KTR-Group KTR-STOP NC Manual

KTR-STOP®NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44545 EN
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Please observe protection
note ISO 16016.
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The KTR-STOP®NC series is a passive clamping and braking system serving for generating a
clamping/braking force or clamping/braking torque on a cylindrical piston rod or shaft to brake its
rotation or keep it at standstill, respectively.
KTR-STOP®NC
The KTR-STOP®NC series was designed for the use both as a clamping system and emergency stop
brake. For any other applications please consult with KTR.
1Technical data 2
2Advice 3
2.1 General advice 3
2.2 Safety and advice symbols 3
2.3 General hazard warnings 3
2.4Intended use 3
3Storage, transport and packaging 4
3.1 Storage 4
3.2 Transport and packaging 4
4Assembly 4
4.1 Components of the clamping and braking system 4
4.2 Hydraulic connection of clamping and braking system 5
4.3 Assembly of the clamping and braking system 6
4.4 Start-up of the clamping and braking system 6
4.5 Recommendation of fluids to be used 7
4.6 Disassembly of the clamping and braking system 8
4.7 Disposal 9
4.8 Maintenance and service 9
Table of contents

KTR-STOP®NC
Operating/Assembly instructions
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44545 EN
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Ilustration 1: Dimensions
of KTR-STOP®NC
Table 1: Dimensions
Type
Size
Dimensions [mm]
d
d1
B
B1
L
L1
L2
L3
L4
L5
KTR-STOP®NC
32
18
10.5
96
72
86
66.5
53
19
40.5
9.75
20
22
24
25
Table 2: Technical data 1)
Type
Size
d
[mm]
Oil filling
[dm3]
Max. opening
pressure [bar]
Lock torque
[Nm]
„Axial locking
force“ [N]
KTR-STOP®NC
32
18
0.011
100
75
8300
20
85
8500
22
95
8600
24
105
8750
25
110
8800
1) All figures are based on a fit pair shaft k6, bush D8.
2) Other bore diameters and sizes on request.
Tolerances and surface of shaft
Shaft material:
Minimum strength ≥ 235 N/mm2
Illustration 2: Tolerance and surface
1 Technical data

KTR-STOP®NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44545 EN
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note ISO 16016.
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Please read through these operating/assembly instructions carefully before you start up the clamping/braking
system. Please pay special attention to the safety instructions!
The operating/assembly instructions are part of your product. Please store them carefully.
The copyright for these operating/assembly instructions remains with KTR.
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 undesirable results or conditions.
STOP
With assembly, operation and maintenance of the clamping and braking system 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 clamping and braking system 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 clamping and braking
system..
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 clamping and braking system as long as it is in operation.
Protect all components of the clamping and braking system from falling down before assembly and
disassembly, in particular vertical axes or vertical piston rods.
Protect the clamping and braking system and adjacent rotating components from accidental contact. Please
provide for the necessary protection devices.
You may only assemble, operate and maintain the clamping and braking system if you
have carefully read through the operating/assembly instructions and understood them
had technical training
are authorized by your company
The clamping and braking system may only be used in accordance with the technical data (see chapter 1).
Unauthorized modifications on the clamping and braking system 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 clamping and braking system of KTR-STOP® NC described in here corresponds to the technical status at
the time of printing of these assembly instructions.
2 Advice
2.1 General advice
2.2 Safety and advice symbols
2.3 General hazard warnings
2.4 Intended use

KTR-STOP®NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44545 EN
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Please observe protection
note ISO 16016.
Drawn:
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The clamping and braking system is delivered in a preserved condition and can be stored in a closed, dry place
during 24 months.
With proper storage conditions its properties remain unchanged up to 12 months.
If the clamping and braking system is stored over a longer period exceeding 12 months and after every transport,
the clamping and braking system needs to be operated over the full distance to prevent the gaskets from sticking
together.
!
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 %.
!
In order to avoid any injuries and any kind of damage please always make use of proper
lifting equipment.
The clamping and braking system is packed differently each depending on number and kind of transport. Unless
otherwise contractually agreed, packaging will follow the in-house packaging specifications of KTR.
The clamping and braking system is supplied in assembled condition. Before assembly the clamping and braking
system has to be inspected for completeness.
Components/component assemblies of KTR-STOP®NC
Component
Quantity
Description
Illustration 3: Components/component assemblies of KTR-
STOP®NC
1
1
Clamping and braking system
2
2
Locking screws
3 Storage, transport and packaging
3.1 Storage
3.2 Transport and packaging
4 Assembly
4.1 Components of the clamping and braking system

KTR-STOP®NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44545 EN
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note ISO 16016.
Drawn:
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!
Leakages have to be removed immediately. Oil which has escaped has to be removed
completely, since oil remains may vaporize on hot components and ignite.
!
As long as there is no shaft or cylindrical piston rod in the clamping area of KTR-STOP®NC
it is absolutely necessary to keep the clamping/braking system open under pressure.

Please make sure that the connections and hoses are
adapted to the system with regard to pressure, flow rate,
temperature and liquidity.
Any hoses which are located close to mobile
components should be secured or coated accordingly.
Illustration 4: Pressure port

Connection 2 serves as an alternative oil connection (see
illustration 4). In order to assure its operation, a
hydraulic hose may only be connected to one out of the
two connections 1 or 2 (illustration 5).
Connect a manual hydraulic pump to one of the two oil connections (see
illustration 4). For that purpose remove the screw plug (illustration 2)
beforehand.
Vent the clamping and braking system and the hydraulic system. Use
the oil connection on top for venting.
!
Make sure that the venting holes always point upwards to ensure that the air can escape
from the system.
Illustration 5: Releasing the clamping and braking system
(unlocking)
Illustration 6: Clamping the clamping and braking system
(locking)
For locking or clamping release the pressure from the hydraulic system (see illustration 6).
!
Make sure there is a shaft in the clamping area of the system.
4 Assembly
4.2 Hydraulic connection of clamping and braking system

KTR-STOP®NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44545 EN
6 of 9
1
Please observe protection
note ISO 16016.
Drawn:
09.06.15 Kb/Brs
Replacing:
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Verified:
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Replaced by:
!
As long as there is no shaft or cylindrical piston rod in the clamping area of KTR-STOP®NC,
it is absolutely necessary to keep the clamping/braking system open under pressure.
Unlock the clamping and braking system by applying
pressure (max. 100 bar) after filling and venting (see
illustration 5).
Remove the transportation shaft (illustration 7).
Illustration 7: Removal of transport lock
Illustration 8: Assembly of clamping and braking system
!
Never turn off the pressure before a shaft
or piston rod has been assembled.
Shift and position the clamping and braking system on
the shaft and hand-tighten it to the adjacent
components (illustration 8) for the time being so that it
fully fits.
Release the pressure. The system clamps on the shaft
centering on it.

The fastening screws may only be
tightened if the clamping and braking
system is locked and thus centered
(illustration 6).
Tighten the fastening screws M10 (not included in the
scope of delivery) evenly crosswise to the respective
tightening torque.
Set the clamping and braking system under pressure
and re-tighten the screws at the full tightening torque.

Secure the screw connection additionally against working loose, e. g. conglutinating with
Loctite (average strength).
Release the pressure and remove the manual pump.
Connect the oil pressure ports of the hydraulic system to the pressure connections.

Before start-up and after each operation on the clamping and braking system the hydraulic
system has to be generally vented.
Repeat bleeding the clamping and braking system regularly in usual maintenance intervals,
since any air in the hydraulic system may affect the operation of the clamping and braking
system and the plant.
!
Please make sure that there is sufficient liquid in the hydraulic system during and after the
venting process (recommendation of liquid, see chapter 4.5).
Remove the screw plug of the oil connection not used and make use of the venting hole on top.
Switch on the hydraulic system for a short term to make sure that the system is flushed with hydraulic oil.
Repeat this process until a stream of oil without any bubbles dissipates from the hole.
4 Assembly
4.3 Assembly of the clamping and braking system
4.4 Start-up of the clamping and braking system

KTR-STOP®NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44545 EN
7 of 9
1
Please observe protection
note ISO 16016.
Drawn:
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Screw the screw plug into the hole and dispose of the hydraulic oil of the collection container as per chapter
4.8.
Inspect the screw connection for the tightening torque specified.
STOP
Make sure that the shaft cannot be moved manually during the clamping process.
!
The hydraulic system must never be operated at a higher pressure than the figures
specified in table 2. In case that any figures or types/sizes are modified, please contact KTR.

Before the system is started up, it must be operated over the full distance several times.
!
You may only use hydraulic fluids meeting the demands of DIN 51524. KTR recommends
those fluids corresponding to DIN 51524-3.
KTR recommends the following fluids (other manufacturers may be selected):
Manufacturer
Fluids
Mineral oil
- 20 °C to + 40 °C
(- 4 °F to 104 °F)
+ 10 °C to + 60 °C
(+ 50 °F to + 140 °F)
Castrol
Hyspin HVI 32
Hyspin HVI 46
Shell
Tellus S3 V32
Tellus S3 V46
Mobil
DTE 10 Excel 32
DTE 10 Excel 46
Hydro Texaco
Rando HDZ32
Rando HDZ46
Valvoline
Ultramax HVLP32
Ultramax HVLP46

The permissible operating temperatures of the components from - 20 °C to + 60 °C (- 4 °F to
+ 140 °F) have to be observed. For different operating temperatures please consult with
KTR.
Viscosity
We would recommend a viscosity range from 20 to 220 mm2/s (cSt) of the hydraulic fluid with operating
temperature. The viscosity during starting should not exceed 500 mm2/s and the viscosity during operation should
not fall below 12 mm2/s.
Filtration
When filling and re-filling the hydraulic system and replacing the hydraulic fluid, the oil needs to be filtered. For
that purpose use an offline filter or a respective fill unit. In addition we would recommend to use an inline filter.

The service life of the clamping and braking system is extended depending on the degree of
purity of the oil.
In order to ensure the reliability of the system, only those oils originating from the following purity classes are
permitted:
ISO 4406, class 20/17/12
4 Assembly
4.4 Start-up of the clamping and braking system
4.5 Recommendation of fluids to be used

KTR-STOP®NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44545 EN
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Please observe protection
note ISO 16016.
Drawn:
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Maintenance operations on the hydraulic system
In order to ensure a smooth operation of the overall system, the maintenance operations on the hydraulic system
(inspection of level and degree of dirt, replacing the hydraulic fluid or filter elements, etc.) have to be performed as
per the manufacturer's operating instructions.
The system has to be scavenged or bleeded after each replacement of the hydraulic fluid.
!
Adverse reactions may be generated by mixing different fluids or fluids of various
manufacturers.

Please contact the manufacturer of mineral oils if you intend to replace the hydraulic fluid.
STOP
Parts released or falling down may cause injury to persons or damage on the machine.
Secure the driving components before disassembly.
!
As long as there is no shaft or cylindrical piston rod in the clamping area of KTR-STOP®NC,
it is absolutely necessary to keep the clamping-/braking system open under pressure.
Remove the 4-off fastening screws.
Set the clamping and braking system under pressure so that it comes off the shaft. Here the maximum
pressure of 100 bar must not be exceeded (see table 2).
Remove the clamping and braking system and fit the transporting shaft into the bore (see illustration 7).
Release the pressure fully from the hydraulic system.
STOP
Please make sure that the entire clamping system is depressurized.
Drain the hydraulic oil completely from the clamping system.
Dispose of the hydraulic oil as per chapter 4.8.
Disconnect the oil pressure ports and screw the screw plugs (component 2) in the tapped holes.
4 Assembly
4.5 Recommendation of fluids to be used
4.6 Disassembly of the clamping and braking system

KTR-STOP®NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44545 EN
9 of 9
1
Please observe protection
note ISO 16016.
Drawn:
09.06.15 Kb/Brs
Replacing:
---
Verified:
11.06.15 Kb
Replaced by:
In respect of environmental protection we would ask you to dispose of the products on termination of their service
life in accordance with the legal regulations and standards that apply, respectively.
Metal
Any metal components have to be cleaned and disposed of by scrap metal.
Gaskets
Gaskets can be disposed of by residual waste.
Hydraulic oil
Hydraulic oils have to be collected in suitable tanks and disposed of by a waste disposal company.
KTR-STOP®NC is a low-maintenance clamping and braking system. We recommend to perform a visual
inspection and an operational testing on the clamping system at least once a year. Here you should put special
emphasis on leakages, corrosion and the condition of the screw connections and the clamping element.

If you find any irregularities or faulty components please consult with KTR. If any repairs
need to be done on the clamping and braking system, please send in the system to us.

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.
4 Assembly
4.7 Disposal
4.8 Maintenance and service