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Wittenstein Alpha TK PLUS ATEX Operating Manual

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2022-D034859
02a
+
TK
ATEX
Operating Manual
2022-D034859
Revision: 02a

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Summary of Contents for Wittenstein Alpha TK PLUS ATEX

  • Page 1 2022-D034859 ATEX Operating Manual 2022-D034859 Revision: 02a...
  • Page 2 E-mail: service-alpha@wittenstein.de © WITTENSTEIN alpha GmbH 2012 This documentation is copyright protected. WITTENSTEIN alpha GmbH reserves all the rights to photo-mechanical reproduction, copying, and the distribution by special processes (such as computers, file media, data networks), even in parts. Subject to technical and content changes without notice..

  • Page 3: Table Of Contents

    ATEX Contents Regarding this manual..................3 1.1 Signal words ......................3 1.2 Safety symbols.....................3 1.3 Design of the safety instructions ................4 1.4 Information symbols .....................4 Safety........................5 2.1 EC directive for devices and protective systems in areas with explosion hazards ....................5 2.2 Dangers .......................5 2.3 Personnel ......................5 2.4 Intended use ......................5 2.5 Reasonably predictable misuse ................6...
  • Page 4 ATEX 9.2 Specifications on mounting onto a machine............22 9.3 Specifications on mounting on the gear output side.......... 22 9.4 Tightening torques for common thread sizes in general mechanics ....22 9.5 Technical specifications ................... 23 9.5.1 Technical specifications for TK 004 for use in areas with explosion hazards..................

  • Page 5: Regarding This Manual

    ATEX Regarding this manual Regarding this manual These instructions contain necessary information for the safe operation of the angle gear TK areas with explosion hazards, referred to as gearhead in the following. The operator must make sure that this operating manual is read through by all persons assigned to install, operate, or maintain the gearhead, and that they understand them.

  • Page 6: Design Of The Safety Instructions

    Regarding this manual ATEX Design of the safety instructions The safety instructions of this operating manual are designed according to the following pattern: A = Safety symbol (see Chapter 1.2 "Safety symbols") B = Signal word (see Chapter 1.1 "Signal words") C = Type and consequence of the danger D = Prevention of the danger Information symbols...

  • Page 7: Safety

    ATEX Safety Safety These instructions, especially the safety instructions and the rules and regulations valid for the operating site, must be observed by all persons working with the gearhead. In addition to the safety specifications mentioned in this operating manual, the general and also the local regulations on the prevention of accidents and on environmental protection should be observed.

  • Page 8: Reasonably Predictable Misuse

    - Operating the gearhead in an atmosphere whose ignition temperature lies under the temperature class specified on the type plate. - Modifications or reconstructions that have been executed without written approval of WITTENSTEIN alpha GmbH General safety instructions Operating the gearhead in areas for which it is not approved can lead to explosions that can cause serious injuries and even death.
  • Page 9 ATEX Safety Table "Tbl-1" lists a summary of the possible hazards, their causes and protective measures for areas with explosion hazards. Dangers Possible causes Protective measures Hot surfaces Increased friction and dissipated Reduction of the torques and power because of wear, improper speeds in comparison to standard assembly, overload, or leaks.
  • Page 10 Safety ATEX Objects flung out by rotating components can cause serious injuries. Remove objects and tools from the gearhead before putting it into  operation. Rotating components on the gearhead can pull in parts of the body and cause serious injuries and even death. Keep a sufficient distance to rotating machinery while the gearhead is ...

  • Page 11: Description Of The Gearhead

    SN: 1234567 DMF: 34/08 Made in Germany T : 480 Nm / n : 2500rpm 1max WITTENSTEIN alpha GmbH - Walter-Wittenstein-Str.1 - 97999 Igersheim Ordering code (see Chapter 3.2 Production date "Ordering code") Ratio Maximum permitted gear output torque Lubricant...

  • Page 12: Atex Identification In Gas Atmospheres With Explosion Hazard

    Description of the gearhead ATEX 3.1.1 Atex identification in gas atmospheres with explosion hazard Designation Group, category II 2 G c k IIC T3 X Type of ignition protection, explosion group, temperature class Ambient temperature Tbl-3: Type plate (sample values) 3.1.2 Atex identification in dust-air atmosphere with explosion hazard Designation Group, category...

  • Page 13: Dimensioning

    - Use sealing plates between motor flange and adapter plate to seal the through-holes of the adapter plate. Sealing plates are available upon request from WITTENSTEIN alpha GmbH. Weight The table "Tbl-5" specifies the gearhead dimensions with medium-sized adapter plate. If another adapter plate is mounted, the actual dimensions can deviate by up to 10%.

  • Page 14: Transport And Storage

    Check the completeness of the delivery against the delivery note.   Missing parts or damage must be notified immediately in writing to the carrier, the insurance, or WITTENSTEIN alpha GmbH. Packaging The gearhead is delivered packed in foil and cardboard boxes.

  • Page 15: Assembly

    ATEX Assembly Assembly Be informed of the general safety instructions before beginning work. (see Chapter 2.7  "General safety instructions"). Preparations Pressurized air can damage the gearhead seals. Do not use pressurized air to clean the gearhead.  Directly sprayed cleaning agents can alter the frictional values of the clamping hub.
  • Page 16 Assembly ATEX If the motor shaft has a feather key, remove the  feather key.  If recommended by the motor manufacturer, apply a half wedge. Remove the plug (D) from the mounting bore in the  adaptor plate (B). Under no circumstance remove the plug (E) in the ...

  • Page 17: Mounting Gearhead On A Machine

    ATEX Assembly Width across flats [mm] Tightening torque [Nm] Tbl-7: Torques for the plugs Gearhead size TK ± 0,25 ± 0,3 ± 0,4 ± 0,5 ± 0,6 Axial offset [mm] Angle offset [°] Tbl-8: Permissible offset of the coupling, gearhead singlestaged (MF1) Mounting gearhead on a machine Observe the safety and processing instructions of the screw-bonding ...

  • Page 18: Startup And Operation

    Startup and operation ATEX Startup and operation Be informed of the general safety instructions before beginning work. (see Chapter 2.7  "General safety instructions"). Operating the gearhead in areas for which it is not approved can lead to explosions that can cause serious injuries and even death. Make sure that the gearhead is only used in those areas for which it is ...

  • Page 19: Inadmissible Operational Conditions

    - Co-riding the gearhead on the drive axle is prohibited. Exceptions require a written approval and technical statement from WITTENSTEIN alpha GmbH. - Use during permanent operation (S1 operation: power-on time greater than 60% or longer than 20 minutes)

  • Page 20: Maintenance And Disposal

    "Cymex®" design or total catalogue: Chapter "Information" or "Detailed construction"). - At the latest after a total of 20,000 operating hours.  Alternatively, the gearhead can be checked by WITTENSTEIN alpha GmbH and if necessary, released for further operation. en-18...

  • Page 21: Startup After Maintenance Work

    ATEX Maintenance and disposal Startup after maintenance work Clean the outside of the gearhead.  Attach all safety devices.  Do a trial run before releasing the gearhead again for operation.  Maintenance schedule Maintenance work After After every 500 Every 5,000 Every 10,000 initial...

  • Page 22: Malfunctions

    Malfunctions ATEX Malfunctions Changed operational behavior can be an indication of existing damage to the gearhead or cause damage to the gearhead. Do not put the gearhead back into operation until the cause of the  malfunction has been rectified. Rectifying of malfunctions may be done by only by especially trained technicians.

  • Page 23: Appendix

    ATEX Appendix Appendix Specifications on mounting onto a motor Designation Clamping bolt Clamping ring (part of the clamping hub) Bushing Shaft Tbl-11: Arrangement of motor shaft, clamping hub, and bushing Gearhead Clamping Clamping bolt Width Tightening max. axial force size hub interior (H)/ property across...

  • Page 24: Specifications On Mounting Onto A Machine

    Appendix ATEX Specifications on mounting onto a machine Through-holes in gearhead housing Size / Hole circle Ø Quantity x For screw size/ Tightening torque Version diameter property class [mm] [Nm] [ ] x [mm] 8 x 4,5 M4 / 12.9 4,55 8 x 5,5 M5 / 12.9...

  • Page 25: Technical Specifications

    ATEX Appendix Technical specifications 9.5.1 Technical specifications for TK 004 for use in areas with explosion hazards Technical specifications for TK 004, 1-stage Ratio Max. acceleration torque T (max. 1000 cycles per hour) in.lb 17.5 17.5 17.5 Nominal torque at gear output T (At n in.lb (1000 times...
  • Page 26 Appendix ATEX Technical specifications for TK 004, 1-stage Ratio 0.57 0.46 0.41 0.37 0.35 Mass moment of inertia J kgcm referring to the drive; 0.50 0.41 0.36 0.33 0.31 in.lb.s Bore diameters of the clamping hub: 14 mm 0.92 0.82 0.76 0.72 0.70...

  • Page 27: Technical Specifications For Tk + 010 For Use In Areas With Explosion Hazards

    ATEX Appendix Technical specifications for TK 004, 2-stage Ratio Weight incl. standard adapter plate m ≤ 64 Noise level L dB(A) =3000 rpm w/o load) Max. permissible °C housing temperature 0 to +40 Ambient temperature °C 32 to 104 Blue RAL 5002 Paint Drive and gear output counter-directional Direction of rotation...
  • Page 28 Appendix ATEX Technical specifications for TK 010, 1-stage Ratio 2350 Max. axial force F 2AMax 2800 Max. radial force F 2RMax Max. tilting moment M 2KMax 2655 in.lb 7.1.4 "Replacing the See chapter Life L gearhead" Calculation see "Technical Basics" Weight incl.
  • Page 29 ATEX Appendix Technical specifications for TK 010, 2-stage Ratio 4000 4000 4000 4000 4000 4000 4000 4000 4000 4000 Max. continuous speed (At 20% T 1Ncym 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 Max. drive speed n 1Max Average no-load running torque T...

  • Page 30: Technical Specifications For Tk + 025 For Use In Areas With Explosion Hazards

    Appendix ATEX 9.5.3 Technical specifications for TK 025 for use in areas with explosion hazards Technical specifications for TK 025, 1-stage Ratio Max. acceleration torque T (max. 1000 cycles per hour) 1106 1106 1106 in.lb Nominal torque at gear output T (At n in.lb (1000 times...
  • Page 31 ATEX Appendix Technical specifications for TK 025, 1-stage Ratio 5.46 4.26 3.63 3.13 2.87 Mass moment of inertia J kgcm referring to the drive; 4.83 3.77 3.22 2.77 2.54 in.lb.s Bore diameters of the clamping hub: 28 mm 12.7 11.5 10.9 10.4 10.1...

  • Page 32: Technical Specifications For Tk + 050 For Use In Areas With Explosion Hazards

    Appendix ATEX Technical specifications for TK 025, 2-stage Ratio 10.6 Weight incl. standard adapter plate m ≤ 66 Noise level L dB(A) =3000 rpm w/o load) Max. permissible °C housing temperature 0 to +40 Ambient temperature °C 32 to 104 Blue RAL 5002 Paint Drive and gear output counter-directional...
  • Page 33 ATEX Appendix Technical specifications for TK 050, 1-stage Ratio Torsional rigidity C Nm/arcmin in.lb/arcmin 6900 Max. axial force F 2AMax 1553 6600 Max. radial force F 2RMax 1485 1180 Max. tilting moment M 2KMax 10443 in.lb 7.1.4 "Replacing the See chapter Life L gearhead"...
  • Page 34 Appendix ATEX Technical specifications for TK 050, 2-stage Ratio 4500 4500 4500 4500 4500 4500 4500 4500 4500 4500 Max. drive speed n 1Max Average no-load running torque T 15.0 in.lb =3000 rpm and 20°C gearhead temperature) ≤ 4 Max. torsional backlash arcmin Torsional rigidity C arcmin...

  • Page 35: Technical Specifications For Tk + 110 For Use In Areas With Explosion Hazards

    ATEX Appendix 9.5.5 Technical specifications for TK 110 for use in areas with explosion hazards Technical specifications for TK 110, 1-stage Ratio Max. acceleration torque T (max. 1000 cycles per hour) 3540 3540 3540 3098 2655 in.lb Nominal torque at gear output T (At n 2213 2213...
  • Page 36 Appendix ATEX Technical specifications for TK 110, 2-stage Ratio Max. acceleration torque T 3540 3540 3540 3540 3540 3540 3540 3540 3098 2655 in.lb (max. 1000 cycles per hour) Nominal torque at gear output T 2213 2213 2213 2213 2213 2213 2213 2213 2036 1947 in.lb (At n Emergency-stop torque...

  • Page 37: Lubricant Quantity

    ATEX Appendix Technical specifications for TK 110, 2-stage Ratio 0 to +40 Ambient temperature °C 32 to 104 Blue RAL 5002 Paint Drive and gear output counter-directional Direction of rotation IP 65 Protection class 16.8 14.8 12.9 12.3 11.2 10.9 10.3 10.1 10.0 Mass moment of inertia kgcm 14.8 13.1 11.4 10.9...

  • Page 38: Declaration Of Conformity

    Appendix ATEX Declaration of Conformity en-36 2022-D034859 Revision: 02a...
  • Page 39 ATEX Appendix Revision: 02a 2022-D034859 en-37...
  • Page 40 2022-D016962 : 01 WITTENSTEIN alpha GmbH · Walter-Wittenstein-Straße 1 · 97999 Igersheim · Germany Tel. +49 7931 493-12900 · info@wittenstein.de WITTENSTEIN - being one with the future www.wittenstein-alpha.de enAC: XXXXXXXX 2022-D016962 Revision: 01...

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