Mayr EAS-reverse 4100 User manual

Disengaging torque limiters with automatic re-engagement
EAS®-reverse
Type 4100/4103/4104
Sizes 3 –6
Issue status 2021-07
Translation of the Original Operational
Instructions
B.4100.EN
© Copyright by mayr®–power transmission
All rights reserved.
Reprints and copies –even extracts –are only permitted with the consent of the manufacturer.
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Operational Instructions for
EAS®-reverse Type 4100/4103/4104
Sizes 3 –6 (B.4100.EN)
14/07/2021 VN/GF/GC/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten
Phone: [phone], Fax: [phone]
Page 2 of 16 www.mayr.com, E-Mail: [e-mail]
your reliable partner
Contents
1Safety............................................................3
1.1 Safety and Guideline Signs 3
2Product Description ....................................4
2.1 State of Delivery 4
2.2 Application –Operation –Function 4
2.3 Views 5
2.4 Parts List 6
3Technical Data .............................................7
3.1 Guidelines 7
3.1.1 Application Conditions 7
3.1.2 Ambient Temperature 7
3.1.3 Installation Position 7
3.1.4 Pre-requisites for Product Application 7
3.2 Cup Spring Layering 7
3.3 Storage 7
3.4 Technical Data 7
4Installation....................................................8
4.1 Installation preparations (customer-side) 8
4.2 Important Installation Guidelines for Types
4103/4104 8
4.3 Guidelines for elastomer ring 8
4.4 Installation Type 4100 9
4.5 Installation Type 4103 9
4.6 Installation Type 4104 9
4.7 Alignment of the clutch Types 4103/4104 10
5Options......................................................... 11
5.1 Limit Switch Installation 11
6Operation / Initial Operation....................... 12
6.1 Permitted Shaft Misalignments 12
6.2 Clutch Engagement After Overload Occurence12
7Torque Adjustment ..................................... 13
7.1 Guideline on Torque Adjustment 13
7.2 Torque Adjustment 13
7.2.1 Changing the Torque (Fig. 14) 13
8Maintenance and Maintenance Intervals .. 15
9Disposal ....................................................... 15
10 Malfunctions / Breakdowns........................ 16
10.1 Malfunctions / Breakdowns for Type 4100 16
10.2 Malfunctions / Breakdowns for Types 4103 and
4104 16

Operational Instructions for
EAS®-reverse Type 4100/4103/4104
Sizes 3 –6 (B.4100.EN)
14/07/2021 VN/GF/GC/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten
Phone: [phone], Fax: [phone]
Page 3 of 16 www.mayr.com, E-Mail: [e-mail]
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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
Operational Instructions are part of the delivery.
Please keep the Installation and Operational Instructions handy and near to the clutch at all times.
1 Safety
1.1 Safety and Guideline Signs
Symbol
Signal word
Meaning
DANGER
Designates a directly pending danger.
If not avoided, death or severe injuries will be the consequence.
WARNING
Designates a possibly hazardous situation.
If not avoided, death or severe injuries will be the consequence.
CAUTION
Designates a hazardous situation.
If not avoided, slight or minor injuries can be the consequence.
ATTENTION
Possible property damage can be the consequence.
Please Observe
Designates tips for application and other particularly useful information. Not
a signal word for dangerous or damaging situations.
Safety Regulations
These Installation and Operational Instructions are part of the clutch delivery.
Please keep the Installation and Operational Instructions handy and near to the clutch at all times.
It is forbidden to start use of the product until you have ensured that all applicable EU directives, 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®-reverse clutches 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 risk of
explosion. This statement is based on the ATEX directive.
CAUTION
If the EAS®-reverse clutches have been changed or converted.
If the relevant standards for safety and / or installation conditions are ignored.
User-implemented Protective Measures
Cover all moving parts to protect against seizure, dust impacts or foreign body impact.
The clutches may not be put into operation without a limit switch unless mayr® has been contacted and
has agreed otherwise.
To prevent injury or damage, only professionals and specialists should work on the devices,
following the relevant standards and directives. 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!

Operational Instructions for
EAS®-reverse Type 4100/4103/4104
Sizes 3 –6 (B.4100.EN)
14/07/2021 VN/GF/GC/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten
Phone: [phone], Fax: [phone]
Page 4 of 16 www.mayr.com, E-Mail: [e-mail]
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2 Product Description
2.1 State of Delivery
EAS®-reverse clutches are completely manufacturer-
assembled, including the finish bore and the keyway.
Torque Adjustment:
The clutch is set manufacturer-side to the torque
stipulated in the order.
2.2 Application –Operation –Function
EAS®-reverse clutches are positive locking, disconnecting
overload clutches.
In case of an exceedance of the set limit torque (in case
of overload), the clutch disengages and disconnects the
input and output side almost residual torque-free.
The disengagement must be recorded
and a signal issued to switch off the
system via a customer-side installed limit
switch.

Operational Instructions for
EAS®-reverse Type 4100/4103/4104
Sizes 3 –6 (B.4100.EN)
14/07/2021 VN/GF/GC/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten
Phone: [phone], Fax: [phone]
Page 5 of 16 www.mayr.com, E-Mail: [e-mail]
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2.3 Views
Fig. 1: Type 4100
Fig. 2: Type 4103 Size 3 –5 Fig 3: Type 4103 Size 6 (depicted without switching disk)
Fig. 4: Type 4104 Size 3 –5 Fig. 5: Type 4104 Size 6 (depicted without switching disk)
CENTAFLEX-A
(elastomer coupling)
EAS®-reverse
(overload clutch)

Operational Instructions for
EAS®-reverse Type 4100/4103/4104
Sizes 3 –6 (B.4100.EN)
14/07/2021 VN/GF/GC/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten
Phone: [phone], Fax: [phone]
Page 6 of 16 www.mayr.com, E-Mail: [e-mail]
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2.4 Parts List
(Only use mayr® original parts)
Parts for Type 4100
Additional parts for Types 4103 and 4104
Item
Name
Item
Name
1
Hub overload-side
9
Intermediate flange
2
Pressure flange
10
Elastomer ring
3
Control element
11
Hub flexible side
4
Cup spring
12
Spring pin
5
Thrust ring
21
Cap screw, flexible, radial
6
Needle bearing
22
Cap screw, flexible, radial
7
Adjusting nut
23
Washer
8
Output flange
24
Socket bolt
13
Locking ring
14
Ball bearing
15
Magnetic disk
16
Cover ring
17
Cylinder roller
18
Set screw
19
Plug
20
Cap screw output flange
25
Switching disk
26
Cover ring cup springs
27
Cap screw cover ring
28
Eyebolt

Operational Instructions for
EAS®-reverse Type 4100/4103/4104
Sizes 3 –6 (B.4100.EN)
14/07/2021 VN/GF/GC/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten
Phone: [phone], Fax: [phone]
Page 7 of 16 www.mayr.com, E-Mail: [e-mail]
your reliable partner
3 Technical Data
3.1 Guidelines
3.1.1 Application Conditions
The stated values are guideline values
which have been determined in test
facilities. It may be necessary to carry out
your own tests for the intended
application.
Mounting dimensions and connection dimensions
must be adjusted according to the size at the place
of installation.
Use in extreme environmental conditions or
outdoors, directly exposed to the weather, is not
permitted.
The surfaces of the outer components have been
phosphated manufacturer-side to form a basic
corrosion protection.
3.1.2 Ambient Temperature
-20 °C to +80 °C
The Technical Data refers to the stated temperature
range.
3.1.3 Installation Position
The EAS®-reverse can be operated in any installation
position.
3.1.4 Pre-requisites for Product Application
Compare the limit values stated in these Operational
Instructions with the actual application, e.g.
Masses
Temperatures etc.
3.2 Cup Spring Layering
Correct cup spring layering is a prerequisite for problem-
free clutch function and torque adjustment.
The respective adjustment range results for the limit
torque for overload depending on the cup spring layering.
3.3 Storage
Store in a horizontal position, in dry rooms and
dust and vibration-free.
Relative air humidity < 50 %.
Temperature without major fluctuations within a
range from 0 °C up to +40 °C.
Do not store in direct sunlight or UV light.
Do not store aggressive, corrosive substances
(solvents / acids / lyes / salts etc.) near to the
brakes.
For longer storage lasting more than 2 years, special
measures are required.
►Please contact mayr®power transmission.
3.4 Technical Data
Technical Data
Size
3
4
5
6
Limit torques
for overload
Type 410_.4_400
MG
[Nm]
75 –150
125 –250
250 –500
500 –1000
Type 410_.5_400
MG
[Nm]
150 –300
250 –500
500 –1000
1000 –2000
Type 410_.6_400
MG
[Nm]
300 –600
500 –1000
1000 –2000
2000 –4000
Type 410_.7_400
MG
[Nm]
375 –750
625 –1250
1250 –2500
3000 –6000
Inspection dimension "a" at 75 % of
maximum torque MG
[mm]
1.3
2.6
2.7
3.5
Max. speed
nmax
[rpm]
3600
2000
2000
2000
Control elements (3) stroke on overload
[mm]
3
4
5
6
Axial displacement Types 4103 and 4104
[mm]
5.0
5.0
5.0
5.0
Radial misalignment Types 4103 and 4104
[mm]
2.0
2.0
2.0
2.0
Angular misalignment Types 4103 and 4104
[°]
2.0
2.0
2.0
2.0
Tightening torque set screw (18)
[Nm]
5
5
10
20
Tightening torque cap screw (20)
[Nm]
74
127
310
310
Tightening torque cap screw (21)
[Nm]
220
500
500
610
Tightening torque cap screw (22)
[Nm]
220
500
500
1050
Tightening torque cap screw (27)
[Nm]
2.6
5.1
5.1
9.0

Operational Instructions for
EAS®-reverse Type 4100/4103/4104
Sizes 3 –6 (B.4100.EN)
14/07/2021 VN/GF/GC/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten
Phone: [phone], Fax: [phone]
Page 8 of 16 www.mayr.com, E-Mail: [e-mail]
your reliable partner
4 Installation
4.1 Installation preparations (customer-side)
Bore or shaft surface quality:
Ra = 0.8 µm acc. ISO 4762.
Standard bore or shaft tolerances: h6.
Standard tolerance of the keyway: JS9.
4.2 Important Installation Guidelines for
Types 4103/4104
Tighten all cap screws (21) which connect the
elastomer ring (10) with the hub (11) to the
tightening torque according to the table (section
3.4) using the torque wrench.
When tightening the screw, ensure that the
aluminium bushing in the elastomer ring (10) is not
turned as well; instead it should sit straight (Fig.
6). In order to reduce the friction between the
screw head and the alumnum part, you must apply
a small amount of grease under the screw head
before starting the installation. If necessary,
prevent a rotation (tilt) of the elastomer ring (10)
when tightening the screws through the
application of counter-pressure using a suitable
tool.
If the clutch is pre-assembled on delivery, it should
not be dismantled again, but rather installed in its
pre-assembled state.
Checking the tightening torques.
4.3 Guidelines for elastomer ring
Please only use the screws included in
delivery - they are marked by a colored
mass (blue) on the threads. This mass
contains micro-capsulated adhesive, which
glues the screws in the thread and
therefore reliably protects against
loosening. After screwing in, the hardening
time of this adhesive at room temperature
(20 °C) is approximately 4 - 5 hours to take
adequate effect. The clutch should not be
operated beforehand.
The hardening is fully completed after 24
hours. Higher temperatures accelerate the
hardening, e.g. the hardening time is only
15 minutes at +70 °C (heated via a warm
air blower). The micro-capsulated adhesive
is temperature-resistant from -80 °C to
+90 °C, and the screws can be re-used a
maximum of 3 times.
Any adhesive which may have been
removed during screwing in, will get caught
between the hub (11) and the aluminium
part. This is not a disadvantage; on the
contrary, it is an advantage as this
increases the frictional locking between
these parts. Attention: Anaerobic adhesives
(such as Loctite, Omnifit etc.) loosen the
rubber adhesion on the metal and therefore
lead to destruction of the clutch. If possible,
do not use these adhesives. If using these
adhesives cannot be avoided (e.g. for
securing screws), then apply economically,
so that no excess adhesive wets the
rubber. We cannot be held reliable for
rubber parts that have become defective
due to adhesives.
Fig. 6
radial
radial
Incorrect
Correct

Operational Instructions for
EAS®-reverse Type 4100/4103/4104
Sizes 3 –6 (B.4100.EN)
14/07/2021 VN/GF/GC/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten
Phone: [phone], Fax: [phone]
Page 9 of 16 www.mayr.com, E-Mail: [e-mail]
your reliable partner
4.4 Installation Type 4100
1. Position the hub overload side (1) on the shaft
end and secure axially (e.g. using a press cover).
4.5 Installation Type 4103
1. Unscrew the radial cap screws (21).
2. Position the hub overload side (1) on the shaft
end and secure axially (e.g. using a press cover).
3. Position the hub for flexible coupling (11) with the
mounted elastomer ring (10) onto the shaft end.
4. Push both clutch parts together (elastic part and
overload part).
5. Insert the radial cap screws (21) including the
washers (23 / only for Size 6) into the elastomer
ring (10).
6. First apply the cap screws (21) until bore and
thread are aligned.
7. Tighten evenly in several steps until the specified
torque according to the table (section 3.4) is
reached.
Observe the installation guidelines 4.2
Fig. 7 Type 4103 Sizes 3 –5
4.6 Installation Type 4104
1. Position the hub overload side (1) on the shaft
end and secure axially (e.g. using a press cover).
2. Position the hub for flexible coupling (11) with the
mounted elastomer ring (10) onto the shaft end.
3. Lightly grease the bores for the socket bolts (24)
in the elastomer ring (10).
4. Turn the elastomer ring (10) towards the
intermediate flange (9) until the bores in the
elastomer ring (10) and the socket bolts (24) are
aligned.
5. Push both clutch parts together (elastic part and
overload part).
Fig. 8 Type 4104 Size 6

Operational Instructions for
EAS®-reverse Type 4100/4103/4104
Sizes 3 –6 (B.4100.EN)
14/07/2021 VN/GF/GC/SU Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten
Phone: [phone], Fax: [phone]
Page 10 of 16 www.mayr.com, E-Mail: [email protected]
your reliable partner
4.7 Alignment of the clutch Types 4103/4104
The flexible coupling compensates for radial, axial and
angular shaft misalignments (please observe the
maximum permitted values).
However, exact alignment of the coupling increases the
coupling service lifetime, reduces the load on the shaft
bearings and improves the operational behaviour of the
overload clutch.
After clutch installation, it must be aligned carefully,
unless the coupled aggregates align well already having
been flanged together. The higher the speed, the more
careful the clutch should be aligned to make sure that it
has a long service lifetime. On this design, alignment can
be checked easily by means of a ruler (Fig. 9). In the
process, the outer diameter of the elastomer ring (10) on
the sides where the radial screws are located must be
align with the intermediate flange (9) and on various
planes.
Fig. 9