Wittenstein Alpha Advanced TP+ Series User manual

2022-D020259 Revision: 04
alpha Advanced Line
TP+ ATEX
Operating Manual

TP+ ATEX
2022-D020259 Revision: 04
WITTENSTEIN alpha GmbH
Walter-Wittenstein-Straße 1
D-97999 Igersheim
Germany
Customer Service department
Deutschland WITTENSTEIN alpha GmbH [email protected] [phone]
Benelux WITTENSTEIN BVBA [email protected] [phone]
Brasil WITTENSTEIN do Brasil [email protected] [phone]
[email protected] [phone]
Österreich WITTENSTEIN GmbH offi[email protected] [phone]
Danmark WITTENSTEIN AB [email protected] [phone]
France WITTENSTEIN sarl [email protected] [phone]
Great Britain WITTENSTEIN Ltd. [email protected] [phone]
Italia WITTENSTEIN S.P.A. [email protected] [phone]
[email protected] [phone]
North America WITTENSTEIN holding Corp. [email protected] [phone]
España WITTENSTEIN S.L.U. [email protected] [phone]
Sverige WITTENSTEIN AB [email protected] [phone]
Schweiz WITTENSTEIN AG Schweiz [email protected] [phone]
[email protected] [phone]
Türkiye WITTENSTEIN Güç Aktarma
Sistemleri Tic. Ltd. Şti. [email protected] [phone]
© WITTENSTEIN alpha GmbH 2019
Subject to technical and content changes without notice.

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Table of Contents
1 About this manual ................................................................................................3
1.1 Information symbols and cross references ..........................................................3
1.2 Scope of delivery .................................................................................................3
2 Safety.....................................................................................................................4
2.1 EC/EU Directive ...................................................................................................4
2.1.1 Machinery Directive.........................................................................................4
2.1.2 EU directive for devices and protective systems in
potentially explosive atmospheres ..................................................................4
2.2 Personnel.............................................................................................................4
2.3 Intended use ........................................................................................................5
2.4 Reasonably foreseeable misuse..........................................................................6
2.5 General safety instructions ..................................................................................6
2.6 Structure of warning instructions..........................................................................7
2.6.1 Safety symbols ................................................................................................8
2.6.2 Signal words....................................................................................................8
3 Description of the gearbox..................................................................................9
3.1 Overview of gearbox components .......................................................................9
3.2 Name plate.........................................................................................................10
3.2.1 ATEX marking for use in potentially explosive gas atmospheres..................10
3.3 Ordering code ....................................................................................................11
3.4 Ex model ............................................................................................................11
3.5 Dimensions and performance data ....................................................................11
3.6 Dimensioning .....................................................................................................12
3.6.1 Inspection ......................................................................................................12
3.7 Information about the lubricant ..........................................................................12
4 Transport and storage .......................................................................................13
4.1 Packaging ..........................................................................................................13
4.2 Transport............................................................................................................13
4.2.1 Transport of gearboxes up to and including size 050....................................13
4.2.2 Transport of gearboxes starting from size 110..............................................13
4.3 Storage ..............................................................................................................13
5 Assembly ............................................................................................................14
5.1 Preparations.......................................................................................................14
5.2 Installation conditions.........................................................................................15
5.3 Mounting the motor to the gearbox ....................................................................15
5.4 Mounting the gearbox on a machine..................................................................16
5.4.1 Mounting with through-holes .........................................................................17
5.4.2 Mounting with slotted holes ..........................................................................17
5.4.3 Mounting with threaded bores .......................................................................18
5.5 Components mounted to the output side ...........................................................18
5.5.1 Mounting with shrink disk ..............................................................................19
6 Startup and operation ........................................................................................20
6.1 Note the following during startup .......................................................................20
6.2 Checking run-in behavior ...................................................................................21

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7 Maintenance and disposal................................................................................ 22
7.1 Maintenance schedule ...................................................................................... 22
7.2 Maintenance work ............................................................................................. 22
7.2.1 Visual/Noise inspection................................................................................. 22
7.2.2 Checking the tightening torques ................................................................... 23
7.2.3 Replacing the gearbox.................................................................................. 23
7.3 Startup after maintenance work ........................................................................ 23
7.4 Disposal............................................................................................................. 23
8 Disassembly....................................................................................................... 24
8.1 Removing the components of the output side................................................... 24
8.1.1 Removing the shrink disc.............................................................................. 24
8.2 Disassembling the gearbox with the motor from the machine........................... 25
8.3 Disassembling the motor................................................................................... 25
9 Malfunctions ...................................................................................................... 26
10 Appendix ............................................................................................................ 27
10.1Specifications for mounting to a motor.............................................................. 27
10.2Specifications for mounting to a machine.......................................................... 28
10.2.1Specifications for mounting with through-holes ........................................... 28
10.3Specifications for mounting to the output side................................................... 28
10.4Specifications for startup and operation............................................................ 29
10.4.1Impermissible operating conditions.............................................................. 29
10.5Tightening torques for common thread sizes in
general mechanical engineering ....................................................................... 30
10.6Technical specifications .................................................................................... 30
10.6.1Technical data for TP+ 004 for use in potentially explosive atmospheres ... 30
10.6.2Technical data for TP+ 010 for use in potentially explosive atmospheres ... 34
10.6.3Technical data for TP+ 025 for use in potentially explosive atmospheres ... 38
10.6.4Technical data for TP+ 050 for use in potentially explosive atmospheres ... 42
10.6.5Technical data for TP+ 110 MF for use in
potentially explosive atmospheres................................................................ 46
10.6.6Technical data for TP+ 110 MA for use in
potentially explosive atmospheres................................................................ 50
10.7Declaration of Conformity.................................................................................. 52

TP+ ATEX About this manual
Revision: 04 2022-D020259 en-3
1 About this manual
This operating manual contains necessary information to safely operate the gearbox.
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 void.
The operator must ensure that all persons assigned to install, operate, or maintain the gearbox have
read and understood these instructions in full.
Store these instructions within reach of the gearbox.
Inform colleagues who work in the area around the machine about the safety and warning notices
to avoid injuries.
The original instructions were prepared in German; all other language versions are translations of
these instructions.
1.1 Information symbols and cross references
The following information symbols are used:
Indicates an action to be performed
Indicates the results of an action
Provides additional information about the action
A cross reference refers to the chapter number and the header of the target section (e. g. 2.3
"Intended use").
A cross reference on a table refers to the table number (e. g. Table "Tbl-15").
1.2 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 company, or WITTENSTEIN alpha GmbH.

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2 Safety
These instructions, especially the safety and warning notices and the rules and regulations valid for
the operating site, must be observed by all persons working with the gearbox.
The following, especially, must be strictly adhered to:
Observe the instructions for transport and storage.
Use the gearbox only in accordance with its intended use.
Carry out maintenance and repair work appropriately and professionally in conformity with the
specified intervals.
Always mount, dismantle, and operate the gearbox properly (e.g. even test run only with
secure mounting).
The manufacturer of the higher-level machine shall, in accordance with its risk assessment,
install protective devices and equipment as appropriate to protect the user from the residual
hazards of the gearbox. Only operate the gearbox with intact and active protective devices
and equipment.
Only operate the gearbox with the correct lubricant (type and amount).
Prevent the gearbox from becoming extremely soiled.
Only carry out modifications or reconstructions when these are approved in writing by the
WITTENSTEIN alpha GmbH.
Personal injuries or material damage, or other claims arising from non-observance of these
minimum requirements, are the sole responsibility of the operator.
In addition to the safety-related information in this manual, also observe any legal and otherwise
applicable rules and regulations, particularly for accident prevention (e.g. personal safety
equipment) and environmental protection.
2.1 EC/EU Directive
2.1.1 Machinery Directive
The gearbox is considered a "machine component" and is therefore not subject to the EC
Machinery Directive 2006/42/EC.
Startup is prohibited within the scope of the EC directive until it has been determined that the
machine in which this gearbox is installed corresponds to the regulations within this directive.
2.1.2 EU directive for devices and protective systems in potentially explosive atmospheres
2.2 Personnel
Only technicians who have read and understood this operating manual may perform work on the
gearbox. Based on their training and experience, technicians must be able to evaluate the tasks
assigned to them, in order to recognize and avoid risks.
An "explosion protection symbol" indicates information and requirements for handling
in potentially explosive atmospheres.
According to Directive 2014/34/EU, the gearbox is considered a device that is
installed together with other devices in a machine. A declaration of conformity for this
gearbox can be found in the appendix (see Chapter 10.7 "Declaration of
Conformity").
Operation is prohibited within the area of validity of the directive until it has been
determined that the machine in which this product is installed corresponds to the
regulations within this directive.

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2.3 Intended use
The gearbox serves to convert torques and speeds. It is suitable for all industrial applications.
In food processing / pharmaceutical / cosmetics, the gearbox may only be used next to or under the
product area. Product-specific deviation regarding the positioning and mounting position are
described in Chapter 3 "Description of the gearbox".
The gearbox has been constructed according to current technological standards and accepted
safety regulations.
To avoid danger to the operator or damage to the machine, apply the gearbox only for its
intended use and in a technically flawless and safe state.
If you notice any altered operating behavior, check the gearbox in accordance with Chapter 9
"Malfunctions".
Read the general safety instructions before beginning to work (see Chapter 2.5 "General
safety instructions").
Screw connections between gearbox and attached component such as motors have to be
calculated, dimensioned, mounted, and tested according to current technological standards. Use
the VDI directives VDI 2862 sheet 2 and VDI 2230 for example.
The tightening torques recommended by us can be found in Chapter 10 "Appendix".
Deviating from the recommendations in Chapter 5 "Assembly", washers may be used if the material
of the screw surface features a too low interface pressure.
The hardness of the washer needs to match the property class of the screw.
Take into account the washer for the screw calculation (joint, additional compression set,
surface pressure under screw head and under washer).
The gearbox can be used in the potentially explosive atmospheres defined in
Chapter 3.4 "Ex model".
Observe the instructions on the name plate and the appendix on the written
certificate of conformity.
The gearbox is manufactured and certified for use in potentially explosive
atmospheres in compliance with standard DIN EN?ISO 80079 and the following EU
Directive?:
-2014/34/EU
Strictly observe the restrictions on speeds and torques (see Chapter 10.6
"Technical specifications").
Our Customer Service department (technical customer service) is available to
answer any questions.
The gearbox is intended for installation on motors that:
- correspond to type B5 (in the event of deviations, consult our Customer Service
department [Technical Customer Service department]).
- have a radial and axial runout tolerance according to DIN EN 50347.
- have a cylindrical shaft end with tolerance class h6 to k6.
For motor shaft diameters of 55?mm and up, m6 is also permissible.
- Feature at least the same temperature class as the gearbox (see also Chapter 3.2
"Name plate").
We recommend this temperature class and higher, because the gearbox may
not be allowed to exceed the maximum permitted housing temperature under
normal conditions (see chapter 10.4 "Specifications for startup and operation").
The gearbox can be heated additionally through heat connection to the motor,
and thus reach a higher housing temperature. The performance of our gearbox
in explosion-risk areas would therefore no longer be guaranteed.

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2.4 Reasonably foreseeable misuse
2.5 General safety instructions
The operation of the gearbox involves residual risks even when adhering to the intended use.
Rotating components can cause serious injuries:
Before startup, remove objects, loose components (e.g. feather keys), and tools from the
gearbox, in order to avoid danger from thrown parts.
Keep a sufficient distance to moving machine components when the gearbox is running.
Secure the higher-level machine against restarting and unintentional movements during
assembly and maintenance work (e.g. uncontrolled lowering of lifting axes).
A hot gearbox can cause serious burns:
Touch the hot gearbox only with protective gloves.
The noise emissions can lead to hearing damage. The continuous noise pressure level may vary
according to product type and gearbox size:
Information about the operating noise LPA of your gearbox is available in Chapter 10.6
"Technical specifications", in the customized performance data (X093–D...) or from our
Customer Service / Sales department.
For noise protection measures, observe the total noise pressure level of the machine.
Loose or overloaded screw connections can cause damage to the gearbox:
Always use a calibrated torque wrench to tighten and check all screw connections for which a
tightening torque has been specified.
Solvents and lubricants are flammable, can cause skin irritation, and can pollute soil and water:
In case of fire: Do not spray with water to extinguish.
Suitable extinguishing agents are powder, foam, water mist and carbon dioxide. Observe
the safety instructions of the lubricant manufacturer (see Chapter 3.7 "Information about
the lubricant").
Use protective gloves to avoid direct skin contact with solvents and lubricants.
Use and dispose of cleaning solvents and lubricants properly.
A damaged gearbox can cause accidents and injury:
Immediately shut down a gearbox that has been overloaded due to misuse or a machine
crash (see Chapter 2.4 "Reasonably foreseeable misuse").
Replace the damaged gearbox, even if no external damage is visible.
Explosions can cause serious injuries and even death:
Ensure that the gearbox is only used in those areas for which it is approved according to the
name plate (see Chapter 3.2 "Name plate").
Be certain that there is no explosive atmosphere and that no dust enters the adapter plate
during assembly and maintenance.
Any use that deviates from the approved technical data (e.g. speed, force, torque,
temperature, service life) is not use as intended and is therefore not permitted (also
see Chapter 3.5 "Dimensions and performance data").
Table "Tbl-1" lists a summary of the possible hazards, their causes and protective
measures for potentially explosive atmospheres.

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2.6 Structure of warning instructions
Dangers Possible causes Protective measures
Hot surfaces Increased friction and dissipated
power because of wear, improper
assembly, overload or leaks.
Reduce torques and speeds
compared to standard gearboxes
Limit the motor current and
maximum speed of the motor
Maintenance intervals for wear
parts and lubricant according to
maintenance schedule
Check the temperature behavior
and the run-in behavior before
startup
Regular visual and acoustic
inspections
Prohibit certain mounting
positions and conditions
Increased surface temperature
due insulation by dust deposits.
Cleaning regulations according to
maintenance plan
Mechanically
caused sparks
Overload on shafts, moving parts
and connection elements.
Reduce torques and external
loads compared to standard
gearboxes
Limit the motor current of the
motor
Perform maximum load test
before startup
Static electricity Potential differences between
components, cleaning processes,
insulating layers
Ground the gearbox and the
motor
Tbl-1: Summary of the hazards and protective measures for potentially explosive atmospheres
Warning instructions are situation-specific. They
will be precisely where tasks are described in
which dangers can arise.
The warning instructions in this manual are
designed according to the following pattern:
A = Safety symbol (see Chapter 2.6.1 "Safety
symbols")
B = Signal word (see Chapter 2.6.2 "Signal words")
C = Type and consequence of the danger
D = Avoiding the danger
AB
CD

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2.6.1 Safety symbols
The following safety symbols are used to indicate possible hazards, prohibitions, and important
information:
2.6.2 Signal words
The following signal words are used to indicate possible hazards, prohibitions, and important
information:
General hazard Hot surface Suspended loads Entanglement
Environmental
protection
Information Explosion
This signal word indicates an imminent danger that will cause serious
injuries or even death.
This signal word indicates a potential hazard that could cause serious
injuries and even death.
This signal word indicates a potential hazard that could cause minor
or serious injuries.
This signal word indicates a potential hazard that could lead to
material damage.
A note without a signal word indicates application hints or especially
important information for handling the gearbox.