NEUGART HLAE Series User manual

Instruction Manual
Hygienic Design Planetary Gearbox
Series:
HLAE070 (1- & 2-stage)
HLAE090 (1- & 2-stage)
HLAE110 (1- & 2-stage)
GB_ 100225294 / Rev. status "004"

Instruction manual Hygienic Design Planetary Gearbox
1 Table of contents
1 GB_ 100225294 / Rev. status "004"
1Table of contents
1Table of contents 1
2About this document 2
2.1 Warnings 2
2.2 Notes and accentuations 3
3Safety 4
3.1 Intended use 5
3.2 Non-intended use 6
3.3 Personnel qualification 6
3.4 General safety instructions 7
3.5 Standards/directives 8
4Description 9
4.1 Technical data 10
4.2 Accessories 10
4.3 Lubrication 11
4.4 Rating plate 11
4.5 Approved detergents 12
5Storage, transport 13
6Installation 14
6.1 Conditions governing the location 14
6.2 Preparing the installation 14
6.3 Installing the motor on the gearbox 15
6.4 Installing the gearbox 17
7Commissioning 19
7.1 Measuring the surface temperature 19
8Cleaning 20
9Maintenance / repair 21
9.1 Lubrication 21
9.1.1 Determining the pot life of the lubricant 21
9.2 Seals 22
10 Troubleshooting 23
11 Disposal 23
12 Service 23

Instruction manual Hygienic Design Planetary Gearbox
2 About this document
GB_ 100225294 / Rev. status "004" 2
2About this document
This instruction manual describe the installation and commissioning of the NEUGART
Hygienic Design Planetary Gearbox with the designation HLAE. The instruction manual
contain the chapters Technical data, instruction as well as information on intended use /
maintenance and care of the product.
The machine operator must guarantee and ensure that these instructions are read and
understood by any person who is entrusted or commissioned with the installation,
operation or maintenance of the product. These instructions must be kept in an
accessible place in the vicinity of the machine so that they can be immediately consulted
as and when required.
Persons working in the machine surroundings must also be familiarised with the safety
instructions.
2.1 Warnings
Warnings point out specific dangers and specify measures for avoiding the danger.
Warnings are categorised in three levels:
Warning
word
Meaning
Danger
Immediately threatening danger for life and health
Warning
Possibly threatening danger for life and health
Caution
Possibly threatening danger of light injuries or damage to property
Warnings are structured as follows:
Danger
Type and source of the danger
 Action to avoid the danger

Instruction manual Hygienic Design Planetary Gearbox
2 About this document
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2.2 Notes and accentuations
The following signs and icons are used in these instruction manual:
Warning icon. This icon points out dangers and warnings.
Information icon. Here you receive particularly important information you should
heed for a correct and safe installation of the gearbox.
Action. Here an action is required from you.

Instruction manual Hygienic Design Planetary Gearbox
3 Safety
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3Safety
This chapter describes the safety instructions you have to heed for a safe and hazard-
free use of the Hygienic Design Planetary Gearbox. It points out possible sources of
danger and necessary safety measures.
Observe the technical data!
Observe the technical data and the installation details (rating plate and documentation).
If the permissible technical data are exceeded, permanent damage to the product may
occur and the warranty claim will be forfeited.
Draw up risk assessment after installation into the machine!
The machine manufacturer must draw up a risk assessment for the machine and take
suitable measures to prevent unexpected movements from causing personal injuries or
damage to property. Additional requirements on specialised personnel may possibly
arise from the risk assessment.
Secure feather key!
Remove or secure any shaft feather keys, if the gearbox is started up without coupled
load to prevent the feather key from being flung out and the associated injury hazard.
Avoid contact between dissimilar metals!
The gearbox casing consists of stainless steel. Prevent the gearbox from coming into
direct contact with more active metals such as aluminium or steel so as to prevent
contact corrosion. Contact corrosion may cause damage to the gearbox surfaces, which
in turn can lead to contamination of the end product.
Note: Please also select the corresponding tools for this.

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3 Safety
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3.1 Intended use
The gearboxes have been in particular designed for use in machines in food, cosmetic,
pharmaceutical, medical and similar applications with highest demands on the
cleanability of the machine (hygiene design).
Operation of the HLAE gearboxes is permitted in applications with indirect contact to
foodstuffs.
You may only operate the gearboxes taking into consideration the ambient conditions
defined in this documentation.
Operation of the HLAE gearboxes is permitted in environments with detergents taking
into consideration the conditions defined in chapter 4.5.
Do not exceed permissible operating data.
Only start up the gearbox once the machine into which the gearbox is installed as a
component complies with the provisions of the directives and statutory provisions to be
applied (see Chapter 3.5).
Hygienic design uses
A hygienic design use comprises among others also the connection to the motor and to
the application. It is therefore important that on the part of the customer the
corresponding measures in terms of the hygienic design are taken into consideration. In
order to achieve this, we propose the following measures:
Gearbox:
The gearbox can be mounted in any position. There are no restrictions in this
regard.
Connection to the motor:
To seal the motor flange, an O-ring in the motor's A-bearing shield must be
provided according to hygienic design.
Use the sealing screws according to hygienic design provided by the motor
manufacturer to fasten the motor.
Connection to the application:
To seal the gearbox flange, the O-ring included in the supply must be inserted
in the gearbox output flange.
Depending on the application, the optionally available sealing kit can be used
for sealing. Detailed installation instructions see Chapter 4.2 and 6.4.
To meet the 3-A Sanitary Standard for General Requirements for your
application, the gearbox must be located outside the product contact surface
with at least 1 in. (25.4 mm) clearance between the gearbox and the nearest
product contact surface with the clearance open for inspection.

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3 Safety
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3.2 Non-intended use
It is forbidden to operate the HLAE gearboxes in explosive
areas.
HLAE gearboxes may not be used in clean room applications.
It is forbidden to commission the gearbox if the machine into which it has been
incorporated does not comply with the country-specific provisions (standards /
directives) or laws.
3.3 Personnel qualification
Only qualified specialist staff may carry out work such as transport, installation,
commissioning and maintenance. Qualified specialist staff designates persons who are
acquainted with the transport, installation, assembly, commissioning and operation of
gearboxes and who are in possession of the minimum qualifications corresponding to
their occupation and have read and understood the instruction manual:
Transport: only by personnel with corresponding qualification / training in
handling the product.
Installation: only by specialists who have undergone training in machine
engineering.
Commissioning / maintenance: only by specialists with extensive
knowledge in the field of drive engineering. Specialist staff must also know and
heed the national regulations for the prevention of accidents.
Use of the machine: only by specialists with knowledge of the hygiene
regulations valid in the area of application.
Hygienic cleaning: only by instructed cleaning personnel, who are acquainted
with the specified detergents and cleaning cycles and observe these according
to protocol. Failure to observe these can lead to permanent damage to the
product. Likewise, all cleaning instructions and specifications mentioned in this
document must be heeded and observed.
Ensure that personnel has read and understood these instruction manual.

Instruction manual Hygienic Design Planetary Gearbox
3 Safety
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3.4 General safety instructions
Caution
Improper use, faulty installation and operation as well as inadequate maintenance may
lead to serious damage to property and personal injuries.
Heed the following safety instructions before commissioning the gearbox:
Do not carry out any modifications/conversions on the gearbox.
Do not carry out any other work on the gearbox then the one described in these
instruction manual.
Before making use of the gearbox, ensure that all sealing elements and shafts
have been correctly connected.
Ensure that possible sources of danger are covered/secured (e.g. rotating parts).
Observe the conditions for commissioning requested by the manufacturer.
Never use the gearbox with damaged parts.
Always provide for adequate convection at the gearbox during operation.
The gearbox may get very hot during operation. Allow the gearbox to cool down
before working on it. Pay attention to hot lubricants when opening the gearbox.
Only work on the gearbox once it has come to a standstill and the driving motor
has been switched off and secured against unintentional restart.
Have repairs within the guarantee period only performed by NEUGART.

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3 Safety
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3.5 Standards/directives
The CE-mark of conformity and the EC declaration of conformity are not necessary, as
these gearboxes are not considered to be a machine within the meaning of the EC
Machinery Directive 2006/42/EC, but a component.
Commissioning the gearbox within the scope of application of the EC Machinery
Directive is forbidden until it has been determined that the machine into which the
gearbox has been installed as component complies with the EC machinery directive.
HYGIENIC DESIGN
The HLAE series has been designed in accordance with the stringent design
specifications of the EHEDG (European Hygienic Engineering & Design Group)
committee.
In addition, the HLAE series complies with the 3-A Sanitary Standard for General
Requirements and is certified under the Replacement Parts and System Component
Qualification Certificate Program (RPSCQC).
FDA (Food and Drug Administration)
Only FDA-compliant materials are used for the gearbox.
NSF (National Sanitation Foundation)
It goes without saying that attention is also paid to the inside of the HLAE series so that
the lubricant is certified as suitable for use in foodstuffs.

Instruction manual Hygienic Design Planetary Gearbox
4 Description
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4Description
The HLAE is a planetary gearbox which has been developed with an optimised
cleanability in mind. The gearbox is available in 3 design sizes
(HLAE070, HLAE090, HLAE110) and a single- and double-stage design is offered for
each. The drive flange is adapted to the respective "hygienic design" motor. A reducing
bush is used between motor shaft and gearbox input shaft as necessary (this is then
included in the scope of supply). It is recommended to use the optional sealing kit on
the application side.
Hygienic design motor
Hygienic design
screws for fastening
the motor
O-rings with FDA
approval
(EPDM)
Gearbox contour
without dead spaces
Gearing components
from well-proven
gearbox series
Lubrication suitable
for use in foodstuffs
according to NSF (H1
approval)
Electro-polished
gearbox surface
Optional sealing kit
Fig. 1: HLAE090 completely assembled

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4 Description
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4.1 Technical data
Gearbox series
HLAE070
HLAE090
HLAE110
Maximum permissible
operating temperature
-25°C to +90°C
Type of protection
IP69K
Rotation shaft sealing
O-rings
High-quality PTFE shaft sealing rings
EPDM (standard) / FFKM (on request)
Dimension sheet number
MB-4398
MB-4460
MB-4463
MB-4380
MB-4461
MB-4462
Additional technical data can be found on the Internet under www.neugart.com
4.2 Accessories
Sealing kit (output side)
For gearbox series
HLAE070
HLAE090
HLAE110
Item number
63911
63858
64130
O-ring EPDM O-ring EPDM
Mounting plate
Hygienic design
sealing washer
Hygienic design
screws
Fig. 2: Sealing kit

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4 Description
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4.3 Lubrication
Only lubricants with H1 approval are used for the HLAE series. The amount of lubricant
is dimensioned such that lifetime lubrication is achieved (see Chapter 9.1).
4.4 Rating plate
The rating plate serves the explicit identification of the gearbox and must be legible at
all times (e.g. to allow the tracing of gearboxes by NEUGART).
The rating plate is laser-printed and must also be cleaned during the cleaning process.
1
2
3
5
4
6
Fig. 3: Example rating plate
1 Product key
4 Serial number
2 Type
5 Transmission ratio
3 Design size
6 Month/year of construction

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4 Description
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4.5 Approved detergents
During several exacting test series, the HLAE's resistance against the following industrial
detergents was tested under the toughest conditions:
Products by ECOLAB
P3-topax 19
P3-topax 12
P3-topax 52
P3-topax 56
P3-topax 66
P3-topax 990
P3- topactive OKTO
P3-topactive DES *
* P3-topax 12, P3-topax 56, P3-topactive DES are usable according to the material
suitability test carried out with the respectively more aggressive medium.
Test setup:
The material suitability test has been carried out by Ecolab in accordance with test
method 40-1. During this test, the surfaces of the gearbox materials were placed into
the respective detergent at a 3% concentration at a temperature of 21°C.
After successfully passed material suitability test, the compatibility with the detergents
specified is given.
This should correspond to approx. 2500 cleaning cycles with respectively 15 minutes
contact to the detergent or approx. 1500 cleaning cycles with cleaning and subsequent
disinfection.
Neugart can only provide a guarantee for the gearbox service life if the tested
detergents are used. Other detergents than the ones mentioned can be tested and
where appropriate approved by Neugart on request.

Instruction manual Hygienic Design Planetary Gearbox
5 Storage, transport
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5Storage, transport
Max. 2 years at –30° C to +60° C, dry, inside the original packaging.
Please observe the guarantee period according to our general terms and conditions.
Restrict the storage time to a minimum.
The seals will age if you store the gearbox at temperatures >60° C or expose it to
direct sunlight or ultraviolet light and ozone.
Storage temperatures up to 85° C are allowed for short periods (approx. 2 weeks).
However, already during this short period, temperatures >60° C may lead to
premature ageing of the seals. The seals should therefore be checked before using the
gearbox.
Caution
Gearbox damage due to improper transport
 Do not drop the gearbox.
 Only transport the gearbox inside its packaging.
 Protect packaging and contents from humidity.
Storage
Transport:

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6 Installation
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6Installation
6.1 Conditions governing the location
Observe the following information for a smooth operation and an as long as possible
service life of the gearbox:
Provide adequate convection for the gearbox.
Pay attention that the gearbox is able to adequately dissipate heat via the output
flange.
The motor and other external heat sources can heat up the gearbox. Obtain
information about occurring motor temperatures from the respective manufacturer.
Adhere to the restrictions demanded by the respective type of protection of the
gearbox (see Chapter 4.1, Technical data).
6.2 Preparing the installation
So as to be able to use the gearbox without any restrictions, it is important to prevent
any dents, scratches or other damages to the product while assembling and handling
the product. Background: An increased formation of germs is to be expected inside the
dent caused by a scratch.
Observe the information with regard to contact corrosion (Chapter 3)
Before installing or mounting the product, first check the enclosed accessories for
completeness and check that the product does not exhibit any damages.
Before commissioning, the entire installation must be cleaned once according to
cleaning specification to avoid contamination of the first production batch.

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6 Installation
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6.3 Installing the motor on the gearbox
Ensure that
the motor does not exceed the maximum permissible motor weight for the
gearbox,
the concentricity and axial run-out tolerance "N" according to DIN 42955 is
observed on the motor side.
Motors with smooth shaft and B5-flange are to be preferred. During installation,
the motor manufacturer's specifications with regard to safety and the use of
screw locking varnish must be observed.
Install the motor according to the motor installation instructions enclosed in the gearbox
packaging.
1. Check that it is geometrically possible to install motor and gearbox.
2. Install the motor pinion that is included in the supply (gearbox sun gear with
deep groove ball bearing) on the cleaned motor shaft. Fix the clamping screw
with the specified tightening torque.
Caution: The specified installation dimension MUST be observed as failure to
do so will result in immediate damage to the components.
3. Place the sealing element enclosed by the motor manufacturer into the groove
between motor flange and gearbox provided on the "Hygienic Design motor".
4. Introduce the motor pinion parallel to the axis in vertical position carefully into
the gearing by means of slight turning movements.
Caution: Improper handling can damage the gearing.
5. Now fix the motor on the gearbox with the motor-side sealing screws. Fix the
screws with the tightening torque specified by the motor manufacturer.
Caution
The work steps specified in the motor installation instructions must be observed. You
can also download the motor installation instructions under www.neugart.com.
Installation

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6 Installation
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Hygienic design
motor
Hygienic design screws
with sealing washer
Hygienic design planetary
gearbox
Reducing bush
Motor-side
sealing
Motor pinion

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6 Installation
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6.4 Installing the gearbox
The gearboxes can be used in any installation position. The thickness of the
application plate may be varied within the specified limits.
Caution
Gearbox damage due to objects getting pressed or knocked against the
shaft
 Only fasten couplings, washers, gear wheels, chain wheels, etc. on the shaft with
suitable clamping sets.
Caution
Gearbox damage due to sealing leak
 Make sure that the seals on the gearbox do not get damaged or soiled during
installation.
Assemble the motor according to the motor installation instructions enclosed in the
gearbox packaging.
1. Check that it is geometrically possible to install the gearbox on the application.
2. Thoroughly clean / degrease the flange face and centring on the gearbox (no
aggressive detergents)
3. Clamp the enclosed O-ring into the groove intended for this purpose between
output flange and application plate.
Note: pull the O-ring onto the casing. Once the gearbox rests against the
application plate (see item 4 and 5), carefully slide the O-ring into the groove.
4. Carefully introduce the gearbox parallel to the axis into the application centring.
Caution: the O-ring may not be crushed or pushed out of position in doing so.
5. Fix the gearbox on your application using suitable sealing screws. Observe the
tightening torques intended for this purpose and use a suitable screw locking
device.
Note: We recommend the optionally available sealing kit, which comprises the
matching sealing screws (see Chapter 4.2).
6. When the sealing kit is used, the mounting plate (including matching O-rings)
must be installed on the application side subsequent to point 4 using the sealing
screws intended for this purpose (as described in point 5).
Note: Insert the O-ring in mounting plate and application in the groove
intended for this purpose and if necessary, fix for installation with a suitable
adhesive agent.

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6 Installation
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If due to the application, there are still gaps or dead spaces, these must be sealed
accordingly.
O-ring EPDM
O-ring EPDM
Mounting plate
O-ring EPDM
Sealing washer
hygienic
Hygienic design
screws

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7 Commissioning
19 GB_ 100225294 / Rev. status "004"
7Commissioning
Ensure that ...
all components are correctly interconnected.
the ambient temperature ranges within the specification.
all seals are free of dirt / ice to prevent these from being damaged when they are
loosened.
none of the parameters specified for the gearbox are exceeded (e.g. limit torque,
speed, etc. in the controller).
nobody is staying in the danger zone.
7.1 Measuring the surface temperature
Caution
Gearbox damage due to overheating
Exceeding the maximum permissible temperature of the gearbox will lead to gearbox
damage.
Ensure that during operation the maximum permissible temperature of the gearbox is
not exceeded.
Ensure that the equipment is switched off if the max. permissible temperature is
exceeded and consult NEUGART. This can for instance be implemented by means of
motor current monitoring.
Measure the temperature on the casing centre at maximum load. (preferably by means
of contact measurement)
The gearbox has reached a stationary thermal state if the temperature increase does
not exceed 2° C/h.
Danger
The surface temperature may reach up to 90°C
Risk of burns: Take corresponding precautions!
With the measured temperature you can determine the lubricant's pot life (see Chapter
9.1.1).