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FLENDER ZAPEX, Руководство по сборке и эксплуатации

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M3560-02en

Edition 09/2022

25

Assembly

5

Assembly of the coupling comprises the following steps:

• Preparatory work (Page 25)

• Mounting the coupling (Page 30)

• Aligning the coupling (Page 33)

• Fill with lubricant (Page 36)

 DANGER

Danger due to bursting of the coupling

If you do not observe the information stipulated here regarding assembly, this can lead to
bursting of the coupling during operation. There is a risk of fatal injury from flying frag-
ments. If a coupling bursts in an area at risk of explosion, then this can result in an explo-
sion.

•

Carefully observe all of the specifications relating to assembly.

Notes regarding assembly of the coupling

• Only use undamaged components when assembling the coupling.

• 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 without
any risk.

• If a dimension drawing has been created for the coupling, please observe the informa-

tion it contains as a matter of priority.

5.1

Preparatory work

5.1 Preparatory work

Please consult Flender if you want to machine a conical finished bore.

Carry out the following steps if the coupling does not have a finished bore:

• Mill the finished bore (Page 26)

• Mill the parallel keyway (Page 27)

• Machining an axial locking mechanism (Page 27)

• 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.

Содержание ZAPEX

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

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 73: ......

Страница 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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