BAWE 009-GBR-0 05/2004 Installation and Operation Manual TSCHAN Highly flexible shaft coupling TSCHAN - TORMAX VSG TSCHAN GmbH Zweibruecker Strasse 104 D-66538 Neunkirchen-Saar Telephone: +49(0) 6821 866 0 Telefax: +49(0) 6821 883 53 www.tschan.de
Contents Chapter Page 1 Safety Instructions...2 2 Function...3 2.1 Designated use...3 3 Storage...3 4 Construction...4 5 Assembly...5 5.1 Before assembly...5 6 Operation...6 7 Maintenance...8 7.1 Inspection and servicing intervals...8 7.2 Replacing the rubber element...9 8 Disposal...9 1 Safety Instructions These assembly and operating instructions form part of the coupling schedule. Always keep these assembly and operating instructions easily accessible near the coupling. Please ensure that all persons authorised to assemble, operate, maintain and repair the product have read and understood the assembly and operating instructions and observe them in all points in order to: - Avoid hazards to life and limb of operating personnel or third-parties. - Guarantee the operational safety of the coupling. - Eradicate stand-still time and environmental hazards caused by improper handling. During transport, assembly, dismantling and maintenance, the relevant health and safety regulations and environmental protection regulations must be observed. Ensure that suitable means of transport are available. The coupling may only be operated, assembled, maintained and repaired by authorised, trained personnel. In the interests of progress, we reserve the right to carry out technical modifications. TSCHAN GmbH accepts no responsibility of any kind for damage arising from the use of non-original accessories and spare parts. 05/2004 TSCHAN -TORMAX VSG - 2 -
2 Function The TSCHAN TORMAX VSG Coupling is a highly flexible shaft coupling for use in drive trains between the combustion engine and the cardan shaft. When correctly dimensioned, it reduces dynamic stresses on the drive train caused by torsional vibrations. The axial prestressing of the elastic coupling element enables play-free transmission of axial forces in tension and compression. Forced ventilation guarantees good heat dissipation and the high degree of coupling damping results in small resonance peaks. 2.1 Designated use In order to guarantee fault-free, enduring operating of the coupling, it must be dimensioned in accordance with dimensioning regulations, e.g. pursuant to DIN 740, Part 2 (or TSCHAN TORMAX Catalogue), with an application factor appropriate to the respective operating conditions. The coupling can be used at ambient temperatures of 60 C, or up to a maximum of 90 C, taking the appropriate temperature factors i nto consideration. The standard model can compensate for cardan shaft angles of up to 13. The coupling may only be used and operated under the conditions specified in the service and supply agreement. Any change in operating conditions or parameters makes a renewed examination of the coupling dimensioning necessary. 3 Storage All goods should be inspected for completeness upon receipt. Any transport damage and / or missing components must be notified in writing. In delivery condition, the coupling can be stored for up to six months in a dry, roofed location at normal room temperature. Long-term preservation is necessary for longer storage periods (please contact TSCHAN GmbH). The flexible coupling element may not be subjected to ozonic media, direct sunlight or strong light sources containing ultra-violet light. Relative humidity should not exceed 65%. If correctly stored the elastic properties of the coupling element remain practically unchanged for up to three years. 05/2004 TSCHAN -TORMAX VSG - 3 -
4 Construction Fig. 1 Section through the TORMAX VSG 1 Coupling flange Part 627 2 Flexible coupling element Part WE01 3 Connecting flange Part 628 4 Bearing flange Part 629 5 Bearing ring Part 592 6 Friction disk Part 591 7 Cheese head screw DIN 912 Note: The coupling is delivered fully assembled. 05/2004 TSCHAN -TORMAX VSG - 4 -
5 Assembly 5.1 Before assembly Injury hazard! Switch off the drive before commencing any work on the coupling! Secure the drive against accidental activation and rotation! Incorrectly tightened screws can lead to serious personal injury and material damage! Assemble outside of the danger zone. Ensure that suitable means of transport are available and that transport routes are free of obstacles. In accordance with health and safety regulations, all rotating parts must be protected against accidental contact and against falling parts by fixed protective installations. To avoid sparks, use stainless steel covers! As a minimum requirement, the covers must comply with the IP2X protective system. The covers should be designed such that no dust can settle on the coupling. The cover may not contact the coupling and hinder its correct functioning in any way. Clean all coupling components before assembly. Do not use petrol, paraffin or oil to clean the rubber element. The connecting surfaces of the flange must be clean, dry and free of grease. Place the coupling with the coupling flange (Figure 1, Item 1) in the centre of the flywheel on the combustion engine. Take care that the components do not cant. Tighten the fastening screws uniformly. Connect the cardan shaft to the connecting flange (Figure 1, Item 3). 05/2004 TSCHAN -TORMAX VSG - 5 -
6 Operation The coupling parameters must be observed (TSCHAN TORMAX Catalogue). These may not be exceeded except with written permission from TSCHAN GmbH. In order to guarantee fault-free, enduring operating of the coupling, it must be dimensioned in accordance with dimensioning regulations, e.g. pursuant to DIN 740, Part 2 (or TSCHAN TORMAX Catalogue), with an application factor appropriate to the respective operating conditions. Any change in operating conditions or parameters makes an examination of the coupling dimensioning necessary. Injury hazard! Switch off the drive before commencing any work on the coupling! Secure the drive against accidental activation and rotation! Incorrectly tightened screws can lead to parts flying off and serious personal injury and material damage! Before commissioning the coupling, check the alignment and all screw connections for the prescribed torque and tightness of fit! Before commissioning the equipment, all devices for protection against accidental contact with moving or rotating parts must be installed. To avoid sparks, use stainless steel covers! As a minimum, the covers must comply with the IP2X protective system. The covers should be designed such that no dust can settle on the coupling components. The cover may not contact the coupling and hinder its correct functioning in any way. When the coupling is operating please monitor: Changes in running noises Vibrations Missing components Attention! If you notice any irregularities while the coupling is operating, switch off the drive immediately. Using Table 1, Operating faults and their possible causes, below, find the cause of the fault and remedy it. The faults listed are only a few examples to help you troubleshooting. All machine components and operating conditions must be taken into consideration for fault-finding and remedy! 05/2004 TSCHAN -TORMAX VSG - 6 -
Table 1 Operating faults and their possible causes: Fault Cause Hazard Remedy Rubber element worn Irregular running noises/vibrati ons Premature wear of the rubber element Imbalance Loose screw connection s Impermissi ble temperatur es Contact with aggressive media Overstressi ng due to excessive torque Torsional limiting devices strike each other. Sparks, increased reaction forces. Increases reaction forces on coupled equipment. Flying components can cause serious damage. Material properties of rubber element are altered. The transmission properties are impaired. Material properties of rubber element are altered. The transmission properties are impaired. Coupling is destroyed. May also be detrimental to connected equipment. - Examine coupling components for damage, replace if necessary - Replace rubber element - Check balance on system components and correct if necessary - Examine coupling components for damage, replace if necessary - Tighten screws with the prescribed torque and secure against loosening where necessary - Replace rubber element - Regulate ambient temperature - Examine coupling components and rubber element for damage, replace if necessary - Avoid contact with aggressive media - Examine coupling dimensioning in cooperation with TSCHAN GmbH - Replace coupling - Use a larger coupling where necessary 05/2004 TSCHAN -TORMAX VSG - 7 -
7 Maintenance The flexible TSCHAN TORMAX VSG coupling is maintenance free when operating. During routine equipment monitoring examine: The condition of the rubber element Tight fit of all screws Remove dust deposits from the coupling components and the coupling element 7.1 Inspection and servicing intervals Injury hazard! Switch off the drive before commencing any work on the coupling! Secure the drive against accidental activation and rotation! Adhere to the inspection and servicing intervals given in Table 2. If damage to the coupling is noted on the initial inspection, in particular to the rubber element, check if one of the causes given in Table 1 Operating faults may be responsible. The inspection intervals should then be adjusted to suit the governing operating conditions. Under special operating conditions, inspection and servicing work may also be necessary at shorter intervals. Table 2 Inspection and servicing intervals Industry 1. Inspection After 4 weeks Visual inspection 1. Service After 6 months Visual inspection 2. Service After 12 months Visual inspection and remove dust from coupling components Each further inspection Every 12 months Visual inspection and remove dust from coupling components Mining 1. Inspection After 4 weeks Visual inspection 1. Service After 6 months Visual inspection 2. Service After 6 months Visual inspection and remove dust from coupling components Each further inspection Every 6 months Visual inspection and remove dust from coupling components 05/2004 TSCHAN -TORMAX VSG - 8 -
7.2 Replacing the rubber element Injury hazard! Switch off the drive before commencing any work on the coupling! Secure the drive against accidental activation and rotation! To replace the rubber element the coupling must be completely removed. Lay the coupling flat on the bearing flange (Figure 1, Item 4) and remove the hexagon socket screws (Figure 1, Item 7). Dismantle the coupling and clean all coupling components. Examine the coupling components for wear or damage. When replacing the rubber element (Figure 1, Item 2), we recommend you also replace the friction disk and bearing ring (Figure 1, Items 5 and 6). Reassemble the coupling components with the new rubber element. Please observe the correct relative positioning of the torsional limiting device stops in the coupling flange and the bearing flange. Gradually and uniformly tighten the hexagon socket screws (Figure 1, Bild / Fig. 2 Lage der Durchdrehsicherung Item 7) in the correct order, until reaching the torque TAn given in Table 3. Table 3 Cheese head screw torques: VSG 6 8 10 16 22 DIN 912-10.9 M8 M8 M12 M12 M12 T An (Nm) 36 36 125 125 125 8 Disposal Disposal is in accordance with the specific regulations of the respective country in which the equipment is used. 05/2004 TSCHAN -TORMAX VSG - 9 -