TSCHAN TORMAX VSG User manual

TSCHAN GmbH Zweibruecker Strasse 104 D-66538 Neunkirchen-Saar
Telephone: [phone] Telefax: [phone] www.tschan.de
BAWE 009-GBR-0
05/2004
Installation and Operation Manual TSCHAN
®
Highly flexible shaft coupling
TSCHAN®- TORMAX VSG

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-TORMAX VSG - 2 -
Contents
Chapter Page
1Safety Instructions............................................................................................................2
2Function............................................................................................................................3
2.1 Designated use............................................................................................................3
3Storage.............................................................................................................................3
4 Construction .....................................................................................................................4
5Assembly..........................................................................................................................5
5.1 Before assembly..........................................................................................................5
6Operation..........................................................................................................................6
7Maintenance.....................................................................................................................8
7.1 Inspection and servicing intervals................................................................................8
7.2 Replacing the rubber element......................................................................................9
8Disposal............................................................................................................................9
1 Safety Instructions
These assembly and operating instructions form part of the coupling schedule. Always keep
these assembly and operating instructions easily accessible near the coupling.
Please ensure that all persons authorised to assemble, operate, maintain and repair the
product have read and understood the assembly and operating instructions and observe
them in all points in order to:
- Avoid hazards to life and limb of operating personnel or third-parties.
- Guarantee the operational safety of the coupling.
- Eradicate stand-still time and environmental hazards caused by improper handling.
During transport, assembly, dismantling and maintenance, the relevant health and safety
regulations and environmental protection regulations must be observed.
Ensure that suitable means of transport are available.
The coupling may only be operated, assembled, maintained and repaired by authorised,
trained personnel.
In the interests of progress, we reserve the right to carry out technical modifications.
TSCHAN GmbH accepts no responsibility of any kind for damage arising from the use of
non-original accessories and spare parts.

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2 Function
The TSCHAN
®
TORMAX VSG Coupling is a highly flexible shaft coupling for use in drive
trains between the combustion engine and the cardan shaft . When correctly dimensioned, it
reduces dynamic stresses on the drive train caused by torsional vibrations.
The axial prestressing of the elastic coupling element enables play-free transmission of axial
forces in tension and compression.
Forced ventilation guarantees good heat dissipation and the high degree of coupling damping
results in small resonance peaks.
2.1 Designated use
• In order to guarantee fault-free, enduring operating of the coupling, it must be dimen-
sioned in accordance with dimensioning regulations, e.g. pursuant to DIN 740, Part 2 (or
TSCHAN

TORMAX Catalogue), with an application factor appropriate to the respective
operating conditions.
• The coupling can be used at ambient temperatures of 60 °C, or up to a maximum of
90 °C, taking the appropriate temperature factors into consideration.
• The standard model can compensate for cardan shaft angles of up to 13°.
• The coupling may only be used and operated under the conditions specified in the service
and supply agreement.
• Any change in operating conditions or parameters makes a renewed examination of the
coupling dimensioning necessary.
3 Storage
All goods should be inspected for completeness upon receipt. Any transport damage and / or
missing components must be notified in writing.
In delivery condition, the coupling can be stored for up to six months in a dry, roofed location
at normal room temperature. Long-term preservation is necessary for longer storage periods
(please contact TSCHAN GmbH). The flexible coupling element may not be subjected to
ozonic media, direct sunlight or strong light sources containing ultra-violet light. Relative
humidity should not exceed 65%. If correctly stored the elastic properties of the coupling
element remain practically unchanged for up to three years.

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-TORMAX VSG - 4 -
4 Construction
1 Coupling flange Part 627
2 Flexible coupling element Part WE01
3 Connecting flange Part 628
4 Bearing flange Part 629
5 Bearing ring Part 592
6 Friction disk Part 591
7 Cheese head screw DIN 912
Note:
The coupling is delivered fully assembled.
Fig. 1 Section through the TORMAX VSG

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5 Assembly
5.1 Before assembly
• Injury hazard!
• Switch off the drive before commencing any work on the coupling!
• Secure the drive against accidental activation and rotation!
• Incorrectly tightened screws can lead to serious personal injury
and material damage!
• Assemble outside of the danger zone. Ensure that suitable means
of transport are available and that transport routes are free of ob-
stacles.
•
In accordance with health and safety regulations, all rotating parts
must be protected against accidental contac
t and against falling
parts by fixed protective installations.
• To avoid sparks, use stainless steel covers!
•
As a minimum requirement, the covers must comply with the IP2X
protective system.
• The covers should be designed such that no dust can settle on th
e
coupling.
• The cover may not contact the coupling and hinder its correct
functioning in any way.
Clean all coupling components before assembly. Do not use petrol, paraffin or oil to clean the
rubber element. The connecting surfaces of the flange must be clean, dry and free of grease.
Place the coupling with the coupling flange (Figure 1, Item 1) in the centre of the flywheel on
the combustion engine. Take care that the components do not cant. Tighten the fastening
screws uniformly.
Connect the cardan shaft to the connecting flange (Figure 1, Item 3).

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6 Operation
The coupling parameters must be observed (TSCHAN TORMAX

Catalogue). These may
not be exceeded except with written permission from TSCHAN GmbH.
In order to guarantee fault-free, enduring operating of the coupling, it must be dimensioned in
accordance with dimensioning regulations, e.g. pursuant to DIN 740, Part 2 (or TSCHAN
TORMAX

Catalogue), with an application factor appropriate to the respective operating
conditions.
Any change in operating conditions or parameters makes an examination of the coupling
dimensioning necessary.
 Injury hazard!
 Switch off the drive before commencing any work on the coupling!
 Secure the drive against accidental activation and rotation!

Incorrectly tightened screws can lead to parts flying off and serious
personal injury and material damage!
 Before commissioning the coupling, check the alignment and all
screw connections for the prescribed torque and tightness of fit!
 Before commissioning the equipment, all devices for protection
against accidental contact with moving or rotating parts must be
installed.
 To avoid sparks, use stainless steel covers!
 As a minimum, the covers must comply with the IP2X protective
system.
 The covers should be designed such that no dust can settle on the
coupling components.
 The cover may not contact the coupling and hinder its correct
functioning in any way.
When the coupling is operating please monitor:
 Changes in running noises
 Vibrations
 Missing components
Attention!
• If you notice any irregularities while the coupling is operating, switch off the drive
immediately.
• Using Table 1, “Operating faults and their possible causes”, below, find the cause of the
fault and remedy it.
The faults listed are only a few examples to help you troubleshooting.
• All machine components and operating conditions must be taken into
consideration for fault-finding and remedy!

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Table 1 Operating faults and their possible causes:
Fault Cause Hazard Remedy
Rubber
element
worn
Torsional limiting
devices strike
each other.
Sparks, increased
reaction forces.
- Switch off drive
- Examine coupling components for
damage, replace if necessary
- Replace rubber element
Imbalance Increases reaction
forces on coupled
equipment.
- Switch off drive
- Check balance on system
components and correct if
necessary
Irregular
running
noises/vibrati
ons
Loose
screw
connection
s
Flying
components can
cause serious
damage.
- Switch off drive
- Examine coupling components for
damage, replace if necessary
- Tighten screws with the prescribed
torque and secure against loosening
where necessary
Impermissi
ble
temperatur
es
Material
properties of
rubber element
are altered. The
transmission
properties are
impaired.
- Switch off drive
- Replace rubber element
- Regulate ambient temperature
Contact
with
aggressive
media
Material
properties of
rubber element
are altered. The
transmission
properties are
impaired.
- Switch off drive
- Examine coupling components and
rubber element for damage, replace
if necessary
- Avoid contact with aggressive media
Premature
wear of the
rubber
element
Overstressi
ng due to
excessive
torque
Coupling is
destroyed. May
also be
detrimental to
connected
equipment.
- Switch off drive
- Examine coupling dimensioning in
cooperation with TSCHAN GmbH
- Replace coupling
- Use a larger coupling where
necessary

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7 Maintenance
The flexible TSCHAN
®
TORMAX VSG coupling is maintenance free when operating.
During routine equipment monitoring examine:
• The condition of the rubber element
• Tight fit of all screws
• Remove dust deposits from the coupling components and the coupling element
7.1 Inspection and servicing intervals
 Injury hazard!
 Switch off the drive before commencing any work on the coupling!
 Secure the drive against accidental activation and rotation!
Adhere to the inspection and servicing intervals given in Table 2. If damage
to the coupling is noted on the initial inspection, in particular to the rubber
element, check if one of the causes given in Table 1 “Operating faults” may
be responsible. The inspection intervals should then be adjusted to suit the
governing operating conditions. Under special operating conditions, inspec-
tion and servicing work may also be necessary at shorter intervals.
Table 2 Inspection and servicing intervals
Industry
1. Inspection After 4 weeks Visual inspection
1. Service After 6 months Visual inspection
2. Service After 12 months Visual inspection and remove dust from coupling
components
Each further
inspection Every 12 months Visual inspection and remove dust from coupling components
Mining
1. Inspection After 4 weeks Visual inspection
1. Service After 6 months Visual inspection
2. Service After 6 months Visual inspection and remove dust from coupling
components
Each further
inspection Every 6 months Visual inspection and remove dust from coupling components

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7.2 Replacing the rubber element
 Injury hazard!
 Switch off the drive before commencing any work on the coupling!
 Secure the drive against accidental activation and rotation!
• To replace the rubber element the coupling must be completely removed.
• Lay the coupling flat on the bearing flange (Figure 1, Item 4) and remove the hexagon
socket screws (Figure 1, Item 7).
• Dismantle the coupling and clean all coupling components.
• Examine the coupling components
for wear or damage.
• When replacing the rubber element
(Figure 1, Item 2), we recommend
you also replace the friction disk
and bearing ring (Figure 1, Items 5
and 6).
• Reassemble the coupling compo-
nents with the new rubber element.
• Please observe the correct relative
positioning of the torsional limiting
device stops in the coupling flange
and the bearing flange.
• Gradually and uniformly tighten the
hexagon socket screws (Figure 1,
Item 7) in the correct order, until
reaching the torque T An given in Table 3.
Table 3 Cheese head screw torques:
VSG 6 8 10 16 22
DIN 912 - 10.9 M8 M8 M12 M12 M12
T
An
(Nm) 36 36 125 125 125
8 Disposal
Disposal is in accordance with the specific regulations of the respective country in which the
equipment is used.
Bild / Fig. 2 Lage der Durchdrehsicherung