KTR POLY-NORM Operating/Mounting Instructions
KTR POLY-NORM is a torsionally flexible jaw coupling designed to compensate for shaft misalignment. It's commonly used in industrial machinery to connect shafts while accommodating variations in alignment, which can be caused by thermal expansion, manufacturing tolerances, or other factors. The coupling can handle various misalignments, including angular, parallel, and axial misalignments, making it suitable for a wide range of applications.
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KTR-N Sheet: Edition: POLY-NORM® Operating/Assembly instructions 49510 EN 1 of 34 17 POLY-NORM® Flexible jaw couplings type AR, ADR, AVR, AZR, AR/AZR, AZVR, AR with taper clamping sleeve and their combinations Type AR according to directive 2014/34/EU and UK directive SI 2016 No. 1107 Type ADR, ADR-K and AVR Type AZR and AZR short Type AR/AZR Type AZVR Type AR with taper clamping sleeve Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions KTR-N Sheet: Edition: 49510 EN 2 of 34 17 POLY-NORM® 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 9 2.1 2.2 2.3 2.4 2.5 2.6 9 10 10 10 11 11 3 4 General advice Safety and advice symbols General hazard warnings Proper use Coupling selection Reference to EC Machinery Directive 2006/42/EC Storage, transport and packaging 11 3.1 3.2 11 11 Storage Transport and packaging Assembly 12 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 12 16 17 17 18 19 20 21 22 Components of the coupling Advice for finish bore Assembly of the coupling (general) Assembly of type AR Assembly of type ADR, ADR-K and AVR Assembly of type AZR, AZR short and AZVR Assembly of type AR/AZR Assembly of taper clamping sleeve Displacements - alignment of the coupling 5 Start-up 23 6 Breakdowns, causes and elimination 24 7 Disposal 26 8 Maintenance and service 27 9 Spares inventory, customer service addresses 27 10 Enclosure A Advice and instructions regarding the use in 10.1 Intended use in potentially explosive atmospheres potentially explosive atmospheres 10.2 Inspection intervals for couplings in 10.3 Standard values of wear Please observe protection note ISO 16016. Drawn: Verified: 28 potentially explosive atmospheres 10.4 marking of coupling for potentially explosive atmospheres 10.5 EU Certificate of conformity 10.6 UK Declaration of conformity 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: 28 29 30 31 33 34 KTR-N dated 2019-07-24 KTR-N Sheet: Edition: POLY-NORM® Operating/Assembly instructions 1 49510 EN 3 of 34 17 Technical data Size 28 to 125 Size 140 to 280 Illustration 1: POLY-NORM® type AR Table 1: Dimensions and torques - type AR POLY-NORM® AR Cast iron (EN-GJL-250) 1) Size 28 32 38 42 48 55 60 65 75 85 90 100 110 125 140 160 180 200 220 240 260 280 Elastomer ring (component 2) Torque [Nm] TKN TKmax. 40 80 60 120 90 180 150 300 220 440 300 600 410 820 550 1100 850 1700 1350 2700 2000 4000 2900 5800 3900 7800 5500 11000 7200 14400 10000 20000 13400 26800 19000 38000 30000 60000 43000 86000 55000 110000 67000 134000 Dimensions [mm] Finish bore dmax. 2) Setscrew 3) General LAR 59 68 80 88 101 115 125 135 155 175 185 206 226 256 286 326 366 408 448 488 530 570 12-30 12-35 19-40 19-45 19-50 19-60 19-65 19-70 32-80 32-90 32-95 42-110 50-120 55-140 65-155 75-175 75-200 85-200 95-220 105-240 115-260 125-280 l1 28 32 38 42 48 55 60 65 75 85 90 100 110 125 140 160 180 200 220 240 260 280 s 3 4 4 4 5 5 5 5 5 5 5 6 6 6 6 6 6 8 8 8 10 10 DH 69 78 87 96 106 118 129 140 158 182 200 224 250 280 315 350 400 450 500 550 650 700 D 46 53 62 69 78 90 97 105 123 139 148 165 185 210 235 265 300 335 370 405 440 475 dH 36.5 41.5 50.0 55.5 64 73 81 86 100 116 128 143 158 178 216 246 290 - N 12.0 14.0 19.5 20.0 24.0 29.0 33.0 36.0 42.5 48.5 49.0 55.0 60.0 70.0 76.5 94.5 111.5 126 140 154 158 172 G M5 M8 M8 M8 M8 M8 M8 M10 M10 M10 M12 M12 M16 M16 M20 M20 M20 M24 M24 M24 M24 M24 t 7 7 10 10 15 14 15 20 20 25 25 25 30 35 35 45 50 50 50 50 60 60 Weight 4) [kg] 0.77 1.14 1.59 2.17 3.03 4.27 5.32 6.86 10.25 15.05 19.50 26.98 38.12 54.21 77.28 106.24 155.20 218.50 296.10 390.00 575.00 716.00 1) Material Perbunan (NBR) 78 Shore A with size 28 to 180; material T-PUR 84 Shore A with size 200 to 280; with size 140 to 280 use of DZ individual elastomers 2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew on the keyway 3) For tightening torques of setscrews see table 2 4) Weights apply for max. bore diameters with feather keyway according to DIN 6885 sheet 1 Table 2: Setscrew DIN EN ISO 4029 Size Dimension G [mm] Tightening torque TA [Nm] 28 M5 32 M8 38 M8 42 M8 48 M8 55 M8 60 M8 65 M10 75 M10 85 M10 90 M12 2 10 10 10 10 10 10 17 17 17 40 Size Dimension G [mm] Tightening torque TA [Nm] 100 M12 110 M16 125 M16 140 M20 160 M20 180 M20 200 M24 220 M24 240 M24 260 M24 280 M24 40 100 100 140 140 140 240 240 240 240 240 Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 KTR-N Sheet: Edition: POLY-NORM® Operating/Assembly instructions 1 49510 EN 4 of 34 17 Technical data Illustration 2: POLY-NORM® type ADR (three-part) Illustration 3: POLY-NORM® type ADR-K (three-part) Table 3: Dimensions – type ADR and ADR-K POLY-NORM® ADR and ADR-K (type AVR corresponding to components 3D and 4D mirrored) cast iron (EN-GJL-250), component 3D/3Dk flange hub nodular iron (EN-GJS-400-15) Size 38 42 48 55 60 65 75 85 90 100 110 125 140 160 180 200 220 240 260 280 Dimensions [mm] General Max. finish bore 1) LADR, d1 d2 LADR-K 40 34 80 45 38 88 50 44 101 60 50 115 65 56 125 70 60 135 80 68 155 90 78 175 95 85 185 110 95 206 50-120 105 226 55-140 115 256 65-155 55-135 286 75-175 65-155 326 75-200 65-175 366 85-200 73-200 408 95-220 83-220 448 105-240 93-240 488 115-260 103-260 530 125-280 113-280 570 Setscrew 2) l1, l2 s s1 DH D D1 dH N M W G t t1 38 42 48 55 60 65 75 85 90 100 110 125 140 160 180 200 220 240 260 280 4 4 5 5 5 5 5 5 5 6 6 6 6 6 6 8 8 8 10 10 12.0 14.5 16.0 17.0 18.0 20.0 23.5 27.0 29.5 33.0 36.0 39.0 - 87 96 106 118 129 140 158 182 200 224 250 280 315 350 400 450 500 550 650 700 62 69 78 90 97 105 123 139 148 165 185 210 235 265 300 335 370 405 440 475 48 54 62 72 80 86 98 112 122 136 150 168 195 225 255 290 320 350 380 410 50 55.5 64 73 81 86 100 116 128 143 158 178 216 246 290 - 19.5 20.0 24.0 29.0 33.0 36.0 42.5 48.5 49.0 55.0 60.0 70.0 76.5 94.5 111.5 126 140 154 158 172 11 12 13.7 18.7 22.2 26.7 27.8 33.7 31.5 37.5 39.5 48.0 47.0 65.0 79.0 95 103 119 109 109 12 16 16 15 14 11 16 18 26 28 30 35 59 43 33 7 8 1 34 29 M8 M8 M8 M8 M8 M10 M10 M10 M12 M12 M16 M16 M20 M20 M20 M24 M24 M24 M24 M24 10 10 15 14 15 20 20 25 25 25 30 35 35 45 50 50 50 50 60 60 7 7 7 14 15 20 20 25 25 25 30 35 35 45 50 50 50 50 60 60 Table 4: Torques and weights - type ADR and ADR-K Size Elastomer ring 3) (component 2) Torque [Nm] Weight 4) [kg] Size Elastomer ring 3) (component 2) Torque [Nm] Weight 4) [kg] 38 42 48 55 60 65 75 85 90 100 TKN 90 150 220 300 410 550 850 1350 2000 2900 TKmax. 180 300 440 600 820 1100 1700 2700 4000 5800 ADR ADR-K 1.75 1.70 2.34 2.26 3.23 3.12 4.41 4.24 5.43 5.24 7.10 6.67 10.50 10.01 15.29 14.44 20.06 19.02 27.83 26.28 110 125 140 160 180 200 220 240 260 280 TKN 3900 5500 7200 10000 13400 19000 30000 43000 55000 67000 TKmax. 7800 11000 14400 20000 26800 38000 60000 86000 110000 134000 ADR ADR-K 38.95 37.31 55.67 53.26 80.30 77.90 108.00 104.70 155.00 150.30 215 207 294 280 380 - 593 - 728 - 1) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew on the keyway 2) For tightening torques of setscrews see table 2 3) Material Perbunan (NBR) 78 Shore A with size 28 to 180; material T-PUR 84 Shore A with size 200 to 280; with size 140 to 280 use of DZ individual elastomers 4) Weights apply for max. bore diameters with feather keyway according to DIN 6885 sheet 1 Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 KTR-N Sheet: Edition: POLY-NORM® Operating/Assembly instructions 1 49510 EN 5 of 34 17 Technical data Type ADR and ADR-K: Table 5: Assignment of cap screws DIN EN ISO 4762 - 12.9 Size Screw size M Screw length l Number z 5) Dimension D4 Tightening torque TA [Nm] 38 M6 16 5 62 42 M8 16 5 69 48 M8 20 6 78 55 M8 20 6 88 60 M8 20 6 98 65 M10 20 6 104 75 M10 25 6 120 85 M12 25 6 138 90 M16 30 6 149 100 M16 30 6 163 10 25 25 25 25 49 49 86 210 210 Size Screw size M Screw length l Number z 5) Dimension D4 Tightening torque TA [Nm] 110 M16 40 8 183 125 M20 40 8 202 140 M20 50 8 237 160 M20 55 9 267 180 M20 60 10 304 200 M20 60 10 342 220 M24 70 10 378 240 M27 70 10 416 260 M30 90 10 480 280 M30 90 10 520 210 410 410 410 410 580 1000 1500 2000 2000 Please observe protection note ISO 16016. Drawn: Verified: 5) per flange hub 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 KTR-N Sheet: Edition: POLY-NORM® Operating/Assembly instructions 1 49510 EN 6 of 34 17 Technical data Illustration 4: POLY-NORM® type AZR Table 6: Dimensions and torques - type AZR POLY-NORM® AZR cast iron (EN-GJL-250), component 4N steel (S355J2) Size 28 32 38 42 48 55 60 65 75 85 90 100 Drop-out center length L [mm] 100 140 100 140 100 140 100 140 100 140 100 140 180 100 140 180 100 140 180 140 180 250 140 180 250 140 180 250 140 180 250 Elastomer ring 1) (component 2) Torque [Nm] TKN TKmax. Dimensions [mm] Finish bore 2) dmax. 40 80 34 60 120 38 90 180 45 150 300 50 220 440 55 300 600 65 410 820 70 550 1100 75 850 1700 90 1350 2700 100 2000 4000 110 2900 5800 120 Setscrew 3) General LAZR 170 210 170 210 184 224 190 230 204 244 210 250 290 220 260 300 230 270 310 290 330 400 310 350 420 320 360 430 340 380 450 l2 35 35 42 45 52 55 60 65 75 85 90 100 l3 49.5 69.5 49 69 49 69 49 69 49 69 49 69 89 49 69 89 49 69 89 69 89 124 69 89 124 69 89 124 69 89 124 s l4 DH DF dH M G t 3 1 69 46 36.5 26 M5 7 4 1 78 53 41.5 26 M8 7 4 1 87 62 50 33 M8 10 4 1 96 69 55.5 35 M8 10 5 1.5 106 78 64 41.5 M8 15 5 1.5 118 88 73 43.5 M8 14 5 1.5 129 97 81 47.5 M8 15 5 1.5 140 105 86 51.5 M10 20 5 1.5 158 123 100 60.5 M10 20 5 1.5 182 139 116 69.5 M10 25 5 1.5 200 148 128 73.5 M12 25 6 2 224 165 143 83 M12 25 55 M8 25 103 6 35 60 M8 25 114 6 35 85 M10 30 160 6 69 90 M12 35 180 6 120 Weight 4) [kg] 2.33 2.91 2.86 3.50 3.78 4.57 4.56 5.41 6.03 6.98 7.81 9.21 10.57 9.49 11.05 12.61 11.85 13.61 15.37 19.71 22.15 26.18 27.57 30.65 36.22 32.00 35.35 41.22 42.31 46.44 53.67 Table 7: Assignment of cap screws DIN EN ISO 4762 - 12.9 Size Screw size M Screw length l Dimension D4 Number z 5) Tightening torque TA [Nm] 1) 2) 3) 4) 5) 28 M6 18 58 4 14 32 M6 18 67 4 14 38 M6 20 76 5 14 42 M6 20 85 5 14 48 M6 20 95 6 14 65 M8 25 124 6 35 75 M10 30 141 6 69 100 M12 35 200 6 120 Material Perbunan (NBR) 78 Shore A Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew on the keyway For tightening torques of setscrews see table 2 Weights apply for max. bore diameters with feather keyway according to DIN 6885 sheet 1 Per flange connection Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 KTR-N Sheet: Edition: POLY-NORM® Operating/Assembly instructions 1 49510 EN 7 of 34 17 Technical data Illustration 5: POLY-NORM® type AZR short Illustration 6: POLY-NORM® type AR/AZR Table 8: Dimensions - type AZR short and AR/AZR POLY-NORM® AZR short and AR/AZR cast iron (EN-GJL-250), component 4N steel (S355J2) Dimensions [mm] General Size 28 32 38 42 48 55 60 65 75 85 90 100 Setscrew 1) LAZR short LAR/AZR l1 l2 l3 s l4 L DH D, DF dH N M 101 102 116 128 144 154 166 180 206 234 252 280 80 85 98 108 122.5 134.5 145.5 157.5 108.5 204.5 218.5 243 28 32 38 42 48 55 60 65 75 85 90 100 35 35 42 45 52 55 60 65 75 85 90 100 15 15 15 18 19 21 22 24 27 31 35 39 3 4 4 4 5 5 5 5 5 5 5 6 1 1 1 1 1.5 1.5 1.5 1.5 1.5 1.5 1.5 2 31 32 32 38 40 44 46 50 56 64 72 80 69 78 87 96 106 118 129 140 158 182 200 224 46 53 62 69 78 90/88 97 105 123 139 148 165 36.5 41.5 50 55.5 64 73 81 86 100 116 128 143 12 14 19.5 20 24 29 33 36 42.5 48.5 49 55 26 26 33 35 41.5 43.5 47.5 51.5 60.5 69.5 73.5 83 G M5 M8 M8 M8 M8 M8 M8 M10 M10 M10 M12 M12 t 7 7 10 10 15 14 15 20 20 25 25 25 Table 9: Torques and finish bores - type AZR short and AR/AZR Size Elastomer ring 2) (component 2) Torque [Nm] Max. finish bore 3) [mm] Weight 4) [kg] TKN 28 40 32 60 38 90 42 150 48 220 55 300 60 410 65 550 75 850 85 1350 90 2000 100 2900 TKmax. 80 120 180 300 440 600 820 1100 1700 2700 4000 5800 d1 d2 AZR short AR/AZR 30 30 1.24 1.01 35 35 1.57 1.35 40 40 2.20 1.89 45 45 2.98 2.57 50 50 4.07 3.55 60 60 5.18 4.72 65 65 6.76 6.04 70 70 8.11 7.48 80 80 11.34 10.79 90 90 20.06 17.54 100 95 24.43 21.94 110 110 34.16 30.56 90 M12 35 180 6 120 100 M12 35 200 6 120 Table 10: Assignment of cap screws DIN EN ISO 4762 - 12.9 Size Screw size M Screw length l Dimension D4 Number z 5) Tightening torque TA [Nm] 1) 2) 3) 4) 5) 28 M6 16 58 4 14 32 M6 16 67 4 14 38 M6 16 76 5 14 42 M6 20 85 5 14 48 M6 20 95 6 14 55 M8 25 103 6 35 60 M8 25 114 6 35 65 M8 25 124 6 35 75 M10 30 141 6 69 85 M10 30 160 6 69 For tightening torques of setscrews see table 2 Material Perbunan (NBR) 78 Shore A Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew on the keyway Weights apply for max. bore diameters with feather keyway according to DIN 6885 sheet 1 Per flange connection Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 KTR-N Sheet: Edition: POLY-NORM® Operating/Assembly instructions 1 49510 EN 8 of 34 17 Technical data Illustration 7: POLY-NORM® type AZVR Table 11: Dimensions - type AZVR POLY-NORM® AZVR cast iron (EN-GJL-250), component 4N and 4Nv steel (S355J2) Dimensions [mm] General Size 38 42 48 55 60 65 75 85 Setscrew 1) LAZVR l2 l3 s l4 l5 L DH DF dH M 224 230 244 250 290 260 300 270 310 330 450 350 470 42 45 52 69 69 69 49 89 49 89 49 89 89 209 89 209 4 4 5 1 1 1.5 69 69 69 87 96 106 62 69 78 50 55.5 64 33 35 41.5 G M8 M8 M8 t 10 10 15 5 1.5 89 118 88 73 43.5 M8 14 5 1.5 89 129 97 81 47.5 M8 15 5 1.5 89 140 105 86 51.5 M10 20 5 1.5 89 158 123 100 60.5 M10 20 5 1.5 89 140 140 140 140 180 140 180 140 180 180 300 180 300 182 139 116 69.5 M10 25 55 60 65 75 85 Weight 2) [kg] 4.33 5.25 6.83 8.59 9.97 10.66 12.22 12.74 14.50 21.34 28.58 29.91 39.25 Table 12: Torques and finish bores - type AZVR Size Elastomer ring 3) (component 2) Torque [Nm] Finish bore 4) [mm] 38 42 48 55 60 65 75 85 TKN 90 150 220 300 410 550 850 1350 TKmax. 180 300 440 600 820 1100 1700 2700 dmax. 40 45 50 60 65 70 80 90 65 M8 25 124 6 35 75 M10 30 141 6 69 85 M10 30 160 6 69 Table 13: Assignment of cap screws DIN EN ISO 4762 - 12.9 Size Screw size M Screw length l Dimension D4 Number z 5) Tightening torque TA [Nm] 1) 2) 3) 4) 5) 38 M6 20 76 5 14 42 M6 20 85 5 14 48 M6 20 95 6 14 55 M8 25 103 6 35 60 M8 25 114 6 35 For tightening torques of setscrews see table 2 Weights apply for max. bore diameters with feather keyway according to DIN 6885 sheet 1 Material Perbunan (NBR) 78 Shore A Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew on the keyway Per flange connection Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 KTR-N Sheet: Edition: POLY-NORM® Operating/Assembly instructions 1 49510 EN 9 of 34 17 Technical data Illustration 8: POLY-NORM® type with taper clamping sleeve Table 14: Dimensions - type with taper clamping sleeve POLY-NORM® with taper clamping sleeve hub TB1 and TB2 cast iron (EN-GJL-250) 32 42 Elastomer ring 1) (component 2) Torque [Nm] TKN TKmax. 60 120 150 300 48 220 60 65 75 Speed nmax. [rpm] 7300 6000 Finish bore 2) d1, d2 Min. Max. 10 25 11 32 440 5400 14 40 410 550 850 820 1100 1700 4400 4100 3600 85 1350 2700 3150 90 100 125 2000 2900 5500 4000 5800 11000 2900 2600 2050 14 16 16 16 35 25 35 40 50 60 60 60 75 75 90 100 Size Dimensions [mm] General l1, l2 s L D DH N 25.5 31.0 30.0 42.5 38.5 62.5 52.5 46.5 82.0 52.0 98.0 111.5 4 4 55 66 65 90 80 130 110 98 169 109 202 229 53 69 78 96 78 106 97 105 123 129 140 158 132 182 200 224 280 7.5 9.0 6.0 18.5 10.5 20.0 5 5 5 5 5 5 6 6 139 148 165 210 10.0 11.0 53.0 56.5 Taper clamping sleeve Weight 3) [kg] 1108 1210 1610 1615 2012 2517 2517 2517 3030 3020 3535 4040 1.05 1.98 2.35 2.96 4.16 9.13 8.54 11.60 14.81 14.88 27.41 48.70 1) Material Perbunan (NBR) 78 Shore A 2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] 3) Weights apply for max. bore diameters with feather keyway according to DIN 6885 sheet 1 POLY-NORM® couplings with attachments that can generate heat, sparks and static charging (e. g. combinations with brake drums, brake disks, overload systems such as torque limiters, fan impellers etc.) are not permitted for the use in potentially explosive atmospheres. A separate analysis must be performed. 2 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 POLY-NORM® coupling is suitable and approved for the use in potentially explosive atmospheres. When using the coupling in potentially explosive atmospheres, observe the special advice and instructions regarding safety in enclosure A. The operating/assembly instructions are part of your product. Please store them carefully and close to the coupling. The copyright for these operating/assembly instructions remains with KTR. Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 2 KTR-N Sheet: Edition: 49510 EN 10 of 34 17 Advice 2.2 Safety and advice symbols STOP ! Warning of potentially explosive atmospheres This symbol indicates notes which may contribute to preventing bodily injuries or serious bodily injuries that may result in death caused by explosion. Warning of personal injury This symbol indicates notes which may contribute to preventing bodily injuries or serious bodily injuries that may result in death. Warning of product damages This symbol indicates notes which may contribute to preventing material or machine damage. General advice This symbol indicates notes which may contribute to preventing adverse results or conditions. Warning of hot surfaces This symbol indicates notes which may contribute to preventing burns with hot surfaces resulting in light to serious bodily injuries. 2.3 General hazard warnings STOP With assembly, operation and maintenance of the coupling it has to be made sure that the entire drive train is secured against accidental switch-on. You may be seriously hurt by rotating parts. Make absolutely sure to read through and observe the following safety indications. • All operations on and with the coupling have to be performed taking into account "safety first". • Make sure to switch off the power pack before you perform your work on the coupling. • Secure the power pack against accidental switch-on, e. g. by providing warning signs at the place of switch-on or removing the fuse for current supply. • Do not reach into the operating area of the coupling as long as it is in operation. • Secure the coupling against accidental contact. Provide for the necessary protection devices and covers. 2.4 Proper use You may only assemble, operate and maintain the coupling if you • have carefully read through the operating/assembly instructions and understood them • are technically qualified and specifically trained (e. g. safety, environment, logistics) • are authorized by your company The coupling may only be used in accordance with the technical data (see chapter 1). Unauthorized modifications on the coupling design are not admissible. We will not assume liability for any damage that may arise. In the interest of further development we reserve the right for technical modifications. The POLY-NORM® 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: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 2 KTR-N Sheet: Edition: 49510 EN 11 of 34 17 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 "POLY-NORM®"). If the operating conditions (performance, speed, modifications on engine and machine) change, the coupling selection must be reviewed. Make sure that the technical data regarding torque refer to the elastomer part only. The transmittable torque of the shaft-hub-connection must be reviewed by the customer and is subject to his responsibility. For drives subject to torsional vibrations (drives with cyclic stress due to torsional vibrations) it is necessary to perform a torsional vibration calculation to ensure a reliable selection. Typical drives subject to torsional vibrations are e. g. drives with diesel engines, piston pumps, piston compressors etc. If requested, KTR will perform the coupling selection and the torsional vibration calculation. 2.6 Reference to EC Machinery Directive 2006/42/EC The couplings supplied by KTR should be considered as components, not machines or partly completed machines according to EC Machinery Directive 2006/42/EC. Consequently KTR does not have to issue a declaration of incorporation. For details about safe assembly, start-up and safe operation refer to the present operating/assembly instructions considering the warnings. 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 elastomer rings/DZ individual elastomers remain unchanged for up to 5 years with favourable storage conditions. ! The storage rooms must not include any ozone-generating devices like e. g. fluorescent light sources, mercury-vapour lamps or electrical high-voltage appliances. Humid storage rooms are not suitable. Make sure that condensation is not generated. The best relative air humidity is less than 65 %. 3.2 Transport and packaging ! In order to avoid any injuries and any kind of damage always make use of proper transport and lifting equipment. The couplings are packed differently each depending on size, number and kind of transport. Unless otherwise contractually agreed, packaging will follow the in-house packaging specifications of KTR. Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 KTR-N Sheet: Edition: POLY-NORM® Operating/Assembly instructions 4 49510 EN 12 of 34 17 Assembly The coupling is generally supplied in individual parts. Before assembly the coupling has to be inspected for completeness. 4.1 Components of the coupling Components of POLY-NORM® type AR Component Quantity Description 1 2 Hub 2 1 Elastomer ring/DZ individual elastomers 9 2 Setscrews DIN EN ISO 4029 Material EN-GJL-250 Balancing condition According to customer specification NBR (Perbunan) from size 200 T-PUR Steel Size 28 to 125 Size 140 to 280 ® Illustration 9: POLY-NORM type AR Components of POLY-NORM® type ADR (three-part) type AVR corresponding to components of 3D and 4D mirrored Component Quantity Description 1 1 Hub 2 1 Elastomer ring/DZ individual elastomers 3D 1 Flange hub 4D 9 10 1 2 see table 5 Material EN-GJL-250 Cam ring Setscrews DIN EN ISO 4029 Cap screws DIN EN ISO 4762 NBR (Perbunan) from size 200 T-PUR EN-GJS-400-15 from size 200 steel (S355J2) EN-GJL-250 Steel Steel Size 28 to 125 Balancing condition According to customer specification According to customer specification Size 140 to 280 Illustration 10: POLY-NORM® type ADR (three-part) Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 KTR-N Sheet: Edition: POLY-NORM® Operating/Assembly instructions 4 49510 EN 13 of 34 17 Assembly 4.1 Components of the coupling Components of POLY-NORM® type ADR-K (three-part) Component Quantity Description Material 1 1 Hub 2 1 Elastomer ring/DZ individual elastomers 3Dk 1 Flange hub K 4D 9 10 1 2 see table 5 EN-GJL-250 Cam ring Setscrews DIN EN ISO 4029 Cap screws DIN EN ISO 4762 NBR (Perbunan) from size 200 T-PUR EN-GJS-400-15 from size 200 steel (S355J2) EN-GJL-250 Steel Steel Size 28 to 125 Balancing condition According to customer specification According to customer specification Size 140 to 280 ® Illustration 11: POLY-NORM type ADR-K (three-part) Components of POLY-NORM® type AZR and AZR short Componen t 2 3N Quantity 1 2 Elastomer ring Driving flange 4N 2 Coupling flange 9 2 see table 7 and 10 10 Description Material Balancing condition According to customer specification Setscrews DIN EN ISO 4029 NBR (Perbunan) EN-GJL-250 EN-GJL-250 / S355J2 Steel Cap screws DIN EN ISO 4762 Steel Illustration 12: POLY-NORM® type AZR and AZR short Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 4 KTR-N Sheet: Edition: 49510 EN 14 of 34 17 Assembly 4.1 Components of the coupling Components of POLY-NORM® type AR/AZR Component Quantity Description 1 1 Hub 2 3N 1 1 Elastomer ring Driving flange 4N 1 Coupling flange 9 10 2 see table 10 Material EN-GJL-250 Setscrews DIN EN ISO 4029 Cap screws DIN EN ISO 4762 NBR (Perbunan) EN-GJL-250 EN-GJL-250 / S355J2 Steel Steel Balancing condition According to customer specification According to customer specification Illustration 13: POLY-NORM® type AR/AZR Components of POLY-NORM® type AZVR Component Quantity 2 1 3N 1 4N 1 4Nv 1 8 1 9 2 10 see table 13 Description Elastomer ring Driving flange Coupling flange Coupling flange AZVR Driving flange AZVR Setscrews DIN EN ISO 4029 Cap screws DIN EN ISO 4762 Material NBR (Perbunan) EN-GJL-250 EN-GJL-250 / S355J2 EN-GJL-250 Steel Steel Balancing condition According to customer specification Illustration 14: POLY-NORM® type AZVR Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 4 KTR-N Sheet: Edition: 49510 EN 15 of 34 17 Assembly 4.1 Components of the coupling Components of POLY-NORM® type with taper clamping sleeve Component 2 9 Quantity 1 2 1) Description Elastomer ring Setscrew Material NBR (Perbunan) Steel TB1 2 Hub for taper clamping sleeve EN-GJL-250 11 2 Taper clamping sleeve EN-GJL-250 Balancing condition According to customer specification 1) For each taper clamping sleeve from size 100, 3-off setscrews are needed. Illustration 15: POLY-NORM® type with taper clamping sleeve Coupling design: TB1 TB2 Screw connection on cam side Screw connection on collar side Various combinations of types TB1 and TB2 are available. Illustration 16: Type with taper clamping sleeve hub design TB1 and TB2 Taper clamping sleeves used without a feather key are not permitted in potentially explosive atmospheres and are thus not provided with a relevant explosion protection marking. Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 KTR-N Sheet: Edition: POLY-NORM® Operating/Assembly instructions 4 49510 EN 16 of 34 17 Assembly 4.2 Advice for finish bore The maximum permissible bore diameters d (see chapter 1 - technical data) must not be exceeded. If these figures are disregarded, the coupling may tear. Rotating particles may cause danger to life. STOP • Hub bores machined by the customer have to observe concentricity resp. axial runout (see illustration 17). • Make absolutely sure to observe the figures for Ød. • Carefully align the hubs when the finish bores are drilled. • Provide for a setscrew according to DIN EN ISO 4029 with a cup point or an end plate to fasten the hubs axially. For dimensions G and t resp. t1 see the respective table of the particular type (see chapter 1). Illustration 17: Concentricity and axial runout The customer bears the sole responsibility for all machining processes performed subsequently on unbored or pilot bored as well as finish machined coupling components and spare parts. KTR does not assume any warranty claims resulting from insufficient remachining. ! KTR supplies unbored or pilot bored coupling components and spare parts only upon explicit request of the customer. These parts are additionally marked with the symbol . Reference to unbored resp. pilot bored coupling components with explosion protection marking: Basically the company KTR Systems GmbH supplies couplings resp. coupling hubs with explosion protection marking as an unbored or pilot bored type only on explicit request of the customer. The prerequisite is a declaration of exemption submitted by the customer assuming any responsibility and liability for respective remachining performed on the product of KTR Systems GmbH. Table 15: 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 standard operating conditions or ISO P9 with sophisticated operating conditions (frequently alternating torsional direction, shock loads, etc.). The keyway should preferably be located between the cams. With axial fastening by the setscrew the tapped hole should be located on 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: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 4 KTR-N Sheet: Edition: 49510 EN 17 of 34 17 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, coupling flanges or flange hubs lightly (approx. 80 °C) allows for an easier mounting on the shaft. Please pay attention to the ignition risk in potentially explosive atmospheres! STOP ! Touching the heated hubs causes burns. Please wear safety gloves. With assembly make sure that the dimension s resp. L (see table 1 to 14 of the different types) is observed so that the hubs are not in contact with each other during the operation. Disregarding this advice may cause damage to the coupling. If used in potentially explosive atmospheres the setscrews to fasten the hubs as well as all screw connections must be secured against working loose additionally, e. g. conglutinating with Loctite (average strength). 4.4 Assembly of type AR • Mount the hubs on the shaft of driving and driven side (see illustration 18). • Insert the elastomer ring respectively DZ individual elastomers in the cam section of the hub on the driving or driven side (see illustration 19.1 and 19.2). Insert the DZ individual elastomers with the web in the cam section of the hub first (see illustration 19.2). Illustration 19.1: Assembly of elastomer ring Illustration 18: Assembly of hub Illustration 19.2: Assembly of DZ individual elastomers • Shift the power packs in axial direction until the distance dimension s is achieved (see illustration 20). • If the power packs are already firmly assembled, shifting the hubs axially on the shafts allows for adjusting dimension s (see illustration 20). • Fasten the hubs by tightening the setscrews DIN EN ISO 4029 with a cup point (tightening torque see table 2). Illustration 20: Assembly of coupling Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 4 KTR-N Sheet: Edition: 49510 EN 18 of 34 17 Assembly 4.5 Assembly of type ADR, ADR-K and AVR • Plug the flange hub and the cam ring together (see illustration 21). • Hand-tighten the components first. • Mount the hub and flange hub with cam ring on the shaft of driving and driven side (see illustration 22). • Tighten the screws at the tightening torques TA specified in table 5 by means of a suitable torque key. Illustration 21: Assembly of flange hub with cam ring • Insert the elastomer ring resp. DZ individual elastomers in the cam section of the hub on the driving or driven side respectively cam ring (see illustration 23.1 and 23.2). Illustration 22: Assembly of hub and flange hub with cam ring Insert the DZ individual elastomers with the web in the cam section of the hub resp. cam ring first (see illustration 23.2). Illustration 23.1: Assembly of elastomer ring ! Illustration 23.2: Assembly of DZ individual elastomers To facilitate the assembly of the elastomer ring when the power packs are already firmly assembled, we recommend to separate the elastomer ring up to size 65 in one position between the dampers (see illustration 24). From size 75 on we recommend to separate the elastomer ring between every second damper to facilitate the assembly (see illustration 25). Illustration 24: Mounting aid of elastomer ring up to size 65 Illustration 25: Mounting aid of elastomer ring from size 75 • Shift the power packs in axial direction until the distance dimension s is achieved (see illustration 26). • If the power packs are already firmly assembled, shifting the hubs axially on the shafts allows for adjusting dimension s (see illustration 26). • Fasten the hub or flange hubs by tightening the setscrews DIN EN ISO 4029 with a cup point (tightening torque see table 2). Illustration 26: Assembly of coupling ! Having started up the coupling, the wear of the elastomer ring has to be inspected at regular maintenance intervals and the elastomer ring has to be replaced, if necessary. Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 4 KTR-N Sheet: Edition: 49510 EN 19 of 34 17 Assembly 4.6 Assembly of type AZR, AZR short and AZVR • Mount the coupling flanges on the shaft of driving and driven side (see illustration 27). The internal sides of the coupling flanges must be flush with the front sides of the shafts. • Shift the power packs in axial direction until the distance dimension L is achieved (see illustration 4). • Fasten the coupling flanges by tightening the setscrews DIN EN ISO 4029 with a cup point (tightening torque see table 2). Illustration 27: Assembly of coupling flanges • Plug the driving flanges and the elastomer ring together (see illustration 28). Illustration 28: Assembly of driving flanges with elastomer ring • Put the components plugged together between the coupling flanges (see illustration 29). • Hand-tighten the components first. • Tighten the screws to the tightening torques TA specified in table 7, 10 and 13 by means of a suitable torque key. • Check the dimension s or L (see table 6, 8 and 11). • If the power packs are already firmly assembled, shifting the coupling flanges axially on the shafts allows for adjusting dimension s or L (see illustration 29). Illustration 29: Assembly of coupling ! Having started up the coupling, the wear of the elastomer ring has to be inspected at regular maintenance intervals and the elastomer ring has to be replaced, if necessary. Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 4 KTR-N Sheet: Edition: 49510 EN 20 of 34 17 Assembly 4.7 Assembly of type AR/AZR • Mount the coupling flange on the shaft of driving or driven side (see illustration 30). The internal side of the coupling flange must be flush with the faces of the shafts. Illustration 30: Assembly of coupling flange • Plug the hub, the elastomer ring and the driving flange together (see illustration 31). Illustration 31: Assembly of hub, elastomer ring and driving flange • Assemble the components plugged together on the other shaft end (see illustration 32). • Fasten the hub and coupling flange by tightening the setscrews DIN EN ISO 4029 with a cup point (tightening torques see table 2). Illustration 32: Assembly of component assembly • Position the machine such that the driving flange and coupling flange can be screwed together. Hand-tighten the components for the time being and tighten the screws to the tightening torque TA specified in table 10 by means of a suitable torque key • Review the dimension s (see illustration 33). Illustration 33: Assembly of coupling ! Having started up the coupling, the wear of the elastomer ring has to be inspected at regular maintenance intervals and the elastomer ring has to be replaced, if necessary. Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 4 KTR-N Sheet: Edition: 49510 EN 21 of 34 17 Assembly 4.8 Assembly of taper clamping sleeve Assembly of taper clamping sleeve: Clean the contact surfaces of the taper clamping sleeves and of shaft and hub and afterwards apply thin oil lightly (e. g. Ballistol Universal oil or Klüber Quietsch-Ex). The taper clamping sleeves have got axially parallel, cylindrical and smooth tapped blind holes. Only half of these holes are located in the material of the sleeve. The other half located in the hub has got threads. Fit the coupling element and the taper clamping sleeve into each other, make sure that the bores cover each other and tighten the setscrews lightly. Fit the coupling element along with the taper clamping sleeve on the shaft and tighten the setscrews at the tightening torque specified in table 16. During the screwing process the hub is mounted on the taper sleeve and thus the sleeve is pressed on the shaft. By light blows of the hammer the taper clamping sleeve must be pushed further into the taper bore by means of a suitable sleeve. Afterwards re-tighten the setscrews at the tightening torque specified in table 16. This process must be performed at least once. Having operated the drive under load for a short while inspect if the setscrews are released. Axial fixing of the Taper Lock hub (coupling hub with taper clamping sleeve) is obtained by proper assembly only. ! ! If used in potentially explosive atmospheres the setscrews to fasten the taper clamping sleeves have to be secured against working loose additionally, e. g. conglutinating with Loctite (average strength). Taper clamping sleeves used without a feather key are not permitted in potentially explosive atmospheres and are thus not provided with a relevant explosion protection marking. Oils and greases with molybdenum disulphide or high-pressure additives, additives of Teflon and silicone as well as internal lubricants reducing the coefficient of friction significantly must not be used. Illustration 34: POLY-NORM® type with taper clamping sleeve Disassembly of taper clamping sleeve: The taper clamping sleeve is released by removing the setscrews. Afterwards one of the setscrews used as forcing screw is screwed in the thread of the sleeve and tightened. The coupling hub untightened that way can be manually removed from the shaft with the taper clamping sleeve. Table 16: Taper clamping sleeve 1108 1210 1610 1615 2012 2517 3020 3030 3535 4040 G [inch] 1/4 3/8 3/8 3/8 7/16 1/2 5/8 5/8 1/2 5/8 Please observe protection note ISO 16016. Screw dimensions L SW [inch] [mm] 1/2 3 5/8 5 5/8 5 5/8 5 7/8 6 7/8 6 1 1/4 8 1 1/4 8 1 1/2 10 1 3/4 12 Drawn: Verified: TA [Nm] 5.7 20 20 20 31 49 92 92 115 170 Number 2 2 2 2 2 2 2 3 3 3 2022-07-01 Pz/Wb 2022-07-28 Pz Illustration 35: Withworth setscrew (BSW) Replacing: Replaced by: KTR-N dated 2019-07-24 KTR-N Sheet: Edition: POLY-NORM® Operating/Assembly instructions 4 49510 EN 22 of 34 17 Assembly 4.9 Displacements - alignment of the coupling The POLY-NORM® compensates for displacements generated by the shafts to be combined as shown in table 17. 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 and avoid dangers with the use in potentially explosive atmospheres, the shaft ends must be accurately aligned. Please absolutely observe the displacement figures specified (see table 17). If the figures are exceeded, the coupling will be damaged. The more accurate the alignment of the coupling, the longer is its service life. If used in potentially explosive atmospheres for explosion group IIC, only half of the displacement figures (see table 17) are permissible. ! Please note: • The displacement figures specified in table 17 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. • Please inspect with a dial gauge, ruler or feeler gauge whether the permissible displacement figures specified in table 17 can be observed. Axial displacements Radial displacements Ladm. = L + Ka [mm] Angular displacements Kw = smax. - smin. [mm] Illustration 36: Displacements Examples of the displacement combinations specified in illustration 37: Illustration 37: Combinations of displacement Example 1: Kr = 30 % Kw = 70 % Example 2: Kr = 60 % Kw = 40 % Ktotal = Kr + Kw 100 % Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 KTR-N Sheet: Edition: POLY-NORM® Operating/Assembly instructions 49510 EN 23 of 34 17 Assembly 4.9 Displacements - alignment of the coupling Table 17: Displacement figures Size Max. axial displacement Ka [mm] Max. radial 1500 rpm displacement Kr 3000 rpm [mm] with Max. angular displacement Kw [mm] 1500 rpm (1 degree) 3000 rpm (0.5 degree) Size Max. axial displacement Ka [mm] Max. radial displacement Kr [mm] with Max. angular displacement Kw [mm] 5 28 ±1 32 ±1 38 ±1 42 ±1 48 ±1.5 55 ±1.5 60 ±1.5 65 ±1.5 75 ±1.5 85 ±1.5 90 ±1.5 0.2 0.25 0.25 0.25 0.3 0.3 0.3 0.35 0.4 0.4 0.5 0.15 0.18 0.18 0.18 0.22 0.22 0.22 0.26 0.3 0.3 0.33 1.2 1.4 1.5 1.7 1.8 2.0 2.2 2.4 2.7 3.0 3.4 0.6 0.7 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.5 1.7 100 ±3 110 ±3 125 ±3 140 ±3 160 ±3 180 ±3 200 ±4 0.65 - 0.65 - 0.65 - 240 ±4 1220 rpm 0.70 1220 rpm 9.6 260 ±4 1030 rpm 0.85 1030 rpm 11.3 280 ±4 960 rpm 0.85 960 rpm 12.2 - - - 0.5 0.37 0.6 - 0.6 - 3.9 4.3 4.8 5.5 6.1 6.0 7.8 220 ±4 1350 rpm 0.70 1350 rpm 8.7 1.9 - - - - - - - 1500 rpm 3000 rpm 1500 rpm (1 degree) 3000 rpm (0.5 degree) 0.6 1500 rpm Start-up Before start-up of the coupling, inspect the tightening of the setscrews in the hubs, the alignment and the distance dimension E and adjust, if necessary, and also inspect all screw connections for the tightening torques specified. If used in potentially explosive atmospheres the setscrews to fasten the hubs as well as all screw connections must be secured against working loose additionally, e. g. conglutinating with Loctite (average strength). Finally the coupling protection against accidental contact must be fitted. It is required in accordance with DIN EN ISO 12100 (Safety of Machinery) and directives 2014/34/EU and SI 2016 No. 1107 and must protect against • access with the little finger • falling down of solid foreign objects. The coupling protection is not part of KTR's scope of delivery and is the customer's responsibility. It must have sufficient distance to the rotating components to avoid contact safely. Depending on the outside diameter DH of the coupling, we recommend the following minimum distance: ØDH to 50 mm = 6 mm, ØDH 50 mm to 120 mm = 10 mm, ØDH from 120 mm = 15 mm. Please check if a proper enclosure (ignition protection, coupling protection, contact protection) has been mounted and the operation of the coupling is not affected by the enclosure. The same applies for test runs and rotational direction inspections. The cover may provide for openings intended for necessary heat dissipation. These openings have to comply with DIN EN ISO 13857. The cover must be electrically conductive and included in the equipotential bonding. Bellhousings (magnesium share below 7.5 %) made of aluminium and damping rings (NBR) can be used as connecting element between pump and electric motor. The cover may only be taken off with standstill of the unit. Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 5 KTR-N Sheet: Edition: 49510 EN 24 of 34 17 Start-up If the couplings are used in locations subject to dust explosion and in mining the user must make sure that there is no accumulation of dust in a dangerous volume between the cover and the coupling. The coupling must not operate in an accumulation of dust. For covers with unlocked openings on the top face no light metals must be used if the couplings are used as equipment of equipment group ll (if possible, from stainless steel). If the couplings are used in mining (equipment group l M2), the cover must not be made of light metal. In addition, it must be resistant to higher mechanical loads than with use as equipment of equipment group ll. During operation of the coupling, please pay attention to • different operating noise • vibrations occurring. ! If you note any irregularities with the coupling during operation, the drive unit must be switched off immediately. The cause of the breakdown must be specified by means of the table „Breakdowns“ and, if possible, be eliminated according to the proposals. The potential breakdowns specified can be hints only. To find out the cause all operating factors and machine components must be considered. Coating of coupling: If coated (priming, paintings, etc.) couplings are used in potentially explosive atmospheres, the requirements on conductibility and coating thickness must be considered. With paintings up to 200 µm electrostatic load does not have to be expected. If thicker paintings resp. coatings up to a layer thickness of a maximum of 2.0 mm are applied, the couplings are not permissible for gases and vapours of category IIC in potentially explosive areas, but only for gases and vapours of category IIA and IIB. This also applies for multiple coatings exceeding an overall thickness of 200 µm. Make sure with painting or coating that the coupling components are conductively connected with the device/devices to be connected so that the equipotential bonding is not impeded by the paint or coat applied. Basically painting of the elastomer ring is not admitted to ensure an equipotential bonding. In addition, make sure that the marking of the coupling remains legible. 6 Breakdowns, causes and elimination The below-mentioned failures can lead to a use of the POLY-NORM® 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. If used other than intended the coupling can become a source of ignition. Directive 2014/34/EU and UK directive SI 2016 No. 1107 require special care by the manufacturer and the user. Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 6 KTR-N Sheet: Edition: 49510 EN 25 of 34 17 Breakdowns, causes and elimination General failures with use other than intended: • • • • • • • • • • Important data for the coupling selection are not forwarded. The calculation of the shaft-hub-connection is not considered. Coupling components with damage occurred during transport are assembled. If the heated hubs are assembled, the permissible temperature is exceeded. The clearance of the components to be assembled is not coordinated with one another. Tightening torques have been fallen below/exceeded. Components are mixed up by mistake/assembled incorrectly. A wrong or no elastomer ring/DZ individual elastomers are inserted in the coupling. No original KTR components (purchased parts) are used. Old/already worn off elastomer rings resp. DZ individual elastomers or those which are stored for too long are used. • Maintenance intervals are not observed. Breakdowns Causes Hazard notes for potentially explosive atmospheres Misalignment Different operating noise and/or vibrations occuring Wear of elastomer ring, short-term torque transmission due to metal contact Screws for axial fastening of hubs working loose Wear of elastomer ring, torque transmission due to metal contact Ignition risk due to sparking Fracture of the cams due to high impact energy/overload Fracture of cams Elimination 1) Set the unit out of operation 2) Eliminate the reason for the misalignment (e. g. loose foundation bolts, fracture of the engine mount, heat expansion of unit components, modification of the mounting dimension s of the coupling) 3) For inspection of wear see chapter 10.2 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the elastomer ring 3) Inspect coupling components and replace coupling components that have been damaged 4) Insert elastomer ring, assemble coupling components 5) Inspect alignment, adjust if necessary 1) Set the unit out of operation 2) Inspect alignment of coupling 3) Tighten the screws to fasten the hubs and secure against working loose 4) For inspection of wear see chapter 10.2 1) Set the unit out of operation 2) Replace complete coupling 3) Inspect alignment 1) Set the unit out of operation 2) Replace complete coupling 3) Inspect alignment 4) Find out the reason for overload Operating parameters do not meet with the performance of the coupling 1) Set the unit out of operation 2) Review the operating parameters and select a bigger coupling (consider mounting space) 3) Assemble new coupling size 4) Inspect alignment Operating error of the unit 1) Set the unit out of operation 2) Replace complete coupling 3) Inspect alignment 4) Instruct and train the service staff Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 6 49510 EN 26 of 34 17 Breakdowns, causes and elimination Breakdowns Causes Hazard notes for potentially explosive atmospheres Misalignment Early wear of elastomer ring e. g. contact with aggressive liquids/oils, influence by ozone, too high/low ambient temperature etc. causing a physical modification of the elastomer ring excessively high ambient/contact temperatures for the elastomer ring, max. permissible -30 °C/+75 °C Early wear of elastomer ring (Hardening/embrittlem ent of the elastomer cam) ! 7 KTR-N Sheet: Edition: Ignition risk due to sparking with metallic contact of the cams Vibrations of drive Elimination 1) Set the unit out of operation 2) Eliminate the reason for the misalignment (e. g. loose foundation bolts, fracture of the engine mount, heat expansion of unit components, modification of the mounting dimension s of the coupling) 3) For inspection of wear see chapter 10.2 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the elastomer ring 3) Inspect coupling components and replace coupling components that have been damaged 4) Insert elastomer ring, assemble coupling components 5) Inspect alignment, adjust if necessary 6) Make sure that other physical modifications of the elastomer ring are excluded 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the elastomer ring 3) Inspect coupling components and replace coupling components that have been damaged 4) Insert elastomer ring, assemble coupling components 5) Inspect alignment, adjust if necessary 6) Inspect and adjust ambient/contact temperature 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the elastomer ring 3) Inspect coupling components and replace coupling components that have been damaged 4) Insert elastomer ring, assemble coupling components 5) Inspect alignment, adjust if necessary 6) Find out the reason for vibrations When operating with a worn elastomer ring/DZ individual elastomers (see chapter 10.3) proper operation is not ensured. 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. • Nylon materials Nylon materials have to be collected and disposed of by a waste disposal company. Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 8 KTR-N Sheet: Edition: 49510 EN 27 of 34 17 Maintenance and service POLY-NORM® 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 elastomer rings or DZ individual elastomers of the coupling. • Since the flexible machine bearings of the driving and driven side settle during the course of load, inspect the alignment of the coupling and re-align the coupling, if necessary. • The coupling components have to be inspected for damages. • The screw connections have to be visually inspected. With the use in potentially explosive atmospheres observe chapter 10.2 "Inspection intervals for couplings in potentially explosive atmospheres". 9 Spares inventory, customer service addresses We recommend to store major spare parts on site to ensure the readiness for use of the machine in case if a coupling fails. Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage at www.ktr.com. KTR does not assume any liability or warranty for the use of spare parts and accessories which are not provided by KTR and for the damages which may incur as a result. KTR Systems GmbH Carl-Zeiss-Str. 25 D-48432 Rheine Phone: +49 5971 798-0 E-mail: [email protected] Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 KTR-N Sheet: Edition: POLY-NORM® Operating/Assembly instructions 10 49510 EN 28 of 34 17 Enclosure A Advice and instructions regarding the use in potentially explosive atmospheres Types available: AR, ADR, ADR-K, AVR, AZR, AR/AZR, AZVR and AR with taper clamping sleeve Taper clamping sleeves used without a feather key are not permitted in potentially explosive atmospheres and are thus not provided with a relevant explosion protection marking. 10.1 Intended use in potentially explosive atmospheres Conditions of operation in potentially explosive atmospheres The POLY-NORM® couplings are suitable for the use according to directives 2014/34/EU and SI 2016 No. 1107. • Protection against hazards arising from lightning must follow the lightning protection concept of the machine or plant. The relevant regulations and policy for lightning protection must be observed. • The equipotential bonding of the couplings is made by metal contact between coupling hub and shaft. This equipotential bonding must not be affected. 1. Industry (with the exception of mining) • • • • Equipment group II of category 2 and 3 (coupling is not approved/not suitable for equipment group 1) Substance group G (gases, fogs, vapours), zone 1 and 2 (coupling is not approved/not suitable for zone 0) Substance group D (dusts), zone 21 and 22 (coupling is not approved/not suitable for zone 20) Explosion group IIC (gases, fogs, vapours) (explosion groups IIA and IIB are included in IIC) and explosion group IIIC (dusts) (explosion groups IIIA and IIIB are included in IIIC) Temperature class: Temperature class T5 T6 Ambient or operating temperature Ta 1) -30 °C to +75 °C -30 °C to +60 °C Max. surface temperature 2) +95 °C +80 °C Explanation: The maximum surface temperatures each result from the maximum permissible ambient or operating temperature T a plus the maximum temperature increase T of 20 K to be considered. For the temperature class a safety margin subject to standard of 5 K is added. 1) The ambient or operating temperature Ta is limited to +75 °C due to the permissible permanent operating temperature of the elastomers used. 2) The maximum surface temperature of +95 °C applies for the use in locations which are potentially subject to dust explosion. In potentially explosive atmospheres • the ignition temperature of dusts generated must at least be 1.5 times the surface temperature to be considered • the glow temperature must at least be the surface temperature to be considered plus a safety distance of 75 K. • the gases and vapours generated must amount to the temperature class specified. 2. Mining Equipment group I of category M2 (coupling is not approved/not suitable for equipment group M1). Permissible ambient temperature -30 °C to +75 °C. Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 10 KTR-N Sheet: Edition: 49510 EN 29 of 34 17 Enclosure A Advice and instructions regarding the use in 10.2 Inspection intervals for couplings in Equipment category potentially explosive atmospheres Inspection intervals M2 2G 2D No gases and vapours of explosion group IIC 2G 2D Gases and vapours of explosion group IIC potentially explosive atmospheres An inspection of the circumferential backlash and a visual inspection of the elastomer ring/DZ individual elastomers must be performed after 3,000 operating hours for the first time, at the latest after 6 months after start-up of the coupling. If you note insignificant or no wear on the elastomer ring/DZ individual elastomers upon this initial inspection, further inspections can each be performed after 6,000 operating hours or at the latest after 18 months, provided that the operating parameters remain the same. If you note significant wear during the initial inspection so that it would be recommendable to replace the elastomer ring/DZ individual elastomers, find out the cause according to the table „Breakdowns“, if possible. The maintenance intervals must be adjusted to the modified operating parameters without fail. An inspection of the circumferential backlash and a visual inspection of the elastomer ring/DZ individual elastomers must be performed after 2,000 operating hours for the first time, at the latest after 3 months after start-up of the coupling. If you note insignificant or no wear on the elastomer ring/DZ individual elastomers upon this initial inspection, further inspections can each be performed after 4,000 operating hours or at the latest after 12 months, provided that the operating parameters remain the same. If you note significant wear during the initial inspection so that it would be recommendable to replace the elastomer ring/DZ individual elastomers, find out the cause according to the table „Breakdowns“, if possible. The maintenance intervals must be adjusted to the modified operating parameters without fail. Inspection of torsional backlash Here the backlash between the coupling cams and the elastomer teeth must be inspected by means of reversing backlash. The friction/wear may be 25 % of the original tooth thickness of the elastomer before the elastomer rings/DZ individual elastomers must be replaced. When reaching the limit of wear and tear smax., the elastomer rings/DZ individual elastomers must be replaced immediately, irrespective of the inspection intervals. Illustration 38: POLY-NORM® type AR Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 10 KTR-N Sheet: Edition: 49510 EN 30 of 34 17 Enclosure A Advice and instructions regarding the use in potentially explosive atmospheres 10.3 Standard values of wear Reaching the limits for replacing depends on the operating conditions and the existing operating parameters. With torsional backlash smax. [mm] the elastomer rings/DZ individual elements must be replaced. With wear 25 % of the original thickness of the elastomer teeth it is necessary to replace the elastomer rings/DZ individual elements. In order to ensure a long service life of the coupling and avoid dangers with the use in potentially explosive atmospheres, the shaft ends must be accurately aligned. Please absolutely observe the displacement figures specified (see table 17). If the figures are exceeded, the coupling will be damaged. ! Illustration 39: Inspection of the limit of wear Illustration 40: Wear of elastomer ring Table 18: Limits of wear Size 28 32 38 42 48 55 60 65 75 85 90 Thickness of elastomer tooth [mm] 7.2 8.8 9.0 9.6 10.3 11.9 12.6 13.4 15.6 19.1 20.0 Please observe protection note ISO 16016. Wear Xmax. [mm] 1.80 2.20 2.20 2.40 2.55 2.95 3.15 3.35 3.90 4.75 5.00 Drawn: Verified: Limits of wear Torsional backlash Smax. [mm] 3.0 3.6 3.6 4.0 4.2 4.7 5.1 5.4 6.1 7.4 7.0 100 110 125 140 160 180 200 220 240 260 280 Thickness of elastomer tooth [mm] 23.0 22.5 24.5 23.8 25.4 26.2 28.0 29.5 32.5 38.0 40.0 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: Size Wear Xmax. [mm] 5.75 5.5 6.0 6.0 6.4 6.6 7.0 7.4 8.1 9.5 10.0 Torsional backlash Smax. [mm] 9.1 8.0 9.0 9.0 9.6 9.9 13.0 13.4 14.1 15.5 16.0 KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 10 KTR-N Sheet: Edition: 49510 EN 31 of 34 17 Enclosure A Advice and instructions regarding the use in 10.4 potentially explosive atmospheres marking of coupling for potentially explosive atmospheres The explosion protection marking of the POLY-NORM® coupling is applied on the outer sheath or on the front side. The elastomer ring or DZ individual elastomer is not marked. For the complete marking refer to the operating/assembly instructions and/or the delivery note/package. Marking is as follows: I M2 II 2G II 2D Ex h I Mb Ex h IIC T6 … T5 Gb Ex h IIIC T80 °C … T95 °C Db <Year> -30 °C ≤ Ta ≤ +60 °C … +75 °C KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine X X X Short marking: (A short marking is only made if not possible differently for reason of space or functioning.) POLY-NORM® <Year> Deviating marking applied until 31st October 2019: Short marking: (standard) II 2GD c IIC T X/I M2 c X II 2G c IIC T6 resp. T5 -30 °C Ta +65 °C resp. +80 °C II 2D c T 100 °C -30 °C Ta +80 °C / I M2 c -30 °C Ta +80 °C Complete marking: Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 10 49510 EN 32 of 34 17 Enclosure A Advice and instructions regarding the use in 10.4 KTR-N Sheet: Edition: potentially explosive atmospheres marking of coupling for potentially explosive atmospheres Comments on marking Equipment group I Equipment group II Equipment category 2G Equipment category 2D Equipment category M2 Mining Non-mining Equipment ensuring a high level of safety, suitable for zone 1 Equipment ensuring a high level of safety, suitable for zone 21 Equipment ensuring a high level of safety must be able to be switched off when an explosive atmosphere occurs D Dust G Gases and vapours Ex h Nonelectrical explosion protection IIC Gases and vapours of class IIC (including IIA and IIB) IIIC Electrically conductive dusts of class IIIC (including IIIA and IIIB) T6 … T5 Temperature class to be considered, depending on the ambient temperature T80 °C … T95 °C Maximum surface temperature to be considered, depending on the ambient temperature -30 °C ≤ Ta ≤ +60 °C … +75 °C or Permissible ambient temperature from -30 °C to +60 °C resp. -30 °C ≤ Ta ≤ +75 °C -30 °C to +75 °C Gb, Db, Mb Equipment protection level, analogous to the equipment category X For a safe use of the couplings particular conditions apply If the symbol was punched in addition to marking , the coupling component was supplied by KTR as an unbored or pilot bored version (see chapter 4.2 of the present operating/assembly instructions). Please observe protection note ISO 16016. Drawn: Verified: 2022-07-01 Pz/Wb 2022-07-28 Pz Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 10 KTR-N Sheet: Edition: 49510 EN 33 of 34 17 Enclosure A Advice and instructions regarding the use in potentially explosive atmospheres 10.5 EU Certificate of conformity EU Declaration of Conformity resp. Certificate of Conformity corresponding to EU directive 2014/34/EU dated 26 February 2014 and to the legal regulations adopted for its implementation The manufacturer - KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine - states that the POLY-NORM® couplings in an explosion-proof design described in these assembly instructions are equipment resp. components corresponding to article 2, 1. of directive 2014/34/EU and comply with the general safety and health specifications according to enclosure II of directive 2014/34/EU. This declaration of conformity resp. certificate of conformity is issued under the sole responsibility of the manufacturer KTR Systems GmbH. The coupling described in here complies with the specifications of the following standards/rules: EN ISO 80079-36:2016-12 EN ISO 80079-37:2016-12 EN ISO/IEC 80079-38:2017-10 IEC/TS 60079-32-1:2020-01-24 The POLY-NORM® is in accordance with the specifications of directive 2014/34/EU. According to article 13 (1) b) ii) of directive 2014/34/EU the technical documentation is deposited with the notified body (type examination certificate IBExU02ATEXB006_05 X): IBExU Institut für Sicherheitstechnik GmbH Identification number: 0637 Fuchsmühlenweg 7 09599 Freiberg Rheine, Place 2022-07-01 Date Please observe protection note ISO 16016. Drawn: Verified: i. V. Reinhard Wibbeling Engineering/R&D 2022-07-01 Pz/Wb 2022-07-28 Pz i. V. Michael Brüning Product Manager Replacing: Replaced by: KTR-N dated 2019-07-24 POLY-NORM® Operating/Assembly instructions 10 KTR-N Sheet: Edition: 49510 EN 34 of 34 17 Enclosure A Advice and instructions regarding the use in potentially explosive atmospheres 10.6 UK Declaration of conformity UK Declaration of Conformity resp. Certificate of Conformity corresponding to UK directive SI 2016 No. 1107 dated 26 February 2014 and to the legal provisions adopted for its implementation The manufacturer - KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine - states that the POLY-NORM® couplings in an explosion-proof design described in these assembly instructions are equipment resp. components corresponding to directive SI 2016 No. 1107 and comply with the general safety and health requirements according to directive SI 2016 No. 1107. This declaration of conformity resp. certificate of conformity is issued under the sole responsibility of the manufacturer KTR Systems GmbH. The coupling described in here complies with the specifications of the following standards/rules: EN ISO 80079-36:2016-12 EN ISO 80079-37:2016-12 EN ISO/IEC 80079-38:2017-10 IEC/TS 60079-32-1:2020-01-24 The POLY-NORM® is in accordance with the specifications respectively the applicable specifications of directive SI 2016 No. 1107. According to directive SI 2016 No. 1107 the technical documentation is deposited with the notified body: Eurofins CML Identification number: 2503 Rheine, Place 2022-07-01 Date Please observe protection note ISO 16016. Drawn: Verified: i. V. Reinhard Wibbeling Engineering/R&D 2022-07-01 Pz/Wb 2022-07-28 Pz i. V. Michael Brüning Product Manager Replacing: Replaced by: KTR-N dated 2019-07-24 ">

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Key features
- Torsionally flexible
- Shaft misalignment compensation
- Multiple types (AR, ADR, AVR, AZR)
- Explosion-protected versions
- High torque capacity
- Durable construction
Frequently asked questions
KTR POLY-NORM can handle angular, parallel, and axial misalignments, as specified in the manual.
The maximum torque capacity varies between different KTR POLY-NORM types and sizes. Refer to the "Technical Data" section in the manual for specific torque values.
Yes, certain KTR POLY-NORM types and configurations are certified for use in hazardous areas. Refer to "Enclosure A" in the manual for specific details and requirements.