FLENDER BIPEX-S BNN User manual

BNN, BGG, BCC, BHH, BKK, BCS, BHH-W
Assembly and operating instructions M3410-01en
Edition 09/2022
BIPEX-S

Original assembly and operating instructions
M3410-01
Edition 09/2022
Copyright (©2022 Flender GmbH)
V5
20/10/2022
09:26:00

M3410-01en Edition 09/2022 3
Table of contents
1 Introduction...............................................................................................................................................11
1.1 Legal information .....................................................................................................................11
1.2 About these instructions...........................................................................................................12
1.3 Text attributes ..........................................................................................................................12
1.4 Copyright..................................................................................................................................13
2 Safety instructions ...................................................................................................................................15
2.1 General information .................................................................................................................15
2.2 Intended use ............................................................................................................................16
2.3 General warning notices ..........................................................................................................17
3 Description................................................................................................................................................19
4 Application planning ................................................................................................................................25
4.1 Transport of the coupling .........................................................................................................25
4.2 Storage of the coupling ............................................................................................................25
5 Assembly...................................................................................................................................................27
5.1 Preparatory work......................................................................................................................27
5.2 Assembling the coupling ..........................................................................................................27
5.2.1 Assembling the coupling parts .................................................................................................28
5.2.1.1 Attach the coupling part N (1) with parallel key to the shaft.....................................................28
5.2.1.2 Attaching coupling part G (2), C (3), H (4) or K (5) to the shaft with a clamping connection ...29
5.2.1.3 Attach coupling part S (6) to the hollow shaft with a clamping connection ..............................29
5.2.2 Plug-in assembly of the coupling halves..................................................................................29
5.2.2.1 Plug-in assembly of types BNN, BGG, BCC, BHH, BKK and BCS.......................................... 30
5.2.2.2 Plug-in assembly of type BHH-W.............................................................................................30
5.3 Aligning the coupling................................................................................................................30
5.3.1 Purpose of alignment ...............................................................................................................30
5.3.2 Possible misalignment .............................................................................................................31
5.3.2.1 Axial misalignment ...................................................................................................................31
5.3.2.2 Angular misalignment ..............................................................................................................31
5.3.2.3 Radial misalignment.................................................................................................................32
6 Commissioning.........................................................................................................................................33
7 Operation...................................................................................................................................................35

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4 Edition 09/2022 M3410-01en
7.1 Normal operation of the coupling .............................................................................................35
7.2 Faults - causes and rectification ..............................................................................................35
7.2.1 Procedure in the event of malfunctions....................................................................................35
7.2.2 Identifying the fault cause ........................................................................................................35
7.2.2.1 Possible faults..........................................................................................................................36
7.2.2.2 Possible causes .......................................................................................................................37
7.2.2.2.1 Unsuitable coupling..................................................................................................................37
7.2.2.2.2 Assembly-related causes.........................................................................................................37
7.2.2.2.3 Maintenance-related causes....................................................................................................38
7.2.2.2.4 Specific installation-related and maintenance-related causes .................................................38
7.2.3 Correcting faults.......................................................................................................................38
7.2.3.1 Replacing wearing parts ..........................................................................................................38
7.2.3.2 Correcting the changed alignment ...........................................................................................38
8 Servicing ...................................................................................................................................................41
8.1 Maintenance intervals ..............................................................................................................41
8.2 Maximum permissible torsional backlash ................................................................................42
8.3 Replacing wearing parts ..........................................................................................................42
8.4 Removing coupling part N(1) ..................................................................................................43
8.5 Removing coupling part G (2), C (3), H (4) or K (5) .................................................................43
8.6 Removing coupling part S(6) ..................................................................................................44
9 Service and support .................................................................................................................................45
9.1 Contact.....................................................................................................................................45
10 Disposal.....................................................................................................................................................47
11 Spare parts................................................................................................................................................49
11.1 Ordering spare parts ................................................................................................................49
11.2 Spare parts drawing and spare parts list .................................................................................50
11.2.1 Type BNN ................................................................................................................................50
11.2.2 Type BGG ................................................................................................................................51
11.2.3 Type BCC ................................................................................................................................52
11.2.4 Type BHH ................................................................................................................................53
11.2.5 Type BKK.................................................................................................................................54
11.2.6 Type BCS.................................................................................................................................55
11.2.7 Type BHH-W............................................................................................................................56
A Technical data...........................................................................................................................................57
A.1 Speeds, geometry data and weights........................................................................................57
A.1.1 Type BNN ................................................................................................................................57

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M3410-01en Edition 09/2022 5
A.1.2 Type BGG ................................................................................................................................58
A.1.3 Type BCC ................................................................................................................................59
A.1.4 Type BHH ................................................................................................................................60
A.1.5 Type BKK.................................................................................................................................60
A.1.6 Type BCS.................................................................................................................................61
A.1.7 Type BHH-W............................................................................................................................62
A.2 Shaft misalignment values during operation ............................................................................62
A.3 Tightening torques and widths A/F ..........................................................................................64
A.4 Tightening procedure ...............................................................................................................64
A.5 Cam rings.................................................................................................................................65
A.5.1 Use and storage of the cam rings ............................................................................................65
A.5.2 BIPEX-S cam ring (20).............................................................................................................65

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M3410-01en Edition 09/2022 7
List of tables
Table2-1 General warnings .......................................................................................................................15
Table4-1 Types of preservative agents for long-term storage...................................................................26
Table7-1 Table of faults.............................................................................................................................36
Table8-1 Maintenance intervals ................................................................................................................41
Table8-2 Maximum permissible torsional backlash for the BIPEX-S coupling..........................................42
Table11-1 Spare parts list for type BNN .....................................................................................................50
Table11-2 Spare parts list for type BGG ....................................................................................................51
Table11-3 Spare parts list for type BCC .....................................................................................................52
Table11-4 Spare parts list for type BHH .....................................................................................................53
Table11-5 Spare parts list for type BKK .....................................................................................................54
Table11-6 Spare parts list for type BCS .....................................................................................................55
Table11-7 Spare parts list for type BHH-W ................................................................................................56
TableA-1 Geometry data and weights of BNN type ..................................................................................57
TableA-2 Geometry data and weights of type BGG .................................................................................58
TableA-3 Geometry data and weights of type BCC ..................................................................................59
TableA-4 Geometry data and weights of type BHH ..................................................................................60
TableA-5 Geometry data and weights of type BKK ..................................................................................61
TableA-6 Geometry data and weights of type BCS ..................................................................................61
TableA-7 Geometry data and weights of type BHH-W .............................................................................62
TableA-8 Maximum permissible shaft misalignment values during operation ...........................................62
TableA-9 Tightening torques TAand widths A/FSW for part 11, part 12 and part 13 ..............................64
TableA-10 Tightening procedure .................................................................................................................64
TableA-11 BIPEX-S cam ring ......................................................................................................................65

List of tables
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M3410-01en Edition 09/2022 9
List of figures
Figure3-1 Type BNN ..................................................................................................................................20
Figure3-2 Type BGG .................................................................................................................................20
Figure3-3 Type BCC ..................................................................................................................................21
Figure3-4 Type BHH ..................................................................................................................................21
Figure3-5 Type BKK ..................................................................................................................................22
Figure3-6 Type BCS ..................................................................................................................................22
Figure3-7 Type BHH-W .............................................................................................................................23
Figure4-1 Transport symbols......................................................................................................................25
Figure5-1 Possible misalignment................................................................................................................31
Figure8-1 Markings for calculating the torsional backlash..........................................................................42
Figure11-1 Spare parts drawing for type BNN .............................................................................................50
Figure11-2 Spare parts drawing for type BGG ............................................................................................51
Figure11-3 Spare parts drawing for type BCC .............................................................................................52
Figure11-4 Spare parts drawing for type BHH .............................................................................................53
Figure11-5 Spare parts drawing for type BKK .............................................................................................54
Figure11-6 Spare parts drawing for type BCS .............................................................................................55
Figure11-7 Spare parts drawing for type BHH-W ........................................................................................56
FigureA-1 BNN type ...................................................................................................................................57
FigureA-2 BGG type ...................................................................................................................................58
FigureA-3 BCC type ...................................................................................................................................59
FigureA-4 BHH type ...................................................................................................................................60
FigureA-5 BKK type ...................................................................................................................................60
FigureA-6 BCS type ...................................................................................................................................61
FigureA-7 BHH-W type ..............................................................................................................................62

List of figures
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M3410-01en Edition 09/2022 11
Introduction 1
1.1 Legal information1.1 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. Depending on the hazard class, the warn-
ings shall be depicted as follows, in descending order.
DANGER
means that death or severe physical 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
means that mild physical injury may occur if the relevant precautionary measures are not
taken.
NOTICE
means that damage to property may occur if the relevant precautionary measures are not
taken.
If multiple hazard classes come into play, the warning for the highest level in question shall
always be used. If a warning containing the warning triangle warns of harm to individuals, the
same warning may also include a warning regarding damage to property.
Information
Information
Information offers additional notes, assistance and tips for handling the product.

Introduction
1.2 About these instructions
12 Edition 09/2022 M3410-01en
Qualified personnel
The product/system associated with this documentation may only be used by qualified per-
sonnel trained to perform the relevant tasks, taking into account the associated documenta-
tion for the relevant tasks, particularly the safety information and warnings included therein.
Due to their qualification and experience, qualified personnel are capable of detecting risks
and avoiding potential hazards when dealing with these products/systems.
Intended use of Flender products
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. The permissible environmental conditions must be adhered
to. Instructions in the associated 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 by third parties
for their own purposes may violate the rights of the owner.
Liability disclaimer
We have assessed the contents of these instructions for compliance with the hardware and
software described. However, deviations cannot be ruled out, so we are unable to accept li-
ability for full compliance. The details in these instructions are regularly reviewed and neces-
sary corrections are contained in subsequent editions.
1.2 About these instructions1.2 About these instructions
These instructions describe the coupling and provide information about its handling - from
assembly to maintenance. Please keep these instructions for later use.
Please read these instructions prior to handling the coupling and follow the information in
them.
1.3 Text attributes1.3 Text attributes
The warning notice system is explained on the back of the inner cover. Always follow the
safety information and notices in these instructions.
In addition to the warning notices, which have to be observed without fail, you will find the
following text attributes in these instructions:

Introduction
1.4 Copyright
M3410-01en 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 Copyright1.4 Copyright
The copyright for 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45)).

Introduction
1.4 Copyright
14 Edition 09/2022 M3410-01en

M3410-01en Edition 09/2022 15
Safety instructions 2
2.1 General information2.1 General information
Instructions
These instructions are part of the delivery. Always keep these instructions close to the coup-
ling.
Please make sure that every person who is commissioned to work on the coupling has read
and understood these instructions prior to handling the coupling and observes all of the
points.
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.
State of the art
The coupling described here has been designed in consideration of the latest findings for de-
manding technical requirements. This coupling is state-of-the-art at the time of printing these
instructions.
In the interest of further development, Flender reserves the right to make such changes to
the individual assembly units and accessories that increase performance and safety while
maintaining the essential features.
Symbols
ISO ANSI Warning
Warning – hazardous electrical voltage
Warning – explosive substances
--- Warning – entanglement hazard
--- Warning – hot surfaces
--- Warning – corrosive substances
--- Warning – suspended load

Safety instructions
2.2 Intended use
16 Edition 09/2022 M3410-01en
ISO ANSI Warning
--- Warning – hand injuries
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.
Protective clothing
In addition to the generally prescribed personal protective equipment (safety shoes, overalls,
helmet, etc.), also wear suitable protective gloves and safety glasses when handling the
coupling.
Using the coupling
The 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.
Only qualified personnel may operate, assemble, maintain and repair the coupling. Informa-
tion about qualified personnel can be found in the legal notes at the beginning of these in-
structions.
If hoisting gear or load lifting devices are used for transporting, these have to be suitable for
the weight of the coupling.
If the coupling has visible damage, it may not be assembled or put into operation.
The coupling may only be operated in a suitable housing or with touch protection according
to applicable standards. This also applies to test runs and rotational direction checks.
Work on the coupling
Only carry out work on the coupling when it is not in operation and is not under load.
Take measures to prevent the accidental restarting of the drive aggregate. Attach an inform-
ation notice to the start switch stating clearly that work is being carried out on the coupling.
Ensure that the entire unit is not under load.
2.2 Intended use2.2 Intended use
Only use the coupling according to the conditions specified in the service and delivery con-
tract and the technical data in the annex. Deviating operating conditions are considered im-
proper use. The user or operator of the machine or system is solely liable for any resulting
damage.
When using the coupling please specifically observe the following:
• 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.

Safety instructions
2.3 General warning notices
M3410-01en Edition 09/2022 17
• Use only original replacement parts from Flender. Flender only accepts liability for ori-
ginal replacement parts from Flender.
Other replacement parts are not tested and approved by Flender. Non-approved re-
placement parts may possibly change the design characteristics of the coupling and thus
impact active and/or passive safety.
Flender will accept no 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 queries, please contact our customer service organisation (see Service and
support (Page45)).
2.3 General warning notices2.3 General warning notices
WARNING
Danger due to bursting of the coupling
The coupling may burst if it is not used properly. There is a risk of fatal injury from flying
fragments.
• Use the coupling for the purpose for which it is intended.
WARNING
Danger from hot coupling parts
Risk of injury due to hot surfaces.
• Wear suitable protective equipment (gloves, safety goggles).
WARNING
Risk of chemical burns due to chemical substances
There is a risk of chemical burns when handling aggressive cleaning agents.
• Please observe the manufacturer's information on how to handle cleaning agents and
solvents.
• Wear suitable protective equipment (gloves, safety goggles).
CAUTION
Physical injury
Risk of injury due to falling coupling parts.
• Secure the coupling parts to prevent them from falling.

Safety instructions
2.3 General warning notices
18 Edition 09/2022 M3410-01en

M3410-01en Edition 09/2022 19
Description 3
The BIPEX-S couplings described here are torsionally flexible claw couplings that are free of
torsional backlash and are available in various types and sizes. They are characterised by a
very compact design.
BIPEX-S couplings are fail-safe.
These instructions describe the assembly and operation of a BIPEX-S coupling arranged ho-
rizontally with a shaft-hub connection made by a cylindrical or conical bore with a parallel key
or by various clamping connections. Please consult Flender if you want to use a different
type of installation.
Application
BIPEX-S couplings are designed for use in all kinds of machines. They are primarily used in
drive units with torque transmission without any backlash and only low misalignment.
Design
A BIPEX-S coupling consists of two hub parts that are connected to one another by a cam
ring made of an elastomer material. In the BHH-W type the hub parts are connected to one
another by two cam rings and a spacer.
The cam ring is fitted between the hub cams with a small amount of interference. The coup-
ling characteristic of zero backlash is based on this.
The hub parts are joined to the shaft by finished bores with a parallel key or various clamping
connections.

Description
20 Edition 09/2022 M3410-01en
The diagrams show the various types with their constituent parts and their part numbers.

Figure3-1:Type BNN
1 Coupling part N
11 Set screw
20 Cam ring

Figure3-2:Type BGG
2 Coupling part G
12 Cylinder-head screw
20 Cam ring