INSTRUCTION MANUAL

SUPERFLEX Coupling
type “SF”
INSTRUCTION MANUAL

SUPERFLEX SF

INDICE

1 TECHNICAL DATA................................................................................................... 3
1.1 Geometric data .................................................................................................................................3
1.2 Performances ...................................................................................................................................4
1.3 Service factor fs ................................................................................................................................4
2 GENERAL NOTES ................................................................................................... 5

3 SAFETY NOTES ...................................................................................................... 6

4 TRANSPORT, STORAGE AND ELEVATION .......................................................... 7

4.1 Transport ..........................................................................................................................................7
4.2 Storage .............................................................................................................................................7
4.3 Elevation ...........................................................................................................................................7
5 TECHNICAL DESCRIPTION.................................................................................... 8
5.1 General description ..........................................................................................................................8
5.2 Flexible element ...............................................................................................................................8
5.3 Marking the coupling parts for explosion protection .........................................................................9
5.4 Service conditions ............................................................................................................................9
6 ASSEMBLY ............................................................................................................ 10
6.1 Notes to the fit pairs of the bore / shaft. ........................................................................................ 10
6.2 General information on installation ................................................................................................ 10
6.3 Mounting the coupling parts .......................................................................................................... 11
6.4 Tightening torques ......................................................................................................................... 12
7 START-UP ............................................................................................................. 12
7.1 Procedure before start-up ............................................................................................................. 12
8 OPERATION .......................................................................................................... 12
8.1 General operating data .................................................................................................................. 12
9 FAULTS, CAUSES AND REMEDIES ..................................................................... 13
9.1 General .......................................................................................................................................... 13
9.2 Possible faults ............................................................................................................................... 13
9.3 Incorrect use .................................................................................................................................. 14
10 MAINTENANCE AND REPAIR .............................................................................. 15
10.1 Replacement of the flexible element ......................................................................................... 15
11 SPARE PARTS ...................................................................................................... 16
11.1 Spare parts list .......................................................................................................................... 16
11.2 Spare parts and customer service adresses............................................................................. 16
12 CERTIFICATES OF APPROVAL ........................................................................... 17

13 GUARANTEE ......................................................................................................... 19

2
INSTRUCTION MANUAL

SUPERFLEX SF

1 TECHNICAL DATA

1.1 Geometric data

Moment of
N° of Ød min/max ØA B C ØD E M Weight inertia
Type unless hole
pins
2
[mm] [mm] [mm] [mm] [mm] [mm] [mm] [kg] [kgm ]
SF3 14 19/45 115 102 67 72 47 8 3 0,0017

SF4 14 19/50 140 115 77 85 53 9 4,8 0,0035

SF5 12 24/60 160 132 92 92 62 8 7,6 0,0072

SF6 12 28/70 190 148 102 110 68 12 10,5 0,017

SF7 12 38/85 220 185 123 135 85 15 20 0,037

Dimentions, Weights e Moments of inertia

3
INSTRUCTION MANUAL

SUPERFLEX SF

1.2 Performances

Nominal Max Static torsional

Power rating [kW] per 100 rpm
Type Torque TCN speed stiffness
[Nm] [rpm]
fs 1 fs 1,5 fs 2 fs 2,5 fs 3 Nm/° Nm/rd
SF3 41,5 0,42 0,28 0,21 0,17 0,14 3600 3,44 197,7

SF4 94,6 0,96 0,64 0,48 0,38 0,32 3600 7,34 421,8

SF5 162,7 1,65 1,1 0,82 0,66 0,55 3600 12,1 692

SF6 255,5 2,58 1,72 1,29 1,03 0,86 1800 16,3 935,8

SF7 380,6 3,85 2,57 1,93 1,54 1,28 1800 23,5 1351

The performances data are valid for

- max 20 starts per hour
- daily operating cycle of up to 24 h
- operation with the specified alignment
- Operation in the temperature range -20° C a +80° C

Caution! For sustained fault free operation the coupling must be designed with a service factor fs
in accordance with item 1.3 and appropriate to the application. In case of a change in
operating conditions the design must always be checked (see item 1.2.1).

1.2.1 Checking the selected coupling size

The following must be apply for the coupling :

TCN ≥ TN x fs TCN = Rated coupling torque

TN = Rated system torque, rated drive torque acting on the
coupling
fs = Service factor in accordance with item 1.3

Caution! When selecting the coupling, the permissible maximum speed and the permissible
maximum bore must also be taken into consideration.

Caution! The shaft displacement values specified in section 6.3, must not be exceeded.

1.3 Service factor fs

Load type Exemple of applications fs Service factor
Agitators, centrifugal pumps, conveyor belt, ventilators,
Light loads 1
dynamo
Plunger pumps, metal working machines, textile
Middle loads 1,5
machines, mixers
Plunger pumps, presses, bending machines, mills,
High loads 2
piston compressors
Rotating crushers, rod mills, kneading machines,
Very high loads 2,5
continuous conveyor systems
Vibrations and load variations, internal-combustion
Special loads 3
engine

4
INSTRUCTION MANUAL

SUPERFLEX SF

2 GENERAL NOTES

This manual forms an integral part of the pump and must accompany it until its demolition. The
SUPERFLEX coupling SF series is a component destined to work in industrial areas and as such the
instruction manual must form part of the legislative dispositions and the applicable technical standards
and does not substitute any installation standard or eventual additional standard.

Couplings are components that due to their moving parts can present dangers:
Improper use
Removing the protections and/or disconnecting the protection device
The lack of inspections and maintenance
CAN CAUSE SERIOUS DAMAGE OR INJURY

CAUTION! All persons involved in the installation, operation, maintenance and repair of the
coupling must have read and understood this Instruction manual and must comply
with them at all times. We accept no responsibility for damage or disruption caused by
disregard of this manual.

Every body that follow the installation is responsible for advising that coupling have to be installed in a
group, taking any safety advisement.

The “Coupling” described in this instruction manual has been developed for stationary in general
engineering applications. The coupling serves to transmit power and torque between two shafts or
flanges connected by this coupling.

The coupling is designed only for applications described in section “Technical data”. Any other operating
conditions will be considered by OMAC s.r.l. “no complying” and such condition shall cancel the
guarantee and responsibility existing between the manufacturer and the user. So new conditions must be
contractually agreed.

5
INSTRUCTION MANUAL

SUPERFLEX SF

3 SAFETY NOTES

The coupling has been manufactured in accordance with the state of the art and is delivered in a
condition for safe and reliable use. Any changes on the part of the user which may affect safety and
reliability are prohibited. This applies equally to safety features designed to prevent accidental contact.

The coupling must be used and operate strictly in accordance with the conditions laid down in the
contract governing performance and supply.

Obligations

- The operator must ensure that all persons involved in installation, operation, maintenance and repair
have read and understood this instruction manual and comply with them at all times in order to:
- Avoid injury or damage
- Ensure the safety and reliability of the coupling.

- During transport, mounting, installation, dismantling, operation and maintenance of the unit the
relevant safety and environmental regulations must be complied with all the times.

- The coupling must be operated, maintened or repaired only by authorised, duly trained and qualified
personnel.

- All work must be carried out with great care and with due regard to safety.

- All work on the coupling must be carried out only when it is at a stanstill. The drive unit must be
secured against being switched on accidentally.

- The drive unit must be shut down as soon as changes to the coupling are detected during
ooperation.

- If the coupling is intended for installation in plant or equipment, the manufacturer of such plant or
equipment must ensure that the contents of the present instructions manual are incorporeted in his
own instructions.

- All spare parts must be obtained from OMAC s.r.l.

Warnings and symbols used in this manual

This symbol indicates safety measures which must observed with regard to explosion
protection

This symbol indicates safety measures which must be observed to avoid personal injury.

Caution! This symbol indicates safety measures which must be observed to avoid damaging the
coupling.

Note: This symbol indicates general operating instructions which are of particular importance.

6
INSTRUCTION MANUAL

SUPERFLEX SF

4 TRANSPORT, STORAGE AND ELEVATION

4.1 Transport
The products supplied are listed in the despatch papers. Check immediately on receipt to ensure that all
the products listed have actually been delivered. Parts damaged during transportation or missing parts
must be reported in writing immediately.
The parts must be provided with explosion protection marking in accordance with chapter 5.

Note: The coupling must be transported using suitable transport equipment only.

Different forms of packaging may be used depending on the size of the coupling and method of transport.
Unless otherwise agreed, the packaging complies with the HPE Packaging Guidelines.

4.2 Storage

- The storage area must be dry and free from dust.

- Avoid areas open to inclement wheather or excessive humidity.

- For storage periods of longer than 60 days, protect the coupling surfaces (clamps, reducers, motor)
with adequate anti-oxidant products.

- Flexible elements must be stored in a covered, dry place. Unfavourable storage conditions and
improper treatment will negatively affect the physical properties of flexible elements. Correctly stored
flexible elements retain their properties unchanged for up to five years.

4.3 Elevation

For elevation and transportation operations use only lifting and handling equipment of sufficient
load-bearing capacity! (see § 1.1)

7
INSTRUCTION MANUAL

SUPERFLEX SF

5 TECHNICAL DESCRIPTION

5.1 General description

As shown in the figure below, the coupling design is very simple and stout. It’s useful for connecting
machine and can adjust light displacement of shaft.
It’s composed by 2 flanges(1), 1 flexible element(2) that connects flanges and an elastic ring(3). One
flange is keyed to shaft and fixed axially with grain(4); at same manner the other flange to the driven
shaft.
Flanges have a crown of pins that enter in corresponding holes of flexible element. A ring in stainless
steel contained this element.
4

So drive can be send from driving to driven shaft.

In this type of coupling there isn’t any metal-metal contact, in fact metallic parts are designed for
geometric coupling. This kind of coupling don’t have a “functioning in emergency”, because the flexible
element in case of overloads, break down and interrupt safely the transmission of torque.

5.2 Flexible element

Flexible element has a toroid design with holes for connections with the pins of flanges. The material is
natural rubber available in 80 Shore hardness.

Caution! Only identical flexible element may be use as spare parts in the same coupling.

8
INSTRUCTION MANUAL

SUPERFLEX SF

5.3 Marking the coupling parts for explosion protection

Note: Coupling which are intended for use in hazardous zones must bear the following engraving
marking on the outer diameter of part (1):

Omac s.r.l. II 2GD c SUPERFLEX Size Year of made

Via Falcone, 8 -20°C ≤ Ta ≤ 80°C Max Speed: Max Torque:
I 42048 RUBIERA TÜV 04 Atex 2703

The outer diameter of the flange (1) have to be marked (engraving) with and with TÜV
certificate number, the flexible element (2) have to be marked (raised) with TÜV certificate number.

5.4 Service conditions

The coupling is suited for service conditions in accordance with Guideline 94/9/EC.

Equipment group II of category 2 and 3 for area where there are explosive gas, vapour, mist, air mixtures
as well as for areas where dust can form explosive atmospheres.

Dangerous zone Category according 94/9/ECdir.

Gas, vapour o mist, dust Zone 1 o 21 2GD

Gas, vapour o mist, dust Zone 2 o 22 3GD

Coupling don’t have a specified class temperature. That means work environment determines the critic
temperature for coupling.

9
INSTRUCTION MANUAL

SUPERFLEX SF

6 ASSEMBLY
The coupling parts are supplied in finished condition in accordance to the order.

6.1 Notes to the fit pairs of the bore / shaft.

Caution! The fits of the bores / shaft must be checked!

For drive by means of parallel keys the following fit pairs are described for the bores :

bore d
Selection of fit over to Shaft tolerances Bore tolerances
mm mm

Shaft tolerances
all h7 G7
to OMAC standard

Shaft tolerances 50 k6
F7
to DIN 748/1 50 m6
50
h6
System standard shaft 50 G7
all h8

Caution! The assigned fits must be adhered to in order, on the one hand, to keep the play in the
shaft hub connection as low as possible, depending on utilisation of the tolerances
zones, or, on the other, to keep the hub tension arising from the oversize within the
permissible load limit.

6.2 General information on installation

During assembly observe safety instructions of charter 3.

Assembly and installation work must be done with great care by trained and qualified personnel.

As early as during the planning phase it must be ensured that sufficient space is available for installation
and subsequent care and maintenance work.

Adequate lifting equipment must be available before beginning the installation and assembly work.

If lacquered couplings are used in hazardous zones, the requirements for the conductivity of
the lacquer coating must be observed. Where lacquer coatings have a thickness less than
200 µm no electrostatic charge is to be expected.

10
INSTRUCTION MANUAL

SUPERFLEX SF

6.3 Mounting the coupling parts

1. Clean carefully shaft ends and coupling parts. Remove any nicks or burrs from the shafts.

Note manufacturer’s instructions for handling solvents.

2. mount a flange to one shaft and tighten securely.

Caution! Tightening the screw with the torque value shown on Tab at Chap. 6.4

3. Slide second flange into position on other shaft, do not tighten.

4. Approach the machines to connect. Shaft ends mustn’t protrude from inner surfaces of hub.
We suggest to place the shaft ends at a S distance (see table below)

Danger of squeezing!

5. Check parallel alignment by laying a straightedge across the flanges at several places around
coupling and flange with a feeler gage.

Caution! The difference can’t be in any case greater than 0,4 mm (see picture).
STRAIGHTEDGE

Radial misalignment

6. Slide loose flange out of the way to facilitate element installation. Engage element (with ring)
over pins in mounted flange. Slide loose flange into position making sure flange pins are
properly engaged in element. Space flanges to dimension “C” shown in the table below.
Tighten flange securely.
Cmax

Angular alignment

Cmin
7. Check angular alignment by measuring flange spacing with calipers. Measure at several
points around the coupling to determine the minimum and maximum spacing, “C” quote.

Caution! The difference between min and max readings should not exceed value
“X” shown in the tab below and should be as close to “0” as possible. If
difference is greater than value “X”, realign shafts

TYPE C X S
SF3 67 1,5 6
SF4 77 2 8
SF5 92 2 8
SF6 102 3 12
SF7 123 3 15
Distance on [mm]
11
INSTRUCTION MANUAL

SUPERFLEX SF

6.4 Tightening torques

Part 4 : MA Tightening torque and CW key size
Type for socket head screw
MA [Nm] CW [mm]

SF3 32 M8

SF4 32 M8

SF5 40 M10

SF6 40 M10

SF7 50 M12

Note: Tightening torques apply to screws with untreated surfaces wich are not or only light
oiled (coefficient of friction µ=0,14). The use of lubricant paint or the like, wich affect the
coefficient of friction µ, is not permitted.

Note: Use glue type “Loctite 243” for socket head screw.

7 START-UP

7.1 Procedure before start-up

Before starting-up check the flexible element, the flanges, and the elastic ring for correct seating. Check
also screw tightening, the distance between flanges and radial misalignment (see § 6.3 point 7 “the C
measure”).

Caution! Then fit the coupling guard to prevent unintentional contact.

Before starting up make sure that machine or parts of machine connected with
coupling and the safety system preventing unintentional contact are earthed.

8 OPERATION

8.1 General operating data

- During operation of the coupling watch for :

- Changes in running noise

- Sudden shocks

Caution! If any irregularities are noticed during operations, switch the drive assembly off at
once. Determine the cause of the fault, using the table in the section 9.
This table contains a list of possible faults, their causes and suggested remedies.
If the cause cannot be identified or the unit repaired with the facilities available, you are
advised to contact Omac s.r.l. for specialist assistance (see chap. 11)

12
INSTRUCTION MANUAL

SUPERFLEX SF

9 FAULTS, CAUSES AND REMEDIES

9.1 General
The following irregularities can serve as a guide for fault tracing.
Where the system is a complex one, all the other components units must be included when tracing faults.
The coupling must run with little noise and without vibration in all operating phases. Irregular behavior
must be treated as a fault requiring immediate remedy.

9.2 Possible faults

MALFUNCTIONS CAUSES REMEDIES
Noise Alignment Take the system out of service

If necessary, rectify causes of

alignment change (e.g. tighten loose
foundation bolts)

Check and adjust the junction of part

(see § 6.4)

Check the wear of coupling part

Transmission break Flexible element wear Take the system out of service

Flexible element must be changed

(see § 10.1).

Axial movement of a flange Take the system out of service

Check parts alignment and the

tightening of grains.

Flexible element alignment change Take the system out of service

Eliminate causes of alignment

changes or vibrations

Check the wear of coupling part

13
INSTRUCTION MANUAL

SUPERFLEX SF

9.3 Incorrect use

Experience has shown that the following faults can result in incorrect use of the SUPERFLEX
coupling. In addition to observing the other instructions in this BA, care must therefore be taken to
avoid these faults.
Guideline 94/9/EC requires the manufacturer and user to exercise special care.

9.3.1 Possible faults when selecting the coupling or coupling size

• Important information for describing the drive and the environment will not be
comunicated to others
• System torque too high
• System speed too high
• Application factor not correctly selected
• Chemically aggressive envirnment not taken into consideration
• The ambient temperature is not permissible. For this, note § 1. and § 5.
• Finished bore with impermissible diameter (see § 1.) and/or impermissible fit
classification (see § 6.)
• The transmission capacity of the shaft-hub connection is not appropriate to the
operating conditions

9.3.2 Possible faults when installing the coupling

• Components with transport or other damage are being fitted
• The shaft diameter is outside the specified tolerance range
• Coupling part are being interchanged, i.e. their assignment to the specified shaft is
incorrect
• Prescribed tightening torques are not being adhered to
• Alignment or shaft misalignment values do not match the operating instructions
• The coupled machines are not correctly fastened to the foundation, so a shifting of the
machines e.g. through loosening of the foundation screw connection is causing
excessive displacement of the coupling parts
• Flexible element is being omitted or incorrectly positioned
• The coupling guard used is not suitable for operation within the meaning of the
explosion protection requirements or Guideline 94/9/EC

9.3.3 Possible faults maintenance

• Maintenance intervals are not being adhered to
• Original Omac flexible element are not being used
• Leakage in the vicinity of the coupling is not being identified and as a result chemically
aggressive media are damaging the coupling

14
INSTRUCTION MANUAL

SUPERFLEX SF

10 MAINTENANCE AND REPAIR

All work on the coupling must be carried out only when it is at a standstill.
The drive unit must be secured against being switched on accidentally.

The alignment between the two parts of the coupling and the flexible element wear must be
checked firstly after 3 months and then once time a year.

Caution! Clean coupling parts only when completely dismantled.

Caution! Take care to have a wet cloth for cleaning flexible element and ring.

10.1 Replacement of the flexible element

- For most applications it’s possible to remove and replace the flexible element without moving the
flanges.

- Slide retaining ring off element and over flange, compress element until pin are disengaged and
remove element.

- To install replacement element; first compress element at the split, then position the end between the
flanges and release.

- Work the element between the flange all around the coupling, making sure that all the pins are
properly engaged

- Fix the flanges on shafts, then replace the retaining ring.

Caution! The flexible element have to be substitute only by flexible element with the same mark.

15
INSTRUCTION MANUAL

SUPERFLEX SF

11 SPARE PARTS
Si consiglia, al fine di garantire un utilizzo senza interruzioni del giunto, di provvedere a mantenere una
scorta delle parti principali di ricambio soggette maggiormente a usura.

Per l’ordinazione delle parti di ricambio si prega di indicare i dati seguenti :

− Original order No.

− Part No (see § 11.1)
− Quantity

We guarantee only the original spare parts supplied by us.

Caution! Please note that spare parts and accessories not supplied by us have not been tested
or approved by us. The installation or use of such products may therefore impair
essential characteristics of the coupling under certain circumstances and so pose an
active or passive hazard. OMAC will assume no liability or guarantee for damage
caused by spare parts and accessories not supplied by OMAC.

11.1 Spare parts list

4

Spare parts

Part No. Description

1 Flange

2 Flexible element

3 Ring

4 Grain

11.2 Spare parts and customer service adresses

OMAC POMPE, s.r.l. via Falcone, 8 - 42048 RUBIERA (RE) - ITALY
Tel. 00–39–0522–629371/629923 Fax. 00–39–0522–628980
www.omacpompe.com; E – mail: info@omacpompe.com

16
INSTRUCTION MANUAL

SUPERFLEX SF

12 CERTIFICATES OF APPROVAL

Declaration of incorporation
According to 2006/42/EEC Directive Annex IIB

We hereby declare that the

SUPERFLEX couplings type

SF3, SF4, SF5, SF6, SF7

in design in accordance with

2014/34/EU for finisched bored couplings

described in this Instructions Manual are intended for incorporation in a machine, and that it is
prohibited to put them into service before verifying that the machine into which they are
incorporated complies with the EC Guidelines (original edition 2006/42/EEC including
subsequent amendments thereto).

Rubiera, __/__/____

Signature (The Legal Representative)

17
INSTRUCTION MANUAL

SUPERFLEX SF

Declaration of conformity
Within the meaning of EC Guideline 2014/34/EU
and with the legal requirements laid down for its implementation

The manufacturer OMAC s.r.l. declares that the

SUPERFLEX couplings type

SF3, SF4, SF5, SF6, SF7

equipment described in this Instructions Manual is in conformity with Article 1 and Article 8,
paragraph 1) b) ii) of Guideline 94/9/EC and complies with the requirements of Guideline
2014/34/EU and the standards EN 1127-1:2011, EN 13463-1:2009, EN 13463-5:2011 and EN
13463-8:2004

The technical documentation has been delivered to the named body

C.S.P. s.r.l. TÜV NORD CERT 40132 BOLOGNA, Code number : 0032
Statement of Conformità Number: TÜV 04 ATEX 2703

Rubiera, __/__/____

Signature (The Legal Representative)

18
INSTRUCTION MANUAL

SUPERFLEX SF

13 GUARANTEE

- We guarantee against all manufacturing defects and guarantee the materials that compose the
coupling OMAC for one year from the date of delivery.

- This guarantee is valid as long as the equipment functions within the parameters indicated in the
technical information chapter or on subsequent changes authorised by OMAC s.r.l.

- This guarantee includes materials and work but not the transportation of material to or from our
warehouses in Rubiera (RE), being necessary to do so arising from the necessities of the client, the
corresponding costs of displacement and expenses will be charged.

19