Ktr Rigiflex-n Manual

KTR Kupplungstechnik

GmbH

D-48407 Rheine

RIGIFLEX®-N

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

47410 EN

1 of 19

Please observe protection

note ISO 16016.

Drawn: 14.01.14 Kb/Sta Replaced for: KTR-N dated 28.05.13

Verified: 16.01.14 Kb Replaced by:

RIGIFLEX®-N

Torsionally stiff steel lamina coupling

type A

according to directive 94/9/EC (ATEX 95)

for finish bored, pilot

bored and unbored couplings

Size 35

Size 50 - 408

KTR Kupplungstechnik

GmbH

D-48407 Rheine

RIGIFLEX®-N

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

47410 EN

2 of 19

Please observe protection

note ISO 16016.

Drawn: 14.01.14 Kb/Sta Replaced for: KTR-N dated 28.05.13

Verified: 16.01.14 Kb Replaced by:

RIGIFLEX®-N is a torsionally stiff, flexible steel lamina coupling which is able to compensate

for shaft displacement, for example caused by thermal expansion.

Table of contents

1 Technical data

2 Advice

2.1 Coupling selection

2.2 General advice

2.3 Safety and advice symbols

2.4 General hazard warnings

2.5 Intended use

3 Storage

4 Assembly

4.1 Components of the couplings

4.2 Advice for finish bore

4.3 Assembly of the coupling hubs

4.4 Assembly of the spacer

4.5 Displacements - alignment of the couplings

4.6 Spares inventory, customer service addresses

5 Enclosure A

Advice and instructions regarding the use in hazardous locations

5.1 Selection of the coupling size

5.2 Intended use in hazardous locations

5.3 Inspection intervals for couplings in hazardous locations

5.4 Visual inspection and measures

5.5 Permissible coupling materials in hazardous locations

5.6 marking of coupling for hazardous locations

5.7 Start-up

5.8 Breakdowns, causes and elimination

5.9 EC certificate of conformity according to the EC directive 94/9/EC dated March 23,

1994

KTR Kupplungstechnik

GmbH

D-48407 Rheine

RIGIFLEX®-N

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

47410 EN

3 of 19

Please observe protection

note ISO 16016.

Drawn: 14.01.14 Kb/Sta Replaced for: KTR-N dated 28.05.13

Verified: 16.01.14 Kb Replaced by:

1 Technical data

Size 35 Size 50 - 408

Illustration 1: RIGIFLEX®-N, type A

Table 1: Type A

RIGIFLEX®-N

Size

Max.

finish

bore

[mm]

d1, d2

Dimensions [mm]

General Setscrew

D DAd

1, l2l

1) G t1t

35 50 - 75 70 38.5 8.5 1.5 6 100 140 - - - M6 15 -

50 50 70 95 55 50 12 1.0 9 100 140 - - - M6 10 -

65 65 100 126 75 62 12 2.0 10 100 140 180 - - M8 20 -

75 75 105 138 85 62 12 2.5 10 100 140 180 - - M8 20 -

85 85 120 156 95 72 15 2.5 12 - 140 180 200 250 M10 20 -

110 110 152 191 120 87 18 3.0 12 - 140 180 200 250 M10 25 -

120 120 165 213 130 102 20 3.0 12 - - 180 200 250 M12 25 -

140 140 200 265 160 126 25 4.0 15 - - - 200 250 M12 30 -

160 160 230 305 170 145 31 5.0 15 - - - - 250 M12 30 -

166 160 230 305 184 155 31 2.0 17

According to customer spe-

cification

M16 30 70

196 190 260 330 200 185 32 2.5 24 M16 40 90

216 210 285 370 220 205 32 2.5 26 M20 50 110

256 250 350 440 265 245 38 2.5 31 M20 70 130

306 300 400 515 310 295 43 3.0 36 M24 70 130

346 340 460 590 370 335 55 3.0 45 M24 95 175

406 400 530 675 420 395 58.5 3.0 50 M24 95 175

168 160 230 305 184 155 31 2.0 17 M16 30 70

198 190 260 330 200 185 32 2.5 24 M16 40 90

218 210 285 370 220 205 32 2.5 26 M20 50 110

258 250 350 440 265 245 38 2.5 31 M20 70 130

308 300 400 515 310 295 43 3.0 36 M24 70 130

348 340 460 590 370 335 55 3.0 45 M24 95 175

408 400 530 675 420 395 58.5 3.0 50 M24 95 175

1. Other shaft distance dimensions available on request

2. For figures Mxl see table 7

KTR Kupplungstechnik

GmbH

D-48407 Rheine

RIGIFLEX®-N

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

47410 EN

4 of 19

Please observe protection

note ISO 16016.

Drawn: 14.01.14 Kb/Sta Replaced for: KTR-N dated 28.05.13

Verified: 16.01.14 Kb Replaced by:

1 Technical data

Table 2: Torque and speed

RIGIFLEX

-N size 35 50 65 75 85 110 120 140 160

Torque

[Nm]

TKN 120 240 450 940 1700 2700 4500 9000 13000

TK max. 240 480 900 1880 3400 5400 9000 18000 26000

TKW 60 120 225 470 850 1350 2250 4500 6500

Max. speed n [rpm] 23000 18000 13600 12400 11000 9000 8000 6400 5600

RIGIFLEX

-N size 166 196 216 256 306 346 406

Torque

[Nm]

TKN 17500 22500 32000 52500 86000 135000 210000

TK max. 35000 45000 64000 105000 172000 270000 420000

TKW 8750 11250 16000 26250 43000 67500 105000

Max. speed n [rpm] 5600 5200 4600 3900 3300 2900 2500

RIGIFLEX

-N size 168 198 218 258 308 348 408

Torque

[Nm]

TKN 23000 30000 42500 70000 115000 180000 280000

TK max. 46000 60000 85000 140000 230000 360000 560000

TKW 11500 15000 21500 35000 57500 90000 140000

Max. speed n [rpm] 5600 5200 4600 3900 3300 2900 2500

RIGIFLEX

-N couplings with attachments that can generate heat, sparks and static charging

(e. g. combinations with brake drums, brake disks, overload systems like torque limiters,

fans etc.) are not permitted for the use in hazardous locations.

A separate analysis must be performed.

2 Advice

2.1 Coupling selection

CAUTION!

For a long-lasting and failure-free operation of the coupling it must be selected according to

the selection instructions for the particular application (see RIGIFLEX®-N catalogue).

If the operating conditions (performance, speed, modifications on engine and machine)

change, the coupling selection must be reviewed again.

Please note that the technical data regarding torque refer to the lamina set only. The trans-

mittable torque of the shaft/hub connection must be reviewed by the customer and is sub-

ject to his responsibility.

For drives subject to torsional vibrations (drives with cyclic stress due to torsional vibrations) it is necessary to

perform a torsional vibration calculation to ensure a reliable selection. Typical drives subject to torsional vibrations

are e. g. drives with diesel engines, piston pumps, piston compressors etc. If requested, KTR will perform the

coupling selection and the torsional vibration calculation.

2.2 General advice

Please read through these assembly instructions carefully before you start up the coupling.

Please pay special attention to the safety instructions!

The RIGIFLEX

-Ncoupling is suitable and approved for the use in hazardous locations. When using

the coupling in hazardous locations please observe the special advice and instructions regarding

safety in enclosure A.

The assembly instructions are part of your product. Please keep them carefully and close to the coupling.

The copyright for these assembly instructions remains with KTR Kupplungstechnik GmbH.

KTR Kupplungstechnik

GmbH

D-48407 Rheine

RIGIFLEX®-N

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

47410 EN

5 of 19

Please observe protection

note ISO 16016.

Drawn: 14.01.14 Kb/Sta Replaced for: KTR-N dated 28.05.13

Verified: 16.01.14 Kb Replaced by:

2 Advice

2.3 Safety and advice symbols

STOP

DANGER! Dangerofinjurytopersons.

! CAUTION! Damagesonthemachinepossible.

A TTE NT IO N! Pointing to important items.

WARNING! Hintsconcerningexplosionprotection.

2.4 General hazard warnings

STOP

DANGER!

With assembly, operation and maintenance of the coupling it has to be made sure that the

entire drive train is secured against accidental switch-on. You may be seriously hurt by ro-

tating parts. Please make absolutely sure to read through and observe the following safety

indications.

All operations on and with the coupling have to be performed taking into account "safety first".

Please make sure to switch off the power pack before you perform your work on the coupling.

Secure the power pack against accidental switch-on, e. g. by providing warning signs at the place of switch-on

or removing the fuse for current supply.

Do not touch the operation area of the coupling as long as it is in operation.

Please secure the coupling against accidental contact. Please provide for the necessary protection devices

and covers.

2.5 Intended use

You may only assemble, operate and maintain the coupling if you

have carefully read through the assembly instructions and understood them

had technical training

are authorized by your company

The coupling may only be used in accordance with the technical data (see table 1 and 2 in chapter 1). Unauthor-

ized modifications on the coupling design are not admissible. We will not assume liability for any damage that

may arise. In the interest of further development we reserve the right for technical modifications.

The RIGIFLEX®-N described in here corresponds to the technical status at the time of printing of these assembly

instructions.

3 Storage

The couplings are supplied in preserved condition and can be stored at a dry and covered place for 6 - 9 months.

CAUTION!

Humid storage rooms are not suitable.

Please make sure that condensation is not generated. The best relative air humidity is less

than 65 %.

KTR Kupplungstechnik

GmbH

D-48407 Rheine

RIGIFLEX®-N

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

47410 EN

6 of 19

Please observe protection

note ISO 16016.

Drawn: 14.01.14 Kb/Sta Replaced for: KTR-N dated 28.05.13

Verified: 16.01.14 Kb Replaced by:

4 Assembly

The spacer is supplied fully assembled. Before assembly the coupling has to be inspected for completeness.

4.1 Components of the couplings

Components of RIGIFLEX®-N type A

Component Quantity Description Component Quantity Description

1 2 Coupling hub 4 see table 4 Setscrews DIN EN ISO

4029

2 1 Spacer complete

3 see table 3 Cap screws

Size 35 Size 50 - 408

Illustration 2: RIGIFLEX®-N, type A

Table 3:

RIGIFLEX

-N size 35 50 65 75 85 110 120 140 160

Number of cap screws

24 16 24 24 36 36 36 36 36

RIGIFLEX

-N size 166 196 216 256 306 346 406

Number of cap screws

24 24 36 36 36 36 36

RIGIFLEX

-N size 168 198 218 258 308 348 408

Number of cap screws

32 32 48 48 48 48 48

1) Number per coupling

Table 4:

RIGIFLEX

-N size 35 50 65 75 85 110 120 140 160

Number of setscrews

2 2 2 2 2 2 2 2 2

RIGIFLEX

-N size 166 196 216 256 306 346 406

Number of setscrews

4 4 4 4 4 4 4

RIGIFLEX

-N size 168 198 218 258 308 348 408

Number of setscrews

4 4 4 4 4 4 4

1) Number per coupling

KTR Kupplungstechnik

GmbH

D-48407 Rheine

RIGIFLEX®-N

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

47410 EN

7 of 19

Please observe protection

note ISO 16016.

Drawn: 14.01.14 Kb/Sta Replaced for: KTR-N dated 28.05.13

Verified: 16.01.14 Kb Replaced by:

4 Assembly

4.2 Advice for 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 danger to life.

Bores of coupling hubs machined by the customer have to observe concentricity or axial runout, respectively

(see illustration 3).

Please make absolutely sure to observe the figures for Ø dmax.

Carefully align the coupling hubs when the finish bores are drilled.

Please provide for a setscrew according to DIN EN ISO 4029 with a cup point or an end plate to fasten the

coupling hubs axially.

CAUTION!

A centering is not available with pilot bored or unbored hubs, respectively. It has to be

drilled according to illustration 3. Size and depth of the centering are shown in table 1.

Size 35 Size 50 - 408

Illustration 3: Concentricity and axial runout

CAUTION!

The customer bears the sole responsibility for all machining processes performed subse-

quently on unbored or pilot bored as well as finish machined coupling components and

spare parts. KTR does not assume any warranty claims resulting from insufficient rema-

chining.

WARNING!

KTR supplies unbored or pilot bored coupling components and spare parts only upon ex-

plicit request of the customer. These parts are additionally labelled with the symbol .

Table 5: Setscrews DIN EN ISO 4029

RIGIFLEX

-N size 35 50 65 75 85 110 120 140 160

Dimension G [mm] M6 M6 M8 M8 M10 M10 M12 M12 M12

Tightening torque TA[Nm] 4.8 4.8 10 10 17 17 40 40 40

RIGIFLEX

-N size 166 196 216 256 306 346 406

Dimension G [mm] M16 M16 M20 M20 M24 M24 M24

Tightening torque TA[Nm] 80 80 140 140 240 240 240

RIGIFLEX

-N size 168 198 218 258 308 348 408

Dimension G [mm] M16 M16 M20 M20 M24 M24 M24

Tightening torque TA[Nm] 80 80 140 140 240 240 240

KTR Kupplungstechnik

GmbH

D-48407 Rheine

RIGIFLEX®-N

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

47410 EN

8 of 19

Please observe protection

note ISO 16016.

Drawn: 14.01.14 Kb/Sta Replaced for: KTR-N dated 28.05.13

Verified: 16.01.14 Kb Replaced by:

4 Assembly

4.3 Assembly of the coupling hubs

ATTENTION!

We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy

before assembly.

Heating the coupling hubs lightly (approx. 80 °C) allows for an easier mounting on the shafts.

WARNING!

Please pay attention to the ignition risk in hazardous locations!

STOP

DANGER!

Touching the heated coupling hubs causes burns.

Please wear safety gloves.

CAUTION!

With the assembly please make sure that the distance dimension E (see table 1) is observed

so that the coupling components are not in contact with each other during the operation.

Disregarding this advice may cause damage to the coupling.

For the axial alignment of the coupling the distance dimension E (see table 1) is decisive. In order to adjust the

right dimension E you should proceed as follows:

Shift the coupling hubs on the shaft of the driving and driven side.

The internal sides of the coupling hubs must be flush with the front sides of the shafts (illustration 4).

Align the power pack in axial direction until the distance dimension E is achieved (see table 1).

Fasten the coupling hubs by tightening the setscrews DIN EN ISO 4029 with a cup point (see table 5).

Illustration 4: Assembly of the coupling hubs

WARNING!

If used in hazardous locations the setscrews to fasten the hubs as well as all screw connec-

tions must be secured against working loose additionally, e. g. conglutinating with Loctite

(average strength).

Disassembly:

STOP

DANGER!

Components falling down may lead to personal injury or damage on the machine.

Secure the driving components during disassembly.

Untighten the setscrew in the hub and unscrew it by 2 – 3 convolutions.

Pull the hub from the shaft.

KTR Kupplungstechnik

GmbH

D-48407 Rheine

RIGIFLEX®-N

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

47410 EN

9 of 19

Please observe protection

note ISO 16016.

Drawn: 14.01.14 Kb/Sta Replaced for: KTR-N dated 28.05.13

Verified: 16.01.14 Kb Replaced by:

4 Assembly

4.4 Assembly of the spacer

The coupling hubs have to be aligned such that the through

holes of the coupling hubs line up.

Clean and degrease the centerings and contact surfaces on the

spacer and coupling hubs.

Pull up the flanges of „spacer complete“ closer to the spacer

each at the maximum value R (table 6) by means of the retaining

screws (illustration 5).

Insert the spacer between the hubs.

Centre the spacer in the coupling hubs by unscrewing and re-

moving the retaining screws.

Illustration 5

Illustration 6

CAUTION!

The retaining screws have to be removed for the

further assembly and the operation.

Hand-screw the spacer to the coupling hubs via the cap screws

(illustration 6).

Tighten the cap screws one after another and with several revo-

lutions until all cap screws have reached the full tightening torque

(see table 7).

Table 6:

RIGIFLEX

-N size 35 50 65 75 85 110 120 140 160

Value R [mm] 1.7 1.2 1.2 1.7 1.7 2.2 2.2 3.2 4.2

RIGIFLEX

-N size 166 / 168 196 / 198 216 / 218 256 / 258 306 / 308 346 / 348 406 / 408

Value R [mm] 2.2 2.7 2.7 2.7 3.2 3.2 3.2

Table 7: Tightening torques of the cap screws

RIGIFLEX

-N size 35 50 65 75 85 110 120 140 160

Dimension Mxl [mm] M4x45 M6x22 M6x25 M8x30 M8x30 M10x35 M12x40 M16x50 M16x55

Tightening torque TA[Nm] 4.1 14 14 35 35 69 120 295 295

RIGIFLEX

-N size 166 / 168 196 / 198 216 / 218 256 / 258 306 / 308 346 / 348 406 / 408

Dimension Mxl [mm] M20x50 M20x50 M20x65 M24x80 M27x100 M30x110 M36x130

Tightening torque TA[Nm] 560 560 560 970 1450 1950 3300

CAUTION!

Having started up the coupling, the tightening torque of the cap screws has to be inspected

at regular maintenance intervals.

For spacers with axial limitation (as an option) please note the follow-

ing:

Before mounting the spacer, remove the screws and disks for

axial limitation.

Having mounted the spacer completely, please re-assemble the

screws and disks of the axial limitation (illustration 7). Please ob-

serve the axial backlash S as per dimension sheet.

Secure the screws against working loose by means of an adhe-

sive (Loctite).

Illustration 7

KTR Kupplungstechnik

GmbH

D-48407 Rheine

RIGIFLEX®-N

Operating/Assembly instructions

KTR-N

Sheet:

Edition:

47410 EN

10 of 19

Please observe protection

note ISO 16016.

Drawn: 14.01.14 Kb/Sta Replaced for: KTR-N dated 28.05.13

Verified: 16.01.14 Kb Replaced by:

4 Assembly

4.5 Displacements - alignment of the coupling

The displacement figures shown in table 8 provide for sufficient safety to compensate for external influences like,

for example, thermal expansion or foundation settling.

CAUTION!

In order to ensure a long service life of the coupling and avoid dangers with the use in haz-

ardous locations, the shaft ends must be accurately aligned.

Please absolutely observe the displacement figures indicated (see table 8). If the figures are

exceeded, the coupling will be damaged.

The more accurate the alignment of the coupling, the longer is its service life.

If used in hazardous locations for the explosion group IIC (marking II 2GD c IIC T X), only

half of the displacement figures (see table 8) are permissible.

Please note:

The displacement figures mentioned in table 8 are maximum figures which must not arise in parallel. If radial,

axial and angular displacement arises at the same time, these values must be reduced (see illustration 9).

Please inspect with a dial gauge, ruler or feeler whether the permissible displacement figures of table 8 can be

observed.

Angular displacements Radial displacements Axial displacements

Illustration 8: Displacements

Examples for the displacement combina-

tions given in illustration 9:

Example 1:

Kr= 10%

Kw= 80%

Ka= 10%

Example 2:

Kr= 30%

Kw= 30%

Ka= 40%

Illustration 9:

Combinations of dis-

placement

Ktotal = Ka+ Kr+ Kw100 %

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