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POLY-NORM
®
- M
Operating/Assembly instructions
Sheet:
Edition:
1 of 14
Please observe protection note ISO 16016. Drawn: 2018 - 01 - 18 Pz/Kr Replacing: KTR-N 49514 POLY-NORM ® -M
Flexible jaw coupling type AFN
for finish bored, pilot bored and unbored couplings
Type AFN
POLY-NORM
®
- M
Operating/Assembly instructions
Sheet:
Edition:
2 of 14
Please observe protection note ISO 16016. Drawn: 2018 - 01 - 18 Pz/Kr Replacing: KTR-N 49514
POLY-NORM®-M is a torsionally flexible jaw coupling. It is able to compensate for shaft misalignment, for
example caused by manufacturing inaccuracies, thermal expansion, etc.
1 Technical data 3
2 Advice 3
2.1 General advice 3
2.2 Safety and advice symbols 4
2.3 General hazard warnings 4
2.4 Intended use 4
2.5 Coupling selection 5
2.6 Reference to EC Machinery Directive 2006/42/EC 5
3 Storage, transport and packaging 5
3.1 Storage 5
3.2 Transport and packaging 5
4 Assembly 6
4.1 Components of the couplings 6
4.2 Advice on remachining 6
4.3 Assembly of the coupling (general) 7
4.4 Assembly of type AFN 7
4.5 Displacements - alignment of the coupling 9
5 Start-up 10
6 Breakdowns, causes and elimination 11
7 Disposal 12
8 Maintenance and service 13
9 Spares inventory, customer service addresses 14
Table of contents
POLY-NORM
®
- M
Operating/Assembly instructions
Sheet:
Edition:
4 of 14
Please observe protection note ISO 16016. Drawn: 2018 - 01 - 18 Pz/Kr Replacing: KTR-N 49514
STOP Warning of personal injury
This symbol indicates notes which may contribute to
preventing bodily injuries or serious bodily injuries that
may result in death.
!^ Warning of product damages^
This symbol indicates notes which may contribute to
preventing material or machine damage.
General advice
This symbol indicates notes which may contribute to
preventing adverse results or conditions.
Warning of hot surfaces
This symbol indicates notes which may contribute to
preventing burns with hot surfaces resulting in light to
serious bodily injuries.
STOP
With assembly, operation and maintenance of the coupling it has to be made sure that the
entire drive train is secured against accidental switch-on. You may be seriously hurt by
rotating parts. Please make absolutely sure to read through and observe the following
safety indications.
All operations on and with the coupling have to be performed taking into account "safety first".
Please make sure to switch off the power pack before you perform your work on the coupling.
Secure the power pack against accidental switch-on, e. g. by providing warning signs at the place of switch-on
or removing the fuse for current supply.
Do not reach into the operating area of the coupling as long as it is in operation.
Please secure the coupling against accidental contact. Please provide for the necessary protection devices
and covers.
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 POLY-NORM®-M described in here corresponds to the technical status at the time of printing of these
operating/assembly instructions.
2 Advice
2.2 Safety and advice symbols
2.3 General hazard warnings
2.4 Intended use
POLY-NORM
®
- M
Operating/Assembly instructions
Sheet:
Edition:
5 of 14
Please observe protection note ISO 16016. Drawn: 2018 - 01 - 18 Pz/Kr Replacing: KTR-N 49514 !
For a permanent and failure-free operation of the coupling it must be selected according to
the selection instructions (according to DIN 740 part 2) for the particular application (see
catalogue drive technology).
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 elastomers 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.
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.
The coupling hubs are supplied in preserved condition and can be stored at a dry and roofed place for 6 - 9
months. The features of the individual elastomers remain unchanged for up to 5 years with favourable stock
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 %.
!
In order to avoid any injuries and any kind of damage please always make use of proper
transport and lifting equipment.
The couplings are packed differently each depending on size, number and kind of transport. Unless otherwise
contractually agreed, packaging will follow the in-house packaging specifications of KTR.
2 Advice
2.5 Coupling selection
2.6 Reference to EC Machinery Directive 2006/42/EC
3 Storage, transport and packaging
3.1 Storage
3.2 Transport and packaging
POLY-NORM
®
- M
Operating/Assembly instructions
Sheet:
Edition:
7 of 14
Please observe protection note ISO 16016. Drawn: 2018 - 01 - 18 Pz/Kr Replacing: KTR-N 49514
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 shaft.
STOP
Touching the heated hubs causes burns.
Please wear safety gloves.
With the assembly 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.
In order to avoid any injuries please always make use of proper lifting equipment.
Tapped holes exist on the face and outside diameter of the coupling serving for using proper sling gears or lifting
equipment, respectively. If proper sling gears are used they should be dismounted after assembly of the coupling.
Mount the flange hub (component 1) and hub (component 2) on the shafts of driving and driven side
(see illustration 3).
With assembly of the hub (component 2) it has to be made sure that the hub side with a
recess (dimension d 3 ) is shifted on first (see illustration 5).
The internal sides of the hubs (component 1 and 2) must be flush with the front sides of the shafts.
Shift the cam ring (component 4) over the hub and take it off carefully or keep the cam ring via a proper lifting
device (see illustration 4).
Shift the power pack with the flange hub in axial direction until the distance dimension E is achieved
(see illustration 5, table 1).
If the power packs are already firmly assembled, shifting the coupling hubs axially on the shafts allows for
adjusting the distance dimension E (see illustration 5, table 1).
The transmittable torque of the shaft-hub-connection must be reviewed by the customer and
is subject to his responsibility.
Illustration 3 Illustration 4 Illustration 5 STOP
4 Assembly
4.3 Assembly of the coupling (general)
4.4 Assembly of type AFN
POLY-NORM
®
- M
Operating/Assembly instructions
Sheet:
Edition:
8 of 14
Please observe protection note ISO 16016. Drawn: 2018 - 01 - 18 Pz/Kr Replacing: KTR-N 49514
Push the cam ring onto the hub and align the bore of the flange hub and the cam ring flush.
Screw up the flange hub and cam ring via hexagon fit bolts (component 7) and hexagon nuts (component 8)
and tighten them evenly to the tightening torques TA1 specified in table 2 by means of a torque key
(see illustration 6).
Align the unit screwed up versus the hub such that the cavities between hub and cam ring are evenly
arranged.
Insert the individual elastomers (component 5) in the cavities between hub and cam ring as per the order
specified in illustration 7 and 8. Please make sure that the arrow on the individual elastomers points towards
the direction of the shaft.
With the assembly make sure that the individual elastomers on the cam ring do not protude
since otherwise it is not possible to mount the cover segments (component 3).
For an easier assembly of the individual elastomers we recommend to use a fitting
lubricant, e. g. REMA TIP TOP Universal mounting paste or a silicone oil having a viscosity
of 1000 cSt.
The respective number of individual elastomers must be used in every cavity (see table 3).
Illustration 6 Illustration 7 Illustration 8: Example of size 700
Hand-tighten the cover segments (component 3) with the cap screws DIN EN ISO 4762 (component 6) for the
time being (see illustration 9 and 10).
With the assembly make sure that a gap of at least 5 mm between hub and cover segments
is observed (see illustration 10).
Tighten the cap screws evenly to the tightening torques TA2 specified in table 2 by means of a suitable torque
key.
Having started up the coupling, the tightening torque of the screws and the wear of the
individual elastomers have to be inspected at regular maintenance intervals.
4 Assembly
4.4 Assembly of type AFN
POLY-NORM
®
- M
Operating/Assembly instructions
Sheet:
Edition:
10 of 14
Please observe protection note ISO 16016. Drawn: 2018 - 01 - 18 Pz/Kr Replacing: KTR-N 49514
Examples of the displacement
combinations specified in illustration 12:
Example 1:
Kr = 30 %
Kw = 70 %
Example 2:
Kr = 60 %
Kw = 40 %
Illustration 12: Combinations of displacement
Ktotal = Kr + Kw 100 %
Table 4: Displacement figures
Size 302 502 703 Max. axial displacement Ka [mm] 3.0 3.0 5. Max. radial displacement Kr [mm] with 2.5^ 3.0^ 3. Max. angular displacement Kw [degree] with 0.5 0.5 0.
Before start-up of the coupling, please inspect the alignment and adjust, if necessary, and also inspect all screw
connections for the tightening torques specified.
Finally the coupling protection against accidental contact must be fitted. It is required in accordance with
DIN EN ISO 12100 (Safety of Machinery) and directive 2014/14/EU and must protect against
access with the little finger
falling down of solid foreign objects.
The cover may provide for openings intended for necessary heat dissipation. These openings have to comply with
DIN EN ISO 13857.
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 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
4.5 Displacements - alignment of the coupling
5 Start-up
POLY-NORM
®
- M
Operating/Assembly instructions
Sheet:
Edition:
11 of 14
Please observe protection note ISO 16016. Drawn: 2018 - 01 - 18 Pz/Kr Replacing: KTR-N 49514
The below-mentioned failures can lead to a use of the POLY-NORM®-M 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.
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.
Wrong or no individual elastomers are inserted in the coupling.
No original KTR components (purchased parts) are used.
Old/already worn off individual elastomers or those which are stored for too long are used.
Maintenance intervals are not observed.
Breakdowns Causes Elimination Different operating noise and/or vibrations occuring Misalignment
- Set the unit out of operation
- Eliminate the reason for 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)
- For inspection of wear see chapter 8 Wear of elastomers, short- term torque transmission due to metal contact
- Set the unit out of operation
- Disassemble the coupling, remove remainders of the elastomers
- Inspect coupling components and replace coupling components that have been damaged
- Insert elastomers, assemble coupling components
- Inspect alignment, adjust if necessary Axial fastening of hub working loose
- Set the unit out of operation
- Inspect alignment of coupling
- Inspect axial fastening of hubs and correct, if necessary
- For inspection of wear see chapter 8 Breaking of cams Wear of elastomers, torque transmission by metal contact
- Set the unit out of operation
- Replace complete coupling
- Inspect alignment Breaking of the cams due to high impact energy/overload
- Set the unit out of operation
- Replace complete coupling
- Inspect alignment
- Find out the reason for overload Operating parameters do not meet with the performance of the coupling
- Set the unit out of operation
- Review the operating parameters and select a bigger coupling (consider mounting space)
- Assemble new coupling size
- Inspect alignment Operating error of the unit
- Set the unit out of operation
- Replace complete coupling
- Inspect alignment
- Instruct and train the service staff
6 Breakdowns, causes and elimination
POLY-NORM
®
- M
Operating/Assembly instructions
Sheet:
Edition:
13 of 14
Please observe protection note ISO 16016. Drawn: 2018 - 01 - 18 Pz/Kr Replacing: KTR-N 49514
POLY-NORM®-M 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 individual elastomer of the coupling.
Since the flexible machine bearings of the driving and driven side settle during the course of load, inspect the
alignment of the coupling and re-align the coupling, if necessary.
The coupling components have to be inspected for damages.
Small volumes of rubber dust are normal, with bigger volumes lubrication of the individual elastomers is
necessary.
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.
In order to perform a visual inspection of the
individual components, remove the cover
segments from the coupling so that the front sides
of the individual elastomers can be seen. For that
purpose you do not need to take the individual
elastomers out of the coupling. Anyway, the
individual elastomers should be replaced if one of
the following items applies:
Having reached the limits of wear
Material deterioration of individual elastomers
Individual elastomers damaged or torn
Illustration 13
8 Maintenance and service
POLY-NORM
®
- M
Operating/Assembly instructions
Sheet:
Edition:
14 of 14
Please observe protection note ISO 16016. Drawn: 2018 - 01 - 18 Pz/Kr Replacing: KTR-N 49514
When reaching the limit of wear and tear Xmax., the individual elastomers must be replaced. Here the backlash
between the cams of the coupling and the individual elastomers must be inspected by means of a feeler gauge
(see illustration 14). Several individual elastomers should be inspected.
Reaching the limits for replacing depends on the operating conditions and the existing operating parameters. With
wear 20 % of the original elastomer thickness it is necessary to replace the individual elements.
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 4). If the
figures are exceeded, the coupling will be damaged.
The more accurate the alignment of the coupling, the longer is its service life.
Illustration 14: Inspection of the limit of wear Illustration 15: Wear of elastomers
Table 5: Limits of wear
Size (^) Thickness of elastomer Limits of wear [mm] Wear Xmax. 302 38.0 7. 502 67.0 13. 703 82.5 16.
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
