KTR DATAFLEX 110/… Torque messuring shaft Operating/Mounting Instructions

DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
49018 EN
1 of 28
3
DATAFLEX®
Torque measuring shaft type 110/…
DATAFLEX® is a maintenance-free torque measuring shaft with two measuring ranges and
integrated speed measurement. Combined with the steel laminae coupling RADEX®-N the
complete system forms a torsionally stiff, double-cardanic coupling with integrated measuring
shaft.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-08-25 Pz/Koe
2022-08-25 Pz
Replacing:
Replaced by:
KTR-N dated 2022-02-23
DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
49018 EN
2 of 28
3
Table of contents
1
Technical data
3
2
Advice
5
2.1
2.2
2.3
2.4
2.5
5
5
5
6
6
3
4
Storage, transport and packaging
6
3.1
3.2
6
6
Storage
Transport and packaging
Assembly
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
5
General advice
Safety and advice symbols
General hazard warnings
Intended use
Reference to EC Machinery Directive 2006/42/EC
7
Components of DATAFLEX® torque measuring shaft
Advice for finish bore
Displacements - alignment of the torque measuring shaft
Assembly of the hubs
Assembly of the RADEX®-N 135 on the DATAFLEX® torque measuring shaft
4.5.1 Assembly of the RADEX®-N 135 clamping ring hubs (component 4)
4.5.2 Assembly of RADEX®-N 135 flange hubs (component 2)
4.5.3 Assembly of the laminae sets, RADEX®-N 135
4.5.4 Tightening torque of dowel screws of the RADEX®-N 135
4.5.5 Advice for assembly of the RADEX®-N 135
Assembly of the RADEX®-N 156 on the DATAFLEX® torque measuring shaft
4.6.1 Assembly of the RADEX®-N 156 flange hub with CLAMPEX® clamping set
(component 5)
4.6.2 Assembly of RADEX®-N 156 flange hubs (component 2)
4.6.3 Assembly of the laminae sets, RADEX®-N 156
4.6.4 Assembly/disassembly of the laminae sets, RADEX®-N 156
4.6.5 Tightening torques of screw connections on the laminae set
4.6.6 Advice for assembly of the RADEX®-N 156
Advice for assembly of the DATAFLEX® torque measuring shaft
Technical description
7
8
8
9
10
10
10
11
12
12
13
13
14
15
16
16
17
17
18
Special functions
23
5.1
5.2
5.3
5.4
23
24
24
24
Sensor test
Measuring range switchover
Automatic zero adjustment (see illustration 31)
Manual zero adjustment
6
Disposal
25
7
Maintenance and service
25
8
Services, customer service addresses
26
9
Declarations of conformity
27
9.1
9.2
27
28
EU Declaration of conformity
UK Declaration of conformity
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-08-25 Pz/Koe
2022-08-25 Pz
Replacing:
Replaced by:
KTR-N dated 2022-02-23
DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
1
KTR-N
Sheet:
Edition:
49018 EN
3 of 28
3
Technical data
DATAFLEX® torque measuring shaft
Illustration 1: DATAFLEX® torque measuring shaft
Table 1: Dimensions
DATAFLEX®
type
110/10000
110/20000
DW
D3
LD
L2
Dimensions [mm]
L3
L4
L5
L6
H
X
110
196
393
120
153
7.5
50
141.4
34
138
Table 2: Technical data
Coupling size of DATAFLEX®
110/10000
110/20000
-10000 ... +10000 Nm
-2000 ... +2000 Nm
-20000 ... +20000 Nm
-10000 ... +10000 Nm
Electrical data
Measuring range 1 - rated torque TKN [Nm]
Measuring range 2 - rated torque TKN2 [Nm]
Band width of torque signal [kHz] (-3dB)
Error in linearity incl. hysteresis [%] 1)
Influence of temperature [%/10K]
Nominal temperature range [°C]
Supply voltage [V] DC
Max. current consumption [mA]
2
< 0.1 (< 0.2 2))
0.05
0 - 55
24 ± 4
100
Torque output
Voltage output torque [V]
-10 ... +10
Speed output 3)
Number of pulses / revolution
Amplitude [V]
DC voltage output [V]
Scale of DC voltage output
Inaccuracy of DC voltage output [%] 4)
Direction signal [V]
2x 720
24/5V
0 - 10
16fold via micro switch
± 0.2
24/5V
Mechanical data
Static load limit TKmax. 1) [%]
Breaking load TK break 1) [%]
Max. bending torque [Nm]
Max. radial force [N]
Max. axial force [kN]
Weight [kg]
Torsion spring stiffness CT [Nm/rad]
Torsion angle with TKN [degrees]
Mass moment of inertia [kgmm2]
Max. speed [rpm]
1)
2)
3)
4)
150
300
320
1700
48
12.30
395000
0.44
7200
520
2800
66
12.45
500000
0.57
7300
4000
Referring to rated torque TKN
Referring to rated torque TKN2
With connection housing DF2
Referring to upper range value
Please observe protection
note ISO 16016.
Drawn:
Verified:
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2022-08-25 Pz
Replacing:
Replaced by:
KTR-N dated 2022-02-23
DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
1
KTR-N
Sheet:
Edition:
49018 EN
4 of 28
3
Technical data
DATAFLEX® torque measuring shaft in combination with RADEX®-N
Illustration 2: DATAFLEX® 110/10000 with RADEX®-N 135
Illustration 3: DATAFLEX® 110/20000 with RADEX®-N 156
Table 3: Dimensions and technical data
Coupling size of DATAFLEX®
Coupling size of RADEX®-N
110/10000
135
110/20000
156
305
184
135
477
747
135
423
27
325
195
150
547
847
150
493
27
Dimensions [mm]
Dimension DH
Dimension DN
Dimension Dmax.
Dimension DBSE
Dimension L
Dimension L1
Dimension L11
Dimension E
Setscrew [mm]
Dimension G
Dimension T
Dimension T1
Dimension T2
Tightening torque TA [Nm]
Mass moment of inertia [kgm2]
Torsion spring stiffness [Nm/rad]
Weight [kg]
Max. speed [rpm] 1)
M20
40
140
Mechanical data of combination (DATAFLEX® with RADEX®-N)
1.026
1.32 x 106
134.2
3000
M12
30
70
40
1.701
2.36 x 106
179.7
3000
1) Higher speeds on request.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-08-25 Pz/Koe
2022-08-25 Pz
Replacing:
Replaced by:
KTR-N dated 2022-02-23
DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
2
Advice
2.1
General advice
KTR-N
Sheet:
Edition:
49018 EN
5 of 28
3
Read through these operating/assembly instructions carefully before you start up the measuring shaft.
Pay special attention to the safety instructions!
The operating/assembly instructions are part of your product. Please store them carefully and close to the
measuring shaft. The copyright for these operating/assembly instructions remains with KTR.
2.2
Safety and advice symbols
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
!
STOP
With assembly, operation and maintenance of the measuring shaft 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 measuring shaft have to be performed taking into account "safety first".
• Make sure to switch off the power pack before you perform your work on the measuring shaft.
• 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 operation area of the measuring shaft as long as it is in operation.
• Secure the rotating components of the measuring shaft against accidental contact. Provide for the necessary
protection devices and covers.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-08-25 Pz/Koe
2022-08-25 Pz
Replacing:
Replaced by:
KTR-N dated 2022-02-23
DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
2
Advice
2.4
Intended use
KTR-N
Sheet:
Edition:
49018 EN
6 of 28
3
You may only assemble, operate and maintain the measuring shaft 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 measuring shaft may only be used in accordance with the technical data (see chapter 1). Unauthorized
modifications on the measuring shaft 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 DATAFLEX® torque measuring shaft described in here corresponds to the state of the art at the time of
printing of these operating/assembly instructions.
2.5
Reference to EC Machinery Directive 2006/42/EC
The measuring shafts supplied by KTR should be considered as components, not machines resp. partly
completed machines according to EC Machinery Directive 2006/42/EC. Consequently KTR does not have to
issue a declaration of incorporation. For details about safe assembly, start-up and safe operation refer to the
present operating/assembly instructions considering the warnings.
3
Storage, transport and packaging
3.1
Storage
The RADEX®-N couplings are supplied in preserved condition. Both DATAFLEX® and RADEX®-N can be stored
in a dry and roofed place for 6 - 9 months.
!
3.2
!
Humid storage rooms are not suitable.
Make sure that condensation is not generated. The best relative air humidity is less than
65 %.
Transport and packaging
In order to avoid any injuries and any kind of damage always make use of proper transport
and lifting equipment.
The couplings are packed differently each depending on size, number and kind of transport. Unless otherwise
contractually agreed, packaging will follow the in-house packaging specifications of KTR.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-08-25 Pz/Koe
2022-08-25 Pz
Replacing:
Replaced by:
KTR-N dated 2022-02-23
DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
49018 EN
7 of 28
3
Assembly
The measuring shaft and the couplings are supplied as single pre-assembled subassemblies. Before assembly
the measuring shaft has to be inspected for completeness.
The mounting position of DATAFLEX® is variable. The measurement system can be mounted both horizontally
and vertically.
4.1
Components of DATAFLEX® torque measuring shaft
Components of DATAFLEX® torque measuring shaft
Component
1
Quantity
1
Component assembly
DATAFLEX® torque measuring shaft
Components of DATAFLEX® torque measuring shaft with RADEX®-N coupling
Component
1
2
3
4
5
6
7
Quantity
1
2
2
2
2
2
2 / 4 1)
Component assembly
DATAFLEX® torque measuring shaft
Flange hub
Laminae set
Clamping ring hub with clamping ring
Flange hub for clamping set
CLAMPEX® clamping set KTR 620
Setscrew DIN EN ISO 4029
1) RADEX®-N 135 = quantity 2; RADEX®-N 156 = quantity 4
Illustration 4: DATAFLEX® 110/10000 torque measuring shaft with RADEX®-N 135
Illustration 5: DATAFLEX® 110/20000 torque measuring shaft with RADEX®-N 156

Consider our operating/assembly instructions KTR-N 47110 additionally when using the
RADEX®-N coupling.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-08-25 Pz/Koe
2022-08-25 Pz
Replacing:
Replaced by:
KTR-N dated 2022-02-23
DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
4
Assembly
4.2
Advice for finish bore
KTR-N
Sheet:
Edition:
49018 EN
8 of 28
3
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.
STOP
• Hub bores machined by the customer have to observe
concentricity resp. axial runout (see illustration 6).
• Make absolutely sure to observe the figures for ØD.
• Carefully align the hubs when the finish bores are
drilled.
• Provide for a setscrew according to DIN EN ISO 4029
with a cup point or an end plate to fasten the hubs
axially.
Illustration 6: Concentricity and axial runout
4.3
Displacements - alignment of the torque measuring shaft
The displacement figures specified in table 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 measuring shaft, the shaft ends have to be
accurately aligned. Please absolutely observe the displacement figures specified (see table
4). If the figures are exceeded, the measuring shaft with coupling will be damaged.
Please note:
• The displacement figures specified in table 4 are maximum figures which must not arise in parallel. If axial,
radial and angular displacement arises at the same time, these values must be reduced (see illustration 8).
• Inspect with a dial gauge, ruler or feeler gauge whether the permissible displacement figures specified in table
4 can be observed.
Axial displacement
Radial displacement
Illustration 7: Displacements
Angular displacement
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-08-25 Pz/Koe
2022-08-25 Pz
Replacing:
Replaced by:
KTR-N dated 2022-02-23
DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
4
Assembly
4.3
Displacements - alignment of the torque measuring shaft
KTR-N
Sheet:
Edition:
49018 EN
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Table 4: Displacement figures
DATAFLEX®
size
110/10000
110/20000
RADEX®-N size
135
156
Max. axial displacement
Ka [mm]
3.5
4.2
Max. radial displacement
Kr [mm]
7.8
9.0
Max. angular displacement
Kw [degree] 1)
1.0
1) each laminae set
Examples of the displacement
combinations specified in illustration 8:
Illustration 8:
Combinations of
displacement
Example:
Kr = 60%
Kw = 20%
Ka = 20%
Ktotal = Ka + Kr + Kw  100%
4.4

Assembly of the hubs
We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-08-25 Pz/Koe
2022-08-25 Pz
Replacing:
Replaced by:
KTR-N dated 2022-02-23
DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
4
Assembly
4.5
Assembly of the RADEX®-N 135 on the DATAFLEX® torque measuring shaft
49018 EN
10 of 28
3
4.5.1 Assembly of the RADEX®-N 135 clamping ring hubs (component 4)
The power transmission is frictionally engaged. Fit pair of shaft-clamping ring hub is specified as H7/h6.
The following process should be observed with the assembly:
• Clean and degrease the contact surfaces of hub bores and shafts before assembly.
!
Oils and greases containing molybdenum disulfide or other high-pressure additives as well
as internal lubricants must not be used.
• Lightly unscrew the clamping screws, push the clamping ring hub on the shaft of the measuring shaft and align
to dimension L11.
• Tighten the clamping screws evenly crosswise. Increase the tightening torque gradually. Repeat this process
until all clamping screws have reached the tightening torque specified in table 5.
Illustration 9: Assembly of clamping ring hubs
Illustration 10: Alignment to dimension L11
Table 5: Tightening torques of clamping screws
Coupling size of DATAFLEX®
Coupling size of RADEX®-N
Size of clamping screws
Tightening torque TA [Nm]
Transmittable torque [Nm] 1) (frictional torque)
110/10000
135
M16
295
25000
1) H7/h6 shaft/hub fit
4.5.2 Assembly of RADEX®-N 135 flange hubs (component 2)
• Mount the hubs on the shaft of driving and driven side (see illustration 11). The shaft ends must not protrude
on the internal sides of the hubs.
• Shift the power packs in axial direction until the distance dimension DBSE is achieved.
• If the power packs have already been firmly assembled, shifting the hubs axially on the shafts allows for
adjusting the DBSE dimension (see illustration 12).
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-08-25 Pz/Koe
2022-08-25 Pz
Replacing:
Replaced by:
KTR-N dated 2022-02-23
DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
4
Assembly
4.5
Assembly of the RADEX®-N 135 on the DATAFLEX® torque measuring shaft
49018 EN
11 of 28
3
4.5.2 Assembly of RADEX®-N 135 flange hubs (component 2)

!
On request the hubs can be provided with a bore for setscrews for axial fastening. Please
specify in your order.
With the assembly make sure that the distance dimension DBSE (see table 3) is observed.
Disregarding this advice may cause damage to the measuring shaft (coupling).
Illustration 11: Assembly of the hubs on the driving and driven side
Illustration 12: Alignment to dimension DBSE
4.5.3 Assembly of the laminae sets, RADEX®-N 135
!
With the assembly make sure that the laminae sets are installed free from distortion in axial
direction. Disregarding this advice may cause damage to the coupling.
• Insert the laminae sets and the DATAFLEX® measuring shaft.
• Hand-tighten the components first, with the dowel screws to be assembled displaced from left to right (see
illustration 13).
• Tighten the dowel screws to the tightening torques specified in table 6 by means of a suitable torque wrench.
Illustration 13: Assembly of the laminae sets
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-08-25 Pz/Koe
2022-08-25 Pz
Replacing:
Replaced by:
KTR-N dated 2022-02-23
DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
4
Assembly
4.5
Assembly of the RADEX®-N 135 on the DATAFLEX® torque measuring shaft
49018 EN
12 of 28
3
4.5.4 Tightening torque of dowel screws of the RADEX®-N 135
The dowel screws have to be tightened to the tightening torques T A specified in table 6.
Table 6: Tightening torques of dowel screws
Coupling size of DATAFLEX®
Coupling size of RADEX®-N
Screw size
Tightening torque TA [Nm]
!
110/10000
135
M24
900
Having started up the coupling, the tightening torque of the dowel screws has to be
inspected at regular maintenance intervals.
4.5.5 Advice for assembly of the RADEX®-N 135
Table 7:
DATAFLEX® size
110/10000
RADEX®-N size
135
Mounting dimensions
Dimension E
27
Dimension DH
305
Dimension L
297
Illustration 14: Assembly of coupling
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-08-25 Pz/Koe
2022-08-25 Pz
Replacing:
Replaced by:
KTR-N dated 2022-02-23
DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
4
Assembly
4.6
Assembly of the RADEX®-N 156 on the DATAFLEX® torque measuring shaft
49018 EN
13 of 28
3
4.6.1 Assembly of the RADEX®-N 156 flange hub with CLAMPEX® clamping set (component 5)
!

Inspect the taper surfaces and clamping screws of the clamping set for the lubrication
specified.
Dirty or used clamping sets have to be disassembled and cleaned before assembly.
Afterwards the taper surfaces and threads have to be lubricated with Molykote MoS 2 (see
illustration 15). For re-lubrication use the multi-purpose grease Molykote G Rapid plus, as an
example.
• Clean and degrease the contact surfaces of the shaft of DATAFLEX® and the bore of the flange hubs
(component 5) (see illustration 15).
!
The contact surfaces of the shaft of DATAFLEX® and
the flange bore must neither be lubricated nor oiled
(see illustration 15).
• Unscrew the clamping screws by several revolutions so that the
external ring detaches slightly from the internal ring.
• Afterwards position the clamping sets KTR 620 on the flange hubs
(component 5) (see illustration 16 and illustration 17).

The external surface of the flange hub can be
lubricated in the area of the external clamping set fit.
Illustration 15: Cleaning and lubricating the
contact surfaces
• Push the flange hubs along with the clamping set on the shaft of DATAFLEX ®.
• Hand-tighten the clamping screws first and align the clamping set with flange hub and the shaft of DATALFEX®
and to dimension L11 (see illustration 19).
!
Mount the shaft before tightening the clamping screws.
• Tighten the clamping screws gradually in several revolutions evenly one after another until the front surfaces
on the screw head side of external and internal ring are flush. Consequently correct clamping of external and
internal ring can be inspected visually (see illustration 18 and 19).
When tightening the clamping screws the maximum screw tightening torque specified (see table 8) must not
be exceeded.
Illustration 16: Pushing the clamping set
on the flange hub

Illustration 17: Pushing on the shaft
of DATAFLEX®
Illustration 18: Visual inspection
During assembly the hub is not displaced axially to the shaft with KTR 620.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-08-25 Pz/Koe
2022-08-25 Pz
Replacing:
Replaced by:
KTR-N dated 2022-02-23
DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
49018 EN
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3
4
Assembly
4.6
Assembly of the RADEX®-N 156 on the DATAFLEX® torque measuring shaft
4.6.1 Assembly of the RADEX®-N 156 flange hub with CLAMPEX® clamping set (component 5)
Table 8: Tightening torques of clamping screws
Coupling size of DATAFLEX®
Coupling size of RADEX®-N
Size of clamping screws
Tightening torque TA [Nm]
Transmittable torque [Nm] 1)
(frictional torque)
110/20000
156
M14
160
27000
1) Fit H7/h6 between the shaft of DATAFLEX® and flange hub
Illustration 19: Alignment to dimension L11
4.6.2 Assembly of RADEX®-N 156 flange hubs (component 2)
• Mount the hubs on the shaft of driving and driven side (see illustration 20). The shaft ends must not protrude
on the internal sides of the hubs.
• Shift the power packs in axial direction until the distance dimension DBSE is achieved.
• If the power packs have already been firmly assembled, shifting the hubs axially on the shafts allows for
adjusting the DBSE dimension (see illustration 21).

!
On request the hubs can be provided with a bore for setscrews for axial fastening. Please
specify in your order.
With the assembly make sure that the distance dimension DBSE (see table 3) is observed.
Disregarding this advice may cause damage to the measuring shaft (coupling).
Illustration 20: Assembly of the hubs on the driving and driven side
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-08-25 Pz/Koe
2022-08-25 Pz
Illustration 21: Alignment to dimension DBSE
Replacing:
Replaced by:
KTR-N dated 2022-02-23
DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
4
Assembly
4.6
Assembly of the RADEX®-N 156 on the DATAFLEX® torque measuring shaft
49018 EN
15 of 28
3
4.6.3 Assembly of the laminae sets, RADEX®-N 156
!
With the assembly make sure that the laminae sets are installed free from distortion in axial
direction. Disregarding this advice may cause damage to the coupling.
• Clean and degrease the contact surfaces of screw connections on the flange hubs and laminae set as well as
the threads of the clamping nut and dowel screw.
• Insert the laminae sets and DATAFLEX® with flange hubs (see illustration 22).
• Hand-tighten the components first, the dowel screws to be assembled reciprocally (see illustration 22).
• The pressure screws in the clamping nut must not protrude on the pressure side (see illustration 23).
!
All components must be superimposed without any gap.
• Afterwards turn back the clamping nut until there is a gap of 1 - 2 mm (see illustration 23).
• Hand-tighten the pressure screws marked in illustration 25.
• Tighten these screws (see illustration 25) at half the tightening torque according to table 10 and afterwards at
the full tightening torque according to table 10.
• Now tighten all pressure screws one after another and with several revolutions until all screws have achieved
the full tightening torque (see illustration 26).
!
The pressure screws must not bear on the heads after assembly (see illustration 24).
• All clamping nuts have to be mounted as per the aforementioned process.
Laminae set
Illustration 22: Assembly of laminae sets, RADEX®-N size 156
Illustration 23
Please observe protection
note ISO 16016.
Drawn:
Verified:
Illustration 24
2022-08-25 Pz/Koe
2022-08-25 Pz
Replacing:
Replaced by:
KTR-N dated 2022-02-23
DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
4
Assembly
4.6
Assembly of the RADEX®-N 156 on the DATAFLEX® torque measuring shaft
49018 EN
16 of 28
3
4.6.4 Assembly/disassembly of the laminae sets, RADEX®-N 156
Pitch 9
Pitch 9
Illustration 25: Tightening of pressure screws
Illustration 26: Tightening of pressure screws (one after another)
Coupling size of RADEX®-N
Pitch circle ØD4
156
260
Table 9:
Disassembly:
STOP
Driving components falling down may cause injury to persons or damage on the machine.
Secure the driving components before disassembly.
• Untighten the pressure screws of the clamping nut with several revolutions each by a quarter revolution until
all screws are released from tension.
!
Do not relieve and unscrew individual pressure screws completely in any case.
• Unscrew the clamping nuts and remove the washers.
• Take out the laminae sets.
4.6.5 Tightening torques of screw connections on the laminae set
Table 10: Tightening torque of screw connections on the laminae set
Coupling size of RADEX®-N
Dimension M [mm]
Dimension M1 [mm]
Pressure screw M1 - Tightening torque TA [Nm]
!
156
M27
9 x M8
30
Having started up the coupling, the tightening torque of the screw connections has to be
inspected at regular maintenance intervals.
Please observe protection
note ISO 16016.
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DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
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Sheet:
Edition:
4
Assembly
4.6
Assembly of the RADEX®-N 156 on the DATAFLEX® torque measuring shaft
49018 EN
17 of 28
3
4.6.6 Advice for assembly of the RADEX®-N 156
Table 11:
DATAFLEX® size
110/20000
RADEX®-N size
156
Mounting dimensions
Dimension E
27
Dimension DH
325
Dimension L
327
Illustration 27: Assembly of coupling
4.7
Advice for assembly of the DATAFLEX® torque measuring shaft
• Fixing the housing
!
!
The housing must be protected from rotation. For that purpose there is a thread size M5
at the bottom side. Make absolutely sure to avoid rigid fixing of the housing!
Opening the housing is not required and may cause damage to the measuring shaft.
• Level of protection
All DATAFLEX® measuring shafts type 110 correspond to protection class IP51 according to DIN EN 60529.
• Maintenance
The DATAFLEX® measuring shaft is maintenance-free. Lubrication or cleaning is not necessary.
• Calibration
The transducer is calibrated when supplied. We recommend an annual inspection of the calibration.
Please observe protection
note ISO 16016.
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DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
4
Assembly
4.8
Technical description
KTR-N
Sheet:
Edition:
49018 EN
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3
1. General description
The measuring shafts type DATAFLEX® 110 are provided with wire strain gauges (DMS) the signals of which
are transmitted contactlessly.
In addition, a two-channel shaft encoder provides two speed signals shifted by 90 degrees. Each signal has a
resolution of 720 periods per revolution. The measuring shaft is connected to the connection housing DF2 via
the connection cable which is available as an accessory.

The measuring shaft should not be switched on before all connections have been properly
connected. After initial switch-on the measuring shaft needs about 5 minutes until the
warm-up period is finished and the measurement device has its standard accuracy.
2. Connection housing DF2
The connection housing DF2 has 12 screw terminals to connect power supply, display equipment and
switches.
The torque signal is displayed as proportional direct voltage from -10 … 10 V.
For the speed display two square wave signals, one scalable voltage signal and one direction signal are
available (for pin configuration see table 12).
The button T1 serves for programming and can be bridged externally against GND via the terminal 12 (T1).
Table 12: Pin assignment of the connection housing DF2
No. Description
10
11
24V
GND
4
5
6
M-U
GND
M-I
7
N1
8
GND
9
N2
1
R/L
2
3
GND
N-U
12
T1
13
14
15
16
17
L1, L2
T1, T2
TP
-
Function
Properties
Input of operating voltage
Supply voltage +
24 V DC ± 4 V / 100 mA
Supply voltage Torque output
Voltage output +
-10 V ... 10 V (RA = 1 k)
Ground of torque output
Without function
Speed output pulse signal
Pulsed output
HTL (24V, 720 pulses/rev.)
speed track 1
TTL (5V, 720 pulses/rev.)
Ground of pulsed output
Pulsed output
HTL (24V, 720 pulses/rev.)
speed track 2
TTL (5V, 720 pulses/rev.)
Speed output DC-voltage
HTL (24V, clockwise = 0)
Direction signal speed
TTL (5V, clockwise = 0)
Ground for DC speed output
Speed of direct voltage output
0 V ... 10 V (scalable)
Other connections / operating devices
External push button connection
Push button T1
T1
Signal LEDs
Sensor T1, T2
Sensor for programming
Switch low pass
On/off switch low-pass
Connection of measuring shaft
Connection cable
Switch for speed scaling
see table 16
Illustration 28:
Connection housing DF2
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Torque Measuring Shaft
Operating/Assembly instructions
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Assembly
4.8
Technical description
KTR-N
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Edition:
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3. Description of connections
a) Supply voltage 24V (No. 10 and 11)
The supply voltage is 24V ± 4V direct current voltage (DC). The current consumption is 100 mA at the
maximum.
b) Torque signal M-U (No. 4 and 5)
The output voltage is proportional to the torque with an output of values between -10V and 10V.
Table 13 shows the relation between torque and output voltage.
Table 13: Assignment of
torque - output values
DATAFLEX®
size
110/10000
110/20000
Measuring
range 1
ΔM / ΔU
1000 Nm / V
2000 Nm / V
Measuring
range 2
ΔM / ΔU
200 Nm / V
400 Nm / V
Illustration 29: Assignment of
torque - output values
Measuring range 1 (measuring range 2)
c) Filter voltage output (No. 15)
The torque signal may be filtered by activating a low-pass filter so that high-frequency shares of the signal are
suppressed.
Table 14: Low pass switch (No. 15)
Switch position TP
Left
Low pass on
Right
Low pass off
The limit frequency of the filter can be changed by varying
the DIP switches (see illustration 30) inside the connection
housing:
Illustration 30: Position of DIP switch
Table 15: Adjustment of the requested filter frequency
Limit frequency [Hz]
2000
1000
100
10
1
Switch 1
OFF
ON
OFF
OFF
OFF
Switch 2
OFF
OFF
ON
OFF
OFF
Switch 3
OFF
OFF
OFF
ON
OFF
Switch 4
OFF
OFF
OFF
OFF
ON
A filter frequency of 1000 Hz is preset.
Please observe protection
note ISO 16016.
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DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
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Assembly
4.8
Technical description
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Sheet:
Edition:
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d) Speed signals N1, N2, N-U, R/L (No. 1, 3, 7, 9)
The connection housing DF2 has 4 connections
for speed output:
-
Two square-wave signals shifted by 90
degrees (N1, N2)
A scalable voltage output (N-U) with direction
signal (R/L)
Illustration 31
Outputs N1 and N2
Each of the speed outputs N1 and N2 provide a square-wave signal with a resolution of 2x 720 periods per
revolution (see illustration 32).
Illustration 32
The speed is calculated as follows:
N [rpm] = f [Hz] / 7.5
The speed channel signals N1 and N2 have a phase shift of 90 degrees to each other. Depending on the
rotational direction one of the two signals leads 90° in phase (see illustration 33).
Clockwise
Illustration 33
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DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
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Assembly
4.8
Technical description
KTR-N
Sheet:
Edition:
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Output circuit (connection N1 and N2)
The speed outputs N1 and N2 have short-circuit proof
push-pull outputs providing a square-wave voltage with
an amplitude of 24V and a maximum switching current of
30 mA. The output terminals must not be charged with an
external voltage (see illustration 34).
The output voltage of speed lines and torsional direction
line can be varied by modifying the jumper position in the
connection housing to 5V level (see illustration 35).
Illustration 34: Output circuit of speed outputs
Illustration 35: Modification of voltage level for the speed signal/direction signal
Please observe protection
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DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
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Assembly
4.8
Technical description
KTR-N
Sheet:
Edition:
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Outputs N-U and R/L
The KTR connection housing DF2 has an integrated f/U
converter which converts the square wave signals of the
encoder into a linear DC voltage output (terminal N-U)
and generates an additional signal for the rotational
direction (terminal R/L).
On the bottom side of the connection housing DF2 there
is a sixfold multiple switch allowing to adapt the scaling
of the speed signal to the type of measuring shaft and
the speed range (see illustration 28 and 35).
Illustration 36: Switch positions
Scaling of the speed direct voltage output
Table 16: Switch position S1-S4 and the corresponding scale of the speed output N-U
Max. speed
10
20
40
60
80
100
200
400
600
800
1000
2000
4000
6000
8000
10000
Scaling
1 rpm / V
2 rpm / V
4 rpm / V
6 rpm / V
8 rpm / V
10 rpm / V
20 rpm / V
40 rpm / V
60 rpm / V
80 rpm / V
100 rpm / V
200 rpm / V
400 rpm / V
600 rpm / V
800 rpm / V
1000 rpm / V
S1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
S2
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
S3
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
S4
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
Illustration 37
Table 17: Selection of DATAFLEX® series
DATAFLEX® type
DATAFLEX® 22, 42, 85, 140
DATAFLEX® 16
DATAFLEX® 32, 42 (red), 110
DATAFLEX® 70
S5
0
1
0
1
S6
0
1
1
0
Table 18: Direction signal
Output voltage R/L
0
24V
*
Torsional direction
Clockwise
Counterclockwise
The signal of the speed direction output R/L
shows the rotational direction (see table 18).
Switching between 5V and 24V possible (see illustration 35 Modification of voltage level for the speed
signal/direction signal)
Please observe protection
note ISO 16016.
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DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
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Assembly
4.8
Technical description
KTR-N
Sheet:
Edition:
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e) Control buttons and LEDs (No. 12 to 14 and illustration 38)
The connection housing DF2 has two LEDs and two push buttons for visual inspection allowing to change
settings.
5
Special functions
The following settings can be made by means of sensors:
1) Self-test
2) Measuring range switchover
3) Automatic zero adjustment
4) Manual zero adjustment
For safety reasons the settings „1) self-test“ and „2) measuring range switchover“ can only be made up to 15
seconds after powering up. „3) Automatic zero adjustment“ and „4) manual zero adjustment“ can only be made
from 15 seconds after powering up.
The termination of the 15 seconds period is signalized by short blinking of the LEDs on the connection housing.
Illustration 38
5.1
Sensor test
The torque sensor can be inspected for operativeness if the sensor T2 is pressed for 2 seconds during the first
15 seconds after powering up the measuring shaft. If the sensor is fine, the output voltage increases to approx. 4
volts for the period of 2 seconds. The output voltage increases to approx -10 volts for 2 seconds in the measuring
range 2.

• The sensor test can only be performed during the first 15 seconds after powering up.
Illustration 39: Sensor test
Please observe protection
note ISO 16016.
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DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
5
Special functions
5.2
Measuring range switchover
KTR-N
Sheet:
Edition:
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The measuring range can be switched over within the first 15 seconds after powering up the supply voltage. For
that purpose press the button T1 on the connection housing DF2 during 2 seconds. The selected measuring
range is displayed by green LEDs on DF2.
Green LED off
= measuring range 1 (e. g. 10000 Nm)
Green LED permanently on = measuring range 2 (e. g. 2000 Nm)
The selected measuring range remains set after powering on again.
5.3
Automatic zero adjustment (see illustration 31)
If the „push button“ T1 is activated for a period of 2 seconds, the output of the torque signal is automatically set to
0 Volt. The adjusting is effected irrespective of the amount of the actual torque.
The termination of the adjustment is confirmed by fast blinking of the LED L1. The new zero point has been saved
and the device is in the measuring mode again.

• The automatic zero adjustment can only be performed if the measuring shaft is switched
on for more than 15 seconds.
• If necessary, the automatic zero adjustment can be performed by an external control, too.
If the potential of the terminal clamp T1 is connected with GND for 2 seconds, an
automatic zero adjustment is performed.
Illustration 40: Automatic zero adjustment
5.4
Manual zero adjustment
The zero point of the torque output can be adjusted manually. For this purpose both push buttons T1 and T2 are
activated simultaneously for 2 seconds. The LED L1 is blinking four times.
Pressing the push button T1 increases the voltage, pressing the push button T2 reduces the voltage. The
modifications are accelerated if the corresponding push button is pressed permanently. Each amendment is
confirmed by short blinking of the LED L2.
Having performed the adjusting the new values are stored lastingly by pressing both push buttons again for
2 seconds. The LED L1 is illuminated once and signalizes the return to the measuring mode.
The manual zero adjustment can be set separately for the two measuring ranges. The zero point of the range that
is currently activated is generally adjusted.
Please observe protection
note ISO 16016.
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2022-08-25 Pz
Replacing:
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DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
5
Special functions
5.4
Manual zero adjustment

KTR-N
Sheet:
Edition:
49018 EN
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3
• The manual zero adjustment can only be performed if the measuring shaft is switched on
for more than 15 seconds and the signal has levelled off.
Illustration 41: Manual zero adjustment
6
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.
7
Maintenance and service
DATAFLEX® is a low-maintenance torque measuring shaft. We recommend to perform a visual inspection on the
torque measuring shaft at least once a year. Pay special attention to the condition, alignment and screw
connection of the torque measuring shaft and the condition of the laminae sets of the RADEX ®-N coupling.
!

Having started up the torque measuring shaft the tightening torques of the screws have to
be inspected during the usual inspection intervals.
Consider our operating/assembly instructions KTR-N 47110 additionally when using the
RADEX®-N coupling.
Please observe protection
note ISO 16016.
Drawn:
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DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
8
KTR-N
Sheet:
Edition:
49018 EN
26 of 28
3
Services, customer service addresses
If requested, we are pleased to perform the calibration of your torque measuring shaft and other services.
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.
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DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
9
Declarations of conformity
9.1
EU Declaration of conformity
KTR-N
Sheet:
Edition:
49018 EN
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3
EU Declaration of conformity
The manufacturer - KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine - states that the
DATAFLEX® torque measuring shaft
described in the present operating/assembly instructions is in accordance with the following directive:
2014/30/EU
Directive of the European Parliament and European Council dated
February 26. 2014 for harmonizing the legal provisions of the
member states regarding electromagnetic compatibility
Standards applied:
EN IEC 61000-6-2:
EN 61000-4-2:
EN IEC 61000-4-3:
EN 61000-4-4:
EN 61000-4-6:
EN IEC 61000-6-4:
EN 55011:
Rheine,
Place
Immunity standard for industrial environments
Electrostatic discharge immunity test (ESD)
Radiated, radio-frequency, electromagnetic field immunity test
Electrical fast transient/burst immunity test
Immunity to conducted disturbances, induced by radio-frequency fields
Emission standard for industrial environments
Intensity of radio interference area (class B)
2022-08-25
Date
Please observe protection
note ISO 16016.
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Reinhard Wibbeling
Engineering/R&D
2022-08-25 Pz/Koe
2022-08-25 Pz
i. A.
Jürgen Kösters
Product Manager
Replacing:
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KTR-N dated 2022-02-23
DATAFLEX® 110/...
Torque Measuring Shaft
Operating/Assembly instructions
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Declarations of conformity
9.2
UK Declaration of conformity
KTR-N
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Edition:
49018 EN
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UK Declaration of conformity
The manufacturer - KTR Systems GmbH, Carl-Zeiss-Str. 25, D-48432 Rheine - states that the
DATAFLEX® torque measuring shaft
described in the present operating/assembly instructions is in accordance with the following directive:
SI 2016/1091
Electromagnetic Compatibility Regulations 2016
Standards applied:
EN IEC 61000-6-2:
EN 61000-4-2:
EN IEC 61000-4-3:
EN 61000-4-4:
EN 61000-4-6:
EN IEC 61000-6-4:
EN 55011:
Immunity standard for industrial environments
Electrostatic discharge immunity test (ESD)
Radiated, radio-frequency, electromagnetic field immunity test
Electrical fast transient/burst immunity test
Immunity to conducted disturbances, induced by radio-frequency fields
Emission standard for industrial environments
Intensity of radio interference area (class B)
Authorised representative:
KTR U.K. Ltd.
Robert House
Unit 7, Acorn Business Park
Woodseats Close
Sheffield
United Kingdom, S8 0TB
Year of UKCA marking: 2022
Rheine,
Place
2022-08-25
Date
Please observe protection
note ISO 16016.
Drawn:
Verified:
i. V.
Reinhard Wibbeling
Engineering/R&D
2022-08-25 Pz/Koe
2022-08-25 Pz
i. A.
Jürgen Kösters
Product Manager
Replacing:
Replaced by:
KTR-N dated 2022-02-23
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