Kop-Flex Training

LUBRICATED COUPLINGS

Emerson Power
Transmission
EPT/Couplings
CONTENTS

• History
• Introduction & Basics
• Product Offering/Matrix
• Industries & Applications
• Gear Couplings
• Grid Couplings
• Miscellaneous Couplings
• Lubricants
• Summary
KOP-FLEX, FASTS, KOP-GRID, MORSE, BROWNING AND MORFLEX ARE REGISTERED TRADEMARKS OF EMERSON POWER
TRANSMISSION MANUFACTURING, L.P.

 Emerson Power Transmission Manufacturing, L.P., 2001. ALL RIGHTS RESERVED 2

EPT/Couplings
Kop – Flex History

• The Koppers Company Founded 1913

(Began making coke ovens for use in steel making & coal processing)
• Gustave Fast invents Fast’s® Gear Coupling 1918
• First Fast’s coupling sold (Bartlett Hayward) 1920
• Koppers acquires Bartlett Hayward 1926
(America’s largest builder of gas holders and gas plant equipment
other interests include, locomotive building, architectural design
elevator manufacturing and SHAFT COUPLINGS)
• Kop-Flex div. of Koppers Company Formed 1986
(Kop-Flex was privately held company)
• EPT acquires Kop-Flex 1996
(EPT a division of Emerson Co.)
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EPT/Couplings
Introduction

Coupling Function
• Connect 2 Shafts
• Transmit power from Driving Shaft to Driven Shaft
• Accommodate Four Types of Misalignment:
– Angular, Offset or Parallel, Combination and Axial
• Protects System

Transmit Power

Accommodate Misalignment

Compensate for
End Movement
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EPT/Couplings
Introduction
Misalignment
Types:
• Angular

2. Offset or Parallel

3. Combination

4. Axial
What causes Misalignment:
• Installation (human) Errors
• Thermal Growth
• Worn Bearings
• Dynamic Twist of Bases Under Load
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• Settling Bases / Foundations
EPT/Couplings
Product Offering

Standard Products

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EPT/Couplings
Product Offering

Mill Products

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EPT/Couplings
Product Offering

High Performance

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Product Matrix

Hi-
Hi-Maintenance Low-
Low-Maintenance

Lubricated Non-
Non-Lubricated

Standard Gear, Grid Elastomeric

Products Chain Jaw, Disc

High HP Disc
Engineered HP Gear
Performance
Diaphragm
Products
Mill Gear Spindle Universal Joint
Products Large Gear Resilient
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EPT/Couplings

Primary Served Industries

• Steel Mills
• Pulp & Paper Mills
• Petrochemical Plants
• Power Plants
• Refineries
• Cement Mills
• Mines
• Rubber

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EPT/Couplings
Served Applications

• Steel Mills: Casters, Run-out/Entry Tables,

Cranes, Edgers, Hot/Cold/Bar Rolling Mills,
Straighteners
• Pulp & Paper: Barker, Calendars, Chippers,
Coaters, Couch/Press Rolls, Dryers, Jordans,
Refiners and Rolling Mill Drives
• Cement Mill / Mines: Rotary Mills (Ball,
Kiln, Hammer Drives), Crushers, Conveyors

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EPT/Couplings
Served Applications

• Petrochemical/Refinery/Power Plant/Gas
Pipe Line: Pumps, Turbine to Compressor or
Generator Drives, Melt Pump, Cooling
Tower, Boiler Feed Pump
• Others: Pumps, Conveyors, Fans, Feeders,
Marine Propulsion Drives, Cranes, Mines

Anywhere There is Driving to Driven

Equipment Shaft Connection
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EPT/Couplings
Introduction

3 Basic Categories (flexible shaft couplings)

• Mechanical ( Lubricated)
• Transmits torque through a lube film. Accommodates
misalignment with rocking motion through gearing.
• Metallic (Non-lubricated)
• Transmits torque through compression or tension of
metal. Accommodates misalignment through
deflection of metal.
• Elastomer (Non-lubricated)
• Transmits torque through compression and/or shear
of Elastomer. Accommodates misalignment through
deflection of Elastomer. 13
EPT/Couplings
Lubricated Couplings

• Gear
– Fasts
– Model B
– Walron
– Series H
• Grid
• Miscellaneous
– Jaw

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Lubricated
EPT Gear Couplings

Fast’s® - Model B - Series H - Waldron

• Advantages of Gear Couplings
– Accommodates Large Misalignment including
most axial misalignment
– Very Economical
– High Torque Capacity (Torque to OD Ratio)
– High Torsional Stiffness

• Disadvantages of Gear Couplings

– Regular Maintenance / Lubrication Required
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EPT/Couplings
Basics

• Flex Hubs – Attached to Shaft

• Sleeves – Slide over hub teeth (shrouded or exposed
bolts)
• Accessories – Bolts/Nuts, Gasket and Seals
• Rigid – Like a flex hub (seats on shaft) but doesn't
accommodate misalignment since it has no teeth

Full Flex Rigid

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EPT/Couplings
Basics

• Hubs have external (male) gear teeth

• Sleeves have internal (female) gear teeth
• Rigid has no teeth
*Sleeve teeth contact hub teeth one for one – unlike gearbox;
power is transmitted from tooth to tooth thru lube
Sleeve Teeth

Hub Teeth
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EPT/Couplings
Basics

• Full Flex or Double Engagement - two

flexible halves bolted together - used
exclusively on 4 Bearing Systems

• Flex Rigid or Semi-Flex or Single

Engagement - one flexible half bolted to a
rigid half - used on 3 bearing Systems and
floating shafts.
(See page M-16)

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EPT/Couplings
Fast’s ®
Overview
• Original Gear Coupling-
Invented 1918
– Set the “standard” for Bolt
Circle,Holes, & Flange Diameters
• Unique Design
• Size 1.5 – 30 Max Bore to 36”
diameter
• All Metal End Ring
• 300 % Greater Lube Capacity
• Oil or Grease Lubricated
• Straight Gear Teeth
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EPT/Couplings
Fast’s ®
Overview (continued)
• 0.5 degree Misalignment per
Gear Mesh (static)
• Straight Face Gear Tooth
• Peak Loads in Excess of 100
million inch pounds
• Available in Exposed bolt or
Shrouded Bolt
• Up to 3 times the life vs. O-
Ring style
• See Catalog KSP- 98
Pages M8 – M23
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EPT/Couplings
Fast’s ®
Features
• Largest Lube Reservoir
• Lifetime Metallic Lube Seal
• Oil or Grease Lube
(exclusive design)
• Straight Faced Teeth
• Interchangeable half for half
with Series H, Waldron and
other competitive couplings
Benefits
Ø Less frequent lube required.
Minimized downtime, savings
on lube and labor
Ø No soft seal to fail or replace.
Lube level above gear teeth,
less worn or rusted teeth
Ø Let application dictate lube.
Tailor lube to application
Ø Less concentration of tooth
loading. Less premature tooth
wear
Ø Competitively priced and
available in distributor and
warehouse stocks worldwide
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EPT/Couplings
Fast’s ® Model B
Overview
• Light Duty Fast’s Coupling
Originally Designed to Compete
with the ‘O’ ring Style Couplings

• Primarily for Low hp Pump or Fan

Applications

• Size 1 – 3 1/3 – up to 4.75” max.

bore- up to 117, 000 in/lbs torque

• Lube Capacity Less than Fast’s but

more than “O” ring style. - Grease
Lube Only See Catalog KSP-98 Pages M24- M26
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EPT/Couplings
Fast’s ® Model B
Features Benefits
• Greater lube capacity Ø Less frequent lube
required. Minimized
than “O” ring style
downtime, savings on
(Less than Fast’s) lube and labor
Ø No soft seal to fail or
replace. Lube level
• All metal end ring above gear teeth, less
worn or rusted teeth
Ø Less concentration of
• Straight faced gear tooth loading. Less
teeth premature tooth wear
• Lower cost than Fast’s Ø Highly featured coupling
at standard coupling
price. 23
EPT/Couplings
Series H
Overview
• Sizes 1 – 30 - Max. Bores to 43.5”
• O-Ring Type End Ring Seal (Buna N)
• Grease Lube Only
• Sizes 1 through 7
– Curved Face Gear Tooth
– + or – 1.5 Degree Misalignment per Gear
Mesh (Static) Size 1 - 7

• Sizes 8 through 30
– Straight face gear tooth
– + or - .5 degree misalignment per mesh
• Peak Shock Loads in Excess of 100
million inch pounds
• See Catalog KSP-98 Pages M29- M43 Size 8 - 30 24
EPT/Couplings
Waldron Flexalign
Overview
• Sizes 1 – 7 - Max. Bores to
9.25”
• High Misalignment Soft
Seal
• Curved Face Gear Tooth
with 40 degree Pressure
Angle
• 1 1/2 Degree Misalignment
per Gear Mesh (Static)
• Grease Lube Only
• Reversible Flex Hubs
• Optional Pilot Rings
• See Catalog KSP-98 Pages
M45- M55 25
EPT/Couplings Waldron Powerlign
Continuous Sleeve
Features
• Sizes 1 1/8 – 12 - Max. Bores to
16.25”
• Flangeless Design
• High Misalignment Lip Seal
• Curved Face Gear Tooth with
40 degree Pressure Angle
• 1 1/2 Degree Misalignment
per gear mesh (static)
• Grease lube only
• Small outside Diameter
• See Catalog KSP-98 Page M56
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EPT/Couplings
Other Types

• Mill Motor Type (Industry standard shaft end,

dimensions, and details)
• Limited End Float
• Floating Shaft
• Electrically Insulated
• Short, Medium and Long Slide (Utilize full length
teeth- compensate for thermal expansion)
• Shear Pin Overload Release Type
• Brake Wheel or Disc Types
• Double Engagement DE Type
• Vertical Adjustable VAR Type
• Cutout Disengaging
Custom Designs Available for Unique Applications 27
EPT/Couplings
Competitors

H Style Fast’s Style Cont. Sleeve

Falk x
Ameridrives x x x
Lovejoy x x x
Systems - x
Components (SCI)
TB Woods x x x
Dodge x
Renold x

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EPT/Couplings
Competitors

Interchanges
• There is an industry standard for flange bolt
patterns for coupling sizes #1.5 through #7.
– All Kop-Flex Gear Couplings (Fast’s, H, and Waldron),
shrouded and exposed bolt styles, will bolt to all major,
North American competitor coupling halves
• Gear Couplings interchangeable half for half only.
– Kop-Flex half couplings will bolt to competitor halves;
however, Kop-Flex hubs will not fit into competitor
sleeves, and vice versa
Note: Model B couplings have a unique flange pattern. Will
not match with competitor
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 EPT/Couplings
Nomenclature

Coupling Size Coupling Model Series Component

1½ F EB FF

F = Fasts EB = Exposed FF = Full Flex

1 ½ - 30 Fast’s
B = Model B SB = Shrouded FR = Flex Rigid
1 – 3 ½ Model B MMFF = Mill Motor
H = Series H
1 – 30 Series H Full Flex
W = Waldron
1 – 7 Waldron FHUB = Flex Hub SSFF = Short Slide Full
RHUB = Rigid Hub Flex
Parts MMHUB = Mill Motor Hub SSFR = Short Slide Flex
SSHUB = Short Slide HUB (Full Flex)
SRHUB = Short Slide Hub (Fl. Rigid)
Rigid
1½F FHUB FB LSHUB = Long Slide Hub MSFF = Medium Slide
SLEEVE = Standard Sleeve Full Flex
MSSLEEVE = Med. Slide Sleeve LSFF = Long Slide Full
LSSLEEVE = Long Slide Sleeve
Size & Style Desc. **Bore
FS = Fastener Set Flex
** For Finished Bore ST = Stop Plate (Slide Couplings) 30
Add FB + Bore Size
EPT/Couplings
Wrap Up

• Change out Competitor’s Gear Coupling

with Fasts, Series H, Waldron or Model B
• Specify Fasts Where You Can
• Use the catalog – Great Information
• Fasts - Highly Featured (Cadillac)
• Model B - Fast’s Features @ Med. Price
• Waldron - Real Value
• Series H - Most Economical
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EPT/Couplings
Lubricated Couplings

• Gear
– Fasts
– Model B
– Walron
– Series H
• Grid
• Miscellaneous

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Tapered Grid

Types
T10 - T20 - T31 - T35
•Advantages:
– Can Replace Flex Element (Tapered Grid) Without Moving Hubs
– Absorbs Medium Shock Loads
– Provides Some Torsional Damping
– High Fatigue Life
– Moderate Torque Capacity
– Very Economical

•Disadvantages:
– Maintenance / Lubrication Required Periodically
– Torsionally Soft
– Balanced Couplings are NOT Available
– Typically Shorter Life than Gear Couplings
– Not Suitable for Critical Applications
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EPT/Couplings
Kop-Grid ®

• Our #1 Target is… Falk

• Kop-Grid is completely interchangeable

with Falk Tapered Grid, component by
component:
Grids, hubs, seals and cover assemblies

• K/F Tapered Grids are shot peened steel

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EPT/Couplings Kop-Grid ® T-10
with Horizontal Split Cover

• Sizes 1020 - 1140

• Max. Bores to 7.25”
• Interchangeable by
Components with Falk
Steelflex and Others
• Absorbs moderate Shock
and Vibratory loads
• Suitable for Reversing
Service
• See Catalog KSP-98 Pages
M57-65
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EPT/Couplings Kop-Grid ® T-20
with Vertical Split Cover

• Sizes 1020 - 1140

• Max. Bores to 7.25”
• Interchangeable by
Components with Falk
Steelflex and Others
• Absorbs Moderate Shock
and Vibratory Loads
• Suitable for Reversing
Service
• See Catalog KSP-98 Pages
M57-65
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EPT/Couplings
Kop-Grid T ® 31 / T35 Spacer

• Sizes 1020 - 1100

• Max. Bores to 4.75”
• Interchangeable, by
Component, with Other
Tapered Grid Couplings
• Designed for Extended Shaft T31 Full Spacer Coupling
Separation
• The Drop-Out Center
Section Permits Easy
Maintenance
• See Catalog KSP-98 Pages
M57-65
T35 Half Spacer Coupling
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 EPT/Couplings
Nomenclature

Coupling Size Coupling Model Series

1 020 T10

T10 = Horizontal Split Cover

1000 Series Size (020 – 140) T20 =Vertical Split cover
T31 = Full Spacer
T35 = Half Spacer
HUB = Rough Bore Hub
HUB x Bore = Finished Bore Hub
HUB x (Bushing Size) = Hubs for Split Taper Bushing
Parts GRID = Tapered Grid
T10 CGA = Cover and Grid (Horizontal)
T20 CGA = Cover and Grid (Vertical)
1020 HUB x5/8** T10 Cover = Horizontal split Cover
T20 Cover = Vertical Split Cover
SHUB = Shaft Hub
Size & Style Desc. **Bore SHUB x (Bushing Size) = Shaft Hub for Split Taper
Bushing
** For Finished Bore 39
SPHxxx = Distance Between Shaft Ends (xxx)
Add FB + Bore Size
EPT/Couplings
Lubricated Couplings

• Gear
– Fasts
– Model B
– Walron
– Series H
• Grid
• Miscellaneous

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EPT/Couplings
Browning and Morse

Chain Type
Inexpensive … Browning DRC chain couplings
provide long service life with the hardened
working members.

Universal Joints
Inexpensive … Browning Universal Joints
provide long service life with
minimum maintenance.

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EPT/Couplings
Selection
Gear
• Select coupling based on bore capacity
• Verify coupling size based on load rating
• Check balance requirements
• Verify Close Coupled or Spacer/Floating Shaft Type
Grid
• Determine service factor
• Calculate required HP/100RPM & select coupling
• Verify operating speed (do not exceed max. allowable
coupling speed rating
• Verify maximum bore
• Check overall dimensions & shaft separation
See selection pages in catalog
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Lubricants

• Couplings must use greases with certain special qualities

that most commercial (bearing) grease formulations do not
possess.
• Coupling grease, unlike bearing or general purpose grease,
must withstand high centrifugal forces.
• High centrifugal force will cause oil (lubricant) to separate
from thickener (called separation or grease breakdown).
• Unlike many standard greases using lithium-based (heavy)
thickeners, Kop-Flex grease uses polyethylene (lighter)
thickeners with a density closer to that of oil, and are much
less susceptible to separation.
• KSG and KHP (Kop-Flex Greases) does not separate at
normal operating speeds.
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EPT/Couplings
Lubricants
Recommended Lubricants
• Oil is the best lubricant (better than grease) and can be
used at all speeds (Fast’s- only stocked coupling that uses
oil due to all-metal end ring design and large lubrication
reservoir)
• Coupling Greases (NLGI Grade #1) which meet the min.
requirements per the application recommended for all
coupling types. (Kop-Flex Grease Preferred)
Not Recommended
• Bearing Greases (NLGI #2) – generally too stiff & prone
to centrifugal separation
• Greases containing “moly” are intended for spindle
couplings with hardened teeth. Can reduce standard
coupling life
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EPT/Couplings
Lubricants
Kop-Flex Coupling Greases Are Specially
Formulated for Use in Couplings
• KSG Standard Coupling Grease – For Standard Motor
Speeds
• KHP - High Performance Coupling Grease - Over 3600 rpm
• Waverly Torque Lube A - Gear Spindle Grease
• Kop-Flex Coupling Grease Resists Centrifugal Separation as
Compared to Other Greases
• Kop-Flex Greases Have a Polyethylene Thickener with a
Density Similar to the Base Oil

• Available from Stock

• See Catalog KSP-98 Page M27

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EPT/Couplings
Lubricants

Grease Type Application Typical Speed Coupling Temp. Range

Type (F)
KSG Standard General Standard Standard gear, -40 to 190
purpose motor speeds grid and chain Degrees
industrial Fahrenheit

KHP High Petrochemical, Highest High -40 to 190

Performance process, and coupling performance Degrees
critical service RPM, Usually gear, Critical Fahrenheit
over 3600 standard
RPM applications
Waverly Rolling mill, Normal Gear spindle Covers mill
Torque Lube high torque Rolling mill and slippers temperature
‘A’ motor speeds range
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EPT/Couplings
Available Resources
• Internet: www.emerson-ept.com
– Price, Availability, Order Entry
– Product Selections
– Smart Interchanges
– CAD Drawings
– eCatalog
– Media Library
• EPT Customer Service (800-626-2120)
– Price, Availability, Order Entry
• Technical Services – Standard Product (800-626-2093)
- Standard / Mill / High Performance (410-768-2000)
– Technical questions regarding products
– Application and interchange assistance 47