Installation and Operating Instructions for ROBA -ES couplings Type 940. _. _ Sizes 14-48

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Jason Cross
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1 Table of contents: Please read and observe this Operating Instruction carefully. A possible malfunction or failure of the clutch and damage may be caused by not observing it. Page 1: - Table of contents - Manufacturer s declaration - Safety regulations Page 2: - Coupling variations - Parts list - Safety and information signs - Function Application - Supply condition Page 3: - Table 1: Technical data Type 940._22._ - Table 2: Technical data Type 940._00._ Page 4: - Table 3: Technical data Type 940._11.A - Table 4: Technical data Type 940._11.P/F Page 5: - Table 5: Torques - Table 6: Permissible misalignment values - Table 7: Spring rigidities Page 8: - Pushing both coupling halves together - Table 9: tightening torques, distance dimension "E" - Shaft misalignments - Alignment of the coupling Page 9: - Balancing of the coupling - with keyway and clamping hubs - with shrink disc hubs - Diagram: balancing of the shrink disc hubs (permissible speeds) - Maintenance - Disposal Page 10: - Breakdowns Page 11: - Breakdowns Page 6: - Elastomeric elements - Media resistance of the elastomeric elements - Temperature resistance of the elastomeric elements - General mounting instructions - Table 8: elastomeric element hardness and temperature ranges Page 7: - Assembly - Assembly of the coupling halves - Assembly of the clamping hubs - Assembly of the keyway hubs - Assembly of the shrink disc hubs - Disassembly of the shrink disc hubs Manufacturer s declaration The product is to be seen as an option or component for installation into machines or equipment according to the machinery directive 98/37/EC. The machinery (product) must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of the applicable EC directives. Safety notes The existing installation and operating instruction (I+O) is part of the coupling supply. Keep the I+O always accessible close by the coupling. Danger! If the ROBA -ES couplings have been modified or reconverted. If the relevant standards of the safety or installation conditions are not observed. Necessary protective measures to be undertaken by the user Cover all moving parts for protection against squeezing, seizing, dust deposit and hit of foreign objects. Only qualified and well-trained specialists should work on the units to avoid any personal injury or damage to machinery under observance of the valid standards and guidelines. The installation and operating instructions are to be read carefully before installation and operation. With these safety notes no claim on completeness is raised! Note: Based on the guideline 94/9/EC (ATEX-guideline) this product is not suitable for the application in potential explosive areas without evaluation of the conformity. Page 1 of 11 Germany info@mayr.de

3 1.1 2 3 1.1 4 1.2 2 1.2 4 1.3 2 1.3 Type 940._00._ Type 940._11._ 1.2b 1.2a Type 940._22._ ROBA -ES with clamping hubs ROBA -ES with shrink disc ROBA -ES with keyways Fig. 1 Fig. 2 Fig.

3 Hub with keyway 2 Elastomeric element 98 Sh A (red) 92 Sh A (yellow) 80 Sh A (blue) (green) 3 Clamping bolt for clamping hub 4 Clamping bolt for shrink disc hub Safety and information signs

2 Type 940._00._ Type 940._11._ 1.2b 1.2a Type 940._22._ ROBA -ES with clamping hubs ROBA -ES with shrink disc ROBA -ES with keyways Fig. 1 Fig. 2 Fig. 3 Parts List (Only mayr original parts are to be used) 1.1 Clamping hub 1.2 Shrink disc hub, assembly 1.2a Shrink disc 1.2b Shrink disc hub 1.3 Hub with keyway 2 Elastomeric element 98 Sh A (red) 92 Sh A (yellow) 80 Sh A (blue) (green) 3 Clamping bolt for clamping hub 4 Clamping bolt for shrink disc hub Safety and information signs Attention! Risk of injury for persons and damage at the machine possible. Note Reference to important points which are to be considered. Supply condition ROBA -ES couplings are supplied ready for assembly (check supply condition). ROBA -ES coupling hubs consists of aluminium or steel depending on size or Type. The star shaped flexible intermediate ring (elastomeric element) is pressed into the especially designed claws under slight pre-tension (Fig. 5). Coupling hub Function Application ROBA -ES consists of two coupling hubs and a flexible star shaped intermediate ring (elastomeric element) Figs ROBA -ES couplings are especially designed for the backlashfree application with comparatively high speeds. ROBA -ES couplings are mainly used in the measurement technique and control and process engineering. ROBA -ES couplings are shaft-shaft connections for flexible, backlash-free torque transmission in highly dynamic servo drives. Fig. 4 Flex. intermediate ring Fig. 5 Page 2 of 11 Germany info@mayr.de

3 Table 1: Technical data for Type 940._22._ (Fig. 3) Size Min. bore Max. bore Max. speed [rpm] Set screw thread (see Fig. 10) M4 M5 M5 M6 M8 M8 M8 Set screw tightening torques 1, ,1 8,5 8,5 8,5 Table 2: Technical data for Type 940._00._ (Fig. 1) Size Min. bore Max. bore Max. speed [rpm] Clamping bolt thread M3 M6 M6 M8 M8 M8 M12 Clamping bolt tightening torques 1, Preferred bores with clamping hubs and friction transmittable torques of the clamping hub with shaft fit k6 Size Ø 6 Ø 7 Ø 8 Ø 9 Ø 10 Ø 11 Ø 12 Ø 14 Ø 15 Ø 16 Ø 19 Ø 20 Ø 22 Ø 24 Ø 25 Ø 28 Ø 30 Ø 32 Ø 35 Ø 38 Ø 40 Ø 42 Ø 45 Ø 48 Ø 50 Ø ,5 3,0 3,4 3,8 4,2 4,7 5,1 6,0 6, Page 3 of 11 Germany info@mayr.de

4 Table 3: Technical data for Type 940._11.A (Fig. 2) - aluminium-design Size Min. bore Max. bore Max. speed [rpm] Clamping bolt thread 4 x M3 6 x M4 4 x M5 8 x M5 8 x M6 - - Clamping bolt tightening torques 1,3 3,0 6,0 6, Preferred bores with clamping hubs and friction transmittable torques of the clamping hub with shaft fit k6 Size Ø 6 Ø 7 Ø 8 Ø 9 Ø 10 Ø 11 Ø 14 Ø 15 Ø 16 Ø 17 Ø 18 Ø 19 Ø 20 Ø 22 Ø 24 Ø 25 Ø 28 Ø 30 Ø 32 Ø 35 Ø 38 Ø 40 Ø 42 Ø Table 4: Technical data for Type 940._11.P and 940._11.F (Fig. 2) steel design Size , Min. bore Max. bore Bore acc. to DIN Max. speed [rpm] Clamping bolt thread Clamping bolt tightening torques 4 x M3 6 x M4 6 x M4 4 x M5 4 x M5 8 x M5 8 x M6 4 x M8 4 x M8 1,3 3,0 3,0 6,0 6,0 6, Preferred bores with shrink disc hubs and friction transmittable torques of the shrink discs with shaft fit k6 Size Ø 6 Ø 7 Ø 8 Ø 9 Ø 10 Ø 11 Ø 14 Ø 15 Ø 16 Ø 17 Ø 18 Ø 19 Ø 20 Ø 22 Ø , Size Ø 25 Ø 28 Ø 30 Ø 32 Ø 35 Ø 38 Ø 40 Ø 42 Ø 45 Ø 48 Ø 50 Ø 52 Ø 55 Ø 58 Ø , Page 4 of 11 Germany info@mayr.de

5 Table 5: torques Here it concerns the rated torques. For a special design the transmittable torques of the respective shaft-hub connections, as well as the design calculation of the current valid ROBA -ES catalogue are to be considered. Torque Type 940. _._ Elastomeric hardness 80 Sh A (blue) Elastomeric hardness 92 Sh A (yellow) Elastomeric hardness 98 Sh A (red) Elastomeric hardness (green) Size T KN T K max T KN T K max Only available as type 940._11.P , Table 6: permissible misalignment values Size T KN Shaft misalignments T K max Axial Radial Angular K a 80/92/98 Sh A K r 80 Sh A K r 92 Sh A K r 98 Sh A K r K w 80 Sh A [ ] K w 92 Sh A [ ] T KN K w 98 Sh A 14 1,0 0,21 0,15 0,09 0,06 1,1 1,0 0,9 0,8 19 1,2 0,15 0,10 0,06 0,04 1,1 1,0 0,9 0,8 24 1,4 0,18 0,14 0,10 0,07 1,1 1,0 0,9 0,8 28 1,5 0,20 0,15 0,11 0,08 1,3 1,0 0,9 0,8 38 1,8-0,17 0,12 0,09-1,0 0,9 0,8 42 2,0-0,19 0,14 0,10-1,0 0,9 0,8 48 2,1-0,21 0,16 0,11-1,0 0,9 0,8 Only available as type 940._11.P ,0 0,21 0,15 0,09 0,06 1,1 1,0 0,9 0, ,5 1,2 0,15 0,10 0,06 0,04 1,1 1,0 0,9 0, ,4 0,18 0,14 0,10 0,07 1,1 1,0 0,9 0,8 Table 7: spring characteristics Size C T stat. 80 Sh A Static spring characteristic Dynamic spring characteristic Static radial stiffness C T stat. 92 Sh A C T stat. 98 Sh A C T stat. C T dyn. 80 Sh A C T dyn. 92 Sh A C T dyn. 98 Sh A C T dyn. C r 80 Sh A [Nm/mm] C r 92 Sh A [Nm/mm] [ ] C r 98 Sh A [Nm/mm] T K max K w [ ] C r [Nm/mm] Only available as type 940._11.P , Page 5 of 11 Germany info@mayr.de

6 Elastomeric elements (2) The elastomeric elements (2) are the central component of the ROBA -ES coupling. They define the application range and behaviour of the shaft connection by the permissible torque, stiffness, damping and misalignment values. By the use of a new polyurethane material and a special injection moulding a high degree of dimensional stability and uniformity of the teeth of elastomeric element (2) is achieved. The elastomeric elements are available in different shore hardness (see Table 8). The teeth of the flexible elastomeric element are laterally chamfered to ease blind assembly. General mounting instructions As standard the bores of the coupling hubs are provided with the designs with shrink discs or with keyways with a H7 tolerance, the design with clamping hub is provided with a F7 fit. We recommend a k6* shaft tolerance. The surfaces of the shafts should be turned or ground finely (Ra = 0,8 µm). In case the bores are made by themselves (in the own factory) the true running tolerance 0,05 as to A (see Fig. 6) must be observed. The bores or shafts must not be oiled or greased when installing the coupling with clamping hub (1.1) or shrink disc hub (1.2). (*Please contact the factory for other shaft fits). Medium resistance elastomeric elements (2) The elastomeric elements (2) are resistant against pure mineral oils (lubricating oils) anhydrous grease. The resistance against fuels is similar, for example standard petrol diesel oil kerosene. Damage can occur in case of longer action of alcohols aromatic fuels (super petrol). The elastomer used is resistant against hydrolisis. Water (or seawater) does not cause any essential alteration of the mechanical characteristics even after many years contact contrary to other polyurethane material. However, hot water reduces the mechanical strength. Please contact the factory in case of difficult environmental conditions or radiation. Fig. 6 ROBA -ES with keyway Temperature resistance elastomeric elements (2) The temperatures arising during operation effect a considerable influence on the torque, stiffness or damping behaviour of the coupling. The permissible temperature ranges according to Table 8 are to be kept. Fig. 7 ROBA -ES with shrink disc hubs Table 8: Elastomeric element hardness and permissible temperature ranges Elastomeric element [Shore] Colour Continuous temperature Permissible temperature range Max. short term temperature 80 Sh A blue -50 up to +80 C -60 up to +120 C 92 Sh A yellow -40 up to +90 C -50 up to +120 C 98 Sh A red -30 up to +90 C -40 up to +120 C green -30 up to +100 C -40 up to +140 C Page 6 of 11 Germany info@mayr.de

7 Assembly Due to its optimum construction the ROBA -ES coupling offers the possibility to connect the coupling axially after the hubs have been assembled onto the input or output shafts. Any additional fitting and special housings are not necessary (see mounting examples pages 6, 7 and 11). Please observe! ROBA -ES-couplings with steel hubs and steel shrink discs are provided with a zinc phosphating, which forms a corrosion protection base. All other components are not treated. In both cases the bores or shafts must be degreased before installing the coupling: with clamping hubs 940._00._ with shrink discs hubs 940._11._ Greasy or oily bores or shafts do not transmit the indicated transmittable torque T R indicated with the order. Assembly of the coupling-shrink disc hubs Type 940._11._ (Fig. 9) The contact surfaces of the cone-shrink disc (1.2b) or coneshrink-disc hub (1.2a) are greased at the factory. Attach coupling hubs (1.2) with a suitable device on both shaft ends and bring them into the correct position. Tighten clamping bolts (4) slightly until contact. Tighten clamping bolts uniformly step by step (in 3 up to max. 6 tightening revolutions) and crosswise to the required torque indicated on Table 3 or 4 (type dependent) using a torque wrench Assembly of the coupling halves (hubs) Assembly of the coupling-clamping hubs Type 940._00._ (Fig. 8) Attach coupling hubs (1.1) with a suitable device on both shaft ends and bring them into the correct position. Tighten clamping bolts (3) uniformly to the required torque indicated on Table 2 by means of a torque wrench Fig. 9 To dismantle 1.2b 1.2a Unscrew all clamping bolts (4) to release some threads. Unscrew the clamping bolts located beside of the extraction holes and screw them into the extraction holes until contact. Tighten clamping bolts (4) uniformly step by step, loosening the shrink disc (1.2.b) from the shrink disc hub (1.2a) (Fig. 9). Fig. 8 Assembly of the coupling hubs with keyway Type 940._22._ (Fig. 10) For the design of the shaft-hub connections or the inspection of the permissible contact pressure of the keyway the standard calculation methods according to DIN 6892 are to be applied. For the calculation the yield point R p 0,2 for aluminium 200 N/mm 2 and for steel 350 N/mm 2 is to be taken. Attach coupling hubs (1.3) with a suitable device on both shaft ends and bring them into the correct position. Axially fix the coupling hubs, e.g. using setscrews (see also installation example, Fig. 6) (setscrew / Fig. 10). Keyway must support on the complete length of the hub Fig. 10 Setscrew thread Page 7 of 11 Germany info@mayr.de

8 Pushing both coupling halves together When pushing both coupling halves ( ) together an axial assembly force must be exerted due to the pretension of the elastomeric element (2) (Fig. 5). This force can be decreased by slightly greasing the elastomeric element. Attention! Use PU-compatible lubrications (e.g. Vaseline or HP 222). Please observe! After both coupling halves have been pushed together no axial force may be exerted onto the elastomeric element (2). Observe distance dimension E according to Fig. 11 and Table 9! Right hub shown in a mirrored way Shaft misalignments The ROBA -ES coupling compensates radial, axial and angular shaft misalignments (Fig. 13), without influencing its backlashfree design. However, the permissible misalignments indicated on Table 6 must not achieve simultaneously the maximum values. In case several kinds of misalignments occur simultaneously they influence each other, i.e. the permissible value of the misalignment depend on each other corresponding to Fig. 12. The amount of the actual misalignments, in percentage of the maximum value, must not exceed 100%. The permissible misalignment values indicated on Table 3 refer to a coupling use with nominal torque, an ambient temperature of +30 C and an operating speed of 1500 rpm. Please contact the factory for other or more extreme coupling applications. Fig. 11 E ROBA -ES with clamping hubs Table 9: Tightening torques and distance dimension E ROBA -ES Size Tightening torques clamping bolts (Pos. 3, Fig. 1) Tightening torques clamping bolts (Pos. 4, Fig. 2) Distance dim. "E" (Fig. 11) 14 1,4 1, K r [%] radial misalignment Fig % 50% 25% Alignment of the coupling 30% K a [%] axial displacement An exact alignment of the coupling increases the service life of the coupling considerably and decreases the load for the shaft misalignments. For drives with a very high speed the coupling should be aligned using a feeler gauge. Normally the alignment of the coupling with a straight-edge in two levels being vertically to each other is sufficient. 0% K w K r K w [%] angular misalignment L K a Fig. 13 Radial misalignment Axial displacement Angular misalignment Page 8 of 11 Germany info@mayr.de

9 Balancing Keyway hubs (1.3) and clamping hubs (1.1): The keyway hubs (1.3) and clamping hubs (1.1) rotate with max. speed with a circumferential speed of 30 m/s. They are not balanced as standard. Shrink disc hubs (1.2): The shrink disc hubs (steel and aluminium) (1.2) keep the balance quality G = 6,3 up to the speed n G (corresponds to approx. 30 m/s) without balancing. Balancing is recommended in case the speed is higher. The hubs are balanced single. The diagram (Fig. 14) indicates reference values for which we recommend to balance the coupling elements. The quiet running of a machine or equipment depends not only on balancing quality of the coupling, but also on many parameters as stiffness or distance of the adjacent bearings. Therefore, there is no fixed rule at which conditions balancing is necessary. Speed [rpm] Fig. 14 balancing recommended Diagram: Balancing of the shrink disc hubs n max Size n G Suitable coupling design For a troublefree application of the coupling it is necessary that the coupling characteristic values (Technical data) indicated in the latest catalogue are kept. An appropriate coupling design is necessary according to the valid ROBA -ES catalogue, so that a troublefree and wear-minimized operation is possible. Large shaft misalignments, especially with high speeds and alternating complex of loads acting on a component with high frequency load and warm up the elastomer material. The coupling can be damaged due to an unacceptable high complex of loads acting on a component, inadmissible high speeds and unacceptable shaft misalignments. For an appropriate coupling design (see calculation in the latest ROBA -ES catalogue) following points are to be observed: a.) coupling nominal torque b.) c.) d.) e.) f.) coupling impact torque max. speed max. shaft misalignments ambient conditions (see latest ROBA -ES catalogue) service factors (see latest ROBA -ES catalogue) Any operation out off the indicated characteristics is not permissible, there is the danger of a coupling damage. The number and kind of the starting impacts must be considered for the coupling design according to the catalogue. Furthermore elastomer heating due to speed resonance can occur. This must be considered according to the catalogue for the coupling design. Changed operating parameters in the equipment require anew examination of the coupling design. The maximum indicated ambient temperatures are to be kept. There is the risk of an elastomer damage when the permissible ambient temperature is exceeded. Page 9 of 11 Germany info@mayr.de

10 Maintenance Following maintenance and inspection intervals are to be kept: 1.) Visual check, inspection of the assembly parameters (misalignment and tightening torques), running behaviour of the coupling before initial start-up. 2.) Visual check, torsional backlash and elastomeric wear, inspection of the misalignment and tightening torques, running behaviour of the coupling after 1000 h, after 3 months the latest. 3.) If no irregularities or wear are noticed with the 2. maintenance and inspection intervals, the further inspection intervals can be carried out after 4000 operating hours or after 12 months the longest, if the operating parameters have not changed. Wear limit of the elastomer: An abrasion is not allowed at the elastomeric element (2), as the ROBA -ES is no backlash-free coupling. The spacing between two claws must be filled out backlash-free with the elastomer. It must not be possible to joint a feeler gauge with 0,1 mm thickness. (Fig. 15). Feeler gauge 0,1 mm Hub 1 Hub 2 Elastomeric element If wear or damage is determined, the components concerned must be exchanged immediately, the reason of the breakdown is to be determined. Failure reasons could be: a.) b.) c.) too large misalignment too large load (change of load, starting impact, overload) ambient influences Wear or damage at the ROBA -ES couplings express itself by: a.) b.) c.) d.) e.) f.) Disposal noise development unsmooth running, vibrations cracking at the components heating loosening of the components friction tracks In case of any irregularities independent of upcoming maintenance and inspection intervals the equipment is brought to a standstill and the breakdown cause is to be determined by means of the table of breakdowns All steel components: steel scrap (Code No ) All aluminium components: non iron metals (Code No ) Elastomers: plastic (Code No ) Fig. 15 Breakdowns Problem Change of the running noises and/or arising vibrations Possible reasons Alignment error Elastomeric element worn, short-term torque transmission by metal contact Clamp bolts and clamping screws or locking set screws for the axial locking of the hubs loose Solution 1) Set plant out of operation 2) Remove reason of the alignment error (e.g. loose foundation screw, breakage of the motor attachment, thermal expansion of the unit components, change of the mounting dimension E of the coupling) 3) Check the coupling regarding wear 2) Dismantle coupling and remove the remaining parts of the elastomeric element 3) Check coupling components and exchange damaged coupling components 4) Locate new elastomeric element, assemble coupling components 5) Check the alignment and correct it, if necessary 2) Check the coupling alignment 3) Tighten clamping bolts and clamping screws for the axial locking of the hubs as well connecting screws to the described torque or locking set screws and secure them with securing lacquer against self loosening 4) Check the coupling regarding wear Page 10 of 11 Germany info@mayr.de

11 Breakdowns Problem Cam breakage Possible reasons Elastomeric element worn, torque transmission by metal contact Breakage of the cams due to high impact energy / overloading / too high shaft misalignment Operating parameters do not correspond to the coupling performance Operating error at the plant package whereby charasteric data of the coupling are exceeded Solution 2) Exchange the coupling completely 3) Check the alignment 2) Exchange the coupling completely 3) Check the alignment 4) Determine the reason of the overload 2) Check operating parameter and select the appropriate coupling (observe mounting space) 3) Assemble new coupling 4) Check alignment 2) Check the coupling design 3) Exchange the coupling completely 4) Check the alignment 5) Instruct the service personal and train them Premature wear of the elastomeric element Premature wear of the elastomeric element Premature wear of the elastomeric element (material liquefaction in the internal of elastomeric element cams) Alignment error e.g. contact with aggressive liquids /oil, ozon influence, too high ambient temperature, etc. effect the physical modifications of the elastomeric element Exceeding of the ambient and contact temperatures permissible for the elastomeric element see Table 8 Drive vibrations 2) Remove reason of the alignment error (e.g. loose foundation screw, breakage of the motor attachment, thermal expansion of the unit components, change of the mounting dimension E of the coupling) 3) Check the coupling regarding wear 2) Dismantle coupling and remove the remaining parts of the elastomeric element 3) Check coupling components and exchange damaged coupling components 4) Locate new elastomeric element, assemble coupling components 5) Check the alignment and correct it, if necessary 6) Guarantee that further physical modifications of the elastomeric element are excluded 2) Dismantle coupling and remove the remaining parts of the elastomeric element 3) Check coupling components and exchange damaged coupling components 4) Locate new elastomeric element, assemble coupling components 5) Check the alignment and correct it, if necessary 1) Check ambient or contact temperatures and regulate it (if necessary, also possible with different elastomeric element material 2) Dismantle coupling and remove the remaining parts of the elastomeric element 3) Check coupling components and exchange damaged coupling components 4) Locate new elastomeric element, assemble coupling components 5) Check the alignment and correct it, if necessary 6) Determine the reason of the vibration (if necessary, countermeasures by an elastomeric element with lower or higher shore hardness Note! When using spare parts and accessories which were not delivered by mayr, and for the damage, developing from it, mayr does neither take over a liability nor any guarantee. Page 11 of 11 Germany info@mayr.de

Installation and Operating Instructions for EAS -NC clutch Type 45_. _. _ Sizes 02 and 03

Installation and Operating Instructions for EAS -NC clutch Type 45_. _. _ Sizes 02 and 03 Table of contents: Please read and observe this Operating Instruction carefully! A possible malfunction or failure of the clutch and any damage may be caused by not observing it. Page 1: - Table of contents