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VARVEL
ATEX Manual

ATEX Manual

Product catalog summary

General Information
Varvel speed reducers and variators are classified as machinery components and must comply with essential health and safety requirements. They are designed to be incorporated into machinery, and proper operation and servicing require adherence to the manual's instructions.

Safety Warnings
Gearboxes and variators may heat up during operation. Handling, assembly, and maintenance must be performed by trained personnel following the manual and safety regulations.

Product Layout
The document details layouts for various gearbox series, including Series RC, RD, RG, RN, RO, RV, RP, XA, RS, and RT, each with specific structural components like input shafts, bearings, gears, and oil seals.

Installation
Installation requires attention to tolerances, precautions, and proper groundwork. Components such as pinions, couplings, and torque arms must be correctly installed, and painting should be considered.

Starting
Instructions for starting different series emphasize the need for correct setup and operation.

Inspections and Maintenance
Regular maintenance intervals and services are outlined to ensure optimal performance and longevity of the gearboxes.

Malfunctioning
Guidance is provided for addressing major malfunctions and accessing customer service support.

Lubricants
Recommended lubricant types and quantities are specified to maintain efficient operation.

Directive 2014/34/UE (ATEX)
The document includes information on compliance with the ATEX directive, ensuring safety in potentially explosive environments.

Declaration of Conformity
A declaration of conformity is included, affirming compliance with relevant standards and directives.

Specifications
The document outlines the components and structure of torque limiters and flange-mounted variators, specifying parts like screws, bearings, oil seals, and friction rings.

Installation Instructions
Recommendations for tolerances are provided according to DIN 748 standards, with precautions for correct sizing, mounting position, stability, and hoisting methods.

Maintenance Guidelines
Details maintenance intervals and procedures, emphasizing not running units at maximum load initially and providing guidelines for lubricant checks and replacements.

Lubricants
Recommendations for synthetic long-life oils are provided, with specific quantities for different gearbox models, advising against mixing synthetic and mineral-based lubricants.

Malfunctioning and Troubleshooting
Common issues such as running noise, oil leakages, and non-rotation of output shafts are addressed with solutions like replacing damaged parts and contacting customer service.

ATEX Directive Compliance
Includes general information on the ATEX Directive 2014/34/EU, safety instructions, marking requirements, maintenance servicing, and temperature classifications for gas.

Overview
This document provides technical specifications, safety instructions, and maintenance guidelines for VARVEL-ATEX gearboxes, designed for use in potentially explosive atmospheres.

Specifications
VARVEL-ATEX gearboxes are manufactured with metallic housings and covers, incorporating transmission elements on ball and roller bearings with Viton oil seals, complying with Directive 2014/34/EU and relevant standards.

Temperature Guidelines
Proper ventilation is crucial to ensure the housing temperature does not exceed 55°C, with a maximum temperature difference of 80°C between housing and ambient.

Safety Instructions
All components, including electric motors, must be ATEX approved. Regular cleaning is necessary to prevent dust accumulation, and gearboxes must be earthed if not mounted on a metal surface.

ATEX Marking
VARVEL Series are marked for Group II, Category 2, suitable for Zones 1 and 2 (gas) and Zones 21 and 22 (dust), with IP66 protection and a maximum surface temperature of 135°C.

Maintenance
Maintenance intervals are critical for ensuring explosion-proof protection, with regular dust removal, monthly oil seal inspections, and synthetic oil replacement every five years.

Gas Temperature Class
Lists various gases and their temperature classifications, indicating the suitability of VARVEL products for different explosive atmospheres.

Declaration of Conformity
Includes a specimen declaration of conformity, affirming compliance with Directive 2014/34/EU and relevant standards, with technical files deposited at INERIS, France.

Global Presence
VARVEL has subsidiaries in India and the USA, with a global network of over 100 commercial partners, reflecting its international success and over 60 years of history.

Catalog excerpts

WORKING INSTRUCTIONS AND MAINTENANCE ATEX MANUAL

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Experience at the service of innovation The Varvel Group has been designing and producing power transmission systems for numerous areas of industry since 1955. “Know-how to do it”: Varvel has the know-how needed to satisfy customers’ requests in the best way possible. Thanks to over sixty years of accumulated experience, Varvel can offer customers a vast range of standard solutions and customise products for speciﬁc needs. The entire product range is designed and made in Italy and sold worldwide through two subsidiaries (in the USA and India) and a global network of over 100 commercial partners....

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IUM - WORKING INSTRUCTIONS AND MAINTENANCE - ATEX MANUAL

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Working Instructions & Maintenance General Information - Safety Warnings - Product Layout GENERAL INFORMATION Varvel speed reducers and variators are not in the field of application of the Machinery Directive 2006/42/CE as considered “machinery components”. Guide of Machinery Directive - § 35 - decrees: "The Machinery Directive does not apply directly to machinery components, such as, for example, valves, hydraulic cylinders or gearboxes, that do not have a specific application as such but are intended to be incorporated into machinery, although the design and construction of such components...

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“G” Working Instructions & MaintenanceFlexible coupling “ A) Reducer half-coupling - Material: steel alloy - One piece built-in input shaft - Two bearing mounting - Unchanged casing dimensions B) Spider - Material: Thermoplastic Elastomer IXEF® - Polyarylamide - Hardness : 90 Shore D - Temperature -30/+135° C(-22/+275°F) - External tooth connection The flexible coupling “G” is supplied as standard fitting on the Series RD, RN, RO, RV, RP, RS, RT. C) Motor half-coupling - Materials: Aluminium die cast (G3, G5, G6) Alloy steel (GS3, GS5, GS6, GS8) - Dynamic balancing - Fitting: Clamp (G3, G5,...

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Working Instructions & Maintenance RC-2Series RC - 2 stages The layout shows the general structure of a two-stage foot-mounted helical gearbox type FRC (sizes 05 to 30). Ask for part list of other sizes 40 to 60, flanged output, input solid shaft and four stage executions. Oil seal Housing Key Output shaft Key Bearing Spacer Gasket Bearing Pinion Key Hollow input Bearing Bearing Pinion Key Gear Bearing Bearing Gear IEC input cover Hollow input Oil seal

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RC-3 Working Instructions & Maintenance Series RC - 3 stages The layout shows the general structure of a two-stage foot-mounted helical gearbox type FRC (sizes 05 to 30). Ask for part list of other sizes 40 to 60, flanged output, input solid shaft and four stage executions. Spacer (RC40, 50, 60) Gear Housing Gasket Parallel pin Input cover Circlip Pinion Key Input hollow shaft, stud Circlip Oil seal Output shaft Intermediate housing Circlip Key Pinion Parallel pin Gasket Bearing Bearing Pinion

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Working Instructions & Maintenance RD-2Series RD - 2 stages The layout shows the general structure of a two-stage foot-mounted helical gearbox type FRD. Ask for part list of flanged output and input solid shaft. Input cover Hollow input IEC Hollow input “G” 3rd stage shaft Pinion Gear Bearing Bearing Bearing Bearing Spacer Oil seal Gear Spacer Circlip Bearing Bearing Bearing Bearing Oil seal Gasket Motor Flange

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RD-3 Working Instructions & Maintenance Series RD - 3 stages The layout shows the general structure of a three-stage Ask for part list of flanged output and input solid shaft. foot-mounted helical gearbox type FRD. Input cover Hollow input IEC Hollow input “G” 3rd stage shaft Pinion Gear Bearing Bearing Bearing Bearing Spacer Oil seal Pinion Gear Housing Upper cover Output shaft Pinion Gear Spacer Spacer Bearing Bearing Bearing Bearing Oil seal Gasket Motor flange

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Working Instructions & Maintenance Series RG - 1 stage The layout shows the general structure of a one-stage planetary gearbox type FRG. Ring gear body Motor flange Planet gear Needle bearing Input flange Planet shaft Planet carrier Clamp coupling Snap ring Input shaft

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Working Instructions & Maintenance Series RG - 2 stages The layout shows the general structure of a two-stage planetary gearbox type FRG. Ring gear body Snap ring Motor flange Planet gear Needle bearing Input flange Planet shaft Snap ring Planet carrier Planet gear Clamp coupling Needle bearing Planet shaft Input shaft Planet carrier

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Working Instructions & Maintenance Series RN - 2 stages The layout shows the general structure of a two-stage parallel shaft gearbox type FRN with through hollow output shaft. Ask for part list of flanged output and input solid shaft. Input flange Snap ring Snap ring Input shaft Snap ring Snap ring Snap ring Output shaft

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RN-3 Working Instructions & Maintenance Series RN - 3 stages The layout shows the general structure of a two-stage parallel shaft gearbox type FRN with through hollow output shaft. Ask for part list of flanged output and input solid shaft. Motor flange Oil seal Snap ring Bearing Input shaft Bearing Pinion Cover Bearing Gear Spacer Key Shaft Bearing Snap ring Pinion Oil seal RCA Snap ring Bearing Pinion Key Bearing Spacer Gear Snap ring Oil seal Snap ring Bearing Spacer Gear Output shaft Key Body Bearing Snap ring Oil seal

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Working Instructions & Maintenance RO-2 Series RO - 2 stages The layout shows the general structure of a two-stage bevel/helical gearbox type FRO with through hollow output shaft. Ask for part list of flanged output and input solid shaft. Motor flange Input shaft Oil seal Circlip Spacer Bearing Gleason pinion Oil seal Circlip Bearing Spacer Gleason gear Spacer Key Pinion Housing Bearing Circlip Oil seal Oil seal Circlip Bearing Output shaft Key Gear Circlip Bearing Circlip Oil seal Plug Cover Screw Gasket

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Working Instructions & Maintenance Series RO - 3 stages The layout shows the general structure of a three-stage bevel/helical gearbox type FRO with through hollow output shaft. Ask for part list of flanged output and input solid shaft. Motor flange Output shaft Snap ring Snap ring Input shaft Snap ring Snap ring Snap ring Snap ring

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