Mayr ROBA-DS 956 Series Quick start guide

Installation and Operational Instructions for
ROBA®-DS Couplings Type 956. _ _ _
Sizes 2200 –11000 (B.9.7.3.EN)
12/11/2015 RM/GC Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 1 of 6 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 coupling failure, resulting in damage to other parts.
Contents
Page 1: - Safety Regulations
- Safety and Guideline Signs
Page 2: - Exemplary Illustration of the ROBA®-DS Coupling
- Parts List
Page 3: - Table 1: Technical Data
- Function - Application
- State of Delivery
- Temperature Resistance
- Installation Position
Page 4: - Shaft-Hub Connection
- Guidelines on Hub Bore and Shaft
- Hub Installation
- Coupling Installation
Page 5: - Coupling Alignment
- Permitted Shaft Misalignments
- Balancing the Coupling
Page 6: - Maintenance
- Disposal
- Malfunctions / Breakdowns
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 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 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.
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!
Safety and Guideline Signs
CAUTION
Danger of injury to personnel and damage to
machines.
Please Observe!
Guidelines on important points.

Installation and Operational Instructions for
ROBA®-DS Couplings Type 956. _ _ _
Sizes 2200 –11000 (B.9.7.3.EN)
12/11/2015 RM/GC Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 2 of 6 www.mayr.com, E-Mail: [e-mail]
S
H
4
3
7 8
6
5
9
10
11
2
2.1
3
1
2 1
A
D
Exemplary Illustration of the ROBA®-DS Coupling Sizes 2200 –11000
with flange, sleeve and hub
Fig. 1a: Detail A
Fig. 1
Fig. 2
Parts List
Only use mayr®original parts
1 Hub
2 Disk pack
2.1 Disks
3 Sleeve
4 Flange
5 Hexagon head screw
6 Press cover
7 Ring
8 Collar bushing
9 Cone bushing
10 Cone bolt
11 O-ring

Installation and Operational Instructions for
ROBA®-DS Couplings Type 956. _ _ _
Sizes 2200 –11000 (B.9.7.3.EN)
12/11/2015 RM/GC Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 3 of 6 www.mayr.com, E-Mail: [e-mail]
Table 1: Technical Data
ROBA®-DS Size
2200
3300
5000
7300
11000
Coupling nominal torque
valid for unchanging load direction as well as
for max. permitted shaft misalignment
TKN
[kNm]
22
33
50
73
110
Coupling alternating torque
valid for changing load direction as well as for
max. permitted shaft misalignment
TKW
[kNm]
14.7
22.0
33.3
48.7
73.3
Coupling peak torque
valid for unchanging load direction
max. load cycles ≤ 105
TKS
[kNm]
44
66
100
146
220
Distance dimension
S
[mm]
17.8
0.25
19.0
0.25
23.0
0.25
24.2
0.25
26.5
0.25
Axial displacement
Values refer to couplings with 2 disk packs.
Only permitted as a static or virtually static
value.
ΔKa
[mm]
1.6
1.7
2.1
2.3
2.3
Angular misalignment
per disk pack
ΔKw
[°]
0.4
0.4
0.4
0.4
0.3
Radial misalignment
for double-jointed couplings
ΔKr
[mm]
(H - S) x 6.98 x 10-3
(H - S) x 5.24 x 10-3
Radial misalignment
for single-jointed couplings
If there is only one disk pack, the shafts must be aligned precisely.
Outer diameter
D
[mm]
290
332
378
431
492
Max. speed 1)
valid if the outer diameter D is not exceeded
nmax
[rpm]
3600
3100
2700
2400
2100
Hexagon head screw (Item 5
Tightening torque
[Nm]
M14x40
196
M16x40
300
M16x50
300
M18x50
420
M18x50
420
Adjusting screws for key hubs (Fig. 3)
Tightening torque
[Nm]
M10
14
M16
90
M12
35
M16
90
M16
90
M16
90
M16
90
1) On double-jointed couplings, the critical bending speed of the respective sleeve must be taken into consideration additionally.
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, and additionally for radial
misalignments on double-jointed couplings.
State of Delivery
The ROBA®-DS couplings are delivered in individual parts and
pre-assembled units.
The disk pack (2) assembly is assembled at the place of
manufacture. The disk pack (2) assembly consists of disks (2.1),
collar bushings (8) and rings (7).
The insertion of the cone bushings (9) into the respective
attachment parts (hubs (1), sleeves (3) or flanges (4)) is carried
out at the place of manufacture.
All screw connections must be pre-tensioned
during the final installation to a torque value
according to Table 1.
Except for the disk pack (2), all parts are phosphated and
therefore have a basic corrosion protection.
Temperature Resistance
Due to their all-steel design, ROBA®-DS couplings are
temperature-resistant up to +250 °C.
At temperatures over +200 °C, it might be necessary to replace
the O-rings (11) when carrying out installation again.
Installation Position
ROBA®-DS couplings are designed for horizontal installation. In
case of vertical or inclined installation, on heavy sleeves the
sleeve's own weight must be supported with a vertical support.
This vertical support is produced at the place of manufacture.

Installation and Operational Instructions for
ROBA®-DS Couplings Type 956. _ _ _
Sizes 2200 –11000 (B.9.7.3.EN)
12/11/2015 RM/GC Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 4 of 6 www.mayr.com, E-Mail: [e-mail]
Shaft-Hub Connection
The torque values stated in Table 1 do not necessarily apply to
the shaft-hub connection. For the shaft-hub connection, a
strength verification must be carried out depending on the shaft
design and the application using appropriate calculation methods
(e.g. DIN 6892 for key hubs). For the hubs, a yield point of 2
75 N/mm² and a tensile strength of 560 N/mm² can be used for
the calculation.
Guidelines on Hub Bore and Shaft
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.
The shaft surfaces should be finely turned or ground
(Ra = 0.8 µm).
Hub Installation
Hubs with external shrink disks
The force is transmitted via frictional locking. Therefore, the
hub bores and the shaft ends must be completely oil and
grease-free during installation. Greasy or oily bores or shafts
reduce the transmittable torque.
The shafts must not have a keyway.
Mount the hubs onto the shafts using a suitable device, bring
them into the correct position and mount the shrink discs
following the Installation Instructions available separately
(Installation Instructions for shrink discs of the types TAS 30.. /
TAS 52..).
Hubs with Keyway
Mount the hubs onto the shafts using a suitable device and
secure them axially (Fig. 3). Axial securement takes place
using a set screw (adjusting screw), which presses radially
onto the key (tightening torques acc. Table 1, page 3); or via a
press cover and a screw, screwed into the shaft threaded
centre hole.
The key must lie over the entire length of the hub.
Adjusting screw
Fig. 3
Coupling Installation
The conical exterior surface of the cone bolts
(10) (including the O-rings (11)) must be
greased with “Klüber Altemp Q NB 50”.
The disk packs (2) are mutually connected with the hubs (1), the
sleeve (3) or the flanges (4) via the cone bolts (10); they are
screwed together via the lightly oiled hexagon head screws (5)
and press covers (6) (Fig. 1a).
The hexagon head screws (5) must be
tightened in several steps to their full
tightening torque acc. Table 1. Please see
Table 2 for the respective tightening torques
for each step.
Table 2
Step
Tightening torques for hexagon head screws
(5)
1
30 % of the nominal tightening torque
2
60 % of the nominal tightening torque
3
100 % of the nominal tightening torque
The hexagon head screws (5) on each connection side must be
tightened cross-wise.
The disk pack (2) must not under any circumstances be distorted
when applying the pre-tension force.
In principle, the disk pack (2) is inserted in a
way so that the press covers (6) press onto
the rings (7) of the disk pack (2). The press
covers (6) do not press onto the collar
bushings (8). See Fig. 1a, page 2.
When inserting the press cover (6), please
make sure that the installation direction is
correct. See Fig. 1a, page 2.
For de-installation of the disk pack (2), the hexagon head
screw (5) is screwed out and together with the press cover (6)
screwed into the cone bolt (10) on the opposite side.
When doing this, please make sure that the installation direction
of the press cover (6) is correct; see Fig. 2, page 2.
This loosens the cone bolt (10) and it can be pulled back axially.
Then, the disk pack (2) can be removed radially (Fig. 2, page 2).

Installation and Operational Instructions for
ROBA®-DS Couplings Type 956. _ _ _
Sizes 2200 –11000 (B.9.7.3.EN)
12/11/2015 RM/GC Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 5 of 6 www.mayr.com, E-Mail: [e-mail]
20
30%
25%
75%
0%
50%
20
40%
40
30%
60
60
80
80
100
100
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, dimension
"S" (Fig. 1a: Detail A on page 2, and Table 1 on page 3) must be
maintained with aligned angular and radial shaft misalignments.
Permitted Shaft Misalignments
ROBA®-DS single-jointed couplings compensate for angular
and axial shaft misalignments;
ROBA®-DS double-jointed couplings compensate for angular,
axial and radial shaft misalignments (Fig. 5) without losing
their backlash-free function. However, the permitted shaft
misalignments indicated in Table 1 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. 4. The sum total of the actual misalignments in
percent of the maximum value must not exceed 100 % (see
example and Fig. 4).
Fig. 4
Fig. 5
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
Required balance quality
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.
All parts of the ROBA®-DS couplings, except special sleeves, are
machined on all sides, and therefore lie in the range G 6.3 acc.
DIN ISO 1940 at medium speeds (1500 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).
ΔKa
Δ
K
w
2
x
Δ
K
w
ΔKr
Axial displacement Radial misalignment Angular misalignment
Example (see Table 1 on page 3 and Fig. 4):
ROBA®-DS Size 5000, double-jointed coupling, dimension H = 300 mm
=> Axial displacement occurrence ΔKa= 0.84 mm equals 40 % of the permitted maximum value ΔKa= 2.1 mm
=> Angular misalignment occurrence in the disk pack ΔKw= 0.12° equals 30 % of the permitted maximum value ΔKw= 0.4°
=> Permitted radial misalignment ΔKr = 30 % of the maximal value ΔKr= (H - S) x 6.98 x 10-3 = 1.94 mm
=> ΔKr= 0.58 mm
Δ Kw[%]
Angular misalignment
Δ Ka[%] Axial displacement
ΔKr[%] Radial misalignment

Installation and Operational Instructions for
ROBA®-DS Couplings Type 956. _ _ _
Sizes 2200 –11000 (B.9.7.3.EN)
12/11/2015 RM/GC Chr. Mayr GmbH + Co. KG
Eichenstraße 1, D-87665 Mauerstetten, Germany
Tel.: [phone], Fax: [phone]
Page 6 of 6 www.mayr.com, E-Mail: [e-mail]
Maintenance
ROBA®-DS couplings are mainly maintenance-free.
The following maintenance and inspection intervals are to be
maintained:
1.) 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 1000 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 4000 operating hours or after maximum 12
months.
In extreme coupling ambient or operating conditions, the
maintenance and inspection intervals should be shortened.
Disposal
All steel components:
Steel scrap (Code No. 160117)
O-rings
Plastic (Code No. 160119)
Malfunctions / Breakdowns
Malfunction
Possible Causes
Solutions
Changes in running
noise and / or vibration
occurrence
Incorrect alignment, incorrect
installation
1) Set the system out of operation
2) Find / resolve the cause of incorrect alignment
3) Check the coupling for wear
Loose connecting screws, minor
fretting corrosion under the screw
head and on the disk pack
1) 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
Tensioning and clamping screws
or locking set screw for axial hub
securement are loose
1) 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
Disk pack breakage
Disk pack breakage due to high
load impacts / overload
1) 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
Operating parameters are not
appropriate for the coupling
performance
1) 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
Incorrect operation of the system
unit
1) 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
Disk packs / connecting
screws cracks or
breakage
Drive vibrations
1) 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.