This document describes the FLUDEX couplings, which are universally applicable hydrodynamic hydraulic couplings in various designs and sizes. These couplings operate according to the Föttinger principle and are designed for use in potentially explosive atmospheres, provided they have a corresponding marking.
Function Description
FLUDEX couplings are designed to transmit power from an input shaft to an output shaft via a fluid medium. The coupling parts of the input and output side are not mechanically connected to each other. Torque transmission takes place via the fluid filling, flowing in the coupling, which is driven via radially arranged blades. A small amount of slip occurs, which is inherent to the Föttinger principle.
FLUDEX couplings are suitable for both directions of rotation. They are also suitable for use with oil. In the case of a steeply inclined or vertical mounting position, the hub carrier part (120) (large prechamber) must be attached at the bottom. The drive should preferably be directed via the hub carrier part (120) to the outer wheel (blade shell 101) to enable the advantages of the prechamber (7) and the working chamber geometry to be utilized.
If the coupling overheats, e.g., due to the driven machine being overloaded, the operating fluid escapes due to the fusible safety plug being activated and the drive is disconnected. To prevent the operating fluid from spraying out, an electronically or mechanically controlled thermal monitoring device can be used. Information on monitoring devices can be found in separate operating instructions.
The delivery is "ready for operation" with or without liquid filling, depending on the order. Couplings filled with operating oil are marked with a corresponding sticker (e.g., HLR 32 DIN 51524/2, operating oil already filled in) near the filling opening. A fusible safety plug (103) and a thermal circuit breaker (110) are supplied loose with each coupling. These instructions describe the assembly and operation of an FLUDEX coupling arranged horizontally with a shaft-hub connection made by a cylindrical or conical bore with parallel key.
Important Technical Specifications
- Coupling Types: FNO, FNA, FND, FNDB, FNDS.
- Ambient Temperature:
- For gases, vapours or mists: Max. ambient temperature 50 °C, Temperature class T3.
- For dust/air mixtures: Max. ambient temperature 50 °C, Max. surface temperature 160 °C.
- Flexible Elements (N-EUPEX):
- Material: NBR, Hardness: 80 Shore A, Marking: Black flexible elements with blue stripes.
- Ambient Temperature: -30 °C to +80 °C.
- Storage: Up to 5 years, protected from direct sunlight, UV-content light, and extreme temperatures. Avoid contact with aggressive media. Replace only complete sets of the same type and age.
- Oil Filling Quantity: Varies by FLUDEX coupling size and speed in rpm. Refer to tables A-1 to A-7 for specific values. For example, for FLUDEX couplings "FN.." Size 370 at 600 rpm, the oil filling quantity is 1.1 litres (for 2.2 kW power).
- Shaft Misalignment: Maximum permissible shaft misalignment values (ΔSperm and ΔKperm) are provided in table A-8, varying by FLUDEX coupling size and N-EUPEX coupling size.
- Tightening Torques: Specific tightening torques (TA) and widths A/F (SW) for hexagon socket screws (parts 13, 23, 24, 103, 110, 142, 163, 130, 131, 139, 153, 173) and retaining screws (M6 to M30) are provided in tables A-9, A-10, and A-11. The tightening torques apply to screws/bolts with untreated surfaces that are not oiled or only lightly oiled, and for screws/bolts used with a liquid screw locking agent.
- Explosion Protection: The couplings are designed for use in potentially explosive atmospheres. The FLUDEX coupling has the following stamping: II 2G Ex h IIB T3 Gb X, II 2D Ex h IIIC T160 °C Db X, I M2 Ex h Mb X. The fusible safety plugs have the following stamping: 110 °C + Ex.
- Operating Fluid: The filling quantity and performance of the FLUDEX couplings are decisively influenced by the amount of operating fluid filled in. The filling quantity increases, the transmission capacity of coupling, the engine load during start-up and the maximum overload torque of coupling increase. The operating slip decreases at the same load. FLUDEX couplings may be filled to a maximum of 80 to 85% of the total volume. Larger filling quantities lead to a strong pressure increase in the coupling during operation. The pressure increase can cause the coupling to burst.
Usage Features
- Assembly: The assembly process involves preparatory work, mounting the coupling, aligning the coupling, filling with liquid, and housing.
- Preparatory Work: Includes milling the finished bore, milling the parallel keyway, machining an axial locking mechanism, and balancing the coupling.
- Mounting: Involves unscrewing the set screw, removing the screws, removing the hub carrier part, cleaning bores and flanges, coating coupling parts with assembly paste, mounting coupling parts onto the shaft, and securing with set screws.
- Alignment: Misalignment can be due to assembly, incorrect position, or operation. The document provides methods for calculating axial, angular, and radial misalignment.
- Filling: The filling plug (153) and the screw plug (163) are used for filling. The filling level is marked on the coupling housing.
- Housing: The housing prevents overheating and protects against contact with rotating components.
- Operation:
- Normal Operation: The coupling runs vibration-free.
- Faults and Correction: The manual provides a table of possible faults and their causes and rectification measures, such as sudden changes in noise level, wear of wearing parts, alignment changes, unsuitable coupling, incorrect coupling assembly, incorrect maintenance, and specific assembly-related and maintenance-related causes.
- Disposal: Dispose of the coupling parts according to applicable national regulations or recycle them.
Maintenance Features
- Maintenance Intervals:
- Initial maintenance: 3 months after commissioning.
- Follow-up maintenance: Every 12 months.
- Operating Fluid: Change the operating fluid at specified maintenance intervals. When changing the operating fluid, ensure that the old operating liquid is drained off completely. This is possible via the openings of the fusible safety plug (103) or via the opening of the screw plug (163). Drain the residual oil from the prechamber via the screw plug (173).
- Operating Temperature/Special Measures:
- Maximum 80 °C: 10000 operating hours (5 years).
- Maximum 95 °C or frequent temperature peaks above 100 °C: 5000 operating hours (2 years).
- Use of Viton seals required over 95 °C: According to specifications of the manufacturer of the operating fluid.
- Only suitable synthetic oils are permissible: According to specifications of the manufacturer of the operating fluid.
- Shaft Sealing Rings: For FLUDEX couplings operated with oil, no maintenance interval needs to be observed for the shaft sealing rings.
- Replacing Flexible Elements: The flexible elements (12) can be replaced without moving the coupled machines. This involves undoing the connection between coupling parts, moving coupling part 3 axially, ensuring flexible elements are freely accessible, removing the flexible elements, and installing new flexible elements.
- Disassembly:
- FLUDEX Coupling: Drain the operating fluid completely. Disassembly involves loosening screws, removing parts, and separating the coupling.
- N-EUPEX Add-on Coupling and Hub Carrier Part (120): Move the machines apart, support/hold up the main coupling, loosen bolts, separate the main coupling axially from the hub carrier part, and pull off the coupling part or hub carrier part.
- Reassembly: Reassembly is carried out in the reverse order of dismantling. Observe the marking on the parts. This includes cleaning components, greasing O-rings, fitting shaft sealing rings, spacing between shaft sealing ring and plates, removing old thread and cleaning sealing surfaces, applying new thread to flange points, and tightening torques for bolt connections.
The manual highlights various warnings and cautions:
- DANGER: Indicates that death or severe physical injury will occur if relevant precautionary measures are not taken. Examples include danger due to igniting deposits, bursting of the coupling, risk of explosion when using coupling parts without Ex marking, danger of explosion, and danger from hot coupling parts.
- WARNING: Indicates that death or severe physical injury may occur if relevant precautionary measures are not taken. Examples include risk of chemical burns from chemical substances and physical injury from rotating parts.
- CAUTION: Indicates that mild physical injury may occur if relevant precautionary measures are not taken. Examples include hearing damage due to noise emission and physical injury from protruding set screw.
- NOTICE: Indicates that damage to property may occur if relevant precautionary measures are not taken. Examples include property damage due to improper storage, property damage resulting from damage to braking surface, coupling damage due to improper components, damage to the shaft end, and risk of injury and danger to the environment from operating fluid.
For technical queries, replacement parts, or customer service, contact Flender GmbH:
Schlavenhorst 100
46395 Bocholt
Germany
Tel.: +49 (0)2871/92-0
Fax.: +49 (0)2871/92-2596
Website: http://www.flender.com/
Further information about service and support can be found on the Internet: https://www.flender.com/service
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