KSLVARIABLE FILL FLUID COUPLINGS

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INTRODUCTION

INTRODUCTION

Transfluid designed the KSL series variable fill fluid coupling toovercome difficulties experienced during ‘start up’ and ‘speedvariation’ operation for medium or high powered machines,driven by electric motors or internal combustion engines.

WORKING OPERATION

Extremely efficient performance is achieved utilizing the KSL’svery simple and effective principle. Oil, as the power medium,is pumped from a sump to the hydrodynamic coupling circuit,where it is finally ‘drained-off’ through a series of orifice plugs,back into the sump.

The variable fill principle:By controlling the oil flow to the working circuit through afrequency converter, changes occur inside the coupling’sworking circuit which alter the coupling’s slip characteristicsdramatically softening the ‘start up’.

Torque limiting function:Having all the same advantages of fluid couplings, variablefill-drain type fluid couplings build up torque gradually.

Disconnect:Interrupting the oil flow into the coupling empties the workingcircuit and disconnects the input from the output.This disconnect can be accelerated by using the quick releasevalves.

In summary, it is possibile to:• have a long start up acceleration, up to several minutes, for

high inertia machines.• position the driven machine for loading, unloading and

maintenance.• obtain sequential starting for more than one drive motor.• adjust or limit the torque• disconnect the load even with the motor running• use for conveyors, for the reduction of the tension to a

minimum level or the possibility of running at an inspectionspeed.

• vary the speed within a 5:1 range for centrifugal machines.

CHARACTERISTICS

Soft starter The KSL working circuit is gradually filled by oil from an emptycondition to a fully filled one. Such behaviour provides anextremely soft controlled start up, especially with high inertiamachinery. The KSL variable oil feed system is controlled by afrequency converter during the ramp up, producing ideal softstarting.

Accurate speed variationBy remote signal, the KSL always guarantees output speedaccuracy, as required by the operator or control system.Speed variation is also possible by manual flow control valveoperation.A frequency converter electronic bypass is supplied standard.

Vibration DampeningOne of the most important characteristics of KSL fluid couplingis its torsional vibration dampening effect, protecting both thedriven gear box, fan, or pump machinery, as well as the motoror engine.

Overload ProtectionThis is a fluid coupling advantage and a big benefit to users.Even more protection can be achieved by installing “quickrelease valves” which discharge oil from the working circuit in afew seconds, limiting any prolonged overload completely.

High EfficencyThe KSL is an extremely efficient device compared to theconstant filled type fluid coupling, because the working circuitvolume is controlled at the fullest possible level to maintain avery small slip rate.

Shaft Labyrinth SealingThis type of seal helps the KSL series to be a low maintenancemachine.

Ease of MaintenanceThanks to its split casing design, it is possible to remove thecomplete fluid coupling impeller assembly without having tomove either the motor/engine or driven machinery, saving theneed for realignment and costly down time.

APPLICATIONS

Mills, crushers, conveyors, fans, blowers, pumps, compressors,centrifuges, mixers, generators, marine propulsion drives.

SELECTION

To correctly select the KSL, Transfluid needs to know thefollowing data:• motor/engine type, power and speed• driven machinery type, power, speed and inertia• output speed range• environmental conditions• cooling water/air characteristics• drive and driven shaft dimensions and tolerances• available voltage for motors and instruments

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8 3

5

2

4

8 - heat exchanger7 - quick release valves6 - bleeding orifices5 - pressure differential transducer4 - pressure gauge3 - heat exchanger oil pump2 - lubrication oil pump

12

13

9

11

7

6

10

15

1

14

15 - temperature gauge14 - pressure gauge13 - vacuum switch

11 - feed oil filter10 - max temperature switch

12 - lub. oil filter

thermostatic controlheat exchanger pump

heat exchanger pump thermostatic control.

outp

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pee

d

main drive motor

MPCB

Display speed,

speeds, start up modulation, oil pressure, oil temperature, filter clogging, oil level,

All parameters under control such as:

driven machine

KSL

gear box

feed oil pumpVariable flow

16 - thermocouple Pt100

1 - variable flow feed pump with variable frequency converter

9 - oil level switch and gauge17 - speed sensors

16

17

inp

ut s

igna

ls fr

om

CONTROL PANEL

speed settings (4-20 mA)

input/output signals to DCS

sens

ors

and

sw

itche

spressure,

from DCS

LOCAL REMOTEtemperature

LOCAL SPEED SETTING

18 - heat exch. pump control19 - manual flow control valve

18

19

PI

IT

WORKING SCHEME

AUTOMATIC or SEMIAUTOMATIC / MANUAL or MANUAL

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PERFORMANCES

* With steel impellers.

NOTE: Standard squirrel cage motors should NOT be derated.Efficency of electric motor is NOT affected by KSL application.Value of electric motor efficency can be found in manufacturer’s catalogue.Slip can vary ±10% according to driven machine characteristics.

r.p.m Size / Kw max

21 27 29 34 D34 46 D46

1000 200 360 750 1300 1700 2000

1200 – 360 630 1300 2300 3000 3500

1500 700 1250 2000 2800

1800 1200 1600 2400* 3350*

3000 1600*

3600 2000*

MOTOR POWER - kW

CENTRIFUGAL APPLICATION

LOSSES % OUTPUT SPEED %

0 100

8.1 90

12.8 80

14.8 70

14.4 60

12.5 50

9.6 40

6.3 30

3.2 20

average value = 9.6

0

25

50

75

100

0255075100

Slip (%)

Pow

er (

% o

f the

max

inpu

t pow

er)

(33.3)

(14.8)

Input power

Output power

Power loss

input = K n2 + K (n1 - n2) n2

output = K n2

losses = K (n1 - n2) n2

3

3

32

2

K = max input power / n1

n1 = input speed

n2 = output speed

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APPLICATIONS

BOILER FEED WATER PUMPS, PIPE LINE PUMPS, CENTRIFUGAL GAS COMPRESSORS,CITY FEED WATER PUMPS, RECYCLING PUMPS, ALL FANS AND BLOWERS

HAMMER MILLS, BALL MILLS, STONE CRUSHERS, METAL SHREDDERS, WOOD CHIPPERS

ELECTRICITY CONTINUITY GROUPS

main drive motor KSL

fan andblower

main drive motor KSL reduction gear

mill

main drive motor KSL

reductiongear

conveyor

Diesel / gas engine

electric motor

KSL step-up gear freewheel

gasturbine

Diesel / gas engine KSL

flywheel

generator

centrifugalpump compressor

GAS TURBINE STARTING DRIVES

BELT CONVEYORS

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DIMENSIONS

WEIGHT ACCORDING TO STANDARD VERSIONSDIMENSIONS ARE SUBJECT TO ALTERATION WITHOUT NOTICE(1)ONLY FOR 21 KSL

Siz

e Dimensions (mm)

A B C D E F G H Weight Kg Oil(without oil) lt

920 1500 580 100 170 700 490 1075 1060 400

900 1100 700 120 150 850 575 1000 1200 / 1300 300

1050 1300 830 140 200 1000 670 1050 2100 450

1400 1300 1080 160 230 1100 670 1050 3000 850

1420 1700 1060 180 250 1300 900 1200 3455 1000

1800 1700 1400 200 280 1300 900 1200 4100 1300

21

27 / 29

34

D34

46

D46

1 Variable flow pump2 Lubrication oil pump3 Feed filter with vacuum switch4 Lube filter with differential

pressure transducer5 Feed pressure gauge6 Lube pressure gauge7 Temperature gauge,

thermocouple Pt1008 Filter by-pass valve9 Speed sensors

10 Temperature switch11 Drain tap12 Electric wiring box13 Breather14 Level switch and gauge15 Manual control valve16 Cooler pipe unions17 Lifting ears

2

3

4

56

7

8

9

10

11

12

13

14

15

16

17

1

5Variable fill fluid couplings - 1102

800(1)

150(1)

1000(1)

MOTOR SIDE

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2x34 KSL, 630 kW - 1000 rpm, ceramic mill (Italy)

34 KSL, 700 kW - 1200 rpm, fan (Brasil)

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185-GB COPERTINA 1102 9-02-2011 9:09 Pagina 1