Man C 14381

GEA Ariete Homogenizer 5200
#14381
Instructions Manual
Translation of the original instructions
Revision: 00
Revision Index
REV. DESCRIPTION DATE SIGN
00 First issue 15/01/2018 ANC
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This manual is the property of GEA Mechanical Equipment Italia S.p.A.any reproduction, even partial, is prohibited.
COVER02_14521
Use and maintenance instructions
FOREWORD
Dear Customer,
we wish to thank you for selecting our product and ensure you our best assistance in order
to enable you to make the most of your machine.
Also, we remind you that a good understanding of the contents of this manual - through
careful reading of all sections - is essential for the correct, safe use and operation of the
machine you have purchased.
No one should operate or perform maintenance on this machine without first having read
and understood the following Instructions for Use & Maintenance.
For any further support or information, you may contact us at the below listed address.
Yours faithfully,
GEA Mechanical Equipment Italia S.p.A.

Via A. M. da Erba Edoari 29, 43123 Parma - Italia
Tel. +39 0521 965411
Fax +39 0521 242819
gea.com/contact
This manual is the property of GEA Mechanical Equipment Italia S.p.A. Any reproduction, even in part, is prohibited.
0C00SE7C
0.1
CONTENTS - SECTIONS
1. Technical Specifications
2. General Information
3. Machine Operation and Use
4. Maintenance
5. List of Spare Parts
6. Wiring Diagrams
7. Documentation about Suppliers and Components
How to use the manual
This manual is made of separate sections as indicated in the list of CONTENTS.

Each section is divided into chapters and paragraphs, and pages are numbered separately in each
section. A specific list of contents is given at the beginning of each section.
The pictures and tables referred to in the text are numbered inside each section.
Before installing the machine you must be thoroughly familiar with the information given in Section
2, Chapter 2.8 and, in particular, paragraph 2.8.5.
NOTE:
Following the last update of the technical material, two names will now be used in the manual to
indicate the machine model: a trade name and a technical name.
The trade name appears in a key position on the cover page.
The technical name, which coincides with the previous nomenclature used until now, will also be
used inside the manual.
Example
Trade name: GEA Ariete Homogenizer 3110
Technical name: NS3110H
0C00SE7C
0.2
SECTION 1
TECHNICAL SPECIFICATIONS
1.0. MACHINE DESCRIPTION

1.1. TECHNICAL DATA
1.2. FLOW-SHEET
1.3. FLOW-SHEET LEGEND (SPEC 102)
1.4. INSTALLATION DRAWING
1.5. CONSUMPTION SPECIFICATION
1.6. OPERATION SEQUENCE
1.7. DECLARATION OF CE CONFORMITY
1.8. FINAL TEST DATA REPORT ( MP10M20 )
1.9. AIRBORNE NOISE EMISSIONS
1.10. LUBRICANT (TT-0038)
1C001E7C
1.1
1.0 Machine description
1.0.1 General description
This GEA Mechanical Equipment Italia S.p.A. homogenizer consists of a positive-displacement piston
pump, equipped with automatic suction and delivery spring-operated valves, and a homogenizing
section connected to it in which the product undergoes a high-pressure micronization process to
reduce the size of the particles suspended in the fluid and achieve homogeneous dimensional
distribution.
This process can be applied to a large range of products, with various viscosity, and makes it possible
to obtain greater product stability through particle dispersion and micronization, depending on the
pressure applied.
As regards the specific configuration of the machine, model, technical data, accessories and optional
features, please refer to the TECHNICAL SPECIFICATIONS enclosed in chapter 1.1 of this manual.
ATTENTION
The machine must not be used for uses other than those indicated in chapter 2 of this manual.
The manufacturer shall not be liable for personal injury or damages caused by improper use
of the machine.
1.0.2 Operation principle
The machine’s operation principle is shown in the diagram below.
1C001E7C
1.0.1
1.0.3 Main machine components
The main components of the machine are shown in the figures below, for a “Homogenizer” machine
(standard and optional versions).
B 4
10 11 2 A 5
Fig. A
1C001E7C
1.0.2
12 13
C 6
F 9
FIG. B
Components of homogenizer machine

Standard version= 1-2-3-4-5-10-11-6-9-12-13
Optional version = A-B-C-F
1C001E7C
1.0.3
Legend Figures A and B Machine components (Homogenizer machine)
Standard units Notes
1) Compression head
2) Homogenizing unit –stage 1
3) Head pressure gauge
4) Head safety valve
5) Manifold unit
6) Lubrication system Option for NS2006 / NS3006
7) Water system (*)
8) Pneumatic system (*) Option for NS2006 / NS3006
9) Transmission body
10) Motor drive
11) Cover panels
12) Control panel
13) On-machine electrical system
Optional units
A Homogenizing unit –stage 2
B Pressure gauge -stage 2
C Suction pressure gauge
D Delivery pressure gauge (*)
E Delivery safety valve (*)
F Suction buffer unit
G Delivery buffer unit (*)
H Partial aseptic system (*)
I Full aseptic system (*)
NOTE: The asterisk (*) indicates components in standard and optional versions that are not
shown in figures A and B.
1C001E7C
1.0.4
GEA Niro Soavi S.p.A. 01/10/2005 - Rev. 2.2
GEA NIRO SOAVI MACHINE TECHNICAL TT-0120C

DATASHEET
1 GENERAL SPECIFICATIONS
1.1 Type of Machine HOMOGENIZER
1.2 Model NS5200H
1.3 Version ARIETE
1.4 Serial Number 14381
1.5 Execution SANITARY
1.6 Special Features NS5200H - OPEN EXECUTION TYPE
1.7 Revision Index 0
1.8 Date 04/12/18
2 WORKING CONDITIONS
2.1 Product VARIOUS TS65%
2.2 MAX Viscosity 500 cP
2.3 MAX Working Pressure 600 bar
2.4 Flow Rate Type V F = Fixed; V = Variable; M = Multi
2.5 MIN Flow Rate 2730 L/h @ 14,6 Hz
2.6 MAX Flow Rate 9100 L/h @ 48,7 Hz
2.7 MIN Feed Pressure 4-5 bar
2.8 MAX Backpressure 400 (600) bar
2.9 MAX Product Temperature 90 °C
2.10 MAX CIP / SIP Temperature 140 °C
2.11 Ambient Conditions 40°C MAX; R.H. 40%; 1000 m above sea level
3 TECH FEATURES - COMPRESSION HEAD

3.1 Type MONOBLOCK
3.2 Material SAF2507
3.3 No. of Plungers 5
3.4 Plunger Material CERAMIC
3.5 Plunger Diameter 50 mm
3.6 Plunger Stroke 100 mm
3.7 Pumping Valve Type PVB1"3/4
3.8 Pumping Valve Material STELLITE GR20
3.9 Pumping Valve Seat Material STELLITE GR20
3.10 Overpressure Valve Type NSSLRV
3.11 Overpressure Valve Setpoint 660
3.12 Packing Material PEEK+KV+PEEK+SS
3.13 Gaskets Material NITRILE
3.14 Overpress. Valve Type / IN LINE /
3.15 Overpr. Valve Setpoint / IN LINE / bar
PAGE 1 / 2
GEA Niro Soavi S.p.A. 01/10/2005 - Rev. 2.2
GEA NIRO SOAVI MACHINE TECHNICAL TT-0120C

DATASHEET
4 TECH FEATURES - CONNECTIONS & ACCESSORIES

4.1 Connection INLET 3" TRICLAMP
4.2 Connection OUTLET FLANGE 2" SCH.160S (SAF 2205)
4.3 Pulsation Dampener INLET YES
4.4 Pulsation Dampener OUTLET /
4.5 Feeding Pump /
5 TECH FEATURES - PRESSURE GAUGES

5.1 Pressure Gauge Inlet TRASD.IFM 0-10 BAR
5.2 Pressure Gauge Compr. Head MANOM. D100 0-1000 BAR
5.3 Pressure Gauge second Stage MANOM. D100 0-1000 BAR
5.4 Pressure Gauge Outlet TRASM. D100 0-600 BAR
6 TECH FEATURES - HOMOGENIZING VALVES

6.1 No. of Stages 2
6.2 Type of Control PNEUMATIC
6.3 Homogenizing Valve Type D28-45
6.4 Homogenizing Valve Material C9M
7 TECH FEATURES - DRIVE END

7.1 RPM Crankshaft MIN 48
7.2 RPM Crankshaft MAX 161
7.3 Stroke 100 mm
7.4 Drive Type GEAR BOX GEN 5,08 STD
7.5 Gearbox Speed Reduction Ratio 5,08
7.6 Main Motor (frame/type) 315MLB/4P
7.7 Main Motor Power 200 kW
8 TECH FEATURES - LUBRICATION

8.1 Type FORCED
8.2 Lubricating System 9.8 (L12)
8.3 Oil Cooling System BPHE
9 TECH FEATURES - ELECTRICAL SUPPLY

9.1 No. of Phases - MAIN 3
9.2 Voltage - MAIN 380 V
9.3 Frequency - MAIN 50 Hz
9.4 Voltage - AUX 24V DC V
9.5 Frequency - AUX / Hz
PAGE 2 / 2
GEA Niro Soavi
LEGEND SPEC - 102 C
Niro-Soavi S.p.A. TO CONCEPT FLOW SHEET
via M. da Erba Edoari, 29/A ____________________ REV.
43100 PARMA (ITALY) DATE
PHONE : +39.0521.965411 - FAX : +39.0521.242819
Page 1 of 2 ____________________ 0
SIG.
1. INSTRUMENT SYMBOLS 5. MACHINERY AND EQUIPMENT
LOCAL AUTOMATIC ACTUATOR FOR REMOTE

CONTROL, GENERAL
IN MAIN PANEL
MANUAL ACTUATOR NOT FOR REMOTE
CONTROL
LIMIT VALUE H
H: HIGH OR OPEN AUTOMATIC ACTUATOR WITH INTEGRATED
MANUAL CONTROL FACILITY
L: LOW OR CLOSED
DIAPHRAGM ACTUATOR
POINT OF MEASUREMENT
T WITHOUT INSTRUMENTATION
SOLENOID ACTUATOR
PISTON ACTUATOR
2. PROCESS LINES
ELECTRIC AC MOTOR
PRIMARY FLOW LINE, GENERAL
ADJUSTABLE SPEED CONTROL
SECONDARY FLOW LINE, GENERAL
COMPRESSOR OR VACUUM PUMP,

MECHANICAL CONNECTION
GENERAL
SUPPLY LIMIT MARKER

FAN
PUMP FOR LIQUIDS GENERAL
3. INSTRUMENT SIGNAL LINES

CENTRIFUGAL PUMP
GENERAL
HIGH PRESSURE PUMP
ELECTRICAL
PNEUMATIC 1-STEP HOMOGENIZER
HYDRAULIC 2-STEP HOMOGENIZER
CAPILLARY
FILTER, GENERAL
HEAT EXCHANGER WITHOUT CROSS

FLOW e.g. ELECTRIC HEATER
4. FLOW LINE ABBREVIATIONS
LIGHT SOURCE
AS AIR SUPPLY
CIP CLEANING IN PLACE
CS CONDENSATE SUPPLY VALVE CLOSES (FC)
CWS CHILLED WATER SUPPLY
ES ELECTRIC SUPPLY VALVE OPENS (FO)
GS GAS SUPPLY
NS NITROGEN SUPPLY
VALVE RETAINS POSITION
OS OIL SUPPLY
SS STEAM SUPPLY
WS WATER SUPPLY FAIL-OPEN INDICATION FOR A 3-WAY VALVE
. R RETURN
LEGEND SPEC - 102 C
Niro-Soavi S.p.A. TO CONCEPT FLOW SHEETS
Specialty Products via M. da Erba Edoari, 29/A 29/01/2003
____________________ REV.
Division 43100 PARMA (ITALY) DATE
PHONE : +39.0521.965411 - FAX : +39.0521.242819
Page 2 of 2 ALB
____________________ 0
SIG.
6. LETTER CODE FOR IDENTIFICATION OF INSTRUMENT FUNCTIONS
FIRST LETTER SUCCEEDING LETTER (1)

MEASURED OR INITIATING VARIABLE MODIFIER DISPLAY OR OUTPUT FUNCTION
A ALARM
B DISPLAY OF STATE (2)
C CONTROLLING (4)
D DENSITY DIFFERENCE
E ALL ELECTRICAL VARIABLES (5) SENSING ELEMENT
F FLOW RATE RATIO
G GAUGING, POSITION OR LENGTH
H HAND (MANUALLY INITIATED) OPERATED
I INDICATING (3)
J SCAN
K TIME OR PROGRAMMED TIME
L LEVEL
M MOISTURE OR HUMIDITY
N USER'S CHOICE USER'S CHOICE
O USER'S CHOICE
P PRESSURE OR VACUUM TEST-POINT CONNECTION
Q QUALITY (5) INTEGRATE OR TOTALIZE INTEGRATING OR SUMMATING
R NUCLEAR RADIATION RECORDING
S SPEED OR FREQUENCY SWITCHING (2)
T TEMPERATURE TRANSMITTING
U MULTIVARIABLE MULTIFUNCTION UNIT
V VISCOSITY VALVE, DAMPER, ACTU, ELEMENT
W WEIGHT OR FORCE
X UNSPECIFIED (5) UNCLASSIFIED FUNCTIONS
Y VIBRATION COMPUTING RELAY, RELAY
Z EMERG. / SAFETY ACTING (2)
EXAMPLE : PDIRC DIFFERENTIAL PRESSURE INDICATION, RECORDING AND CONTROL

FIRST LETTER P, MODIFIER D, SUCCEEDING LETTERS I,R,C
1) NORMAL SEQUENCE OF SUCCEEDING LETTERS : B.I.R.C.T.Q.S.Z.A.

2) SIGNAL TYPE : ON/OFF
3) SIGNAL TYPE : CONTINUOUS
4) SIGNAL TYPE : NORMALLY CONTINUOUS. IF ON-OFF, S IS ADDED
5) A NOTE SPECIFIES THE MEASURED PROPERTY. E.g. FOR LETTER E, I, U, P OR F

1925 2840
1
1845 2195
420 1775
345
10
2
230
390 1
1410
1610+K
270 10
1
150 3
680
200+K
F2 F1
110
255
240
150
175 1495 175 1 575 1470 150
6 11 4 7
LEAVE AT LEAST 1m FROM EACH SIDE OF THE MACHINE
OVERALL DIMENSIONS (mm) K = ± 25 mm
ITEM DESCRIPTION CONNECTION

1 PRODUCT INLET 3" TRICLAMP
2 PRODUCT OUTLET FLANGE 2" Sch.160S (SAF2205)
3 WATER INLET G. 1/2" (BSP, MALE)
4 SUMP DISCHARGE G. 1" 1/2 (BSP, MALE, TO DRAIN)
7 OIL CONDENSATE DISCHARGE INSIDE THE MACHINE
8 AIR INLET G. 1/2" (BSP, MALE)
9 ELECTICAL CABLES INLET HOLE
10 WATER INLET OIL COOLING G. 1/2" (BSP, MALE)
1
11 WATER OUTLET OIL COOLING G. 1/2" (BSP, MALE)
WEIGHT : Kg 5600 ( F1=1850 Kg F2= 3750 Kg)
REV. NUMBER REVISION DESCRIPTION
01 ADDED UTILIES A3O

DESCRIPTION
NS5200_ID_14381
DESIGNER EMISSION DATE SCALE
1 2 RG 25/10/2018 1:25
REVISION DESIGNER REVISION DATE SH. 1 OF 1
SAB 17/12/2018 GEA Niro Soavi DRAWING
APPROVED APPROVAL DATE
via da Erba Edoari, 29 43123 Parma (ITALY)
PHONE:++39.0521.965411 - FAX:++39.0521.242819
NS5200_ID_14381
This drawing is property of GEA Mechanical Equipment Italia S.p.A.I, which will guard its rights by law terms.
Gea Niro Soavi SPECIFICA CONSUMI
TT-0141
Gea Mechanical Equipment Italia S.p.A. UTILITY SPECIFICATION
NS5180H 14381 DD 26.10.18 0

MODELLO MACCHINA N° DI SERIE SIG. DATA REV.
MACHINE MODEL SERIAL No. SIG. DATE REV.
CONSUMI - CONSUMPTION
Fluido Rich. PRESSIONE TEMPERATURA CONSUMI
Liquid Required PRESSURE TEMPERATURE CONSUMPTION
Bar °C l/h
Min Max Min Max Min Max
PISTONI ACQUA SI
2 3 10 25 200
PISTONS WATER YES
RIDUTTORE ACQUA SI
2 3 10 25 800
GEAR BOX WATER YES
SCAMBIATORE OLIO ACQUA NO
OIL EXCHANGER WATER NO
SCAMB. CONDENSA
CONDENSATE EXCHANGER
Note: max. durezza < 15°fH, max. dimensioni particelle 60 micron
Note: max. hardness < 15°fH, max. particle size = 60 microns, filtred water
ARIA COMPRESSA SI
6 10 0
COMPRESSED AIR YES
Note : max. dimensioni particelle < 15 μm, max. concentrazione particelle < 8 mg/m3, max. termperatura di condesazione < 3°C, max. contenuto olio < 5 mg/m3 ( Rif. ISO 8573 )
Note: max. particel size < 15 μm, max. particel concentration < 8 mg/m3, max. presure dew point < 3°C, max. oil concentration < 5 mg/m3 (Ref. ISO8573)
Bar °C kg/h
PROD. CONDENSA
CONDENSATE PROD.
Il Cliente dovrà installare un riduttore al punto di attacco del vapore per adattare la pressione alle esigenze della macchina
The customer must install a pressure reducer at the steam inlet connection to adapt the pressure to the machine's requirements
COMPENSAT. PULS.
PULSATION DAMPER
valore di pressione sul tubo di alimentazione del prodotto
pressure value is referred to the inlet feeding pipe
V Hz kW A V Hz
ELETTRICITA' TENS. AUSILIARIA
3x 380 50 176 333 24 DC
Electrical supply Aux. Voltage
MOTORI - MOTORS
R. bearings / Edm
Collegamento
Rated Output
Fatt. potenza
Start. current
Power factor
Corr. spunto
Connection
Rulli / Edm
Frequenza
Protezione
Frequency
Standards
Protection
Efficienza
Efficiency
Tensione
Corrente
Potenza
Voltage
Current
Codice
Grand.
Norme
Forma
Frame
Marca
Brand
Poles
Code
TAG
TAG
Size
Poli
V Hz kW A A Cosφ %
THERMISTORS
TERMISTORI
YES
SI
315MLA
TRIANGOLO 3x
ABB
M-O 9562-0228-517 IEC-CENELEC 50 4 200 369,2 2363 0,86 95,7 B3

DELTA 380
YES
SI
STELLA 3x
M-VM 9572-0027-026_ IEC 50 4 0,22 0,8 AXIAL
STAR 380
STELLA 3x
M-PO 9562-1206-283 IEC 50 4 0,75 1,7 B14
STAR 380
STELLA 3x
M-VMP 9572-0127-023 IEC 50 4 0,19 0,8 AXIAL
STAR 380
FORNITO NO Quadro Elettrico

SUPPLIED NO Switchboard
Installazione Pos. morsettiera corrente C.C. Protezione
kA IP
Installation Terminal pos. Short circ.current Protection
Materiale Raffreddamento Norme Pot. dissipata
IEC kW
Material Cooling Standards Dissipat. power
Vedere documento disposizione esterna N° Fogli Peso
kg
Reference: external view drawing N° Sheets Weight
45__14381_TT0141_C.xls 1/1
GEA Niro Soavi 15/06/2017 – Rev. 7
GEA Mechanical Equipment Italia S.p.A. Machine Functional Diagram TT-0134
via M. da Erba Edoari, 29 43123 Parma (ITALY)
PHONE : +39.0521.965411 - FAX : +39.0521.242819
SQ-W / SQ-C No cont. open after Yes Light on Low Water /Cond.
MACHINE START MACHINE STOP contact closed 15 sec Flow alarm lamp
B Yes No
Deactivate YV-A, YV-A1LR,

YV-A2LR SP-I No cont. open after Yes Light on Low Feeding
Start M-VM, M.VMP, M-PO, contact closed 15 sec Pressure alarm lamp
M-POP
Local Local/Remote Remote Yes No
activate YV-W, YV-C, YV-S
Inductive Sensor No Light ON SLRV-PO cont. open Yes

Reduce the
Set manuals regulator of Set YU-1, YU-2 to 0Bar SE-OP closed? open lamp after 3 sec pressure to the
st nd
1 ,2 stage to 0 Bar (4mA) nominal value in
A
Yes No order to close the
Deactivate pneumatic Deactivate YV-A, YV-A1 YV- valve
switches of 1st,2nd stages A2 (note 1) (Note 7)
Emergency contact Yes Cut Off the Main supply to

Working Mode? CIP open MAIN & AUX MOTORS
Production Stop M-O (note 4)
M-O at maximum No
SIP speed (note 5) Stop M-VM, M.VMP, M-PO,
M-POP SP-O, SP-OP No cont. open after Yes Light on Low Oil Pressure
Start M-O (note 3) contact closed 15 sec alarm lamp
M-O stopped (note 5)
Deactivate YV-W, YV-C,
activate YV-A after 15 YV-S Yes No
seconds No Activate SLRV-
PO pressure?
MACHINE IS Yes Light on Cabinet Vent. Fault
Cabinet Ventilation
STOPPED Fault
Yes alarm lamp
Activate YV-AOP
No
Inductive Sensor No Light ON malfunctioning

SE-OP open? SLRV-PO warning lamp
Thermal prot. Yes Light on Electrical protection
Yes contact open lamp alarm
Homo/Pump? Pump
No
Homo B
Remote ON/OFF No REFER TO DOC SP-A No Light on Air Pressure

Local/Remote Remote See Note 1 contact closed warning lamp
control only? TT- 0134/PID
OPTIONS LEGEND:
Yes
Local
Yes SP-O, Oil Pressure Switch
SP-OP, Oil Pistons Pressure Switch
activate 2nd st.
Yes ST-O, ST-C No Light on High Oil temp./ SP-A, Air Pressure Switch
pressure? wait 15 sec. from M-O contact closed High Condensate temp. SP-I, Inlet Feeding Pressure Switch
(note6) start Yes warning lamp SQ-W, Water Flow Switch
Yes SQ-C, Condensate Flow Switch
activate 2nd st. wait 15 sec. from M-O
activate pneumatic ST-O, Oil Thermostat
pressure? (note2) start
No switch of 2nd st. ST-C, Condensate Thermostat
SL-LO, Low Oil Level Switch
SL_LO No Light on Low Oil Level YV-W, Water Solenoid Valve
set pres. using 2nd st. No activate YV-A2
contact closed warning lamp YV-C, Condensate Solenoid Valve
manual regulator
YV-S, Steam Solenoid Valve
Adjust 2nd stage pressure, if Yes YV-BY, Feeding Pump Bypass Valve
required, using manual reg. YV-A1LR, 1st stage Air LOC/REM
Valve
A YV-A2LR, 2nd stage Air LOC/REM
1st stage Pressure No Valve
reached?
No wait 15 sec. YV-A, General Air Solenoid Valve
YV-A1, 1st stage Air ON/OFF Valve
Yes Some functions are related to optional features of the machine. Consider only what is related to YV-A2, 2nd stage Air ON/OFF Valve
installed devices or options. YU-1, 1st stage Proportional Valve
YU-2, 2nd stage Proportional Valve
Yes NOTES: M-O, Main motor
activate 1st stage
wait 15 sec. from M-O 1) Activate the REMOTE pressure control referring to the LOCAL/REMOTE options (CF17 or M-PO, Oil pump motor
pressure?
start st Yes M-VM, Machine Fan motor
activate 1 stage CF14) included with the machine.
pressure? activate YV-A1 2) consider this block if the 2nd stage is installed with the remote control and and it's required. M-VMP, Additional Fan motor on
activate pneumatic 3) with variable capacity, close the digital RUN contact to the frequency converter. the main motor
switch of 1st st.
st
Adjust 1 stage pressure, if 4) with variable capacity, open the digital RUN contact to the frequency converter. M-POP, Oil pistons pump motor
No No SE-OP, SLRV opening sensor
required, using manual reg. 5) SIP/CIP procedure may change according to the plant specific requirement.
6) consider this block if the 2nd stage is installed and it's required. SLRV-PO, Pneumatic Safety Valve
set pres. using 1st st. 7) The necessary actions to reduce the pressure are under customer responsibility
manual regulator
page 1/1
EC - Declaration of conformity for machines
in accordance with EC Machinery Directive 2006/42 /EC, Annex II 1. A
Manufacturer: GEA Mechanical Equipment Italia S.p.A.

Via A.M. Da Erba Edoari 29
43123 PARMA - ITALY
We, as manufacturer, declare in sole responsibility that the machinery
Name: HOMOGENIZER
Model: GEA Ariete Homogenizer 5200
Type:
Serial number: 14381
complies to all relevant provisions of this and the following directives:
Relevant EC 2006/42/CE
Regulations: 2014/30/UE
2014/35/UE
Applied harmonized EN ISO 12100:2010

standards, in particular: EN ISO 13849-1:2008
EN 60204-1:2006
Other applied /
standards and
technical
specifications:
Remarks: We also declare that the special technical documentation for this machine has been created in
accordance with Annex VII, Part A and we obligate to provide these upon reasoned request
from the individual national authorities by data transfer.
Authorized person for compiling and handing GEA Mechanical Equipment Italia S.p.A.
over technical documentation: FABRIZIO MICCOLI
Via A.M. Da Erba Edoari 29
43123 PARMA - ITALY
Parma, 15/01/2019
FABRIZIO MICCOLI
Managing Director
MP10M50
MP10M20
Rev. 02
NIRO SOAVI MACHINE TEST REPORT Emesso da RSAQ data 10.04.07
Appr. da RPR data 10.04.07
Serial number 14381
350,00 10000,00
9000,00
300,00
8000,00
250,00 7000,00
6000,00
200,00
5000,00
scale 1
scale 2
150,00
Grafico relativo alla Corrente, Frequenza, Pressione, Portata rilevate 4000,00
100,00 3000,00
2000,00
50,00
1000,00
0,00 0,00
0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,8 1,0
Hours
Inlet Pressure(Bar)x10- scale 1 Current (A)- scale 1 Frequency (Hz)- scale 1 Pressure (Bar)- scale 2 Capacity (l/h)- scale 2
Max. Inlet Press. (Bar)= 4,23 Max Current (A)= 325,66 Max Pressure (Bar)= 600,00 Max Frequency (Hz)= 50,00 Max Capacity (l/h)= 9132,00
RSAQ - Quality Assurance Manager Data collaudo – Test Date 29/1/2019
RPGM - Mechanical Manager

1.9. AIRBORNE NOISE EMISSIONS
1.9.1 SOUND PRESSURE LEVEL
Machine model Sound pressure level dB(A)
NS5200 85 dB(A) ± 2 dB(A)
The table gives A-weighted sound pressure level measured at 1 m from the surface of the
machine and 1.6 m. from the ground, in front of the machine.
The above values are calculated on the basis of measurements made on machines that are
technically comparable and representative of the machine herein described.
This manual is the property of GEA Niro Soavi. Any reproduction, even in part, is prohibited.
1C091E0C
GEA Mechanical Equipment S.p.A.
TT-0038-C
GEA Niro Soavi LUBRICANT 12/04/2017 22
DATA REV.
LAS
SIG.
WARNING
FOR TRANSPORT SAFETY REASONS THE MACHINE IS SUPPLIED WITHOUT LUBRICATING OIL.
BEFORE ANY OPERATION FILL UP THE MACHINE WITH OIL ACCORDING TO THE
"INSTRUCTIONS FOR USE & MAINTENANCE".
LUBRICATING OIL
Class: ISO L-HM; ISO VG 150; DIN 51524-2-HLP
BRAND TYPE BRAND TYPE
Klübersynth
Agip Oso 150 Klüber
GEM4-150N
Klüberoil Harmony 150
Klüber Gulf
GEM1-150N AW
American
IP Hydrus Oil 150 Amoco
industrial oil 150
Energol HLP-
BP Total Azolla ZS 150
HM 150
DTE 10 EXCEL
Mobil Fina Hyidran 150
150
Chevron AIO ISO 150 Api Cis 150
Hyspin AWS
Castrol Kuwait Petr. Int. Q8 haidn 150
150
Mobil Vacuoline 528 ELF Olna DS 150
MORLINA Oil
Shell ARAL Degol CL 150T
150
Rando oil HD
Texaco Lubriplate HO-3
150
LUBRICATION PLANT CAPACITY (litres) *
TYPE OF LUBRIFICATION
MACHINE MODEL
FORCED SPLASH
ONE 7TS / 2,5
ONE11TS-ONE15TS / 9
ONE 37TF 28
ONE 75TF 30
NS 2006 3 1,5
NS 3006 4,5 3
NS 3011 - NS 3015 14
NS 3018 - NS 3024 14
NS 3030 14
NS 3037 28
NS 3045 30
NS 3055 - NS 3075 30
NS 3090 - NS 3110 38
NS 5132 - NS 5180 55
NS 5250 - NS 5355 95
NS 6200 75
NS 8315 105
* APPROXIMATE
Sheet 1 of 2 TT-0038-C_Rev_22.xlsx
TT-0038-C
FOOD GRADE
GEA Niro Soavi 12/04/2017 22
LUBRICANT
DATA REV.
LAS
SIG.
WARNING
FOR TRANSPORT SAFETY REASONS THE MACHINE IS SUPPLIED WITHOUT LUBRICATING OIL.
BEFORE ANY OPERATION FILL UP THE MACHINE WITH OIL ACCORDING TO THE
"INSTRUCTIONS FOR USE & MAINTENANCE".
LUBRICATING OIL
Class: NSF (Class H1)
BRAND TYPE
Shell Cassida GL220
Fuchs Rivolta Geralyn SF220
Klüber Klüberoil 4 UH1-220 N
Mobil Mobil SHC Cibus 220
Molyduval Syntholube A 220 LM
Lubriplate SFGO Ultra 220
LUBRICATION PLANT CAPACITY (litres) *

TYPE OF LUBRIFICATION
MACHINE MODEL
FORCED SPLASH
ONE 7TS / 2,5
ONE11TS-ONE15TS / 9
ONE 37TF 28
ONE 75TF 30
NS 2006 3 1,5
NS 3006 4,5 3
NS 3011 - NS 3015 14
NS 3018 - NS 3024 14
NS 3030 14
NS 3037 28
NS 3045 30
NS 3055 - NS 3075 30
NS 3090 - NS 3110 38
NS 5132 - NS 5180 55
NS 5250 - NS 5355 95
NS 6200 75
NS 8315 105
* APPROXIMATE
Sheet 2 of 2 TT-0038-C_Rev_22.xlsx
TT-0162-C
LUBRICATION OIL FOR
GEA Niro Soavi REDUCTION GEAR 03/12/2012 1
DATE REV.
FG
SIG.
ATTENTION
The type of oil to be used depends on the temperature range where the machine is installed
RACCOMENDED OIL FOR NORMAL OPERATING CONDITIONS

MINERAL OIL WITH VISCOSITY ISO VG 220
Class: WITH EP ADDITIVES
MAKE TYPE
ARAL Degol BG 220 - BMB 220
BP Energol GR-XP 220
ESSO Spartan EP 220
MOBIL Mobilgear 630
SHELL Omala oil 220
TEXACO Meropa 220
IP Mellana 220
AGIP Blasia 220
RACCOMENDED OIL FOR HEAVY-DUTY APPLICATIONS

SYNTHETIC OIL WITH VISCOSITY ISO VG 220
Class: WITH EP ADDITIVES
MAKE TYPE
MOBIL Mobil SHC 630
SHELL Tivela oil 220
KLUBER Klübersynth GEM4-220N
AGIP Blasia S 220
BP Enersyn SG-XP 220
FOOD GRADE OIL

Class: FOOD GRADE OIL
MAKE TYPE
AGIP ROCOL Foodlube HiTorque 220
MOBIL Mobil OTE FM Series 220
SHELL Cassida Fluid GL 220
KLUBER Klüberoil 4 UH1-220 N
CASTROL Vitalube GS 220
CIR Purity FG EPGear Oil 220
Sheet 1 of 2 TT-0162-C_REV1.xlsx
TT-0162-C
LUBRICATION OIL FOR
GEA Niro Soavi REDUCTION GEAR 03/12/2012 1
DATE REV.
FG
SIG.
ATTENTION
The quantity of oil for the gear reducer depend on machine model as specified in the following
table:
OIL QUANTITY FOR REDUCTION GEAR

MODEL QUANTITY (l)
ONE37TF 10,3
ONE75TF 18,0
NS3011 6,3
NS3015 6,3
NS3018 6,3
NS3024 6,3
NS3030 8,8
NS3037 8,8
NS3045 11,8
NS3055 16,5
NS3075 16,5
NS3090 31,5
NS3110 31,5
NS5132 42,5
NS5180 42,5
Sheet 2 of 2 TT-0162-C_REV1.xlsx
TT-0164-C
PNEUMATIC PLANT
GEA Niro Soavi OIL 01/03/2012 0
DATE REV.
TAG
SIG.
RACCOMENDED OIL
Class: ISO VG 32 DIN 51524-2-HLP
MAKE TYPE
AGIP OSO 32
IP HYDRUS OIL 32
SHELL TELLUS V 32
MOBIL DTE LIGHT
BP ENERGOL HLP 32
CHEVRON EP HYDR. OIL 32
CASTROL HYSPIN AWS 32
ESSO/EXXON NUTO H 32
TEXACO RANDO OIL HP 32
GULF HARMONY 32 AW
AMOCO AMERICAN INDUSTRIAL OIL 32
TOTAL AZOLLA ZS 32
FINA HYIDRAN 32
API CIS 32
KUWAIT PETR. INT. Q8 HAIDN 32
ELF OLNA DS 31
FOOD GRADE OIL

Class: FOOD GRADE OIL
MARQUE TYPE
AGIP ROCOL FOODLUBE HI POWER 32
SHELL CASSIDA HF32
FUCHS GERALYN AW32
OIL QUANTITY
NUMBER OF HOMOGENIZING
QUANTITY (l)
STAGE
1 1,5
2 3
Sheet 1 of 1 TT-0164-C.xlsx
SECTION 2
2.1. SAFETY AND ACCIDENT PREVENTION
2.1.1 APPLICATIONS, INTENDED USE
2.1.2 INTENDED USE, IMPROPER USE AND PERMITTED USE
2.1.3 WORK ZONES, CONTROL ZONES, DANGER ZONES
2.1.4 RISKS, HAZARDS AND RESIDUAL RISKS IN THE ENVIRONMENT
2.1.4.1 GENERAL SAFETY
2.1.4.2 RESIDUAL RISKS AND DANGERS
2.1.5 SAFETY DEVICES ADOPTED
2.1.5.1 OVERPRESSURE VALVE
2.1.5.3 EMERGENCY PUSHBUTTON
2.1.5.4 PROTECTIVE PANEL ON HEAD
2.1.5.5 MACHINE PANELS
2.1.6 SAFETY SIGNS
2.2. CE MARK AND ISO 9000 CERTIFICATION
2.3. IDENTIFICATION OF THE MACHINE
2.4. GUARANTEE
2.4.1 SCOPE OF THE GUARANTEE
2.4.2 DURATION OF THE GUARANTEE
2.4.3 APPLICATION OF THE GUARANTEE
2.4.4 EXCLUSIONS AND LIMITATIONS
2.4.5 HOW TO RETURN THE DEFECTIVE MATERIAL
2.5. HANDLING
2.6. RECEIVING AND CHECKING THE MACHINE
2.7. STORAGE
2.7.1 STORAGE BEFORE INSTALLATION
2.7.2 STORAGE FOR PERIODS LONGER THAN 3 MONTHS
2.8. INSTALLATION
2.8.1 POSITIONING
2.8.2 ACCESS TO THE INSIDE OF THE MACHINE
2.8.3 MACHINE LEVELING
2.8.4 CONNECTION TO UTILITIES AND PRODUCT LINE
2.8.5 INSTALLATION
2.8.6 POSITIONING THE ELECTRIC EQUIPMENT
2.8.7 ELECTRICAL CONNECTIONS
2.8.8 DIRECTION OF ROTATION OF ELECTRIC MOTORS
2C001E16C
2.1
2.9. SPECIAL NOTES
2.9.1 CONTROL BOARD TO BE PROVIDED BY THE CUSTOMER
2.9.2 ELECTRIC MOTOR SUPPLIED BY THE CUSTOMER
2.10. NOTES ON MACHINE TEST
2.11. CLEANING THE MACHINE
2.12. DEMOLITION AND DISPOSAL
2.12.1 DEFINITION OF WASTE
2.12.1.1 SPECIAL WASTE
2.12.1.2 TOXIC-HARMFUL WASTE
2.12.2 TEMPORARY STORAGE
2.12.3 CHARACTERISTICS OF THE CONTAINERS
2.12.4 REQUIRED REGISTRATION
2.12.5 DISPOSAL
2.13. OPTIONS
2.13.1 SECOND STAGE HOMOGENIZING VALVE
2.13.2 ASEPTIC EXECUTION
2.13.2.1 STERILIZING THE MACHINE
2.13.2.2 REGULATING THE FLOW OF COOLING WATER
2.13.2.3 DESCALING AND WASHING
2.13.3 PARTIAL HOMOGENIZING SYSTEM
2.13.3.1 HOW THE BYPASS SYSTEM WORKS
2C001E16C
2.2
2.1. Safety and accident prevention
2.1.1 Applications, intended use
This GEA Mechanical Equipment Italia S.p.A. homogenizer consists of a positive-displacement piston
pump, equipped with automatic suction and delivery spring-operated valves, and a homogenizing
section connected to it in which the product undergoes a high-pressure micronization process to
reduce the size of the particles suspended in the fluid and achieve homogeneous dimensional
distribution.
This process can be applied to a large range of products, with various viscosity, and makes it possible
to obtain greater product stability through particle dispersion and micronization, depending on the
pressure applied.
The GEA Mechanical Equipment Italia S.p.A. pump consists of a piston positive-displacement pump,
equipped with automatic suction and delivery spring-operated valves, whose function is to transfer
fluid by increasing head.
As regards the specific configuration of the machine, model, technical data, accessories and optional
features, please refer to the TECHNICAL SPECIFICATIONS enclosed in chapter 1 of this manual.
2.1.2 Intended use, improper use and permitted use
It is not permitted to use the machine for a purpose other than those indicated in chapter 2.1.1.
In particular it is not permitted to treat different products or to use the machine with performance values
(especially flow rate and pressure) other than those defined in the TECHNICAL SPECIFICATIONS
enclosed in chapter 1 of this manual
IMPORTANT
Any use other than the one for which the machine was designed and described in this manual,
shall be considered nonconforming and shall relieve GEA Mechanical Equipment Italia S.p.A.
of all responsibility.
ATTENTION
The machine is not designed for use in explosive environments.
2C001E16C
2.1.1
2.1.3 Work zones, control zones, danger zones
To enable correct understanding of the topics dealt with in this paragraph, the following definitions
are provided:
“Work zones” :
these are the areas where operators can stand during startup and during normal operation.
From these areas they will be able to rapidly intervene in case of need or emergency, always within
the limits of one’s duties and in compliance with intervention procedures.
The work zones are located around the system in the areas where access is allowed during operation.
“Control zones” :
these are the areas where operators can perform system control and adjustment operations, on the
special control panels.
“Danger zones” :
any area inside or around the machine where the presence of an exposed person creates a risk for
the health and safety of this person.
The danger zones are located around the system.
”Exposed person” :
any person that is wholly or partly inside a danger zone.
“Operator” :
a person in charge of installing, operating, adjusting, servicing, cleaning, repairing or transporting
the system.
ATTENTION:
Under normal working conditions, machine control or operation must take place only in the
area designed for its operation.
The control and operation zones are shown in the figure on the following page.
2C001E16C
2.1.2
Control and work zones (a)

Fig. 2.1.3.A
The following points provide some important precautions that relate to the above indications.
ATTENTION
Before starting the work process, an operator must be perfectly familiar with:
• position, function and use of all electric and pneumatic controls
• position, function and use of all safety devices
• the characteristics of the machine
• this manual and how to use it
The operator must also:

• have received adequate training provided on site by the manufacturer’s technicians or an
authorized support service centre
• have performed machine operation trials under the guidance of
GEA Mechanical Equipment Italia S.p.A. technicians
NOTE for operator

The operator is required to instruct any aid personnel used during the production cycle
regarding precise duties and compliance with the regulations that require suitable clothing
as shown in the following pages.
ATTENTION - CLOTHING
The operators in charge of operating and servicing the machine must wear work clothes
(with tight fitting sleeves), personal protection devices (gloves, glasses, safety boots) in
conformity with current laws and safety regulations.
The following figures show the personal protection gear recommended for personnel in charge of
maintenance who need to access danger zones.
2C001E16C
2.1.3
Wear safety boots

Fig. 2.1.3.b
Wear protective gloves

Fig. 2.1.3.c
ATTENTION
Suitable protective gloves must be work in areas with possible high temperature, in particular
in process zones (compression head, homogenizing valves, pipes).
2C001E16C
2.1.4
Overalls must be in perfect condition

Fig. 2.1.3.d
No large objects protruding from pockets

Fig. 2.1.3.e
Do not wear jewellery

Fig. 2.1.3.f
2C001E16C
2.1.5
Muffs or ear plugs must be worn

Fig. 2.1.3.g
No access by personnel not working in the area

Fig. 2.1.3.h
ATTENTION
The work area must NEVER be cluttered with tools or other objects that could cause hindrance.
Nothing must interfere with the free movement of operators.
In case of emergency, personnel in charge must be able to quickly access the line unhindered.
It is the operators’ duty to ensure that these indications are complied with and report any
failure to do so.
2C001E16C
2.1.6
ATTENTION
Personnel not working in the area must not stand in the work zone during machine operation.
Maintenance technicians can work around and inside the machine only after the machine
has been set to “maintenance mode”.
To set machine to maintenance mode, follow the detailed instructions indicated in chapter 4.3.1.3 in
this manual.
2C001E16C
2.1.7
2.1.4 Risks, hazards and residual risks in the environment
2.1.4.1 General safety
Compulsory information and training
This manual does not describe general safety aspects that should already be in place in the factory
to comply with the requirements for workplace safety.
However it is important to go over the main points to ensure that these are overlooked in the manual
and in the factory’s safety plan.
ATTENTION
“Protection from risks starts with information and training of workers”.
Instructing workers
The Employer shall arrange for each worker to receive adequate instruction on:
• safety and health risks connected with the company’s activity in general
• measures and protection/prevention activities adopted
• specific risks to which workers are exposed in relation with the work performed, safety regulations
and company rules
• procedures regarding first aid, fire prevention and evacuation plans
Training workers
The employer will ensure that operators and maintenance technicians receive adequate safety and
health training particularly with respect to issues concerning their role and specific duties.
2C001E16C
2.1.8
2.1.4.2 Residual risks and dangers
The residual risks present in the machine are listed below:
• Noise level (personal protection devices, such as plugs or muffs, must be worn)
•

• Risk of scalding from contact with hot machine parts (protective gloves and
adequate clothing must be worn)
• Risk of injury caused by moving parts (the machine must be used exclusively
with all of the guards in place and correctly fixed, for maintenance follow the
indications given in chapter 4)
• Electrocution hazard due to the presence of live parts (these parts are signalled
by an electrical hazard sticker)
• Trip hazard (only for models with access step for maintenance of processing area)
• Residual risk resulting from the inability to supervise the work area (this residual risk is managed
by indicating the areas involved, chapter 2, and, for maintenance operation, by means of signs
affixed onto the machine and the requirements described in chapter 4)
• Risk of becoming trapped inside the machine (refers to maintenance technician, for models
NS3037 and higher models)
2C001E16C
2.1.9
2.1.5 Safety devices adopted
The machine is equipped with safety devices that prevent it from reaching critical conditions that
would lead to sudden failure and hazard for users.
Intrinsic safety is ensured by accurate design and sizing allowing large safety margins, considering
the high pressure levels that can be reached as a result of incorrect operation by users or problems
in the line where the machine is installed.
The presence of an overpressure valve on the compression head, suitable electric protection on the
main motor, emergency pushbutton and protective panel on the head, are the main safety devices
present on the machine: these devices are described in the following paragraphs.
2.1.5.1 Overpressure valve
The pressure limiting valve (1) has been designed and constructed by
GEA Mechanical Equipment Italia S.p.A. for the protecting the machine in case of overpressure
inside the compression head as a result of the machine’s pumping action.
ATTENTION
The safety valve is used for machine protection; pipes downstream of the machine are only
protected by a valve that may be installed in the line.
The safety valve offers the following advantages:

• reduced maintenance
• it closes automatically in case of overpressure release, allowing production to be resumed
immediately
• it enables precise calibration and exact repeatability of interventio
2C001E16C
2.1.10
Location of overpressure valve

Fig. 2.1.5.1.a
Operation
The valve has a ball which is kept in place by a spring; this spring will allow the valve to open
whenever the calibration value set during the final testing is exceeded.
Spring preloading must never be changed to avoid modifying the valve opening value, as this would
affect the safety conditions designed by GEA Mechanical Equipment Italia S.p.A.i and invalidate the
guarantee; for this reason the preload adjustment nut is sealed.
If the calibration value is reached the valve opens automatically and discharges product via the outlet
pipe;
Once the overpressure valve has closed, it is possible to increase the homogenizing pressure again
up to the desired working value, unless the condition that triggered the valve has damaged it to an
extent that it will cause immediate stopping.
2C001E16C
2.1.11
ATTENTION
The discharge pipe MUST ALWAYS be directed downwards, to prevent hazards for operators;
the Purchaser is responsible for providing a suitable product collection sump connected to
drainage.
ATTENTION
The discharged product must be disposed of properly, in compliance with current regulations
in force in the country where the machine is installed.
ATTENTION
Triggering of the overpressure valve can cause damage to the safety valve seal with
consequent reduction of the opening value set during the calibration phase. It might therefore
prove necessary to replace the seat and ball after a number of opening events, in order to
restore the original operating conditions.
Washing
Washing of the zone in contact with the product (with closed overpressure valve) normally takes
place during the machine washing phase (C.I.P.).
ATTENTION
After triggering of the valve due to the calibration pressure having been exceeded, the valve
MUST ALWAYS be removed from its position and cleaned manually.
ATTENTION
Do not disassemble the valve body and do not remove the plastic cap. It is prohibited to
change the safety valve set value; doing so will invalidate the guarantee and affect protection
of the machine, of its components and of operators.
2C001E16C
2.1.12
2.1.5.2 Protection devices on main motor
The machine is equipped with electrical protection devices to suit motor power, starting system and
operating conditions: they use thermal magnetic switches, fast fuses or automatic switches against
short circuits, automatic switches or inverter for protection against overheating.
2.1.5.3 Emergency pushbutton
An emergency pushbutton (1), highlighted by the specific colour required by current regulations, is
located on the front panel of the machine.
If pressed, this button stops the machine instantly if dangerous situations arise, such as: operating
problems, unusual noise level, possibility of breakage.
Emergency pushbutton
Fig. 2.1.5.3.a
In case of danger you can also use the master switch (2) located on the switchboard as an emergency
shutdown device, as shown in the figure below.
2C001E16C
2.1.13
Master switch
Fig. 2.1.5.3.b
ATTENTION
The position of the machine and its connection with the product line must leave sufficient
space to enable rapid, unhindered access to the emergency pushbutton.
2C001E16C
2.1.14
2.1.5.4 Protective panel on head
The compression head (1) is fitted with an additional panel to protect personnel from the possible
projection of machine parts and from the high temperature that may be reached by the head.
Compression head panel

Fig. 2.1.5.4.a
ATTENTION
Do not enable machine use if the guard is not in place and correctly fixed.
The guards must never be removed during machine operation.
2.1.5.5 Machine panels
The machine is fitted with cover panels (1) made of satin-finish steel sheet which enables:
• protection of internal machine components from dirt, water or product soiling
• external cleaning
• protection of operators from moving parts, live parts or high temperatures which could be a risk
for the safety of personnel, in compliance with CE regulations and safety standards in force in
the country where the machine is installed.
ATTENTION
The machine must be operated EXCLUSIVELY with panels or guards completely closed, to
prevent the danger of operator injury, therefore it is prohibited to open the above protection
devices during machine operation.
2C001E16C
2.1.15
The panels can be removed during maintenance and/or installation procedures.

The side panels have handles (2) and locks with special key to access the inside of the machine,
during maintenance procedures.
ATTENTION
Ensure that ALL the panels are closed and blocked before starting the machine, to prevent
accidents; in handling the panels you should always use the handles provided. Depending
on the size and weight of the panels, two people might be needed to remove and fit back the
panels.
ATTENTION
Before removing the protection panels the operators in charge of installation and maintenance
must set the machine to maintenance mode by following the detailed instructions provided in
chapter 4.3.1.3 in this manual.
Cover panels
Fig. 2.1.5.5.A
2C001E16C
2.1.16
2.1.6 Safety signs
A set of danger signs are affixed onto the machine to call the attention of operators and exposed
persons.
IMPORTANT
The warning signs and compulsory action signs on the machine play an important safety
function; operators and maintenance technicians are required to comply with the indications
on these signs.
The safety signs on the machine have been applied as indicated in the figure on the next page.
ATTENTION
It is prohibited to remove warning signs and compulsory action signs that perform a safety
function.
Failure to comply with this requirement will invalidate the guarantee and transfer all liability
to the purchaser. The user is required to restore any signs that might be accidentally removed
or that are dislodged from their position.
Position of some safety signs present on the machine

Fig. 2.1.6.a
2C001E16C
2.1.17
PROHIBITION SIGN
• No access to personnel not working in this
area.
DANGER SIGN
• Presence of live parts
COMPULSORY ACTION SIGN

• Hearing protection muffs must be worn
DANGER SIGN
• Danger of burning or scalding due to possible
high temperature of machine front
DANGER SIGN
• Danger of burning or scalding due to the
high temperature released by hot surfaces
(homogenizing units)
DANGER SIGN
• Danger of injury caused by moving parts
2C001E16C
2.1.18
2.2. CE mark and ISO 9000 certification
The machine has been designed and built in accordance with EEC standards on the safety of
equipment (2006/42/CE).
GEA Mechanical Equipment Italia S.p.A. guarantees that this machine complies with the above-
mentioned standard by marking the front of the machine with “CE” as shown in figure 2.2.1 here
below, on the front part of the machine.
In Section 1 – TECHNICAL SPECIFICATIONS we have attached the Declaration of Conformity CE
of the machine.
Figure 2.2.1
In addition to this, GEA Mechanical Equipment Italia S.p.A. is certified according to UNI EN ISO
9001 for design, manufacturing and servicing of homogenisers and high pressure pumps, therefore
your machine has been enginnereed and produced according to approved quality procedures.
See figure 2.2.2 for the UNI EN ISO 9001 Quality System Certificate.
2C001E16C
2.2.1
Certificate
Standard ISO 9001:2015
Certificate Registr. No. 01 100 1600162/58
Certificate Holder:
GEA Mechanical Equipment Italia S.p.a.

Via A. M. Da Erba Edoari 29
43123 Parma PR
Italy
Scope: Development, manufacture and service

of homogenisers and high pressure pumps
Proof has been furnished by means of an audit that the

requirements of ISO 9001:2015 are met.
® TÜV, TUEV and TUV are registered trademarks. Utilisation and application requires prior approval.
Validity: The certificate is valid in conjunction with the main certificate

from 2016-06-28 until 2019-06-27.
2017-12-11
TÜV Rheinland Cert GmbH
Am Grauen Stein · 51105 Köln
www.tuv.com
Figure 2.2.2
2C001E16C
2.2.2
2.3. Identification of the machine
The machine is identified by the name plate (fig.2.2.1) located on the front panel (or on the pulley
protection panel, for the Hercules versions without casing), which includes:
- the manufacturer’s name
- model and type
- serial number.
The serial number is also punched on the compression head.

This number should always be quoted in any correspondence addressed to
GEA Mechanical Equipment Italia S.p.A.’s Customer Service in order to identify the machine properly.
2C001E16C
2.3.1
2.4. Guarantee
If not specified otherwise in the order confirmation, the terms and conditions of guarantee are as
follows:
2.4.1 Scope of the guarantee
GEA Mechanical Equipment Italia S.p.A. guarantees the good quality and workmanship of its
products and shall - during the specified guarantee period - repair or replace free of charge any
part whose failure or premature wear and tear are the result of poor quality of materials, defective
workmanship or assembling.
The guarantee shall not apply to those parts whose failure or wear and tear are due to:
• operator’s negligence in checking the levels of the fluids, cleaning the filters, providing the correct
utility lines or improper feeding; insufficient infeed pressure in the machine;
• use of the machine with operating values exceeding the ones specified in the contract, especially
with respect to maximum pressure, flow, product treated, operating and washingtemperatures,
feed pressure, specifications of required utilities.
• use of inappropriate tools for the ordinary or extraordinary maintenance;
• failure to perform or incorrect maintenance;
• alterations or modifications carried out - whether directly or indirectly - without the specific
authorization in writing by GEA Mechanical Equipment Italia S.p.A.;
• failure to comply with the INSTRUCTIONS FOR USE & MAINTENANCE.
• incorrect machine use, incorrect operating procedures and conditions
• incorrect machine installation or incorrect layout of feed line
• use of unsuitable components upstream or downstream the machine, and in particular use of
inadequate feed pump.
For this reason, we strongly recommend that the instructions contained in this Manual are understood
and followed, as a pre-condition for the correct and safe use of the machine.
Using the machine and reading the INSTRUCTIONS FOR USE AND MAINTENANCE imply integral
acceptance of Warranty conditions.
For further information about application of the Warranty, see General Terms of Sale.
2.4.2 Duration of the guarantee
The guarantee shall last for 12 MONTHS from the date of delivery of the machine, unless otherwise
specified in the Order Confirmation.
Such period shall remain unchanged even in the event that spare parts replacements or repairs are
carried out during the 12-month period.
2C001E16C
2.4.1
2.4.3 Application of the guarantee
As a condition of the applied warranty, any parts claimed to be defective by the customer shall be
provided to GEA Mechanical Equipment Italia S.p.A. to establish the cause.
The cost of shipping of materials shall always be charged to the customer.
Any work required for replacement/repair under guarantee shall be executed - at
GEA Mechanical Equipment Italia S.p.A.’s option, on the manufacturer’s premises, on thirds’ party
or directly on the spot.
The cost of shipping materials to the customer’s presmises shall always be charged to the customer,
especially in the case of urgent and specials shipments of material or spare parts.
For any work carried out locally, the customer shall provide and pay for the necessary utilities,
extraordinary equipment, auxiliary personnel that may be required and the costs of travel, board and
accomodation of GEA Mechanical Equipment Italia S.p.A.’s technicians.
2.4.4 Exclusions and limitations
The guarantee shall not cover the materials and parts subject to normal wear and tear such as,
but not limited to, all the gaskets used in the machine, v-belts, plunger seals and relevant packing
and support washers, safety valve seat, filters, etc., As well as those parts whose life can not be
estimated beforehand - such as lamps, fuses, plungers - together with any coating, delivery valve
and their seats, homogenizing valve, pressure gauges.
For the components and accessories bought from independent vendors, the guarantee shall be the
one granted to GEA Mechanical Equipment Italia S.p.A. by such vendors.
2.4.5 How to return the defective material
Before returning to GEA Mechanical Equipment Italia S.p.A. any part for which a replacement/
repair under guarantee is claimed, the necessary approval shall be ontained from
GEA Mechanical Equipment Italia S.p.A.’s Customer Service.
All parts shall be properly packed to avoid any damage in transit, and accompanied by:
• reference to the purchase order number;
• machine serial number;
• code number of the part;
• accurate description of the defect and the circumstances which caused it.
All parts approved to be under guarantee are delivered ex works; replaced parts are the property of
GEA Mechanical Equipment Italia S.p.A. and shall be returned ex works.
2C001E16C
2.4.2
2.5. Handling
CAUTION
These instructions shall be made available to the personnel involved in the handling and
installation of the machine.
The machine is sent to the Customer usually packed in a properly sized wooden crate and wrapped
in plastic film for additional protection, unless otherwise specified in the Order Confirmation.
The wooden crate allows the machine to be handled with a fork lift or crane, and appropriate marks
are provided on the crate at the points for running steel cables or belts for lifting (figure 2.5.1).
Figure 2.5.1
2C001E16C
2.5.1
Concerning the dimensions and weight of the machine, see the “Installation Drawing” shown in
Section 1 – TECHNICAL SPECIFICATIONS, in order to use the proper lifting equipment.
The weight given is merely indicative and should be used only to select the correct handling and
transport means.
Please note that the center of gravity of the machine lies towards the compression head (front part).
When handling unpacked machines use fork lifts (unless otherwise specified in the handling
instructions) and make sure that the compression head lies on the operator’s side. Forks should
be adequately spaced and sized so as to accomodate the entire base of the frame (figure 2.5.2) to
prevent damage to the machine frame or panels.
Side panels can be removed during transport to prevent damage; the front part of the bodywork,
under the compression head, has not been constructed to support the weight of the machine. Do not
use this part as a lifting point as this could result in damage.
G G
Figure 2.5.2
CAUTION
In order to ensure a balanced handling of the machine and avoid damage to the machine
itself or hazards for the personnel, all movements should be carried out VERY SLOWLY by
authorized operators, who must wear suitable protection devices and comply with safety
regulations.
2C001E16C
2.5.2
WARNING
Before handling the machine, make sure that the route to be followed and the intended place
of installation are clear of any obstacle.
WARNING
Operators are required to read these instructions before handling the machine; all
personnel involved in handling of the machine must be acquainted with transport and
handling regulations, as well as with regular safety standards.
WARNING
Use only tested hoisting devices approved to support the machine’s weight, as indicated in
the dimension drawing in Section 1 – TECHNICAL SPECIFICATIONS.
Do not under any circumstances leave suspended loads and never stand below suspended
load
WARNING
The floor on which the machine is to be placed must withstand to at least 150% of the machine’s
weight indicated in the “Installation Drawing” in Section 1 – TECHNICAL SPECIFICATIONS.
2C001E16C
2.5.3
2.6. Receiving and checking the machine
Unless specified otherwise in the Order Confirmation, once the machine has left the Manufacturer’s
premises, any damage shall be under the responsibility of the carrier - whether an independent one
or a Customer’s employee.
Therefore, when receiving the machine, the following should be checked:
• contents of the packing against the Packing List;
• integrity of the packing, so that any evident damage can be immediately reported to the carrier;
• any damage suffered by the machine as a result of improper transport by the carrier.
In order to minimize the amount of inconvenience for the Customer,

GEA Mechanical Equipment Italia S.p.A. Shipping Department is always available to assist with
clarifications, evaluation of any damages, and any other action required to restore the machine to its
proper and safe conditions.
2C001E16C
2.6.1
2.7. Storage
2.7.1 Storage before installation
During the time preceding installation, the machine and its apparatus should be conveniently stored
in closed, clean premises to avoid deterioration and preserve its efficiency.
If no storage place can be provided other than outdoor, a waterproof cover should be provided to
prevent contact with dust, humidity, rain, etc.
Special attention should be given to electric control boards and electronic equipment, which are
easily affected by humidity and low temperature.
If separate from the machine, they should be stored indoors and provided with special humidity
absorbers.
WARNING
Storage temperature should not be less than -5°C and more than +55°C; humidity should be
less than 95%, with no-condensate. Vibrations should be avoided as much as possible.
2.7.2 Storage for periods longer than 3 months
If the machine is expected to remain stored for over three months before installation, provide a
closed storage place protected from bad weather, dust or corrosive releases, as described before.
Observe the above precautions for electric components.
In addition YOU MUST:
• loosen the tension of V-Belts using the appropriate tighteners (sees Section 3 - MAINTENANCE);
• disassemble the plungers and seal packings (see Section 3 - MAINTENANCE)
WARNING
Pistons and seal packings should be reassembled, and belts tensioned at the time of machine
installation.
WARNING
In case the machine plungers are chrome coated, or are using a tungsten carbide detonated
coating (see Section 1 – TECHNICAL SPECIFICATIONS), they must be disassembled together
with the packings if the machine is in storage more than ONE month.
2C001E16C
2.7.1
2.8. Installation
2.8.1 Positioning
Correct positioning of the machine in the production line enables optimal operation and easy
accessibility for the required ordinary maintenance procedures.
For this reason, a clearance area must be allowed around the machine for the activities of maintenance
personnel; the area will depend on the size of the machine. See figure below. This clearance area
must also enable staff to quickly leave the area surrounding the machine in case of accidents.
The front part of the machine and the head require maintenance regularly.
We recommend leaving a suitable space in the front area to enable complete removal of the head
and, on the sides, if the main motor needs to be removed using hoisting means (bridge crane or
fork-lift truck).
It is important to keep the machine away from heat sources that could interfere with the necessary
cooling process, and ensure that no objects are obstructing the flow of air.
Water drainage points should also be available to prevent flooding that could affect the machine.
In particular a drainage sump is needed in the safety valve discharge area.
Lastly, it is necessary to prevent water ingress through the ventilation openings of the machine.
ATTENTION
The floor supporting the machine must be able to withstand at least 150% of its weight, as
indicated in the “Installation drawing”.
Fig. 2.8.1.a
2C001E16C
2.8.1
2.8.2 Access to the inside of the machine
The machine is provided with a satin-finish stainless steel fairing for:
• protection of the internal components from dirt, water or fouling with product;
• easy cleaning of the external parts;
• operator’s protection from moving, under voltage or hot parts which may be hazardous for the
personnel, in compliance with EC standards and CE mark requirements, and safety regulations
in force in the country where the machine is installed.
CAUTION
to avoid any danger of injuries to the operators, the machine should be operated ONLY with
the panneling in place or protections completely closed.
Panels may be removed to allow maintenance and/or installation work to be carried out.
Side panels are fitted with handles and special key locks to access the inside of the machine.
CAUTION
To prevent accidents, ensure that ALL retainers are locked before starting the machine; to
remove or replace panels always use the handles provided. Depending on the size of the
panels, two persons might be needed to remove or instal the panels.
CAUTION
Before removing the protection panels, the installation/ maintenance personnel should cut
off the power input to the machine by locking the appropriate power switch with a padlock.
2C001E16C
2.8.2
2.8.3 Machine leveling
To ensure a smooth, vibration free operation, the machine should be properly leveled and its legs
should rest evenly on the floor.
To this effect, the machine is supplied with adjustable legs and rubber pad (figure 2.8.1, item 1); in
some cases, with fixed legs which do not require to be adjusted or with pivoting wheels which have
to be locked before operating the machine).
For the leveling, proceed as follows:

• lift the machine and place the pads under the legs;
• lower the machine until the legs sit firmly on the blocks;
• adjust height from floor by tightening or loosening the adjustable legs, then check the levelling
with respect to the machined surface of the head;
• make sure that the machine’s weight is divided among all legs;
• lock the legs using the appropriate lock ring (figure 2.8.1, item 2).
In some cases, due to vibrations, the machine may move and consequently cause stress to the
piping; if you wish to avoid this, the leg pads can be secured by steel rings fixed to the floor.
Figure 2.8.1
2C001E16C
2.8.3
2.8.4 Connection to utilities and product line
The type, dimension and position of the connectors normally used to connect the machine to the
production line are specified in the dimension drawing in Section 1 – TECHNICAL SPECIFICATIONS.
The machine also includes (section 1 – TECHNICAL SPECIFICATIONS):
• water connection for lubrication of packs and cooling (max. hardness 8 °dH / 15 °fH;
recommended chloride value < 25 mg/liter, max 200 mg/liter
• water drain pipe;
• (possible) connection for compressed air (for homogenizers provided with air-operated control
system);
• (possible) connection for steam (for aseptic versions)
• condensate drain from lubrication system;
• discharge grid for cooling air.
For the specific requirements of each machine, type of connections and fluid specifications, please
refer to Section 1 – TECHNICAL SPECIFICATIONS.
As far as the utility connections, we recommend providing on/off solenoid valves designed to open
at the machine start (if not already included in the machine) to be placed at the machine’s utilities
inlet ports.
In particular, the manual valves of the lubrication water circuit should remain always open, in a
position which allows controlling an adequate flow of water for lubrication or production of enough
condensate (for the aseptic version).
Keep in mind that excessive lubrication water can lead to flooding of the sump where water is
collected, with the risk of water going into the drive section and polluting the lubrication oil; for this
reason it is important to regularly drain any condensate or water that may be found in the lubrication
circuit, as described in Section 4 - MAINTENANCE.
WARNING
In the case of components made of Tungsten Carbide material, during washing or production,
the use of reverse osmosis purified water, demineralized microfiltered water, Water for
Injection is not recommended.
Its aggressive action would lead to chemical etching of the material in question, drastically
reducing its duration and putting the correct homogenizing operation of the machine at risk.
WARNING
For the machines provided with aseptic system, the Customer shall be responsible to install
a steam pressure reducer to protect the aseptic system and ensure operators’ safety. Fluid
specifications are shown in Section 1 – TECHNICAL SPECIFICATIONS.
In case a pipe is used for the water drainage, when calculating the required diameter and slopes,
remember that water is discharged by gravity and not by pressure. Provide an adequate degree of
slope in the system to avoid water to accumulate in the sump.
WARNING
For the disposal of waste water or cooling water, refer to the specific regulations in force
locally. No traces of lubrication oil or product residues are allowed in the effluents disposed.
2C001E16C
2.8.4
Cooling air is discharged through grids, situated on the top of the machine, controlled by a fan of
suitable size for free discharge (not for all models).
In case the discharged air needs to be conveyed via ducts, please contact
GEA Mechanical Equipment Italia S.p.A.’s Technical Office for details.
WARNING
No device designed to throttle, whether totally or in part, the delivery pipe, is allowed to be
installed downstream the machine, as this may cause risk of excessive pressure in the pipes
and compression head.
In fact, the machine has been designed to withstand output counterpressures not bigger
than those indicated in the Technical Specifications, Section 10 but, as this is a positive-
displacement pump it can create dangerous overpressure which can burst the pipes
downstream the machine when the outlet is closed for the liquid flow.
WARNING
For safety reasons we recommend you ALWAYS install a safety valve downstream the machine
to protect the line and users. You should also ensure that all the valves used downstream the
machine are NORMALLY OPEN valves, so that they will not close in case of accidental stops or
emergency power down, or power failures. The machine has been designed to have a certain
level of inertia, so it will go on pumping even after the main motor has been disconnected.
Figure 2.8.2
ATTENTION
If there are specific requirements of purity or a maximum permissible level of contamination
of the treated product, it is necessary downstream of the homogenizing unit/pump to install
a suitable system or filtering or removing potential contaminants.
2C001E16C
2.8.5
2.8.5 Installation
These guidelines are provided to ensure correct machine installation and operation and guarantee
long life to the machine and its components while preventing situations of danger for operators.
• For high-pressure positive displacement pumps and homogenizers, infeed pressure must
ALWAYS be kept over a minimum level for correct operation without cavitation conditions
which could damage the machine. The minimum values indicated in Section 1 – TECHNICAL
SPECIFICATIONS must be observed strictly; in any case, depending on the process temperature
and viscosity characteristics, it is necessary to ensure that infeed pressure is constant and
sufficient to prevent cavitation and underfeeding of the machine.
For further information or special requirements ALWAYS contact
GEA Mechanical Equipment Italia S.p.A..
• to feed the machine use an infeed pump with delivery 1.2 times greater than the rated flow in
case of machines with 3 or more pistons, and 1.5 times in case of machines with 1 or 2 pistons.
Pump delivery must be calculated at least over the minimum pressure required for feeding.
• If a positive displacement pump (lobe, single screw, etc.) or diaphragm pump is used , a suitable
by-pass pipe regulated by a modulating valve on the infeed pump, and/or an adequate speed
regulating system for the infeed pump, to ensure correct machine feeding
• if the products treated vary greatly in terms of viscosity, or if a positive-displacement pump must
be used for viscous products and washing water, you must use a pump speed adjustment system
regulated by infeed pressure to ensure that machine feeding is correct under all conditions,
including during transitory production stages.
• installation of the two homogenizers or piston pumps in series can only be carried out provided
a few changes are made, such as providing speed variation of both machines controlled by an
an infeed pressure adjustment loop and installation of a by-pass system; for information in this
respect please contact GEA Mechanical Equipment Italia S.p.A..
• it is necessary to use a feeding pump for each single machine; do not install two or more machines
in parallel with one single feeding pump to prevent dangerour pulsation interferences
• the feeding line between the feed pump and the homogenizer or piston pump must be direct,
possibly without bends, and with a size equal to or greater than the size of the homogenizer/
piston pump, without section variations, to prevent loss of load; the radius of curves must be
as large as possible to prevent loss of load especially in the infeed stage and to avoid noise
problems at delivery.
• we recommend you install a pressure gauge near the area where product is fed into the
homogenizer / piston pump in order to check infeed pressure; this pressure gauge can be
supplied as an optional by GEA Mechanical Equipment Italia S.p.A. and can be standard, with
minimum contact or with continuous analog signal for remote control.
• if filters need to be installed on the feeding line, you must allow a clear area at least 3 times the
size of the pipe used; you also need to install a pressure gauge downstream the filter to check
actual infeed pressure and prevent filter clogging and danger of cavitation of the machine. For
cleaning purposes we recommend installing parallel filters to be used alternatingly.
2C001E16C
2.8.6
• every homogenizer or piston pump is characterized by pulsating operation: for this reason,
depending on the kind of system and machine flow, we recommend you install a pulsation damper
both for suction and delivery (providing up to 20 bar maximum counterpressure on the line.
• the pulsation damper is always recommended for flow rates exceeding 5000÷6000 l/h; on the suction
end, it must be installed as close as possible to the machine inlet, while on the delivery end it must be
installed on a horizontal pipe at a distance of minimum 1 meter from adjacent bends. For technical
details about size and installation please contact GEA Mechanical Equipment Italia S.p.A.
• if the feed pump is connected to a tank, ensure that no air is sucked in by the suction inlet through
the creation of vortices by fitting suitable internal barriers to divert the flow; the feeding pump
must have a net positive suction head at all times
• we recommend you install a suitable safety valve downstream the homogenizer or piston pump
in order to protect the system from possible overpressure caused by inexperience or incorrect
operation procedures downstream the machine; the safety valve fitted in the machine, even
where a piston pump is used, will protect the machine, but not the system to which it is connected,
in case of dangerous overpressure.
• Never use the machine to fully drain the feeding tank, to avoid product suddenly running out
during operation under pressure, but provide at least one level sensor to remove pressure (in the
case of a homogenizer) and stop the machine before the product being fed runs out.
• the product treated must contain no air or gas, to prevent cavitation problems in the machine. If
the product contains air because it is very viscous or due to previous processing phases, you
need to remove the air using appropriate deaeration equipment.
• the pulsation damper must be installed in a vertical position; do not install the damper so that
the flow enters the damper directly, otherwise the damper will fill up too quickly and become less
effective as no air will be left at the top.
• if processing temperature exceeds 90 °C, it is absolutely necessary to increase feeding pressure

due to increased steam pressure which can lead to cavitation. Feeding pressure should therefore
be increased by 1 bar for each 5 °C of temperature increase above 90 °C added to the minimum
feeding pressure specified in Section 1 - TECHNICAL SPECIFICATIONS.This value must be
doubled in case of products with a viscosity value greater than 500 cP. For special products and
special process temperatures contact GEA Mechanical Equipment Italia S.p.A.
• the machine is fitted with automatic pumping spring valves; the load is defined according to the
type of valve and the characteristics of the product. This means that if the machine has been
stopped or is inactive, and the feeding line is open and under pressure, you are able to check
the flow of product through the machine. To make sure there is no product flowing through the
machine when the machine is inactive, the user must provide a cutoff valve for the feeding line
upstream the machine.
2C001E16C
2.8.7
2.8.6 Positioning the electric equipment
Our machines are supplied in the standard version without electric power board; this will be designed
and constructed according to the specifications of the machine as an optional; in any case the
machine is fitted with a terminal box which houses all the connections of the electric devices installed
in the machine, excluding the motors.
Where the electric board is supplied, and as a general recommendation, the cabinet containing the
electric control and power equipment - if not built in the machine - should be placed as far as possible
in clean, dry, ventilated premises which should be free from vapour, suspended dust or corrosive
release. Before ordering the machine, the Customer should make sure that the intended place of
installation is suitable to protect the equipment from any aggression.
Besides, it should be ascertained that no heat sources are present in the vicinity to avoid local
overheating and ensure that all electric equipment can be cooled down efficiently.
When forced ventilation is provided, any air vent should remain unobstructed. If it has been established
that the ambient air is not suitable for proper ventilation, an air duct should be provided, in addition
to selecting a control board suitable for the particular operating conditions existing locally.
For the type, overall size, weight and installation requirements of the control board,
see Section 1 TECHNICAL SPECIFICATIONS (if the board has been supplied by
GEA Mechanical Equipment Italia S.p.A.).
2.8.7 Electrical connections
The power line to the control board should be of appropriate type according to the length, type of
routing, ambient temperature, nature of the load, and always in accordance with the provisions
of the local regulations on this matter. If no specific agreements have been made in writing with
GEA Mechanical Equipment Italia S.p.A., the user shall be responsible for establishing the features
of the power line and earthing conductor up to the terminal board of the machine, as well as selecting
appropriate protection devices against short-circuits and contact voltage. Where the electric board
is supplied by GEA Mechanical Equipment Italia S.p.A. we will provide a list of cables with size
calculated assuming a length of 50 meters, closed conduit with three-pole cables and 40 °C ambient
temperature.
As far as the power details of the machine and wiring diagrams, reference should be made to the
electric specifications and diagrams shown in Section 1 - TECHNICAL SPECIFICATIONS and in
Section 6 – WIRING DIAGRAM.
CAUTION
The indications given concerning the wiring refer to standard laying and environmental
conditions; the values shown are purely indicative, therefore they should ALWAYS be cross-
checked by the user depending on the actual operating conditions.
The electric connections between machine and electric power board and between electric power
board and power mains must be made by the Customer who is also responsible for checking that
they have been properly executed and that they comply with the wiring diagram, before the machine
is started up.
GEA Mechanical Equipment Italia S.p.A. shall not be liable for injury to people or damage to objects
caused by incorrect connection of electric equipment; all electric connection must be checked by
authorized personnel.
If in doubt please contact GEA Mechanical Equipment Italia S.p.A..
2C001E16C
2.8.8
2.8.8 Direction of rotation of electric motors
At the time of wiring, make sure that all motors rotate in the correct direction:
CAUTION
To check the direction of rotation, the motors should be operated ONLY by impulses.
When performing these operations, follow strictly the safety rules and stay away from any
moving part inside the machine.
Remove only the panels on the LEFT HAND SIDE of the machine.
Before starting the machine, make sure that the protection panels on the RIGHT HAND SIDE
(drive) of the machine are in place.
• main motor: the correct direction of rotation is shown by the arrow on the flywheel; it is
COUNTERCLOCKWISE for machines with FORCED LUBRICATION and gear reducer);
COUNTERCLOCKWISE for machines with splash lubrication (see Section 1 - TECHNICAL
SPECIFICATIONS), unless otherwise specified by the direction of the arrows on the machine
(flywheel and/or motor)
• oil pump motor (only for machines with motor-driven lubrication pump): follow the direction of the
arrow printed on the pump body. In case of mistake, the low pressure in the circuit triggers the
pressure switch, which prevents the machine operation;;
• electric fan of main motor (only for machines designed for variable speed): follow the direction
indicated by the arrow;
• electric fan of machine body: follow the direction indicated by the arrow.
Auxiliary motors may be installed depending on the type of machine: verify the actual installation with
reference to the technical sheet and the wiring diagrams, Section 1 -TECHNICAL SPECIFICATIONS.
If the direction of rotation is not correct, reverse any of the two phases of the supply cord.
CAUTION
Before starting the motors ensure that ONLY installation personnel are present in the vicinity,
and that NOBODY is in contact with the machine.
2C001E16C
2.8.9
2.9. Special notes
2.9.1 Control board to be provided by the customer
If the electric power and control board (optional) is not supplied with the machine,
GEA Mechanical Equipment Italia S.p.A. will include a Technical Sheet (Section 1 - TECHNICAL
SPECIFICATIONS) showing the electrical requirements of the machine, together with an operation
sequence to enable the Customer to establish the elements of the control board and the operating
features of the required protection devices for a correct execution and the selection of appropriate
control and protection devices.
CAUTION
GEA Mechanical Equipment Italia S.p.A. shall not be held liable for damages caused to either
persons or the machine due to mistakes made in the design and/or execution of the control
board.
CAUTION
The control board should be built in accordance with the local operational and safety
regulations in force.
2.9.2 Electric motor supplied by the customer
The electric motor shall be made in accordance with the general specifications laid down by
GEA Mechanical Equipment Italia S.p.A. as to POWER, NUMBER OF POLES, SIZE, SERVICE
(Section 1 - TECHNICAL SPECIFICATIONS).
The motor shall be placed either on the supporting plate and secured by bolts in the holes provided
(or made at the time of installation) taking care that the motive pulley is in line with the flywheel.
For information on installation and tensioning of V-belts see Section 3 - MAINTENANCE.
2C001E16C
2.9.1
2.10. Notes on machine test
Before shipment all of our machines are accurately tested by qualified personnel through operational
tests which simulate the normal working conditions.
Through the operational tests - run with cold water - it is possible to verify the actual performance
of the machine against the design data, the calibration of safety, control and check devices, the
conditions of any seals, as well as the noise and vibration-free operation of the machine and the
parameters introduced in any programmable instruments or equipment that might be used.
To test the conditions of operation of the machine (flow rate with the maximum operating pressure
allowed, noise level, electric absorption) the machine is run with water at a temperature of approximately
20 °C, so it is possible to verify the deviation of the machine’s actual flow rate compared to the rated
value ± 5% with product.
However, at the time of start-up, after the machine has been installed in the production line, a final
test of the conditions of operation is required.
Upon request of the Customer, GEA Mechanical Equipment Italia S.p.A. can dispatch an engineer
for the first machine start-up in order to check that the wiring has been executed correctly and that
the machine has been properly installed, besides providing any additional information or instruction
to the operators and service personnel with reference to this Manual.
CAUTION
Should the Customer decide not to ask for the attendance of our engineer at the time of
the start-up, GEA Mechanical Equipment Italia S.p.A. shall not be liable for damages to
persons or property caused by failure to observe the instructions provided in this Manual
(INSTRUCTIONS FOR USE AND MAINTENANCE).
2C001E16C
2.10.1
2.11 Cleaning The Machine
The machine is supplied with external paneling in glazed stainless steel plate (ARIETE version)
which is easy to clean with water.
Washing prevents the deposit of product residuals on the machine: wash the bodywork with running
water from time to time, paying particular attention to the compression head and the sump.
If required you may use a cloth and any standard mild detergent.
To prevent water from entering the machine, place a suitable covering over the ventilation hole; do
not wet the electric panel or the control panel.
The HERCULES industrial version is supplied without external paneling, but only with protection
panels to cover moving parts: in this case make sure you do not wet unnecessarily the electrical
components of the machine.
WARNING
Before washing with running water, make sure that power has been cut off by means of the
sectioning switch of the supply line that should be locked with appropriate padlock.
2C001E16C
2.11.1
2.12. Demolition and disposal
2.12.1 Definition of waste
Waste means any substance and object deriving from human activity or natural cycles, which is
abandoned or destined to be abandoned.
2.12.1.1 Special waste
The following can be considered special waste:

• Residues deriving from industrial processes, agricultural, artisan, commercial and service-related
activity which, because of its quality or quantity, cannot be included in municipal wastei
• Deteriorated, obsolete machinery and equipment
• Motor vehicles and discarded parts
2.12.1.2 Toxic-harmful waste
Toxic and harmful waste means all waste containing or contaminated by the substances indicated in
the annex to DPR 915/82, as amended, implementing the directives 75/442/EEC, 76/403/EEC and
768/319/EEC and/or the laws or regulations of the Country in which the machine is installed.
In particular, the classification of waste is now regulated by the environmental consolidation law
D.Lgs 152/06, as amended, and pursuant to European Regulation no. 1357/2014 harmonizing
the hazardous properties with the new labelling for hazardous substances governed by European
Regulation no. 1272/2008
Fig. 2.12.1.2
2C001E16C
2.12.1
2.12.2 Temporary storage
Temporary storage of toxic and harmful waste is allowed prior to planned disposal by means of
treatment and/or final storage. In any case environment protection laws in force in the user’s country
must be complied with.
2.12.3 Characteristics of the containers
All fixed and movable containers destined to contain toxic and harmful waste must have adequate
resistance characteristics depending on the chemical-physical properties and the hazardousness of
the waste contained.
All containers holding dangerous or harmful products or substances must bear indications and signs
designed to reveal the nature of their content.
2.12.4 Required registration
For the disposal of used oil, we recommend the use of in/out registers for special waste or toxic-
harmful waste deriving from machine processes.
2.12.5 Disposal
Any refuse materials product must be disposed of in accordance with the laws in force in the country
where the system is installed.
The substances produced during maintenance or machine demolition procedures are :

• used lubricants;
• recovery materials (coating, electric cables, etc.);
• plastic and rubber materials (pipes, gaskets, etc.);
• metals (head and transmissions components, frame, panels, pipes, bearings, gears, etc.);
• electric and electronic components.
Any polluting product must be disposed of in compliance with the provisions contained in the laws of
the country where the machine is installed.
Pursuant to directives 2002/95/CE (RoHS) and 2002/96/CE (RAEE)relating to disposal, it is

compulsory to ensure that the products subject to these directives are recycles using the best
technology available for treatment, reuse and recycling to safeguard the health of people and the
environment.
The purchaser, i.e. owner of the GEA Mechanical Equipment Italia S.p.A. product, is required to
comply with the obligations laid down by the above mentioned directives.

In particular, it should be noted that:
a) it is prohibited to dispose of RAEE waste as municipal waste; this waste must be disposed of
through the separate collection facilities provided by public or private authorities;
b) potential effects exist for the environment and human health due to the presence of dangerous
substances in the electrical and electronic equipment or due to improper use of the equipment
of part of it.
2C001E16C
2.12.2
2.13. Option
2.13.1 Second stage homogenizing valve
As an option, a second homogenizing stage can be installed on GEA Mechanical Equipment Italia S.p.A.
Homogenizers in series with the first stage valve.
In this way it is possible to reduce the increase of viscosity produced by the treatment of the product,
in case it contains colloidal or thickening substances.
Although the micronization effects obtained with the 1 stage are unaffected, the 2nd homogenizing
stage reduces the product viscosity and allows the distributing of the pressure drop.
Moreover, it is possible to avoid the clustering of micronized particles, due to the homogenizing
effect.
The application of the 2nd stage should be decided on the basis of specific considerations concerning
the type of product.
As a general rule, the second stage pressure is usually applied as 1/10 to 1/5 of the maximum
homogenizing pressure, according to the processed product requirements.
The formula which relates the homogenizing pressures in a two stage system (see figure 2.13.1) is
the following:
Ptot = P1 = P2 + dP
where:
Ptot = P1 is the total pressure measured on the compression head, equivalent to the 1st stage
pressure
P2 is the pressure applied to the 2nd stage
dP = P1 - P2 is the pressure difference between the 1st and the 2nd stage, applied in the
passage through the 1st stage valve.

Do not hesitate to contact GEA Mechanical Equipment Italia S.p.A. for advice and clarifications.
2C001E16C
2.13.1
P2
dP
P tot=P1
Figure 2.13.1
2.13.2 Aseptic execution
Whenever a sterile plant and product needs to be ensured, an aseptic version of the
GEA Mechanical Equipment Italia S.p.A. machine is available.
This can be achieved by running sterile condensate through the plungers in the seal section and
through the seal of the homogenizing valve shaft using appropriate sterile chambers to avoid
contamination from outside sources.
Condensate is produced by steam condensation at a temperature of 140 °C through water run in a
heat exchanger.
The cooling water should be clean and preferably softened to avoid scaling deposits in the exchanger.
Water hardness must be under 8 °dH / 15 °fH, with recommended chloride value < 25 mg/liter and
in no case greater than 200 mg/liter.
The required flow rate and water temperature values are indicated in the consumption tables, Section
1 – TECHNICAL SPECIFICATIONS.
2C001E16C
2.13.2
2.13.2.1 Sterilizing the machine
Before starting up the machine following an extended period of standstill - or at first start-up - we
recommend sterilizing the areas to be maintained aseptic with live steam (max temperature 140
°C at 2.6 bar) and with the machine stopped: to do so, open the steam on/off tap without sending
any water to the exchanger. After sterilizing cool down the system by flowing the sterile condensate
obtained from steam condensation through the aseptic circuit.
This operation should be performed with the machine stopped to avoid damaging irreparably the
seal packings of the plungers.
ATTENTION
If the machine relies on a supply system with a bypass circuit (feed pump and modulating
valve), refer to the sterilization procedures described in the feed pump manual.
• The Control Logic Requires The Feed Pump To Stop In The Sterilization Phase.
• Before restarting in the production phase, reckon on a machine cooling time long enough
to cool the system (t<40°c or three hours).
The machine’s product circuit can be sterilized using live steam or pressurized water, with a maximum
temperature of 140 °C and for maximum 30 minutes. To avoid damaging the seal packings of the
plungers and thus reduce their life, we recommend that you stop the machine before sterilizing it or
that you alternate 1 minute operation phases with 10 minute stops (in case of fixed flow rate/speed
machines), or with the lowest speed possible in case of operation with frequency converter.
During the sterilizing phase the alarm for “ HIGH CONDENSATE TEMPERATURE” may go on: you
may either exclude it or just switch it off
2.13.2.2 Regulating the flow of cooling water
During operation, the cooling water on/off valve (whether manual or solenoid) should remain open.
An additional manual valve on the outlet of the exchanger has been provided to control the water
flow and obtain sterile condensate at a temperature of 40 to 50 °C. This has the extra advantage of
helping reduce any waste of softened water.
2.13.2.3 Descaling and washing
The use of water – even when softened - for steam condensation inevitably produces some deposits
of lime in the exchanger.
Whenever a reduced exchange power is noticed - evidenced by an insufficiently cooled condensation
- a descaling of the aseptic system is required.
It is impossible to predict the frequency of this operation, since the formation of lime deposits depends
largely on the hardness of the water available.
For more details on maintenance operations, see Section 4 - MAINTENANCE.
2C001E16C
2.13.3
2.13.3 Partial homogenizing system
GEA Mechanical Equipment Italia S.p.A. homogenizers can have installed, as an option, a partial
homogenizing system, to homogenize only a part of the total flow which is then mixed with the
remaining non homogenized part in a special mixing chamber (see figure 2.13.2).
The homogenized part is normally around 30% of the total capacity of the system.
A typical application is the homogenization of fresh milk where only the fat part (milk cream) coming
directly from the centrifuge is homogenized then mixed downstream of the homogenizing valve to
get fresh milk with standardized fat content.
The system includes, in addition to the homogenizing valve, a special mixing chamber featuring the
recombination of the two portions using the high speed turbulence of the flow, plus a by-pass system
with pneumatic valve and check valve (see figure 2.13.3) to feed the machine properly during the
centrifuge desludging phase and avoid underfeeding at the homogenizer inlet.
A typical scheme of partial homogenizing system is shown in figure 2.13.4.
Figure 2.13.2
2C001E16C
2.13.4
2.13.3.1 How the bypass system works
To make the by-pass circuit work properly, it is necessary to open and close the pneumatic butterfly
valve (position A, figure 2.13.3) with a signal coming from the centrifuge.
This valve must be closed during normal operation, opened during desludging phase and cleaning
of the equipment.
Figure 2.13.3
Follow the instructions below for the correct operation of the system:
• Open the pneumatic butterfly valve few seconds before the desludging phase of the centrifuge;the
single-acting check valve installed prevents the product to be homogenized from flowing through
the by-pass even when the butterfly valve is open
• Close the pneumatic butterfly valve few seconds after the desludging phase of the centrifuge has
been completed;
• Keep downstream the homogenizer a minimum backpressure of 1÷2 bar, to allow the back
flow of the homogenized product into the suction manifold through the by-pass, when opened.
Thus it is necessary to avoid a free discharge into an open vessel or tank without pressure; if
the backpressure generated by the downstream plant is not enough to make the system work
properly, it will be necessary to install a suitable adjustable backpressure valve necessary to
install a suitable adjustable backpressure valve
2C001E16C
2.13.5
WARNING
To ensure the complete and proper cleaning of the by-pass circuit, it is necessary to keep
the pneumatic butterfly valve (pos. A, figure 2.13.3) during the cleaning phase. Moreover, the
backpressure downstream the homogenizer must always be higher than the suction side
pressure.
Fig. 2.13.4
2C001E16C
2.13.6
SECTION 3
OPERATION & USE OF THE MACHINE - INDEX
3.1. Generals
3.2. Checks before start-up
3.3. Start-up procedure
3.3.1 Operator’s position
3.3.2 Control panel
3.3.3 Start-up
3.4. Operation and adjustment
3.4.1 Homogenizing pressure adjustment – 1 stage
3.4.2 Homogenizing pressure adjustment - 2 stages
3.4.3 Remote pneumatic control (optional)
3.5. Machine stop
3.5.1 Emergency stop
3.6. Cleaning
3.7. Safety devices
3.7.1 Overpressure valve
3.7.1.1 Operation
3.7.1.2 Cleaning
3.7.2 Protections on main motor
3.7.3 Emergency push-button
3.7.4 Compression head guard
3.8. Troubleshooting
3.9. Special features of non standard machines
3C001E12C
3.1
3.1. Generals
The GEA Mechanical Equipment Italia S.p.A. Homogenizer consists of a positive-displacement

piston pump provided with automatic valves with suction and delivery spring , connected to a
homogenizing section where the product undergoes the process of high-pressure micronization to
reduce the size of the solid particles suspended in the fluids and achieve homogenous dimensional
distribution.
This process can be applied to a wide range of products with variable viscosity, and it allows to obtain
more stable suspensions through micronization and dissipation of solid particles, depending on the
level of pressure applied.
To find out about the specific configuretion of the machine, model, technical data, accessories and
optionals, see Section 1 - TECHNICAL SPECIFICATIONS.
WARNING
For safety during transport, the machine is supplied WITHOUT LUBRICATION OIL inside the
drive section.
Before carrying out any operation fill with oil as described in Section 4 –MAINTENANCE,
paragraph 4.9 LUBRICATION.
3C001E12C
3.1.1
3.2. Checks before start-up
WARNING
The operating temperature of the machine must be between +5°C and +40°C; maximum
humidity 90%; maximume altitude 1000 m. For operating conditions outside these value
limits a special version must be used.
WARNING
Any operation involving the removal of the machine panelling should be performed with the
MACHINE STOPPED AND ISOLATED from the power line by locking the isolator switch with
a padlock, so that nobody can accidentally give power to the machine.
Since the GEA Mechanical Equipment Italia S.p.A. homogenizer has been designed to reach high
pressures, good practice is to take certain precautions to avoid injuries/damage to persons, the plant
or the machine itself.
These instructions refer to the first startup or after period during which the machine is not in constant
use.
For correct and safe use of the machine we recommend that you carry out the periodical check
required depending on the type of machine use, to ensure the machine is in perfect condition and
prevent possible problems, if any; it is also a good practice to check from time to time that the
machine is being operated in accordance with the prescription of the manual.
Specific indications concerning normal start are given in chapter 3.3.
• Check the connections with utilities and product line. Refer to Section 1 – TECHNICAL
SPECIFICATIONS for their specifications and location.
• Check that the pipes upstream and downstream the machine are clean and free from
scaling or welding residues which may damage the machine seriously.
CAUTION
Do not use the machine to dispose of any impurities found in the piping up- and downstream
the machine
• Check the V-belt drive assembly. For the correct tensioning and alignment of belts refer to Section
4 - MAINTENANCE.
• Verify the level of lubrication oil through the sightglass: this should be covered with oil by 3/4 or
reach the level shown on the special visual indicator. When checking the oil level, the machine
should be stopped, because normally the start-up causes the level to lower as it fills the circuits.
If topping-up is needed, use only the oil types indicated in Section 4 - MAINTENANCE.
• For machines equipped with gear reducer, check the level of lubrication oil through the inspection
hole provided on the reducer. If topping-up is needed, use only the oil type indicated in Section
4 -- MAINTENANCE.
• Make sure that the high pressure flanges, unions and nuts in the compression head are properly
tightened to the values shown in the “Tightening torque” table, Section 4 - MAINTENANCE
• Verify that plungers are tight and that seal packings are in place, if they have been removed
during storage or after standstill of over 3 months.
• Check the direction of rotation of motors as described in Section 2 - GENERALS, chapter 2.8.8
• Make sure that all protection panels are in place and securely fixed.
3C001E12C
3.2.1
CAUTION
Failure to observe the last recommendation here above may - in case of machine starting -
result in a severe risk of injury for anyone standing near moving parts.
• Make sure that the homogenizing pressure controls (figure 3.2.1) (air-operated switch A and
reducer B) are either completely loosened or on the OFF position, and that any manual controls
are fully loosened (fig.3.2.2).
• Verify that all safety and protection devices are in perfect operating condition.
• Make sure that any valves and parts of the system downstream the homogenizer are open to
prevent overpressure in pipes when the homogenizer is started.
FIGURE 3.2.1
FIGURE 3.2.2
3C001E12C
3.2.2
3.3. Start-up procedure
3.3.1 Operator’s position
To ensure the safe use of the machine during start-up and adjustment operations, we recommend
that the operator should stand as indicated in figure 3.3.1.
The control panel - configurated according to the Customer’s requirements - is on the left hand side
of the machine front; an EMERGENCY STOP PUSH-BUTTON is always fitted on each machine.
ATTENTION
Adequate free space must be provided in front of the machine under any circumstances in
order to allow immediate access to the emergency push-button and any start/stop or setting
devices.
FIGURE 3.3.1
3C001E12C
3.3.1
3.3.2 Control panel
The control panel is located on the front left side of the machine (in the Ariete version with paneling).
There is a single panel for all the different languages which shows the symbols and instruments used
to control the machine (see fig. 3.3.2):
• Emergency Stop push-button to halt the machine instantly in case of emergency
• On/Off push-button (indicated by the symbols I/O); general alarm light (with ! symbol). These controls
are available only if the electric board has been supplied by GEA Mechanical Equipment Italia S.p.A..
• Pneumatic controls for adjustment of the homogenizing pressure (1st and 2nd stage) consisting
in an air-operated control to switch pressure ON and OFF and a pneumatic regulator to increase
or reduce pressure (shown on a measuring scale).
• Pressure gauges for controlling pressure of air sent to the pneumatic head in order to reach
homogenizing pressure.
• Pressure gauge for controlling pressure of drive lubrication oil, identified by a relevant symbol.
FIGURE 3.3.2
3C001E12C
3.3.2
3.3.3 Start-up
WARNING
The lubrication oil indicated in the specifications is suitable for operating temperatures
between +5°C ed i +40°C: DO NOT START the machine if ambient temperature is lower than
+5°C to avoid damage to the lubrication system.
Check with GEA Mechanical Equipment Italia S.p.A. Customer Service for the type of lubricant
suitable for the specific local conditions.
ATTENTION
If ambient temperature is lower than +5°C, do not start the machine before checking the
conditions of the plunger water lubrication system and any water heat exchanger.
Once all preliminary checks have been completed, the machine can be started following the
procedure below.
• Open all on/off valves on utility lines (water, air, steam) and regulate the flow rates if necessary)
ATTENTION
The machine must NEVER be started without water for plunger lubrication, otherwise serious
damage could be caused to the seal packings and plungers; with ceramic plungers, this
incorrect procedure may cause plungers failure because of thermal shock. For further details
on thermal shock problems with ceramic plungers see Section 4 - MAINTENANCE.
WARNING
An excess of cooling water can lead to flooding of the sump or excessive water splashing
on guiding pistons, with the risk of water going into the drive section. Then check the flow of
water and regulate it if needed according to the flow rate per piston indicated in TT-0141 in
Section 1 - TECHNICAL SPECIFICATIONS. The lubrication circuit should be regularly drained
to drain out any water that might have gone inside the oil.
• Feed the machine with product at the required flow rate and pressures as indicated in Section
1 – TECHNICAL SPECIFICATIONS.
WARNING
Feeding pressures lower than the limits given will cause CAVITATION in the machine,
recognized by the typical noise produced by the head, which will seriously damage the
whole machine. GEA Mechanical Equipment Italia S.p.A. shall not be libale for breakages,
malfunctions or damage to the machine caused by CAVITATION even if this occurs during
the 12 month guarantee period.
3C001E12C
3.3.3
• Give power using the main switch on the electric power board.
• Press the start push-button. In case the control board has been supplied by
GEA Mechanical Equipment Italia S.p.A., this operation allows to start the machine according to
the correct sequence, depending on the type of machine and optionals provided:
- opening of any utility solenoid valve (optional)
- start of the oil motor-driven pump (if this type has been provided)
- start of electric fans (if provided)
- start of main motor
In case the control board is supplied by the Customer, the correct operating sequence is provided
(see Section 1 – TECHNICAL SPECIFICATIONS), and should be observed strictly.
To identify the machine configuration refer to Section 1 – TECHNICAL SPECIFICATIONS.
3C001E12C
3.3.4
3.4. Operation and adjustment
Once the machine has been started, before increasing the homogenizing pressure, check that the
machine itself is operating normally, with a particular attention paid to the feed pressure, establishing
it is stable and within limits as prescribed in Section 1 – TECHNICAL SPECIFICATIONS.
Then it is possible to operate the control devices in order to increase the homogenizing pressure up
to the desired process value.
If your machine is equipped with a second stage homogenizing valve, refer to paragraph 3.4.2.
3.4.1 Homogenizing pressure adjustment – 1 stage
This type of adjustment, through an air-operated cylinder, controls the position of the homogenizing
valve to establish the homogenizing pressure.
On the machine front panel (see figure 3.4.1) it is located a pneumatic switch (A) and a pressure
regulator (B).
Adjustment operations consist of:
• make sure that pressure reducer (B) is fully backed off, counterclockwise
• set the pneumatic switch to ON position;
• rotate the reducer knob clockwise until the desired homogenizing pressure is obtained, by reading
the reached value on the pressure gauge.
CAUTION
To allow a slow, gradual pressure increase, the pneumatic adjustment system has been
designed to ensure a certain inertia.
Operate the pressure regulator slowly while checking the actual homogenizing pressure
increase until the operating value has been reached.
WARNING
check the increase of air pressure on the pneumatic head using the pressure gauge installed
on the panel control; this makes it possible to have a slow increase of homogenizing pressure.
It is also possible to use the air pressure gauge to refer to if the head pressure gauge is not
working correctly.
Once the homogenizing pressure has been set to the desired value, lock the reducer knob (B) by
pressing it.
If the set pressure is the one used normally during production, the homogenizing pressure can
be applied or released by operating ONLY the pneumatic selector (A), with the reducer left on the
adjustment position.
3C001E12C
3.4.1
CAUTION
this procedure is allowed ONLY for machines with operating pressure up to 250 bar, to prevent
overstressing the machine and avoid too rapid an increase of pressure as this could cause
the safety valve to open.
2
C
1
A
FIGURE 3.4.1
3C001E12C
3.4.2
3.4.2 Homogenizing pressure adjustment - 2 stages
To adjust the pressure, follow the same steps as for the single-stage machine.
In order to adjust the pressure, please read carefully what is written in paragraph 3.4.1, and in
specific all warnings.
The pressure to be applied by the second stage varies from about 1/10 to 1/5 of the maximum
homogenizing pressure, according to the product handled.
WARNING
The intended homogenizing pressure value must be set FIRST on the second stage, THEN on
the first stage to reach the total desired pressure.
A different operating sequence may result in SERIOUS RISK because the machine may
inadvertently and suddenly reach higher pressure values than those for which the machine
is designed.
Adjustment operations consist of (see figure 3.4.1):

• make sure the pneumatic regulator ( B , D ) is completely backed off counterclockwise
• set the 2nd stage pneumatic switch (C) to ON position;
• rotate the 2nd stage reducer knob (D) until the desired homogenizing pressure is obtained, by
reading the reached value on the pressure gauge.
• set the 1st stage pneumatic switch (A) to ON position;
• rotate the 1st stage reducer knob (B) until the desired homogenizing pressure is obtained, by
reading the reached value on the pressure gauge.
WARNING
check the air pressure increase on the pneumatic adjuster using the air pressure gauge
located on the control panel; this allows a slow rise of the pressure. It is also possible to use
this air gauge as a reference for the homogenizing pressure in case the main gauge on the
compression block is not working properly as a temporary solution to be able to work with
the machine.
Once the homogenizing pressure has been set to the desired value, block the reducer knob (B and
D) by pressing it.
If the set pressure is the one used normally during production, the homogenizing pressure can be
applied or released by operating ONLY the pneumatic selector (A and C), with the reducer left on the
adjustment position
WARNING
To allow a slow, gradual pressure increase, the pneumatic adjustment system has been
designed to ensure a certain inertia.
Operate the pressure regulator slowly while checking the actual homogenizing pressure
increase until the operating value has been reached.
3C001E12C
3.4.3
WARNING
To release homogenizing pressure in a two-stage system you need to reverse the procedure
used to give pressure.
Therefore first release pressure from the 1st stage and then from the 2nd stage.
3.4.3 Remote pneumatic control (optional)
The pneumatic control for adjustment of homogenizing pressure can be designed as a remote
system using a proportional solenoid valve actuated by a 4÷20 mA signal; the type of system used
depends on the configuration selected by the Customer.
The method for adjusting homogenizing pressure is the same as the one described for standard
pneumatic systems in paragraphs 3.4.1 and 3.4.2.
The supervision and control system (installed by the Customer) must send an electric regulation
signal to the proportional valves, with suitable ramp time and graduality.
CAUTION
Even with remote control, if the system has two stage the intended pressure value should be
set FIRST on the second stage, THEN on the first stage to reach the total desired pressure.
A different operative sequence may result in SERIOUS RISK because the machine may
inadvertently reach higher pressure values than those designed for the machine.
It is important to send the signal gradually over approximately 30 seconds/1 minute to avoid a
sudden increase of homogenizing pressure which could cause the overpressure valve located on
the compression head to open.
The remote control system via proportional solenoid valve uses also an ON/OFF solenoid valve
for switching pressure on and off; this can be installed as an optional even with the manual control
system instead of the pneumatic switch (see paragraphs 3.4.1 e 3.4.2).
Another optional available is the automatic pressure control system, actuated by a regulation loop
which can also mount, as an optional, a pressure gauge with 4÷20 mA analog outpu. Using this
system it is possible to set an operating pressure value which will be kept constant even if the
operating conditions of the machine or of the product change (e.g. variations in flow rate.
Fpr further information about operating and control features please contact
Machines fitted with remote system for control of the homogenizing pressure can also be equipped,
upon request by the Customer, with local repetition of remote controls for operation during servicing.
The use of the local system is described in paragraphs 3.4.1 and 3.4.2.
3C001E12C
3.4.4
3.5. Machine stop
To stop the machine, follow these steps:

• release the homogenizing pressure by operating either the pneumatic switch to the OFF position,
or the remote control electric valve (or proportional valve) via an appropriate electric signal;
• press the stop push-button (if available on the machine’s control panel) or give a
stop signal via the control system. For machines with electric board supplied by
GEA Mechanical Equipment Italia S.p.A. this operation makes it possible to stop any auxiliary
electric motors and the main motor by following the correct sequence given in Section 1 -
TECHNICAL SPECIFICATIONS for Customers who wish to make their own board if it has not
been supplied by GEA Mechanical Equipment Italia S.p.A.;
• cut off power using the main switch.
3.5.1 Emergency stop
In case of dangerous situations or serious machine failure, the operation can be immediately halted
by pressing the emergency push-button located on the front panel (figure 3.5.1)
After you have done that, release pressure following the procedure described before.
WARNING
Before resuming the machine operation, elimitate the condition which led to the emergency
stop.
WARNING
By resetting the emergency push-button to its normal status, the machine is not started
automatically, but it is enabled to start operating through the normal startup procedure.
FIGURE 3.5.1
3C001E12C
3.5.1
3.6. Cleaning
A thouroug of the machine will maintain the sanitary or aseptic conditions as necessary to avoid
harmful deterioration or contamination of the product handled.
When designing the machine, special care has been given to the parts in contact with the product to
make them easily cleanable (C.I.P.) and to avoid recesses where the product may stagnate.
However, the following recommendations should be followed to ensure hygiene:
• to avoid the formation of a product film on the inner surfaces and product deposit, the machine
should be cleaned IMMEDIATELY after production. Do not allow the product to rest inside the
machine, and do not let the empty machine stand still without rinsing it;
• make sure that any residue of chemical solution used for cleaning is completely removed by
rinsing the machine thoroughly;
• if the cleaning solutions involve the use of concentrated products or powders, first prepare the
solutions separately in order to avoid any undissolved clods or solid particles.

Cleaning should be performed in a closed cycle (C.I.P.) while the machine is running at homogenizing
pressure equal to zero (for homogenizers).
This allows avoiding energy waste and damage to the homogenizing valve.
WARNING
WARNING
For the machines with variable or double capacity, the cleaning should be performed at the
maximum speed admitted, however not exceeding the maximum operating capacity by more
than 20% (see Section 1 – TECHNICAL SPECIFICATIONS).
WARNING
The products used for cleaning and rinsing of the equipment should contain only the
substances specified in Table 3.6.A.
The presence of CHLORINE and IODINE ions - including simple traces - is very harmful to
the materials used in the construction of the machine, as it may lead to stress corrosion
phenomena which may cause the compression block failure in a short time and unpredictably.
3C001E12C
3.6.1
P R O D UCT max concentr. (%) max temp. (°C)
Caustic Soda (NaOH) 3 90

Nitric Acid (HNO3) 1 70
Phosphoric Acid (H3PO4) 3 85
Hot Water - 90
Hot Pressurized Water / Steam - 140
TABLE 3.6.A
CAUTION
Dispose of the cleaning solution and washing fluids as prescribed by the laws in force locally.
3C001E12C
3.6.2
3.7. Safety devices
GEA Mechanical Equipment Italia S.p.A. machines are provided with safety devices to prevent
reaching critical conditions which may cause sudden breakage of the machine and hazards for the
personnel.
In addition the machines are designed with ample safety margins, in consideration of high pressures
which may be reached as a result of improper operations by the user or failures of the line in which
the machine has been included.
The following safety devices have been incorporated: overpressure valve on the compression head,
electric protections on the main motor (if the machine includes a control board), an emergency push-
button and a guard to protect the head, as described here below.
The pressure relief valve has been designed by GEA Mechanical Equipment Italia S.p.A. to protect
the machine from the possibility of overpressure which might be producted inside the compression
head as a consequence of the pumping action of the machine.
CAUTION
The safety valve is used to protect the machine; piping downstream the machine can be
protected only if a valve is fitted on the line.
ATTENTION
the valve protects only the pressurized chamber on which it is installed.
It features the following advantages:

• reduced maintenance
• designed to “3-A” Standards, suitable for C.I.P.
• it closes automatically in case the overpressure is released to allow the immediate resuming of
production
• accurate calibration and repeatable actuation
3C001E12C
3.7.1
3.7.1.1 Operation
The valve consists of a ball maintained in place in its seat by a spring, which allows it to open when
the calibration set point is exceeded.
The spring loading should not be changed as this would modify the valve opening value and cause the
immediate forfeiture of the safety conditions established by GEA Mechanical Equipment Italia S.p.A.
and the guarantee. Therefore a seal has been applied to the spring load adjustment nut.
In the event the calibration setting is exceeded, the valve opens automatically and lets the product
flow out of the discharge pipe; it closes again when pressure reduces below the opening value. This
can be achieved by adjusting the pressure regulating device until the valve is closing, or reducing
the pump speed in case of high pressure pumps.
Once the valve has closed again, normal operating pressure can be re-established, provided the
machine has not been damaged and the cause of overpressure has been addressed.
ATTENTION
The discharge pipe must ALWAYS be directed downwards to avoid harming the operator; the
Customer shall be responsible to install a funnel to collect the outcoming product and carry
it to the drainage system
ATTENTION
Dispose of any waste fluids as prescribed by the laws in force locally.
ATTENTION
the valve seat of the overpressure relief valve is damaged to some extent each time the valve
blows. This will lower the pressure setpoint of the safety valve. Therefore it is necessary to
replace seat and ball to recover the original setpoint conditions.
3.7.1.2 Cleaning
The part in contact with the product is normally cleaned during the machine washing (C.I.P.).
CAUTION
it is ALWAYS necessary to disassemble the valve from the compression head and clean it
manually, especially the valve seat and the discharge pipe, after any overpressure relief valve
discharge.
For disassembling and maintenance, please refer to Section 4 - MAINTENANCE.
CAUTION
Do not disassemble the valve body and do not remove the plastic cap. Changes to the safety
valve setting are not allowed and shall invalidate the guarantee and affect protection of the
machine, of its components and of the operators, unless a written authorization has been
obtained from GEA Mechanical Equipment Italia S.p.A..
3C001E12C
3.7.2
3.7.2 Protections on main motor
If the machine is supplied by GEA Mechanical Equipment Italia S.p.A. complete with electric power
board, this includes the electric protections suitable for the main motor power and amps, type of
starting device and conditions of operation. These protections consist of magnetic and thermal cutout
switches, quick fuses or automatic switches for short-circuits, automatic switches or the frequency
converter itself for protection against overheating.
For the specific case see Section 1 – TECHNICAL SPECIFICATIONS.
3.7.3 Emergency push-button
On the front panel of the machine there is installed an emergency stop push-button (figure 3.5.1) of
the colour prescribed by the safety standards in force.
This device allows the operator to stop the machine immediately in case of hazardous situations for
the personnel or the machine itself (abnormal operation, unusual noise, risk of failures).
For the stop procedure and relevant notes see paragraph 3.5.
In the event that the machine is supplied complete with the electric power board, the main switch can
be used for emergency stops as well.
WARNING
When positioning the machine and making the connections with the production line, allow
enough space to reach the emergency stop push-button of the machine quickly and without
obstacles.
3.7.4 Compression head guard
The compression head is provided with an additional guard to protect the operator from any projection
of machine parts, from high temperatures possibly reached by the head and from any injury caused
by protruding, sharp parts.
WARNING
The machine should not be used if the guard is not correctly secured in place.
3C001E12C
3.7.3
3.8. Troubleshooting
This chapter lists the most frequent problems which are likely to be encountered during the machine
operation, their possible causes and remedies in order to restore normal working conditions.
If the failure persists, or does not appear among those listed below, our Service Department will be
pleased to give you the advice and means required to achieve the best possible results.
TROUBLE POSSIBLE CAUSE REMEDY
1. The machine does not run • main motor does not start • check the electrical wiring, fuses,
automatic switches
• the drive belts are broken or • replace or tighten the belts

loose
2. There is no product flow • no feed flow or pressure to • feed properly the machine (see Section
the machine inlet 1 – TECHNICAL SPECIFICATIONS)
• feeding piping clogged or • clean properly the pipeline and filters

closed
• bypass valve (if any) opened • close the bypass valve
3. Reduced flow rate • not enough feeding • feed properly the machine
• not correct operation (wear) • clean or remove particles between

of suction/delivery valves valve and seat (see Section 4 -
MAINTENANCE)
• verify the wear conditions of the
seating surface of the valves and if
needed replace
• slipping belts • provide correct belts tension

(Section 4 - MAINTENANCE)
• low main motor speed • verify the correct motor speed (Section
1 – TECHNICAL SPECIFICATIONS)
• leakage on plunger packings • replace

• air into the product • eliminate air
3C001E12C
3.8.1
3. Reduced flow rate • broken valve springs • replace

4. Noisy compression head • broken springs • replace

• not enough or too high • feed properly the machine

feeding pressure
• worn out pumping valves • replace

• pumping valves not working • verify the valve cleaning and wear
properly
• air into the product • eliminate air
5. Noisy drive end • wear of bearings • check, lubricate/grease and eventually

replace the bearings
• loose plungers • tighten

• not enough feeding pressure • feed properly the machine
6. Noisy belt drive • slipping belts • provide correct belts tension (Section
4 - MAINTENANCE)
7.Vibrations of the machine • the machine is not properly • check the machine level adjusting the
supported by all feet feet height
• not enough feeding pressure • feed properly the machine (see Section
1 – TECHNICAL SPECIFICATIONS)
• pulsations at suction and / or • install suitable pulsation

delivery damper (contact
GEA Mechanical Equipment Italia S.p.A.)
8.No cooling water on plungers • valve on water plant closed • open the plant
• water filter clogged • disassemble and clean
3C001E12C
3.8.2
8.No cooling water on plungers • no pressure in the water • check the required water supply
circuit conditions at Section 1–TECHNICAL
SPECIFICATIONS
9. Pulsating delivery pressure • not enough feeding pressure • feed properly the machine
• damaged or worn out • replace (Section 4 - MAINTENANCE)

pumping valves
• pump valves not suitable for • Contact

the product GEA Mechanical Equipment Italia S.p.A.
• valves springs not suitable • Contact

for the product GEA Mechanical Equipment Italia S.p.A.
• Unsteady backpressure • Adjust the backpressure
10.Total lack of homogenizing • Not enough flow • See trouble point 3

pressure
• Damaged homogenizing • Check, clean or replace (Section 4 -
valve MAINTENANCE)
• No air pressure in pneumatic • Check the pneumatic circuit and the air
circuit supply (Section 4 - MAINTENANCE)
• Defective pneumatic • Replace

actuator
11. Homogenizing pressure • Not enough feeding pressure • Feed properly the machine
not reached
• Blocked homogenizing valve • Disassemble and clean (Section 4 –

MAINTENANCE)
• Worn out homogenizing • Replace (Section 4 – MAINTENANCE)

valve
• Faulty pressure gauge • Replace (Section 4 – MAINTENANCE)
• Damaged homogenizing • Replace (Section 4 – MAINTENANCE)

valve shaft
3C001E12C
3.8.3
12.Fluctuating homogenizing • Air or bubbles in the product • Remove air or bubbles

pressure
• Air into the compression • Release pressure, then apply pressure

head again
• Not enough or unsteady • Feed properly the machine

feeding pressure
• Not correct operation of the • Check, clean or replace (Section 4 –

pumping valves MAINTENANCE)
• Not correct operation of • Check the pneumatic plant and

the homogenizing valve dampening device (Section 4 –
dampening device MAINTENANCE)
• Pumping valves not suitable • Contact

for the product GEA Mechanical Equipment Italia S.p.A.
• Unsteady backpressure • Adjust the backpressure
13. Noisy homogenizing valve • Worn out homogenizing • Replace (Section 4 - MAINTENANCE)
valve
• No oil or air pressure into the • Check and restore correct

dampening device operating conditions (Section 4 –
MAINTENANCE)
• Resonance in the plant • Modify the backpressure; install

pulsation damper dowstream; move
away the existing damper; contact
14.Oil level drops quickly • Leakage in the lubricating • Check the plant and look for leakage,
circuit replace gaskets, tighten joints, replace
the oil cooler
15.White foam in the • Water into the oil • Stop the machine for at least 1 hour
lubricating oil and drain water from lowest point
(Section 4 – MAINTENANCE)
3C001E12C
3.8.4
15.White foam in the • Water in the oil because of • Pressure check the oil cooler and
lubricating oil broken oil cooler replace
• Excess of water on the • Adjust the water flow to reduce

plungers splashing and sump flooding
16. Oil overheats and darkens • Machine overload • Eliminate overload
• Faulty oil cooler or lack of • Check the oil cooler and the water flow
cooling water
• Worn out bearings • Contact

17.No oil flow and pressure • Wrong oil pump rotation • Change the direction of rotation of
the oil pump (Section 2 – GENARAL
INFORMATION)
• Failure of the oil pump • Contact

18.Not enough oil pressure • Leakage on the lubricating • Check the oil circuit, replace gaskets
and intervention of pressure circuit and tighten joints
switch
• Low oil level • Restore correct oil level.
• Worn out sliding bearings or • Contact

crankshaft GEA Mechanical Equipment Italia S.p.A.
• Faulty pressure switch • Check the pressure switch

and in case replace; contact
• Leaking oil cooler • Check and replace; contact

19. Main motor • Too high homogenizing • Reduce to nominal value

overload pressure
• Wear on drive end • Check wear and contact

• Too high belts tension • Check belts tension
3C001E12C
3.8.5
19. Excessive absorption of • Faulty main motor • Check main motor; in case replace
the electric motor
20.Oil leakage in the water • Leakage from crossheads • Replace gaskets (Section 4 –
sump seals MAINTENANCE)
• •
• Scratched crosshead • Replace (contact
extensions GEA Mechanical Equipment Italia S.p.A.)
21. Safety relief valve leakage • The safety relief valve seat • Replace the safety relief valve seat
is worn
22. Safety relief valve frequent • Overpressure • Verify machine operation and feeding
openings system
• Cavitation • Verify machine operation and feeding

system
• Loss of safety relief valve • Please contact

calibration GEA Mechanical Equipment Italia S.p.A.
customer service for safety relief valve
re-calibration
23. Safety relief valve sensor • The safety valve inductive • Set the inductive sensor
signals that safety valve is sensor has lost the factory
open, but there is no product setting
discharge
(for machines with NSSLRV-
PO safety relief valve)
24. Safety relief valve sensor • The safety valve inductive • Set the inductive sensor
signals that safety valve is sensor has lost the factory
closed, but there is product setting
discharge
(for machines with NSSLRV- • The inductive sensor has • Replace the inductive sensor
PO safety relief valve) broken
• The union cable is damaged • Replace the cable
3C001E12C
3.8.6
3.9. Special features of non standard machines
Blank page
3C090E3C
3.9.1
Section 4
Maintenance - index
4.1 General maintenance information

4.1.1 General information
4.1.2 Instructions for correct maintenance
4.1.3 Safety, precautions and maintenance procedures
4.2 Ordinary maintenance
4.3. Tighening bolts and studs
4.4. Compression head
4.5. Homogenizing group
4.6. Overpressure valve and pressure gauge
4.7. Transmission
4.8. Power end - crankcase
4.9. Lubrication
4.10. Pneumatic plant
4.11. Aseptic plant
4C00SE7C
4.1
4.1. General information
4.1.1 General information’
4.1.1.1 Definition of personnel duties.
Maintenance operations must be performed in accordance with the following areas of competence.
The manufacturer shall not be liable if the following indications are not complied with.
Duties of person in charge of operating the machine (operator)
An operator is authorized only to the use of controls and instruments in the panel and on the control
board.
Any other procedure on mechanical or electrical equipment is prohibited.
In particular, operators are not allowed to:
remove mechanical components and access internal parts
open electrical boards and access the equipment installed inside them
remove the safety devices protecting live parts on the machine, such as for example: terminal strip
covers of junction boxes, etc.
All these operations must be performed by maintenance technicians and electricians.
Duties of electrician and maintenance technician
This is a suitably trained and experience technician in charge of machine maintenance and eletrical
system maintenance. He is responsible for keeping the key that enables access to live parts.
The maintenance technician must reset all safety devices and guards and will also perform machine
repair jobs within the limits and with the methods indicated by the manual.
ATTENTION
Any new components replacing faulty parts must have the same technical characteristics
and performance; in case of safety components, they must be certified and belong to the
same class as the original being replaced.
The new components must be set to the same values that had been used for the components
replaced.
Any changes applied to the machine and all complex repair jobs must previously be agreed with our
TECHNICAL SUPPORT SERVICE.
The manufacturer shall not be liable if the following indications are not complied with.
4C010E7C
4.1.1
4.1.2 Instructions for correct maintenance
4.1.2.1 For adequate maintenance operations:
Use only original spare parts and tools suited for the purpose and in good condition.
Respect the frequency intervals indicated in the maintenance manual for preventive and periodic
maintenance; the interval (indicated as time or work cycles) between maintenance procedures is
intended as the maximum and should not be exceeded. This interval can be shortened if needed .
Corrective preventive maintenance is based on constant attention and continuous monitoring of the
machine. Promptly check any anomalies such as excessive noise, overheating, leaking of fluids, etc.
and apply the required remedy.
If in doubt, contact the manufacturer.
To perform maintenance operations correctly, please refer to the attached documents, such as:
1) – Functional diagrams for electrical equipment and auxiliary equipment, with indications on power
connections.
2) – List of possible failures and solutions suggested (chapter 8 in this manual).
4.1.2.2 Maintenance plan
From a construction point of view, the operations regard mechanical and electrical parts.
For practical reasons, the operations are grouped according to time criteria and complexity. Therefore
every operation or group of operations may deal with mechanical or electrical aspects.
Ordinary maintenance is divided into two categories:

• scheduled ordinary (or preventive) maintenance.
• ordinary maintenance in response to a specific condition.
Scheduled ordinary maintenance (also referred to as periodic or preventive) includes inspections,

checks and operations designed to prevent shutdowns and failure through a systematic control
program:
• machine lubrication
• condition of wear parts
Ordinary maintenance in response to a specific condition regards machine components that are
not subject to periodic checks and whose wear cannot be estimated beforehand. These need to be
checked or replaced when their condition requires it.
4C010E7C
4.1.2
ATTENTION
All of the actions must be performed by qualified technicians after setting the machine to
maintenance mode, i.e. MACHINE OFF and master switch PADLOCKED in the OPEN POSITION,
for the safety of personnel.
ATTENTION
Do not allow machine use, access to inside parts and maintenance by members of personnel
who are not familiar with the indications contained in this manual and ensure that the manual
is available to all operators.
ATTENTION
The only operations allowed are those described in these INSTRUCTIONS; for any extraordinary
operations please contact our Technical Support Service.
The following paragraphs list the procedures, divided by category.

These are followed by the descriptions and illustrations of the procedures, with safety precautions.
4C010E7C
4.1.3
4.1.3 Safety, precautions and maintenance procedures
4.1.3.1 General safety information
Machine and operator safety depends also on the correct and regular performance of maintenance
procedures in accordance with the indications provided herein.
Ordinary and extraordinary maintenance procedures must be performed exclusively by qualified

technical staff in accordance with the criteria indicated in the introduction of this instruction manual.
ATTENTION
- RISK OF ELECTROCUTION by direct contact with switchboard and power supply cable. It
is prohibited to open the switchboard when the system is powered;
- AFTER EVERY MAINTENANCE PROCEDURE FIT BACK AND RESET ALL GUARDS AND
PROTECTION DEVICES that have been removed or switched off during the procedure.
ATTENTION
All maintenance procedures must be carried out in accordance with the instructions given in
4.1.3.3 “setting machine to maintenance mode”.
4C010E7C
4.1.4
4.1.3.2 Safety symbols
The following symbols indicate the precautions that MUST be complied with during maintenance
operations.
Prohibitions
No access to unauthorized
No naked flames
persons
Do not lubricate, repair or adjust while Do not remove safety

machine on devices
Do not use water to put

No smoking
fires out
Types of inspections and procedures
Visual inspection. Lubrication with oil.
Hearing inspection. Lubrication with grease.
Procedure with tools.
Personal protection devices
Protective helmet must be worn

Overalls must be worn.
at all times.
Protective gloves must be worn. Mufflers must be worn.
Protective glasses must be Protective mask must

worn. be used.
Safety boots must be worn.
4C010E7C
4.1.5
4.1.3.3 Setting machine for maintenance
Before performing any maintenance procedure, the machine must be disconnected from the power
supply line using the necessary precautions to prevent accidental starting and the risk of electrocution.
Before proceeding with any operation on the machine, the electrician and maintenance technician
must wear adequate personal protection devices.
ATTENTION
If the switchboard is not supplied by GEA Mechanical Equipment Italia S.p.A., refer to the
manufacturer’s instructions for information on this procedure.
Procedure for setting machine to maintenance mode
A qualified technician is in charge of this procedure which includes the following steps:
• The master switch on the electrical cabinet must be set to “0” (OPEN), and blocked in that
position with a padlock.
• The padlock key is removed and kept by the maintenance technician in charge until the procedure
has been completed.
Fig. 4.1.3.3.a
4C010E7C
4.1.6
• The emergency pushbutton located in the control pushbutton panelm must be pressed as shown
in the figure.

Fig. 4.1.3.3.b
• If the type of maintenance needed requires the side panels to be removed, use the special key
provided. If the panels are large or very heavy, two people are needed to remove the panels.
ATTENTION
Do not restart the machine before closing the panels and checking that closing and locking
parts are efficient.
4C010E7C
4.1.7
4.2. Ordinary maintenance operations
Here below are the tables showing the periodical maintenance required by the machine to operate
efficiently and safely.
Values shown refer to a normal use of the machine; heavy-duty conditions or particularly abrasive/
aggressive products may reduce sensibly the life of some parts, which should therefore be checked
more frequently.
In case of machine malfunction or abnormal noise, we suggest you try to identify the components
which seem to produce the noise and check whether they have been correctly assembled and
tightened or whether they might be worn and in need of replacement.
In particular, machines operatine on very high pressure (over 600 bar) require frequent servicing
to replace gaskets, plunger seals, delivery valves, valve seats and springs, homogenizing valves,
depending on the type of product used – see the Table of Periodical Maintenance for high pressure
machines – in addition to regular checks.
All the operations listed here below are described with detailed procedures in the following paragraphs.
Execute carefully all the checks prescribed in these tables and note scrupulously the DATE,
MACHINE HOURS, OPERATOR in the Tables for the checks to be performed every 1500 HOURS
- 6 MONTHS and every 3000 HOURS - 12 NONTHS. In this way the machine will be maintained
in the best conditions of running and safety, and a track will be kept of the maintenance operations
actually completed.
WARNING
The Periodical Maintenance tables shown below refer to normal operating conditions and
in any case provide merely an indication as to the average life of a component and not a
guarantee of minimum component life.
Special conditions such as high operating pressure, high temperature, steam sterilization
and frequent washing, incorrect operating procedures, can substantially affect the life of the
machine and of its components and therefore the intervals suggested for maintenance of
compression head components may vary significantly.
As additional tool for ordinary maintenance of the machine, please refer to the form “checklist
for machine inspection” at Section 5 – SPARE PARTS LIST.
4C010E7C
4.2.1
Periodical maintenance table – generic for all machines
When Action required Machine hrs
• Check belt tensioning 200

After first start-up • replace lubrication oil 500
• replace lubrication filter 500
• check oil level and top up and if needed

Every day • visual check for leaks in seals and gaskets
• visual check of plunger gaskets

• drain condensate from lubrication system
• check tightening of nuts and plungers
Once a week - 40 • check drive
hrs • check belt tensioning
• check tightening of drive elements and
reducer support
When
(hrs) Action required Mach. hrs Operator Date
• change lubrication oil

• clean/replace filters (lubrication
system, pneumatic system, water
system)
• check drive belt wear, tensioning and
1500 and if required replace
every • check wear of plungers and if
1500 hrs required replace
• check pressurization of pneumatic
system and oil level
• check oil level in gear reducer
• check / replace springs and pumping

3000 and
valves
every
• check / replace homogenizing valve
3000 hrs
• replace lubrication oil in gear reducer

every (mineral oil)
5000 hrs
4C010E7C
4.2.2
When

system)
4500 if required replace
• check wear of plungers and if
required replace

6000 valves

system)
required replace

9000 valves

system)
required replace

12000 valves
4C010E7C
4.2.3
When

system)
required replace

15000 valves
Periodical maintenance table for high-pressure machines (over 600 bar)
When Action required Machine hrs
• visual check for leaks in packings and head

gaskets
Every 50 hrs
• check tightening of nuts in all high-pressure
head elements
• check packings and head gaskets and if

required replace
• check pumping valve seats and if required
replace
Every 100 hrs • check ball valves and if required replace
• check springs and if required replace
• check homogenizing and if required replace
• check oil-air operated system for vibration

damping in homogenizing valve
• check cooling water piping, check water flow
Every 200 hrs • tighten nuts in high-pressure head using
dynamometric wrench
4C010E7C
4.2.4
ORDINARY MAINTENANCE LOG
When Mach.
(hrs) Action required hrs Operator Date
4C010E7C
4.2.5
4.3. Tightening nuts and studs
All the studs used in the compression head are subject to vibrating stress so, in addition to being
made of special, highly resistant material with an accurate processing cycle, they require specific
tightening in accordance with the values shown in Table 4.3.1.
It is also necessary to frequently check screwn and nuts to make sure that they do not become loose.
GEA Mechanical Equipment Italia S.p.A. supplies a Maintenance box with the wrenches needed for
the nuts fitted on their machines; we suggest you use a dynamometric wrench (not included) to
check tightening torques as specified in the table below.
Stud size Tightening torque (n*m) Tightening torque (lb.*Ft.)
M8 8 ÷10 6 ÷8
M 10 15 ÷ 20 11 ÷ 15
M 12 25 ÷ 30 19 ÷22
M 16 60 ÷ 70 44 ÷52
M 20 120 ÷ 140 89 ÷104
M 24 210 ÷ 230 155 ÷ 170
M24x2 235 ÷ 260 174 ÷ 192
M 27 310 ÷ 340 229 ÷251
M27x2 350 ÷ 390 258 ÷ 288
M 30 410 ÷ 450 304 ÷ 332
M 33 560 ÷ 600 413 ÷ 445
M33x2 635 ÷ 680 469 ÷ 502
M39 880 ÷ 960 650 ÷709
Table 4.3.1
4C010E7C
4.3.1
ATTENTION
The head maintenance operations require disassembling the parts which are secured by
studs and nuts.
When tightening them, refer to the torque values shown in Table 4.3.1 to avoid imposing
abnormal stress and undermining their strentgh.
WARNING
For safety reasons it is strictly forbidden to replace studs in the high-pressure head with non-
original spare parts, which might not be able to stand the stress applied resulting in severe
risk of injury!
4C010E7C
4.3.2
4.4. Compression head (monoblock)
ATTENTION
The compression head maintenance operations require to remove the head guard, unscrewing
the side screws.
The machine should not be used if the guard is not correctly secured in place.
ATTENTION
The head maintenance operations require disassembling the parts which are secured by stud
bolts and nuts.
When tightening them, refer to the torque values shown in Table 4.3.1 to avoid imposing
abnormal or excessive stress and undermining their strentgh.
Before proceeding with the description of maintenance operations on the compression head, it is
necessary to remind that the high pressure sealing between the components of the high pressure
area (main block, flanges) are made using O-Rings of various rubber materials, sometimes with
additional antiextrusion rings. These gaskets are suitable for food contact and can resist to the
temperatures which can be reached with the machine during normal operation or cleaning.
As an option, it is possible to have installed FDA certified and approved material gaskets.
As a good maintenance practice, we suggest to replace the gaskets every time the parts of the
machine are disassembled for maintenance or inspection, in addition to what is required because of
leaking or damaged gaskets.
Gaskets should be greased with food-grade vaseline and assembled with non-sharp tools which
might damage them; in any case remember that forced or incorrect assembling might undermine the
gasket life and effectiveness.
To identify and place the gaskets correctly, refer to the drawings provided herein for the disassembling
of compression head and its components, and in specific at Section 5 – SPARE PARTS CATALOG,
where are available the drawings and the list of parts effectively installed on the machine.
4.4.1 Pumping plungers
Plungers are subject to normal wear and tear; however, wear may be accelerated by certain
conditions of use, such as:
• not enough or no lubrication water;
• washing with unsuitable solutions;
• misalignment caused by fixing with guide piston become loose.
4C041E5C
4.4.1
Pumping plungers are available in different materials, which are suggested by
GEA Mechanical Equipment Italia S.p.A. according to the experience on different products and
various applications.
The available materials are:
• stainless steel with hard chrome coating
• stainless steel with tungsten carbide detonated coating
• solid ceramic.
Chrome-coated plungers and tungsten carbide detonated coated plungers should be replaced when
scratched or flaking on the surface because, in these conditions, they can not guarantee an effective
seal of packings and cause a short lifetime of the same.
Normally, ceramic plungers are not subject to surface wear, however they need replacement in case
of breakage due to a thermal shock, mechanical shock or misalignment.
ATTENTION
if the machine is equipped with ceramic plungers, it it necessary to follow special precautions
of use in order to avoid damage because of thermal shock. Please find listed below some
specific information on ceramic plungers handling:
• thermal shock is due to quick change in temperature, for the fluid in contact with the
plunger, above approx 70 °C
• it is absolutely necessary to avoid to run the plungers dry, without water lubrication, even
for a limited period of time; because of friction, the local temperature raise on the plunger
surface may cause breakage for thermal shock when cold water is opened at a later stage
• it is necessary to avoid any quick change from hot to cold liquid inside the compression
block and product path, where the plunger moves back and forward
• the cooling water temperature must be in the specified range (+10÷+25 °C or +40÷+60 °C
in case of aseptic version). See Section 1 – TECHNICAL SPECIFICATIONS
• the temperature gradient must be not more than 70 °C in 15 minutes (approx 5 °C per
minute).
ATTENTION
check periodically and regularly that the plungers are properly tightened, either with direct
thread connection or with clamp, in order to avoid they can get loos or out of the clamp
during the operation of the machine.
The use of unsuitable cleaning agents or wrong concentrations and temperatures may cause
corrosion of coatings on plungers, therefore causing a shorter packings lifetime than usual.
The damage pof plungers’ coating because of corrosion is not covered by any warranty from
4C041E5C
4.4.2
4.4.1.1 Disassembling
ATTENTION
disassembling of plungers may cause the damage of the gaskets (plungers packings):
check the gaskets and in case replace before reassembling plungers and compression head
components (see paragraph 4.4.2). Before proceeding with disassembling of the parts, check
availability of spare parts.
Disassembling procedure may slightly differ according to the type an material of the plungers,
according to the different fixing system.
Pumping plungers can be:
FIGURE 4.4.1
• connected directly with thread to the crosshead extension (standard configuration for stainless
steel chrome coated plungers): in this case loose the plunger using appropriate wrench, on the
end part of the plunger (see figure 4.4.1)
• connected with clamp (B) (standard configuration for solid ceramic or stainless steel tungsten
carbide detonated plungers): in this case (see figure 4.4.2) loose the clamp screws (A) and move
the plunger away from the crosshead extension (C). To easily open the clamp, it is possible to
use one of the screws in the center hole to enlarge the clamp opening.
4C041E5C
4.4.3
FIGURE 4.4.2
Proceed disassembling the front flanges (see figure 4.4.3):

• loose nuts (A) and remove the front flanges (B); gasket (C) usually remains in position on the
flange
• remove the spacer cage (D);
• remove the valve stop cover (H) if this prevents from easy extraction of the plunger
4C041E5C
4.4.4
FIGURE 4.4.3
To remove the plungers, use the extracting tool supplied in the maintenance box (figure 4.4.4): if
present, use the special groove in the front end of the plunger, otherwise clamp the plunger on its
outside end and pull it out (figure 4.4.5).
4C041E5C
4.4.5
FIGURE 4.4.4
FIGURE 4.4.5
4C041E5C
4.4.6
4.4.1.2 Assembling
ATTENTION
solid ceramic plungers don’t have a specifica direction of assembly (both faces are the same),
while tungsten carbide detonated plungers may have a specific direction of installation; in
this case the center hole must be placed towards the clamp side (figure 4.4.2, item B) and the
extension (figure 4.4.2, item C), NOT towards the product side.
• Put the plunger inside the block cylinder, and fix it into the standard operating position tightening
the thread on the crosshead extension
• In case of use of clamp system, put the plunger completely flat against the crosshead extension,
and the clamp completely against the change of diameter on the crosshead extension, then
tighten the clamp with proper screws (see figure 4.4.2, pos. A), using a tightening torque of 7÷8
N*m
ATTENTION
During assembly check carefully that plunger and clamp are properly assembled and fixed in
the correct position, and there is not interference durino the reciprocating movement of the
pistons. We suggest to turn by hand the pulley bifore starting the machine in order to verify
the correct alternate movement of the pumping plungers.
• check that the position of the packing is correct (figure 4.4.3, item F)
• place valve cap back on (H), if it has been removed
• insert the spacer (D), press the valve cap (H see. Figure 4.4.9 or 4.4.10) to overcome spring
resistance (a screwdrive can sometimes be needed))
• assemble the flange (B)with the gasket (C)
• tighten the nuts (A) as specified in chapter 4.3, Table 4.3.1
WARNING
the packing spacer (D) can be hard to mount if the valve cap has not been mounted correctly
or if it does not move freely in its seat. Make sure it is not blocked or press it down with a
suitable tool (e.g. curved diagonal pliers) while the spacer is being inserted.
4C041E5C
4.4.7
ATTENTION
tighten the nuts and bolts in cross, according to the shown pattern in figure 4.4.6.
FIGURE 4.4.6
4C041E5C
4.4.8
4.4.2 Plunger seals
The lifetime of these parts is dependent on the following factors:

• conditions of plungers surface;
• process temperature;
• type of product;
• machine underfeeding (not enough feeding pressure, see Section 1 – TECHNICAL
SPECIFICATIONS for reference);
• worn parts (washers, spacers) in contact with the seals.
Some of these factors - such as the peeling off of coatings on plungers and the machine underfeeding
- are likely to lead to an early deterioration of the seals.
Replacement is required when product leakage is noticed in the water sump; however, if the machine
is fed correctly, the processing cycle can be completed without risk of contamination of the product
itself.
For the replacement procedure it is necessary to disassemble the pumping plungers, see paragraph
4.4.1.
To avoid situations where production has to be stopped due to leaking plunger gaskets, we suggest
you schedule preventive replacement on the basis of their expected average lifetime.
WARNING
Before you begin with maintenance and gasket replacement make sure all the necessary
spare parts and tools are available.
To increase the life of packings special anti-extrusion and support rings can be used (figure 4.4.14
items Z, W); these rings are made of high-performance plastic. Normally two rings are used on each
plunger: one (W) is placed before the packing (F) on the side which is pressed against the front of the
machine, and one (Z) is placed immediately after the packing (F), before the bronze packing washer
(G); in some configurations washer (G) is not present.
These rings are also considered wearing parts and should be replaced regularly to maintain perfect
coupling with plunger, preferably when changing the packings or when they are showing signs of
wear in the inner diameter.
Refer to figure 4.4.14 and general drawing in sections 5 – SPARE PARTS CATALOGUE.
4C041E5C
4.4.9
FIGURE 4.4.14
4C041E5C
4.4.10
After having removed the plungers, use the supplied packing extractor to remove the packings from
its place (figure 4.4.3, pos. F) and the packing washer (G), accordino to what shown in figure 4.4.7:
• insert the packing extractor tool (A) into the cylinder
• turn the handle to expand its end
• pull out together the packing washer (D) and packing (C).
C D
FIGURE 4.4.7
WARNING
some special versions use additional anti-extrusion rings in the seal packing. Refer to specific
drawings in Section 5 - SPARE PARTS CATALOGUE or to figure 4.4.14.
4C041E5C
4.4.11
4.4.2.2 Assembling
To install the plunger gaskets (packings) first of all you need to assemble the plungers as described
in paragraph 4.4.1.
After you have done that, follow the steps below and refer to figure 4.4.8:
• put the plunger fully backwards
• insert the packing washer (A)
• insert the packing (B) as a SINGLE PIECE, using greasing or lubricating product (food grade if
required)
• put the packing in place using the provided inserting tool (C) and some hammering with plastic
head hammer
• make sure no air is trapped between the packings rings and take care not to damage the packing
or pull it out of shape during assembly.
A B C
FIGURE 4.4.8
Complete the assembly of the compression head parts as decribed at paragraph 4.4.1.
WARNING
check direction of packing: the tip of the “V” on the rings must point towards the back of the
head (see detail in figure 4.4.7).
4C041E5C
4.4.12
4.4.3 Suction and delivery valves
The good conditions of suction and delivery valves are essential for a trouble-free operation of the
machine; an impaired seal of the valves would cause leakage and product backflow, resulting in
pressure and flow instability.
Generally, the valve assembly consists of a shutter, spring, valve cap and seat.
Depending on the type of product handled, the shutter may vary in design; even though it has
generally a long life, because manufactured with heavy-duty materials, it may need replacement
when then seal surface is cut or dented.
The spring tends to lose gradually the original elasticity and, for this reason, it should be replaced
approximately every 3000 hours of operation, unless broken earlier generally because of the machine
is not fed correctly.
For the replacement procedure of the valve assembly see here below; check in Section 1 –
TECHNICAL SPECIFICATIONS the type of valve installed.
The disassembly procedure requires access to inner parts of the head as required for disassembling
the plungers and packings (paragraphs 4.4.1 e 4.4.2)
First remove the front flanges (figure 4.4.3):

• loosen the nuts (A) and rimove the front flanges (B); the gasket (C) is normally left in position on
the flange
• loosen the nuts (N) and remove the upper flanges (O); the gasket (P) is normally left in position
on the flange
• remove the spacer (D) from the plunger cylinder
• for delivery side valves, from the upper side of the block extract the valve cover (H) with spring
(J) and valve (L), figures 4.4.9 or 4.4.10;
• with suction valves proceed likewise through the boring of the plunger cylinder, which first needs
to be moved back to the inner dead center.
4C041E5C
4.4.13
4.4.3.2 Reassembling
Once replacement has been completed, reassemble the valves using the tools provided:
• insert the valve (L) and the valve cover (H) with spring (J), according to figures 4.4.9 or 4.4.10;
• insert the spacer (D) into the cylinder and reassemble the flanges, then tighten nuts crosswise
as described on chapter 4.3.
FIGURE 4.4.9
4C041E5C
4.4.14
With ball type valves (PVB), see figure 4.4.10, the valve cover is slightly different and provides a
guide for the ball’s movement.
FIGURE 4.4.10
WARNING
when tightening the head nuts observe the tightening torques shown in chapter 4.3, Table
4.3.1; use a torque wrench (not provided).
4C041E5C
4.4.15
4.4.4 Valve seats
Valve seats (figure 4.4.11 pos. H and G) are of removable type, inserted into the compression block;
they are made from a particularly hard material to ensure wear resistance and longer life.
Possible light marking by pricks on seat surface does not affect the valve sealing and functionality.
The lifetime of the seats is normally longer than the one of the valves, and depends on the
characteristics of the product and on the working conditions of the machine.
In case of particularly abrasive products, seats can be refurbished or replaced when necessary;
proceed to replacement following the procedure and using the tools described here below.
WARNING
The tools used for removing the valve seats are NOT included in the maintenance box.
Tightening of the head nuts must be made using the torque values indicated in chapter 4.3,
Table 4.3.1.; use a torque wrench (not supplied).
To remove the seats you need to have the rights tools (these can be supplied by
GEA Mechanical Equipment Italia S.p.A. upon request) to be able to follow the steps described
below:
FIGURE 4.4.11
4C041E5C
4.4.16
• procede with disassembling of valve groups (see paragraph 4.4.3);
• remove the suction manifold
• put the pumping plunger fully backwards (inner dead center)
• remove first the suction valve seat (H), then the delivery side seat (G)
• use a rod made of a soft material, such as bronze or aluminium, to be inserted in the head under
the suction valve; the diameter of the bar must be as large as possible, and to make it fit well
with the seat the support can be made with a conical shape to match the bottom part of the seat
• strike the bar with a hammer until the seat has been removed
If this procedure is not sufficient to extract the valve seats a traction system with a threaded bar can
be used.
To follow this procedure (see figure 4.4.12) it is necessary to have:

• a threaded bar (A) made of high-resistance steel with the maximum diameter allowed by the
bores of the valve seats (H)
• a bronze or aluminium pad (D) positioned under the seat, with the bore for the threaded bar
• nuts (B)with washer (C)
• a pad (E) to be laid against the pressure gauge flange (F) used to provide thickness
• once the threaded rod is properly in tension using suitable torque on the nuts it is possibile to
hammer the lower part of the threaded rod (using a plastic hammer or a piece of wood to avoid
the damage of the thread, to remove the seats
4C041E5C
4.4.17
FIGURE 4.4.12
4C041E5C
4.4.18
4.4.4.2 Assembling
• FIRST install the suction valve seat, THEN the delivery valve seat;
• put the seat (H) in place (see figure 4.4.13);
• using a suitable rod (A), see figure 4.4.13, lock the seat in its position with hammer
• repeat the same procedure for the delivery side valve seat
The definitive blocking of the valve seat in its working position is made durino the operation of the
machine because of the pressare.
Proceed wit reassembling of valve groups as described at paragraph 4.4.3
FIGURE 4.4.13
4C041E5C
4.4.19
4.5. Homogenizing valve
4.5.1 Homogenizing valve
The homogenizing valve consists of 3 parts (figure 4.5.1):

• lower head or passage head (A)
• impact head (B)
• impact ring (C).
The homogenizing effect occurs - at very high speed - during the passage between the exposed
surfaces of the two heads, and is completed by the impact with the external ring.
The high pressure fluid dynamic effects which take place inside the homogenizing valve are extremely
complex; generally speaking it is possible to describe the micronization of the particles dispersed in
the liquid phase as a resulting of combined turbulence, shear, local cavitation and high speed impact
effects.
These three parts, manufactured from very hard material, are normally subject to more or less wear,
depending on the type of product handled; therefore, various effects resulting from wear or damage
can be noticed on their surface:
• radial grooves developing from the internal diameter (fig. 22.14-S1);
• small craters next to the external diameter (fig. 22.14-S2);
• large craters and wear next to the internal diameter (fig. 22.15-S3).
FIGURE 4.5.1
4C051E7C
4.5.1
When the grooves reach the external diameter, the homogenizing efficiency collapses, therefore the
component should be replaced either when the grooves cover nearly 3/4 of the useful surface or
whenever a reduced homogenizing efficiency is noticed.
In some cases, because of extreme wear of the parts, the homogenizing pressure cannot be achieved
anymore, therefore the complete homogenizing valve must be replaced.
Some local cavitation effects may sometimes create some craters or strong wear path on the valve
surface, therefore it is necessary to proceed with replacement of the parts.
As far as the impact ring (figure 4.5.1 pos. C), it has the dual function of completing the homogeneization
by impact and protecting the body of the homogenizing assembly from erosion.
Due to wear, a groove (S4) is produced on its internal surface, and good performance is undermined.
We recommend replacing the ring when the groove is approximately 1 mm deep.
ATTENTION
the impact head and the passage head are manufactured from a material whose hardness is
suitable to withstand the abrasive action of the product handled for a long time.
Whenever wear signs appear that may jeopardize the homogenizing efficiency, working
surfaces can be rectified to remove max 1 mm of material: this can be done either at
GEA Mechanical Equipment Italia S.p.A. or at properly equipped workshops.
ATTENTION
The above mentioned indications are related to normal conditions and are general guidelines
for ordinary and preventive maintenance.
It in necessari to mention that the wear of the components of the homogenizing valve is
something absolutely NORMAL, and depends on the various phenomenons which take place
inside the homogenizing valve. In case the wear of the valve is considered too fast, please
contact GEA Mechanical Equipment Italia S.p.A. for advice and possible alternative solutions.
WARNING
4C051E7C
4.5.2
4.5.2 Homogenizing group
Follow the below listed instructions for the ordinary maintenance of the pneumatic actuated
homogenizing group.
Disassembling
Taking figure 4.5.2 as reference:

• disconnect the line of the pneumatic-hydraulic control of the piston on the front panel of the
machine
ATTENTION
oil dripping may occur when disconnecting the pipes of the pneumatic-hydraulic system:
provide a container to collect such oil and dispose as prescribed by the local regulations.
ATTENTION
the homogenizing assembly block is quite heavy! For all handling operations use both hands
to avoid any accident to the personnel, and use suitable personal safety protections.
• Loose the nuts (B) of the studs of the homogenizing group

• Remove the pneumatic actuator group (D) and the supporting flange (R) which are coupled
through the screws (Q)
• Remove the guide (C) together with the complete impact head (F), eventually using the available
groove
• In case the system is affected by severe vibrations, it is necessari to check also the surface of the
impact head shaft (F), and in case replace the sliding bushings (E) made of self lubricant plastic
compound
• Remove the homogenizing valve block (A) and put it on a suitable workbench
4C051E7C
4.5.3
F R
A F
FIGURE 4.5.2
4C051E7C
4.5.4
FIGURE 4.5.3
• Disassemble from the bottom the valve group parts (see details in picture 4.5.3): passage head
spacer (K), passage head (H) and impact ring (G)
Assembling
ATTENTION
the homogenizing assembly is normally subject to high pressure and temperature conditions
which impose a considerable stress on the seal gaskets.
To ensure a correct operation and avoid product leakage or product contamination, it is
recommended to replace all gaskets every time that the homogenizing group is disassembled.
ATTENTION
to facilitate the gasket assembling, grease them with food-grade Vaseline or similar.
• Put the homogenizing valve chamber (A) on its side and proceed to insert in sequence the impact
ring (G), the passage head (H), the spacer (K) complete with gaskets (L) and (N)
• Put the homogenizing valve chamber on the studs and push it towards the compression head
• Place the gasket (M) on the spacer (K) (or inside the compression block, in case the groove for
the basket is machined into the block and not on the spacer (K)) and push the valve group totally
against the compression head itself.
4C051E7C
4.5.5
Prepare for assembling the impact head (F) and its guide (C) (figure 4.5.4):
• Insert from the top the plastic bushings (E) inside the guide (C) ); this is normally not required if
the bushing are not removed from their position or are not damaged
• Place the gaskets (P) and (O) into their grooves
• Put from the bottom the impact head (F) into the guide (C) being careful not to damage the gasket
(P)
• Check the smooth sliding of the impact head (F) into the guide (C)
Proceed with assembling of the homogenizing group:

• Insert the assembly guide and impact head into the homogenizing chamber (A)
• Assemble the flange (R) together with the pneumatic actuator (D) on the homogenizing chamber
(A)
• Tighten completely the nuts (B) in cross
• Connect the piping of the pneumatic control system.
The above indications are valid for both homogenizing valves, on machines supplied with second
stage homogenizing valve (available as option).
C E
F
P
FIGURE 4.5.4
4C051E7C
4.5.6
4.5.3 Possible configurations for the homogenizing valve
A characteristic of the homogenizing assembly is that homogenizing valves of different sizes can be
installed in the same valve housing. Thanks to this possibility you can have configurations other than
the one shown in figure 4.5.2 and 4.5.3 due to the presence of adaptors and spacers (figure 4.5.5
and 4.5.6).
In this case maintenance requires mounting the passage head (H) and impact ring (G) inside a
housing (S) with the relative O-ring gaskets (T, U).
It is important to always refer to the specific detail drawings in Section 5 – SPARE PARTS CATALOGUE.
FIGURE 4.5.5
4C051E7C
4.5.7
FIGURE 4.5.6
4.5.4 Pneumatic actuator
The pneumatic control assembly - comprising a pneumatic actuator (D) - does not require any
particular maintenance (fig. 4.5.2).
In case of oil leak or difficulty to keep the homogenizing pressure not related to any other cause (see
Section 3 – Chapter 3.8) it is possible to replace the gaskets of the pneumatic actuator.
In order to replace the gaskets, it is necessary to ask for the necessary spare set to the
GEA Mechanical Equipment Italia S.p.A. Spare Parts Dept.
To remove the pneumatic actuator (D) it is necessary to remove the four screws used to fix the
actuator itself on its supporting flange.
The pneumatic actuator, used to close the homogenizing valve and achieve homogenizing pressure,
is connected in the bottom part to an hydraulic/pneumatic system for dampening pulsations.
The presence of air in the bottom part of the pneumatic cylinder may cause incorrect operation of
the dampening system resulting in abnormal noise level and vibrations of the homogenizing valve,
particularly if the machine operates with two homogenizing stages.
In this case you need to eliminate the air by pressing the pneumatic switch 3 or 4 times to apply and
release pressure.
Please follow the specific instructions listed at SECTION 4 – Charter 4.10 “Pneumatic Plant”.
ATTENTION
Maximum service pressure for pneumatic plant and pneumatic actuators is 1 MPa (10 bar).
4C051E7C
4.5.8
4.5.5 Aseptic version
The homogenizing assembly used in the aseptic version is the same as the one used in the sanitary
version in terms of functional features; the only difference is that the impact head shaft is flushed with
sterile condensate used as barrier fluid.
The homogenizing chamber body has all the connections with the system for distributing sterile
condensate, and the guide of the impact head shaft has outlets for the condensate with relative
gaskets, as shown in figure 4.5.7.
It is important to always refer to the specific detail drawings in SECTION 5 – Spare Parts Catalogue.
FIGURE 4.5.7
4C051E7C
4.5.9
4.6. Overpressure valve and pressure gauge
The pressure relief valve (see SECTION 3 - Paragraph 3.7.1) is usually installed on the compression
head or on the high-pressure delivery line to protect the machine and operators from accidental
overpressure which can create risk of danger.
Maintenance (see figure 4.6.1) is limited to checking and possibly replacing the gaskets (G) and (H),
the ball (E) and valve seat (F); in some versions an anti-extrusion ring is fitted between the seat and
the O-ring gasket (G) to protect the O-ring.
To remove the valve from its operating position you have to loosen the nuts (A) then remove the
complete valve body (B) and its flange (C); these two parts can be separed once the two-part ring
(D) is removed from its position.
Then remove the O-ring (H), the seat (F) housing the ball (E) and the O-ring (G).
Make sure you do not misplace the ball (E), as the valve cannot work without it; we recommend you
always keep a spare seat and ball in case you need to replace them.
Valve maintenance does NOT require replacing the spring.
Carefully clean the seat (F) from any product residues but take care not to damage the sealing area.
If the sealing area between the seat (F) and the ball (E) is damaged or worn, there can be product
leaks and the valve can be triggered at a pressure value lower than the valve setting; we therefore
recommend you replace the seat and ball.
Steps to be followed for assembly:

• Insert the gasket (G) into its housing in the flange or head; food-grade Vaseline or other suitable
lubricants should be used for easier assembly
• prepare the seat (F) for assembly, place the ball (E) and O-ring gasket (H) inside it
• insert the valve body (B), the flange (C) and place the two semi-rings (D) to hold the flange in
position
• insert the seat (F) prepared on the valve body, and keep it in position with your fingers while you
insert the whole valve on the flange housing (or, in some versions, directly on the head)
• insert the flange (C) on the studs and screw the nuts (A) by hand, so as to correctly lock the valve
by inserting the seat (F) on the O-ring gasket (G)
• when the valve is in a stable position, before tightening the nuts (A), place the discharge pipe in
the correct position. For safety reasons the discharge pipe must always be kept open and turned
downwards.
• tighten the nuts (A) fully.
For futher information on operation of the overpressure valve see paragraph 3.7.1.
4C061E5C
4.6.1
WARNING
it is absolutely FORBIDDEN to modify the overpressure valve setpoint and break the seal,
unless with written authorization by GEA Mechanical Equipment Italia S.p.A..
In case of modification of the valve setpoint without authorization, the warranty on the machine
is immediately void, and moreover this may cause ranger for the safety of the personnel
using the machine, as the overpressure relief valve is a fundamental safety device for the
machine accordino to the CE safety regulations.
WARNING
It is absolutely FORBIDDEN to close the discharge pipe of the overpressure valve with a
valve. The valve discharge must always be unobstructed and turned downwards.
FIGURE 4.6.1
4C061E5C
4.6.2
4.6.2 Pressure gauge
The pressure gauge installed on the machine is a component of fundamental importance as it makes
it possible to measure the machine’s operating pressure and thus keep its operation under control.
With a faulty pressure gauge the required working pressure cannot be maintained, so we recommend
you keep a spare pressure gauge in stock in case a replacement is needed.
The type of pressure gauge installed can vary depending on the machine model or if optional
configurations are used.
The standard pressure gauge is analog with Bourdon spring and sanitary baffle separator especially
designed by GEA Mechanical Equipment Italia S.p.A.; it is also equipped with a separator used to
filter the normal pulsations of the plunger machine to allow steady readings of operating pressure.
Never separate the pressure gauge from its separator.
Other versions of pressure gauges or pressure measuring devices are available as alternatives:
• analog pressure gauge with signal transmitter: with 4÷20 mA output for remote transmission of
pressure signal
• pressure transducer: this is a sensor which gives an electric signal to be amplified in order to
obtain a 4÷20 mA output of the pressure signal
• digital pressure gauge with built-in display: this transducer has a display to directly indicate the
pressure value measured. Powered by internal battery.
The pressure gauge normally requires no maintenance, however we recommend a periodical check
to:
• verify the condition of the diaphragm which comes into contact with the product; if it is punctured
or damaged the pressure gauge must be replaced
• for analog pressure gauges, check the level of glycerine inside the dial; if necessary fill the dial
up to ¾ with 99.5% pure glycerine
• replace the gasket between the pressure gauge and the head
For instruments provided with electric equipment refer to the wiring diagram, which also indicates the
setting range of the instrument.
4C061E5C
4.6.3
Refer to figure 4.6.2: to disassemble the pressure gauge (or pressure gauge with transmitter, or
pressure transducer) you need to loosen the nuts (G) and pull out the pressure gauge complete with
flange (F).
The pressure gauge (A) and flange (F) can be separated once the semi-rings (D) have been removed.
Figure 4.6.3 shows the analog configuration for disassembling the pressure transducer.
FIGURE 4.6.2
Steps to be followed for assembly (figure 4.6.2 or 4.6.3):

• insert the gasket (E) on the pressure gauge rod (used only to protect from dirt)
• insert the gasket (G) inside its housing in the flange or head; food-grade Vaseline or other
suitable lubricants should be used for easier assembly
• insert the anti-extrusion ring (C), if used, on the manometer; this ring is used in high-pressure
versions from 600 bar upwards
• insert the flange (F) on the pressare gauge body (A) and fit the two semi-rings (D) to hold the
flange in position
• insert the pressure gauge prepared in this way into its housing, and place the flange (F) on the
studs (H)
• screw the nuts on (G) by hand before tightening them fully.
4C061E5C
4.6.4
FIGURE 4.6.3
In high-pressure versions, equipped with transducer (T) or digital pressure gauge (M) (see figure
4.6.4), a threaded locking ring (D) is used.
FIGURE 4.6.4
4C061E5C
4.6.5
For disassembly, unscrew the ring (D) and pull the instrument out; remove also the gasket (B) and
anti-extrusion rings (A, C) from their housing.
For assembly follow these steps (figure 4.6.4):

• fit anti-extrusion ring (C), gasket (B) and anti-extrusion ring (A) onto the end of the pressure
gauge (M) or transducer (T); food-grade Vaseline or other suitable lubricants should be used for
easier assembly
• fit the pressure gauge (M) or transducer (T) into its housing; with digital pressure gauges make
sure you do not force the element using the head of the instrument to prevent breakages
• tighten the locking ring (D) fully
The digital pressure gauge (M) will switch automatically after a few minutes if no pressure is measured,
to preserve the internal battery.
To start the pressure gauge simply press the front ZERO/ON push-button; keep this button pressed
for a few seconds to reset the instrument to ZERO if the reading given is NEGATIVE.
If the display reads “BATT” it means that the battery is down and needs to be replaced.
Disassemble the pressure gauge and, on a dry surface, remove the rear screws to lift off the
cover on the battery housing. The battery used is a long life 9V lithium battery, size PP3; in special
circumstances a standard 9V alkaline battery may be used.
4C061E5C
4.6.6
4.7. Transmission
The machine is equipped with a drive system consisting in:

• pivot-mounted parallel-axle reduction gear, fitted on the machine’s crankshaft;
• pulley and V-belt drive between main motor and reduction gear.
WARNING
All inspection and maintenance operations must be carried out with the MACHINE NOT
IN OPERATION; the power mains switch must be LOCKED IN THE OFF POSITION (with a
padlock) for the safety of personnel.
The elements of the drive system usually require only a visual inspection, carried out with the machine
not in operation, to check for possibile lubrication oil leaks and, more importantly, for loosening of
nuts, bolts, belt tensioning components and reduction gear support parts.
Excessive movement of drive components, due to loosening of locking elements caused by vibrations,
can result in slack couplings and consequent breakage of elements during machine operation.
WARNING
It is important to regularly check tightening of nuts and bolts in the belt tensioning system
and reduction gear support system. Abnormal vibrations due to incorrect machine operation
or cavitation conditions can cause these components to loosen and damage the drive system.
Instructions for maintenance of drive components are given below.
4C071E12C
4.7.1
4.7.1 Reduction gear
The reduction gear does not require special maintenance precautions; you only need to check the
level of lubricating oil through the inspection hole in the casing.
It is good maintenance practice to protect the seal rings with waterproofing lubricating grease, and
to protect the locking system on the shaft from the effects of oxidation which would make it difficult
to disassemble the reduction gear, if necessary.
For reduction gears equipped with cooling coil inside the casing for artificial refrigeration, the water
circuit needs to be drained off completely if room temperature drops below +4 °C.
As the reduction unit is pivoting its movement is free and will increase when the machine runs loaded.
This movement can be considered normal when all the belt-tensioning elements and reduction gear
support elements have been properly tightened, using also lock nuts.
WARNING
It is forbidden to alter the tensioning system of the reduction gear, particularly if this will make
the system rigid. Inadequate constraints can cause improper stress on the drive system
resulting in breakage of its elements.
For further information and instructions for disassembling the reduction gear from the machine refer
to the reduction gear manual, included in Section 7 – INFORMATION ABOUT SUPPLIERS.
4C071E12C
4.7.2
LUBRICATION OIL
Only use oil of the type indicated in TT-0162, attached to section 1 of this manual.
OIL CHANGE INTERVALS
The oil must be changed every 5000 hours if using MINERAL OIL or 20000 hours if using SYNTHETIC
OIL.
OIL QUANTITY FOR REDUCTION GEAR
The quantity of oil for the gear reducer depend by the model of machine as specified in TT-0162,
attached to section 1 of this manual.
4.7.2 Installing the belts
WARNING
INSPECTION OF THE PULLEYS
Worn pulleys significantly reduce the life of belts, which can touch the bottom of the groove causing
slipping which provokes wear and superficial burning.
If the sides of the groove are hollow, the contact between the sides of the belt and the pulley is not
uniform, and the lower part of the pulley causes wear of the lower edge of the belt, causing it to break
prematurely.
Thus, it is necessary to check the state of wear of the pulleys and remove any rust, grease or oil that
may be present.
4C071E12C
4.7.3
ALIGNMENT CHECK
Correct alignment is essential to ensure long-life of the drive belts.

This operation must be carried out during assembly by skilled personnel: it is important to check
alignment by placing a metal ruler on the 2 pulleys (fig.4.7.2.1).
FIGURE 4.7.2.1
If necessary alignment can be corrected by loosening the retaining bolts of the conic bush and
slightly move the driven pulley (by a few mm.) to reach optimal position then lock the bushing.
SELECTION OF BELTS
Use at the same time belts of the same make, of the same type and of the same lot, since there may
be differences both in size and in performance.
Moreover, it is essential not to use new belts with others that have already been used, because of a
different extension, adjustment to the grooves of the pulleys, and differences in performance, which
would considerably affect the duration of the drive train.
In order to ensure correct operation and avoid premature breaking, the belts must be stored without
any noticeable bends and must not be exposed to temperatures that are too high or too low, or to a
high degree of humidity.
4C071E12C
4.7.4
ASSEMBLY OF THE BELTS
In GEA Mechanical Equipment Italia S.p.A. machines equipped with reduction gear (figure 4.7.3,
item C) the motor that carries the driving pulley is fixed to the support plate while the reduction gear
is fixed to the pivot-mounted crankshaft.
An adjustable tie rod makes it possible to change the distance between the driving pulley and the
driven one to allow installation and tensioning of the driving belts.
With reference to figure 4.7.3.3, loosen the lock nut (A) retaining the tie rod (B), and then change the
length of the rod to allow disassembly and assembly of belts.
Once the belts have been tensioned lock the tie rod with the lock nut.
For correct belts tensioning refer to paragraph 4.7.3.
During installation belts must never be forced with a tool into the pulley’s grooves to avoid the risk of
damaging both thus reducing the life of the drive.
To make this operation easier simply reduce the distance between the pulleys.
Fit the belts into the grooves and rotate the pulley to facilitate insertion and prevent damage.
FIGURE 4.7.2.2
4C071E12C
4.7.5
4.7.3 Stretching the belts
WARNING
Control and servicing operations must be carried out WITH THE MACHINE NOT IN OPERATION
and with the sectioning switch of the imput line LOCKED (by means of a lock) IN OPEN
POSITION for the safety of the personnel.
WARNING
The V-belt transmission may create danger of crushing or entrapment. Use always the
necessary fixed protections and in case remove them only after having checked the machine
to be completely stopped in any moving part.
The ideal stretch is the lowest at which the belts do not slip under maximum load.
During the first 24-48 hours of running-in, check the stretch frequently; remember that excessive
stretch reduces the life of the belts and of the bearings that support the drive.
Arrange for the stretch to be tightened as soon as any slipping occurs.
Belt slipping can cause overheating and create hazard particularly if the machine is designed for
operation in danger zones (explosion-proof version).
The following are two methods to identify the correct degree of stretching of the belts; the first, which
is easier, can be used when a new train of belts is installed, or after loosening them completely; the
second allows stretch to be checked even during normal operations of servicing and control. The
procedures of the operations are described in paragraph 4.7.2.
4C071E12C
4.7.6
BELTS TENSIONING – FIRST METHOD
Before stretching the belts assembled on the pulleys, trace two fine marks across the back of one
belt and measure the distance between them; they should be as far from each other as possible but
must remain on the straight-line of the belt. Stretch the belts gradually after having them rotate for
approx. 1 minute in successive stages; at each stage, tighten the belts so that the distance between
the two marks has a percentage increase as shown in table 4.7.3.1, considering the case of medium
diameter pulleys.
Type of transmission Not constant Torque

- one small size pulley
- short shaft center distance 0,8%
- medium or big size pulleys

- medium or big shaft center distance 1%
TABLE 4.7.3.1
BELTS TENSIONING – SECOND METHOD
Occorre misurare la lunghezza del tratto libero “t” (figura 4.7.3.1) ed applicare nella sua metà una
forza P perpendicolare alla cinghia che provochi una deformazione F di 1,6 mm. ogni 100 mm. di
lunghezza libera:
F=1,6 x T/100 (mm)
Il valore della forza, in Newton, deve ricadere nell’intervallo di valori indicato in tabella 4.7.3.2; esso
viene misurato mediante un apposito dinamometro non in dotazione.
Per calcolare la velocità periferica è sufficiente utilizzare la formula:
V = 0,052 x n x d x r (m/s)
where n is the number of revolutions per minute of the crankshaft, as indicated in SECTION 1 -
TECHNICAL SPECIFICATIONS, and d is the diameter of the flywheel indicated in metres.
It is important to remember that at hte first stretching, the correct value is 1.3 times maximum value
shown in the table 4.7.3.2, so as to compensate the natural extension and initial setting of the belts.
4C071E12C
4.7.7
FIGURE 4.7.3.1
Forza / Force P (Newton)

Tipo / Type D (mm)
V = 0÷10 m/s V = 10÷20 m/s V = 20÷30 m/s
67÷95 12 – 18 10 – 16 8 - 14
SPZ
> 95 19 – 26 17 – 24 15 – 22
100÷140 22 – 32 18 – 26 15 – 22
SPA
> 141 33 – 48 27 – 40 23 – 34
160÷265 38 – 56 32 – 50 28 – 42
SPB
> 266 57 – 72 51 – 64 43 – 58
224÷355 72 – 102 60 – 90 50 – 80
SPC
> 356 103 – 132 91 – 120 81 - 110
TABLE 4.7.3.2
4C071E12C
4.7.8
4.7.4 Maintenance of belts
The belt drive is an efficient, reliable means for power transmission.

The following are some simple instructions to ensure reliability and long life of the system.
LOOK AND LISTEN
This allows you to easily identify the defects to be corrected:

Visual check if any oil or grease is present on the belts, since this may cause premature deterioration;
excess oil on the supports and bearings may cause the belts to be dirtied, while a lack may cause
increased friction and subsequent burning of the belts due to overload.
- Listening to the noise during transmission.
If there is any screeching when the motor accelerates or during operation at full load, this means that
there is insufficent stretch of the belts.
Once the correct stretch has been restored, if the noise persists try to identify any overload in
transmission (due to wear, seizure, insufficient lubrication...).
The presence of a regular squeaking, similar to that of a bearing that is insufficiently lubricated, does
not cause any damage to the transmission and may be caused by the presence of dirt.
Do not try to eliminate this noise by oiling the belts.
DIRT AND FOREIGN MATERIALS
Dirt and dust may accelerate wear of the belts and pulleys and obstruct a good traction.
It is necessary to regularly clean the drive system and prevent any foreign material from being
trapped between the belts and pulleys.
OVERLOADS
Any overload shortens the life of the belts.

Check that operation is taking place under the initial project conditions, and that no overloads occur
due to wear or slipping and superficial burning.
PROTECTIONS
The drive should always be protected by a suitable guard, which not only protects the operators but
also protects the parts from dust or dirt and contact with foreign objects which may cause serious
damage to the system.
BREAKING AND CRACKS
Check the condition of the belts, and see if there are any cuts or cracks, that are a sign of excessive
wear and the need to replace the part.
4C071E12C
4.7.9
TENSIONING
Check and maintain the correct stretch of the belts, to prevent irregular vibrations.
EXPOSURE TO HEAT
Check that the belts are not exposed to sources of heat; an exposure to temperatures greater than
60°C will shorten their life.
WEAR
Check the condition of the sides of the belt: an anomalous wear may cause slipping or excessive
wear of the grooves of the pulleys.
4C071E12C
4.7.10
4.7.5 Assembling and disassembling of pulleys
Drive pulleys are usually mounted both on the input shaft of the reduction gear and on the motor
shaft using a “Taper-Lock” conical bushings.
With reference to figure 4.7.5.1, the procedure for disassembly is the following:
FIGURE 4.7.5.1
• loosen retaining screws A

• use one of the screws in bore B to force the bush open
• extract the bush and pulley from the shaft
Assembly procedure:
• clean bush and shaft thoroughly
• insert “Taper-Lock” bush into pulley
• partially insert threaded screws into bores (A)
• mount the pulley on the shaft
• align the pulleys
• tighten screws A fully
If the motor pulley is not fitted with a “Taper-Lock” bush, to install or remove the pulley use a suitable
pulley extractor and threaded rod to mount the pulley on the shaft, using the threaded bore on the
end of it.
4C071E12C
4.7.11
4.8. Power end - crankcase
The reciprocating linear motion of the plungers is created by an oversized and sturdy crank mechanism
(crankshaft, connecting rod, crosshead).
The system is illustrated in the general exploded view (figure 4.8.1) below.
FIGURE 4.8.1
The type of construction, the high-quality materials used and the careful assembly by highly-qualified
personnel are a guarantee of excellent reliability and durability.
Correct lubrication is fundamental for the life of the drive body and of its components, so it is absolutely
necessary to comply with the instructions given in terms of recommended change frequency (Chapter
4.2), filter cleaning, level and type of lubricant used (Chpater 4.9).
Under normal conditions the power end does not require servicing. Should you notice abnormal
noise levels, irregular machine operation or low pressure of lubrication oil triggering the pressare
switch, contact GEA Mechanical Equipment Italia S.p.A.’s Customer Service to request technical
service.
Under normal working conditions and without specific faults, it is recommended to check the sleeve
bearings (W) and crank pin bearings (S), the wrist pin (O) and its bearing on the conrod (R) at least
every approx 10.000 hours of operation, and to check the roller bearings (B) of the crankshaft at
least every 20.000 hours of operation.
Such kind of maintenance requires skilled personnel, therefore it is recommended to contact
GEA Mechanical Equipment Italia S.p.A. Customer Service for advice and support.
4C081E6C
4.8.1
The only ordinary maintenance operation required is replacement of guide plunger gaskets, in case
of lubrication oil leaks inside the sump.
If the surface of the crosshead extension is badly scratched, it is necessary to replace the complet
guide pistons.
Such kind of maintenance requires skilled personnel, therefore it is recommended to contact
GEA Mechanical Equipment Italia S.p.A. Customer Service for advice and support.
WARNING
WARNING
Lubricating oils are extremely harmful to environment and should be disposed of correctly
in suitable disposable, in accordance with the local regulations, to avoid environment and
water pollution.
4C081E6C
4.8.2
4.8.1 Replacing guide plunger gaskets
Before removing the flanges you need to drain out, at least partially, the oil inside the body to prevent
accidental spillage.
Refer to figure 4.8.2 for the assembly and disassembly procedures described below.
FIGURE 4.8.2
DISASSEMBLY
• remove the plunger following the procedure described in Charter 4.4
• loosen the screws (K) and extract the flange (M) from the guide plunger (Q)
• remove the scraping ring (L) and the seal gasket (J).
ASSEMBLY
• fit the scraping ring (L) and gasket (J) inside the flange (M), in the seat.
• check and clean the plunger stem, if the surface is badly scored or the chrome plate damages
the whole plunger must be replaced. The guide plunger stem cannot be supplied separately as
spare part
• insert the complete O-Ring flange (H) onto the guide plunger (Q) as far as the edge. During
assembly take care not to damage the sealing lip of the gaskets; use lubrication grease for easier
assembly
• tighten the screws (K).
4C081E6C
4.8.3
In some models a rubber bellows is installed to protect the guide plunger stem. In this case the
bellows (Z) must be removed to replace the gaskets, and then inserted onto the guide plunger stem
(Q) and snapped on locked against the flange (M) in the seat provided.
FIGURE 4.8.3
4C081E6C
4.8.4
4.9. Lubrication
Proper machine lubrication is required to guarantee its correct operation.
For this reason it is absolutely necessari to follow directions for oil change intervals (see Charter 4.2),
the cleaning or replacement of filters, check of oil level and use of specified lubricating oil.
The lubrication system can be either FORCED or SPLASH, depending on the machine model; see
Section 1 – TECHNICAL SPECIFICATIONS to find out type of lubrication used.
For top-ups and oil changes use ONLY one of the oils indicated in document TT-0038, attached to
section 1 of this manual; the same table indicates the capacity of the lubrication plant for the various
models according to the type of lubrication.
ATTENTION:
The lubrication oil is suitable for operating temperatures ranging from 5°C and +40°C: please
contanct GEA Mechanical Equipment Italia S.p.A. Customer Service to obtain the type of
lubricant suitable for any specific conditions found locally.
ATTENTION:
Used oils are extremely harmful to environment and should be disposed of correctly, in
accordance with the local regulations.
ATTENTION:
It is important to periodically ensure there is no foam in the oil as this is a sign that air is being
incorporated due to cavitation in the oil pump or to bad sealing of the lubrication circuit. You also
need to check for a whitish water/oil emulsion which is caused by inefficient drainage of condensate
or water infiltrations inside the body (faulty water/oil exchanger or worn guide plunger gaskets).

Any type of oil used should have the following specifications:
Suitable for hydraulic circuits, of mineral origin, viscosity ISO VG 150 (150 cSt at 40°C) with non-
foaming, antioxidative additives, etc.
The list of recommended oils, including food-grade oils, is given in document TT-0038 attached to
Section 1 of this manual.
4C091E12C
4.9.1
4.9.1 Foorced lubrication with motor-driven pump
Forced lubrication is by means of a lubrication unit (CONTROL UNIT) with separate electric motor,
which makes it possibile to have adeguate flow of lubrication oil and pressure even when the rotation
speed of the crankshaft is low (variable load machine).
The oil circuit inside the drive body is made with rigid or flexible pipes and keeps oil under pressure to
lubricate the crankshaft main bearings, connecting rod bushings and connecting rod pins, to censure
reliable machine operation and durability of contact surfaces in the crank mechanism.
The machine is equipped with a pressure gauge on the front panel for continuous control of lubrication
pressure and a safety pressure switch set to 3 bar to stop the machine if lubrication pressure is
insufficient.
The lubrication system diagram is shown in Section 5 – SPARE PARTS CATALOGUE, while figure
4.9.1 gives an exploded view of the lubrication unit.
The lubrication control unit is made up of the sub-components shown in figure 4.9.1:
• electric motor
• joint between pump and motor (G)
• body (C) with by-pass valve (F)
• gear pump (D)
• tank (A)
• intake filter (B)
The intake filter is fitted inside the tank, so to be able to remove it you need to remove the whole
control unit assembly.
Before removing the control unit, oil needs to be drained out of the body.
The filter must be cleaned or replaced every time the oil is changed according to the indications
given in the PERIODICAL MAINTENANCE TABLES.
ATTENTION:
The by-pass valve (F) MUST NOT BE DISASSEMBLED from the body (C). For adjustment of
lubrication pressure see the instructions given below.
4C091E12C
4.9.2
A - tank
B - intake filter
A C - body
D - gear pump
F - bypass valve
G - joint between pump and
motor
Fig. 4.9.1
4C091E12C
4.9.3
OIL LEVEL CHECK
The oil level needs to be checked every day, before the machine is started; the oil should reach the
level indicated on the sightglass located or inside the machine on the crankcase or on the machine
front panel. The oil level must be checked with the machine stopped for at least 1 hour.
See for reference figure 4.9.2.
Fig. 4.9.2
The start of the machine is causing the oil to flow into and fill the lubricating circuit, then it is normal
to observe a lowering of the oil level on the sightglass during the operation of the machine.
If oil drops below the required level top it up through the orange filler located inside the machine on
the body cover.
To reach the fill you need to remove the side panel of the machine.
4C091E12C
4.9.4
PRESSURE CHECK
The pressure gauge located on the front panel is used to measure the pressure in the lubricating
circuit.
During the final machine test optimal lubrication pressure is calibrated under steady operating
conditions; this value is largely affected by oil viscosity and temperature so when the machine is
started pressure is usually high and then tends to decrease and become stable as the machine
warms up with operation.
If pressure drops too low at high temperatures this may be due to problems with the cooling system
of the water/oil exchanger (where used) connected with scaling or very high water temperature.
The water temperature must conform with the values given in Section 1 –TECHNICAL
SPECIFICATIONS.
The pressure in the lubrication circuit can be adjusted via the by-pass valve (F) in the lubrication unit
body (C) (figure 4.9.3):
A C F
A - tank
B - intake filter
F - bypass valve
Fig. 4.9.3
• DO NOT REMOVE THE VALVE FROM THE BODY

• Loosen the lock nut and turn the Allen screw (Allen spanner) to reach the correct pressure value
• Turn the screw CLOCKWISE to increase pressure and COUNTERCLOCKWISE to reduce it
• Tighten the lock nut.
Adjustments must be made at high temperatures, with a value of approximately 5÷6 bar.
ATTENTION:
If the pressure level is too high the circuit may be damaged, particularly during cold starts: oil
viscosity problems can lead to damage in the delivery oil filter and motor overload triggering
the electric protection devices. When adjusting pressure you need to take into account
ambient conditions and the temperature of cooling water.
4C091E12C
4.9.5
OIL CHANGE
The frequency of oil change intervals is given in the “Tables for Regular Servicing” at Chapter 4.2.
To change the oil (see figure 4.9.1):

• prepare a collection tray of sufficient capacity to contain the quantity of oil contained in the
machine according to TT-0038, attached to section 1 of this manual
• open the filling tap on the crankase cover
• open the drain valve and the plug (J) and let the oil drain out.
• once the oil has drained out completely, close the tap and the plug (J), and pour in the new oil
through the filler plug
• check the oil level through the sightglass.
ATTENTION:
4C091E12C
4.9.6
VAPOUR CONDENSATE DISCHARGE
Inside the crankase it is possible to have condensation of vapours depending on the characteristics
of the ambient where the machine is working in, therefore it is necessary to remove regularly the
condensate to avoid any mixing with lubricating oil.
The frequency of the discharge depends on the amount of condensate formed in the drive unit
(which depends on the working temperature, relative humidity, frequency of starting and stopping the
system); however, refer to the “Tables for Regular Servicing”, chapter 4.2.
The condensate drain can be done when the machine is stopped for at least 4 hours.
To drain the condensate:
• Prepare a basin for collection and open the drain valve at the bottom of the lubricating unit
• Water is heavier than oil, therefore it is collected at the bottom of the oil tank; once the oil starts
to pour out, close again the drain valve
• Check the oil level again and, if necessary, top it up through the filler plug
Presence of water into the oil may be caused by cooling water entering trough the crosshead seals;
it is recommended to check the surface of crosshead extensions for scratches, and to replace
the crosshead seals in case of oil leakage or oil into the water, according to what is mentioned in
paragraph 4.8.1.
OIL FILTERS CHANGE
Oil filters change is extremely important to guarantee proper and reliable operation of the lubricating
system.
It is therefore necessary to replace or cleand the oil filters each change of oil as recommended on
the periodical maintenance indications.
The delivery side filter is of “spin-on” disposable cartridge type; the suction side filter is of metallic
mesh and is placet inside the tank (figure 4.9.1, item B).
If the intake filter is of the type “with disposable cartridge”, it should be replaced as often as indicated
in the “Table for Regular Servicing”, paragraph 4.2.
The filter is equipped with an internal by-pass valve: this opens when the pressure drop due to
clogging exceeds a preset level, bypassing the filtering element.
To replace the filter cartridge it is necessary to empty the complete lubricating circuit:
• Remove the spin-on filter cartridge with suitable too (not supplied)
• Install the new filter cartridge after having lubricated with oil the gasket
The intake filter housed inside the oil tank does not have a built-in by-pass. If the filter clogs up the
pressare drop through the filter will increase leading to cavitation of the gear pump and pressure
switch action. Cleaning frequency is given in the “Table of Periodical Maintenance”, Chapter 4.2.
To clean the metal mesh intake filter (figure 4.9.1, item B):
• remove the oil tank as previously explained
• disconnect the tank (A) from the body (C) by loosening the retaining screws and removing the
filter (B) from the tank
• unscrew the filter (B) off the end of the suction pipe
• put it in a container with petrol or solvent for about 30 minutes;
• clean it with compressed air blown opposite to the filtering direction (i.e. from the inside towards
the outside).
4C091E12C
4.9.7
ATTENTION:
Carry out the operations with utmost caution, wearing suitable protection for the body and
the eyes against any petrol splashes; wear a filtering mask and do not inhale the vapour; if
there is any contact with the eyes, wash abundantly with water and consult a doctor.
OIL COOLER MAINTENANCE
The machine is equipped with a water / oil cooler which is not requiring usually any maintenance.
In case of use of hard water, it is possible to have problems with clogging of the cooler because of
calcium carbonates deposits, which is reducing the heat transfer efficiency.
It is therefore necessary to replace the oil cooler if it is not able to reduce anymore the oil temperature
(usually the temperature difference between oil inlet and outlet is in the range of 5 to 10 °C); in case
the oil cooler is made of stainless steel (optional) it is possible to clean it with suitable cleaning
solution to scale the tubing
4C091E12C
4.9.8
4.10. Pneumatic plant
Machines provided with pneumatic control system of the homogenizing pressure are supplied with
specific hydraulic dampening system of the homogenizing valve.
The force required to close the homogenizing valve and consequently achieve the homogenizing
pressure is applied through a pneumatic actuator using compressed air on its upper part; the lower
part of the actuator is connected with the pressurized oil dampening system.
The dampening system is not installed on the machine when the pneumatic valve installed is type
NanoValve®.
The pneumatic actuator does not require any periodical maintenance but it is recommended to
protect it from extreme temperatures (which may damage the gaskets) and corrosive fluids, as its
body is made with Aluminium alloys and not in stainless steel.
In case the pneumatic actuator is not working properly we recommed its replacement; it’s anyway
available upon request to GEA Mechanical Equipment Italia S.p.A. Spare Parts Dept. the complete
gaskets spare kit.
The pneumatic plant can be configured in various versions, according to the options installed;
on figure 4.10.1 it is shown a basic version for single stage homogenizer with manual pneumatic
adjustment of the homogenizing pressure installed on the machine front panel.
The scheme of the plant actually installed on the machine is given in Section 5 – SPARE PARTS
CATALOG with components list; you can also check the Flow-sheet (P&ID) given in Section 1 –
TECHNICAL SPECIFICATIONS.
4C101E9C
4.10.1
FIGURE 4.10.1
The components present on the circuit according to the scheme presented in figure 4.10.1 are:
• Inlet air pre-treatment unit (A) with pressure gauge (B);
• One pneumatic switch (C) (or as option a solenoid valve) to give pressure to the actuator (G);
• One manual pressure regulator (D) (or as option a proportional valve for remote controls;
• Throttle valves (E, H) to achieve a stable operation of the pneumatic system and to adjust the
speed of the raise of the homogenizing pressure by throttling the oil backflow;
• A pressure gauge (F) installed on the machine front panel, indicating the pressure effectively
supplied to the pneumatic actuator;
• A damper tank (K) for oil and pressurized air.
The effect of dampening of the vibrations induced on the homogenizing valve by the normal
reciprocating movement of the plungers is granted by a suitable air/oil damper vessel (K) which is
connected to the lower part of the pneumatic actuator of the homogenizing group.
This damper tank is preloaded with compressed air, pressure 0,5 bar.
The gauge (L) allows to check the pressure in the tank, and ina case of need it is possibile to use the
quick connection (M) to restore the correct pressure inside the tank.
If the pneumatic dampening system is checked on a regular basis for correct preload pressure
and oil level, it is possible to avoid problems of valve vibrations and resonance, which may cause
reduction of homogenizing efficiency and can be dangerous for the machine itself.
Ordinary maintenance operations are listed below:

• Check regularly the oil level inside the damper tank through the sightglass
• Check regularly into the damper tank the correct pressure value: must be 0,5 bar with machine
stopped
• In case refilling of oil is required, close the valve (J) and open slowly the upper filling plug (there
is pressure inside); once the pressure is gone, fill the necessary oil quantity. The specifications
of the suitable oil are listed on table 4.10.2
4C101E9C
4.10.2
WARNING
the damper tank containing oil is under pressure; open carefuly and slowly to allow air
pressure go down and avoid danger for personnel.
Close the upper plug and connect a compressed air source to the quick connection (M) to restore the
pressure of 0,5 bar inside the damper tank
Open the valve (J) and check if the air pressure is still at the set value of 0,5 bar.
Pressure inside the camper tank cannot be higher than 0,6 bar when the machine is
stopped.
Oil into this circuit does not require any change but only refilling in case the level is low.
If during the above mentioned procedures of filling up, or during the homogenizing valve maintenance
some air bubbles are present into the plastic pipes, it is possible to eliminate the same by application
and release of the pressure to the actuator through the pneumatic switch (C), with machine stopped
and with the manual pressure regulator set to allow some air to go through (not at zero).
The presence of air bubbles, anyway, cannot prevent the system to work properly, even if the
dampening effect may be sometimes reduced.
The adjustment of the throttle valve (E, H) allows to regulate the speed of the homogenizing pressare
raise.
Usually the setting of this valve is made during the machine test, in order to avoid a sudden raise of
the homogenizing pressure which may cause the opening of the overpressure relief valve.
Before making any modification to the setting, please tae note of the original setting on the scale in
order to recover the original setpoint in case of need.
As general information the closing of the valve (H) is slowing down the pressure raise, its opening is
making it faster.
WARNING
4C101E9C
4.10.3
4.10.1 Pneumatic plant with local manual adjustment
The pneumatic plant for local and manual pressure adjustment allows to adjust the homogenizing
pressure from the machine front panel through a pneumatic regulator and pneumatic switch.
No maintenance is required on these components, and in case of evident malfunctioning replacement
of faulty parts is recommended.
4.10.2 Pneumatic plant with remote pressure adjustment
The pneumatic plant with remote pressure adjustment is using a proportional valve (or I/P converter)
to adjust the homogenizing pressure (figure 4.10.2.1). This proportional valve requires a suitable
ramp signal on a 4÷20 mA scale; the signal must be isolated and amplified, with electrical connection
to the proportional valve according to the following diagram shown in figure 4.10.2.2.
FIGURE 4.10.2.1
It is anyway always recommended to follow the indications in the specific wiring diagram supplied
in the manual, which is showing also the numbering of terminals on the terminal board for proper
connection.
In case of malfunctioning of the system, it is possible to follow the below listed indications:
• Wrong connection: make sure the wiring is made according to the supplied diagram
• Not enough air pressure supply (required minimum 7,5 bar air pressure)
• Moisture or oil into the supplied air, which is necessary to eliminate
• Not enough power in the signal coming from valve pilot source (especially if directly connected to
a PLC output): it is necessary to install a suitable signal amplifier.
4C101E9C
4.10.4
FIGURE 4.10.2.2
The proportional valve is tested and calibrated during the machine test run. The setting is related
to the range of pneumatic signal output related to the electrical signal input; in case of need it is
possible to modify the factory settings by following the procedure described below and also indicated
in the specific valve manual in Section 7 – SUPPLIERS CATALOGUE.
The proportional valve is installed inside the machine cabinet, on left hand side, and it is possible to
access to it by removing the left side panel of the machine.
4C101E9C
4.10.5
The proportional valve is normally in LOCKED state. By touching one of the control keys on the top
part of the valve (figure 4.10.2.1) the display will show “LOC” message.
Making reference to figure 4.10.2.3:
FIGURE 4.10.2.3
• Unlock the valve pressing the UNLOCK button for at least 2 seconds, “LOC” will blink on display
• Press the SET button to have F_1 indication shown on display, which corresponds to the output
air pressure equivalent to 4 mA input signal – USUALLY THIS VALUE MUST BE 0,00
• Press the SET button to have F_2 indication shown on display, which corresponds to the output
air pressure equivalent to 20 mA input signal
• Using arrow UP and DOWN buttons, modify the air pressure value (example 4,50) in bar units
which is required to drive the homogenizing valve, equivalent to the max input signal (20 mA)
4C101E9C
4.10.6
ATTENTION
Before changing the factory setting of the valve, take note of the actual setting for future
reference. The set value must be approx 0,5 bar higher than required air pressure used to
achieve the required homogenizing pressure. Such value can be checked during machine
running on the air pressure gauge installed on the front panel of the machine.
• To lock the valve settings (the valve is locked automatically the first time the voltage supply is
switched OFF and ON), press the LOCK button for at least 2 seconds; in this way the indication
“UNL” is blinking on the display, and it is possibile to lock the valve by pressing the SET button
Usually it is not required to have any maintenance on these components, and in case of faulty
operation their replacement is recommended
ATTENTION
Maximum service pressure for pneumatic plant and pneumatic actuators is 1 MPa (10 bar).
4C101E9C
4.10.7
4.11. Aseptic plant
The machine, being supplied in SANITARY execution is NOT equipped with aseptic plant.
4C112E4C
4.11.1
SECTION 5
Spare Parts Catalogue - Index
5.1. How to use the spare parts catalogue

5.2. How to order spare parts
5.3. Recommended spare parts
5.4. Maintenance box
5C001E6C
5.1
5.1. How to use the spare parts catalogue
To ensure that effective operation and quality characteristics are maintained only original spare parts
must be used on GEA Mechanical Equipment Italia S.p.A. machines.
The use of non original spare parts shall instantly invalidate the guarantee.
This catalogue has information on how to order spare parts, selecting the parts in the attached tables
and their code number in the relative tables.
5.2. How to order spare parts
Spare parts can be ordered directly from GEA Mechanical Equipment Italia S.p.A., Service
Department, or through your local GEA Mechanical Equipment Italia S.p.A. agent or Authorized
Dealer, who can provide useful advice and forward your request immediately.
When placing an order please specify:

• SERIAL NUMBER of the machine
• spare part code number
• if necessary, a brief description of the component for easier identification
• if applicable, the item number on the assembly drawing in the SPARE PARTS CATALOGUE
• the means of transport or dispatch requested; if this is not specified
GEA Mechanical Equipment Italia S.p.A. will arrange suitable transport at their discretion
• whether urgent, as this may affect cost
• exact address and name of contact person
To order spare parts or request quotations for spare parts, copy the standard form below and send
it by fax.
5C001E6C
5.2
ORIGINAL SPARE PARTS INQUIRY FORM
To:
Fax No.
From:
Name:
Reply Fax No.
e-mail:
Model:
Serial No.
¨ URGENT ¨ QUOTATION ¨ ORDER No.
Part CODE Qty Description
Shipping Specs.
5C001E6C
5.3
5.3. Recommended spare parts
In order to limit the number of shutdowns during production, and the time required for maintenance of
the machine, we recommend you stock a set of spare parts to replace elements which are normally
subject to wear.
The number of spare parts to be stocked will depend on production needs and on how important it is
to avoid long shutdowns due to unavailable spare parts.
In specific, in case of homogenizing valves, the replacement at due time allows to keep the
homogenizing efficiency and consequently the quality of the processed product.
GEA Mechanical Equipment Italia S.p.A. cannot guarantee that a given spare part will be in stock
either at their central warehouse or at the Dealer’s due to problems with material availability or to
special requirements for dispatch.
Please note that shipment is no guarantee of successful delivery and that delays may occurr due
to customs problems or miscarriage.
In any case GEA Mechanical Equipment Italia S.p.A. shall not be responsible for delays occurring
due to the shipment of spare parts.
The following is a list of spare parts which, in our experience, is important to have in stock:
• a complete set of gaskets, two sets in case of VHP high-pressure compression blocks
• two sets of packings, including packing washers and anti-extrusion rings
• one or two plungers, if ceramic plungers are used
• a homogenizing valve set for each stage (for homogenizers)
• a set of balls and valve seats, for VHP high-pressure heads
• a set of seats and pumping valves, if the machine is used with abrasive products
• a set of pumping valve springs
• a pressure gauge for the compression block
• seat and ball for overpressure relief valve
• oil filters
• a set of guide plunger gaskets
• crankshaft oil guard
In addition to the ordinary maintenance operations described in Section 4 - MAINTENANCE, below

you will find a table with checklist for machine inspection that you can use to check which spare parts
are needed before performing ordinary maintenance on the machine.
5C001E6C
5.4

CHECKLIST FOR MACHINE INSPECTION
Machine Type : Serial Number :
Working Hours : Date :
Checked Replaced Checked Replaced

1 Compression head 34 Transmission
2 Suction Valves 35 Main motor
3 Suction Springs 36 Auxiliary motors
4 Suction valve seats 37 Gear box
5 Delivery Valves 38 Gear box tightening kit
6 Delivery Springs 39 Gear box oil level
7 Delivery valve seats 40 Belts
8 Gaskets 41 Pulley
9 Plungers 42 Water plant
10 Plunger Packings 43 Water filter
11 Overpressure cleaning/seat 44 Water solenoid valve
12 Homogenizing group 45 Water drain check
13 Passage head 1°st 46
14 Impact ring 1°st 47 Lubrication plant
15 Impact head 1°st 48 Lubrication unit
16 Gaskets 1°st 49 Pump driven by crankshaft
17 Passage head 2°st 50 Heat exchanger (oil/water)
18 Impact ring 2°st 51 Suction oil filter
19 Impact head 2°st 52 Delivery oil filter
20 Gaskets 2°st 53 Condensate discharge
21 54 Gaskets
22 55 Oil level
23 56 Oil piping check
57 Pneumatic plant
24 Transmission body 58 Dampening system check
25 Crankshaft 59 Air filter/Pressure regulator

26 Conrods 60 Accessories
27 Guide pistons 61 Tightening of the nuts
28 Conrod bronze bearings 62 Tightening of plungers

29 Main bronze bearings 63 Pressure gauges
30 Pins 64 Aseptic plant
31 Bearings 65 Steam heat exchanger

32 Gaskets 66 Steam valve
33 Oil splash guards 67 Aseptic chambers gaskets

Notes:

5C001E6C
5.5
5.4. Maintenance box
The machine is supplied complete with a set of spanners and tools to be used during ordinary
maintenance; they include special tools for installing or removing plungers and packings, where
required.
The set of spanners DOES NOT INCLUDE a Torque Wrench, which is recommended for correct
tightening of nuts and studs to the torque values given in Section 4 - MAINTENANCE.
The maintenance box includes a basic set of spare gaskets.
Please find attached a list of the tools supplied for ordinary maintenance.
5C001E6C
5.6
Maintenance box
Maintenance box - Mitgeliefertes werkzeug - Herramientas suministradas en la caja de mantenimiento - Liste des outils et des pièces de rechange livrées avec la
trousse d’entretien
Item Part Code Qty Descrizione Description Beschreibung Descripción Description
- 9538-1213-000 1 CHIAVE WRENCH GABELSCHLUSSEL LLAVE CLEF
- 9538-1003-000 1 PINZA CURVA PINCERS ZANGE PINZAS PINCE
- 9538-1612-000 1 LEVA GOMME PRY BAR HEBEL PRY BAR BARRE D'EXTRACTION
- 9538-1612-000 1 LEVA GOMME PRY BAR HEBEL PRY BAR BARRE D'EXTRACTION
- 9538-1246-000 1 CHIAVE WRENCH GABELSCHLUESSEL LLAVE CLEF
- 9512-0619-030 1 ESTRATTORE EXTRACTOR AUSZIHER EXTRACTOR EXTRACTEUR
- 9512-9313-000 1 ESTRATTORE PISTONE PLUNGER EXTRACTOR KOLBENAUSZIHER EXTRACTOR PARA PISTON EXTRACTEUR DE PISTON
- 9538-1546-000 1 ESPANSORE EXPANDER EXPANDER EXPANSOR EXPANSEUR
- 9510-4613-000 1 MANICO HANDLEGRIP GRIFF MANGO MANCHE
- 9536-9112-060 1 VITE SCREW SCHRAUBE TORNILLO VIS
- 9512-4417-000 1 INTRODUTTORE PACCHETTO PACKING INTRODUCER PACKUNGINFUHRE ÚTIL EMPLAZAMIENTO EMPAQUETADURAS
INTRODUCTEUR DE GARNITURE
- 9538-8003-000 1 ATTREZZO TOOL WERKZEUG HERRAMIENTA OUTILLAGE
- 9533-5229-000 1 CHIAVE UNIFAST UNIFAST KEY UNIFAST KEIL LLAVE UNIFAST CLEF UNIFAST
- 9534-1792-509 5 PACCHETTO PACKING PACKUNG EMPAQUETADURA GARNITURE DE PISTON
- 9513-5677-010 10 MOLLA SPRING FEDER MUELLE RESSORT
- 9531-4067-595 5 O-RING O-RING O-RING JUNTA TÓRICA JOINT TORIQUE
- 9513-2590-000 10 RONDELLA WASHER UNTERLEGSCHEIBE ARENDELA RONDELLE
- 9513-3784-000 5 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING STÜTZRING ANILLO ANTIEXTRUSION BAGUE ANTIEXTRUSION
5C041E3_14381.xlsm 1/2 GEA Mechanical Equipment / GEA Niro Soavi

Maintenance box
Maintenance box - Mitgeliefertes werkzeug - Herramientas suministradas en la caja de mantenimiento - Liste des outils et des pièces de rechange livrées avec la
trousse d’entretien
- 9531-4571-405 2 GUARNIZIONE GASKET DICHTUNG JUNTA JOINT

5.5. Spare parts list and assembly drawings
You will find attached assembly drawings and a list of components and spare parts.
The first code of each spare parts list indicates the assembly drawing which the components refer
to.
5C050E4C
5.1
Spare parts list
Compression head - Kompressionkopf - Cabezal de compresión - Tete de compression
0010 9512-9113-290 1 ASSIEME ASSEMBLY DRAWING BAUGRUPPEN ZEICHNUNG DESPIECE DESSIN D'ENSEMBLE
0020 9513-6606-240 1 TESTATA COMPRESSION HEAD ZYLINDERBLOCK CABEZAL DE COMPRESIÓN BLOC DE COMPRESSION
0050 9513-1899-000 16 PRIGIONIERO STUD STIFTSCHRAUBE PRISIONERO GOUJON
0060 9537-6012-000 16 DADO NUT MUTTER TUERCA ECROU
0070 9531-4067-595 5 O-RING O-RING O-RING JUNTA TÓRICA JOINT TORIQUE
0080 9513-3788-000 3 FLANGIA FLANGE FLANSCH BRIDA BRIDE
0200 9513-5123-010 5 DISTANZIERE SPACER DISTANZSTUECK DISTANCIADOR ENTRETOISE
0210 9534-1792-509 5 PACCHETTO PACKING PACKUNG EMPAQUETADURA GARNITURE DE PISTON
0220 9513-2590-000 5 RONDELLA WASHER UNTERLEGSCHEIBE ARENDELA RONDELLE
0260 9513-3784-000 5 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING STÜTZRING ANILLO ANTIEXTRUSION BAGUE ANTIEXTRUSION
5C051E3_14381.xlsm 1 / 18 GEA Mechanical Equipment / GEA Niro Soavi

Spare parts list
Suction valve group - Saugventil Baugruppe - Grupo válvula aspiración - Ensemble clapets d'aspiration
0020 9511-8869-000 5 SEDE VALVOLA VALVE SEAT VENTILSITZ ASIENTO VALVULA SIEGE DE SOUPAPE
0030 9531-9058-000 5 SFERA BALL KUGEL BOLA SPHERE
0040 9513-5677-010 5 MOLLA SPRING FEDER MUELLE RESSORT
0050 9513-2594-120 5 COPERCHIO VALVOLA VALVE COVER VENTILKAPPE TAPA PARA VALVULA CAPUCHON DE SOUPAPE

Spare parts list
Delivery valve group - Druckventil Baugruppe - Grupo válvula salida - Ensemble clapets de refoulement

Spare parts list
Plunger group - Kolbengruppe - Grupo piston - Ensemble piston pompant
0020 9513-9309-180 5 PISTONE PLUNGER KOLBEN PISTON PISTON
0030 9512-9179-000 5 MORSETTO CLAMP KLEMME ABRAZADERA MORS
0040 9513-4121-000 5 PROLUNGA EXTENSION VERLAENGERUNG PROLONGADOR PROLONGATEUR
0050 9536-9108-025 10 VITE SCREW SCHRAUBE TORNILLO VIS

Spare parts list
Pressure gauge - Manometer - Gr. Manómetro - Ensemble manometre
0020 9533-1002-011 1 MANOMETRO PRESSURE GAUGE MANOMETER MANOMETRO MANOMÈTRE
0040 - 1 CODICE NON PRESENTE NOT EXISTING CODE NICHT BESTEHENDER KODE CÒDIGO NO PRESENTE CODE ABSENT

Spare parts list
Pressure transducer - Druckaufnehmer - Gr. Transductor - Transmetteur de pression
0020 9533-2010-011 1 MANOTRASMETTITORE PRESSURE TRANSMITTER DRUCKAUFNEHMER TRANSMISOR DE PRESION MANOTRANSMETTEUR DE PRESSION

Spare parts list
Manifold group - Einlassrohr - Gr. Colector - Collecteur
0020 9513-4071-000 1 COLLETTORE MANIFOLD EINLASSROHR COLECTOR COLLECTEUR
0040 9532-7154-000 1 TRONCHETTO FERRULE ANSCHLUSS-STUTZEN TENAZAS INTERRUPTEUR

Spare parts list
Suction pulsation damper - Pulsationsdampfer-auslass - Amortiguador pulaciones salida - Amortisseur de pulsation en entree
0020 9532-7194-090 1 RACCORDO A T TEE CONNECTION T-STUECK CONEXIÓN TIPO T RACCORD EN T
0030 9531-4571-405 2 GUARNIZIONE GASKET DICHTUNG JUNTA JOINT
0050 9514-1173-000 1 POLMONE PULSATION DAMPER PULSATIONSDAEMPFER DAMPEER/PULMÓN COMPESADOR AMORTISSEUR
0070 9533-3026-000 1 TRASDUTTORE TRANSDUCER SIGNALUMFORMER TRANSMISOR DE PRESIÓN TRANSDUCTEUR

Spare parts list
Outlet flange group - Auslassflansch baugruppe - Gr. Brida de salida - Bride de refoulement

Spare parts list
Relief valve - Druckbegrenzungsventil - Gr. Válvula de seguridad - Vanne de securite
0070 9512-6123-030 1 ALBERINO PUSHROD WELLE EJE ARBRE
0090 9513-8009-010 1 CORPO BODY GEHAEUSE CUERPO CORPS
0120 9513-8048-010 1 TUBO DI SCARICO DISCHARGE PIPE AUSLASSROHR TUBO DE DESCARGA TUBE DE PURGE
0160 9512-4714-000 1 BRONZINA BRONZE BUSHING BRONZELAGER COJINETE DE BRONCE COUSSINET EN BRONZE
0170 9512-4712-000 1 CONTENITORE MOLLA SPRING HOUSING FEDERGEHAEUSE ALOJAMIENTO MUELLE CONTENEUR RESSORT
0260 9533-5043-000 1 PIOMBO SEAL PIOMBO PLOMO PLOMB

Spare parts list
1st Stage homogenizing group - Homogenisierventil baugruppe 1s - GR. Homogeneización 1 etapa - Gr. Homogeneisant 1er etage
0020 9513-2439-090 1 CAMERA OMOGENEIZZANTE HOMOGENIZING CHAMBER HOMOGENISIERKAMMER CÁMARA DE HOMOGENEIZACIÓN CHAMBRE HOMOGÉNÉISANTE
0030 9513-6883-000 1 GUIDA GUIDE FUEHRUNG GUIA GUIDE
0040 9513-0462-000 1 TESTINA D'URTO IMPACT HEAD PRALLKOPF CABEZA DE CHOQUE TÊTE DE CHOC
0050 9512-2594-000 1 ANELLO D'URTO IMPACT RING PRALLRING ANILLO DE CHOQUE ANNEAU DE CHOC
0060 9512-2008-000 1 TESTINA DI PASSAGGIO PASSAGE HEAD PRALLPLATTE CABEZA DE PASO TÊTE DE PASSAGE
0100 9513-2418-000 1 CONTENITORE ANELLO URTO IMPACT RING HOUSING PRALLRINGGEHAEUSE ALOJAMIENTO ANILLO CHOQUE CONTENEUR BAGUE DE CHOC
0150 9532-6352-000 4 BUSSOLA BUSHING BUCHSE MANGUITO FOURREAU
0200 9533-5247-030 1 CILINDRO PNEUMATICO PNEUMATIC ACTUATOR PNEUMATIKZYLINDER CILINDRO NEUMATICO CYLINDRE PNEUMATIQUE
0240 9513-0878-000 1 SUPPORTO SUPPORT LAGER SOPORTE SUPPORT
0250 9532-6119-000 1 RACCORDO CONNECTION ANSCHLUSS RACOR RACCORD
0260 9532-7219-000 2 RIDUZIONE REDUCTION REDUZIERUNG REDUCION RÉDUCTION
0280 9531-1698-000 4 TAPPO PLUG STOPFEN TAPON BOUCHON

Spare parts list
2nd Stage homogenizing group - Homogenisierventil baugruppe 2s - GR. Homogeneización 2 etapa - Gr. Homogeneisant 2eme etage
0020 9513-2439-000 1 CAMERA OMOGENEIZZANTE HOMOGENIZING CHAMBER HOMOGENISIERKAMMER CÁMARA DE HOMOGENEIZACIÓN CHAMBRE HOMOGÉNÉISANTE
0030 9513-6883-000 1 GUIDA GUIDE FUEHRUNG GUIA GUIDE
0040 9513-0462-000 1 TESTINA D'URTO IMPACT HEAD PRALLKOPF CABEZA DE CHOQUE TÊTE DE CHOC
0050 9512-2594-000 1 ANELLO D'URTO IMPACT RING PRALLRING ANILLO DE CHOQUE ANNEAU DE CHOC
0060 9512-2008-000 1 TESTINA DI PASSAGGIO PASSAGE HEAD PRALLPLATTE CABEZA DE PASO TÊTE DE PASSAGE
0100 9513-2418-000 1 CONTENITORE ANELLO URTO IMPACT RING HOUSING PRALLRINGGEHAEUSE ALOJAMIENTO ANILLO CHOQUE CONTENEUR BAGUE DE CHOC
0200 9533-5247-030 1 CILINDRO PNEUMATICO PNEUMATIC ACTUATOR PNEUMATIKZYLINDER CILINDRO NEUMATICO CYLINDRE PNEUMATIQUE
0260 9532-7221-000 2 RIDUZIONE REDUCTION REDUZIERUNG REDUCION RÉDUCTION

Spare parts list
Transmission body - Antriebsgehause baugruppe - Gr. Cuerpo transmisión - Carter de transmission
0020 9513-1080-000 1 CORPO DI TRASMISSIONE TRANSMISSION BODY ANTRIEBSGEHAEUSE CUERPO DE TRANSMISIÓN CORPS DE TRANSMISSION
0030 9513-8412-000 1 ALBERO A GOMITI CRANKSHAFT KURBELWELLE CIGÜEÑAL VILEBREQUIN
0040 9532-2400-000 2 CUSCINETTO BEARING LAGER COJINETE ROULEMENT
0120 9512-6778-000 5 PISTONE DI GUIDA CROSS-HEAD KREUZKOPF PISTÓN GUÍA GUIDE PISTON
0130 9532-5019-000 5 SPINOTTO WHRIST PIN KOLBENBOLZEN CLAVIJA AXE
0150 9513-5775-000 5 BIELLA CONROD PLEUEL BIELA BIELLE
0180 9531-6131-516 5 ANELLO RASCHIATORE ROD SCRAPER ABSTREIFER ANILLO RASCADOR JOINT RACLEUR
0220 9513-3774-000 5 SOFFIETTO BELLOWS PNEUGEBLASE FUELLE SOUFFLET
0230 9513-1082-000 1 COPERCHIO COVER ABDECKUNG TAPA COUVERCLE
0270 9513-1083-000 1 COPERCHIO COVER ABDECKUNG TAPA COUVERCLE
0300 9538-1896-000 1 LINGUETTA KEY PASSFEDER LENGUETA CLAVETTE
A COMPLETAMENTO: IN ADDITION: ZUR ERGAENZUNG: PARA COMPLETAMIENTO POUR COMPLETE:
- 9537-9061-000 1 TUBO PIPE ROHR TUBO TUBE - CONDUITE

- 9512-2927-000 1 RACCORDO CONNECTION ANSCHLUSS RACOR RACCORD
- 9531-2180-000 1 FASCETTA HOSE CLAMP ROHR CLEMME ABRAZADERA BANDEAU
- 9532-7224-000 1 TAPPO PLUG STOPFEN TAPON BOUCHON
- 9532-7226-000 1 TAPPO PLUG STOPFEN TAPON BOUCHON
- 9532-6146-000 3 NIPPLO THREAD NIPPEL NIPLE NIPPLE
- 9532-6267-000 4 RACCORDO A T TEE CONNECTION T-STUECK CONEXIÓN TIPO T RACCORD EN T
- 9532-7215-000 1 NIPPLO THREAD NIPPEL NIPLE NIPPLE
- 9532-6159-000 1 MANICOTTO SLEEVE KUPPLUNG MANGUITO MANCHON
- 9532-6074-000 1 RACCORDO CONNECTION ANSCHLUSS RACOR RACCORD

26 24 25
A A
29
27
8
4 14 13 12 2
31 28
7
22
17
21
20
16
23
11
19
9
5 18
6 32 30 3 10 4 15
. . . .
REF. PART-CODE PART-DESCRIPTION U. QTY. MATERIAL M.CODE NOTE
DESCRIPTION MATERIAL M.CODE
ESPLOSO CORPO TRASMISSIONE NS5180 RIDUTTORE A4
DESIGNER APPROV. CHECKED DATE SCALE
Niro-Soavi S.p.A. 1:12
LS . . 17-06-2005
via M. da Erba Edoari, 29/A SH.1 OF 1
REV. DESCRIPTION SIGN. DATE
SEZIONE A-A
43100 PARMA (ITALY) DRAWING
PHONE:++39.(0)521.965411 - FAX:++39.(0)521.242819 0135782

T h i s d r a w i n g i s p ro p e rt y o f N I R O - S O AV I , w h i ch w i l l g u a r d i t s ri g h t s b y l a w t e rm s.
Spare parts list
Drive end - Antrieb - Gr. Motorización - Ensemble de Motorisation
0020 9569-0000-001 1 MOTORE MOTOR MOTOR MOTOR MOTEUR
0030 9533-4067-000 1 RIDUTTORE GEARBOX ZAHNRADGETRIEBE REDUCTOR RÉDUCTEUR
0070 9536-1110-000 1 PULEGGIA PULLEY SCHEIBE POLEA POULIE
0080 9536-1111-000 1 BUSSOLA CONICA TAPER BUSHING BUCHSE KONISCH MANGUITO CÓNICO FOURREAU CONIQUE
0090 9534-0023-150 6 CINGHIA BELT RIEMEN CORREA COURROIE
0100 9536-1114-000 1 PULEGGIA PULLEY SCHEIBE POLEA POULIE
0110 9536-1365-000 1 BUSSOLA CONICA TAPER BUSHING BUCHSE KONISCH MANGUITO CÓNICO FOURREAU CONIQUE
0130 9535-3016-000 50 OLIO OIL OEL ACEITE HUILE
0140 9536-7012-000 2 GRANO GRIB SCREW SCHRAUBE TORNILLO VIS
0170 9533-5047-000 1 SLITTA MOTORE MOTOR SLIDE MOTORSCHLITTEN CORREDERA DE MOTOR CHARIOT MOTEUR

3 21 5 14
6
QUOTE SENZA INDICAZIONE DI TOLLERANZA CLASSE DI TOLL. FINE UNI EN 22768/1-f
DETTAGLIO A
SCALA 1 : 10
9
A
11
16 15 4 10
2 18 17
19 20
. . . .
REF. PART-CODE PART-DESCRIPTION U. QTY. MATERIAL M.CODE NOTE
DESCRIPTION MATERIAL M.CODE
NS5180 G-FX DRIVE END A4
DESIGNER APPROV. CHECKED DATE SCALE
1:50
ANS . . 08-07-2011
Niro-Soavi S.p.A.
via M. da Erba Edoari, 29/A SH. 1 OF 1
REV. DESCRIPTION SIGN. DATE
43100 PARMA (ITALY) DRAWING
MACCH. N.P. PHONE:++39.(0)521.965411 - FAX:++39.(0)521.242819 0135783-1

This drawing is property of NIRO-SOAVI, which will guard its rights by law terms.
Spare parts list
Pneumatic plant - Pneumatiksystem - Planta Neumática - Circuit pneumatique
0020 9532-6162-000 1 NIPPLO THREAD NIPPEL NIPLE NIPPLE
0040 9533-9286-000 1 FILTRO FILTER FILTER FILTRO FILTRE
0080 9533-8100-110 1 PRESSOSTATO PRESSURE SWITCH DRUCKWAECHTER PRESOSTATO PRESSOSTAT
0100 9532-6932-620 2 INTERRUTTORE PNEUMATICO PNEUMATIC SWITCH PNEUMATIKSCHALTER INTERRUPTOR NEUMÁTICO INTERRUPTEUR PNEUMATIQUE
0110 9532-6932-270 2 RIDUTTORE PRESSIONE PRESSURE REDUCER DRUCKREDUZIERER REDUCTOR DE PRESION RÉDUCTEUR DE PRESSION
0120 9535-8104-280 2 DOSATORE FLOW BATCHER FLOSSDOSIERANLAGE DOSIFICADOR DOSEUR
0140 9532-6310-000 2 GIUNTO COUPLING KUPPLUNG ACOPLAMIENTO JOINT À CARDAN
0210 9535-3006-000 4 OLIO OIL OEL ACEITE HUILE
0230 9538-8008-000 1 SERBATOIO TANK BEHAELTER TANQUE/TAMPON RÉSERVOIR
0280 9538-8009-000 1 SERBATOIO TANK BEHAELTER TANQUE/TAMPON RÉSERVOIR

Spare parts list
Lubrication plant - Schmiersystem - Planta Lubricación - Circuit de lubrification
0020 9532-6932-360 1 CENTRALINA LUBRICATION UNIT ZENTRALSCHMIERUNG CENTRAL DE LUBRICACIÓN CENTRALE DE LUBRIFICATION
0030 9569-0000-001 1 MOTORE MOTOR MOTOR MOTOR MOTEUR
0050 9533-6101-000 1 SCAMBIATORE HEAT EXCHANGER WAERMETAUSCHER INTERCAMBIADOR EXCHANGEUR DE CHALEUR
0070 9533-8100-110 1 PRESSOSTATO PRESSURE SWITCH DRUCKWAECHTER PRESOSTATO PRESSOSTAT
0100 9531-7013-000 1 LIVELLO OLIO OIL LEVEL OELSTAND-ANZEIGE NIVEL DE ACEITE NIVEAU D'HUILE
0110 9535-8012-000 1 RUBINETTO BALL TAP HAHN VÁLVULA DE BOLA ROBINET
0190 9537-9060-000 1 TUBO PIPE ROHR TUBO TUBE - CONDUITE
0210 9532-6932-630 2 PORTAGOMMA HOSE COUPLING SCHLAUCHKUPPLUNG ACOPLAMIENTO GOMA PORTE CAOUTCHOUC
0220 9533-5167-000 1 VALVOLA STROZZATORE THROTTLE VALVE REDUZIERVENTIL EXTRANGULADOR VANNE D'ÉTRANGLEMENT
A COMPLETAMENTO: IN ADDITION: ZUR ERGAENZUNG: PARA COMPLETAMIENTO POUR COMPLETE:
- 9532-6670-000 2 MANICOTTO SLEEVE KUPPLUNG MANGUITO MANCHON
- 9538-8059-000 1 ADATTATORE ADAPTER ADAPTER ADAPTADOR ADAPTATEUR

GEA Niro Soavi 8/07/2013 - Rev. 3.0
Description Code
GEA Niro Soavi Lubricating Unit TP3 TT - 0100
1 Type NSOA Code
FP - GR 1-9,8 (L12) 9532-6932-360 (Motor Type IEC)
1.1 Description
Lubricating unit with gear type oil pump (displacement 9,8 cm3/rev), adjustable bypass valve to
regulate the operating pressure, suction side filter and oil tank, volume 12 L. The unit is prearranged
for electric motor installation, including adapter flange and two-parts elastic joint.
1.2 Technical Data
Data Unit Note
3
Gear Pump Displacement 9,8 cm /rev
Motor RPM @ 50 Hz 1500 rpm
Motor RPM @ 60 Hz 1800 rpm
Motor Type IEC 0,75 kW Frame 80 B14 4 poles
Oil Tank Volume 12 l
Suction Filter Type 90 micron
Max Working Pressure 15 bar
Oil Type ISO VG 150
1.3 Performances
Data Unit Note
Nominal Flow @ 50 Hz 14,7 l/min
Nominal Flow @ 60 Hz 17,6 l/min
STD Pressure @ 35°C 6 bar higher value allowed at cold start
1.4 List of Components - drawing 9514-1900-000 (NS5132 - NS5180)
Description Part code Item Description Part code Item
Motor Flange 9532-6932-400 A Filter kit 9532-6932-520 F
Motor flange (IEC size 80 B14) 27 Suction filter 1"G mesh 90 18
Coupling 1"G-3/8"G 16
Body Kit 9532-6932-410 B Copper washer 1"G 17
Body TP3A 1 Oring 6
Supporting bracket 20 Tank 9532-6932-530 G
Overpressure valve 10+2 Tank Lt. 12 1"G 9
By-Pass 9532-6932-420 C Plug kit 9532-6932-540 H

Overpressure valve 10 PLUG TCEI G1/4 7
PLUG VSC 04 8
Joint 9532-6932-450 D PLUG G 1/4 22
Motor/Pump joint 29-30-31 EXTENSION 24
COUPLING 35
Main pump kit 9532-6932-510 E COUPLING+PLUG 34-33-4
Pump OT100 P65 D/N16 B2 13 PLUG G 1/2 19
Discharge manifold kit 23-25-36
Motor /Pump joint 29-30-31
Screw kit 9532-6932-500 I
Screw TCEI M6X45 11
SCREW TCEIM8+M10+M8 12-21-28
file: TT-0100.xls - TT-0100 page 1/1

Spare parts list
Water plant - Kuhlwassersystem - Planta de agua - Circuit d'eau
0010 9513-3601-136 1
0020 9550-0000-491 2 ADATTATORE ADAPTER ADAPTER ADAPTADOR ADAPTATEUR
0050 9533-7202-000 2 ELETTROVALVOLA ELECTROVALVE MAGNETVENTIL ELECTROVALVULA ÉLECTROVANNE
0070 9533-8200-140 1 FLUSSOSTATO FLOW SWITCH STROEMUNGSWAECHTER DETECTOR DE FLUJO INDICATEUR DE DÉBIT
0100 9532-6000-000 1 PORTAGOMMA HOSE COUPLING SCHLAUCHKUPPLUNG ACOPLAMIENTO GOMA PORTE CAOUTCHOUC
0110 9531-2001-000 2 FASCETTA HOSE CLAMP ROHR CLEMME ABRAZADERA BANDEAU
0160 9532-6045-000 2 VALVOLA VALVE VENTIL VALVULA SOUPAPE - VANNE
0200 9532-6702-000 5 UGELLO NOZZLE DUESE TOBERA BUSE

Spare parts list
Extra spare parts - Zusatliche ersatzteile - Lista de ricambios añadidos - Liste des pièces détachées additionnelles
- 9513-5677-010 10 MOLLA SPRING FEDER MUELLE RESSORT
- 9531-6131-516 5 ANELLO RASCHIATORE ROD SCRAPER ABSTREIFER ANILLO RASCADOR JOINT RACLEUR
- 9532-3002-000 2 CARTUCCIA FILTRO FILTER CARTRIDGE FILTEREINSATZ CARTUCHO FILTRO CARTOUCHE FILTRANTE
- 9532-6932-520 2 CARTUCCIA FILTRO FILTER CARTRIDGE FILTEREINSATZ CARTUCHO FILTRO CARTOUCHE FILTRANTE
- 9512-3798-000 1 SEDE VALVOLA VALVE SEAT VENTILSITZ ASIENTO VALVULA SIEGE DE SOUPAPE
- 9531-9044-010 1 SFERA BALL KUGEL BOLA SPHERE
- 9513-9309-180 1 PISTONE PLUNGER KOLBEN PISTON PISTON
- 9513-6970-180 5 PISTONE PLUNGER KOLBEN PISTON PISTON

SECTION 6
ELECTRICAL DIAGRAMS - INDEX
6.1. Electrical diagrams
6C001E5C
6.1
6.1. Electrical diagrams
In the following pages it is possibile to find the wiring diagrams of the electrical devices installed
onboard the machine, or as an alternative, the complete electrical diagram of the Electric Power
Board if the same or its engineering is supplied by GEA Mechanical Equipment Italia S.p.A..
We recommend to check carefully the wiring diagrams to proceed with correct connection of the
machinhe and its components.
The wiring of the machine and its components must be done by qualified personnel who must be
able to understand properly the supplied electrical documentation and wiring diagrams.
6C001E5C
6.2
Electrical list
Electrical list - Elektrische - Lista parte eléctrica - Liste de pièces électrique
- 9562-1206-283 1 MOTORE MOTOR MOTOR MOTOR MOTEUR
- 9562-0228-517 1 MOTORE MOTOR MOTOR MOTOR MOTEUR

Section 7
Suppliers catalogue - index
7.1. Sub-suppliers and components catalogue
7C001E5C
7.1
7.1. Sub-suppliers and components catalogue
We have included copies of the suppliers’ catalogues and of components installed in the machine.
In addition to the maintenance guidelines provided in this USE AND MAINTENANCE MANUAL, you
should refer to the specific instructions of any installed components
7C001E5C
7.2
GEA Niro Soavi
LIST OF SUB-SUPPLIERS COMPONENTS
Ref. Part Code Description Description

7.01.1 9562-1206-283 MOTORE MOTOR
7.01.2 9562-0228-517 MOTORE MOTOR
7.01.3 9533-1002-011 MANOMETRO PRESSURE GAUGE
7.01.4 9533-2010-011 MANOTRASMETTITORE PRESSURE TRANSMITTER
7.01.5 9533-3026-000 TRASDUTTORE TRANSDUCER
7.01.6 9533-4067-000 RIDUTTORE GEARBOX
7.01.7 9532-6932-360 CENTRALINA LUBRICATION UNIT
7C011E0_C_14381
1 of 1
GEA Niro Soavi
7.01.1 9562-1206-283 MOTORE MOTOR
7.01.1
GEA Niro Soavi
7.01.2 9562-0228-517 MOTORE MOTOR
7.01.2
Low Voltage Motors
Manual for Low Voltage Motors
Installation, operation and

maintenance manual GB 3
Example of the Declaration of Conformity
given by ABB.
GB
EC Declaration of Conformity
The Manufacturer :- (Name and address of the manufacturer)
hereby declares that
The Products :- (Product identification)
are in conformity with provisions of the following Council Directives :
Low Voltage Directive 73/23/EEC (amended by 93/68/EEC),
and, as components, with the essential requirements of the following :
EMC Directive 89/336/EEC (amended by 92/31/EEC and 93/68/EEC), regarding the intrinsic
characteristics to emission and immunity levels,
and are in conformity with :
EN 60 034-1
Additional Information :-
By design, the machines, considered as components, comply with the essential requirements of
Machinery Directive 98/37/EEC provided that the installation be correctly realised by the manufacturer
of the machinery (for example : in compliance with our Installation Instructions and EN 60 204 “Electri-
cal Equipment of Industrial Machines”).
Certificate of Incorporation (Directive 98/37/EEC, Art 4.2 and Annex II, Sub B) :
The machines above must not be put into service until the machinery into which they have
been incorporated have been declared in conformity with the Machinery Directive.
Year of CE marking : CE00.
Signed by ..................................................
Title ...........................................................
Date ..........................................................
Translations into other languages are available from ABB.
GB – 2 ABB / Low Voltage Motors / Manual 12-2004

Low Voltage Motors
Installation, operation and maintenance manual
GB
Contents Page
1. General ................................................................................................................................. 4
1.1 Declaration of Conformity ............................................................................................ 4
1.2 Validity ........................................................................................................................ 4
2. Installation ........................................................................................................................... 4
2.1 Putting into service (starting) ....................................................................................... 4
2.1.1 Reception check .............................................................................................. 4
2.1.2 Insulation resistance check.............................................................................. 4
2.1.3 Direct-on-line or star/delta starting ................................................................... 5
2.1.4 Terminals and direction of rotation .................................................................. 5
2.2 Handling ...................................................................................................................... 5
2.2.1 Storage ............................................................................................................ 5
2.2.2 Transportation.................................................................................................. 5
2.2.3 Lifting ............................................................................................................... 5
2.2.4 Machine weights .............................................................................................. 6
2.3 Installation .................................................................................................................... 6
2.3.1 Cooling............................................................................................................. 6
2.3.2 Foundation ....................................................................................................... 6
2.3.3 Alignment ......................................................................................................... 6
2.3.4 Slide rails and belt drives ................................................................................. 6
2.4 Connection ................................................................................................................... 7
2.4.1 Connection for variable speed drive ................................................................ 7
2.5 Balancing ........................................................................................................................ 7
3. Operating ............................................................................................................................. 8
3.1 Use ............................................................................................................................... 8
3.1.1 Operating conditions ........................................................................................ 8
3.2 Safety considerations ................................................................................................... 8
3.2.1 Points to observe ............................................................................................. 8
3.3 Assembly and dismantling ........................................................................................... 8
3.3.1 General ............................................................................................................ 8
3.3.2 Bearings........................................................................................................... 8
3.3.3 Fitting coupling halves and pulleys .................................................................. 8
4. Maintenance ........................................................................................................................ 9
4.1 Maintenance and lubrication ........................................................................................ 9
4.1.1 General inspection ........................................................................................... 9
4.1.2 Lubrication ....................................................................................................... 9
4.1.3 Machines with permanently greased bearings ................................................ 9
4.1.4 Motors with regreasing nipples ........................................................................ 9
4.1.5 Lubrication intervals and amounts ................................................................... 10
4.1.6 Lubricants ........................................................................................................ 10
4.1.7 Frequency converter drives ............................................................................. 11
4.1.8 Spare parts ...................................................................................................... 11
4.1.9 Rewinding ........................................................................................................ 11
5. Environmental requirements ............................................................................................. 11
5.1 Noise levels .................................................................................................................. 11
6. Troubleshooting .................................................................................................................. 12
ABB / Low Voltage Motors / Manual 12-2004 3 – GB

1. General 2. Installation
NOTE! 2.1 Putting into service (starting)
These instructions must be followed to ensure safe
GB
and proper installation, operation and maintenance of

the motor. They should be brought to the attention of
2.1.1 Reception check
anyone who installs, operates or maintains this Immediately upon receipt check the machine for external
equipment. Ignoring the instruction may invalidate damage and if found, inform the forwarding agent
the warranty. without delay.
Check all rating plate data, especially voltage and
1.1 Declaration of Conformity winding connection (star or delta). The type of bearing is
Declarations of Conformity with respect to the Low specified on the rating plate of all motors except the
voltage Directive 73/23/EEC amended by Directive smallest frame sizes.
93/68 EEC are issued separately with individual Remove transport locking if employed.Turn shaft by
machines. hand to check free rotation.
The Declaration of Conformity also satisfies the
Do not exceed permissible loading values of bearings
requirements of a Declaration of Incorporation with
stated in the product catalogue.
respect to the Machinery Directive 98/37/EEC, Art 4.2
Annex II, sub B Motors equipped with roller bearings: Running the
motor with no radial force applied to the shaft may
damage the roller bearing.
1.2 Validity
Motors equipped with angular contact bearing:
The instructions are valid for the following ABB
Running the motor with no axial force applied in the right
electrical machine types, in both motor and generator
direction to the shaft may damage the angular contact
operation.
bearing.
series MT*, MBT*, MXMA,
Motors equipped with regreasing nipples:
series M2A*/M3A*, M2B*/M3B*, M2C*/M3C*,
When starting the motor for the first time, or after long
M2F*/M3F*, M2L*/M3L*, M2M*/M3M*, M2Q*,
storage of the motor, apply the specified quantity of
M2R*/M3R*, M2V*/M3V*
grease until grease is forced out of the grease outlet.
in frame sizes 56 - 450.
For details see section “Manual lubrication" on page 9.
There is a separate manual for e.g. Ex motors ‘Low
voltage motors for hazardous areas: Installation, 2.1.2 Insulation resistance check
operation and maintenance Manual’ (Low Voltage
Motors/Manual for Ex-motors). Measure insulation resistance before commissioning
and when winding dampness is suspected.
Additional information is required for some machine
types due to special application and/or design Resistance, measured at 25°C, shall exceed the
considerations. Additional information is available for reference value, i.e. 10 M ohm (measured with 500 V dc
the following motors: Megger)
– roller table motors

– water-cooled motors WARNING
– open drip proof motors Windings should be discharged immediately after
– smoke venting motors measurement to avoid risk of electric shock.
– brake motors
– permanent magnet motors Insulation resistance reference value is halved for each
20°C rise in ambient temperature.
If the reference resistance value is not attained, the
winding is too damp and must be oven dried.
Oven temperature should be 90°C for 12-16 hours
followed by 105°C for 6-8 hours.

Drain hole plugs, if fitted, must be removed and closing
valve, if fitted, must be opened during heating.
2.2 Handling
Windings drenched in seawater normally need to be 2.2.1 Storage
rewound.
GB
The machine should always be stored indoors, in dry,
vibration free and dust free conditions.
2.1.3 Direct-on-line or star/delta
starting Unprotected machined surfaces (shaft-ends and
flanges) should be protected with anti-corrosive
The terminal box on standard single speed machines treatment.
normally contains 6 winding terminals and at least one
earth terminal. It is recommended that shafts be rotated periodically by
hand to prevent grease migration.
Earthing must be carried out according to local
regulations before the machine is connected to the Anti condensation heaters, if fitted, should preferably be
supply voltage. energised.
The voltage and connection are stamped on the rating The characteristics of electrolytic capacitors, if fitted to
plate. single-phase motors, will require “reforming” following
periods of storage exceeding 1-2 years.
Direct-on-line starting (DOL): Contact ABB Sales Office for details.
Y or D winding connections may be used.
e.g. 660 VY, 380 VD indicates Y-connection for 660 V
2.2.2 Transportation
and D-connection for 380 V. Machines fitted with cylindrical-roller and/or angular
contact bearings must be fitted with locking devices
Star/Delta starting (Y/D): during transport.
The supply voltage must be equal to the rated voltage
of the machine in D-connection. 2.2.3 Lifting
Remove all connection links from the terminal block. Lift the motor using the lifting lugs only, if not otherwise
For two-speed, single phase and special machines, stated in the separate lifting instruction.
supply connection must follow the instructions inside The center of gravity of motors with the same frame
the terminal box. may vary due to different outputs, mounting
If direct-on-line starting lasts for more than 10 seconds arrangements and auxiliary equipment.
or Y/D starting more than 30 seconds, consult ABB Check that eyebolts or the lifting lugs integrated with the
Sales Office or see the publication ‘The Motor Guide' motor frame are undamaged before lifting. Damaged
(also available on the internet on www.abb.com/ lifting lugs must not be used.
motors&drives).
Lifting eyebolts must be tightened before lifting.
If needed the position of the eyebolt must be adjusted
2.1.4 Terminals and direction of with suitable washers.
rotation
Ensure that proper lifting equipment is used and that
Direction of rotation is clockwise when viewing the shaft the sizes of the hooks are suitable for the lifting lugs.
face at the machine drive end, when the line phase
sequence L1, L2, L3 is connected to the terminals as Care must be taken not to damage auxiliary equipment
shown in the figure 1. and cables attached to the motor.
To alter the direction of rotation, interchange the

connection of any two line cables.
If the machine has a uni-directional fan, ensure that the
direction of rotation is according to the arrow marked on
the machine.

2.2.4 Machine weights Before mounting the motor, the foundation surface for
the shims or for the feet must be clean from thick paint,
Total machine weight can vary within the same frame paint drops and dirt. Then it should be checked in order
size (center height) depending on different output, to discover any height differences between the
mounting arrangements and added features.
GB
individual foot locations. Also, the smoothness within

The following table shows estimated maximum weights each footprint area has to be checked. The
for machines in their basic versions as a function of requirements are noted in the figure below.
frame material.
The actual weight of all our motors is stated on the Note! Height
Ruler difference shall not
rating plate except the smallest frame sizes.
exceed ± 0,1 mm
Aluminum Cast iron Steel referred to any other
Frame Weight Add. Weight Weight motor foot location
size kg for brake kg kg
56 4.5 - - -
63 6 - - -
71 8 5 13 -
Foot location
80 12 8 20 -
90 17 10 30 -
100 25 16 40 - Foundation studs
112 36 20 50 - Bolt the foundation studs to the feet of the motor and
132 63 30 90 - place a 1-to-2 mm shim between the stud and the feet.
160 110 30 175 - Align the motor directly using appropriate means.
180 160 45 250 - Grout the studs with concrete, check alignment and drill
200 220 55 310 - holes for locating pins.
225 295 75 400 -
250 370 75 550 - Drain holes
280 405 - 800 600 Always check that open drain holes face downward.
315 - - 1700 1000
355 - - 2700 2200 In extremely dusty environments, all drain holes should
400 - - 3500 3000 be closed.
450 - - 5000 4500
Table 1 2.3.3 Alignment
Correct alignment is essential to avoid bearing failures,
vibrations and possible fractured shaft extensions.
2.3 Installation
2.3.1 Cooling 2.3.4 Slide rails and belt drives
– Fasten the machine to the slide rails as shown in
Normal ambient temperatures should not exceed 40°C
figure 2.
(marine standard +45 or +50°C) if standard
– Place the slide rails horizontally on the same level.
performance is to be achieved. Check that the motor
– Check that the machine shaft is parallel with driven,
has sufficient airflow. Ensure that no nearby equipment,
or driving, shaft.
surfaces or direct sunshine, radiate additional heat to
– Any belt must be tensioned according to the
the motor. For more information about higher ambient
supplier's instructions.
temperatures and cooling, see “the Motor Guide” or
contact ABB Sales Office.
WARNING
2.3.2 Foundation Excessive belt tension will damage bearings and
can cause shaft breakage.
The purchaser bears full responsibility for preparation of
the foundation. Do not exceed the maximum belt forces (i.e. radial
Metal foundations should be painted to avoid corrosion. bearing loading) stated in the relevant product
catalogues.
Foundations must be even, and sufficiently rigid to
withstand possible short circuit forces. They shall be
dimensioned as to avoid the occurrence of vibration due
to resonance.

2.4 Connection Potential equalisation
Normal machine design has the terminal box on top
with cable entry possible from both sides. Plate/strip Cables/wires
GB
Some machines are available with top mounted terminal
boxes rotatable 4 x 90°, and some with side mounted
terminal boxes.
Driven machinery
Availability of these solutions is described in the product
catalogues.
Unused cable entries must be closed. To comply with EMC-requirements, use only cables and
As well as main winding and earthing terminals, the connectors approved for this purpose. (See instruction
terminal box can also contain connections for for frequency converters.)
thermistors, standstill heating elements, bimetallic, The highest permissible rotational speed of a cast iron
switches, or PT 100 resistance elements. motor used in variable speed drive (M2BA/M3BP) must
not exceed maximum permissible speeds as stated in
WARNING the table 2 below or the speed stamped on the rating
Voltage may be connected at standstill inside the plate. For information on the highest permissible
terminal box for heating elements or direct winding rotational speed for other motor sizes and types, please
heating. contact ABB. Bearing lubrication should follow the
directions mentioned later.
Connection diagrams for auxiliary elements are found Frame Speed r/min
inside the terminal box cover or in additional labels on size 2 pole 4 pole
the frame of the machine.
280 3600 2600
315 3600 2300
WARNING
The capacitor in single-phase motors can retain 355 3600 2000
a charge that appears across the motor terminals, 400 3600 1800
even when the motor has reached standstill. 450 3600 1800
2.4.1 Connection for variable Table 2

speed drive
If there is uncertainty concerning the suitability of the
Variable speed drives cause higher voltage stresses motor for the variable speed drive, please contact ABB.
than the sinusoidal supply on the winding of the motor
and may cause high frequency shaft voltages and
bearing currents. Therefore the winding and the bearing WARNING
insulation of the motor as well as the filter at the The maximum operating temperature of the
converter output must be dimensioned according to grease and bearings must not be exceeded.
"Selection rules for VSD applications/Insulation"
(3GZF500930-2), available on request from ABB. 2.5 Balancing
In variable speed drives the motor (Pn > 30 kW) must The rotor of the machine is dynamically balanced.
be cabled by using shielded symmetrical cables and
As standard, balancing has been carried out using half
cable glands providing 360° bonding (also called EMC
key, and the shaft is marked with a RED tape, with the
glands). More information can be found in ABB’s
text “Balanced with half key”. In case of motors
manual “Grounding and cabling of the drive system”
delivered without any tape defining the type of
(3AFY61201998).
balancing, these motors are also balanced with half
In frequency converter applications motor frame key.
external earthing must be used for equalising the
To avoid vibration the coupling-half or pulley must be
potential between the motor frame and the driven
balanced with half key after the keyway has been
machine, unless the two machines are mounted on the
machined.
same metallic base.
In the event of balancing with full key the shaft is
For motor frame sizes above IEC 280, use 0.75 x
marked with a YELLOW tape, with the text “Balanced
70 mm flat conductor or at least two 50 mm2 round
with full key”.
conductors. The distance of the round conductors must
be at least 150 mm from each other. In case balancing without key, the shaft is marked
with a BLUE tape, with the text “Balanced without
This arrangement has no electrical safety function; the
key".
purpose is to equalise the potentials. When the motor
and the gearbox are mounted on a common steel
fundament, no potential equalisation is required.

3. Operating 3.3 Assembly and dismantling
3.1 Use 3.3.1 General

GB
Dismantling and assembly of machines must be carried

3.1.1 Operating conditions out by qualified personnel using only suitable tools and
working methods. All repairs must be carried out
The machines are intended for use in industrial drive according to the standard IEC-60079-19.
applications.
Normal ambient temperature limits are -20° to +40°C.
Maximum altitude 1000 m above sea level.
3.3.2 Bearings
Special care should be taken with the bearings.
These must be removed using pullers and fitted by
3.2 Safety considerations heating or using special tools for the purpose.
The machine is intended for installation and use by How to replace bearings is described in detail in a
qualified personnel, familiar with relevant safety separate instruction leaflet available from ABB Sales
requirements. Office.
Safety equipment necessary for the prevention of
accidents at the installation and operating site must be 3.3.3 Fitting coupling halves and
provided in accordance with the local regulations.
pulleys
WARNING Coupling halves and pulleys must be fitted using
Small motors with supply current directly suitable equipment and tools that do not damage the
switched by thermally sensitive switches can bearings.
start automatically.
Never fit a coupling half or pulley by hammering into
3.2.1 Points to observe place or remove it using a lever pressed against the
body of the machine.
1. Do not use the machine to step on.
2. The temperature of the outer casing of the Mounting accuracy of coupling half:
machine may be hot to the touch during normal check that the clearance b is less than 0.05 mm and
operation. that the difference a1 to a2 is also less than 0.05 mm.
3. Some special machine applications require See figure 3.
special instructions (e.g. using frequency
converter supplies).
4. Lifting lugs must only be used for lifting the motor.
They must not be used to lift the motor when it is
attached to other equipment.

4. Maintenance Hours of operation for vertical motors are half of the
above values.
Motors with roller bearings have considerably shorter
4.1 Maintenance and lubrication grease life. For continuous operation regreasing nipples
GB
should be considered.
4.1.1 General inspection
– Inspect the machine at regular intervals. 4.1.4 Motors with regreasing nipples
– Keep the machine clean and ensure free
ventilation airflow. Lubrication information plate and general
– Check the condition of shaft seals (e.g. V-ring) and lubrication advice
replace if necessary.
If the machine is fitted with a lubrication information
– Check the condition of connections and mounting
plate, follow the given values.
and assembly bolts.
– Check the bearing condition by listening for On the lubrication information plate, regreasing intervals
unusual noise, vibration measurement, bearing with regard to mounting, ambient temperature and
temperature, inspection of spent grease or SPM speed of rotation can be defined.
bearing monitoring.
* When changes of condition occur, During the first start or after a bearing lubrication it may
dismantle the machine, check the parts appear a temporary temperature rise, appr. 10-20
and replace if necessary. hours. ABB policy is to have reliability as a vital issue in
bearing lubrication intervals. That is why we follow the
L1-principle.
4.1.2 Lubrication
A. Manual lubrication
WARNING Regreasing while motor is running
Beware of all rotating parts! – Remove grease outlet plug or open closing valve if
fitted.
WARNING – Be sure that the lubrication channel is open
Grease can cause skin irritation and eye – Press the specified amount of grease into the
inflammation. Follow all safety precautions bearing.
specified by the manufacturer. – Let the motor run 1-2 hours to ensure that all
excess grease is forced out of the bearing.
Close the grease outlet plug or closing valve if fitted.
4.1.3 Machines with permanently
Regreasing while motor is at a standstill
greased bearings Regrease motors while running. If this is not possible,
Bearings are usually permanently greased bearings of lubrication can be carried out while the machine is at a
either Z or 2Z types. standstill.
Bearing types are specified in the respective product – In this case, use only half the quantity of grease, then
catalogues and on the rating plate of all our motors run the motor for a few minutes at full speed.
except smaller frame sizes. – When the motor has stopped, press the rest of the
specified amount of grease into the bearing.
As a guide, adequate lubrication for sizes up to 200 can – After 1-2 running hours close the grease outlet plug
be achieved for the following duration, according to L1 or closing valve if fitted.
(i.e. that 99 % of the motors are sure to make the
interval time) at ambient temperature of 25°C. For B. Automatic lubrication
duties with ambient temperatures higher than 25°C, The grease outlet plug must be removed permanently
see the respective product catalogue. with automatic lubrication or open closing valve if fitted.
Some motors may be equipped with a collector for old
Frame size Poles Duty hours grease. Follow the special instructions given for the
56-80 2-8 for life equipment.
90-112 2-8 40 000
We recommend only the use of electromechanical
132 2-8 40 000
systems. Contact your local ABB Sales Office.
160 2-8 40 000
180 2-8 40 000 The amount of grease per each lubrication interval
200 2 27 000 stated in the tables 4-5 should be doubled if an
200 4 40 000 automatic regreasing system is used.
Table 3 If 2-pole motors are being automatically regreased, the
note (NOTE!) concerning lubricant recommendations
Depending on application and load conditions, see given for 2-pole motors in the chapter Lubricants shall
applicable product catalogue. be followed.

4.1.5 Lubrication intervals and Factors influencing the lubrication intervals
Lubrication intervals for vertical machines are half of the
amounts above values.
Frame Amount 3600 3000 1800 1500 1000 500-900 The lubrication intervals are based on bearing operating
GB
size of grease r/min r/min r/min r/min r/min r/min temperature 80°C (ambient temperature of about
g/bearing + 25°). Note! An increase in the ambient temperature
Ball bearings
raises the temperature of the bearings correspondingly.
Lubrication intervals in duty hours
112 10 10000 13000 18000 21000 25000 28000
The values should be halved for 15°C increase in
132 15 9000 11000 17000 19000 23000 26500 bearing temperature and may be doubled for 15°C
160 25 7000 9500 14000 17000 21000 24000 decrease in bearing temperature.
180 30 6000 8000 13500 16000 20000 23000
200 40 4000 6000 11000 13000 17000 21000
225 50 3000 5000 10000 12500 16500 20000
WARNING
250 60 2500 4000 9000 11500 15000 18000 The maximum operating temperature of the grease
280 70 20001) 35001) 8000 10500 14000 17000 and bearings must not be exceeded.
1) 1)
315 90 6500 8500 12500 16000
1) 1)
355 120 4200 6000 10000 13000
400 120 1)
1)
1)
1)
4200 6000 10000 13000 4.1.6 Lubricants
400 M3BP 130 2800 4600 8400 12000
450 140 2400 4000 8000 8800
WARNING
Table 4
Do not mix different types of grease.
Roller bearings Incompatible lubricants may cause bearing
Lubrication intervals in duty hours damage.
160 25 3500 4500 7000 8500 10500 12000
180 30 3000 4000 7000 8000 10000 11500
200 40 2000 3000 5500 6500 8500 10500 When regreasing, use only special ball bearing grease
225 50 1500 2500 5000 6000 8000 10000 with the following properties:
250 60 1300 2200 4500 5700 7500 9000 – good quality grease with lithium complex soap and
280 70 10001) 20001) 4000 5300 7000 8500
1) 1)
with mineral- or PAO-oil
315 90 3300 4300 6000 8000
355 120 1) 1)
2000 3000 5000 6500 – base oil viscosity 100-160 cST at 40°C
400 120 1) 1)
2000 3000 5000 6500 – consistency NLGI grade 1.5 - 3 *)
400 M3BP 130 1) 1)
1400 2300 4200 6000 – temperature range -30°C - +120°C, continuously.
450 140 1200 2000 4000 4400
*) For vertical mounted motors or in hot conditions a
Table 5 stiffer end of scale is recommended.
1)
Values for IEC sizes 280 to 450 (cast iron and steel motors) in certain
motor types (3600 and 3000 r/min), see tables 6-7. Grease with the correct properties is available from all
major lubricant manufacturers.
Lubrication intervals and amounts, 2-pole, Admixtures are recommended, but a written guarantee
IEC frame sizes 280 to 450 must be obtained from the lubricant manufacturer
Frame Amount 3600 3000 especially concerning EP admixtures, that admixtures
size of grease r/min r/min
g/bearing do not damage bearings or the properties of lubricants
Ball bearings at the operating temperature range.
280 M2B*, M2C*, M3B* 35 2000 3500
315 M2B*, M2C*, M3B* 35 2000 3500 WARNING
355 M2B*, M2C* 45 1200 2000 Lubricants containing EP admixtures are not
355 M3B* 35 1200 2000 recommended in high bearing temperatures in
400 M2B*, M2C* 45 1200 2000 frame sizes 280 to 450.
400 M3B* 40 1000 1600
450 M3B* 40 1000 1600
If the ambient temperature is below -25°C or above
Table 6 +55°C, or bearing temperature is above 110°C, consult
Roller bearings ABB Sales Office regarding suitable grease.
280 M2B*, M2C*, M3B* 35 1000 1800 The following high performance grease can be used
315 M2B*, M2C*, M3B* 35 1000 1800
355 M2B*, M2C* 45 600 1000 – Esso Unirex N2, N3 or S2 (lithium complex base)
355 M3B* 35 600 1000 – Mobil Mobilith SHC 100 (lithium complex base)
400 M2B*, M2C* 45 600 1000 – Shell Albida EMS 2 (lithium complex base)
400 M3B* 40 500 800 – SKF LGHQ 3 (lithium complex base)
450 M3B* 40 500 800
– Klüber Klüberplex BEM 41-132
Table 7 (special lithium base)
– FAG Arcanol TEMP110 (lithium complex base)
Lubrication intervals for other grease fullfilling the
required properties, contact your local ABB Sales
Office.

NOTE! 5. Environmental
Always use high speed grease for high speed
machines and some other models, e.g. M2BA 355
requirements
GB
and 400 2-pole machines, where the speed factor is
higher than 400 000 (calculated as Dm x n where 5.1 Noise levels
Dm = average bearing diameter, mm; n = rotational
speed, r/min). Most of our motors have a sound pressure level not
exceeding 82 dB(A) refer to 50 Hz sinusoidal supply
The following grease can be used: conditions, tolerance ± 3 dB(A).
– FAG L69 (polyurea base)
Values for specific machines can be found in the
– Klüber Klüber quiet BH 72-102 (polyurea base)
relevant product catalogues.
– Lubcon Turmogrease PU703 (polyurea base)
For sound pressure levels for 60 Hz sinusoidal supply
If other lubricants are used, check with the
and with non-sinusoidal supplies, contact ABB Sales
manufacturer that the qualities correspond to those of
Office.
the above mentioned lubricants, or if the compatibility of
the lubricant is uncertain, contact your local ABB Sales Sound pressure levels for all machines having separate
Office. cooling systems and for series M2F*/M3F*, M2L*/M3L*,
M2R*/M3R*, M2BJ/M3BJ and M2LJ/M3LJ are indicated
WARNING in separate Manuals.
Especially in high rotational speed (the speed
factor > 400000) over greasing may cause
damage.
4.1.7 Frequency converter drives

Higher speed operation, e.g. in frequency converter
applications, or lower speed with heavy load will require
shorter lubrication intervals. Consult your local ABB
Sales Office in such cases.
Typically a doubling of speed will require a reduction of
lubrication intervals to approx. 40 % of values tabulated
above.
WARNING
The constructional maximum speed of the motor
must not be exceeded (see table 2).
Suitability of bearings for high speed operation must be

checked.
4.1.8 Spare parts

When ordering spare parts, the full type designation
and product code, as stated on the rating plate, must be
specified.
If the machine is stamped with a serial manufacturing
number, this should also be given.
For more information, please visit our web site
www.abb.com/partsonline.
4.1.9 Rewinding
Rewinding should always be carried out by qualified
repair shops.
Smoke venting and other special motors should not be
rewound without first contacting ABB.

6. Troubleshooting
These instructions do not cover all details or variations in equipment nor provide for every possible condition to be
met in connection with installation, operation or maintenance. Should additional information required, please
GB
contact the nearest ABB Sales Office.
Motor troubleshooting chart

Your motor service and any troubleshooting must be handled by qualified persons with proper tools and equipment.
TROUBLE CAUSE WHAT TO DO

Motor fails to start Blown fuses Replace fuses with proper type and rating.
Overload trips Check and reset overload in starter.
Improper power supply Check to see that power supplied agrees with
motor rating plate and load factor.
Improper line connections Check connections with diagram supplied with
motor.
Open circuit in winding or control Indicated by humming sound when switch is
switch closed. Check for loose wiring connections.
Also, ensure that all control contacts are closed.
Mechanical failure Check to see if motor and drive turn freely.
Check bearings and lubrication.
Short circuited stator Indicated by blown fuses. Motor must be
Poor stator coil connection rewound. Remove end bells, locate with test
lamp.
Rotor defective Look for broken bars or end rings.
Motor may be overloaded Reduce load.
Motor stalls One phase may be open Check lines for open phase.
Wrong application Change type or size. Consult manufacturer.
Overload Reduce load.
Low voltage Ensure the rating plate voltage is maintained.
Check connection.
Open circuit Fuses blown, check overload relay, stator and
push buttons.
Motor runs and then Power failure Check for loose connections to line, to fuses and
dies down to control.
Motor does not come up Not applied properly Consult supplier for proper type.
to speed Voltage too low at motor terminals Use higher voltage or transformer terminals
because of line drop or reduce load. Check connections. Check
conductors for proper size.
Starting load too high Check load motor is supposed to carry at start.
Broken rotor bars or loose rotor Look for cracks near the rings. A new rotor may
be required, as repairs are usually temporary.
Open primary circuit Locate fault with testing device and repair.
Motor takes too long to Excessive load Reduce load.
accelerate and/or draws Low voltage during start Check for high resistance. Adequate wire size.
high amp
Defective squirrel cage rotor Replace with new rotor.
Applied voltage too low Get power company to increase power tap.
Wrong rotation Wrong sequence of phases Reverse connections at motor or at switchboard.

TROUBLE CAUSE WHAT TO DO
Motor overheats while Overload Reduce load.
running underloaded Frame or bracket vents may be Open vent holes and check for a continuous
GB
clogged with dirt and prevent proper stream of air from the motor.
ventilation of motor
Motor may have one phase open Check to make sure that all leads are well
connected.
Grounded coil Locate and repair.
Unbalanced terminal voltage Check for faulty leads, connections and
transformers.
Motor vibrates Motor misaligned Realign.
Weak support Strengthen base.
Coupling out of balance Balance coupling.
Driven equipment unbalanced Rebalance driven equipment.
Defective bearings Replace bearings.
Bearings not in line Line up properly.
Balancing weights shifted Rebalance motor.
Contradiction between balancing of Rebalance coupling or motor.
rotor and coupling (half key - full key)
Polyphase motor running single Check for open circuit.
phase
Excessive end play Adjust bearing or add shim.
Scraping noise Fan rubbing fan cover Remove interference.
Fan striking insulation Clear fan.
Motor loose on bedplate Tighten holding bolts.
Noisy operation Airgap not uniform Check and correct bracket fits or bearing.
Rotor unbalance Rebalance.
Hot bearings ball Bent or sprung shaft Straighten or replace shaft.
Excessive belt pull Decrease belt tension.
Pulleys too far away Move pulley closer to motor bearing.
Pulley diameter too small Use larger pulleys.
Misalignment Correct by realignment of drive.
Insufficient grease Maintain proper quality of grease in bearing.
Deterioration of grease or lubricant Remove old grease, wash bearings thoroughly
contaminated in kerosene and replace with new grease.
Excess lubricant Reduce quantity of grease, bearing should not
be more than 1/2 filled.
Overloaded bearing Check alignment, side and end thrust.
Broken ball or rough races Replace bearing, first clean housing thoroughly.

Figure 1. Connection diagram
Bild 1. Anschlußdiagram
Figure 1. Connection
Figura 1. Conexión
Figura 1. Collegamento
Figur 1. Anslutningdiagramm
Kuva 1. Kytkentäkaavio
Figure 2. Belt drive

Bild 2. Riementrieb
Figure 2. Glissières et entraînements à courroie
Figure 2. Carriles tensores y correas
Figura 2. Slitte tendicinghia e pulegge
Figur 2. Remdrift
Kuva 2. Hihnakäyttö
86 ABB / Low Voltage Motors / Manual 12-2004

Figure 3. Mounting of half-coupling or pulley
Bild 3. Anbau von Kupplungshälften und Riemenscheiben
Figure 3. Montage des demi-accouplements et des poulies
Figura 3. Montaje de mitades de acoplamiento y poleas
Figura 3. Montaggio di semigiunti e pulegge
Figur 3. Montering av kopplinshalvor och drivskivor
Kuva 3. Kytkinpuolikkaan ja hihnapyörän asennus
ABB / Low Voltage Motors / Manual 12-2004 87

Low Voltage Motors
Manufacturing sites (*) and some of the biggest sales companies.
Printed in Finland, Ykkös-Offset Oy Vaasa 12-2004, 20 000

Australia France Korea Switzerland
ABB Industry Pty Ltd ABB Automation ABB Korea Ltd. ABB Schweiz AG
2 Douglas Street Rue du Général de Gaulle 7-9fl, Oksan Bldg., 157-33 Normelec/CMC Components
Port Melbourne, Champagne-sur-Seine Sungsung-dong, Kangnam-ku Motors&Drives
Victoria, 3207 FR-77811 Moret-sur-Loing Cedex Seoul Badenerstrasse 790
Tel: +61 (0) 3 9644 4100 Tel: +33 (0) 1 60 746 500 Tel: +82 2 528 2329 Postfach
Fax: +61 (0) 3 9646 9362 Fax: +33 (0) 1 60 746 565 Fax: +82 2 528 2338 CH-8048 Zürich
Tel: +41 (0) 58 586 0000
Austria Germany Malaysia Fax: +41 (0) 58 586 0603
ABB AG ABB Automation Products GmbH ABB Malaysia Sdn. Bhd.
Wienerbergstrasse 11 B Edisonstrasse 15 Lot 608, Jalan SS 13/1K Taiwan
AT-1810 Wien DE-68623 Lampertheim 47500 Subang Jaya, Selangor ABB Ltd.
Tel: +43 (0) 1 601 090 Tel: +49 (0) 6206 503 503 Tel: +60 3 5628 4888 6F, No. 126, Nanking East Road,
Fax: +43 (0) 1 601 09 8305 Fax: +49 (0) 6206 503 600 Fax: +60 3 5631 2926 Section 4i
Taipei, 105 Taiwan, R.O.C.
Belgium Hong Kong Mexico Tel: +886 (0) 2 2577 6090
Asea Brown Boveri S.A.-N.V. ABB (Hong Kong) Ltd. ABB México, S.A. de C.V. Fax: +886 (0) 2 2577 9467
Hoge Wei 27 Tai Po Industrial Estate, Apartado Postal 111
BE-1930 Zaventem 3 Dai Hei Street, CP 54000 Tlalnepantla Thailand
Tel: +32 (0) 2 718 6311 Tai Po, New Territories, Edo. de México, México ABB Limited (Thailand)
Fax: +32 (0) 2 718 6657 Hong Kong Tel: +52 5 328 1400 161/1 SG Tower,
Tel: +852 2929 3838 Fax: +52 5 390 3720 Soi Mahadlekluang 3,
Canada Fax: +852 2929 3505 Rajdamri, Bangkok 10330
ABB Inc., BA Electrical Machines The Netherlands Tel: +66 2 665 1000
10300 Henri-Bourassa Blvd, West, India* ABB B.V. Fax: +66 2 665 1042
Saint-Laurent, Quebec ABB Ltd. Dept. LV motors (APP2R)
Canada H4S 1N6 32, Industrial Area, N.I.T P.O.Box 301 The United Kingdom
Tel: +1 514 832-6583 Faridabad 121 001 NL-3000 AH Rotterdam ABB Automation Ltd
Fax: +1 514 332-0609 Tel: +91 (0) 129 502 3001 Tel: +31 (0) 10 4078 879 9 The Towers, Wilmslow Road
Fax: +91 (0) 129 502 3006 Fax: +31 (0) 10 4078 345 Didsbury
China* Manchester, M20 2AB
ABB Shanghai Motors Indonesia Norway Tel: +44 (0) 161 445 5555
Company Limited PT. ABB Sakti Industri ABB AS Fax: +44 (0) 161 448 1016
8 Guang Xing Rd.,Rong Bei JL. Gajah Tunggal Km.1 P.O.Box 154 Vollebekk
Town, Songjiang County, Jatiuwung, Tangerang 15136 NO-0520 Oslo USA
Shanghai 201613 Banten, Indonesia Tel: +47 22 872 000 ABB Inc.
Tel: +86 21 5778 0988 Tel: + 62 21 590 9955 Fax: +47 22 872 541 Low Voltage Motors
Fax: +86 21 5778 1364 Fax: + 62 21 590 0115 - 6 16250 W. Glendale Drive
Singapore New Berlin, WI 53151
Chile Ireland ABB Industry Pte Ltd Tel: +1 262 785 3200
Asea Brown Boveri S.A. Asea Brown Boveri Ltd 2 Ayer Rajah Crescent Fax: +1 262 785 8628
P.O.Box 581-3 Components Division Singapore 139935
Santiago Belgard Road Tel: +65 6776 5711 Venezuela
Tel: +56 (0) 2 5447 100 Tallaght, Dublin 24 Fax: +65 6778 0222 Asea Brown Boveri S.A.
Fax: +56 (0) 2 5447 405 Tel: +353 (0) 1 405 7300 P.O.Box 6649
Fax: +353 (0) 1 405 7327 Spain* Carmelitas,
Denmark ABB Automation Products S.A. Caracas 1010A
ABB A/S Italy* Division Motores Tel: +58 (0) 2 238 2422
Automation Technology Electrical ABB SACE SpA P.O.Box 81 Fax: +58 (0) 2 239 6383
Machines LV Motors ES-08200 Sabadell
Petersmindevej 1 Via Della Meccanica, 22 Tel: +34 93 728 8500
DK-5000 Odense C IT-20040 Caponago - MI Fax: +34 93 728 8741
ABB / Low Voltage Motors / Manual 12-2004

Tel: +45 65 477 070 Tel: +39 02 959 6671
Fax: +45 65 477 713 Fax: +39 02 959 667216 Sweden*
ABB Automation Technologies AB
Finland* Japan LV Motors
ABB Oy ABB K.K. SE-721 70 Västerås
LV Motors 26-1 Cerulean Tower Tel: +46 (0) 21 329 000
P.O.Box 633 Sakuragaoka-cho, Shibuya-ku Fax: +46 (0) 21 329 140
FI-65101 Vaasa Tokyo 150-8512
Tel: +358 (0) 10 22 11 Tel: +81 (0) 3 578 46251
Fax: +358 (0) 10 22 47372 Fax: +81 (0) 3 578 46260
http://www.abb.com/motors&drives
http://online.abb.com/motors&drives
GEA Niro Soavi
7.01.3 9533-1002-011 MANOMETRO PRESSURE GAUGE
7.01.3
GEA Niro Soavi
7.01.4 9533-2010-011 MANOTRASMETTITORE PRESSURE TRANSMITTER
7.01.4
GEA Niro Soavi
7.01.5 9533-3026-000 TRASDUTTORE TRANSDUCER
7.01.5
PI2794
PI-010-REA01-MFRKG/US/ /P Pressure sensors
1: 4-digit alphanumeric display

2: LEDs
3: Programming button
Made in Germany
Product characteristics
Combined pressure sensor
Quick disconnect
Process connection: G 1 A / Aseptoflex Vario
Display units:
bar, psi, MPa, % of the span
Function programmable
2-wire connection technology:
analogue output
2 outputs
OUT1 = switching output
OUT2 = switching output or analogue output
4-digit alphanumeric display
Measuring range: -1.00...10.00 bar / -14.5...145.0 psi / -0.100...1.000 MPa
Application
Application Type of pressure: relative pressure
Hygienic systems, viscous media and liquids with suspended particles
Liquids and gases
Pressure rating 50 bar 725 psi 5 MPa
Bursting pressure min. 150 bar 2175 psi 15 MPa
Medium temperature [°C] -25...125 (145 max. 1h)
Electrical data
Electrical design 2 wires DC / 3 wires DC PNP/NPN
Operating voltage [V] 20...32 DC (2L) / 18...32 DC (3L)
Current consumption [mA] 3.6...21 (2L) / < 45 (3L)
Insulation resistance [MΩ] > 100 (500 V DC)
Protection class III
Reverse polarity protection yes
Outputs
PI2794
Output 2-wire connection technology:

analogue output
2 outputs
OUT1 = switching output
OUT2 = switching output or analogue output
Output function 1 x normally open / normally closed programmable + 1 x normally open / normally
closed programmable or 1 x analog (4...20 / 20...4 mA, scalable)
Current rating [mA] --- (2L) / 250 (3L)
Voltage drop [V] --- (2L) / < 2 (3L)
Short-circuit protection Yes (non-latching)
Overload protection yes
Switching frequency [Hz] --- (2L) / 125 (3L)
Analog output I: 4...20 mA (Ineg: 20...4 mA)
Max. load [Ω] 300 (2L) / max. (Ub - 10 V) x 50 (3L)
Measuring / setting range
Measuring range -1.00...10.00 bar -14.5...145.0 psi -0.100...1.000 MPa
Setting range
Set point, SP -0.98...10.00 bar -14.2...145.0 psi -0.098...1.000 MPa
Reset point, rP -1.00...9.98 bar -14.5...144.7 psi -0.100...0.998 MPa
Analog start point, ASP -1.00...7.50 bar -14.5...108.7 psi -0.100...0.750 MPa
Analog end point, AEP 1.50...10.00 bar 21.8...145.0 psi 0.150...1.000 MPa
in steps of 0.01 bar 0.1 psi 0.001 MPa
Factory setting SP1 = 2.50 bar; rP1 = 2.30 bar
SP2 = 7.50 bar; rP2 = 7.30 bar
ASP = 0.00 bar; AEP = 10.00 bar
Accuracy / deviations
Accuracy / deviations
(in % of the span) Turn down 1:1
Switch point accuracy < ± 0.2
Characteristics deviation *) < ± 0.2
Linearity < ± 0.15
Hysteresis < ± 0.15
Repeatability **) < ± 0.1
Long-term stability ***) < ± 0.1
Temperature coefficients (TEMPCO) in the temperature range 0...70° C (in % of the span per 10 K)
Greatest TEMPCO of the zero point < ± 0.05
Greatest TEMPCO of the span < ± 0.15
Reaction times
Power-on delay time [s] 1 (2L) / 0.5 (3L)
Integrated watchdog yes
Interfaces
IO-Link Device
Transfer type COM2 (38.4 kBaud)
Environment
Ambient temperature [°C] -25...80
Storage temperature [°C] -40...100
Protection IP 67 / IP 68 / IP 69K
PI2794
Tests / approvals
EMC EN 61000-4-2 ESD: 4 kV CD / 8 kV AD
EN 61000-4-3 HF radiated: 10 V/m
EN 61000-4-4 Burst: 2 kV
EN 61000-4-5 Surge: 0.5/1 kV
EN 61000-4-6 HF conducted: 10 V
Shock resistance DIN IEC 68-2-27: 50 g (11 ms)
Vibration resistance DIN IEC 68-2-6: 20 g (10...2000 Hz)
MTTF [Years] 160
Mechanical data
Process connection G 1 A / Aseptoflex Vario
Materials (wetted parts) ceramics (99.9 % Al2 O3); PTFE; stainless steel 316L / 1.4435; surface
characteristics: Ra < 0.4 / Rz 4
Housing materials stainless steel 316L / 1.4404; FPM (Viton); PTFE; PBT (Pocan); PEI; PFA
Switching cycles min. 100 million
Weight [kg] 0.312
Displays / operating elements
Display Display unit LED green
Switching status LED yellow
Function display 4-digit alphanumeric display
Measured values 4-digit alphanumeric display
Electrical connection
Connection M12 connector; gold-plated contacts
Wiring
1 connection for 2-wire operation

2 connection for 3-wire operation
3 connection for IO-Link parameter setting (P = communication via IO-Link)
Remarks
Remarks (2L) = value for 2-wire operation
(3L) = value for 3-wire operation
*) linearity, incl. hysteresis and repeatability;
(limit value setting to DIN 16086)
**) with temperature fluctuations < 10 K
***) in % of the span per year
Pack quantity [piece] 1
Other data
Step response time analogue output
[ms] 45 (2L) / 7 (3L)
PI2794
Min. response time switching output

[ms] --- (2L) / 3 (3L)
Damping for the switching output
(dAP) [s] 0.00...30.00
Damping for the analog output (dAA)
[s] 0.01...99.99
ifm efector, inc. 782 Springdale Drive, Exton, PA 19341 — We reserve the right to make technical alterations without prior notice. — US — PI2794 — 07.08.2012
Operating instructions
Electronic pressure sensor
UK
PI27xx
704924/00 01/2011
Contents
1 Preliminary note��4
1.1 Symbols used��4
2 Safety instructions��4
3 Functions and features��5
3.1 Applications��5
4 Function��5
4.1 Operating modes��6
4.1.1 2-wire operation��6
4.1.2 3-wire operation��6
4.2 Switching function (only for 3-wire operation)��6
4.3 Analogue function��7
4.4 Customer-specific calibration��9
5 Installation��10
6 Electrical connection�� 11
6.1 Connection for 2-wire operation�� 11
6.2 Connection for IO-Link parameter setting��12
6.3 Connection for 3-wire operation��12
7 Operating and display elements��13
8 Menu��14
8.1 Menu structure: main menu��14
8.2 Explanation of the main menu��15
8.3 Menu structure: level 2 (extended functions)��16
8.4 Explanation of the menu level 2��17
8.5 Menu structure: level 3 (simulation)��18
8.6 Explanation of the menu level 3��19
9 Parameter setting��20
9.1 General parameter setting��20
9.2 Configure display (optional)��22
9.3 Set output signals��22
9.3.1 Set output functions��22
9.3.2 Set switching limits��23
9.3.3 Scale analogue value for OUT2��23
9.4 User settings (optional)��24
9.4.1 Carry out zero point calibration ��24
2
9.4.2 Setting of the error behaviour of the outputs��24
9.4.3 Set delay for the switching outputs��25
9.4.4 Set switching logic for the switching outputs��25
9.4.5 Set damping for the switching signal��25
9.4.6 Set damping for the analogue signal��25
9.4.7 Calibrate curve of measured values��25
9.5 Service functions��26
9.5.1 Read min/max values for system pressure��26
9.5.2 Reset all parameters to factory setting��26
9.6 Simulation function��26 UK
9.6.1 Open menu level 3 (simulation)��26
9.6.2 Set simulation value��27
9.6.3 Set time for simulation��27
9.6.4 Start simulation��27
10 Operation��28
10.1 Read set parameters��28
10.2 Change the display in the Run mode ��28
10.3 Self-diagnosis / error indications��28
11 Scale drawing ��31
12 Technical data��31
12.1 Setting ranges��33
13 Factory setting��35
3
1 Preliminary note
1.1 Symbols used
► Instructions
> Reaction, result
[…] Designation of pushbuttons, buttons or indications
→ Cross-reference
Important note
Non-compliance can result in malfunction or interference.
Information
Supplementary note.
2 Safety instructions
• Please read this document prior to set-up of the unit. Ensure that the product is
suitable for your application without any restrictions.
• If the operating instructions or the technical data are not adhered to, personal
injury and/or damage to property can occur.
• Check the compatibility of the product materials (→ chapter 12 Technical data)
with the media to be measured in all applications.
For the scope of validity cULus:
The device shall be supplied from an isolating transformer having a secondary
Listed fuse rated either
a) max 5 amps for voltages 0~20 Vrms (0~28.3 Vp) or
b) 100/Vp for voltages of 20~30 Vrms (28.3~42.4 Vp).
The Sensor shall be connected only by using any R/C (CYJV2) cord, having
suitable ratings.
4
3 Functions and features
The unit measures and monitors the system pressure in a plant.
3.1 Applications
Type of pressure: relative pressure
Permissible Bursting
Order no. Measuring range
overpressure pressure
bar PSI bar PSI bar PSI
PI2793 -1...25 -14.4...362.7 100 1450 350 5075
PI2794 -1...10 -14.5...145 50 725 150 2175 UK
PI2795 -1...4 -14.5...58 30 435 100 1450
PI2796 -0.124...2.5 -1.8...36.27 20 290 50 725
PI2797 -0.05...1 -0.73...14.5 10 145 30 435
PI2799 -1...1 -14.5...14.5 10 145 30 435
mbar inH2O bar inH2O bar inH2O
PI2798 -12.4...250 -5.0..100.4 10 4015 30 12044
PI2789 -5...100 -2.00...40.16 4 1606 30 12044
Avoid static and dynamic overpressure exceeding the given overload
pressure by taking appropriate measures.
The indicated bursting pressure must not be exceeded.
Even if the bursting pressure is exceeded only for a short time, the unit
may be destroyed. ATTENTION: Risk of injury!
Not suitable for use where the criteria for paragraph D10.1.2/74-03 of the 3A
standard 74-03 have to be met.
4 Function
• The unit displays the current system pressure.
• It generates output signals according to the operating mode and the parameter
setting.
• It moreover provides the process data via IO-Link.
• The unit is laid out for fully bidirectional communication. So, the following
options are possible:
-- Remote display: reading and display of the current system pressure.
-- Remote parameter setting: reading and changing the current parameter
setting.
5
-- Using the FDT service program ifm Container, the current parameter settings
can be stored and transferred to other units of the same type.
The program library of the available DTM objects can be found at www.ifm.com
→ Service → Download.
Device-specific parameter lists for IO-Link parameter setting are available at:
www.ifm.com
4.1 Operating modes
The operating mode is defined by the wiring (→ 6 Electrical connection) and
automatically recognised.
4.1.1 2-wire operation
OUT2 (pin 2) analogue signal proportional to pressure 4…20 mA or 20...4 mA
4.1.2 3-wire operation

• switching signal for system pressure limit value
OUT1 (pin 4)
• communication via IO-Link
3 options:
• switching signal for system pressure limit value
OUT2 (pin 2)
• analogue signal proportional to pressure 4...20 mA
• analogue signal proportional to pressure 20...4 mA
4.2 Switching function (only for 3-wire operation)

OUTx changes its switching state if it is above or below the set switching limits
(SPx, rPx). The following switching functions can be selected:
• Hysteresis function / normally open: [OUx] = [Hno] (→ fig. 1).
• Hysteresis function / normally closed: [OUx] = [Hnc] (→ fig. 1).
First the set point (SPx) is set, then the reset point (rPx) with the requested
difference.
• Window function / normally open: [OUx] = [Fno] (→ fig. 2).
• Window function / normally closed: [OUx] = [Fnc] (→ fig. 2).
The width of the window can be set by means of the difference between SPx
and rPx. SPx = upper value, rPx = lower value.
6
1 2

UK

P = system pressure; HY = hysteresis; FE = window
4.3 Analogue function

The analogue output can be configured.
• [OU2] defines whether the set measuring range is provided as 4...20 mA
([OU2] = [I]) or as 20...4 mA ([OU2] = [InEG]).
Scaling can be set by means of the teaching process or by entering a value for the
ASP and AEP parameters.
• Teaching the analogue start point [tASP] or setting the parameter [ASP] defines
at which measured value the analogue signal is 4 mA (20 mA at [InEG]).
• Teaching the analogue end point [tAEP] or setting the parameter [AEP] defines
at which measured value the output signal is 20 mA (4 mA at [InEG]).
7
Minimum distance between [ASP] and [AEP] = 25 % of the final value of the
measuring range (turn-down 1:4); for PI2799: 25 % of the measuring span.
Factory setting Measuring range scaled

P = system pressure , MAW = initial value of the measuring range, MEW = final value of
the measuring range
1 : [OU2] = [I]; 2 : [OU2] = [InEG]
In the set measuring range the output signal is between 4 and 20 mA ([OU2] = [I])
or between 20 and 4 mA ([OU2] = [InEG]).
It is also indicated:
• System pressure above the measuring range:
-- Output signal > 20 mA at [OU2] = [I].
-- Output signal 4 to 3.8 mA at [OU2] = [InEG].
• System pressure below the measuring range:
-- Output signal 4 to 3.8 mA at [OU2] = [I].
-- Output signal > 20 mA at [OU2] = [InEG].
8
4.4 Customer-specific calibration
The customer-specific calibration changes the curve of measured values
compared to the real measured values (shifting / change of the gradient; → 9.4.6
[CAL]).
• Two calibration points can be defined (CP1, CP2). The two points are
independent of each other.
• The two calibration points must be within the scaled measuring range (→ 4.3
Pressure monitoring / analogue function).
• The zero point calibration [COF] influences the calibration of the curve of
measured values. Recommendation: set [COF] to 0 (→ 9.4.1 [COF]), then UK
calibrate the curve of measured values.
After a change the calibration can be reset to factory setting (→ 9.5.2 [rES]).
• P = measured pressure;
P‘ = modified measured value

• CP1 = calibration point 1;
CP1‘ = modified measured value for

CP1
• 1 = curve of measured values at
factory setting
• 2 = curve of measured values after
calibration

CP2 = calibration point 2;
CP2
factory setting
calibration
9
CP1

CP2
factory setting
calibration
5 Installation
Before installing and removing the unit: make sure that no pressure is
applied to the system. Please consider when the system pressure is
displayed in % of the span: “0” does not mean that no pressure is applied
to the system!
Use in hygienic areas to 3A
Orientation of the unit in pipes and tanks
For optimised cleaning of the measuring
element according to the 3A criteria for
hygienic areas please take the following into
account:
Do not install the unit at the lowest point of
the pipe or tank (see fig., position 5) in order
that the medium can run off the area of the
measuring element.
Use in hygienic areas to EHEDG

►► Make sure that the sensors are integrated into the system in accordance with
EHEDG.
The unit can be fixed to different process connections. Options are as follows:
10
1 Installation using an adapter with sealing ring (order no. E332xx / E333xx)
The adapters are supplied with EPDM O-ring (order no. E30054). More sealing rings
are available as accessories: FKM O-ring (order no. E30123); PEEK sealing ring
(order no. E30124).
Concerning installation → Installation instructions attached to the adapter.
2 Installation using an adapter with metal-to-metal seal
Order no. E337xx / E338xx
3 Installation using a welding adapter
• Order no. E30122 UK
• Order no. E30130; adapter with leakage port
The adapters are supplied with EPDM O-ring (order no. E30054). More sealing rings
are available as accessories: FKM O-ring, order no. E30123.
4 Installation to G 1 flange
The sealing ring on the sensor is used as process seal.
The upper sealing area on the process connection must be flush with the tapped hole
and have a surface characteristic of min. Rz 6.3.
►► Grease the sensor thread with a suitable paste.
►► Insert the unit into the process connection.
►► Tighten it using a spanner. Tightening torque: 35 Nm.
6 Electrical connection
The unit must be connected by a qualified electrician.
The national and international regulations for the installation of electrical
equipment must be adhered to.
Voltage supply according to EN 50178, SELV, PELV.
►► Disconnect power.
►► Connect the unit as follows:
6.1 Connection for 2-wire operation

11
6.2 Connection for IO-Link parameter setting
1 L+

2

4 P
3
L
Pin 1 Ub+
Pin 2 Output function according to the OU2 setting
Pin 3 Ub- for programming mode
Pin 4 (P) Communication via IO-Link
6.3 Connection for 3-wire operation

2 x positive switching 2 x negative switching
1 1
L+ L+
2 2
4 4
2: Out 2 2: Out 2 3
4: Out 1 3 4: Out 1
L L
1 x positive switching / 1 x analogue 1 x negative switching / 1 x analogue
1 1
L+ L+
2 4
4 2
2: Out 2 2: Out 2
4: Out 1 3 4: Out 1 3
L L
Pin 1 Ub+
Pin 3 Ub-
• Binary switching output pressure monitoring
Pin 4 (OUT1)
• Communication via IO-Link
Binary switching output pressure monitoring or analogue output for
Pin 2 (OUT2)
system pressure.
12
7 Operating and display elements
1 2 3 4 5 6 7 8
Mode/Enter Set
10
11 UK
1 to 8: Indicator LEDs
-- LED 1 to LED 5 = system pressure in the specified unit of measurement.
-- LED 6 = System pressure in % of the set scaling of the analogue output if [OU2] is
configured as analogue output.
System pressure in % of the final value of the measuring range if [OU2] is configured as
switching output.
-- LED 7 = switching status OUT2 (lights if output 2 is switched).
-- LED 8 = switching status OUT1 (lights if output 1 is switched)
9: Alphanumeric display, 4 digits
-- Display of the current system pressure.
-- Indication of the parameters and parameter values.
10: Set pushbutton
-- Setting of the parameter values (scrolling by holding pressed; incrementally by pressing
once).
11: Mode/Enter button
-- Selection of the parameters and acknowledgement of the parameter values.
13
8 Menu
8.1 Menu structure: main menu
M
RUN
S
M
M
S
M
M
S
M
M
S
M
M
S S
M M
M M
S S
M M
M M
S S
M M
M M
S
1
M
1: Change to menu level 2 (extended functions)

Menu items highlighted grey ( SP1 ) are not active in 2-wire operation.
14
8.2 Explanation of the main menu
SP1/rP1* Upper / lower limit value for system pressure at which OUT1 switches.
OU1* Output function for OUT1:
• Switching signal for the pressure limit values: hysteresis function [H ..] or
window function [F ..], either normally open [. no] or normally closed [. nc].
OU2 Output function for OUT2:
• Switching signal for the pressure limit values: hysteresis function [H ..] or
window function [F ..], either normally open [. no] or normally closed [. nc];
(only available for 3-wire operation).
• Analogue signal for the current system pressure: 4...20 mA [I], 20...4 mA
UK
[InEG].
tCOF Teach zero-point calibration.
tASP Teach analogue start point for system pressure: set measured value at which
4 mA is provided (20 mA if [OU2] = [InEG]).
tAEP Teach analogue end point for system pressure: set measured value at which
20 mA is provided (4 mA if [OU2] = [InEG]).
SP2/rP2* Upper / lower limit value for system pressure at which OUT2 switches.
EF Extended functions / opening of menu level 2.
* menu items not active in 2-wire operation
15
8.3 Menu structure: level 2 (extended functions)
S
1 M
M
S
S M
M M
M
S
S M
M M
M S
S M
M M
M S
M
S M
M S
M M
S M
M S
M M
S M
M S
M
S M
M S
M M
M
S
M S
M M
M
S
M S
M 2
S M
M S
M M
M
1
1: Change to the main menu; 2: Change to menu level 3 (simulation)

Menu items highlighted grey ( ASP ) are not active in 2-wire operation.
16
8.4 Explanation of the menu level 2
Uni Standard unit of measurement for system pressure.
Display mode:
SELd • Pressure in the unit set in [Uni].
• Pressure in % of the set scaling of the analogue output.
ASP Analogue start point for system pressure: measured value at which 4 mA is
provided (20 mA if [OU2] = [InEG]).
AEP Analogue end point for system pressure: measured value at which 20 mA is
provided (4 mA if [OU2] = [InEG]).
HI Maximum value memory for system pressure. UK
LO Minimum value memory for system pressure.
COF Zero-point calibration.
dS1* Switch-on delay for OUT1.
dr1* Switch-off delay for OUT1.
dS2* Switch-on delay for OUT2; only active if [OU2] = [Hnc], [Hno], [Fnc] or [Fno].
dr2* Switch-off delay for OUT2; only active if [OU2] = [Hnc], [Hno], [Fnc] or [Fno].
FOU1* Behaviour of output 1 in case of an internal fault.
FOU2 Behaviour of output 2 in case of an internal fault.
P-n* Switching logic for the outputs: pnp or npn.
dAP Damping for switching outputs and display.
dAA Damping for analogue output (OUT2); also has effect on the IO-Link process
value.
diS Update rate and orientation of the display.
CAL Calibration function (setting the curve of measured values).
CP1 Calibration point 1
CP2 Calibration point 2
SIM Change to menu level 3 (simulation)
rES Restore factory settings.
* menu items not active in 2-wire operation
17
8.5 Menu structure: level 3 (simulation)
For setting SEL = OU
S
2 M
M
S
M
M
S
M
M
S
M
M
S M
M 2s
2 1...60 min
For setting SEL = Proc
S
2 M
M
S
M
M
S
M
M
S M
M 2s
2 1...60 min
2: Change to menu level 2 (extended functions)

Menu items highlighted grey ( S.OU1 ) are not active in 2-wire operation.
18
8.6 Explanation of the menu level 3
For setting SEL = OU
SEL Status to be simulated:
• Output functions [OU].
S.OU1* Simulation values for OUT1; only active for 3-wire operation and if [SEL] =
[OU].
• Output inactive [OPEN] or output active [CLOS].
S.OU2 Simulation values for OUT2; only active if [SEL] = [OU].
• For 3-wire operation and if OUT2 has been configured as switching output:
output inactive [OPEN] or active [CLOS]. UK
• If OUT2 is set as analogue output: analogue signal between 3.6 and 21.1
mA (depending on the set value → 9.6.2).
S.TIM Time for the simulation process in minutes.
Start of the simulation process.
During the simulation process the display alternately shows [SIM] and the
S.ON current operation indication (9.6.4 )→.
If the simulation process is aborted (press [Mode/Enter] or [Set] briefly),
[S.OFF] is indicated for 2 s, then [SEL] is active again.
* menu item not active in 2-wire operation
For setting SEL = Proc

SEL Status to be simulated:
• Process value [Proc].
S.Pr Simulation of a process value; only active if [SEL] = [Proc].
• Any value between initial value of the measuring range and final value of
the measuring range.
S.TIM Time for the simulation process in minutes.
Start of the simulation process.
During the simulation process the display alternately shows [SIM] and the
S.ON current operation indication (→ 9.6.4).
If the simulation process is aborted (press [Mode/Enter] or [Set] briefly)
[S.OFF] is indicated for 2 s, then [SEL] is active again.
19
9 Parameter setting
During parameter setting the unit remains in the operating mode. It continues its
monitoring function with the existing parameters until the parameter setting has
been completed.
Exceptions: changes to the parameters COF (→ 9.4.1), CP1 and CP2 (→ 9.4.7) take effect
immediately.
9.1 General parameter setting
3 steps must be taken for each parameter setting:
1 Select parameter
►► Press [Mode/Enter] until the
requested parameter is displayed.
If the main menu is protected by an
access code, [Cod0] flashes in the
display.
►► Press [Set] and keep it pressed until
the valid code no. is displayed.
►► Press [Mode/Enter] briefly.
On delivery by ifm electronic: no access
restriction.
2 Set parameter value
►► Press [Set] and keep it pressed.
>> Current setting value of the
parameter flashes for 5 s.
>> After 5 s: setting value is changed:
incrementally by pressing the button
once or continuously by keeping the
button pressed.
Numerical values are incremented continuously. For reducing the value: let the
display move to the maximum setting value. Then the cycle starts again at the
minimum setting value.
3 Acknowledge parameter value
►► Press [Mode/Enter] briefly

>> The parameter is displayed again.
The new setting value is stored.
Set other parameters
►► Start again with step 1.
Finish parameter setting
►► Press [Mode/Enter] several times until the current measured value is displayed or wait for 15 s.
>> The unit returns to the operating mode.
20
For 2-wire operation those menu items referring to switching functions are
not active (→ 8 Menu structure); for some menu items those parameter
values referring to switching functions cannot be selected.
• If [SLoc] is displayed when attempting a modification of a parameter value,
the sensor is locked via software. This locking can only be removed via a
parameter setting software.
• When parameter setting with the user interface of the ifm Container program,
the values can be directly entered in the specified fields.
• For IO-Link parameter setting → device-specific parameter lists at: www.ifm.com
• Change from menu level 1 to menu level 2: UK
►► Press [Mode/Enter] until [EF] is
displayed.

►► Press [Set] briefly

>> The first parameter of the submenu is
displayed (here: [Uni]).
If the menu level 2 is protected by an
access code, "Cod1" flashes in the display.

►► Press [Set] and keep it pressed until
the valid code no. is displayed.
On delivery by ifm electronic: no access
restriction.
• Locking / unlocking
The unit can be locked electronically to prevent unintentional settings.
►► Make sure that the unit is in the
normal operating mode.
►► Press [Mode/Enter] + [Set] for 10 s.
>> [Loc] is displayed.

During operation: [Loc] is briefly displayed if you try to change parameter values.
For unlocking:
►► Press [Mode/Enter] + [Set] for 10 s.
>> [uLoc] is displayed.

On delivery: unlocked.
21
• Timeout:
If no button is pressed for 15 s during parameter setting, the unit returns to the
operating mode with unchanged values.
9.2 Configure display (optional)

►► Select [Uni] and set the unit of measurement:
-- [bAr], [mbAr].
-- [MPA], [kPA].
-- [PSI] (only PI2793, PI2794, PI2795, PI2796, PI2797, PI2799).
-- [InHO] (only PI2789, PI2796, PI2797, PI2798, PI2799).
-- [mWS] (only PI2796, PI2797, PI2799).
-- [mmWS] (only PI2789 and PI2798).
►► Select [SELd] and set type of indication:
-- [P]: system pressure in the unit set in Uni.
-- [P%]: system pressure in % of the set scaling of the analogue output;
the following applies: 0% = ASP value / 100% = AEP value.
If OU2 has been configured as switching output, [ASP] and [AEP] are
not active. In this case the following applies: 0% = initial value of the
measuring range/ 100% = final value of the measuring range.
If [SELd] = [P%] please take the following into account: “0” does not mean
that no pressure is applied to the system!
►► Select [diS] and set the update rate and orientation of the display:
-- [d1]: update of the measured values every 50 ms.
-- [rd1], [rd2], [rd3]: display as for d1, d2, d3; rotated by 180°
-- [OFF] = The measured value display is deactivated in the Run mode.
Touching one of the buttons indicates the current measured value for
15 s. Pressing the [Mode/Enter] button again activates the display
mode. The LEDs remain active even if the display is deactivated.
Error messages are displayed even if the display is deactivated.
9.3 Set output signals

9.3.1 Set output functions
►► Select [OU1] and set the switching function:
-- [Hno] = hysteresis function/NO,
-- [Hnc] = hysteresis function/NC,
-- [Fno] = window function/NO,
-- [Fnc] = window function/NC.
22
►► Select [OU2] and set the function:
-- [Hno] = hysteresis function/NO,
-- [Hnc] = hysteresis function/NC,
-- [Fno] = window function/NO,
-- [Fnc] = window function/NC.
-- [I] = current signal proportional to pressure 4…20 mA.
-- [InEG] = current signal proportional to pressure 20…4 mA.
9.3.2 Set switching limits
►► Select [SP1] / [SP2] and set the value at which the output switches.
UK
►► Select [rP1] / [rP2] and set the value at which the output switches back.
rPx is always smaller than SPx. The unit only accepts values which are
lower than the value for SPx.
9.3.3 Scale analogue value for OUT2
►► Set the minimum pressure requested in the system.
►► Press [Mode/Enter] until [tASP] appears.
>> Current setting value flashes.
►► Release [Set] when the display stops flashing.
>> New setting value is displayed.
>> The current system pressure is defined as start value for the analogue
signal.
►► Set the maximum pressure requested in the system.
►► Press [Mode/Enter] until [tASP] appears.
>> Current setting value flashes.
►► Release [Set] when the display stops flashing.
>> New setting value is displayed.
>> The current system pressure is defined as end value for the analogue
signal.
ASP / AEP can only be set automatically within defined limits (→ 12.1 Setting ranges).
If automatic setting is carried out at an invalid pressure value, [UL] or [OL] is displayed.
After acknowledgement by [Mode/Enter] [Err] flashes, the ASP value / AEP value is not
changed.
23
As an alternative:
►► Select [ASP] and set the measured value at which 4 mA is provided
(20 mA at [OU2] = [InEG]).
►► Select [AEP] and set the measured value at which 20 mA is provided
(4 mA at [OU2] = [InEG]).
Minimum distance between ASP and AEP = 25 % of the final value of the
measuring range (turn-down 1:4).
9.4 User settings (optional)

9.4.1 Carry out zero point calibration
►► Select [COF] and set a value between -5% and 5% of the final value of
the measuring range. The internal measured value "0" is shifted by this
value.
As an alternative: automatic adjustment of the offset in the range 0 bar
± 5%.
►► Make sure that no pressure is applied to the system.
►► Press [Mode/Enter] until [tCOF] appears.
>> The current offset value (in %) flashes briefly.
>> The current system pressure is displayed.
►► Release [SET].
►► Press [Mode/Enter] briefly (= to confirm the new offset value).
9.4.2 Setting of the error behaviour of the outputs
►► Select [FOU1] and set the value:
-- [On] = output 1 switches ON in case of a fault.
-- [OFF] = output 1 switches OFF in case of a fault.
-- [OU] = output 1 switches irrespective of the error as defined with the
parameters SP1, rP1 and OU1.
►► Select [FOU2] and set the value:
-- [On] = output 2 switches ON in case of a fault, the analogue signal
goes to the upper end stop value.
-- [OFF] = output 2 switches OFF in case of a fault, the analogue signal
goes to the lower end stop value.
-- [OU] = Output 2 switches irrespective of the error as defined with the
parameters SP2, rP2 and OU2. The analogue signal corresponds to
the measured value.
Error indications → 10.3
24
9.4.3 Set delay for the switching outputs
[dS1] / [dS2] = switch-on delay for OUT1 / OUT2.
[dr1] / [dr2] = switch-off delay for OUT1 / OUT2.
►► Select [dS1], [dS2], [dr1] or [dr2] and set a value between 0.1 and 50 s
(at 0.0 the delay time is not active).
9.4.4 Set switching logic for the switching outputs

►► Select [P-n] and set [PnP] or [nPn].
UK
9.4.5 Set damping for the switching signal
►► Select [dAP] and set a value between 0.00 and 30.00 s; (at 0.00 [dAP]
is not active).
dAP value = response time between pressure change and change of the
switching status in seconds.
[dAP] influences the switching frequency: fmax = 1 ÷ 2dAP.
[dAP] also has an effect on the display.
9.4.6 Set damping for the analogue signal

►► Select [dAA] and set a value between 0.01 and 99.99 s; (at 0.00 [dAA]
is not active).
dAA value = response time between pressure change and change of the
analogue signal in seconds.
9.4.7 Calibrate curve of measured values
►► Set a defined reference pressure between ASP and AEP in the system.
►► Select [CAL].
►► Press [Set] briefly.
>> [CP1] is displayed.
►► Press [Set] for 5 s.
>> The pressure measured by the unit is displayed.
►► Press [Set] until the set reference pressure is indicated (measured
pressure = reference pressure) or the corresponding analogue signal is
provided on OUT2.
Maximum correction value = ± 2 % of the final value of the measuring
range.
Continue with a) or b)
25
a) Finish calibration:
>> [CAL] is displayed.
b) Change a 2nd point on the curve of measured values
►► Set a second defined reference pressure in the system.
Minimum distance between the calibration points CP1 and CP2 = 5 % of
the final value of the measuring range.
►► Press [Set] for 5 s.
>> The pressure measured by the unit is displayed.
►► Press [Set] until the set reference pressure is indicated (measured
pressure = reference pressure) or the corresponding analogue signal is
provided on OUT2.
Maximum correction value = ± 2 % of the final value of the measuring
range.
>> [CAL] is displayed, the process is finished.
9.5 Service functions

9.5.1 Read min/max values for system pressure
►► Select [HI] or [LO] and press [Set] briefly.
[HI] = maximum value, [LO] = minimum value.
Delete memory:
►► Select [HI] or [LO].
►► Press [Set] and keep it pressed until [----] is displayed.
9.5.2 Reset all parameters to factory setting
►► Select [rES].
►► Press [Set] and keep it pressed until [----] is displayed.
It is recommended to take down your own settings in the table before
carrying out a reset (→13 Factory setting).
9.6 Simulation function

9.6.1 Open menu level 3 (simulation)
►► Select [EF] and press [Set] briefly (= to open menu level 2).
►► Select [SIM] and press [Set] briefly (= to open menu level 3).
>> [SEL] is displayed.
26
9.6.2 Set simulation value
Output states
If [SEL] is active:
►► Press [Set] and keep it pressed until [OU] is displayed.
>> [S.OU1] is displayed (in 2-wire operation [S.OU2] is displayed).
►► Press [Set] to set the requested value:
-- [OPEN] = output 1 not active / open.
-- [CLOS] = output 1 active / closed.
>> [S.OU2] is displayed. UK
►► Press [Set] to set the requested value:
• If [OU2] = [Hnc], [Hno], [Fnc] or [Fno] (not in 2-wire operation):
-- [OPEN] = output 2 not active / open.
-- [CLOS] = output 2 active / closed.
• If [OU2] = [I] or [InEG]:
-- 3.60...21.10 mA in steps of 0.01 mA.
Process value
If [SEL] is active:
►► Press [Set] and keep it pressed until [Proc] is displayed.
>> [S.Pr] is displayed.
►► Press [Set] to set the requested pressure value.
9.6.3 Set time for simulation
►► Select [S.TIM] and set the value between 1...60 minutes.
9.6.4 Start simulation

►► Select [S.ON].
►► Press [Set] and keep it pressed until the display alternately shows [SIM]
and the current operation indication.
Current operation indication:
-Current
- system pressure if [SEL] = [OU].
-Simulated
- measured value set in [S.Pr] if [SEL] = [Proc].
After the simulation time has elapsed [S.OFF] is displayed for 2 s, then
[SEL].
Abort simulation:
►► Press [Mode/Enter] or [Set] briefly.
>> [S.OFF] is displayed for 2 s, then [SEL].
27
10 Operation
After power on, the unit is in the Run mode (= normal operating mode). It carries
out its measurement and evaluation functions and provides output signals
according to the set parameters.
Operating indicators → Chapter 7 Operating and display elements.
10.1 Read set parameters
►► Press [Mode/Enter] until the requested parameter is displayed.
►► Press [Set] briefly.
>> The unit displays the corresponding parameter value for approx. 15 s. After
another 15 s the parameter is displayed again, then the unit returns to the Run
mode.
10.2 Change the display in the Run mode
►► Press [Set] briefly in the Run mode.
>> The unit indicates the current measured value in the selected type of indication
for approx. 15 s:
-- System pressure in the unit set in Uni.
-- System pressure in % of the set scaling of the analogue output if [OU2] is
configured as analogue output.
-- System pressure in % of the final value of the measuring range if [OU2] is
configured as switching output.
10.3 Self-diagnosis / error indications
The unit has many self-diagnostic options.
• It monitors itself automatically during operation.
• It indicates warnings and faults via IO-Link and via display (even if the display
is deactivated).
• If a fault is found, the outputs are set according to the set parameters FOU1
and FOU2 (→ 9.4.2).
28
IO-Link PDValid
IO-Link Device-
IO-Link event
Status Idx 36
Type of fault
Corrective
measures
number
Display
-/-* 0x5111 no 2** Supply voltage ►► Check / correct the supply voltage.
too low. ►► In 2-wire operation: Check / correct
the connected load.
SC1 0x8CB3 yes Excessive 2** ►► Check switching output 1 for short-
current circuit or excessive current; remove UK
switching the fault.
output 1.
SC2 0x8CB4 yes 2** Excessive ►► Check switching output 2 for short-
current circuit or excessive current; remove
switching the fault.
output 2.
Para 0x1810/ no 2** Parameter ►► Define the parameters via IO-Link
0x1Fxx setting fault event number 0x1Fxx.
via IO-Link; ►► Change parameters via IO-Link or
setting of one setting buttons.
parameter ►► Reset all parameters to factory
outside the setting (→ 9.5.2).
permitted area.
OL 0x8C10 yes 2** Process value ►► Check / reduce system pressure.
too high.
UL 0x8C30 yes 2** Process value ►► Check / increase the system
too low. pressure.
E100 0x5000 no 4** Internal sensor ►► Replace the unit.
error detected.
W531 0x8CA1 yes 2** Analogue ►► Increase AEP value if possible (for
output at the [OU2] = [InEG] ASP value) or reduce
upper limit system pressure.
(20.5 mA).
W530 0x8CA0 yes 2** Analogue ►► Reduce ASP value if possible
output at the (for [OU2] = [InEG] AEP value) or
lower limit increase system pressure.
(3.8 mA).
* In case of undervoltage (fault no. W403) the display shows nothing
** 2 = Out of Spec / 4 = Failure
29
IO-Link PDValid
IO-Link Device-
IO-Link event
Status Idx 36
Type of fault
Corrective
measures
number
Display
W532 0x8CA5 yes Load at 2**►► Reduce load at output 2 or increase

analogue the supply voltage.
output too
high.***
W203 0x1822 yes 2** Error during the The unit uses a higher temperature
temperature coefficient (i.e. with reduced accuracy).
compensation ►► Replace the unit.
of the pressure
measurement.
W703 0x8CC2 yes 2** Medium Reduce the medium temperature.
temperature
too high
(> 150 °C).
W704 0x8CC3 yes 2** Medium Increase the medium temperature.
temperature
too low
(< -30 °C).
W161 0x4210 yes 2** Unit Unit outside the specification.
temperature ►► Do not insulate the installation.
too high
(> 90°C).
W162 0x4220 yes 2** Unit Unit outside the specification.
temperature ►► Insulate the installation.
too low
(< -30 °C).
* In case of undervoltage (fault no. W403) the display shows nothing
** 2 = Out of Spec / 4 = Failure
*** This message is only displayed for 3-wire operation. For 2-wire operation undervoltage
is detected and displayed. If OU2 is not used for the application, the message can be
suppressed by defining a switching function for OU2 (→ 9.3.1).
30
11 Scale drawing
2 3
50 64
M12 x1
1 UK
105,8
52,8
16,8
34 G1
Dimensions in mm
1: Display
2: LEDs
3: Programming button
12 Technical data

2-wire operation 3-wire operation
Operating voltage [V] 20...32 DC 18...32 DC
Current consumption [mA] 3.6...21 < 45
Current rating [mA] --- 250
Analogue output 4...20 mA / 20...4 mA
Max. load [Ω] 300 (Ub - 10) x 50
Step response time analogue output [ms] 45 7
Voltage drop [V] --- <2
Min. response time switching output [ms] --- 3
Switching frequency [Hz] --- 125
Power-on delay time [s] 1 0.5
Short-circuit protection; reverse polarity protection / overload protection, integrated
watchdog
31
IO-Link Device
Transfer type..........................................................................................COM2 (38.4 kBaud)
Accuracy / deviations (in % of the span)1)
PI279x PI2789
Switch point accuracy [%] < ± 0.2 < ± 0.5
Characteristics deviation (linearity, incl. hysteresis and
< ± 0.2 < ± 0.5
repeatability)2)
Linearity < ± 0.15 < ± 0.25
Hysteresis < ± 0.15 < ± 0.2
Repeatability (in case of temperature fluctuations < 10 K) < ± 0.1 < ± 0.1
Long-term stability (in % of the span per year) < ± 0.1 < ± 0.1
Temperature coefficients (TC) in the compensated temperature range 0 ...70°C (in % of
the span per 10 K)
PI279x PI2789
Greatest TEMPCO of the zero point < ± 0.05 < ± 0.1
Greatest TEMPCO of the span < ± 0.15 < ± 0.2
Materials (wetted parts)
................................ stainless steel 316L / 1.4435, surface characteristics: Ra < 0.4 / Rz 4
ceramics (99.9 % Al2O3); PTFE
Housing materials......... high-grade stainless steel (316L/1.4404); FPM (Viton); PTFE; PBT
(Pocan); PEI; PFA
Protection rating ................................................................................. IP 67 / IP 68 / IP 69K
Protection class...................................................................................................................III
Insulation resistance [MΩ]..........................................................................> 100 (500 V DC)
Shock resistance [g]................................................................. 50 (DIN IEC 68-2-27, 11 ms)
Vibration resistance [g].................................................... 20 (DIN IEC 68-2-6, 10 - 2000 Hz)
Switching cycles min............................................................................................ 100 million
Ambient temperature [°C]........................................................................................ -25 ... 80
Medium temperature [°C]................................................................ -25...125 (145 max. 1 h)
Storage temperature [°C]........................................................................................ -40...100
EMC EN 61000-4-2 ESD: ........................................................................................ 4 / 8 kV
EN 61000-4-3 HF radiated: ............................................................................. 10 V/m
EN 61000-4-4 Burst: ............................................................................................ 2 kV
EN 61000-4-5 Surge: ................................................................................... 0.5 / 1 kV
EN 61000-4-6 HF conducted: ............................................................................. 10 V
1)
All indications are referred to a turn-down of 1:1
2)
Limit value setting to DIN 16086
32
12.1 Setting ranges
SP1 / SP2 rP1 / rP2 ASP AEP
ΔP
min max min max min max min max
mbar -4.8 100.0 -5.0 99.8 -5.0 75.0 20.0 100.0 0.1
PI2789
kPa -0.48 10.00 -0.50 9.98 -0.50 7.50 2.00 10.00 0.01
inH2O -1.92 40.16 -2.00 40.08 -2.00 30.12 8.04 40.16 0.04
mmWS -49 1020 -51 1018 -51 765 204 1020 1
bar -0.96 25.00 -1.00 24.96 -1.00 18.74 5.24 25.00 0.02
PI2793
PSI -13.8 362.7 -14.4 362.1 -14.4 271.8 76.2 362.7 0.3 UK
MPa -0.096 2.500 -0.100 2.496 -0.100 1.874 0.524 2.500 0.002
bar -0.98 10.00 -1.00 9.98 -1.00 7.50 1.50 10.00 0.01
PI2794
PSI -14.2 145.0 -14.5 144.7 -14.5 108.7 21.8 145.0 0.1
MPa -0.098 1.000 -0.100 0.998 -0.100 0.750 0.150 1.000 0.001
bar -0.990 4.000 -1.000 3.990 -1.000 3.000 0.000 4.000 0.005
PI2795
PSI -14.35 58.00 -14.50 57.85 -14.50 43.50 0.00 58.00 0.05
kPa -99.0 400.0 -100.0 399.0 -100.0 300.0 0.0 400.0 0.5
bar -0.120 2.500 -0.124 2.496 -0.124 1.880 0.500 2.500 0.002
PSI -1.74 36.27 -1.80 36.21 -1.80 27.27 7.26 36.27 0.03
PI2796
kPa -12.0 250.0 -12.4 249.6 -12.4 188.0 50.0 250.0 0.2
inH2O -48 1004 -50 1002 -50 755 201 1004 1
mWS -1.22 25.49 -1.26 25.45 -1.26 19.17 5.10 25.49 0.01
mbar -48 1000 -50 998 -50 750 200 1000 1
PSI -0.70 14.50 -0.73 14.47 -0.73 10.88 2.90 14.50 0.01
PI2797
kPa -4.8 100.0 -5.0 99.8 -5.0 75.0 20.0 100.0 0.1
inH2O -19.2 401.6 -20.0 400.8 -20.0 301.2 80.4 401.6 0.4
mWS -0.49 10.20 -0.51 10.18 -0.51 7.65 2.04 10.20 0.01
mbar -12.0 250.0 -12.4 249.6 -12.4 187.4 50.0 250.0 0.2
PI2798
kPa -1.20 25.00 -1.24 24.96 -1.24 18.74 5.00 25.0 0.02
inH2O -4.8 100.4 -5.0 100.2 -5.0 75.2 20.1 100.4 0.1
mmWS -122 2550 -126 2546 -126 1912 510 2550 2
ΔP = step increment
33
SP1 / SP2 rP1 / rP2 ASP AEP
ΔP
min max min max min max min max
mbar -998 1000 -1000 998 -1000 500 -500 1000 1
PSI -14.45 14.50 -14.50 14.45 -14.50 7.25 -7.25 14.50 0.05
PI2799
kPa -99.8 100.0 -100.0 99.8 -100.0 50.0 -50.0 100.0 0.1
inH2O -400 401 -401 400 -401 201 -201 401 1
mWS -10.18 10.20 -10.20 10.18 -10.20 5.10 -5.10 10.20 0.01
ΔP = step increment
More information at www.ifm.com
34
13 Factory setting
Factory setting User setting
SP1 25% VMR *
rP1 23% VMR *
OU1 Hno
OU2 I
SP2 75% VMR *
rP2 73% VMR * UK
COF / tCOF 0.0
0% VMR *
ASP / tASP
PI2799: -1 bar
AEP / tAEP 100% VMR *
Uni bAr / mbAr
SELd P
dS1 0.0
dr1 0.0
dS2 0.0
dr2 0.0
FOU1 OUT
FOU2 OUT
P-n pnp
dAP 0.06
dAA 0.03
dis d2
CP1 0.00
CP2 0.00
* = the indicated percentage of the final value of the measuring range (VMR) of the
respective sensor (for PI2799 the percentage of the measuring span) is set.
35
GEA Niro Soavi
7.01.6 9533-4067-000 RIDUTTORE GEARBOX
7.01.6
Services
Media No. 4090
Riduttori e motoriduttori
Gear reducers and gearmotors
Istruzioni d'uso
Operating instructions
Edition December 2010

Istruzioni d'uso riduttori e motoriduttori
Indice
1 - Avvertenze generali sulla sicurezza 3 7.2 - Raffreddamento artificiale con serpentina 8
7.3 - Unità autonoma di raffreddamento 8
2 - Condizioni di impiego
3 - Stato di fornitura
3
3
8 - Messa in servizio 8 IT
3.1 - Ricevimento 3 9 - Manutenzione 8
3.2 - Targa di identificazione 3 9.1 - Generalità 8
3.3 - Verniciatura 3 9.2 - Serpentina 9
3.4 - Protezioni e imballo 4 9.3 - Anelli di tenuta 9
9.4 - Sostituzione motore 9
4 - Immagazzinamento 4 9.5 - Cuscinetti 9
5 - Installazione 4 9.6 - Tappo di carico metallico con filtro e valvola 9
5.1 - Generalità 4 10 - Livelli sonori 9

5.2 - Montaggio di organi sulle estremità d’albero
5.3 - Fissaggio pendolare
5
5
Tabella verniciatura 9 EN
5.4 - Albero lento cavo 5 Tabella momenti di serraggio per le viti di fissaggio
assiale e dell’unità di bloccaggio 10
6 - Lubrificazione 8
6.1 - Generalità 8 Tabella momenti di serraggio per le viti di
6.2 - Tabella lubrificazione 6 fissaggio (piedi e flange) 10
6.3 - Lubrificazione sopporto estrusore 8 Tabella momenti di serraggio per i tappi 10
7 - Sistema di raffreddamento 8 Anomalie riduttore: cause e rimedi 11
7.1 - Raffreddamento artificiale con ventola 8
Riciclaggio (tenere presente le prescrizioni in vigore): il componente è stato incorporato non sia stato dichiarato
– gli elementi della carcassa, gli ingranaggi, gli alberi e conforme:
i cuscinetti del riduttore devono essere trasformati in –a lla Direttiva macchine 2006/42/CE e successivi aggiorna-
rottami d’acciaio. Gli elementi in ghisa grigia subiranno menti; in particolare, eventuali protezioni antinfortunistiche
il medesimo trattamento nella misura in cui non esiste per estremità d’albero non utilizzate e per passaggi copri-
alcuna prescrizione specifica; ventola eventualmente accessibili (o altro), sono a cura
– le ruote a vite sono realizzate in bronzo e devono essere trattate dell’Acquirente;
di conseguenza; –a lla Direttiva «Compatibilità elettromagnetica (EMC)»
– gli oli esausti dovranno essere recuperati e trattati conformemente 2004/108/CE e successivi aggiornamenti.
alle prescrizioni. Qualunque tipo di operazione sul riduttore (motoriduttore) o su
I paragrafi contrassegnati dal simbolo qui a lato contengono dispo- componenti ad esso connessi deve avvenire a macchina ferma:
sizioni da osservare tassativamente onde garantire l’incolumità scollegare il motore (compresi gli equipaggiamenti ausiliari) dall’ali-
delle persone ed evitare danni rilevanti alla macchina o mentazione, il riduttore dal carico e assicurarsi che si siano attivati
all’impianto (es: lavori effettuati sotto tensione, su apparec- i sistemi di sicurezza contro ogni avviamento involontario e, ove si
chi di sollevamento, ecc.); I’installatore o il manutentore renda necessario, prevedere dispositivi meccanici di bloccaggio (da
deve comunque attenersi scrupolosamente a tutte le rimuovere prima della messa in servizio).
istruzioni contenute nel presente manuale. In caso di funzionamento anomalo (aumento di temperatura, rumoro-
sità inusuale, ecc.) arrestare immediatamente la macchina.
1 - Avvertenze generali sulla sicurezza I prodotti relativi a questo manuale corrispondono al livello tecnico
I riduttori e i motoriduttori presentano parti pericolose in quanto raggiunto al momento della stampa del manuale stesso. Rossi si
possono essere: riserva il diritto di apportare, senza preavviso, le modifiche ritenute
– poste sotto tensione; opportune per il miglioramento del prodotto.
– a temperatura superiore a +50 °C;
– in movimento durante il funzionamento; 2 - Condizioni di impiego
– eventualmente rumorose (livelli sonori > 85 dB(A)). I riduttori sono progettati per utilizzo in applicazioni industriali in
Un’installazione non corretta, un uso improprio, la rimozione delle accordo con i dati di targa, temperature ambiente 0  +40 °C (con
protezioni, lo scollegamento dei dispositivi di protezione, la carenza punte a -10 °C e +50 °C), altitudine massima 1 000 m.
di ispezioni e manutenzione, i collegamenti impropri, possono causa- Non è consentito l’impiego in atmosfere aggressive, con pericolo di
re danni gravi a persone o cose. Pertanto, il componente deve essere esplosione, ecc. Le condizioni di funzionamento devono corrispon-
movimentato, installato, messo in servizio, gestito, ispezionato, dere ai dati di targa.
manutenuto e riparato esclusivamente da personale responsabi-
le qualificato (definizione secondo IEC 364). 3 - Stato di fornitura
Si raccomanda di attenersi a tutte le istruzioni del presente manuale, alle 3.1 - Ricevimento
istruzioni relative all’impianto, alle vigenti disposizioni legislative di sicu- Al ricevimento verificare che la merce corrisponda a quanto ordinato
rezza, e a tutte le normative applicabili in materia di corretta installazione. e che non abbia subito danni durante il trasporto; nel caso contestarli
Attenzione! Componenti in esecuzione speciale o con varianti immediatamente allo spedizioniere.
costruttive possono differire nei dettagli rispetto a quelli descritti e Evitare di mettere in servizio riduttori o motoriduttori danneggiati
possono richiedere informazioni aggiuntive. anche solo lievemente.
Attenzione! Per l’installazione, I’uso e la manutenzione del motore
elettrico (normale, autofrenante o comunque speciale) e/o appa- 3.2 - Targa di identificazione
recchiatura elettrica di alimentazione (convertitore di frequenza, Ogni riduttore è dotato di targa di identificazione di alluminio anodizzato
soft-start ecc.), e eventuali accessori (flussostato, unità autonoma contenente le principali informazioni tecniche relative alle caratteristiche
di raffreddamento, termostati ecc;) consultare la documentazione funzionali e costruttive e ne definisce assieme agli accordi contrattuali,
specifica ad essi allegata. All’occorrenza richiederla. i limiti applicativi (ved. fig. 1); la targa non deve essere rimossa, e deve
Attenzione! Per eventuali chiarimenti e/o informazioni ulteriori, inter- essere mantenuta integra e leggibile. Tutti i dati riportati in targa devono
pellare Rossi, specificando tutti i dati di targa. essere specificati sugli eventuali ordini di parti di ricambio.
I riduttori e i motoriduttori del presente manuale sono normalmente 3.3 - Verniciatura
destinati ad essere impiegati in aree industriali: protezioni sup- I prodotti sono verniciati come da tabella verniciatura riportata a pag.
plementari eventualmente necessarie per impieghi diversi devono 10. In caso di sovraverniciatura (possibile solo con prodotti bicompo-
essere adottate e garantite da chi è responsabile dell’installazione. nente) occorre proteggere adeguatamente gli anelli di tenuta (che
IMPORTANTE: i componenti forniti da Rossi sono destinati ad essere non devono essere né danneggiati né verniciati), sgrassare e carteg-
incorporati in apparecchi o sistemi finiti e ne è vietata la messa giare le superfici del riduttore (o motoriduttore).
in servizio fino a quando l’apparecchio o il sistema nel quale
Istruzioni d'uso 4090INS.VPR-it1210HQM Rossi 3

Designazione (ved. Bimestre e anno di Designazione
tabella a lato) costruzione Prodotto
Macchina Rotismo Grand. Esecuzione
Esecuzioni speciali Forma costruttiva (se
diversa da IM B3 o B5) R, MR V, IV, 2IV 32 ... 250 UO ... Vite
R, MR 2I, 3I 32 ... 180 FC ..., PC ..., UC ... Coassiali
Potenza motore Fattore di servizio R, MR I, 2I, 3I, 4I 40 ... 631 UP ... Assi paralleli
motoriduttore
R, MR CI, ICI, C2I, C3I 40 ... 631 UO ... Assi ortogonali
Velocità di uscita
motoriduttore Rapporto di R C 80 ... 320 PO ..., FO ... Rinvii
trasmissione R 2I 85 ... 250 OP Pendolari
Potenza nominale Ø Flangia - albero
IT
riduttore motore
Fig. 1 (per maggiori indicazioni, ved. cataloghi tecnici Rossi; interpellarci).
Nota: A decorrere dal 04/05/2010 la società già ROSSI MOTORIDUTTORI S.p.A. ha assunto la denominazione sociale Rossi S.p.A. e le targhe sono state aggiornate corrispondentemente.
Attenzione! per la manutenzione, l’installazione dei riduttori accoppiati ai servomotori sincroni e asincroni (anche se targati diversamente da quanto sopra indicato) valgono le prescrizioni del presente manuale.
3.4 - Protezioni e imballo tale da sfondare la sede filettata o non assicurare il corretto
Le estremità libere degli alberi sporgenti e gli alberi cavi vengono serraggio del riduttore alla macchina.
protetti con olio antiruggine di lunga durata e con cappellotto (solo Attenzione! La durata dei cuscinetti e il buon funzio-
fino a D  48 mm per alberi sporgenti, D  110 mm per alberi cavi) namento di alberi e giunti dipendono anche dalla
in materiale plastico (polietilene). Tutte le parti interne sono protette precisione dell’allineamento tra gli alberi. Pertanto, occorre pre-
EN con olio antiruggine. stare la massima cura nelI’allineamento del riduttore con il motore e con
la macchina da comandare (se necessario, spessorare; per riduttori
Se non concordato diversamente in sede d’ordine, i prodotti vengono
adeguatamente imballati: su pallet, protetti mediante pellicola di grand.  400 servirsi dei fori filettati di livellamento), interponendo tutte
polietilene, nastrati e reggiati (grandezze superiori); in carton-pallet le volte che è possibile giunti elastici.
nastrati e reggiati (grandezze inferiori); in cartoni nastrati (per piccole Un allineamento errato può dar luogo a rotture degli alberi (che
dimensioni e quantità). All’occorrenza i riduttori sono convenientemen- possono causare danni gravi alle persone) e/o cuscinetti (che
te separati con cellule di schiuma antiurto o cartone da riempimento. possono causare surriscaldamenti).
I prodotti imballati non devono essere accatastati l’uno sull’altro. Non utilizzare, per il sollevamento dei motoriduttori, i golfari del motore.
Collocare il riduttore o il motoriduttore in modo da garantire un ampio
passaggio d’aria per il raffreddamento e del riduttore e del motore
4 - Immagazzinamento (soprattutto dal lato ventola sia riduttore, sia motore).
Evitare: strozzature nei passaggi dell’aria; vicinanza con fonti di calore
L’ambiente deve essere sufficientemente pulito, secco, esente da che possano aumentare la temperatura dell’aria di raffreddamento e del
vibrazioni eccessive (veff  0,2 mm/s) per non danneggiare i cuscinetti riduttore (per irraggiamento); insufficiente ricircolazione d’aria e in gene-
(tale necessità di contenere le vibrazioni, pur se entro limiti più ampi, rale applicazioni che compromettano il regolare smaltimento del calore.
deve essere soddisfatta anche durante il trasporto) e a una temperatu-
ra di 0  +40 °C: sono ammesse punte di 10 °C in meno o in più. Montare iI riduttore o motoriduttore in modo che non subisca vibrazioni.
Durante il trasporto e l’immagazzinamento, i riduttori completi di olio Le superfici di fissaggio (del riduttore e della macchina) devono essere
devono essere posizionati nella forma costruttiva prevista all’ordine. pulite e di rugosità sufficiente (orientativamente Ra  6,3 m) a garan-
tire un buon coefficiente di attrito: asportare con un raschietto o con
Ruotare semestralmente gli alberi di qualche giro per prevenire dan- solvente l’eventuale vernice delle superfici di accoppiamento del ridut-
neggiamenti a cuscinetti e anelli di tenuta. tore.
In ambienti normali e purché vi sia stata una adeguata protezione In presenza di carichi esterni impiegare, se necessario, spine o arre-
durante il trasporto, il componente viene fornito per un periodo di sti positivi.
immagazzinamento fino a 1 anno. Nelle viti di fissaggio e nel fissaggio tra riduttore e macchina e/o tra
Per un periodo di immagazzinamento fino a 2 anni in ambienti norma- riduttore ed eventuale flangia B5, si raccomanda l’impiego di adesivi
li è necessario seguire le seguenti ulteriori disposizioni: bloccanti (anche nei piani di unione per fissaggio con flangia).
– ingrassare abbondantemente le tenute, gli alberi e le eventuali Prima di effettuare l’allacciamento del motoriduttore assicurarsi che
superfici lavorate non verniciate, controllando periodicamente lo la tensione del motore corrisponda a quella di alimentazione; se il
stato di conservazione dell’olio antiruggine; senso di rotazione non corrisponde a quello desiderato, invertire due
– per i riduttori e motoriduttori forniti senza olio: inserire pastiglie fasi della linea di alimentazione.
anticondensa nei riduttori sostituendole alla scadenza e togliendole Quando l’avviamento è a vuoto (o comunque a carico molto ridotto)
prima della messa in servizio (in alternativa riempire completamen- ed è necessario avere avviamenti dolci, correnti di spunto basse,
te i riduttori con l’olio di lubrificazione riportandolo a livello prima sollecitazioni contenute, adottare l’avviamento Y-.
della messa in servizio). Nel caso si prevedano sovraccarichi di lunga durata, urti o pericoli di
Per immagazzinamento con durata superiore ai 2 anni o in ambiente bloccaggio, installare salvamotori, limitatori elettronici di momento
aggressivo o all’aperto, interpellare Rossi. torcente, giunti idraulici, di sicurezza, unità di controllo o altri disposi-
tivi similari.
In generale proteggere sempre il motore elettrico con adegua-
5 - Installazione to interruttore magnetotermico; però per servizi con elevato
5.1 - Generalità numero di avviamenti a carico è necessaria la protezione del motore
con sonde termiche (incorporate nello stesso); il relé termico non è
Prima di effettuare l’installazione, verificare che: idoneo, in quanto dovrebbe essere tarato a valori superiori alla cor-
– non vi siano stati danni durante l’immagazzinamento o il trasporto; rente nominale del motore.
– I’esecuzione sia adeguata all’ambiente (temperatura, atmosfera, ecc.); Collegare sempre le eventuali sonde termiche ai circuiti ausiliari
– I’allacciamento elettrico (rete o altro) corrisponda ai dati di targa del di sicurezza.
motore; Limitare i picchi di tensione dovuti ai contattori mediante l’impiego di
– la forma costruttiva di impiego corrisponda a quella indicata in varistori e/o filtri RC.
targa. Qualora il riduttore sia provvisto di dispositivo antiretro1), prevedere
Attenzione! Per il sollevamento e la movimentazione del un sistema di protezione nel caso in cui un cedimento dell’antiretro
riduttore o del motoriduttore utilizzare i fori passanti o filetta- possa causare danni a persone e cose.
ti della carcassa riduttore, accertarsi che il carico sia conve- Quando una perdita accidentale di lubrificante può comportare gravi
nientemente bilanciato e che siano disponibili apparecchia danni, aumentare la frequenza delle ispezioni e/o adottare accorgi-
ture di sollevamento, sistemi di aggancio e cavi di portata adeguata. menti opportuni (es.: indicatore a distanza di livello, lubrificante per
All’occorrenza l’entità delle masse dei riduttori e dei motoriduttori è industria alimentare, ecc.).
indicata sui cataloghi tecnici Rossi. In presenza di ambiente inquinante, impedire in modo adeguato la
Assicurarsi che la struttura sulla quale viene fissato il riduttore o il possibilità di contaminazione del lubrificante attraverso gli anelli di
motoriduttore sia piana, livellata e sufficientemente dimensionata per tenuta o altro.
garantire la stabilità del fissaggio e l’assenza di vibrazioni (sono Per installazione all’aperto o in ambiente aggressivo (classe di corro-
accettabili velocità di vibrazione veff  3,5 mm/s per PN  15 kW e veff sività C3 secondo ISO 12944-2) sovraverniciare il riduttore o il moto-
 4,5 mm/s per PN > 15 kW), tenuto conto di tutte le forze trasmesse riduttore con adeguata vernice (bicomponente) anticorrosiva, proteg-
dovute alle masse, al momento torcente, ai carichi radiali e assiali. gendolo eventualmente anche con grasso idrorepellente (specie in
Per le dimensioni delle viti di fissaggio dei piedi riduttore e la profon- corrispondenza delle sedi rotanti degli anelli di tenuta e delle zone di
dità dei fori filettati consultare i cataloghi tecnici Rossi. accesso alle estremità dell’albero).
Nel caso di utilizzo, per il fissaggio, dei fori filettati scegliere accura- 1) La presenza sul riduttore del dispositivo antiretro è segnalata dalla freccia in prossimità del-
tamente la lunghezza delle viti di fissaggio che deve essere tale da I’asse lento che indica il senso della rotazione libera, ad eccezione dei riduttori pendolari per i
garantire un tratto di filetto in presa sufficientemente esteso, ma non quali è segnalata dalla esecuzione B o C (ved. cataloghi tecnici Rossi).
4 Rossi Istruzioni d'uso 4090INS.VPR-it1210HQM

Quando è possibile, proteggere il riduttore o il motoriduttore con oppor- 5.4 - Albero lento cavo
tuni accorgimenti dall’irraggiamento solare e dalle intemperie; in quest’ul- Per il perno della macchina sul quale deve essere calettato l’albero
timo caso la protezione diventa necessaria quando gli assi lento e cavo del riduttore, si raccomandano le tolleranze h6, j6, k6 secondo
veloce sono verticali o quando il motore è verticale con ventola in alto. le esigenze.
Per funzionamento a temperatura ambiente maggiore di +40 °C o
Importante! Il diametro del perno della macchina in battuta contro il
minore di 0 °C interpellare Rossi.
riduttore deve essere almeno pari a 1,18  1,25 volte il diametro interno
Nel caso in cui il riduttore o motoriduttore sia fornito con il raffredda-
dell’albero cavo. Per altri dati sul perno macchina, nel caso di albero lento
mento artificiale con serpentina o unità autonoma di raffreddamento
cavo normale, differenziato, con anelli o bussola di bloccaggio, con unità
ved. cap. 7.
di bloccaggio ved. cataloghi tecnici Rossi.
5.2 - Montaggio di organi sulle estremità d’albero Attenzione! Per montaggi verticali a soffitto, e solo per
Per il foro degli organi calettati sulle estremità d’albero, si raccoman- riduttori dotati di anelli o bussola di bloccaggio, il sostenta-
da la tolleranza H7; per estremità d’albero veloce con D  55 mm,
purché il carico sia uniforme e leggero, la tolleranza può essere G7,
mento del riduttore è dovuto al solo attrito per cui è neces-
sario prevedere un sistema di arresto.
IT
per estremità d’albero lento con D  180 mm, salvo che il carico non Per facilitare il montaggio e lo smontaggio dei riduttori e motori-
sia uniforme e leggero, la tolleranza deve essere K7. duttori ad albero lento cavo provvisti di gola per anello elastico – sia
Prima di procedere al montaggio, pulire accuratamente e lubrificare con cava linguetta sia con unità di bloccaggio – procedere come
le superfici di contatto per evitare il pericolo di grippaggio e l’ossida- raffigurato a pag. 12 fig. 4a e 4b rispettivamente.
zione di contatto. Avvertenza. Pur essendo gli alberi lenti cavi lavorati complessiva-
Attenzione! ll montaggio e lo smontaggio devono essere effettuati mente in tolleranza H7, un controllo mediante tampone potrebbe
con l’ausilio di tiranti e di estrattori servendosi del foro filettato in rivelare due zone con diametro leggermente minorato (ved. Fig.
testa all’estremità d’albero (ved. tabella in fig. 2), avendo cura di 5a): tale minorazione è intenzionale e non pregiudizievole della qua-
evitare urti e colpi che potrebbero danneggiare irrimediabilmente
cuscinetti, anelli elastici o altre parti, per accoppiamenti H7/m6 e
lità del calettamento - che anzi ne risulta migliorato in termini di
durata e precisione - e non costituisce ostacolo al montaggio del
EN
K7/j6 è consigliabile effettuare il montaggio a caldo riscaldando l’or- perno macchina eseguito con gli usuali metodi come ad esempio
gano da calettare fino a 80  100 °C. quello illustrato a pag. 12 in Fig. 4a.
Estremità d’albero
D d
Ø Ø Fig. 5a
11  00 M 5
14  19 M 6
24  28 M 8
30  38 M 10
42  55 M 12
60  75 M 16 Per lo smontaggio dell’albero
lento cavo dei riduttori ad
80  95 M 20
assi paralleli e ortogonali (è la
100  110 M 24
prima operazione da esegui-
125  140 M 30 lato gola 
re per smontare il riduttore)
160  210 M 36 orientare la cava linguetta
UT.C 886
240  320 M 45 verso l’asse intermedio

Fig. 2 come indicato nella fig. 5b e
spingere l’albero sul lato gola
I giunti con velocità periferica sul diametro esterno fino a 20 m/s de- di riferimento (scanalatura cir- UT.C 322
vono essere equilibrati staticamente; per velocità periferiche superio- conferenziale sulla battuta lato opposto gola
ri occorre effettuare l’equilibratura dinamica. dell’albero). Fig. 5b
Quando il collegamento tra riduttore e macchina o motore è realizza- Per il fissaggio assiale si può adottare il sistema raffigurato a pag. 12
to con una trasmissione che genera carichi sull’estremità d’albero fig. 4c e 4d; quando il perno della macchina è senza battuta (metà
(ved. fig. 3), è necessario che: inferiore del disegno) si può interporre un distanziale tra l’anello ela-
– non vengano superati i carichi massimi indicati a catalogo; stico e il perno stesso. Le parti a contatto con l’anello elastico devono
– lo sbalzo della trasmissione sia ridotto al minimo; essere a spigolo vivo.
– le trasmissioni a ingranaggi non abbiano punti senza gioco; Utilizzando gli anelli di bloccaggio (pag. 12 fig. 4e) o la bussola di
– le trasmissioni a catena non siano tese (all’occorrenza – carico e/o bloccaggio (pag. 12 fig. 4f) è possibile conseguire un montaggio e
moto alterni – prevedere opportuni tendicatena); uno smontaggio più facili e precisi e l’eliminazione del gioco tra lin-
– le trasmissioni a cinghia non siano eccessivamente tese. guetta e relativa cava.
UT.C 117
Gli anelli o la bussola di bloccaggio devono essere inseriti dopo il mon-
taggio e dopo avere accuratamente sgrassato le superfici da accoppiare.
Non utilizzare bisolfuro di molibdeno o lubrificanti equivalenti per la lubri-
ficazione delle superfici a contatto. Per il montaggio della vite si racco-
manda l’impiego di adesivi bloccanti.
UT.C 666
Rispettare i momenti di serraggio riportati in tabella a pag. 10.

Errato Corretto Errato Corretto In caso di fissaggio assiale con anelli o bussola di bloccaggio – so-
Fig. 3 prattutto in presenza di cicli gravosi di lavoro, con frequenti inversioni del
moto – verificare, dopo alcune ore di funzionamento, il momento di
serraggio della vite ed eventualmente riapplicare l’adesivo bloccante.
5.3 - Fissaggio pendolare
Per il calettamento con l’unità di bloccaggio (pag. 12 fig. 4g) pro-
Nel fissaggio pendolare il riduttore deve essere sopportato radialmente
cedere come segue:
e assialmente (anche per forme costruttive B3 ... B8) dal perno della
macchina e ancorato contro la sola rotazione mediante un vincolo libero – sgrassare accuratamente le superfici dell’albero cavo e del per-no
assialmente e con giochi di accoppiamento sufficienti a consentire le macchina da accoppiare;
piccole oscillazioni, sempre presenti, senza generare pericolosi carichi – montare il riduttore sul perno macchina seguendo il metodo indi-
supplementari sul riduttore stesso. Lubrificare con prodotti adeguati le cato a pag. 12 fig. 4a;
cerniere e le parti soggette a scorrimento; per il montaggio delle viti si – serrare le viti dell’unità di bloccaggio in modo graduale e uniforme
raccomanda l’impiego di adesivi bloccanti. con sequenza continua (non in croce!) e in più fasi sino al raggiun
Per il montaggio del «kit di reazione a molle a tazza» (grand.  125 gimento del momento di serraggio riportato in tabella a pag. 10;
ad assi paralleli) servirsi del foro filettato in testa al perno macchina – al termine delle operazioni verificare il momento di serraggio delle
e delI’invito all’imbocco dell’incavo di reazione per comprimere e viti con chiave dinamometrica (piatta, in caso di montaggio sul lato
inserire il pacco di molle a tazza nell’incavo medesimo. macchina).
In relazione al sistema di reazione, attenersi alle indicazioni di progetto
indicate nei cataloghi tecnici Rossi. In ogni caso qualora vi siano peri-
coli per persone o cose derivanti da cadute o proiezione del riduttore
o di parti di esso, prevedere appropriate sicurezze contro:
– la rotazione o lo sfilamento del riduttore dal perno macchina con-
seguenti a rotture accidentali del vincolo di reazione;
– la rottura accidentale del perno macchina.

6.2 - Tabella lubrificazione
Prodotto Stato di fornitura* e tappi Norme per l’eventuale primo riempimento

COMPLETI DI OLIO
SINTETICO
AGIP Blasia S 320,
KLÜBER Klübersynth GH 6-320
MOBIL Glygoyle HE 320,
SHELL Tivela S 320
Vite Con velocità vite  280 min-1
IT grand. 32 ... 81 KLÜBER Klübersynth GH 6-680
MOBIL Glygoyle HE 680
SHELL Tivela S 680
Tappo di carico
1 tappo di carico per grand. 32 ... 64
Tappo di carico/scarico
2 tappi di carico/scarico per grand. 80, 81
SENZA OLIO Gradazione di viscosità ISO [cSt]

(salvo diversa indicazione
EN sulla targa di lubrificazione)
Prima della messa in
funzione, immettere

Velocità vite
Temperatura ambiente 0  +40 °C2)
Grandezza riduttore
fino a livello, olio sin min-1
tetico (AGIP Blasia 100 125 ... 161 200, 250
S, ARAL Degol GS, B31), V5, V6 B6, B7, B8 B31), V5, V6 B6, B7, B8
BP-Energol SG-XP,
Vite 2 800  1 400 3) 320 320 220 220
MOBIL Glygoyle HE,
grand. 100 ... 250 1 400  710 3) 320 320 320 220
SHELL Tivela S ... ,
KLÜBER Klübersynth 710  355 3) 460 460 460 320
GH 6...) avente la 355  180 3) 680 680 460 460
gradazione di visco- < 180 680 680 680
sità ISO indicata in
tabella. 1) N on indicata in targa.
Tappi di carico con valvola, 2) Sono ammesse punte di temperatura ambiente di 10 °C (20 °C per  460 cSt)
in meno o 10 °C in più.
scarico e livello 3) Per questa velocità si consiglia di sostituire l’olio dopo il rodaggio.
COMPLETI DI GRASSO
SINTETICO
Coassiali SHELL Tivela GL 00
grand. 32 ... 41 IP Telesia Compound A
MOBIL Glygoyle Grease 00
Rinvii (cat. L)
grand. 80 ... 125
(solo per coassiali)
COMPLETI DI OLIO
SINTETICO
KLÜBER Klübersynth GH 6-220,
MOBIL Glygoyle 30
SHELL Tivela S 220
Coassiali
grand. 50 ... 81
Assi paralleli e
ortogonali
grand. 40 ... 81
2 tappi di carico/scarico
per grand. 80, 81
SENZA OLIO** Prima della messa in funzio- Gradazione di viscosità ISO [cSt]
(salvo diversa indicazione ne, immettere fino a livello,
Coassiali sulla targa di lubrificazione) olio minerale (AGIP Blasia, Velocità n2 Temperatura ambiente1) [°C]
grand. 100 ... 180 ARAL Degol BG, BP-Energol min-1 olio minerale olio sintetico
GR-XP, ESSO Spartan EP, IP Rinvii
Assi paralleli e Mellana oil, MOBIL Mobil- ad angolo Altri 0  20 10  40 0  40
ortogonali gear 600, SHELL Omala,
grand. 100 ... 631 TEXACO Meropa, TOTAL > 710 000 > 224 150 150 150
Carter EP) oppure olio sin- 710  280 224  22,4 150 220 220
Rinvii (cat. L) tetico a base di poliglico- 280  90 22,4 5,6 220 320 320
grand. 160 ... 320 li** (KLÜBER Klübersynth < 90 000 < 5,6 320 460 460
GH6 ..., MOBIL Glygoyle,
1) Sono ammesse punte di temperatura ambiente di 10 °C (20 °C) in meno o
Pendolari Tappi di carico con valvola SHELL Tivela S) o di polial- 10 °C in più.
(con sfiato, per riduttori faolefine** (AGIP Blasia SX,
pendolari), CASTROL Tribol 1510, ELF Reductelf SYNTHESE, ESSO Spartan SEP, KLÜBER Klübersynth EG4,
scarico e livello MOBIL SHC Molykote L11 ...) avente la gradazione di viscosità ISO indicata in tabella.
Cuscinetti con lubrificazione indipendente, cuscinetti motore, dispositivo antiretro montato sul motore:
la lubrificazione è «a vita» (escluso il caso di motori nei quali è previsto il dispositivo di rilubrificazione). In caso di possibilità di inquinamento
del grasso o in presenza di servizi particolarmente gravosi è bene verificare (tra un cambio e l’altro oppure ogni 1 o 2 anni) lo stato del grasso e
asportare e sostituire (ogni 1 o 2 cambi oppure ogni 2 o 4 anni) il grasso nei cuscinetti con lubrificazione indipendente. Il cuscinetto va riempito
completamente con grasso per cuscinetti ESSO BEACON 3 se a sfere, KLÜBER STABURAGS NBU 8 EP se a rulli; lubrificare il dispositivo antiretro
con ESSO BEACON 2.

Intervallo di lubrificazione e quantità di lubrificante
Quantità di olio [l] per riduttori a vite grand. 32 ... 81

Per le altre grand. la quantità è individuata dal livello segnalato dall’apposito tappo
R V, MR V R IV, MR IV MR 2IV
Grand. B31), V5, B6, B7 B81) B31), V5, B6, B7 B81) B31) B6, B7 B81) V5, V6
V6 V6 IT
32 0,16 0,2 0,16 0,2 0,25 0,2 – – – –
40 0,26 0,35 0,26 0,32 0,4 0,32 0,42 0,5 0,42 0,42
50 0,4 0,6 0,4 0,5 0,7 0,5 0,6 0,8 0,6 0,6
63, 64 0,8 1,15 0,8 1 1,3 1 1,2 1,55 1,2 1,2
80, 81 1,3 2,2 1,7 1,5 2,5 2 1,7 2,8 2,3 1,8
1) Non indicata in targa (B8, solo per grand. 32 ... 64).
Temperatura ambiente 0  +40 °C con punte fino a –20 °C e +50 °C.
EN
Temperatura Intervallo di
Orientativamente l’intervallo di lubrificazione, in assenza di inquinamento dall’esterno, è olio [°C] lubrificazione [h]
quello indicato in tabella. Per sovraccarichi forti, dimezzare i valori.
0 0 65 18 000
Indipendentemente dalle ore di funzionamento, sostituire o rigenerare l’olio ogni 5  8 anni 65  80 12 500
secondo la grandezza, le condizioni di servizio e ambientali. 80  95 9 000
95  110 6 300
Quantità di grasso [kg] per riduttori coassiali

R 2I MR 2I, 3I
Grand. B31), B6, B7, B8 V5, V6 B51) V1, V3
Lubrificazione «a vita» (in assenza di inquinamento dall’esterno).
32 0,14 0,25 0,1 0,18
40, 41 0,26 0,47 0,19 0,35
1) Non indicata in targa.
Temperatura ambiente 0  +40 °C con punte fino a –20 °C e +50 °C.
Lubrificazione «a vita» (in assenza di inquinamento dall’esterno). Quantità d’olio [l] per grand. 50 ... 81
R I R 2I, MR 2I R 3I, MR 3I MR 4I
R 2I, 3I MR 2I, 3I Paralleli 1) 1) 1) 1)
Coassiali grand. B31), B7 B6, B3 , B7, B3 , B7, B3 , B7,
grand. B6, B7, B62) B6 B6 V53)
B31) V5 B8 , V5, V6 B81), V5, V6 B81), V53), V6 B81), V6,
B8, V6
40, 00 – – – 0,4 0,9 0,55 0,47 0,7 0,6 – – – –
50, 51 0,8 1,1 1,4 50, 00 – – – 0,6 0,9 0,80 0,70 1,05 0,9 – – – –
63, 64 1,6 2,2 2,8 63, 64 0,7 0,8 1,0 0,9 1,4 1,20 1,00 1,50 1,3 1,1 1,8 1,4 1,3
80, 81 3,1 4,3 5,5 80, 81 1,2 1,5 1,9 1,5 2,7 2,30 1,70 2,90 2,5 1,9 3,2 2,7 2,5
1) Non indicata in targa.
2) Valori validi per R 2I; per MR 2I i valori sono R CI, MR CI R ICI, MR ICI MR C3I
rispettivamente 0,8; 1,2; 2,3. Ortog.
3) La prima riduzione (le prime due per 4I) è lubri grand. B31), V5, B31), V5, B31), V5,
B8 B6 B8 B6 B8
ficata con grasso a vita. B6, B7 V6, B71), V6, B71), V6,
Temperatura ambiente 0  +40 °C con punte fino a
–20 °C e +50 °C. 40, 00 0,26 0,35 0,3 0,31 0,5 0,40 0,35 – – – –
50, 00 0,4 0,60 0,45 0,45 0,8 0,65 0,50 0,5 0,9 0,7 0,55
63, 64 0,8 1,00 0,95 1,00 1,6 1,20 1,15 1,2 1,8 1,4 1,35
80, 81 1,3 2,00 1,80 1,60 2,7 2,20 2,00 1,9 3,0 2,5 2,30
Orientativamente l’intervallo di lubrificazione, in assenza di inquinamento

dall’esterno, è quello indicato in tabella. Per sovraccarichi forti, dimezzare i Temperatura Intervallo di lubrificazione [h]
olio [°C] olio minerale olio sintetico
valori.
Indipendentemente dalle ore di funzionamento:  65 1) 8 000 25 000
– sostituire l’olio minerale ogni 3 anni; 65  80 1) 4 000 18 000
– sostituire o rigenerare l’olio sintetico ogni 5  8 anni secondo la grandez- 80  95 1) 2 000 12 500
za del riduttore, le condizioni di servizio e ambientali. 95  110 1) – 9 000
La quantità d’olio è individuata dal livello segnalato dall’apposito tappo. 1) Valori ammessi solo per assi paralleli, ortogonali e rinvii e per servizi non
continuativi.
** Individuazione anche mediante targa di lubrificazione specifica.

** Lubrificazione con olio sintetico (a base di poliglicoli; necessaria verniciatura interna speciale; a base di polialfaolefine: consigliabile per grand.  200 e tassativo per grand.  400). Sempre
raccomandabile, in particolare per riduttori veloci: per aumentare l’intervallo di lubrificazione («lunga vita»); per aumentare il campo della temperatura ambiente; per aumentare la potenza
termica o ridurre la temperatura dell’olio.

6 - Lubrificazione 7.2 - Raffreddamento artificiale con serpentina
6.1 - Generalità La presenza della serpentina è segnalata dagli attacchi (raccordi DIN
I riduttori e motoriduttori possono essere, secondo il tipo e la gran- 2353) per l’acqua sporgenti dalla carcassa come da figura sottostante.
dezza, lubrificati con grasso e vengono forniti COMPLETI Dl GRAS- Attenzione: Non manomettere l’eventuale piastrina che mantiene
SO, o con olio (sintetico o minerale) e vengono forniti COMPLETI Dl
OLIO o SENZA OLIO secondo il tipo e la grandezza (ved. cap. 6.2). grand. d A1) chiave
Nel caso di fornitura SENZA OLIO, il riempimento fino a livello Ø ≈
(segnalato normalmente dal tappo trasparente di livello) è a cura del 125 ... 180 12 140 22
Cliente. 200 ... 280 12 150 22
Ogni riduttore è dotato di targa di lubrificazione. A 320 ... 360 16 160 30
Per tipo e quantità di lubrificante, tipo di riduttore, stato di fornitura, 400 ... 631 16 200 30
IT tappi, norme per il riempimento, intervallo di lubrificazione, ecc. ved.
cap. 6.2 «Tabella lubrificazione». 1) Questi valori per alcune forme
costruttive possono variare
Assicurarsi che, per riduttori e motoriduttori grand.  100, il tappo di
carico sia del tipo munito di valvola (simbolo ); in caso contrario,
sostituirlo con quello sfuso che in tali occasioni viene fornito in dota-
zione. bloccati i raccordi; in particolare mantenere bloccato il raccordo men-
Se il riduttore o motoriduttore è dotato di tappo di livello a sfiora- tre si stringe il dado di serraggio del tubo di collegamento.
mento (colore rosso) il riempimento deve essere effettuato svitando L’acqua di alimentazione deve possedere i seguenti requisiti:
il tappo medesimo onde verificare il raggiungimento del livello di
sfioramento. – bassa durezza;
Se il riduttore o motoriduttore è dotato – temperatura max +20 °C;
EN di tappo di livello con astina, riempi-
re con olio fino al raggiungimento del
– portata 10  20 dm3/min;
– pressione 0,2  0,4 MPa (2  4 bar).
livello indicato dalla tacca. Per temperatura ambiente minore di 0 °C prevedere scarico acqua e
Qualora il riduttore o motoriduttore sia attacco aria, per lo svuotamento della serpentina mediante aria com-
fornito di tappo di livello (grand.  pressa onde evitare il pericolo di congelamento dell’acqua.
100), la quantità di lubrificante da Se vi è il rischio di avere picchi elevati di pressione in mandata, monta
immettere è quella che consente il re una valvola di sicurezza tarata a un’opportuna soglia di intervento.
UT.C 764
raggiungimento del livello suddetto

a riduttore non in moto in mezzeria 7.3 - Unità autonoma di raffreddamento
del tappo e non quella, solo indicativa, menzionata a catalogo. Ved. documentazione specifica fornita in dotazione con l’unità.
I cuscinetti sono normalmente lubrificati in modo automatico e con-
tinuo (a bagno d’olio, a sbattimento, mediante appositi condotti o 8 - Messa in servizio
pompa) dal lubrificante stesso del riduttore; questo vale anche per Effettuare un controllo generale assicurandosi in particolare che il
l’eventuale dispositivo antiretro montato sul riduttore. riduttore sia completo di lubrificante.
Per certi riduttori in forma costruttiva verticale V1, V3, V5, V6 e anche Nel caso di avviamento Y-, la tensione di alimentazione deve corri-
orizzontale B3, B6, B51 per riduttori (non motoriduttori, per i quali spondere a quella più bassa (collegamento ) del motore.
vale quanto detto sopra) ad assi ortogonali, i cuscinetti superiori
hanno lubrificazione indipendente con grasso speciale per lubrifica- Per il motore asincrono trifase, se il senso di rotazione non corrispon-
zione «a vita» in assenza di inquinamento dall’esterno; questo vale de a quello desiderato, invertire due fasi della linea di alimentazione.
anche per i cuscinetti motore (esclusi alcuni casi nei quali è previsto Per i riduttori muniti di dispositivo antiretro, controllare – prima
il dispositivo di rilubrificazione) e per l’eventuale dispositivo antiretro delI’avviamento – che ci sia corrispondenza tra il senso di rotazio-
quando è montato sul motore. ne libera e i sensi di rotazione della macchina da azionare e del
Verificare che iI riduttore venga montato nella forma costruttiva pre- motore.
vista all’ordine, che è indicata sulla targa; quando non è indicata, il Attenzione! Uno o più avviamenti nel senso bloccato, anche
riduttore è previsto per essere montato in forma costruttiva orizzon- se brevi, possono danneggiare irrimediabilmente il dispositivo
tale B3 o B5 (B3, B8, riduttori a vite grand.  64), verticale V1 (per antiretro, le sedi accoppiate e/o il motore elettrico.
rinvii ad angolo in esecuzione con flangia FO1...). È consigliabile un rodaggio:
Gruppi riduttori (combinati). La lubrificazione è indipendente e – di circa 400  1 600 h per i riduttori con ingranaggio a vite, affinché
pertanto valgono le norme dei singoli riduttori. si possa raggiungere il massimo rendimento;
6.3 - Lubrificazione sopporto estrusore (assi paralleli e ortogonali) – di circa 200  400 h per i riduttori con ingranaggi cilindrici e/o coni-
ci, affinché si possa raggiungere la massima funzionalità.
La lubrificazione del sopporto estrusore è separata rispetto al ridut- Durante questo periodo la temperatura del lubrificante e del riduttore
tore tranne che: può raggiungere valori più elevati del normale. Dopo tale periodo può
– per esecuzioni HA ... HC essere necessario verificare il serraggio dei bulloni di fissaggio riduttore.
– in presenza dell’unità autonoma di raffreddamento se utilizzata
per lubrificare sia il riduttore sia il sopporto stesso. Nota: il rendimento dei riduttori a vite è più basso nelle prime ore di
La lubrificazione separata del supporto estrusore migliora sensibil- funzionamento (circa 50) e in occasione di ogni avviamento a freddo
mente l’affidabilità e la durata del cuscinetto assiale; la separazione (il rendimento migliora con l’aumentare della temperatura dell’olio).
fra riduttore e sopporto è realizzata con un anello di tenuta. Per ulteriori informazioni consultare i cataloghi tecnici Rossi.
Con la lubrificazione separata, utilizzare per il supporto estrusore olio
sintetico a base di polialfaolefine (MOBIL SHC XMP 680, CASTROL 9 - Manutenzione
Tribol 1510/680) con gradazione di viscosità ISO 680 cSt.
9.1 - Generalità
Con la lubrificazione congiunta (esecuzioni HA ... HC, in presenza
dell’unità autonoma di raffreddamento se è utilizzata per lubrificare A macchina ferma, controllare periodicamente (più o meno frequen-
sia il riduttore sia il supporto stesso) la gradazione di viscosità ISO del temente secondo l’ambiente e l’impiego):
lubrificante deve essere secondo quanto indicato al cap. 6.2 tabella a) la pulizia delle superfici esterne e dei passaggi d’aria di ventilazio-
di lubrificazione e l’olio deve essere sintetico a base di polialfaolefine. ne del riduttore o del motoriduttore, in modo da non pregiudicare
Per il riempimento d’olio del supporto estrusore vedi tabella seguen- lo smaltimento del calore;
te. b) il livello e il grado di deterioramento dell’olio (controllare a ridutto-
Per la lubrificazione del riduttore fare riferimento a quanto indicato al re freddo);
cap. 6.2, tabella lubrificazione. c) il corretto serraggio delle viti di fissaggio.
Grandezza Lubrificazione sopporto estrusore In esercizio controllare:
riduttore Lubrificazione separata1) Lubrificazione congiunta2) – rumorosità;
– vibrazioni;
Riempimento fino Riempimento fino
125 ... 451 – tenute;
a livello (del sopporto) a livello (del riduttore)
– ecc.
1) Sopporto con tappo di carico metallico con filtro e con valvola, livello e scarico. Attenzione! Dopo un periodo di funzionamento, il riduttore
2) Il livello è quello della carcassa riduttore.
(eccetto i pendolari) è soggetto a una lieve sovrapressione
interna che può causare fuoriuscita di fluido ustionante.
7 - Sistema di raffreddamento Pertanto, prima di allentare i tappi (di qualunque tipo) atten-
7.1 - Raffreddamento artificiale con ventola dere che il riduttore si sia raffreddato, diversamente avvalersi di oppor-
aria tune protezioni contro le ustioni derivanti dal contatto con l’olio caldo.
Quando il riduttore sia dotato di ventola è In ogni caso procedere sempre con la massima cautela.
necessario prevedere e verificare che resti Le massime temperature dell’olio, indicate nella tabella lubrificazione
un adeguato spazio per l’aspirazione (ved. cap. 6.2), non sono pregiudizievoli per il buon funzionamento
dell’aria di raffreddamento, anche dopo del riduttore.
aver montato la protezione (carter forato o
rete metallica) del giunto. Se necessario Cambio olio. Eseguire l'operazione a macchina ferma e riduttore
smussare il mozzo del giunto. freddo.

Predisporre un adeguato sistema di raccolta dell'olio esausto, svitare prestare attenzione a non danneggiare la superficie esterna del
sia il tappo di scarico sia quello di carico per favorire lo svuotamento; distanziale;
smaltire il lubrificante esausto in conformità alle disposizioni vigenti – la linguetta nella cava, assicurandosi che sia garantito un tratto in
in materia. presa di almeno 0,9 volte la larghezza del pignone;
Lavare internamente la carcassa del riduttore utilizzando lo stesso – il pignone preriscaldato a 80 ÷ 100 °C;
tipo di olio previsto per il funzionamento; l'olio impiegato per questo – il sistema di fissaggio assiale ove previsto (vite autobloccante in
lavaggio può essere riutilizzato per ulteriori lavaggi previo filtraggio testa con fondello e distanziale o collare con uno o più grani, fig. a);
con 25 μm di potere filtrante. per i casi previsti senza fissaggio assiale (fig. b), cospargere di
Riempire nuovamente fino a livello il riduttore. mastice tipo LOXEAL 58-14 anche la porzione di albero motore
È sempre opportuno sostituire gli anelli di tenuta (ved. cap. 9.3). sottostante il pignone;
Qualora venga smontato il coperchio (per i riduttori che ne sono – in caso di sistema di fissaggio assiale con collare e grani, assicurar-
provvisti), ripristinare la tenuta con mastice dopo aver pulito e sgras- si che questi non sporgano rispetto alla superficie esterna del
sato accuratamente le superfici di accoppiamento. distanziale: avvitare a fondo il grano e se necessario improntare
l’albero motore con una punta;
IT
9.2 - Serpentina – lubrificare con grasso (tipo KLÜBER Petamo GHY 133N) la denta-
Se il riduttore è destinato a soste prolungate a temperature ambien- tura del pignone, la sede rotante delI’anello di tenuta e l’anello di
te inferiori a 0 °C, effettuare lo svuotamento dell’acqua dalla serpen- tenuta stesso, ed effettuare – con molta cura – il montaggio.
tina mediante pompaggio di aria compressa, per prevenire possibili
danni causati dal congelamento.
9.3 - Anelli di tenuta
È sempre opportuno sostituire gli anelli di tenuta nel caso in cui:
vengano smontati o in occasione delle revisioni periodiche del ridut-
tore; in tal caso, il nuovo anello deve essere abbondantemente
ingrassato e collocato in modo che il filo di tenuta non lavori sulla
EN
stessa pista di scorrimento dell’anello precedente.
In particolare gli anelli di tenuta devono essere protetti contro le
radiazioni del calore, anche durante eventuali lavori di montaggio a
caldo di componenti.
La durata dipende da molti fattori quali velocità di strisciamento, tem-
peratura, condizioni ambientali, ecc,; orientativamente può variare da
3 150 a 25 000h.
9.4 - Sostituzione motore
Poiché i motoriduttori sono realizzati con motore normalizzato, la
sostituzione del motore – in caso di avaria – è facilitata al massimo.
È sufficiente osservare le seguenti norme:
– assicurarsi che il motore abbia gli accoppiamenti lavorati in classe
precisa (IEC 60072-1);
– pulire accuratamente le superfici di accoppiamento;
– controllare ed eventualmente ribassare la linguetta, in modo che tra
la sua sommità e il fondo della cava del foro ci sia un gioco di
0,1  0,2 mm; se la cava sull’albero è uscente, spinare la linguetta.
Per motoriduttori a vite MR V ad assi paralleli MR 2I e MR 3I 140
... 360, ad assi ortogonali MR CI, MR C2I (estremità d'albero moto-
re calettata direttamente nel codolo vite, nel pignone cilindrico o
conico rispettivamente):
– controllare che la tolleranza dell’accoppiamento (di spinta) foro/
estremità d’albero sia G7/j6 per D  28 mm, F7/k6 per D  38 mm;
– lubrificare le superfici di accoppiamento contro l’ossidazione di 9.5 - Cuscinetti
contatto.
Per motoriduttori ad assi paralleli (2I, 3I) con motori grand. 200 Poiché ogni riduttore contiene più cuscinetti, anche di diversa tipolo-
... 315 e motoriduttori MR V, MR 2I e MR CI in esecuzione «Flan- gia (a sfera, a rulli conici, a rulli cilindrici, ecc.), ciascuno dei quali fun-
gia quadrata per servomotori», per lo smontaggio procedere ziona con carichi e velocità dipendenti dalla velocità in entrata, dalla
come segue: natura del carico della macchina azionata, dal rapporto di trasmissio-
ne ecc., e con diverso tipo di lubrificazione (a bagno d’olio, a sbat-
– allineare il foro passaggio chiave con la vite di serraggio del collare timento, a grasso, a circolazione.) non è ragionevolmente possibile
di bloccaggio; stabilire a priori interventi manutentivi di sostituzione dei cuscinetti.
– allentare la vite di serraggio e di conseguenza il collare di bloccaggio; Se si desidera una manutenzione preventiva eseguire periodici
– smontare il motore. controlli della rumorosità e delle vibrazioni utilizzando idonee
Per motoriduttori a vite MR IV e MR 2IV, ad assi paralleli MR 3I apparecchiature e qualora si constati un peggioramento nei valori
40 ... 125 e MR 4I, ad assi ortogonali MR ICI e MR C3I, coassiali rilevati, anche di modesta entità, arrestare il riduttore o motoriduttore
(pignone cilindrico calettato sull'estremità d'albero motore); ed eseguire un’ispezione visiva interna e, se necessario, procedere
– controllare che la tolleranza dell’accoppiamento (bloccato normale) alla sostituzione dei cuscinetti ritenuti a rischio.
foro/estremità d’albero sia K6/j6 per D  28 mm, J6/k6 per D  38
mm; 9.6 - Tappo di carico metallico con filtro e valvola
– assicurarsi che i motori abbiano cuscinetti e sbalzi (quota S) come Qualora il riduttore o motoriduttore (grand.  100) sia
indicato in tabella; equipaggiato con tappo di carico metallico con filtro e val-
vola (ved. fig.) per la pulizia del medesimo occorre svitarlo
Grandezza Capacità di carico dinamico min Sbalzo max ‘S’ dal riduttore (proteggere il riduttore dall’ingresso della
motore daN mm polvere e corpi estranei ecc.), smontarne la calotta, lavarlo
con solvente, asciugarlo con aria compressa, rimontarlo).
Anteriore Posteriore
Effettuare tale intervento in funzione dell’ambiente.
63 450 335 16
71 630 475 18 10 - Livelli sonori
80 900 670 20 Macchina/rotismo iN Grand.
90 1 320 1 000 22,5 La maggior parte della gamma
dei prodotti Rossi è caratte- Assi paralleli R I  3,15  160
100 2 000 1 500 25
112 2 500 1 900 28 rizzata da livelli di pressione  4  200
sonora LpA (media dei valori
132 3 550 2 650 33,5 misurati, a carico nominale e R 2I tutti  320
160 4 750 3 350 37,5 velocità entrata n1 = 1 400 min-
180 6 300 4 500 40 1
R 3I tutti  400
, a 1 m dalla superficie esterna
200 8 000 5 600 45 del riduttore situato in campo R 4I  160  500
225 10 000 7 100 47,5 libero e su piano riflettente,
250 12 500 9 000 53  200  630
secondo ISO/CD 8579) inferio-
280 16 000 11 200 56 ri o uguali a 85 dB(A). Assi ortogonali R CI tutti  320
Nella tabella a lato sono indi- R C2I  63  400
–m ontare sull’albero motore, nell’ordine: cati i prodotti che possono
– il distanziale preriscaldato a 65 °C avendo cura di cospargere la superare tale soglia. Ulteriori  71  500
porzione di albero motore interessata con mastice tipo LOXEAL informazioni sui livelli sonori dei R C3I tutti  630
58-14 e assicurandosi che fra la cava linguetta e la battuta dell’albe- singoli prodotti sono contenute
ro motore vi sia un tratto cilindrico rettificato di almeno 1,5 mm; nei cataloghi tecnici Rossi. Rinvii ad angolo R C 1  250

Tabella verniciatura
Prodotto Grand. Verniciatura interna Verniciatura esterna Note
Colore finale Caratteristiche
blu RAL 50101)
Vite 32 … 81 Resistente agli agenti Le parti lavorate restano
atmosferici e aggressivi. non verniciate e vengono
Assi paralleli e Polveri epossidiche Polveri epossidiche (classe di corrosività C3 protette con olio antiruggine
40 … 81 (preverniciato) (preverniciato) secondo ISO 12944-2) facilmente asportabile
ortogonali
Sovraverniciabile solo con (prima di verniciarle, aspor-
prodotti bicomponente3)
IT Coassiali 32 … 41 tare il protettivo)
Vite 100 … 250 La verniciatura interna non
Fondo resiste agli oli sintetici a
Coassiali 50 … 81 Fondo monocomponente a base di poliglicoli (si può
monocomponente base di resine estere Resistente agli agenti
atmosferici e aggressivi. impiegare olio sintetico a
Assi paralleli e a base di resine epossidiche o fenoliche base di polialfaolefine)
100 … 631
ortogonali estere epossidiche o (preverniciato) (classe di corrosività C3
fenoliche + secondo ISO 12944-2) Asportare con un raschietto
Coassiali 100 … 180 (preverniciato) Smalto bicomponente Sovraverniciabile solo con o con solvente la vernice
poliacrilico all’acqua prodotti bicomponente3) dalle superfici di accoppia-
Rinvii (cat. L) 160 … 320 Parti lavorate verniciate con mento del riduttore
EN Rinvii (cat. L) 80 … 125 smalto bicomponente
poliacrilico all’acqua
Asportare con un raschietto
Smalto bicomponente o con solvente la vernice
–
Pendolari poliacrilico all’acqua dalle superfici di accoppia-
mento del riduttore
Fondo epossipoliammidico Resistente agli agenti Le parti lavorate restano
Coassiali2) 56 … 142 atmosferici e aggressivi
bicomponente non verniciate e vengono
+ (classe di corrosività C3 protette con olio antiruggine
–
Smalto bicomponente secondo ISO 12944-2) facilmente asportabile
Ortogonali2) 85 … 142 poliacrilico all’acqua Sovraverniciabile solo con (prima di verniciarle, aspor-
(nero opaco RAL 9005) prodotti bicomponente3) tare il protettivo)
1) Quando i riduttori sono accoppiati a servomotori (servomotoriduttori) il colore finale è nero opaco RAL 9005.
2) Servomotoriduttori epicicloidali di precisione integrati.
3) Prima di sovraverniciare, proteggere adeguatamente gli anelli di tenuta e procedere alla sgrassatura delle superfici del riduttore.
Tabella momenti di serraggio per le viti di fissaggio assiale e dell’unità di bloccaggio2)

Grand. riduttori 32 40 50 — 63, — 80, 100 125, 160 161 — 200 — 250 — — — — — — — — —
a vite 64, 81, 126,
Grand. riduttori 40 50 — 63 64 80 81 100 125 140 — 160 180 200 225 250 280 320, 360 400, 450, 500, 560, 630,
paralleli e ortogonali 321, 401, 451, 501, 561, 631,
M [daN m]
2,9 3,5 4,3 4,3 4,3 5,1 5,3 9,2 17 21 21 34 43 66 83 135 166 257 315 — — — — —
per anelli o bussola
Viti fissaggio assiale
UNI 5737-88 M81) M81) M101) M10 M10 M10 M10 M12 M14 M16 M16 M20 M20 M24 M24 M30 M30 M36 M36 M30 M30 M36 M36 M36
classe 10.9
M [daN m]
— 0,4 — 1,2 1,2 1,2 — 3,0 3 3 — 6 6 10 10 25 25 25 25 49 49 49 49 84
per unità di blocc.
Viti unità di blocc.
UNI 5737-88 — M5 — M6 M6 M6 — M8 M8 M8 — M10 M10 M12 M12 M16 M16 M16 M16 M20 M20 M20 M20 M24
classe 10.9
1) Per riduttori a vite UNI 5931-84.
2) Le viti dell’unità di bloccaggio devono essere serrate in modo graduale e uniforme con sequenza continua (non diagonalmente!) e in più fasi sino al raggiungimento del momento di
serraggio massimo indicato in tabella.
Tabella momenti di serraggio per le viti di fissag- Tabella momenti di serraggio per i tappi
gio (piedi e flange)
Dimensione
Vite M (daN m) [daN m]
filettatura
UNI 5737-88
G 1/4’’ 0,7
classe 8.8 classe 10.9 16 MB 1,4
G 1/2’’ 1,4
M50 000,6 0,85
M60 001,1 1,50 G 3/4’’ 1,4
M80 002,5 0003,55 G 1’’ 2,5
M10 005,6 0007,15
M12 008,5 0012,85
M14 013,5 0019,85
M16 020,5 0029,85
M18 028,5 0040,85
M20 040,5 56
M22 055,5 0077,00
M24 071,5 0100,00
M27 100,5 0140,00
M30 138,5 0195,00
M33 200,5 0280,00
M36 250,5 0355,00
M39 295,5 0420,00
M42 410,5 0580,00
Nota:
M45 500,5 0710,00 - normalmente è sufficiente la classe 8.8.
M48 610,5 0860,00 - prima di serrare le viti accertarsi che gli eventuali centraggi delle flange siano inseriti
- l’uno nell’altro
M56 980,5 1380 - le viti devono essere serrate diagonalmente con il massimo momento di serraggio.

Anomalie riduttore: cause e rimedi
Anomalia Possibili cause Rimedi
Eccessiva temperatura Lubrificazione inadeguata: Controllare:
dell’olio – olio in quantità eccessiva o insufficiente – il livello dell’olio (a riduttore fermo) o la quantità
– lubrificante inadatto (tipologia, troppo viscoso, – il tipo e/o stato del lubrificante (ved. cap. 6.2, tabella
esausto, ecc.) lubrificazione) ed eventualmente sostituirlo
Forma costruttiva errata Cambiare la forma costruttiva
Cuscinetti a rulli conici registrati troppo stretti Interpellare Rossi
Riduttore a vite con carico eccessivo durante il Ridurre il carico
rodaggio IT
Temperatura ambiente eccessiva Aumentare il raffreddamento o correggere la tempe-
ratura ambiente
Passaggio aria ostruito Togliere il materiale ostruente
Aria lenta o mancanza di ricircolo Creare ventilazione ausiliaria
Irraggiamento Schermare in modo adeguato riduttore e motore
Inefficienza dell’eventuale sistema ausiliario di lubrifi Controllare la pompa e i condotti
cazione cuscinetti
Cuscinetti in avaria o mal lubrificati o difettosi
Sistema di raffreddamento dell’olio inefficiente o fuori
Interpellare Rossi
Controllare la pompa, i condotti, il filtro dell’olio e
EN
servizio: filtro intasato, portata dell’olio (scambiatore) l’efficienza degli indicatori di sicurezza (pressostati,
o dell’acqua (serpentina) insufficiente, pompa fuori termostati, flussostati, ecc.)
servizio, temperatura dell’acqua 20 °C, ecc.
Rumorosità anomala Uno o più denti con:
– ammaccature o sbeccature Interpellare Rossi
– rugosità eccessiva sui fianchi
Cuscinetti in avaria o mal lubrificati o difettosi Interpellare Rossi
Cuscinetti a rulli conici con gioco eccessivo Interpellare Rossi
Vibrazioni Controllare il fissaggio e i cuscinetti
Perdita di lubrificante Anello di tenuta con labbro di tenuta usurato, bacheliz- Sostituire l’anello di tenuta (ved. cap. 8.3)
dagli anelli di tenuta zato, danneggiato o montato erroneamente
Sede rotante danneggiata (rigatura, ruggine, ammac- Rigenerare la sede
cattura, ecc.)
Posizionamento in forma costruttiva diversa da quella Orientare correttamente il riduttore
prevista in targa
Perdite di lubrificante Troppo olio Controllare livello olio o quantità
dal tappo di carico Forma costruttiva errata Controllare la forma costruttiva
Valvola di sfiato inefficiente Pulire o sostituire il tappo di carico con valvola
Asse lento non ruota Rottura linguetta
anche se l’asse veloce Interpellare Rossi
o il motore ruotano Ingranaggio usurato completamente
Perdita di lubrificante dalle Tenuta difettosa Interpellare Rossi
giunzioni (coperchi o
giunzioni semicarcasse)
Acqua nell’olio Serpentina o scambiatore di calore difettosi Interpellare Rossi
Per il motore vedere il relativo manuale.
NOTA
Quando si interpella Rossi, indicare:
– tutti i dati di targa del riduttore o motoriduttore;
– la natura e la durata dell’avaria;
– quando e sotto quali condizioni l’avaria si è verificata;
– nel periodo di validità della garanzia, per non farne decadere la validità, non eseguire smontaggi o manomissioni del riduttore o del motori-
duttore in nessun caso senza l’autorizzazione di Rossi.

Montaggio fig. 4a) e
smontaggio fig. 4b)
Installing fig. 4a) and

removing fig. 4b)
fig. 4a) fig. 4b)
IT
Vite grand. Assi paralleli e ortogonali Assi paralleli e ortogonali Vite grand. Assi paralleli e ortogonali
32 ... 50 grand. 50 grand. MR 3I 50 63 ... 161 grand. 64 ... 160
Worm sizes Parallel and right angle Parallel and right angle Worm sizes Parallel and right angle
32 ... 50 shaft size 50 shaft size MR 3I 50 63 ... 161 shaft sizes 64 ... 160
EN
Assi paralleli e ortogonali Assi paralleli e ortogonali Assi paralleli e ortogonali

Vite grand. 200, 250
grand. 63 grand. MR 3I 63 grand. 180 ... 360
Parallel and right angle Parallel and right angle Worm sizes 200, 250 Parallel and right angle
shaft size 63 shaft size MR 3I 63 shaft sizes 180 ... 360
fig. 4c) Fissaggio assiale fig. 4d)
Axial fastening
Vite grand. 32 ... 50 Assi paralleli e ortogonali Vite grand. 63 ... 161 Assi paralleli e ortogonali
grand. 50 grand. 64 ... 160
Worm sizes 32 ... 50 Parallel and right angle Worm sizes 63 ... 161 Parallel and right angle
shaft size 50 Calettamento con shaft sizes 64 ... 160
linguetta e anelli di
bloccaggio fig. 4e),
con linguetta e bussola
di
bloccaggio fig. 4f)
Fitting with key

Assi paralleli e ortogonali
and locking rings Vite grand. 200, 250 Assi paralleli e ortogonali
grand. 63 fig. 4e), with key grand. 180 ... 360
and locking bush Worm sizes 200, 250
Parallel and right angle Parallel and right angle
shafts size 63 fig. 4f) shaft sizes 180 ... 360
fig. 4e)
fig. 4f)
Assi paralleli e ortogonali Assi paralleli e ortogonali Assi paralleli e ortogonali

grand. 50 ... 125 grand. 140 ... 631 grand. 400 ... 631
Parallel and right angle Parallel and right angle Parallel and right angle
shaft sizes 50 ... 125 shaft sizes 140 ... 631 shaft sizes 400 ... 631
1)
fig. 4g)
Calettamento con unità di bloccaggio fig. 4g)

Fitting with shrink disk fig. 4g)
1) Vale solo per grand. 140 ... 360.
1) Valid only for sizes 140 ... 360.
UT.C 825A

Operating instructions gear reducers and gearmotors
Contents 7.2 - Water cooling by coil 18

7.3 - Independent cooling unit 18
1 - General safety instructions 13
2 - Operating conditions 13
8 - Commissioning 18 IT
3 - How supplied 13 9 - Maintenance 18
3.1 - Receipt 13 9.1 - General 18
3.2 - Name plate 13 9.2 - Coil 19
3.3 - Painting 13 9.3 - Seal rings 19
3.4 - Protections and packing 13 9.4 - Motor replacement 19
9.5 - Bearings 19
4 - Storing 14 9.6 - Metal filler plug with filter and valve 19
5 - Installation 14 10 - Sound levels 19

5.1 - General
5.2 - Fitting of components to shaft ends
14
15 Painting table 20 EN
5.3 - Shaft-mounting 15
5.4 - Hollow low speed shaft 15 Table of tightening torques for axial fastening
bolts and shrink disc 20
6 - Lubrication 18
6.1 - General 18 Table of tightening torques for fastening
6.2 - Lubrication table 16 bolts (foot and flange) 20
6.3 - Extruder support lubrication 18 Table of tightening torques for plugs 20
7 - Cooling system 18 Gear reducer troubles: causes and
7.1 - Cooling by fan 18 corrective actions 21
Recycling (keeping in mind the instructions in force): in particular, possible safety guards for shaft ends not being
– the elements of casing, gear pairs, shafts and bearings of gear used and for eventually accessible fan cover passages (or
reducer must be transformed into steel scraps. The ele- other) are the Buyer’s responsibility;
ments in grey cast iron will be subjected to the same tre- – «Electromagnetic compatibility (EMC)» directive 2004/108/
atment if there is no particular instruction; EC and subsequent updatings.
– t he worm wheels are made in bronze and must be treated When operating on gear reducer (gearmotor) or on components
adequately; connected to it the machine must be at rest: disconnect motor
– exhausted oils must be recycled and treated according to the (including auxiliary equipments) from power supply, gear reducer
instructions. from load, be sure that safety systems are on against any accidental
The paragraphs marked with present symbol contain starting and, if necessary, pre-arrange mechanical locking devices (to
dispositions to be strictly respected in order to assure be removed before commissioning).
personal safety and to avoid any heavy damages to the If deviations from normal operation occur (temperature increase,
machine or to the system (e.g.: works on live parts, on lif- unusual noise, etc.) immediately switch off the machine.
ting machines, etc.); the responsible for the installation or mainte- The products relevant to this handbook correspond to the technical
nance must scrupulously follow all instructions contained in level reached at the moment the handbook is printed. ROSSI MO-
present handbook. TORIDUTTORI reserves the right to introduce, without notice, the
necessary changes for the increase of product performances.
1 - General safety instructions
Gear reducers and gearmotors present dangerous parts because 2 - Operating conditions
they may be: Gear reducers are designed for industrial applications according to
– live; name plate data, at ambient temperature 0  +40 °C (with peaks at
– at temperature higher than +50 °C; -10 °C and +50 °C), maximum altitude 1 000 m.
– rotating during the operation; Not allowed running conditions: application in aggressive environ-
– eventually noisy (sound levels > 85 dB(A)). ments having explosion danger, etc. Ambient conditions must com-
An incorrect installation, an improper use, the removing or disconnec- ply with specifications stated on name plate.
tion of protection devices, the lack of inspections and maintenance,
improper connections may cause severe personal injury or property 3 - How supplied
damage. Therefore the component must be moved, installed, commis- 3.1 - Receipt
sioned, handled, controlled, serviced and repaired exclusively by At receipt verify that the unit corresponds to the one ordered and has
responsible qualified personnel (definition to IEC 364). not been damaged during the transport, in case of damages, report
It is recommended to pay attention to all instructions of present them immediately to the courier.
handbook, all instructions relevant to the system, all existing safety Avoid commissioning gear reducers and gearmotors, that are even if
laws and standards concerning correct installation. slightly damaged.
Attention! Components in non-standard design or with constructive
variations may differ in the details from the ones described here fol- 3.2 - Name plate
lowing and may require additional information. Every gear reducer presents a name plate in anodised aluminium
Attention! For the installation, use and maintenance of the electric containing main technical information relevant to operating and con-
motor (standard, brake or non-standard motor) and/or the electric sup- structive specifications and defining, according to contractual agree-
ply device (frequency converter, soft-start, etc.) and accessories, if any ments, the application limits (see fig. 1); the name plate must not be
(flow indicators, independent cooling unit, thermostat, ecc) consult the removed and must be kept integral and readable. All name plate data
attached specific documentation. If necessary, require it. must be specified on eventual spare part orders.
Attention! For any clarification and/or additional information consult 3.3 - Painting
Rossi and specify all name plate data.
Products are painted according to the painting table shown on page 20.
Gear reducers and gearmotors of present handbook are normally Before adding further coats of paint (use dual-compound paints only),
suitable for installations in industrial areas: additional protection properly protect the seal rings (which must neither be damaged nor
measures, if necessary for different employs, must be adopted and painted), degrease and sand the gear reducer (or gearmotor) surfaces.
assured by the person responsible for the installation.
IMPORTANT: the components supplied by Rossi must be incorpora- 3.4 - Protections and packing
ted into machinery and should not be commissioned before the Overhanging free shaft ends and hollow shafts are treated with protec-
machinery in which the components have been incorporated tive anti-rust long life oil and protected with a plastic (polyethylene) cap
conforms to: (only up to D  48 mm for overhanging shafts, D 110 mm for hollow
–M achinery directive 2006/42/EC and subsequent updatings; shafts). All internal parts are protected with protective anti-rust oil.
Operating instructions 4090INS.VPR-en1210HQM Rossi 13

Designation (see Two months and year Designation
table on the right) of manufacture Product
Machine Train of gears Size Design
Non-standard designs Mounting position (when
differing from IM B3 R, MR V, IV, 2IV 32 ... 250 UO ... Worm
or B5) R, MR 2I, 3I 32 ... 180 FC ..., PC ..., UC ... Coaxial
Motor power
R, MR I, 2I, 3I, 4I 40 ... 631 UP ... Parallel shafts
Gearmotor
service factor R, MR CI, ICI, C2I, C3I 40 ... 631 UO ... Right angle shafts
Gearmotor
output speed R C 80 ... 320 PO ..., FO ... Right angle shafts
Transmission R 2I 85 ... 250 OP Shaft mounted
ratio
Gear reducer
IT
nominal power Ø Flange - motor
shaft
Fig. 1 (for more information, see Rossi technical catalogs; consult us).
Note: Starting from 04/05/2010 the company name ROSSI MOTORIDUTTORI S.p.A. has been changed into Rossi S.p.A., and the nameplates have been updated accordingly.
Attention! for the maintenance, installation of gear reducers coupled with synchronous and asynchronous servomotors (even if with a different name plate) follow the instructions of present handbook.
Unless otherwise agreed in the order, products are adequately Incorrect alignment may cause breakdown of shafts and/or bear-
packed: on pallet, protected with a polyethylene film, wound with ings (which may cause overheatings) which may represent heavy
adhesive tape and strap (bigger sizes); in carton pallet, wound with danger for people.
adhesive tape and strap (smaller sizes); in carton boxes wound with Do not use motor eyebolts when lifting the gearmotors.
tape (for small dimensions and quantities). If necessary, gear redu- Position the gear reducer or gearmotor so as to allow a free passage
EN cers are conveniently separated by means of anti-shock foam cells or
of filling cardboard.
of air for cooling both gear reducer and motor (especially at their fan
side).
Do not stock packed products on top of each other.
Avoid: any obstruction to the air flow; heat sources near the gear
reducer that might affect the temperature of cooling air and of gear
4 - Storing reducer (for radiation); insufficient air recycle and applications hinder-
Surroundings should be sufficiently clean, dry and free from ex- ing the steady dissipation of heat.
cessive vibrations (veff  0,2 mm/s) to avoid damage to bearings (ex- Mount the gear reducer or gearmotor so as not to receive vibrations.
cessive vibration should also be guarded during transit, even if within
wider range) and ambient storage temperature should be 0  +40 °C: Mating surfaces (of gear reducer and machine) must be clean and suffi-
peaks of 10 °C above and below are acceptable. ciently rough (approximately Ra  6,3 m) to provide a good friction
The gear reducers filled with oil must be positioned according to the coefficient: remove by a scraper or solvent the eventual paint of gear
mounting position mentioned on the order during transport and storage. reducer coupling surfaces.
Every six months rotate the shafts (some revolutions are sufficient) When external loads are present use pins or locking blocks, if ne-
to prevent damage to bearings and seal rings. cessary.
Assuming normal surroundings and the provision of adequate pro- When fitting gear reducer and machine and/or gear reducer and even-
tection during transit, the unit is protected for storage up to 1 year. tual flange B5 it is recommended to use locking adhesives on the
For a 2 year storing period in normal surroundings it is necessary to fastening screws (also on flange mating surfaces).
pay attention also to following instructions: Before wiring-up the gearmotor make sure that motor voltage corre-
– generously grease the sealings, the shafts and the unpainted sponds to input voltage. If direction of rotation is not as desired,
machined surfaces, if any, and periodically control conservation invert two phases at the terminals.
state of the protective anti-rust oil; Y- starting should be adopted for no-load starting (or with a very
– for gear reducers and gearmotors supplied without oil: insert anti- small load) and for smooth starts, low starting current and limited
condensation pastilles into the gear reducers to be replaced befo- stresses, if requested.
re due date and remove them before commissioning (as alternati-
ve completely fill the gear reducers with lubrication oil and the If overloads are imposed for long periods or if shocks or danger of
specified level before commissioning). jamming are envisaged, then motor-protection, electronic torque li-
miters, fluid couplings, safety couplings, control units or other similar
For storages longer than 2 years or in aggressive surroundings or devices should be fitted.
outdoors, consult Rossi.
Usually protect the motor with a thermal cut-out however,
5 - lnstallation where duty cycles involve a high number of on-load starts, it is nec-
essary to utilise thermal probes for motor protection (fitted on the
5.1 - General wiring); magnetothermic breaker is unsuitable since its threshold
Before the installation, verify that: must be set higher than the motor nominal current of rating.
– there were no damages during the storing or the transport; Connect thermal probes, if any, to auxiliary safety circuits.
– design is suitable to the environment (temperature, atmosphere, Use varistors and/or RC filters to limit voltage peaks due to con
etc.); tactors.
– electrical connection (power supply, etc.) corresponds to motor When gear reducer is equipped with a backstop device1), provide a
name plate data; protection system where a backstop device breaking could cause
– used mounting position corresponds to the one stated in name personal injury or property damage.
plate.
Whenever a leakage of lubricant could cause heavy damages, increase
Attention! When lifting and transporting the gear reducer the frequency of inspections and/or envisage appropriate control devic-
or gearmotor use through holes or tapped holes of the es (e.g.: remote level gauge, lubricant for food industry, etc.).
gear reducer casing; be sure that load is properly balanced
and provide lifting systems, and cables of adequate sec- In polluting surroundings, take suitable precautions against lubricant
tion. If necessary, gear reducer and gearmotor masses are stated contamination through seal rings or other.
in Rossi technical catalogues. For outdoor installation or in a hostile environment (atmospheric cor-
Be sure that the structure on which gear reducer or gearmotor is rosivity category C3 according to ISO 12944-2), protect the gear
fitted is plane, levelled and sufficiently dimensioned in order to assu- reducer or gearmotor with a proper dual-compound anticorrosion paint;
re fitting stability and vibration absence (vibration speed veff  3,5 added protection may be afforded by applying water-proof grease
mm/s for PN  15 kW and veff  4,5 mm/s for PN > 15 kW are accep- (especialIy around the rotary seating of seal rings and at shaft end
table), keeping in mind all transmitted forces due to the masses, to access points).
the torque, to the radial and axial loads. Gear reducers and gearmotors should be protected whenever pos-
For the dimensions of fixing screws of gear reducer feet and the sible and by appropriate means from solar radiation and extremes of
depth of tapped holes consult the Rossi technical catalogues. weather: protection becomes essential when high or low speed
Carefully select the length of fixing screws when using tapped holes shafts are vertically disposed or when the motor is installed vertical
for gear reducer fitting, in order to assure a sufficient meshing thread with fan uppermost.
length for the correct gear reducer fitting to the machine without For ambient temperature greater than +40 °C or less than 0 °C, con-
breaking down the threading seat. sult Rossi.
Attention! Bearing life and good shaft and coupling When gear reducer or gearmotor is supplied with water cooling by
running depend on alignment precision between the coil or independent cooling unit, see ch 7.
shafts. Carefully align the gear reducer with the motor and
the driven machine (with the aid of shims if need be, for
gear reducers size  400 use level tapped holes), interposing flexible
couplings whenever possible. 1) The presence on gear reducer of backstop device is stated by the arrow near the low
speed shaft, indicating the free rotation, excluding shaft mounted gear reducers where
B or C designs are stated (see Rossi technical catalogues).
14 Rossi Operating instructions 4090INS.VPR-en1210HQM

5.2 - Fitting of components to shaft ends Attention! For vertical ceiling-type mounting and only
It is recommended that the holes of parts keyed onto shaft ends for gear reducers equipped with locking rings or bush, gear
should be machined to H7 tolerance; for high speed shaft ends hav- reducer support is due only to friction, for this reason it is
ing D  55 mm, tolerance G7 is permissible provided that the load advisable to provide it with a fastening system.
is uniform and light; for low speed shaft end having D  180 mm, When installing and removing gear reducers and gearmotors with
tolerance must be K7 if load is not uniform and light. hollow low speed shaft incorporating a circlip groove – whether
Before mounting, thoroughly clean mating surfaces and lubricate with keyway or shrink disc – proceed as per fig. 4a and 4b, respec-
against seizure and fretting corrosion. tively, on page 12.
Attention! Installing and removal operations should be carried out Warning. Even if low speed shafts are principally machined within
with the aid of jacking screws and pullers using the tapped hole at H7 tolerance, a check using a plug could detect two areas with
the shaft butt-end (see table in fig. 2) taking care to avoid impacts slightly smaller diameters (see Fig. 5a): this reduction is inten-
and shocks which may irremediably damage the bearings, the
circlips or other parts, for H7/m6 and K7/j6 fits it is advisable that the
tional and does not affect the quality of keying - which in fact
will be improved in terms of duration and precision - and it does
IT
part to be keyed is preheated to a temperature of 80  100 °C. not represent an obstacle to the assembly of a machine shaft end
executed according to the usual methods, such as to the one shown
Shaft ends on Fig. 4a.
D d
Ø Ø
11  00 M 5
14  19 M 6 Fig. 5a
24  28 M 8
30  38 M 10 EN
42  55 M 12
60  75 M 16
80  95 M 20
100  110 M 24 In order to remove the hol-
125  140 M 30 low low speed shaft of the
160  210 M 36 parallel and right angle
UT.C 886
240  320 M 45 shaft gear reducers (this is

Fig. 2 the first operation to per-
groove side 
form when disassembling
The couplings having a tip speed on external diameter up to 20 m/s the gear reducer) turn the
must be statically balanced; for higher tip speeds they must be shaft until the keyway is fac
dynamically balanced. ing the intermediate shaft
as indicated in fig. 5b and
Where the transmission link between gear reducer and machine or push the shaft from the ref-
motor generates shaft end loads, (see fig. 3), ensure that: erence groove side (circum-
UT.C 322
opposite side to groove
– loads do not rise above catalogue values; ferencial keyway on shaft Fig. 5b
– transmission overhang is kept to a minimum; shoulder).
– gear-type transmissions must guarantee a minimum of backlash The system shown in fig. 4c and 4d, page 12, is good for axial fas-
on all mating flanks; tening; when the shaft end of the driven machine has no shoulder
– drive-chains should not be tensioned (if necessary – alternating (as in the lower half of the drawing) a spacer may be located
loads and/or motion – foresee suitable chain tighteners); between the circlip and the shaft end itself. Parts in contact with the
– drive-belts should not be over-tensioned. circlip must have sharp edges.
The use of locking rings (fig. 4e, page 12) or locking bush (fig. 4f
page 12),will permit easier and more accurate installing and removing
and eliminate backlash between the key and keyway.
The locking rings or bush are fitted after mounting and after having
UT.C 666
carefully degreased the coupling surfaces. Do not use molybdenum

bisulphide or equivalent lubricant for the lubrication of the parts in
Incorrect Correct Incorrect Correct contact. When tightening the bolt, we recommend the use of a lock-
UT.C 117
Fig. 3 ing adhesive.
5.3 - Shaft-mounting Respect the tightening torques stated in the table on page 20.
When shaft mounted, the gear reducer must be supported both axially In case of axial fastening with locking rings or bush – especially
and radially (also for mounting positions B3 ... B8) by the machine shaft when having heavy duty cycles, with frequent reversals – verify,
end, as well as anchored against rotation only, by means of a reaction after some hours of running, the bolt tightening torque and eventu-
having freedom of axial movement and sufficient clearance in its ally apply the locking adhesive again.
couplings to permit minor oscillations always in evidence without When fitting with shrink disc (fig. 4g, page 12) proceed as follows:
provoking dangerous overloading on the gear reducer. – carefully degrease the surfaces of hollow shaft and shaft end of
Lubricate with proper products the hinges and the parts subject to driven machine to be fitted;
sliding; when mounting the screws it is recommended to apply lock- – mount the gear reducer onto the shaft end of driven machine fol-
ing adhesives. lowing the method indicated in fig. 4a, page 12;
For the mounting of the “kit using reaction disc springs” (sizes 125 – gradually and uniformly tighten the screws of shrink disc by a
parallel shafts) use the tapped butt end hole on the shaft end of the continuous sequence (not crossing) and during several phases up
driven machine and the flat machined chamfered surface for com- to a torque stated in the table on page 20;
pressing and fitting the disc springs into the reaction recess.
– at operation end verify the screw tightening torque by means of a
Concerning the reaction system, follow the project indications sta- dynamometric key (flat, when it is mounted onto machine end).
ted in the technical catalogues Rossi. When-ever personal injury or
property damage may occur, foresee adequate supplementary
protection devices against:
– rotation or unthreading of the gear reducer from shaft end of driven
machine following to accidental breakage of the reaction arrange-
ment;
– accidental breakage of shaft end of driven machine.
5.4 - Hollow low speed shaft
For machine shaft ends onto which the hollow shafts of gear reduc-
ers are to be keyed, h6, j6, and k6 tolerances are recommended,
according to requirements.
Important! The shoulder diameter of the shaft end of the driven
machine abutting with the gear reducer must be at least 1,18  1,25
times the internal diameter of hollow shaft. For other data on
machine shaft end, in case of standard hollow low speed shaft,
stepped shaft, with locking rings or bush, with shrink disc see Rossi
technical catalogues.

6.2 - Lubrication table
Product How supplied* and plugs Directions for first filling

FILLED WITH
SYNTHETIC OIL
AGIP Blasia S 320, KLÜBER
Klübersynth GH 6-320,
MOBIL Glygoyle HE 320, SHELL
Tivela S 320
Worm Worm speed  280 min-1
IT sizes 32 ... 81 KLÜBER Klübersynth GH 6-680
MOBIL Glygoyle HE 680
SHELL Tivela S 680
Filler plug
1 filler plug sizes 32 ... 64
Filler/drain plug
2 filler/drain plugs for sizes 80, 81
WITHOUT OIL ISO viscosity grade [cSt]

(except different statement on
EN lubrication name plate) Before putting into
Worm speed
Ambient temperature 0  +40 °C2)
Gear reducer size
service, fill to speci-
fied level with syn- min-1
thetic oil (AGIP Blasia 100 125 ... 161 200, 250
S, ARAL Degol GS, B31), V5, V6 B6, B7, B8 B31), V5, V6 B6, B7, B8
Worm BP-Energol SG-XP,
2 800  1 400 3) 320 320 220 220
sizes 100 ... 250 MOBIL Glygoyle HE,
1 400  710 3) 320 320 320 220
SHELL Tivela S ... ,
710  355 3) 460 460 460 320
KLÜBER Klübersynth
GH 6...) having the 355  180 3) 680 680 460 460
ISO viscosity grade < 180 680 680 680
given in the table. 1) N ot stated on the name plate.
Filler plug with valve, 2) Peaks of 10 °C above and 10 °C (20 °C for  460 cSt) below the ambient tem
perature range are acceptable.
drain and level plug 3) For these speeds we advise to replace oil after running-in.
FILLED WITH
SYNTHETIC GREASE
Coaxial
sizes 32 ... 41 SHELL Tivela GL 00
IP Telesia Compound A
Right angle shaft MOBIL Glygoyle Grease 00
(cat. L)
sizes 80 ... 125
Filler/drain plug
(only for coaxial)
FILLED WITH
SYNTHETIC OIL
KLÜBER Klübersynth GH 6-220
MOBIL Glygoyle 30
SHELL Tivela S 220
Coaxial
sizes 50 ... 81
Parallel and
right angle shaft
sizes 40 ... 81
Filler/drain plug
2 filler/drain plugs for sizes 80, 81
WITHOUT OIL** Before putting into service, ISO viscosity grade [cSt]
(except different statement fill to specified level with
Coaxial on lubrication name plate) mineral oil (AGIP Blasia, Speed n2 Ambient temperature1) [°C]
sizes 100 ... 180 ARAL Degol BG, BP-Energol min-1 mineral oil synthetic oil
GR-XP, ESSO Spartan EP, IP Right
Parallel and Mellana oil, MOBIL Mobilge- angle shaft Others 0  20 10  40 0  40
right angle shaft ar 600, SHELL Omala, TEXA-
sizes 100 ... 631 CO Meropa, TOTAL Carter > 710 000 > 224 150 150 150
EP) or polyglycol** synthe- 710  280 224  22,4 150 220 220
Right angle shaft tic oil (KLÜBER Klübersynth 280  90 22,4 5,6 220 320 320
(cat. L) GH6 ..., MOBIL Glygoyle, < 90 000 < 5,6 320 460 460
sizes 160 ... 320 SHELL Tivela S) or polyal-
1) Peaks of 10 °C (20 °C) below and 10 °C above the ambient temperature
Filler plug with valve phaolefines** synthetic oil range are acceptable.
Shaft mounted (with breathing for shaft (AGIP Blasia SX, CASTROL
mounted gear reducers), Tribol 1510, ELF Reductelf SYNTHESE, ESSO Spartan SEP, KLÜBER Klübersynth EG4, MOBIL SHC
drain and level plugs Molykote L11 ...) having the ISO viscosity grade given in the table.
Independently-lubricated bearings, motor-bearings, backstop device fitted to motor:

lubrication is «for life» (except some cases of motors in which relubrication device is adopted). Should there be either a possibility of the grease
becoming contaminated, or a very heavy type of duty-cycle, it is good policy to check on the state of the grease (between one change and the
next, or every year or 2 years) and remove and replace grease in independently-lubricated bearings (every change or every other change, or every 2
or 4 years). Bearings should be filled with ESSO BEACON 3 bearing-grease for ball bearings, KLÜBER STABURAGS NBU 8 EP for roller bearings;
lubricate the backstop device with ESSO BEACON 2.

Oil-change interval and lubricant quantity
Oil quantity [l] for worm gear reducers sizes 32 ... 81

For the other sizes the quantity is given by the level stated by the proper plug.
R V, MR V R IV, MR IV MR 2IV
Size B31), V5, B6, B7 B81) B31), V5, B6, B7 B81) B31) B6, B7 B81) V5, V6
V6 V6 IT
32 0,16 0,2 0,16 0,2 0,25 0,2 – – – –
40 0,26 0,35 0,26 0,32 0,4 0,32 0,42 0,5 0,42 0,42
50 0,4 0,6 0,4 0,5 0,7 0,5 0,6 0,8 0,6 0,6
63, 64 0,8 1,15 0,8 1 1,3 1 1,2 1,55 1,2 1,2
80, 81 1,3 2,2 1,7 1,5 2,5 2 1,7 2,8 2,3 1,8
1) Not stated on name plate (B8, only sizes 32 ... 64).
Ambient temperature 0  +40 °C with peaks up to –20 °C and +50 °C.
EN
Oil Oil-change
An overall guide to oil-change interval is given in the table, and assumes pollution-free temperature [°C] interval [h]
surroundings. Where heavy overloads are present, halve the values.
 65 18 000
Apart from running hours, replace or regenerate the oil each 5  8 years according to size, 65  80 12 500
running and environmental conditions. 80  95 9 000
95  110 6 300
Grease quantity [kg] for coaxial gear reducers

R 2I MR 2I, 3I
Size B31), B6, B7, B8 V5, V6 B51) V1, V3
Lubrication «for life» (assuming external pollution-free environment).
32 0,14 0,25 0,1 0,18
40, 41 0,26 0,47 0,19 0,35
1) Non stated on name plate
Ambient temperature 0  +40 °C with peaks up to –20 °C and +50 °C.
Lubrication «for life» (assuming external pollution-free environment). Oil quantity [l] for sizes 50 ... 81
R I R 2I, MR 2I R 3I, MR 3I MR 4I
R 2I, 3I MR 2I, 3I Parallel 1)
Coaxial size B3 , B6, B31), B7, B31), B7, B31), B7,
B7 B62) B6 B6 V53)
size
B31)
B6, B7,
V5 B81), V5, V6 B81), V5, V6 B81), V53), V6 B81), V6,
B8, V6
40, 00 – – – 0,4 0,9 0,55 0,47 0,7 0,6 – – – –
50, 51 0,8 1,1 1,4 50, 00 – – – 0,6 0,9 0,80 0,70 1,05 0,9 – – – –
63, 64 1,6 2,2 2,8 63, 64 0,7 0,8 1,0 0,9 1,4 1,20 1,00 1,50 1,3 1,1 1,8 1,4 1,3
80, 81 3,1 4,3 5,5 80, 81 1,2 1,5 1,9 1,5 2,7 2,30 1,70 2,90 2,5 1,9 3,2 2,7 2,5
1) Not stated on name plate.
2) Values valid for R 2I; for MR 2I the values are Right R CI, MR CI R ICI, MR ICI MR C3I
respectively: 0,8; 1,2; 2,3. angle B31), V5, B31), V5, B31), V5,
3) The first reduction stage (the first two for 4I) is B8 B6 B8 B6 B8
lubricated with grease for life.
size B6, B7 V6, B71), V6, B71), V6,
Ambient temperature 0  +40 °C with peaks up to
–20 °C and +50 °C. 40, 00 0,26 0,35 0,3 0,31 0,5 0,40 0,35 – – – –
50, 00 0,4 0,60 0,45 0,45 0,8 0,65 0,50 0,5 0,9 0,7 0,55
63, 64 0,8 1,00 0,95 1,00 1,6 1,20 1,15 1,2 1,8 1,4 1,35
80, 81 1,3 2,00 1,80 1,60 2,7 2,20 2,00 1,9 3,0 2,5 2,30
An overall guide to oil-change interval is given in the table, and assumes

pollution-free surroundings. Where heavy overloads are present, halve the Oil Oil-change interval [h]
values. temperature [°C] mineral oil synthetic oil
Apart from running hours:  65 1) 8 000 25 000
— replace mineral oil each 3 years; 65  80 1) 4 000 18 000
— replace or regenerate synthetic oil each 5  8 years according to gear 80  95 1) 2 000 12 500
reducer size, running and environmental conditions. 95  110 1) – 9 000
The oil quantity is given by the level stated by the proper plug. 1) Values admissible only for parallel, right angle shaft gear reducers (cat. G and
L) an for non-continuous duties.
** Identification through specific lubrication name plate.

** Lubrication with synthetic oil (polyglycol basis must be with special internal painting; polyalphaolefines basis is advisable for sizes  200 and obligatory for sizes  400). It is always
recommended, particularly for: high speed gear reducers, increase of oil-change interval («long life»), increase of the ambient temperature range, increase of the thermal power or
decrease of oil temperature.

6 - Lubrication 7.2 - Water cooling by coil
The presence of coil is given by water inlets (pipes DIN 2353) protru-
6.1 - General
ding from the casing as shown in the following figure.
Depending on type and size, gear reducers and gearmotors may be Size d A1) spanner
grease-lubricated and supplied FILLED WITH GREASE, or (synthetic Ø ≈
or mineral) oil-lubricated and supplied FlLLED WlTH OlL or WlTHOUT
OIL depending on type and size (see ch. 6.2). When supplying 125 ... 180 12 140 22
WITHOUT OIL, the filling up to specified level (normally stated by 200 ... 280 12 150 22
means of transparent level plug) is Buyer’s responsibility. A 320 ... 360 16 160 30
400 ... 631 16 200 30
Every gear reducer has a lubrication plate.
1) These values for some mounting
Concerning lubricant type and quantity, gear reducer type, how sup- positions and designs can vary.
IT plied, plugs, filling instructions, oil-change interval, etc. see lubrica-
tion table (6.2).
Be sure that for gear reducers and gearmotors size  100, the filler
plug is provided with a valve (symbol ); otherwise, replace it Attention: Do not tamper with the eventual stop plate in order to keep
with the one normally supplied with. the pipes them locked; in particular keep the pipe locked while tighte-
ning the nut of connection pipe. Water fed into the system must:
When gear reducer or gearmotor is provi-
ded with a spilway plug (red colour) fill – be not too hard;
after unscrewing a.m. plug in order to – be at max temperature +20 °C;
check the obtained level by oil outlet. – flow at 10  20 dm3/min;
When gear reducer or gearmotor is provi- – have a pressure 0,2  0,4 MPa (2  4 bar).
EN ded with a level plug with rod, fill with oil Where ambient temperature may be less than 0 °C, make provision
UT.C 764
up to specified level on rod. for water drain and compressed air inlet, so as to be able to empty
When gear reducer or gearmotor is supplied with a level plug (size out the coil completely and avoid freezing up.
100), the necessary lubricant quantity is that which reaches a.m. When risking high input pressure peaks, install a safety valve set to
Ievel in center line of plug (gear reducer at rest) and not the a proper operating threshold.
approximate quantity given on the catalogue.
Usually bearings are automatically and continuously lubricated 7.3 - Independent cooling unit
(bathed, splashed, through pipes or by a pump) utilising the main See specific documentation supplied together with the unit.
gear reducer lubricant. The same applies for backstop devices, when
fitted to gear reducers. 8 - Commissioning
In certain gear reducers in vertical mounting positions V1, V3, V5 and Carry out an overall check, making particularly sure that the gear
V6, and right-angle shaft gear reducers in horizontal positions B3, B6 reducer is filled with lubricant.
and B51 (though not gearmotors in this case, for which the above Where star-delta starting is being used, input voltage must match
indications hold good) upper bearings are independently lubricated the motor lower voltage ( connection).
with a special grease «for life», assuming pollution-free surroun- For asynchronous three-phase motor, if the direction of rotation is
dings. The same applies for motor bearings (except some cases in not as desired, invert two phases at the terminals.
which relubrication device is adopted) and backstop devices when
fitted to motors. Before running gear reducers fitted with backstop device, make
sure that the direction of rotation in machine, gear reducer and
Always be sure that the gear reducer is located as per the mounting motor all correspond correctly.
position ordered, which appears on the name plate. When no indica- Attention! One or more startings in the false direction,
tion is given, the gear reducer may be used in horizontal mounting even if short, could irremediably damage the backstop
position B3 or B5 (B3, B8, worm gear reducers size  64), or vertical device, the coupling seats and/or the electric motor.
position V1 (in the case of right angle shaft gear reducers in the
design incorporating flange FO1...). A running-in period is advisable:
– of approx. 400  1 600 h for gear reducers with worm gear pairs
Combined gear reducer units. Lubrication remains independent, in order to reach maximum efficiency;
thus data relative to each single gear reducer hold good.
– of approx. 200  400 h for gear reducers with bevel and/or cylin-
6.3 - Extruder support lubrication (parallel and right angle shaft) drical gear pairs in order to reach maximum functionality.
The lubrication of extruder support is separate from the gear redu- The temperature of both gear reducer and lubricant may well rise
cer, except: beyond normal values during running-in. After the running-in period it
may be necessary to verify the gear reducer fastening bolt tightness.
– for designs HA ... HC;
Note: worm gear reducer efficiency is lower in the first running
– in presence of the independent cooling unit, if applied to lubricate hours (about 50) and at every cold starting (efficiency will be better
both the gear reducer and the support. with oil temperature increasing). For further information consult
The separate lubrication of extruder support sensibly improves the Rossi technical catalogues.
reliability and real life of the axial bearing; the separation between
gear reducer and support is granted by a seal ring. 9 - Maintenance
With separate lubrication, for the extruder support, use polyalphao-
lephines based synthetic oil (MOBIL SHC XMP 680, CASTROL Tribol 9.1 - General
1510/680) with ISO 680 cSt viscosity grade. At machine rest, verify at regular intervals (more or less frequently
With common lubrication (designs HA ... HC in presence of inde- according to environment and use):
pendent cooling unit, if applied to lubricate both the gear reducer a) all external surfaces are clean and air passages to the gear redu-
and the support), lubricant ISO viscosity grade must be according to cer or gearmotors are free, in order that cooling remains fully
the instructions given in ch. 6.2 «lubrication table» and oil must be effective;
polyalphaolephine based synthetic type. b) oil level and deterioration degree (check with cold gear reducer at
For the filling up of oil of extruder support, see the table below. rest);
c) the correct fastening screws tightening.
Gear reducer Lubrication of extruder support During the operation check:
size Separate lubrication1) Joint lubrication2) – noise level;
Filling up Filling up – vibrations;
125 ... 451 – seals;
to the level (of support) to the level (of gear reducer)
1) Support with metal filler plug with filter and valve, level and draining plug.
– etc.
2) The level is metal only in the gear reducer casing. Attention! After a running period, gear reducer (excluding
the shaft mounted gear reducers) is subject to a light inter-
For the lubrication of gear reducer refer to ch. 6.2, lubrication table. nal overpressure which may cause burning liquid dischar-
ge. Therefore, before loosening whichever plug wait until
gear reducer has become cold; if not possible, take the necessary
7 - Cooling system protection measures against burning due to warm oil contact. ln all
cases, always proceed with great care.
7.1 - Cooling by fan air Maximum oil temperatures indicated in lubrication table (see ch.6.2)
If there is fan on the gear reducer verify do not represent a hindrance to the gear reducer regular running.
that there is sufficient space allowing for
adequate circulation of cooling air also Oil change. Execute this operation at machine rest and cold gear
after fitting coupling protection. If a cou- reducer.
pling protection is fitted (drilled case or Prearrange a proper drain oil collection, unscrew both the drain plug
wire netting), smooth, the coupling hub, if and the filler plug in order to facilitate oil draining; dispose the
necessary. exhaust lubricant in compliance with the laws in force.

Wash the inside part of gear reducer housing using the same oil type – t he axial fastening system when foreseen (self locking screw on
suitable for the running; the oil used for this wash can be applied for motor shaft butt-end with washer and spacer or hub clamp with 1
further washings after proper filtering by 25 μm of filtration standard. or more dowels, fig. a); for the cases foreseen without axial faste-
Fill in the gear reducer again up to level. ning (fig. b), apply adhesive type LOXEAL 58-14 also on the motor
shaft part laying under the pinion;
It is always recommended to replace the seal rings (see ch. 9.3) – in case of axial fastening system with hub clamp and dowels, make
When dismounting the cap (whenever gear reducers are provided sure that they do not overhung from spacer external surface:
with), reset the sealing with adhesive on cleaned and degreased screw the dowels completely and, if necessary, imprint the motor
mating surfaces. shaft with a point;
– grease (with grease type KLÜBER Petamo GHY 133N) the pinion
9.2 - Coil teeth, the seal ring rotary seating and the ring itself, and assemble
In case of long non-running periods at ambient temperatures lower carefully.
than 0 °C, the coil should be emptied out using compressed air to
blast out all the coolant, so as to avoid freezing-up which would IT
cause the coil to break.
9.3 - Seal rings
It is always recommended that the seal rings are replaced with new
ones when they are removed or during periodic checks of gear redu-
cer; in this case, the new ring should be generously greased and
positioned so that the seal line does not work on the same point of
sliding contact as the previous ring.
Oil seals must be protected against heat radiation, also during the
shrink fitting of parts, if applicable.
Durating depends on several factor such as dragging speed, tempe-
EN
rature, ambient conditions, ect.; as a rough guide; it can vary from
3 150 to 25 000h.
9.4 - Motor replacement

Since gearmotors are realised with standardised motor, motor
replacement – in case of failure – is extremely easy. Simply observe
the following instructions:
– be sure that the mating surfaces are machined under accuracy
rating (IEC 60072-1);
– clean surfaces to be fitted thoroughly;
– check and, if necessary, lower the parallel key so as to leave a
clearance of 0,1  0,2 mm between its top and the bottom of the
keyway of the hole. If shaft keyway is without shoulder, lock the
key with a pin.
For worm gearmotors MR V, parallel shaft gearmotrs MR 2I and
MR 3I 140 ... 360, right angle shaft gearmotors MR CI, C2I (motor
shaft end keyed directly into the worm, the cylindrical or bevel pnion
shaft, respectively);
– check that the fit-tolerance (push-fit) between hole and shaft end is
G7/j6 for D  28 mm, F7/k6 for D  38 mm; 9.5 - Bearings
– lubricate surfaces to be fitted against fretting corrosion. Since there are many different types of bearings in a gear reducer
For parallel shaft gearmotors (2I, 3I) with motor size 200 ... 315 (roller, tapered roller, straight roller, etc.) and each bearing works with
and gearmotors MR V, MR 2I and MR CI with non-standard different loads and speeds depending on the input speed, the nature
design «Square flange for servomotors», proceed as follows for of the load of the driven machine, the transmission ratio, etc., and
disassembling: with different lubricants (oil bath, oil splash, grease, oil circulation,
– align the key through hole with the tightening screw of the hub etc.), it is not possible to define any periodical maintenance and
clamp; replacement of bearings in advance.
– loosen the tightening screw and consequently the hub clamp; If a precautionally maintenance is required, undertake periodical
– disassemble the motor. checks to verify noise level and vibration with the help of appro-
For worm gearmotors MR IV and MR 2IV, parallel shaft gearmo- piate diagniostic equipment and instruments. If the measured
tors MR 3I 40 ... 125 and MR 4I, right angle shafts gearmotors MR values worsen even slightly it is necessary to stop gear reducer or
ICI and MR C3I, coaxial gearmotors (cylindrical pinion keyed on to gear motor and after having inspected inside the unit replace the
the motor shaft end); bearings which are subject to breakdown.
– check that the fit-tolerance (standard locking) between hole and 9.6 - Metal filler plug with filter and valve
shaft end is K6/j6 for D  28 mm, and J6/k6 for D  38 mm; When the gear reducer or gearmotor (size  100) is
– make sure that the motors have bearing location and overhang equipped with metal filler plug with filter and valve
(distance S) as shown in the table; (see fig.), in order to clean it, it is necessary to
unscrew it from the gear reducer (preventing any
Motor Min dynamic load capacity Max dimension debris or other foreign items from entering the
size daN ‘S’ mm reducer, disassemble the cover, wash it with solvent, dry with com-
Front Rear pressed air and reassemble it). This operation is to be made accor-
ding to environment conditions.
63 450 335 16
71 630 475 18 10 - Sound levels
80 900 670 20
Most of the Rossi product range Machine/Train of gears iN Size
90 1 320 1 000 22,5
100 2 000 1 500 25 is characterised by sound pres- Parallel shaft R I  3,15  160
112 2 500 1 900 28 sure levels L̄pA (mean value of
mea-surement, assuming nomi-  4  200
132 3 550 2 650 33,5 nal load and input speed n1 =
160 4 750 3 350 37,5 R 2I all  320
180 6 300 4 500 40 1 400 min -1, at 1 m from exter-
nal profile of gear reducer stan- R 3I all  400
200 8 000 5 600 45 ding in free field on a reflecting
225 10 000 7 100 47,5 R 4I  160  500
surface, according to draft pro-
250 12 500 9 000 53
posal ISO/CD 8579) lower or  200  630
280 16 000 11 200 56 equal to 85 dB(A). Right angle shaft R CI all  320
–m ount onto the motor shaft as follows: The table indicates the products
which can exceed a.m. thre- R C2I  63  400
– the spacer pre-heated at 65° C treating the relevant motor shaft shold. For further information
area with adhesive type LOXEAL 58-14 and checking that betwe-  71  500
about sound levels of every sin-
en keyway and motor shaft shoulder there is a cylindrical part gle product see Rossi technical R C3I all  630
ground by 1,5 mm at least; pay attention not to damage the
external surface of spacer; catalogues. Right angle shaft R C 1  250
– the key in the keyway, making sure that a contact length of at least
0,9 times the pinion width is present;
– the pinion pre-heated at 80 ÷ 100 °C;

Painting table
Product Size Internal painting External painting Notes
Final color Features
Blue RAL 5010
Worm 32 … 81 Resistant to atmospheric
and aggressive agents Machined parts remain
Parallel and 40 … 81 unpainted and are protect-
Epoxy powder Epoxy powder (atmospheric corrosivity category C3
right angle ed with an easily removable
(prepainted) (prepainted) according to ISO 12944-2)
anti-rust oil (before painting
Suitable for further coats of remove the protective oil)
IT
3)
Coaxial type 32 … 41 dual-compound paints only
Worm 100 … 250
Single-compound ester The internal painting does
Coaxial type 50 … 81 epoxy or phenolic resin not resist polyglycol syn-
Single-compound Resistant to atmospheric thetic oils (polyalphaolefines
Parallel and 100 … 631 basis primer
ester epoxy or and aggressive agents synthetic oils are suitable).
right angle (prepainted)
phenolic resin basis (atmospheric corrosivity category C3
+ Remove by a scraper or
primer according to ISO 12944-2).
Water-soluble
Coaxial type 100 … 180 (prepainted)
polyacrylic Suitable for further coats of solvent the possible paint
dual-compound paints only3) of gear reducer coupling
Right angle 160 … 320 dual-compound enamel surfaces
(cat. L) Machined parts are painted
EN Right angle 80 … 125
wih water-soluble polyacrylic
dual-compound enamel Remove by a scraper or
Water-soluble
(cat. L) solvent the possible paint
– polyacrylic
of gear reducer coupling
Shaft mounted dual-compound enamel
surfaces
Coaxial2) 56 … 142 Dual-compound epoxy Resistant to atmospheric Machined parts remain
polyamide primer and aggressive agents unpainted and are protect-
+ (atmospheric corrosivity category C3
– ed with an easily removable
Right angle 85 … 142 Water-soluble dual-com- according to ISO 12944-2).
anti-rust oil (before painting
shaft2) pound polyacrylic enamel Suitable for further coats of
(matt black RAL 9005) dual-compound paints only3) remove the protective oil)
1) When gear reducers are coupled with servomotors (servogearmotors) the final colors is matt black RAL 9005.
2) Integrated low backlash planetary servogearmotors.
3) Before adding further coats of paint, properly protect the seal rings and carefully degrease and sand the gear reducer surfaces.
Table of tightening torques for axial fastening bolts and shrink disc2)
Worm gear 32 40 50 — 63, — 80, 100 125, 160 161 — 200 — 250 — — — — — — — — —
reducers size 64, 81, 126,
Parallel and right 40 50 — 63 64 80 81 100 125 140 — 160 180 200 225 250 280 320, 360 400, 450, 500, 560, 630,
angle shaft size 321, 401, 451, 501, 561, 631,
M [daN m]
2,9 3,5 4,3 4,3 4,3 5,1 5,3 9,2 17 21 21 34 43 66 83 135 166 257 315 — — — — —
for rings or bush
Bolts for axial fastening
UNI 5737-88 M81) M81) M101) M10 M10 M10 M10 M12 M14 M16 M16 M20 M20 M24 M24 M30 M30 M36 M36 M30 M30 M36 M36 M36
class 10.9
M [daN m]
— 0,4 — 1,2 1,2 1,2 — 3,0 3 3 — 6 6 10 10 25 25 25 25 49 49 49 49 84
for shrink disc
Bolts for shrink
disc UNI 5737-88 — M5 — M6 M6 M6 — M8 M8 M8 — M10 M10 M12 M12 M16 M16 M16 M16 M20 M20 M20 M20 M24
class 10.9
1) For worm gear reducers UNI 5931-84.
2) The bolts of shrink disc must be gradually and uniformly tightened, with continuous sequence (not diagonally!) and in several phases up to the reaching of maximum tightening torque stated on table.
Table of tightening torques fastening bolts (foot Table of tightening torques for plugs
and flange)
Thread
[daN m]
dimension
Bolt M (daN m)

UNI 5737-88
G 1/4’’ 0,7
class 8.8 class 10.9 16 MB 1,4
G 1/2’’ 1,4
M50 000,6 0000,85 G 3/4’’ 1,4
M60 001,1 0001,50 G 1’’ 2,5
M80 002,5 0003,55
M10 005,6 0007,15
M12 008,5 0012,85
M14 013,5 0019,85
M16 020,5 0029,85
M18 028,5 0040,85
M20 040,5 56
M22 055,5 0077,00
M24 071,5 0100,00
M27 100,5 0140,00
M30 138,5 0195,00
M33 200,5 0280,00
M36 250,5 0355,00
M39 295,5 0420,00
M42 410,5 0580,00
M45 500,5 0710,00 Note
- Class 8.8 is usually sufficient.
M48 610,5 0860,00 - Before tightening the bolt be sure that the eventual centering of flanges are inserted properly
M56 980,5 1380 - The bolts are to be diagonally tightened with the maximum tightening torque.

Gear reducer troubles: causes and corrective actions
Trouble Possible causes Corrective actions
Excessive oil temperature Inadequate lubrication: Check:
– excessive or insufficient oil quantity; – oil level (gear reducer at rest) or quantity
–u nsuitable lubricant (different type, too viscous, – lubricant type and/or state (see ch. 6.2 lubrication
exhausted, etc.) table); replace if necessary
wrong mounting position Change mounting position
Too tightened taper roller bearings Consult Rossi
Worm gear reducer with excessive load during Reduce the load IT
running-in
Excessive ambient temperature Increase the cooling or correct the ambient temperature
Obstructed passage of air Eliminate obstructive material
Slow or missing air recycle Arrange auxiliary ventilation
Radiance Screen gear reducer and motor properly
Inefficiency of auxiliar y bearing lubrication Check the pump and the pipes
system
Worn, faulty or badly lubricated bearings Consult Rossi
Inefficient or out of service oil cooling system: obstruc- Check pump, pipes, oil filter and safety devices effi- EN
ted filter, insufficient oil (exchanger) or water (coil) flow ciency (pressure switchs, thermostats, flow indica-
rate, pump out of service, water temperature 20 tors, etc.)
°C, etc.
Anomalous noise One or more teeth with:
– dents or spallings Consult Rossi
– excessive flanks roughness
Worn, faulty or badly lubricated bearings Consult Rossi
Taper roller bearings with excessive clearance Consult Rossi
Vibrations Check the fastening and the bearings
Lubricant leaking Seal ring with worn, bakelized, damaged or false Replace seal ring (see ch. 8.3)
from seal rings mounted seal lip
Damaged raceway surface (scoring, rust, dent, etc.) Restore the raceway
Mounting position differs from the one stated on the Position the gear reducer correctly
name plate
Oil leaking from filler plug Too much oil Check oil level/quantity
Incorrect mounting position Check mounting position
Inefficient vent valve Clean/replace filler plug with vent valve
Low speed shaft not rotating Broken key
even with high speed shaft/ Consult Rossi
motor running Completely worn gear pair
Lubricant leaking from Defective oil seals Consult Rossi
joints (covers or
half-casing joints)
Water in the oil Defective cooling coil or heat exchanger Consult Rossi
Motor: see specific instructions.
NOTE
When consulting Rossi state:
– all data of gear reducer or gearmotor name plate;
– nature and duration of failure;
– when and under which conditions the failure occured;
– during the warranty period, in order not to loose validity, do not disassemble nor tamper the gear reducer or gearmotor without approval
by Rossi.

Note Notes
IT
EN

19 - Installazione e manutenzione 19 - Installation and maintenance
Il montaggio e lo smontaggio si effettuano con l’ausilio di tiranti ed Installing and removal operations should be carried out with pullers
estrattori servendosi del foro filettato in testa all’estremità d’albero; per and jacking screws using the tapped hole at the shaft butt-end; for H7/
accoppiamenti H7/m6 e K7/j6 è consigliabile effettuare il montaggio a m6 and K7/j6 fits it is advisable that the part to be keyed is pre-heated
caldo riscaldando l’organo da calettare a 80 100 °C. to a temperature of 80 100 °C.
Albero lento cavo Hollow low speed shaft
Per lo smontaggio dell’albero lento cavo (è la prima operazione da ese- In order to remove the hollow low speed shaft (this is the first operation
guire per smontare il riduttore) orientare la cava linguetta verso l’asse to perform when disassembling the gear reducer) turn the shaft until
intermedio co me indicato nella figura a fianco e spingere l’albero sul the keyway is facing the intermediate shaft, as shown in the drawing
lato gola di riferimento (ved. cap. 18). alongside, and push the shaft from the reference groove
Per il perno delle macchine sul quale va calettato l’albero side (see ch. 18).
cavo del riduttore, raccomandiamo le tolleranze h6, j6 For the shaft end of machines where the hollow shaft of
oppure k6 secondo le esigenze. Altri dati se condo quanto the gear reducer is to be keyed, h6, j6 or k6 tolerances are
indicato al paragrafo «Estremità d’albero» e «Perno mac- recommended (according to requirements). Other details
china» (cap. 18). are given under «Shaft end» and «Shaft end of driven
Per facilitare il montaggio e lo smontaggio dei riduttori machine» (ch. 18).
grandezze 64 ... 360 (con gola anello elastico), proce dere In order to have an easier installing and removing of gear
come raffigurato nelle figg. a, b rispettivamente (escluso reducer sizes 64 ... 360 with circlip groove proceed as per
MR 3l 100 con grand. motore 112 e 3I 125 con grand. the drawings a, b, respectively (excluding MR 3l 100 with
motore 132; interpellarci) motor size 112 and 3I 125 with motor size 132; consult us).
Per MR 3I 64 ... 81, prima inserire nell’albero cavo del ridut- For MR 3I 64 ... 81 first insert the washer with screw and
tore (dal lato opposto motore) la rosetta munita di vite e l’anello elastico, the circlip into gear reducer hollow shaft (on motor opposite side); then
quindi montare sul perno macchina. mount on machine shaft end.
Per il fissaggio assiale si può adottare il sistema raffigurato nelle figg. c, The system illustrated in the fig. c, d is good for axial fastening.
d. Per grandezze 64 ... 360, quando il perno macchina è senza battuta, For sizes 64 ... 360, when shaft end of driven machine has no shoulder
si può interporre un distanziale tra l’anello elastico e il perno stesso a spacer may be located between the circlip and the shaft end itself
(metà inferiore della figura d). (as in the lower half of the fig. d).
Utilizzando gli anelli di bloccaggio (grandezze 40 ... 63, fig. e), o la The use of locking rings (sizes 40 ... 63, fig. e), or of locking bush
bussola di bloccaggio (grandezze 64 ... 360, fig. f) si possono avere (sizes 64 ... 360, fig. f) will permit easier and more accurate installing
un montaggio e uno smontaggio più facili e precisi e l’eliminazione del and removing and to eliminate backlash between key and keyway,
gioco tra linguetta e relativa cava, sistema ad atrito compatibile con friction system complying with Atex.
Atex.
The locking rings or the locking bush are fitted after mounting (for MR
Gli anelli o la bussola di bloccaggio devono essere inseriti dopo il 3I 64 ... 81 insert the bush onto machine shaft end or into hollow shaft
montaggio (per MR 3I 64 ... 81 inserire la bussola sul perno macchina before mounting; pay attention when positioning the keyway); the shaft
o nell’albero cavo prima del montaggio; fare attenzione ad orientare end of the driven machine must be as prescribed at ch. 18 (or 20 in
la cava linguetta); il perno macchina deve essere come indicato al case of hollow low speed shaft: stepped, with locking assembly). Do
cap. 18 (o 20 nel caso di albero lento cavo: differenziato, con unità di not use molybdenum bisulphide or equivalent lubricant for the lubrica-
bloccaggio). Non utilizzare bisolfuro di molibdeno o lubrificanti equi- tion of the parts in contact. When tightening the bolt, we recommend
valenti per la lubrificazione delle superfici a contatto. Per il montaggio the use of a locking adhesive such as LOCTITE 601. For vertical
della vite si raccomanda l’impiego di adesivi bloccanti tipo LOCTI- ceiling-type mounting, contact us.
TE 601. Per montaggi verticali a soffitto interpellarci.
In case of axial fastening with locking rings or bush – especially when
In caso di fissaggio assiale con anelli o bussola di bloccaggio – soprat- having heavy duty cycles, with frequent reversals – verify, after some
tutto in presenza di cicli gravosi di lavoro, con frequenti inversioni del hours of running, the bolt tightening torque and eventu-ally apply the
moto – verificare, dopo alcune ore di funzionamento, il mo mento di locking adhesive again.
serraggio della vite ed eventualmente riapplicare l’adesivo bloccante.
A washer for installing, removing (excluding sizes 40 ... 63) and
A richiesta si può fornire (cap. 20) la rosetta di montaggio, smontag- axial fastening of gear reducer (ch. 20) with or without locking rings,
gio (escluso grand. 40 ... 63) e fissaggio assiale riduttore con o senza locking bush (dimensions shown in the table) or hollow low speed
gli anelli o la bussola di bloccaggio (dimensioni indicate in tabella) shaft with shrink disc (dimensions stated on ch. 20), and a protection
o l’albero lento cavo con unità di bloccaggio (dimensioni indicate al cap for the hollow low speed shaft can be supplied on request. Parts
cap. 20) e il cappellotto di protezione albero lento cavo. Le parti a in contact with the circlip must have sharp edges.
contatto con l’eventuale anello elastico devono essere a spigolo vivo.
Whenever personal injury or property damage may occur, foresee
Se vi sono pericoli per persone o cose derivanti da cadute o proiezio- adequate supplementary protection devices against:
ni del riduttore o di parti di esso, prevedere appropriate sicurezze
– rotation or un threading of the gear reducer from shaft end of driven
contro:
machine following to accidental breakage of the reaction arrange-
– la rotazione o lo sfilamento del riduttore dal perno macchina conse- ment;
guenti a rotture accidentali del vincolo di reazione;
– accidental breakage of shaft end of driven machine.
– la rottura accidentale del perno macchina.
Montaggio a) e
smontaggio b).
Installing a) and
removing b).
Fissaggio assiale
Axial fastening
Callettamento con linguetta e anelli di bloccaggio e),

con linguetta e bussola di bloccaggio f).
Fitting with key and locking rings e),
with key and locking bush f).
G05 June 2011 139

19 - Installazione e manutenzione 19 - Installation and maintenance
Grandezza A D D 1 D 3 E 3 F F 1 h h 1 h 2 L n Vite fissaggio assiale
riduttore Ø Ø Ø ≈ Bolt for axial fastening
Gear reducer
size UNI 5737-88 M [daN m]1)
40 – 4)
19 22,5 15 4)
– – – 14,8 2,8 4 12,6 4)
1,1 M 8 252) 2,9
50 – 24 27,5 194) – – – 14,8 2,8 4 12,64) 1,2 M 8 252) 3,5
63 – 30 34 254) – – – 18,5 3,7 5 18,94) 1,4 M 10 302) 4,3
64 18 32 23 27 9 M 10 M 65) 10 – – 19 6 M 10 35 4,3
80 18 38 27 32 11 M 10 M 65) 12 – – 23 6 M 10 353) 5,1
81 18 40 28 34 11 M 10 M 60 12 – – 23 6 M 10 353) 5,3
100 23 48 35 41 13 M 12 M 80 14 – – 28 7 M 12 453) 9,2
125 30 60 45 52 15 M 14 M 10 16 – – 35 7 M 14 453) 17
140 36 70 54 62 15 M 16 M 12 19 – – 40 8 M 16 50 21
160 45 80 63 70 20 M 20 M 12 19 – – 45 8 M 20 60 34
180 49 90 72 80 20 M 20 M 16 23 – – 49 9 M 20 603) 43
200 56 100 81 88 24 M 24 M 16 23 – – 52 10 M 24 70 66
225 64 110 89 98 24 M 24 M 16 24 – – 60 10 M 24 703) 83
250 72 125 102,5 110 30 M 30 M 20 28 – – 67 11 M 30 90 135
280 87 140 117 125 30 M 30 M 20 30 – – 76 12 M 30 903) 166
320, 321 97 160 133,5 140 41 M 36 M 24 33 – – 86 13 M 36 110 257
360 117 180 153 160 41 M 36 M 24 36 – – 95 14 M 36 1103) 315
1) Momento di serraggio per anelli o bussola di bloccaggio. 1) Tightening torque for locking rings or bush.
2) UNI 5931-84. Per MR 3I: M 8 35 e M 10 40 UNI 5737-88. 2) UNI 5931-84. For MR 3I: M 8 35 and M 10 40 UNI 5737-88.
3) Per bussola di bloccaggio: M 10 35, M 12 45, M 14 45, classe 10.9; M 20 65, 3) For locking bush: M 10 35, M 12 45, M 14 45, class 10.9; M 20 65, M 24 80 and
M 24 80 e M 30 100 UNI 5737-88 classe 10.9; M 36 120 UNI 5931-84 classe 10.9. M 30 100 UNI 5737-88 class 10.9; M 36 120 UNI 5931-84 class 10.9.
4) Bussola di bloccaggio non possibile per MR 3I. 4) Locking bush is not possible for MR 3I.
5) Non utilizzabile per lo smontaggio MR 3I. 5) It cannot be used for the disassembly of MR 3I.
Lubrificazione Lubrication
La lubrificazione degli ingranaggi è a bagno d’olio eccetto la prima Gear pairs are oil-bath lubricated with the exception of the first reduc-
ri duzione dei riduttori ad assi paralleli rotismo 3I e le prime due riduzio ni tion stage in parallel shaft gear reducers train of gears 3I and the first
dei motoriduttori 4I grandezze 125 in forma costruttiva V5 che so no two reduction stages of gearmotors 4I sizes 125 in V5 mounting
lubrificate con grasso «a vita» (SHELL Tivela Compound A). An che i position, which are lubricated «for life» with grease (SHELL Tivela
cuscinetti sono lubrificati a bagno d’olio, o a sbattimento, eccetto i Compound A). Bearings are either oil-bathed or splashed with the
cuscinetti superiori che sono lubrificati con pompa (ved. cap. 20) o con exception of the top bearings which are lubricated with a pump (see
grasso «a vita» (con o senza anello NILOS secondo la velocità). ch. 20) or lubricated «for life» with grease (with or without NILOS ring
Grandezze 40 ... 81: i riduttori vengono forniti completi di olio sin- according to speed).
tetico (KLÜBER Klübersynth GH 6-220, MOBIL Glygoyle 30), per Sizes 40 ... 81: the gear reducers are supplied filled with synthetic
lubrificazione – in assenza di inquinamento dall’esterno – «a vita». oil (KLÜBER Klübersynth GH 6-220, MOBIL Glygoyle 30) providing
Temperatura ambiente 0 40 °C con punte fino a -20 °C e +50 °C. lubrication «for life» – assuming pollution-free surroundings. Ambi-
Importante: verificare la forma costruttiva tenendo presente che se ent temperature range 0 40 °C with peaks of –20 °C and +50 °C.
il riduttore viene installato in forma costruttiva diversa da quella indi- Important: verify mounting position keeping in mind that if gear
cata in targa potrebbe richiedere l’aggiunta – attraverso l’apposito re ducer is installed in a mounting position differing from the one stated
foro – della differenza tra le due quantità di lubrificante indicate nei on name plate, it could need the addition – through the proper hole
cap. 8, 10, 12 e 14. – of the difference between the two lubricant quantities as shown in
ch. 8, 10, 12 and 14.
Grandezze 100 ... 360: i riduttori vengono forniti senza olio; occorre Sizes 100 ... 360: gear reducers are supplied without oil; before
quindi, prima di metterli in funzione, immettere fino a livello1), olio putting into service, fill to the specified level1) with mineral oil (AGIP
minerale (AGIP Blasia, ARAL Degol BG, BP-Energol GR-XP, Blasia, ARAL Degol BG, BP-Energol GR-XP, ESSO Spartan EP, IP
ESSO Spartan EP, IP Mellana oil, MOBIL Mobilgear 600, SHELL Mellana oil, MOBIL Mobilgear 600, SHELL Omala, TEXACO Meropa,
Omala, TEXACO Meropa, TOTAL Carter EP) avente la gradazione di TOTAL Carter EP) having the ISO viscosity grade given in the table.
viscosità ISO indicata in tabella. Normalmente il primo campo di Under normal conditions the first speed range is for train of gears I,
velocità riguarda il rotismo I, il secondo riguarda i rotismi 2I e CI, il the second is for trains of gears 2I and CI, the third is for trains of
terzo riguarda i rotismi 3I, 4I, C2I, ICI e C3I, il quarto riguarda i gruppi. gears 3I, 4I, C2I, ICI and C3I, while the fourth is for combined units.
Quando si vuole aumentare l’intervallo di lubrificazione («lunga When it is required to increase oil change interval («long life»), the
vi ta»), il campo della temperatura ambiente e/o ridurre la tempera- ambient temperature range, and/or reduce oil temperature, use
tura dell’olio impiegare olio sintetico (a base di poliglicoli: KLÜBER synthetic oil (with polyglycol basis: KLÜBER Klübersynth GH6
Klübersynth GH6 ..., MOBIL Glygoyle, SHELL Tivela S oil...; a base ..., MOBIL Glygoyle, SHELL Tivela S oil...; with polyalphaolefines
di polialfaolefine, sempre consigliati, soprattutto per grand. 200: basis, always suggested especially for sizes 200: AGIP Blasia
AGIP Blasia SX, CASTROL Tribol 1510, ELF Reductelf SYNTHESE, SX, CASTROL Tribol 1510, ELF Reductelf SYNTHESE, ESSO Spar-
ESSO Spartan SEP, KLÜBER Klübersynth EG4, MOBIL SHC Molyko- tan SEP, KLÜBER Klübersynth EG4, MOBIL SHC Molykote L11 ...)
te L11 ...) avente la gradazione di viscosità ISO indicata in tabella. having ISO viscosity grade as indicated in the table.
1) Le quantità di lubrificante indicate ai cap. 8, 10, 12, 14 sono da intendersi orientative 1) The lubricant quantities contained in ch. 8, 10, 12, 14 are approximate and indicative
ai fini dell’approvvigionamento. La quantità esatta di olio da immettere nel riduttore è for provisioning. The exact oil quantity the gear reducer is to be filled with is definitely
definita dal livello. given by the level.
Gradazione di viscosità ISO ISO viscosity grade

Valore medio [cSt] della viscosità cinematica a 40 °C. Mean kinematic viscosity [cSt] at 40 °C.
Velocità n2 Temperatura ambiente1) [°C] Speed n2 Ambient temperature1) [°C]
min-1 olio minerale olio sintetico min-1 mineral oil synthetic oil
0 20 10 40 0 40 0 20 10 40 0 40
224 150 150 150 224 150 150 150
224 22,4 150 220 220 224 22,4 150 220 220
22,4 5,6 220 320 320 22,4 5,6 220 320 320
5,6 320 460 460 5,6 320 460 460
1) Sono ammesse punte di temperatura ambiente di 10 °C (20 °C per olio sintetico) in 1) Peaks of 10 °C above and 10 °C (20 °C for synthetic oil) below the ambient temperature
meno o 10 °C in più. range are acceptable.
Se il servizio è continuo, è consigliabile impiegare olio sintetico nei For continuous duty, the use of synthetic oil is recommended in the
seguenti casi: following cases:
– R ICI, MR C3I 100, 125 e MR ICI 100 ... 200 forma costruttiva B6; – R ICI, MR C3I 100, 125 and MR ICI 100 ... 200 mounting position B6;
– R I 100 con n2 375 min-1; – R I 100 with n2 375 min-1;
– R CI 100 con n2 150 min-1; – R CI 100 with n2 150 min-1;
– R 2I e MR 2I 125 con iN 12,5, forma costruttiva B7, n1 950 min-1; – R 2I and MR 2I 125 with iN 12,5, mounting position B7, n1 950 min-1;
– MR ICI 200 con motore grandezza 225; – MR ICI 200 with motor size 225;
– riduttori e motoriduttori di grandezza e forma costruttiva contras- – gear reducers and gearmotors with size and mounting position
140 G05 June 2011

20 - Accessori ed esecuzioni speciali 20 - Accessories and non-standard designs
2I, 3I, C2I 140 ... 360 CI 125 ... 360 Grandezza Vite Molla a tazza T F R
riduttore Bolt Disc spring Ø 1)
Gear
reducer
size UNI 5737-88 DIN 2093
125, 140 M 16 110 A 50 n. 2 25 32 20 13,1

160, 180 M 20 130 A 63 n. 3 25 38 24 17,9
200, 225 M 24 160 A 80 n. 2 29 48 30 20,7
250, 280 M 30 200 A 100 n. 2 37 60 36 26,2
320 ... 360 M 36 260 A 100 n. 3 45 75 42 32,2
1) Valore teorico: tolleranza 0 -1. 1) Theoretical value: tolerance 0 -1.
Descrizione aggiuntiva alla designazione per l’ordinazione: bullo- Supplementary description when ordering by designation: reac-
ne di reazione a molle a tazza. tion bolt using disc springs.
Albero lento cavo differenziato Stepped hollow low speed shaft
I riduttori e motoriduttori grandezze 64 ... 360 possono anche essere Gear reducers and gearmotors sizes 64 ... 360 can be also supplied
forniti ad albero lento cavo differenziato sempre con cava linguetta; with stepped hollow low speed shaft always with keyway; this design
questa esecuzione facilita il montaggio e lo smontaggio e aumenta facilitates installation and removal and affords a notable increase
notevolmente la rigidezza e la resistenza a flessotorsione del perno in rigidity and resistance to bending and torsional stresses at the
macchina. shaft end of the driven machine.
Il foro con Ø D2 è sempre lato opposto gola. Hole with Ø D2 is always opposite to groove side.
Grandezza D D 2 D3 E E 1 E2 E 3 l m n r
riduttore Ø Ø Ø
Gear reducer
size H7/h6
H7/j6, k6
64 32 35 27 110 63 28 10 70 28 6 1,5
80 38 40 32 134 75 35 12 90 30 6 1,5
81 40 42 34 134 72 38 12 90 30 6 1,5
100 48 52 41 162 92 41 14 110 35 7 2
125 60 65 52 201 118 47 16 140 40 7 2
140 70 75 62 228 135 52 16 180 35 8 2
160 80 85 70 250 147 57 21 200 36 8 3
180 90 100 80 274 162 63 21 200 50 9 3
200 100 110 88 308 188 66 25 250 42 10 3
225 110 120 98 331 195 75 25 250 55 10 3,5
H7/h6, j6
250 125 135 110 380 228 84 32 320 40 11 4
280 140 150 125 410 238 94 32 320 60 12 4
320, 321 160 170 140 471 276 107 43 400 45 13 5
360 180 195 160 506 293 116 43 400 72 14 5
Posizione gola di riferimento (ved. cap. 18). Position of the reference groove (see ch. 18).
Il disegno a sinistra raffigura il perno macchina per calettamento The left drawing shows a shaft end of driven machine for coupling
con linguetta. with a key.
Il disegno a destra raffigura il perno macchina per calettamento con The right drawing shows a shaft end of driven machine for coupling
linguetta e bussola di bloccaggio (ved. cap. 19). with a key and locking bush (see ch. 19).
Importante: il diametro del perno della macchina in battuta contro Important: the shoulder diameter of the shaft end of the driven ma chine
il riduttore deve essere almeno (1,18 1,25) · D. abutting with the gear reducer must be at least (1,18 1,25) · D.
Descrizione aggiuntiva alla designazione per l’ordinazione: albero Supplementary description when ordering by designation: stepped
lento cavo differenziato. hollow low speed shaft.
G05 June 2011 149

IT
EN

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Habasit GmbH Habasit AB Habasit GmbH Habasit GmbH
A-1234 Wien S - 430 63 Hindås A-1234 Wien CH - Reinach - Basel
Phone +43 1 690 66 Phone +46 301 226 00 Phone +43 1 690 66 Phone +41 61 715 15 75
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Division of Habasit Canada Limited S - 430 63 Hindås A-1234 Wien A Division of Habasit America
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Rossi Gearmotors China P.T.I. IN - Coimbatore E - Viladecans (Barcelona)
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Habasit AB A Division of Habasit America S - 430 63 Hindås
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Phone +45 48 28 80 87 Phone +1 800 931 2044 fax +46 301 226 01
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4090INS.VPR-it1210HQM
publication, however Rossi can accept no responsibility for any errors, omissions or outdated data. Due to
4090INS.VPR-en1210HQM
the constant evolution of the state of the art, Rossi reserves the right to make any modification whenever to
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GEA Niro Soavi
7.01.7 9532-6932-360 CENTRALINA LUBRICATION UNIT
7.01.7
Istruzioni assemblaggio – Assembly instructions
Serie MR – MW – MC – MS – FP
MK – VT – P1509 – P1507 – TP – TPS – TPM DOC00032 Rev. C 1/8
Applicare
etichetta
Brevini Fluid Power S.p.A.
Via Moscova, 6 – 42124 Reggio Emilia (RE) – Italy
Tel. +39 0522 270711 - Fax +39 0522 270660
www.brevinifluidpower.com – www.hydr-app.com – info@brevinifluidpower.com
INDICE TABLE OF CONTENTS

LEGENDA ACRONIMI E SIMBOLI ........................................................ 1 LEGEND OF ABBREVIATIONS AND SYMBOLS ................................. 1
CARATTERISTICHE GENERALI DEL MANUALE ............................... 1 GENERAL INSTRUCTIONS FOR THE USE OF THIS MANUAL ......... 1
USO PREVISTO DELLA UNITÀ DI POTENZA ...................................... 2 PRESCRIBED USE OF THIS POWER UNIT ........................................... 2
LIMITI DI IMPIEGO .................................................................................. 2 LIMITS OF USE ........................................................................................ 2
SPECIFICHE DI SICUREZZA................................................................... 2 SAFETY SPECIFICATIONS ..................................................................... 2
IDENTIFICAZIONE DEL PRODOTTO .................................................... 3 IDENTIFYING THE UNIT ........................................................................ 3
CONFORMITÀ ALLE DIRETTIVE .......................................................... 3 COMPLIANCE WITH DIRECTIVES ....................................................... 3
LIMITI DI FUNZIONAMENTO ................................................................ 4 OPERATIONAL LIMITS .......................................................................... 4
STOCCAGGIO ........................................................................................... 4 STORAGE .................................................................................................. 4
SCELTA DEL FLUIDO IDRAULICO ....................................................... 4 CHOOSING THE HYDRAULIC FLUID .................................................. 4
INSTALLAZIONE ..................................................................................... 5 INSTALLATION ....................................................................................... 5
Norme generali per una corretta installazione .......................................................................... 5 General rules for correct installation ....................................................................................... 5
Collegamento elettrico per motore DC ...................................................................................... 5 Connecting a DC motor ........................................................................................................... 5
Collegamento motore AC .......................................................................................................... 6 Connecting an AC motor ......................................................................................................... 6
Collegamento valvola ad intervento elettrico............................................................................. 6 Connecting electrically actuated valves ................................................................................... 6
Collegamento idraulico ............................................................................................................. 6 Hydraulic connection............................................................................................................... 6
Montaggio leva comando manuale ............................................................................................ 6 Installation of manual pressure control group ........................................................................ 6
AVVIAMENTO .......................................................................................... 7 START UP ................................................................................................. 7
RACCOMANDAZIONI ............................................................................. 7 TIPS ............................................................................................................ 7
MANUTENZIONE ..................................................................................... 7 MAINTENANCE ....................................................................................... 7
Sostituzione del filtro................................................................................................................. 8 Replacing the filter................................................................................................................... 8
Smontaggio e rimontaggio dei serbatoi ..................................................................................... 8 Removing and reinstalling the tanks........................................................................................ 8
Serraggi consigliati ................................................................................................................... 8 Recommended tightening torque values .................................................................................. 8

DEMOLIZIONE E SMALTIMENTO ........................................................ 8 DISMANTLING AND DISPOSAL ........................................................... 8
LEGENDA ACRONIMI E SIMBOLI LEGEND OF ABBREVIATIONS AND SYMBOLS

UP Unità di potenza, centralina idraulica PU Power unit, Hydraulic power pack
BFP Brevini Fluid Power S.p.A. BFP Brevini Fluid Power S.p.A.
AC Corrente alternata AC Alternating current
DC Corrente continua DC Direct current
VM Valvola di massima RV Relief valve
CW Orario CW Clockwise
PE Polietilene PE Polyethylene
PP Polipropilene PP Polypropylene
Le operazioni che rappresentano una situazione di potenziale Operations that may create a dangerous situation to persons,
pericolo per persone, animali o cose sono evidenziate tramite il animals or property are indicated by the symbol on the left.
simbolo riportato a fianco.
Le operazioni che necessitano di particolare attenzione per il buon Procedures that require special attention to obtain proper system
funzionamento dell’ impianto sono evidenziate tramite il simbolo operation are indicated by the symbol on the left.
riportato a fianco.
Coppia di serraggio da applicare, espressa in Nm Tightening torque to be applied, in Nm
CARATTERISTICHE GENERALI DEL MANUALE GENERAL INSTRUCTIONS FOR THE USE OF THIS MANUAL
Il presente manuale fa riferimento alle unità di potenza (di seguito UP) serie This manual applies to hydraulic power units (hereafter called PU) of the following
MR, MW, MC, MS, FP, MK, VT, P1509, P1507, TP, TPS, TPM. L’ Utilizzatore series: MR, MW, MC, MS, FP, MK, VT, P1509, P1507, TP, TPS, TPM. The User
è il solo responsabile dell’ uso di questo manuale. Il rischio relativo è assunto is solely responsible for the use of this manual and completely assumes the relative
completamente dall’ Utilizzatore. In nessun caso la Brevini Fluid Power S.p.A. risk. Brevini Fluid Power S.p.A. (hereafter called BFP) will not be responsible for
(di seguito BFP) sarà responsabile per danni speciali, indiretti, accidentali o special, indirect, accidental or consequential damage deriving from the use of this
consequenziali dipendenti dall’ uso o dall’ inesperienza nell’ utilizzo del manuale manual or the product, or from inexperience with the use of this manual or of the
o del prodotto. BFP non sarà responsabile per una cattiva od impropria product. BFP will not be responsible - even to third parties - for poor or improper
installazione, manutenzione, riparazione del prodotto, anche nei confronti di installation, maintenance, or repair of the product, or for the use of non-original
Proprietà dell’ azienda Brevini Fluid Power S.p.A. vietata qualsiasi riproduzione anche parziale senza l’ autorizzazione della stessa. ISTRUZIONI ORIGINALI
Property of Brevini Fluid Power S.p.A. Reproduction in whole or in part without express written consent is prohibited. ORIGINAL INSTRUCTIONS
terzi, nonché per l’ utilizzo di ricambi non originali. Nessuna parte di questo replacement parts. This manual may not be reproduced, in whole or in part, in any
manuale può essere riprodotta in qualsiasi forma o mezzo, per qualsiasi uso, che form or by any means, for any use which is not the User’s personal use, without the
non sia quello personale dell’ Utilizzatore, senza il permesso scritto della BFP. express written consent of BFP. BFP thanks you for choosing one of its products.
BFP ringrazia per aver scelto uno dei suoi prodotti ed invita l’ Utilizzatore a In order to use the product correctly, BFP asks you to carefully follow the
seguire attentamente le istruzioni ed i suggerimenti di questo manuale per un instructions and suggestions contained in this manual. This manual is intended for
corretto utilizzo del prodotto. Questo manuale è indirizzato ad Utilizzatori con Users with trained personnel (who specialize in the hydraulics, electrical and
personale competente (specializzato nel settore idraulico, elettrico e meccanico). mechanical sectors). This manual is no substitute for the professionalism and skill
Questo manuale non può sostituire la professionalità e le competenze del of the User’s personnel. The User must make sure that its personnel have been
personale dell’ Utilizzatore. L’ Utilizzatore deve accertarsi che il proprio provided with this manual and understand the instructions contained in it. Since
personale abbia ricevuto questo manuale e abbia recepito le istruzioni in esso BFP is committed to ongoing research and development, it reserves the right to
contenute. La BFP è orientata ad una continua ricerca e sviluppo dei propri modify the technical characteristics of its products, at any time and without prior
prodotti e pertanto si riserva il diritto di modificare in qualunque momento e notice, as deemed necessary. To ensure the availability of certain components, BFP
senza alcun preavviso tutte le caratteristiche tecniche ritenute necessarie. Per draws upon a network of select, qualified suppliers; as a result, these components
assicurare la disponibilità di alcuni componenti, la BFP si avvale di una rete di may vary in size and appearance. This manual is subject to change and addition,
fornitori selezionati e qualificati, pertanto potranno esistere differenze but must not be considered to be out of date. Since PU are complex products with
dimensionali e di aspetto degli stessi componenti. Il presente manuale potrà configurations that vary a great deal, the diagrams contained in this manual are
subire variazioni ed integrazioni, ma non potrà in alcun caso ritenersi superato. intended only to make it easier to understand the text and often do not show the
L’ UP è un prodotto complesso con configurazioni molto variabili, pertanto i product exactly as it is.
disegni rappresentati hanno la funzione di agevolare la comprensione dei testi,
ma spesso non rappresentano l’ esatta realtà del prodotto.
Operazioni di assemblaggio, installazione, manutenzione ed The PU and its components may be assembled, installed, started and
avviamento delle UP e dei componenti applicati devono essere maintained by trained technical personnel, only.
effettuate da personale tecnico competente.
The User is responsible for choosing the product and its accessories. Thus,
L’ Utilizzatore è responsabile della scelta del prodotto e dei suoi it is important for the User to investigate the problems associated with its
accessori. Risulta quindi importante che l’ Utilizzatore analizzi le specific application by performing suitable analyses and tests. The User is
problematiche della propria applicazione, eseguendo analisi e prove also responsible for installing the safety systems and affixing the warnings that
adeguate. E’ inoltre il responsabile dell’ applicazione, delle sicurezze e delle are required by current regulations.
avvertenze richieste dalle direttive in vigore.
USO PREVISTO DELLA UNITÀ DI POTENZA PRESCRIBED USE OF THIS POWER UNIT
La UP è destinata ad automazione oleodinamica come organo di comando. Data This PU is designed to be the main control unit in hydraulic automation systems.
la vastità applicativa della UP e non essendo sempre nota la destinazione finale Given the wide range of applications of PU, and since the final destination of the
del prodotto, questo manuale è stato realizzato limitatamente in funzione delle unit is not always known to the manufacturer, this manual will provide information
generiche applicazioni conosciute come ad esempio: carrelli elevatori, only on popular applications such as forklifts, lifting platforms and beds, lifts for
piattaforme e tavole elevatrici, ponti sollevatori per auto, gru per piccoli cars, cranes on small trucks, snowplows, and automated systems in the industrial
autocarri, spartineve, automazioni settore industriale. sector.
LIMITI DI IMPIEGO LIMITS OF USE

Non sempre è nota la destinazione finale del prodotto. L’ Utilizzatore, nella The manufacturer does not always know the final destination of the product. When
scelta della UP, deve identificare il prodotto adeguato anche con l’ ausilio di test the User chooses a PU, it must therefore determine which product is suitable by
attraverso un prototipo campione. I nostri uffici sono a disposizione per aiutare l’ running a test with a sample prototype. Our offices are available to help the User
Utilizzatore nella scelta della UP idonea. choose the correct PU for its needs.
La UP non deve essere utilizzata nelle seguenti applicazioni : A PU must not be used in the following applications:
• ambienti dove esista il pericolo di esplosione e di incendio; • environments where there is a danger of explosion or fire
• veicoli ed impianti aeronautici e spaziali; • aeronautical/space vehicles and systems
• sistemi frenanti, di blocco e di stallo in genere; • braking, locking and retention systems in general
• attrezzature ed impianti di applicazione in campo militare, nucleare, • equipment and systems used in military, nuclear, medical or hospital
medicale ed ospedaliero applications
Tuttavia la BFP si riserva, dietro richiesta, di valutare le applicazioni sopra citate In any case, BFP reserves the right - upon request - to evaluate the applications
e di darne, qualora lo ritenga opportuno, l’ autorizzazione. listed above and to authorize an application, if appropriate.
La UP non deve essere utilizzata per assolvere funzione di sicurezza. A PU must not be used to perform safety functions.
Alcune condizioni che possono causare problemi: The following are possible problem areas:
• forti sollecitazioni e vibrazioni possono causare fuoriuscita di fluido dal • Strong stresses and vibration may cause fluid to be ejected from the breather
tappo carico-sfiato. and fill cap.
• Ambienti particolarmente polverosi possono causare l’ occlusione del tappo • Highly dusty environments may cause the breather and fill cap to become
carico-sfiato. plugged.
• Forti pressioni di scarico nel serbatoio possono generare schiuma e alterare • Strong discharge pressure into the tank may generate foam and alter the
il fluido idraulico. characteristics of the hydraulic fluid.
• Esposizione dell’ UP ai raggi solari possono causare danni alle parti in • Exposing the PU to sunlight may cause damage to the exposed plastic parts
plastica esposte (soprattutto i serbatoi). (especially the tanks).
• Il collegamento elettrico dei motori DC deve essere eseguito con cavi • The DC motors must be wired using suitably large cables.
adeguati
• Nella scelta dei motori AC monofase è necessario considerare la minima • Single-phase AC motors must be chosen to handle the minimum voltage
tensione di alimentazione di rete. available from the power mains.
• Le valvole elettriche normalmente utilizzate non sono a tenuta perfetta, • The electrically actuated valves that are normally used in these applications
pertanto tale caratteristica deve essere considerata dall’ Utilizzatore in sede are not perfectly sealed, and this characteristic must be considered by the
di progettazione della propria macchina o attrezzatura. User when designing its machinery or equipment.
• Le UP subiscono un collaudo funzionale e di verifica della tenuta idraulica • Each PU is given a final leak test under pressure, and its internal ducts are
in pressione, inoltre un flussaggio garantisce la pulizia dei condotti interni. flushed to ensure cleanliness. As a result, the system where the PU is
È pertanto consigliabile la massima pulizia dell’ impianto sul quale l’ UP installed should be perfectly clean, and the hydraulic fluid used must be clean
deve essere applicata, nonché l’ utilizzo di fluido idraulico pulito e filtrato. and filtered.
SPECIFICHE DI SICUREZZA SAFETY SPECIFICATIONS

L’ UP è realizzata secondo lo stato dell’ arte, della tecnica e delle normative Your PU has been designed and built to the current state of the art and complies
applicabili. Assemblare l’ UP alle macchine o attrezzature è compito dell’ with all applicable laws and regulations. The User is responsible for connecting the
Utilizzatore. Assemblaggio, avviamento e manutenzione devono essere eseguiti PU to its machineries or equipment. The unit and the system where it is installed
da personale competente. Di seguito vengono descritte alcune situazioni di must be assembled, placed into service and maintained by properly trained
pericolo che possono essere ancora presenti durante il funzionamento. A volte personnel. A number of dangerous conditions that may occur during operation will
alcune situazioni possono risultare apparentemente banali, ma comunque da non now be described. Sometimes, a potentially dangerous situation may seem to be
sottovalutare, come da non sottovalutare è l’ eccessiva confidenza e normal, but must not be underestimated. Likewise, the possibility of
abitudinarietà al lavoro che possono prevalere sull’ attenzione da dedicare alla overconfidence and performing tasks by habit, which may take the place of paying
sicurezza. proper attention to safety, must also not be underestimated.
Durante le operazioni di avviamento, normale lavoro, manutenzione, Unexpected spurts and leaks of hydraulic fluid hot enough to cause burns
regolazione, sfiato dell’ impianto, intervento e azionamento di valvole e may occur during startup, normal operation, maintenance, adjustment,
vari elementi di controllo possono verificarsi degli schizzi improvvisi e delle bleeding of the system, and operation and actuation of the valves and the control
fuoriuscite di fluido idraulico, il quale può raggiungere temperature tali da systems.
causare ustioni alla pelle.
Il fluido idraulico può essere pericoloso per la salute in quanto il contatto Hydraulic fluid may be hazardous to health, since contact with the skin and
con la pelle e gli occhi può causare gravi danni. Attenersi eyes can cause serious damages. Carefully follow the instructions on
scrupolosamente alle disposizioni di protezione e sicurezza imposte dal personal protection and safety that are specified by the manufacturer of the fluid, as
produttore del fluido idraulico riportate sulla scheda tecnica e tossicologica. specified on the technical/toxicological information sheet.
Il fluido idraulico può essere un prodotto inquinante. E’ perciò buona Hydraulic fluid may be a pollutant. As a result, it is good practice to avoid
norma evitare perdite di fluido idraulico servendosi di vasche di raccolta losing fluid by using basins to collect it. Also, use oil-absorbent products
e cautelarsi contro accidentali perdite e fuoriuscite del fluido idraulico con to protect the skin from accidental leaks and spurts of fluid.
prodotti oleoassorbenti.
Non manomettere alcun tipo di valvola, raccordo, accessorio o Never tamper with any valve, connection, accessory or component on the
componente della UP; un semplice allentamento di una valvola potrebbe PU. Simply loosening a valve may cause loads to fall freely or structures to
provocare la caduta libera di carichi o il cedimento di strutture. give way.
Tutte le operazioni d’ installazione, montaggio, manutenzione, All installation, assembly, maintenance, disassembly and replacement
smontaggio e sostituzione della UP e dei componenti ad essa applicati operations on the PU and its components must be performed in full
devono essere eseguiti nel massimo rispetto delle norme di sicurezza. Durante compliance with safety regulations. During these operations, the hydraulic circuit
queste operazioni, all’ interno del circuito oleodinamico non deve mai essere must never be pressurized (zero pressure), and no load must be exerted on the tool
presente pressione (pressione zero) e non deve esistere nessun tipo di carico sulla or machinery the PU is connected to (zero load).
struttura dell’attrezzatura o della macchina a cui la UP è applicata (carico zero).
Tutti i collegamenti e scollegamenti elettrici devono essere eseguiti da All electrical connections and disconnections must be performed by
personale specializzato e competente. trained, specialized personnel.
Prima di procedere a qualsiasi tipo di operazione o di intervento sulla UP, Before performing any type of operation or service on the PU, electrically
devono essere scollegati dalla linea elettrica di alimentazione (sia AC che disconnect the power line (whether AC or DC) from the motors and from
DC) i motori e qualsiasi altro dispositivo di tipo elettrico. any other electrical device on the PU.
Nel caso di motorizzazioni o dispositivi diversi da quelli elettrici Before servicing non-electrical devices or motorization systems (whether
(pneumatici, idraulici, meccanici, ecc…), essi devono sempre essere pneumatic, hydraulic, mechanical, etc.), such devices and systems must
preventivamente scollegati dalla rete di alimentazione e messi in first be disconnected from the relative feed lines and must be set up so that
condizioni di non produrre, nemmeno in condizioni accidentali, energia e quindi they cannot produce energy and thus cause movements, even accidentally.
movimento.
Nelle UP con motore DC ventilato, alcune zone della UP potrebbero non On PU with a ventilated DC motor, some areas of the PU may not be
essere protette dagli organi in movimento (ventola): è compito dell’ protected from moving parts (the fan). In this case, the User is responsible
Utilizzatore predisporre ripari adeguati. Le zone non protette sono segnalate da for providing suitable guards. Unprotected areas are labeled with a suitable
opportuno avviso. warning.
Alcune parti dell’ UP e lo stesso fluido idraulico possono raggiungere Some parts of the PU - and the hydraulic fluid itself - may reach high
temperature elevate e causare ustioni alla pelle: attenersi alle prescrizioni temperatures and burn the skin. Be sure to follow all safety instructions.
di sicurezza.
L’ Utilizzatore deve prevedere l’ installazione della UP sulle macchine e The User must install the PU in a position on the machinery and equipment
attrezzature in posizione tale da facilitare qualsiasi tipo di intervento di that makes repair and maintenance procedures easy to perform.
riparazione e manutenzione. When performing any such operation, it is good practice to:
Per tutte le operazioni si consiglia di: Use proper safety equipment (goggles, gloves, shoes, etc.);
Usare protezioni antinfortunistiche (occhiali, guanti, scarpe, etc); lavorare in Work in conditions of utmost cleanliness and use tools, equipment and benches
condizioni di massima pulizia, usare strumenti, attrezzi e banchi di servizio that are clean and in good operating condition;
adatti, puliti ed efficienti; lavorare in condizioni di massima sicurezza; usare Work in conditions of maximum safety;
prodotti oleoassorbenti. Use oil-absorbent products.
IDENTIFICAZIONE DEL PRODOTTO IDENTIFYING THE UNIT

Tutte le UP sono corredate di etichette. PU are provided with identification labels.
Alcuni campi possono essere opzionali. Nei documenti di accompagnamento le Some fields may be optional. PU are identified by a part number and an ordering
UP sono identificate mediante codice anagrafico e codice di selezione. Tutte le code on the documents provided with the units (invoice). All requests for
richieste di chiarimenti o di ricambi devono essere accompagnate dai codici explanations or replacement parts must be accompanied by the identification codes
sopradescritti. described above.
CONFORMITÀ ALLE DIRETTIVE COMPLIANCE WITH DIRECTIVES

Direttiva Macchine 2006/42/CE Machinery Directive 2006/42/EC
La UP è costruita per essere incorporata in una macchina e può essere messa in This PU is designed to be incorporated into another machinery and may be placed
servizio solo quando la macchina (in cui è incorporata) è stata dichiarata into service only when that machinery has been certified as complying with
conforme alle disposizioni della Direttiva Macchine 2006/42/CE. Machinery Directive 2006/42/EC.
Direttiva EMC 2004/108/CE EMC Directive 2004/108/EC
Motore AC – Trifase e Monofase: non applicabile. AC Motor – Three-phase or single-phase: not applicable.
Motore DC – Campi avvolti: conforme. DC motor - Field wound: compliant.
Motore DC – Magneti permanenti: non conforme, è compito dell’ Utilizzatore DC Motor - Permanent-magnet type: not compliant. The User must install an
predisporre un filtro antidisturbo sulla linea di alimentazione. interference filter on the power line.
Direttiva BT 2006/95/CE LV Directive 2006/95/EC
Motore AC – Trifase e Monofase: conforme. AC Motor - Three-phase or single-phase: compliant.
Motore DC: escluso dalla Direttiva (fino a 75 V). DC motor - Excluded from the Directive (up to 75 V).
LIMITI DI FUNZIONAMENTO OPERATIONAL LIMITS

Portata: è determinata dalla pompa e dal motore scelti ed utilizzati. La UP è Flow rate: The flow rate is determined by the pump and motor chosen. This PU is
realizzata per gestire una portata ottimale di min. 5 litri/min ed una max. di 20 designed to handle an optimal minimum flow rate of 5 liters/min and a maximum
litri/min. flow rate of 20 liters/min.
Pressione minima: la UP è realizzata per controllare una pressione minima di 10 Minimum pressure: This PU is built to control a minimum pressure of 10 bars.
bar. La stessa pressione minima occorre per il buon funzionamento di eventuali The same minimum pressure is also required for proper operation of possible flow
regolatori di portata che controllano il flusso in scarico. regulators that control the outgoing flow.
Pressione massima: è determinata dalla pompa, dal motore e dalla valvola di Maximum pressure: The maximum pressure is determined by the pump, the
massima pressione (di seguito VM). Pertanto tutti i componenti della UP sono motor and the relief valve (hereafter referred to as the RV). Nevertheless, all the
scelti in funzione della VM adottata. components in the PU have been chosen to suit the RV that is installed.
Nelle massime condizioni e con componenti specifici, i limiti di pressione sono i Under the most severe conditions and with specific components, the pressure limits
seguenti: are as follows:
250 bar: pressione intermittente di lavoro 250 bar: intermittent operating pressure
290 bar: pressione intermittente per max 20 s 290 bar: intermittent peak pressure for a max. of 20 s
320 bar: pressione di picco 320 bar: overshooting pressure
Si fa divieto di sostituire la VM senza previa autorizzazione della The RV must not be replaced without prior authorization from BFP.
BFP
Temperatura: la UP è realizzata per una temperatura del fluido -10 ÷ 70 °C. Temperature: This PU is designed to operate with fluid at a temperature of -10 to
Consultare il capitolo “scelta del fluido idraulico” per verificare le temperature 70° C. See the chapter, “Choosing the Hydraulic Fluid” for more information on
limite. temperature limits.
Rapide variazioni di temperatura possono pregiudicare sia le caratteristiche che Since rapid temperature changes may deteriorate the properties and service life of
la durata del prodotto, pertanto è indispensabile proteggerlo da queste situazioni. the fluid, it is essential to protect the fluid from this type of situation.
STOCCAGGIO STORAGE
Le UP sono un prodotto da maneggiare con cura ed attenzione. Alcune parti, PU must be handled with care and attention. Certain protruding parts may be
normalmente sporgenti, possono essere soggette a rottura, come ad esempio il subject to breakage, such as the breather and fill cap on the tank. Another weak
tappo di carico-sfiato posto sul serbatoio. Altro punto debole è il serbatoio di point is the tank made of plastic. Pay special attention to the flange, its valves and
materiale plastico. Una particolare attenzione deve essere riservata alla flangia, its components since they are particularly vulnerable to impact. If the PU is
alle sue valvole e ai suoi componenti poiché particolarmente esposte agli urti. equipped with valve assemblies, they must be protected from impacts and dents.
Quando la UP è provvista di blocchetti, è necessario proteggere gli stessi da urti, Also, avoid bending the assemblies excessively, as this could cause irreversible
da ammaccature, ed evitare di creare pericolose flessioni che potrebbero dare damage. For PU with tanks of small dimensions, since the motor is the heaviest
origine a danni irreversibili. Per UP con serbatoi di piccole dimensioni, poiché il component on a PU, it is essential that the PU be stored horizontally (and never
motore è la parte più pesante della UP, è indispensabile che la stessa sia riposta, vertically, with the tank underneath and the motor on top).
nell’ immagazzinamento, in senso orizzontale (mai in verticale col serbatoio in A PU must be placed in an environment that is protected from dust and direct
basso e il motore in alto). La UP deve essere riposta in ambiente protetto da sunlight (UV rays), and at an ambient temperature of -10 to +30 °C (up to 40°C
polvere e al riparo da luce solare (raggi UV) con temperatura ambiente compresa max. for brief periods).
tra -10+30°C (fino a un massimo di 40°C per brevi periodi).
SCELTA DEL FLUIDO IDRAULICO CHOOSING THE HYDRAULIC FLUID

Tutti i fluidi idraulici a base minerale sono adatti all' impiego. Nella loro scelta è Any mineral-based hydraulic fluid can be used. When choosing a fluid, the
necessario considerare i dati di funzionamento e della temperatura ambientale per operational parameters of the system and the ambient temperature must be taken
ottenere un’ ottimale prestazione di esercizio. Utilizzare fluido idraulico a base into consideration to obtain best performance. Use HM-HR-HV mineral-based
minerale HM-HR-HV secondo ISO 6743/4 (DIN 51524), classe di viscosità hydraulic fluid meeting ISO 6743/4 (DIN 51524) specifications, with an ISO 3448-
secondo ISO 3448 con le seguenti condizioni di utilizzo: compliant viscosity class, and with the following conditions of use:
• viscosità minima: 12 cSt viscosità massima: 80 cSt • minimum viscosity: 12 cSt - maximum viscosity: 80 cSt
• viscosità massima all' avviamento: 500 cSt • maximum viscosity at startup: 500 cSt
• viscosità d’ esercizio: 20÷50 cSt • operating viscosity: 20 to 50 cSt
• temperatura ottimale d’ esercizio dell’ olio: 30° ÷ 60 °C • oil optimum operating temperature: 30° to 60 °C
• temperatura ambiente minima: -15 °C • minimum ambient temperature: -15 °C
• temperatura ambiente massima: 40 °C (con picchi di 50 °C) • maximum ambient temperature: 40 °C (with peaks of 50 °C)
L’ utilizzo di altri fluidi può danneggiare e compromettere il buon The use of other fluids may damage the system and prevent it from
funzionamento dell’impianto. Tuttavia la BFP si riserva, dietro richiesta, operating properly. In any case, BFP reserves the right - upon request - to
di valutare l’ utilizzo di altri fluidi e di darne, qualora lo ritenga evaluate the use of other fluids and to authorize such use if appropriate.
opportuno, l’ autorizzazione.
Since each PU is given a final test for proper operation, several cc of fluid
L’ UP subisce un collaudo funzionale e nel suo interno possono rimanere with the above characteristics may remain in the unit.
alcuni cc di fluido con le caratteristiche sopradescritte.
It is important not to mix hydraulic fluids from different manufacturers or
È importante non miscelare fluidi idraulici di diversi produttori o di fluids of different types. Such mixing may cause sludge and sediment to
diverso tipo poiché possono essere causa di formazione di fanghi e di form that could prevent the PU from operating properly.
sedimentazioni che potrebbero compromettere il buon funzionamento della UP.
The values reported above are standard conditions of use that do not take
I valori sopradescritti sono le condizioni di utilizzo standard, ma non into account the various types of tanks that may be installed and the
tengono in considerazione le varie tipologie di serbatoi e le conseguenti resulting limitations. If plastic tanks are used, it is a good idea to consider
limitazioni. Se si utilizzano dei serbatoi in plastica è opportuno that they offer poorer temperature performance.
considerare le loro inferiori prestazioni nei confronti della temperatura Optimal temperature for using tanks made of sheet metal and polyethylene (PE):
Temperature ottimale di utilizzo dei serbatoi in lamiera e polietilene (PE): -10 °C (ambient) to 70 °C (operating)
-10 °C (ambientale) ÷ 70 °C (di esercizio) Temperature limits for using tanks made of sheet metal : -15 °C (ambient) to 80
Temperature limite di utilizzo dei serbatoi in lamiera : -15 °C (ambientale) ÷ °C (operating)
80 °C (di esercizio) Temperature limits for using tanks made of polypropylene (PP) : -10 °C (ambient)
Temperature limite di utilizzo dei serbatoi in polipropilene (PP): -10 °C to 60 °C (operating)
(ambientale) ÷ 60 °C (di esercizio) The above parameters, which are the result of experience and laboratory tests, take
I dati riportati sono frutto di esperienza e test di laboratorio, e tengono conto di into account the mounting systems and fasteners that are essential to machineries
fissaggi essenziali alle macchine o attrezzature con medie vibrazioni (trans pallet or equipment with average levels of vibration (transpallets in a workshop
in ambiente da officina). environment).
INSTALLAZIONE INSTALLATION
Durante l’ installazione preoccuparsi della massima pulizia effettuando le During installation, be sure that important assembling operations are
principali operazioni di collegamento in un locale pulito e non polveroso. carried out with the greatest degree of cleanliness in a clean, dust-free area.
La UP deve essere montata in posizione ergonomica in modo tale da The PU must be installed in an ergonomic position that provides easy
permettere una facile accessibilità alle ispezioni e alla manutenzione. È access for inspection and maintenance. It is just as important to install it in
altrettanto indispensabile che essa venga montata in una zona protetta da urti an area which is protected from accidental impact and kept away from accidental
accidentali e riparata da casuali contatti fisici, poiché la temperatura raggiunta physical contact, since the high temperature of the unit during operation may cause
durante il funzionamento può essere causa di ustioni. burns.
La UP deve essere fissata saldamente alla macchina nei punti di maggiore The PU must be securely fastened to the machinery at its sturdiest points
resistenza (es: telaio portante, longheroni, ecc..), lontano da qualsiasi fonte (such as the load-bearing frame, longitudinal members, etc), away from all
o parte di macchina che possano vibrare, trasmettere o amplificare rumore sources of noise and vibration, and away from parts of machinery that may
e vibrazioni. vibrate or transmit and/or amplify noise and vibration.
La UP con serbatoio in plastica deve essere applicata in ambienti protetti PU with a plastic tank must be installed in areas with limited temperature
da esposizione ai raggi solari e con limitate escursioni termiche. swings and away from direct exposure to sunlight.
La UP deve essere fissata con i due fori ISO M10 presenti sul corpo in alluminio. The PU must be installed using the two ISO M10 holes in its aluminum body. The
Le stesse UP sopra descritte si possono fissare con l’ utilizzo dell’ apposito PU described above may be installed with a special foot that is available upon
piedino fornito a richiesta. Su macchine fisse (posizione orizzontale o verticale) request. On fixed machineries (horizontal or vertical position), the weight limits
i limiti di peso consigliati per il fissaggio con i 2 fori M10 sono: recommended for fastening with the two M10 holes are:
• con motore AC B14 Grandezza 112 • with B14 AC motor, size 112
• con serbatoio 10 litri • with 10 liter tank
• con serbatoio 12 litri utilizzando anche i piedi del serbatoio stesso • with 12 liter tank and the additional support of the feet on the tank
Sulle macchine mobili (prediligere posizione verticale e fissare vicino al On moving machineries (the vertical position is preferable, mount the unit close to
baricentro) i limiti di peso consigliati per il fissaggio con i 2 fori M10 sono: the center of gravity), the weight limits recommended for fastening with two M10
• con tutti i motori DC holes are:
• con serbatoi 6 litri in lamiera • with all DC motors
• con serbatoi 5 litri in plastica PP • with 6 liter tanks in sheet steel
• con serbatoi 4 litri in plastica PE • with 5 liter tanks in PP
Se l’ Utilizzatore analizza la propria applicazione si possono applicare alle UP • with 4 liter tanks in PE
serbatoi di capacità superiore ancorando, per esempio, anche lo stesso serbatoio Tanks with a higher capacity can be installed on PU for special applications. For
alla struttura del mezzo mobile. example, the tank can be anchored to the frame of a moving vehicle.
Norme generali per una corretta installazione General rules for correct installation
Prendere visione dello schema oleodinamico e dell’eventuale schema Examine the hydraulic diagram and the electrical diagram (if available).
elettrico (il nostro ufficio tecnico/commerciale è a Vostra disposizione Our technical/business office is at your disposal for further
per qualsiasi spiegazione). information/explanations.
Evitare di asportare i tappi in plastica di protezione fino al momento del Avoid removing the plastic protection plugs until you connect the hoses.
collegamento dei tubi.
Alcune valvole ad intervento elettrico sono munite di emergenza manuale Some electrically actuated valves have a screw-type manual safety device.
a vite, tale emergenza deve sempre essere disattivata prima di rimettere in This safety must be deactivated before operating the system.
funzione l’ impianto.
Per UP con blocchi modulari CETOP utili per il collegamento di For PU equipped with CETOP modular assemblies for connecting
elettrodistributori, utilizzare per i fori di attacco raccordi cilindrici proportional solenoid valves, use DIN 3852 cylindrical fittings with UNI-
secondo la normativa DIN 3852 e le filettature in accordo con le ISO 228 threads as the connection ports.
normative UNI-ISO 228.
Si ricorda che l’avvitamento di raccordi (in acciaio) con ammaccature sul Remember that when a steel fitting with a dented male thread is tightened,
filetto maschio provoca una asportazione di truciolo nella sede femmina it will remove burrs from a female (aluminum) seat. These burrs are the
(in alluminio) causa principale del difettoso funzionamento di valvole. main cause of valve malfunctions.
Collegamento elettrico per motore DC Connecting a DC motor
Esempio di schema di collegamento: Sample connection diagram:
Nel collegamento elettrico è importante considerare la sezione e la When wiring a motor, it is important to consider the cross-sectional area
lunghezza dei cavi di alimentazione: sezioni troppo piccole e lunghezze and length of the power cables. Cables with overly small cross-sections
troppo elevate possono causare cadute di tensione tali da compromettere il buon and overly long lengths may cause voltage drops that could prevent the PU from
funzionamento della UP. operating properly.
Prima della messa in funzione si consiglia di effettuare alcuni cicli di Before placing the unit into service, we recommend cycling the start switch
assestamento al teleruttore con cariche medio basse. several times at low to medium loads to break in the switching system.
Per i poli del motore e del teleruttore, attenersi alle seguenti coppie di Use these tightening torque
serraggio values on the motor terminals ISO M8 5 to 7
ISO M8 5÷7
and the start switch ISO M6 3 to 5
ISO M6 3÷5
Collegamento motore AC Connecting an AC motor
Collegamento meccanico dei motori AC forma B14: il giunto di trasmissione lato Mechanical connection to AC motors with form factor B14: the motor side of the
motore deve essere montato secondo le dimensioni specificate in tabella transmission coupling must be mounted at the distances shown on the table
Quote accoppiamento Coupling distances
Z ( pompa Z (pompa Z (pump, Z (pump,
Grand. gruppo 1) gruppo 0.5) Size group1) group 0.5)
mm mm in mm in mm
63 42.8 62.7 63 42.8 62.7
71 42 42 71 42 42
80 53 53 80 53 53
90 63 63 90 63 63
100 81.5 81.5 100 81.5 81.5
Esempio di collegamento elettrico motori AC trifase: Sample electrical connection of three-phase AC motors:
L’ allacciamento elettrico del motore e delle valvole ad intervento Electrical connections to the motor and to electrically actuated valves must
elettrico devono essere realizzati da personale competente. Entrambi i be made by trained personnel. Before these devices are connected to the
dispositivi devono essere collegati alla linea elettrica considerando: power line, the following factors must be considered:
• Le Leggi e le Norme tecniche vigenti nel luogo di installazione • The laws and technical standards applicable in the installation location
• I dati riportati sulla targa del motore e sulle valvole. • The data indicated on the motor identification plate and on the valves
L’alimentazione elettrica del motore deve essere effettuata tramite cavo The electric power feed line connected to the motor must be a multi-core
multipolare con sezione adeguata alla normativa vigente. L’ingresso del cable with a cross-sectional area that is large enough to meet current
cavo nella morsettiera è previsto con apposito pressacavo e la regulations. The cable enters the terminal board through a special cable
connessione deve avvenire tramite i morsetti. La tensione di alimentazione deve gland and is connected to the terminals. The voltage supplied to the motor must be
essere quella specificata nei dati di targa del motore. the same as the voltage specified on its identification plate.
La scatola della morsettiera contiene elementi metallici che si The housing for the terminal board contains metal components
trovano a tensione pericolosa; dopo avere effettuato i collegamenti carrying dangerously high voltage. Be sure to close the cover of the
richiudere sempre il coperchio della scatola. housing after wiring the terminal board.
Nella scelta del motore monofase è necessario considerare la minima Single-phase AC motors must be chosen that operate at the minimum
tensione di alimentazione di rete: tensioni troppo basse invalidano il voltage supplied by the power mains. The motor will not operate properly if
funzionamento del motore. the voltage is too low.
Collegamento valvola ad intervento elettrico Connecting electrically actuated valves

Nelle UP con valvole ad intervento elettrico, le bobine devono essere On PU with electrically actuated valves, the coils must be supplied with the
alimentate con le tensioni previste e con i seguenti limiti: -10+5% della prescribed voltages with the following limits: -10 to +5% of nominal
tensione nominale. Il superamento di tali limiti può compromettere il voltage. If these limits are exceeded, valve operation and coil life may be adversely
funzionamento delle valvole e la vita della bobina. affected.
Collegamento idraulico Hydraulic connection

Il collegamento idraulico deve essere eseguito con raccordi cilindrici e The hydraulic connection must be made with cylindrical fittings and copper
con guarnizione di tenuta in rame. Si consiglia di utilizzare raccordi sealing gaskets. We recommend using DIN 3852 fittings with UNI-ISO 228
secondo le norme DIN 3852 con filettature secondo le norme UNI-ISO threads and DIN 7603 gaskets. The ports on the PU and on the valve
228 e guarnizioni secondo le norme DIN 7603. Gli utilizzi della UP ed assemblies (if installed) are protected by plastic plugs that must be removed when
eventualmente dei blocchetti sono protetti da tappi in plastica, i quali devono the fittings are installed. Check the thread on the fittings, which must be clean and
essere rimossi al momento del montaggio dei raccordi. Controllare la filettatura without dents. Use rigid or flexible hoses whose internal diameter is the same as or
dei raccordi che deve essere pulita e senza ammaccature. Utilizzare tubazioni larger than the connecting orifices on the PU. The speed of the fluid in the hoses
rigide o flessibili con diametro interno corrispondente o superiore alle bocche di must be as follows:
collegamento dell’ UP, con riferimento ai seguenti parametri di velocità del
fluido entro le tubazioni : delivery (pressure): 4 to 6 m/sec. return (discharge): 1.5 to 3 m/sec.
mandata (pressione) 4 ÷ 6 m/s ritorno (scarico) 1,5 ÷ 3 m/s
Per tratti di tubazione di notevole sviluppo (oltre 3 m), i valori consigliati devono The recommended values must be increased if very long sections of hose (over 3
essere aumentati. m) are used.
La pulizia dell’ impianto è essenziale per il buon funzionamento dell’ UP. The system must be clean to obtain proper operation from the PU.
La Tab. seguente descrive le portate e i serraggi consigliati in riferimento alle The following table lists flow rates and tightening torque values for UNI-ISO 228
filettature GAS UNI-ISO 228 gas threads:
Portata (l/min) Filettatura Flow rate (l/min) Thread
<5 ÷ 10 G. 1/4 30 <5 to 10 G. 1/4 30
10 ÷ 20 G. 3/8 30 10 to 20 G. 3/8 30
>20 G. 1/2 30 >20 G. 1/2 30
Montaggio leva comando manuale Installation of manual pressure control group
Il gruppo leva è normalmente non montato: Usually, the manual pressure control group is not installed.
• ingrassare le parti interne del gruppo leva e della valvola sulla quale il • Grease the internal parts of the manual pressure control and the valve where
gruppo leva deve essere montato (grasso per guarnizioni); the unit will be installed (use gasket grease).
• introdurre il gruppo leva fino al contatto fra camma e perno; • Insert the lever until the cam hits the pin.
• orientare secondo esigenze e fissare con le due viti: 4 Nm. • Arrange as desired and fasten with the two screws: 4 Nm.
In caso di avaria (difficoltà di funzionamento, perdita olio, ecc..) In case of malfunction (difficult operation, oil leaks, etc.), remove the
smontare il gruppo leva a macchina ferma e non alimentata manual pressure control group from the machinery when it is shut down
elettricamente, con pressione “zero” nell’ impianto idraulico. with the power disconnected. Make sure the pressure in the hydraulic
Ogni intervento sulla UP deve essere eseguito a macchina ferma e system is zero.
non alimentata elettricamente, con pressione “zero” nell’ impianto All operations on the PU must be carried out with the machinery shut
idraulico. down and with the power disconnected. Make sure the pressure in the
hydraulic system is zero.
AVVIAMENTO START UP
Senso di rotazione, osservando la UP dal lato motore è orario CW (a meno che The direction of motor rotation is clockwise CW, as observed from the side of the
non sia stato specificato un senso di rotazione differente in fase di ordine e se PU where the motor is located (unless a different direction of rotation was
previsto dalla tipologia di flangia). I motori che devono essere sottoposti al specified on the order and the different direction is determined by the type of
controllo di rotazione sono tutti gli AC e i DC a magneti permanenti. È flange on the unit). The direction of rotation must be checked on all AC motors
preferibile controllare il senso di rotazione con motore smontato, oppure and on DC motors with permanent magnets. It is better to check the direction of
procedere nel seguente modo: rotation when the motor is not installed; or, proceed as follows:
• Collegare elettricamente il motore • Wire the motor as specified
• Regolare al minimo la VM • Adjust the RV to minimum
• Azionare l’ UP con brevissimi impulsi • Actuate the PU with very short pulses
• Ripristinare la VM • Adjust the RV for normal operation
Il senso di rotazione errato causa danni irreparabili alla pompa quando la If the motor rotates in the wrong direction, the pump may be permanently
stessa è in pressione. L' operazione di verifica del corretto collegamento damaged when it reaches operating pressure. The connections to the motor
elettrico e del corretto senso di rotazione del motore, deve essere ripetuta ogni and its direction of rotation must be checked every time the PU or the system is
volta che la UP o il sistema venga disconnesso dalla rete. disconnected from the power mains.
Una volta avviato l’ impianto controllare l’ esatto funzionamento di tutti i After the system is started, make sure all the controls operate properly.
comandi. Nei primi movimenti dello stesso, occorre effettuare lo sfiato When executing the first movements with the system, air must be bled from
dell’ aria contenuta nell’ impianto per evitare la formazione di schiuma the system to prevent foam forming in the tank and possible undesired and
nel serbatoio ed eventuali movimenti indesiderati ed incontrollati degli attuatori. uncontrollable movements of the actuators. Also, recheck the fluid level and top it
In contemporanea verificare di nuovo il livello del fluido e se necessario up if necessary. After the system has operated for a few hours, check the entire PU
ripristinarne il livello. Dopo qualche ora di funzionamento verificare l’ eventuale for fluid seepage, recheck the fluid level in the tank, and again look for foam in the
presenza di trafilamenti in tutta la UP, controllare ancora il livello del fluido nel tank.
serbatoio e l’eventuale presenza di schiuma.
RACCOMANDAZIONI TIPS
Leggere i capitoli: “Uso previsto dell’ Unità di Potenza”, “Limiti di impiego”, Read the following chapters: “Prescribed use of this Power Unit”, "Limits of Use”,
“Specifiche di sicurezza”, “Limiti di funzionamento”, “Installazione”. “Safety Specifications”, “Operational Limits”, “Installation”.
Nelle fasi sottodescritte si vuole consigliare una serie di operazioni da eseguire, The operations described below are the recommended way to start up the unit
per un corretto avviamento. properly.
Eseguire il riempimento del serbatoio con fluido idraulico nuovo e filtrato Fill the tank with new, filtered hydraulic fluid (see the chapter, “Choosing the
(vedere capitolo “Scelta del fluido idraulico”). Hydraulic Fluid”).
Scollegare la linea di pressione del cilindro e riporla all’ interno di un contenitore Disconnect the pressure hose from the cylinder and place it into a clean container.
pulito. Deve essere garantito che il fluido idraulico non possa finire negli Do not allow hydraulic fluid to flow into drains or discharge channels, or onto the
scarichi, nelle canalizzazioni o nel terreno. ground.
Avviare e spegnere il motore della UP con cicli ON/OFF di 1 s, procedere fino Turn the motor on the PU on and off at intervals of 1 sec. until hydraulic fluid is
alla fuoriuscita del fluido idraulico dalla linea di pressione. ejected from the pressure hose.
Ricollegare la linea di pressione al cilindro e rabboccare il serbatoio. Reconnect the pressure hose to the cylinder and top up the tank.
Effettuare diverse corse complete del cilindro per spurgare dall’ aria il circuito e Execute a number of complete cycles on the cylinder to purge the air from the
verificare di nuovo il livello del fluido idraulico. circuit and check the level of hydraulic fluid once again.
Controllare la taratura della VM. Make sure the RV is set correctly.
La maggior causa di rottura, cattivo funzionamento ed usura precoce dei sistemi The most common cause of breakage, poor operation and premature wear of
idraulici è lo scarso livello di pulizia, quindi all’assemblaggio, assicurarsi della hydraulic systems is lack of cleanliness. For this reason, make sure all hoses and
pulizia dei tubi, dei cilindri. cylinders are perfectly clean during assembly.
MANUTENZIONE MAINTENANCE
Il buon funzionamento della UP (e dell’ impianto) dipende anche da una corretta Proper operation of the PU (and of the system it is installed in) also depends on
manutenzione. Dopo un breve periodo di funzionamento verificare il corretto correct maintenance. After a short period of operation, make sure all the screws
serraggio delle viti e dei raccordi, poiché pulsazioni e vibrazioni possono causare and fittings are tight, since pulsation and vibration may cause these components to
allentamenti e conseguenti perdite o trafilamenti di fluido idraulico; a tale loosen, which may lead to leakage and seepage of hydraulic fluid. It is important
proposito è importante mantenere la UP pulita per individuare meglio detti to keep the PU clean so that leaks and seepage can be more easily seen. Only use
trafilamenti: per la pulizia utilizzare esclusivamente stracci puliti. clean cloths for cleaning.
Escludere assolutamente solventi o detergenti. Never use solvents or detergents.
Controllare il livello e lo stato del fluido idraulico, si consiglia di eseguire Check the level and the condition of the hydraulic fluid. We recommend
il primo cambio del fluido idraulico dopo le prime 10 ore di lavoro. changing the fluid the first time after the first 10 hours of operation.
Eseguire i successivi cambi ogni 3000 ore di lavoro ( o una volta all’ Afterwards, change the fluid every 3000 hours of operation (or once a
anno). year).
Ad ogni cambio del fluido idraulico sostituire il filtro d’ aspirazione (ed Whenever the hydraulic fluid is changed, replace the intake filter (and the other
eventualmente altri filtri) ed eseguire la pulizia interna del serbatoio, si consiglia filters, if installed) and clean the inside of the tank. It is a good idea to change the
di eseguire il cambio del fluido idraulico smontando direttamente il serbatoio fluid by removing the tank (see the chapters, " Removing and reinstalling the tanks
(vedere capitoli “Smontaggio dei serbatoi” e “Sostituzione del filtro”). " and “Replacing the Filter”).
Prima di effettuare il cambio del fluido idraulico svuotare completamente tutto l’ Before changing the hydraulic fluid, empty the entire system completely. The fluid
impianto. La frequenza del cambio del fluido idraulico sopra descritto è riferito a change interval described above applies at operating temperatures of 30° C to 60
temperature di esercizio comprese fra 30° ÷ 60°C (temperatura del fluido °C (temperature of the hydraulic fluid).
idraulico).
Temperature più elevate possono determinare una drastica riduzione delle Higher temperatures may seriously reduce the service life of the fluid.
caratteristiche di durata del fluido idraulico.
Sostituzione del filtro Replacing the filter

Il filtro può essere sostituito con uno stesso filtro nuovo oppure può essere lavato The filter can be replaced with a new filter of the same type or it can be washed,
e pulito, quindi riutilizzato (vedere “Specifiche di sicurezza”) cleaned and reused (see the section, "Safety Specifications").
Azioni da eseguire: Proceed as follows:
• svitare il filtro bloccando il tubo di aspirazione onde evitare lo svitamento • Unscrew the filter while holding on to the intake hose to prevent it from
dello stesso; unscrewing
• cambiare o pulire il filtro; • Clean or replace the filter
• avvitare il filtro percorrendo lo stesso tratto utile filettato del tubo, forzare • Screw the filter back into place onto the same section of threading on the
in modo da far compenetrare la filettatura metallica del filtro sul tubo. hose. Use enough force so that the metal thread on the filter is snugly seated
on the hose.
Smontaggio e rimontaggio dei serbatoi Removing and reinstalling the tanks

Smontaggio Removal
• svitare il sistema di fissaggio • Unscrew the mounting system
• sfilare il serbatoio senza l’ aiuto di leve che possono causare ammaccature • Pull out the tank, but without the aid of levers that could cause dents
Rimontaggio Reinstallation
• controllare la pulizia del serbatoio • Make sure the tank is clean
• verificare il buono stato della guarnizione di tenuta • Make sure the sealing gasket is in good condition
• verificare il buono stato della bocca del collare del serbatoio (pulito, senza • Make sure the opening on the collar of the tank is in good condition (it must
ammaccature, senza solchi anomali) be clean, free from dents and without unusual grooves)
• ingrassare la bocca del collare del serbatoio • Grease the opening on the collar of the tank
• introdurre il serbatoio • Install the tank
• Fissare il serbatoio stringendo le viti in modo uniforme • Secure the tank tightening the screw evenly
È consigliato ingrassare la bocca del serbatoio e non la guarnizione, in It is a good idea to grease the opening of the tank and not the gasket. The
questo modo l’ UP rimarrà più pulita, il grasso scorrerà verso l’ interno PU will be cleaner because the grease will flow toward the inside of the
del serbatoio. tank.
I serbatoi hanno differenti metodi di fissaggio The tanks have different mounting systems
Fissaggio diretto con filettatura diretta sul serbatoio Direct mounting using the threading on the tank (usually
(normalmente in lamiera) made of sheet metal)
M6 6 M6 6
Fissaggio con staffa (normalmente per serbatoi in PP) Mounting with a bracket (usually for PP tanks)
Fissaggio con fascetta (normalmente per serbatoi in PE) Mounting with a collar band (usually for PE tanks)
Avvitamento tappi sui serbatoi Screwing plugs into the tank

Tappi di plastica con chiave Filettatura 10 Plastic plug with key Thread 10
Tappi di plastica ad avvitamento manuale G. 1/2 A mano Manually tightened plastic plugs G. 1/2 By hand
Tappi metallici G. 3/4 30 Metal plugs G. 3/4 30
Serraggi consigliati Recommended tightening torque values

Nel caso si rendano necessari eventuali smontaggi e rimontaggi di componenti If components on the PU must be removed and reinstalled, tighten them at the
delle UP, nelle tabelle seguenti sono riportate le coppie di serraggio consigliate torque values listed on the following table:
Coppie di serraggio da applicare alle viti o ai tiranti per il montaggio dei motori Tightening torque values to be used on the screws or tie rods used to fasten motors
M8 M6 M5 1/4-20 UNC M8 M6 M5 1/4-20 UNC
25 10 6 10 25 10 6 10
Per le coppie di serraggio dei poli dei motori DC e dei teleruttori, For tightening torque values used on the terminals of DC motors and
vedere paragrafo “Collegamento elettrico per motore DC” start switches, see the paragraph, “Connecting a DC motor”
Coppie di serraggio da applicare sul corpo flangia Tightening torque values to be used on the flange body
3/4 -16 BSPP BSPP 3/4-16 BSPP BSPP
M6 M8 M10x1.5 M16x1.5 M6 M8 M10x1.5 M16x1.5
UNF 1/4 3/8 UNC 1/4 3/8
10 25 45 30 30 30 30* 10 25 45 30 30 30 30*
*= non applicabile nelle cavità di scarico del lato serbatoio *= not applicable in the discharge cavities on the tank side of the unit
I serraggi consigliati nella tabella sono considerati in riferimento al The recommended tightening torque values on the table are differentiated
materiale, al tipo di filettatura del corpo flangia e ai più comuni according to material and type of thread on the flange body and apply to the
componenti montabili. I serraggi non sono validi per altri componenti in components that are most commonly removed. The values do not apply to other
materiali diversi (plastiche) o componenti che hanno diverse possibilità di components made of different materials (plastic) or components that are tightened
avvitamento (come cacciaviti a taglio, croce o altro) o se diversamente using other methods (such as slot-head or Philips head screwdrivers, or other
specificato. I serraggi non sono validi per tappi e raccordi con filettature coniche. tools), or unless otherwise specified. The torque values do not apply to plugs and
fittings with tapered threads.
DEMOLIZIONE E SMALTIMENTO DISMANTLING AND DISPOSAL
Nel caso in cui la UP debba essere demolita la si dovrà svuotare dall’ olio If the PU must be dismantled, empty the fluid and dispose of it according to the
contenuto che verrà smaltito secondo le prescrizioni di legge in vigore nel Paese laws that apply in the country where it will be disposed of. The same holds true for
in cui avviene lo smaltimento. Lo stesso vale anche per le altre parti della UP, the other parts of the PU; that is, dispose of them according to the laws that apply
considerando la tipologia dei materiali che la compongono, plastici e ferrosi. to disposal of plastic and ferrous materials, as the case may be.
All' atto della Demolizione è necessario separare le parti in materiale plastico When dismantling the unit, separate the plastic parts from the electrical
dalla componentistica elettrica, che devono essere inviate a raccolta differenziata components, which must be disposed of separately in accordance with current
nel rispetto delle Normative vigenti. regulations.
Per quanto concerne la massa metallica della UP, è sufficiente procedere alla The large metal sections of the PU should be separated into parts made of steel and
suddivisione tra le parti in acciaio e quelle in altri metalli o leghe, per un corretto parts made of other metals or alloys, so that they can be correctly melted down for
invio al riciclaggio per fusione. L' operazione di demolizione non presenta rischi recycling. Dismantling is not a particularly risky operation, as long as it is
particolari, a condizione che sia effettuata da persone sufficientemente preparate performed by properly trained personnel using adequate tools (see the chapter,
e dotate di mezzi adeguati (vedere capitolo “Specifiche di sicurezza”). “Safety Specifications”).
We live our values.
Excellence • Passion • Integrity • Responsibility • GEA-versity
GEA Group is a global engineering company with multi-billion euro sales and operations in more
than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and
process technology. GEA Group is listed in the STOXX® Europe 600 Index.
GEA Italy
Via A. M. Da Erba Edoari, 29 Phone + 39 0521 965411

43123 Parma (Italy) Fax +39 0521 242819 gea.com/contact

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GEA Ariete Homogenizer 5200

REV. DESCRIPTION DATE SIGN

00 First issue 15/01/2018 ANC

GEA Mechanical Equipment Italia S.p.A.

How to use the manual

This manual is made of separate sections as indicated in the list of CONTENTS.

1.0. MACHINE DESCRIPTION

1.0.1 General description

1.0.2 Operation principle

The machine’s operation principle is shown in the diagram below.

Components of homogenizer machine

Standard units Notes

2) Homogenizing unit –stage 1

3) Head pressure gauge

4) Head safety valve

6) Lubrication system Option for NS2006 / NS3006

7) Water system (*)

8) Pneumatic system (*) Option for NS2006 / NS3006

10) Motor drive

11) Cover panels

12) Control panel

13) On-machine electrical system

A Homogenizing unit –stage 2

B Pressure gauge -stage 2

C Suction pressure gauge

D Delivery pressure gauge (*)

E Delivery safety valve (*)

F Suction buffer unit

G Delivery buffer unit (*)

H Partial aseptic system (*)

I Full aseptic system (*)

GEA NIRO SOAVI MACHINE TECHNICAL TT-0120C

3 TECH FEATURES - COMPRESSION HEAD

GEA NIRO SOAVI MACHINE TECHNICAL TT-0120C

4 TECH FEATURES - CONNECTIONS & ACCESSORIES

5 TECH FEATURES - PRESSURE GAUGES

6 TECH FEATURES - HOMOGENIZING VALVES

7 TECH FEATURES - DRIVE END

8 TECH FEATURES - LUBRICATION

9 TECH FEATURES - ELECTRICAL SUPPLY

1. INSTRUMENT SYMBOLS 5. MACHINERY AND EQUIPMENT

LOCAL AUTOMATIC ACTUATOR FOR REMOTE

COMPRESSOR OR VACUUM PUMP,

SUPPLY LIMIT MARKER

PUMP FOR LIQUIDS GENERAL

3. INSTRUMENT SIGNAL LINES

PNEUMATIC 1-STEP HOMOGENIZER

HYDRAULIC 2-STEP HOMOGENIZER

HEAT EXCHANGER WITHOUT CROSS

6. LETTER CODE FOR IDENTIFICATION OF INSTRUMENT FUNCTIONS

FIRST LETTER SUCCEEDING LETTER (1)

EXAMPLE : PDIRC DIFFERENTIAL PRESSURE INDICATION, RECORDING AND CONTROL

1) NORMAL SEQUENCE OF SUCCEEDING LETTERS : B.I.R.C.T.Q.S.Z.A.

5) A NOTE SPECIFIES THE MEASURED PROPERTY. E.g. FOR LETTER E, I, U, P OR F

LEAVE AT LEAST 1m FROM EACH SIDE OF THE MACHINE

OVERALL DIMENSIONS (mm) K = ± 25 mm

ITEM DESCRIPTION CONNECTION

01 ADDED UTILIES A3O

NS5180H 14381 DD 26.10.18 0

M-O 9562-0228-517 IEC-CENELEC 50 4 200 369,2 2363 0,86 95,7 B3

FORNITO NO Quadro Elettrico

Deactivate YV-A, YV-A1LR,

Inductive Sensor No Light ON SLRV-PO cont. open Yes