SECUREX

Assembly and operating instructions M3950-01en

Edition 09/2022

SECUREX T
Original assembly and operating instructions

M3950-01
Edition 09/2022 V1
17/01/2023
Copyright (©2022 Flender GmbH) 15:28:52
Table of contents

1 Introduction ................................................................................................................................................ 9

1.1 Legal information ....................................................................................................................... 9

1.2 About these instructions........................................................................................................... 10

1.3 Text attributes .......................................................................................................................... 10

1.4 Copyright.................................................................................................................................. 11

2 Safety information.................................................................................................................................... 13

2.1 General information ................................................................................................................. 13

2.2 Intended use ............................................................................................................................ 15

2.3 General warning notices .......................................................................................................... 15

3 Description ............................................................................................................................................... 17

4 Application planning................................................................................................................................ 19

4.1 Transporting the torque limiter ................................................................................................. 19

4.2 Storing the torque limiter.......................................................................................................... 19

4.3 Attachment requirements......................................................................................................... 20

5 Assembly .................................................................................................................................................. 21

5.1 Preparatory work...................................................................................................................... 21

5.2 Assembling the torque limiter................................................................................................... 21

5.3 Adjusting the torque ................................................................................................................. 22

5.3.1 SECUREX T 130/85 and T 240/85 .......................................................................................... 23
5.3.2 SECUREX T 190/95, T 340/95, T 350/120, T 650/120, T 650/140, T 1200/140, T 1000/170
and T 1800/170........................................................................................................................ 23
5.3.3 SECUREX T 2200/200, T 4000/200, T 3800/254, T 6800/254, T 5500/280 and T 10000/280
................................................................................................................................................. 23
5.3.4 Adjustment tables for the limiting torque.................................................................................. 24
5.3.5 Running in the friction linings ................................................................................................... 25

6 Commissioning ........................................................................................................................................ 27

7 Operation .................................................................................................................................................. 29

7.1 Normal operation of the torque limiter...................................................................................... 29

7.2 Faults - causes and rectification .............................................................................................. 29

7.2.1 Procedure in the event of malfunctions.................................................................................... 29
7.2.2 Identifying the fault cause ........................................................................................................ 30

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Table of contents

7.2.2.1 Possible faults.......................................................................................................................... 30

7.2.2.2 Possible causes ....................................................................................................................... 31
7.2.2.2.1 Unsuitable torque limiter .......................................................................................................... 31
7.2.2.2.2 Assembly-related causes......................................................................................................... 31
7.2.2.2.3 Maintenance-related causes.................................................................................................... 32
7.2.2.2.4 Specific installation-related and maintenance-related causes ................................................. 32
7.2.3 Correcting faults....................................................................................................................... 32
7.2.3.1 Replacing wearing parts .......................................................................................................... 32
7.2.3.2 Correcting the changed alignment ........................................................................................... 32

8 Maintenance ............................................................................................................................................. 33

8.1 Maintenance intervals .............................................................................................................. 33

8.2 Maximum permissible wear ..................................................................................................... 34

8.3 Replacing wearing parts .......................................................................................................... 34

9 Service and support................................................................................................................................. 37

9.1 Contact..................................................................................................................................... 37

10 Disposal .................................................................................................................................................... 39

10.1 Information about disposal....................................................................................................... 39

11 Replacement parts ................................................................................................................................... 41

11.1 Ordering spare parts ................................................................................................................ 41

11.2 Spare parts list ......................................................................................................................... 41

A Technical data .......................................................................................................................................... 43

A.1 Speeds, geometry data and weights........................................................................................ 43

A.1.1 SECUREX T model.................................................................................................................. 43
A.1.1.1 Geometry data, dimensions and weights................................................................................. 44
A.1.1.2 Speeds and limiting torques..................................................................................................... 44

A.2 Tightening torques and widths A/F .......................................................................................... 45

A.3 Tightening procedure ............................................................................................................... 46

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List of figures

Figure 3-1 Structure of the SECUREX T torque limiter ...............................................................................18

Figure 4-1 Surface requirement for slip module ..........................................................................................20

Figure A-1 SECUREX T model ....................................................................................................................43

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List of figures

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List of tables

Table 2-1 General warnings .......................................................................................................................13

Table 7-1 Table of faults.............................................................................................................................30

Table 8-1 Maintenance intervals ................................................................................................................33

Table A-1 Geometry data, dimensions and weights of the SECUREX T model.........................................44

Table A-2 Speeds and set screws of the SECUREX T model....................................................................44

Table A-3 Thread, tightening torques and widths A/F of set screws (2) .....................................................45

Table A-4 Tightening procedure .................................................................................................................46

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List of tables

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Introduction
1
1.1 Legal information 1.1 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.

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Introduction
1.2 About these instructions

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 instructions 1.2 About these instructions

These instructions describe the torque limiter 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 torque limiter and observe the informa-
tion they contain.

1.3 Text attributes 1.3 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:

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 Introduction
1.4 Copyright

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 Copyright 1.4 Copyright

The copyright for 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).

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Introduction
1.4 Copyright

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Safety information
2
2.1 General information 2.1 General information

Instructions
These instructions are part of the delivery. Always keep these instructions close to the torque
limiter.
Please make sure that every person who is commissioned to work on the torque limiter has
read and understood these instructions prior to handling the torque limiter and adheres to all
of the points.
Only the knowledge of these instructions can prevent faults at the torque limiter and ensure
fault-free and safe operation. Non-adherence to the instructions can cause product or prop-
erty damage or personal injury. Flender does not accept any liability for damage or operating
failures that are due to non-adherence to these instructions.

State of the art

The torque limiter described here has been designed in consideration of the latest findings
for demanding technical requirements. This torque limiter represents the 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

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Safety information
2.1 General information

ISO ANSI Warning

--- Warning – hand injuries

Explosion protection approval

Table 2-1: General warnings

Explanation regarding Machinery Directive 2006/42/EC

The torque limiter described here is a component in accordance with the Machinery Directive
and does not require a Declaration of Incorporation.

Protective clothing
In addition to the generally prescribed personal protective equipment (safety shoes, overall,
helmet etc.), also wear suitable protective gloves and safety glasses when handling the
torque limiter.

Using the torque limiter

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, install, maintain and repair the torque limiter. Informa-
tion about qualified personnel can be found in the legal notes at the beginning of these in-
structions.
If hoisting gears or load lifting devices are used for transporting, then these have to be suit-
able for the weight of the torque limiter.
If the torque limiter has visible damage, it may not be assembled or put into operation.
The torque limiter may only be operated in a suitable housing or with touch protection ac-
cording to applicable standards. This also applies to test runs and rotational direction
checks.

Working on the torque limiter

Only carry out work on the torque limiter when it is not in operation and is free of 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 torque lim-
iter. Ensure that the entire unit is not under load.

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 Safety information
2.2 Intended use

2.2 Intended use 2.2 Intended use

Only use the torque limiter 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 operator of the machine or system is solely liable for any resulting
damage.
When using the torque limiter, please specifically observe the following:
• Do not make any modifications to the torque limiter which go beyond the permissible
handling 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 torque limiter and
thus impact the active 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).

2.3 General warning notices 2.3 General warning notices

WARNING
Danger due to bursting of the torque limiter
The torque limiter may burst if it is not used as intended. There is a risk of fatal injury from
flying fragments.
• Use the torque limiter as intended.

WARNING
Danger due to heated parts
Risk of injury due to hot surfaces.
• Wear suitable protective equipment (gloves, safety glasses).

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).

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Safety information
2.3 General warning notices

CAUTION
Physical injury
Risk of injury due to falling parts.
• Carefully secure the parts and components so that they cannot fall.

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Description
3
The SECUREX torque limiters described here are universally applicable, load-limiting ma-
chine elements that are used to protect the system and its components.

Application
The SECUREX torque limiters are designed for use in all kinds of machines.

Structure
The diagrams show the various types with their constituent parts and their part numbers. De-
tailed information on the dimensions can be found in chapter Technical data (Page 43).

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Description

Figure 3-1: Structure of the SECUREX T torque limiter

1 Hub ① Sizes T130/85

2 Set screw ② Sizes T240/85
3 Clamping nut ③ Sizes T190/95, T350/120, T650/140, T1000/170
4 Friction lining ④ Sizes T340/95, T650/120, T1200/140, T1800/170
5 Race ⑤ Sizes T2200/200, T3800/254, T5500/280
6 Pressure plate ⑥ Sizes T4000/200, T6800/254, T10000/280
7 Cup spring
8 Locking plate
9 Spacer washer
10 Adjusting screw
11 Locking bolt

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Application planning
4
Check the delivery for damage and for completeness. Report any damage and/or missing
parts to Flender immediately.
The torque limiter is delivered in preassembled groups.

4.1 Transporting the torque limiter 4.1 Transporting the torque limiter

WARNING
Severe personal injury due to improper transport
Severe personal injury due to falling components or due to crushing. Damage to torque
limiter is possible due to use of unsuitable means of transport.
• Only use hoisting gear and load lifting devices with sufficient load bearing capacity for
transport.
• The symbols which appear on the packaging must be observed.

If not specifically contractually agreed otherwise, the packaging complies with the HPE Pack-
aging Directive.

8S )UDJLOHJRRGV .HHSGU\ .HHSFRRO &HQWUHRI 'RQRWXVH $WWDFKLQJ

JUDYLW\ KDQGKRRNV WKHORDG

4.2 Storing the torque limiter 4.2 Storing the torque limiter

If not clearly ordered otherwise, you will receive the torque limiter in preserved condition.
You can store the torque limiter for up to 12 months in a dry and dust-free storage room.

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Application planning
4.3 Attachment requirements

4.3 Attachment requirements 4.3 Attachment requirements

The surfaces of the slip module that are in contact with the friction linings must have a sur-
face roughness of Ra 3.2 or better.

Figure 4-1: Surface requirement for slip module

12 Slip module (not part of the scope of delivery)

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Assembly
5
Assembling the torque limiter comprises the following steps:
• Preparatory work (Page 21)
• Assembling the torque limiter (Page 21)
• Adjusting the torque (Page 22)

WARNING
Danger due to bursting of the torque limiter
If you do not observe the information stipulated here regarding assembly, this can lead to
the torque limiter bursting during operation. There is a risk of fatal injury from flying frag-
ments.
• Use the torque limiter as intended.

Information about the assembly of the torque limiter

• Only use undamaged components when assembling the torque limiter.
• Follow the assembly sequence.
• Please ensure that there is sufficient space at the assembly location and that the loca-
tion is tidy and clean in order to be able to assemble the torque limiter without any risk.
• If a dimension drawing is available for the torque limiter, please observe the information
it contains as a matter of priority.

5.1 Preparatory work 5.1 Preparatory work

No preparatory work is required, since the torque limiter is supplied finish bored, grooved
and balanced.
Balancing is performed according to the half-parallel key agreement (DIN ISO 21940-32) to
balancing quality G16 (DIN ISO 21940).

5.2 Assembling the torque limiter 5.2 Assembling the torque limiter

Procedure
1. Ensure that the surfaces to be joined are in a perfect state.
2. Turn the set screw (2) so far out of the hub that no collision with the parallel key or the
shaft is possible.
3. Clean the bore, the shaft end and the friction surfaces of the slip module (12).
4. Loosen the clamping nut (3).
5. Unscrew the clamping nut (3) fully.

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Assembly
5.3 Adjusting the torque

6. Remove all parts one at a time up to and including the first friction lining (4, 6, 7, 8, 9, 10,
11).
7. Push the slip module (12) onto the race (5).
8. Reassemble all the previously removed parts (4, 6, 7, 8, 9, 10, 11) in their original order.
Ensure that the cup springs are correctly aligned. Tighten the clamping nut (3) only
slightly until it is in contact.
9. Check the centric fit of all components, especially the outer friction lining. Correct this if
required.
10.Coat the bore of the hub (1) and the shaft with MoS2 assembly paste (e.g. Microgleit LP
405).
11.Place the pre-assembled torque limiter on the shaft so that the shaft end and hub end
are aligned.
12.Secure the torque limiter hub using the set screw (2).
13.Tighten this with the specified tightening torque TA, see section Tightening torques and
widths A/F (Page 45).

5.3 Adjusting the torque 5.3 Adjusting the torque

WARNING
Severe personal injury and property damage due to improper use
Unpredictable behaviour and malfunction of the torque limiter may result and cause per-
sonal injury and property damage.
• Do not exceed the specified range for adjusting the limiting torque.

NOTICE
Tolerance of the limiting torque
The material and surface quality of the slip module, environmental influences and vari-
ations in assembly are subject to tolerances and thus cause a certain scatter in the accur-
acy of the limiting torque that is being set.
• If the limiting torque needs to be more accurate, run in the torque limiter while initially
installing or replacing the friction linings.

Please observe the relevant information from section Running in the friction linings
(Page 25).

NOTICE
Wear of the friction linings
The friction linings of the torque limiter are subject to a certain amount of wear.
• Readjust the limiting torque depending on the slip frequency.

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 Assembly
5.3 Adjusting the torque

5.3.1 SECUREX T 130/85 and T 240/85 5.3 Adjusting the torque

1. Secure the shaft and/or the torque limiter against turning.

2. Tighten the clamping nut (3) until it comes into contact with the locking plate (8).
3. This is the zero position. Mark the current position of the clamping nut (3) with a suitable
marker.
4. Tighten the clamping nut (3) according to the required torque limit from table Adjustment
tables for the limiting torque (Page 24).
5. Bend one of the locking plate lugs (8) into the groove provided in the clamping nut (3) to
prevent the clamping nut from loosening on its own.

5.3.2 SECUREX T 190/95, T 340/95, T 350/120, T 650/120, T 650/140, T 1200/140,

T 1000/170 and T 1800/170 5.3 Adjusting the torque

1. Secure the shaft and/or the torque limiter against turning.

2. Turn the adjusting screws (10) into the clamping nut (3) until the head contact.
3. Tighten the clamping nut (3) until the bolt heads come into contact with the spacer
washer (9).
4. If individual screw heads of the adjusting screws (10) are not yet in contact, unscrew
them accordingly so that all adjusting screws (10) are in contact with the spacer washer
(9).
5. This is the zero position. Mark the current position of the adjusting screws (10) with a
suitable marker.
6. Tighten the adjusting screws (10) according to the required torque limit from table Ad-
justment tables for the limiting torque (Page 24). Count every 1/6 turns as you do so.
7. Proceed one step at a time. Tighten each bolt with no more than 4/6 turns at a time.

5.3.3 SECUREX T 2200/200, T 4000/200, T 3800/254, T 6800/254, T 5500/280 and

T 10000/280 5.3 Adjusting the torque

1. Secure the shaft and/or the torque limiter against turning.

2. Turn back the adjusting screws (10) until the cup springs (7) comes into contact with the
clamping nut (3).

NOTICE
Damage to the torque limiter due to the adjusting screws being unscrewed too far.
If you unscrew the adjusting screws beyond the noticeable resistance, the locking ring may
be unintentionally pushed out of position.
• Work gently.

3. Tighten the clamping nut (3) until it comes into contact with the pressure plate (6).
4. If individual adjusting screws (10) have not yet come into contact, screw them in further
so that all adjusting screws (10) come into contact with the pressure plate (6).
5. This is the zero position. Mark the current position of the adjusting screws (10) with a
suitable marker.

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Assembly
5.3 Adjusting the torque

6. Tighten the adjusting screws (10) according to the required torque limit from table Ad-
justment tables for the limiting torque (Page 24).
7. Count every 1/6 turns as you do so.
8. Proceed one step at a time so that each screw is tightened no more than 4/6 turns at a
time.
9. Secure the clamping nut (3) by tightening the locking bolt (11) (M8; TA=21 Nm).

5.3.4 Adjustment tables for the limiting torque 5.3 Adjusting the torque
Limiting torque in Nm

Limiting torque in Nm

Clamping nut turns Adjusting screw turns

Limiting torque in Nm
Limiting torque in Nm

Adjusting screw turns Adjusting screw turns

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 Assembly
5.3 Adjusting the torque

Limiting torque in Nm

Limiting torque in Nm
Adjusting screw turns Adjusting screw turns

Limiting torque in Nm
Limiting torque in Nm

Adjusting screw turns Adjusting screw turns

5.3.5 Running in the friction linings 5.3 Adjusting the torque

Environmental influences such as surface roughness, material pairings or even longer down-
times can have an influence on the accuracy of the adjusted torque.
Although these influences cannot be prevented, they can be reduced by running in the fric-
tion linings.
If the limiting torque needs to be more accurate, allow the friction linings to run in. To do this,
operate the torque limiter for 100 to 200 revolutions at low speed with approx. 25 % of the
max. permissible torque.
The process leads to a consistent contact pattern of the friction linings.

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Assembly
5.3 Adjusting the torque

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Commissioning
6
In order to ensure safe commissioning, carry out various tests prior to commissioning.

Testing before commissioning

DANGER
Danger
Overload conditions can occur during the commissioning of the torque limiter. The torque
limiter can burst and metal parts can be flung out. There is a risk of fatal injury from flying
fragments.
• Carry out the tests prior to commissioning.
• Do not touch the rotating torque limiter.

1. Check the tightening torques of the screws of the torque limiter in accordance with sec-
tion Tightening torques and widths A/F.
2. Check the tightening torques of the foundation bolts of the coupled machines.
3. Check whether suitable housings (coupling guard, touch protection) have been installed
and that the function of the torque limiter has not been adversely affected by the hous-
ing. This also applies to test runs and rotational direction checks.

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Commissioning

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Operation
7
SECUREX torque limiters are components that absorb individual load peaks. This is how the
torque limiters protect the system. Prevent continuous slippage, especially at high relative
speeds. This leads to premature wear of the friction linings.

NOTICE
Prevent slippage from occurring with a duration of > 1 second so that the friction linings do
not heat up excessively.

7.1 Normal operation of the torque limiter 7.1 Normal operation of the torque limiter

The torque limiter runs quietly and shock-free during normal operation.

7.2 Faults - causes and rectification 7.2 Faults - causes and rectification

A form of behaviour which is different to normal operation is classed as a fault and has to be
rectified immediately.
Look out specifically for the following faults during torque limiter operation:
• Unusual coupling noise
• Sudden occurrence of shocks

7.2.1 Procedure in the event of malfunctions 7.2 Faults - causes and rectification

WARNING
Danger due to bursting of the torque limiter
There is a risk of fatal injury from flying fragments.
• Switch off the unit at once if any faults occur.
• Note during the repair work the possible causes of faults and the notes on rectifying
them.

Continue as described below if there is a malfunction of the torque limiter during operation:
1. Turn the drive off immediately.
2. Initiate the required action for repair taking into consideration the applicable safety regu-
lations.
If you cannot determine the cause or if you cannot carry out repair work with your own
means, request one of our customer service technicians.

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Operation
7.2 Faults - causes and rectification

7.2.2 Identifying the fault cause 7.2 Faults - causes and rectification

Faults occur frequently due to application errors or they occur due to operational circum-
stances such as wear of wearing parts or changes to the system.
The faults and fault causes listed below only serve as an indication for troubleshooting. In
the case of a complex system be sure to include all the system components in the search for
the fault.

WARNING
Physical injury
Injury from rotating parts.
• Only work on the torque limiter when it is stopped.
• Secure the drive aggregate against unintentional startup.
• Place an information notice to the start switch stating clearly that work is being carried
out on the torque limiter.
• Before starting any work, make sure that the unit is free from loads.

Intended use
The torque limiter is only approved for the applications specified in these instructions. Please
observe all the stipulations in section Intended use.

7.2.2.1 Possible faults 7.2 Faults - causes and rectification

Fault Cause Rectification

Sudden changes in the noise level and/ Wear of wearing parts Follow the instructions given in section
or sudden occurrences of shocks Replacing wearing parts (Page 34).

Alignment changes Follow the instructions given in section

Correcting the changed alignment
(Page 32).

Torque limiter not suitable for the oper- Use a torque limiter that is suitable for
ating conditions. the operating conditions.
Check the possible causes given in
section Unsuitable torque limiter
(Page 31).

Incorrect assembly of the torque limiter. Assemble the torque limiter in compli-
Check the possible causes given in ance with these instructions.
sections Assembly-related causes Please observe all the stipulations and
(Page 31) and Specific installation-re- requirements given in chapter As-
lated and maintenance-related causes sembly.
(Page 32).

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 Operation
7.2 Faults - causes and rectification

Fault Cause Rectification

Sudden changes in the noise level and/ Incorrect maintenance of the torque lim- Please observe all the stipulations and
or sudden occurrences of shocks iter. requirements given in chapter Servi-
Check the possible causes given in cing.
sections Maintenance-related causes
(Page 32) and Specific installation-re-
lated and maintenance-related causes
(Page 32).

Table 7-1: Table of faults

7.2.2.2 Possible causes 7.2 Faults - causes and rectification

7.2.2.2.1 Unsuitable torque limiter 7.2 Faults - causes and rectification

• Important information on the description of the drive unit and the environment were not
available when the torque limiter was chosen.
• System torque too high and/or torque dynamics not permissible.
• System speed too high.
• Application factor not selected correctly.
• Chemically aggressive environment not taken into consideration.
• Torque limiter not suitable for the ambient temperature.
• Diameter and/or assigned fit of the finished bore not permissible.
• Width across corners of the parallel keyways greater than the width across corners of
the parallel keyways in accordance with DIN 6885/1 for the maximum permissible bore.
• Shaft-hub connection incorrectly sized.
• Maximum permissible load conditions not taken into consideration.
• Maximum permissible overload conditions not taken into consideration.
• Dynamic load conditions not taken into consideration.
• The torque limiter and the machine and/or drive train form a critical torsional, axial or
bending vibration system.

7.2.2.2.2 Assembly-related causes 7.2 Faults - causes and rectification

• Damaged component installed.

• Shaft diameter outside the stipulated tolerance range.
• Torque limiters mixed up and hence not assigned to the right shaft.
• Stipulated locking elements to prevent axial movements not installed.
• Stipulated tightening torques not adhered to.
• Bolts inserted dry or greased.
• Flange surfaces of screwed connections not cleaned.
• Alignment and/or shaft misalignment values not set in accordance with the instructions.
• Coupled machines were not correctly connected to the foundation so that a shifting of
the machines leads to an impermissible displacement of the coupling parts.
• Coupled machines not earthed adequately.

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Operation
7.2 Faults - causes and rectification

• Coupling guard used is not suitable.

7.2.2.2.3 Maintenance-related causes 7.2 Faults - causes and rectification

• Stipulated maintenance intervals not adhered to.

• Replacement parts that were used were not original replacement parts from Flender.
• Flender replacement parts that were used were old or damaged.
• Leak in the area of the torque limiter not detected so that chemically aggressive sub-
stances damage the torque limiter.
• Indications of faults, such as noise or vibration, were not heeded.
• Stipulated tightening torques not adhered to.
• Alignment and/or shaft misalignment values not set in accordance with the instructions.

7.2.2.2.4 Specific installation-related and maintenance-related causes 7.2 Faults - causes and rectification

• Friction linings not replaced in time.

7.2.3 Correcting faults 7.2 Faults - causes and rectification

7.2.3.1 Replacing wearing parts 7.2 Faults - causes and rectification

Friction linings are subject to wear.

Procedure
1. Check the wear on the friction linings (see section Maximum permissible wear
(Page 34)).
2. Replace the friction linings if necessary (see section Replacing wearing parts
(Page 34)).

7.2.3.2 Correcting the changed alignment 7.2 Faults - causes and rectification

A changed alignment of the torque limiter during operation often occurs when the coupled
machines shift compared to one another. A cause of this can be loose foundation bolts.

Procedure
1. Correct the cause for the change in alignment.
2. Check the wearing parts for wear and replace them as required.
3. Check the locking elements that prevent axial movements and correct these as required.
4. Realign the assembly unit.

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Maintenance
8
8.1 Maintenance intervals 8.1 Maintenance intervals

WARNING
Danger due to torque limiter heating up
If you do not observe the maintenance intervals stipulated here, this can lead to the torque
limiter slipping continuously during operation. The friction energy that then occurs can
cause the torque limiter to heat up.
• Please observe all information about maintenance in this section.

WARNING
Danger due to torque limiter heating up
If you do not observe the instructions stipulated here for replacing the wear parts, this can
lead to the torque limiter slipping continuously during operation.
The friction energy that then occurs can cause the torque limiter to heat up.
• Please observe all the stipulations concerning the replacement of wearing parts in this
section.

WARNING
Physical injury
Injury from rotating parts.
• Only work on the torque limiter when it is stopped.
• Secure the drive aggregate against unintentional startup.
• Place an information notice to the start switch stating clearly that work is being carried
out on the torque limiter.
• Before starting any work, make sure that the unit is free from loads.

Check the wear of the friction linings at the indicated maintenance intervals.
The maximum permissible wear is listed in section Maximum permissible wear (Page 34).

Initial maintenance Follow-up maintenance

3 months after commissioning Every 12 months

Table 8-1: Maintenance intervals

Shorter maintenance intervals

If necessary, set shorter maintenance intervals depending on actual wear.

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Maintenance
8.2 Maximum permissible wear

8.2 Maximum permissible wear 8.2 Maximum permissible wear

Measure the friction lining strength. Check if there is still 50% of the original strength left. If
this is not the case, replace the friction linings as described in section Replacing wearing
parts (Page 34). The material strength of the friction linings can be found in section Geo-
metry data, dimensions and weights (Page 44).

8.3 Replacing wearing parts 8.3 Replacing wearing parts

WARNING
Danger due to torque limiter heating up
If you do not observe the maintenance intervals stipulated here, this can lead to the torque
limiter slipping continuously during operation.
The friction energy that then occurs can cause the torque limiter to heat up.
• Please observe all information about maintenance in this section.

Replace the friction linings if the maximum permissible wear has been reached.

Procedure
1. Loosen the clamping nut (3) by first unbending the locking plate (8) or loosening the
locking bolt (11), depending on the size and if present.
2. Now loosen all the adjusting screws (10), if any, until the cup springs (7) are free of
force.
3. Next, loosen the clamping nut (3).
4. Depending on the mounting position of the torque limiter on the shaft, it may have to be
disassembled from the shaft to replace the friction linings (4).
5. If this is necessary, loosen the set screw (2) and slide the hub axially off the shaft.
6. Now unscrew the clamping nut (3) fully from the hub thread. Remove all parts one at a
time up to and including both friction linings (4, 6, 7, 8, 9, 10, 11, 12).
7. Clean the contact surfaces of the slip module (12) and replace the worn friction linings
with the new linings.
8. Now reassemble all the previously removed parts (4, 6, 7, 8, 9, 10, 11, 12) in their ori-
ginal order. Align the cup springs correctly.
9. Tighten the clamping nut (3) only slightly until it is in contact.
10.Check the centric fit of all components, especially the outer friction lining and correct this
if necessary.
11.If you have disassembled the torque limiter from the shaft, clean the bore of the hub (1)
and the shaft.
12.Next, coat the bore of the hub (1) and the shaft with MoS2 assembly paste (e.g. Mi-
crogleit LP 405).
13.Place the pre-assembled torque limiter on the shaft so that the shaft end and hub end
are aligned.
14.Secure the torque limiter hub with the set screw (2) by tightening it to the specified tight-
ening torque TA.

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 Maintenance
8.3 Replacing wearing parts

15.Observe the section on speeds, geometry data and weights, see Speeds, geometry data
and weights (Page 43).

M3950-01en Edition 09/2022 35

Maintenance
8.3 Replacing wearing parts

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Service and support
9
9.1 Contact 9.1 Contact

When ordering replacement parts, requesting a customer service technician or if you have
any technical queries, contact our factory or one of our Customer Service addresses:
Flender GmbH
Schlavenhorst 100
46395 Bocholt
Germany

Tel.: +49 (0)2871/92-0

Fax.: +49 (0)2871/92-2596

Flender GmbH (http://www.flender.com/)

More information
Further information about service and support can be found on the Internet:
Service & Support (https://www.flender.com/service)

M3950-01en Edition 09/2022 37

Service and support
9.1 Contact

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Disposal
10
10.1 Information about disposal 10.1 Information about disposal

Dispose of and recycle the components in accordance with the applicable national regula-
tions.

M3950-01en Edition 09/2022 39

Disposal
10.1 Information about disposal

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Replacement parts
11
11.1 Ordering spare parts 11.1 Ordering spare parts

By stocking the most important replacement parts at the installation site, you can ensure that
the torque limiter is ready to use all the time.
Use only original replacement parts from Flender. Flender only accepts liability for original
replacement parts from Flender.
The replacement parts available for the torque limiter described here can be found under
Spare parts drawing and spare parts list.
You can find our contact data for ordering replacement parts at Service and support.

Information required when ordering replacement parts

• Flender order number with item
• Flender drawing number
• Coupling type and size
• Part number (refer to Spare parts drawing and spare parts list)
• Dimensions of the replacement part, for example:
– Bore
– Bore tolerance
– Parallel keyway and balancing
• Special dimensions, for example, flange connection dimensions, intermediate sleeve
length or brake drum dimensions
• Any special properties of the replacement part, such as, for example:
– Temperature resistance
– Electrical insulation
– Operating fluid
– Use in potentially explosive atmospheres
• Quantity

11.2 Spare parts list 11.2 Spare parts list

Information
Flender torque limiters are available exclusively as assembly units. Only the friction linings
can be ordered as replacement parts.

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Replacement parts
11.2 Spare parts list

SECUREX T model

Part number Designation

4 Set of friction linings (consisting of 2 friction linings)

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Technical data
A
A.1 Speeds, geometry data and weights Speeds, geometry data and weights

In this section you can find dimension drawings and technical data for Flender torque limiters
of the following models:
• SECUREX T

A.1.1 SECUREX T model Speeds, geometry data and weights

Figure A-1: SECUREX T model

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Technical data
Speeds, geometry data and weights

A.1.1.1 Geometry data, dimensions and weights Speeds, geometry data and weights

2)
Size Maximum Dimensions Weight
1)
bore

D1 [mm] DA DZ NL A B F M [kg]
[mm] [mm] [mm] [mm] [mm] [mm]

T 130/85 30 85 52 55 17 11 4 0.89

T 240/85 30 85 52 55 17 11 4 0.99

T 190/95 35 95 60 66 18 11 4 1.53

T 340/95 35 95 60 66 18 11 4 1.63

T 350/120 45 120 73 77 21 16 4 2.59

T 650/120 45 120 73 77 21 16 4 2.79

T 650/140 60 140 90 86 23 17 4 4.34

T 1200/140 60 140 90 86 23 17 4 4.54

T 1000/170 65 170 100 93 26.5 18 4.6 6.39

T 1800/170 65 170 100 93 26.5 18 4.6 6.69

T 2200/200 80 200 120 105 27 18 4.6 10.6

T 4000/200 80 200 120 105 27 18 4.6 10.6

T 3800/254 90 254 140 120 33 26 5 19.9

T 6800/254 90 254 140 120 33 26 5 19.9

T 5500/280 120 280 170 120 35 26 5 22.9

T 10000/280 120 280 170 120 35 26 5 22.9

Table A-1: Geometry data, dimensions and weights of the SECUREX T model
1)
Maximum bore for parallel keyway in accordance with DIN 6885/1.
2)
Weight applies to one torque limiter with maximum bore.

A.1.1.2 Speeds and limiting torques Speeds, geometry data and weights

Size Max. limiting torque Permissible speed Slipping speed nR

-1 -1
TR [Nm] nmax [min ] [min ]

T 130/85 130 3800 600

T 240/85 240 3800 600

T 190/95 190 3600 500

T 340/95 340 3600 500

T 350/120 350 3000 400

T 650/120 650 3000 400

T 650/140 650 2500 350

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 Technical data
Tightening torques and widths A/F

Size Max. limiting torque Permissible speed Slipping speed nR

-1 -1
TR [Nm] nmax [min ] [min ]

T 1200/140 1200 2500 350

T 1000/170 1,000 2100 300

T 1800/170 1800 2100 300

T 2200/200 2200 1800 250

T 4000/200 4000 1800 250

T 3800/254 3800 1500 200

T 6800/254 6800 1500 200

T 5500/280 5500 1500 180

T 10000/280 10000 1500 180

Table A-2: Speeds and set screws of the SECUREX T model

A.2 Tightening torques and widths A/F Tightening torques and widths A/F

Apply the specified tightening torques as listed in section Tightening procedure (Page 46).

Size Thread [mm] Tightening torque TA Width A/F [mm]

[Nm]

T 130/85 M6 4 5

T 240/85 M6 4 5

T 190/95 M6 4 5

T 340/95 M6 4 5

T 350/120 M8 8 6

T 650/120 M8 8 6

T 650/140 M8 8 6

T 1200/140 M8 8 6

T 1000/170 M10 15 8

T 1800/170 M10 15 8

T 2200/200 M10 15 8

T 4000/200 M10 15 8

T 3800/254 M10 15 8

T 6800/254 M10 15 8

T 5500/280 M10 15 8

T 10000/280 M10 15 8

Table A-3: Thread, tightening torques and widths A/F of set screws (2)

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Technical data
Tightening procedure

A.3 Tightening procedure Tightening procedure

Tightening torques must be observed taking into account the following table:

Scatter of the torque ap- Tightening procedure

plied at the tool (As a rule, the tightening procedures listed are within the spe-
cified tool torque scatter.)

±5 % • Hydraulic tightening with mechanical screwdriver

• Torque-controlled tightening with a torque wrench or a torque

wrench that gives a signal

• Tightening with a precision mechanical screwdriver with dynamic

torque measurement

Table A-4: Tightening procedure

The tightening torques apply to screws/bolts with untreated surfaces that are not oiled or are
only lightly oiled, and for screws/bolts that are used with a liquid screw locking agent in ac-
cordance with these instructions. Use with lubricant paint or lubricant is not permitted.

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SECUREX
Assembly and operating instructions M3950-01en
Edition 09/2022

Flender GmbH
Alfred-Flender-Straße 77
46395 Bocholt