PENCOFLEX COUPLING Réf: 89301e271

ASSEMBLY AND MAINTENANCE Ed : b 10/05/2004

ATEX

1-ASSEMBLY

- During the final boring of couplings supplied with a pre-bore, make sure that the
plate to be machined is centered correctly on its larger diameter.
In this way, the bore will be absolutely concentric, a primordial condition for fault-free
alignment. Indeed, the premature wear of the elastic packing can result from
incorrect bore concentricity.

- For couplings starting from size 510, it is essential to avoid that the shaft end
coincides with the hole provided in the hub (see figure 1). In this case, use a hub
without a hole.

- It is not advisable to assemble the plates on the shafts by driving them with hammer
blows so as to avoid damage to the bearings supporting the shafts to be connected.
Assembly will be carried out preferably with a threaded rod fitted with a nut and
washer. Simply screw this rod into the tapped hole of the shaft. A ball stop will
greatly simplify the task (see fig.2).

- To facilitate the assembly of large size couplings, the prior heating of the plates is
advisable. However, avoid exceeding a temperature of 100°C and first remove the
rubber collets.

2-ALIGNMENT

Correct alignment presupposes that the shafts to be connected:

a) Are parallel (see fig.3A);
b) Are not offset radially with respect to one another (see fig.3B).

When inspection using a thickness gauge shows that the clearance between the
plates is equal all over (see at bottom of fig.4) the shaft axes are parallel.

When a rule placed on the outer cylinder of the plates touches them simultaneously
at any point (see the upper part of fig.4), there is no misalignment.

It is important to note that the alignment of the shafts to be connected must be as

accurate as possible. Indeed although the PENCOFLEX coupling is capable of
neutralizing the alignment defects, it is still true that a misalignment that is relatively
too large can cause premature wear of the rubber collets.

La belle Orge – 88110 Raon L’Etape

REXNORD S.A / PTP Operation Tel : (33) 3 29 52 62 72 / Fax : (33) 3 29 41 92 03 Page 1 / 10
Customerservice.raon@rexnord.com
 PENCOFLEX COUPLING Réf: 89301e271

ASSEMBLY AND MAINTENANCE Ed : b 10/05/2004

Size 145 155 175 200 235 245 280 315 355 385
PN & PB 3.5±1.5 3.5±1.5 4±2 5.5±2.5
E∆E PD +1.5 +1.5
3.5 4
∆α (b-a) 0.3 0.45 0.6
∆r 0.2 0.25 0.3

Size 460 510 575 670 725 850 990 1060 1220 1420
PN & PB 5.5±2.5 7±3 8.5±3.5 10.5±4.5
E∆E PD
∆α (b-a) 0.6 0.9 1.2 2.2
∆r 0.3 0.4 0.5 0.75

In practice, measure each misalignment value, report this value with respect to the
maximum indicated value.
The sum of these ratios shall not exceed 1.

dr/∆r+ dα/∆α<1

With:
dr: value of measured radial misalignment
∆r: value of maximum radial misalignment (e.g. 0.25 mm for PN280)
dα: value of maximum measured radial alignment
∆α: value of maximum angular misalignment (e.g. (b-a)=0.45 mm for PN280)

The misalignment measurements must be made on two perpendicular planes and the
verification measurements be made at four points at 90°.

Check the adjustment values when the machine is warm.

La belle Orge – 88110 Raon L’Etape

REXNORD S.A / PTP Operation Tel : (33) 3 29 52 62 72 / Fax : (33) 3 29 41 92 03 Page 2 / 10
Customerservice.raon@rexnord.com
 PENCOFLEX COUPLING Réf: 89301e271

ASSEMBLY AND MAINTENANCE Ed : b 10/05/2004

3- EARTHING
The plates or the shafts on which they are mounted must be grounded.

4-INSPECTION AND REPLACEMENT OF RUBBER COLLETS

Disassemble the nuts or circlips retaining them. This means that the inspection and
possible replacement of the collets may be effected without having to back off or
move the coupled devices. It is advisable to smear the spindles with grease when
replacing the collets. The spindles may also be removed without needing to move the
two plates.

For sizes PN510 to PN1420 and for all the PD devices, simply remove the bolts or
nuts retaining the spindles. These taper end spindles can be removed through the
facing holes. When the spindles are put back in place for sizes PN145 to PN200, they
must be coated with Loctite 601.

It is advisable to check the collets at regular intervals to detect any wear or

misalignment occurring after bearing wear or a movement of the foundation.

5 - CLEANING OF ELASTIC ELEMENTS

Clean the elastic elements with a damp cloth. Do not use solvent but soapy water.

6 – COUPLING DISASSEMBLY

All the coupling plates have two tapped holes that can be used with suitable
accessories (see fig.5), for removing with ease (and without hammer blows) the shaft
end plates.
Any retaining screws should be released beforehand.

La belle Orge – 88110 Raon L’Etape

REXNORD S.A / PTP Operation Tel : (33) 3 29 52 62 72 / Fax : (33) 3 29 41 92 03 Page 3 / 10
Customerservice.raon@rexnord.com
 PENCOFLEX COUPLING Réf: 89301e271

ASSEMBLY AND MAINTENANCE Ed : b 10/05/2004

Type 145-460 Type 510-1220

Fig. 1 Fig. 2

Fig. 3 Fig. 4 Fig. 5

La belle Orge – 88110 Raon L’Etape

REXNORD S.A / PTP Operation Tel : (33) 3 29 52 62 72 / Fax : (33) 3 29 41 92 03 Page 4 / 10
Customerservice.raon@rexnord.com
 PENCOFLEX COUPLING Réf: 89301e271

ASSEMBLY AND MAINTENANCE Ed : b 10/05/2004

Size M L ØD
145 M8 15 75
155 M8 15 80
175 M10 20 95
200 M10 20 105
235 M12 22 120
245 M12 22 135
280 M12 22 145
M

315 M12 22 165

M
ØD

L L 355 M16 30 190

385 M16 30 220
460 M20 34 232
510 M20 40 260
575 M24 45 300
670 M24 45 320
725 M24 45 350
850 M30 60 390
990 M30 60 430
1060 M30 60 470
M
M
ØD

1220 M36 75 515

L L
1420 M36 75 560
B
C

A
La belle Orge – 88110 Raon L’Etape
REXNORD S.A / PTP Operation Tel : (33) 3 29 52 62 72 / Fax : (33) 3 29 41 92 03 Page 5 / 10
Customerservice.raon@rexnord.com
 PENCOFLEX COUPLING Réf: 89301e271

ASSEMBLY AND MAINTENANCE Ed : b 10/05/2004

Number of spindles Dimensions

Collet No

Number
Size Type of coupling Rubber collets

PN PB-L PD PN PB-L PD
145 PN1M PN1 4
155 PN1M PN1M PN1D PN1 6
27 24 10
175 PN1M PN1M PN1D PN1 8
200 PN1M PN1M PN1D PN1 10
235 PN2 PN2D PN2 6
245 PN2 PN2M PN2D PN2 9
41 36 16
280 PN2 PN2M PN2D PN2 12
315 PN2 PN2M PN2D PN2 16
355 PN3 PN3 12
385 PN3 PN3 15 59 52 24
460 PN3 PN3 18
510 PN4 PN4 12
575 PN4 PN4 15 86 76 35
670 PN4 PN4 18
725 PN5 PN5 13
850 PN5 PN5 16 120 106 50
990 PN5 PN5 19
1060 PN6 PN6 14
1220 PN6 PN6 17 166 146 70
1420 PN6 PN6 21

7-USE IN EXPLOSIVE ATMOSPHERES

Indications and instructions concerning use in explosive zones:

7-1- Inspection intervals for use in an explosive atmosphere

Explosion group Inspection intervals

II 2D c 120°C The visual inspection of elastic element wear must be carried
out after 100 hours of operation, or one month at the latest.
If no significant deformation is observed, the following
inspections can be performed every 2000 hours of operation or
at most every 3 months.
If the elements are worn or show signs of major deformation
and if tearing is observed, it will be necessary to replace the
elements and seek the possible causes as described in the
chapter “Malfunctions and remedies”.
The periodicity of the maintenance intervals must be restarted
if the operating parameters are changed.

7-2-Indication of wear values

The wear of the elastic elements is checked by the angular offset between the plates:
The measurement must be made at a
La belle Orge – 88110 Raon L’Etape
REXNORD S.A / PTP Operation Tel : (33) 3 29 52 62 72 / Fax : (33) 3 29 41 92 03 Page 6 / 10
Customerservice.raon@rexnord.com
ap
 PENCOFLEX COUPLING Réf: 89301e271

ASSEMBLY AND MAINTENANCE Ed : b 10/05/2004

stop and without any load in order to measure the angular clearance. C

New elements Worn elements

Size 145 155 175 200 235 245 280 315 355 385
Max play
1,8 1,7 2,5 2,4 3,5 3,4
mm

Size 460 510 575 670 725 850 990 1060 1220 1420
Max play
3,3 5,1 5 4,9 7 6,7 6,5 9,3 9 8,8
mm

! CAUTION: To ensure lasting operation, risk-free in an explosive

atmosphere, its is particularly important to check misalignment.
If the values indicated in chapter 2 are exceeded, the couplings should be
considered as damaged and replaced.

7-3- Materials used.

Plate materials: EN-GJL-200 (formerly FGL200).
Elastic element material: Mixture of natural rubber – Styrene Butadiene –Carbon
black.
Spindle material: steel.

7-4- Marking of couplings for explosive zones.

Couplings for use in an explosive zone are marked:

II 2 D 120°C

7-5-Startup.
Before startup, check that the radial screws (if there are any) are tight, or check
that the shaft end screw is tight.
La belle Orge – 88110 Raon L’Etape
REXNORD S.A / PTP Operation Tel : (33) 3 29 52 62 72 / Fax : (33) 3 29 41 92 03 Page 7 / 10
Customerservice.raon@rexnord.com
 PENCOFLEX COUPLING Réf: 89301e271

ASSEMBLY AND MAINTENANCE Ed : b 10/05/2004

Check the alignment and the size between the plates.

Check the tightness of the elastic element attaching nuts (or the correct
positioning of the circlips).

In an explosive atmosphere, the screws must be protected from any possible

loosening off, for instance, by the application of threadlock to the threads.

7-6-Malfunctions and remedies

Indication of risk in
Malfunction Cause Solution
hazard zone.
1) Turn off the machine.
2) Eliminate the cause of
misalignment (loose attaching
screw, broken fastener, and
dilatation, assembly
Noise and vibration Danger of elastic
Misalignment. dimensions not complied
during operation. elements overheating.
with, deformation of support
under load).
3) Check the wear of the
components and replace as
necessary.

La belle Orge – 88110 Raon L’Etape

REXNORD S.A / PTP Operation Tel : (33) 3 29 52 62 72 / Fax : (33) 3 29 41 92 03 Page 8 / 10
Customerservice.raon@rexnord.com
 PENCOFLEX COUPLING Réf: 89301e271

ASSEMBLY AND MAINTENANCE Ed : b 10/05/2004

1) Turn off the machine.

2) Disassemble the end stop
on the elastic elements and
Wear of elastic remove them.
elements, short- 3) Check the coupling parts
Danger of ignition due
term risk of and replace them if
to sparks
metal on metal necessary.
contact. 4) Fit new elastic elements.
5) Check the alignment at a
stop and in operation and
correct if necessary.
1) Turn off the machine.
2) Check the alignment of the
coupling.
3) Tighten the end attaching
Loosening of
screws of the plates and lock
the plate end Danger of ignition due
them.
attaching to sparks.
4) Check the wear of the
screws.
elements.
5) Check the alignment at a
stop and in operation and
correct if necessary.
1) Turn off the machine.
2) Replace the elastic
Premature wear of elements.
elastic elements Machine Danger of elastic 3) Check the alignment at a
(degradation of vibration. elements overheating. stop and in operation and
material inside plates). correct if necessary.
4) On the machine seek the
cause of vibration.

7-6-Malfunctions and remedies (continued)

Indication of risk in
Malfunction Cause Solution
hazard zone.
Wear of elastic 1) Turn off the machine.
elements, 2) Replace the entire coupling
Pin breakage Danger of ignition due
transmission of 3) Check the alignment at a
to sparks.
torque by metal on stop and in operation and
metal contact. correct if necessary.

La belle Orge – 88110 Raon L’Etape

REXNORD S.A / PTP Operation Tel : (33) 3 29 52 62 72 / Fax : (33) 3 29 41 92 03 Page 9 / 10
Customerservice.raon@rexnord.com
 PENCOFLEX COUPLING Réf: 89301e271

ASSEMBLY AND MAINTENANCE Ed : b 10/05/2004

1) Turn off the machine.

2) Identify and eliminate the
Pin breakage due cause of overload.
Danger of ignition due
to shock or 3) Replace the entire coupling
to sparks.
overtorque. 4) Check the alignment at a
stop and in operation and
correct if necessary.
1) Turn off the machine.
2) Check the operating
The conditions of
conditions and select a larger
use do not Danger of
coupling.
correspond to the ignition due to
3) Install the new coupling
coupling sparks.
4) Check the alignment at a
performance.
stop and in operation and
correct if necessary.
1) Turn off the machine.
2) Replace the entire coupling
3) Check the alignment at a
Error on machine Danger of ignition due
stop and in operation and
commissioning to sparks.
correct if necessary.
4) Train the operating and
maintenance personnel.

7-6 - Malfunctions and remedies (continued)

Indication of risk in
Malfunction Cause Solution
hazard zone.

La belle Orge – 88110 Raon L’Etape

REXNORD S.A / PTP Operation Tel : (33) 3 29 52 62 72 / Fax : (33) 3 29 41 92 03 Page 10 / 10
Customerservice.raon@rexnord.com
 PENCOFLEX COUPLING Réf: 89301e271

ASSEMBLY AND MAINTENANCE Ed : b 10/05/2004

1) Turn off the machine.

2) Disassemble the end stop of
the elastic elements and remove
them.
3) Check the coupling parts and
Loosening of nuts or Danger of destruction of replace them if necessary.
Incorrect assembly
circlips retaining the elastic elements and 4) Assemble new coupling
of elastic elements.
elastic elements. ignition due to sparks. elements while checking the
correct assembly of the
stopping parts.
5) Check the alignment at a
stop and in operation and
correct if necessary.
1) Turn off the machine.
2) Disassemble the end stop of
the elastic elements and remove
Contact with harsh
Danger of overheating them.
product such as
and ignition due to 3) Check the coupling parts and
hydrocarbons,
sparks. replace them if necessary.
ozone…
4) Fit new elastic elements.
5) Protect the coupling from all
contact with the fluid in question.
1) Turn off the machine.
2) Disassemble the end stop of
the elastic elements and remove
Operating Danger of them.
Premature wear of temperature outside overheating and 3) Check the coupling parts and
elastic elements. the authorized range ignition due to replace them if necessary.
–20°C/+40°C. sparks. 4) Assemble new coupling
elements.
5) Measure and regulate the
ambient temperature.
1) Turn off the machine.
2) Eliminate the cause of
misalignment (loose attaching
screw, broken fastener, and
Danger of overheating
dilatation, assembly dimensions
Misalignment and ignition due to
not complied with, deformation
sparks.
of support under load).
3) Check the wear of the
components and replace as
necessary.

CAUTION! REXNORD cannot assume liability or provide guarantee coverage in

the event of parts that are not original REXNORD parts being used.

La belle Orge – 88110 Raon L’Etape

REXNORD S.A / PTP Operation Tel : (33) 3 29 52 62 72 / Fax : (33) 3 29 41 92 03 Page 11 / 10
Customerservice.raon@rexnord.com