Wittenstein Alpha Advanced SP+ Series Operating Manual
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Wittenstein Alpha Advanced SP+ Series Operating Manual

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alpha Advanced Line
+
SP
ATEX MC
Operating Manual
2022-D014985
Revision: 07

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Summary of Contents for Wittenstein Alpha Advanced SP+ Series

  • Page 1 alpha Advanced Line ATEX MC Operating Manual 2022-D014985 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-D014985 Revision: 07...

  • Page 3: Table Of Contents

    ATEX MC 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 MC 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-D014985 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 MC 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 MC 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 MC 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 MC 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 MC 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

    DMF: 28/19 Made in Germany T : 170 Nm / n : 3000 rpm 1max WITTENSTEIN alpha GmbH - Walter-Wittenstein-Str.1 - 97999 Igersheim Ordering code Production date CW/YY (see Chapter 3.3 "Ordering code") Maximum permitted gear output torque Ratio i...

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

    ATEX MC 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 MC 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.

  • Page 15: Dimensioning

    Observe all instructions in this chapter.  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 MC 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 MC 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 MC 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 MC  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 MC 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 MC 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 MC 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

    30,000 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:  - In addition, the radial shaft seal on the output must be replaced every 10,000 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 MC 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 MC 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 MC 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 MC 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 (.)* Code Width Tightening torque [Nm]...

  • Page 32: Specifications For Mounting To A Machine

    Appendix ATEX MC 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 Gearbox Hole Bore Ø Screw size / Tightening size circle Ø Property torque [mm] class [mm] [Nm] M6 / 12.9...

  • Page 33: Specifications For Startup And Operation

    - Lateral forces or bending torques acting on the blind hollow shaft / hollow shaft / 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: Technical Specifications

    Appendix ATEX MC 10.6 Technical specifications 10.6.1 Technical data for SP 075 for use in potentially explosive atmospheres Technical data for SP 075, 1-stage Clamping Ratio i hub Ø [mm] Max. acceleration torque T – [Nm] (max. 1000 cycles per hour) Nominal output torque T –...
  • Page 35 ATEX MC Appendix Technical data for SP 075, 1-stage Clamping Ratio i hub Ø [mm] Direction of rotation – In- and output same direction Mass moment of inertia J 0.78 0.68 0.59 0.54 0.54 [kgcm 2.40 Refers to the drive No-load running torques diminish during operation Refers to the center of the output shaft or flange Tbl-21: SP...
  • Page 36 Appendix ATEX MC Technical data for SP 075, 2-stage, i = 16 – 35 Clamping Ratio i hub Ø [mm] Operating noise L [dB(A)] – ≤ 59 (For n = 3000 min w/o load) Max. permissible housing – temperature [°C] Ambient temperature [°C] –...

  • Page 37: 2Technical Data For Sp + 100 For Use In Potentially Explosive Atmospheres

    ATEX MC Appendix Technical data for SP 075, 2-stage, i = 40 – 100 Clamping Ratio i hub Ø [mm] 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 MC Technical data for SP 100, 1-stage Clamping Ratio i hub Ø [mm] Average no-load running – 0.84 0.78 0.64 torque T [Nm] (For n =3000 min and gearbox temperature 20 °C) Max. backlash j [arcmin] – Standard ≤ 4 / Reduced ≤ 2 Torsional rigidity C –...
  • Page 39 ATEX MC Appendix Technical data for SP 100, 2-stage, i = 16 – 35 Clamping Ratio i 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 Appendix ATEX MC Technical data for SP 100, 2-stage, i = 16 – 35 Clamping Ratio i hub Ø [mm] Direction of rotation – In- and output same direction Mass moment of inertia J 0.81 0.70 0.68 0.60 0.43 0.59 [kgcm Refers to the drive No-load running torques diminish during operation...

  • Page 41: 3Technical Data For Sp + 140 For Use In Potentially Explosive Atmospheres

    ATEX MC Appendix Technical data for SP 100, 2-stage, i = 40 – 100 Clamping Ratio i hub Ø [mm] 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 42 Appendix ATEX MC Technical data for SP 140, 1-stage Clamping Ratio i hub Ø [mm] Max. tilting moment M – 2KMax [Nm] Service life L – see Chapter 7.2.4 "Replacing the gearbox" Weight incl. standard adapter – 17.2 plate m [kg] Operating noise L [dB(A)] –...
  • Page 43 ATEX MC Appendix Technical data for SP 140, 2-stage, i = 16 – 35 Clamping Ratio i hub Ø [mm] Average no-load running – 0.96 0.80 0.72 0.60 torque T [Nm] (For n =3000 min and gearbox temperature 20 °C) Max.
  • Page 44 Appendix ATEX MC Technical data for SP 140, 2-stage, i = 40 – 100 Clamping Ratio i hub Ø [mm] Max. acceleration torque T [Nm] (max. 1000 cycles per hour) Nominal output torque T [Nm] (At n Emergency stop torque T [Nm] –...

  • Page 45: 4Technical Data For Sp + 180 For Use In Potentially Explosive Atmospheres

    ATEX MC Appendix 10.6.4 Technical data for SP 180 for use in potentially explosive atmospheres Technical data for SP 180, 1-stage Clamping Ratio i hub Ø [mm] Max. acceleration torque T [Nm] (max. 1000 cycles per hour) Nominal output torque T –...
  • Page 46 Appendix ATEX MC Technical data for SP 180, 1-stage Clamping Ratio i hub Ø [mm] 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 No-load running torques diminish during operation Refers to the center of the output shaft or flange Tbl-30: SP...
  • Page 47 ATEX MC Appendix Technical data for SP 180, 2-stage, i = 16 – 35 Clamping Ratio i hub Ø [mm] Weight incl. standard adapter – 36.4 plate m [kg] Operating noise L [dB(A)] – ≤ 66 (For n = 3000 min w/o load) Max.

  • Page 48: 5Technical Data For Sp + 210 For Use In Potentially Explosive Atmospheres

    Appendix ATEX MC Technical data for SP 180, 2-stage, i = 40 – 100 Clamping Ratio i hub Ø [mm] Max. lateral force F – 10200 2QMax Max. tilting moment M [Nm] – 1120 2KMax Service life L – see Chapter 7.2.4 "Replacing the gearbox"...
  • Page 49 ATEX MC Appendix Technical data for SP 210, 1-stage Clamping Ratio i hub Ø [mm] Average no-load running – torque T [Nm] (For n =3000 min and gearbox temperature 20 °C) Max. backlash j [arcmin] – Standard ≤ 4 / Reduced ≤ 2 Torsional rigidity C –...

  • Page 50: Declaration Of Conformity

    Appendix ATEX MC 10.7 Declaration of Conformity en-48 2022-D014985 Revision: 07...
  • Page 51 ATEX MC Revision history Revision Date Comment Chapter 14.12.2004 New version 04.11.2008 Type plate WITTENSTEIN alpha 10.11.2008 Type plate WITTENSTEIN alpha 18.10.2010 Technical Data, Layout WITTENSTEIN 09.06.2015 Lubricant 3.1, 7.1.4 23.03.2016 2014/34/EU 2.1, 2.4, 2.7, 3.2, 3.4.1, 09.12.2019 EN ISO 80079...
  • Page 52 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-D014985 Revision: 07...

This manual is also suitable for:

Advanced sp+ 075Advanced sp+ 100Advanced sp+ 140Advanced sp+ 180Advanced sp+ 210Sp 140e-mc1-3-1k1-2k

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