Bonfiglioli C Series ATEX Explosion proof Reducer Selection

Environmental temperature: must be within−twenty℃∼+forty℃

Operate within the range of -20 ℃ to+40 ℃.

Installation position: It must be completely consistent with the installation position specified in the order and cannot be changed arbitrarily - because the design of the lubricating oil circuit, the position of the vent plug, and the oil level height are all bound to the installation orientation.

Do not tilt installation: Unless authorized in writing by Bonfiglioli's technical department, do not tilt the gearbox at any angle.

Maximum motor speed limit: Input speed

n≤one thousand and five hundred

min−one n≤1500 min  −1

This is the hard boundary of ATEX certification, exceeding this speed may result in temperature exceeding the standard.

Additional restrictions on the use of variable frequency drives: If variable frequency drives are used, the parameters of the variable frequency drive must not allow the motor to exceed its maximum speed (1500 min ⁻¹), nor overload the gearbox. At the same time, the frequency converter motor must be clearly labeled as "frequency converter specific" and comply with ATEX usage requirements.

Dual constraints of geometry and power for motor availability matching

1. Geometric compatibility

The matrix table on page 27 of the manual lists the geometric compatibility between different C Series specifications and IEC motor frame numbers. For example:

C 12 2 supports motor flanges from P63 to P132

C 22 2 supports P71 to P112

C 61 2 supports P90 to P180

It cannot be assumed that installation is possible solely based on matching bolt hole positions. It is necessary to verify whether there are corresponding horizontal and vertical intersection points in the table.

2. Maximum installable power

On page 28 of the manual, it is listed that n one=one thousand and four hundred min−one n one=1400 min −1

The maximum input power that each reducer size can withstand. For example:

C 12 2 with P100 flange, maximum allowable input power is 2.2 kW

C 51 2 with P160 flange, maximum allowable input power is 15 kW

If a higher power motor (such as 18.5kW) is forcibly installed on the C 51 2, even if the flange holes can align, the gears and bearings inside the gearbox will quickly be damaged due to overload.

Common selection misconceptions and pitfalls avoidance guide

Misconception 1: Ignoring the distinction between ATEX explosion-proof temperature rating and operating temperature

The T3/T4 on the ATEX nameplate refers to the highest surface temperature, not the internal oil temperature. Even if the internal oil temperature is only 80 ℃, if external dust accumulation leads to poor heat dissipation, the surface temperature may exceed the limit. The surface temperature is affected by installation conditions, and even small changes (such as insufficient heat dissipation space) may significantly alter the heat dissipation effect, "emphasized on page 10 of the manual

Misconception 2: Applying the wrong formula when verifying the radial load of shaft extension

Many engineers adopt F=two T/d The simplified formula for calculating belt tension with F=2T/d ignores the additional load caused by belt pre tension. Recommended by the manual Kt Coefficient (belt drive)one point five∼two

1.5-2.0) The influence of pre tension has been taken into account.

Misconception 3: Mixing solid shaft input and IEC flange input for selection

The selection basis for solid shaft input is torque（Mn two）The selection of IEC flange input is based on power（Pn one）. If the power meter is mistakenly used to select the actual spindle model, it will lead to serious deviation - because the torque at different speed ratios under the same power varies several times.

Misconception 4: Neglecting the pre startup action of "replacing the breathable plug"

ATEX reducers are shipped with Dummy plugs to prevent lubricant leakage during transportation. On page 16 of the manual, it is emphasized that users must replace the blind plug with the Vented Plug that comes with the product before turning it on. If not replaced, the increase in pressure inside the box during operation will cause oil seal failure and oil splashing, which is neither safe nor compliant.