FLENDER N-EUPEX, N-EUPEX DS Operating Instructions Manual

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Page 1

FLENDER COUPLINGS

N-EUPEX / N-EUPEX DS

Operating Instructions 3100en Edition 10/2017

A, B, ADS, BDS

Page 2

21.09.2017 14:39 V6.00

Page 3

FLENDER COUPLINGS

N-EUPEX / N-EUPEX DS 3100en

A, B, ADS, BDS

Introduction

Operating Instructions

Safety instructions

Description

Application planning

Assembly

Commissioning

Operation

Servicing

Service and support

Disposal

Spare parts

Technical data

Quality documents

Edition 10/2017

Page 4

Legal information

Warning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.

DANGER

indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING

indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION

indicates that minor personal injury can result if proper precautions are not taken.

NOTICE

indicates that property damage can result if proper precautions are not taken.

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified Personnel

The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Proper use of Flender products

Note the following:

WARNING

Flender products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Flender. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks

All names identified by ® are registered trademarks of Flender GmbH. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Flender GmbH Alfred-Flender-Straße 77 46395 BOCHOLT GERMANY

Document order number: 3100en Ⓟ 09/2017 Subject to change

Page 5

1 Introduction...................................................................................................................................................9

1.1 About these instructions...........................................................................................................9

1.2 Text attributes..........................................................................................................................9

1.3 Copyright..................................................................................................................................9

2 Safety instructions......................................................................................................................................11

2.1 General information................................................................................................................11

2.2 Intended use..........................................................................................................................13

2.3 Safety instructions for a coupling for use in potentially explosive atmospheres....................13

2.3.1 Marking..................................................................................................................................13

2.3.2 Conditions of use...................................................................................................................15

2.4 General warning notices........................................................................................................16

3 Description..................................................................................................................................................19

4 Application planning...................................................................................................................................21

4.1 Transport of the coupling.......................................................................................................21

4.2 Storage of the coupling..........................................................................................................21

5 Assembly....................................................................................................................................................23

5.1 Preparatory work....................................................................................................................23

5.1.1 Milling the parallel keyway.....................................................................................................24

5.1.2 Milling the parallel keyway.....................................................................................................25

5.1.3 Machining an axial locking mechanism..................................................................................26

5.1.4 Balancing the coupling...........................................................................................................28

5.2 Assembling the coupling........................................................................................................30

5.3 Aligning the coupling..............................................................................................................31

5.3.1 Purpose of alignment.............................................................................................................31

5.3.2 Possible misalignment...........................................................................................................32

5.3.2.1 Axial misalignment.................................................................................................................32

5.3.2.2 Angular misalignment.............................................................................................................32

5.3.2.3 Radial misalignment...............................................................................................................33

6 Commissioning...........................................................................................................................................35

7 Operation....................................................................................................................................................37

7.1 Normal operation of the coupling...........................................................................................37

7.2 Faults - causes and rectification.............................................................................................37

7.2.1 Procedure in the event of malfunctions..................................................................................37

7.2.2 Identifying the fault cause......................................................................................................37

7.2.2.1 Possible faults........................................................................................................................38

7.2.2.2 Possible causes.....................................................................................................................39

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Table of contents

7.2.3 Correcting faults.....................................................................................................................40

7.2.3.1 Replacing wearing parts.........................................................................................................40

7.2.3.2 Correcting the changed alignment.........................................................................................41

8 Servicing.....................................................................................................................................................43

8.1 Maintenance intervals............................................................................................................43

8.2 Maximum permissible torsional backlash...............................................................................44

8.3 Replacing wearing parts.........................................................................................................45

8.4 Removing the coupling...........................................................................................................46

9 Service and support....................................................................................................................................49

9.1 Contact...................................................................................................................................49

10 Disposal......................................................................................................................................................51

11 Spare parts.................................................................................................................................................53

11.1 Ordering spare parts..............................................................................................................53

11.2 Spare parts drawing and spare parts list................................................................................54

11.2.1 Types A and ADS...................................................................................................................54

11.2.2 Types B and BDS...................................................................................................................55

A Technical data............................................................................................................................................57

A.1 Speeds, geometry data and weights......................................................................................57

A.1.1 Type A....................................................................................................................................57

A.1.2 Type B....................................................................................................................................59

A.1.3 Type ADS...............................................................................................................................60

A.1.4 Type BDS...............................................................................................................................61

A.2 Shaft misalignment values during operation..........................................................................62

A.3 Tightening torques and widths A/F.........................................................................................63

A.4 Tightening procedure.............................................................................................................64

A.5 Flexible elements (12)............................................................................................................64

A.5.1 Use and storage of flexible elements (12)..............................................................................64

A.5.2 N-EUPEX flexible elements (12)............................................................................................65

A.5.3 N-EUPEX DS flexible elements (12)......................................................................................66

B Quality documents......................................................................................................................................67

B.1 Declaration of Conformity.......................................................................................................67

Tables

Table 2-1 General warnings........................................................................................................................11

Table 2-2 Temperature classes (TX) for explosive atmospheres as a result of gases, vapours or mists......16

Table 2-3 Maximum surface temperature (TX) for an explosive atmosphere as a result of dust/air

mixtures.......................................................................................................................................16

Table 4-1 Types of preservative agents for long-term storage....................................................................22

Table 5-1 Recommended assigned fits for bores with parallel key connection...........................................24

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Table of contents

Table 5-2 Position of the parallel keyway....................................................................................................25

Table 5-3 Diameter and axial position of the tapped hole, tightening torque..............................................27

Table 5-4 Position of the tapped hole with respect to the parallel keyway..................................................28

Table 7-1 Table of faults..............................................................................................................................38

Table 8-1 Maintenance intervals.................................................................................................................43

Table 8-2 Maximum permissible torsional backlash for the types A and B (sizes 58 to 250)......................44

Table 8-3 Maximum permissible torsional backlash for the types A and B (sizes 280 to 710)....................44

Table 8-4 Maximum permissible torsional backlash for the types ADS and BDS (sizes 66 to 218)............44

Table 8-5 Maximum permissible torsional backlash for the types ADS and BDS (sizes 245 to 556)..........45

Table 11-1 Spare parts list for types A and ADS...........................................................................................54

Table 11-2 Spare parts list for types B and BDS...........................................................................................55

Table A-1 Speeds, geometry data and weights of type A............................................................................57

Table A-2 Speeds, geometry data and weights of type B............................................................................59

Table A-3 Speeds, geometry data and weights of type ADS.......................................................................60

Table A-4 Speeds, geometry data and weights of type BDS.......................................................................61

Table A-5 Maximum permissible shaft misalignment values during operation............................................62

Table A-6 Tightening torques for part 13 of types A and ADS.....................................................................63

Table A-7 Tightening procedure..................................................................................................................64

Table A-8 N‑EUPEX flexible elements.........................................................................................................65

Table A-9 N‑EUPEX DS flexible elements...................................................................................................66

Figures

Figure 3-1 Type A and ADS..........................................................................................................................19

Figure 3-2 Type B and BDS..........................................................................................................................20

Figure 4-1 Transport symbols.......................................................................................................................21

Figure 5-1 Tolerances for finished bore........................................................................................................25

Figure 5-2 Diameter and axial position of the tapped hole in the hub..........................................................26

Figure 5-3 Position of the balancing bore for single-plane balancing...........................................................29

Figure 5-4 Position of the balancing bore for two-plane balancing...............................................................29

Figure 5-5 Possible misalignment.................................................................................................................32

Figure 8-1 Markings for calculating the torsional backlash...........................................................................44

Figure 8-2 Tapped jacking hole for loosening coupling part 3 (3).................................................................45

Figure 11-1 Spare parts drawing for types A and ADS...................................................................................54

Figure 11-2 Spare parts drawing for types B and BDS...................................................................................55

Figure A-1 Type A.........................................................................................................................................57

Figure A-2 Type B.........................................................................................................................................59

Figure A-3 Type ADS....................................................................................................................................60

Figure A-4 Type BDS....................................................................................................................................61

N-EUPEX / N-EUPEX DS 3100en Operating Instructions 10/2017 7

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Table of contents

N-EUPEX / N-EUPEX DS 3100en

8 Operating Instructions 10/2017

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Introduction

1.1 About these instructions

These instructions describe the coupling and provide information about its handling - from assembly to maintenance. Please keep these instructions for later use.

Please read these instructions prior to handling the coupling and follow the information in them.

1.2 Text attributes

The warning notice system is explained on the back of the inner cover. Always follow the safety information and notices in these instructions.

In addition to the warning notices, which have to be observed without fail, you will find the following text attributes in these instructions:

1. Procedural instructions are shown as a numbered list. Always perform the steps in the order given.

● Lists are formatted as bulleted lists.

– The dash is used for lists at the second level.

(1) Numbers in brackets are part numbers.

Note

A note is an important item of information about the product, the handling of the product or the relevant section of the instructions. The note provides you with help or further suggestions/ ideas.

1.3 Copyright

The copyright for these instructions is held by Flender.

These instructions must not be used wholly or in parts without our authorisation or be given to third parties.

If you have any technical queries, please contact our factory or one of our service outlets (refer to Service and support (Page 49)).

N-EUPEX / N-EUPEX DS 3100en Operating Instructions 10/2017 9

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Introduction

1.3 Copyright

N-EUPEX / N-EUPEX DS 3100en

10 Operating Instructions 10/2017

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Safety instructions

2.1 General information

Instructions

These instructions are part of the delivery. Always keep these instructions close to the coupling.

Please make sure that every person who is commissioned to work on the coupling has read and understood these instructions prior to handling the coupling and observes all of the points.

Only the knowledge of these instructions can avoid faults on the coupling and ensure fault-free and safe operation. Non-adherence to the instructions can cause product or property damage or personal injury. Flender does not accept any liability for damage or operating failures that are due to non-adherence to these instructions.

State of the art

The coupling described here has been designed in consideration of the latest findings for demanding technical requirements. This coupling is state-of-the-art at the time of printing these instructions.

In the interest of further development, Flender reserves the right to make such changes to the individual components and accessories that increase performance and safety whilst maintaining the essential features.

Symbols

Table 2-1 General warnings

ISO ANSI Warning

Warning - hazardous electrical voltage

Warning - explosive substances

--- Warning - entanglement hazard

--- Warning - hot surfaces

--- Warning - substances that are harmful to health or are irritants

N-EUPEX / N-EUPEX DS 3100en Operating Instructions 10/2017 11

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Safety instructions

2.1 General information

ISO ANSI Warning

--- Warning - corrosive substances

--- Warning - suspended load

--- Warning - hand injuries

ATEX certification

Explanation regarding Machinery Directive 2006/42/EC

The couplings described here are “components” in accordance with the Machinery Directive and do not require a declaration of incorporation.

ATEX Directive

Protective clothing

Using the coupling

The term "ATEX Directive" used in these instructions stands for the harmonisation legislation of the European Union in compliance with the declaration of conformance for equipment and protective systems for correct use in hazardous zones.

In addition to the generally prescribed personal protective equipment (safety shoes, overalls, helmet, etc.), also wear suitable safety gloves and safety goggles when handling the coupling.

The relevant work safety and environmental protection regulations must be complied with at all times during transport, assembly, installation, dismantling, operation and maintenance of the coupling.

Only qualified personnel may operate, assemble, maintain and repair the coupling. Information about qualified personnel can be found in the legal notes at the beginning of these instructions.

If lifting gear or load suspension devices are used for transporting, these have to be suitable for the weight of the coupling.

If the coupling has visible damage, it may not be assembled or put into operation.

The coupling may only be operated in a suitable housing or with touch protection according to applicable standards. This also applies to test runs and rotational direction checks.

Work on the coupling

Only carry out work on the coupling when it is not in operation and is not under load.

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12 Operating Instructions 10/2017

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Secure the drive unit against being switched on accidentally. Attach a notice to the switch stating clearly that work is being carried out on the coupling. Ensure that the entire unit is not under load.

2.2 Intended use

Only use the coupling according to the conditions specified in the service and delivery contract and the technical data in the annex. Deviating operating conditions are considered improper use. The user or owner of the machine or plant is solely liable for any resulting damage.

When using the coupling please specifically observe the following:

● Do not make any modifications to the coupling that go beyond the permissible machining described in these instructions. This also applies to touch protection facilities.

● Only use original spare parts from Flender. Flender only accepts liability for original spare parts from Flender. Other spare parts are not tested and approved by Flender. Non-approved spare parts may possibly change the design characteristics of the coupling and thus impact active and/or passive safety. Flender will accept no liability or warranty whatsoever for damage occurring as a result of the use of non-approved spare parts. The same applies to any accessories that were not supplied by Flender.

Safety instructions

2.2 Intended use

If you have any queries, please contact our customer service (see Service and support (Page 49)).

2.3 Safety instructions for a coupling for use in potentially explosive atmospheres

2.3.1 Marking

You can find a description of the coupling parts in chapter Description (Page 19).

A coupling designed in accordance with the ATEX Directive has a marking on the coupling parts.

Coupling part 1 without electrically insulating flexible elements

One of the following markings is visible on the outer diameter of coupling part 1:

Version 1:

Flender GmbH II 2GD c IIC TX

46393 Bocholt - Germany I M2 c X

FLENDER couplings N‑EUPEX <Year of man‐

ufacture>

N-EUPEX / N-EUPEX DS 3100en Operating Instructions 10/2017 13

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Safety instructions

2.3 Safety instructions for a coupling for use in potentially explosive atmospheres

Version 2:

Flender GmbH II 2G c IIC T4/T5/T6

-30 °C ≤ Ta ≤ +80 °C/+70 °C/+55 °C

46393 Bocholt - Germany II 2D c T 110 °C -30 °C ≤ Ta ≤ +80 °C

FLENDER couplings N‑EUPEX <Year of man‐

ufacture>

Coupling part 1 with flexible elements for low-temperature use

One of the following markings is visible on the outer diameter of coupling part 1:

Version 1:

Flender GmbH II 2GD c IIC TX

46393 Bocholt - Germany I M2 c X

FLENDER couplings N‑EUPEX <Year of man‐

ufacture>

Version 2:

Flender GmbH II 2G c IIC T6 -50 °C ≤ Ta ≤ +50 °C

46393 Bocholt - Germany II 2D c T 80 °C -50 °C ≤ Ta ≤ +50 °C

FLENDER couplings N‑EUPEX <Year of man‐

ufacture>

I M2 c -30 °C ≤ Ta ≤ +80 °C

I M2 c -50 °C ≤ Ta ≤ +50 °C

Coupling part 1 with electrically insulating flexible elements

One of the following markings is visible on the outer diameter of coupling part 1:

Version 1:

Flender GmbH II 2GD c IIB TX

46393 Bocholt - Germany I M2 c X

FLENDER couplings N‑EUPEX <Year of man‐

ufacture>

Version 2:

Flender GmbH II 2G c IIB T4/T5/T6

46393 Bocholt - Germany II 2D c T 110 °C -30 °C ≤ Ta ≤ +80 °C

FLENDER couplings N‑EUPEX <Year of man‐

ufacture>

14 Operating Instructions 10/2017

-30 °C ≤ Ta ≤ +80 °C/+70 °C/+55 °C

I M2 c -30 °C ≤ Ta ≤ +80 °C

N-EUPEX / N-EUPEX DS 3100en

Page 15

Coupling part 2 or 4

Safety instructions

2.3 Safety instructions for a coupling for use in potentially explosive atmospheres

Coupling part 2 or coupling part 4 is stamped with

Undrilled or predrilled coupling

A coupling part with Ex marking, the letter "U" and the Flender order number has been delivered undrilled or predrilled.

Note Undrilled or predrilled coupling with Ex marking

Flender only supplies an undrilled or predrilled coupling with Ex marking on the condition that the customer assumes the responsibility and liability for correct finishing work in a declaration of exemption.

2.3.2 Conditions of use

Note

Note also the material-dependent permissible ambient temperature of the flexible elements (12) in accordance with sections N-EUPEX flexible elements (12) (Page 65) and N-EUPEX DS flexible elements (12) (Page 66).

A coupling designed in accordance with the ATEX Directive is suitable for the following conditions of use:

● Equipment group I

– Category M2

● Equipment group II

– Category 2 and 3

– Group of substances G, zone 1 and 2

– Group of substances D, zone 21 and 22

– Explosion group IIA, IIB and IIC

– Explosion group IIA and IIB when electrically insulating flexible elements are used

Conditions of use for products with TX marking

The maximum ambient temperature stated in the following tables applies to the temperature in the direct vicinity of the coupling and the temperature of adjacent components.

N-EUPEX / N-EUPEX DS 3100en Operating Instructions 10/2017 15

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Safety instructions

2.4 General warning notices

1. Gases, vapours or mists

Check the ambient temperature for use of the coupling in the relevant temperature class.

Table 2-2 Temperature classes (TX) for explosive atmospheres as a result of gases, vapours or mists

2. Dust/air mixtures

Check the ambient temperature.

Table 2-3 Maximum surface temperature (TX) for an explosive atmosphere as a result of dust/air

Max. ambient temperature Temperature class

80 °C T4

70 °C T5

55 °C T6

mixtures

Max. ambient temperature Max. surface temperature

80 °C 110 °C

Notes concerning operation of the coupling in potentially explosive atmospheres

● Only use the coupling underground in mines in potentially explosive atmospheres together

with drive motors that can be switched off in the event of the formation of an explosive atmosphere.

● Earth machines that are connected via the coupling with a leakage resistance of less than

106 Ω.

● If you want to use a coated coupling in potentially explosive atmospheres, please note the

requirements concerning the conductivity of the paint and the limitation on the paint layer thickness applied in accordance with EN 13463-1. No build-up of electrostatic charges is to be expected with a paint layer thickness of less than 200 μm.

2.4 General warning notices

DANGER

Danger due to bursting of the coupling

The coupling may burst if it is not used properly. There is a risk of fatal injury from flying fragments. Bursting of the coupling can lead to an explosion in potentially explosive atmospheres.

● Use the coupling for the purpose for which it is intended.

N-EUPEX / N-EUPEX DS 3100en

16 Operating Instructions 10/2017

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Safety instructions

2.4 General warning notices

DANGER

Risk of explosion when using coupling parts without Ex marking

Coupling parts without Ex marking have not been approved for use in potentially explosive atmospheres. These coupling parts can lead to an explosion during operation.

● Only use couplings with Ex marking in potentially explosive atmospheres.

DANGER

Danger

Risk of injury due to the use of unsuitable and/or damaged components. The use of unsuitable and/or damaged components can lead to an explosion in potentially explosive atmospheres.

● Observe the information regarding conditions of use.

DANGER

Danger of explosion

Improper operation of the coupling can lead to an explosion in potentially explosive atmospheres.

● Please observe the notes concerning operation of the coupling in potentially explosive atmospheres.

DANGER

Danger from hot coupling parts

Risk of injury due to hot surfaces. Hot coupling parts can lead to an explosion in potentially explosive atmospheres.

● Wear suitable protective equipment (gloves, safety goggles).

● Ensure that the area is not at risk of explosion.

WARNING

Risk of chemical burns due to chemical substances

There is a risk of chemical burns when handling aggressive cleaning agents.

● Please observe the manufacturer's information on how to handle cleaning agents and solvents.

● Wear suitable protective equipment (gloves, safety goggles).

CAUTION

Physical injury

Risk of injury due to falling coupling parts.

● Secure the coupling parts to prevent them from falling.

N-EUPEX / N-EUPEX DS 3100en Operating Instructions 10/2017 17

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Safety instructions

2.4 General warning notices

N-EUPEX / N-EUPEX DS 3100en

18 Operating Instructions 10/2017

Page 19

Description

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Application

Design

The N‑EUPEX or N‑EUPEX DS couplings described here are torsionally flexible, damping pin couplings and are available in various types and sizes. The couplings can be used in accordance with the ATEX Directive in potentially explosive atmospheres if they have a CE marking.

Types A and B are fail-safe. Types ADS and BDS have no fail-safe device.

These instructions describe the assembly and operation of an N‑EUPEX or N‑EUPEX DS coupling arranged horizontally with a shaft-hub connection made by a cylindrical or conical bore with parallel key. Please consult Flender if you want to use a different type of installation.

N‑EUPEX couplings are designed for use in all kinds of machines.

N‑EUPEX DS couplings are used for applications which require the input and output to be disconnected from one another in the event of destruction of the flexible elements.

The diagrams show the various types with their constituent parts and their part numbers.

N-EUPEX / N-EUPEX DS 3100en Operating Instructions 10/2017 19

1 Coupling part 1

2 Coupling part 2

3 Coupling part 3

12 Flexible element

13 Cylinder-head screw

16 Cylindrical pin

only with type A sizes 560 to 710

Figure 3-1 Type A and ADS

Page 20

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Description

1 Coupling part 1

4 Coupling part 4

12 Flexible element

Figure 3-2 Type B and BDS

20 Operating Instructions 10/2017

N-EUPEX / N-EUPEX DS 3100en

Page 21

Application planning

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Check the delivery for damage and for completeness. Report any damage and/or missing parts to Flender immediately.

The coupling is delivered in individual parts and preassembled groups. Preassembled groups may not be dismantled.

4.1 Transport of the coupling

WARNING

Severe personal injury due to improper transport

Severe personal injury due to falling components or due to crushing. Damage to coupling parts possible due to use of unsuitable transport means.

● Only use lifting gear and load suspension devices with sufficient load bearing capacity for transport.

● Please observe the symbols applied on the packaging.

If not specifically contractually agreed otherwise, the packaging complies with the HPE Packaging Directive.

Figure 4-1 Transport symbols

4.2 Storage of the coupling

NOTICE

Property damage due to improper storage

Negative changes to the physical properties of the coupling and/or coupling damage.

● Please observe the information about storing the coupling.

N-EUPEX / N-EUPEX DS 3100en Operating Instructions 10/2017 21

Page 22

Application planning

4.2 Storage of the coupling

The coupling, unless not specifically ordered otherwise, is supplied with preservation and can be stored for up to 3 months.

Note Information about storing the coupling

● Ensure that the storage room is dry (relative humidity < 65 %) and free of dust.

● Ensure that there is no condensation.

● Do not store the coupling together with corrosive chemicals, acids, caustic solutions, etc.

● If the coupling contains elastomer components, ensure that there are no devices in the storage room that produce ozone, such as fluorescent lights, mercury vapour lamps or highvoltage electrical equipment.

● Store the coupling on suitable supports or in suitable containers.

Long-term storage

NOTICE

Property damage due to improper long-term storage

Negative changes to the physical properties of the coupling and/or coupling damage.

● Note the handling instructions for long-term storage.

1. You can find the required type of preservative agent in the following table (types of preservative agents for long-term storage).

2. Remove the elastomer components. These must not come into contact with cleaning agents and long-term preservative agents.

3. Clean the coupling parts.

4. Apply the stipulated preservative agent.

5. Store the coupling parts and the elastomer components separately.

Table 4-1 Types of preservative agents for long-term storage

Preservative agents Features Indoor storage Outdoor storage

Oil spray Anti-corrosion agent Up to 12 months Up to 4 months

Tectyl 846 or similar Long-term preservative agent on

wax basis

Emulsion cleaner + VCI foil Active system, reusable Up to 5 years Up to 5 years

Up to 36 months Up to 12 months

N-EUPEX / N-EUPEX DS 3100en

22 Operating Instructions 10/2017

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Assembly

Assembly of the coupling comprises the following steps:

● Preparatory work (Page 23)

● Assembling the coupling (Page 30)

● Aligning the coupling (Page 31)

DANGER

Danger due to bursting of the coupling

If you do not observe the information stipulated here regarding assembly, this can lead to bursting of the coupling during operation. There is a risk of fatal injury from flying fragments. Bursting of the coupling can lead to an explosion in potentially explosive atmospheres.

● Please observe all the stipulations concerning assembly.

Note Information about the assembly of the coupling

● Only use undamaged components for the assembly of the coupling.

● Follow the assembly sequence.

● Please ensure that there is sufficient space at the assembly location and that the location

is tidy and clean in order to be able to assemble and maintain the coupling without any risk.

● If a dimension drawing has been created for the coupling, please observe the information

it contains as a matter of priority.

5.1 Preparatory work

Note

Please consult Flender if you want to machine a conical finished bore.

Carry out the following steps if the coupling does not have a finished bore:

● Milling the parallel keyway (Page 24)

● Milling the parallel keyway (Page 25)

● Machining an axial locking mechanism (Page 26)

● Balancing the coupling (Page 28)

N-EUPEX / N-EUPEX DS 3100en Operating Instructions 10/2017 23

Page 24

Assembly

5.1 Preparatory work

Note

The customer is responsible for execution of the finishing work on the coupling. Flender shall have no liability whatsoever for claims under warranty arising from finishing work that has not been carried out adequately.

5.1.1 Milling the parallel keyway

The diameter of the finished bore depends on the shaft used.

Recommended assigned fits

In the following table you can find the recommended assigned fits for bores with a parallel key connection. The assigned fit m6 / H7 is especially suitable for a host of applications.

Table 5-1 Recommended assigned fits for bores with parallel key connection

Procedure

Description Push fit Press fit Interference fit

Not suitable for reversing operation Suitable for reversing operation

Shaft tolerance j6 h6 h6 k6 m6 n6 h6

Bore tolerance H7 J7 K7 H7 H7 H7 M7

1. Remove the flexible elements (12).

2. Remove the preservation and clean the coupling parts 1 (1) and 2 (2) or 4 (4) to be machined.

3. Clamp the coupling to the areas marked with

in the diagram below.

4. Machine the finished bore in accordance with the diagram below.

Note Diameter of the finished bore

The diameter of the finished bore may not exceed the specified maximum diameter.

● Please observe the maximum diameters specified in section Speeds, geometry data

and weights (Page 57).

N-EUPEX / N-EUPEX DS 3100en

24 Operating Instructions 10/2017

Page 25

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① Coupling part 1 ② Coupling part 4 ③ Coupling part 2 ④ Coupling part 2/3

Figure 5-1 Tolerances for finished bore

Assembly

5.1 Preparatory work

5.1.2 Milling the parallel keyway

Position of the parallel keyway

The table below states the required position for the parallel keyway in the coupling parts depending on the coupling type.

Table 5-2 Position of the parallel keyway

Coupling part Coupling Position of the parallel keyway

1 N‑EUPEX Centred between the flexible element webs

1 N‑EUPEX DS Centred between the flexible element pockets

2 N‑EUPEX Centred between the tapped holes

2 N‑EUPEX DS Centred between the tapped holes and offset relative to the

4 N‑EUPEX

N‑EUPEX DS

recesses for replacement of flexible elements

Beneath a cam

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Assembly

5.1 Preparatory work

Applicable standards

● If the coupling is intended for use under normal operating conditions, mill the parallel keyway according to DIN 6885/1 ISO JS9.

● If the coupling is intended for reversing operation, mill the parallel keyway according to DIN 6885/1 ISO P9.

● If you want to mill a parallel keyway that does not correspond to DIN 6885/1, please consult Flender.

5.1.3 Machining an axial locking mechanism

The coupling part is secured by a set screw or an end plate to prevent axial movements.

Please consult Flender if you want to use an end plate.

Note the following when using a set screw:

● Diameter and axial position of the tapped hole in the hub

● Position of the tapped hole with respect to the parallel keyway

● Selection of the set screw

Diameter and axial position of the tapped hole in the hub

The following diagram shows the axial position of the tapped hole.

① Coupling part 1; axial position of the tapped hole up to size 125 / 135 ② Coupling part 1; axial position of the tapped hole as of size 140 / 152 ③ Coupling part 2 ④ Coupling part 4

Figure 5-2 Diameter and axial position of the tapped hole in the hub

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Assembly

5.1 Preparatory work

The following table contains the values for the diameter and axial position of the tapped hole depending on the size of the coupling.

Table 5-3 Diameter and axial position of the tapped hole, tightening torque

Size

58 / 66 M5 10 - - 8 3

68 / 76 M6 10 - - 8 4

80 / 88 M6 11 - - 12 4

95 / 103 M6 15 - - 15 4

110 / 118 M6 18 - 9 18 4

125 / 135 M8 20 - 12 20 8

140 / 152 M8 - 13 15 22 8

160 / 172 M10 - 13 20 25 15

180 / 194 M12 - 16 30 32 25

200 / 218 M12 - 20 30 40 25

225 / 245 M12 - 22 35 40 25

250 / 272 M16 - 24 40 45 70

280 / 305 M16 - 28 45 45 70

315 / 340 M16 - 35 50 - 70

350 / 380 M20 - 40 60 - 130

400 / 430 M20 - 50 70 - 130

440 / 472 M24 - 60 80 - 230

480 / 514 M24 - 70 90 - 230

520 / 556 M24 - 80 100 - 230

560 M24 - 75 100 - 230

610 M24 - 85 110 - 230

660 M24 - 100 130 - 230

710 M24 - 115 140 - 230

Tightening torque

Apply the recommended tightening torques in accordance with the stipulations in section Tightening procedure (Page 64).

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Assembly

5.1 Preparatory work

Position of the tapped hole with respect to the parallel keyway

The tapped hole for the set screw is generally positioned on the parallel keyway. This does not apply to the coupling parts listed in the following table.

Table 5-4 Position of the tapped hole with respect to the parallel keyway

Coupling part Size Finished bore

Selection of the set screw

CAUTION

Physical injury

Danger of injury from protruding set screw.

● Please observe the information about selecting the set screw.

As set screws use threaded studs in accordance with ISO 4029 with a toothed cup point. The size of the set screw is determined by the bore made. The set screw should fill out the tapped hole as much as possible and must not protrude beyond the hub.

Position of the tapped hole

[mm]

1 58 / 66 ≥ 15 Offset 180° relative to parallel keyway

68 / 76 ≥ 20 Offset 144° relative to parallel keyway

80 / 88 ≥ 25 Offset 180° relative to parallel keyway

95 / 103 ≥ 38 Offset 180° relative to parallel keyway

2 110 / 118 ≥ 30 Offset 180° relative to parallel keyway

4 58 / 66 ≥ 18 Offset 180° relative to parallel keyway

68 / 76 ≥ 20 Offset 180° relative to parallel keyway

5.1.4 Balancing the coupling

Notes on balancing the coupling

NOTICE

Damage to coupling part 1 (1)

If you completely drill through the base of a flexible element pocket on coupling part 1 (1), then coupling part 1 (1) is no longer allowed to be used for operation.

● Please observe the stipulations about machining the balancing hole.

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Assembly

5.1 Preparatory work

Please note the following when balancing the coupling:

● Select the balancing quality according to the application (but at least G16 in accordance

with DIN ISO 21940).

● Observe the balancing specification according to DIN ISO 21940-32.

● Machine the balancing bore on a large radius with adequate clearance to the flexible

element webs / pockets and to the cams and the outer circumference.

① Balancing bore ② Part 1 for N‑EUPEX or N‑EUPEX DS coupling ③ Part 2 for N‑EUPEX or N‑EUPEX DS coupling ④ Part 4 for N‑EUPEX or N‑EUPEX DS coupling

Figure 5-3 Position of the balancing bore for single-plane balancing

① Balancing bore ② Part 1 for N‑EUPEX or N‑EUPEX DS coupling ③ Part 2 for N‑EUPEX or N‑EUPEX DS coupling ④ Part 4 for N‑EUPEX or N‑EUPEX DS coupling

Figure 5-4 Position of the balancing bore for two-plane balancing

Note

A better balancing result can be achieved by balancing the coupling parts (2 and 3) when they are bolted together as an assembly. When balancing all parts together, mark the position of the components relative to one another.

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Assembly

5.2 Assembling the coupling

NOTICE

Property damage

Damage to the elastomer components from cleaning agents.

● Ensure that the elastomer components do not come into contact with cleaning agents.

NOTICE

Property damage

Damage to the shaft end, the coupling parts and/or the parallel key.

● Note the following handling instruction.

Procedure

1. Unscrew the set screw until it is no longer possible for there to be a collision with the parallel key or the shaft.

2. Clean the bores and shaft ends.

3. Coat the bores of coupling parts 1 (1) and 2 (2) or 4 (4) and the shafts with MoS2 assembly paste (e.g. Microgleit LP 405).

4. If you have dismantled the coupling part 3 (3), mount the coupling part 3 (3) on the shaft before fitting the coupling part 2 (2).

5. Mount the coupling parts 1 (1) and 2 (2) or 4 (4) on the shaft.

Note Coupling parts with conical bore

Mount the coupling parts 1 (1) and 2 (2) or 4 (4) with conical bore and parallel keyway on the shaft in cold condition. Secure the coupling parts with suitable end plates without pulling the coupling parts further onto the cone (fitting dimension = 0).

Note Coupling parts with cylindrical bore

To make assembly easier, you can heat coupling parts 1 (1) and 2 (2) or 4 (4) with cylindrical bore up to a maximum of 150 °C if required. Note when doing this the temperature range of the flexible elements (12) (see sections N-EUPEX flexible elements (12) (Page 65)and N-EUPEX DS flexible elements (12) (Page 66)). Remove the flexible elements (12) if necessary. Protect adjacent components against damage and heating to temperatures above 80 °C.

6. Secure the coupling parts 1 (1) and 2 (2) or 4 (4) with a set screw or an end plate. When securing with a set screw the shaft must not protrude or be set back from the inner side of the hub.

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7. Tighten up the set screw or the screw to attach the end plate to the specified tightening

torque TA (for the set screw please see section Machining an axial locking mechanism (Page 26)).

8. If you have removed the flexible elements (12), reinstall them.

9. Tighten the bolts in the coupling part 2 (2) and 3 (3) to the specified torque TA (see section

Tightening torques and widths A/F (Page 63)).

5.3 Aligning the coupling

5.3.1 Purpose of alignment

The shafts that are joined by the coupling are never on an ideal precise axis but have a certain amount of misalignment.

Misalignment in the coupling leads to restoring forces that can stress adjacent machine parts (e.g. the bearings) to an unacceptable extent.

Assembly

5.3 Aligning the coupling

The misalignment values in operation result from the following:

● Misalignment due to assembly

Incorrect position due to a lack of precision when aligning

● Misalignment due to operation

Example: Load-related deformation, thermal expansion

You can minimise misalignment by aligning after assembly. A lower misalignment in the coupling has the following advantages:

● Reduced wear of the elastomer components

● Reduced restoring forces

● Misalignment reserves for operation of the coupling

You can find the maximum permitted shaft misalignment values during operation in section Shaft misalignment values during operation (Page 62).

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Assembly

5.3 Aligning the coupling

5.3.2 Possible misalignment

The following types of misalignment can occur:

① Axial misalignment (ΔKa) ② Angular misalignment (ΔKw) ③ Radial misalignment (ΔKr)

Figure 5-5 Possible misalignment

5.3.2.1 Axial misalignment

Set the axial misalignment ΔKa to a value within the permissible tolerance range of dimension S.

You can find the values for dimension S in section Speeds, geometry data and weights (Page 57).

5.3.2.2 Angular misalignment

Determine the value ΔS (ΔS = S ΔS

perm

You can find the values for ΔS (Page 62).

If required, you can calculate the angular misalignment ΔKw as follows:

ΔKw [rad] = ΔS / DA

ΔKw [deg] = (ΔS / DA) · (180 / π)

If required, you can calculate the permissible angular misalignment ΔKw

ΔKw

DA in mm see section Speeds, geometry data and weights (Page 57)

[rad] = ΔS

perm

[deg] = (ΔS

perm

/ DA

/ DA) · (180 / π)

perm

- S

max

). The determined value ΔS may not exceed the value

min

in section Shaft misalignment values during operation

as follows:

perm

ΔS

see section Shaft misalignment values during operation (Page 62)

perm

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5.3.2.3 Radial misalignment

Assembly

5.3 Aligning the coupling

Determine the value ΔKr. The determined value ΔKr may not exceed the value ΔKr

You can find the permissible radial misalignment ΔKr

in section Shaft misalignment values

perm

during operation (Page 62).

perm

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Assembly

5.3 Aligning the coupling

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Commissioning

DANGER

Danger due to igniting deposits

During use in potentially explosive atmospheres deposits from heavy metal oxides (rust) can ignite due to friction, impact or friction sparks and lead to an explosion.

● Ensure through the use of an enclosure or other suitable measures that the deposition of heavy metal oxides (rust) on the coupling is not possible.

In order to ensure safe commissioning, carry out various tests prior to commissioning.

Testing before commissioning

DANGER

Danger

Overload conditions can occur during the commissioning of the coupling. The coupling can burst and metal parts can be flung out. There is a risk of fatal injury from flying fragments. Bursting of the coupling can lead to an explosion in potentially explosive atmospheres.

● Carry out the tests prior to commissioning.

● Do not touch the rotating coupling.

1. Check the tightening torques of the screws of the coupling in accordance with section Tightening torques and widths A/F (Page 63).

2. Check the tightening torques of the foundation bolts of the coupled machines.

3. Check whether the enclosures (coupling guard, touch protection) have been installed and that the function of the coupling has not been adversely affected by the enclosure. This also applies to test runs and rotational direction checks.

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Commissioning

N-EUPEX / N-EUPEX DS 3100en

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Operation

7.1 Normal operation of the coupling

The coupling runs quietly and shock-free during normal operation.

7.2 Faults - causes and rectification

A form of behaviour which is different to normal operation is classed as a fault and has to be rectified immediately.

Look out specifically for the following faults during coupling operation:

● Unusual coupling noise

● Sudden occurrence of shocks

7.2.1 Procedure in the event of malfunctions

DANGER

Danger due to bursting of the coupling

There is a risk of fatal injury from flying fragments. Bursting of the coupling can lead to an explosion in potentially explosive atmospheres.

● Switch off the unit at once if any malfunctions occur.

● Note during the maintenance work the possible causes of faults and the notes on rectifying them.

Proceed as described below if there is a malfunction of the coupling during operation:

1. De-energise the drive immediately.

2. Initiate the required action for repair, taking into consideration the applicable safety regulations.

If you cannot determine the cause or if you cannot carry out repair work with your own means, request one of our customer service technicians.

7.2.2 Identifying the fault cause

Faults occur frequently due to application errors or they occur due to operational circumstances such as wear of wearing parts or changes to the system.

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Operation

7.2 Faults - causes and rectification

The faults and fault causes listed below only serve as an indication for troubleshooting. In the case of a complex system be sure to include all the system components in the search for the fault.

WARNING

Physical injury

Injury from rotating parts.

● Only carry out work on the coupling when it is not moving.

● Secure the drive unit against being operated accidentally.

● Attach a notice to the switch stating clearly that work is being carried out on the coupling.

● Before starting any work, make sure that the unit is free from loads.

Intended use

The coupling is only approved for the applications specified in these instructions. Please observe all the stipulations in section Intended use (Page 13).

7.2.2.1 Possible faults

Table 7-1 Table of faults

Fault Cause Rectification

Sudden changes in the noise level and/ or sudden occurrences of shocks

Wear of wearing parts Follow the instructions given in section

Replacing wearing parts (Page 40).

Changed alignment Follow the instructions given in section

Correcting the changed alignment (Page 41).

Coupling not suitable for the operating conditions.

Check the possible causes given in sec‐ tion Unsuitable coupling (Page 39).

Incorrect assembly of the coupling. Check the possible causes given in sec‐

tions Assembly-related causes (Page 39) and Specific installation-rela‐ ted and maintenance-related causes (Page 40).

Incorrect maintenance of the coupling. Check the possible causes given in sec‐

tions Maintenance-related causes (Page 40) and Specific installation-rela‐ ted and maintenance-related causes (Page 40).

Use a coupling that is suitable for the operating conditions.

Reassemble the coupling in accordance with these instructions.

Please observe all the stipulations and requirements given in chapter Assem‐ bly (Page 23).

Please observe all the stipulations and requirements given in chapter Servic‐ ing (Page 43).

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7.2 Faults - causes and rectification

Fault Cause Rectification

Presence of vibration Coupling not suitable for the operating

conditions. Check the possible causes given in sec‐

tion Unsuitable coupling (Page 39).