FLENDER FASTEX IC240 User manual

flender.com
FLENDER COUPLINGS
FASTEX
Compact assembly and operating instructions 3907en
Edition 05/2022
FASTEX IC240

FLENDER COUPLINGS
FASTEX IC240
Clamping elements
3907en
Compact assembly and
operating instructions
Edition 05/2022
Introduction
1
Description
2
Application planning
3
Assembly
4
Disassembly
5
Disposal
6
Services and support
7
Technical data
A

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.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the
specific task in accordance with the relevant documentation, in particular its warning notices and safety
instructions. Qualified 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 identified 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: 3907de
℗04/2022 Subject to change
Copyright © Flender GmbH 2022.
All rights reserved

4
FASTEX IC240 Clamping element 3907de
Compact assembly and operating instructions 05/2022
Table of contents
1Introduction ...............................................................................................................................5
1.1 Main operation instructions ....................................................................................5
1.2 General information................................................................................................5
1.3 Intended use...........................................................................................................6
1.4 Safety instructions for a clamping element for use in potentially explosive
atmospheres...........................................................................................................6
2Description ................................................................................................................................7
3Application planning ................................................................................................................8
3.1 Transport of the clamping element........................................................................8
3.1 Storage of the clamping element............................................................................8
4Assembly ...................................................................................................................................9
4.1 Assembling the clamping element..........................................................................10
5Disassembly ..............................................................................................................................11
6Disposal .....................................................................................................................................12
7Service und support .................................................................................................................12
ATechnical data...........................................................................................................................13
A.1 Geometry data and tightening torques...................................................................13
Tables
Table 1-1 General warnings ...................................................................................................5
Table 4-1 Recommended assigned fits..................................................................................9
Table 7-1 Geometry data, weights, tightening torques...........................................................14
Figures
Figure 2-1 Construction of the clamping element FASTEX IC240 ..........................................7
Figure 4-1 Fit assignment ........................................................................................................9
Figure 4-2 Alignment clamping element ..................................................................................10
Figure 7-1 Parts overview FASTEX IC240 .............................................................................13

5
FASTEX IC240 Clamping element 3907de
Compact assembly and operating instructions 05/2022
1 Introduction
1.1 Main operation instructions
These instructions are only valid in conjunction with the associated operating instructions
from the component supplier.
1.2 General information
Instructions
Notice the information and regulations in these installation instructions and in the main
operating instructions from the component supplier.
Please make sure that every person who is commissioned to work on the clamping element
has read and understood these instructions prior to handling the clamping element and
observes all of the points.
Only the knowledge of these instructions can avoid faults on the clamping element 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.
.
Symbols
Table 1-1 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
---
Warning - corrosive substances
---
Warning - suspended load
---
Warning - hand injuries
ATEX certification

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FASTEX IC240 Clamping element 3907de
Compact assembly and operating instructions 05/2022
Explanation regarding Machinery Directive 2006/42/EG
The clamping elements described here are components in accordance with the Machinery
Directive and do not require a declaration of incorporation.
Work on the clamping element
Only carry out work on the clamping element when it is not in operation and is not under
load. 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 clamping element. Ensure that the
entire unit is not under load..
1.3 Intended use
Only use the clamping element according to the conditions specified 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 clamping element please specifically observe the following:
•Do not make any modifications to the clamping element that go beyond the permissible
machining described in these instructions. This also applies to touch protection facilities.
•Do not use the clamping element as a torque-limiting safety element.
If you have any queries, please contact our customer service (see Service and support
(Page 12)).
1.4 Safety instructions for a clamping element for use in
potentially explosive atmospheres
The assembly supplier is responsible for the guideline-compliant design of the system
clamping element with all associated components. In potentially explosive areas, it must be
ensured that the design torque TCl according to Table 7-1 is not exceeded at any operating
point. The identification and information on the conditions of use can be found in the main
operating instructions of the assembly supplier.

7
FASTEX IC240 Clamping element 3907de
Compact assembly and operating instructions 05/2022
2 Description
The clamping elements described here are universally applicable, self-centering clamping
elements whose function is the tensionally locked transmission of torque between shaft and
hub.
The installation and operation of the specified clamping elements in combination with
cylindrically bored hubs is described in these instructions.
Design
Detailed information on the dimensions can be found in Appendix A Technical data
(Page 13).
1 Frontal pressur ring
2 Outer ring
3 Reat pressure ring
4 Cylinder-head screw
Figure 2-1 Construction of the clamping element FASTEX IC240
Contact surfaces 3 2 1 4

8
FASTEX IC240 Clamping element 3907de
Compact assembly and operating instructions 05/2022
3 Application planning
Check the delivery for damage and for completeness. Report any damage and/or missing
parts to Flender immediately.
The coupling is delivered in preassembled groups. These may be dismantled.
3.1 Transport of the clamping element
WARNING
Severe personal injury due to improper transport
Severe personal injury due to falling components or due to crushing. Damage to clamping
element parts possible due to use of unsuitable transport means.
•Only use lifting gear and load suspension devices with sufficient load bearing capacity
for transport.
•Please observe the symbols applied on the packaging.
3.1 Storage of the clamping element
The clamping element, unless not specifically ordered otherwise, is supplied with
preservation and can be stored for up to 12 months in a dry and dust-free storage room.

9
FASTEX IC240 Clamping element 3907de
Compact assembly and operating instructions 05/2022
4 Assembly
DANGER
Danger due to bursting of the assembly group
If not used as intended, the assembly can burst. There is a risk of fatal injury from flying
fragments. Bursting of the assembly can lead to an explosion in potentially explosive
atmospheres.
•Use the clamping element as intended
Note
Information about the assembly of the clamping element
•Only use undamaged components for the assembly of the clamping element.
•Follow the assembly sequence.
•Please ensure that there is sufficient space at the assembly location and that the
location is tidy and clean in order to be able to assemble and maintain the clamping
element without any risk.
•If a dimension drawing has been created for the clamping element, please observe the
information it contains as a matter of priority
Recommended assigned fits
In the following table you will find the permissible fits of the clamping element and the shaft.
Table 4-1 Recommended assigned fits
component
tolerance
surface quality
Shaft tolerance
h8
Ra ≤ 3,2 µm
Bore tolerance
H8
Ra ≤ 3,2 µm
Figure 4-1 Fit assignment

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FASTEX IC240 Clamping element 3907de
Compact assembly and operating instructions 05/2022
4.1 Assembling the clamping element
WARNING
The design torque TC l must not be exceeded at any operating point. It must be
ensured that the cylinder head bolts are tightened with the tightening torques
according to Table 7-1
Preparatory work
1. Make sure the surfaces to be joined are in perfect condition.
2. Clean the contact surfaces as well as the shaft and hub.
3. Slightly oil the contact surfaces. Do not use any grease or oil that contains molybdenum
disulfide or other additives that significantly reduce the coefficient of friction.
4. Insert the frontal pressure ring (1) and the rear pressure ring (3) into the outer ring (2).
Place the rear pressure ring (3), the frontal pressure ring (1) and outer ring (2) that the
slots are aligned with each other and offset to the forcing threads.
5. Screw the frontal pressure ring (1) and the rear pressure ring (3) without tightening the
cylinder-head screws (4).
Assemble
1. Position the pre-assembled clamping element in the hub bore and then place both parts
on the shaft.
2. Slightly tighten the cylinder-head screws (4) so that the clamping element can still be
moved.
3. Align the Clamping element on the shaft.
4. The shaft must fill the entire length of the clampingelement.
5. Tighten the cylinder-head screws (4) crosswise in several turns. The specified tightening
torque can be found in the Tightening torques and widths A/F section.
Figure 4-2 Alignment clamping element
Formula for calculating the clearance
during disassembly

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FASTEX IC240 Clamping element 3907de
Compact assembly and operating instructions 05/2022
5 Disassembly
Procedure
1. Loosen and remove all cylinder-head screws (4) one after the other.
2. Screw the cylinder-head screws (4) into the existing release threads of the frontal
pressure ring (1).
3. Remove the clamping element. Use suitable lifting gear when doing this.
4. Check the hub bore and the shaft for damage and protect them against corrosion.
When reinstalling the clamping element please observe the information in the chapter
Assembly (Page 10).

12
FASTEX IC240 Clamping element 3907de
Compact assembly and operating instructions 05/2022
6 Disposal
Dispose of the clamping element parts according to applicable national regulations or recycle
them.
7 Service und support
When ordering spare parts, requesting a customer service technician or in the case of
technical queries, please contact our factory or one of our customer service addresses:
Flender GmbH
Schlavenhorst 100
46395 Bocholt
Deutschland
Tel.: [phone]
Fax.: [phone]
Flender GmbH (http://www.flender.com)

flender.com
A Technical data
A.1 Geometry data and tightening torques
In this section you can find dimension drawings and technical data for the Flender clamping
elements.:
1 Frontal pressur ring
2 Outer ring
3 Reat pressure ring
4 Cylinder-head screw
Figure 7-1 Parts overview FASTEX IC240
3 2 1 4

flender.com
Table 7-1 Geometry data, weights, tightening torques
mm mm mm mm mm Nm mm Nm mm mm kg
24 x 50 51 45 41 16 700 M6 17 635 5 0,54
25 x 50 51 45 41 16 730 M6 17 635 5 0,53
28 x 55 51 45 41 16 1100 M6 17 835 5 0,50
30 x 55 51 45 41 16 1180 M6 17 835 5 0,47
32 x 60 51 45 41 16 1270 M6 17 835 5 0,77
35 x 60 51 45 41 16 1390 M6 17 835 5 0,71
38 x 65 51 45 41 16 1880 M6 17 10 35 5 1,10
40 x 65 51 45 41 16 1980 M6 17 10 35 5 1,06
40 x 75 51 45 41 16 2880 M8 41 835 6 1,10
42 x 75 51 45 41 16 3000 M8 41 835 6 1,16
45 x 75 51 45 41 16 3250 M8 41 835 6 1,08
48 x 80 70 62 58 23 3450 M8 41 855 6 1,45
50 x 80 70 62 58 23 3600 M8 41 855 6 1,38
55 x 85 70 62 58 23 3950 M8 41 855 6 1,49
60 x 90 70 62 58 23 5400 M8 41 10 55 6 1,60
65 x 95 70 62 58 23 5850 M8 41 10 55 6 1,70
70 x 110 86 76 70 28 10200 M10 83 10 60 8 3,10
75 x 115 86 76 70 28 10950 M10 83 10 60 8 3,29
80 x 120 86 76 70 28 14000 M10 83 12 60 8 3,46
85 x 125 86 76 70 28 15000 M10 83 12 60 8 3,64
90 x 130 86 76 70 28 15800 M10 83 12 60 8 3,80
95 x 135 86 76 70 28 16800 M10 83 12 60 8 4,00
100 x 145 110 98 92 35 26000 M12 145 12 80 10 6,10
110 x 155 110 98 92 35 28600 M12 145 12 80 10 6,60
120 x 165 110 98 92 35 36300 M12 145 14 80 10 7,10
130 x 180 128 114 108 41 46000 M14 230 12 90 12 10,00
140 x 190 128 114 108 41 57800 M14 230 14 90 12 10,60
150 x 200 128 114 108 41 70800 M14 230 16 90 12 11,20
160 x 210 128 114 108 41 75500 M14 230 16 90 12 11,90
170 x 225 162 146 136 52 95900 M16 355 14 110 14 17,60
180 x 235 162 146 136 52 108800 M16 355 15 110 14 18,50
190 x 250 162 146 136 52 122500 M16 355 16 110 14 21,40
200 x 260 162 146 136 52 128900 M16 355 16 110 14 22,40
220 x 285 162 146 136 52 171800 M16 355 18 110 14 26,60
240 x 305 162 146 136 52 208000 M16 355 20 110 14 28,70
260 x 325 166 150 134 55 237000 M16 355 21 110 14 31,23
280 x 355 197 177 165 66 340000 M20 690 18 130 17 46,77
300 x 375 197 177 165 66 405000 M20 690 20 130 17 69,72
320 x 405 197 177 165 66 453000 M20 690 21 130 17 60,52
340 x 425 197 177 165 66 504900 M20 690 22 130 17 63,86
360 x 455 224 203 190 76 626000 M22 930 21 150 17 86,78
380 x 475 224 203 190 76 692000 M22 930 22 150 17 91,04
400 x 495 224 203 190 76 795000 M22 930 24 150 17 95,30
420 x 515 224 203 190 76 835000 M22 930 24 150 17 100,00
440 x 535 224 203 190 76 875000 M22 930 24 150 17 105,00
460 x 555 224 203 190 76 914000 M22 930 24 150 17 109,00
480 x 575 224 203 190 76 1113000 M22 930 28 150 17 114,00
500 x 595 224 203 190 76 1160000 M22 930 28 150 17 119,00
520 x 615 224 203 190 76 1292000 M22 930 30 150 17 122,50
540 x 635 224 203 190 76 1342000 M22 930 30 150 17 128,00
560 x 655 224 203 190 76 1484000 M22 930 32 150 17 131,00
580 x 675 224 203 190 76 1537000 M22 930 32 150 17 136,00
600 x 695 224 203 190 76 1640000 M22 930 33 150 17 139,00
LS
SW
m
L3
TCl
SC
TA
D1x D2
LG
L1
L2
Size
Dimensions
Limit Torque
Hexagon socked-head screws aac. to DIN EN ISO 4762- 12.9
Weight
Screw size
Tightening
torque
Quantity
Screwlength
widht A/F

flender.com
FASTEX IC240
Compact assembly and operating instructions 3907de
Edition 05/2022
Flender GmbH
Alfred-Flender-Straße 77
46395 Bocholt
Germany