a complete product range
offering drive package solutions
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a c o m p l e t e p r o d u c t r a n g e
Our mission:
In Gear For Your Success
Driven by gear technology, Hansen
Transmissions’ Business Unit Industry
fulfils the needs of its global customer
base by offering them reliable
mechanical power transmission
solutions for demanding industrial
applications.
P R O D U C T S
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a c o m p l e t e p r o d u c t r a n g e
Hansen Transmissions International manufactures top quality products
and offers complete drive solutions, tailored to customer needs.
Our main product line is the Hansen P4 range of standardized industrial
gear units.
Low noise and minimum weight are merely a few of its outstanding
characteristics which have also been incorporated in the Hansen P4
range of single stage gear units and the Hansen M-Series range of
functional drives.
Our complete portfolio of products and total drive solutions is reflected
in this detailed product brochure.
Torsten Schultz
Managing Director Business Unit Industry
In the late 1940’s, any company producing
industrial transmission drive systems was faced
with a problem that at the time seemed
insoluble. No company had succeeded in
standardizing the production of gear units.
Expensive, custom-made solutions – time-con-
suming to produce, assemble and maintain –
were the norm.
David Hansen, however, was a born innovator,
who tackled the problem through original think-
ing based on scientifically researched concepts.
The result, launched in 1950, was the Hansen
Patent-I – a revolutionary new concept for the
design and manufacture of standard gear units.
As David Hansen himself was able to say with
understandable pride:
"The Hansen Patent-I speed reducer constitutes
an original and complete answer to the
problem of standardization, meeting the
requirements of application selling, mass
production, quality and competitive prices."
c o n t i n u o u s
Moving from customized to serial manufacture
led to a number of important benefits:
• Production costs were reduced.
• Improved quality control procedures
could be implemented.
• The number of spare parts was reduced.
• Delivery times were slashed.
Gear units were never the same again as
other manufacturers followed Hansen’s lead.
Since then Hansen has consistently been at
the forefront of transmission technology.
H a n s e n T r a n s m i s s i o n s , a h i s t o r y o f
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i n n o v a t i o n
P R O D U C T S
■ HANSEN PATENT-I
Common gear sets allowed Hansen Patent-I
gear units to be inter-related, as one size of
gear unit determined the preceding and
following sizes. This is expressed in the
"law of centre distances", a principle
which is still applied today in the latest
Hansen products.
■ HANSEN PATENT-I I
In 1970 the product line was re-evaluated to
respond to changing market requirements and
to take advantage of new technologies such as
improved hardening and grinding techniques.
Based on the Hansen Patent-I principles of
standardization of housings and gearings,
Hansen Patent-II established new standards
with the concept of market adequacy of the
torque scale.
The launch of Hansen Patent-II confirmed
Hansen’s position as the worldwide leader in
transmission drive systems.
■ HANSEN POWERPLUS
By 1980 Hansen took another step ahead of
the competition. The objective was to incorpo-
rate new technologies and achieve the highest
performance and reliability in this area.
Emphasis was placed on the introduction
of new rigid housings, in line with the high
stiffness requirements for load distribution
and low noise behaviour.
Hansen Patent I (1950) Hansen Patent II (1970) Hansen PowerPlus(1980)
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P R O D U C T S
ansen
"Compliance with application requirements"
The launch of the Hansen P4 range in 1995
revealed new standards in how gear units are
matched to the market applications: simplified
product selection; gear units fine-tuned to
specific applications; accessories more easily
integrated; special features included as standard.
"An innovative approach to user-friendliness"
Through creative industrial design techniques,
lower noise levels, 100% oil-tightness (Oil-Lock™
as a new standard), easy handling and simplified
maintenance procedures were established.
"A balanced line-up of components for
excellence in service"
Reduced number of pinion shafts; fewer spare
parts; standardized components; proven well-
The new range of single stage gear units has
been designed from scratch: every existing
multi-stage dogma has been questioned, alter-
natives have been developed and evaluated.
A typical example of this approach is the use of
variable centre distances in a given housing size.
In "traditional" designs, with fixed centre distan-
ce and torque rating, the reduction ratio of a
single stage gear unit has a major effect on the
power rating. This means that for small reduc-
tion ratios, very large powers can be transmit-
ted, which may lead to thermal limitations.
At the other end, for large ratios, gear casings
become oversized for the transmitted power.
For a given size of unit this leads to inefficient
compromises on bearing selection and
mechanical and thermal rating.
known brands for accessories created a greater
availability of spare parts and unparalleled com-
mitment to customer service.
"Power and reliability through quality
and technology"
State-of-the-art technology resulted in the
most powerful gear units available today.
Development and manufacturing according
to ISO 9001 standards leads to quality
in all aspects.
To complement its current range of standardized
multi-stage gear units, Hansen Transmissions
introduced an innovative range of single stage
gear units for various applications requiring
small reduction ratios: e.g. paper machines,
pumps, compressors, etc.
Hansen P4 (1995) Hansen P4 single stage (1999)
s ingle & mult i -stage gear units
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The P4 range excels in low noise and vibra-
tion levels as well as in minimum weight: for
a given output, a Hansen P4 is just one-fifth
of the weight of its 1950 ancestor. Hansen P4
multi-stage units come in 18 sizes from 6 to
800 kNm. The Hansen P4 single stage range
caters for 5 sizes in two mounting positions
for mechanical powers from 100 kW up to
4 MW.
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The Hansen M-Series consists of 8 sizes
with a torque range up to 100 kNm.
monobloc gear units
Hansen M4 ACC (2006) Hansen M-Series (2008)
Merely two years after the product launch of
the Hansen M4 ACC for air cooled condensers,
more than 2000 of these gear units are
successfully operating air cooled condensers in
energy generation plants in the main markets
worldwide.
Its dedicated design has been developed in
close cooperation with customers of Air Cooled
Condensers, a technical high demanding
application. It makes use of the very latest in
gear technology and gear unit design. Major
interest has been paid to the reliability and user
friendliness of these gear units by using the
extensive in-house experience of Hansen. The
Hansen M4 ACC range excels in low noise and
gearing performance by using the second to
none Hansen P4 gear technology.
The Hansen M-Series, a complementary range to
the Hansen P4 product offering caters for opti-
mised application requirements, which have been
integrated into the design phase and resulted in a
reliable and functional gear drive solution which
will be brought to market in several phases.
Both the horizontal and vertical gearboxes are
easy to configure-to-order and as a result meet
the demands of a wide variety of applications.
Tailor-made solutions for high volumes or
repetitive orders are also possible within this
series and a broad range of specific application
options ensure high effectiveness in both
dimension and capability.
This new series of monobloc gearboxes
provides a functional approach to
application and user requirements. The
development and final design are the result
of Hansen’s tradition of close cooperation
with its customers. Every piece of advice
and every field experience has been taken
on board in the design, so that both
customer and user needs were carefully
considered.
Short delivery times, flexible gearbox sizes
and optional accessories will allow the
customer to select the optimum product
for his needs. The M-Series requires
fewer components and is manufactured
using Hansen’s state-of-the-art production
techniques. The renowned and proven
Hansen gear technology guarantees reliability,
durability and, therefore, quality.
The Hansen M4 ACC product line is available
in 6 sizes within an output torque range from
20000 to 70000 Nm and a wide range of reduc-
tion ratio’s.
monobloc gear units
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ENVIRONMENTAL ASPECTS ■
The Hansen M-Series uses a very rigid and
sound dampening monoblock housing. This
housing was designed to exploit the latest cast-
ing techniques, resulting in a reduced number
of production steps. Machining has been
reduced to an absolute minimum, for example,.
footpads are created in the casting process and
no longer need to be bored afterwards. Hansen
products, which are renowned for low noise
and vibration levels, also operate with consid-
eration for the environment.
RELIABILITY ■
Hansen is without doubt a world leader in gear
technology. The Hansen M-Series makes use of
the proven track record of the Hansen P4 gear-
ing and the Hansen in-house core competences
in production expertise.
DRIVE PACKAGE APPROACH ■
Optional package drive components and instru-
mentation have been taken into account during
development and design of the M-Series range.
This caters for optimised package solutions
from one single source, even in configured-to-
order requirements.
The Hansen M4 ACC monobloc range is
designed to comply with the Standard Cooling
Tower Institute specifications for gearboxes.
Its helical gears are designed and rated in
accordance with AGMA for maximum load
capacity, minimum losses and quiet operation.
The low speed shaft bearings are selected to
allow considerable thrust loads.
The heat generated in the gearbox due to
losses can be dissipated by natural cooling
through the housing or additional fan cool-
ing. The low speed shaft has a regreasable
labyrinth and a drywell construction. The built-
in backstop (optional) prevents the cooling
tower fan from “windmilling”.
Internal lubrication is assured and the back-
stop is accessible after removing the motor
and lantern housing.
Hansen M4 ACC
The Hansen M-Series range consists of hori-
zontal and vertical gear units with right angle
or parallel shaft configurations, offering the
customer the best solution for his application
without the risk of over-sizing. Pre-engineered
options fully answer the specific needs of the
application. Hansen gear technology guaran-
Hansen M-Series
tees optimum use of materials and construc-
tion techniques resulting in a high power
output to weight ratio.
We have optimised design, using fewer parts
and implementing solutions such as the mono-
bloc housing, application oriented sealing sys-
tems, integrated cooling devices – if required
– and eliminating the use of covers and rings.
h n o l o g y
P R O D U C T S
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NOISE AT A MINIMUM ■
Minimal noise contributes to the comfort of
the workplace and is therefore an important
criterion when selecting industrial gear units.
The Hansen P4 is designed to generate as
little noise as possible; the basic design rules
guarantee maximum stiffness of all gear unit
components under load. Together with the
most rigid pinion shafts and housings, the gear
units transmit exceptional high power and
a minimum of noise. Standard manufactur-
ing processes help to minimize noise: precise
machining of the housing on advanced CNC
machines guarantees that the bores of the
gear units are exact; an imperative for optimal
gear mesh. Precision grinding of the gears and
adapted gear geometry in the high-speed
gear sets diminishes vibration levels; this ‘low
noise geometry’ is applied to both bevel and
helical gears.
FIRM ON ITS FEET ■
The rigid gear casing design of the Hansen
P4 series maintains a correct gear alignment.
The vertical P4 housing has been designed to
ensure smooth transition of forces from the
centre bore to the mounting feet, which are
positioned concentric to the low speed shaft.
An important feature for e.g. mixers and agita-
tors or surface aerators.
INTEGRATED DRYWELL ■
The integrated drywell is a standard feature for
all vertical Hansen P4 gear units. It guarantees
oil-tightness for life. A highly appreciated fea-
ture in many industries, including food process-
ing and water treatment.
NEVER A DRY START-UP ■
Centralized oil filling in Hansen P4 gear units
guarantees initial oil ubrication and circulation
through all bearings, thus avoiding any risk of
a dry start-up. This results in minimized wear
on the bearings, simplified overall maintenance
and a longer bearing life.
100% OIL TIGHT ■
Hansen Transmissions’ unique Oil-LockTM
system offers a maintenance free seal on high
speed shaft extensions, and is standard on all
Hansen P4 units. It is designed to keep the oil
in and dirt out and is the most secure high
speed shaft sealing solution available, which
has proven its effectiveness on thousands of
Hansen P4 gear units.
For tilted or inclined operation, Hansen pro-
vides Its unique Oil-GuardTM. It consists of a
tapered ring, rotating close to the machined
housing and functioning as a centrifugal pump.
It is located between the oil and a radial seal.
During operation,
even in submerged conditions, the Hansen
Oil-GuardTM ensures leak free running condi-
tions.
Hansen P4
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P R O D U C T S
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P R O D U C T S
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h n o l o g y
P R O D U C T S
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P R O D U C T S
F O R A N O V E R V I E W O F W H A T ’ S A V A I L A B L E , C H E C K O U R C O M P R E H E N S I V E C A T A L O G U E W I T H R E F . 2 2 0
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
T
6
9
15
23
35
53
75
100
130
170
230
290
350
420
500
600
700
800
y z a b c d e f g h j k l m n p q r s t
kNmCentre distanceSize
800700600500420350290230170130100755335231596
TSRQPNMLKJHGFEDCBA
VERT ICAL APPL I CAT IONS HOR IZONTAL APPL I CAT IONS
y o u r b e n e f i t s
o u r p r o d u c t f e a t u r e s
MULT I - S TAGE GEAR BOXESansen
Stage
Stage
2
3-
4
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M U LT I - S TA G E G E A R B O x E S
FITNESS FOR USE
With the Hansen P4 product line you can easily select what you need,
thereby optimizing your investement.
■ FEATURE
Specific housings for horizon-
tal and vertical applications
Standard higher bearing span
for vertical applications
Simple, standard systems for
cooling and lubrication
Accessories and instrumenta-
tion are offered as catalogue
options
Improved component
standardization
Special ratios up to 1% of
the requested ratio at
moderate cost
■ YOUR BENEFIT
Easy to select the optimal gear
unit for a specific application -
value for money
Stronger shaft support for
surface aerators, mixers...
Proven and cost- effective
solutions
Easy and fast customization
possibilities
Shorter delivery times
Cost efficient tailor-made
solution
POWER & RELIABILITY
The excellent constructional rigidity of Hansen P4, together with the com-
mitment to apply state-of-the-art gear technology, leads to remarkable
power and performance
■ FEATURE
Rigid, standardized pinion
shafts and housings
Full-scale application of:
High torque geometry in
low speed gear sets
Low noise geometry in high
speed gear sets
Profile-controlled gas
carburizing
Precision grinding with
sophisticated tooth contact
analysis
Assured oil circulation through
the bearings
■ YOUR BENEFIT
Better lateral load distribu-
tion, lower noise and
vibration levels
Better strength/surface
durability rating balance
Lower noise and vibration
levels
Optimal load capacity
Optimal transverse and later-
al load distribution, lower
noise and vibration levels
Long, troublefree working life
P R O D U C T S
INSTALLATION
Even the larger Hansen P4 models are easy to transport, manoeuvre
and install.
■ FEATURE
Provision for crowbar or
adjusting screws, oval transport
slots or hoist eyes & standard
fixation points for accessories
Internal construction ensures
oil supply to all bearings on
first oil filling
Large mounting pads can
accommodate extra dowel pins
■ YOUR BENEFIT
Easy installation procedure;
easy to handle, install and to
mount accessories such as
protection caps
Bearings safely lubricated from
the start
Easy realignment
SPARE PARTS, SERVICE & MAINTENANCE
The Hansen P4 is one of the easiest to maintain gear units on the market.
The maintenance operation itself has been simplified and shortened.
■ FEATURE
Housings for horizontal and
vertical applications both with
horizontal split
Maintenance-free Oil-Lock™
seal as a standard on the high
speed shaft extensions
Drywell standard for vertically
down shaft
Easy to remove inspection cover
with O-seal above the oil level
Provision for easy removal
of covers
Specific housings for horizon-
tal and vertical applications
Rounded external design
■ YOUR BENEFIT
Easy to open for inspection
and service on-the-spot
Oil-tight for life -
no maintenance required
Oil-tight for life
Easy and quick inspection
without oil drainage
Easy to open for service
on-the-spot
Total oil evacuation possible
Smooth surface without
dirt-retaining cavities
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5000
4500
4000
3500
3000
2500
2000
1500
1000
500
0
1,2 1,25 1,4 1,6 1,8 2 2,24 2,5 2,8 3,15 3,55 4 4.5 5 5,6
Nominal ratio
Sizes
G
F
E
D
C
Po
w
er
a
t
15
00
m
h-
1
FITNESS FOR USE
■ FEATURE
Simple, standard systems for
cooling and lubrication
Accessories and instrumentation
are offered as catalogue options
Two mounting positions and
alternative mounting with both
shafts in a vertical plane
Left hand execution equals
right hand execution
Enlarged though compact
housing and increased shaft
height
Variable centre distances
Improved component
standardization
Special ratios up to 1% of
the requested ratio at
moderate cost
■ YOUR BENEFIT
Proven and cost- effective
solutions
Easy and fast customization
possibilities
Increased flexibility in mount-
ing arrangements
Easy change of shaft handing,
and only one spare unit need-
ed for both
The input shaft height matches
the large motor shaft height
even better
Easy replacement and
improvement of existing instal-
lations at a minimum effort
and cost
Shorter delivery times
Cost efficient Tailor-made
solution
POWER & RELIABILITY
■ FEATURE
Rigid, standardized pinion
shafts and housings
Full-scale application of:
High torque geometry in
low speed gear sets
Low noise geometry in high
speed gear sets
Profile-controlled gas
carburizing
Precision grinding with
sophisticated tooth contact
analysis
Assured oil circulation through
the bearings
Optimal balance between
mechanical, thermal and
bearing rating
Specific macro gear geometry
Tapered roller bearings in
the monolithic housing
Increased shaft height
■ YOUR BENEFIT
Better lateral load distribu-
tion, lower noise and
vibration levels
Better strength/surface
durability rating balance
Lower noise and vibration
levels
Optimal load Capacity
Optimal transverse and later-
al load distribution, lower
no
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