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FLENDER COUPLINGS
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ZAPEX
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Operating instructions 3548 en
Edition 02/2019
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ZIBT, ZIBG, ZIB
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Summary of Contents for FLENDER ZAPEX ZIBT
- Page 1 FLENDER COUPLINGS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
- Page 3 Technical data General notes FLENDER COUPLINGS Safety instructions Transport and storage ZAPEX 3548 en Technical description Fitting Operating instructions Translation of the original operating instructions Start-up Operation Faults, causes and remedy Maintenance and repair Spare parts, customer service ZIBT, ZIBG, ZIB...
- Page 4 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.
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Page 5: Table Of Contents
Contents Technical data ........... . . Types ZIBT, ZIBG and ZIB . - Page 6 Startup ............Requirements for grease .
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Page 7: Technical Data
Technical data Types ZIBT, ZIBG and ZIB For dimensions, technical data and a detailed view, see the dimensioned drawing in the coupling documentation. The user of the system must make the dimensioned drawing available. The information entered on it must be given priority. For the dimensions marked *, refer to the dimensioned drawing. - Page 8 Version A Version AB Version B Axial Rated torque Bore backlash Size from up to 1700 3350 129.5 6000 10000 16000 23600 249.5 33500 47500 67000 425.5 332.5 90000 125000 423.5 Table 1.1: Torques T and dimensions The max. speed is limited by the brake disk / brake drum. Speed n and weight according to dimensioned drawing.
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Page 9: General Notes
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. -
Page 10: Safety Instructions
If the coupling is intended for installation 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 instructions. • All spare parts must be obtained from Flender. ZAPEX 3548 en Operating instructions 02/2019... -
Page 11: Transport And Storage
The coupling is delivered in a preserved condition and can be stored in a covered, dry place for up to 3 months. If the unit is to be stored for a protracted period, it should be treated with a longterm preservative agent (Flender must be consulted). 4.3.2 Storage of Orings... -
Page 12: Technical Description
Technical description Observe the instructions in section 3, "Safety instructions"! The user of the system must make the dimensioned drawing available. The information entered on it must be given priority. General description ZAPEX type ZIBT, ZIBG and ZIB couplings are specified for connecting two shafts. The shaft ends to be connected must be supported immediately upstream of and downstream of the coupling. -
Page 13: Finished Bore For Parallelkey Connection
Flender should be consulted. If other shafthub connections (e.g. spline bore hub profile, tapered or stepped bores, parallelkey connections with tightening) are to be used instead of the provided parallelkey connection, Flender should be consulted. Failure to observe these instructions may result in breakage of the coupling. -
Page 14: Set Screws In Case Of Parallelkey Connection
6.1.3 Set screws in case of parallelkey connection Hexagon socket set screws with cup points to DIN 916 must be used for set screws. The following guidelines must be observed! The length of the set screw must be selected so that it fills the threaded hole, but does not project from the hub (L min. -
Page 15: Balancing
Material must be removed only at the points indicated (see illustration). Under no circumstances may the tooth system be damaged. If balancing is to be done after cutting the keyways, Flender must be consulted. Balancing bore Part 1/2... -
Page 16: Fitting The Coupling Parts (1/2) In Case Of Shafthub Connection With Parallel Key
Fitting the coupling parts (1/2) in case of shafthub connection with parallel key Before starting assembly all coupling parts and shaft ends must be carefully cleaned. The Orings (12) must not come into contact with solvents and cleaning agents. Note manufacturer’s instructions for handling solvent. The cleaned flangedsleeve grooves must be greased and the Orings (12) then inserted. -
Page 17: Installation Of The Coupling
The Orings (12) must be inserted into the cleaned and greased flangedsleeve grooves. The flanged sleeves (5) must be located on the shaft before pulling on the coupling parts (1/2). Protect Orings (12) and seals for the input and output side against damage and heating to above + 80 °C. -
Page 18: Alignment
Alignment Type ZIB compensates for positional errors of up to 0.5° on the shaft ends to be connected. Due to axial backlash limitation types ZIBG and ZIBT compensate only for a positional error of up to 0.2°. When aligning, the radial and angular misalignment of the shaft ends must be kept as small as possible, because, other conditions being equal, this increases the service life of the coupling. -
Page 19: Possible Misalignments
Possible misalignments Δ Kr Δ Kw Δ Ka Δ Ka Δ S = S Axial misalignment Angular misalignment Radial misalignment Axial, radial and angular Fig. 6.7.1 Fig. 6.7.2 Fig. 6.7.3 misalignment Fig. 6.7.4 Misalignments of the coupling parts in relation to each other can be caused by inaccurate alignment during assembly, but also by actual operation of the equipment (expansion due to heat, shaft deflection, insufficiently rigid machine frames, etc.). -
Page 20: Alignment Values
Alignment values ZIBT ZIBG Angular misalignment ΔKw : ΔS = S – S x tan 0.1° For the hub diameter d , refer to section 1, "Technical Data". Radial misalignment ΔKr : ZIBT, ZIBG: ΔKr = V x tan 0.1° ZIB: ΔKr = V x tan 0.1°... -
Page 21: Assignment Of The Tightening Torques And Wrench Widths
Assignment of the tightening torques and wrench widths The use of an impact screwdriver is not permissible! Tightening torques apply to bolts with untreated surfaces which are not or only lightly oiled (coefficient of friction μ = 0.14). The use of lubricant paint or lubricant, which affects the coefficient of friction "μ", is not permitted. -
Page 22: Recommended Lubricants
Recommended lubricants The following lubricant recommendations apply to the ZAPEX couplings described in these instructions. Lubricant performance Energrease Tribol 3020/1000‐00 FLENDER Liquefied greases FDP 00 LS‐EP 00 ◆ Longtime PD 00 Hochleistungsfett Lubricant RENOLIT GRAFLOSCON Liquefied greases Mobilux EP 004 GADUS S2 V220 00 SO‐D 6024... -
Page 23: Operation
Flender will not be bound by the terms of the guarantee or warranty nor otherwise be responsible in cases of improper use of the coupling, modifications carried out without the agreement of Flender, or use of spare parts not supplied by Flender. -
Page 24: Possible Faults
Possible faults Faults Causes Remedy Sudden changes in the noise Exceeding the permissible Stop the installation. level and/or sudden vibrations. misalignment values. If necessary align as described in section 6. Insufficient lubricant. Stop the installation. Change the lubricant as described in section 10, making sure to check the teeth and the seals at the same time. -
Page 25: Possible Faults When Installing The Coupling
9.3.2 Possible faults when installing the coupling • Components with transport or other damage are being fitted. • When mounting coupling parts in a heated condition, Orings (12) are being excessively heated. • Specified tightening torques are not being adhered to. •... -
Page 26: Changing Grease
10.2 Changing grease During regular inspections the coupling must be checked for leaks, and the lubricant level checked and, if necessary, topped up. Lubricant change approx. every 8000 operating hours or at latest every 2 years in case of operation at up to 70 °C;... -
Page 27: Demounting The Coupling
10.9, material of nuts identical to that of the screws). • 1 hydraulic cylinder ("Lukas") with oil pump. Note displacement and pressure of the hydraulic cylinder ("Lukas") (for axial force, consult Flender or refer to dimensioned drawing). Observe manufacturer's instructions for using forcingoff/detaching device and pumps. -
Page 28: 10.6.1 Demounting The Coupling Parts (1/2) In Case Of Cylindrical Interference Fit
10.6.1 Demounting the coupling parts (1/2) in case of cylindrical interference fit Retaining plate Threaded spindle Shaft ”Lukas” Using suitable tools, secure coupling part (1/2) and retaining device! The screw plugs (22) must be removed from the oil channels. An oil pump must be bled and connected up to the middle oil channel (here oil channel I). -
Page 29: 10.6.2 Demounting The Coupling Parts (1/2) In Case Of Tapered Interference Fit
10.6.2 Demounting the coupling parts (1/2) in case of tapered interference fit Shaft Retaining plate Hydraulic cylinder (”Lukas”) Stroke Threaded spindle Eye nut Inspection window Using suitable tools, secure coupling part (1/2) and retaining device! To prevent the coupling part (1/2) suddenly coming off, it must be secured axially as shown in the diagram. -
Page 30: Spare Parts, Customer Service
11.1 Spareparts and customerservice addresses When ordering spare parts or requesting a service specialist, please contact Flender first (see section 2, "General notes"). ZAPEX 3548 en Operating instructions 02/2019... -
Page 31: Spareparts List
11.2 Spareparts list Spare-parts list Part Designation ZIBT ZIBG Part 1/2 Part 1/2 Flanged sleeve Screw plug Sealing ring Close-fitting bolt Hexagon nut O-ring Brake disk Brake drum Screw plug Sealing compound Retaining ring Table 11.2: Spareparts list The sealing ring (7) is provided only on size 1.0. On the other sizes the sealing ring is integrated into the screw plug (6). - Page 32 FLENDER COUPLINGS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
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