Rossi EP Series User manual

Operating instructions
Planetary gear reducers and gearmotors
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EP series

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1General and safety informations 5
1.1 Recycling 5
1.2 Safety 5
2Use conditions and limits 6
3Supply status 7
3.1 Name plate 7
3.2 Lubricant 8
3.3 Painting 8
3.4 Protections and packing 8
4Lifting, handling and storage 9
4.1 Receipt 9
4.2 Lifting and handling 9
4.3 Storage 10
5Installation 11
5.1 General 11
5.2 Screws and tightening torques 12
5.3 Flange mounting 14
5.4 Gear reducer mounting with slewing outputs 15
5.5 Foot mounting 15
5.6 Shaft mounting arrangements 16
5.7 Torque arm 16
5.8 Shaft end mounting 20
5.9 Hollow shaft mounting with shrink disc 20
5.10 Accessories mounting 23
6Universal ange adapter 28
Index
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7Motor mounting or replacement 29
7.1 Electric motors 29
7.2 Hydraulic motors 30
8Lubrication 31
9Commissioning 33
10 Cooling unit systems 35
11 Backstop device 39
12 Maintenance 39
13 Mounting positions, oil quantities and tanks 41
14 Plug positions and types 52
15 Troubles: causes and corrective actions 56
16 PB series - Parking brakes 57
Commissioning 63
Maintenance 63
Oil change 64
Seal change 64
Troubles: causes and corrective actions 64
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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 cast iron will be subjected to the same treatment if there is no particular instructions;
• exhausted oils must be recycled and treated in accordance with environmental legislation.
This document provide information about handling, installation and maintenance of the planetary gear reducers.
All the people who work with the products presented in this operating instructions must carefully read and apply them rigorously.
The products correspond to the technical level reached at the moment the document is printed. Rossi S.p.A. reserves the right
to introduce, without notice, the necessary changes to improve e󰀩 ciency and safety of its products.
General and safety informations 1
1.1
Recycling
1.2
Safety
• Live
• At temperature higher than 50 °C
• Rotating during operations
• attention
• Don’t use to lift
• Lifting point
The paragraphs marked with symbols shown below 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.
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:
• Machinery directive 2006/42/CE and subsequent updatings;
• "Electromagnetic compatibility (EMC)" directive 2004/108/EC and subsequent updatings.
ATTENTION!
Components in non-standard design or with special executions or with constructive variations may di󰀨 er 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) or of the
possible motor-variator and/or the electric supply device (frequency converter, soft-start, etc.) and accessories,
if any ( ow indicators, independent cooling unit, thermostat, ect) consult the attached speci c documentation.
If necessary, require it.
ATTENTION!
For any clari cation and/or additional information consult Rossi S.p.A. and specify all name plate data.
Gear reducers and gearmotors of presented in this operating instruction are normally suitable for installations in industrial areas:
additional protection measures, if necessary for di󰀨 erent employs, must be adopted and assured by the person responsible
for the installation.
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 products must be moved, installed, commissioned, handled, controlled, serviced and re-paired exclusively by
responsible quali ed personnel.
Quali ed personnel must be specially trained and have the experience necessary to recognize risks associated with these
products and to avoid possible hazards.
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General and safety informations 1
Use conditions and limits 2
It is recommended to pay attention to all existing safety laws and standards concerning correct installation.
Whenever personal injury or property damage may occur, due to falling or projecting parts of gear reducer or of its parts, foresee
adequate supplementary protection devices against:
• release or breakage of fastening screws;
• rotation or unthreading of the gear reducer from shaft end of driven machine following to accidental breakage of the reaction
arrangement;
• accidental breakage of the shaft end of driven machine.
When operating on gear reducer 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).
ATTENTION!
During the operation the gear reducers may have hot surfaces.
ATTENTION!
During the operations take protection due to possible warm oil contact.
If deviations from normal operation occur (temperature increase, unusual noise, etc) immediately switch o󰀨 the machine.
Gear reducers are suitable to operate at ambient temperature 0 °C ÷+40 °C (with peaks -20 °C ÷+50 °C), with standard seal
rings and components.
The operation outside this range, with a minimum of -40 °C and a maximum of +60 °C, must be evaluated in relation to the
speci c operating conditions, duty cycle, type of lubricant, type of seals and cooling/heating system (where possible); please
contact Rossi S.p.A.
Allowed operational and storage ambient temperature in relation to lubricant type 1)
Synthetic
Lubricant Mineral Lubricant
Ambient Tem-
perature
Tamb
Running conditions
Minimum ambient temperature -20 °C -10 °C
Maximum ambient temperature +50 °C +40 °C
Minimum ambient temperature for ATEX design -20 °C -10 °C
Maximum ambient temperature for ATEX design +40 °C +40 °C
Storage condition
Minimum ambient temperature of storage condition -10 °C -10 °C
Maximum environment temperature of storage condition +50 °C +50 °C
Oil Tempera-
ture
Toil
Minimum oil temperature for partial load starting condition 2) -20 °C -10 °C
Minimum oil temperature for full load starting condition -10 °C -5 °C
Maximum nominal stabilized oil temperature allowed in continuos running condition (S1) +95 °C +95 °C 3)
Maximum peak and occasional oil temperature allowed with intermittent duty only +110 °C +110 °C
1) For selection of lubricant and optimal viscosity according to temperature T
amb
and in case of independent lubrication unit, refer to chapter
8.8 (Lubrication).
For starts and services with T
oil
< 0 °C , consider higher absorption on the electric motor according to the type of lubricant.
2) If full load service is required, provide gradual starting and stopping ramps, avoiding overloads and shocks.
3) For temperature value of T
oil
> 75 °C and < 95 °C it is recommended to use oils with at least viscosity grade 30 cSt at 95 °C.
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Supply status 3
3.1
Name plate
Assembled by subsidiaries
Gear
reducer size
Ratio
Product
code
Serial
number
Mass
Output
Date
Input
Mounting
position
Name plate
Every gear reducer is provided with a name plate in anodized aluminium containing main information necessary for a correct
identi cation of the product; the name plate must not be removed and must be kept integral and readable. All name plate data
must be speci ed on eventual spare part orders.
Gear
reducer size
Ratio
Product
code
Serial
number
Output
Date
Input
Mounting
position
QR code
Mass
Assembled by Rossi Italy
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Supply status and product designation 3
Overhanging free shaft ends and hollow shafts are treated with protective anti-rust long life oil.
All internal parts are protected with protective anti-rust oil. Unless otherwise agreed in the order, products are adequately
packed: on pallet, protected with a polyethylene lm, 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 lling cardboard.
Generally the packing is suitable for the normal road/rail transport. For sea transport it is necessary to foresee a special packing,
when ordering.
Before handling or transporting the gear reducers, be sure that the packing is in good conditions and suitable for the transport.
Do not stock packed products on top of each other.
3.3
Painting
3.4
Protections and packing
3.2
Lubricant
If not di󰀨erently stated, gear reducers until size 021A are supplied lled for the specic mounting position involved with synthe-
tic PAO oil as indicated in an additional label.
1) Before adding further coats of paint, properly protect the seal rings and carefully degrease and sand the gear reducer surfaces (instead of
sanding it is possible to apply a water-based primer coat).
Internal painting External painting Notes
Final color Blue RAL 5010 Features
Single-compound ester epoxy
or phenolic resin basis primer
(prepainted)
Single-compound ester epoxy
or phenolic resin basis primer
(prepainted)
+
Water-soluble
polyurethane
dual-compound enamel
Resistant to atmospheric and
aggressive agents
(atmospheric corrosivity category C3
according to ISO 12944-2).
Suitable for further coats of
dual-compound paints only1)
The internal painting does not
resist polyglycol synthetic oils
(polyalphaolefines synthetic oils
are suitable).
Remove by a scraper or sol-
vent the possible paint of gear
reducer coupling surfaces
Standard painting
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