Rexnord XG Series, Installation And Maintenance Instructions Manual

Page 1: ...ety 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 1...

Page 2: ... 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 alternati...

Page 3: ...ness 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 co...

Page 4: ...miter 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 ...

Page 5: ...togard 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 ...

Page 6: ...hone 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 d h T ...

Page 7: ... 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 ...

Page 8: ...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 cov...

Page 9: ...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 d h T ...

Page 10: ... 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 ...

Page 11: ...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 ...

Page 12: ...01 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 d h T ...

Page 13: ...cester 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 ...

Page 14: ...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 Re...

Page 15: ... 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 ...

Page 16: ...X0001 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 ...

Page 17: ...elephone 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 ...

Page 18: ... 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...

Page 19: ...ne 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 d h T ...

Page 20: ...cester 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 d h T ...

Page 21: ...ine Rectify Torque setting too low Adjust trip torque within safe limits for driving and driven equipment All modules not reset Reset all modules Worn module plungers or seats Replace modules Failure to trip on overload Torque setting too high Adjust trip torque Module seized Replace module Torque limiter bearing seized Replace bearing Excessive backlash Modules loose or incorrectly fitted Follow ...