KTR-Group ROTEX SP Non Sparkling Manual

ROTEX®SP "Non Sparking"
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
40228 EN
1 of 28
6
Please observe protection
note ISO 16016.
Drawn:
2019-10-10 Pz/Bru
Replacing:
KTR-N dated 2017-01-02
Verified:
2019-10-10 Pz
Replaced by:
ROTEX®SP "Non Sparking"
Single-cardanic
Torsionally flexible jaw couplings
type GN, GND, EN
and their combinations
according to directive 2014/34/EU
Type GN (No. 080)
Type GND (No. 082)
Type EN (No. 081)
Double-cardanic
Torsionally flexible jaw couplings
type E4-DKM, ZS-DKM-C
and their combinations
according to directive 2014/34/EU
Type E4-DKM (No. 086)
Type ZS-DKM-C (No. 085)

ROTEX®SP "Non Sparking"
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
40228 EN
2 of 28
6
Please observe protection
note ISO 16016.
Drawn:
2019-10-10 Pz/Bru
Replacing:
KTR-N dated 2017-01-02
Verified:
2019-10-10 Pz
Replaced by:
ROTEX®SP „Non Sparking“ is part of the product line of torsionally flexible jaw couplings. Subject to
its design it is furthermore a shear type system providing for emergency operating features. Moreover,
ROTEX®SP „Non Sparking“ is a non-sparking/electrically conductive coupling system.
Type ZS-DKM-C (No. 085) is characterized by its ability for radial disassembly.
1Technical data 3
2Advice 9
2.1 General advice 9
2.2 Safety and advice symbols 9
2.3 General hazard warnings 9
2.4 Intended use 10
2.5 Coupling selection 10
2.6 Reference to EC Machinery Directive 2006/42/EC 10
3Storage, transport and packaging 10
3.1 Storage 10
3.2 Transport and packaging 11
4Assembly 11
4.1 Components of the couplings 11
4.2 Advice for finish bore 13
4.3 Assembly of the coupling (general) 14
4.4 Assembly of types GN, GND and EN 15
4.5 Assembly of type E4-DKM 15
4.6 Assembly of type ZS-DKM-C 16
4.7 Displacements - alignment of the couplings 17
5Start-up 19
6Breakdowns, causes and elimination 20
7Disposal 21
8Maintenance and service 22
9Spares inventory, customer service addresses 22
10 Enclosure A
Advice and instructions regarding the use in potentially explosive atmospheres 22
10.1 Intended use in potentially explosive atmospheres 23
10.2 Inspection intervals for couplings in potentially explosive atmospheres 24
10.3 Standard values of wear 25
10.4 marking of coupling for potentially explosive atmospheres 26
10.5 EU Certificate of conformity 28
Table of contents

ROTEX®SP "Non Sparking"
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
40228 EN
3 of 28
6
Please observe protection
note ISO 16016.
Drawn:
2019-10-10 Pz/Bru
Replacing:
KTR-N dated 2017-01-02
Verified:
2019-10-10 Pz
Replaced by:
Illustration 1: Type GN (No. 080) - component 1, 1a, 1b: steel (St)
Illustration 2: Type GN (No. 080) - component 1, 1a, 1b: cast iron (GJL)
Table 1: Type GN (No. 080) - component 1, 1a, 1b: steel (St)
Size
Spider 1)
(component
2)
Rated torque
[Nm]
Com-
po-
nent
(St)
Dimensions [mm] 3)
Component 1, 1a, 1b steel (St)
Com-
po-
nent
Dimensions [mm] 3)
Component 1c
Max.
finish
bore d12)
L
l1
E
b
s
DH
dH
D, D1
N
Max.
finish
bore d22)
l2
DA
24
35
1a
35
78
30
18
14
2.0
55
27
55
-
1c
28
30
61
1b
98
50
28
95
1a
40
90
35
20
15
2.5
65
30
65
-
1c
32
35
72
1b
115
60
38
190
1
48
114
45
24
18
3.0
80
38
70
27
1c
42
45
87
1b
139
70
80
-
42
265
1
55
126
50
26
20
3.0
95
46
85
28
1c
48
50
103
1b
151
75
995
-
48
310
1
62
140
56
28
21
3.5
105
51
95
32
1c
55
56
114
1b
164
80
105
-
55
410
1
74
160
65
30
22
4.0
120
60
110
37
1c
65
65
130
1b
185
90
120
-
65
625
1
80
185
75
35
26
4.5
135
68
115
47
1c
75
75
146
1b
210
100
135
-
Table 2: Type GN (No. 080) - component 1, 1a, 1b: cast iron (GJL)
Size
Spider 1)
(component
2)
Rated torque
[Nm]
Com-
po-
nent
(GJL)
Dimensions [mm] 3)
Component 1, 1a, 1b: cast iron (GJL)
Com-
po-
nent
Dimensions [mm] 3)
Component 1c
Max.
finish
bore d12)
L
l1
E
b
s
DH
dH
D, D1
N
Max.
finish
bore d22)
l2
DA
38
190
1
40
114
45
24
18
3.0
80
38
66
37
1c
42
45
87
1a
48
78
1b
139
70
62
42
265
1
45
126
50
26
20
3.0
95
46
75
40
1c
48
50
103
1a
55
94
1b
151
75
65
48
310
1
52
140
56
28
21
3.5
105
51
85
45
1c
55
56
114
1a
62
104
1b
164
80
69
55
410
1
60
160
65
30
22
4.0
120
60
98
52
1c
65
65
130
1a
74
118
65
625
1
70
185
75
35
26
4.5
135
68
115
61
1c
75
75
146
1) Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2
2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew
3) Dimensions G and t see table 9.
1 Technical data

ROTEX®SP "Non Sparking"
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
40228 EN
4 of 28
6
Please observe protection
note ISO 16016.
Drawn:
2019-10-10 Pz/Bru
Replacing:
KTR-N dated 2017-01-02
Verified:
2019-10-10 Pz
Replaced by:
Illustration 3: Type GND (No. 082)
Table 3: Type GND (No. 082)
Size
Spider 1) (component 2)
Rated torque [Nm]
Dimensions [mm] 3)
Component 1c
Max. finish bore
d12)
L
l1, l2
E
b
s
DA
dH
a
24
35
28
78
30
18
14
2.0
61
27
4
28
95
32
90
35
20
15
2.5
72
30
38
190
42
114
45
24
18
3.0
87
38
42
265
48
126
50
26
20
3.0
103
46
48
310
55
140
56
28
21
3.5
114
51
55
410
65
160
65
30
22
4.0
130
60
65
625
75
185
75
35
26
4.5
146
68
1) Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2
2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew
3) Dimensions G and t see table 9.
1 Technical data

ROTEX®SP "Non Sparking"
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
40228 EN
5 of 28
6
Please observe protection
note ISO 16016.
Drawn:
2019-10-10 Pz/Bru
Replacing:
KTR-N dated 2017-01-02
Verified:
2019-10-10 Pz
Replaced by:
Illustration 4: Type EN (No. 081) - component 1, 1a, 1b: steel (St)
Illustration 5: Type EN (No. 081) - component 1, 1a, 1b: cast iron (GJL)
Table 4: Type EN (No. 081) - component 1, 1a, 1b: steel (St)
Size
Spider 1)
(component
2)
Rated torque
[Nm]
Com-
po-
nent
(St)
Dimensions [mm] 3)
Component 1, 1a, 1b steel (St)
Com-
po-
nent
Dimensions [mm] 3)
Component 5c
Max.
finish
bore d12)
L
l1
E
b
s
DH
dH
D, D1
N
Max.
finish
bore d22)
l2
l3
DA
24
35
1a
35
78
30
18
14
2.0
55
27
55
-
5c
19
36
22
61
1b
98
50
28
95
1a
40
90
35
20
15
2.5
65
30
65
-
5c
22
42
26
72
1b
115
60
38
190
1
48
114
45
24
18
3.0
80
38
70
27
5c
28
50
30
87
1b
139
70
80
-
42
265
1
55
126
50
26
20
3.0
95
46
85
28
5c
35
56
34
103
1b
151
75
995
-
48
310
1
62
140
56
28
21
3.5
105
51
95
32
5c
40
60
36
114
1b
164
80
105
-
55
410
1
74
160
65
30
22
4.0
120
60
110
37
5c
45
66
40
130
1b
185
90
120
-
65
625
1
80
185
75
35
26
4.5
135
68
115
47
5c
55
75
44
146
1b
210
100
135
-
Table 5: Type EN (No. 081) - component 1, 1a, 1b: cast iron (GJL)
Size
Spider 1)
(component
2)
Rated torque
[Nm]
Comp
onent
(GJL)
Dimensions [mm] 3)
Component 1, 1a, 1b: cast iron (GJL)
Com-
po-
nent
Dimensions [mm] 3)
Component 5c
Max.
finish
bore d12)
L
l1
E
b
s
DH
dH
D, D1
N
Max.
finish
bore d22)
l2
l3
DA
38
190
1
40
114
45
24
18
3.0
80
38
66
37
5c
28
45
30
87
1a
48
78
1b
139
70
62
42
265
1
45
126
50
26
20
3.0
95
46
75
40
5c
35
50
34
103
1a
55
94
1b
151
75
65
48
310
1
52
140
56
28
21
3.5
105
51
85
45
5c
40
56
36
114
1a
62
104
1b
164
80
69
55
410
1
60
160
65
30
22
4.0
120
60
98
52
5c
45
65
40
130
1a
74
118
65
625
1
70
185
75
35
26
4.5
135
68
115
61
5c
55
75
44
146
1) Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2
2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew
3) Dimensions G, t and t1see table 9.
1 Technical data

ROTEX®SP "Non Sparking"
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
40228 EN
6 of 28
6
Please observe protection
note ISO 16016.
Drawn:
2019-10-10 Pz/Bru
Replacing:
KTR-N dated 2017-01-02
Verified:
2019-10-10 Pz
Replaced by:
Illustration 6: Type E4-DKM (No. 086)
Table 6: Type E4-DKM (No. 086)
Size
Spider 1)
(component
2)
Rated torque
[Nm]
Dimensions [mm] 3)
Component 5bc
Dimensions [mm]
Component 6
Max. finish
bore d22)
l1, l2
l3, l4
DA
a
Ltotal
DH
dH
l11
E
b
s
24
35
20
22
46
61
4.0
96
55
27
16
18
14
2.0
28
95
22
26
53
72
4.0
110
65
30
18
20
15
2.5
38
190
28
30
62
87
4.0
128
80
38
20
24
18
3.0
42
265
38
34
69
103
4.0
142
95
46
22
26
20
3.0
48
310
42
36
74
114
4.0
152
105
51
24
28
21
3.5
55
410
45
40
82
130
4.0
168
120
60
28
30
22
4.0
65
625
55
44
93
146
4.0
190
135
68
32
35
26
4.5
1) Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2
2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew
3) Dimensions G and t1see table 9.
1 Technical data

ROTEX®SP "Non Sparking"
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
40228 EN
7 of 28
6
Please observe protection
note ISO 16016.
Drawn:
2019-10-10 Pz/Bru
Replacing:
KTR-N dated 2017-01-02
Verified:
2019-10-10 Pz
Replaced by:
Illustration 7: Type ZS-DKM-C (No. 085)
Table 7: Type ZS-DKM-C (No. 085)
Size
Drop-
out
center
length
L [mm]
Spider 1)
(component
2)
Rated torque
[Nm]
Dimensions [mm]
Component 7.5/7.6 steel (St)
Dimensions
[mm]
Component
6c Al-H 3)
Max.
finish
bore d 2)
Ltotal
l1,
l2
x1,
x2
E
b
s
DH
D
DA
dH
N
M
TA
[Nm]
dB
l11
24
100
35
28
145
30
22.5
18
14
2.0
55
-
61
27
-
M6
14
14
49
140
185
89
28
100
95
38
151
35
25.5
20
15
2.5
65
-
72
30
-
M8
35
16
41
140
191
81
38
100
190
45
171
45
35.5
24
18
3.0
80
-
87
38
-
M8
35
22
33
140
211
73
42
100
265
55
178
50
39
26
20
3.0
95
85
103
46
28
M10
69
30
26
140
218
66
48
140
310
60
230
56
45
28
21
3.5
105
95
114
51
32
M12
120
35
62
55
140
410
70
240
65
50
30
22
4.0
120
110
130
60
37
M12
120
40
50
180
280
90
200
300
110
65
140
625
80
260
75
60
35
26
4.5
135
115
146
68
47
M12
120
48
40
180
300
80
1) Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2; transmittable torque as per 92 ShA-GS
2) Bores H7 with keyway to DIN 6885 sheet 1 [JS9] and setscrew
3) Size 42 with drop-out center length L=100 mm made of steel
Illustration 8
Type 7.5 clamping hub type DH without feather keyway for
double-cardanic combination
Type 7.6 clamping hub type DH with feather keyway for
double-cardanic combination
Hubs, clamping hubs or similar types (type 7.5) without feather keyways may be used in
category 3 only and are marked with category 3 accordingly.
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.
1 Technical data

ROTEX®SP "Non Sparking"
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
40228 EN
8 of 28
6
Please observe protection
note ISO 16016.
Drawn:
2019-10-10 Pz/Bru
Replacing:
KTR-N dated 2017-01-02
Verified:
2019-10-10 Pz
Replaced by:
Table 8: Type ZS-DKM-C - Friction torques and surface pressure of DH clamping hubs type 7.5
Size
24
28
38
42
48
55
65
Clamping screw M11)
M6
M8
M8
M10
M12
M12
M12
Dimension t2
10.5
12
17
18
21
26
33
Dimension e1
20
25
30
34
38
44
50
Dimension ØDK1
57.5
72.6
83.2
96.7
108.4
121.8
132.4
Dimension e2
-
-
-
32
36
42.5
45
Dimension ØDK2
-
-
-
93.3
105.0
119.2
123.5
Tightening torque TA
[Nm]
14
35
35
69
120
120
120
Bore Ø
Transmittable friction torque of clamping hub [Nm]
Surface pressure [N/mm2]
Ø10
37.1
68.3
75.0
123.4
Ø11
40.8
75.2
68.2
112.2
Ø12
44.5
82.0
62.5
102.8
Ø14
52.0
95.7
95.7
152.2
53.6
88.1
61.8
90.3
Ø15
55.7
102.5
102.5
163.0
238.6
50.0
82.3
55.7
84.2
105.9
Ø16
59.4
109.3
109.3
173.9
254.5
46.9
77.1
54.1
79.0
99.3
Ø18
66.8
123.0
123.0
195.6
286.3
41.7
68.6
48.1
70.2
88.2
Ø19
70.5
129.8
129.8
206.5
302.2
39.5
64.9
45.6
66.5
83.6
Ø20
74.2
136.7
136.7
217.4
318.1
318.1
37.5
61.7
43.3
63.2
79.4
71.1
Ø22
81.6
150.3
150.3
239.1
349.9
349.9
34.1
56.1
39.3
57.4
72.2
64.6
Ø24
89.1
164.0
164.0
260.8
381.7
381.7
381.7
31.3
51.4
36.1
52.7
66.2
59.2
49.3
Ø25
92.8
170.8
170.8
271.7
397.6
397.6
397.6
30.0
49.4
34.6
50.5
63.5
56.8
47.4
Ø28
103.9
191.3
191.3
304.3
445.3
445.3
445.3
26.8
44.1
30.9
45.1
56.7
50.8
42.3
Ø30
205
205
326
477
477
477
41.1
28.9
42.1
52.9
47.4
39.5
Ø32
219
219
348
509
509
509
38.6
27.1
39.5
49.6
44.4
37.0
Ø35
239
239
380
557
557
557
35.3
24.7
36.1
45.4
40.6
33.8
Ø38
260
260
413
604
604
604
32.5
22.8
33.3
41.8
37.4
31.2
Ø40
273
435
636
636
636
21.6
31.6
39.7
35.5
29.6
Ø42
287
456
668
668
668
20.6
30.1
37.8
33.8
28.2
Ø45
307
489
716
716
716
19.2
28.1
35.3
31.6
26.3
Ø48
522
763
763
763
26.3
33.1
29.6
24.7
Ø50
543
795
795
795
25.3
31.8
28.4
23.7
Ø55
598
875
875
875
23.0
28.9
25.8
21.5
Ø60
954
954
954
26.5
23.7
19.7
Ø65
1034
1034
21.9
18.2
Ø70
1113
1113
20.3
16.9
Ø75
1193
15.8
Ø80
1272
14.8
1 Technical data

ROTEX®SP "Non Sparking"
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
40228 EN
9 of 28
6
Please observe protection
note ISO 16016.
Drawn:
2019-10-10 Pz/Bru
Replacing:
KTR-N dated 2017-01-02
Verified:
2019-10-10 Pz
Replaced by:
Please read through these operating/assembly instructions carefully before you start up the coupling.
Please 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.
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.
STOP
Warning of personal injury
This symbol indicates notes which may contribute to
preventing bodily injuries or serious bodily injuries that
may result in death.
!
Warning of product damages
This symbol indicates notes which may contribute to
preventing material or machine damage.

General advice
This symbol indicates notes which may contribute to
preventing adverse results or conditions.
Warning of hot surfaces
This symbol indicates notes which may contribute to
preventing burns with hot surfaces resulting in light to
serious bodily injuries.
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. Please 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".
•Please 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.
•Please secure the coupling against accidental contact. Please provide for the necessary protection devices
and covers.
2 Advice
2.1 General advice
2.2 Safety and advice symbols
2.3 General hazard warnings

ROTEX®SP "Non Sparking"
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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®SP „Non Sparking“ described in here corresponds to the state of the art at the time of printing of
these operating/assembly instructions.
!
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.
Please make sure that the technical data regarding torque refer to the spider only. The
transmittable torque of the shaft-hub-connection must be reviewed by the customer and is
subject to his responsibility.
For drives subject to torsional vibrations (drives with cyclic stress due to torsional vibrations) it is necessary to
perform a torsional vibration calculation to ensure a reliable selection. Typical drives subject to torsional vibrations
are e. g. drives with diesel engines, piston pumps, piston compressors etc. If requested, KTR will perform the
coupling selection and the torsional vibration calculation.
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.
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 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.
Please make sure that condensation is not generated. The best relative air humidity is less
than 65 %.
2 Advice
2.4 Intended use
2.5 Coupling selection
2.6 Reference to EC Machinery Directive 2006/42/EC
3 Storage, transport and packaging
3.1 Storage

ROTEX®SP "Non Sparking"
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!
In order to avoid any injuries and any kind of damage please 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.
The coupling is generally supplied in individual parts. Before assembly the coupling has to be inspected for
completeness.
Components of ROTEX®, type GN (No. 080)
Component
Quantity
Description
Illustration 9: Type GN (No. 080)
1
1
Hub
1c
1
GN hub SP
2
1
Spider (92 ShA)
3
2
Setscrews
DIN EN ISO 4029
Components of ROTEX®, type GND (No. 082)
Component
Quantity
Description
Illustration 10: Type GND (No. 082)
1c
2
GN hub SP
2
1
Spider (92 ShA)
3
2
Setscrews
DIN EN ISO 4029
3 Storage, transport and packaging
3.2 Transport and packaging
4 Assembly
4.1 Components of the couplings

ROTEX®SP "Non Sparking"
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Components of ROTEX®, type EN (No. 081)
Component
Quantity
Description
Illustration 11: Type EN (No. 081)
1
1
Hub
2
1
Spider (92 ShA)
3
2
Setscrews
DIN EN ISO 4029
5c
1
EN hub SP
Components of ROTEX®, type E4-DKM (No. 086)
Component
Quantity
Description
Illustration 12: Type E4-DKM (No. 086)
2
2
Spider (92 ShA)
3
2
Setscrews
DIN EN ISO 4029
5bc
2
E4 hub SP
6
1
DKM spacer
Components of ROTEX®, type ZS-DKM-C (No. 085)
Component
Quantity
Description
Illustration 13: Type ZS-DKM-C (No. 085)
2
2
Spider
(98 ShA-GS)
4
2 1)
Cap screws
DIN EN ISO 4762
6c
1
DKM spacer SP
7.5/7.6
2
DH clamping hub
with half length
tapered groove pin
DIN EN ISO 8745
(2 pieces)
1) each DH clamping hub
Hubs, clamping hubs or similar types without feather keyways may be used in category 3
only and are marked with category 3 accordingly.
4 Assembly
4.1 Components of the couplings

ROTEX®SP "Non Sparking"
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Features of standard spiders
Spider hardness
(Shore)
92 Shore A 1)
98 Shore A-GS 2)
T-PUR®(orange)
PUR (red)
Marking
(colour)
1) Use of spiders applies with all types except for type ZS-DKM-C (No. 085)
2) Use of spiders applies with type ZS-DKM-C (No. 085) only
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 or axial runout, respectively (see
illustration 14).
•Please make absolutely sure to observe the figures for
Ø dmax.
•Carefully align the hubs when the finish bores are drilled.
•Applies with all types except for type ZS-DKM-C:
Please provide for a setscrew according to
DIN EN ISO 4029 with a cup point or an end plate to
fasten the hubs axially.
•Only valid with type ZS-DKM-C:
Please provide for a setscrew or an end plate to fasten
the hubs axially.
Illustration 14: Concentricity and axial run-out
!
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 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
remachining performed properly.
4 Assembly
4.1 Components of the couplings
4.2 Advice for finish bore

ROTEX®SP "Non Sparking"
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Table 9: Setscrew DIN EN ISO 4029
Size
24
28
38
42
48
55
65
Dimension G
M5
M8
M8
M8
M8
M10
M10
Dimension t 1)
10
15
15
20
20
20
20
Dimension t12)
6
7
7
10
10
12
12
Tightening torque TA[Nm]
2
10
10
10
10
17
17
1) Dimension t applies for types GN and GND only
2) Dimension t1applies for types EN and E4-DKM
Table 10: Cap screws DIN EN ISO 4762 - 12.9
Size
24
28
38
42
48
55
65
Dimension G
M6x20
M8x25
M8x30
M10x30
M12x35
M12x40
M12x40
Number z 1)
2
2
2
2
2
2
2
Tightening torque TA[Nm]
14
35
35
69
120
120
120
1) each DH clamping hub
Table 11: Recommended fit pairs acc. to DIN 748/1
Bore [mm]
Shaft tolerance
Bore tolerance
above
up to
50
k6
H7
(KTR standard)
50
m6
If a feather keyway is intended to be used in the hub, it should correspond to the tolerance ISO JS9 (KTR
standard) with standard operating conditions or ISO P9 with complicated operating conditions (frequently
alternating torsional direction, shock loads, etc.). The keyway should preferably be located between the cams.
With axial fastening by the setscrew the tapped hole should be located on the keyway.
The transmittable torque of the shaft-hub-connection must be reviewed by the customer and is subject to his
responsibility.

We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Heating the hubs lightly (approx. 80 °C) allows for an easier mounting on the shafts. Not
necessary with type ZS-DKM-C.
Please pay attention to the ignition risk in potentially explosive atmospheres!
STOP
Touching the heated hubs causes burns.
Please wear safety gloves.
!
With the assembly please make sure that the distance dimension E or a (see table 1 to 7) is
observed to allow for axial clearance of the spider when in operation.
Disregarding this advice may cause damage to the coupling.
If used in potentially explosive atmospheres the setscrews to fasten the hubs as well as all
screw connections must be secured against working loose additionally, e. g. conglutinating
with Loctite (average strength).

Basically align the spider centrally with the hubs or spacers after assembly.
4 Assembly
4.2 Advice for finish bore
4.3 Assembly of the coupling (general)

ROTEX®SP "Non Sparking"
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•Mount the hubs on the shaft of driving and driven side (see illustration 15).
•Insert the spider into the cam section of the hub on the driving or driven side.
•Shift the power packs in axial direction until the distance dimension L is achieved (see illustration 16).
•If the power packs are already firmly assembled, shifting the hubs axially on the shafts allows for setting the
distance dimension L.
•Fasten the hubs by tightening the setscrews DIN EN ISO 4029 with a cup point (tightening torques see
table 9).

If the shaft diameters with inserted feather key are smaller than dimension dH(see table 1 to
5) of the spider, one or two shaft ends may protude into the spider.
Illustration 15: Assembly of the hubs
Illustration 16: Assembly of coupling
•Mount the E4 hubs onto the shaft of driving and driven side (see illustration 17).
•The internal sides of the E4 hubs must be flush with the front sides of the shafts.
•Fasten the E4 hubs by tightening the setscrews DIN EN ISO 4029 with a cup point (tightening torque see
table 9).
•Insert both spiders into the cam section of the E4 hubs on the driving and driven side.
•Put the DKM spacer into one of the two spiders.
•Shift the power packs in axial direction until the dimension Ltotal is achieved (see illustration 18 and table 6).
Illustration 17: Assembly of the E4 hubs
Illustration 18: Assembly of coupling
4 Assembly
4.4 Assembly of types GN, GND and EN
4.5 Assembly of type E4-DKM

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•Remove the half shells from the hub body (see illustration 19).
•Fit the hub bodies together with the spiders and DKM spacer SP (see illustration 20).
•Mount the fitted unit along with the shells and the clamping screws onto the shaft ends of the driving and
driven machine (see illustration 21).
•Hand-tighten the components first until the hub bodies with the half shells fit closely to the shaft.
•Shift the DH clamping hubs in axial direction until the dimension Ltotal is achieved (see illustration 22 and
table 7).
•Secure the DH clamping hubs by tightening the clamping screws reciprocally. The screws have to be tightened
at the tightening torques TA specified in table 10 by means of a suitable torque wrench.
!
Having started up the coupling the tightening torques of the screws have to be inspected
during the usual inspection intervals.
Illustration 19: Disassembly of shells
Illustration 20: Assembly of hub bodies,
spiders and DKM spacer SP
Illustration 21: Assembly of component assembly
onto the shafts
Illustration 22: Assembly of coupling
4 Assembly
4.6 Assembly of type ZS-DKM-C

ROTEX®SP "Non Sparking"
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The displacement figures specified in table 12 to 14 provide for sufficient safety to compensate for external
influences like, for example, heat expansion or foundation settling.
!
In order to ensure a long service life of the coupling and avoid dangers with the use in
potentially explosive atmospheres, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures indicated (see table 12 to 14). If the
figures are exceeded, the coupling will be damaged.
The more accurate the alignment of the coupling, the longer is its service life.
If used in potentially explosive atmospheres for explosion group IIC, only half of the
displacement figures (see table 12 to 14) are permissible.
Please note:
•The displacement figures specified in table 12 to 14 are maximum figures which must not arise in parallel. If
radial and angular displacements arise at the same time, the permissible displacement values may only be
used proportionally (see illustration 25).
•Please inspect with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 12 to
14 can be observed.
Angular displacements
Radial displacements
Axial displacements
Kw= L1max. - L1min. [mm]
Lmax = L + Ka[mm]
Illustration 23: Displacements (single-cardanic)
Angular displacements
Axial displacements
Illustration 24: Displacements (double-cardanic)
Radial displacements
4 Assembly
4.7 Displacements - alignment of the couplings

ROTEX®SP "Non Sparking"
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Examples of the displacement combinations
specified in illustration 25:
Example 1:
Kr= 30 %
Kw= 70 %
Example 2:
Kr= 60 %
Kw= 40 %
Illustration 25:
Combinations of
displacement
Ktotal = Kr+ Kw100 %
Table 12: Displacement figures for 92 Shore A
Size
24
28
38
42
48
55
65
Max. axial displacement Ka[mm]
-0.5
-0.7
-0.7
-1.0
-1.0
-1.0
-1.0
+1.4
+1.5
+1.8
+2.0
+2.1
+2.2
+2.6
Max. radial displacement
Kr[mm] with
1500 rpm
0.22
0.25
0.28
0.32
0.36
0.38
0.42
3000 rpm
0.15
0.17
0.19
0.21
0.25
0.26
0.28
Kw[degree] max. angular displacement
with n=1500 rpm Kw[mm]
0.9
0.9
1.0
1.0
1.1
1.1
1.2
0.85
1.05
1.35
1.70
2.00
2.30
2.70
Kw[degree] max. angular displacement
with n=3000 rpm Kw[mm]
0.8
0.8
0.9
0.9
1.0
1.0
1.1
0.75
0.85
1.10
1.40
1.60
2.00
2.30
Table 13: Displacement figures - type E4-DKM (No. 086)
Size
24
28
38
42
48
55
65
Max. axial displacement Ka[mm]
+1.4
+1.5
+1.8
+2.0
+2.1
+2.2
+2.6
-1.0
-1.4
-1.4
-2.0
-2.0
-2.0
-2.0
Max. radial displacement
Kr[mm] with n =
1500 rpm
0.59
0.66
0.77
0.84
0.91
1.01
1.17
3000 rpm
0.53
0.60
0.70
0.75
0.82
0.81
1.05
Kw[degree] max. angular
displacement with n =
1500 rpm
1.0
1.0
1.0
1.0
1.0
1.0
1.0
3000 rpm
0.9
0.9
0.9
0.9
0.9
0.9
0.9
Table 14: Displacement figures for 98 Shore A-GS - Type ZS-DKM-C (No. 085)
Size
Max. axial
displace-
ment Ka
[mm]
Max. angular
displacement Kw
[degree] with n =
Max. radial displacement Kr[mm]
with shaft distance dimension L with n =
1500 rpm
3000 rpm
1500
rpm
3000
rpm
100
140
180
250
100
140
180
250
24
+1.4 / -1.0
1.0
0.75
1.17
1.87
-
-
0.87
1.40
-
-
28
+1.5 / -1.4
1.0
0.75
1.06
1.76
-
-
0.80
1.32
-
-
38
+1.8 / -1.4
1.0
0.75
0.99
1.69
-
-
0.74
1.27
-
-
42
+2.0 / -2.0
1.0
0.75
0.91
1.60
-
-
0.68
1.20
-
-
48
+2.1 / -2.0
1.0
0.75
0.87
1.57
-
-
0.65
1.18
-
-
55
+2.2 / -2.0
1.0
0.75
0.70
1.40
2.09
-
0.52
1.05
1.57
-
65
+2.6 / -2.0
1.0
0.75
-
1.31
2.00
-
-
0.98
1.50
-
4 Assembly
4.7 Displacements - alignment of the couplings

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Before start-up of the coupling, inspect the tightening of the setscrews in the hubs, the alignment and the distance
dimension E and adjust, if necessary, and also inspect all screw connections for the tightening torques specified.
If used in potentially explosive atmospheres the setscrews to fasten the hubs as well as all
screw connections must be secured against working loose additionally, e. g. conglutinating
with Loctite (average strength).
Finally the coupling protection against accidental contact must be fitted. It is required in accordance with
DIN EN ISO 12100 (Safety of Machinery) and directive 2014/34/EU and must protect against
•access with a little finger
•falling down of solid foreign objects.
The cover may provide for openings intended for necessary heat dissipation. These openings have to comply with
DIN EN ISO 13857.
The cover must be electrically conductive and included in the equipotential bonding. Bellhousings (magnesium
share below 7.5 %) made of aluminium and damping rings (NBR) can be used as connecting element between
pump and electric motor. The cover may only be taken off with standstill of the unit.
If the couplings are used in locations subject to dust explosion and in mining the user must
make sure that there is no accumulation of dust in a dangerous volume between the cover
and the coupling. The coupling must not operate in an accumulation of dust.
For covers with unlocked openings on the top face no light metals must be used if the
couplings are used as equipment of equipment group ll (if possible, from stainless steel).
If the couplings are used in mining (equipment group l M2), the cover must not be made of
light metal. In addition, it must be resistant to higher mechanical loads than with use as
equipment of equipment group ll.
During operation of the coupling, please pay attention to
•different operating noise
•vibrations occurring.
!
If you note any irregularities with the coupling during operation, the drive unit must be
switched off immediately. The cause of the breakdown must be specified by means of the
table „Breakdowns“ and, if possible, be eliminated according to the proposals. The potential
breakdowns specified can be hints only. To find out the cause all operating factors and
machine components must be considered.
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. Paintings and
coatings exceeding a thickness of 200 µm are generally impermissible for potentially
explosive atmospheres. It 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. In addition, make sure that the marking
of the coupling remains legible. Painting or coating of the spider is generally not admitted.
5 Start-up

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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.
If used other than intended the coupling can become a source of ignition.
EU directive 2014/34/EU requires special care by the manufacturer and the user.
General failures with use other than intended:
•Important data for the coupling selection are not forwarded.
•The calculation of the shaft-hub-connection is not considered.
•Coupling components with damage occurred during transport are assembled.
•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 have been fallen below/exceeded.
•Components are mixed up by mistake/assembled incorrectly.
•A wrong or no spider/DZ elements are inserted in the coupling.
•No original KTR components (purchased parts) are used.
•Old/already worn out spiders/DZ elements or spiders/DZ elements stored for too long are used.
•Maintenance intervals are not observed.
Breakdowns
Causes
Hazard notes for
potentially explosive
atmospheres
Elimination
Different operating
noise and/or
vibrations occuring
Misalignment
Increased temperature on
the spider surface; ignition
risk by hot surfaces
1) Set the unit out of operation
2) Eliminate the reason for the misalignment
(e. g. loose foundation bolts, breaking of the
engine mount, heat expansion of unit
components, modification of the installation
dimension E of the coupling)
3) For inspection of wear see chapter 10.2
Screws for axial
fastening of hubs
working loose
Ignition risk due to hot
surfaces and sparking
1) Set the unit out of operation
2) Inspect alignment of coupling
3) Tighten the screws to fasten the hubs and
secure against working loose
4) For inspection of wear see chapter 10.2
Breaking of cams
Breaking of the cams
due to high impact
energy/overload
Danger by rotating cam
fragments
1) Set the unit out of operation
2) Replace complete coupling
3) Inspect alignment
4) Find out the reason for overload
Operating parameters
do not meet with the
performance of the
coupling
1) Set the unit out of operation
2) Review the operating parameters and select
a bigger coupling (consider mounting space)
3) Assemble new coupling size
4) Inspect alignment
Operating error of the
unit
1) Set the unit out of operation
2) Replace complete coupling
3) Inspect alignment
4) Instruct and train the service staff
Early wear of spider
Misalignment
Increased temperature on
the spider surface; ignition
risk by hot surfaces
1) Set the unit out of operation
2) Eliminate the reason for the misalignment
(e. g. loose foundation bolts, breaking of the
engine mount, heat expansion of unit
components, modification of the installation
dimension E of the coupling)
3) For inspection of wear see chapter 10.2
6 Breakdowns, causes and elimination