KTR CLAMPEX 150 Operating/Mounting Instructions

CLAMPEX® KTR 150
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
40812 EN
1 of 9
7
CLAMPEX® KTR 150
The CLAMPEX® clamping set is a frictionally engaged, detachable shaft-hub-connection for cylindrical
shafts and bores without feather key.
Table of contents
1
Technical data
2
2
Advice
4
2.1
2.2
2.3
2.4
General advice
Safety and advice symbols
General hazard warnings
Intended use
4
4
5
5
Storage, transport and packaging
5
3.1
3.2
5
5
3
4
Storage
Transport and packaging
Assembly
6
4.1
4.2
4.3
6
7
9
Components of clamping set
Assembly of clamping set
Disassembly of clamping set
5
Disposal
9
6
Spares inventory, customer service addresses
9
7
Advice regarding the use in
directive 2014/34/EU
9
Please observe protection
note ISO 16016.
Drawn:
Verified:
potentially explosive atmospheres according to EU
2017-11-29 Shg/Jh
2017-11-29 Shg
Replacing:
Replaced by:
KTR-N dated 2017-04-27
CLAMPEX® KTR 150
Operating/Assembly instructions
1
KTR-N
Sheet:
Edition:
40812 EN
2 of 9
7
Technical data
1) Dimension DN: For calculation
of hub see catalogue "Drive
Technology"
Tolerances for d and D
d ≤ 38 mm = d h6/D H7
d > 38 mm = d h8/D H8
Illustration 1: CLAMPEX® KTR 150
Table 1: Technical data
Dimensions
[mm]
Distance dimension
A [mm]
1)
B
B1
6x9
7 x 10
8 x 11
9 x 12
10 x 13
12 x 15
13 x 16
14 x 18
15 x 19
16 x 20
17 x 21
18 x 22
19 x 24
20 x 25
22 x 26
24 x 28
25 x 30
28 x 32
30 x 35
32 x 36
35 x 40
36 x 42
38 x 44
40 x 45
42 x 48
45 x 52
48 x 55
50 x 57
55 x 62
56 x 64
60 x 68
63 x 71
65 x 73
70 x 79
4.5
4.5
4.5
4.5
4.5
4.5
4.5
6.3
6.3
6.3
6.3
6.3
6.3
6.3
6.3
6.3
6.3
6.3
6.3
6.3
7
7
7
8
8
10
10
10
10
12
12
12
12
14
3.7
3.7
3.7
3.7
3.7
3.7
3.7
5.3
5.3
5.3
5.3
5.3
5.3
5.3
5.3
5.3
5.3
5.3
5.3
5.3
6
6
6
6.6
6.6
8.6
8.6
8.6
8.6
10.4
10.4
10.4
10.4
12.2
dxD
1)
Clamping elements
1
2
3
4
3
3
3
4
3
3
3
4
3
3
3
4
3
3
3
4
3
3
3
4
3
3
3
4
3
3
3
4
3
4
4
5
3
4
4
5
3
4
4
5
3
4
4
5
3
4
4
5
3
4
4
5
3
4
4
5
3
4
4
5
3
4
4
5
3
4
4
5
3
4
4
5
3
4
4
5
3
4
4
5
3
4
4
5
4
5
5
6
4
5
5
6
4
5
5
6
4
5
5
6
4
5
5
6
4
5
5
6
4
5
5
6
4
5
5
6
4
5
5
6
4
5
6
7
4
5
6
7
4
5
6
7
4
5
6
7
Clamping screws
clamping force required
total = 0.14
PA = PO + PS
PO [kN] PS [kN]
[kN]
**
3
3
**
5
5
**
6
6
8
8
16
7
9
16
7
8
15
6
10
16
11
15
26
11
15
26
10
15
25
10
16
26
9
17
26
13
19
32
12
20
32
9
21
30
8
26
34
10
27
37
7
30
37
8
31
39
8
34
42
13
42
55
15
43
58
14
46
60
14
53
67
16
57
73
26
80
106
25
82
107
24
86
110
22
97
119
29
122
151
27
129
156
26
134
160
25
142
167
31
171
202
Transmittable
torque
or axial force
T
Fax
[Nm]
[kN]
2
0.6
4
1
5
1
8
1
10
2
11
1
13
2
22
3
25
3
26
3
30
3
33
3
40
4
44
4
50
4
68
5
75
6
90
6
100
6
120
7
160
9
170
9
190
10
230
11
260
12
390
17
430
17
470
18
580
21
740
26
840
28
920
29
1000
30
1300
37
Surface pressure
between clamp2
ing set [N/mm ]
Shaft
Hub
PW
PN
80
53
117
82
112
81
142
106
143
110
110
88
110
90
112
87
111
88
102
81
104
84
102
83
111
88
110
88
103
87
118
101
120
100
115
101
111
95
117
104
115
101
116
99
116
100
116
103
118
104
119
103
115
100
116
102
118
105
120
105
119
105
118
105
121
108
115
102
Replacing:
Replaced by:
KTR-N dated 2017-04-27
Weight
~ kg
0.0015
0.0014
0.0015
0.0017
0.0018
0.0022
0.0023
0.0049
0.0053
0.0055
0.0058
0.0061
0.0078
0.0082
0.0072
0.0079
0.01
0.009
0.012
0.01
0.02
0.02
0.02
0.02
0.03
0.05
0.05
0.05
0.05
0.07
0.07
0.08
0.08
0.11
Other sizes on request
** Slotted type
PO = Setting force
PS = Clamping force
PA = Total force
Please observe protection
note ISO 16016.
Drawn:
Verified:
2017-11-29 Shg/Jh
2017-11-29 Shg
CLAMPEX® KTR 150
Operating/Assembly instructions
1
KTR-N
Sheet:
Edition:
40812 EN
3 of 9
7
Technical data
1) Dimension DN: For calculation
of hub see catalogue "Drive
Technology"
Tolerances for d and D
d ≤ 38 mm = d h6/D H7
d > 38 mm = d h8/D H8
Illustration 1: CLAMPEX® KTR 150
Table 1: Technical data
Dimensions
[mm]
dxD
1)
71 x 80
75 x 84
80 x 91
85 x 96
90 x 101
95 x 106
100 x 114
110 x 124
120 x 134
130 x 148
140 x 158
150 x 168
160 x 178
170 x 191
180 x 201
190 x 211
200 x 224
210 x 234
220 x 244
230 x 257
240 x 267
250 x 280
260 x 290
270 x 300
280 x 313
290 x 323
300 x 333
320 x 360
340 x 380
360 x 400
380 x 420
400 x 440
420 x 460
440 x 480
1)
Distance dimension
A [mm]
B
B1
14
14
17
17
17
17
21
21
21
28
28
28
28
33
33
33
38
38
38
43
43
48
48
48
53
53
53
65
65
65
65
65
65
65
12.2
12.2
15
15
15
15
18.7
18.7
18.7
25.3
25.3
25.3
25.3
30
30
30
34.5
34.5
34.5
39.5
39.5
44
44
44
49
49
49
59
59
59
59
59
59
59
Clamping elements
1
2
3
4
4
5
6
7
4
5
6
7
5
6
7
8
5
6
7
8
5
6
7
8
5
6
8
9
5
6
8
9
5
6
8
9
5
6
8
9
6
7
9
11
6
7
9
11
6
7
9
11
6
7
9
11
7
8
10 12
7
8
10 12
7
9
10 12
7
9
11 13
7
9
11 13
7
9
11 13
7
9
12 14
7
9
12 14
8
10 13 16
8
10 13 16
8
10 13 16
9
11 14 17
9
11 14 17
9
11 14 17
10 15 20 25
10 15 20 25
10 15 20 25
10 15 20 25
10 15 20 25
10 15 20 25
10 15 20 25
Clamping screws
clamping force required
total = 0.14
P = PO + PS
PO [kN] PS [kN] A
[kN]
31
181
212
34
184
218
48
241
289
45
260
305
43
276
319
41
290
331
61
386
447
65
393
458
60
391
451
96
573
669
89
618
707
84
674
758
79
833
912
118
1054
1172
112
1082
1194
106
1166
1272
133
1425
1558
127
1532
1659
122
1587
1709
165
1579
1744
158
1801
1959
188
1912
2100
181
1997
2178
174
2077
2251
205
2381
2586
221
2457
2678
214
2544
2758
291
3275
3566
275
3474
3749
261
3677
3938
269
3870
4139
256
4091
4347
244
4290
4534
234
4492
4726
Transmittable
torque
or axial force
T
Fax
[Nm]
[kN]
1400
39
1500
40
2100
52
2400
56
2700
60
3000
63
4200
84
4700
85
5100
85
8100
124
9400
134
11000
146
14500
181
19500
229
21200
235
24100
253
31000
310
35000
333
38000
345
39500
343
47000
391
52000
416
56500
434
61000
451
72500
517
77500
534
83000
553
114000
712
128500
755
144000
800
160000
842
178000
890
196000
933
215000
977
Surface pressure
between clamp2
ing set [N/mm ]
Shaft
Hub
PW
PN
121
107
116
104
116
102
117
104
118
105
118
105
119
105
110
98
100
90
101
88
101
89
103
92
119
107
119
106
116
104
118
106
119
106
122
110
121
109
100
90
110
99
100
90
101
90
101
91
100
90
100
90
100
90
100
89
100
89
100
90
100
90
100
91
100
91
100
92
Replacing:
Replaced by:
KTR-N dated 2017-04-27
Weight
~ kg
0.11
0.12
0.12
0.2
0.2
0.22
0.4
0.4
0.5
0.85
0.91
0.97
1.02
1.5
1.6
1.7
2.3
2.5
2.5
3.4
3.5
4.7
4.8
4.9
6.3
6.5
6.7
10.9
11.5
12.2
12.8
13.5
14.1
14.7
Other sizes on request
PO = Setting force
PS = Clamping force
PA = Total force
Please observe protection
note ISO 16016.
Drawn:
Verified:
2017-11-29 Shg/Jh
2017-11-29 Shg
CLAMPEX® KTR 150
Operating/Assembly instructions
1
KTR-N
Sheet:
Edition:
40812 EN
4 of 9
7
Technical data
Calculation of torque with clamping elements positioned in a row multiple times
Ttotal = Tsingle ∙ 1.00
Ttotal = Tsingle ∙ 1.55
Ttotal = Tsingle ∙ 1.85
Ttotal = Tsingle ∙ 2.02
1 clamping element
2 clamping elements
3 clamping elements
4 clamping elements
Calculation of pressure flange
Recommended dimensions of
pressure flanges:
N1 [mm] ≥ 1.5 ∙ B
D2 [mm] = D + 12 + M
F1 [mm] = M ∙ 1.3 (with screws 8.8)
Illustration 2: Dimensions for calculation of pressure flange
2
F1 [mm] = M ∙ 1.8 (with screws 10.9/12.9)
Advice
2.1 General advice
Please read through these operating/assembly instructions carefully before you mount the clamping set.
Please pay special attention to the safety instructions!
The operating/assembly instructions are part of your product. Please store them carefully and close to the clamping set.
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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2017-11-29 Shg/Jh
2017-11-29 Shg
Replacing:
Replaced by:
KTR-N dated 2017-04-27
CLAMPEX® KTR 150
Operating/Assembly instructions
2
KTR-N
Sheet:
Edition:
40812 EN
5 of 9
7
Advice
2.3 General hazard warnings
STOP
With assembly and disassembly of the clamping set it has to be made sure that the entire
drive train is secured against accidental switch-on. You may be seriously hurt by rotating
parts. Please make absolutely sure to read through and observe the following safety indications.
 All operations on and with the clamping set have to be performed taking into account "safety first".
 Please make sure to switch off the power pack before you perform your work on the clamping set.
 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 operation area of the machine as long as it is in operation.
 Please secure the rotating drive components against accidental contact. Please provide for the necessary
protection devices and covers.
2.4 Intended use
You may only assemble and disassemble the clamping set if you
 have carefully read through the operating/assembly instructions and understood them
 had technical training
 are authorized by your company
The clamping set may only be used in accordance with the technical data (see table 1). Unauthorized modifications on the clamping set 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 clamping set described in here corresponds to the technical status at the time of printing of these operating/assembly instructions.
3
Storage, transport and packaging
3.1 Storage
The clamping sets are supplied in preserved condition and can be stored at a dry and covered place for 6 - 9
months.
!
Humid storage rooms are not suitable.
Please make sure that condensation is not generated.
3.2 Transport and packaging
!
In order to avoid any injuries and any kind of damage please always make use of proper
transport and lifting equipment.
The clamping sets are packed differently each depending on size, quantity and kind of transport. Unless otherwise contractually agreed, packaging will follow the in-house packaging specifications of KTR.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2017-11-29 Shg/Jh
2017-11-29 Shg
Replacing:
Replaced by:
KTR-N dated 2017-04-27
CLAMPEX® KTR 150
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
40812 EN
6 of 9
7
Assembly
Generally the clamping set is supplied in mounted condition. Before assembly the clamping set has to be inspected for completeness.
4.1 Components of clamping set
®
Components of clamping set CLAMPEX KTR 150
Component
1
2
Quantity
1
1
Description
Internal taper ring
External taper ring
Illustration 3: Components of clamping set

Dirty or used clamping elements have to be disassembled and cleaned before assembly.
Afterwards apply thin fluid oil lightly (e. g. Ballistol Universal oil or Klüber Quietsch-Ex).
Please observe protection
note ISO 16016.
Drawn:
Verified:
2017-11-29 Shg/Jh
2017-11-29 Shg
Replacing:
Replaced by:
KTR-N dated 2017-04-27
KTR-N
Sheet:
Edition:
CLAMPEX® KTR 150
Operating/Assembly instructions
4
40812 EN
7 of 9
7
Assembly
4.2 Assembly of clamping set

Inspect the fit of shaft and hub for the tolerance specified (see illustration 1).

Clean the hub bore and shaft and afterwards apply a thin-fluid oil (e. g. Ballistol Universal oil or Klüber Quietsch-Ex).
!
Oils and greases with molybdenum disulphide or other high-pressure additives, additives of
Teflon and silicone as well as internal lubricants reducing the coefficient of friction significantly must not be used. When mounting the tapers of the clamping set free from oil the
tabular and calculated parameters deviate.

Shift the hub onto the shaft.

If there is a recess, it has to be bridged via a distance ring (see illustration 4 and 5). The distance ring can be
done without if the recess is missing.

"wrong"
"right"
Illustration 4: Clamping element in recess
Illustration 5: Distance ring in recess
If several KTR 150 ring pairs (4 ring pairs at the maximum) are installed, make sure uniform arrangement of
KTR 150 elements (see illustration 6 and 7).
"wrong"
"right"
Illustration 6: Wrong installation of several clamping elements
Illustration 7: Installation of several clamping elements

Observe distance dimension A (see illustration 8, 9
and 10).
Illustration 8: Observe distance dimension A
Please observe protection
note ISO 16016.
Drawn:
Verified:
2017-11-29 Shg/Jh
2017-11-29 Shg
Replacing:
Replaced by:
KTR-N dated 2017-04-27
KTR-N
Sheet:
Edition:
CLAMPEX® KTR 150
Operating/Assembly instructions
4
40812 EN
8 of 9
7
Assembly
4.2 Assembly of clamping set

Do not assemble the clamping element in a clamping position, make sure easy shifting.

The pressure flange can optionally be assembled either with a collar or distance ring. Make sure easy shifting
as well.

Tighten the clamping screws lightly and align the clamping set.

Tighten the screws evenly crosswise step by step to the tightening torque TA specified in table 2. Repeat this
process until all clamping screws have reached the tightening torque. Inspect the remaining gap A for uniformity (see illustration 9 and 10).

If possible, repeat the previous item after test run.
Illustration 9: Assembly 1
Clamping on hub side
Component
1
2
3
Quantity
1
1
1

Description
Internal taper ring
External taper ring
Pressure flange
Illustration 10: Assembly 2
Clamping on shaft side
Component
Quantity
Description
4
Acc. to
selection
Cap screw DIN EN ISO 4762
During assembly the hub is not displaced axially towards the shaft with KTR 150.
Table 2: Screws
Dimensions M
M3
M4
M5
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
Please observe protection
note ISO 16016.
Preload force FV and tightening torque TA with total = 0.14
Preload force FV [N]
Tightening torque TA [Nm]
8.8
10.9
12.9
8.8
10.9
12.9
2210
3110
3730
1.34
1.89
2.25
3900
5450
6550
2.9
4.1
4.9
6350
8950
10700
6
8.5
10
9000
12600
15100
10
14
17
16500
23200
27900
25
35
41
26200
36900
44300
49
69
83
38300
54000
64500
86
120
145
52500
74000
88500
135
190
230
73000
102000
123000
210
295
355
88000
124000
148000
290
405
485
114000
160000
192000
410
580
690
141000
199000
239000
550
780
930
164000
230000
276000
710
1000
1200
215000
302000
363000
1050
1500
1800
262000
368000
442000
1450
2000
2400
Drawn:
Verified:
2017-11-29 Shg/Jh
2017-11-29 Shg
Replacing:
Replaced by:
KTR-N dated 2017-04-27
CLAMPEX® KTR 150
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
40812 EN
9 of 9
7
Assembly
4.3 Disassembly of clamping set
Parts released or falling down may cause injury to persons or damage on the machine.
Secure the components before disassembly.
STOP

Untighten and unscrew all clamping screws evenly one after another.

The clamping elements are not self-locking. If the internal and external taper ring are still stuck, the process of
releasing should be initiated by putting light pressure on the hub in several positions on the circumference or
the hub.

Remove the clamping elements released between shaft and hub.
If these hints are not observed or operating conditions are not considered with the selection
of the clamping element, the operation of the clamping element may be affected.
!
5
Disposal
In respect of environmental protection we would ask you to dispose of the packaging or products on termination of
their service life in accordance with the legal regulations and standards that apply, respectively.
All clamping sets consist of metal. Any metal components have to be cleaned and disposed of by scrap metal.
6
Spares inventory, customer service addresses
A basic requirement to ensure the readiness for use of the drive components is a stock of some clamping sets on
site.
Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage at
www.ktr.com.

7
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.
Advice regarding the use in
rective 2014/34/EU
potentially explosive atmospheres according to EU di-
If used in potentially explosive atmospheres the type and size of clamping set (for category 3 only) has to be selected such that the difference between the peak torque of the machine including all operating parameters and the
rated torque of the clamping hub at least corresponds to a safety factor of s = 2.
®
CLAMPEX clamping sets are not part of directive 2014/34/EU, since

this product is a torsionally rigid, backlash-free, frictionally engaged connection with one or more taper clamping ring(s) by means of several screws.
(Clamping screws have to be secured, e. g. by means of a medium strength adhesive.)

due to the design of clamping sets a fracture/failure is not likely (frictional heat is only caused by improper
assembly/tightening torques, i. e. not with intended use).
Please observe protection
note ISO 16016.
Drawn:
Verified:
2017-11-29 Shg/Jh
2017-11-29 Shg
Replacing:
Replaced by:
KTR-N dated 2017-04-27
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