Emerson KD2 DVD VCR Combo User Manual
Contents
1. bore size should be based on the actual measured shaft dimen sion regardless of whether straight or taper shaft For keyed shafts a light interference fit based on a nominal interference rate of 0 0005 inch per inch of shaft diameter is suggested or refer to published AGMA standards Do not exceed an interference fit of 0 001 inch inch of shaft diameter If other than a light interference fit is desired consult the published AGMA boring and keyway standards For Straight Bores the rigid hub diameter should be chucked in the bor ing lathe and dial indicated as shown of Figure 11 For Taper Bores chuck and indicate as shown on Figure 11 Machine the counterbore and SKIM A REFERENCE DIAMETER on the hub body Then chuck the hub as shown on Figure 12 and indicate using the reference diameter before final boring Run outs should be as near zero as possible It is essential that the fin ished bore be concentric with the two indicating surfaces 10 0 Keyways Keyways should be cut to give a tight fit on the sides and slight clearance over the key Keyways should not have sharp corners Refer to published AGMA standards for specific dimensioning of coupling bores and keyways 11 0 General Recommendations 11 1 KOP FLEX KD2 and KD20 disc couplings are designed to operate for extended periods without the need for lubrication or maintenance Visual inspection of the disc packs is sufficient to assess the operational condition of the coupling 112. both hubs use the separate collapsing screws to pull the adapter rings toward the center of the pre assembled cen ter section This is made up of the spacer two disc packs and two adapter rings ADAPTER RING COLLAPSING BOLT DISC PACK SPACER Yi Figure 4 Collapsing center section 4 2 For each side of the center section insert the collapsing bolts through the spacer clearance holes into tapped holes in the ring see Figure 4 4 3 Tighten them evenly and collapse the disc packs equally only enough to allow the center assembly to drop into place see Figure 5 CENTER ASSEMBLY HUB BOLTS O D PILOT Figure 5 Installing center section 5 0 6 0 4 4 Put the center assembly spacer and rings between the rigid hubs engage the pilot and install the hub bolts in one hub flange 4 5 Release all the collapsing bolts and install the hub flange bolts on the second rigid hub flange 4 6 Torque the hub flange bolts to the value specified in Table 1 3 Tightening Torque Lightly Oiled Coupling Size KD20 ftlo Nm ftb Nm 8 10 253 254 303 304 353 354 403 404 453 454 504 554 604 705 805 905 Table 1 Flange Bolt Tightening Torques Removal 5 1 Disassemble the coupling in the reverse order as per the applicable assembly procedure 5 2 KEYED HUBS Install a puller on the hub using the tapped holes provided in the hub face Pull the hub off the shaft Disc Pack Replacement Th
3. 2 All machinery should be monitored to detect unusual or changing vi bration levels KOP FLEX KD2 and KD20 couplings under normal condi tions have no wearing parts and will retain their original balance quality Any change in vibration levels should be investigated and remedial action should be taken immediately iY A Z z REFERENCE DIAMETER Figure 11 Figure 12 5 YEAR WARRANTY REGISTRATION CARD Name Last First Title Company Name Location Phone APPLICATION DATA Coupling Type HP RPM Application Shaft Size s Driving Driven Distance Between Shaft Ends Plant Identification Pump Motor Send Warranty Card To Attention Marketing Department KOP FLEX Inc Mail to P O Box 1696 or Fax to 410 787 8424 Baltimore MD 21203 1696 AWARNING Important Safety Instructions Before start up for reasons of safety and to extend shaft coupling life KOP FLEX EEE eE a ollow these requirements E sare pinata E ALL COUPLINGS MUST BE COVERED WITH A GUARD AS PER OSHA REQUIREMENTS Emerson Powar Transmission could Fane 2 Recheck alignment after all foundation bolts and mechanical connections are tightened i P O Box 1696 personal injury 3 Make sure all fasteners are properly installed and tightened j ie or equipment 4 Take the time to double check your work Baltimore MD 21203 1696 5 Only authorized KOP FLEX replacement parts are to be used www emerson ept com damage 6 Call KOP FLEX for any clarif
4. KD2 amp KD20 Disc Coupling KOP FLEX INC P O BOX 1696 BALTIMORE MARYLAND 21203 410 768 2000 KOP FLEX CANADA LTD 19 METEOR DRIVE REXDALE ONTARIO CANADA M9W 1A3 416 675 7144 AWARNING High voltage and rotating parts may cause Installation and Alignment Instructions FORM 15 111 APRIL 2002 KOP FLEX Emerson Power Transmission serious or fatal injury AWARNING 1 0 Turn off power to install or service Operate with guards in place Read and follow all instructions in this manual nf e Because of the possible danger to person s or property from accidents which may result from the improper use or unapproved modification of the product this product must be installed maintained and operated in accordance with the procedures standards and engineering information specified in the product brochures and illustrations To assure 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 specified in safety codes should be installed by the user Guards and other safety equipment are not provided nor are they the responsibility of Emerson Power Transmis sion General Instructions Prior to installation inspect the coupling for any signs of damage that may have occured during shipment Check that all parts are on hand and a
5. e terminology used to identify parts and the order of assembly may differ from one coupling style to another Follow the instructions which match the coupling style being installed KD2 For KD20 skip to 6 7 6 1 Remove the center assembly in reverse order as per the applicable assembly procedure Remove disc pack bolts and nuts 6 2 Insert the disc pack removal socket into one of the clearance holes in the spacer flange or ring Figure 6 Install the removal cap screw and turn it until it cannot be tightened any more Note The removal socket is supplied as part of the parts kit DISC PACK CLEARANCE HOLE BUSHING Y REMOVAL SOCKET REMOVAL SCREW WASHER Figure 6 Bolt Disc Pack to Adapter 6 3 Remove the tool and repeat step 6 2 on all bushings to free the disc pack from the ring and spacer AWARNING Disconnect all power before adjusting units The Emerson logo is a trademark and a service mark of Emerson Electric Co Emerson Power Transmission Manufacturing L P or affiliates 2002 All Rights Reserved 6 4 Line up the bushings of the new disc pack with the reamed holes in KD20 the ring lightly tap on the bushings to start them into the holes Insert 3 disc pack bolts and nuts with the bolt heads in the ring counterbore 6 7 Remove the center assembly in reverse order as per the applicable hole tighten them evenly to pull the bushing into the ring flange see assembly procedure Figure 7 6 8 Unbolt t
6. ges for accurate spac ing See Figure 2 The amount of hub draw is dependent upon the desired interference and taper angle as specified by the machine manu facturer or as given on the coupling drawing See Figure 3 Advance in FEELER GAUGES SPLIT COLLAR Zi Figure 2 Using Split Collar to Set Advance Diametral Taper Rate 070 1 2 ft 5 8 ft 060 3 4 ft 050 040 1 1 4 ft 030 1 1 2 ft 020 010 000 0000 0005 0010 0015 0020 0025 0030 0035 0040 Interference in Figure 3 Hub Advance vs Interference Chart 2 6 Heat the hub to expand the bore DO NOT allow the hub temperature to exceed 600 F 300 C DO NOT apply an open flame to any part of the coupling an oven is recommended AWARNING To avoid the risk of explosion fire or damage to the coupling and equipment and or injury to per sonnel do not use an open flame or oil bath to expand the hub If heat is used at any time for in stallation DO NOT allow the hub temperature to exceed 600 F 300 C 2 7 Place the hub in the proper position on the shaft Hold the hub in place as it cools For taper bores verify the hub advance see Fig ures 1 and 2 and install the shaft retaining nut Remove the split collar from the shaft EMERSON Industrial Automation 3 0 4 0 Alignment Note Exact values and procedures for aligning equipment are normally specified by the equipment manufacturers Good init
7. he adapter ring from the disc pack Unbolt the disc pack from the spacer DISK PACK NUT 6 9 Clean and deburr all of the coupling parts DISK PACK 6 10 Line up the new disc pack between the adapter ring and the spacer BUSHING Insert the disc pack bolt into the counterbored hole in the adapter ADAPTER RING ring and through the disc pack SPACER 6 11 Make sure that the spacer is properly indexed for the large clear ance holes to receive the bolt ends Place the spacing washer and disc pack nut on the bolt Repeat for the other bolts see Figure 9 DISC PACK NUT SPACING WASHER DISC PACK Sy ADAPTER RING SPACER DISK PACK BOLT Figure 7 Bolt Disc Pack to Adapter Ring 6 5 Line up the bushings with the spacer reamed holes lightly tap the BIS PACK BOLL bushings to start them in the holes Install and tighten 3 disc pack Figure 9 Bolt Disc Pack to Adapter Ring bolts and nuts with bolt heads in the ring see Figure 8 6 12 Place a spacing washer over a disc pack bolt Insert the bolt through DISK PACK BOLT the large hole in the adapter ring and through the disc pack bushing and reamed hole in the spacer Place the disc pack nut on the bolt ADAPTER RING Repeat for the other bolts see Figure 10 DISC PACK ADAPTER RING SPACING WASHER DISC PACK BUSHING SPACER DISC PACK NUT SPACER cram 8 DISC PACK NUT Figure 8 Bolt Disc Pack to Spacer DISC PACK BOLT 6 6 Torque all disc pack fastene
8. ial alignment to the minimum possible values will promote optimum machinery per formance and eliminate potential operating problems After securely tightening the foundation bolts the hub separation and alignment should be rechecked and adjusted if necessary The coupling alignment should be checked periodically Even when a coupling is well aligned at installation subsequent settling of foundations shifting of equipment etc may cause the alignment to deteriorate Offset and Angular Alignment 3 1 Reverse dial indication or optical methods of alignment such as la ser are recommended A cold alignment and a hot check with cor rections if necessary are required The hub flange OD can be used to mount the alignment equipment The hub flange OD is machined to R concentric to the coupling bore and can be used as the reference iameter 3 2 The maximum recommended operating misalignment is 0 10 degrees per disc pack 0 0035 in in TIR equivalent parallel offset Important Total misalignment is the combination of equipment par allel offset and angular misalignment Note that improving the alignment below these values will promote optimum machinery performance Axial Alignment 3 3 Align the hubs until they are at the correct hub separation The hub separation is measured from the two flange faces not from the pilot face Hub Separation Center Assembly Length Final Assembly KD2 and KD20 4 1 After correctly installing
9. ication or questions Emerson Power Transmission Manufacturing L P or affiliates 2002 All Rights Reserved
10. re as ordered AWARNING ONLY BOLTS AND NUTS SUPPLIED BY KOP FLEX ARE TO BE USED 2 0 Components should be cradled or supported during handling to avoid dam age and should be wrapped for protection Flanges and pilot surfaces should be kept free of nicks and burrs Read all of the installation instructions and review the procedure before the actual coupling installation Installation of Coupling Hubs Keyed Mounting 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 tapered bores check the fit of the bore to the shaft 2 3 Keys must be precisely fitted to the keyways in the shaft and hub Each key should have a tight fit on the sides with a slight clearance on top To maintain dynamic balance the keys should fill the keyways exactly and not be too short or too long 2 4 Clean the hub bore and shaft For straight bores proceed to step 2 6 For taper bores mount the hub handtight on the shaft and lightly rap it with a soft mallet to establish the initial line to line fit This is the START position With a depth gauge measure the amount the hub overhangs the shaft end and record this value See Figure 1 DEPTH GAUGE Figure 1 Measuring Hub Overhang 2 5 Taper Bores Only A recommended method to measure the hub ad vance is to install a split collar on the shaft away from the hub by the amount of the specified advance Use feeler gau
11. rs evenly and in successive steps to the Figure 10 Bolt Disc Pack to Spacer value specified in Table 2 6 13 Torque all disc pack fasteners evenly in successive steps to the value specified in Table 2 Tightening Torque Lightly Oiled Sie KD20 7 0 Dynamic Balance 8 10 Balanced parts will be marked with the letter B The couplings may be component balanced hubs and center assembly with no match marks or 153 A assembly balanced as a complete coupling with match marks of the hub to 203 204 ea 253 254 ring connections If the coupling is supplied with match marks it must be 303 304 assembled with the match marks in line a o Note For balanced couplings disconnecting the disc packs from the cen 453 454 ter assemblies disturbs the balance of the coupling When disc packs 504 are replaced in balanced couplings the couplings must be balanced 554 z before placing back in operation ae z 8 0 Finish Boring and Keyways 805 Coupling hubs are often furnished with a rough stock bore This rough 905 bore is not necessarily concentric to other hub diameters To prepare for boring set up and indicate the hub as shown in Figure 11 103 Table 2 Disc Pack Bolt Tightening Torques AWARNING Disconnect all power before adjusting units Emerson Power Transmission Manufacturing L P or affiliates 2002 All Rights Reserved 9 0 Bore Sizing and Recommended Fit The finish
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