KTR SYNTEX-NC Series Product guide

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
1 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
SYNTEX®-NC
Backlash-free overload
system
Type DK
(ratchet design)
Type SK
(synchronous design)
SYNTEX®-NC
SYNTEX®-NC with ROTEX®GS
SYNTEX®-NC with TOOLFLEX®

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
2 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
SYNTEX®-NC is a torque limiting, backlash-free overload system operating with positive locking
protecting adjacent components from damage.
In case of overload on the coupling the torque is considerably reduced to a lower residual torque.
SYNTEX®-NC is a not load-holding coupling.
In case of overload type DK (ratchet design) re-engages every 15° with the next following ball
indentation.
In case of overload type SK (synchronous design) re-engages after a rotation of 360°.
1Technical data 3
2Advice 7
2.1 General advice 7
2.2 Safety and advice symbols 7
2.3 General hazard warnings 7
2.4 Intended use 8
2.5 Coupling selection 8
3Storage, transport and packaging 8
3.1 Storage 8
3.2 Transport and packaging 8
4Assembly 9
4.1 Components of the couplings 9
4.2 Advice on remachining 10
4.3 Assembly (general) 10
4.4 Assembly of SYNTEX®-NC (hub design 1.0) 11
4.5 Assembly of SYNTEX®-NC (hub design 6.1) 11
4.6 Notes with the use of hollow shafts 12
4.7 Assembly of SYNTEX®-NC with ROTEX®GS 12
4.8 Assembly of SYNTEX®-NC with TOOLFLEX®13
5Adjustment of torque 14
5.1 Torque setting - SYNTEX®-NC 14
5.2 Replacement of layering of disk springs 16
5.3 Setting diagrammes 18
5.3 Setting diagrammes 19
6Assembly of limit switch 20
7Breakdowns, causes and elimination 21
8Disposal 22
9Maintenance and service 22
10 Notes for using drive components/attachments 23
11 Spares inventory, customer service addresses 23
Table of contents

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
3 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
Illustration 1: SYNTEX®-NC
(hub design 1.0)
Illustration 2: SYNTEX®-NC
(hub design 6.1)
Table 1: Technical data and dimensions
Size
Speed
[rpm]
Torques [Nm]
Dimensions [mm]
T1
T2
T3
Max. bore d 1)
D
D1
D2
D3
DA
15
3500
2 - 3.5
3.5 - 7
7 - 14
12
32
33
37
42
42
25
3000
9 - 15
20 - 30
40 - 65
22
42
50
48
56
61
32
3000
25 - 38
50 - 75
100 - 150
30
52
60
60
67
74
42
2500
30 - 65
60 - 135
120 - 265
38
65
72
75
83
90
60
2000
70 - 140
120 - 280
220 - 550
50
90
96
100
113
116
Size
Dimensions [mm]
l1
l2
l3
l4
l5
l6
L
z x dM
H=stroke
15
5.0
7.0
9.2
2
4
18.8
28
12 x M3
0.8
25
5.5
11.5
9.1
2
5
23.9
33
8 x M4
1.2
32
6.0
12.5
9.9
2
5
25.1
35
8 x M4
1.5
42
7.0
16.0
11.2
2
6
31.8
43
8 x M5
1.5
60
8.0
21.0
11.8
2
7
38.2
52
12 x M6
1.8
1) Max. finish bore, feather keyway according to DIN 6885 sheet 3
Table 2: Technical data and dimensions –hub design 6.1
Size
Bore d1
Dimensions [mm]
Weight 2)
[kg]
Mass moment
of inertia 2)
Jtotal [kgm2]
Pilot
bored
Max.
D4
DK
L1
e
M
TA[Nm]
15
7.5
15
40
43.0
38
15
M4
1.7
0.124
2.9 × 10-5
25
9.5
25
55
-
45
21
M6
14
0.282
1.4 × 10-4
32
13.5
32
70
-
53
27
M8
34
0.471
3.5 × 10-4
42
18.5
42
86
91.2
63
33
M10
67
0.815
9.5 × 10-4
60
24.0
60
112
119.4
75
45
M12
115
3.04
5.9 × 10-3
2) With max. finish bore
1 Technical data

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
4 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
Illustration 3: SYNTEX®-NC with ROTEX®GS (hub design 2.8, from size 60 - 6.0/6.1)
Illustration 4: SYNTEX®-NC with ROTEX®GS (hub design 2.9, from size 60 1.0/1.0)
Table 3: Dimensions and technical data with ROTEX®GS
Size
ROTEX®GS
size
Speed [rpm]
Torques [Nm]
Max. bore [mm]
T1
T2
T3
d
d1
d2
15
19
3500
2 - 3.5
3.5 - 7
7 - 14
12
15
24
25
24
3000
9 - 15
20 - 30
40 - 65
22
25
32
32
28
3000
25 - 38
50 - 75
100 - 150
30
32
35
42
38
2500
30 - 65
60 - 135
120 - 265
38
42
45
60
48
2000
70 - 140
120 - 280
220 - 550
50
60
55
Size
Dimensions [mm]
D5
DH
DK
DK1
DA
l1
l2
l3
E
15
45
40
-
46.7
42
17
40.0
40
16
25
58
55
-
57.5
61
18
47.5
35.5
18
32
70
65
-
69.0
74
21
55.0
37.0
20
42
88
80
91.2
86.0
90
26
66.0
46.0
24
60
113
105
119.4
-
116
56
83.0
60
28
Size
Dimensions [mm]
e
e1
LG
L1
LG1
M
TA[Nm]
M1
TA1 [Nm]
15
15
15.5
63
38
73.0
M4
1.7
M5
6
25
21
20.0
71.5
45
83.5
M6
14
M6
10
32
27
23.8
78.0
53
96.0
M8
34
M8
25
42
33
30.5
96.0
63
116.0
M10
67
M10
49
60
45
-
144
75
167.0
M12
115
M10
49
1 Technical data

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
5 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
Illustration 5: SYNTEX®-NC with TOOLFLEX®
Table 4: Technical data and dimensions with TOOLFLEX®
Size
TOOLFLEX®
size
Speed [rpm]
Torques [Nm]
Max. bore [mm]
T1
T2
T3
d1
d2
15
20
3500
2 - 3.5
3.5 - 7
7 - 14
15
20
25
38
3000
9 - 15
20 - 30
40 - 65
25
38
32
42
3000
25 - 38
50 - 75
100 - 150
32
42
42
45
2500
30 - 65
60 - 135
120 - 265
42
45
60
65
2000
70 - 140
120 - 280
220 - 550
60
65
Size
Dimensions [mm]
D4
DH
DA
DK
DK1
l1
L1
E
15
40
40
52 1)
43
43.5
21.5
38
16.5
25
55
65
61
-
72.6
25.5
45
18.0
32
70
70
74
-
76.1
30.0
53
24.0
42
86
83
90
91.2
89.0
32.0
63
22.5
60
112
125
140 1)
119.4
127.1
45.0
84
36.0
Size
Dimensions [mm]
e
e1
LG
M
TA[Nm]
M1
TA1 [Nm]
15
15
14.5
76
M4
1.7
M5
6
25
21
25.0
88
M6
14
M8
25
32
27
27.0
107
M8
34
M8
25
42
33
30.0
114
M10
67
M10
49
60
45
45.0
165
M12
115
M14
185
1) Outside diameter shifting ring see table 1.
1 Technical data

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
6 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
Table 5: Torques and surface pressure –hub design 6.1 (without feather keyway)
Size
15
25
32
42
60
Clamping screw M
M4
M6
M8
M10
M12
Tightening torque TA[Nm]
1.7
14
34
67
115
Bore Ø
Transmittable torque [Nm]
Surface pressure [N/mm2]
8
8
94.5
10
12
30
92
131
11
14
35
90.5
129.5
12
16
42
88
127.5
14
22
55
85
123.5
15
24
62
74
83.5
121
97
16
69
83
119
96
18
48
104
66
94
19
53
114
65
93
20
58
125
149
64.5
92
99
22
69
148
178
63
90
97.5
24
80
116
209
61.5
59.5
96
25
86
125
225
247
61
59
95
113.5
28
153
275
310
57.5
93
113.5
30
172
310
356
56.5
91.5
113.5
32
192
264
405
55.5
68.5
113.5
35
309
485
67
113.5
36
324
513
66.5
113.5
38
356
571
65.5
113.5
40
389
633
64.5
113.5
42
422
394
63.5
63.98
45
452
63.98
48
514
63.98
50
558
63.98
55
674
63.98
60
803
63.98
1 Technical data

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
7 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
Please read through these operating/assembly instructions carefully before you start up the coupling.
Please pay special attention to the safety instructions!
The operating/assembly instructions are part of your product. Please store them carefully and close to the
coupling. The copyright for these operating/assembly instructions remains with KTR.
STOP
Warning of personal injury
This symbol indicates notes which may contribute to
preventing bodily injuries or serious bodily injuries that
may result in death.
!
Warning of product damages
This symbol indicates notes which may contribute to
preventing material or machine damage.

General advice
This symbol indicates notes which may contribute to
preventing adverse results or conditions.
Warning of hot surfaces
This symbol indicates notes which may contribute to
preventing burns with hot surfaces resulting in light to
serious bodily injuries.
STOP
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
rotating 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 reach into the operating 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 Advice
2.1 General advice
2.2 Safety and advice symbols
2.3 General hazard warnings

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
8 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
You may only assemble, operate and maintain the coupling if you
have carefully read through the operating/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 chapter 1). Unauthorized 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 SYNTEX®-NC described in here corresponds to the technical status at the time of printing of these
operating/assembly instructions.
!
To review the coupling selection please consult with KTR.
The couplings are supplied in preserved condition and can be stored at a dry and covered place for 6 - 9 months.
!
Humid storage rooms are not suitable.
Please make sure that condensation is not generated. The best relative air humidity is less
than 65 %.
!
In order to avoid any injuries and any kind of damage please always make use of proper
transport and lifting equipment.
The couplings are packed differently each depending on size, number and kind of transport. Unless otherwise
contractually agreed, packaging will follow the in-house packaging specifications of KTR.
2 Advice
2.4 Intended use
2.5 Coupling selection
3 Storage, transport and packaging
3.1 Storage
3.2 Transport and packaging

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
9 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
The coupling is supplied fully assembled (as specified by the buyer) and optionally with the torque set.
Component assembly 1: Components of SYNTEX®-NC (hub design 1.0)
Component
Quantity
Description
Illustration 6: SYNTEX®-NC (hub design 1.0)
1.1
1
Hub 1.0
1.2
1
Flange ring DK or SK
1.3
1
Shifting ring
1.4
see table
9
Disk springs (set)
1.5
1
Setting nut with cap screw
DIN EN ISO 4762 - 12.9
1.6
1 1)
Balls
1.7
1
Groove ball bearing
DIN 625
1.8
1
Circlip
1) Complete set
Component assembly 2: Components of SYNTEX®-NC (hub design 6.1)
Component
Quantity
Description
Illustration 7: SYNTEX®-NC (hub design 6.1)
2.1
1
Clamping ring hub
design 6.1
2.2
1
Flange ring DK or SK
2.3
1
Shifting ring
2.4
see table
9
Disk springs (set)
2.5
1
Setting nut with cap screw
DIN EN ISO 4762 - 12.9
2.6
1 1)
Balls
2.7
1
Groove ball bearing
DIN 625
2.8
1
Circlip
2.9
1
Clamping ring
2.10
1
Clamping screw
DIN EN ISO 4762 - 12.9
1) Complete set
Components of SYNTEX®-NC with ROTEX®GS
Component/
component
assembly
Quantity
Description
Illustration 8: SYNTEX®-NC with ROTEX®GS
1/2
1
SYNTEX®-NC
(complete coupling)
3
1
ROTEX®GS driving
flange
4
1
ROTEX®GS spider
5
1
ROTEX®GS clamping
hub
6
1)
Cap screws
DIN EN ISO 4762 - 12.9
1) see quantity in table 1
4 Assembly
4.1 Components of the couplings

SYNTEX®-NC
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
46110 EN
10 of 23
4
Please observe protection
note ISO 16016.
Drawn:
2017-02-10 Pz/Koh
Replacing:
KTR-N dated 2014-08-11
Verified:
2017-03-03 Pz
Replaced by:
Components of SYNTEX®-NC with TOOLFLEX®
Component/
component
assembly
Quantity
Description
Illustration 9: SYNTEX®-NC with TOOLFLEX®
7
1
SYNTEX®-NC
(complete coupling)
!
The customer bears the sole responsibility for all machining processes performed
subsequently 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
remachining.

We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Heating the SYNTEX®-NC (hub design 1.0) lightly (approx. 80 °C) allows for an easier
mounting on the shafts.
STOP
Touching the heated coupling or clamping hub causes burns.
Please wear safety gloves.
Please make sure the perfect technical condition of the SYNTEX®-NC overload system.
Please only use original KTR components (no purchased parts).
4 Assembly
4.1 Components of the couplings
4.2 Advice on remachining
4.3 Assembly (general)