FLENDER RUPEX RWN Assembly And Operating Instructions Manual
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FLENDER RUPEX RWN Assembly And Operating Instructions Manual

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RUPEX
Assembly and operating instructions M3600-02en
Edition 09/2022
RWN, RWS, RFN, RFS

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Summary of Contents for FLENDER RUPEX RWN

  • Page 1 RUPEX Assembly and operating instructions M3600-02en Edition 09/2022 RWN, RWS, RFN, RFS...
  • Page 2 Original assembly and operating instructions M3600-02 Edition 09/2022 20/10/2022 Copyright (©2022 Flender GmbH) 09:30:12...

  • Page 3: Table Of Contents

    Table of contents Introduction...............................11 Legal information ........................11 About these instructions......................12 Text attributes ..........................12 Copyright..........................13 Safety instructions ...........................15 General information .........................15 Intended use ..........................17 Safety instructions for a coupling for use in potentially explosive atmospheres ...... 17 2.3.1 Marking ............................17 2.3.2 Conditions of use ........................18 General warning notices ......................19 Description ..............................21...
  • Page 4 Table of contents Commissioning............................35 Operation..............................37 Normal operation of the coupling .....................37 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 7.2.2.2.1 Unsuitable coupling........................39 7.2.2.2.2 Assembly-related causes ......................39 7.2.2.2.3...
  • Page 5 Table of contents 11.1 Ordering spare parts ........................57 11.2 Spare parts drawing and spare parts list ................. 58 11.2.1 Types RWN and RWS ......................58 11.2.2 Types RFN and RFS........................60 Technical data............................63 Speeds, geometry data and weights..................63 A.1.1 RWN type..........................63 A.1.2 RWS type ..........................66 A.1.3 RFN type ..........................68...
  • Page 6 Table of contents Edition 09/2022 M3600-02en...
  • Page 7 List of tables Table 2-1 General warnings ........................15 Table 2-2 Temperature classes (TX) for explosive atmospheres as a result of gases, vapours or mists ............................18 Table 2-3 Maximum surface temperature (TX) for an explosive atmosphere as a result of dust/air mixtures............................19 Table 4-1 Types of preservative agents for long-term storage..............24 Table 5-1 Recommended assigned fits for bores with parallel key connection..........26 Table 5-2...
  • Page 8 List of tables Edition 09/2022 M3600-02en...
  • Page 9 List of figures Figure 3-1 RWN, RWS, RFN and RFS types .....................21 Figure 3-2 Bolt connection...........................22 Figure 4-1 Transport symbols........................23 Figure 5-1 Tolerances for the finished bore in coupling part 1 (1) or 2 (2) ..........27 Figure 5-2 Position of the balancing bore for single-plane balancing ............29 Figure 5-3 Position of the balancing bore for two-plane balancing..............30 Figure 5-4...
  • Page 10 List of figures Edition 09/2022 M3600-02en...

  • Page 11: Introduction

    Introduction Legal information 1.1 Legal information Warning system These instructions contain information you must observe for your own personal safety as well as to avoid damage to property and persons. The information regarding your personal safety is highlighted with a warning triangle. Information exclusively regarding property dam- age alone is not marked with a warning triangle.

  • Page 12: About These Instructions

    Please note the following: WARNING Flender products are only suitable for the uses set out in the catalogue and associated technical documentation. If third-party products and components are used, these must be recommended and/or authorised by Flender. Safe and flawless operation of the products requires proper transport, proper storage, setup, assembly, installation, commissioning, operation and maintenance.

  • Page 13: Copyright

    (1) Numbers in brackets are part numbers. Copyright 1.4 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 53)).
  • Page 14 Introduction 1.4 Copyright Edition 09/2022 M3600-02en...

  • Page 15: Safety Instructions

    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 fail- ures that are due to non-adherence to these instructions.

  • Page 16: Table 2-1 General Warnings

    Safety instructions 2.1 General information ANSI Warning Warning – hand injuries Explosion protection approval Table 2-1: General warnings Explanation regarding regulation 2008 No. 1597 The couplings described here are “components” in accordance with the regulation 2008 No. 1597 and do not require a UK declaration of incorporation. Explosion Protection Directive The term “Explosion protection regulations”...

  • Page 17: Intended Use

    • 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. • Use only original replacement parts from Flender. Flender only accepts liability for ori- ginal replacement parts from Flender.

  • Page 18: Conditions Of Use

    2.3 Safety instructions for a coupling for use in potentially explosive atmospheres Coupling part 1 with electrically insulating buffers The following marking is visible on the outer diameter of coupling part 1: Flender GmbH II 2G Ex h IIB T6 ... T4 Gb X D 46393 Bocholt II 2D Ex h IIIC T85 °C ...

  • Page 19: General Warning Notices

    Safety instructions 2.4 General warning notices Max. ambient temperature Max. surface temperature 80 °C 110 °C Table 2-3: Maximum surface temperature (TX) for an explosive atmosphere as a result of dust/air mix- tures Notes concerning operation of the coupling in potentially explosive atmospheres •...
  • Page 20 Safety instructions 2.4 General warning notices DANGER Danger of explosion Improper operation of the coupling can lead to an explosion in potentially explosive atmo- spheres. • 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.

  • Page 21: Description

    Types RWN and RWS have two shaft-hub connections. Types RFN and RFS have one shaft-hub connection and a flange. Please consult Flender if you want to use a different type of installation.

  • Page 22: Figure 3-2 Bolt Connection

    Description Figure 3-2: Bolt connection ① Bolt connection for sizes 105 to 400 ② Bolt connection for sizes 450 to 630 ③ Bolt connection for sizes 710 to 2,000 Bolt Buffer Washer Hexagon nut, self-locking Washer Hexagon bolt Locking ring Edition 09/2022 M3600-02en...

  • Page 23: Application Planning

    Application planning 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. Transport of the coupling 4.1 Transport of the coupling...

  • Page 24: Table 4-1 Types Of Preservative Agents For Long-Term Storage

    Application planning 4.2 Storage of the coupling • 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 high-voltage electrical equipment.

  • Page 25: Assembly

    • Balancing the coupling (Page 29) Information 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.

  • Page 26: Milling The Finished Bore

    Assembly 5.1 Preparatory work 5.1.1 Milling the finished bore 5.1 Preparatory work 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.

  • Page 27: Milling The Parallel Keyway

    5.1 Preparatory work 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 threaded hole in the hub •...

  • Page 28: Table 5-2 Threaded Hole, Tightening Torque And Width A/F For Types Rwn And Rfn

    Assembly 5.1 Preparatory work Finished bore Threaded hole Tightening torque Width A/F Hexagon socket Over Up to Table 5-2: Threaded hole, tightening torque and width A/F for types RWN and RFN Apply the specified tightening torques as listed in Section Tightening procedure (Page 74). Finished bore Threaded hole Tightening torque...

  • Page 29: Balancing The Coupling

    Assembly 5.1 Preparatory work Selection of the set screw CAUTION Physical injury Danger of injury from protruding set screw. • Please observe the information about selecting the set screw. Use set screws in accordance with ISO 4029 with a toothed cup point. The size of the set screw is determined by the bore made.

  • Page 30: Assembling The Coupling

    Assembly 5.2 Assembling the coupling Figure 5-3: Position of the balancing bore for two-plane balancing ① Balancing bore Information A better balancing result can be achieved by balancing with bolt (4) fitted. When total balan- cing, mark the bolt (4) and the bolt fitting hole. Assembling the coupling 5.2 Assembling the coupling NOTICE...

  • Page 31: Assembling Coupling Parts With Shaft And Hub Connected By A Pressurised Oil Interference Fit

    Assembly 5.2 Assembling the coupling 2. Clean the bores and shaft ends. 3. Coat the bores of coupling parts 1 (1) and/or 2 (2) and the shafts with MoS assembly paste (e.g. Microgleit LP 405). 4. Mount the coupling parts 1 (1) and/or 2 (2) on the shaft. WARNING Danger due to bursting of the coupling If you do not observe the information stipulated here when assembling coupling parts with...

  • Page 32: Assembling The Coupling Part 20 (20) With Types Rfn And Rfs

    Assembly 5.2 Assembling the coupling Make sure that no dirt or contaminants can soil the bores again during the heating pro- cess. 7. Mount the coupling parts 1 (1) and/or 2 (2) quickly on the shaft according to the instruc- tions in the dimension drawing. 8.

  • Page 33: Possible Misalignment

    Assembly 5.3 Aligning the coupling You can find the maximum permitted shaft misalignment values during operation in section Shaft misalignment values during operation (Page 71). 5.3.2 Possible misalignment 5.3 Aligning the coupling The following types of misalignment can occur: Figure 5-4: Possible misalignment ①...

  • Page 34: Radial Misalignment

    Assembly 5.3 Aligning the coupling 5.3.2.3 Radial misalignment 5.3 Aligning the coupling Determine the value ΔKr. The determined value ΔKr may not exceed the value ΔKr perm You can find the permissible radial misalignment ΔKr in section Shaft misalignment val- perm ues during operation (Page 71).

  • Page 35: Commissioning

    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.
  • Page 36 Commissioning Edition 09/2022 M3600-02en...

  • Page 37: Operation

    Operation Normal operation of the coupling 7.1 Normal operation of the coupling The coupling runs quietly and shock-free during normal operation. Faults - causes and rectification 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.

  • Page 38: Possible Faults

    Operation 7.2 Faults - causes and rectification 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 coup- ling.

  • Page 39: Possible Causes

    Operation 7.2 Faults - causes and rectification Fault Cause Rectification Presence of vibration Incorrect assembly of the coupling. Reassemble the coupling in accord- ance with these instructions. Check the possible causes given in sections Assembly-related causes Please observe all the stipulations and (Page 39) and Specific installation-re- requirements given in chapter As- lated and maintenance-related causes...

  • Page 40: Maintenance-Related Causes

    7.2 Faults - causes and rectification • Stipulated maintenance intervals not adhered to. • Spare parts that were used were not original spare parts from Flender. • Flender spare parts that were used were old or damaged. • Leak in the area of the coupling not detected so that chemically aggressive substances damage the coupling.
  • Page 41 Operation 7.2 Faults - causes and rectification Procedure 1. Correct the cause for the change in alignment. 2. Check the wearing parts for wear and replace them as required. 3. Check the locking elements that prevent axial movements and correct these as required. 4.
  • Page 42 Operation 7.2 Faults - causes and rectification Edition 09/2022 M3600-02en...

  • Page 43: Servicing

    Servicing Maintenance intervals 8.1 Maintenance intervals DANGER Danger due to bursting of the coupling The coupling can burst if the maintenance intervals are not adhered to. There is a risk of fatal injury from flying fragments. Bursting of the coupling can lead to an explosion in po- tentially explosive atmospheres.

  • Page 44: Maximum Permissible Torsional Backlash

    Servicing 8.2 Maximum permissible torsional backlash Shorter maintenance intervals If necessary, set shorter maintenance intervals depending on actual wear. Maximum permissible torsional backlash 8.2 Maximum permissible torsional backlash In order to calculate the torsional backlash, rotate one coupling part without applying torque up to the stop.

  • Page 45: Replacing Wearing Parts

    Servicing 8.3 Replacing wearing parts Replacing wearing parts 8.3 Replacing wearing parts DANGER Danger due to bursting of the coupling If you do not observe the information stipulated here regarding replacement of wearing parts, this can lead to bursting of the coupling during operation. There is a risk of fatal in- jury from flying fragments.

  • Page 46: Replacing Buffers (5) As Of Coupling Size 450 To 630

    Servicing 8.3 Replacing wearing parts 8.3.2 Replacing buffers (5) as of coupling size 450 to 630 8.3 Replacing wearing parts NOTICE Blockage of cross bore of bolts (4) The liquid screw locking agent can seal the cross bore of the bolts (4). Pressing out the bolts (4) with grease then becomes difficult or completely impossible.

  • Page 47: Replacing Buffers (5) With Removal Of The Bolts (4)

    (4). 8.3.4.1 Pressing out bolts (4) with the "demounting box" 8.3 Replacing wearing parts Flender can supply a "demounting box" which is a hydraulic press-out fixture for removing bolts. Flender can supply the demounting box on request. M3600-02en Edition 09/2022...

  • Page 48: Pressing Out Bolts (4) With Grease

    Servicing 8.3 Replacing wearing parts Information Separate operating instructions If you use the "demounting box" to remove the bolts (4), please observe the operating in- structions BA 3600.1, "Demounting box for extraction of RUPEX bolts". 8.3.4.2 Pressing out bolts (4) with grease 8.3 Replacing wearing parts WARNING Risk of injury from flying bolts (4)

  • Page 49: Potential Problems When Pressing Out Bolts (4) With Grease

    Servicing 8.3 Replacing wearing parts 8.3.4.3 Potential problems when pressing out bolts (4) with grease 8.3 Replacing wearing parts Problem Cause Possible solutions Bolt (4) is not released despite Pressure is too low to release • Use a longer screw (11) (min- the fact that the screw is fully in- the bolt (4).

  • Page 50: Removing Coupling Part 1 (1) Or 2 (2) With Shaft And Hub Connected By A Pressurised Oil Interference Fit

    Servicing 8.4 Removing coupling part 1 (1), 2 (2) or 20 (20) 5. Heat up the coupling part 1 (1) and/or 2 (2) using a burner above the parallel keyway along its length to maximum 80 °C. Note when doing this the permissible temperature range of the buffers (5) (refer to sec- tion RUPEX buffers (5) (Page 75)).
  • Page 51 Servicing 8.4 Removing coupling part 1 (1), 2 (2) or 20 (20) NOTICE Risk of injury and danger to the environment from escaping oil. • Catch any oil which escapes. • Dispose of the oil according to the valid regulations. Tools required •...

  • Page 52: Removing Coupling Part 20 (20) With Flange Connection

    Servicing 8.4 Removing coupling part 1 (1), 2 (2) or 20 (20) NOTICE Removal in several strokes If several strokes of the hydraulic cylinder are required to remove the part, make sure that the shaft end is positioned between two oil channels at the end of the stroke. 12.Dismantle the oil pumps and the pulling fixture from the coupling part 1 (1) or 2 (2).

  • Page 53: Service And Support

    Customer Service addresses: Flender GmbH Schlavenhorst 100 46395 Bocholt Germany Tel.: +49 (0)2871/92-0 Fax.: +49 (0)2871/92-2596 Flender GmbH (http://www.flender.com/) More information Further information about service and support can be found on the Internet: Service & Support (https://www.flender.com/service) M3600-02en Edition 09/2022...
  • Page 54 Service and support 9.1 Contact Edition 09/2022 M3600-02en...

  • Page 55: Disposal

    Disposal Disposal of the coupling Dispose of the coupling parts according to applicable national regulations or recycle them. M3600-02en Edition 09/2022...
  • Page 56 Disposal Edition 09/2022 M3600-02en...

  • Page 57: Spare Parts

    By stocking the most important replacement parts at the installation site you can ensure that the coupling is ready for use at any time. Use only original replacement parts from Flender. Flender only accepts liability for original replacement parts from Flender.

  • Page 58: Spare Parts Drawing And Spare Parts List

    Spare parts 11.2 Spare parts drawing and spare parts list 11.2 Spare parts drawing and spare parts list 11.2 Spare parts drawing and spare parts list 11.2.1 Types RWN and RWS 11.2 Spare parts drawing and spare parts list Figure 11-1: Replacement parts drawing for RWN and RWS types ①...

  • Page 59: Table 11-1 Spare Parts List For Types Rwn And Rws

    Spare parts 11.2 Spare parts drawing and spare parts list Part number Designation Washer Hexagon head screw Locking ring Screw plug Screw plug Table 11-1: Spare parts list for types RWN and RWS Screw plugs (101, 201) are only used in combination with a pressurised oil interference fit. Figure 11-2: Screw plug M3600-02en Edition 09/2022...

  • Page 60: Types Rfn And Rfs

    Spare parts 11.2 Spare parts drawing and spare parts list 11.2.2 Types RFN and RFS 11.2 Spare parts drawing and spare parts list Figure 11-3: Replacement parts drawing for RFN and RFS types ① Types RFN and RFS ② Bolt connection for coupling sizes 105 to ③...

  • Page 61: Table 11-2 Spare Parts List For Types Rfn And Rfs

    Spare parts 11.2 Spare parts drawing and spare parts list Part number Designation Coupling part 20 Screw plug Table 11-2: Spare parts list for types RFN and RFS Screw plugs (101) are only used in combination with a pressurised oil interference fit. Figure 11-4: Screw plug M3600-02en Edition 09/2022...
  • Page 62 Spare parts 11.2 Spare parts drawing and spare parts list Edition 09/2022 M3600-02en...

  • Page 63: Technical Data

    Technical data Speeds, geometry data and weights Speeds, geometry data and weights In this section you can find dimension drawings and technical data for RUPEX couplings of the following types: • RWN type (Page 63) • RWS type (Page 66) • RFN type (Page 68) •...
  • Page 64 Technical data Speeds, geometry data and weights Size Speed  Maximum bore                 Weight 3,750 2 … 5 11.5 3,300 2 … 5 17.7 3,000 2 … 5 2,650 3 … 6 2,350 3 … 6 2,100 3 … 6 2,050 3 … 6 1,800 4 … 7 1,600 4 … 7 1,500 4 … 8 1,280...

  • Page 65: Table A-1 Speed, Geometry Data And Weights For Rwn Type

    Technical data Speeds, geometry data and weights Size Speed  Maximum bore                 Weight 1,400 1,400 6 … 12 2,820 2,900 3,180 3,260 1,600 1,600 6 … 12 3,780 3,870 4,150 4,290 1,800 1,800 8 … 16 5,550 5,630 6,000 6,250 2,000 2,000...

  • Page 66: Rws Type

    Technical data Speeds, geometry data and weights A.1.2 RWS type Speeds, geometry data and weights Figure A-2: Dimension drawing RWS type Coupling part 1 Coupling part 2 Size Speed  Maximum bore                 Weight max. 10,000 2 … 4 9,000 2 … 4...
  • Page 67 Technical data Speeds, geometry data and weights Size Speed  Maximum bore                 Weight max. 1,800 4 … 8 1,600 5 … 9 1,400 5 … 9 1,250 5 … 10 1,000 1,000 1,100 1,000 5 … 10 1,170 1,208 1,290 1,220 1,120 1,000 1,120 6 … 11 1,560...

  • Page 68: Rfn Type

    Technical data Speeds, geometry data and weights Size Speed  Maximum bore                 Weight max. 1,800 1,800 8 … 16 6,230 6,460 6,770 6,390 2,000 2,000 8 … 16 8,140 8,430 8,860 8,280 Table A-2: Speed, geometry data and weights for RWS type Maximum bore for parallel keyway in accordance with DIN 6885/1.

  • Page 69: Table A-3 Speed, Geometry Data And Weights For Rfn Type

    Technical data Speeds, geometry data and weights Size Speed Maximum                             Weigh bore                             max.

  • Page 70: Rfs Type

    Technical data Speeds, geometry data and weights A.1.4 RFS type Speeds, geometry data and weights Figure A-4: Dimension drawing RFS type Coupling part 1 Coupling part 20 Size Speed Maximum                          ...

  • Page 71: Shaft Misalignment Values During Operation

    Technical data Shaft misalignment values during operation Size Speed Maximum                             Weigh bore                             max.

  • Page 72: Tightening Torques And Widths A/F

    Technical data Tightening torques and widths A/F Size Coupling speed in rpm 1 000 1 500 2 000 3 000 4 000 5 000 1.35 0.95 0.55 0.45 1.05 0.85 0.75 1.65 1.15 0.95 0.65 0.55 1.85 1.05 0.75 2.05 1.45 1.15 2.25 1.75 1.45 1.25 1 000 2.75 1.95...

  • Page 73: Coupling Part 20 To The Mating Part

    Technical data Tightening torques and widths A/F Size Tightening torque Width A/F External hexagon 1,000 1,120 1,150 1,250 1,150 1,400 1,150 1,600 1,150 1,800 2,000 2,000 2,000 Table A-6: Tightening torques and widths A/F of bolt connection A.3.2 Coupling part 20 to the mating part Tightening torques and widths A/F Size Bolt size...

  • Page 74: Tightening Procedure

    Technical data Tightening procedure Size Bolt size Tightening torque 1,450 1,450 2,530 Table A-7: Tightening torques for bolt connection of coupling part 20 to the mating part Tightening procedure Tightening procedure Tightening torques must be observed taking into account the following table: Scatter of the torque ap- Tightening procedure plied at the tool...

  • Page 75: Rupex Buffers (5)

    Technical data Buffers (5) • Avoid contact with aggressive media • Only replace complete sets • Only use buffers (5) of the same type and age A.5.2 RUPEX buffers (5) Buffers (5) Material Hardness Comment Marking Ambient temper- Approved for ex- ature plosion group 80 Shore A...
  • Page 76 Technical data Buffers (5) Edition 09/2022 M3600-02en...

  • Page 77: Declaration Of Conformity

    Declaration of Conformity UK Declaration of Conformity UK Declaration of Conformity Product: FLENDER RUPEX® couplings RWN, RWS, RFN and RFS types Name and address of the manufacturer: Flender GmbH Schlavenhorst 100 46395 Bocholt Germany This Declaration of Conformity is issued under the sole responsibility of the manufacturer.
  • Page 78 Declaration of Conformity UK Declaration of Conformity Edition 09/2022 M3600-02en...
  • Page 80 RUPEX Assembly and operating instructions M3600-02en Edition 09/2022 Flender GmbH Alfred-Flender-Straße 77 46395 Bocholt Germany...

This manual is also suitable for:

Rupex rwsRupex rfnRupex rfsRupex

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