KTR REVOLEX KX / KX-D Operating/Mounting Instructions

REVOLEX® KX / KX-D
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
49410 EN
1 of 30
15
REVOLEX® KX / KX-D
Pin & bush coupling
Flexible bolt & bush couplings types
KX and KX-D and their combinations
according to directive 2014/34/EU and UK directive SI 2016 No. 1107
Type KX (taper bolt design B)
Type KX-D (taper bolt design B)
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
KTR-N
Sheet:
Edition:
REVOLEX® KX / KX-D
Operating/Assembly instructions
49410 EN
2 of 30
15
REVOLEX® KX / KX-D is a torsionally flexible pin & bush 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
5
2.1
2.2
2.3
2.4
2.5
2.6
5
5
6
6
6
7
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
7
3.1
3.2
7
7
Storage
Transport and packaging
Assembly
8
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
8
10
11
12
13
14
15
16
Components of the couplings
Components of the pins
Advice for finish bore
Assembly of the coupling (general)
Assembly of type KX
Assembly of type KX-D
Replacement of elastomer rings
Displacements - alignment of the couplings
5
Start-up
18
6
Breakdowns, causes and elimination
19
7
Disposal
21
8
Maintenance and service
21
9
Spares inventory, customer service addresses
22
10
Enclosure A Advice and instructions regarding the use in
atmospheres
10.1 Intended use in
potentially explosive
potentially explosive atmospheres
10.2 Inspection intervals for couplings in
10.3 Standard values of wear
Drawn:
Verified:
23
potentially explosive atmospheres
10.4
marking of coupling for potentially explosive atmospheres
10.5 Rating of danger of ignition
10.6 EU Declaration of conformity
10.7 UK Declaration of conformity
Please observe protection
note ISO 16016.
22
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
24
25
26
28
29
30
KTR-N dated 2019-07-26
KTR-N
Sheet:
Edition:
REVOLEX® KX / KX-D
Operating/Assembly instructions
1
49410 EN
3 of 30
15
Technical data
Illustration 1: REVOLEX® type KX (taper bolt design B)
Table 1: Torques and dimensions - type KX (taper bolt design B)
REVOLEX® KX
Cast iron
Max.
Max. finish
speed 2)
bore 3)
[rpm]
d1, d2
2000
110/125
1800
125/145
1600
140/150
1450
160
1250
180
1100
205
1000
230
900
250
800
285
Torque 1) [Nm]
Size
75
85
95
105
120
135
150
170
190
215
240
265
TKN
TK max.
3440
4580
5140
7050
10855
15000
19440
29285
40500
52500
70000
100500
6880
9160
10280
14100
21710
30000
38880
58570
81000
105000
140000
201000
Steel
Max.
Max. finish
speed 2)
bore 3)
[rpm]
d1, d2
4500
100/110
4175
110/120
3825
125/140
3475
130
3100
150
2725
170
2500
185
2150
220
1900
245
1725
275
1550
310
1375
350
Dimensions [mm]
General
L
l1, l2
E
DH
D1, D2
N1
N2
M*
193
213
227
237
270
300
336
382
428
480
534
590
95
105
112
117
132
147
165
188
211
237
264
292
3
3
3
3
6
6
6
6
6
6
6
6
255
274
298
330
370
419
457
533
597
660
737
826
136
152
168
180
206
230
256
292
330
368
407
457
56
56
56
56
76
76
76
92
92
92
122
122
30
30
30
30
46
46
46
63
63
63
76
76
76
76
76
76
100
100
100
130
130
130
170
170
1) Standard material NBR (Perbunan) 80 ± 5 Shore A
* Drop-out center dimension required
2) Dynamic balancing required
3) Bores H7 with keyway according to DIN 6885 sheet 1 [JS9] and setscrew on the keyway (see table 7)
Table 2: Pins - type KX (taper bolt design B)
Size
Pin size
M1 [mm]
SW1 [mm]
Tightening torque TA
[Nm]
75
Please observe protection
note ISO 16016.
85
3
M10
17
95
135
4
M12
19
67
115
Drawn:
Verified:
105
120
2022-07-06 Pz/Wb
2022-08-09 Pz
150
170
190
5
M16
24
290
Replacing:
Replaced by:
215
240
265
6
M24
36
970
KTR-N dated 2019-07-26
KTR-N
Sheet:
Edition:
REVOLEX® KX / KX-D
Operating/Assembly instructions
1
49410 EN
4 of 30
15
Technical data
Illustration 2: REVOLEX® type KX-D (taper pin design B)
Table 3: Torques and dimensions - type KX-D (taper bolt design B)
REVOLEX® KX-D
Torque 1) [Nm]
Size
75
85
95
105
120
135
150
170
190
215
240
265
280
305
330
355
370
470
520
590
650
TKN
TK max.
4300
5500
7200
9400
15200
20000
25000
41000
54000
67500
98000
134000
170000
205000
265000
350000
430000
520000
810000
1000000
1350000
8600
11000
14400
18800
30400
40000
50000
82000
108000
135000
196000
268000
340000
410000
530000
700000
860000
1040000
1620000
2000000
2700000
Cast iron
Max.
Max. finish
speed 2)
bore 3)
[rpm]
d1, d2
2000
110
1800
125
1600
140
1450
160
1250
180
1100
205
1000
230
900
250
800
285
720
315
675
330
625
355
575
380
535
450
-
Steel
Max.
Max. finish
speed 2)
bore 3)
[rpm]
d1, d2
4500
100
4175
110
3825
125
3475
130
3100
150
2725
170
2500
190
2150
220
1900
245
1725
275
1550
310
1375
350
1225
385
1150
405
1075
435
975
450
900
530
855
520
740
560
680
630
590
700
Dimensions [mm]
General
L
l1, l2
E
DH
D1, D2
N1, N2
M*
193
213
227
237
270
300
336
382
428
480
534
590
628
654
666
721
773
969
1092
1212
1332
95
105
112
117
132
147
165
188
211
237
264
292
311
324
330
356
382
480
540
600
660
3
3
3
3
6
6
6
6
6
6
6
6
6
6
6
9
9
9
12
12
12
255
274
298
330
370
419
457
533
597
660
737
826
927
991
1067
1156
1250
1340
1540
1735
1935
136
152
168
180
206
230
256
292
330
368
407
457
508
533
572
610
720
705
780
885
975
56
56
56
56
76
76
76
92
92
92
122
122
122
122
122
164
164
164
220
220
220
76
76
76
76
100
100
100
130
130
130
170
170
170
170
170
220
220
220
300
300
300
1) Standard material NBR (Perbunan) 80 ± 5 Shore A
* Drop-out center dimension required
2) Dynamic balancing required
3) Bores H7 with keyway according to DIN 6885 sheet 1 [JS9] and setscrew on the keyway (see table 7)
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
KTR-N
Sheet:
Edition:
REVOLEX® KX / KX-D
Operating/Assembly instructions
1
49410 EN
5 of 30
15
Technical data
Table 4: Pins - type KX-D (taper bolt design B)
Size
Pin size
M1 [mm]
SW1 [mm]
Tightening torque TA [Nm]
75
Size
Pin size
M1 [mm]
SW1 [mm]
Tightening torque TA [Nm]
240
2
85
95
105
120
135
4
M12
19
115
3
M10
17
67
265
280
6
M24
36
970
305
330
355
150
370
7
M30
46
1350
470
170
520
190
5
M16
24
290
215
590
8
M36
55
2250
650
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 REVOLEX® KX / KX-D 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.
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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
2
KTR-N
Sheet:
Edition:
49410 EN
6 of 30
15
Advice
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 REVOLEX® KX / KX-D described in here corresponds to the technical status at the time of printing of these
operating/assembly instructions.
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 "REVOLEX® KX").
We recommend balancing from a circumferential speed of 30 m/s.
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 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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
2
KTR-N
Sheet:
Edition:
49410 EN
7 of 30
15
Advice
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 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:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
49410 EN
8 of 30
15
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 REVOLEX® type KX (taper pin design B)
Component
1 1)
2 1)
3a
4
7 2)
Quantity
1
1
see table 5
see table 5
Description
Hub part 1
Hub part 2
Pins KX complete (design B)
KX bush
Setscrew DIN EN ISO 4029
1) Material and balancing condition as specified by the customer
2) Axial fastening of the hub and tolerances of the shaft-hub-connections as specified by the customer
Illustration 3: REVOLEX® type KX (taper bolt design B)
Table 5:
Size
Number z of
components
3a, 4
75
8
85
10
95
10
Number z of
components
3a, 4
150
14
170
10
190
12
Please observe protection
note ISO 16016.
105
12
120
10
135
12
215
14
240
10
265
12
Size
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
KTR-N
Sheet:
Edition:
REVOLEX® KX / KX-D
Operating/Assembly instructions
4
49410 EN
9 of 30
15
Assembly
4.1 Components of the couplings
Components of REVOLEX® type KX-D (taper bolt design B)
Component
3c
5 1)
6
7 2)
Quantity
see table 6
2
see table 6
Description
Pin KX-D complete (design B)
Hub part 5
KX-D bush
Setscrew DIN EN ISO 4029
1) Material and balancing condition as specified by the customer
2) Axial fastening of the hub and tolerances of the shaft-hub-connections as specified by the customer
Illustration 4: REVOLEX® type KX-D (taper pin design B)
Table 6:
Size
Number z of
components
3c, 6
75
10
85
12
Number z of
components
3c, 6
240
14
265
16
Please observe protection
note ISO 16016.
95
14
280
18
Drawn:
Verified:
105
16
305
20
120
14
330
24
135
16
Size
355
16
2022-07-06 Pz/Wb
2022-08-09 Pz
150
18
370
20
470
22
Replacing:
Replaced by:
170
14
520
18
190
16
215
18
590
20
650
24
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
49410 EN
10 of 30
15
Assembly
4.2 Components of the pins
Components of complete pin KX (design B) - component 3a
Component
3.1b
3.2
3.3b
3.4a
3.5
Quantity
1
4
2
1
1
Description
Pin KX (design B)
Elastomer ring
Disk
Hexagon screw DIN EN ISO 4014/4017
Circlip DIN 471
Illustration 5: Pin KX complete (design B)
Components of complete pin KX-D (design B) - component 3c
Component
3.1b
3.2
3.3b
3.4c
3.5
Quantity
1
4
2
1
1
Description
Bolt KX-D (design B)
Elastomer ring
Disk
Hexagon screw DIN EN ISO 4014/4017
Circlip DIN 471
Illustration 6: Pin KX-D complete (design B)
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
KTR-N
Sheet:
Edition:
REVOLEX® KX / KX-D
Operating/Assembly instructions
4
49410 EN
11 of 30
15
Assembly
4.3 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 7).
• Make absolutely sure to observe the figures for Ød.
• Carefully align the hubs when the finish bores are drilled.
• The bore tolerance should preferably be selected as per table 8.
• Provide for a setscrew according to DIN EN ISO 4029 with a cup
point or an end plate to fasten the hubs axially.
Illustration 7: 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 7: Setscrew DIN EN ISO 4029
Size
Dimension G [mm]
Dimension t1 [mm]
Dimension t2 [mm]
Tightening torque TA [Nm]
75
M16
25
80
85
M16
25
80
Size
Dimension G [mm]
Dimension t1 [mm]
Dimension t2 [mm]
Tightening torque TA [Nm]
240
M24
50
110
220
265
M24
60
120
220
95
M20
30
140
280
M24
70
140
220
105
M20
40
140
305
M24
70
150
220
120
M24
30
220
330
M24
70
150
220
135
M24
45
220
355
M24
80
160
220
150
M24
45
220
370
M24
80
160
220
470
M24
125
225
220
170
M24
50
220
520
M24
125
225
220
190
M24
50
220
215
M24
50
110
220
590
M24
150
250
220
650
M24
150
250
220
Table 8: Recommended fit pairs acc. to DIN 748/1
Bore [mm]
above
up to
50
50
Please observe protection
note ISO 16016.
Drawn:
Verified:
Shaft tolerance
Bore tolerance
k6
m6
H7
(KTR standard)
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
KTR-N
Sheet:
Edition:
REVOLEX® KX / KX-D
Operating/Assembly instructions
4
49410 EN
12 of 30
15
Assembly
4.3 Advice for finish bore
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.). In this case the keyway should be flush with one of the locating
bores for the pins. 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.
Unbored/pilot bored hubs are supplied without
balancing. If balancing is necessary subject to the
application, it should be made on completion of the
finish bore. The balancing bores have to be made in the
positions marked in illustration 8.
!
The balancing bores have to be made
between the pin bores in every case.
Illustration 8
4.4 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.
Please pay attention to the ignition risk in potentially explosive atmospheres!
STOP
!
Touching the heated hubs causes burns.
Please wear safety gloves.
With the assembly make sure that the distance dimension E (see table 1 and 3) is observed
so that the coupling components are not in contact with each other during the operation.
Disregarding this advice may cause damage to the coupling.
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).
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 or
lifting equipment, respectively. If proper sling gears are used they should be dismounted after assembly of the
coupling.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
49410 EN
13 of 30
15
Assembly
4.5 Assembly of type KX
• Drive the sleeves (component 4) into the bores of the hub
part 2 (component 2) by blows of a soft face hammer and/or
cool the sleeves in the fridge or with nitrogen before assembly
(see illustration 9).
Illustration 9
• Please assemble the hubs onto the shafts of the driving and
driven side in a way that the flat faces of the coupling hubs
are flush with the faces of the shafts (see illustration 10).
Illustration 10
• Shift the power packs in axial direction until the distance
dimension E has been achieved (see illustration 11).
• If the power packs are already firmly assembled, shifting the
hubs axially on the shafts allows for adjusting the distance
dimension E.
• Fasten the hubs by tightening the setscrews
DIN EN ISO 4029 with a cup point (tightening torque see
table 7).
• Align the coupling hubs in a way that the bores for the pins
are flush.
!
Please consider permissible shaft
displacements of chapter 4.8!
Illustration 11
• Insert the pins (component 3a) in the hub part 1 (component
1) (see illustration 12).
• Screw up the pins to the hexagon screws (component 3.4a)
and tighten them evenly to the tightening torques mentioned
in table 2 by means of a torque key (see illustration 12).
!
The screws have to be secured against working
loose, e. g. by conglutinating with Loctite
(average strength).
Having started up the coupling, the coupling
has to be inspected for damages at regular
maintenance intervals and it has to be replaced,
if necessary.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Illustration 12
Replacing:
Replaced by:
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
49410 EN
14 of 30
15
Assembly
4.6 Assembly of type KX-D
• Drive the sleeves (component 6) into the smaller bores of the
hub (component 5) by blows of a soft face hammer and/or
cool the sleeves in the fridge or with nitrogen before assembly
(see illustration 13).
Illustration 13
• Please assemble the hubs onto the shafts of the driving and
driven side in a way that the flat faces of the coupling hubs
are flush with the faces of the shafts (see illustration 14).
Illustration 14
• Shift the power packs in axial direction until the distance
dimension E has been achieved (see illustration 15).
• If the power packs are already firmly assembled, shifting the
hubs axially on the shafts allows for adjusting the distance
dimension E.
• Fasten the hubs by tightening the setscrews
DIN EN ISO 4029 with a cup point (tightening torque see
table 7).
• Align the coupling hubs in a way that the bores for the pins
are flush.
Illustration 15
!
Please consider permissible shaft
displacements of chapter 4.8!
• Insert the bolts (component 3c) in the larger holes of the hub
part 5 (see illustration 16).
• Screw up the bolts to the hexagon screws (component 3.4c)
and tighten them evenly to the tightening torques mentioned
in table 4 by means of a torque key (see illustration 16).
!
The screws have to be secured against working
loose, e. g. by conglutinating with Loctite
(average strength).
Having started up the coupling, the coupling
has to be inspected for damages at regular
maintenance intervals and it has to be
replaced, if necessary.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Illustration 16
Replacing:
Replaced by:
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
49410 EN
15 of 30
15
Assembly
4.7 Replacement of elastomer rings
Option 1: Replacement of elastomer rings without dismounting the pins:
• Pull the driving and driven side far apart so that the coupling is separated or shift the coupling free from load.
• Remove the circlip (component 3.5) and the disk (component 3.3b).
• Disassemble the elastomers (component 3.2).
• Replace the elastomer rings in sets only.

Elastomer rings of the same size only may be used.
• The new elastomer rings are mounted in reverse order.
Option 2: Replacement of pins or elastomer rings by dismounting the pins:
• Pull the driving and driven side far apart so that the coupling is separated or shift the coupling free from load.
• Disassemble the screw (illustration 17; component 3.4a or 3.4c). Afterwards clean the tapping and the thread
of the screw.
Illustration 17: Disassembly of hexagon screw
Illustration 18: Cleaning the tapping
Wear safety glasses.
STOP
• Fill the tapped holes of the pin (component 3.1b) with standard grease by three quarters.
• Wrap a thread sealing tape Loctite 55 around the screw. Leave out the first 2 to 3 threads to make sure that
the screw can be screwed in properly (see illustration 18).
• Screw the screw manually into the pin by 2 to 3 threads.
Illustration 19: Assembly of hexagon screw
Please observe protection
note ISO 16016.
Drawn:
Verified:
Illustration 20: Unscrewing the pin
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
49410 EN
16 of 30
15
Assembly
4.7 Replacement of elastomer rings
STOP
Abrupt movement of the screw (component 3.4a or 3.4c) or sudden unscrewing of the pin
(component 3.1b) results in the risk of getting jammed.
Sudden movement of the pin can be realized by loud noise.
• Screw the screw slowly deeper into the pin via a spanner. The grease flows through the cross hole of the pin
pressing between pin and bush (illustration 20; component 4 or 6).
• If feasible resistance is not generated, it may be necessary to refill the grease or vent the system.

If grease escapes from the tapped hole, the screw needs to be re-sealed with thread sealing
tape Loctite 55.
• As soon as the pin has come off the taper seat of the bush, the extraction process is completed.
• Press all pins out of their seats one after another following the process described above.
• Replace the elastomer rings on the pins as per chapter 4.7 of option 1 described.

If the pins are re-used they have to be cleaned from grease free from any residues.
• The pins are mounted as per chapter 4.5 or 4.6.
4.8 Displacements - alignment of the couplings
The REVOLEX® KX / KX-D compensates for displacements generated by the shafts to be combined as specified
in table 9. 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 hazards with the use in
potentially explosive atmospheres, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures specified (see table 9). 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 9) are permissible.
Please note:
• The displacement figures specified in table 9 are maximum figures which must not arise in parallel. If radial
and angular displacement occur at the same time, the sum of the displacement figures must not exceed Kr or
Kw (see illustration 22).
• Please check with a dial gauge, ruler, feeler or laser measuring device whether the permissible displacement
figures of table 9 can be observed.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
KTR-N
Sheet:
Edition:
REVOLEX® KX / KX-D
Operating/Assembly instructions
4
49410 EN
17 of 30
15
Assembly
4.8 Displacements - alignment of the couplings
Axial displacements
Radial displacements
Angular displacements
Ladm. = L + Ka [mm]
Kw = Emax. - Emin. [mm]
Illustration 21: Displacements
Examples of the displacement
combinations specified in illustration 22:
Illustration 22:
Combinations of
displacement
Example 1:
Kr = 30 %
Kw = 70 %
Example 2:
Kr = 60 %
Kw = 40 %
Ktotal = Kr + Kw  100 %
Table 9: Displacement figures
Size
Max. axial displacement Ka [mm]
250
500
Max. radial displacement Kr
750
[mm] or
max. angular displacement
1000
Kw [mm]
1500
with speed n [rpm]
2000
3000
75
±1.5
0.95
0.70
0.60
0.50
0.40
0.35
0.30
85
±1.5
1.10
0.80
0.65
0.55
0.45
0.40
0.35
Size
Max. axial displacement Ka [mm]
250
500
Max. radial displacement Kr
750
[mm] or
max. angular displacement
1000
Kw [mm]
1500
with speed n [rpm]
2000
3000
240
±2.5
2.2
1.6
1.3
1.1
0.9
-
265
±2.5
2.5
1.7
1.4
1.2
1.0
-
Please observe protection
note ISO 16016.
Drawn:
Verified:
95
±1.5
1.10
0.80
0.65
0.55
0.45
0.40
0.35
280
±2.5
2.7
1.9
1.6
1.4
-
105
±2
1.2
0.9
0.7
0.6
0.5
0.4
0.4
305
±2.5
2.9
2.0
1.7
1.4
-
2022-07-06 Pz/Wb
2022-08-09 Pz
120
±2
1.3
0.9
0.8
0.7
0.5
0.5
0.4
330
±4
3.1
2.2
1.8
1.5
-
135
±2
1.4
1.0
0.8
0.7
0.6
0.5
355
±4
3.3
2.3
1.9
1.7
-
150
±2
1.5
1.1
0.9
0.8
0.6
0.5
370
±4
3.5
2.5
2.0
1.8
-
Replacing:
Replaced by:
170
±2.5
1.7
1.2
1.0
0.9
0.7
0.6
-
470
±4
3.8
2.8
2.2
-
520
±4
4.4
3.1
2.4
-
190
±2.5
1.9
1.3
1.1
0.9
0.8
0.7
-
215
±2.5
2.0
1.4
1.2
1.0
0.8
-
590
±4
4.9
3.5
-
650
±4
5.4
3.8
-
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
5
KTR-N
Sheet:
Edition:
49410 EN
18 of 30
15
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 flange 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.
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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
5
KTR-N
Sheet:
Edition:
49410 EN
19 of 30
15
Start-up
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 rings 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 may result in a use of the REVOLEX® KX / KX-D 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.
The coupling can become a source of ignition with improper use.
Directive 2014/34/EU and UK directive SI 2016 No. 1107 require special care by the
manufacturer and the user.
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 pin/elastomer ring is inserted in the coupling.
• No original KTR components (purchased parts) are used.
• Old/already worn out elastomer rings or elastomer rings stored for too long are used.
• Maintenance intervals are not observed.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
6
KTR-N
Sheet:
Edition:
49410 EN
20 of 30
15
Breakdowns, causes and elimination
Breakdowns
Different operating
noise and/or
vibrations occuring
Fracture of hub
Early wear of
elastomers
Causes
Hazard notes for
potentially explosive
atmospheres
Elimination
1) Set the unit out of operation
2) Eliminate the reason for the misalignment
Increased temperature on
(e. g. loose foundation bolts, fracture of the
the elastomer ring surface;
Misalignment
engine mount, heat expansion of unit
ignition risk by hot
components, modification of the installation
surfaces
dimension E 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 rings/pins
3) Inspect coupling components and replace
Ignition risk due to
Wear of elastomers
coupling hubs that are damaged
sparking
4) Generally assemble new elastomer rings
with new pins
5) Assemble coupling components
6) Inspect alignment, adjust if necessary
1) Set the unit out of operation
Screws for axial
2) Inspect alignment of coupling
Ignition risk due to hot
fastening of hubs
3) Tighten the screws to fasten the hubs and
surfaces and sparking
working loose
secure against working loose
4) For inspection of wear see chapter 10.2
1) Set the unit out of operation
Fracture of hub due to
2) Replace complete coupling
high impact
3) Find out the reason for overload
energy/overload
4) Inspect alignment
Ignition risk due to
sparking
1) Set the unit out of operation
Operating error of the
2) Replace complete coupling
unit
3) Inspect alignment
4) Instruct and train the service staff
1) Set the unit out of operation
2) Disassemble the coupling and remove
e. g. contact with
remainders of the elastomer rings/pins
aggressive liquids/oils,
3) Inspect coupling components and replace
ozone influence, too
coupling hubs that are damaged
high/low ambient
4) Generally assemble new elastomer rings
temperatures etc.
with new pins
causing a physical
5) Assemble coupling components
modification of the
6) Inspect alignment, adjust if necessary
elastomer rings
7) Make sure that further physical modifications
Ignition risk due to
of the pins are excluded
sparking with metallic
1) Set the unit out of operation
contact of the cams
2) Disassemble the coupling and remove
remainders of the elastomer rings/pins
Ambient/contact
3) Inspect coupling components and replace
temperatures which
coupling hubs that are damaged
are too high for the
4) Generally assemble new elastomer rings
elastomer ring, max.
with new pins
permissible
5) Assemble coupling components
-30 °C/+75 °C
6) Inspect alignment, adjust if necessary
7) Inspect and adjust ambient/contact
temperature
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
6
49410 EN
21 of 30
15
Breakdowns, causes and elimination
Breakdowns
Early wear of pins
(hardening/embrittlem
ent of the pin
elastomer)
!
7
KTR-N
Sheet:
Edition:
Causes
Vibrations of drive
Hazard notes for
potentially explosive
atmospheres
Elimination
Ignition risk due to
sparking with metallic
contact of the cams
1) Set the unit out of operation
2) Disassemble the coupling and remove
remainders of the elastomer rings/pins
3) Find out the reason for vibrations
4) Inspect coupling components and replace
coupling hubs that are damaged
5) Generally assemble new elastomer rings
with new pins
6) Assemble coupling components
7) Inspect alignment, adjust if necessary
If you operate with worn elastomer rings (see chapter 10.3) proper operation is not ensured.
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.
8
Maintenance and service
REVOLEX® KX / KX-D 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 pins 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 inspected visually.
With the use in potentially explosive atmospheres observe chapter 10.2 "Inspection
intervals for couplings in
potentially explosive atmospheres".
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
9
KTR-N
Sheet:
Edition:
49410 EN
22 of 30
15
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]
10
Enclosure A
Advice and instructions regarding the use in
potentially explosive atmospheres
Types available:
KX and KX-D
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
KTR-N
Sheet:
Edition:
REVOLEX® KX / KX-D
Operating/Assembly instructions
10
49410 EN
23 of 30
15
Enclosure A
Advice and instructions regarding the use in
10.1 Intended use in
potentially explosive atmospheres
potentially explosive atmospheres
Conditions of operation in
potentially explosive atmospheres
The REVOLEX® KX / KX-D 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.
The couplings may only be used if their materials are resistant to mechanical and/or chemical influences with
different operating conditions in a way that the explosion protection is not 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.
In addition the current national mining instructions which each apply for the application have to be respected for
the use in mining.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
49410 EN
24 of 30
15
Enclosure A
Advice and instructions regarding the use in
10.2 Inspection intervals for couplings in
Equipment category
Please observe protection
note ISO 16016.
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 torsional backlash and a visual inspection of the elastomer
rings 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 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, please specify 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 torsional backlash and a visual inspection of the elastomer
rings 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 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, please specify the cause
according to the table „Breakdowns“, if possible.
The maintenance intervals must be adjusted to the modified operating
parameters without fail.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
KTR-N
Sheet:
Edition:
REVOLEX® KX / KX-D
Operating/Assembly instructions
10
49410 EN
25 of 30
15
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 a twisting backlash  smax. in mm or a wall thickness Xmin. in mm the elastomer rings need to be replaced.
In order to ensure a long service life of the coupling and avoid hazards with the use in
potentially explosive atmospheres, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures specified (see table 9). If the figures are
exceeded, the coupling will be damaged.
!
Illustration 23: Inspection of the limit of wear
Illustration 24:
Wear of elastomer ring
Table 10:
Size
Diameter of
elastomer
75
85
95
105
120
135
150
170
190
215
240
50.0
50.0
50.0
50.0
63.0
63.0
63.0
85.5
85.5
85.5
113.7
Limits of wear [mm]
New
Wall
condition
thickness
B
Xmind.
12.25
8.60
12.25
8.60
12.25
8.60
12.25
8.60
16.15
11.30
16.15
11.30
16.15
11.30
21.15
14.80
21.15
14.80
21.15
14.80
27.65
19.40
Please observe protection
note ISO 16016.
Drawn:
Verified:
Torsional
backlash
Smax.
5
5
5
5
6
6
6
9
9
9
16
Size
Diameter of
elastomer
265
280
305
330
355
370
470
520
590
650
113.7
113.7
113.7
113.7
150.0
150.0
150.0
200.0
200.0
200.0
2022-07-06 Pz/Wb
2022-08-09 Pz
Limits of wear [mm]
New
Wall
condition
thickness
B
Xmind.
27.65
19.40
27.65
19.40
27.65
19.40
27.65
19.40
37.50
26.25
37.50
26.25
37.50
26.25
52.50
36.75
52.50
36.75
52.50
36.75
Replacing:
Replaced by:
Torsional
backlash
Smax.
16
16
16
16
20
20
20
30
30
30
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
10
49410 EN
26 of 30
15
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
The explosion protection marking of the REVOLEX® KX / KX-D coupling is applied on the outer sheath or on the
front side.
The pins along with elastomer rings are 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.)
REVOLEX® KX / KX-D
<Year>
Deviating marking applied until 31st October 2019:
Short marking:
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/I M2 c -30 °C  Ta  +80 °C
Complete marking:
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
10
49410 EN
27 of 30
15
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, high level of safety, 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:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
49410 EN
28 of 30
15
Enclosure A
Advice and instructions regarding the use in
potentially explosive atmospheres
10.5 Rating of danger of ignition
Source of danger
Inaccurate coupling
assembly
Hubs are working loose on
the shafts
Elimination
With a rough error in assembly the two coupling flanges being opposite to each other might touch
(e. g. with angular displacements exceeding the permissible tolerances by far) or the elastomers
might be compressed exceeding their load limit (e. g. with impermissible radial displacement), but
which may be avoided by a test run.
The fixed connection of the shaft-hub-connection should be inspected in regular intervals by the
operator and re-arranged, if necessary.
The couplings need to be protected against contact by suitable protective devices (e. g. solid
covers) in order to exclude friction of foreign substances on the couplings as a failure anticipated.
The minimum distance between the protective device and rotating parts has to be defined in a
way that even if the protection against contact is damaged (e. g. indentation), no friction is
generated on the rotating coupling. Moreover, when defining the distance deflections caused by
vibrations of the shaft need to be considered.
Friction of foreign substances For the use of couplings in mining the protective device needs to be particularly solid to make
on the coupling
sure that the damage which must not be excluded with rough operating conditions (e. g. by
impressing) does not generate trailing/friction on the coupling. Moreover, the protective devices in
mining must not consist of light-weight metals.
Contact/impact of foreign
substances on the coupling
Dust deposit on couplings
which are not dustproof all
over
Please observe protection
note ISO 16016.
The protective device for mining has to pass the shock test as per EN 13463-1:2009, section
8.4.1, table 10 according to the degree of mechanical danger “high” (impact energy 20 J). This
fact needs to be observed by the user (e. g. mechanical engineer) or the operator of the
couplings.
If the coupling gets in contact with objects, mechanical sparks may be produced each
depending on the material and the energy of impact by swinging and striking against other
objects (e. g. objects made of light-weight metal or rusty iron). Since the couplings have to be
provided with protective devices by the user which may have openings (see rules for protection
against contact by rotating parts) for a better heat dissipation by convection, the contact or
striking of dangerous objects on or against the couplings may be excluded as an anticipated
failure.
For the protective device a material has to be used excluding the production of ignitable
mechanical sparks as far as possible.
In order to ensure a troublefree normal operation even in an explosive dust atmosphere it has to
be made sure that the couplings are inspected in regular intervals to be free from critical dust
deposits (e. g. free from coating) and are not running in a dust accumulation. This needs to be
observed particularly if the couplings are provided with non-dustproof protective devices against
contact.
Moreover, in places of work which are subject to dust explosion as well as in mining a higher
amount of wear of the elastomer rings has to be considered. The elastomer rings must not be
worn off in a way that the pins slide brightly in the holes.
The source of ignition „self-ignition and glowing of dust deposits“ cannot be assumed as an
anticipated failure with a proper maintenance of the coupling. Here corresponding maintenance
means that the couplings need to be inspected in regular intervals to make sure that they are
free from dangerous dust deposits and are not running in a dust accumulation.
The corresponding inspection and cleaning rules have to be determined by the operator. The
interval has to be determined depending on the operating conditions and safety specifications of
dust like temperature of self-ignition and glowing at one’s own responsibility.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
49410 EN
29 of 30
15
Enclosure A
Advice and instructions regarding the use in
potentially explosive atmospheres
10.6 EU Declaration 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
REVOLEX® KX / KX-D 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 is issued under the sole responsibility of the manufacturers
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 REVOLEX® KX / KX-D is in accordance with the specifications of the 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 IBExU06ATEXB009 X):
IBExU
Institut für Sicherheitstechnik GmbH
Identification number: 0637
Fuchsmühlenweg 7
09599 Freiberg
Rheine,
Place
2022-07-06
Date
Please observe protection
note ISO 16016.
Drawn:
Verified:
i. V.
Reinhard Wibbeling
Engineering/R&D
2022-07-06 Pz/Wb
2022-08-09 Pz
i. V.
Michael Brüning
Product Manager
Replacing:
Replaced by:
KTR-N dated 2019-07-26
REVOLEX® KX / KX-D
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
49410 EN
30 of 30
15
Enclosure A
Advice and instructions regarding the use in
potentially explosive atmospheres
10.7 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
REVOLEX® KX / KX-D 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 REVOLEX® KX / KX-D 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
2022-07-06
Date
Please observe protection
note ISO 16016.
Drawn:
Verified:
i. V.
Reinhard Wibbeling
Engineering/R&D
2022-07-06 Pz/Wb
2022-08-09 Pz
i. V.
Michael Brüning
Product Manager
Replacing:
Replaced by:
KTR-N dated 2019-07-26
">