FLENDER ZAPEX User manual

ZNN, ZNNA, ZNNV, ZNZS, ZNZA, ZNZV
Assembly and operating instructions M3560-02en
Edition 09/2022
ZAPEX

Original assembly and operating instructions
M3560-02
Edition 09/2022
Copyright (©2022 Flender GmbH)
V3
22/11/2022
15:14:08

M3560-02en 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 information ....................................................................................................................................15
2.1 General information .................................................................................................................15
2.2 Intended use ............................................................................................................................17
2.3 Safety information for a coupling when used in potentially explosive atmospheres ................17
2.3.1 Marking ....................................................................................................................................17
2.3.2 Conditions of use .....................................................................................................................18
2.4 General warning notices ..........................................................................................................19
3 Description................................................................................................................................................21
4 Application planning ................................................................................................................................23
4.1 Transport of the 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
5.1.4 Balancing the coupling.............................................................................................................30
5.2 Mounting the coupling..............................................................................................................30
5.2.1 Assembling coupling parts with shaft-hub connection using a parallel key .............................31
5.2.2 Assembling coupling parts with shaft-hub connection using a pressurised oil interference fit
.................................................................................................................................................32
5.2.3 Assembling the coupling ..........................................................................................................33
5.3 Aligning the coupling................................................................................................................33
5.3.1 Purpose of alignment ...............................................................................................................33
5.3.2 Possible misalignment .............................................................................................................34
5.3.2.1 Axial misalignment ...................................................................................................................34
5.3.2.2 Angular misalignment ..............................................................................................................34
5.3.2.3 Radial misalignment.................................................................................................................35

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5.3.2.4 Angular and radial misalignment..............................................................................................35
5.4 Fill with lubricant ......................................................................................................................36
5.4.1 Lubricant ..................................................................................................................................36
5.4.2 Filling quantity ..........................................................................................................................37
5.4.3 Fill with lubricant ......................................................................................................................38
6 Commissioning.........................................................................................................................................39
7 Operation...................................................................................................................................................41
7.1 Normal operation of the coupling .............................................................................................41
7.2 Fault – causes and correction ..................................................................................................41
7.2.1 Procedure in the event of faults ...............................................................................................41
7.2.2 Identifying the fault cause ........................................................................................................41
7.2.2.1 Possible faults..........................................................................................................................42
7.2.2.2 Possible causes .......................................................................................................................43
7.2.2.2.1 Unsuitable coupling..................................................................................................................43
7.2.2.2.2 Assembly-related causes.........................................................................................................43
7.2.2.2.3 Maintenance-related causes....................................................................................................44
7.2.2.2.4 Specific 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 intervals ..............................................................................................................47
8.2 Lubricant replacement .............................................................................................................47
8.3 Replacing O-rings ....................................................................................................................48
8.4 Dismantling the coupling..........................................................................................................49
8.4.1 Dismantling coupling part 1 (1) or 2 (2) with shaft-hub connection using a parallel key ..........49
8.4.2 Dismantling coupling part 1 (1) or 2 (2) with shaft-hub connection using pressurised oil inter-
ference fit .................................................................................................................................50
9 Service and support .................................................................................................................................53
9.1 Contact.....................................................................................................................................53
10 Disposal.....................................................................................................................................................55
11 Replacement parts ...................................................................................................................................57
11.1 Ordering replacement parts .....................................................................................................57
11.2 Spare parts drawing and spare parts list .................................................................................58
11.2.1 Spare parts list .........................................................................................................................58
11.2.2 Spare parts drawing for ZNN, ZNNA, ZNNV, ZNZS, ZNZA and ZNZV types.......................... 59

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M3560-02en Edition 09/2022 5
11.2.3 Screw plug ...............................................................................................................................60
A Technical specifications ..........................................................................................................................61
A.1 Speeds, geometry data and weights........................................................................................61
A.1.1 Dimension drawing for ZNN and ZNNA types .........................................................................61
A.1.2 Dimension drawing for ZNZS and ZNZA types........................................................................62
A.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 angular and radial mis-
alignment .................................................................................................................................67
A.4 Tightening torques and widths A/F ..........................................................................................68
A.5 Tightening procedure ...............................................................................................................69
A.6 O-rings .....................................................................................................................................69
A.6.1 Use and storage of the O-rings (12) ........................................................................................69
A.6.2 O-rings .....................................................................................................................................70
B Declaration of conformity ........................................................................................................................71
B.1 UK Declaration of Conformity ..................................................................................................71

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M3560-02en Edition 09/2022 7
List of tables
Table2-1 General warnings .......................................................................................................................15
Table2-2 Temperature classes for explosive atmospheres as a result of gases, vapours or mists ..........18
Table4-1 Types of preservative agents for long-term storage...................................................................24
Table5-1 Recommended assigned fits for bores with parallel key connection..........................................26
Table5-2 Diameter and axial position of the threaded 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 parts list for ZNN, ZNNA, ZNNV, ZNZS, ZNZA and ZNZV types ...................................58
TableA-1 Speeds, geometry data and weights for coupling sizes 83 to 424 .............................................66
TableA-2 Clearance S................................................................................................................................67
TableA-3 Distances between teeth VA and recommended alignment values for radial and angular
misalignment ..............................................................................................................................68
TableA-4 Tightening torques and widths A/F.............................................................................................68
TableA-5 Tightening procedure .................................................................................................................69
TableA-6 O-rings........................................................................................................................................70

List of tables
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M3560-02en Edition 09/2022 9
List of figures
Figure3-1 ZNN, ZNNA, ZNZS, ZNZA, ZNNV and ZNZV types...................................................................22
Figure4-1 Transport symbols......................................................................................................................23
Figure5-1 Tolerances for the finished bore in coupling part 1 (1) or 2 (2) ..................................................27
Figure5-2 Diameter and axial position of the threaded hole in the hub .....................................................28
Figure5-3 Position 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, ZNNA, ZNNV, ZNZS, ZNZA and ZNZV types ...........................59
Figure11-2 Screw plug (22) ..........................................................................................................................60
FigureA-1 Dimension drawing for ZNN types .............................................................................................61
FigureA-2 Dimension drawing for ZNNA types ..........................................................................................62
FigureA-3 Dimension drawing for ZNZS types ...........................................................................................62
FigureA-4 General ZNZA illustration ..........................................................................................................63
FigureA-5 ZNNV type .................................................................................................................................64
FigureA-6 ZNZV type .................................................................................................................................65

List of figures
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M3560-02en 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 M3560-02en
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
M3560-02en Edition 09/2022 13
1. Procedural instructions are shown as a numbered list. Always perform the steps in the
order given.
• Lists are formatted as bulleted lists.
– The dash is used for lists at the second level.
(1) Numbers in brackets are part numbers.
1.4 Copyright1.4 Copyright
The copyright of these instructions is held by Flender.
These instructions must not be used wholly or in parts without our authorisation or be given
to third parties.
If you have any technical queries, please contact our factory or one of our service outlets
(refer to Service and support (Page53)).

Introduction
1.4 Copyright
14 Edition 09/2022 M3560-02en

M3560-02en Edition 09/2022 15
Safety information 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 information
2.1 General information
16 Edition 09/2022 M3560-02en
ISO ANSI Warning
--- Warning – hand injuries
Explosion protection approval
Table2-1: General warnings
Explanation regarding regulation 2008 No. 1597
The couplings described here are “components” in accordance with the regulation 2008 No.
1597 and do not require a UK declaration of incorporation.
Explosion Protection Directive
The term “Explosion protection regulations” used in these instructions refers to the relevant
notified standards and “The Equipment and Protective Systems Intended for Use in Poten-
tially Explosive Atmospheres Regulations” complied with in accordance with the applicable
UK Declaration of Conformity.
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.

Safety information
2.2 Intended use
M3560-02en Edition 09/2022 17
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.
• 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53)).
2.3 Safety information for a coupling when used in potentially
explosive atmospheres2.3 Safety information for a coupling when used in potentially explosive atmospheres
Information
Declaration of conformity
A declaration of conformity required according to the respective Explosion Protection Direct-
ive can be found in chapter Declaration of conformity (Page71)
2.3.1 Marking2.3 Safety information for a coupling when used in potentially explosive atmospheres
You can find a description of the coupling parts in chapter Description (Page21).
A coupling designed in accordance with the Explosion Protection Directive has a marking on
the coupling parts.
The following marking is visible on the outer diameter of a coupling part (e.g. the flanged
sleeve):
Flender GmbH II 2G Ex h IIC T6 ... T5 Gb X
D 46393 Bocholt II 2D Ex h IIIC T85 °C ... 100 °C Db X
ZAPEX <Year of manufacture> I M2 Ex h Mb X

Safety information
2.3 Safety information for a coupling when used in potentially explosive atmospheres
18 Edition 09/2022 M3560-02en
2.3.2 Conditions of use2.3 Safety information for a coupling when used in potentially explosive atmospheres
Note also the material-dependent permissible ambient temperature of the O-ring (12) ac-
cording to chapter O-rings (Page69).
A coupling designed in accordance with the Explosion Protection 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
1. Gases, vapours or mists
Check the ambient temperature for use of the coupling in the relevant temperature class.
The maximum surface temperature of the coupling for a potentially explosive atmosphere as
a result of gas/vapour/mist mixtures is obtained from the maximum ambient temperature
and/or the maximum temperature of the adjacent 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 temperature Temperature class Max. surface temperature
-45°C to +80°C T4 <135°C
-45°C to +60°C T5 <100°C
-45°C to +45°C T6 <85°C
Table2-2: Temperature classes for explosive atmospheres as a result of gases, vapours or mists
2. Dust/air mixtures
Check the ambient temperature.
The maximum surface temperature of the coupling for a potentially explosive atmosphere as
a result of dust/air mixtures is obtained from the maximum ambient temperature and/or the
maximum temperature of the adjacent components. The self-heating of the coupling is
minor. In normal atmospheric conditions for explosion protection applications, a maximum
surface temperature<85°C can be expected.
Notes concerning operation of the coupling in potentially explosive atmospheres
• Only use the coupling in potentially explosive atmospheres together with drive motors
that can be switched off 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.

Safety information
2.4 General warning notices
M3560-02en Edition 09/2022 19
• 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.
2.4 General warning notices2.4 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 flying
fragments. Personal injury, property damage and fire damage caused by sparks may oc-
cur. If a coupling bursts in an area at risk of explosion, then this can result in an explosion.
• 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.
DANGER
Danger
Risk of injury due to the use of unsuitable and/or damaged components. The use of unsuit-
able and/or damaged components can lead to an explosion in potentially explosive atmo-
spheres.
• Observe the information regarding conditions of use.
DANGER
Danger of explosion
Improper operation of the coupling can lead to an explosion in potentially explosive atmo-
spheres.
• 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 glasses).
• Ensure that the area is not at risk of explosion.

Safety information
2.4 General warning notices
20 Edition 09/2022 M3560-02en
WARNING
Risk of chemical burns from chemical substances
There is 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 (gloves, safety glasses).
CAUTION
Physical injury
Risk of injury due to falling coupling parts.
• Secure the coupling parts to prevent them from falling.