KTR POLY PKZ Series Manual

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
49610 EN
1 of 24
9
Gezeichnet: 11.03.10 Pz/Bru Ersatz für: KTR-N vom 25.04.07Schutzvermerk
ISO 16016 beachten. Geprüft: 16.03.10 Pz Ersetzt durch:
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
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
49610 EN
2 of 24
9
Gezeichnet: 11.03.10 Pz/Bru Ersatz für: KTR-N vom 25.04.07Schutzvermerk
ISO 16016 beachten. Geprüft: 16.03.10 Pz Ersetzt durch:
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
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
49610 EN
3 of 24
9
Gezeichnet: 11.03.10 Pz/Bru Ersatz für: KTR-N vom 25.04.07Schutzvermerk
ISO 16016 beachten. Geprüft: 16.03.10 Pz Ersetzt durch:
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.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
49610 EN
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ISO 16016 beachten. Geprüft: 16.03.10 Pz Ersetzt durch:
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

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
49610 EN
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ISO 16016 beachten. Geprüft: 16.03.10 Pz Ersetzt durch:
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

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
49610 EN
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ISO 16016 beachten. Geprüft: 16.03.10 Pz Ersetzt durch:
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.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
49610 EN
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ISO 16016 beachten. Geprüft: 16.03.10 Pz 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 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.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
49610 EN
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ISO 16016 beachten. Geprüft: 16.03.10 Pz 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
•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 %.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
49610 EN
9 of 24
9
Gezeichnet: 11.03.10 Pz/Bru Ersatz für: KTR-N vom 25.04.07Schutzvermerk
ISO 16016 beachten. Geprüft: 16.03.10 Pz 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 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

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
49610 EN
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Gezeichnet: 11.03.10 Pz/Bru Ersatz für: KTR-N vom 25.04.07Schutzvermerk
ISO 16016 beachten. Geprüft: 16.03.10 Pz Ersetzt durch:
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