KTR BoWex junior Manual

KTR Kupplungstechnik
GmbH
D-48407 Rheine
BoWex®
Operating-/Assembly Instructions
Design 001, 002, 003 and 006
KTR-N
sheet:
edition:
40110 EN
1
8
Gezeichnet: 27.06.08 Sha/Hk Ersatz für: KTR-N vom 17.01.03Schutzvermerk
ISO 16016 beachten. Geprüft: 30.06.08 Sha Ersetzt durch:
design No. 001 – junior plug-in coupling (2 parts)
design No. 002 – junior M coupling (3 parts)
design No. 003 – M and M...C
BoWex®
puncture
curved-tooth gear couplings®
types
No. 001 – junior plug-in coupling,
No. 002 – junior M coupling,
No. 003 – M and M...C
No. 006 - I
and their combinations
according to Standard 94/9/EC
(ATEX 95) for finish bored, pilot
bored and unbored couplings
design No. 006 - I

KTR Kupplungstechnik
GmbH
D-48407 Rheine
BoWex®
Operating-/Assembly Instructions
Design 001, 002, 003 and 006
KTR-N
sheet:
edition:
40110 EN
2
8
Gezeichnet: 27.06.08 Sha/Hk Ersatz für: KTR-N vom 17.01.03Schutzvermerk
ISO 16016 beachten. Geprüft: 30.06.08 Sha Ersetzt durch:
BoWex®curved-tooth gear couplings®are flexible shaft connections. They are able to
compensate for shaft displacement caused by, as an example, inaccuracies in production,
heat expansion, etc.
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 Hint Regarding the Finish Bore
4.3 Assembly of the Hubs
4.4 Displacements - Alignment of the Couplings
4.5 Spares Inventory, Customer Service Addresses
5 Enclosure A
Hints and Instructions Regarding the Use in Hazardous Areas
5.1 Use in Hazardous Areas According to the Regulations
5.2 Control Intervals for Couplings in Hazardous Areas
5.3 Checking of Torsional Backlash
5.4 Approximate Values of Wear
5.5 Permissible Coupling Materials in the Hazardous Area
5.6 Marking of Coupling for the Hazardous Area
5.7 Starting
5.8 Breakdowns, Causes and Elimination
5.9 EC Certificate of Conformity according to the EC Standards 94/9/EC
dated 23 March 1994

KTR Kupplungstechnik
GmbH
D-48407 Rheine
BoWex®
Operating-/Assembly Instructions
Design 001, 002, 003 and 006
KTR-N
sheet:
edition:
40110 EN
3
8
Gezeichnet: 27.06.08 Sha/Hk Ersatz für: KTR-N vom 17.01.03Schutzvermerk
ISO 16016 beachten. Geprüft: 30.06.08 Sha Ersetzt durch:
1 Technical Data
picture 1: BoWex®junior plug-in coupling (2 parts) picture 2: BoWex®junior M coupling (3 parts)
Table 1:
BoWex®junior plug-in coupling and BoWex®junior M coupling
torque
[Nm] finish bore [mm] thread for setscrews [mm]
BoWex®
size TKN T
K max. hub
component 1b
d1D1plug-in sleeve
component 2b
d2D2G
1t 1t 2TA
[Nm]
max. speed
[1/min]
Ø6, Ø7, Ø8, Ø9 22 Ø8 22
Ø10, Ø11 25 Ø10, Ø11 25
14 5 10
Ø12, Ø14 26 Ø12, Ø14 26 M5 6 8 1,4 6000
Ø12, Ø14 27
Ø16 30
Ø14, Ø15 29
19 8 16
Ø19 32 Ø19 35
M5 6 10 1,4 6000
Ø10, Ø11, Ø12 26
Ø14, Ø15, Ø16 32 Ø14, Ø16 32
Ø18, Ø19, Ø20 36 Ø19, Ø20 36
24 12 24
Ø24 38 Ø24 40
M5 6 10 1,4 6000
Table 2:
BoWex®junior plug-in coupling and BoWex®junior M coupling
dimensions
[mm]
BoWex®
size DHl
1; l2E 1L 1L H1 M 1F G E L LHM; N
14 40 23 2 48 40 8 18,5 21,5 4 50 37 6,5
19 47 25 2 52 42 10 19,0 23,0 4 54 37 8,5
24 53 26 2 54 45 9 21,5 23,5 4 56 41 7,5

KTR Kupplungstechnik
GmbH
D-48407 Rheine
BoWex®
Operating-/Assembly Instructions
Design 001, 002, 003 and 006
KTR-N
sheet:
edition:
40110 EN
4
8
Gezeichnet: 27.06.08 Sha/Hk Ersatz für: KTR-N vom 17.01.03Schutzvermerk
ISO 16016 beachten. Geprüft: 30.06.08 Sha Ersetzt durch:
1 Technical Data
picture 3: BoWex®design M picture 4: BoWex®design I
Table 3:
BoWex®design M and design I
BoWex®
size pilot bore dimensions
[mm] threads for setscrews 2) [mm]
un-
bored pilot bore
max.
finish
bore
d1; d2l1; l2E L LHM; N l3D DHD
Z1) G t TA
[Nm]
M-14 M-14C x - 15 23 4 50 37 6,5 10 25 40 33 M5 6 2
M-19 M-19C x - 20 25 4 54 37 8,5 10 32 47 39 M5 6 2
M-24 M-24C x - 24 26 4 56 41 7,5 14 36 53 45 M5 6 2
M-28 M-28C x - 28 40 4 84 46 19 13 44 65 54 M8 10 10
M-32 M-32C x - 32 40 4 84 48 18 13 50 75 63 M8 10 10
M-38 M-38C x - 38 40 4 84 48 18 13 58 83 69 M8 10 10
M-42 x - 42 42 4 88 50 19 13 65 92 78 M8 10 10
M-48 M-48C x - 48 50 4 104 50 27 13 68 95 78 M8 10 10
M-65 M-65C x 27
70 lg. 65 55 4 114 68 23 16 96 132 110 M10
15 /
20 3) 17
I-80 - 31 80 90 6 186 93 46,5 20 124 175 145 M10 20 17
I-100 - 35 100 110 8 228 102 63 22 152 210 176 M12 30 40
I-125 - 45 125 140 10 290 134 78 30 192 270 225 M16 40 80
1) tip circle of the hub
2) position of the threads for setscrews BoWex M-14 to M-24 opposite the keyway; BoWex M-28 to I-125 on the keyway
3) hub length 55 mm t = 15 mm, 70 mm t = 20 mm
BoWex®couplings with attached parts that 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.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
BoWex®
Operating-/Assembly Instructions
Design 001, 002, 003 and 006
KTR-N
sheet:
edition:
40110 EN
5
8
Gezeichnet: 27.06.08 Sha/Hk Ersatz für: KTR-N vom 17.01.03Schutzvermerk
ISO 16016 beachten. Geprüft: 30.06.08 Sha Ersetzt durch:
2 Hints
2.1 Coupling Selection
!
CAUTION!
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 BoWex®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 sleeve. 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 torsional 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 BoWex®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
STOP DANGER! Dangerofinjurytopersons.
! CAUTION! Damagesonthemachinepossible.
)A TTE NT IO N! Pointing to important items.
PRECAUTION! Hintsconcerningexplosionprotection.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
BoWex®
Operating-/Assembly Instructions
Design 001, 002, 003 and 006
KTR-N
sheet:
edition:
40110 EN
6
8
Gezeichnet: 27.06.08 Sha/Hk Ersatz für: KTR-N vom 17.01.03Schutzvermerk
ISO 16016 beachten. Geprüft: 30.06.08 Sha Ersetzt durch:
2 Hints
2.4 General Hints of Danger
STOP
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.
•All operations on and with the coupling have to be performed taking into account "safety first".
•Please make sure to disengage the power pack before you perform your work.
•Protect the power pack against unintentional engagement, e. g. by providing hints at the place of engagement
or removing the fuse for current supply.
•Do not touch the operation area of the coupling as long as it is in operation.
•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
•carefully read through the mounting instructions and understood them
•had technical training
•are authorized to do so by your company
The coupling may only be used in accordance with the technical data (see table 1 to 3 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 BoWex®described in here corresponds to the technical status at the time of printing of these mounting
instructions.
3 Storage
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 sleeves 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. 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%.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
BoWex®
Operating-/Assembly Instructions
Design 001, 002, 003 and 006
KTR-N
sheet:
edition:
40110 EN
7
8
Gezeichnet: 27.06.08 Sha/Hk Ersatz für: KTR-N vom 17.01.03Schutzvermerk
ISO 16016 beachten. Geprüft: 30.06.08 Sha Ersetzt durch:
4 Assembly
Basically the coupling is supplied in individual parts. Before assembly the coupling has to be controlled for
completeness.
4.1 Components of the Couplings
Design from nylon
Components of BoWex®junior plug-in coupling design No. 001
Component Quantity Designation
1 1 hub
2 1 plug-in sleeve
3 2
setscrew
DIN EN ISO 4029
picture 5: BoWex®junior plug-in coupling
Components of BoWex®junior M coupling design No. 002
Component Quantity Designation
1 2 hub
2 1 sleeve
3 2
setscrew
DIN EN ISO 4029
picture 6: BoWex®junior M coupling
Design from steel/nylon
Components of BoWex®M coupling (size 14 - 65) design No. 003
Component Quantity Designation
1 2 hub
2 1 M-sleeve
3 2
setscrew
DIN EN ISO 4029
picture 7: BoWex®M coupling

KTR Kupplungstechnik
GmbH
D-48407 Rheine
BoWex®
Operating-/Assembly Instructions
Design 001, 002, 003 and 006
KTR-N
sheet:
edition:
40110 EN
8
8
Gezeichnet: 27.06.08 Sha/Hk Ersatz für: KTR-N vom 17.01.03Schutzvermerk
ISO 16016 beachten. Geprüft: 30.06.08 Sha Ersetzt durch:
4 Assembly
4.1 Components of the Couplings
Components of BoWex I coupling (size 80 - 125) design No. 006
Component Quantity Designation
1 2 hub
2 1 I-sleeve
1)
3 2 circlips1)
4 2
setscrew
DIN EN ISO 4029
1) Circlips and sleeve are delivered pre-assembled.
picture 8: BoWex®I coupling
4.2 Hint Regarding the Finish Bore
STOP
DANGER!
The maximum permissible bore diameters d (see
table 1 to 3 in chapter 1 - Technical Data) must not be
exceeded. If these figures are disregarded, the coupling
may tear. Rotating particles may cause serious danger.
•Hub bores (steel hubs) machined by the customer have to
observe concentric running or axial running, respectively
(see picture 9).
•Please make absolutely sure to observe the figures for dmax.
•Carefully align the hubs when the finish bores are brought
in.
•Please use a setscrew according to DIN EN ISO 4029 with a
cup point or an end plate to fasten the hubs axially.
picture 9: concentric running
and axial running
!
CAUTION!
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.
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.
Table 4: setscrews
BoWex®size 14 1) 19
1) 24 1) 28 32 38 42 48 65 80 100 125
dimension G M5 M5 M5 M8 M8 M8 M8 M8 M10 M10 M12 M16
tightening torque TA[Nm 2 2 2 10 10 10 10 10 17 17 40 80
1) tightening torques of the BoWex ®junior plug-in coupling and BoWex®junior M coupling TA= 1,4 Nm

KTR Kupplungstechnik
GmbH
D-48407 Rheine
BoWex®
Operating-/Assembly Instructions
Design 001, 002, 003 and 006
KTR-N
sheet:
edition:
40110 EN
9
8
Gezeichnet: 27.06.08 Sha/Hk Ersatz für: KTR-N vom 17.01.03Schutzvermerk
ISO 16016 beachten. Geprüft: 30.06.08 Sha Ersetzt durch:
4 Assembly
4.3 Assembly of the Hubs
)ATTENTION!
We recommend to check bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Heating the hubs slightly (approx. 80 °C) allows for an easier installation onto the shaft.
PRECAUTION!
Please pay attention to the danger of ignition in hazardous areas.
STOP
DANGER!
Touching the heated hubs causes burns.
We would recommend to wear safety gloves.
!
CAUTION!
For the assembly please make sure that the distance dimension E (see table 2 and 3) is kept
to ensure that the sleeve can be moved axially.
Disregarding this hint may cause damage on the coupling.
•Assemble the hubs onto the shaft of driving and driven side.
•Move the power packs in axial direction until the dimension E is achieved.
•If the power packs are already firmly assembled, axial movement of the hubs on the shafts allows for adjusting
the dimension E.
•Fasten the hubs by tightening the setscrews DIN EN ISO 4029 with cup point (tightening torque see table 4).
4.4 Displacements - Alignment of the Couplings
The displacement figures shown in tables 5 and 6 offer sufficient safety to compensate for environmental
influences like, for example, heat expansion or lowering of foundation.
!
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 tables 5 and 6). 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 tables 5 and 6) are permissible.
Please note:
•The displacement figures mentioned in tables 5 and 6 are maximum figures which must not arise in parallel. If
radial and angular displacement arises at the same time, the permissible radial displacements of the coupling
halves have to be reduced as follows:
Ww
Kw2 Kr
KrKrperm Δ•
Δ
Δ
−Δ=Δ
ΔWw = angular shaft displacement
•The displacement figures mentioned are general figures that apply up to an ambient temperature of 80 °C,
ensuring a sufficient service life of the BoWex®coupling.
Displacement figures between the speeds indicated have to be interpolated accordingly. If necessary, please
ask about the displacement for the corresponding coupling type.
•Please check with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 5 and 6
can be observed.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
BoWex®
Operating-/Assembly Instructions
Design 001, 002, 003 and 006
KTR-N
sheet:
edition:
40110 EN
10
8
Gezeichnet: 27.06.08 Sha/Hk Ersatz für: KTR-N vom 17.01.03Schutzvermerk
ISO 16016 beachten. Geprüft: 30.06.08 Sha Ersetzt durch:
4 Assembly
4.4 Displacements - Alignment of the Couplings
angular displacements radial displacements axial displacements radial and angular
displacements
picture 10: displacements
Example for the misalignment
combinations given in picture 11:
Example 1:
ΔKr= 30 %
ΔKw= 70 %
Example 2:
ΔKr= 60 %
ΔKw= 40 %
ΔKtotal = ΔKr+ ΔKw≤100 %
picture 11:
combinations of
displacement
Table 5: Displacement figures
BoWex®junior plug-in coupling and BoWex®junior M coupling
coupling size 14 19 24
max. axial displacement ΔKa [mm] ±1 ±1 ±1
max. radial displacement with n=1500 1/min ΔKr [mm] 0,1 0,1 0,1
max. radial displacment with n=3000 1/min ΔKr [mm] 0,1 0,1 0,1
ΔKw max. angular displacement with n=1500 1/min [degree] 1,0 1,0 0,9
ΔKw max. angular displacement with n=3000 1/min [degree] 0,7 0,7 0,6
Table 6: Displacement figures
BoWex®design M and design I
coupling size 14 19 24 28 32 38 42 48 65 80 100 125
max. axial displacement ΔKa [mm] ±1 ±1 ±1 ±1 ±1 ±1 ±1 ±1 ±1 ±1 ±1 ±1
max. radial displacement
with n=1500 1/min ΔKr [mm] 0,30 0,30 0,35 0,35 0,35 0,40 0,40 0,40 0,45 0,45 0,45 0,45
max. radial displacment
with n=3000 1/min ΔKr [mm] 0,20 0,20 0,23 0,23 0,23 0,25 0,25 0,25 0,28 0,28 0,28 0,28
ΔKw max. angular displacement
with n=1500 1/min [degree] 1,0 1,0 0,9 0,9 0,9 0,9 0,9 0,9 0,7 0,6 0,6 0,4
ΔKw max. angular displacement
with n=3000 1/min [degree] 0,7 0,7 0,6 0,6 0,6 0,6 0,6 0,6 0,5 0,4 0,4 0,3