KTR POLY Manual

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
Design PKD
KTR-N
sheet:
edition:
49612 E
1
5
Gezeichnet: 13.01.03 Sha/At Ersatz für: KTR-N v. 18.02.02 Verteiler
Urheberschutz
gemäß DIN 34
Geprüft: 14.01.03 Sha Ersetzt durch: W KVVA MKC
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.
The POLY type PKD enables a change of the elastomer package without having to
disassemble the drive or driven machine in case of low shaft distance dimension.
Table of Contents
1Technical Data
2Hints
2.1 General Hints
2.2 Safety and Advice Hints
2.3 General Hints to Danger
2.4 Proper Use
3Storage
4Assembly
4.1 Components of the Couplings
4.2 Hint regarding the finish bore
4.3 Assembly of the Coupling
4.4 Displacements -Alignment of the Couplings
5Enclosure A
Hints and instructions regarding the use in hazardous areas
5.1 Selection of the Coupling Size
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 Certificate of Conformity according to the EG Standards 94/9/EG
dated 23 March 1994

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
Design PKD
KTR-N
sheet:
edition:
49612 E
2
5
Gezeichnet: 13.01.03 Sha/At Ersatz für: KTR-N v. 18.02.02 Verteiler
Urheberschutz
gemäß DIN 34
Geprüft: 14.01.03 Sha Ersetzt durch: W KVVA MKC
1 Technical Data
Bild 2: Poly -Elastomerpaket
NBR (Perbunan) 92 ShA
picture 1: POLY design PKD
Components:
1cam part (preferably to be
used at the driving end)
2D flange hub
3D cam ring
Table 1: dimensions design PKD
dimensions [mm]finish bore
dmax. [mm] general thread of setscrew
POLY
size pilot bore compo-
nent 1 compo- nent 2D DHDDDl1, l2MDNELPKD Gttightening torque TA[Nm]
15 -50 45 157 90 75 65 35 21 4134 M8 15 10
17 -60 50 176 100 90 70 40 26 4144 M8 15 10
19 -75 65 195 125 107 75 45 27 4154 M8 15 10
20 -65 60 205 115 105 80 45 22 4164 M8 15 10
22 -85 75 224 140 129 90 59 38 4184 M10 20 17
25 -90 85 257 150 140 100 60 43 5205 M12 20 40
28 -100 95 288 165 160 110 65 44 5225 M12 20 40
30 -110 100 308 180 170 130 75 58 5265 M16 20 80
35 60 130 130 373 210 210 160 95 70 5325 M16 25 80
40 70 145 145 423 240 240 180 115 85 5365 M16 25 80
45 80 160 160 473 270 270 180 110 74 6366 M16 30 80
50 90 170 170 543 290 290 200 130 80 6406 M16 30 80
55 100 180 180 580 310 310 200 120 74 8408 M16 30 80
60 110 200 190 630 350 330 230 135 85 8468 M16 30 80
65 120 210 200 685 360 340 250 150 90 10 510 M16 30 80
Table 2: dimensions elastomer packages
coupling size 15 17 19 20 22 25 28 30 35 40 45 50 55 60 65
quantity of packages 1) 12 12 12 12 16 16 16 16 20 20 20 20 20 20 20
package size 33a 43b 45678910 11 12 13
h24,6 26,8 34,6 29,6 34,6 40,6 42,4 45,1 52,6 58,1 70,1 75,5 91,4 103
b27,2 27,7 34,9 29,6 34,9 40,0 43,7 60 59,9 69 79 81 98,2 108,1
dimensions
[mm] t16,1 18,4 19,6 18,4 19,6 22,2 23,7 22,3 29,6 29,3 36,3 42,5 44,3 48,5
1) Quantity for the complete coupling.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
Design PKD
KTR-N
sheet:
edition:
49612 E
3
5
Gezeichnet: 13.01.03 Sha/At Ersatz für: KTR-N v. 18.02.02 Verteiler
Urheberschutz
gemäß DIN 34
Geprüft: 14.01.03 Sha Ersetzt durch: W KVVA MKC
1 Technical Data
Table 3: torque and speed
POLY size 15 17 19 20 22 25 28 30
TKN 320 400 660 820 1100 1600 2500 3950torque
[Nm] TKmax. 640 800 1320 1640 2200 3200 5000 7900
max. speed n [1/min.] 1) 4300 3800 3500 3300 3000 2700 2350 2200
POLY size 35 40 45 50 55 60 65
TKN 6100 9000 14300 21500 27000 34000 46000torque
[Nm] TKmax. 12200 18000 28600 43000 54000 68000 92000
max. speed n [1/min.] 1) 1850 1600 1400 1300 1150 1050 980
1) For peripheral speeds of more than v=30 m/sec a dynamical balancing is necessary.
Table 4: cap screws DIN 912
coupling size 15 17 19 20 22 25 28 30 35 40 45 50 55 60 65
quantity of cap screws
DIN 912 2) 6666888810 10 10 10 10 10 10
screw size M8 M8 M8 M10 M8 M10 M10 M12 M12 M14 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 86 135 210 210 210 210 410
2) Quantity for the complete coupling.
!
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.
2 Hints
2.1 General Hints
Please read through these mounting instructions carefully before you set the coupling into operation.
The POLY coupling is 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.
Please pay special attention to the safety instructions!
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.
2.2 Safety and Advice Hints
STOP DANGER ! Danger of injury to persons.
!
CAUTION ! Damages on the machine possible.
FATTENTION ! Pointing to important items.
PRECAUTION ! Hints concerning explosion protection.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
Design PKD
KTR-N
sheet:
edition:
49612 E
4
5
Gezeichnet: 13.01.03 Sha/At Ersatz für: KTR-N v. 18.02.02 Verteiler
Urheberschutz
gemäß DIN 34
Geprüft: 14.01.03 Sha Ersetzt durch: W KVVA MKC
2 Hints
2.3 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.
2.4 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 4 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-coupling 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 packages 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%.
4 Assembly
Basically the coupling is supplied in individual parts. Before assembly the coupling has to be controlled for
completeness.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
Design PKD
KTR-N
sheet:
edition:
49612 E
5
5
Gezeichnet: 13.01.03 Sha/At Ersatz für: KTR-N v. 18.02.02 Verteiler
Urheberschutz
gemäß DIN 34
Geprüft: 14.01.03 Sha Ersetzt durch: W KVVA MKC
4 Assembly
4.1 Components of the Couplings
Components of POLY design PKD
Component
Quantity Designation Material Balancing Condition 1)
11cam part EN-GJL-250 2)
2see table 5 elastomer packages NBR (buna N)
92 ShA
2D 1flange hub EN-GJL-250 /
EN-GJS-400-15 2)
3D 1cam ring EN-GJL-250 2)
42set screw DIN 916 steel
5see table 5 cap screw DIN 912 steel
1) Component 2D,
3D and 5 is
balanced in
assembled
condition.
2) acc. to
customer’s
request
picture 3: POLY design PKD
Table 5:
coupling size 15 17 19 20 22 25 28 30 35 40 45 50 55 60 65
quantity of packages 1) 12 12 12 12 16 16 16 16 20 20 20 20 20 20 20
package size 33a 43b 45678910 11 12 13
quantity of cap screws
DIN 912 1) 6666888810 10 10 10 10 10 10
1) Quantity for the complete coupling (dimension elastomer packages -see table 2).
4.2 Hint regarding the finish bore
STOP
DANGER !
The maximum permissible bore diameters d (see table
1 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 machined by the customer have to observe
concentric running or axial running, respectively (see
picture 4).
•Please make absolutely sure to observe the figures for
dmax.
•Carefully align the hubs when the finish bores are
brought in.
•Please provide for a setscrew or an end plate for the
axial fastening of the hubs.
picture 4: concentric running
and axial running

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
Design PKD
KTR-N
sheet:
edition:
49612 E
6
5
Gezeichnet: 13.01.03 Sha/At Ersatz für: KTR-N v. 18.02.02 Verteiler
Urheberschutz
gemäß DIN 34
Geprüft: 14.01.03 Sha Ersetzt durch: W KVVA MKC
4 Assembly
4.3 Assembly of the Coupling
FATTENTION !
We recommend to check bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Heating the cam part and flange hub 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 parts causes burns.
We would recommend to wear safety gloves.
!
CAUTION !
During the assembly please make sure that the L dimension (see table 1) is observed, so
that the spacer and the driving flange do not conact each other during the operation.
Disregarding this hint may cause damage on the coupling.
•Plug cam ring and flange hub together (see picture 5).
•Hand-screw the parts first of all.
•Mount cam part and flange hub with cam ring to the shaft of the drive and driven side (see picture 6).
•Tighten the screws with a suitable torque wrench to the tightening torques TAmentioned in table 4.
•Insert the packages in the cam and the pocket section (see picture 7).
•Move the power packs in axial direction until the dimension E is achieved (see picture 8).
•If the power packs are already firmly assembled, axial movement of the hubs on the shafts allows for
adjusting the dimension E (see picture 8).
•Fasten the hubs by tightening the setscrews DIN 916 with cup point (see table 1).
picture 5: assembly of flange hub with cam ring picture 6: assembly of cam part and flange hub with cam ring

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
Design PKD
KTR-N
sheet:
edition:
49612 E
7
5
Gezeichnet: 13.01.03 Sha/At Ersatz für: KTR-N v. 18.02.02 Verteiler
Urheberschutz
gemäß DIN 34
Geprüft: 14.01.03 Sha Ersetzt durch: W KVVA MKC
4 Assembly
4.3 Assembly of the Coupling
picture 7: assembly of packages picture 8: coupling assembly
!
CAUTION !
Having set the coupling into operation, the tightening torque of the screws and wear of
elastomer packages have to be inspected in usual maintenance intervals.
4.4 Displacements -Alignment of the Couplings
The displacement figures shown in table 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 table 6). If the figures
are exceeded, the coupling is damaged.
In case of a use in hazardous areas for the explosion group IIC (marking II 2G c IIC T4) only
the half displacement figures (see table 6) are permissible.
Please note:
•Please check with a dial gauge, ruler or feeler whether the permissible displacement figures of table 6 can be
observed.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
Design PKD
KTR-N
sheet:
edition:
49612 E
8
5
Gezeichnet: 13.01.03 Sha/At Ersatz für: KTR-N v. 18.02.02 Verteiler
Urheberschutz
gemäß DIN 34
Geprüft: 14.01.03 Sha Ersetzt durch: W KVVA MKC
4 Assembly
4.4 Displacements -Alignment of the Couplings
axial displacements radial displacements angular displacements
LPKD perm. = LPKD + ∆KA[mm] ∆KW= Emax. -Emin. [mm]
picture 9: displacements
The radial and angular displacements can occur simultaneously. The sum V = ∆Kr + (Emax. -Emin.) shall not
exceed the values in table 6.
Example for the misalignment
combinations given in picture 10:
Example 1:
∆KR= 30%
∆KW= 70%
Example 2:
∆KR= 60%
∆KW= 40%
∆Ktotal = ∆KR+ ∆KW≤100 % picture 10: combinations of displacement
Table 6: displacement figures
coupling size 15 17 19 20 22 25 28 30 35 40 45 50 55 60 65
max. axial displacement ∆Ka [mm] ±2 ±2 ±2 ±2 ±2 ±2 ±2 ±2 ±3 ±3 ±3 ±3 ±4 ±4 ±4
n= bis 750
1/min 1,0 1,0 1,0 1,0 1,0 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 0,9 0,9 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 0,7 0,7 0,7 0,7 0,7 0,9 0,9 0,9 0,9 0,9 0,9 0,9
max. radial displace-
ment ∆Kr [mm]
or
max. angular displace-
ment ∆Kw [mm]
or
sum V n=3000
1/min 0,5 0,5 0,5 0,5 0,5 0,5 0,5 0,5 -------

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
Design PKD
KTR-N
sheet:
edition:
49612 E
9
5
Gezeichnet: 13.01.03 Sha/At Ersatz für: KTR-N v. 18.02.02 Verteiler
Urheberschutz
gemäß DIN 34
Geprüft: 14.01.03 Sha Ersetzt durch: W KVVA MKC
5 Enclosure A
Hints and instructions regarding the use in hazardous areas
design PKD: flange hub and cam ring / elastomer packages / cam part
5.1 Selection of the Coupling Size
If the coupling is used in explosion proof areas, the size must be selected in a way that there is a minimum
safety of s = 2,0 from the unit torque to the nominal torque of the coupling.
5.2 Control intervals for couplings in hazardous areas
explosion group control intervals
II 2G c IIB T4
The torsional backlash of the coupling (see chapter 5.3) according to Guideline 94/9/EG
(ATEX 95) must only be controlled if a friction of the elastomer packages (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 packages
must be effected after 3000 operating hours for the first time, after 6 months at the latest.
If you note an unconsiderable or no wear at the elastomer packages after this first
inspection, the further inspections can be effected, in case of the same operating
parameters, respectively after 6000 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 packages 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 2G c IIC T4
The torsional backlash of the coupling (see chapter 5.3) according to Guideline 94/9/EG
(ATEX 95) must only be controlled if a friction of the elastomer packages (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 packages
must be effected after 2000 operating hours for the first time, after 3 months at the latest.
If you note an unconsiderable or no wear at the elastomer packages after this first
inspection, the further inspections can be effected, in case of the same operating
parameters, respectively after 4000 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 packages 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.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
Design PKD
KTR-N
sheet:
edition:
49612 E
10
5
Gezeichnet: 13.01.03 Sha/At Ersatz für: KTR-N v. 18.02.02 Verteiler
Urheberschutz
gemäß DIN 34
Geprüft: 14.01.03 Sha Ersetzt durch: W KVVA MKC
5 Enclosure A
Hints and instructions regarding the use in hazardous areas
5.2 Control intervals for couplings in hazardous areas
picture 11: POLY design PKD
Checking of torsional backlash
Here the backlash between coupling cams and the elastomer packages must be checked by reverse backlash.
The friction / wear may be 20% of the original thickness of the elastomer package before exchanging the
elastomer packages. After having reached the limit of wear ∆smax. the elastomer packages must be exchanged
immediately, irrespective of the inspection intervals.
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 ≥∆smax. in mm, the elastomer packages must be exchanged.
Friction of ≥20% of the original thickness of the elastomer package -exchange necessary!
!
CAUTION !
When changing the elastomer packages please do only use packages 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 6). If the figures
are exceeded, the coupling is damaged.
picture 12: checking of the limit of wear picture 13: wear of elastomer packages

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
Design PKD
KTR-N
sheet:
edition:
49612 E
11
5
Gezeichnet: 13.01.03 Sha/At Ersatz für: KTR-N v. 18.02.02 Verteiler
Urheberschutz
gemäß DIN 34
Geprüft: 14.01.03 Sha Ersetzt durch: W KVVA MKC
5 Enclosure A
Hints and instructions regarding the use in hazardous areas
5.3 Approximate values of wear
Table 7: limits of wear
standard design design with low backlash
(enlarged elastomer packages)
POLY
size thickness of
elastomer
packages [mm]
friction
Xmax. [mm]
torsional
backlash
∆smax. [mm]
thickness of
elastomer
packages [mm]
friction
Xmax. [mm]
torsional
backlash
∆smax. [mm]
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 22,3 4,0 11,7 31,3 6,3 9,4
40 29,6 6,0 14,5 ---
45 29,3 6,0 15,4 ---
50 36,3 7,0 18,3 ---
55 42,5 8,5 20,4 ---
60 44,3 9,0 21,9 ---
65 48,5 10,0 24,0 ---
5.4 Permissible coupling materials in the hazardous area
In the explosion groups IIB and IIC only the following material combinations may be used:
EN-GJL-250 -EN-GJL-250 (old designation GG 25)
EN-GJS-400-15 -EN-GJS-400-15 (old designation GGG 40)
steel -steel
stainless steel -stainless steel
Aluminium as coupling material is generally excluded for the explosion area.
5.5 Marking of coupling for the hazardous area
Couplings for the use in hazardous areas are marked for the respectively permissible conditions of use.
Explosion group IIC: e. g. II 2G c IIC T4
In the marking II 2G c IIC T4 the explosion group IIB is included.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
Design PKD
KTR-N
sheet:
edition:
49612 E
12
5
Gezeichnet: 13.01.03 Sha/At Ersatz für: KTR-N v. 18.02.02 Verteiler
Urheberschutz
gemäß DIN 34
Geprüft: 14.01.03 Sha Ersetzt durch: W KVVA MKC
5 Enclosure A
Hints and instructions regarding the use in hazardous areas
5.6 Starting
Before putting the coupling into operation, check the tightness of the setscrews in the cam part 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 setscrews must be additionally secured against self-loosening to fix
the cam part and flange hub, e. g. with Loctite (medium strength).
Last but not least, the coupling protection against unintended contact must be fixed.
Coupling protection in the hazardous area.
Covering of the coupling
The couplings must be provided with firm coverings (if possible, made from stainless steel)
protecting the couplings against falling objects. There can be regular openings in the coverings
which may not exceed the following dimensions:
circular openings
diameter in mm rectangular openings side length in mm
top surface of the covering 44
side parts of the covering 88
The distance between the cover and the rotating parts must be at least 5 mm.
The cover must be electrically conductive and be included in the equipotential bonding. Bellhousings made from
aluminium and damping rings (NBR) can be used as connecting element between pump and electro motor if the
magnesium part is below 7,5 %. The cover may only be taken off after having stopped the unit.
During operation, please pay attention to
•strange running noises
•occurring vibrations.
!
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.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
Design PKD
KTR-N
sheet:
edition:
49612 E
13
5
Gezeichnet: 13.01.03 Sha/At Ersatz für: KTR-N v. 18.02.02 Verteiler
Urheberschutz
gemäß DIN 34
Geprüft: 14.01.03 Sha Ersetzt durch: W KVVA MKC
5 Enclosure A
Hints and instructions regarding the use in hazardous areas
5.7 Breakdowns, Causes and Elimination
breakdowns causes danger hints for
hazardous areas elimination
misalignment danger of ignition due
to sparking
1) put the unit out of operation
2) eliminate the reason for the
misalignment (e. g. loose foundation
bolts, break of the engine fixing, heat
expansion of unit components, change
of the assembly dimension E of the
coupling)
3) check coupling parts and exchange
damaged coupling parts
4) checking of wear see under point
Control
wear of elastomer
package, low / no
torque transmission
since coupling cams
slip through
danger of ignition due
to hot surfaces
1) put the unit out of operation
2) disassemble the coupling and remove
rests of the elastomer packages
3) check coupling parts and exchange
damaged coupling parts
4) insert elastomer packages, assemble
coupling parts
5) check alignment, correct if necessary
change of the
running noises
and / or occurring
vibrations
loose screws for
axial securement of
hubs
danger of ignition due
to sparking
1) put the unit out of operation
2) check alignment of coupling
3) tighten the screws to secure the hubs
and secure against self-loosening
4) check coupling parts and exchange
damaged coupling parts
5) checking of wear see under point
Control
break of the
elastomer packages
due to high shock
energy / overload,
coupling cams slip
through
danger of ignition due
to hot surfaces
1) put the unit out of operation
2) disassemble the coupling and remove
rests of the elastomer packages
3) check coupling parts and exchange
damaged coupling parts
4) insert elastomer packages, assemble
coupling parts
5) find out the reason of overload
failure of the
elastomer
packages operating
parameters do not
correspond to the
coupling
performance /
coupling cams slip
through
danger of ignition due
to hot surfaces
1) put the unit out of operation
2) check the operating parameters and
select a larger coupling (consider
installation space)
3) assemble new coupling size
4) check alignment

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
Design PKD
KTR-N
sheet:
edition:
49612 E
14
5
Gezeichnet: 13.01.03 Sha/At Ersatz für: KTR-N v. 18.02.02 Verteiler
Urheberschutz
gemäß DIN 34
Geprüft: 14.01.03 Sha Ersetzt durch: W KVVA MKC
5 Enclosure A
Hints and instructions regarding the use in hazardous areas
5.7 Breakdowns, Causes and Elimination
breakdowns causes danger hints for
hazardous areas elimination
failure of the
elastomer
packages
mistake in service of
the unit / coupling
cams slip through
danger of ignition due
to hot surfaces
1) put the unit out of operation
2) disassemble the coupling and remove
rests of the elastomer packages
3) check coupling parts and exchange
damaged coupling parts
4) insert elastomer packages, assemble
coupling parts
5) instruct and train the service staff
misalignment
1) put the unit out of operation
2) eliminate the reason for the
misalignment (e. g. loose foundation
bolts, break of the engine fixing, heat
expansion of unit components, change
of the assembly dimension E of the
coupling)
3) check coupling parts and exchange
damaged coupling parts
4) checking of wear see under point
Control
e. g. contact with
aggressive liquids /
oils, ozone-
influence, too high
ambient
temperatures etc.
effecting a physical
change of the
elastomer packages
1) put the unit out of operation
2) disassemble the coupling and remove
rests of the elastomer packages
3) check coupling parts and exchange
damaged coupling parts
4) insert elastomer packages, assemble
coupling parts
5) check alignment, correct if necessary
6) make sure that further physical
changes of the spider are excluded
premature wear of
elastomer
packages
ambient / contact
temperatures which
are too high for the
elastomer
packages, max.
permissible
-20 °C / +80 °C
danger of ignition due
to hot surfaces
1) put the unit out of operation
2) disassemble the coupling and remove
rests of the elastomer packages
3) check coupling parts and exchange
damaged coupling parts
4) insert elastomer packages, assemble
coupling parts
5) check alignment, correct if necessary
6) check and regulate ambient / contact
temperature

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
Design PKD
KTR-N
sheet:
edition:
49612 E
15
5
Gezeichnet: 13.01.03 Sha/At Ersatz für: KTR-N v. 18.02.02 Verteiler
Urheberschutz
gemäß DIN 34
Geprüft: 14.01.03 Sha Ersetzt durch: W KVVA MKC
5 Enclosure A
Hints and instructions regarding the use in hazardous areas
5.7 Breakdowns, Causes and Elimination
breakdowns causes danger hints for
hazardous areas elimination
premature wear of
elastomer
packages
(liquefaction of
material inside the
elastomer
packages cam)
drive vibrations danger of ignition due
to hot surfaces
1) put the unit out of operation
2) disassemble the coupling and remove
rests of the elastomer packages
3) check coupling parts and exchange
damaged coupling parts
4) insert elastomer packages, assemble
coupling parts
5) check alignment, correct if necessary
6) find out the reason for the vibrations
break of cams or
hubs
blockade due to
destroyed elastomer
packages
danger of ignition due
to sparking
1) put the unit out of operation
2) change complete coupling
3) check alignment
4) determine the cause, remove the
mistakes
FATTENTION !
KTR does not assume any liabilities or guarantees regarding the use of spare parts and
accessories which are not provided by KTR and for the damages resulting herefrom.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
POLY
Operating-/Assembly Instructions
Design PKD
KTR-N
sheet:
edition:
49612 E
16
5
Gezeichnet: 13.01.03 Sha/At Ersatz für: KTR-N v. 18.02.02 Verteiler
Urheberschutz
gemäß DIN 34
Geprüft: 14.01.03 Sha Ersetzt durch: W KVVA MKC
5 Enclosure A
Hints and instructions regarding the use in hazardous areas
5.8 Certificate of Conformity
Certificate of Conformity
corresponding to EG Standard 94/9/EG dated 23 March 1994
and to the legal regulations
The manufacturer -KTR Kupplungstechnik GmbH, D-48432 Rheine -states that the
POLY couplings
described in these mounting instructions and explosion-proof designed correspond to Article 1 (3) b)
of Standard 94/9/EG and comply with the general Safety and Health Requirements according to
enclosure II of Standard 94/9/EG.
The couplings are certified according to Type Examination Certificate IBExU02ATEXB007 X.
According to article 8 (1) of Standard 94/9/EG the technical documentation is deposited with the:
IBExU
Institut für Sicherheitstechnik GmbH
Fuchsmühlenweg 7
09599 Freiberg
Rheine, 20.08.02 ppa. i. V.
Date Dr. Norbert Partmann
Engineering Manager
Bernd Tenfelde
Product Manager