KTR ROTEX ZS-DKM Series User manual

KTR Kupplungstechnik
GmbH
D-48407 Rheine
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
40224 E
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design ZS-DKM1
design ZS-DKM3
ROTEX®
Torsionally flexible jaw-type
couplings types
ZS-DKM,
ZS-DKM-H
and their combinations
according to Standard 94/9/EC
(ATEX 95) for finish bored, pilot
bored and unbored couplings
design ZS-DKM-H

KTR Kupplungstechnik
GmbH
D-48407 Rheine
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
40224 E
2
4
Gezeichnet: 14.07.06 Sha/At Ersatz für:Schutzvermerk
ISO 16016 beachten. Geprüft: 07.08.06 Sha Ersetzt durch:
ROTEX®is a torsionally flexible jaw coupling. It is able to compensate for shaft displacement
caused by, as an example, inaccuracies in production, heat expansion, etc.
The ROTEX®design ZS-DKM and ZS-DKM-H is suitable for a larger radial misalignment due
to its double cardanic type. The standard type can only be used for the horizontal assembly.
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 Hint Regarding the Finish Bore
4.3 Assembly of the Hubs
4.4 Assembly of the Design ZS-DKM1
4.5 Assembly of the Design ZS-DKM3
4.6 Assembly of the Design ZS-DKM-H
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
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
40224 E
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1 Technical Data
Design ZS-DKM1
picture 1: ROTEX®, design ZS-DKM1
Table 1: dimensions – design ZS-DKM1
dimensions
[mm]
size
finish
bore
dmax.
[mm]
spider
compo-
nent 2 1)
TKN
[Nm] DHD dHl
1; l2E s b l7l 62) D 4
24 35 35 55 - 27 30 18 2 14 8 6/9 45
28 40 95 65 - 30 35 20 2,5 15 10
3) 6/9 54
38 48 190 80 66 38 45 24 3 18 10 4/9 66
42 55 265 95 75 46 50 26 3 20 12 6/9 80
48 62 310 105 85 51 56 28 3,5 21 12 6/9 90
55 74 410 120 98 60 65 30 4 22 16 6/9 102
65 80 625 135 115 68 75 35 4,5 26 16 9 116
75 95 1280 160 135 80 85 40 5 30 19 9 136
90 110 2400 200 160 100 100 45 5,5 34 20 10 172
100 115 3300 225 180 105 110 50 6 38 25 15 195
dimensions
[mm]
Lz– dimension for shaft distance dimension L
[mm]
hexagon head cap screws
DIN EN ISO 4017 – 10.9
size
daL
ZS-DKM1 100 120 140 160 180 200 250 Mxl z
4) TA
[Nm]
24 30 L+60 48 68 88 108 128 148 198 M5x14
5) 8 6
28 38 L+70 40 60 80 100 120 140
3) 190 3) M6x16 8 14
38 44 L+90 32 52 72 92 112 132 182 M8x18
6) 8 35
42 56 L+100 - 44 64 84 104 124 174 M8x18 8 35
48 62 L+112 - 40 60 80 100 120 170 M8x18 8 35
55 68 L+130 - - 48 68 88 108 158 M10x20 8 69
65 91 L+150 - - - 58 78 98 148 M10x25 8 69
75 102 L+170 - - - - 62 82 132 M12x25 10 120
90 132 L+200 - - - - - 70 120 M16x30 10 295
100 140 L+220 - - - - - - 100 M16x40 10 295
1) maximum torque of the coupling TKmax. = rated torque of the coupling TKN x 2
size 24 to size 75 – spider type 95/98 Sh A-GS; from size 90 on – spider type 95 Sh A with internal ring
transmittable torque according to 92 Sh A-GS
2) narrow width of flange l6with min. Lz-dimension
3) when dimension L = 200 mm and L = 250 mm dimension l7is 30 mm
4) each flange connection
5) property class 8.8
6) M8x12 for Lz= 100

KTR Kupplungstechnik
GmbH
D-48407 Rheine
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
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1 Technical Data
Design ZS-DKM3
picture 2: ROTEX®, design ZS-DKM3
Tabelle 2: dimensions – design ZS-DKM3
dimensions
[mm]
size
finish
bore
d1max.
[mm]
spider
compo-
nent 2 1)
TKN
[Nm] DHD
FD 4d Hl 1; l2l 3; l4l 6l 7
24 24 35 55 36 45 27 30 30,5 10 8
28 28 95 65 42 54 30 35 35,5 12 10
38 38 190 80 52 66 38 45 45,5 12 10
42 42 265 95 62 80 46 50 51,0 13 12
48 48 310 105 70 90 51 56 57,0 13 12
55 55 410 120 80 102 60 65 66,0 15 16
65 65 625 135 94 116 68 75 76,0 15 16
75 75 1280 160 108 136 80 85 86,5 20 19
90 100 2400 200 142 172 100 100 101,5 20 20
dimensions
[mm]
l11 – dimension for shaft distance
dimension E1[mm]
cap screws
DIN EN ISO 4762 – 12.9
size
s b E LZS-DKM3 100 140 180 250 Mxl z
2) TA
[Nm]
24 2,0 14 18 E1+61 49 - - - M5x16 8 10
28 2,5 15 20 E1+71 41 81 - - M6x20 8 17
38 3,0 18 24 E1+91 33 73 - - M8x22 8 41
42 3,0 20 26 E1+102 26 66 - - M8x25 12 41
48 3,5 21 28 E1+114 22 62 - - M8x25 12 41
55 4,0 22 30 E1+132 10 50 90 - M10x30 8 83
65 4,5 26 35 E1+152 - 40 80 - M10x30 12 83
75 5,0 30 40 E1+173 - 25 65 135 M12x40 15 120
90 5,5 34 45 E1+203 - - 53 123 M16x40 15 295
1) maximum torque of the coupling TKmax. = rated torque of the coupling TKN x 2
size 24 to size 75 – spider type 95/98 Sh A-GS; from size 90 on – spider type 95 Sh A with internal ring
transmittable torque according to 92 Sh A-GS
2) each flange connection

KTR Kupplungstechnik
GmbH
D-48407 Rheine
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
40224 E
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1 Technical Data
Design ZS-DKM-H
picture 3: ROTEX®, design ZS-DKM-H
Table 3: dimensions – design ZS-DKM-H
dimensions
[mm]
size
finish
bore
dmax.
[mm]
spider
compo-
nent 2 1)
TKN [Nm] DHD dHl
1; l2x 1; x2s b E
24 28 35 55 - 27 30 22,5 2,0 14 18
28 38 95 65 - 30 35 25,5 2,5 15 20
38 45 190 80 - 38 45 35,5 3,0 18 24
42 55 265 95 85 46 50 39,0 3,0 20 26
48 60 310 105 95 51 56 45,0 3,5 21 28
55 70 410 120 110 60 65 50,0 4,0 22 30
65 80 625 135 115 68 75 60,0 4,5 26 35
75 90 1280 160 135 80 85 67,5 5,0 30 40
90 110 2400 200 160 100 100 81,5 5,5 34 45
dimensions
[mm]
l11 – dimension for shaft distance
dimension L [mm]
cap screws
DIN EN ISO 4762 – 12.9
weight 3) for shaft distance
dimension L [kg]
size
LZS-DKM-H 100 140 180 250 Mxl z
2) TA
[Nm] 100 140 180 250
24 L+45 49 89 - - M6x20 2 14 1,40 1,60 - -
28 L+51 41 81 - - M8x25 2 35 1,90 2,20 - -
38 L+71 33 73 - - M8x30 2 35 3,90 4,10 - -
42 L+78 26 66 - - M10x30 2 69 5,10 5,70 - -
48 L+90 22 62 - - M12x35 2 120 7,10 7,90 - -
55 L+100 10 50 90 - M12x40 2 120 9,50 11,20 12,30 -
65 L+120 - 40 80 - M12x40 2 120 - 16,10 16,80 -
75 L+135 - 25 65 135 M16x50 2 295 - 23,60 26,00 29,50
90 L+163 - - 53 123 M20x60 2 580 - - 48,90 52,60
1) maximum torque of the coupling TKmax. = rated torque of the coupling TKN x 2
size 24 to size 75 – spider type 95/98 Sh A-GS; from size 90 on – spider type 95 Sh A with internal ring
transmittable torque according to 92 Sh A-GS
2) each clamping hub tpye DH
3) refer to max. bore
ROTEX®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
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
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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 ROTEX®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 spider. 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 ROTEX®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 TTE NT IO N! Pointing to important items.
PRECAUTION! Hintsconcerningexplosionprotection.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
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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
•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 3 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 ROTEX®ZS-DKM and ZS-DKM-H 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 coupling spiders (elastomers) 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
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
40224 E
8
4
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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 ZS-DKM1
component quantity designation component quantity designation
1 2 hub
2 2 spider 5 s. table 1 hexagon head cap screw
DIN EN ISO 4017
3Na 2 driving flange N design A 6x 1 ZS-DKM-spacer
7 2 setscrew DIN EN ISO 4029
picture 4: ROTEX®, design ZS-DKM1
Components of ZS-DKM3
component quantity designation component quantity designation
2 2 spider
3Na 2 driving flange N design A 5 s. table 2 cap screws
DIN EN ISO 4762
4N 2 coupling flange N 6x 1 DKM-middle piece spec.
7 2 setscrew DIN EN ISO 4029
picture 5: ROTEX®, design ZS-DKM3

KTR Kupplungstechnik
GmbH
D-48407 Rheine
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
40224 E
9
4
Gezeichnet: 14.07.06 Sha/At Ersatz für:Schutzvermerk
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4 Assembly
4.1 Components of Couplings
Components of ZS-DKM-H
component quantity designation component quantity designation
5 2
1) cap screws
DIN EN ISO 4762
1Dh 2
clamping hub DH with half
length taper-grooved dowel pin
DIN EN ISO 874 (2 pieces) 6x 2 DKM-H-middle piece
2 2 spider
1) each clamping hub DH
picture 6: ROTEX®, design ZS-DKM-H
Features of the standard spiders
spider hardness
(Shore)
marking
(colour)
95/98 Sh A red
4.2 Hint Regarding the Finish Bore
STOP
DANGER!
The maximum permissible bore diameters d (see
table 1 to 3 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 7).
•Please make absolutely sure to observe the figures for
dmax.
•Carefully align the hubs when the finish bores are
brought in.
•Only applying with design ZS-DKM1 and ZS-DKM3:
Please use a set screw or an end plate to axially fasten
the hubs.
picture 7: concentric running
and axial running

KTR Kupplungstechnik
GmbH
D-48407 Rheine
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
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4 Assembly
4.2 Hint Regarding the Finish Bore
Continuation:
!
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 4: setscrew – DIN EN ISO 4029
ROTEX®Größe 24 28 38 42 48 55 65 75 90 100
Maß G M5 M8 M8 M8 M8 M10 M10 M10 M12 M12
tightening torque
TA[Nm] 2 10 10 10 10 17 17 17 40 40
4.3 Assembly of the Hubs
)ATTENTION!
We recommend to check bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Heating the hubs slightly (approx. 80 °C) allows for an easier installation onto the shaft.
Not necessary with design ZS-DKM-H.
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!
For the assembly please make sure that the distance dimension L/E1(see table 1 to 3) is
kept to ensure that the spider can be moved axially.
Disregarding this hint may cause damage on the coupling.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
40224 E
11
4
Gezeichnet: 14.07.06 Sha/At Ersatz für:Schutzvermerk
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4 Assembly
4.3 Assembly of the Hubs
Only applying with design ZS-DKM1 and ZS-DKM3:
•Assemble the hubs/coupling flanges onto the shaft of
driving and driven side (see picture 8).
•The internal sides of the hubs/coupling flanges must
occlude flushly with the faces of the shafts.
•Move the power packs in axial direction until the
dimension L/E1is achieved.
•Fasten the hubs by tightening the setscrews
DIN EN ISO 4029 with cup point or by an end disk
(tightening torque see table 4).
picture 8: assembly of the hubs
4.4 Assembly of the Design ZS-DKM1
•Insert the spiders into the cam part of the hubs (see picture 9).
•Insert the driving flanges with the cams into the spider (see picture 10).
•Insert the ZS-DKM-spacer between the driving flanges (see picture 11).
•At first hand-screw the parts.The screws have to be tightened with a suitable torque wrench to the tightening
torques TAindicated in table 1.
•Center the spiders between the driving flange and the hub and check the dimension E and s (see picture 1
and table 1).
picture 9: assembly of the spiders picture 10: assembly of the driving flange
picture 11: assembly of the
ZS-DKM-spacer

KTR Kupplungstechnik
GmbH
D-48407 Rheine
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
40224 E
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4
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4 Assembly
4.5 Assembly of the Design ZS-DKM3
•Put the driving flanges, the spiders and the DKM-middle piece spec. together (see picture 12).
•Put the assembled part between the coupling flanges (see picture 13).
•At first hand-screw the parts.The screws have to be tightened with a suitable torque wrench to the tightening
torques TAindicated in table 2.
•Center the spiders between the driving flanges and the DKM-middle piece spec. and check the dimension E
and s (see picture 2 and table 2).
picture 12: assembly of the driving flanges,
spiders and DKM-middle piece spec.
picture 13: assembly of subassembly
4.6 Assembly of the Design ZS-DKM-H
•Remove the shells from the hub body (see picture 14).
•Fit the hub body together with the spiders and the DKM-H-middle piece (see picture 15).
•Assemble the fitted unit with the shells and the clamping screws to the shaft ends of driving and driven
machine (see picture 16).
•Initially screw up the parts finger-tight so that the hub bodies fit closely to the shaft with the shells.
•Shift the clamping hubs DH in axial direction until the dimension L mentioned in table 3 is realized.
•Secure the clamping hubs DH by tightening the clamping screws reciprocally. Tighten the screws to the
tightening torques TA mentioned in table 3 by means of a suitable dynamometric screwdriver.
•Center the spiders between the clamping hubs DH and the DKM-H-middle piece and check the dimension E
and s (see picture 3 and table 3).
picture 14: disassembly of shells picture 15: assembly of hub bodies, spiders and DKM-H-middle piece

KTR Kupplungstechnik
GmbH
D-48407 Rheine
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
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4 Assembly
4.6 Assembly of the Design ZS-DKM-H
picture 16: assembly the subassembly onto the shafts
4.7 Displacements - Alignment of the Couplings
The displacement figures shown in tables 5 and 6 offer sufficient safety to compensate for environmental
influences like, for example, heat expansion.
!
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 tables 5 and 6). 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 tables 5 and 6) are permissible.
Please note:
•The displacement figures mentioned in tables 5 and 6 are maximum figures which must not arise in parallel. If
radial and angular displacement arises at the same time, the permissible displacement values may only be
used in part (see picture 18).
•Please check with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 5 and 6
can be observed.
angular displacements axial displacements
radial displacements
picture 17: displacements
Example for displacements
of the ZS-DKM1.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
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edition:
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4 Assembly
4.7 Displacements - Alignment of the Couplings
Continuation:
picture 18:
combinations of
displacement
Example:
ROTEX 24 ZS-DKM 1,
speed 1500 1/min,
shaft distance dimension L = 160,
max. radial displacement ΔKr= 2,48 mm
max. angular displacement ΔKw= 1°
with radial displacement of 1,5 mm = 60 % of the max.
radial displacement 2,48 mm,
results in an allowable angular displacement of 40 % of
the max. angular displacement 1° = 0,4°
ΔKtotal = ΔKw+ ΔKr≤100 %
Table 5: displacement figures for design ZS-DKM1 (spider 98 Sh A-GS)
max. radial displacement ΔKr [mm]
with shaft distance dimension L
max. angular
displacement
ΔKw [degree]
with n = 1500 1/min 3000 1/min
size
max. axial
displace-
ment
ΔKa [mm] 1500
1/min
3000
1/min 100 120 140 160 180 200 250 100 120 140 160 180 200 250
24 1,4 1,0 0,75 1,43 1,78 2,13 2,48 2,83 3,18 4,05 1,07 1,34 1,60 1,86 2,12 2,38 3,04
28 1,5 1,0 0,75 1,40 1,75 2,09 2,44 2,79 3,14 4,01 1,05 1,31 1,57 1,83 2,09 2,36 3,01
38 1,8 1,0 0,75 1,33 1,68 2,02 2,37 2,72 3,07 3,94 0,99 1,26 1,52 1,78 2,04 2,30 2,96
42 2,0 1,0 0,75 - 1,64 1,99 2,34 2,69 3,04 3,91 - 1,23 1,49 1,75 2,02 2,28 2,93
48 2,1 1,0 0,75 - 1,61 1,95 2,30 2,65 3,00 3,87 - 1,20 1,46 1,73 1,99 2,25 2,91
55 2,2 1,0 0,75 - - 1,92 2,27 2,62 2,97 3,84 - - 1,44 1,70 1,96 2,23 2,88
65 2,6 1,0 0,75 - - - 2,18 2,53 2,88 3,75 - - - 1,63 1,90 2,16 2,81
75 3,0 1,0 0,75 - - - - 2,44 2,79 3,67 - - - - 1,83 2,09 2,75
90 3,4 1,0 0,75 - - - - - 2,70 3,58 - - - - - 2,03 2,68
100 3,8 1,0 0,75 - - - - - - 3,49 - - - - - - 2,62
Table 6: displacement figures for design ZS-DKM3 and ZS-DKM-H (spider 98 Sh A-GS)
max. radial displacement ΔKr [mm]
with shaft distance dimension L
max. angular
displacement
ΔKw [degree]
with n = 1500 1/min 3000 1/min
size
max. axial
displace-
ment
ΔKa [mm] 1500
1/min
3000
1/min 100 140 180 250 100 140 180 250
24 1,4 1,0 0,75 1,17 1,87
1) - - 0,87 1,40 1) - -
28 1,5 1,0 0,75 1,06 1,76 - - 0,80 1,32 - -
38 1,8 1,0 0,75 0,99 1,69 - - 0,74 1,27 - -
42 2,0 1,0 0,75 0,91 1,60 - - 0,68 1,20 - -
48 2,1 1,0 0,75 0,87 1,57 - - 0,65 1,18 - -
55 2,2 1,0 0,75 0,70 1,40 2,09 - 0,52 1,05 1,57 -
65 2,6 1,0 0,75 - 1,31 2,00 - - 0,98 1,50 -
75 3,0 1,0 0,75 - 1,13 1,83 3,05 - 0,85 1,37 2,29
90 3,4 1,0 0,75 - - 1,71 2,93 - - 1,28 2,19
1) only design ZS-DKM-H available
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.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
40224 E
15
4
Gezeichnet: 14.07.06 Sha/At Ersatz für:Schutzvermerk
ISO 16016 beachten. Geprüft: 07.08.06 Sha Ersetzt durch:
5 Enclosure A
Hints and Instructions Regarding the Use in Hazardous Areas
Design ZS-DKM1: hub/spider/driving flange/ZS-DKM-spacer/driving flange/spider/hub
Design ZS-DKM3: coupling flange/driving flange/spider/DKM-middle piece spec./spider/
driving flange/coupling flange
Design ZS-DKM-H: clamping hub DH/spider/ DKM-H-middle piece/spider/clamping hub DH
PRECAUTION!
ROTEX®ZS-DKM is only suitable and confirmed for the use in explosive areas up to size 90.
ROTEX®DKM and ROTEX®ZS-DKM only with spacer from steel or aluminium semifinished-products with a yield
point of Rp0,2 ≥250 N/mm2.
5.1 Use in Hazardous Areas According to the Regulations
Conditions of operation in hazardous locations
ROTEX®ZS-DKM 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 temperature Tamax. surface temperature 1)
T4, T3, T2, T1 - 30 °C to + 90 °C 110 °C 2)
T5 - 30 °C to + 80 °C 100 °C
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 + 90 °C due to the permissible permanent operating temperature of
the elastomers used.
2) The maximum surface temperature of 110 °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 + 90 °C.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
40224 E
16
4
Gezeichnet: 14.07.06 Sha/At Ersatz für:Schutzvermerk
ISO 16016 beachten. Geprüft: 07.08.06 Sha Ersetzt durch:
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 ROTEX®ZS-DKM: ΔT = 20 K
II 2GD c IIB
T4, T5, T6
A checking of the circumferential backlash and a visual check of the flexible spider 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 spider 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 spider
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
A checking of the circumferential backlash and a visual check of the flexible spider 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 spider 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 spider
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.
ROTEX®ZS-DKM-H coupling
picture 19: ROTEX®ZS-DKM-H coupling picture 20: ROTEX®GS spider
Here the backlash between coupling cams and the flexible spider must be checked by a feeler gauge.
When reaching the limit of wear of max. friction, the spider must be exchanged immediately, independent of the
inspection intervals.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
40224 E
17
4
Gezeichnet: 14.07.06 Sha/At Ersatz für:Schutzvermerk
ISO 16016 beachten. Geprüft: 07.08.06 Sha Ersetzt durch:
5 Enclosure A
Hints and Instructions Regarding the Use in Hazardous Areas
5.3 Approximate Values of Wear
In case of a backlash of more than X mm, the flexible spider must be exchanged.
The reaching of the exchange values depends on the operating conditions and the existing operating parameters.
!
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 tables 5 and 6). If the
figures are exceeded, the coupling is damaged.
picture 21: checking of the limit of wear picture 22: wear of spider
Table 7:
limits of wear (friction) limits of wear (friction)
ROTEX®
size Xmax. [mm]
ROTEX®
size Xmax. [mm]
24 3 55 5
28 3 65 5
38 3 75 6
42 4 90 8
48 4 100 9
5.4 Permissible Coupling Materials in the

KTR Kupplungstechnik
GmbH
D-48407 Rheine
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
40224 E
18
4
Gezeichnet: 14.07.06 Sha/At Ersatz für:Schutzvermerk
ISO 16016 beachten. Geprüft: 07.08.06 Sha Ersetzt durch:
5 Enclosure A
Hints and Instructions Regarding the Use in 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 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 flexible spider is excluded.
Complete labelling: II 2G c IIC T6, T5 bzw. T4 - 30 °C ≤Ta≤+ 65°C, + 80 °C bzw. +90 °C
II 2D c T 110 °C/I M2 c - 30 °C ≤Ta≤+ 90 °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 hubs, 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.
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.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
40224 E
19
4
Gezeichnet: 14.07.06 Sha/At Ersatz für:Schutzvermerk
ISO 16016 beachten. Geprüft: 07.08.06 Sha Ersetzt durch:
5 Enclosure A
Hints and Instructions Regarding the Use in Hazardous Areas
5.6 Starting
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 5mm.
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.
5.7 Breakdowns, Causes and Elimination
The below-mentioned errors can lead to an incorrect use of the ROTEX®coupling. In addition to the stipulations
in these operating and mounting instructions please make sure to avoid these errors.
The errors listed can only be clues to search for the errors. When searching for the error the adjacent
components must be generally included.
Due to incorrect use the coupling can become a source of ignition.
EC Standard 94/9/EC requires a special care from the manufacturer and the user.
General errors incorrect use
•Important data for the coupling selection was not forwarded.
•The calculation of the shaft/hub connection was not considered.
•Coupling parts with damage occurred during transport are assembled.
•If the heated hubs are assembled, the permissible temperature is exceeded.
•The fits of the parts to be assembled are not coordinated with each other.
•Tightening torques are below/exceeded.
•Components are exchanged by mistake/put together incorrectly.
•A wrong or no spider is inserted into the coupling.

KTR Kupplungstechnik
GmbH
D-48407 Rheine
ROTEX®mounting
instructions
design ZS-DKM and ZS-DKM-H
KTR-N
sheet:
edition:
40224 E
20
4
Gezeichnet: 14.07.06 Sha/At Ersatz für:Schutzvermerk
ISO 16016 beachten. Geprüft: 07.08.06 Sha Ersetzt durch:
5 Enclosure A
Hints and Instructions Regarding the Use in Hazardous Areas
5.7 Breakdowns, Causes and Elimination
Continuation:
•No original KTR parts (purchased parts) are used.
•Old spiders/already worn out spiders or superposed spiders are used.
•The coupling used/the coupling protection used is not suitable for the operation in hazardous areas and does
not correspond to EC Standard 94/9/EC, respectively.
•Maintenance intervals are not observed.
breakdowns causes danger hints for
hazardous areas elimination
misalignment
increased temperature
the the spider surface;
danger of ignition by
hot surfaces
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) checking of wear see under point
Control
wear of spider,
short-term torque
transmission due to
metal contact
danger of ignition due
to sparking
1) put the unit out of operation
2) disassemble the coupling and remove
rests of the spider
3) check coupling parts and exchange
damaged coupling parts
4) insert spider, 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 hot surfaces and
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) checking of wear see under point
Control
wear of spider,
torque transmission
due to metal contact
danger of ignition due
to sparking
1) put the unit out of operation
2) change complete coupling
3) check alignment
break of the cams
due to high shock
energy/overload
danger of ignition due
to sparking
1) put the unit out of operation
2) change complete coupling
3) check alignment
4) find out the reason of overload
operating
parameters do not
correspond to the
performance of the
coupling
danger of ignition due
to sparking
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
break of cam
mistake in service of
the unit
danger of ignition due
to sparking
1) put the unit out of operation
2) change complete coupling
3) check alignment
4) instruct and train the service staff