KTR RIGIFLEX-N Manual

KTR Kupplungstechnik
GmbH
D-48407 Rheine
RIGIFLEX®-N
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
47410 EN
1 of 19
6
Gezeichnet: 02.02.12 Kb/Sta Ersatz für: KTR-N vom 15.11.10Schutzvermerk
ISO 16016 beachten. Geprüft: 09.02.12 Kb Ersetzt durch:
RIGIFLEX®-N
Torsionally stiff, steel laminae couplings
type A
according to Standard 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
6
Gezeichnet: 02.02.12 Kb/Sta Ersatz für: KTR-N vom 15.11.10Schutzvermerk
ISO 16016 beachten. Geprüft: 09.02.12 Kb Ersetzt durch:
RIGIFLEX®-N is a torsionally stiff, flexible steel laminae coupling which is able to compensate
for shaft misalignment caused by, for example, thermal expansion.
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 Hints Regarding the Finish Bore
4.3 Assembly of the Coupling Hubs
4.4 Assembly of Spacer
4.5 Displacements - Alignment of the Couplings
4.6 Spares Inventory, Customer Service Addresses
5 Enclosure A
Hints and Instructions Regarding the Use in Hazardous Areas
5.1 Selection of the Coupling Size
5.2 Use in Hazardous Areas According to the Regulations
5.3 Control Intervals for Couplings in Hazardous Areas
5.4 Visual Check and Measures
5.5 Permissible Coupling Materials in the Hazardous Area
5.6 Marking of Coupling for the Hazardous Area
5.7 Starting
5.8 Breakdowns, Causes and Elimination
5.9 EC Certificate of Conformity according to the EC Standards 94/9/EC
dated 23 March 1994

KTR Kupplungstechnik
GmbH
D-48407 Rheine
RIGIFLEX®-N
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
47410 EN
3 of 19
6
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1 Technical Data
size 35 size 50 - 408
illustration 1: RIGIFLEX®-N, type A
Table 1: type A
Dimensions [mm]
General Thread for
setscrews
RIGIFLEX®-N
Size
Max.
finish
bore
[mm]
d1, d2D DAd
3l 1, l2l 3l 4E 1E
1) G t1t
2
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 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
On request of customer
M24 95 175
1) Other shaft distances available on request 2) Values Mxl see table 6

KTR Kupplungstechnik
GmbH
D-48407 Rheine
RIGIFLEX®-N
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
47410 EN
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1 Technical Data
Table 2: torque and speed
RIGIFLEX®-N Size 35 50 65 75 85 110 120 140 160
TKN 120 240 450 940 1700 2700 4500 9000 13000
TK max. 240 480 900 1880 3400 5400 9000 18000 26000
Torque
[Nm] TKW 30 120 225 470 850 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
TKN 17500 22500 32000 52500 86000 135000 210000
TK max. 35000 45000 64000 105000 172000 270000 420000
Torque
[Nm] TKW 8750 11250 16000 26250 43000 67500 105000
Max. speed n [rpm] 5600 5600 5200 4600 3900 3300 2900
RIGIFLEX®-N Size 168 198 218 258 308 348 408
TKN 23000 30000 42500 70000 115000 180000 280000
TK max. 46000 60000 85000 140000 230000 360000 560000
Torque
[Nm] TKW 11500 15000 21500 35000 57500 90000 140000
Max. speed n [rpm] 5600 5200 4600 3900 3300 2900 2500
RIGIFLEX®-N 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.
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 for the particular application (see RIGIFLEX®-N 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 laminae
package. 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 RIGIFLEX®-N 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.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
RIGIFLEX®-N
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
47410 EN
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2 Hints
2.3 Safety and Advice Hints
STOP
DANGER! Dangerofinjurytopersons.
! CAUTION! Damagesonthemachinepossible.
)A TTE NT IO N! Pointing to important items.
PRECAUTION! Hintsconcerningexplosionprotection.
2.4 General Hints of Danger
STOP
DANGER!
With assembly, operation and maintenance of the coupling it has to be made sure that the
entire drive train is protected against unintentional engagement. You can be seriously hurt
by rotating parts. Please make absolutely sure to read through and observe the following
safety instructions.
•All operations on and with the coupling have to be performed taking into account "safety first".
•Please make sure to disengage the power pack before you perform your work.
•Protect the power pack against unintentional engagement, e. g. by providing hints at the place of engagement
or removing the fuse for current supply.
•Do not touch the operation area of the coupling as long as it is in operation.
•Please protect the coupling against unintentional touch. Please provide for the necessary protection devices
and caps.
2.5 Proper Use
You may only assemble, operate and maintain the coupling if you
•carefully read through the mounting instructions and understood them
•had technical training
•are authorized to do so by your company
The coupling may only be used in accordance with the technical data (see table 1 and 2 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 RIGIFLEX®-N 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.
!
CAUTION!
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
RIGIFLEX®-N
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
47410 EN
6 of 19
6
Gezeichnet: 02.02.12 Kb/Sta Ersatz für: KTR-N vom 15.11.10Schutzvermerk
ISO 16016 beachten. Geprüft: 09.02.12 Kb Ersetzt durch:
4 Assembly
The spacer is supplied fully assembled. Before assembly the coupling has to be controlled for completeness.
4.1 Components of the Couplings
Components of RIGIFLEX®-N type A
Component Quantity Designation Component Quantity Designation
1 2 Coupling hub
2 1 Spacer complete 4 see table 4 Setscrews
DIN EN ISO 4029
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
Quantity of cap screws 1) 24 16 24 24 36 36 36 36 36
RIGIFLEX®-N Size 166 196 216 256 306 346 406
Quantity of cap screws 1) 24 24 36 36 36 36 36
RIGIFLEX®-N Size 168 198 218 258 308 348 408
Quantity of cap screws 1) 32 32 48 48 48 48 48
1) quantity each coupling
Table 4:
RIGIFLEX®-N Size 35 50 65 75 85 110 120 140 160
Quantity of setscrews 1) 2 2 2 2 2 2 2 2 2
RIGIFLEX®-N Size 166 196 216 256 306 346 406
Quantity of setscrews 1) 4 4 4 4 4 4 4
RIGIFLEX®-N Size 168 198 218 258 308 348 408
Quantity of setscrews 1) 4 4 4 4 4 4 4
1) quantity each coupling

KTR Kupplungstechnik
GmbH
D-48407 Rheine
RIGIFLEX®-N
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
47410 EN
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4 Assembly
4.2 Hints 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.
•Coupling hub bores machined by the customer have to observe concentric running or axial running,
respectively (see illustration 3).
•Please make absolutely sure to observe the figures for dmax.
•Carefully align the coupling hubs when the finish bores are brought in.
•Please use a setscrew according to DIN EN ISO 4029 with a cup point or an end plate to fasten the hubs
axially.
size 35 size 50 - 408
illustration 3: concentric running and axial running
!
CAUTION!
The orderer is responsible for all subsequently made machinings to unbored or pilot bored
and to finish machined coupling parts and spare parts. KTR does not assume any warranty
claims resulting from insufficient refinish.
PRECAUTION!
Any mechanical rework to couplings that are used in hazardous areas require an explicit
release by KTR.
The orderer must send a drawing to KTR acc. to which the manufacture must be made. KTR
checks this drawing and returns it to the orderer with approval.
KTR supplies unbored or pilot bored coupling parts and spare parts on explicit customer´s
request. 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 M20
Tightening torque TA[Nm] 4,8 4,8 10 10 17 17 40 40 140
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 80 140 140 140 140 140
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 80 140 140 140 140 140

KTR Kupplungstechnik
GmbH
D-48407 Rheine
RIGIFLEX®-N
Operating-/Assembly Instructions
KTR-N
sheet:
edition:
47410 EN
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4 Assembly
4.3 Assembly of the Coupling Hubs
)ATTENTION!
We recommend to check bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Heating the coupling hubs slightly (approx. 80 °C) allows for an easier installation onto the shaft.
PRECAUTION!
Please pay attention to the danger of ignition in hazardous areas.
STOP
DANGER!
Touching the heated coupling hubs causes burns.
We would recommend to wear safety gloves.
!
CAUTION!
During the assembly please make sure that the E dimension (see table 1) is observed, so
that the coupling parts do not contact each other during the operation.
Disregarding this hint may cause damage on the coupling.
For the axial alignment of the coupling the dimensions E (see table 1) are decisive. In order to adjust the right
dimension E you should proceed as follows:
•Push the coupling hubs onto the shaft of the drive and driven side.
•The inner sides of the coupling hubs must end flushly with the front sides of the shafts (illustration 4).
•Move the power pack in axial direction until you have reached dimension E (see table 1).
•Secure the coupling hubs by tightening the setscrews DIN EN ISO 4029 with cup point (see table 5).
illustration 4: assembly of the coupling hubs
ATTENTION!
For the applications in hazardous areas the setscrews to fasten the hubs as well as all
screw connections have to be secured against self-slackening additionally, e. g. by glueing
with Loctite (medium-tight).
Disassembly:
STOP
DANGER!
Falling parts can lead to personal injury or damage to the machine.
Secure the driving parts 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
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edition:
47410 EN
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4 Assembly
4.4 Assembly of the Spacer
•Align the coupling hubs so that the through holes from the
coupling hubs line up.
•Clean and degrease the centrings and contact surfaces at the
spacer and at the coupling hubs.
•Pull up the flanges of „spacer complete“ closer to the spacer at
the maximum value R (table 6) in each case by means of the
return screws (illustration 5).
•Insert the spacer between the hubs.
•Centre the spacer in the coupling hubs by unscrewing the
return screws.
!
CAUTION!
The return screws have to be removed for the
further assembly and the operation.
•Assemble the spacer to the coupling hubs with the cap screws
hand tight (illustration 6).
•Tighten the cap screws one after another and with several
revolutions until they all cap screws have the full tightening
torque (see table 7).
illustration 5
illustration 6
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 3900
!
CAUTION!
Having set the coupling into operation, the tightening torque of the cap screws has to be
investigated at regular maintenance intervals.
For spacers with axial limitation (as an option) please note the
following:
•Before mounting the spacer, remove the screws and discs of the
axial limitation.
•Having mounted the spacer completely, please re-assemble the
screws and discs of the axial limitation (illustration 7). Please
note the axial backlash S as per dimension sheet.
•Secure the screws against untightening by means of adhesive
(e. g. Loctite).
illustration 7

KTR Kupplungstechnik
GmbH
D-48407 Rheine
RIGIFLEX®-N
Operating-/Assembly Instructions
KTR-N
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edition:
47410 EN
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4 Assembly
4.5 Displacements - Alignment of the Couplings
The displacement figures shown in table 8 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 8). 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 8) are permissible.
Please note:
•The displacement figures mentioned in table 8 are maximum figures which must not arise in parallel. In case
of a simultaneous radial, axial and angular displacement, these values must be reduced (see illustration 9).
•Please check 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
Example for the misalignment
combinations given in illustration 9:
Example 1:
∆Kr= 10%
∆Kw= 80%
∆Ka= 10%
Example 2:
∆Kr= 30%
∆Kw= 30%
∆Ka= 40%
∆Ktotal = ∆Ka+ ∆Kr+ ∆Kw≤100 %
illustration 9:
combinations of
displacement