Mayr EAS-Compact Type 49. 4. Size 4 Series Quick start guide

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 1 of 19 www.mayr.com, E-Mail: [e-mail]
Please read these Operational Instructions carefully and follow them accordingly!
Ignoring these Instructions may lead to malfunctions or to clutch failure, resulting in damage to other parts.
These Installation and Operational Instructions (I + O) are part of the clutch delivery.
Please keep them handy and near to the clutch at all times.
The product must be specially marked for use in areas where there is a danger of explosion.
The product will only be marked if it is ordered especially for an Ex-area.
Contents
Page 1: - Contents
Page 2: - Safety and Guideline Signs
- Safety Regulations
Page 3: - EAS®-Compact®overload clutch, Type 490. _ _ 4._
- Clutch Illustrations
- Parts List
Page 4: - EAS®-Compact®overload clutch, lastic, Type 494. _ _ _ 4._
- Clutch Illustrations
- Parts List
Page 5: - Technical Data
Page 6: - Technical Data
Page 7: - Design
- Scope of Delivery / State of Delivery
- Function
- Re-engagement
- General Installation Guidelines
Page 8: - Output Elements Installation
Page 9: - Mounting onto the Shaft
- De-installation
- Shaft Installation via Key Connection
- Joining Both Clutch Components EAS®-Compact®Type 494._ _4._
- Cup Spring Layering
Page 10: - Permitted Shaft Misalignments Type 494._ _4._
- Clutch Alignment Type 494._ _4._
Page 11: - Torque Adjustment
Page 12: - Limit Switch
- Maintenance and Maintenance Intervals
- Disposal
Pages 13 to 15: Guidelines and Directives for Operation in Areas Where There is a Danger of Explosion (Dependent on
Type)
- Classification of Areas Where There is a Danger of Explosion and Permitted Types
- Conditions to Observe in Areas Where There is a Danger of Explosion
- Initial Operation
- Maintenance and Inspection Intervals for ROBA®-ES Couplings in Areas Where There is a Danger of Explosion
Page 16: - Malfunctions / Breakdowns Type 490._ _4._
Page 17: - Malfunctions / Breakdowns Type 494._ _4._
Page 18: - Malfunctions / Breakdowns Type 494._ _4._
Page 19: - Declaration of Conformity

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 2 of 19 www.mayr.com, E-Mail: [e-mail]
Safety and Guideline Signs
DANGER
Immediate and impending danger, which can
lead to severe physical injuries or to death.
CAUTION
Danger of injury to personnel and damage to
machines.
Please Observe!
Guidelines on important points.
Guidelines on explosion protection
Safety Regulations
These Installation and Operational Instructions (I + O) are part of the clutch delivery.
Please keep them handy and near to the clutch 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 EAS®-clutches accord with the known technical
specifications and are operationally safe at the time of delivery.
DANGER
If the EAS®-clutches are modified.
The relevant standards for safety and / or installation conditions are ignored.
The EAS®-clutch is permitted for use in areas where there is a danger of explosion.
For application in Ex-areas, please observe the special safety-related guidelines and directives on pages 13
and 15. The product must be especially marked for this area.
The product will only be marked if it is ordered especially for an Ex-area.
User-implemented Protective Measures
Cover all moving parts to protect against seizure, dust or foreign body impact.
The clutches may not be put into operation without a limit switch (for Ex-areas) unless mayr® has been contacted
and has agreed otherwise.
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.

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 3 of 19 www.mayr.com, E-Mail: [e-mail]
Maximum
screw-in depth
in the pressure flange
Stroke
Dim. “a”
Facing direction
Attention!
Remove the screws after
re-engagement,
otherwise no
overload function!
Thread in
pressure flange
Design with keyway Design with cone bushing
Fig. 2
Fig. 1
Parts List (Only use mayr® original parts)
Item
Name
Item
Name
1
Hub
10
Steel ball
2
Pressure flange
11
Cup spring
3
Thrust washer
12
Steel ball
4
Thrust ring
13
Sealing cover
5
Supporting ring
14
Engagement disk
6
Intermediate disk
15
Cap screw
7
Adjusting nut
16
Cone bushing
7.1
Set screw1)
17
Hexagon head screw
8
Deep groove ball bearing
18
Type tag
9
Locking ring
19
Limit switch 2)
1) Secure the set screws Item 7.1 with Loctite 243
2) The limit switch Item 17 is not part of the standard scope of delivery.

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 4 of 19 www.mayr.com, E-Mail: [e-mail]
Dimension “S”
EAS®-Compact®overload clutch, lastic, Type 494. _ _ 4._
Type 494. _ 24._
Lastic-side: Keyway
EAS®-side: Keyway
Fig. 3
Type 494. _ 14._
Lastic-side: Keyway
EAS®-side: Cone bushing
Parts List (Only use mayr® original parts)
Item
Name
1 –19
see Type 490._ _ 4._ (page 3)
20
Cap screw
21
Flange
22
Cap screw
23
Cam ring
24
Flexible intermediate ring (elastomeric element)
25
Hub
26
Set screw
Fig. 4

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 5 of 19 www.mayr.com, E-Mail: [e-mail]
Technical Data
Table 1
Limit torques for overload MG
Thrust washer
stroke
(Fig. 1; Item 3/13)
on overload
[mm]
Bore from –to
Sizes
Type 49_.5_4._
[Nm]
Type 49_.6_4._
[Nm]
Type 49_.7_4._
[Nm]
Max.
speed
[rpm]
Type
49_._14._
[mm]
Type
49_._24._
[mm]
4
175 –350
350 –700
700 –1400
3000
5.5
42 –65
40 –70
5
350 –700
700 –1400
1400 –2800
2000
7.0
50 –75
45 –90
Table 2:
Type 49_.5_4._
Type 49_.6_4._
Type 49_.7_4._
Sizes
Maximum
torque MG
[Nm]
Inspection
dimension “a”
(Fig. 1)
at approx.70 % MG
[mm]
Maximum
torque MG
[Nm]
Inspection
dimension “a”
(Fig. 1)
at approx.70 % MG
[mm]
Maximum
torque MG
[Nm]
Inspection
dimension “a”
(Fig. 1)
at approx.70 % MG
[mm]
4
350
12.4
700
10.4
1400
6.2
5
700
13.6
1400
11.2
2800
6.1
Table 3
Sizes
Thread
in pressure
flange (2)
(Fig. 1)
Max. screw-in depth
in the pressure flange
(2)
(Fig. 1)
[mm]
Thread “M” in the
engagement disk
(14)
(Fig. 1)
Permitted
ambient
temperature
Max. permitted
axial
forces
[N]
radial
forces
[N]
transverse
force
torques 3)
[Nm]
4
6 x M12
20
4 x M8
-15 °C to +80 °C
4800
4800
50
5
6 x M16
22
4 x M10
-15 °C to +80 °C
7700
7700
70
3) Torques, which put strain on the deep groove ball bearing due to the non-centric axial forces having an effect on the pressure flange.
Table 4
Sizes
Screw tightening torques [Nm]
for mounting the output element onto the pressure flange (2) for Type
Item 7.1
Item 17
49_.5_4._ and 49_.6_4._
screw quality 8.8
49_.7_4._
screw quality 12.9
4
4.1
40
80
135
5
8.5
60
195
330

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 6 of 19 www.mayr.com, E-Mail: [e-mail]
Technical Data
Table 5
Sizes
Flexible shaft coupling Type 494._ _ 4._
Bore hub from –to
Dimension “S”
Screw tightening torques
Item 25
[mm]
[mm]
Item 20
[Nm]
Item 22
[Nm]
4
55 –95
4
120
74
5
60 –110
4
175
120
Table 6
Sizes
Flexible shaft coupling Type 494._ _ 4._
Nominal and maximum torques
Max. permitted shaft misalignments
TKN
[Nm]
TK max.
[Nm]
Axial
ΔKa
[mm]
Radial
ΔKr
[mm]
Angular
ΔKw
[mm]
4
1500
3100
± 2
0.15
0.15
5
2400
4800
± 2
0.15
0.15

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 7 of 19 www.mayr.com, E-Mail: [e-mail]
Design
The EAS®-Compact®overload clutch is designed as a
mechanically disengaging overload clutch according to the ball
detent principle.
Scope of Delivery / State of Delivery
The clutch is manufacturer-assembled ready for installation.
The torque is set manufacturer-side according to the
customer's request (please compare the torque stipulated in
the order with the torque imprinted/engraved in the
identification).
Unless the customer requests a particular torque setting
when ordering, the clutch will be pre-set to approx. 70 % of
the maximum torque.
The 4 locking set screws (7.1) are not provided with screw
securement on a pre-set clutch.
Before initial operation of the clutch, please
secure the locking set screws (7.1), e.g. using
Loctite 243.
Please check the scope of delivery according to the Parts List as
well as the state of delivery immediately after receiving the
goods.
mayr®will take no responsibility for belated complaints.
Please report transport damage immediately to the deliverer.
Please report incomplete delivery and obvious defects
immediately to the manufacturer.
Function
The clutch protects the drive line from excessively high,
unpermitted torque impacts which can occur due to unintentional
blockages. After overload has taken place, the transmitting
mechanism is completely disconnected. Only the bearing friction
continues to have an effect.
This means that no re-engagement impacts or metallic sliding
movements occur on the clutch torque transmission geometries
when using this clutch variant.
When in operation, the set torque is transmitted backlash-free
onto the output from the motor shaft via the EAS®-Compact®
overload clutch (pressure flange (2)). If the set limit torque is
exceeded (overload), the clutch disengages. The input and the
output are separated residual torque-free.
A limit switch with ATEX-approval (not included in the
standard scope of delivery) must be installed. The limit switch
registers the disengagement movement and switches off the
drive.
After-acting masses can run free.
CAUTION
After overload occurrence, the clutch has no
load-holding function.
In order to make the clutch functional again after an overload
occurrence, the clutch must be engaged using the engagement
disk (14) and 4 screws.
After re-engagement has taken place, the screws must be
removed immediately from the engagement disk (14) (blockage,
danger of ignition).
Re-engagement
Re-engagement must only take place when the
device
is not running or at low differential speed (< 10
rpm).
EAS®-Compact®overload clutch re-engagement is carried out by
applying axial pressure to the sealing cover (13) using 4 screws
(Fig. 1; provided by the customer: M8 for Size 4; M10 for Size 5),
evenly screwed into the engagement disk (14).
It may be necessary to turn slightly between the pressure flange
(2) and the thrust washer (3) incl. the sealing cover (13).
CAUTION
After re-engagement has taken place, the four
screws must be removed immediately, as they
could stop the clutch functioning (blockage).
General Installation Guidelines
As standard the bores in the hub (Items 1 and 25) are provided
with a H7 tolerance.
The surface roughness depth in the bore is produced to
Ra = 1.6 μm.

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 8 of 19 www.mayr.com, E-Mail: [e-mail]
Installation of the Output Elements (Fig. 5)
The output element is centred on a deep groove ball bearing (8)
(tolerance H7/h5) and bolted together with the pressure flange
(2).
Please observe the maximum screw-in depth in
the pressure flange (2), see Fig. 1, page 3 and
Table 7.
If the resulting radial force from the output element is anywhere
near the centre of the ball bearing (8) and under the max.
permitted radial load acc. Table 3, an additional bearing for the
output element is not necessary.
No appreciable axial forces (see Table 3) should be
transferred from the output element onto the clutch
pressure flange (2).
The EAS®-Compact®with a long protruding hub (Type
490._ _ 4.1) is recommended for extremely wide output
elements, or for elements with small diameters. On very small
diameters, the output element is screwed together with the clutch
pressure flange (2) via a customer-side intermediate flange.
Ball bearings, needle bearings or bearing bushings are suitable
as bearings for the output element, depending on the installation
situation and the installation space.
In order to prevent the output element (pressure flange (2))
from moving axially in the direction of the thrust washer (3)
during overload, please make sure that the bearing of the
output element is designed as a locating bearing (Fig. 5).
Fig. 5
Please observe the connection dimensions
“a” and “e” for the output elements
(Fig. 5 and Table 7).
Table 7
Sizes
Connection dimensions
a
e
4
13 +0.1
160 h5
5
14 +0.1
180 h5
Tapped extracting hole

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 9 of 19 www.mayr.com, E-Mail: [e-mail]
Mounting onto the Shaft
EAS®-Compact®clutches include cone bushings or keyways as
part of the standard delivery.
During installation of cone bushings, please observe the
following:
Shaft tolerances from h8 to k6 are permitted.
Shaft surface: finely turned or ground
(Ra = 0.8 µm).
Shaft material: Yield point at least 400 N/mm2,
e. g. St 60, St 70, C 45, C 60.
Degrease or remove conserving layers on the shafts and
bores before installing the clutch.
Greasy or oily bores or shafts do not transmit the
torques defined in the catalogue.
Mount the clutch onto the shaft using a suitable device and
bring it into the correct position.
Tighten the tensioning screws (hexagon head screws Item
17) in 2 steps cross-wise and then in 3 to max. 6 tightening
sequences evenly using a torque wrench to the torque stated
in Table 2.
The transmittable torques of the shaft-hub connection are
dependent on the bore diameter and the quality of the drive
shafts used. Please observe the respective transmission
tables in the valid and applicable product catalogue.
The clutch or clutch hub carries out an axial
movement in the direction of the cone bushing
(16) when tightening the cone bushing (16).
De-installation
There are tapped extracting holes next to the tensioning screws
(hexagon head screws Item 17) in the cone bushings (16).
1) Loosen all tensioning screws (17).
2) Screw out the tensioning screws (17) located next to the
tapped extracting holes and screw them into the tapped
extracting holes up to their limits.
Then tighten these screws until the tensioning connection
loosens.
Shaft Installation via Key Connection
On the EAS®-Compact®with a keyway, the clutch must be axially
fixed onto the shaft after mounting.
This securing procedure can be carried out e.g. via a press cover
and a screw, screwed into the threaded centre hole of the shaft,
and on the lastic-side via a set screw. Please see Figs. 1 and 3.
Joining Both Clutch Components
EAS®-Compact®Type 494._ _4._ (Figs. 3 and 4)
The flexible intermediate ring (24) is pre-tensioned between the
metal claws by joining component 23 with component 25. To do
this, an axial installation force is required.
The amount of force required can be reduced by lightly greasing
the intermediate ring (24).
Use PU-compatible lubricants (e. g. Mobilith
SHC460)!
No unpermittedly high axial pressure should be
placed on the intermediate ring (24) in
completely assembled condition.
Keep to distance dimension “S”, see Fig. 3
and Table 5!
Cup Spring Layering (Fig. 4)
Correct cup spring layering is a prerequisite for problem-free
clutch function and torque adjustment.
For the lower torque range, one cup spring
(Type 49_.5_ 4._),
for the medium torque range, two cup springs (Type 49_.6_ 4._),
and for the high torque range, four cup springs
(Type 49_.7_ 4._) are installed.
1x 2x 4x
layered layered layered
Type 49_.5_4._ Type 49_.6_4._ Type 49_.7_4._
Fig. 6

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 10 of 19 www.mayr.com, E-Mail: [e-mail]
Permitted Shaft Misalignments
Type 494._ _4._
The EAS®-Compact®clutches Type 494._ _ 4._ compensate for
radial, axial and angular shaft misalignments (Fig. 8).
However, the permitted shaft misalignments indicated in Table 6
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. 7. The sum total of the actual misalignments in percent
of the maximum value must not exceed 100 % (see example,
below).
The permitted misalignment values given in Table 6 refer to
clutch operation at nominal torque, an ambient temperature of
+30 °C and an operating speed of 1500 rpm. If the clutch is
operated in other or more extreme operating conditions, please
contact the manufacturers.
Example:
Axial displacement occurrence Ka = 0.8 mm equals 40 % of the
permitted maximum value Ka max = 2 mm.
Angular misalignment occurrence Kw = 0.045 mm
equals 30 % of the permitted maximum value Kw max = 0.15 mm.
=> permitted radial misalignment Kr = 30 % of the maximum
valueKr max = 0.15 mm => Kr = 0.045 mm
Clutch Alignment Type 494._ _4._
Exact alignment of the clutch increases the clutch service lifetime
and reduces the load on the shaft bearings.
We recommend alignment of the clutch using a dial gauge or
special alignment devices on drives operating at very high
speeds. However, clutch alignment using a straight edge in two
levels vertical to each other is usually sufficient.
Fig. 7
Type 494._ _4.2 (Size 5)
Difference dimension ΔKw= ΔKw1 - ΔKw2
Please measure dimensions ΔKw1 and ΔKw2
vertically and horizontally offset by 180°.
Axial Radial Angular
displacement misalignment misalignment
Fig. 8
20
30%
25%
75%
0%
50%
20
40%
40
30%
60
60
80
80
100
100
ΔKw[%]
Angular misalignment
ΔK [%] Axial displacement
a
ΔK [%] Radial misalignment
r
ΔKw1
ΔKw2
ΔKw
ΔKa
ΔKr

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 11 of 19 www.mayr.com, E-Mail: [e-mail]
Torque Adjustment
The torque is set manufacturer-side according to the customer's
request.
Torque adjustment is carried out by turning the adjusting nut (7).
The installed cup springs (11) are operated in the negative range
of the characteristic curve (see Fig. 11); this means that a
stronger pre-tensioning of the cup spring results in a decrease of
the spring force.
Turning the adjusting nut (7) clockwise causes
a reduction in torque.
Turning it anti-clockwise causes an increase in
torque.
You should be facing the adjusting nut (7) as
shown in Figs. 9 and 10.
Changing the Torque
a) Please convert the required torque using the formula below
into percent of the maximum adjustment value (see Table 2).
Required torque adjustment
x 100 = Adjustment in %
max. adjustment value
b) Loosen the 4 locking set screws (7.1) in the adjusting nut (7).
c) Turn the adjusting nut (7) using the engraved adjustment
scale (Fig. 10) clockwise or anti-clockwise using a hook or a
face wrench until the required torque is reached.
d) The required torque results from the marking overlap on the
hub (1) and the percent value on the adjusting nut (Item 7 /
Fig. 10).
Alternatively, adjustment can be carried out via dimension
“a” (Fig. 9) acc. Adjustment Diagram (if necessary, please
order the Adjustment Diagram from the manufacturers).
e) Paint the 4 locking set screws (7.1) with Loctite 243, screw
them in and tighten them
(observe the tightening torque acc. Table 4).
Adjusting the adjusting nut (7) or distorting the
cup springs (11) outside of the cup spring
characteristic curve (see Fig. 11) stops the clutch
functioning.
The inspection dimension “a” (see Table 2) can
show deviations due to construction tolerances or to clutch
wear.
Fig. 9
Fig. 10
Fig. 11
Dim. “a”
Move to
operating range
Graph of spring
characteristic
curve
Operating
range
Spring path S
Torque
Facing
direction
Force F

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 12 of 19 www.mayr.com, E-Mail: [e-mail]
Limit Switch (Item 19; Figs. 1 and 12)
In order to limit run-out times after overload has taken place, a
limit switch must be mounted onto the overload clutch.
Limit switches with appropriate explosion protection certification
are suitable.
Grinding, mechanically actuated limit switches are only permitted
for application in areas where there is a danger of explosion if it
can be proved that there is no danger of ignition caused by the
grinding movement of the mechanical limit switch on the clutch.
The contactless limit switch is to be mounted onto the switching
edge of the clutch (Fig. 12) so that no signal changes are caused
during normal operation on the limit switch by the usual clutch
run-out errors.
In case of overload, the thrust washer (3) incl. the sealing cover
(13) carries out a stroke (see Table 1, page 5) in the direction of
the engagement disk (14) (Figs. 1 and 12), which is used to
signal change on the limit switch (37).
The signal change should take place at the latest after an axial
stroke of 0.5 mm of the thrust washer (3) incl. the sealing cover
(13). At the same time, please maintain a radial minimum
distance of 0.5 mm in order to prevent rubbing of the contactless
limit switch, meaning a danger of ignition.
Limit Switch Installation
Adjust the switch distances for the contactless
Ex-limit switch acc. Fig. 12.
The correct switch adjustment must be
checked and guaranteed by manually
disengaging the overload clutch.
In order to secure limit switch function, please
keep it free from oil, grease and other dirt
particles.
Contactless limit switch (mounting example)
Fig. 12
Maintenance and Maintenance Intervals
Maintenance work, which should be carried out after 2000
operating hours, after 1000 disengagements or at the latest after
1 year, includes:
Visual inspection
Functional inspection
Inspection of the shaft-hub connection
Inspection of the screw tightening torques
The specified tightening torques (see Tables 4 and 6) must
be maintained.
Inspection of the set torque
Clutch release inspection
Bearing or bearing pre-tension inspection
We recommend that this maintenance work is carried out at
the site of manufacture.
Re-greasing of the transmission geometries, balls, recesses
and sealing elements.
Clutch re-greasing must only be carried out at the place of
manufacture or by specially trained personnel.
For greasing, please use NLGI Class 1.5 grease with a basic oil
viscosity of 460 mm2/s at 40 °C, e.g. Mobilith SHC460.
When re-installing the clutch, please secure all screws with
Loctite 243 (medium hard).
If large amounts of dirt or dust are present or in extreme ambient
conditions, it may well be necessary to carry out inspections at
shorter intervals.
Disposal
Electronic components (Limit switch):
Products which have not been disassembled can be disposed of
under Code No. 160214 (mixed materials) or components under
Code No. 160216, or can be disposed of by a certified disposal
firm.
Steel components:
Steel scrap (Code No. 160117)
All aluminium components:
Non-ferrous metals (Code No. 160118)
Seals, O-rings, V-seals, elastomers:
Plastic (Code No. 160119)
Item 14
Item 3
Detail “X”
Item 19
Not included in
the standard
scope of delivery
Item 13
min. 0.5

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 13 of 19 www.mayr.com, E-Mail: [e-mail]
Guidelines and Directives for Operation in Areas Where There is a Danger of Explosion
Conditions to Observe in Areas Where
There is a Danger of Explosion
For malfunction-free clutch operation, it is necessary to keep to
the clutch characteristic values (Technical Data) indicated on
pages 4 and 5 and in the catalogue.
Clutch Dimensioning
A suitable adjustment factor (service factor) is required so that
the clutch can protect the drive line from overload without
excessive wear over a long lifetime. The service factor is the
relationship between the maximum load torque on the system in
normal operation and the set clutch torque. This factor must be
at least 1.5 and is selected depending on the complex of loads
acting on the system. Adjustment factors of up to 3 may be
necessary for very severe impacts and load peaks or alternating
loads.
Regular functional inspections on the clutch (see Maintenance
Intervals) confirm the functioning, unworn condition of the clutch.
Wear on the clutch can lead to changes in the switch-off torque,
or even to clutch blockage.
On overload, the clutch run-out times must be limited via a limit
switch capable of recognising a clutch overload occurrence
(usually with an inductive proximity switch for Ex-areas). Max.
permitted run-out time: 3 minutes, with reference to an average
speed of 1750 rpm. After overload has been registered, the
sensor must emit a signal to stop the drive line. The blockage or
malfunction must be removed.
CAUTION
Operation outside of the indicated
characteristic data is not permitted. There is a
danger of clutch destruction and of ignition.
Torque Adjustment
The clutch must only be adjusted within the specified torque
range. The torque range is defined through the adjustment
dimension “a” from 40 % to 100 %.
If the clutch is set outside of the permitted adjustment range, it is
possible that the clutch will not actuate in case of overload. This
means that the overload protection will be blocked. This does not
mean that the clutch can directly cause ignition. However, if the
system torque increases to an unpermitted value, component
breakage can be expected.
The user must ensure via simulated disengagement of the clutch
before initial operation that the clutch actuates at the required
torque value after torque adjustment or torque changes have
taken place.
CAUTION
Danger of ignition!
Table 8 (Max. Permitted Bearing Loads)
Sizes
Axial
forces
[N]
Radial
forces
[N]
Transverse
force
torques
[Nm]
4
4800
4800
50
5
7700
7700
70
Re-engagement
Attention: Impacts using metal tools made of steel or aluminium
are not to be used for re-engagement, as there is a danger of
impact sparks. Tools made of plastic or bronze are suitable.
Please observe the danger of electrostatic charging when using
plastic tools. In general, please observe the Guidelines in EN
1127-1. When using an automatic re-engagement mechanism, a
locking device must be provided which guarantees free stroke on
the thrust washer (3) in case of overload, even if re-engagement
is actuated. Interfering contours which prevent the thrust washer
(3) from disengaging or which are mounted especially for this
purpose are not permitted. Free rotation of the clutch and free
movement of the clutch components must be ensured before
initial operation.
CAUTION
Danger of ignition!
Initial Operation
If no stipulations regarding lacquering or other surface
treatments have been made customer-side on order, the clutch
surface is protected by a phosphate coating. The clutch must
only be used in areas protected from the weather. Additional
corrosion protection is required for use in the open air or if the
device is subject to weather conditions. Severely corroded clutch
components mean a danger of ignition.
The functional components of the clutch must not be stuck
together due to paint coatings or other sticky media, and
electrostatic charges must not be caused (see EN 13463-1 7.4).
A functional inspection must be carried out before initial
operation.
The penetration of dirt or dust influences the grease condition of
the clutch and therefore its lifetime. Organic dust binds the
grease filling and the lubrication qualities of the grease are lost.
The clutch must be axially secured onto the shaft. Correct
securement must be checked before initial operation.
Do not allow bending torques to be transmitted onto the
pressure flange (2) when output elements (toothed belt
wheel, sprocket wheels, flanges) are mounted onto the
pressure flange (2).
Please observe the permitted thread screw-in depths (Table
3, page 5). If the screws inserted into the pressure flange (2)
are too long, there is a danger of component destruction
and therefore of ignition.
Overload clutches are rotating parts, which can cause danger of
injury due to striking foreign bodies or can cause danger of
ignition, should they not be secured properly by a cover. The
user is responsible for providing covers for these parts (we
recommend rustproof steel). The minimum distance of 5 mm
must be observed. The covers must not be made of aluminium.
The respective guidelines and standards must be observed.
Operation in dust layers or in piles of dust is not permitted.
Only minor radial and axial forces or transverse force
torques are permitted to be transferred onto the clutch
bearing (Table 8).
Modifications of the clutch are not permitted. This also refers to
changes to the cup spring layering.

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 14 of 19 www.mayr.com, E-Mail: [e-mail]
Guidelines and Directives for Operation in Areas Where There is a Danger of Explosion
EAS®-Compact®overload clutch without a mounted coupling Type 490._ _4._
Classification of Areas Where There is a
Danger of Explosion and Permitted Types
Torque transmission via a key connection acc. DIN 6885/1:
Dimensioning according to the requirements shaft diameter,
transmittable torque and operating conditions must be carried
out. For this, the corresponding user data must be known or the
customer must carry out the dimensioning according to the valid
calculation basis DIN 6892. For the calculation, a hub quality of
Re = 400 N/mm2should be used.
For the dimensioning of the key connections, the permitted
tensions common in machine construction must be considered.
During initial operation, check whether the key is inserted
correctly and whether the clutch is secured axially.
According to the described clutch combinations and if the
measures and guidelines described in the Installation and
Operational Instructions are observed, the EAS®-Compact®
overload clutch is suitable for use in areas where there is a
danger of explosion according to the category:
II 2G c T5 –15°CTa+80°C D110°C
Permitted Types: 490.524._ / 490.624._ / 490.724._
If they are professionally mounted according to the regulations,
backlash-free cone-shaft-hub connections on the overload
clutch are secure connections.
Malfunctions are to be expected if parameters which cannot be
influenced by the manufacturers affect the device (surface
quality, strength class, shaft tolerance quality) and affect each
other. Designs with backlash-free cone-shaft-hub connections
are suitable without an additional keyway or without inspection of
the transmittable torque in the system (the calculatory
transmission guarantee of at least S = 2 must be maintained) for
application in areas in which there is a danger of explosion,
category:
II 3G c T5 –15°CTa+80°C D110°C
Permitted Types: 490.514._ / 490.614._ / 490.714._
Please observe the guidelines referring to the transmittable
torque on cone bushing hubs in the currently valid EAS®-
Compact®overload clutch catalogue.
Expected malfunctions can be avoided if the respective
customer-side application constellation is checked as to whether
the torque transmission capability of the shaft-hub connection
can be sufficiently guaranteed (at least 1.5 to the maximum
torque on the system). This inspection must be repeated at
regular intervals during maintenance work (see maintenance
intervals). Furthermore, the transmission guarantee is
maintained if a positive locking e.g. a key connection is used in
addition to a clamping connection. In these conditions, clutch
application is possible in the following areas:
II 2G c T5 –15°CTa+80°C D110°C
Permitted Types: 490.514._ / 490.614._ / 490.714._

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 15 of 19 www.mayr.com, E-Mail: [e-mail]
Guidelines and Directives for Operation in Areas Where There is a Danger of Explosion
EAS®-Compact®overload clutch with a mounted Nor-Mex®coupling Type 494._ _4._
Classification of Areas Where There is a
Danger of Explosion and Permitted Types
Nor-Mex®mounted coupling with key hub
According to the described clutch combinations and if the
measures and guidelines described in the Installation and
Operational Instructions are observed, the EAS®-Compact®
overload clutch with a mounted elastomer coupling is suitable for
use in areas where there is a danger of explosion according to
the category:
II 2G c T4/T5
–15°CTa+80/60°C D110°C
Permitted Types: 494.524._ / 494.624._ / 494.724._
For the dimensioning of the key connections, the permitted
tensions common in machine construction must be considered.
During initial operation, check whether the key is inserted
correctly and whether the clutch is secured axially.
Nor-Mex® mounted couplingwith EAS®-side cone bushing
The designs with backlash-free shaft-hub connections are in the
standard design suitable for application in areas where there is a
danger of explosion according to the category:
II 3G c T4/T5
–15°CTa+80/60°C D110°C
Permitted Types: 494.514._ / 494.614._ / 494.714._
Secure torque transmission is guaranteed if the respective
customer-side application constellation is checked as to whether
the torque transmission capability of the shaft-hub connection
can be sufficiently guaranteed (at least 1.5 to the maximum
torque on the system). This inspection must be repeated at
regular intervals during maintenance work (see maintenance
intervals).
In these conditions, clutch application is possible in the following
areas:
II 2G c T4/T5
–15°CTa+80/60°C D110°C
Permitted Types: 494.514._ / 494.614._ / 494.714._
Please observe the guidelines in the valid Nor-Mex®Installation
and Operational Instructions for application in areas where there
is a danger of explosion.

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 16 of 19 www.mayr.com, E-Mail: [e-mail]
Malfunctions / Breakdowns Type 490._ _4._
Result of
Malfunction
Possible Causes
Danger Guidelines
for Areas
Solutions
Premature clutch
release
Incorrect
torque adjustment
None
1) Set the system out of operation
2) Check the torque adjustment
3) Secure the adjusting nut
4) If the cause of malfunction cannot be found, the
clutch must be inspected at the place of
manufacture
Adjusting nut has
changed position
Worn clutch
Clutch does not
release on overload
Incorrect
torque adjustment
Danger of
component destruction
and related danger
of ignition
1) Set the system out of operation
2) Check whether foreign bodies influence the
disengagement mechanism function
3) Check the torque adjustment
4) Secure the adjusting nut
5) If the cause of malfunction cannot be found, the
clutch must be inspected at the place of
manufacture
Adjusting nut has
changed position
Disengagement
mechanism blocked
by a foreign body
Worn clutch
Running noises on
overload occurrence
as clutch slows down
Bearing on output flange
is worn or has been
previously damaged
Bearing heat-up to
bearing destruction
Danger of ignition
1) Set the system out of operation
2) Inspect the clutch at the place of manufacture
Worn disengagement
mechanism
Running noises in
normal operation
Insufficient clutch
securement
Danger of ignition
1) Set the system out of operation
2) Check the clutch securement
3) Check the screw tightening torques
4) Check the torque adjustment and that the
adjusting nut sits securely
Loosened screws
Loosened adjusting nut

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 17 of 19 www.mayr.com, E-Mail: [e-mail]
Malfunctions / Breakdowns Type 494._ _ 4._
Result of
Malfunction
Possible Causes
Danger Guidelines
for Areas
Solutions
Changes in running
noise
and / or
vibration
occurrence
Incorrect alignment
Increased temperature on
the elastomeric element
surface; Danger of ignition
due to hot surfaces
1) Set the system out of operation
2) Find / resolve the cause of incorrect alignment (e.
g. loose foundation screws, motor securement
breakage, heat expansion of system components,
changes in the clutch installation dimension “Z”)
3) Check the clutch for wear
Wear on the
elastomeric element,
temporary torque
transmission
due to metal contact
Danger of ignition due to
formation of sparks
1) Set the system out of operation
2) Dismantle the clutch and remove the remainders
of the elastomeric element
3) Check the clutch parts and replace if damaged
4) Insert a new elastomeric element, install clutch
components
5) Check the alignment and correct if necessary
Unbalance
Danger of ignition due to
hot surfaces
1) Set the system out of operation
2) Check the balance condition of the system
components and correct if necessary
3) Check the clutch parts for wear
4) Check the alignment and correct if necessary
Loose connection screws
Danger of ignition
due to hot surfaces and
formation of sparks
1) Set the system out of operation
2) Check the clutch alignment
3) Tighten the connection screws to the required
torque or tighten the locking set screw and secure
it against self-loosening using sealing lacquer
4) Check the clutch for wear
Cam breakage
Wear on the elastomeric
element, torque
transmission due to metal
contact
Danger of ignition due to
hot surfaces
and formation of sparks
1) Set the system out of operation
2) Replace the entire clutch
3) Check the alignment
Cam breakage due to
high impact energy /
overload
Danger of ignition due to
hot surfaces
and formation of sparks
1) Set the system out of operation
2) Replace the entire clutch
3) Check the alignment
4) Find the cause of overload
Operating parameters are
not appropriate for the
clutch performance
Danger of ignition due to
hot surfaces
and formation of sparks
1) Set the system out of operation
2) Check the operating parameters and select a
suitable clutch (observe installation space)
3) Install a new clutch
4) Check the alignment
Operational mistakes on
the system unit due to
clutch characteristic data
being exceeded
Danger of ignition due to
hot surfaces
and formation of sparks
1) Set the system out of operation
2) Check clutch dimensioning
3) Replace the entire clutch
4) Check the alignment
5) Train and advise operating personnel

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 18 of 19 www.mayr.com, E-Mail: [e-mail]
Malfunctions / Breakdowns Type 494._ _ 4._ (continued)
Result of
Malfunction
Possible Causes
Danger Guidelines
for Areas
Solutions
Premature wear
on the elastomeric
element
Incorrect alignment
Increased temperature on
the elastomeric element
surface;
Danger of ignition due to
hot surfaces
1) Set the system out of operation
2) Find / resolve the cause of incorrect alignment
(e. g. loose foundation screws, motor securement
breakage, heat expansion of system components,
changes in the clutch installation dimension “Z”)
3) Check the clutch for wear
4) Insert a new elastomeric element
e.g. contact with
aggressive liquids / oils,
ozone influences,
excessively high ambient
temperature etc., which
lead to physical changes
in the
elastomeric element
Danger of ignition due to
formation of sparks
on metallic contact of the
cams
1) Set the system out of operation
2) Dismantle the clutch and remove the remainders
of the elastomeric element
3) Check the clutch parts and replace if damaged
4) Insert a new elastomeric element, install clutch
components
5) Check the alignment and correct if necessary
6) Make sure that further physical changes to the
elastomeric element can be ruled out
The ambient or contact
temperatures permitted
for the elastomeric
element
are exceeded
Danger of ignition due to
formation of sparks
on metallic contact of the
cams
1) Set the system out of operation
2) Dismantle the clutch and remove the remainders
of the elastomeric element
3) Check the clutch parts and replace if damaged
4) Insert a new elastomeric element, install clutch
components
5) Check the alignment and correct if necessary
6) Check the ambient or contact temperature and
regulate them (if necessary, use other
elastomeric element materials)
Premature wear
on the elastomeric
element
(material liquidation
inside the elastomeric
element toothing)
Drive vibrations
Danger of ignition due to
formation of sparks
on metallic contact of the
cams
1) Set the system out of operation
2) Dismantle the clutch and remove the remainders
of the elastomeric element
3) Check the clutch parts and replace if damaged
4) Insert a new elastomeric element, install clutch
components
5) Check the alignment and correct if necessary
6) Find the cause of vibration (if necessary, use an
elastomeric element with a lower or higher shore
hardness)
Please Observe!
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.

Installation and Operational Instructions for
EAS®-Compact®overload clutch Type 49_._ _4._
Sizes 4 and 5 (B.4.14.2.ATEX.EN)
30/05/2016 TK/GH/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 19 of 19 www.mayr.com, E-Mail: [e-mail]
EU Declaration of Conformity
According to the EU Directive on the harmonisation of the laws of the Member States concerning devices and protective systems intended
for use in areas where there is a danger of explosion (ATEX) 2014/34/EU, we:
Chr. Mayr GmbH + Co. KG
Eichenstraße 1
D-87665 Mauerstetten
hereby declare that the product described in these Installation and Operational Instructions
EAS®-Compact®overload clutch
Type 49_._ _4._X
Sizes 4 and 5
has been developed, constructed and produced by us in accordance with the EU Directive named above.
Applied Standards, Regulations and Inspections (ASRI)
1 DIN EN 1127-1: 2011-10
Explosive atmospheres - Explosion prevention and protection - Part 1: Basic concepts and methodology
2 DIN EN 13463-1: 2009-07
Non-electrical equipment intended for use in potentially explosive atmospheres - Part 1: Basic method and requirements
3 DIN EN 13463-5: 2011-10
Non-electrical equipment intended for use in potentially explosive atmospheres - Part 5: Protection by constructional safety “c”
Mauerstetten, May 25, 2016
Place / Date
Graduate Engineer (FH, University of Applied
Science) Günther Klingler
(Managing Director ppa.)