Wittenstein Alpha LP+ Manuale utente

2022

D039182

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.: +49 7931 493-10900

Fax: +49 7931 493-10903

E-mail: [email protected]

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

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.

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