KTR KTR-SI FRA Operating/Mounting Instructions

KTR-SI FRA
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46312 EN
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1
KTR-SI FRA
Type FT
(Flange type)
KTR-SI FRA
Type FT
KTR-SI FRA
®
Type FT with torsionally flexible POLY-NORM
Please observe protection
note ISO 16016.
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---
KTR-SI FRA
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46312 EN
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1
KTR-SI FRA is a torque limiting and idle rotating overload system with positive locking. It protects
adjacent components from damage.
Re-engagement is generated by reversing the direction of rotation.
Table of contents
1
Technical data
3
2
Advice
4
2.1
2.2
2.3
2.4
2.5
2.6
4
5
5
5
6
6
3
4
General advice
Safety and advice symbols
General hazard warnings
Intended use
Selection of overload system
Reference to EC Machinery Directive 2006/42/EC
Storage, transport and packaging
6
3.1
3.2
6
6
Storage
Transport and packaging
Assembly
7
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
7
8
8
9
9
10
11
13
13
Components of the couplings
Advice for finish bore
Assembly (general)
Assembly of the KTR-SI FRA overload system
Assembly of KTR-SI FRA with torsionally flexible POLY-NORM® coupling
Torque setting - KTR-SI FRA
Torque setting diagrammes
Advice for the use of drive components
Assembly of limit switch
5
Re-engagement of overload system
14
6
Breakdowns, causes and elimination
14
7
Disposal
15
8
Maintenance and service
16
9
Spares inventory, customer service addresses
16
Please observe protection
note ISO 16016.
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KTR-SI FRA
Operating/Assembly instructions
1
46312 EN
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1
Technical data
Illustration 1: KTR-SI FRA - type FT
Table 1: Dimensions and weights
Dimensions [mm]
Size
2
3
4
5
Max. bore
d
35
45
55
80
D j7
D1
D2
D3
D4
DA
75
95
122
155
92
114
144
184
70
77
88
152
98
131
147
196
114
149
166
223
140
184
203
279
Dimensions [mm]
Size
2
3
4
5
l1
l2
l3
l4
l5
L
z
63
69
75
94
45
42
46
70
4.7
4.7
4.7
6.3
14
15
15
23
3.5
4.0
2.3
108
111
121
164
6xM8
7xM10
8xM12
8xM16
Weight with
max. bore
[kg]
5
10
13
32
1) Dimensions H=stroke see table 7
Table 2: Torques and speed
Size
2
3
4
5
T1
5-20
24-104
45-210
90-415
Please observe protection
note ISO 16016.
Adjustable torques [Nm] of disk spring layers
T2
T3
15-70
40-135
57-360
110-540
145-435
340-960
240-640
490-1880
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Max. speed [rpm]
T4
80-260
245-730
465-1320
1060-3000
Replacing:
Replaced by:
3600
3600
2000
2000
---
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KTR-SI FRA
Operating/Assembly instructions
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46312 EN
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Technical data
Illustration 2: KTR-SI FRA - type FT with torsionally flexible POLY-NORM® coupling
Table 3: Dimensions and torques
POLY-NORM®
Size
Size
2
3
4
5
55
75
85
100
Cap screws DIN 7984
- 8.8
Dimensions [mm]
Torque [Nm]
TKN
TKmax
300
600
850
1700
1350
2700
2900
5800
Max. bore
d
d1
35
60
45
70
55
90
80
110
D
DH
l5
s
LG
Mxl
TA [Nm]
90
123
139
165
118
158
182
224
55
75
85
100
5
5
5
6
189.3
218.8
257.6
326.2
M8x20
M10x20
M12x25
M16x30
23
46
79
195
1) Dimensions H=stroke see table 7
Table 4: Torques and speed
Size
2
3
4
5
2
T1
5-20
24-104
45-210
90-415
Adjustable torques [Nm] of disk spring layers
T2
T3
15-70
40-135
57-360
110-540
145-435
340-960
240-640
490-1880
Max. speed [rpm]
T4
80-260
245-730
465-1320
1060-3000
3600
3600
2000
2000
Advice
2.1 General advice
Please read through these operating/assembly instructions carefully before you start up the overload system.
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
overload system. The copyright for these operating/assembly instructions remains with KTR.
Please observe protection
note ISO 16016.
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KTR-SI FRA
Operating/Assembly instructions
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Advice
2.2 Safety and advice symbols
STOP
!

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 overload system 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 overload system 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 overload system.
 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 overload system as long as it is in operation.
 Please secure the overload system against accidental contact. Please provide for the necessary protection
devices and covers.
2.4 Intended use
You may only assemble, operate and maintain the overload system if you
 have carefully read through the operating/assembly instructions and understood them
 had technical training
 are authorized by your company
The overload system may only be used in accordance with the technical data (see chapter 1). Unauthorized
modifications on the overload system 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 KTR-SI FRA described in here corresponds to the state of the art at the time of printing of these
operating/assembly instructions.
Please observe protection
note ISO 16016.
Drawn:
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KTR-SI FRA
Operating/Assembly instructions
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Advice
2.5 Selection of overload system
For a long-lasting and failure-free operation of the overload system the overload system
(with coupling, where appropriate) must be selected according to the selection instructions
for the particular application (see catalogue drive technology "KTR-SI").
If the operating conditions (performance, speed, modifications on engine and machine)
change, the coupling selection must be reviewed.
The transmittable torque of the shaft-hub-connection must be reviewed by the customer and
is subject to his responsibility.
!
Please observe the potential operating temperature from -30 °C to +90 °C of KTR-SI FRA.
!

We recommend to use a limit switch or something similar to switch off the drive in case of overload
as quickly as possible.
2.6 Reference to EC Machinery Directive 2006/42/EC
The overload systems 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 please refer to the
present operating/assembly instructions considering the warnings.
3
Storage, transport and packaging
3.1 Storage
The overload systems are supplied in preserved condition and can be stored at a dry and roofed place for 6 - 9
months.
!
Humid storage rooms are not suitable.
Please 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 please always make use of proper
transport and lifting equipment.
The overload systems/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.
Please observe protection
note ISO 16016.
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KTR-SI FRA
Operating/Assembly instructions
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Assembly
The overload system is supplied in assembled condition.
4.1 Components of the couplings
Component asssembly 1: Components of KTR-SI FRA - type FT
Component
1
2
3
4
5
6
7
Quantity
1
1
1
1
1
1
1
Description
Connection flange
Slide bearing
Axial disk
Hub
Axial bearing
Bearing flange
Flange ring
Component
8
9
10
11
12
13
14
Quantity
1
1
1
1
1
1
1
Description
Balls (set)
Shifting ring
Springs (set)
Pressure ring
Lock washer
Setting nut
Locking screw
Illustration 3: KTR-SI FRA - type FT
Components of KTR-SI FRA - type FT with torsionally flexible POLY-NORM® coupling
Component/
subassembly
Quantity
1
1
2
3
1
1
Description
KTR-SI FRA
(complete overload system)
®
POLY-NORM SI flange
®
POLY-NORM elastomer ring
Component/
subassembly
4
Quantity
Description
1
POLY-NORM hub
Cap screws
DIN 7984 - 8.8
Setscrew DIN EN ISO 4029
5
6
6
1
®
Illustration 4: KTR-SI FRA - type FT with torsionally flexible POLY-NORM® coupling
Please observe protection
note ISO 16016.
Drawn:
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Operating/Assembly instructions
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Assembly
4.2 Advice for finish bore
A subsequent modification of the finish bore by the customer is not permissible.
STOP
Table 5: Recommended fit pairs acc. to DIN 748/1
Bore [mm]
above
up to
50
50
Shaft tolerance
Bore tolerance
k6
m6
H7
(KTR standard)
If a feather keyway is intended to be used in the hub, it should correspond to the tolerance ISO JS9 (KTR
standard) with normal operating conditions or ISO P9 with difficult 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 (general)

We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
®
Heating the KTR-SI FRA overload system respectively POLY-NORM hub lightly
(approx. 80 °C) allows for easier mounting on the shafts.
STOP
Touching the heated coupling or hub causes burns.
Please wear safety gloves.

During assembly of the overload system it is not allowed to generate any forces
(e. g. by hammer blows or mounting equipment) on the pressure ring (component 11) or
setting nut (component 13) (see illustration 5).
 Please make sure the perfect technical condition of the KTR-SI FRA overload system.
 Please only use original KTR components (no purchased parts).
Please observe protection
note ISO 16016.
Drawn:
Verified:
2018-07-16 Pz/Rt
2018-07-19 Pz
Replacing:
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KTR-SI FRA
Operating/Assembly instructions
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Assembly
4.4 Assembly of the KTR-SI FRA overload system
 Mount the KTR-SI FRA flange type (component 1) on the
shaft of the driving or driven side.
 Provide for an end plate to fasten the KTR-SI FRA
overload system axially (see illustration 5).
Illustration 5
4.5 Assembly of KTR-SI FRA with torsionally flexible POLY-NORM® coupling

Please consider our operating/assembly instructions KTR-N 49510 additionally when using
®
the POLY-NORM coupling.
 Mount the KTR-SI FRA overload system (subassembly
®
1) respectively POLY-NORM hub (component 4) on
the shafts of the driving or driven side.
 Provide for an end plate to fasten the KTR-SI FRA
overload system axially (see illustration 5 in chapter
4.4).
 Hand-tighten the POLY-NORM -SI flange (component
2) with the KTR-SI FRA overload system first.
®
 Tighten the cap screws crosswise by a suitable torque
key to the tightening torques T A specified in table 3
(see chapter 1).
Illustration 6: KTR-SI FRA Type FT with torsionally flexible POLY-NORM® coupling
 Insert the POLY-NORM elastomer ring (component 3)
®
into the cam section of the POLY-NORM hub.
®
 Shift the power packs in axial direction until the
distance dimension s is achieved (see illustration 7).
 If the power packs are already firmly assembled,
®
shifting the POLY-NORM hub axially on the shaft
allows for setting the dimension s.
 Fasten the POLY-NORM hub by tightening the
setscrew DIN EN ISO 4029 with a cup point (tightening
torques TA see KTR-N 49510).
®
Illustration 7: Assembly of coupling
!
With the assembly please make sure that the distance dimension s (see table 3) is observed
so that the coupling components are not in contact with each other during the operation.
Disregarding this advice may cause damage to the coupling.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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Assembly
4.6 Torque setting - KTR-SI FRA
Depending on the layering of the disk
springs used the requested torque can
be set by adjusting the torque of the
setting nut:
 Fix the hub (component 4) to avoid
twisting.
 Unscrew the locking screw
(component 14).
Illustration 8: KTR-SI FRA - type FT
 Screw the setting nut (component 13) manually to the springs (component 10) against a stop
(zero point  backlash-free prestress of spring).
 Choose any reference point of the setting nut (component 13) versus a scale mark of the lock washer
(component 12, with size 2 scale marks on the pressure ring (component 11).
 Insert the face spanner (see table 6) into the respective
bores of the setting nut (see illustration 14).
 The accurate torque is adjusted by turning the setting nut
(component 13) clockwise.

With torque setting please observe the
setting diagrammes of the respective sizes
(see diagramme 1 to 4 in chapter 4.7).
 Having set the torque the setting nut (component 13) is
secured against working loose by means of the locking
screw (component 14).
Illustration 9: Torque setting
Once the KTR-SI FRA has been set to the required torque as per these operating/mounting instructions, the
figure of the ratchet torque can be considered as a reference value only. For a more accurate setting the ratchet
torque should be inspected by means of a suitable measuring system. In order to achieve the optimum accuracy,
the ratchet torque has to be reinspected after the initial ratchings and reset, if necessary.
Table 6: Tools for torque setting
Hook spanner
DIN 1810-A
Jointed pin wrench
Jointed face wrench
Ø80-90
Ø60-90x4
Ø40-80x5
Ø95-100
Ø180-195
Ø90-155x8
Ø165-230x10
Ø80-125x6
Ø125-200x8
Size
2
3
4
5
Please observe protection
note ISO 16016.
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KTR-SI FRA
Operating/Assembly instructions
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KTR-N
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Assembly
4.7 Torque setting diagrammes
Diagramme 1: KTR-SI FRA - size 2
Diagramme 2: KTR-SI FRA - size 3
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note ISO 16016.
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KTR-SI FRA
Operating/Assembly instructions
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Assembly
4.7 Torque setting diagrammes
Diagramme 3: KTR-SI FRA - size 4
Diagramme 4: KTR-SI FRA - size 5
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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Assembly
4.8 Advice for the use of drive components
With the use of drive components such as sprockets, belt pulleys or gear wheels radial forces may be expected
during operation. The customer should provide for a separate bearing of the drive component. The non-positive
connection of the drive components with the overload hub is done by screwing using usual standard screws of
property class 10.9.
 If torsional vibrations of the overall drive have to be expected, we would recommend to lock the screw by
means of a suitable screw lock.
 Do not give any axial pressure on the overload system. The drive element needs a corresponding bearing.
4.9 Assembly of limit switch
The limit switch should be mounted to the washer of the pressure ring (component 11) (see illustration 10). The
position and dimensions of the pressure ring are specified in table 7.
Table 7: Position of limit switch
Size
2
3
4
5
l2
45
42
46
70
Dimensions [mm]
ØDA
140
184
203
279
H=stroke
2.8
3.5
3.5
4.4
Illustration 10: Mechanical limit switch
Function
The axial stroke of the pressure ring generated with overload may activate a mechanical limit switch or an
inductive sensor. As a result a control signal is generated which can be evaluated for disengaging the drive.
Assembly
The sensor needs to be mounted in a solid device to ensure a smooth operation. The sensor should be protected
from dirt and potential mechanical faults.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2018-07-16 Pz/Rt
2018-07-19 Pz
Replacing:
Replaced by:
---
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Operating/Assembly instructions
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Assembly
4.9 Assembly of limit switch
Adjustment
When the overload system disengages, the pressure ring makes an axial thrust (see table 7). The sensor or limit
switch, respectively, has to be mounted within this shifting range. In order to adapt the mechanical limit switch and
the shifting travel to the machine, the limit switch has to be adjusted accordingly.
!
5
We recommend using a limit switch!
Please absolutely observe the operation of the limit switch before the machine is supplied.
Please also observe the operating instructions for the sensor or limit switch, respectively.
The axial stroke of the shifting ring must not be blocked by any other components.
As soon as the limit switch or sensor is activated (overload: release of overload system) the
drive should immediately be stopped (< 1 minute).
With higher speeds respective braking devices may be necessary.
Re-engagement of overload system
We recommend to switch off the drive as quickly as possible once an overload occurs.
The KTR-SI FRA is re-engaged by reversing the direction of rotation. In this case it is important to make sure that
re-engagement is generated with a slow speed (< 50 rpm).
6
Breakdowns, causes and elimination
The below-mentioned failures can result in a use of the KTR-SI FRA overload system other than intended. In
addition to the specifications given in these operating and assembly instructions please 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.
General failures with improper use:









Important data for the selection of the overload system were not forwarded.
The calculation of the shaft-hub-connection was not considered.
Components with damage occurred during transport are assembled.
If the heated hubs are assembled, the permissible temperature is exceeded.
The clearance of the components to be assembled is not coordinated with one another.
Tightening torques have been fallen below/exceeded.
Components are mixed up by mistake/assembled incorrectly.
No original KTR components (purchased parts) are used.
Maintenance intervals are not observed.
Please observe protection
note ISO 16016.
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Verified:
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Operating/Assembly instructions
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Breakdowns, causes and elimination
Breakdowns
Different operating
noise and/or
vibrations occuring
The overload system
releases in an
undefined position.
The overload system
does not release in
case of overload.
KTR-SI FRA with
®
POLY-NORM
Torque is no longer
transmitted
®
POLY-NORM
7
KTR-N
Sheet:
Edition:
Causes
Elimination
1) Set the unit out of operation
2) Eliminate the reason for the misalignment (e. g. loose
Misalignment
foundation bolts, breaking of the engine mount, heat expansion
of unit components, modification of the mounting dimension s of
the coupling)
1) Set the unit out of operation
2) Inspect coupling components and replace coupling components
that have been damaged
Screws working loose
3) Tighten the dowel screws until the permissible tightening torque
has been reached
4) Inspect alignment, adjust if necessary
1) Set the unit out of operation
Screws/fastening screw for
2) Inspect alignment of coupling
axial fastening of flange hubs
3) Tighten the screws to fasten the flange hubs and secure against
working loose
working loose
1) Set the unit out of operation
Faulty storage
2) Send the overload system to KTR for inspection/repair.
1) Set the unit out of operation
2) Disassemble the coupling and remove remainders of the
Wear of elastomer ring, shortelastomer ring
term torque transmission due to 3) Inspect coupling components and replace components that
metal contact
have been damaged
4) Insert elastomer ring, assemble components
5) Inspect alignment, adjust if necessary
Torque is not set
1) Set the unit out of operation
Torque set incorrectly
2) Adjust torque, see chapter 4.6 and 4.7
Setting nut has worked loose
1) Set the unit out of operation
2) Send the overload system to KTR for inspection/repair.
Wear
®
POLY-NORM flange has
worked loose
1) Set the unit out of operation
2) Tighten the fastening screws
Please consider our operating/assembly instructions KTR-N 49510 additionally when using the
®
POLY-NORM coupling.
See chapter 6 Breakdowns, causes and elimination
Disposal
In respect of environmental protection we would ask you to dispose of the packaging or products on termination of
their service life in accordance with the legal regulations and standards that apply, respectively.
 Metal
Any metal components have to be cleaned and disposed of by scrap metal.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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Maintenance and service
KTR-SI FRA is a low-maintenance overload system. It is finish bored and provided with grease filling. We
recommend to perform a visual inspection on the overload system at least once a year. With normal drive
conditions this grease filling is sufficient during the overall service life. In case of extreme drive conditions or
heavy dirt, respectively, the KTR-SI FRA has to be regularly inspected for its operation.
 Since the flexible machine bearings of the driving and driven side settle during the course of load, inspect the
alignment and re-align the coupling/the overload system, if necessary.
 The components have to be inspected for damages.
 The screw connections have to be inspected visually.
Having started up the overload system the tightening torques of the screws have to be
inspected during the usual inspection intervals.
!
9
Spares inventory, customer service addresses
A basic requirement to ensure the readiness for use 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 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.
Please observe protection
note ISO 16016.
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