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FLENDER ZAPEX, Assembly And Operating Instructions Manual

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FLENDER ZAPEX Assembly And Operating Instructions Manual Download Page 13

Introduction

1.4 Copyright

M3560-02en

Edition 09/2022

13

1. Procedural instructions are shown as a numbered list. Always perform the steps in the

order given.

• Lists are formatted as bulleted lists.

– The dash is used for lists at the second level.

(1) Numbers in brackets are part numbers.

1.4

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 53)).

Summary of Contents for ZAPEX

Page 1: ...ZNN ZNNA ZNNV ZNZS ZNZA ZNZV Assembly and operating instructions M3560 02en Edition 09 2022 ZAPEX...

Page 2: ...Original assembly and operating instructions M3560 02 Edition 09 2022 Copyright 2022 Flender GmbH V3 22 11 2022 15 14 08...

Page 3: ...he coupling 23 4 2 Storage of the coupling 23 5 Assembly 25 5 1 Preparatory work 25 5 1 1 Mill the finished bore 26 5 1 2 Mill the parallel keyway 27 5 1 3 Machining an axial locking mechanism 27 5 1...

Page 4: ...assembly related and maintenance related causes 44 7 2 3 Resolving faults 44 7 2 3 1 Resolving lubricant shortage 44 7 2 3 2 Correcting the changed alignment 45 8 Maintenance 47 8 1 Maintenance inter...

Page 5: ...1 3 Dimension drawing for ZNNV types 63 A 1 4 Dimension drawing for ZNZV types 64 A 1 5 Dimension table 66 A 2 Clearance S 66 A 3 Distances between teeth VA and recommended alignment values for angula...

Page 6: ...Table of contents 6 Edition 09 2022 M3560 02en...

Page 7: ...ded hole tightening torque and width A F 28 Table 5 3 Grease filling quantity 38 Table 7 1 Table of faults 42 Table 8 1 Operating temperatures operating hours and years of use 47 Table 11 1 Spare part...

Page 8: ...List of tables 8 Edition 09 2022 M3560 02en...

Page 9: ...ion of the balancing bore for two plane balancing 30 Figure 5 4 Possible misalignment 34 Figure 5 5 Fill with lubricant 38 Figure 8 1 Draining the lubricant 48 Figure 11 1 Spare parts drawing for ZNN...

Page 10: ...List of figures 10 Edition 09 2022 M3560 02en...

Page 11: ...al injury will occur if the relevant precautionary meas ures are not taken WARNING means that death or severe physical injury may occur if the relevant precautionary meas ures are not taken CAUTION me...

Page 12: ...documentation must be followed Trademarks All designations marked with the trademark symbol are registered trademarks of Flender GmbH Other designations in this document may be trademarks whose use b...

Page 13: ...sh is used for lists at the second level 1 Numbers in brackets are part numbers 1 4 Copyright1 4 Copyright The copyright of these instructions is held by Flender These instructions must not be used wh...

Page 14: ...Introduction 1 4 Copyright 14 Edition 09 2022 M3560 02en...

Page 15: ...amage or personal injury Flender does not accept any liability for damage or operating fail ures that are due to non adherence to these instructions State of the art The coupling described here has be...

Page 16: ...e relevant occupational safety and environmental protection regulations must be complied with at all times during transport assembly installation dismantling operation and mainten ance of the coupling...

Page 17: ...o liability or warranty whatsoever for damage occurring as a result of the use of non approved replacement parts The same applies to any accessories that were not supplied by Flender If you have any q...

Page 18: ...t components The self heating of the coup ling is minor In normal atmospheric conditions for explosion protection applications a max imum surface temperature 85 C can be expected Max ambient temperatu...

Page 19: ...DANGER Risk of explosion when using coupling parts without Ex marking Coupling parts without Ex marking have not been approved for use in potentially explosive atmospheres These coupling parts can le...

Page 20: ...a risk of chemical burns when handling aggressive cleaning agents Please observe the manufacturer s instructions on how to handle cleaning agents and solvents Wear suitable protective equipment glove...

Page 21: ...gh torques and harsh operating conditions Structure The ZAPEX coupling consists of the two hub parts 1 and 2 with external teeth which are fitted onto the machine shafts The external teeth engage in a...

Page 22: ...eir part numbers 1 6 1 9 11 119 1 11 Figure 3 1 ZNN ZNNA ZNZS ZNZA ZNNV and ZNZV types 1 Coupling part 1 2 2 Coupling part 1 2 4 Spacer 5 Flanged sleeve 6 Screw plug 7 Sealing ring in size 83 8 Fittin...

Page 23: ...be observed If not specifically contractually agreed otherwise the packaging complies with the HPE Pack aging Directive 2EHQ HUEUHFKOLFKHV XW 9RU 1 VVH VFK W HQ 9RU LW H VFK W HQ 6FKZHUSXQNW DQGKDNHQ...

Page 24: ...rm storage 1 You can find the required type of preservative agent in the following table types of pre servative agents for long term storage 2 Remove the elastomer components These must not come into...

Page 25: ...Follow the assembly sequence Please ensure that there is sufficient space at the assembly location and that the loca tion is tidy and clean in order to be able to assemble and maintain the coupling w...

Page 26: ...g If you exceed the maximum diameter of the finished bore then this can cause the coupling to burst in operation There is a risk of fatal injury from flying fragments If a coupling bursts in an area a...

Page 27: ...eyway that does not correspond to DIN 6885 1 please con sult Flender 5 1 3 Machining an axial locking mechanism5 1 Preparatory work The coupling part 1 2 1 or 2 is secured by a set screw or an end pla...

Page 28: ...hreaded hole depending on the coupling size and the finished bore D and the axial position of the threaded hole on the hub Coupling size Finished bore D Threaded hole d1 Tightening torque TA Width A F...

Page 29: ...n of the threaded hole tightening torque and width A F Apply the specified tightening torques as listed in Section Tightening procedure Page 69 Position of the threaded hole with respect to the parall...

Page 30: ...940 Observe the balancing specification according to DIN ISO 21940 32 Machine the balancing bore on a large radius with adequate clearance to the outer cir cumference Figure 5 3 Position of the balanc...

Page 31: ...s 1 1 and 2 2 6 Coat the bores of coupling parts 1 1 and 2 2 and the shafts with MoS2 assembly paste e g Microgleit LP 405 7 Smear the parallel keyway in the area of the set screw using sealing compou...

Page 32: ...cleaned flanged sleeve keyway and then insert the O rings 12 5 Smear the gear of the flanged sleeve 5 with a lubricant coating e g Castrol Opticoat ing N to minimise running in wear After the lubrica...

Page 33: ...eve 5 and if fitted of the spacer 4 with liquid plastic 50 10 Align the fitting holes of the flanges Observe any markings that might be provided 11 Insert the fitting bolts 8 and tighten the nuts 9 to...

Page 34: ...nt 5 3 2 1 Axial misalignment5 3 Aligning the coupling Set the axial misalignment Ka to a value within the permissible tolerance range for the S clearance The values for the S clearance are to be cons...

Page 35: ...aximum possible radial misalignment Krmax corres ponds to a maximum angular deviation for each coupling half of Kwmax 0 2 Determine the value Kr ZNN ZNNV ZNZS ZNZV types Kr VA tan 0 5 VA 100 ZNNA ZNZA...

Page 36: ...lubricant to confirm the compatibility of the new lubricant with the old one in writing Lubricant requirements For ZAPEX couplings only greases which contain active substances for improving corrosion...

Page 37: ...xxonMobil Mobilux EP004 Shell Gadus S2 V220 00 TotalEnergies Multis EP 00 NOTICE The quality and purity of the lubricant dictate the service life of the sealing rings 5 4 2 Filling quantity5 4 Fill wi...

Page 38: ...4 3 Fill with lubricant5 4 Fill with lubricant NOTICE Risk of injury and danger to the environment from lubricant Collect spilled lubricant and dispose of it according to the valid regulations Procedu...

Page 39: ...sioning of the coupling The coupling can burst and metal parts can be flung out There is a risk of fatal injury from flying fragments Bursting of the coupling can lead to an explosion in potentially e...

Page 40: ...Commissioning 40 Edition 09 2022 M3560 02en...

Page 41: ...lly explosive atmospheres Switch off the unit at once if any faults occur Note during the repair work the possible causes of faults and the notes on rectifying them Proceed as described below if there...

Page 42: ...tructions given in Section Correcting the changed alignment Page 45 Coupling not suitable for the operating conditions Check the possible causes given in section Unsuitable coupling Page 43 Use a coup...

Page 43: ...was chosen System torque too high and or torque dynamics not permissible System speed too high Application factor not selected correctly Chemically aggressive environment not taken into consideration...

Page 44: ...noise or vibration were not heeded Stipulated tightening torques not adhered to Alignment and or shaft misalignment values not set in accordance with the instructions 7 2 2 2 4 Specific assembly rela...

Page 45: ...coupling during operation often occurs when the coupled ma chines shift compared to one another A cause of this can be loose foundation bolts Procedure 1 Correct the cause for the change in alignment...

Page 46: ...Operation 7 2 Fault causes and correction 46 Edition 09 2022 M3560 02en...

Page 47: ...ng Sparks can lead to an explosion in potentially explosive atmospheres Carefully observe the specified lubricant quantity WARNING Physical injury Injury from rotating parts Only carry out work on the...

Page 48: ...e 2 Place a suitable container under the drainage hole 3 Unscrew all of the screw plugs 6 4 Make sure you capture all of the lubricant 5 Disposal of the lubricant When doing this carefully observe app...

Page 49: ...htening torque TA see Section Tightening torques and widths A F Page 68 12 Fill with grease according to Section Fill with lubricant Page 38 8 4 Dismantling the coupling8 4 Dismantling the coupling Pr...

Page 50: ...indicated in the dimension drawing is exceeded There is a risk of fatal injury from flying fragments If a coupling bursts in an area at risk of explosion then this can result in an explosion Do not ex...

Page 51: ...efer to the dimension drawing for the required axial force Procedure 1 Use a suitable pulling fixture 2 Secure the coupling part 1 1 or 2 2 and the pulling fixture in position to prevent them from fal...

Page 52: ...M3560 02en 11 Check the gear sealing surfaces hub bore and shaft for damage and protect them against corrosion 12 Replace damaged parts When reinstalling the coupling parts please observe the informa...

Page 53: ...u have any technical queries contact our factory or one of our Customer Service addresses Flender GmbH Schlavenhorst 100 46395 Bocholt Germany Tel 49 0 2871 92 0 Fax 49 0 2871 92 2596 Flender GmbH htt...

Page 54: ...Service and support 9 1 Contact 54 Edition 09 2022 M3560 02en...

Page 55: ...M3560 02en Edition 09 2022 55 Disposal 10 Disposal of the coupling Dispose of the coupling parts according to applicable national regulations or recycle them...

Page 56: ...Disposal 56 Edition 09 2022 M3560 02en...

Page 57: ...ist Page 58 You can find our contact data for ordering replacement parts at Service and support Page 53 Information required when ordering replacement parts Flender order number with item Flender draw...

Page 58: ...x 20 Plate pulley 2 x x x 22 Screw plug 3 33 Support ring x x 34 Thrust element x x 50 Sealing compound Liquid plastic Loc tite 5922 x x x x x x 51 Retaining ring x Table 11 1 Spare parts list for ZNN...

Page 59: ...parts list M3560 02en Edition 09 2022 59 11 2 2 Spare parts drawing for ZNN ZNNA ZNNV ZNZS ZNZA and ZNZV types11 2 Spare parts drawing and spare parts list 1 6 1 9 11 119 1 11 Figure 11 1 Spare parts...

Page 60: ...parts 11 2 Spare parts drawing and spare parts list 60 Edition 09 2022 M3560 02en 11 2 3 Screw plug11 2 Spare parts drawing and spare parts list The diagram below shows the screw plug 22 Figure 11 2 S...

Page 61: ...drawing for ZNZS and ZNZA Page 62 type Dimension drawing for ZNNV Page 63 type Dimension drawing for ZNZV Page 64 type Dimension table Page 66 A 1 1 Dimension drawing for ZNN and ZNNA typesSpeeds geom...

Page 62: ...The ZNZA type is only produced in variant A S17 For clearance S8 S9 and S17 refer to Chapter Clearance S Page 66 S Dimensions according to the orderer s specifications LZ Dimensions 200 are delivered...

Page 63: ...s geometry data and weights M3560 02en Edition 09 2022 63 4 Figure A 4 General ZNZA illustration A 1 3 Dimension drawing for ZNNV typesSpeeds geometry data and weights For clearance S11 and S12 refer...

Page 64: ...n find the dimension table in Chapter Dimension table Page 66 1 1 2 2 4 4 Figure A 5 ZNNV type top bottom A 1 4 Dimension drawing for ZNZV typesSpeeds geometry data and weights For clearance S8 and S1...

Page 65: ...echnical specifications Speeds geometry data and weights M3560 02en Edition 09 2022 65 You can find the dimension table in Chapter Dimension table Page 66 1 1 2 2 4 4 4 Figure A 6 ZNZV type top bottom...

Page 66: ...20 91 145 115 333 87100 3550 100 216 425 5 283 175 332 5 1 0 250 104 145 155 364 117000 3400 120 242 457 312 190 364 1 0 265 126 145 180 424 162500 3200 150 288 527 371 220 423 5 1 0 300 140 145 275 T...

Page 67: ...12 5 33 0 5 16 5 9 4 5 211 6 23 40 1 20 3 15 40 0 5 20 11 5 5 250 6 24 42 1 21 3 17 42 0 5 21 10 5 274 8 29 50 1 5 25 4 19 5 50 0 75 25 13 6 5 307 8 32 56 1 5 28 4 22 56 0 75 28 14 7 333 8 39 70 1 5 3...

Page 68: ...15 130 79 82 0 13 0 14 0 18 156 93 97 0 16 0 17 0 22 181 109 113 0 19 0 19 0 26 211 128 133 0 22 0 23 0 31 250 144 148 0 25 0 25 0 37 274 164 169 0 28 0 29 0 40 307 182 188 0 31 0 32 0 45 333 214 220...

Page 69: ...in 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 Tightening with a prec...

Page 70: ...for storage onto the coupling part 1 2 A 6 2 O ringsO rings Material Hardness Comment Marking Ambient temper ature Approved for ex plosion group 72NBR871 72 Shore A Standard black 30 C 80 C IIA IIB I...

Page 71: ...ation refers to the product mentioned above The object of this declaration described above complies with the statutory requirements Regulations 2016 No 1107 Specification of designated standards or ot...

Page 72: ...Declaration of conformity UK Declaration of Conformity 72 Edition 09 2022 M3560 02en...

Page 73: ......

Page 74: ...ZAPEX Assembly and operating instructions M3560 02en Edition 09 2022 Flender GmbH Alfred Flender Stra e 77 46395 Bocholt Germany...

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