Siemens Flender FLUDEX 4600 FAM, Flender FLUDEX 4600 FAD, Flender FLUDEX 4600, Flender FLUDEX 4600 FADB, Flender FLUDEX 4600 FADS Operating Instructions Manual
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FLENDER COUPLINGS
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FLUDEX
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Operating instructions 4600 en
Edition 10/2017
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FAO, FAD, FAE, FAM, FADB, FADS, FAK, FAKB, FAR
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flender.com
T
echnical data
T
T
1
General notes
FLENDER COUPLINGS
FLUDEX
4600 en
Operating instructions
Safety instructions
ransport
and storage
echnical
description
Fitting
Start-up
Operation
Faults, causes
and remedy
2
3
4
5
6
7
8
9
FAO, FAD, FAE, FAM, FADB, FADS, FAK, FAKB,
FAR
Maintenance
and repair
Spare parts,
customer service
Declarations
10
11
12
Edition 10/2017
Legal notes
Warning note concept
This manual comprises notes which must be observed for your personal safety and for preventing material
damage. Notes for your personal safety are marked with a warning triangle or an "Ex" symbol (when applying
Directive 2014/34/EU), those only for preventing material damage with a "STOP" sign.
WARNING! Imminent explosion!
The notes indicated by this symbol are given to prevent explosion damage.
Disregarding these notes may result in serious injury or death.
WARNING! Imminent personal injury!
The notes indicated by this symbol are given to prevent personal injury.
Disregarding these notes may result in serious injury or death.
WARNING! Imminent damage to the product!
The notes indicated by this symbol are given to prevent damage to the product.
Disregarding these notes may result in material damage.
NOTE!
The notes indicated by this symbol must be treated as general operating information.
Disregarding these notes may result in undesirable results or conditions.
WARNING! Hot surfaces!
The notes indicated by this symbol are made to prevent risk of burns due to hot surfaces
and must always be observed.
Disregarding these notes may result in light or serious injury.
Where there is more than one hazard, the warning note for whichever hazard is the most serious is always used.
If in a warning note a warning triangle is used to warn of possible personal injury, a warning of material damage
may be added to the same warning note.
Qualified personnel
The product/system to which this documentation relates may be handled only by persons qualified for the work
concerned and in accordance with the documentation relating to the work concerned, particularly the safety and
warning notes contained in those documents.
Qualified personnel must be specially trained and have the experience necessary to recognise risks associated
with these products and to avoid possible hazards.
Proper use of Flender products
Observe also the following:
Flender products must be used only for the applications provided for in the catalogue and the relevant technical
documentation. If products and components of other makes are used, they must be recommended or approved
by Flender. The faultfree, safe operation of the products calls for proper transport, proper storage, erection,
assembly, installation, startup, operation and maintenance. The permissible ambient conditions must be
adhered to. Notes in the relevant documentations must be observed.
Trade marks
All designations to which the registered industrial property mark ® is appended are registered trademarks of
Flender GmbH. Other designations used in this document may be trademarks the use of which by third parties
for their own purposes may infringe holders’ rights.
Exclusion of liability
We have checked the content of the document for compliance with the hard and software described.
Nevertheless, variances may occur, and so we can offer no warranty for complete agreement. The information
given in this document is regularly checked, and any necessary corrections are included in subsequent editions.
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.
Flender GmbH
Alfred-Flender-Straße 77
46395 Bocholt
GERMANY
Document number: 4600 en
10/2017 Subject to alterations
Copyright © Flender GmbH 2017
All rights reserved
Contents
1. Technical data 7.....................................................
1.1 General data 7.......................................................................
1.2 Coupling versions 7...................................................................
1.3 Data relating specifically to the coupling 7................................................
2. General notes 8.....................................................
2.1 Introduction 8........................................................................
2.2 Copyright 8..........................................................................
3. Safety instructions 9.................................................
3.1 Obligations of the user 9...............................................................
4. Transport and storage 10.............................................
4.1 Scope of supply 10....................................................................
4.2 Transport 10..........................................................................
4.3 Storage of the coupling 10..............................................................
4.4 Storage area for a protracted period 10...................................................
5. Technical description 11..............................................
5.1 General description Type ”FA..” 11.......................................................
5.2 Construction of couplings 11............................................................
5.3 Marking the coupling parts for explosion protection 12......................................
5.4 Conditions of use for FLUDEX couplings in potentially explosive areas 13......................
6. Fitting 13.............................................................
6.1 Instructions for applying the finished bore and fitting the axial retaining means, set screws
6.1.1 Finished bore 13.......................................................................
6.1.2 Parallel keyway 15.....................................................................
6.1.3 Axial fastening 15......................................................................
6.1.4 Set screws 16.........................................................................
6.1.5 Balancing 17..........................................................................
6.2 General information on fitting 18.........................................................
6.3 Mounting the coupling parts 18..........................................................
6.4 Alignment 19..........................................................................
6.5 Possible misalignments 20..............................................................
6.5.1 Axial misalignment 20..................................................................
6.5.2 Angular misalignment 20................................................................
6.5.3 Radial misalignment 20.................................................................
6.5.4 Permissible shaftmisalignment values for radial misalignment ΔKrperm. and
6.6 Assignment of tightening torques 21......................................................
and balancing 13......................................................................
difference in gap dimension ΔSperm. 20..................................................
7. Startup 21...........................................................
7.1 Procedure before startup 21............................................................
7.2 Fluid filling 21.........................................................................
7.2.1 Operating fluid: oil 23...................................................................
7.2.2 Operating fluid: water or water emulsion 23................................................
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8. Operation 24.........................................................
8.1 General operating data 24..............................................................
9. Faults, causes and remedy 24.........................................
9.1 General 24............................................................................
9.2 Possible faults 25......................................................................
9.3 Incorrect use 25.......................................................................
9.3.1 Possible faults when selecting the coupling and/or coupling size 26...........................
9.3.2 Possible faults when installing the coupling 26.............................................
9.3.3 Possible faults in maintenance 27........................................................
10. Maintenance and repair 27............................................
10.1 Changing the operating fluid 27..........................................................
10.2 Changing the shaft-sealing rings 28......................................................
10.3 Maintenance interval of the NEUPEX addon coupling 28...................................
10.4 Replacement of the flexible elements 28..................................................
10.5 Disassembling the FLUDEX coupling 29..................................................
10.5.1 Disassembling the sizes 222 to 342 29....................................................
10.5.2 Disassembling the sizes 395 to 590 30....................................................
10.6 Disassembling the FLUDEX coupling 31..................................................
10.7 Reassembling the FLUDEX coupling 31...................................................
10.8 Refitting the FLUDEX coupling 31........................................................
10.9 Filling quantities for FLUDEX ”FA..” couplings, sizes 297, 395 and 516 32......................
10.10 Filling quantities for FLUDEX ”FA..” couplings, sizes 222, 342, 450 and 590 33.................
11. Spare parts, customer service 34......................................
11.1 Spareparts and customerservice addresses 34...........................................
11.2 Spare parts list, types FAO, FAK, FAD, FAE, FAM, FADB, FADS 35...........................
11.3 Spare parts list, type FAR 36............................................................
12. Declarations 37.......................................................
12.1 EU declaration of conformity 37..........................................................
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Operating instructions 10/2017
FLUDEX 4600 en
1. Technical data
1.1 General data
These operating instructions apply generally to FLUDEX couplings of the ”FA..” series.
1.2 Coupling versions
FAD
FAE
FAO
FADB
FADS
FAR
FAM
Fig. 1: Coupling types
1.3 Data relating specifically to the coupling
The orderspecific data relating to a delivery are, if known in case of an order, listed on the title
orderreleated page. In this case this title page diverges from that published on the Internet. The contents
of the operating instructions are, however, in this case identical.
The order number serves as the coupling’s ident number. This number appears on the coupling in light
raised relief.
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2. General notes
2.1 Introduction
These instructions are an integral part of the delivery of the coupling and must be kept in its vicinity for
reference at all times.
All persons involved in the installation, operation, maintenance and repair of the
coupling must have read and understood these operating instructions and must
comply with them at all times. Flender accepts no responsibility for damage or
disruption caused by disregard of these instructions.
The "FLENDER coupling" described in these instructions has been developed for stationary use in
general engineering applications.
The coupling is designed only for the application described in section 1, "Technical data". Other operating
conditions must be contractually agreed.
The coupling has been manufactured in accordance with the state of the art and is delivered in a condition
for safe and reliable use. It complies with the requirements in Directive 2014/34/EU.
The coupling must be used and operated strictly in accordance with the conditions laid down in the contract
governing performance and supply agreed by Flender and the customer.
The coupling described in these instructions reflects the state of technical development at the time these
instructions went to print.
In the interest of technical progress we reserve the right to make changes to the individual assemblies and
accessories which we regard as necessary to preserve their essential characteristics and improve their
efficiency and safety.
2.2 Copyright
The copyright to these operating instructions is held by Flender.
These instructions must not be wholly or partly reproduced for competitive purposes, used in any
unauthorised way or made available to third parties without our agreement.
Technical enquiries should be addressed to the following factory or to one of our customer services:
Flender GmbH
Schlavenhorst 100
46395 Bocholt
Tel.: +49 (0)2871 / 92-0
Fax: +49 (0)2871 / 92-2596
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Operating instructions 10/2017
FLUDEX 4600 en
3. Safety instructions
Any changes on the part of the user are not permitted. This applies equally to safety
features designed to prevent accidental contact.
3.1 Obligations of the user
• The operator must ensure that all persons involved in installation, operation, maintenance and repair
have read and understood these operating instructions and comply with them at all times in order to:
─ avoid injury or damage,
─ ensure the safety and reliability of the coupling,
─ avoid disruptions and environmental damage through incorrect use.
• During transport, assembly, installation, demounting, operation and maintenance of the unit, the
relevant safety and environmental regulations must be complied with at all times.
• The housing of the FLUDEX coupling is made of aluminium (ACAlSi10Mg). Depending on the
individual case, if necessary, further requirements must be taken into account when handling
aluminium.
• The coupling may only be operated, maintained and/or repaired by persons qualified for the work
concerned (see "Qualified personnel" on page 3 of this manual).
• All work must be carried out with "great care" and with due regard to safety.
• All work on the coupling must be carried out only when it is at a standstill.
The drive unit must be secured against being switched on accidentally (e.g. by locking the key switch
or removing the fuses from the power supply). A notice should be attached to the ON switch stating
clearly that work is in progress.
• The coupling must be fitted with suitable safeguards to prevent accidental contact. This fixture must
also offer protection against spurting hot operating fluid without substantially impairing the coupling
ventilation. The fusible safety plugs and filling plugs should remain accessible.
• The use of suitable operating fluids (usually oil) is necessary for the operation of the coupling. The
instructions for use enclosed by the operating fluid manufacturer must be observed.
• The drive unit must be shut down as soon as changes to the coupling are detected during operation.
• When the coupling is installed in plant or equipment, the manufacturer of such plant or equipment must
ensure that the contents of the present operating instructions are incorporated in his own prescription,
instructions and descriptions in his operating instructions.
• All spare parts must be obtained from Flender.
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4. Transport and storage
Observe the instructions in section 3, "Safety instructions"!
4.1 Scope of supply
The products supplied are listed in the dispatch papers. Check on receipt to ensure that all the products
listed have actually been delivered. Parts damaged during transport or missing parts must be reported in
writing immediately.
The equipment is delivered ready for operation, depending upon an order with or without fluid filling.
Couplings filled with operating medium are marked by a label ("...L, HLP 32 DIN 51524/2, operating oil
already put in") in the vicinity of the filling hole. Delivered separately with every coupling is a fusible safety
plug (depending on design also a thermal circuit breaker) with sealing rings, a locking plate and a retaining
screw, if provided for.
The coupling in design in accordance with the Directive 2014/34/EU is provided with the
CE identification mark as described in section 5.
4.2 Transport
When transporting the unit, use only lifting and handling equipment of sufficient
loadbearing capacity.
The coupling must be transported using suitable transport equipment only.
Different forms of packaging may be used depending on the size of the coupling and method of transport.
Unless otherwise agreed, the packaging complies with the HPE Packaging Guidelines.
The symbols marked on the packing must be observed at all times. These have the following meanings:
Top Fragile Keep dry Keep cool Centre of
Fig. 2: Transport symbols
4.3 Storage of the coupling
Unless otherwise expressly agreed, the coupling is delivered in a preserved condition and can be stored
in a covered, dry place for up to 3 months. If storage is provided for a protracted period, the unit should be
treated with a longterm preservative agent on all outer surfaces with the exception of the aluminium
housing (Flender must be consulted).
+Before cleaning the coupling and applying the longterm preservative agent, any
flexible elements of the NEUPEX addon coupling must be removed. The shaft-sealing
rings must not come into contact with solvents.
Correctly stored couplings retain their properties unchanged for up to five years. Unfavourable storage
conditions and improper treatment of the flexible elements and/or seals will negatively affect their physical
properties. Such negative effects may be caused by e.g. the action of oxygen, ozone, extreme
temperatures, light, moisture, or solvents.
gravity
Use no hand
hook
Attach
here
4.4 Storage area for a protracted period
The storage area must be dry and free from dust. The couplings must not be stored with chemicals,
solvents, motor fuels, acids, etc. Furthermore, the flexible elements and seals should be protected against
light, in particular direct sunlight and bright artificial light with a high ultraviolet content.
The storage areas must not contain any ozonegenerating equipment, such as
fluorescent light sources, mercury vapour lamps, highvoltage electrical equipment.
Damp storage areas are unsuitable. Ensure that no condensation occurs. The most
favourable atmospheric humidity is below 65 %.
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5. Technical description
Observe the instructions in section 3, "Safety instructions"!
5.1 General description Type ”FA..”
103
102
105
106
163
FAD
7
8
FAR
153
101
12
120
7 Compensating chamber
8 Working chamber
9 NEUPEX addon coupling
12 Flexible element (NEUPEX)
101 Blade shell (outer wheel)
9
102 Cover
103 Fusible safety plug
105 Bucket wheel (inner wheel)
106 Hollow shaft
120 Vbelt pulley
153 Filling plug
163 Screw plug
Fig. 3: General description Type ”FA..”
The FLUDEX coupling is a hydrodynamic fluid coupling working on the Föttinger principle. The coupling
parts on the in and output side are not connected to one another mechanically. The torque is transmitted
by the fluid flowing in the coupling and conducted via radial blades. During continuous operation very low
rotary speed slip occurs.
FLUDEX couplings of the ”FA..” series are sutiable for both directions of rotation. They can be fitted in
a horizontal, angled or vertical position. The drive should preferably take place via the hollow shaft (106)
and the bucket wheel (105) to enable the advantages of the compensating chamber (7) and the working
chamber geometry to be utilised.
If locked or overloaded by the driven machine, the coupling heats up until the fusing temperature of the
safety fuse is reached.
When the safety fuse fuses, the operating fluid escapes and the drive motor is disconnected from the
driven machine. To prevent the operating fluid spurting out, electronically or mechanically controlled
thermal monitoring equipment (see separate operating instructions) can be used.
5.2 Construction of couplings
FLUDEX couplings are made up of a few, robust parts.
The inner rotor includes the hollow shaft (106), on which the bucket wheel (105) is mounted. The outer
housing comprises the cover (102) and the blade shell (101), which are connected via a screwed flange
connection.
The outer housing and the inner rotor are doublemounted one inside the other and sealed towards the
outside by shaft-sealing rings.
For filling the coupling, two filling plugs (153) are located in filling channels offset by 180° (to prevent
overfilling). For this a screw plug (163), offset on the periphery (by approx. 60°), to be used for ventilation
while filling, for checking the filling level and for draining off the operating fluid, is located in the coupling
flange. Opposite it is the fusible safety plug (103).
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In the standard design the fusing temperature of the fusible safety screw is 140 °C, and the material used
for the seals is Perbunan (for a maximum continuous operating temperature of 85 °C). As an extended
standard (for continuous operating temperatures of up to 110 °C and/or synthetic oil ), the coupling can be
fitted with seals made of Viton. In this case a fusible safety plug with a fusing temperature of 160 °C is used
in the coupling.
Couplings to be used in potentially explosive areas are designed with the fusible
safety plugs (103) permitted for the temperature class.
The fusing temperature of the fusible safety plugs is stamped on their end faces, the 140 °C plugs also
being marked red, the 160 °C plugs green.
For applications where frequent faults or locking of the drive may occur it is recommended that a thermal
monitoring system be provided. This will prevent the operating fluid from escaping and being lost and the
environment from being polluted and endangered. The transmitter (EOC system) or the thermal circuit
breaker (mechanical switching equipment) is screwed into the coupling flange in place of the screw plug
(163). The fusible safety plug (103) remains in the coupling as an emergency safety device.
A thermal circuit breaker with a fusing temperature of 110 °C can be used on a coupling with Perbunan
seals and a 140 °C fusible safety plug.
A thermal circuit breaker with a fusing temperature of 140 °C can be used on a coupling with Viton seals
and a 160 °C fusible safety plug.
A 160 °C fusible safety plug can be used with an EOC system (transmitter release temperature of 125 °C),
including with Perbunan seals.
The type FAO includes only the components of the fluid coupling (without attachment) and incorporates
a connection flange point on the output side. The types FAK/FAD/FAE/FAM are couplings with NEUPEX
addon coupling integrated on the output side for connecting two shafts. The types FAKB/FADB are
FAK/FAD couplings with a brake drum. The type FADS is a FAD coupling with brake disk. The type FAR
is a coupling with Vbelt pulley on the output side.
In the flexible NEUPEX addon coupling the Hshaped Perbunan flexible elements are delivered in a
standard Shore hardness of 80.
Coupling with worn flexible elements (12) (for wear mark ΔS
be operated in potentially explosive areas.
5.3 Marking the coupling parts for explosion protection
Couplings which are intended for use in potentially explosive areas must bear the following
marking:
Flender GmbH
46393 Bocholt - Germany
FLENDER couplings FLUDEX <year built>
Marking of the fusible safety plug:
The N-EUPEX add-on coupling must have stamped on the hub parts.
, see section 10) must not
V
II 2G c b IIB T3 -30 °C ≤ Ta ≤ +50 °C
II 2D c b T 160 °C -30 °C ≤ Ta ≤ +50 °C
I M2 c b -30 °C ≤ Ta ≤ +50 °C
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Operating instructions 10/2017
FLUDEX 4600 en
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