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

Core process of mechanical installation: tightening disc and hollow shaft

The F series and some A/C series use hollow output shafts with shrink discs for installation. This is the most common installation difficulty, and the following is the standardized workflow:

Cleaning and lubrication (key steps): It is absolutely forbidden to apply molybdenum disulfide or any lubricating grease on the mating surface between the tightening disc and the machine shaft, as this will significantly reduce the friction coefficient and cause the tightening disc to slip and fail. These contact surfaces must be thoroughly cleaned and degreased. On the contrary, solid lubricants with a friction coefficient of μ=0.04 (such as Kl ü ber Molybdenum UMF T4) should be used on the non mating surface of the tightening disc (i.e. the sliding surface of the tightening disc itself).

Installation steps:

Install the reducer onto the machine shaft.

Install the tightening disc and pre tighten the bolts by hand.

It is necessary to use a torque wrench to gradually tighten all bolts in a clockwise sequence in multiple times until the final torque Mt specified in Table 4 is reached. This operation usually requires repeating 2-3 cycles to ensure uniform clamping.

Axial fixation: In the presence of external axial thrust, vibration, or installation posture with the output shaft facing downwards (such as B6 or H5 installation method), additional axial fixation devices (such as stop rings or retaining rings) must be installed to prevent the tightening disc from accidentally disengaging due to vibration.

Protective cover reset: After installation, the protective cover must be reinstalled. For the ATEX version, the joint surface of the protective cover also needs to be coated with sealant.

Lubrication management: Oil selection and oil change cycle

Lubrication is the decisive factor in the lifespan of a gearbox. The manual provides an extremely detailed classification of oil selection and replacement cycles.

Oil compatibility: Bonfiglioli strongly recommends using PAG (polyethylene glycol) synthetic oil (such as Shell Omala S4 WE 320) or PAO (poly alpha olefin) synthetic oil. It is strictly prohibited to mix different brands or types of oil.

Oil level inspection: The oil level varies at different installation positions (B3, B6, V5, etc.). For models without overflow type oil level plugs (such as C12, C22, C32, and A05), a dipstick must be inserted into the dedicated hole for measurement. The measured value (X) must be less than the value corresponding to the installation position in Table 12/13 of the manual.

Oil change cycle (key data):

A70 and above/C/F/S series: If the oil temperature (t ₀) is below 65 ° C, mineral oil needs to be replaced in 8000 hours, and PAO/PAG synthetic oil only needs to be replaced in 25000 hours.

If the oil temperature is in the dangerous range of 80-95 ° C: the replacement cycle for mineral oil is shortened to 2000 hours (and continuous operation is not recommended), and for synthetic oil it is 12500 hours.

Practical operation suggestion: The first oil change should be carried out after 100 hours of operation to remove metal particles generated during running in. Afterwards, strictly follow the cycle corresponding to the oil temperature.

Long Term Stock: For equipment with the "LONG TERM STOCK" option and filled with anti rust oil:

Scenario A: If the rust proof oil is compatible with the mineral oil/PAO oil used later, simply add working oil.

Scenario B: If the rust proof oil is incompatible with the later used PAG oil (PAG is incompatible with mineral oil), the rust proof oil must be drained first, then about 20% capacity of PAG oil must be injected for a "washing test" - run empty for a few minutes, then drain, and finally add new PAG working oil.

Common troubleshooting and temperature monitoring

The manual provides a practical troubleshooting table (Table 18), which on-site engineers can use to quickly locate problems.

High bearing temperature: usually caused by low oil level, aging oil, or damage to the bearing itself.

High operating temperature: may be caused by high oil level, oil aging, or oil contamination.

Abnormal operating noise: may be caused by gear damage, excessive bearing wear, or excessive external load. Special attention: Loose installation bolts can also produce abnormal noise, which is extremely common under vibration conditions.

Oil leakage: It may be due to high oil level or seal failure. No leakage is allowed in ATEX environment as oil stains can adsorb dust and increase the risk of ignition.

Unable to start/output shaft not rotating: Check if the oil viscosity is too high (especially during low-temperature starting) or if the load is too heavy.

Surface temperature measurement protocol: In order to ensure ATEX compliance, the surface temperature at the interface between the gearbox and motor, as well as the area least affected by motor fan cooling, must be measured after 3 hours of full load operation. The maximum temperature difference Δ T shall not exceed 75K of the ambient temperature. If it exceeds this value, the machine must be stopped immediately and Bangfeili technical support must be contacted.