95. _ (disk pack HF) Sizes 6 22 Please read these Operational Instructions carefully and follow them accordingly! Ignoring these Instructions may lead to malfunctions or to coupling failure, resulting in damage to other parts. Contents: Page : - Contents Page 2: - Safety and Guideline Signs - Safety Regulations Page 3: - Summary of Constructional Designs for Sizes 6 to 6 - Parts List (Sizes 6 6) Page 4: - Summary of Constructional Designs for Sizes 8 to 22 - Parts List (Sizes 8 22) Page 5: - Table : Technical Data for Sizes 6 to 6 Page 6: - Table 2: Technical Data for Sizes 8 to 22 Page 7: - Table 3: Transmittable Torques on Clamping Ring s - Table 4: Transmittable Torques on Clamping s Page 8: - Tables 5 and 6: Transmittable Torques on Shrink Disk s Page 9: - Table 7: Transmittable Torques on Split Clamping s - Function - Application - State of Delivery - Temperature Resistance - Storage - Installation Position Page : - Guidelines on Bore and Shaft - Installation Page : - Installation Page 2: - Coupling Installation - Coupling Alignment - Permitted Shaft Misalignments Page 3: - Balancing the Coupling - Diagram : Balancing Coupling with Sleeve S/CRD/CFRP - Diagram 2: Permitted Speeds for Sleeve S Page 4: - Diagram 3: Permitted Speeds for Sleeve CRD - Diagram 4: Permitted Speeds for Sleeve CFRP Page 5: - Maintenance - Disposal - Malfunctions / Breakdowns 9/9/27 TK/GH/HH/GC/SU Chr. Mayr GmbH + Co. KG Tel.: +49 834 84-, Fax: +49 834 84-42 Page of 5
95. _ (disk pack HF) Sizes 6 22 Safety and Guideline Signs CAUTION Danger of injury to personnel and damage to machines. Please Observe! Guidelines on important points. Attention! Possible property damage can be the consequence. Safety Regulations These Installation and Operational Instructions (I + O) are part of the coupling delivery. Please keep them handy and near to the coupling at all times. It is forbidden to start initial operation of the product until you have ensured that all applicable EU directives and directives for the machine or system, into which the product has been installed, have been fulfilled. At the time these Installation and Operational Instructions go to print, the ROBA -DS couplings accord with the known technical specifications and are operationally safe at the time of delivery. Without a conformity evaluation, this product is not suitable for use in areas where there is a high danger of explosion. This statement is based on the ATEX directive. CAUTION If the ROBA -DS couplings are modified. The relevant standards for safety and / or installation conditions are ignored. User-implemented Protective Measures Cover all moving parts to protect against seizure, dust or foreign body impact. Replace self-locking hexagon nuts when they become ineffective after frequent loosening and tightening. To prevent injury or damage, only specialist personnel are allowed to work on the components. They must be familiar with the dimensioning, transport, installation, initial operation, maintenance and disposal according to the relevant standards and regulations. Please read the Installation and Operational Instructions carefully prior to installation and initial operation of the device. These Safety Regulations are user hints only and may not be complete! 9/9/27 TK/GH/HH/GC/SU Chr. Mayr GmbH + Co. KG Tel.: +49 834 84-, Fax: +49 834 84-42 Page 2 of 5
95. _ (disk pack HF) Sizes 6 22 Summary of Constructional Designs for Sizes 6 to 6 95_. 95_. 95_.2 Single-jointed coupling 95. 95_.3 95_.4 Double-jointed coupling 95. with connection plate Flange 95_.6 95_.5 95_.8 Double-jointed coupling 2 = Sleeve 95. 3 = Sleeve S 4 = CRD sleeve 5 = CFRP with sleeve sleeve 95_.9 Sleeve connection to hub 95_.8 Fig. Parts List (Sizes 6 6) Only use mayr original parts 95_.. 95_.2.. Hexagon head screws for hubs 95_.2..2 Shrink disk.2 95_.3.2. Cap screws for hubs 95_.3.3 95_.4.3. Cap screw for hubs 95_.4.3.2 Clamping ring.4 95_..6 Flange 95_.6.7 95_.8.7. Cap screws for hubs 95_.8.8 95_.9.8. Hexagon head screws for hubs 95_.9.8.2 Shrink disk.9 95_.5.9. Cap screws for hubs 95_.5 2 Disk pack 3 Sleeve 4 Connection plate 5 Hexagon head screw 6 Hexagon head screw 7 Washer 8 Hexagon nut 9/9/27 TK/GH/HH/GC/SU Chr. Mayr GmbH + Co. KG Tel.: +49 834 84-, Fax: +49 834 84-42 Page 3 of 5
95. _ (disk pack HF) Sizes 6 22 Summary of Constructional Designs for Sizes 8 to 22 95_. 95_.2 Single-jointed coupling 95. Flange 95_.6 Double-jointed coupling 95. with connection plate Double-jointed coupling 95_.8 2 = Sleeve 95. 3 = Sleeve S 4 = CRD sleeve 5 = CFRP sleeve with sleeve 95_.7 Sleeve connection to 95_.8 Fig. 2 Parts List (Sizes 8 22) Only use mayr original parts 95_.. 95_.2.. Hexagon head screws for hubs 95_.2..2 Shrink disk.5 95_.7.6 Flange 95_.6.7 95_.8.7. Cap screws for hubs 95_.8 2 Disk pack 3 Sleeve 4 Connection plate 5 Hexagon head screw 6 Hexagon head screw 7 Washer 8 Hexagon nut 9/9/27 TK/GH/HH/GC/SU Chr. Mayr GmbH + Co. KG Tel.: +49 834 84-, Fax: +49 834 84-42 Page 4 of 5
95. _ (disk pack HF) Sizes 6 22 Table : Technical Data for Sizes 6 to 6 ROBA -DS Size 6 25 4 64 6 d P max 95_. () [mm] 32 4 5 55 7 8 d G max 95_. (.4) [mm] 45 55 65 75 95 d S max 95_.2/3 (./2) [mm] 26 36 45 45 55 65 d KR max 95_.4 (.3) [mm] 4 45 55 68 8 d K max 95_.5 (.9) [mm] 45 52 6 7 9 d H max 95_.8 (.7) [mm] 28 32 4 45 6 75 d SG max 95_.9 (.8) [mm] 45 52 6 7 9 ) Coupling nominal torque T KN 9 29 45 72 6 valid for changing load direction as well as for max. permitted shaft misalignment Coupling peak torque T KS 285 4 675 8 5 24 valid for unchanging load direction, max. load cycles 5 Max. speed n max [rpm] 36 8 85 73 62 Distance dimension S [mm] 7..2 7.2.2 8.4.2 9.6.25.25.6.25 Axial displacement ΔK 2) a [mm] ±. ±.3 ±.5 ±.8 ±2. ± 2.5 Values refer to couplings with 2 disk packs. Only permitted as a static or virtually static value. Radial misalignment ΔKr for 95. [mm].3.3.4.45.45.55 Radial misalignment ΔKr for 95. 2 [mm]..2.5.8 2. 2.2 Radial misalignment ΔKr for 95. 3 2) [mm] (H S S) x.74 x -2 Radial misalignment for single-jointed coupling If there is only one disk pack, the shafts must be aligned exactly. Angular misalignment ΔK w per disk pack 2) [ ] Hexagon head screws Item.. ( 95_.2 ) M5x3 6 M5x 6 M5x4 M6x45 M8x5 25 M8x55 25 Cap screws Item.2. ( 95_.3 ) M5x8 M5x8 M5x2 M6x2 M8x22 M8x25 Cap screws Item.3. ( 95_.4 ) Cap screws Item.7. ( 95_.8 ) Hexagon head screws Item.8. ( 95_.9 ) Cap screws Item.9. ( 95_.5 ) Hexagon head screws Item 5 Hexagon nut Item 8 Hexagon head screws Item 5 Hexagon nut Item 8 (for hub 95_. ) Hexagon head screws Item 5 Hexagon nut Item 8 (for hub 95_.5 ) Hexagon head screws Item 6 Hexagon nut Item 8 Adjusting screws for hub 95_. with hub bore Adjusting screws for hub 95_. 6 M8x25 4 M6x8 4.9 M5x3 6 M6x25 7.4 M5x23 M5x45 M5x8 M5x M5 22 2 M6 >22 4. 6 Mx3 83 M8x25 24 M5x 6.5 M8x25 42 M5x23 M5x5 M5x2 M5x M5 22 2 M6 >22 4. ) For split clamping hubs ( 95_.8 ), the following applies: Valid for unchanging load direction as well as for max. permitted shaft misalignment. When the load direction changes, max. 6% of the stated nominal torque is permitted. M2x 45 M8x25 36 M5x4 Mx 83 M6x25 4 M6x65 4 M6x22 4 M6x45 4 M6 M4x4 23 Mx3 7 M6x45 4 M2x4 22 M8x3 M8x7 M8x3 M8x5 2) For s 95. 4 and 95. 5 the permitted shaft misalignments must be reduced to one-third of the Table values. M8 M8 4. M 4 M8 M 4 25 M6x5 5 M2x 2 M8x5 25 M2x45 43 M8x3 M8x8 M8x3 M8x5 M 4 M2 25 M8x55 485 M2x 22 M8x55 32 M4x5 22 Mx4 69 Mx9 69 Mx 69 Mx65 69 M2 M2 9/9/27 TK/GH/HH/GC/SU Chr. Mayr GmbH + Co. KG Tel.: +49 834 84-, Fax: +49 834 84-42 Page 5 of 5
95. _ (disk pack HF) Sizes 6 22 Table 2: Technical Data for Sizes 8 to 22 ROBA -DS Size 8 3 5 85 4 22 d P max 95_. () [mm] 75 9 5 2 4 7 d S max 95_.2/3 (./2) [mm] 75 85 2 4 7 d Pi max hub 95_.7 (.5) [mm] 55 7 85 95 3 d H max 95_.8 (.7) [mm] 65 8 95 2 5 ) Coupling nominal torque T KN 2 58 95 5 24 valid for changing load direction as well as for max. permitted shaft misalignment Coupling peak torque T KS valid for unchanging load direction, max. load cycles 5 35 525 87 425 225 36 Max. speed n max (only on s 95_.8 / 95_._ 8 _) [rpm] 73 (5) 62 (43) 52 (36) 44 (3) 38 (26) 33 (23) Distance dimension S [mm].2.25.2.25 2.25 4.25 6.25 7.8.25 Axial displacement ΔK a 2) Values refer to couplings with 2 disk packs. Only permitted as a static or virtually static value. [mm] ±. ±.2 ±.4 ±.6 ±.9 ±2.2 Radial misalignment ΔKr for 95. [mm].25.25..4.5.55 Radial misalignment ΔKr for 95. 2 [mm].2.25..7 2 2.6 Radial misalignment ΔKr for 95. 3 2) [mm] (H S S) x 8.73 x -3 Radial misalignment for single-jointed coupling If there is only one disk pack, the shafts must be aligned exactly. Angular misalignment ΔK w per disk pack 2) [ ].5.5.5.5.5.5 Hexagon head screws Item.. ( 95_.2 ) M8x55 25 M8x6 Mx7 56 M2x8 93 M4x 44 M4x2 96 Cap screws Item.7. ( 95_.8 ) Mx 48 M2x4 83 M4x45 33 M6x55 2 M2x6 4 M2x7 45 Hexagon head screws Item 5 Hexagon nut Item 8 Mx4 69 M2x4 2 M6x5 24 M2x6 45 M24x7 76 M24x75 9 Hexagon head screws Item 6 Hexagon nut Item 8 Mx6 69 M2x65 2 M6x75 24 M2x95 45 M24x 76 M24x2 9 Adjusting screws for hub 95_. with hub bore M2 65 M > 65 4 M2 M2 M6 9 M6 9 M6 9 Adjusting screws for hub 95_.7 M 4 ) For split clamping hubs ( 95_.8 ), the following applies: Valid for unchanging load direction as well as for max. permitted shaft misalignment. The split clamping hubs are only available with keyway acc. DIN 6885. They transmit only 3 4 % of the value T KN using frictional locking. Larger torques are transmitted via positive locking with the key. The hubs are not suitable for changing load direction. 2) For s 95. 4 and 95. 5 the permitted shaft misalignments must be reduced to one-third of the Table values. M2 M2 M6 9 M6 9 M6 9 9/9/27 TK/GH/HH/GC/SU Chr. Mayr GmbH + Co. KG Tel.: +49 834 84-, Fax: +49 834 84-42 Page 6 of 5
95. _ (disk pack HF) Sizes 6 22 Table 3: Transmittable Torques on Clamping Ring s (.3) - dependent on bore - suitable for H7/h6 - Sizes 6 to 6 Sizes Bore 6 25 4 64 6 Ø2 26 - - - - - Ø22 38 99 - - - - Ø25 68 226 327 - - - Ø28 2 253 366 523 - - Ø3 26 29 42 56 - - Ø32 23 325 47 598 785 - Ø 25 5 55 7 859 - Ø38-386 559 798 932 - Ø4-46 588 84 5 256 Ø45 - - 66 945 24 43 Ø5 - - - 5 378 68 Ø55 - - - 55 56 94 Ø6 - - - - 654 27 Ø65 Attention! - Please observe - the permitted coupling - - 792 2293 torques of the coupling size used. Ø68 - - - - 874 2399 Ø7 - - - - - 247 Ø8 - - - - - 2822 Table 4: Transmittable Torques on Clamping s (.9) - dependent on bore - suitable for H7/h6 - Sizes 6 to 6 Sizes Bore 6 25 4 64 6 Ø2 83 - - - - - Ø22 22 4 - - - - Ø25 229 42 64 - - - Ø28 257 45 677 82 - - Ø3 275 483 725 88 - - Ø32 293 55 773 938 2 - Ø 32 563 846 26 25 - Ø38 348 6 98 4 39 - Ø4 367 643 967 73 378 839 Ø42 385 676 5 232 447 93 Ø45 42 724 87 39 55 269 Ø48-772 6 47 653 227 Ø5-84 28 466 722 2299 Ø52 836 257 525 79 239 Ø55 - - 329 63 894 2529 Ø6 - - 45 759 266 2759 Ø65 - - - 96 2239 2989 Ø68 - - - 994 2342 327 Ø7 - - - 253 24 329 Ø75 - - - - 2583 3449 Ø8 - - - - 2755 3679 Ø85 Attention! - Please observe - the permitted coupling - - 2927 399 torques of the coupling size used. Ø9 - - - - 3 439 Ø95 - - - - - 4369 Ø - - - - - 4599 9/9/27 TK/GH/HH/GC/SU Chr. Mayr GmbH + Co. KG Tel.: +49 834 84-, Fax: +49 834 84-42 Page 7 of 5
95. _ (disk pack HF) Sizes 6 22 Table 5: Transmittable Torques on Shrink Disk s, Large (.8) - dependent on bore - suitable for H7/g6 - Sizes 6 to 6 Sizes Bore 6 25 4 64 6 Ø25 339 - - - - - Ø28 44 - - - - - Ø3 448 - - - - - Ø32 492 526 - - - - Ø 558 62 - - - - Ø38 62 679 - - - - Ø4 659 73 873 - - - Ø42 694 78 937 - - - Ø45 738 85 36 268 - - Ø48-93 32 394 - - Ø5-948 95 48 - - Ø52-978 255 565 - - Ø55 - - 338 69 274 - Ø6 - - 454 89 2366 - Ø65 - - - 265 2658 3246 Ø7 - - - 224 2943 368 Ø75 - - - - 323 399 Attention! Please observe the permitted coupling Ø8 - torques of - the coupling size used. - - 3458 43 Ø85 - - - - 3666 4695 Ø9 - - - - 3828 57 Ø - - - - - 5497 Table 6: Transmittable Torques on Shrink Disk s (./.2) - dependent on bore - suitable for H7/g6 - Sizes 6 to 22 Sizes Bore 6 25 4 64 6 8 3 5 85 4 22 Ø4 58 - - - - - - - - - - - Ø6 86 - - - - - - - - - - - Ø2 24 283 - - - - - - - - - - Ø22 269 32 - - - - - - - - - - Ø25 32 375 429 - - - - - - - - - Ø28-428 495 - - - - - - - - - Ø3-468 546 74 - - - - - - - - Ø32-59 6 769 - - - - - - - - Ø - 568 669 863 57 - - - - - - - Ø38 - - 74 96 76 - - - - - - - Ø4 - - 796 3 269 783 - - - - - - Ø42 - - 852 4 366 99 2234 - - - - - Ø45 - - 932 26 5 27 2453 - - - - - Ø5 - - - - 692 24 2794 69 - - - - Ø55 - - - - 889 268 35 424 - - - - Ø6 - - - - - 2967 3488 45 597 - - - Ø65 - - - - - 3263 38 577 6629 - - - Ø68 - - - - - - 472 5658 78 - - - Ø7 - - - - - - 4255 6334 75 723 - - Ø75 - - - - - - 4627 7348 856 79 - - Ø8 - - - - - - - 8453 883 275 7942 - Ø85 - - - - - - - 9652 9523 375 9444 - Ø9 - - - - - - - - 234 4777 2 - Ø - - - - - - - - 542 6665 23683 2936 Ø - - - - - - - - - 867 26442 3248 Ø2 - - - - - - - - - 263 29279 896 Attention! Please observe the permitted coupling Ø3 - - torques - of the coupling - size - used. - - - - - 3295 3947 Ø4 - - - - - - - - - - 9 4344 Ø5 - - - - - - - - - - - 4692 Ø6 - - - - - - - - - - - 5798 Ø7 - - - - - - - - - - - 54783 9/9/27 TK/GH/HH/GC/SU Chr. Mayr GmbH + Co. KG Tel.: +49 834 84-, Fax: +49 834 84-42 Page 8 of 5
95. _ (disk pack HF) Sizes 6 22 Table 7: Transmittable Torques on Split Clamping s (.7) - dependent on bore - suitable for H7/g6 - Sizes 6 to 6 Sizes Bore 6 25 4 64 6 Ø8 3 - - - - - Ø2 44 - - - - - Ø22 58 98 - - - - Ø25 8 225 326 - - - Ø28 22 252 365 - - - Ø3-27 39 623 - - Ø32-288 48 665 - - Ø - - 457 727 897 - Ø38 - - 496 79 973 - Ø4 - - 522 83 25 28 Ø42 - - - 873 76 279 Ø45 - - - 9 53 37 Ø5 - - - - 28 522 Ø55 - - - - 49 675 Ø6 - - - - 537 827 Attention! Please observe the permitted coupling Ø65 - torques of - the coupling size used. - - - 979 Ø68 - - - - - 27 Ø7 - - - - - 23 Ø75 - - - - - 2284 Function Application ROBA -DS couplings are shaft connections for torsionally rigid, backlash-free torque transmission. At the same time they compensate for angular misalignments and axial displacements on single-jointed couplings ( 95. _), and additionally for radial misalignments on double-jointed couplings ( 95. _). Installation Position ROBA -DS couplings are designed for horizontal installation. In case of vertical or inclined installation, on long sleeves (sleeves S/CRD/CFRP) the sleeve's own weight must be supported with a vertical support (Fig. 4). This vertical support including both centerings in the hub and in the sleeve is produced at the place of manufacture. State of Delivery The ROBA -DS couplings are delivered in individual parts and pre-assembled units. All screw connections must be checked and pre-tensioned during the final installation to a torque value according to Table and Table 2. Except for the disk pack (2), all parts are phosphated and therefore have a basic corrosion protection. All hub designs can be delivered either pilot bored or finish bored. The preferred bore tolerance is H7; deviating bores are possible (please contact the manufacturer). The key hubs (Items,.4 and.5) additionally have a keyway acc. DIN 6885 sheet or 3, as well as an adjusting screw for axial securement. The split clamping hub (Item.7) on Sizes 8 to 22 is also additionally designed with a keyway according to DIN 6885 sheet or 3. Fig. 3 Temperature Resistance Due to their all-steel design, ROBA -DS couplings are temperature-resistant up to +25 C. At temperatures of over +2 C, the standard self-locking hexagon nuts must be replaced with self-locking all-steel nuts (8) acc. EN ISO 742. Storage To avoid corrosion, the coupling must be stored in dry rooms protected from the weather. Preservative oil can be used for protecting (treating) the coupling. Fig. 4 9/9/27 TK/GH/HH/GC/SU Chr. Mayr GmbH + Co. KG Tel.: +49 834 84-, Fax: +49 834 84-42 Page 9 of 5
95. _ (disk pack HF) Sizes 6 22 Guidelines on Bore and Shaft General Guidelines: The maximum bore diameter according to Tables and 2 may not be exceeded. The hub bores are usually produced with tolerance H7. The required shaft tolerance depends on the hub type used as well as on the basic overall load configuration. - Shrink disk hubs/clamping ring hubs/split clamping hubs/clamping hubs: h6/g6 - Key hubs: r6/s6 (alternating rotational direction), k6/n6 (one-way rotational direction) The recommended bore tolerances are to be produced using the position and tolerance width as references; at the same time, please keep to the shaft run-out and axial run-out tolerances of.3 mm (see Fig. 3). After producing the finish bore, please clean it using suitable cleaning agents. The shaft surfaces should be finely turned or ground (Ra =.8 μm). The required yield point for the shafts used is at least N/mm² (St6, St7, C45, C6). Fig. 5 Adjusting screw Please observe the following when boring the hub with keyway (Items,.4,.5 and.7) s 95_. / 95_. / 95_.7 and 95_.8 : The specified form (DIN 6885 sheet or 3) and position* of the keyway. * Position of the keyway on : 95_. (Item. ) and 95_.8 (Item.7) aligned with a fixing hole. 95_. (Item.4) 25 offset to a fixing hole. 95.7 (Item.5) 45 offset to a fixing hole. For axial securement, please provide an additional adjusting screw (ISO 429-45H) as an alternative to a press cover (see Figs. 5 and 6). The adjusting screw dimensions and tightening torques stated in Tables and 2 must be kept to. On split clamping hubs (.7), no axial securement is necessary. Please observe the following when boring the shrink disk and clamping ring hubs (Items.,.2,.3 and.8) s 95_.2 / 95_.3 / 95_.4 and 95_.9 : The shrink disk hubs or clamping ring hubs are generally delivered greased and pre-assembled. For production of the finish bore, the clamping ring or the shrink disk is de-installed and the hub is de-greased. Deburr the hubs, in particular in the area of the slots. Clean and re-grease the hubs in the clamping ring or shrink disk contact areas. Permitted grease: Klüber Alltemp QNB 5 Installation The configuration of the different individual components can be seen in Figs. and 2. Installation s 95_.2 / 95_.3 / 95_.9 (s with Shrink Disk) and s 95_.4 (s with Clamping Ring) The force transmission of the shrink disk hubs or the clamping ring hubs (./.2/.3/.8) takes place using frictional locking. The contact surfaces between the shrink disk and the hub as well as between the clamping ring and the hub are greased manufacturer-side. The hub bores and the shaft ends must be completely grease-free during installation. Greasy or oily bores or shafts do not transmit the maximum coupling torque. The shafts must not have a keyway. The hub and the shrink disk (..2/.8.2) or the clamping ring (.3.2) must be completely relaxed; if necessary, loosen the screws (../.2./.3./.8.) by several thread turns. Installation s 95_.2 / 95_.3 / 95_.9 (s with Shrink Disk) a) Mount the hubs (./.2/.8) onto the shafts using a suitable device and bring them into the correct position. b) Tighten the tensioning screws (../.2./.8.) using a torque wrench evenly and one after the other in 3 to max. 6 tightening sequences to the torque stated in Tables or 2. c) Check the tightening torque produced after 5 to operating hours. For de-installation: a) Loosen all tensioning screws (../.2./.8.) in several sequences by several thread turns. b) Screw out the tensioning screws located next to the tapped extracting holes and screw them into the tapped extracting holes up to their limits. On Sizes 8 22, only one hub with outer clamping is offered. Additional threads are provided on the hub (./.8) as well as on the shrink disk (..2/.8.2) in order to extract the shrink disk (..2/.8.2). Please take the axial space requirements for the tensioning screws to be screwed into the tapped extracting holes into account (length of the hexagon head screws Item.. / Item.8., see Tables and 2). c) Tighten the tensioning screws (../.2./.8.) evenly and step-wise so that the shrink disk (..2/.8.2) is loosened from the hub. Installation 95_.4 (s with Clamping Ring) a) Mount the hubs (.3) onto the shafts using a suitable device and bring them into the correct position. b) Tighten the clamping screw (.3.) using a torque wrench to the torque stated in Table. c) Check the tightening torque produced after 5 to operating hours. 9/9/27 TK/GH/HH/GC/SU Chr. Mayr GmbH + Co. KG Tel.: +49 834 84-, Fax: +49 834 84-42 Page of 5
95. _ (disk pack HF) Sizes 6 22 Installation 95_.5 (Clamping s) The hub bores and the shaft ends must be completely grease-free during installation. Greasy or oily bores or shafts do not transmit the maximum coupling torque. The shafts must not have a keyway. The clamping hub (.9) must be completely relaxed; if necessary, loosen the screws (.9.) by several thread turns. a) Mount the hubs (.9) onto the shafts using a suitable device and bring them into the correct position. b) Tighten the clamping screws (.9.) using a torque wrench to the torque stated in Table. c) Check the tightening torque produced after 5 to operating hours. Installation s 95_. / 95_. / 95.7 (s with Keyway) a) Mount the hubs ( /.4 /.5) onto the shafts using a suitable device and secure them axially (Fig. 6). Axial securement takes place using a set screw (adjusting screw), which presses radially onto the key; or via a press cover and a screw, screwed into the shaft threaded centre hole. b) The key must lie over the entire length of the hub. or Coupling Installation 95_.8 (Split Clamping s) On 95.8_, no radial installation is possible due to the angular correlation of both hubs (.7). On 95.8, radial installation is only possible if the half-shell is axially moved by a minimum dimension a (Fig. 8 / Table 8). a) Partly assemble the coupling, observing the Point Coupling Installation (page 2). b) Loosen the pre-assembled half-shells from the hubs (.7), making sure that their correlation to the hub is maintained. c) Place the coupling from above onto the shafts and pre-assemble it with the respective half-shells (Fig. 8). d) Tighten the cap screws (.7.) cross-wise and in several tightening sequences to the tightening torque stated in Table. Please make sure that the gap "X" (Fig. 7) has the same size on both hub sides. If necessary, re-adjust it. Fig. 6 Table 8: Minimum Dimension a [mm] Sizes s 95. 2 / 3 / 4 / 5 (Sleeve) 95. (Connection plate) 6 3.5 25.5 4 64 3 2.5 6 8 8.5 7.5 3.5 9.5 5 3 85 4.5 4 4 2 5 22 5 8 Fig. 7 Axial displacement Half-shell Axial displacement Hexagon head screw (5) Hexagon nut (8) Fig. 8 Dim. a Dim. a 9/9/27 TK/GH/HH/GC/SU Chr. Mayr GmbH + Co. KG Tel.: +49 834 84-, Fax: +49 834 84-42 Page of 5
95. _ (disk pack HF) Sizes 6 22 Coupling Installation (Figs., 2 and 9) The disk packs (2) are screwed together alternately with the sleeve (3) and the hubs or the connection plate (4) using lightly oiled hexagon head screws (5 and 6), washers (7) and hexagon nuts (8). Here, the tightening torque acc. Tables or 2 must be produced in several steps. The hexagon nuts (8) or the hexagon head screws (5 and 6) must be tightened in several steps to their full tightening torque acc. Tables or 2. Please see Table 9 for the respective tightening torques for each step. Table 9 Step Starting with Size 8, the hexagon nuts (8) and the hexagon head screws (5 and 6) on each connection side must be tightened crosswise. for hexagon nuts (8) or hexagon head screws (5 and 6) 3 % of the nominal tightening torque 2 6 % of the nominal tightening torque 3 % of the nominal tightening torque The disk pack (2) must not under any circumstances be distorted when applying the pre-tension force. The disk pack (2) is always to be inserted so that the collar bushing radius (part 2a, Fig. 9, detail X ) lies in the hub grooves, the sleeve grooves or the connection plate grooves. Coupling Alignment Exact coupling alignment reduces the reaction forces and therefore increases the lifetime of the coupling and the shaft bearing. In most of the applications, coupling alignment using a straight edge in two levels vertical to each other is sufficient. However, we recommend alignment of the coupling (of the shaft ends) using a dial gauge or laser on drives operating at very high speeds. In order to prevent axial distortion of the disk packs, the dimension S (Fig. 9, detail X, Tables or 2) must be maintained with aligned angular and radial shaft misalignments. Permitted Shaft Misalignments ROBA -DS single-jointed couplings ( 95. _) compensate for angular and axial shaft misalignments. ROBA -DS double-jointed couplings ( 95. _) compensate for angular, axial and radial shaft misalignments (Fig. ) without losing their backlash-free function. However, the permitted shaft misalignments indicated in Tables or 2 must not simultaneously reach their maximum value. If more than one kind of misalignment takes place simultaneously, they influence each other. This means that the permitted misalignment values are dependent on one another, see Fig.. The sum total of the actual misalignments in percent of the maximum value must not exceed % (see example and Fig. ). Due to the enlarged diameter of the shrink disks (..2) on Sizes 8 to 22 and the shrink disks (.8.2), please make sure that the installation sequence is suitable. In this way, normal torque wrenches can be used for installation of the disk pack (2). Fig. 9 Fig. Example: ROBA -DS, Size 4, 95.2 Axial displacement occurrence ΔK a =.6 mm equals 4 % of the permitted maximum value ΔK a =.5 mm Angular misalignment occurrence in the disk pack ΔK w =.3 equals 3 % of the permitted maximum value ΔK w = => permitted radial misalignment ΔK r = 3 % of the maximum value ΔK r =.5 mm => ΔK r =.45 mm ΔK a 2x ΔK w ΔK r Δ Kr [%] Radial misalignment Δ Kw [%] Angular misalignment Δ Ka [%] Axial displacement ΔKw Fig. 9: Detail X Axial Radial Angular displacement misalignment misalignment Fig. 9/9/27 TK/GH/HH/GC/SU Chr. Mayr GmbH + Co. KG Tel.: +49 834 84-, Fax: +49 834 84-42 Page 2 of 5
95. _ (disk pack HF) Sizes 6 22 Balancing the Coupling In most applications, balancing the ROBA -DS coupling is not necessary. In general, the following points are crucial when deciding whether the coupling needs balancing: Circumferential speed of the coupling Length of the sleeves S/CRD/CFRP (Diagram ) Required balance quality Diagram : Balancing Couplings with Sleeve S/CRD/CFRP (Special Length) Operating speed [rpm] 3 28 26 24 22 2 8 6 4 2 8 6 4 2 Balancing dependent on application case Balancing not necessary Dynamic balancing recommended 2 4 6 8 2 4 6 8 2 Sleeve length [mm] Smooth running of the machine is not only ensured by the coupling balance quality, but is also influenced by parameters such as rigidity and distance to the adjacent bearings as well as by the sensitivity and mass of the entire construction. Diagram, therefore, only shows reference values as recommendations for balancing. All parts of the ROBA -DS couplings, except the sleeves S/CRD/CFRP, are machined on all sides, and therefore lie in the range G6.3 acc. DIN ISO 94 at medium speeds (5 rpm). If higher demands are placed on the balance quality, it is possible to balance individual parts or even the entire installed coupling (on request). However, for this option, the hubs must have a finish bore. Diagram 2: Permitted Speeds (Bend-critical) for Sleeves S 95. 3 6 Permitted speed [rpm] 55 5 45 4 3 25 2 5 2 DS 6 DS 25 DS 4 DS 64 DS 8 DS DS 6 /DS 3 DS 5 DS 85 DS 4 DS 22 5 8 75 25 5 75 2 225 25 275 3 325 375 Sleeve length [mm] Example: Size 4, sleeve length H S = 8 mm = > permitted speed 2 rpm. 4 9/9/27 TK/GH/HH/GC/SU Chr. Mayr GmbH + Co. KG Tel.: +49 834 84-, Fax: +49 834 84-42 Page 3 of 5
95. _ (disk pack HF) Sizes 6 22 Diagram 3: Permitted Speeds (Bend-critical) for Sleeves CRD 95. 4 6 Permitted speed [rpm] 55 5 45 4 3 25 2 5 5 DS 8 DS 6 / DS3 DS 5 DS 85 DS 4 5 2 25 3 4 45 5 55 Sleeve length [mm] 6 Diagram 4: Permitted Speeds (Bend-critical) for Sleeves CFRP 95. 5 6 Permitted speed [rpm] 55 5 45 4 3 25 2 5 5 DS 6 DS 25 DS 4 DS 8 DS 64 DS 3 DS DS 6 DS 5 DS 85 DS 4 DS 22 5 2 25 3 4 45 5 55 Sleeve length [mm] 6 9/9/27 TK/GH/HH/GC/SU Chr. Mayr GmbH + Co. KG Tel.: +49 834 84-, Fax: +49 834 84-42 Page 4 of 5
95. _ (disk pack HF) Sizes 6 22 Maintenance ROBA -DS couplings are mainly maintenance-free. The following maintenance and inspection intervals are to be maintained:.) Visual inspection, inspection of the installation parameters (misalignment and tightening torques) and the coupling running behaviour before initial operation. 2.) Visual inspection, torsional backlash, inspection of the misalignment and the tightening torques, coupling running behaviour after h, at the latest after 3 months. 3.) If no irregularities or wear are found during the second maintenance and inspection interval, further inspection intervals can, with unchanged operating parameters, take place after 4 operating hours or after maximum 2 months. In extreme coupling ambient or operating conditions, the maintenance and inspection intervals should be shortened. Disposal All steel components and carbon pipes: Steel scrap (Code No. 67) Malfunctions / Breakdowns Malfunction Possible Causes Solutions Changes in running noise and / or vibration occurrence Disk pack breakage Disk packs / connecting screws cracks or breakage Incorrect alignment, incorrect installation Loose connecting screws, minor fretting corrosion under the screw head and on the disk pack Tensioning and clamping screws or locking set screw for axial hub securement are loose Disk pack breakage due to high load impacts / overload Operating parameters are not appropriate for the coupling performance Incorrect operation of the system unit Drive vibrations ) Set the system out of operation 2) Find / resolve the cause of incorrect alignment 3) Check the coupling for wear ) Set the system out of operation 2) Check the coupling parts and replace if damaged 3) Tighten the connecting screws to the specified torque 4) Check the alignment and correct if necessary ) Set the system out of operation 2) Check the coupling alignment 3) Tighten the tensioning and clamping screws for axial hub securement to the required torque or tighten the locking set screw and secure it against self-loosening using sealing lacquer 4) Check the coupling for wear ) Set the system out of operation 2) Dismantle the coupling and remove the remainders of the disk packs 3) Check the coupling parts and replace if damaged 4) Find the cause of overload and remove it ) Set the system out of operation 2) Check the operating parameters and select a suitable coupling (observe installation space) 3) Install a new coupling 4) Check the alignment ) Set the system out of operation 2) Dismantle the coupling and remove the remainders of the disk packs 3) Check the coupling parts and replace if damaged 4) Train and advise operating personnel ) Set the system out of operation 2) Dismantle the coupling and remove the remainders of the disk packs 3) Check the coupling parts and replace if damaged 4) Check the alignment and correct if necessary 5) Find the cause of vibration and remove it mayr will take no responsibility or guarantee for replacement parts and accessories which have not been delivered by mayr, or for damage resulting from the use of these products. 9/9/27 TK/GH/HH/GC/SU Chr. Mayr GmbH + Co. KG Tel.: +49 834 84-, Fax: +49 834 84-42 Page 5 of 5