Varvel RO series Instructions for use

WORKING INSTRUCTIONS
& MAINTENANCE
ATEX MANUAL
RO
RN RV
RD RT
RG
RC RS
RP XA
VR

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Working Instructions & Maintenance
Contents
1 GENERAL INFORMATION ........................................................................................................................................................ 3
2 SAFETY WARNINGS
2.1 Product Operation ....................................................................................................................................................... 3
2.2 Prevalent Use ............................................................................................................................................................. 3
2.3 Transport .................................................................................................................................................................... 3
2.4 Long-Term Storage ..................................................................................................................................................... 3
2.5 Environmental Management ....................................................................................................................................... 3
3 PRODUCT LAYOUT ..................................................................................................................................................................... 3
Elastic Coupling G ............................................................................................................................................................ 4
Gearboxes Series RC ....................................................................................................................................................... 5
Gearboxes Series RD ....................................................................................................................................................... 6
Gearboxes Series RG ....................................................................................................................................................... 8
Gearboxes Series RN ..................................................................................................................................................... 10
Gearboxes Series RO ..................................................................................................................................................... 12
Gearboxes Series RV ..................................................................................................................................................... 13
Gearboxes Series RP/XA ............................................................................................................................................... 14
Gearboxes Series RS ..................................................................................................................................................... 15
Gearboxes Series RT ..................................................................................................................................................... 16
Torque Limiter Option TLE ............................................................................................................................................. 17
Torque Limiter Option TLI ............................................................................................................................................... 18
Variators Series VR ........................................................................................................................................................ 19
Variators Series VS ........................................................................................................................................................ 20
4 INSTALLATION ............................................................................................................................................................................ 21
4.1 Tolerances ................................................................................................................................................................ 21
4.2 Precautions ............................................................................................................................................................... 21
4.3 Groundwork .............................................................................................................................................................. 21
4.4 Set up ....................................................................................................................................................................... 21
4.5 Pinions, Couplings .................................................................................................................................................... 21
4.6 Torque Arms ............................................................................................................................................................. 21
4.7 Painting ..................................................................................................................................................................... 21
5 STARTING ..................................................................................................................................................... 22
5.1 Series RS, RT ........................................................................................................................................................... 22
5.2 Series RC, RD, RP, XA, VR ...................................................................................................................................... 22
6 INSPECTIONS AND MAINTENANCE .................................................................................................................................. 22
6.1 Intervals .................................................................................................................................................................... 22
6.2 Maintenance Service ................................................................................................................................................ 22
7 MALFUNCTIONING ..................................................................................................................................................................... 24
7.1 Major Events ............................................................................................................................................................. 24
7.2 Customers Service ................................................................................................................................................... 24
8 LUBRICANTS ............................................................................................................................................................................... 25
8.1 Recommended Types ............................................................................................................................................... 25
8.2 Quantity .................................................................................................................................................................... 25
9 DIRECTIVE 94/9/CE - (ATEX) ............................................................................................................................................... 28
10 DECLARATION OF CONFORMITY .................................................................................................................................... 32
.

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Working Instructions & Maintenance
General Information - Safety Warnings - Product Layout
GENERAL INFORMATION
Varvel speed reducers and variators are not in the field of application of the Machinery Directive 2006/42/CE as consid-
ered “machinery components”.
Guide of Machinery Directive - § 35 - decrees:
"The Machinery Directive does not apply directly to machinery components, such as, for example, valves, hydraulic cylin-
ders or gearboxes, that do not have a specific application as such but are intended to be incorporated into machinery,
although the design and construction of such components must enable the complete machinery to comply with the rele-
vant essential health and safety requirements."
Regular operation and the right to guarantee servicing request the observance of information contained in this manual that
must be read before the gearbox is put into service.
SAFETY WARNINGS
2.1 Product Operation
During operation, outer surfaces of gearboxes and variators may warm up because of in motion parts and also by external
environmental conditions.
Everything referred to transport, stocking, assembling, setting up, starting and maintenance must be performed by trained
personnel and that follows this manual within specific national / regional regulations about safety and prevention of acci-
dents.
2.2 Prevalent Use
Gearboxes and variators referred to in this manual are destined to operate industrial applications and they correspond to
standards and regulations where applicable.
Performances and technical data are available in the unit’s nameplate and from the related documentation.
2.3 Transport
Carefully check the state of the goods at their receipt and immediately notify the possible damages to the carrier.
2.4 Long-Term Storage
Stocked units must be kept in dry warehouse and dust free.
For storage longer than 3 months, apply anti-oxidants on the shafts and machined surfaces paying special attention to oil
seal lips.
Storages longer than one year reduce bearing grease lifetime .
2.5 Environmental Management
In conformity with Environmental Certification ISO14001, we recommend the following to dispose of
scrapped gearbox components: to deliver to authorised centres for metal object collection:
drained oils and lubricants: to deliver to Exhausted Oil Centres;
product accompanying packages (pallets, carton boxes, paper, plastic, etc.): to deliver into regeneration / recycling cir-
cuits as far as possible, by delivering separate waste classes to authorised companies.
.
PRODUCT LAYOUT
The following layouts supply a generic help in finding out the most significant parts of the products.
Various design executions, assembling versions, number of stages actually origin a variety of solutions and therefore, we
recommend to refer to the appropriate catalogue and/or Engineering Department.

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Working Instructions & Maintenance
Product Layout
The elastic coupling “G” is supplied as standard fitting on the Series RD, RN, RO, RV, RP, RS, RT.
Reducer half-coupling
Material: steel alloy
One piece built-in input shaft
Two bearing mounting
Unchanged casing dimensions
Spider
External tooth connection
Material: Thermoplastic Elastomer
- Elastollan ®TPU - Polyurethane
- Hytrel ®TPE - Polyester
Hardness
- TPU 98 Shore A
- TPE 72 Shore D
Temperature
- TPU -20/+75°C (-4 / +167°F)
- TPE -30/+100°C (-22 / +212°F)
Motor half-coupling
Material:
- Aluminium die cast (G3, G5, G6)
- Alloy steel (GS8)
Dynamic balancing
Fitting:
- Clamp (G3, G5, G6)
- Key (GS8)
Bores:
- IEC 72 / N42948
- NEMA C y TC
Advantages:
One gearbox only for each reduction ratio
Greater flexibility
Increased stock rotation
Fretting corrosion elimination between key and keyway
Zero backlash in gearbox/motor connection
Allowed angular misalignment 1° max
Torsional rigidity
High vibration damping
Input flanges:
Material:
- Aluminium up to IEC112 and NEMA TC180
- Cast iron from IEC 132 and NEMA TC200
Elastic Coupling “G”

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Working Instructions & Maintenance
Product Layout
Series RC - 2 stages
The layout shows the general structure of a two-stage foot-mounted helical gearbox type FRC (sizes 05 to 30).
RC
01 Oil seal 19 Bearing
02 Housing 20 Bearing
03 Key 21 Pinion
04 Output shaft 22 Key
05 Key 23 Gear
06 Bearing 24 Bearing
07 Spacer 26 Bearing
11 Gasket 27 Gear
13 Bearing 29 IEC input cover
15 Pinion 33 Hollow input
16 Key 35 Oil seal
17 Hollow input

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Working Instructions & Maintenance
Product Layout
Series RD - 2 stages
The layout shows the general structure of a two-stage foot-mounted helical gearbox type FRD.
RD
01 Input cover 54 Gear
02A Hollow input IEC 55 Spacer
02B Hollow input “G” 65 Bearing
04 Pinion 66 Bearing
15 Bearing 67 Bearing
16 Bearing 68 Bearing
20 Oil seal 69 Oil seal
41 Gear 82 Gasket
50 Housing 85 Motor Flange
51 Upper cover
52 Output shaft
53 Pinion

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Working Instructions & Maintenance
Product Layout
Series RD - 3 stages
The layout shows the general structure of a three-stage foot-mounted helical gearbox type FRD.
RD
01 Input cover 40 Pinion 68 Bearing
02A Hollow input IEC 41 Gear 69 Oil seal
02B Hollow input “G” 50 Housing 82 Gasket
03 3rd stage shaft 51 Upper cover 85 Motor flange
04 Pinion 52 Output shaft
05 Gear 53 Pinion
15 Bearing 54 Gear
16 Bearing 55 Spacer
17 Bearing 56 Spacer
18 Bearing 65 Bearing
19 Spacer 66 Bearing
20 Oil seal 67 Bearing

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Working Instructions & Maintenance
RG
Product Layout
Series RG - 1 stage
The layout shows the general structure of a one-stage reduced backlash planetary gearbox type FRG.
01 Screw 13 Sun gear
02 Plug 14 Ring gear body
03 Motor flange 15 Planet gear
04 Screw 16 Needle bearing
05 Input flange 17 Planet shaft
06 Plug 18 Planet carrier
07 Adapter 19 Key
08 Clamp coupling 20 Bearing
09 Bearing 21 Snap ring
10 Input shaft 22 Shim
11 Shim 23 Bearing
12 Spacer 24 Snap ring

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Working Instructions & Maintenance
RG
Product Layout
Series RG - 2 stages
The layout shows the general structure of a two-stage reduced backlash planetary gearbox type FRG.
01 Screw 13 Sun gear 25 Bearing
02 Plug 14 Ring gear body 26 Snap ring
03 Motor flange 15 Planet gear 27 Shim
04 Screw 16 Needle bearing 28 Bearing
05 Input flange 17 Planet shaft 29 Snap ring
06 Plug 18 Planet carrier
07 Adapter 19 Planet gear
08 Clamp coupling 20 Needle bearing
09 Bearing 21 Planet shaft
10 Input shaft 22 Spacer
11 Shim 23 Planet carrier
12 Spacer 24 Key

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Working Instructions & Maintenance RN
Product Layout
Series RN - 2 stages
The layout shows the general structure of a two-stage parallel shaft gearbox type FRN with through hollow output shaft.
01 Input flange 13 Bearing 25 Spacer
02 Oil seal 14 Key 26 Bearing
03 Snap ring 15 Pinion 27 Snap ring
04 Bearing 16 Bearing 28 Oil seal
05 Input shaft 17 Snap ring
06 Bearing 18 Oil seal
07 Cover 19 Snap ring
08 Pinion 20 Bearing
09 Oil seal RCA 21 Body
10 Snap ring 22 Key
11 Gear 23 Output shaft
12 Spacer 24 Gear

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Working Instructions & MaintenanceRN
Product Layout
Series RN - 3 stages
The layout shows the general structure of a three-stage parallel shaft gearbox type FRN with through hollow output shaft.
01 Motor flange 13 Shaft 25 Snap ring
02 Oil seal 14 Bearing 26 Oil seal
03 Snap ring 15 Snap ring 27 Snap ring
04 Bearing 16 Pinion 28 Bearing
05 Input shaft 17 Oil seal RCA 29 Spacer
06 Bearing 18 Snap ring 30 Gear
07 Pinion 19 Bearing 31 Output shaft
08 Cover 20 Pinion 32 Key
09 Bearing 21 Key 33 Body
10 Gear 22 Bearing 34 Bearing
11 Spacer 23 Spacer 35 Snap ring
12 Key 24 Gear 36 Oil seal

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Working Instructions & Maintenance RO
Product Layout
Series RO
The layout shows the general structure of a three-stage bevel/helical gearbox type FRO with through hollow output shaft.
01 Motor flange 13 Gear 25 Output shaft
02 Oil seal 14 Spacer 26 Body
03 Snap ring 15 Bearing 27 Snap ring
04 Input shaft 16 Cover 28 Bearing
05 Bearing 17 Pinion 29 Pinion
06 Pinion 18 Oil seal RCA 31 Bearing
07 Oil seal RCA 19 Oil seal 32 Spacer
08 Snap ring 20 Snap ring 33 Gear
09 Bearing 21 Bearing 34 Snap ring
10 Key 22 Spacer 35 Bearing
11 Shaft 23 Gear 36 Snap ring
12 Spacer 24 Key 37 Oil seal

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Working Instructions & MaintenanceRV
Product Layout
Series RV
The layout shows the general structure of a three-stage bevel/helical gearbox type FRV with through hollow output shaft.
01 Motor flange 13 Bearing 25 Bearing
02 Oil seal 14 Shaft 26 Snap ring
03 Snap ring 15 Key 27 Oil seal
04 Input shaft 16 Bearing 28 Snap ring
05 Bearing 17 Snap ring 29 Bearing
06 Pinion 18 Oil seal RCA 30 Body
07 Oil seal RCA 19 Snap ring 31 Output shaft
08 Pinion 20 Gear 33 Gear
09 Cover 21 Spacer 34 Spacer
10 Bearing 22 Bearing 35 Bearing
11 Spacer 23 Key 36 Snap ring
12 Gear 24 Pinion 37 Oil seal

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Working Instructions & Maintenance
RP & XA
Product Layout
FXA
FRP90
Series RP and XA
The layout shows the general structure of a one-stage helical gearbox type FRP and FXA, flange mounting.
01 Body 15 Bearing
02 Snap ring 16 Bearing
03 Oil seal 18 Snap ring
04 Output shaft 19 Bearing
05 Key 20 Key
06 Screw 21 Adapter
07 Bearing 24 Snap ring
08 Gear 25 Spacer
10 Motor flange 26 Plug
11 Snap ring 27 Flexible coupling
12 Oil seal
13 Pinion

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Working Instructions & MaintenanceRS
Product Layout
Series RS
The layout shows the general structure of a worm gearbox type FRS with through hollow output shaft and shaft mounting.
The Series TA (helical / worm) are made of a helical one-stage gearbox XA mounted as input stage onto a standard worm
box RS and the Series RS/RS (two stage worm) of two standard worm boxes RS and an appropriate combination kit.
01 Body 84 Oil seal RCA
04 Side cover 125 Snap ring
07 Motor flange 126 Snap ring
31 Worm wheel
50 Worm shaft
60 Bearing
61 Bearing
62 Bearing
63 Bearing
80 Oil seal
81 Oil seal
82 Oil seal

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Working Instructions & Maintenance
RT
Product Layout
Series RT
The layout shows the general structure of a foot-mounted worm gearbox type FRT.
The Series TA (helical / worm) are made of a helical one-stage gearbox XA mounted as input stage onto a standard worm
box RT and the Series RT/RT (two stage worm) of two standard worm boxes RT and an appropriate combination kit.
01 Housing 82 Oil seal
04 Side cover 84 Oil seal RCA
07 Motor flange 125 Seeger ring
31 Worm wheel 126 Seeger ring
50A Worm shaft IEC
50B Worm shaft “G”
60 Bearing
61 Bearing
62 Bearing
63 Bearing
80 Oil seal
81 Oil seal

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Working Instructions & Maintenance
Product Layout
TLE
TLE - Torque Limiter Option
The layout shows the general structure of a torque limiter type TLE to fit inside a worm gearbox Series RS or RT.
The Torque Limiter TLE is directly fitted into the hollow shaft of already assembled standard gearboxes with-
out any special tooling.
01 Setting torque hand wheel 13 Front washer
02 Belville washer 14 Front friction
03 Spacer 15 Front protection
04 Spacer 16 Front bush
05 Rear protection 17 Key
06 Belville washer 18 Low speed shaft
07 Key
08 Thrust washer
09 Rear friction
10 Rear washer
11 Key
12 Rear bush
RS
RT

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Working Instructions & Maintenance
Product Layout
TLI
TLI - Torque Limiter Option
The layout shows the general structure of a built-in torque limiter type TLI incorporated inside a worm gearbox Series RS
or RT.
01 Lock nut 81 Oil seal
02 Bellville washer
03 Bush
04 Oil seal
05 Key
06 Spacer
07 Worm wheel
08 Hollow output shaft
10 Cover
60 Bearing
61 Bearing
80 Oil seal
RS
RT

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Working Instructions & Maintenance
Product Layout
VR
Series VR
The layout shows the general structure of a flange-mounted variator without gearbox type.
01 Screw 14 Control hand wheel 27 Spacer
02 IEC motor flange 15 Control shaft lock 28 Bearing
03 Screw 16 Control shaft 29 Snap ring
04 Seal plate 17 Oil seal OR 30 Oil seal
05 Bearing 18 Screw 31 Index scale
06 Spacer 19 Output shaft 32 Snap ring
07 Cone 20 Key 33 Spring
09 Body 21 Bearing 34 Friction ring carrier
10 Cylindrical slide 22 Snap ring 35 Friction ring
11 Oil seal OR 23 Snap ring 39 Cone holder
12 Oil seal OR 24 Oil seal 40 Bellows seal
13 Screw 26 Output flange 41 Index

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Working Instructions & Maintenance
Product Layout
VS
Series VS
The layout shows the general structure of a flange-mounted variator without gearbox type.
01 Output shaft
02 Planet carrier
03 Sliding bush
04 Adjusting track
05 Ball carrier
06 External mobile track
07 Planet
08 Adjusting box
09 External fixed track
10 Internal fixed track
11 Internal mobile track
12 Belville washer