FLENDER ZAPEX couplings Type ZWT Operating instructions FLENDER couplings
FLENDER ZAPEX couplings Type ZWT Operating instructions Translation of the original operating instructions Technical data Notes Fitting Start-up and operation Faults, causes and remedy Maintenance and repair 1 2 3 4 5 6 Stocking spare parts 7 2 / 16
Notes and symbols in these operating instructions Note: The term "operating instructions" will in the following also be shortened to "instructions" or "manual". Legal notes Warning-note concept This manual comprises notes which must be observed for your personal safety and for preventing material damage. Notes for your personal safety are marked with a warning triangle or an "Ex" symbol (when applying Directive 94/9/EC), those only for preventing material damage with a "STOP" sign. WARNING! Imminent explosion! The notes indicated by this symbol are given to prevent explosion damage. Disregarding these notes may result in serious injury or death. WARNING! Imminent personal injury! The notes indicated by this symbol are given to prevent personal injury. Disregarding these notes may result in serious injury or death. WARNING! Imminent damage to the product! The notes indicated by this symbol are given to prevent damage to the product. Disregarding these notes may result in material damage. NOTE! The notes indicated by this symbol must be treated as general operating information. Disregarding these notes may result in undesirable results or conditions. WARNING! Hot surfaces! The notes indicated by this symbol are made to prevent risk of burns due to hot surfaces and must always be observed. Disregarding these notes may result in light or serious injury. Where there is more than one hazard, the warning note for whichever hazard is the most serious is always used. If in a warning note a warning triangle is used to warn of possible personal injury, a warning of material damage may be added to the same warning note. Qualified personnel The product or system to which these instructions relate may be handled only by persons qualified for the work concerned and in accordance with the instructions relating to the work concerned, particularly the safety and warning notes contained in those instructions. Qualified personnel must be specially trained and have the experience necessary to recognise risks associated with these products or systems and to avoid possible hazards. 3 / 16
Intended use of Siemens products Observe also the following: Trademarks Siemens products must be used only for the applications provided for in the catalogue and the relevant technical documentation. If products and components of other makes are used, they must be recommended or approved by Siemens. The faultfree, safe operation of the products calls for proper transport, proper storage, erection, assembly, installation, start up, operation and maintenance. The permissible ambient conditions must be adhered to. Notes in the relevant documentations must be observed. All designations indicated with the registered industrial property mark are registered trademarks of Siemens AG. Other designations used in these instructions may be trademarks the use of which by third parties for their own purposes may infringe holders rights. Exclusion of liability We have checked the content of the instructions for compliance with the hard and software described. Nevertheless, variances may occur, and so we can offer no warranty for complete agreement. The information given in these instructions is regularly checked, and any necessary corrections are included in subsequent editions. Note on the EC Machinery Directive 2006/42/EC Siemens couplings in the "FLENDER couplings" product range must be treated as "components" in the sense of the EC Machinery Directive 2006/42/EC. Therefore, Siemens needs not issue a declaration of incorporation. Information on safe fitting, safe startup and safe operation can be found in this instructions manual; in addition the "warning note concept" therein must be observed. 4 / 16
Contents 1. Technical data... 6 1.1 Speeds, geometric data and weights... 6 2. Notes... 7 2.1 Safety instructions and general notes... 7 3. Fitting... 8 3.1 Placing the coupling parts (1; 3) in the case of shaft hub connection with parallel key... 8 3.2 Mounting of coupling parts (1; 3) in the case of a cylindrical and tapered interference fit set up for oil hydraulic shrinking-off... 8 3.3 Installation of the coupling... 9 3.4 Assignment of the tightening torques and wrench widths... 9 4. Start up and operation... 10 5. Faults, causes and remedy... 10 5.1 Possible cause of the fault:... 10 5.2 Incorrect use... 10 5.2.1 Frequent faults when selecting the coupling and/or coupling size... 10 5.2.2 Frequent faults when fitting the coupling... 11 5.2.3 Frequent faults in maintenance... 11 6. Maintenance and repair... 12 6.1 General... 12 6.2 Demounting the coupling... 12 6.3 Demounting the coupling parts (1; 3) in case of shaft-hub connection with parallel key... 12 6.4 Demounting the coupling parts (1; 3) in case of cylindrical and tapered interference fit set up for oil hydraulic shrinking-off... 12 6.4.1 Demounting the coupling parts (1; 3) in case of cylindrical interference fit... 13 6.4.2 Demounting the coupling parts (1; 3) in case of tapered interference fit... 14 7. Stocking spare parts... 15 7.1 Spare parts... 15 5 / 16
1. Technical data If a dimensioned drawing has been made out for the coupling, the data in this drawing must be given priority. The dimensioned drawing including any other documents should be made available to the user of the system. For part numbers and part designations, see the corresponding spare parts drawing in section 7 or the dimensioned drawing. 1.1 Speeds, geometric data and weights Oil outlet Oil inlet Oil inlet Oil outlet S8 D4 D1 NL1 D8 S NL2 D2 DA L1 LG L2 Fig. 1: Table 1: Type ZWT Table 1: Speeds, geometric data and weights Size Rated torque Impulse operation Bore 1) Speed NL1 Wght. D1 / D2 DA D4 D8 S L1 L2 LG S8 NL2 T T n max. min. max. 2) Nm Nm 1/min mm mm mm mm mm mm mm mm mm mm mm kg 112 1300 2600 12000 20 60 143 95 45 50 140 75 98 240 1 7.9 128 2500 5000 12000 25 70 157 110 60 60 140 89 115 260 1.5 11 146 4300 8600 12000 30 90 177 135 76 75 140 108 138 290 1.5 17 175 7000 14000 11000 35 100 215 160 92 90 160 133 172 340 2 30 198 11600 23200 9500 40 120 237 184 108 100 180 156 186 380 2 42 230 19000 38000 8300 50 140 265 218 127 110 250 162 206 470 2 60 255 27000 54000 7500 60 160 294 234 152 125 250 175 223 500 2 73 290 39000 78000 6500 70 180 330 266 168 140 300 198 261 580 2.5 109 315 54000 108000 6000 80 200 366 300 188 160 350 222 275 670 2.5 151 342 69000 138000 5500 90 220 392 328 208 180 350 246 305 710 3 196 375 98000 196000 5000 100 240 430 363 238 200 350 271 333 750 3 257 415 130000 260000 4500 120 260 478 390 258 220 400 295 368 840 3 329 1) Max. bore with keyway to DIN 6885/1 2) Weights are valid for maximum bores 6 / 16
2. Notes 2.1 Safety instructions and general notes All persons involved in the installation, operation, maintenance and repair of the coupling or clutch must have read and understood these instructions and must comply with them at all times. Disregarding these instructions may cause damage to the product and material and/or injury to persons. Damage caused by disregard of these instructions will result in exclusion of liability. During transport, installation, dismantling, operation and maintenance of the unit, the relevant safety and environmental regulations must be complied with at all times. When using lifting gears and load equipment for handling the components they must be suitable for the weight of the coupling. Depending on national regulations, coupling and clutch components may have to be disposed of separately or separated for recycling. The coupling must be stored in a dry environment. Adequate preservation must be carried out. Operators and users must not make any changes to the coupling themselves over and above the treatment specified in these instructions. If there is any visible damage the coupling or clutch must not be fitted or put into operation! The coupling must not be operated unless housed in a suitable enclosure in accordance with the standards applying. This also applies to test runs and when checking the direction of rotation. All work on the coupling must be carried out only when it is at a standstill. Secure the drive unit to prevent unintentional switch on. A notice should be attached to the ON switch stating clearly that work is in progress. In addition to any generally prescribed personal safety equipment (such as safety shoes, safety clothing, helmet) suitable safety gloves and suitable safety glasses must be worn when handling the coupling or clutch! Only spare parts made by the manufacturer Siemens must be used. Any enquiries should be addressed to: Siemens AG Schlavenhorst 100 46395 Bocholt Tel.: +49 (0)2871 / 92-0 Fax: +49 (0)2871 / 92-2596 7 / 16
3. Fitting The clutch parts are supplied in finished condition in accordance with the order. 3.1 Placing the coupling parts (1; 3) in the case of shaft hub connection with parallel key Clean holes and shaft ends. Coupling parts (1; 3) with tapered bore and parallel key connection must be mounted in cold condition and secured with suitable end plates. In the case of coupling parts (1; 3) with cylindrical bores the set screws must be unscrewed from the coupling parts (1; 3). Fit coupling parts, heating them to max. 80 C, if necessary. Shafts must not project from the inner sides of the hub. When the parts have cooled to room temperature, insert the set screws (for tightening torques, see table 3) or axially secure the coupling part with the end plate. 3.2 Mounting of coupling parts (1; 3) in the case of a cylindrical and tapered interference fit set up for oil hydraulic shrinking off The information specified on the dimensioned drawing should be observed with priority. Unscrew screw plugs (22) from the coupling parts (1; 3). Clean and dry holes and shaft ends. The oil channels and oil circulation grooves must also be free from dirt. The machine shaft and the bore of the coupling part must be absolutely clean and free of grease and oil! Protect seals for the input and output side against damage and heating to over + 80 C. (Use heat shields to protect against radiant heat). The coupling parts (1; 3) must be mounted in hot condition and, depending on the shrink dimension, heated to the temperature indicated on the dimensioned drawing. Heating may be done inductively, in a stove or with a burner. Before mounting, the bore size of the heated coupling parts (1; 3) must be checked, e.g. with a bore hole gauge. The coupling parts (1; 3) should be pushed smartly onto the shaft up to the position specified in the dimensioned drawing. The coupling parts (1; 3) must be held in position on the shaft with the aid of a suitable retaining device, until they cool down and seat firmly. After the coupling parts (1; 3) have cooled down to ambient temperature the oil channels must be filled with clean forcing oil, e.g. ISO VG 150, and re sealed with the screw plugs (22) (rust protection). 8 / 16
3.3 Installation of the coupling Push together the machines to be coupled and align them according to the dimensioned drawing. Oil the teeth of the coupling part (1), the flanged sleeve (5) and the adapter (4). Push the flanged sleeve (5) over the teeth of the adapter (4) and position and hold the assembly (4; 5) between the coupling parts (1; 3). Noting the marking, feed the adapter (4) into the teeth of the coupling part (1). Noting the marking, push the flanged sleeve (5) onto the teeth of the adapter (4) again and hold it. Bring the marking of the flanged sleeve (5) and that of coupling part 3 into line. Insert the close fitting bolts (8) and tighten the hexagonal nuts (9) (for tightening torques, see table 2). Insert the circlips (6) into the coupling parts (1; 3) without leaving a gap. 3.4 Assignment of the tightening torques and wrench widths The use of an impact screwdriver is not permissible! Tightening torques apply to bolts with untreated surfaces which are not or only lightly oiled (coefficient of friction μ = 0.14). The use of lubricant paint or lubricant, which affects the coefficient of friction "μ", is not permitted. The specified tightening torques T A must be complied with, applying DIN 25202 Screw Connection Class "C", with an output torque scatter of ± 5 %. Table 2: Tightening torques and wrench widths of the close fitting screw connection (8; 9) Size Tightening torques T A for bolts of the strength class 8.8 to DIN ISO 898 Part 1 (with μ = 0.14) Nm Wrench width SW Hexagon wrench mm 112 25 13 128 25 13 146 25 13 175 49 17 198 49 17 230 49 17 255 86 19 290 86 19 315 210 24 342 210 24 375 210 24 415 410 30 Table 3: Tightening torques and wrench widths of the set screws Size M5 M6 M8 M10 M12 M16 M20 M24 Tightening torque T A Nm Wrench width Hexagon socket mm 3 4 8 15 25 70 130 230 2.5 3 4 5 6 8 10 12 9 / 16
4. Start up and operation Bolt tightening torques for the coupling and tightening torques for the foundation bolts of the coupled machine must be checked before start up. Enclosures (coupling protection, contact guard) must be fitted! Overload conditions during start up cannot be excluded. If the coupling breaks through overload, metal parts may fly off and cause personal injury and/or material damage. For the oil quantity, refer to the dimensioned drawing. The coupling must run with little noise and without vibration. Irregular behaviour must be treated as a fault requiring immediate remedy. In case of fault the drive must be stopped at once. The necessary measures for repair must be taken in accordance with the safety regulations applying. 5. Faults, causes and remedy 5.1 Possible cause of the fault: Change of alignment: Rectify cause of alignment change (e.g. loose foundation bolts). Align the coupling. Check the axial fastening and, if necessary, adjust. Insufficient lubricant: Check lubricant supply. 5.2 Incorrect use Failure to observe these instructions may result in breakage of the coupling. Danger from flying fragments! 5.2.1 Frequent faults when selecting the coupling and/or coupling size Important information for describing the drive and the environment are not communicated. System torque too high. System speed too high. Application factor not correctly selected. Chemically aggressive environment not taken into consideration. The ambient temperature is not permissible. Finished bore with inadmissible diameter and/or inadmissible assigned fits. Machining of parallel keyways of which the width across corners is greater than the width across corners of the parallel keyways to DIN 6885/1 with a maximum permissible bore. The transmission capacity of the shaft hub connection is not appropriate to the operating conditions. Maximum load conditions are not being taken into consideration. Dynamic load conditions are not being taken into consideration. 10 / 16
Shaft hub connection resulting in impermissible material stress on the coupling. Operating conditions are being changed without authorisation. Coupling and machine / drive train form a critical torsional, axial and bending vibration system. Fatigue torque load too high. 5.2.2 Frequent faults when fitting the coupling Components with transport or other damage are being fitted. The shaft diameter is beyond the specified tolerance range. Coupling parts are being interchanged, i.e. their assignment to the specified shaft is incorrect. Specified axial fastenings are not fitted. Specified tightening torques are not being adhered to. Bolts are inserted dry or greased. Flange surfaces of screwed connections have not been cleaned. Alignment and/or shaft misalignment values do not match the specifications in the instructions manual. The coupled machines are not correctly fastened to the foundation, and as a result shifting of the machines e.g. through loosening of the foundation screw connection is causing excessive displacement of the coupling parts. 5.2.3 Frequent faults in maintenance Maintenance intervals are not being adhered to. No genuine ZAPEX spare parts are being used. Old or damaged ZAPEX spare parts are being used. Leakage in the vicinity of the coupling is not being identified and as a result chemically aggressive media are damaging the coupling. Fault indications (noise, vibration, etc.) are not being observed. Specified tightening torques are not being adhered to. Alignment and/or shaft misalignment values do not match the specifications in the instructions manual. 11 / 16
6. Maintenance and repair 6.1 General The coupling must be checked for heating and any change in the noise level at general maintenance intervals or at least every three months. The coupling must run with little noise and without vibration in all operating phases. Irregular behaviour must be treated as a fault requiring immediate remedy. 6.2 Demounting the coupling Using suitable tools, hold or support the adapter (4) and the flanged sleeve (5). Remove the close fitting screw connection and demount the circlips (6). Push the flanged sleeve (5) and the adapter (4) together and demount. Move the coupled machines apart. The teeth must be examined for damage and protected against rust. Damaged parts must be replaced. 6.3 Demounting the coupling parts (1; 3) in case of shaft-hub connection with parallel key Remove set screw and/or axial retaining means. Mount suitable detaching device. Using a burner, heat coupling part (1; 3) along its length and above the parallel keyway (max. + 80 C). Pull off coupling part (1; 3). Examine the teeth, the hub bore and the shaft for damage and protect against rust. Damaged parts must be replaced. For re assembly, the instructions in sections 3 and 4 must be observed. 6.4 Demounting the coupling parts (1; 3) in case of cylindrical and tapered interference fit set up for oil hydraulic shrinking off For demounting the following tools are needed: For each oil channel (for number, see the dimensioned drawing) an oil pump with pressure gauge (min. 2500 bar) or motor pump with corresponding number of independently closable connections. In case of coupling hubs with stepped bore, a motor driven pump must be connected up to the oil channel located at the point of transition from the smaller bore to the larger, as a large quantity of oil per unit of time is needed here. Suitable connections and pipes. 1 detaching device or retaining plate with retaining screws or threaded spindles with nuts (material of screws and spindles min. 10.9, material of nuts identical to that of the screws). 1 hydraulic cylinder with oil pump. Note displacement and pressure of the hydraulic cylinder (for axial force, consult Siemens or refer to the dimensioned drawing). Observe manufacturer's instructions for using forcing off/detaching device and pumps. Before detaching the coupling hub the detaching device must be mounted as shown in diagrams, illustrations, etc. 12 / 16
6.4.1 Demounting the coupling parts (1; 3) in case of cylindrical interference fit Shaft III 22 I II Threaded spindle Threaded spindle II I 22 III Shaft Retaining plate Hydraulic cylinder Fig. 2: Demounting the coupling parts (1; 3) in case of cylindrical interference fit Secure coupling part (1; 3) and detaching device, using suitable equipment! The screw plugs (22) must be removed from the oil channels. An oil pump must be bled and connected up to the middle oil channel (here oil channel I). Then the pump must be operated at the pressure specified on the dimensioned drawing until oil emerges from the adjacent connections (oil channels II and III). The max. pressure specified on the dimensioned drawing must not be exceeded. During the entire operation the pressure must be maintained at a constant level on all the oil channels to which pressure is applied. Bleed the next oil pump, connect it up to oil channel II and operate it at the pressure specified on the dimensioned drawing until a ring of oil emerges at the end face. Bleed the next oil pump, connect it up to oil channel III and operate it at the pressure specified on the dimensioned drawing until a ring of oil emerges at the end face. If, when pressure is applied, oil emerges to the extent that pressure cannot be maintained, a thicker oil must be specified. Only when an unbroken ring of oil emerges from both end faces may pressure be applied to the hydraulic cylinder to slide the coupling hub smartly off the shaft. All the oil must be completely collected and disposed of in accordance with the regulations applying. Note stroke of hydraulic cylinder. If re adjustment is necessary, the end face of the hydraulic cylinder must stop between 2 oil channels. After detaching, the oil pumps and the detaching device must be removed from the coupling part (1; 3). Examine the teeth, the hub bore and the shaft for damage and protect against rust. Damaged parts must be replaced. For re assembly, the instructions in sections 3 and 4 must be observed. 13 / 16
6.4.2 Demounting the coupling parts (1; 3) in case of tapered interference fit Retaining plate 22 I Shaft Hydraulic cylinder Stroke Threaded spindle Eye nut Inspection window Fig. 3: Demounting the coupling parts (1; 3) in case of tapered interference fit Secure coupling part (1; 3) and detaching device, using suitable equipment! To prevent the coupling part (1; 3) from suddenly coming off, it must be secured axially as shown in the diagram. The screw plugs (22) must be removed from the oil channels. Sufficient pressure must be applied to the hydraulic cylinder for it to generate at least the axial force specified on the dimensioned drawing. The oil pump must be bled, connected up to oil channel I and operated at the pressure indicated on the dimensioned drawing until a ring of oil emerges at the end face or from the adjacent connection. The max. pressure specified on the dimensioned drawing must not be exceeded. If, when pressure is applied, oil emerges to the extent that pressure cannot be maintained, a thicker oil must be specified. The pressure must be maintained until a ring of oil emerges at both end faces. This must be monitored through the inspection window at the side of the detaching device. All the oil must be completely collected and disposed of in accordance with the regulations applying. The hydraulic cylinder must then be bled. The coupling part (1; 3) slides off the shaft until there is no adhesion between the coupling part (1; 3) and the shaft. Detach the oil pump and detaching device. Remove coupling part (1; 3). Examine the teeth, the hub bore and the shaft for damage and protect against rust. Damaged parts must be replaced. For re assembly, the instructions in sections 3 and 4 must be observed. 14 / 16
7. Stocking spare parts 7.1 Spare parts ZAPEX type ZWT FLENDER couplings are couplings designed for use in turbo areas. All parts are precisely coordinated. Exchanging single couplings parts is not possible. For ordering spare parts the Siemens order number and position and/or the drawing number should be stated. 1 6 4 6 5 9 8 3 22 Fig. 4: Drawing Fig. 5 Screw plug Table 4: Parts list Part number Designation Part number Designation 1 Coupling part 1 6 Circlip 3 Coupling part 3 8 Close-fitting bolt 4 Adapter 9 Hexagon nut 5 Flanged sleeve 22 Screw plug 1) 1) The screw plugs (22; see fig. 5) are used only with an hydraulic interference fit (see section 6, item 6.4). 15 / 16
Further Information: "FLENDER gear units" on the Internet www.siemens.com/gearunits "FLENDER couplings" on the Internet www.siemens.com/couplings Service & Support: http://support.automation.siemens.com/ww/view/en/10803928/133300 Lubricants: http://support.automation.siemens.com/ww/view/en/42961591/133000 Siemens AG Industry Sector Mechanical Drives Alfred-Flender-Straße 77 46395 Bocholt GERMANY Subject to modifications Siemens AG 2011 www.siemens.com/drive technologies