KTR ROTEX GS Operating/Mounting Instructions

ROTEX® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
45510 EN
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25
ROTEX® GS
Torsionally flexible jaw-type couplings
ROTEX® GS, shaft coupling
shaft coupling,
clamping hubs,
Compact,
clamping ring hubs light,
clamping ring hubs,
DKM and their combinations
according to directive 2014/34/EU
and UK directive SI 2016 No. 1107
ROTEX® GS, clamping hubs
ROTEX® GS, Compact
ROTEX® GS, clamping ring hubs light
ROTEX® GS, clamping ring hubs steel
ROTEX® GS, clamping ring hubs
ROTEX® GS, DKM
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
KTR-N dated 2022-08-05
ROTEX® GS
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
45510 EN
2 of 41
25
ROTEX® GS is a plug-in shaft coupling for measuring technology and automatic control engineering. It
is able to compensate for shaft misalignment, for example caused by manufacturing inaccuracies, thermal expansion, etc.
Table of contents
1
2
3
4
Technical data
4
1.1
1.2
1.3
4
5
6
Types of hubs
Torques and finish bores
Coupling dimensions
Advice
17
2.1
2.2
2.3
2.4
2.5
2.6
17
18
18
18
19
19
General advice
Safety and advice symbols
General hazard warnings
Proper use
Coupling selection
Reference to EC Machinery Directive 2006/42/EC
Storage, transport and packaging
19
3.1
3.2
19
19
Storage
Transport and packaging
Assembly
20
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
20
23
23
24
24
25
25
27
27
Components of the coupling
Advice for assembly
Advice for finish bore
Assembly of the coupling (general)
Assembly of the hubs (hub type 1.0, 1.1 and 1.2)
Assembly of the clamping hubs (hub types 2.0, 2.1, 2.5, 2.6, 2.8 and 2.9)
Assembly of clamping ring hubs (hub type 6.0 light, 6.0 steel and 6.0)
Disassembly of clamping ring hubs (hub type 6.0 light, 6.0 steel and 6.0)
Displacements - alignment of the couplings
5
Start-up
29
6
Breakdowns, causes and elimination
30
7
Disposal
32
8
Maintenance and service
33
9
Spares inventory, customer service addresses
33
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
KTR-N dated 2022-08-05
KTR-N
Sheet:
Edition:
ROTEX® GS
Operating/Assembly instructions
45510 EN
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25
Table of contents
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:
35
potentially explosive atmospheres
10.4
marking of coupling for potentially explosive atmospheres
10.5 EU Certificate of conformity
10.6 UK Declaration of conformity
Please observe protection
note ISO 16016.
34
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
36
37
38
40
41
KTR-N dated 2022-08-05
ROTEX® GS
Operating/Assembly instructions
1
KTR-N
Sheet:
Edition:
45510 EN
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Technical data
1.1 Types of hubs
Type 1.0
Hub with feather keyway and setscrew
Type 1.1 1)
Hub without feather keyway, with setscrew
Type 1.2 2)
Hub without feather keyway, without setscrew
Type 2.8 (Compact) 1)
Short clamping hub C
with axial slot, without feather keyway
(from size 24 standard)
(size 7 - 19 single slot)
Type 2.9 (Compact)
Short clamping hub C
with axial slot, with feather keyway
(from size 24 standard)
(size 7 - 19 single slot)
Type 2.0 1)
Clamping hub single slot without feather
keyway (up to size 14 standard)
Type 2.5 1)
Clamping hub double slot without feather
keyway (from size 19 standard)
Type 2.1
Clamping hub single slot with feather keyway
(up to size 14 standard)
Type 2.6
Clamping hub double slot with feather keyway
(from size 19 standard)
Type 6.0 light
Clamping ring hub light
(size 14 - 48)
Type 6.0 (steel)
Clamping ring hub steel
(size 19 - 90)
Type 6.0 3)
Clamping ring hub
(size 14 - 38)
Illustration 1: Types of hubs
1)
Hubs, clamping hubs or similar types without feather keyway may be used in category 3
only and are marked with category 3 accordingly.
2)
Hub type 1.2 is not approved for potentially explosive atmospheres!
3)
Hub material - aluminium (Al-H); clamping ring material - steel
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
KTR-N dated 2022-08-05
ROTEX® GS
Operating/Assembly instructions
1
KTR-N
Sheet:
Edition:
45510 EN
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Technical data
1.2 Torques and finish bores
Table 1: Torques of spiders
Spider 1) (component 2)
Rated torque in Nm
98 ShA-GS
57 ShD-GS
0.9
2.0
2.0
5.0
9.0
11.0
12.5
15.0
21
23
60
68
160
180
325
365
450
495
525
590
685
940
1920
3600
-
Size
5
7
8
9
12
13
14
16
19
24
28
38
42
48
55
65
75
90
80 ShA-GS
0.3
0.7
0.7
1.8
3.0
3.6
4.0
5.0
6
-
92 ShA-GS
0.5
1.2
3.0
5.0
7.5
12
35
95
190
265
310
410
-
64 ShD-GS
2.4
2.4
6.0
12.0
14.5
16.0
19.0
26
75
200
405
560
655
825
1175
2400
4500
72 ShD-GS 2)
97
260
525
728
852
1072
1527
3120
5850
2.8
7
8
9
12
12.7
16
16
27
32
35
45
-
6.0 light
14
20
32
38
48
51
55
1) Maximum torque of the coupling TKmax. = rated torque of the coupling TKN x 2
For coupling selection see catalogue drive technology "ROTEX® GS"
2) When using the spider 72 ShD, we recommend to use hubs made of steel.
Table 2: Finish bores
Size
Unbored
Dmin.
5
7
8
9
12
13
14
16
19
24
28
38
42
48
55
65
75
90
x
x
x
x
x
x
x
x
x
-
2
3
4
4
5
6
8
10
12
14
15
20
22
30
40
Please observe protection
note ISO 16016.
1.0
7
10
12
16
24
28
38
45
55
62
74
80
95
110
Drawn:
Verified:
1.1
6
7
11
12
16
-
1.2
5
7
11
12
16
-
2.0
5
7
11
12
16
-
Finish bore in mm
Dmax.
for hub type
2.1
2.5
2.6
7
11
12
16
24
24
28
28
38
38
45
45
50
45
55
55
68
68
70
70
80
80
90
90
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
2.9
7
8
9
12
12.7
16
16
27
32
35
45
-
6.0
20
28
38
48
51
55
70
70
80
105
KTR-N dated 2022-08-05
KTR-N
Sheet:
Edition:
ROTEX® GS
Operating/Assembly instructions
1
45510 EN
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25
Technical data
1.3 Coupling dimensions
Standard shaft coupling
Illustration 2: ROTEX® GS
(size 5 - 38)

Illustration 3: ROTEX® GS
(size 42 - 90)
Please refer to table 1 for torques and table 2 for finish bores.
Table 3: Dimensions - Standard shaft coupling
B1
S
A
Setscrew
DIN EN ISO 4029
G
T
4
6
8
10
10
12
14
15
18
0.5
1.0
1.0
1.0
1.5
2.0
2.0
2.5
3.0
4.0
6.0
1.5
3.5
2.0
3.0
3.0
4.0
4.0
M2
M3
M4
M4
M4
M5
M5
M8
M8
2.5
3.5
5.0
5.0
5.0
10
10
15
15
20
21
22
26
30
34
3.0
3.5
4.0
4.5
5.0
5.5
4.0
4.0
4.5
4.5
5.0
6.5
M8
M8
M10
M10
M10
M12
20
20
20
20
25
30
Dimensions in mm
Size
DN
DH
DI1
L
5
7
9
12
14
19
24
28
38
-
10
14
20
25
30
40
55
65
80
7.2
8.5
10.5
18
27
30
38
15
22
30
34
35
66
78
90
114
42
48
55
65
75
90
85
95
110
115
135
160
95
105
120
135
160
200
46
51
60
68
80
104
126
140
160
185
210
245
Please observe protection
note ISO 16016.
Drawn:
Verified:
L1, L2
N
E
Hub material - aluminium
5
5
7
8
10
10
11
12
11
13
25
16
30
18
35
20
45
24
Hub material - steel
50
28
26
56
32
28
65
37
30
75
47
35
85
53
40
100
62
45
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
KTR-N dated 2022-08-05
KTR-N
Sheet:
Edition:
ROTEX® GS
Operating/Assembly instructions
1
45510 EN
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25
Technical data
1.3 Coupling dimensions
Clamping hubs
Illustration 4: ROTEX® GS
hub type 2.0 (from size 5 - 14)

Illustration 5: ROTEX® GS
hub type 2.5 (from size 19 - 90)
Please refer to table 1 for torques and table 2 for finish bores.
Table 4: Dimensions - clamping hubs
Dimensions 3) in mm
Size
DN
DH
DI1
L
L1, L2
5
7
9
12
14
19
24
28
38
-
10
14
20
25
30
40
55
65
80
7.2
8.5
10.5
18
27
30
38
15
22
30
34
35
66
78
90
114
5
7
10
11
11
25
30
35
45
42
48
55
65
75
90
85
95
110
115
135
160
95
105
120
135
160
200
46
51
60
68
80
104
126
140
160
185
210
245
50
56
65
75
85
100
N
E
B1
Hub material - aluminium
5
4
8
6
10
8
12
10
13
10
16
12
18
14
20
15
24
18
Hub material - steel
28
26
20
32
28
21
37
30
22
47
35
26
53
40
30
62
45
34
Clamping screw DIN EN ISO 4762
(ROTEX® GS 5 - DIN EN ISO 1207)
TA in
M
A1
K
DK
Nm
S
A
0.5
1.0
1.0
1.0
1.5
2.0
2.0
2.5
3.0
4.0
6.0
1.5
3.5
2.0
3.0
3.0
4.0
4.0
M1.2
M2
M2.5
M3
M3
M6 2)
M6
M8
M8
2.5
3.5
5.0
5.0
5.0
11.0
10.5
11.5
15.5
3.5
5.0
7.5
9.0
11.5
14.5 2)
20.0
25.0
30.0
11.4
16.5
23.4
27.5
32.2
46.0
57.5
73.0
83.5
- 1)
0.37
0.76
1.34
1.34
10.5 2)
10.5
25
25
3.0
3.5
4.0
4.5
5.0
5.5
4.0
4.0
4.5
4.5
5.0
6.5
M10
M12
M12
M12
M16
M20
18
21
26
33
36
40
32.0
36.0
42.5
45.0
51.0
60.0
93.5
105.0
119.5
124.0
147.5
176.0
69
120
120
120
295
580
1) Slotted screw, tightening torque not defined
2) Size 19: Bore Ø22 - Ø24 with 2-off clamping screws M4, TA = 2.9 Nm and dimension K = 15.0
3) Transmittable friction torques of clamping hubs see table 5
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
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KTR-N
Sheet:
Edition:
ROTEX® GS
Operating/Assembly instructions
1
45510 EN
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25
Technical data
1.3 Coupling dimensions
Table 5: Friction torques and surface pressure of clamping hubs (hub type 2.0 and 2.5)
Size
5
7
9
12
1.6
82
1.9
64
2.2
52
2.6
44
2.9
38
3.2
33
3.5
29
3.8
26
2.4
113
2.9
88
3.4
72
3.9
61
4.4
53
4.9
46
5.4
41
5.8
37
6.3
33
Bore Ø
14
19
24
28
38
42
48
Transmittable friction torque TR of clamping hub in Nm
surface pressure in N/mm2
65
75
90
456
84
493
76
529
69
553
65
577
62
611
57
499
64
536
58
560
55
584
52
620
48
1107
89
1175
82
1764
116
1876
107
-
Ø2
-
Ø3
-
Ø4
-
Ø5
Ø6
Ø7
0.7
90
0.9
65
1.1
51
1.2
41
1.4
34
Ø8
Ø9
Ø10
Ø11
Ø12
Ø14
Ø15
Ø16
Ø18
Ø19
Ø20
Ø22
Ø24
Ø25
Ø28
Ø30
Ø32
Ø35
Ø38
3.1
93
3.6
76
4.2
64
4.7
56
5.2
49
5.7
43
6.2
39
6.7
35
7.6
29
8.0
27
8.5
25
19
142
21
125
23
111
25
100
27
91
31
76
33
70
35
65
39
57
41
54
42
51
24
98
26
88
28
80
33
68
35
63
37
58
41
51
43
48
45
45
48
41
52
37
54
35
59
31
63
116
67
108
71
100
79
88
82
83
86
78
94
70
101
63
105
61
115
53
122
49
129
46
139
41
148
37
Ø40
Ø42
Ø45
*
55
67
80
71
75
79
66
83
62
87
59
95
53
102
48
106
46
117
40
124
37
131
34
142
31
152
28
158
27
165
25
175
23
188
129
197
122
214
110
231
100
240
95
264
84
281
78
297
72
320
65
343
59
358
56
373
53
395
49
356
130
394
115
418
106
442
99
478
89
513
81
536
76
558
72
592
67
Hub type 2.0 only
Clamping hubs without feather keyway may be used in category 3 only and are marked with
category 3 accordingly.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
KTR-N dated 2022-08-05
ROTEX® GS
Operating/Assembly instructions
1
KTR-N
Sheet:
Edition:
45510 EN
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25
Technical data
1.3 Coupling dimensions
Table 5 continued:
Size
5
Friction torques and surface pressure of clamping hubs
(hub type 2.0 and 2.5)
7
9
Bore Ø
Ø48
Ø50
Ø55
12
14
19
24
28
38
42
48
Transmittable friction torque TR of clamping hub in Nm
surface pressure in N/mm2
417
624
45
62
431
646
43
59
699
53
Ø60
Ø65
Ø70
Ø75
Ø80
Ø85
Ø90
55
65
75
90
646
53
668
51
724
45
778
41
830
37
882
34
655
45
677
43
734
38
789
34
842
31
895
29
946
26
1242
76
1287
73
1396
65
1503
59
1607
54
1709
49
1810
45
1908
42
2005
39
1985
100
2057
95
2235
86
2409
77
2579
71
2746
65
2911
60
3072
56
3231
52
3387
48
Clamping hubs without feather keyway may be used in category 3 only and are marked with
category 3 accordingly.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
KTR-N dated 2022-08-05
KTR-N
Sheet:
Edition:
ROTEX® GS
Operating/Assembly instructions
1
45510 EN
10 of 41
25
Technical data
1.3 Coupling dimensions
Compact
Illustration 6: ROTEX® GS 8, 13 and 16 Compact
single slot (hub type 2.8/2.9)
Illustration 7: ROTEX® GS 7, 9, 12, 14 and 19 Compact
single slot (hub type 2.8/2.9)
Illustration 8: ROTEX® GS 24 to 38 Compact
axial slot (hub type 2.8/2.9)

Please refer to table 1 for torques and table 2 for finish bores.
Table 6: Dimensions - Compact
Size
7
8
9
12
13
14
16
19
24
28
38
DH
14
15
20
25
25
30
30
40
55
65
80
DK
16.6
17.3
21.3
26.2
25.7
31.6 1)
45.5 2)
57.5
69.0
86.0
L
18
20
24
26
26
32
32
50
54
62
76
Dimensions 3) in mm
L1, L2
E
5
8
7
6
7
10
7
12
8
10
9.5
13
10.3
11.4
17
16
18
18
21
20
26
24
B1
6
5
8
10
8
10
9.4
12
14
15
18
S
1
0.5
1
1
1
1.5
1
2
2
2.5
3
DI1
6.2
10
14
-
Clamping screw DIN EN ISO 4762
A1
K
M
TA in Nm
2.5
5.0
M2
0.37
4.0
5.4
M2
0.52
3.5
6.7
M2.5
0.76
3.5
8.3
M3
1.34
4.0
8.0
M3
1.9
4.5
10.0 1)
M4 1)
2.9 1)
5.3
10.5
M4
4.1
9.0
14.0 2)
M6 2)
10 2)
11.0
20.0
M6
10
12.0
23.8
M8
25
15.0
29.5
M10
49
1) Bores from Ø14 with clamping screw M3, TA = 1.34 Nm, dimension K = 10.4 and dimension DK = 30.5
2) Bores from Ø21 with clamping screw M5, TA = 6 Nm, dimension K = 15.5 and dimension DK = 47.0
3) Transmittable friction torques of type Compact see table 7
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
KTR-N dated 2022-08-05
ROTEX® GS
Operating/Assembly instructions
1
KTR-N
Sheet:
Edition:
45510 EN
11 of 41
25
Technical data
1.3 Coupling dimensions
Table 7: Friction torques and surface pressure of type Compact (hub type 2.8)
Size
7
8
0.7
126
0.9
91
1.1
71
1.2
58
1.4
48
1.0
127
1.2
92
1.5
72
1.8
58
2.0
49
2.3
42
9
12
13
14
16
19
24
Transmittable friction torque TR of clamping hub in Nm
surface pressure in N/mm2
Bore Ø
Ø3
Ø4
Ø5
Ø6
Ø7
Ø8
Ø9
Ø10
Ø11
Ø12
1.5
110
1.8
86
2.1
70
2.4
59
2.7
51
3.0
44
2.3
169
2.8
133
3.3
109
3.8
92
4.3
79
4.7
69
5.2
62
5.6
55
6.0
50
3.1
204
3.9
161
4.6
132
5.2
111
5.9
96
6.5
84
7.1
74
7.8
67
8.4
60
Ø14
Ø15
Ø16
5.0
176
5.9
144
6.8
122
7.7
105
8.5
92
9.4
82
10.2
74
11.0
67
7.2
32
7.7
30
8.1
28
7.2
233
8.5
191
9.8
161
11.0
139
12.2
122
13.4
108
14.6
97
15.7
88
17.9
74
19.0
68
20.0
63
Ø18
Ø19
Ø20
Ø24
Ø25
Ø28
Ø30
Ø32
Ø35
Ø38
Ø40
Ø42
Ø45
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
18.7
143
20.8
126
22.9
112
24.9
101
26.9
92
30.8
77
32.7
71
34.6
66
38.2
58
40.0
54
41.8
51
36.0
31
34
100
37
91
41
83
48
71
51
67
54
63
61
56
64
53
68
50
81
42
85
40
95
36
102
33
109
31
28
87
112
93
105
100
98
112
87
118
53
124
50
149
65
156
63
174
56
187
52
199
49
218
45
38
148
134
158
126
178
112
188
106
198
101
237
84
247
81
277
72
296
67
316
63
346
58
375
53
395
50
415
48
444
45
KTR-N dated 2022-08-05
KTR-N
Sheet:
Edition:
ROTEX® GS
Operating/Assembly instructions
1
45510 EN
12 of 41
25
Technical data
1.3 Coupling dimensions
Clamping ring hubs 6.0 light, 6.0 steel and 6.0
Extraction thread M1 between clamping
screws.
Clamping ring hub 6.0 light with block
mounting
(hub and clamping ring mounted as a block)
1) From Ø55 tolerance G7/m6
®
Illustration 9: ROTEX GS, clamping ring hubs

Please refer to table 1 for torques and table 2 for finish bores.
Table 8: Dimensions - Clamping ring hubs 6.0 light, 6.0 steel and 6.0
Size
14
19
24
28
38
42
48
19
24
28
38
42
48
55
65
75
90
2)
DH
DI1
L
6.0 light (size 14 - 48)
6.0 (size 14 - 38)
30
10.5
50
40
18
66
55
27
78
65
30
90
80
38
114
95
46
126
105
51
140
6.0 steel (size 19 - 90)
40
18
66
55
27
78
65
30
90
80
38
114
95
46
126
105
51
140
120
60
160
135
68
185
160
80
210
200
104
245
Dimensions 4) in mm
L1, L2
L3
E
B1
S
A
Material of hub/clamping ring - aluminium
Hub material - aluminium/clamping ring material - steel
18.5
13.5
13
10
1.5
2.0
25
18
16
12
2.0
3.0
30
22
18
14
2.0
3.0
35
27
20
15
2.5
4.0
45
35
24
18
3.0
4.0
50
35
26
20
3.0
4.0
56
41
28
21
3.5
4.0
Material of hub and clamping ring - steel
25
18
16
12
2.0
3.0
30
22
18
14
2.0
3.0
35
27
20
15
2.5
4.0
45
35
24
18
3.0
4.0
50
35
26
20
3.0
4.0
56
41
28
21
3.5
4.0
65
45
30
22
4.0
4.5
75
55
35
26
4.5
4.5
85
63
40
30
5.0
5.0
100
75
45
34
5.5
6.5
Clamping screws DIN EN ISO 4762
M
Z 3)
TA in Nm
M1
M3
M4
M5
M5
M6
M8
M10
4
6
4
8
8
4
4
1.34
3
6
6
10
25
49
M3
M4
M5
M5
M6
M8
M10
M4
M5
M5
M6
M8
M10
M10
M12
M12
M16
6
4
8
8
4
4
4
4
5
5
4.1
8.5
8.5
14
41
69
69
120
120
295
M4
M5
M5
M6
M8
M10
M10
M12
M12
M16
2) ØDH + 2 mm with high speeds for expansion of spider
3) Z = Number each clamping ring hub
4) Consider transmittable friction torques of the respective clamping ring hubs 6.0 light, 6.0 steel and 6.0 (see table 9 to 11)
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
KTR-N dated 2022-08-05
KTR-N
Sheet:
Edition:
ROTEX® GS
Operating/Assembly instructions
1
45510 EN
13 of 41
25
Technical data
1.3 Coupling dimensions
Table 9: Friction torque and surface pressure of clamping ring hubs 6.0 light
Size
14
Bore Ø
Ø6
Ø8
Ø9
Ø10
Ø11
Ø14
Ø15
Ø16
Ø19
Ø20
Ø24
Ø25
Ø28
Ø30
Ø32
Ø35
Ø38
Ø40
Ø42
Ø45
Ø48
Ø50
Ø55
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
G7/m6
G7/h6
19
24
28
38
42
Transmittable friction torque TR of clamping ring hub in Nm / surface pressure in N/mm2
Nm
N/mm2
8.2
5.8
13.1
9.5
18.7
15.7
20.5
16.6
25.9
21.6
36.2
24.7
194
160
176
147
166
147
155
135
151
134
121
111
Nm
N/mm2
33
27
41
35
59
52
71
65
51
39
80
68
92
81
178
157
174
156
152
138
147
137
121
103
114
102
111
101
Nm
N/mm2
84
75
99
92
93
79
139
125
157
145
160
119
177
136
232
190
179
164
173
163
166
147
157
144
153
143
126
115
123
114
116
111
Nm
N/mm2
140
121
207
187
188
157
289
263
316
293
355
318
414
381
324
245
404
324
422
343
184
165
175
162
164
144
152
141
149
140
134
125
130
124
110
101
105
99
94
89
Nm
N/mm2
290
247
439
403
480
447
567
530
656
626
617
499
759
636
733
606
825
696
922
792
808
678
937
809
184
164
172
160
169
159
158
149
153
147
143
133
137
130
120
113
117
111
114
110
95
90
92
89
48
Nm
N/mm2
Nm
N/mm2
651
574
752
681
747
613
916
774
1001
881
1115
1001
1044
888
1218
1058
1404
1241
1432
1295
169
160
165
158
159
149
153
146
141
134
138
132
126
119
122
117
118
115
111
107
765
678
822
760
927
837
1121
1047
1220
1085
1357
1231
1318
1128
1536
1339
1768
1566
1535
1331
1823
1475
173
164
166
156
164
154
158
151
149
141
145
140
136
129
132
127
128
125
113
108
109
104
The transmittable friction torques of the clamping connection consider the max. fitting tolerance with shaft tolerance k6 resp. h6/bore H7, from
Ø55 G7/m6 or G7/h6. The friction torque is reduced with bigger fitting tolerance and use of a hollow shaft (see chapter 4.6).
The surface pressure of the clamping connection specified considers the minimum fitting tolerance with shaft fit k6 resp. h6/bore H7, from
Ø55 G7/m6 resp. G7/h6.
!
A calculation of the hollow shaft strength is necessary if hollow shafts are used (see chapter
4.6)!
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
KTR-N dated 2022-08-05
KTR-N
Sheet:
Edition:
ROTEX® GS
Operating/Assembly instructions
1
45510 EN
14 of 41
25
Technical data
1.3 Coupling dimensions
Table 10: Friction torques and surface pressure of clamping ring hubs 6.0 steel
Size
Bore Ø
Ø10
Ø11
Ø14
Ø15
Ø16
Ø19
Ø20
Ø24
Ø25
Ø28
Ø30
Ø32
Ø35
Ø38
Ø40
Ø42
Ø45
Ø48
Ø50
Ø55
Ø60
Ø65
Ø70
Ø80
Ø90
Ø95
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
H7/k6
H7/h6
G7/m6
G7/h6
G7/m6
G7/h6
G7/m6
G7/h6
G7/m6
G7/h6
G7/m6
G7/h6
G7/m6
G7/h6
G7/m6
G7/h6
19
24
28
38
42
48
55
65
75
Transmittable friction torque TR of clamping ring hub in Nm / surface pressure in N/mm2
Nm
N/mm2
Nm
N/mm2
27
15
32
18
69
57
84
74
57
38
94
76
110
94
335
262
334
262
298
262
288
262
241
197
228
197
221
197
25
10
30
12
70
55
87
74
56
32
97
72
114
93
116
84
133
103
192
173
296
223
296
223
260
223
250
223
212
168
200
168
193
168
157
130
153
130
141
130
Nm
N/mm2
108
74
131
97
207
172
148
94
253
207
285
242
315
267
382
343
330
260
433
377
503
453
296
243
289
243
277
243
237
190
217
190
213
190
190
168
184
168
168
144
160
144
150
137
Nm
N/mm2
208
136
353
290
395
337
439
373
531
476
463
367
603
525
593
491
689
601
793
721
776
677
248
200
229
200
120
200
200
178
194
178
177
152
169
152
152
133
148
134
144
133
132
119
Nm
N/mm2
445
387
495
429
595
540
526
429
677
600
671
569
775
687
718
599
872
773
1043
970
1061
978
246
221
219
197
213
197
194
169
185
169
166
148
162
148
149
131
144
131
140
131
133
125
Nm
N/mm2
616
513
704
590
899
806
896
775
1030
924
962
822
1160
1042
1379
1290
1222
1073
1543
1373
217
191
216
191
208
191
186
167
182
167
167
149
162
149
158
149
143
130
138
125
Nm
N/mm2
Nm
N/mm2
863
750
856
710
991
863
918
750
1119
976
1110
934
1247
1089
1277
972
1665
1454
1605
1287
2008
1792
179
161
161
141
157
141
145
126
140
126
129
114
126
114
115
95
110
98
99
84
95
86
1446
1275
1355
1135
1637
1447
1635
1404
1827
1619
1887
1488
2429
2142
2368
1949
2930
2635
178
161
163
144
158
144
145
130
143
130
130
110
125
113
112
97
108
99
90
Nm
N/mm2
1710
1460
2053
1836
2059
1797
2294
2056
2384
1929
3040
2708
2983
2507
3664
3323
4293
3945
180
160
175
160
160
145
158
145
144
123
138
126
124
108
120
110
106
98
Nm
N/mm2
3845
3445
4249
3556
4795
4080
5859
5260
5906
5153
7036
6253
8047
7104
9247
8484
221
200
205
178
191
168
186
170
168
150
150
136
136
123
134
124
The transmittable friction torques of the clamping connection consider the max. fitting tolerance with shaft tolerance k6 resp. h6/bore H7, from
Ø55 G7/m6 or G7/h6. The friction torque is reduced with bigger fitting tolerance and use of a hollow shaft (see chapter 4.6).
The surface pressure of the clamping connection specified considers the minimum fitting tolerance with shaft fit k6 resp. h6/bore H7, from
Ø55 G7/m6 resp. G7/h6.
!
A calculation of the hollow shaft strength is necessary if hollow shafts are used (see chapter
4.6)!
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
KTR-N dated 2022-08-05
KTR-N
Sheet:
Edition:
ROTEX® GS
Operating/Assembly instructions
1
45510 EN
15 of 41
25
Technical data
1.3 Coupling dimensions
Table 10 continued: Friction torques and surface pressure of clamping ring hubs 6.0 steel
Size
19
Bore Ø
Ø100
Ø105
Nm
N/mm2
24
Nm
28
38
42
48
55
65
75
Transmittable friction torque TR of clamping ring hub in Nm / surface pressure in N/mm2
N/mm2
Nm
N/mm2
Nm
N/mm2
Nm
N/mm2
Nm
N/mm2
Nm
N/mm2
Nm
N/mm2
G7/m6
G7/h6
G7/m6
G7/h6
Nm
N/mm2
90
Nm
N/mm2
9575
8722
10845
10202
126
117
124
118
The transmittable friction torques of the clamping connection consider the max. fitting tolerance with shaft tolerance k6/bore H7, from
Ø55 G7/m6. The friction torque is reduced with bigger fitting tolerance and use of a hollow shaft (see chapter 4.6).
The surface pressure of the clamping connection specified considers the minimum clearance with shaft fit k6/bore H7, from Ø55 G7/m6.
!
A calculation of the hollow shaft strength is necessary if hollow shafts are used (see chapter
4.6)!
Table 11: Friction torque and surface pressure of clamping ring hubs 6.0
Size
14
Bore Ø
Ø6
Ø10
Ø11
Ø14
8.6
225
13.8
130
14.7
118
22.7
108
Ø15
Ø16
Ø19
Ø20
19
24
28
Transmittable friction torque TR of clamping ring hub in Nm
surface pressure in N/mm2
41
272
45
248
62
211
68
203
67
171
83
153
90
149
Ø22
Ø24
Ø25
Ø28
48
214
67
182
74
175
72
148
90
132
97
129
99
107
112
102
120
100
143
96
142
243
154
231
189
203
188
178
212
167
237
157
250
153
280
136
307
131
310
115
353
110
389
103
Ø30
Ø32
Ø35
Ø38
Ø40
Ø42
Ø45
38
269
196
307
183
337
172
356
167
398
148
436
142
442
126
501
120
533
107
572
104
615
102
644
92
The transmittable friction torques of the clamping connection consider the max. fitting tolerance with shaft tolerance k6/bore H7. The friction
torque is reduced with bigger fitting tolerance and use of a hollow shaft (see chapter 4.6).
The surface pressure of the clamping connection specified considers the minimum fitting tolerance with shaft fit k6/bore H7.
!
A calculation of the hollow shaft strength is necessary if hollow shafts are used (see chapter
4.6)!
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
KTR-N dated 2022-08-05
ROTEX® GS
Operating/Assembly instructions
1
KTR-N
Sheet:
Edition:
45510 EN
16 of 41
25
Technical data
1.3 Coupling dimensions
DKM
Illustration 10: ROTEX® GS DKM

Please refer to table 1 for torques and table 2 for finish bores.
Table 12: Dimensions - DKM
Size
5
7
9
12
14
19
24
28
38
42
48
55
DN
DH
85
95
110
10
14
20
25
30
40
55
65
80
95
105
120
Please observe protection
note ISO 16016.
Dimensions in mm
DI1
DI
L1, L2
N
L11
DBSE
L
Spacer material - aluminium/hub material depends on hub type
5
3
13
23
7
4
20
34
7.2
10
5
25
45
8.5
11
6
30
52
10.5
11
8
34
56
18
18
25
10
42
92
27
27
30
16
52
112
30
30
35
18
58
128
38
38
45
20
68
158
46
46
50
28
22
74
174
51
51
56
32
24
80
192
60
60
65
37
28
88
218
Drawn:
Verified:
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
E
B1
S
A
5
8
10
12
13
16
18
20
24
26
28
30
4
6
8
10
10
12
14
15
18
20
21
22
0.5
1.0
1.0
1.0
1.5
2.0
2.0
2.5
3.0
3.0
3.5
4.0
4.0
6.0
1.5
3.5
2.0
3.0
3.0
4.0
4.0
4.0
4.0
4.5
KTR-N dated 2022-08-05
ROTEX® GS
Operating/Assembly instructions
2
KTR-N
Sheet:
Edition:
45510 EN
17 of 41
25
Advice
The ROTEX® GS coupling was developed for a backlash-free power
transmission and easy plug-in assembly. This backlash-free power
transmission arises in the area of prestress (see illustration 11).
The big concave surface contact results in a lower surface pressure on
the involute tooth. Consequently the tooth can be overloaded many
times over with no wear/deformation.
Safe operation in the range of prestress is ensured, because the coupling operates according to the principle of positive-locking rubber spring
prestress with high damping features. The star-shape coupling spider is
Illustration 11: Prestress of spider
inserted in the cams of the hubs which are machined specifically accurately with a small amount of prestress, resulting in the necessary
backlash-free power transmission.
The axial insertion force varies depending on the coupling size, different kinds of Shore hardness and production tolerances.
The flexible teeth compensating for misalignment are radially supported in the internal diameter by a web. An external deformation is limited by the concave shape of the cams, ensuring smooth operation even with bigger
masses to be accelerated (e. g. machine tables, articulated arms, etc.).
The flexible spiders for the GS series are available in five different kinds of Shore hardness, injected in different
colours, either as a torsionally soft or hard material.
2.1 General advice
Please read carefully through these operating/assembly instructions before you start up the coupling.
Pay special attention to the safety instructions!
The ROTEX® GS 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.
In order to ensure the operating principle of ROTEX® GS and avoid early wear of the coupling, a respective operating factor „SB“ has to be considered with the selection, each depending on the application (see catalogue
"Drive Technology"). Temperatures and shocks are provided with the corresponding factors, too (see catalogue
"Drive Technology").
The operating/assembly instructions are part of your product. Please store them carefully and close to the coupling. The copyright for these operating/assembly instructions remains with KTR.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
KTR-N dated 2022-08-05
ROTEX® GS
Operating/Assembly instructions
2
KTR-N
Sheet:
Edition:
45510 EN
18 of 41
25
Advice
2.2 Safety and advice symbols
STOP
!

Warning of potentially explosive atmospheres
This symbol indicates notes which may contribute to preventing bodily injuries or serious bodily injuries that may
result in death caused by explosion.
Warning of personal injury
This symbol indicates notes which may contribute to preventing bodily injuries or serious bodily injuries that may
result in death.
Warning of product damages
This symbol indicates notes which may contribute to preventing material or machine damage.
General advice
This symbol indicates notes which may contribute to preventing adverse results or conditions.
Warning of hot surfaces
This symbol indicates notes which may contribute to preventing burns with hot surfaces resulting in light to serious
bodily injuries.
2.3 General hazard warnings
STOP
With assembly, operation and maintenance of the coupling it has to be made sure that the
entire drive train is secured against accidental switch-on. You may be seriously hurt by rotating parts. Make absolutely sure to read through and observe the following safety indications.
• All operations on and with the coupling have to be performed taking into account "safety first".
• Make sure to switch off the power pack before you perform your work on the coupling.
• Secure the power pack against accidental switch-on, e. g. by providing warning signs at the place of switch-on
or removing the fuse for current supply.
• Do not reach into the operating area of the coupling as long as it is in operation.
• Secure the coupling against accidental contact. Provide for the necessary protection devices and covers.
2.4 Proper use
You may only assemble, operate and maintain the coupling if you
• have carefully read through the operating/assembly instructions and understood them
• are technically qualified and specifically trained (e. g. safety, environment, logistics)
• are authorized by your company
The coupling may only be used in accordance with the technical data (see chapter 1). Unauthorized modifications
on the coupling design are not admissible. We will not assume liability for any damage that may arise. In the interest of further development we reserve the right for technical modifications.
The ROTEX® GS described in here corresponds to the technical status at the time of printing of these operating/assembly instructions.
Please observe protection
note ISO 16016.
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Advice
2.5 Coupling selection
!
For a long-lasting and failure-free operation of the coupling it must be selected according to
the selection instructions (following DIN 740, part 2 with specific factors) for the particular
application (see catalogue drive technology "ROTEX® GS").
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 spider only. The transmittable
torque of the shaft-hub-connection must be reviewed by the customer and is subject to his
responsibility.
For drives subjected to torsional vibrations (drives with cyclic stress due to torsional vibrations) it is necessary to
perform a torsional vibration calculation to ensure a reliable selection. Typical drives subjected to torsional vibrations are e. g. drives with diesel engines, piston pumps, piston compressors etc. If requested, KTR will perform the
coupling selection and the torsional vibration calculation.
2.6 Reference to EC Machinery Directive 2006/42/EC
The couplings supplied by KTR should be considered as components, not machines or partly completed machines according to EC Machinery Directive 2006/42/EC. Consequently KTR does not have to issue a declaration of
incorporation. For details about safe assembly, start-up and safe operation refer to the present operating/assembly instructions considering the warnings.
3
Storage, transport and packaging
3.1 Storage
The coupling hubs made of steel are supplied in preserved condition and can be stored in a dry and roofed place
for 6 - 9 months.
The coupling hubs made of aluminium can be stored at a dry and roofed place for several years.
The features of the coupling spiders (elastomers) remain unchanged for up to 5 years with favourable storage
conditions.
!
The storage rooms must not include any ozone-generating devices like e. g. fluorescent
light sources, mercury-vapour lamps or electrical high-voltage appliances.
Humid storage rooms are not suitable.
Make sure that condensation is not generated. The best relative air humidity is less than
65 %.
3.2 Transport and packaging
!
In order to avoid any injuries and any kind of damage always make use of proper transport
and lifting equipment.
The couplings are packed differently each depending on size, number and kind of transport. Unless otherwise
contractually agreed, packaging will follow the in-house packaging specifications of KTR.
Please observe protection
note ISO 16016.
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Assembly
The coupling is generally supplied in individual parts. Before assembly the coupling has to be inspected for completeness.
4.1 Components of the coupling
Features of standard spiders
Increasing hardness
Spider hardness
(Shore)
Size
80 ShA-GS
(blue)
5 - 24
92 ShA-GS
(yellow)
5 - 55
98 ShA-GS
(red)
5 - 90
57 ShD-GS
(sky blue)
19 - 48
Material
Polyurethane
Polyurethane
Polyurethane
Polyurethane
64 ShD-H-GS 64 ShD-GS 72 ShD-H-GS 72 ShD-GS
(green)
(green)
(grey)
(grey)
7 - 38
42 - 90
24 - 38
42 - 90
PoPoHytrel
Hytrel
lyurethane
lyurethane
Marking
(colour)
Components of ROTEX® GS, hub type 1.0, 1.1 or 1.2
Component
1
2
3
Quantity
2
1
2
Description
Hub
Spider
Setscrew DIN EN ISO 4029
Illustration 12: ROTEX® GS
(size 5 - 38)
Illustration 13: ROTEX® GS
(size 42 - 90)
Hubs, clamping hubs or similar types without feather keyway may be used in category 3
only and are marked with category 3 accordingly.
Hub type 1.2 is not approved for potentially explosive atmospheres!
Please observe protection
note ISO 16016.
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Assembly
4.1 Components of the coupling
Components of ROTEX® GS clamping hubs, hub type 2.0, 2.1, 2.5 or 2.6
Component
1
2
3
Quantity
2
1
2
Description
Clamping hub
Spider
Cap screw DIN EN ISO 4762
Illustration 14: ROTEX® GS clamping hub

Hubs, clamping hubs or similar types without feather keyway may be used in category 3
only and are marked with category 3 accordingly.
Components of ROTEX® GS Compact, hub type 2.8 or 2.9
Component
1
2
3
Quantity
2
1
2/4
Description
Clamping hub C
Spider
Cap screw DIN EN ISO 4762
Illustration 15: ROTEX® GS Compact
(size 7 - 19)
Illustration 16: ROTEX® GS Compact
(size 24 - 38)
Hubs, clamping hubs or similar types without feather keyway may be used in category 3
only and are marked with category 3 accordingly.
Please observe protection
note ISO 16016.
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Assembly
4.1 Components of the coupling
Components of ROTEX® GS clamping ring hubs, hub type 6.0 light, 6.0 steel or 6.0
Component
1.1
1.2
2
3
Quantity
2
2
1
see table 5, 6 and 7
Description
Clamping ring
Clamping ring hub
Spider
Cap screw DIN EN ISO 4762
Illustration 17: ROTEX® GS clamping ring hub
Components of ROTEX® GS DKM
Component
1
2
3
4
Quantity
2
2
1
2
Description
Hub
Spider
DKM spacer
Setscrew DIN EN ISO 4029
Illustration 18: ROTEX® GS DKM
Hubs, clamping hubs or similar types without feather keyway may be used in category 3
only and are marked with category 3 accordingly.
Hub type 1.2 is not approved for potentially explosive atmospheres!
Please observe protection
note ISO 16016.
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Assembly
4.2 Advice for assembly
Subject to its design ROTEX® GS allows to axially plug in the coupling having assembled the hubs onto the shaft
journal. Consequently there is no need for subsequent screwing and the respective mounting holes in the housing.
The pegs on the spider arranged reciprocally prevent contact of the spider on the hubs over the full surface. Observing the distance dimension E, the ability for displacement of the coupling is ensured in this way. All teeth are
chamfered on the face which allows for blind assembly. When the coupling hubs are pushed together with the
ROTEX® GS spider an axial assembly force is generated resulting from the flexible prestress of the star-shape
elastomer. This assembly force varies depending on the coupling size, spider hardness and machining tolerances.
The axial insertion force is offset after having pushed together the hubs and consequently does not mean any risk
of axial load affecting adjacent bearings.
The mounting force can be reduced by lightly greasing or lubricating the elastomer or the hubs. For this purpose
please only use oils and greases on a mineral oil basis without any additives. Lubricants on a silicone basis or
vaseline have proven their worth, too.
4.3 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 19).
• 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.
Illustration 19: 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 13: Setscrew DIN EN ISO 4029
Size
Dimension G in mm
Dimension T in mm
Tightening torque TA
in Nm
5
M2
2.5
7
M3
3.5
9
M4
5
12
M4
5
14
M4
5
19
M5
10
24
M5
10
28
M8
15
38
M8
15
42
M8
20
48
M8
20
55
M10
20
65
M10
20
75
M10
25
90
M12
30
0.35
0.6
1.5
1.5
1.5
2
2
10
10
10
10
17
17
17
40
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Assembly
4.4 Assembly of the coupling (general)

We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Before starting with the assembly preserving agents have to be removed from the bores. Moreover, the shaft
ends have to be cleaned carefully, too.
Please note the manufacturer’s instructions regarding the use of detergents.
!
Heating the hubs lightly (approx. 80 °C) allows for an easier mounting on the shaft.
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 3 and 12) is observed
to allow for axial clearance of the spider when in operation.
Disregarding this advice may cause damage to the coupling.
If used in potentially explosive atmospheres the setscrews to fasten the hubs as well as all
screw connections must be secured against working loose additionally, e. g. conglutinating
with Loctite (average strength).
4.5 Assembly of the hubs (hub type 1.0, 1.1 and 1.2)
• Mount the hubs on the shaft of driving and driven side.
• Insert the spider into the cam section of the hub on the driving or driven side.
• Shift the power packs in axial direction until the distance dimension E is achieved.
• If the power packs are already firmly assembled, shifting the hubs axially on the shafts allows for setting the
distance dimension E.
• Applies with hub type 1.0 and 1.1 only:
Fasten the hubs by tightening the setscrews DIN EN ISO 4029 with a cup point (tightening torques see table
13).

If the shaft diameters with inserted feather key are smaller than dimension DI1 (see table 3
and 12) of the spider, one or two shaft ends may protrude into the spider.
Hubs, clamping hubs or similar types without feather keyway may be used in category 3
only and are marked with category 3 accordingly.
Hub type 1.2 is not approved for potentially explosive atmospheres!
Please observe protection
note ISO 16016.
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Assembly
4.6 Assembly of the clamping hubs (hub types 2.0, 2.1, 2.5, 2.6, 2.8 and 2.9)
The power transmission of ROTEX® GS clamping hubs (hub type 2.0, 2.5 and 2.8) is frictionally engaged. With
hub type 2.1, 2.6 and 2.9 a feather key additionally provides for positive locking power transmission.
If used in potentially explosive atmospheres all screw connections must be secured against
working loose additionally, e. g. conglutinating with Loctite (average strength).
• Clean and degrease the hub bore and the shaft.
• Lightly unscrew the clamping screws.
• Slip the hub onto the shaft. Please observe dimension L1 or L2.
• Tighten the clamping screws at the tightening torques specified in table
4.
With hub type 2.8 or 2.9 (with feather keyway) the screws have to be
tightened alternately in equal steps at the tightening torques specified in
table 6.
!
The transmittable friction torques of the clamping hubs
depend on the bore diameter.
Illustration 20: Assembly of clamping hub
Please note: hub type 2.8 or 2.9
have 2 clamping screws
Hubs, clamping hubs or similar types without feather keyway may be used in category 3
only and are marked with category 3 accordingly.
!
If the clamping screws are not tightened at the correct tightening torque, there is the risk of
a) a fracture of the hub and plastic deformation with a too high tightening torque T A
b) early slippling, untightening of the screws with a too low tightening torque T A
4.7 Assembly of clamping ring hubs (hub type 6.0 light, 6.0 steel and 6.0)
The power transmission of ROTEX® GS clamping hubs is frictionally engaged. The necessary surface pressure is
transmitted via the clamping ring with internal taper to the taper hub and consequently to the shaft. The friction
torques specified in table 5 to 7 consider a fit pair H7/k6, from Ø55 G7/m6. With a bigger fitting tolerance the friction torques specified in table 9 to 11 are reduced.
The strength and dimensions of the shafts (specifically hollow shafts) have to be defined such that sufficient safety against plastic deformation is ensured. This may roughly be reviewed as per the following criterion.
Please observe protection
note ISO 16016.
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Assembly
4.7 Assembly of clamping ring hubs (hub type 6.0 light, 6.0 steel and 6.0)
For clamping connections with hollow shafts the required internal diameter of the hollow shaft diW is calculated based on the following formula:
d iW  d 
Shear stress on the internal shaft diameter for hollow
shaft:
 tiW
 −
 tW
= − p W
=
=
yield strength of shaft material in N/mm2
surface pressure of hub/shaft in N/mm2
mm 
R p 0 ,2
Shear stress for solid shaft:
Rp0.2
pW
R p 0 ,2 − 2  p W
diW
d
CW
=
=
=
2  pW
1 − C W
N / mm 
2
2
N / mm
2

internal diameter of hollow shaft in mm
shaft diameter in mm
diW / d
The strength required is not provided if the hollow shaft bore is bigger than the max. internal bore calculated or if
the shear stress exceeds the yield strength of the material.
For a detailed calculation please contact KTR.
If used in potentially explosive atmospheres all screw connections must be secured against
working loose additionally, e. g. conglutinating with Loctite (average strength).
• Clean the hub bore and shaft and review for dimensional accuracy, afterwards lubricate with a thin oil (e. g. Castrol 4 in 1, Klüber Quietsch-Ex or
WD-40).
!
Oils and greases containing molybdenum disulfide or other
high-pressure additives as well as internal lubricants must
not be used.
• Lightly untighten the clamping screw and pull the clamping ring from the
hub only marginally to make sure that the clamping ring is fitted loosely.
• Shift the clamping ring hub onto the shaft. Dimension L3 should be observed at the minimum (see table 8).
• Tighten the clamping screws evenly crosswise gradually to the tightening
torque specified in table 8. Repeat this process until all clamping screws
have reached the tightening torque.
!
Illustration 21: Assembly of
clamping ring hub with clamping ring
If the clamping screws are not tightened at the correct tightening torque, there is the risk of
a) a fracture of the hubs/cams and plastic deformation with a too high tightening torque T A
b) early slippling, untightening of the screws with a too low tightening torque T A
• Applies with hub type 6.0 light only:
Tighten the clamping screws evenly gradually and crosswise at 1/3 or 2/3 tightening torque T A, respectively
(see table 8) until the ring gets in contact. Afterwards tighten the screws at the tightening torque mentioned in
table 8 one after another.
Please observe protection
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Assembly
4.8 Disassembly of clamping ring hubs (hub type 6.0 light, 6.0 steel and 6.0)
Unscrew the clamping screws evenly one after another. During each revolution every screw may only be unscrewed by half a turn. Unscrew all clamping
screws by 3 - 4 pitches.
Remove the screws located next to the extraction threads and screw them
into the intended extraction threads until they fit.
The clamping ring is released by tightening the screws in the extraction
threads evenly gradually and crosswise.
!
If these hints are not observed, the operation of the coupling may be affected.
Illustration 22: Disassembly of clamping
ring hub with clamping ring
If the assembly is repeated the bore of the hub and shaft have to be cleaned and afterwards lubricated with a thin
oil (e. g. Castrol 4 in 1, Klüber Quietsch-Ex or WD-40). The same applies for the taper surfaces of clamping ring
hub and clamping ring.
!
Oils and greases containing molybdenum disulfide or other high-pressure additives as well
as internal lubricants must not be used.
Applies with hub type 6.0 light only:

With reassembly the taper surfaces, bores of the hub and the shaft have to be cleaned. The
bore of the hub and shaft have to be lubricated with thin oil (e. g. Castrol 4 in 1, Klüber
Quietsch-Ex or WD-40). Lightly paint the taper surfaces of the clamping ring hub or clamping ring with the grease Gleitmo 800, afterwards twist the components against one another
by one revolution in order to spread the grease evenly.
4.9 Displacements - alignment of the couplings
The displacement figures specified in tables 14 and 15 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 tables 14 and 15). 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 tables 14 and 15) is permissible.
Please note:
• The displacement figures specified in tables 14 and 15 are maximum figures which must not arise in parallel. If
radial and angular displacements arise simultaneously, the permissible displacement figures may only be used
proportionally (see illustration 24).
• Inspect with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 14 and 15 can
be observed.
Please observe protection
note ISO 16016.
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Assembly
4.9 Displacements - alignment of the couplings
Axial displacements
Radial displacements
Angular displacements
Lmax = L +/- Ka
Kw in mm = L1max - L1min
Illustration 23: Displacements
Examples of the displacement combinations specified in illustration 24:
Illustration 24: Combinations of displacement
Example 1:
Kr = 30 %
Kw = 70 %
Example 2:
Kr = 60 %
Kw = 40 %
Ktotal = Kr + Kw  100 %
Table 14: Displacement figures
Size
5
7
8
9
12
13
14
16
19
24
28
38
42
48
55
65
75
90
Max. radial displacement Kr in mm
Max. axial
displacement DKa
in mm
80
ShAGS
92
ShAGS
98
ShAGS
57
ShDGS
64
ShDGS
72
ShDGS
+0.4 / -0.2
+0.6 / -0.3
+0.6 / -0.5
+0.8 / -0.4
+0.9 / -0.4
+0.9 / -0.8
+1.0 / -0.5
+1.0 / -0.8
+1.2 / -0.5
+1.4 / -0.5
+1.5 / -0.7
+1.8 / -0.7
+2.0 / -1.0
+2.1 / -1.0
+2.2 / -1.0
+2.6 / -1.0
+3.0 / -1.5
+3.4 / -1.5
0.12
0.15
0.15
0.19
0.20
0.20
0.21
0.21
0.15
-
0.06
0.10
0.13
0.14
0.15
0.10
0.14
0.15
0.17
0.19
0.23
0.24
-
0.04
0.06
0.08
0.08
0.08
0.08
0.09
0.10
0.06
0.10
0.11
0.12
0.14
0.16
0.17
0.18
0.21
0.23
0.05
0.08
0.09
0.10
0.12
0.13
-
0.04
0.06
0.05
0.05
0.05
0.06
0.08
0.04
0.07
0.08
0.09
0.10
0.11
0.12
0.13
0.15
0.17
0.04
0.05
0.06
0.07
0.08
0.09
0.10
0.11
0.13
80
ShA-GS
Max. angular displacement Kw in degree
92
98
57
64
ShA-GS ShA-GS ShD-GS ShD-GS
72
ShD-GS
Degr
ee
Degr
ee
Degr
ee
1.1
1.1
1.1
1.1
1.1
1.1
1.1
1.1
1.1
-
mm
0.2
0.25
0.4
0.5
0.5
0.5
0.6
0.6
0.75
-
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
-
mm
0.15
0.2
0.35
0.45
0.5
0.7
1.0
1.1
1.4
1.65
1.85
2.1
-
Degr
ee
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
mm
0.15
0.2
0.3
0.3
0.4
0.4
0.5
0.5
0.6
0.85
1.0
1.25
1.5
1.65
1.85
2.1
2.5
3.1
Degr
ee
mm
-
-
0.85
0.85
0.85
0.85
0.85
0.85
0.59
0.80
0.95
1.18
1.4
1.55
-
-
Degr
ee
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
mm
0.2
0.3
0.3
0.35
0.35
0.4
0.4
0.55
0.75
0.9
1.1
1.3
1.45
1.7
1.9
2.2
2.8
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
0.7
mm
0.65
0.8
1.0
1.1
1.3
1.4
1.6
2.0
2.4
The permissible displacement figures of the flexible ROTEX® GS couplings specified are general standard values taking into account the load
of the coupling up to the rated torque TKN of the coupling and an ambient temperature of +30 °C.
Please observe protection
note ISO 16016.
Drawn:
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Replacing:
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KTR-N
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ROTEX® GS
Operating/Assembly instructions
4
45510 EN
29 of 41
25
Assembly
4.9 Displacements - alignment of the couplings
Table 15: Displacement figures - type DKM
Size
5
7
9
12
14
19
24
28
38
42
48
55
Max. axial
displace80
ment DKa in
ShA-GS
mm
+0.4 / -0.4
0.15
+0.6 / -0.6
0.23
+0.8 / -0.8
0.29
+0.9 / -0.9
0.35
+1.0 / -1.0
0.40
+1.2 / -1.0
0.49
+1.4 / -1.0
+1.5 / -1.4
+1.8 / -1.4
+2.0 / -2.0
+2.1 / -2.0
+2.2 / -2.0
-
Max. radial displacement Kr in mm
Max. angular displacement Kw in degree
92
ShA-GS
98
ShA-GS
57
ShD-GS
64
ShD-GS
72
ShD-GS
80
ShA-GS
92
ShA-GS
98
ShA-GS
57
ShD-GS
64
ShD-GS
72
ShD-GS
0.14
0.21
0.26
0.32
0.37
0.45
0.59
0.66
0.77
0.84
0.91
1.01
0.13
0.19
0.24
0.29
0.33
0.41
0.53
0.60
0.69
0.75
0.82
0.91
0.39
0.50
0.56
0.65
0.71
0.77
-
0.17
0.21
0.25
0.29
0.36
0.47
0.53
0.61
0.67
0.73
0.81
0.42
0.46
0.54
0.59
0.64
0.71
1.1
1.1
1.1
1.1
1.1
1.1
-
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.9
0.85
0.85
0.85
0.85
0.85
0.85
-
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.7
0.7
0.7
0.7
0.7
0.7
The permissible displacement figures of the flexible ROTEX® GS couplings specified are general standard values taking into account the load
of the coupling up to the rated torque TKN of the coupling and an ambient temperature of +30 °C.
5
Start-up
Before start-up of the coupling, inspect the tightening of the setscrews in the hubs, the alignment and the distance
dimension E and adjust, if necessary, and also inspect all screw connections for the tightening torques specified.
If used in potentially explosive atmospheres the setscrews to fasten the hubs as well as all
screw connections must be secured against working loose additionally, e. g. conglutinating
with Loctite (average strength).
Finally the coupling protection against accidental contact must be fitted. It is required in accordance with
DIN EN ISO 12100 (Safety of Machinery) and directives 2014/34/EU and SI 2016 No. 1107 and must protect
against
• access with a little finger
• falling down of solid foreign objects.
The coupling protection is not part of KTR's scope of delivery and is the customer's responsibility. It must have
sufficient distance to the rotating components to safely avoid contact. Depending on the outside diameter DH of
the coupling, we recommend the following minimum distance:
ØDH to 50 mm = 6 mm, ØDH 50 mm to 120 mm = 10 mm, ØDH from 120 mm = 15 mm.
Please check if a proper enclosure (ignition protection, coupling protection, contact protection) has been mounted
and the operation of the coupling is not affected by the enclosure. The same applies for test runs and rotational
direction inspections.
The cover may provide for openings intended for necessary heat dissipation. These openings have to comply with
DIN EN ISO 13857.
The cover must be electrically conductive and included in the equipotential bonding. Bellhousings (magnesium
share below 7.5 %) made of aluminium and damping rings (NBR) can be used as connecting element between
pump and electric motor. The cover may only be taken off with standstill of the unit.
Please observe protection
note ISO 16016.
Drawn:
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2023-08-30 Ka
Replacing:
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ROTEX® GS
Operating/Assembly instructions
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KTR-N
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Edition:
45510 EN
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25
Start-up
If the couplings are used in locations subject to dust explosion and in mining the user must
make sure that there is no accumulation of dust in a dangerous volume between the cover
and the coupling. The coupling must not operate in an accumulation of dust.
For covers with unlocked openings on the top face no light metals must be used if the couplings are used as equipment of equipment group ll (if possible, from stainless steel).
If the couplings are used in mining (equipment group l M2), the cover must not be made of
light metal. In addition, it must be resistant to higher mechanical loads than with use as
equipment of equipment group ll.
During operation of the coupling, please pay attention to
• different operating noise
• vibrations occurring.
!
If you note any irregularities with the coupling during operation, the drive unit must be switched off immediately. The cause of the breakdown must be specified by means of the table
„Breakdowns“ and, if possible, be eliminated according to the proposals. The potential
breakdowns specified can be hints only. To find out the cause all operating factors and machine components must be considered.
Coating of coupling:
If coated (priming, paintings, etc.) couplings are used in potentially explosive atmospheres,
the requirements on conductibility and coating thickness must be considered. With paintings up to 200 µm electrostatic load does not have to be expected. If thicker paintings resp.
coatings up to a layer thickness of a maximum of 2.0 mm are applied, the couplings are not
permissible for gases and vapours of category IIC in potentially explosive areas, but only for
gases and vapours of category IIA and IIB.
This also applies for multiple coatings exceeding an overall thickness of 200 µm. Make sure
with painting or coating that the coupling components are conductively connected with the
device/devices to be connected so that the equipotential bonding is not impeded by the
paint or coat applied. Basically painting of the spider is not admitted to ensure an equipotential bonding.
In addition, make sure that the marking of the coupling remains legible.
6
Breakdowns, causes and elimination
The below-mentioned failures can lead to a use of the ROTEX® GS 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.
Please observe protection
note ISO 16016.
Drawn:
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KTR-N
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Breakdowns, causes and elimination
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.
• If the heated hubs are assembled, the permissible temperature is exceeded.
• The clearance of the components to be assembled is not coordinated with one another.
• Tightening torques are fallen below/exceeded.
• Components are mixed up by mistake/assembled incorrectly.
• A wrong or no spider is inserted in the coupling.
• No original KTR components (purchased parts) are used.
• Old/already worn out spiders or spiders stored for too long are used.
• Maintenance intervals are not observed.
Breakdowns
Different operating
noise and/or vibrations occuring
Breaking of cams
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
Misalignment
the spider surface; ignition
engine mount, heat expansion of unit comporisk by hot surfaces
nents, 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) Disassemble the coupling and remove resiWear of spider, shortdues of the spider
term torque transmisIgnition risk due to spar- 3) Inspect coupling components and replace
sion due to metal
king
coupling components that have been damacontact
ged
4) Insert spider, assemble coupling components
5) Inspect alignment, adjust if necessary
1) Set the unit out of operation
Screws for axial fasten2) Inspect alignment of coupling
Ignition risk due to hot
ing of hubs working
3) Tighten the screws to fasten the hubs and
surfaces and sparking
loose
secure against working loose
4) For inspection of wear see chapter 10.2
Wear of spider, torque
1) Set the unit out of operation
transmission due to
2) Replace complete coupling
metal contact
3) Inspect alignment
1) Set the unit out of operation
Breaking of the cams
2) Replace complete coupling
due to high impact
3) Inspect alignment
energy/overload
4) Find out the reason for overload
Ignition risk due to spar- 1) Set the unit out of operation
Operating parameters
king
2) Review the operating parameters and select
do not meet with the
a bigger coupling (consider mounting space)
performance of the
3) Assemble new coupling size
coupling
4) Inspect alignment
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
Please observe protection
note ISO 16016.
Drawn:
Verified:
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2023-08-30 Ka
Replacing:
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ROTEX® GS
Operating/Assembly instructions
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KTR-N
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Edition:
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Breakdowns, causes and elimination
Breakdowns
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
Misalignment
the spider surface; ignition
engine mount, heat expansion of unit comporisk by hot surfaces
nents, 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
Early wear of spider
2) Disassemble the coupling and remove resior reverse backlash
e. g. contact with agdues of the spider
gressive liquids/oils,
3) Inspect coupling components and replace
ozone influence, too
Ignition risk due to sparcoupling components that have been damahigh/low ambient tem- king with metallic contact
ged
peratures etc. causing
of the cams
4) Insert spider, assemble coupling components
physical modification of
5) Inspect alignment, adjust if necessary
the spider
6) Make sure that further physical modifications
of the spider are excluded
1) Set the unit out of operation
2) Disassemble the coupling and remove residues of the spider
excessively high/low
3) Inspect coupling components and replace
ambient/contact temcoupling components that have been damaEarly wear of spider
peratures for the spiged
or reverse backlash
der, max. permissible
4) Insert spider, assemble coupling components
-30 °C/+90 °C
5) Inspect alignment, adjust if necessary
6) Inspect and adjust ambient/contact temperature (correct by using other spider materials,
Ignition risk due to sparif necessary)
king with metallic contact
1)
Set the unit out of operation
of the cams
2) Disassemble the coupling and remove residues of the spider
3) Inspect coupling components and replace
Early wear of spider
coupling components that have been dama(liquefaction of mateVibrations of drive
ged
rial inside the spider
4) Insert spider, assemble coupling components
cam)
5) Inspect alignment, adjust if necessary
6) Find out the reason for the vibrations (possibly corrective by spider with lower or higher
Shore hardness)
When operating with a worn spider (see chapter 10.3) proper operation is not ensured.
!
7
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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
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2023-08-30 Ka
Replacing:
Replaced by:
KTR-N dated 2022-08-05
ROTEX® GS
Operating/Assembly instructions
8
KTR-N
Sheet:
Edition:
45510 EN
33 of 41
25
Maintenance and service
ROTEX® GS 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 coupling spiders.
• Since the flexible machine bearings of the driving and driven side settle during the course of load, inspect the
alignment of the coupling and re-align the coupling, if necessary.
• The coupling components have to be inspected for damages.
• The screw connections have to be visually inspected.
With the use in potentially explosive atmospheres observe chapter 10.2 "Inspection intervals for couplings in potentially explosive atmospheres".
9
Spares inventory, customer service addresses
We recommend to store major spare parts on site to ensure the readiness for use of the machine in case if a
coupling fails.
Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage at
www.ktr.com.

KTR does not assume any liability or warranty for the use of spare parts and accessories
which are not provided by KTR and for the damages which may incur as a result.
KTR Systems GmbH
Carl-Zeiss-Str. 25
D-48432 Rheine
Phone: +49 5971 798-0
E-mail: [email protected]
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
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ROTEX® GS
Operating/Assembly instructions
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KTR-N
Sheet:
Edition:
45510 EN
34 of 41
25
Enclosure A
Advice and instructions regarding the use in
explosive atmospheres
potentially
Applicable hub designs/types:
a) Hubs that may be used in group II, category 2 and 3 :
(hubs with feather keyway and hubs with CLAMPEX® clamping set or clamping ring hubs)
• 1.0 Hub with feather keyway and setscrew
• 2.1 Clamping hub single slot with feather keyway
• 2.6 Clamping hub double slot with feather keyway
• 2.9 Clamping hub with axial slot with feather keyway
• 6.0 Clamping ring hub light
• 6.0 Clamping ring hub
• 6.5 Clamping ring hub
(hub type as 6.0, but external clamping screws only)
• Type DKM with hubs corresponding to the aforementioned details
b) Hubs which may be used in group II, category 3 only:
(hubs without feather keyway)
• 1.1 Hub without feather keyway, with setscrew
• 2.0 Clamping hub single slot without feather keyway
• 2.5 Clamping hub double slot without feather keyway
• 2.8 Clamping hub with axial slot without feather keyway
• Type DKM with hubs corresponding to the aforementioned details
ROTEX® GS type DKM only with spacer made of steel or aluminium wrought products with a yield stress
Rp0.2 ≥ 250 N/mm2.
Hubs, clamping hubs or similar types without feather keyway may be used in category 3
only and are marked with category 3 accordingly.
Hub type 1.2 is not approved for potentially explosive atmospheres!
Please observe protection
note ISO 16016.
Drawn:
Verified:
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2023-08-30 Ka
Replacing:
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KTR-N
Sheet:
Edition:
ROTEX® GS
Operating/Assembly instructions
10
45510 EN
35 of 41
25
Enclosure A
Advice and instructions regarding the use in
explosive atmospheres
10.1 Intended use in
potentially
potentially explosive atmospheres
Conditions of operation in
potentially explosive atmospheres
The ROTEX® GS couplings are suitable for the use according to directives 2014/34/EU and SI 2016 No. 1107.
• Protection against hazards arising from lightning must follow the lightning protection concept of the machine or
plant. The relevant regulations and policy for lightning protection must be observed.
• The equipotential bonding of the couplings is made by metal contact between coupling hub and shaft. This
equipotential bonding must not be affected.
1. Industry (with the exception of mining)
•
•
•
•
Equipment group II of category 2 and 3 (coupling is not approved/not suitable for equipment group 1)
Substance group G (gases, fogs, vapours), zone 1 and 2 (coupling is not approved/not suitable for zone 0)
Substance group D (dusts), zone 21 and 22 (coupling is not approved/not suitable for zone 20)
Explosion group IIC (gases, fogs, vapours) (explosion groups IIA and IIB are included in IIC) and
explosion group IIIC (dusts) (explosion groups IIIA and IIIB are included in IIIC)
Temperature class:
Temperature class
T4
T5
T6
Ambient or operating temperature Ta 1)
-30 °C to +90 °C
-30 °C to +75 °C
-30 °C to +60 °C
Max. surface temperature 2)
+110 °C
+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 +90 °C due to the permissible permanent operating temperature of the elastomers
used.
2) The maximum surface temperature of +110 °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 +90 °C.
In mining for equipment group I of category M2 coupling hubs and DKM spacers made of steel only are permissible.
Please observe protection
note ISO 16016.
Drawn:
Verified:
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2023-08-30 Ka
Replacing:
Replaced by:
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ROTEX® GS
Operating/Assembly instructions
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KTR-N
Sheet:
Edition:
45510 EN
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25
Enclosure A
Advice and instructions regarding the use in
explosive atmospheres
10.2 Inspection intervals for couplings in
Equipment category
3G
3D
M2
2G
2D
No gases and vapours of
explosion group IIC
M2
2G
2D
Gases and vapours of
explosion group IIC
potentially
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 flexible spider 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 spider 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 spider, please 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 flexible spider 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 spider 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 spider, please find out the cause according to the table „Breakdowns“, if possible.
The maintenance intervals must be adjusted to the modified operating parameters without fail.
Hubs, clamping hubs or similar types without feather keyway may be used in category 3
only and are marked with category 3 accordingly.
ROTEX® GS backlash-free shaft couplings
Illustration 25: ROTEX® GS backlash-free shaft coupling
Illustration 26: ROTEX® GS spider
If the drive allows for, backlash between the cams of the coupling and the flexible spider has to be measured by
means of a feeler gauge.
When reaching the wear limit maximum friction, the spider must be replaced immediately, irrespective of the
inspection intervals.
Please observe protection
note ISO 16016.
Drawn:
Verified:
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2023-08-30 Ka
Replacing:
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ROTEX® GS
Operating/Assembly instructions
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KTR-N
Sheet:
Edition:
45510 EN
37 of 41
25
Enclosure A
Advice and instructions regarding the use in
explosive atmospheres
potentially
10.3 Standard values of wear
In case of backlash > X mm, the flexible spider must be replaced.
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.
Reaching the limits for replacing depends on the operating conditions and the existing operating parameters.
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 tables 14 and 15). If the
figures are exceeded, the coupling will be damaged.
!
Illustration 27: Inspection of the limit of wear

Illustration 28: Wear of spider
For backlash-free applications no wear is permitted, since otherwise the operating principle
of the coupling (backlash-free condition) is no longer ensured. If a backlash-free operation
is not required, the following figures apply:
Table 16:
Size
5
7
8
9
12
13
14
16
19
Please observe protection
note ISO 16016.
Limits of wear (friction)
Xmax in mm
0.4
0.5
0.4
0.9
0.6
0.5
1.25
0.7
0.9
Drawn:
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Limits of wear (friction)
Xmax in mm
1.0
1.4
1.7
2.0
2.25
2.50
2.75
3.00
3.25
Size
24
28
38
42
48
55
65
75
90
Replacing:
Replaced by:
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ROTEX® GS
Operating/Assembly instructions
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KTR-N
Sheet:
Edition:
45510 EN
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25
Enclosure A
Advice and instructions regarding the use in
explosive atmospheres
10.4
potentially
marking of coupling for potentially explosive atmospheres
The explosion protection marking of the ROTEX® GS coupling is applied on the outer sheath or on the front side.
The flexible spider is not marked.
For the complete marking refer to the operating/assembly instructions and/or the delivery note/package.
The following marking applies for the products:
• Type without aluminium, with feather keyway and/or clamping ring hub (Category 2)
I M2
II 2G
II 2D
Ex h
I
Mb
Ex h
IIC T6
… T4
Gb
Ex h
IIIC T80 °C … T110 °C Db
<Year>
-30 °C ≤ Ta ≤ +60 °C … +90 °C
KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine
X
X
X
• Type without aluminium, without feather keyway (Category 3)
I M2
II 3G
II 3D
Ex h
I
Mb
Ex h
IIC T6
… T4
Gc
Ex h
IIIC T80 °C … T110 °C Dc
<Year>
-30 °C ≤ Ta ≤ +60 °C … +90 °C
KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine
X
X
X
• Type with aluminium, with feather keyway and/or clamping ring hub (Category 2)
Ex h
IIC T6
… T4
Gb
Ex h
IIIC T80 °C … T110 °C Db
<Year>
-30 °C ≤ Ta ≤ +60 °C … +90 °C
KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine
II 2G
II 2D
X
X
• Type with aluminium, without feather keyway (Category 3)
Ex h
IIC T6
… T4
Gc
Ex h
IIIC T80 °C … T110 °C Dc
<Year>
-30 °C ≤ Ta ≤ +60 °C … +90 °C
KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine
II 3G
II 3D
X
X
Short marking:
(A short marking is only made if not possible differently for reason of space or functioning.)
ROTEX® GS
<Year>
Please observe protection
note ISO 16016.
Drawn:
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ROTEX® GS
Operating/Assembly instructions
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KTR-N
Sheet:
Edition:
45510 EN
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Enclosure A
Advice and instructions regarding the use in
explosive atmospheres
10.4
potentially
marking of coupling for potentially explosive atmospheres
Deviating marking applied until 31st October 2019:
Short marking:
II 2GD c IIC T X/I M2 c X
Category 3:
II 3G c IIC T6, T5 resp. T4 -30 °C  Ta  +65 °C, +80 °C resp.
+90 °C
II 3D c T 110 °C
-30 °C  Ta  +90 °C
Complete marking:
II 2G c IIC T6, T5 resp. T4 -30 °C  Ta  +65 °C, +80 °C resp.
+90 °C
II 2D c T 110 °C
I M2 c -30 °C  Ta  +90 °C
Comments on marking
Equipment group I
Equipment group II
Equipment category 2G
Equipment category 3G
Equipment category 2D
Equipment category 3D
Equipment category M2
Mining
Non-mining
Equipment ensuring a high level of safety, suitable for zone 1
Equipment ensuring a normal level of safety, suitable for zone 2
Equipment ensuring a high level of safety, suitable for zone 21
Equipment ensuring a normal level of safety, suitable for zone 22
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 … T4
Temperature class to be considered, depending on the ambient temperature
T80 °C … T110 °C
Maximum surface temperature to be considered, depending on the ambient
temperature
-30 °C ≤ Ta ≤ +60 °C … +90 °C or Permissible ambient temperature from -30 °C to +60 °C resp.
-30 °C ≤ Ta ≤ +90 °C
-30 °C to +90 °C
Gb, Db, Mb
Equipment protection level, high level of safety, analogous to the equipment
category
Gc, Dc
Equipment protection level, normal 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 4.3 of the present operating/assembly instructions).
Please observe protection
note ISO 16016.
Drawn:
Verified:
2023-08-30 Ka/Ht
2023-08-30 Ka
Replacing:
Replaced by:
KTR-N dated 2022-08-05
ROTEX® GS
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
45510 EN
40 of 41
25
Enclosure A
Advice and instructions regarding the use in
explosive atmospheres
potentially
10.5 EU Certificate of conformity
EU Declaration of Conformity resp.
Certificate of Conformity
corresponding to EU directive 2014/34/EU dated 26 February 2014
and to the legal regulations adopted for its implementation
The manufacturer - KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine - states that the
ROTEX® GS backlash-free shaft 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 ROTEX® GS 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 IBExU03ATEXB002_05 X):
IBExU
Institut für Sicherheitstechnik GmbH
Identification number: 0637
Fuchsmühlenweg 7
09599 Freiberg
Rheine,
Place
2022-03-21
Date
Please observe protection
note ISO 16016.
Drawn:
Verified:
i. V.
Reinhard Wibbeling
Engineering/R&D
2023-08-30 Ka/Ht
2023-08-30 Ka
i. V.
Johannes Deister
Product Manager
Replacing:
Replaced by:
KTR-N dated 2022-08-05
ROTEX® GS
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
45510 EN
41 of 41
25
Enclosure A
Advice and instructions regarding the use in
explosive atmospheres
potentially
10.6 UK Declaration of conformity
UK Declaration of Conformity resp.
Certificate of Conformity
corresponding to UK directive SI 2016 No. 1107 dated 26 February 2014
and to the legal provisions adopted for its implementation
The manufacturer - KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine - states that the
ROTEX® GS backlash-free shaft 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 ROTEX® GS 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
2022-03-21
Date
Please observe protection
note ISO 16016.
Drawn:
Verified:
i. V.
Reinhard Wibbeling
Engineering/R&D
2023-08-30 Ka/Ht
2023-08-30 Ka
i. V.
Johannes Deister
Product Manager
Replacing:
Replaced by:
KTR-N dated 2022-08-05
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