or
stainless steel, polished
Surface mounting lugs on case, stainless steel
Ambient temperature -40 °C: silicon oil filling
Alarm contacts (see data sheet AC 08.01)
Transmitter (model 89X.34, see data sheet AE 08.02)
Standard version
Radial bottom pressure entry (LM)
1034 588
Movement
Stainless steel
Dial
White aluminium with black lettering,
63 mm with pointer stop pin
Pointer
Black aluminium
Case
Natural finish stainless steel, case with solid baffle wall and
blow-out back
Lower back pressure entry (LBM)
1)
1034 596
Window
Laminated safety glass
Bezel ring
Cam ring (bayonet type), natural finish stainless steel
Liquid filling (for model 233.30)
Glycerine 99.7 %
1) Connector position back mount only for gauges NS 63 and 100 without liquid filling
Dimensions in mm
NS
63
100
160
Dimensions in mm
Weight in kg
a
b
b1
b2
D1
D2
e
f
G
h±1
SW
Mod. 232.30
Mod. 233.30
17.5
25
27 1)
42
59.5
42
59.5
61
93
63
101
63
100
14.5
17
18.5
30
G¼B
G½B
54
87
14
22
0.20
0.65
0.26
1.08
65 2)
-
-
161
159
17.5
-
G½B
118
22
1.30
2.34
Standard pressure entry with parallel thread and sealing to EN 837-1 / 7.3
1) 41.5 mm with pressure ranges ≥ 100 bar
2) 79 mm with pressure ranges ≥ 100 bar
Ordering information
Pressure gauge model / Nominal size / Scale range / Size and location of connection / Optional extras required
Page 2 of 2
WIKA Data Sheet PM 02.04 · 01/2004
WIKA Alexander Wiegand GmbH & Co. KG
Alexander-Wiegand-Straße 30
63911 Klingenberg/Germany
Phone (+49) 93 72/132-0
Fax
(+49) 93 72/132-406
E-Mail info@wika.de
www.wika.de
9019766 01/2004 GB
Modifications may take place and materials specified may be replaced by others without prior notice.
Specifications and dimensions given in this leaflet represent the state of engineering at the time of printing.
Mechanische
Druckmesstechnik
Druckmessgerät mit Rohrfeder
CrNi-Stahl, Sicherheitsausführung
Typ 232.30/233.30, ohne/mit Flüssigkeitsfüllung
WIKA Datenblatt PM 02.04
k
Anwendungen
T Erhöhte sicherheitstechnische Anforderungen für
Personenschutz
T Mit Gehäuseflüssigkeitsfüllung bei hohen dynamischen
Druckbelastungen und Vibrationen
T Für gasförmige und flüssige, aggressive, nicht hochviskose und nicht kristallisierende Messstoffe, auch in
aggressiver Umgebung
T Für die Prozessindustrie in: Chemie, Petrochemie,
Kraftwerke, Bergbau, On-/Offshore, Umweltsektor,
Maschinenbau und allgemeiner Anlagenbau
Leistungsmerkmale
T Sicherheitsdruckmessgerät mit bruchsicherer Trennwand
nach Anforderungen und Prüfbedingungen gemäß EN 837-1
T Höchste Lastwechselbeständigkeit und Schockresistenz
T Komplett aus CrNi-Stahl
T Anzeigebereiche bis 0 … 1600 bar
Rohrfederdruckmessgerät Typ 232.30
Beschreibung
Ausführung
EN 837-1
Nenngröße
63, 100, 160
Genauigkeitsklasse
NG 63:
1,6
NG 100, 160: 1,0
Anzeigebereiche
NG 63: 0 ... 1 bis 0 ... 1000 bar
NG 100: 0 ... 0,6 bis 0 ... 1000 bar
NG 160: 0 ... 0,6 bis 0 ... 1600 bar
sowie alle entsprechenden Bereiche für negativen bzw.
negativen und positiven Überdruck
Verwendungsbereiche
NG 63:
Ruhebelastung:
Wechselbelastung:
kurzzeitig:
NG 100, 160: Ruhebelastung:
Wechselbelastung:
kurzzeitig:
Skalenendwert
0,9 x Skalenendwert
1,1 x Skalenendwert
Skalenendwert
0,9 x Skalenendwert
1,3 x Skalenendwert
Zulässige Temperaturen
Umgebung: –40 … +60 °C bei ungefüllten Geräten
–20 … +60 °C bei Geräten mit Glyzerinfüllung
Messstoff:
+200 °C maximal bei ungefüllten Geräten
+100 °C maximal bei gefüllten Geräten
Temperatureinfluss
Bei Abweichung von der Referenztemperatur (+20 °C) am
Messsystem: max. ±0,4 %/10 K vom jeweiligen Skalenwert
Schutzart
IP 65 (EN 60 529 / lEC 529)
WIKA Datenblatt PM 02.04 · 01/2004
CrNi-Stahl-Ausführung
Typ 232.50 siehe Datenblatt PM 02.02
Hochdruckausführung
Typ 222.30 siehe Datenblatt PM 02.09
Für UHP-Anwendungen, Sicherheitsausführung Typ 232.35 siehe Datenblatt PM 02.11
Seite 1 von 2
Standardausführung
Optionen
Druckanschlusszapfen
CrNi-Stahl 316L, Außengewinde unten oder rückseitig 1)
NG 63:
G ¼ B, SW 14
NG 100, 160: G ½ B, SW 22 (NG 160 nur unten)
T
T
T
T
T
T
T
T
Messglied
CrNi-Stahl 316L,
< 100 bar: Kreisform
≥ 100 bar: Schraubenform
Zeigerwerk
CrNi-Stahl
Anderer Prozessanschluss
Messsystem Monel (Typ 262.30)
Messsystem CrNi-Stahl 1.4571
Befestigungsrand vorn, CrNi-Stahl oder CrNi-Stahl poliert
Befestigungswinkel hinten, CrNi-Stahl
Umgebungstemperaturen –40 °C: Silikonölfüllung
Grenzsignalgeber (Datenblatt AC 08.01)
Ferngeber (Typ 89X.34, Datenblatt AE 08.02)
Standardausführung
Anschluss radial unten
1034 588
Zifferblatt
Aluminium, weiß, Skalierung schwarz,
NG 63 mit Anschlagstift
Zeiger
Aluminium, schwarz
Gehäuse
CrNi-Stahl, mit bruchsicherer Trennwand (Solidfront) und
ausblasbarer Rückwand
Sichtscheibe
Mehrschichten-Sicherheitsglas
1)
1034 596
Anschluss rückseitig exzentrisch
Ring
Bajonettring, CrNi-Stahl
Füllflüssigkeit (bei Typ 233.30)
Glyzerin 99,7 %
1) Anschlusslage rückseitig nur bei ungefüllten Geräten NG 63 und 100
Abmessungen in mm
NG
63
100
160
Maße in mm
Masse in kg
a
b
b1
b2
D1
D2
e
f
G
h±1
SW
Typ 232.30
Typ 233.30
17,5
25
27 1)
42
59,5
65 2)
42
59,5
-
61
93
-
63
101
161
63
100
159
14,5
17
17,5
18,5
30
-
G¼B
G½B
G½B
54
87
118
14
22
22
0,20
0,65
1,30
0,26
1,08
2,34
Druckanschlusszapfen nach EN 837-1 / 7.3
1) Bei Anzeigebereichen ≥ 100 bar: 41,5 mm
2) Bei Anzeigebereichen ≥ 100 bar: 79 mm
Bestellangaben
Typ / Nenngröße / Anzeigebereich / Anschlussgröße / Anschlusslage / Optionen
Seite 2 von 2
WIKA Datenblatt PM 02.04 · 01/2004
WIKA Alexander Wiegand GmbH & Co. KG
Alexander-Wiegand-Straße 30
63911 Klingenberg
Telefon 0 93 72/132-0
Telefax 0 93 72/132-406
E-Mail info@wika.de
www.wika.de
9098127 01/2004 D
Änderungen und den Austausch von Werkstoffen behalten wir uns vor.
Die beschriebenen Geräte entsprechen in ihren Konstruktionen, Maßen und Werkstoffen dem derzeitigen Stand der Technik.
GEA Niro Soavi
Ref.
Part Code
Description
Description
7.01.4
9533-4086-000
RIDUTTORE
GEARBOX
7.01.4
Services
Media No. 4090
Riduttori e motoriduttori
Gear reducers and gearmotors
Istruzioni d'uso
Operating instructions
Edition December 2010
Istruzioni d'uso riduttori e motoriduttori
Indice
1 - Avvertenze generali sulla sicurezza
3
2 - Condizioni di impiego
3
3 - Stato di fornitura
3.1 - Ricevimento
3.2 - Targa di identificazione
3.3 - Verniciatura
3.4 - Protezioni e imballo
3
3
3
3
4
4 - Immagazzinamento
4
5 - Installazione
5.1 - Generalità
5.2 - Montaggio di organi sulle estremità d’albero
5.3 - Fissaggio pendolare
5.4 - Albero lento cavo
4
4
5
5
5
6 - Lubrificazione
6.1 - Generalità
6.2 - Tabella lubrificazione
6.3 - Lubrificazione sopporto estrusore
7 - Sistema di raffreddamento
7.1 - Raffreddamento artificiale con ventola
8
8
6
8
8
8
Riciclaggio (tenere presente le prescrizioni in vigore):
– gli elementi della carcassa, gli ingranaggi, gli alberi e
i cuscinetti del riduttore devono essere trasformati in
rottami d’acciaio. Gli elementi in ghisa grigia subiranno
il medesimo trattamento nella misura in cui non esiste
alcuna prescrizione specifica;
– le ruote a vite sono realizzate in bronzo e devono essere trattate
di conseguenza;
– gli oli esausti dovranno essere recuperati e trattati conformemente
alle prescrizioni.
I paragrafi contrassegnati dal simbolo qui a lato contengono disposizioni da osservare tassativamente onde garantire l’incolumità
delle persone ed evitare danni rilevanti alla macchina o
all’impianto (es: lavori effettuati sotto tensione, su apparecchi di sollevamento, ecc.); I’installatore o il manutentore
deve comunque attenersi scrupolosamente a tutte le
istruzioni contenute nel presente manuale.
1 - Avvertenze generali sulla sicurezza
I riduttori e i motoriduttori presentano parti pericolose in quanto
possono essere:
– poste sotto tensione;
– a temperatura superiore a +50 °C;
– in movimento durante il funzionamento;
– eventualmente rumorose (livelli sonori > 85 dB(A)).
Un’installazione non corretta, un uso improprio, la rimozione delle
protezioni, lo scollegamento dei dispositivi di protezione, la carenza
di ispezioni e manutenzione, i collegamenti impropri, possono causare danni gravi a persone o cose. Pertanto, il componente deve essere
movimentato, installato, messo in servizio, gestito, ispezionato,
manutenuto e riparato esclusivamente da personale responsabile qualificato (definizione secondo IEC 364).
Si raccomanda di attenersi a tutte le istruzioni del presente manuale, alle
istruzioni relative all’impianto, alle vigenti disposizioni legislative di sicurezza, e a tutte le normative applicabili in materia di corretta installazione.
Attenzione! Componenti in esecuzione speciale o con varianti
costruttive possono differire nei dettagli rispetto a quelli descritti e
possono richiedere informazioni aggiuntive.
Attenzione! Per l’installazione, I’uso e la manutenzione del motore
elettrico (normale, autofrenante o comunque speciale) e/o apparecchiatura elettrica di alimentazione (convertitore di frequenza,
soft-start ecc.), e eventuali accessori (flussostato, unità autonoma
di raffreddamento, termostati ecc;) consultare la documentazione
specifica ad essi allegata. All’occorrenza richiederla.
Attenzione! Per eventuali chiarimenti e/o informazioni ulteriori, interpellare Rossi, specificando tutti i dati di targa.
I riduttori e i motoriduttori del presente manuale sono normalmente
destinati ad essere impiegati in aree industriali: protezioni supplementari eventualmente necessarie per impieghi diversi devono
essere adottate e garantite da chi è responsabile dell’installazione.
IMPORTANTE: i componenti forniti da Rossi sono destinati ad essere
incorporati in apparecchi o sistemi finiti e ne è vietata la messa
in servizio fino a quando l’apparecchio o il sistema nel quale
7.2 - Raffreddamento artificiale con serpentina
7.3 - Unità autonoma di raffreddamento
8
8
8
8 - Messa in servizio
9 - Manutenzione
9.1 - Generalità
9.2 - Serpentina
9.3 - Anelli di tenuta
9.4 - Sostituzione motore
9.5 - Cuscinetti
9.6 - Tappo di carico metallico con filtro e valvola
10 - Livelli sonori
8
8
9
9
9
9
9
9
9
Tabella verniciatura
Tabella momenti di serraggio per le viti di fissaggio
assiale e dell’unità di bloccaggio
10
Tabella momenti di serraggio per le viti di
fissaggio (piedi e flange)
10
Tabella momenti di serraggio per i tappi
10
Anomalie riduttore: cause e rimedi
11
il componente è stato incorporato non sia stato dichiarato
conforme:
–a
lla Direttiva macchine 2006/42/CE e successivi aggiornamenti; in particolare, eventuali protezioni antinfortunistiche
per estremità d’albero non utilizzate e per passaggi copriventola eventualmente accessibili (o altro), sono a cura
dell’Acquirente;
–a
lla Direttiva «Compatibilità elettromagnetica (EMC)»
2004/108/CE e successivi aggiornamenti.
Qualunque tipo di operazione sul riduttore (motoriduttore) o su
componenti ad esso connessi deve avvenire a macchina ferma:
scollegare il motore (compresi gli equipaggiamenti ausiliari) dall’alimentazione, il riduttore dal carico e assicurarsi che si siano attivati
i sistemi di sicurezza contro ogni avviamento involontario e, ove si
renda necessario, prevedere dispositivi meccanici di bloccaggio (da
rimuovere prima della messa in servizio).
In caso di funzionamento anomalo (aumento di temperatura, rumorosità inusuale, ecc.) arrestare immediatamente la macchina.
I prodotti relativi a questo manuale corrispondono al livello tecnico
raggiunto al momento della stampa del manuale stesso. Rossi si
riserva il diritto di apportare, senza preavviso, le modifiche ritenute
opportune per il miglioramento del prodotto.
2 - Condizioni di impiego
I riduttori sono progettati per utilizzo in applicazioni industriali in
accordo con i dati di targa, temperature ambiente 0  +40 °C (con
punte a -10 °C e +50 °C), altitudine massima 1 000 m.
Non è consentito l’impiego in atmosfere aggressive, con pericolo di
esplosione, ecc. Le condizioni di funzionamento devono corrispondere ai dati di targa.
3 - Stato di fornitura
3.1 - Ricevimento
Al ricevimento verificare che la merce corrisponda a quanto ordinato
e che non abbia subito danni durante il trasporto; nel caso contestarli
immediatamente allo spedizioniere.
Evitare di mettere in servizio riduttori o motoriduttori danneggiati
anche solo lievemente.
3.2 - Targa di identificazione
Ogni riduttore è dotato di targa di identificazione di alluminio anodizzato
contenente le principali informazioni tecniche relative alle caratteristiche
funzionali e costruttive e ne definisce assieme agli accordi contrattuali,
i limiti applicativi (ved. fig. 1); la targa non deve essere ri­mossa, e deve
essere mantenuta integra e leggibile. Tutti i dati riportati in targa devono
essere specificati sugli eventuali ordini di parti di ricambio.
3.3 - Verniciatura
I prodotti sono verniciati come da tabella verniciatura riportata a pag.
10. In caso di sovraverniciatura (possibile solo con prodotti bicomponente) occorre proteggere adeguatamente gli anelli di tenuta (che
non devono essere né danneggiati né verniciati), sgrassare e carteggiare le superfici del riduttore (o motoriduttore).
Istruzioni d'uso 4090INS.VPR-it1210HQM
Rossi
3
IT
EN
Designazione (ved.
tabella a lato)
Bimestre e anno di
costruzione
Esecuzioni speciali
Forma costruttiva (se
diversa da IM B3 o B5)
Potenza motore
Fattore di servizio
motoriduttore
Velocità di uscita
motoriduttore
IT
Potenza nominale
riduttore
Rapporto di
trasmissione
Designazione
Macchina
Rotismo
Grand.
R, MR
R, MR
R, MR
R, MR
R
R
V, IV, 2IV
2I, 3I
I, 2I, 3I, 4I
CI, ICI, C2I, C3I
C
2I
32 ... 250
32 ... 180
40 ... 631
40 ... 631
80 ... 320
85 ... 250
Esecuzione
UO ...
FC ..., PC ..., UC ...
UP ...
UO ...
PO ..., FO ...
OP
Prodotto
Vite
Coassiali
Assi paralleli
Assi ortogonali
Rinvii
Pendolari
Ø Flangia - albero
motore
Fig. 1 (per maggiori indicazioni, ved. cataloghi tecnici Rossi; interpellarci).
Nota: A decorrere dal 04/05/2010 la società già ROSSI MOTORIDUTTORI S.p.A. ha assunto la denominazione sociale Rossi S.p.A. e le targhe sono state aggiornate corrispondentemente.
Attenzione! per la manutenzione, l’installazione dei riduttori accoppiati ai servomotori sincroni e asincroni (anche se targati diversamente da quanto sopra indicato) valgono le prescrizioni del presente manuale.
EN
3.4 - Protezioni e imballo
Le estremità libere degli alberi sporgenti e gli alberi cavi vengono
protetti con olio antiruggine di lunga durata e con cappellotto (solo
fino a D  48 mm per alberi sporgenti, D  110 mm per alberi cavi)
in materiale plastico (polietilene). Tutte le parti interne sono protette
con olio antiruggine.
Se non concordato diversamente in sede d’ordine, i prodotti vengono
adeguatamente imballati: su pallet, protetti mediante pellicola di
po­lietilene, nastrati e reggiati (grandezze superiori); in carton-pallet
na­strati e reggiati (grandezze inferiori); in cartoni nastrati (per piccole
di­mensioni e quantità). All’occorrenza i riduttori sono convenientemente separati con cellule di schiuma antiurto o cartone da riempimento.
I prodotti imballati non devono essere accatastati l’uno sull’altro.
4 - Immagazzinamento
L’ambiente deve essere sufficientemente pulito, secco, esente da
vi­brazioni eccessive (veff  0,2 mm/s) per non danneggiare i cuscinetti
(tale necessità di contenere le vibrazioni, pur se entro limiti più ampi,
deve essere soddisfatta anche durante il trasporto) e a una temperatura di 0  +40 °C: sono ammesse punte di 10 °C in meno o in più.
Durante il trasporto e l’immagazzinamento, i riduttori completi di olio
devono essere posizionati nella forma costruttiva prevista all’ordine.
Ruotare semestralmente gli alberi di qualche giro per prevenire danneggiamenti a cuscinetti e anelli di tenuta.
In ambienti normali e purché vi sia stata una adeguata protezione
durante il trasporto, il componente viene fornito per un periodo di
immagazzinamento fino a 1 anno.
Per un periodo di immagazzinamento fino a 2 anni in ambienti normali è necessario seguire le seguenti ulteriori disposizioni:
– ingrassare abbondantemente le tenute, gli alberi e le eventuali
superfici lavorate non verniciate, controllando periodicamente lo
stato di conservazione dell’olio antiruggine;
– per i riduttori e motoriduttori forniti senza olio: inserire pastiglie
anticondensa nei riduttori sostituendole alla scadenza e togliendole
prima della messa in servizio (in alternativa riempire completamente i riduttori con l’olio di lubrificazione riportandolo a livello prima
della messa in servizio).
Per immagazzinamento con durata superiore ai 2 anni o in ambiente
aggressivo o all’aperto, interpellare Rossi.
5 - Installazione
5.1 - Generalità
Prima di effettuare l’installazione, verificare che:
– non vi siano stati danni durante l’immagazzinamento o il trasporto;
– I’esecuzione sia adeguata all’ambiente (temperatura, atmosfera, ecc.);
– I’allacciamento elettrico (rete o altro) corrisponda ai dati di targa del
motore;
– la forma costruttiva di impiego corrisponda a quella indicata in
targa.
Attenzione! Per il sollevamento e la movimentazione del
ri­duttore o del motoriduttore utilizzare i fori passanti o filettati della carcassa riduttore, accertarsi che il carico sia convenientemente bilanciato e che siano disponibili apparecchia­
ture di sollevamento, sistemi di aggancio e cavi di portata adeguata.
All’occorrenza l’entità delle masse dei riduttori e dei motoriduttori è
indicata sui cataloghi tecnici Rossi.
Assicurarsi che la struttura sulla quale viene fissato il riduttore o il
mo­toriduttore sia piana, livellata e sufficientemente dimensionata per
ga­rantire la stabilità del fissaggio e l’assenza di vibrazioni (sono
accetta­bili velocità di vibrazione veff  3,5 mm/s per PN  15 kW e veff
 4,5 mm/s per PN > 15 kW), tenuto conto di tutte le forze trasmesse
dovute alle masse, al momento torcente, ai carichi radiali e assiali.
Per le dimensioni delle viti di fissaggio dei piedi riduttore e la profondità dei fori filettati consultare i cataloghi tecnici Rossi.
Nel caso di utilizzo, per il fissaggio, dei fori filettati scegliere accuratamente la lunghezza delle viti di fissaggio che deve essere tale da
garantire un tratto di filetto in presa sufficientemente esteso, ma non
4
Rossi
tale da sfondare la sede filettata o non assicurare il corretto
serraggio del riduttore alla macchina.
Attenzione! La durata dei cuscinetti e il buon funzionamento di alberi e giunti dipendono anche dalla
precisione dell’allineamento tra gli alberi. Pertanto, occorre prestare la massima cura nelI’allineamento del riduttore con il motore e con
la macchina da comandare (se necessario, spessorare; per riduttori
grand.  400 servirsi dei fori filettati di livellamento), interponendo tutte
le volte che è possibile giunti elastici.
Un allineamento errato può dar luogo a rotture degli alberi (che
possono causare danni gravi alle persone) e/o cuscinetti (che
possono causare surriscaldamenti).
Non utilizzare, per il sollevamento dei motoriduttori, i golfari del motore.
Collocare il riduttore o il motoriduttore in modo da garantire un ampio
passaggio d’aria per il raffreddamento e del riduttore e del motore
(soprattutto dal lato ventola sia riduttore, sia motore).
Evitare: strozzature nei passaggi dell’aria; vicinanza con fonti di calore
che possano aumentare la temperatura dell’aria di raffreddamento e del
riduttore (per irraggiamento); insufficiente ricircolazione d’aria e in generale applicazioni che compromettano il regolare smaltimento del calore.
Montare iI riduttore o motoriduttore in modo che non subisca vibrazioni.
Le superfici di fissaggio (del riduttore e della macchina) devono essere
pulite e di rugosità sufficiente (orientativamente Ra  6,3 m) a garantire un buon coefficiente di attrito: asportare con un raschietto o con
solvente l’eventuale vernice delle superfici di accoppiamento del riduttore.
In presenza di carichi esterni impiegare, se necessario, spine o arresti positivi.
Nelle viti di fissaggio e nel fissaggio tra riduttore e macchina e/o tra
riduttore ed eventuale flangia B5, si raccomanda l’impiego di adesivi
bloccanti (anche nei piani di unione per fissaggio con flangia).
Prima di effettuare l’allacciamento del motoriduttore assicurarsi che
la tensione del motore corrisponda a quella di alimentazione; se il
senso di rotazione non corrisponde a quello desiderato, invertire due
fasi della linea di alimentazione.
Quando l’avviamento è a vuoto (o comunque a carico molto ridotto)
ed è necessario avere avviamenti dolci, correnti di spunto basse,
sollecitazioni contenute, adottare l’avviamento Y-.
Nel caso si prevedano sovraccarichi di lunga durata, urti o pericoli di
bloccaggio, installare salvamotori, limitatori elettronici di momento
torcente, giunti idraulici, di sicurezza, unità di controllo o altri dispositivi similari.
In generale proteggere sempre il motore elettrico con adeguato interruttore magnetotermico; però per servizi con elevato
numero di avviamenti a carico è necessaria la protezione del motore
con sonde termiche (incorporate nello stesso); il relé termico non è
idoneo, in quanto dovrebbe essere tarato a valori superiori alla corrente nominale del motore.
Collegare sempre le eventuali sonde termiche ai circuiti ausiliari
di sicurezza.
Limitare i picchi di tensione dovuti ai contattori mediante l’impiego di
varistori e/o filtri RC.
Qualora il riduttore sia provvisto di dispositivo antiretro1), prevedere
un sistema di protezione nel caso in cui un cedimento dell’antiretro
possa causare danni a persone e cose.
Quando una perdita accidentale di lubrificante può comportare gravi
danni, aumentare la frequenza delle ispezioni e/o adottare accorgimenti opportuni (es.: indicatore a distanza di livello, lubrificante per
industria alimentare, ecc.).
In presenza di ambiente inquinante, impedire in modo adeguato la
possibilità di contaminazione del lubrificante attraverso gli anelli di
tenuta o altro.
Per installazione all’aperto o in ambiente aggressivo (classe di corrosività C3 secondo ISO 12944-2) sovraverniciare il riduttore o il motoriduttore con adeguata vernice (bicomponente) anticorrosiva, proteggendolo eventualmente anche con grasso idrorepellente (specie in
corrispondenza delle sedi rotanti degli anelli di tenuta e delle zone di
accesso alle estremità dell’albero).
1) La presenza sul riduttore del dispositivo antiretro è segnalata dalla freccia in prossimità delI’asse lento che indica il senso della rotazione libera, ad eccezione dei riduttori pendolari per i
quali è segnalata dalla esecuzione B o C (ved. cataloghi tecnici Rossi).
Istruzioni d'uso 4090INS.VPR-it1210HQM
Quando è possibile, proteggere il riduttore o il motoriduttore con opportuni accorgimenti dall’irraggiamento solare e dalle intemperie; in quest’ultimo caso la protezione diventa necessaria quando gli assi lento e
veloce sono verticali o quando il motore è verticale con ventola in alto.
Per funzionamento a temperatura ambiente maggiore di +40 °C o
minore di 0 °C interpellare Rossi.
Nel caso in cui il riduttore o motoriduttore sia fornito con il raffreddamento artificiale con serpentina o unità autonoma di raffreddamento
ved. cap. 7.
5.2 - Montaggio di organi sulle estremità d’albero
Per il foro degli organi calettati sulle estremità d’albero, si raccomanda la tolleranza H7; per estremità d’albero veloce con D  55 mm,
purché il carico sia uniforme e leggero, la tolleranza può essere G7,
per estremità d’albero lento con D  180 mm, salvo che il carico non
sia uniforme e leggero, la tolleranza deve essere K7.
Prima di procedere al montaggio, pulire accuratamente e lubrificare
le superfici di contatto per evitare il pericolo di grippaggio e l’ossidazione di contatto.
Attenzione! ll montaggio e lo smontaggio devono essere effettuati
con l’ausilio di tiranti e di estrattori servendosi del foro filettato in
testa all’estremità d’albero (ved. tabella in fig. 2), avendo cura di
evitare urti e colpi che potrebbero danneggiare irrimediabilmente
cuscinetti, anelli elastici o altre parti, per accoppiamenti H7/m6 e
K7/j6 è consigliabile effettuare il montaggio a caldo riscaldando l’organo da calettare fino a 80  100 °C.
5.4 - Albero lento cavo
Per il perno della macchina sul quale deve essere calettato l’albero
cavo del riduttore, si raccomandano le tolleranze h6, j6, k6 secondo
le esigenze.
Importante! Il diametro del perno della macchina in battuta contro il
ri­duttore deve essere almeno pari a 1,18  1,25 volte il diametro interno
dell’albero cavo. Per altri dati sul perno macchina, nel caso di albero len­to
cavo normale, differenziato, con anelli o bussola di bloccaggio, con unità
di bloccaggio ved. cataloghi tecnici Rossi.
Attenzione! Per montaggi verticali a soffitto, e solo per
riduttori dotati di anelli o bussola di bloccaggio, il sostentamento del riduttore è dovuto al solo attrito per cui è necessario prevedere un sistema di arresto.
Per facilitare il montaggio e lo smontaggio dei riduttori e motoriduttori ad albero lento cavo provvisti di gola per anello elastico – sia
con cava linguetta sia con unità di bloccaggio – procedere come
raffigurato a pag. 12 fig. 4a e 4b rispettivamente.
Avvertenza. Pur essendo gli alberi lenti cavi lavorati complessivamente in tolleranza H7, un controllo mediante tampone potrebbe
rivelare due zone con diametro leggermente minorato (ved. Fig.
5a): tale minorazione è intenzionale e non pregiudizievole della qualità del calettamento - che anzi ne risulta migliorato in termini di
durata e precisione - e non costituisce ostacolo al montaggio del
perno macchina eseguito con gli usuali metodi come ad esempio
quello illustrato a pag. 12 in Fig. 4a.
Estremità d’albero
11  00
14  19
24  28
30  38
42  55
60  75
80  95
100  110
125  140
160  210
240  320
d
Ø
M 5
M 6
M 8
M 10
M 12
M 16
M 20
M 24
M 30
M 36
M 45
Fig. 5a
UT.C 886
D
Ø
Fig. 2
I giunti con velocità periferica sul diametro esterno fino a 20 m/s devono essere equilibrati staticamente; per velocità periferiche superiori occorre effettuare l’equilibratura dinamica.
Quando il collegamento tra riduttore e macchina o motore è realizzato con una trasmissione che genera carichi sull’estremità d’albero
(ved. fig. 3), è necessario che:
– non vengano superati i carichi massimi indicati a catalogo;
– lo sbalzo della trasmissione sia ridotto al minimo;
– le trasmissioni a ingranaggi non abbiano punti senza gioco;
– le trasmissioni a catena non siano tese (all’occorrenza – carico e/o
moto alterni – prevedere opportuni tendicatena);
– le trasmissioni a cinghia non siano eccessivamente tese.
Errato
UT.C 666
UT.C 117
Corretto
Errato
Corretto
Fig. 3
5.3 - Fissaggio pendolare
Nel fissaggio pendolare il riduttore deve essere sopportato radialmente
e assialmente (anche per forme costruttive B3 ... B8) dal perno della
macchina e ancorato contro la sola rotazione mediante un vincolo libero
assialmente e con giochi di accoppiamento sufficienti a consentire le
piccole oscillazioni, sempre presenti, senza generare pericolosi carichi
supplementari sul riduttore stesso. Lubrificare con prodotti adeguati le
cerniere e le parti soggette a scorrimento; per il montaggio del­le viti si
raccomanda l’impiego di adesivi bloccanti.
Per il montaggio del «kit di reazione a molle a tazza» (grand.  125
ad assi paralleli) servirsi del foro filettato in testa al perno macchina
e delI’invito all’imbocco dell’incavo di reazione per comprimere e
inserire il pacco di molle a tazza nell’incavo medesimo.
In relazione al sistema di reazione, attenersi alle indicazioni di progetto
indicate nei cataloghi tecnici Rossi. In ogni caso qualora vi siano pericoli per persone o cose derivanti da cadute o proiezione del riduttore
o di parti di esso, prevedere appropriate sicurezze contro:
– la rotazione o lo sfilamento del riduttore dal perno macchina conseguenti a rotture accidentali del vincolo di reazione;
– la rottura accidentale del perno macchina.
Per lo smontaggio dell’albe­ro
lento cavo dei riduttori ad
assi paralleli e ortogonali (è la
prima operazione da eseguilato gola 
re per smontare il riduttore)
orientare la cava linguetta
verso l’asse intermedio
come indicato nella fig. 5b e
spingere l’albero sul lato gola
di riferimento (scanalatura cirUT.C 322
conferenziale sulla battuta
lato opposto gola
Fig. 5b
dell’albero).
Per il fissaggio assiale si può adottare il sistema raffigurato a pag. 12
fig. 4c e 4d; quando il perno della macchina è senza battuta (metà
inferiore del disegno) si può interporre un distanziale tra l’anello elastico e il perno stesso. Le parti a contatto con l’anello elastico devono
essere a spigolo vivo.
Utilizzando gli anelli di bloccaggio (pag. 12 fig. 4e) o la bussola di
bloccaggio (pag. 12 fig. 4f) è possibile conseguire un montaggio e
uno smontaggio più facili e precisi e l’eliminazione del gioco tra linguetta e relativa cava.
Gli anelli o la bussola di bloccaggio devono essere inseriti dopo il montaggio e dopo avere accuratamente sgrassato le superfici da accoppiare.
Non utilizzare bisolfuro di molibdeno o lubrificanti equivalenti per la lubrificazione delle superfici a contatto. Per il montaggio della vite si raccomanda l’impiego di adesivi bloccanti.
Rispettare i momenti di serraggio riportati in tabella a pag. 10.
In caso di fissaggio assiale con anelli o bussola di bloccaggio – soprattutto in presenza di cicli gravosi di lavoro, con frequenti inversioni del
moto – verificare, dopo alcune ore di funzionamento, il momento di
serraggio della vite ed eventualmente riapplicare l’adesivo bloccante.
Per il calettamento con l’unità di bloccaggio (pag. 12 fig. 4g) procedere come segue:
– sgrassare accuratamente le superfici dell’albero cavo e del per-no
macchina da accoppiare;
– montare il riduttore sul perno macchina seguendo il metodo indicato a pag. 12 fig. 4a;
– serrare le viti dell’unità di bloccaggio in modo graduale e uniforme
con sequenza continua (non in croce!) e in più fasi sino al raggiun­
gimento del momento di serraggio riportato in tabella a pag. 10;
– al termine delle operazioni verificare il momento di serraggio delle
viti con chiave dinamometrica (piatta, in caso di montaggio sul lato
macchina).
Istruzioni d'uso 4090INS.VPR-it1210HQM
Rossi
5
IT
EN
6.2 - Tabella lubrificazione
Prodotto
IT
Vite
grand. 32 ... 81
Stato di fornitura* e tappi
Norme per l’eventuale primo riempimento
COMPLETI DI OLIO
SINTETICO
AGIP Blasia S 320,
KLÜBER Klübersynth GH 6-320
MOBIL Glygoyle HE 320,
SHELL Tivela S 320
Con velocità vite  280 min-1
KLÜBER Klübersynth GH 6-680
MOBIL Glygoyle HE 680
SHELL Tivela S 680
Tappo di carico
1 tappo di carico per grand. 32 ... 64
Tappo di carico/scarico
2 tappi di carico/scarico per grand. 80, 81
SENZA OLIO
(salvo diversa indicazione
sulla targa di lubrificazione)
EN
Vite
grand. 100 ... 250
Tappi di carico con valvola,
scarico e livello
Coassiali
grand. 32 ... 41
Rinvii (cat. L)
grand. 80 ... 125
Gradazione di viscosità ISO [cSt]
Prima della messa in
funzione, immettere
fino a livello, olio sin­
tetico (AGIP Blasia
S, ARAL Degol GS,
BP-Energol SG-XP,
MOBIL Glygoyle HE,
SHELL Tivela S ... ,
KLÜBER Klübersynth
GH 6...) avente la
gradazione di viscosità ISO indicata in
ta­bella.
Temperatura ambiente 0  +40 °C2)
Velocità vite
Grandezza riduttore
min-1
100 125 ... 161 200, 250
B31), V5, V6 B6, B7, B8 B31), V5, V6 B6, B7, B8
2 800  1 400 3)
1 400  710 3)
710  355 3)
355  180 3)
< 180
320
320 220 220
320 320
320
460 460
460
680
680 460 460
680 680 680
220
320
1) N
on indicata in targa.
2) Sono ammesse punte di temperatura ambiente di 10 °C (20 °C per  460 cSt)
in meno o 10 °C in più.
3) Per questa velocità si consiglia di sostituire l’olio dopo il rodaggio.
COMPLETI DI GRASSO
SINTETICO
SHELL Tivela GL 00
IP Telesia Compound A
MOBIL Glygoyle Grease 00
Tappo di carico/scarico
(solo per coassiali)
COMPLETI DI OLIO
SINTETICO
KLÜBER Klübersynth GH 6-220,
MOBIL Glygoyle 30
SHELL Tivela S 220
Coassiali
grand. 50 ... 81
Assi paralleli e
ortogonali
grand. 40 ... 81
Tappo di carico/scarico
2 tappi di carico/scarico
per grand. 80, 81
Coassiali
grand. 100 ... 180
SENZA OLIO**
(salvo diversa indicazione
sulla targa di lubrificazione)
Assi paralleli e
ortogonali
grand. 100 ... 631
Rinvii (cat. L)
grand. 160 ... 320
Pendolari
Tappi di carico con valvola
(con sfiato, per riduttori
pendolari),
scarico e livello
Prima della messa in funzio- Gradazione di viscosità ISO [cSt]
ne, immettere fino a livello,
Temperatura ambiente1) [°C]
olio minerale (AGIP Blasia, Velocità n2
ARAL Degol BG, BP-Energol min-1
olio minerale
olio sintetico
GR-XP, ESSO Spartan EP, IP
Rinvii
Mellana oil, MOBIL Mobilad angolo
Altri
0  20 10  40 0  40
gear 600, SHELL Omala,
> 710 000 > 224
150
150
150
TEXACO Meropa, TOTAL
710  280 224  22,4
150
220
220
Carter EP) oppure olio sin280  90 22,4 5,6
220
320
320
tetico a ba­se di poliglicoli** (KLÜBER Klübersynth
< 90
000 < 5,6
320
460
460
GH6 ..., MOBIL Glygoyle,
1) Sono ammesse punte di temperatura ambiente di 10 °C (20 °C) in meno o
SHELL Tivela S) o di polial10 °C in più.
faolefine** (AGIP Blasia SX,
CASTROL Tribol 1510, ELF Reductelf SYNTHESE, ESSO Spartan SEP, KLÜBER Klübersynth EG4,
MOBIL SHC Molykote L11 ...) avente la gradazione di viscosità ISO indicata in tabella.
Cuscinetti con lubrificazione indipendente, cuscinetti motore, dispositivo antiretro montato sul motore:
la lubrificazione è «a vita» (escluso il caso di motori nei quali è previsto il dispositivo di rilubrificazione). In caso di possibilità di inquinamento
del grasso o in presenza di servizi particolarmente gravosi è bene verificare (tra un cambio e l’altro oppure ogni 1 o 2 anni) lo stato del grasso e
asportare e sostituire (ogni 1 o 2 cambi oppure ogni 2 o 4 anni) il grasso nei cuscinetti con lubrificazione indipendente. Il cuscinetto va riempito
completamente con grasso per cuscinetti ESSO BEACON 3 se a sfere, KLÜBER STABURAGS NBU 8 EP se a rulli; lubrificare il dispositivo antiretro
con ESSO BEACON 2.
6
Rossi
Istruzioni d'uso 4090INS.VPR-it1210HQM
Intervallo di lubrificazione e quantità di lubrificante
Quantità di olio [l] per riduttori a vite grand. 32 ... 81
Per le altre grand. la quantità è individuata dal livello segnalato dall’apposito tappo
R V, MR V R IV, MR IV
Grand. B31), V5, B6, B7 B81) B31), V5, B6, B7
B81)
B31)
V6
V6
32
40
50
63, 64
80, 81
0,16
0,26
0,4
0,8
1,3
0,2
0,35
0,6
1,15
2,2
0,16
0,26
0,4
0,8
1,7
0,2
0,32
0,5
1
1,5
0,25
0,4
0,7
1,3
2,5
MR 2IV
B6, B7 B81)
V5, V6
IT
0,2––––
0,32
0,42
0,5
0,42
0,42
0,5
0,6
0,8
0,6
0,6
1
1,2
1,55
1,2
1,2
2
1,7
2,8
2,3
1,8
1) Non indicata in targa (B8, solo per grand. 32 ... 64).
Temperatura ambiente 0  +40 °C con punte fino a –20 °C e +50 °C.
EN
Temperatura
olio [°C]
Orientativamente l’intervallo di lubrificazione, in assenza di inquinamento dall’esterno, è
quello indicato in tabella. Per sovraccarichi forti, dimezzare i valori.
0 0
65 
80 
95 
Indipendentemente dalle ore di funzionamento, sostituire o rigenerare l’olio ogni 5  8 anni
secondo la grandezza, le condizioni di servizio e ambientali.
Intervallo di
lubrificazione [h]
18 000
12 500
9 000
6 300
65
80
95
110
Quantità di grasso [kg] per riduttori coassiali
R 2I MR 2I, 3I
Grand.
B31), B6, B7, B8 V5, V6
B51)
Lubrificazione «a vita» (in assenza di inquinamento dall’esterno).
0,14
0,26
32
40, 41
0,25
0,47
V1, V3
0,1
0,19
0,18
0,35
1) Non indicata in targa.
Temperatura ambiente 0  +40 °C con punte fino a –20 °C e +50 °C.
Lubrificazione «a vita» (in assenza di inquinamento dall’esterno). Quantità d’olio [l] per grand. 50 ... 81
R 2I, 3I MR 2I, 3I
Coassiali
B6, B7,
grand.
V5
B31)
B8, V6
50, 51
63, 64
80, 81
0,8
1,6
3,1
1,1
2,2
4,3
1,4
2,8
5,5
1) Non indicata in targa.
2) Valori validi per R 2I; per MR 2I i valori sono
ri­spettivamente 0,8; 1,2; 2,3.
3) La prima riduzione (le prime due per 4I) è lubri­
ficata con grasso a vita.
Temperatura ambiente 0  +40 °C con punte fino a
–20 °C e +50 °C.
Paralleli
grand.
40, 00
50, 00
63, 64
80, 81
Ortog.
grand.
40, 00
50, 00
63, 64
80, 81
RI
1)
B3 ,
B7
B81),
–
–
–
–
0,7 0,8
1,2 1,5
R 2I, MR 2I
1)
B6,
B3 ,
B62)
V5, V6 B81),
–
0,4 0,9
–
0,6 0,9
1,0
0,9 1,4
1,9
1,5 2,7
R CI, MR CI
B31),
B8
B6, B7
0,26
0,35
0,4
0,60
0,8
1,00
1,3
2,00
R 3I, MR 3I
B7,
V5, V6
0,55
0,80
1,20
2,30
1)
B3 ,
B7,
B6
B81), V53), V6
0,47 0,7
0,6
0,70 1,05
0,9
1,00 1,50
1,3
1,70 2,90
2,5
R ICI, MR ICI
V5,
V6,
0,3
0,45
0,95
1,80
B31),
B6
B8
B71),
0,31
0,5
0,40
0,45
0,8
0,65
1,00
1,6
1,20
1,60
2,7
2,20
Orientativamente l’intervallo di lubrificazione, in assenza di inquinamento
dall’esterno, è quello indicato in tabella. Per sovraccarichi forti, dimezzare i
valori.
Indipendentemente dalle ore di funzionamento:
– sostituire l’olio minerale ogni 3 anni;
– sostituire o rigenerare l’olio sintetico ogni 5  8 anni secondo la grandezza del riduttore, le condizioni di servizio e ambientali.
La quantità d’olio è individuata dal livello segnalato dall’apposito tappo.
Temperatura
olio [°C]

65 
80 
95 
65
80
95
110
1)
1)
1)
1)
MR 4I
1)
B3 ,
B6
B81),
–
–
–
–
1,1 1,8
1,9 3,2
B7,
V6,
–
–
1,4
2,7
V53)
–
–
1,3
2,5
MR C3I
V5,
V6,
0,35
0,50
1,15
2,00
B31),
B6
B8
B71),
–
–
–
0,5
0,9
0,7
1,2
1,8
1,4
1,9
3,0
2,5
V5,
V6,
–
0,55
1,35
2,30
Intervallo di lubrificazione [h]
olio minerale
olio sintetico
8 000
25 000
4 000
18 000
2 000
12 500
– 9 000
1) Valori ammessi solo per assi paralleli, ortogonali e rinvii e per servizi non
continuativi.
** Individuazione anche mediante targa di lubrificazione specifica.
** Lubrificazione con olio sintetico (a base di poliglicoli; necessaria verniciatura interna speciale; a base di polialfaolefine: consigliabile per grand.  200 e tassativo per grand.  400). Sempre
raccomandabile, in particolare per riduttori veloci: per aumentare l’intervallo di lubrificazione («lunga vita»); per aumentare il campo della temperatura ambiente; per aumentare la potenza
termica o ridurre la temperatura dell’olio.
Istruzioni d'uso 4090INS.VPR-it1210HQM
Rossi
7
6 - Lubrificazione
EN
UT.C 764
IT
6.1 - Generalità
I riduttori e motoriduttori possono essere, secondo il tipo e la grandezza, lubrificati con grasso e vengono forniti COMPLETI Dl GRASSO, o con olio (sintetico o minerale) e vengono forniti COMPLETI Dl
OLIO o SENZA OLIO secondo il tipo e la grandezza (ved. cap. 6.2).
Nel caso di fornitura SENZA OLIO, il riempimento fino a livello
(segnalato normalmente dal tappo trasparente di livello) è a cura del
Cliente.
Ogni riduttore è dotato di targa di lubrificazione.
Per tipo e quantità di lubrificante, tipo di riduttore, stato di fornitura,
tappi, norme per il riempimento, intervallo di lubrificazione, ecc. ved.
cap. 6.2 «Tabella lubrificazione».
Assicurarsi che, per riduttori e motoriduttori grand.  100, il tappo di
); in caso contrario,
ca­rico sia del tipo munito di valvola (simbolo
so­stituirlo con quello sfuso che in tali occasioni viene fornito in dotazione.
Se il riduttore o motoriduttore è dotato di tap­po di livello a sfioramento (colore ros­so) il riempimento deve essere effettuato svitando
il tappo medesimo onde verificare il raggiungimento del livello di
sfioramento.
Se il riduttore o motoriduttore è dotato
di tappo di livello con astina, riempire con olio fino al raggiungimento del
livello indicato dalla tacca.
Qualora il riduttore o motoriduttore sia
fornito di tappo di livello (grand. 
100), la quantità di lubrificante da
immettere è quella che consente il
raggiungimento del livello suddetto
a riduttore non in moto in mezzeria
del tappo e non quella, solo indicativa, menzionata a catalogo.
I cuscinetti sono normalmente lubrificati in modo automatico e continuo (a bagno d’olio, a sbattimento, mediante appositi condotti o
pompa) dal lubrificante stesso del riduttore; questo vale anche per
l’eventuale dispositivo antiretro montato sul riduttore.
Per certi riduttori in forma costruttiva verticale V1, V3, V5, V6 e anche
orizzontale B3, B6, B51 per riduttori (non motoriduttori, per i quali
vale quanto detto sopra) ad assi ortogonali, i cuscinetti superiori
hanno lubrificazione indipendente con grasso speciale per lubrificazione «a vita» in assenza di inquinamento dall’esterno; questo vale
anche per i cuscinetti motore (esclusi alcuni casi nei quali è previsto
il dispositivo di rilubrificazione) e per l’eventuale dispositivo antiretro
quando è montato sul motore.
Verificare che iI riduttore venga montato nella forma costruttiva prevista all’ordine, che è indicata sulla targa; quando non è indicata, il
riduttore è previsto per essere montato in forma costruttiva orizzontale B3 o B5 (B3, B8, riduttori a vite grand.  64), verticale V1 (per
rinvii ad angolo in esecuzione con flangia FO1...).
Gruppi riduttori (combinati). La lubrificazione è indipendente e
pertanto valgono le norme dei singoli riduttori.
6.3 - Lubrificazione sopporto estrusore (assi paralleli e ortogonali)
La lubrificazione del sopporto estrusore è separata rispetto al riduttore tranne che:
– per esecuzioni HA ... HC
– in presenza dell’unità autonoma di raffreddamento se utilizzata
per lubrificare sia il riduttore sia il sopporto stesso.
La lubrificazione separata del supporto estrusore migliora sensibilmente l’affidabilità e la durata del cuscinetto assiale; la separazione
fra riduttore e sopporto è realizzata con un anello di tenuta.
Con la lubrificazione separata, utilizzare per il supporto estrusore olio
sintetico a base di polialfaolefine (MOBIL SHC XMP 680, CASTROL
Tribol 1510/680) con gradazione di viscosità ISO 680 cSt.
Con la lubrificazione congiunta (esecuzioni HA ... HC, in presenza
dell’unità autonoma di raffreddamento se è utilizzata per lubrificare
sia il riduttore sia il supporto stesso) la gradazione di viscosità ISO del
lubrificante deve essere secondo quanto indicato al cap. 6.2 tabella
di lubrificazione e l’olio deve essere sintetico a base di polialfaolefine.
Per il riempimento d’olio del supporto estrusore vedi tabella seguente.
Per la lubrificazione del riduttore fare riferimento a quanto indicato al
cap. 6.2, tabella lubrificazione.
Grandezza
riduttore
125 ... 451
Lubrificazione sopporto estrusore
Lubrificazione separata1) Lubrificazione congiunta2)
Riempimento fino
a livello (del sopporto)
Riempimento fino
a livello (del riduttore)
1) Sopporto con tappo di carico metallico con filtro e con valvola, livello e scarico.
2) Il livello è quello della carcassa riduttore.
7 - Sistema di raffreddamento
7.1 - Raffreddamento artificiale con ventola
Quando il riduttore sia dotato di ventola è
necessario prevedere e verificare che resti
un adeguato spazio per l’aspirazione
dell’aria di raffreddamento, anche dopo
aver montato la protezione (carter forato o
rete metallica) del giunto. Se necessario
smussare il mozzo del giunto.
8
Rossi
aria
7.2 - Raffreddamento artificiale con serpentina
La presenza della serpentina è segnalata dagli attacchi (raccordi DIN
2353) per l’acqua sporgenti dalla carcassa come da figura sottostante.
Attenzione: Non manomettere l’eventuale piastrina che mantiene
A
grand.
125 ... 180
200 ... 280
320 ... 360
400 ... 631
d
Ø
12
12
16
16
A1) chiave
≈
140 22
150 22
160 30
200 30
1) Questi valori per alcune forme
costruttive possono variare
bloccati i raccordi; in particolare mantenere bloccato il raccordo mentre si stringe il dado di serraggio del tubo di collegamento.
L’acqua di alimentazione deve possedere i seguenti requisiti:
– bassa durezza;
– temperatura max +20 °C;
– portata 10  20 dm3/min;
– pressione 0,2  0,4 MPa (2  4 bar).
Per temperatura ambiente minore di 0 °C prevedere scarico acqua e
attacco aria, per lo svuotamento della serpentina mediante aria compressa onde evitare il pericolo di congelamento dell’acqua.
Se vi è il rischio di avere picchi elevati di pressione in mandata, monta­
re una valvola di sicurezza tarata a un’opportuna soglia di intervento.
7.3 - Unità autonoma di raffreddamento
Ved. documentazione specifica fornita in dotazione con l’unità.
8 - Messa in servizio
Effettuare un controllo generale assicurandosi in particolare che il
riduttore sia completo di lubrificante.
Nel caso di avviamento Y-, la tensione di alimentazione de­ve corrispondere a quella più bassa (collegamento ) del motore.
Per il motore asincrono trifase, se il senso di rotazione non corrisponde a quello desiderato, invertire due fasi della linea di alimentazione.
Per i riduttori muniti di dispositivo antiretro, controllare – prima
delI’avviamento – che ci sia corrispondenza tra il senso di rotazione libera e i sensi di rotazione della macchina da azionare e del
motore.
Attenzione! Uno o più avviamenti nel senso bloccato, an­che
se brevi, possono danneggiare irrimediabilmente il di­spositivo
antiretro, le sedi accoppiate e/o il motore elettrico.
È consigliabile un rodaggio:
– di circa 400  1 600 h per i riduttori con ingranaggio a vite, affinché
si possa raggiungere il massimo rendimento;
– di circa 200  400 h per i riduttori con ingranaggi cilindrici e/o conici, affinché si possa raggiungere la massima funzionalità.
Durante questo periodo la temperatura del lubrificante e del riduttore
può raggiungere valori più elevati del normale. Dopo tale periodo può
essere necessario verificare il serraggio dei bulloni di fissaggio riduttore.
Nota: il rendimento dei riduttori a vite è più basso nelle prime ore di
funzionamento (circa 50) e in occasione di ogni avviamento a freddo
(il rendimento migliora con l’aumentare della temperatura dell’olio).
Per ulteriori informazioni consultare i cataloghi tecnici Rossi.
9 - Manutenzione
9.1 - Generalità
A macchina ferma, controllare periodicamente (più o meno frequentemente secondo l’ambiente e l’impiego):
a)la pulizia delle superfici esterne e dei passaggi d’aria di ventilazione del riduttore o del motoriduttore, in modo da non pregiudicare
lo smaltimento del calore;
b)il livello e il grado di deterioramento dell’olio (controllare a riduttore freddo);
c)il corretto serraggio delle viti di fissaggio.
In esercizio controllare:
– rumorosità;
– vibrazioni;
– tenute;
– ecc.
Attenzione! Dopo un periodo di funzionamento, il riduttore
(eccetto i pendolari) è soggetto a una lieve sovrapressione
interna che può causare fuoriuscita di fluido ustionante.
Pertanto, prima di allentare i tappi (di qualunque tipo) attendere che il riduttore si sia raffreddato, diversamente avvalersi di opportune protezioni contro le ustioni derivanti dal contatto con l’olio caldo.
In ogni caso procedere sempre con la massima cautela.
Le massime temperature dell’olio, indicate nella tabella lubrificazione
(ved. cap. 6.2), non sono pregiudizievoli per il buon funzionamento
del riduttore.
Cambio olio. Eseguire l'operazione a macchina ferma e riduttore
freddo.
Istruzioni d'uso 4090INS.VPR-it1210HQM
Predisporre un adeguato sistema di raccolta dell'olio esausto, svitare
sia il tappo di scarico sia quello di carico per favorire lo svuotamento;
smaltire il lubrificante esausto in conformità alle disposizioni vigenti
in materia.
Lavare internamente la carcassa del riduttore utilizzando lo stesso
tipo di olio previsto per il funzionamento; l'olio impiegato per questo
lavaggio può essere riutilizzato per ulteriori lavaggi previo filtraggio
con 25 μm di potere filtrante.
Riempire nuovamente fino a livello il riduttore.
È sempre opportuno sostituire gli anelli di tenuta (ved. cap. 9.3).
Qualora venga smontato il coperchio (per i riduttori che ne sono
provvisti), ripristinare la tenuta con mastice dopo aver pulito e sgrassato accuratamente le superfici di accoppiamento.
9.2 - Serpentina
Se il riduttore è destinato a soste prolungate a temperature ambiente inferiori a 0 °C, effettuare lo svuotamento dell’acqua dalla serpentina mediante pompaggio di aria compressa, per prevenire possibili
danni causati dal congelamento.
–
–
–
–
–
prestare attenzione a non danneggiare la superficie esterna del
distanziale;
la linguetta nella cava, assicurandosi che sia garantito un tratto in
presa di almeno 0,9 volte la larghezza del pignone;
il pignone preriscaldato a 80 ÷ 100 °C;
il sistema di fissaggio assiale ove previsto (vite autobloccante in
testa con fondello e distanziale o collare con uno o più grani, fig. a);
per i casi previsti senza fissaggio assiale (fig. b), cospargere di
mastice tipo LOXEAL 58-14 anche la porzione di albero motore
sottostante il pignone;
in caso di sistema di fissaggio assiale con collare e grani, assicurarsi che questi non sporgano rispetto alla superficie esterna del
distanziale: avvitare a fondo il grano e se necessario improntare
l’albero motore con una punta;
lubrificare con grasso (tipo KLÜBER Petamo GHY 133N) la dentatura del pignone, la sede rotante delI’anello di tenuta e l’anello di
tenuta stesso, ed effettuare – con molta cura – il montaggio.
9.3 - Anelli di tenuta
È sempre opportuno sostituire gli anelli di tenuta nel caso in cui:
vengano smontati o in occasione delle revisioni periodiche del riduttore; in tal caso, il nuovo anello deve essere abbondantemente
ingrassato e collocato in modo che il filo di tenuta non lavori sulla
stessa pista di scorrimento dell’anello precedente.
In particolare gli anelli di tenuta devono essere protetti contro le
radiazioni del calore, anche durante eventuali lavori di montaggio a
caldo di componenti.
La durata dipende da molti fattori quali velocità di strisciamento, temperatura, condizioni ambientali, ecc,; orientativamente può variare da
3 150 a 25 000h.
9.4 - Sostituzione motore
Poiché i motoriduttori sono realizzati con motore normalizzato, la
so­stituzione del motore – in caso di avaria – è facilitata al massimo.
È sufficiente osservare le seguenti norme:
– assicurarsi che il motore abbia gli accoppiamenti lavorati in classe
precisa (IEC 60072-1);
– pulire accuratamente le superfici di accoppiamento;
– controllare ed eventualmente ribassare la linguetta, in modo che tra
la sua sommità e il fondo della cava del foro ci sia un gioco di
0,1  0,2 mm; se la cava sull’albero è uscente, spinare la linguetta.
Per motoriduttori a vite MR V ad assi paralleli MR 2I e MR 3I 140
... 360, ad assi ortogonali MR CI, MR C2I (estremità d'albero motore calettata direttamente nel codolo vite, nel pignone cilindrico o
conico rispettivamente):
– controllare che la tolleranza dell’accoppiamento (di spinta) foro/
estremità d’albero sia G7/j6 per D  28 mm, F7/k6 per D  38 mm;
– lubrificare le superfici di accoppiamento contro l’ossidazione di
contatto.
Per motoriduttori ad assi paralleli (2I, 3I) con motori grand. 200
... 315 e motoriduttori MR V, MR 2I e MR CI in esecuzione «Flangia quadrata per servomotori», per lo smontaggio procedere
come segue:
– allineare il foro passaggio chiave con la vite di serraggio del collare
di bloccaggio;
– allentare la vite di serraggio e di conseguenza il collare di bloccaggio;
– smontare il motore.
Per motoriduttori a vite MR IV e MR 2IV, ad assi paralleli MR 3I
40 ... 125 e MR 4I, ad assi ortogonali MR ICI e MR C3I, coassiali
(pignone cilindrico calettato sull'estremità d'albero motore);
– controllare che la tolleranza dell’accoppiamento (bloccato normale)
foro/estremità d’albero sia K6/j6 per D  28 mm, J6/k6 per D  38
mm;
– assicurarsi che i motori abbiano cuscinetti e sbalzi (quota S) come
indicato in tabella;
Grandezza
motore
Capacità di carico dinamico min
daN
Anteriore
Posteriore
63 450 335
71 630 475
80 900 670
90 1 320 1 000
100 2 000 1 500
112 2 500 1 900
132 3 550 2 650
160 4 750 3 350
180 6 300 4 500
200 8 000 5 600
225
10 000 7 100
250
12 500 9 000
280
16 000
11 200
Sbalzo max ‘S’
mm
16
18
20
22,5
25
28
33,5
37,5
40
45
47,5
53
56
–m
ontare sull’albero motore, nell’ordine:
– il distanziale preriscaldato a 65 °C avendo cura di cospargere la
porzione di albero motore interessata con mastice tipo LOXEAL
58-14 e assicurandosi che fra la cava linguetta e la battuta dell’albero motore vi sia un tratto cilindrico rettificato di almeno 1,5 mm;
IT
EN
9.5 - Cuscinetti
Poiché ogni riduttore contiene più cuscinetti, anche di diversa tipologia (a sfera, a rulli conici, a rulli cilindrici, ecc.), ciascuno dei quali funziona con carichi e velocità dipendenti dalla velocità in entrata, dalla
natura del carico della macchina azionata, dal rapporto di trasmissione ecc., e con diverso tipo di lubrificazione (a bagno d’olio, a sbattimento, a grasso, a circolazione.) non è ragionevolmente possibile
stabilire a priori interventi manutentivi di sostituzione dei cuscinetti.
Se si desidera una manutenzione preventiva eseguire periodici
controlli della rumorosità e delle vibrazioni utilizzando idonee
apparecchiature e qualora si constati un peggioramento nei valori
rilevati, anche di modesta entità, arrestare il riduttore o motoriduttore
ed eseguire un’ispezione visiva interna e, se necessario, procedere
alla sostituzione dei cuscinetti ritenuti a rischio.
9.6 - Tappo di carico metallico con filtro e valvola
Qualora il riduttore o motoriduttore (grand.  100) sia
equipaggiato con tappo di carico metallico con filtro e valvola (ved. fig.) per la pulizia del medesimo occorre svitarlo
dal riduttore (proteggere il riduttore dall’ingresso della
polvere e corpi estranei ecc.), smontarne la calotta, lavarlo
con solvente, asciugarlo con aria compressa, rimontarlo).
Effettuare tale intervento in funzione dell’ambiente.
10 - Livelli sonori
La maggior parte della gamma
dei prodotti Rossi è caratterizzata da livelli di pressione
sonora LpA (media dei valori
misurati, a ca­rico nominale e
velocità entrata n1 = 1 400 min1
, a 1 m dalla su­perficie esterna
del riduttore si­tuato in campo
libero e su piano riflettente,
secondo ISO/CD 8579) inferiori o uguali a 85 dB(A).
Nella tabella a lato sono indicati i prodotti che possono
superare tale soglia. Ulteriori
informazioni sui livelli sonori dei
singoli prodotti sono contenute
nei cataloghi tecnici Rossi.
Istruzioni d'uso 4090INS.VPR-it1210HQM
iN
Macchina/rotismo
Assi paralleli
RI
Grand.
 3,15  160
4
 200
R 2I
tutti
 320
R 3I
tutti
 400
R 4I
 160  500
 200  630
R CI
tutti
 320
R C2I
 63
 400
 71
 500
R C3I
tutti
 630
RC
1
 250
Assi ortogonali
Rinvii ad angolo
Rossi
9
Tabella verniciatura
Prodotto
Grand.
Verniciatura interna
Verniciatura esterna
Colore finale
blu RAL 50101)
IT
Vite
32 … 81
Assi paralleli e
ortogonali
40 … 81
Coassiali
32 … 41
Vite
100 … 250
Coassiali
Assi paralleli e
ortogonali
EN
50 … 81
100 … 631
Coassiali
100 … 180
Rinvii (cat. L)
160 … 320
Rinvii (cat. L)
80 … 125
Polveri epossidiche
(preverniciato)
Coassiali2)
Ortogonali2)
Caratteristiche
Polveri epossidiche
(preverniciato)
Fondo
monocomponente a
Fondo
base di resine estere
monocomponente
epossidiche o fenoliche
a base di resine
(preverniciato)
estere epossidiche o
+
fenoliche
Smalto bicomponente
(preverniciato)
poliacrilico all’acqua
Pendolari
–
Smalto bicomponente
poliacrilico all’acqua
–
Fondo epossipoliammidico
bicomponente
+
Smalto bicomponente
poliacrilico all’acqua
(nero opaco RAL 9005)
56 … 142
85 … 142
Note
Resistente agli agenti
atmosferici e aggressivi.
(classe di corrosività C3
secondo ISO 12944-2)
Sovraverniciabile solo con
prodotti bicomponente3)
Le parti lavorate restano
non verniciate e vengono
protette con olio antiruggine
facilmente asportabile
(prima di verniciarle, asportare il protettivo)
La verniciatura interna non
resiste agli oli sintetici a
base di poliglicoli (si può
Resistente agli agenti
impiegare olio sintetico a
atmosferici e aggressivi.
base di polialfaolefine)
(classe di corrosività C3
secondo ISO 12944-2)
Asportare con un raschietto
o con solvente la vernice
Sovraverniciabile solo con
dalle superfici di accoppiaprodotti bicomponente3)
mento del riduttore
Parti lavorate verniciate con
smalto bicomponente
Asportare con un raschietto
poliacrilico all’acqua
o con solvente la vernice
dalle superfici di accoppiamento del riduttore
Resistente agli agenti
atmosferici e aggressivi
(classe di corrosività C3
secondo ISO 12944-2)
Sovraverniciabile solo con
prodotti bicomponente3)
Le parti lavorate restano
non verniciate e vengono
protette con olio antiruggine
facilmente asportabile
(prima di verniciarle, asportare il protettivo)
1) Quando i riduttori sono accoppiati a servomotori (servomotoriduttori) il colore finale è nero opaco RAL 9005.
2) Servomotoriduttori epicicloidali di precisione integrati.
3) Prima di sovraverniciare, proteggere adeguatamente gli anelli di tenuta e procedere alla sgrassatura delle superfici del riduttore.
Tabella momenti di serraggio per le viti di fissaggio assiale e dell’unità di bloccaggio2)
Grand. riduttori
32 40 50 —
a vite
63, —
64,
80, 100 125, 160 161
81, 126,
—
200
—
250
—
—
—
—
—
—
—
—
—
Grand. riduttori
40 50 — 63 64 80 81 100 125 140 — 160 180 200 225 250 280 320, 360 400, 450, 500, 560, 630,
paralleli e ortogonali 321, 401, 451, 501, 561, 631,
M [daN m]
per anelli o bussola
2,9
3,5
4,3
4,3
4,3
5,1
5,3
9,2
17
21
21
34
43
66
83
135 166 257 315
—
—
—
—
—
Viti fissaggio assiale
UNI 5737-88
M81) M81) M101) M10 M10 M10 M10 M12 M14 M16 M16 M20 M20 M24 M24 M30 M30 M36 M36 M30 M30 M36 M36 M36
classe 10.9
M [daN m]
per unità di blocc.
—
0,4
—
1,2
1,2
—
3,0 3 3
— 6 6
Viti unità di blocc.
UNI 5737-88
classe 10.9
—
M5
—
M6 M6 M6
—
M8 M8 M8
— M10 M10 M12 M12 M16 M16 M16 M16 M20 M20 M20 M20 M24
1,2
10
10 25 25 25 25
49
49
49
49
84
1) Per riduttori a vite UNI 5931-84.
2) Le viti dell’unità di bloccaggio devono essere serrate in modo graduale e uniforme con sequenza continua (non diagonalmente!) e in più fasi sino al raggiungimento del momento di
serraggio massimo indicato in tabella.
Tabella momenti di serraggio per le viti di fissaggio (piedi e flange)
M (daN m)
UNI 5737-88
Vite
classe 8.8
M50
M60
M80
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
M33
M36
M39
M42
M45
M48
M56
10
Rossi
000,6
001,1
002,5
005,6
008,5
013,5
020,5
028,5
040,5
055,5
071,5
100,5
138,5
200,5
250,5
295,5
410,5
500,5
610,5
980,5
classe 10.9
0,85
1,50
0003,55
0007,15
0012,85
0019,85
0029,85
0040,85
56
0077,00
0100,00
0140,00
0195,00
0280,00
0355,00
0420,00
0580,00
0710,00
0860,00
1380
Tabella momenti di serraggio per i tappi
Dimensione
filettatura
[daN m]
G 1/4’’
16 MB
G 1/2’’
G 3/4’’
G 1’’
0,7
1,4
1,4
1,4
2,5
Nota:
- normalmente è sufficiente la classe 8.8.
- prima di serrare le viti accertarsi che gli eventuali centraggi delle flange siano inseriti
- l’uno nell’altro
- le viti devono essere serrate diagonalmente con il massimo momento di serraggio.
Istruzioni d'uso 4090INS.VPR-it1210HQM
Anomalie riduttore: cause e rimedi
Anomalia
Eccessiva temperatura
dell’olio
Rumorosità anomala
Perdita di lubrificante
dagli anelli di tenuta
Perdite di lubrificante
dal tappo di carico
Asse lento non ruota
anche se l’asse veloce
o il motore ruotano
Perdita di lubrificante dalle
giunzioni (coperchi o
giunzioni semicarcasse)
Acqua nell’olio
Possibili cause
Rimedi
Lubrificazione inadeguata:
– olio in quantità eccessiva o insufficiente
– lubrificante inadatto (tipolo­gia, troppo viscoso,
esausto, ecc.)
Forma costruttiva errata
Cuscinetti a rulli conici registrati troppo stretti
Riduttore a vite con carico eccessivo durante il
ro­daggio
Temperatura ambiente ec­cessiva
Controllare:
– il livello dell’olio (a riduttore fermo) o la quantità
– il tipo e/o stato del lubrificante (ved. cap. 6.2, tabella
lubrificazione) ed eventualmente sostituirlo
Cambiare la forma costruttiva
Interpellare Rossi
Ridurre il carico
Passaggio aria ostruito
Aria lenta o mancanza di ricircolo
Irraggiamento
Inefficienza dell’eventuale si­stema ausiliario di lubrifi­
ca­zio­ne cuscinetti
Cuscinetti in avaria o mal lubrificati o difettosi
Sistema di raffreddamento dell’olio inefficiente o fuori
servizio: filtro intasato, portata dell’olio (scambiatore)
o dell’acqua (serpentina) insufficiente, pompa fuori
servizio, temperatura dell’acqua 20 °C, ecc.
Uno o più denti con:
– ammaccature o sbeccature
– rugosità eccessiva sui fianchi
Cuscinetti in avaria o mal lubrificati o difettosi
Cuscinetti a rulli conici con gioco eccessivo
Vibrazioni
Anello di tenuta con labbro di tenuta usurato, bachelizzato, danneggiato o montato erroneamente
Sede rotante danneggiata (ri­gatura, ruggine, ammaccattura, ecc.)
Posizionamento in forma co­struttiva diversa da quella
prevista in targa
Troppo olio
Forma costruttiva errata
Valvola di sfiato inefficiente
Togliere il materiale ostruente
Creare ventilazione ausiliaria
Schermare in modo adeguato riduttore e motore
Controllare la pompa e i condotti
Rottura linguetta
Ingranaggio usurato completamente
Aumentare il raffreddamento o correggere la temperatura am­biente
Interpellare Rossi
Controllare la pompa, i condotti, il filtro dell’olio e
l’efficienza degli indicatori di sicurezza (pressostati,
termostati, flussostati, ecc.)
Interpellare Rossi
Interpellare Rossi
Interpellare Rossi
Controllare il fissaggio e i cuscinetti
Sostituire l’anello di tenuta (ved. cap. 8.3)
Rigenerare la sede
Orientare correttamente il ri­duttore
Controllare livello olio o quantità
Controllare la forma costruttiva
Pulire o sostituire il tappo di carico con valvola
Interpellare Rossi
Tenuta difettosa
Interpellare Rossi
Serpentina o scambiatore di calore difettosi
Interpellare Rossi
Per il motore vedere il relativo manuale.
NOTA
Quando si interpella Rossi, indicare:
– tutti i dati di targa del riduttore o motoriduttore;
– la natura e la durata dell’avaria;
– quando e sotto quali condizioni l’avaria si è verificata;
– nel periodo di validità della garanzia, per non farne decadere la validità, non eseguire smontaggi o manomissioni del riduttore o del motoriduttore in nessun caso senza l’autorizzazione di Rossi.
Istruzioni d'uso 4090INS.VPR-it1210HQM
Rossi
11
IT
EN
Montaggio fig. 4a) e
smontaggio fig. 4b)
Installing fig. 4a) and
removing fig. 4b)
fig. 4a)
fig. 4b)
IT
Vite grand.
32 ... 50
Assi paralleli e ortogonali
grand. 50
Assi paralleli e ortogonali
grand. MR 3I 50
Vite grand.
63 ... 161
Assi paralleli e ortogonali
grand. 64 ... 160
Worm sizes
32 ... 50
Parallel and right angle
shaft size 50
Parallel and right angle
shaft size MR 3I 50
Worm sizes
63 ... 161
Parallel and right angle
shaft sizes 64 ... 160
Assi paralleli e ortogonali
grand. MR 3I 63
Parallel and right angle
shaft size MR 3I 63
Vite grand. 200, 250
Assi paralleli e ortogonali
grand. 180 ... 360
Parallel and right angle
shaft sizes 180 ... 360
EN
Assi paralleli e ortogonali
grand. 63
Parallel and right angle
shaft size 63
Worm sizes 200, 250
Fissaggio assiale
fig. 4c)
fig. 4d)
Axial fastening
Vite grand. 32 ... 50
Assi paralleli e ortogonali
grand. 50
Worm sizes 32 ... 50
Parallel and right angle
shaft size 50
Calettamento con
linguetta e anelli di
bloccaggio fig. 4e),
con linguetta e bussola
di
bloccaggio fig. 4f)
Fitting with key
and locking rings
fig. 4e), with key
and locking bush
fig. 4f)
Assi paralleli e ortogonali
grand. 63
Parallel and right angle
shafts size 63
Vite grand. 63 ... 161
Assi paralleli e ortogonali
grand. 64 ... 160
Worm sizes 63 ... 161
Parallel and right angle
shaft sizes 64 ... 160
Vite grand. 200, 250
Assi paralleli e ortogonali
grand. 180 ... 360
Parallel and right angle
shaft sizes 180 ... 360
Worm sizes 200, 250
fig. 4e)
fig. 4f)
Assi paralleli e ortogonali
grand. 140 ... 631
Parallel and right angle
shaft sizes 140 ... 631
Assi paralleli e ortogonali
grand. 50 ... 125
Parallel and right angle
shaft sizes 50 ... 125
Assi paralleli e ortogonali
grand. 400 ... 631
Parallel and right angle
shaft sizes 400 ... 631
1)
fig. 4g)
Calettamento con unità di bloccaggio fig. 4g)
Fitting with shrink disk fig. 4g)
1) Vale solo per grand. 140 ... 360.
1) Valid only for sizes 140 ... 360.
UT.C 825A
12
Rossi
Istruzioni d'uso 4090INS.VPR-it1210HQM
Operating instructions gear reducers and gearmotors
Contents
1 - General safety instructions
13
2 - Operating conditions
13
3 - How supplied
3.1 - Receipt
3.2 - Name plate
3.3 - Painting
3.4 - Protections and packing
13
13
13
13
13
4 - Storing
14
5 - Installation
5.1 - General
5.2 - Fitting of components to shaft ends
5.3 - Shaft-mounting
5.4 - Hollow low speed shaft
14
14
15
15
15
6 - Lubrication
6.1 - General
6.2 - Lubrication table
6.3 - Extruder support lubrication
18
18
16
18
7 - Cooling system
7.1 - Cooling by fan
18
18
Recycling (keeping in mind the instructions in force):
– the elements of casing, gear pairs, shafts and bearings of gear
reducer must be transformed into steel scraps. The elements in grey cast iron will be subjected to the same treatment if there is no particular instruction;
– t he worm wheels are made in bronze and must be treated
adequately;
– exhausted oils must be recycled and treated according to the
instructions.
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
Gear reducers and gearmotors present dangerous parts because
they may be:
– live;
– at temperature higher than +50 °C;
– rotating during the operation;
– eventually noisy (sound levels > 85 dB(A)).
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 IEC 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.
Attention! Components in non-standard design or with constructive
variations may differ in the details from the ones described here following and may require additional information.
Attention! For the installation, use and maintenance of the electric
motor (standard, brake or non-standard motor) and/or the electric supply device (frequency converter, soft-start, etc.) and accessories, if any
(flow indicators, independent cooling unit, thermostat, ecc) consult the
attached specific documentation. If necessary, require it.
Attention! For any clarification and/or additional information consult
Rossi 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 must be incorporated into machinery and should not be commissioned before the
machinery in which the components have been incorporated
conforms to:
–M
achinery directive 2006/42/EC and subsequent updatings;
7.2 - Water cooling by coil
7.3 - Independent cooling unit
18
18
8 - Commissioning
18
9 - Maintenance
9.1 - General
9.2 - Coil
9.3 - Seal rings
9.4 - Motor replacement
9.5 - Bearings
9.6 - Metal filler plug with filter and valve
18
18
19
19
19
19
19
19
10 - Sound levels
Painting table
20
Table of tightening torques for axial fastening
bolts and shrink disc
20
Table of tightening torques for fastening
bolts (foot and flange)
20
Table of tightening torques for plugs
20
Gear reducer troubles: causes and
corrective actions
21
in particular, possible safety guards for shaft ends not being
used and for eventually accessible fan cover passages (or
other) are the Buyer’s responsibility;
– «Electromagnetic compatibility (EMC)» directive 2004/108/
EC and subsequent updatings.
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
starting 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 °C (with peaks at
-10 °C and +50 °C), 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 according to the painting table shown on page 20.
Before adding further coats of paint (use dual-compound paints only),
properly protect the seal rings (which must neither be damaged nor
painted), degrease and sand the gear reducer (or gearmotor) surfaces.
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.
Operating instructions 4090INS.VPR-en1210HQM
Rossi
13
IT
EN
Designation (see
table on the right)
Two months and year
of manufacture
Non-standard designs
Mounting position (when
differing from IM B3
or B5)
Motor power
Gearmotor
output speed
IT
Gear reducer
nominal power
Gearmotor
service factor
Transmission
ratio
Designation
Machine Train of gears
Size
R, MR
R, MR
R, MR
R, MR
R
R
V, IV, 2IV
2I, 3I
I, 2I, 3I, 4I
CI, ICI, C2I, C3I
C
2I
32 ... 250
32 ... 180
40 ... 631
40 ... 631
80 ... 320
85 ... 250
Design
UO ...
FC ..., PC ..., UC ...
UP ...
UO ...
PO ..., FO ...
OP
Product
Worm
Coaxial
Parallel shafts
Right angle shafts
Right angle shafts
Shaft mounted
Ø Flange - motor
shaft
Fig. 1 (for more information, see Rossi technical catalogs; consult us).
Note: Starting from 04/05/2010 the company name ROSSI MOTORIDUTTORI S.p.A. has been changed into Rossi S.p.A., and the nameplates have been updated accordingly.
Attention! for the maintenance, installation of gear reducers coupled with synchronous and asynchronous servomotors (even if with a different name plate) follow the instructions of present handbook.
EN
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 and free from excessive vibrations (veff  0,2 mm/s) to avoid damage to bearings (excessive vibration should also be 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 mentioned on the order during transport and storage.
Every six months rotate the shafts (some revolutions are sufficient)
to prevent damage to bearings and seal rings.
Assuming normal surroundings and the provision of adequate protection during transit, the unit is protected for storage up to 1 year.
For a 2 year storing period in normal surroundings it is necessary to
pay attention also to following instructions:
– generously grease the sealings, the shafts and the unpainted
machined surfaces, if any, and periodically control conservation
state of the protective anti-rust oil;
– for gear reducers and gearmotors supplied without oil: insert anticondensation pastilles into the gear reducers to be replaced before due date and remove them before commissioning (as alternative completely fill the gear reducers with lubrication oil and the
specified level before commissioning).
For storages longer than 2 years or in aggressive surroundings or
outdoors, consult Rossi.
5 - lnstallation
5.1 - General
Before the installation, verify that:
– there were no damages during the storing or the transport;
– 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.
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 lifting systems, and cables of adequate section. If necessary, gear reducer and gearmotor masses are stated
in Rossi technical catalogues.
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 veff  3,5
mm/s for PN  15 kW and veff  4,5 mm/s for PN > 15 kW are acceptable), keeping in mind all transmitted forces due to the masses, to
the torque, to the radial and axial loads.
For the dimensions of fixing screws of gear reducer feet and the
depth of tapped holes consult the Rossi technical catalogues.
Carefully select the length of fixing screws when using tapped holes
for gear reducer fitting, in order to assure a sufficient meshing thread
length 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.
14
Rossi
Incorrect alignment may cause breakdown of shafts and/or bearings (which may cause overheatings) which may represent heavy
danger for people.
Do not use motor eyebolts when lifting the gearmotors.
Position the gear reducer or gearmotor so as to allow a free passage
of air for cooling both gear reducer and motor (especially at their fan
side).
Avoid: any obstruction to the air flow; heat sources near the gear
reducer that might affect the temperature of cooling air and of gear
reducer (for radiation); insufficient air recycle and applications hindering the steady dissipation of heat.
Mount the gear reducer or gearmotor so as not to receive vibrations.
Mating surfaces (of gear reducer and machine) must be clean and sufficiently rough (approximately Ra  6,3 m) to provide a good friction
coefficient: remove 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.
When fitting gear reducer and machine and/or gear reducer and eventual flange B5 it is recommended to use locking adhesives on the
fastening 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.
Y- starting should be adopted for no-load starting (or with a very
small load) and for smooth 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.
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 breaker is unsuitable since its threshold
must be set higher than the motor nominal current of rating.
Connect thermal probes, if any, to auxiliary safety circuits.
Use varistors and/or RC filters to limit voltage peaks due to con­
tactors.
When gear reducer is equipped with a backstop device1), provide a
protection system where a backstop device breaking could cause
personal injury or property damage.
Whenever a leakage of lubricant could cause heavy damages, increase
the frequency of inspections and/or envisage appropriate control devices (e.g.: remote level gauge, lubricant for food industry, etc.).
In polluting surroundings, take suitable precautions against lubricant
contamination through seal rings or other.
For outdoor installation or in a hostile environment (atmospheric corrosivity category C3 according to ISO 12944-2), protect the gear
reducer or gearmotor with a proper dual-compound anticorrosion paint;
added protection may be afforded by applying water-proof grease
(especialIy around the rotary seating of seal rings and at shaft end
access points).
Gear reducers and gearmotors should be protected whenever possible and by appropriate means from solar radiation and extremes of
weather: protection becomes essential when high or low speed
shafts are vertically disposed or when the motor is installed vertical
with fan uppermost.
For ambient temperature greater than +40 °C or less than 0 °C, consult Rossi.
When gear reducer or gearmotor is supplied with water cooling by
coil or independent cooling unit, see ch 7.
1) The presence on gear reducer of backstop device is stated by the arrow near the low
speed shaft, indicating the free rotation, excluding shaft mounted gear reducers where
B or C designs are stated (see Rossi technical catalogues).
Operating instructions 4090INS.VPR-en1210HQM
5.2 - Fitting of components to shaft ends
It is recommended that the holes of parts keyed onto shaft ends
should be machined to H7 tolerance; for high speed shaft ends having D  55 mm, tolerance G7 is permissible provided that the load
is uniform and light; for low speed shaft end having D  180 mm,
tolerance must be K7 if load is not uniform and light.
Before mounting, thoroughly clean mating surfaces and lubricate
against seizure and fretting corrosion.
Attention! Installing and removal operations should be carried out
with the aid of jacking screws and pullers using the tapped hole at
the shaft butt-end (see table in fig. 2) taking care to avoid impacts
and shocks which may irremediably damage the bearings, the
circlips or other parts, for H7/m6 and K7/j6 fits it is advisable that the
part to be keyed is preheated to a temperature of 80  100 °C.
Shaft ends
11  00
14  19
24  28
30  38
42  55
60  75
80  95
100  110
125  140
160  210
240  320
M 5
M 6
M 8
M 10
M 12
M 16
M 20
M 24
M 30
M 36
M 45
Fig. 5a
Fig. 2
UT.C 666
The couplings having a tip speed on external diameter up to 20 m/s
must be statically balanced; for higher tip speeds they must be
dynamically balanced.
Where the transmission link between gear reducer and machine or
motor generates shaft end loads, (see fig. 3), ensure that:
– loads do not rise above catalogue values;
– transmission overhang is kept to a minimum;
– gear-type transmissions must guarantee a minimum of backlash
on all mating flanks;
– drive-chains should not be tensioned (if necessary – alternating
loads and/or motion – foresee suitable chain tighteners);
– drive-belts should not be over-tensioned.
Incorrect
IT
d
Ø
UT.C 886
D
Ø
Attention! For vertical ceiling-type mounting and only
for gear reducers equipped with locking rings or bush, gear
reducer support is due only to friction, for this reason it is
advisable to provide it with a fastening system.
When installing and removing gear reducers and gearmotors with
hollow low speed shaft incorporating a circlip groove – whether
with keyway or shrink disc – proceed as per fig. 4a and 4b, respectively, on page 12.
Warning. Even if low speed shafts are principally machined within
H7 tolerance, a check using a plug could detect two areas with
slightly smaller diameters (see Fig. 5a): this reduction is intentional and does not affect the quality of keying - which in fact
will be improved in terms of duration and precision - and it does
not represent an obstacle to the assembly of a machine shaft end
executed according to the usual methods, such as to the one shown
on Fig. 4a.
Correct
Incorrect
Fig. 3
Correct
UT.C 117
5.3 - Shaft-mounting
When shaft mounted, the gear reducer must be supported both axially
and radially (also for mounting positions B3 ... B8) 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.
Lubricate with proper products the hinges and the parts subject to
sliding; when mounting the screws it is recommended to apply locking adhesives.
For the mounting of the “kit using reaction disc springs” (sizes 125
parallel shafts) use the tapped butt end hole on the shaft end of the
driven machine and the flat machined chamfered surface for compressing and fitting the disc springs into the reaction recess.
Concerning the reaction system, follow the project indications stated in the technical catalogues Rossi. When-ever personal injury or
property damage may occur, foresee adequate supplementary
protection devices against:
– rotation or unthreading of the gear reducer from shaft end of driven
machine following to accidental breakage of the reaction arrangement;
– accidental breakage of shaft end of driven machine.
EN
In order to remove the hollow low speed shaft of the
parallel and right angle
shaft gear reducers (this is
the first operation to pergroove side 
form when disassembling
the gear reducer) turn the
shaft until the keyway is fac­
ing the intermediate shaft
as indicated in fig. 5b and
push the shaft from the refUT.C 322
opposite side to groove
erence groove side (circumFig. 5b
ferencial keyway on shaft
shoulder).
The system shown in fig. 4c and 4d, page 12, is good for axial fastening; when the shaft end of the driven machine has no shoulder
(as in the lower half of the drawing) a spacer may be located
between the circlip and the shaft end itself. Parts in contact with the
circlip must have sharp edges.
The use of locking rings (fig. 4e, page 12) or locking bush (fig. 4f
page 12),will permit easier and more accurate installing and removing
and eliminate backlash between the key and keyway.
The locking rings or bush are fitted after mounting and after having
carefully degreased the coupling surfaces. Do not use molybdenum
bisulphide or equivalent lubricant for the lubrication of the parts in
contact. When tightening the bolt, we recommend the use of a locking adhesive.
Respect the tightening torques stated in the table on page 20.
In case of axial fastening with locking rings or bush – especially
when having heavy duty cycles, with frequent reversals – verify,
after some hours of running, the bolt tightening torque and eventually apply the locking adhesive again.
When fitting with shrink disc (fig. 4g, page 12) proceed as follows:
– carefully degrease the surfaces of hollow shaft and shaft end of
driven machine to be fitted;
– mount the gear reducer onto the shaft end of driven machine following the method indicated in fig. 4a, page 12;
– gradually and uniformly tighten the screws of shrink disc by a
continuous sequence (not crossing) and during several phases up
to a torque stated in the table on page 20;
– at operation end verify the screw tightening torque by means of a
dynamometric key (flat, when it is mounted onto machine end).
5.4 - Hollow low speed shaft
For machine shaft ends onto which the hollow shafts of gear reducers are to be keyed, h6, j6, and k6 tolerances are recommended,
according to requirements.
Important! The shoulder diameter of the shaft end of the driven
machine abutting with the gear reducer must be at least 1,18  1,25
times the internal diameter of hollow shaft. For other data on
machine shaft end, in case of standard hollow low speed shaft,
stepped shaft, with locking rings or bush, with shrink disc see Rossi
technical catalogues.
Operating instructions 4090INS.VPR-en1210HQM
Rossi
15
6.2 - Lubrication table
Product
IT
Worm
sizes 32 ... 81
How supplied* and plugs
Directions for first filling
FILLED WITH
SYNTHETIC OIL
AGIP Blasia S 320, KLÜBER
Klübersynth GH 6-320,
MOBIL Glygoyle HE 320, SHELL
Tivela S 320
Worm speed  280 min-1
KLÜBER Klübersynth GH 6-680
MOBIL Glygoyle HE 680
SHELL Tivela S 680
Filler plug
1 filler plug sizes 32 ... 64
Filler/drain plug
2 filler/drain plugs for sizes 80, 81
EN
Worm
sizes 100 ... 250
Coaxial
sizes 32 ... 41
Right angle shaft
(cat. L)
sizes 80 ... 125
WITHOUT OIL
(except different statement on
Before putting into
lubrication name plate)
service, fill to specified level with synthetic oil (AGIP Blasia
S, ARAL Degol GS,
BP-Energol SG-XP,
MOBIL Glygoyle HE,
SHELL Tivela S ... ,
KLÜBER Klübersynth
GH 6...) having the
ISO viscosity grade
given in the table.
Filler plug with valve,
drain and level plug
ISO viscosity grade [cSt]
Ambient temperature 0  +40 °C2)
Worm speed
Gear reducer size
min-1
100 125 ... 161 200, 250
B31), V5, V6 B6, B7, B8 B31), V5, V6 B6, B7, B8
2 800  1 400 3)
1 400  710 3)
710  355 3)
355  180 3)
< 180
320
320 220 220
320 320
320
460 460
460
680
680 460 460
680 680 680
220
320
1) N
ot stated on the name plate.
2) Peaks of 10 °C above and 10 °C (20 °C for  460 cSt) below the ambient tem­
perature range are acceptable.
3) For these speeds we advise to replace oil after running-in.
FILLED WITH
SYNTHETIC GREASE
SHELL Tivela GL 00
IP Telesia Compound A
MOBIL Glygoyle Grease 00
Filler/drain plug
(only for coaxial)
FILLED WITH
SYNTHETIC OIL
Coaxial
sizes 50 ... 81
KLÜBER Klübersynth GH 6-220
MOBIL Glygoyle 30
SHELL Tivela S 220
Parallel and
right angle shaft
sizes 40 ... 81
Filler/drain plug
2 filler/drain plugs for sizes 80, 81
Coaxial
sizes 100 ... 180
WITHOUT OIL**
(except different statement
on lubrication name plate)
Parallel and
right angle shaft
sizes 100 ... 631
Right angle shaft
(cat. L)
sizes 160 ... 320
Shaft mounted
Filler plug with valve
(with breathing for shaft
mounted gear reducers),
drain and level plugs
Before putting into service, ISO viscosity grade [cSt]
fill to specified level with
Ambient temperature1) [°C]
mineral oil (AGIP Blasia, Speed n2
ARAL Degol BG, BP-En­ergol min-1
mineral oil
synthetic oil
GR-XP, ESSO Spartan EP, IP
Right
Mellana oil, MOBIL Mobilgeangle shaft Others
0  20 10  40 0  40
ar 600, SHELL Omala, TEXA> 710 000 > 224
150
150
150
CO Meropa, TOTAL Carter
710  280 224  22,4
150
220
220
EP) or poly­glycol** synthe280  90 22,4 5,6
220
320
320
tic oil (KLÜBER Klübersynth
GH6 ..., MOBIL Glygoyle,
< 90
000 < 5,6
320
460
460
SHELL Tivela S) or polyal1) Peaks of 10 °C (20 °C) below and 10 °C above the ambient temperature
phaolefines** synthetic oil
range are acceptable.
(AGIP Blasia SX, CASTROL
Tribol 1510, ELF Reductelf SYNTHESE, ESSO Spartan SEP, KLÜBER Klübersynth EG4, MOBIL SHC
Molykote L11 ...) having the ISO viscosity grade given in the table.
Independently-lubricated bearings, motor-bearings, backstop device fitted to motor:
lubrication is «for life» (except some cases of motors in which relubrication device is adopted). Should there be either a possibility of the grease
becoming contaminated, or a very heavy type of duty-cycle, it is good policy to check on the state of the grease (between one change and the
next, or every year or 2 years) and remove and replace grease in independently-lubricated bearings (every change or every other change, or every 2
or 4 years). Bearings should be filled with ESSO BEACON 3 bearing-grease for ball bearings, KLÜBER STABURAGS NBU 8 EP for roller bearings;
lubricate the backstop device with ESSO BEACON 2.
16
Rossi
Operating instructions 4090INS.VPR-en1210HQM
Oil-change interval and lubricant quantity
Oil quantity [l] for worm gear reducers sizes 32 ... 81
For the other sizes the quantity is given by the level stated by the proper plug.
R V, MR V R IV, MR IV
Size B31), V5, B6, B7 B81) B31), V5, B6, B7
B81)
B31)
V6
V6
32
40
50
63, 64
80, 81
0,16
0,26
0,4
0,8
1,3
0,2
0,35
0,6
1,15
2,2
0,16
0,26
0,4
0,8
1,7
0,2
0,32
0,5
1
1,5
0,25
0,4
0,7
1,3
2,5
MR 2IV
B6, B7 B81)
V5, V6
IT
0,2––––
0,32
0,42
0,5
0,42
0,42
0,5
0,6
0,8
0,6
0,6
1
1,2
1,55
1,2
1,2
2
1,7
2,8
2,3
1,8
1) Not stated on name plate (B8, only sizes 32 ... 64).
Ambient temperature 0  +40 °C with peaks up to –20 °C and +50 °C.
EN
An overall guide to oil-change interval is given in the table, and assumes pollution-free
surroundings. Where heavy overloads are present, halve the values.
Oil
temperature [°C]
Oil-change
interval [h]
 65
65  80
80  95
95  110
18 000
12 500
9 000
6 300
Apart from running hours, replace or regenerate the oil each 5  8 years according to size,
running and environmental conditions.
Grease quantity [kg] for coaxial gear reducers
R 2I MR 2I, 3I
Size
B31), B6, B7, B8 V5, V6
B51)
Lubrication «for life» (assuming external pollution-free environment).
0,14
0,26
32
40, 41
0,25
0,47
V1, V3
0,1
0,19
0,18
0,35
1) Non stated on name plate
Ambient temperature 0  +40 °C with peaks up to –20 °C and +50 °C.
Lubrication «for life» (assuming external pollution-free environment). Oil quantity [l] for sizes 50 ... 81
R 2I, 3I MR 2I, 3I
Coaxial
B6, B7,
size
V5
B31)
B8, V6
50, 51
63, 64
80, 81
0,8
1,6
3,1
1,1
2,2
4,3
1,4
2,8
5,5
1) Not stated on name plate.
2) Values valid for R 2I; for MR 2I the values are
respectively: 0,8; 1,2; 2,3.
3) The first reduction stage (the first two for 4I) is
lu­bricated with grease for life.
Ambient temperature 0  +40 °C with peaks up to
–20 °C and +50 °C.
Parallel
size
RI
R 2I, MR 2I
40, 00
50, 00
63, 64
80, 81
B31),
B7
B81),
–
–
–
–
0,7 0,8
1,2 1,5
Right
angle
size
R CI, MR CI
B31),
V5,
B8
B6, B7
V6,
40, 00
50, 00
63, 64
80, 81
0,26
0,4
0,8
1,3
B6,
B31),
B62)
V5, V6 B81),
–
0,4 0,9
–
0,6 0,9
1,0
0,9 1,4
1,9
1,5 2,7
0,35
0,60
1,00
2,00
0,3
0,45
0,95
1,80
An overall guide to oil-change interval is given in the table, and assumes
pollution-free surroundings. Where heavy overloads are present, halve the
values.
Apart from running hours:
— replace mineral oil each 3 years;
— replace or regenerate synthetic oil each 5  8 years according to gear
reducer size, running and environmental conditions.
The oil quantity is given by the level stated by the proper plug.
R 3I, MR 3I
B7,
V5, V6
0,55
0,80
1,20
2,30
MR 4I
B31),
B7,
B6
B81), V53), V6
0,47 0,7
0,6
0,70 1,05
0,9
1,00 1,50
1,3
1,70 2,90
2,5
B31),
B6
B81),
–
–
–
–
1,1 1,8
1,9 3,2
B7,
V6,
–
–
1,4
2,7
V53)
–
–
1,3
2,5
R ICI, MR ICI
B31),
B6
B8
B71),
V5,
V6,
MR C3I
B31),
B6
B8
B71),
V5,
V6,
0,31
0,45
1,00
1,60
0,35
0,50
1,15
2,00
–
0,5
1,2
1,9
–
0,55
1,35
2,30
0,5
0,8
1,6
2,7
0,40
0,65
1,20
2,20
Oil
temperature [°C]

65 
80 
95 
65
80
95
110
1)
1)
1)
1)
–
0,9
1,8
3,0
–
0,7
1,4
2,5
Oil-change interval [h]
mineral oil
synthetic oil
8 000
25 000
4 000
18 000
2 000
12 500
– 9 000
1) Values admissible only for parallel, right angle shaft gear reducers (cat. G and
L) an for non-continuous duties.
** Identification through specific lubrication name plate.
** Lubrication with synthetic oil (polyglycol basis must be with special internal painting; polyalphaolefines basis is advisable for sizes  200 and obligatory for sizes  400). It is always
recommended, particularly for: high speed gear reducers, increase of oil-change interval («long life»), increase of the ambient temperature range, increase of the thermal power or
decrease of oil temperature.
Operating instructions 4090INS.VPR-en1210HQM
Rossi
17
6 - Lubrication
EN
UT.C 764
IT
6.1 - General
Depending on type and size, gear reducers and gearmotors may be
grease-lubricated and supplied FILLED WITH GREASE, or (synthetic
or mineral) oil-lubricated and supplied FlLLED WlTH OlL or WlTHOUT
OIL depending on type and size (see ch. 6.2). When supplying
WITHOUT OIL, the filling up to specified level (normally stated by
means of transparent level plug) is Buyer’s responsibility.
Every gear reducer has a lubrication plate.
Concerning lubricant type and quantity, gear reducer type, how supplied, plugs, filling instructions, oil-change interval, etc. see lubrication table (6.2).
Be sure that for gear reducers and gearmotors size  100, the filler
plug is provided with a valve (symbol
); otherwise, replace it
with the one normally supplied with.
When gear reducer or gearmotor is provided with a spilway plug (red colour) fill
after unscrewing a.m. plug in order to
check the obtained level by oil outlet.
When gear reducer or gearmotor is provided with a level plug with rod, fill with oil
up to specified level on rod.
When gear reducer or gearmotor is supplied with a level plug (size
100), the necessary lubricant quantity is that which reaches a.m.
Ievel in center line of plug (gear reducer at rest) and not the
approximate quantity given on the catalogue.
Usually bearings are automatically and continuously lubricated
(bathed, splashed, through pipes or by a pump) utilising the main
gear reducer lubricant. The same applies for backstop devices, when
fitted to gear reducers.
In certain gear reducers in vertical mounting positions V1, V3, V5 and
V6, and right-angle shaft gear reducers in horizontal positions B3, B6
and B51 (though not gearmotors in this case, for which the above
indications hold good) upper bearings are independently lubricated
with a special grease «for life», assuming pollution-free surroundings. The same applies for motor bearings (except some cases in
which relubrication device is adopted) and backstop devices when
fitted to motors.
Always be sure that the gear reducer is located as per the mounting
position ordered, which appears on the name plate. When no indication is given, the gear reducer may be used in horizontal mounting
position B3 or B5 (B3, B8, worm gear reducers size  64), or vertical
position V1 (in the case of right angle shaft gear reducers in the
design incorporating flange FO1...).
Combined gear reducer units. Lubrication remains independent,
thus data relative to each single gear reducer hold good.
6.3 - Extruder support lubrication (parallel and right angle shaft)
The lubrication of extruder support is separate from the gear reducer, except:
– for designs HA ... HC;
– in presence of the independent cooling unit, if applied to lubricate
both the gear reducer and the support.
The separate lubrication of extruder support sensibly improves the
reliability and real life of the axial bearing; the separation between
gear reducer and support is granted by a seal ring.
With separate lubrication, for the extruder support, use polyalphaolephines based synthetic oil (MOBIL SHC XMP 680, CASTROL Tribol
1510/680) with ISO 680 cSt viscosity grade.
With common lubrication (designs HA ... HC in presence of independent cooling unit, if applied to lubricate both the gear reducer
and the support), lubricant ISO viscosity grade must be according to
the instructions given in ch. 6.2 «lubrication table» and oil must be
polyalphaolephine based synthetic type.
For the filling up of oil of extruder support, see the table below.
Gear reducer
size
125 ... 451
Lubrication of extruder support
Separate lubrication1)
Joint lubrication2)
Filling up
to the level (of support)
Filling up
to the level (of gear reducer)
1) Support with metal filler plug with filter and valve, level and draining plug.
2) The level is metal only in the gear reducer casing.
For the lubrication of gear reducer refer to ch. 6.2, lubrication table.
7 - Cooling system
7.1 - Cooling by fan
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.
18
Rossi
air
7.2 - Water cooling by coil
The presence of coil is given by water inlets (pipes DIN 2353) protruding from the casing as shown in the following figure.
Size
d A1) spanner
Ø ≈
125 ... 180 12 140 22
200 ... 280 12 150 22
320 ... 360 16 160 30
A
400 ... 631 16 200 30
1) These values for some mounting
positions and designs can vary.
Attention: Do not tamper with the eventual stop plate in order to keep
the pipes them locked; in particular keep the pipe locked while tightening the nut of connection pipe. Water fed into the system must:
– be not too hard;
– be at max temperature +20 °C;
– flow at 10  20 dm3/min;
– have a pressure 0,2  0,4 MPa (2  4 bar).
Where ambient temperature may be less than 0 °C, make provision
for water drain and compressed air inlet, so as to be able to empty
out the coil completely and avoid freezing up.
When risking high input pressure peaks, install a safety valve set to
a proper operating threshold.
7.3 - Independent cooling unit
See specific documentation supplied together with the unit.
8 - Commissioning
Carry out an overall check, making particularly sure that the gear
reducer is filled with lubricant.
Where star-delta starting is being used, input voltage must match
the motor lower voltage ( connection).
For asynchronous three-phase motor, if the direction of rotation is
not as desired, invert two phases at the terminals.
Before running gear reducers fitted with backstop device, make
sure that the direction of rotation in machine, gear reducer and
motor all correspond correctly.
Attention! One or more startings in the false direction,
even if short, could irremediably damage the backstop
device, the coupling seats and/or the electric motor.
A running-in period is advisable:
– of approx. 400  1 600 h for gear reducers with worm gear pairs
in order to reach maximum efficiency;
– of approx. 200  400 h for gear reducers with bevel and/or cylindrical gear pairs in order to reach maximum functionality.
The temperature of both gear reducer and lubricant may well rise
beyond normal values during running-in. After the running-in period it
may be necessary to verify the gear reducer fastening bolt tightness.
Note: worm gear reducer efficiency is lower in the first running
hours (about 50) and at every cold starting (efficiency will be better
with oil temperature increasing). For further information consult
Rossi technical catalogues.
9 - Maintenance
9.1 - General
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 the gear reducer or gearmotors are free, in order that cooling remains fully
effective;
b)oil level and deterioration degree (check with cold gear reducer at
rest);
c)the correct fastening screws tightening.
During the operation check:
– noise level;
– vibrations;
– seals;
– etc.
Attention! After a running period, gear reducer (excluding
the shaft mounted gear reducers) is subject to a light internal overpressure which may cause burning liquid discharge. Therefore, before loosening whichever plug wait until
gear reducer has become cold; if not possible, take the necessary
protection measures against burning due to warm oil contact. ln all
cases, always proceed with great care.
Maximum oil temperatures indicated in lubrication table (see ch.6.2)
do not represent a hindrance to the gear reducer regular running.
Oil change. Execute this operation at machine rest and cold gear
reducer.
Prearrange a proper drain oil collection, unscrew both the drain plug
and the filler plug in order to facilitate oil draining; dispose the
exhaust lubricant in compliance with the laws in force.
Operating instructions 4090INS.VPR-en1210HQM
Wash the inside part of gear reducer housing using the same oil type
suitable for the running; the oil used for this wash can be applied for
further washings after proper filtering by 25 μm of filtration standard.
Fill in the gear reducer again up to level.
It is always recommended to replace the seal rings (see ch. 9.3)
When dismounting the cap (whenever gear reducers are provided
with), reset the sealing with adhesive on cleaned and degreased
mating surfaces.
9.2 - Coil
In case of long non-running periods at ambient temperatures lower
than 0 °C, the coil should be emptied out using compressed air to
blast out all the coolant, so as to avoid freezing-up which would
cause the coil to break.
– t he axial fastening system when foreseen (self locking screw on
motor shaft butt-end with washer and spacer or hub clamp with 1
or more dowels, fig. a); for the cases foreseen without axial fastening (fig. b), apply adhesive type LOXEAL 58-14 also on the motor
shaft part laying under the pinion;
– in case of axial fastening system with hub clamp and dowels, make
sure that they do not overhung from spacer external surface:
screw the dowels completely and, if necessary, imprint the motor
shaft with a point;
– grease (with grease type KLÜBER Petamo GHY 133N) the pinion
teeth, the seal ring rotary seating and the ring itself, and assemble
carefully.
9.3 - Seal rings
It is always recommended that the seal rings are replaced with new
ones when they are removed or during periodic checks of gear reducer; in this case, the new ring should be generously greased and
positioned so that the seal line does not work on the same point of
sliding contact as the previous ring.
Oil seals must be protected against heat radiation, also during the
shrink fitting of parts, if applicable.
Durating depends on several factor such as dragging speed, temperature, ambient conditions, ect.; as a rough guide; it can vary from
3 150 to 25 000h.
9.4 - Motor replacement
Since gearmotors are realised with standardised motor, motor
re­placement – in case of failure – is extremely easy. Simply observe
the following instructions:
– be sure that the mating surfaces are machined under accuracy
rating (IEC 60072-1);
– clean surfaces to be fitted thoroughly;
– check and, if necessary, lower the parallel key so as to leave a
clearance of 0,1  0,2 mm between its top and the bottom of the
keyway of the hole. If shaft keyway is without shoulder, lock the
key with a pin.
For worm gearmotors MR V, parallel shaft gearmotrs MR 2I and
MR 3I 140 ... 360, right angle shaft gearmotors MR CI, C2I (motor
shaft end keyed directly into the worm, the cylindrical or bevel pnion
shaft, respectively);
– check that the fit-tolerance (push-fit) between hole and shaft end is
G7/j6 for D  28 mm, F7/k6 for D  38 mm;
– lubricate surfaces to be fitted against fretting corrosion.
For parallel shaft gearmotors (2I, 3I) with motor size 200 ... 315
and gearmotors MR V, MR 2I and MR CI with non-standard
design «Square flange for servomotors», proceed as follows for
disassembling:
– align the key through hole with the tightening screw of the hub
clamp;
– loosen the tightening screw and consequently the hub clamp;
– disassemble the motor.
For worm gearmotors MR IV and MR 2IV, parallel shaft gearmotors MR 3I 40 ... 125 and MR 4I, right angle shafts gearmotors MR
ICI and MR C3I, coaxial gearmotors (cylindrical pinion keyed on to
the motor shaft end);
– check that the fit-tolerance (standard locking) between hole and
shaft end is K6/j6 for D  28 mm, and J6/k6 for D  38 mm;
– make sure that the motors have bearing location and overhang
(distance S) as shown in the table;
Motor
size
Min dynamic load capacity
daN
Front
Rear
63 450 335
71 630 475
80 900 670
90 1 320 1 000
100 2 000 1 500
112 2 500 1 900
132 3 550 2 650
160 4 750 3 350
180 6 300 4 500
200 8 000 5 600
225
10 000 7 100
250
12 500 9 000
280
16 000
11 200
Max dimension
‘S’ mm
16
18
20
22,5
25
28
33,5
37,5
40
45
47,5
53
56
–m
ount onto the motor shaft as follows:
– the spacer pre-heated at 65° C treating the relevant motor shaft
area with adhesive type LOXEAL 58-14 and checking that between keyway and motor shaft shoulder there is a cylindrical part
ground by 1,5 mm at least; pay attention not to damage the
external surface of spacer;
– the key in the keyway, making sure that a contact length of at least
0,9 times the pinion width is present;
– the pinion pre-heated at 80 ÷ 100 °C;
IT
EN
9.5 - Bearings
Since there are many different types of bearings in a gear reducer
(roller, tapered roller, straight roller, etc.) and each bearing works with
different loads and speeds depending on the input speed, the nature
of the load of the driven machine, the transmission ratio, etc., and
with different lubricants (oil bath, oil splash, grease, oil circulation,
etc.), it is not possible to define any periodical maintenance and
replacement of bearings in advance.
If a precautionally maintenance is required, undertake periodical
checks to verify noise level and vibration with the help of appropiate diagniostic equipment and instruments. If the measured
values worsen even slightly it is necessary to stop gear reducer or
gear motor and after having inspected inside the unit replace the
bearings which are subject to breakdown.
9.6 - Metal filler plug with filter and valve
When the gear reducer or gearmotor (size  100) is
equipped with metal filler plug with filter and valve
(see fig.), in order to clean it, it is necessary to
unscrew it from the gear reducer (preventing any
debris or other foreign items from entering the
reducer, disassemble the cover, wash it with solvent, dry with compressed air and reassemble it). This operation is to be made according to environment conditions.
10 - Sound levels
Most of the Rossi product range
is cha­racterised by sound pressure levels L̄pA (mean value of
mea-surement, assuming nominal load and input speed n1 =
1 400 min -1, at 1 m from external profile of gear reducer standing in free field on a reflecting
surface, according to draft proposal ISO/CD 8579) lower or
equal to 85 dB(A).
The table indicates the pro­ducts
which can exceed a.m. threshold. For further information
about sound levels of every single product see Rossi technical
catalogues.
Operating instructions 4090INS.VPR-en1210HQM
iN
Machine/Train of gears
Parallel shaft
RI
Size
 3,15  160
4
 200
R 2I
all
 320
R 3I
all
 400
R 4I
 160  500
 200  630
R CI
all
 320
R C2I
 63
 400
 71
 500
R C3I
all
 630
RC
1
 250
Right angle shaft
Right angle shaft
Rossi
19
Painting table
Product
Size
Internal painting
External painting
Final color
Blue RAL 5010
IT
EN
Worm
32 … 81
Parallel and
right angle
40 … 81
Coaxial type
Worm
32 … 41
100 … 250
Coaxial type
50 … 81
Epoxy powder
(prepainted)
Parallel and
right angle
100 … 631
Coaxial type
100 … 180
Right angle
(cat. L)
Right angle
(cat. L)
160 … 320
80 … 125
–
Shaft mounted
Coaxial2)
56 … 142
Right angle
shaft2)
85 … 142
Features
Resistant to atmospheric
and aggressive agents
Machined parts remain
unpainted and are protected with an easily removable
anti-rust oil (before painting
Suitable for further coats of remove the protective oil)
3)
dual-compound paints only
Epoxy powder
(prepainted)
Single-compound
ester epoxy or
phenolic resin basis
primer
(prepainted)
Notes
(atmospheric corrosivity category C3
according to ISO 12944-2)
The internal painting does
not resist polyglycol synResistant to atmospheric thetic oils (polyalphaolefines
and aggressive agents
synthetic oils are suitable).
(atmospheric corrosivity category C3
Remove by a scraper or
according to ISO 12944-2).
Suitable for further coats of solvent the possible paint
of gear reducer coupling
dual-compound paints only3)
surfaces
Machined parts are painted
wih water-soluble polyacrylic
Remove by a scraper or
dual-compound enamel
Water-soluble
solvent the possible paint
polyacrylic
of gear reducer coupling
dual-compound enamel
surfaces
Single-compound ester
epoxy or phenolic resin
basis primer
(prepainted)
+
Water-soluble
polyacrylic
dual-compound enamel
Dual-compound epoxy
Resistant to atmospheric
Machined parts remain
polyamide primer
and aggressive agents
unpainted and are protect+
(atmospheric corrosivity category C3
ed with an easily removable
according to ISO 12944-2).
Water-soluble dual-comanti-rust oil (before painting
pound polyacrylic enamel Suitable for further coats of
dual-compound paints only3) remove the protective oil)
(matt black RAL 9005)
–
1) When gear reducers are coupled with servomotors (servogearmotors) the final colors is matt black RAL 9005.
2) Integrated low backlash planetary servogearmotors.
3) Before adding further coats of paint, properly protect the seal rings and carefully degrease and sand the gear reducer surfaces.
Table of tightening torques for axial fastening bolts and shrink disc2)
Worm gear
32 40 50 —
reducers size
63, —
64,
80, 100 125, 160 161
81, 126,
—
200
—
250
—
—
—
—
—
—
—
—
—
Parallel and right
40 50 — 63 64 80 81 100 125 140 — 160 180 200 225 250 280 320, 360 400, 450, 500, 560, 630,
angle shaft size 321, 401, 451, 501, 561, 631,
M [daN m]
for rings or bush
2,9
3,5
4,3
4,3
4,3
5,1
5,3
9,2
17
21
21
34
43
66
83
135 166 257 315
—
—
—
—
—
Bolts for axial fastening
UNI 5737-88
M81) M81) M101) M10 M10 M10 M10 M12 M14 M16 M16 M20 M20 M24 M24 M30 M30 M36 M36 M30 M30 M36 M36 M36
class 10.9
M [daN m]
for shrink disc
—
0,4
—
1,2
1,2
—
3,0 3 3
— 6 6
Bolts for shrink
disc UNI 5737-88
class 10.9
—
M5
—
M6 M6 M6
—
M8 M8 M8
— M10 M10 M12 M12 M16 M16 M16 M16 M20 M20 M20 M20 M24
1,2
10
10 25 25 25 25
49
49
49
49
84
1) For worm gear reducers UNI 5931-84.
2) The bolts of shrink disc must be gradually and uniformly tightened, with continuous sequence (not diagonally!) and in several phases up to the reaching of maximum tightening torque stated on table.
Table of tightening torques fastening bolts (foot
and flange)
Bolt
M (daN m)
UNI 5737-88
class 8.8
M50
M60
M80
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
M33
M36
M39
M42
M45
M48
M56
20
Rossi
000,6
001,1
002,5
005,6
008,5
013,5
020,5
028,5
040,5
055,5
071,5
100,5
138,5
200,5
250,5
295,5
410,5
500,5
610,5
980,5
class 10.9
0000,85
0001,50
0003,55
0007,15
0012,85
0019,85
0029,85
0040,85
56
0077,00
0100,00
0140,00
0195,00
0280,00
0355,00
0420,00
0580,00
0710,00
0860,00
1380
Table of tightening torques for plugs
Thread
dimension
[daN m]
G 1/4’’
16 MB
G 1/2’’
G 3/4’’
G 1’’
0,7
1,4
1,4
1,4
2,5
Note
- Class 8.8 is usually sufficient.
- 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.
Operating instructions 4090INS.VPR-en1210HQM
Gear reducer troubles: causes and corrective actions
Trouble
Excessive oil temperature
Anomalous noise
Lubricant leaking
from seal rings
Possible causes
Corrective actions
Inadequate lubrication:
– excessive or insufficient oil quantity;
Check:
– oil level (gear reducer at rest) or quantity
–u
nsuitable lubricant (diffe­rent type, too viscous,
ex­hausted, etc.)
wrong mounting position
Too tightened taper roller bearings
Worm gear reducer with excessive load during
running-in
Excessive ambient tempe­rature
Obstructed passage of air
Slow or missing air recycle
Radiance
Inefficiency of auxilia­r y bearing lubrication
system
Worn, faulty or badly lubricated bearings
– lubricant type and/or state (see ch. 6.2 lubrication
table); replace if necessary
Change mounting position
Consult Rossi
Reduce the load
Inefficient or out of service oil cooling system: obstructed filter, insufficient oil (exchanger) or water (coil) flow
rate, pump out of service, water temperature 20
°C, etc.
One or more teeth with:
– dents or spallings
– excessive flanks roughness
Worn, faulty or badly lubricated bearings
Taper roller bearings with ex­cessive clearance
Vibrations
Seal ring with worn, bakelized, damaged or false
mounted seal lip
Damaged raceway surface (scoring, rust, dent, etc.)
Increase the cooling or correct the ambient temperature
Eliminate obstructive material
Arrange auxiliary ventilation
Screen gear reducer and motor properly
Check the pump and the pipes
Consult Rossi
Check pump, pipes, oil filter and safety devices efficiency (pressure switchs, thermostats, flow indicators, etc.)
Consult Rossi
Consult Rossi
Consult Rossi
Check the fastening and the bearings
Replace seal ring (see ch. 8.3)
Restore the raceway
Mounting position differs from the one stated on the Position the gear re­ducer correctly
name pla­te
Oil leaking from filler plug
Too much oil
Check oil level/quantity
Incorrect mounting position
Check mounting position
Inefficient vent valve
Clean/replace filler plug with vent valve
Low speed shaft not rotating Broken key
even with high speed shaft/
Consult Rossi
Completely worn gear pair
motor running
Lubricant leaking from
joints (covers or
half-casing joints)
Water in the oil
IT
Defective oil seals
Consult Rossi
Defective cooling coil or heat exchanger
Consult Rossi
Motor: see specific instructions.
NOTE
When consulting Rossi state:
– all data of gear reducer or gearmotor name plate;
– nature and duration of failure;
– when and under which conditions the failure occured;
– during the warranty period, in order not to loose validity, do not disassemble nor tamper the gear reducer or gearmotor without approval
by Rossi.
Operating instructions 4090INS.VPR-en1210HQM
Rossi
21
EN
Note
Notes
IT
EN
22
Rossi
Operating instructions 4090INS.VPR-en1210HQM
19 - Installazione e manutenzione
19 - Installation and maintenance
Il montaggio e lo smontaggio si effettuano con l’ausilio di tiranti ed
estrattori servendosi del foro filettato in testa all’estremità d’albero; per
accoppiamenti H7/m6 e K7/j6 è consigliabile effettuare il montaggio a
caldo riscaldando l’organo da calettare a 80 100 °C.
Installing and removal operations should be carried out with pullers
and jacking screws using the tapped hole at the shaft butt-end; for H7/
m6 and K7/j6 fits it is advisable that the part to be keyed is pre-heated
to a temperature of 80 100 °C.
Albero lento cavo
Hollow low speed shaft
Per lo smontaggio dell’albero lento cavo (è la prima operazione da eseguire per smontare il riduttore) orientare la cava linguetta verso l’asse
intermedio come indicato nella figura a fianco e spingere l’albero sul
lato gola di riferimento (ved. cap. 18).
Per il perno delle macchine sul quale va calettato l’albero
cavo del riduttore, raccomandiamo le tolleranze h6, j6
oppure k6 secondo le esigenze. Altri dati secondo quanto
indicato al paragrafo «Estremità d’albero» e «Perno macchina» (cap. 18).
Per facilitare il montaggio e lo smontaggio dei riduttori
grandezze 64 ... 360 (con gola anello elastico), procedere
come raffigurato nelle figg. a, b rispettivamente (escluso
MR 3l 100 con grand. motore 112 e 3I 125 con grand.
motore 132; interpellarci)
Per MR 3I 64 ... 81, prima inserire nell’albero cavo del riduttore (dal lato opposto motore) la rosetta munita di vite e l’anello elastico,
quindi montare sul perno macchina.
Per il fissaggio assiale si può adottare il sistema raffigurato nelle figg. c,
d. Per grandezze 64 ... 360, quando il perno macchina è senza battuta,
si può interporre un distanziale tra l’anello elastico e il perno stesso
(metà inferiore della figura d).
Utilizzando gli anelli di bloccaggio (grandezze 40 ... 63, fig. e), o la
bussola di bloccaggio (grandezze 64 ... 360, fig. f) si possono avere
un montaggio e uno smontaggio più facili e precisi e l’eliminazione del
gioco tra linguetta e relativa cava, sistema ad atrito compatibile con
Atex.
Gli anelli o la bussola di bloccaggio devono essere inseriti dopo il
montaggio (per MR 3I 64 ... 81 inserire la bussola sul perno macchina
o nell’albero cavo prima del montaggio; fare attenzione ad orientare
la cava linguetta); il perno macchina deve essere come indicato al
cap. 18 (o 20 nel caso di albero lento cavo: differenziato, con unità di
bloccaggio). Non utilizzare bisolfuro di molibdeno o lubrificanti equivalenti per la lubrificazione delle superfici a contatto. Per il montaggio
della vite si raccomanda l’impiego di adesivi bloccanti tipo LOCTITE 601. Per montaggi verticali a soffitto interpellarci.
In caso di fissaggio assiale con anelli o bussola di bloccaggio – soprattutto in presenza di cicli gravosi di lavoro, con frequenti inversioni del
moto – verificare, dopo alcune ore di funzionamento, il momento di
serraggio della vite ed eventualmente riapplicare l’adesivo bloccante.
A richiesta si può fornire (cap. 20) la rosetta di montaggio, smontaggio (escluso grand. 40 ... 63) e fissaggio assiale riduttore con o senza
gli anelli o la bussola di bloccaggio (dimensioni indicate in tabella)
o l’albero lento cavo con unità di bloccaggio (dimensioni indicate al
cap. 20) e il cappellotto di protezione albero lento cavo. Le parti a
contatto con l’eventuale anello elastico devono essere a spigolo vivo.
Se vi sono pericoli per persone o cose derivanti da cadute o proiezioni del riduttore o di parti di esso, prevedere appropriate sicurezze
contro:
– la rotazione o lo sfilamento del riduttore dal perno macchina conseguenti a rotture accidentali del vincolo di reazione;
– la rottura accidentale del perno macchina.
In order to remove the hollow low speed shaft (this is the first operation
to perform when disassembling the gear reducer) turn the shaft until
the keyway is facing the intermediate shaft, as shown in the drawing
alongside, and push the shaft from the reference groove
side (see ch. 18).
For the shaft end of machines where the hollow shaft of
the gear reducer is to be keyed, h6, j6 or k6 tolerances are
recommended (according to requirements). Other details
are given under «Shaft end» and «Shaft end of driven
machine» (ch. 18).
In order to have an easier installing and removing of gear
reducer sizes 64 ... 360 with circlip groove proceed as per
the drawings a, b, respectively (excluding MR 3l 100 with
motor size 112 and 3I 125 with motor size 132; consult us).
For MR 3I 64 ... 81 first insert the washer with screw and
the circlip into gear reducer hollow shaft (on motor opposite side); then
mount on machine shaft end.
The system illustrated in the fig. c, d is good for axial fastening.
For sizes 64 ... 360, when shaft end of driven machine has no shoulder
a spacer may be located between the circlip and the shaft end itself
(as in the lower half of the fig. d).
The use of locking rings (sizes 40 ... 63, fig. e), or of locking bush
(sizes 64 ... 360, fig. f) will permit easier and more accurate installing
and removing and to eliminate backlash between key and keyway,
friction system complying with Atex.
The locking rings or the locking bush are fitted after mounting (for MR
3I 64 ... 81 insert the bush onto machine shaft end or into hollow shaft
before mounting; pay attention when positioning the keyway); the shaft
end of the driven machine must be as prescribed at ch. 18 (or 20 in
case of hollow low speed shaft: stepped, with locking assembly). Do
not use molybdenum bisulphide or equivalent lubricant for the lubrication of the parts in contact. When tightening the bolt, we recommend
the use of a locking adhesive such as LOCTITE 601. For vertical
ceiling-type mounting, contact us.
In case of axial fastening with locking rings or bush – especially when
having heavy duty cycles, with frequent reversals – verify, after some
hours of running, the bolt tightening torque and eventu-ally apply the
locking adhesive again.
A washer for installing, removing (excluding sizes 40 ... 63) and
axial fastening of gear reducer (ch. 20) with or without locking rings,
locking bush (dimensions shown in the table) or hollow low speed
shaft with shrink disc (dimensions stated on ch. 20), and a protection
cap for the hollow low speed shaft can be supplied on request. Parts
in contact with the circlip must have sharp edges.
Whenever personal injury or property damage may occur, foresee
adequate supplementary protection devices against:
– rotation or unthreading of the gear reducer from shaft end of driven
machine following to accidental breakage of the reaction arrangement;
– accidental breakage of shaft end of driven machine.
Montaggio a) e
smontaggio b).
Installing a) and
removing b).
Fissaggio assiale
Axial fastening
Callettamento con linguetta e anelli di bloccaggio e),
con linguetta e bussola di bloccaggio f).
Fitting with key and locking rings e),
with key and locking bush f).
G05 June 2011
139
19 - Installazione e manutenzione
Grandezza
riduttore
Gear reducer
size
40
50
63
64
80
81
100
125
140
160
180
200
225
250
280
320, 321
360
A
D
Ø
D1
Ø
D3
Ø
19 - Installation and maintenance
E3
≈
F
F1
h
h1
h2
L
n
Vite fissaggio assiale
Bolt for axial fastening
UNI 5737-88
4)
4)
–
–
–
19
24
30
22,5
27,5
34
15
194)
254)
–
–
–
–
–
–
–
–
–
18
18
18
32
38
40
23
27
28
27
32
34
9
11
11
M 10
M 10
M 10
M 65)
M 65)
M 60
23
30
36
48
60
70
35
45
54
41
52
62
13
15
15
M 12
M 14
M 16
45
49
56
80
90
100
63
72
81
70
80
88
20
20
24
64
72
87
110
125
140
89
98
102,5 110
117
125
97
117
160
180
133,5 140
153
160
14,8
14,8
18,5
4)
2)
M [daN m]1)
2,8
2,8
3,7
4
4
5
12,6
12,64)
18,94)
1,1
1,2
1,4
M 8 25
M 8 252)
M 10 302)
2,9
3,5
4,3
10
12
12
–
–
–
–
–
–
19
23
23
6
6
6
M 10
M 10
M 10
35
353)
353)
4,3
5,1
5,3
M 80
M 10
M 12
14
16
19
–
–
–
–
–
–
28
35
40
7
7
8
M 12
M 14
M 16
453)
453)
50
9,2
17
21
M 20
M 20
M 24
M 12
M 16
M 16
19
23
23
–
–
–
–
–
–
45
49
52
8
9
10
M 20
M 20
M 24
60
603)
70
34
43
66
24
30
30
M 24
M 30
M 30
M 16
M 20
M 20
24
28
30
–
–
–
–
–
–
60
67
76
10
11
12
M 24
M 30
M 30
703)
90
903)
83
135
166
41
41
M 36
M 36
M 24
M 24
33
36
–
–
–
–
86
95
13
14
M 36
M 36
110
1103)
257
315
1) Momento di serraggio per anelli o bussola di bloccaggio.
2) UNI 5931-84. Per MR 3I: M 8 35 e M 10 40 UNI 5737-88.
3) Per bussola di bloccaggio: M 10 35, M 12 45, M 14 45, classe 10.9; M 20 65,
M 24 80 e M 30 100 UNI 5737-88 classe 10.9; M 36 120 UNI 5931-84 classe 10.9.
4) Bussola di bloccaggio non possibile per MR 3I.
5) Non utilizzabile per lo smontaggio MR 3I.
1) Tightening torque for locking rings or bush.
2) UNI 5931-84. For MR 3I: M 8 35 and M 10 40 UNI 5737-88.
3) For locking bush: M 10 35, M 12 45, M 14 45, class 10.9; M 20 65, M 24 80 and
M 30 100 UNI 5737-88 class 10.9; M 36 120 UNI 5931-84 class 10.9.
4) Locking bush is not possible for MR 3I.
5) It cannot be used for the disassembly of MR 3I.
Lubrificazione
Lubrication
La lubrificazione degli ingranaggi è a bagno d’olio eccetto la prima
riduzione dei riduttori ad assi paralleli rotismo 3I e le prime due riduzioni
dei motoriduttori 4I grandezze 125 in forma costruttiva V5 che sono
lubrificate con grasso «a vita» (SHELL Tivela Compound A). Anche i
cuscinetti sono lubrificati a bagno d’olio, o a sbattimento, eccetto i
cuscinetti superiori che sono lubrificati con pompa (ved. cap. 20) o con
grasso «a vita» (con o senza anello NILOS secondo la velocità).
Grandezze 40 ... 81: i riduttori vengono forniti completi di olio sintetico (KLÜBER Klübersynth GH 6-220, MOBIL Glygoyle 30), per
lubrificazione – in assenza di inquinamento dall’esterno – «a vita».
Temperatura ambiente 0 40 °C con punte fino a -20 °C e +50 °C.
Importante: verificare la forma costruttiva tenendo presente che se
il riduttore viene installato in forma costruttiva diversa da quella indicata in targa potrebbe richiedere l’aggiunta – attraverso l’apposito
foro – della differenza tra le due quantità di lubrificante indicate nei
cap. 8, 10, 12 e 14.
Grandezze 100 ... 360: i riduttori vengono forniti senza olio; occorre
quindi, prima di metterli in funzione, immettere fino a livello1), olio
minerale (AGIP Blasia, ARAL Degol BG, BP-Energol GR-XP,
ESSO Spartan EP, IP Mellana oil, MOBIL Mobilgear 600, SHELL
Omala, TEXACO Meropa, TOTAL Carter EP) avente la gradazione di
viscosità ISO indicata in tabella. Normalmente il primo campo di
velocità riguarda il rotismo I, il secondo riguarda i rotismi 2I e CI, il
terzo riguarda i rotismi 3I, 4I, C2I, ICI e C3I, il quarto riguarda i gruppi.
Quando si vuole aumentare l’intervallo di lubrificazione («lunga
vita»), il campo della temperatura ambiente e/o ridurre la temperatura dell’olio impiegare olio sintetico (a base di poliglicoli: KLÜBER
Klübersynth GH6 ..., MOBIL Glygoyle, SHELL Tivela S oil...; a base
di polialfaolefine, sempre consigliati, soprattutto per grand. 200:
AGIP Blasia SX, CASTROL Tribol 1510, ELF Reductelf SYNTHESE,
ESSO Spartan SEP, KLÜBER Klübersynth EG4, MOBIL SHC Molykote L11 ...) avente la gradazione di viscosità ISO indicata in tabella.
Gear pairs are oil-bath lubricated with the exception of the first reduction stage in parallel shaft gear reducers train of gears 3I and the first
two reduction stages of gearmotors 4I sizes 125 in V5 mounting
position, which are lubricated «for life» with grease (SHELL Tivela
Compound A). Bearings are either oil-bathed or splashed with the
exception of the top bearings which are lubricated with a pump (see
ch. 20) or lubricated «for life» with grease (with or without NILOS ring
according to speed).
Sizes 40 ... 81: the gear reducers are supplied filled with synthetic
oil (KLÜBER Klübersynth GH 6-220, MOBIL Glygoyle 30) providing
lubrication «for life» – assuming pollution-free surroundings. Ambient temperature range 0 40 °C with peaks of –20 °C and +50 °C.
Important: verify mounting position keeping in mind that if gear
reducer is installed in a mounting position differing from the one stated
on name plate, it could need the addition – through the proper hole
– of the difference between the two lubricant quantities as shown in
ch. 8, 10, 12 and 14.
Sizes 100 ... 360: gear reducers are supplied without oil; before
putting into service, fill to the specified level1) with mineral oil (AGIP
Blasia, ARAL Degol BG, BP-Energol GR-XP, ESSO Spartan EP, IP
Mellana oil, MOBIL Mobilgear 600, SHELL Omala, TEXACO Meropa,
TOTAL Carter EP) having the ISO viscosity grade given in the table.
Under normal conditions the first speed range is for train of gears I,
the second is for trains of gears 2I and CI, the third is for trains of
gears 3I, 4I, C2I, ICI and C3I, while the fourth is for combined units.
When it is required to increase oil change interval («long life»), the
ambient temperature range, and/or reduce oil temperature, use
synthetic oil (with polyglycol basis: KLÜBER Klübersynth GH6
..., MOBIL Glygoyle, SHELL Tivela S oil...; with polyalphaolefines
basis, always suggested especially for sizes 200: AGIP Blasia
SX, CASTROL Tribol 1510, ELF Reductelf SYNTHESE, ESSO Spartan SEP, KLÜBER Klübersynth EG4, MOBIL SHC Molykote L11 ...)
having ISO viscosity grade as indicated in the table.
1) Le quantità di lubrificante indicate ai cap. 8, 10, 12, 14 sono da intendersi orientative
ai fini dell’approvvigionamento. La quantità esatta di olio da immettere nel riduttore è
definita dal livello.
1) The lubricant quantities contained in ch. 8, 10, 12, 14 are approximate and indicative
for provisioning. The exact oil quantity the gear reducer is to be filled with is definitely
given by the level.
Gradazione di viscosità ISO
ISO viscosity grade
Valore medio [cSt] della viscosità cinematica a 40 °C.
Mean kinematic viscosity [cSt] at 40 °C.
Velocità n2
min-1
224
224 22,4
22,4 5,6
5,6
Temperatura ambiente1) [°C]
olio minerale
olio sintetico
0 20
10 40
0 40
150
150
220
320
150
220
320
460
Speed n2
min-1
224
224 22,4
22,4 5,6
5,6
150
220
320
460
Ambient temperature1) [°C]
mineral oil
synthetic oil
0 20
10 40
0 40
150
150
220
320
150
220
320
460
150
220
320
460
1) Sono ammesse punte di temperatura ambiente di 10 °C (20 °C per olio sintetico) in
meno o 10 °C in più.
1) Peaks of 10 °C above and 10 °C (20 °C for synthetic oil) below the ambient temperature
range are acceptable.
Se il servizio è continuo, è consigliabile impiegare olio sintetico nei
seguenti casi:
– R ICI, MR C3I 100, 125 e MR ICI 100 ... 200 forma costruttiva B6;
– R I 100 con n2 375 min-1;
– R CI 100 con n2 150 min-1;
– R 2I e MR 2I 125 con iN 12,5, forma costruttiva B7, n1 950 min-1;
– MR ICI 200 con motore grandezza 225;
– riduttori e motoriduttori di grandezza e forma costruttiva contras-
For continuous duty, the use of synthetic oil is recommended in the
following cases:
– R ICI, MR C3I 100, 125 and MR ICI 100 ... 200 mounting position B6;
– R I 100 with n2 375 min-1;
– R CI 100 with n2 150 min-1;
– R 2I and MR 2I 125 with iN 12,5, mounting position B7, n1 950 min-1;
– MR ICI 200 with motor size 225;
– gear reducers and gearmotors with size and mounting position
140
G05 June 2011
20 - Accessori ed esecuzioni speciali
2I, 3I, C2I 140 ... 360
20 - Accessories and non-standard designs
CI 125 ... 360
Grandezza
riduttore
Gear
reducer
size
125, 140
160, 180
200, 225
Vite
Bolt
Molla a tazza
Disc spring
UNI 5737-88
DIN 2093
T
F
R
Ø
1)
M 16
M 20
M 24
110
130
160
A 50 n. 2
A 63 n. 3
A 80 n. 2
25 32
25 38
29 48
20 13,1
24 17,9
30 20,7
250, 280 M 30
320 ... 360 M 36
200
260
A 100 n. 2 37 60
A 100 n. 3 45 75
36 26,2
42 32,2
1) Valore teorico: tolleranza 0 -1.
1) Theoretical value: tolerance 0 -1.
Descrizione aggiuntiva alla designazione per l’ordinazione: bullone di reazione a molle a tazza.
Supplementary description when ordering by designation: reaction bolt using disc springs.
Albero lento cavo differenziato
Stepped hollow low speed shaft
I riduttori e motoriduttori grandezze 64 ... 360 possono anche essere
forniti ad albero lento cavo differenziato sempre con cava linguetta;
questa esecuzione facilita il montaggio e lo smontaggio e aumenta
notevolmente la rigidezza e la resistenza a flessotorsione del perno
macchina.
Il foro con Ø D2 è sempre lato opposto gola.
Gear reducers and gearmotors sizes 64 ... 360 can be also supplied
with stepped hollow low speed shaft always with keyway; this design
facilitates installation and removal and affords a notable increase
in rigidity and resistance to bending and torsional stresses at the
shaft end of the driven machine.
Hole with Ø D2 is always opposite to groove side.
Grandezza
riduttore
Gear reducer
size
D
D2
Ø
Ø
D3
Ø
E
E1
E2
E3
l
m
n
r
H7/h6
64
80
81
100
125
140
160
180
200
225
32
38
40
48
60
70
80
90
100
110
250
280
320, 321
360
125
140
160
180
H7/j6, k6
H7/h6, j6
35
40
42
52
65
75
85
100
110
120
27
32
34
41
52
62
70
80
88
98
110
134
134
162
201
228
250
274
308
331
63
75
72
92
118
135
147
162
188
195
28
35
38
41
47
52
57
63
66
75
10
12
12
14
16
16
21
21
25
25
70
90
90
110
140
180
200
200
250
250
28
30
30
35
40
35
36
50
42
55
6
6
6
7
7
8
8
9
10
10
1,5
1,5
1,5
2
2
2
3
3
3
3,5
135
150
170
195
110
125
140
160
380
410
471
506
228
238
276
293
84
94
107
116
32
32
43
43
320
320
400
400
40
60
45
72
11
12
13
14
4
4
5
5
Posizione gola di riferimento (ved. cap. 18).
Position of the reference groove (see ch. 18).
Il disegno a sinistra raffigura il perno macchina per calettamento
con linguetta.
Il disegno a destra raffigura il perno macchina per calettamento con
linguetta e bussola di bloccaggio (ved. cap. 19).
Importante: il diametro del perno della macchina in battuta contro
il riduttore deve essere almeno (1,18 1,25) · D.
The left drawing shows a shaft end of driven machine for coupling
with a key.
The right drawing shows a shaft end of driven machine for coupling
with a key and locking bush (see ch. 19).
Important: the shoulder diameter of the shaft end of the driven machine
abutting with the gear reducer must be at least (1,18 1,25) · D.
Descrizione aggiuntiva alla designazione per l’ordinazione: albero
lento cavo differenziato.
Supplementary description when ordering by designation: stepped
hollow low speed shaft.
G05 June 2011
149
IT
EN
Operating instructions 4090INS.VPR-en1210HQM
Rossi
23
Austria
Habasit GmbH
A-1234 Wien
Phone +43 1 690 66
fax +43 1 690 66 10
e-mail: info.austria@habasit.com
www.habasit.com
Finland
Habasit AB
S - 430 63 Hindås
Phone +46 301 226 00
fax +46 301 226 01
e-mail: info@habasit.se
www.habasit.se
Moldova
Habasit GmbH
A-1234 Wien
Phone +43 1 690 66
fax +43 1 690 66 10
e-mail: info.austria@habasit.com
www.habasit.com
Switzerland
Habasit GmbH
CH - Reinach - Basel
Phone +41 61 715 15 75
fax +41 61 715 15 56
e-mail: info.ch@habasit.com
www.habasit.ch
Australia
Rossi Gearmotors Australia Pty. Ltd.
AU - Perth WA
Phone +61 8 94557399
fax +61 8 94557299
e-mail: info.australia@rossi-group.com
www.rossigearmotors.com.au
France
Rossi Motoréducteurs SARL
F - Saint Priest
Phone +33 472 47 79 30
fax +33 472 47 79 49
e-mail: info.france@rossi-group.com
www.rossimotoreducteurs.fr
New Zealand
Rossi Gearmotors New Zealand Ltd.
NZ - Auckland
Phone +61 9 263 4551
fax +61 9 263 4557
e-mail: info.nz@rossi-group.com
www.rossigearmotors.com.au
Taiwan
Habasit Rossi (Taiwan) LTD.
TW - Taipei Hsien
Phone +886 2 22670538
fax +886 2 22670578
e-mail: info.hea@habasit.com
www.rossi-group.com
Benelux
Habasit Netherlands B.V.
NL - Nijkerk
Phone +31 33 247 20 30
Fax: +31 33 246 15 99
e-mail: netherlands@habasit.com
www.rossi-group.com
Germany
Habasit GmbH
D - Eppertshausen
Phone +49 6071 / 969 - 0
fax +49 6071 / 969 -150
e-mail: rossi.germany@habasit.com
www.habasit.de
Norway
Habasit Norge A/S
N - 1001 OSLO
Phone +47 81 558 458
fax +47 22 301 057
e-mail: info@habasit.se
www.habasit.no
Ucraina
Habasit GmbH
A-1234 Wien
Phone +43 1 690 66
fax +43 1 690 66 10
e-mail: info.austria@habasit.com
www.habasit.com
Bielorussia
Habasit GmbH
A-1234 Wien
Phone +43 1 690 66
fax +43 1 690 66 10
e-mail: info.austria@habasit.com
www.habasit.com
Hungary
Habasit GmbH
A-1234 Wien
Phone +43 1 690 66
fax +43 1 690 66 10
e-mail: info.austria@habasit.com
www.habasit.com
Portugal
Rossi Motorreductores S.L.
E - Viladecans (Barcelona)
Phone +34 93 6377248
fax +34 93 6377404
e-mail: info.spain@rossi-group.com
www.rossimotorreductores.es
United Kingdom
Habasit Rossi Limited
UK - Coventry
Phone +44 2476 644646
fax +44 2476 644535
e-mail: info.uk@habasitrossi.com
www.habasitrossi.co.uk
Canada
Rossi Gearmotors
Division of Habasit Canada Limited
CA - Oakville, Ontario
Phone +1 905 8274 131
fax +1 905 8252 612
e-mail: info.canada@habasit.com
www.rossi-group.com
Iceland
Habasit AB
S - 430 63 Hindås
Phone +46 301 226 00
fax +46 301 226 01
e-mail: info@habasit.se
www.habasit.se
Russia
Habasit GmbH
A-1234 Wien
Phone +43 1 690 66
fax +43 1 690 66 10
e-mail: info.austria@habasit.com
www.habasit.com
India
Rossi Gearmotors Pvt. Ltd.
IN - Coimbatore
Phone +91 422 262 7879
fax +91 422 262 7214
e-mail: info.india@rossi-group.com
www.rossi-group.com
Spain
Rossi Motorreductores S.L.
E - Viladecans (Barcelona)
Phone +34 93 6377248
fax +34 93 6377404
e-mail: info.spain@rossi-group.com
www.rossimotorreductores.es
United States
Rossi Gearmotors
A Division of Habasit America
US - Suwanee
Phone +1 800 931 2044
fax +1 678 288 3658
e-mail: rossi.info@us.habasit.com
www.habasitamerica.com
Mexico
Rossi Gearmotors
A Division of Habasit America
US - Suwanee
Phone +1 800 931 2044
fax +1 678 288 3658
e-mail: rossi.info@us.habasit.com
www.habasitamerica.com
Sweden
Habasit AB
S - 430 63 Hindås
Phone +46 301 226 00
fax +46 301 226 01
e-mail: info@habasit.se
www.habasit.se
China
Rossi Gearmotors China P.T.I.
CN - Shanghai
Phone +86 21 3350 5345
fax +86 21 3350 6177
e-mail: info.china@rossi-group.com
www.rossigearmotors.cn
Denmark
Habasit AB
DK - 3400 Hillerød
Phone +45 48 28 80 87
fax +45 48 28 80 89
e-mail: info@habasit.se
www.habasit.dk
Responsabilità relative ai prodotti e al loro uso
Il Cliente è responsabile delle corretta scelta e dell’uso del prodotto in relazione alle proprie esigenze
industriali e/o commerciali, salvo il caso in cui l’utilizzo sia stato raccomandato da personale tecnico Rossi,
debitamente informato dal Cliente delle proprie necessità operative. In questo caso, tutti i dati necessari per
la selezione dovranno essere comunicati fedelmente e per iscritto dal Cliente, riportati nell’ordine e confermati da Rossi. Il Cliente è sempre responsabile della sicurezza nell’ambito delle applicazioni del prodotto. Nella
stesura del catalogo è stata dedicata la massima attenzione al fine di assicurare accuratezza delle informazioni. Tuttavia Rossi non può accettare responsabilità dirette o indirette per eventuali errori, omissioni o dati non
aggiornati. A causa della costante evoluzione dello stato dell’arte, Rossi si riserva la possibilità di apportare in
qualsiasi momento modifiche al contenuto della presente pubblicazione. Il responsabile ultimo della selezione
del prodotto è il Cliente, salvo accordi diversi debitamente formalizzati per iscritto e sottoscritti dalle Parti.
Product liability, application considerations
The Customer is responsible for the correct selection and application of product in view of its industrial and/
or commercial needs, unless the use has been recommended by technical qualified personnel of 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. Due to
the constant evolution of the state of the art, Rossi reserves the right to make any modification whenever to
this publication contents. The responsibility for the product selection is of the customer, excluding different
agreements duly legalized in writing and undersigned by the Parties.
Rossi S.p.A.
Via Emilia Ovest 915/A
41123 Modena - Italy
Phone +39 059 33 02 88
fax +39 059 82 77 74
e-mail: info@rossi-group.com
www.rossi-group.com
Registered trademarks
Copyright Rossi S.p.A.
Subject to alterations
Printed in Italy
Publication data
4090INS.VPR-it1210HQM
4090INS.VPR-en1210HQM
GEA Niro Soavi
Ref.
Part Code
Description
Description
7.01.5
9532-6932-320
CENTRALINA
LUBRICATION UNIT
7.01.5
Istruzioni assemblaggio – Assembly instructions
Serie MR – MW – MC – MS – FP
MK – VT – P1509 – P1507 – TP – TPS – TPM
DOC00032 Rev. C
1/8
Applicare
etichetta
Brevini Fluid Power S.p.A.
Via Moscova, 6 – 42124 Reggio Emilia (RE) – Italy
Tel. +39 0522 270711 - Fax +39 0522 270660
www.brevinifluidpower.com – www.hydr-app.com – info@brevinifluidpower.com
INDICE
LEGENDA ACRONIMI E SIMBOLI ........................................................ 1
CARATTERISTICHE GENERALI DEL MANUALE ............................... 1
USO PREVISTO DELLA UNITÀ DI POTENZA ...................................... 2
LIMITI DI IMPIEGO .................................................................................. 2
SPECIFICHE DI SICUREZZA................................................................... 2
IDENTIFICAZIONE DEL PRODOTTO .................................................... 3
CONFORMITÀ ALLE DIRETTIVE .......................................................... 3
LIMITI DI FUNZIONAMENTO ................................................................ 4
STOCCAGGIO ........................................................................................... 4
SCELTA DEL FLUIDO IDRAULICO ....................................................... 4
INSTALLAZIONE ..................................................................................... 5
TABLE OF CONTENTS
LEGEND OF ABBREVIATIONS AND SYMBOLS ................................. 1
GENERAL INSTRUCTIONS FOR THE USE OF THIS MANUAL ......... 1
PRESCRIBED USE OF THIS POWER UNIT ........................................... 2
LIMITS OF USE ........................................................................................ 2
SAFETY SPECIFICATIONS ..................................................................... 2
IDENTIFYING THE UNIT ........................................................................ 3
COMPLIANCE WITH DIRECTIVES ....................................................... 3
OPERATIONAL LIMITS .......................................................................... 4
STORAGE .................................................................................................. 4
CHOOSING THE HYDRAULIC FLUID .................................................. 4
INSTALLATION ....................................................................................... 5
Norme generali per una corretta installazione .......................................................................... 5
General rules for correct installation ....................................................................................... 5
Collegamento elettrico per motore DC ...................................................................................... 5
Connecting a DC motor ........................................................................................................... 5
Collegamento motore AC .......................................................................................................... 6
Connecting an AC motor ......................................................................................................... 6
Collegamento valvola ad intervento elettrico............................................................................. 6
Connecting electrically actuated valves ................................................................................... 6
Collegamento idraulico ............................................................................................................. 6
Hydraulic connection............................................................................................................... 6
Montaggio leva comando manuale ............................................................................................ 6
Installation of manual pressure control group ........................................................................ 6
AVVIAMENTO .......................................................................................... 7
RACCOMANDAZIONI ............................................................................. 7
MANUTENZIONE ..................................................................................... 7
START UP ................................................................................................. 7
TIPS ............................................................................................................ 7
MAINTENANCE ....................................................................................... 7
Sostituzione del filtro................................................................................................................. 8
Replacing the filter................................................................................................................... 8
Smontaggio e rimontaggio dei serbatoi ..................................................................................... 8
Removing and reinstalling the tanks........................................................................................ 8
Serraggi consigliati ................................................................................................................... 8
Recommended tightening torque values .................................................................................. 8
DEMOLIZIONE E SMALTIMENTO ........................................................ 8
DISMANTLING AND DISPOSAL ........................................................... 8
LEGENDA ACRONIMI E SIMBOLI
Unità di potenza, centralina idraulica
UP
Brevini Fluid Power S.p.A.
BFP
Corrente alternata
AC
Corrente continua
DC
Valvola di massima
VM
Orario
CW
Polietilene
PE
Polipropilene
PP
Le operazioni che rappresentano una situazione di potenziale
pericolo per persone, animali o cose sono evidenziate tramite il
simbolo riportato a fianco.
Le operazioni che necessitano di particolare attenzione per il buon
funzionamento dell’ impianto sono evidenziate tramite il simbolo
riportato a fianco.
Coppia di serraggio da applicare, espressa in Nm
LEGEND OF ABBREVIATIONS AND SYMBOLS
Power unit, Hydraulic power pack
PU
Brevini Fluid Power S.p.A.
BFP
Alternating current
AC
Direct current
DC
Relief valve
RV
Clockwise
CW
Polyethylene
PE
Polypropylene
PP
Operations that may create a dangerous situation to persons,
animals or property are indicated by the symbol on the left.
CARATTERISTICHE GENERALI DEL MANUALE
Il presente manuale fa riferimento alle unità di potenza (di seguito UP) serie
MR, MW, MC, MS, FP, MK, VT, P1509, P1507, TP, TPS, TPM. L’ Utilizzatore
è il solo responsabile dell’ uso di questo manuale. Il rischio relativo è assunto
completamente dall’ Utilizzatore. In nessun caso la Brevini Fluid Power S.p.A.
(di seguito BFP) sarà responsabile per danni speciali, indiretti, accidentali o
consequenziali dipendenti dall’ uso o dall’ inesperienza nell’ utilizzo del manuale
o del prodotto. BFP non sarà responsabile per una cattiva od impropria
installazione, manutenzione, riparazione del prodotto, anche nei confronti di
GENERAL INSTRUCTIONS FOR THE USE OF THIS MANUAL
This manual applies to hydraulic power units (hereafter called PU) of the following
series: MR, MW, MC, MS, FP, MK, VT, P1509, P1507, TP, TPS, TPM. The User
is solely responsible for the use of this manual and completely assumes the relative
risk. Brevini Fluid Power S.p.A. (hereafter called BFP) will not be responsible for
special, indirect, accidental or consequential damage deriving from the use of this
manual or the product, or from inexperience with the use of this manual or of the
product. BFP will not be responsible - even to third parties - for poor or improper
installation, maintenance, or repair of the product, or for the use of non-original
Procedures that require special attention to obtain proper system
operation are indicated by the symbol on the left.
Tightening torque to be applied, in Nm
Proprietà dell’ azienda Brevini Fluid Power S.p.A. vietata qualsiasi riproduzione anche parziale senza l’ autorizzazione della stessa.
Property of Brevini Fluid Power S.p.A. Reproduction in whole or in part without express written consent is prohibited.
ISTRUZIONI ORIGINALI
ORIGINAL INSTRUCTIONS
Istruzioni assemblaggio – Assembly instructions
Serie MR – MW – MC – MS – FP
MK – VT – P1509 – P1507 – TP – TPS – TPM
terzi, nonché per l’ utilizzo di ricambi non originali. Nessuna parte di questo
manuale può essere riprodotta in qualsiasi forma o mezzo, per qualsiasi uso, che
non sia quello personale dell’ Utilizzatore, senza il permesso scritto della BFP.
BFP ringrazia per aver scelto uno dei suoi prodotti ed invita l’ Utilizzatore a
seguire attentamente le istruzioni ed i suggerimenti di questo manuale per un
corretto utilizzo del prodotto. Questo manuale è indirizzato ad Utilizzatori con
personale competente (specializzato nel settore idraulico, elettrico e meccanico).
Questo manuale non può sostituire la professionalità e le competenze del
personale dell’ Utilizzatore. L’ Utilizzatore deve accertarsi che il proprio
personale abbia ricevuto questo manuale e abbia recepito le istruzioni in esso
contenute. La BFP è orientata ad una continua ricerca e sviluppo dei propri
prodotti e pertanto si riserva il diritto di modificare in qualunque momento e
senza alcun preavviso tutte le caratteristiche tecniche ritenute necessarie. Per
assicurare la disponibilità di alcuni componenti, la BFP si avvale di una rete di
fornitori selezionati e qualificati, pertanto potranno esistere differenze
dimensionali e di aspetto degli stessi componenti. Il presente manuale potrà
subire variazioni ed integrazioni, ma non potrà in alcun caso ritenersi superato.
L’ UP è un prodotto complesso con configurazioni molto variabili, pertanto i
disegni rappresentati hanno la funzione di agevolare la comprensione dei testi,
ma spesso non rappresentano l’ esatta realtà del prodotto.
Operazioni di assemblaggio, installazione, manutenzione ed
avviamento delle UP e dei componenti applicati devono essere
effettuate da personale tecnico competente.
L’ Utilizzatore è responsabile della scelta del prodotto e dei suoi
accessori. Risulta quindi importante che l’ Utilizzatore analizzi le
problematiche della propria applicazione, eseguendo analisi e prove
adeguate. E’ inoltre il responsabile dell’ applicazione, delle sicurezze e delle
avvertenze richieste dalle direttive in vigore.
DOC00032 Rev. C
2/8
replacement parts. This manual may not be reproduced, in whole or in part, in any
form or by any means, for any use which is not the User’s personal use, without the
express written consent of BFP. BFP thanks you for choosing one of its products.
In order to use the product correctly, BFP asks you to carefully follow the
instructions and suggestions contained in this manual. This manual is intended for
Users with trained personnel (who specialize in the hydraulics, electrical and
mechanical sectors). This manual is no substitute for the professionalism and skill
of the User’s personnel. The User must make sure that its personnel have been
provided with this manual and understand the instructions contained in it. Since
BFP is committed to ongoing research and development, it reserves the right to
modify the technical characteristics of its products, at any time and without prior
notice, as deemed necessary. To ensure the availability of certain components, BFP
draws upon a network of select, qualified suppliers; as a result, these components
may vary in size and appearance. This manual is subject to change and addition,
but must not be considered to be out of date. Since PU are complex products with
configurations that vary a great deal, the diagrams contained in this manual are
intended only to make it easier to understand the text and often do not show the
product exactly as it is.
The PU and its components may be assembled, installed, started and
maintained by trained technical personnel, only.
The User is responsible for choosing the product and its accessories. Thus,
it is important for the User to investigate the problems associated with its
specific application by performing suitable analyses and tests. The User is
also responsible for installing the safety systems and affixing the warnings that
are required by current regulations.
USO PREVISTO DELLA UNITÀ DI POTENZA
La UP è destinata ad automazione oleodinamica come organo di comando. Data
la vastità applicativa della UP e non essendo sempre nota la destinazione finale
del prodotto, questo manuale è stato realizzato limitatamente in funzione delle
generiche applicazioni conosciute come ad esempio: carrelli elevatori,
piattaforme e tavole elevatrici, ponti sollevatori per auto, gru per piccoli
autocarri, spartineve, automazioni settore industriale.
PRESCRIBED USE OF THIS POWER UNIT
This PU is designed to be the main control unit in hydraulic automation systems.
Given the wide range of applications of PU, and since the final destination of the
unit is not always known to the manufacturer, this manual will provide information
only on popular applications such as forklifts, lifting platforms and beds, lifts for
cars, cranes on small trucks, snowplows, and automated systems in the industrial
sector.
LIMITI DI IMPIEGO
Non sempre è nota la destinazione finale del prodotto. L’ Utilizzatore, nella
scelta della UP, deve identificare il prodotto adeguato anche con l’ ausilio di test
attraverso un prototipo campione. I nostri uffici sono a disposizione per aiutare l’
Utilizzatore nella scelta della UP idonea.
La UP non deve essere utilizzata nelle seguenti applicazioni :
LIMITS OF USE
The manufacturer does not always know the final destination of the product. When
the User chooses a PU, it must therefore determine which product is suitable by
running a test with a sample prototype. Our offices are available to help the User
choose the correct PU for its needs.
A PU must not be used in the following applications:
•
•
•
•
•
•
•
•
ambienti dove esista il pericolo di esplosione e di incendio;
veicoli ed impianti aeronautici e spaziali;
sistemi frenanti, di blocco e di stallo in genere;
attrezzature ed impianti di applicazione in campo militare, nucleare,
medicale ed ospedaliero
Tuttavia la BFP si riserva, dietro richiesta, di valutare le applicazioni sopra citate
e di darne, qualora lo ritenga opportuno, l’ autorizzazione.
environments where there is a danger of explosion or fire
aeronautical/space vehicles and systems
braking, locking and retention systems in general
equipment and systems used in military, nuclear, medical or hospital
applications
In any case, BFP reserves the right - upon request - to evaluate the applications
listed above and to authorize an application, if appropriate.
La UP non deve essere utilizzata per assolvere funzione di sicurezza.
A PU must not be used to perform safety functions.
Alcune condizioni che possono causare problemi:
•
forti sollecitazioni e vibrazioni possono causare fuoriuscita di fluido dal
tappo carico-sfiato.
•
Ambienti particolarmente polverosi possono causare l’ occlusione del tappo
carico-sfiato.
•
Forti pressioni di scarico nel serbatoio possono generare schiuma e alterare
il fluido idraulico.
•
Esposizione dell’ UP ai raggi solari possono causare danni alle parti in
plastica esposte (soprattutto i serbatoi).
•
Il collegamento elettrico dei motori DC deve essere eseguito con cavi
adeguati
•
Nella scelta dei motori AC monofase è necessario considerare la minima
tensione di alimentazione di rete.
•
Le valvole elettriche normalmente utilizzate non sono a tenuta perfetta,
pertanto tale caratteristica deve essere considerata dall’ Utilizzatore in sede
di progettazione della propria macchina o attrezzatura.
•
Le UP subiscono un collaudo funzionale e di verifica della tenuta idraulica
in pressione, inoltre un flussaggio garantisce la pulizia dei condotti interni.
È pertanto consigliabile la massima pulizia dell’ impianto sul quale l’ UP
deve essere applicata, nonché l’ utilizzo di fluido idraulico pulito e filtrato.
The following are possible problem areas:
•
Strong stresses and vibration may cause fluid to be ejected from the breather
and fill cap.
•
Highly dusty environments may cause the breather and fill cap to become
plugged.
•
Strong discharge pressure into the tank may generate foam and alter the
characteristics of the hydraulic fluid.
•
Exposing the PU to sunlight may cause damage to the exposed plastic parts
(especially the tanks).
•
The DC motors must be wired using suitably large cables.
SPECIFICHE DI SICUREZZA
L’ UP è realizzata secondo lo stato dell’ arte, della tecnica e delle normative
applicabili. Assemblare l’ UP alle macchine o attrezzature è compito dell’
Utilizzatore. Assemblaggio, avviamento e manutenzione devono essere eseguiti
da personale competente. Di seguito vengono descritte alcune situazioni di
SAFETY SPECIFICATIONS
Your PU has been designed and built to the current state of the art and complies
with all applicable laws and regulations. The User is responsible for connecting the
PU to its machineries or equipment. The unit and the system where it is installed
must be assembled, placed into service and maintained by properly trained
•
•
•
Single-phase AC motors must be chosen to handle the minimum voltage
available from the power mains.
The electrically actuated valves that are normally used in these applications
are not perfectly sealed, and this characteristic must be considered by the
User when designing its machinery or equipment.
Each PU is given a final leak test under pressure, and its internal ducts are
flushed to ensure cleanliness. As a result, the system where the PU is
installed should be perfectly clean, and the hydraulic fluid used must be clean
and filtered.
Proprietà dell’ azienda Brevini Fluid Power S.p.A. vietata qualsiasi riproduzione anche parziale senza l’ autorizzazione della stessa.
Property of Brevini Fluid Power S.p.A. Reproduction in whole or in part without express written consent is prohibited.
ISTRUZIONI ORIGINALI
ORIGINAL INSTRUCTIONS
Istruzioni assemblaggio – Assembly instructions
Serie MR – MW – MC – MS – FP
MK – VT – P1509 – P1507 – TP – TPS – TPM
pericolo che possono essere ancora presenti durante il funzionamento. A volte
alcune situazioni possono risultare apparentemente banali, ma comunque da non
sottovalutare, come da non sottovalutare è l’ eccessiva confidenza e
abitudinarietà al lavoro che possono prevalere sull’ attenzione da dedicare alla
sicurezza.
Durante le operazioni di avviamento, normale lavoro, manutenzione,
regolazione, sfiato dell’ impianto, intervento e azionamento di valvole e
vari elementi di controllo possono verificarsi degli schizzi improvvisi e delle
fuoriuscite di fluido idraulico, il quale può raggiungere temperature tali da
causare ustioni alla pelle.
Il fluido idraulico può essere pericoloso per la salute in quanto il contatto
con la pelle e gli occhi può causare gravi danni. Attenersi
scrupolosamente alle disposizioni di protezione e sicurezza imposte dal
produttore del fluido idraulico riportate sulla scheda tecnica e tossicologica.
Il fluido idraulico può essere un prodotto inquinante. E’ perciò buona
norma evitare perdite di fluido idraulico servendosi di vasche di raccolta
e cautelarsi contro accidentali perdite e fuoriuscite del fluido idraulico con
prodotti oleoassorbenti.
Non manomettere alcun tipo di valvola, raccordo, accessorio o
componente della UP; un semplice allentamento di una valvola potrebbe
provocare la caduta libera di carichi o il cedimento di strutture.
Tutte le operazioni d’ installazione, montaggio, manutenzione,
smontaggio e sostituzione della UP e dei componenti ad essa applicati
devono essere eseguiti nel massimo rispetto delle norme di sicurezza. Durante
queste operazioni, all’ interno del circuito oleodinamico non deve mai essere
presente pressione (pressione zero) e non deve esistere nessun tipo di carico sulla
struttura dell’attrezzatura o della macchina a cui la UP è applicata (carico zero).
Tutti i collegamenti e scollegamenti elettrici devono essere eseguiti da
personale specializzato e competente.
Prima di procedere a qualsiasi tipo di operazione o di intervento sulla UP,
devono essere scollegati dalla linea elettrica di alimentazione (sia AC che
DC) i motori e qualsiasi altro dispositivo di tipo elettrico.
Nel caso di motorizzazioni o dispositivi diversi da quelli elettrici
(pneumatici, idraulici, meccanici, ecc…), essi devono sempre essere
preventivamente scollegati dalla rete di alimentazione e messi in
condizioni di non produrre, nemmeno in condizioni accidentali, energia e quindi
movimento.
Nelle UP con motore DC ventilato, alcune zone della UP potrebbero non
essere protette dagli organi in movimento (ventola): è compito dell’
Utilizzatore predisporre ripari adeguati. Le zone non protette sono segnalate da
opportuno avviso.
Alcune parti dell’ UP e lo stesso fluido idraulico possono raggiungere
temperature elevate e causare ustioni alla pelle: attenersi alle prescrizioni
di sicurezza.
L’ Utilizzatore deve prevedere l’ installazione della UP sulle macchine e
attrezzature in posizione tale da facilitare qualsiasi tipo di intervento di
riparazione e manutenzione.
Per tutte le operazioni si consiglia di:
Usare protezioni antinfortunistiche (occhiali, guanti, scarpe, etc); lavorare in
condizioni di massima pulizia, usare strumenti, attrezzi e banchi di servizio
adatti, puliti ed efficienti; lavorare in condizioni di massima sicurezza; usare
prodotti oleoassorbenti.
DOC00032 Rev. C
3/8
personnel. A number of dangerous conditions that may occur during operation will
now be described. Sometimes, a potentially dangerous situation may seem to be
normal, but must not be underestimated.
Likewise, the possibility of
overconfidence and performing tasks by habit, which may take the place of paying
proper attention to safety, must also not be underestimated.
Unexpected spurts and leaks of hydraulic fluid hot enough to cause burns
may occur during startup, normal operation, maintenance, adjustment,
bleeding of the system, and operation and actuation of the valves and the control
systems.
Hydraulic fluid may be hazardous to health, since contact with the skin and
eyes can cause serious damages. Carefully follow the instructions on
personal protection and safety that are specified by the manufacturer of the fluid, as
specified on the technical/toxicological information sheet.
Hydraulic fluid may be a pollutant. As a result, it is good practice to avoid
losing fluid by using basins to collect it. Also, use oil-absorbent products
to protect the skin from accidental leaks and spurts of fluid.
Never tamper with any valve, connection, accessory or component on the
PU. Simply loosening a valve may cause loads to fall freely or structures to
give way.
All installation, assembly, maintenance, disassembly and replacement
operations on the PU and its components must be performed in full
compliance with safety regulations. During these operations, the hydraulic circuit
must never be pressurized (zero pressure), and no load must be exerted on the tool
or machinery the PU is connected to (zero load).
All electrical connections and disconnections must be performed by
trained, specialized personnel.
Before performing any type of operation or service on the PU, electrically
disconnect the power line (whether AC or DC) from the motors and from
any other electrical device on the PU.
Before servicing non-electrical devices or motorization systems (whether
pneumatic, hydraulic, mechanical, etc.), such devices and systems must
first be disconnected from the relative feed lines and must be set up so that
they cannot produce energy and thus cause movements, even accidentally.
On PU with a ventilated DC motor, some areas of the PU may not be
protected from moving parts (the fan). In this case, the User is responsible
for providing suitable guards. Unprotected areas are labeled with a suitable
warning.
Some parts of the PU - and the hydraulic fluid itself - may reach high
temperatures and burn the skin. Be sure to follow all safety instructions.
The User must install the PU in a position on the machinery and equipment
that makes repair and maintenance procedures easy to perform.
When performing any such operation, it is good practice to:
Use proper safety equipment (goggles, gloves, shoes, etc.);
Work in conditions of utmost cleanliness and use tools, equipment and benches
that are clean and in good operating condition;
Work in conditions of maximum safety;
Use oil-absorbent products.
IDENTIFICAZIONE DEL PRODOTTO
Tutte le UP sono corredate di etichette.
IDENTIFYING THE UNIT
PU are provided with identification labels.
Alcuni campi possono essere opzionali. Nei documenti di accompagnamento le
UP sono identificate mediante codice anagrafico e codice di selezione. Tutte le
richieste di chiarimenti o di ricambi devono essere accompagnate dai codici
sopradescritti.
Some fields may be optional. PU are identified by a part number and an ordering
code on the documents provided with the units (invoice). All requests for
explanations or replacement parts must be accompanied by the identification codes
described above.
CONFORMITÀ ALLE DIRETTIVE
Direttiva Macchine 2006/42/CE
La UP è costruita per essere incorporata in una macchina e può essere messa in
servizio solo quando la macchina (in cui è incorporata) è stata dichiarata
conforme alle disposizioni della Direttiva Macchine 2006/42/CE.
Direttiva EMC 2004/108/CE
Motore AC – Trifase e Monofase: non applicabile.
Motore DC – Campi avvolti: conforme.
Motore DC – Magneti permanenti: non conforme, è compito dell’ Utilizzatore
COMPLIANCE WITH DIRECTIVES
Machinery Directive 2006/42/EC
This PU is designed to be incorporated into another machinery and may be placed
into service only when that machinery has been certified as complying with
Machinery Directive 2006/42/EC.
EMC Directive 2004/108/EC
AC Motor – Three-phase or single-phase: not applicable.
DC motor - Field wound: compliant.
DC Motor - Permanent-magnet type: not compliant. The User must install an
Proprietà dell’ azienda Brevini Fluid Power S.p.A. vietata qualsiasi riproduzione anche parziale senza l’ autorizzazione della stessa.
Property of Brevini Fluid Power S.p.A. Reproduction in whole or in part without express written consent is prohibited.
ISTRUZIONI ORIGINALI
ORIGINAL INSTRUCTIONS
Istruzioni assemblaggio – Assembly instructions
Serie MR – MW – MC – MS – FP
MK – VT – P1509 – P1507 – TP – TPS – TPM
predisporre un filtro antidisturbo sulla linea di alimentazione.
Direttiva BT 2006/95/CE
Motore AC – Trifase e Monofase: conforme.
Motore DC: escluso dalla Direttiva (fino a 75 V).
DOC00032 Rev. C
interference filter on the power line.
LV Directive 2006/95/EC
AC Motor - Three-phase or single-phase: compliant.
DC motor - Excluded from the Directive (up to 75 V).
4/8
LIMITI DI FUNZIONAMENTO
Portata: è determinata dalla pompa e dal motore scelti ed utilizzati. La UP è
realizzata per gestire una portata ottimale di min. 5 litri/min ed una max. di 20
litri/min.
Pressione minima: la UP è realizzata per controllare una pressione minima di 10
bar. La stessa pressione minima occorre per il buon funzionamento di eventuali
regolatori di portata che controllano il flusso in scarico.
Pressione massima: è determinata dalla pompa, dal motore e dalla valvola di
massima pressione (di seguito VM). Pertanto tutti i componenti della UP sono
scelti in funzione della VM adottata.
Nelle massime condizioni e con componenti specifici, i limiti di pressione sono i
seguenti:
250 bar: pressione intermittente di lavoro
290 bar: pressione intermittente per max 20 s
320 bar: pressione di picco
Si fa divieto di sostituire la VM senza previa autorizzazione della
BFP
Temperatura: la UP è realizzata per una temperatura del fluido -10 ÷ 70 °C.
Consultare il capitolo “scelta del fluido idraulico” per verificare le temperature
limite.
Rapide variazioni di temperatura possono pregiudicare sia le caratteristiche che
la durata del prodotto, pertanto è indispensabile proteggerlo da queste situazioni.
OPERATIONAL LIMITS
Flow rate: The flow rate is determined by the pump and motor chosen. This PU is
designed to handle an optimal minimum flow rate of 5 liters/min and a maximum
flow rate of 20 liters/min.
Minimum pressure: This PU is built to control a minimum pressure of 10 bars.
The same minimum pressure is also required for proper operation of possible flow
regulators that control the outgoing flow.
Maximum pressure: The maximum pressure is determined by the pump, the
motor and the relief valve (hereafter referred to as the RV). Nevertheless, all the
components in the PU have been chosen to suit the RV that is installed.
Under the most severe conditions and with specific components, the pressure limits
are as follows:
250 bar: intermittent operating pressure
290 bar: intermittent peak pressure for a max. of 20 s
320 bar: overshooting pressure
The RV must not be replaced without prior authorization from BFP.
STOCCAGGIO
Le UP sono un prodotto da maneggiare con cura ed attenzione. Alcune parti,
normalmente sporgenti, possono essere soggette a rottura, come ad esempio il
tappo di carico-sfiato posto sul serbatoio. Altro punto debole è il serbatoio di
materiale plastico. Una particolare attenzione deve essere riservata alla flangia,
alle sue valvole e ai suoi componenti poiché particolarmente esposte agli urti.
Quando la UP è provvista di blocchetti, è necessario proteggere gli stessi da urti,
da ammaccature, ed evitare di creare pericolose flessioni che potrebbero dare
origine a danni irreversibili. Per UP con serbatoi di piccole dimensioni, poiché il
motore è la parte più pesante della UP, è indispensabile che la stessa sia riposta,
nell’ immagazzinamento, in senso orizzontale (mai in verticale col serbatoio in
basso e il motore in alto). La UP deve essere riposta in ambiente protetto da
polvere e al riparo da luce solare (raggi UV) con temperatura ambiente compresa
tra -10+30°C (fino a un massimo di 40°C per brevi periodi).
STORAGE
PU must be handled with care and attention. Certain protruding parts may be
subject to breakage, such as the breather and fill cap on the tank. Another weak
point is the tank made of plastic. Pay special attention to the flange, its valves and
its components since they are particularly vulnerable to impact. If the PU is
equipped with valve assemblies, they must be protected from impacts and dents.
Also, avoid bending the assemblies excessively, as this could cause irreversible
damage. For PU with tanks of small dimensions, since the motor is the heaviest
component on a PU, it is essential that the PU be stored horizontally (and never
vertically, with the tank underneath and the motor on top).
A PU must be placed in an environment that is protected from dust and direct
sunlight (UV rays), and at an ambient temperature of -10 to +30 °C (up to 40°C
max. for brief periods).
SCELTA DEL FLUIDO IDRAULICO
Tutti i fluidi idraulici a base minerale sono adatti all' impiego. Nella loro scelta è
necessario considerare i dati di funzionamento e della temperatura ambientale per
ottenere un’ ottimale prestazione di esercizio. Utilizzare fluido idraulico a base
minerale HM-HR-HV secondo ISO 6743/4 (DIN 51524), classe di viscosità
secondo ISO 3448 con le seguenti condizioni di utilizzo:
•
viscosità minima: 12 cSt viscosità massima: 80 cSt
•
viscosità massima all' avviamento: 500 cSt
•
viscosità d’ esercizio: 20÷50 cSt
•
temperatura ottimale d’ esercizio dell’ olio: 30° ÷ 60 °C
•
temperatura ambiente minima: -15 °C
•
temperatura ambiente massima: 40 °C (con picchi di 50 °C)
L’ utilizzo di altri fluidi può danneggiare e compromettere il buon
funzionamento dell’impianto. Tuttavia la BFP si riserva, dietro richiesta,
di valutare l’ utilizzo di altri fluidi e di darne, qualora lo ritenga
opportuno, l’ autorizzazione.
CHOOSING THE HYDRAULIC FLUID
Any mineral-based hydraulic fluid can be used. When choosing a fluid, the
operational parameters of the system and the ambient temperature must be taken
into consideration to obtain best performance. Use HM-HR-HV mineral-based
hydraulic fluid meeting ISO 6743/4 (DIN 51524) specifications, with an ISO 3448compliant viscosity class, and with the following conditions of use:
•
minimum viscosity: 12 cSt - maximum viscosity: 80 cSt
•
maximum viscosity at startup: 500 cSt
•
operating viscosity: 20 to 50 cSt
•
oil optimum operating temperature: 30° to 60 °C
•
minimum ambient temperature: -15 °C
•
maximum ambient temperature: 40 °C (with peaks of 50 °C)
The use of other fluids may damage the system and prevent it from
operating properly. In any case, BFP reserves the right - upon request - to
evaluate the use of other fluids and to authorize such use if appropriate.
L’ UP subisce un collaudo funzionale e nel suo interno possono rimanere
alcuni cc di fluido con le caratteristiche sopradescritte.
È importante non miscelare fluidi idraulici di diversi produttori o di
diverso tipo poiché possono essere causa di formazione di fanghi e di
sedimentazioni che potrebbero compromettere il buon funzionamento della UP.
I valori sopradescritti sono le condizioni di utilizzo standard, ma non
tengono in considerazione le varie tipologie di serbatoi e le conseguenti
limitazioni. Se si utilizzano dei serbatoi in plastica è opportuno
considerare le loro inferiori prestazioni nei confronti della temperatura
Temperature ottimale di utilizzo dei serbatoi in lamiera e polietilene (PE):
-10 °C (ambientale) ÷ 70 °C (di esercizio)
Temperature limite di utilizzo dei serbatoi in lamiera : -15 °C (ambientale) ÷
80 °C (di esercizio)
Temperature limite di utilizzo dei serbatoi in polipropilene (PP): -10 °C
(ambientale) ÷ 60 °C (di esercizio)
I dati riportati sono frutto di esperienza e test di laboratorio, e tengono conto di
fissaggi essenziali alle macchine o attrezzature con medie vibrazioni (trans pallet
in ambiente da officina).
Temperature: This PU is designed to operate with fluid at a temperature of -10 to
70° C. See the chapter, “Choosing the Hydraulic Fluid” for more information on
temperature limits.
Since rapid temperature changes may deteriorate the properties and service life of
the fluid, it is essential to protect the fluid from this type of situation.
Since each PU is given a final test for proper operation, several cc of fluid
with the above characteristics may remain in the unit.
It is important not to mix hydraulic fluids from different manufacturers or
fluids of different types. Such mixing may cause sludge and sediment to
form that could prevent the PU from operating properly.
The values reported above are standard conditions of use that do not take
into account the various types of tanks that may be installed and the
resulting limitations. If plastic tanks are used, it is a good idea to consider
that they offer poorer temperature performance.
Optimal temperature for using tanks made of sheet metal and polyethylene (PE):
-10 °C (ambient) to 70 °C (operating)
Temperature limits for using tanks made of sheet metal : -15 °C (ambient) to 80
°C (operating)
Temperature limits for using tanks made of polypropylene (PP) : -10 °C (ambient)
to 60 °C (operating)
The above parameters, which are the result of experience and laboratory tests, take
into account the mounting systems and fasteners that are essential to machineries
or equipment with average levels of vibration (transpallets in a workshop
environment).
Proprietà dell’ azienda Brevini Fluid Power S.p.A. vietata qualsiasi riproduzione anche parziale senza l’ autorizzazione della stessa.
Property of Brevini Fluid Power S.p.A. Reproduction in whole or in part without express written consent is prohibited.
ISTRUZIONI ORIGINALI
ORIGINAL INSTRUCTIONS
Istruzioni assemblaggio – Assembly instructions
Serie MR – MW – MC – MS – FP
MK – VT – P1509 – P1507 – TP – TPS – TPM
INSTALLAZIONE
Durante l’ installazione preoccuparsi della massima pulizia effettuando le
principali operazioni di collegamento in un locale pulito e non polveroso.
La UP deve essere montata in posizione ergonomica in modo tale da
permettere una facile accessibilità alle ispezioni e alla manutenzione. È
altrettanto indispensabile che essa venga montata in una zona protetta da urti
accidentali e riparata da casuali contatti fisici, poiché la temperatura raggiunta
durante il funzionamento può essere causa di ustioni.
La UP deve essere fissata saldamente alla macchina nei punti di maggiore
resistenza (es: telaio portante, longheroni, ecc..), lontano da qualsiasi fonte
o parte di macchina che possano vibrare, trasmettere o amplificare rumore
e vibrazioni.
La UP con serbatoio in plastica deve essere applicata in ambienti protetti
da esposizione ai raggi solari e con limitate escursioni termiche.
DOC00032 Rev. C
5/8
INSTALLATION
During installation, be sure that important assembling operations are
carried out with the greatest degree of cleanliness in a clean, dust-free area.
The PU must be installed in an ergonomic position that provides easy
access for inspection and maintenance. It is just as important to install it in
an area which is protected from accidental impact and kept away from accidental
physical contact, since the high temperature of the unit during operation may cause
burns.
The PU must be securely fastened to the machinery at its sturdiest points
(such as the load-bearing frame, longitudinal members, etc), away from all
sources of noise and vibration, and away from parts of machinery that may
vibrate or transmit and/or amplify noise and vibration.
PU with a plastic tank must be installed in areas with limited temperature
swings and away from direct exposure to sunlight.
La UP deve essere fissata con i due fori ISO M10 presenti sul corpo in alluminio.
Le stesse UP sopra descritte si possono fissare con l’ utilizzo dell’ apposito
piedino fornito a richiesta. Su macchine fisse (posizione orizzontale o verticale)
i limiti di peso consigliati per il fissaggio con i 2 fori M10 sono:
•
con motore AC B14 Grandezza 112
•
con serbatoio 10 litri
•
con serbatoio 12 litri utilizzando anche i piedi del serbatoio stesso
The PU must be installed using the two ISO M10 holes in its aluminum body. The
PU described above may be installed with a special foot that is available upon
request. On fixed machineries (horizontal or vertical position), the weight limits
recommended for fastening with the two M10 holes are:
•
with B14 AC motor, size 112
•
with 10 liter tank
•
with 12 liter tank and the additional support of the feet on the tank
Sulle macchine mobili (prediligere posizione verticale e fissare vicino al
baricentro) i limiti di peso consigliati per il fissaggio con i 2 fori M10 sono:
On moving machineries (the vertical position is preferable, mount the unit close to
the center of gravity), the weight limits recommended for fastening with two M10
holes are:
•
con tutti i motori DC
•
con serbatoi 6 litri in lamiera
•
con serbatoi 5 litri in plastica PP
•
con serbatoi 4 litri in plastica PE
Se l’ Utilizzatore analizza la propria applicazione si possono applicare alle UP
serbatoi di capacità superiore ancorando, per esempio, anche lo stesso serbatoio
alla struttura del mezzo mobile.
Norme generali per una corretta installazione
Prendere visione dello schema oleodinamico e dell’eventuale schema
elettrico (il nostro ufficio tecnico/commerciale è a Vostra disposizione
per qualsiasi spiegazione).
Evitare di asportare i tappi in plastica di protezione fino al momento del
collegamento dei tubi.
Alcune valvole ad intervento elettrico sono munite di emergenza manuale
a vite, tale emergenza deve sempre essere disattivata prima di rimettere in
funzione l’ impianto.
Per UP con blocchi modulari CETOP utili per il collegamento di
elettrodistributori, utilizzare per i fori di attacco raccordi cilindrici
secondo la normativa DIN 3852 e le filettature in accordo con le
normative UNI-ISO 228.
Si ricorda che l’avvitamento di raccordi (in acciaio) con ammaccature sul
filetto maschio provoca una asportazione di truciolo nella sede femmina
(in alluminio) causa principale del difettoso funzionamento di valvole.
Collegamento elettrico per motore DC
Esempio di schema di collegamento:
•
with all DC motors
•
with 6 liter tanks in sheet steel
•
with 5 liter tanks in PP
•
with 4 liter tanks in PE
Tanks with a higher capacity can be installed on PU for special applications. For
example, the tank can be anchored to the frame of a moving vehicle.
General rules for correct installation
Examine the hydraulic diagram and the electrical diagram (if available).
Our technical/business office is at your disposal for further
information/explanations.
Avoid removing the plastic protection plugs until you connect the hoses.
Some electrically actuated valves have a screw-type manual safety device.
This safety must be deactivated before operating the system.
For PU equipped with CETOP modular assemblies for connecting
proportional solenoid valves, use DIN 3852 cylindrical fittings with UNIISO 228 threads as the connection ports.
Remember that when a steel fitting with a dented male thread is tightened,
it will remove burrs from a female (aluminum) seat. These burrs are the
main cause of valve malfunctions.
Connecting a DC motor
Sample connection diagram:
When wiring a motor, it is important to consider the cross-sectional area
Nel collegamento elettrico è importante considerare la sezione e la
and length of the power cables. Cables with overly small cross-sections
lunghezza dei cavi di alimentazione: sezioni troppo piccole e lunghezze
troppo elevate possono causare cadute di tensione tali da compromettere il buon and overly long lengths may cause voltage drops that could prevent the PU from
operating properly.
funzionamento della UP.
Prima della messa in funzione si consiglia di effettuare alcuni cicli di Before placing the unit into service, we recommend cycling the start switch
several times at low to medium loads to break in the switching system.
assestamento al teleruttore con cariche medio basse.
Proprietà dell’ azienda Brevini Fluid Power S.p.A. vietata qualsiasi riproduzione anche parziale senza l’ autorizzazione della stessa.
ISTRUZIONI ORIGINALI
Property of Brevini Fluid Power S.p.A. Reproduction in whole or in part without express written consent is prohibited.
ORIGINAL INSTRUCTIONS
Istruzioni assemblaggio – Assembly instructions
Serie MR – MW – MC – MS – FP
MK – VT – P1509 – P1507 – TP – TPS – TPM
Per i poli del motore e del teleruttore, attenersi alle seguenti coppie di
serraggio
ISO M8
5÷7
ISO M6
3÷5
DOC00032 Rev. C
Use these tightening torque
values on the motor terminals
and the start switch
ISO M8
ISO M6
6/8
5 to 7
3 to 5
Collegamento motore AC
Collegamento meccanico dei motori AC forma B14: il giunto di trasmissione lato
motore deve essere montato secondo le dimensioni specificate in tabella
Quote accoppiamento
Z ( pompa
Z (pompa
Grand.
gruppo 1)
gruppo 0.5)
mm
mm
63
42.8
62.7
71
42
42
80
53
53
90
63
63
100
81.5
81.5
Esempio di collegamento elettrico motori AC trifase:
Connecting an AC motor
Mechanical connection to AC motors with form factor B14: the motor side of the
transmission coupling must be mounted at the distances shown on the table
Coupling distances
Z (pump,
Z (pump,
Size
group1)
group 0.5)
in mm
in mm
63
42.8
62.7
71
42
42
80
53
53
90
63
63
100
81.5
81.5
Sample electrical connection of three-phase AC motors:
L’ allacciamento elettrico del motore e delle valvole ad intervento
elettrico devono essere realizzati da personale competente. Entrambi i
dispositivi devono essere collegati alla linea elettrica considerando:
•
Le Leggi e le Norme tecniche vigenti nel luogo di installazione
•
I dati riportati sulla targa del motore e sulle valvole.
L’alimentazione elettrica del motore deve essere effettuata tramite cavo
multipolare con sezione adeguata alla normativa vigente. L’ingresso del
cavo nella morsettiera è previsto con apposito pressacavo e la
connessione deve avvenire tramite i morsetti. La tensione di alimentazione deve
essere quella specificata nei dati di targa del motore.
La scatola della morsettiera contiene elementi metallici che si
trovano a tensione pericolosa; dopo avere effettuato i collegamenti
richiudere sempre il coperchio della scatola.
Nella scelta del motore monofase è necessario considerare la minima
tensione di alimentazione di rete: tensioni troppo basse invalidano il
funzionamento del motore.
Electrical connections to the motor and to electrically actuated valves must
be made by trained personnel. Before these devices are connected to the
power line, the following factors must be considered:
•
The laws and technical standards applicable in the installation location
•
The data indicated on the motor identification plate and on the valves
The electric power feed line connected to the motor must be a multi-core
cable with a cross-sectional area that is large enough to meet current
regulations. The cable enters the terminal board through a special cable
gland and is connected to the terminals. The voltage supplied to the motor must be
the same as the voltage specified on its identification plate.
The housing for the terminal board contains metal components
carrying dangerously high voltage. Be sure to close the cover of the
housing after wiring the terminal board.
Single-phase AC motors must be chosen that operate at the minimum
voltage supplied by the power mains. The motor will not operate properly if
the voltage is too low.
Collegamento valvola ad intervento elettrico
Nelle UP con valvole ad intervento elettrico, le bobine devono essere
alimentate con le tensioni previste e con i seguenti limiti: -10+5% della
tensione nominale. Il superamento di tali limiti può compromettere il
funzionamento delle valvole e la vita della bobina.
Connecting electrically actuated valves
On PU with electrically actuated valves, the coils must be supplied with the
prescribed voltages with the following limits: -10 to +5% of nominal
voltage. If these limits are exceeded, valve operation and coil life may be adversely
affected.
Collegamento idraulico
Il collegamento idraulico deve essere eseguito con raccordi cilindrici e
con guarnizione di tenuta in rame. Si consiglia di utilizzare raccordi
secondo le norme DIN 3852 con filettature secondo le norme UNI-ISO
228 e guarnizioni secondo le norme DIN 7603. Gli utilizzi della UP ed
eventualmente dei blocchetti sono protetti da tappi in plastica, i quali devono
essere rimossi al momento del montaggio dei raccordi. Controllare la filettatura
dei raccordi che deve essere pulita e senza ammaccature. Utilizzare tubazioni
rigide o flessibili con diametro interno corrispondente o superiore alle bocche di
collegamento dell’ UP, con riferimento ai seguenti parametri di velocità del
fluido entro le tubazioni :
mandata (pressione) 4 ÷ 6 m/s
ritorno (scarico) 1,5 ÷ 3 m/s
Per tratti di tubazione di notevole sviluppo (oltre 3 m), i valori consigliati devono
essere aumentati.
La pulizia dell’ impianto è essenziale per il buon funzionamento dell’ UP.
La Tab. seguente descrive le portate e i serraggi consigliati in riferimento alle
filettature GAS UNI-ISO 228
Hydraulic connection
The hydraulic connection must be made with cylindrical fittings and copper
sealing gaskets. We recommend using DIN 3852 fittings with UNI-ISO 228
threads and DIN 7603 gaskets. The ports on the PU and on the valve
assemblies (if installed) are protected by plastic plugs that must be removed when
the fittings are installed. Check the thread on the fittings, which must be clean and
without dents. Use rigid or flexible hoses whose internal diameter is the same as or
larger than the connecting orifices on the PU. The speed of the fluid in the hoses
must be as follows:
Portata (l/min)
<5 ÷ 10
10 ÷ 20
>20
Montaggio leva comando manuale
30
30
30
Il gruppo leva è normalmente non montato:
•
ingrassare le parti interne del gruppo leva e della valvola sulla quale il
gruppo leva deve essere montato (grasso per guarnizioni);
•
introdurre il gruppo leva fino al contatto fra camma e perno;
return (discharge): 1.5 to 3 m/sec.
The recommended values must be increased if very long sections of hose (over 3
m) are used.
The system must be clean to obtain proper operation from the PU.
The following table lists flow rates and tightening torque values for UNI-ISO 228
gas threads:
Flow rate (l/min)
Filettatura
G. 1/4
G. 3/8
G. 1/2
delivery (pressure): 4 to 6 m/sec.
Thread
<5 to 10
G. 1/4
10 to 20
G. 3/8
>20
G. 1/2
Installation of manual pressure control group
30
30
30
Usually, the manual pressure control group is not installed.
•
Grease the internal parts of the manual pressure control and the valve where
the unit will be installed (use gasket grease).
•
Insert the lever until the cam hits the pin.
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ISTRUZIONI ORIGINALI
ORIGINAL INSTRUCTIONS
Istruzioni assemblaggio – Assembly instructions
Serie MR – MW – MC – MS – FP
MK – VT – P1509 – P1507 – TP – TPS – TPM
orientare secondo esigenze e fissare con le due viti: 4 Nm.
In caso di avaria (difficoltà di funzionamento, perdita olio, ecc..)
smontare il gruppo leva a macchina ferma e non alimentata
elettricamente, con pressione “zero” nell’ impianto idraulico.
Ogni intervento sulla UP deve essere eseguito a macchina ferma e
non alimentata elettricamente, con pressione “zero” nell’ impianto
idraulico.
DOC00032 Rev. C
7/8
Arrange as desired and fasten with the two screws: 4 Nm.
In case of malfunction (difficult operation, oil leaks, etc.), remove the
manual pressure control group from the machinery when it is shut down
with the power disconnected. Make sure the pressure in the hydraulic
system is zero.
All operations on the PU must be carried out with the machinery shut
down and with the power disconnected. Make sure the pressure in the
hydraulic system is zero.
AVVIAMENTO
START UP
Senso di rotazione, osservando la UP dal lato motore è orario CW (a meno che
non sia stato specificato un senso di rotazione differente in fase di ordine e se
previsto dalla tipologia di flangia). I motori che devono essere sottoposti al
controllo di rotazione sono tutti gli AC e i DC a magneti permanenti. È
preferibile controllare il senso di rotazione con motore smontato, oppure
procedere nel seguente modo:
•
Collegare elettricamente il motore
•
Regolare al minimo la VM
•
Azionare l’ UP con brevissimi impulsi
•
Ripristinare la VM
Il senso di rotazione errato causa danni irreparabili alla pompa quando la
stessa è in pressione. L' operazione di verifica del corretto collegamento
elettrico e del corretto senso di rotazione del motore, deve essere ripetuta ogni
volta che la UP o il sistema venga disconnesso dalla rete.
Una volta avviato l’ impianto controllare l’ esatto funzionamento di tutti i
comandi. Nei primi movimenti dello stesso, occorre effettuare lo sfiato
dell’ aria contenuta nell’ impianto per evitare la formazione di schiuma
nel serbatoio ed eventuali movimenti indesiderati ed incontrollati degli attuatori.
In contemporanea verificare di nuovo il livello del fluido e se necessario
ripristinarne il livello. Dopo qualche ora di funzionamento verificare l’ eventuale
presenza di trafilamenti in tutta la UP, controllare ancora il livello del fluido nel
serbatoio e l’eventuale presenza di schiuma.
The direction of motor rotation is clockwise CW, as observed from the side of the
PU where the motor is located (unless a different direction of rotation was
specified on the order and the different direction is determined by the type of
flange on the unit). The direction of rotation must be checked on all AC motors
and on DC motors with permanent magnets. It is better to check the direction of
rotation when the motor is not installed; or, proceed as follows:
•
Wire the motor as specified
•
Adjust the RV to minimum
•
Actuate the PU with very short pulses
•
Adjust the RV for normal operation
If the motor rotates in the wrong direction, the pump may be permanently
damaged when it reaches operating pressure. The connections to the motor
and its direction of rotation must be checked every time the PU or the system is
disconnected from the power mains.
After the system is started, make sure all the controls operate properly.
When executing the first movements with the system, air must be bled from
the system to prevent foam forming in the tank and possible undesired and
uncontrollable movements of the actuators. Also, recheck the fluid level and top it
up if necessary. After the system has operated for a few hours, check the entire PU
for fluid seepage, recheck the fluid level in the tank, and again look for foam in the
tank.
RACCOMANDAZIONI
Leggere i capitoli: “Uso previsto dell’ Unità di Potenza”, “Limiti di impiego”,
“Specifiche di sicurezza”, “Limiti di funzionamento”, “Installazione”.
Nelle fasi sottodescritte si vuole consigliare una serie di operazioni da eseguire,
per un corretto avviamento.
Eseguire il riempimento del serbatoio con fluido idraulico nuovo e filtrato
(vedere capitolo “Scelta del fluido idraulico”).
Scollegare la linea di pressione del cilindro e riporla all’ interno di un contenitore
pulito. Deve essere garantito che il fluido idraulico non possa finire negli
scarichi, nelle canalizzazioni o nel terreno.
Avviare e spegnere il motore della UP con cicli ON/OFF di 1 s, procedere fino
alla fuoriuscita del fluido idraulico dalla linea di pressione.
Ricollegare la linea di pressione al cilindro e rabboccare il serbatoio.
Effettuare diverse corse complete del cilindro per spurgare dall’ aria il circuito e
verificare di nuovo il livello del fluido idraulico.
Controllare la taratura della VM.
La maggior causa di rottura, cattivo funzionamento ed usura precoce dei sistemi
idraulici è lo scarso livello di pulizia, quindi all’assemblaggio, assicurarsi della
pulizia dei tubi, dei cilindri.
TIPS
Read the following chapters: “Prescribed use of this Power Unit”, "Limits of Use”,
“Safety Specifications”, “Operational Limits”, “Installation”.
The operations described below are the recommended way to start up the unit
properly.
Fill the tank with new, filtered hydraulic fluid (see the chapter, “Choosing the
Hydraulic Fluid”).
Disconnect the pressure hose from the cylinder and place it into a clean container.
Do not allow hydraulic fluid to flow into drains or discharge channels, or onto the
ground.
Turn the motor on the PU on and off at intervals of 1 sec. until hydraulic fluid is
ejected from the pressure hose.
Reconnect the pressure hose to the cylinder and top up the tank.
Execute a number of complete cycles on the cylinder to purge the air from the
circuit and check the level of hydraulic fluid once again.
Make sure the RV is set correctly.
The most common cause of breakage, poor operation and premature wear of
hydraulic systems is lack of cleanliness. For this reason, make sure all hoses and
cylinders are perfectly clean during assembly.
MANUTENZIONE
Il buon funzionamento della UP (e dell’ impianto) dipende anche da una corretta
manutenzione. Dopo un breve periodo di funzionamento verificare il corretto
serraggio delle viti e dei raccordi, poiché pulsazioni e vibrazioni possono causare
allentamenti e conseguenti perdite o trafilamenti di fluido idraulico; a tale
proposito è importante mantenere la UP pulita per individuare meglio detti
trafilamenti: per la pulizia utilizzare esclusivamente stracci puliti.
Escludere assolutamente solventi o detergenti.
Controllare il livello e lo stato del fluido idraulico, si consiglia di eseguire
il primo cambio del fluido idraulico dopo le prime 10 ore di lavoro.
Eseguire i successivi cambi ogni 3000 ore di lavoro ( o una volta all’
anno).
Ad ogni cambio del fluido idraulico sostituire il filtro d’ aspirazione (ed
eventualmente altri filtri) ed eseguire la pulizia interna del serbatoio, si consiglia
di eseguire il cambio del fluido idraulico smontando direttamente il serbatoio
(vedere capitoli “Smontaggio dei serbatoi” e “Sostituzione del filtro”).
Prima di effettuare il cambio del fluido idraulico svuotare completamente tutto l’
impianto. La frequenza del cambio del fluido idraulico sopra descritto è riferito a
temperature di esercizio comprese fra 30° ÷ 60°C (temperatura del fluido
idraulico).
MAINTENANCE
Proper operation of the PU (and of the system it is installed in) also depends on
correct maintenance. After a short period of operation, make sure all the screws
and fittings are tight, since pulsation and vibration may cause these components to
loosen, which may lead to leakage and seepage of hydraulic fluid. It is important
to keep the PU clean so that leaks and seepage can be more easily seen. Only use
clean cloths for cleaning.
Never use solvents or detergents.
Check the level and the condition of the hydraulic fluid. We recommend
changing the fluid the first time after the first 10 hours of operation.
Afterwards, change the fluid every 3000 hours of operation (or once a
year).
Whenever the hydraulic fluid is changed, replace the intake filter (and the other
filters, if installed) and clean the inside of the tank. It is a good idea to change the
fluid by removing the tank (see the chapters, " Removing and reinstalling the tanks
" and “Replacing the Filter”).
Before changing the hydraulic fluid, empty the entire system completely. The fluid
change interval described above applies at operating temperatures of 30° C to 60
°C (temperature of the hydraulic fluid).
•
•
Proprietà dell’ azienda Brevini Fluid Power S.p.A. vietata qualsiasi riproduzione anche parziale senza l’ autorizzazione della stessa.
Property of Brevini Fluid Power S.p.A. Reproduction in whole or in part without express written consent is prohibited.
ISTRUZIONI ORIGINALI
ORIGINAL INSTRUCTIONS
Istruzioni assemblaggio – Assembly instructions
Serie MR – MW – MC – MS – FP
MK – VT – P1509 – P1507 – TP – TPS – TPM
Temperature più elevate possono determinare una drastica riduzione delle
caratteristiche di durata del fluido idraulico.
DOC00032 Rev. C
Higher temperatures may seriously reduce the service life of the fluid.
8/8
Sostituzione del filtro
Il filtro può essere sostituito con uno stesso filtro nuovo oppure può essere lavato
e pulito, quindi riutilizzato (vedere “Specifiche di sicurezza”)
Azioni da eseguire:
•
svitare il filtro bloccando il tubo di aspirazione onde evitare lo svitamento
dello stesso;
•
cambiare o pulire il filtro;
•
avvitare il filtro percorrendo lo stesso tratto utile filettato del tubo, forzare
in modo da far compenetrare la filettatura metallica del filtro sul tubo.
Replacing the filter
The filter can be replaced with a new filter of the same type or it can be washed,
cleaned and reused (see the section, "Safety Specifications").
Proceed as follows:
•
Unscrew the filter while holding on to the intake hose to prevent it from
unscrewing
•
Clean or replace the filter
•
Screw the filter back into place onto the same section of threading on the
hose. Use enough force so that the metal thread on the filter is snugly seated
on the hose.
Smontaggio e rimontaggio dei serbatoi
Smontaggio
•
svitare il sistema di fissaggio
•
sfilare il serbatoio senza l’ aiuto di leve che possono causare ammaccature
Rimontaggio
•
controllare la pulizia del serbatoio
•
verificare il buono stato della guarnizione di tenuta
•
verificare il buono stato della bocca del collare del serbatoio (pulito, senza
ammaccature, senza solchi anomali)
•
ingrassare la bocca del collare del serbatoio
•
introdurre il serbatoio
•
Fissare il serbatoio stringendo le viti in modo uniforme
È consigliato ingrassare la bocca del serbatoio e non la guarnizione, in
questo modo l’ UP rimarrà più pulita, il grasso scorrerà verso l’ interno
del serbatoio.
I serbatoi hanno differenti metodi di fissaggio
Fissaggio diretto con filettatura diretta sul serbatoio
(normalmente in lamiera)
6
M6
Fissaggio con staffa (normalmente per serbatoi in PP)
Fissaggio con fascetta (normalmente per serbatoi in PE)
Removing and reinstalling the tanks
Removal
•
Unscrew the mounting system
•
Pull out the tank, but without the aid of levers that could cause dents
Reinstallation
•
Make sure the tank is clean
•
Make sure the sealing gasket is in good condition
•
Make sure the opening on the collar of the tank is in good condition (it must
be clean, free from dents and without unusual grooves)
•
Grease the opening on the collar of the tank
•
Install the tank
•
Secure the tank tightening the screw evenly
It is a good idea to grease the opening of the tank and not the gasket. The
PU will be cleaner because the grease will flow toward the inside of the
tank.
The tanks have different mounting systems
Direct mounting using the threading on the tank (usually
made of sheet metal)
6
M6
Mounting with a bracket (usually for PP tanks)
Mounting with a collar band (usually for PE tanks)
Avvitamento tappi sui serbatoi
Tappi di plastica con chiave
Tappi di plastica ad avvitamento manuale
Tappi metallici
Screwing plugs into the tank
Plastic plug with key
Manually tightened plastic plugs
Metal plugs
10
A mano
30
Filettatura
G. 1/2
G. 3/4
10
By hand
30
Thread
G. 1/2
G. 3/4
Serraggi consigliati
Nel caso si rendano necessari eventuali smontaggi e rimontaggi di componenti
delle UP, nelle tabelle seguenti sono riportate le coppie di serraggio consigliate
Recommended tightening torque values
If components on the PU must be removed and reinstalled, tighten them at the
torque values listed on the following table:
Coppie di serraggio da applicare alle viti o ai tiranti per il montaggio dei motori
M8 M6 M5 1/4-20 UNC
Tightening torque values to be used on the screws or tie rods used to fasten motors
M8 M6 M5 1/4-20 UNC
25
10
6
10
Per le coppie di serraggio dei poli dei motori DC e dei teleruttori,
vedere paragrafo “Collegamento elettrico per motore DC”
Coppie di serraggio da applicare sul corpo flangia
3/4 -16
M6 M8 M10x1.5 M16x1.5
UNF
10
25
45
30
30
BSPP
1/4
BSPP
3/8
30
30*
25
10
6
10
For tightening torque values used on the terminals of DC motors and
start switches, see the paragraph, “Connecting a DC motor”
Tightening torque values to be used on the flange body
3/4-16
M6 M8 M10x1.5 M16x1.5
UNC
10
25
45
30
30
BSPP
1/4
BSPP
3/8
30
30*
*= non applicabile nelle cavità di scarico del lato serbatoio
*= not applicable in the discharge cavities on the tank side of the unit
I serraggi consigliati nella tabella sono considerati in riferimento al
materiale, al tipo di filettatura del corpo flangia e ai più comuni
componenti montabili. I serraggi non sono validi per altri componenti in
materiali diversi (plastiche) o componenti che hanno diverse possibilità di
avvitamento (come cacciaviti a taglio, croce o altro) o se diversamente
specificato. I serraggi non sono validi per tappi e raccordi con filettature coniche.
The recommended tightening torque values on the table are differentiated
according to material and type of thread on the flange body and apply to the
components that are most commonly removed. The values do not apply to other
components made of different materials (plastic) or components that are tightened
using other methods (such as slot-head or Philips head screwdrivers, or other
tools), or unless otherwise specified. The torque values do not apply to plugs and
fittings with tapered threads.
DISMANTLING AND DISPOSAL
If the PU must be dismantled, empty the fluid and dispose of it according to the
laws that apply in the country where it will be disposed of. The same holds true for
the other parts of the PU; that is, dispose of them according to the laws that apply
to disposal of plastic and ferrous materials, as the case may be.
When dismantling the unit, separate the plastic parts from the electrical
components, which must be disposed of separately in accordance with current
regulations.
The large metal sections of the PU should be separated into parts made of steel and
parts made of other metals or alloys, so that they can be correctly melted down for
recycling. Dismantling is not a particularly risky operation, as long as it is
performed by properly trained personnel using adequate tools (see the chapter,
“Safety Specifications”).
DEMOLIZIONE E SMALTIMENTO
Nel caso in cui la UP debba essere demolita la si dovrà svuotare dall’ olio
contenuto che verrà smaltito secondo le prescrizioni di legge in vigore nel Paese
in cui avviene lo smaltimento. Lo stesso vale anche per le altre parti della UP,
considerando la tipologia dei materiali che la compongono, plastici e ferrosi.
All' atto della Demolizione è necessario separare le parti in materiale plastico
dalla componentistica elettrica, che devono essere inviate a raccolta differenziata
nel rispetto delle Normative vigenti.
Per quanto concerne la massa metallica della UP, è sufficiente procedere alla
suddivisione tra le parti in acciaio e quelle in altri metalli o leghe, per un corretto
invio al riciclaggio per fusione. L' operazione di demolizione non presenta rischi
particolari, a condizione che sia effettuata da persone sufficientemente preparate
e dotate di mezzi adeguati (vedere capitolo “Specifiche di sicurezza”).
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ISTRUZIONI ORIGINALI
ORIGINAL INSTRUCTIONS
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