Flender ONE H2SHN0096 Industrial Helical Gearbox
The Flender ONE H2SHN0096 is a benchmark 2-stage parallel shaft helical industrial gearbox from Flender's next-generation Flender ONE platform, engineered to replace traditional FZG Size 7 gearboxes[cite: 23]. Utilizing the newly developed Metaperform® gearing and Perfect Sizing philosophy[cite: 23], Flender ONE achieves up to 50% lower friction power losses, a 35% larger surface cooling area, over 80% extended bearing service life (100,000+ hours), and up to 20% reduced oil consumption[cite: 23]. Every unit comes factory-equipped with the AIQ® Core sensor for real-time digital condition monitoring and predictive maintenance[cite: 23]. Flender ONE maintains identical mounting and shaft centerline dimensions as previous generations, ensuring seamless 1:1 drop-in replacement with higher power density and substantially lower operating expenses (OPEX)[cite: 23].
Technical Specifications
| Model / Part Number | H2SHN0096 (2-Stage Parallel Shaft, Size 0096 Flender ONE)[cite: 23] |
|---|---|
| Brand / Manufacturer | Flender GmbH[cite: 23] |
| Gearbox Design Types | Single-Stage Helical (H1SHN), 2-Stage (H2SHN), 3-Stage (H3SHN), 2-Stage Bevel (B2SHN), 3-Stage Bevel (B3SHN)[cite: 23] |
| Legacy Size Cross-Reference | Direct 1:1 drop-in replacement for Flender FZG H2SH07 / H2DH07[cite: 23] |
| Nominal Torque Output | 24.0 kNm (Size 0096) / 6.7 kNm to 153 kNm (Standard Matrix)[cite: 23] |
| Gearing Technology | Metaperform® optimized tooth geometry with precision ratio matching[cite: 23] |
| Smart Intelligence | AIQ® Core integrated sensor (Vibration, Temperature, Oil Quality, Torque)[cite: 23] |
| Efficiency & Thermal Upgrades | Power losses reduced by up to 50%, thermal capacity increased by +30%[cite: 23] |
Documentation & Resources
Flender ONE Platform Modular Architecture Matrix
Full-range structural configuration guide for Flender ONE single-stage and multi-stage industrial gearboxes[cite: 23]. Review supported stage layouts, new size codes, and smart monitoring accessories:
| Gearbox Stage & Architecture Designation | New Size Code Range | Nominal Torque Rating (kNm) | Standard Factory Accessories & Smart Features |
|---|---|---|---|
| H1SHN / NH1 (Single-Stage High Speed Helical)[cite: 23] | 0026 to 0541 (11 Sizes)[cite: 23] | 6.7 kNm - 153.0 kNm[cite: 23] | AIQ® Core (Integrated Vibration/Temp Sensor)[cite: 23] |
| H2SHN / H3SHN / H4SHN (Multi-Stage Parallel Helical)[cite: 23] | 0024 to 0541 (16 Sizes)[cite: 23] | 6.7 kNm - 153.0 kNm[cite: 23] | Metaperform® (50% Lower Friction Loss)[cite: 23] |
| B2SHN / B3SHN / B4SHN (Multi-Stage Right-Angle Bevel)[cite: 23] | 0042 to 0541 (15 Sizes)[cite: 23] | 6.7 kNm - 153.0 kNm[cite: 23] | Perfect Sizing (Tailor-made Ratios)[cite: 23] |
| Hollow Shaft Shrink Disc (DHN Series)[cite: 23] | 0063 to 0312 (10 Sizes)[cite: 23] | 12.0 kNm - 110.0 kNm[cite: 23] | 100,000h+ (Extended Bearing Life)[cite: 23] |
| Hollow Shaft Keyway (HHN Series)[cite: 23] | 0096 to 0234 (4 Sizes)[cite: 23] | 24.0 kNm - 75.0 kNm[cite: 23] | -20% Oil (Reduced Oil Fill Volume)[cite: 23] |
Legacy Flender FZG to Flender ONE Replacement Guide
Obsolete Flender FZG gearboxes installed on industrial production lines can be directly replaced with Flender ONE next-generation gear units[cite: 23]. Refer to the 1:1 dimensional replacement mapping below:
| Legacy FZG Size Code (Obsolete) | Original FZG Model | Current Flender ONE Equivalent | ONE Torque Rating | 1:1 Retrofit & Operational Efficiency Upgrades |
|---|---|---|---|---|
| FZG Size 3 / Size 4[cite: 23] | H1SH03 / H2SH04[cite: 23] | H1SHN0026 / H2SHN0042 Flender ONE[cite: 23] | 6.7 - 12.0 kNm[cite: 23] | Direct 1:1 footprint & shaft match. 50% lower friction loss[cite: 23]. |
| FZG Size 5 / Size 6[cite: 23] | H2SH05 / H2SH06[cite: 23] | H2SHN0063 / H2SHN0070 Flender ONE[cite: 23] | 15.0 - 18.0 kNm[cite: 23] | Identical shaft centerline height. 35% larger cooling area[cite: 23]. |
| FZG Size 7 / Size 8[cite: 23] | H2SH07 / H2SH08[cite: 23] | H2SHN0096 / H2SHN0104 Flender ONE[cite: 23] | 24.0 - 30.0 kNm[cite: 23] | Drop-in replacement for Size 7. Factory AIQ® Core monitoring[cite: 23]. |
| FZG Size 9 / Size 10[cite: 23] | H2SH09 / H2SH10[cite: 23] | H2SHN0136 / H2SHN0151 Flender ONE[cite: 23] | 42.0 - 48.0 kNm[cite: 23] | Preserves base bolt pattern. Bearing life extended to 100,000h+[cite: 23]. |
| FZG Size 11 to Size 19[cite: 23] | H2SH11 to H2SH19[cite: 23] | H2SHN0179 to H2SHN0541 Flender ONE[cite: 23] | 60.0 - 153.0 kNm[cite: 23] | Heavy conveyor & mill replacement. Reduced oil volume requirement[cite: 23]. |
Expert Selection & Retrofit Engineering Notes
When replacing an older Flender FZG H2SH07, H2SH09, H2SH11, or competitor industrial gearbox[cite: 23], upgrading to Flender ONE ensures 1:1 mechanical interchangeability without modifying foundation steelwork or drive shafts, while substantially lowering operating noise, thermal stress, and energy costs[cite: 23]. Simply supply us with your existing Flender serial number or nameplate data, and our engineering team will provide a 100% compliant replacement specification and proposal[cite: 23].
Core Benchmark Model Standard Configurations
- H1SHN0026 (6.7 kNm)[cite: 23]
- H1SHN0063 (15.0 kNm)[cite: 23]
- H1SHN0096 (24.0 kNm)[cite: 23]
- H1SHN0136 (42.0 kNm)[cite: 23]
- H2SHN0042 (12.0 kNm)[cite: 23]
- H2SHN0063 (15.0 kNm)[cite: 23]
- H2SHN0096 (24.0 kNm)[cite: 23]
- H2SHN0136 (42.0 kNm)[cite: 23]
- H2SHN0179 (60.0 kNm)[cite: 23]
- H2SHN0234 (85.0 kNm)[cite: 23]
- H3SHN0096 (24.0 kNm)[cite: 23]
- H3SHN0136 (42.0 kNm)[cite: 23]
- B2SHN0096 (Right-Angle)[cite: 23]
- B2SHN0136 (Right-Angle)[cite: 23]
- B3SHN0096 (Right-Angle)[cite: 23]
- B3SHN0151 (Right-Angle)[cite: 23]
- H2DHN0096 (Shrink Disc)[cite: 23]
- H2HHN0096 (Keyway Hollow)[cite: 23]
- H2KHN0096 (Splined Hollow)[cite: 23]
- AIQ® Core Sensor Module[cite: 23]
