Wittenstein Alpha LP+ User manual

2022
-
D039182
03
2022-D039182 Revision: 03
LP+/LPB+Generation 3
Assembly Instructions

LP+/LPB+
2022-D039182 Revision: 03
Revision history
Revision Date Comment Chapter
01 28.03.2011 New version All
02 16.05.2012 Generation 3 All
03 28.11.2012 Safety 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 2012
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+
Motor mounting video
LPB+
Motor mounting video

LP+/LPB+
Revision: 03 2022-D039182 en-1
Contents
1 Regarding this manual.........................................................................................2
1.1 Information symbols.............................................................................................2
2 General safety instructions.................................................................................2
2.1 Identification plate ................................................................................................2
2.2 Intended use ........................................................................................................2
2.3 Reasonably predictable misuse ...........................................................................2
2.4 Guarantee and liability .........................................................................................2
2.5 General safety instructions ..................................................................................3
2.6 Storage ................................................................................................................4
2.7 Checking the tightening torques ..........................................................................4
2.8 Maintenance schedule .........................................................................................4
2.9 Malfunctions.........................................................................................................4
3 Technical data sheets..........................................................................................5
3.1 Transport of gearheads up to and including size LP+/LPB+155..........................5
3.2 Preparations.........................................................................................................5
3.3 Attaching a gearhead to a machine (LPB+) .........................................................6
3.4 Mounting the motor onto the gearhead................................................................7
3.4.1 Pre-mounting adapter plate (only LPB+) .........................................................7
3.4.2 Mounting the motor (LP+/ LPB+) .....................................................................7
3.5 Mounted components on the gear output side.....................................................8
3.5.1 Mountings on the output flange (LPB+) ...........................................................8
3.6 Mounting the gearhead to a machine (LP+) .........................................................9
3.7 Startup and operation ..........................................................................................9
3.8 Notes on the lubricant used ...............................................................................10
3.9 Specifications for fastening to a motor...............................................................10
3.10Specifications on mounting onto a machine ......................................................10
3.11Tightening torques for common thread sizes in general mechanics..................11
3.12Performance statistics........................................................................................11
3.13Supplementary information ................................................................................11

Regarding this manual LP+/LPB+
en-2 2022-D039182 Revision: 03
1 Regarding this manual
The original instructions were prepared in German; all other language versions are translations of
these instructions.
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.
1.1 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
2 General safety instructions
2.1 Identification plate
The type plate is attached to the gearhead housing as well input flange.
2.2 Intended use
The gearhead serves to convert torques and speeds in industrial applications.
The gearhead may not be operated in areas with explosion hazards. In food processing, the
gearhead may be used only next to or under the foodstuff area.
2.3 Reasonably predictable misuse
Any usage that exceeds the maximum permitted speeds, torques and temperature is considered a
misuse and is therefore prohibited.
2.4 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 (e.g. test run without secure
attachment)
- 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
Designation
A Ordering code (see Chapter 3.13
"Supplementary information")
BRatio
C Serial number
D Lubricant
E Production date
Tbl-1: Identification plate (template)
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

LP+/LPB+General safety instructions
Revision: 03 2022-D039182 en-3
2.5 General safety instructions
Suspended loads can fall and can cause serious injuries and even
death.
Only use hoisting equipment and transports with sufficient capacity.
Do not stand under suspended loads.
Objects flung out by rotating components can cause serious injury
and death.
Remove objects and tools from the gearhead before putting it into
operation.
Remove/Secure the shaft key (if available) if the gearhead is operated
without attachments on the output/drive side.
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 and maintenance work (e.g. uncontrolled lowering of
lifting axes).
A damaged gearhead can cause accidents and injury.
Never use a gearhead that has been overloaded to due misuse or a
machine crash (see chapter 2.3 "Reasonably predictable misuse").
Replace the concerned gearhead, even if external damage is visible.
Lubricants are flammable.
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.
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.
Solvents and lubricants can cause skin irritations.
Avoid direct skin contact.
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.
All gearheads are permanently lubricated by the manufacturer with
synthetic gear oil (polyglycols) or with a grease (see identification
plate).
Do not mix polyglycols with mineral oils.

General safety instructions LP+/LPB+
en-4 2022-D039182 Revision: 03
2.6 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.
2.7 Checking the tightening torques
Check the tightening torque of the fastening screws on the gearhead housing.
For LPB+–gearheads, also check the fastening screws on the toothed belt pulley.
Check the tightening torque of the threaded pin on the motor mounting.
The prescribed tightening torque can be found in 3 "Technical data sheets" in this manual.
2.8 Maintenance schedule
2.9 Malfunctions
Unusual operating behavior (noise, heat, vibration) can be an indication of faulty assembly,
improper dimensioning, or technical defects.
Do not put the gearhead back into operation until the cause of the malfunction has been
rectified.
Solvents and lubricants can pollute soil and water.
Use and dispose of cleaning solvents as well as lubricants appropriately.
Maintenance work At startup First time after
500 operating hours or
3 months
Every 3
months Yearly
Visual inspection XXX
Checking the
tightening torques XX X
Tbl-2: Maintenance schedule
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. Consult our Customer Service
department.
Damaged bearings.
Damaged gear teeth.
Toothed belt pretension too
great (if it exists).

LP+/LPB+Technical data sheets
Revision: 03 2022-D039182 en-5
3 Technical data sheets
Be informed of the general safety instructions before beginning work. (see Chapter 2.5
"General safety instructions").
The gearhead can be used in any mounting position.
If your application has to meet special safety requirements (e.g. vertical axes, tensioned
drives), we recommend using exclusively our alpheno®, RP+, TP+, TP+HIGH TORQUE
products or contact WITTENSTEIN alpha for advice.
3.1 Transport of gearheads up to and including size LP+/LPB+155
No special transport mode is prescribed for transporting the gearhead.
3.2 Preparations
Check the fitting surfaces additionally for damage and impurities.
Ensure that the bushing included in the delivery may be slid on the motor shaft with a tight
sliding fit.
Fault Possible cause Solution
Loss of lubricant Lubricant quantity too high. Wipe off discharged lubricant and
continue to watch the gearhead.
Lubricant discharge should stop after a
short time.
Seals not tight. Consult our Customer Service
department.
Tbl-3: Malfunctions
Pressurized air can damage the gearhead seals.
Do not use pressurized air to clean the gearhead.
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.
In rare situations, for a gearhead with grease lubrication (see
identification plate), a leak can occur at the drive (seeping).
To avoid seeping, we recommend that between the following surfaces:
- Adapter plate and drive housing (gearhead) as well as
- Adapter plate and motor
be sealed with a surface sealing adhesive (e.g. Loctite®573 or 574).
For more information, please contact our Customer Service department.
Clean/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
- The bushing inside and out
- the toothed belt pulley (only applies to LPB+)

Technical data sheets LP+/LPB+
en-6 2022-D039182 Revision: 03
The different assembly order of LP+and LPB+is listed in table "Tbl-4".
If you have any questions, get in touch with our Customer Service department.
3.3 Attaching a gearhead to a machine (LPB+)
The gearhead exhibits two centering means for the attachment to the machine (A=motor side;
B=gear output side).
A spacer (E) must be assembled between the gearhead and your machine for the dimensionally
accurate positioning of the gearhead if required. This spacer is not included in the scope of
delivery and must be provided by the customer.
Fastening screws must be provided by the customer.
You may find the required screw sizes and tightening torques in chapter 3.10 "Specifications on
mounting onto a machine", table "Tbl-13".
When using hollow profiles (C): Position the toothed belt pulley (D) in the hollow profile prior to
attaching the gearhead.
Coat the fastening screws with a threadlocker (e.g. Loctite 243).
Mount the gearhead with the fastening screws via the through-holes at the machine.
Install the gearhead in such a manner that the type plate remains readable if possible.
Do not use washers (e.g. flat washers, lock washers).
LP+LPB+
—1.) 3.3 "Attaching a
gearhead to a machine
(LPB+)"
1.) 3.4 "Mounting the motor
onto the gearhead"
2.) 3.4 "Mounting the motor
onto the gearhead"
2.) 3.5 "Mounted
components on the gear
output side"
3.) 3.5 "Mounted
components on the gear
output side"
3.) 3.6 "Mounting the
gearhead to a machine
(LP+)"
—
Tbl-4: Assembly order

LP+/LPB+Technical data sheets
Revision: 03 2022-D039182 en-7
3.4 Mounting the motor onto the gearhead
3.4.1 Pre-mounting adapter plate (only LPB+)
The following information is valid for only the LPB+. On the LP+, the adapter plate is already
mounted.
3.4.2 Mounting the motor (LP+/ LPB+)
No gap is permitted between motor (C) and the adapter plate (D).
The adapter plate (B) along with the four
fastening screws (A) are included in the scope
of delivery of the gearhead.
Place the adapter plate onto the gearhead
housing and hand-tighten the screws at first.
Tighten the screws in diagonal order in at
least two passes to the required tightening
torque. See table "Tbl-5"
Gearhead size LPB+Size Tightening torque [Nm]
070 M4 2,6
090 M6 9,0
120 M6 9,0
Tbl-5: Fastening screws adapter plate
Observe the specifications and safety instructions of the motor
manufacturer.
Observe the safety and processing instructions of the screw-bonding
agents to be used.
Ensure that the motor is mounted if possible in a
vertical direction.
If the motor shaft has a shaft key, remove the
shaft key.
If recommended by the motor manufacturer,
insert a half wedge.
Turn the plug receptacle (A) so that the threaded
pin (B) can be reached through the mounting
bore, see table "Tbl-6"
Push the motor shaft into the plug receptacle of
the gearhead.
The maximum permitted axial forces may not
be exceeded, see Chapter 3.9 "Specifications
for fastening to a motor", table "Tbl-11". The
motor shaft should slip in easily. If this is not
the case, the threaded pin needs to be
loosened more.
The slit of the bushing 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-6".

Technical data sheets LP+/LPB+
en-8 2022-D039182 Revision: 03
Coat the four screws (E) with a threadlocker (e.g. Loctite 243).
Fasten the motor (C) onto the adapter plate (D) with the four screws (E).
Tighten the threaded pin (B) of the plug receptacle (A).
For screw sizes and prescribed tightening torques refer to Chapter 3.9 "Specifications for
fastening to a motor", Tables "Tbl-11".
Press the enclosed stopper plugs up to their stop in the mounting bores of the adapter
plate (D).
3.5 Mounted components on the gear output side
3.5.1 Mountings on the output flange (LPB+)
Designation
A Plug receptacle
B Threaded pin
F Bushing
G Smooth shaft
H Keyed shaft
Tbl-6: Arrangement of motor shaft, plug receptacle and bushing
Distortions during mounting operations can damage the gearhead.
Mount gearwheels and toothed belt pulleys onto the output shaft without
forcing.
Do not on any account attempt an assembly by force or hammering!
Only use suitable tools and equipment for assembly.
If a gear wheel is pulled or shrink-fit onto the output shaft, make sure that
the maximum permitted static axial forces of the output bearing (see
table "Tbl-7") are not exceeded.
Size LP+/ LPB+050 070 090 120 155
Fa max[N] 1800 4300 5100 11300 18500
Tbl-7: Maximum permitted static axial forces at static bearing statistic (s0) = 1.8 and radial force (Fr) = 0
Observe the safety and processing instructions of the cleaning agents
and screw-bonding agents to be used.
Only the version LPB+features an output flange on
which a toothed belt pulley can be mounted with the
bolts.
Thoroughly clean the output flange, centering,
fitting surface and toothed belt pulley. The anti-
corrosion agent on the toothed belt pulley must
be removed.
To remove the Aceton or Loctite 7063 anti-
corrosion agent, use a clean, lint-free cloth.
Also clean the browned toothed belt pulley with a
brush and remove any salt residue between the
flanged wheel and toothed belt wheel.
B
G
F
A
H

LP+/LPB+Technical data sheets
Revision: 03 2022-D039182 en-9
Place the toothed belt pulley onto the output flange.
Brush the screws with a screw-bonding agent (such as Loctite 243) and tighten the screws by
hand initially.
Tighten 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-8").
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.
Determine the theoretical bearing life for each case using our analysis software cymex®.
Set the toothed belt so that there are no lateral starting loads pressing on the toothed belt
pulley.
3.6 Mounting the gearhead to a machine (LP+)
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).
3.7 Startup and operation
Gearhead
size
LPB+
Close-tolerance bolt Fastening bolts
Thread x
depth
[mm] x [mm]
Tightening torque
[Nm]
(Property class 10.9)
QuantityxThread
x Depth
[ ] x [mm] x [mm]
Tightening torque
[Nm]
(Property class 12.9)
070 M5 x 12 7,69 5 x M5 x 12 9
090 M6 x 16 13,2 7 x M6 x 16 15,4
120 M6 x 16 13,2 7 x M8 x 20 37,3
Tbl-8: Fastening the toothed belt pulley
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 3.10
"Specifications on mounting onto a machine", table "Tbl-12".
Smear screw-bonding agent (for example Loctite 243) onto the
four bolts.
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 3.12 "Performance statistics".
Only use the gearhead only in a clean, dust-free and dry environment.

Technical data sheets LP+/LPB+
en-10 2022-D039182 Revision: 03
3.8 Notes on the lubricant used
The manufacturer listed below will provide any further information on the lubricants:
3.9 Specifications for fastening to a motor
3.10 Specifications on mounting onto a machine
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 identification 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-9: Lubricant manufacturers
Designation
A Plug receptacle
B Threaded pin
F Bushing
G Smooth shaft
H Keyed shaft
Tbl-10: Arrangement of motor shaft, plug receptacle and bushing
Gearheadsize
LP+/ LPB+Plug receptacle inside Ø (standard / large) [mm] Width across flats, threaded pin (B) [mm] Tightening torque [Nm] Max. axial force [N]
050 11 / 14 3 5.6 45
070 16 / 19 4 14 80
090 24 / 28 5 23 100
120 32 / 38 6 45 150
155, 1–stage 42 8 78 180
155, 2–stage 32 / 38 6 45 150
Tbl-11: Specifications for fastening to a motor
Gearhead
size LP+Bore Ø [mm] Bolt size / property class Tightening torque [Nm]
050 44 M4 / 12.9 4.55
070 62 M5 / 12.9 9.0
090 80 M6 / 12.9 15.4
120 108 M8 / 12.9 37.3
155 140 M10 / 12.9 73.4
Tbl-12: Threaded bores in the gearhead housing LP+
A
B
F
G
H

LP+/LPB+Technical data sheets
Revision: 03 2022-D039182 en-11
3.11 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 %
3.12 Performance statistics
Refer to our catalogue or our Internet page for the maximum permitted speeds and torques:
http://www.wittenstein-alpha.de
3.13 Supplementary information
Gearhead
size LPB+Bore Ø [mm] Bolt size / property class Tightening torque [Nm]
070 82 M8 / 12.9 37.3
090 106 M10 / 12.9 73.4
120 144 M12 / 12.9 126
Tbl-13: Through-holes in gearhead housing LPB+
Tightening torque [Nm] for threads
Property
class
Screw / 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-14: Tightening torques for headless screws and nuts
Consult our Customer Service department if the gearhead is older
than a year. You will then receive the valid performance data.
The complete operating manual can be found on our website:
www.wittenstein-alpha.de/en/operating-manuals
or scan this code, to receive the detailed operating manual directly
as a PDF (max. 1 MB).

2022
-
D016962
:
01
enAC: XXXXXXXX 2022-D016962 Revision: 01
WITTENSTEIN alpha GmbH · Walter-Wittenstein-Straße 1 · 97999 Igersheim · Germany
Tel. [phone] · [email protected]
WITTENSTEIN - being one with the future
www.wittenstein-alpha.de
LP+
Motor mounting video
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Motor mounting video