Renova Turborex TX 180 User manual

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

2
This product complies with the Directive 2006/42/CE
© Copyright Renova Srl, 2013. All rights reserved.
MANTX180ENA4V0421

3
index
introduction …………………………………………………………….…….…………………
page 4
warnings ….….…………………………………………………….…….…….…………………
page 4
assistance ………………………………….……………..………....……………………………
page 4
description ……………………………….…………………..……………………………………
page 5
functioning…………………………………………………………………………………………
page 5
High dissipation series version ..….………………………………………………………
page 6
brake parts designations ………..……………………..…………………………………….
page 6
disassembly, control and storage .……………………………………………….……..
page 7
package contents ……………………………………………………………………………….
page 8
assembly procedures ….…………………………………………….…..………………….
page 10
pneumatic connection procedures ……..…………………….…..………………….
page 11
electrical connection procedures ………..…………………….…..………………….
page 12
fans ……………………………………..…………...……………………….…..………………….
page 14
maintenance instructions.…………..…....……………………….…..………………….
page 15
spare kit (replacement) .……..……………………...…………….…..………………….
page 17
accessories ..………………………………………...…….…………….…..………………….
page 18
dimensions .………….……………………..……………….…………….…..………………….
page 24
technical data ….………………………………………….…………….…..………………….
page 25
parts replacement ..……………………………………….…………….…..……………….
page 25
warrantee …………...……………………………………….…………….…..………………….
page 32
declaration of conformity …………....…………….…………….…..………………..….
page 33

4
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 (TX), in the Selematic version (TS) or in its High Dissipation series (TX
HD – TS HD) and on all its parts and/or options that can be supplied by Renova.
Inside you will find:
-Unpacking instructions for our TX - TX/HD - TS - TS/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.
Contact Renova support
[e-mail]

5
description
The Turborex TX - TX/HD - TS - TS/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, require 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 frequent 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 air to pass through the disc pack, cool the surfaces and maintain constant working
temperatures.
The maximum operating pressure of our TX - TX/HD - TS - TS/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.

6
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 disc TX Self-venting disc 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.
brake parts designations

7
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.

8
package contents
Turborex TX 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 disc
1
Double plate holder
2
Single plate holder
2
Hub
If purchased by the
customer
1
Allen screw M6
8
Springs
Soft wire Ø same if
in standard TX
version. Soft wire Ø
different if
Selematic version
12

9
Turborex TX version
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
4
Pressure disc
1
Double plate holder
3
Single plate holder
2
Hub
If purchased by the
customer
1
Allen screw M6
8
Springs
Soft wire Ø same if
in standard TX
version. Soft wire Ø
different if
Selematic version
16

10
assembly procedures
Hub mounting on the machine shoulder
Check that the mounting dimensions on the frame and on the shaft correspond to those
of the brake.
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 disc, the double shoe holder disc.
• Continue with the other springs, central discs and staple holder plates in sequence, then mount the last single staple
holder disc with the pads facing inside of the brake

11
• Fit the pressure disc.
• Press the disc 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.

12
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

13
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

14
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.

15
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.

16
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

17
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.

18
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.
These discs, as for the standard versions, are also available in the High dissipation series version.
Disc standard with notches for RPM Disc HD with notches for RPM
• position the sensor at a distance of about one millimeter from the central disc, 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 disc 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
Customer request
10 - 30 V CC
<200 mA
1,5mm
NPN (NO)
CG00000NPN
Customer request
10 - 30 V CC
<200 mA
1,5mm
PNP (NC)
CG00000000-NC
Customer request
10 - 30 V CC
<200 mA
1,5mm
NPN (NC)
CG00000NPN-NC

19
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
these options 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
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

20
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.
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 of the fans into the approp.
• 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.