Wittenstein Alpha LP Series User manual

2022
-
D018479
03
2022-D018479 Revision: 03
LP+/ LPB+
Operating Manual

LP+/ LPB+
2022-D018479 Revision: 03
Revision history
Revision Date Comment Chapter
120.01.03 new version all
2 16.01.07 technical data updated 6.4.1
3 22.12.08 technical data updated
Layout WITTENSTEIN
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 2008
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.

LP+/ LPB+
Revision: 03 2022-D018479 en-1
Contents
1 On this manual .....................................................................................................2
1.1 Signal words ........................................................................................................2
1.2 Safety symbols.....................................................................................................2
1.3 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 Guarantee and Liability ........................................................................................4
2.6 General safety instructions ..................................................................................5
3 Description of the gearhead................................................................................6
3.1 General Information .............................................................................................6
3.2 Overview of the gearhead components ...............................................................6
3.2.1 Overview of the gearhead components LP+....................................................6
3.2.2 Overview of the gearhead components LPB+.................................................6
3.3 Type plate ............................................................................................................7
3.4 Ordering key ........................................................................................................7
3.5 Performance statistics..........................................................................................8
3.6 Weight..................................................................................................................8
4 Transport and storage .........................................................................................9
4.1 Scope of delivery .................................................................................................9
4.2 Packaging ............................................................................................................9
4.3 Transport..............................................................................................................9
4.4 Storage ................................................................................................................9
5 Assembly ............................................................................................................10
5.1 Preparation ........................................................................................................10
5.2 Mounting the gearhead to a machine (LPB+).....................................................11
5.3 Mounting the motor onto the gearhead (LP+/ LPB+)..........................................13
5.3.1 Pre-mounting adapter plate (only LPB+) .......................................................13
5.3.2 Mounting the motor (LP+/ LPB+) ...................................................................14
5.4 Mounted components on the gear output side...................................................15
5.4.1 Mountings on the output flange (LPB+) .........................................................15
5.5 Mounting the gearhead to a machine (LP+) .......................................................16
6 Startup and operation ........................................................................................17
7 Maintenance and disposal.................................................................................18
7.1 Maintenance work..............................................................................................18
7.1.1 Visual inspection ...........................................................................................18
7.1.2 Checking the tightening torques....................................................................18
7.2 Start-up after maintenance work........................................................................18
7.3 Maintenance schedule .......................................................................................19
7.4 Notes on the lubricant used ...............................................................................19
7.5 Supplementary information ................................................................................19
8 Malfunctions .......................................................................................................20
9 Appendix .............................................................................................................21
9.1 Specifications on mounting onto a motor...........................................................21
9.2 Specifications on mounting onto a machine ......................................................21
9.3 Tightening torques for common thread sizes in general mechanics..................22

On this manual LP+/ LPB+
en-2 2022-D018479 Revision: 03
1 On this manual
These instructions contain necessary information for the safe operation of the planetary gearhead
LP+/LPB+, referred to as gearhead in the following.
The operator must make sure that this operating manual is read through by all persons assigned to
install, operate, or maintain the gearhead, and that they understand them.
Store these instructions within reach near the gearhead.
1.1 Signal words
The following signal words are used to bring your attention to dangers, prohibitions, and important
information:
1.2 Safety symbols
The following safety symbols are used to bring your attention to dangers, prohibitions, and
important information:
This signal word points out to an immanent danger that can cause
serious injuries and even death.
This signal word points out to a possible danger that can cause
serious injuries and even death.
This signal word points out to a possible danger that can cause slight
to serious injuries.
This signal word (without warning symbol) points out to a possible
danger that can cause material damage.
This signal word draws your attention to application tips or especially
important information when handling the gearhead.
General danger Hot surface Suspended loads Danger of pull-in
Environment
protection
Information

LP+/ LPB+On this manual
Revision: 03 2022-D018479 en-3
1.3 Information symbols
The following information symbols are used:
zrequires you to carry out an action
Âindicates the results of an action
Lprovides additional information on handling

Safety LP+/ LPB+
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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 and on environmental protection should be
observed.
2.1 EC – Machinery directive
Within terms of the EC machinery directive 2006/42/EC, the gearhead is not considered as an
autonomous machine, but as a "component to install in machines".
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.
2.3 Personnel
Only persons who have read and understood these disassembly instructions may carry out work on
the gearhead.
2.4 Intended use
The gearhead 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, please 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 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
- 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

LP+/ LPB+Safety
Revision: 03 2022-D018479 en-5
2.6 General safety instructions
Objects flung out by rotating components can cause serious injuries.
zRemove 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.
zKeep a sufficient distance to rotating machinery while the gearhead is
running.
Hot gearhead housing can cause serious burns.
zTouch the gearhead housing only when wearing protective gloves or
after the gearhead has been idle for some time.
Solvents can pollute soil and water.
zUse and dispose of cleaning solvents appropriately.

Description of the gearhead LP+/ LPB+
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3 Description of the gearhead
3.1 General Information
The gearhead is a single- or multistage, low-backlash planetary gearhead, which is manufactured
as standard in the "M" version (motor installation). The output shaft bearing is designed to receive
high overturning torques and axial forces.
The motor is centered using the clamping hub and not with the adapter plate. Avoid a radial
distortion of the motor.
Adaptation to various motors is done by an adaptor plate and a spacer sleeve.
The optional LPB+has an output flange instead of an output shaft. You thus have the option of
mounting a toothed belt pulley.
3.2 Overview of the gearhead components
3.2.1 Overview of the gearhead components LP+
3.2.2 Overview of the gearhead components LPB+
Gearhead components LP+
A Gearhead housing
B Output shaft
C Adaptor plate
Tbl-1: Overview of the gearhead components
Gearhead components LPB+
A Gearhead housing
B Output flange
C Adaptor plate
D Mountable flange
Tbl-2: Overview of the gearhead components

LP+/ LPB+Description of the gearhead
Revision: 03 2022-D018479 en-7
3.3 Type plate
The type plate is attached to the gearhead housing.
3.4 Ordering key
Designation
A Ordering key (see chapter 3.4
"Ordering key")
BRatio
C Serial number
D Lubrication information
E Production date
Tbl-3: Type plate (sample values)
The ratio (e.g. i = 10) can also be found on a label on the plug socket. The
spacer sleeve is properly aligned when the slit points to the label.
WITTENSTEIN alpha GmbH - Walter Wittenstein-Str.1 - 97999 Igersheim
LP 155-M01-10 -111-000
SN: 1234567
DMF: 24/08
Lubrication: For Lifetime
Made in Germany
i= 10
A
CD
B
E
10
Size
LPB+ 070/090/120
LP+ 050/070/090/120/155
Gearhead versions
Motor-mounted gearhead
M=
Gearhead type
Standard designO=
Stage number
1 = 1-stage
2 = 2-stage (only LP+)
Ratio i
Type of output shaft
Type of output shaft
0 = Smooth shaft
1 = Feather key DIN6885 type A
LP+
1 = centering on output side
3 = centering on motor side
LPB+
Clearance specification
1 = Standard
Bore diameters of the
clamping hub
ee catalogue)1 = Standard (S
LPB 090-MO1-3-111

Description of the gearhead LP+/ LPB+
en-8 2022-D018479 Revision: 03
3.5 Performance statistics
Please refer to our catalogue or our Internet page for the maximum permitted speeds and torques:
http://www.wittenstein-alpha.de
3.6 Weight
The table "Tbl-4" specifies the gearhead dimensions with medium-sized adaptor plate. If another
adaptor plate is mounted, the actual dimensions can deviate by up to 20%.
Please consult our service department if your gearhead is older than
a year. You will then receive the valid performance data.
Gearhead size LP+050 070 090 120 155
1-stage [kg] 0.75 2.0 4.0 8.6 17.0
2-stage [kg] 0.95 2.4 5.0 11.0 21.0
Gearhead size LPB+050 070 090 120 155
1-stage [kg] — 1.6 3.3 7.3 —
Tbl-4: Weight

LP+/ LPB+Transport and storage
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4 Transport and storage
4.1 Scope of delivery
zCheck the completeness of the delivery against the delivery note.
LMissing 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.
zDispose of the packaging materials at the recycling sites intended for that. Observe the locally
valid regulations for disposals.
4.3 Transport
Specifications on the weights, refer to Chapter 3.6 "Weight".
4.4 Storage
Store the gearhead in horizontal position and dry surroundings at a temperature of 0 °C to + 30 °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, for instance because of falling or hard dropping, can
damage the gearhead.
zOnly use hoisting equipment and transports with sufficient capacity.
zThe maximum permitted lift capacity of a hoist may not be exceeded.
zLower the gearhead slowly.
Suspended loads can fall and can cause serious injuries and even
death.
zDo not stand under suspended loads.

Assembly LP+/ LPB+
en-10 2022-D018479 Revision: 03
5 Assembly
5.1 Preparation
The differences in the assembly sequence of LP+and LPB+are listed in the table "Tbl-5".
LPlease consult our Customer Service Department if you have any questions.
The bolts for mounting are not included in the delivery and need to be provided by the customer.
Information for that can be found in the individual assembly steps.
Loose or overloaded screw connections can damage the gearhead.
zUse a calibrated torque wrench to tighten and check all screw
connections for which a tightening torque has been specified.
Intensive distortions when assembling the motor (e.g. for motors with
shaft shoulder, extensive chamfer radius or longer shafts than
permitted for the gearhead) can damage the gearhead and the motor.
zCheck the interfering edges by measuring, or by a measurement check
based on our catalogue specifications and the information of the motor
manufacturer.
zContact our Customer Service Department.
LP+LPB+
—1
5.2 "Mounting the
gearhead to a
machine (LPB+)"
1
5.3 "Mounting the
motor onto the
gearhead (LP+/
LPB+)"
2
5.3 "Mounting the
motor onto the
gearhead (LP+/
LPB+)"
2
5.4 "Mounted
components on the
gear output side"
3
5.4 "Mounted
components on the
gear output side"
3
5.5 "Mounting the
gearhead to a
machine (LP+)"
—
Tbl-5: Assembly sequence

LP+/ LPB+Assembly
Revision: 03 2022-D018479 en-11
zClean/de-grease the following components with a clean and lint-free cloth and grease-
dissolving, non-aggressive detergent:
- all fitting surfaces to neighboring components
- centering
- the motor shaft
- the inner diameter of the plug receptacle
zCheck the fitting surfaces in addition for damage and foreign bodies.
5.2 Mounting the gearhead to a machine (LPB+)
There are two centering mechanisms for assembling the gearhead to the machine:
Pressurized air can damage the gearhead seals.
zDo not use pressurized air to clean the gearhead.
centering
Amotor side
Bgear output side
Tbl-6: Centering mechanisms

Assembly LP+/ LPB+
en-12 2022-D018479 Revision: 03
When a toothed belt pulley (D), an adapter plate (F) and a motor (G) are ordered, these arrive with
mountings that have only been tightened by hand.
zLoosen the motor, adapter plate and the toothed belt pulley from the gearhead.
LIf necessary, a spacer (E) may need to be placed between the gear reducer and your machine
to position the gear reducer precisely. Such a spacer is not part of the drive's delivery and
needs to be provided by the customer.
zThoroughly clean the output flange, centering, fitting surface and spacer.
The bolts need to be provided by the customer. You can find the prescribed screw sizes and
tightening torques in Chapter 9.2 "Specifications on mounting onto a machine", table "Tbl-16".
LWhen using hollow profiles (C): Position the toothed belt pulley (D) in the hollow profile before
you attach the gearhead.
zSmear screw-bonding agent (for example Loctite 243) onto the four bolts.
zFasten the gearhead on the machine with the four fastening bolts through the through-holes.
LMount the gearhead in such a way that the type plate remains legible, if possible.
LDo not use washers (e.g. plain washers, tooth lock washers).

LP+/ LPB+Assembly
Revision: 03 2022-D018479 en-13
5.3 Mounting the motor onto the gearhead (LP+/ LPB+)
The standard delivery of a gearhead does not have a motor. The motor to be mounted has to:
- correspond to the B5 design
- have a radial and axial runout tolerance of ”N” according to DIN 42955 and
- if possible, have a smooth shaft.
LIf a motor is included in the delivery, then it is:
- already firmly mounted on the LP+(no assembly necessary).
- only mounted hand-tight on the LPB+(assembly necessary).
5.3.1 Pre-mounting adapter plate (only LPB+)
The following information is valid for only the LPB+. On the LP+, the adapter plate is already
mounted.
The adapter plate (B) along with the four
fastening bolts (A) are included in the scope of
delivery.
zPlace the adapter plate onto the housing and
hand-tighten the bolts at first.
zTighten the bolts in diagonal order in at least
two passes to the required tightening torque.
See table "Tbl-7"
Gearhead size
LPB+
Size Tightening torque
[Nm]
070 M4 2,64
090 M6 8,99
120 M6 8,99
Tbl-7: Fastening bolts adapter plate

Assembly LP+/ LPB+
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5.3.2 Mounting the motor (LP+/ LPB+)
zSmear screw-bonding agent (for example Loctite 243) onto the four bolts (E).
zFasten the motor (C) onto the adapter plate (D) with the four screws (E).
zTighten the threaded pin (B) of the plug receptacle (A).
LFor bolt sizes and specified torques refer to chapter 9.1 "Specifications on mounting onto a
motor", table "Tbl-14".
zPress the enclosed stopper plugs up to their stop in the mounting bores of the adapter plate
(D).
zEnsure that the motor is mounted if possible
in a vertical direction.
zClean the motor shaft, the plug socket bore
hole, the spacer sleeve and the fitting
surfaces of motor and gearhead.
zIf the motor shaft has a shaft key, remove the
shaft key.
LIf recommended by the motor
manufacturer, insert a half wedge.
zTurn the plug socket (A) so that the threaded
pin (B) can be reached through the mounting
holes.
zPush the motor shaft into the plug receptacle
of the gearhead.
LThe maximum permitted axial forces may
not be exceeded, see Chapter 9.1
"Specifications on mounting onto a
motor", table "Tbl-14". The motor shaft
should slip in easily. If this is not the case,
the threaded pin needs to be loosened
more.
LThe slit of the spacer sleeve has to line up
with the groove (if existing) of the motor
shaft and be turned by 90°to the threaded
pin, see table "Tbl-8".
LNo gap is permitted between motor (C)
and the adapter plate (D).
Designation
A Plug receptacle
B Threaded pin
F Spacer sleeve
G Smooth shaft
H Grooved shaft
Tbl-8: Arrangement of motor shaft, plug receptacle and spacer sleeve
B
G
F
A
H

LP+/ LPB+Assembly
Revision: 03 2022-D018479 en-15
5.4 Mounted components on the gear output side
5.4.1 Mountings on the output flange (LPB+)
Distortions during mounting operations can damage the gearhead.
zMount gearwheels and toothed belt pulleys onto the output shaft without
forcing.
zDo not on any account attempt an assembly by force or hammering!
zOnly use suitable tools and equipment for assembly.
zIf you pull on or shrink-fit a gear wheel onto the output shaft, you must
make sure that the maximum permitted static axial forces of the output
bearing (see table "Tbl-9") are not exceeded.
Size LP+/ LPB+050 070 090 120 155
Fa max[N] 1800 4300 5100 11300 18500
Tbl-9: Maximum permitted static axial forces at static bearing statistic (s0) = 1.8 and
radial force (Fr) = 0
Only the version LPB+features an output flange
on which a toothed belt pulley can be mounted
with the bolts.
zCoat the contact surfaces lightly with grease
or lubricant in order to prevent contact
corrosion.
zPlace the toothed belt pulley onto the output
flange and tighten the bolts initially by hand.
zTighten the fastening bolts (F) and the close-
tolerance bolt (E) (1 piece) in diagonal order
making at least two passes to the required
tightening torque (see table "Tbl-10").

Assembly LP+/ LPB+
en-16 2022-D018479 Revision: 03
The tension of the tooth belt is brought about by its construction. The toothed belt's prestressing
force influences the ball bearing life of the gearhead.
zYou can determine the theoretical bearing life for each case using our analysis software
cymex®.
zSet your toothed belt so that there are no lateral starting loads pressing on the toothed belt
pulley.
5.5 Mounting the gearhead to a machine (LP+)
Size LPB+Close-tolerance bolt
(property class 12.9)
Fastening bolts
(property class 12.9)
Size Tightening torque
[Nm]
Size Tightening torque
[Nm]
070 M5x12 9 5 x M5x12 9
090 M6x16 15.4 7 x M6x16 15.4
120 M6x16 15.4 7 x M8x20 37.3
Tbl-10: Fastening the toothed belt pulley
Four threaded bores are available in the gear unit housing for
bolting it to your machine.
zThoroughly 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 "Specifications on mounting onto a machine",
table "Tbl-15".
zSmear screw-bonding agent (for example Loctite 243) onto
the four bolts.
zFasten the gearhead on the machine with the fastening bolt
through the holes.
LMount the gearhead in such a way that the type plate
remains legible.
LDo not use washers (e.g. plain washers, tooth lock
washers).

LP+/ LPB+Startup and operation
Revision: 03 2022-D018479 en-17
6 Startup and operation
Operational conditions and requirements for the surroundings:
- Because of the factory-filled lubricant, the ambient temperature may not lie under 0 °C or over
+40 °C. Operating temperature may not exceed +90 °C.
LFor other conditions of use, please consult our Customer Service Department.
- Only use the gearhead only up to its maximum limit values, see Chapter 3.5 "Performance
statistics".
- Only use the gearhead only in a clean, dust-free and dry environment.
Objects flung out by rotating components can cause serious injuries.
zRemove 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.
zKeep a sufficient distance to rotating machinery while the gearhead is
running.
Hot gearhead housing can cause serious burns.
zTouch the gearhead housing only when wearing protective gloves or
after the gearhead has been idle for some time.

Maintenance and disposal LP+/ LPB+
en-18 2022-D018479 Revision: 03
7 Maintenance and disposal
7.1 Maintenance work
7.1.1 Visual inspection
zCheck the entire gearhead for exterior damage.
zThe radial shaft seals are subject to wear. Therefore also check the gearhead for leakage
during each visual inspection.
LYou can find more general information on radial shaft seals on our partner's Internet site at
http://www.simrit.de.
LCheck the mounting position, so that no foreign medium (e.g. oil) has collected on the
output shaft.
7.1.2 Checking the tightening torques
zCheck the tightening torque of the fastening bolts on the gearhead housing. For LPB+
gearheads, also check the fastening bolts on the toothed belt pulley.
LYou can find the prescribed tightening torques in Chapter 9.2 "Specifications on mounting
onto a machine", tables "Tbl-15" and "Tbl-16" as well as in Chapter 5.4.1 "Mountings on
the output flange (LPB+)", table "Tbl-10".
zCheck the tightening torque of the threaded pin on the motor mounting.
LYou can find the prescribed tightening torques in chapter 9.1 "Specifications on mounting
onto a motor", table "Tbl-14".
7.2 Start-up after maintenance work
zClean the outside of the gearhead.
zAttach all safety devices.
zDo a trial run before releasing the gearhead again for operation.
Hot gearhead housing can cause serious burns.
zTouch the gearhead housing only when wearing protective gloves or
after the gearhead has been idle for some time.
Rotating components on the gearhead can pull in parts of the body
and cause serious injuries and even death.
zDisconnect the machine from the mains before starting maintenance
work.
zSecure the motor against restarting during maintenance work.