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KTR Kupplungstechnik GmbH D-48407 Rheine BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR-N sheet: edition: 40110 EN 1 8 BoWex® puncture curved-tooth gear couplings® types No. 001 – junior plug-in coupling, No. 002 – junior M coupling, No. 003 – M and M...C No. 006 - I and their combinations design No. 001 – junior plug-in coupling (2 parts) according to Standard 94/9/EC (ATEX 95) for finish bored, pilot bored and unbored couplings design No. 002 – junior M coupling (3 parts) design No. 003 – M and M...C design No. 006 - I Schutzvermerk ISO 16016 beachten. Gezeichnet: Geprüft: 27.06.08 Sha/Hk 30.06.08 Sha Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 KTR Kupplungstechnik GmbH D-48407 Rheine BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR-N sheet: edition: 40110 EN 2 8 BoWex® curved-tooth gear couplings® are flexible shaft connections. They are able to compensate for shaft displacement caused by, as an example, inaccuracies in production, heat expansion, etc. Table of Contents 1 Technical Data 2 Hints 2.1 2.2 2.3 2.4 2.5 Coupling Selection General Hints Safety and Advice Hints General Hints to Danger Proper Use 3 Storage 4 Assembly 4.1 4.2 4.3 4.4 4.5 5 Components of the Couplings Hint Regarding the Finish Bore Assembly of the Hubs Displacements - Alignment of the Couplings Spares Inventory, Customer Service Addresses Enclosure A Hints and Instructions Regarding the Use in 5.1 Use in Hazardous Areas Hazardous Areas According to the Regulations 5.2 Control Intervals for Couplings in 5.3 Checking of Torsional Backlash 5.4 Approximate Values of Wear 5.5 Permissible Coupling Materials in the Hazardous Areas Hazardous Area 5.6 Marking of Coupling for the Hazardous Area 5.7 Starting 5.8 Breakdowns, Causes and Elimination 5.9 EC Certificate of Conformity according to the EC Standards 94/9/EC dated 23 March 1994 Schutzvermerk ISO 16016 beachten. Gezeichnet: Geprüft: 27.06.08 Sha/Hk 30.06.08 Sha Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 KTR Kupplungstechnik GmbH D-48407 Rheine BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR-N sheet: edition: 40110 EN 3 8 1 Technical Data ® ® picture 1: BoWex junior plug-in coupling (2 parts) picture 2: BoWex junior M coupling (3 parts) Table 1: BoWex® junior plug-in coupling and BoWex® junior M coupling torque [Nm] ® BoWex size TKN TK max. 14 5 10 19 8 16 24 12 24 hub component 1b d1 Ø6, Ø7, Ø8, Ø9 Ø10, Ø11 Ø12, Ø14 Ø12, Ø14 Ø16 Ø19 Ø10, Ø11, Ø12 Ø14, Ø15, Ø16 Ø18, Ø19, Ø20 Ø24 finish bore [mm] plug-in sleeve D1 component 2b d2 22 Ø8 25 Ø10, Ø11 26 Ø12, Ø14 27 Ø14, Ø15 30 32 Ø19 26 Ø14, Ø16 32 36 Ø19, Ø20 38 Ø24 thread for setscrews [mm] max. speed [1/min] D2 G1 t1 t2 TA [Nm] 22 25 26 M5 6 8 1,4 6000 M5 6 10 1,4 6000 M5 6 10 1,4 6000 29 35 32 36 40 Table 2: BoWex® junior plug-in coupling and BoWex® junior M coupling dimensions [mm] ® BoWex size 14 19 24 DH l1; l2 E1 L1 LH1 M1 F G E L LH M; N 40 47 53 23 25 26 2 2 2 48 52 54 40 42 45 8 10 9 18,5 19,0 21,5 21,5 23,0 23,5 4 4 4 50 54 56 37 37 41 6,5 8,5 7,5 Schutzvermerk ISO 16016 beachten. Gezeichnet: Geprüft: 27.06.08 Sha/Hk 30.06.08 Sha Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR Kupplungstechnik GmbH D-48407 Rheine KTR-N sheet: edition: 40110 EN 4 8 1 Technical Data ® ® picture 3: BoWex design M picture 4: BoWex design I Table 3: BoWex® design M and design I ® BoWex size pilot bore M-14 M-19 M-24 M-28 M-32 M-38 M-42 M-48 M-14C M-19C M-24C M-28C M-32C M-38C M-48C unbored x x x x x x x x M-65 M-65C x I-80 I-100 I-125 - pilot bore 27 70 lg. 31 35 45 max. finish bore d1; d2 15 20 24 28 32 38 42 48 dimensions [mm] 1) l1; l2 E L LH M; N l3 D DH 23 25 26 40 40 40 42 50 4 4 4 4 4 4 4 4 50 54 56 84 84 84 88 104 37 37 41 46 48 48 50 50 6,5 8,5 7,5 19 18 18 19 27 10 10 14 13 13 13 13 13 25 32 36 44 50 58 65 68 40 47 53 65 75 83 92 95 33 39 45 54 63 69 78 78 65 55 4 114 68 23 16 96 132 110 80 100 125 90 110 140 6 8 10 186 228 290 93 102 134 46,5 63 78 20 22 30 124 152 192 175 210 270 145 176 225 DZ threads for 2) setscrews [mm] TA G t [Nm] M5 6 2 M5 6 2 M5 6 2 M8 10 10 M8 10 10 M8 10 10 M8 10 10 M8 10 10 15 / 17 M10 3) 20 M10 20 17 M12 30 40 M16 40 80 1) tip circle of the hub 2) position of the threads for setscrews BoWex M-14 to M-24 opposite the keyway; BoWex M-28 to I-125 on the keyway 3) hub length 55 mm t = 15 mm, 70 mm t = 20 mm BoWex® couplings with attached parts that can generate heat, sparks and static charging (e. g. combinations with brake drums, brake disks, overload systems like torque limiters, impellers etc.) are not allowed for the use in hazardous areas. A separate checking must be made. Schutzvermerk ISO 16016 beachten. Gezeichnet: Geprüft: 27.06.08 Sha/Hk 30.06.08 Sha Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 KTR Kupplungstechnik GmbH D-48407 Rheine BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR-N sheet: edition: 40110 EN 5 8 2 Hints 2.1 Coupling Selection ! CAUTION! For a continuous and troublefree operation of the coupling it must be designed according to the selection instructions (according to DIN 740 part 2) for the particular application (see BoWex® catalogue). If the operating conditions (performance, speed, changes at engine and machine) change, the coupling selection must be checked again. Please make sure that the technical data regarding torque only refers to the sleeve. The transmissible torque of the shaft/hub connection must be checked by the orderer, and he is responsible for the same. For drives with endangered torsional vibration (drives with periodical load on torsional vibration) it is necessary to make a torsional vibration calculation to ensure a perfect selection. Typical drives with endangered torsional vibration are e. g. drives with diesel engines, piston pumps, piston compressors etc. On request KTR makes the coupling selection and the torsional vibration calculation. 2.2 General Hints Please read through these mounting instructions carefully before you set the coupling into operation. Please pay special attention to the safety instructions! The BoWex® coupling is suitable and approved for the use in hazardous areas. When using the coupling in hazardous areas please observe the special hints and instructions regarding safety in enclosure A. The mounting instructions are part of your product. Please keep them carefully and close to the coupling. The copyright for these mounting instructions remains with KTR Kupplungstechnik GmbH. 2.3 Safety and Advice Hints STOP DANGER! Danger of injury to persons. ! CAUTION! Damages on the machine possible. ATTENTION! Pointing to important items. PRECAUTION! Hints concerning explosion protection. ) Schutzvermerk ISO 16016 beachten. Gezeichnet: Geprüft: 27.06.08 Sha/Hk 30.06.08 Sha Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 KTR Kupplungstechnik GmbH D-48407 Rheine BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR-N sheet: edition: 40110 EN 6 8 2 Hints 2.4 General Hints of Danger STOP DANGER! With assembly, operation and maintenance of the coupling it has to be made sure that the entire drive train is protected against unintentional engagement. You can be seriously hurt by rotating parts. Please make absolutely sure to read through and observe the following safety instructions. • All operations on and with the coupling have to be performed taking into account "safety first". • Please make sure to disengage the power pack before you perform your work. • Protect the power pack against unintentional engagement, e. g. by providing hints at the place of engagement or removing the fuse for current supply. • Do not touch the operation area of the coupling as long as it is in operation. • Please protect the coupling against unintentional touch. Please provide for the necessary protection devices and caps. 2.5 Proper Use You may only assemble, operate and maintain the coupling if you • carefully read through the mounting instructions and understood them • had technical training • are authorized to do so by your company The coupling may only be used in accordance with the technical data (see table 1 to 3 in chapter 1). Unauthorized modifications on the coupling design are not admissible. We do not take any warranty for resulting damages. To further develop the product we reserve the right for technical modifications. The BoWex® described in here corresponds to the technical status at the time of printing of these mounting instructions. 3 Storage The coupling hubs are supplied in preserved condition and can be stored at a dry and roofed place for 6 - 9 months. The features of the coupling sleeves remain unchanged for up to 5 years in case of favourable stock conditions. ! CAUTION! The storage rooms may 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 there is no condensation. The best relative air humidity is under 65%. Schutzvermerk ISO 16016 beachten. Gezeichnet: Geprüft: 27.06.08 Sha/Hk 30.06.08 Sha Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 KTR Kupplungstechnik GmbH D-48407 Rheine BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR-N sheet: edition: 40110 EN 7 8 4 Assembly Basically the coupling is supplied in individual parts. Before assembly the coupling has to be controlled for completeness. 4.1 Components of the Couplings Design from nylon Components of BoWex® junior plug-in coupling design No. 001 Component 1 2 Quantity 1 1 3 2 Designation hub plug-in sleeve setscrew DIN EN ISO 4029 ® picture 5: BoWex junior plug-in coupling Components of BoWex® junior M coupling design No. 002 Component 1 2 Quantity 2 1 3 2 Designation hub sleeve setscrew DIN EN ISO 4029 ® picture 6: BoWex junior M coupling Design from steel/nylon Components of BoWex® M coupling (size 14 - 65) design No. 003 Component 1 2 Quantity 2 1 3 2 Designation hub M-sleeve setscrew DIN EN ISO 4029 ® picture 7: BoWex M coupling Schutzvermerk ISO 16016 beachten. Gezeichnet: Geprüft: 27.06.08 Sha/Hk 30.06.08 Sha Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR Kupplungstechnik GmbH D-48407 Rheine KTR-N sheet: edition: 40110 EN 8 8 4 Assembly 4.1 Components of the Couplings Components of BoWex I coupling (size 80 - 125) design No. 006 Component 1 2 3 Quantity 2 1 2 4 2 Designation hub I-sleeve 1) circlips 1) setscrew DIN EN ISO 4029 1) Circlips and sleeve are delivered pre-assembled. ® picture 8: BoWex I coupling 4.2 Hint Regarding the Finish Bore STOP DANGER! The maximum permissible bore diameters d (see table 1 to 3 in chapter 1 - Technical Data) must not be exceeded. If these figures are disregarded, the coupling may tear. Rotating particles may cause serious danger. • Hub bores (steel hubs) machined by the customer have to observe concentric running or axial running, respectively (see picture 9). • Please make absolutely sure to observe the figures for dmax. • Carefully align the hubs when the finish bores are brought in. • Please use a setscrew according to DIN EN ISO 4029 with a cup point or an end plate to fasten the hubs axially. picture 9: concentric running and axial running CAUTION! The orderer is responsible for all subsequently made machinings to unbored or pilot bored and to finish machined coupling parts and spare parts. KTR does not assume any warranty claims resulting from insufficient refinish. ! PRECAUTION! Any mechanical rework to couplings that are used in hazardous areas require an explicit release by KTR. The orderer must send a drawing to KTR acc. to which the manufacture must be made. KTR checks this drawing and returns it to the orderer with approval. Table 4: setscrews ® BoWex size dimension G tightening torque TA [Nm 1) 1) tightening torques of the BoWex Schutzvermerk ISO 16016 beachten. 1) 14 M5 2 19 M5 2 ® 1) 24 M5 2 28 M8 10 32 M8 10 38 M8 10 42 M8 10 48 M8 10 65 M10 17 80 M10 17 100 M12 40 ® junior plug-in coupling and BoWex junior M coupling TA = 1,4 Nm Gezeichnet: Geprüft: 27.06.08 Sha/Hk 30.06.08 Sha Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 125 M16 80 KTR Kupplungstechnik GmbH D-48407 Rheine BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR-N sheet: edition: 40110 EN 9 8 4 Assembly 4.3 Assembly of the Hubs ) ATTENTION! We recommend to check bores, shaft, keyway and feather key for dimensional accuracy before assembly. Heating the hubs slightly (approx. 80 °C) allows for an easier installation onto the shaft. PRECAUTION! Please pay attention to the danger of ignition in hazardous areas. STOP ! DANGER! Touching the heated hubs causes burns. We would recommend to wear safety gloves. CAUTION! For the assembly please make sure that the distance dimension E (see table 2 and 3) is kept to ensure that the sleeve can be moved axially. Disregarding this hint may cause damage on the coupling. • Assemble the hubs onto the shaft of driving and driven side. • Move the power packs in axial direction until the dimension E is achieved. • If the power packs are already firmly assembled, axial movement of the hubs on the shafts allows for adjusting the dimension E. • Fasten the hubs by tightening the setscrews DIN EN ISO 4029 with cup point (tightening torque see table 4). 4.4 Displacements - Alignment of the Couplings The displacement figures shown in tables 5 and 6 offer sufficient safety to compensate for environmental influences like, for example, heat expansion or lowering of foundation. ! CAUTION! In order to ensure a long lifetime of the coupling and to avoid dangers regarding the use in hazardous areas, the shaft ends must be accurately aligned. Please absolutely observe the displacement figures indicated (see tables 5 and 6). If the figures are exceeded, the coupling is damaged. The exacter the alignment of the coupling, the higher is its lifetime. In case of a use in hazardous areas for the explosion group IIC (marking II 2GD c IIC T X), only the half displacement figures (see tables 5 and 6) are permissible. Please note: • The displacement figures mentioned in tables 5 and 6 are maximum figures which must not arise in parallel. If radial and angular displacement arises at the same time, the permissible radial displacements of the coupling halves have to be reduced as follows: ΔKrperm = ΔKr − ΔWw = angular shaft displacement ΔKr • ΔWw 2ΔKw • The displacement figures mentioned are general figures that apply up to an ambient temperature of 80 °C, ensuring a sufficient service life of the BoWex® coupling. Displacement figures between the speeds indicated have to be interpolated accordingly. If necessary, please ask about the displacement for the corresponding coupling type. • Please check with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 5 and 6 can be observed. Schutzvermerk ISO 16016 beachten. Gezeichnet: Geprüft: 27.06.08 Sha/Hk 30.06.08 Sha Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR Kupplungstechnik GmbH D-48407 Rheine KTR-N sheet: edition: 40110 EN 10 8 4 Assembly 4.4 Displacements - Alignment of the Couplings angular displacements radial displacements axial displacements radial and angular displacements picture 10: displacements Example for the misalignment combinations given in picture 11: picture 11: combinations of displacement Example 1: ΔKr = 30 % ΔKw = 70 % Example 2: ΔKr = 60 % ΔKw = 40 % ΔKtotal = ΔKr + ΔKw ≤ 100 % Table 5: Displacement figures BoWex® junior plug-in coupling and BoWex® junior M coupling coupling size 14 19 24 max. axial displacement ΔKa [mm] max. radial displacement with n=1500 1/min ΔKr [mm] max. radial displacment with n=3000 1/min ΔKr [mm] ΔKw max. angular displacement with n=1500 1/min [degree] ΔKw max. angular displacement with n=3000 1/min [degree] ±1 0,1 0,1 1,0 0,7 ±1 0,1 0,1 1,0 0,7 ±1 0,1 0,1 0,9 0,6 Table 6: Displacement figures BoWex® design M and design I coupling size 14 19 24 28 32 38 42 48 65 80 100 125 max. axial displacement ΔKa [mm] max. radial displacement with n=1500 1/min ΔKr [mm] max. radial displacment with n=3000 1/min ΔKr [mm] ΔKw max. angular displacement with n=1500 1/min [degree] ΔKw max. angular displacement with n=3000 1/min [degree] ±1 ±1 ±1 ±1 ±1 ±1 ±1 ±1 ±1 ±1 ±1 ±1 0,30 0,30 0,35 0,35 0,35 0,40 0,40 0,40 0,45 0,45 0,45 0,45 0,20 0,20 0,23 0,23 0,23 0,25 0,25 0,25 0,28 0,28 0,28 0,28 1,0 1,0 0,9 0,9 0,9 0,9 0,9 0,9 0,7 0,6 0,6 0,4 0,7 0,7 0,6 0,6 0,6 0,6 0,6 0,6 0,5 0,4 0,4 0,3 Schutzvermerk ISO 16016 beachten. Gezeichnet: Geprüft: 27.06.08 Sha/Hk 30.06.08 Sha Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 KTR Kupplungstechnik GmbH D-48407 Rheine BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR-N sheet: edition: 40110 EN 11 8 4 Assembly 4.5 Spares Inventory, Customer Service Addresses A basic requirement to guarantee the operational readiness of the coupling is a stock of the most important spare parts on site. Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage under www.ktr.com. 5 Enclosure A Hints and Instructions Regarding the Use in design 003: Hazardous Areas hub / sleeve / hub Enclosure A only valid for BoWex M coupling (type 003). 5.1 Use in Hazardous Areas According to the Regulations Conditions of operation in hazardous locations BoWex® couplings are suitable for the use according to EC standard 94/9/EC. 1. Industry (with the exception of mining) • • • • device class II of category 2 and 3 (coupling is not approved for device class 1) media class G (gases, fogs, steams), zone 1 and 2 (coupling is not approved for zone 0) media class D (dusts), zone 21 and 22 (coupling is not approved for zone 20) explosion class IIC (explosion class IIA and IIB are included in IIC) Temperature class: Temperature class T4, T3, T2, T1 T5 T6 standard sleeve „light“ ambient or operating max. surface temperature temperature 1) - 30 °C to + 90 °C 120 °C 2) - 30 °C to + 70 °C 90 °C - 30 °C to + 55 °C 75 °C conductive sleeve „black“ ambient or operating max. surface temperature temperature 1) - 30 °C to + 100 °C 120 °C 2) - 30 °C to + 80 °C 100 °C - 30 °C to + 65 °C 85 °C Explanation: The maximum surface temperatures result from each the maximum permissible ambient or operating temperature Ta plus the maximum temperature increase ΔT of 30 K (standard sleeve “light”) and ΔT of 20 K (conductive sleeve “black”) which has to be taken into account. 1) The ambient or operating temperature Ta is limited to + 90 °C (standard sleeve “light”) and + 100 °C (conductive sleeve “black”) due to the permissible permanent operating temperature of the sleeves used. 2) The maximum surface temperature of 120 °C applies for the use in locations which are potentially subject to dust explosion, too. 2. Mining Device class I of category M2 (coupling is not approved for device category M1). Permissible ambient temperature - 30 °C to + 90 °C (standard sleeve “light”) and - 30 °C bis + 100 °C (conductive sleeve “black”) respectively. Schutzvermerk ISO 16016 beachten. Gezeichnet: Geprüft: 27.06.08 Sha/Hk 30.06.08 Sha Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 KTR Kupplungstechnik GmbH D-48407 Rheine BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR-N sheet: edition: 40110 EN 12 8 5 Enclosure A Hints and Instructions Regarding the Use in 5.2 Control Intervals for Couplings in Hazardous Areas explosion group 3G 3D II 2GD c IIB T4, T5, T6 II 2GD c IIC T4, T5, T6 Hazardous Areas control intervals For couplings which are classified in category 3G or 3D the operating and assembly instructions that are usual for standard operation apply. During the standard operation which has to be subject to the analysis of danger of ignition the couplings are free from any ignition source. Merely the temperature increase produced by proper heating and depending on the coupling type has to be considered: for BoWex®: ΔT = 30 K (standard sleeve „light“) for BoWex®: ΔT = 20 K (conductive sleeve „black“) A checking of the circumferential backlash and a visual check of the flexible sleeve must be effected after 3,000 operating hours for the first time, after 6 months at the latest. Except for centered, stiff connecting flanges (e. g. bellhousings). If you note an unconsiderable or no wear at the sleeve after this first inspection, the further inspections can be effected, in case of the same operating parameters, respectively after 6,000 operating hours or after 18 months at the latest. If you note a considerable wear during the first inspection, so that a change of the sleeve would be recommended, please find out the cause according to the table „Breakdowns“, as far as possible. The maintenance intervals must be adjusted according to the changed operating parameters. A checking of the circumferential backlash and a visual check of the flexible sleeve must be effected after 2,000 operating hours for the first time, after 3 months at the latest. Except for centered, stiff connecting flanges (e. g. bellhousings). If you note an unconsiderable or no wear at the sleeve after this first inspection, the further inspections can be effected, in case of the same operating parameters, respectively after 4,000 operating hours or after 12 months at the latest. If you note a considerable wear during the first inspection, so that a change of the sleeve would be recommended, please find out the cause according to the table „Breakdowns“, as far as possible. The maintenance intervals must be adjusted according to the changed operating parameters. BoWex® coupling ® picture 12: BoWex coupling Here the backlash between the hub and the nylon toothing must be checked by a torsional backlash, separately from the drive and the driven end. The friction / wear may only be Xmax. of the original toothing strength before the nylon sleeves must be exchanged. When reaching the torsional backlash ΔSmax, the nylon sleeve must be exchanged immediately, irrespective of the inspection intervals. Schutzvermerk ISO 16016 beachten. Gezeichnet: Geprüft: 27.06.08 Sha/Hk 30.06.08 Sha Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 KTR Kupplungstechnik GmbH D-48407 Rheine BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR-N sheet: edition: 40110 EN 13 8 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas 5.3 Checking of Torsional Backlash CAUTION! To check the torsional backlash the turned off drive aggregate must be secured against unintended turning on. ! Drive end • Turn the hub in opposite direction to the direction of drive. ! CAUTION! Here the sleeve may not be axially displaced from its wear position. • Mark sleeve and hub (see picture 13). • Turn the hub in the direction of drive and measure the torsional backlash ΔSmax. • When reaching the torsional backlash ΔSmax the nylon sleeve must be exchanged. Driven end • Turn the hub in the direction of drive. ! CAUTION! Here the sleeve may not be axially displaced from its wear position. • Mark sleeve and hub (see picture 13). • Turn the hub in opposite direction to the direction of drive and measure the torsional backlash ΔSmax. • When reaching the torsional backlash ΔSmax the nylon sleeve must be exchanged. picture 13: marking of the sleeve and the hub Schutzvermerk ISO 16016 beachten. Gezeichnet: Geprüft: 27.06.08 Sha/Hk 30.06.08 Sha Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 KTR Kupplungstechnik GmbH D-48407 Rheine BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR-N sheet: edition: 40110 EN 14 8 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas 5.4 Approximate Values of Wear If the torsional backlash is ≥ ΔSmax. [mm] / friction ≥ Xmax. [mm], the nylon sleeves must be exchanged. The reaching of the exchange values depends on the operating conditions and the existing operating parameters. CAUTION! In order to ensure a long lifetime of the coupling and to avoid dangers regarding the use in hazardous areas, the shaft ends must be accurately aligned. Please absolutely observe the displacement figures indicated (see tables 5 and 6). If the figures are exceeded, the coupling is damaged. ! picture 14: sleeve in new condition picture 15: wear of sleeve Table 7: BoWex® size 14 19 24 28 32 38 42 limits of wear each hub torsional backlash friction Xmax. [mm] ΔSmax. [mm] 0,8 1,3 0,8 1,4 1,0 1,5 1,0 1,6 1,0 1,7 1,0 1,7 1,0 1,7 5.5 Permissible Coupling Materials in the explosion group BoWex® size 45 48 65 80 100 125 limits of wear each hub torsional backlash friction Xmax. [mm] ΔSmax. [mm] 1,0 1,8 1,0 1,8 1,4 2,5 1,6 2,7 1,8 3,1 2,0 3,5 Hazardous Area permitted coupling materials / size IIB BoWex M14 to M65 with sleeve material PA (light) BoWex M14 to M19 with sleeve material PA (light) BoWex M14 to M65 with sleeve material PA12CF15 (black) IIC In the Explosion Groups IIB and IIC the following materials may be combined: steel stainless steel Schutzvermerk ISO 16016 beachten. Gezeichnet: Geprüft: 27.06.08 Sha/Hk 30.06.08 Sha Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 KTR Kupplungstechnik GmbH D-48407 Rheine BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR-N sheet: edition: 40110 EN 15 8 5 Enclosure A Hints and Instructions Regarding the Use in 5.6 Hazardous Areas Marking of Coupling for the Hazardous Area The ATEX marking of the BoWex® curved-tooth gear couplings® is shown on the nylon sleeve. • up to BoWex® M 32-C at the outer casing only sign • form BoWex® M 38-C at the front Complete labelling: II 2G c IIC T6, T5 bzw. T4 - 30 °C ≤ Ta ≤ + 65°C, + 80 °C bzw. + 100 °C II 2D c T 120 °C - 30 °C ≤ Ta ≤ + 100 °C I M2 c - 30 °C ≤ Ta ≤ + 100 °C Short labelling: II 2GD c IIC T X/I M2 c X The labelling with Explosion Group llC included the Explosion Group llB. ! CAUTION! Any mechanical rework to couplings that are used in hazardous areas require an explicit release by KTR. The orderer must send a drawing to KTR acc. to which the manufacture must be made. KTR checks this drawing and returns it to the orderer with approval. 5.7 Starting Before putting the coupling into operation, check the tightness of the setscrews in the hubs, the alignment and the distance dimension E and correct, if necessary, and also check all screw connections regarding the stipulated tightening torques dependent on the type of coupling. If used in hazardous areas the grub screws to fix the hub as well as all screw connections must be additionally secured against self-loosening, e. g. glue with Loctite (medium strength). Last but not least, the coupling protection against unintended contact must be fixed. The cover must be electrically conductive and be included in the equipotential bonding. Bellhousings (magnesium part below 7,5 %) made from aluminium and damping rings (NBR) can be used as connecting element between pump and electro motor. The cover may only be taken off after having stopped the unit. During operation, please pay attention to • strange running noises • occurring vibrations. If the couplings are used in dust explosive areas and in mining the user must make sure that there is no accumulation of dust in a critical quantity between the cover and the coupling. The coupling must no operate in an accumulation of dust. For covers with unlocked openings on the upper side no light metals may be used if the couplings are used as appliances of appliance group ll (if possible, from stainless steel). If the couplings are used in mining (appliance group l M2), the cover must not be made from light metal. In addition, it must be resistant to higher mechanical loads than if it is used as appliance of appliance group ll. Schutzvermerk ISO 16016 beachten. Gezeichnet: Geprüft: 27.06.08 Sha/Hk 30.06.08 Sha Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR Kupplungstechnik GmbH D-48407 Rheine KTR-N sheet: edition: 40110 EN 16 8 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas 5.6 Starting The minimum distance of the protection device to the rotating parts must be at least 5mm. If the protection device is used as cover, regular openings complying with the explosion protection demands can be made that must not exceed the following dimensions: circular openings diameter in mm top surface of the covering side parts of the covering ! 4 8 form of the openings straight or bended slot distance rectangular openings of the side limit side length in mm in mm 4 prohibited 8 8 CAUTION! If you note any irregularities at the coupling during operation, the drive unit must be turned off immediately. The cause of the breakdown must be found out with the table „Breakdowns“ and, if possible, be eliminated according to the proposals. The possible breakdowns mentioned can be hints only. To find out the cause all operating factors and machine components must be considered. Coupling layer: If coated (priming, painting etc.) couplings are used in hazardous areas, the requirements to conductability and layer thickness must be considered. In case of paintings up to 200 µm no electrostatic load can be expected. Multiple coatings that are thicker than 200 µm are prohibited for explosion group llC. 5.8 Breakdowns, Causes and Elimination The below-mentioned errors can lead to an incorrect use of the BoWex® coupling. In addition to the stipulations in these operating and mounting instructions please make sure to avoid these errors. The errors listed can only be clues to search for the errors. When searching for the error the adjacent components must be generally included. Due to incorrect use the coupling can become a source of ignition. EC Standard 94/9/EC requires a special care from the manufacturer and the user. General errors incorrect use • • • • • • • • • • Important data for the coupling selection was not forwarded. The calculation of the shaft/hub connection was not considered. Coupling parts with damage occurred during transport are assembled. If the heated hubs are assembled, the permissible temperature is exceeded. The fits of the parts to be assembled are not coordinated with each other. Tightening torques are below/exceeded. Components are exchanged by mistake/put together incorrectly. No original KTR parts (purchased parts) are used. Old sleeves/already worn out sleeves or sleeves stored too long are used. The coupling used/the coupling protection used is not suitable for the operation in hazardous areas and does not correspond to EC Standard 94/9/EC, respectively. • Maintenance intervals are not observed. Schutzvermerk ISO 16016 beachten. Gezeichnet: Geprüft: 27.06.08 Sha/Hk 30.06.08 Sha Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 KTR Kupplungstechnik GmbH D-48407 Rheine BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR-N sheet: edition: 40110 EN 17 8 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas 5.8 Breakdowns, Causes and Elimination breakdowns change of the running noises and / or occurring vibrations break of the nylon sleeve / toothing Schutzvermerk ISO 16016 beachten. danger hints for hazardous areas causes misalignment micro friction at the toothing of the nylon sleeve danger of ignition due to hot surfaces loose screws for axial securement of hubs danger of ignition due to hot surfaces break of the nylon sleeve / toothing due to high shock energy / overload --- operating parameters do not correspond to the performance of the coupling --- mistake in service of the unit --- Gezeichnet: Geprüft: 27.06.08 Sha/Hk 30.06.08 Sha elimination 1) put the unit out of operation 2) eliminate the reason for the misalignment (e. g. loose foundation bolts, break of the engine fixing, heat expansion of unit components, change of the assembly dimension E of the coupling) 3) checking of wear see under point Control 1) put the unit out of operation 2) check alignment of coupling 3) tighten the screws to secure the hubs and secure against self-loosening 4) checking of wear see under point Control 1) put the unit out of operation 2) disassemble the coupling and remove rests of the sleeve 3) check coupling parts and exchange damaged coupling parts 4) insert sleeve, assemble coupling parts 5) find out the reason of overload 1) put the unit out of operation 2) check the operating parameters and select a larger coupling (consider installation space) 3) assemble new coupling size 4) check alignment 1) put the unit out of operation 2) disassemble the coupling and remove rests of the sleeve 3) check coupling parts and exchange damaged coupling parts 4) insert sleeve, assemble coupling parts 5) instruct and train the service staff Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 KTR Kupplungstechnik GmbH D-48407 Rheine BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR-N sheet: edition: 40110 EN 18 8 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas 5.8 Breakdowns, Causes and Elimination breakdowns excessive wear at the sleeve toothing danger hints for hazardous areas causes drive vibrations danger of ignition due to hot surfaces ambient / contact temperatures which are too high for the sleeve, max. permissible e. g. T4 = -30 °C / +100 °C danger of ignition due to hot surfaces e. g. contact with aggressive liquids / oils, ozoneinfluence, too high ambient temperatures etc. effecting a physical change of the sleeve --- elimination 1) put the unit out of operation 2) disassemble the coupling and remove rests of the sleeve 3) check coupling parts and exchange damaged coupling parts 4) insert sleeve, assemble coupling parts 5) check alignment, correct if necessary 6) find out the reason for the vibrations 1) put the unit out of operation 2) disassemble the coupling and remove rests of the sleeve 3) check coupling parts and exchange damaged coupling parts 4) insert sleeve, assemble coupling parts 5) check alignment, correct if necessary 6) check and regulate ambient / contact temperature 1) put the unit out of operation 2) disassemble the coupling and remove rests of the sleeve 3) check coupling parts and exchange damaged coupling parts 4) insert sleeve, assemble coupling parts 5) check alignment, correct if necessary 6) make sure that further physical changes of the sleeve are excluded If you operate with a worn sleeve (see item 5.2) a due operation meeting the explosion protection requirements and acc. to Standard 94/9/EC is not ensured. ) ATTENTION! KTR does not assume any liabilities or guarantees regarding the use of spare parts and accessories which are not provided by KTR and for the damages resulting herefrom. Schutzvermerk ISO 16016 beachten. Gezeichnet: Geprüft: 27.06.08 Sha/Hk 30.06.08 Sha Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 KTR Kupplungstechnik GmbH D-48407 Rheine BoWex® Operating-/Assembly Instructions Design 001, 002, 003 and 006 KTR-N sheet: edition: 40110 EN 19 8 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas 5.9 EC Certificate of Conformity EC Certificate of Conformity corresponding to EG Standard 94/9/EG dated 23 March 1994 and to the legal regulations The manufacturer - KTR Kupplungstechnik GmbH, D-48432 Rheine - states that the BoWex® - curved-tooth gear couplings® described in these mounting instructions and explosion-proof designed correspond to Article 1 (3) b) of Standard 94/9/EG and comply with the general Safety and Health Requirements according to enclosure II of Standard 94/9/EG. According to article 8 (1) of Standard 94/9/EG the technical documentation is deposited with the: IBExU Institut für Sicherheitstechnik GmbH Fuchsmühlenweg 7 09599 Freiberg Rheine, Schutzvermerk ISO 16016 beachten. 27.06.08 Date Gezeichnet: Geprüft: i. V. Reinhard Wibbeling Engineering Manager 27.06.08 Sha/Hk 30.06.08 Sha i. V. Josef Schürhörster Product Manager Ersatz für: Ersetzt durch: KTR-N vom 17.01.03 ">
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