KTR ROTEX GS DKM Operating / Mounting Instructions

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KTR Kupplungstechnik

GmbH

D-48407 Rheine

ROTEX

®

GS

Torsionally flexible jaw couplings types shaft coupling, clamping hubs, clamping ring hubs, clamping ring hubs light,

DKM, Compact and combinations in accordance with standard

94/9/EC (ATEX 95) for finish bored and pilot bored/unbored couplings

ROTEX

Operating/mounting instructions

KTR-N sheet: edition:

ROTEX

GS, shaft coupling

ROTEX

GS, clamping hubs

45510 EN

1 of 33

ROTEX

GS, clamping ring hubs

ROTEX

GS, clamping ring hubs light

ROTEX

GS, DKM

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ROTEX

GS, Compact

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D-48407 Rheine

ROTEX

Operating/mounting instructions

KTR-N sheet: edition:

45510 EN

2 of 33

ROTEX

is a plug-in shaft coupling for measuring technology and automatic control engineering. It is able to compensate for shaft misalignment produced by, as an example, inaccuracies in production, thermal expansion, etc.

1 Technical

2 Hints

General

2.3 Safety and Advice Hints

2.4 General Hint to Danger

2.5

3 Storage

4 Assembly

Coupling

4.3 Hints for Assembly

4.4 Hint for Finish Bore

4.5 Assembly of Hubs (Types 1.0, 1.1 and 1.2)

4.6 Assembly of Clamping Hubs

(Types 2.0, 2.1, 2.5, 2.6, 2.8, 2.9, 7.5, 7.6, 7.8 and 7.9)

4.7 Assembly of Clamping Ring Hubs (Types 6.0, 6.0 steel, 6.0 light and 6.5)

4.8 Displacements – Alignment of the Couplings

4.9 Spares Inventory, Customer Service Addresses

Hints and Instructions Regarding the Use in Hazardous Areas

5.1 Use Hazardous Areas According to the Regulations

5.2 Control Intervals for Couplings in

5.3 Approximate Values of Wear

5.4 Permissible Coupling Materials in the

Hazardous Areas

Hazardous Area

5.5 Marking of Coupling for Hazardous Area

Starting

5.7 Breakdowns, Causes and Elimination

5.8 EC Certificate of Conformity according to the EC Standards 94/9/EC dated 23.03.1994

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D-48407 Rheine

1 Technical Data

Standard shaft coupling

ROTEX

Operating/mounting instructions

KTR-N sheet: edition:

45510 EN

3 of 33

14 illustration 1: ROTEX ® GS, size 5 - 38

Table 1: Dimensions illustration 2: ROTEX ® GS, size 42 - 75

ROTEX ®

Size

D D

Dimensions [mm] d

L l

; l

M / N E

Hub material - Aluminium (Al-H) b s a

Setscrew 1)

G t

Hub material - Steel (St-H)

85 95 46 126 50 28 26 20 3,0 4,0 M8 20

95 105 51 140 56 32 28 21 3,5 4,0 M8 20

110 120 60 160 65 37 30 22 4,0 4,5 M10 20

115 135 68 185 75 47 35 26 4,5 4,5 M10 20

135 160 80 210 85 53 40 30 5,0 5,0 M10 25

A T T E N T I O N !

For the applications in hazardous areas the setscrews to fasten the hubs as well as all screw connections have to be secured against self-slackening additionally, e. g. by glueing with Loctite

(medium-tight).

Table 2: Torques and finish bores

ROTEX ®

Size

Spider (part 2) 1)

Rated torque [Nm]

80 Sh A-GS 92 Sh A-GS 98 Sh A-GS 64 Sh D-GS 72 Sh D-GS

Unbored d

Finish bore [mm] – Hub type min.

1.0 d max.

1.1, 1.2

d max.

2.0, 2.1

d max.

0,2 - - 2 - 6 5

1,8

3,0

4,0

3,0

5,0

5,0 6,0

9,0 12,0

7,5 12,5 16,0

- 4 10 11 11

- 4 12 12 12

- 5 15 16 16

4,9 10,0 17,0 21

1.0, 1.1 d max.

2.5 max.

2.6 max.

- x 6 24 24 24 x 8 28 28 28

260 x 12 45 45 45

728 x 15 62 55 55

685

940

1175 1527

2400 - x 22 80 70 70 x 30 95 80 80

1) Maximum torque of coupling T

Kmax.

= Rated torque of coupling T

K Nenn.

x 2 with the exception of clamping hubs types 2.0 and 2.5 (see table 3)

2) Figures for spider 70 Sh A-GS 3) Figures for spider 95 Sh A-GS

4) When using the 72 Sh D spider, we recommend to use hubs in steel.

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1 Technical Data

Clamping hubs

ROTEX

Operating/mounting instructions

KTR-N sheet: edition:

45510 EN

4 of 33

14 illustration 3: ROTEX ® GS, size 5 – 14

(type 2.0) illustration 4: ROTEX ® GS, size 19 – 75

(type 2.5)

Table 3: Torques and surface pressure of clamping hubs types 2.0 / 2.5

ROTEX ®

Size

Clamping 1) screw M

Dimension t

5 7 9 12 14 19 24 28 38 42 48 55 65 75

M1,2 M2 M2,5 M3 M3 M6 M6 M8 M8 M10 M12 M12 M12 M16

Dimension ØD

11,4 16,5 23,4 27,5 32,2 46 57,5 73 83,5 93,5 105 119,5 124 147,5

Tightening torque T

[Nm]

- 0,37 0,76 1,34 1,34 10,5 10,5 25 25 69 120 120 120 295

Bore Ø

Ø2

Ø3

- 0,84

71,02 transmittable torque of Clamping hub [Nm]

Surface pressure [N/mm

]

Ø4

Ø5

Ø6

Ø7

Ø8

Ø9

Ø10

Ø11

Ø12

A T T E N T I O N !

For the applications in hazardous areas the setscrews to fasten the hubs as well as all screw connections have to be secured against self-slackening additionally, e. g. by glueing with Loctite

(medium-tight).

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ROTEX

Operating/mounting instructions

KTR-N sheet: edition:

1 Technical Data

Continuation of table 3: Torques and surface pressure of clamping hubs types 2.0 / 2.5

ROTEX ®

Size

Clamping 1) screw M

Dimension t

45510 EN

5 of 33

5 7 9 12 14 19 24 28 38 42 48 55 65 75

M1,2 M2 M2,5 M3 M3 M6 M6 M8 M8 M10 M12 M12 M12 M16

Ø38

Ø40

Ø42

Ø45

Ø48

Ø50

Ø55

Ø28

Ø30

Ø32

Ø35

Ø20

Ø22

Ø24

Ø25

Dimension ØD

11,4 16,5 23,4 27,5 32,2 46 57,5 73 83,5 93,5 105 119,5 124 147,5

Tightening torque T

[Nm]

- 0,37 0,76 1,34 1,34 10,5 10,5 25 25 69 120 120 120 295

Bore Ø transmittable torque of Clamping hub [Nm]

Surface pressure [N/mm

]

Ø14

Ø15

Ø16

6,30 29,7 37,1 80,4 92,8 219 352

13,5 28,0 42,7 82,5 70,6 152 225

6,46 30,4 37,8 81,7 94,1 221 356

12,2 25,2 38,2 73,6 62,9 135 200

Ø19

30,4* 41,9 89,1 101,5 238 381 433

13,3* 22,4 42,5 35,9 77 113 108

31,59* 43,2 91,6 104,0 244 389 441 462 964

Ø60

20 17 31

Ø65

17 15 27

Ø70

Ø75

Ø80

* only type 2.0

= 2 x Clamping screw M4; T

= 2,9 Nm

1) A T T E N T I O N !

For the applications in hazardous areas the setscrews to fasten the hubs as well as all screw

1354

1392

20 connections have to be secured against self-slackening additionally, e. g. by glueing with Loctite

(medium-tight).

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D-48407 Rheine

ROTEX

Operating/mounting instructions

1 Technical Data

Clamping ring hubs 6.0, 6.0 steel and 6.0 light

KTR-N sheet: edition:

45510 EN

6 of 33

Pull-off thread M

between clamping screws. illustration 5: ROTEX ® GS clamping ring hubs

Table 4: dimensions

ROTEX

Size

Spider (part 2)

Torques [Nm]

2) d

L l

Dimensions [mm]

; l

2 l

6.0 light (size 14 – 48) Hub/Clamping ring material - Aluminium (Al-H)

30 10,5 50 18,5 13,5 13 10 1,5 2,0 M3

Figures see table 2

40 18 66 25 18 16 12 2,0 3,0 M4

55 27 78 30 22 18 14 2,0 3,0 M5

65 30 90 35 27 20 15 2,5 4,0 M5

80 38 114 45 35 24 18 3,0 4,0 M6

95 46 126 50 35 26 20 3,0 4,0 M8

105 51 140 56 41 28 21 3,5 4,0 M10

6.0 steel (size 19 – 75)

6.0 (size 14 – 38)

Figures see table 2

Hub and clamping ring material - Steel (St-H)

Hub material – Aluminium (Al-H)/clamping ring material – steel (St-H)

40 18 66 25 18 16 12 2,0 3,0 M4

55 27 78 30 22 18 14 2,0 3,0 M5

65 30 90 35 27 20 15 2,5 4,0 M5

80 38 114 45 35 24 18 3,0 4,0 M6

95 46 126 50 35 26 20 3,0 4,0 M8

105 51 140 56 41 28 21 3,5 4,0 M10

120 60 160 65 45 30 22 4,0 4,5 M10

135 68 185 75 55 35 26 4,5 4,5 M12

A T T E N T I O N !

160 80 210 85 63 40 30 5,0 5,0 M12

GS catalogue.

Please note transmittable torques of clamping connections (see table 5 and 6)

2) ØD

+ 2 mm with high speeds for expansion of spider

1) For coupling selection please see ROTEX

For the applications in hazardous areas the setscrews to fasten the hubs as well as all screw connections have to be secured against self-slackening additionally, e. g. by glueing with Loctite (medium-tight).

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Ø35

Ø38

Ø40

Ø42

Ø25

Ø28

Ø30

Ø32

Ø45

Ø48

Ø19

Ø20

Ø22

Ø24

Ø11

Ø14

Ø15

Ø16

KTR Kupplungstechnik

GmbH

D-48407 Rheine

ROTEX

Operating/mounting instructions

1 Technical Data

Table 5: Torques and surface pressure of clamping ring hubs 6.0 light

ROTEX ®

Clamping screw M 1)

Number z

(for each clamping ring hub)

Tightening torque

[Nm]

KTR-N sheet: edition:

45510 EN

7 of 33

M3 M4 M5 M5 M6 M8 M10

4 6 4 8 8 4 4

Bore Ø d

Ø6

Hub/Clamping ring material – Aluminium (Al-H)

1,34 3 6 6 10 25 49 transmittable torque of clamping ring hub [Nm]

Surface pressure [N/mm

]

5,4

49,4

Ø10

175 248 394 444

285 452 508 572

253 453 535 638

307 543 638 762

329 550 692 842

Ø50

Ø55

1336

77,4

The transmittable torques of the clamping connection consider the max. clearance with bore H7/k6 shaft fit.

The torque is reduced in case of bigger fit clearance.

1) A T T E N T I O N !

C A U T I O N !

An calculation is necessary if hollow shafts are used!

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Ø35

Ø38

Ø40

Ø42

Ø25

Ø28

Ø30

Ø32

Ø19

Ø20

Ø22

Ø24

Ø11

Ø14

Ø15

Ø16

Ø45

Ø48

Ø50

Ø55

Ø60

Ø65

KTR Kupplungstechnik

GmbH

D-48407 Rheine

ROTEX

Operating/mounting instructions

KTR-N sheet: edition:

45510 EN

8 of 33

1 Technical Data

Table 6: Torques and surface pressure of clamping ring hubs 6.0 steel

ROTEX ®

Clamping screw M 1)

Number z (for each clamping ring hub)

Tightening torque

[Nm]

Bore Ø d

6 4 8 8 4 4 4 4 5

Hub and clamping ring material – Steel

4,1 8,5 8,5 14 35 69 69 120 120

Transmittable torque of clamping ring hub [Nm]

Surface pressure [N/mm 2 ]

Ø10

110 114 148 208

166 135 129 138

133 285 395 358 489

101 159 168 152 179

192 315 439 398 658

116 141 149 135 192

382 531 483 616

148 157 143 157

330 463 416 704

433 603 547 899 863

123 131 119 168 138

503 593 536 896 856

689 625 1030 991 1446

114 104 147 121 140

793 571 962 918 1355 1710

119 86 125 102 119 134

776 704 1160 1119 1637 2053

102 92 131 108 125 141

Ø70

Ø80

The transmittable torques of the clamping connection consider the max. clearance with bore H7/k6 shaft fit.

The torque is reduced in case of bigger fit clearance.

1) A T T E N T I O N !

For the applications in hazardous areas the setscrews to fasten the hubs as well as all screw connections have to be secured against selfslackening additionally, e. g. by glueing with Loctite (medium-tight).

4148

C A U T I O N !

An calculation is necessary if hollow shafts are used!

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Ø24

Ø25

Ø28

Ø30

Ø16

Ø19

Ø20

Ø22

Ø32

Ø35

KTR Kupplungstechnik

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D-48407 Rheine

ROTEX

Operating/mounting instructions

KTR-N sheet: edition:

45510 EN

9 of 33

1 Technical Data

Table 7: Torques and surface pressure of clamping ring hubs 6.0

ROTEX ® GS Size

Clamping screw M 1)

Number z (for each clamping ring hub)

Tightening torque

[Nm]

Bore Ø d

Ø6

Ø10

Ø11

Ø14

14 19 24 28 38

M3 M4 M5 M5 M6

4 6 4 8 8

Hub material – Aluminium (Al-H); Clamping ring material - steel

1,34 3 6 6 10

Transmittable torque of clamping ring hub [Nm]

Surface pressure [N/mm 2 ]

8,6

225

13,8 41

130 272

14,7 45 48

118 248 214

22,7 62 67

108 211 182

Ø15

Ø38

Ø40

Ø42

Ø45

572

104

615

102

644

The transmittable torques of the clamping connection consider the max. clearance with bore H7/k6 shaft fit.

The torque is reduced in case of bigger fit clearance.

A T T E N T I O N !

C A U T I O N !

An calculation is necessary if hollow shafts are used!

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1 Technical Data

DKM

ROTEX

Operating/mounting instructions

KTR-N sheet: edition:

45510 EN

10 of 33

14 illustration 6: ROTEX ® GS, DKM

Table 8: Dimensions

ROTEX ®

Size

Finish bore Dimensions [mm] d max.

1) D

H d

; l

M; l

11 l

DKM

E b s a

Hub material - Aluminium (Al-H) Spacer material - Aluminium (Al-H)

- 30 2,0

- 40 18 18 25 - 10 42 92 16 12 2,0 3,0

- 55 27 27 30 - 16 52 112 18 14 2,0 3,0

- 65 30 30 35 - 18 58 128 20 15 2,5 4,0

- 80 38 38 45 - 20 68 158 24 18 3,0 4,0

Hub material - Steel (St-H) Spacer material - Aluminium (Al-H)

55 85 95 46 46 50 28 22 74 174 26 20 3,0 4,0

95 105 51 51 56 32 24 80 192 28 21 3,5 4,0

110 120 60 60 65 37 28 88 218 30 22 4,0 4,5

1) depend on hub type

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1 Technical Data

Compact

ROTEX

Operating/mounting instructions

KTR-N sheet: edition:

45510 EN

11 of 33

14 illustration 7: ROTEX ® GS 7 - 19 Compact single slotted 1) type 2.0

Table 9: Dimensions illustration 8: ROTEX ® GS 24 - 38 Compact axially slotted type 2.8

ROTEX

Compact

Size

Spider

(part 2)

Torques

[Nm] d max.

Dimensions [mm]

L l

7 14 18 5 8 6 1 2,5 5,0

9 20 M2,5 0,76

12 25 26 7 12 10 1 3,5 8,3

Figures see table 2 1)

30 30,5

40 45,0

32 9,5 13 10 1,5 4,5 9,6 M4 2,9

50 17 16 12 2 9 14,0 M6 10

32 55 57,5 54 18 18 14 2 11 20,0 M6 10

35 65 69,0 62 21 20 15 2,5 12 23,8 M8 25

45 80 86,0 76 26 24 18 3 16 30,5 M10 49

1) Size 14 with screw M3 and dimension e=10,4; size 19 with screw M5 and dimension e=15,5

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Operating/mounting instructions

KTR-N sheet: edition:

45510 EN

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1 Technical Data

Table 10: Torques and surface pressure of clamping hubs 2.0 (shortened) / 2.8

ROTEX ® GS

Compact

Size

7 9 12 14 19 24 28 38

Clamping screw M

4) M2,5 M3 M3 M4 M6 M6 M8 M8

Dimension t

Dimension e

Dimension ØD

Tightening torque T

[Nm]

6,7

0,76

8,3

1,34

9,6

2,9

11,5

1,34

14,5

23,8

30,5

Bore Ø

Ø3

Ø4

Ø5

Ø6

Ø7 transmittable torque of clamping hub [Nm]

Surface pressure [N/mm

]

0,8

173,5

0,9 1,9 3,4

105,1 151,6 273,6

1,0 2,0 3,6 7,1

72,1 102,6 183,6 262,2

1,0 2,1 3,7 7,4

1,1 2,2 3,9 7,7

41,7 58 102,3

Ø8

Ø14

Ø15

Ø16

Ø18

Ø9

Ø10

Ø11

Ø12

5,5 28,4 29,7 54,4

26,0 73,1 58,8 92,0

5,7 29,0 31,8 58,3 92,6

23,3 65,2 54,9 85,9 109,6

5,8 29,7 33,9 62,2 98,8

21,1 58,6 51,4 80,5 102,7

34,4 45,7 71,5 91,3

Ø19

Ø28

Ø30

Ø32

Ø35

Ø20

Ø22

Ø24

Ø25

Ø38

Ø40

Ø42

Ø45

ROTEX ® GS 14: 1 x clamping screw M3, T

ROTEX ® GS 19: 1 x clamping screw M5, T

= 1,34 Nm

= 6 Nm

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31,6 43,3 67,8 86,5

29,1 41,1 64,4 82,2

24,0 46,7 85,5 135,8

25 37,4 58,5 74,7

25,0 50,9 93,3 148,2

21,9 34,3 53,7 68,5

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234,6

43,3

246,9

41,1

259,3

39,1

277,8

36,5

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D-48407 Rheine

ROTEX

Operating/mounting instructions

KTR-N sheet: edition:

45510 EN

13 of 33

2 Hints

The ROTEX

GS coupling was developped for a backlashfree power transmission and easy plug-in assembly. This backlash-free power transmission is realized in the range of prestress (see illustration 9). 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.

The safe operation in the range of prestress is ensured, because the coupling operates according to the principle of the positive-locking rubber spring prestress with high damping features. The star-shape coupling spider is inserted into the cams of the hubs which are machined specifically accurately with a small amount of prestress, resulting in the necessary backlash-free power transmission. illustration 9: prestress of spider

The flexible teeth compensating for misalignments 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 a smooth operation even with bigger masses (e. g. steel mills, articulated arms, etc.). The flexible spiders for the GS series are available in three different kinds of Shore hardness, injected in different colours, either as a torsionally soft or hard material.

2.1 Coupling Selection

C A U T I O N !

For a long-term smooth operation of the coupling the coupling has to be selected based on the selection standards applying for the application (in accordance with DIN 740, part 2)

(see ROTEX

GS catalogue).

In case that the operating conditions change (power, speed, modifications on engine and machine) it is absolutely necessary to verify the coupling selection.

Please note that the technical details concerning the torque refer to the spider only. The transmittable torque of the shaft-hub-connection has to be reviewed by the customer and is subject to his responsibility.

For drives subject to dangerous torsional vibrations (drives with periodical torsional vibration load) it is necessary to perform a torsional vibration calculation to ensure a safe operation. Typical examples of drives subject to dangerous torsional vibrations are drives with diesel engines, piston pumps, piston compressors, etc. If requested, KTR will perform the coupling selection and torsional vibration calculation.

2.2 General Hints

Please read through these mounting instructions carefully before you set the coupling into operation.

Please pay special attention to the safety instructions.

The ROTEX

GS coupling is suitable and approved for the application in hazardous areas.

For the use of couplings in hazardous areas please note the special safety hints and regulations as per appendix A.

In order to ensure the operating principle of ROTEX

GS and avoid an early wear of the coupling, a corresponding torsional stiffness factor „Sd“ has to be considered for the selection, each depending on the application (see catalogue). Temperatures and shocks are provided with the corresponding factors, too (see catalogue).

The mounting instructions are part of your product. Please keep them carefully and close to the coupling. The copyright for these mounting instructions remains with KTR Kupplungstechnik GmbH.

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2 Hints

2.3 Safety and Advice Hints

STOP

D A N G E R !

ROTEX

Operating/mounting instructions

Danger of injury to persons

KTR-N sheet: edition:

45510 EN

14 of 33

! C A U T I O N ! Damages on the machine possible

)

A T T E N T I O N ! Pointing to important items

A T T E N T I O N ! Pointing to explosion-proof applications

2.4 General Hint to Danger

STOP

D A N G E R !

With the assembly, operation and maintenance of the coupling it has to be made sure that the entire drive train is protected against unintentional engagement. You may be seriously hurt by rotating parts. Please make absolutely sure to read through and observe the following safety instructions.

• All operations on and with the coupling have to be performed taking into account „safety first“.

• Please make sure to disengage the power pack before you perform your work on the coupling.

• Protect the power pack against unintentional engagement, e. g. by providing hints at the place of engagement or removing the fuse for current supply.

• Do not touch the operation area of the coupling as long as it is in operation.

• Please protect the coupling against unintentional touch. Please provide for the necessary protection devices and caps.

2.5 Proper Use

You may only assemble, operate and maintain the coupling if you

• have carefully read through the mounting instructions and understood them

• had technical training

• are authorized to do so by your company

The coupling may only be used in accordance with the technical details (see tables 1 to 9, chapter 1).

Unauthorized modifications on the coupling type are not admissible. We do not take any warranty for resulting damages. To further develop the product 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 mounting instructions.

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KTR Kupplungstechnik

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D-48407 Rheine

ROTEX

Operating/mounting instructions

KTR-N sheet: edition:

45510 EN

15 of 33

3 Storage

The couplings are supplied in preserved condition and can be stored in a dry place with a roof up to 6 – 9 months.

With favourable storage conditions the coupling spiders (elastomers) keep their characteristics unchanged up to

5 years.

C A U T I O N !

The storage rooms must not contain any equipment producing ozone, e. g. fluorescent light sources, mercury lamps, electric high-voltage devices. Humid storage rooms are not suitable.

Please make sure that no condensation is produced. It is best to keep the relative air moisture beneath 65 %.

4 Assembly

Generally the coupling is delivered in parts. Before the assembly, the coupling has to be inspected regarding its completeness.

4.1 Hub Types

Type

1.0 with keyway and thread

1.1 without keyway with thread

1.2 without keyway without thread

Type up to size 14 standard/

Compact up to size 19

2.0 single slotted without keyway

2.1 single slotted with keyway

Type from size 19 standard

2.5 double slotted without keyway

2.6 double slotted with keyway

Type 2.8 with ROTEX ® size 24 standard

GS Compact from

2.8 axially slotted without keyway

2.9 axially slotted with keyway

Type 4.2 1) with CLAMPEX ®

KTR 250

Type 6.0/6.0 steel/

6.0 light

Clamping ring hub

Type 7.5 (without keyway) and

7.6 (with keyway)

Split clamping hub for DKM/ZR3

Type 7.8 (without keyway) and

7.9 (with keyway)

Please note: Subject to the position of the clamping screws the application is recommended for single-cardanic couplings only. illustration 10: Hub types

1) ) A T T E N T I O N !

Selection of clamping sets

With the use in explosion-proof areas the clamping hubs have to be selected in a way that the difference between the peak torque of the machine including all operation parameters and the rated torque of the clamping hub is at least a service factor of s = 2.

A T T E N T I O N !

Hub types 1.1, 2.0, 2.5, 2.8, 7.5 and 7.8 (without feather key) may only be used in category 3.

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D-48407 Rheine

ROTEX

Operating/mounting instructions

4 Assembly

4.2 Coupling Components

Standard spiders

Spider hardness

(Shore)

Identification

(Colour)

Spider hardness

(Shore)

80 Sh A-GS

92 Sh A-GS

95/98 Sh A-GS blue yellow red

64 Sh D-GS

72 Sh D-GS

Components of ROTEX

GS, backlash-free shaft couplings

Component Quantity Description

KTR-N sheet: edition:

45510 EN

16 of 33

Identification

(Colour) green size 7 - 38 pale green size 42 - 75 grey size 24 - 55

3 2 setscrew DIN EN ISO 4029 illustration 11: ROTEX ® GS, size 5 - 38

Components of ROTEX

GS, clamping hubs illustration 12: ROTEX ® GS, size 42 - 75

Component Quantity

1 2

Description clamping hub (hub type 2.0, 2.1, 2.5 or 2.6)

3 2 cap screws DIN EN ISO 4762 illustration 13: ROTEX ® GS, clamping hub

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Operating/mounting instructions

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4 Assembly

4.2 Coupling Components

Components of ROTEX

GS, clamping ring hubs (types 6.0, 6.0 steel, 6.0 light and type 6.5)

Component Quantity Description

2 clamping ring hub see table

5 6 and 7 cap screws DIN EN ISO 4762 illustration 14: ROTEX ® GS, clamping ring hub

) A T T E N T I O N !

Selection of clamping hubs

With the use in explosion-proof areas the clamping hubs have to be selected in a way that the difference between the peak torque of the machine including all operation parameters and the frictionally engaged torque of the clamping hub is at least a service factor of s = 2.

Components of ROTEX

GS, DKM

Component Quantity Description

4 2 setscrew DIN EN ISO 4029 illustration 15: ROTEX ® GS, DKM

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ROTEX

Operating/mounting instructions

4 Assembly

4.2 Coupling Components

Components of ROTEX

GS Compact, clamping hubs

Component Quantity

1 2

Description clamping hub (hub types 2.0, 2.1, 2.8 or 2.9)

3 2 / 4 cap screws DIN EN ISO 4762

KTR-N sheet: edition:

45510 EN

18 of 33

14 illustration 16: ROTEX ® GS Compact, size 7 - 19 illustration 17: ROTEX ® GS Compact, size 24 - 38

A T T E N T I O N !

Hub types 1.1, 2.0, 2.5, 2.8, 7.5 and 7.8 (without feather key) may be used in category 3 only.

) A T T E N T I O N !

Selection of clamping hubs

With the use in explosion-proof areas the clamping hubs have to be selected in a way that the difference between the peak torque of the machine including all operation parameters and the frictionally engaged torque of the clamping ring hub is at least a service factor of s = 2.

4.3 Hints for Assembly

Subject to its type housing.

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 corresponding mounting holes in the

The pegs on the spider arranged reciprocally avoid 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 a blind assembly. When the coupling hubs are combined with the ROTEX

GS spider an axial mounting force is produced resulting from the flexible prestress of the star-shape elastomer. This mounting force varies depending on the coupling size, the spider hardness and the machining tolerances. The axial mounting force is compensated for after assembly of the hubs and consequently does not mean any danger of axial load onto adjacent bearings.

The mounting force can be reduced by slightly greasing or oiling 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.

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Operating/mounting instructions

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45510 EN

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4 Assembly

4.4 Hint for Finish Bore

D A N G E R !

STOP The maximum permissible bore diameters d (see tables 1 to 10 in chapter 1 – Technical Data) must not be exceeded.

If these figures are not observed, the coupling may tear.

Rotating fragments may be hazardous.

• If the hub bore is machined by the customer, the accuracy in concentric running or run-out, respectively (see illustration

18) has to be observed.

• Please make absolutely sure to observe the figures for

Ød max.

• Align the hubs carefully when machining the finish bore.

• Please use a setscrew according to DIN EN ISO 4029 with cup point or an end plate to secure the hubs axially. illustration 18: accuracy in concentric running or run-out

C A U T I O N !

The customer is responsible for all machinings made subsequently to unbored or pilot bored and to finish machined coupling parts and spare parts. KTR does not assume any warranty claims resulting from insufficient machining.

A T T E N T I O N !

Any mechanical remachining on couplings which are to be used in hazardous areas requires an explicit release by KTR.

The customer has to provide KTR with a production drawing which the production is based on. KTR will investigate this drawing and return it to the customer along with a corresponding approval note.

KTR will supply unbored or pilot bored coupling components and spare parts on special request by the customer only. Such components are marked with the symbol additionally.

Table 11: Setscrews DIN EN ISO 4029

ROTEX

Size

5 7 9 12 14 19 24 28 38 42 48 55 65 75

Tightening torque T

[Nm]

- - 1,5 1,5 1,5 2 2 10 10 10 10 17 17 17

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Operating/mounting instructions

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4 Assembly

4.5 Assembly of Hubs (Types 1.0, 1.1 and 1.2)

) A T T E N T I O N !

We recommend to check bores, shaft, keyway and feather key for dimensional accuracy before assembly.

Before mounting preservatives have to be removed from the bores. Moreover, the shaft ends have to be cleaned carefully, too.

C A U T I O N !

Please note the manufacturer’s instructions regarding the use of detergents.

If the hubs are sligthly heated (approx. 80 °C) they can be assembled onto the shaft more easily.

A T T E N T I O N !

Please note the danger of ignition in hazardous areas.

STOP

D A N G E R !

Touching the heated hubs causes burns. For that reason we recommend to wear safety gloves.

C A U T I O N !

Please observe the dimension E (see tables 1 to 9) for the assembly to make sure that the spider can be moved axially during the operation. The coupling may be damaged if this recommendation is not followed.

• Please assemble the hubs onto the shaft of driving and driven side.

• Please shift the power pack into axial direction until the dimension E is reached.

• If the power packs have already been mounted firmly, the dimension E has to be adjusted by shifting the hubs on the shafts axially.

• Secure the hubs by tightening the setscrews DIN EN ISO 4029 at the tightening torques T

A table 10.

) A T T E N T I O N !

mentioned in

If the shaft diameters with inserted feather key fall below the dimension d

of the spider

(see tables 1 to 10), one or both shaft ends may protude into the spider.

C A U T I O N !

Hub type 1.1 (without feather key) may be used in category 3 only.

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Operating/mounting instructions

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4 Assembly

4.6 Assembly of Clamping Hubs (Types 2.0, 2.1, 2.5, 2.6, 2.8, 2.9, 7.5, 7.6, 7.8 and 7.9)

The power transmission of ROTEX

GS clamping hubs (types 2.0, 2.5, 2.8, 7.5 and 7.8) is done frictionally engaged. With types 2.1, 2.6, 2.9, 7.6 and 7.9 a feather key additionally provides for positive locking power transmission.

The following process should be noted for the assembly:

• Clean and degrease the hub bore and the shaft.

• Slightly detach the clamping screw.

• Slip the hub onto the shaft. Please observe the dimension l

• Tighten the clamping screws at the tightening torques mentioned in table 3.

For types 2.8, 7.5, 7.8 or 2.9, 7.6, 7.9 (with keyway) the screws have to be tightened alternately at the tightening torques mentioned in table 3.

A T T E N T I O N !

Please note: types 2.8, 2.9, 7.5, 7.6, 7,8 or 7.9 have 2 clamping screws

C A U T I O N !

The frictionally engaged transmittable torques of the clamping hubs depend on the bore diameter.

A T T E N T I O N !

Hub types 2.0, 2.5, 2.8, 7.5 and 7.8 (without feather key) may be used in category 3 only.

4.7 Assembly of Clamping Ring Hubs (Types 6.0, 6.0 steel, 6.0 light and 6.5)

The power transmission of ROTEX

GS clamping ring 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 torques mentioned in tables 5 - 7 take into account a combination of fit H7/k6 from Ø55 G7/m6. With a higher backlash of fit the torques mentioned in tables 5 - 7 are reduced.

The stiffness and dimensions of the shafts (here specifically hollow shafts) have to be selected in a way that sufficient safety against plastic deformation is ensured. This may roughly be reviewed as per the following criterion.

A T T E N T I O N !

For the use in hazardous areas the setscrews/capscrews and setscrews to fasten the hubs additionally have to be secured against slackening, e. g. by conglutinating with Loctite

(average joint strength).

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ROTEX

Operating/mounting instructions

KTR-N sheet: edition:

4 Assembly

4.7 Assembly of Clamping Ring Hubs (Types 6.0, 6.0 steel, 6.0 light and 6.5)

For clamping connections with hollow shafts the required internal diameter of the hollow shaft d iW calculated based on the following formula:

is d iW

≤

⋅

R p 0 , 2

−

0 , 2

⋅

45510 EN

22 of 33

Shearing stress on the internal shaft diameter for hollow shaft:

σ tiW

≈ −

−

⋅ p

[

N / mm 2

]

Shearing stress for solid shaft: σ tW

= − p

[

N / mm 2

]

R p p0,2

= proof stress of shaft material [Nmm

= surface pressure hub/shaft [N/mm

]

] d iW

= internal diameter of hollow shaft [mm] d = shaft diameter [mm]

= d iW

/ d

The required strength does not exist if the hollow shaft bore is bigger than the max. internal bore calculated or if the shearing stress exceeds the yield strength of the material. For a detailed calculation please contact the KTR engineering department.

• Clean the hub bore and shaft and review for dimensional accuracy, afterwards lubricate with a thin-bodied oil (e. g. Castrol 4 in 1 or Klüber

Quietsch-Ex).

C A U T I O N !

Oils and greases containing molybdenum disulfide or other high-pressure additives as well as internal lubricants must not be used.

• Slightly detach the clamping screw and pull the clamping ring from the hub only marginally to make sure that the clamping ring is loosened.

• Slip the claming ring hub onto the shaft. The dimension L adhered to at least.

should be

• Tighten the clamping screws evenly stepwise and crosswise to the tightening torque mentioned in table 6 or 7. This process has to be repeated until the tightening torque is reached for all clamping screws. illustration 20: Assembly of clamping ring hub with clamping ring

• Assembly of the clamping ring hub 6.0 light:

Tighten the clamping screws evenly stepwise and crosswise at 1/3 or 2/3 tightening torque T

, respectively

(see table 6) until the ring gets in contact. Afterwards tighten the screws at the tightening torque mentioned in table 6 one after another.

A T T E N T I O N !

) A T T E N T I O N !

Selection of clamping hubs

With the use in explosion-proof areas the clamping hubs have to be selected in a way that the difference between the peak torque of the machine including all operation parameters and the frictionally engaged torque of the clamping hub is at least a service factor of s = 2.

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ROTEX

Operating/mounting instructions

KTR-N sheet: edition:

45510 EN

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4 Assembly

4.7 Assembly of Clamping Ring Hubs (Types 6.0, 6.0 steel, 6.0 light and 6.5)

Disassembly:

Untighten the clamping screws evenly one after the other. Each screw may only be untightened by half a revolution for each cycle. Unscrew all clamping screws by 3 – 4 convolutions.

Remove the screws situated next to the pull-off threads and screw them into the respective pull-off threads.

The clamping ring is untightened if the screws in the pull-off threads are tightened evenly stepwise and crosswise.

C A U T I O N !

! If these hints are not observed, the operation of the coupling may be damaged. illustration 21: Disassembly of clamping ring hub with clamping ring

In case of a repeated assembly the hub bore and shaft have to be cleaned and afterwards lubricated with a thinbodied oil (e. g. Castrol 4 in 1 or Klüber Quitsch EX). The same applies for the taper surfaces of clamping ring hub and clamping ring.

C A U T I O N !

Oils and greases containing molybdenum disulfide or other high-pressure additives as well as internal lubricants must not be used.

For type 6.0 light only:

) A T T E N T I O N !

In case of re-assembly the taper surfaces, hub bores and the shaft have to be cleaned. The hub bore and shaft have to be lubricated with thin-bodied oil (e. g. Castrol 4 in 1 or Klüber

Quietsch-Ex). Lightly paint the taper surfaces of the clamping ring hub or clamping ring with the grease Gleitmo 800, afterwards turn the parts by one revolution in order to spread the grease evenly.

4.8 Displacements – Alignment of the Couplings

The displacement figures mentioned in table 12 and 13 provide for safety in order to compensate for external influences like, for example, thermal expansion or sinking of basement.

C A U T I O N !

In order to ensure a long lifetime of the coupling and avoid danger with the use in hazardous areass, the shaft ends have to be aligned accurately. Please make absulutely sure to observe the displacement figures indicated (see table 12 and 13). If these figures are exceeded, the coupling will be damaged.

The more precisely the coupling is aligned, the higher is its service life.

For the use in hazardous areass for explosion class IIC (designation II 2GD c IIC T X) only

Please note: the displacement figures (see table 12 and 13) have to be carefully reviewed and adhered to.

• The displacement figures mentioned in table 12 and 13 are maximum figures which must not arise in parallel.

If radial and angular displacements arise at the same time, the permissible displacement figures may only be used proportionally.

• Please review by means of a metering clockwork, ruler or feeler gauge if the permissible displacement figures mentioned in table 12 and 13 are observed.

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Operating/mounting instructions

4 Assembly

4.8 Displacements – Alignment of the Couplings

KTR-N sheet: edition:

45510 EN

24 of 33

Angular displacements

∆ K w

[mm] = L

1max

- L

1min

Examples of the combinations of displacements shown in picture 15:

Example 1:

∆ K

= 30%

∆ K

= 70%

Example 2:

∆ K

= 60%

∆ K

= 40%

Radial displacements illustration 22: displacements illustration 15: combination of displacements

Axial displacements

L max

= L + ∆ K a

∆ K total

= ∆ K

+ ∆ K

≤ 100 %

Table 12: Displacements

Size

14 max. axial displacement

∆ Ka [mm]

+0,4 / -0,2

+0,6 / -0,3

+0,8 / -0,4

+0,9 / -0,4

+1,0 / -0,5

+1,2 / -0,5

+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

ShA-GS

0,12

0,15

0,19

0,20

0,21

0,15

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∆ Kr [mm]

ShA-GS

95/98

ShA-GS

ShD-GS

0,06

0,10

0,13

0,14

0,15

0,10

0,14

0,15

0,17

0,19

0,23

0,24

0,04

0,11

0,12

0,14

0,16

0,17

0,18

0,21

ShD-GS

ShA-GS

1,1 max. angular displacement

1,0

∆ Kw [degrees]

ShA-GS

95/98

ShA-GS

0,9

ShD-GS

0,06 0,04 - 1,1 1,0 0,9 0,8 -

0,08 0,05 - 1,1 1,0 0,9 0,8 -

0,09 0,06 - 1,1 1,0 0,9 0,8 -

0,06 0,04 - 1,1 1,0 0,9 0,8 -

0,10 0,07 0,04 - 1,0 0,9 0,8 0,7

0,08 0,05 - 1,0 0,9 0,8 0,7

0,09 0,06 - 1,0 0,9 0,8 0,7

0,10 0,07 - 1,0 0,9 0,8 0,7

0,11 0,08 - 1,0 0,9 0,8 0,7

0,12 0,09 - 1,0 0,9 0,8 0,7

0,13

0,15

0,10

0,9

0,8

0,7

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Operating/mounting instructions

4 Assembly

4.8 Displacements – Alignment of the Couplings

Table 13: Displacements – Type DKM

KTR-N sheet: edition:

45510 EN

25 of 33

Size

14 max. axial displacement

∆ Ka [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

ShA-GS

0,15

0,23

0,29

0,35

0,40

0,49

- max. radial displacement

∆ Kr [mm]

ShA-GS

95/98

ShA-GS

ShD-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

0,13

0,60

0,69

0,75

0,82

0,91

ShD-GS

ShA-GS

1,1 max. angular displacement

1,0

∆ Kw [degrees]

ShA-GS

95/98

ShA-GS

0,9

ShD-GS

0,19 0,17 - 1,1 1,0 0,9 0,8 -

0,24 0,21 - 1,1 1,0 0,9 0,8 -

0,29 0,25 - 1,1 1,0 0,9 0,8 -

0,33 0,29 - 1,1 1,0 0,9 0,8 -

0,41 0,36 - 1,1 1,0 0,9 0,8 -

0,53 0,47 0,42 - 1,0 0,9 0,8 0,7

0,53 0,46 - 1,0 0,9 0,8 0,7

0,61 0,54 - 1,0 0,9 0,8 0,7

0,67 0,59 - 1,0 0,9 0,8 0,7

0,73 0,64 - 1,0 0,9 0,8 0,7

0,81 0,71 - 1,0 0,9 0,8 0,7

The permissible displacement figures of the flexible ROTEX

® account the load of the coupling until the rated torque T

GS couplings mentioned are general standard values taking into

of the coupling and an ambient temperature of +30 °C.

Spares Inventory, Customer Service Addresses

A basic requirement to guarantee the operational readiness of the coupling is a stock of the most important spare parts on site.

Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage under www.ktr.com.

5 Enclosure A

Hints and Instructions Regarding the Use in Hazardous Areas

Current types: a) Hubs with feather key or CLAMPEX

clamping set or clamping ring hubs

• 1.0 Hub with feather key and thread for setscrews

• 2.1 Clamping hub single slot with feather key

• 2.6 Clamping hub double slot with feather key

• 2.9 Clamping hub with axial slot with feather key

• 4.1 with

• 4.2 with

clamping set KTR 200

clamping set KTR 250

• 6.0 Clamping ring hub

• 6.0 Clamping ring hub light

• 6.0 P Precision clamping ring hub

• 6.5 Clamping ring hub

(Please note: external clamping screws)

• 7.6 Split clamping hub with feather key for double-cardanic combinations

• 7.9 Split clamping hub with feather key for single-cardanic combinations

• Type DKM with hubs corresponding to the aforementioned details

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5 Enclosure A

ROTEX

Operating/mounting instructions

KTR-N sheet: edition:

45510 EN

26 of 33

Hints and Instructions Regarding the Use in Hazardous Areas

Current types: b) Hubs without feather key (category 3 only)

• 1.1 Hub without feather key, with thread for setscrews

• 2.0 Clamping hub single slot without feather key

• 2.5 Clamping hub double slot without feather key

• 2.8 Clamping hub with axial slot without feather key

• 7.5 Split clamping hub without feather key for double-cardanic combinations

• 7.8 Split clamping hub without feather key for single-cardanic combinations

• Type DKM with hubs corresponding to the aforementioned details

ROTEX

R p0,2

® GS type DKM only with spacer from steel or aluminium wrought products with a yield stress

≥ 250 N/mm

5.1 Use in Hazardous Areas According to the Regulations

Conditions of operation in

ROTEX

hazardous locations

GS couplings are suitable for the use according to EC standard 94/9/EC.

1. Industry (with the exception of mining)

• device class II of category 2 and 3 ( coupling is not approved for device class 1 )

• media class G ( gases, fogs, steams ), zone 1 and 2 ( coupling is not approved for zone 0 )

• media class D ( dusts ), zone 21 and 22 ( coupling is not approved for zone 20)

• explosion class IIC ( explosion class IIA and IIB are included in IIC )

Temperature class:

Temperature class

T4, T3, T2, T1

T6 ambient or operating temperature T a

- 30 °C to + 90 °C

- 30 °C to + 80 °C

- 30 °C to + 65 °C max. surface temperature

100 °C

85 °C

Explanation:

The maximum surface temperatures result from each the maximum permissible ambient or operating temperature T maximum temperature increase ∆ T of 20 K which has to be taken into account.

1) The ambient or operating temperature T a

plus the 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, too.

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ROTEX

Hints and Instructions Regarding the Use in

Operating/mounting instructions

Hazardous Areas

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5.1 Use in Hazardous Areas According to the Regulations

Operating temperature (spider):

Description of spider hardness

[Shore]

80 Sh A-GS

92 Sh A-GS

95/98 Sh A-GS

64 Sh D-H-GS

64 Sh D-GS

72 Sh D-H-GS

72 Sh D-GS

Permissible temperature range [°C]

Permanent temperature Max. temperature shore-term

-50 to +80

-40 to +90

-30 to +90

-50 to +120

-20 to +110

-50 to +120

-20 to +110

-60 to +120

-50 to +120

-40 to +120

-60 to +150

-30 to +120

-60 to +150

-30 to +120

C A U T I O N !

In case that the operating temperature change it is absolutely necessary to verify the coupling selection (see ROTEX

GS catalogue).

2. Mining

Device class I of category M2 (coupling is not approved for device category M1).

Permissible ambient temperature - 30 °C to + 90 °C.

5.2 Control Intervals for Couplings in Hazardous Areas explosion group control intervals

II 2GD c IIB

T4, T5, T6

II 2GD c IIC

T4, T5, T6

For couplings which are classified in category 3G or 3D the operating and assembly instructions that are usual for standard operation apply. During the standard operation which has to be subject to the analysis of danger of ignition the couplings are free from any ignition source. Merely the temperature increase produced by proper heating and depending on the coupling type has to be considered:

GS: ∆ T = 20 K

A checking of the circumferential backlash and a visual check of the flexible spider must be effected after 3,000 operating hours for the first time, after 6 months at the latest. Except for centered, stiff connecting flanges (e. g. bellhousings).

If you note an unconsiderable or no wear at the spider after this first inspection, the further inspections can be effected, in case of the same operating parameters, respectively after

6,000 operating hours or after 18 months at the latest.

If you note a considerable wear during the first inspection, so that a change of the spider would be recommended, please find out the cause according to the table „Breakdowns“, as far as possible.

The maintenance intervals must be adjusted according to the changed operating parameters.

A checking of the circumferential backlash and a visual check of the flexible spider must be effected after 2,000 operating hours for the first time, after 3 months at the latest. Except for centered, stiff connecting flanges (e. g. bellhousings).

If you note an unconsiderable or no wear at the spider after this first inspection, the further inspections can be effected, in case of the same operating parameters, respectively after

4,000 operating hours or after 12 months at the latest.

The maintenance intervals must be adjusted according to the changed operating parameters.

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Operating/mounting instructions

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Hints and Instructions Regarding the Use in Hazardous Areas

5.2 Control Intervals for Couplings in

A T T E N T I O N !

Hazardous Areas

Hub types 1.1, 2.0, 2.5, 2.8, 7.5 and 7.8 (without feather key) may be used in category 3 only.

ROTEX

GS backlash-free shaft coupling illustration 24: ROTEX ® GS backlash-free shaft coupling illustration 25: ROTEX ® GS spider

If the drive allows, the backlash between the cams of the coupling and the flexible spider has to be measured by means of a feeler gauge. Regardless of the inspection intervals, the spider has to be replaced immediately if the wear limit maximum wear has been achieved.

5.3 Approximate Values of Wear

In case of a backlash of more than x mm, the flexible spider must be exchanged.

Whether the limit for replacement has been achieved or not depends on the conditions of operation and the existing operating parameters.

C A U T I O N !

In order to ensure a long lifetime of the coupling and avoid danger with the use in hazardous areas, the shaft ends have to be aligned accurately. Please make absolutely sure to adhere to the displacement figures mentioned (see table 12 and 13). If these figures are exceeded, the coupling will be damaged. illustration 18: checking of the limit of wear illustration 19: wear of spider

) A T T E N T I O N !

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:

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Operating/mounting instructions

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Hints and Instructions Regarding the Use in

5.3 Approximate Values of Wear

Table 14:

Hazardous Areas

ROTEX

Size

GS Wear limits

X max.

[mm]

ROTEX

Size

GS Wear limits

X max.

[mm]

5 0,4 28 1,4

7 0,5 38 1,7

9 0,9 42 2,0

12 0,6 48 2,25

14 1,25 55 2,50

19 0,9 65 2,75

24 1,0 75 3,00

5.4 Permissible Coupling Materials in the Hazardous Area

In the Explosion Groups IIA, IIB and IIC the following materials may be combined: steel stainless steel aluminium wrought products

Semifinished products from aluminium with a magnesium part of up to 7,5 % and a yield point of

R p0,2

≥ 250 N/mm

are permitted for the use in hazardous areas.

Aluminium diecast is generally excluded for hazardous areas.

5.5 Marking of Coupling for the Hazardous Area

Couplings for the use in hazardous areas are marked on at least one component completely and on the remaining components at the outside diameter of the hub or on the front side with an label for the respectively permitted conditions of use. The flexible spider is excluded.

For reason of the limited space only the symbol is stamped up to size 19.

Complete labelling: II 2G c IIC T6, T5 bzw. T4 - 30 °C ≤ T

II 2D c T 110 °C/I M2 c - 30 °C ≤ T a

≤ + 65°C, + 80 °C bzw. +90 °C a

≤ + 90 °C

Category 3: II 3G c IIC T6, T5 bzw. T4 - 30 °C

II 3D c T 110 °C - 30 °C ≤ T

≤ T a

≤ + 65°C, + 80 °C bzw. +90 °C a

≤ + 90 °C

Short labelling:

II 2GD c IIC T X/I M2 c X

The former marking remains valid:

II 2G c IIC T4/T5/T6 - 30 °C ≤ T a

≤ + 80/60/45 °C

II 2D c T 110 °C/I M2 c - 30 °C ≤ T a

≤ + 80 °C

The labelling with Explosion Group llC includes the Explosion Groups llA and llB.

If the coupling part is labelled with in addition to , KTR supplied it unbored or pilot bored.

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Hints and Instructions Regarding the Use in

Operating/mounting instructions

Hazardous Areas

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5.5 Marking of Coupling for the Hazardous Area

C A U T I O N !

Any mechanical rework to couplings that are used in hazardous areas require an explicit release by KTR.

The orderer must send a drawing to KTR acc. to which the manufacture must be made. KTR checks this drawing and returns it to the orderer with approval.

5.6 Starting

Before putting the coupling into operation, check the tightness of the setscrews in the hubs, the alignment and the distance dimension E and correct, if necessary, and also check all screw connections regarding the stipulated tightening torques dependent on the type of coupling.

If used in hazardous areas the grub screws to fix the hub as well as all screw connections must be additionally secured against self-loosening, e. g. glue with Loctite (medium strength).

Last but not least, the coupling protection against unintended contact must be fixed.

The cover must be electrically conductive and be included in the equipotential bonding. Bellhousings (magnesium part below 7,5 %) made from aluminium and damping rings (NBR) can be used as connecting element between pump and electro motor. The cover may only be taken off after having stopped the unit.

During operation, please pay attention to

• strange running noises

• vibrations.

If the couplings are used in dust explosive areas and in mining the user must make sure that there is no accumulation of dust in a critical quantity between the cover and the coupling. The coupling must no operate in an accumulation of dust.

For covers with unlocked openings on the upper side no light metals may be used if the couplings are used as appliances of appliance group ll ( if possible, from stainless steel ).

If the couplings are used in mining (appliance group l M2), the cover must not be made from light metal. In addition, it must be resistant to higher mechanical loads than if it is used as appliance of appliance group ll.

The minimum distance “Sr” of the protection device of the rotating parts must be at least the values listed below.

If the protection device is used as cover, regular openings complying with the explosion protection demands can be made that must not exceed the following dimensions: openings top surface

4 covering side parts

8 distance „Sr“

≥ 10

≥ 10 circular – max. diameter rectangular – max. side length

Straight or bended slot – max. side length/height prohibited 8 ≥ 20

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Operating/mounting instructions

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Hints and Instructions Regarding the Use in Hazardous Areas

5.6 Starting

C A U T I O N !

If you note any irregularities at the coupling during operation, the drive unit must be turned off immediately. The cause of the breakdown must be found out with the table

„Breakdowns“ and, if possible, be eliminated according to the proposals. The possible breakdowns mentioned can be hints only. To find out the cause all operating factors and machine components must be considered.

Coupling layer:

If coated (priming, painting etc.) couplings are used in hazardous areas, the requirements to conductability and layer thickness must be considered. In case of paintings up to 200 µm no electrostatic load can be expected. Multiple coatings that are thicker than 200 µm are prohibited for explosion group llC.

5.7 Breakdowns, Causes and Elimination

The below-mentioned errors can lead to an incorrect use of the ROTEX

® coupling. In addition to the stipulations in these operating and mounting instructions please make sure to avoid these errors.

The errors listed can only be clues to search for the errors. When searching for the error the adjacent components must be generally included.

Due to incorrect use the coupling can become a source of ignition.

EC Standard 94/9/EC requires a special care from the manufacturer and the user.

General errors incorrect use

• Important data for the coupling selection was not forwarded.

• The calculation of the shaft/hub connection was not considered.

• Coupling parts with damage occurred during transport are assembled.

• If the heated hubs are assembled, the permissible temperature is exceeded.

• The fits of the parts to be assembled are not coordinated with each other.

• Tightening torques are below/exceeded.

• Components are exchanged by mistake/put together incorrectly.

• A wrong or no spider is inserted into the coupling.

• No original KTR parts (purchased parts) are used.

• Old/already worn out spiders or spiders stored too long are used.

• The coupling used/the coupling protection used is not suitable for the operation in hazardous areas and does not correspond to EC Standard 94/9/EC, respectively.

• Maintenance intervals are not observed.

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Operating/mounting instructions

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Hints and Instructions Regarding the Use in Hazardous Areas

5.7 Breakdowns, Causes and Elimination danger hints for breakdowns causes hazardous areas change of the running noises and/or occurring vibrations break of cam misalignment wear of spider, shortterm torque transmission due to metal contact loose screws for axial securement of hubs wear of spider, torque transmission due to metal contact break of the cams due to high shock energy/overload operating parameters do not correspond to the performance of the coupling mistake in service of the unit increased temperature the the spider surface; danger of ignition by hot surfaces danger of ignition due to sparking danger of ignition due to hot surfaces and sparking danger of ignition due to sparking danger of ignition due to sparking danger of ignition due to sparking danger of ignition due to sparking elimination

1) put the unit out of operation

2) eliminate the reason for the misalignment (e. g. loose foundation bolts, break of the engine fixing, heat expansion of unit components, change of the assembly dimension E of the coupling)

3) checking of wear see under point Control

1) put the unit out of operation

2) disassemble the coupling and remove rests of the spider

3) check coupling parts and exchange damaged coupling parts

4) insert spider, assemble coupling parts

5) check alignment, correct if necessary

1) put the unit out of operation

2) check alignment of coupling

3) tighten the screws to secure the hubs and secure against self-loosening

4) checking of wear see under point Control

1) put the unit out of operation

2) change complete coupling

3) check alignment

1) put the unit out of operation

2) change complete coupling

3) check alignment

4) find out the reason of overload

1) put the unit out of operation

2) check the operating parameters and select a larger coupling (consider installation space)

3) assemble new coupling size

4) check alignment

1) put the unit out of operation

2) change complete coupling

3) check alignment

4) instruct and train the service staff

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Operating/mounting instructions

KTR-N sheet: edition:

45510 EN

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)

Hints and Instructions Regarding the Use in Hazardous Areas

5.7 Breakdowns, Causes and Elimination danger hints for breakdowns causes hazardous areas

Early wear of spider or reverse backlash premature wear of spider (liquefaction of material inside the spider cam) misalignment e. g. contact with aggressive liquids/ oils, ozone-influence, too high/low ambient temperatures etc. effecting a physical change of the spider

Excessively high/low ambient/contact temperatures for the spider; max. permissible e. g. T4 =

- 30 °C/+ 90 °C drive vibrations elimination increased temperature the the spider surface; danger of ignition by hot surfaces

1) put the unit out of operation

2) eliminate the reason for the misalignment (e. g. loose foundation bolts, break of the engine fixing, heat expansion of unit components, change of the assembly dimension E of the coupling)

3) checking of wear see under point Control danger of ignition due to sparking in case of metallic contact of the cams danger of ignition due to sparking in case of metallic contact of the cams danger of ignition due to sparking in case of metallic contact of the cams

1) put the unit out of operation

2) disassemble the coupling and remove rests of the spider

3) check coupling parts and exchange damaged coupling parts

4) insert spider, assemble coupling parts

5) check alignment, correct if necessary

6) make sure that further physical changes of the spider are excluded

1) put the unit out of operation

2) disassemble the coupling and remove rests of the spider

3) check coupling parts and exchange damaged coupling parts

4) insert spider, assemble coupling parts

5) check alignment, correct if necessary

6) check and regulate ambient/contact temperature (eventually even elimination by using other spider materials)

1) put the unit out of operation

2) disassemble the coupling and remove rests of the spider

3) check coupling parts and exchange damaged coupling parts

4) insert spider, assemble coupling parts

5) check alignment, correct if necessary

6) find out the reason for the vibrations

(eventually elimination by spider with lower or higher shore hardness)

If you operate with a worn spider (see item 5.2) and the subsequent contact of metal parts a due operation meeting the explosion protection requirements and acc. to Standard 94/9/EC is not ensured.

A T T E N T I O N !

KTR does not assume any liabilities or guarantees regarding the use of spare parts and accessories which are not provided by KTR and for the damages resulting herefrom.

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Hints and Instructions Regarding the Use in

5.8 EC Certificate of Conformity

Operating/mounting instructions

Hazardous Areas

KTR-N sheet: edition:

45510 EN

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EC Certificate of Conformity

Corresponding to EC Standard 94/9/EC dated 23 March 1994 and to the legal regulations

The manufacturer - KTR Kupplungstechnik GmbH, D-48432 Rheine – states that the

ROTEX

GS backlash-free shaft couplings described in these mounting instructions and explosion-proof designed correspond to Article 1 (3) b) of Standard 94/9/EC and comply with the general Safety and Health Requirements according to enclosure II of Standard 94/9/EC.

According to article 8 (1) b) ii) of Standard 94/9/EC the technical documentation is desposited with the:

IBExU

Institut für Sicherheitstechnik GmbH

Fuchsmühlenweg 7

09599 Freiberg

Rheine, 08.01.09 i. V.

Date Reinhard

Engineering Manager i. V.

Product Manager

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