R+W EK2 User manual

Operation Manual
Page
1
Of
10
EK2 Elastomer Coupling series 20 to 800
Created
2019-12-19
Version
2021-08-13
R+W Antriebselemente GmbH
Hattsteinstraße 4
63939 Wörth am Main
R+W EK2 Elastomer Coupling
Type EK2/xxx/D/xx/xx for use in hazardous area
Translation of Original operating instructions in German
EK2 20-800 englisch.docx
The operating instructions are an essential part of the EK2 elastomer coupling. It provides information for proper assembly, operation
and maintenance. Please read them carefully and observe all instructions. Failure to do so may lead to malfunctions or failure of the
EK2 elastomer coupling. The installation of the coupling may only be carried out by trained personnel.
EK2 elastomer coupling may only be used in accordance with the technical data specified here.
SAFETY AND
GENERAL INFORMATION, USE
1
PLANNING AND TECHNICAL DATA
2
ASSEMBLY AND DISASSEMBLY
3
FIRST COMMISSIONING AND OPERATION
4
MAINTENANCE AND REPAIR
5
SPARE PARTS AND CUSTOMER SERVICE
6

Operation Manual
Page
2
Of
10
EK2 Elastomer Coupling series 20 to 800
Created
2019-12-19
Version
2021-08-13
1. SAFTY AND GENERAL INFORMATION, USE
This manual enables the appropriate personnel for the respective activity to handle the EK2 elastomer coupling over their lifetime
phases.
Residual risks to persons and materials exist in certain activities. These activities are marked with warnings.
Symbol declaration and warnings
The following sections represent all the symbols and abbreviations used.
Symbol
In this section, learn which symbols are used in this operation manual.
Symbol
Importance
Warning signs are triangular with a yellow base colour, black border, and symbol
Highlighting sections of this operating manual for explosion-proof pump designs by EX symbol and grey
deposit
Bid signs are round with a blue base colour and a white symbol
Information is marked with an i. This is information about optimized use.
Environmental requirements are highlighted with a crossed-out garbage can. Environmental
requirements are indications of government requirements for the disposal of substances.
Warnings
Structure of the warnings
Severity of danger by signal word
Kind and source of danger
Consequences
Escape from danger
Signal words
Signal words in the head of the warning indicate the severity of the hazard if the escape measure is not followed.
Signal word and colour
Heavy
Indicates a high-risk hazard resulting in death or serious injury.
Indicates a medium-risk hazard that could result in death or serious
injury.
Indicates a hazard that could result in minor or moderate injury.
Warns of possible damage to property or the environment that may
interfere with the operation.

Operation Manual
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Warning signs
These warning signs are used in the alerts.
Symbol
Importance
General warning
Warning of explosive atmosphere
Warning of floating loads
Warning of hand injuries caused by rotating parts with danger of
inflow
Warning of hot surface
Warning of electrical voltage
Commandment signs
These commandment signs indicate the personal protective equipment to be worn. Also, follow local regulations.
Symbol
Importance
Use hand protection
Use foot protection
Defective personal protective equipment does not adequately protect against the respective hazards and could
result in death or serious injury. Replace protective equipment in the event of defects.
Target groups
The manual distinguishes three groups of specialist personnel:
•Plans / projectiles
•Craftsmen / operators
•Service / repair
The groups have experience in:
•Certificates, regulations; Accident prevention regulations and standards
•Techniques for selecting and constructing mechanical devices
•Work permit system
For explosion-proof versions additionally:
•Design, selection and construction of plants in hazardous areas DIN EN 60079-14
•Principles of explosive protection
•Ignition protection type, device identification
•Tests according to DIN EN 60079-17
Depth of experience:
•Plans / projectiles:
Detailed knowledge of the points listed in Experience in order to plan, pre-set and monitor the activities.
•Craftsmen / operators:
Understanding the points listed in Experience in order to carry out the activities.
•Service / repair
Understanding the points listed in Experience in order to carry out the activities.
Practical experience in the execution of repairs.

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Safety-conscious working
All persons carrying out work concerning installation, commissioning, operation and maintenance must read this manual in full and
attentively and observe all the safety rules and warnings described.
•Plans / Projectiles:
oPlanning the use
•Craftsmen / operators:
oImplementation of planned activities
oOperation of the elastomer coupling
Keep this guide in an appropriate place. Provide these instructions with the elastomer coupling during an operator change.
Intended use in compliance with Directive 2014/34/EU (ATEX)
Only EK2 elastomer couplings with elastomer insert made of black, conductive TPU material with
marking D at the end of the product code are suitable for use in potentially explosive areas:
Category
Explosion subgroup
EPL
Temperature
II 2G
IIC
Gb
T4
II 2D
IIIC
Db
T135°C
The intended use of the EK2 elastomer coupling is:
Torque transmission between 2 horizontal shafts with offset. The coupling equals axial, lateral
and angular offset up to the values specified in the technical data.
Use in zones 1, 2, 21, 22 of subgroups IIC and IIIC.
The evaluation and labelling are carried out in accordance with DIN EN ISO 80079-36 and 37.
The operating parameters specified in this operating manual must be adhered to and the prescribed
conditions for installation, assembly, initial commissioning, operation, maintenance and dismantling
must be considered.
According to Directive 2014/34/EU (ATEX), the EK2 elastomer couplings are treated as a device that
transmits energy and has its own ignition sources. Accordingly, they must be marked with CE and
receive an EU declaration of conformity as a device.
The electrical conductivity of the TPU material prevents the electrostatic charging of the elastomer
insert. This prevents the formation of sparks by the elastomer insert.
Execution
Shore
hardness
Colour
Material
Relative
attenuation (Ψ)
Temperature range
Properties
D
64 D
black
TPU
0,3 –0,45
-10°C to +70°C
Electrically
conductive
Incorrect elastomer material can lead to a charge of the elastomer insert, which can lead to an
effective source of ignition and thus to an explosion. Operate the EK2 elastomer coupling for
potentially explosive areas only with electroconductive, black elastomer inserts.
Explanation of the EC Machinery Directive 2006/42/EC
Due to its elastomer segments, the EK2 elastomer coupling is an elastic coupling. As an elastic
coupling, it is a component for installation in different machines with different applications.
In accordance with the Machinery Directive 2006/42/EC and the guideline for the application of the
Machinery Directive 2006/42/EC of the European Commission Enterprise and Industry, 2nd edition June
2010, general editor Ian Fraser, EK2 elastomer coupling is as a flexible coupling a component and
therefore no machine and no incomplete machine. As a component within the meaning of the Machinery
Directive, the EK2 elastomer coupling is not to be CE marked, receives neither CE declaration of
conformity nor incorporation or serial number, and is therefore not covered by the Machinery Directive.
Conformity to Directive 2006/42/EC can only be declared as a whole after it has been installed in a
machine by the manufacturer of that complete machine. Information on safe installation, safe
commissioning and safe operation can be found in this manual. Commissioning is prohibited until the
requirements of the Machinery Directive are met by the installer through or after integration into the final
product.
Coupling protection
The installer shall provide suitable coupling protection in order to prevent contact between personal
body parts or the retraction of parts with the rotating EK2 elastomer coupling. The cover housing must
be sufficiently robust as it is intended to protect the coupling from falling objects. Openings should
ensure a possible heat dissipation.

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Rotating drive elements are hazard potentials and can cause serious injury when touching or feeding
body parts or clothing. They shall be provided with an appropriate cover which corresponds at least
to class IP2X or comparable national standards. It is the responsibility of the user to use appropriate
cover. The cover shall have a radial distance from the main/outer diameter of the coupling of at least
20 mm and ensure adequate ventilation.
The coupling protection must be carried out in accordance with the material requirements of
DIN EN ISO 60079-0 and must be included in the potential equalisation of the entire system.
Components that are not included in the potential equalisation can charge electrostatically and lead
to an explosion when discharged. Before commissioning, the devices to be connected, the shafts of
which are connected by the coupling, and the coupling protection must be included in the potential
equalisation in such a way that no dangerous charge can be built up on the coupling.
Deposits:
The operator must ensure that no dust accumulates in a dangerous amount between the EK2 elastomer
coupling and the coupling protection. The coupling must not run in a dust filling.
Dust can cause improper heating due to friction on the rotating coupling and thus cause an
explosion. The coupling must not be operated in a dust filling. Clean regularly depending on the
application.
Depending on the ambient temperatures, including the shaft end temperatures to be connected, the
coupling can become warm up to 135°C. A contact of the hot coupling by the operator must be
prevented by the coupling protection to be installed by the installer.
The torque transmission of the coupling leads to a hot surface, which can cause severe burns when
touched. A coupling protection, installed by the installer, restricts the possibility of touching.
Openings in the coupling protection should ensure a possible heat dissipation of the coupling to the
outside.
Missing cooling openings in the coupling protection can lead to unacceptably high ambient
temperatures of the coupling and thus to the explosion. Pay attention to adequate ventilation of the
coupling.
The elastomer coupling is suitable for indoor and outdoor installation.
The couplings are delivered unpainted. If the user-painted couplings are used in potentially explosive
areas, the requirements for the conductivity of the coating or the limitation of the layer thickness of the
applied paintwork in potentially explosive areas must be observed.
Painted surfaces can be electrostatically charged and become an effective source of ignition,
triggering an explosion. The specifications for electrostatics must be observed by the operator. The
elastomer couplings must not be painted inadmissible.
The couplings may only be used if their materials are resistant to mechanical and/or chemical influences
or corrosion in such a way that the explosion protection is not lifted.
Mechanical or corrosion-related damage can cause an explosion. Note that the materials used match
the conditions at the site, so that the explosion protection is not lifted.
Foreseeable improper use:
The elastomer coupling is NOT suitable for the following applications:
•Use in Gas Zone 0
•Use in Dust Zone 20

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Marking
The EK2/xxx/D/xx/xx elastomer couplings for use in potentially explosive atmospheres are marked with a job-specific identification
number. The last digit is the end digit of production year. Regarding Directive 2014/34/EU (ATEX), it is a device that receives a CE
mark and an EU declaration of conformity.
Type plate example
Attached to a hub. If the complete type plate cannot be mounted on the coupling, it is replaced by a shortened version. The "x" stands
for special conditions.
2. PLANNING AND TECHNICAL DATA
Planning
Installation as an example
Pos
Lot
Naming
DIN/ISO
Standard,
short-term,
drawing or
material
1
2
Hub
420008
2
1
Elastomer insert 64D
black
4000203
3
2
Clamping screw
ISO 4762
lateral offset
angular offset
axial offset
R+W EK2 elastomer couplings shall compensate lateral, angular and axial offset of two horizontal shafts by means of an elastomer
insert consisting of several segments. Zero backlash of the coupling is given by pre-tensioning of this elastomer insert.
Explanation of the type key
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
E
K
2
/
x
x
x
/
D
/
x
x
/
x
x
Elastomer
coupling
with clamping
hub
Separator
Size
Separator
Elastomer
insert
Separator
Hole diameter
Separator
Hole diameter
Spaces are not populated, and the type key may be shortened accordingly.
D at position 9 as a mark for ATEX execution with electroconductive elastomer insert.
In the event of incorrect operation or misuse, including vertical installation, there are risks that can
also result in personal and/or material damage caused by an explosion. The elastomer couplings are
to be used only for the intended use as well as in a safety-perfect condition.

Operation Manual
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EK2 Elastomer Coupling series 20 to 800
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Technical data
EK2
Size, Series
20
60
150
300
450
800
Elastomer insert
D
D
D
D
D
D
Rated torque (Nm)
TKN
21
75
200
405
660
1100
Max. torque* (Nm)
TKmax
42
150
400
810
1350
2150
Overall length (mm)
A
66
78
90
114
126
162
Outside diameter (mm)
B
42
56
66,5
82
102
136,5
Outside diameter with screw head (mm)
B5
44,5
57
68
85
105
139
Mounting length (mm)
C
25
30
35
45
50
65
Inside diameter range H7 (mm)
D1/2
8 –25
12 –32
19 –36
20 –45
28 –60
32 –80
Inside diameter of elastomer (mm)
DE
19,2
26,2
29,2
36,2
46,2
60,5
Clamping screw (ISO 4762)
E
M5
M6
M8
M10
M12
M16
Tightening torque (Nm)
8
15
35
70
120
290
Distance between centers (mm)
F
8,5
10
12
15
17,5
23
Distance (mm)
G
15,5
21
24
29
38
50,5
Hub length (mm)
H
39
46
52,5
66
73
93,5
Moment of inertia (10-3kgm²)
J1/J2
0,016
0,05
0,13
0,4
1,1
12
Approx. weight (kg)
0,15
0,35
0,6
1,1
1,7
10
Speed standard (min-1)
12500
11000
10000
9000
8000
4000
Max. offset lateral ± (mm)
0,08
0,1
0,12
0,14
0,18
0,2
Max. offset angular ± (°)
0,8
0,8
0,8
0,8
0,8
0,8
Max. offset axial ± (mm)
2
2
2
2
2
2
*Maximum transmittable torque (Nm) of the clamping hub depends on the bore diameter
Series
Ø8
Ø16
Ø19
Ø25
Ø30
Ø32
Ø35
Ø45
Ø50
Ø55
Ø60
Ø65
Ø70
Ø75
Ø80
20
20
35
45
60
60
50
80
100
110
120
150
120
160
180
200
220
300
200
230
300
350
380
420
450
420
480
510
600
660
750
850
800
700
750
800
835
865
900
925
950
1000
Higher torque possible with keyway.
For the design, the torque to be transmitted between the devices is determined with all design guarantees. With this value, the coupling
size is selected according to the rated torque. The hubs of the EK2 have a clamping hub connection to the shaft.
The transferable torques of the clamping hub connection depending on the shaft and hub bore diameter must be considered by the
user.
An overloaded clamping hub connection leads to the formation of sparks with explosion. The
maximum torque to be transmitted from the clamping hub connection must be observed.
R+W EK2 elastomer couplings have an H7 fit. The fit play of the shaft/hub connection must be in the tolerance of 0.01 to 0.05mm.
Elastomer couplings compensate lateral, axial and angular shaft offsets. In the table you will find maximum permissible guide values for
the individual types of relocation. They provide safety to compensate for operational influences such as thermal expansion and/or
foundation reductions.

Operation Manual
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3. ASSEMBLY AND DISASSEMBLY
Unpacking
Unpacking from the film packaging causes an electrostatic charge of the film and the coupling. An
uncontrolled charge outflow generates sparks with possible explosion.
Remove the film packaging of the coupling outside the potentially explosive atmosphere and
discharge electrical charge to the ground outside the potentially explosive atmosphere.
Storage
EK2 couplings are supplied pre-assembled with screws secured against self-loosening. After the goods receipt inspection, the coupling
must be stored in its original packaging and only unpacked for assembly. Handed over unpacked to the assembly in potentially
explosive areas.
Transport
To lift depending on the weight, which can be found in the technical data, place a ring screw. Ring screw must be removed after
assembly.
When handling floating loads, there may be bruises. Wear protective gloves and safety shoes according to local
regulations.
Assembly and disassembly
Rotating drive elements are hazard potentials and can cause serious injury when touching or feeding body parts or
clothing.
•They shall be provided with an appropriate cover which corresponds at least to class IP2X or comparable
national standards. It is the responsibility of the user to use appropriate cover. The cover shall have a
radial distance from the main/outer diameter of the coupling of at least 20 mm and ensure adequate
ventilation.
•Do not reach into the working area of the coupling when it is still spinning.
•Secure the machine against unintentional switching on during assembly work.
Assembly preparation
The horizontal shafts to be connected and the bores of the hubs must be free of dirt and burr. Check shaft connection dimensions and
check tolerances. The holes of the coupling hubs have an "H7" fit. The oiling of the shaft ends facilitates the assembly and disassembly
of the coupling hubs. Fit rust is thus reduced.
Observe the fit and stop lengths of the hub holes during axial positioning. Tighten coupling hubs with suitable device on the shaft ends
and roughly axially pre-positioning. Threaded pins are used to fix the coupling hubs. Install the elastomer insert in one hub. The pre-
tensioning of the elastomer inserts when pushing the coupling hubs requires an axial assembly force. This force can be reduced after
cleaning the elastomer insert by light oiling of the contact surfaces.
Oils and greases with molybdenum disulphide or other high-pressure additives as well as sliding
grease pastes affect the life of the elastomer insert and lead to premature failure with collapsing of
the coupling parts, ignition sparks and explosion. Only use TPU, material of the elastomer inserts,
compatible lubricants, e.g. Vaseline.

Operation Manual
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Insert the coupling hubs into each other by moving them on the shafts and / or the devices to be connected and position them axially.
Observe the distance size A according to the table.
Series
20
60
150
300
450
800
Distance [mm]
A
16
18
20
24
26
31
Incorrect distance size A leads to a contact of the metallic coupling parts with improper heating, spark
formation and explosion. The distance size A must be observed.
Tighten the clamping screw (E1) with the tightening torque indicated in the data sheet.
Loose components can cause the coupling to malfunction, form hot surfaces or sparks, and ignite an
explosion.
•When used in potentially explosive areas, the screws must be secured with a screw lock in
a medium-tight way; pay attention to the operating temperature of the screw fuse.
•Never put the coupling into operation with loose screws or visible damage.
The ring screw can grind to the parts or loosen and fly out during rotation. This results in ignition-
effective sparks with explosion.
After installation, remove the ring screw before switching on for the first time.
Precise alignment
Precise alignment of the devices connected by the EK2 couplings increases the service life of the elastomer insert. The loads for the
adjacent components are reduced and the smooth running of the entire drive train is positively influenced.
The technical data shows the maximum permissible guide values for the individual displacement types. They provide security to
compensate for operational influences such as thermal expansion and/or foundation reductions.
Cover mount
Dismantling
Remove cover. Loosen threaded pins. Separate devices and/or hubs in an axial way. Remove the hubs with the appropriate tool. To
the handling observe section transport.
4. FIRST COMMISSIONING AND OPERATION
First commissioning
1) Before the first commissioning, the tightening torques of the screw connections of the coupling as well as the devices to be
connected must be checked. The alignment and thus the offsets must be controlled with suitable measuring means.
A suitable cover for the respective place of use is properly installed by the installer/operator.
Visual inspection.
2) If possible, start machine gently and slowly. Check the running behaviour at the start, switch off in case of increased vibrations
or noise and check the overall structure in a secure standstill.
3) After 1,000 hours in operation or at the latest 3 months control of the tightening torques, the running behaviour and visual
inspection see section Maintenance and repair.

Operation Manual
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10
EK2 Elastomer Coupling series 20 to 800
Created
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Version
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Rotating drive elements are hazard potentials and can cause serious injury when touching or feeding
body parts or clothing.
•Do not reach into the working area of the coupling when it is still spinning.
•Secure the machine against unintentional switching on during assembly work.
5. MAINTENANCE AND REPAIR
1) After 1,000 hours in operation or at the latest 3 months control of the
tightening torques, the running behaviour and visual inspection. Control
the alignment and thus the offsets with suitable measuring equipment.
Determine the wear of the elastomer insert. To do this, measure the gap
between the elastomer insert and the claw of the hubs, for example,
with a feeler gauge.
Wear limit < 0.1 mm. If the elastomer has more than 0.1 mm on one
side, it is worn out and needs to be replaced. The alignment of the
devices must be checked.
2) Determine further test intervals according to the test result but repeated
the latest every 4,000 operating hours or 12 months of operation.
When installing a new elastomer insert, pay attention to distance A. Use only
electroconductive elastomer inserts.
Worn elastomer inserts lead to sparks and explosions. The inspection as maintenance in accordance
with DIN EN 80079-36 must be carried out as an elementary component of the explosion protection.
6. SPARE PARTS KEEPING AND CUSTOMER SERVICE
•Third-party spare parts can cause malfunctions. An explosion may result. Use only original
R+W spare parts.
•No subsequent changes to the couplings
•Use only high-strength screws.
•Use only electroconductive elastomer inserts.
Hub 1
Feeler gauge
0,1mm
Hub 2
Elastomer insert
R+W Antriebselemente GmbH
Hattsteinstraße 4 ·D-63939 Wörth am Main
Tel. [phone] ·Fax [phone]
[email protected] ·www.rw-kupplungen.de