KTR ROTEX Operating/Mounting Instructions

ROTEX®
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
40210 EN
1 of 31
25
ROTEX®
Torsionally flexible jaw couplings
No. 001 - shaft coupling,
No. 018 - DKM,
with taper clamping sleeve
and their combinations
Type No. 001 - shaft coupling
according to directive 2014/34/EU
and UK directive SI 2016 No. 1107
Type No. 018 - DKM
double-cardanic coupling
Type with taper clamping sleeve
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
40210 EN
2 of 31
25
ROTEX® is a torsionally flexible jaw coupling. It is able to compensate for shaft misalignment, for
example caused by manufacturing inaccuracies, thermal expansion, etc.
Table of contents
1
Technical data
3
2
Advice
8
2.1
2.2
2.3
2.4
2.5
2.6
8
8
8
9
9
9
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
10
3.1
3.2
10
10
Storage
Transport and packaging
Assembly
10
4.1
4.2
4.3
4.4
4.5
4.6
4.7
10
12
13
14
15
16
17
Components of the coupling
Advice for finish bore
Assembly of the coupling (general)
Assembly of standard type
Assembly of type DKM
Assembly/disassembly of type taper clamping sleeve
Displacements - alignment of the couplings
5
Start-up
19
6
Breakdowns, causes and elimination
20
7
Disposal
22
8
Maintenance and service
23
9
Spares inventory, customer service addresses
23
10
Enclosure A
Advice and instructions regarding the use in
10.1 Intended use in
potentially explosive atmospheres
potentially explosive atmospheres
10.2 Inspection intervals for couplings in
10.3 Standard values of wear
Please observe protection
note ISO 16016.
Drawn:
Verified:
25
potentially explosive atmospheres
10.4
marking of coupling for potentially explosive atmospheres
10.5 EU Certificate of conformity
10.6 UK Declaration of conformity
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
24
26
27
28
30
31
KTR-N dated 2020-06-23
KTR-N
Sheet:
Edition:
ROTEX®
Operating/Assembly instructions
1
40210 EN
3 of 31
25
Technical data
Illustration 1: ROTEX® (material: Sint, Al-D and Al-H)
Table 1: Material sintered steel (Sint)
Size
Component
14
19
24
1a
1a
1a
Spider 1) (component 2)
Rated torque [Nm]
92 ShA 98 ShA 64 ShD
7.5
12.5
10
17
34
60
-
2)
Finish bore
D (min-max)
6 - 16
6 - 24
9 - 28
L
35
66
78
L1, L2
11
25
30
Dimensions [mm] 3)
General
E
B1
S
13
10
1.5
16
12
2.0
18
14
2.0
DH
30
40
56
DI1
10
18
27
DN1
-
N
-
Dimensions [mm] 3)
General
E
B1
S
DH
DI1
DN1
32
41
40
56
48
67
N
Table 2: Material aluminium diecast (Al-D) - no approval for ATEX
Size
19
24
28
Component
1
1a
1
1a
1
1a
Spider 1) (component 2)
Rated torque [Nm]
92 ShA 98 ShA 64 ShD
10
17
-
35
60
-
95
160
-
Finish bore 2)
D (min-max)
6 - 19
19 - 24
9 - 24
22 - 28
10 - 28
28 - 38
L
L1, L2
66
25
16
12
2.0
41
18
78
30
18
14
2.0
56
27
90
35
20
15
2.5
67
30
DH
10
14
20
25
30
40
55
65
80
95
105
DI1
7.2
8.5
10.5
18
27
30
38
46
51
20
24
28
Table 3: Material aluminium (Al-H)
Size
Component
5
7
9
12
14
19
24
28
38
42
48
1a
1a
1a
1a
1a
1a
1a
1a
1a
1a
1a
Spider 1) (component 2)
Rated torque [Nm]
92 ShA 98 ShA 64 ShD
0.5
0.9
1.2
2.0
2.4
3.0
5.0
6.0
5.0
9.0
12
7.5
12.5
16
10
17
26
35
60
75
95
160
200
190
325
405
265
450
560
310
525
655
Finish bore 2)
D (min-max)
0-6
0-7
0 - 11
0 - 12
0 - 16
0 - 24
0 - 28
0 - 38
0 - 45
0 - 55
0 - 62
L
15
22
30
34
35
66
78
90
114
126
140
L1, L2
5
7
10
11
11
25
30
35
45
50
56
Dimensions [mm] 3)
General
E
B1
S
5
4
0.5
8
6
1.0
10
8
1.0
12
10
1.0
13
10
1.5
16
12
2.0
18
14
2.0
20
15
2.5
24
18
3.0
26
20
3.0
28
21
3.0
DN1
-
N
-
1) Maximum torque of coupling TK max. = rated torque of coupling TKN x 2
2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew
3) For dimensions G and T see table 8; there is a setscrew on the keyway (only with Al-D opposite the keyway)
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
KTR-N
Sheet:
Edition:
ROTEX®
Operating/Assembly instructions
1
40210 EN
4 of 31
25
Technical data
Illustration 2: ROTEX® (material: GJL/GJS)
Table 4: Material cast iron (GJL)/nodular iron (GJS)
Size
Component
Spider 1) (component 2)
Rated torque [Nm]
92 ShA 98 ShA 64 ShD
410
685
825
65
75
90
1
1a
1b
1
1a
1b
1
1a
1b
1
1a
1
1
1
625
1280
2400
940
1920
3600
1175
2400
4500
100
110
125
140
160
180
1
1
1
1
1
1
3300
4800
6650
8550
12800
18650
4950
7200
10000
12800
19200
28000
6185
9000
12500
16000
24000
35000
38
42
48
55
190
325
265
450
310
525
405
560
655
2)
Finish bore
D (min-max)
L
L1, L2
Cast iron (GJL)
12 - 40
114
45
38 - 48
12 - 48
164
70
14 - 45
126
50
42 - 55
14 - 55
176
75
15 - 52
140
56
48 - 62
15 - 62
188
80
20 - 60
160
65
55 - 74
22 - 70
185
75
30 - 80
210
85
40 - 97
245
100
Nodular iron (GJS)
50 - 115
270
110
60 - 125
295
120
60 - 145
340
140
60 - 160
375
155
80 - 185
425
175
85 - 200
475
185
Dimensions [mm] 3)
General
E
B1
S
DH
DI1
24
38
DN, DN1
66
18
3.0
80
78
75
26
20
3.0
95
46
94
85
28
21
3.5
105
51
104
30
22
4.0
120
60
35
40
45
26
30
34
4.5
5.0
5.5
135
160
200
68
80
100
98
118
115
135
160
50
55
60
65
75
85
38
42
46
50
57
64
6.0
6.5
7.0
7.5
9.0
10.5
225
255
290
320
370
420
113
127
147
165
190
220
180
200
230
255
290
325
N
37
62
40
65
45
69
52
61
69
81
89
96
112
124
140
156
1) Maximum torque of coupling TK max. = rated torque of coupling TKN x 2
2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew
3) For dimensions G and T see table 8; there is a setscrew on the keyway
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
KTR-N
Sheet:
Edition:
ROTEX®
Operating/Assembly instructions
1
40210 EN
5 of 31
25
Technical data
Illustration 3: ROTEX® (material: steel)
Table 5: Material steel
Size
14
19
24
28
38
42
48
55
65
75
90
100
110
125
140
160
180
Component
1a
1b
1a
1b
1a
1b
1a
1b
1
1b
1
1b
1
1b
1
1b
1
1b
1
1b
1
1b
1
1
1
1
1
1
Spider 1) (component 2)
Rated torque [Nm]
92 ShA 98 ShA 64 ShD
2)
Finish bore
D (min-max)
7.5
12.5
16
0 - 16
10
17
21
0 - 25
35
60
75
0 - 35
95
160
200
0 - 40
190
325
405
0 - 48
265
450
560
0 - 55
310
525
655
0 - 62
410
685
825
0 - 75
625
940
1175
0 - 80
1280
1920
2400
0 - 95
2400
3600
4500
0 - 110
3300
4800
6650
8550
12800
18650
4950
7200
10000
12800
19200
28000
6185
9000
12500
16000
24000
35000
0 - 115
0 - 125
60 - 145
60 - 160
80 - 185
85 - 200
L
35
50
66
90
78
118
90
140
114
164
126
176
140
188
160
210
185
235
210
260
245
295
270
295
340
375
425
475
L1, L2
11
18.5
25
37
30
50
35
60
45
70
50
75
56
80
65
90
75
100
85
110
100
125
110
120
140
155
175
195
Dimensions [mm] 3)
General
E
B1
S
DH
DI1
DN1
N
13
10
1.5
30
10
30
-
16
12
2.0
40
18
40
-
18
14
2.0
55
27
55
-
20
15
2.5
65
30
65
-
24
18
3.0
80
38
26
20
3.0
95
46
28
21
3.5
105
51
30
22
4.0
120
60
35
26
4.5
135
68
40
30
5.0
160
80
45
34
5.5
200
100
50
55
60
65
75
85
38
42
46
50
57
64
6.0
6.5
7.0
7.5
9.0
10.5
225
255
290
320
370
420
113
127
147
165
190
220
70
80
85
95
95
105
110
120
115
135
135
160
160
200
180
200
230
255
290
325
27
28
32
37
47
53
62
89
96
112
124
140
156
1) Maximum torque of coupling TK max. = rated torque of coupling TKN x 2
2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew
3) For dimensions G and T see table 8; there is a setscrew on the keyway
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
1
KTR-N
Sheet:
Edition:
40210 EN
6 of 31
25
Technical data
Illustration 4: ROTEX® type DKM
Table 6: Type DKM
19
24
28
38
42
48
55
65
75
90
Spider 1) (component 2)
Rated torque [Nm]
92 ShA
98 ShA
10
17
35
60
95
160
190
325
265
450
310
525
410
685
625
940
1280
1920
2400
3600
Dimensions
D 2), DN, DN1
see table 1 to 5
Size
LDKM
92
112
128
158
174
192
218
252
286
330
L1, L2
25
30
35
45
50
56
65
75
85
100
Dimensions [mm] 3)
General
E
B1
S
16
12
2.0
18
14
2.0
20
15
2.5
24
18
3.0
26
20
3.0
28
21
3.5
30
22
4.0
35
26
4.5
40
30
5.0
45
34
5.5
DH
40
55
65
80
95
105
120
135
160
200
DI, DI1
18
27
30
38
46
51
60
68
80
100
L11
10
16
18
20
22
24
28
32
36
40
DBSE
42
52
58
68
74
80
88
102
116
130
1) Maximum torque of coupling TK max. = rated torque of coupling TKN x 2
2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew
3) For dimensions G and T see table 8; there is a setscrew on the keyway (only with Al-D opposite the keyway)
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
KTR-N
Sheet:
Edition:
ROTEX®
Operating/Assembly instructions
1
40210 EN
7 of 31
25
Technical data
Coupling design:
TB1
TB2
Screw connection on cam side
Screw connection on collar side
Various combinations of types TB1 and TB2
are available.
Illustration 5: ROTEX® type with taper clamping sleeve
Table 7: Type with taper clamping sleeve
Spider 1) (component 2)
Rated torque [Nm]
92 ShA
98 ShA
35
60
95
160
190
325
265
450
310
525
410
685
625
940
Size
Component
24
28
38
42
48
55
65
1a
1a
1a
1a
1a
1a
1
75
1
1280
1920
90
100
125
1
1
1
2400
3300
6650
3600
4950
10000
Finish bore
D (min-max)
10 - 25
10 - 25
10 - 25
14 - 25
14 - 40
14 - 50
14 - 50
16 - 60
25 - 75
25 - 75
35 - 90
55 - 110
L
64
66
70
78
106
96
101
Dimensions [mm]
General
L1, L2
E
B1
S
DH
22
18
14
2.0
55
23
20
15
2.5
65
23
24
18
3.0
80
26
26
20
3.0
95
39
28
21
3.5
105
33
30
22
4.0
120
33
35
26
4.5
135
DI1
27
30
38
46
51
60
68
DN
78
94
104
118
115
N
15
16
28
20
5
144
52
40
30
5.0
160
80
158
36
149
230
288
52
90
114
45
50
60
34
38
46
5.5
6.0
7.0
200
225
290
100
113
147
160
180
230
14
69
86
Taper
clamping
sleeve
1008
1108
1108
1610
1615
2012
2012
2517
3020 2)
3020
3535
4545
1) Maximum torque of coupling TK max. = rated torque of coupling TKN x 2
2) Available for type TB2 only
ROTEX® 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:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
2
KTR-N
Sheet:
Edition:
40210 EN
8 of 31
25
Advice
2.1 General advice
Please read through these operating/assembly instructions carefully before you start up the coupling.
Pay special attention to the safety instructions!
The ROTEX® 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:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
2
KTR-N
Sheet:
Edition:
40210 EN
9 of 31
25
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 ROTEX® 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 permanent and failure-free operation of the coupling it must be selected according to
the selection instructions (according to DIN 740 part 2) for the particular application (see
catalogue drive technology "ROTEX®").
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 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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
3
KTR-N
Sheet:
Edition:
40210 EN
10 of 31
25
Storage, transport and packaging
3.1 Storage
The coupling hubs are supplied in preserved condition and can be stored in a dry and roofed place for 6 - 9
months.
The features of the 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.
4
Assembly
The coupling is generally supplied in individual parts. Before assembly the coupling has to be inspected for
completeness.
4.1 Components of the coupling
Components of ROTEX®, shaft coupling type No. 001
Component
1
2
3
Quantity
2
1
2
Description
Hub
Spider
Setscrew DIN EN ISO 4029
Illustration 6: ROTEX®
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
40210 EN
11 of 31
25
Assembly
4.1 Components of the coupling
Components of ROTEX® type DKM
Component
1
2
4
4
Quantity
2
2
1
2
Description
Hub
Spider
DKM spacer
Setscrew DIN EN ISO 4029
Illustration 7: ROTEX® type DKM
Components of ROTEX® type with taper clamping sleeve
Component
TB1/TB2
1
2
3
Quantity
2
2
1
4
Description
Hub for taper clamping sleeve
Taper clamping sleeve
Spider
Setscrew DIN EN ISO 4029
Illustration 8: ROTEX® type with taper clamping sleeve
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
KTR-N
Sheet:
Edition:
ROTEX®
Operating/Assembly instructions
4
40210 EN
12 of 31
25
Assembly
4.1 Components of the coupling
Features of standard spiders
Spider hardness
(Shore)
92 Shore A
T-PUR®
PUR
(orange)
(yellow)
98 Shore A
T-PUR®
PUR
(purple)
(red)
64 Shore D
T-PUR®
PUR
(light green)
(natural white 1))
Marking
(colour)
1) Natural white with green marking of teeth
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 9).
• 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 9: 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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
KTR-N
Sheet:
Edition:
ROTEX®
Operating/Assembly instructions
4
40210 EN
13 of 31
25
Assembly
4.2 Advice for finish bore
Table 8: Setscrew DIN EN ISO 4029
Size
Dimension G
Dimension T
Tightening
torque TA [Nm]
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
100
M12
30
110
M16
35
125
M16
40
140
M20
45
160
M20
50
180
M20
50
1.5
2
2
10
10
10
10
17
17
17
40
40
80
80
140
140
140
Table 9: Recommended fit pairs acc. to DIN 748/1
Bore [mm]
above
up to
50
Shaft tolerance
Bore tolerance
k6
m6
H7
(KTR standard)
50
If a feather keyway is intended to be used in the hub, it should correspond to the tolerance ISO JS9 (KTR
standard) with standard operating conditions or ISO P9 with sophisticated operating conditions (frequently
alternating torsional direction, shock loads, etc.). The keyway should preferably be located between the cams.
With axial fastening via setscrew the tapped hole should be positioned on the keyway except for Al-D which
should be positioned opposite the keyway.
The transmittable torque of the shaft-hub-connection must be reviewed by the customer and is subject to his
responsibility.
4.3 Assembly of the coupling (general)

We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Heating the hubs 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 1 to 7) 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).
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
40210 EN
14 of 31
25
Assembly
4.4 Assembly of standard type
• Mount the hubs on the shaft of driving and driven
side (see illustration 10).
• The internal sides of the hubs must be flush with the
front sides of the shafts.
Illustration 10: Assembly of hubs
• Insert the spider in the cam section of the hubs on
the driving or driven side (see illustration 11).
Illustration 11: Assembly of spider
• Shift the power packs in axial direction until the
distance dimension E is achieved (see illustration
12).
• If the power packs are already firmly assembled,
shifting the hubs axially on the shafts allows for
setting the distance dimension E.
• Fasten the hubs by tightening the setscrews
DIN EN ISO 4029 with a cup point (tightening torque
see table 8).
• Centre the spider between the hubs and check the
dimensions E and S (see illustration 12 and chapter
1).

!
Illustration 12: Assembly of coupling
If the shaft diameters with inserted feather key are smaller than dimension DI1 (see table 1 to
7) of the spider, one or two shaft ends may protrude into the spider.
Having started up the coupling, the wear of spider has to be inspected at regular
maintenance intervals and the spider has to be replaced, if necessary.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
40210 EN
15 of 31
25
Assembly
4.5 Assembly of type DKM
• Mount the hubs on the shaft of driving and driven
side (see illustration 13).
• The internal sides of the hubs must be flush with the
front sides of the shafts.
Illustration 13: Assembly of hubs
• Insert the spiders in the cam section of the hubs
(see illustration 14).
Illustration 14: Assembly of spiders
• Insert the DKM spacer in the spider of the driving or
driven side hub (see illustration 15).
Illustration 15: Assembly of the DKM spacer
• Shift the power packs in axial direction until the
distance dimension E or DBSE is achieved (see
illustration 16).
• If the power packs are already firmly assembled,
shifting the hubs axially on the shafts allows for
setting the distance dimension DBSE.
• Fasten the hubs by tightening the setscrews
DIN EN ISO 4029 with a cup point (tightening torque
see table 8).
• Centre the spider between the hubs and check the
dimensions E and DBSE (see illustration 16 and
chapter 1).

!
Illustration 16: Assembly of coupling
If the shaft diameters with inserted feather key are smaller than dimension DI1 (see table 1 to
7) of the spider, one or two shaft ends may protrude into the spider.
Having started up the coupling, the wear of spider has to be inspected at regular
maintenance intervals and the spider has to be replaced, if necessary.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
40210 EN
16 of 31
25
Assembly
4.6 Assembly/disassembly of type taper clamping sleeve
Assembly of taper clamping sleeve:
Clean the contact surfaces of the taper clamping sleeves and of shaft and hub and afterwards apply thin oil lightly
(e. g. Ballistol Universal oil or Klüber Quietsch-Ex).
The taper clamping sleeves have axially parallel, cylindrical and smooth tapped blind holes. Only half of these
holes are located in the material of the sleeve. The other half located in the hub has got threads.
Fit the coupling element and the taper clamping sleeve into each other, make sure that the bores cover each
other and tighten the setscrews lightly. Fit the coupling element along with the taper clamping sleeve on the shaft
and tighten the setscrews at the tightening torque specified in table 10.
During the screwing process the hub is mounted on the taper sleeve and thus the sleeve is pressed on the shaft.
By light blows of the hammer the taper clamping sleeve must be pushed further into the taper bore by means of a
suitable sleeve. Afterwards re-tighten the setscrews at the tightening torque specified in table 10. This process
must be performed at least once.
Having operated the drive under load for a short while inspect if the setscrews are released.
Axial fixing of the Taper Lock hub (coupling hub with taper clamping sleeve) is obtained by proper assembly only.
If used in potentially explosive atmospheres the setscrews to fasten the taper clamping
sleeves have to be secured against working loose additionally, e. g. conglutinating with
Loctite (average strength).
Taper clamping sleeves used without a feather key are not permitted in potentially explosive
atmospheres and are thus not provided with a relevant explosion protection marking.
!
Oils and greases with molybdenum disulphide or high-pressure additives, additives of
Teflon and silicone as well as internal lubricants reducing the coefficient of friction
significantly must not be used.
!
Illustration 17: ROTEX® type with taper clamping sleeve
Disassembly of taper clamping sleeve:
The taper clamping sleeve is released by removing the setscrews. Afterwards one of the setscrews used as
forcing screw is screwed in the thread of the sleeve and tightened.
The coupling hub released that way can be manually pulled off the shaft with the taper clamping sleeve.
Table 10:
Taper clamping
sleeve
1008
1108
1610
1615
2012
2517
3020
3535
4545
G
[inch]
1/4
1/4
3/8
3/8
7/16
1/2
5/8
1/2
3/4
Please observe protection
note ISO 16016.
Screw dimensions
L
SW
[inch]
[mm]
1/2
3
1/2
3
5/8
5
5/8
5
7/8
6
7/8
6
1 1/4
8
1 1/2
10
1 3/4
12
Drawn:
Verified:
TA
[Nm]
5.7
5.7
20
20
31
49
92
115
170
Number
2
2
2
2
2
2
2
3
3
2022-07-04 Pz/Wb
2022-08-04 Pz
Illustration 18: Withworth setscrew (BSW)
Replacing:
Replaced by:
KTR-N dated 2020-06-23
KTR-N
Sheet:
Edition:
ROTEX®
Operating/Assembly instructions
4
40210 EN
17 of 31
25
Assembly
4.7 Displacements - alignment of the couplings
The displacement figures specified in table 11 to 13 provide for sufficient safety to compensate for external
influences like, for example, heat 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 to 13).
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 to 13) are permissible.
!
Please note:
• The displacement figures specified in table 11 to 13 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 20).
• Inspect with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 11 to 13 can
be observed.
Axial displacements
Radial displacements
Lmax = L + Ka [mm]
Angular displacements
Kw = L1max. - L1min. [mm]
Illustration 19: Displacements
Examples of the displacement
combinations specified in illustration 20:
Illustration 20:
Combinations of
displacement
Example 1:
Kr = 30 %
Kw = 70 %
Example 2:
Kr = 60 %
Kw = 40 %
Ktotal = Kr + Kw  100 %
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
KTR-N
Sheet:
Edition:
ROTEX®
Operating/Assembly instructions
4
40210 EN
18 of 31
25
Assembly
4.7 Displacements - alignment of the couplings
Table 11: Displacement figures for 92 and 98 Shore A
Size
Max. axial displacement Ka
[mm]
Max. radial
1500 rpm
displacement
Kr [mm] with
3000 rpm
n=
Max. angular
[degree]
displacement Kw
[mm]
with n=1500 rpm
Max. angular
[degree]
displacement Kw
[mm]
with n=3000 rpm
14
19
24
28
38
42
48
55
65
75
90
100 110 125 140 160 180
-0.5 -0.5 -0.5 -0.7 -0.7 -1.0 -1.0 -1.0 -1.0 -1.5 -1.5 -1.5 -2.0 -2.0 -2.0 -2.5 -3.0
+1.0 +1.2 +1.4 +1.5 +1.8 +2.0 +2.1 +2.2 +2.6 +3.0 +3.4 +3.8 +4.2 +4.6 +5.0 +5.7 +6.4
0.17 0.20 0.22 0.25 0.28 0.32 0.36 0.38 0.42 0.48 0.50 0.52 0.55 0.60 0.62 0.64 0.68
0.11 0.13 0.15 0.17 0.19 0.21 0.25 0.26 0.28 0.32 0.34 0.36 0.38
-
-
-
-
1.2
1.3
1.2
1.2
1.2
1.2
0.9
0.9
1.0
1.0
1.1
1.1
1.2
1.2
1.2
1.2
1.3
0.67 0.82 0.85 1.05 1.35 1.70 2.00 2.30 2.70 3.30 4.30 4.80 5.60 6.50 6.60 7.60 9.00
1.1
1.1
0.8
0.8
0.9
0.9
1.0
1.0
1.1
1.1
1.1
1.1
1.2
-
-
-
-
0.60 0.70 0.75 0.85 1.10 1.40 1.60 2.00 2.30 2.90 3.80 4.20 5.00
-
-
-
-
Table 12: Displacement figures for 64 Shore D
Size
Max. axial displacement Ka
[mm]
Max. radial
1500 rpm
displacement
Kr [mm] with
3000 rpm
n=
Max. angular
[degree]
displacement Kw
[mm]
with n=1500 rpm
Max. angular
[degree]
displacement Kw
[mm]
with n=3000 rpm
14
19
24
28
38
42
48
55
65
75
90
100 110 125 140 160 180
-0.5 -0.5 -0.5 -0.7 -0.7 -1.0 -1.0 -1.0 -1.0 -1.5 -1.5 -1.5 -2.0 -2.0 -2.0 -2.5 -3.0
+1.0 +1.2 +1.4 +1.5 +1.8 +2.0 +2.1 +2.2 +2.6 +3.0 +3.4 +3.8 +4.2 +4.6 +5.0 +5.7 +6.4
0.11 0.13 0.15 0.18 0.21 0.23 0.25 0.27 0.30 0.34 0.36 0.37 0.40 0.43 0.45 0.46 0.49
0.08 0.09 0.10 0.13 0.15 0.16 0.18 0.19 0.21 0.24 0.25 0.26 0.28
-
-
-
-
1.1
1.2
1.1
1.1
1.1
1.1
0.8
0.8
0.9
0.9
1.0
1.0
1.1
1.1
1.1
1.1
1.2
0.57 0.77 0.77 0.90 1.25 1.40 1.80 2.00 2.50 3.00 3.80 4.30 5.30 6.00 6.10 7.10 8.00
1.1
-
-
-
-
0.52 0.70 0.67 0.80 1.00 1.30 1.60 1.80 2.20 2.70 3.50 4.00 4.90
1.0
1.0
0.7
0.7
0.8
0.8
0.9
0.9
1.0
1.0
1.0
1.0
-
-
-
-
Table 13: Displacement figures for type DKM only
Size
Max. axial displacement Ka [mm]
Max. radial displacement Kr
[mm] with n=
Max. angular displacement
Kw [degree] with n=
Please observe protection
note ISO 16016.
1500 rpm
3000 rpm
1500 rpm
3000 rpm
Drawn:
Verified:
19
-1.0
+1.2
0.45
0.40
1.0
0.9
24
-1.0
+1.4
0.59
0.53
1.0
0.9
28
-1.4
+1.5
0.66
0.60
1.0
0.9
2022-07-04 Pz/Wb
2022-08-04 Pz
38
-1.4
+1.8
0.77
0.70
1.0
0.9
42
-2.0
+2.0
0.84
0.75
1.0
0.9
48
-2.0
+2.1
0.91
0.82
1.0
0.9
Replacing:
Replaced by:
55
-2.0
+2.2
1.01
0.81
1.0
0.9
65
-2.0
+2.6
1.17
1.05
1.0
0.9
75
-3.0
+3.0
1.33
1.19
1.0
0.9
90
-3.0
+3.4
1.48
1.33
1.0
0.9
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
5
KTR-N
Sheet:
Edition:
40210 EN
19 of 31
25
Start-up
Before start-up of the coupling, inspect the tightening of the setscrews in the hubs, the alignment and the distance
dimension E or 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. Depending on the outside diameter DH of
the coupling, we recommend the following minimum distance:
ØDH to 50 mm = 6 mm, ØDH 50 mm to 120 mm = 10 mm, ØDH from 120 mm = 15 mm.
Please check if a proper enclosure (ignition protection, coupling protection, contact protection) has been mounted
and the operation of the coupling is not affected by the enclosure. The same applies for test runs and rotational
direction inspections.
The cover may provide for openings intended for necessary heat dissipation. These openings have to comply with
DIN EN ISO 13857.
The cover must be electrically conductive and included in the equipotential bonding. Bellhousings (magnesium
share below 7.5 %) made of aluminium and damping rings (NBR) can be used as connecting element between
pump and electric motor. The cover may only be taken off with standstill of the unit.
If the couplings are used in locations subject to dust explosion and in mining the user must
make sure that there is no accumulation of dust in a dangerous volume between the cover
and the coupling. The coupling must not operate in an accumulation of dust.
For covers with unlocked openings on the top face no light metals must be used if the
couplings are used as equipment of equipment group ll (if possible, from stainless steel).
If the couplings are used in mining (equipment group l M2), the cover must not be made of
light metal. In addition, it must be resistant to higher mechanical loads than with use as
equipment of equipment group ll.
During operation of the coupling, please pay attention to
• different operating noise
• vibrations occurring.
!
If you note any irregularities with the coupling during operation, the drive unit must be
switched off immediately. The cause of the breakdown must be specified by means of the
table „Breakdowns“ and, if possible, be eliminated according to the proposals. The potential
breakdowns specified can be hints only. To find out the cause all operating factors and
machine components must be considered.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
5
KTR-N
Sheet:
Edition:
40210 EN
20 of 31
25
Start-up
Coating of coupling:
If coated (priming, paintings, etc.) couplings are used in potentially explosive atmospheres,
the requirements on conductibility and coating thickness must be considered. With
paintings up to 200 µm electrostatic load does not have to be expected. If thicker paintings
resp. coatings up to a layer thickness of a maximum of 2.0 mm are applied, the couplings
are not permissible for gases and vapours of category IIC in potentially explosive areas, but
only for gases and vapours of category IIA and IIB.
This also applies for multiple coatings exceeding an overall thickness of 200 µm. Make sure
with painting or coating that the coupling components are conductively connected with the
device/devices to be connected so that the equipotential bonding is not impeded by the
paint or coat applied. Basically painting of the 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 improper use of the ROTEX® 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 use other than intended:
• Important data for the coupling selection are not forwarded.
• The calculation of the shaft-hub-connection is not considered.
• Coupling components with damage occurred during transport are assembled.
• 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 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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
6
KTR-N
Sheet:
Edition:
40210 EN
21 of 31
25
Breakdowns, causes and elimination
Breakdowns
Different operating
noise and/or
vibrations occuring
Causes
Hazard notes for
potentially explosive
atmospheres
Misalignment
Increased temperature on
the spider surface; ignition
risk by hot surfaces
Wear of spider, shortterm torque
transmission due to
metal contact
Ignition risk due to
sparking
Screws for axial
fastening of hubs
working loose
Ignition risk due to hot
surfaces and sparking
Wear of spider, torque
transmission due to
metal contact
Fracture of the cams
due to high impact
energy/overload
Fracture of cams
Operating parameters
do not meet with the
performance of the
coupling
Ignition risk due to
sparking
Operating error of the
unit
Early wear of spider
Misalignment
Increased temperature on
the spider surface; ignition
risk by hot surfaces
e. g. contact with
aggressive liquids/oils,
ozone influence, too
high/low ambient
temperatures etc.
causing physical
modification of the
spider
Ignition risk due to
sparking with metallic
contact of the cams
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Please observe protection
note ISO 16016.
Elimination
1) Set the unit out of operation
2) Eliminate the reason for the misalignment
(e. g. loose foundation bolts, fracture of the
engine mount, heat 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) Disassemble the coupling and remove
residues of the spider
3) Inspect coupling components and replace
coupling components that have been
damaged
4) Insert spider, assemble coupling
components
5) Inspect alignment, adjust if necessary
1) Set the unit out of operation
2) Inspect alignment of coupling
3) Tighten the screws to fasten the hubs and
secure against working loose
4) For inspection of wear see chapter 10.2
1) Set the unit out of operation
2) Replace complete coupling
3) Inspect alignment
1) Set the unit out of operation
2) Replace complete coupling
3) Inspect alignment
4) Find out the reason for overload
1) Set the unit out of operation
2) Review the operating parameters and select
a bigger coupling (consider mounting space)
3) Assemble new coupling size
4) Inspect alignment
1) Set the unit out of operation
2) Replace complete coupling
3) Inspect alignment
4) Instruct and train the service staff
1) Set the unit out of operation
2) Eliminate the reason for the misalignment
(e. g. loose foundation bolts, fracture of the
engine mount, heat expansion of unit
components, modification of the 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
residues of the spider
3) Inspect coupling components and replace
coupling components that have been
damaged
4) Insert spider, assemble coupling
components
5) Inspect alignment, adjust if necessary
6) Make sure that further physical modifications
of the spider are excluded
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
6
40210 EN
22 of 31
25
Breakdowns, causes and elimination
Breakdowns
Early wear of spider
Early wear of spider
(liquefaction of
material inside the
spider cam)
!
7
KTR-N
Sheet:
Edition:
Causes
Hazard notes for
potentially explosive
atmospheres
Elimination
Ignition risk due to
sparking with metallic
contact of the cams
1) Set the unit out of operation
2) Disassemble the coupling and remove
residues of the spider
3) Inspect coupling components and replace
coupling components that have been
damaged
4) Insert spider, assemble coupling
components
5) Inspect alignment, adjust if necessary
6) Inspect and adjust ambient/contact
temperature (correct by using other spider
materials, if necessary)
1) Set the unit out of operation
2) Disassemble the coupling and remove
residues of the spider
3) Inspect coupling components and replace
coupling components that have been
damaged
4) Insert spider, assemble coupling
components
5) Inspect alignment, adjust if necessary
6) Find out the reason for the vibrations
(possibly corrective by spider with lower or
higher Shore hardness)
Ambient/contact
temperatures which
are too high for the
spider, max.
permissible
-30 °C/+90 °C
Vibrations of drive
When operating with a worn spider (see chapter 10.3) proper operation is not ensured.
Disposal
In respect of environmental protection we would ask you to dispose of the packaging resp. products on
termination of their service life in accordance with the legal regulations resp. standards that apply.
• Metal
Any metal components have to be cleaned and disposed of by scrap metal.
• Nylon materials
Nylon materials have to be collected and disposed of by a waste disposal company.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
8
KTR-N
Sheet:
Edition:
40210 EN
23 of 31
25
Maintenance and service
ROTEX® 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 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:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
40210 EN
24 of 31
25
Enclosure A
Advice and instructions regarding the use in
potentially explosive atmospheres
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
• 1.3 Hub with spline
• 1.4 Hub with feather keyway, without setscrew
• 2.1 Clamping hub single slot with feather keyway
• 2.3 Clamping hub single slot with spline
• 2.6 Clamping hub double slot with feather keyway
• 4.0 Hub with CLAMPEX® clamping set KTR 150
• 4.1 Hub with CLAMPEX® clamping set KTR 200
• 4.2 Hub with CLAMPEX® clamping set KTR 250
• 4.3 Hub with CLAMPEX® clamping set KTR 400
• 4.4 Hub with CLAMPEX® clamping set KTR 401
• 6.0 Clamping ring hub
• 6.5 Clamping ring hub (hub type as 6.0, but external clamping screws only)
• 7.1 SPLIT hub with feather keyway
• 7.6 Half shell hub (DH) with feather keyway
• 7.9 Half shell hub (H) with feather keyway
• Type standard, AFN, BFN, CF, CFN, DF, DFN, DKM, ZS-DKM, ZS-DKM-H, SP and TB with hubs
corresponding to the specifications above
b) Hubs which may be used in group II, category 3 only:
(hubs without feather keyway)
• 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
• 7.0 SPLIT hub without feather keyway
• 7.5 Half shell hub (DH) without feather keyway
• 7.8 Half shell hub (H) without feather keyway
• Type standard, AFN, BFN, CF, CFN, DKM, ZS-DKM, ZS-DKM-H and SP with hubs corresponding to the
specifications above
ROTEX® DKM and ROTEX® ZS-DKM only with spacer made of steel or aluminium semi-finished products with a
yield point of Rp0.2 ≥ 250 N/mm2.
Hubs, clamping hubs (SPLIT hubs) or similar types without feather keyway may be used in
category 3 only and are marked with category 3 accordingly.
The hub types 1.1 and 1.2 are not approved for potentially explosive atmospheres!
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
40210 EN
25 of 31
25
Enclosure A
Advice and instructions regarding the use in
10.1 Intended use in
potentially explosive atmospheres
potentially explosive atmospheres
Conditions of operation in
potentially explosive atmospheres
The ROTEX® 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
PUR / T-PUR®
Ambient or operating temperature Ta 1)
Max. surface temperature 2)
-30 °C to +90 °C
+110 °C
-30 °C to +75 °C
+95 °C
-30 °C to +60 °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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
40210 EN
26 of 31
25
Enclosure A
Advice and instructions regarding the use in
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 explosive atmospheres
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, 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, 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® coupling
Illustration 21: ROTEX® coupling
Illustration 22: ROTEX® spider
Here the backlash between the cams of the coupling and the flexible spider must be inspected 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:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
40210 EN
27 of 31
25
Enclosure A
Advice and instructions regarding the use in
potentially explosive atmospheres
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 table 11 to 13).
If the figures are exceeded, the coupling will be damaged.
!
Illustration 23: Inspection of the limit of wear
Illustration 24: Wear of spider
Table 14:
Size
9
14
19
24
28
38
42
48
55
Please observe protection
note ISO 16016.
Limits of wear (friction)
Xmax. [mm]
2
2
3
3
3
3
4
4
5
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Limits of wear (friction)
Xmax. [mm]
5
6
8
9
9
10
12
14
14
Size
65
75
90
100
110
125
140
160
180
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
40210 EN
28 of 31
25
Enclosure A
Advice and instructions regarding the use in
10.4
potentially explosive atmospheres
marking of coupling for potentially explosive atmospheres
The explosion protection marking of the ROTEX® coupling is applied on the outer sheath or on the front side.
The flexible spider is excluded.
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®
<Year>
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
10
40210 EN
29 of 31
25
Enclosure A
Advice and instructions regarding the use in
10.4
KTR-N
Sheet:
Edition:
potentially explosive atmospheres
marking of coupling for potentially explosive atmospheres
Deviating marking applied until 31st October 2019:
Short marking:
II 2GD c IIC T X/I M2 c X
Complete marking:
(valid for T-PUR® only)
II 2G c IIC T6, T5, T4 resp. T3 -50 °C  Ta  +65 °C, +80 °C,
+115 °C resp. +120 °C
II 2D c T 140 °C/I M2 c -50 °C  Ta  +120 °C
Complete marking:
(valid for PUR only)
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 4.2 of the present operating/assembly instructions).
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-07-04 Pz/Wb
2022-08-04 Pz
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
40210 EN
30 of 31
25
Enclosure A
Advice and instructions regarding the use in
potentially explosive atmospheres
10.5 EU Certificate of conformity
EU Declaration of Conformity resp.
Certificate of Conformity
corresponding to EU directive 2014/34/EU dated 26 February 2014
and to the legal regulations adopted for its implementation
The manufacturer - KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine - states that the
flexible ROTEX® 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® 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 IBExU13ATEXB016 X):
IBExU
Institut für Sicherheitstechnik GmbH
Identification number: 0637
Fuchsmühlenweg 7
09599 Freiberg
Rheine,
Place
2022-07-04
Date
Please observe protection
note ISO 16016.
Drawn:
Verified:
i. V.
Reinhard Wibbeling
Engineering/R&D
2022-07-04 Pz/Wb
2022-08-04 Pz
i. V.
Michael Brüning
Product Manager
Replacing:
Replaced by:
KTR-N dated 2020-06-23
ROTEX®
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
40210 EN
31 of 31
25
Enclosure A
Advice and instructions regarding the use in
potentially explosive atmospheres
10.6 UK Declaration of conformity
UK Declaration of Conformity resp.
Certificate of Conformity
corresponding to UK directive SI 2016 No. 1107 dated 26 February 2014
and to the legal provisions adopted for its implementation
The manufacturer - KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine - states that the
flexible ROTEX® 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® 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
2022-07-04
Date
Please observe protection
note ISO 16016.
Drawn:
Verified:
i. V.
Reinhard Wibbeling
Engineering/R&D
2022-07-04 Pz/Wb
2022-08-04 Pz
i. V.
Michael Brüning
Product Manager
Replacing:
Replaced by:
KTR-N dated 2020-06-23
">