Rotomotive Powerdrives ROBUS 12 User manual

ROBUS
helical in-line gearboxes
Operation and maintenance manual ROBUS units Page 1 OF 13
operation and maintenance manual

COMPONENTS LIST
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STORAGE
• Do not store outdoors, in areas exposed to weather or with excessive humidity.
• For storage periods longer than 0 days, all machined and unpainted surfaces such as
flanges, bases, and
shafts must be protected with a suitable anti-oxidation product
• Oil seals must be touched by the oil. Before putting them into operation restore correct
quantity and type of oil.
• At intervals of 4 to 5 months, the output shaft should be rotated
INSTALLATION
• Make sure that the ROBUS unit is correctly secured to avoid vibrations.
• If shocks or overloads are expected, install hydraulic couplings, clutches, electronic torque
limiters, control units,etc.
• For a satisfactory gearbox performance, it is essential to align correctly the motor and the
driven machine.
• Whenever possible, we suggest to interpose flexible couplings
• Align with precision the eventual outboard bearing, because any misalignment would cause
high overloads, with a subsequent rupture of a bearing or the shaft
• Before starting up the machine, make sure that the oil level is conform to the mounting
position specified for the STON unit by checking the level plug
• For outdoors installation provide adequate guards in order to protect the drive from rainfalls
as well as direct sun radiation.
• It is recommended to clean and lubricate the connection shafts with grease having a copper
base (example Castrol Optimol Paste HT) in order to avoid fretting corrosion and seizure.
Copper, in fact, being very malleable, is like a barrier against the direct contact between two
similar metals. In alternative, you can use a grease having high viscosity base oil which
remains particularly adhesive (example Mobilgrease XTC)
• Whenever there are outer loads, it is recommended to use pins and positive stops
• Self-locking adhesives should be used on the bolts and joining surfaces of the machine
frame to prevent gearbox and driven machine to get loose
• It is recommended to avoid to fit cantilever pinions. If this is not possible, minimize the
distance between pinion and output shaft to avoid excessive radial loads
• He pre-loading of belts and chains to the minimum
• Never use the hammer for mounting/dismantling of the jeyed parts, but use the tapped holes
provided on the head of the shafts
• For a smooth and silent working, it is recommended the use of Motive motors
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ROUTINE CHECKS
• Periodically check that the outer surfaces of the ENDURO unit and the cooling air passages
are clean.
• Verify that the breather plug hole is clean.
• Regularly make sure that there are no lubricant leaks.
• Using the level plug window, verify periodically the correct quantity of lubricant
OPERATING TEMPERATURE
The operating temperature depends on a number of factor such
as the type of power transmission, the quantity of lubricant, the
speed and power applied and the environment in which the
gearbox is operating. With a standard helical gearbox,
the maximum allowable inside temperature is 80°C.
In case of control, it is important to check that the operating
temperature when the gearbox runs at normal speed is constant;
this indicates that the gearbox is running in a trouble-free manner
-If we use a 2 poles motor (n1 about 2800RPM), a few potential
problems, like the temperature inside the gearbox,vibrations
or noise, can grow. As a general rule, we recommend the use
of worm gearboxes with 2 poles motors only in applications
having a relatively low service factor (1.25 max.) and a very low
degree of intermittency.
- during the first 4 hours, you may assist to a gradual decrease of the
inner temperature due to the gearbox components settling.
MAINTENANCE
Maintenance is essentially limited to the requests reported in the charter “lubrication” and to
an accurate external cleaning, usually carried out with bland solvents in order to not to
damage the paint
When it is necessary to fill the oil but there is no compatibility of the new oil with the one
inside the gearbox, we suggest to empty the gearbox from its oil and wash it before putting
the new oil
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LUBRICATION
Unless otherwise specified, each ENDURO is supplied long-life synthetic oil
(quantity as per position B3). You must replace the oil each 20.000 working
hours and anyway every 5 years at least After an eventual oil addition, each
ROBUS can be mounted in any mounting position, thus giving big advantages
in the stock management and lead time All units are supplied with plugs for
loading, discharging and checking the level of the oil. Furthermore, they are
accompanied by a breather plug. Before start-up, we suggest to re-place the
filler plug in the upper side of the unit with the breather plug .
Level plugs, correctly positioned as per following
tablechart, are a useful reference for the verification of the
correct oil quantity
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V5 / V1 B7
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Mounting positions
breather plug level plug filler plug
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OIL SEALS REPLACEMENT
When a shaft seal doesn’t work properly, it must be replaced rapidly, in order to avoid that the
oil leakage goes further on, and that the damage extends to some other components.
When fitting a new seal, the following precautions are required:
• take particular care in handling, and make sure that the seal is in
good conditions, particularly if long times of stocking could have
caused a premature ware, especially in presence of excessive
humidity
• always check that the shaft seal seat is in good conditions, free of
surface defects. If the area where the ring seal comes into contact
with the shaft has worn down by more than 0,2-0,3mm, do not
install a new seal
• care to prevent the new seal lip from working exactly on the same
trace left by the previous one
• fit the shaft seal perpendicularly to the axis, with the lips wholly
free, not curled under or pinched
• install the ring seal so that the lip faces the oil that must be kept in
or the side from where the pressure is exerted
• for ring seals without a dust-tight lip, coat the outside of the lip with grease
• for ring seals provided with a dust-tight lip, fill the gap between the seal lip and dust-tight lip
with grease
• lubricate the seal seat on the shaft
• do not use sealants because if they get on the seal lip or shaft surface they can cause rapid
wear
• when installing the seal, press down as near as possible the outside edge
• do not block the ring seal axially or apply too much load
• always use suitable tools to avoid damaging the seal lip with threads, grooves, sharp edges
or keyways
• always cover the seal lip and the seat on the shaft when repainting the gearbox
• use oil seals of the type indicated in table 1
MF KIT
“MF KIT” is composed by all the needed parts to transform a
standard flange motor-mounting BOX into a BOX+MF.
In order to mount a KIT MF, you must request the specific
instructions to Motive.
Only Motive authorized assembly centers and distributors are
allowed to make these operations and the consequent final test.
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Max FR1 (at 0Kg FA1) - ROBUS-MF
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Max FR2 (at 0Kg FA2)
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CAUSE
PROBLEM POSSIBLE CAUSES REMEDY (1) REMEDY (2)
the motor doesn't start a)problems in the power
supply.
b)faulty electrical wiring.
c) faulty motor.
d)wrong size of the motor
check the connections and
the
power supply
replace the motor.
the current absorption of the
electric motor is too high
a) wrong motor size.
b) motor faulty.
check the
installation/application
replace the motor and
eventually also the gearbox
the temperature of the motor
frame is too high
a)wrong motor size.
b)motor faulty.
c) Wrong evaluation of the
surface
temperature
check the
installation/application
replace the motor and
eventually also the gearbox
the temperature of the
gearbox housing is too high
a)Wrong gearbox size.
b)Wrong mounting position.
c) Not enough lubricant
d)Defective bearing
check the
installation/application
correct the mounting position
or the lubricant level
replace the bearing
output speed is different from
expected
a)wrong reduction ratio.
b)wrong motor polarity.
a)verify the reduction ratio.
b)verify the motor polarity
replace the gearbox and/or
the electric motor
oil leaks from the shafts a)defective seals.
b)seal seats on the shafts
a)replace the seals.
b)replace the seals and install
them in a very slightly
different position or replace
the shafts.
send the unit to Rotomotive
oil leaks from the seals a)flanges are not tightened
properly.
b)defective seals or damaged
during the transport
a)tighten the flanges.
b)replace the seals, verifying
that the seals seats are
perfectly worked.
send the unit to Rotomotive
the output shaft turns in the
wrong
sense
wrong electric motor wiring invert the position of the 2
phases of the electrical motor
power supply
send the unit to Rotomotive if
the noise is important in the
specific application
cyclical noise in the gearbox damaged gears no practical problem if the
noise is not important in the
specific application.
send the unit to Rotomotive if
the noise is important in the
specific application
not cyclical noise inside the
gearbox
dirty inside the gearbox no practical problem if the
noise is not important in the
specific application, or if it
disappears after 3 working
hours
send the unit to Rotomotive if
the noise is important in the
specific application
a whistling noise is coming
from
the gearbox
a)defective bearings or not
correctly
assembled.
b)defective gears.
c) not enough lubricant
a) reassemble or replace the
bearings
b) replace the gears
c) put the correct quantity of
lubricant
send the unit to Rotomotive
vibrations of the electric
motor
coupling geometrical errors a)check the geometrical
tolerances of the electric
motor flange. Eventually
replace
b)check geometry and
tolerances of the electric
motor shaft key. Eventually
replace
c) Check the motor vibration
replace the motor with a
Rotomotive one.
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ALL INFORMATION AND DATA PRESENTED IN THIS INSTRUCTION MANUAL HAS
BEEN CHECKED WITH MA IMUM CARE. WE HOWEVER DO NOT ASSUME
RESPONSIBILITY FOR ANY UNINTENDED ERRORS AND OMMISSIONS.
ROTOMOTIVE RESERVES THE RIGHT TO CHANGE THE SPECIFICATIONS OF ITS
PRODUCTS AT ANY TIME.
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rotomotive
Rotomotive Powerdrives India ltd.
223, Napa Talpad,
Gana-Borsad Road, Tal : Borsad, Anand
Gujarat – 388 5 0, INDIA.
Ph. : +91 – 9227110030
Fax: +91 – 2 92 – 235209
E-Mail: inf[email protected]m
Web site : www.rotomotive.com
powerdrives