KTR RIGIFLEX-N Operating/Mounting Instructions

RIGIFLEX®-N
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
47410 EN
1 of 24
14
RIGIFLEX®-N
Torsionally stiff steel lamina
coupling
Type A, size 35
according to directive 2014/34/EU
and UK directive
SI 2016 No. 1107
Type A, size 50 - 408
Type A-J
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-05
RIGIFLEX®-N
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
47410 EN
2 of 24
14
RIGIFLEX®-N is a torsionally stiff flexible steel laminae coupling. 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
6
6
6
3
4
General advice
Safety and advice symbols
General hazard warnings
Intended use
Coupling selection
Reference to EC Machinery Directive 2006/42/EC
Storage, transport and packaging
6
3.1
3.2
6
7
Storage
Transport and packaging
Assembly
7
4.1
4.2
4.3
4.4
4.5
7
8
10
11
13
Components of the coupling
Advice for finish bore
Assembly of coupling hubs
Assembly of the spacer
Displacements - alignment of the couplings
5
Start-up
14
6
Breakdowns, causes and elimination
16
7
Disposal
17
8
Maintenance and service
18
9
Spares inventory, customer service addresses
18
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
Please observe protection
note ISO 16016.
Drawn:
Verified:
19
potentially explosive atmospheres
10.3
marking of coupling for potentially explosive atmospheres
10.4 EU Declaration of conformity
10.5 UK Declaration of conformity
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
19
20
21
23
24
KTR-N dated 2019-11-05
RIGIFLEX®-N
Operating/Assembly instructions
1
KTR-N
Sheet:
Edition:
47410 EN
3 of 24
14
Technical data
Illustration 1: RIGIFLEX®-N type A, size 35
Illustration 2: RIGIFLEX®-N type A, size 50 - 408
Table 1: Dimensions - type A
Size
35
50
65
75
85
110
120
140
160
166
196
216
256
306
346
406
168
198
218
258
308
348
408
Max. finish
bore [mm]
D
50
50
70
75
90
110
120
150
165
165
195
210
260
305
350
405
165
195
210
260
305
350
405
DN
70
100
105
120
152
165
200
230
230
260
285
350
400
460
530
230
260
285
350
400
460
530
DH
75
95
126
138
156
191
213
265
305
305
330
370
440
515
590
675
305
330
370
440
515
590
675
L1, L2
38.5
50
63
62.5
72.5
87
102
126
145
155
185
205
245
295
335
395
155
185
205
245
295
335
395
L7
8.5
12
12
12
15
18
20
25
31
31
32
32
38
43
55
58.5
31
32
32
38
43
55
58.5
Dimensions [mm]
General
E
DBSE 1)
6
100
140
9
100
140
11
100
140
180
11
100
140
180
12
140
180
200
250
12
140
180
200
250
12
180
200
250
15
200
250
15
250
17
24
26
31
36
45
50
According to customer specification
17
24
26
31
36
45
50
G
M6
M6
M8
M8
M10
M10
M12
M12
M12
M16
M16
M20
M20
M24
M24
M24
M16
M16
M20
M20
M24
M24
M24
Setscrew
T
15
10
20
20
20
25
25
30
30
30
40
50
70
70
95
95
30
40
50
70
70
95
95
T1
70
90
110
130
130
175
175
70
90
110
130
130
175
175
1) Other shaft distance dimensions available on request
2) For figures MxLM see table 9
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-05
KTR-N
Sheet:
Edition:
RIGIFLEX®-N
Operating/Assembly instructions
1
47410 EN
4 of 24
14
Technical data
Illustration 3: RIGIFLEX®-N, type A-J
Table 2: Dimensions - type A-J
Max. finish bore [mm]
D
D1
50
70
70
90
75
100
90
110
110
150
120
165
150
195
Size
50
65
75
85
110
120
140
Size
50
65
75
85
110
120
140
DN
70
100
105
120
152
165
200
DN1
100
120
140
152
200
230
260
Setscrew
DH
95
126
138
156
191
213
265
DH1
126
156
180
191
265
305
330
G
M6
M8
M8
M10
M10
M12
M12
T
10
20
20
20
25
25
30
L1
50
62
62
72
87
102
126
Dimensions [mm]
L2
E
63.0
9
72.5
11
83.0
11
87.5
12
127
12
147
12
186
15
75
1100
2200
550
12400
85
1900
3800
950
11000
G1
M8
M10
M10
M10
M12
M12
M16
100
100
100
-
140
140
140
140
140
-
T1
20
20
20
25
30
30
40/90
DBSE 1)
180
180
180
180
180
-
200
200
200
200
250
250
250
250
1) Other shaft distance dimensions available on request
2) For figures MxLM and M1xLM1 see table 10
Table 3: Torque and speed
Size
TKN
Torque
TK max
[Nm]
TKW
Max. speed n [rpm]
Size
TKN
Torque
TK max
[Nm]
TKW
Max. speed n [rpm]
!
35
130
260
65
23000
50
270
540
135
18000
65
550
1100
275
13600
256
52500
105000
26250
3900
306
86000
172000
43000
3300
346
135000
270000
67500
2900
406
210000
420000
105000
2500
110
3500
7000
1750
9000
168
25000
50000
12500
5600
120
5750
11500
2875
8000
198
30000
60000
15000
5200
140
10500
21000
5250
6400
218
42500
85000
21500
4600
160
16000
32000
8000
5600
258
70000
140000
35000
3900
166
19000
38000
9500
5600
196
22500
45000
11250
5200
216
32000
64000
16000
4600
308
115000
230000
57500
3300
348
180000
360000
90000
2900
408
280000
560000
140000
2500
In case if a dimensional drawing was prepared for the coupling, the dimensions specified
have to be primarily observed.
The operator of the machine should be provided with the dimensional drawing.
RIGIFLEX®-N 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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-05
RIGIFLEX®-N
Operating/Assembly instructions
2
KTR-N
Sheet:
Edition:
47410 EN
5 of 24
14
Advice
2.1 General advice
Read through these operating/assembly instructions carefully before you start up the coupling.
Pay special attention to the safety instructions!
The RIGIFLEX®-N 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.
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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-05
RIGIFLEX®-N
Operating/Assembly instructions
2
KTR-N
Sheet:
Edition:
47410 EN
6 of 24
14
Advice
2.4 Intended use
You may only assemble, operate and maintain the coupling if you
• have carefully read through the operating/assembly instructions and understood them
• 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 RIGIFLEX®-N described in here corresponds to the state of the art at the time of printing of these
operating/assembly instructions.
2.5 Coupling selection
!
For a long-lasting and failure-free operation of the coupling it must be selected according to
the selection instructions for the particular application (see catalogue drive technology
"RIGIFLEX®-N").
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 laminae 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.
2.6 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 couplings are supplied in preserved condition and can be stored in a dry and roofed place for 6 - 9 months.
!
Humid storage rooms are not suitable.
Make sure that condensation is not generated. The best relative air humidity is less than
65 %.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-05
KTR-N
Sheet:
Edition:
RIGIFLEX®-N
Operating/Assembly instructions
3
47410 EN
7 of 24
14
Storage, transport and packaging
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.
4
Assembly
The spacer is supplied fully assembled. Before assembly the coupling has to be inspected for completeness.
4.1 Components of the coupling
Components of RIGIFLEX®-N type A
Component
1
2
3
4
Quantity
2
1
see table 4
see table 4
Description
Coupling hub
Spacer complete
Cap screws DIN EN ISO 4762
Setscrew DIN EN ISO 4029
Size 35
Size 50 - 408
Illustration 4: RIGIFLEX®-N type A
Table 4:
Size
Number of cap screws 1)
Number of setscrews 1)
35
24
2
50
16
2
65
24
2
Size
Number of cap screws 1)
Number of setscrews 1)
256
36
4
306
36
4
346
36
4
75
24
2
406
36
4
85
36
2
110
36
2
168
32
4
120
36
2
198
32
4
140
36
2
218
48
4
160
36
2
258
48
4
166
24
4
308
48
4
196
24
4
216
36
4
348
48
4
408
48
4
1) Number per coupling
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-05
KTR-N
Sheet:
Edition:
RIGIFLEX®-N
Operating/Assembly instructions
4
47410 EN
8 of 24
14
Assembly
4.1 Components of the coupling
Components of RIGIFLEX®-N type A-J
Component
1.1
1.2
2
3.1
3.2
4.1
4.2
Quantity
1
1
1
see table 5
see table 5
see table 5
see table 5
Description
Coupling hub
Coupling hub J
Spacer complete
Cap screws DIN EN ISO 4762
Cap screws DIN EN ISO 4762
Setscrew DIN EN ISO 4029
Setscrew DIN EN ISO 4029
Illustration 5: RIGIFLEX®-N, type A-J
Table 5:
Size
Number of cap screws
Number of setscrews
Component
3.1
3.2
4.1
4.2
50
8
12
1
1
65
12
18
1
1
75
12
18
1
1
85
18
18
1
1
110
18
18
1
1
120
18
18
1
1
140
18
12
1
2
4.2 Advice for finish bore
STOP
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.
• Hub bores machined by the customer have to observe concentricity resp. axial runout (see illustration 6).
• 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.
!
A centering is not available with pilot bored or unbored hubs, respectively. It has to be
drilled according to illustration 6. Size and depth of the centering are shown in table 1.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-05
KTR-N
Sheet:
Edition:
RIGIFLEX®-N
Operating/Assembly instructions
4
47410 EN
9 of 24
14
Assembly
4.2 Advice for finish bore
Type A, size 35
Type A, size 50 - 408
Type A-J, component 1.1
Type A-J, component 1.2
Illustration 6: 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 6: Setscrew DIN EN ISO 4029 - type A
Size
Dimension G [mm]
Tightening torque TA [Nm]
35
M6
4.8
50
M6
4.8
65
M8
10
Size
Dimension G [mm]
Tightening torque TA [Nm]
256
M20
140
306
M24
240
346
M24
240
75
M8
10
85
M10
17
406
M24
240
168
M16
80
110
M10
17
120
M12
40
198
M16
80
140
M12
40
218
M20
140
160
M12
40
258
M20
140
166
M16
80
308
M24
240
196
M16
80
216
M20
140
348
M24
240
408
M24
240
Table 7: Setscrew DIN EN ISO 4029 - type A-J
Size
Dimension G [mm]
Tightening torque TA [Nm]
Dimension G1 [mm]
Tightening torque TA1 [Nm]
50
M6
4.8
M8
10
Please observe protection
note ISO 16016.
Drawn:
Verified:
65
M8
10
M10
17
75
M8
10
M10
17
2022-07-06 Pz/Wb
2022-08-09 Pz
85
M10
17
M10
17
110
M10
17
M12
40
Replacing:
Replaced by:
120
M12
40
M12
40
140
M12
40
M16
80
KTR-N dated 2019-11-05
RIGIFLEX®-N
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
47410 EN
10 of 24
14
Assembly
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.
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 DBSE (see table 1 and 2) 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).
For axial alignment of the coupling the distance dimension DBSE (see table 1 and 2) is decisive. In order to set
the right DBSE dimension you should proceed as follows:
• Shift the coupling hubs onto the shaft of
the driving and driven side.
• The internal sides of the coupling hubs
must be flush with the front sides of the
shafts (see illustration 7).
• Align the power pack in axial direction
until the distance dimension DBSE is
achieved (see table 1 and 2).
• Fasten the coupling hubs by tightening the
setscrews DIN EN ISO 4029 with a cup
point (see table 6 or 7).
Illustration 7: Assembly of coupling hubs
Disassembly:
STOP
Parts released or falling down may cause injury to persons or damage on the machine.
Secure the components before disassembly.
• Release the setscrew in the hub and unscrew it by 2 - 3 pitches.
• Pull the hub from the shaft.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-05
KTR-N
Sheet:
Edition:
RIGIFLEX®-N
Operating/Assembly instructions
4
47410 EN
11 of 24
14
Assembly
4.4 Assembly of the spacer
If the coupling is supplied with a transportation lock (optionally), the
following has to be observed:
!
The spacer sleeves (steel) have to be removed for
further assembly and operation (see illustration 8).
• Disassemble the transport screws and spacer sleeves.
• Afterwards the transport screws can be reassembled and used as
retraction screws.
Illustration 8: Transport lock
If the coupling is supplied with limitation for axial clearance
(optionally), the following has to be observed:
• Before mounting the spacer, remove the screws and sleeves for
limitation of axial clearance.
• Having mounted the spacer completely, re-assemble the screws
and sleeves for limitation of axial clearance (see illustration 9).
Please observe the axial clearance S as per dimension sheet.
• Secure the screws against working loose by means of a highstrength adhesive (e. g. omniFIT 230M or Loctite 2701).
Illustration 9: Limitation of axial clearance
!
Please consider whether a limitation for axial clearance with two nylon sleeves per screw or
one transport lock with one steel sleeve per screw was installed (see illustration 8 and 9).
• The coupling hubs have to be aligned such that the through holes
of the coupling hubs line up.
• Clean and degrease the centerings and contact surfaces on the
spacer and coupling hubs.
• Pull up the flanges of „spacer complete“ closer to the spacer each
by the maximum value R (see table 8) by means of the retraction
screws (see illustration 10).
The transport screws (see illustration 8) or cap screws (component
3, see illustration 4 and 5) can be used as retraction screws.
• Insert the spacer between the hubs, align the through hole flush
with the threaded hole for screwing.
Illustration 10
Table 8
Size
Value R [mm]
35
1.7
Size
Value R [mm]
166 / 168
2.2
Please observe protection
note ISO 16016.
Drawn:
Verified:
50
1.2
65
1.2
196 / 198
2.7
75
1.7
216 / 218
2.7
2022-07-06 Pz/Wb
2022-08-09 Pz
85
1.7
110
2.2
256 / 258
2.7
120
2.2
306 / 308
3.2
Replacing:
Replaced by:
140
3.2
160
3.2
346 / 348
3.2
406 / 408
3.2
KTR-N dated 2019-11-05
KTR-N
Sheet:
Edition:
RIGIFLEX®-N
Operating/Assembly instructions
4
47410 EN
12 of 24
14
Assembly
4.4 Assembly of the spacer
• With assembly-balanced couplings make sure that the balancing marking X (Y) of the hub is flush with the
balancing marking X (Y) of the spacer (see illustration 11) (optionally).
• Centre the spacer in the coupling hubs by unscrewing and removing the retraction screws.
!
The retraction screws have to be removed for further assembly and operation.
• Hand-screw the spacer to the coupling hubs via the cap screws (see illustration 12).
• Tighten the cap screws one after another and with several revolutions until all cap screws have reached the
full tightening torque (see table 9 or 10).
Illustration 11: Alignment of spacer
Illustration 12
Table 9: Tightening torques of the cap screws - type A
Size
Dimension MxLM [mm]
Tightening torque TA [Nm]
35
M4x45
4.1
Size
Dimension MxLM [mm]
Tightening torque TA [Nm]
166 / 168
M20x50
560
50
M6x22
14
65
M6x25
14
196 / 198
M20x50
560
75
M8x30
35
216 / 218
M20x65
560
85
M8x30
35
110
M10x35
69
120
M12x40
120
140
M16x50
295
160
M16x55
295
256 / 258
M24x80
970
306 / 308
M27x100
1450
346 / 348
M30x110
1950
406 / 408
M36x130
3300
85
M8x30
35
M10x30
69
110
M10x35
69
M16x45
295
120
M12x40
120
M16x45
295
140
M16x50
295
M20x45
560
Table 10: Tightening torques of the cap screws - type A-J
Size
Dimension MxLM [mm]
Tightening torque TA [Nm]
Dimension M1xLM1 [mm]
Tightening torque TA1 [Nm]
Please observe protection
note ISO 16016.
50
M6x22
14
M6x25
14
Drawn:
Verified:
65
M6x25
14
M8x25
35
75
M8x30
35
M8x30
35
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-05
RIGIFLEX®-N
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
47410 EN
13 of 24
14
Assembly
4.5 Displacements - alignment of the couplings
The displacement figures specified in table 11 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 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 11). 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 11) are permissible.
!
Please note:
• The displacement figures specified in table 11 are maximum figures which must not arise in parallel. If axial,
radial and angular displacement arises at the same time, these values must be reduced (see illustration 14).
• Please inspect with a dial gauge, ruler or feeler gauge whether the permissible displacement figures specified
in table 11 can be observed.
Axial displacements
Radial displacements
Angular displacements
Illustration 13: Displacements
Examples of the displacement
combinations specified in illustration 14:
Illustration 14:
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:
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Replacing:
Replaced by:
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RIGIFLEX®-N
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
47410 EN
14 of 24
14
Assembly
4.5 Displacements - alignment of the couplings
Table 11: Displacement figures
Size
35
50
65
75
85
110
120
140
160
166
196
216
256
306
346
406
168
198
218
258
308
348
408
Axial
displacement
Ka [mm]
1.2
1.4
1.5
1.8
2.1
2.4
2.6
3.3
3.8
3.7
4.2
4.5
5.2
6.0
6.7
7.5
2.6
2.6
2.9
3.5
4.2
4.8
5.0
DBSE = 100
0.90
0.77
0.75
0.73
-
Radial displacement
Kr [mm]
DBSE = 140
DBSE = 180
DBSE = 200
1.40
1.26
1.23
1.72
1.22
1.71
1.14
1.62
1.87
1.05
1.54
1.78
1.00
1.49
1.73
1.55
-
Mounting dimension DBSE as specified by the customer
DBSE = 250
2.48
2.39
2.35
2.16
1.99
Angular
displacement 1)
Kw [°]
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.5
0.5
0.5
0.5
0.5
0.5
0.5
1) each laminae set
5
Start-up
!
Before start-up make absolutely sure that the transport lock (see illustration 8) and
retraction screws (see illustration 10) have been removed.
Before start-up of the coupling, inspect the tightening of the setscrews in the hubs, the alignment and the distance
dimension DBSE 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. We recommend a minimum distance of 15
mm from the outside diameter DH of the coupling.
Please observe protection
note ISO 16016.
Drawn:
Verified:
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2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-05
RIGIFLEX®-N
Operating/Assembly instructions
5
KTR-N
Sheet:
Edition:
47410 EN
15 of 24
14
Start-up
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.
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 laminae set is not admitted to ensure an
equipotential bonding.
In addition, make sure that the marking of the coupling remains legible.
Please observe protection
note ISO 16016.
Drawn:
Verified:
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2022-08-09 Pz
Replacing:
Replaced by:
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RIGIFLEX®-N
Operating/Assembly instructions
6
KTR-N
Sheet:
Edition:
47410 EN
16 of 24
14
Breakdowns, causes and elimination
The below-mentioned failures can result in an improper use of the RIGIFLEX®-N coupling. 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 by 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 improper use:
• 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.
• When 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 laminae 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
Fracture of steel
laminae set
Causes
Hazard notes for
potentially explosive
atmospheres
Misalignment
none
Cap screws working
loose, low micro friction
under the screw head
and on the steel
laminae set
Danger of ignition due to
hot surfaces
Screws for axial
fastening of hubs
working loose
none
Fracture of steel
laminae set due to high
impact
energy/overload
Ignition risk due to
sparking
Operating parameters
do not meet with the
performance of the
coupling
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
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, thermal expansion of unit
components, modification of the installation
dimension E of the coupling)
3) For inspection of wear see chapter 10.2
1) Set the unit out of operation
2) Inspect coupling components and replace
coupling components that have been
damaged
3) Tighten the cap screws until the permissible
tightening torque has been 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 chapter 10.2
1) Set the unit out of operation
2) Disassemble the coupling and remove
remainders of the steel laminae sets
3) Inspect coupling components and replace
coupling components that have been
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
Replacing:
Replaced by:
KTR-N dated 2019-11-05
RIGIFLEX®-N
Operating/Assembly instructions
6
47410 EN
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14
Breakdowns, causes and elimination
Breakdowns
Fracture of steel
laminae set
Cracks in / fracture of
the steel laminae set /
fastening screws
!
7
KTR-N
Sheet:
Edition:
Causes
Hazard notes for
potentially explosive
atmospheres
Elimination
Ignition risk due to
sparking
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 have been
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 have been
damaged
4) Insert spacer, mount coupling components
5) Inspect alignment, adjust if necessary
6) Find out the reason for vibrations
Operating error of the
unit
Vibrations of drive
When operating with a faulty laminae set (see chapter 10.2), proper operation is not assured.
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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-05
RIGIFLEX®-N
Operating/Assembly instructions
8
KTR-N
Sheet:
Edition:
47410 EN
18 of 24
14
Maintenance and service
Monitoring of the general condition of the coupling can be done both at standstill and during operation. If the
coupling is tested during operation, the operator must ensure an appropriate and proven test procedure (e. g.
stroboscopic lamp, high-speed camera, etc.) which is definitely comparable to testing at standstill. If any
distinctive features occur, an inspection must be made with the machine stopped.
RIGIFLEX®-N is a low-maintenance coupling. We recommend to perform a visual inspection on the coupling at
least once a year. Pay special attention to the condition of the laminae sets, alignment and screw connection 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.
• If some individual laminas are broken, the laminae sets of the coupling have to be replaced. 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".
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:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-05
KTR-N
Sheet:
Edition:
RIGIFLEX®-N
Operating/Assembly instructions
10
47410 EN
19 of 24
14
Enclosure A
Advice and instructions regarding the use in
potentially explosive atmospheres
Types available:
Type A
RIGIFLEX®-N with spacer made of steel only.
10.1 Intended use in
potentially explosive atmospheres
Conditions of operation in
potentially explosive atmospheres
The RIGIFLEX®-N 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
T2
T3
T4
T5
T6
Ambient or operating temperature Ta 1)
-40 °C to +230 °C
-40 °C to +175 °C
-40 °C to +110 °C
-40 °C to +75 °C
-40 °C to +60 °C
Max. surface temperature 2)
+250 °C
+195 °C
+130 °C
+95 °C
+80 °C
Explanation:
The maximum surface temperatures each result from the maximum permissible ambient or operating temperature Ta plus the maximum
temperature increase T of 20 K to be considered. For the temperature classes T6 to T3 (≤ 200 °C) a safety margin subject to standard of 5 K
and from temperature class T3 (≥ 200 °C) a safety margin subject to standard of 10 K is added.
1) The ambient or operating temperature Ta is limited to +250 °C due to the permissible permanent operating temperature (surface
temperature).
2) The maximum surface temperature of +230 °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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-05
RIGIFLEX®-N
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
47410 EN
20 of 24
14
Enclosure A
Advice and instructions regarding the use in
10.1 Intended use in
potentially explosive atmospheres
potentially explosive atmospheres
2. Mining
Equipment group I of category M2 (coupling is not approved/not suitable for equipment group M1).
Permissible ambient temperature -40 °C to +130 °C.
10.2 Inspection intervals for couplings in
Equipment category
3G
3D
M2
2G
2D
No gases and vapours of
explosion group IIC
2G
2D
Gases and vapours of
explosion group IIC
potentially explosive atmospheres
Inspection intervals
For couplings operated in zone 2 or zone 22 the inspection and maintenance intervals of
the usual operating/assembly instructions for standard operation apply. During the
standard operation which has to be taken as a basis of the ignition risk analysis the
couplings are free from any ignition source. For gases, vapours and dusts generated the
permissible glow and ignition temperatures specified in chapter 10.1 have to be
considered and observed.
An inspection of the torsional backlash and a visual inspection of the laminae sets must
be performed after 3,000 operating hours for the first time, at the latest 6 months after
start-up of the coupling.
If you note insignificant or no wear on the lamina sets 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 laminae sets, 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 torsional backlash and a visual inspection of the laminae sets must
be performed after 2,000 operating hours for the first time, at the latest 3 months after
start-up of the coupling.
If you note insignificant or no wear on the lamina sets 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 laminae sets, find out the cause according to the table
„Breakdowns“, if possible.
The maintenance intervals must be adjusted to the modified operating parameters
without fail.
During the visual inspection the laminae sets
must be inspected for cracks and screws
working loose. Screws working loose must
be tightened at the screw tightening torque
specified (consult with KTR). Regardless of
the inspection intervals those laminae sets
that are damaged or have cracks have to be
replaced by a new „complete spacer“
immediately.
Illustration 15: RIGIFLEX®-N type A
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-05
RIGIFLEX®-N
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
47410 EN
21 of 24
14
Enclosure A
Advice and instructions regarding the use in
10.3
potentially explosive atmospheres
marking of coupling for potentially explosive atmospheres
The explosion protection marking of the RIGIFLEX®-N coupling is applied on the outer sheath or on the front side.
The laminae sets are not marked.
For the complete marking refer to the operating/assembly instructions and/or the delivery note/package.
Marking is as follows:
• Marking for unpainted res. coated or painted couplings with a layer thickness < 200 µm
I M2
II 2G
II 2D
Ex h
I
Mb
Ex h
IIC T6
… T2
Gb
Ex h
IIIC T80 °C … T250 °C Db
<Year>
-40 °C ≤ Ta ≤ +60 °C … +230 °C
KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine
X
X
X
-40 °C ≤ Ta ≤ +130 °C
• Marking for painted couplings with a layer thickness of 0.2 mm to max. 2.0 mm
I M2
II 2G
II 2D
Ex h
I
Mb
Ex h
IIB T6
… T2
Gb
Ex h
IIIC T80 °C … T250 °C Db
<Year>
-40 °C ≤ Ta ≤ +60 °C … +230 °C
KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine
X
X
X
-40 °C ≤ Ta ≤ +130 °C
Short marking:
(A short marking is only made if not possible differently for reason of space or functioning.)
RIGIFLEX®-N
<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, T5, T4, T3 resp. T2 -30 °C  Ta  +75 °C, +90 °C,
+125 °C, +190 °C resp. +250 °C
II 2D c T 110 °C -30 °C  Ta  +100 °C /I M2 c -30 °C  Ta  +140 °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 2019-11-05
RIGIFLEX®-N
Operating/Assembly instructions
10
47410 EN
22 of 24
14
Enclosure A
Advice and instructions regarding the use in
10.3
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
IIB
Gases and vapours of class IIB (including IIA)
IIC
Gases and vapours of class IIC (including IIA and IIB)
IIIC
Electrically conductive dusts of class IIIC (including IIIA and IIIB)
T6 … T2
Temperature class to be considered, depending on the ambient temperature
T80 °C … T250 °C
Maximum surface temperature to be considered, depending on the ambient
temperature
-40 °C ≤ Ta ≤ +60 °C … +230 °C, Permissible ambient temperature from -40 °C to +60 °C resp.
-40 °C ≤ Ta ≤ +230 °C or
-40 °C to +230 °C or -40 °C to +130 °C
-40 °C ≤ Ta ≤ +130 °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:
2022-07-06 Pz/Wb
2022-08-09 Pz
Replacing:
Replaced by:
KTR-N dated 2019-11-05
RIGIFLEX®-N
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
47410 EN
23 of 24
14
Enclosure A
Advice and instructions regarding the use in
potentially explosive atmospheres
10.4 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
RIGIFLEX®-N Steel Lamina 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 RIGIFLEX®-N 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 IBExU07ATEXB004 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.
Reiner Banemann
Product Manager
Replacing:
Replaced by:
KTR-N dated 2019-11-05
RIGIFLEX®-N
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
47410 EN
24 of 24
14
Enclosure A
Advice and instructions regarding the use in
potentially explosive atmospheres
10.5 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
RIGIFLEX®-N Steel Lamina 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 RIGIFLEX®-N 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.
Reiner Banemann
Product Manager
Replacing:
Replaced by:
KTR-N dated 2019-11-05
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