Siemens FLENDER FLUDEX FNA, Operating Instructions Manual

Page 1: ...FLENDER COUPLINGS FNO FNA FND FNDB FNDS Operating fluid Water Operating instructions 4612 en Edition 10 2017 FLUDEX flender com ...

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Page 3: ...FND FNDB FNDS Edition 10 2017 Technical data Spare parts customer service Maintenance and repair Faults causes and remedy Operation Start up Fitting Technical description Transport and storage Safety instructions General notes Declarations 1 12 11 10 9 8 7 6 5 4 3 2 ...

Page 4: ...ly 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 fo...

Page 5: ...C The couplings described here are components in accordance with the Machinery Directive and do not require a declaration of incorporation Symbols in these operating instructions This symbol additionally indicates an imminent risk of explosion in the meaning of Directive 2014 34 EU This symbol additionally indicates an imminent risk of burns due to hot surfaces in the meaning of standard DIN EN IS...

Page 6: ...or FLUDEX couplings in potentially explosive areas 18 6 Fitting 19 6 1 Instructions for machining the finished bore for axial fastening set screws and balancing 20 6 1 1 Finished bore 20 6 1 2 Parallel keyway 22 6 1 3 Axial securing 23 6 1 4 Set screws 23 6 1 5 Balancing 25 6 2 General information on fitting 26 6 3 Fitting the coupling parts 26 6 4 Alignment 29 6 5 Possible misalignments 30 6 5 1 ...

Page 7: ...erval of the N EUPEX add on coupling 46 10 4 Replacement of the flexible elements 47 10 5 Disassembling the FLUDEX coupling 47 10 6 Disassembling the FLUDEX coupling 50 10 7 Reassembling the FLUDEX coupling 51 10 8 Refitting the FLUDEX coupling 51 10 9 Filling quantities for FLUDEX FN couplings sizes 370 490 655 and 887 52 10 10 Filling quantities for FLUDEX FN couplings sizes 425 565 and 755 53 1...

Page 8: ...ion with water or with a water emulsion DANGER Risk of explosion Risk of explosion when using unsuitable components in potentially explosive areas Use the coupling only for the approved zones and equipment groups In case of doubt contact Flender DANGER Risk of explosion Risk of explosion in case of inadequate design and combination of the brake disk and or brake drum in potentially explosive areas...

Page 9: ...9 FLUDEX 4612 en Operating instructions 10 2017 1 2 Coupling version FNO FNA FND FNDB FNDS SB FNDS HB Fig 1 Coupling types ...

Page 10: ...y this coupling The coupling has been manufactured in accordance with the state of the art and is delivered in a condition for safe and reliable use The coupling 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 The coupling described in these instructio...

Page 11: ...components Operating the coupling with damaged coupling parts is not permitted in potentially explosive environments in accordance with Directive 2014 34 EU 3 1 Obligations of the user The operator must ensure that everyone carrying out work on the coupling has read and understood these instructions and is adhering to them in every point in order to avoid injury or damage ensure the safety and rel...

Page 12: ...ithout substantially impairing the coupling ventilation The fusible safety plug the filler plug and the drain plug should remain accessible WARNING Risk of serious injury through flying fragments Coupling may burst The operating fluid to be used is specified in item 7 2 1 The filling quantity is defined by the works in relation to the order if the drive details are available Otherwise the filling ...

Page 13: ...been tested or approved by Flender Non genuine spare parts may alter technical characteristics of the coupling thereby posing an active or passive risk to safety Flender will assume no liability or guarantee for damage caused by spare parts not supplied by Flender The same applies to any accessories not supplied by Flender Note Depending on national regulations coupling parts and operating fluid h...

Page 14: ...l description 4 2 Transport 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 following symbols with their meanings are applied to the packaging and must be observed Top Fragile Keep dry Keep cool Centre of gravity Use no hand hook Attach here Fig 2 Transport sy...

Page 15: ...ng term preservative agent the flexible elements 12 in figure 3 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 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 ozo...

Page 16: ...ioned drawing available FND FNDB 141 140 153 10 101 103 102 105 9 12 11 7 120 173 106 163 8 9 12 32 Fig 3 General description of the FN series 7 Prechamber 8 Working chamber 9 N EUPEX add on coupling 10 Stowage space 11 Part 11 12 Flexible element N EUPEX 32 Part 32 101 Blade shell outer wheel 102 Cover 103 Fusible safety plug 105 Bucket wheel inner wheel 106 Shaft 120 Hub carrier part large prech...

Page 17: ...ount of fluid in the working chamber 8 when starting Thus the starting torque is considerably reduced While the coupling is rotating the fluid in the prechamber flows back into the working chamber through small holes time dependently so that in continuous operation the entire filling is effective For filling the coupling two filling plugs 153 are located in filling channels offset by 180 to preven...

Page 18: ...ble atmospheres Equipment group I underground applications of the category M2 DANGER Risk of explosion Risk of explosion in case of non observance of the prescription relating to aluminium used below ground If it is to be used below ground in potentially explosive areas the coupling which is made of aluminium must be provided with a robust casing to preclude the risk of ignition from e g friction ...

Page 19: ... through flying fragments and or unauthorized welding work on the coupling or on coupling parts No welding work must be done on the coupling or coupling components The FLUDEX coupling is delivered preferably with finish bored and grooved hubs At the customer s request Flender also delivers unbored or prebored coupling parts The necessary refinishing must be carried out in strict compliance with th...

Page 20: ...sonal protective equipment gloves safety glasses When machining the finished bore the parts must be carefully aligned For the permissible radial and axial runout errors and the permissible cylindricity tolerances see standard DIN ISO 286 The parts must be fitted on the marked faces When machining the finished bore in the hub carrier part 120 the axial run out face of the outer flange must be finis...

Page 21: ...D 2 A IT8 IT6 Part 1 A 3 2 D 2 Fig 4 Finished bore Table 1 Maximum bores of the hub parts FLUDEX c N EUPEX Maximum bore D1 Maximum bore D2 Part 120 Part 1 Part 11 Part 11 32 Part 32 brake disk Size Size FNA FND FNDS SB 32 HB 11 FNDB D x B D 2 370 180 200 80 75 70 80 315 x 118 400 x 150 80 90 425 200 100 85 80 80 315 x 118 400 x 150 80 90 490 225 250 110 90 90 90 400 x 150 500 x 190 90 100 565 250 ...

Page 22: ...ng items must be observed Keep the play in the shaft hub connection as low as possible Keep the hub tension arising from the oversize within the permissible load limit Failure to adhere to the fit assignments may impair the shaft hub connection If the tolerance values of the shafts deviate from those in table 2 Flender must be consulted 6 1 2 Parallel keyway The parallel keyways must be designed i...

Page 23: ...incorrect fit set screw bore To prevent damage to the shafts the set screw bore should be arranged on the parallel keyway In exceptional cases the set screws must be offset 180 to the parallel keyway if because of the diameter of the drilled hole and hub core too little material is left between the parallel keyway and the hub core If the hub carrier part 120 and brake drum od brake disk 32 have be...

Page 24: ...of the set screws FLUDEX size N EUPEX size d1 Part 120 Part 1 Part 11 Part 32 Tightening torque of the set screw Nm maximum e1 e2 e5 e6 370 180 200 M12 23 16 30 25 25 425 200 M12 25 20 40 25 25 490 225 250 M12 25 22 40 30 25 565 250 M16 23 24 50 50 70 655 315 M16 50 35 60 75 70 755 350 M20 40 40 70 75 130 887 440 M24 50 60 90 75 230 Note The set screws must always be positioned on the keyway ...

Page 25: ...d When two level balancing the brake drum 32 or the brake disk 32 and part 11 should be balanced together with part 10 and part 11 of the FNDB HB together with part 10 and the brake disk 8 WARNING Risk of serious injury through flying fragments Risk of serious injury through flying fragments and or incorrect bore position and bore design Balancing bores must not affect the load bearing capacity of...

Page 26: ...ICE Damage to the coupling Risk of damage to the shaft ends and or parallel keys Unscrew the set screws from the coupling parts before fitting NOTICE Damage to the coupling Damage to the coupling and or disruptions to operation through insufficient cleaning The surfaces to be joined must be absolutely clean and grease free CAUTION Risk of corrosion burns through chemical substances Avoid burns whe...

Page 27: ...temperatures over 80 C the flexible elements must be removed from the coupling part 1 before heating DANGER Risk of explosion Risk of explosion when exceeding the ignition temperature when using a burner or similar equipment Burner and heated coupling parts form an explosion hazard therefore a non explosive environment must be ensured WARNING Risk of burns Serious injury through burns on hot surfa...

Page 28: ... sealing surfaces are not damaged The flange may be attached by means of the screws 139 Care must be taken to ensure that the flange surfaces fit closely for tightening torque of screws see item 6 6 On part 1 1 the flexible elements 12 which have been removed must be refitted It must be ensured that the flexible elements 12 are of identical size and have identical markings The coupling parts must ...

Page 29: ...nds must be kept as small as possible because other conditions being equal this increases the service life of the flexible elements Alignment has to be done in two axial planes arranged perpendicularly to each other This can be done by means of a ruler radial misalignment and feeler gauge angular misalignment as shown in the illustration Coupling gap S should be adhered to see item 6 5 4 The align...

Page 30: ...ended to align the coupling as precisely as possible so as to have an additional margin for misalignment in operation 6 5 1 Axial misalignment Axial misalignment ΔKa Fig 10 of the coupling parts relative to one another is permissible within the permissible deviation for dimension S see order related title page 6 5 2 Angular misalignment The angular misalignment ΔKw Fig 10 can usefully be measured ...

Page 31: ...f tightening torques for part numbers refer to section 11 FLUDEX Size N EUPEX Size Tightening torque TA and wrench width SW for screws Part number 13 23 24 103 163 130 131 139 153 173 182 192 TA SW TA SW TA SW TA SW TA SW TA SW TA SW TA SW TA SW Nm mm Nm mm Nm mm Nm mm Nm mm Nm mm Nm mm Nm mm Nm mm 370 180 44 8 49 8 16 60 10 21 13 31 8 60 10 25 7 31 16 18 7 13 200 67 5 10 86 10 18 60 10 21 13 31 8...

Page 32: ...be flush with the the end face of the hub Tightening of the set screws Rectify the alignment and the distance dimension S if necessary Check tightening torques of all the screw connections see section 1 and section 6 7 2 Fluid filling DANGER Risk of explosion Risk of explosion when using not permitted operating fluid below ground in potentially explosive areas Only specifically permitted operating...

Page 33: ...se the filling quantity is selected from the table in the operating instructions FLUDEX couplings must not be filled up to more than 80 to 85 of the total volume Higher filling quantites cause a sharp rise in pressure in the coupling which may cause the coupling to burst The instructions for use enclosed by the operating fluid manufacturer must be observed Only the filling openings prescribed must...

Page 34: ... may be done by holding a clean piece of paper parallel to the turning axis and close to the rotating surface envelope of the coupling Any operating fluid spurting out will be visible on the paper WARNING Risk of serious injury through escaping operating fluid Risk of serious injury through incorrectly tightened screw plugs After topping up the tightening torques specified in the maunal must be ad...

Page 35: ...ler plug and the drain plug must remain accessible DANGER Risk of explosion Risk of explosion in case of non observance of the prescription relating to aluminium used below ground If it is to be used below ground in potentially explosive areas the coupling which is made of aluminium must be provided with a robust casing to preclude the risk of ignition from e g friction impact or friction sparks T...

Page 36: ...tor output NOTICE Risk of damage to the coupling through improper storage Damage to the coupling through freezing of operating fluid In case of types provided for operation with water the water or water emulsion must be drained off before storing at temperatures below 0 C Frost hazard CAUTION Risk of corrosion burns through chemical substances Avoid burns when working with corrosive cleaning agent...

Page 37: ...and or insufficient operation factors In the event of a change in operating conditions output speed change to the prime mover and driven machine the design must unconditionally be checked WARNING Risk of serious injury through flying fragments Risk of serious injury through inadequate design of the braking device Locking brakes holding brakes must be fitted with an interlock to prevent the drive f...

Page 38: ... be carried out only when it is at a standstill Secure the drive unit to prevent unintentional switch on A notice should be attached to the ON switch stating clearly that work on the coupling is in progress The relevant accident prevention regulations at the place of installation apply as well WARNING Risk of serious injury through flying fragments Risk of serious injury through flying fragments a...

Page 39: ...n specified in the order Other operating conditions are regarded as incorrect and must be contractually agreed For any damage resulting therefrom only the user or operator of the machine or plant is responsible WARNING Risk of serious injury through flying fragments Risk of serious injury through flying fragments and or risk of damage to the coupling If any malfunctions or changes are noticed duri...

Page 40: ...cedure as described in section 10 Stop the installation Demount coupling and remove remains of flexible elements 12 Check and replace damaged coupling parts Flexible elements 12 must be changed in sets use only identical N EUPEX flexible elements 12 Fitting of coupling according to section 6 and section 7 No torque transmission The fusible safety plugs have fused through overheating or locking and...

Page 41: ...arts are consequently in contact proper operation within the meaning of the requirements in Directive 2014 34 EU can no longer be guaranteed Measurement and assessment of the wear condition of the N EUPEX flexible elements 12 should be done in accordance with section 10 9 3 Incorrect use Experience has shown that the following faults can result in incorrect use of the FLUDEX coupling In addition t...

Page 42: ...arrier part 120 the O rings 117 138 are not fitted The shaft diameter is beyond the specified tolerance range Coupling sides are being interchanged i e their assignment to the specified drive direction is incorrect Specified axial fixtures are not fitted Specified tightening torques are not being adhered to Alignment shaft misalignment values do not match the operating instructions An incorrect op...

Page 43: ...ating fluid is being put in No genuine Flender spare parts are being fitted Specified tightening torques are not being adhered to Old or damaged N EUPEX flexible elements 12 are being used Fusible safety plugs 103 with an unsuitable fusing temperature are being used Leakage in the vicinity of the coupling is not being identified and as a result chemically aggressive media are damaging the coupling...

Page 44: ...omponents may cause injury during work on the still rotating coupling All work on the coupling must be carried out only when it is at a standstill Secure the drive unit to prevent unintentional switch on A notice should be attached to the ON switch stating clearly that work on the coupling is in progress The relevant accident prevention regulations at the place of installation apply as well CAUTIO...

Page 45: ... burns immediately after switching off Never change the operating fluid immediately after operation Allow the coupling and operating fluid to cool down The operating fluid must be changed in accordance with the specifications in table 8 When changing the operating fluid care must be taken that the old operating fluid is completely drained off This can be done through the holes in the fusible safet...

Page 46: ...xplosive areas is then not permitted The flexible elements 12 can continue to be used up to a specified wear limit To assess wear the permitted torsional backlash converted to the chord dimension ΔSV on the outer coupling diameter is shown in table 9 To obtain the dimension ΔSV one coupling part is rotated without torque as far as the stop and a mark applied to both sides see figure 13 If the coup...

Page 47: ... WARNING Risk of scalding Risk of serious injury through escaping hot operating fluid when it is being changed Wear suitable protective gloves protective glasses and protective clothing Allow the operating fluid to cool down WARNING Serious injury Risk of serious injury through falling coupling parts Secure all coupling parts before undoing the clamping bolts For removing the coupling first loosen...

Page 48: ...t radially after the bolts 139 have been loosened At the same time care must be taken that the O rings 117 138 are exposed see figure 15 1 2 120 139 117 138 Fig 15 Removing the FLUDEX coupling b 1 O rings 2 Main coupling WARNING Serious injury Risk of serious injury through incorrect handling of the device and pump when demounting press fits Observe manufacturer s instructions for using the forcin...

Page 49: ...commercially available tools after releasing the axial fixture Located at the end face side in the hub in the hub carrier part 120 are two tapped holes offset by 180 which may be used to insert drawing bolts see figure 16 1 2 3 4 5 6 Fig 16 Removing the FLUDEX coupling c 1 Shaft 2 Hub carrier part 3 Drawing bolts 4 Pressure spindle 5 Bridge 6 Brake drum ...

Page 50: ...crews must first be removed To pull off the shell and cover a pressure spindle with a bridge and pulling screws must be applied as shown in figure 17 The pressure acts on the end face of the shaft The pulling screws are inserted in the flange threads of the shell or cover 5 4 3 1 2 Fig 17 Disassembling the FLUDEX coupling 1 Shaft 2 Shell 101 3 Drawing bolts 4 Pressure spindle 5 Bridge After the sh...

Page 51: ...aminar ring seal the space between the shaft sealing ring and the plates and the plate mounting groove in the shaft must be filled with grease 1 Fig 18 Filling the rolling bearings and the shaft sealing rings with grease 1 Grease filling see also table 10 With bolts 130 and nuts 131 screw the shell 101 and cover 102 on the outer flange see section 10 6 of the main coupling together observe part ma...

Page 52: ... 0 4 5 30 37 6 20 3 16 6 15 0 8 5 6 7 5 4 37 40 3 33 2 17 9 16 2 13 0 7 2 5 9 45 43 8 35 2 19 4 17 3 14 1 7 8 6 3 4 3 55 48 8 37 3 20 7 18 7 15 2 8 4 6 8 4 8 75 53 7 41 6 34 7 20 8 17 0 13 2 7 6 5 7 90 78 0 45 3 36 6 33 6 18 2 14 3 10 7 6 1 4 2 370 110 82 7 50 6 38 9 35 8 19 7 15 4 12 0 6 6 4 7 132 87 1 53 0 41 8 37 7 32 1 16 5 13 3 7 0 5 2 160 92 3 76 9 45 8 40 1 33 8 17 7 14 4 5 7 200 101 1 81 9...

Page 53: ... 0 22 0 12 6 11 2 9 1 6 5 30 31 5 25 0 13 8 12 7 10 3 7 6 37 33 6 26 9 21 7 13 6 11 1 8 6 6 4 45 49 6 29 0 23 6 20 9 11 9 9 3 7 0 55 52 6 31 3 25 5 22 8 12 9 10 1 7 8 75 57 8 47 9 28 5 25 7 20 5 11 3 9 2 90 62 4 50 5 30 7 27 4 22 1 12 1 9 8 6 7 425 110 69 2 53 5 32 8 29 6 24 0 17 3 10 6 7 4 132 74 8 56 5 48 1 31 6 25 8 19 3 11 3 8 3 160 77 6 61 0 50 9 46 9 27 6 21 3 15 8 9 0 180 77 6 64 4 52 6 48 ...

Page 54: ...haracteristics of the coupling thereby posing an active or passive risk to safety Flender will assume no liability or guarantee for damage caused by spare parts not supplied by Flender The same applies to any accessories not supplied by Flender Please note that certain components often have special production and supply specifications and that we supply you with spare parts which comply fully with...

Page 55: ...number is stamped on the coupling blade shell and specified on the order related title page 102 182 181 188 135 180 132 118 106 134 184 187 199 196 183 186 185 130 151 131 195 197 155 173 174 193 109 111 140 141 138 125 190 198 192 191 120 139 117 153 107 101 114 107 103 105 2 13 3 12 23 10 11 FND FNA 2 13 3 12 1 FNO 112 122 151 163 Fig 19 Spare parts drawing of types FNO FNA and FND ...

Page 56: ... 188 Sealing thread C 101 Blade shell B 138 O ring C 190 Flange cover 102 Cover 139 Cheese head bolt 191 Screw stud 103 Fusible safety plug 140 Locking plate 192 Hexagon nut 105 Bucket wheel A 141 Retaining screw 193 Shaft sealing ring C 106 Shaft A 195 V ring C 107 Threaded insert B 151 Washer 196 Washer 109 Rolling bearing D 153 Filling plug Fusible safety plug 197 Circlip 111 Shaft sealing ring...

Page 57: ...upling blade shell and specified on the order related title page 183 187 184 134 106 118 132 180 135 188 181 182 102 199 193 109 111 140 141 138 125 190 198 192 191 120 196 186 185 112 122 163 195 197 139 117 101 114 107 103 105 153 107 155 173 174 FNDB 2 13 3 12 23 10 32 50 51 2 13 3 12 23 10 8 FNDS HB 24 11 FNDS SB 2 13 3 12 23 10 32 50 51 130 151 151 131 Fig 20 Spare parts drawing of types FNDB...

Page 58: ...V ring C 24 Hexagon head bolt 131 Hexagon nut 186 Washer 32 Brake drum disk 132 Shaft sealing ring C 187 Circlip 50 Locking plate 134 Rolling bearing D 188 Sealing thread C 51 Retaining screw 135 O ring D 190 Flange cover 101 Blade shell B 138 O ring C 191 Screw stud 102 Cover 139 Cheese head bolt 192 Hexagon nut 103 Fusible safety plug 140 Locking plate 193 Shaft sealing ring C 105 Bucket wheel A...

Page 59: ...ing standards EN 1127 1 2011 EN 13463 1 2009 EN 13463 5 2011 EN 1710 2008 This declaration of conformity is issued under the sole responsibility of the manufacturer The object of the declaration described above is in conformity with the relevant Union harmonisation legislation Directive 2014 34 EU OJ L 96 29 03 2014 p 309 356 effective from 20 04 2016 00 00 a m Directive 94 9 EC OJ L 100 19 04 199...

Page 60: ...FLENDER COUPLINGS FLUDEX Operating instructions 4612 en Edition 10 2017 Flender GmbH Alfred Flender Straße 77 46395 Bocholt GERMANY flender com ...