Wittenstein Alpha Advanced HG+ 060 Operating Manual Download

Page: 1 / 48

2022-D034857

Revision: 07

alpha Advanced Line

ATEX

Operating Manual

Summary of Contents for Advanced HG+ 060

Page 1: ...2022 D034857 Revision 07 alpha Advanced Line HG 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 wittenstein jp 81 3 6680 2835 North America WITTENSTEIN holding Corp technicalsupport wittenstein us com 1 630 540 5300 España WITTENSTEIN S L U info wittenstein es 34 93 479 1305 Sverige WITTENSTEIN AB...

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 about the lubricant 13 4 Transport and storage 14 4 1 Packaging 14 4 2 Transport 14 4 2 1 Transport of gearboxes up to and including size 140 14 4 2 2 Transport of gearboxes starting from size 180 14...

Page 4: ...10 2Specifications for mounting to a machine 30 10 2 1Specifications for mounting with through holes 30 10 3Specifications for mounting to the output side 30 10 4Specifications for startup and operation 30 10 4 1Mounting position 31 10 4 2Impermissible operating conditions 31 10 5Tightening torques for common thread sizes in general mechanical engineering 32 10 6Technical specifications 32 10 6 1T...

Page 5: ...und 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 Information symbols and cross references The following information symbols are used Indicates an action to be performed Indicates the results of an action Provides additional information about the action A cr...

Page 6: ...ition 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 environmental protection 2 1 EC EU Directive 2 1 1 Machinery Directive The gearbox is considered a machine component and is therefore not subject to the EC Machinery Directive 2006 42 EC Startup is prohib...

Page 7: ...ke 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 defined in Chapter 3 4 Ex model Observe the instructions on the name plate and the appendix on the written certificate of conformity The gearbox is manufactured and certified for use in potentially ...

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 spray with water to extinguish Suitable extinguishing agents are powder foam water mist and carbon dioxide Observe the safety instructions of the lubricant manufacturer see Chapter 3 7 Information abo...

Page 9: ...ng 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 the motor current of the motor Perform maximum load test before startup Static electricity Potential differences between components cleaning processes insulating layers Ground the gearbox and the motor...

Page 10: ...s 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 that could cause serious injuries and even death This signal word indicates a potential hazard that could cause minor or serious injuries This signal word indicates a potential hazard that could lead...

Page 11: ...d with an integrated linear length compensation to compensate for the expansion of the motor shaft when heated up The gearbox can be used in the potentially explosive atmospheres defined in Chapter 3 4 Ex model 3 1 Overview of gearbox components Gearbox components E Gear housing E2 Mounting opening The sealed mounting opening may not be opened Q Hollow shaft B Adapter plate Tbl 2 Overview of gearb...

Page 12: ...l 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 listed ignition sources under normal operation and in the event of expected malfunctions P Restrictions regarding ambient temperature and mounting position see Chapter 10 4 Specifications for startup and ope...

Page 13: ...nductive 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 Restrictions regarding ambient temperature and mounting position see Chapter 10 4 Specifications for startup and operation Tbl 6 Name plate sample values L II 2D Ex h IIIC T150 C Db X M N O P Product ...

Page 14: ...up 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 Observe the instructions on the name plate and the appendix on the written certificate of conformity The gearbox is manufactured and certified for use in potentially explosive atmospheres in complian...

Page 15: ...ation 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 Customer Service department is available to answer any questions Note the instructions in Chapter 7 2 4 Replacing the gearbox if the calculated storage life is under 20 000 h Prevent gearbox overloading by...

Page 16: ...e recommend the use of hoisting equipment The following table shows a gearbox for which at least one support bore R is provided for an eye bolt e g in accordance with to DIN 580 The eye bolts are used for attaching the gearbox securely to the hoisting equipment Suspended loads can fall and can cause serious injuries and even death Do not stand under suspended loads Secure the gearbox before transp...

Page 17: ...arbox 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 For storage logistics we recommend the first in first out method ...

Page 18: ...rder 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 air to clean the gearbox Directly sprayed cleaning agents can alter the frictional values of the clamping hub Only spray cleaning agents onto a cloth for wiping off the clamping hub Operation without...

Page 19: ...g 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 The value for the tightening torque can also be found in Chapter 10 1 Specifications for mounting to a motor Preferably the motor should be mounted in a vert...

Page 20: ...rews 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 with threadlocker such as Loctite 243 Tighten the clamping bolt H of the clamping hub C The value for the tightening torque can also be found in Chapter 10 1 Specifications for mounting to a motor Sc...

Page 21: ...ide 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 Customer Service department on request Please always provide the serial number We recommend doing without washers as long as the material of the screw surface features sufficient interface pressure Fa...

Page 22: ...s 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 Optionally there are two bore holes N on the gear housing for pinning the gearbox to the machine You can fasten the gearbox to the machine with cylinder pins Drill pin holes into the machine bed accordin...

Page 23: ...Use 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 shaft hollow shaft hollow shaft interface also refer to Chapter 10 4 2 Impermissible operating conditions The slip on shaft hollow shaft hollow shaft interface Q is axially secured to the load shaft by m...

Page 24: ...tment 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 only used in those areas for which it is approved according to the name plate see Chapter 3 2 Name plate A damaged gearbox can lead to explosions that can cause serious injuries and even death Never ...

Page 25: ...wo 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 housing temperature is exceeded see chapter 10 6 Technical specifications Check the proper assembly of the clamping hub before startup by a maximum load test Increased running noises may be caused by faul...

Page 26: ...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 vibrations during operation For special information on maintenance related issues contact our Customer Service department Maintenance work At startup After running in 4 hours After every 500 operating hours or 3 mo...

Page 27: ...late 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 gearbox Replace the gearbox When 90 of the calculated life of the output bearing has been reached see Chapter 3 6 Dimensioning or Cymex design At the latest after a total of 20 000 operating hours Alte...

Page 28: ...shaft 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 instructions in Chapter 8 1 1 Removing the shrink disc There are customer specific designs for all other types of outputs The removal of these outputs cannot be described here 8 1 1 Removing the shrink disc ...

Page 29: ...inst 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 13 Arrangement of motor shaft clamping bolt and bushing Clamping forces can damage the motor and the gearbox Ensure that the motor is removed in a vertical position Remove the plug A from the mounting bore in the adapter plate B...

Page 30: ...ling Increased noises during operation increased vibrations Distortion in motor mounting misalignment Consult our Customer Service department Damaged bearings Damaged gear teeth Loss of lubricant Excessive amount of lubricant Wipe off discharged lubricant and continue to watch the gearbox Lubricant discharge should stop after a short time Only in the case of grease lubrication Seeping at the outpu...

Page 31: ...cross 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 H 6 35 32 I 8 79 69 38 K 8 79 69 79 48 M 10 135 86 135 55 N 10 135 60 O 14 330 1 The availability of particular clamping hub diameters can be found in the catalog 2 Ordering code xxxx xxx xxxxx xxx...

Page 32: ...e separate manual Shrink disk doc no 2022 D063039 The manual will be provided by our Sales Customer Service department on request Please always provide the serial number 10 4 Specifications for startup and operation Gearbox size HG Hole circle Ø mm Bore Ø mm Screw size Property class Tightening torque Nm 060 68 5 5 M5 12 9 9 075 85 6 6 M6 12 9 15 4 100 120 9 M8 12 9 37 5 140 165 11 M10 12 9 73 5 1...

Page 33: ...g position V1 B5 output shaft downwards motor shaft horizontal Mounting position V3 B5 output shaft upwards motor shaft horizontal Mounting position B5 B5 output shaft horizontal motor shaft horizontal The following operating conditions are not permitted Mounting position B5 V1 output shaft horizontal motor shaft downwards Lateral forces or bending torques acting on the blind hollow shaft hollow s...

Page 34: ...8 8 1 15 2 64 5 2 9 0 21 5 42 5 73 5 118 180 258 362 495 625 10 9 10 1 68 3 88 7 6 13 2 32 0 62 5 108 173 264 368 520 700 890 12 9 12 1 97 4 55 9 0 15 4 37 5 73 5 126 202 310 430 605 820 1040 Tbl 19 Tightening torques for set screws and nuts Technical data for HG 060 1 stage Ratio i 3 4 5 7 10 Max acceleration torque T2B Nm max 1000 cycles per hour 24 24 24 20 16 Nominal output torque T2N Nm At n1...

Page 35: ...n potentially explosive atmospheres Technical data for HG 060 2 stage Ratio i 12 16 20 25 28 35 40 50 70 100 Max acceleration torque T2B Nm max 1000 cycles per hour 24 24 24 24 24 24 24 24 20 16 Nominal output torque T2N Nm At n1N 17 5 17 5 17 5 17 5 17 5 17 5 17 5 17 5 16 12 Emergency stop torque T2Not Nm 1000 times possible during the service life of the gearbox 40 40 40 40 40 40 40 40 40 40 Per...

Page 36: ...ia J1 kgcm2 Refers to the drive Bore diameter of the clamping hub 14 mm 0 20 0 20 0 19 0 19 0 18 0 18 0 17 0 17 0 17 0 17 a No load running torques diminish during operation b Refers to the center of the output shaft or flange Tbl 21 HG 060 2 stage Technical data for use in potentially explosive atmospheres Technical data for HG 075 1 stage Ratio i 3 4 5 7 10 Max acceleration torque T2B Nm max 100...

Page 37: ...90 Mass moment of inertia J1 kgcm2 Refers to the drive Bore diameter of the clamping hub 28 mm 2 86 2 60 2 47 2 36 2 31 a No load running torques diminish during operation b Refers to the center of the output shaft or flange Tbl 22 HG 075 1 stage Technical data for use in potentially explosive atmospheres Technical data for HG 075 2 stage Ratio i 12 16 20 25 28 35 40 50 70 100 Max acceleration tor...

Page 38: ...ee 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 J1 kgcm2 Refers to the drive Bore diameter of the clamping hub 14 mm 0 28 0 27 0 23 0 23 0 20 0 20 0 18 0 18 0 18 0 18 Mass moment of inertia J1 kgcm2 Refers to the drive Bore diameter of the...

Page 39: ...21 Nm arcmin 10 7 12 1 14 0 14 2 14 4 Max axial force F2AMax N b 3950 Service life Lh h see Chapter 7 2 4 Replacing the gearbox Weight incl standard adapter plate m kg 9 3 Operating noise LPA dB A For n1 3000 min 1 w o load 66 Max permissible housing temperature C 80 Ambient temperature C see Chapter 10 4 Specifications for startup and operation Lubrication synthetic gear oil see also Chapter 7 1 ...

Page 40: ...00 3700 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 0 7 0 7 0 6 0 4 0 4 0 3 0 2 0 2 0 2 0 2 Max backlash jt arcmin 4 Torsional rigidity Ct21 Nm arcmin 12 1 12 1 12 1 12 1 12 1 12 1 12 1 14 14 2 14 4 Max axial force F2AMax N b 3950 Service life Lh h see Chapter 7 2 4 Replacing t...

Page 41: ... 1 stage Ratio i 3 4 5 7 10 Max acceleration torque T2B Nm max 1000 cycles per hour 190 190 205 185 170 Nominal output torque T2N Nm At n1N 120 120 130 130 130 Emergency stop torque T2Not Nm 1000 times possible during the service life of the gearbox 400 420 420 420 400 Permissible average input speed n1N min 1 At T2N 1200 1200 1400 1300 1400 Max input speed n1Max min 1 2200 3000 4000 4200 4200 Ave...

Page 42: ...T2B Nm max 1000 cycles per hour 190 190 190 205 190 205 190 205 185 170 Nominal output torque T2N Nm At n1N 120 120 120 120 120 120 120 130 130 130 Emergency stop torque T2Not Nm 1000 times possible during the service life of the gearbox 400 420 420 420 420 420 420 420 420 400 Permissible average input speed n1N min 1 At T2N 2600 2600 2600 2600 2600 2600 2600 2800 2800 3500 Max input speed n1Max m...

Page 43: ...37 9 34 9 33 a No load running torques diminish during operation b Refers to the center of the output shaft or flange Tbl 27 HG 140 2 stage Technical data for use in potentially explosive atmospheres Technical data for HG 180 1 stage Ratio 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 ...

Page 44: ...0 1 stage Technical data for use in potentially explosive atmospheres Technical data for HG 180 2 stage Ratio i 12 16 20 25 28 35 40 50 70 100 Max acceleration torque T2B Nm max 1000 cycles 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 life of the gea...

Page 45: ...tenance schedule Direction of rotation In and output opposite directions Mass moment of inertia J1 kgcm2 Refers to the drive Bore diameter of the clamping hub 38 mm 15 3 13 9 12 3 12 0 10 9 10 7 10 1 10 0 9 95 9 91 Mass moment of inertia J1 kgcm2 Refers to the drive Bore diameter of the clamping hub 48 mm 30 0 28 7 27 0 26 7 25 6 25 4 24 8 24 7 24 7 24 6 a No load running torques diminish during o...

Page 46: ...Appendix HG ATEX en 44 2022 D034857 Revision 07 10 7 Declaration of Conformity ...

Page 47: ... New version All 02 01 03 2010 Technical specifications 9 4 1 03 31 08 2010 2 stage design 1 3 5 7 9 03a 03 12 2012 Translation corrections 2 4 7 3 04 16 05 2013 Shrink disk 2 7 5 5 05 28 05 2015 Lubricant 3 1 9 5 06 10 03 2016 2014 34 EU 2 1 2 4 3 1 3 2 3 4 1 9 6 07 23 10 2019 EN ISO 80079 All ...

Page 48: ...XXXXX 2022 D034857 Revision 07 WITTENSTEIN alpha GmbH ꞏ Walter Wittenstein Straße 1 ꞏ 97999 Igersheim ꞏ Germany Tel 49 7931 493 0 ꞏ info wittenstein de WITTENSTEIN one with the future www wittenstein alpha de ...

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