Wittenstein Alpha TP+ User manual

2022
-
D036009
03
2022-D036009 Revision: 03
TP+
Assembly Instructions

TP+
2022-D036009 Revision: 03
Revision history
Revision Date Comment Chapter
01 27.10.10 New version All
02 18.04.11 Technical Data 2
03 22.10.12 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.
Motor mounting video

TP+
Revision: 03 2022-D036009 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 TP+050...................................5
3.2 Transport of gearheads as of size TP+110 .........................................................5
3.3 Preparations.........................................................................................................5
3.4 Mounting the motor onto the gearhead................................................................5
3.5 Mounting the gearhead to a machine .................................................................6
3.6 Mounted components on the gear output side.....................................................7
3.7 Startup and operation ..........................................................................................7
3.8 Notes on the lubricant used .................................................................................7
3.9 Details regarding the attachment to a motor........................................................8
3.10Specifications on mounting onto a machine ........................................................9
3.11Specifications on mounting on the gear output side ..........................................10
3.12Tightening torques for common thread sizes in general mechanics..................10
3.13Performance statistics........................................................................................11
3.14Supplementary information ................................................................................11

Regarding this manual TP+
en-2 2022-D036009 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 3.14
"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

TP+General safety instructions
Revision: 03 2022-D036009 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 TP+
en-4 2022-D036009 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.
Check the tightening torque of the clamping bolt 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).
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

TP+Technical data sheets
Revision: 03 2022-D036009 en-5
3 Technical data sheets
Be informed of the general safety instructions before beginning work. (see Chapter 2.5
"General safety instructions").
3.1 Transport of gearheads up to and including size TP+050
No special transport mode is prescribed for transporting the gearhead.
3.2 Transport of gearheads as of size TP+110
For gearheads of size TP+110 or greater, we recommend the use of hoisting equipment.
3.3 Preparations
3.4 Mounting the motor onto the gearhead
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.
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 inside diameter of the clamping hub
- The bushing inside and out
Check the fitting surfaces additionally for damage
and impurities.
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.
Remove the plug (A) from the mounting bore in
the adapter plate (B).
Turn the clamping hub until the clamping bolt
(H, see table "Tbl-4") can be reached by the
mounting bore.
Loosen the clamping bolt (H) of the clamping hub
by one revolution.

Technical data sheets TP+
en-6 2022-D036009 Revision: 03
Push the motor shaft into the clamping hub of the gearhead.
The motor shaft should slip in easily. If this is not the case, the clamping bolt needs to be
loosened some more.
A slotted bushing has to be installed extra for certain motor shaft diameters and applications.
The slot of the bushing (if provided) and clamping hub have to be flush with the groove (if
provided) of the motor shaft, see table "Tbl-4".
No gap is permitted between motor (D) and the adapter plate (B).
Motor centering of the motor-mounted gearhead is performed:
- up to gearhead size TP+025 and a motor shaft diameter of 28 mm by the clamping hub
(socket or coupling)
- from gearhead size TP+050 and a motor shaft diameter of >28 mm through the centering
collar of the motor
Coat the four screws (F) with a threadlocker (e.g. Loctite 243).
Fasten the motor (D) onto the adapter plate (B) with the four screws (F).
Select the tightening torque for the clamping bolt (H) according to the material of the clamping
ring (I).
- Clamping bolt for steel clamping ring: Property class 12.9
- Clamping bolt for aluminum clamping ring: Property class 8.8
For screw sizes and specified torques refer to chapter 3.9 "Details regarding the
attachment to a motor", table "Tbl-8".
Tighten the clamping bolt (H) of the clamping hub.
Screw in plug (A) of the adapter plate (B).
For screw sizes and tightening torques, see Table "Tbl-5".
3.5 Mounting the gearhead to a machine
Center the gearhead in the machine base.
Coat the fastening screws with a threadlocker (e.g. Loctite 243).
Fasten the gearhead to the machine with the fastening screws through the through-holes.
Mount the gearhead in such a way that the identification plate remains legible.
Designation
H Clamping bolt
I Clamping ring [part of the clamping hub]
J Bushing
K Keyed motor shaft
L Smooth motor shaft
Tbl-4: Arrangement of motor shaft, clamping hub, and bushing
Width across flats [mm] 5 8 10 12
Tightening torque [Nm] 10 35 50 70
Tbl-5: Tightening torque for the plugs
Observe the safety and processing instructions of the screw-bonding
agents to be used.

TP+Technical data sheets
Revision: 03 2022-D036009 en-7
Do not use washers (e.g. plain washers, tooth lock washers).
For prescribed screw sizes and torques refer to Chapter 3.10 "Specifications on mounting
onto a machine", table "Tbl-9".
3.6 Mounted components on the gear output side
For prescribed screw sizes and tightening torques refer to Chapter 3.11 "Specifications on
mounting on the gear output side", table "Tbl-10".
3.7 Startup and operation
3.8 Notes on the lubricant used
The manufacturer listed below will provide any further information on the lubricants:
Distortions during mounting operations can damage the gearhead.
Mount gearwheels and toothed belt pulleys onto the output flange
without forcing.
Do not on any account attempt an assembly by force or hammering!
Only use suitable tools and equipment for assembly.
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 3.13 "Performance statistics".
Only use the gearhead only in a clean, dust-free and dry environment.
All gearheads are permanently lubricated by the manufacturer with
synthetic gear oil (polyglycols) of viscosity class ISO VG100, ISO VG220 or
with a high-performance lubricant (see type plate). All bearings are
permanently lubricated by the company.
Standard lubricants Lubricants for the food industry
(NSF-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-6: Lubricant manufacturers

Technical data sheets TP+
en-8 2022-D036009 Revision: 03
3.9 Details regarding the attachment to a motor
Designation
H Clamping bolt
I Clamping ring (part of the clamping hub)
J Bushing
K Motorshaft
Tbl-7: Arrangement of motor shaft, clamping hub, and bushing
Gearhead
size TP+Clamping hub
interior Ø
“x” [mm]
Clamping
screw(H)
/ DIN ISO
4762
Width
across
flats
[mm]
Tightening torque
[Nm] property class Max. axial force clamping hub [N]
12.9
(steel) 8.8 (alu) Plug receptacle Coupling
004 1-stage x≤11
11< x ≤14
14< x ≤19
M4
M5
M6
3
4
5
4.1
9.5
14
2.8
5.6
9.5
100 10
2-stage x≤11
11< x ≤14
M4
M5
3
4
4.1
9.5
2.8
5.6
80 —
010 1-stage x≤14
14< x ≤19
19< x ≤24
M5
M6
M8
4
5
6
9.5
14
35
5.6
9.5
23
120 20
2-stage x≤11
11< x ≤14
14< x ≤19
M4
M5
M6
3
4
5
4.1
9.5
14
2.8
5.6
9.5
100 10
3-stage x≤14 M5 4 9.5 5.6 100 10
025 1-stage x≤19
19< x ≤24
24< x ≤28
28< x ≤38
M6
M8
M6
M10
5
6
5
8
14
35
14
79
9.5
23
9.5
45
150 30
2-stage x≤14
14< x ≤19
19< x ≤24
M5
M6
M8
4
5
6
9.5
14
35
5.6
9.5
23
120 20
3-stage x≤19 M6 5 14 9.5 120 20
050 1-stage x≤24
24< x ≤38
38< x ≤48
M8
M10
M12
6
8
10
35
79
135
23
45
78
200 50
2-stage x≤19
19< x ≤24
24< x ≤38
M6
M8
M10
5
6
8
14
35
79
9.5
23
45
150 30
3-stage x≤24 M8 6 35 23 150 30

TP+Technical data sheets
Revision: 03 2022-D036009 en-9
3.10 Specifications on mounting onto a machine
110 1-stage x≤38
38< x ≤48
M10
M12
8
10
79
135
45
78
250 200
2-stage x≤24
24< x ≤38
38< x ≤48
M8
M10
M12
6
8
10
35
79
135
23
45
78
200 50
3-stage x≤38 M10 8 79 45 200 50
300 1-stage x≤55 M12 10 135 78 300 —
2-stage x≤48 M12 10 135 78 250 —
3-stage x≤38 M10 8 79 45 250 —
500 1-stage x≤60 M16 14 330 195 300 —
2-stage x≤48 M12 10 135 78 250 —
3-stage x≤38
38< x ≤48
M10
M12
8
10
79
135
45
78
250 —
Tbl-8: Specifications on mounting onto a motor
Through-holes in gearhead housing
Gearheadsize
/ Design TP+Bore Ø [mm] Quantity x diameter [ ] x [mm] For screw size / property class Tightening torque [Nm]
004 MF 79 8 x 4.5 M4 / 12.9 4.55
010 MF 109 8 x 5.5 M5 / 12.9 9
025 MF 135 8 x 5.5 M5 / 12.9 9
050 MF 168 12 x 6.6 M6 / 12.9 15.4
110 MF 233 12 x 9.0 M8 / 12.9 37.3
300 MF 280 16 x 13.5 M12 / 12.9 126
500 MF 310 16 x 13.5 M12 / 12.9 126
010 MA 109 16 x 5.5 M5 / 12.9 9
025 MA 135 16 x 5.5 M5 / 12.9 9
050 MA 168 24 x 6.6 M6 / 12.9 15.4
110 MA 233 24 x 9.0 M8 / 12.9 37.3
300 MA 280 32 x 13.5 M12 / 12.9 126
500 MA 285 32 x 13.5 M12 / 12.9 126
MA = HIGH TORQUE
Tbl-9: Specifications on mounting onto a machine
Gearhead
size TP+Clamping hub
interior Ø
“x” [mm]
Clamping
screw(H)
/ DIN ISO
4762
Width
across
flats
[mm]
Tightening torque
[Nm] property class Max. axial force clamping hub [N]
12.9
(steel) 8.8 (alu) Plug receptacle Coupling

Technical data sheets TP+
en-10 2022-D036009 Revision: 03
3.11 Specifications on mounting on the gear output side
3.12 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 %
Thread in output flange
Gearheadsize
/ Design TP+Bore Ø
[mm] Quantity x Thread x
Depth
[ ] x [mm] x [mm]
Tightening torque
[Nm]
Property class 12.9
004 MF 31.5 8 x M5 x 7 9
010 MF 50 8 x M6 x 10 15.4
025 MF 63 12 x M6 x 12 15.4
050 MF 80 12 x M8 x 15 37.3
110 MF 125 12 x M10 x 20 73.4
300 MF 140 12 x M16 x 31 310
500 MF 160 12 x M20 x 31 604
010 MA 50 12 x M6 x 10 15.4
025 MA 63 12 x M8 x 12 37.3
050 MA 80 12 x M10 x 15 73.4
110 MA 125 12 x M12 x 19 126
300 MA 145 12 x M20 x 31 604
500 MA 166 12 x M24 x 37 1042
MA = HIGH TORQUE
Tbl-10: Specifications on mounting on the gear output side
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-11: Tightening torques for headless screws and nuts

TP+Technical data sheets
Revision: 03 2022-D036009 en-11
3.13 Performance statistics
Refer to our catalogue or our Internet page for the maximum permitted speeds and torques:
http://www.wittenstein-alpha.de
3.14 Supplementary information
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
Motor mounting video