KTR POLY PKZ Series Manual

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
49610 EN
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Type PKZ
Type PKD
POLY
Torsionally flexible couplings types,
not failsafe
PKZ, PKD, PKA,
and their combinations
according to Standard 94/9/EC
(ATEX 95) for finish bored, pilot
bored and unbored couplings
Type PKA

KTR Kupplungstechnik
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D-48407 Rheine
POLY
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
49610 EN
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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 Hazardous Areas
5.1 Use in Hazardous Areas According to the Regulations
5.2 Control Intervals for Couplings in Hazardous Areas
5.3 Approximate Values of Wear
5.4 Permissible Coupling Materials in the 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

KTR Kupplungstechnik
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D-48407 Rheine
POLY
Operating-/Assembly Instructions
KTR-N
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edition:
49610 EN
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1 Technical Data
Components:
1 cam section
2Z pocket section
(to be preferably used
drive-sided)
picture 1: POLY, type PKZ
Table 1: dimensions - type PKZ
dimensions [mm]finish bore 1)
dmax. [mm] general thread for setscrews
POLY
size component
1
component
2Z DHD DZl
1, l2M ZN E LPKZ G t TA
[Nm]
weight 2)
[kg]
8 20 28 86 43 50 35 26 3 3 73 M5 18 2 1,47
9 28 38 97 55 65 40,5 30 7 3 84 M8 23 10 2,22
10 32 42 107 60 70 45 35 10 4 94 M8 27 10 2,86
12 35 48 131 70 80 55 43 11 4 114 M8 30 10 4,80
14 44 55 142 80 93 60 46 17 4 124 M8 10 10 6,26
15 50 60 157 90 100 65 52 21 4 134 M8 15 10 7,97
17 60 65 176 100 110 70 56 26 4 144 M8 15 10 10,43
19 75 75 195 125 125 75 63 27 4 154 M8 15 10 14,02
20 65 75 205 115 127 80 65 22 4 164 M8 15 10 17,17
22 85 85 224 140 140 90 75 38 4 184 M10 20 17 21,23
25 90 90 257 150 150 100 84 43 5 205 M12 20 40 29,19
28 100 100 288 165 165 110 90 44 5 225 M12 20 40 42,29
30 110 110 308 180 180 130 108 58 5 265 M16 20 80 54,70
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 9 10 12 14 15 17 19 20 22
TKN 42 72 100 170 210 320 400 660 820 1100torque
[Nm] TKmax. 84 144 200 340 420 640 800 1320 1640 2200
max. speed 1) n [rpm] 5000 5000 5000 5000 4800 4300 3800 3500 3300 3000
POLY size 25 28 30 35 40 45 50 55 60 65
TKN 1600 2500 3950 6100 9000 14300 21500 27000 34000 46000torque
[Nm] TKmax. 3200 5000 7900 12200 18000 28600 43000 54000 68000 92000
max. speed 1) n [rpm] 2700 2350 2200 1850 1600 1400 1300 1150 1050 980
1) For peripheral speeds of more than v=30 m/sec a dynamical balancing is necessary.

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1 Technical Data
Components:
1 cam section
(to be preferably used
drive-sided)
2D flange hub
3D cam ring
picture 2: POLY, type PKD
Table 3: dimensions - type PKD
dimensions [mm]finish bore 1)
dmax. [mm] general thread for setscrews
POLY
size
pilot
bore component
1
component
2D DHD DDl
1, l2M DN E LPKD G t TA
[Nm]
weight 2)
[kg]
15 - 50 45 157 90 75 65 35 21 4 134 M8 15 10 8,42
17 - 60 50 176 100 90 70 40 26 4 144 M8 15 10 10,37
19 - 75 65 195 125 107 75 45 27 4 154 M8 15 10 14,42
20 - 65 60 205 115 105 80 45 22 4 164 M8 15 10 17,18
22 - 85 75 224 140 129 90 59 38 4 184 M10 20 17 21,66
25 - 90 85 257 150 140 100 60 43 5 205 M12 20 40 29,75
28 - 100 95 288 165 160 110 65 44 5 225 M12 20 40 44,32
30 - 110 100 308 180 170 130 75 58 5 265 M16 20 80 55,64
35 60 130 130 373 210 210 160 95 70 5 325 M16 25 80 103,78
40 70 145 145 423 240 240 180 115 85 5 365 M16 25 80 146,66
45 80 160 160 473 270 270 180 110 74 6 366 M16 30 80 197,35
50 90 170 170 543 290 290 200 130 80 6 406 M16 30 80 287,36
55 100 180 180 580 310 310 200 120 74 8 408 M16 30 80 327,12
60 110 200 190 630 350 330 230 135 85 8 468 M16 30 80 446,05
65 120 210 200 685 360 340 250 150 90 10 510 M16 30 80 565,78
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
coupling size 15 17 19 20 22 25 28 30 35 40 45 50 55 60 65
quantity for cap screws
DIN EN ISO 4762 1) 6 6 6 6 8 8 8 8 10 10 10 10 10 10 10
screw size M8 M8 M8 M10 M8 M10 M10 M12 M12 M16 M16 M16 M16 M16 M20
screw length 30 25 25 30 30 30 40 40 55 55 60 65 70 75 75
tightening torque TA[Nm] 25 25 25 49 25 49 49 86 86 295 210 210 210 210 410
1) quantity for the complete coupling

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POLY
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1 Technical Data
Components:
1a / 2a coupling flange
1b spacer
2b driving flange
Component 1a with 1b to be preferably used
drive-sided.
picture 3: POLY, type PKA
Table 5: dimensions - type PKA
dimensions [mm]
general thread for setscrews
POLY
size
finish bore 1)
dmax. [mm]
component
1a/2a DHD
Fl 1, l2b MAE L LPKA L ZG t TA
[Nm]
weight 2)
[kg]
8 38 86 55 35 1,5 25,5 3 100 170 66 M5 15 2 3,04
100 182 63 4,26
9 45 97 70 41 1,5 30,5 3 140 222 103 M8 15 10 4,66
100 192 61 5,42
10 50 107 78 46 1,5 35,5 4 140 232 101 M8 20 10 5,88
100 210 55 9,49
140 250 95 10,15
12 60 131 95 55 1,5 43,0 4
180 290 135
M8 20 10
10,86
100 220 54 11,46
140 260 94 12,16
14 70 142 105 60 1,5 48,0 4
180 300 134
M8 25 10
13,01
100 230 53 14,77
140 270 93 15,63
180 310 133 16,50
15 70 157 110 65 1,5 49,5 4
250 380 203
M8 25 10
18,01
100 240 53 18,79
140 280 93 19,60
180 320 133 20,41
17 80 176 125 70 1,5 54,5 4
250 390 203
M8 25 10
21,83
140 290 91 24,63
180 330 131 25,91
19 90 195 135 75 1,5 59,5 4
250 400 201
M8 30 10
28,15
140 300 81 30,96
180 340 121 32,18
20 100 205 150 80 2,0 61,0 4
250 410 191
M8 30 10
34,79
180 360 127 37,79
22 105 224 160 90 2,0 71,0 4 250 430 197 M10 35 17 39,94
140 340 81 54,73
180 380 121 56,50
25 125 257 195 100 2,0 81,0 5
250 450 191
M12 40 40
59,60
140 360 74 75,22
180 400 114 77,84
28 140 288 215 110 2,0 91,0 5
250 470 184
M12 45 40
82,41
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 6: cap screws DIN EN ISO 4762
coupling size 8 9 10 12 14 15 17 19 20 22 25 28
quantity for cap screws
DIN EN ISO 4762 1) 4 5 5 5 5 6 6 6 6 8 8 8
screw size M6 M6 M6 M8 M8 M10 M10 M10 M10 M10 M10 M12
screw length 16 18 18 20 20 25 25 25 30 30 30 30
tightening torque TA[Nm] 10 10 10 25 25 49 49 49 49 49 49 86
1) each coupling flange

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D-48407 Rheine
POLY
Operating-/Assembly Instructions
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1 Technical Data
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)
coupling size 8 9 10 12 14 15 17 19 20 22
quantity of elements 1) 8 10 10 10 10 12 12 12 12 16
element size 1 2 3 3a 4 3b
b 18,4 24,9 27,2 27,7 34,9 29,6
t 10,0 15,3 16,1 18,4 19,6 18,4
dimensions
[mm] h 18,9 23,9 24,6 26,8 34,6 29,6
coupling size 25 28 30 35 40 45 50 55 60 65
quantity of elements 1) 16 16 16 20 20 20 20 20 20 20
element size 4 5 6 7 8 9 10 11 12 13
b 34,9 40,0 43,7 45,7 52,1 58,1 70,1 75,5 91,5 103,0
t 19,6 22,2 23,7 21,8 28,6 29,3 36,3 41,3 44,3 48,5
dimensions
[mm] h 34,6 40,6 42,4 60,0 59,7 69,0 79,0 81,0 98,2 108,1
1) quantity for the complete coupling
Table 8: dimensions of elastomer elements with excessive height (see picture 5)
coupling size 8 9 10 12 14 15 17 20 25 28 30 35
quantity of elements 1) 8 10 10 10 10 12 12 12 16 16 16 20
element size 1ü 2ü 3ü 4ü 5ü 6ü 7ü
b 18,2 25,0 28,0 35,1 40,9 43,3 45,7
b17,5 14,5 16,0 15,0 17,5 21,5 22,5
t 10,5 11,7 16,4 20,4 22,7 24,8 25,0
t111,8 17,5 18,7 22,9 23,9 28,6 21,8
dimensions
[mm]
h 18,7 24,2 24,3 35,0 39,4 41,1 60,0
1) quantity for the complete coupling
POLY 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.

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POLY
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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 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 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 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
STOP
DANGER! Dangerofinjurytopersons.
! CAUTION! Damagesonthemachinepossible.
)A TTEN T IO N ! Pointing to important items.
PRECAUTION! Hintsconcerningexplosionprotection.

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POLY
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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
•have 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 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.
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 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. 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 %.

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POLY
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4 Assembly
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
component 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 steel
picture 6: POLY, type PKZ
Components of POLY, type PKD
component quantity designation material balancing condition
1)
1 1 cam section EN-GJL-250 acc. to customers request
2 see table 9 elastomer elements NBR (buna N) 90 ShA
2D 1 flange hub EN-GJL-250/
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 see table 9 cap screw DIN EN ISO 4762 steel
1) Component 2D, 3D and 5 is balanced in assembled condition.
picture 7: POLY, type PKD

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POLY
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4 Assembly
4.1 Components of Couplings
Components of POLY, type PKA
component quantity designation material balancing condition1
1a/2a 2 coupling flange EN-GJL-250/S355 J2G3 balanced on request
1b 1 spacer EN-GJL-250
from length 100 mm
on balanced
2 see table 9 elastomer elements NBR (buna N) 90 ShA
2b 1 driving flange EN-GJL-250 generally balanced
4 2 setscrew DIN EN ISO 4029 steel
5 see table 9 cap screw DIN EN ISO 4762 steel
picture 8: POLY, type PKA
Table 9: quantity of elastomer elements and cap screws
coupling size 8 9 10 12 14 15 17 19 20 22
quantity of elements 1) 8 10 10 10 10 12 12 12 12 16
element size 1 2 3 3a 4 3b
quantity of
cap screws 2)
DIN EN ISO 4762
4 5 5 5 5 6 6 6 6 8
coupling size 25 28 30 35 40 45 50 55 60 65
quantity of elements 1) 16 16 16 20 20 20 20 20 20 20
element size 4 5 6 7 8 9 10 11 12 13
quantity of
cap screws 2)
DIN EN ISO 4762
8 8 8 10 10 10 10 10 10 10
1) for the complete coupling (dimension elastomer elements - see tables 7 and 8).
2) each coupling flange

KTR Kupplungstechnik
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D-48407 Rheine
POLY
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49610 EN
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4 Assembly
4.2 Assembly of the Coupling (General)
)ATTENTION!
We recommend 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.
STOP
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
•Assemble the cam and the pocket section onto the
shaft of the drive and the driven side (see picture 9).
picture 9: assembly of the cam and pocket section
•Insert the elastomer elements into the cam and the
pocket section (see picture 10).
•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).
picture 10: assembly of the elastomer elements
•Move the power packs in axial direction until the
dimension E is achieved (see picture 11).
•If the power packs are already firmly assembled,
axial movement of the cam or the pocket section on
the shafts allows for adjusting the dimension E (see
picture 11).
•Fasten the cam or the pocket section by tightening
the setscrews DIN EN ISO 4029 with cup point
(tightening torque see table 1).
picture 11: coupling assembly

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4 Assembly
4.4 Assembly of the Type PKD
•Plug flange hub and cam ring together
(see picture 12).
•Hand-screw the parts first of all.
picture 12: assembly of the flange hub with cam ring
•Assemble the cam section and flange hub with
cam ring to the shaft of the drive and driven side
(see picture 13).
•Tighten the screws with a suitable torque key to the
tightening torque TAshown in table 4.
picture 13: assembly of cam section and flange hub with cam ring
•Insert the elastomer elements in the cam section or
cam ring (see picture 14).
picture 14: assembly of the elastomer elements
•Move the power packs in axial direction until the
dimension E is achieved (see picture 15).
•If the power packs are already firmly assembled,
axial movement of the hubs on the shafts allows for
adjusting the dimension E (see picture 15).
•Fasten the hubs by tightening the setscrews
DIN EN ISO 4029 with cup point (tightening torque
see table 3).
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.

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D-48407 Rheine
POLY
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4 Assembly
4.5 Assembly of the Type PKA
•Assemble the coupling flanges onto the shaft of the
drive and the driven side (see picture 16).
•The inner side of the coupling flanges must end
flushly with the front sides of the shafts.
•Move the power packs in axial direction until the
dimension L is achieved (see table 5).
•Fasten the coupling flanges by tightening the
setscrews DIN EN ISO 4029 with cup point
(tightening torque see table 5).
picture 16: assembly of the coupling flanges
•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
•Put the assembled parts between the coupling
flanges (see picture 18).
•At first hand-screw the parts.
•Tighten the screws with a suitable torque key to the
tightening torque TAshown in table 6.
•Please check the L or the E dimension (see picture
18 and table 5).
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.

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D-48407 Rheine
POLY
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4 Assembly
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 .
!
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.
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.
!
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.
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.
Please note:
•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
ΔKror ΔKW.
•Please check with a dial gauge, ruler or feeler whether the permissible displacement figures of table 10 can be
observed.
axial displacements radial displacements angular displacements
LPKZ perm. = LPKZ + ΔKa [mm] ΔKw = Emax. - Emin. [mm]
picture 19: displacements

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4 Assembly
4.7 Displacements - Alignment of the Couplings
Continuation:
Example for the misalignment
combinations given in picture 20:
Example 1:
ΔKr= 30 %
ΔKw= 70 %
Example 2:
ΔKr= 60 %
ΔKw= 40 %
ΔKtotal = ΔKr + ΔKw ≤100 % picture 20: combinations of displacement
Table 10: displacement figures
coupling size 8 9 10 12 14 15 17 19 20 22
max. axial displacement ΔKa[mm] ±1 ±1 ±1 ±2 ±2 ±2 ±2 ±2 ±2 ±2
n= up to
750 1/min 0,8 0,8 0,8 0,8 0,8 1,0 1,0 1,0 1,0 1,0
n=1000 1/min 0,7 0,7 0,7 0,7 0,7 0,9 0,9 0,9 0,9 0,9
n=1500 1/min 0,5 0,5 0,5 0,5 0,5 0,7 0,7 0,7 0,7 0,7
max. radial
displacement ΔKr[mm]
or max. angular
displacement ΔKw
[mm] or
total V n=3000 1/min 0,3 0,3 0,3 0,3 0,3 0,5 0,5 0,5 0,5 0,5
coupling size 25 28 30 35 40 45 50 55 60 65
max. axial displacement ΔKa [mm] ±2 ±2 ±2 ±3 ±3 ±3 ±3 ±4 ±4 ±4
n= up to
750 1/min 1,0 1,0 1,0 1,2 1,2 1,2 1,2 1,2 1,2 1,2
n=1000 1/min 0,9 0,9 0,9 1,1 1,1 1,1 1,1 1,1 1,1 1,1
n=1500 1/min 0,7 0,7 0,7 0,9 0,9 0,9 0,9 0,9 0,9 0,9
max. radial
displacement ΔKr[mm]
or max. angular
displacement ΔKw
[mm] or
total V n=3000 1/min 0,5 0,5 0,5 - - - - - - -
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
parts on site.
Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage
under www.ktr.com.

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GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
49610 EN
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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 Hazardous Areas According to the Regulations
Conditions of operation in 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:
temperature class ambient or operating
temperature Tamax. surface temperature
T5, T4, T3, T2, T1 - 30 °C to + 80 °C 1) 100 °C
2)
T6 - 30 °C to + 65 °C 85 °C
Explanation:
The maximum surface temperatures result from each the maximum permissible ambient or operating temperature Taplus the
maximum temperature increase ΔT of 20 K which has to be taken into account.
1) The ambient or operating temperature Tais 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 I of category M2 (coupling is not approved for device category M1).
Permissible ambient temperature - 30 °C to + 80 °C.

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D-48407 Rheine
POLY
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
49610 EN
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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
3G
3D
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 the coupling type has to be considered: for POLY: ΔT = 20 K
II 2GD c IIB
T4, T5, T6
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.
II 2GD c IIC
T4, T5, T6
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 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
parameters.
picture 21: POLY type PKZ
Checking of torsional backlash
Here the backlash between coupling cams
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
elements. After having reached the limit of
wear Δsmax. the elastomer elements must
be exchanged immediately, irrespective of
the inspection intervals.

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D-48407 Rheine
POLY
Operating-/Assembly Instructions
KTR-N
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edition:
49610 EN
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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 ≥Δsmax. in mm, the elastomer elements must be exchanged.
Friction of ≥20% of the original thickness of the elastomer elements - exchange necessary!
!
CAUTION!
When changing the elastomer elements please do only use elements with the same Shore
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.
picture 22: checking of the limit of wear picture 23: wear of elastomer elements
Table 11: limits of wear
standard design design with low backlash
(enlarged elastomer elements)
POLY
size thickness of
elastomer
elements t [mm]
friction
Xmax. [mm]
torsional
backlash
Δsmax. [mm]
thickness of
elastomer
elements t [mm]
friction
Xmax. [mm]
torsional
backlash
Δsmax. [mm]
8 10,0 2,0 5,0 11,8 2,4 3,6
9 10,0 2,0 5,1 11,8 2,4 3,5
10 10,0 2,0 5,3 11,8 2,4 3,5
12 15,3 3,0 7,5 17,5 3,5 5,2
14 15,3 3,0 7,7 17,5 3,5 5,2
15 16,1 3,0 8,2 18,7 3,8 5,5
17 16,1 3,0 8,7 18,7 3,8 5,5
19 18,4 3,5 9,7 - - -
20 19,6 4,0 10,3 22,9 4,6 6,7
22 18,4 3,5 10,3 - - -
25 19,6 4,0 9,4 22,9 4,6 6,8
28 22,2 4,0 10,6 23,9 4,8 7,3
30 23,7 4,5 11,3 28,6 5,7 8,4
35 21,8 4,0 9,4 24,8 4,8 7,8

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D-48407 Rheine
POLY
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
49610 EN
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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
Rp0,2 ≥250 N/mm2are permitted for the use in hazardous areas.
Aluminium diecast is generally excluded for hazardous areas.
5.5 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: II 2G c IIC T6 bzw. T5 - 30 °C ≤Ta≤+ 65 °C bzw. + 80 °C
II 2D c T 100 °C - 30 °C ≤Ta≤+ 80 °C / I M2 c - 30 °C ≤Ta≤+ 80 °C
Short labelling: II 2GD c IIC T X / I M2 c X
The former marking
remains valid:
II 2G c IIC T4/T5/T6 - 30 °C ≤Ta≤+ 80/60/45 °C
II 2D c T 110 °C/I M2 c - 30 °C ≤Ta≤+ 80 °C
The labelling with Explosion Group llC includes the Explosion Groups llA and llB.
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.
5.6 Starting
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.

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D-48407 Rheine
POLY
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
49610 EN
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5 Enclosure A
Hints and Instructions Regarding the Use in Hazardous Areas
5.6 Starting
During operation, please pay attention to
•strange running noises
•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 ll (if possible, from stainless steel).
If the couplings are used in mining (appliance group l 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 ll.
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
circular openings
diameter in mm
rectangular openings
side length in mm
straight or bended slot
distance of the side limit
in mm
top surface of the covering 4 4 prohibited
side parts of the covering 8 8 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 µm no
electrostatic load can be expected. Multiple coatings that are thicker than 200 µm are prohibited for
explosion group llC.