FLENDER COUPLINGS N-EUPEX 3103en User manual

FLENDER COUPLINGS
N-EUPEX
Assembly and operating instructions 3103en
Edition 10/2020
O, P

16.11.2020 12:40
V11.00

FLENDER COUPLINGS
N-EUPEX
3103en
Assembly and operating instructions
O, P
Edition 10/2020
Introduction 1
Safety instructions 2
Description 3
Application planning 4
Assembly 5
Commissioning 6
Operation 7
Servicing 8
Service and support 9
Disposal 10
Spare parts 11
Technical data A
Quality documents B

Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage
to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices
referring only to property damage have no safety alert symbol. These notices shown below are graded according to
the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property
damage.
Quali󹪝ed Personnel
The product/system described in this documentation may be operated only by personnel quali󹪝ed for the speci󹪝c
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Quali󹪝ed personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Flender products
Note the following:
WARNING
Flender products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended or
approved by Flender. Proper transport, storage, installation, assembly, commissioning, operation and maintenance
are required to ensure that the products operate safely and without any problems. The permissible ambient
conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identi󹪝ed by ® are registered trademarks of Flender GmbH. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this
publication is reviewed regularly and any necessary corrections are included in subsequent editions.
Flender GmbH
Alfred-Flender-Straße 77
46395 BOCHOLT
GERMANY
Document order number: 3103en
Ⓟ 11/2020 Subject to change
Copyright © Flender GmbH 2020.
All rights reserved

Table of contents
1 Introduction ........................................................................................................................................... 9
1.1 About these instructions ...................................................................................................... 9
1.2 Text attributes...................................................................................................................... 9
1.3 Copyright ............................................................................................................................ 9
2 Safety instructions............................................................................................................................... 11
2.1 General information........................................................................................................... 11
2.2 Intended use...................................................................................................................... 13
2.3 Safety instructions for a coupling for use in potentially explosive atmospheres.................... 13
2.3.1 Marking............................................................................................................................. 13
2.3.2 Conditions of use............................................................................................................... 14
2.4 General warning notices .................................................................................................... 15
3 Description........................................................................................................................................... 17
4 Application planning ........................................................................................................................... 19
4.1 Transport of the coupling................................................................................................... 19
4.2 Storage of the coupling...................................................................................................... 19
5 Assembly.............................................................................................................................................. 21
5.1 Preparatory work ............................................................................................................... 21
5.1.1 Milling the 󹪝nished bore..................................................................................................... 22
5.1.2 Milling the parallel keyway................................................................................................. 23
5.1.3 Machining an axial locking mechanism .............................................................................. 24
5.1.4 Balancing the coupling....................................................................................................... 26
5.2 Assembling the coupling.................................................................................................... 28
5.3 Aligning the coupling......................................................................................................... 29
5.3.1 Purpose of alignment......................................................................................................... 29
5.3.2 Possible misalignment ....................................................................................................... 30
5.3.2.1 Axial misalignment ............................................................................................................ 30
5.3.2.2 Angular misalignment........................................................................................................ 30
5.3.2.3 Radial misalignment .......................................................................................................... 31
6 Commissioning .................................................................................................................................... 33
7 Operation............................................................................................................................................. 35
7.1 Normal operation of the coupling ...................................................................................... 35
7.2 Faults - causes and recti󹪝cation .......................................................................................... 35
7.2.1 Procedure in the event of malfunctions .............................................................................. 35
7.2.2 Identifying the fault cause.................................................................................................. 36
7.2.2.1 Possible faults.................................................................................................................... 37
7.2.2.2 Possible causes .................................................................................................................. 38
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7.2.3 Correcting faults ................................................................................................................ 39
7.2.3.1 Replacing wearing parts..................................................................................................... 39
7.2.3.2 Correcting the changed alignment ..................................................................................... 39
8 Servicing .............................................................................................................................................. 41
8.1 Maintenance intervals........................................................................................................ 41
8.2 Maximum permissible torsional backlash............................................................................ 42
8.3 Replacing wearing parts..................................................................................................... 42
8.4 Removing the coupling ...................................................................................................... 43
9 Service and support............................................................................................................................. 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 O ............................................................................................................................... 50
11.2.2 Type P................................................................................................................................ 51
A Technical data...................................................................................................................................... 53
A.1 Speeds, geometry data and weights................................................................................... 53
A.1.1 Type O ............................................................................................................................... 54
A.1.2 Type P................................................................................................................................ 56
A.2 Shaft misalignment values during operation....................................................................... 57
A.3 Tightening torques and widths A/F ..................................................................................... 58
A.4 Tightening procedure......................................................................................................... 58
A.5 Flexible elements (12) ....................................................................................................... 59
A.5.1 Use and storage of 󹪞exible elements (12)........................................................................... 59
A.5.2 N-EUPEX 󹪞exible elements (12).......................................................................................... 59
B Quality documents .............................................................................................................................. 61
B.1 EU declaration of conformity.............................................................................................. 61
Tables
Table 2-1 General warnings ................................................................................................................... 11
Table 2-2 Temperature classes (TX) for explosive atmospheres as a result of gases, vapours or mists ....... 14
Table 2-3 Maximum surface temperature (TX) for an explosive atmosphere as a result of dust/air
mixtures ................................................................................................................................. 15
Table 4-1 Types of preservative agents for long-term storage.................................................................. 20
Table 5-1 Recommended assigned 󹪝ts for bores with parallel key connection .......................................... 22
Table 5-2 Position of the parallel keyway ................................................................................................ 23
Table 5-3 Diameter and axial position of the tapped hole, tightening torque ........................................... 25
Table 7-1 Table of faults ......................................................................................................................... 37
Table 8-1 Maintenance intervals............................................................................................................. 41
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Table 8-2 Maximum permissible torsional backlash for the types O and P ................................................ 42
Table 11-1 Spare parts list for type O........................................................................................................ 50
Table 11-2 Spare parts list for type P......................................................................................................... 51
Table A-1 Speeds, geometry data and weights of type O......................................................................... 54
Table A-2 Speeds, geometry data and weights of type P.......................................................................... 56
Table A-3 Maximum permissible shaft misalignment values during operation ......................................... 57
Table A-4 Tightening torques for parts 13 and 23 of types O and P.......................................................... 58
Table A-5 Tightening procedure ............................................................................................................. 58
Table A-6 N‑EUPEX 󹪞exible elements ...................................................................................................... 59
Figures
Figure 3-1 Type O.................................................................................................................................... 17
Figure 3-2 Type P..................................................................................................................................... 18
Figure 4-1 Transport symbols................................................................................................................... 19
Figure 5-1 Tolerances for 󹪝nished bore .................................................................................................... 23
Figure 5-2 Diameter and axial position of the tapped hole in the hub ....................................................... 25
Figure 5-3 Position of the balancing bore for single-plane balancing ........................................................ 27
Figure 5-4 Position of the balancing bore for two-plane balancing ........................................................... 27
Figure 5-5 Possible misalignment ............................................................................................................ 30
Figure 8-1 Markings for calculating the torsional backlash........................................................................ 42
Figure 11-1 Spare parts drawing for type O................................................................................................ 50
Figure 11-2 Spare parts drawing for type P................................................................................................. 51
Figure A-1 Type O.................................................................................................................................... 54
Figure A-2 Type P..................................................................................................................................... 56
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Table of contents
Assembly and operating instructions 3103en
8Edition 10/2020

Introduction 1
1.1 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.
1.2 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 󹪝nd the
following text attributes in these instructions:
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.
Note
A note is an important item of information about the product, the handling of the product or the
relevant section of the instructions. The note provides you with help or further suggestions/
ideas.
1.3 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)).
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Introduction
1.3 Copyright
Assembly and operating instructions 3103en
10 Edition 10/2020

Safety instructions 2
2.1 General information
Instructions
These instructions are part of the delivery. Always keep these instructions close to the coupling.
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 failures 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 󹪝ndings for
demanding 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 components and accessories that increase performance and safety whilst
maintaining the essential features.
Symbols
Table 2-1 General warnings
ISO ANSI Warning
Warning - hazardous electrical voltage
Warning - explosive substances
--- Warning - entanglement hazard
--- Warning - hot surfaces
--- Warning - substances that are harmful to health or are irritants
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ISO ANSI Warning
--- Warning - corrosive substances
--- Warning - suspended load
--- Warning - hand injuries
ATEX certi󹪝cation
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.
ATEX Directive
The term "ATEX Directive" used in these instructions stands for the harmonisation legislation of
the European Union in compliance with the declaration of conformance for equipment and
protective systems for correct use in hazardous zones.
Protective clothing
In addition to the generally prescribed personal protective equipment (safety shoes, overalls,
helmet, etc.), also wear suitable safety gloves and safety goggles when handling the coupling.
Using the coupling
The relevant work safety and environmental protection regulations must be complied with at all
times during transport, assembly, installation, dismantling, operation and maintenance of the
coupling.
Only quali󹪝ed personnel may operate, assemble, maintain and repair the coupling. Information
about quali󹪝ed personnel can be found in the legal notes at the beginning of these instructions.
If lifting gear or load suspension 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.
Safety instructions
2.1 General information
Assembly and operating instructions 3103en
12 Edition 10/2020

Secure the drive unit against being switched on accidentally. Attach a notice to the switch
stating clearly that work is being carried out on the coupling. Ensure that the entire unit is not
under load.
2.2 Intended use
Only use the coupling according to the conditions speci󹪝ed in the service and delivery contract
and the technical data in the annex. Deviating operating conditions are considered improper
use. The user or owner of the machine or plant is solely liable for any resulting damage.
When using the coupling please speci󹪝cally observe the following:
• Do not make any modi󹪝cations to the coupling that go beyond the permissible machining
described in these instructions. This also applies to touch protection facilities.
• Only use original spare parts from Flender. Flender only accepts liability for original spare
parts from Flender.
Other spare parts are not tested and approved by Flender. Non-approved spare 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 spare parts. The same applies to any accessories that were not supplied
by Flender.
If you have any queries, please contact our customer service (see Service and support
(Page 45)).
2.3 Safety instructions for a coupling for use in potentially explosive
atmospheres
2.3.1 Marking
You can 󹪝nd a description of the coupling parts in chapter Description (Page 17).
A coupling designed in accordance with the ATEX Directive has a marking on the coupling.
Coupling part 10 without electrically insulating 󹪞exible elements
The following marking is visible on the outer diameter of coupling part 10:
Flender GmbH II 2G Ex h IIC T6 ... T4 Gb X
D 46393 Bocholt II 2D Ex h IIIC T85 °C ... 110 °C Db X
N‑EUPEX <Year of manufacture> I M2 Ex h Mb X
Safety instructions
2.3 Safety instructions for a coupling for use in potentially explosive atmospheres
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Coupling part 10 with electrically insulating 󹪞exible elements
The following marking is visible on the outer diameter of coupling part 10:
Flender GmbH II 2G Ex h IIB T6 ... T4 Gb X
D 46393 Bocholt II 2D Ex h IIIC T85 °C ... 110 °C Db X
N‑EUPEX <Year of manufacture> I M2 Ex h Mb X
2.3.2 Conditions of use
Note
Note also the material-dependent permissible ambient temperature of the 󹪞exible elements
(12) in accordance with section Flexible elements (12) (Page 59).
A coupling designed in accordance with the ATEX Directive is suitable for the following
conditions of use:
• Equipment group I
– Category M2
• Equipment group II
– Category 2 and 3
– Group of substances G, zone 1 and 2
– Group of substances D, zone 21 and 22
– Explosion group IIA, IIB and IIC
– Explosion group IIA and IIB when electrically insulating 󹪞exible elements are used
Conditions of use for products with TX marking
The maximum ambient temperature stated in the following tables applies to the temperature in
the direct vicinity of the coupling and the temperature of adjacent components.
1. Gases, vapours or mists
Check the ambient temperature for use of the coupling in the relevant temperature class.
Table 2-2 Temperature classes (TX) for explosive atmospheres as a result of gases, vapours or mists
Max. ambient temperature Temperature class
80 °C T4
70 °C T5
55 °C T6
Safety instructions
2.3 Safety instructions for a coupling for use in potentially explosive atmospheres
Assembly and operating instructions 3103en
14 Edition 10/2020

2. Dust/air mixtures
Check the ambient temperature.
Table 2-3 Maximum surface temperature (TX) for an explosive atmosphere as a result of dust/air
mixtures
Max. ambient temperature Max. surface temperature
80 °C 110 °C
Notes concerning operation of the coupling in potentially explosive atmospheres
• Only use the coupling underground in mines in potentially explosive atmospheres together
with drive motors that can be switched o󹪜 in the event of the formation of an explosive
atmosphere.
• Earth machines that are connected via the coupling with a leakage resistance of less than
106 Ω.
• If you want to use a coated coupling in potentially explosive atmospheres, please note the
requirements concerning the conductivity of the paint and the limitation on the paint layer
thickness applied in accordance with EN 80079-36. No build-up of electrostatic charges is to
be expected with a paint layer thickness of less than 200 μm.
• The supplier of the assembly is responsible for ensuring that the brake system and all of its
components are designed in accordance with the relevant directive.
2.4 General warning notices
DANGER
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 󹪞ying
fragments. Bursting of the coupling can lead to an explosion in potentially explosive
atmospheres.
• Use the coupling for the purpose for which it is intended.
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 lead to an explosion during operation.
• Only use couplings with Ex marking in potentially explosive atmospheres.
Safety instructions
2.4 General warning notices
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DANGER
Danger
Risk of injury due to the use of unsuitable and/or damaged components. The use of unsuitable
and/or damaged components can lead to an explosion in potentially explosive atmospheres.
• Observe the information regarding conditions of use.
DANGER
Danger of explosion
Improper operation of the coupling can lead to an explosion in potentially explosive
atmospheres.
• Please observe the notes concerning operation of the coupling in potentially explosive
atmospheres.
DANGER
Danger from hot coupling parts
Risk of injury due to hot surfaces. Hot coupling parts can lead to an explosion in potentially
explosive atmospheres.
• Wear suitable protective equipment (gloves, safety goggles).
• Ensure that the area is not at risk of explosion.
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
2.4 General warning notices
Assembly and operating instructions 3103en
16 Edition 10/2020

Description 3
The N‑EUPEX couplings described here are torsionally 󹪞exible, damping pin couplings and are
available in various types and sizes. The couplings can be used in accordance with the ATEX
Directive in potentially explosive atmospheres if they have a CE marking.
Types O and P are fail-safe. Types O and P are designs that feature a brake drum (coupling part
32).
These instructions describe the assembly and operation of an N‑EUPEX coupling arranged
horizontally with a shaft-hub connection made by a cylindrical or conical bore with parallel key.
Please consult Flender if you want to use a di󹪜erent type of installation.
Application
N‑EUPEX couplings are designed for use in all kinds of machines.
Design
The diagrams show the various types with their constituent parts and their part numbers.

4 Coupling part 4
10 Coupling part 10
12 Flexible element
23 Cylinder-head screw
24 Cylindrical pin
32 Coupling part 32
Figure 3-1 Type O
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
2 Coupling part 2
3 Coupling part 3
10 Coupling part 10
12 Flexible element
13 Cylinder-head screw
23 Cylinder-head screw
24 Cylindrical pin
32 Coupling part 32
Figure 3-2 Type P
Description
Assembly and operating instructions 3103en
18 Edition 10/2020

Application planning 4
Check the delivery for damage and for completeness. Report any damage and/or missing parts
to Flender immediately.
The coupling is delivered in individual parts and preassembled groups. Preassembled groups
may not be dismantled.
4.1 Transport of the coupling
WARNING
Severe personal injury due to improper transport
Severe personal injury due to falling components or due to crushing. Damage to coupling parts
possible due to use of unsuitable transport means.
• Only use lifting gear and load suspension devices with su󹪟cient load bearing capacity for
transport.
• Please observe the symbols applied on the packaging.
If not speci󹪝cally contractually agreed otherwise, the packaging complies with the HPE
Packaging Directive.
7KLVZD\XS)UDJLOH.HHSGU\.HHSGU\&HQWUHRIJUDYLW\'RQRWXVHKDQGKRRN$WWDFKKHUH
Figure 4-1 Transport symbols
4.2 Storage of the coupling
NOTICE
Property damage due to improper storage
Negative changes to the physical properties of the coupling and/or coupling damage.
• Please observe the information about storing the coupling.
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The coupling, unless not speci󹪝cally ordered otherwise, is supplied with preservation and can be
stored for up to 3 months.
Note
Information about storing the coupling
• Ensure that the storage room is dry (relative humidity < 65 %) and free of dust.
• Ensure that there is no condensation.
• Do not store the coupling together with corrosive chemicals, acids, caustic solutions, etc.
• If the coupling contains elastomer components, ensure that there are no devices in the
storage room that produce ozone, such as 󹪞uorescent lights, mercury vapour lamps or high-
voltage electrical equipment.
• Store the coupling on suitable supports or in suitable containers.
Long-term storage
NOTICE
Property damage due to improper long-term storage
Negative changes to the physical properties of the coupling and/or coupling damage.
• Note the handling instructions for long-term storage.
1. You can 󹪝nd the required type of preservative agent in the following table (types of
preservative agents for long-term storage).
2. Remove the elastomer components. These must not come into contact with cleaning agents
and long-term preservative agents.
3. Clean the coupling parts.
4. Apply the stipulated preservative agent.
5. Store the coupling parts and the elastomer components separately.
Table 4-1 Types of preservative agents for long-term storage
Preservative agents Features Indoor storage Outdoor storage
Oil spray Anti-corrosion agent Up to 12 months Up to 4 months
Tectyl 846 or similar Long-term preservative agent on
wax basis
Up to 36 months Up to 12 months
Emulsion cleaner + VCI foil Active system, reusable Up to 5 years Up to 5 years
Application planning
4.2 Storage of the coupling
Assembly and operating instructions 3103en
20 Edition 10/2020