KTR BoWex Operating/Mounting Instructions

KTR-N
Sheet:
Edition:
BoWex®
Operating/Assembly instructions
40110 EN
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17
BoWex®
Non-failsafe
curved-tooth gear couplings
types
junior plug-in coupling,
junior M coupling,
M und M...C
I
and their combinations
Type junior plug-in coupling (two-part)
according to directive 2014/34/EU
and UK directive SI 2016 No. 1107
Type junior M coupling (three-part)
Type M and M...C
Type I
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
40110 EN
2 of 26
17
The BoWex® curved-tooth gear coupling is a flexible shaft connection. It is able to compensate for shaft
misalignment, for example caused by manufacturing inaccuracies, thermal expansion, etc.
Table of contents
1
Technical data
3
2
Advice
5
2.1
2.2
2.3
2.4
2.5
2.6
5
5
5
6
6
6
3
4
General advice
Safety and advice symbols
General hazard warnings
Proper use
Coupling selection
Reference to EC Machinery Directive 2006/42/EC
Storage, transport and packaging
7
3.1
3.2
7
7
Storage
Transport and packaging
Assembly
7
4.1
4.2
4.3
4.4
4.5
4.6
7
9
10
11
12
13
Components of the coupling
Advice for finish bore
Assembly of the coupling (general)
Assembly of type junior plug-in coupling
Assembly of type junior M, M and I
Displacements - alignment of the couplings
5
Start-up
14
6
Breakdowns, causes and elimination
15
7
Disposal
17
8
Maintenance and service
18
9
Spares inventory, customer service addresses
18
10
Enclosure A
Advice and instructions regarding the use in
10.1 Proper use in
potentially explosive atmospheres
potentially explosive atmospheres
10.2 Inspection intervals for couplings in
10.3 Inspection of torsional backlash
10.4 Standard values of wear
Please observe protection
note ISO 16016.
Drawn:
Verified:
19
potentially explosive atmospheres
10.5
marking of couplings for potentially explosive atmospheres
10.6 EU Declaration of conformity
10.7 UK Declaration of conformity
2022-07-05 Pz/Wb
2022-08-02 Pz
Replacing:
Replaced by:
19
20
21
22
23
25
26
KTR-N dated 2019-07-01
KTR-N
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Edition:
BoWex®
Operating/Assembly instructions
1
40110 EN
3 of 26
17
Technical data
Illustration 1: BoWex® junior plug-in coupling (two-part)
Illustration 2: BoWex® junior M coupling (three-part)
Table 1: Dimensions - BoWex® junior plug-in coupling (two-part)
Size
14
19
24
Finish bores [mm]
D
D1
Ø6, Ø7, Ø8, Ø9
Ø8
Ø10, Ø11
Ø10, Ø11
Ø12, Ø14
Ø12, Ø14
Ø12, Ø14
Ø14, Ø15
Ø16
Ø19
Ø19
Ø10, Ø11, Ø12
Ø14, Ø16
Ø14, Ø15, Ø16
Ø18, Ø19, Ø20
Ø19, Ø20
Ø24
Ø24
DH
40
47
53
DN
22
25
26
27
30
32
26
32
36
38
DN1
22
25
26
L
29
Dimensions 1) [mm]
L1, L2
E
LH1
LH2
LH3
NH
48
23
2
40
18.5
21.5
8
52
25
2
42
19.0
23.0
10
54
26
2
45
21.5
23.5
9
35
32
36
40
1) For dimensions G, T and T1 see table 6
Table 2: Dimensions - BoWex® junior M coupling (three-part)
Size
Finish bores D [mm]
DH
Ø6, Ø7, Ø8, Ø9
Ø10, Ø11
Ø12, Ø14
Ø12, Ø14
Ø16
Ø19
Ø10, Ø11, Ø12
Ø14, Ø15, Ø16
Ø18, Ø19, Ø20
Ø24
14
19
24
40
47
53
DN
22
25
26
27
30
32
26
32
36
38
L
Dimensions 2) [mm]
L1, L2
E
LH
NH
50
23
4
37
6.5
54
25
4
37
8.5
56
26
4
41
7.5
2) For dimensions G and T see table 6
Table 3: Torque and speed - BoWex® junior plug-in coupling and BoWex® junior M coupling
Size
14
19
24
Please observe protection
note ISO 16016.
TKN
5
8
12
Torque [Nm]
TK max
10
16
24
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
TKW
2.5
4.0
6.0
Replacing:
Replaced by:
Max. speed [rpm]
6000
KTR-N dated 2019-07-01
KTR-N
Sheet:
Edition:
BoWex®
Operating/Assembly instructions
1
40110 EN
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17
Technical data
Illustration 3: BoWex® type M
Illustration 4: BoWex® type I
Table 4: Dimensions - BoWex® type M and type I
Size
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-65
M-65C
M-48C
I-80
I-100
I-125
Pilot bore
Pilot
Unbored
bored
x
x
x
x
x
x
x
x
27
x
70 lg.
31
35
45
Dimensions 1) [mm]
Max. finish bore
D [mm]
DH
DN
L
L1, L2
E
E1
LH
NH
DZ 2)
15
20
24
28
32
38
42
48
40
47
53
65
75
83
92
95
25
32
36
44
50
58
65
68
50
54
56
84
84
84
88
104
23
25
26
40
40
40
42
50
4
4
4
4
4
4
4
4
10
10
14
13
13
13
13
13
37
37
41
46
48
48
50
50
6.5
8.5
7.5
19
18
18
19
27
33
39
45
54
63
69
78
78
65
132
96
114
55
4
16
68
23
110
80
100
125
175
210
270
124
152
192
186
228
290
90
110
140
6
8
10
20
22
30
93
102
134
46.5
63
78
145
176
225
1) For dimensions G and T see table 7
2) Tip circle of hub
Table 5: Torque and speed - BoWex® type M and type I
Size
TKN
10
16
20
45
60
80
100
140
380
700
1200
2500
14
19
24
28
32
38
42
48
65
80
100
125
Torque [Nm]
TK max
30
48
60
135
180
240
300
420
1140
2100
3600
7500
TKW
5
8
10
23
30
40
50
70
190
350
600
1250
Max. speed [rpm]
14000
11800
10600
8500
7500
6700
6000
5600
4000
3150
3000
2120
BoWex® couplings with attachments that can generate heat, sparks and static charging (e. g.
combinations with brake drums, brake disks, overload systems such as torque limiters, fan
impellers etc.) are not permitted for the use in potentially explosive atmospheres.
A separate analysis must be performed.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
2
KTR-N
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Edition:
40110 EN
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Advice
2.1 General advice
Please read through these operating/assembly instructions carefully before you start up the coupling.
Pay special attention to the safety instructions!
The BoWex® coupling is suitable and approved for the use in potentially explosive atmospheres.
When using the coupling in potentially explosive atmospheres, observe the special advice and
instructions regarding safety in enclosure A.
The operating/assembly instructions are part of your product. Please store them carefully and close to the
coupling. The copyright for these operating/assembly instructions remains with KTR.
2.2 Safety and advice symbols
STOP
!

Warning of potentially explosive
atmospheres
This symbol indicates notes which may contribute to
preventing bodily injuries or serious bodily injuries that
may result in death caused by explosion.
Warning of personal injury
This symbol indicates notes which may contribute to
preventing bodily injuries or serious bodily injuries that
may result in death.
Warning of product damages
This symbol indicates notes which may contribute to
preventing material or machine damage.
General advice
This symbol indicates notes which may contribute to
preventing adverse results or conditions.
Warning of hot surfaces
This symbol indicates notes which may contribute to
preventing burns with hot surfaces resulting in light to
serious bodily injuries.
2.3 General hazard warnings
STOP
With assembly, operation and maintenance of the coupling it has to be made sure that the
entire drive train is secured against accidental switch-on. You may be seriously hurt by
rotating parts. Make absolutely sure to read through and observe the following safety
indications.
• All operations on and with the coupling have to be performed taking into account "safety first".
• Make sure to switch off the power pack before you perform your work on the coupling.
• Secure the power pack against accidental switch-on, e. g. by providing warning signs at the place of switch-on
or removing the fuse for current supply.
• Do not reach into the operating area of the coupling as long as it is in operation.
• Secure the coupling against accidental contact. Provide for the necessary protection devices and covers.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
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KTR-N
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Edition:
40110 EN
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Advice
2.4 Proper use
You may only assemble, operate and maintain the coupling if you
• have carefully read through the operating/assembly instructions and understood them
• are technically qualified and specifically trained (e. g. safety, environment, logistics)
• are authorized by your company
The coupling may only be used in accordance with the technical data (see chapter 1). Unauthorized modifications
on the coupling design are not admissible. We will not assume liability for any damage that may arise. In the
interest of further development we reserve the right for technical modifications.
The BoWex® described in here corresponds to the state of the art at the time of printing of these
operating/assembly instructions.
2.5 Coupling selection
!
For a long-lasting and failure-free operation of the coupling it must be selected according to
the selection instructions (according to DIN 740 part 2) for the particular application (see
catalogue drive technology „BoWex®“).
If the operating conditions (performance, speed, modifications on engine and machine)
change, the coupling selection must be reviewed.
Make sure that the technical data regarding torque refer to the sleeve only. The transmittable
torque of the shaft-hub-connection must be reviewed by the customer and is subject to his
responsibility.
For drives subjected to torsional vibrations (drives with cyclic stress due to torsional vibrations) it is necessary to
perform a torsional vibration calculation to ensure a reliable selection. Typical drives subject to torsional vibrations
are e. g. drives with diesel engines, piston pumps, piston compressors etc. If requested, KTR will perform the
coupling selection and the torsional vibration calculation.
2.6 Reference to EC Machinery Directive 2006/42/EC
The couplings supplied by KTR should be considered as components, not machines or partly completed
machines according to EC Machinery Directive 2006/42/EC. Consequently KTR does not have to issue a
declaration of incorporation. For details about safe assembly, start-up and safe operation refer to the present
operating/assembly instructions considering the warnings.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
3
KTR-N
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Edition:
40110 EN
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Storage, transport and packaging
3.1 Storage
The coupling hubs are supplied in preserved condition and can be stored in a dry and roofed place for 6 - 9
months.
The features of the coupling sleeves remain unchanged for up to 5 years with favourable storage conditions.
The storage rooms must not include any ozone-generating devices like e. g. fluorescent
light sources, mercury-vapour lamps or electrical high-voltage appliances.
Humid storage rooms are not suitable.
Make sure that condensation is not generated. The best relative air humidity is less than
65 %.
!
3.2 Transport and packaging
In order to avoid any injuries and any kind of damage always make use of proper transport
and lifting equipment.
!
The couplings are packed differently each depending on size, number and kind of transport. Unless otherwise
contractually agreed, packaging will follow the in-house packaging specifications of KTR.
4
Assembly
The coupling is generally supplied in individual parts. Before assembly the coupling has to be inspected for
completeness.
4.1 Components of the coupling
Type made of nylon
Components of BoWex® junior plug-in coupling
Component
1
2
3
Quantity
1
1
2
Description
Hub
Plug-in sleeve
Setscrew DIN EN ISO 4029
Illustration 5: BoWex® junior plug-in coupling
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
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KTR-N
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Edition:
40110 EN
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Assembly
4.1 Components of the coupling
Components of BoWex® junior M coupling
Component
1
2
3
Quantity
2
1
2
Description
Hub
Sleeve
Setscrew DIN EN ISO 4029
Illustration 6: BoWex® junior M coupling
Type made of steel/nylon
Components of BoWex® M coupling (size 14 - 65)
Component
1
2
3
Quantity
2
1
2
Description
Hub
Sleeve type M
Setscrew DIN EN ISO 4029
Illustration 7: BoWex® type M
Components of BoWex® I coupling (size 80 - 125)
Component
1
2
3
4
Quantity
2
1
2
2
Description
Hub
Sleeve type I1)
Setscrew DIN EN ISO 4029
Seeger circlip 1)
1) The sleeve type I is supplied completely assembled by the manufacturer.
Illustration 8: BoWex® type I
Please observe protection
note ISO 16016.
Drawn:
Verified:
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Replacing:
Replaced by:
KTR-N dated 2019-07-01
KTR-N
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Edition:
BoWex®
Operating/Assembly instructions
4
40110 EN
9 of 26
17
Assembly
4.2 Advice for finish bore
STOP
The maximum permissible bore diameters D (see chapter
1 - technical data) must not be exceeded. If these figures
are disregarded, the coupling may tear. Rotating particles
may cause danger to life.
• Hub bores (steel hubs) machined by the customer have to
observe concentricity resp. axial run-out (see illustration 9).
• Make absolutely sure to observe the figures for ØD.
• Carefully align the hubs when the finish bores are drilled.
• Provide for a setscrew according to DIN EN ISO 4029 with
a cup point or an end plate to fasten the hubs axially.
Illustration 9: Concentricity and axial runout
!
The customer bears the sole responsibility for all machining processes performed
subsequently on unbored or pilot bored as well as finish machined coupling components
and spare parts. KTR does not assume any warranty claims resulting from insufficient
remachining.
KTR supplies unbored or pilot bored coupling components and spare parts only upon
explicit request of the customer. These parts are additionally marked with the symbol
.
Reference to unbored resp. pilot bored coupling components with explosion protection
marking:
Basically the company KTR Systems GmbH supplies couplings resp. coupling hubs with explosion
protection marking as an unbored or pilot bored type only on explicit request of the customer. The
prerequisite is a declaration of exemption submitted by the customer assuming any responsibility
and liability for respective remachining performed on the product of KTR Systems GmbH.
Table 6: Setscrew DIN EN ISO 4029 - BoWex® junior plug-in coupling and BoWex® junior M coupling
Size
Dimension G
Dimension T
Dimension T1
Tightening torque TA [Nm]
14
M5
6
8
1.4
19
24
M5
6
10
1.4
Table 7: Setscrew DIN EN ISO 4029 - BoWex® type M and type I
Size
Dimension G
Dimension T
Tightening torque TA
[Nm]
14
19
M5
6
24
28
32
2
38
M8
10
42
48
65
80
M10
15 / 20 1)
10
20
17
100
M12
30
125
M16
40
40
80
1) Length of hub 55 mm T = 15 mm, length of hub 70 mm T = 20 mm
Please observe protection
note ISO 16016.
Drawn:
Verified:
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2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
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KTR-N
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Assembly
4.2 Advice for finish bore
Table 8: Recommended fit pairs acc. to DIN 748/1
Bore [mm]
above
up to
50
Shaft tolerance
Bore tolerance
k6
m6
H7
(KTR standard)
50
If a feather keyway is intended to be used in the hub, it should correspond to the tolerance ISO JS9 (KTR
standard) with standard operating conditions or ISO P9 with sophisticated operating conditions (frequently
alternating torsional direction, shock loads, etc.).
The transmittable torque of the shaft-hub-connection must be reviewed by the customer and is subject to his
responsibility.
4.3 Assembly of the coupling (general)

We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Heating the hubs lightly (approx. 80 °C) allows for easier mounting on the shaft.
Please pay attention to the ignition risk in potentially explosive atmospheres!
STOP
!
Touching the heated hubs causes burns.
Please wear safety gloves.
With the assembly make sure that the distance dimension E (see chapter 1) is observed to
allow for axial clearance of the coupling sleeve while in operation.
Disregarding this advice may cause damage to the coupling.
If used in potentially explosive atmospheres the setscrews to fasten the hubs as well as all
screw connections must be secured against working loose additionally, e. g. conglutinating
with Loctite (average strength).
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
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KTR-N
Sheet:
Edition:
40110 EN
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Assembly
4.4 Assembly of type junior plug-in coupling
• Mount the hub resp. plug-in sleeve on the shaft of
driving and driven side (see illustration 10).
• The internal sides of the hub and plug-in sleeve
must be flush with the front sides of the shafts.
Illustration 10: Assembly of hub and plug-in sleeve
• Shift the power packs in axial direction until the
distance dimension E or NH is achieved (see
illustration 11).
• Fasten the hubs by tightening the setscrews
DIN EN ISO 4029 with a cup point (tightening torque
see table 6).
Illustration 11: Assembly of coupling
!
With the assembly make sure that the spline of the hub is fully covered by the internal spline
of the plug-in sleeve (observe mounting dimensions L).
Disregarding this advice may cause damage to the coupling.
!
Having started up the coupling, the wear of the plug-in sleeve has to be inspected at regular
maintenance intervals and it has to be replaced, if necessary.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
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KTR-N
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Edition:
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Assembly
4.5 Assembly of type junior M, M and I
• Mount the hubs on the shaft of driving and driven
side (see illustration 12).
• The internal sides of the hubs must be flush with the
front sides of the shafts.
Illustration 12: Assembly of hubs
• Put the sleeve on the spline of the driving or driven
side hubs (see illustration 13).
Illustration 13: Assembly of the sleeve
• Shift the power packs in axial direction until the
distance dimension E is achieved (see illustration
14).
• Fasten the hubs by tightening the setscrews
DIN EN ISO 4029 with a cup point (tightening
torques see table 6 or 7).
• Align the sleeve via the hubs and check the
dimensions E resp. NH (see illustration 14 and
chapter 1).
Illustration 14: Assembly of coupling
!
With the assembly make sure that the spline of the hub is fully covered by the internal spline
of the sleeve (observe mounting dimensions L).
Disregarding this advice may cause damage to the coupling.
!
Having started up the coupling, the wear of the sleeve has to be inspected at regular
maintenance intervals and it has to be replaced, if necessary.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
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KTR-N
Sheet:
Edition:
40110 EN
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Assembly
4.6 Displacements - alignment of the couplings
The displacement figures specified in table 9 and 10 provide for sufficient safety to compensate for external
influences like, for example, thermal expansion or foundation settling.
In order to ensure a long service life of the coupling and avoid hazards with the use in
potentially explosive atmospheres, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures specified (see tables 9 and 10). If the
figures are exceeded, the coupling will be damaged.
The more accurate the alignment of the coupling, the longer is its service life.
If used in potentially explosive atmospheres for explosion group IIC, only half of the
displacement figures (see tables 9 and 10) is permissible.
!
Please note:
• The displacement figures specified in table 9 and 10 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:
Krzul = Kr −
Kr
• Ww
2Kw
Ww = angular shaft displacement
• The displacement figures specified are general standard figures that apply up to an ambient temperature of
80 °C, ensuring a sufficient service life of the BoWex® coupling.
Displacement figures between the speeds specified have to be interpolated accordingly. If necessary, ask
about the displacement for the corresponding coupling type.
• Inspect with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 9 and 10 can
be observed.
Axial displacements
Radial displacements
Angular displacements
Radial and angular displacements
Illustration 15: Displacements
Examples of the displacement
combinations specified in illustration 16:
Illustration 16:
Combinations of
displacement
Example 1:
Kr = 30 %
Kw = 70 %
Example 2:
Kr = 60 %
Kw = 40 %
Ktotal = Kr + Kw  100 %
Please observe protection
note ISO 16016.
Drawn:
Verified:
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2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
KTR-N
Sheet:
Edition:
BoWex®
Operating/Assembly instructions
4
40110 EN
14 of 26
17
Assembly
4.6 Displacements - alignment of the couplings
Table 9: Displacement figures - BoWex® junior plug-in coupling and BoWex® junior M coupling
Size
Max. axial displacement Ka [mm]
Max. radial displacement with n=1500 rpm Kr [mm]
Max. radial displacement with n=3000 rpm Kr [mm]
Kw [degree] max. angular displacement with n=1500 rpm
Kw [degree] max. angular displacement with n=3000 rpm
Type junior plug-in coupling
14
19
24
±1
±1
±1
±0.1
±0.1
±0.1
±0.1
±0.1
±0.1
±1.0
±1.0
±0.9
±0.7
±0.7
±0.6
Type junior M
19
±1
±0.3
±0.3
±1.0
±0.7
14
±1
±0.3
±0.3
±1.0
±0.7
24
±1
±0.4
±0.4
±0.9
±0.6
Table 10: Displacement figures - BoWex® type M and type I
Size
Max. axial displacement Ka [mm]
Max. radial displacement with
n=1500 rpm Kr [mm]
Max. radial displacement with
n=3000 rpm Kr [mm]
Kw [degree] max. angular
displacement with n=1500 rpm
Kw [degree] max. angular
displacement with n=3000 rpm
5
14
±1
19
±1
24
±1
28
±1
32
±1
38
±1
42
±1
48
±1
65
±1
80
±1
100
±1
125
±1
±0.30
±0.30
±0.35
±0.35
±0.35
±0.40
±0.40
±0.40
±0.45
±0.45
±0.45
±0.45
±0.20
±0.20
±0.23
±0.23
±0.23
±0.25
±0.25
±0.25
±0.28
±0.28
±0.28
±0.28
±1.0
±1.0
±0.9
±0.9
±0.9
±0.9
±0.9
±0.9
±0.7
±0.6
±0.6
±0.4
±0.7
±0.7
±0.6
±0.6
±0.6
±0.6
±0.6
±0.6
±0.5
±0.4
±0.4
±0.3
Start-up
Before start-up of the coupling, inspect the tightening of the setscrews in the hubs, the alignment and the distance
dimension E and adjust, if necessary, and also inspect all screw connections for the tightening torques specified.
If used in potentially explosive atmospheres the setscrews to fasten the hubs as well as all
screw connections must be secured against working loose additionally, e. g. conglutinating
with Loctite (average strength).
Finally the coupling protection against accidental contact must be fitted. It is required in accordance with
DIN EN ISO 12100 (Safety of Machinery) and directives 2014/34/EU and SI 2016 No. 1107 and must protect
against
• access with a little finger
• falling down of solid foreign objects.
The coupling protection is not part of KTR's scope of delivery and is the customer's responsibility. It must have
sufficient distance to the rotating components to avoid contact safely. Depending on the outside diameter DH of
the coupling, we recommend the following minimum distance:
ØDH to 50 mm = 6 mm, ØDH 50 mm to 120 mm = 10 mm, ØDH from 120 mm = 15 mm.
Please check if a proper enclosure (ignition protection, coupling protection, contact protection) has been mounted
and the operation of the coupling is not affected by the enclosure. The same applies for test runs and rotational
direction inspections.
The cover may provide for openings intended for necessary heat dissipation. These openings have to comply with
DIN EN ISO 13857.
The cover must be electrically conductive and included in the equipotential bonding. Bellhousings (magnesium
share below 7.5 %) made of aluminium and damping rings (NBR) can be used as connecting element between
pump and electric motor. The cover may only be taken off with standstill of the unit.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
5
KTR-N
Sheet:
Edition:
40110 EN
15 of 26
17
Start-up
If the couplings are used in locations subject to dust explosion and in mining the user must
make sure that there is no accumulation of dust in a dangerous volume between the cover
and the coupling. The coupling must not operate in an accumulation of dust.
For covers with unlocked openings on the top face no light metals must be used if the
couplings are used as equipment of equipment group ll (if possible, from stainless steel).
If the couplings are used in mining (equipment group l M2), the cover must not be made of
light metal. In addition, it must be resistant to higher mechanical loads than with use as
equipment of equipment group ll.
During operation of the coupling, pay attention to
• different operating noise
• vibrations occurring.
!
If you note any irregularities with the coupling during operation, the drive unit must be
switched off immediately. The cause of the breakdown must be specified by means of the
table „Breakdowns“ and, if possible, be eliminated according to the proposals. The potential
breakdowns specified can be hints only. To find out the cause all operating factors and
machine components must be considered.
Coating of coupling:
If coated (priming, paintings, etc.) couplings are used in potentially explosive atmospheres,
the requirements on conductibility and coating thickness must be considered. With
paintings up to 200 µm electrostatic load does not have to be expected. If thicker paintings
resp. coatings up to a layer thickness of a maximum of 2.0 mm are applied, the couplings
are not permissible for gases and vapours of category IIC in potentially explosive areas, but
only for gases and vapours of category IIA and IIB.
This also applies for multiple coatings exceeding an overall thickness of 200 µm. Make sure
with painting or coating that the coupling components are conductively connected with the
device/devices to be connected so that the equipotential bonding is not impeded by the
paint or coat applied. Basically painting of the sleeve is not admitted to ensure an
equipotential bonding.
In addition, make sure that the marking of the coupling remains legible.
6
Breakdowns, causes and elimination
The below-mentioned failures can result in an improper use of the BoWex® coupling. In addition to the
specifications given in these operating/assembly instructions make sure to avoid such failures.
The errors listed can only be clues to search for the failures. When searching for the failure the adjacent
components must generally be considered.
If used other than intended the coupling can become a source of ignition.
Directive 2014/34/EU and UK directive SI 2016 No. 1107 require special care by the
manufacturer and the user.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
6
KTR-N
Sheet:
Edition:
40110 EN
16 of 26
17
Breakdowns, causes and elimination
General failures with improper use:
• Important data for the coupling selection are not forwarded.
• The calculation of the shaft-hub-connection is not considered.
• Coupling components with damage occurred during transport are assembled.
• If the heated hubs are assembled, the permissible temperature is exceeded.
• The clearance of the components to be assembled is not coordinated with one another.
• Tightening torques are fallen below/exceeded.
• Components are mixed up by mistake/assembled incorrectly.
• A wrong or no spider is inserted in the coupling.
• No original KTR components (purchased parts) are used.
• Old/already worn out sleeves or sleeves stored for too long are used.
• Maintenance intervals are not observed.
Breakdowns
Different operating
noise and/or vibrations
occuring
Causes
Hazard notes for
potentially explosive
atmospheres
Micro friction by faulty
alignment on the spline
of the nylon sleeve
Ignition risk due to hot
surfaces
Screws for axial
fastening of hubs
working loose
Fracture of the nylon
sleeve/spline due to
high shock
energy/overload
Fracture of the nylon
sleeve/spline
Operating parameters
do not meet with the
performance of the
coupling
none
Operating error of the
unit
Excessive wear on the
spline of sleeve
Vibrations of drive
Please observe protection
note ISO 16016.
Drawn:
Verified:
Ignition risk due to hot
surfaces
2022-07-05 Pz/Wb
2022-08-02 Pz
Elimination
1) Set the unit out of operation
2) Eliminate the reason for the misalignment (e. g.
loose foundation bolts, fracture of the engine
mount, heat expansion of unit components,
modification of the installation dimension E of
the coupling)
3) For inspection of wear see chapter 10.2
1) Set the unit out of operation
2) Inspect alignment of coupling
3) Tighten the screws to fasten the hubs and
secure against working loose
4) For inspection of wear see chapter 10.2
1) Set the unit out of operation
2) Disassemble the coupling and remove
remainders of the nylon sleeve
3) Inspect coupling components and replace
coupling components that have been damaged
4) Insert nylon sleeve, assemble coupling
components
5) Find out the reason for overload
1) Set the unit out of operation
2) Review the operating parameters and select a
bigger coupling (consider mounting space)
3) Assemble new coupling size
4) Inspect alignment
1) Set the unit out of operation
2) Disassemble the coupling and remove
remainders of the nylon sleeve
3) Inspect coupling components and replace
coupling components that have been damaged
4) Insert nylon sleeve, assemble coupling
components
5) Instruct and train the service staff
1) Set the unit out of operation
2) Disassemble the coupling and remove
remainders of the nylon sleeve
3) Inspect coupling components and replace
coupling components that have been damaged
4) Insert nylon sleeve, assemble coupling
components
5) Inspect alignment, adjust if necessary
6) Find out the reason for vibrations
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
6
40110 EN
17 of 26
17
Breakdowns, causes and elimination
Breakdowns
Causes
Hazard notes for
potentially explosive
atmospheres
Ambient/contact
temperatures which are
too high for the sleeve,
max. permissible
-30 °C/+100 °C
Ignition risk due to hot
surfaces
E. g. contact with
aggressive liquids/oils,
ozone influence, too
high/low ambient
temperatures etc.
causing a physical
modification of the nylon
sleeve
none
Excessive wear on the
spline of sleeve
!
7
KTR-N
Sheet:
Edition:
Elimination
1) Set the unit out of operation
2) Disassemble the coupling and remove
remainders of the nylon sleeve
3) Inspect coupling components and replace
coupling components that have been damaged
4) Insert nylon sleeve, assemble coupling
components
5) Inspect alignment, adjust if necessary
6) Inspect and adjust ambient/contact
temperature
1) Set the unit out of operation
2) Disassemble the coupling and remove
remainders of the nylon sleeve
3) Inspect coupling components and replace
coupling components that have been damaged
4) Insert nylon sleeve, assemble coupling
components
5) Inspect alignment, adjust if necessary
6) Make sure that further physical modifications of
the sleeve are not the case
If you operate with a worn sleeve (see chapter 10.3 and 10.4) proper operation is not
ensured.
Disposal
In respect of environmental protection we would ask you to dispose of the packaging resp. products on
termination of their service life in accordance with the legal regulations resp. standards that apply.
•
Metal
Any metal components have to be cleaned and disposed of by scrap metal.
•
Nylon materials
Nylon materials have to be collected and disposed of by a waste disposal company.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
8
KTR-N
Sheet:
Edition:
40110 EN
18 of 26
17
Maintenance and service
BoWex® is a low-maintenance coupling. We recommend to perform a visual inspection on the coupling at least
once a year. Pay special attention to the condition of the sleeve of the coupling.
• Since the flexible machine bearings of the driving and driven side settle during the course of load, inspect the
alignment of the coupling and re-align the coupling, if necessary.
• The coupling components have to be inspected for damages.
• The screw connections have to be inspected visually.
With the use in potentially explosive atmospheres observe chapter 10.2 "Inspection
intervals for couplings in
potentially explosive atmospheres".
9
Spares inventory, customer service addresses
We recommend to store major spare parts on site to ensure the readiness for use of the machine in case if a
coupling fails.
Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage at
www.ktr.com.

KTR does not assume any liability or warranty for the use of spare parts and accessories
which are not provided by KTR and for the damages which may incur as a result.
KTR Systems GmbH
Carl-Zeiss-Str. 25
D-48432 Rheine
Phone: +49 5971 798-0
E-mail: [email protected]
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
40110 EN
19 of 26
17
Enclosure A
Advice and instructions regarding the use in
potentially explosive atmospheres
Enclosure A only valid for BoWex® coupling.
10.1 Proper use in
potentially explosive atmospheres
Conditions of operation in
potentially explosive atmospheres
The BoWex® couplings are suitable for the use according to directives 2014/34/EU and SI 2016 No. 1107.
• Protection against hazards arising from lightning must follow the lightning protection concept of the machine or
plant. The relevant regulations and policy for lightning protection must be observed.
• The equipotential bonding of the couplings is made by metal contact between coupling hub and shaft. This
equipotential bonding must not be affected.
1. Industry (with the exception of mining)
•
•
•
•
Equipment group II of category 2 and 3 (coupling is not approved/not suitable for equipment group 1)
Substance group G (gases, fogs, vapours), zone 1 and 2 (coupling is not approved/not suitable for zone 0)
Substance group D (dusts), zone 21 and 22 (coupling is not approved/not suitable for zone 20)
Explosion group IIC (gases, fogs, vapours) (explosion groups IIA and IIB are included in IIC) and
explosion group IIIC (dusts) (explosion groups IIIA and IIIB are included in IIIC)
Temperature class:
Temperature class
T4
T5
T6
Standard sleeve „light“
Conductive sleeve „black“
Ambient or operating temperature Ta 1)
Max. surface temperature 2)
-30 °C to +100 °C
+120 °C
-30 °C to +75 °C
+95 °C
-30 °C to +60 °C
+80 °C
Explanation:
The maximum surface temperatures result from each the maximum permissible ambient or operating temperature T a plus the maximum
temperature increase T of 20 K (standard sleeve “light” and conductive sleeve “black”) to be considered. A relevant standard safety margin of
5 K has to be added to the temperature class.
1) The ambient resp. operating temperature Ta is limited to + +100 °C (standard sleeve “light” and conductive sleeve “black”) due to the
permissible permanent operating temperature of the BoWex® sleeves used.
2) The maximum surface temperature of +120 °C applies for the use in locations which are potentially subject to dust explosion.
In potentially explosive atmospheres
• the ignition temperature of dusts generated must at least be 1.5 times the surface temperature to be
considered
• the glow temperature must at least be the surface temperature to be considered plus a safety distance of 75 K.
• the gases and vapours generated must amount to the temperature class specified.
2. Mining
Equipment group I of category M2 (coupling is not approved/not suitable for equipment group M1).
Permissible ambient temperature - 30 °C to + 100 °C (standard sleeve “light” and conductive sleeve “black”).
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
40110 EN
20 of 26
17
Enclosure A
Advice and instructions regarding the use in
10.2 Inspection intervals for couplings in
Equipment category
potentially explosive atmospheres
Inspection intervals
M2
2G
2D
No gases and vapours of
explosion group IIC
M2
2G
2D
Gases and vapours of
explosion group IIC
potentially explosive atmospheres
The torsional backlash of the coupling (see chapter 10.3 and 10.4) according to
directive 2014/34/EU only has to be inspected if a failure of the coupling and
consequently a downtime of the drive causes explosion hazard.
We recommend a preventive inspection of circumferential backlash and visual
inspection of the sleeve. This should be performed after 3,000 operating hours
for the first time, at the latest 6 months after start-up of the coupling.
If you note insignificant or no wear on the sleeve upon this initial inspection,
further inspections can each be performed after 6,000 operating hours or at the
latest after 18 months, provided that the operating parameters remain the same.
If you note significant wear during the initial inspection so that it would be
recommendable to replace the sleeve, find out the cause according to the table
„Breakdowns“, if possible.
The maintenance intervals must be adjusted to the modified operating
parameters without fail.
The torsional backlash of the coupling (see chapter 10.3 and 10.4) according to
directive 2014/34/EU only has to be inspected if a failure of the coupling and
consequently a downtime of the drive causes explosion hazard.
We recommend a preventive inspection of circumferential backlash and visual
inspection of the sleeve. This should be performed after 2,000 operating hours
for the first time, at the latest 3 months after start-up of the coupling.
If you note insignificant or no wear on the sleeve upon this initial inspection,
further inspections can each be performed after 4,000 operating hours or at the
latest after 12 months, provided that the operating parameters remain the same.
If you note significant wear during the initial inspection so that it would be
recommendable to replace the sleeve, find out the cause according to the table
„Breakdowns“, if possible.
The maintenance intervals must be adjusted to the modified operating
parameters without fail.
BoWex® coupling
Here the backlash between the hub and the
nylon spline must be inspected via torsional
backlash, each separately from the driving and
the driven side.
The friction/wear may only be Xmax. of the
original spline thickness before the nylon
sleeves must be replaced.
When reaching the torsional backlash Smax.,
the nylon sleeve must be replaced
immediately, irrespective of the inspection
intervals.
Illustration 17: BoWex® coupling
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
40110 EN
21 of 26
17
Enclosure A
Advice and instructions regarding the use in
potentially explosive atmospheres
10.3 Inspection of torsional backlash
!
To inspect the torsional backlash the power pack switched off needs to be secured against
accidental switch-on.
Driving side
• Rotate the hub opposite the direction of drive.
!
Here the sleeve must not be axially displaced from its position of wear.
• Mark sleeve and hub (see Illustration 18).
• Rotate the hub in the driving direction and measure the torsional backlash Smax.
• When reaching the torsional backlash Smax. the nylon sleeve must be replaced.
Driven side
• Rotate the hub in the direction of the drive.
!
Here the sleeve must not be axially displaced from its position of wear.
• Mark sleeve and hub (see Illustration 18).
• Rotate the hub opposite the drive direction and measure the torsional backlash Smax.
• When reaching the torsional backlash Smax. the nylon sleeve must be replaced.
Illustration 18: Marking of sleeve and hub
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
KTR-N
Sheet:
Edition:
BoWex®
Operating/Assembly instructions
10
40110 EN
22 of 26
17
Enclosure A
Advice and instructions regarding the use in
potentially explosive atmospheres
10.4 Standard values of wear
If the torsional backlash is  Smax. [mm] / friction  Xmax. [mm], the nylon sleeves must be replaced.
Reaching the limits for replacing depends on the operating conditions and the existing operating parameters.
In order to ensure a long service life of the coupling and avoid hazards with the use in
potentially explosive atmospheres, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures specified (see tables 9 and 10). If the
figures are exceeded, the coupling will be damaged.
!
Illustration 19: Sleeve in new condition
Illustration 20: Wear of sleeve
Table 8:
Size
14
19
24
28
32
38
42
Limits of wear each hub
Torsional backlash
Wear
Xmax. [mm]
Smax. [mm]
0.8
1.3
0.8
1.4
1.0
1.5
1.0
1.6
1.0
1.7
1.0
1.7
1.0
1.7
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
Size
45
48
65
80
100
125
Limits of wear each hub
Torsional backlash
Wear
Xmax. [mm]
Smax. [mm]
1.0
1.8
1.0
1.8
1.4
2.5
1.6
2.7
1.8
3.1
2.0
3.5
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
40110 EN
23 of 26
17
Enclosure A
Advice and instructions regarding the use in
10.5
potentially explosive atmospheres
marking of couplings for potentially explosive atmospheres
The explosion protection marking of the BoWex® curved-tooth gear coupling is applied on the outer sheath or on
the front side.
For the complete marking refer to the operating/assembly instructions and/or the delivery note/package.
The following marking applies for the products:
•
•
•
•
Type M with standard sleeve (light), sizes M-14 and M-19
Type S..-St with standard sleeve (light), sizes S14-St to S24-St inclusive
Type M with conductive sleeve (black), sizes M-14C to M-80C inclusive
Type SSR with Seeger circlips with conductive sleeve (black),
sizes 24 SSR to 125 SSR inclusive
• Type S..-St with conductive sleeve (black), sizes S14-St to S55-St inclusive
I M2
II 2G
II 2D
Ex h
I
Mb
Ex h
IIC T6
… T4
Gb
Ex h
IIIC T80 °C … T120 °C Db
<Year>
-30 °C ≤ Ta ≤ +60 °C … +100 °C
KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine
X
X
X
• Type M with standard sleeve (light), sizes M-24 to M-65 inclusive
• Type SSR with Seeger circlips with standard sleeve (light), sizes 24 SSR to 45 SSR inclusive
• Type S..-St with standard sleeve (light), sizes S28-St to S55-St inclusive
I M2
II 2G
II 2D
Ex h
I
Mb
Ex h
IIB T6
… T4
Gb
Ex h
IIIC T80 °C … T120 °C Db
<Year>
-30 °C ≤ Ta ≤ +60 °C … +100 °C
KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine
X
X
X
Short marking:
(A short marking is only made if not possible differently for reason of space or functioning.)
BoWex®
<Year>
Deviating marking applied until 31st October 2019:
Short marking:
II 2GD c IIC T X/I M2 c X
II 2G c IIC T6, T5 resp. T4
-30 °C  Ta  +65 °C, +80 °C resp. +100 °C
II 2D c T 120 °C -30 °C  Ta  +100 °C
I M2 c -30 °C  Ta  +100 °C
Complete marking:
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
10
40110 EN
24 of 26
17
Enclosure A
Advice and instructions regarding the use in
10.5
KTR-N
Sheet:
Edition:
potentially explosive atmospheres
marking of couplings for potentially explosive atmospheres
Comments on marking
Equipment group I
Equipment group II
Equipment category 2G
Equipment category 2D
Equipment category M2
D
G
Ex h
IIB
IIC
IIIC
T6 … T4
T80 °C … T120 °C
-30 °C ≤ Ta ≤ +60 °C … +100 °C
or -30 °C ≤ Ta ≤ +100 °C
Gb, Db, Mb
X
Mining
Non-mining
Equipment ensuring a high level of safety, suitable for zone 1
Equipment ensuring a high level of safety, suitable for zone 21
Equipment ensuring a high level of safety must be able to be switched off
when an explosive atmosphere occurs
Dust
Gases and vapours
Nonelectrical explosion protection
Gases and vapours of class IIB (including IIA)
Gases and vapours of class IIC (including IIA and IIB)
Electrically conductive dusts of class IIIC (including IIIA and IIIB)
Temperature class to be considered, depending on the ambient temperature
Maximum surface temperature to be considered, depending on the ambient
temperature
Permissible ambient temperature from -30 °C to +60 °C resp.
-30 °C to +100 °C
Equipment protection level, high level of safety, analogous to the equipment
category
For a safe use of the couplings particular conditions apply
If the symbol
was punched in addition to marking , the coupling component was supplied by KTR as an
unbored or pilot bored version (see chapter 4.2 of the present operating/assembly instructions).
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-05 Pz/Wb
2022-08-02 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
40110 EN
25 of 26
17
Enclosure A
Advice and instructions regarding the use in
potentially explosive atmospheres
10.6 EU Declaration of conformity
EU Declaration of Conformity resp.
Certificate of Conformity
corresponding to EU directive 2014/34/EU dated 26 February 2014
and to the legal provisions adopted for its implementation
The manufacturer - KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine - states that the
BoWex® curved-tooth gear couplings®
in an explosion-proof design described in these assembly instructions are equipment resp.
components corresponding to article 2, 1. of directive 2014/34/EU and comply with the general safety
and health specifications according to enclosure II of directive 2014/34/EU.
This declaration of conformity is issued under the sole responsibility of the manufacturers
KTR Systems GmbH.
The coupling described in here complies with the specifications of the following standards/rules:
EN ISO 80079-36:2016-12
EN ISO 80079-37:2016-12
EN ISO/IEC 80079-38:2017-10
IEC/TS 60079-32-1:2020-01-24
The BoWex® complies with the specifications of directive 2014/34/EU.
According to article 13 (1) b) ii) of directive 2014/34/EU the technical documentation is deposited with
the notified body (type examination certificate IBExU13ATEXB007 X):
IBExU
Institut für Sicherheitstechnik GmbH
Identification number: 0637
Fuchsmühlenweg 7
09599 Freiberg
Rheine,
Place
2022-07-05
Date
Please observe protection
note ISO 16016.
Drawn:
Verified:
i. V.
Reinhard Wibbeling
Engineering/R&D
2022-07-05 Pz/Wb
2022-08-02 Pz
i. A.
Andreas Hücker
Product Manager
Replacing:
Replaced by:
KTR-N dated 2019-07-01
BoWex®
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
40110 EN
26 of 26
17
Enclosure A
Advice and instructions regarding the use in
potentially explosive atmospheres
10.7 UK Declaration of conformity
UK Declaration of Conformity resp.
Certificate of Conformity
corresponding to UK directive SI 2016 No. 1107 dated 26 February 2014
and to the legal provisions adopted for its implementation
The manufacturer - KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine - states that the
BoWex® curved-tooth gear couplings®
in an explosion-proof design described in these assembly instructions are equipment resp.
components corresponding to directive SI 2016 No. 1107 and comply with the general safety and
health requirements according to directive SI 2016 No. 1107.
This declaration of conformity resp. certificate of conformity is issued under the sole responsibility of
the manufacturer KTR Systems GmbH.
The coupling described in here complies with the specifications of the following standards/rules:
EN ISO 80079-36:2016-12
EN ISO 80079-37:2016-12
EN ISO/IEC 80079-38:2017-10
IEC/TS 60079-32-1:2020-01-24
The BoWex® complies with the specifications respectively the applicable specifications of directive SI
2016 No. 1107.
According to directive SI 2016 No. 1107 the technical documentation is deposited with the notified
body:
Eurofins CML
Identification number: 2503
Rheine,
Place
2022-07-05
Date
Please observe protection
note ISO 16016.
Drawn:
Verified:
i. V.
Reinhard Wibbeling
Engineering/R&D
2022-07-05 Pz/Wb
2022-08-02 Pz
i. A.
Andreas Hücker
Product Manager
Replacing:
Replaced by:
KTR-N dated 2019-07-01
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