Mayr EAS-NC User manual

Installation and Operating Instructions for
EAS®-NC clutch Type 45_. _ _ _ . _ Sizes 02 and 03 (B.4.8.2.1.GB)
13/02/2009 TK/KR/GC Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 1 of 10 Germany eMail: [e-mail]
Please read and observe this Operating Instruction carefully!
A possible malfunction or failure of the clutch and any damage may be caused by not observing it.
Table of contents:
Page 1: - Table of contents
- Declaration of conformity
- Safety regulations
Page 2: - Clutch views
Page 3: - Parts list
- Safety and information signs
- Design
- Supply condition
- Function
Page 4: - Technical data
-Table 1: Torques, speeds, stroke of the
thrust washer, bores EAS®-side
-Table 2: Thread and maximum
reach of screw in the pressure flange (2),
Max. permissible axial forces,
screw tightening torques
-Table 3: Shaft misalignments Type 453,
nominal torque steel bellows side,
bores steel bellows side
Page 5: - Assembly of the drive elements
- Attachment onto the shaft
- Dismantle
Page 6: - Shaft assembly via keyway connection
- Cup spring layer
- Joint (screwing) of the coupling hubs
with Type 453.-
- Permissible shaft misalignments
- Alignment of the coupling
Page 7: - Torque adjustment
- Adjustment of the torque with size 02
- Adjustment of the torque with size 03
Page 8: - Adjusting diagram
Page 9: - Fitting the limit switch
- Maintenance
- Disposal
Page 10: - Breakdowns
Please Observe!
According to German notation, decimal
points in this document are represented with
a comma (e.g. 0,5 instead of 0.5).
Declaration of Conformity
A conformity evaluation for the applicable EU directives has been carried out for this product.
The conformity evaluation is set out in writing in a separate document and can be requested if required.
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 all
applicable EU directives.
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.
Safety regulations
The submitted installation and operating instructions (E+B) is part of the clutch shipment.
Keep the E+B always well accessible near the clutch.
Danger!
 If the EAS®-clutches have been modified or reconverted.
 If the relevant standards of the safety or installation conditions are not observed.
Necessary protective measures to be undertaken by the user
 Cover all moving parts for protection against squeezing, seizing, dust deposit and hit of foreign objects.
 The clutches must not be put into operation without limit switch, unless otherwise agreed with mayr®.
Only qualified and well-trained specialists should work on the units to avoid any personal injury or damage to
machinery under observance of the valid standards and guidelines. The installation and operating instructions
are to be read carefully before installation and operation.
With these safety notes no claim on completeness is raised!

Installation and Operating Instructions for
EAS®-NC clutch Type 45_. _ _ _ . _ Sizes 02 and 03 (B.4.8.2.1.GB)
13/02/2009 TK/KR/GC Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 2 of 10 Germany eMail: [e-mail]
Fig. 1
11
10
10
3
3
9
9
7
1
1
8
8
7
2
2
23
23
4 5 6
6
19
20
16 15 18
21
17
18
15
13
12
22
Type 453._2_.0
Type 453._1_.0
Size 02 Type 450._ _ _._
Size 03 Type 450._ _ _._
14
stroke
stroke

Installation and Operating Instructions for
EAS®-NC clutch Type 45_. _ _ _ . _ Sizes 02 and 03 (B.4.8.2.1.GB)
13/02/2009 TK/KR/GC Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 3 of 10 Germany eMail: [e-mail]
Parts List (only mayr®-original parts are to be used)
Parts for size 02
1 Hub
2 Pressure flange
3 Thrust washer
4 Thrust ring
5 Locking ring
6 Adjusting nut
7 Deep groove ball bearing
8 Locking ring
9 Steel ball
10 Cup spring
11 Countersunk screw
13 Hexagon head cap screw
14 Limit switch (see size 03)
15 Steel bellows with welding flanges
16 Hub for cone bushing
17 Hub with keyway (see size 03)
18 Cap screw
19 Cap screw
20 Hexagon head cap screw
21 Cone bushing
22 Cone bushing
23 Type tag
Parts for size 03
1 Hub
2 Pressure flange
3 Thrust washer
6 Adjusting nut
7 Deep groove ball bearing
8 Locking ring
9 Steel ball
10 Cup spring
12 Setscrew
13 Hexagon head cap screw (see size 02)
14 Limit switch
15 Steel bellows with welding flanges
16 Hub for cone bushing (see size 02)
17 Hub with keyway
18 Cap screw
19 Cap screw
20 Hexagon head cap screw
21 Cone bushing
22 Cone bushing (see size 02)
23 Type tag
Please Observe!
 The limit switch pos. 14 does not belong to the scope of supply as standard
 Lock the cap screws pos. 18 with Loctite 243
Safety and information signs
Caution!
Danger of injury to personnel and
damage to machines.
Please Observe!
Guidelines on important points.
Design
The EAS®-NC clutch is designed as mechanical torque limiter
according to the ball-detent principle.
Supply condition
The clutch is completely assembled and adjusted to the torque
requested in the order.
The clutch must be set according to the adjusting diagram as
described in the item torque adjustment, if the customer does not
request any other torque adjustment.
Check supply condition!
Function
The clutch has the task to the protect the drive line against high
changes in torque, which can occur due to unintended
blockages.
During operation the EAS-NC clutch transmits the set torque
backlash-free from the hub (1) via the pressure flange (2) to the
output element on the customer side.
If the set limiting torque (overload) is exceeded the clutch
disengages, the thrust washer (3) makes an axial stroke
movement, a limit switch on the customer side scans this
movement and provides a signal to switch off the drive.
The residual torque amounts to approx. 5 – 15 % (with approx.
1500 rpm).
The EAS-NC clutch is consequently not load-holding. The
clutch is automatically ready for operation after removing the
overload.
Re-engagement
EAS-NC ratchetting clutch Type 45_._ _ 0._ after 15°
EAS-NC synchronous clutchType 45_._ _ 5._ after 360°

Installation and Operating Instructions for
EAS®-NC clutch Type 45_. _ _ _ . _ Sizes 02 and 03 (B.4.8.2.1.GB)
13/02/2009 TK/KR/GC Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 4 of 10 Germany eMail: [e-mail]
Technical data
Table 1:
Limiting torques for overload MGBore hub (1) from – to
Size Type 45_.5_ _._ [Nm] Type 45_.6_ _._ [Nm] Type 45_.7_ _._ [Nm]
Max.
speed
[rpm]
Stroke of the
thrust washer
(Fig. 1, Pos. 3)
with overload
[mm]
Type 45_._1_._
[mm]
Type 45_._2_._
[mm]
03 0,65 – 1,3 1,3 – 2,6 2 – 3,8 4000 0,8 6 – 12 6 – 11
02 2 – 5 5 – 10 6 – 15 4000 1,0 8 – 15 8 – 16
Table 2:
Max. permitted Screw tightening torques
Size
Thread in the
pressure flange (2)
with Type 450 (Fig. 2)
with
tightening torque
Max. reach of screw
in pressure flange (2)
with Type 450. (Fig. 2)
[mm]
Axial
forces
[N]
Radial
forces
[N]
Shear force
torques*
[Nm] Pos. 13
[Nm] Pos. 18 [Nm] Pos. 19 [Nm] Pos. 20 [Nm]
03 6 x M3 / 1,3 Nm 5 120 100 0,5 1,3 1,3 1,3 1,3
02 6 x M3 / 1,3 Nm 5 280 250 1,5 1,3 1,3 1,3 1,3
*Torques which place strain on the deep groove ball bearing due to axial forces acting on the pressure flange.
Fig. 2
Table 3:
Bores steel bellows side
Shaft misalignments steel bellows coupling
Type 453.-
Size Axial ∆Ka
[mm] Radial ∆Kr [mm] Angular ∆K w [°]
Nominal torque TKN
Steel bellows coupling
Type 453.-
[Nm]
Type 453._1_.0
[mm]
Type 453._2_.0
[mm]
03 ±0,2 0,1 2 12 6 – 12 6 – 11
02 ±0,3 0,1 2 25 8 – 15 8 – 16
Max. reach of screw
in the pressure flange
T
h
r
e
a
d
i
n
t
h
e
pressure f
l
a
n
g
e

Installation and Operating Instructions for
EAS®-NC clutch Type 45_. _ _ _ . _ Sizes 02 and 03 (B.4.8.2.1.GB)
13/02/2009 TK/KR/GC Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 5 of 10 Germany eMail: [e-mail]
Assembly of the output elements (Figs. 1 and 3)
Please Observe!
Observe thread diameter and max. reach of
screw in the pressure flange (2) according
to Table 2.
In case of the EAS®-NC Type 450.- the output element is
located on the deep groove ball bearing (6) and screwed with the
pressure flange (2).
If the resulting radial force of the output element is nearly in the
centre of the ball bearing (7) an additional bearing of the output
element is not required.
In case of very wide output elements and a force application of
the resulting radial force outside the bearing centre, the output
element is additionally located on the shaft, Fig. 3.
Ensure that no significant axial forces (see Table 2) are
transmitted from the output element onto the pressure
flange (2) of the clutch.
For extremely wide output elements or for elements with a small
diameter, the EAS®-NC with long projecting hub is
recommended (Type 450._ _ _.1).
In the case of a very small diameter the output element is
attached to the pressure flange (2) of the clutch via an
intermediate adapter flange provided by the customer.
Ball bearings, needle bearings or bearing bushings are suitable
as bearing for the output element depending on the mounting
situation and installation facility.
Ensure that the bearing of the output element is designed as
location bearing (Fig. 3).
Fig. 3
Type 450.61_.0
Attachment onto the shaft
The EAS®-NC clutches are supplied with cone bushings or
keyways already fitted as standard.
Following points have to be noticed for the assembly of
cone bushings:
 Shaft fits: h6 up to k6,
 Surface of the shafts:
fine 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.
 Shafts and bores must be degreased or the preservation is to
be washed off before installation of the clutch or clutch hubs.
Greasy or oily bores or shafts do not transmit the torque
TRindicated in the order.
 Push the clutch or clutch hub onto both shaft ends with a
suitable device and bring them to the correct position.
 Uniformly tighten the clamping screws one after another (in 3
to max. 6 tightening circulations) using a torque wrench to the
torque indicated in Table 2.
Please Observe!
The clutch or clutch hub executes an axial
displacement in direction of the cone
bushing when tightening the cone bushing.
In case of the EAS®-NC clutch with steel
bellows (Type 453._ _ _.0) it must be
observed that at first only one cone bushing
is completely tightened (e.g. component
13/22), and then the other (steel bellows)
side (component 20/21, Fig. 5) because of
the above mentioned effect.
Additionally it must be observed when
assembling the Type 453._ _ _.0, that no
axial pressure is exerted on the steel
bellows (damage).
Disassembly
There are extractor threads beside of clamping screws
(13 and 20) in the cone bushings.
1) Release all clamping screws by several threads.
2) Unscrew the clamping screws located beside the extraction
threads and screw them into the extraction threads until
contact. Afterwards tighten these screws until the clamping
connection is released.
Fig. 5
1
22
2 3
14
22
20
21
13
Extraction
thread
Extraction
thread

Installation and Operating Instructions for
EAS®-NC clutch Type 45_. _ _ _ . _ Sizes 02 and 03 (B.4.8.2.1.GB)
13/02/2009 TK/KR/GC Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 6 of 10 Germany eMail: [e-mail]
L - ∆
0
K
a
L + ∆
0
K
a
∆
K
r
∆
K
w
Shaft assembly via keyway connection
In case of an EAS®-NC with keyway the clutch must be fixed
axially after pushing it onto the shaft, e.g. with a cover and a
screw (Fig. 6), screwed into the tapped centre hole of the shaft.
Fig. 6
Cup spring layer (Fig. 7)
A troublefree function of the clutch and a torque adjustment is
only possible with the correct cup spring configuration.
For all sizes
one cup spring (Type 45_.5_ _._) is fitted for the low torque
range,
two cup springs (Type 45_.6_ _._) are fitted for the medium
torque range and
three cup springs (Type 45_.7_ _._) are fitted for the high torque
range.
Check Type indication (Type tag)!
single layer double layer triple layer
Type 45_.5_ _._ Type 45_.6_ _._ Type 45_.7_ _._
Fig. 7
Jointing (screwing) of both
coupling hubs (1/17)
EAS®-NC Type 453._ _ _.0 (Fig. 1)
Caution!
When fitting the hubs (1 and 17) the jointing
force must not be initiated via the steel
bellows.
=> Danger of bellows deformation.
Permissible shaft misalignments
EAS®-NC clutches of the Type 453._ _ _.0 (with steel bellows)
compensate radial, axial and angular shaft misalignments
(Fig. 8) without loosening its backlash-free design.
Radial misalignment Axial displacement Angular misalignment
Fig. 8
However, the permissible shaft misalignments indicated in
Table 3 must not achieve simultaneously the maximum value.
Should several types of misalignments occur simultaneously,
they will influence each other, i.e. the permissible values of the
misalignment depend on each other according to Fig. 9.
The amount of the actual misalignment in percentage of the
maximum value must not exceed 100 %.
Fig. 9
Example:
EAS®-NC size 02,
Existing axial displacement ∆Ka= 0,12 mm
corresponds to 40 % of the permissible maximum value.
Existing angular misalignment ∆KW= 0,6°
corresponds to 30 % of the permissible maximum value.
=> permissible radial misalignment ∆Kr of 30 % = 0,03 mm
The permissible misalignment values indicated in Table 3 refer to
a coupling application with a nominal torque, an ambient
temperature of +30 °C and a operation speed of 1500 rpm.
Please contact the factory in case of different or extreme
coupling-application conditions.
Alignment of the coupling
An exact alignment of the coupling increases the service life of
the coupling considerably and decreases the load for the shaft
misalignments.
For drives with a very high speed the coupling should be aligned
by means of a dial gauge or special devices for alignment.
Normally the alignment of the coupling with a straight-edge in
two levels being vertically to each other is sufficient.
20
30%
25%
75%
0%
50%
20
40%
40
30%
60
60
80
80
100
100
∆
a
∆
K [%]
r
∆ K
w
[%]
angular misalignment
axial displacement
radial misalignment
K [%]

Installation and Operating Instructions for
EAS®-NC clutch Type 45_. _ _ _ . _ Sizes 02 and 03 (B.4.8.2.1.GB)
13/02/2009 TK/KR/GC Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 7 of 10 Germany eMail: [e-mail]
Torque adjustment (Figs. 10, 11, and 12)
The adjustment is made by turning the adjusting nut (6). The
fitted cup springs (10) operate in the negative area of their
characteristics (see Fig. 12), i.e. a tightening of the adjusting
nut (6) effects a decrease of the spring force, or a release of the
adjusting nut (6) an increase of the spring force.
Please Observe!
The clutch is only pre-assembled at the
factory, if the customer does not require a
different torque adjustment. In this case
generally a torque adjustment must be
executed as described subsequently.
Please Observe!
Turning the adjusting nut (6) within the
setting range in a clockwise direction
reduces the torque, and in anti-clockwise
direction increases the torque.
Viewed in the direction of the adjusting nut
(6) as indicated on Figs. 10 and 11.
Adjustment of the torque with size 02
(Fig. 10):
a) Release the locking screw (11).
b) Grease thread and contact surface of the adjusting nut (6),
locking ring (5) and hub (1).
c) Manually move the adjusting nut (6) until contact of the cup
spring (9).
d) Continue turning until the four notches at the circumference
of the adjusting nut (6) and the notches in the locking ring (5)
coincide.
e) Continue turning the adjusting nut (6) with a face wrench by
the number of graduations, which correspond to the required
torque
(corresponding diagram 1 to 3 on page 8).
f) The notches at the circumference of the adjusting nut (6) and
the notches at the locking ring (5) must be in the same
position.
g) Put Loctite 243 onto the locking screw (11) and screw it into
the adjusting nut (6).
Fig. 10
Adjustment of the torque with size 03
(Fig. 11):
a) Unscrew both setscrews (12) from the adjusting nut (6).
b) Grease thread of the adjusting nut (6) and hub (1).
c) Adjust the adjusting nut (6) to the required dimension “a”
using a hook wrench.
Dimension "a" see corresponding diagrams 4 to 6, page 8.
d) Put Loctite 243 onto both setscrews (12) and screw it into the
adjusting nut (6) and tighten them.
Fig. 11
Fig. 12
10
3
11
Direction of view
6
5
4
Spring path S
Setting range
Graphics on spring
characteristic
F
o
r
c
e
F
Movement till
setting range
103
Direction of view
Inspection dimension
"a"
12
6

Installation and Operating Instructions for
EAS®-NC clutch Type 45_. _ _ _ . _ Sizes 02 and 03 (B.4.8.2.1.GB)
13/02/2009 TK/KR/GC Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 8 of 10 Germany eMail: [e-mail]
0,65
0,7
0,75
0,8
0,85
0,9
0,95
1
1,05
1,1
1,15
1,2
1,25
1,3
5,65
5,7
5,75
5,8
5,85
5,9
5,95
66,05
Maß / dimension "a" [mm]
D
r
e
h
m
o
m
e
n
t
/
t
o
r
q
u
e
[
N
m
]
1,3
1,4
1,5
1,6
1,7
1,8
1,9
2
2,1
2,2
2,3
2,4
2,5
2,6
6,056,16,156,26,256,36,356,46,45
Maß / dimension "a" [mm]
D
r
e
h
m
o
m
e
n
t
/
t
o
r
q
u
e
[
N
m
]
Maß / dimension "a" [mm]
2,2
2,4
2,6
2,8
3
3,2
3,4
3,6
3,8
6,45
6,5
6,55
6,6
6,65
6,76,756,86,856,9
D
r
e
h
m
o
m
e
n
t
/
t
o
r
q
u
e
[
N
m
]
Adjusting diagrams
Diagram 1: size 02 / Type 45_.5_ _._
Diagram 2: size 02 / Type 45_.6_ _._
Diagram 3: size 02 / Type 45_.7_ _._
Diagram 4: size 03 / Type 45_.5_ _._
Diagram 5: size 03 / Type 45_.6_ _._
Diagram 6: size 03 / Type 45_.7_ _._
2
2,5
3
3,5
4
4,5
5
16 18 20 22 24 26
Teilstriche / graduations
D
r
e
h
m
o
m
e
n
t
/
t
o
r
q
u
e
[
N
m
]
Teilstriche / graduations
D
r
e
h
m
o
m
e
n
t
/
t
o
r
q
u
e
[
N
m
]
4
5
6
7
8
9
10
20 22 24 26 28
Teilstriche / graduations
D
r
e
h
m
o
m
e
n
t
/
t
o
r
q
u
e
[
N
m
]
6
7
8
9
10
11
12
13
14
15
20 22 24 26 28

Installation and Operating Instructions for
EAS®-NC clutch Type 45_. _ _ _ . _ Sizes 02 and 03 (B.4.8.2.1.GB)
13/02/2009 TK/KR/GC Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 9 of 10 Germany eMail: [e-mail]
Fitting the limit switch
Adjust the switch distance for the contactless limit switch
according to Fig. 13.
The distance of the thrust washer (3) from the switching point
can sensitively be adjusted with a hexagon head cap screw SW7
(Fig. 13).
The limit switch is located at the edge of the thrust washer (3)
(switching edge see details “X” in Fig. 13).
Contactless limit switch
Fig. 13
Maintenance
The EAS®-NC clutch is nearly maintenance-free.
Special maintenance work may become necessary only where
there is considerable amount of dust and dirt or under extreme
ambient conditions.
See maintenance and inspection intervals for clutches in
hazardous areas.
Disposal
Electronic Components
(Limit switch):
Products which have not been dismantled can be disposed of
under Code No. 160214 (Mixed Materials) or Components under
Code No. 160216; or the objects can be disposed of by a
certified waste disposal firm.
All 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)
SW7
x
0
,
5
2,6

Installation and Operating Instructions for
EAS®-NC clutch Type 45_. _ _ _ . _ Sizes 02 and 03 (B.4.8.2.1.GB)
13/02/2009 TK/KR/GC Chr. Mayr GmbH + Co. KG Tel.: 08341 / 804-241
Eichenstraße 1 Fax: 08341 / 804-422
D-87665 Mauerstetten http://www.mayr.de
Page 10 of 10 Germany eMail: [e-mail]
Breakdowns
Failures Possible
reasons Solution
False torque adjustment
Adjustment of the adjusting nut has
changed (position)
Premature activation of the clutch
Clutch worn
1) Set the equipment out of operation
2) Check torque adjustment
3) Lock the adjusting nut
4) If the cause of defect cannot be determined, the
clutch must be checked in the factory
False torque adjustment
Clutch does not act in the case of an
overload
Adjustment of the adjusting nut has
changed (position)
1) Set the equipment out of operation
2) Check torque adjustment
3) Lock the adjusting nut
4) If the cause of defect cannot be determined, the
clutch must be checked in the factory
Fixing of the clutch insufficient
Screws loosened
Running noises in a standard
operation
Adjusting nut released
1) Set the equipment out of operation
2) Check clutch attachment
3) Check tightening torques of the screws
4) Check torque adjustment and safe location of
the adjusting nut
Alignment error 1) Set the equipment out of operation
2) Completely exchange the clutch
3) Check alignment
Pre-damage of the bellows by transport or
assembly
1) Set the equipment out of operation
2) Completely exchange the clutch
3) Check alignment
Operating parameter does not correspond
to the clutch capacity
1) Set the equipment out of operation
2) Check the operating parameter and select the
correct clutch (observe installation space)
3) Install new clutch
4) Check alignment
Breakage of the bellows
Type 493.-
Bellows are excited in natural frequency,
resonance
1) Set the equipment out of operation
2) The drive train characteristics must be
designed newly
3) Completely exchange the clutch
4) Check alignment
Change of the running noises and
arising vibrations
Type 493.-
Loosening of screws,
resonances, fixing of the clutch insufficient
1) Set the equipment out of operation
2) Check tightening torques of the screws
3) The drive train characteristics must be checked
4) Check the clutch components and exchange
damaged components
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.