KTR POLY-NORM-M Operating/Mounting Instructions

POLY-NORM®-M
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
49810 EN
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5
POLY-NORM®-M
Flexible jaw coupling type AFN
for finish bored, pilot bored and unbored couplings
Type AFN
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POLY-NORM®-M
Operating/Assembly instructions
KTR-N
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Edition:
49810 EN
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POLY-NORM®-M is a torsionally flexible jaw coupling. 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
4
2.1
2.2
2.3
2.4
2.5
2.6
4
4
4
4
5
5
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
5
3.1
3.2
5
5
Storage
Transport and packaging
Assembly
6
4.1
4.2
4.3
4.4
4.5
6
6
7
7
9
Components of the couplings
Advice on remachining
Assembly of the coupling (general)
Assembly of type AFN
Displacements - alignment of the coupling
5
Start-up
10
6
Breakdowns, causes and elimination
11
7
Disposal
12
8
Maintenance and service
13
9
Spares inventory, customer service addresses
15
Please observe protection
note ISO 16016.
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POLY-NORM®-M
Operating/Assembly instructions
1
KTR-N
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Edition:
49810 EN
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D5
360
460
510
650
830
830
1110
1250
1500
1500
d3
300
360
430
530
700
700
950
1100
1300
1300
Technical data
Illustration 1: POLY-NORM®-M type AFN
Table 1: Dimensions
Dimensions [mm]
Size
202
252
302
402
502
503
703
803
903
905
Max. finish
bore
d1
d2
350
200
355
250
380
300
480
400
650
500
650
500
700
700
1000
800
1000
900
1000
900
General
L
425
438
464
580
654
777
845
1040
982
1376
l1
195
208
203
224
228
228
309
406
406
406
l2
215
215
247
335
407
530
507
600
541
857
l3
200
213
209
230
234
234
315
416
412
416
l4
218
218
255
350
360
505
500
530
550
920
DH
640
720
770
1000
1200
1200
1560
1800
2060
2060
D1
500
550
600
760
1000
1000
1100
1600
1400
1650
D2
552
635
682
885
1080
1075
1395
1630
1865
1865
D3
530
610
660
860
1050
1340
1340
1550
1800
1800
D4
600
680
730
945
1140
1140
1480
1720
1975
1975
D6
480
570
625
800
990
990
1280
1450
1730
1730
E
12
12
13
14
19
19
19
24
25
114
W
150
150
175
250
250
415
360
390
390
715
Table 2: Technical data
Size
202
252
302
402
502
503
703
803
903
905
Torque [kNm]
TKN
TK max.
100
200
140
280
200
400
400
800
650
1300
950
1900
1200
2400
2400
4800
3300
6600
5500
11000
Max. speed 1)
[rpm]
600
530
500
380
320
320
245
220
190
190
M1
M24
M24
M24
M30
M30
M30
M42
M48
M48
M48
Tightening torque [Nm]
TA1
M2
970
M16
970
M16
970
M16
1950
M16
1950
M16
1950
M16
3600
M16
5450
M24
5450
M24
5450
M24
TA2
290
290
290
290
290
290
290
970
970
970
Weight 2) [kg]
430
590
730
1750
2240
3090
5150
9300
9800
14800
1) Maximum circumferential speed v = 20 m/s referring to the maximum outside diameter. Higher speed on request.
2) Weights apply for max. bore diameters with feather keyway according to DIN 6885 sheet 1
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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. 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.
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
• 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 POLY-NORM®-M described in here corresponds to the technical status at the time of printing of these
operating/assembly instructions.
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Advice
2.5 Coupling selection
!
For a permanent 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).
If the operating conditions (performance, speed, modifications on engine and machine)
change, the coupling selection must be reviewed.
Please make sure that the technical data regarding torque refer to the elastomers 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 subjected 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.
3
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 individual elastomers remain unchanged for up to 5 years with favourable stock
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.
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POLY-NORM®-M
Operating/Assembly instructions
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49810 EN
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Assembly
The coupling is generally supplied in individual parts. Before assembly the coupling has to be inspected for
completeness.
4.1 Components of the couplings
Components of POLY-NORM®-M type AFN
Component
1
2
3
4
5
6
7
8
Quantity
1
1
2 1)
1
see table 3
see table 3
see table 3
see table 3
Description
Flange hub
Hub
Cover segment
Cam ring
Individual elastomer
Cap screw DIN EN ISO 4762 - 12.9
Hexagon fit bolt DIN 609 - 10.9 2)
Hexagon nut DIN EN ISO 4032 - 10
1) With size 903 and 905 the number is 4.
2) With size 202 and 252 - hexagon screws DIN EN ISO 4017 - 10.9
Illustration 2: POLY-NORM®-M type AFN
Table 3:
Number z
Size
202
252
302
402
502
503
703
803
903
905
Component 5
Coupling
32
36
48
40
48
72
84
84
96
160
per cavity
2
2
2
2
2
3
3
3
3
5
Component 6
Component 7
Component 8
16
18
24
20
24
24
28
28
32
32
24
30
20
18
24
24
20
24
40
40
24
30
20
18
24
24
20
24
40
40
4.2 Advice on remachining
!
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.
Please observe protection
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Operating/Assembly instructions
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KTR-N
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Assembly
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 an easier mounting on the shaft.
STOP
!
Touching the heated hubs causes burns.
Please wear safety gloves.
With the assembly please make sure that the distance dimension E (see table 1) 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.
In order to avoid any injuries always make use of proper lifting equipment.
STOP
There are tapped holes on the face and outside diameter of the coupling serving for using proper sling gears resp.
lifting equipment. If proper sling gears are used they should be dismounted after assembly of the coupling.
4.4 Assembly of type AFN
• Mount the flange hub (component 1) and hub (component 2) on the shafts of driving and driven side (see
illustration 3).
!
With assembly of the hub (component 2) it has to be made sure that the hub side with a
recess (dimension d3) is shifted on first (see illustration 5).
• The internal sides of the hubs (component 1 and 2) must be flush with the front sides of the shafts.
• Shift the cam ring (component 4) over the hub and take it off carefully or keep the cam ring via a proper lifting
device (see illustration 4).
• Shift the power pack with the flange hub in axial direction until the distance dimension E is achieved (see
illustration 5, table 1).
• If the power packs are already firmly assembled, shifting the coupling hubs axially on the shafts allows for
adjusting the distance dimension E (see illustration 5, table 1).
!
The transmittable torque of the shaft-hub-connection must be reviewed by the customer and
is subject to his responsibility.
Illustration 3
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Operating/Assembly instructions
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49810 EN
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Assembly
4.4 Assembly of type AFN
• Push the cam ring onto the hub and align the bore of the flange hub and the cam ring flush.
• Screw up the flange hub and cam ring via hexagon fit bolts (component 7) and hexagon nuts (component 8)
and tighten them evenly to the tightening torques TA1 specified in table 2 by means of a torque key (see
illustration 6).
• Align the unit screwed up versus the hub such that the cavities between hub and cam ring are evenly
arranged.
• Insert the individual elastomers (component 5) in the cavities between hub and cam ring as per the order
specified in illustration 7 and 8. Please make sure that the arrow on the individual elastomers points towards
the direction of the shaft.
!
With the assembly make sure that the individual elastomers on the cam ring do not protude
since otherwise it is not possible to mount the cover segments (component 3).

For an easier assembly of the individual elastomers we recommend to use a fitting lubricant,
e. g. REMA TIP TOP Universal mounting paste or a silicone oil having a viscosity of
1000 cSt.
!
The respective number of individual elastomers must be used in every cavity (see table 3).
Illustration 6
•
Illustration 7
Illustration 8: Example of size 703
Hand-tighten the cover segments (component 3) with the cap screws DIN EN ISO 4762 (component 6) for the
time being (see illustration 9 and 10).
!
•
With the assembly make sure that a gap of at least 5 mm between hub and cover segments
is observed (see illustration 10).
Tighten the cap screws evenly to the tightening torques T A2 specified in table 2 by means of a suitable torque
key.
!
Having started up the coupling, the tightening torque of the screws and the wear of the
individual elastomers have to be inspected at regular maintenance intervals.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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49810 EN
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Assembly
4.4 Assembly of type AFN
Illustration 9
Illustration 10
4.5 Displacements - alignment of the coupling
The POLY-NORM®-M compensates for displacements generated by the shafts to be combined as shown in table
4. Excessive misalignment may be generated by inaccurate alignment, production tolerances, thermal expansion,
shaft deflection, twisting of machine frames, etc.
In order to ensure a long service life of the coupling, the shaft ends have to be accurately
aligned. Please absolutely observe the displacement figures specified (see table 4). If the
figures are exceeded, the coupling will be damaged.
The more accurate the alignment of the coupling, the longer is its service life.
!
Please note:
• The displacement figures specified in table 4 are maximum figures which must not arise in parallel. If radial
and angular displacement occurs at the same time, the sum of the displacement figures must not exceed Kr
or Kw.
• Inspect with suitable measuring tools whether the permissible displacement figures specified in table 4 can be
observed.
Axial displacements
Radial displacements
Angular displacements
Ladm. = L + Ka [mm]
Illustration 11: Displacements
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Assembly
4.5 Displacements - alignment of the coupling
Examples of the displacement
combinations specified in illustration 12:
Illustration 12:
Combinations of
displacement
Example 1:
Kr = 30 %
Kw = 70 %
Example 2:
Kr = 60 %
Kw = 40 %
Ktotal = Kr + Kw  100 %
Table 4: Displacement figures
Size
Max. axial displacement Ka [mm]
Max. radial displacement Kr [mm] with
Max. angular displacement Kw [degree]
with
5
202
± 3.0
2.0
252
± 3.0
2.0
302
± 3.0
2.5
402
± 3.0
2.5
502
± 3.0
3.0
503
± 3.0
3.0
703
± 5.0
3.0
803
± 5.0
3.5
903
± 6.0
4.0
905
± 6.0
4.0
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
Start-up
Before start-up of the coupling, inspect the alignment and adjust, if necessary, and also inspect all screw
connections for the tightening torques specified.
Finally the coupling protection against accidental contact must be fitted. It is required in accordance with
DIN EN ISO 12100 (Safety of Machinery) 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. We recommend a minimum distance of 15
mm from the outside diameter DH of the coupling.
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.
During operation of the coupling, please pay attention to
• different operating noise
• vibrations occurring.
Please observe protection
note ISO 16016.
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49810 EN
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Start-up
!
6
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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.
Breakdowns, causes and elimination
The below-mentioned failures can lead to a use of the POLY-NORM®-M coupling other than intended. 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.
General failures with improper use:
•
•
•
•
•
•
•
•
•
•
•
Important data for the coupling selection were not forwarded.
The calculation of the shaft-hub-connection was disregarded.
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.
Wrong or no individual elastomers are inserted in the coupling.
No original KTR components (purchased parts) are used.
Old/already worn off individual elastomers or those which are stored for too long are used.
Maintenance intervals are not observed.
Breakdowns
Different operating
noise and/or
vibrations occuring
Breaking of cams
Elimination
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
Misalignment
components, modification of the installation dimension E of the
coupling)
3) For inspection of wear see chapter 8
1) Set the unit out of operation
2) Disassemble the coupling, remove remainders of the elastomers
Wear of elastomers, short3) Inspect coupling components and replace coupling components
term torque transmission due
that have been damaged
to metal contact
4) Insert elastomers, assemble coupling components
5) Inspect alignment, adjust if necessary
1) Set the unit out of operation
Axial fastening of hub working 2) Inspect alignment of coupling
loose
3) Inspect axial fastening of hubs and correct, if necessary
4) For inspection of wear see chapter 8
1) Set the unit out of operation
Wear of elastomers, torque
2) Replace complete coupling
transmission by metal contact
3) Inspect alignment
1) Set the unit out of operation
Breaking of the cams due to 2) Replace complete coupling
high impact energy/overload 3) Inspect alignment
4) Find out the reason for overload
Please observe protection
note ISO 16016.
Causes
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Breakdowns, causes and elimination
Breakdowns
Elimination
1) Set the unit out of operation
Operating parameters do not 2) Review the operating parameters and select a bigger coupling
meet with the performance of
(consider mounting space)
the coupling
3) Assemble new coupling size
4) Inspect alignment
Breaking of cams
1) Set the unit out of operation
2) Replace complete coupling
Operating error of the unit
3) Inspect alignment
4) Instruct and train the service staff
Alignment error
1) Set the unit out of operation
(e. g. indications are large
2) Eliminate the reason for the misalignment (e. g. loose foundation
volumes of rubber dust or
bolts, breaking of the engine mount, heat expansion of unit
impressions of the cams of
components, modification of the installation dimension E of the
the hub on the cover
coupling)
segment)
3) For inspection of wear see chapter 8
1) Set the unit out of operation
e. g. contact with aggressive 2) Disassemble the coupling, remove remainders of the elastomers
liquids/oils, ozone influence, 3) Inspect coupling components and replace coupling components
too high/low ambient
that have been damaged
Early wear of
temperatures etc. causing a 4) Insert elastomers, assemble coupling components
elastomers
physical modification of the 5) Inspect alignment, adjust if necessary
elastomers
6) Make sure that further physical modifications of the elastomers
are excluded
1) Set the unit out of operation
2) Disassemble the coupling, remove remainders of the elastomers
ambient/contact temperatures
3) Inspect coupling components and replace coupling components
which are too high for the
that have been damaged
elastomers, max. permissible
4) Insert elastomers, assemble coupling components
-30 °C/+80 °C
5) Inspect alignment, adjust if necessary
6) Inspect and adjust ambient/contact temperature
1) Set the unit out of operation
2) Disassemble the coupling, remove remainders of the elastomers
Early wear of
3) Inspect coupling components and replace coupling components
elastomer (hardening/
Vibrations of drive
that have been damaged
embrittlement of
4) Insert elastomers, assemble coupling components
elastomers)
5) Inspect alignment, adjust if necessary
6) Find out the reason for vibrations
7
Causes
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.
• Greases/oils
Greases and oils have to be collected and disposed of by a waste disposal company.
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Operating/Assembly instructions
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49810 EN
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5
Maintenance and service
POLY-NORM®-M is a low-maintenance coupling. We recommend to perform a visual inspection on the coupling
at least once a year. Please pay special attention to the condition of the individual elastomer 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.
• Small volumes of rubber dust are normal, with bigger volumes lubrication of the individual elastomers is
necessary.
• The screw connections have to be inspected visually.
In order to perform a visual inspection of the
individual components, remove the cover
segments from the coupling so that the front sides
of the individual elastomers can be seen. For that
purpose you do not need to take the individual
elastomers out of the coupling. Anyway, the
individual elastomers should be replaced if one of
the following items applies:
• Having reached the limits of wear
• Material deterioration of individual elastomers
• Individual elastomers damaged or torn
Illustration 13
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-01-24 Pz/Kr
2023-01-25 Pz
Replacing:
Replaced by:
KTR-N dated 2021-03-05
POLY-NORM®-M
Operating/Assembly instructions
8
KTR-N
Sheet:
Edition:
49810 EN
14 of 15
5
Maintenance and service
When reaching the limit of wear and tear Xmax., the individual elastomers must be replaced. Here the backlash
between the cams of the coupling and the individual elastomers must be inspected by means of a feeler gauge
(see illustration 14). Several individual elastomers should be inspected.
Reaching the limits for replacing depends on the operating conditions and the existing operating parameters. With
wear  20 % of the original elastomer thickness it is necessary to replace the individual elements.
!
In order to ensure a long service life of the coupling, the shaft ends have to be accurately
aligned. Please absolutely observe the displacement figures specified (see table 4). If the
figures are exceeded, the coupling will be damaged.
The more accurate the alignment of the coupling, the longer is its service life.
Illustration 14: Inspection of the limit of wear
Illustration 15: Wear of elastomers
Table 5: Limits of wear
Limits of wear [mm]
Size
Thickness of elastomer B
46.0
46.0
39.0
67.0
67.0
67.0
82.5
91.0
91.0
91.0
202
252
302
402
502
503
703
803
903
905
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-01-24 Pz/Kr
2023-01-25 Pz
Friction Xmax.
9.0
9.0
7.5
13.5
13.5
13.5
16.5
18.0
18.0
18.0
Replacing:
Replaced by:
KTR-N dated 2021-03-05
POLY-NORM®-M
Operating/Assembly instructions
9
KTR-N
Sheet:
Edition:
49810 EN
15 of 15
5
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.
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:
2023-01-24 Pz/Kr
2023-01-25 Pz
Replacing:
Replaced by:
KTR-N dated 2021-03-05
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