RIGIFLEX -HP - KTR

RIGIFLEX®-HP Operating/Assembly instructions

KTR-N Sheet: Edition:

47510 EN 1 of 14 2

Please observe protection note ISO 16016.

Drawn: 2016-10-27 Shg/ Wig Replacing: KTR-N dated 2013-03-06

Verified: 2016-11-09 Shg Replaced by:

RIGIFLEX®-HP

Torsionally stiff steel lamina coupling types

C and L

Type C

Type L



47510 EN 2 of 14 2




RIGIFLEX®-HP is a torsionally stiff flexible steel lamina coupling for high-speed drive trains. It is able to compensate for shaft misalignment, for example caused by thermal expansion, etc.

1 Technical data 3

2 Advice 5

2.1 Coupling selection 5 2.2 General advice 5 2.3 Safety and advice symbols 5 2.4 General hazard warnings 5 2.5 General hazard warnings 6 2.6 Reference to EC Machinery Directive 2006/42/EC 6

3 Storage, transport and packaging 6

3.1 Storage 6 3.2 Transport and packaging 6

4 Assembly 6

4.1 Components of the coupling 7 4.2 Advice for finish bore 8 4.3 Assembly of coupling hubs 8 4.4 Assembly of the spacer - type C 9 4.5 Assembly of the spacer - type L 9 4.6 Displacements - alignment of the coupling 10

5 Start-up 11

6 Breakdowns, causes and elimination 12

7 Disposal 13

8 Maintenance and service 14

9 Spares inventory, customer service addresses 14

Table of contents



47510 EN 3 of 14 2




Type C

Illustration 1: RIGIFLEX®-HP, type C

Table 1: Dimensions – type C

Size

Max. finish bore d1; d2

Dimensions [mm]

D DA DZ DR E1 E Emin. CG1/CG21)

l1/l2 l3/l4 l5/l6

158 85 119 220 195 135 17

Accord

ing to c

usto

mer

specific

atio

n

335 46 85 189 130

168 100 139 255 220 155 23 395 55 100 229 155

188 105 147 265 235 165 23 375 55 105 229 155

208 120 168 298 245 186 23 350 57 120 229 155

228 125 178 315 270 199 33 425 65 125 265 175

248 140 196 335 300 217 33 395 67 140 265 175

278 160 225 380 335 248 33 355 70 160 265 175

318 180 252 445 370 280 48 495 88 180 348 225

358 210 295 500 415 326 48 435 93 210 348 225

388 235 330 545 464 362 48 400 97 235 348 225

1) with E=457.2 mm and cylindrical maximum finish bore

Table 2: Torque and speed - type C

Size Torque [Nm]

Max. speed [rpm] TKN TK max.

158 20000 26000 17300

168 30000 39000 14900

188 38000 49400 14400

208 50000 65000 12800

228 59000 76700 12100

248 72000 93600 11400

278 115000 149500 10000

318 180000 234000 8500

358 253000 328900 7600

388 330000 429000 7000

1 Technical data



47510 EN 4 of 14 2




Type L

Illustration 2: RIGIFLEX®-HP, type L

Table 3: Dimensions – type L

Size

Max. finish bore d1; d2

Dimensions [mm]

D DA DZ DR E1 E Emin. CG1/CG21)

l1/l2 l3/l4 l5/l6

158 150 210 310 220 135 17

Accord

ing to c

usto

mer

specific

atio

n

265 140 150 163.5 37.5

168 165 230 320 255 155 23 340 148 165 168.5 48.0

188 180 250 335 265 165 23 340 156 180 183.5 48.0

208 200 280 362 298 186 23 340 165 200 203.5 48.0

228 220 310 390 315 199 33 390 179 220 223.5 54.5

248 240 340 420 334 217 33 390 185 235 238.5 54.5

278 270 380 455 380 248 33 390 202 270 273.5 54.5

318 315 445 550 445 280 48 510 246 315 318.5 71.5

358 350 490 600 500 326 48 510 263 350 353.5 71.5

388 380 535 650 545 362 48 510 277 380 383.5 71.5


Table 4: Torque and speed - type L

Size Torque [Nm]

Max. speed [rpm] TKN TK max.

158 20000 26000 13800

168 30000 39000 12300

188 38000 49400 11400

208 50000 65000 10500

228 59000 76700 9700

248 72000 93600 9000

278 115000 149500 8300

318 180000 234000 6900

358 253000 328900 6300

388 330000 429000 5800

1 Technical data



47510 EN 5 of 14 2




!

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

®-HP catalogue).

If the operating conditions (performance, speed, modifications on engine and machine) change, the coupling selection must be reviewed. 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.

Please read through these assembly instructions carefully before you start up the coupling. Please pay special attention to the safety instructions! The assembly instructions are part of your product. Please store them carefully and close to the coupling. The copyright for these assembly instructions remains with KTR.

STOP

Warning of personal injury This symbol indicates notes which may contribute to pre-venting bodily injuries or serious bodily injuries that may result in death.

!

Warning of product damages This symbol indicates notes which may contribute to pre-venting material or machine damage.

General advice This symbol indicates notes which may contribute to pre-venting adverse results or conditions.

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 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 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 Coupling selection

2.2 General advice

2.3 Safety and advice symbols

2.4 General hazard warnings



47510 EN 6 of 14 2




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 chapter 1). Unauthorized modifications on the coupling design are not admissible. We will not assume liability for any damage that may arise. In the in-terest of further development we reserve the right for technical modifications. The RIGIFLEX

®-HP described in here corresponds to the technical status at the time of printing of these assem-

bly instructions.

The couplings supplied by KTR should be considered as components, not machines or partly completed ma-chines according to EC Machinery Directive 2006/42/EC. Consequently KTR does not have to issue a declaration of incorporation. For details about safe assembly, start-up and safe operation please refer to the present operat-ing/assembly instructions considering the warnings.

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.

The coupling hubs are supplied fully assembled. Before assembly the coupling has to be inspected for complete-ness.

STOP

Driving components falling down may cause injury to persons or damage on the machine. Secure the driving components with assembly or disassembly.

2 Advice

2.5 General hazard warnings

2.6 Reference to EC Machinery Directive 2006/42/EC

3 Storage, transport and packaging

3.1 Storage

3.2 Transport and packaging

4 Assembly



47510 EN 7 of 14 2




Components of RIGIFLEX®-HP type C

Component Quantity Description

1 2 Coupling hub C

2 1 Spacer C

3 see table 5 Double hexagon bolt

4 see table 5 Double hexagon nut

Illustration 3: RIGIFLEX®-HP, type C

Table 5:

Size 158 168 188 208 228 248 278 318 358 388

Number of double hexagon bolt

1)/nut

1)

18 24 30 30 24 25 30 25 30 34

Tightening torque TA [Nm] 115 115 115 115 290 290 290 560 560 560

1) Quantity for each coupling half

Components of RIGIFLEX®-HP type L

Component Quantity Description

1 2 Coupling hub L

2 1 Spacer L

3 see table 6 Double hexagon bolt

4 see table 6 Double hexagon nut

Illustration 4: RIGIFLEX®-HP, type L

Table 6:

Size 158 168 188 208 228 248 278 318 358 388

Number of double hexagon bolt

1)/nut

1)

13 18 20 24 15 18 20 20 25 30

Tightening torque TA [Nm] 115 115 115 115 290 290 290 560 560 560

1) Quantity for each coupling half

4 Assembly

4.1 Components of the coupling



47510 EN 8 of 14 2




!

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.

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

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

Please pay attention to the ignition risk in potentially explosive atmospheres!

STOP

Touching the heated hubs causes burns. Please wear safety gloves.

!

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 axial alignment of the coupling the distance dimension E (see table 1 and 3) is decisive. In order to adjust the right dimension E you should proceed as follows:

Mount the coupling hubs (component 1) onto the shaft of driving and driven side.

The internal sides of the coupling hubs must be flush with the front sides of the shafts (type C see illustration 5 resp. type L see illustration 6).

Shift the power packs in axial direction until the distance dimension E is achieved.

If the power packs are already firmly assembled, shifting the coupling hubs axially on the shafts allows for adjusting the distance dimension E.

Illustration 5: Assembly of coupling hubs C Illustration 6: assembly of the coupling hubs L

4 Assembly

4.2 Advice for finish bore

4.3 Assembly of coupling hubs



47510 EN 9 of 14 2




The coupling hubs (component 1) have to be aligned such that the screws of the lamina sets line up (see illustration 5).

Clean and degrease the centerings and contact surfaces on the spacer (component 2) and coupling hubs.

!

The transportation screws and spacer sleeves have to be removed for further assembly and operation (see illustration 7).

Insert the spacer between the coupling hubs.

Hand-screw the spacer on the coupling hubs by means of the double hexagon screws and double hexagon nuts.

Tighten the double nuts at the tightening torque (see table 5) spec-ified while protecting the double hexagon screws from rotating.

Illustration 7: Disassembly of transport lock

For each coupling only screws with the same weight (tared) may be used.

!

Having started up the coupling, the tightening torque of the screws has to be inspected at regular maintenance intervals.

The coupling hubs (component 1) have to be aligned such that the holes of the coupling hubs line up (see illustration 6).

Clean and degrease the centerings and contact surfaces on the spacer (component 2) and coupling hubs.

!

The transportation screws and spacer sleeves have to be removed for further assembly and operation (see illustration 8).

Insert the spacer between the coupling hubs.

Hand-screw the spacer on the coupling hubs by means of the double hexagon screws and double hexagon nuts.

Tighten the double hexagon nuts at the tightening torque (see table 6) specified while protecting the double hexagon screws from rotating.

Illustration 8: Disassembly of transport lock

For each coupling only screws with the same weight (tared) may be used.

!

Having started up the coupling, the tightening torque of the screws has to be inspected at regular maintenance intervals.

4 Assembly

4.4 Assembly of the spacer - type C

4.5 Assembly of the spacer - type L



47510 EN 10 of 14 2




The displacement figures specified in table 7 provide for sufficient safety to compensate for external influences like, for example, thermal expansion or foundation settling.

!

In order to ensure a long service life of the coupling, the shaft ends have to be accurately aligned. Please absolutely observe the displacement figures specified (see table 7). If the figures are exceeded, the coupling will be damaged. The more accurate the alignment of the coupling, the longer is its service life.

Please note:

The displacement figures specified in table 7 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 10).

Please inspect with a dial gauge, ruler or feeler gauge whether the permissible displacement figures specified in table 7 can be observed.

Angular displacements Radial displacements

Illustration 9: Displacements (example: type C)

Axial displacements

Examples of the displacement combina-tions specified in illustration 10: Example 1:

Kr = 10%

Kw = 80%

Ka = 10% Example 2:

Kr = 30%

Kw = 30%

Ka = 40%

Illustration 10: Combina-tions of displacement

Ktotal = Ka + Kr + Kw 100 %

4 Assembly

4.6 Displacements - alignment of the coupling



47510 EN 11 of 14 2




Table 7: Displacement figures

Size

Angular displace-ment

1)

Kw [°]

Axial displacement

Ka [mm]

Radial displacement 2)

DKr [mm]

Type C Type L

158 0.25 ±3.0 2.30 1.56

168 0.25 ±3.0 2.32 1.45

188 0.25 ±3.3 2.37 1.45

208 0.25 ±3.8 2.50 1.45

228 0.25 ±4.0 2.44 1.34

248 0.25 ±4.2 2.58 1.34

278 0.25 ±4.5 2.75 1.34

318 0.25 ±5.2 2.70 1.13

358 0.25 ±6.0 2.96 1.13

388 0.25 ±6.5 3.18 1.13

1) each lamina set


Before start-up of the coupling, please inspect the tightening of the setscrews in the hubs, the alignment and the distance dimension E and adjust, if necessary, and also inspect all screw connections for the tightening torques specified, dependent on the type of coupling. Finally the coupling protection against accidental contact must be fitted. The cover must be electrically conductive and included in the equipotential bonding. Bellhousings (magnesium share below 7.5 %) made of aluminium and damping rings (NBR) can be used as connecting element between pump and electric motor. The cover may only be taken off with standstill of the unit. During operation of the coupling, please pay attention to

different operating noise

vibrations occurring.

The minimum distance „Sr“ between the protective device and the rotating parts must at least correspond to the figures specified below. If the protective device is used as cover, regular openings can be arranged from the point of view explosion pro-tection that must not exceed the following dimensions:

Openings Cover [mm]

Top side Lateral components Distance „Sr“

Circular - max. diameter 4 8 10

Rectangular - max. lateral length 4 8 10

Straight or curved slot - max. lateral length/height

not permissible 8 20

!

If you note any irregularities with the coupling during operation, the drive unit must be switched off immediately. The cause of the breakdown must be specified by means of the table „Breakdowns“ and, if possible, be eliminated according to the proposals. The potential breakdowns mentioned can be hints only. To find out the cause all operating factors and machine components must be considered.

4 Assembly

4.6 Displacements - alignment of the coupling

5 Start-up



47510 EN 12 of 14 2




The below-mentioned failures can result in a use of the RIGIFLEX

®-HP coupling other than intended. In addition

to the specifications given in these operating and assembly instructions please make sure to avoid such failures. The errors listed can only be clues to search for the failures. When searching for the failure the adjacent compo-nents must generally be considered. General failures with use other than intended:

Important data for the coupling selection were not forwarded.

The calculation of the shaft-hub-connection was not considered.

Coupling components with damage occurred during transport are assembled.

If the heated hubs are assembled, the permissible temperature is exceeded.

The clearance of the components to be assembled is not coordinated with one another.

Tightening torques have been fallen below/exceeded.

Components are mixed up by mistake/assembled incorrectly.

A wrong or no lamina set is inserted in the coupling.

No original KTR components (purchased parts) are used.

Maintenance intervals are not observed.

Breakdowns Causes Hazard notes for haz-

ardous locations Elimination

Different operating noise and/or vibra-

tions occuring

Misalignment none

1) Set the unit out of operation 2) Eliminate the reason for the misalign-

ment (e. g. loose foundation bolts, breaking of the engine mount, heat ex-pansion of unit components, modifica-tion of the installation dimension E of the coupling)

3) For inspection of wear see item inspec-tion

Cap screws working loose, low micro friction under the

screw head and on the steel lamina set

Danger of ignition due to hot surfaces

1) Set the unit out of operation 2) Inspect coupling components and re-

place coupling components that are damaged

3) Tighten the cap screws until the per-missible tightening torque is reached

4) Inspect alignment, adjust if necessary

Screws for axial fastening of hubs

working loose none

1) Set the unit out of operation 2) Inspect alignment of coupling 3) Tighten the screws to fasten the hubs

and secure against working loose 4) For inspection of wear see item inspec-

tion

6 Breakdowns, causes and elimination



47510 EN 13 of 14 2




Breakdowns Causes Hazard notes for haz-

ardous locations Elimination

Breaking of steel lamina set

Breaking of the steel lamina set due to high impact ener-

gy/overload

Ignition risk due to sparking

1) Set the unit out of operation 2) Disassemble the coupling and remove

remainders of the steel lamina sets 3) Inspect coupling components and re-


4) Insert spacer, mount coupling compo-nents

5) Find out the reason for overload

Operating parame-ters do not meet with the perfor-

mance of the cou-pling


1) Set the unit out of operation 2) Review the operating parameters and

select a bigger coupling (consider mounting space)

3) Assemble new coupling size 4) Inspect alignment

Operating error of the unit



remainders of the spacer 3) Inspect coupling components and re-



5) Instruct and train the service staff

Cracks in / fracture of the steel lamina set / locking screws

Vibrations of drive Ignition risk due to

sparking


remainders of the spacer 3) Inspect coupling components and re-



5) Inspect alignment, adjust if necessary 6) Find out the reason for vibrations

In respect of environmental protection we would ask you to dispose of the packaging or products on termination of their service life in accordance with the legal regulations and standards that apply, respectively. All coupling components consist of metal. Any metal components have to be cleaned and disposed of by scrap metal.

6 Breakdowns, causes and elimination

7 Disposal



47510 EN 14 of 14 2




RIGIFLEX

®-HP is a low-maintenance coupling. We recommend to perform a visual inspection on the coupling at

least once a year. Please pay special attention to the condition of the lamina sets as well as the alignment and screw connection of the coupling.

Since the flexible machine bearings of the driving and driven side settle during the course of load, please in-spect the alignment of the coupling and re-align the coupling, if necessary.

If some individual laminas are broken, the lamina sets of the coupling have to be replaced. The coupling parts have to be inspected for damages.

The screw connections have to be inspected visually.

!

After start-up of the coupling the tightening torques of the screws of the lamina sets have to be inspected during usual maintenance intervals.

A basic requirement to ensure the readiness for use 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 at www.ktr.com.

KTR does not assume any liability or warranty for the use of spare parts and accessories which are not provided by KTR and for the damages which may incur as a result.

8 Maintenance and service

9 Spares inventory, customer service addresses

RIGIFLEX -HP - KTR

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