Wittenstein Alpha Advanced Line SP+ 075 ATEX MC Operating Manual Download

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2022-D014985

Revision: 08

alpha Advanced Line

ATEX MC

Operating Manual

Summary of Contents for Advanced Line SP+ 075 ATEX MC

Page 1: ...2022 D014985 Revision 08 alpha Advanced Line SP ATEX MC Operating Manual ...

Page 2: ...France 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 A...

Page 3: ...rformance data 12 3 6 Dimensioning 12 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 4 3 Storage 15 5 Assembly 16 5 1 Preparations 16 5 2 Installation conditions 17 5 3 Mounting the motor to the gearbox 17 5 4 M...

Page 4: ...fications for mounting to the output side 30 10 4Specifications for startup and operation 31 10 4 1Impermissible operating conditions 31 10 5Tightening torques for common thread sizes in general mechanical engineering 31 10 6Technical specifications 32 10 6 1Technical data for SP 075 for use in potentially explosive atmospheres 32 10 6 2Technical data for SP 100 for use in potentially explosive at...

Page 5: ...ound 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 c...

Page 6: ...dition 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 prohi...

Page 7: ...Take 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 potentiall...

Page 8: ...n 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 ab...

Page 9: ...ing 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 moto...

Page 10: ...ads 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 le...

Page 11: ...ated linear length compensation to compensate for the expansion of the motor shaft when heated up With gearbox size SP 210 only use motors with a drive side fixed bearing 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 Q Output shaft B Adapter plate Tbl 2 Overview of gearbox compon...

Page 12: ...al 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 op...

Page 13: ...conductive 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 Produc...

Page 14: ...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 compliance with standard DIN EN ISO 80079 and EU ...

Page 15: ...ha 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 the motor by limiting motor current and motor speed Clarify the chemical stability of t...

Page 16: ...we 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 trans...

Page 17: ...earbox 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: ... order 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 witho...

Page 19: ...ng 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 ver...

Page 20: ...screws 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 ...

Page 21: ...side 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 F...

Page 22: ...ons 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 accord...

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 1 Impermissible operating conditions The slip on shaft hollow shaft hollow shaft interface Q is axially secured to the load shaft by ...

Page 24: ...artment 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 Neve...

Page 25: ...two 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 fau...

Page 26: ...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 months Visual Noise inspection X X X Checking the tightening torques X X X Checking for leakage X X X Chapter 6 2 Checking ru...

Page 27: ...ter 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 Alternative...

Page 28: ...w 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 dis...

Page 29: ...ainst 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 ...

Page 30: ...oling 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 outp...

Page 31: ... across 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 x...

Page 32: ...size SP Hole circle Ø mm Bore Ø mm Screw size Property class Tightening torque Nm 075 85 6 6 M6 12 9 15 4 100 120 9 M8 12 9 37 5 140 165 11 M10 12 9 73 5 180 215 13 5 M12 12 9 126 210 250 17 M16 12 9 310 Tbl 17 Specifications for mounting to a machine SP Maximum permitted axial forces Gearbox size SP MC 075 100 140 180 210 Fa max N 10750 18500 31250 49750 83250 Tbl 18 Maximum permissible static ax...

Page 33: ...to set your tools Ambient temperature Product type Minimum temperature C Maximum temperature C SP 0 40 Operating temperature Product type Max permissible housing temperature C SP 80 Tbl 19 Ambient temperature Operating temperature The following operating conditions are not permitted Lateral forces or bending torques acting on the blind hollow shaft hollow shaft hollow shaft interface If necessary ...

Page 34: ...0 3200 3200 3600 3600 3600 Max input speed n1Max min 1 3750 3800 4000 4500 4500 4500 Average no load running torque T012 Nm For n1 3000 min 1 and gearbox temperature 20 C a 1 1 0 88 0 72 0 49 0 42 0 40 Max backlash jt arcmin Standard 6 Reduced 4 Torsional rigidity Ct21 Nm arcmin 10 Max axial force F2AMax N b 2350 Max lateral force F2QMax N b 1770 Max tilting moment M2KMax Nm 165 Service life Lh h ...

Page 35: ... output torque T2N Nm At n1N 50 50 50 50 50 50 Emergency stop torque T2Not Nm 1000 times possible during the service life of the gearbox 115 115 115 115 115 115 Permissible average input speed n1N min 1 At T2N 3600 3600 3600 3600 3600 3600 Max input speed n1Max min 1 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 36 0 24 0 18...

Page 36: ...losive atmospheres Technical data for SP 075 2 stage i 40 100 Clamping hub Ø mm Ratio i 40 50 64 70 100 Max acceleration torque T2B Nm max 1000 cycles per hour 60 60 46 60 46 Nominal output torque T2N Nm At n1N 50 50 30 50 30 Emergency stop torque T2Not Nm 1000 times possible during the service life of the gearbox 115 115 115 115 115 Permissible average input speed n1N min 1 At T2N a 3600 3600 360...

Page 37: ... 0 49 0 49 a In the case of mounting position V1 reduce the average drive speed n1N by 20 b No load running torques diminish during operation c Refers to the center of the output shaft or flange Tbl 23 SP 075 2 stage i 40 100 Technical data for use in potentially explosive atmospheres Technical data for SP 100 1 stage Clamping hub Ø mm Ratio i 3 4 5 7 8 10 Max acceleration torque T2B Nm max 1000 c...

Page 38: ...ting noise LPA dB A For n1 3000 min 1 w o load 64 Max permissible housing temperature C 80 Ambient temperature C see Chapter 10 4 Specifications for startup and operation Lubrication High performance lubricating grease based on mineral oil Direction of rotation In and output same direction Mass moment of inertia J1 kgcm2 Refers to the drive 24 4 0 3 0 2 6 2 3 2 3 2 1 38 11 10 9 7 9 4 9 6 9 1 a No ...

Page 39: ...n1Max min 1 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 52 0 53 0 48 0 43 0 38 0 28 Max backlash jt arcmin Standard 6 Reduced 4 Torsional rigidity Ct21 Nm arcmin 31 Max axial force F2AMax N b 3950 Max lateral force F2QMax N b 3670 Max tilting moment M2KMax Nm 340 Service life Lh h see Chapter 7 2 4 Replacing the gearbox We...

Page 40: ... 68 Emergency stop torque T2Not Nm 1000 times possible during the service life of the gearbox 335 335 320 335 330 Permissible average input speed n1N min 1 At T2N a 3600 3600 3600 3600 3600 Max input speed n1Max min 1 4500 4500 4500 4500 4500 Average no load running torque T012 Nm For n1 3000 min 1 and gearbox temperature 20 C b 0 28 0 30 0 25 0 20 0 19 Max backlash jt arcmin Standard 6 Reduced 4 ...

Page 41: ... data for use in potentially explosive atmospheres Technical data for SP 140 1 stage Clamping hub Ø mm Ratio i 3 4 5 7 8 10 Max acceleration torque T2B Nm max 1000 cycles per hour 170 264 264 264 210 210 Nominal output torque T2N Nm At n1N 127 195 182 187 160 160 Emergency stop torque T2Not Nm 1000 times possible during the service life of the gearbox 710 710 710 710 380 380 Permissible average in...

Page 42: ...48 30 27 26 25 25 24 a No load running torques diminish during operation b Refers to the center of the output shaft or flange Tbl 27 SP 140 1 stage Technical data for use in potentially explosive atmospheres Technical data for SP 140 2 stage i 16 35 Clamping hub Ø mm Ratio i 16 20 25 28 32 35 Max acceleration torque T2B Nm max 1000 cycles per hour 264 264 264 264 264 264 Nominal output torque T2N ...

Page 43: ...LPA dB A For n1 3000 min 1 w o load 63 Max permissible housing temperature C 80 Ambient temperature C see Chapter 10 4 Specifications for startup and operation Lubrication High performance lubricating grease based on mineral oil Direction of rotation In and output same direction Mass moment of inertia J1 kgcm2 Refers to the drive 24 3 2 2 7 2 7 2 3 1 7 2 3 38 10 9 8 9 7 9 4 2 3 9 4 a No load runni...

Page 44: ...t21 Nm arcmin 53 Max axial force F2AMax N c 6900 Max lateral force F2QMax N c 6600 Max tilting moment M2KMax Nm 660 Service life Lh h see Chapter 7 2 4 Replacing the gearbox Weight incl standard adapter plate m kg 17 Operating noise LPA dB A For n1 3000 min 1 w o load 63 Max permissible housing temperature C 80 Ambient temperature C see Chapter 10 4 Specifications for startup and operation Lubrica...

Page 45: ...put speed n1N min 1 At T2N 1850 2400 2800 3200 3200 3200 Max input speed n1Max min 1 2040 2720 3400 4000 4000 4000 Average no load running torque T012 Nm For n1 3000 min 1 and gearbox temperature 20 C a 8 8 7 4 6 0 4 4 4 4 3 2 Max backlash jt arcmin Standard 4 Reduced 2 Torsional rigidity Ct21 Nm arcmin 175 Max axial force F2AMax N b 9900 Max lateral force F2QMax N b 10200 Max tilting moment M2KMa...

Page 46: ...our 528 528 528 528 528 528 Nominal output torque T2N Nm At n1N 422 422 422 422 422 422 Emergency stop torque T2Not Nm 1000 times possible during the service life of the gearbox 1330 1330 1330 1330 1330 1330 Permissible average input speed n1N min 1 At T2N 3600 3600 3600 3600 3600 3600 Max input speed n1Max min 1 4500 4500 4500 4500 4500 4500 Average no load running torque T012 Nm For n1 3000 min ...

Page 47: ...a for use in potentially explosive atmospheres Technical data for SP 180 2 stage i 40 100 Clamping hub Ø mm Ratio i 40 50 64 70 100 Max acceleration torque T2B Nm max 1000 cycles per hour 528 528 420 528 420 Nominal output torque T2N Nm At n1N 422 422 336 422 336 Emergency stop torque T2Not Nm 1000 times possible during the service life of the gearbox 1330 1330 1330 1330 1330 Permissible average i...

Page 48: ... 9 7 9 7 5 5 9 6 9 6 a In the case of mounting position V1 reduce the average drive speed n1N by 20 b No load running torques diminish during operation c Refers to the center of the output shaft or flange Tbl 32 SP 180 2 stage i 40 100 Technical data for use in potentially explosive atmospheres Technical data for SP 210 1 stage Clamping hub Ø mm Ratio i 3 4 5 7 8 10 Max acceleration torque T2B Nm ...

Page 49: ... 56 Operating noise LPA dB A For n1 3000 min 1 w o load 64 Max permissible housing temperature C 80 Ambient temperature C see Chapter 10 4 Specifications for startup and operation Lubrication High performance lubricating grease based on mineral oil Direction of rotation In and output same direction Mass moment of inertia J1 kgcm2 Refers to the drive 55 139 94 3 76 9 61 5 61 5 53 1 a No load runnin...

Page 50: ...Appendix SP ATEX MC en 48 2022 D014985 Revision 08 10 7 Declaration of Conformity ...

Page 51: ...l 02 04 11 2008 Type plate WITTENSTEIN alpha All 03 10 11 2008 Type plate WITTENSTEIN alpha All 04 18 10 2010 Technical Data Layout WITTENSTEIN All 05 09 06 2015 Lubricant 3 1 7 1 4 06 23 03 2016 2014 34 EU 2 1 2 4 2 7 3 2 3 4 1 9 5 07 09 12 2019 EN ISO 80079 All 08 19 05 2020 Replacing the gearbox 3 6 7 1 7 2 4 ...

Page 52: ...XXXXX 2022 D014985 Revision 08 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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