KTR-Group BoWex M-65 Operating & Assembly Instructions
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KTR-N Sheet: Edition: BoWex® Operating/Assembly instructions 40110 EN 1 of 22 16 BoWex® Non-failsafe curved-tooth gear couplings types junior plug-in coupling, junior M coupling, M und M...C I and their combinations Type junior plug-in coupling (two-part) according to directive 2014/34/EU Type junior M coupling (three-part) Type M and M...C Type I Please observe protection note ISO 16016. Drawn: Verified: 2019-07-01 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 BoWex® Operating/Assembly instructions KTR-N Sheet: Edition: 40110 EN 2 of 22 16 The BoWex® curved-tooth gear coupling is a flexible shaft connection. It is able to compensate for shaft misalignment, for example caused by manufacturing inaccuracies, thermal expansion, etc. Table of contents 1 Technical data 3 2 Advice 5 2.1 2.2 2.3 2.4 2.5 2.6 5 5 5 6 6 6 3 4 General advice Safety and advice symbols General hazard warnings Intended use Coupling selection Reference to EC Machinery Directive 2006/42/EC Storage, transport and packaging 7 3.1 3.2 7 7 Storage Transport and packaging Assembly 4.1 4.2 4.3 4.4 7 Components of the couplings Advice for finish bore Assembly of the hubs Displacements - alignment of the couplings 7 9 10 11 5 Start-up 12 6 Breakdowns, causes and elimination 13 7 Disposal 15 8 Spares inventory, customer service addresses 15 9 Enclosure A Advice and instructions regarding the use in potentially explosive atmospheres 9.1 Intended use in 9.2 9.3 9.4 Inspection intervals for couplings in Inspection of torsional backlash Standard values of wear 9.5 9.6 marking of coupling for potentially explosive atmospheres EU Certificate of conformity Please observe protection note ISO 16016. Drawn: Verified: potentially explosive atmospheres 16 potentially explosive atmospheres 2019-07-01 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: 16 17 18 19 20 22 KTR-N dated 2017-01-02 KTR-N Sheet: Edition: BoWex® Operating/Assembly instructions 1 40110 EN 3 of 22 16 Technical data Illustration 1: BoWex® junior plug-in coupling (two-part) Illustration 2: BoWex® junior M coupling (three-part) Table 1: BoWex® junior plug-in coupling and BoWex® junior M coupling Torque [Nm] Size TKN TK max 14 5 10 19 8 16 24 12 24 Hub component 1b d1 Ø6, Ø7, Ø8, Ø9 Ø10, Ø11 Ø12, Ø14 Ø12, Ø14 Ø16 Ø19 Ø10, Ø11, Ø12 Ø14, Ø15, Ø16 Ø18, Ø19, Ø20 Ø24 Finish bores [mm] Plug-in sleeve D1 component 2b d2 22 Ø8 25 Ø10, Ø11 26 Ø12, Ø14 27 Ø14, Ø15 30 32 Ø19 26 Ø14, Ø16 32 36 Ø19, Ø20 38 Ø24 Setscrew [mm] Max. speed [rpm] D2 G1 t1 t2 TA [Nm] 22 25 26 M5 6 8 1.4 6000 M5 6 10 1.4 6000 M5 6 10 1.4 6000 29 35 32 36 40 Table 2: BoWex® junior plug-in coupling and BoWex® junior M coupling Size 14 19 24 DH 40 47 53 l1, l2 23 25 26 Please observe protection note ISO 16016. E1 2 2 2 Drawn: Verified: L1 48 52 54 LH1 40 42 45 Dimensions [mm] M1 F 8 18.5 10 19.0 9 21.5 2019-07-01 Pz/Wb 2019-07-23 Pz G 21.5 23.0 23.5 E 4 4 4 Replacing: Replaced by: L 50 54 56 LH 37 37 41 M, N 6.5 8.5 7.5 KTR-N dated 2017-01-02 KTR-N Sheet: Edition: BoWex® Operating/Assembly instructions 1 40110 EN 4 of 22 16 Technical data Illustration 3: BoWex® type M Illustration 4: BoWex® type I Table 3: BoWex® type M and type I Size Pilot bore Unbored Pilot bored 27 70 lg. 31 35 45 M-14 M-19 M-24 M-28 M-32 M-38 M-42 M-48 M-14C M-19C M-24C M-28C M-32C M-38C M-48C x x x x x x x x M-65 M-65C x I-80 I-100 I-125 - Max. finish bore d1, d2 15 20 24 28 32 38 42 48 Setscrew 2) [mm] Dimensions [mm] l1, l2 E L LH M, N l3 D DH DZ 1) G t 23 25 26 40 40 40 42 50 4 4 4 4 4 4 4 4 50 54 56 84 84 84 88 104 37 37 41 46 48 48 50 50 6.5 8.5 7.5 19 18 18 19 27 10 10 14 13 13 13 13 13 25 32 36 44 50 58 65 68 40 47 53 65 75 83 92 95 33 39 45 54 63 69 78 78 M5 M5 M5 M8 M8 M8 M8 M8 65 55 4 114 68 23 16 96 132 110 M10 80 100 125 90 110 140 6 8 10 186 228 290 93 102 134 46.5 63 78 20 22 30 124 152 192 175 210 270 145 176 225 M10 M12 M16 6 6 6 10 10 10 10 10 15 / 20 3) 20 30 40 TA [Nm] 2 2 2 10 10 10 10 10 17 17 40 80 1) Tip circle of hub 2) Position of setscrew BoWex® M-14 to M-24 opposite the keyway; BoWex® M-28 to I-125 on the keyway 3) Length of hub 55 mm t = 15 mm, 70 mm t = 20 mm BoWex® couplings with attachments that can generate heat, sparks and static charging (e. g. combinations with brake drums, brake disks, overload systems such as torque limiters, fan impellers etc.) are not permitted for the use in potentially explosive atmospheres. A separate analysis must be performed. Please observe protection note ISO 16016. Drawn: Verified: 2019-07-01 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 BoWex® Operating/Assembly instructions 2 KTR-N Sheet: Edition: 40110 EN 5 of 22 16 Advice 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 BoWex® 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. 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. 2.2 Safety and advice symbols STOP ! 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. 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 This symbol indicates notes which may contribute to preventing material or machine damage. General advice 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. Please observe protection note ISO 16016. Drawn: Verified: 2019-07-01 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 BoWex® Operating/Assembly instructions 2 KTR-N Sheet: Edition: 40110 EN 6 of 22 16 Advice 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 BoWex® described in here corresponds to the technical status at the time of printing of these operating/assembly instructions. 2.5 Coupling selection ! For a long-lasting and failure-free operation of the coupling it must be selected according to the selection instructions (according to DIN 740 part 2) for the particular application (see catalogue drive technology „BoWex®“). 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 sleeve 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. Please observe protection note ISO 16016. Drawn: Verified: 2019-07-01 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 BoWex® Operating/Assembly instructions 3 KTR-N Sheet: Edition: 40110 EN 7 of 22 16 Storage, transport and packaging 3.1 Storage The coupling hubs are supplied in preserved condition and can be stored at a dry and roofed place for 6 - 9 months. The features of the coupling sleeves 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 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. 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 couplings Type made of nylon Components of BoWex® junior plug-in coupling Component 1 2 Number 1 1 3 2 Description Hub Plug-in sleeve Setscrew DIN EN ISO 4029 Illustration 5: BoWex® junior plug-in coupling Please observe protection note ISO 16016. Drawn: Verified: 2019-07-01 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 BoWex® Operating/Assembly instructions 4 KTR-N Sheet: Edition: 40110 EN 8 of 22 16 Assembly 4.1 Components of the couplings Components of BoWex® junior M coupling Component 1 2 Number 2 1 3 2 Description Hub Sleeve Setscrew DIN EN ISO 4029 Illustration 6: BoWex® junior M coupling Type made of steel/nylon Components of BoWex® M coupling (size 14 - 65) Component 1 2 Number 2 1 3 2 Description Hub Sleeve type M Setscrew DIN EN ISO 4029 Illustration 7: BoWex® type M Components of BoWex® I coupling (size 80 - 125) Component 1 2 3 Number 2 1 2 4 2 Description Hub Sleeve type I1) Seeger Circlip 1) Setscrew DIN EN ISO 4029 1) Seeger circlips and sleeve are delivered pre-assembled. Illustration 8: BoWex® type I Please observe protection note ISO 16016. Drawn: Verified: 2019-07-01 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 KTR-N Sheet: Edition: BoWex® Operating/Assembly instructions 4 40110 EN 9 of 22 16 Assembly 4.2 Advice for finish bore 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. STOP • Hub bores (steel hubs) machined by the customer have to observe concentricity or axial run-out, respectively (see illustration 9). • Please make absolutely sure to observe the figures for Ø dmax. • 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 9: 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 4: Setscrew DIN EN ISO 4029 Size Dimension G Tightening torque TA [Nm] 14 1) M5 19 1) M5 24 1) M5 28 M8 32 M8 38 M8 42 M8 48 M8 65 M10 80 M10 100 M12 125 M16 2 2 2 10 10 10 10 10 17 17 40 80 1) Tightening torques of BoWex® junior plug-in coupling and BoWex® junior M coupling TA = 1.4 Nm Table 5: Recommended fit pairs acc. to DIN 748/1 Bore [mm] above up to 50 50 Shaft tolerance Bore tolerance k6 m6 H7 (KTR standard) If a feather keyway is intended to be used in the hub, it should correspond to the tolerance ISO JS9 (KTR standard) with standard operating conditions or ISO P9 with complicated operating conditions (frequently alternating torsional direction, shock loads, etc.). The transmittable torque of the shaft-hub-connection must be reviewed by the customer and is subject to his responsibility. Please observe protection note ISO 16016. Drawn: Verified: 2019-07-01 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 BoWex® Operating/Assembly instructions 4 KTR-N Sheet: Edition: 40110 EN 10 of 22 16 Assembly 4.3 Assembly of the hubs We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy before assembly. 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 make sure that the distance dimension E (see table 2 and 3) is observed to allow for axial clearance of the sleeve while being 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. • Does not apply with type BoWex® junior plug-in coupling: Put the sleeve onto the spline 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. • Fasten the hubs by tightening the setscrews DIN EN ISO 4029 with a cup point (tightening torques see table 4). Please observe protection note ISO 16016. Drawn: Verified: 2019-07-01 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 BoWex® Operating/Assembly instructions 4 KTR-N Sheet: Edition: 40110 EN 11 of 22 16 Assembly 4.4 Displacements - alignment of the couplings The displacement figures specified in tables 6 and 7 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 6 and 7). If the figures are exceeded, the coupling will be damaged. 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 6 and 7) is permissible. ! Please note: • The displacement figures specified in tables 6 and 7 are maximum figures which must not arise in parallel. If radial and angular displacement arise at the same time, the permissible radial displacements of the coupling halves have to be reduced as follows: Krzul = Kr − Kr • Ww 2Kw Ww = angular shaft displacement • The displacement figures specified are general standard figures that apply up to an ambient temperature of 80 °C, ensuring a sufficient service life of the BoWex® coupling. Displacement figures between the speeds specified have to be interpolated accordingly. If necessary, ask about the displacement for the corresponding coupling type. • Please inspect with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 6 and 7 can be observed. Angular displacements Radial displacements Axial displacements Radial and angular displacements Illustration 10: Displacements Examples of the displacement combinations specified in illustration 11: Example 1: Kr = 30 % Kw = 70 % Illustration 11: Combinations of displacement Example 2: Kr = 60 % Kw = 40 % Ktotal = Kr + Kw 100 % Please observe protection note ISO 16016. Drawn: Verified: 2019-07-01 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 KTR-N Sheet: Edition: BoWex® Operating/Assembly instructions 4 40110 EN 12 of 22 16 Assembly 4.4 Displacements - alignment of the couplings Table 6: Displacement figures - BoWex® junior plug-in coupling and BoWex® junior M coupling Type junior plug-in coupling 14 19 24 ±1 ±1 ±1 ±0.1 ±0.1 ±0.1 ±0.1 ±0.1 ±0.1 ±1.0 ±1.0 ±0.9 ±0.7 ±0.7 ±0.6 Size Max. axial displacement Ka [mm] Max. radial displacement with n=1500 rpm Kr [mm] Max. radial displacement with n=3000 rpm Kr [mm] Kw [degree] max. angular displacement with n=1500 rpm Kw [degree] max. angular displacement with n=3000 rpm Type junior M 19 ±1 ±0.3 ±0.3 ±1.0 ±0.7 14 ±1 ±0.3 ±0.3 ±1.0 ±0.7 24 ±1 ±0.4 ±0.4 ±0.9 ±0.6 Table 7: Displacement figures - BoWex® type M and type I Size Max. axial displacement Ka [mm] Max. radial displacement with n=1500 rpm Kr [mm] Max. radial displacement with n=3000 rpm Kr [mm] Kw [degree] max. angular displacement with n=1500 rpm Kw [degree] max. angular displacement with n=3000 rpm 5 14 ±1 19 ±1 24 ±1 28 ±1 32 ±1 38 ±1 42 ±1 48 ±1 65 ±1 80 ±1 100 ±1 125 ±1 ±0.30 ±0.30 ±0.35 ±0.35 ±0.35 ±0.40 ±0.40 ±0.40 ±0.45 ±0.45 ±0.45 ±0.45 ±0.20 ±0.20 ±0.23 ±0.23 ±0.23 ±0.25 ±0.25 ±0.25 ±0.28 ±0.28 ±0.28 ±0.28 ±1.0 ±1.0 ±0.9 ±0.9 ±0.9 ±0.9 ±0.9 ±0.9 ±0.7 ±0.6 ±0.6 ±0.4 ±0.7 ±0.7 ±0.6 ±0.6 ±0.6 ±0.6 ±0.6 ±0.6 ±0.5 ±0.4 ±0.4 ±0.3 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 2014/34/EU and must protect against • access with the 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. Please observe protection note ISO 16016. Drawn: Verified: 2019-07-01 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 BoWex® Operating/Assembly instructions 5 KTR-N Sheet: Edition: 40110 EN 13 of 22 16 Start-up 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. 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 sleeve is generally not admitted. 6 Breakdowns, causes and elimination The below-mentioned failures can result in a use of the BoWex® 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. Please observe protection note ISO 16016. Drawn: Verified: 2019-07-01 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 BoWex® Operating/Assembly instructions 6 KTR-N Sheet: Edition: 40110 EN 14 of 22 16 Breakdowns, causes and elimination 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 have been fallen below/exceeded. Components are mixed up by mistake/assembled incorrectly. No original KTR components (purchased parts) are used. Old/already worn out sleeves or sleeves stored for too long are used. Maintenance intervals are not observed. Breakdowns Different operating noise and/or vibrations occuring Causes Micro friction by faulty alignment on the spline of the nylon sleeve Hazard notes for potentially explosive atmospheres Danger of ignition due to hot surfaces Screws for axial fastening of hubs working loose Breaking of the nylon sleeve/spline due to high shock energy/overload Breaking of the nylon sleeve/spline Operating parameters do not meet with the performance of the coupling none Operating error of the unit Excessive wear on the spline of sleeve Vibrations of drive Danger of ignition due to hot surfaces Drawn: Verified: 2019-07-01 Pz/Wb 2019-07-23 Pz Please observe protection note ISO 16016. Elimination 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 9.2 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 9.2 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the nylon sleeve 3) Inspect coupling components and replace coupling components that have been damaged 4) Insert nylon sleeve, assemble coupling components 5) 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) Disassemble the coupling and remove remainders of the nylon sleeve 3) Inspect coupling components and replace coupling components that have been damaged 4) Insert nylon sleeve, assemble coupling components 5) Instruct and train the service staff 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the nylon sleeve 3) Inspect coupling components and replace coupling components that have been damaged 4) Insert nylon sleeve, assemble coupling components 5) Inspect alignment, adjust if necessary 6) Find out the reason for vibrations Replacing: Replaced by: KTR-N dated 2017-01-02 BoWex® Operating/Assembly instructions 6 40110 EN 15 of 22 16 Breakdowns, causes and elimination Breakdowns Causes Hazard notes for potentially explosive atmospheres ambient/contact temperatures which are too high for the sleeve, max. permissible -30 °C/+100 °C Danger of ignition due to hot surfaces e. g. contact with aggressive liquids/oils, ozone influence, too high/low ambient temperatures etc. causing a physical modification of the nylon sleeve none Excessive wear on the spline of sleeve Elimination 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the nylon sleeve 3) Inspect coupling components and replace coupling components that have been damaged 4) Insert nylon sleeve, assemble coupling components 5) Inspect alignment, adjust if necessary 6) Inspect and adjust ambient/contact temperature 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the nylon sleeve 3) Inspect coupling components and replace coupling components that have been damaged 4) Insert nylon sleeve, assemble coupling components 5) Inspect alignment, adjust if necessary 6) Make sure that further physical modifications of the sleeve are excluded If you operate with a worn sleeve (see chapter 9.3 and 9.4) a proper operation is not ensured. ! 7 KTR-N Sheet: Edition: 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. 8 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: 2019-07-01 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 BoWex® Operating/Assembly instructions 9 KTR-N Sheet: Edition: 40110 EN 16 of 22 16 Enclosure A Advice and instructions regarding the use in potentially explosive atmospheres Enclosure A only valid for BoWex® coupling. 9.1 Intended use in potentially explosive atmospheres Conditions of operation in potentially explosive atmospheres BoWex® 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, fogs, 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, fogs, 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 Standard sleeve „light“ Conductive sleeve „black“ Ambient or operating temperature Ta 1) Max. surface temperature 2) -30 °C to +100 °C +120 °C -30 °C to +75 °C +95 °C -30 °C to +60 °C +80 °C Explanation: The maximum surface temperatures result from each the maximum permissible ambient or operating temperature T a plus the maximum temperature increase T of 20 K (standard sleeve “light” and conductive sleeve “black”) to be considered. A relevant standard safety margin of 5 K has to be added to the temperature class. 1) The ambient or operating temperature Ta is limited to + 100 °C (standard sleeve “light” and conductive sleeve “black”) due to the permissible permanent operating temperature of the BoWex® sleeves used. 2) The maximum surface temperature of +120 °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 + 100 °C (standard sleeve “light” and conductive sleeve “black”). Please observe protection note ISO 16016. Drawn: Verified: 2019-07-01 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 BoWex® Operating/Assembly instructions 9 KTR-N Sheet: Edition: 40110 EN 17 of 22 16 Enclosure A Advice and instructions regarding the use in 9.2 Inspection intervals for couplings in Equipment category potentially explosive atmospheres Inspection intervals M2 2G 2D no gases and vapours of explosion group IIC M2 2G 2D Gases and vapours of explosion group IIC potentially explosive atmospheres The torsional backlash of the coupling (see chapter 9.3 and 9.4) according to directive 2014/34/EU only has to be inspected if a failure of the coupling and consequently a standstill of the drive causes explosion hazard. We recommend a preventive inspection of circumferential backlash and visual inspection of the sleeve. This should be performed after 3,000 operating hours for the first time, at the latest 6 months after start-up of the coupling. If you note insignificant or no wear on the sleeve 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 sleeve, 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. The torsional backlash of the coupling (see chapter 9.3 and 9.4) according to directive 2014/34/EU only has to be inspected if a failure of the coupling and consequently a standstill of the drive causes explosion hazard. We recommend a preventive inspection of circumferential backlash and visual inspection of the sleeve. This should be performed after 2,000 operating hours for the first time, at the latest 3 months after start-up of the coupling. If you note insignificant or no wear on the sleeve 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 sleeve, 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. BoWex® coupling Here the backlash between the hub and the nylon spline must be inspected via torsional backlash, each separately from the driving and the driven side. The friction/wear may only be Xmax. of the original spline thickness before the nylon sleeves must be replaced. When reaching the torsional backlash Smax., the nylon sleeve must be replaced immediately, irrespective of the inspection intervals. Illustration 12: BoWex® coupling Please observe protection note ISO 16016. Drawn: Verified: 2019-07-01 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 BoWex® Operating/Assembly instructions 9 KTR-N Sheet: Edition: 40110 EN 18 of 22 16 Enclosure A Advice and instructions regarding the use in potentially explosive atmospheres 9.3 Inspection of torsional backlash ! To inspect the torsional backlash the power pack which is switched off needs to be secured against accidental switch-on. Driving side • Turn the hub opposite the direction of drive. ! Here the sleeve must not be axially displaced from its position of wear. • Mark sleeve and hub (see Illustration 13). • Turn the hub in the driving direction and measure the torsional backlash Smax. • When reaching the torsional backlash Smax. the nylon sleeve must be replaced. Driven side • Turn the hub in the direction of the drive. ! Here the sleeve must not be axially displaced from its position of wear. • Mark sleeve and hub (see Illustration 13). • Turn the hub in the opposite drive direction and measure the torsional backlash Smax. • When reaching the torsional backlash Smax. the nylon sleeve must be replaced. Illustration 13: Marking of sleeve and hub Please observe protection note ISO 16016. Drawn: Verified: 2019-07-01 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 KTR-N Sheet: Edition: BoWex® Operating/Assembly instructions 9 40110 EN 19 of 22 16 Enclosure A Advice and instructions regarding the use in potentially explosive atmospheres 9.4 Standard values of wear If the torsional backlash is Smax. [mm] / friction Xmax. [mm], the nylon sleeves must be replaced. 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 6 and 7). If the figures are exceeded, the coupling will be damaged. ! Illustration 14: Sleeve in new condition Illustration 15: Wear of sleeve Table 8: Size 14 19 24 28 32 38 42 Limits of wear each hub Torsional backlash Wear Xmax. [mm] Smax. [mm] 0.8 1.3 0.8 1.4 1.0 1.5 1.0 1.6 1.0 1.7 1.0 1.7 1.0 1.7 Please observe protection note ISO 16016. Drawn: Verified: Size 2019-07-01 Pz/Wb 2019-07-23 Pz 45 48 65 80 100 125 Limits of wear each hub Torsional backlash Wear Xmax. [mm] Smax. [mm] 1.0 1.8 1.0 1.8 1.4 2.5 1.6 2.7 1.8 3.1 2.0 3.5 Replacing: Replaced by: KTR-N dated 2017-01-02 BoWex® Operating/Assembly instructions 9 KTR-N Sheet: Edition: 40110 EN 20 of 22 16 Enclosure A Advice and instructions regarding the use in 9.5 potentially explosive atmospheres marking of coupling for potentially explosive atmospheres The ATEX marking of the BoWex® curved-tooth gear coupling is applied on the outer sheath or on the front side. For the complete marking refer to the operating/assembly instructions and/or the delivery note/package. The following marking applies for the products: • • • • Type M with standard sleeve (light), sizes M-14 and M-19 Type S..-St with standard sleeve (light), sizes S14-St to S24-St inclusive Type M with conductive sleeve (black), sizes M-14C to M-80C inclusive Type SSR with Seeger circlips with conductive sleeve (black), sizes 24 SSR to 125 SSR inclusive • Type S..-St with conductive sleeve (black), sizes S14-St to S55-St inclusive BoWex® <Year> I M2 Ex h I II 2G Ex h IIC T6 … T4 II 2D Ex h IIIC T80 °C … T120 °C -30 °C ≤ Ta ≤ +60 °C … +100 °C KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine Mb Gb Db • Type M with standard sleeve (light), sizes M-24 to M-65 inclusive • Type SSR with Seeger circlips with standard sleeve (light), sizes 24 SSR to 45 SSR inclusive • Type S..-St with standard sleeve (light), sizes S28-St to S55-St inclusive BoWex® <Year> I M2 Ex h I II 2G Ex h IIB T6 … T4 II 2D Ex h IIIC T80 °C … T120 °C -30 °C ≤ Ta ≤ +60 °C … +100 °C KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine Mb Gb Db Short marking: (A short marking is only made if not possible differently for reason of space or functioning.) BoWex® <Year> Deviating marking applies until 31st October 2019: Short marking: II 2GD c IIC T X/I M2 c X II 2G c IIC T6, T5 resp. T4 -30 °C Ta +65 °C, +80 °C resp. +100 °C II 2D c T 120 °C -30 °C Ta +100 °C I M2 c -30 °C Ta +100 °C Complete marking: Please observe protection note ISO 16016. Drawn: Verified: 2019-07-01 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 BoWex® Operating/Assembly instructions 9 KTR-N Sheet: Edition: 40110 EN 21 of 22 16 Enclosure A Advice and instructions regarding the use in 9.5 potentially explosive atmospheres marking of coupling for potentially explosive atmospheres Substance group - gases, fogs 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 4.2 of the present operating/assembly instructions). Please observe protection note ISO 16016. Drawn: Verified: 2019-07-01 Pz/Wb 2019-07-23 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 BoWex® Operating/Assembly instructions 9 KTR-N Sheet: Edition: 40110 EN 22 of 22 16 Enclosure A Advice and instructions regarding the use in potentially explosive atmospheres 9.6 EU Certificate of conformity 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 BoWex® curved-tooth gear 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 BoWex® 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 IBExU13ATEXB007 X: IBExU Institut für Sicherheitstechnik GmbH Identification number: 0637 Fuchsmühlenweg 7 09599 Freiberg Rheine, Place 2019-07-01 Date Please observe protection note ISO 16016. Drawn: Verified: i. V. Reinhard Wibbeling Engineering/R&D 2019-07-01 Pz/Wb 2019-07-23 Pz i. A. Andreas Hücker Product Manager Replacing: Replaced by: KTR-N dated 2017-01-02 ">

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