KTR KTR-SI Operating/Mounting Instructions
KTR KTR-SI is a torque limiting overload system that protects adjacent components from damage in case of overload. It offers various types, including DK (ratchet design), SR (synchronous design), FR (idle rotation design), and SGR (fail-safe synchronous design). Each type has specific features and re-engagement mechanisms that can be selected based on the application requirements. KTR-SI is designed for different sizes (0 to 7) and can be combined with a torsionally flexible ROTEX® coupling. This manual explains how to assemble and configure KTR-SI based on the specific type and size chosen.
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KTR-SI Operating/Assembly instructions KTR-N Sheet: Edition: 46310 EN 1 of 22 4 KTR-SI Type DK (ratchet design) Type SR (synchronous design) KTR-SI size 0 to 5 Type FR (Idle rotation design) Type SGR (fail-safe synchronous design) KTR-SI size 6 to 7 KTR-SI with torsionally flexible ROTEX® coupling Please observe protection note ISO 16016. Drawn: Verified: 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-SI Operating/Assembly instructions KTR-N Sheet: Edition: 46310 EN 2 of 22 4 KTR-SI is a torque limiting overload system with positive locking operation protecting adjacent components from damage. • In case of overload type DK (ratchet design) re-engages every 15° with the next following ball indentation. • In case of overload type SR (synchronous design) re-engages after a rotation of 360°. • Type FR (idle rotation design) remains separated with overload. The overload system re-engages manually or via a mechanism with standstill of machine. • Type SGR (fail-safe synchronous design) is purely intended for torque measurement without any ratchet operation. In case of overload a signal is generated by a limit switch along with mechanical separation of driving and driven side = ratching is not possible. 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 Intended use Coupling selection 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 Components of the couplings 4.2 Layering of disk springs 4.3 Advice for finish bore 4.4 Assembly (general) 4.5 Assembly of the KTR-SI coupling 4.6 Assembly of KTR-SI with torsionally flexible ROTEX® coupling 4.7 Disassembly of the coupling / replacement of single parts 4.8 Assembly of the coupling 4.9 Torque setting - KTR-SI size 0 to 5 4.10 Torque setting - KTR-SI size 6 to 7 4.11 Setting diagrammes - type DK 4.12 Setting diagrammes - type SR/SGR 4.13 Setting diagrammes - type FR 4.14 Advice for the use of drive components 4.15 Assembly of limit switch 7 8 9 10 10 10 11 12 12 13 14 16 17 18 19 5 Re-engagement of KTR-SI design FR 20 6 Breakdowns, causes and elimination 20 7 Disposal 21 8 Maintenance and service 22 9 Spares inventory, customer service addresses 22 Please observe protection note ISO 16016. Drawn: Verified: 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-N Sheet: Edition: KTR-SI Operating/Assembly instructions 1 46310 EN 3 of 22 4 Technical data Illustration 1: KTR-SI type FT Illustration 2: KTR-SI type KT Illustration 3: KTR-SI type LT Table 1: Dimensions and weights Dimensions [mm] Size Bore d Pilot bore Max. 7 20 10 25 14 35 18 45 24 55 30 65 40 80 50 100 0 1 2 3 4 5 6 7 d1 D D1 D2 DA l1 l2 l3 l4 41.0 60.0 78.0 90.5 105.0 120.5 136.0 168.0 28 38 52 65 78 90 108 135 38 50 60 80 100 120 130 160 48 70 89 105 125 155 160 200 55 82 100 120 146 176 200 240 4.0 4.0 5.0 5.0 6.5 6.5 7.0 8.0 6.5 8.0 10.0 12.0 15.0 17.0 20.0 25.0 3.0 6.0 5.0 8.5 11.0 12.0 14.0 15.0 7.5 11.5 12.0 21.0 27.0 33.0 39.0 46.0 Dimensions [mm] Size 0 1 2 3 4 5 6 7 l5 l6 l7 l8 L L1 L2 z SW 9 9 9 10 9 9 9 9 8 10 12 12 16 18 20 25 27.5 33.0 39.0 47.0 52.5 57.5 64.0 72.0 15 21 38.5 52.0 61.0 78.0 100.0 113.5 119.0 141.0 51.0 70.0 78.0 96.0 124.5 140.0 150.0 175.0 66.0 85.0 100.0 125.0 152.5 171.0 183.0 213.0 6 x M5 6 x M5 6 x M6 6 x M8 6 x M10 2) 6 x M12 2) 6 x M12 2) 6 x M16 2) 30 24 Weight with max. bore [kg] 0.41 1.30 2.27 3.88 8.34 13.51 21 37 1) Dimensions H=stroke see table 9 2) Type T4 SR and SGR: tightening torques according to 12.9 Table 2: Torques Size T1 0 1 2 3 4 5 6 7 Torques [Nm] Type SR and SGR Type DK T2 T3 T4 T1 T2 Type FR T3 T4 T1 T2 T3 nmax. 3) [rpm] 2.5-5 5-20 - 20-40 5-10 10-40 - - 5-10 10-20 20-40 6000 6-12 12-25 25-55 55-100 12-25 25-50 50-100 - 12-25 25-50 50-100 5000 12-25 25-50 50-120 120-200 25-50 50-100 100-200 - 25-50 50-100 100-200 4000 25-50 50-100 100-250 200-450 50-100 100-200 200-450 - 50-100 100-200 200-450 3500 50-100 100-200 200-500 500-1000 100-200 200-400 400-800 800-2000 100-200 200-400 400-800 3000 85-250 230-600 300-1000 600-2000 170-450 350-900 600-1800 1200-3400 170-450 350-900 600-1800 2300 180-480 360-960 720-1950 1600-3300 300-750 600-1500 1200-3000 2900-5800 - - - - 250-520 500-1050 1000-2100 2000-3600 550-1100 1100-2200 2200-4400 3000-8200 - - - - 3) Only valid for type FR Please observe protection note ISO 16016. Drawn: Verified: 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-N Sheet: Edition: KTR-SI Operating/Assembly instructions 1 46310 EN 4 of 22 4 Technical data Illustration 4: KTR-SI with torsionally flexible ROTEX® coupling Table 3: Dimensions Size 0 1 2 3 4 5 6 7 ROTEX® size 19 28 24 38 28 48 38 55 48 75 55 90 100 110 Dimensions [mm] Max. bore d d2 25 20 40 35 25 48 40 35 62 48 45 74 62 55 95 75 65 110 80 115 100 125 dH DH 18 30 27 38 30 51 38 60 51 80 60 100 113 127 40 65 55 80 65 105 80 120 105 160 120 200 225 255 DA 55 82 100 120 146 176 200 240 l9 l10 E 25 35 30 45 35 56 45 65 56 85 65 100 110 120 22.0 28.5 24.0 32.5 28.0 38.0 32.0 43.0 38.0 56.5 44.0 62.0 72.0 78.0 16 20 18 24 20 28 24 30 28 40 30 45 50 55 L LG 38.5 52.0 61.0 78.0 100.0 113.5 119.0 141.0 85.5 102.0 106.0 129.5 124.0 155.0 155.0 186.0 194.0 241.5 222.5 275.5 301.0 339.0 Cap screws DIN EN ISO 4762 - 12.9 Mxl TA [Nm] M5 x 10 2) M5 x 12 M5 x 10 M6 x 16 M6 x 12 M8 x 18 M8 x 16 M10 x 20 M12 x 30 M12 x 20 M12 x 30 M16 x 35 5.5 8.1 14 34 67 115 115 290 1) Dimensions H=stroke see table 9 2) DIN 6912 - 8.8 Table 4: Torques ROTEX® torque [Nm] 98 ShA TKN TKmax. Please observe protection note ISO 16016. 19 17 34 Drawn: Verified: 24 60 120 28 160 320 38 325 650 ROTEX® size 48 55 525 685 1050 1370 2023-06-02 Shg/Koh 2023-06-02 Shg 75 1920 3840 Replacing: Replaced by: 90 3600 7200 100 4950 9900 110 7200 14400 KTR-N dated 2017-02-10 KTR-SI Operating/Assembly instructions 2 KTR-N Sheet: Edition: 46310 EN 5 of 22 4 Advice 2.1 General advice Please read through these operating/assembly instructions carefully before you start up the coupling. 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 coupling. The copyright for these operating/assembly instructions remains with KTR. 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 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. Please 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". • Please 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. • Please secure the coupling against accidental contact. Please provide for the necessary protection devices and covers. Please observe protection note ISO 16016. Drawn: Verified: 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-SI Operating/Assembly instructions 2 KTR-N Sheet: Edition: 46310 EN 6 of 22 4 Advice 2.4 Intended use You may only assemble, operate and maintain the coupling if you • have carefully read through the operating/assembly instructions and understood them • had technical training • 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 KTR-SI 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 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. 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 please refer to the present operating/assembly instructions considering the warnings. 3 Storage, transport and packaging 3.1 Storage The couplings 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. 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 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. Drawn: Verified: 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-SI Operating/Assembly instructions 4 KTR-N Sheet: Edition: 46310 EN 7 of 22 4 Assembly The coupling is supplied in assembled condition. 4.1 Components of the couplings Components of KTR-SI size 0 to 5 Component 1 2 3 4 5 6 7 8 9 10 11 Quantity 1 1 1 1 1 1 1 see table 5 1 1 1 Description Hub Flange ring (type DK) Shifting ring (type DK) Ball bearing cage Lock washer Slide bush Setting nut Illustration 5: KTR-SI size 0 to 5 Disk springs (set) Axial needle bearing 1) Axial disk Locking screw 1) With size 0: bearing balls (1 set) Components of KTR-SI size 6 to 7 Component 1 2 3 6 7 9 12 13 14 15 Quantity Description 1 1 1 1 1 1 see table 6 6 1 Hub Flange ring (type DK) Shifting ring (type DK) Slide bush Setting nut Bearing balls (set) Setting screws Lock nut Setscrew DIN EN ISO 4029 Additional ring Illustration 6: KTR-SI size 6 to 7 Components of KTR-SI with torsionally flexible ROTEX® coupling Component 1 2 3 4 Quantity Description 1 1 1 1 KTR-SI (complete coupling) ROTEX®-SI flange 1) ROTEX® spider ROTEX® hub Cap screws DIN EN ISO 4762 - 12.9 2) Setscrew DIN EN ISO 4029 5 6 6 1 ® 1) from ROTEX size 75 with additional feather key on the front side 2) Size 0: Cap screws DIN 6912 - 8.8 Please observe protection note ISO 16016. Drawn: Verified: Illustration 7: KTR-SI with torsionally flexible ROTEX® coupling 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-N Sheet: Edition: KTR-SI Operating/Assembly instructions 4 46310 EN 8 of 22 4 Assembly 4.2 Layering of disk springs Layering of disk springs with KTR-SI size 0 to 5 Table 5: Disk springs Layering of disk springs Size T1 T2 0 to 5 0 to 5 T3 0 and 5 Type T4 1 to 4 0 1 to 4 5 4x1L 3x2L 3x2M DK, SR and SGR Illustration Designation 6x1S 5x1M Type 5x1M 5x1L FR Illustration Designation 2x1S 2x1M 2x1M 2x1L Arrangement of setting screw with KTR-SI size 6 to 7 Illustration 8: Structure of setting screw Table 6: Disk springs Layering of disk springs Size T1 6 Quantity of components 12.1, 12.3, 12.4, 13 T2 7 6 T3 7 3 6 6 T4 7 6 12 Type 7 12 DK Illustration Designation 13x1S 17x1S 13x1S Type 17x1S 13x1S 17x1S 11x1M 15x1M 15x1M 15x1M 13x1L SR and SGR Illustration Designation 17x1S Please observe protection note ISO 16016. 15x1M Drawn: Verified: 17x1S 15x1M 2023-06-02 Shg/Koh 2023-06-02 Shg 17x1S Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-SI Operating/Assembly instructions 4 KTR-N Sheet: Edition: 46310 EN 9 of 22 4 Assembly 4.3 Advice for finish bore The maximum permissible bore diameters d (see table 1 and 3 in chapter 1 - technical data) must not be exceeded. If these figures are disregarded, the coupling may tear. Rotating particles may cause danger to life. STOP • If the bore of the hub is machined by the customer, the coupling needs to be disassembled (see chapter 4.6). • Axial run-out or concentricity (see illustration 9) need to be adhered to. • Please make absolutely sure to observe the figures for Ø dmax. • Carefully align the hubs when the finish bores are drilled. 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. ! Table 7: 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.). (Applies only in combination with a ROTEX® coupling): The keyway should preferably be located between the cams. With axial fastening by setscrews the tapping should be located on the keyway with the exception of Al-D which should be located opposite to the keyway. The transmittable torque of the shaft-hub-connection must be reviewed by the customer and is subject to his responsibility. Please observe protection note ISO 16016. Drawn: Verified: 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-SI Operating/Assembly instructions 4 KTR-N Sheet: Edition: 46310 EN 10 of 22 4 Assembly 4.4 Assembly (general) We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy before assembly. Heating the KTR-SI coupling or ROTEX® hub lightly (approx. 80 °C) allows for an easier mounting on the shaft. STOP Touching the heated coupling or hub causes burns. Please wear safety gloves. When mounting the coupling, do not exert any force on the flange (component 2, see illustration 17) (e. g. by hammer blows or a mounting device). • Please make sure the perfect technical condition of the KTR-SI overload system. • Please only use original KTR components (no purchased parts). 4.5 Assembly of the KTR-SI coupling • Mount the KTR-SI coupling (component 1) on the shaft of driving or driven side. • Please provide for an end plate to fasten the KTR-SI coupling axially (see illustration 9 in chapter 4.3). 4.6 Assembly of KTR-SI with torsionally flexible ROTEX® coupling Please consider our operating/assembly instructions KTR-N 40210 additionally when using the ROTEX® coupling. • Mount the KTR-SI coupling (component 1) or ROTEX® hub (component 4) onto the shafts of the driving or driven side. • Please provide for an end plate to fasten the KTR-SI coupling axially (see illustration 9 in chapter 4.3). • Hand-tighten the ROTEX®-SI flange (component 2) with the KTR-SI coupling for the time being. • For sizes 5 to 7 an extra feather key is provided between component 1 and 2 (see illustration 10). Please observe protection note ISO 16016. Drawn: Verified: 2023-06-02 Shg/Koh 2023-06-02 Shg Illustration 10: KTR-SI with torsionally flexible ROTEX® coupling Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-SI Operating/Assembly instructions 4 KTR-N Sheet: Edition: 46310 EN 11 of 22 4 Assembly 4.6 Assembly of KTR-SI with torsionally flexible ROTEX® coupling • Tighten the screws crosswise by means of a suitable torque wrench to the tightening torques TA specified in table 3. • Insert the ROTEX® spider (component 3) into the cam section of the ROTEX® hub. • Shift the power packs in axial direction until the distance dimension E has been achieved (see illustration 11). • If the power packs are already firmly assembled, shifting the hubs axially on the shafts allows for adjusting the distance dimension E. • Fasten the hubs by tightening the setscrews DIN EN ISO 4029 with a cup point (tightening torque T A see KTR-N 40210). ! Illustration 11: Assembly of coupling With the assembly please make sure that the distance dimension E (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. 4.7 Disassembly of the coupling / replacement of single parts Only valid for size 0 to 5: • Disassemble the locking screw (component 11) and setting nut (component 7). • Remove the locking washer (component 5) from the hub. • Remove the disk springs (component 8) and the shifting ring (component 3). Illustration 12: KTR-SI size 0 to 5 Please note the disk spring layer for the assembly. Only valid for size 6 to 7: • Unscrew the locking nuts (component 13). • Turn the setting screw (component 12) counterclockwise until the disk spring is in contact with the setting nut (component 7). • Remove the setscrews (component 14) and afterwards disassemble the setting nut (component 7). Illustration 13: KTR-SI size 6 to 7 Continuation of disassembly with all sizes: • Remove the shifting ring (component 3) and flange ring (component 2) from the hub (component 1). • Remove the slide bush (component 6) and the axial needle bearing or bearing balls, respectively (component 9). ! For sizes 0, 6 and 7 bearing balls are mounted between hub (component 1) and flange ring (component 2) instead of the axial needle bearing (component 9) (see illustration 6 and 7). Please observe protection note ISO 16016. Drawn: Verified: 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-SI Operating/Assembly instructions 4 KTR-N Sheet: Edition: 46310 EN 12 of 22 4 Assembly 4.8 Assembly of the coupling The assembly is done in reverse order with the disassembly (see chapter 4.7). For that purpose please observe the exploded-view drawings illustration 12 and 13. Components lubricated by the manufacturer may have to be re-lubricated. ! Greasing by usual greases has to be done. Please note the disk spring layer for the assembly as per chapter 4.2. 4.9 Torque setting - KTR-SI size 0 to 5 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 1) to avoid twisting. • Unscrew the locking screw (component 11). • Screw the setting nut (component 7) manually to the disk springs (component 8) against a stop (zero point ➔ backlash-free prestress of disk spring). • Choose any reference point of the setting nut (component 7) versus a scale mark of the shifting ring (component 3). • Insert the face spanner (see table 8) into the respective bores of the adjusting nut (see illustration 14). • The accurate torque is adjusted by turning the setting nut (component 7) clockwise. With torque setting please note the adjusting diagrammes of the respective sizes (see diagramme 1 to 6 in chapter 4.10). • Having set the torque the setting nut (component 7) is secured against working loose by means of the locking screw (component 11). Illustration 14: Torque setting - KTR-SI size 0 to 5 Once the KTR-SI has been set to the required torque as per these operating/mounting instructions, the figure of the ratchet torque can be 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. Please observe protection note ISO 16016. Drawn: Verified: 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-SI Operating/Assembly instructions 4 KTR-N Sheet: Edition: 46310 EN 13 of 22 4 Assembly 4.9 Torque setting - KTR-SI size 0 to 5 Table 8: Tools for torque setting Hook spanner DIN 1810-A Jointed pin wrench Jointed face wrench Size 0 1 2 3 4 5 Ø40-42 Ø52-55 Ø68-75 Ø80-90 Ø110-115 Ø120-130 Ø18-40x4 Ø35-60x4 Ø40-80x5 Ø60-90x5 Ø80-125x6 Ø90-155x8 Ø125-200x8 4.10 Torque setting - KTR-SI size 6 to 7 Depending on the layering of the disk springs used the requested torque can be set by adjusting the torque of the setting nut: KTR supplies the coupling in pre-assembled condition as a standard. Continue with item 2 torque setting. If a new assembly has been performed or the buyer has made modifications subsequently, please go on with item 1 preparation of torque setting. 1. Preparation of torque setting • Fix the hub (component 1) to avoid twisting. • Unscrew the locking nuts (component 13). • Turn the adjusting screws (component 12) manually counter-clockwise against a stop (contact between internal disk springs and adjusting nut). • Remove each the first one out of the three setscrews arranged twice (component 14) and afterwards unscrew the second setscrew. • Turn the setting nut (component 7) manually against a stop. • Afterwards turn back the setting nut counterclockwise until the balance of the three setscrews is flush with three out of the total of six keyways of the hub. • Screw in the three setscrews (component 14) in order to lock the setting nut by positive fit on the hub. Afterwards counter the setscrews each by the second setscrew. Please observe protection note ISO 16016. Drawn: Verified: 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-SI Operating/Assembly instructions 4 KTR-N Sheet: Edition: 46310 EN 14 of 22 4 Assembly 4.10 Torque setting - KTR-SI size 6 to 7 2. Torque setting • Screw the adjusting screws (component 12) manually with only little effort to the disk springs (component 8) against a stop (➔ backlash-free contact between disk springs and shifting ring). • Tighten the adjusting screws (component 12) stepwise evenly in several revolutions (max. 360°) clockwise to the requested torque (6/6 corresponds to one complete revolution). The torque can be set by means of a hexagon socket wrench (component 16). With torque setting please observe the adjusting diagrammes of the respective sizes (see diagramme 7 to 8 in chapter 4.10). • Having set the torque the adjusting screws (component 12) are protected from working loose by locking nuts (component 13) (see illustration 15). Illustration 15: Torque setting - KTR-SI size 6 to 7 Once the KTR-SI has been set to the required torque as per these operating/mounting instructions, the figure of the ratchet torque can be 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. 4.11 Setting diagrammes - type DK Diagramme 1: KTR-SI 0 Please observe protection note ISO 16016. Drawn: Verified: Diagramme 2: KTR-SI 1 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-SI Operating/Assembly instructions 4 KTR-N Sheet: Edition: 46310 EN 15 of 22 4 Assembly 4.11 Setting diagrammes - type DK Diagramme 3: KTR-SI 2 Diagramme 4: KTR-SI 3 Diagramme 5: KTR-SI 4 Diagramme 6: KTR-SI 5 Diagramme 7: KTR-SI 6 Diagramme 8: KTR-SI 7 Please observe protection note ISO 16016. Drawn: Verified: 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-SI Operating/Assembly instructions 4 KTR-N Sheet: Edition: 46310 EN 16 of 22 4 Assembly 4.12 Setting diagrammes - type SR/SGR Diagramme 9: KTR-SI 0 Diagramme 10: KTR-SI 1 Diagramme 11: KTR-SI 2 Diagramme 12: KTR-SI 3 Diagramme 13: KTR-SI 4 Diagramme 14: KTR-SI 5 Please observe protection note ISO 16016. Drawn: Verified: 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-SI Operating/Assembly instructions 4 KTR-N Sheet: Edition: 46310 EN 17 of 22 4 Assembly 4.12 Setting diagrammes - type SR/SGR Diagramme 15: KTR-SI 6 Diagramme 16: KTR-SI 7 4.13 Setting diagrammes - type FR Diagramme 17: KTR-SI 0 Diagramme 18: KTR-SI 1 Diagramme 19: KTR-SI 2 Diagramme 20: KTR-SI 3 Please observe protection note ISO 16016. Drawn: Verified: 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-SI Operating/Assembly instructions 4 KTR-N Sheet: Edition: 46310 EN 18 of 22 4 Assembly 4.13 Setting diagrammes - type FR Diagramme 21: KTR-SI 4 Diagramme 22: KTR-SI 5 4.14 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. For the design FT 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. For the designs KT and LT the drive components are mounted to the coupling hub and screwed to the flange ring. The resulting radial force on the drive element should be within the level of the bearing in order to avoid twisting of the drive elements and consequently the flange ring. • 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 coupling. The drive element needs a corresponding bearing. • With higher torque shocks an extra feather key can be used for additional positive locking power transmission. Please observe protection note ISO 16016. Drawn: Verified: 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-N Sheet: Edition: KTR-SI Operating/Assembly instructions 4 46310 EN 19 of 22 4 Assembly 4.15 Assembly of limit switch The limit switch should be assembled in the keyway of the shifting ring (see illustration 16). The positions and dimensions of the keyway are shown in table 11. Table 11: Position of limit switch Dimensions [mm] Size 0 1 2 3 4 5 6 7 l4 l5 ØD4 7.5 11.5 12.0 21.0 27.0 33.0 39.0 46.0 9 9 9 10 9 9 9 9 50.0 72.5 90.5 112 140 170 190 230 DK 1.4 2.3 2.4 2.7 3.7 4.6 5.0 5.5 H=stroke Type SR SGR 1.2 0.6 1.8 0.8 2.0 1.1 2.2 1.2 2.5 1.2 3.0 1.6 3.5 2.5 4.0 2.7 FR 1.6 2.3 3.0 3.5 3.8 4.5 - Illustration 16: Mechanical limit switch Function The axial stroke of the shifting 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. Adjustment When the overload coupling slips, the shifting ring makes an axial thrust (see table 9). 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. ! We recommend to use 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 other components. As soon as the limit switch or sensor is activated (overload: release of overload coupling) the drive should immediately be stopped . With higher speeds respective braking devices may be necessary. Please observe protection note ISO 16016. Drawn: Verified: 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-SI Operating/Assembly instructions 5 KTR-N Sheet: Edition: 46310 EN 20 of 22 4 Re-engagement of KTR-SI design FR Re-engagement is generated by axial pressure on the shifting ring . Depending on the existing tools, accessibility, etc., re-engagement can be performed in different ways. The coupling can be re-engaged by several axial blows with a plastic hammer on the shifting ring (see illustration 17, on top) or pneumatic respectively hydraulic ratching mechanisms (automatic ratching process). Illustration 17: Re-engagement 6 Breakdowns, causes and elimination The below-mentioned failures can result in a use of the KTR-SI coupling 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 use other than intended: • • • • • • • • • Important data for the coupling selection were not forwarded. The calculation of the shaft-hub-connection was 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 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. Drawn: Verified: 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-SI Operating/Assembly instructions 6 46310 EN 21 of 22 4 Breakdowns, causes and elimination Breakdowns Causes Elimination Misalignment Different operating noise and/or vibrations occuring Screws working loose Screws/fastening screw for axial fastening of flange hubs working loose Faulty storage The coupling releases in an undefined position. The coupling does not release in case of overload. The torque of KTR SI with ROTEX® is no longer transmitted ROTEX® 7 KTR-N Sheet: Edition: Torque is not set Torque set incorrectly Setting nut has worked loose 1) Set the unit out of operation 2) Eliminate the reason for the misalignment (e. g. loose foundation bolts, breaking of the engine mount, heat expansion of unit components, modification of the installation dimension E of the coupling) 1) Set the unit out of operation 2) Inspect coupling components and replace coupling components that are damaged 3) Tighten the fit bolts to the tightening torque specified. 4) Inspect alignment, adjust if necessary 1) Set the unit out of operation 2) Inspect alignment of coupling 3) Tighten the screws to fasten the flange hubs and secure against working loose 1) Set the unit out of operation 2) Send the coupling to KTR for inspection/repair. 1) Set the unit out of operation 2) Adjust torque, see chapter 4.8 or 4.9 1) Set the unit out of operation 2) Send the coupling to KTR for inspection/repair. Wear ROTEX® driving flange has worked loose 1) Set the unit out of operation 2) Tighten the fastening screws Please consider our operating/assembly instructions KTR-N 40210 additionally when using the ROTEX® 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. Drawn: Verified: 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 KTR-SI Operating/Assembly instructions 8 KTR-N Sheet: Edition: 46310 EN 22 of 22 4 Maintenance and service KTR-SI is a low-maintenance coupling. It is finish bored and provided with grease filling. We recommend to perform a visual inspection on the coupling 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 has to be regularly inspected for its operation. If KTR-SI is ordered in a pilot bored design, the customer has to disassemble it in order to machine a finish bore. With subsequent assembly please lubricate with standard bearing greases. ! • Since the flexible machine bearings of the driving and driven side settle during the course of load, please 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. Having started up the coupling 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. Drawn: Verified: 2023-06-02 Shg/Koh 2023-06-02 Shg Replacing: Replaced by: KTR-N dated 2017-02-10 ">

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Key features
- Torque limiting overload system
- Positive locking operation
- Various types (DK, SR, FR, SGR)
- Torsionally flexible ROTEX® coupling
- Different sizes (0 to 7)
- Detailed assembly instructions
Frequently asked questions
A torque limiting overload system, like the KTR-SI, is designed to protect machinery from damage caused by overloads. It does this by limiting the maximum amount of torque that can be transmitted through the system. When the torque exceeds the limit, the system activates to prevent further damage.
The KTR-SI comes in four types: DK (ratchet design), SR (synchronous design), FR (idle rotation design), and SGR (fail-safe synchronous design). The primary difference between these lies in their re-engagement mechanism. The DK type re-engages every 15° with the next following ball indentation, SR re-engages after a rotation of 360°, FR remains separated with overload and requires manual re-engagement, and SGR is purely for torque measurement with a mechanical separation in overload.
The assembly process depends on the specific size of the KTR-SI. You can find detailed instructions on assembling the KTR-SI coupling, including the different components and steps, in chapter 4 of the viewed document.
Yes, you can. Chapter 4 of the viewed document describes the assembly process for combining the KTR-SI with a torsionally flexible ROTEX® coupling.