Installation and Operational Instructions for
CAUTION
Danger of injury to personnel and
damage to machines.
Please Observe!
Guidelines on important points.
Safety Regulations
These Installation and Operational Instructions (I + O) are part of the clutch delivery.
Please keep them handy and near to the clutch at all times.
It is forbidden to start use of the product until you have ensured that all applicable EU directives and directives for the
machine or system into which the product has been installed have been fulfilled.
At the time these Installation and Operational Instructions go to print, the EAS®-smartic® clutches accord with the known
technical specifications and are operationally safe at the time of delivery.
Without a conformity evaluation, this product is not suitable for use in areas where there is a high danger of explosion.
This statement is based on the ATEX directive.
CAUTION
If the EAS®-smartic® clutches are modified.
If the relevant standards for safety and / or installation conditions are ignored.
User-implemented Protective Measures
Cover all moving parts to protect against seizure, dust or foreign body impact.
The clutch may not be put into operation without a limit switch unless mayr ® has been contacted and has agreed
otherwise.
To prevent injury or damage, only professionals and specialists should work on the devices, following the
relevant standards and directives. Please read the Installation and Operational Instructions carefully before
installation and initial operation of the device.
These Safety Regulations are user hints only and may not be complete!
EAS®-smartic
®
synchronous clutch Type 48_._ _5._
Sizes 01 – 2 (B.4.17.1.GB)
Please read these Operational Instructions carefully and follow them accordingly!
Ignoring these Instructions may lead to malfunctions or to clutch failure, resulting in damage to other parts.
Contents:
Page 1: - Contents
- Safety and Guideline Signs
- Safety Regulations
Page 2: - Illustrations Type 481._ _5._
- Illustrations Type 484._ _5._
Page 3: - Illustrations Type 486._ _5._
Page 4: - Parts List
Page 5: - Table 1: Technical Data
Page 6: - Table 2: Screws Overview
Page 7: - Design
- State of Delivery
- Function
- Installation of the Output Elements
Page 8: - Mounting onto the Shaft on Type 481
Page 9: - Mounting onto the Shaft on Type 484
Page 10: - Mounting onto the Shaft on Type 486
Page 11: - Permitted Shaft Misalignments
- Shaft Alignment
Page 12: - Torque Adjustment
- Cup Spring Layering
- Changing the Torque
- Table 3: Cup Spring Layering and
Torque Ranges
Page 13: - Changing the Torque Adjustment Range
by Changing the Cup Spring Layering
Page 14: - Limit Switch Installation
- Maintenance
- Disposal
Page 15: - General Malfunctions / Breakdowns
Page 16: - Malfunctions / Breakdowns Type 484.
Page 17: - Malfunctions / Breakdowns Type 484.
Page 18: - Malfunctions / Breakdowns Type 486.
Safety and Guideline Signs
25/11/2011 TK/NU/SU Chr. Mayr GmbH + Co. KG Tel.: +49 8341 804-0
Eichenstraße 1 Fax: +49 8341 804-421
D-87665 Mauerstetten http://www.mayr.com
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Installation and Operational Instructions for
15 14 13
17
16/16.1
23
24
Item 18 (contactless limit switch)
8 87 73 39 912 1210 105
22
21
20
1.2
19
6
1/1.1
2
11
11
44 4 Item 18
EAS®-smartic
®
synchronous clutch Type 48_._ _5._
Sizes 01 – 2 (B.4.17.1.GB)
Type 481._ _ _._
Clamping ring hub with and without keyway Hub key design
Fig. 1
Type 484._ _ _._
Clamping hub Clamping ring hub
with and without with and without
keyway keyway
Hub Hub
key key
design design
Fig. 2
25/11/2011 TK/NU/SU Chr. Mayr GmbH + Co. KG Tel.: +49 8341 804-0
Eichenstraße 1 Fax: +49 8341 804-421
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28
27
27
27
37
31
30
30
30
29
31
26
263825
30 3827
38
25
32/32.1
35
33
33
34
36/36.1
29
29
40
29
39
Installation and Operational Instructions for
EAS®-smartic
®
synchronous clutch Type 48_._ _5._
Sizes 01 – 2 (B.4.17.1.GB)
Type 486._ _ _._
Clamping hub
with and without
keyway Single-jointed
Size 2 design
Hub
key
design
Size 2
Clamping ring hub
with and without
keyway
Hub large Double-jointed
keyway design
design
Size 2
Flange
Size 2
Single-jointed
design
Hub
key design
Clamping hub
with and without
keyway
Sizes 01 to 1
Double-jointed
design
Fig. 3
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Eichenstraße 1 Fax: +49 8341 804-421
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Installation and Operational Instructions for
Item
Name
Item
Name
1
Clamping ring hub
20
Adjusting nut (for key design)
1.1
Clamping ring hub with keyway
21
Locking ring (for key design)
1.2
Clamping ring
22
Hexagon head screw (for key design)
1.3
Spring pin (Fig. 15 / page 13)
23
Hub Type 484. (key design)
2
Cap screw
24
Set screw
3
Pressure flange
25
Connection flange Type 486.
4
Thrust washer
26
Cap screw
5
Adjusting nut (for clamping ring hub design)
27
Screw
6
Hexagon head screw (for clamping ring hub design)
28
Hexagon head screw
7
Deep groove ball bearing
29
Hexagon nut
8
Locking ring
30
Disk pack assembly
9
Steel ball
31
Connection plate
10
Cup spring (layering dependent on Type)
32
Clamping hub Type 486. (Size 2)
11
Adjustment Table
32.1
Clamping hub Type 486. with keyway (Size 2)
12
Type tag
33
Cap screw
13
Connection flange Type 484.
34
Hub Type 486. (key design / Size 2)
14
Cap screw
35
Set screw
15
Flexible elastomeric element
36
Clamping hub Type 486. (Sizes 01 to 1)
16
Clamping hub Type 484.
36.1
Clamping hub Type 486. with keyway (Sizes 01 to 1)
16.1
Clamping hub Type 484. with keyway
37
Cap screw
17
Cap screw
38
Screw
18
Limit switch
39
Hub, large (key design)
19
Hub (key design)
40
Flange
The limit switch Item 18 is not included in the
standard delivery.
EAS®-smartic
®
synchronous clutch Type 48_._ _5._
Sizes 01 – 2 (B.4.17.1.GB)
Parts List (Only use mayr
original parts)
25/11/2011 TK/NU/SU Chr. Mayr GmbH + Co. KG Tel.: +49 8341 804-0
Eichenstraße 1 Fax: +49 8341 804-421
D-87665 Mauerstetten http://www.mayr.com
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Installation and Operational Instructions for
Size
01 0 1
2
Thread in the pressure flange (Item 3)
8 x M4
8 x M4
8 x M5
8 x M6
Max. screw-in depth b
max
in the pressure flange (Item 3) [mm]
6
6,5 7 9,5
Connection dimension "a" +0,1 [mm]
2,5
2,5
2,5
3
Connection dimension "e" [mm]
42 h5
52 h5
65 h5
78 h5
Tightening torque (Item 2) [Nm]
40
40
83
140
Tightening torque (Item 14) 1) [Nm]
4
4,5 9 16
Tightening torque (Item 17) [Nm]
Types 484.2_5._ to 484.7_5._
10 25 25 120
Type 484.8_5._
17
40
40
140
Tightening torque (Item 26) 1) [Nm]
4
4,5 9 16
Tightening torque (Items 27 / 28 / 38) [Nm]
8,5
8,5
8,5
8,5
Tightening torque (Item 33) [Nm]
13
33
33
42
Tightening torque (35) up to bore Ø 22 [Nm]
more than bore Ø 22 [Nm]
2
4,1
Tightening torque (37) [Nm]
8,5
8,5
8,5
-
Axial forces [N]
400
500
800
1200
Radial forces [N]
400
500
800
1200
Transverse force torques 2) [Nm]
3 5 10
15
Distance dimension "E" (see Figs. 5 and 6) [mm]
18
20
24
28
Distance dimension "U1" (see Figs. 7 and 8) [mm]
14,7
15,5
15,8
26,4
Distance dimension "S" (see Fig. 9) [mm]
2,6 3 2,9
7,2
Permitted shaft misalignments Type 484._ _ 5._
Radial misalignment ΔK
r
92 Sh A [mm]
98 Sh A [mm]
0,14
0,10
0,15
0,11
0,17
0,12
0,21
0,16
Axial displacement ΔKa [mm]
1,4
1,5
1,8
2,1
Angular misalignment ΔKw 92 Sh A [°]
98 Sh A [°]
1,0
0,9
1,0
0,9
1,0
0,9
1,0
0,9
Permitted shaft misalignments Type 486._ _ 5.0 (Double-jointed coupling)
Radial misalignment ΔKr [mm]
0,15
0,2
0,2
0,3
Axial displacement ΔKa [mm]
0,7
0,9
1,1
1,3
Angular misalignment ΔKw [°]
2,0
2,0
2,0
2,0
Permitted shaft misalignments Type 486._ _ 5.8 (Single-jointed coupling)
Radial misalignment ΔK
r
[mm]
- - -
-
Axial displacement ΔKa [mm]
0,35
0,45
0,55
0,65
Angular misalignment ΔKw [°]
1,0
1,0
1,0
1,0
EAS®-smartic
®
synchronous clutch Type 48_._ _5._
Sizes 01 – 2 (B.4.17.1.GB)
Table 1: Technical Data
1)
Secure Items 14 and 26 wit Loctite 243.
2)
Torques, which put strain on the deep groove ball bearing due to the non-centric axial forces having an effect on the pressure flange.
25/11/2011 TK/NU/SU Chr. Mayr GmbH + Co. KG Tel.: +49 8341 804-0
Eichenstraße 1 Fax: +49 8341 804-421
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Installation and Operational Instructions for
Item
Design
Size 01
Size 0
Size 1
Size 2
2
with hub
Items 1 / 1.1
1x cap screw
M8 x 25
DIN EN ISO 4762
12.9
1x cap screw
M8 x 25
DIN EN ISO 4762
12.9
1x cap screw
M10 x 30
DIN EN ISO 4762
12.9
1x cap screw
M12 x 35
DIN EN ISO 4762
12.9
6
with hub
Items 1 / 1.1
1x hexagon head screw
M4 x 24,2 SO
(DIN EN ISO 4014)
8.8
1x hexagon head screw
M4 x 24,2 SO
(DIN EN ISO 4014)
8.8
1x hexagon head screw
M5 x 28 SO
(DIN EN ISO 4014)
8.8
1x hexagon head screw
M6 x 31,5 SO
(DIN EN ISO 4014)
8.8
14
Type
484._ _5._
8x cap screw
M4 x 16
DIN EN ISO 4762
12.9
8x cap screw
M4 x 16
DIN EN ISO 4762
12.9
8x cap screw
M5 x 18
DIN EN ISO 4762
12.9
8x cap screw
M6 x 22
DIN EN ISO 4762
12.9
17
with hub
Items 16 / 16.1
1x cap screw
M6 x 20
DIN EN ISO 4762
8.8
1x cap screw
M8 x 25
DIN EN ISO 4762
8.8
1x cap screw
M8 x 30
DIN EN ISO 4762
8.8
1x cap screw
M12 x 35
DIN EN ISO 4762
12.9
22
with hub
Item 19
1x hexagon head screw
M3 x 8
DIN EN ISO 4017
8.8
1x hexagon head screw
M4 x 10
DIN EN ISO 4017
8.8
1x hexagon head screw
M5 x 10
DIN EN ISO 4017
8.8
1x hexagon head screw
M5 x 12
DIN EN ISO 4017
8.8
26
Type
486._ _5._
4x cap screw
M4 x 16
DIN EN ISO 4762
12.9
8x cap screw
M4 x 16
DIN EN ISO 4762
12.9
6x cap screw
M5 x 20
DIN EN ISO 4762
12.9
6x cap screw
M6 x 20
DIN EN ISO 4762
12.9
27
with hub
Items 32 / 32.1 / 34 /
36 / 36.1 on
double-jointed design
2x cap screw
M5 x 16
DIN EN ISO 4762
10.9
2x cap screw
M5 x 18
DIN EN ISO 4762
12.9
3x cap screw
M5 x 20
DIN EN ISO 4762
12.9
3x cap screw
M5 x 20
DIN EN ISO 4017
10.9
with hub
Items 32 / 32.1 / 34 /
36 / 36.1 on
single-jointed design
2x cap screw
M5 x 16
DIN EN ISO 4762
10.9
2x cap screw
M5 x 18
DIN EN ISO 4762
12.9
3x hexagon head screw
M5 x 16
DIN EN ISO 4017
10.9
3x cap screw
M5 x 20
DIN EN ISO 4017
10.9
with hub
Item 39
- - -
- - -
- - -
3x hexagon head screw
M5 x 50
DIN EN ISO 4014
10.9
with flange
Item 40
- - -
- - -
- - -
3x hexagon head screw
M5 x 23
DIN EN ISO 4017
10.9
28
Type
486._ _5.0
- - -
- - -
- - -
3x hexagon head screw
M5 x 35
DIN EN ISO 4014
10.9
33
with hub
Items 32 / 32.1 /
36 / 36.1
1x cap screw
M6 x 20
DIN EN ISO 4762
12.9
1x cap screw
M8 x 25
DIN EN ISO 4762
12.9
1x cap screw
M8 x 30
DIN EN ISO 4762
12.9
2x cap screw
M8 x 25
DIN EN ISO 4762
12.9
37
Type
486._ _5.0
4x cap screw
M5 x 16
DIN EN ISO 4762
10.9
4x cap screw
M5 x 16
DIN EN ISO 4762
12.9
3x hexagon head screw
M5 x 16
DIN EN ISO 4017
10.9
+
3x cap screw
M5 x 16
DIN EN ISO 4762
12.9
- - -
38
Type
486._ _5._
2x cap screw
M5 x 16
DIN EN ISO 4762
10.9
2x cap screw
M5 x 18
DIN EN ISO 4762
12.9
3x cap screw
M5 x 16
DIN EN ISO 4762
12.9
3x hexagon head screw
M5 x 23
DIN EN ISO 4017
10.9
EAS®-smartic
®
synchronous clutch Type 48_._ _5._
Sizes 01 – 2 (B.4.17.1.GB)
Table 2: Screws Overview (dependent on Type or hub connection)
25/11/2011 TK/NU/SU Chr. Mayr GmbH + Co. KG Tel.: +49 8341 804-0
Eichenstraße 1 Fax: +49 8341 804-421
D-87665 Mauerstetten http://www.mayr.com
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