Wittenstein Alpha Advanced TP+ Series Operating Manual
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Wittenstein Alpha Advanced TP+ Series Operating Manual

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alpha Advanced Line
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TP
ATEX
Operating Manual
2022-D020259
Revision: 04

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  • Page 1 alpha Advanced Line ATEX Operating Manual 2022-D020259 Revision: 04...
  • Page 2 +41 81 300 10 30 info@wittenstein.tw +886 3 287 0191 WITTENSTEIN Güç Aktarma Türkiye info@wittenstein.com.tr +90 216 709 21 23 Sistemleri Tic. Ltd. Şti. © WITTENSTEIN alpha GmbH 2019 Subject to technical and content changes without notice. 2022-D020259 Revision: 04...

  • Page 3: Table Of Contents

    ATEX Table of Contents About this manual ....................3 1.1 Information symbols and cross references ............3 1.2 Scope of delivery ....................3 Safety........................4 2.1 EC/EU Directive ....................4 2.1.1 Machinery Directive..................4 2.1.2 EU directive for devices and protective systems in potentially explosive atmospheres ..............4 2.2 Personnel ......................4 2.3 Intended use ......................5 2.4 Reasonably foreseeable misuse ................6...
  • Page 4 ATEX Maintenance and disposal................22 7.1 Maintenance schedule ..................22 7.2 Maintenance work ..................... 22 7.2.1 Visual/Noise inspection................. 22 7.2.2 Checking the tightening torques ..............23 7.2.3 Replacing the gearbox.................. 23 7.3 Startup after maintenance work ................ 23 7.4 Disposal......................23 Disassembly.......................

  • Page 5: About This Manual

    A cross reference on a table refers to the table number (e. g. Table "Tbl-15"). Scope of delivery 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 company, or WITTENSTEIN alpha GmbH. Revision: 04 2022-D020259 en-3...

  • Page 6: Safety

    Only carry out modifications or reconstructions when these are approved in writing by the  WITTENSTEIN alpha GmbH. Personal injuries or material damage, or other claims arising from non-observance of these minimum requirements, are the sole responsibility of the operator.

  • Page 7: Intended Use

    ATEX Safety Intended use The gearbox serves to convert torques and speeds. It is suitable for all industrial applications. The gearbox can be used in the potentially explosive atmospheres defined in Chapter 3.4 "Ex model". Observe the instructions on the name plate and the appendix on the written ...

  • Page 8: Reasonably Foreseeable Misuse

    Safety ATEX Reasonably foreseeable misuse Any use that deviates from the approved technical data (e.g. speed, force, torque, temperature, service life) is not use as intended and is therefore not permitted (also see Chapter 3.5 "Dimensions and performance data"). General safety instructions The operation of the gearbox involves residual risks even when adhering to the intended use.

  • Page 9: Structure Of Warning Instructions

    ATEX Safety Dangers Possible causes Protective measures Hot surfaces Increased friction and dissipated Reduce torques and speeds power because of wear, improper compared to standard gearboxes assembly, overload or leaks. Limit the motor current and maximum speed of the motor Maintenance intervals for wear parts and lubricant according to maintenance schedule...

  • Page 10: Safety Symbols

    Safety ATEX 2.6.1 Safety symbols The following safety symbols are used to indicate possible hazards, prohibitions, and important information: General hazard Hot surface Suspended loads Entanglement Environmental Information Explosion protection 2.6.2 Signal words The following signal words are used to indicate possible hazards, prohibitions, and important information: This signal word indicates an imminent danger that will cause serious injuries or even death.

  • Page 11: Description Of The Gearbox

    ATEX Description of the gearbox Description of the gearbox The gearbox is a single- or multi-stage low-backlash gear that can be used in any mounting position. Various types of motors can be accommodated using an adapter plate and, where necessary, a bushing.

  • Page 12: Name Plate

    SN: 1234567 DMF: 29/19 Made in Germany T : 496 Nm / n : 4000 rpm 1max WITTENSTEIN alpha GmbH - Walter-Wittenstein-Str.1 - 97999 Igersheim Ordering code (see Chapter 3.3 Production date CW/YY "Ordering code") Maximum permitted gear output Ratio i...

  • Page 13: Ordering Code

    ATEX Description of the gearbox Ordering code xxxxxxx x - x x x - xxxxx - x x x - x x xxxxx Product type optional Characteristic Motor connection Gearbox variant Generation Gearbox model Backlash Number of stages Clamping hub diameter Ratio Output shape More information is available in our catalog or at www.wittenstein-alpha.de.

  • Page 14: Dimensioning

    The following conditions apply to this dimensioning: Use the dimensioning information specified in the "Information" or "Detailed  dimensioning" chapter of the general catalog, or contact WITTENSTEIN alpha GmbH. During dimensioning, note the reduced performance data in Chapter 10.6 ...

  • Page 15: Transport And Storage

    ATEX Transport and storage Transport and storage Packaging The gearbox is delivered packed in foil and cardboard boxes. Dispose of the packaging materials at the recycling sites intended for this purpose. Observe  the applicable national regulations concerning disposal. Transport Suspended loads can fall and can cause serious injuries and even death.

  • Page 16: Assembly

    Assembly ATEX Assembly Read the general safety instructions before beginning to work (see Chapter 2.5 "General  safety instructions"). If you have questions about correct mounting, consult our Customer Service department.  Preparations Pressurized air can damage the gearbox seals. Do not use pressurized air to clean the gearbox.

  • Page 17: Installation Conditions

    Place an appropriate sealing ring between adapter plate and motor for  gearboxes in Hygienic Design to avoid leaks.  In addition, WITTENSTEIN alpha GmbH offers a suitable sealing plate. The tightening torque value [TA] of the clamping bolt [H] can be found on the clamping hub [C].

  • Page 18: Mounting The Gearbox On A Machine

    Assembly ATEX  If the clamping bolt [H ] is loosened too far or removed, the clamping ring [I] can rotate on the clamping hub. Align it so that the clamping bolt [H ] is in the keyway of the clamping hub (see table "Tbl-8").

  • Page 19: Mounting With Through-Holes

    (doc. no. 2022–D063351) applies for this. The manual will be provided by our Sales / Customer Service department on request. Please always provide the serial number.  WITTENSTEIN alpha GmbH offers corresponding mounting kits for gearboxes in Hygienic Design. The separate instructions "Hygienic Design Instruction Sheet, Mounting Kit" (Doc. no.

  • Page 20: Mounting With Threaded Bores

    Assembly ATEX Slide the washers onto the fastening screws.  Fasten the gearbox to the machine with the  fastening screws through the slotted holes [M]. Pinning the mounted and aligned gearbox (optional) Optionally, there are two bore holes [N] on the gear housing for pinning the gearbox to the machine.

  • Page 21: Mounting With Shrink Disk

     WITTENSTEIN alpha GmbH offers corresponding mounting kits for gearboxes in Hygienic Design. The separate instructions "Hygienic Design Instruction Sheet, Mounting Kit" (Doc. no. 2022–D062618) are valid for this. The manual will be provided by our Sales / Customer Service department on request.

  • Page 22: Startup And Operation

    Startup and operation ATEX Startup and operation Read the general safety instructions before beginning to work (see Chapter 2.5 "General  safety instructions"). Operating the gearbox in areas for which it is not approved can lead to explosions that may cause serious injuries and even death. Ensure that the gearbox is only used in those areas for which it is ...

  • Page 23: Checking Run-In Behavior

    ATEX Startup and operation Checking run-in behavior Make sure there is no explosive atmosphere during the test.  After 4 running hours in maximum operating conditions, check the gearbox for leakage  between gear and motor and on the output shaft seal. Measure the surface temperature at two points on the gear housing (on near the drive ...

  • Page 24: Maintenance And Disposal

    Maintenance and disposal ATEX Maintenance and disposal Read the general safety instructions before beginning to work (see Chapter 2.5 "General  safety instructions"). Secure the higher-level machine against restarting and unintentional movements during  assembly and maintenance work (e.g. uncontrolled lowering of lifting axes). Maintenance schedule Maintenance work At startup...

  • Page 25: Checking The Tightening Torques

    " design). - At the latest after a total of 20,000 operating hours.  Alternatively, the gearbox can be checked by WITTENSTEIN alpha GmbH and if necessary, approved for further operation.  For removal of the gearbox, please also refer to the Chapter 8 "Disassembly".

  • Page 26: Disassembly

    Disassembly ATEX Disassembly If you need to remove the gearbox for maintenance or replacement, complete the steps in this  chapter. Read the general safety instructions before beginning to work (see Chapter 2.5 "General  safety instructions"). Secure the higher-level machine against restarting and unintentional movements during ...

  • Page 27: Disassembling The Gearbox With The Motor From The Machine

    ATEX Disassembly Disassembling the gearbox with the motor from the machine Disconnect the electrical connections of the motor.  Secure the gearbox and the motor so it cannot fall.  Loosen the screws [S] connecting the gearbox to the whole ...

  • Page 28: Malfunctions

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

  • Page 29: Appendix

    ATEX Appendix Appendix 10.1 Specifications for mounting to a motor Designation Clamping bolt, eccentrical Tbl-13: Arrangement of motor shaft, clamping bolt and bushing Tightening torque for clamping bolt (H Ordering code: xxxxxxxx-xxx-xxxxx-x(.)*x-xx (see Chapter 3.2 "Name plate") Clamping hub (.)* Width Tightening torque [Nm] Ø...

  • Page 30: Specifications For Mounting To A Machine

    Appendix ATEX 10.2 Specifications for mounting to a machine Any mounting position can be selected for this gearbox. 10.2.1 Specifications for mounting with through-holes Ordering code: TP..xxxx-xFx-xxxxx-xxx-xx; Standard Gearbox Hole Quantity x Screw size / Tightening size circle Ø diameter Property torque class...

  • Page 31: Specifications For Startup And Operation

    The following operating conditions are not permitted: - Co-riding the gearbox on the drive axle is prohibited. Exceptions require a written approval and technical statement from WITTENSTEIN alpha GmbH. - Use in continuous duty (S1 duty: power-on time greater than 60% or longer than...

  • Page 32: Tightening Torques For Common Thread Sizes In General Mechanical Engineering

    Appendix ATEX 10.5 Tightening torques for common thread sizes in general mechanical engineering The specified tightening torques for set screws and nuts are calculated values and are based on the following conditions: - Calculation in accordance with VDI 2230 (February 2003 version) - Friction value for thread and contact surfaces µ=0.10 - Utilization of the yield stress 90% - Torque tools type II classes A and D in accordance with ISO 6789...
  • Page 33 ATEX Appendix Technical data for TP 004, 1-stage Clam- Ratio i ping hub Ø [mm] Max. axial force F – 1304 2AMax Max. tilting moment M [Nm] – 2KMax Service life L – see Chapter 7.2.3 "Replacing the gearbox" Weight incl. standard adapter –...
  • Page 34 Appendix ATEX Technical data for TP 004, 2-stage, i = 16 – 35 Clam- Ratio i ping hub Ø [mm] Max. input speed n – 4800 4800 4800 4800 4800 4800 4800 4800 1Max [min Average no-load running – 0.28 0.23 0.24 0.22...
  • Page 35 ATEX Appendix Technical data for TP 004, 2-stage, i = 40 – 100 Clam- Ratio i ping hub Ø [mm] Max. acceleration torque T – [Nm] (max. 1000 cycles per hour) Nominal output torque T – [Nm] (At n Emergency stop torque T –...

  • Page 36: 2Technical Data For Tp + 010 For Use In Potentially Explosive Atmospheres

    Appendix ATEX Technical data for TP 004, 2-stage, i = 40 – 100 Clam- Ratio i ping hub Ø [mm] Direction of rotation – In- and output same direction Mass moment of inertia J 0.057 0.057 0.058 0.06 0.056 0.057 0.056 [kgcm 0.15 0.15...
  • Page 37 ATEX Appendix Technical data for TP 010, 1-stage Clam- Ratio i ping hub Ø [mm] Operating noise L [dB(A)] – ≤ 57 (For n = 3000 min w/o load) Max. permissible housing – temperature [°C] Ambient temperature [°C] – see Chapter 10.4 "Specifications for startup and operation"...
  • Page 38 Appendix ATEX Technical data for TP 010, 2-stage, i = 16 – 35 Clam- Ratio i ping hub Ø [mm] Max. backlash j [arcmin] – Standard ≤ 3 / Reduced ≤ 1 Torsional rigidity C – [Nm/arcmin] Max. axial force F –...
  • Page 39 ATEX Appendix Technical data for TP 010, 2-stage, i = 40 – 100 Clam- Ratio i ping hub Ø [mm] Max. acceleration torque T – [Nm] (max. 1000 cycles per hour) Nominal output torque T – [Nm] (At n Emergency stop torque T –...

  • Page 40: 3Technical Data For Tp + 025 For Use In Potentially Explosive Atmospheres

    Appendix ATEX Technical data for TP 010, 2-stage, i = 40 – 100 Clam- Ratio i ping hub Ø [mm] Mass moment of inertia J 0.09 0.09 0.09 0.10 0.09 0.09 0.09 [kgcm 0.17 0.17 0.17 0.17 0.16 0.17 0.16 Refers to the drive 0.49 0.49...
  • Page 41 ATEX Appendix Technical data for TP 025, 1-stage Clam- Ratio i ping hub Ø [mm] Operating noise L [dB(A)] – ≤ 61 (For n = 3000 min w/o load) Max. permissible housing – temperature [°C] Ambient temperature [°C] – see Chapter 10.4 "Specifications for startup and operation"...
  • Page 42 Appendix ATEX Technical data for TP 025, 2-stage, i = 16 – 35 Clam- Ratio i ping hub Ø [mm] Average no-load running – 0.90 0.80 0.84 0.80 0.60 torque T [Nm] (For n =3000 min gearbox temperature 20 °C) Max.
  • Page 43 ATEX Appendix Technical data for TP 025, 2-stage, i = 40 – 100 Clam- Ratio i ping hub Ø [mm] Max. acceleration torque T – [Nm] (max. 1000 cycles per hour) Nominal output torque T – [Nm] (At n Emergency stop torque T –...

  • Page 44: 4Technical Data For Tp + 050 For Use In Potentially Explosive Atmospheres

    Appendix ATEX Technical data for TP 025, 2-stage, i = 40 – 100 Clam- Ratio i ping hub Ø [mm] Mass moment of inertia J 0.38 0.38 0.39 0.40 0.37 0.38 0.37 [kgcm 0.55 0.55 0.55 0.57 0.54 0.55 0.54 Refers to the drive 1.92 1.92...
  • Page 45 ATEX Appendix Technical data for TP 050, 1-stage Clam- Ratio i ping hub Ø [mm] Operating noise L [dB(A)] – ≤ 64 (For n = 3000 min w/o load) Max. permissible housing – temperature [°C] Ambient temperature [°C] – see Chapter 10.4 "Specifications for startup and operation"...
  • Page 46 Appendix ATEX Technical data for TP 050, 2-stage, i = 16 – 35 Clam- Ratio i ping hub Ø [mm] Average no-load running – torque T [Nm] (For n =3000 min gearbox temperature 20 °C) Max. backlash j [arcmin] – Standard ≤...
  • Page 47 ATEX Appendix Technical data for TP 050, 2-stage, i = 40 – 100 Clam- Ratio i ping hub Ø [mm] Max. acceleration torque T – [Nm] (max. 1000 cycles per hour) Nominal output torque T – [Nm] (At n Emergency stop torque T –...

  • Page 48: 5Technical Data For Tp + 110 Mf For Use In Potentially Explosive Atmospheres

    Appendix ATEX Technical data for TP 050, 2-stage, i = 40 – 100 Clam- Ratio i ping hub Ø [mm] Mass moment of inertia J 1.44 1.42 1.46 1.51 1.41 1.43 1.40 [kgcm 2.13 2.12 2.15 2.20 2.10 2.12 2.09 Refers to the drive 9.20 9.18...
  • Page 49 ATEX Appendix Technical data for TP 110 MF, 1-stage Clam- Ratio i ping hub Ø [mm] Max. permissible housing – temperature [°C] Ambient temperature [°C] – see Chapter 10.4 "Specifications for startup and operation" Lubrication – High-performance lubricating grease based on mineral oil Direction of rotation –...
  • Page 50 Appendix ATEX Technical data for TP 110 MF, 2-stage, i = 16 – 35 Clam- Ratio i ping hub Ø [mm] Torsional rigidity C – [Nm/arcmin] Max. axial force F – 8040 2AMax Max. tilting moment M – 2624 2KMax [Nm] Service life L –...
  • Page 51 ATEX Appendix Technical data for TP 110 MF, 2-stage, i = 40 – 100 Clam- Ratio i ping hub Ø [mm] Max. acceleration torque T – 1280 1280 1120 1120 1280 1040 1120 [Nm] (max. 1000 cycles per hour) Nominal output torque T –...

  • Page 52: 6Technical Data For Tp + 110 Ma For Use In Potentially Explosive Atmospheres

    Appendix ATEX Technical data for TP 110 MF, 2-stage, i = 40 – 100 Clam- Ratio i ping hub Ø [mm] Mass moment of inertia J 5.63 5.54 5.63 5.78 5.44 5.51 5.40 [kgcm 8.80 8.70 8.80 8.95 8.61 8.67 8.56 Refers to the drive 9.87...
  • Page 53 ATEX Appendix Technical data for TP 110 MA, 3-stage Ratio i Lubrication High-performance lubricating grease based on mineral oil Direction of rotation In- and output same direction Mass moment of inertia J [kgcm Refers to the drive; Bore diameter of the clamping hub: 19 mm No-load running torques diminish during operation Refers to the center of the output shaft or flange Tbl-35: TP...

  • Page 54: Declaration Of Conformity

    Appendix ATEX 10.7 Declaration of Conformity en-52 2022-D020259 Revision: 04...
  • Page 55 ATEX Revision history Revision Date Comment Chapter 07.05.2009 New version 26.11.2010 Technical Data; Layout Wittenstein 23.03.2016 2014/34/EU 2.1, 2.4, 2.7, 3.1, 3.2, 3.4.1, 9.1, 9.5, 9.6 13.11.2019 EN ISO 80079 Revision: 04 2022-D020259...
  • Page 56 WITTENSTEIN alpha GmbH ꞏ Walter-Wittenstein-Straße 1 ꞏ 97999 Igersheim ꞏ Germany Tel. +49 7931 493-0 ꞏ info@wittenstein.de WITTENSTEIN ‒ with the future www.wittenstein-alpha.de AC: XXXXXXXX 2022-D020259 Revision: 04...

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Advanced tp+ 004Advanced tp+ 010Advanced tp+ 025Advanced tp+ 050Advanced tp+ 110Tp 050e-mf2-31-0g1-2s-g ... Show all

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