TSCHAN SD-5 Owner's manual

TSCHAN GmbH Zweibrücker Straße 104 D-66538 Neunkirchen-Saar
Telefon: [phone] Telefax: [phone] www.TSCHAN.de
BAWS 002-GBR-0
11/2004
Installation and Operation Manual TSCHAN®
Flexible Coupling
TSCHAN®-S SD-5

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Table of Contents
Chapter Page
1 Safety Instructions............................................................................................................2
2 Technical Description .......................................................................................................3
2.1 Intended Application..................................................................................................3
3 Coupling Marking..............................................................................................................4
3.1 Marking of Buffer Rings.............................................................................................4
4 Storage.............................................................................................................................4
5 Construction .....................................................................................................................5
6 Technical Data..................................................................................................................6
7 Installation ........................................................................................................................8
7.1 To be observed prior to installation............................................................................8
7.2 Finish Bores...............................................................................................................9
7.3 Coupling Installation................................................................................................10
8 Coupling Alignment.........................................................................................................11
8.1 Angular Misalignment..............................................................................................12
8.2 Radial Misalignment................................................................................................12
1.1 ................................................................................................................................12
8.3 Axial Misalignment...................................................................................................13
9 Operation........................................................................................................................14
9.1 Check of Direction of Rotation.................................................................................17
10 Maintenance...................................................................................................................19
10.1 Wear Inspection on the Buffer Ring.........................................................................19
10.2 Wear Inspection - Equipment at standstill ...............................................................20
10.3 Replacement of the buffer ring................................................................................21
11 Disposal .........................................................................................................................21
12 Manufacturer’s Declaration ............................................................................................22
1 Safety Instructions
This installation and operation manual is an essential component of the coupling
delivery. Always keep this manual in a readily accessible place near the coupling.
Take care that all persons being charged with the installation, operation, maintenance and
repair of the coupling have read and understood this manual and that all instructions con-
tained therein are carefully observed in order to:
- avoid danger to life and limb of the user or third persons,
- ensure the operational safety of the coupling,
- preclude operation failures and environmental damages due to wrong handling and
misuse.
The relevant instructions and regulations regarding safety at work and environmental protec-
tion have to be observed while transporting, mounting and dismounting the coupling.
Make sure that appropriate transportation means and tools are at disposal.
The coupling shall be operated, mounted, maintained and repaired by authorized, trained and
instructed personnel only.

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In the interest of further development, we reserve the right to carry out modifications serving
the technical progress.
We do not assume any liability or warranty for any damages resulting from the use of
accessories and parts that are not originally manufactured by TSCHAN GmbH.
2 Technical Description
The TSCHAN®-S SD-5 coupling is a torsionally flexible, puncture proof claw coupling.
It compensates for angular, radial and axial shaft misalignments within defined limits. The
coupling transmits torque through elastic buffers loaded in shear. These buffers come in
Perbunan (Pb) or polyurethane (Vk), standard Vulkollan red (VkR), and are connected to
each other to form an elastic buffer ring.
This elastic buffer ring dampens shocks and torsional vibrations and is resistant to oil.
Buffer rings made of Perbunan are electrically conductive.
One of the coupling halves consists of a flange hub to which a claw ring is bolted. When the
claw ring is removed, it is easily possible to check the rotational direction of the drive.
The coupling is suitable for use in every direction of rotation and installation position.
2.1 Intended Application
• In order to ensure trouble-free and reliable operation, the coupling has to be sized
according to the design specifications, e.g. according to DIN 740, part 2, (or acc. to cata-
logue TSCHAN®-S), with a service factor appropriate for the service conditions.
• Except for the production of a finish bore with keyway, no further modifications are
allowed to be carried out on the coupling!
• The coupling shall only be used and operated within the frame of the conditions as
defined in the performance or delivery contract.
• Any change in the operation conditions or service parameters requires the verification of
the coupling design.

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3 Coupling Marking
3.1 Marking of Buffer Rings
The buffer rings are marked on the face of one buffer element as follows:
- Coupling size and material abbreviation (Vk for Polyurethane or Pb for Perbunan)
- Year of construction
- Pb72 = buffer ring of Perbunan, 72 Shore(A) / black
- Pb82 = buffer ring of Perbunan, 82 Shore(A) / black
- VkB = buffer ring of Polyurethane, 83 Shore(A) / blue
- VkR = buffer ring of Polyurethane, 93 Shore(A) / red
- Vk60D = buffer ring of Polyurethane, 60 Shore(D) white/beige
4 Storage
On receipt of the goods, immediately check that all parts are on hand and are as ordered.
Eventual shipping damages and/or missing parts have to be reported in writing.
The coupling parts can be stored in the delivered state in a dry place under roof at normal
ambient temperatures for a time period of 6 months. Storage for a longer period requires the
application of a long-term preservation. (Please consult TSCHAN GmbH in this respect.)
The buffer rings must not be exposed to ozonic media, direct sun light or intensive light
sources with UV light. The air humidity should not exceed 65 %. If the parts are properly
stored, the quality characteristics of the elastic buffer rings remains almost unchanged for up
to three years.
Size DA
[mm] h [mm] z
50 48 12 4
70 70 18 6
85 82 18 6
100 100 20 6
125 121 25 6
145 139 30 6
170 166 30 8
200 194 35 8
230 222 35 10
260 253 45 10
300 294 50 10
360 350 55 12
400 393 55 14

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5 Construction
1 Coupling hub, part 200
2 Elastic buffer ring, part 020
3 Claw ring, part 366
4 Flange hub, part 361
5 Cheese head screw DIN 912
Note:
Flange hub (part 4) and claw ring (part 3) are delivered in bolted state.
Balanced parts are match-marked to each other.
Fig. 1 Construction of TSCHAN-S SD-5

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6 Technical Data
Tabelle 1 Technical Data:
Size
SD-5
nmax
[min-1]
TKnom
Pb72
[Nm]
TKmax
Pb72
[Nm]
TKnom
Pb82
[Nm]
TKmax
Pb82
[Nm]
TKnom
VkR
[Nm]
TKmax
VkR
[Nm]
TKnom
Vk60D
[Nm]
TKmax
Vk60D
[Nm]
TKnom
VkB
[Nm]
TKmax
VkB
[Nm]
100 7250 40 120 70 210 130 390 195 585 76 228
125 6000 70 210 128 385 250 750 370 1110 140 420
145 5250 120 360 220 660 400 1200 600 1800 240 720
170 4500 180 540 340 1020 630 1900 950 2850 370 1110
200 3750 330 990 590 1770 1100 3300 1650 4950 640 1920
230 3250 500 1500 900 2700 1700 5150 2580 7740 980 2940
260 3000 800 2400 1400 4200 2650 7950 3980 11940 1530 4590
300 2500 1180 3540 2090 6270 3900 11700 5850 17550 2280 6840
360 2150 1940 5820 3450 10350 6500 19500 9700 29100 3760 11280
400 1900 2670 8010 4750 14250 8900 26700 13350 40050 5180 15540
- Pb72 = buffer ring of - 72 Shore(A) / black
- Pb82 = buffer ring of - 82 Shore(A) / black
- VkR = buffer ring of Polyurethane / red
- Vk60D = buffer ring of Polyurethane / white-beige
- VkB = buffer ring of Polyurethane / blue
Bild / Fig. 2 TSCHAN-S SD-5

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Size
SD-5
d1
max
[mm]
d2
max
[mm]
D1
[mm]
D2
[mm]
D3
[mm]
L
[mm]
L1
[mm]
l1
[mm]
l2
[mm]
S
[mm]
S1
[mm]
z x M x Ls m
unbored
[kg]
100 42 45 105 65 65 137,5 39,0 37,5 49,0 3,0 7,0 9 x M 8 x 20 4,7
125 55 53 / 55 126 75 75 / 80 157,5 45,0 44,0 56,0 3,5 7,0 9 x M10 x 25 7,9 / 8,1
145 65 60 / 65 145 85 85 / 92 174,5 53,0 47,5 60,5 4,0 7,0 9 x M12 x 30 11,2 / 11,9
170 85 75 170 110 110 203,5 54,0 60,5 74,5 5,0 7,0 12 x M12 x 30 18,9
200 95 95 200 135 135 259,5 62,0 79,5 98,5 6,0 8,5 12 x M14 x 30 33,0
230 105 110 230 160 160 285,5 65,5 88,5 110,0 7,0 10,0 15 x M14 x 35 47,9
260 125 125 260 180 180 303,0 78,0 88,5 112,5 7,0 11,5 15 x M16 x 40 67,1
300 140 140 300 200 200 353,0 90,0 107,5 131,5 7,0 11,5 15 x M20 x 50 100,0
360 150 160 360 225 225 443,0 99,0 140,0 172,0 8,0 11,5 12 x M24 x 55 162,6
400 160 160 400 225 225 434,5 99,0 137,0 172,0 7,5 11,5 14 x M24 x 55 178,6
The torques TKnom and TKmax. are valid for:
- Ambient temperatures of –30°C up to +30°C for Polyurethane (Vk),
- Ambient temperatures of -30°C up to + 60°C for Perbunan (Pb)
- Operation within the range of the specified alignment values.
For determining the size of the coupling according to DIN 740, part 2, (or to catalogue
TSCHAN®-S) various factors have to be taken into account:
- the temperature factor Sυin case of higher temperatures,
- the start-up factor Sz depending on the frequency of starts,
- the shock factor SA, SLdepending on the service conditions.
For circumferential speeds above 22 m/s, referred to the nominal size of the coupling, we
recommend balancing the steel parts of the coupling.

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7 Installation
7.1 To be observed prior to installation
• Danger of injuries!
• Disconnect the drive before carrying out any work on the coupling!
• Secure the drive against unintentional re-start and rotation!
• Incorrectly tightened bolts can cause serious personal injuries and
property damages!
• Assemble the coupling outside of the danger zone. Take care that
suitable transportation means are at disposal and that the transpor-
tation ways are free of obstacles.
• In compliance with accident prevention regulations, you are
obliged to protect all freely rotating parts by means of permanently
installed guards/ covers against unintentional contact and falling
down objects.
• To avoid sparks, the covers for couplings used should be made of
stainless steel!
• As a minimum, the covers have to fulfil the requirements of protec-
tion type IP2X.
• The covers have to be designed to prevent dust from depositing on
the coupling.
• The cover must not contact the coupling or impair the proper
function of the coupling.
• Make sure that the speeds, torques and ambient temperatures as stated in chapter 6
‘Technical Data’ are not exceeded.
• The maximum permissible bore diameters must not be exceeded.
• Check whether the shaft-hub connections safely transmit the occurring operating torques.
• The standard tolerance of TSCHAN for finish bores is fit H7.
• Standard keyways comply with DIN 6885, sheet 1.
• Check the dimensions and tolerances of shafts, hub bores, keys and keyways.
• Set screws as required.

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7.2 Finish Bores
The following procedure has to be observed to produce a finish bore in a coupling hub/flange
hub:
• Clean and remove all preservatives from the coupling hub and flange hub.
• Mount the coupling hub and flange hub in between the surfaces marked with éand
carefully align the coupling hub to the claw pattern and the flange hub to the outer diame-
ter.
• The values for ød1max and ød2max listed in table 1 are valid for keyed connections accord-
ing to DIN 6885/1 and must not be exceeded.
• Select the bore fit so that an interference fit such as H7/m6 results when mating it with the
shaft tolerance.
• Axially lock the hub, for example by means of a setscrew on the back of the hub above
the keyway
Consult TSCHAN GmbH in case of other shaft-hub connections.
• The stated maximum bore diameters are valid for keyed connec-
tions according to DIN 6885/1 and must not be exceeded.
• If these values are exceeded, the coupling can break.
• Flying off coupling fragments are a danger to life!

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Fig. 4
Fig. 3
7.3 Coupling Installation
• Remove the elastic buffer ring (Fig.
3, pos. 1).
• Prior to installation, carefully clean
the bores of the coupling hub, flange
hub, and the shaft ends. The sur-
faces must be clean, dry and free of
grease.
• For larger couplings use suitable
mounting tools and hoisting devices
such as cranes or pulley blocks.
• Mount the coupling hub and the
flange hub complete with claw ring
attached in the proper position on
the shaft ends (Fig. 3, pos.2).
Note:
To facilitate mounting, the hubs can be uniformly heated to 80°C to 120°C.
§ Warning!
§ Always wear heat-resistant gloves to protect yourself against
injuries due to hot coupling components!
• Mount the hub in such a manner that
the shaft end is flush with the inner
bore opening (Fig. 4).
Observe deviant agreements, which
may exist!!
• When tightening setscrews, secure
them with an adhesive, such as e.g.
Loctite 222, to prevent the screws
from working loose and dropping out.