KTR SYNTEX-NC 25 Operating And Assembly Instruction Manual
KTR SYNTEX-NC 25 is a torque limiting, backlash-free overload system that protects adjacent components from damage. It operates with positive locking, and in case of overload, the torque is reduced to a lower residual torque. This coupling is ideal for applications requiring precise torque control and overload protection, such as machine tools, packaging machines, and other industrial equipment.
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KTR-N Sheet: Edition: SYNTEX®-NC Operating/Assembly instructions 46110 EN 1 of 23 4 SYNTEX®-NC Backlash-free overload system Type DK (ratchet design) ® SYNTEX -NC Type SK (synchronous design) ® ® SYNTEX -NC with ROTEX GS ® SYNTEX -NC with TOOLFLEX Please observe protection note ISO 16016. Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: ® KTR-N dated 2014-08-11 SYNTEX®-NC Operating/Assembly instructions KTR-N Sheet: Edition: 46110 EN 2 of 23 4 SYNTEX®-NC is a torque limiting, backlash-free overload system operating with positive locking protecting adjacent components from damage. In case of overload on the coupling the torque is considerably reduced to a lower residual torque. SYNTEX®-NC is a not load-holding coupling. In case of overload type DK (ratchet design) re-engages every 15° with the next following ball indentation. In case of overload type SK (synchronous design) re-engages after a rotation of 360°. Table of contents 1 Technical data 3 2 Advice 7 2.1 2.2 2.3 2.4 2.5 7 7 7 8 8 3 4 General advice Safety and advice symbols General hazard warnings Intended use Coupling selection Storage, transport and packaging 8 3.1 3.2 8 8 Storage Transport and packaging Assembly 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 5 9 Components of the couplings Advice on remachining Assembly (general) Assembly of SYNTEX®-NC (hub design 1.0) Assembly of SYNTEX®-NC (hub design 6.1) Notes with the use of hollow shafts Assembly of SYNTEX®-NC with ROTEX® GS Assembly of SYNTEX®-NC with TOOLFLEX® 9 10 10 11 11 12 12 13 Adjustment of torque 5.1 5.2 5.3 5.3 14 ® Torque setting - SYNTEX -NC Replacement of layering of disk springs Setting diagrammes Setting diagrammes 14 16 18 19 6 Assembly of limit switch 20 7 Breakdowns, causes and elimination 21 8 Disposal 22 9 Maintenance and service 22 10 Notes for using drive components/attachments 23 11 Spares inventory, customer service addresses 23 Please observe protection note ISO 16016. Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 KTR-N Sheet: Edition: SYNTEX®-NC Operating/Assembly instructions 1 46110 EN 3 of 23 4 Technical data Illustration 1: SYNTEX®-NC (hub design 1.0) Illustration 2: SYNTEX®-NC (hub design 6.1) Table 1: Technical data and dimensions Size 15 25 32 42 60 Size 15 25 32 42 60 Speed [rpm] 3500 3000 3000 2500 2000 T1 2 - 3.5 9 - 15 25 - 38 30 - 65 70 - 140 Torques [Nm] T2 3.5 - 7 20 - 30 50 - 75 60 - 135 120 - 280 T3 7 - 14 40 - 65 100 - 150 120 - 265 220 - 550 l1 5.0 5.5 6.0 7.0 8.0 l2 7.0 11.5 12.5 16.0 21.0 l3 9.2 9.1 9.9 11.2 11.8 l4 2 2 2 2 2 Max. bore d 12 22 30 38 50 1) D 32 42 52 65 90 Dimensions [mm] l5 4 5 5 6 7 Dimensions [mm] D1 D2 33 37 50 48 60 60 72 75 96 100 l6 18.8 23.9 25.1 31.8 38.2 L 28 33 35 43 52 D3 42 56 67 83 113 z x dM 12 x M3 8 x M4 8 x M4 8 x M5 12 x M6 DA 42 61 74 90 116 H=stroke 0.8 1.2 1.5 1.5 1.8 1) Max. finish bore, feather keyway according to DIN 6885 sheet 3 Table 2: Technical data and dimensions – hub design 6.1 Size 15 25 32 42 60 Bore d1 Pilot Max. bored 7.5 15 9.5 25 13.5 32 18.5 42 24.0 60 Dimensions [mm] D4 DK L1 e M TA [Nm] 40 55 70 86 112 43.0 91.2 119.4 38 45 53 63 75 15 21 27 33 45 M4 M6 M8 M10 M12 1.7 14 34 67 115 Weight [kg] 0.124 0.282 0.471 0.815 3.04 2) Mass moment 2) of inertia 2 Jtotal [kgm ] -5 2.9 × 10 -4 1.4 × 10 -4 3.5 × 10 -4 9.5 × 10 -3 5.9 × 10 2) With max. finish bore Please observe protection note ISO 16016. Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 KTR-N Sheet: Edition: SYNTEX®-NC Operating/Assembly instructions 1 46110 EN 4 of 23 4 Technical data Illustration 3: SYNTEX®-NC with ROTEX® GS (hub design 2.8, from size 60 - 6.0/6.1) Illustration 4: SYNTEX®-NC with ROTEX® GS (hub design 2.9, from size 60 1.0/1.0) ® Table 3: Dimensions and technical data with ROTEX GS ® Size 15 25 32 42 60 Size 15 25 32 42 60 Size 15 25 32 42 60 ROTEX GS size 19 24 28 38 48 Speed [rpm] 3500 3000 3000 2500 2000 T1 2 - 3.5 9 - 15 25 - 38 30 - 65 70 - 140 Torques [Nm] T2 3.5 - 7 20 - 30 50 - 75 60 - 135 120 - 280 T3 7 - 14 40 - 65 100 - 150 120 - 265 220 - 550 Max. bore [mm] d1 15 25 32 42 60 d 12 22 30 38 50 d2 24 32 35 45 55 D5 45 58 70 88 113 DH 40 55 65 80 105 DK 91.2 119.4 DK1 46.7 57.5 69.0 86.0 - Dimensions [mm] DA 42 61 74 90 116 l1 17 18 21 26 56 l2 40.0 47.5 55.0 66.0 83.0 l3 40 35.5 37.0 46.0 60 E 16 18 20 24 28 e 15 21 27 33 45 e1 15.5 20.0 23.8 30.5 - LG 63 71.5 78.0 96.0 144 L1 38 45 53 63 75 Dimensions [mm] LG1 73.0 83.5 96.0 116.0 167.0 M M4 M6 M8 M10 M12 TA [Nm] 1.7 14 34 67 115 M1 M5 M6 M8 M10 M10 TA1 [Nm] 6 10 25 49 49 Please observe protection note ISO 16016. Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 KTR-N Sheet: Edition: SYNTEX®-NC Operating/Assembly instructions 1 46110 EN 5 of 23 4 Technical data Illustration 5: SYNTEX®-NC with TOOLFLEX® Table 4: Technical data and dimensions with TOOLFLEX ® Size 15 25 32 42 60 Size 15 25 32 42 60 Size 15 25 32 42 60 TOOLFLEX size 20 38 42 45 65 D4 40 55 70 86 112 e 15 21 27 33 45 Speed [rpm] 3500 3000 3000 2500 2000 DH 40 65 70 83 125 e1 14.5 25.0 27.0 30.0 45.0 T1 2 - 3.5 9 - 15 25 - 38 30 - 65 70 - 140 ® Torques [Nm] T2 3.5 - 7 20 - 30 50 - 75 60 - 135 120 - 280 T3 7 - 14 40 - 65 100 - 150 120 - 265 220 - 550 Dimensions [mm] DK DK1 43 43.5 72.6 76.1 91.2 89.0 119.4 127.1 DA 1) 52 61 74 90 1) 140 LG 76 88 107 114 165 Dimensions [mm] M M4 M6 M8 M10 M12 l1 21.5 25.5 30.0 32.0 45.0 TA [Nm] 1.7 14 34 67 115 Max. bore [mm] d1 d2 15 20 25 38 32 42 42 45 60 65 L1 38 45 53 63 84 M1 M5 M8 M8 M10 M14 E 16.5 18.0 24.0 22.5 36.0 TA1 [Nm] 6 25 25 49 185 1) Outside diameter shifting ring see table 1. Please observe protection note ISO 16016. Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 SYNTEX®-NC Operating/Assembly instructions 1 KTR-N Sheet: Edition: 46110 EN 6 of 23 4 Technical data Table 5: Torques and surface pressure – hub design 6.1 (without feather keyway) Size Clamping screw M Tightening torque TA [Nm] 15 M4 1.7 25 M6 14 10 11 12 14 15 60 M12 115 Surface pressure [N/mm2] 8 94.5 12 92 14 90.5 16 88 22 85 24 83.5 16 18 19 20 22 24 25 30 131 35 129.5 42 127.5 55 123.5 62 121 69 119 48 66 53 65 58 64.5 69 63 80 61.5 86 61 28 30 32 74 97 83 96 104 94 114 93 125 92 148 90 116 59.5 125 59 153 57.5 172 56.5 192 55.5 35 36 38 40 42 45 48 50 55 60 Please observe protection note ISO 16016. 42 M10 67 Transmittable torque [Nm] Bore Ø 8 32 M8 34 Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: 149 99 178 97.5 209 96 225 95 275 93 310 91.5 264 68.5 309 67 324 66.5 356 65.5 389 64.5 422 63.5 247 113.5 310 113.5 356 113.5 405 113.5 485 113.5 513 113.5 571 113.5 633 113.5 394 63.98 452 63.98 514 63.98 558 63.98 674 63.98 803 63.98 KTR-N dated 2014-08-11 SYNTEX®-NC Operating/Assembly instructions 2 KTR-N Sheet: Edition: 46110 EN 7 of 23 4 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 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 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: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 SYNTEX®-NC Operating/Assembly instructions 2 KTR-N Sheet: Edition: 46110 EN 8 of 23 4 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 had technical training 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 SYNTEX -NC described in here corresponds to the technical status at the time of printing of these operating/assembly instructions. 2.5 Coupling selection To review the coupling selection please consult with KTR. ! 3 Storage, transport and packaging 3.1 Storage The couplings are supplied in preserved condition and can be stored at a dry and covered place for 6 - 9 months. ! Humid storage rooms are not suitable. Please make sure that condensation is not generated. The best relative air humidity is less than 65 %. 3.2 Transport and packaging ! In order to avoid any injuries and any kind of damage please always make use of proper transport and lifting equipment. The couplings are packed differently each depending on size, number and kind of transport. Unless otherwise contractually agreed, packaging will follow the in-house packaging specifications of KTR. Please observe protection note ISO 16016. Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 SYNTEX®-NC Operating/Assembly instructions 4 KTR-N Sheet: Edition: 46110 EN 9 of 23 4 Assembly The coupling is supplied fully assembled (as specified by the buyer) and optionally with the torque set. 4.1 Components of the couplings Component assembly 1: Components of SYNTEX®-NC (hub design 1.0) Component 1.1 1.2 1.3 1.4 1.5 1.6 Quantity 1 1 1 see table 9 1 1 1) 1.7 1 1.8 1 Description Hub 1.0 Flange ring DK or SK Shifting ring Disk springs (set) Setting nut with cap screw DIN EN ISO 4762 - 12.9 Balls Groove ball bearing DIN 625 Circlip 1) Complete set Illustration 6: SYNTEX®-NC (hub design 1.0) Component assembly 2: Components of SYNTEX®-NC (hub design 6.1) Component Quantity 2.1 1 2.2 2.3 1 1 see table 9 2.4 2.5 2.6 1 1 1) 2.7 1 2.8 2.9 1 1 2.10 1 Description Clamping ring hub design 6.1 Flange ring DK or SK Shifting ring Disk springs (set) Setting nut with cap screw DIN EN ISO 4762 - 12.9 Balls Groove ball bearing DIN 625 Circlip Clamping ring Clamping screw DIN EN ISO 4762 - 12.9 Illustration 7: SYNTEX®-NC (hub design 6.1) 1) Complete set Components of SYNTEX®-NC with ROTEX® GS Component/ component assembly Quantity 1/2 1 3 1 4 1 5 1 6 1) Description ® SYNTEX -NC (complete coupling) ® ROTEX GS driving flange ® ROTEX GS spider ® ROTEX GS clamping hub Cap screws DIN EN ISO 4762 - 12.9 Illustration 8: SYNTEX®-NC with ROTEX® GS 1) see quantity in table 1 Please observe protection note ISO 16016. Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 SYNTEX®-NC Operating/Assembly instructions 4 KTR-N Sheet: Edition: 46110 EN 10 of 23 4 Assembly 4.1 Components of the couplings Components of SYNTEX®-NC with TOOLFLEX® Component/ component assembly Quantity 7 1 Description ® SYNTEX -NC (complete coupling) Illustration 9: SYNTEX®-NC with TOOLFLEX® 4.2 Advice on remachining ! 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. 4.3 Assembly (general) We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy before assembly. ® Heating the SYNTEX -NC (hub design 1.0) lightly (approx. 80 °C) allows for an easier mounting on the shafts. STOP Touching the heated coupling or clamping hub causes burns. Please wear safety gloves. Please make sure the perfect technical condition of the SYNTEX -NC overload system. ® Please only use original KTR components (no purchased parts). Please observe protection note ISO 16016. Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 KTR-N Sheet: Edition: SYNTEX®-NC Operating/Assembly instructions 4 46110 EN 11 of 23 4 Assembly 4.4 Assembly of SYNTEX®-NC (hub design 1.0) Clean the hub bore and shaft and review for dimensional accuracy, afterwards lubricate with a thin-fluid oil (e. g. Castrol 4 in 1 or Klüber Quietsch-Ex). ! Oils and greases containing molybdenum disulfide or other high-pressure additives as well as internal lubricants must not be used. Mount the SYNTEX -NC (component assembly 1) on the shaft of the driving or driven side. ® Please provide for an end plate to fasten the SYNTEX -NC axially (see illustration 9). ® Illustration 10: axial locking We recommend to secure all screw connections against working loose additionally, e. g. conglutinating with Loctite (average strength). 4.5 Assembly of SYNTEX®-NC (hub design 6.1) ® With the use of hollow shafts please observe chapter 4.6 before assembly of SYNTEX -NC. Unscrew the clamping screw (component 2.10) in the clamping ring (component 2.9). Clean the hub bore and shaft and review for dimensional accuracy, afterwards lubricate with a thin-fluid oil (e. g. Castrol 4 in 1 or Klüber Quietsch-Ex). ! Oils and greases containing molybdenum disulfide or other high-pressure additives as well as internal lubricants must not be used. Mount the SYNTEX -NC (component assembly 2) on the shaft of the driving or driven side. ® Tighten the clamping screw to the tightening torque T A specified in table 2. Illustration 11: Assembly of SYNTEX®-NC (hub design 6.1) If the assembly is repeated the bore of the hub and shaft have to be cleaned and afterwards lubricated with a thin-fluid oil (e. g. Castrol 4 in 1 or Klüber Quietsch-Ex). All screw connections must be secured against working loose additionally, e. g. conglutinating with Loctite (average strength). Please observe protection note ISO 16016. Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 KTR-N Sheet: Edition: SYNTEX®-NC Operating/Assembly instructions 4 46110 EN 12 of 23 4 Assembly 4.6 Notes with the use of hollow shafts ® The power transmission of SYNTEX -NC with hub design 6.1 is frictionally engaged. The necessary surface pressure is transmitted via the clamping ring to the clamping ring hub and consequently to the shaft. The torques or surface pressure specified in table 5 have to be considered. 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. Rp0,2 2 pW With clamping connections with hollow shafts the internal diameter of the hollow shaft diW required is calculated based on the following formula: diW d Shear stress on the internal shaft diameter for hollow shaft: tiW Shear stress for solid shaft: tW pW N / mm2 Rp0.2 pW = = N / mm 2 pW 1 CW 2 2 2 yield strength of shaft material [N/mm ] 2 surface pressure of hub/shaft [N/mm ] diW d CW = = = mm Rp0,2 internal diameter of hollow shaft [mm] shaft diameter [mm] diW / d The strength required is not provided if the hollow shaft bore is bigger than the max. internal bore calculated or if the shear stress exceeds the yield strength of the material. For a detailed calculation please contact KTR. 4.7 Assembly of SYNTEX®-NC with ROTEX® GS Mount the SYNTEX -NC on the shaft of the driving or driven side each depending on the hub design as per chapter 4.4 or 4.5, respectively. ® Clean the hub bore of the ROTEX GS clamping hub (component 5) and review for dimensional accuracy, afterwards lubricate with a thin-fluid oil (e. g. Castrol 4 in 1 or Klüber Quietsch-Ex). ® ! Oils and greases containing molybdenum disulfide or other high-pressure additives as well as internal lubricants must not be used. Illustration 12: SYNTEX®-NC with ROTEX® GS Mount the ROTEX GS clamping hub on the shaft of the driving or driven side. ® Tighten the cap screws of the ROTEX GS clamping hub to the tightening torques T A1 specified in table 3. ® Hand-tighten the ROTEX GS driving flange (component 3) with the SYNTEX -NC coupling for the time being. ® ® Tighten the cap screws (component 6, see illustration 11) crosswise to the tightening torques T A specified in table 6. Insert the ROTEX GS spider (component 4) into the cam section of the ROTEX GS clamping hub. ® Please observe protection note ISO 16016. ® Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 SYNTEX®-NC Operating/Assembly instructions 4 KTR-N Sheet: Edition: 46110 EN 13 of 23 4 Assembly 4.7 Assembly of SYNTEX®-NC with ROTEX® GS Shift the power packs in axial direction until the distance dimension E is achieved (see illustration 12, table 3). If the power packs are already firmly assembled, shifting the hubs axially on the shafts allows for adjusting the distance dimension E. With the assembly please make sure that the distance dimension E (see table 3) is observed so that the coupling components are not in contact with each other during the operation. Disregarding this advice may cause damage to the coupling. ! Illustration 13: Assembly of coupling All screw connections must be secured against working loose additionally, e. g. conglutinating with Loctite (average strength). Table 6: Cap screws DIN EN ISO 4762 Size Screw dimension dM Tightening torque TA [Nm] 15 M3 1.7 25 M4 2.8 32 M4 4.1 42 M5 8.1 60 M6 14 Please consider our operating/assembly instructions KTR-N 45510 additionally when using ® the ROTEX GS coupling. 4.8 Assembly of SYNTEX®-NC with TOOLFLEX® Clean the hub bore and shaft and review for dimensional accuracy, afterwards lubricate with a thin-fluid oil (e. g. Castrol 4 in 1 or Klüber Quietsch-Ex). ! Oils and greases containing molybdenum disulfide or other high-pressure additives as well as internal lubricants must not be used. Unscrew the clamping screws of TOOLFLEX . ® Insert the shaft end of the driving machine in the coupling half of ® TOOLFLEX . Illustration 14: SYNTEX®-NC with TOOLFLEX® Secure the clamping hub by tightening the clamping screws at the tightening torques TA1 specified in table 4. Insert the shaft end of the driven machine in the coupling half of SYNTEX -NC. ® Shift the power packs in axial direction until the distance dimension LG is achieved (see illustration 13, table 4). Secure the clamping ring hub of SYNTEX -NC by tightening the clamping screws at the tightening torques T A specified in table 4. ® Please observe protection note ISO 16016. Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 KTR-N Sheet: Edition: SYNTEX®-NC Operating/Assembly instructions 4 46110 EN 14 of 23 4 Assembly 4.8 Assembly of SYNTEX®-NC with TOOLFLEX® All screw connections must be secured against working loose additionally, e. g. conglutinating with Loctite (average strength). Please consider our operating/assembly instructions KTR-N 45810 additionally when using ® the TOOLFLEX coupling. 5 Adjustment of torque KTR supplies the torque limiter pre-set to each approx. 75 % of the maximum torque of the ® respective disk spring layering in case that SYNTEX -NC is ordered without torque setting by the customer. If the torque pre-set cannot be modified by the customer any more, the screw of the setting nut (component 1.5 or 2.5) has to be removed and coated with Loctite (average strength). Afterwards tighten the screw at the tightening torque TA specified in table 2. 5.1 Torque setting - SYNTEX®-NC Modifying the torque pre-set (release torque) The right disk spring layering is a pre-condition to perform a correct torque adjusting. Please use the respective disk spring layering as per table 9 each depending on the setting range (chapter 1). Release the cap screw in the setting nut (component 1.5 or 2.5) by a maximum of one rotation. Specify the torque pre-set (see step 1 in illustration 14). Mark the torque pre-set on the label (see step 2 in illustration 14). Set a reference mark on the setting nut (see step 3 in illustration 14). Illustration 15 Please observe protection note ISO 16016. Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 KTR-N Sheet: Edition: SYNTEX®-NC Operating/Assembly instructions 5 46110 EN 15 of 23 4 Adjustment of torque 5.1 Torque setting - SYNTEX®-NC Rotate the setting nut by the requested number of notches (see step 1 and 2 in illustration 15) by means of a hook spanner (see table 8). With torque setting please note the setting diagrammes of the respective sizes (see chapter 5.3). Remove the torque value from the label (see step 3 in illustration 15). Illustration 16 Mark the coupling with the new torque pre-set (see step 1 in illustration 16). Remove the reference mark from the setting nut (see step 2 in illustration 16). Remove the cap screw from the setting nut. Coat the cap screw with Loctite (average strength). Afterwards screw in the cap screw and tighten at the tightening torque TA specified in table 7. Illustration 17 All screw connections must be secured against working loose additionally, e. g. conglutinating with Loctite (average strength). Table 7: Cap screws DIN EN ISO 4762 Size Screw size Tightening torque TA [Nm] ! 15 M3 1.2 25 M3 1.2 32 M3 1.2 42 M3 1.2 60 M4 2.8 Please bear in mind that setting the torque beyond the torque range (see chapter 1) may result in misoperation and damage of the coupling. ® In order to ensure an optimum torque setting, SYNTEX -NC should be inspected after initial disengagement processes and reset, if necessary. If SYNTEX -NC was pre-set only or set to the requested torque as per these operating/assembly instructions, the torque should be considered as a reference value only. For accurate torque setting we would recommend to inspect the torque by means of a suitable measuring system and reset, if necessary. We basically recommend to perform torque setting on KTR's test benches in order to ensure the optimum accuracy of torque setting. ® Table 8: Tools for torque setting Size 10 25 32 42 60 Hook spanner DIN 1810-A Please observe protection note ISO 16016. Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Hook spanner Ø34-36 Ø45-50 Ø58-62 Ø68-75 Ø95-100 Replacing: Replaced by: KTR-N dated 2014-08-11 SYNTEX®-NC Operating/Assembly instructions 5 KTR-N Sheet: Edition: 46110 EN 16 of 23 4 Adjustment of torque 5.2 Replacement of layering of disk springs STOP If torque setting is beyond the requested torque range as per chapter 1, the coupling can be reset to the requested torque by adapting the disk spring layering. We recommend to have the modification and resetting of the coupling performed by KTR's qualified staff. Driving components falling down may cause injury to persons or damage on the machine. Secure the driving components during disassembly. Release the clamping screw (component 2.10) of the clamping ring (component 2.9). [Applies with hub design 6.1 only] Illustration 18: Example - Assembly of SYNTEX®-NC (hub design 6.1) Disassemble the coupling from the machine and mount it onto a suitable auxiliary shaft. Release the cap screw in the setting nut (component 1.5 or 2.5). Do not fully unscrew the cap screw. Turn back the setting nut by means of a hook spanner (see illustration 17 and table 8) until the disk springs are fully released. Remove the clamping ring (component 2.9) from the clamping ring hub (component 2.1). [Applies with hub design 6.1 only] Remove the setting nut from the hub (component 1.1) or clamping ring hub (component 2.1), respectively. Adjust the disk spring layering as per table 9 to the requested torque (see chapter 1). Table 9: Layering of disk springs Layering of disk springs T1 Design DK and SK T2 T3 1x1 1x2 1x4 Illustration Designation Please observe protection note ISO 16016. Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 SYNTEX®-NC Operating/Assembly instructions 5 KTR-N Sheet: Edition: 46110 EN 17 of 23 4 Adjustment of torque 5.2 Replacement of layering of disk springs Screw the setting nut onto the hub or clamping ring hub and hand-tighten it. Hand-tighten the cap screw in the setting nut. Afterwards turn back the cap screw by half a rotation. Mount the clamping ring onto the clamping ring hub. [Applies with hub design 6.1 only] With the assembly please make sure that the balancing bores of the clamping ring (component 2.9) point towards the disk spring(s). Screw in the setting nut by means of a hook spanner (see illustration 17 and table 8) until it cannot be turned any more. Afterwards turn back the setting nut by one notch (see illustration 19). The torque pre-set corresponds to the minimum release torque (see illustration 20) now. Set the torque required as described in chapter 5.1. Illustration 19: Notches of setting nut The disk springs are operated in the negative sector of the characteristic curve. Tightening the setting nut causes a reduced release torque. The release torque is increased by untightening the setting nut. Remove the cap screw from the setting nut and paint with Loctite (average strength). Afterwards screw in the cap screw and tighten at the tightening torque T A specified in table 7. Unscrew the clamping screw of the clamping ring. [Applies with hub design 6.1 only] Disassemble the coupling from the auxiliary shaft. ! Illustration 20: Spring characteristic Please bear in mind that setting the torque beyond the torque range (see chapter 1) may result in misoperation and damage of the coupling. ® In order to ensure an optimum torque setting, SYNTEX -NC should be inspected after initial disengagement processes and reset, if necessary. If SYNTEX -NC was pre-set only or set to the requested torque as per these operating/assembly instructions, the torque should be considered as a reference value only. For accurate torque setting we would recommend to inspect the torque by means of a suitable measuring system and reset, if necessary. We basically recommend to perform torque setting on KTR's test benches in order to ensure the optimum accuracy of torque setting. All screw connections must be secured against working loose additionally, e. g. conglutinating with Loctite (average strength). ® Please observe protection note ISO 16016. Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 SYNTEX®-NC Operating/Assembly instructions 5 KTR-N Sheet: Edition: 46110 EN 18 of 23 4 Adjustment of torque 5.3 Setting diagrammes Diagramme 1: SYNTEX®-NC size 15 Diagramme 2: SYNTEX®-NC size 25 Diagramme 3: SYNTEX®-NC size 32 Please observe protection note ISO 16016. Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 SYNTEX®-NC Operating/Assembly instructions 5 KTR-N Sheet: Edition: 46110 EN 19 of 23 4 Adjustment of torque 5.3 Setting diagrammes Diagramme 4: SYNTEX®-NC size 42 Diagramme 5: SYNTEX®-NC size 60 Please observe protection note ISO 16016. Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 KTR-N Sheet: Edition: SYNTEX®-NC Operating/Assembly instructions 6 46110 EN 20 of 23 4 Assembly of limit switch If the torque set is exceeded, the coupling disengages with the shifting ring being moved back axially by dimension H (see table 10). The sensor or limit switch has to be mounted such that signal recording is ensured in this shifting range. ® The sensor or limit switch has to be aligned versus SYNTEX -NC such that signal recording of the disengagement process is ensured. Table 10: Position of limit switch Size 15 25 32 42 60 l2 7.0 11.5 12.5 16.0 21.0 Dimensions [mm] l3 ØDA 9.2 42 9.1 61 9.9 74 11.2 90 11.8 116 H=stroke 0.8 1.2 1.5 1.5 1.8 Illustration 21: Mechanical limit switch Function The axial stroke of the shifting ring generated with overload may activate a mechanical limit switch or an inductive sensor. As a result a control signal is generated which can be evaluated for disengaging the drive. Assembly The sensor needs to be mounted in a solid device to ensure a smooth operation. The sensor should be protected from dirt and potential mechanical faults. ! We recommend using a limit switch! Please absolutely observe the operation of the limit switch before the machine is supplied. Please also observe the operating instructions for the sensor or limit switch, respectively. The axial stroke of the shifting ring must not be blocked by any other components. As soon as the limit switch or sensor is activated (overload: release of overload coupling) the drive should immediately be stopped. With higher speeds respective braking devices may be necessary. Please observe protection note ISO 16016. Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 KTR-N Sheet: Edition: SYNTEX®-NC Operating/Assembly instructions 7 46110 EN 21 of 23 4 Breakdowns, causes and elimination ® The below-mentioned failures can result in a use of the SYNTEX -NC coupling other than intended. In addition to the specifications given in these operating and assembly instructions please 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. General failures with use other than intended: Important data for the coupling selection were not forwarded. The calculation of the shaft-hub-connection was 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. Maintenance intervals are not observed. Breakdowns Causes Different operating noise and/or vibrations occurring Screws working loose The coupling releases undefinedly Elimination Setting nut has worked loose Torque is not set Torque set incorrectly Setting nut has worked loose Please observe protection note ISO 16016. Setting nut has worked loose Drawn: Verified: Set the unit out of operation Inspect tightening torque of screws. Inspect torque setting. If you cannot find out the cause of the failure, return the coupling to KTR for inspection. 1) Set the unit out of operation 2) Adjust torque 3) If you cannot find out the cause of the failure, return the coupling to KTR for inspection. 1) Set the unit out of operation 2) Send the coupling to KTR for inspection/repair. Wear Torque is no longer transmitted 1) 2) 3) 4) 1) Set the unit out of operation 2) Reset the release torque 3) Tighten and fasten clamping screw of setting nut 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 SYNTEX®-NC Operating/Assembly instructions 8 KTR-N Sheet: Edition: 46110 EN 22 of 23 4 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. Greases/oils Greases and oils have to be collected and disposed of by a waste disposal company. 9 Maintenance and service ® SYNTEX -NC is a low-maintenance coupling. We recommend to perform a visual inspection on the coupling at least once a year. Please pay special attention to the condition, alignment and screw connection of the coupling and the condition of the spider (if applicable). ® The SYNTEX -NC overload hub is finish bored and provided with grease filling. With normal drive conditions this grease filling is sufficient during the overall service life. In case of extreme drive conditions or heavy dirt, ® respectively, the SYNTEX -NC has to be regularly inspected for its operation. In case of overload the drive should be stopped by return. ! ! Having started up the coupling the tightening torques of the screws have to be inspected during the usual inspection intervals. ® When using the ROTEX GS coupling please consider our operating/mounting instructions as per KTR-N 45510 additionally or the mounting instructions as per KTR-N 45810 when ® using the TOOLFLEX coupling, respectively. Please observe protection note ISO 16016. Drawn: Verified: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 SYNTEX®-NC Operating/Assembly instructions 10 KTR-N Sheet: Edition: 46110 EN 23 of 23 4 Notes for using drive components/attachments Insert the drive element such as belt pulleys or gear wheels with the centering (H7 fit) on the deep groove ball bearing (component 1.7 or 2.7). Design the deep groove ball bearing as a fixed bearing. Screw the drive component to the flange ring (component 1.2 or 2.2). With the asssembly the maximum depth of engagement l5 (see table 1, illustration 22) needs to be observed. The customer needs to select the screw connection for transmitting the torque. ! The pitch line of radial forces Fr arising has to lead through the center of the bearing (see illustration 22). The radial and axial forces passed into the coupling bearing must not exceed the maximum permissible figures (see table 11). Illustration 22 Table 11: Max. bearing load Size Axial force [N] Radial force [N] 11 15 300 300 25 400 400 32 500 500 42 800 800 60 1200 1200 Spares inventory, customer service addresses A basic requirement to ensure the readiness for use 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 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: 2017-02-10 Pz/Koh 2017-03-03 Pz Replacing: Replaced by: KTR-N dated 2014-08-11 ">

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Key features
- Torque limiting
- Backlash-free
- Overload protection
- Positive locking
- Compact design
- Easy installation
- Adjustable torque
- High load capacity
- Low residual torque
- Long service life
Frequently asked questions
The maximum speed for the SYNTEX-NC 25 is 3000 rpm.
The SYNTEX-NC 25 has torque ranges of T1: 9-15 Nm, T2: 20-30 Nm, and T3: 40-65 Nm.
You can adjust the torque setting by rotating the setting nut with a hook spanner. Refer to the setting diagrammes in the manual for specific instructions.
Use a thin-fluid oil, like Castrol 4 in 1 or Klüber Quietsch-Ex. Do not use oils or greases containing molybdenum disulfide or other high-pressure additives.