KTR ROTEX GS Operating / Mounting Instructions
KTR ROTEX GS is a plug-in shaft coupling designed for measuring technology and automatic control engineering. It compensates for shaft misalignment, making it ideal for applications where precise power transmission is required. The coupling operates with high damping features, ensuring smooth operation even with large masses. It is suitable for use in hazardous areas and is approved according to ATEX 95 standards.
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KTR Kupplungstechnik GmbH D-48407 Rheine KTR-N Sheet: Edition: ROTEX® GS Operating/mounting instructions 45510 EN 1of36 15 ROTEX® GS Torsionally flexible jaw couplings types: shaft coupling, clamping hubs, clamping ring hubs,clamping ring hubs light, DKM, Compactand their combinations according toStandard 94/9/EC (ATEX 95) for finish bored, pilot bored and unbored couplings ® ROTEX GS, DKM ® ® ROTEX GS, Compact ROTEX GS, shaft coupling ® ROTEX GS, clamping hubs ® ROTEX GS, clamping ring hubs ® ROTEX GS, clamping ring hubs steel ® ROTEX GS, clamping ring hubs light Expansion hubs and their combinations for finish bored, pilot bored and unbored couplings ® ROTEX GS, expansion hubs Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 2of36 15 ROTEX® GS is a plug-in shaft coupling for measuring technology and automatic control engineering. It is able to compensate for shaft misalignment produced by, as an example, inaccuracies in production, thermal expansion, etc. With the designing of our ROTEX® GS coupling, the engineering standards and regulations, in particular DIN EN 12100, part 2 as well as DIN EN ISO 13849, part 1 and 2 „Safety of machines” have been taken into account. 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 Hint to Danger Proper Use 3 Storage 4 Assembly 4.1 4.2 4.3 4.4 4.5 4.6 Hub Types Coupling Components Hints for Assembly Hint for Finish Bore Assembly of Hubs (Types 1.0, 1.1 and 1.2) Assembly of Clamping Hubs (Types 2.0, 2.1, 2.5, 2.6, 2.8, 2.9, 7.5, 7.6, 7.8 and 7.9) 4.7 Assembly of Clamping Ring Hubs (Types 6.0, 6.0 steel, 6.0 light and 6.5) 4.8 Assembly of Expansion Hubs (Type 9.0) 4.9 Displacements – Alignment of the Couplings 4.10 Spares Inventory, Customer Service Addresses 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas 5.1 Use in 5.2 5.3 Control Intervals for Couplings in Approximate Values of Wear 5.4 Permissible Coupling Materials in the 5.5 5.6 5.7 5.8 Marking of Coupling for Hazardous Area Starting Breakdowns, Causes and Elimination EC Certificate of Conformity according to the EC Standards 94/9/EC dated 23.03.1994 Please note protection mark ISO 16016. Hazardous Areas According to the Regulations Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Hazardous Areas Hazardous Area Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 3of36 15 1 Technical Data Standard shaft coupling Illustration 1: ROTEX® GS, size 5 - 38 Illustration 2: ROTEX® GS, size 42 - 90 Table 1: Dimensions Size Setscrew1) Dimensions [mm] D DH dH 5 7 9 12 14 19 24 28 38 - 10 14 20 25 30 40 55 65 80 7,2 8,5 10,5 18 27 30 38 42 48 55 65 75 90 85 95 110 115 135 160 95 105 120 135 160 200 46 51 60 68 80 104 L l1 ; l2 M/N E Hub material - Aluminium (Al-H) 15 5 5 22 7 8 30 10 10 34 11 12 35 11 13 66 25 16 78 30 18 90 35 20 114 45 24 Hub material - Steel (St-H) 126 50 28 26 140 56 32 28 160 65 37 30 185 75 47 35 210 85 53 40 245 100 62 45 b s a G t 4 6 8 10 10 12 14 15 18 0,5 1,0 1,0 1,0 1,5 2,0 2,0 2,5 3,0 4,0 6,0 1,5 3,5 2,0 3,0 3,0 4,0 4,0 M2 M3 M4 M4 M4 M5 M5 M8 M8 2,5 3,5 5,0 5,0 5,0 10 10 15 15 20 21 22 26 30 34 3,0 3,5 4,0 4,5 5,0 5,5 4,0 4,0 4,5 4,5 5,0 6,5 M8 M8 M10 M10 M10 M12 20 20 20 20 25 30 PRECAUTION! For the applications in hazardous areas the setscrews to fasten the hubs as well as all screw connections have to be secured against self-slackening additionally, e. g. by glueing with Loctite (medium-tight). 1) Table 2: Torques and finish bores Size 5 7 9 12 14 80 Sh-A-GS 0,3 0,7 1,8 3,0 4,0 Spider (part 2) 1) Rated torque [Nm] 92 Sh-A-GS 98 Sh-A-GS 64 Sh-D-GS 0,5 0,9 0,2 2) 1,2 2,0 2,4 3,0 5,0 6,0 5,0 9,0 12,0 7,5 12,5 16,0 Unbored 72 Sh-D-GS - - Finish bore[mm] –Hub type 1.0 1.1, 1.2 2.0, 2.1 dmin. dmax. dmax. dmax. 2 3 4 4 5 19 4,9 10,0 17,0 21 x 6 24 35 60 75 97 4) x 8 4) 28 95 160 200 260 x 10 38 190 325 405 525 4) x 12 42 265 450 560 728 4) x 14 48 310 525 655 852 4) x 15 55 410 685 825 7072 4) x 20 65 940 3) 1175 1527 4) x 22 75 1920 3) 2400 x 30 3) 90 3600 4500 40 1) Maximum torque of coupling TKmax. = Rated torque of coupling TK Nenn.x 2 with the exception of clamping hubs types 2.0 and 2.5 (see table 3) 2) Figures for spider 70 Sh-A-GS 3) Figures for spider 95 Sh-A-GS 4) When using the 72 Sh-D spider, we recommend to use hubs in steel. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: 7 10 12 16 1.0, 1.1 dmax. 24 28 38 45 55 62 74 80 95 110 6 7 11 12 16 2.5 dmax. 24 28 38 45 50 55 68 70 80 90 5 7 11 12 16 2.6 dmax. 24 28 38 45 45 55 68 70 80 90 KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 4of36 15 1 Technical Data Clamping hubs Illustration 3: ROTEX® GS, size 5 – 14(type 2.0) Illustration 4: ROTEX® GS, size 19 - 75(type 2.5) Table 3:Torques and surface pressure of clamping hubs types 2.0 / 2.5 Size Clamping screw M1 Dimension t1 Dimension e Dimension ØDK Tightening torque TA [Nm] 5 7 9 12 14 M1,2 M2 M2,5 M3 M3 M6 M6 2,5 3,5 11,4 3,5 5,0 16,5 5,0 7,5 23,4 5,0 9,0 27,5 5,0 11,5 32,2 11,0 14,5 46 10,5 20 57,5 - 0,37 0,76 1,34 1,34 Ø3 Ø4 Ø5 24 28 38 42 48 55 65 75 90 M8 M8 M10 M12 M12 M12 M16 M20 11,5 25 73 15,5 30 83,5 18 32 93,5 21 36 105 26 42,5 119,5 33 45 124 36 51 147,5 40 60 192 10,5 10,5 25 25 69 120 120 120 295 580 Transmittable torque of Clamping hub [Nm] Bore Ø Ø2 19 Surface pressure [N/mm2] - Ø6 Ø7 Ø8 Ø9 Ø10 Ø11 0,84 71,02 0,91 43,02 0,97 29,50 1,04 21,85 1,10 17,06 1,17 13,83 2,07 68,51 2,18 46,15 2,28 33,65 2,39 25,90 2,50 20,73 2,61 17,09 2,72 14,42 2,83 12,40 Ø12 3,65 109,9 3,81 73,5 3,98 53,3 4,14 40,8 4,31 32,5 4,48 26,6 4,64 22,4 4,81 19,2 4,97 16,7 4,48 134,9 4,64 89,5 4,81 64,4 4,97 48,9 5,14 38,7 5,30 31,6 5,47 26,4 5,64 22,5 5,80 19,4 23,6 139,3 24,3 105,2 25,0 82,8 25,7 67,2 26,3 55,9 27,0 47,4 27,7 40,8 32,4 131,0 33,1 105,7 33,8 87,3 34,4 73,6 35,1 63,1 74,3 171,3 75,5 143,9 76,7 122,9 89,1 105,9 PRECAUTION! For the applications in hazardous areas the setscrews to fasten the hubs as well as all screw connections have to be secured against self-slackening additionally, e. g. by glueing with Loctite (medium-tight). ATTENTION! Clamping hubs type 2.0 and 2.5 without keyway are not permissible for applications according to DIN EN ISO 13849, part 2. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 5of36 15 1 Technical Data Continuation of table 3: Torques and surface pressure of clamping hubs types 2.0 / 2.5 Size Clamping screw M1 Dimension t1 Dimension e Dimension ØDK Tightening torque TA [Nm] 5 7 9 12 14 19 24 28 38 42 48 55 65 75 90 M1,2 M2 M2,5 M3 M3 M6 M6 2,5 3,5 11,4 3,5 5,0 16,5 5,0 7,5 23,4 5,0 9,0 27,5 5,0 11,5 32,2 11,0 14,5 46 10,5 20 57,5 M8 M8 M10 M12 M12 M12 M16 M20 11,5 25 73 15,5 30 83,5 18 32 93,5 21 36 105 26 42,5 119,5 33 45 124 36 51 147,5 40 60 192 - 0,37 0,76 1,34 1,34 10,5 10,5 25 25 69 120 120 120 295 580 462 80 466 75 478 61 486 54 494 48 506 41 518 36 527 33 535 30 547 27 559 24 567 23 587 19 608 17 626 15 648 13 964 150 972 140 995 114 1010 101 1025 90 1048 77 1071 67 1086 61 1102 56 1125 50 1148 45 1163 42 1201 36 1239 31 1278 27 1316 24 1354 22 1392 20 Transmittable torque of Clamping hub [Nm] Bore Ø 6,13 15,1 6,30 13,5 6,46 12,2 Ø14 Ø15 Ø16 Ø19 Ø20 Ø22 Ø24 Ø25 Ø28 Ø30 Ø32 Ø35 Ø38 Ø40 Ø42 Ø45 Surface pressure [N/mm2] 36,5 79,2 91,6 48,1 93,2 80,0 37,1 80,4 92,8 42,7 82,5 70,6 37,8 81,7 94,1 38,2 73,6 62,9 39,8 85,4 97,8 28,5 54,6 46,3 40,5 86,6 99,0 26,2 50,0 42,4 41,9 89,1 101,5 22,4 42,5 35,9 31,59* 43,2 91,6 104,0 11,6* 19,4 36,7 30,9 43,9 92,8 105,2 18,2 34,3 28,8 96,5 108,9 45,9 15,2 28,4 23,8 99,0 111,4 25,4 21,2 101,5 113,9 22,9 19,0 105,2 117,6 19,8 16,4 108,9 121,3 17,4 14,4 123,8 13,2 126,2 12,2 129,9 11,0 29,0 31,4 29,7 28,0 30,4 25,2 32,4 19,0 33,1 17,5 30,4* 13,3* Ø48 Ø50 216 172 219 152 221 135 230 99 232 91 238 77 244 66 246 61 255 51 260 45 266 40 274 35 282 31 288 28 293 26 302 23 310 21 315 20 Ø55 Ø60 Ø65 Ø70 Ø75 Ø80 Ø85 Ø90 * only type 2.0 352 225 356 200 369 149 373 134 381 113 389 97 393 90 405 74 413 66 421 59 433 51 446 44 454 41 462 38 474 34 486 30 494 28 514 24 425 128 433 108 441 92 446 86 458 70 466 62 474 56 486 48 498 42 506 38 514 35 527 31 539 28 547 26 567 23 587 20 608 17 1776 167 1800 147 1824 131 1860 112 1896 97 1920 88 1944 81 1980 72 2016 64 2040 60 2100 51 2160 44 2220 39 2280 34 2340 31 2400 28 2460 25 2520 23 = 2 x Clamping screw M4; TA = 2,9 Nm PRECAUTION! For the applications in hazardous areas the setscrews to fasten the hubs as well as all screw connections have to be secured against self-slackening additionally, e. g. by glueing with Loctite (medium-tight). ATTENTION! Clamping hubs type 2.0 and 2.5 without keyway are not permissible for applications according to DIN EN ISO 13849, part 2. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 6of36 15 1 Technical Data Clamping ring hubs 6.0, 6.0 steel and 6.0 light Pull-off thread M1 between clamping screws. Illustration 5: ROTEX® GS clamping ring hubs Table 4:Dimensions 1) Size 14 19 24 28 38 42 48 19 24 28 38 42 48 55 65 75 90 Dimensions [mm] 2) 3) DH dH L l1; l2 l3 E b s a M1 Hub/Clamping ring material - Aluminium (Al-H) 30 10,5 50 18,5 13,5 13 10 1,5 2,0 M3 40 18 66 25 18 16 12 2,0 3,0 M4 55 27 78 30 22 18 14 2,0 3,0 M5 Figures see 65 30 90 35 27 20 15 2,5 4,0 M5 table 2 80 38 114 45 35 24 18 3,0 4,0 M6 95 46 126 50 35 26 20 3,0 4,0 M8 105 51 140 56 41 28 21 3,5 4,0 M10 6.0 steel (size 19 – 90) Hub and clamping ring material - Steel (St-H) 6.0 (size 14 – 38) Hub material – Aluminium (Al-H)/clamping ring material – steel (St-H) 40 18 66 25 18 16 12 2,0 3,0 M4 55 27 78 30 22 18 14 2,0 3,0 M5 65 30 90 35 27 20 15 2,5 4,0 M5 80 38 114 45 35 24 18 3,0 4,0 M6 95 46 126 50 35 26 20 3,0 4,0 M8 Figures see table 2 105 51 140 56 41 28 21 3,5 4,0 M10 120 60 160 65 45 30 22 4,0 4,5 M10 135 68 185 75 55 35 26 4,5 4,5 M12 160 80 210 85 63 40 30 5,0 5,0 M12 200 104 245 100 75 45 34 5,5 6,5 M16 Spider (part 2) Torques [Nm] 6.0 light (size 14 – 48) ® 1) For coupling selection please see ROTEX GS catalogue. Please note transmittable torques of clamping connections (see table 5 to7) 2) ØDH + 2 mm with high speeds for expansion of spider PRECAUTION! 3) For the applications in hazardous areas the setscrews to fasten the hubs as well as all screw connections have to be secured against self-slackening additionally, e. g. by glueing with Loctite (medium-tight). ATTENTION! Subject to the increased safety with the assembly (several screws are tightened) and the high friction torque of the clamping ring hub, this type is permissible for applications according to DIN EN ISO 13849, part 2. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 7of36 15 1 Technical Data Table 5: Torques and surface pressure of clamping ring hubs 6.0 light Size Clamping screw M 1) Number z (for each clamping ring hub) Tightening torque TA [Nm] 14 M3 19 M4 24 M5 28 M5 38 M6 42 M8 48 M10 4 6 4 8 8 4 4 1,34 3 25 49 Hub/Clamping ring material – Aluminium (Al-H) 6 6 10 Transmittable torque of clamping ring hub [Nm] Bore Ø d1 Surface pressure [N/mm2] 5,4 49,4 7,5 39,3 11,3 49,7 24,5 57,6 Ø6 Ø10 Ø11 Ø14 Ø15 Ø16 Ø19 Ø20 Ø22 Ø24 Ø25 Ø28 17 65,9 20 67,3 41 87,9 49 92,5 36 55,3 56 64 64 67 47 80,6 57 85,3 67 89,4 98 96,6 110 99 135 102,8 127 76,3 139 77,9 175 81,5 Ø30 Ø32 Ø35 Ø38 99 102 145 109 133 88 165 92,4 201 95,7 219 97 248 86,9 285 88,6 253 66,5 307 69,3 329 63,6 203 102,9 252 107 304 110 331 110,2 394 104,9 452 106,3 453 91 543 93,2 550 78,4 609 79,5 669 80,3 634 63,6 Ø40 Ø42 Ø45 Ø48 Ø50 Ø55 444 113,6 508 114,8 535 103,5 638 105,4 692 95 763 95,8 754 83,4 858 84,6 964 85,2 976 79 572 108 638 107,2 762 108,9 842 100 929 101,1 943 91 1074 91,9 1208 92,3 1136 77,3 1336 77,4 The transmittable torques of the clamping connection consider the max. clearance with bore H7/k6 shaft fit. The torque is reduced in case of bigger fit clearance. 1) PRECAUTION! For the applications in hazardous areas the setscrews to fasten the hubs as well as all screw connections have to be secured against self-slackening additionally, e. g. by glueing with Loctite (mediumtight). Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz ! Replaced for: Replaced by: CAUTION! An calculation is necessary if hollow shafts are used! KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine KTR-N Sheet: Edition: ROTEX® GS Operating/mounting instructions 45510 EN 8of36 15 1 Technical Data Table6: Torques and surface pressure of clamping ring hubs 6.0 steel Size Clamping screw M 1) Number z (for each clamping ring hub) Tightening torque TA [Nm] 19 M4 24 M5 28 M5 38 M6 42 M8 48 M10 55 M10 65 M12 75 M12 90 M16 6 4 8 8 4 4 4 4 5 5 4,1 8,5 8,5 120 120 295 27 160 32 160 69 211 84 225 57 134 94 157 110 166 25 119 30 119 70 170 87 184 56 104 97 127 114 135 86 84 116 96 133 101 192 116 Bore Ø d1 Hub and clamping ring material – Steel 14 35 69 69 Transmittable torque of clamping ring hub [Nm] Surface pressure [N/mm2] Ø10 Ø11 Ø14 Ø15 Ø16 Ø19 Ø20 Ø22 Ø24 Ø25 Ø28 Ø30 Ø32 Ø35 Ø38 Ø40 Ø42 Ø45 - 108 168 131 178 207 200 148 129 197 142 253 154 285 159 315 141 382 148 330 79 433 123 503 122 208 138 275 151 253 163 395 168 439 149 531 157 463 120 603 131 593 118 689 114 793 119 776 102 Ø48 Ø50 Ø55 358 152 398 135 483 143 416 108 547 119 536 99 625 104 571 86 704 92 851 98 865 92 489 179 658 192 616 157 704 158 899 168 896 142 1030 147 962 125 1160 131 1379 137 1222 112 1543 117 Ø60 Ø65 Ø70 863 138 856 116 991 121 918 102 1119 108 1110 94 1247 97 1277 83 1672 91 1605 74 2008 80 Ø80 1446 140 1355 119 1637 125 1635 110 1827 113 1887 97 2429 104 2368 87 2930 92 1710 134 2053 141 2059 124 2294 127 2384 109 3040 117 2983 98 3664 104 4148 92 Ø90 Ø95 3845 176 4249 161 4794 153 5858 159 5900 138 7036 126 8047 114 9247 118 The transmittable torques of the clamping connection take into account the max. fitting tolerance for shaft clearance k6/bore H7, from Ø 55 G7/m6. With a higher fitting tolerance the torque is reduced. 1) PRECAUTION! For the applications in hazardous areas the setscrews to fasten the hubs as well as all screw connections have to be secured against selfslackening additionally, e. g. by glueing with Loctite (medium-tight). Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz ! Replaced for: Replaced by: CAUTION! An calculation is necessary if hollow shafts are used! KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine KTR-N Sheet: Edition: ROTEX® GS Operating/mounting instructions 45510 EN 9of36 15 1 Technical Data Continuation of table 6: Torques and surface pressure of clamping ring hubs 6.0 steel Size Clamping screw M 1) Number z (for each clamping ring hub) Tightening torque TA [Nm] 19 M4 24 M5 28 M5 6 4 8 4,1 8,5 Bore Ø d1 8,5 38 M6 42 M8 48 M10 55 M10 65 M12 75 M12 90 M16 8 4 4 4 4 5 5 120 120 295 Hub and clamping ring material – Steel 14 35 69 69 Transmittable torque of clamping ring hub [Nm] Surface pressure [N/mm2] 9575 110 10845 113 Ø100 Ø105 Table 7: Torques and surface pressure of clamping ring hubs 6.0 Size Clamping screw M 1) Number z (for each clamping ring hub) Tightening torque TA [Nm] 14 M3 19 M4 24 M5 28 M5 38 M6 4 6 4 8 8 1,34 Bore Ø d1 Hub material – Aluminium (Al-H); Clamping ring material - steel 3 6 6 Transmittable torque of clamping ring hub [Nm] 10 Surface pressure [N/mm2] 8,6 225 13,8 130 14,7 118 22,7 108 Ø6 Ø10 Ø11 Ø14 Ø15 Ø16 Ø19 Ø20 41 272 45 248 62 211 68 203 67 171 83 153 90 149 Ø22 Ø24 Ø25 Ø28 48 214 67 182 74 175 72 148 90 132 97 129 99 107 112 102 120 100 143 96 142 243 154 231 189 203 188 178 212 167 237 157 250 153 280 136 307 131 310 115 353 110 389 103 Ø30 Ø32 Ø35 Ø38 269 196 307 183 337 172 356 167 398 148 436 142 442 126 501 120 533 107 572 104 615 102 644 92 Ø40 Ø42 Ø45 The transmittable torques of the clamping connection take into account the max. fitting tolerance for shaft clearance k6/bore H7, from Ø 55 G7/m6. With a higher fitting tolerance the torque is reduced. 1) PRECAUTION! For the applications in hazardous areas the setscrews to fasten the hubs as well as all screw connections have to be secured against selfslackening additionally, e. g. by glueing with Loctite (medium-tight). Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz ! Replaced for: Replaced by: CAUTION! An calculation is necessary if hollow shafts are used! KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 10of36 15 1 Technical Data DKM Illustration 6: ROTEX® GS, DKM Table 8: Dimensions ROTEX GS Size 5 7 9 12 14 19 24 28 38 42 48 55 ® Finish bore 1) dmax. Dimensions [mm] D DH dH dH1 Hub material - Aluminium (Al-H) 5 10 7 14 11 20 7,2 12 25 8,5 16 30 10,5 24 40 18 18 28 55 27 27 38 65 30 30 45 80 38 38 Hub material - Steel (St-H) 55 85 95 46 46 62 95 105 51 51 74 110 120 60 60 l1; l2 M; N l11 l12 LDKM E b Spacer material - Aluminium (Al-H) 5 3 13 23 5 4 7 4 20 34 8 6 10 5 25 45 10 8 11 6 30 52 12 10 11 8 34 56 13 10 25 10 42 92 16 12 30 16 52 112 18 14 35 18 58 128 20 15 45 20 68 158 24 18 Spacer material - Aluminium (Al-H) 50 28 22 74 174 26 20 56 32 24 80 192 28 21 65 37 28 88 218 30 22 s a 0,5 1,0 1,0 1,0 1,5 2,0 2,0 2,5 3,0 4,0 6,0 1,5 3,5 2,0 3,0 3,0 4,0 4,0 3,0 3,5 4,0 4,0 4,0 4,5 1) depend on hub type Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 11of36 15 1Technical Data Compact Illustration 7: ROTEX® GS 7 - 19 Compact single slotted1)(type 2.8/2.9) Illustration 8: ROTEX® GS 24 - 38 Compact axially slotted (type 2.8/2.9) Table 9: Dimensions Size 7 9 12 14 19 24 28 38 Spider (part 2) Torques [Nm] Figures see table 2 Dimensions [mm] dmax. DH DK L l1; l2 E b s t e M 7 9 12 1) 16 1) 24 32 35 45 14 20 25 30 40 55 65 80 16,6 21,3 26,2 30,5 45,0 57,5 69,0 86,0 18 24 26 32 50 54 62 76 5 7 7 9,5 17 18 21 26 8 10 12 13 16 18 20 24 6 8 10 10 12 14 15 18 1 1 1 1,5 2 2 2,5 3 2,5 3,5 3,5 4,5 9,0 11,0 12,0 16,0 5,0 6,7 8,3 9,6 14,0 20,0 23,8 30,5 M2 M2,5 M3 M4 M6 M6 M8 M10 1) Size 14 with screw M3 and dimension e=10,4; size 19 with screw M5 and dimension e=15,5 Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 12of36 15 1 Technical Data Table10: Torques and surface pressure of short clamping hubs type 2.8 / 2.9 Size Clamping screw M Dimension t Dimension e Dimension ØDK Tightening torque TA [Nm] 7 M2 2,5 5,0 16,6 0,37 9 M2,5 3,5 6,7 21,3 0,76 12 14 19 24 M3 M4 M6 M6 3,5 4,5 9,0 11,0 8,3 9,6 14,0 20,0 26,2 30,5 45,0 57,5 1,34 2,9 10 10 Transmittable torque of clamping hub [Nm] Bore Ø Ø3 Ø4 Ø5 Ø6 Ø7 38 M10 16,0 30,5 86,0 49 Surface pressure [N/mm2] 0,8 173,5 0,9 105,1 1,0 72,1 1,0 53,4 1,1 41,7 Ø8 Ø9 1,9 151,6 2,0 102,6 2,1 75,1 2,2 58 2,3 46,6 2,4 38,6 Ø10 Ø11 Ø12 3,4 273,6 3,6 183,6 3,7 133,4 3,9 102,3 4,1 81,7 4,2 67,2 4,4 56,5 4,6 48,5 4,7 42,2 Ø14 Ø15 Ø16 Ø18 Ø19 Ø20 Ø22 Ø24 7,1 262,2 7,4 189,6 7,7 144,8 8,0 115,1 8,2 94,3 8,5 79,1 8,8 67,6 9,1 58,7 5,8 27,2 5,9 24,4 6,1 22,1 24,3 191,8 25,0 155,7 25,7 129,5 26,3 109,9 27,0 94,7 28,4 73,1 29,0 65,2 29,7 58,6 31,1 48,4 31,7 44,4 32,4 40,9 25,4 26,5 26,4 23,1 Ø25 Ø28 Ø30 Ø32 Ø35 Ø38 Ø40 Ø42 Ø45 = 28 M8 12,0 23,8 69,0 25 21,2 82,3 23,3 74,8 25,4 68,6 29,7 58,8 31,8 54,9 33,9 51,4 38,2 45,7 40,3 43,3 42,4 41,1 46,7 37,4 50,9 34,3 53,0 32,9 59,4 29,4 63,6 27,4 67,9 25,7 54,4 92,0 58,3 85,9 62,2 80,5 70,0 71,5 73,9 67,8 77,8 64,4 85,5 58,5 93,3 53,7 97,2 51,5 108,9 46,0 116,6 42,9 124,4 40,2 136,1 36,8 92,6 109,6 98,8 102,7 111,1 91,3 117,3 86,5 123,5 82,2 135,8 74,7 148,2 68,5 154,3 65,8 172,9 58,7 185,2 54,8 197,5 51,4 216,1 47,0 234,6 43,3 246,9 41,1 259,3 39,1 277,8 36,5 ROTEX® GS 14: 1 x clamping screw M3, TA = 1,34 Nm, e = 10,4; ROTEX® GS 19: 1 x clamping screw M5, TA = 6 Nm, e = 15,5 Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine KTR-N Sheet: Edition: ROTEX® GS Operating/mounting instructions 45510 EN 13of36 15 1 Technical Data Expansion hubs Illustration 9: ROTEX® GS, expansion hubs (type 9.0) with clamping hub 1) Table 11: Dimensions Size 9 12 14 19 24 28 Spider (part 2) Torques [Nm] Clamping screw Dimensions [mm] Figures see table 2 D1 D2 DH l1 l4 l5 l6 E b s M TA 10 10 12 20 25 35 20 24 35 45 55 20 25 30 40 55 65 20 19 18,5 28 38 44 11 14 12,5 20 30 36 1,5 3 1 1 1 0 2 2 0 4 5 10 12 13 16 18 20 8 10 10 12 14 15 1,0 1,0 1,5 2,0 2,0 2,5 M4 M4 M4 M6 M8 M10 2,9 2,9 2,9 10 25 49 1) The expansion hub can be combined with other hub types being the opposite side, too. l2 depends on the hub design. For further hub designs see chapter 4.1. 2) For coupling selection – see ROTEX® GS catalogue ATTENTION! Transmittable friction torques for D1 on request (depending on the hollow shaft). ATTENTION! Expansion hubs without keyway are not permissible for applications according to DIN EN ISO 13849, part 2. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 14of36 15 2 Hints ® The ROTEX GS coupling was developed for a backlashfree power transmission and easy plug-in assembly. This backlash-free power transmission is realized in the range of prestress (see illustration10). The big concave surface contact results in a lower surface pressure on the involute tooth. Consequently the tooth can be overloaded many times over with no wear/deformation. The safe operation in the range of prestress is ensured, because the coupling operates according to the principle of the positive-locking rubber spring prestress with high damping features. The star-shape coupling spider is inserted into the cams of the hubs which are machined Illustration 10: prestress of spider specifically accurately with a small amount of prestress, resulting in the necessary backlash-free power transmission. The flexible teeth compensating for misalignments are radially supported in the internal diameter by means of a web. An external deformation is limited by the concave shape of the cams, ensuring a smooth operation even with bigger masses (e. g. steel mills, articulated arms, etc.). The flexible spiders for the GS series are available in five different kinds of Shore hardness, injected in different colours, either as a torsionally soft or hard material. 2.1 Coupling Selection ! CAUTION! For a long-term smooth operation of the coupling the coupling has to be selected based on the selection standards applying for the application (in accordance with DIN 740, part 2) ® (see ROTEX GS catalogue). In case that the operating conditions change (power, speed, modifications on engine and machine) it is absolutely necessary to verify the coupling selection. Please note that the technical details concerning the torque refer to the spider only. The transmittable torque of the shaft-hub-connection has to be reviewed by the customer and is subject to his responsibility. For drives subject to dangerous torsional vibrations (drives with periodical torsional vibration load) it is necessary to perform a torsional vibration calculation to ensure a safe operation. Typical examples of drives subject to dangerous torsional vibrations are drives with diesel engines, piston pumps, piston compressors, etc. If requested, KTR will perform the coupling selection and torsional vibration calculation. 2.2 General Hints Please read through these mounting instructions carefully before you set the coupling into operation. Please pay special attention to the safety instructions. ® The ROTEX GS coupling is suitable and approved for the application in hazardous areas. For the use of couplings in hazardous areas please note the special safety hints and regulations as per appendix A. ® In order to ensure the operating principle of ROTEX GS and avoid an early wear of the coupling, a corresponding torsional stiffness factor „Sd“ has to be considered for the selection, each depending on the application (see catalogue). Temperatures and shocks are provided with the corresponding factors, too (see catalogue). The mounting instructions are part of your product. Please keep them carefully and close to the coupling. The copyright for these mounting instructions remains with KTRKupplungstechnik GmbH. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 15of36 15 2 Hints 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! Pointing to explosion-proof applications 2.4 General Hint to Danger STOP DANGER! With the assembly, operation and maintenance of the coupling it has to be made sure that the entire drive train is protected against unintentional engagement. You may be seriously hurt by rotating parts. Please make absolutely sure to read through and observe the following safety instructions. • All operations on and with the coupling have to be performed taking into account „safety first“. • Please make sure to disengage the power pack before you perform your work on the coupling. • Protect the power pack against unintentional engagement, e. g. by providing hints at the place of engagement or removing the fuse for current supply. • Do not touch the operation area of the coupling as long as it is in operation. • Please protect the coupling against unintentional touch. Please provide for the necessary protection devices and caps. 2.5 Proper Use You may only assemble, operate and maintain the coupling if you • have carefully read through the mounting instructions and understood them • had technical training • are authorized to do so by your company The coupling may only be used in accordance with the technical details (see tables 1 to 11, chapter 1). Unauthorized modifications on the coupling type are not admissible. We do not take any warranty for resulting ® damages. To further develop the product we reserve the right for technical modifications. The ROTEX GS described in here corresponds to the technical status at the time of printing of these mounting instructions. 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 spiders (elastomers) 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 less than 65%. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 16of36 15 4 Assembly Generally the coupling is delivered in parts. Before the assembly, the coupling has to be inspected regarding its completeness. 4.1 Hub Types Type 1.0 with keyway and thread 1.1 without keyway with thread 1.2 without keyway without thread Hint: No ATEX release. Type up to size 14 standard/ Compact up to size 19 2.0 single slotted without keyway 2.1 single slotted with keyway Type from size 19 standard 2.5 double slotted without keyway 2.6 double slotted with keyway Type 4.2 1) with CLAMPEX® KTR 250 Type 6.0/6.0 steel/ 6.0 light Clamping ring hub Type 7.5 (without keyway) and 7.6 (with keyway) Split clamping hub for DKM/ZR3 Type 2.8 axially slotted without keyway (size 7 to size 19 single slotted) 2.9 axially slotted with keyway (size 7 to size 19 single slotted) Type 7.8 (without keyway) and 7.9 (with keyway) Hint: Subject to the position of the clamping screws the application is recommended for single-cardanic couplings only. Type 9.0 Expansion hub Hint: No ATEX release. Illustration 11: Hub types 1) ATTENTION! Selection of clamping sets With the use in explosion-proof areas the clamping hubs have to be selected in a way that the difference between the peak torque of the machine including all operation parameters and the rated torque of the clamping hub is at least a service factor of s = 2. PRECAUTION! Hub types 1.1, 2.0, 2.5, 2.8, 7.5 and 7.8 (without feather key) may only be used in category 3and are not permissible for applications according to DIN EN ISO 13849, part 2. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 17of36 15 4 Assembly 4.2 Coupling Components Features of the standard spiders Spider hardness (Shore) Size Material 80 Sh-A-GS 92 Sh-A-GS 95/98 Sh-A-GS 64 Sh-D-H-GS 64 Sh-D-GS 72 Sh-D-H-GS 72 Sh-D-GS 42 - 90 Polyurethane 24 - 38 42 - 65 Polyurethane 5 - 24 5 - 55 5 - 90 7 - 38 Polyurethane Polyurethane Polyurethane Hytrel Hytrel Marking (colour) Components of ROTEX® GS, backlash-free shaft couplings Component 1 2 3 Quantity 2 1 2 Description hub spider setscrewDIN EN ISO 4029 Illustration 12: ROTEX® GS, size 5 - 38 Illustration 13: ROTEX® GS, size 42 - 90 Components of ROTEX® GS, clamping hubs Component 1 2 3 Quantity 2 1 2 Description clamping hub (hub type 2.0, 2.1, 2.5 or 2.6) spider cap screwsDIN EN ISO 4762 Illustration 14: ROTEX® GS, clamping hub ATTENTION! Clamping hubs type 2.0 and 2.5 without keyway are not permissible for applications according to DIN EN ISO 13849, part 2. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 18of36 15 4 Assembly 4.2 Coupling Components Components of ROTEX® GS, clamping ring hubs (types 6.0, 6.0 steel, 6.0 light and type 6.5) Component 1 2 3 4 Quantity 2 2 1 see table 5,6 and 7 Description clamping ring clamping ring hub spider cap screwsDIN EN ISO 4762 Illustration 15: ROTEX® GS, clamping ring hub ATTENTION! Selection of clamping hubs With the use in explosion-proof areas the clamping hubs have to be selected in a way that the difference between the peak torque of the machine including all operation parameters and the frictionally engaged torque of the clamping hub is at least a service factor of s = 2. ATTENTION! Subject to the increased safety with the assembly (several screws are tightened) and the high friction torque of the clamping ring hub, this design is permissible for applications according to DIN EN ISO 13849, part 2. Components of ROTEX® GS, DKM Component 1 2 3 4 Quantity 2 2 1 2 Description hub spider DKM spacer setscrewDIN EN ISO 4029 Illustration 16: ROTEX® GS, DKM Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 19of36 15 4 Assembly 4.2 Coupling Components Components of ROTEX® GS Compact, clamping hubs Component 1 2 3 Quantity 2 1 2/4 Description clamping hub (hub types 2.8 or 2.9) spider cap screwsDIN EN ISO 4762 Illustration 17: ROTEX® GS Compact, size 7 - 19 Illustration 18: ROTEX® GS Compact, size 24 - 38 PRECAUTION! Hub types 1.1, 2.0, 2.5, 2.8, 7.5 and 7.8 (without feather key) may only be used in category 3 and are not permissible for applications according to DIN EN ISO 13849, part 2. ATTENTION! Selection of clamping hubs With the use in explosion-proof areas the clamping hubs have to be selected in a way that the difference between the peak torque of the machine including all operation parameters and the frictionally engaged torque of the clamping ring hub is at least a service factor of s = 2. Components of ROTEX® GS, Expansion hubs Component 1 2 3 4 5 6 1) Quantity 1) 1 1 1 1) 1 Description hub spider expansion hub clamping pin for expansion hub cap screws DIN EN ISO 4762 cap screws DIN EN ISO 4762 The expansion hub can be combined with other hub designs being the opposite side, too, please note your dimension sheet. Illustration 19: ROTEX® GS, expansion hubs Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 20of36 15 4 Assembly 4.3 Hints for Assembly ® Subject to its typeROTEX GS allows to axially plug in the coupling having assembled the hubs onto the shaft journal. Consequently there is no need for subsequent screwing and the corresponding mounting holes in the housing. The pegs on the spider arranged reciprocally avoid a contact between the spider and the hubs over the full surface. Observing the distance dimension E, the ability for displacement of the coupling is ensured in this way.All teeth are chamfered on the face which allows a blind assembly. When the coupling hubs are combined with the ® ROTEX GS spider an axial mounting force is produced resulting from the flexible prestress of the star-shape elastomer. This mounting force varies depending on the coupling size, the spider hardness and the machining tolerances. The axial mounting force is compensated for after assembly of the hubs and consequently does not mean any danger of axial load onto adjacent bearings. The mounting force can be reduced by slightly greasing or oiling the elastomer or the hubs. For this purpose please only use oils and greases on a mineral oil basis without any additives. Lubricants on a silicone basis (e. g. OptimolOptisit WX) or vaseline have proven their worth, too. 4.4 Hint for Finish Bore STOP DANGER! The maximum permissible bore diameters d (see tables 1 to 11 in chapter 1 – Technical Data) must not be exceeded. If these figures are not observed, the coupling may tear. Rotating fragments may be hazardous. • If the hub bore is machined by the customer, the accuracy in concentric running or run-out, respectively (see illustration20) has to be observed. • Please make absolutely sure to observe the figures for Ødmax.. • Align the hubs carefully when machining the finish bore. • Please use a setscrew according to DIN EN ISO 4029 with cup point or an end plate to secure the hubs axially. ! Illustration 20: accuracy in concentric running or run-out CAUTION! The buyer 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! KTR supplies unbored or pilot bored coupling parts and spare parts on explicit customer´s request. These parts are additionally labelled with the symbol . Table 12: SetscrewsDIN EN ISO 4029 Size Dimension G Dimension t Tightening torque TA [Nm] 5 M2 2,5 7 M3 3,5 9 M4 5 12 M4 5 14 M4 5 19 M5 10 24 M5 10 28 M8 15 38 M8 15 42 M8 20 48 M8 20 - - 1,5 1,5 1,5 2 2 10 10 10 10 Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: 55 65 75 M10 M10 M10 20 20 25 17 17 17 90 M12 30 40 KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 21of36 15 4 Assembly 4.5 Assembly of Hubs (Types 1.0, 1.1 and 1.2) ATTENTION! We recommend to check bores, shaft, keyway and feather key for dimensional accuracy before assembly. Before mounting preservatives have to be removed from the bores. Moreover, the shaft ends have to be cleaned carefully, too. ! CAUTION! Please note the manufacturer’s instructions regarding the use of detergents. If the hubs are sligthly heated (approx. 80 °C) they can be assembled onto the shaft more easily. PRECAUTION! Please note the danger of ignition in hazardous areas. STOP ! DANGER! Touching the heated hubs causes burns. For that reason we recommend to wear safety gloves. CAUTION! Please observe the dimension E (see tables 1 to 11) for the assembly to make sure that the spider can be moved axially during the operation. The coupling may be damaged if this recommendation is not followed. • Please assemble the hubs onto the shaft of driving and driven side. • Please shift the power pack into axial direction until the dimension E is reached. • If the power packs have already been mounted firmly, the dimension E has to be adjusted by shifting the hubs on the shafts axially. • Secure the hubs by tightening the setscrews DIN EN ISO 4029 at the tightening torques TA mentioned in table 12. ATTENTION! If the shaft diameters with inserted feather key fall below the dimension dH of the spider (see tables 1 to 10), one or both shaft ends may protude into the spider. ! CAUTION! Hub type 1.1 (without feather key) may be used in category 3 only. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 22of36 15 4 Assembly 4.6 Assembly of Clamping Hubs (Types 2.0, 2.1, 2.5, 2.6, 2.8,2.9, 7.5, 7.6, 7.8 and 7.9) ® The power transmission of ROTEX GS clamping hubs (types 2.0, 2.5, 2.8, 7.5 and 7.8) is done frictionally engaged. With types 2.1, 2.6, 2.9, 7.6 and 7.9 a feather key additionally provides for positive locking power transmission. The following process should be noted for the assembly: • Clean and degrease the hub bore and the shaft. • Slightly detach the clamping screw. • Slip the hub onto the shaft. Please observe the dimension l1/l2. • Tighten the clamping screws at the tightening torques mentioned in table 3. For types 2.8, 7.5, 7.8 or 2.9, 7.6, 7.9 (with keyway) the screws have to be tightened alternately at the tightening torques mentioned in table 3. PRECAUTION! For the applications in hazardous areas the setscrews to fasten the hubs as well as all screw connections have to be secured against self-slackening additionally, e. g. by glueing with Loctite (medium-tight). Illustration 21: Assembly clamping hub Please note: types 2.8, 2.9, 7.5, 7.6, 7,8 or 7.9 have 2 clamping screws ! CAUTION! The frictionally engaged transmittable torques of the clamping hubs depend on the bore diameter. PRECAUTION! Hub types 2.0, 2.5, 2.8, 7.5 and 7.8 (without feather key) may only be used in category 3 and are not permissible for applications according to DIN EN ISO 13849, part 2. ! CAUTION! If the clamping screws are not tightened at the correct tightening torque, there is the danger of a) a fracture of the hub and plastic deformation with a too high tightening torque TA b) type 6.0: a fracture of the hubs/cams and plastic deformation with a too high tightening torque TA c) an early slippling, untightening of the screws with a too small tightening torque TA 4.7 Assembly of Clamping Ring Hubs (Types 6.0, 6.0 steel, 6.0 light and 6.5) ® The power transmission of ROTEX GS clamping ring hubs is frictionally engaged. The necessary surface pressure is transmitted via the clamping ring with internal taper to the taper hub and consequently to the shaft. The torques mentioned in tables 5 to 7 take into account a combination of fit H7/k6 from Ø55 G7/m6. With a higher backlash of fit the torques mentioned in tables 5 to 7 are reduced. The stiffness and dimensions of the shafts (here specifically hollow shafts) have to be selected in a way that sufficient safety against plastic deformation is ensured. This may roughly be reviewed as per the following criterion. PRECAUTION! For the use in hazardous areas the setscrews/capscrews and setscrews to fasten the hubs additionally have to be secured against slackening, e. g. by conglutinating with Loctite (average joint strength). Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine KTR-N Sheet: Edition: ROTEX® GS Operating/mounting instructions 45510 EN 23of36 15 4 Assembly 4.7 Assembly of Clamping Ring Hubs (Types 6.0, 6.0 steel, 6.0 light and 6.5) Rp0,2 − 2 ⋅ pW For clamping connections with hollow shafts the required internal diameter of the hollow shaft diW is calculated based on the following formula: diW ≤ d ⋅ Shearing stress on the internal shaft diameter for hollow shaft: σtiW ≈ − Shearing stress for solid shaft: σ tW = − p W N / mm2 Rp0,2 pW = = 2 ⋅ pW 1 − CW 2 [ 2 proof stress of shaft material [Nmm ] 2 surface pressure hub/shaft [N/mm ] diW d CW = = = [mm] Rp0,2 [N / mm ] 2 ] internal diameter of hollow shaft [mm] shaft diameter [mm] diW / d The required strength does not exist if the hollow shaft bore is bigger than the max. internal bore calculated or if the shearing stress exceeds the yield strength of the material. For a detailed calculation please contact the KTR engineering department. • Clean the hub bore and shaft and review for dimensional accuracy, afterwards lubricate with a thin-bodied oil (e. g. Castrol 4 in 1 or KlüberQuietsch-Ex). ! CAUTION! Oils and greases containing molybdenum disulfide or other high-pressure additives as well as internal lubricants must not be used. • Slightly detach the clamping screw and pull the clamping ring from the hub only marginally to make sure that the clamping ring is loosened. • Slip the clamping ring hub onto the shaft. The dimension L3 should be adhered to at least. • Tighten the clamping screws evenly stepwise and crosswise to the tightening torque mentioned in table 6 or 7. This process has to be repeated until the tightening torque is reached for all clamping screws. ! Illustration 22: Assembly of clamping ring hub with clamping ring CAUTION! If the clamping screws are not tightened at the correct tightening torque, there is the danger of a) a fracture of the hub and plastic deformation with a too high tightening torque TA b) an early slipping, untightening of the screws with a too small tightening torque TA • Assembly of the clamping ring hub 6.0 light: Tighten the clamping screws evenly stepwise and crosswise at 1/3 or 2/3 tightening torque TA , respectively (see table 5) until the ring gets in contact. Afterwards tighten the screws at the tightening torque mentioned in table 5 one after another. PRECAUTION! For the applications in hazardous areas the setscrews to fasten the hubs as well as all screw connections have to be secured against self-slackening additionally, e. g. by glueing with Loctite (medium-tight). ATTENTION! Selection of clamping hubs With the use in explosion-proof areas the clamping hubs have to be selected in a way that the difference between the peak torque of the machine including all operation parameters and the frictionally engaged torque of the clamping hub is at least a service factor of s = 2. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 24of36 15 4 Assembly 4.7 Assembly of Clamping Ring Hubs (Types 6.0, 6.0 steel, 6.0 light and 6.5) Disassembly: Untighten the clamping screws evenly one after the other. Each screw may only be untightened by half a revolution for each cycle. Unscrew all clamping screws by 3 – 4 convolutions. Remove the screws situated next to the pull-off threads and screw them into the respective pull-off threads. The clamping ring is untightened if the screws in the pull-off threads are tightened evenly stepwise and crosswise. ! CAUTION! If these hints are not observed, the operation of the coupling may be damaged. Illustration 23: Disassembly of clamping ring hub with clamping ring In case of a repeated assembly the hub bore and shaft have to be cleaned and afterwards lubricated with a thinbodied oil (e. g. Castrol 4 in 1 or KlüberQuitsch EX). The same applies for the taper surfaces of clamping ring hub and clamping ring. ! CAUTION! Oils and greases containing molybdenum disulfide or other high-pressure additives as well as internal lubricants must not be used. For type 6.0 light only: ATTENTION! In case of re-assembly the taper surfaces, hub bores and the shaft have to be cleaned. The hub bore and shaft have to be lubricated with thin-bodied oil (e. g. Castrol 4 in 1 or KlüberQuietsch-Ex). Lightly paint the taper surfaces of the clamping ring hub or clamping ring with the grease Gleitmo 800, afterwards turn the parts by one revolution in order to spread the grease evenly. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 25of36 15 4 Assembly 4.8 Assembly of Expansion Hubs (Type 9.0) The following process should be noted for the assembly: • Untighten clamping screw and clamping pin. • Clean and degrease the internal diameter of the hollow shaft and the outside contact surface of the expansion hub (see illustration 24). • Insert the expansion hub along with clamping pin and clamping screw in the hollow shaft. Tighten the clamping screw at the tightening torque mentioned in table 11. ATTENTION! The tightening torques apply for the figures mentioned in table 11 only. ! ! Illustration 24: Cleaning the expansion hub and hollow shaft CAUTION! The frictionally engaged transmittable torques of the clamping hubs depend on the bore diameter. CAUTION! If the clamping screws are not tightened at the correct tightening torque, there is the danger of a) a fracture of the hub and plastic deformation with a too high tightening torque TA b) an early slipping, untightening of the screws with a too small tightening torque TA Disassembly: Unscrew the clamping screw only slightly so that the clamping pin gets loosened. If the clamping pin did not loosen, apply a light beat on the screw head. Afterwards remove the clamping screw fully. 4.9Displacements – Alignment of the Couplings The displacement figures mentioned in table 13 and 14 provide for safety in order to compensate for external influences like, for example, thermal expansion or sinking of basement. ! CAUTION! In order to ensure a long lifetime of the coupling and avoid danger with the use in hazardous areas, the shaft ends have to be aligned accurately. Please make absolutely sure to observe the displacement figures indicated (see table 13 and 14). If these figures are exceeded, the coupling will be damaged. The more precisely the coupling is aligned, the higher is its service life. For the use in hazardous areas for explosion class IIC (designation II 2GD c IIC T X) only the displacement figures (see table 13 and 14) have to be carefully reviewed and adhered to. Please note: • The displacement figures mentioned in table 13 and 14 are maximum figures which must not arise in parallel. If radial and angular displacements arise at the same time, the permissible displacement figures may only be used proportionally. • Please review by means of a metering clockwork, ruler or feeler gauge if the permissible displacement figures mentioned in table 13 and 14 are observed. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 26of36 15 4 Assembly 4.9 Displacements – Alignment of the Couplings Angular displacements Radial displacements Axial displacements ∆Kw [mm] = L1max - L1min Lmax = L + ∆Ka Illustration 25: displacements Illustration 26: combination of displacements Examples of the combinations of displacements shown in picture 26: Example 1: ∆Kr = 30% ∆Kw = 70% Example 2: ∆Kr = 60% ∆Kw = 40% ∆Ktotal = ∆Kr + ∆Kw≤ 100 % Table13: Displacements Size max. axial displacement ∆Ka [mm] 5 7 9 12 14 19 24 28 38 42 48 55 65 75 90 +0,4 / -0,2 +0,6 / -0,3 +0,8 / -0,4 +0,9 / -0,4 +1,0 / -0,5 +1,2 / -0,5 +1,4 / -0,5 +1,5 / -0,7 +1,8 / -0,7 +2,0 / -1,0 +2,1 / -1,0 +2,2 / -1,0 +2,6 / -1,0 +3,0 / -1,5 +3,4 / -1,5 Please note protection mark ISO 16016. max. radial displacement max. angular displacement ∆Kr [mm] ∆Kw [degrees] 80 92 95/98 64 72 80 92 95/98 64 72 ShA-GS ShA-GS ShA-GS ShD-GS ShD-GS ShA-GS ShA-GS ShA-GS ShD-GS ShD-GS 0,12 0,06 0,04 1,1 1,0 0,9 0,15 0,10 0,06 0,04 1,1 1,0 0,9 0,8 0,19 0,13 0,08 0,05 1,1 1,0 0,9 0,8 0,20 0,14 0,08 0,05 1,1 1,0 0,9 0,8 0,21 0,15 0,09 0,06 1,1 1,0 0,9 0,8 0,15 0,10 0,06 0,04 1,1 1,0 0,9 0,8 0,14 0,10 0,07 0,04 1,0 0,9 0,8 0,7 0,15 0,11 0,08 0,05 1,0 0,9 0,8 0,7 0,17 0,12 0,09 0,06 1,0 0,9 0,8 0,7 0,19 0,14 0,10 0,07 1,0 0,9 0,8 0,7 0,23 0,16 0,11 0,08 1,0 0,9 0,8 0,7 0,24 0,17 0,12 0,09 1,0 0,9 0,8 0,7 0,18 0,13 0,10 0,9 0,8 0,7 0,21 0,15 0,9 0,8 0,23 0,17 0,9 0,8 - Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 27of36 15 4 Assembly 4.9 Displacements – Alignment of the Couplings Table14: Displacements – Type DKM Size max. axial displacement ∆Ka [mm] 5 7 9 12 14 19 24 28 38 42 48 55 +0,4 / -0,4 +0,6 / -0,6 +0,8 / -0,8 +0,9 / -0,9 +1,0 / -1,0 +1,2 / -1,0 +1,4 / -1,0 +1,5 / -1,4 +1,8 / -1,4 +2,0 / -2,0 +2,1 / -2,0 +2,2 / -2,0 max. radial displacement max. angular displacement ∆Kr [mm] ∆Kw [degrees] 80 92 95/98 64 72 80 92 95/98 64 72 ShA-GS ShA-GS ShA-GS ShD-GS ShD-GS ShA-GS ShA-GS ShA-GS ShD-GS ShD-GS 0,15 0,14 0,13 1,1 1,0 0,9 0,23 0,21 0,19 0,17 1,1 1,0 0,9 0,8 0,29 0,26 0,24 0,21 1,1 1,0 0,9 0,8 0,35 0,32 0,29 0,25 1,1 1,0 0,9 0,8 0,40 0,37 0,33 0,29 1,1 1,0 0,9 0,8 0,49 0,45 0,41 0,36 1,1 1,0 0,9 0,8 0,59 0,53 0,47 0,42 1,0 0,9 0,8 0,7 0,66 0,60 0,53 0,46 1,0 0,9 0,8 0,7 0,77 0,69 0,61 0,54 1,0 0,9 0,8 0,7 0,84 0,75 0,67 0,59 1,0 0,9 0,8 0,7 0,91 0,82 0,73 0,64 1,0 0,9 0,8 0,7 1,01 0,91 0,81 0,71 1,0 0,9 0,8 0,7 ® The permissible displacement figures of the flexible ROTEX GS couplings mentioned are general standard values taking into account the load of the coupling until the rated torque TKN of the coupling and an ambient temperature of +30 °C. 4.10 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. 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. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 28of36 15 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas Available types: ® a) Hubs with feather key or CLAMPEX clamping set or clamping ring hubs • 1.0 Hub with feather key and thread for setscrews • 2.1 Clamping hub single slot with feather key • 2.6 Clamping hub double slot with feather key • 2.9 Clamping hub with axial slot with feather key ® • 4.1 with CLAMPEX clamping set KTR 200 ® • 4.2 with CLAMPEX clamping set KTR 250 • 6.0 Clamping ring hub • 6.0 Clamping ring hub light • 6.0 P Precision clamping ring hub • 6.5 Clamping ring hub (Hint: external clamping screws) • 7.6 Split clamping hub with feather key for double-cardanic combinations • 7.9 Split clamping hub with feather key for single-cardanic combinations • Type DKM with hubs corresponding to the aforementioned details b) Hubs without feather key (category 3 only) • 1.1 Hub without feather key, with thread for setscrews • 2.0 Clamping hub single slot without feather key • 2.5 Clamping hub double slot without feather key • 2.8 Clamping hub with axial slot without feather key • 7.5 Split clamping hub without feather key for double-cardanic combinations • 7.8 Split clamping hub without feather key for single-cardanic combinations • Type DKM with hubs corresponding to the aforementioned details ® ROTEX GS type DKM only with spacer from steel or aluminium wrought products with a yield stress 2 Rp0,2≥ 250 N/mm . Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine KTR-N Sheet: Edition: ROTEX® GS Operating/mounting instructions 45510 EN 29of36 15 5 Enclosure A Hints and Instructions Regarding the Use in 5.1 Use in Hazardous Areas Hazardous Areas According to the Regulations Conditions of operation in hazardous locations ® ROTEX GS couplings are suitable for the use according to EC standard 94/9/EC. 1. Industry (with the exception of mining) • • • • device class II of category 2 and 3 (coupling is not approved for device class 1) media class G (gases, fogs, steams), zone 1 and 2 (coupling is not approved for zone 0) media class D (dusts), zone 21 and 22 (coupling is not approved for zone 20) explosion class IIC (explosion class IIA and IIB are included in IIC) Temperature class: Ambient or operating temperature Ta 1) - 30 °C to + 90 °C - 30 °C to + 80 °C - 30 °C to + 65 °C Temperature class T4, T3, T2, T1 T5 T6 Max. surface temperature 110 °C 100 °C 85 °C 2) Explanation: The maximum surface temperatures result from each the maximum permissible ambient or operating temperature Ta plus the maximum temperature increase ∆T of 20 K which has to be taken into account. 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, too. Operating temperature of the spider: Spider hardness (Shore) 80 Sh A-GS 92 Sh A-GS 95/98 Sh A-GS 64 Sh D-H-GS 64 Sh D-GS 72 Sh D-H-GS 72 Sh D-GS ! Permissible temperature range [°C] Permanent temperature Max. temperature short-term -50 to +80 -60 to +120 -40 to +90 -50 to +120 -30 to +90 -40 to +120 -50 to +120 -60 to +150 -20 to +110 -30 to +120 -50 to +120 -60 to +150 -20 to +110 -30 to +120 CAUTION! In case that the operating temperature changes it is absolutely necessary to verify the ® coupling selection (see ROTEX GS catalogue). 2. Mining Device class I of category M2 (coupling is not approved for device category M1). Permissible ambient temperature - 30 °C to + 90 °C. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 30of36 15 5 Enclosure A Hints and Instructions Regarding the Use in 5.2 Control Intervals for Couplings in explosion group 3G 3D II 2GD c IIB T4, T5, T6 II 2GD c IIC T4, T5, T6 Hazardous Areas 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 ROTEX GS: ∆T = 20 K A checking of the circumferential backlash and a visual check of the flexible spider must be effected after 3,000 operating hours for the first time, after 6 months at the latest. If you note an unconsiderable or no wear at the spider after this first inspection, the further inspections can be effected, in case of the same operating parameters, respectively after 6,000 operating hours or after 18 months at the latest. If you note a considerable wear during the first inspection, so that a change of the spider would be recommended, please find out the cause according to the table „Breakdowns“, as far as possible. The maintenance intervals must be adjusted according to the changed operating parameters. A checking of the circumferential backlash and a visual check of the flexible spider must be effected after 2,000 operating hours for the first time, after 3 months at the latest. If you note an unconsiderable or no wear at the spider after this first inspection, the further inspections can be effected, in case of the same operating parameters, respectively after 4,000 operating hours or after 12 months at the latest. If you note a considerable wear during the first inspection, so that a change of the spider would be recommended, please find out the cause according to the table „Breakdowns“, as far as possible. The maintenance intervals must be adjusted according to the changed operating parameters. PRECAUTION! Hub types 1.1, 2.0, 2.5, 2.8, 7.5 and 7.8 (without feather key) may only be used in category 3. ® ROTEX GS backlash-free shaft coupling Illustration 27: ROTEX® GS backlash-free shaft coupling Illustration 28: ROTEX® GS spider If the drive allows, the backlash between the cams of the coupling and the flexible spider has to be measured by means of a feeler gauge. Regardless of the inspection intervals, the spider has to be replaced immediately if the wear limit maximum wear has been achieved. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 31of36 15 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas 5.3 Approximate Values of Wear In case of a backlash of more than x mm, the flexible spider must be exchanged. Whether the limit for replacement has been achieved or not depends on the conditions of operation and the existing operating parameters. CAUTION! In order to ensure a long lifetime of the coupling and avoid danger with the use in hazardous areas, the shaft ends have to be aligned accurately. Please make absolutely sure to adhere to the displacement figures mentioned (see table 13 and 14). If these figures are exceeded, the coupling will be damaged. ! Illustration 29: checking of the limit of wear Illustration 30: wear of spider ATTENTION! For backlash-free applications no wear is permitted, since otherwise the operating principle of the coupling (backlash-free condition) is no longer ensured. If a backlash-free operation is not required, the following figures apply: Table 15: ® Wear limits Xmax. [mm] 0,4 0,5 0,9 0,6 1,25 0,9 1,0 1,4 ROTEX GS Size 5 7 9 12 14 19 24 28 5.4 Permissible Coupling Materials in the ® ROTEX GS Size 38 42 48 55 65 75 90 Wear limits Xmax. [mm] 1,7 2,0 2,25 2,50 2,75 3,00 3,25 Hazardous Area In the Explosion Groups IIA, IIB and IIC the following materials may be combined: steel stainless steel aluminium wrought products Semifinished products from aluminium with a magnesium part of up to 7,5 % and a yield point of 2 Rp0,2 ≥ 250 N/mm are permitted for the use in hazardous areas. Aluminium diecast is generally excluded for hazardous areas. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 32of36 15 5 Enclosure A Hints and Instructions Regarding the Use in 5.5 Hazardous Areas Marking of Coupling for the Hazardous Area Couplings for the use in hazardous areas are marked on at least one component completely and on the remaining components at the outside diameter of the hub or on the front side with an label for the respectively permitted conditions of use. The flexible spider is excluded. For reason of the limited space only the symbol is stamped up to size 19. Short labelling: (standard) II 2GD c IIC T X/I M2 c X Category 3: II 3G c IIC T6, T5 bzw. T4 - 30 °C ≤ Ta≤ + 65°C, + 80 °C bzw. +90 °C II 3D c T 110 °C - 30 °C ≤ Ta≤ + 90 °C Complete labelling: II 2G c IIC T6, T5 bzw. T4 - 30 °C ≤ Ta≤ + 65°C, + 80 °C bzw. +90 °C II 2D c T 110 °C/I M2 c - 30 °C ≤ Ta≤ + 90 °C The former marking remains valid: II 2G c IIC T4/T5/T6 - 30 °C ≤ Ta≤ + 80/60/45 °C II 2D c T 110 °C/I M2 c - 30 °C ≤ Ta≤ + 80 °C The labelling with Explosion Group llC includes the Explosion Groups llA and llB. If the coupling part is labelled with in addition to , KTR supplied it unbored or pilot bored. 5.6 Starting Before putting the coupling into operation, check the tightness of the setscrews in the hubs, the alignment and the distance dimension E and correct, if necessary, and also check all screw connections regarding the stipulated tightening torques dependent on the type of coupling. If used in hazardous areas the grub screws to fix the hub as well as all screw connections must be additionally secured against self-loosening, e. g. glue with Loctite (medium strength). Last but not least, the coupling protection against unintended contact must be fixed. The cover must be electrically conductive and be included in the equipotential bonding. Bellhousings (magnesium part below 7,5 %) made from aluminium and damping rings (NBR) can be used as connecting element between pump and electric 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. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 33of36 15 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas 5.6 Starting The minimum distance “Sr” of the protection device of the rotating parts must be at leastthe values listed below. If the protection device is used as cover, regular openings complying with the explosion protection demands can be made that must not exceed the following dimensions: openings circular – max. diameter rectangular – max. side length Straight or bended slot – max. side length/height ! top surface 4 4 prohibited covering side parts 8 8 distance „Sr“ ≥ 10 ≥ 10 8 ≥ 20 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. 5.7 Breakdowns, Causes and Elimination ® The below-mentioned errors can lead to an incorrect use of the ROTEX coupling. In addition to the stipulations in these operating and mounting instructions please make sure to avoid these errors. The errors listed can only be clues to search for the errors. When searching for the error the adjacent components must be generally included. Due to incorrect use the coupling can become a source of ignition. EC Standard 94/9/EC requires a special care from the manufacturer and the user. General errors incorrect use • • • • • • • • • • Important data for the coupling selection was not forwarded. The calculation of the shaft/hub connection was not considered. Coupling parts with damage occurred during transport are assembled. If the heated hubs are assembled, the permissible temperature is exceeded. The fits of the parts to be assembled are not coordinated with each other. Tightening torques arefallen below/exceeded. Components are exchanged by mistake/put together incorrectly. A wrong or no spider is inserted into the coupling. No original KTR parts (purchased parts) are used. Old/already worn out spiders or spiders stored too long are used. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 34of36 15 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas 5.7 Breakdowns, Causes and Elimination Continuation: • 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. Breakdowns Causes Danger hints for hazardous areas Elimination 1) put the unit out of operation 2) eliminate the reason for the misalignment (e. increased temperature the g. loose foundation bolts, break of the engine misalignment the spider surface; danger fixing, heat expansion of unit components, of ignition by hot surfaces change of the assembly dimension E of the coupling) 3) checking of wear see under point Control 1) put the unit out of operation change of the running 2) disassemble the coupling and remove rests noises wear of spider, shortof the spider and/or occurring term torque danger of ignition due to 3) check coupling parts and exchange vibrations transmission due to sparking damaged coupling parts metal contact 4) insert spider, assemble coupling parts 5) check alignment, correct if necessary 1) put the unit out of operation 2) check alignment of coupling loose screws for axial danger of ignition due to 3) tighten the screws to secure the hubs and securement of hubs hot surfaces and sparking secure against self-loosening 4) checking of wear see under point Control wear of spider, torque 1) put the unit out of operation danger of ignition due to transmission due to 2) change complete coupling sparking metal contact 3) check alignment 1) put the unit out of operation break of the cams due danger of ignition due to 2) change complete coupling to high shock sparking 3) check alignment energy/overload 4) find out the reason of overload 1) put the unit out of operation break of cam operating parameters 2) check the operating parameters and select a do not correspond to danger of ignition due to larger coupling (consider installation space) the performance of the sparking 3) assemble new coupling size coupling 4) check alignment 1) put the unit out of operation mistake in service of danger of ignition due to 2) change complete coupling the unit sparking 3) check alignment 4) instruct and train the service staff Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 35of36 15 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas 5.7 Breakdowns, Causes and Elimination Breakdowns Danger hints for hazardous areas Causes 1) put the unit out of operation 2) eliminate the reason for the misalignment (e. increased temperature the g. loose foundation bolts, break of the engine the spider surface; danger fixing, heat expansion of unit components, change of the assembly dimension E of the of ignition by hot surfaces coupling) 3) checking of wear see under point Control misalignment Early wear of spider or reverse backlash premature wear of spider(liquefaction of material inside the spider cam) Elimination e. g. contact with aggressive liquids/ oils, ozone-influence, too high/low ambient temperatures etc. effecting a physical change of the spider danger of ignition due to sparking in case of metallic contact of the cams Excessively high/low ambient/contact temperatures for the spider; max. permissible e. g. T4 = - 30 °C/+ 90 °C danger of ignition due to sparking in case of metallic contact of the cams drive vibrations danger of ignition due to sparking in case of metallic contact of the cams 1) put the unit out of operation 2) disassemble the coupling and remove rests of the spider 3) check coupling parts and exchange damaged coupling parts 4) insert spider, assemble coupling parts 5) check alignment, correct if necessary 6) make sure that further physical changes of the spider are excluded 1) put the unit out of operation 2) disassemble the coupling and remove rests of the spider 3) check coupling parts and exchange damaged coupling parts 4) insert spider, assemble coupling parts 5) check alignment, correct if necessary 6) check and regulate ambient/contact temperature (eventually even elimination by using other spider materials) 1) put the unit out of operation 2) disassemble the coupling and remove rests of the spider 3) check coupling parts and exchange damaged coupling parts 4) insert spider, assemble coupling parts 5) check alignment, correct if necessary 6) find out the reason for the vibrations (eventually elimination by spider with lower or higher shore hardness) If you operate with a worn spider (see item 5.2) and the subsequent contact of metal parts a due operation meeting the explosion protection requirements and acc. to Standard 94/9/EC is not ensured. Please note protection mark ISO 16016. Drawn: Verified: 15.10.12 Pz 29.10.12 Pz Replaced for: Replaced by: KTR-N valid from 08.02.12 KTR Kupplungstechnik GmbH D-48407 Rheine ROTEX® GS Operating/mounting instructions KTR-N Sheet: Edition: 45510 EN 36of36 15 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas 5.8 EC Certificate of Conformity EC Certificate of Conformity Corresponding to EC Standard 94/9/EC dated 23 March1994 and to the legal regulations The manufacturer - KTR Kupplungstechnik GmbH, D-48432 Rheine – states that the ROTEX GS backlash-free shaft couplings described in these mounting instructions and explosion-proof designed correspond to Article 1 (3) b) of Standard 94/9/EC and comply with the general Safety and Health Requirements according to enclosure II of Standard 94/9/EC. ® The ROTEX GS coupling is in accordance with the specifications of the standard 94/9/EC. One or several standards mentioned in the corresponding EC type test certificate IBExU03ATEXB002_05 X were in part replaced by updated versions. KTR Kupplungstechnik GmbH as the manufacturer confirms that the product mentioned above is in accordance with the specifications of the new standards, too. According to article 8 (1) b) ii) of Standard 94/9/EC the technical documentation is desposited with the: IBExU Institut für Sicherheitstechnik GmbH Fuchsmühlenweg 7 09599 Freiberg Rheine, Please note protection mark ISO 16016. 15.10.12 Date Drawn: Verified: i. V. Reinhard Wibbeling Engineering Manager 15.10.12 Pz 29.10.12 Pz i. V. Johannes Deister Product Manager Replaced for: Replaced by: KTR-N valid from 08.02.12 ">

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Key features
- Backlash-free power transmission
- Compensation for shaft misalignment
- High damping features
- Suitable for hazardous areas
- ATEX 95 compliant
Frequently asked questions
The KTR ROTEX GS coupling is designed for backlash-free power transmission and compensation of shaft misalignment in applications such as measuring technology and automatic control engineering.
It is approved for use in hazardous areas and complies with ATEX 95 standards. The coupling provides high damping capabilities, preventing damage from shocks, and operates with a positive-locking rubber spring prestress for reliable operation.
The KTR ROTEX GS coupling offers various hub types, including standard shaft couplings, clamping hubs, clamping ring hubs, expansion hubs, and DKM and Compact versions. Each type is designed for specific applications and installation requirements.