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ROTEX ® GS
Operating/Assembly instructions
ROTEX
®
GS
Torsionally flexible jaw couplings type shaft coupling, clamping hubs,
Compact, clamping ring hubs light, clamping ring hubs,
DKM and their combinations according to directive 2014/34/EU
KTR-N
Sheet:
Edition:
ROTEX ® GS, shaft coupling
ROTEX ® GS, clamping hubs
45510 EN
1 of 40
23
ROTEX ® GS, Compact
ROTEX ® GS, clamping ring hubs light
ROTEX ® GS, clamping ring hubs steel
ROTEX ® GS, clamping ring hubs
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
ROTEX ® GS, DKM
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
45510 EN
2 of 40
23
ROTEX ® GS is a plug-in shaft coupling for measuring technology and automatic control engineering. It is able to compensate for shaft misalignment, for example caused by manufacturing inaccuracies, thermal expansion, etc.
Table of contents
Reference to EC Machinery Directive 2006/42/EC
3 Storage, transport and packaging
Assembly of the hubs (hub type 1.0, 1.1 and 1.2)
Assembly of the clamping hubs (hub types 2.0, 2.1, 2.5, 2.6, 2.8 and 2.9)
Assembly of clamping ring hubs (hub type 6.0 light, 6.0 steel and 6.0)
Disassembly of clamping ring hubs (hub type 6.0 light, 6.0 steel and 6.0)
Displacements - alignment of the couplings
6 Breakdowns, causes and elimination
9 Spares inventory, customer service addresses
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
Table of contents
Advice and instructions regarding the use in
KTR-N
Sheet:
Edition:
45510 EN
3 of 40
23
potentially explosive atmospheres 34
Intended use in potentially explosive atmospheres
Inspection intervals for couplings in
potentially explosive atmospheres
marking of couplings for potentially explosive atmospheres
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
1 Technical data
1.1 Types of hubs
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
45510 EN
4 of 40
23
Type 1.0
Hub with feather keyway and setscrew
Type 1.1
1)
Hub without feather keyway, with setscrew
Type 1.2 2)
Hub without feather keyway, without setscrew
Type 2.0 1)
Clamping hub single slot without feather keyway (up to size 14 standard)
Type 2.1
Clamping hub single slot with feather keyway
(up to size 14 standard)
Type 2.5 1)
Clamping hub double slot without feather keyway (from size 19 standard)
Type 2.6
Clamping hub double slot with feather keyway (from size 19 standard)
Type 2.8 (Compact) 1)
Short clamping hub C with axial slot, without feather keyway
(from size 24 standard)
(size 7 - 19 single slot)
Type 2.9 (Compact)
Short clamping hub C with axial slot, with feather keyway
(from size 24 standard)
(size 7 - 19 single slot)
1)
Type 6.0 light
Clamping ring hub light
(size 14 - 48)
Type 6.0 (steel)
Clamping ring hub steel
(size 19 - 90)
Type 6.0 3)
Clamping ring hub
(size 14 - 38)
Illustration 1: Types of hubs
Hubs, clamping hubs or similar types without feather keyway may be used in category 3 only and are marked with category 3 accordingly.
2) Hub type 1.2 is not approved for potentially explosive atmospheres!
3) Hub material - aluminium (Al-H); clamping ring material - steel
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
1 Technical data
1.2 Torques and finish bores
Table 1: Torques of spiders
Size
16
19
24
28
38
42
48
55
65
75
90
5
7
8
9
12
13
14
80 ShA-GS
-
-
-
-
5.0
6
-
-
-
-
-
0.3
0.7
0.7
1.8
3.0
3.6
4.0
92 ShA-GS
-
12
35
95
190
265
310
410
-
-
-
0.5
1.2
-
3.0
5.0
-
7.5
Spider 1) (component 2)
Rated torque [Nm]
98 ShA-GS
15.0
21
60
160
325
450
525
685
940
1920
3600
0.9
2.0
2.0
5.0
9.0
11.0
12.5
KTR-N
Sheet:
Edition:
64 ShD-GS
19.0
26
75
200
405
560
655
825
1175
2400
4500
-
2.4
2.4
6.0
12.0
14.5
16.0
24
28
38
42
48
55
65
75
90
5
7
8
9
12
13
14
16
19
1) Maximum torque of the coupling T
Kmax.
= rated torque of the coupling T
K rated
x 2
For coupling selection see catalogue drive technology "ROTEX ® GS"
2) When using the spider 72 ShD, we recommend to use hubs made of steel.
Table 2: Finish bores
Size
Unbore d d min.
1.0 1.1 1.2 2.0
Finish bore [mm] d max.
for hub type
2.1 2.5 2.6 x x x x x x x x
-
-
-
- x
-
-
-
-
-
8
10
12
14
15
20
22
30
40
-
5
-
6
2
3
-
4
4
28
38
45
55
62
74
80
95
110
-
7
-
10
12
-
16
-
24
-
-
-
-
-
-
-
-
-
6
7
-
11
12
-
16
-
-
-
-
-
-
-
-
-
-
-
5
7
-
11
12
-
16
-
-
-
-
-
-
-
-
-
-
-
5
7
-
11
12
-
16
-
-
-
-
-
-
-
-
-
-
-
-
7
-
11
12
-
16
-
-
28
38
45
50
55
68
70
80
90
-
-
-
24
-
-
-
-
-
28
38
45
45
55
68
70
80
90
-
-
-
24
-
-
-
-
-
2.8
-
-
-
32
35
45
-
-
-
-
7
8
9
12
12.7
16
16
27
2.9
-
-
-
32
35
45
-
-
-
-
7
8
9
12
12.7
16
16
27
45510 EN
5 of 40
23
72 ShD-GS 2)
-
-
97
260
525
728
852
1072
1527
3120
5850
-
-
-
-
-
-
-
6.0 light
32
38
48
51
55
-
14
-
20
-
-
-
-
-
6.0
28
38
48
51
55
70
70
80
105
-
-
-
20
-
-
-
-
-
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
1 Technical data
1.3 Coupling dimensions
Standard shaft coupling
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
45510 EN
6 of 40
23
Illustration 2: ROTEX ® GS
(size 5 - 38)
Illustration 3: ROTEX ® GS
(size 42 - 90)
Please refer to table 1 for torques and table 2 for finish bores.
Table 3: Dimensions - Standard shaft coupling
Size
Setscrew
DIN EN ISO 4029
G t
42
48
55
65
75
90
5
7
9
12
14
19
24
28
38
D
85
95
110
115
135
160
-
-
-
-
-
-
-
-
-
D
H
95
105
120
135
160
200
10
14
20
25
30
40
55
65
80 d
H
46
51
60
68
80
104
-
-
7.2
8.5
10.5
18
27
30
38
L
126
140
160
185
210
245
15
22
30
34
35
66
78
90
114
Dimensions [mm] l
1
, l
2
M, N E
Hub material - aluminium
5 - 5
7
10
11
-
-
-
8
10
12
11
25
30
35
45
-
-
-
-
-
13
16
18
20
24
Hub material - steel
50 28 26
56
65
32
37
28
30
75
85
100
47
53
62
35
40
45 b
20
21
22
26
30
34
4
6
8
10
10
12
14
15
18 s
3.0
3.5
4.0
4.5
5.0
5.5
0.5
1.0
1.0
1.0
1.5
2.0
2.0
2.5
3.0 a
4.0
4.0
4.5
4.5
5.0
6.5
4.0
6.0
1.5
3.5
2.0
3.0
3.0
4.0
4.0
M8
M8
M10
M10
M10
M12
M2
M3
M4
M4
M4
M5
M5
M8
M8
2.5
3.5
5.0
5.0
5.0
10
10
15
15
20
20
20
20
25
30
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
1 Technical data
1.3 Coupling dimensions
Clamping hubs
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
45510 EN
7 of 40
23
Illustration 4: ROTEX
®
GS hub type 2.0 (from size 5 - 14)
Illustration 5: ROTEX
®
GS hub type 2.5 (from size 19 - 90)
Please refer to table 1 for torques and table 2 for finish bores.
Table 4: Dimensions - clamping hubs
Size
5
7
9
12
14
19
24
28
38
42
48
55
65
75
90
D
-
-
-
-
-
-
-
-
-
D
H
10
14
20
25
30
40
55
65
80 d
H
85
95
95
105
46
51
110 120
115 135
135 160
60
68
80
160 200 104
-
-
7.2
8.5
10.5
18
27
30
38
Dimensions
3)
[mm]
15
22
30
34
35
66
78
90
114
L
126
140
50
56
160
185
210
65
75
85
245 100
5
7
10
11
11
25
30
35
45 l
1
, l
2
M, N E b s
-
-
-
-
-
Hub material - aluminium
- 5 4
-
-
-
8
10
12
6
8
10
13
16
18
20
24
10
12
14
15
18
Hub material - steel
28 26 20
32 28 21
37
47
53
62
30
35
40
45
22
26
30
34
0.5
1.0
1.0
1.0
1.5
2.0
2.0
2.5
3.0
3.0
3.5
4.0
4.5
5.0
5.5 a
Clamping screw DIN EN ISO 4029
(ROTEX ® GS 5 - DIN EN ISO 1207)
M
1 t
1 e D
K
T
A
[Nm]
4.0 M1.2 2.5
6.0 M2 3.5
1.5 M2.5 5.0
3.5 11.4 - 1)
5.0 16.5 0.37
7.5 23.4 0.76
3.5 M3 5.0 9.0 27.5 1.34
2.0 M3 5.0 11.5 32.2 1.34
3.0 M6 2) 11.0 14.5 2) 46.0 10.5 2)
3.0
4.0
4.0
M6 10.5 20.0 57.5 10.5
M8 11.5 25.0 73.0 25
M8 15.5 30.0 83.5 25
4.0 M10
4.0 M12
4.5 M12
4.5 M12
5.0 M16
6.5 M20
1) Slotted screw, tightening torque not defined
2) Size 19: Bore Ø22 - Ø24 with 2-off clamping screws M4, T
A
= 2.9 Nm and dimension e = 15.0
3) Transmittable friction torques of clamping hubs see table 5
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
18
21
26
33
36
40
32.0 93.5 69
36.0 105.0 120
42.5 119.5 120
45.0 124.0 120
51.0 147.5 295
60.0 176.0 580
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
1 Technical data
1.3 Coupling dimensions
Table 5: Friction torques and surface pressure of clamping hubs (hub type 2.0 and 2.5)
Size
Bore Ø
Ø2
Ø3
Ø4
Ø5
Ø6
Ø7
Ø8
Ø9
Ø10
Ø11
Ø12
Ø14
Ø15
Ø16
Ø18
Ø19
Ø20
Ø22
Ø24
Ø25
Ø28
Ø30
Ø32
Ø35
Ø38
Ø40
Ø42
Ø45
5
-
-
-
-
7
1.2
41
1.4
34
0.7
90
0.9
65
1.1
51
9
33
3.5
29
3.8
26
2.2
52
2.6
44
2.9
38
3.2
1.6
82
1.9
64
12
46
5.4
41
5.8
37
6.3
33
3.4
72
3.9
61
4.4
53
4.9
2.4
113
2.9
88
45510 EN
8 of 40
23
14 19 24 28 38 42 48 55 65 75 90
54
42
51
59
31
48
45
45
48
41
52
37
54
35
33
70
35
65
39
57
41
125
23
111
25
100
27
91
31
76
8.0
27
8.5
25
49
5.7
43
6.2
39
6.7
35
7.6
29
3.1
93
3.6
76
4.2
64
4.7
56
5.2
Transmittable friction torque T
R
of clamping hub [Nm]
Surface pressure [N/mm 2 ]
19
142
21
24
98
26
88
28
80
33
68
35
63
37
58
41
51
43
63
116
67
108
71
100
79
88
82
67
80
71
75
79
66
83 188
83
86
78
94
62
87
59
95
70 53 110
101 102 231
63 48 100
105 106 240 356
61 46 95 130
115 117 264 394
53 40 84 115
122 124 281 418
49 37 78 106
129 131 297 442 456
46 34 72 99 84
139 142 320 478 493 499
41 31 65 89 76 64
148 152 343 513 529 536
37 28 59 81 69 58
158 358 536 553 560
27
165
25
175
23
129
197
122
214
56
373
53
395
49
76
558
72
592
67
65
577
62
611
57
55
584
52
620
48
1107
89
1175
82
1764
116
1876
107
* Hub type 2.0 only
Clamping hubs without feather keyway may be used in category 3 only and are marked with category 3 accordingly.
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
45510 EN
9 of 40
23
1 Technical data
1.3 Coupling dimensions
Table 5 continued: Friction torques and surface pressure of clamping hubs (hub type 2.0 and 2.5)
Size
Bore Ø
Ø48
Ø50
Ø55
Ø60
Ø65
Ø70
Ø75
Ø80
Ø85
Ø90
5 7 9 12 14 19 24 28 38 42 48 55 65 75 90
Transmittable friction torque T
R
of clamping hub [Nm]
Surface pressure [N/mm 2 ]
417
45
624
62
646
53
655
45
1242
76
1985
100
431 646 668 677 1287 2057
43 59
699
53
51
724
45
43
734
38
73
1396
65
95
2235
86
778 789 1503 2409
41 34 59 77
830 842 1607 2579
37 31 54 71
882 895 1709 2746
34 29
946
26
49
1810
45
1908
42
39
65
2911
60
3072
56
2005 3231
52
3387
48
Clamping hubs without feather keyway may be used in category 3 only and are marked with category 3 accordingly.
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
1 Technical data
1.3 Coupling dimensions
Compact
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
45510 EN
10 of 40
23
Illustration 6: ROTEX ® GS 8, 13 and 16 Compact single slot (hub type 2.8/2.9)
Illustration 7: ROTEX ® GS 7, 9, 12, 14 and 19 Compact single slot (hub type 2.8/2.9)
Illustration 8: ROTEX ® GS 24 to 38 Compact axial slot (hub type 2.8/2.9)
Please refer to table 1 for torques and table 2 for finish bores.
Table 6: Dimensions - Compact
Size
7
8
9
12
13
14
16
19
24
28
38
D
H
14
15
20
25
25
30
30
40
55
65
80
D
K
16.6
17.3
21.3
26.2
25.7
31.6 1)
-
45.5 2)
57.5
69.0
86.0
L
18
20
24
26
26
32
32
50
54
62
76
Dimensions 3) [mm] l
1
, l
5
7
2
7
7
8
9.5
10.3
17
18
21
26
E
8
6
10
12
10
13
11.4
16
18
20
24 b
6
5
8
10
8
10
9.4
12
14
15
18 s
1
0.5
1
1
1
1.5
1
2
2
2.5
3 d h
-
6.2
-
-
10
-
14
-
-
-
-
Clamping screw DIN EN ISO 4762 t
2.5
4.0
3.5
3.5
4.0
4.5
5.3
9.0
11.0
12.0
15.0 e
5.0
5.4
6.7
8.3
8.0
10.0 1)
10.5
14.0 2)
20.0
23.8
29.5
M
M2
M2
M2.5
M3
M3
M4 1)
M4
M6 2)
M6
M8
M10
T
A
[Nm]
0.37
0.52
0.76
1.34
1.9
2.9 1)
4.1
10 2)
10
25
49
1) Bores from Ø14 with clamping screw M3, T
A
= 1.34 Nm, dimension e = 10.4 and dimension D
K
= 30.5
2) Bores from Ø21 with clamping screw M5, T
A
= 6 Nm, dimension e = 15.5 and dimension D
K
= 47.0
3) Transmittable friction torques of type Compact see table 7
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
1 Technical data
1.3 Coupling dimensions
Table 7: Friction torques and surface pressure of type Compact (hub type 2.8 and 2.9)
Size
Bore Ø
Ø3
Ø4
Ø5
Ø6
Ø7
Ø8
Ø9
Ø10
Ø11
Ø12
Ø14
Ø15
Ø16
Ø18
Ø19
Ø20
Ø22
Ø24
Ø25
Ø28
Ø30
Ø32
Ø35
Ø38
Ø40
Ø42
Ø45
7
0.8
173.5
0.9
105.1
1.0
72.1
1.0
53.4
1.1
41.7
8
1.5
37.0
1.7
32.4
0.65
86.4
0.85
64.8
1.1
51.9
1.3
43.2
9 12 13 14 16 19 24
Transmittable friction torque T
R
of clamping hub [Nm]
Surface pressure [N/mm 2 ]
1.9 3.4 2.2
151.6 273.6 145.8
2.0 3.6 2.75 7.1 4.8
102.6 183.6 116.6 262.2 158.7
2.1
75.1
3.7
133.4
3.3
97.2
7.4
189.6
5.8
132.3
2.2
58
2.3
46.6
2.4
38.6
3.9
102.3
4.1
81.7
4.2
67.2
4.4
3.8
83.3
4.4
72.9
4.9
64.8
5.5
7.7 6.4
144.8 113.4
8.0
115.1
8.2
94.3
8.5
7.7
99.2
8.7
88.2
9.6
24.3
191.8
25.0
155.7
25.7 21.2
56.5
4.6
48.5
4.7
42.2
58.3
6.0
53.0
6.6
48.6
79.1
8.8
67.6
9.1
58.7
5.8
27.2
5.9
24.4
6.1
22.1
79.4
10.5
72.2
11.6
66.1
13.5
56.7
14.5
52.9
15.4
49.6
129.5
26.3
109.9
27.0
94.7
28.4
73.1
29.0
65.2
29.7
58.6
31.1
48.4
31.7
44.4
82.3
23.3
74.8
25.4
68.6
29.7
58.8
31.8
54.9
33.9
51.4
38.2
45.7
40.3
43.3
32.4
40.9
25.4
26.5
26.4
23.1
32.9
59.4
29.4
63.6
27.4
67.9
25.7
42.4
41.1
46.7
37.4
50.9
34.3
53.0
45510 EN
11 of 40
23
28 38
36.8
77.8
64.4
85.5
58.5
93.3
53.7
97.2
123.5
82.2
135.8
74.7
148.2
68.5
154.3
51.5 65.8
108.9 172.9
46.0 58.7
116.6 185.2
42.9 54.8
124.4 197.5
40.2 51.4
136.1 216.1
47.0
234.6
43.3
246.9
41.1
259.3
39.1
277.8
36.5
54.4
92.0
58.3
85.9
62.2
80.5
70.0
71.5
73.9
67.8
92.6
109.6
98.8
102.7
111.1
91.3
117.3
86.5
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
1 Technical data
1.3 Coupling dimensions
Clamping ring hubs 6.0 light, 6.0 steel and 6.0
KTR-N
Sheet:
Edition:
45510 EN
12 of 40
23
Illustration 9: ROTEX
®
GS, clamping ring hubs
Please refer to table 1 for torques and table 2 for finish bores.
Table 8: Dimensions - Clamping ring hubs 6.0 light, 6.0 steel and 6.0
Extraction thread M
1
between clamping screws.
Clamping ring hub 6.0 light with block mounting
(hub and clamping ring mounted as a block)
1) From Ø55 tolerance G7/m6
Size
19
24
28
38
42
48
55
65
75
90
14
19
24
28
38
42
48
D
H
2) d
H
6.0 light (size 14 - 48)
6.0 (size 14 - 38)
L
30
40
55
65
10.5
18
27
30
50
66
78
90
80
95
105
38
46
51
114
126
140
6.0 steel (size 19 - 90)
40 18 66
55
65
80
27
30
38
78
90
114
95
105
120
135
160
200
46
51
60
68
80
104
126
140
160
185
210
245
Dimensions 4) [mm] l
1
, l
2 l
3
E b s
Material of hub/clamping ring – aluminium a
Hub material - aluminium/clamping ring material - steel
18.5
25
30
35
13.5
18
22
27
13
16
18
20
10
12
14
15
1.5
2.0
2.0
2.5
2.0
3.0
3.0
4.0
45
50
56
35
35
41
24
26
28
18
20
21
3.0
3.0
3.5
4.0
4.0
4.0
Material of hub and clamping ring - steel
25 18 16 12 2.0
30
35
45
22
27
35
18
20
24
14
15
18
2.0
2.5
3.0
50
56
65
75
85
100
35
41
45
55
63
75
26
28
30
35
40
45
20
21
22
26
30
34
3.0
3.5
4.0
4.5
5.0
5.5
3.0
3.0
4.0
4.0
4.0
4.0
4.5
4.5
5.0
6.5
Clamping screws DIN EN ISO 4762
M z 3) T
A
[Nm] M
1
M4
M5
M5
M6
M8
M10
M10
M12
M12
M16
M3
M4
M5
M5
M6
M8
M10
6
4
8
8
4
4
4
4
5
5
8
4
4
4
6
4
8
4.1
8.5
8.5
14
41
69
69
120
120
295
1.34
3
6
6
10
25
49
M4
M5
M5
M6
M8
M10
M10
M12
M12
M16
M3
M4
M5
M5
M6
M8
M10
2) Ø D
H
+ 2 mm with high speeds for expansion of spider
3) z = Number each clamping ring hub
4) Consider transmittable friction torques of the respective clamping ring hubs 6.0 light, 6.0 steel and 6.0 (see table 9 to 11)
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
1 Technical data
1.3 Coupling dimensions
Table 9: Friction torque and surface pressure of clamping ring hubs 6.0 light
KTR-N
Sheet:
Edition:
45510 EN
13 of 40
23
Ø6
Ø8
Ø9
Ø10
Ø11
Ø14
Ø15
Ø16
Ø19
Ø20
Ø24
Ø25
Ø28
Ø30
Ø32
Ø35
Ø38
Ø40
Ø42
Ø45
Ø48
Ø50
Ø55
Size
Bore Ø
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
G7/m6
G7/h6
14 19 24 28 38 42 48
Transmittable friction torque T
R
of clamping ring hub [Nm] / surface pressure [N/mm 2 ]
Nm N/mm 2 Nm N/mm 2 Nm N/mm 2 Nm N/mm 2 Nm N/mm 2 Nm N/mm 2 Nm N/mm 2
8.2 194
5.8 160
13.1 176
9.5 147
18.7 166
15.7 147
20.5 155
16.6 135
33
27
178
157
25.9 151
21.6 134
36.2 121
24.7 111
41
35
59
52
71
65
51
39
80
68
92
81
174
156
152
138
147
137
121
103
114
102
111
101
84
75
99
92
93
79
119
179
164
173
163
166
147
139 157
125 144
157 153
145 143
160 126
115
177 123
136 114
232 116
190 111
140
121
207
187
188
157
289
263
184
165
175
162
164
144
152
141
316 149
293 140
355 134
318 125
290
247
439
403
480
447
567
530
184
164
172
160
169
159
158 651
149 574
169
160
765 173
678 164
343
414 130
381 124
324 110
245 101
404 105
324 99
422 94
89 606
825
696
922
792
808
678
937
809
656
626
617
499
759
636
733
153 752
147 681
143 747
133 613
165
158
159
149
822 166
760 156
927 164
837 154
137 916
130 774
153
146
1121
1047
158
151
120 1001 141 1220 149
113 881 134 1085 141
117 1115 138 1357 145
111 1001 132 1231 140
114 1044 126 1318 136
110 888 119 1128 129
95 1218 122 1536 132
90 1058 117 1339 127
92 1404 118 1768 128
89 1241 115 1566 125
1432 111 1535 113
1295 107 1331 108
1823
1475
109
104
The transmittable friction torques of the clamping connection consider the max. fitting tolerance with shaft tolerance k6 resp. h6/bore H7, from
Ø55 G7/m6 or G7/h6. The friction torque is reduced with bigger fitting tolerance and use of a hollow shaft (see chapter 4.6).
The surface pressure of the clamping connection specified considers the minimum fitting tolerance with shaft fit k6 resp. h6/bore H7, from
Ø55 G7/m6 resp. G7/h6.
!
A calculation of the hollow shaft strength is necessary if hollow shafts are used (see chapter 4.6)!
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
1 Technical data
1.3 Coupling dimensions
Table 10: Friction torques and surface pressure of clamping ring hubs 6.0 steel
KTR-N
Sheet:
Edition:
45510 EN
14 of 40
23
Size
Bore Ø
Ø10
Ø11
Ø14
Ø15
Ø16
Ø19
Ø20
Ø24
Ø25
Ø28
Ø30
Ø32
Ø35
Ø38
Ø40
Ø42
Ø45
Ø48
Ø50
Ø55
Ø60
Ø65
Ø70
Ø80
Ø90
Ø95
19
Nm
24 28 38 42 48 55 65
Transmittable friction torque T
R
of clamping ring hub [Nm] / surface pressure [N/mm 2 ]
N/mm 2 Nm N/mm 2 Nm N/mm 2 Nm N/mm 2 Nm N/mm 2 Nm N/mm 2 Nm N/mm 2 Nm
75
N/mm 2
90
Nm N/mm 2 Nm N/mm 2
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
G7/m6
G7/h6
G7/m6
G7/h6
G7/m6
G7/h6
H7/k6 27 335 25 296
H7/h6 15 262 10 223
H7/k6 32 334 30 296
H7/h6 18 262 12 223
H7/k6 69 298 70 260
H7/h6 57 262 55 223
H7/k6 84 288 87 250 108 296
H7/h6 74 262 74 223 74 243
H7/k6 57 241 56 212 131 289
H7/h6 38 197 32 168 97 243
H7/k6 94 228 97 200 207 277
H7/h6 76 197 72 168 172 243
H7/k6 110 221 114 193 148 237 208 248
H7/h6 94 197 93 168 94 190 136 200
H7/k6 116 157 253 217 353 229
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
84 130 207 190 290 200
133 153 285 213 395 120 445 246
103 130 242 190 337 200 387 221
192 141 315 190 439 200 495 219
173 130 267 168 373 178 429 197
382 184 531 194 595 213 616 217
G7/m6
G7/h6
G7/m6
G7/h6
G7/m6
G7/h6
G7/m6
G7/h6
343 168 476 178 540 197 513 191
330 168 463 177 526 194 704 216
260 144 367 152 429 169 590 191
863
1665
1454
1605
1287
141
110
98
99
84
1275
2429
2142
2368
1949
161
125
113
112
97
3040
2708
2983
2507
793 144 718 149 962 167 918 145 1355 163 1710 180
721 133 599 131 822 149 750 126 1135 144 1460 160
134 687
1043
970
1061
978
148
140
131
133
125
924
1379
1290
1222
1073
167
158
149
143
130
1543 138 1277 115 1887 130 2384 144 4249 205
1373 125 972 95 1488 110 1929 123 3556 178
1110
934
1247
1089
433 160 603 169 677 185 899 208 863 179
377 144 525 152 600 169 806 191 750 161
503 150 593 152 671 166 896 186 856 161
453 137 491 133 569 148 775 167 710 141
689
601
148 775 162 1030 182 991 157
129
114
126
114
1446
1635
1404
1827
1619
178
776 132 872 144 1160 162 1119 140 1637 158 2053 175
677 119 773 131 1042 149 976 126 1447 144 1836 160
145
130
143
130
2059
1797
2294
2056
160
145
158
145
138
126
124
108
3845
3445
4795
4080
5859
5260
221
200
191
168
186
170
2008 95 2930 108 3664 120 5906 168
1792 86 2635 99 3323 110 5153 150
4293 106 7036 150
3945 98 6253 136
8047 136
7104 123
9247 134
8484 124
The transmittable friction torques of the clamping connection consider the max. fitting tolerance with shaft tolerance k6 resp. h6/bore H7, from
Ø55 G7/m6 or G7/h6. The friction torque is reduced with bigger fitting tolerance and use of a hollow shaft (see chapter 4.6).
The surface pressure of the clamping connection specified considers the minimum fitting tolerance with shaft fit k6 resp. h6/bore H7, from
Ø55 G7/m6 resp. G7/h6.
!
A calculation of the hollow shaft strength is necessary if hollow shafts are used (see chapter 4.6)!
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
1 Technical data
1.3 Coupling dimensions
Table 10 continued: Friction torques and surface pressure of clamping ring hubs 6.0 steel
45510 EN
15 of 40
23
Size
Bore Ø
19
Nm
24 28 38 42 48 55 65
Transmittable friction torque T
R
of clamping ring hub [Nm] / surface pressure [N/mm
2
]
75
N/mm 2 Nm N/mm 2 Nm N/mm 2 Nm N/mm 2 Nm N/mm 2 Nm N/mm 2 Nm N/mm 2 Nm N/mm 2
90
Nm N/mm 2 Nm N/mm 2
Ø100
Ø105
G7/m6
G7/h6
G7/m6
G7/h6
9575 126
8722 117
10845 124
10202 118
The transmittable friction torques of the clamping connection consider the max. fitting tolerance with shaft tolerance k6/bore H7, from
Ø55 G7/m6. The friction torque is reduced with bigger fitting tolerance and use of a hollow shaft (see chapter 4.6).
The surface pressure of the clamping connection specified considers the minimum fitting tolerance with shaft fit k6/bore H7, from Ø55 G7/m6.
!
A calculation of the hollow shaft strength is necessary if hollow shafts are used (see chapter 4.6)!
Table 11: Friction torque and surface pressure of clamping ring hubs 6.0
Size 14 19 24 28 38
Bore Ø
Ø6
Ø10
Ø11
Ø14
Ø15
Ø16
Ø19
Ø20
Ø22
Ø24
Ø25
Ø28
Ø30
Ø32
Ø35
Ø38
Ø40
Ø42
Ø45
8.6
225
13.8
130
14.7
118
22.7
108
153
90
149
Transmittable friction torque T
R
of clamping ring hub [Nm]
Surface pressure [N/mm 2 ]
41
272
45
248
48
214
62
211
68
203
67
171
83
67
182
74
175
72
148
90
142
243
154
231
189
132
97
129
99
107
112
102
120
100
143
96
157
250
153
280
136
307
131
310
203
188
178
212
167
237
115
353
110
389
103
126
501
120
533
107
572
104
615
172
356
167
398
148
436
142
442
102
644
92
269
196
307
183
337
The transmittable friction torques of the clamping connection consider the max. fitting tolerance with shaft tolerance k6/bore H7. The friction torque is reduced with bigger fitting tolerance and use of a hollow shaft (see chapter 4.6).
The surface pressure of the clamping connection specified considers the minimum fitting tolerance with shaft fit k6/bore H7.
A calculation of the hollow shaft strength is necessary if hollow shafts are used (see
! chapter 4.6)!
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
1 Technical data
1.3 Coupling dimensions
DKM
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
45510 EN
16 of 40
23
Illustration 10: ROTEX ® GS DKM
Please refer to table 1 for torques and table 2 for finish bores.
Table 12: Dimensions - DKM
Size
5
7
9
12
14
19
24
28
38
42
48
55
D
-
-
-
-
-
-
-
-
-
85
95
110
D
H
10
14
20
25
30
40
55
65
80
95
105
120
10.5
18
27
30
38
46
51
60 d
H d
H1 l
1
, l
2
Dimensions [mm]
M, N l
11 l
12
L
DKM
Spacer material - aluminium/hub material depends on hub type
-
-
7.2
8.5
-
-
-
-
5
7
10
11
-
-
-
-
3
4
5
6
13
20
25
30
23
34
45
52
-
18
27
30
38
46
51
60
11
25
30
35
45
50
56
65
-
-
-
-
-
28
32
37
8
10
16
18
20
22
24
28
34
42
52
58
68
74
80
88
56
92
112
128
158
174
192
218
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
5
8
10
12
13
16
18
20
24
26
28
30
E b
4
6
8
10
10
12
14
15
18
20
21
22 s
0.5
1.0
1.0
1.0
1.5
2.0
2.0
2.5
3.0
3.0
3.5
4.0 a
KTR-N dated 2019-11-22
4.0
6.0
1.5
3.5
2.0
3.0
3.0
4.0
4.0
4.0
4.0
4.5
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
45510 EN
17 of 40
23
2 Advice
The ROTEX ® GS coupling was developed for a backlash-free power transmission and easy plug-in assembly. This backlash-free power transmission arises in the area of prestress (see illustration 11).
The big concave surface contact results in a lower surface pressure on the involute tooth. Consequently the tooth can be overloaded many times over with no wear/deformation.
Safe operation in the range of prestress is ensured, because the coupling operates according to the principle of positive-locking rubber spring prestress with high damping features. The star-shape coupling spider is inserted in the cams of the hubs which are machined specifically accurately with a small amount of prestress, resulting in the necessary backlash-free power transmission.
The axial insertion force varies depending on the coupling size,
Illustration 11: Prestress of spider different kinds of Shore hardness and production tolerances.
The flexible teeth compensating for misalignment are radially supported in the internal diameter by means of a web. An external deformation is limited by the concave shape of the cams, ensuring smooth operation even with bigger masses to be accelerated (e. g. machine tables, articulated arms, etc.).
The flexible spiders for the GS series are available in five different kinds of Shore hardness, injected in different colours, either as a torsionally soft or hard material.
2.1 General advice
Please read through these operating/assembly instructions carefully before you start up the coupling.
Please pay special attention to the safety instructions!
The ROTEX ® GS coupling is suitable and approved for the use in potentially explosive atmospheres. When using the coupling in potentially explosive atmospheres, observe the special advice and instructions regarding safety in enclosure A.
In order to ensure the operating principle of ROTEX ® GS and avoid early wear of the coupling, a respective operating factor „S
B
“ has to be considered with the selection, each depending on the application (see catalogue
"Drive Technology"). Temperatures and shocks are provided with the corresponding factors, too (see catalogue
"Drive Technology").
The operating/assembly instructions are part of your product. Please store them carefully and close to the coupling. The copyright for these operating/assembly instructions remains with KTR.
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
45510 EN
18 of 40
23
2 Advice
2.2 Safety and advice symbols
Warning of potentially explosive atmospheres
This symbol indicates notes which may contribute to preventing bodily injuries or serious bodily injuries that may result in death caused by explosion.
STOP Warning of personal injury
This symbol indicates notes which may contribute to preventing bodily injuries or serious bodily injuries that may result in death.
Warning of product damages !
General advice
This symbol indicates notes which may contribute to preventing material or machine damage.
This symbol indicates notes which may contribute to preventing adverse results or conditions.
Warning of hot surfaces
This symbol indicates notes which may contribute to preventing burns with hot surfaces resulting in light to serious bodily injuries.
2.3 General hazard warnings
STOP
With assembly, operation and maintenance of the coupling it has to be made sure that the entire drive train is secured against accidental switch-on. You may be seriously hurt by rotating parts. Please make absolutely sure to read through and observe the following safety indications.
•
All operations on and with the coupling have to be performed taking into account "safety first".
•
Please make sure to switch off the power pack before you perform your work on the coupling.
•
Secure the power pack against accidental switch-on, e. g. by providing warning signs at the place of switch-on or removing the fuse for current supply.
•
Do not reach into the operating area of the coupling as long as it is in operation.
•
Please secure the coupling against accidental contact. Please provide for the necessary protection devices and covers.
2.4 Intended use
You may only assemble, operate and maintain the coupling if you
•
have carefully read through the operating/assembly instructions and understood them
•
are technically qualified and specifically trained (e. g. safety, environment, logistics)
•
are authorized by your company
The coupling may only be used in accordance with the technical data (see chapter 1). Unauthorized modifications on the coupling design are not admissible. We will not assume liability for any damage that may arise. In the interest of further development we reserve the right for technical modifications.
The ROTEX ® GS described in here corresponds to the technical status at the time of printing of these operating/assembly instructions.
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
45510 EN
19 of 40
23
2 Advice
2.5 Coupling selection
!
For a long-lasting and failure-free operation of the coupling it must be selected according to the selection instructions (following DIN 740, part 2 with specific factors) for the particular application (see catalogue drive technology "ROTEX ® GS").
If the operating conditions (performance, speed, modifications on engine and machine) change, the coupling selection must be reviewed.
Please make sure that the technical data regarding torque refer to the spider only. The transmittable torque of the shaft-hub-connection must be reviewed by the customer and is subject to his responsibility.
For drives subject to torsional vibrations (drives with cyclic stress due to torsional vibrations) it is necessary to perform a torsional vibration calculation to ensure a reliable selection. Typical drives subject to torsional vibrations are e. g. drives with diesel engines, piston pumps, piston compressors etc. If requested, KTR will perform the coupling selection and the torsional vibration calculation.
2.6 Reference to EC Machinery Directive 2006/42/EC
The couplings supplied by KTR should be considered as components, not machines or partly completed machines according to EC Machinery Directive 2006/42/EC. Consequently KTR does not have to issue a declaration of incorporation. For details about safe assembly, start-up and safe operation refer to the present operating/assembly instructions considering the warnings.
3 Storage, transport and packaging
3.1 Storage
The coupling hubs made of steel are supplied in preserved condition and can be stored at a dry and roofed place for 6 - 9 months.
The coupling hubs made of aluminium can be stored at a dry and roofed place for several years.
The features of the coupling spiders (elastomers) remain unchanged for up to 5 years with favourable storage conditions.
!
The storage rooms must not include any ozone-generating devices like e. g. fluorescent light sources, mercury-vapour lamps or electrical high-voltage appliances.
Humid storage rooms are not suitable.
Please make sure that condensation is not generated. The best relative air humidity is less than 65 %.
3.2 Transport and packaging
!
In order to avoid any injuries and any kind of damage please always make use of proper transport and lifting equipment.
The couplings are packed differently each depending on size, number and kind of transport. Unless otherwise contractually agreed, packaging will follow the in-house packaging specifications of KTR.
Please observe protection note ISO 16016.
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45510 EN
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4 Assembly
The coupling is generally supplied in individual parts. Before assembly the coupling has to be inspected for completeness.
4.1 Components of the coupling
Features of standard spiders
Spider hardness
(Shore)
Size
Material
80 ShA-GS
(blue)
5 - 24
Polyurethane
92 ShA-GS
(yellow)
5 - 55
Polyurethane
98 ShA-GS
(red)
5 - 90
Polyurethane
Increasing hardness
64 ShD-H-GS
(green)
7 - 38
Hytrel
64 ShD-GS
(green)
42 - 90
Polyurethan e
72 ShD-H-GS
(grey)
24 - 38
Hytrel
72 ShD-GS
(grey)
42 - 90
Polyurethane
Marking
(colour)
Components of ROTEX ® GS, hub type 1.0, 1.1 or 1.2
Component Quantity Description
1
2
3
2
1
2
Hub
Spider
Setscrew DIN EN ISO 4029
Illustration 12: ROTEX ® GS
(size 5 - 38)
Illustration 13: ROTEX ® GS
(size 42 - 90)
Hubs, clamping hubs or similar types without feather keyway may be used in category 3 only and are marked with category 3 accordingly.
Hub type 1.2 is not approved for potentially explosive atmospheres!
Please observe protection note ISO 16016.
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ROTEX ® GS
Operating/Assembly instructions
4 Assembly
4.1 Components of the coupling
Components of ROTEX ® GS clamping hubs, hub type 2.0, 2.1, 2.5 or 2.6
Component Quantity Description
1
2
3
2
1
2
Clamping hub
Spider
Cap screw DIN EN ISO 4762
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45510 EN
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Illustration 14: ROTEX ® GS clamping hub
Hubs, clamping hubs or similar types without feather keyway may be used in category 3 only and are marked with category 3 accordingly.
Components of ROTEX ® GS Compact, hub type 2.8 or 2.9
Component Quantity Description
1
2
3
2
1
2 / 4
Clamping hub C
Spider
Cap screw DIN EN ISO 4762
Illustration 15: ROTEX
®
GS Compact
(size 7 - 19)
Illustration 16: ROTEX
®
GS Compact
(size 24 - 38)
Hubs, clamping hubs or similar types without feather keyway may be used in category 3 only and are marked with category 3 accordingly.
Please observe protection note ISO 16016.
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4 Assembly
4.1 Components of the coupling
Components of ROTEX ® GS clamping ring hubs, hub type 6.0 light, 6.0 steel or 6.0
Component Quantity Description
1.1
1.2
2
3
2
2
1 see table
5, 6 and 7
Clamping ring
Clamping ring hub
Spider
Cap screw DIN EN ISO 4762
45510 EN
22 of 40
23
Illustration 17: ROTEX ® GS clamping ring hub
Components of ROTEX ® GS DKM
Component
1
2
3
4
Quantity
2
2
1
2
Description
Hub
Spider
DKM spacer
Setscrew DIN EN ISO 4029
Illustration 18: ROTEX ® GS DKM
Hubs, clamping hubs or similar types without feather keyway may be used in category 3 only and are marked with category 3 accordingly.
Hub type 1.2 is not approved for potentially explosive atmospheres!
Please observe protection note ISO 16016.
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4 Assembly
4.2 Advice for assembly
Subject to its design ROTEX ® GS allows to axially plug in the coupling having assembled the hubs onto the shaft journal. Consequently there is no need for subsequent screwing and the respective mounting holes in the housing.
The pegs on the spider arranged reciprocally prevent a contact between the spider and the hubs over the full surface. Observing the distance dimension E, the ability for displacement of the coupling is ensured in this way.
All teeth are chamfered on the face which allows for blind assembly. When the coupling hubs are pushed together with the ROTEX ® GS spider an axial assembly force is generated resulting from the flexible prestress of the starshape elastomer. This assembly force varies depending on the coupling size, spider hardness and machining tolerances.
The axial insertion force is offset after having pushed together the hubs and consequently does not mean any risk of axial load affecting adjacent bearings.
The mounting force can be reduced by lightly greasing or lubricating the elastomer or the hubs. For this purpose please only use oils and greases on a mineral oil basis without any additives. Lubricants on a silicone basis (e. g.
Optimol Optisit WX) or vaseline have proven their worth, too.
4.3 Advice for finish bore
STOP
The maximum permissible bore diameters d (see chapter 1
- technical data) must not be exceeded. If these figures are disregarded, the coupling may tear. Rotating particles may cause danger to life.
•
Hub bores machined by the customer have to observe concentricity or axial runout, respectively (see illustration
19).
•
Please make absolutely sure to observe the figures for
Ø d max
.
•
Carefully align the hubs when the finish bores are drilled.
•
Please provide for a setscrew according to
DIN EN ISO 4029 with a cup point or an end plate to fasten the hubs axially.
Illustration 19: Concentricity and axial run-out
!
The customer bears the sole responsibility for all machining processes performed subsequently on unbored or pilot bored as well as finish machined coupling components and spare parts. KTR does not assume any warranty claims resulting from insufficient remachining.
KTR supplies unbored or pilot bored coupling components and spare parts only upon explicit request of the customer. These parts are additionally marked with the symbol .
Reference to unbored resp. pilot bored coupling components with explosion protection marking:
Basically the company KTR supplies couplings resp. coupling hubs with explosion protection marking as an unbored or pilot bored type only on explicit request of the customer. The prerequisite is a declaration of exemption submitted by the customer assuming any responsibility and liability for remachining performed properly.
Table 13: Setscrew DIN EN ISO 4029
Size
Dimension G
Dimension t
Tightening torque T
A
[Nm]
5
M2
2.5
Please observe protection note ISO 16016.
7 9
M3 M4
3.5 5
0.35 0.6 1.5
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12 14
M4 M4
5 5
1.5 1.5
19 24
M5 M5
10 10
2 2
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28 38
M8 M8
15 15
10 10
42 48 55 65 75 90
M8 M8 M10 M10 M10 M12
20 20 20 20 25 30
10
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10 17 17 17 40
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ROTEX ® GS
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4 Assembly
4.4 Assembly of the hubs (hub type 1.0, 1.1 and 1.2)
We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy before assembly.
Before starting with the assembly preserving agents have to be removed from the bores. Moreover, the shaft ends have to be cleaned carefully, too.
Please note the manufacturer’s instructions regarding the use of detergents.
!
Heating the hubs lightly (approx. 80 °C) allows for an easier mounting on the shaft.
Please pay attention to the ignition risk in potentially explosive atmospheres!
STOP
Touching the heated hubs causes burns.
Please wear safety gloves.
!
With the assembly please make sure that the distance dimension E (see table 3 and 12) is observed to allow for axial clearance of the spider when in operation.
Disregarding this advice may cause damage to the coupling.
If used in potentially explosive atmospheres the setscrews to fasten the hubs as well as all screw connections must be secured against working loose additionally, e. g. conglutinating with Loctite (average strength).
•
Mount the hubs on the shaft of driving and driven side.
•
Insert the spider into the cam section of the hub on the driving or driven side.
•
Shift the power packs in axial direction until the distance dimension E is achieved.
•
If the power packs are already firmly assembled, shifting the hubs axially on the shafts allows for setting the distance dimension E.
•
Applies with hub type 1.0 and 1.1 only:
Fasten the hubs by tightening the setscrews DIN EN ISO 4029 with a cup point (tightening torques see table 13).
If the shaft diameters with inserted feather key are smaller than dimension d
H
(see table 3 and 12) of the spider, one or two shaft ends may protude into the spider.
Hubs, clamping hubs or similar types without feather keyway may be used in category 3 only and are marked with category 3 accordingly.
Hub type 1.2 is not approved for potentially explosive atmospheres!
Please observe protection note ISO 16016.
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4 Assembly
4.5 Assembly of the clamping hubs (hub types 2.0, 2.1, 2.5, 2.6, 2.8 and 2.9)
The power transmission of ROTEX ® GS clamping hubs (hub type 2.0, 2.5 and 2.8) is frictionally engaged.
With hub type 2.1, 2.6 and 2.9 a feather key additionally provides for positive locking power transmission.
If used in potentially explosive atmospheres all screw connections must be secured against working loose additionally, e. g. conglutinating with Loctite (average strength).
•
Clean and degrease the hub bore and the shaft.
•
Lightly detach the clamping screws.
•
Slip the hub onto the shaft. Please observe dimension l
1
or l
2
.
•
Tighten the clamping screws at the tightening torques specified in table 4.
With hub type 2.8 or 2.9 (with feather keyway) the screws have to be tightened alternately in equal steps at the tightening torques specified in table 6.
!
The transmittable friction torques of the clamping hubs depend on the bore diameter.
Illustration 20: Assembly of clamping hub
Please note: hub type 2.8 or 2.9 have 2 clamping screws
Hubs, clamping hubs or similar types without feather keyway may be used in category 3 only and are marked with category 3 accordingly.
!
If the clamping screws are not tightened at the correct tightening torque, there is the risk of a) a fracture of the hub and plastic deformation with a too high tightening torque T
A b) early slippling, untightening of the screws with a too low tightening torque T
A
4.6 Assembly of clamping ring hubs (hub type 6.0 light, 6.0 steel and 6.0)
The power transmission of ROTEX ® GS clamping hubs is frictionally engaged. The necessary surface pressure is transmitted via the clamping ring with internal taper to the taper hub and consequently to the shaft. The friction torques specified in table 5 to 7 consider a fit pair H7/k6, from Ø55 G7/m6. With a bigger fitting tolerance the friction torques specified in table 9 to 11 are reduced.
The strength and dimensions of the shafts (specifically hollow shafts) have to be dimensioned such that sufficient safety against plastic deformation is ensured. This may roughly be reviewed as per the following criterion.
Please observe protection note ISO 16016.
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4 Assembly
4.6 Assembly of clamping ring hubs (hub type 6.0 light, 6.0 steel and 6.0)
For clamping connections with hollow shafts the required internal diameter of the hollow shaft d iW
is calculated based on the following formula: d iW
d
R p 0 , 2
R
−
p
2
p
W
0 , 2
45510 EN
26 of 40
23
Please observe protection note ISO 16016.
Shear stress on the internal shaft diameter for hollow shaft:
tiW
−
2
1
−
p
W
C
W
2
N / mm 2
Shear stress for solid shaft: tW
= − p
W
N / mm 2
R p0.2
= yield strength of shaft material [N/mm 2 ] p
W
= surface pressure of hub/shaft [N/mm 2 ] d iW
= internal diameter of hollow shaft [mm] d = shaft diameter [mm]
C
W
= d iW
/ d
The strength required is not provided if the hollow shaft bore exceeds the max. internal bore calculated or if the shear stress exceeds the yield strength of the material.
For a detailed calculation please contact KTR.
If used in potentially explosive atmospheres all screw connections must be secured against working loose additionally, e. g. conglutinating with Loctite (average strength).
•
Clean the hub bore and shaft and review for dimensional accuracy, afterwards lubricate with a thin oil (e. g. Castrol 4 in 1, Klüber Quietsch-Ex or WD 40).
!
Oils and greases containing molybdenum disulfide or other high-pressure additives as well as internal lubricants must not be used.
•
Lightly untighten the clamping screw and pull the clamping ring from the hub only marginally to make sure that the clamping ring is fitted loosely.
•
Shift the clamping ring hub onto the shaft. Dimension l
3
should at least be observed (see table 8).
•
Tighten the clamping screws evenly crosswise gradually to the tightening torque specified in table 8. Repeat this process until all clamping screws have reached the tightening torque.
Illustration 21: Assembly of clamping ring hub with clamping ring
!
If the clamping screws are not tightened at the correct tightening torque, there is the risk of a) a fracture of the hubs/cams and plastic deformation with a too high tightening torque T
A b) early slippling, untightening of the screws with a too low tightening torque T
A
•
Applies with hub type 6.0 light only:
Tighten the clamping screws evenly gradually and crosswise at 1/3 or 2/3 tightening torque T
A
, respectively
(see table 8) until the ring gets in contact. Afterwards tighten the screws at the tightening torque mentioned in table 8 one after another.
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4 Assembly
4.7 Disassembly of clamping ring hubs (hub type 6.0 light, 6.0 steel and 6.0)
Unscrew the clamping screws evenly one after another. During every revolution every screw may only be unscrewed by half a turn. Unscrew all clamping screws by 3 - 4 pitches.
Remove the screws located next to the extraction threads and screw them into the respective extraction threads until they fit.
The clamping ring is released by tightening the screws in the extraction threads evenly gradually and crosswise.
!
If these hints are not observed, the operation of the coupling may be affected.
Illustration 22: Disassembly of clamping ring hub with clamping ring
If the assembly is repeated the bore of the hub and shaft have to be cleaned and afterwards lubricated with a thin oil (e. g. Castrol 4 in 1, Klüber Quietsch-Ex or WD 40). The same applies for the taper surfaces of clamping ring hub and clamping ring.
Oils and greases containing molybdenum disulfide or other high-pressure additives as well
! as internal lubricants must not be used.
Applies with hub type 6.0 light only:
If the assembly is repeated the taper surfaces, bores of the hub and the shaft have to be cleaned. The bore of the hub and shaft have to be lubricated with thin oil (e. g. Castrol 4 in 1,
Klüber Quietsch-Ex or WD 40). Lightly paint the taper surfaces of the clamping ring hub or clamping ring with the grease Gleitmo 800, afterwards twist the components against one another by one revolution in order to spread the grease evenly.
4.8 Displacements - alignment of the couplings
The displacement figures specified in tables 14 and 15 provide for sufficient safety to compensate for external influences like, for example, thermal expansion or foundation settling.
!
In order to ensure a long service life of the coupling and avoid dangers with the use in potentially explosive atmospheres, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures specified (see tables 14 and 15). If the figures are exceeded, the coupling will be damaged.
Please note:
The more accurate the alignment of the coupling, the longer is its service life.
If used in potentially explosive atmospheres for explosion group IIC, only half of the displacement figures (see tables 14 and 15) is permissible.
•
The displacement figures specified in tables 14 and 15 are maximum figures which must not arise in parallel.
If radial and angular displacements arise at the same time, the permissible displacement values may only be used proportionally (see illustration 24).
•
Please inspect with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 14 and
15 can be observed.
Please observe protection note ISO 16016.
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ROTEX ® GS
Operating/Assembly instructions
4 Assembly
4.8 Displacements - alignment of the couplings
KTR-N
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Edition:
45510 EN
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23
Angular displacements
K w
[mm] = L
1max
- L
1min
Radial displacements
Illustration 23: Displacements
Axial displacements
L max
= L +/-
K a
Examples of the displacement combinations specified in illustration 24:
Example 1:
K r
= 30%
K w
= 70%
Example 2:
K r
K w
= 60%
= 40%
Illustration 24:
Combinations of displacement
24
28
38
42
48
55
65
75
90
12
13
14
16
19
5
7
8
9
K total
=
K r
+
K w
100 %
Table 14: Displacement figures
Size
Max. axial displacement
K a
[mm]
Max. radial displacement
K r
[mm]
80
ShA-
GS
92
ShA-
GS
98
ShA-
GS
64
ShD-
GS
72
ShD-
GS
+0.4 / -0.2 0.12 0.06 0.04 -
+0.6 / -0.3 0.15 0.10 0.06 0.04
+0.6 / -0.5 0.15 - 0.08 0.06
+0.8 / -0.4 0.19 0.13 0.08 0.05
+0.9 / -0.4 0.20 0.14 0.08 0.05
+0.9 / -0.8 0.20 - 0.08 0.05
+1.0 / -0.5 0.21 0.15 0.09 0.06
+1.0 / -0.8 0.21 - 0.10 0.08
+1.2 / -0.5 0.15 0.10 0.06 0.04
+1.4 / -0.5
+1.5 / -0.7
+1.8 / -0.7
+2.0 / -1.0
+2.1 / -1.0
+2.2 / -1.0
+2.6 / -1.0
+3.0 / -1.5
+3.4 / -1.5
-
-
-
-
-
-
-
-
-
0.14
0.15
0.17
0.19
0.23
0.24
-
-
-
0.10
0.11
0.12
0.14
0.16
0.17
0.18
0.21
0.23
0.07
0.08
0.09
0.10
0.11
0.12
0.13
0.15
0.17
0.04
0.05
0.06
0.07
0.08
0.09
0.10
0.11
0.13
-
-
-
-
-
-
-
-
-
80
ShA-GS
Max. angular displacement
K w
[degree/mm]
92
ShA-GS
98
ShA-GS
64
ShD-GS
Degree mm Degree mm Degree mm Degree mm
72
ShD-GS
Degree mm
-
-
-
-
-
-
-
-
-
1.1 0.2 1.0 0.15 0.9 0.15 - -
1.1 0.25 1.0 0.2 0.9 0.2 0.8 0.2
1.1 0.4 - - 0.9 0.3 0.8 0.3
1.1 0.5 1.0 0.35 0.9 0.3 0.8 0.3
1.1 0.5 1.0 0.45 0.9 0.4 0.8 0.35 -
1.1 0.5 - - 0.9 0.4 0.8 0.35 -
1.1 0.6 1.0 0.5 0.9 0.5 0.8 0.4
1.1 0.6 - - 0.9 0.5 0.8 0.4
1.1 0.75 1.0 0.7 0.9 0.6 0.8 0.55 -
-
-
-
-
-
-
1.0
1.0
1.0
1.0
1.0
1.0
-
-
-
1.0
1.1
1.4
1.65
1.85
2.1
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.85
1.0
1.25
1.5
1.65
1.85
2.1
2.5
3.1
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.75
0.9
1.1
1.3
1.45
1.7
1.9
2.2
2.8
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.65
0.8
1.0
1.1
1.3
1.4
1.6
2.0
2.4
-
-
-
-
-
-
-
-
-
The permissible displacement figures of the flexible ROTEX ® GS couplings specified are general standard values taking into account the load of the coupling up to the rated torque T
KN
of the coupling and an ambient temperature of +30 °C.
Please observe protection note ISO 16016.
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ROTEX ® GS
Operating/Assembly instructions
4 Assembly
4.8 Displacements - alignment of the couplings
Table 15: Displacement figures - type DKM
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Edition:
45510 EN
29 of 40
23
Size
5
7
9
12
14
19
24
28
38
42
48
55
Max. axial displacement
K a
[mm]
+0.4 / -0.4
+0.6 / -0.6
+0.8 / -0.8
+0.9 / -0.9
+1.0 / -1.0
+1.2 / -1.0
+1.4 / -1.0
+1.5 / -1.4
+1.8 / -1.4
+2.0 / -2.0
+2.1 / -2.0
+2.2 / -2.0
80
ShA-GS
-
-
-
-
0.15
0.23
0.29
0.35
0.40
0.49
-
-
Max. radial displacement
K r
[mm]
92
ShA-GS
0.14
0.21
0.26
0.32
0.37
0.45
0.59
0.66
0.77
0.84
0.91
1.01
98
ShA-GS
0.13
0.19
0.24
0.29
0.33
0.41
0.53
0.60
0.69
0.75
0.82
0.91
64
ShD-GS
-
0.17
0.21
0.25
0.29
0.36
0.47
0.53
0.61
0.67
0.73
0.81
72
ShD-GS
-
-
-
-
-
-
0.42
0.46
0.54
0.59
0.64
0.71
Max. angular displacement
K w
[degree]
80
ShA-GS
1.1
1.1
1.1
1.1
1.1
1.1
-
-
-
-
-
-
92
ShA-GS
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
98
ShA-GS
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
64
ShD-GS
-
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
72
ShD-GS
-
-
-
-
-
-
0.7
0.7
0.7
0.7
0.7
0.7
The permissible displacement figures of the flexible ROTEX ® GS couplings specified are general standard values taking into account the load of the coupling up to the rated torque T
KN
of the coupling and an ambient temperature of +30 °C.
5 Start-up
Before start-up of the coupling, inspect the tightening of the setscrews in the hubs, the alignment and the distance dimension E and adjust, if necessary, and also inspect all screw connections for the tightening torques specified.
If used in potentially explosive atmospheres the setscrews to fasten the hubs as well as all screw connections must be secured against working loose additionally, e. g. conglutinating with Loctite (average strength).
Finally the coupling protection against accidental contact must be fitted. It is required in accordance with
DIN EN ISO 12100 (Safety of Machinery) and directive 2014/14/EU and must protect against
•
access with a little finger
•
falling down of solid foreign objects.
The cover may provide for openings intended for necessary heat dissipation. These openings have to comply with
DIN EN ISO 13857.
The cover must be electrically conductive and included in the equipotential bonding. Bellhousings (magnesium share below 7.5 %) made of aluminium and damping rings (NBR) can be used as connecting element between pump and electric motor. The cover may only be taken off with standstill of the unit.
If the couplings are used in locations subject to dust explosion and in mining the user must make sure that there is no accumulation of dust in a dangerous volume between the cover and the coupling. The coupling must not operate in an accumulation of dust.
For covers with unlocked openings on the top face no light metals must be used if the couplings are used as equipment of equipment group ll (if possible, from stainless steel).
If the couplings are used in mining (equipment group l M2), the cover must not be made of light metal. In addition, it must be resistant to higher mechanical loads than with use as equipment of equipment group ll.
Please observe protection note ISO 16016.
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Verified:
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2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
45510 EN
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23
5 Start-up
During operation of the coupling, please pay attention to
•
different operating noise
•
vibrations occurring.
!
If you note any irregularities with the coupling during operation, the drive unit must be switched off immediately. The cause of the breakdown must be specified by means of the table „Breakdowns“ and, if possible, be eliminated according to the proposals. The potential breakdowns specified can be hints only. To find out the cause all operating factors and machine components must be considered.
Coating of coupling:
If coated (priming, paintings, etc.) couplings are used in potentially explosive atmospheres, the requirements on conductibility and coating thickness must be considered. With paintings up to 200 µm electrostatic load does not have to be expected. Paintings and coatings exceeding a thickness of 200 µm are generally impermissible for potentially explosive atmospheres. It also applies for multiple coatings exceeding an overall thickness of 200 µm. Make sure with painting or coating that the coupling components are conductively connected with the device/devices to be connected so that the equipotential bonding is not impeded by the paint or coat applied. In addition, make sure that the marking of the coupling remains legible. Painting or coating of the spider is generally not admitted.
6 Breakdowns, causes and elimination
The below-mentioned failures can lead to a use of the ROTEX ® GS coupling other than intended. In addition to the specifications given in these operating/assembly instructions make sure to avoid such failures.
The errors listed can only be clues to search for the failures. When searching for the failure the adjacent components must generally be considered.
If used other than intended the coupling can become a source of ignition.
EU directive 2014/34/EU requires special care by the manufacturer and the user.
General failures with use other than intended:
•
Important data for the coupling selection are not forwarded.
•
The calculation of the shaft-hub-connection is not considered.
•
Coupling components with damage occurred during transport are assembled.
•
If the heated hubs are assembled, the permissible temperature is exceeded.
•
The clearance of the components to be assembled is not coordinated with one another.
•
Tightening torques are fallen below/exceeded.
•
Components are mixed up by mistake/assembled incorrectly.
•
A wrong or no spider is inserted in the coupling.
•
No original KTR components (purchased parts) are used.
•
Old/already worn out spiders or spiders stored for too long are used.
•
Maintenance intervals are not observed.
Please observe protection note ISO 16016.
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2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
45510 EN
31 of 40
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6 Breakdowns, causes and elimination
Breakdowns Causes
Hazard notes for potentially explosive atmospheres
Different operating noise and/or vibrations occuring
Breaking of cams
Early wear of spider or reverse backlash
Misalignment
Wear of spider, shortterm torque transmission due to metal contact
Screws for axial fastening of hubs working loose
Wear of spider, torque transmission due to metal contact
Breaking of the cams due to high impact energy/overload
Operating parameters do not meet with the performance of the coupling
Operating error of the unit
Misalignment e. g. contact with aggressive liquids/oils, ozone influence, too high/low ambient temperatures etc. causing physical modification of the spider
Elimination
Increased temperature on the spider surface; ignition risk by hot surfaces
Ignition risk due to sparking
Ignition risk due to hot surfaces and sparking
Ignition risk due to sparking
Increased temperature on the spider surface; ignition risk by hot surfaces
Ignition risk due to sparking with metallic contact of the cams
1) Set the unit out of operation
2) Eliminate the reason for the misalignment
(e. g. loose foundation bolts, breaking of the engine mount, heat expansion of unit components, modification of the installation dimension E of the coupling)
3) For inspection of wear see chapter 10.2
1) Set the unit out of operation
2) Disassemble the coupling and remove residues of the spider
3) Inspect coupling components and replace coupling components that have been damaged
4) Insert spider, assemble coupling components
5) Inspect alignment, adjust if necessary
1) Set the unit out of operation
2) Inspect alignment of coupling
3) Tighten the screws to fasten the hubs and secure against working loose
4) For inspection of wear see chapter 10.2
1) Set the unit out of operation
2) Replace complete coupling
3) Inspect alignment
1) Set the unit out of operation
2) Replace complete coupling
3) Inspect alignment
4) Find out the reason for overload
1) Set the unit out of operation
2) Review the operating parameters and select a bigger coupling (consider mounting space)
3) Assemble new coupling size
4) Inspect alignment
1) Set the unit out of operation
2) Replace complete coupling
3) Inspect alignment
4) Instruct and train the service staff
1) Set the unit out of operation
2) Eliminate the reason for the misalignment
(e. g. loose foundation bolts, breaking of the engine mount, heat expansion of unit components, modification of the installation dimension E of the coupling)
3) For inspection of wear see chapter 10.2
1) Set the unit out of operation
2) Disassemble the coupling and remove residues of the spider
3) Inspect coupling components and replace coupling components that have been damaged
4) Insert spider, assemble coupling components
5) Inspect alignment, adjust if necessary
6) Make sure that further physical modifications of the spider are excluded
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
6 Breakdowns, causes and elimination
Breakdowns Causes
Hazard notes for potentially explosive atmospheres
Early wear of spider or reverse backlash
Early wear of spider
(liquefaction of material inside the spider cam) excessively high/low ambient/contact temperatures for the spider, max. permissible
-30 °C/+90 °C
Vibrations of drive
Ignition risk due to sparking with metallic contact of the cams
KTR-N
Sheet:
Edition:
45510 EN
32 of 40
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Elimination
1) Set the unit out of operation
2) Disassemble the coupling and remove residues of the spider
3) Inspect coupling components and replace coupling components that have been damaged
4) Insert spider, assemble coupling components
5) Inspect alignment, adjust if necessary
6) Inspect and adjust ambient/contact temperature (correct by using other spider materials, if necessary)
1) Set the unit out of operation
2) Disassemble the coupling and remove residues of the spider
3) Inspect coupling components and replace coupling components that have been damaged
4) Insert spider, assemble coupling components
5) Inspect alignment, adjust if necessary
6) Find out the reason for vibrations (correct by spider with lower or higher Shore hardness, if necessary)
When operating with a worn spider (see chapter 10.3) proper operation is not ensured.
!
7 Disposal
In respect of environmental protection we would ask you to dispose of the packaging or products on termination of their service life in accordance with the legal regulations and standards that apply, respectively.
•
Metal
Any metal components have to be cleaned and disposed of by scrap metal.
•
Nylon materials
Nylon materials have to be collected and disposed of by a waste disposal company.
Please observe protection note ISO 16016.
Drawn:
Verified:
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2020-02-10 Pz
Replacing:
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KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
45510 EN
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8 Maintenance and service
ROTEX ® GS is a low-maintenance coupling. We recommend to perform a visual inspection on the coupling at least once a year . Please pay special attention to the condition of the coupling spiders.
•
Since the flexible machine bearings of the driving and driven side settle during the course of load, inspect the alignment of the coupling and re-align the coupling, if necessary.
•
The coupling components have to be inspected for damages.
•
The screw connections have to be inspected visually.
!
Having started up the coupling the tightening torques of the screws have to be inspected during the usual inspection intervals.
With the use in potentially explosive atmospheres observe chapter 10.2 "Inspection intervals for couplings in potentially explosive atmospheres".
9 Spares inventory, customer service addresses
We recommend to store major spare parts on site to ensure the readiness for use of the machine in case if a coupling fails.
Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage at www.ktr.com.
KTR does not assume any liability or warranty for the use of spare parts and accessories which are not provided by KTR and for the damages which may incur as a result.
Please observe protection note ISO 16016.
Drawn:
Verified:
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2020-02-10 Pz
Replacing:
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KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
45510 EN
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10 Enclosure A
Advice and instructions regarding the use in potentially explosive atmospheres
Applicable hub designs/types: a) Hubs that may be used in group II, category 2 and 3 :
(hubs with feather keyway and hubs with CLAMPEX ® clamping set or clamping ring hubs)
•
1.0 Hub with feather keyway and setscrew
•
2.1 Clamping hub single slot with feather keyway
•
2.6 Clamping hub double slot with feather keyway
•
2.9 Clamping hub with axial slot with feather keyway
•
6.0 Clamping ring hub light
•
6.0 Clamping ring hub
•
6.5 Clamping ring hub
(hub type as 6.0, but external clamping screws only)
•
Type DKM with hubs corresponding to the aforementioned details b) Hubs which may be used in group II, category 3 only: hubs without feather keyway
•
1.1 Hub without feather keyway, with setscrew
•
2.0 Clamping hub single slot without feather keyway
•
2.5 Clamping hub double slot without feather keyway
•
2.8 Clamping hub with axial slot without feather keyway
•
Type DKM with hubs corresponding to the aforementioned details
ROTEX ® GS type DKM only with spacer made of steel or aluminium wrought products with a yield stress
R p0.2
≥ 250 N/mm 2 .
Hubs, clamping hubs or similar types without feather keyway may be used in category 3 only and are marked with category 3 accordingly.
Hub type 1.2 is not approved for potentially explosive atmospheres!
Please observe protection note ISO 16016.
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Verified:
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2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
10 Enclosure A
Advice and instructions regarding the use in
KTR-N
Sheet:
Edition:
45510 EN
35 of 40
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potentially explosive atmospheres
10.1 Intended use in potentially explosive atmospheres
Conditions of operation in potentially explosive atmospheres
ROTEX ® GS couplings are suitable for the use according to EU directive 2014/34/EU.
1. Industry (with the exception of mining)
•
Equipment group II of category 2 and 3 ( coupling is not approved/not suitable for equipment group 1 )
•
Substance group G ( gases, mists, vapours ), zone 1 and 2 ( coupling is not approved/not suitable for zone 0 )
•
Substance group D ( dusts ), zone 21 and 22 ( coupling is not approved/not suitable for zone 20 )
•
Explosion group IIC ( gases, mists, vapours ) (explosion group IIA and IIB are included in IIC) and explosion group IIIC ( dusts ) (explosion group IIIA and IIIB are included in IIIC)
Temperature class:
Temperature class
T4
T5
T6
Ambient or operating temperature T a
1)
-30 °C to +90 °C
-30 °C to +75 °C
-30 °C to +60 °C
Max. surface temperature 2)
+110 °C
+95 °C
+80 °C
Explanation:
The maximum surface temperatures each result from the maximum permissible ambient or operating temperature T a
plus the maximum temperature increase
T of 20 K to be considered. For the temperature class a safety margin subject to standard of 5 K is added.
1) The ambient or operating temperature T a
is limited to +90 °C due to the permissible permanent operating temperature of the elastomers used.
2) The maximum surface temperature of +110 °C applies for the use in locations which are potentially subject to dust explosion.
In potentially explosive atmospheres
•
the ignition temperature of dusts generated must at least be 1.5 times the surface temperature to be considered
•
the glow temperature must at least be the surface temperature to be considered plus a safety distance of 75 K.
•
the gases and vapours generated must amount to the temperature class specified.
2. Mining
Equipment group I of category M2 (coupling is not approved/not suitable for equipment group M1 ).
Permissible ambient temperature -30 °C to +90 °C.
In mining for equipment group I of category M2 coupling hubs and DKM spacers made of steel only are permissible.
Please observe protection note ISO 16016.
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Verified:
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2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
10 Enclosure A
Advice and instructions regarding the use in
KTR-N
Sheet:
Edition:
45510 EN
36 of 40
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potentially explosive atmospheres
10.2 Inspection intervals for couplings in
Equipment category
3G
3D
M2
2G
2D
No gases and vapours of explosion group IIC
M2
2G
2D
Gases and vapours of explosion group IIC
potentially explosive atmospheres
Inspection intervals
For couplings operated in zone 2 or zone 22 the inspection and maintenance intervals of the usual operating/assembly instructions for standard operation apply. During the standard operation which has to be taken as a basis of the ignition risk analysis the couplings are free from any ignition source. For gases, vapours and dusts generated the permissible glow and ignition temperatures specified in chapter 10.1 have to be considered and observed.
An inspection of the torsional backlash and a visual inspection of the flexible spider must be performed after 3,000 operating hours for the first time, at the latest after 6 months after start-up of the coupling.
If you note insignificant or no wear on the spider upon this initial inspection, further inspections can each be performed after 6,000 operating hours or at the latest after 18 months, provided that the operating parameters remain the same.
If you note significant wear during the initial inspection so that it would be recommendable to replace the spider, please find out the cause according to the table
„Breakdowns“, if possible.
The maintenance intervals must be adjusted to the modified operating parameters without fail.
An inspection of the torsional backlash and a visual inspection of the flexible spider must be performed after 2,000 operating hours for the first time, at the latest after 3 months after start-up of the coupling.
If you note insignificant or no wear on the spider upon this initial inspection, further inspections can each be performed after 4,000 operating hours or at the latest after 12 months, provided that the operating parameters remain the same.
If you note significant wear during the initial inspection so that it would be recommendable to replace the spider, please find out the cause according to the table
„Breakdowns“, if possible.
The maintenance intervals must be adjusted to the modified operating parameters without fail.
Hubs, clamping hubs or similar types without feather keyway may be used in category 3 only and are marked with category 3 accordingly.
ROTEX ® GS backlash-free shaft couplings
Illustration 25: ROTEX ® GS backlash-free shaft coupling Illustration 26: ROTEX ® GS spider
If the drive allows for, backlash between the cams of the coupling and the flexible spider has to be measured by means of a feeler gauge.
When reaching the wear limit maximum friction , the spider must be replaced immediately, irrespective of the inspection intervals.
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
45510 EN
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10 Enclosure A
Advice and instructions regarding the use in
10.3 Standard values of wear
potentially explosive atmospheres
In case of backlash > X mm, the flexible spider must be replaced.
Monitoring of the general condition of the coupling can be done both at standstill and during operation. If the coupling is tested during operation, the operator must ensure an appropriate and proven test procedure (e. g. stroboscopic lamp, high-speed camera, etc.) which is definitely comparable to testing at standstill. If any distinctive features occur, an inspection must be made with the machine stopped.
Reaching the limits for replacing depends on the operating conditions and the existing operating parameters.
In order to ensure a long service life of the coupling and avoid dangers with the use in
! potentially explosive atmospheres, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures specified (see tables 14 and 15). If the figures are exceeded, the coupling will be damaged.
Illustration 28: Wear of spider
Table 16:
Illustration 27: Inspection of the limit of wear
For backlash-free applications no wear is permitted, since otherwise the operating principle of the coupling (backlash-free condition) is no longer ensured. If a backlash-free operation is not required, the following figures apply:
Size
5
7
8
9
12
13
14
16
19
Please observe protection note ISO 16016.
Limits of wear (friction)
X max.
[mm]
0.4
0.5
0.4
0.9
0.6
0.5
1.25
0.7
0.9
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Size
24
28
38
42
48
55
65
75
90
Replacing:
Replaced by:
Limits of wear (friction)
X max.
[mm]
1.0
1.4
1.7
2.0
2.25
2.50
2.75
3.00
3.25
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
10 Enclosure A
Advice and instructions regarding the use in
KTR-N
Sheet:
Edition:
45510 EN
38 of 40
23
potentially explosive atmospheres
10.4 marking of couplings for potentially explosive atmospheres
The ATEX marking of the ROTEX ® GS coupling is applied on the outer sheath or on the front side.
The flexible spider is excluded.
For the complete marking refer to the operating/assembly instructions and/or the delivery note/package.
The following marking applies for the products:
•
Hubs resp. spacer without aluminium
Category 2 (hubs resp. clamping hubs with feather keyway)
ROTEX ® GS
<Year>
I M2 Ex h I
II 2G Ex h IIC T6
… T4
Mb
Gb
II 2D Ex h IIIC T80 °C … T110 °C Db
30 °C ≤ T a
≤ +60 °C … +90 °C
KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine
•
Hubs resp. spacer without aluminium
Category 3 (hubs resp. clamping hubs without feather keyway)
ROTEX ® GS
<Year>
I M2 Ex h I Mb
II 3G Ex h IIC T6 … T4 Gc
II 3D Ex h IIIC T80 °C
… T110 °C Dc
-
30 °C ≤ T a
≤ +60 °C … +90 °C
KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine
•
Hubs resp. spacer made of aluminium only
Category 2 (hubs resp. clamping hubs with feather keyway)
ROTEX ® GS
<Year>
II 2G Ex h IIC T6 … T4 Gb
II 2D Ex h IIIC T80 °C … T110 °C Db
30 °C ≤ T a
≤ +60 °C … +90 °C
KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine
•
Hubs resp. spacer made of aluminium only
Category 3 (hubs resp. clamping hubs without feather keyway)
ROTEX ® GS
<Year>
II 3G Ex h IIC T6 … T4 Gc
II 3D Ex h IIIC T80 °C
… T110 °C Dc
-
30 °C ≤ T a
≤ +60 °C … +90 °C
KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine
Short marking:
(A short marking is only made if not possible differently for reason of space or functioning.)
ROTEX
®
GS
<Year>
Please observe protection note ISO 16016.
Drawn:
Verified:
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2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
10 Enclosure A
Advice and instructions regarding the use in
KTR-N
Sheet:
Edition:
45510 EN
39 of 40
23
potentially explosive atmospheres
10.4 marking of couplings for potentially explosive atmospheres
Deviating marking applies until 31st October 2019:
Short marking:
II 2GD c IIC T X/I M2 c X
Category 3: II 3G c IIC T6, T5 resp. T4 -30 °C
T a
+65 °C, +80 °C resp.
Complete marking:
+90 °C
II 3D c T 110 °C
-30 °C
T a
+90 °C
II 2G c IIC T6, T5 resp. T4 -30 °C
T a
+65 °C, +80 °C resp.
+90 °C
II 2D c T 110 °C
I M2 c -30 °C
T a
+90 °C
Substance group - gases, mists and vapours:
The marking with explosion group llC includes the explosion groups llA and llB.
Substance group - dusts:
The marking with explosion group lIlC includes the explosion groups lIlA and lIlB.
If the symbol was punched in addition to marking , the coupling component was supplied by KTR as an unbored or pilot bored version (see chapter 4.3 of the present operating/assembly instructions).
Please observe protection note ISO 16016.
Drawn:
Verified:
2020-02-10 Pz/Ht
2020-02-10 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-22
ROTEX ® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
45510 EN
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10 Enclosure A
Advice and instructions regarding the use in
10.5 EU Declaration of conformity
potentially explosive atmospheres
EU Certificate of conformity
corresponding to EU directive 2014/34/EU dated 26 February 2014 and to the legal regulations
The manufacturer - KTR Systems GmbH, D-48432 Rheine - states that the
ROTEX ® GS backlash-free shaft couplings in an explosion-proof design described in these operating/assembly instructions are devices corresponding to article 2, 1. of directive 2014/34/EU and comply with the general safety and health requirements according to enclosure II of directive 2014/34/EU.
The coupling described in here complies with the specifications of the following standards/rules:
DIN EN ISO 80079-36
DIN EN ISO 80079-37
DIN EN ISO 80079-38
IEC/TS 60079-32-1
The ROTEX ® GS is in accordance with the specifications of directive 2014/34/EU.
According to article 13 (1) b) ii) of directive 2014/34/EU the technical documentation is deposited with the notified body (type examination certificate IBExU03ATEXB002_05 X):
IBExU
Institut für Sicherheitstechnik GmbH
Identification number: 0637
Fuchsmühlenweg 7
09599 Freiberg
Rheine,
Place
2019-11-22
Date i. V.
Reinhard Wibbeling
Engineering/R&D i. V.
Johannes Deister
Product Manager
Please observe protection note ISO 16016.
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2020-02-10 Pz
Replacing:
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