KTR RIGIFLEX-HP Operating/Mounting Instructions
KTR RIGIFLEX-HP is a torsionally stiff steel lamina coupling for high-speed drive trains. It compensates for shaft misalignment caused by thermal expansion and other factors. The coupling is designed for use in a variety of applications, including industrial machinery, power generation, and material handling. RIGIFLEX-HP is available in two types: Type C and Type L, with different dimensions and torque ratings. Consult the RIGIFLEX-HP catalogue for detailed product information and selection instructions.
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RIGIFLEX®-HP Operating/Assembly instructions KTR-N Sheet: Edition: 47510 EN 1 of 14 2 RIGIFLEX®-HP Torsionally stiff steel lamina coupling types C and L Type C Type L Please observe protection note ISO 16016. Drawn: Verified: 2016-10-27 Shg/ Wig 2016-11-09 Shg Replacing: Replaced by: KTR-N dated 2013-03-06 RIGIFLEX®-HP Operating/Assembly instructions KTR-N Sheet: Edition: 47510 EN 2 of 14 2 RIGIFLEX®-HP is a torsionally stiff flexible steel lamina coupling for high-speed drive trains. It is able to compensate for shaft misalignment, for example caused by 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 5 5 6 6 3 4 Coupling selection General advice Safety and advice symbols General hazard warnings General hazard warnings Reference to EC Machinery Directive 2006/42/EC Storage, transport and packaging 6 3.1 3.2 6 6 Storage Transport and packaging Assembly 6 4.1 4.2 4.3 4.4 4.5 4.6 7 8 8 9 9 10 Components of the coupling Advice for finish bore Assembly of coupling hubs Assembly of the spacer - type C Assembly of the spacer - type L Displacements - alignment of the coupling 5 Start-up 11 6 Breakdowns, causes and elimination 12 7 Disposal 13 8 Maintenance and service 14 9 Spares inventory, customer service addresses 14 Please observe protection note ISO 16016. Drawn: Verified: 2016-10-27 Shg/ Wig 2016-11-09 Shg Replacing: Replaced by: KTR-N dated 2013-03-06 KTR-N Sheet: Edition: RIGIFLEX®-HP Operating/Assembly instructions 1 47510 EN 3 of 14 2 Technical data Type C Illustration 1: RIGIFLEX®-HP, type C Table 1: Dimensions – type C 158 168 188 208 228 248 278 318 358 388 Dimensions [mm] D DA DZ DR E1 119 139 147 168 178 196 225 252 295 330 220 255 265 298 315 335 380 445 500 545 195 220 235 245 270 300 335 370 415 464 135 155 165 186 199 217 248 280 326 362 17 23 23 23 33 33 33 48 48 48 E Emin. CG1/CG2 According to customer specification Size Max. finish bore d1; d2 85 100 105 120 125 140 160 180 210 235 335 395 375 350 425 395 355 495 435 400 46 55 55 57 65 67 70 88 93 97 1) l1/l2 l3/l4 l5/l6 85 100 105 120 125 140 160 180 210 235 189 229 229 229 265 265 265 348 348 348 130 155 155 155 175 175 175 225 225 225 1) with E=457.2 mm and cylindrical maximum finish bore Table 2: Torque and speed - type C Torque [Nm] Size TKN 20000 30000 38000 50000 59000 72000 115000 180000 253000 330000 158 168 188 208 228 248 278 318 358 388 Please observe protection note ISO 16016. Drawn: Verified: TK max. 26000 39000 49400 65000 76700 93600 149500 234000 328900 429000 2016-10-27 Shg/ Wig 2016-11-09 Shg Replacing: Replaced by: Max. speed [rpm] 17300 14900 14400 12800 12100 11400 10000 8500 7600 7000 KTR-N dated 2013-03-06 KTR-N Sheet: Edition: RIGIFLEX®-HP Operating/Assembly instructions 1 47510 EN 4 of 14 2 Technical data Type L Illustration 2: RIGIFLEX®-HP, type L Table 3: Dimensions – type L 158 168 188 208 228 248 278 318 358 388 Dimensions [mm] D DA DZ DR E1 210 230 250 280 310 340 380 445 490 535 310 320 335 362 390 420 455 550 600 650 220 255 265 298 315 334 380 445 500 545 135 155 165 186 199 217 248 280 326 362 17 23 23 23 33 33 33 48 48 48 E Emin. CG1/CG2 According to customer specification Size Max. finish bore d1; d2 150 165 180 200 220 240 270 315 350 380 265 340 340 340 390 390 390 510 510 510 140 148 156 165 179 185 202 246 263 277 1) l1/l2 l3/l4 l5/l6 150 165 180 200 220 235 270 315 350 380 163.5 168.5 183.5 203.5 223.5 238.5 273.5 318.5 353.5 383.5 37.5 48.0 48.0 48.0 54.5 54.5 54.5 71.5 71.5 71.5 1) with E=457.2 mm and cylindrical maximum finish bore Table 4: Torque and speed - type L Torque [Nm] Size TKN 20000 30000 38000 50000 59000 72000 115000 180000 253000 330000 158 168 188 208 228 248 278 318 358 388 Please observe protection note ISO 16016. Drawn: Verified: TK max. 26000 39000 49400 65000 76700 93600 149500 234000 328900 429000 2016-10-27 Shg/ Wig 2016-11-09 Shg Replacing: Replaced by: Max. speed [rpm] 13800 12300 11400 10500 9700 9000 8300 6900 6300 5800 KTR-N dated 2013-03-06 RIGIFLEX®-HP Operating/Assembly instructions 2 KTR-N Sheet: Edition: 47510 EN 5 of 14 2 Advice 2.1 Coupling selection ! For a long-lasting and failure-free operation of the coupling it must be selected according to ® the selection instructions for the particular application (see RIGIFLEX -HP catalogue). If the operating conditions (performance, speed, modifications on engine and machine) change, the coupling selection must be reviewed. Please note that the technical data regarding torque refer to the lamina set 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. 2.2 General advice Please read through these assembly instructions carefully before you start up the coupling. Please pay special attention to the safety instructions! The assembly instructions are part of your product. Please store them carefully and close to the coupling. The copyright for these assembly instructions remains with KTR. 2.3 Safety and advice symbols STOP ! Warning of personal injury This symbol indicates notes which may contribute to preventing bodily injuries or serious bodily injuries that may result in death. Warning of product damages This symbol indicates notes which may contribute to preventing material or machine damage. General advice This symbol indicates notes which may contribute to preventing adverse results or conditions. 2.4 General hazard warnings STOP With assembly, operation and maintenance of the coupling it has to be made sure that the entire drive train is secured against accidental switch-on. You may be seriously hurt by rotating parts. Please make absolutely sure to read through and observe the following safety indications. All operations on and with the coupling have to be performed taking into account "safety first". Please make sure to switch off the power pack before you perform your work on the coupling. Secure the power pack against accidental switch-on, e. g. by providing warning signs at the place of switch-on or removing the fuse for current supply. Do not reach into the operating area of the coupling as long as it is in operation. Please secure the coupling against accidental contact. Please provide for the necessary protection devices and covers. Please observe protection note ISO 16016. Drawn: Verified: 2016-10-27 Shg/ Wig 2016-11-09 Shg Replacing: Replaced by: KTR-N dated 2013-03-06 RIGIFLEX®-HP Operating/Assembly instructions 2 KTR-N Sheet: Edition: 47510 EN 6 of 14 2 Advice 2.5 General hazard warnings You may only assemble, operate and maintain the coupling if you have carefully read through the assembly instructions and understood them had technical training are authorized by your company The coupling may only be used in accordance with the technical data (see chapter 1). Unauthorized modifications on the coupling design are not admissible. We will not assume liability for any damage that may arise. In the interest of further development we reserve the right for technical modifications. ® The RIGIFLEX -HP described in here corresponds to the technical status at the time of printing of these assembly instructions. 2.6 Reference to EC Machinery Directive 2006/42/EC The couplings supplied by KTR should be considered as components, not machines or partly completed machines according to EC Machinery Directive 2006/42/EC. Consequently KTR does not have to issue a declaration of incorporation. For details about safe assembly, start-up and safe operation please refer to the present operating/assembly instructions considering the warnings. 3 Storage, transport and packaging 3.1 Storage The couplings are supplied in preserved condition and can be stored at a dry and covered place for 6 - 9 months. Humid storage rooms are not suitable. Please make sure that condensation is not generated. The best relative air humidity is less than 65 %. ! 3.2 Transport and packaging In order to avoid any injuries and any kind of damage please always make use of proper transport and lifting equipment. ! The couplings are packed differently each depending on size, number and kind of transport. Unless otherwise contractually agreed, packaging will follow the in-house packaging specifications of KTR. 4 Assembly The coupling hubs are supplied fully assembled. Before assembly the coupling has to be inspected for completeness. STOP Driving components falling down may cause injury to persons or damage on the machine. Secure the driving components with assembly or disassembly. Please observe protection note ISO 16016. Drawn: Verified: 2016-10-27 Shg/ Wig 2016-11-09 Shg Replacing: Replaced by: KTR-N dated 2013-03-06 RIGIFLEX®-HP Operating/Assembly instructions 4 KTR-N Sheet: Edition: 47510 EN 7 of 14 2 Assembly 4.1 Components of the coupling Components of RIGIFLEX®-HP type C Component 1 2 3 4 Quantity 2 1 see table 5 see table 5 Description Coupling hub C Spacer C Double hexagon bolt Double hexagon nut Illustration 3: RIGIFLEX®-HP, type C Table 5: Size Number of double hexagon 1) 1) bolt /nut Tightening torque TA [Nm] 158 168 188 208 228 248 278 318 358 388 18 24 30 30 24 25 30 25 30 34 115 115 115 115 290 290 290 560 560 560 1) Quantity for each coupling half Components of RIGIFLEX®-HP type L Component 1 2 3 4 Quantity 2 1 see table 6 see table 6 Description Coupling hub L Spacer L Double hexagon bolt Double hexagon nut Illustration 4: RIGIFLEX®-HP, type L Table 6: Size Number of double hexagon 1) 1) bolt /nut Tightening torque TA [Nm] 158 168 188 208 228 248 278 318 358 388 13 18 20 24 15 18 20 20 25 30 115 115 115 115 290 290 290 560 560 560 1) Quantity for each coupling half Please observe protection note ISO 16016. Drawn: Verified: 2016-10-27 Shg/ Wig 2016-11-09 Shg Replacing: Replaced by: KTR-N dated 2013-03-06 RIGIFLEX®-HP Operating/Assembly instructions 4 KTR-N Sheet: Edition: 47510 EN 8 of 14 2 Assembly 4.2 Advice for finish bore ! 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. 4.3 Assembly of coupling hubs 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 shafts. 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 please make sure that the distance dimension E (see table 1) is observed so that the coupling components are not in contact with each other during the operation. Disregarding this advice may cause damage to the coupling. For axial alignment of the coupling the distance dimension E (see table 1 and 3) is decisive. In order to adjust the right dimension E you should proceed as follows: Mount the coupling hubs (component 1) onto the shaft of driving and driven side. The internal sides of the coupling hubs must be flush with the front sides of the shafts (type C see illustration 5 resp. type L see illustration 6). Shift the power packs in axial direction until the distance dimension E is achieved. If the power packs are already firmly assembled, shifting the coupling hubs axially on the shafts allows for adjusting the distance dimension E. Illustration 5: Assembly of coupling hubs C Please observe protection note ISO 16016. Drawn: Verified: Illustration 6: assembly of the coupling hubs L 2016-10-27 Shg/ Wig 2016-11-09 Shg Replacing: Replaced by: KTR-N dated 2013-03-06 RIGIFLEX®-HP Operating/Assembly instructions 4 KTR-N Sheet: Edition: 47510 EN 9 of 14 2 Assembly 4.4 Assembly of the spacer - type C The coupling hubs (component 1) have to be aligned such that the screws of the lamina sets line up (see illustration 5). Clean and degrease the centerings and contact surfaces on the spacer (component 2) and coupling hubs. ! The transportation screws and spacer sleeves have to be removed for further assembly and operation (see illustration 7). Insert the spacer between the coupling hubs. Hand-screw the spacer on the coupling hubs by means of the double hexagon screws and double hexagon nuts. Tighten the double nuts at the tightening torque (see table 5) specified while protecting the double hexagon screws from rotating. Illustration 7: Disassembly of transport lock For each coupling only screws with the same weight (tared) may be used. Having started up the coupling, the tightening torque of the screws has to be inspected at regular maintenance intervals. ! 4.5 Assembly of the spacer - type L The coupling hubs (component 1) have to be aligned such that the holes of the coupling hubs line up (see illustration 6). Clean and degrease the centerings and contact surfaces on the spacer (component 2) and coupling hubs. ! The transportation screws and spacer sleeves have to be removed for further assembly and operation (see illustration 8). Insert the spacer between the coupling hubs. Hand-screw the spacer on the coupling hubs by means of the double hexagon screws and double hexagon nuts. Tighten the double hexagon nuts at the tightening torque (see table 6) specified while protecting the double hexagon screws from rotating. ! Illustration 8: Disassembly of transport lock For each coupling only screws with the same weight (tared) may be used. Having started up the coupling, the tightening torque of the screws has to be inspected at regular maintenance intervals. Please observe protection note ISO 16016. Drawn: Verified: 2016-10-27 Shg/ Wig 2016-11-09 Shg Replacing: Replaced by: KTR-N dated 2013-03-06 RIGIFLEX®-HP Operating/Assembly instructions 4 KTR-N Sheet: Edition: 47510 EN 10 of 14 2 Assembly 4.6 Displacements - alignment of the coupling The displacement figures specified in table 7 provide for sufficient safety to compensate for external influences like, for example, thermal expansion or foundation settling. ! In order to ensure a long service life of the coupling, the shaft ends have to be accurately aligned. Please absolutely observe the displacement figures specified (see table 7). If the figures are exceeded, the coupling will be damaged. The more accurate the alignment of the coupling, the longer is its service life. Please note: The displacement figures specified in table 7 are maximum figures which must not arise in parallel. If radial, axial and angular displacement arises at the same time, these values must be reduced (see illustration 10). Please inspect with a dial gauge, ruler or feeler gauge whether the permissible displacement figures specified in table 7 can be observed. Angular displacements Radial displacements Illustration 9: Displacements (example: type C) Axial displacements Examples of the displacement combinations specified in illustration 10: Illustration 10: Combinations of displacement Example 1: Kr = 10% Kw = 80% Ka = 10% Example 2: Kr = 30% Kw = 30% Ka = 40% Ktotal = Ka + Kr + Kw 100 % Please observe protection note ISO 16016. Drawn: Verified: 2016-10-27 Shg/ Wig 2016-11-09 Shg Replacing: Replaced by: KTR-N dated 2013-03-06 KTR-N Sheet: Edition: RIGIFLEX®-HP Operating/Assembly instructions 4 47510 EN 11 of 14 2 Assembly 4.6 Displacements - alignment of the coupling Table 7: Displacement figures Angular displace1) ment Kw [°] 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 0.25 Size 158 168 188 208 228 248 278 318 358 388 Radial displacement Axial displacement Ka [mm] 2) DKr [mm] Type C Type L 2.30 2.32 2.37 2.50 2.44 2.58 2.75 2.70 2.96 3.18 1.56 1.45 1.45 1.45 1.34 1.34 1.34 1.13 1.13 1.13 ±3.0 ±3.0 ±3.3 ±3.8 ±4.0 ±4.2 ±4.5 ±5.2 ±6.0 ±6.5 1) each lamina set 2) with E=457.2 mm and cylindrical maximum finish bore 5 Start-up Before start-up of the coupling, please 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, dependent on the type of coupling. Finally the coupling protection against accidental contact must be fitted. The cover must be electrically conductive and included in the equipotential bonding. Bellhousings (magnesium share below 7.5 %) made of aluminium and damping rings (NBR) can be used as connecting element between pump and electric motor. The cover may only be taken off with standstill of the unit. During operation of the coupling, please pay attention to different operating noise vibrations occurring. The minimum distance „Sr“ between the protective device and the rotating parts must at least correspond to the figures specified below. If the protective device is used as cover, regular openings can be arranged from the point of view explosion protection that must not exceed the following dimensions: Openings Circular - max. diameter Rectangular - max. lateral length Straight or curved slot - max. lateral length/height ! Top side 4 4 Cover [mm] Lateral components 8 8 Distance „Sr“ 10 10 not permissible 8 20 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 mentioned 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: 2016-10-27 Shg/ Wig 2016-11-09 Shg Replacing: Replaced by: KTR-N dated 2013-03-06 RIGIFLEX®-HP Operating/Assembly instructions 6 KTR-N Sheet: Edition: 47510 EN 12 of 14 2 Breakdowns, causes and elimination ® The below-mentioned failures can result in a use of the RIGIFLEX -HP coupling other than intended. In addition to the specifications given in these operating and assembly instructions please make sure to avoid such failures. The errors listed can only be clues to search for the failures. When searching for the failure the adjacent components must generally be considered. General failures with use other than intended: Important data for the coupling selection were not forwarded. The calculation of the shaft-hub-connection was not considered. Coupling components with damage occurred during transport are assembled. If the heated hubs are assembled, the permissible temperature is exceeded. The clearance of the components to be assembled is not coordinated with one another. Tightening torques have been fallen below/exceeded. Components are mixed up by mistake/assembled incorrectly. A wrong or no lamina set is inserted in the coupling. No original KTR components (purchased parts) are used. Maintenance intervals are not observed. Breakdowns Different operating noise and/or vibrations occuring Causes Hazard notes for hazardous locations Misalignment none Cap screws working loose, low micro friction under the screw head and on the steel lamina set Danger of ignition due to hot surfaces Screws for axial fastening of hubs working loose none Drawn: Verified: 2016-10-27 Shg/ Wig 2016-11-09 Shg Please observe protection note ISO 16016. Elimination 1) Set the unit out of operation 2) Eliminate the reason for the misalignment (e. g. loose foundation bolts, breaking of the engine mount, heat expansion of unit components, modification of the installation dimension E of the coupling) 3) For inspection of wear see item inspection 1) Set the unit out of operation 2) Inspect coupling components and replace coupling components that are damaged 3) Tighten the cap screws until the permissible tightening torque is reached 4) Inspect alignment, adjust if necessary 1) Set the unit out of operation 2) Inspect alignment of coupling 3) Tighten the screws to fasten the hubs and secure against working loose 4) For inspection of wear see item inspection Replacing: Replaced by: KTR-N dated 2013-03-06 RIGIFLEX®-HP Operating/Assembly instructions 6 47510 EN 13 of 14 2 Breakdowns, causes and elimination Breakdowns Breaking of steel lamina set Cracks in / fracture of the steel lamina set / locking screws 7 KTR-N Sheet: Edition: Causes Hazard notes for hazardous locations Breaking of the steel lamina set due to high impact energy/overload Ignition risk due to sparking Operating parameters do not meet with the performance of the coupling Ignition risk due to sparking Operating error of the unit Ignition risk due to sparking Vibrations of drive Ignition risk due to sparking Elimination 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the steel lamina sets 3) Inspect coupling components and replace coupling components that are damaged 4) Insert spacer, mount coupling components 5) Find out the reason for overload 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 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the spacer 3) Inspect coupling components and replace coupling components that are damaged 4) Insert spacer, mount coupling components 5) Instruct and train the service staff 1) Set the unit out of operation 2) Disassemble the coupling and remove remainders of the spacer 3) Inspect coupling components and replace coupling components that are damaged 4) Insert spacer, mount coupling components 5) Inspect alignment, adjust if necessary 6) Find out the reason for vibrations 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. All coupling components consist of metal. Any metal components have to be cleaned and disposed of by scrap metal. Please observe protection note ISO 16016. Drawn: Verified: 2016-10-27 Shg/ Wig 2016-11-09 Shg Replacing: Replaced by: KTR-N dated 2013-03-06 RIGIFLEX®-HP Operating/Assembly instructions 8 KTR-N Sheet: Edition: 47510 EN 14 of 14 2 Maintenance and service ® RIGIFLEX -HP 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 lamina sets as well as the alignment and screw connection of the coupling. Since the flexible machine bearings of the driving and driven side settle during the course of load, please inspect the alignment of the coupling and re-align the coupling, if necessary. If some individual laminas are broken, the lamina sets of the coupling have to be replaced. The coupling parts have to be inspected for damages. The screw connections have to be inspected visually. After start-up of the coupling the tightening torques of the screws of the lamina sets have to be inspected during usual maintenance intervals. ! 9 Spares inventory, customer service addresses A basic requirement to ensure the readiness for use of the coupling is a stock of the most important spare parts on site. Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage at www.ktr.com. KTR does not assume any liability or warranty for the use of spare parts and accessories which are not provided by KTR and for the damages which may incur as a result. Please observe protection note ISO 16016. Drawn: Verified: 2016-10-27 Shg/ Wig 2016-11-09 Shg Replacing: Replaced by: KTR-N dated 2013-03-06 ">
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Key features
- Torsionally stiff
- Steel lamina coupling
- High-speed drive trains
- Shaft misalignment compensation
- Type C & L variations
Frequently asked questions
The KTR RIGIFLEX-HP coupling is designed to connect two shafts together, while allowing for some degree of misalignment between the shafts. This is important in applications where the shafts may move slightly due to factors such as thermal expansion or vibration.
The KTR RIGIFLEX-HP coupling can compensate for radial, axial, and angular misalignment between the shafts.
The KTR RIGIFLEX-HP coupling is available in two types: Type C and Type L. The main difference between the two types is the dimensions and torque ratings.