Power Transmission Solutions Regal Beloit America, Inc. 7120 New Bufngton Road Florence, KY 41042 Application Engineering: Engineering: 800 626 2093 www.RegalPTS.com
High Performance Disc Coupling “RM” and “RZ” Style • Read and follow all instructions carefully. • Disconnect and lock-out power before installation and maintenance. Working on or near energized equipment can result in severe injury or death.
FORM 16-601-1E Revised November 2015
• Periodic inspections should be performed. Failure to perform proper maintenance can result in premature product failure and personal injury.
• Do not operate equipment without guards guards in place. Exposed equipment can result in severe injury or death.
WARNING! Because of the possible danger to person(s) or property from accidents which may result from the improper use or unapproved modication of the product, this product must be installed, maintained, and operated in accordance with the procedures, standards and engineering information specied in the product brochures and illustrations. For safe operation, this product should be inspected in accordance with the instructions described in this form. Proper guards and other suitable safety devices or procedures as may be desirable, or as may be specied in safety codes, should be installed by the user. Guards and other safety equipment are not provided, nor are they the responsibility of Regal Power Transmission.
1.0 General Instructions Instructions The KOP-FLEX ® High Performance disc coupling is dynamically balanced and must be assembled with all parts in the positions specied
Prior to installation, inspect the coupling for any signs of damage during shipment. Check that all parts are on hand and are as ordered.
by the match marks on the coupling. Each coupling assembly has a unique serial number marked on every major component. Make sure that the serial numbers match exactly on every component used for a complete coupling. The spacer bolts and nuts are individually weight balanced so that any nut may be used on any bolt.
Components should be cradled or supported during handling to avoid damage and should be wrapped for protection. Flanges and rabbets should be kept free of nicks and burrs. The preassembled coupling halves are made rigid during manufacturing by shipping screws (see gure). The red locking screws (setscrews) hold the disc pack in the neutral position. The yellow collapsing screws (socket head capscrews) lock the half coupling assembly in place. DO NOT REMOVE OR LOOSEN THESE SCREWS UNTIL INSTRUCTED.
WARNING! Only bolts and nuts supplied by Kop-Flex are to be used. For optimum coupling life, balance quality, and ease of installation,
Read all of the installation instructions and review the procedure before the acutal coupling installation.
KOP-FLEX High Performance disc couplings are supplied in factory preassembled units. DO NOT ATTEMPT TO DISASSEMBLE THE DO NOT TIGHTEN OR LOOSEN LOOSEN THE DISC PACK BOLTS OR NUTS
HALF COUPLINGS. DO NOT TIGHTEN OR LOOSEN THE DISC PACK BOLTS AND NUTS.
SHIPPING SCREWS (YELLOW COLLAPSING CAPSCREW)
DO NOT TIGHTEN OR LOOSEN THE DISC PACK BOLTS OR NUTS
SHIPPING SCREWS (RED LOCKING SET SCREW)
“RZ” STYLE STYLE
“RM “RM ” STYLE STYLE
SHIPPING SCREWS (YELLOW COLLAPSING CAPSCREW)
SHIPPING SCREWS (RED LOCKING SET SCREW)
2.0 Installation of Coupling Halves Note: The half couplings are preassembled from the factory and locked in place by the shipping screws, see general section.
Keyed 2.1 Check the hub bore and shaft for nicks and burrs, dress if necessary. Make sure that the bore and shaft are clean. 2.2 For taper bores, check the t of the bore to the shaft. 2.3 Keys must be precisely tted to the keyways in the shaft and hub. Each key should have a tight t on the sides with a slight clearance on top. To maintain dynamic balance, the keys should ll the keyways exactly and not be too short or too long. 2.4 Clean the hub bore and shaft. Record the position of the hub on the shaft as the “start” position for advancing taper bored couplings. 2.5 Heat the entire half coupling to expand the bore; DO NOT allow the coupling temperature to exceed 450 degrees F (230 degrees C). DO NOT apply an open ame to the disc packs. An oil bath or oven is recommended. 2.6 Place the half coupling in the proper position on the shaft. For taper bored hubs, the hub must be advanced the correct amount as specied by the machine manufacturer or as given on the coupling drawing. 2.7 Hold the hub in place as it cools. For taper bores, verify the hub advance and install the shaft retaining nut.
2.15 Remove the hub pusher after the bore oil has drained and verify the correct advance of the hub on the shaft. Install the shaft nut (if used) and lock in place. CAUTION: If sufcient time is not allowed for the oil to drain from the bore, the hub could move off the shaft with great force when the pusher is removed. Make sure proper safety procedures are followed. WARNING! If heat is used at any time for installation, DO NOT allow the coupling temperature to exceed 450 degrees F (230 degrees C). DO NOT apply an open ame to to disc packs. An oil bath or oven is recommended.
3.0 Solo Operation After the half coupling is mounted on the shaft the equipment can be soloed (i.e.., run uncoupled for testing purposes). 3.1 If a moment simulator plate or solo adapter is required, see Form 16-611 “Moment Simulator and Solo Plate Installation Instructions.” Note that API 671 species the use of plates for solo operation and also pecies that they are piloted on both the hub and sleeve.
4.0 Alignment Note:Exact values and procedures for aligning equipment are nor-mally specied by the equipment manufacturers. The amounts given below represent values that would provide excellent coupling performance in operation.
Hydraulic Specic instructions for hydraulic mounting of coupling hubs are given by the manufacturers of the connected equipment. The following general instructions on mounting are given for reference. Make sure that the equipment manufacturer’s instructions are supplied and are followed. 2.8 Check the hub bore and shaft for nicks and burrs, dress if necessary. Make sure that the bore and shaft are clean. 2.9 Check the t of the bore to the shaft, at least 85% contact is required. Make sure there are no O-rings or backup rings in the oil seal grooves. DO NOT lap the hub on the shaft to obtain the required contact, use special gauges. Record the position of the hub on the shaft as the “start” position for advancing. 2.10 Clean the hub bore and shaft and install the O-rings and backup rings (if used). 2.11 Place the half coupling on the shaft and install the necessary hydraulic mounting equipment. 2.12 Place the hub in the “start” position and inject oil to pressurize the bore and expand the hub. Check for leaks. 2.13 Push the coupling onto the shaft to the specied advance. Keep the proper pressure in the bore. DO NOT exceed the maximum allowable assembly pressure specied on the coupling general arrangement drawing or on equipment manufacturer’s installation instructions. 2.14 Release the bore pressure slowly and allow some time for the oil to drain from the bore. Leave the pusher in place to hold the hub in position.
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MCIM15111E • Form 16-601-1E • Printed in USA
Good initial alignment to the minimum possible values will promote optimum machinery performance and eliminate potential operating problems. Offset and angular misalignment 4.1 Reverse dial indication or optical methods of alignment are recommended. A cold alignment and a hot check (with corrections if necessary) are required. The sleeve anges of the assembled halves can be used to mount the alignment equipment (the ange outer diameter is machined to be concentric to the coupling bore and can be used as the reference diameter). If the shipping screws have been released, the ange outer diameter concentricity to the bore will have to be zeroed by adjusting the shipping screws until the r unout is minimal. 4.2 The maximum recommended operating misalignment is: 0.10 degrees per disc pack (0.0035 in/in TIR offset)
Note that improving the alignment below t hese values will promote optimum machinery performance.
4.3 Check the axial position of the coupling halves by measuring the sleeve ange separation. The correct separation at the coupling installation is equal to the design ange separation given on the coupling drawing plus the installation prestretch. CALCULATED FLANGE SEPARATION = DESIGN FLANGE-TO-FL ANGE DIMENSION + PRESTRETCH
5.1 Remove the red locking screws and tighten the yellow screws; this collapses the disc pack and pulls the sleeves apart to allow clearance of the spacer rabbets. Tighten the screws progressively and in small increments; DO NOT tighten them one at a time.
The installation prestretch accommodates thermal growth and initial axial misalignment.
5.2 Place the coupling spacer with the correct amount of shim between the two halves and line up the match marks, make sure the identifying letters or numbers with the match marks are the same.
If the shipping screws have been released, the sleeve ange face will rest in approximately the neutral position, and measurements can be taken from the ange in this condition. Use an average of at least four (4) measurements at 90 degrees.
5.3 Release the collapsing screws; this must be done progressively and in small increments. DO NOT loosen them one at a time. Store the yellow collapsing screws for future use.
4.4 Compare the measured ange separation to the calculated ange separation and adjust t he connected equipment accordingly. 4.5 If the correct ange separation cannot be obtained by moving the equipment, the spacer ange shim packs can be used to adjust for axial position. Two packs are supplied with individual shims of various thickness; the coupling is designed so that one pack is installed if the measured ange separation is EQUAL to the calculated separation. 4.6 If the measured ange separation is LESS than the calculated value, remove shims from one pack equal to the difference between the measured and calculated values and install the r emainder of the shim pack on the spacer (the shims have a piloted t with t he spacer rabbet). Store the removed shims and the other shim pack for future use. 4.7 If the measured ange separation is MORE than the calculated value, install one complete shim pack on the spacer and install shims form the second pack equal to the difference between the measured and calculated values (place the shims on both spacer rabbets, DO NOT put all the shims on one rabbet). Store the remaining shims from the second pack for future use. 4.8 The axial shim adjustment can be represented by: SHIM ADJUST = MEASURED SEPARATION - CALCULATED SEPARATION If SHIM ADJUST is zero, place one shim pack on the spacer and store the second shim pack. If SHIM ADJUST is a negative number, remove shims equal in thickness to SHIM ADJUST form one pack and put the remainder of the pack on the spacer (store the removed shims and the second pack), see 3.5. If SHIM ADJUST is a positive number, place one shim pack on the spacer and remove shims equal in thickness to SHIM ADJUST from the second pack and place them on the other end of t he spacer (store the remainder of the second pack), see 3.6. WARNING! Do not put more than one shim pack on any spacer ange.
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5.0 Final assembly
MCIM15111E • Form 16-601-1E • Printed in USA
5.4 Line up the match marks exactly and push the spacer and sleeve anges together. KOP-FLEX High Performance disc couplings are designed with interference rabbets so they must be pressed or lightly tapped together. DO NOT use excessive force. 5.5 Install the ange bolts and nut in the direction as shown on the coupling general arrangement drawing. The proper tightening torque is listed on the coupling drawing; they are also marked on the coupling ange for reference. 5.6 Recheck the coupling alignment after the machinery has reached a stable operating temperature and correct if necessary.
6.0 Removal 6.1 Remove the spacer bolts and nuts and break the anges apart using the jacking screw holes located between the spacer bolt holes. 6.2 Install the yellow collapsing screws in the counterbored clearance holes in the sleeve and tighten them to collapse the disc pack. The collapsing screws must be tightened progressively and in small increments; DO NOT tighten them one at a time. This operation will pull t he sleeve away from the spacer and allow the rabbets to clear so that the spacer can be removed. 6.3 KEYED - Install a puller on the hub using the tapped holes provided in the hub face; pull the hub off the shaft. DO NOT PULL ON THE SLEEVE OR DISC PACK. 6.4 HYDRAULIC - Install the hydraulic equipment and remove the hub from the shaft, reversing the installation procedure. DO NOT exceed the maximum allowable assembly pressure specied on the coupling general arrangement drawing, or on equipment manufacturer’s installation instructions. CAUTION: If heat is used in removing the half coupling from the shaft, apply it directly to the hub. DO NOT use extreme temperatures. DO NOT apply direct ame to the disc pack. If direct ame is required to remove the hub, the disc pack MUST be protected with insulating wool or ame resistant material. Excessive heat on the disc pack will destroy the disc coating and reduce the service life of the coupling.
7.0 General recommendations KOP-FLEX High Performance disc couplings are designed to operate for extended periods without the need for lubrication or maintenance. Visual inspection of the disc packs is sufcient to assess the operational condition of the coupling. All high speed machinery should be constantly monitored to detect unusual or changing vibration levels. The KOP-FLEX coupling, under normal operation conditions, has no wearing parts and will retain its original balance quality. Any change in vibration levels should be investigated and remedial action should be taken immediately.
8.0 Reference instruction sheets Form 16-602 - “MP”, “MS” Style Installation Instructions Form 16-611 - “Moment Simulator and Solo Plate Installation Instructions
The serial number of the coupling is marked on every major component of the coupling. It is required for accurate identication and is sufcient for ordering an exact duplicate of the coupling or its components.
CAUTION: The self-locking nuts on the spacer bolts should be replaced after they have been assembled and removed from the bolts TEN (10) times. WARNING! Only KOP-FLEX FURNISHED REPLACEMENT PARTS ARE ALLOWED FOR USE. WARNING! KOP-FLEX High Performance disc couplings are factory preassembled. DO NOT TIGHTEN OR LOOSEN THE DISC PACK NUTS. DO NOT ATTEMPT TO DISASSEMBLE THE DISC PACKS. WARNING! REPAIR OR REPLACEMENT OF KOP-FLEX HIGH PERFOR MANCE DISC COUPLINGS IS RESTRICTED TO KOP-FLEX AUTHORIZED FACILITIES.
Important Safety Instructions Before start-up . . . for reasons of safety and to extend shaft coupling life, follow these requirements. 1. Coupling guards protect personnel. ALL COUPLINGS MUST BE COVERED WITH A GUARD AS PER OSHA REQUIREMENTS. 2. Recheck alignment after all foundation bolts and mechanical connections are tightened. 3. Make sure all fasteners are properly installed and tightened. 4. Take the time to double check your work. 5. Only authorized KOP-FLEX replacement parts are to be used. 6. Call KOP-FLEX for any clarication or questions.
Kop-Flex is a trademark of Regal Beloit Corporation or one of its afliated companies. ©2015 Regal Beloit Corporation, All Rights Reserved. MCIM15111E • Form 16-601-1E • Printed in USA
