Bonfiglioli EVOX CP Explosion proof Reducer: Quick Guide for Installation and Maintenance

Bonfiglioli EVOX CP Explosion proof Reducer: Quick Guide for Installation and Maintenance

In the field of modern industrial transmission, space constraints and maintenance efficiency often become the two major challenges faced by engineers. Bonfiglioli's EVOX CP series coaxial gearbox provides an elegant solution to this problem with its compact modular design and innovative "Universal Mounting" concept. When this platform is combined with ATEX explosion-proof technology, the EVOX CP ATEX series is born - an ideal transmission equipment designed specifically for potentially explosive environments, while balancing installation flexibility and long maintenance cycles.

Overview of core features of EVOX CP series

The design concept of EVOX CP series revolves around "simplification" and "universality".

Universal Mounting: This is the most prominent feature of this series. Unlike traditional reducers that require different oil levels and plug positions for specific installation positions such as B3, B6, V5, EVOX CP allows for a unique internal cavity design that allows for the use of a single product code to adapt to all standard installation positions. This means that whether you install the gearbox horizontally, vertically, or diagonally, its internal oil circuit design can ensure that critical bearings and gears receive sufficient lubrication. This greatly simplifies inventory management and on-site installation decisions.

Lifetime Lubrication: The EVOX CP series is filled with "lifetime" synthetic oil (standard Shell Omala S4 WE 320 or equivalent PAG oil) at the factory. Under normal operating conditions without external pollution, there is no need to regularly replace lubricating oil. This significantly reduces maintenance workload, especially for hard to reach installation points. Of course, users can choose the SO option to require the gearbox to be shipped without lubricating oil to meet specific customer oil preferences.

Compact coaxial design: The motor input shaft and output shaft are in the same straight line, making it very suitable for situations with limited installation space.

Special installation requirements in ATEX environment

When EVOX CP is used in 2D/2G class (Zone 21/Zone 1) explosion-proof areas, in addition to following standard installation procedures, additional attention should be paid to the following key points to ensure the integrity of explosion-proof performance.

Handling of unused threaded holes: There may be some spare threaded holes on the gearbox housing for different installation methods. In ATEX installation, all unused threaded holes must be plugged with the accompanying plugs. When installing these plugs, apply Loctite 510 thread locking adhesive and screw them flush with the surface. This operation aims to prevent dust from entering the reducer through the thread gap or accumulating in the thread groove, thereby avoiding the formation of potential ignition sources.

Sealing of flange joint surface: When installing the motor onto the IEC input flange of EVOX CP, in addition to cleaning the joint surface, sealant (such as Loctite 510) must be applied to the flange joint surface and positioning stop. After the motor and reducer are fully fastened, Loctite 5366 (or similar product) should be applied to the gap between the flange outer ring to form a continuous seal and prevent dust and water vapor from entering.

Electrostatic protection: The manual clearly warns that no object with a resistance value greater than 10 ΩΩ should be connected to the reducer. At the same time, plastic components on the equipment (if any) must be ensured not to accumulate dangerous electrostatic charges.

Installation posture limitation: Although EVOX CP supports universal installation, for special models equipped with reinforced output bearings (options OHA or OHR), if the output shaft needs to face upwards or have an angle within 60 ° with the vertical direction, it is necessary to consult Bonfiglioli's technical department in advance to confirm whether the standard oil level is still applicable or whether a customized lubrication plan is needed.

Unique oil level inspection method

Due to the lack of a traditional Spill type level plug, the EVOX CP uses a dedicated dipstick method for oil level inspection, which is provided with the gearbox.

Preparation: Place the gearbox in a horizontal mounting position.

Insert dipstick: Find the yellow service plug and screw in the dipstick rod that comes with the goods until it reaches the limit.

Read the oil level: Wait for a moment and then unscrew the dipstick. Observe the location of the scratches on the dipstick that have been soaked in oil. For different machine base numbers (CP 07, CP 17,..., CP 67), the manual provides corresponding "X" dimensional tolerance values (e.g. CP 07 is 0.35L, tolerance is 0/-3mm).

Judgment criteria: If the oil level mark on the dipstick shows that the oil level exceeds the tolerance range (i.e. the oil level is too high), it is necessary to drain to the correct oil level. If the oil level is insufficient, it is necessary to replenish the oil.

Core Tip: For ATEX version (EX option), only 6 standard installation positions (B3, B6, B7, B8, V5, V6) are supported. Although a single oil level can cover these 6 positions, any angle deviation should be avoided.

Maintenance points and quick troubleshooting

Thanks to its lifetime lubrication design, the routine maintenance work of EVOX CP has been greatly simplified, but regular visual inspections and condition monitoring are still required.

Regular inspection checklist:

Every 24 hours: Monitor noise and vibration levels.

Every 170-720 hours: Check for dirt or oil buildup on the exterior of the casing.

Every 720 hours (or monthly): Check for oil level, external seals, and oil plugs for leaks.

Every 2000-4000 hours: Check the tightening of all installation bolts and coupling elastic components.

ATEX Additional Inspection (Zone 21/22):

Every 100 hours or every two weeks: The surface temperature of the interface between the reducer and the motor must be measured. The measurement point should be selected in the area that is least affected by the cooling of the motor fan. The measured temperature difference Δ T (surface temperature ambient temperature) shall not exceed 75K. This is a key indicator to ensure compliance with explosion-proof temperature levels.

Regular cleaning: A regular cleaning plan must be developed and implemented to ensure that the thickness of dust accumulation on the surface and depressions of the reducer does not exceed 5mm.

Quick troubleshooting: The troubleshooting table (Tab 8) in the manual provides direct guidance for common problems:

Bearing temperature too high: Check if the oil level is too low or if the oil is aging.

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

Abnormal operating noise: usually refers to gear damage, bearing wear, or excessive external load. Comprehensive judgment based on current detection is required.

Oil leakage: Check if the oil level is too high or if the seals have failed. For ATEX environments, any leaks must be dealt with immediately as oil stains can adsorb dust and increase the risk of ignition.

Precautions for disassembly and replacement

When it is necessary to remove the motor from EVOX CP, it is strictly prohibited to use tools such as screwdrivers or pry bars to forcefully pry open the flange surface, in order to avoid damaging the precision fitting joint. The manual recommends using specialized disassembly bolt holes to smoothly push the motor out by screwing in the bolts.