Wittenstein Alpha CP Series User manual

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2022
-
D020863
05
2022-D020863 Revision: 05
CP
Operating Manual
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CP
2022-D020863 Revision: 05
Revision history
Revision Date Comment Chapter
01 22.11.2005 New version All
02 01.07.2008 Layout WITTENSTEIN All
03 01.08.2009 Machinery Directive 2, 3, 4, 5, 7
04 15.03.2011 Technical data; Layout
Wittenstein
All
05 12.12.2017 Identification CP All
Service
In case you have technical questions,
please contact:
WITTENSTEIN alpha GmbH
Customer Service
Walter-Wittenstein-Straße 1
D-97999 Igersheim
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
© WITTENSTEIN alpha GmbH 2017
This documentation is copyright protected.
WITTENSTEIN alpha GmbH reserves all the rights to photo-mechanical reproduction,
copying, and the distribution by special processes (such as computers, file media, data
networks), even in parts.
Subject to technical and content changes without notice..
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CP
Revision: 05 2022-D020863 en-1
Contents
1 Regarding this manual........................................................................................ 2
1.1 Signal words........................................................................................................ 2
1.2 Safety symbols.................................................................................................... 3
1.3 Design of the safety instructions ......................................................................... 3
1.4 Information symbols ............................................................................................ 3
2 Safety.................................................................................................................... 4
2.1 EC – Machinery directive .................................................................................... 4
2.2 Dangers............................................................................................................... 4
2.3 Personnel............................................................................................................ 4
2.4 Intended use ....................................................................................................... 4
2.5 Reasonably predictable misuse .......................................................................... 4
2.6 Guarantee and liability ........................................................................................ 4
2.7 General safety instructions.................................................................................. 5
3 Description of the gearhead............................................................................... 6
3.1 Overview of the gearhead components .............................................................. 6
3.2 Type plate ........................................................................................................... 6
3.3 Performance statistics......................................................................................... 6
3.4 Weight................................................................................................................. 6
4 Transport and storage ........................................................................................ 7
4.1 Scope of delivery................................................................................................. 7
4.2 Packaging ........................................................................................................... 7
4.3 Transport............................................................................................................. 7
4.4 Storage................................................................................................................ 7
5 Assembly ............................................................................................................. 8
5.1 Preparations........................................................................................................ 8
5.2 Mounting the motor to the gearhead................................................................... 8
5.3 Mounting the gearhead to a machine................................................................ 10
5.4 Mounted components at the output side........................................................... 10
6 Startup and operation....................................................................................... 11
7 Maintenance and disposal................................................................................ 12
7.1 Maintenance work ............................................................................................. 12
7.1.1 Visual inspection .......................................................................................... 12
7.1.2 Control of the tightening torques .................................................................. 12
7.2 Startup after maintenance work ........................................................................ 12
7.3 Maintenance schedule ...................................................................................... 12
7.4 Notes on the lubricant used .............................................................................. 12
7.5 Disposal ............................................................................................................ 13
8 Malfunctions ...................................................................................................... 14
9 Appendix............................................................................................................ 15
9.1 Details regarding the attachment to a motor ..................................................... 15
9.2 Details regarding the attachment to a machine................................................. 15
9.3 Tightening torques for common thread sizes in general mechanics ................. 16
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Regarding this manual CP
en-2 2022-D020863 Revision: 05
1 Regarding this manual
This manual contains information that is necessary for using the planetary gearhead CP,
subsequently referred to as gearhead, in a safe manner.
If this manual is supplied with an amendment (e.g. for special applications), then the information in
the amendment is valid. Contradictory specifications in this manual thereby become obsolete.
The operator must ensure that these instructions are read through by all persons assigned to install,
operate, or maintain the gearhead, and that they fully comprehend them.
Store these instructions within reach of the gearhead.
These safety instructions should be shared with colleagues working in the vicinity of the device
to ensure individual safety.
The original instructions were prepared in German; all other language versions are translations of
these instructions.
1.1 Signal words
The following signal words are used to bring your attention to dangers, prohibitions, and important
information:
This signal word points to an imminent danger that can cause serious
injuries and even death.
This signal word points to a possible danger that can cause serious
injuries and even death.
This signal word points to a possible danger that can cause slight to
serious injuries.
This signal word points to a possible danger that can cause material
damage.
A note without signal word draws your attention to application tips or
especially important information when handling the gearhead.
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CP Regarding this manual
Revision: 05 2022-D020863 en-3
1.2 Safety symbols
The following safety symbols are used to bring your attention to dangers, prohibitions, and
important information:
1.3 Design of the safety instructions
The safety instructions of these instructions are designed according to the following pattern:
1.4 Information symbols
The following information symbols are used:
Indicates an action to be performed
Indicates the results of an action
Provides additional information on handling
General danger Hot surface Suspended loads Danger of being
pulled in
Environment
protection
Information
A= Safety symbol (see Chapter 1.2 "Safety symbols")
B= Signal word (see Chapter 1.1 "Signal words")
C= Type and consequence of the danger
D= Prevention of the danger
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Safety CP
en-4 2022-D020863 Revision: 05
2 Safety
These instructions, especially the safety instructions and the rules and regulations valid for the
operating site, must be observed by all persons working with the gearhead.
In addition to the safety specifications mentioned in this operating manual, the general and also the
local regulations on the prevention of accidents (for instance, personal safety equipment) and on
environmental protection should be observed.
2.1 EC – Machinery directive
The gearhead is considered a "machine component" and is therefore not subject to the EC
Machinery Directive 2006/42/EC.
Operation is prohibited within the area of validity of the EC directive until it has been determined
that the machine in which this gearhead is installed corresponds to the regulations within this
directive.
2.2 Dangers
The gearhead has been constructed according to current technological standards and accepted
safety regulations.
To avoid danger to the operator or damage to the machine, the gearhead may be put to use only
for its intended usage (see chapter 2.4 "Intended use") and in a technically flawless and safe state.
Be informed of the general safety instructions before beginning work.
(see Chapter 2.7 "General safety instructions").
2.3 Personnel
Only persons who have read and understood these instructions may carry out work on the
gearhead.
2.4 Intended use
The gearhead serves to convert torques and speeds. It is built for industrial applications that do not
fall under article 2 of the directive 2002/95/EU (usage restriction of certain dangerous materials on
electro and electronic equipment).
The gearhead is specified for installment on motors that:
- correspond to the design B5 (for any divergences, consult our Customer Service Department
[technical customer service])
- show a radial and axial runout tolerance of at least “N” according to DIN 42955 and
- have a smooth shaft
2.5 Reasonably predictable misuse
Any usage that exceeds the maximum permitted speeds, torques and temperature is considered a
misuse and is therefore prohibited.
2.6 Guarantee and liability
Guarantee and liability claims are excluded for personal injury and material damage in case of
- Ignoring the information on transport and storage
- Improper use (misuse)
- Improper or neglected maintenance and repair
- Improper assembly / disassembly or improper operation
- Operation of the gearhead when safety devices and equipment are defective
- Operation of the gearhead without lubricant
- Operation of a heavily soiled gearhead
- Modifications or reconstructions that have been carried out without the approval of
WITTENSTEIN alpha GmbH
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CP Safety
Revision: 05 2022-D020863 en-5
2.7 General safety instructions
Objects flung out by rotating components can cause serious injuries.
Remove objects and tools from the gearhead before putting it into
operation.
Rotating components on the gearhead can pull in parts of the body
and cause serious injuries and even death.
Keep a sufficient distance to rotating machinery while the gearhead is
running.
Secure the machine against restarting and unintentional movements
during assembly maintenance work.
Hot gearhead housing can cause serious burns.
Touch the gearhead housing only when wearing protective gloves or
after the gearhead has been at standstill for some time.
Loose or overloaded screw connections can damage the gearhead.
Use a calibrated torque wrench to tighten and check all screw
connections for which a tightening torque has been specified.
Solvents and lubricants can pollute soil and water.
Use and dispose of cleaning solvents as well as lubricants appropriately.
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Description of the gearhead CP
en-6 2022-D020863 Revision: 05
3 Description of the gearhead
The gearhead is a single or multistage planetary gearhead which is manufactured in the version "M"
(motor-mounted) by default. The output shaft bearing is realized in such a manner that it can
accommodate extensive tilting moments and axial forces.
The motor centering is realized via the held receptacle for tabs, and not via the adapter plate. Radial
clamping of the motor is avoided.
An adaptation to various motors is realized via an adapter plate and a bushing.
3.1 Overview of the gearhead components
3.2 Type plate
The type plate is attached to the housing.
3.3 Performance statistics
Refer to our catalogue or our Internet page for the maximum permitted speeds and torques:
http://www.wittenstein-alpha.de
3.4 Weight
The weights of the gearheads with a medium-sized adapter plate are detailed in table "Tbl-3". If
another adapter plate has been assembled, the actual weight may deviate up to 10%.
Gearhead components CP
A Housing
B Output shaft
C Adapter plate
Tbl-1: Overview of the gearhead components
Identification
A Ordering code
B Ratio
C Serial number
D Lubricant
E Production date
Tbl-2: Type plate (example values)
Consult our Customer Service department if the gearhead is older
than a year. You will then receive the valid performance data.
Gearhead size CP 040 060 080 115
1 stage [kg] 0.31 0.88 2.1 5.2
2 stages [kg] 0.52 1.1 2.8 6.9
Tbl-3: Weight
WITTENSTEIN alpha GmbH - Walter-Wittenstein-Str.1 - 97999 Igersheim
XX XXXX-XX-XXXXX-XX
SN: 1234567
DMF: 05/12
Lubricant
Made in Germany
i=XX
AB
CD
E
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CP Transport and storage
Revision: 05 2022-D020863 en-7
4 Transport and storage
4.1 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, or WITTENSTEIN alpha GmbH.
4.2 Packaging
The gearhead is delivered packed in foil and cardboard boxes.
Dispose of the packaging materials at recycling sites intended for that. Observe the locally
valid regulations for disposals.
4.3 Transport
No special transport mode is prescribed for transporting the gearhead.
Specifications on the weights, refer to Chapter 3.4 "Weight".
4.4 Storage
Store the gearhead in horizontal position and dry surroundings at a temperature of 0 °C to +40 °C
in the original packaging. Store the gearhead for a maximum of 2 years.
For storage logistics, we recommend the "first in – first out" method.
Hard knocks, because of falling or hard dropping, can damage the
gearhead.
Only use hoisting equipment and transports with sufficient capacity.
The maximum permitted lift capacity of a hoist may not be exceeded.
Lower the gearhead slowly.
Suspended loads can fall and can cause serious injuries and even
death.
Do not stand under suspended loads.
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Assembly CP
en-8 2022-D020863 Revision: 05
5 Assembly
Be informed of the general safety instructions before beginning work.
(see Chapter 2.7 "General safety instructions").
5.1 Preparations
The screws for fastening are not included in the scope of delivery and must be provided by the
customer. You may find related information in the individual assembly steps.
Clean / de-grease the following components with a clean and lint-free cloth as well as a
grease-dissolving, non-aggressive cleaning agent:
- All fitting surfaces to neighboring components
- The centering
- The motor shaft
- The inner diameter of the plug receptacle
- The bushing on the inside and outside
Also check the fitting surfaces for damage and impurities.
Ensure that the bushing included in the delivery may be slid on the motor shaft with a tight
sliding fit.
5.2 Mounting the motor to the gearhead
The standard delivery of a gearhead does not include a motor. The motor to be mounted must:
- Conform to design B5
- have a radial and axial runout tolerance according to DIN EN 50347
- And exhibit a shaft that is as smooth as possible.
Pressurized air can damage the gearhead seals.
Do not use pressurized air to clean the gearhead.
Observe the general information and safety instructions of the motor
manufacturer.
Observe the safety and processing instructions of the screw-bonding
agents to be used.
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CP Assembly
Revision: 05 2022-D020863 en-9
Coat the four screws (E) with a threadlocker (e.g. Loctite 243).
Fasten the motor (C) by means of the four screws (E) to the adapter plate (D).
Tighten the threaded pin (B) of the plug receptacle (A).
Screw sizes and prescribed tightening torques, ref. chapter 9.1 "Details regarding the
attachment to a motor", table "Tbl-10".
Push the enclosed stopper plug to the stop of the stopper plug into the mounting bore of the
adapter plate (D).
Ideally perform the motor mounting in vertical
direction.
If the motor shaft includes a shaft key,
remove it.
Use a half wedge if recommended by the
motor manufacturer.
Turn the plug receptacle (A) until the
threaded pin (B) may be reached via the
mounting bore.
Slide the motor shaft into the plug receptacle
of the gearhead.
The max. permissible axial forces may not
be exceeded, ref. chapter 9.1 "Details
regarding the attachment to a motor",
table "Tbl-10". The motor shaft must be
easy to insert. If this is not the case, the
threaded pin must be loosened further.
The slot of the bushing must align with the
groove of the motor shaft (if available) and
be positioned with a 90° offset to the
threaded pin, ref. table "Tbl-4".
There may be no gap between the
motor (C) and the adapter plate (D).
Identification
A Plug receptacle
B Threaded pin
F Bushing
G Smooth shaft
H Keyed shaft
Tbl-4: Arrangement of the motor shaft, plug receptacle, and bushing
B
G
F
A
H
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Assembly CP
en-10 2022-D020863 Revision: 05
5.3 Mounting the gearhead to a machine
5.4 Mounted components at the output side
Four threaded bores are available in the gear unit housing for
bolting it to your machine.
Thoroughly clean the output shaft, centering, and fitting
surface.
The bolts need to be provided by the customer. You can find
the prescribed screw sizes and tightening torques in
Chapter 9.2 "Details regarding the attachment to a machine",
table "Tbl-11".
Smear screw-bonding agent (for example Loctite 243) onto
the four bolts.
Fasten the gearhead on the machine with the fastening bolt
through the holes.
Mount the gearhead in such a way that the type plate
remains legible.
Do not use washers (e.g. plain washers, tooth lock
washers).
Clamping forces during the assembly may damage the gearhead.
Assemble the gears and the toothed belt pulleys without force on the
output shaft.
Do not attempt an assembly by driving or hammering under any
circumstances!
Only use suitable tools or mechanisms for the assembly.
if you fit or shrink-fit a gear on the output shaft, you must ensure that the
maximum permissible static axial forces of the output bearing will not be
exceeded (ref. table "Tbl-5").
Size CP 040 060 080 115
Fa max[N] 230 750 1600 2100
Tbl-5: Maximum permissible static axial forces for the static load rating (s0) = 1.8 and
the radial force (Fr) = 0
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CP Startup and operation
Revision: 05 2022-D020863 en-11
6 Startup and operation
Be informed of the general safety instructions before beginning work.
(see Chapter 2.7 "General safety instructions").
Improper use can cause damage to the gearhead.
Make sure that
- the ambient temperature does not drop below –15 °C or exceed
+40 °C and
- the operating temperature does not exceed +90 °C.
Avoid icing, which can damage the seals.
For other conditions of use, consult our Customer Service Department.
Only use the gearhead only up to its maximum limit values, see
Chapter 3.3 "Performance statistics".
Only use the gearhead only in a clean, dust-free and dry environment.
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Maintenance and disposal CP
en-12 2022-D020863 Revision: 05
7 Maintenance and disposal
Be informed of the general safety instructions before beginning work.
(see Chapter 2.7 "General safety instructions").
7.1 Maintenance work
7.1.1 Visual inspection
Check the entire gearhead for exterior damage.
The sealings are subject to wear. Therefore also check the gearhead for leakage during each
visual inspection.
Check the mounting position, so that no foreign medium (e.g. oil) has collected on the
output shaft.
7.1.2 Control of the tightening torques
Check the tightening torque of the fastening screws at the housing.
You may find the prescribed tightening torques in chapter 9.2 "Details regarding the
attachment to a machine", table "Tbl-11".
Check the tightening torque of the threaded pin at the motor mount.
You may find the prescribed tightening torques in chapter 9.1 "Details regarding the
attachment to a motor", table "Tbl-10".
7.2 Startup after maintenance work
Clean the outside of the gearhead.
Attach all safety devices.
Do a trial run before releasing the gearhead again for operation.
7.3 Maintenance schedule
7.4 Notes on the lubricant used
You can receive further information on the lubricants directly from the manufacturer:
Maintenance work At
startup Firsttimeafter500operating hours or 3 months Every 3 months Yearly
Visual inspection XX X
Checking the
tightening torques XX X
Tbl-6: Maintenance schedule
All gearheads are lubricated for their service life by the manufacturer with a
mineral oil-based lithium soap grease or with a food-safe synthetic grease
(carbon hydride oil, aluminum complex soap) (see type plate). All bearings
are permanently lubricated by the company.
Standard lubricants Lubricants for the food industry
(USDA-H1 registered)
Castrol Industrie GmbH, Mönchengladbach
Tel.: + 49 2161 909-30
www.castrol.com
Klüber Lubrication München KG, Munich
Tel.: + 49 89 7876–0
www.klueber.com
Tbl-7: Lubricant manufacturers
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CP Maintenance and disposal
Revision: 05 2022-D020863 en-13
7.5 Disposal
Additional information regarding the disassembly and the disposal of the gearhead is available from
our Customer Service department.
Dispose of the gearhead at the recycling sites intended for this purpose.
Observe the valid national regulations during disposal.
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Malfunctions CP
en-14 2022-D020863 Revision: 05
8 Malfunctions
Changedoperationalbehaviorcanbean indicationofexistingdamage
to the gearhead or cause damage to the gearhead.
Do not put the gearhead back into operation until the cause of the
malfunction has been rectified.
Rectifying of malfunctions may only be done by specially trained
technicians.
Fault Possible cause Solution
Increased operating
temperature
The gearhead is not suited
for the task.
Check the technical
specifications.
Motor is heating the
gearhead.
Check the wiring of the motor.
Ensure adequate cooling.
Change the motor.
Ambient temperature too
high.
Ensure adequate cooling.
Increased noises during
operation
Distortion in motor mounting Please consult our Customer
Service Department.
Damaged bearings
Damaged gear teeth
Loss of lubricant Lubricant quantity too high Wipe off discharged lubricant
and continue to watch the
gearhead. Lubricant
discharge must stop after a
short time.
Seals not tight Please consult our Customer
Service Department.
Tbl-8: Malfunctions
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CP Appendix
Revision: 05 2022-D020863 en-15
9 Appendix
9.1 Details regarding the attachment to a motor
9.2 Details regarding the attachment to a machine
Identification
A Plug receptacle
B Threaded pin
F Bushing
G Smooth shaft
H Keyed shaft
Tbl-9: Arrangement of the motor shaft, plug receptacle, and bushing
Gearhead size
CP Inner plug receptacle Ø
[mm]
Width across
flats threaded
pin (B)
[mm]
Tightening
torque
[Nm]
Max. axial force
[N]
040 9 3 5.6 45
060 14 4 14 80
080 19 5 23 100
115 24 6 45 150
Tbl-10: Details regarding the attachment to a motor
Gearhead
size
CP
Pitch circle Ø
[mm] Screw size /
property
class
Tightening
torque
[Nm]
040 34 M4 / 10.9 3.88
060 52 M5 / 10.9 7.69
080 70 M6 / 10.9 13.2
115 100 M10 / 10.9 62.7
Tbl-11: Tapped bores in the housing
A
B
F
G
H
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Appendix CP
en-16 2022-D020863 Revision: 05
9.3 Tightening torques for common thread sizes in general mechanics
The specified tightening torques for headless screws and nuts are calculated values and are based
on the following conditions:
- Calculation acc. VDI 2230 (Issue February 2003)
- Friction value for thread and contact surfaces μ=0.10
- Exploitation of the yield stress 90 %
Tightening torque [Nm] for threads
Property
class
Bolt / nut
M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24
8.8 / 8 1.15 2.64 5.24 8.99 21.7 42.7 73.5 118 180 258 363 493 625
10.9 / 10 1.68 3.88 7.69 13.2 31.9 62.7 108 173 265 368 516 702 890
12.9 / 12 1.97 4.55 9.00 15.4 37.3 73.4 126 203 310 431 604 821 1042
Tbl-12: Tightening torques for headless screws and nuts
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2022
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D016962
:
01
enAC: XXXXXXXX 2022-D016962 Revision: 01
WITTENSTEIN alpha GmbH · Walter-Wittenstein-Straße 1 · 97999 Igersheim · Germany
Tel. [phone] · [email protected]
WITTENSTEIN - one with the future
www.wittenstein-alpha.de
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