Rexnord XG Series User manual
DX0001 Issue 1 21st October 2017 The English language version constitutes “Original Instructions”
in accordance with the EU Machinery Directive
AUTOGARD SERIES XG TORQUE LIMITER
Sizes 3 & 4
Instructions for use
Contents
1. General Notes 1
2. Safety Warnings 1
3. Residual risks 1
4. Symbols used in this manual 1
5. Handling 2
6. Storage 2
7. Surface Protection 2
8. Cleaning 2
9. Disposal 2
10. General Arrangment 3
11. Principle of Operation 3
12. Labelling 3
13. Installation 4
14. Operation 9
a. Reset after trip 9
b. Torque Adjustment 10
c. Removing Modules 12
d. Re-fitting Modules 13
e. Fitting New Modules 14
f. Seat Replacement 16
15. Regular Inspection 17
16. Maintenance 18
17. Troubleshooting 20
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 1 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
1. General Notes
This manual and any accompanying drawings constitute part of the supply. They should be kept together and
accessible to the user at all times. We accept no liability for damage resulting from non-observance of
instructions provided.
When the product is installed in equipment or systems, the supplier of the equipment or system is obliged to
include the instructions, notes and description contained in this manual in their own Operating Instructions and to
ensure that essential health and safety requirements are met.
The product described here is in accordance with the state of the art at the time of printing. In the interest of
further development, we reserve the right to introduce modifications which we consider appropriate, while
retaining the essential features of the design.
Unauthorised modifications are not permitted, invalidate any warranties and will impair reliability.
The product should only be used and operated under the conditions specified in the performance and supply
contract.
The user has to ensure that the persons entrusted with installation, operation care and maintenance, as well as
repair, have read and understood the instructions given in this manual and that they observe them in all respects.
During the course of handling, assembly, disassembly, operation, as well as care and maintenance, all local
regulations regarding industrial safety and pollution control are to be observed.
The product may only be operated, maintained and repaired by authorised, trained and suitably supervised
personnel.
This product is intended for use as a mechanical overload protection device for industrial equipment. It is
designed to release the transmitted torque in the event of an overload. It is not expected to operate under normal
running conditions. For applications where repeated disengagement or slipping occur, please consult Rexnord
for an alternative solution.
To ensure sustained trouble-free operation, the product must be used as originally specified and selected. In the
event of any change in the operating conditions (power, speed, modifications to prime mover and driven
machine), it is essential to confirm the overall design and suitability. If in doubt, consult Rexnord.
2. Safety Warnings
Work on the product may only be carried out when it is stationary. The drive unit must be isolated to prevent
accidental start-up (for example by locking the key switch or removing the fuses from the power supply). A notice
should be affixed to the start-up point stating that work on the product is in progress.
During operation, the drive should be shut down immediately if changes are detected, for example increased
vibration or noise.
It is the responsibility of the supplier of the equipment or system in which the product is used, to ensure that local
codes of safety are complied with (e.g. EU Safety of Machinery Regulations in Europe) and that suitable guarding
is fitted.
This product is not intended for use as a personnel safety device.
It is for the protection of machinery only.
3. Residual risks
There may be residual risks of accidental contact with rotating equipment - take normal precautions according to
local codes.
4. Symbols used in this manual
This manual includes notes which must be observed for your personal safety and for preventing damage to the
product:
WARNING: RISK OF PERSONAL INJURY
This symbol draws attention to measures which MUST be
observed to prevent personal injury.
!
!
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 2 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
WARNING: RISK OF DAMAGE TO EQUIPMENT
This symbol draws attention to measures which MUST be
observed to prevent malfunction or damage to the product
SPECIAL INFORMATION
This symbol indicates additional information to assist in use of the
product.
5. Handling
All parts are listed in the dispatch documents. Check for completeness on receipt. Any shipping damage and/or
missing parts should be reported immediately in writing. Any symbols or instructions applied to the packaging
should be noted.
6. Storage
The product should be stored in a clean, dry environment. Storage limits -20°C
to +100°C.
7. Surface Protection
Steel surfaces (except any stainless steel parts) are treated with manganese-
phosphate and oil and are resistant to corrosion for long periods of time. We do
not recommend painting.
8. Cleaning
Keep the product clean. Wipe down periodically with an oiled cloth. Do not use
solvents and avoid complete wash down or direct high pressure spray.
9. Disposal
At the end of life, dispose of this product in accordance with local codes. Consult your local authority or refer to
Rexnord for further information.
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 3 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
10. General Arrangment
11. Principle of Operation
Autogard XG Series modular torque limiters include hardened seats in one half of the torque limiter and module
sub-assemblies in the other half. Torque is transmitted between the plungers in the module sub-assemblies and
seats. If the application torque exceeds the trip torque of the torque limiter the plungers are pushed away from
the seats and the torque limiter disengages. The trip torque is externally adjustable. When the cause of the
torque overload has been removed the torque limiter can be reset by aligning the two torque limiter halves and
then tapping or levering on the exposed plunger ends.
A proximity switch can be used to detect torque limiter trip by monitoring the rotation of the driven side of the
torque limiter. If a trip is detected, the drive should be stopped as soon as possible and the cause of trip
investigated.
If specified the torque limiter will be factory set to the required trip torque within +/- 5% otherwise the trip torque
will be set at ~70% of the maximum possible for the torque limiter, the trip torque can be adjusted to the required
level on initial commissioning.
12. Labelling
Ref
Notes
1
Model type and size. XG Series Size 3 shown.
2
Reference general arrangement drawing number (if applicable).
3
Serial number –corresponds to Autogard sales order number advised with order acknowledgement.
4
Torque limiter serial number for this order if applicable.
5
Factory set torque. Or “NOT SET” if no setting specified with order.
SEAT
MODULE
BEARING
PLUNGER
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 4 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
13. Installation
1. Verify XG correctly supplied.
2. Inspect for transport
damage.
3. Clean hub bores.
4. Stop and lock drive.
5. Use lifting eyes.
= ?
!
!
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 5 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
6. Mount hubs onto shafts.
Push Fit
OR
Use puller tool
OR
Oil Bath/Oven//Induction Heater -
Max 135 °C 275 °F
1.1.
7. Fit hub set screws.
= Use Loctite 243
1.2.
d
h
mm
T
Nm
lbf.in
M5
2.5
4
35
M6
3
7.2
64
M8
4
17
150
M10
5
33
290
M12
6
54
480
M16
8
134
1190
1.3.
8. Place Wrapflex Ring over S2 hub.
0.0
0.0
dh
T
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 6 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
9. For XG4 only remove 1 module.
10.Position centre assembly between
hubs.
11.Fit S1 hub fixings
= Use Loctite 243
Size
d
h
mm
T
Nm
lbf.ft
XG3
M14
12
95
70
XG4
M16
14
236
174
12. For XG4 only refit module.
See Section 14.d
= Use Loctite 243
d
h
mm
T
Nm
lbf.ft
M6
5
11
8.4
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 7 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
13.Shaft Alignment
Axial Position Limits.
GAP G
mm
in
4.5 –5.5
0.17 - 0.21
Parallel Misalignment Limits.
Maximum P
Installation
Operation
mm
in
mm
in
1
0.04
2
0.08
Angular Misalignment Limits
Size
Installation
Operation
Max(X-Y)
s
°
Max(X-Y)
s
°
m
m
in
m
m
in
XG
3
1.0
0.0
4
0.2
5
4.0
0.1
6
1
XG
4
1.2
0.0
5
0.2
5
4.7
0.1
9
1
14.Fit Wrapflex element.
15.Slide Wrapflex cover over element.
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 8 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
16.Fit cover screws.
d
h
mm
T
Nm
lbf.in
M10
6
15
135
17. Fit trip sensor:
S1 is driving.
S2 is Driving
Operating voltage [V] 10...30 DC
dh
T
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 9 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
18. Note space required to remove
module
Size
W (mm)
XG3
0
XG4
22.5
19. Complete installation by fitting guards compliant with local codes
14. Operation
a. Reset after trip
1. Stop and lock drive.
2. Remove cause of overload.
!
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 10 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
3. Align markers.
4. Pry or Tap plunger ends.
5. Replace guards
6. Resume normal operation.
b. Torque Adjustment
Do not adjust red set screws
!
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 11 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
1. If Torque Limiter is tripped follow reset
procedure.
2. Withdraw unpainted lock screws
3. Adjust trip torque using adjuster. All modules must be adjusted equally.
Increase Trip Torque
Decrease Trip Torque
4. Re-tighten lock screws
= Use Loctite 243
d
h
mm
T
Nm
lbf.in
M4
2
2.3
20
dh
T
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 12 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
5. Replace guards
6. Resume normal operation.
c. Removing Modules
1. Check modules are set.
If modules are tripped follow reset
procedure.
2. Identify modules and their positions
3. Remove 4 screws
4. Remove module
!
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 13 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
5. Only reset modules when fitted in a torque limiter
d. Re-fitting Modules
If modules are to be re-fitted into their original ports with the original module seats, and the module clamp screws
have not been disturbed, proceed as follows, otherwise proceed as for new modules Section e : Fitting New
Modules.
1. Align red markers.
2. Apply BP Energrease LS3 or similar to seats
3. Match and refit modules
4. Refit screws
= Use Loctite 243
d
h
T
Nm
ft.lbf
M6
5
11
8
!
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 14 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
e. Fitting New Modules
Only reset modules when fitted in a torque limiter
1. Align red markers.
2. Apply BP Energrease LS3 or similar
to seats
3. Press and release plunger end by
1mm
4. Fit Clamp Ring to Module
5. Fit clamp screw
6. Ensure module is seated.
!
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 15 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
7. Adjust gap to 0.25mm by rotating module body
8. Mark Body and Clamp Collar
9. Remove Clamp Collar Screw
10.Refit Clamp Screw
= Use Loctite 243
d
h
T
Nm
ft.lbf
M5
4
6.7
4.9
11.Fit 4 screws
= Use Loctite 243
d
h
T
Nm
ft.lbf
M6
5
11
8
12. Repeat Steps 3 to 11 for remaining modules
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 16 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
13.Fit guards
f. Seat Replacement
Remove modules as described in Section c
1. Remove seat screw.
d
h
M5
4
2. Remove seat using extractor
Item
Description
1*
M8 Screw
2*
Washer
3*
Tube
4
Seat
* Not supplied by Autogard
4. Clean and degrease seat hole and
new seat
5. Press in new seat. Use Loctite 241
!
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 17 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
6. Replace screw.
= Use Loctite 243
d
h
T
Nm
ft.lbf
M5
4
6.7
4.9
7. Clean excess loctite
8. Follow procedure for fitting modules
as described in sections d and e.
15. Regular Inspection
During routine regular maintenance when the drive is already shutdown.
1. Stop and lock drive.
2. Inspect Wrapflex Element
Check for element wear debris or cracks in the side of
the element just underneath the cover.
If wear debris or cracks are seen the maintenance
procedure should be followed.
3. Refit guards compliant with local codes.
!
!
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 18 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
16. Maintenance
At least annually remove and inspect the Wrapflex element to avoid unscheduled breakdowns or work
stoppages.
1. Stop and lock drive.
2. Remove Wrapflex cover set screws.
Size
d
h
XG3
M10
6
XG4
3. Slide off Wrapflex cover.
4. Remove Wrapflex element.
5. Inspect element for damage and wear.
!
dh
T
Autogard Series XG •Installation and Maintenance Instructions
Sizes 3 & 4 (Page 19 of 21)
British Autogard Ltd. 2 Wilkinson Road, Cirencester, Gloucestershire, GL7 1YT, UK DX0001
Telephone: +44 (0)1285 640333 October 2017
http://www.rexnord.com/autogard Supersedes NEW
Size
A
XG3
2.25
XG4
2.65
6. Fit Wrapflex element.
7. Slide Wrapflex cover over element.
8. Fit cover screws.
d
h
mm
T
Nm
lbf.in
M10
6
15
135
9. Check all fastener tightening torques.
Use Loctite 242 or 243
dh
T
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