Sabroe AMR Tpack Installation guide

Brand
Sabroe
Model
AMR Tpack
Type
Installation guide
Mounting instruction 23 October 2012
Mounting instruction
009980 (replaces 0179-053 - same content as original release from 2007)
Installation and maintenance instructions for AMR TPackTM
ATEX: In order for this coupling to meet the ATEX requirements, it is mandatory to pre-
cisely follow these installation instructions along with the included supplement form
0005-08-49-01 (on yellow paper). This supplement outlines the ATEX requirements. If the
operator does not adhere to these instructions, conformity is immediately invalidated.
Warning!
Because of the possible danger to person(s) or property from accidents which may result from improper use or
installations of products, it is extremely important to follow the proper selection, installation, maintenance and op-
erational procedures.
• All rotating power transmission products are potentially dangerous and can cause serious injury. They
must be properly guarded in compliance with OSHA, ANSI, and any other local or governmental stand-
ards for the speeds and applications in which they are used. It is the responsibility of the user to provide
proper guarding.
• For ATEX requirements the guard must have a minimum of 12.7 mm (½ inch) radial clearance to the cou-
pling major diameter “A” (see Fig. 1 to Fig. 4) and be of the open mesh design.
Johnson Controls Denmark ApS
Christian X's Vej 201 ∙ 8270 Højbjerg ∙ Denmark
Phone +45 87 36 70 00 ∙ Fax +45 87 36 70 05 ∙ www.sabroe.com
CVR No 19 05 61 71
Page 1 of 8
Fig. 1 Fig. 2
Fig. 3 Fig. 4
I. Purpose
These instructions are intended to help you install, align, and maintain your THOMAS ® coupling.
II. Scope
Covered here will be general information, hub mounting, alignment, assembly, locknut torque, disc pack replace-
ment and part numbers.
III. General information
The coupling, as received, may or may not be assembled. If assembled, the locknuts are not fully tightened. Ex-
amine the parts to assure that there is no visible damage. If coupling is assembled, remove the bolts, locknuts and
washers that attach the hub(s) to the disc packs. Remove the hub(s). Leave the disc packs attached to the centre
ring and the flywheel adapter (when used).
IV. Hub mounting
A. General
Clean the hub bores and shafts. Remove any nicks or burrs. If the bore is tapered, check for good contact pattern.
If the bore is straight, measure the bore and shaft diameters to assure proper fit. The key(s) should have a snug
side-to-side fit with a small clearance over the top and the corners must be chamfered.
Johnson Controls Denmark ApS
Christian X's Vej 201 ∙ 8270 Højbjerg ∙ Denmark
Phone +45 87 36 70 00 ∙ Fax +45 87 36 70 05 ∙ www.sabroe.com
CVR No 19 05 61 71
Page 2 of 8
B. Straight bore
Install the key(s) in the shaft. If the hub is an interference fit, heat the hub in an oil bath or oven until the bore is
sufficiently larger than the shaft. 175°C (350°F) is usually sufficient. An open flame is not recommended. However,
if flame heating is necessary use a very large rose bud tip to give even heat distribution. A thermal heat stick will
help determine the hub temperature. DO NOT SPOT HEAT THE HUB OR DISTORTION MAY OCCUR. With the
hub expanded, slide it quickly up the shaft to the desired axial position. A pre-set axial stop device can be helpful.
C. Straight bore slip fit
Install the key(s) in the shaft. Install the set screw(s) in the hub making sure they do not protrude into the keyway
or the bore. Now slide the hub up the shaft to the desired axial position. Tighten the set screw(s) which hold the
hub in place using a torque wrench to the values shown in Table 2.
Note: Never use two set screws with one on top of the other.
D. Taper bore
Put the hub on the shaft without the key(s) in place. Lightly tap the hub on the shaft with a soft hammer. This will
assure a metal-to-metal fit between shaft and hub. This is the starting point for the axial draw. Record the position
between shaft end and hub face with a depth micrometer. Mount a dial indicator to read axial hub movement. Set
the indicator to "0". Remove the hub and install the key(s). Heat the hub in an oil bath or oven until the bore is
sufficiently larger than the shaft. 175°C (350°F) is usually sufficient. An open flame is not recommended. However,
if flame heating is necessary, use a very large rose bud tip to give even heat distribution. A thermal heat stick will
help determine the hub temperature.
DO NOT SPOT HEAT THE HUB OR DISTORTION MAY OCCUR. With the hub expanded, slide it quickly up the
shaft to the "0" set point. Continue to advance the hub up the taper to the desired axial position. Use the indicator
as a guide only. A pre-set axial stop device can be helpful. Check the final results with a depth micrometer. Install
the hub retention device to hold the hub in place.
E. Hub with shrink element
1. Supply mode
Hubs are supplied in greased condition.
2. Inspection
Check dimensional tolerances of shaft and hub bore. Make sure that mating surface are undamaged and free from
burrs.
Johnson Controls Denmark ApS
Christian X's Vej 201 ∙ 8270 Højbjerg ∙ Denmark
Phone +45 87 36 70 00 ∙ Fax +45 87 36 70 05 ∙ www.sabroe.com
CVR No 19 05 61 71
Page 3 of 8
3. Assembly
Caution!
Never tighten clamping bolts before hub is positioned on the shaft.
Degrease the shaft and hub bore first. Remaining grease at the mating surface, especially molybdenum disulphide
materials could limit the torque transmission ability.
Apply a thin coat of MoS2 lubricant on taper hub.
After placing the hub onto the shaft, slide it to its final position. Axial clamping screws will then be tightened one
after the other using a torque wrench only in clockwise or anti-clockwise direction of the circumference with a step-
wise increasing torque. Start with 20% of the nominal torque specified in Table 3 until all bolts are tightened with
20%. This procedure is to be repeated with 40%, etc.
The tightening procedure is completed when all bolts reach their nominal torque as specified in Table 3.
F. Split hub
Install the key(s) in the shaft. Install the 2 radial tightening bolts in the hub making sure they remain slack. Now
slide the hub up the shaft to the desired axial position. Tighten the radial bolts that hold the hub in place, using a
torque wrench, to the values shown in Table 4.
V. Shaft alignment: Move equipment into place
A. Soft foot
The equipment must sit flat on its base. Any soft foot must now be corrected.
B. Axial spacing
The axial spacing of the shafts should be positioned so that the disc packs (flexing elements) are flat when the
equipment is running under normal operating conditions. This means there is a minimal amount of waviness in the
disc pack when viewed from the side. This will result in a flexing element that is centred and parallel to its mating
flange faces. Move the connected equipment to accomplish the above. Refer to the assembly drawing and the
connected equipment installation procedures for specific axial spacing requirements.
Note: The disc pack is designed to an optimal thickness and is not to be used for axial adjustments by removing or
adding individual discs. As a guideline, maximum and minimum values for dimension “C" are given. These dimen-
sions are suggested for initial installation. Additional capacity is available to compensate for thermal and structural
movement. Maximum axial capacity values for these couplings are also given. See Table 1 and Fig. 1 to Fig. 4.
Johnson Controls Denmark ApS
Christian X's Vej 201 ∙ 8270 Højbjerg ∙ Denmark
Phone +45 87 36 70 00 ∙ Fax +45 87 36 70 05 ∙ www.sabroe.com
CVR No 19 05 61 71
Page 4 of 8
C. Alignment
Laser alignment is an option. [If not available proceed with dial indicator method.]
1. Angular alignment
Rigidly mount a dial indicator on one hub or shaft, reading the face of the other hub flange, as shown in Fig. 5.
Rotate both shafts together making sure the shaft axial spacing remains constant. Adjust the equipment by shim-
ming and/or moving so that the indicator reading is as per Chart A.
2. Parallel offset
Rigidly mount a dial indicator on one hub or shaft, reading the other hub flange outside diameter, as shown in
Fig. 6. Compensate for indicator set-up sag. Rotate both shafts together. Adjust the equipment by shimming
and/or moving so that the indicator reading is within Chart A values.
Note: If the driver or driven equipment alignment tolerances are more stringent than our recommendations, the
driver or driven equipment tolerances should be used. Also, be sure to compensate for thermal movement in the
equipment. The coupling is capable of approximately four times above shaft misalignment tolerances. However,
close alignment at installation will provide longer service with smoother operation.
Fig. 5 Fig. 6
Chart A: Suggested maximum alignment values
Coupling size
Total indicator reading
(T.I.R)
Angular for AMR Parallel
225 0.30 0.15
312 0.41 0.20
350 0.46 0.23
450 0.61 0.30
VI. Final assembly
A. when two hubs are used - AMR
Note: All bolt threads should be lubricated. Clean motor oil is recommended. See also Note 3 below Table 1.
1. If the coupling was assembled on arrival, the disc packs are still attached to the centre ring.
Remove the disc packs from the centre ring but do not remove the bolts from the centre ring.
2. With the hubs mounted and the span length “C” set, position the centre ring between the two hubs. Be
careful when handling the centre ring. Support the centre ring on wood blocks with nylon straps from a
hoist or some other convenient way. It may help to support the end not being worked on with bolts
through the centre ring bolt holes and into the hub flange bolt holes. This will hold the parts in line at that
end.
Johnson Controls Denmark ApS
Christian X's Vej 201 ∙ 8270 Højbjerg ∙ Denmark
Phone +45 87 36 70 00 ∙ Fax +45 87 36 70 05 ∙ www.sabroe.com
CVR No 19 05 61 71
Page 5 of 8
3. Rotate the hub or centre ring so that the hub bolt holes line up between the centre ring fingers. If the cou-
pling is not preassembled, place a thin washer on each bolt and install the bolts through all eight bolt
holes in the centre ring as shown in Fig. 7.
a. Note: The thin washer must be placed under the bolt head so that it is between the bolt head
and the flange. If it is placed on the bolt after the single headed bushing, it could get trapped
between the locknut and the bolt body. This could prevent the locknut from fully clamping the
disc pack which would result in failure. Slide the disc pack between the centre ring fingers and
the hub so that the single headed bushings are opposite the centre ring and hub bosses as
shown in Fig. 7. Install the bolts from the centre ring through the disc pack bushings. Place a
thin washer on four of the remaining bolts and install these bolts through the bolt holes in the
hub and into the disc pack bushings. Install a locknut on each bolt and slightly tighten them. The
disc pack, when installed, should look flat and parallel with the mating hub and centre ring fin-
gers.
4. Proceed to the other end to install the remaining disc pack. Support the centre ring and remove the sup-
port bolts, if used. Rotate the hub or centre ring so that the hub bolt holes line up between the centre ring
fingers. It may help with installation of the second pack to compress the disc pack on the flywheel adapter
side. Use clamps to squeeze the centre ring toward the flywheel adapter or a pry bar on the other end to
push the centre ring toward the flywheel adapter. Place a thin washer on each of the remaining bolts. Us-
ing paragraph 3 above, install the second disc pack and bolts. Add the locknuts to these bolts and slightly
tighten them. The disc pack, when installed, should look flat and parallel with the mating hub and centre
ring fingers.
5. Make the final coupling alignment check at this time.
6. Tighten the locknuts. See Table 1 for torque values. It is recommended that all locknuts be retightened
after several hours of initial operation whenever possible.
7. For further help with the installation or alignment, consult Rexnord.
a. Note: It may be necessary to use an open end wrench to tighten the locknuts due to the lack of
room.
Fig. 7
Johnson Controls Denmark ApS
Christian X's Vej 201 ∙ 8270 Højbjerg ∙ Denmark
Phone +45 87 36 70 00 ∙ Fax +45 87 36 70 05 ∙ www.sabroe.com
CVR No 19 05 61 71
Page 6 of 8
Coupling
size
Assembly
as per
figure
AMR =
”A” diam-
eter
(mm)
Nominal “C”
Dia. Axial
capacity
(mm)
Thread
size
Torque
mm In. Nm ft-lbs
(in-lbs)
225 1 152.4 76.45 3.00 +/- 0.91 5/16 - 24 34 25
312 2 174.8 101.70 4.00 +/- 1.30 7/16 - 20 54 40
3 206.2 103.53 4.08
350 2 231.6 113.10 4.45 +/- 1.42 1/2 - 20 129 95
3 255.5 114.73 4.52
450 4 301.8 149.35 5.88 +/- 1.83 11/16 - 16 203* 150*
Table 1: Locknuts - tightening torque
Note:
1. These torque values are approximate for steel bolts with lubricated threads.
2. Bolts should be held from rotating while the locknuts are tightened to the values shown.
3. *These locknuts are cadmium plated.
Set screw thread size Torque
(Nm)
Torque
(in-lbs)
torque
(ft-lbs)
1/4 - 20 7 66 6
1/4 - 28 9 76 6
5/16 - 18 15 132 11
5/16 - 24 16 144 12
3/8 - 16 27 240 20
3/8 - 24 31 276 23
1/2 - 13 68 600 50
1/2 - 20 75 660 55
Table 2: Setscrews - tightening torque
Coupling size Screw type Torque
(Nm)
Torque
(in-lbs)
torque
(ft-lbs)
312 M8 x 35
12.9
43 380 32
350 M8 x 35
12.9
43 380 32
Table 3: Hub with shrink element - screw tightening torque
Coupling size Bolt size Torque
(Nm)
Torque
(in-lbs)
torque
(ft-lbs)
312/350 M16 174 1540 128
450 M20 340 3010 250
Table 4: Split hub bolts tightening torque
Johnson Controls Denmark ApS
Christian X's Vej 201 ∙ 8270 Højbjerg ∙ Denmark
Phone +45 87 36 70 00 ∙ Fax +45 87 36 70 05 ∙ www.sabroe.com
CVR No 19 05 61 71
Page 7 of 8
VII. Disc pack replacement
If it becomes necessary to replace the disc pack, it can be done as follows:
Note: Sizes 225 through 750 use the TPackTM unitized disc pack. If original Thomas round, non-unitized disc
packs are being replaced by the TPackTM, the original thick bevelled washers must be discarded, and the thin
washers that accompanied the TPackTM must be used instead. Use of the thick bevelled washers with the
TPackTM could cause insufficient thread engagement by the locknut and result in failure.
1. At the hub end of the coupling, remove all locknuts. Back out and remove all but one bolt. It may be nec-
essary to tap the ends of the bolts with a soft hammer to start them out. Pivot the disc pack out. Remove
the last bolt and slide the pack out.
2. Now disassemble the other end per Paragraph 1 above being sure to support the centre ring when taking
out the last bolts. Remove the centre ring.
3. Replace parts as necessary. Recheck alignment as described in Section V. Reassemble as described in
Section VI.A.
VIII. For replacement parts
Coupling size TPackTM kit (1) Hardware kits (2)
JCI part no. Quantity JCI part no. Quantity
225 1524.338 1 1524.342 1
312 1524.339 1 1524.343 1
350 1524.340 1 1524.344 1
450 1524.341 1 1524.345 1
* Use this kit when replacing original Thomas, round, non-unitized packs.
It includes the special washers as noted in Section 0.
** These locknuts are cadmium plated.
(1) Include 2 Disc Pack (4) + 16 Ultra Thin Washers (7)
(2) Include 16 bolts (5) + 16 locknuts (6) + 8 Thin washers for TPackTM (8) + 16 thick washers for classic disc
packs (9). (To be discarded accordingly if used with TPackTM Disc packs)
†None are supplied for 225-AMR and 4 only for 450-AMR
Bold numbers in ( ) refer to position numbers in Fig. 1 to Fig. 4.
Erhardt Nielsen
Manager, Reciprocating Compressors
Technical Support and Development
Direct no.: +45 87 36 77 20
Fax no.: +45 87 36 77 05
E-mail: [email protected]
Johnson Controls Denmark ApS
Christian X's Vej 201 ∙ 8270 Højbjerg ∙ Denmark
Phone +45 87 36 70 00 ∙ Fax +45 87 36 70 05 ∙ www.sabroe.com
CVR No 19 05 61 71
Page 8 of 8
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Sabroe AMR Tpack Installation guide

Brand
Sabroe
Model
AMR Tpack
Type
Installation guide
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