Boston Gear WOR Series Mechanical Overload Release Clutches for the Water and Wastewater Industry

Transcription

1 Bstn Gear WOR Series Mechanical Overlad Release Clutches fr the Water and Wastewater Industry P-303-BG Installatin and Operatin WOR Series Mdel H1900 a divisin f Altra Industrial Mtin

2 Cntents I. Intrductin II. Munting Sprckets and Jaw Clutches t Clutch III. Munting Clutch t Shaft IV. Resetting Instructins V. Limit Switches I. Intrductin A. Operating Principle The WOR Series Mdel H1900 is a mechanical, ball detent style, verlad release clutch. It has been designed t prvide accurate and dependable trque discnnect prtectin fr mechanical wastewater treatment equipment. The trque is transmitted thrugh the clutch in ne f tw paths as shwn in Figure 1. VI. Trque Adjustment Spring Curves VII. Remval & Installatin f Spring Pack Trque Input 3 VIII. Autmatic - Manual Cnversin Trque Output IX. General Maintenance Trque Input X. General Disassembly XI General Assembly Part Numbering System Eplded View Drawings, Basic Catalg Numbers & Identificatin Trque Output Trque Path 1 Plate Sprcket Sheave, Etc. 3 Husing Balls 4 Mtr 5 Drive Shaft 4 3 Trque Path 1 Drive Shaft 3 Rtr Balls 4 Husing 5 Plate Sprcket Sheave, Etc. Figure 1 Trque transmissin between the balls and the detents f the rtr is the key t the disengagement f the clutch as shwn in Figure. The balls are frced int the detents f the rtr by an aial lad generated by cmpressing a spring pack. This aial lad is what determines the trque capacity f the clutch. Increasing r decreasing the spring cmpressin r changing spring packs prvides a means fr multiple trque adjustments. When a trque verlad cnditin ccurs, the balls rll ut f the rtr detents. This rlling actin increases the efficiency in which the clutch perates and reduces any fluctuatin f trque setting due t frictinal changes. The mvement f the cver during disengagement f the balls can be used t trip a limit switch and signal a trque verlad cnditin. The drive shuld be shut dwn immediately and the surce f verlad determined and cleared. The drive can then be restarted. Bstn Gear WOR Series P-303-BG

3 Reset Ring Size Qty. Capscrews Thread Seating Trque Thread Depth Bld Circle Pilt Engaged 05 Styles A/B, M/N 6 5/ in-lb Rtr Detent Chrme Ally Balls 06 Styles A/B, M/N 8 1/ in-lb Style A/B 8 1/ in-lb Disengaged 09 Style M/N 8 1/ in-lb Styles A/B, M/N 8 1/ in-lb Nte: Capscrews shuld be minimum 80,000 PSI tensile, Rb Cver Figure II. Munting Sprckets and Jaw Clutches t Clutch A. Munting Sprckets t Husing 1. Inspect mating pilts n clutch and sprcket fr nicks r burrs and remve as required.. Psitin sprcket n clutch husing and align munting hles. 3. Attach sprcket t husing using stainless steel heagn head capscrews, high cllar lck washers and flat washers. See Figure 3 fr munting patterns, screw sizes, screw quantities and recmmended screw seating trques. See Figures 4 and 5 fr standard Type B NH-78 sprcket munts. Figure 4 Type B, Thrugh Bre Standard NH-78 Sprcket Munting Figure 3 Standard Munting Hle Patterns Figure 5 Type B, End Shaft Standard NH-78 Sprcket Munting P-303-BG Bstn Gear WOR Series 3

4 Clutch Size Screw Size Seating Trque 05 1/ in-lb 06 3/ in-lb 09 1/ in-lb 11 1/ in-lb 5. Secure clutch t shaft by tightening the rtr setscrews. Refer t the fllwing table fr setscrew seating trques. IV. Resetting Instructins Figure 6 Type J with Handwheel Half f Jaw Clutch B. Munting Jaw Clutch t Type J Husing 1. Inspect hub and key f Type J husing fr any nicks r burrs and remve as required.. Slide handwheel half f jaw clutch n Type J husing. The handwheel shuld be free t flat alng the hub f the J husing. See Figure 6 fr pssible jaw clutch munting. A. Manual Reset 1. Befre resetting the clutch, the verlad cnditin must first be crrected.. After the clutch has disengaged, it can be reset in multiple psitins. There are fur tapped hles n the O.D. f the rtr and tw lube fittings n the O.D. f the husing as shwn in Figure 7. III. Munting Clutch t Shaft A. Munting Basic Clutch 1. Inspect shaft and key fr any nicks r burrs and remve as required.. Lsen the setscrews n the rtr t make sure that the tips f the screws clear the bre and keyway. 3. Psitin shaft key and slide clutch nt shaft. On sme bre sizes, a setscrew will nt be ver the key. It may be necessary t stake the key t the shaft. Nte: A minimum shaft engagement f 1-1/ times the shaft diameter is recmmended fr clutch installatin. 4. Align sprcket r jaw clutch munted t verlad clutch with mating sprcket in drivetrain. Refer t installatin and alignment instructins furnished with sprcket and/r jaw clutch. Align A Lube Fitting With A Rtr Setscrew Figure 7 Push Evenly On Bth Sides Of Actuating Plate 3. Rtate the drive until a lube fitting n the husing lines up with a tapped hle n the rtr. The rtr keyway shuld als be lined up with a lube fitting n the husing. 4. After the prper psitin has been established, push/pull evenly n bth sides f the limit switch actuating plate as shwn in Figure 7. When the clutch is prperly reset, the steel balls will mve back int their pckets and the cver and reset plate will return t their riginal psitins. An audible sund will be detected when the clutch re-engages. 4 Bstn Gear WOR Series P-303-BG

5 Mvement Limit Switch Disengaged Engaged Start Jg Stp T Mtr B. Autmatic Reset Disengagement Travel Clutch Size Mvement in in in in. Figure 8 VI. Trque Adjustment The autmatic reset versin f the clutch will re-engage withut manual assistance. The steel balls will mve back int their pckets every 1/4 f a revlutin (1/8 f a revlutin n a size 11). After the verlad cnditin has been cleared, jg the drive until the steel balls mve back int their pckets and the cver and reset plate return t their riginal psitins. An audible sund will be detected when the clutch re-engages. V. Limit Switch The WOR Clutch Series is ffered in an autmatic reset design. Because f this feature, it is imprtant that the drive be shut dwn immediately upn a trque verlad cnditin. Figure 8 utilizes a single limit switch t detect an verlad. The switch shuld be able t perate within the disengagement travel f the clutch. Upn an verlad, an versized stainless steel plate attached t the cver will mve t actuate the limit switch and shut dwn the drive. The spring curves n page 6 can be used t apprimate the adjustment f the bearing nut required t yield a desired trque setting. A. Estimated adjustment frm spring curves 1. Determine what size verlad release clutch and disc springs are being used.. Find the apprpriate spring chart and curve fr yur situatin. 3. Draw a line hrizntally frm a pint n the trque scale, equal t the trque setting, t intersect with the spring curve. 4. Draw a line vertically dwn frm this pint f intersectin t the deflectin scale. This will be the amunt f adjustment required n the bearing nut. B. The epnential curve equatins fund n each spring chart culd als be used t determine the amunt f adjustment required t apprimate any desired trque setting. P-303-BG Bstn Gear WOR Series 5

6 Trque (IN-LBS) Trque (IN-LB) Deflectin (Inches) 0 1/ 1 1 1/ 1/ 3 3 1/ 4 4 1/ 5 Crrespnding Number Of Nut Revlutins Fr Desired Setting = = = = W H M L Deflectin = (Trque/10970) Deflectin = (Trque/6500) Deflectin = (Trque/5000) Deflectin = (Trque/4400) Deflectin (Inches) 0 1/ 1 1 1/ 1/ 3 3 1/ 4 Crrespnding Number Of Nut Revlutins Fr Desired Trque Setting Deflectin = (Trque/16177) = W = H Deflectin = (Trque/1108) = M = L Deflectin = (Trque/7844) Deflectin = (Trque/6000) Trque (IN-LB) Trque (IN-LB) Deflectin (Inches) Deflectin (Inches) 0 1/ 1 1 1/ 1/ 3 3 1/ 4 4 1/ 5 5 1/ 6 Crrespnding Number Of Nut Revlutins Fr Desired Deflectin = W Deflectin = (Trque/34000) = H = M Deflectin = (Trque/55) = L Deflectin = (Trque/14700) Deflectin = (Trque/1100) 0 1/ 1 1 1/ 1/ 3 3 1/ 4 4 1/ Crrespnding Number Of Nut Revlutins Fr Desired Trque Setting = W Deflectin = (Trque/57000) = H Deflectin = (Trque/43000) = M = L Deflectin = (Trque 30000) Deflectin = (Trque 0000) Spring Curves 6 Bstn Gear WOR Series P-303-BG

7 Eample: Clutch Size -05 Trque Range,500-5,000 in.-lb. (W) Trque Setting - 5,000 in-lb Deflectin by Curve-.19 in. Deflectin by Equatin-.0 in. Apprimately 3-1/ turns f nut Spring Pack Free State Spacer Is Cntacting Spring Pack But Springs Are Nt Deflected Spacer Bearing Nut Size Thread Adjustment Per Turn Pitch 1/8 1/4 3/8 1/ Size Spring Pack N. Clr Cde Trque Range (In-Lb) Minimum Maimum Cde White,500 5,000 W Blue 1,400,800 H Yellw 1,100,00 M Black 850 1,700 L White 4,000 8,000 W Blue,500 5,500 H Yellw 1,800 3,750 M Black 1,50,500 L White 8,500 0,000 W Blue 5,500 1,000 H Yellw 3,750 8,500 M Black,50 5,750 L White 16,000 30,000 W Blue 1,000 5,000 H Yellw 9,000 16,500 M Black 5,000 1,000 L Nte: Each spring pack cnsists f three disc springs and a spacer. Figure 9 Spanner Wrench Deflectin Spring Pack In Laded State Bearing Nut Is Adjusted T Cmpress Spring Pack T Deflected Value Fund On Spring Curves Or Deflectin Equatins Figure 10 C. The amunt f adjustment required (spring deflectin) can be estimated by cunting the turns f the bearing nut r can be measured as shwn in Figure Remve eight screws frm face f trip plate.. Remve eight screws frm the O.D. f the cver. 3. Slide the trip plate and seal ff the end f the rtr. Clutch Size Armstrng Tl C. Wrench Part N. McMaster-Carr Supply C Snap-On Tl C 05, A13 AHS A14 AHS A Diameter Range Specificatins (inches/millimeters) Hk Thickness Hk Depth Length.00 t t t t t t P-303-BG Bstn Gear WOR Series 7

8 4. Slide the cver tward the husing until the bearing nut and lck washer are epsed. 5. Lift tab f lck washer securing the adjustment nut in psitin. 6. Use a spanner wrench t adjust nut t desired trque setting. 7. Once the trque is set, fld ne f the lck washer tabs ver ne slt n the adjusting nut. Cat bearing nut and washer with a lithium-base, water-resistant, NLGI grade grease. 8. Reinstall the trip plate and seal n the rtr and attach the trip plate t the cver with the trip plate screws. Tighten the trip plate screws t a trque f 100 in-lb. 9. Slide the cver back int its riginal psitin making sure that the O.D. hles line up with the tapped hles in the reset ring. Attach the cver t the reset ring with the cver screws and tighten the screws t a trque f 100 in-lb. D. Standard bearing nuts are used t adjust the spring lad which cntrls the release trque f the clutch. These nuts are sltted and can easily be turned using a cmmn, cmmercially available hk-style spanner wrench. Refer t Figure 9 fr wrenches which are cmpatible with ur trque verlad release clutch. E. Fr applicatins requiring a precise trque, the release trque setting f the clutch shuld be tested as shwn in Figure 11. Verificatin f the release trque several times in bth clckwise and cunterclckwise directins is recmmended. This service is available at the factry. VII. Remval and Installatin f Spring Pack A. Remval f ld spring pack 1. Remve the eight screws frm the trip plate.. Slide the trip plate away frm the cver just t the end f the rtr. 3. Remve the eight screws frm the O.D. f the cver. 4. Slide the cver tward the husing just enugh t epse the bearing nut and lck washer. 5. Lift the tab f the lck washer securing the bearing nut. 6. Turning cunterclckwise, lsen nut with a spanner wrench. 7. Lsen rtr setscrews and remve clutch frm shaft, if applicable. 8. Remve nut, lck washer, disc springs and spacer. Vice Jaws Arbr Figure 11 Trque Wrench B. Installatin f new spring pack 1. Lubricate disc springs with a lithium base, water-resistant, NLGI grade grease.. Stack springs n thrust plate and rtr as shwn in Figure Place spacer prvided with the spring pack in psitin n clutch as shwn in Figure Lubricate lck washer and threads f nut with a graphite-based lubricant like Never-Seez. 5. Install lck washer and nut nt clutch. 8 Bstn Gear WOR Series P-303-BG

9 6. Adjust nut t desired release trque as utlined in Sectin Vl. 7. Cat bearing nut and washer with a lithiumbase, water-resistant, NLGI grade grease. Figure 1 Spacer VIII. Autmatic-Manual Cnversin Spring Thrust Plate A. Remve the eight screws frm the O.D. f the cver. B. Remve the cver and trip plate frm the clutch assembly. C. Lift the tab f the lck washer securing the bearing nut. D. Turning cunterclckwise, lsen the nut with a spanner wrench. E. Remve nut, lck washer, disc springs and spacer. F. Lift ff autmatic reset ring assembly frm the husing and shulder plate f the clutch. G. Apply a cating f grease t the entire inside surface f the new reset ring and thrust plate. H. Place the reset ring ver the rtr with the chamfered side facing the husing. Press dwn n the reset ring until it is firmly seated. I. Insert an -ring int the grve n the O.D. f the new reset ring. J. Lubricate the disc springs and stack the springs against the reset ring r thrust plate. K. Line up the l.d. tab f lck washer with the slt f the shulder plate and slip the lck washer ver the threads f the shulder plate. L. Lubricate the lck washer and threads f nut with a graphite-based lubricant such as Never-Seez and tighten nut nt shulder plate. See Sectin Vl fr trque adjustment. IX. General Maintenance A. Lubricatin The WOR Series clutch is prelubricated at the factry and is als equipped with lube fittings fr scheduled lubricatin. The clutch shuld be lubricated with a lithium base, water-resistant, grade grease. The lubricatin schedule shuld be in accrdance with gd perating practices fr the equipment n which the clutch is munted. D Nt Over Lubricate. On a clutch with a Type J adapter, it is als imprtant t peridically lubricate the internal brnze bushings. This is accmplished by sliding the handwheel half f the jaw clutch, epsing the capscrew hlding the key n the J husing. Remve the capscrew and inject a liberal amunt f grease int the cavity between the tw brnze bushings. Reinsert the capscrew and tighten, then slide the handwheel back int psitin. B. Annual Inspectin The WOR SERIES verlad release clutch is cnstructed f heavy-duty materials. Under reasnable cnditins the unit will perate with a minimum f maintenance. A scheduled annual inspectin f seals, bearings and ther internal cmpnents is suggested. Hwever, the actual frequency shuld be in accrdance with gd perating practices fr the equipment n which the clutch is installed. X. General Disassembly A. Cver and miscellaneus internal cmpnents 1. Remve the eight capscrews frm the trip plate.. Slide the trip plate and trip plate seal ver the end f the rtr. 3. Remve the eight capscrews frm the O.D. f the cver. 4. Remve cver by sliding the cver tward the end f the rtr. P-303-BG Bstn Gear WOR Series 9

10 5. Lift tab f lck washer securing the bearing nut int psitin. 6. Remve bearing nut by turning nut cunterclckwise with a spanner wrench. 7. Remve lck washer and spring pack. 8. Lift ff reset ring. Fr manual reset, the thrust plate, springs and shulder screws will be attached t reset ring. 9. Remve -ring seal frm the O.D. f the reset ring. 10. Use a magnet t remve steel balls frm the shulder plate pckets. B. Husing and miscellaneus internal cmpnents 1. Remve any adapters r sprckets frm the husing.. Remve the capscrews attaching the shulder plate t the husing. 3. Remve the shulder plate frm the husing by sliding the shulder plate ff the rtr. 4. Remve the bearing strip frm the l.d. f the shulder plate. 5. Remve the rtr frm the husing by pulling the rtr away frm the husing. 6. Fr sizes 05 and 06, remve the quad ring seal frm the O.D. f the husing. Fr sizes 09 and 11, remve the quad ring seal frm the l.d. f the reset ring. Fr all sizes, remve the -ring seal frm the l.d. f the husing. XI. General Assembly A. Husing and miscellaneus internal cmpnents 1. Grease pack -ring grve in l.d. f husing and insert -ring seal.. Insert the rtr int the l.d. f the husing until the rtr flange is against the husing. Fr a thrugh bre style, the shrter end f the rtr is inserted int the husing and fr an end shaft style, the lnger end f the rtr is inserted. Apply a cating f grease t the pcket area f the rtr. 3. Insert the bearing strip int the l.d. grve f the shulder plate and lightly cat the bearing strip with grease. 4. With the flange side f the shulder plate facing the husing, slide the shulder plate nt the rtr until the shulder plate flange meets the munting surface f the husing. 5. Rtate the shulder plate until the cunterbred hles line up with the tapped hles in the husing and the dwel pin hles f the shulder plate line up with the dwel pins in the husing. 6. Thrughly clean and dry threads f lw head capscrews. 7. Apply sme thread-lcking cmpund like Lctite #71 t the threads f the lw head capscrews and insert the lw head capscrews int the cunterbred hles and tighten t the trques in the fllwing chart. 8. Rtate the rtr until the rtr pckets line up with the hles in the shulder plate. 9. Apply a cating f grease t each hle in the shulder plate. 10. Insert a steel ball int each hle in the shulder plate until the ball sits firmly in the rtr pcket. 11. Grease pack the quad ring grve n the O.D. f the husing r n the l.d. f the reset ring and install the quad seal. 1. Cat the entire inside surface f the reset ring assembly and the utside surface f the husing with grease and place the reset ring ver the rtr with the chamfered side facing the husing. Press dwn n the reset ring assembly until it is firmly seated. 10 Bstn Gear WOR Series P-303-BG

11 Size Screw Size Qty. Seating Trque 05 1/4-0 UNC 8 80 in-lb 06 1/4-0 UNC 8 80 in-lb 09 3/8-16 UNC 8 73 in-lb 11 3/8-16 UNC 8 73 in-lb Retaining cmpund must cure at 70 F fr a 4-hur perid befre clutch is placed int service. B. Cver and miscellaneus internal cmpnents 1. Grease pack the grve n the O.D. f the reset ring and insert the -ring seal.. Lubricate disc springs and stack the springs against the thrust plate as shwn in Figure Stack spacer n tp f disc springs as shwn in Figure Line up l.d. tab f lck washer with the slt f the shulder plate and slip the lck washer ver the threads f the shulder plate. 5. Lubricate lck washer and threads f nut with a graphite-based lubricant such as Never- Seez and tighten nut nt the shulder plate. See Sectin Vl fr trque adjustment. 6. Lubricate the l.d. f the cver and slide the cver nt the reset ring making sure that the thru hles n the O.D. f the cver line up with the tapped hles n the O.D. f the reset ring. 7. Install the trip plate U-channel seal int the l.d. f the trip plate. The end shaft style des nt have a trip plate seal. 8. Fr a thrugh shaft style nly, lubricate the trip plate seal and slide the trip plate ver the rtr until the trip plate meets the cver. 9. Make sure that the gasket is still attached t the trip plate. Line up the trip plate hles with the hles in the cver and insert the eight trip plate screws int these hles and tighten t a trque f 100 in-lb. 10. Insert the eight capscrews int the O.D. hles f the cver and tighten t a trque f 100 in-lb. WOR Series Part Numbering System WOR 05 A B - L P16 Series Style Trque Range Wastewater A = Autmatic Reset Thrugh Bre L = Light Overlad B = Autmatic Reset End Shaft M = Medium Release M = Manual Reset Thrugh Bre H = Heavy Clutch N = Manual Reset End Shaft W = Etra Heavy Size Type 05 B = Basic 06 J = Jaw Unit Bre 09 P = Bred t Size (in 1/16 ) 11 M = Metric Bred t Size (mm) P-303-BG Bstn Gear WOR Series 11

12 Figure 13 - Type B, Thrugh Shaft Style 1 Bstn Gear WOR Series P-303-BG

13 Part Identificatin Fr Type B, Thrugh Shaft Style, Basic Unit Item N. Name Qty Assembly - Autmatic Assembly - Manual Spring Pack XXX XXX XXX XXX 3 Husing Rtr (Thrugh Shaft) Cver Manual Reset Ring Autmatic Reset Ring **7 Thrust Plate Shulder Plate Trip Plate Lck Washer Bearing Nut Husing Bearing Bearing Strip Gasket **15 Shulder Screw **16 Spring *17 Ball Lube Fitting Cver Seal Husing Seal Rtr Seal Trip Plate Seal Cver Screw Lw Head Capscrew Setscrew Dwel Pin * Size 11 uses eight balls. ** Nt included in autmatic design. Nte: Please include clutch catalg number when rdering any spare parts. P-303-BG Bstn Gear WOR Series 13

14 Figure 14 - Type B, End Shaft Style 14 Bstn Gear WOR Series P-303-BG

15 Part Identificatin Fr Type B, End Shaft Style Item N. Name Qty Assembly - Autmatic Assembly - Manual Spring Pack XXX XXX XXX XXX 3 Husing Rtr (End Shaft) Cver Manual Reset Ring Autmatic Reset Ring **7 Thrust Plate Shulder Plate Trip Plate Lck Washer Bearing Nut Husing Bearing Bearing Strip Gasket **15 Shulder Screw **16 Spring *17 Ball Lube Fitting Cver Seal Husing Seal Rtr Seal Cver Screw Lw Head Capscrew Setscrew Dwel Pin * Size 11 uses eight balls. ** Nt included in autmatic design. Nte: Please include clutch catalg number when rdering any spare parts. P-303-BG Bstn Gear WOR Series 15

16 Figure 15 - Type J, Thrugh Shaft Style 16 Bstn Gear WOR Series P-303-BG

17 Part Identificatin Fr Type J, Thrugh Shaft Style With Jaw Clutch Adapter Item Number Name Qty Assembly - Autmatic Assembly - Manual Spring Pack XXX XXX XXX XXX 3 Husing Rtr (Thrugh Shaft) Cver Manual Reset Ring Autmatic Reset Ring **7 Thrust Plate Shulder Plate Trip Plate Lck Washer Bearing Nut Husing Bearing Bearing Strip Gasket **15 Shulder Screw **16 Spring *17 Ball Lube Fitting Cver Seal Husing Seal Rtr Seal Trip Plate Seal Cver Screw Lw Head Capscrew Setscrew Dwel Pin Capscrew Key Bushing XXX XXX XXX XXX * Size 11 uses eight balls. ** Nt included in autmatic design. Nte: Please include clutch catalg number when rdering any spare parts. Rtating equipment is ptentially dangerus and culd cause injury r damage if nt prperly prtected. Fllw all applicable cdes and regulatins. In accrdance with ur established plicy t cnstantly imprve ur prducts, the specificatins cntained herein are subject t change withut ntice. P-303-BG Bstn Gear WOR Series 17

18 Warranty Bstn Gear warrants that prducts manufactured r sld by it shall be free frm defects in material and wrkmanship. Any prducts which shall within ne (1) year f delivery, be prved t the Cmpany s satisfactin t have been defective at the time f delivery in these respects will be replaced r repaired by the Cmpany at its ptin. Freight is the respnsibility f the custmer. The Cmpany s liability under this limited warranty is limited t such replacement r repair and it shall nt be held liable in any frm f actin fr direct r cnsequential damages t prperty r persn. The freging limited warranty is epressly made in lieu f all ther warranties whatsever, epress, implied and statutry and including withut limitatin the implied warranties f merchantability and fitness. N emplyee, agent, distributr, r ther persn is authrized t give additinal warranties n behalf f Bstn Gear, nr t assume fr Bstn Gear any ther liability in cnnectin with any f its prducts, ecept an fficer f Bstn Gear by a signed writing. Bstn Gear 14 Hayward Street Quincy, MA Fa: a divisin f Altra Industrial Mtin P-303-BG 01/07 Printed in USA