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FLENDER RUPER RWB Assembly And Operating Instructions Manual

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RUPEX
Assembly and operating instructions M3602-01en
Edition 09/2022
RWB, RBS

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Summary of Contents for FLENDER RUPER RWB

  • Page 1 RUPEX Assembly and operating instructions M3602-01en Edition 09/2022 RWB, RBS...
  • Page 2 Original assembly and operating instructions M3602-01 Edition 09/2022 20/10/2022 Copyright (©2022 Flender GmbH) 09:44:09...

  • 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 11.2 Spare parts drawing and spare parts list ................. 58 11.2.1 Types RWB and RBS with brake drum in accordance with DIN 15431........58 11.2.2 Types RWB and RBS with brake disk..................60 Technical data............................63 Speeds, geometry data and weights..................63 A.1.1 RWB type with brake drum according to DIN 15431 ...............
  • Page 6 Table of contents Edition 09/2022 M3602-01en...
  • 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 M3602-01en...
  • Page 9 List of figures Figure 3-1 RWB and RBS types .........................21 Figure 3-2 Bolt connection...........................22 Figure 4-1 Transport symbols........................23 Figure 5-1 Tolerances for finished bore.......................27 Figure 5-2 Angular position of the set screw hole in coupling part 3 (brake drum) ........28 Figure 5-3 Position of the balancing bore for single-plane balancing ............30 Figure 5-4 Position of the balancing bore for two-plane balancing..............31 Figure 5-5...
  • Page 10 List of figures Edition 09/2022 M3602-01en...

  • 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 M3602-01en...

  • 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 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. Explosion Protection Directive The term “Explosion Protection Directive”...

  • 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

    These instructions describe the assembly and operation of a RUPEX coupling arranged hori- zontally with a shaft-hub connection made by a cylindrical or conical bore with parallel key or by a pressurised oil interference fit. 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 144 to 400 ② Bolt connection for sizes 450 to 630 ③ Bolt connection for sizes 710 to 1,000 Bolt Buffer Washer Hexagon nut, self-locking Washer Hexagon bolt Locking ring Edition 09/2022 M3602-01en...

  • 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 30) 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

    • Mill the parallel keyway in coupling part 3 (3) in accordance with DIN 6885/1 ISO P9. • If you want to mill a parallel keyway that does not correspond to DIN 6885/1, please con- sult Flender. 5.1.3 Machining an axial locking mechanism 5.1 Preparatory work...

  • Page 28: Table 5-2 Threaded Hole, Tightening Torque And Width A/F For Rwb Type

    Assembly 5.1 Preparatory work 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 • Position of the threaded hole with respect to the parallel keyway •...

  • Page 29: Table 5-3 Threaded Hole, Tightening Torque And Width A/F For Rbs Type

    Assembly 5.1 Preparatory work Apply the specified tightening torques as listed in Section Tightening procedure (Page 73). Finished bore Threaded hole Tightening torque Width A/F Hexagon socket Over Up to Table 5-3: Threaded hole, tightening torque and width A/F for RBS type Apply the specified tightening torques as listed in Section Tightening procedure (Page 73).

  • Page 30: Balancing The Coupling

    Assembly 5.1 Preparatory work 5.1.4 Balancing the coupling 5.1 Preparatory work Notes on balancing the coupling NOTICE Property damage to coupling part 1 (1) or coupling part 3 (3) If you completely drill through the flange on coupling part 1 (1), then coupling part 1 (1) is no longer allowed to be used for operation.

  • Page 31: Assembling The Coupling

    Assembly 5.2 Assembling the coupling Figure 5-4: Position of the balancing bore for two-plane balancing ① Balancing bore ② Coupling part 1 ③ Coupling part 3 (brake drum) ④ Coupling part 3 (brake disk) 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.

  • Page 32: Assembling Coupling Parts With Shaft And Hub Connected By A Parallel Key

    Assembly 5.2 Assembling the coupling 5.2.1 Assembling coupling parts with shaft and hub connected by a parallel key 5.2 Assembling the coupling Procedure 1. Unscrew the set screw out of coupling parts 1 (1) and/or 3 (3) until it is no longer pos- sible for there to be a collision with the parallel key or the shaft.

  • Page 33: Aligning The Coupling

    Assembly 5.3 Aligning the coupling 3. Clean, degrease, de-oil and dry the hub bores and shaft ends. 4. Clean and dry the oil channels and the oil circulation grooves. 5. Protect adjacent components against damage and heating to temperatures above 80 °C. 6.

  • Page 34: Possible Misalignment

    Assembly 5.3 Aligning the coupling 5.3.2 Possible misalignment 5.3 Aligning the coupling Figure 5-5: Possible misalignment ① Axial misalignment (ΔKa) ② Angular misalignment (ΔKw) ③ Radial misalignment (ΔKr) 5.3.2.1 Axial misalignment 5.3 Aligning the coupling Set the axial misalignment ΔKa to a value within the permissible tolerance range of dimen- sion S.

  • 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 M3602-01en...

  • 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 M3602-01en...

  • 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 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. Mark both of the coupling halves in the way shown in the diagram below. Turn the coupling part in the opposite direction up to the stop.

  • Page 45: Replacing Buffers (5) Up To Coupling Size 400

    Servicing 8.3 Replacing wearing parts 8.3.1 Replacing buffers (5) up to coupling size 400 8.3 Replacing wearing parts Procedure 1. Remove the hexagon nuts (7). 2. Remove the bolts (4) with the washers (6) and the buffers (5) through the buffer fitting holes. 3.

  • Page 46: Replacing Buffers (5) As Of Coupling Size 710

    Servicing 8.3 Replacing wearing parts 9. Secure the bolts (4) with the screws (11) and washers (8). 10.Tighten the screws (11) to the specified tightening torque T (see section Tightening torques and widths A/F (Page 72)). 8.3.3 Replacing buffers (5) as of coupling size 710 8.3 Replacing wearing parts You can use the following methods to replace the buffers (5) on couplings of size 710 or lar- ger.

  • Page 47: Pressing Out Bolts

    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. Information Separate operating instructions If you use the "demounting box"...

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

    Servicing 8.3 Replacing wearing parts WARNING Risk of injury When you are pressing out the bolts (4), grease can escape under high pressure. If bolt (4) suddenly works loose, fragments can become detached and fly through the air at high speed. •...

  • Page 49: Removing Coupling Part 1 (1) Or 3 (3) With Shaft And Hub Connected By A Parallel Key

    Servicing 8.4 Removing coupling part 1 (1) or 3 (3) • Removing coupling part 1 (1) or 3 (3) with shaft and hub connected by a parallel key (Page 49) • Removing coupling part 1 (1) or 3 (3) with shaft and hub connected by a pressurised oil interference fit (Page 49) 8.4.1 Removing coupling part 1 (1) or 3 (3) with shaft and hub connected by a...
  • Page 50 Servicing 8.4 Removing coupling part 1 (1) or 3 (3) DANGER Danger as a result of improper handling of fixtures and pumps Failure to handle fixtures and pumps properly can result in injuries and cause the coupling to burst. There is a risk of fatal injury from flying fragments. Bursting of the coupling can lead to an explosion in potentially explosive atmospheres.
  • Page 51 Servicing 8.4 Removing coupling part 1 (1) or 3 (3) 2. Remove the buffers (5). For further information, refer to section Replacing wearing parts (Page 44). 3. Use a suitable pulling fixture. 4. Secure the coupling part 1 (1) or 3 (3) and the pulling fixture in position to prevent them from falling.
  • Page 52 Servicing 8.4 Removing coupling part 1 (1) or 3 (3) Edition 09/2022 M3602-01en...

  • 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) M3602-01en Edition 09/2022...
  • Page 54 Service and support 9.1 Contact Edition 09/2022 M3602-01en...

  • Page 55: Disposal

    Disposal Disposal of the coupling Dispose of the coupling parts according to applicable national regulations or recycle them. M3602-01en Edition 09/2022...
  • Page 56 Disposal Edition 09/2022 M3602-01en...

  • 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 RWB and RBS with brake drum in accordance with DIN 15431 11.2 Spare parts drawing and spare parts list Figure 11-1: Replacement parts drawing for RWB and RBS types with brake drum ①...

  • Page 59: Table 11-1 Spare Parts List For Types Rwb And Rbs With Brake Drum

    Spare parts 11.2 Spare parts drawing and spare parts list Part number Designation Screw plug Table 11-1: Spare parts list for types RWB and RBS with brake drum Screw plugs (101, 301) are only used in combination with a pressurised oil interference fit. Figure 11-2: Screw plug M3602-01en Edition 09/2022...

  • Page 60: Types Rwb And Rbs With Brake Disk

    Spare parts 11.2 Spare parts drawing and spare parts list 11.2.2 Types RWB and RBS with brake disk 11.2 Spare parts drawing and spare parts list Figure 11-3: Replacement parts drawing for RWB and RBS types with brake disk ① Types RWB and RBS with brake disk ②...

  • Page 61: Table 11-2 Spare Parts List For Types Rwb And Rbs With Brake Disk

    Spare parts 11.2 Spare parts drawing and spare parts list Part number Designation Washer Hexagon nut, self-locking Washer Hexagon head screw Locking ring Screw plug Screw plug Table 11-2: Spare parts list for types RWB and RBS with brake disk Screw plugs (101, 301) are only used in combination with a pressurised oil interference fit. Figure 11-4: Screw plug M3602-01en Edition 09/2022...
  • Page 62 Spare parts 11.2 Spare parts drawing and spare parts list Edition 09/2022 M3602-01en...

  • 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: • RWB type with brake drum according to DIN 15431 (Page 63) •...

  • Page 64: Table A-1 Speeds, Geometry Data And Weights Of Rwb Type With Brake Drum In Accordance With

    Technical data Speeds, geometry data and weights Size Speed Maximum                   Weight bore max. 4,800 2 … 4 3,800 2 … 5 3,800 2 … 5 3,000 3,800 2 … 5 3,000 2,400 2 … 5 2,400 2 … 5 1,900 1,900 3 … 6 1,500 1,500 3 … 6 1,300...

  • Page 65: Rbs Type With Brake Drum According To Din 15431

    Technical data Speeds, geometry data and weights A.1.2 RBS type with brake drum according to DIN 15431 Speeds, geometry data and weights Figure A-2: Dimension drawing RBS type with brake drum Coupling part 1 Coupling part 3 Size Speed Maximum        ...

  • Page 66: Rwb Type With Brake Disk 12.7 Mm Wide

    Technical data Speeds, geometry data and weights Size Speed Maximum                   Weight bore max. 2,700 3 … 6 2,400 Table A-2: Speeds, geometry data and weights of RBS type with brake drum in accordance with DIN 15431 Maximum bore for parallel keyway in accordance with DIN 6885/1.

  • Page 67: Rbs Type With Brake Disk 12.7 Mm Wide

    Technical data Speeds, geometry data and weights Size Speed Maximum                         Weigh bore max. min. min. max. 2550 2 … 5 12.7 18.35 2300 2 … 5 12.7 19.35 1,800 3 … 6 12.7 19.35 1,600 3 … 6 12.7 21.35...

  • Page 68: Rwb Type With Brake Disk 30 Mm Wide, In Accordance With Din 15432

    Technical data Speeds, geometry data and weights Size Speed Maximum                         Weigh bore max. min. min. max. 4,800 2 … 4 12.7 17.35 11.3 3,800 2 … 5 12.7 17.35 18.3 3,800 2 … 5 12.7 17.35 3,400 2 … 5...

  • Page 69: Table A-5 Speeds, Geometry Data And Weights Of Rwb Type With Brake Disk 30 Mm Wide

    Technical data Speeds, geometry data and weights Size Speed Maximum                         Weigh bore max. max. min. min. max. 2300 2 … 4 2050 2 … 5 2050 2 … 5 2050 2 … 5 1,400 2 … 5 1,400 2 … 5 1,400 3 … 6...

  • Page 70: Rbs Type With Brake Disk 30 Mm Wide, In Accordance With Din 15432

    Technical data Speeds, geometry data and weights A.1.6 RBS type with brake disk 30 mm wide, in accordance with DIN 15432 Speeds, geometry data and weights Figure A-6: Dimension drawing RBS type with brake disk 30 mm wide Coupling part 1 Coupling part 3 Size Speed Maximum...

  • Page 71: Shaft Misalignment Values During Operation

    Technical data Shaft misalignment values during operation Size Speed Maximum                         Weigh bore max. max. min. min. max. 1100 140 5 … 9 80 1,000 1,400 760 140 5 … 9 80 1,250 1,600 840 1080 1090 1090...

  • Page 72: Tightening Torques And Widths A/F

    Technical data Tightening torques and widths A/F Size Coupling speed [rpm] 1 000 1 500 2 000 3 000 4 000 5 000 1.25 0.85 0.45 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...

  • Page 73: Tightening Procedure

    Technical data Tightening procedure Size Tightening torque Width A/F External hexagon 1,000 Table A-8: Tightening torques and widths A/F of bolt connection 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 (As a rule, the tightening procedures listed are within the spe-...

  • Page 74: Rupex Buffers (5)

    Technical data Buffers (5) • 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 Standard Black buffer -30 °C to +80 °C...

  • Page 75: Declaration Of Conformity

    Declaration of Conformity EU Declaration of Conformity EU Declaration of Conformity Product: FLENDER RUPEX® couplings RWB and RBS 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 76 Declaration of Conformity EU Declaration of Conformity Edition 09/2022 M3602-01en...
  • Page 78 RUPEX Assembly and operating instructions M3602-01en Edition 09/2022 Flender GmbH Alfred-Flender-Straße 77 46395 Bocholt Germany...

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