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ROTEX® GS
Operating/Assembly instructions
45510 EN
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19
ROTEX® GS
Torsionally flexible jaw-type couplings
shaft coupling, clamping hubs, clamping ring hubs, clamping ring hubs light,
DKM, Compact and their combinations
according to directive 2014/34/EU
for finish bored, pilot bored and unbored couplings
®
ROTEX GS, DKM
®
®
ROTEX GS, Compact
ROTEX GS, shaft coupling
®
ROTEX GS, clamping hubs
®
ROTEX GS, clamping ring hubs
®
ROTEX GS, clamping ring hubs steel
®
ROTEX GS, clamping ring hubs light
Expansion hubs and their combinations
for finish bored, pilot bored and unbored couplings
®
ROTEX GS, expansion hubs
Please observe protection
note ISO 16016.
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Verified:
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2016-05-11 Pz
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ROTEX® GS
Operating/Assembly instructions
KTR-N
Sheet:
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45510 EN
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19
ROTEX® GS is a plug-in shaft coupling for measuring technology and automatic control engineering. It
is able to compensate for shaft misalignment, for example caused by manufacturing inaccuracies,
thermal expansion, etc.
With the designing of our ROTEX® GS coupling, the engineering standards and regulations, in
particular DIN EN 12100, part 2 as well as DIN EN ISO 13849, part 1 and 2 „Safety of machines” have
been taken into account.
Table of contents
1
Technical data
2
Advice
15
2.1
2.2
2.3
2.4
2.5
2.6
15
15
16
16
16
16
3
4
4
General advice
Safety and advice symbols
General hazard warnings
Intended use
Coupling selection
Reference to EC Machinery Directive 2006/42/EC
Storage, transport and packaging
17
3.1
3.2
17
17
Storage
Transport and packaging
Assembly
18
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
18
19
22
22
23
24
24
27
27
Types of hubs
Components of the coupling
Advice for assembly
Advice for finish bore
Assembly of hubs (types 1.0, 1.1 and 1.2)
Assembly of clamping hubs (types 2.0, 2.1, 2.5, 2.6, 2.8, 2.9, 7.5, 7.6, 7.8 and 7.9)
Assembly/disassembly of clamping ring hubs (types 6.0, 6.0 steel, 6.0 light and 6.5)
Assembly/disassembly of expansion hubs (type 9.0)
Displacements - alignment of the couplings
5
Start-up
29
6
Breakdowns, causes and elimination
30
7
Disposal
32
8
Maintenance and service
33
9
Spares inventory, customer service addresses
33
Please observe protection
note ISO 16016.
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ROTEX® GS
Operating/Assembly instructions
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45510 EN
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Table of contents
10
Enclosure A
Advice and instructions regarding the use in
10.1 Intended use in
hazardous locations
hazardous locations
10.2 Inspection intervals for couplings in
10.3 Standard values of wear
10.4 Permissible coupling materials in
35
hazardous locations
hazardous locations
10.5
marking of coupling for hazardous locations
10.6 EU Certificate of conformity
Please observe protection
note ISO 16016.
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34
36
37
37
38
39
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ROTEX® GS
Operating/Assembly instructions
1
45510 EN
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19
Technical data
Standard shaft couplings
Illustration 1:
ROTEX® GS,
size 5 - 38
Illustration 2:
ROTEX® GS,
size 42 - 90
Table 1: Dimensions
Size
D
DH
dH
5
7
9
12
14
19
24
28
38
-
10
14
20
25
30
40
55
65
80
7.2
8.5
10.5
18
27
30
38
42
48
55
65
75
90
85
95
110
115
135
160
95
105
120
135
160
200
46
51
60
68
80
104
Dimensions [mm]
l1 ; l2
M/N
E
Hub material - aluminium (Al-H)
15
5
5
22
7
8
30
10
10
34
11
12
35
11
13
66
25
16
78
30
18
90
35
20
114
45
24
Hub material - Steel (St-H)
126
50
28
26
140
56
32
28
160
65
37
30
185
75
47
35
210
85
53
40
245
100
62
45
L
Setscrew 1)
G
t
b
s
a
4
6
8
10
10
12
14
15
18
0.5
1.0
1.0
1.0
1.5
2.0
2.0
2.5
3.0
4.0
6.0
1.5
3.5
2.0
3.0
3.0
4.0
4.0
M2
M3
M4
M4
M4
M5
M5
M8
M8
2.5
3.5
5.0
5.0
5.0
10
10
15
15
20
21
22
26
30
34
3.0
3.5
4.0
4.5
5.0
5.5
4.0
4.0
4.5
4.5
5.0
6.5
M8
M8
M10
M10
M10
M12
20
20
20
20
25
30
If used in hazardous locations the setscrews to fasten the hubs as well as all screw connections must be secured
against working loose additionally, e. g. conglutinating with Loctite (average strength).
1)
Table 2: Torques and finish bores
Size
5
7
8
9
12
13
14
16
80 ShA-GS
0.3
0.7
0.5
1.8
3.0
3.6
4.0
5.0
Spider 1) (component 2)
Rated torque [Nm]
92 ShA-GS 98 ShA-GS 64 ShD-GS
0.5
0.9
0.2 2)
1.2
2.0
2.4
2.0
2.4
3.0
5.0
6.0
5.0
9.0
12.0
11.0
14.5
7.5
12.5
16.0
15.0
19.0
72 ShD-GS
-
Unbore
d
-
Finish bore [mm] - hub design
1.0
1.1, 1.2
2.0, 2.1
dmin.
dmax.
dmax.
dmax.
2
6
5
3
7
7
7
4
10
11
11
4
12
12
12
5
16
16
16
1.0, 1.1
2.5
2.6
dmax.
dmax.
dmax.
6
24
24
24
8
28
28
28
10
38
38
38
12
45
45
45
14
55
50
45
15
62
55
55
20
74
68
68
22
80
70
70
30
95
80
80
40
110
90
90
19
6
12
21
26
x
24
35
60
75
97 3)
x
28
95
160
200
260 3)
x
38
190
325
405
525 3)
x
3)
42
265
450
560
728
x
48
310
525
655
852 3)
x
55
410
685
825
1072 3)
x
65
940
1175
1527 3)
x
75
1920
2400
3120 3)
x
90
3600
4500
5850 3)
1) Maximum torque of the coupling TKmax. = rated torque of the coupling TK rated x 2
except for clamping hubs types 2.0 and 2.5 (see table 3), for coupling selection please see catalogue drive technology "ROTEX® GS"
2) Figures for spider 70 ShA-GS
3) When using the spider 72 ShD, we recommend to use hubs made of steel.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
1
45510 EN
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19
Technical data
Clamping hubs
Illustration 3: ROTEX® GS, size 5 - 14 (type
2.0)
Illustration 4: ROTEX® GS, size 19 - 90 (type 2.5)
Table 3: Torques and surface pressure of clamping hubs types 2.0 / 2.5
Size
Clamping screw
M1
Dimension t1
Dimension e
Dimension ØDK
Tightening
torque TA [Nm]
5
7
9
12
14
M1.2
M2
M2.5
M3
M3
M6
M6
2.5
3.5
11.4
3.5
5.0
16.5
5.0
7.5
23.4
5.0
9.0
27.5
5.0
11.5
32.2
11.0
14.5
46
10.5
20
57.5
- 1)
0.37
0.76
1.34
1.34
10.5
10.5
25
Ø3
Ø4
Ø5
Ø6
Ø7
Ø8
24
28
38
42
48
55
65
75
90
M8
M8
M10
M12
M12
M12
M16
M20
11.5
25
73
15.5
30
83.5
18
32
93.5
21
36
105
26
42.5
119.5
33
45
124
36
51
147.5
40
60
192
25
69
120
120
120
295
580
Transmittable torque of clamping hub [Nm]
Surface pressure [N/mm 2]
Bore Ø
Ø2
19
-
0.84
71.02
0.91
43.02
0.97
29.50
1.04
21.85
1.10
17.06
1.17
13.83
Ø9
Ø10
Ø11
Ø12
2.07
68.51
2.18
46.15
2.28
33.65
2.39
25.90
2.50
20.73
2.61
17.09
2.72
14.42
2.83
12.40
3.65
109.9
3.81
73.5
3.98
53.3
4.14
40.8
4.31
32.5
4.48
26.6
4.64
22.4
4.81
19.2
4.97
16.7
4.48
134.9
4.64
89.5
4.81
64.4
4.97
48.9
5.14
38.7
5.30
31.6
5.47
26.4
5.64
22.5
5.80
19.4
23.6
139.3
24.3
105.2
25.0
82.8
25.7
67.2
26.3
55.9
27.0
47.4
27.7
40.8
32.4
131.0
33.1
105.7
33.8
87.3
34.4
73.6
35.1
63.1
74.3
171.3
75.5
143.9
76.7
122.9
89.1
105.9
1) Slotted screw, tightening torque not defined
If used in hazardous locations the setscrews to fasten the hubs as well as all screw connections must
be secured against working loose additionally, e. g. conglutinating with Loctite (average strength).

Clamping hubs type 2.0 and 2.5 without keyway are not permissible for applications according to
DIN EN ISO 13849, part 2.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
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KTR-N
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ROTEX® GS
Operating/Assembly instructions
1
45510 EN
6 of 39
19
Technical data
Continuation of table 3: Torques and surface pressure of clamping hubs types 2.0 / 2.5
Size
Clamping screw
M1
Dimension t1
Dimension e
Dimension ØDK
Tightening
torque TA [Nm]
5
7
9
12
14
19
24
28
38
42
48
55
65
75
90
M1.2
M2
M2.5
M3
M3
M6
M6
M8
M8
M10
M12
M12
M12
M16
M20
2.5
3.5
11.4
3.5
5.0
16.5
5.0
7.5
23.4
5.0
9.0
27.5
5.0
11.5
32.2
11.0
14.5
46
10.5
20
57.5
11.5
25
73
15.5
30
83.5
18
32
93.5
21
36
105
26
42.5
119.5
33
45
124
36
51
147.5
40
60
192
- 1)
0.37
0.76
1.34
1.34
10.5
10.5
25
25
69
120
120
120
295
580
462
80
466
75
478
61
486
54
494
48
506
41
518
36
527
33
535
30
547
27
559
24
567
23
587
19
608
17
626
15
648
13
964
150
972
140
995
114
1010
101
1025
90
1048
77
1071
67
1086
61
1102
56
1125
50
1148
45
1163
42
1201
36
1239
31
1278
27
1316
24
1354
22
1392
20
Bore Ø
6.13
15.1
6.30
13.5
6.46
12.2
Ø14
Ø15
Ø16
Ø19
Ø20
Ø22
Ø24
Ø25
Ø28
Ø30
Ø32
Ø35
Ø38
Ø40
Ø42
Ø45
Ø48
Ø50
Transmittable torque of clamping hub [Nm]
Surface pressure [N/mm 2]
29.0
36.5
79.2
91.6
216
31.4
48.1
93.2
80.0
172
29.7
37.1
80.4
92.8
219
28.0
42.7
82.5
70.6
152
30.4
37.8
81.7
94.1
221
25.2
38.2
73.6
62.9
135
32.4
39.8
85.4
97.8
230
19.0
28.5
54.6
46.3
99
33.1
40.5
86.6
99.0
232
17.5
26.2
50.0
42.4
91
30.4*
41.9
89.1 101.5
238
13.3*
22.4
42.5
35.9
77
31.59*
43.2
91.6 104.0
244
11.6*
19.4
36.7
30.9
66
43.9
92.8 105.2
246
18.2
34.3
28.8
61
45.9
96.5 108.9
255
15.2
28.4
23.8
51
99.0 111.4
260
25.4
21.2
45
101.5 113.9
266
22.9
19.0
40
105.2 117.6
274
19.8
16.4
35
108.9 121.3
282
17.4
14.4
31
123.8
288
13.2
28
126.2
293
12.2
26
129.9
302
11.0
23
310
21
315
20
Ø55
352
225
356
200
369
149
373
134
381
113
389
97
393
90
405
74
413
66
421
59
433
51
446
44
454
41
462
38
474
34
486
30
494
28
514
24
Ø60
Ø65
Ø70
425
128
433
108
441
92
446
86
458
70
466
62
474
56
486
48
498
42
506
38
514
35
527
31
539
28
547
26
567
23
587
20
608
17
Ø75
Ø80
Ø85
Ø90
1776
167
1800
147
1824
131
1860
112
1896
97
1920
88
1944
81
1980
72
2016
64
2040
60
2100
51
2160
44
2220
39
2280
34
2340
31
2400
28
2460
25
2520
23
1) Slotted screw, tightening torque not defined
* type 2.0 only
= 2 x clamping screw M4; TA = 2.9 Nm
If used in hazardous locations the setscrews to fasten the hubs as well as all screw connections must be secured
against working loose additionally, e. g. conglutinating with Loctite (average strength).

Clamping hubs type 2.0 and 2.5 without keyway are not permissible for applications according to
DIN EN ISO 13849, part 2.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
Replacing:
Replaced by:
KTR-N dated 2015-10-07
ROTEX® GS
Operating/Assembly instructions
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KTR-N
Sheet:
Edition:
45510 EN
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19
Technical data
Clamping ring hubs 6.0, 6.0 steel and 6.0 light
Pull-off thread M1 between clamping screws.
Illustration 5: ROTEX® GS, clamping ring hubs
Table 4: Dimensions
Size
14
19
24
28
38
42
48
19
24
28
38
42
48
55
65
75
90
1)
Dimensions [mm]
Spider (component 2)
2)
Rated torque [Nm]
DH
dH
L
l 1; l 2
l3
E
b
s
6.0 light (size 14 - 48)
Material of hub/clamping ring - aluminium (Al-H)
30
10.5
50
18.5
13.5
13
10
1.5
40
18
66
25
18
16
12
2.0
55
27
78
30
22
18
14
2.0
Figures see table 2
65
30
90
35
27
20
15
2.5
80
38
114
45
35
24
18
3.0
95
46
126
50
35
26
20
3.0
105
51
140
56
41
28
21
3.5
6.0 steel (size 19 - 90)
Material of hub and clamping ring - steel (St-H)
6.0 (size 14 - 38)
Hub material – aluminium (Al-H)/clamping ring material – steel (St-H)
40
18
66
25
18
16
12
2.0
55
27
78
30
22
18
14
2.0
65
30
90
35
27
20
15
2.5
80
38
114
45
35
24
18
3.0
95
46
126
50
35
26
20
3.0
Figures see table 2
105
51
140
56
41
28
21
3.5
120
60
160
65
45
30
22
4.0
135
68
185
75
55
35
26
4.5
160
80
210
85
63
40
30
5.0
200
104
245
100
75
45
34
5.5
a
M1
3)
2.0
3.0
3.0
4.0
4.0
4.0
4.0
M3
M4
M5
M5
M6
M8
M10
3.0
3.0
4.0
4.0
4.0
4.0
4.5
4.5
5.0
6.5
M4
M5
M5
M6
M8
M10
M10
M12
M12
M16
®
1) For coupling selection please see catalogue drive technology "ROTEX GS".
Consider transmittable torques of the clamping connection (see table 5 to 7)
2) Ø DH + 2 mm with high speeds for expansion of spider
If used in hazardous locations the setscrews to fasten the hubs as well as all screw connections must
3)
be secured against working loose additionally, e. g. conglutinating with Loctite (average strength).

Subject to the increased safety with the assembly (several screws are tightened) and the
high friction torque of the clamping ring hub, this type is permissible for applications
according to DIN EN ISO 13849, part 2.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
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KTR-N dated 2015-10-07
KTR-N
Sheet:
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ROTEX® GS
Operating/Assembly instructions
1
45510 EN
8 of 39
19
Technical data
Table 5: Torques and surface pressure of clamping ring hubs 6.0 light
Size
Clamping screw M 1)
Quantity z (for each
clamping ring hub)
Tightening torque TA
[Nm]
14
M3
19
M4
4
6
1.34
3
Bore Ø d1
Ø6
Ø10
Ø11
Ø14
6.9
137
17
116
22
115
31
95
28
135
35
134
51
119
61
118
43
89
68
88
78
87
Ø15
Ø16
Ø19
Ø20
Ø22
Ø24
Ø25
Ø28
24
M5
28
M5
38
M6
42
M8
48
M10
4
8
8
4
4
25
49
Hub/clamping ring material - aluminium (Al-H)
6
6
10
Transmittable torque of clamping ring hub [Nm]
Surface pressure [N/mm2]
72
141
85
140
79
127
119
124
134
123
116
100
145
99
160
98
211
96
Ø30
Ø32
Ø35
Ø38
120
142
177
139
161
124
202
123
247
121
271
120
305
108
355
106
294
87
366
85
382
77
248
141
309
140
376
138
411
137
486
128
563
127
553
114
673
112
665
97
748
96
832
95
732
78
848
76
Ø40
Ø42
Ø45
Ø48
Ø50
Ø55
559
138
645
136
666
128
806
126
859
115
957
114
924
102
1069
101
1221
99
1229
92
706
134
795
133
962
130
1047
122
1165
120
1160
111
1339
109
1527
107
1393
93
1662
91
The transmittable torques of the clamping connection include the max. fitting tolerance with shaft clearance k6/bore H7, from Ø 55 G7/m6.
The torque is reduced with bigger fit clearance.
1)
If used in hazardous locations the setscrews to fasten the hubs as
well as all screw connections must be secured against working loose
additionally, e. g. conglutinating with Loctite (average strength).
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
!
Replacing:
Replaced by:
A calculation is necessary if
hollow shafts are used!
KTR-N dated 2015-10-07
KTR-N
Sheet:
Edition:
ROTEX® GS
Operating/Assembly instructions
1
45510 EN
9 of 39
19
Technical data
Table 6: Torques and surface pressure of clamping ring hubs 6.0 steel
Size
Clamping screw M 1)
Quantity z (for each
clamping ring hub)
Tightening torque TA
[Nm]
19
M4
24
M5
28
M5
38
M6
42
M8
48
M10
55
M10
65
M12
75
M12
90
M16
6
4
8
8
4
4
4
4
5
5
4.1
8.5
8.5
120
120
295
27
160
32
160
69
211
84
225
57
134
94
157
110
166
25
119
30
119
70
170
87
184
56
104
97
127
114
135
86
84
116
96
133
101
192
116
Bore Ø d1
Ø10
Ø11
Ø14
Ø15
Ø16
Ø19
Ø20
Ø22
Ø24
Ø25
Ø28
Ø30
Ø32
Ø35
Ø38
Ø40
Ø42
Ø45
Ø48
Ø50
Hub and clamping ring material - steel
14
35
69
69
Transmittable torque of clamping ring hub [Nm]
Surface pressure [N/mm 2]
-
108
168
131
178
207
200
148
129
197
142
253
154
285
159
315
141
382
148
330
79
433
123
503
122
208
138
275
151
353
163
395
168
439
149
531
157
463
120
603
131
593
118
689
114
793
119
776
102
358
152
398
135
483
143
416
108
547
119
536
99
625
104
571
86
704
92
851
98
865
92
Ø55
489
179
658
192
616
157
704
158
899
168
896
142
1030
147
962
125
1160
131
1379
137
1222
112
1543
117
Ø60
Ø65
Ø70
863
138
856
116
991
121
918
102
1119
108
1110
94
1247
97
1277
83
1672
91
1605
74
2008
80
Ø80
Ø90
Ø95
1446
140
1355
119
1637
125
1635
110
1827
113
1887
97
2429
104
2368
87
2930
92
1710
134
2053
141
2059
124
2294
127
2384
109
3040
117
2983
98
3664
104
4148
92
3845
176
4249
161
4794
153
5858
159
5900
138
7036
126
8047
114
9247
118
The transmittable torques of the clamping connection include the max. fitting tolerance with shaft clearance k6/bore H7, from Ø 55 G7/m6.
The torque is reduced with bigger fit clearance.
1)
If used in hazardous locations the setscrews to fasten the hubs as
well as all screw connections must be secured against working loose
additionally, e. g. conglutinating with Loctite (average strength).
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
!
Replacing:
Replaced by:
A calculation is necessary if
hollow shafts are used!
KTR-N dated 2015-10-07
KTR-N
Sheet:
Edition:
ROTEX® GS
Operating/Assembly instructions
1
45510 EN
10 of 39
19
Technical data
Continuation of table 6: Torques and surface pressure of clamping ring hubs 6.0 steel
Size
Clamping screw M 1)
Quantity z (for each
clamping ring hub)
Tightening torque TA
[Nm]
19
M4
24
M5
28
M5
38
M6
42
M8
48
M10
55
M10
65
M12
75
M12
90
M16
6
4
8
8
4
4
4
4
5
5
4.1
8.5
8.5
120
120
295
Bore Ø d1
Hub and clamping ring material - steel
14
35
69
69
Transmittable torque of clamping ring hub [Nm]
Surface pressure [N/mm 2]
9575
110
10845
113
Ø100
Ø105
Table 7: Torques and surface pressure of clamping ring hubs 6.0
Size
Clamping screw M 1)
Quantity z (for each clamping
ring hub)
Tightening torque TA [Nm]
14
M3
19
M4
24
M5
28
M5
38
M6
4
6
4
8
8
1.34
Bore Ø d1
Ø6
Ø10
Ø11
Ø14
8.6
225
13.8
130
14.7
118
22.7
108
Ø15
Ø16
Ø19
Ø20
Hub material - aluminium (Al-H); clamping ring material - steel
3
6
6
Transmittable torque of clamping ring hub [Nm]
Surface pressure [N/mm 2]
41
272
45
248
62
211
68
203
67
171
83
153
90
149
Ø22
Ø24
Ø25
Ø28
48
214
67
182
74
175
72
148
90
132
97
129
99
107
112
102
120
100
143
96
142
243
154
231
189
203
188
178
212
167
237
157
250
153
280
136
307
131
310
115
353
110
389
103
Ø30
Ø32
Ø35
Ø38
Ø40
Ø42
Ø45
10
269
196
307
183
337
172
356
167
398
148
436
142
442
126
501
120
533
107
572
104
615
102
644
92
The transmittable torques of the clamping connection include the max. fitting tolerance with shaft clearance k6/bore H7, from Ø 55 G7/m6.
The torque is reduced with bigger fit clearance.
1)
If used in hazardous locations the setscrews to fasten the hubs as
well as all screw connections must be secured against working loose
additionally, e. g. conglutinating with Loctite (average strength).
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
!
Replacing:
Replaced by:
A calculation is necessary if
hollow shafts are used!
KTR-N dated 2015-10-07
ROTEX® GS
Operating/Assembly instructions
1
KTR-N
Sheet:
Edition:
45510 EN
11 of 39
19
Technical data
DKM
Illustration 6: ROTEX® GS, DKM
Table 8: Dimensions
Size
Finish bore
1)
dmax.
5
7
9
12
14
19
24
28
38
5
7
11
12
16
24
28
38
45
42
48
55
55
62
74
Dimensions [mm]
D
DH
dH
dH1
l1; l2 M; N
l11
l12
LDKM
Hub material - aluminium (Al-H); Spacer material - aluminium (Al-H)
10
5
3
13
23
14
7
4
20
34
20
7.2
10
5
25
45
25
8.5
11
6
30
52
30
10.5
11
8
34
56
40
18
18
25
10
42
92
55
27
27
30
16
52
112
65
30
30
35
18
58
128
80
38
38
45
20
68
158
Hub material - steel (St-H); Spacer material - aluminium (Al-H)
85
95
46
46
50
28
22
74
174
95
105
51
51
56
32
24
80
192
110
120
60
60
65
37
28
88
218
E
b
s
a
5
8
10
12
13
16
18
20
24
4
6
8
10
10
12
14
15
18
0.5
1.0
1.0
1.0
1.5
2.0
2.0
2.5
3.0
4.0
6.0
1.5
3.5
2.0
3.0
3.0
4.0
4.0
26
28
30
20
21
22
3.0
3.5
4.0
4.0
4.0
4.5
1) dependent on type of hub
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
Replacing:
Replaced by:
KTR-N dated 2015-10-07
KTR-N
Sheet:
Edition:
ROTEX® GS
Operating/Assembly instructions
1
45510 EN
12 of 39
19
Technical data
Compact
Illustration 7: ROTEX® GS 7, 9, 12, 14 and 19 Compact
single slotted 1) (type 2.8/2.9)
Illustration 8: ROTEX® GS 24 - 38 Compact
axially slotted (type 2.8/2.9)
Illustration 9: ROTEX® GS 8, 13 and 16 Compact
single slotted (type 2.8/2.9)
Table 9: Dimensions
Size
7
8
9
12
13
14
16
19
24
28
38
Spider
(component 2)
Rated torque
[Nm]
Figures see
table 2
Dimensions [mm]
dmax.
DH
DK
L
l 1; l 2
E
b
s
dh
t
e
M
7
8
9
12
12.7
1)
16
16
1)
24
32
35
45
14
15
20
25
25
30
30
40
55
65
80
16.6
17.1
21.3
26.2
25.7
30.5
45.0
57.5
69.0
86.0
18
20
24
26
26
32
32
50
54
62
76
5
7
7
7
8
9.5
10.3
17
18
21
26
8
6
10
12
10
13
11.4
16
18
20
24
6
5
8
10
8
10
9.4
12
14
15
18
1
0.5
1
1
1
1.5
1
2
2
2.5
3
6.2
10
14
-
2.5
4.0
3.5
3.5
4.0
4.5
5.3
9.0
11.0
12.0
16.0
5.0
5.5
6.7
8.3
8.0
9.6
10.5
14.0
20.0
23.8
30.5
M2
M2
M2.5
M3
M3
M4
M4
M6
M6
M8
M10
1) Size 14 bore Ø14 - Ø16 with screw M3 and dimension e=10.4; size 19 bore Ø22 - Ø24 with screw M5 and dimension e=15.5
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
Replacing:
Replaced by:
KTR-N dated 2015-10-07
ROTEX® GS
Operating/Assembly instructions
1
KTR-N
Sheet:
Edition:
45510 EN
13 of 39
19
Technical data
Table 10: Torques and surface pressure of short clamping hubs type 2.8 / 2.9
Size
Clamping screw M
Dimension t
Dimension e
Dimension ØDK
Tightening torque TA [Nm]
7
M2
2.5
5.0
16.6
0.37
8
M2
4.0
5.5
17.1
0.52
0.8
173.5
0.9
105.1
1.0
72.1
1.0
53.4
1.1
41.7
0.65
86.4
0.85
64.8
1.1
51.9
1.3
43.2
1.5
37.0
1.7
32.4
9
M2.5
3.5
6.7
21.3
0.76
12
13
14
16
19
M3
M3
M4
M4
M6
3.5
4.0
4.5
5.3
9.0
8.3
8.0
9.6
10.5
14.0
26.2
25.7
30.5
45.0
1.34
1.9
2.9
4.1
10
Transmittable torque of clamping hub [Nm]
Surface pressure [N/mm2]
1.9
151.6
2.0
102.6
2.1
75.1
2.2
58
2.3
46.6
2.4
38.6
3.4
273.6
3.6
183.6
3.7
133.4
3.9
102.3
4.1
81.7
4.2
67.2
4.4
56.5
4.6
48.5
4.7
42.2
Bore Ø
Ø3
Ø4
Ø5
Ø6
Ø7
Ø8
Ø9
Ø10
Ø11
Ø12
2.2
145.8
2.75
116.6
3.3
97.2
3.8
83.3
4.4
72.9
4.9
64.8
5.5
58.3
6.0
53.0
6.6
48.6
Ø14
Ø15
Ø16
7.1
262.2
7.4
189.6
7.7
144.8
8.0
115.1
8.2
94.3
8.5
79.1
8.8
67.6
9.1
58.7
5.8
27.2
5.9
24.4
6.1
22.1
4.8
158.7
5.8
132.3
6.4
113.4
7.7
99.2
8.7
88.2
9.6
79.4
10.5
72.2
11.6
66.1
13.5
56.7
14.5
52.9
15.4
49.6
Ø18
Ø19
Ø20
Ø22
Ø24
Ø25
Ø28
Ø30
Ø32
Ø35
Ø38
Ø40
Ø42
Ø45
=
24.3
191.8
25.0
155.7
25.7
129.5
26.3
109.9
27.0
94.7
28.4
73.1
29.0
65.2
29.7
58.6
31.1
48.4
31.7
44.4
32.4
40.9
25.4
26.5
26.4
23.1
24
M6
11.0
20.0
57.5
10
21.2
82.3
23.3
74.8
25.4
68.6
29.7
58.8
31.8
54.9
33.9
51.4
38.2
45.7
40.3
43.3
42.4
41.1
46.7
37.4
50.9
34.3
53.0
32.9
59.4
29.4
63.6
27.4
67.9
25.7
28
M8
12.0
23.8
69.0
25
54.4
92.0
58.3
85.9
62.2
80.5
70.0
71.5
73.9
67.8
77.8
64.4
85.5
58.5
93.3
53.7
97.2
51.5
108.9
46.0
116.6
42.9
124.4
40.2
136.1
36.8
38
M10
16.0
30.5
86.0
49
92.6
109.6
98.8
102.7
111.1
91.3
117.3
86.5
123.5
82.2
135.8
74.7
148.2
68.5
154.3
65.8
172.9
58.7
185.2
54.8
197.5
51.4
216.1
47.0
234.6
43.3
246.9
41.1
259.3
39.1
277.8
36.5
ROTEX® GS 14: 1 x clamping screw M3, TA = 1.34 Nm, e = 10.4;
ROTEX® GS 19: 1 x clamping screw M5, TA = 6 Nm, e = 15.5
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
Replacing:
Replaced by:
KTR-N dated 2015-10-07
KTR-N
Sheet:
Edition:
ROTEX® GS
Operating/Assembly instructions
1
45510 EN
14 of 39
19
Technical data
Expansion hubs
Illustration 10: ROTEX® GS, expansion hub (type 9.0) with clamping hub 1)
Table 11: Dimensions
2)
Size
9
12
14
19
24
28
Spider
(component 2)
Rated torque
[Nm]
Figures see
table 2
Clamping
screw
Dimensions [mm]
D1
D2
DH
l1
l4
l5
l6
E
b
s
M
TA
10
10
12
20
25
35
20
24
35
45
55
20
25
30
40
55
65
20
19
18.5
28
38
44
11
14
12.5
20
30
36
1.5
3
1
1
1
0
2
2
0
4
5
10
12
13
16
18
20
8
10
10
12
14
15
1.0
1.0
1.5
2.0
2.0
2.5
M4
M4
M4
M6
M8
M10
2.9
2.9
2.9
10
25
49
1) The expansion hub can be combined with other types of hubs to form the opposite side, too. l 2 depends on the hub design. For further
types of hubs see chapter 4.1.
2) For coupling selection please see catalogue drive technology "ROTEX® GS".

Transmittable friction torques for D1 on request (depending on the hollow shaft).

Expansion hubs without keyway are not permissible for applications according to
DIN EN ISO 13849, part 2.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
Replacing:
Replaced by:
KTR-N dated 2015-10-07
ROTEX® GS
Operating/Assembly instructions
2
KTR-N
Sheet:
Edition:
45510 EN
15 of 39
19
Advice
®
The ROTEX GS coupling was developed for a backlash-free power
transmission and easy plug-in assembly. This backlash-free power
transmission is realized in the area of prestress (see illustration 11).
The big concave surface contact results in a lower surface pressure on
the involute tooth. Consequently the tooth can be overloaded many
times over with no wear/deformation.
The safe operation in the range of prestress is ensured, because the
coupling operates according to the principle of positive-locking rubber
spring prestress with high damping features. The star-shape coupling
Illustration 11: Prestress of spider
spider is inserted in the cams of the hubs which are machined
specifically accurately with a small amount of prestress, resulting in the
necessary backlash-free power transmission.
The flexible teeth compensating for misalignment are radially supported in the internal diameter by means of a
web. An external deformation is limited by the concave shape of the cams, ensuring a smooth operation even
with bigger masses (e. g. machine tables, articulated arms, etc.).
The flexible spiders for the GS series are available in five different kinds of Shore hardness, injected in different
colours, either as a torsionally soft or hard material.
2.1 General advice
Please read through these operating/assembly instructions carefully before you start up the coupling.
Please pay special attention to the safety instructions!
®
The ROTEX GS coupling is suitable and approved for the use in hazardous areas. When using
the coupling in hazardous locations, please observe the special advice and instructions regarding
safety in enclosure A.
®
In order to ensure the operating principle of ROTEX GS and avoid early wear of the coupling, a corresponding
operating factor „SB“ has to be considered for the selection, each depending on the application (see catalogue).
Temperatures and shocks are provided with the corresponding factors, too (see catalogue).
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.
2.2 Safety and advice symbols
STOP
!

Warning of potentially explosive
atmospheres
This symbol indicates notes which may contribute to
preventing bodily injuries or serious bodily injuries that
may result in death caused by explosion.
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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
Replacing:
Replaced by:
KTR-N dated 2015-10-07
ROTEX® GS
Operating/Assembly instructions
2
KTR-N
Sheet:
Edition:
45510 EN
16 of 39
19
Advice
2.3 General hazard warnings
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 operation 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.
2.4 Intended use
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 ROTEX GS described in here corresponds to the technical status at the time of printing of these
operating/assembly instructions.
2.5 Coupling selection
!
For a long-lasting and failure-free operation of the coupling it must be selected according to
the selection instructions (following DIN 740, part 2 with specific factors) for the particular
®
application (see catalogue drive technology "ROTEX GS").
If the operating conditions (performance, speed, modifications on engine and machine)
change, the coupling selection must be reviewed.
Please make sure that the technical data regarding torque refer to the spider only. The
transmittable torque of the shaft-hub-connection must be reviewed by the customer and is
subject 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.
2.6 Reference to EC Machinery Directive 2006/42/EC
The couplings supplied by KTR should be considered as components, not machines or partly completed
machines 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 operating/assembly instructions considering the warnings.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
Replacing:
Replaced by:
KTR-N dated 2015-10-07
ROTEX® GS
Operating/Assembly instructions
3
KTR-N
Sheet:
Edition:
45510 EN
17 of 39
19
Storage, transport and packaging
3.1 Storage
The coupling hubs are supplied in preserved condition and can be stored at a dry and covered place for
6 - 9 months.
The features of the coupling spiders (elastomers) remain unchanged for up to 5 years with favourable storage
conditions.
!
The storage rooms must 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 condensation is not generated. The best relative air humidity is less
than 65 %.
3.2 Transport and packaging
!
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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
Replacing:
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KTR-N
Sheet:
Edition:
ROTEX® GS
Operating/Assembly instructions
4
45510 EN
18 of 39
19
Assembly
The coupling is generally supplied in individual parts. Before assembly the coupling has to be inspected for
completeness.
4.1 Types of hubs
Type
1.0 with keyway and
thread
1.1 without keyway
with thread
1.2 without keyway
without thread
Please note: No
ATEX approval.
Standard type up to
size 14/
Compact up to
size 19
2.0 single slotted
without keyway
2.1 single slotted
with keyway
Standard type from
size 19
2.5 double slotted
without keyway
2.6 double slotted
with keyway
Type 4.2 1)
with CLAMPEX®
KTR 250
Type
6.0/
6.0 steel/
6.0 light
Clamping ring hub
Type 7.5 (without keyway) and 7.6 (with
keyway)
Split clamping hub for DKM/ZR3
Type
2.8 axially slotted without keyway
(size 7 to size 19 single slotted)
2.9 axially slotted with keyway
(size 7 to size 19 single slotted)
Type 7.8 (without keyway) and 7.9 (with
keyway)
Please note: Subject to the position of the
clamping screws the application is
recommended for single-cardanic couplings
only.
Type 9.0
Expansion hub
Please note: No ATEX approval.
Illustration 12: Types of hubs
1)

Selection of clamping ring hubs, clamping hubs and clamping sets
With the use in hazardous locations the clamping ring hubs, clamping hubs or type and size
of clamping sets have to be selected such that there is a minimum safety factor of s°=°2.0
covering the peak torque of the machine including all operating parameters and the friction
torque of the clamping ring hub, clamping hubs or clamping sets.
Hub types 1.1, 2.0, 2.5, 2.8, 7.5 and 7.8 (without feather keyway) may only be used in
category 3 and are not permissible for applications according to DIN EN ISO 13849, part 2.
Please observe protection
note ISO 16016.
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KTR-N
Sheet:
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45510 EN
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19
Assembly
4.2 Components of the coupling
Features of standard spiders
Increasing hardness
Spider hardness
(Shore)
Size
80 ShA-GS
(blue)
5 - 24
92 ShA-GS
(yellow)
5 - 55
98 ShA-GS
(red)
5 - 90
64 ShD-H-GS
(green)
7 - 38
Material
Polyurethane
Polyurethane
Polyurethane
Hytrel
64 ShD-GS
(green)
42 - 90
Polyurethan
e
72 ShD-H-GS
(grey)
24 - 38
72 ShD-GS
(grey)
42 - 90
Hytrel
Polyurethane
Marking
(colour)
Components of ROTEX® GS, backlash-free shaft couplings
Component
1
2
3
Quantity
2
1
2
Description
Hub
Spider
Setscrews DIN EN ISO 4029
Illustration 13: ROTEX® GS, size 5 - 38
Illustration 14: ROTEX® GS, size 42 - 90
Components of ROTEX® GS, clamping hubs
Component
1
2
3
Quantity
2
1
2
Description
Clamping hub (type of hub 2.0, 2.1, 2.5 or 2.6)
Spider
Cap screws DIN EN ISO 4762
Illustration 15: ROTEX® GS, clamping hub

Clamping hubs type 2.0 and 2.5 without keyway are not permissible for applications according to
DIN EN ISO 13849, part 2.
Please observe protection
note ISO 16016.
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Assembly
4.2 Components of the coupling
Components of ROTEX® GS, clamping ring hubs (types 6.0, 6.0 steel, 6.0 light and type 6.5)
Component
1
2
3
4
Quantity
2
2
1
see table 5, 6
and 7
Description
Clamping ring
Clamping ring hub
Spider
Cap screws DIN EN ISO 4762
Illustration 16: ROTEX® GS, clamping ring hub

Selection of clamping ring hubs
With the use in hazardous locations the clamping ring hubs have to be selected such that there is a
minimum safety factor of s = 2.0 covering the peak torque of the machine including all operating
parameters and the friction torque of the clamping ring hub.

Subject to the increased safety with the assembly (several screws are tightened) and the high friction
torque of the clamping ring hub, this type is permissible for applications according to DIN EN ISO
13849, part 2.
Components of ROTEX® GS, DKM
Component
1
2
3
4
Quantity
2
2
1
2
Description
Hub
Spider
DKM spacer
Setscrews DIN EN ISO 4029
Illustration 17: ROTEX® GS, DKM
Please observe protection
note ISO 16016.
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Assembly
4.2 Components of the coupling
Components of ROTEX® GS Compact, clamping hubs
Component
1
2
3
Quantity
2
1
2/4
Description
Clamping hub (type of hub 2.8 or 2.9)
Spider
Cap screws DIN EN ISO 4762
Illustration 18: ROTEX® GS Compact, size 7 - 19
Illustration 19: ROTEX® GS Compact, size 24 - 38
Hub types 1.1, 2.0, 2.5, 2.8, 7.5 and 7.8 (without feather keyway) may only be used in category 3 and
are not permissible for applications according to DIN EN ISO 13849, part 2.

Selection of clamping hubs
With the use in hazardous locations the clamping hubs have to be selected such that there is a
minimum safety factor of s = 2.0 covering the peak torque of the machine including all operating
parameters and the friction torque of the clamping hub.
Components of ROTEX® GS, expansion hubs
Component
1
2
3
4
5
6
Quantity
1)
1
1
1
1)
1
Description
Hub
Spider
Expansion hub
Clamping bolt for expansion hub
Cap screws DIN EN ISO 4762
Cap screws DIN EN ISO 4762
1) The expansion hub can be combined with other hub designs to form the opposite side, too, please refer to your dimension sheet.
Illustration 20: ROTEX® GS, expansion hubs
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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45510 EN
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19
Assembly
4.3 Advice for assembly
®
Subject to its design ROTEX GS allows to axially plug in the coupling having assembled the hubs onto the shaft
journal. Consequently there is no need for subsequent screwing and the respective mounting holes in the
housing.
The pegs on the spider arranged reciprocally prevent a contact between the spider and the hubs over the full
surface. Observing the distance dimension E, the ability for displacement of the coupling is ensured in this way.
All teeth are chamfered on the face which allows a blind assembly. When the coupling hubs are combined with
®
the ROTEX GS spider an axial assembly force is generated resulting from the flexible prestress of the starshape elastomer. This assembly force varies depending on the coupling size, the spider hardness and the
machining tolerances.
The axial assembly force is compensated for after assembly of the hubs and consequently does not mean any
risk of axial load being applied to adjacent bearings.
The mounting force can be reduced by lightly greasing or lubricating the elastomer or the hubs. For this purpose
please only use oils and greases on a mineral oil basis without any additives. Lubricants on a silicone basis (e. g.
Optimol Optisit WX) or vaseline have proven their worth, too.
4.4 Advice for finish bore
STOP
The maximum permissible bore diameters d (see table 1 to
11 in chapter 1 - technical data) must not be exceeded. If
these figures are disregarded, the coupling may tear.
Rotating particles may cause danger to life.
 Hub bores machined by the customer have to observe
concentricity or axial runout, respectively (see illustration
21).
 Please make absolutely sure to observe the figures for
Ø dmax.
 Carefully align the hubs when the finish bores are drilled.
 Please provide for a setscrew according to
DIN EN ISO 4029 with a cup point or an end plate to fasten
the hubs axially.
Illustration 21: Concentricity
and axial runout
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.
!
KTR supplies unbored or pilot bored coupling components and spare parts only upon
explicit request of the customer. These parts are additionally labelled with the symbol
.
Table 12: Setscrews DIN EN ISO 4029
Size
5
7
9
12
14
19
24
28
38
42
48
55
65
75
90
Dimension G
Dimension t
Tightening
torque TA [Nm]
M2
2.5
M3
3.5
M4
5
M4
5
M4
5
M5
10
M5
10
M8
15
M8
15
M8
20
M8
20
M10
20
M10
20
M10
25
M12
30
-
-
1.5
1.5
1.5
2
2
10
10
10
10
17
17
17
40
Please observe protection
note ISO 16016.
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45510 EN
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19
Assembly
4.5 Assembly of hubs (types 1.0, 1.1 and 1.2)

We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Before starting with the assembly preserving agents have to be removed from the bores. Moreover, the shaft
ends have to be cleaned carefully, too.
Please note the manufacturer’s instructions regarding the use of detergents.
!
Heating the hubs lightly (approx. 80 °C) allows for an easier mounting on the shaft.
Please pay attention to the ignition risk in hazardous locations!
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 to 11) is
observed to allow for axial clearance of the spider when in operation.
Disregarding this advice may cause damage to the coupling.
 Mount the hubs on the shaft of driving and driven side.
 Insert the spider into the cam section of the hub on the driving or driven side.
 Shift the power packs in axial direction until the distance dimension E is achieved.
 If the power packs are already firmly assembled, shifting the hubs axially on the shafts allows for adjusting the
distance dimension E.
 Fasten the hubs by tightening the setscrews DIN EN ISO 4029 with a cup point (tightening torques see
table 12).

If the shaft diameters with inserted feather key are smaller than dimension dH (see table 1 to
11) of the spider, one or two shaft ends may protude into the spider.
If used in hazardous locations the setscrews to fasten the hubs as well as all screw
connections must be secured against working loose additionally, e. g. conglutinating with
Loctite (average strength).
Hub type 1.1 (without feather keyway) may be used in category 3 only.
!
Please observe protection
note ISO 16016.
Drawn:
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Operating/Assembly instructions
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45510 EN
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19
Assembly
4.6 Assembly of clamping hubs (types 2.0, 2.1, 2.5, 2.6, 2.8, 2.9, 7.5, 7.6, 7.8 and 7.9)
®
The power transmission of ROTEX GS clamping hubs (types 2.0, 2.5, 2.8, 7.5 and 7.8) is frictionally engaged.
With types 2.1, 2.6, 2.9, 7.6 and 7.9 a feather key additionally provides for positive locking power transmission.
 Clean and degrease the hub bore and the shaft.
 Lightly detach the clamping screws.
 Slip the hub onto the shaft. Please observe the dimension l1/l2.
 Tighten the clamping screws at the tightening torques mentioned in
table 3.
With types 2.8, 7.5, 7.8 or 2.9, 7.6, 7.9 (with keyway) the screws have
to be tightened alternately in equal steps at the tightening torques
specified in table 3.
If used in hazardous locations the clamping screws to
fasten the hubs as well as all screw connections must be
secured against working loose additionally, e. g.
conglutinating with Loctite (average strength).
Illustration 22: Assembly of clamping hub
Please note: types 2.8, 2.9, 7.5, 7.6, 7,8 or
7.9 have 2 clamping screws
!
The frictionally engaged transmittable torques of the clamping hubs depend on the bore
diameter.
Hub types 2.0, 2.5, 2.8, 7.5 and 7.8 (without feather keyway) may only be used in category 3
and are not permissible for applications according to DIN EN ISO 13849, part 2.
!
If the clamping screws are not tightened at the correct tightening torque, there is the risk of
a) a fracture of the hub and plastic deformation with a too high tightening torque T A
b) type 6.0: a fracture of the hubs/cams and plastic deformation with a too high tightening
torque TA
c) early slippling, untightening of the screws with a too small tightening torque T A
4.7 Assembly/disassembly of clamping ring hubs (types 6.0, 6.0 steel, 6.0 light and 6.5)
®
The power transmission of ROTEX GS clamping hubs is frictionally engaged. The necessary surface pressure is
transmitted via the clamping ring with internal taper to the taper hub and consequently to the shaft. The torques
mentioned in tables 5 to 7 include a fit pair H7/k6 from Ø 55 G7/m6. With a higher fit clearance the torques
mentioned in tables 5 to 7 are reduced.
The stiffness and dimensions of the shafts (here specifically hollow shafts) have to be selected in a way that
sufficient safety against plastic deformation is ensured. This may roughly be reviewed as per the following
criterion.
If used in hazardous locations the setscrews to fasten the hubs as well as all screw
connections must be secured against working loose additionally, e. g. conglutinating with
Loctite (average strength).
Please observe protection
note ISO 16016.
Drawn:
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2016-05-11 Pz
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ROTEX® GS
Operating/Assembly instructions
4
45510 EN
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19
Assembly
4.7 Assembly/disassembly of clamping ring hubs (types 6.0, 6.0 steel, 6.0 light and 6.5)
Rp0,2  2  pW
With clamping connections with hollow shafts the
required internal diameter of the hollow shaft diW is
calculated based on the following formula:
diW  d 
Shear stress on the internal shaft diameter for hollow
shaft:
tiW  
Shear stress for solid shaft:
tW   pW N / mm2
Rp0.2
pW
=
=
2  pW
1  CW 2

2
yield strength of shaft material [N/mm ]
2
surface pressure of hub/shaft [N/mm ]
diW
d
CW
=
=
=
mm
Rp0,2
N / mm 
2

internal diameter of hollow shaft [mm]
shaft diameter [mm]
diW / d
The strength required is not provided if the hollow shaft bore is bigger than the max. internal bore calculated or if
the shear stress exceeds the yield strength of the material.
For a detailed calculation please contact KTR’s engineering department.
 Clean the hub bore and shaft and review for dimensional accuracy,
afterwards lubricate with a thin-fluid oil (e. g. Castrol 4 in 1, Klüber
Quietsch-Ex or WD 40).
!
Oils and greases containing molybdenum disulfide or other
high-pressure additives as well as internal lubricants must
not be used.
 Lightly untighten the clamping screw and pull the clamping ring from the
hub only marginally to make sure that the clamping ring is loosened.
 Slip the clamping ring hub onto the shaft. The dimension l3 should at least
be observed (see table 4).
 Tighten the clamping screws evenly crosswise step by step to the
tightening torque specified in table 6 or 7. Repeat this process until all
clamping screws have reached the tightening torque.
!
Illustration 23: Assembly of
clamping ring hub with clamping ring
If the clamping screws are not tightened at the correct tightening torque, there is the risk of
a) a fracture of the hub and plastic deformation with a too high tightening torque T A
b) early slippling, untightening of the screws with a too small tightening torque T A
 Assembly of the clamping ring hub 6.0 light:
Tighten the clamping screws evenly stepwise and crosswise at 1/3 or 2/3 tightening torque T A, respectively
(see table 5) until the ring gets in contact. Afterwards tighten the screws at the tightening torque mentioned in
table 5 one after another.
If used in hazardous locations the setscrews to fasten the hubs as well as all screw
connections must be secured against working loose additionally, e. g. conglutinating with
Loctite (average strength).

Selection of clamping ring hubs
With the use in hazardous locations the clamping ring hubs have to be selected such that
there is a minimum safety factor of s = 2 covering the peak torque of the machine including
all operating parameters and the friction torque of the clamping ring hub.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
Replacing:
Replaced by:
KTR-N dated 2015-10-07
KTR-N
Sheet:
Edition:
ROTEX® GS
Operating/Assembly instructions
4
45510 EN
26 of 39
19
Assembly
4.7 Assembly/disassembly of clamping ring hubs (types 6.0, 6.0 steel, 6.0 light and 6.5)
Disassembly:
Unscrew the clamping screws evenly one after another. During every
revolution every screw may only be unscrewed by half a turn. Unscrew all
clamping screws by 3 - 4 pitches.
Remove the screws located next to the pull-off threads and screw them into
the respective pull-off threads until they are in contact.
The clamping ring is released if the screws in the pull-off threads are
tightened evenly stepwise and crosswise.
!
If these hints are not observed, the operation of the
coupling may be affected.
Illustration 24: Disassembly of clamping
ring hub with clamping ring
If the assembly is repeated the bore of the hub and shaft have to be cleaned and afterwards lubricated with a thinfluid oil (e. g. Castrol 4 in 1, Klüber Quietsch-Ex or WD 40). The same applies for the taper surfaces of clamping
ring hub and clamping ring.
!
Oils and greases containing molybdenum disulfide or other high-pressure additives as well
as internal lubricants must not be used.
For type 6.0 light only:

If the assembly is repeated the taper surfaces, bores of the hub and the shaft have to be
cleaned. The bore of the hub and shaft have to be lubricated with thin-fluid oil (e. g. Castrol
4 in 1, Klüber Quietsch-Ex or WD 40). Lightly paint the taper surfaces of the clamping ring
hub or clamping ring with the grease Gleitmo 800, afterwards turn the components by one
revolution in order to spread the grease evenly.
Please observe protection
note ISO 16016.
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ROTEX® GS
Operating/Assembly instructions
4
45510 EN
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19
Assembly
4.8 Assembly/disassembly of expansion hubs (type 9.0)
 Untighten clamping screw and clamping bolt.
 Clean and degrease the internal diameter of the hollow shaft and the
outside contact surface of the expansion hub (see illustration 25).
 Insert the expansion hub along with clamping bolt and clamping screw in
the hollow shaft. Tighten the clamping screw at the tightening torque
mentioned in table 11.

!
!
The tightening torques apply for the figures mentioned in
table 11 only.
Illustration 25: Cleaning the expansion hub
and hollow shaft
The frictionally engaged transmittable torques of the expansion hub depend on the internal
and external diameter of the hollow shaft as well as the material.
If the clamping screws are not tightened at the correct tightening torque, there is the risk of
a) a fracture of the hub and plastic deformation with a too high tightening torque T A
b) early slippling, untightening of the screws with a too small tightening torque T A
Disassembly:
Unscrew the clamping screw only lightly so that the clamping bolt loosens. If the clamping bolt did not loosen,
apply a light beat on the screw head. Afterwards remove the clamping screw fully.
4.9 Displacements - alignment of the couplings
The displacement figures specified in tables 13 and 14 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 and avoid dangers with the use in
hazardous locations, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures specified (see tables 13 and 14). If the
figures are exceeded, the coupling will be damaged.
The more accurate the alignment of the coupling, the longer is its service life.
If used in hazardous areas for the explosion group IIC (marking II 2GD c IIC T X), only half of
the displacement figures (see tables 13 and 14) are permissible.
Please note:
 The displacement figures specified in tables 13 and 14 are maximum figures which must not arise in parallel. If
radial and angular displacements arise at the same time, the permissible displacement values may only be
used proportionally (see illustration 27).
 Please inspect with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 13 and
14 can be observed.
Please observe protection
note ISO 16016.
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2016-05-11 Pz
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Edition:
45510 EN
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Assembly
4.9 Displacements - alignment of the couplings
Angular displacements
Radial displacements
Axial displacements
Kw [mm] = L1max - L1min
Lmax = L + Ka
Illustration 26: Displacements
Examples of the displacement combinations
specified in illustration 27:
Illustration 27:
Combinations of
displacement
Example 1:
Kr = 30%
Kw = 70%
Example 2:
Kr = 60%
Kw = 40%
Ktotal = Kr + Kw  100 %
Table 13: Displacement figures
Size
5
7
8
9
12
13
14
16
19
24
28
38
42
48
55
65
75
90
Max. axial
displacement
Ka [mm]
+0.4 / -0.2
+0.6 / -0.3
±1.0
+0.8 / -0.4
+0.9 / -0.4
±1.0
+1.0 / -0.5
±1.0
+1.2 / -0.5
+1.4 / -0.5
+1.5 / -0.7
+1.8 / -0.7
+2.0 / -1.0
+2.1 / -1.0
+2.2 / -1.0
+2.6 / -1.0
+3.0 / -1.5
+3.4 / -1.5
80
ShA-GS
0.12
0.15
0.15
0.19
0.20
0.20
0.21
0.21
0.15
-
Please observe protection
note ISO 16016.
Max. radial displacement Kr [mm]
92
98
64
72
ShA-GS ShA-GS ShD-GS ShD-GS
0.06
0.04
0.10
0.06
0.04
0.08
0.06
0.13
0.08
0.05
0.14
0.08
0.05
0.08
0.05
0.15
0.09
0.06
0.10
0.08
0.10
0.06
0.04
0.14
0.10
0.07
0.04
0.15
0.11
0.08
0.05
0.17
0.12
0.09
0.06
0.19
0.14
0.10
0.07
0.23
0.16
0.11
0.08
0.24
0.17
0.12
0.09
0.18
0.13
0.10
0.21
0.15
0.11
0.23
0.17
0.13
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Max. angular displacement Kw [degree/mm]
80
92
98
64
72
ShA-GS
ShA-GS
ShA-GS
ShD-GS
ShD-GS
1.1 0.2 1.0 0.15 0.9 0.15
1.1 0.25 1.0 0.2 0.9 0.2 0.8 0.2
1.1 0.4
0.9 0.3 0.8 0.3
1.1 0.5 1.0 0.35 0.9 0.3 0.8 0.3
1.1 0.5 1.0 0.45 0.9 0.4 0.8 0.35
1.1 0.5
0.9 0.4 0.8 0.35
1.1 0.6 1.0 0.5 0.9 0.5 0.8 0.4
1.1 0.6
0.9 0.5 0.8 0.4
1.1 0.75 1.0 0.7 0.9 0.6 0.8 0.55
1.0 1.0 0.9 0.85 0.8 0.75 0.7 0.65
1.0 1.1 0.9 1.0 0.8 0.9 0.7 0.8
1.0 1.4 0.9 1.25 0.8 1.1 0.7 1.0
1.0 1.65 0.9 1.5 0.8 1.3 0.7 1.1
1.0 1.85 0.9 1.65 0.8 1.45 0.7 1.3
1.0 2.1 0.9 1.85 0.8 1.7 0.7 1.4
0.9 2.1 0.8 1.9 0.7 1.6
0.9 2.5 0.8 2.2 0.7 2.0
0.9 3.1 0.8 2.8 0.7 2.4
Replacing:
Replaced by:
KTR-N dated 2015-10-07
ROTEX® GS
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
45510 EN
29 of 39
19
Assembly
4.9 Displacements - alignment of the couplings
Table 14: Displacement figures - type DKM
Size
5
7
9
12
14
19
24
28
38
42
48
55
Max. axial
displacement
Ka [mm]
+0.4 / -0.4
+0.6 / -0.6
+0.8 / -0.8
+0.9 / -0.9
+1.0 / -1.0
+1.2 / -1.0
+1.4 / -1.0
+1.5 / -1.4
+1.8 / -1.4
+2.0 / -2.0
+2.1 / -2.0
+2.2 / -2.0
80
ShA-GS
0.15
0.23
0.29
0.35
0.40
0.49
-
Max. radial displacement Kr [mm]
92
98
64
72
ShA-GS
ShA-GS
ShD-GS ShD-GS
0.14
0.13
0.21
0.19
0.17
0.26
0.24
0.21
0.32
0.29
0.25
0.37
0.33
0.29
0.45
0.41
0.36
0.59
0.53
0.47
0.42
0.66
0.60
0.53
0.46
0.77
0.69
0.61
0.54
0.84
0.75
0.67
0.59
0.91
0.82
0.73
0.64
1.01
0.91
0.81
0.71
Max. angular displacement Kw [degree]
80
92
98
64
72
ShA-GS
ShA-GS
ShA-GS
ShD-GS ShD-GS
1.1
1.0
0.9
1.1
1.0
0.9
0.8
1.1
1.0
0.9
0.8
1.1
1.0
0.9
0.8
1.1
1.0
0.9
0.8
1.1
1.0
0.9
0.8
1.0
0.9
0.8
0.7
1.0
0.9
0.8
0.7
1.0
0.9
0.8
0.7
1.0
0.9
0.8
0.7
1.0
0.9
0.8
0.7
1.0
0.9
0.8
0.7
®
The permissible displacement figures of the flexible ROTEX GS couplings mentioned are general standard values taking into
account the load of the coupling up to the rated torque TKN of the coupling and an ambient temperature of + 30 °C.
5
Start-up
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.
If used in hazardous locations the setscrews to fasten the hubs as well as all screw connections
must be secured against working loose additionally, e. g. conglutinating with Loctite (average
strength).
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.
If the couplings are used in locations subject to dust explosion and in mining the user must make sure that there
is no accumulation of dust in a dangerous volume between the cover and the coupling. The coupling must not
operate in an accumulation of dust.
For covers with unlocked openings on the top face no light metals must be used if the couplings are used as
equipment of equipment group ll (if possible, from stainless steel).
If the couplings are used in mining (equipment group l M2), the cover must not be made of light metal. In addition,
it must be resistant to higher mechanical loads than if it is used as equipment of equipment group ll.
The minimum distance „Sr“ between the protective device and the rotating parts must at least correspond to the
figures specified below.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
Replacing:
Replaced by:
KTR-N dated 2015-10-07
ROTEX® GS
Operating/Assembly instructions
5
KTR-N
Sheet:
Edition:
45510 EN
30 of 39
19
Start-up
If the protective device is used as cover, regular openings can be arranged from the point of view explosion
protection that must not exceed the following dimensions:
Top side
4
4
Cover [mm]
Lateral components
8
8
Distance „Sr“
 10
 10
not permissible
8
 20
Openings
Circular - max. diameter
Rectangular - max. lateral length
Straight or curved slot - max. lateral
length/height
!
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.
Coating of coupling:
If coated (priming, paintings, etc.) couplings are used in hazardous locations, the requirements on
conductibility and coating thickness must be considered. In case of paintings up to 200 µm
electrostatic load does not have to be expected. Multiple coatings exceeding 200 µm are prohibited
for explosion group llC.
6
Breakdowns, causes and elimination
®
The below-mentioned failures can lead to a use of the ROTEX GS 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
components must generally be considered.
If used other than intended the coupling can become a source of ignition.
EU directive 2014/34/EU requires special care by the manufacturer and the user.
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 spider is inserted in the coupling.
 No original KTR components (purchased parts) are used.
 Old/already worn out spiders or spiders stored for too long are used.

: The coupling used/the coupling protection used is not suitable for the operation in hazardous locations
and does not correspond to EU directive 2014/34/EU, respectively.
 Maintenance intervals are not observed.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
Replacing:
Replaced by:
KTR-N dated 2015-10-07
ROTEX® GS
Operating/Assembly instructions
6
KTR-N
Sheet:
Edition:
45510 EN
31 of 39
19
Breakdowns, causes and elimination
Breakdowns
Different operating
noise and/or
vibrations occuring
Causes
Hazard notes for
hazardous locations
Misalignment
Increased temperature on
the spider surface; ignition
risk by hot surfaces
Wear of spider, shortterm torque
transmission due to
metal contact
Ignition risk due to
sparking
Screws for axial
fastening of hubs
working loose
Ignition risk due to hot
surfaces and sparking
Wear of spider, torque
transmission due to
metal contact
Breaking of the cams
due to high impact
energy/overload
Breaking of cams
Operating parameters
do not meet with the
performance of the
coupling
Ignition risk due to
sparking
Operating error of the
unit
Early wear of spider
or reverse backlash
Misalignment
Increased temperature on
the spider surface; ignition
risk by hot surfaces
e. g. contact with
aggressive liquids/oils,
ozone influence, too
high/low ambient
temperatures etc.
causing physical
modification of the
spider
Ignition risk due to
sparking with metallic
contact of the cams
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
Please observe protection
note ISO 16016.
Elimination
1) Set the unit out of operation
2) Eliminate the reason for the misalignment
(e. g. loose foundation bolts, breaking of the
engine mount, heat expansion of unit
components, modification of the installation
dimension E of the coupling)
3) For inspection of wear see item inspection
1) Set the unit out of operation
2) Disassemble the coupling and remove
remainders of the spider
3) Inspect coupling components and replace
coupling components that are damaged
4) Insert spider, assemble coupling
components
5) Inspect alignment, adjust if necessary
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 inspection
1) Set the unit out of operation
2) Replace complete coupling
3) Inspect alignment
1) Set the unit out of operation
2) Replace complete coupling
3) Inspect alignment
4) Find out the reason for overload
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
1) Set the unit out of operation
2) Replace complete coupling
3) Inspect alignment
4) Instruct and train the service staff
1) Set the unit out of operation
2) Eliminate the reason for the misalignment
(e. g. loose foundation bolts, breaking of the
engine mount, heat expansion of unit
components, modification of the installation
dimension E of the coupling)
3) For inspection of wear see item inspection
1) Set the unit out of operation
2) Disassemble the coupling and remove
remainders of the spider
3) Inspect coupling components and replace
coupling components that are damaged
4) Insert spider, assemble coupling
components
5) Inspect alignment, adjust if necessary
6) Make sure that further physical modifications
of the spider are excluded
Replacing:
Replaced by:
KTR-N dated 2015-10-07
ROTEX® GS
Operating/Assembly instructions
6
KTR-N
Sheet:
Edition:
45510 EN
32 of 39
19
Breakdowns, causes and elimination
Breakdowns
Early wear of spider
or reverse backlash
Causes
Hazard notes for
hazardous locations
excessively high/low
ambient/contact
temperatures for the
spider; max.
permissible e. g.
T4 = - 30 °C/+ 90 °C
Ignition risk due to
sparking with metallic
contact of the cams
Early wear of spider
(liquefaction of
material inside the
spider cam)
Vibrations of drive
Elimination
1) Set the unit out of operation
2) Disassemble the coupling and remove
remainders of the spider
3) Inspect coupling components and replace
coupling components that are damaged
4) Insert spider, assemble coupling
components
5) Inspect alignment, adjust if necessary
6) Inspect and adjust ambient/contact
temperature (possibly corrective by using
different spider materials)
1) Set the unit out of operation
2) Disassemble the coupling and remove
remainders of the spider
3) Inspect coupling components and replace
coupling components that are damaged
4) Insert spider, assemble coupling
components
5) Inspect alignment, adjust if necessary
6) Find out the reason for the vibrations
(possibly corrective by spider with lower or
higher Shore hardness)
If you operate with a worn spider (see item 10.3) and with subsequent contact of metal parts
a proper operation meeting the explosion protection requirements and acc. to directive
2014/34/EU is not ensured.
7
Disposal
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.
 Metal
Any metal components have to be cleaned and disposed of by scrap metal.
 Nylon materials
Nylon materials have to be collected and disposed of by a waste disposal company.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
Replacing:
Replaced by:
KTR-N dated 2015-10-07
ROTEX® GS
Operating/Assembly instructions
8
KTR-N
Sheet:
Edition:
45510 EN
33 of 39
19
Maintenance and service
®
ROTEX GS 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 spider of the coupling.
 Since the flexible machine bearings of the driving and driven side settle during the course of load, please
inspect the alignment of the coupling and re-align the coupling, if necessary.
 The coupling parts have to be inspected for damages.
 The screw connections have to be inspected visually.
Having started up the coupling the tightening torques of the screws have to be inspected
during the usual inspection intervals.
!
With the use in hazardous locations please observe chapter 10.2 Inspection intervals for
couplings in
- hazardous locations.
9
Spares inventory, customer service addresses
A basic requirement to ensure 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 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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
Replacing:
Replaced by:
KTR-N dated 2015-10-07
ROTEX® GS
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
45510 EN
34 of 39
19
Enclosure A
Advice and instructions regarding the use in
hazardous locations
Types available:
®
a) Hubs with feather keyway or CLAMPEX clamping set or clamping ring hubs
 1.0 Hub with feather keyway and thread for setscrews
 2.1 Clamping hub single slot with feather keyway
 2.6 Clamping hub double slot with feather keyway
 2.9 Clamping hub with axial slot with feather keyway
®
 4.1 with CLAMPEX clamping set KTR 200
®
 4.2 with CLAMPEX clamping set KTR 250
 6.0 Clamping ring hub
 6.0 Clamping ring hub light
 6.0 P Precision clamping ring hub
 6.5 Clamping ring hub
(Hint: external clamping screws)
 7.6 Split clamping hub with feather keyway for double-cardanic combinations
 7.9 Split clamping hub with feather keyway for single-cardanic combinations
 Type DKM with hubs corresponding to the aforementioned details
b) Hubs which may be used in group II, category 3 only: hubs without feather keyway
 1.1 Hub without feather keyway, with thread for setscrews
 2.0 Clamping hub single slot without feather keyway
 2.5 Clamping hub double slot without feather keyway
 2.8 Clamping hub with axial slot without feather keyway
 7.5 Split clamping hub without feather keyway for double-cardanic combinations
 7.8 Split clamping hub without feather keyway for single-cardanic combinations
 Type DKM with hubs corresponding to the aforementioned details
®
ROTEX GS type DKM only with spacer made of steel or aluminium wrought products with a yield stress
2
Rp0.2 ≥ 250 N/mm .
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
Replacing:
Replaced by:
KTR-N dated 2015-10-07
KTR-N
Sheet:
Edition:
ROTEX® GS
Operating/Assembly instructions
10
45510 EN
35 of 39
19
Enclosure A
Advice and instructions regarding the use in
10.1 Intended use in
hazardous locations
hazardous locations
Conditions of operation in
hazardous locations
®
ROTEX GS couplings are suitable for the use according to EU directive 2014/34/EU.
1. Industry (with the exception of mining)




Equipment group II of category 2 and 3 (coupling is not approved for equipment group 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 group IIC (explosion class IIA and IIB are included in IIC)
Temperature class:
Temperature class
T4, T3, T2, T1
T5
T6
Ambient or operating temperature Ta
1)
- 30 °C to + 90 °C
- 30 °C to + 80 °C
- 30 °C to + 65 °C
Max. surface temperature
2)
+ 110 °C
+ 100 °C
+ 85 °C
Explanation:
The maximum surface temperatures each result from the maximum permissible ambient or operating temperature T a plus the maximum
temperature increase T of 20 K which has to be taken into account.
1) The ambient or operating temperature Ta is 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
Equipment group I of category M2 (coupling is not approved for equipment group M1).
Permissible ambient temperature - 30 °C to + 90 °C.
In mining for equipment group I of category M2 coupling hubs and DKM spacers made of steel only are
permissible.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
Replacing:
Replaced by:
KTR-N dated 2015-10-07
ROTEX® GS
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
45510 EN
36 of 39
19
Enclosure A
Advice and instructions regarding the use in
10.2 Inspection intervals for couplings in
Explosion group
3G
3D
II 2GD c IIB
T4, T5, T6
II 2GD c IIC
T4, T5, T6
hazardous locations
hazardous locations
Inspection intervals
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 ignition risk analysis the couplings are free from any ignition
source. Merely the temperature increase produced by self-heating and depending on the
coupling type has to be considered:
®
for ROTEX GS: T = 20 K
An inspection of the torsional backlash and a visual inspection of the flexible spider must
be performed after 3,000 operating hours for the first time, at the latest after 6 months after
start-up of the coupling.
If you note insignificant or no wear on the spider upon this initial inspection, further
inspections can each be performed after 6,000 operating hours or at the latest after 18
months, provided that the operating parameters remain the same.
If you note significant wear during the initial inspection so that it would be recommendable
to replace the spider, please find out the cause according to the table „Breakdowns“, if
possible.
The maintenance intervals must be adjusted to the modified operating parameters without
fail.
An inspection of the torsional backlash and a visual inspection of the flexible spider must
be performed after 2,000 operating hours for the first time, at the latest after 3 months after
start-up of the coupling.
If you note insignificant or no wear on the spider upon this initial inspection, further
inspections can each be performed after 4,000 operating hours or at the latest after 12
months, provided that the operating parameters remain the same.
If you note significant wear during the initial inspection so that it would be recommendable
to replace the spider, please find out the cause according to the table „Breakdowns“, if
possible.
The maintenance intervals must be adjusted to the modified operating parameters without
fail.
Hub type 1.1, 2.0, 2.5, 2.8, 7.5 and 7.8 (without feather keyway) may be used in category 3
only.
®
ROTEX GS backlash-free shaft couplings
Illustration 28: ROTEX® GS backlash-free shaft coupling
Illustration 29: ROTEX® GS spider
If the drive permits, the backlash between the cams of the coupling and the flexible spider has to be measured by
means of a feeler gauge.
When reaching the wear limit maximum friction, the spider must be replaced immediately, irrespective of the
inspection intervals.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
Replacing:
Replaced by:
KTR-N dated 2015-10-07
ROTEX® GS
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
45510 EN
37 of 39
19
Enclosure A
Advice and instructions regarding the use in
hazardous locations
10.3 Standard values of wear
In case of a backlash > X mm, the flexible spider must be replaced.
Reaching the limits for replacing depends on the operating conditions and the existing operating parameters.
In order to ensure a long service life of the coupling and avoid dangers with the use in
hazardous locations, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures specified (see tables 13 and 14). If the
figures are exceeded, the coupling will be damaged.
!
Illustration 30: Inspection of the limit of wear

Illustration 31: Wear of spider
For backlash-free applications no wear is permitted, since otherwise the operating principle
of the coupling (backlash-free condition) is no longer ensured. If a backlash-free operation
is not required, the following figures apply:
Table 15:
Size
5
7
8
9
12
13
14
16
19
Limits of wear (friction)
Xmax. [mm]
0.4
0.5
0.4
0.9
0.6
0.5
1.25
0.7
0.9
10.4 Permissible coupling materials in
Limits of wear (friction)
Xmax. [mm]
1.0
1.4
1.7
2.0
2.25
2.50
2.75
3.00
3.25
Size
24
28
38
42
48
55
65
75
90
hazardous locations
In the explosion groups IIA, IIB and IIC the following materials may be combined:
Steel
Stainless steel
aluminium wrought products
Semi-finished products of aluminium with a magnesium share of up to 7.5°% and a yield point of
2
Rp0.2 ≥ 250 N/mm are permitted for the use in hazardous locations.
Aluminium diecast is generally excluded for hazardous locations.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2016-05-04 Pz/De
2016-05-11 Pz
Replacing:
Replaced by:
KTR-N dated 2015-10-07
ROTEX® GS
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
45510 EN
38 of 39
19
Enclosure A
Advice and instructions regarding the use in
10.5
hazardous locations
marking of coupling for hazardous locations
Couplings for the use in hazardous locations are marked on at least one component completely and on the
remaining components by an
label on the outside diameter of the hub or on the front side each for the
operating conditions permitted. The flexible spider is excluded. For reason of limited space only the symbol
stamped up to size 19.
Short labelling:
(standard)
is
II 2GD c IIC T X/I M2 c X
Category 3:
II 3G c IIC T6, T5 resp. T4 - 30 °C  Ta  + 65 °C, + 80 °C resp.
+ 90 °C
II 3D c T 110 °C - 30 °C  Ta  + 90 °C
Complete labelling:
II 2G c IIC T6, T5 resp. T4 - 30 °C  Ta  + 65 °C, + 80 °C resp.
+ 90 °C
II 2D c T 110 °C/I M2 c - 30 °C  Ta  + 90 °C
The labelling with explosion group llC includes the explosion groups llA and llB.
If the symbol
KTR.
was stamped in addition to
Please observe protection
note ISO 16016.
Drawn:
Verified:
, the coupling component was supplied unbored or pilot bored by
2016-05-04 Pz/De
2016-05-11 Pz
Replacing:
Replaced by:
KTR-N dated 2015-10-07
ROTEX® GS
Operating/Assembly instructions
10
KTR-N
Sheet:
Edition:
45510 EN
39 of 39
19
Enclosure A
Advice and instructions regarding the use in
hazardous locations
10.6 EU Certificate of conformity
EU Certificate of conformity
corresponding to EU directive 2014/34/EU dated 26 February 2014
and to the legal regulations
The manufacturer - KTR Kupplungstechnik GmbH, D-48432 Rheine - states that the
ROTEX® GS backlash-free shaft couplings
in an explosion-proof design described in these operating/assembly instructions are devices
corresponding to article 2, 1. of directive 2014/34/EU and comply with the general safety and health
requirements according to enclosure II of directive 2014/34/EU.
The coupling described in here complies with the specifications of the following standards/guidelines:
DIN EN 1127-1
DIN EN 1127-2
DIN EN 13463-1
DIN EN 13463-5
®
The ROTEX GS is in accordance with the specifications of the directive 2014/34/EU. One or several
directives mentioned in the corresponding type examination certificate IBExU03ATEXB002_05 X were
in part replaced by updated versions.
KTR Kupplungstechnik GmbH being the manufacturer confirms that the product mentioned above is in
accordance with the specifications of the new directives, too.
According to article 13 (1) b) ii) of directive 2014/34/EU the technical documentation is deposited with
the institution:
IBExU
Institut für Sicherheitstechnik GmbH
Fuchsmühlenweg 7
09599 Freiberg
Rheine,
Place
2016-05-04
Date
Please observe protection
note ISO 16016.
Drawn:
Verified:
i. V.
Reinhard Wibbeling
Engineering/R&D
2016-05-04 Pz/De
2016-05-11 Pz
i. V.
Johannes Deister
Product Manager
Replacing:
Replaced by:
KTR-N dated 2015-10-07