Bonfiglioli C/A/F/S Reducer ATEX Installation and Maintenance Practice Guide

Bonfiglioli C/A/F/S series reducers ATEX installation and maintenance practice guide

In industrial fields such as chemical, pharmaceutical, and grain processing where explosive dust or gases exist, the installation and maintenance of reducers as key power transmission equipment are directly related to the safety of the entire production facility. Bonfiglioli's C-series (parallel axis), A-series (bevel helical gear), F-series (shaft mounted), and S-series (single-stage) reducers are widely used in various heavy-duty conditions due to their modular design and strong load-bearing capacity. When these devices are designated for use in ATEX explosion-proof areas, their installation, operation, and maintenance have more stringent requirements than conventional equipment.

Security and Reception: The Foundation of Project Success

Before any installation work begins, safety is the primary consideration. The Bonfiglioli manual clearly states that as a component of the machine, the safety of the gearbox after final integration is the responsibility of the manufacturer of the entire machine. But for on-site installation personnel, the following points are crucial:

Nameplate verification: The equipment's Nameplate contains all key information, such as serial number, model, mounting position, and ATEX classification. When the serial number is 17 digits, the year is in the 3rd to 4th digits; At position 13, it is in positions 5-6. During acceptance, it is necessary to confirm that the "installation position" on the nameplate is completely consistent with the actual installation method. Any deviation, even a slight angle tilt, must be authorized in writing by Bonfiglioli's technical department before execution, otherwise ATEX certification will automatically become invalid.

Long Term Stock: If the device is not installed immediately, the manual provides detailed long-term storage guidance. For devices with the "LONG TERM STOCK" option, they are packaged in VpCI (vapor phase anti rust) bags and clearly labeled "ON before installation". The storage environment of such devices must be strictly controlled: temperature -10 ° C to+40 ° C, dry and without direct sunlight. Storage exceeding 2 years must be sent to Bonfiglioli service center for re inspection.

Packaging treatment: Standard packaging is not designed to be waterproof and is only suitable for dry warehouses with roofs. After unpacking, it is necessary to check whether the plastic protective cover during transportation has been removed, and it is forbidden to use the lifting ring bolts on the motor to lift the entire reduction motor, which will seriously change the center of gravity and cause safety accidents.

Key installation points in ATEX environment

When the gearbox is used in hazardous areas such as Zone 21 (dust) or Zone 1 (gas), a series of special regulations must be followed during the installation process to prevent potential ignition sources.

Surface temperature management: The core of ATEX certification is to control the surface temperature of equipment. The nameplate indicates the maximum surface temperature (e.g. T4 is 135 ° C). During installation, it is necessary to ensure that the on-site ambient temperature does not exceed+40 ° C (synthetic oil) or+40 ° C (mineral oil), and that the surface temperature of the gearbox does not exceed+100 ° C (housing) and+95 ° C (oil temperature) during continuous operation. The manual emphasizes that continuous operation is not recommended if the surface temperature (ts) and oil temperature (to) are within the range of 80 ° C to 95 ° C.

Dust prevention and sealing: For Zone 21/22 (dusty environment), after installation, it is necessary to:

Clean all unused threaded holes: Block all unused installation holes with the screw plugs (coated with Loctite 510 thread locking adhesive) provided with the goods to prevent dust accumulation.

Apply sealant: Apply sealant (such as Loctite 5366) on the flange joint surface and positioning joint of the motor and reducer to prevent dust from entering or accumulating through the gap.

Torque arm installation: F-series shaft mounted reducers must use the original anti vibration kit provided by the factory. It is necessary to ensure that there is no sliding friction between metal parts during operation, and non-metallic anti friction components should be installed if necessary.

Static protection: Do not connect objects with a resistance exceeding 10 ΩΩ to the reducer. Plastic components, such as fan covers, must be ensured not to accumulate static charges.

Bolt tightening torque: In ATEX environment, all external bolts (including installation bolts and oil plugs) need to be coated with Loctite 510. The tightening torque must strictly follow the manual's "Table 1" (for structural bolts, grade 8.8 or 10.9) and "Table 2" (for oil plugs, such as 1/2 "oil plug torque of 14 Nm and M14x2 torque of 30 Nm). Special warning: If the gearbox housing is made of aluminum (such as small models), it is strictly prohibited to use bolts higher than grade 8.8 for installation to avoid crushing the threads.