KTR-Group EN, GN Operating & Assembly Instructions
KTR-Group GN is a single-cardanic, torsionally flexible jaw coupling designed for emergency operating features. It's a non-sparking, electrically conductive coupling system ideal for use in potentially explosive atmospheres. The GN is part of the ROTEX® SP product line and is compliant with Directive 2014/34/EU.
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ROTEX® SP "Non Sparking" Operating/Assembly instructions KTR-N Sheet: Edition: 40228 EN 1 of 28 6 ROTEX® SP "Non Sparking" Single-cardanic Torsionally flexible jaw couplings type GN, GND, EN and their combinations according to directive 2014/34/EU Type GN (No. 080) Type GND (No. 082) Type EN (No. 081) Double-cardanic Torsionally flexible jaw couplings type E4-DKM, ZS-DKM-C and their combinations according to directive 2014/34/EU Type E4-DKM (No. 086) Type ZS-DKM-C (No. 085) Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 ROTEX® SP "Non Sparking" Operating/Assembly instructions KTR-N Sheet: Edition: 40228 EN 2 of 28 6 ROTEX® SP „Non Sparking“ is part of the product line of torsionally flexible jaw couplings. Subject to its design it is furthermore a shear type system providing for emergency operating features. Moreover, ROTEX® SP „Non Sparking“ is a non-sparking/electrically conductive coupling system. Type ZS-DKM-C (No. 085) is characterized by its ability for radial disassembly. Table of contents 1 Technical data 3 2 Advice 9 2.1 2.2 2.3 2.4 2.5 2.6 3 4 General advice Safety and advice symbols General hazard warnings Intended use Coupling selection Reference to EC Machinery Directive 2006/42/EC 9 9 9 10 10 10 Storage, transport and packaging 10 3.1 3.2 10 11 Storage Transport and packaging Assembly 11 4.1 4.2 4.3 4.4 4.5 4.6 4.7 11 13 14 15 15 16 17 Components of the couplings Advice for finish bore Assembly of the coupling (general) Assembly of types GN, GND and EN Assembly of type E4-DKM Assembly of type ZS-DKM-C Displacements - alignment of the couplings 5 Start-up 19 6 Breakdowns, causes and elimination 20 7 Disposal 21 8 Maintenance and service 22 9 Spares inventory, customer service addresses 22 10 Enclosure A Advice and instructions regarding the use in 10.1 Intended use in potentially explosive atmospheres potentially explosive atmospheres 10.2 Inspection intervals for couplings in 10.3 Standard values of wear Please observe protection note ISO 16016. Drawn: Verified: 23 potentially explosive atmospheres 10.4 marking of coupling for potentially explosive atmospheres 10.5 EU Certificate of conformity 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: 22 24 25 26 28 KTR-N dated 2017-01-02 KTR-N Sheet: Edition: ROTEX® SP "Non Sparking" Operating/Assembly instructions 1 40228 EN 3 of 28 6 Technical data Illustration 1: Type GN (No. 080) - component 1, 1a, 1b: steel (St) Illustration 2: Type GN (No. 080) - component 1, 1a, 1b: cast iron (GJL) Table 1: Type GN (No. 080) - component 1, 1a, 1b: steel (St) Size Spider 1) (component 2) Rated torque [Nm] 24 35 28 95 38 190 42 265 48 310 55 410 65 625 Component (St) 1a 1b 1a 1b 1 1b 1 1b 1 1b 1 1b 1 1b Dimensions [mm] 3) Component 1, 1a, 1b steel (St) Max. finish bore d1 2) 35 40 48 55 62 74 80 L l1 78 98 90 115 114 139 126 151 140 164 160 185 185 210 30 50 35 60 45 70 50 75 56 80 65 90 75 100 Dimensions [mm] 3) Component 1c Max. finish l2 DA bore d2 2) E b s DH dH D, D1 N Component 18 14 2.0 55 27 55 - 1c 28 30 61 20 15 2.5 65 30 65 - 1c 32 35 72 70 80 85 995 95 105 110 120 115 135 27 28 32 37 47 - 1c 42 45 87 1c 48 50 103 1c 55 56 114 1c 65 65 130 1c 75 75 146 24 18 3.0 80 38 26 20 3.0 95 46 28 21 3.5 105 51 30 22 4.0 120 60 35 26 4.5 135 68 Table 2: Type GN (No. 080) - component 1, 1a, 1b: cast iron (GJL) Size 38 42 48 Spider 1) (component 2) Rated torque [Nm] 190 265 310 55 410 65 625 Component (GJL) 1 1a 1b 1 1a 1b 1 1a 1b 1 1a 1 Dimensions [mm] 3) Component 1, 1a, 1b: cast iron (GJL) Max. finish bore d1 2) 40 48 45 55 52 62 60 74 70 L l1 114 45 139 70 126 50 151 75 140 56 E b s DH dH 24 18 3.0 80 38 D, D1 66 78 75 26 20 3.0 95 46 94 85 28 21 3.5 105 51 164 80 160 65 30 22 4.0 120 60 185 75 35 26 4.5 135 68 104 98 118 115 N 37 Component Dimensions [mm] 3) Component 1c Max. finish l2 DA bore d2 2) 1c 42 45 87 1c 48 50 103 1c 55 56 114 52 1c 65 65 130 61 1c 75 75 146 62 40 65 45 69 1) Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2 2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew 3) Dimensions G and t see table 9. Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 KTR-N Sheet: Edition: ROTEX® SP "Non Sparking" Operating/Assembly instructions 1 40228 EN 4 of 28 6 Technical data Illustration 3: Type GND (No. 082) Table 3: Type GND (No. 082) Size 24 28 38 42 48 55 65 Spider 1) (component 2) Rated torque [Nm] 35 95 190 265 310 410 625 Dimensions [mm] 3) Component 1c Max. finish bore d1 2) 28 32 42 48 55 65 75 L l1, l2 E b s DA dH a 78 90 114 126 140 160 185 30 35 45 50 56 65 75 18 20 24 26 28 30 35 14 15 18 20 21 22 26 2.0 2.5 3.0 3.0 3.5 4.0 4.5 61 72 87 103 114 130 146 27 30 38 46 51 60 68 4 1) Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2 2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew 3) Dimensions G and t see table 9. Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 KTR-N Sheet: Edition: ROTEX® SP "Non Sparking" Operating/Assembly instructions 1 40228 EN 5 of 28 6 Technical data Illustration 4: Type EN (No. 081) - component 1, 1a, 1b: steel (St) Illustration 5: Type EN (No. 081) - component 1, 1a, 1b: cast iron (GJL) Table 4: Type EN (No. 081) - component 1, 1a, 1b: steel (St) Size Spider 1) (component 2) Rated torque [Nm] 24 35 28 95 38 190 42 265 48 310 55 410 65 625 Component (St) 1a 1b 1a 1b 1 1b 1 1b 1 1b 1 1b 1 1b Dimensions [mm] 3) Component 1, 1a, 1b steel (St) Max. finish bore d1 2) 35 40 48 55 62 74 80 L l1 78 98 90 115 114 139 126 151 140 164 160 185 185 210 30 50 35 60 45 70 50 75 56 80 65 90 75 100 Dimensions [mm] 3) Component 5c Max. finish l2 l3 DA bore d2 2) E b s DH dH D, D1 N Component 18 14 2.0 55 27 55 - 5c 19 36 22 61 20 15 2.5 65 30 65 - 5c 22 42 26 72 70 80 85 995 95 105 110 120 115 135 27 28 32 37 47 - 5c 28 50 30 87 5c 35 56 34 103 5c 40 60 36 114 5c 45 66 40 130 5c 55 75 44 146 24 18 3.0 80 38 26 20 3.0 95 46 28 21 3.5 105 51 30 22 4.0 120 60 35 26 4.5 135 68 Table 5: Type EN (No. 081) - component 1, 1a, 1b: cast iron (GJL) Size 38 42 48 Spider 1) (component 2) Rated torque [Nm] 190 265 310 55 410 65 625 Comp onent (GJL) 1 1a 1b 1 1a 1b 1 1a 1b 1 1a 1 Dimensions [mm] 3) Component 1, 1a, 1b: cast iron (GJL) Max. finish bore d1 2) 40 48 45 55 52 62 60 74 70 L l1 114 45 139 70 126 50 151 75 140 56 E b s DH dH 24 18 3.0 80 38 D, D1 66 78 75 26 20 3.0 95 46 94 85 28 21 3.5 105 51 164 80 160 65 30 22 4.0 120 60 185 75 35 26 4.5 135 68 104 98 118 115 N 37 Component Dimensions [mm] 3) Component 5c Max. finish l2 l3 DA bore d2 2) 5c 28 45 30 87 5c 35 50 34 103 5c 40 56 36 114 52 5c 45 65 40 130 61 5c 55 75 44 146 62 40 65 45 69 1) Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2 2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew 3) Dimensions G, t and t1 see table 9. Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 KTR-N Sheet: Edition: ROTEX® SP "Non Sparking" Operating/Assembly instructions 1 40228 EN 6 of 28 6 Technical data Illustration 6: Type E4-DKM (No. 086) Table 6: Type E4-DKM (No. 086) Size 24 28 38 42 48 55 65 Spider 1) (component 2) Rated torque [Nm] 35 95 190 265 310 410 625 Dimensions [mm] 3) Component 5bc Dimensions [mm] Component 6 Max. finish bore d2 2) l1, l2 l3, l4 DA a Ltotal DH dH l11 E b s 20 22 28 38 42 45 55 22 26 30 34 36 40 44 46 53 62 69 74 82 93 61 72 87 103 114 130 146 4.0 4.0 4.0 4.0 4.0 4.0 4.0 96 110 128 142 152 168 190 55 65 80 95 105 120 135 27 30 38 46 51 60 68 16 18 20 22 24 28 32 18 20 24 26 28 30 35 14 15 18 20 21 22 26 2.0 2.5 3.0 3.0 3.5 4.0 4.5 1) Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2 2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew 3) Dimensions G and t1 see table 9. Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 KTR-N Sheet: Edition: ROTEX® SP "Non Sparking" Operating/Assembly instructions 1 40228 EN 7 of 28 6 Technical data Illustration 7: Type ZS-DKM-C (No. 085) Table 7: Type ZS-DKM-C (No. 085) Size 24 28 38 42 48 55 65 Dropout center length L [mm] 100 140 100 140 100 140 100 140 140 140 180 200 140 180 Spider 1) (component 2) Rated torque [Nm] Dimensions [mm] Component 6c Al-H 3) Dimensions [mm] Component 7.5/7.6 steel (St) Max. finish bore d 2) 35 28 95 38 190 45 265 55 310 60 410 70 625 80 Ltotal 145 185 151 191 171 211 178 218 230 240 280 300 260 300 l1, l2 x1, x2 E b s DH D DA dH N M TA [Nm] dB 30 22.5 18 14 2.0 55 - 61 27 - M6 14 14 35 25.5 20 15 2.5 65 - 72 30 - M8 35 16 45 35.5 24 18 3.0 80 - 87 38 - M8 35 22 50 39 26 20 3.0 95 85 103 46 28 M10 69 30 56 45 28 21 3.5 105 95 114 51 32 M12 120 35 65 50 30 22 4.0 120 110 130 60 37 M12 120 40 60 35 26 4.5 135 115 146 68 47 M12 120 48 75 l11 49 89 41 81 33 73 26 66 62 50 90 110 40 80 1) Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2; transmittable torque as per 92 ShA-GS 2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew 3) Size 42 with drop-out center length L=100 mm made of steel Type 7.5 clamping hub type DH without feather keyway for double-cardanic combination Type 7.6 clamping hub type DH with feather keyway for double-cardanic combination Illustration 8 Hubs, clamping hubs or similar types (type 7.5) without feather keyways may be used in category 3 only and are marked with category 3 accordingly. ROTEX® 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: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 KTR-N Sheet: Edition: ROTEX® SP "Non Sparking" Operating/Assembly instructions 1 40228 EN 8 of 28 6 Technical data Table 8: Type ZS-DKM-C - Friction torques and surface pressure of DH clamping hubs type 7.5 Size Clamping screw M1 1) Dimension t2 Dimension e1 Dimension ØDK1 Dimension e2 Dimension ØDK2 Tightening torque TA [Nm] 24 M6 10.5 20 57.5 - 28 M8 12 25 72.6 - 38 M8 17 30 83.2 - 42 M10 18 34 96.7 32 93.3 48 M12 21 38 108.4 36 105.0 55 M12 26 44 121.8 42.5 119.2 65 M12 33 50 132.4 45 123.5 14 35 35 69 120 120 120 Transmittable friction torque of clamping hub [Nm] Surface pressure [N/mm2] Bore Ø Ø10 Ø11 Ø12 Ø14 Ø15 Ø16 Ø18 Ø19 Ø20 Ø22 Ø24 Ø25 Ø28 37.1 75.0 40.8 68.2 44.5 62.5 52.0 53.6 55.7 50.0 59.4 46.9 66.8 41.7 70.5 39.5 74.2 37.5 81.6 34.1 89.1 31.3 92.8 30.0 103.9 26.8 Ø30 Ø32 Ø35 Ø38 Ø40 Ø42 Ø45 68.3 123.4 75.2 112.2 82.0 102.8 95.7 88.1 102.5 82.3 109.3 77.1 123.0 68.6 129.8 64.9 136.7 61.7 150.3 56.1 164.0 51.4 170.8 49.4 191.3 44.1 205 41.1 219 38.6 239 35.3 260 32.5 95.7 61.8 102.5 55.7 109.3 54.1 123.0 48.1 129.8 45.6 136.7 43.3 150.3 39.3 164.0 36.1 170.8 34.6 191.3 30.9 205 28.9 219 27.1 239 24.7 260 22.8 273 21.6 287 20.6 307 19.2 Ø48 Ø50 Ø55 Ø60 152.2 90.3 163.0 84.2 173.9 79.0 195.6 70.2 206.5 66.5 217.4 63.2 239.1 57.4 260.8 52.7 271.7 50.5 304.3 45.1 326 42.1 348 39.5 380 36.1 413 33.3 435 31.6 456 30.1 489 28.1 522 26.3 543 25.3 598 23.0 238.6 105.9 254.5 99.3 286.3 88.2 302.2 83.6 318.1 79.4 349.9 72.2 381.7 66.2 397.6 63.5 445.3 56.7 477 52.9 509 49.6 557 45.4 604 41.8 636 39.7 668 37.8 716 35.3 763 33.1 795 31.8 875 28.9 954 26.5 Ø65 Ø70 Ø75 Ø80 Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: 318.1 71.1 349.9 64.6 381.7 59.2 397.6 56.8 445.3 50.8 477 47.4 509 44.4 557 40.6 604 37.4 636 35.5 668 33.8 716 31.6 763 29.6 795 28.4 875 25.8 954 23.7 1034 21.9 1113 20.3 381.7 49.3 397.6 47.4 445.3 42.3 477 39.5 509 37.0 557 33.8 604 31.2 636 29.6 668 28.2 716 26.3 763 24.7 795 23.7 875 21.5 954 19.7 1034 18.2 1113 16.9 1193 15.8 1272 14.8 KTR-N dated 2017-01-02 ROTEX® SP "Non Sparking" Operating/Assembly instructions 2 KTR-N Sheet: Edition: 40228 EN 9 of 28 6 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 ROTEX® 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: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 ROTEX® SP "Non Sparking" Operating/Assembly instructions 2 KTR-N Sheet: Edition: 40228 EN 10 of 28 6 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 ROTEX® SP „Non Sparking“ described in here corresponds to the state of the art at the time of printing of these operating/assembly instructions. 2.5 Coupling selection ! For a permanent 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 "ROTEX®"). If the operating conditions (performance, speed, modifications on engine and machine) change, the coupling selection must be reviewed. Please make sure that the technical data regarding torque refer to the spider only. The transmittable torque of the shaft-hub-connection must be reviewed by the customer and is subject to his responsibility. For drives subject to torsional vibrations (drives with cyclic stress due to torsional vibrations) it is necessary to perform a torsional vibration calculation to ensure a reliable selection. Typical drives subject to torsional vibrations are e. g. drives with diesel engines, piston pumps, piston compressors etc. If requested, KTR will perform the coupling selection and the torsional vibration calculation. 2.6 Reference to EC Machinery Directive 2006/42/EC The couplings supplied by KTR should be considered as components, not machines or partly completed machines according to EC Machinery Directive 2006/42/EC. Consequently KTR does not have to issue a declaration of incorporation. For details about safe assembly, start-up and safe operation refer to the present operating/assembly instructions considering the warnings. 3 Storage, transport and packaging 3.1 Storage The coupling hubs are supplied in preserved condition and can be stored at a dry and roofed place for 6 - 9 months. The features of the coupling spiders (elastomers) remain unchanged for up to 5 years with favourable storage conditions. ! The storage rooms must not include any ozone-generating devices like e. g. fluorescent light sources, mercury-vapour lamps or electrical high-voltage appliances. Humid storage rooms are not suitable. Please make sure that condensation is not generated. The best relative air humidity is less than 65 %. Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 ROTEX® SP "Non Sparking" Operating/Assembly instructions 3 KTR-N Sheet: Edition: 40228 EN 11 of 28 6 Storage, transport and packaging 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. 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 Components of ROTEX®, type GN (No. 080) Component 1 1c 2 Quantity 1 1 1 3 2 Description Hub GN hub SP Spider (92 ShA) Setscrews DIN EN ISO 4029 Illustration 9: Type GN (No. 080) Components of ROTEX®, type GND (No. 082) Component 1c 2 Quantity 2 1 3 2 Description GN hub SP Spider (92 ShA) Setscrews DIN EN ISO 4029 Illustration 10: Type GND (No. 082) Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 ROTEX® SP "Non Sparking" Operating/Assembly instructions 4 KTR-N Sheet: Edition: 40228 EN 12 of 28 6 Assembly 4.1 Components of the couplings Components of ROTEX®, type EN (No. 081) Component 1 2 Quantity 1 1 3 2 5c 1 Description Hub Spider (92 ShA) Setscrews DIN EN ISO 4029 EN hub SP Illustration 11: Type EN (No. 081) Components of ROTEX®, type E4-DKM (No. 086) Component 2 Quantity 2 3 2 5bc 6 2 1 Description Spider (92 ShA) Setscrews DIN EN ISO 4029 E4 hub SP DKM spacer Illustration 12: Type E4-DKM (No. 086) Components of ROTEX®, type ZS-DKM-C (No. 085) Component Quantity 2 2 4 2 1) 6c 1 7.5/7.6 2 Description Spider (98 ShA-GS) Cap screws DIN EN ISO 4762 DKM spacer SP DH clamping hub with half length tapered groove pin DIN EN ISO 8745 (2 pieces) 1) each DH clamping hub Illustration 13: Type ZS-DKM-C (No. 085) Hubs, clamping hubs or similar types without feather keyways may be used in category 3 only and are marked with category 3 accordingly. Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 ROTEX® SP "Non Sparking" Operating/Assembly instructions 4 KTR-N Sheet: Edition: 40228 EN 13 of 28 6 Assembly 4.1 Components of the couplings Features of standard spiders 92 Shore A 1) T-PUR® (orange) Spider hardness (Shore) 98 Shore A-GS 2) PUR (red) Marking (colour) 1) Use of spiders applies with all types except for type ZS-DKM-C (No. 085) 2) Use of spiders applies with type ZS-DKM-C (No. 085) only 4.2 Advice for finish bore STOP The maximum permissible bore diameters d (see chapter 1 - technical data) must not be exceeded. If these figures are disregarded, the coupling may tear. Rotating particles may cause danger to life. • Hub bores machined by the customer have to observe concentricity or axial runout, respectively (see illustration 14). • Please make absolutely sure to observe the figures for Ø dmax. • Carefully align the hubs when the finish bores are drilled. • Applies with all types except for type ZS-DKM-C: Please provide for a setscrew according to DIN EN ISO 4029 with a cup point or an end plate to fasten the hubs axially. • Only valid with type ZS-DKM-C: Please provide for a setscrew or an end plate to fasten the hubs axially. ! Illustration 14: 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. Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 KTR-N Sheet: Edition: ROTEX® SP "Non Sparking" Operating/Assembly instructions 4 40228 EN 14 of 28 6 Assembly 4.2 Advice for finish bore Table 9: Setscrew DIN EN ISO 4029 Size Dimension G Dimension t 1) Dimension t1 2) Tightening torque TA [Nm] 24 M5 10 6 2 28 M8 15 7 10 38 M8 15 7 10 42 M8 20 10 10 48 M8 20 10 10 55 M10 20 12 17 65 M10 20 12 17 28 M8x25 2 35 38 M8x30 2 35 42 M10x30 2 69 48 M12x35 2 120 55 M12x40 2 120 65 M12x40 2 120 1) Dimension t applies for types GN and GND only 2) Dimension t1 applies for types EN and E4-DKM Table 10: Cap screws DIN EN ISO 4762 - 12.9 Size Dimension G Number z 1) Tightening torque TA [Nm] 24 M6x20 2 14 1) each DH clamping hub Table 11: Recommended fit pairs acc. to DIN 748/1 Bore [mm] above up to 50 Shaft tolerance Bore tolerance k6 m6 H7 (KTR standard) 50 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 keyway should preferably be located between the cams. With axial fastening by the setscrew the tapped hole should be located on the keyway. The transmittable torque of the shaft-hub-connection must be reviewed by the customer and is subject to his responsibility. 4.3 Assembly of the coupling (general) 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 shafts. Not necessary with type ZS-DKM-C. Please pay attention to the ignition risk in potentially explosive atmospheres! STOP ! Touching the heated hubs causes burns. Please wear safety gloves. With the assembly please make sure that the distance dimension E or a (see table 1 to 7) is observed to allow for axial clearance of the spider when in operation. Disregarding this advice may cause damage to the coupling. If used in potentially explosive atmospheres the setscrews to fasten the hubs as well as all screw connections must be secured against working loose additionally, e. g. conglutinating with Loctite (average strength). Basically align the spider centrally with the hubs or spacers after assembly. Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 KTR-N Sheet: Edition: ROTEX® SP "Non Sparking" Operating/Assembly instructions 4 40228 EN 15 of 28 6 Assembly 4.4 Assembly of types GN, GND and EN • Mount the hubs on the shaft of driving and driven side (see illustration 15). • Insert the spider into the cam section of the hub on the driving or driven side. • Shift the power packs in axial direction until the distance dimension L is achieved (see illustration 16). • If the power packs are already firmly assembled, shifting the hubs axially on the shafts allows for setting the distance dimension L. • Fasten the hubs by tightening the setscrews DIN EN ISO 4029 with a cup point (tightening torques see table 9). If the shaft diameters with inserted feather key are smaller than dimension dH (see table 1 to 5) of the spider, one or two shaft ends may protude into the spider. Illustration 15: Assembly of the hubs Illustration 16: Assembly of coupling 4.5 Assembly of type E4-DKM • Mount the E4 hubs onto the shaft of driving and driven side (see illustration 17). • The internal sides of the E4 hubs must be flush with the front sides of the shafts. • Fasten the E4 hubs by tightening the setscrews DIN EN ISO 4029 with a cup point (tightening torque see table 9). • Insert both spiders into the cam section of the E4 hubs on the driving and driven side. • Put the DKM spacer into one of the two spiders. • Shift the power packs in axial direction until the dimension Ltotal is achieved (see illustration 18 and table 6). Illustration 17: Assembly of the E4 hubs Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Illustration 18: Assembly of coupling Replacing: Replaced by: KTR-N dated 2017-01-02 ROTEX® SP "Non Sparking" Operating/Assembly instructions 4 KTR-N Sheet: Edition: 40228 EN 16 of 28 6 Assembly 4.6 Assembly of type ZS-DKM-C • Remove the half shells from the hub body (see illustration 19). • Fit the hub bodies together with the spiders and DKM spacer SP (see illustration 20). • Mount the fitted unit along with the shells and the clamping screws onto the shaft ends of the driving and driven machine (see illustration 21). • Hand-tighten the components first until the hub bodies with the half shells fit closely to the shaft. • Shift the DH clamping hubs in axial direction until the dimension Ltotal is achieved (see illustration 22 and table 7). • Secure the DH clamping hubs by tightening the clamping screws reciprocally. The screws have to be tightened at the tightening torques TA specified in table 10 by means of a suitable torque wrench. ! Having started up the coupling the tightening torques of the screws have to be inspected during the usual inspection intervals. Illustration 19: Disassembly of shells Illustration 20: Assembly of hub bodies, spiders and DKM spacer SP Illustration 21: Assembly of component assembly onto the shafts Illustration 22: Assembly of coupling Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 KTR-N Sheet: Edition: ROTEX® SP "Non Sparking" Operating/Assembly instructions 4 40228 EN 17 of 28 6 Assembly 4.7 Displacements - alignment of the couplings The displacement figures specified in table 12 to 14 provide for sufficient safety to compensate for external influences like, for example, heat 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 indicated (see table 12 to 14). 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 table 12 to 14) are permissible. ! Please note: • The displacement figures specified in table 12 to 14 are maximum figures which must not arise in parallel. If radial and angular displacements arise at the same time, the permissible displacement values may only be used proportionally (see illustration 25). • Please inspect with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 12 to 14 can be observed. Angular displacements Radial displacements Axial displacements Kw = L1max. - L1min. [mm] Lmax = L + Ka [mm] Illustration 23: Displacements (single-cardanic) Angular displacements Axial displacements Illustration 24: Displacements (double-cardanic) Radial displacements Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 KTR-N Sheet: Edition: ROTEX® SP "Non Sparking" Operating/Assembly instructions 4 40228 EN 18 of 28 6 Assembly 4.7 Displacements - alignment of the couplings Examples of the displacement combinations specified in illustration 25: Illustration 25: Combinations of displacement Example 1: Kr = 30 % Kw = 70 % Example 2: Kr = 60 % Kw = 40 % Ktotal = Kr + Kw 100 % Table 12: Displacement figures for 92 Shore A Size Max. axial displacement Ka [mm] Max. radial displacement 1500 rpm 3000 rpm Kr [mm] with Kw [degree] max. angular displacement with n=1500 rpm Kw [mm] Kw [degree] max. angular displacement with n=3000 rpm Kw [mm] 24 -0.5 +1.4 0.22 0.15 0.9 0.85 0.8 0.75 28 -0.7 +1.5 0.25 0.17 0.9 1.05 0.8 0.85 38 -0.7 +1.8 0.28 0.19 1.0 1.35 0.9 1.10 42 -1.0 +2.0 0.32 0.21 1.0 1.70 0.9 1.40 48 -1.0 +2.1 0.36 0.25 1.1 2.00 1.0 1.60 55 -1.0 +2.2 0.38 0.26 1.1 2.30 1.0 2.00 65 -1.0 +2.6 0.42 0.28 1.2 2.70 1.1 2.30 38 +1.8 -1.4 0.77 0.70 1.0 0.9 42 +2.0 -2.0 0.84 0.75 1.0 0.9 48 +2.1 -2.0 0.91 0.82 1.0 0.9 55 +2.2 -2.0 1.01 0.81 1.0 0.9 65 +2.6 -2.0 1.17 1.05 1.0 0.9 Table 13: Displacement figures - type E4-DKM (No. 086) Size Max. axial displacement Ka [mm] Max. radial displacement Kr [mm] with n = Kw [degree] max. angular displacement with n = 1500 rpm 3000 rpm 1500 rpm 3000 rpm 24 +1.4 -1.0 0.59 0.53 1.0 0.9 28 +1.5 -1.4 0.66 0.60 1.0 0.9 Table 14: Displacement figures for 98 Shore A-GS - Type ZS-DKM-C (No. 085) Size 24 28 38 42 48 55 65 Max. axial displacement Ka [mm] +1.4 / -1.0 +1.5 / -1.4 +1.8 / -1.4 +2.0 / -2.0 +2.1 / -2.0 +2.2 / -2.0 +2.6 / -2.0 Please observe protection note ISO 16016. Max. angular displacement Kw [degree] with n = 1500 3000 rpm rpm 1.0 0.75 1.0 0.75 1.0 0.75 1.0 0.75 1.0 0.75 1.0 0.75 1.0 0.75 Drawn: Verified: Max. radial displacement Kr [mm] with shaft distance dimension L with n = 1500 rpm 3000 rpm 100 140 180 250 100 140 180 250 1.17 1.06 0.99 0.91 0.87 0.70 - 1.87 1.76 1.69 1.60 1.57 1.40 1.31 2.09 2.00 - 0.87 0.80 0.74 0.68 0.65 0.52 - 1.40 1.32 1.27 1.20 1.18 1.05 0.98 1.57 1.50 - 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 ROTEX® SP "Non Sparking" Operating/Assembly instructions 5 KTR-N Sheet: Edition: 40228 EN 19 of 28 6 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 a little finger • falling down of solid foreign objects. The cover may provide for openings intended for necessary heat dissipation. These openings have to comply with DIN EN ISO 13857. The cover must be electrically conductive and included in the equipotential bonding. Bellhousings (magnesium share below 7.5 %) made of aluminium and damping rings (NBR) can be used as connecting element between pump and electric motor. The cover may only be taken off with standstill of the unit. If the couplings are used in locations subject to dust explosion and in mining the user must make sure that there is no accumulation of dust in a dangerous volume between the cover and the coupling. The coupling must not operate in an accumulation of dust. For covers with unlocked openings on the top face no light metals must be used if the couplings are used as equipment of equipment group ll (if possible, from stainless steel). If the couplings are used in mining (equipment group l M2), the cover must not be made of light metal. In addition, it must be resistant to higher mechanical loads than with use as equipment of equipment group ll. During operation of the coupling, please pay attention to • different operating noise • vibrations occurring. ! If you note any irregularities with the coupling during operation, the drive unit must be switched off immediately. The cause of the breakdown must be specified by means of the table „Breakdowns“ and, if possible, be eliminated according to the proposals. The potential breakdowns specified can be hints only. To find out the cause all operating factors and machine components must be considered. Coating of coupling: If coated (priming, paintings, etc.) couplings are used in potentially explosive atmospheres, the requirements on conductibility and coating thickness must be considered. With paintings up to 200 µm electrostatic load does not have to be expected. Paintings and coatings exceeding a thickness of 200 µm are generally impermissible for potentially explosive atmospheres. It also applies for multiple coatings exceeding an overall thickness of 200 µm. Make sure with painting or coating that the coupling components are conductively connected with the device/devices to be connected so that the equipotential bonding is not impeded by the paint or coat applied. In addition, make sure that the marking of the coupling remains legible. Painting or coating of the spider is generally not admitted. Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 ROTEX® SP "Non Sparking" Operating/Assembly instructions 6 KTR-N Sheet: Edition: 40228 EN 20 of 28 6 Breakdowns, causes and elimination The below-mentioned failures can lead to a use of the ROTEX® coupling other than intended. In addition to the specifications given in these operating/assembly instructions make sure to avoid such failures. The errors listed can only be clues to search for the failures. When searching for the failure the adjacent components must generally be considered. If used other than intended the coupling can become a source of ignition. EU directive 2014/34/EU requires special care by the manufacturer and the user. General failures with use other than intended: • • • • • • • • • • • Important data for the coupling selection are not forwarded. The calculation of the shaft-hub-connection is not considered. Coupling components with damage occurred during transport are assembled. If the heated hubs are assembled, the permissible temperature is exceeded. The clearance of the components to be assembled is not coordinated with one another. Tightening torques have been fallen below/exceeded. Components are mixed up by mistake/assembled incorrectly. A wrong or no spider/DZ elements are inserted in the coupling. No original KTR components (purchased parts) are used. Old/already worn out spiders/DZ elements or spiders/DZ elements stored for too long are used. Maintenance intervals are not observed. Breakdowns Causes Hazard notes for potentially explosive atmospheres Misalignment Increased temperature on the spider surface; ignition risk by hot surfaces Screws for axial fastening of hubs working loose Ignition risk due to hot surfaces and sparking Different operating noise and/or vibrations occuring Breaking of the cams due to high impact energy/overload Breaking of cams Operating parameters do not meet with the performance of the coupling Danger by rotating cam fragments Operating error of the unit Early wear of spider Please observe protection note ISO 16016. Misalignment Increased temperature on the spider surface; ignition risk by hot surfaces Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz 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 10.2 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 10.2 1) Set the unit out of operation 2) Replace complete coupling 3) Inspect alignment 4) Find out the reason for overload 1) Set the unit out of operation 2) Review the operating parameters and select a bigger coupling (consider mounting space) 3) Assemble new coupling size 4) Inspect alignment 1) Set the unit out of operation 2) Replace complete coupling 3) Inspect alignment 4) Instruct and train the service staff 1) Set the unit out of operation 2) Eliminate the reason for the misalignment (e. g. loose foundation bolts, breaking of the engine mount, heat expansion of unit components, modification of the installation dimension E of the coupling) 3) For inspection of wear see chapter 10.2 Replacing: Replaced by: KTR-N dated 2017-01-02 ROTEX® SP "Non Sparking" Operating/Assembly instructions 6 40228 EN 21 of 28 6 Breakdowns, causes and elimination Breakdowns Causes Hazard notes for potentially explosive atmospheres Elimination Danger by rotating cam fragments 1) Set the unit out of operation 2) Disassemble the coupling and remove residues of the spider 3) Inspect coupling components and replace coupling components that have been damaged 4) Insert spider, assemble coupling components 5) Inspect alignment, adjust if necessary 6) Make sure that further physical modifications of the spider are excluded 1) Set the unit out of operation 2) Disassemble the coupling and remove residues of the spider 3) Inspect coupling components and replace coupling components that have been damaged 4) Insert spider, assemble coupling components 5) Inspect alignment, adjust if necessary 6) Inspect and adjust ambient/contact temperature (correct by using other spider materials, if necessary) 1) Set the unit out of operation 2) Disassemble the coupling and remove residues of the spider 3) Inspect coupling components and replace coupling components that have been damaged 4) Insert spider, assemble coupling components 5) Inspect alignment, adjust if necessary 6) Find out the reason for the vibrations (correct by spider with lower or higher Shore hardness, if necessary) e. g. contact with aggressive liquids/oils, ozone influence, too high/low ambient temperatures etc. causing physical modification of the spider Early wear of spider Ambient/contact temperatures which are too high for the spider, max. permissible -30 °C/+90 °C Early wear of spider (liquefaction of material inside the spider cam) ! 7 KTR-N Sheet: Edition: Vibrations of drive When operating with a worn spider (see chapter 10.3) proper operation is not ensured. Disposal In respect of environmental protection we would ask you to dispose of the packaging or products on termination of their service life in accordance with the legal regulations and standards that apply, respectively. • Metal Any metal components have to be cleaned and disposed of by scrap metal. • Nylon materials Nylon materials have to be collected and disposed of by a waste disposal company. Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 ROTEX® SP "Non Sparking" Operating/Assembly instructions 8 KTR-N Sheet: Edition: 40228 EN 22 of 28 6 Maintenance and service ROTEX® is a low-maintenance coupling. We recommend to perform a visual inspection on the coupling at least once a year. Please pay special attention to the condition of the coupling spiders. • Since the flexible machine bearings of the driving and driven side settle during the course of load, inspect the alignment of the coupling and re-align the coupling, if necessary. • The coupling components have to be inspected for damages. • The screw connections have to be inspected visually. Having started up the coupling the tightening torques of the screws have to be inspected during the usual inspection intervals. ! With the use in potentially explosive atmospheres observe chapter 10.2 "Inspection intervals for couplings in potentially explosive atmospheres". 9 Spares inventory, customer service addresses We recommend to store major spare parts on site to ensure the readiness for use of the machine in case if a coupling fails. Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage at www.ktr.com. 10 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. Enclosure A Advice and instructions regarding the use in potentially explosive atmospheres Applicable hub designs/types: a) Hubs that may be used in group II, category 2 and 3 : (hubs with feather keyway and hubs with CLAMPEX® clamping set or clamping ring hubs) • 1.0 Hub with feather keyway and setscrew • 7.6 Half shell hub (DH) with feather keyway • Type GN, EN, GND, ZS-DKM-C and E4-DKM with hubs corresponding to the specifications above b) Hubs which may be used in group II, category 3 only: hubs without feather keyway • 7.5 Half shell hub (DH) without feather keyway • Type GN, EN, GND, ZS-DKM-C and E4-DKM with hubs corresponding to the specifications above ROTEX® type E4-DKM (No. 086) only with spacer made of steel or aluminium wrought products with a yield strength Rp0.2 ≥ 250 N/mm2. Hubs, clamping hubs or similar types (type 7.5) without feather keyways may be used in category 3 only and are marked with category 3 accordingly. Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 ROTEX® SP "Non Sparking" Operating/Assembly instructions 10 KTR-N Sheet: Edition: 40228 EN 23 of 28 6 Enclosure A Advice and instructions regarding the use in 10.1 Intended use in potentially explosive atmospheres potentially explosive atmospheres Conditions of operation in potentially explosive atmospheres ROTEX® SP couplings are suitable for the use according to EU directive 2014/34/EU. 1. Industry (with the exception of mining) • • • • Equipment group II of category 2 and 3 (coupling is not approved/not suitable for equipment group 1) Substance group G (gases, mists, vapours), zone 1 and 2 (coupling is not approved/not suitable for zone 0) Substance group D (dusts), zone 21 and 22 (coupling is not approved/not suitable for zone 20) Explosion group IIC (gases, 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 PUR / T-PUR® Ambient or operating temperature Ta 1) Max. surface temperature 2) -30 °C to +90 °C +110 °C -30 °C to +75 °C +95 °C -30 °C to +60 °C +80 °C Explanation: The maximum surface temperatures each result from the maximum permissible ambient or operating temperature Ta plus the maximum temperature increase T of 20 K to be considered. For the temperature class a safety margin subject to standard of 5 K is added. 1) The ambient or operating temperature Ta is limited to +90 °C due to the permissible permanent operating temperature of the elastomers used. 2) The maximum surface temperature of +110 °C applies for the use in locations which are potentially subject to dust explosion. In potentially explosive atmospheres • the ignition temperature of dusts generated must at least be 1.5 times the surface temperature to be considered • the glow temperature must at least be the surface temperature to be considered plus a safety distance of 75 K. • the gases and vapours generated must amount to the temperature class specified. 2. Mining Equipment group I of category M2 (coupling is not approved/not suitable for equipment group M1). Permissible ambient temperature -30 °C to +90 °C. Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 ROTEX® SP "Non Sparking" Operating/Assembly instructions 10 KTR-N Sheet: Edition: 40228 EN 24 of 28 6 Enclosure A Advice and instructions regarding the use in 10.2 Inspection intervals for couplings in Equipment category 3G 3D M2 2G 2D No gases and vapours of explosion group IIC M2 2G 2D Gases and vapours of explosion group IIC potentially explosive atmospheres potentially explosive atmospheres Inspection intervals For couplings operated in zone 2 or zone 22 the inspection and maintenance intervals of the usual operating/assembly instructions for standard operation apply. During the standard operation which has to be taken as a basis of the ignition risk analysis the couplings are free from any ignition source. For gases, vapours and dusts generated the permissible glow and ignition temperatures specified in chapter 10.1 have to be considered and observed. The torsional backlash of the coupling (see chapter 10.3) 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 danger of explosion. We recommend a preventive inspection of torsional backlash and a visual inspection of the flexible spiders. 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 spider upon this initial inspection, further inspections can each be performed after 6,000 operating hours or at the latest after 18 months, provided that the operating parameters remain the same. If you note significant wear during the initial inspection so that it would be recommendable to replace the spider, please find out the cause according to the table „Breakdowns“, if possible. The maintenance intervals must be adjusted to the modified operating parameters without fail. The torsional backlash of the coupling (see chapter 10.3) 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 danger of explosion. We recommend a preventive inspection of torsional backlash and a visual inspection of the flexible spiders. 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 spider upon this initial inspection, further inspections can each be performed after 4,000 operating hours or at the latest after 12 months, provided that the operating parameters remain the same. If you note significant wear during the initial inspection so that it would be recommendable to replace the spider, please find out the cause according to the table „Breakdowns“, if possible. The maintenance intervals must be adjusted to the modified operating parameters without fail. Hubs, clamping hubs or similar types (type 7.5) without feather keyways may be used in category 3 only and are marked with category 3 accordingly. ROTEX® SP coupling Illustration 26: ROTEX® SP coupling Illustration 27: ROTEX® spider Here the backlash between the cams of the coupling and the flexible spider must be inspected by means of a feeler gauge. When reaching the wear limit maximum friction, the spider must be replaced immediately, irrespective of the inspection intervals. Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 ROTEX® SP "Non Sparking" Operating/Assembly instructions 10 KTR-N Sheet: Edition: 40228 EN 25 of 28 6 Enclosure A Advice and instructions regarding the use in potentially explosive atmospheres 10.3 Standard values of wear In case of a backlash > X mm, the flexible spider must be replaced. Monitoring of the general condition of the coupling can be done both at standstill and during operation. If the coupling is tested during operation, the operator must ensure an appropriate and proven test procedure (e. g. stroboscopic lamp, high-speed camera, etc.) which is definitely comparable to testing at standstill. If any distinctive features occur, an inspection must be made with the machine stopped. Reaching the limits for replacing depends on the operating conditions and the existing operating parameters. ! In order to ensure a long service life of the coupling and avoid dangers with the use in potentially explosive atmospheres, the shaft ends must be accurately aligned. Please absolutely observe the displacement figures indicated (see table 12 to 14). If the figures are exceeded, the coupling will be damaged. Illustration 28: Inspection of the limit of wear Illustration 29: Wear of spider Table 15: Limits of wear (friction) Xmax. [mm] ROTEX® spider ROTEX® GS spider 3.00 1.00 3.00 1.40 3.00 1.70 4.00 2.00 4.00 2.25 5.00 2.50 5.00 2.75 Size 24 28 38 42 48 55 65 Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 ROTEX® SP "Non Sparking" Operating/Assembly instructions 10 KTR-N Sheet: Edition: 40228 EN 26 of 28 6 Enclosure A Advice and instructions regarding the use in 10.4 potentially explosive atmospheres marking of coupling for potentially explosive atmospheres The ATEX marking of the ROTEX® coupling is applied on the outer sheath or on the front side. The flexible spider resp. DZ element is not marked. For the complete marking refer to the operating/assembly instructions and/or the delivery note/package. The following marking applies for the products: • Hubs resp. spacer without aluminium Category 2 (hubs resp. clamping hubs with feather keyway) ROTEX® <Year> I M2 Ex h I II 2G Ex h IIC T6 … T4 II 2D Ex h IIIC T80 °C … T110 °C -30 °C ≤ Ta ≤ +60 °C … +90 °C KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine Mb Gb Db • Hubs resp. spacer without aluminium Category 3 (hubs resp. clamping hubs without feather keyway) ROTEX® <Year> I M2 Ex h I II 3G Ex h IIC T6 … T4 II 3D Ex h IIIC T80 °C … T110 °C -30 °C ≤ Ta ≤ +60 °C … +90 °C KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine Mb Gc Dc • Hubs resp. spacer made of aluminium only Category 2 (hubs resp. clamping hubs with feather keyway) ROTEX® <Year> II 2G Ex h IIC T6 … T4 II 2D Ex h IIIC T80 °C … T110 °C -30 °C ≤ Ta ≤ +60 °C … +90 °C KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine Gb Db • Hubs resp. spacer made of aluminium only Category 3 (hubs resp. clamping hubs without feather keyway) ROTEX® <Year> II 3G Ex h IIC T6 … T4 II 3D Ex h IIIC T80 °C … T110 °C -30 °C ≤ Ta ≤ +60 °C … +90 °C KTR Systems GmbH, Carl-Zeiss-Straße 25, D-48432 Rheine Gc Dc Short marking: (A short marking is only made if not possible differently for reason of space or functioning.) ROTEX® <Year> Please observe protection note ISO 16016. Drawn: Verified: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 ROTEX® SP "Non Sparking" Operating/Assembly instructions 10 40228 EN 27 of 28 6 Enclosure A Advice and instructions regarding the use in 10.4 KTR-N Sheet: Edition: potentially explosive atmospheres marking of coupling for potentially explosive atmospheres Deviating marking applies until 31st October 2019: Short marking: II 2GD c IIC T X/I M2 c X Valid for all types except for ZS-DKM-C: Complete marking: (valid for T-PUR® only) Valid for type ZS-DKM-C only: Complete marking: (valid for PUR only) II 2G c IIC T6, T5, T4 resp. T3 -50 °C Ta +65 °C, +80 °C, +115 °C resp. +120 °C II 2D c T 140 °C -50 °C Ta +120 °C II 2G c IIC T6, T5 resp. T4 -30 °C Ta +65 °C, +80 °C resp. +90 °C II 2D c T 110 °C/I M2 c -30 °C Ta +90 °C 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: 2019-10-10 Pz/Bru 2019-10-10 Pz Replacing: Replaced by: KTR-N dated 2017-01-02 ROTEX® SP "Non Sparking" Operating/Assembly instructions 10 KTR-N Sheet: Edition: 40228 EN 28 of 28 6 Enclosure A Advice and instructions regarding the use in potentially explosive atmospheres 10.5 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 flexible ROTEX® SP "Non Sparking" couplings in an explosion-proof design described in these operating/assembly instructions are devices corresponding to article 2, 1. of directive 2014/34/EU and comply with the general safety and health requirements according to enclosure II of directive 2014/34/EU. The coupling described in here complies with the specifications of the following standards/rules: DIN EN ISO 80079-36 DIN EN ISO 80079-37 DIN EN ISO 80079-38 IEC/TS 60079-32-1 The ROTEX® 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 IBExU13ATEXB016 X: IBExU Institut für Sicherheitstechnik GmbH Identification number: 0637 Fuchsmühlenweg 7 09599 Freiberg Rheine, Place 2019-10-10 Date Please observe protection note ISO 16016. Drawn: Verified: i. V. Reinhard Wibbeling Engineering/R&D 2019-10-10 Pz/Bru 2019-10-10 Pz i. V. Michael Brüning Product Manager Replacing: Replaced by: KTR-N dated 2017-01-02 ">

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Key features
- Non-sparking
- Electrically conductive
- Torsionally flexible
- Emergency operating
- Directive 2014/34/EU compliant
Frequently asked questions
The maximum permissible bore diameters are listed in the Technical Data section of the manual (chapter 1). You should not exceed these values, as doing so could damage the coupling and cause injury.
The assembly instructions can be found in Chapter 4 of the manual. It's important to ensure the correct distance dimension L is achieved and to tighten the setscrews to the specified torque.
The displacement figures (maximum axial, radial, and angular) are specified in Tables 12 to 14 of the manual. It's critical to ensure that these figures are not exceeded during alignment.