Renova turborex TXP 180 User manual

Renova srl –viale Rimembranze 93 –20099 Sesto San Giovanni - Italy –tel: [phone] –fax: [phone]
www.renova-srl.com –email: [email protected]
pneumatic brake
TXP 180 | TXP 180 HD
TSP 180 | TSP 180 HD
operating instructions

2
This product complies with the Directive 2006/42/CE
© Copyright Renova Srl, 2013. All rights reserved.
MANTX180ITA4V0721

3
index
introduction …………………………………………………………….…….…………………
page 4
warnings ….….…………………………………………………….…….…….………………….
page 4
assistance ………………………………….……………...………....……………………………
page 4
description ……………………………….…………………...……………………………………
page 5
functioning ……………………………….…………………...……………………………………
page 5
high dissipation series version...….………………………………………………………
page 6
disassembly, control and storage………………………...…………………….……….
page 7
package contents.……………………………………………………………………………….
page 8
assembly procedures...……………………………………….…..………………………….
page 9
pneumatic connection procedures..………………….…..……………………………
page 10
electrical connection procedures …..…………………….…..……………………….
page 11
fans ..……………………………..…………...……………………….…..……………………….
page 13
maintenance instructions ………..…....……………………….…..………………….
page 14
spare kit (replacement) ……………………...…………….…..…………………………
page 15
accessories …...………………………………………...…….…………….…..………………
page 17
dimensions ………….……………………..……………….…………….…..………………….
page 21
technical data …..….………………………………………….…………….…..…………….
page 22
parts replacement …...……………………………………….…………….…..……………
page 23
warrantee ..…………...……………………………………….…………….…..………………
page 28
declaration of conformity...…………….…………….…..……………………………….
page 29
notes...…………….…………….…..………………………………………………………………
page 30
manual revision index...…………….…………….…..……………………………………
page 32

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introduction
The following manual is intended for installers and users of the product and provides descriptions and
explanations on the Turborex brake in its standard version (TXP), in the Selematic version (TSP) ) or in its
High Dissipation series (TXP/HD –TSP/HD) and on all its parts and/or options that can be supplied by
Renova.
Inside you will find:
-Unpacking instructions for our TXP - TXP/HD - TSP - TSP/HD brakes
-Instructions for assembly and storage of our brakes and related maintenance
-Electric/pneumatic connections of our brakes
-Instructions for replacing the component parts of our brakes and various kits
-Assembly instructions for the various optionals that Renova can supply for our Turborex brakes
-Dimensions and technical data of our brakes
Since the product and Renova itself are constantly changing in order to improve the quality and
performance of our products, Renova reserves the right to update the manuals without obligation to
update products already marketed and/or any previous manuals.
warnings
CAREFULLY READ THE INSTRUCTIONS AND WARNINGS IN THIS MANUAL AND KEEP THEM FOR
FURTHER REFERENCE FOR THE ENTIRE LIFE OF THE PRODUCT. IN THIS MANUAL THERE ARE
IMPORTANT INSTRUCTIONS RELATED TO OPERATION AND SAFETY FOR INSTALLING, USE AND
MAINTENANCE OF THE PRODUCT.
WE STRONGLY RECOMMEND THAT THE DEVICE BE ASSEMBLED AND INSPECTED BY A
QUALIFIED TECHNICAL STAFF IN ORDER TO AVOID ANY RISK OF DAMAGE TO PERSONS OR TO
THE PRODUCT ITSELF.
IN THE EVENT OF ANY BREAKAGE OF THE PRODUCT, THE OPERATOR SHOULD BE AWARE OF
THIS MANUAL AND THE INFORMATION INSIDE IT, KNOWING AND KNOWING TO AVOID ANY
RISKS AND / OR DANGERS, BEFORE AN INTERVENTION BY OUR SPECIALIZED TECHNICIAN.
assistance
Renova is worldwide present with Agents and Distributors.
To contact Renova service, please, write to: [email protected]

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description
The Turborex TXP - TXP/HD - TSP –TSP/HD brakes, made entirely by Renova in its factory, are mainly
designed for use in the field of tension control of unwinding materials, an application that requires
excellent heat dissipation and great sensitivity. Tension control on core, which by varying the diameter,
requires a continuous variation of the braking parameters to guarantee the quality of production. A brake
with excellent cooling capacity was thus created to ensure constant performance during its work,
infinitesimal wear of the friction elements with consequent practically zero emission of fine dust to protect
the health of the personnel present next to the machine. Maintenance costs are therefore very low and
limited over the years. Particular attention was then paid to the flexibility of the brake in order to offer
performance adaptable to the various types of processing. There are thus numerous possibilities to
customize the brake by varying the number of pistons that operate it, their size, the number of discs, the
material of the friction pads and the adoption of the Selematic system to enhance its sensitivity to low
torques.
THIS COMPONENT IS DESIGNED TO BE INCORPORATED IN A MACHINE AND CANNOT
WORK INDEPENDENTLY.
IT IS FORBIDDEN TO USE IT IF ITS USE ON THE MACHINE DOES NOT COMPLY WITH THE
REGULATIONS IN FORCE.
functioning
The brake is activated by a series of pneumatic actuators (cylinder + piston), mounted uniformly in the cover;
the number can vary from 2 to 6 according to the needs of the couple. These actuators (which we will call
from now on simply pistons) can be connected all together or even in groups (2 + 4) (2 + 2) in order to diversify
the torque according to the type of use: voltage control braking and emergency braking, braking of papers
with different weights or reel sizes, etc.
The pistons compress the pressure disc, used as a wear indicator, which in turn presses a series of steel discs,
which slide on teeth, against brake linings mounted on supports that slide on 4 guides.
A series of springs separates the discs in the absence of pressure, eliminating residual torques that can hinder
the positioning of the coils or other.
The TS version (Turborex Selematic) is instead the more “flexible” version compared to our normal Turborex.
Constructively identical, in this brake the only variant lies in the springs. While the Turborex has 16 identical
springs (12 for the HD version), the Selematic springs are designed to have different stiffnesses and
resistances, from the hardest located between the first disc and lining plate, to the softer one, located near
the last record. This involves a wider use than the standard Turborex, managing to adapt to non-continuous
work changes. The Turborex Selematic, therefore, is recommended in particular uses where there are
changes in work, pressure, etc... while for continuous and uniform uses, we recommend the standard
Turborex.
The heat generated by the action of the brake is disposed of by 2 peripheral fans, one under pressure and
the other in suction, which force the airto pass through the disc pack, cool the surfaces and maintain constant
working temperatures.
The maximum operating pressure of our TXP - TXP/HD - TSP - TSP/HD brakes is 6 Bar. . Renova
strongly advises against using a higher pressure in order to avoid breakdowns and malfunctions
harmful to the machine and/or to the 'operator. We also remind you that incorrect use of the brake
does not fall within our warranty coverage guidelines.

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high dissipation series version
The High Dissipation series version (abbreviated to HD) has now become the Renova standard. The
operation of these brakes is identical to its standard version, but they differ, as indicated by the name of
the brake itself, as they possess a high working heat dissipation thanks to the innovative design of our self-
ventilating central discs.
These discs, with a different profile from the standard ones, provide greater heat dissipation, making the
brake more performing.
Standard disk TX Self-venting disk TX/HD
This innovative design also allows the use of one less disc than the standard version of the brake, making the brake
itself lighter and more efficient.

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disassembly, inspection and storage
Check that the packaging has not been damaged
during transport.
Check that the following details are included in the
package and correspond to the brake ordered whose
code is mentioned on the label stuck on the brake
casing.
Remove the transport guards from the fans.
Also remove the protection on the sensors in models with tachometer,
taking care not to damage the sensor cable.
ATTENTION:
If this requirement is neglected, the ventilation of the brake is compromised and the
consequent overheating can damage various components such as brake linings, central
discs, electric cables.
Renova guarantees a detailed dimensional and quality control on all the parts that
make up our TX-TX / HD brake. We also guarantee total control over any electrical part
present in the chosen brake configuration, 100% tested by our operators during the
brake assembly phase.
If the brake is stored in stock, leave the brake in its original packaging. Despite
the galvanic protections on the metal parts, very humid or aggressive
environments can over time affect the surfaces of the hub, central discs and
sliding guides and inflate the friction pads.
If the brake is stored for a long time, the film of grease that lubricates the
movement of the piston can dry out.
It is therefore advisable to relubricate the internal surfaces of the cylinder and
the central guide with a very thin film of lubricating, water-repellent, anti-adhesive silicone grease specific
for metal-rubber. Be careful not to use excessive amounts of grease which, reaching the brake linings, affect
their performance.

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package contents
Turborex HD version (no optional)
Cover with
assembled and
wired pistons
1
Housing with 4
guides and two
carters with fans
assembled and
connected to the
connector
1
Central discs
design HD
3
Pressure disk
1
Double plate holder
2
Single plate holder
2
Hub
If purchased by the
customer
1
Allen screw M6
8
Soft wire Ø same
if in standard TX
version. Soft wire
Ø different if
Selematic version
12

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assembly procedures
Hub mounting on the machine shoulder
Controllare che le dimensioni di montaggio sul telaio e sull’albero corrispondano
a quelle del freno.
▪Check that there is no grease or oil from faulty shaft bearing seals.
▪Fit the hub up to the support surface of the brake body.
▪Axially block the hub with a screw threaded ring nut or Seeger or
screw/washer in the shaft head.
ATTENTION:
A badly locked hub can slide on the shaft and by rotating damage
the pistons with consequent detachment of fragments that are
thrown.
Brake mounting:
• Open the brake by unscrewing the 8 screws on the cover and remove
the discs and springs.
• Fit the brake body centering it on its seat and positioning the fans
horizontally to prevent them sucking dirt from the floor
• Secure it firmly with screws with tightening torque suitable for
aluminum alloys (M8>15Nm, M10>20Nm).
• Insert the first single shoe holder plate onto the guides with the pads
facing the operator.
• Mount the first set of 4 springs on the guides, the central disk, the double shoe holder disk.
• Continue with the other springs, central discs and staple holder plates in sequence, then mount the last
single staple holder disk with the pads facing inside of the brake.

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• Fit the pressure disk.
• Press the disk pack to check that it moves freely and with a springy motion.
• Fit the cover by aligning the holes with the guides and close it with a slight pressure.
Then tighten the 8 screws that connect it to the brake body with a tightening torque suitable for the
aluminum alloy (~6Nm).
Once all the steps listed have been completed, the mechanical assembly is complete and the pneumatic
and electrical connections must be made to make the brake operational.
pneumatic connection procedures
• Connect the air supply hose to the fitting or
fittings in the brake cover.
Depending on the number of pistons mounted on
the brake and the connection system, there may be
several entries which connect separately groups of
pistons.
• If there is a manual selection valve for feeding to the piston group, position it open.
• If there is a different differentiated power supply system, such as two solenoid valves that feed groups of
pistons, position it in the opening position.
• Bring the brake to maximum pressure (6 bar) and check that there are no load drops or hisses that signal
air leaks.
• In the case of drives connected to regulation system with electro-
pneumatic transducers or proportional valves, etc. controlled by PLC
or computer, check that at signal “0” there is 0 bar of pressure and
the internal brake discs are completely free to turn.
• The maximum recommended pressure is 6 bar.

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Possible configurations of the pistons present in the cover:
electrical connection procedures
•Connect the power supply wires of the fans and the rev counter (if
present) to the connector in the side brake casing, taking care of the
polarity. The electronic card that controls the fans requires this
prescription. The same attention also applies to the connections of the
tachometer sensor in the models that provide it; in addition to the power
contacts, there is also the pulsating signal that will be processed by the
PLC.
• Some types of double-pole or multi-pole connectors are used which are mounted according to the brake
equipment or customer specifications.
tripolar code CNTH100P3
EN17530-803 three-pole connector
Cable diameter 2,5 mm
Rated voltage max 300 V AC
Maximum range 16 A
C-VDE insulation
Degree of protection IP 65
Screw connection
Used for fans connection
• Connect positive pole 90° times from
neutral
• Connect negative pole opposite connector

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Box/mammut code CNTH100F0
Multipole connector
Cable diameter 2,5 mm
Max rated voltage 380 V AC
Maximum range 2 A
Screw connection
Degree of protection IP 54
Used to connect fans, tachometer sensor (in some
applications even double) and other sensors such as the
temperature sensor.
Diagram 1 shows the inlet connections from the fans and
the rev counter; out to the wires of the multipolar cable.
Diagram 2 shows the inlet connections from the fans and
2 rev counter sensors; out to wires of the multipolar
cable.
Diagram 3 shows the incoming connections from the fans
and the temperature sensor; out to the wires of the
multipolar cable.
Diagram 4 shows the connections to the fans only.
The advantage of this type of connector is the absence, in case of failure and therefore replacement of the
fans or the tachometer sensor, of welded contacts that are more complicated to make and which can give
to cold welding.
electrical connection diagrams

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fans
• After making the various connections, turn on the fans.
The voltage of the standards fans is 24 VDC.
At the request of customers, we sometimes mount voltage of 110
VAC and 220 VAC which we do not recommended because they are
potentially dangerous for the people working on the brake.
It is preferable to use a transformer that we can supply as an option.
The fans normally used are divided into standard and hp (high power)
with enhanced cooling characteristics.
Type
Voltage
Power
Sound level
Renova code
Standard
24 V CC
11 W
57 dB(A)
VT12038024
High performance HP4
24 V CC
30 W
67 dB(A)
VT120380H4
High performance HP6
24 V CC
65 W
73 dB(A)
VT120380H6
Standard 110 V
110 V AC
20 W
51 dB(A)
VT12038110
Standard 220 V
220 V AC
19 W
47 dB(A)
VT12038220
Fans dimensions: 120mm x 120mm x 38mm.
• Check that the fans are working correctly, one in suction and the opposite in pressure
Once all the mechanical, pneumatic and electrical steps have been carried out, the brake is ready for use.

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maintenance instructions
Our TX - TX HD brakes require periodic maintenance as they have parts subject to wear. In order to avoid
problems on the brake and to corrupt its operation, below you will find the checks to be carried out on our
brakes and the replacement procedures if something should be changed.
maintenance
• Check when the systems are switched on or in any case on a daily basis that the
suction and pressure fans are working correctly. Operation of the brake without
sufficient ventilation can lead to excessive overheating which seriously damages
brake linings, fans and other components.
• Check the wear indicator on the side casing every month. If
the indicator is positioned in the yellow area, check the state
of the linings and if some are more worn than others, swap their position. If the
indicator is positioned in the red area it is necessary to replace them.
• Check every 3 months that the pistons are not full of dust
or dirt. Clean the sliding surface with compressed air. Check
that the pistons slide freely. If not, spread a thin film of
lubricating, water-repellent, anti-adhesive silicone grease
specific for metal-rubber, the internal surfaces of the
cylinder and the guide. Also check the good condition of the
lip seals. If not, replace them.
• Check every 3 months that there are no lumps of dirt between the toothing of the
hub and the discs that could obstruct their free sliding. If not, clean them with a
wire brush.
ATTENTION:
Before working on the brake, always disconnect the power supply to the fans. The
moving blades can be dangerous for the operator's fingers.

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spare kit (replacements)
replacement of the ferrodic plate
• Remove the power supply to the fans because the moving blades can be dangerous for the operator’s
fingers.
• Remove the pneumatic power supply.
• Open the brake and remove the old brake pads.
• Check that the 4 shoe-holder plates do not show any lesions that could affect the sliding of the brake
lining discs. If necessary, replace the guides
• Fit the new plates on the brake according to the assembly instructions described above (ref. Pag. 10/11)
replacement of the central discs
• Remove the power supply to the fans because the moving blades can be dangerous for the operator’s
fingers.
• Remove the air supply.
• Open the brake and remove the old central discs.
• Check that the hub toothing does not show any cracks that could affect the free sliding of the discs. If
necessary, replace the hub. If there is dirt, clean with a wire brush
• Fit the new plates on the brake according to the assembly instructions described above (ref. Pag. 10/11)
replacement of the fans
• Remove the power supply to the fans because
the moving blades can be dangerous for the
operator’s fingers.
• Remove the pneumatic power supply.
• Disassemble the carter of the fan to be replaced
and then the fan taking note of the direction of
assembly that characterizes the function of air
suction or compression.
• Disconnect the plug located on the side of the fan.
• Mount the new fan on the carter and connect it to the flying socket.
• Secure the carter with the screws on the brake body.
• Power up the fan and check that it is working properly
Note: some types of fans do not have a flying socket that cuts the connection wire. In this case, removing
the fan, remove the wire up to the electrical connector and then reinsert that of the new fan. It is then
necessary to reconnect the wire to the connector with locking

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replacement of the pistons
Piston lip seal replacement
•Remove the piston from the cylinder, if it is stuck, feed the brake at very
low pressure until the piston comes out of its seat
• Remove the damaged gasket and replace it carefully so as not to cut it on
the edge of the groove.
• Check that the internal surface of the cylinder is regular without marks or
scoring.
• Spread a thin film of lubricating, water-repellent, anti-adhesive silicone grease
specific for metal-rubber, on the internal surfaces cylinder and guide.
• Put the piston back in its seat.
•Check the piston seal at maximum pressure.
Piston and cylinder replacement
•Disconnect the air hose from the connector or
connectors. Depending on the position inside the cover,
there may be three types of cylinder.
• Unscrew the corresponding screw on the brake cover
and remove the piston.
• Insert the new cylinder, the O-ring, the
piston guide and tighten the screw without
tightening.
• Insert the template (available as an
option) for centering the piston guide and
tighten the screw on the cover.
• Spread a thin film of lubricating,
water-repellent, anti-adhesive silicone
grease specific for metal-rubber, on the internal surfaces cylinder and guide.
• Insert the piston inside the cylinder, taking
care not to damage the gasket on the inner edge of the cylinder
• Connect the air pipes to the connectors.
• Check the piston seal at a pressure of 6 bar.
If present, check your configuration of pistons on
the label on the cover.

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accessories
Our TX - TX / HD brakes can have, on customer request, some accessories that are not present in our
standard versions.
RPM counter
One of the most used and requested accessories not present in our standard is the tachometer with its
sensor. These brakes will be supplied in the same composition as the standard brakes, except that a central
disc (the last in the assembly phase) will be replaced by a specially built central disc with one or more
"notches" for the tachometer.
Disco con tacche per contagiri HD
• position the sensor at a distance of about one millimeter from the central disk, shaped with notches
whose number and shape depend on the type of PLC management.
• then power up the sensor and check by turning the shaped central disk that the warning light on its upper
end flashes.
Below is the list of our available tachometers. By default, Renova supplies on its brakes a tachometer with
PNP connection normally open (NO), but on request the PNP versions normally closed (NC) and the NPN
versions both normally closed and normally open are also available.
Type
Voltage
Current
Signal
distance
Wiring
Renova Code
Standard
10 - 30 V CC
<200 mA
1,5mm
PNP (NO)
CG00000000
Su richiesta
10 - 30 V CC
<200 mA
1,5mm
NPN (NO)
CG00000NPN
Su richiesta
10 - 30 V CC
<200 mA
1,5mm
PNP (NC)
CG00000000-NC
Su richiesta
10 - 30 V CC
<200 mA
1,5mm
NPN (NC)
CG00000NPN-NC

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replacement of RPM counter
• Remove the power supply to the fans because the moving blades can be
dangerous for the operator’s fingers.
• Remove the pneumatic power supply.
• Disconnect the sensor from the connector.
• Remove the sensor by unscrewing the nut that locks it on the bracket.
• Remove it from the eyelets and from the thermal protection sheath.
• Mount the new sensor on the bracket and adjust the distance from the
central disc to about 1mm.
• Insert the cable into the eyelets and into the thermal protection sheath.
• Connect the 3 poles to the connector contacts according to the previously shown diagram (ref page 13).
• Power up the tachometer and check for proper operation by turning the central cam disc and observing
the light on the sensor head turning on.
kit temperature sensor - lamp (KT000000000)
Another optional that Renova provides concerns the kit including the temperature sensor and signaling lamp.
Thanks to theseoptions it is possible to monitor that the brake temperature does not rise above the threshold
and if this happens it will be signaled by a light signal emitted by the lamp.
Signalation lamp Temperature sensor

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installation
• Disconnect the fans from the power supply; moving blades can be dangerous for the operator’s fingers.
• Remove the pneumatic power supply.
• Remove the cover and the pressure discs.
• Remove the two-side carter, being careful, if there is a 3-pole socket to cut the fan power supply wires
near the connector.
• Place the new kit and store the pressure disc with the bimetal thermostat facing the cover.
• Reassemble the brake.
• Power up the fans and check that they are working properly.
kit for 4 fans brake
For those applications where more heat dissipation is required, you can switch from 2 fans to 4 fans thanks
to the use of a special casing that allows the assembly of 2 fans one above the other.

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Installation of fan kit
• Disconnect the fans from the power supply; moving blades can be dangerous for the operator’s fingers.
• Remove the pneumatic power supply.
• Disconnect the flying plug located on the side of the fan.
• Remove the cover and all the components inside the brake.
• Remove the fan carter and the cover where the electrical connector is located.
• Place the new kit.
• Insert the electrical wiring into the appropriate cable holder.
• Secure the fan carter and the electrical connector carter with the screws on the brake body.
• Reassemble the brake.
• Power up the fans and check that they are working properly.