POLY Operating-/Assembly Instructions KTR
Contents
1. e Put the assembled parts between the coupling flanges see picture 18 e Atfirst hand screw the parts e Tighten the screws with a suitable torque key to the III ZZ tightening torque Ta shown in table 6 N Se WV ZZZZZ ZZ A SEILER N gt gt e Please check the L or the E dimension see picture ee N 18 and table 5 Sl 4 ani nl L picture 18 coupling assembly CAUTION Having set the coupling into operation the tightening torque of the screws and wear of elastomer elements have to be inspected in usual maintenance intervals Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz fur KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN GmbH f A re Rheine Operating Assembly Instructions 4 Assembl 4 6 Hint Regarding the Finish Bore KTR supplies unbored or pilot bored coupling parts and spare parts on explicit customer s request These parts are additionally labelled with the symbol sheet 14 of 24 edition 9 CAUTION AN The orderer is responsible for all subsequently made machinings to unbored or pilot bored and to finish machined coupling parts and spare parts KTR does not assume any warranty claims resulting from insufficient refinish PRECAUTION Any mechanical rework to couplings that are used in hazardous areas require an explicit release by KTR The2. ZZZ E Lpxz pay axial displacements radial displacements angular displacements Lpekz perm Lpxz AKa mm AKw Emax a Emin mm picture 19 displacements Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz f r KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN GmbH f A Ere Rheine Operating Assembly Instructions 4 Assembl sheet 15 of 24 edition 9 lacements Alignment of the Couplin Continuation Example for the misalignment combinations given in picture 20 Example 1 AK 30 AK 70 ar displacemer ts Example 2 AK 60 AKy 40 angl radial displacements AK AK total AKr AKw lt 100 picture 20 combinations of displacement Table 10 displacement figures coupling size max axial displacement AK mm n up to max radial 750 1 min displacement AK mm or max angular n 1000 1 min we at n 1500 1 min total V n 3000 1 min coupling size max axial displacement AKa mm n up to max radial 750 1 min displacement AK mm or max angular n 1000 1 min iae AKu n 1500 1 min total V n 3000 1 min 4 8 Spares Inventory Customer Service Addresses A basic requirement to guarantee the operational readiness of the coupling is a stock of the most important spare pa
3. picture 7 POLY type PKD Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz fur KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN GmbH f A re Rheine Operating Assembly Instructions 4 Assembl 4 1 Components of Couplings Components of POLY type PKA designation material balancing condition EN GJL 250 S355 J2G3 balanced on request 1b spacer EN GJL 250 from length 100 mm on balanced see table 9 elastomer elements NBR buna N 90 ShA 1 driving flange EN GJL 250 generally balanced 2 2b 5 see table 9 cap screw DIN EN ISO 4762 steel sheet 10 of 24 edition 9 picture 8 POLY type PKA Table 9 quantity of elastomer elements and cap screws quantity of elements 8 10 10 12 12 16 element size 1 4 quantity au cap screws DIN EN ISO 4762 quantity of elements 16 element size 4 quantity of cap screws 2 8 DIN EN ISO 4762 1 for the complete coupling dimension elastomer elements see tables 7 and 8 2 each coupling flange Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz f r KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN GmbH f sheet 11 of 24 D 48407 Rheine Operating Assembly Instructions dition 9 4 Assembl 4 2 Assembly of the Coupling General ATTENTION ee We recomme
4. Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz fur KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN GmbH f 3 sheet 20 of 24 D 48407 Rheine Operating Assembly Instructions dition 9 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas During operation please pay attention to e strange running noises e occurring vibrations If the couplings are used in dust explosive areas and in mining the user must make sure that there is no accumulation of dust in a critical quantity between the cover and the coupling The coupling must no operate in an accumulation of dust For covers with unlocked openings on the upper side no light metals may be used if the couplings are used as appliances of appliance group II if possible from stainless steel If the couplings are used in mining appliance group M2 the cover must not be made from light metal In addition it must be resistant to higher mechanical loads than if it is used as appliance of appliance group Il The minimum distance of the protection device to the rotating parts must be at least 5 mm If the protection device is used as cover regular openings complying with the explosion protection demands can be made that must not exceed the following dimensions form of the openings straight or bended slot distance of the side limit inmm circular openings rectangular opening
5. C T6 30 C to 65 C 85 C Explanation The maximum surface temperatures result from each the maximum permissible ambient or operating temperature T plus the maximum temperature increase AT of 20 K which has to be taken into account 1 The ambient or operating temperature T is limited to 80 C due to the permissible permanent operating temperature of the elastomers used 2 The maximum surface temperature of 100 C applies for the use in locations which are potentially subject to dust explosion too 2 Mining Device class of category M2 coupling is not approved for device category M1 Permissible ambient temperature 30 C to 80 C Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz fur KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN bH A A ae Rheine Operating Assembly Instructions nl ee edition 9 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas 5 2 Control Intervals for Couplings in Hazardous Areas explosion group control intervals For couplings which are classified in category 3G or 3D the operating and assembly instructions that are usual for standard operation apply During the standard operation which has to be subject to the analysis of danger of ignition the couplings are free from any ignition source Merely the temperature increase produced by proper heating and depending on th
6. Tmax 84 max speed n rpm 5000 25 torque Ten 1600 Nm Triax 3200 max speed n rpm 2700 1 For peripheral speeds of more than v 30 m sec a dynamical balancing is necessary Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz fur KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN GmbH f 3 sheet 4 of 24 D 48407 Rheine Operating Assembly Instructions edition 9 1 Technical Data Component 1 3 2 Components 1 cam section to be preferably used drive sided 2D flange hub 3 z u 3D cam ring picture 2 POLY type PKD Table 3 dimensions type PKD finish bore dimensions mm POLY pilot dmax mm general thread for setscrews weight size bore component component D D D Fi M N Ta kg H D 1 12 D Lpko G t 60 70 80 90 100 ce Koei Keri Ke iK ny oo BBB BR BRP Mm 190 630 200 685 80 446 05 80 565 78 oO 1 bore H7 with keyway DIN 6885 sheet 1 JS9 and threads for setscrews on the keyway 2 weights apply for max bore diameters with feather key according to DIN 6885 sheet 1 Table 4 cap screws DIN EN ISO 4762 15 quantity for cap screws 6 DIN EN ISO 4762 screw size M8 screw length 30 tightening torque Ta Nm 25 1 quantity for the comp
7. gt KTR Kupplungstechnik POLY KTR N 49610 EN bH f A see Rheine Operating Assembly Instructions wa noe edition 9 POLY Torsionally flexible couplings types re gt a not failsafe I T PKZ PKD PKA N and their combinations Type PKZ according to Standard 94 9 EC ATEX 95 for finish bored pilot bored and unbored couplings Type PKD Type PKA Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz f r KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN KTR GmbH sheet 2 0f24 7 D 48407 Rheine Operating Assembly Instructions edition 9 The POLY is a torsionally elastic claw coupling It is able to compensate offset of shafts e g caused by manufacturing inaccuracies thermal expansion etc in case of low shaft distance dimension Table of Contents 1 Technical Data 2 Hints 2 1 Coupling Selection 2 2 General Hints 2 3 Safety and Advice Hints 2 4 General Hints to Danger 2 5 Proper Use 3 Storage 4 Assembly 4 1 Components of the Couplings 4 2 Assembly of the Coupling General 4 3 Assembly of the Type PKZ 4 4 Assembly of the Type PKD 4 5 Assembly of the Type PKA 4 6 Hint Regarding the Finish Bore 4 7 Displacements Alignment of the Couplings 4 8 Spares Inventory Customer Service Addresses 5 Enclosure A Hints and Instructions Regarding the Use in x Hazardous Areas 5 1 Use in Ex Hazardous Areas Accordi
8. the setscrews DIN EN ISO 4029 with cup point tightening torque see table 1 E picture 11 coupling assembly Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz f r KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN GmbH f sheet 12 of 24 A D 48407 Rheine Operating Assembly Instructions dition 9 4 Assembl 4 4 Assembly of the Type PKD e Plug flange hub and cam ring together see picture 12 e Hand screw the parts first of all KX N U WES ight ey picture 12 assembly of the flange hub with cam ring e Assemble the cam section and flange hub with cam ring to the shaft of the drive and driven side see picture 13 e Tighten the screws with a suitable torque key to the tightening torque T shown in table 4 e Insert the elastomer elements in the cam section or cam ring see picture 14 picture 14 assembly of the elastomer elements e Move the power packs in axial direction until the z dimension E is achieved see picture 15 e f the power packs are already firmly assembled axial movement of the hubs on the shafts allows for H adjusting the dimension E see picture 15 pP PA bf MNG e Fasten the hubs by tightening the setscrews FAR E A aT DIN EN ISO 4029 with c
9. 6 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN bH A A ae Rheine Operating Assembly Instructions a en edition 9 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas 5 3 Approximate Values of Wear The reaching of the exchange values depends on the operating conditions and the existing operating parameters If the torsional backlash is gt ASmax in mm the elastomer elements must be exchanged Friction of 20 of the original thickness of the elastomer elements exchange necessary hardness CAUTION In order to ensure a long lifetime of the coupling and to avoid dangers regarding the use in hazardous areas the shaft ends must be accurately aligned Please absolutely observe the displacement figures indicated see table 10 If the figures are exceeded the coupling is damaged CAUTION AN When changing the elastomer elements please do only use elements with the same Shore t new state m lt X wear and tear approximate value circumferential backlash L Se IN picture 22 checking of the limit of wear picture 23 wear of elastomer elements Table 11 limits of wear design with low backlash enlarged elastomer elements thickness of friction torsional thickness of friction torsional elastomer backlash elastomer backlash elements t mm Xmax mm ASmax mm ele
10. arking x Il 2G c IIC T4 T5 T6 30 C lt T lt 80 60 45 C remains valid II2DcT 110 C I M2 c 30 C lt T lt 80 C The labelling with Explosion Group IIC includes the Explosion Groups IIA and IIB If the coupling part is labelled with in addition to KTR supplied it unbored or pilot bored CAUTION Any mechanical rework to couplings that are used in hazardous areas require an explicit release by KTR The orderer must send a drawing to KTR acc to which the manufacture must be made KTR checks this drawing and returns it to the orderer with approval Before putting the coupling into operation check the tightness of the setscrews in the cam section or pocket section the alignment and the distance dimension E and correct if necessary and also check all screw connections regarding the stipulated tightening torques dependent on the type of coupling If used in hazardous areas the grub screws to fix the hub as well as all screw connections must be additionally secured against self loosening e g glue with Loctite medium strength Last but not least the coupling protection against unintended contact must be fixed The cover must be electrically conductive and be included in the equipotential bonding Bellhousings magnesium part below 7 5 made from aluminium and damping rings NBR can be used as connecting element between pump and electro motor The cover may only be taken off after having stopped the unit
11. at can generate heat sparks and static charging e g combinations with brake drums brake disks overload systems like torque limiters impellers etc are not allowed for the use in hazardous areas A separate checking must be made Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz fur KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN GmbH i 3 sheet 7 of 24 D 48407 Rheine Operating Assembly Instructions edition 9 2 1 Coupling Selection CAUTION AN For a continuous and troublefree operation of the coupling it must be designed according to the selection instructions according to DIN 740 part 2 for the particular application see POLY catalogue If the operating conditions performance speed changes at engine and machine change the coupling selection must be checked again Please make sure that the technical data regarding torque only refers to the elastomer elements The transmissible torque of the shaft hub connection must be checked by the orderer and he is responsible for the same For drives with endangered torsional vibration drives with periodical load on torsional vibration it is necessary to make a torsional vibration calculation to ensure a perfect selection Typical drives with endangered torsional vibration are e g drives with diesel engines piston pumps piston compressors etc On request KTR makes the coupling selection and the t
12. coupling parts and exchange damaged coupling parts 4 checking of wear see under point Control 1 put the unit out of operation 2 disassemble the coupling and remove rests of the elastomer elements danger of ignition due 3 check coupling parts and exchange to hot surfaces damaged coupling parts 4 insert elastomer elements assemble coupling parts 5 check alignment correct if necessary Een danger of ignition due misalignment to sparking change of the running noises and or occurring vibrations wear of elastomer elements low no torque transmission because the cams of coupling slip Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz fur KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN bH A A ae Rheine Operating Assembly Instructions nl N edition 9 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas 5 7 Breakdowns Causes and Elimination danger hints for elimination hazardous areas breakdowns causes 1 put the unit out of operation 2 check alignment of coupling 3 tighten the screws to secure the hubs running noises danger of ignition due and secure against self loosening axial securement of and or occurring hubs to sparking 4 check coupling parts and exchange vibrations damaged coupling parts 5 checking of wear see under point Control 1 put the unit out of operation 2 disass
13. e coupling have to be performed taking into account safety first e Please make sure to disengage the power pack before you perform your work e Protect the power pack against unintentional engagement e g by providing hints at the place of engagement or removing the fuse for current supply e Do not touch the operation area of the coupling as long as it is in operation e Please protect the coupling against unintentional touch Please provide for the necessary protection devices and caps 2 5 Proper Use You may only assemble operate and maintain the coupling if you e have carefully read through the mounting instructions and understood them e had technical training e are authorized to do so by your company The coupling may only be used in accordance with the technical data see table 1 to 8 in chapter 1 Unauthorized modifications on the coupling design are not admissible We do not take any warranty for resulting damages To further develop the product we reserve the right for technical modifications The POLY described in here corresponds to the technical status at the time of printing of these mounting instructions The coupling hubs are supplied in preserved condition and can be stored at a dry and roofed place for 6 9 months The features of the elastomer elements remain unchanged for up to 5 years in case of favourable stock conditions CAUTION The storage rooms may not include any ozone generating devices like e g
14. e coupling type has to be considered for POLY AT 20K The torsional backlash of the coupling see chapter 5 3 according to Guideline 94 9 EC ATEX 95 must only be controlled if a friction of the elastomer elements part 2 and consequently a machine down time of the drive leads to explosion hazard A preventive checking of torsional backlash is recommended A checking of the circumferential backlash and a visual check of the elastomer elements must be effected after 3 000 operating hours for the first time after 6 months at the latest Except for centered stiff connecting flanges e g bellhousings If you note an unconsiderable or no wear at the elastomer elements after this first inspection the further inspections can be effected in case of the same operating parameters respectively after 6 000 operating hours or after 18 months at the latest If you note a considerable wear during the first inspection so that a change of the elastomer elements would be recommended please find out the cause according to the table Breakdowns as far as possible The maintenance intervals must be adjusted according to the changed operating parameters The torsional backlash of the coupling see chapter 5 3 according to Guideline 94 9 EC ATEX 95 must only be controlled if a friction of the elastomer elements part 2 and consequently a machine down time of the drive leads to explosion hazard A preventive checking of torsional backlash is recom
15. emble the coupling and remove rests of the elastomer elements danger of ignition due 3 check coupling parts and exchange to hot surfaces damaged coupling parts 4 insert elastomer elements assemble slip coupling parts 5 find out the reason of overload operating parameters do not correspond to the performance of the coupling 3 cams of coupling 4 1 2 change of the loose screws for break of the eleastomer elements due to high shock energy overload cams of coupling 1 put the unit out of operation 2 check the operating parameters and danger of ignition due select a larger coupling consider to hot surfaces installation space assemble new coupling size check alignment shearing of elastomer elements slip put the unit out of operation disassemble the coupling and remove mistake in service rests of the elastomer elements of the unit danger of ignition due 3 check coupling parts and exchange cams of coupling to hot surfaces damaged coupling parts slip 4 insert elastomer elements assemble coupling parts 5 instruct and train the service staff 1 put the unit out of operation 2 eliminate the reason for the misalignment e g loose foundation bolts break of the engine fixing heat expansion of unit components change misalignment of the assembly dimension E of the coupling 3 check coupling parts and exchange damaged coupling parts 4 checking of wear see under point Control premature
16. et 1 JS9 and threads for setscrews on the keyway 2 weights apply for max bore diameters with feather key according to DIN 6885 sheet 1 Table 6 cap screws DIN EN ISO 4762 quantity for cap screws DIN EN ISO 4762 screw size screw length tightening torque Ta Nm 1 each coupling flange Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz f r KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN GmbH f sheet 6 of 24 7 D 48407 Rheine Operating Assembly Instructions edition 9 1 Technical Data h En Re picture 4 POLY elastomer elements NBR buna N 90 ShA picture 5 POLY elastomer elements NBR buna N 90 ShA with excessive height Table 7 dimensions of elastomer elements see picture 4 ui 2 ID 14 15 17 quantity of elements element size dimensions mm quantity of elements element size dimensions mm 1 quantity for the complete coupling Table 8 dimensions of elastomer elements with excessive height see picture 5 sen 020 14 15 17 20 10 12 12 12 quantity of elements element size b by t t h 1 quantity for the complete coupling dimensions mm POLY couplings with attached parts th
17. fluorescent light sources mercury vapour lamps or electrical high voltage appliances Humid storage rooms are not suitable Please make sure that there is no condensation The best relative air humidity is under 65 Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz fur KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN GmbH f sheet 9 of 24 7 D 48407 Rheine Operating Assembly Instructions edition 9 4 Assembl Basically the coupling is supplied in individual parts Before assembly the coupling has to be controlled for completeness 4 1 Components of Couplings Components of POLY type PKZ quantity designation material balancing condition 1 1 cam section EN GJL 250 acc to customers request 2 see table 9 elastomer elements NBR buna N 90 ShA 2Z 1 pocket section EN GJL 250 acc to customers request 4 2 setscrew DIN EN ISO 4029 picture 6 POLY type PKZ Components of POLY type PKD quantity designation material balancing condition cam section EN GJL 250 acc to customers request see aE 9 elastomer elements NBR buna N 90 ShA EN GJL 250 2D flange hub EN GJS 400 15 acc to customers request 3D 1 cam ring EN GJL 250 acc to customers request 4 2 setscrew DIN EN ISO 4029 steel 5 5 seetable 9 cap screw DIN EN ISO 4762 steel 1 Component 2D 3D and 5 is balanced in assembled condition
18. ignition due to hot surfaces danger of ignition due to hot surfaces danger of ignition due to sparking 1 put the unit out of operation 2 disassemble the coupling and remove rests of the elastomer elements 3 check coupling parts and exchange damaged coupling parts 4 insert elastomer elements assemble coupling parts 5 check alignment correct if necessary 6 check and regulate ambient contact temperature 1 put the unit out of operation 2 disassemble the coupling and remove rests of the elastomer elements 3 check coupling parts and exchange damaged coupling parts 4 insert elastomer elements assemble coupling parts check alignment correct if necessary find out the reason for the vibrations put the unit out of operation change complete coupling check alignment finding out the reason repairing the damage If you operate with a worn elastomer elements see item 5 2 and the subsequent contact of metal parts a due operation meeting the explosion protection requirements and acc to Standard 94 9 EC KTR does not assume any liabilities or guarantees regarding the use of spare parts and accessories which are not provided by KTR and for the damages resulting herefrom Gezeichnet 11 03 10 Pz Bru Ersatz f r KTR N vom 25 04 07 16 03 10 Pz Ersetzt durch Schutzvermerk ISO 16016 beachten Gepr ft N KTR Kupplungstechnik POLY KTR N 49610 EN GmbH f A ar Rheine Operating Assembly Instruction
19. lete coupling Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz fur KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN GmbH f sheet 5 of 24 7 D 48407 Rheine Operating Assembly Instructions edition 9 1 Technical Data Components la 23 ka L PKA ar Components I 1a 2a coupling flange 1b spacer 2b driving flange u 2 efile il gt _ LER ac Component 1a with 1b to be preferably used i drive sided I YS EF RER yy YW lt A U LLLLZ 2 EZ t AG N i mat E A L Ma B nal L eurer picture 3 POLY type PKA finish bore dimensions mm dmax mm general thread for setscrews weight component Ta kg 1a 2a Ma t Nm 3 04 gt N ez 4 66 oO gt N 5 88 9 49 10 15 10 86 11 46 12 16 13 01 14 77 15 63 16 50 18 01 18 79 19 60 20 41 21 83 24 63 25 91 28 15 30 96 32 18 34 79 37 79 39 94 54 73 56 50 59 60 75 22 77 84 82 41 1 bore H7 with keyway DIN 6885 she
20. mended A checking of the circumferential backlash and a visual check of the elastomer elements must be effected after 2 000 operating hours for the first time after 3 months at the latest Except for centered stiff connecting flanges e g bellhousings If you note an unconsiderable or no wear at the elastomer elements after this first inspection the further inspections can be effected in case of the same operating parameters respectively after 4 000 operating hours or after 12 months at the latest If you note a considerable wear during the first inspection so that a change of the elastomer elements would be recommended please find out the cause according to the table Breakdowns as far as possible The maintenance intervals must be adjusted according to the changed operating II 2GD c IIB T4 T5 T6 II 2GD c IIC T4 T5 T6 parameters a a g g Checking of torsional backlash i ES Here the backlash between coupling cams N ie U and the elastomer elements must be checked by reverse backlash The friction wear may be 20 of the original thickness of the elastomer element before exchanging the elastomer l l c elements After having reached the limit of Z wear ASmax the elastomer elements must L i be exchanged immediately irrespective of N Z the inspection intervals picture 21 POLY type PKZ Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz f r KTR N vom 25 04 07 ISO 1601
21. ments t mm Xmax mm ASmax mm standard design Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz fur KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN GmbH f 3 sheet 19 of 24 D 48407 Rheine Operating Assembly Instructions dition 9 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas 5 4 Permissible Coupling Materials in the Hazardous Area In the Explosion Groups IIA IIB and IIC the following materials may be combined EN GJL 250 GG 25 EN GJS 400 15 GGG 40 steel stainless steel Semifinished products from aluminium with a magnesium part of up to 7 5 and a yield point of Rpo 2 2 250 N mm are permitted for the use in hazardous areas Aluminium diecast is generally excluded for hazardous areas 5 5 Ex Marking of Coupling for the Hazardous Area Couplings for the use in hazardous areas are marked on at least one component short or completely and on the remaining components at the outside diameter of the hub or on the front side with an label for the respectively permitted conditions of use The elastomer elements are excluded Complete labelling Il 2G c IIC T6 bzw T5 30 C lt Ta lt 65 C bzw 80 C Il 2D c T 100 C 30 C lt T lt 80 C I M2 c 30 C lt T lt 80 C Short labelling x IL 2GD clIC TX IM2cX The former m
22. nd to check bores shaft keyway and feather key for dimensional accuracy before assembly Heating the hubs or coupling flanges slightly approx 80 C allows for an easier installation onto the shaft PRECAUTION Please pay attention to the danger of ignition in hazardous areas DANGER Touching the heated hubs causes burns We would recommend to wear safety gloves CAUTION During the assembly please make sure that the E or L dimension see table 1 3 and 5 is observed so that the parts do not conact each other during the operation Disregarding this hint may cause damage on the coupling 4 3 Assembly of the Type PKZ e Assemble the cam and the pocket section onto the shaft of the drive and the driven side see picture 9 e Insert the elastomer elements into the cam and the pocket section see picture 10 fs e Only valid for the cam section size 8 to 12 Fasten the cam section by tightening the setscrews DIN EN ISO 4029 with cup point tightening torque see table 1 j 7 aKa LZ picture 10 assembly of the elastomer elements e Move the power packs in axial direction until the dimension E is achieved see picture 11 e If the power packs are already firmly assembled axial movement of the cam or the pocket section on ee Pe the shafts allows for adjusting the dimension E see en picture 11 i m e Fasten the cam or the pocket section by tightening
23. ng to the Regulations 5 2 Control Intervals for Couplings in Ex Hazardous Areas 5 3 Approximate Values of Wear 5 4 Permissible Coupling Materials in the Ex Hazardous Area 5 5 Marking of Coupling for the Hazardous Area 5 6 Starting 5 7 Breakdowns Causes and Elimination 5 8 EC Certificate of Conformity according to the EC Standards 94 9 EC dated 23 March 1994 Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz f r KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN GmbH f sheet 3 of 24 7 D 48407 Rheine Operating Assembly Instructions edition 9 1 Technical Data Components 22 L p K A Components 1 cam section 27 pocket section to be preferably used es i drive sided G u a picture 1 POLY type PKZ Table 1 dimensions type PKZ finish bore dimensions mm dmax mm general component component l l2 E 3 3 4 4 4 4 4 4 4 4 5 5 5 1 bore H7 with keyway DIN 6885 sheet 1 JS9 and threads for setscrews on the keyway 2 weights apply for max bore diameters with feather key according to DIN 6885 sheet 1 Table 2 torques and speeds POLY size 8 torque Ten 42 Nm
24. orderer must send a drawing to KTR acc to which the manufacture must be made KTR checks this drawing and returns it to the orderer with approval 4 7 Displacements Alignment of the Couplings The POLY compensates for displacements produced by the shafts to be combined as shown in table 10 Excessive misalignment may be caused by inaccurate alignment production tolerances thermal expansion shaft deflection twisting of machine frames etc hazardous areas the shaft ends must be accurately aligned Please absolutely observe the displacement figures indicated see table 10 If the figures are exceeded the coupling is damaged The exacter the alignment of the coupling the higher is its lifetime In case of a use in hazardous areas for the explosion group IIC marking II 2GD c IIC T X only the half displacement figures see table 10 are permissible CAUTION In order to ensure a long lifetime of the coupling and to avoid dangers regarding the use in Please note e The displacement values mentioned in table 10 are maximum values which may not occur at the same time If the radial and the angular displacement occur at the same time the sum of the displacements may not exceed AK or AKw e Please check with a dial gauge ruler or feeler whether the permissible displacement figures of table 10 can be observed i
25. orsional vibration calculation 2 2 General Hints Please read through these mounting instructions carefully before you set the coupling into operation Please pay special attention to the safety instructions The POLY coupling is suitable and approved for the use in hazardous areas When using the coupling in hazardous areas please observe the special hints and instructions regarding safety in enclosure A The mounting instructions are part of your product Please keep them carefully and close to the coupling The copyright for these mounting instructions remains with KTR Kupplungstechnik GmbH 2 3 Safety and Advice Hints DANGER Danger of injury to persons AN CAUTION Damages on the machine possible Ee ATTENTION Pointing to important items x PRECAUTION Hints concerning explosion protection Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz fur KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik GmbH KTR N 49610 EN sheet 8 of 24 edition 9 POLY ET D 48407 Rheine Operating Assembly Instructions 2 4 General Hints of Danger DANGER With assembly operation and maintenance of the coupling it has to be made sure that the entire drive train is protected against unintentional engagement You can be seriously hurt by rotating parts Please make absolutely sure to read through and observe the following safety instructions e All operations on and with th
26. rs When searching for the error the adjacent components must be generally included Due to incorrect use the coupling can become a source of ignition EC Standard 94 9 EC requires a special care from the manufacturer and the user General errors incorrect use e Important data for the coupling selection was not forwarded e The calculation of the shaft nub connection was not considered e Coupling parts with damage occurred during transport are assembled e Ifthe heated hubs are assembled the permissible temperature is exceeded e The fits of the parts to be assembled are not coordinated with each other e Tightening torques are below exceeded e Components are exchanged by mistake put together incorrectly e A wrong or no elastomer elements is inserted into the coupling e No original KTR parts purchased parts are used e Old elastomer elements already worn out elastomer elements or superposed elastomer elements are used e The coupling used the coupling protection used is not suitable for the operation in hazardous areas and does not correspond to EC Standard 94 9 EC respectively e Maintenance intervals are not observed danger hints for elimination hazardous areas breakdowns causes 1 put the unit out of operation 2 eliminate the reason for the misalignment e g loose foundation bolts break of the engine fixing heat expansion of unit components change of the assembly dimension E of the coupling 3 check
27. rts on site Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage under www ktr com Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz f r KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN GmbH f 3 sheet 16 of 24 D 48407 Rheine Operating Assembly Instructions dition 9 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas Type PKZ cam section elastomer elements pocket section Type PKD flange hub cam ring elastomer elements pocket section Type PKA coupling flange driving flange elastomer elements spacer coupling flange POLY type PKA only with spacer made from EN GJL 250 or EN GJS 400 15 5 1 Use in Ex Hazardous Areas According to the Regulations Conditions of operation in Ex hazardous locations POLY couplings are suitable for the use according to EC standard 94 9 EC 1 Industry with the exception of mining device class II of category 2 and 3 coupling is not approved for device class 1 media class G gases fogs steams zone 1 and 2 coupling is not approved for zone 0 media class D dusts zone 21 and 22 coupling is not approved for zone 20 explosion class IIC explosion class IIA and IIB are included in IIC Temperature class ambient or operating temperature class max surface temperature temperature T T5 T4 T3 T2 T1 30 C to 80 C 100
28. s sheet 24 of 24 edition 9 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas 5 8 EC Certificate of Conformity EC Certificate of Conformity corresponding to EC Standard 94 9 EC dated 23 March 1994 and to the legal regulations The manufacturer KTR Kupplungstechnik GmbH D 48432 Rheine states that the POLY couplings described in these mounting instructions and explosion proof designed correspond to Article 1 3 b of Standard 94 9 EC and comply with the general Safety and Health Requirements according to enclosure Il of Standard 94 9 EC According to article 8 1 of Standard 94 9 EC the technical documentation is deposited with the IBExU Institut f r Sicherheitstechnik GmbH Fuchsm hlenweg 7 09599 Freiberg ie m W DEN dr Rheine 11 03 10 i V i V Date Reinhard Wibbeling Michael Br ning Leiter TECHNIK Product Manager Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz fur KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch
29. s diameter in mm side length in mm top surface of the covering prohibited side parts of the covering 8 CAUTION If you note any irregularities at the coupling during operation the drive unit must be turned off immediately The cause of the breakdown must be found out with the table Breakdowns and if possible be eliminated according to the proposals The possible breakdowns mentioned can be hints only To find out the cause all operating factors and machine components must be considered Coupling layer If coated priming painting etc couplings are used in hazardous areas the requirements to conductability and layer thickness must be considered In case of paintings up to 200 um no electrostatic load can be expected Multiple coatings that are thicker than 200 um are prohibited for explosion group IIC Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz fur KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN bH f A ae Rheine Operating Assembly Instructions nl a edition 9 5 Enclosure A Hints and Instructions Regarding the Use in Hazardous Areas 5 7 Breakdowns Causes and Elimination The below mentioned errors can lead to an incorrect use ofthe POLY coupling In addition to the stipulations in these operating and mounting instructions please make sure to avoid these errors The errors listed can only be clues to search for the erro
30. up point tightening torque eA SS see table 3 ARRAN E picture 15 coupling assembly CAUTION Having set the coupling into operation the tightening torque of the screws and wear of elastomer elements have to be inspected in usual maintenance intervals Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz f r KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik POLY KTR N 49610 EN GmbH f sheet 13 of 24 7 D 48407 Rheine Operating Assembly Instructions dition 9 4 Assembl 4 5 Assembly of the Type PKA e Assemble the coupling flanges onto the shaft of the z drive and the driven side see picture 16 i e The inner side of the coupling flanges must end flushly with the front sides of the shafts e Move the power packs in axial direction until the dimension L is achieved see table 5 l e Fasten the coupling flanges by tightening the setscrews DIN EN ISO 4029 with cup point da tightening torque see table 5 a7 drivin ide 0 pling flange picture 16 assembly of the coupling flanges e Please plug the driving flanges spacer and the elastomer elements together see picture 17 picture 17 assembly of the driving flange spacer and elastomer elements
31. wear of elastomer elements Schutzvermerk Gezeichnet 11 03 10 Pz Bru Ersatz f r KTR N vom 25 04 07 ISO 16016 beachten Gepr ft 16 03 10 Pz Ersetzt durch N KTR Kupplungstechnik GmbH gt 5 Enclosure A D 48407 Rheine POLY Operating Assembly Instructions KTR N 49610 EN sheet 23 of 24 edition 9 Hints and Instructions Regarding the Use in Hazardous Areas 5 7 Breakdowns Causes and Elimination breakdowns premature wear of elastomer elements premature wear of elastomer elements Hardening embrittlement of the elastomer elements fracture of cams or hubs respectively amp causes e g contact with aggressive liquids oils ozone influence too high low ambient temperatures etc effecting a physical change of the elastomer elements danger hints for hazardous areas elimination 1 put the unit out of operation 2 disassemble the coupling and remove rests of the elastomer elements 3 check coupling parts and exchange damaged coupling parts 4 insert elastomer elements assemble coupling parts 5 check alignment correct if necessary 6 make sure that further physical changes of the elastomer elements are excluded ambient contact temperatures which are too high for the elastomer elements max permissible e g T4 30 C 80 C drive vibrations locking by elastomer elements that have failed is not ensured ATTENTION danger of
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