Wittenstein Alpha Advanced HG+ Series Operating Manual
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Wittenstein Alpha Advanced HG+ Series Operating Manual

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alpha Advanced Line
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HG
ATEX
Operating Manual
2022-D034857
Revision: 07

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  • Page 1 alpha Advanced Line ATEX Operating Manual 2022-D034857 Revision: 07...
  • 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-D034857 Revision: 07...

  • 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................24 7.1 Maintenance schedule ..................24 7.1.1 Further maintenance intervals ..............24 7.2 Maintenance work ..................... 24 7.2.1 Visual/Noise inspection................. 24 7.2.2 Checking the tightening torques ..............25 7.2.3 Checking for leakage ..................25 7.2.4 Replacing the gearbox.................. 25 7.3 Startup after maintenance work ................

  • 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: 07 2022-D034857 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 gearbox. Certain product types may be used only in a defined 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 : 480 Nm / n 2500rpm 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 torque T...

  • Page 13: Atex Marking For Use In Potentially Explosive Dust Atmospheres

    ATEX Description of the gearbox 3.2.2 ATEX marking for use in potentially explosive dust atmospheres Designation Equipment category "Ex h: non- electrical” II 2D Ex h IIIC T150 °C Db X Equipment group "III: Explosive dust atmospheres" Subgroup "C: suitable for combustible suspended solids, non-conductive and conductive dust"...

  • Page 14: Ex Model

    Description of the gearbox ATEX Ex model The gearbox can be used in potentially explosive atmosphere group II, zones 1 and 2 as well as group III, zones 21 and 22. The gearbox can be operated in a gas atmosphere in temperature class T3. In a dust atmosphere, a maximum surface temperature of 150 °C is possible.

  • Page 15: 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 16: Transport And Storage

    Transport and storage ATEX 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 17: Storage

    ATEX Transport and storage Storage Store the gearbox in horizontal position and dry surroundings at a temperature of 0 °C to +40 °C in the original packaging. Store the gearbox for a maximum of 2 years. Consult our Customer Service department if the conditions are different.

  • Page 18: 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 19: 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 20: 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-10").

  • Page 21: 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 22: 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 23: 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 24: 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 25: 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 26: Maintenance And Disposal

    20,000 operating hours. Tbl-12: Maintenance schedule 7.1.1 Further maintenance intervals Send the gearbox to WITTENSTEIN alpha GmbH for the following types of maintenance:  - The radial shaft seal on the drive must be replaced and an oil change is required every 5,000 operating hours.

  • Page 27: 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 28: 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 29: 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 30: 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 31: Appendix

    ATEX Appendix Appendix 10.1 Specifications for mounting to a motor Designation Clamping bolt, eccentrical Tbl-15: 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 32: Specifications For Mounting To A Machine

    Appendix ATEX 10.2 Specifications for mounting to a machine The gearbox may only be operated in the approved mounting position. Further information on the mounting position can be found in chapters 10.4.1 "Mounting position" and 10.4.2 "Impermissible operating conditions". 10.2.1 Specifications for mounting with through-holes Gearbox Hole Bore Ø...

  • Page 33: 1Mounting Position

    / hollow shaft interface. If necessary, install external bearing points for the load shaft. In case of unclear installation situations, contact WITTENSTEIN alpha GmbH. - Co-riding the gearbox on the drive axle is prohibited. Exceptions require a written approval and technical statement from WITTENSTEIN alpha GmbH.

  • Page 34: 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 35 ATEX Appendix Technical data for HG 060, 1-stage Ratio i Max. permissible housing temperature [°C] Ambient temperature [°C] see Chapter 10.4 "Specifications for startup and operation" Lubrication synthetic gear oil (see also Chapter 7.1 "Maintenance schedule") Direction of rotation In- and output opposite directions Mass moment of inertia J [kgcm 0.52...

  • Page 36: 2Technical Data For Hg + 075 For Use In Potentially Explosive Atmospheres

    Appendix ATEX Technical data for HG 060, 2-stage Ratio i Service life L see Chapter 7.2.4 "Replacing the gearbox" Weight incl. standard adapter plate m [kg] Operating noise L ≤ 64 [dB(A)] (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 37 ATEX Appendix Technical data for HG 075, 1-stage Ratio i Max. backlash j [arcmin] ≤ 4 Torsional rigidity C [Nm/arcmin] Max. axial force F 2350 2AMax Service life L see Chapter 7.2.4 "Replacing the gearbox" Weight incl. standard adapter plate m [kg] Operating noise L [dB(A)] ≤...
  • Page 38 Appendix ATEX Technical data for HG 075, 2-stage Ratio i Average no-load running torque T [Nm] (For n =3000 min gearbox temperature 20 °C) Max. backlash j [arcmin] ≤ 4 Torsional rigidity C [Nm/arcmin] Max. axial force F 2350 2AMax Service life L see Chapter 7.2.4 "Replacing the gearbox"...

  • Page 39: 3Technical Data For Hg + 100 For Use In Potentially Explosive Atmospheres

    ATEX Appendix 10.6.3 Technical data for HG 100 for use in potentially explosive atmospheres Technical data for HG 100, 1-stage Ratio i Max. acceleration torque T [Nm] (max. 1000 cycles per hour) Nominal output torque T [Nm] (At n Emergency stop torque T [Nm] 2Not (1000 times possible during the service life of the...
  • Page 40 Appendix ATEX Technical data for HG 100, 2-stage Ratio i Max. acceleration torque [Nm] (max. 1000 cycles per hour) Nominal output torque T [Nm] (At n Emergency stop torque [Nm] 2Not (1000 times possible during the service life of the gearbox) Permissible average input 2700 2700 2700 2700 2700 2700 2700 3100 3700 3700...

  • Page 41: 4Technical Data For Hg + 140 For Use In Potentially Explosive Atmospheres

    ATEX Appendix Technical data for HG 100, 2-stage Ratio i Direction of rotation In- and output opposite directions Mass moment of inertia J 1.02 0.97 0.86 0.84 0.75 0.74 0.69 0.69 0.68 0.68 [kgcm Refers to the drive; Bore diameter of the clamping hub: 19 mm Mass moment of inertia J 2.59 2.54 2.42 2.40 2.31 2.30 2.26 2.25 2.25 2.25...
  • Page 42 Appendix ATEX Technical data for HG 140, 1-stage Ratio i Ambient temperature [°C] see Chapter 10.4 "Specifications for startup and operation" Lubrication synthetic gear oil (see also Chapter 7.1 "Maintenance schedule") Direction of rotation In- and output opposite directions Mass moment of inertia J [kgcm 25.0 19.1...

  • Page 43: 5Technical Data For Hg + 180 For Use In Potentially Explosive Atmospheres

    ATEX Appendix Technical data for HG 140, 2-stage Ratio i Operating noise L ≤ 68 [dB(A)] (For n = 3000 min w/o load) Max. permissible housing temperature [°C] Ambient temperature [°C] see Chapter 10.4 "Specifications for startup and operation" Lubrication synthetic gear oil (see also Chapter 7.1 "Maintenance schedule") Direction of rotation In- and output opposite directions...
  • Page 44 Appendix ATEX Technical data for HG 180, 1-stage Ratio i Service life L see Chapter 7.2.4 "Replacing the gearbox" Weight incl. standard adapter plate m [kg] 45.4 Operating noise L [dB(A)] ≤ 68 (For n = 3000 min w/o load) Max.
  • Page 45 ATEX Appendix Technical data for HG 180, 2-stage Ratio i Max. axial force F 9900 2AMax Service life L see Chapter 7.2.4 "Replacing the gearbox" Weight incl. standard 47.0 adapter plate m [kg] Operating noise L ≤ 68 [dB(A)] (For n = 3000 min w/o load) Max.

  • Page 46: Declaration Of Conformity

    Appendix ATEX 10.7 Declaration of Conformity en-44 2022-D034857 Revision: 07...
  • Page 47 ATEX Revision history Revision Date Comment Chapter 16.12.2009 New version 01.03.2010 Technical 9.4.1 specifications 31.08.2010 2-stage design 1, 3, 5, 7, 9 03.12.2012 Translation 2.4, 7.3 corrections 16.05.2013 Shrink disk 2.7, 5.5 28.05.2015 Lubricant 3.1, 9.5 10.03.2016 2014/34/EU 2.1, 2.4, 3.1, 3.2, 3.4.1, 23.10.2019 EN ISO 80079 Revision: 07...
  • Page 48 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-D034857 Revision: 07...

This manual is also suitable for:

Advanced hg+ 060Advanced hg+ 075Advanced hg+ 100Advanced hg+ 140Advanced hg+ 180

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