KTR ROTEX Operating/Mounting Instructions
KTR ROTEX is a torsionally flexible jaw coupling designed to compensate for shaft misalignment. It is suitable for use in potentially explosive atmospheres and features a modular design allowing for easy replacement of components. The ROTEX is ideal for applications requiring reliable torque transmission and vibration damping.
PDF
Download
Document
Advertisement
Advertisement
ROTEX® Operating/Assembly instructions Type AH KTR-N Sheet: Edition: 40226 EN 1 of 24 8 ROTEX® Torsionally flexible jaw couplings type AH and their combinations according to directive 2014/34/EU and UK directive SI 2016 No. 1107 Type AH, Size 19 - 90 Type AH, Size 100 - 180 Please observe protection note ISO 16016. Drawn: Verified: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH KTR-N Sheet: Edition: 40226 EN 2 of 24 8 ROTEX® is a torsionally flexible jaw coupling. It is able to compensate for shaft misalignment, for example caused by manufacturing inaccuracies, thermal expansion, etc. Type AH allows to replace a spider/coupling without having to disassemble the driving resp. driven machine. Table of contents 1 Technical data 3 2 Advice 5 2.1 2.2 2.3 2.4 2.5 2.6 5 5 5 6 6 6 3 4 General advice Safety and advice symbols General hazard warnings Intended use Coupling selection Reference to EC Machinery Directive 2006/42/EG Storage, transport and packaging 7 3.1 3.2 7 7 Storage Transport and packaging Assembly 7 4.1 4.2 4.3 4.4 4.5 7 9 9 10 11 Components of the coupling Advice for finish bore Assembly of the coupling (general) Assembly of type AH Displacements - alignment of the couplings 5 Start-up 12 6 Breakdowns, causes and elimination 14 7 Disposal 16 8 Maintenance and service 16 9 Spares inventory, customer service addresses 16 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: 17 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. 17 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: 18 20 21 23 24 KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 1 KTR-N Sheet: Edition: 40226 EN 3 of 24 8 Technical data Illustration 1: ROTEX® type AH (material: steel) Table 1: Dimensions - Material steel Size 19 24 28 38 42 48 55 65 75 90 Size Spider 1) (component 2) rated torque TKN in Nm 92 ShA 98 ShA 64 ShD 10 17 21 35 60 75 95 160 200 190 325 405 265 450 560 310 525 655 410 685 825 625 940 1175 1280 1920 2400 2400 3600 4500 Max. fiComponish nent bore D L 66 78 90 114 126 140 160 185 210 245 L1, L2 25 30 35 45 50 56 65 75 85 100 E 16 18 20 24 26 28 30 35 40 45 Dimensions in mm General B1 12 14 15 18 20 21 22 26 30 34 Dimensions in mm General S 2.0 2.0 2.5 3.0 3.0 3.5 4.0 4.5 5.0 5.5 DH 40 55 65 80 95 105 120 135 160 200 DI1 18 27 30 38 46 51 60 68 80 100 Cap screws DIN EN ISO 4762 DN DK DK1 X1, X2 DBSE MxLM TA in Nm 85 95 110 115 135 160 - 46.0 57.5 73.0 83.5 97.0 108.5 122.0 132.5 158.0 197.0 93.5 105.0 119.5 123.5 147.5 176.0 - 17.5 22.5 25.5 35.5 31 33 39 43 14 14 35 35 39.0 48 45.0 50 50.0 60 60.0 65 M6x16 M6x20 M8x25 M8x30 M10x30 M10x35 M12x35 M12x40 M12x40 M12x45 M12x40 M12x45 67.5 75 M16x50 295 81.5 82 M20x60 580 2) 19 24 28 38 42 48 55 65 75 90 1a 1a 1a 1a 1 1a 1 1a 1 1a 1 1a 1 1a 1 1a 20 28 38 45 50 55 55 60 65 70 70 80 80 90 90 110 69 120 120 120 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] Please observe protection note ISO 16016. Drawn: Verified: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 1 KTR-N Sheet: Edition: 40226 EN 4 of 24 8 Technical data Illustration 2: ROTEX® type AH (material: EN-GJS-400-15) Table 2: Dimensions - Material EN-GJS-400-15 Size 100 110 125 140 160 180 Size Spider 1) (component 2) rated torque TKN in Nm 92 ShA 98 ShA 64 ShD 3300 4950 6185 4800 7200 9000 6650 10000 12500 8550 12800 16000 12800 19200 24000 18650 28000 35000 Max. fiComponish nent bore D L 270 295 340 375 425 475 L1, L2 110 120 140 155 175 195 E 50 55 60 65 75 85 Dimensions in mm General B1 S 38 6.0 42 6.5 46 7.0 50 7.5 57 9 64 10.5 Dimensions in mm General DH 225 255 290 320 370 420 DI1 113 127 147 165 190 220 Cap screws DIN EN ISO 4762 DN DK DK1 X1, X2 DBSE MxLM TA in Nm 180 200 230 225 290 325 - 185.5 208.0 242.5 268.5 302.5 336 84 90 105 115 130 142.5 102 115 130 145 165 190 M16x50 M20x60 M24x70 M24x80 M24x80 M24x90 295 580 1000 1000 1000 1000 2) 100 110 125 140 160 180 1 1 1 1 1 1 110 120 140 160 185 200 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] 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: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 2 KTR-N Sheet: Edition: 40226 EN 5 of 24 8 Advice 2.1 General advice Read carefully through these operating/assembly instructions 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. 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: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 2 KTR-N Sheet: Edition: 40226 EN 6 of 24 8 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 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/EG 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: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 3 KTR-N Sheet: Edition: 40226 EN 7 of 24 8 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 must be inspected for completeness. 4.1 Components of the coupling Components of ROTEX® type AH, size 19 - 90 Component Quantity 1 2 2 3 1 2 1) Description Clamping hub type H with half length tapered groove pin DIN EN ISO 8745 (2 pieces) Spider Cap screws DIN EN ISO 4762 1) each clamping hub Illustration 3: ROTEX® type AH, size 19 - 90 Please observe protection note ISO 16016. Drawn: Verified: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 4 KTR-N Sheet: Edition: 40226 EN 8 of 24 8 Assembly 4.1 Components of the coupling Components of ROTEX® type AH, size 100 - 180 Component Quantity 1 2 2 3 1 4 1) Description Clamping hub type H with half length tapered groove pin DIN EN ISO 8745 (2 pieces) Spider Cap screws DIN EN ISO 4762 1) each clamping hub Illustration 4: ROTEX® type AH, size 100 - 180 Hubs without feather keyway may be used in category 3 only and are marked with category 3 accordingly. 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 Please observe protection note ISO 16016. Drawn: Verified: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 4 KTR-N Sheet: Edition: 40226 EN 9 of 24 8 Assembly 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 5). • Make absolutely sure to observe the figures for ØD. • Carefully align the hubs when the finish bores are drilled. Illustration 5: 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. 4.3 Assembly of the coupling (general) We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy before assembly. Pay attention to the ignition risk in potentially explosive atmospheres! ! With the assembly make sure that the distance dimension E (see table 1 and 2) is observed to allow for axial clearance of the spider when in operation. Disregarding this advice may cause damage to the coupling. If the shaft diameters with inserted feather key are smaller than dimension DI1 (see table 1 and 2) of the spider, one or two shaft ends may protrude into the spider. If used in potentially explosive atmospheres 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: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 4 KTR-N Sheet: Edition: 40226 EN 10 of 24 8 Assembly 4.4 Assembly of type AH • Remove the half shells from the hub body (see illustration 6). Illustration 6: Disassembly of shells • Fit the hub body along with the spider (see illustration 7). Illustration 7: Assembly of hub bodies, spiders and DKM-H spacer • Mount the fitted unit along with the half shells and the clamping screws on the shaft ends of the driving and driven machine (see illustration 8). • Hand-tighten the components first until the hub bodies with the half shells fit allover to the shaft. • Shift the H clamping hubs in axial direction until the dimension DBSE specified in table 1 resp. 2 is achieved. • Secure the clamping hubs type H by tightening the clamping screws gradually reciprocally (see illustration 9). Start with 1/3 in the first stage, 2/3 in the second stage and the full tightening torque in the last stage. The screws have to be tightened at the tightening torques TA specified in table 1 or 2 by means of a suitable torque wrench. Tighten all screws until the full tightening torque is achieved for all screws. Illustration 8: Assembly of subassembly on the shafts ! Illustration 9: Tightening of screws 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. 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: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 4 KTR-N Sheet: Edition: 40226 EN 11 of 24 8 Assembly 4.5 Displacements - alignment of the couplings The displacement figures specified in tables 3 and 4 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 specified displacement figures (see tables 3 and 4). 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 3 and 4) is permissible. ! Please note: • The displacement figures specified in tables 3 and 4 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 10). • Inspect with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 3 and 4 can be observed. Axial displacements Radial displacements Lmax = L + Ka in mm Angular displacements Kw = L1max. - L1min. in mm Illustration 10: Displacements Examples of the displacement combinations specified in illustration 11: Illustration 11: 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: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 4 KTR-N Sheet: Edition: 40226 EN 12 of 24 8 Assembly 4.5 Displacements - alignment of the couplings Table 3: Displacement figures for 92 and 98 Shore A Size Max. axial displacement DKa in mm Max. radial dis- 1500 rpm placement Kr 3000 rpm in mm with 19 -0.5 +1.2 24 -0.5 +1.4 28 -0.7 +1.5 38 -0.7 +1.8 42 -1.0 +2.0 48 -1.0 +2.1 55 -1.0 +2.2 65 -1.0 +2.6 75 -1.5 +3.0 90 -1.5 +3.4 100 -1.5 +3.8 110 -2.0 +4.2 125 -2.0 +4.6 140 -2.0 +5.0 160 -2.5 +5.7 180 -3.0 +6.4 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 0.13 0.15 0.17 0.19 0.21 0.25 0.26 0.28 0.32 0.34 0.36 0.38 - - - - Max. angular dis- in degree placement Kw in mm with n=1500 rpm Max. angular dis- in degree placement Kw in mm with n=3000 rpm 1.2 0.9 0.9 1.0 1.0 1.1 1.1 1.2 1.2 1.2 1.2 1.3 1.3 1.2 1.2 1.2 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 0.8 0.8 0.9 0.9 1.0 1.0 1.1 1.1 1.1 1.1 1.2 - - - - 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 4: Displacement figures for 64 Shore D Size Max. axial displacement DKa in mm Max. radial dis- 1500 rpm placement Kr 3000 rpm in mm with 19 -0.5 +1.2 24 -0.5 +1.4 28 -0.7 +1.5 38 -0.7 +1.8 42 -1.0 +2.0 48 -1.0 +2.1 55 -1.0 +2.2 65 -1.0 +2.6 75 -1.5 +3.0 90 -1.5 +3.4 100 -1.5 +3.8 110 -2.0 +4.2 125 -2.0 +4.6 140 -2.0 +5.0 160 -2.5 +5.7 180 -3.0 +6.4 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 0.09 0.10 0.13 0.15 0.16 0.18 0.19 0.21 0.24 0.25 0.26 0.28 - - - - Max. angular dis- in degree placement Kw in mm with n=1500 rpm Max. angular dis- in degree placement Kw in mm with n=3000 rpm 1.1 0.8 0.8 0.9 0.9 1.0 1.0 1.1 1.1 1.1 1.1 1.2 1.2 1.1 1.1 1.1 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 5 1.0 0.7 0.7 0.8 0.8 0.9 0.9 1.0 1.0 1.0 1.0 1.1 - - - - 0.70 0.67 0.80 1.00 1.30 1.60 1.80 2.20 2.70 3.50 4.00 4.90 - - - - Start-up Before start-up of the coupling, inspect 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 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 whether 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. Please observe protection note ISO 16016. Drawn: Verified: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 5 KTR-N Sheet: Edition: 40226 EN 13 of 24 8 Start-up 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, 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. Please observe protection note ISO 16016. Drawn: Verified: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 6 KTR-N Sheet: Edition: 40226 EN 14 of 24 8 Breakdowns, causes and elimination The below-mentioned failures can lead to a use of the ROTEX® coupling other than intended. In addition to the specifications given in these operating/assembly instructions make sure to avoid such failures. The errors listed can only be clues to search for the failures. When searching for the failure the adjacent components must generally be considered. The coupling can become a source of ignition with improper use. Directive 2014/34/EU and UK directive SI 2016 No. 1107 require special care by the manufacturer and the user. General failures with 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 Fracture 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 comrisk by hot surfaces ponents, modification of the installation dimension E of the coupling) 3) For inspection of wear see chapter 10.3 1) Set the unit out of operation 2) Disassemble the coupling and remove residues of the spider Wear of spider, short3) Inspect coupling components and replace term torque transmis- Ignition risk due to sparkcoupling components that have been damsion due to metal coning aged tact 4) Insert spider, assemble coupling components 5) Inspect alignment, adjust if necessary 1) Set the unit out of operation Screws for axial fas2) Inspect alignment of coupling Ignition risk due to hot surtening of hubs working 3) Tighten the screws to fasten the hubs and faces and sparking loose secure against working loose 4) For inspection of wear see chapter 10.3 Wear of spider, torque 1) Set the unit out of operation transmission due to 2) Replace complete coupling metal contact 3) Inspect alignment Ignition risk due to spark1) Set the unit out of operation ing Fracture of the cams 2) Replace complete coupling due to high impact en3) Inspect alignment ergy/overload 4) Find out the reason for overload Please observe protection note ISO 16016. Drawn: Verified: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 6 KTR-N Sheet: Edition: 40226 EN 15 of 24 8 Breakdowns, causes and elimination Breakdowns Causes Hazard notes for potentially explosive atmospheres Elimination 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 Ignition risk due to spark4) Inspect alignment Fracture of cams ing 1) Set the unit out of operation Operating error of the 2) Replace complete coupling unit 3) Inspect alignment 4) Instruct and train the service staff 1) Set the unit out of operation 2) 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 comrisk by hot surfaces ponents, 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 resie. g. contact with agdues of the spider gressive liquids/oils, 3) Inspect coupling components and replace ozone influence, too coupling components that have been damhigh/low ambient temaged peratures etc. causing 4) Insert spider, assemble coupling compophysical modification of nents Early wear of spider the spider 5) Inspect alignment, adjust if necessary 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 3) Inspect coupling components and replace Ambient/contact temcoupling components that have been damperatures which are aged Ignition risk due to sparktoo high for the spider, ing with metallic contact of 4) Insert spider, assemble coupling compomax. permissible nents the cams -30 °C/+90 °C 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 Early wear of spider coupling components that have been dam(liquefaction of mateaged Vibrations of drive rial inside the spider 4) Insert spider, assemble coupling compocam) nents 5) Inspect alignment, adjust if necessary 6) Find out the reason for the vibrations (possibly corrective by spider with lower or higher Shore hardness) Operating parameters do not meet with the performance of the coupling When operating with a worn spider (see chapter 10.3) proper operation is not ensured. Please observe protection note ISO 16016. Drawn: Verified: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 7 KTR-N Sheet: Edition: 40226 EN 16 of 24 8 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 and standards that apply. • Metal Any metal components have to be cleaned and disposed of by scrap metal. • Nylon materials Nylon materials have to be collected and disposed of by a waste disposal company. 8 Maintenance and service 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 must be inspected for damages. • The screw connections must 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: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 10 KTR-N Sheet: Edition: 40226 EN 17 of 24 8 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) • 7.6 Half shell hub (DH) with feather keyway • 7.9 Half shell hub (H) with feather keyway b) Hubs which may be used in group II, category 3 only: (hubs without feather keyway) • 7.5 Half shell hub (DH) without feather keyway • 7.8 Half shell hub (H) without feather keyway Hubs, clamping hubs or similar types without feather keyway may be used in category 3 only and are marked with category 3 accordingly. 10.1 Intended use in 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. Please observe protection note ISO 16016. Drawn: Verified: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 10 KTR-N Sheet: Edition: 40226 EN 18 of 24 8 Enclosure A Advice and instructions regarding the use in explosive atmospheres 10.1 Intended use in potentially potentially explosive atmospheres 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. 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 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. Please observe protection note ISO 16016. Drawn: Verified: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 10 KTR-N Sheet: Edition: 40226 EN 19 of 24 8 Enclosure A Advice and instructions regarding the use in explosive atmospheres 10.2 Inspection intervals for couplings in potentially potentially explosive atmospheres ROTEX® coupling Illustration 12: ROTEX® type AH Illustration 13: 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: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 10 KTR-N Sheet: Edition: 40226 EN 20 of 24 8 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 specified displacement figures (see tables 3 and 4). If the figures are exceeded, the coupling will be damaged. ! Illustration 14: Inspection of the limit of wear Illustration 15: Wear of spider Table 5: Size 19 24 28 38 42 48 55 65 Please observe protection note ISO 16016. Limits of wear (friction) Xmax in mm 3 3 3 3 4 4 5 5 Drawn: Verified: 2024-10-09 Fes/At 2024-10-10 Ka Limits of wear (friction) Xmax in mm 6 8 9 9 10 12 14 14 Size 75 90 100 110 125 140 160 180 Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 10 KTR-N Sheet: Edition: 40226 EN 21 of 24 8 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® 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 (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 Short marking: (A short marking is only made if not possible differently for reason of space or functioning.) ROTEX® <Year> 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 Please observe protection note ISO 16016. Drawn: Verified: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 10 40226 EN 22 of 24 8 Enclosure A Advice and instructions regarding the use in explosive atmospheres 10.4 KTR-N Sheet: Edition: potentially marking of coupling for potentially explosive atmospheres Comments on marking Equipment group I Equipment group II Equipment category 2G Equipment category 3G Equipment category 2D Equipment category 3D Equipment category M2 D G Ex h IIC IIIC T6 … T4 T80 °C … T110 °C -30 °C ≤ Ta ≤ +60 °C … +90 °C or 30 °C ≤ Ta ≤ +90 °C Gb, Db, Mb Gc, Dc X 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 Dust Gases and vapours Nonelectrical explosion protection Gases and vapours of class IIC (including IIA and IIB) Electrically conductive dusts of class IIIC (including IIIA and IIIB) Temperature class to be considered, depending on the ambient temperature Maximum surface temperature to be considered, depending on the ambient temperature Permissible ambient temperature from -30 °C to +60 °C resp. -30 °C to +90 °C Equipment protection level, high level of safety, analogous to the equipment category Equipment protection level, normal level of safety, analogous to the equipment category 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: 2024-10-09 Fes/At 2024-10-10 Ka Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 10 KTR-N Sheet: Edition: 40226 EN 23 of 24 8 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 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 2024-10-09 Date Please observe protection note ISO 16016. Drawn: Verified: ppa. Dr. Norbert Partmann Head of Engineering and R&D 2024-10-09 Fes/At 2024-10-10 Ka i. V. Michael Brüning Product Manager Replacing: Replaced by: KTR-N dated 2023-11-09 ROTEX® Operating/Assembly instructions Type AH 10 KTR-N Sheet: Edition: 40226 EN 24 of 24 8 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 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 2024-10-09 Date Please observe protection note ISO 16016. Drawn: Verified: ppa. Dr. Norbert Partmann Head of Engineering and R&D 2024-10-09 Fes/At 2024-10-10 Ka i. V. Michael Brüning Product Manager Replacing: Replaced by: KTR-N dated 2023-11-09 ">

Public link updated
The public link to your chat has been updated.
Advertisement
Key features
- Torsionally flexible
- Shaft Misalignment Compensation
- Modular design
- Explosion proof
- Vibration damping
- High torque transmission
Frequently asked questions
Yes, the ROTEX is approved for use in potentially explosive atmospheres. Please consult the document for safety instructions and specifications.
Refer to the document for displacement figures and alignment instructions. Proper alignment is crucial for optimal performance and longevity.
The manual lists 92 Shore A, 98 Shore A, and 64 Shore D options. Choose the appropriate hardness based on your application requirements.
The document provides guidance on inspection intervals, especially for couplings used in potentially explosive atmospheres. Regular maintenance is vital for safety and reliability.