Please read these Installation and Operational Instructions carefully and follow them accordingly! Ignoring these Instructions may lead to malfunction or to clutch failure, resulting in damage to other parts. Contents: Page 1: Page 2 - Contents - Manufacturer s Declaration - Safety Regulations - Appointed Use - Guidelines for Electromagnetic Compatibility - Device Conditions - Protection Class - Ambient Temperature - Thermic Class Page 4 Page 5: - Fig.1 Clutch Illustration - Parts List - State of Delivery - Design - Figs 2 and 3: Installation Examples - Description: Installation Examples - Fig. 4 Boring the Rotor Hub - Table 2: Technical Data Page 3 - Nominal Torque M 2 - Protective Measures - Standards and Directives - Liability - Guarantee - Conformity Marks - Identification Page 6: - Figs. 5 and 6: Installation Drawings - Installation - Electrical Connection - Disassembly - Maintenance and Inspection - Disposal - Malfunctions / Breakdowns Manufacturer s Declaration This product is intended for installation in a machine or system, based on the machine directive 98/37/EC. It is forbidden to start use of the product until the machine or system into which it should be built is operating in accordance with the EC directives. The product corresponds to the low voltage directive 73/23/EEC. The customer is responsible for compliance with the EMC directive 89/336/EEC. Page 1 of 6 Germany email: info@mayr.de
Safety Regulations These Safety Regulations are user hints only and may not be complete! Danger! Danger of death! Do not touch voltage-carrying cables and components. To prevent injury or damage, only professionals and specialists should work on the devices. Danger! This warning applies if: the electromagnetic clutch is used incorrectly. the electromagnetic clutch is modified. the relevant standards for safety and / or installation conditions are ignored. Warning: Without a conformity inspection, this product is not suitable for use in areas where there is a high danger of explosion. This statement is based on the directive 94/9/EC (ATEX directive). Please Observe! Warning! Before product installation and initial operation, please read the Installation and Operational Instructions carefully and observe the Safety Regulations. Incorrect operation can cause injury or damage. The electromagnetic clutches have been developed in accordance with the latest technology regulations and are, at the point of delivery, operationally safe. Only specialists who are trained in the transport, installation, operation, maintenance and general operation of these devices and who are aware of the relevant standards should be allowed to carry out this work. Technical data and specifications (Type tags and documentation) must be followed. The correct connection voltage must be connected according to the Type tag. Never loosen electrical connections or carry out installations, maintenance or repairs while the voltage connection is energised! Cable connections must not be placed under mechanical strain. Check electrical components for signs of damage before putting them into operation. Never bring them into contact with water or other fluids. The braking torque is lost if the friction lining and / or the friction surface come into contact with oil or grease. Appointed Use ROBATIC -clutch devices are for use in machines and systems and must only be used in the situations for which they are ordered and confirmed. Using them for any other purpose is not allowed! Guidelines for Electromagnetic Compatibility (EMC) In accordance with the EMC directives 89/336/EEC, the individual components produce no emissions. However, functional components e.g. rectifiers or similar controls for mains-side energisation of the clutches can produce disturbance which lies above the allowed limit values. For this reason it is important to read the Installation and Operational Instructions very carefully and to keep to the EMC directives. Device Conditions Please Observe! The catalogue values are standards which can, in certain cases, vary. When dimensioning the clutches, please remember that installation situations, braking torque fluctuations, permitted friction work, run-in behaviour and wear as well as general ambient conditions can all affect the given values. These factors should therefore be carefully assessed, and alignments made accordingly. Mounting dimensions and connecting dimensions must be adjusted according to the size of the clutch at the place of installation. The clutches are designed for a relative duty cycle of 100%. The clutches are only designed for dry running. The torque is lost if the friction surfaces come into contact with oil, grease, water or similar substances. The torque is dependent on the present run-in condition of the friction surfaces. Required condition is usually reached after min. 100 switchings in dynamic operation. Manufacturer-side corrosion protection of the metallic surfaces is provided using phosphation (on blank shafts, using a preserving method). The friction surfaces are blank. Protection Class I This protection can only be guaranteed if the basic insulation is intact and if all conductive parts are connected to the PE conductor. Should the basic insulation fail, the contact voltage cannot remain (VDE 0580). Ambient Temperature 20 C up to +40 C Warning! At temperatures of around or under freezing point, condensation can strongly reduce the torque, or the rotors can freeze up. The user is responsible for taking appropriate countermeasures. Thermic Class F (+155 C) The magnetic coil and the casting compound are suitable for use up to a maximum operational temperature of +155 C. Page 2 of 6 Germany email: info@mayr.de
Nominal Torque M 2 in New Conditions for ROBATIC -clutch In new condition, the catalogue nominal torque M 2 is transmitted to c. 50 % in: a.) static operation b.) dynamic operation, if it falls short of the minimum values in Table 1. In order to achieve the specified nominal torque M 2, dynamic operation with min. friction work "Q a" or min. speed "n" according to Table 1 (see below) is required. Size Min friction work Q a [J] Min speed n [rpm] 3 4 5 6 7 Table 1 16 29 55 105 200 300 250 200 160 130 User-implemented Protective Measures: Please cover moving parts to protect against injury through seizure and catapulted objects. Place a cover on the magnetic part to protect against injury through high temperatures. Protect against electric shocks by installing a conductive connection between the magnetic component and the PE conductor on the permanent installation (Protection Class I). Protect against highly inductive switch-off peaks by installing varistors, spark quenching units or similar devices according to VDE 0580/2000-07, Paragraph 4.6, to prevent damage to the coil insulations or switch contact consumption in extreme conditions. Install additional protective measures against corrosion if the brake is subject to extreme ambient conditions or is installed in open air conditions, unprotected from the weather. Take precautions against freeze-up of the armature disc and the rotor in high humidity and at low temperatures. Please Observe the Following Standards: DIN EN ISO 12100 1 and 2 DIN EN61000-6-4 DIN EN61000-6-2 EN60204 Liability Machine safety Noise emission Interference resistance Electrical machine equipment The information, guidelines and technical data in these documents were up to date at the time of printing. Demands on previously delivered clutches are not valid. Liability for damage and operational malfunctions will not be taken if - the Installation and Operational Instructions are ignored or neglected. - the clutches are used inappropriately. - the clutches are modified. - the clutches are worked on unprofessionally. - the clutches are handled or operated incorrectly. Guarantee The guarantee conditions correspond with the Chr. Mayr GmbH + Co. KG Sales and Delivery Conditions. Mistakes or deficiencies are to be reported to mayr at once! Conformity Marks The product conforms to the CE according to the low voltage directives 73/23/EEC. Identification mayr components are clearly marked and described on the Type tag: Standards and Directives The clutches are developed and produced in accordance with the national standard DIN VDE 0580, according to the Low voltage directive 73/23/EEC. Regulations, Standards and Directives Used: 98/37/EC 73/23/EEC 89/336/EEC Machine directive Low voltage directive EMC directive Manufacturer mayr Product name / Type Article number Serial number Page 3 of 6 Germany email: info@mayr.de
Fig. 1 Parts List (Only use mayr original parts) 1 Coil carrier assembly with magnetic coil and Type tag 2 Armature disk assembly with transmission spring and fixing screws 3 Rotor 4 Flange hub State of Delivery Please check the state of delivery immediately! mayr will take no responsibility for belatedly returned goods. Please report transport damage immediately to the deliverer. Please report incomplete delivery and obvious defects immediately to the manufacturer. Design ROBATIC -clutch devices have electrical Protection IP54 and Insulation Class F (up to 155 C) for coil, casting compound and connection strands. At 100 % duty cycle, the coil has a temperature of c. 65 C. The coil carrier, rotor and flange hub surfaces are phosphated, the armature disk is tenifer-treated (ground friction surface), and the transmission spring is made of stainless steel. The clutch rotor is pilot bored, or delivered finish bored with a keyway according to DIN 6885. It essential that the Guidelines on Page 5 in the Instructions on Boring the rotor hub are followed for finish-boring the rotor bore and the keyway. Page 4 of 6 Germany email: info@mayr.de
Installation Examples (Figs. 2 and 3) Fig. 2 Example Fig. 2 In operation, the armature disk (2) is pulled against the rotor (3). The torque is transmitted via frictional locking from the drive shaft (7), via the rotor (3) and the armature disk (2) onto the V-belt disk (6). The coil carrier (1) is screwed onto the machine wall, centred on the shaft bearing (8). The air gap a between the rotor (3) and the armature disk (2) is defined using the distance ring (9) between the rotor (3) and the V- belt disk bearing. The V-belt disk (6) should be made of a material which does not conduct well magnetically, in order to avoid magnetic flux leakage loss. Example Fig. 3 This is an electromagnetic clutch with a flange hub (4) to connect two aligning shafts. Torque process: Drive shaft rotor (3) armature disk (2) flange hub (4) output shaft. The coil carrier (1) and the rotor (3) are mounted on the input side, and the flange hub (4) is mounted with the screwed-on armature disk (2) onto the output shaft. The rotor (3) is fixed axially via a press cover and a screw, screwed into the shaft centre thread. A set screw (5) fixes the flange hub (4) onto the output shaft. In order to readjust the air gap a between the rotor (3) and the armature disk (2), the set screw (5) is loosened and the flange hub (4) on the output shaft is moved. Boring the Hub (Fig. 4) Do not place pressure here Bore intake Fig. 4 Fig. 3 The rotor (3) may not be bent during boring. Do not place pressure on thin-walled outer rotor areas, see Fig. 4. To bore, clamp the rotor onto the rotor hub. The maximum permitted bore diameter d max., Table 2 may not be exceeded. The keyway is produced according to DIN 6885/1. We recommend H7/k6 as a suitable hub-shaft tolerance. Table 2 Technical Data Size 3 4 5 6 7 Maximum bore rotor d max. [mm] 25 35 42 55 65 Air gap "a" (Figs. 2 and 3) [mm] 0.2 + 0.1/- 0.05 0.2 + 0.15/- 0.05 0.2 + 0.15/- 0.05 0.3 + 0.15/- 0.05 + 0.15/- 0.05 0.3 Max. permitted centre misalignment "V" (Figs. 5 and 6) [mm] 0.05 0.05 0.05 0,05 0.1 Max. permitted centre misalignment "V 1" (Figs. 5 and 6) [mm] 0.1 0.15 0.15 0,15 0.2 Dimension "H" (Fig. 5) [mm] 80 h9 100 h9 125 h9 150 h9 190 h9 Dimension "Z" Type 500.20-.0 (Fig. 5) [mm] 42 H8 52 H8 62 H8 80 H8 100 H8 Dimension "Z" Type 500.21-.0 (Fig. 5) [mm] 35 H8 42 H8 52 H8 62 H8 80 H8 Dimension "z" Type 500.20-.0 (Fig. 6) [mm] 3.5 4.5 5 6 6 Dimension "z" Type 500.21-.0 (Fig. 6) [mm] 2 2.5 3 3.5 3.5 Tightening torque fixing screws Armature disk Type 500.200.0 [Nm] 2.9 5.8 9.9 24 24 Tightening torque fixing screws Armature disk Type 500.210.0 [Nm] 1.1 2.9 5.7 9.9 24 Tightening torque fixing screws Coil carrier Type 500. _.0 [Nm] 2.9 5.7 9.9 9.9 24 Page 5 of 6 Germany email: info@mayr.de
Installation Drawings (Figs. 5 and 6) It is essential that the rotor (3) is kept free of grease. The rotor (3) must be fixed axially when in operation, see the Installation Examples Figs. 2 and 3. Axial play can lead to the rotor (3) rubbing against the armature disk (2) or the coil carrier (1). 3. Armature Disk Installation: Lay the spring washers under the fixing screws. Mount the armature disk (2) onto the mounting part or onto the flange hub (4). (Please observe the tightening torques according to Table 2). Align the armature disk (2) (for permitted radial impact, please see Table 2). Warning: Secure the fixing screws with Loctite medium hard 243. It is essential that the armature disk is kept free of grease. Fig. 5 4. Installation of Mounting Part or the Flange Hub: Adjust air gap a, Table 2, Fig. 5 or Fig. 6. Fix the mounting part or flange hub (4) axially backlash-free. Axial backlash changes the air gap a and can lead to the rotor (3) rubbing against the armature disk (see Installation Examples Figs. 2 and 3). Please observe the max. permitted center misalignment V, Table 2, Fig. 5 or Fig. 6. Electrical Connection The clutch coil is connected to a DC voltage supply. The voltage level is shown on the Type tag. Rotor Disassembly In order to remove the rotors (3) from the shaft, there are threaded bores in the rotor hub. Do not place pressure on the thin-walled outer rotor area (Fig. 4). Fig. 6 Installation 1. Mounting the coil carrier: Screw the coil carrier (1) onto the machine wall (please observe the tightening torque according to Table 2. Use screws with a low head DIN 6912 or DIN 7984). - Center via ball bearing, Figs. 2 and 3. - Center on the diameter Z, Fig. 5 and Table 2. - Center on the outer diameter H, Fig. 5 and Table 2. The maximum permitted center misalignment V 1 may not be exceeded, see Table 2 and Fig. 6. 2. Rotor Installation: The rotor (3) is mounted onto the shaft using a suitable mounting device. Warning: - Do not place pressure on the outer area of the rotor (3) (Fig. 4). - Do not install by hammering. - Keep to dimension z, see Table 2 and Fig. 6. Maintenance and Inspection Please inspect the air gap a and the permitted centre misalignment V and V 1. Bearing backlash occurrence and wear on the friction surfaces change the permitted Table values. Apart from this, ROBATIC -electromagnetic clutches require no further maintenance. Special Guidelines: In new condition, a clutch unit transmits only c. 50 % of the nominal torque during the first switching. For specialized operation applications (high switching frequency, low friction work, low mass moment of inertia, operation under 300 rpm, exact coupling etc), the clutch should run in for c. 100 switchings. If this is the case, please contact the manufacturers. Disposal Coil carrier (steel girders with coils and strands) and all other steel components: Steel scrap (Code No. 160117) Clutch rotor (steel with friction linings): Friction linings (Code No. 160112) Malfunctions / Breakdowns Malfunction Possible Causes Solutions The clutch does not switch Incorrect voltage on rectifier ROBA -switch fast acting rectifier failure Air gap too large (worn rotor) Interrupted coil Apply correct voltage Replace ROBA -switch fast acting rectifier Replace rotor Replace clutch Page 6 of 6 Germany email: info@mayr.de