Wittenstein Alpha Advanced TK+ 004 Page 1 Operating Manual Download

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2022-D034859

Revision: 05

alpha Advanced Line

ATEX

Operating Manual

Summary of Contents for Advanced TK+ 004

Page 1: ...2022 D034859 Revision 05 alpha Advanced Line TK ATEX Operating Manual...

Page 2: ...rance WITTENSTEIN sarl info wittenstein fr 33 134 17 90 95 Great Britain WITTENSTEIN Ltd sales uk wittenstein co uk 44 1782 286 427 Italia WITTENSTEIN S P A info wittenstein it 39 02 241357 1 sales wi...

Page 3: ...2 ATEX marking for use in potentially explosive dust atmospheres 11 3 3 Ordering code 11 3 4 Ex model 12 3 5 Dimensions and performance data 12 3 6 Dimensioning 13 3 6 1 Inspection 13 3 7 Information...

Page 4: ...tions for mounting to a machine 29 10 2 1Specifications for mounting with through holes 29 10 3Specifications for mounting to the output side 29 10 4Specifications for startup and operation 30 10 4 1M...

Page 5: ...nd the machine about the safety and warning notices to avoid injuries The original instructions were prepared in German all other language versions are translations of these instructions 1 1 Informati...

Page 6: ...tion to the safety related information in this manual also observe any legal and otherwise applicable rules and regulations particularly for accident prevention e g personal safety equipment and envir...

Page 7: ...e into account the washer for the screw calculation joint additional compression set surface pressure under screw head and under washer The gearbox can be used in the potentially explosive atmospheres...

Page 8: ...and check all screw connections for which a tightening torque has been specified Solvents and lubricants are flammable can cause skin irritation and can pollute soil and water In case of fire Do not s...

Page 9: ...g regulations according to maintenance plan Mechanically caused sparks Overload on shafts moving parts and connection elements Reduce torques and external loads compared to standard gearboxes Limit th...

Page 10: ...Entanglement Environmental protection Information Explosion This signal word indicates an imminent danger that will cause serious injuries or even death This signal word indicates a potential hazard...

Page 11: ...here necessary a bushing The gearbox is equipped with an integrated linear length compensation to compensate for the expansion of the motor shaft when heated up 3 1 Overview of gearbox components Gear...

Page 12: ...trical M Equipment group II Flammable materials gases vapors Subgroup C a typical gas is hydrogen N Temperature class T3 Max surface temperature 200 C O Equipment protection level EPL Use in zone 1 li...

Page 13: ...ductive and conductive dust N Max surface temperature 150 C O Equipment protection level EPL Use in zone 21 listed ignition sources under normal operation and in the event of expected malfunctions P R...

Page 14: ...p 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: ...tion or Detailed dimensioning chapter of the general catalog or contact WITTENSTEIN alpha GmbH During dimensioning note the reduced performance data in Chapter 10 6 Technical specifications Our Custom...

Page 16: ...use of hoisting equipment 4 3 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 year...

Page 17: ...der to achieve the proper friction values of the screw connections In addition check the fitting surfaces for damage and impurities Pressurized air can damage the gearbox seals Do not use pressurized...

Page 18: ...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...

Page 19: ...ws F Fasten the motor D onto the adapter plate B with the four screws Evenly tighten the screws crosswise with increasing torque If the gearbox is a single stage gearbox MF1 coat the clamping bolt H w...

Page 20: ...de installation M on a machine you will find more information in the separate manual Reverse centering device for motor side installation doc no 2022 D063062 The manual will be provided by our Sales C...

Page 21: ...in Chapter 10 3 Specifications for mounting to the output side Slide the washers onto the fastening screws Fasten the gearbox to the machine with the fastening screws through the slotted holes M Opti...

Page 22: ...se only shrink discs provided by WITTENSTEIN alpha GmbH for the gearbox also refer to the Shrink Disc manual doc no 2022 D063039 Avoid lateral forces or bending torques acting on the blind hollow shaf...

Page 23: ...ment 6 1 Note the following during startup 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...

Page 24: ...o points on the gear housing on near the drive and one near the output see also Chapter 3 1 Overview of gearbox components Consult with our Customer Service department if the maximum permissible housi...

Page 25: ...gearbox for exterior damage and corrosion Check the clamping hub for external damage when inspecting the tightening torques of the clamping bolt Check the gearbox for unusual running noises and vibra...

Page 26: ...ate after brief operation Lubricant discharge should stop after a short time In case lubricant still is emitted shut down the gearbox and consult our Customer Service department 7 2 4 Replacing the ge...

Page 27: ...haft hollow shaft interface flange hollow shaft Flange With mounted output pinion For details on how to remove the components of slip on shaft hollow shaft hollow shaft interface refer to the instruct...

Page 28: ...nst damage Designation H1 Clamping bolt eccentrical H2 Clamping bolt centrical I Clamping ring J Bushing K Keyed motor shaft L Motor shaft with shaft key L1 Shaft key Tbl 12 Arrangement of motor shaft...

Page 29: ...ing Increased noises during operation increased vibrations Distortion in motor mounting misalignment Consult our Customer Service department Damaged bearings Damaged gear teeth Loss of lubricant Exces...

Page 30: ...oss flats mm Tightening torque Nm Coaxial Angle Coupling K 2 Clamping hub socket S 2 8 Z 2 5 2 9 A 2 5 2 11 B 3 4 1 4 1 14 C 4 9 5 8 5 9 5 16 D 5 14 14 19 E 5 14 14 14 24 G 6 35 35 35 28 3 H 5 14 28 4...

Page 31: ...e Property class Tightening torque Nm 004 79 8 x 4 5 M4 12 9 4 55 010 109 8 x 5 5 M5 12 9 9 025 135 8 x 5 5 M5 12 9 9 050 168 12 x 6 6 M6 12 9 15 4 110 233 12 x 9 M8 12 9 37 5 Tbl 16 Specifications fo...

Page 32: ...ure that the gearbox is mounted in the mounting positions depicted below to ensure the lubrication of all gearbox components In the case of application conditions and mounting positions that differ fr...

Page 33: ...rmitted Mounting position B5 V1 output shaft horizontal motor shaft downwards Lateral forces or bending torques acting on the blind hollow shaft hollow shaft hollow shaft interface If necessary instal...

Page 34: ...ity Ct21 Nm arcmin 2 6 2 8 3 0 2 6 2 3 Max axial force F2AMax N b 1650 Max tilting moment M2KMax Nm 175 Service life Lh h See Chapter 7 2 4 Replacing the gearbox Weight incl standard adapter plate m k...

Page 35: ...ax input speed n1Max min 1 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 Average no load running torque T012 Nm For n1 3000 min 1 and gearbox temperature 20 C a 0 2 0 2 0 2 0 2 0 2 0 2 0 1 0 1 0 1...

Page 36: ...tio i 3 4 5 7 10 Max acceleration torque T2B Nm max 1000 cycles per hour 56 56 56 48 40 Nominal output torque T2N Nm At n1N 37 37 37 33 30 Emergency stop torque T2Not Nm 1000 times possible during the...

Page 37: ...nical specifications for TK 010 2 stage Ratio i 12 16 20 25 28 35 40 50 70 100 Max acceleration torque T2B Nm max 1000 cycles per hour 56 56 56 56 56 56 56 56 48 40 Nominal output torque T2N Nm At n1N...

Page 38: ...drive Bore diameter of the clamping hub 19 mm 0 75 0 72 0 68 0 68 0 63 0 63 0 63 0 63 0 63 0 63 a No load running torques diminish during operation b Refers to the center of the output shaft or flang...

Page 39: ...rtia J1 kgcm2 Refers to the drive Bore diameter of the clamping hub 38 mm 12 7 11 5 10 9 10 4 10 1 a No load running torques diminish during operation b Refers to the center of the output shaft or fla...

Page 40: ...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 direction...

Page 41: ...5 4 9 6 6 Max backlash jt arcmin 4 Torsional rigidity Ct21 Nm arcmin 36 40 46 44 42 Max axial force F2AMax N b 6900 Max tilting moment M2KMax Nm 1180 Service life Lh h See Chapter 7 2 4 Replacing the...

Page 42: ...2800 3500 Max input speed n1Max min 1 4500 4500 4500 4500 4500 4500 4500 4500 4500 4500 Average no load running torque T012 Nm For n1 3000 min 1 and gearbox temperature 20 C a 1 4 0 9 0 7 0 5 0 5 0 4...

Page 43: ...i 3 4 5 7 10 Max acceleration torque T2B Nm max 1000 cycles per hour 400 400 400 350 300 Nominal output torque T2N Nm At n1N 250 250 250 230 220 Emergency stop torque T2Not Nm 1000 times possible duri...

Page 44: ...ycles per hour 400 400 400 400 400 400 400 400 350 300 Nominal output torque T2N Nm At n1N 250 250 250 250 250 250 250 250 230 220 Emergency stop torque T2Not Nm 1000 times possible during the service...

Page 45: ...Mass moment of inertia J1 kgcm2 Refers to the drive Bore diameter of the clamping hub 38 mm 16 8 14 8 12 9 12 3 11 2 10 9 10 3 10 1 10 0 9 93 Mass moment of inertia J1 kgcm2 Refers to the drive Bore d...

Page 46: ...Appendix TK ATEX en 44 2022 D034859 Revision 05 10 7 Declaration of Conformity...

Page 47: ...9 Revision history Revision Date Comment Chapter 01 18 12 2009 New version All 02 31 08 2010 2 stage design 1 3 5 7 9 03 27 05 2015 Lubricant 3 1 9 6 04 10 03 2016 2014 34 EU 2 1 2 4 3 1 3 2 3 4 1 9 7...

Page 48: ...XXXXXXXX 2022 D034859 Revision 05 WITTENSTEIN alpha GmbH Walter Wittenstein Stra e 1 97999 Igersheim Germany Tel 49 7931 493 0 info wittenstein de WITTENSTEIN one with the future www wittenstein alpha...

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