Table of contents Introduction .............................. 11 Legal information ........................11 About these instructions......................12 Text attributes .......................... 12 Copyright..........................13 Safety information............................ 15 General information ......................... 15 Intended use ..........................17 Safety information for a coupling when used in potentially explosive atmospheres ....17 2.3.1 Marking ............................
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Table of contents 5.3.2.2 Angular misalignment ......................38 5.3.2.3 Radial misalignment......................... 38 Filling the gear unit with operating fluid..................39 5.4.1 Operating fluid, oil ........................39 5.4.2 Filling quantity .......................... 41 5.4.3 Procedure ..........................41 Housing............................ 43 Commissioning ............................45 Operation ..............................
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Table of contents Disposal ..............................65 Replacement parts ........................... 67 11.1 Ordering replacement parts ..................... 67 11.2 Spare parts drawing and spare parts list ................. 67 11.2.1 Types FAO, FAK, FAD, FAE, FAM, FADB, FADS..............67 11.2.2 Types FAR ..........................70 Technical specifications..........................
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Table of contents Edition 09/2022 M4600-01en...
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List of tables Table 2-1 General warnings ........................15 Table 2-2 Temperature classes (X) for explosive atmospheres as a result of gases, vapours or mists ............................18 Table 2-3 Maximum surface temperature (X) for a potentially explosive atmosphere as a result of dust/air mixtures .........................18 Table 4-1 Types of preservative agents for long-term storage..............26 Table 5-1...
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List of tables Table A-14 N-EUPEX flexible elements......................82 Edition 09/2022 M4600-01en...
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List of figures Figure 3-1 General description of FA series ....................22 Figure 3-2 Coupling model ..........................24 Figure 4-1 Transport symbols........................25 Figure 5-1 Tolerances for finished bore.......................29 Figure 5-2 Diameter and axial position of the threaded hole in the hub ............31 Figure 5-3 Position of the balancing bore for single-plane balancing ............33 Figure 5-4 Position of the balancing bore for two-plane balancing..............34 Figure 5-5...
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List of figures Edition 09/2022 M4600-01en...
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.
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.
(1) Numbers in brackets are part numbers. Copyright 1.4 Copyright The copyright of 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 63)).
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.
Safety information 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”...
• 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.
Safety information 2.4 Conditions of use The marking of the fusible safety plug is intended to exclude any risk of confusion with other fusible safety plugs. However, the marking is not to be understood as component or protect- ive system marking in the sense of the Explosion Protection Directive. Conditions of use 2.4 Conditions of use Note also the material-dependent permissible ambient temperature of the flexible elements...
Safety information 2.5 General warning notices Notes concerning operation of the coupling in potentially explosive atmospheres • Only use the coupling in potentially explosive atmospheres together with drive motors that can be switched off in the event of the formation of an explosive atmosphere. •...
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Safety information 2.5 General warning notices DANGER Danger Risk of injury due to the use of unsuitable and/or damaged components. The use of unsuit- able and/or damaged components can lead to an explosion in potentially explosive atmo- spheres. • Observe the information regarding conditions of use. DANGER Danger of explosion Improper operation of the coupling can lead to an explosion in potentially explosive atmo-...
Please consult Flender if you want to use a different type of installation. The order-specific data for a delivery shall be listed on the order-dependent title page, provided they are known for the order.
Description 3.1 Design of the couplings Design of the couplings 3.1 Design of the couplings The illustration shows the different types with their components using the types FAD and FAR as examples. Figure 3-1: General description of FA series ① ② Compensating chamber Working chamber N-EUPEX add-on coupling Flexible element (N-EUPEX)
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Description 3.1 Design of the couplings The FLUDEX coupling consists of an inner rotor and a housing supported on it. The inner ro- tor includes the hollow shaft (106) on which the bucket wheel (105) is mounted. The housing includes the cover (102) and the blade shell (101), which are connected to each other via a flange bolt connection.
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...
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.
(DIN ISO 21940-32) to balancing quality G6.3 (DIN ISO 21940) for 1800 rpm. N-EUPEX add-on coupling Please consult Flender if you want to machine a tapered finished bore. Carry out the following steps if the coupling does not have a finished bore: • Mill the finished bore (Page 28) •...
• Balancing the coupling (Page 33) 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.
Assembly 5.1 Preparatory work – For part 1: Remove the flexible elements (12) – For part 5: Remove part 8 – For part 13: Remove part 3 – For part 32: Remove part 6 2. Remove the preservation and clean the coupling parts to be machined. 3.
5.1.3 Machining an axial locking mechanism 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. Edition 09/2022 M4600-01en...
Assembly 5.1 Preparatory work 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 • Selection of the set screw Diameter and axial position of the threaded hole in the hub The following diagram shows the axial position of the threaded hole: Figure 5-2: Diameter and axial position of the threaded hole in the hub...
Assembly 5.1 Preparatory work ⑧ Brake disk (32) The following table contains the values for the diameter and axial position of the threaded hole depend- ing on the coupling size. FLUDEX N-EUPEX Tightening torque T Size Size Table 5-4: Diameter and axial position of the threaded hole, tightening torque Apply the specified tightening torques as listed in Section Tightening procedure (Page 81).
Assembly 5.1 Preparatory work 5.1.4 Balancing the coupling 5.1 Preparatory work NOTICE Property 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. •...
Assembly 5.1 Preparatory work ⑧ Brake disk (32) ⑨ Braking surface Figure 5-4: Position of the balancing bore for two-plane balancing ① Coupling part 1 ② Coupling part 2 ③ Coupling part 4 ④ Coupling part 5 ⑤ Coupling part 9 ⑥ Balancing bore ⑦...
Assembly 5.2 Mounting the coupling Mounting the coupling 5.2 Mounting the coupling NOTICE Coupling damage, damage to further components Risk of damage to the coupling through fitting forces by way of the aluminium housing. • Ensure that the fitting forces are not applied via the aluminium housing. •...
Assembly 5.2 Mounting the coupling 5. Secure the FLUDEX coupling axially using the retaining washer (140) and retaining screw (141). The tightening torques are listed in Chapter Tightening torques and widths A/F (Page 80). 5.2.2 Mounting the N-EUPEX coupling 5.2 Mounting the coupling 1.
You can find the maximum permitted shaft misalignment values during operation in Chapter Shaft misalignment values during operation (Page 79). Consult with Flender if the FLUDEX coupling is bolted to components which introduce axial forces or bending moments into the coupling.
Assembly 5.3 Aligning the coupling 5.3.2 Possible misalignment 5.3 Aligning the coupling The following types of misalignment can occur: Figure 5-6: Possible misalignments 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 for the “S”...
Assembly 5.4 Filling the gear unit with operating fluid Filling the gear unit with operating fluid 5.4 Filling the gear unit with operating fluid 5.4.1 Operating fluid, oil 5.4 Filling the gear unit with operating fluid DANGER Risk of explosion due to an unsuitable operating fluid Using an operating fluid that is not approved for use in potentially explosive atmospheres will cause an explosion.
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Assembly 5.4 Filling the gear unit with operating fluid Manufacturer Type ISO VG Pour point in °C Flash point in °C Castrol Alpha VT 32 Hyspin ZZ 32 Hyspin AWS 32 Klüber Lubrication LAMORA HLP 32 ≤ -18 ≥ 200 Mobile DTE 22 Ultra DTE 25 Ultra...
Assembly 5.4 Filling the gear unit with operating fluid 5.4.2 Filling quantity 5.4 Filling the gear unit with operating fluid The behaviour and performance of the FLUDEX couplings are decisively influenced by the amount of operating fluid filled in. As the filling quantity increases, the transmission capacity of coupling, the engine load during start-up and the maximum overload torque of coupling in- crease.
Assembly 5.4 Filling the gear unit with operating fluid As a tool for filling the coupling and for checking the filling level, there are marking lines with litre information cast on the coupling housing in raised relief. Figure 5-7: Filling the coupling ①...
Assembly 5.5 Housing 4. After filling, tighten the filling plug (153) and the screw plug (163)/the fusible safety plug (103) to the prescribed tightening torque. For the tightening torques, see Chapter Tightening torques and widths A/F (Page 80). 5. Check the coupling for leakage during a short test run. Hold a sheet of clean paper near the rotating outer shell of the coupling, parallel to the axis of rotation.
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Assembly 5.5 Housing WARNING Severe personal injury due to the use of unsuitable housing 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. •...
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 heavy metal oxide (rust) deposits on the coupling are not possible.
Operation CAUTION Hearing damage due to noise emission Wear ear protection when the sound pressure level is > 80 dB(A), otherwise hearing dam- age may result from noise emissions. Normal operation of the coupling 7.1 Normal operation of the coupling During normal operation, the coupling runs vibration-free. Fault –...
Operation 7.2 Fault – causes and correction 7.2.2 Identifying the fault cause 7.2 Fault – causes and correction Faults occur frequently due to application errors or they occur due to operational circum- stances such as wear of wearing parts or changes to the system. The faults and fault causes listed below only serve as an indication for troubleshooting.
Operation 7.2 Fault – causes and correction Fault Cause Rectification No torque transmission The fusible safety plugs have respon- Follow the instructions given in Section ded to overheating or blocking and the Replacing the fusible safety plug fluid is pouring out of the coupling. (Page 51).
7.2 Fault – causes and correction • Stipulated maintenance intervals not adhered to. • Replacement parts that were used were not original replacement parts from Flender. • Flender replacement 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.
Operation 7.2 Fault – causes and correction Procedure 1. Check the wear on the flexible elements (12) (see Section Maximum permissible tor- sional backlash (Page 54)). 2. Replace the flexible elements (12) if necessary (see Section Replacing the flexible ele- ments (Page 55)). 7.2.3.2 Correcting the changed alignment 7.2 Fault –...
Maintenance 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.
Maintenance 8.1 Maintenance intervals Check the torsional backlash between the coupling parts at the specified maintenance inter- vals. The maximum permissible torsional backlash for the various coupling sizes can be found in section Maximum permissible torsional backlash (Page 54). Initial maintenance Follow-up maintenance 3 months after commissioning Every 12 months...
Maintenance 8.3 Replacing the flexible elements 2. Mark both of the coupling halves in the way shown in the diagram below. Figure 8-1: Markings for calculating the torsional backlash 3. Turn the coupling part in the opposite direction up to the stop. The markings on both halves will then move apart.
Maintenance 8.4 Disassembling the FLUDEX coupling 3. Install the new flexible elements (12). Please observe the information in Section Use and storage of flexible elements (12) (Page 82) when replacing flexible elements (12). When reinstalling the coupling parts please observe the information in chapters Assembling (Page 27) and Commissioning (Page 45).
Maintenance 8.4 Disassembling the FLUDEX coupling NOTICE Risk of injury and danger to the environment from operating fluid Collect the remaining operating fluid and dispose of the operating fluid in accordance with the applicable regulations. WARNING Risk of injury due to falling coupling parts Severe personal injury can be caused by falling coupling parts when loosening the tension- ing screws if the parts are not adequately secured.
Maintenance 8.4 Disassembling the FLUDEX coupling 7. Insert the spindle with the pull nut so that the collar (D) of the pull nut is behind the re- cess for the locking ring (124). See ② in the image “Disassembling sizes 222 to 342”. 8.
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Maintenance 8.4 Disassembling the FLUDEX coupling Size Spindle thread G (DIN 228/1) G 1 1/2 G 1 1/2 Threaded head K M68 x 2 M68 x 2 M100 x 2 M100 x 2 Spindle length FAO, FAK, FAKB, FAD, [mm] FADB, FAE, FAM, FADS 5.
8.6 Dismantling the FLUDEX coupling Information We recommend having the FLUDEX coupling dismantled by Flender. Before dismantling, mark the position of the housing parts on the flange in relation to each other. For type FAR, also mark the mounting position of the flange of the belt pulley to the adjacent housing part.
Maintenance 8.6 Dismantling the FLUDEX coupling Type FAR 1. With the FAR type, the lubricating oil in the belt pulley cannot be drained off before dis- mantling. Collect the lubricating oil completely when dismantling the belt pulley. NOTICE Risk of injury and danger to the environment from operating fluid Collect the remaining operating fluid and dispose of the operating fluid in accordance with the applicable regulations.
Maintenance 8.7 Reassembling the FLUDEX coupling Reassembling the FLUDEX coupling 8.7 Reassembling the FLUDEX coupling Reassembly is carried out in the reverse order of dismantling. Observe the marking on the parts. 1. Before reassembly, clean all components from old grease residues. 2.
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) M4600-01en Edition 09/2022...
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Service and support 9.1 Contact Edition 09/2022 M4600-01en...
Disposal Disposal of the coupling Dispose of the coupling parts according to applicable national regulations or recycle them. M4600-01en Edition 09/2022...
By stocking the most important replacement parts at the installation site, you can ensure that the coupling is ready for use at any time. Only ever use original replacement parts from Flender. Flender only accepts liability for ori- ginal replacement parts from Flender.
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Replacement parts 11.2 Spare parts drawing and spare parts list ① Type FAK, size 297 and 342 ② From size 297 version with thermal circuit breaker/ with EOC transmitter ③ Sizes 395 up to 590 all types without part no. 10 + 121 Part number Designation Part number...
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Replacement parts 11.2 Spare parts drawing and spare parts list Part number Designation Part number Designation Coupling part 10 (N- Locking ring EUPEX) Flexible elements (N- O-ring EUPEX) Cylinder-head screw Hexagon bolt Brake drum Hexagon nut Cylinder-head screw Shaft sealing ring Cylinder-head screw Rolling-contact bearings Hexagon / cylinder-head...
Replacement parts 11.2 Spare parts drawing and spare parts list 11.2.2 Types FAR 11.2 Spare parts drawing and spare parts list When ordering replacement parts, please state the order number of the original delivery. The order number is stamped on the coupling (blade shell) and indicated on the order-dependent title page.
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Replacement parts 11.2 Spare parts drawing and spare parts list Part number Designation Part number Designation Hollow shaft Shaft sealing ring Threaded insert Locking ring Rolling-contact bearings Rolling-contact bearings thermal circuit breaker Retaining washer Shaft sealing ring Retaining screw Cylinder-head screw EOC transmitter O-ring Threaded bushing...
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Replacement parts 11.2 Spare parts drawing and spare parts list Edition 09/2022 M4600-01en...
Technical specifications Filling quantity Filling quantity A.1.1 Filling quantity for FLUDEX couplings FA.. Filling quantity Guide values for mineral oil VG 22 / VG 32 For drive via hollow shaft (106) (inner wheel), valid for T = 2.0 x T max.
Technical specifications Filling quantity Power Speed in rpm 1180 1470 1770 2300 2950 Oil filling quantity in litres Table A-4: Filling quantity for FLUDEX couplings “FA..” Size 395 Information Observe the maximum permissible oil filling quantity of 9.5 litres. A.1.1.5 Filling quantity for FLUDEX couplings “FA..” Size 450 Filling quantity Power Speed in rpm...
Technical specifications Bearing lubrication for rolling-contact bearing, type FAR Power Speed in rpm 1180 1470 1770 Oil filling quantity in litres 28.6 24.2 21.2 24.9 21.8 25.6 22.3 26.3 22.9 27.1 23.6 24.2 26.4 Table A-7: Filling quantity for FLUDEX couplings “FA..” Size 590 Information Observe the maximum permissible oil filling quantity of 33 litres.
Technical specifications Tightening torques and widths A/F FLUDEX N‑EUPEX Tightening torque T and width A/F SW for hexagon socket screws Coupling Coupling according to DIN EN ISO 4762 Size Size Part no. Part no. Part no. 22, 23, 24 Table A-10: Tightening torques for parts 13, 22, 23, 24 and 103 A.4.2 Tightening torques for parts 110, 142, 163, 121, 130, 131 and 153 Tightening torques and widths A/F...
Technical specifications Flexible elements (12) Scatter of the torque ap- Tightening procedure plied at the tool (As a rule, the tightening procedures listed are within the spe- cified tool torque scatter.) ±5 % • Hydraulic tightening with mechanical screwdriver • Torque-controlled tightening with a torque wrench or a torque wrench that gives a signal •...
Declaration of conformity EU Declaration of Conformity EU Declaration of Conformity Product: FLENDER FLUDEX® coupling Types FAO, FAD, FAE, FAM, FADB, FADS, FAK, FAKB, FAR Operating fluid: Oil 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.
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Declaration of conformity EU Declaration of Conformity Edition 09/2022 M4600-01en...