BHARAT HEAVY ELECTRICALS LIMITED RAMACHANDRAPURAM :: HYDERABAD – 502 032

OPERATING AND MAINTENANCE INSTRUCTIONS OF

PUMPS

VOLUME-2

HYDRAULIC COUPLING TYPE: R18KGS-14API FOR BOILER FEED PUMP

MEJIA PHASE-II T.P.S - 2x500MW, UNIT-1&2

DAMODAR VALLEY CORPORATION

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2009-01-19 airev-RSe / Frk

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Instruction Manual for

VOITH Geared Variable Speed Coupling Type: R 18 KGS - 14 API Voith Code: Bharat S 150 Serial No.: 8203542 In case of queries with regard to this unit, please always state the coupling serial number.

s s

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Instruction Manual for VOITH Geared Variable Speed Coupling

- Data Sheet -

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Geared Variable Speed Coupling: R 18 KGS - 14 API Code: Bharat S 150 Serial No.: 8203542 Voith Order No.: 38001272 Rotation seen in direction Input shaft Hydr. circuit Output shaft of the power flow: CCW CW CCW Geared variable speed pump as boiler feed pump drive Power requirement of driven machine: Pa = 6475 kW Motor speed: ne = 1495 rpm Gear ratio: U1 = Ze/Z1 = 109/32 Primary speed: n1 = 5092 rpm Full load slip: s = 2,0 % Gear ratio: U2 = Z2/Za = 59/51 Max. output speed: na = 5773 rpm Regulation range: 4 : 1 downwards Weight (without oil filling) approx. 10000 kg Hydraulic oil types: HLP 32 to DIN 51524, part 2 Oil tank filling: approx. 2500 l Lube oil flow rate for booster pump: ) Lube oil flow rate for main motor: ) Lube oil flow rate for driven machine: ) Σ 300 l/min. at 1,5 to 2,0 kg/cm2 Lube oil quantity for connecting couplings ) Noise emission Measuring surface sound pressure level: LPA max. 94 dB(A) According to DIN 45635, section 23 or ISO 495 Pump insert: Working oil pump (centrifugal pump) and lube oil pump (gear pump) Jointly driven as gear-tooth system drive via the pump shaft. Auxiliary lube oil pump: MZP 820 Motor for aux. lube oil pump: DE 200 LA2 Technical data: 30 kW; 415 V; 50 Hz; 2950 rpm; IP 55; B5 Actuator: PME 120 AN Continuous electronic power unit: EAS 822; Power supply AC 230 V (190 V ... 260 V) Connecting couplings: Input side: * Output side: * * not Voith supply

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Instruction Manual for VOITH Geared Variable Speed Coupling

- Data Sheet -

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Operating Data for Geared Variable Speed Coupling: Bearing temperatures nom. value < 90 °C (46 - 51, 54 - 63, 66 - 69) alarm / trip 90 / 95 °C Working oil temperature nom. value >60 - <110 °C upstream of heat exchanger alarm 110 °C (81, 86, 87, 88) trip 130 °C Working oil temperature downstream nom. value >35 - <75 °C of heat exchanger (80, 89) alarm 75 °C Lube oil temperature upstream nom. value >45 - <65 °C of heat exchanger (78, 82) alarm 70 °C Lube oil temperature nom. value >35 - <55 °C downstream of heat exchanger alarm 55 °C (79, 83, 84, 85) trip 60 °C

Lube oil pressure, gauge (42) nom. value >1,5 - <3 kg/cm2 Pressure transmitter (71 - 73) main motor ON >1.2 kg/cm2 aux. lube oil pump OFF >3.0 kg/cm2 aux. lube oil pump ON <1.2 kg/cm2 alarm <1.0 kg/cm2 trip <0,8 kg/cm2 Differential pressure at lube oil filter alarm / change-over filter (25, 25.1) and clean at 0,6 kg/cm2 Control oil pressure, gauge (43) nom. value >3 -<4 kg/cm2 Pressure transmitter (74 - 76) alarm <2.5 kg/cm2 trip <2.2 kg/cm2 Working oil pump pressure,

test connection (44, I see at assembly plan) >1.6 - <2.1 kg/cm2 Working oil pressure upstream of circulation control valve, test connection (21, II see at assembly plan) >1.0 - <1.8 kg/cm2 Working oil pressure downstream of scoop tube, test connection (45, III see at assembly plan) >1.8 - <3.5 kg/cm2 Oil level, sight glass (90) nom. Value max. - min. mark Oil level switch (70) alarm 10mm > max. / 10mm < min. mark

GEARED VARIABLE SPEED TURBO COUPLING Type R18KGSCode : BHEL-Test Field.: Serial No. : 114 - 0018s4 4

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049

1.2.2 Heat exchanger

(Please have the design data filled in by the cooler supplier). Design data

Heat exchanger LUBE oil Shell cham-ber (oil)

Tube cham-ber (water)

Medium Oil (ISOVG32) Water

Oil volume l/cooler ____l

Nominal flow rate V nom 49,2 - m3/hr 58,8 - m3/hr

Minimum flow rate due to corro-sion Vmin

______l/min

Inlet temperature 65 - ºC 38 - ºC

Outlet temperature 50 - ºC 43 - ºC

Max. allowable working temper-ature

120 - ºC 70 - ºC

Max.allowable working pressure 10 - kg/cm2 10 - kg/cm2

Test pressure (HYD) 13 - kg/cm2

- (Hydraulic)13 - kg/cm2

- (Hydraulic)

Heat exchanger WORKING oil Shell cham-ber (oil)

Tube cham-ber (water)

Medium Oil (ISOVG32) Water

Oil volume l/cooler ____l

Nominal flow rate V nom 90 - m3/hr 132,3 - m3/hr

Minimum flow rate due to corro-sion Vmin

______l/min

Inlet temperature 95 - º C 38 - º C

Outlet temperature 57 - º C 48 - º C

Max. allowable working temper-ature

120 - º C 70 - º C

Max.allowable working pressure 10 - kg/cm2 10 - kg/cm2

Test pressure kg 13 - kg/cm2

- (Hydraulic)13 - kg/cm2

- (Hydraulic)

1 Technical Data 1.2 Operating data

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Instruction Manual for VOITH Geared Variable Speed Coupling

- General Contents -

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DaData Sheet, General Contenta Sheet, General Contents 91800009010 en Data Sheet / Techn. Data for Geared Variable Speed Coupling Data Sheet for Heat Exchanger Amendment Report of Instruction Manual 2009-01-19 Part 1 Instruction Manual, Text Trouble-shooting Table Part 2 Parts List Part 3 Drawings Part 4 Voith Information Sheets Part 5 Attaching Parts (Descriptions)

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Instruction Manual for VOITH Geared Variable Speed Coupling

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Part 1 Instruction Manual, Text Trouble-shooting Table

Instruction Manual for VOITH Geared Variable Speed Coupling

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CONTENTS Safety information 1. Design and Operation 2. Oil Circuits 2.1 Working oil circuit 2.2 Lube and control oil circuit 2.3 Lube oil circuit to the individual machines 3. Control 3.1 Scoop tube positioning (normal operation) 3.1.1 Setting and checking of scoop tube control 3.2 Oil flow control 4. As Delivered Condition 5. Assembly, Mounting Instructions 5.1 Important information - transport 5.2 Installation preparations for steel foundation 5.3 Positioning geared variable speed coupling on steel foundation 5.4 Alignment accuracy 5.5 Alignment procedure 5.6 Site pipework, cooler arrangement and cooler venting 5.7 Lube oil supplied to individual machines 5.8 Guards 5.9 Preservation after installation 5.10 Electric installation 6. Operating Oil 6.1 Filling with operating oil 7. Commissioning 7.1 Trial run preparations 7.2 Trial run 7.3 Measures to be taken at standstill periods 8. Operation of the Geared Variable Speed Coupling 8.1 Start-up, operation and shutdown of the geared variable speed coupling as well as measures to be taken when the unit is at standstill 8.2 Operating data 8.3 Lube oil pressure, control oil pressure and monitoring of lube oil pressure 8.4 Monitoring of working oil

Instruction Manual for VOITH Geared Variable Speed Coupling

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8.5 Bearing temperatures 8.6 Lube oil filter 8.7 Oil level indication 8.8 Lubricating points of scoop tube control 9. Maintenance of Geared Variable Speed Coupling 9.1 Maintenance of double filter 9.2 Maintenance measures which can be taken with the unit running 9.3 Maintenance measures which can only be taken when the unit is at standstill 10. General Overhaul of the Geared Variable Speed Coupling 10.1 General remarks 10.2 Preconditions 10.3 Dismantling and reassembling 11. Dismantling the Geared Variable Speed Coupling 11.1 General remarks 11.1.1 Removing the housing cover 11.1.2 Removing the scoop tube control and scoop tube 11.1.3 Removing the coupling runner 11.1.4 Dismantling the coupling runner 11.1.5 Removing the complete input shaft 11.1.6 Removing the output shaft (pinion shaft) 11.1.7 Removing the pump insert 11.1.8 Removing the aux. lube oil pump 11.2 Cleaning and checking the coupling parts 11.3 Reassembling the geared variable speed coupling 11.3.1 Preconditions and remarks 11.3.2 Reassembling the coupling runner 11.3.3 Mounting the coupling runner into the housing 11.3.4 Mounting the thrust bearings - primary side and secondary side 11.3.5 Fitting the scoop tube 11.3.6 Mounting the scoop tube control 11.3.7 Mounting the input shaft with gear 11.3.8 Mounting the output shaft (pinion shaft) 11.3.9 Mounting the pump insert 11.3.10 Mounting the aux. lube oil pump 11.3.11 Mounting the housing cover 11.4 Remaining commissioning work

Instruction Manual for VOITH Geared Variable Speed Coupling

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ATTENTION Dangerous voltages and/or high pressures and temperatures may occur in equipment, subassemblies and pipework during operation of the unit. This unit and the equipment and pipework contain among others oil as operating medium. Improper handling may therefore cause bodily injury or damage to property. Improper handling of oils and lubricants may pollute the environment. Filling, changing, handling and waste disposal of oil is to be done by qualified personnel. IMPORTANT

Only qualified personnel is allowed to operate this unit, the equipment and its media.

A condition for sound and safe operation of this unit is proper transportation, appropriate storage, setup and installation, proper handling according to instructions, conscientious use of the operating medium oil as well as careful operation and servicing. If you should need any further information or any particular problems should occur which are not dealt with in detail in the manual, please contact the VOITH Subsidiaries or the factory directlly. Qualified Personnel are persons who are familiar with the transportation, storage, setup, installation, commissioning, operation and maintenance of the product and qualified to do their job, as e.g.: - training, instruction and entitled to operate and service the equipment, units, systems in

accordance with established safety practices for electrical circuits/wiring, high pressures and temperatures and media harmful or detrimental to the environment

- proper handling and disposal of media and their components, e.g. filters/one-way systems/oils etc.

- training or instruction according to established safety practices for maintenance and use of safety equipment

- training in first aid

Safety Information

Instruction Manual for VOITH Geared Variable Speed Coupling

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1. Design and Operation The geared variable speed coupling consists of a two-stage spur gear and a variable speed

coupling arranged between the two stages. The torque of driven machine is transmitted to the input shaft by a connecting coupling. The torque between input and primary shaft is transmitted by means of a gear stage. The power flow between primary and secondary wheel is achieved by a fluid flow. The torque is also transmitted to the output shaft via a gear stage. A connecting coupling connects the output shaft and the machine to be driven.

The torque generated by the driving machine is provided to accelerate the fluid in the primary

wheel (pump impeller). This is delayed in the secondary wheel (turbine wheel) to produce an equal torque. The fluid can only circulate in case of a pressure drop between the primary and secondary wheel. This requires that the secondary wheel speed is lower than that of the primary wheel. Thus, a slip is required for power transmission.

The coupling size is selected so that the full power can be transmitted with a low slip, the "full

load slip" (at max. filling). The output speed can be regulated infinitely by changing the oil filling in the working chamber between the primary and secondary wheel. This is accomplished by positioning the scoop tube accordingly, which will determine the oil filling of the working chamber.

The power loss caused by the slip will heat up the working oil. The heat is then dissipated in

the working oil cooler.

Instruction Manual for VOITH Geared Variable Speed Coupling

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2. Oil Circuits (see Oil Circuit and Measuring Point Scheme) The same oil is used as working and lube oil. The working oil pump (13, a centrifugal pump)

and the main lube pump (14, a gear pump) are combined to form a pump insert and are driven by the input shaft of geared variable speed coupling.

The electrically driven aux. lubricating pump (15) is provided to supply the unit with lube oil for

start-up, when running down as well as in case of any troubles.

2.1 Working oil circuit The working oil circuit consists of a closed circuit superposed by an open circuit so

that the filling can be changed. In the closed circuit, the oil which flows into the variable speed coupling (19) via the

circulating control valve (30) for power transmission and heat dissipation is removed by the displaceable scoop tube (39). Under the action of dynamic pressure, the oil flows through the working oil cooler (22) and circulating control valve (30) back into the coupling.

The open circuit is made up of the working oil pump (13), throttle (26) and pressure

relief valve (27). The coupling (19) is filled with oil flowing from the open to the closed circuit. Any excessive oil supplied by the working oil pump flows through the pressure relief valve (27) back into the oil tank. The same applies when the coupling filling is reduced.

The connecting line with orifice plate (91) between lube and working oil circuit is

provided for faster filling of the working oil circuit during start-up. The operating pressure of working oil is set on the pressure relief valve (27), see

section 8.4. If the closed circuit is broken and the oil temperature of variable speed coupling (19)

rises to 180 °C, the fusible plug screws (20) blow. Bores in the plugs are thereby released and the coupling (19) drains. If the fusible plug screws blow due to a temporary thermal overloading of the oil circuit, due to cooler failure or overloading of coupling, the control behaviour of the coupling only changes slightly and the sump temperature rises a little e.g. the control behaviour of the variable speed coupling only changes slightly. However, other features are a slight rise of the sump temperature, longer run-up time of driven machine and almost reaching the max. output power.

The fusible plug screws (item 0310/0010/0060, see Vertical Section) can be replaced

by removing the inspection cover II on the housing cover and turning the input shaft until the three fusible plug screws are accessible.

Instruction Manual for VOITH Geared Variable Speed Coupling

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2.2 Lube and control oil circuit The main lube pump (14) pumps oil out of the sump and feeds through the non-return

valve (17), pressure relief valve (28), lube oil cooler (23) and the reversible double filter (24) to the bearing points and the gear wheels.

Oil for hydraulic scoop tube control is branched off upstream of the adjustable orifice

plate (29). The control pressure is >3 - <4 kg/ cm2, see indication at the pressure gauge (43).

The lube oil pressure is set to >1.5 - <3 kg/cm2, see indication at the pressure gauge

(42). Control oil pressure and lube oil pressure are set on the pressure relief valve (28) and on the adjustable orifice plate (29) as a function of each other.

To ensure the bearings are coated with oil during coupling start-up, run-down and

failure, they are supplied with oil by the aux. lube oil pump (15) before the drive motor is switched on and after it is switched off (see section 8.3 Lube pressure monitoring).

The aux. lube oil pump, which is driven by the electric motor (16), draws lube oil out of

the sump and pumps it through a non-return valve (17) into the lube oil circuit.

2.3 Lube oil circuit to the individual machines The lube oil for the individual machines, such as drive motor, driven machine or

connecting coupling etc., is taken from the lube oil circuit of the geared variable speed coupling and is fed again to the oil tank of the coupling. By means of the orifice plates installed at the flanged connection geared variable speed coupling and/or upstream of the lubricating points of the individual units, the flow rate and the lube oil pressure are pre-set to the admissible values. Data concerning the lube oil supply of individual machines are indicated and described in section 5.7.

Instruction Manual for VOITH Geared Variable Speed Coupling

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3. Control (see Oil Circuit and Measuring Point Scheme) The output speed of the geared variable speed coupling is controlled by an actuator (33)

adjusting the scoop tube (39) and thus the filling in the variable speed coupling (19). The cam disc (32) serves for linearization the angle of adjustment of actuator as a function of

the controlled variable (speed). The standard cam disc is designed so that, at a nominal angle of rotation, the scoop tube can

be set between 100 % and minimum. As a function of the regulating range and the torque characteristic of the driven machine, machining of the cam disc can be necessary.

3.1 Scoop tube positioning (normal operation) (see Oil Circuit and Measuring Point Scheme) The scoop tube which regulates the amount of oil in the turbo coupling is controlled

by turning the cam disc (32) by means of the actuator. The control valve (35) is actuated by a roller which is held by spring pressure against the cam disc.

If the cam disc (32) is moved in direction "full output speed", the pressure oil flows

into the chamber (38) of the double-acting positioning cylinder. The scoop tube (39) which is connected to the piston (37) is moved in direction "full output speed" and the degree of filling in the coupling (19) is increased. Simultaneously, the control valve (35) is returned to its starting position by a spring-load roller which presses against the slope of the scoop tube and shuts off the oil feed as soon as the scoop tube position pre-set by the actuator is reached.

When the cam disc (32) is turned in direction "low output speed", the pressure oil

flows into the chamber (36) and causes the oil to flow in the opposite direction to that described above.

Instruction Manual for VOITH Geared Variable Speed Coupling

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3.1.1 Setting and checking of scoop tube control The rotational angle of the cam disc is 120° between min. % and 100 %

scoop tube position. The positioning distance must be limited by stops. These stops must not

touch the cam discs but instead a flat steel bar could be welded on the cam disc hub, for example.

Check the setting for 100 % scoop tube position after mounting the actuator.

For this purpose, switch on the aux. lube oil pump and set the cam disc to 100 % position. The scoop tube stroke indicator must indicate 100 % scoop tube position. If not, correct the indication setting by

unscrewing the check nut (see opposite sketch).

Turn the set screw 0270/0040 guiding the guide bolt (see Drawing “Section through Control” Sheet 1, Section C-D)

out of the keyway. The guide bush has a - <--> + mark. Turn the guide bolt, dependent on the position of scoop tube stroke indicator in direction - or + until the scoop tube stroke indicator indicates 100 % scoop tube position.

Secure the guide bolt by inserting the set screw in the keyway. The set screw must not touch the keyway base. Secure the set screw using the check nut.

Important: After taking this measure check floating of the guide bolt over

the complete regulating range. If min. scoop tube position has to be limited, for example, to prevent running

slower than a certain output speed, file the scoop tube cam disc at this point and weld on the oil flow cam disc in this angle area in which the scoop tube cam disc was filed. The stroke as it was the original condition of the scoop tube positions has to be maintained.

Instruction Manual for VOITH Geared Variable Speed Coupling

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3.2 Oil flow control (see Oil Circuit and Measuring Point Scheme) The duty of the circulating control valve (30) is to supply the coupling with enough

working oil to compensate for the losses. The cam disc (31) controls the circulating control valve as a function of the scoop tube position (see sketch below). The maximum oil flow is factory-set based on values calculated from the output.

If the oil temperatures are too low or too high at certain operating points, the oil flow

through the circulating control valve can be changed. There are three possibilities: a) Set the maximum oil flow (between 60 and 70 % output speed by turning the cam disc by max. +/- 13°. b) After releasing the check nut remove the set screw and turn the guide bolt in direction + or - (+ more oil flow, - less oil flow which is punched into the guide bolt or guide bush). c) Reshape the oil flow cam disc: This means: Building up the cam = more oil flow, Filing off the cam = less oil flow. Important: After carrying out one of these modifications, check

floating of piston over the whole regulating range.

Instruction Manual for VOITH Geared Variable Speed Coupling

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3.3 Rapid regulation of variable speed coupling (cam control by-passed using solenoid valves) Using this arrangement, the scoop tube is moved from any position towards "low

output speed" and back in the direction "full output speed" more rapidly than is possible with the actuator. Normal emptying and filling times of the variable speed coupling with up to 75 mm2/s oil viscosity are around 5 to 10 seconds. Rapid regulation is used, for example, in the following cases:

1) Quick run-up of drive motor and driven machine by rapid draining of the

variable speed coupling The two 3/2-way solenoid valves (92 and 93) are energized for rapid run-up

of drive motor under no load. Valve (92) lets pressure oil flow into the chamber (36) of the scoop tube positioning cylinder, irrespective of the position of the control valve (35). At the same time, the valve (93) stops the supply of pressure oil and allows the oil in the chamber (38) to flow unhindered into the oil tank. The scoop tube (39) moves in the position 0 % filling.

After run-up of drive motor (with approx. 95 % nominal speed), the solenoid

valves (92 and 93) are deenergized and the scoop tube (39) moves at once to the position fixed by the actuator. The variable speed coupling fills within the specified time and the driven machine runs up to the corresponding speed.

2) Quick run-down of drive motor and driven machine by rapid draining of the

variable speed coupling The two solenoid valves (92 and 93) are energized for rapid drain of the

variable speed coupling. The scoop tube (39) immediately moves in the position 0 % filling, as per description in section 1. The variable speed coupling drains and power transmission from drive motor to driven machine is interrupted.

GEARED VARIABLE SPEED TURBO COUPLING Type R18 KGSCode : BHEL-Test Field.: Cplg serial No.: 114-00184 16

Ord

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- 0

49

Instruction Manual for VOITH Geared Variable Speed Coupling

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4. As Delivered Condition In as delivered condition, the geared variable speed coupling cannot be operated

independently. Prior to commissioning, the tests and, if necessary, measures for meeting with the safety instructions of the complete unit have to be effected.

The geared variable speed coupling (machine) cannot be used in as delivered condition. The

conditions are good for taking measures on the complete unit to protect persons, material, property and the environment. These measures are to be determined by the supplier in the planning phase or prior to initial commissioning.

Before leaving the factory each coupling undergoes a test run. Parameters measured: No-load losses, oil temperatures, vibration. The vibration is assessed as per VDI 2056. Parameters set: Oil flow rates / oil pressures, switch points of fitted monitoring instruments. The geared variable speed coupling is mounted on the oil tank. All internal piping for lube and

operating oil is assembled. Instruments are fixed to an instrument stand. The instrument stand is flexibly mounted on the housing by means of silentbloc type rubber-metal connections.

All weld-neck flanges are fitted with seals and blanked off for transport. The connecting coupling hubs will be mounted by Voith if they belong to the Voith supply. The monitoring instruments fitted are marked. Preservation: The preservation and packing for sea transport and/or 12 to 24 months storage is described in

Sheet 740080119, please see Part 4.

Instruction Manual for VOITH Geared Variable Speed Coupling

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5. Assembly, Mounting Instructions

5.1 Important information - transport The Voith geared variable speed coupling is an industrial high-quality unit of well-

known machinery technique, with an easy construction, and any malfunctions can be easily recognized. The following work must only be carried out by qualified personnel (see safety information). Therefore, we recommend that the assembly and first commissioning be carried out by one of our service engineers. Any faulty installation may result in unsatisfactory operation and premature wear of the units. Installation dimensions etc. are shown in the assembly plan.

The geared variable speed coupling is a machine with piping, cooler and single-wall

tank for mineral oil. Any additional environmental conditions must be determined at site.

The Voith geared variable speed coupling will be shipped in a transport frame in

installation position. After removing the transport frame, the coupling must only be placed down on the feet of the oil tank or on the feet of the foundation fixing.

The perfect condition of geared variable speed coupling and their assemblies is to be

preserved during installation and assembly work, long periods of storage and after installation or in cases of standstill for operational reasons.

During assembly please consider the shaft displacements of the units due to

operation. Shaft displacements of the geared variable speed coupling are shown in the attached Sheet No. 3644-006536en, please see Part 4.

Warning!

Improper lifting of the geared variable speed coupling may cause personal injury and damage to property.

Hang the geared variable speed coupling only on the marked lifting points, see Assembly Plan.

Use only proper lifting appliances in compliance with the safety regulations! Keep away from any suspended load.

Transport the geared variable speed coupling in lashed condition and in transport skids only (if available) and always set it on a suitable, solid and level ground! Set it down on the contact surfaces of the housing or oil reservoir only!

Instruction Manual for VOITH Geared Variable Speed Coupling

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Lifting points located on the gearbox housing are provided for the own weight

of the geared variable speed coupling only! Do not lift it together with any other machine/base frame!

Hang the geared variable speed coupling on the marked lifting points only considering the included angle and the minimum height of crane hook, see Assembly Plan.

Lift the geared variable speed coupling only without oil filling!

- Average out the axial tooth clearance of the input shaft of the geared

variable speed coupling by turning the shaft. The shaft distances can be found in the assembly instructions for the connecting couplings. If the drive motor rotor is axially located by the connecting coupling and the primary side herringbone gear stage in the geared variable speed coupling's thrust bearing, ensure that thermal expansion cannot cause the drive motor rotor to move from its magnetic centre.

- It must be prevented that creeping or external currents reach the geared variable speed coupling via input and output shaft. Bearings and driving gear wheels of the filling pump can be damaged due to spark erosion.

- During assembly at site cover the geared variable speed coupling completely

with a tarpaulin against dirt, sparks, grinding dust and other environmental influences harmful to the coupling. Especially protect the monitoring instruments and the electric cables or cable ducts on the coupling.

Instruction Manual for VOITH Geared Variable Speed Coupling

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5.2 Installation preparation for steel foundation 1. Foundation check Prior to starting installation, check the foundations made on-site for all machines

(e.g. booster pump, motor, geared variable speed coupling and main pump) for correct dimensions, using the foundation plan. We recommend to preliminarily arrange all machines with correct shaft distance to each other for checking. Eliminate any differences by machining.

2. Iron shims for alignment The height of steel foundations is to be dimensioned so that a free space of

10 mm is provided to place shims underneath the Voith geared variable speed coupling. This free space is balanced during alignment by means of supplied liners and shims.

Instruction Manual for VOITH Geared Variable Speed Coupling

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3. Mounting connecting couplings Note! Suitable are gear couplings or all-metal couplings with low radial

restoring forces. Flexible connecting couplings are to be agreed in each individual case.

Usually the input and output coupling halves are

already mounted prior to shipment, i.e. the cover and coupling hub are mounted on

the shaft end while the coupling sleeve is packed separately. Should the geared variable speed coupling be supplied without the connecting coupling attached, the assembly at site should be carried out as follows:

Clean shaft and hub from preserving agents using fuel, nitro thinner (no

petroleum) and degrease. Check the bore, shaft, keyway and key for dimensional accuracy.

Remove the key from the keyway and fit it into the hub groove, then reinsert the

key into the keyway, check height of key. The clearance between keyway and key should be 0.2 - 0.3 mm. Apply a thin coat of Molykote or an equivalent lubricant. As a function of the connecting coupling, slip cover and 0-seals over shaft end, mount coupling hub using mounting aid.

Slip the sleeve over the hub - this applies only to connecting couplings without

intermediate piece. For couplings with adequate spacing between shaft ends, the sleeves with intermediate piece can be mounted at a later date.

4. Mounting oil drain pipe As the oil tank bottom is usually inaccessible when mounted, an oil drain pipe

should be flanged on before the coupling is placed in position (see assembly plan).

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5.3 Positioning geared variable speed coupling on steel foundation Pre-positioning checks Have the coupling sleeves of the connecting couplings been mounted? Is, in the case of connecting couplings with intermediate piece, the shaft spacing

large enough to allow subsequent mounting of the spacer sleeve? Can the oil drain pipe be fitted after placing the coupling in position?

If the driving machine has already been mounted, check axial clearance. Move rotor

into zero position by averaging the axial clearance. Usually, the driven machine is fixed in axial direction. This should be checked.

When positioning the units on the foundation, check the axial clearance of the

connecting couplings. Tapped holes for adjusting screws are provided on the gear housing to align the

geared variable speed coupling. Mount these adjusting screws prior to assembly. We supply different shim sizes.

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5.4 Alignment accuracy The alignment is satisfactory if the radial measurement "A" and the axial difference

measurements "B" and "C" show dial gauge deviations not in excess of +/- 0.03 mm when turning the shafts by 360°. Please note the shaft displacements due to operation. Make alignment when the machine is cold.

The natural sagging of motor and pump shafts (I pump installed first, II motor installed first) results in a slight inclination of the geared variable speed turbo coupling. For I and II in longitudinal direction, level location is therefore not required. The horizontal position at right angles to the main axis is checked with removed inspection hole cover. In case of vibration-isolated foundations prior to the alignment of the first machine, all

other machines must have been placed on the foundation. Should one machine or other not yet be available at the time when the assembly is started, a weight should be used instead of the machine to simulate the location and the size of the machine still missing.

Alignment as described above is required even if parts of the equipment are supplied

mounted on a common base plate, as foundation plates cannot be made so stiff at reasonable expense as to be free from distortion during transit or when being placed on an uneven foundation. Shims must be placed underneath the plates in such a way that the machines have the correct position relative to one another (alignment as described above).

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5.5 Alignment The erection sequence depends on the sequence of the delivery of the parts and the

local conditions. Usual sequence: Pump, geared variable speed coupling, motor. The geared variable speed coupling is aligned to the existing driving or driven

machine during assembly. For the alignment, the adjusting screws M 20 supplied by us will be required. With these screws, the coupling is adjusted in the height. Bear in mind the shaft misalignment (height increase) of the units between the hot and cold conditions. By means of a pinch bar, the geared variable speed coupling can be shifted sideways. This job requires a minimum of effort if the greased iron shims can readily slide one on the other.

1. Alignment of connecting couplings without extension sleeve Note! Suitable are gear couplings or all-metal couplings with low radial

restoring forces. Flexible connecting couplings are to be agreed in each individual case.

e.g. between geared variable speed coupling and motor. Check distance "E" at

different points on the periphery, using a "feeler gauge" or flat steel. Check center offset using a short straight edge.

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For alignment, have a clamp made as shown on the sketch. Fit clamps on the

shafts. Set dial gauges at 5.00 mm and secure by means of set screws. Connect coupling sleeves by means of two connecting bolts and two spacers of about 20 mm. Turn coupling shafts by 180° using a flat iron inserted between the two sleeves. Enter the measurement in a coordinate system, e.g.:

As the shafts may shift in axial direction, find the difference between the two axial

measurements. Half of this difference is the dimension for the angular deflection. Correct the coupling gap and height by means of the adjusting screws. Repeat the same measurement in the horizontal plane, moving alignment clamp into the horizontal position, i.e. turn it by 90° relative to the original position.

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Reset dial gauges at 5.00 mm, then turn the shafts by 180° and enter measured

values in the coordinate system. Find mean values (as described above) and shift machine sideways accordingly:

Example: This alignment is satisfactory, if at the time of turning the coupling by 360° the

radial measurement "A" and the axial difference measurement "B" and "C" show dial gauge deviations not exceeding +/- 0.03 mm.

2. Alignment of couplings with intermediate piece or extended coupling sleeve e.g. between geared variable speed coupling and pump. Note! Suitable are gear couplings or all-metal couplings with low radial

restoring forces. Flexible connecting couplings are to be agreed in each individual case.

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Make a mounting device according to sketch. Use flat steel (at least 20x10 mm).

Connect alignment aid with shaft end of the machine to be aligned by bolting. Fit dial gauges set at 5.00 mm and secure them in position by means of an adjusting screw. Set 1/100 scale at "0". Turn shaft II by 360° (runout test). With axial runout of a shaft, the difference of the readings on the dial gauges "B" and "C" is the dimension for the angular deflection. Satisfactory true-running is ensured if the reading on the dial gauge is 0.01 mm or less.

Set dial gauge again at 5.00 mm. Turn shaft II by 180° by means of mounting aid. Enter readings into coordinate system. As the shafts may be displaceable in axial direction, the difference must also be

determined by measurements as described above. Correct the coupling gap and shaft location by means of the adjusting screw. Carry out similar measurements in the horizontal plane. For this purpose, move alignment clamp into horizontal position, i.e. turn it by 90° from the original position. Set dial gauges again at 5.00 mm. Turn shaft II by 180°. Enter measured values into coordinate system. Find average value as described above and shift machine to be aligned sideways.

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3. Shimming of gear housing, alignment report After alignment, all fixing bolts of the gear housing are shimmed. The load is to be

distributed uniformly on all shims preventing twisting of the housing when tightening the foundation bolts.

After slackening the adjusting screws, tighten the foundation bolts and check the

alignment. Alignment is satisfactory if both the radial measurement "A " and the axial

difference measurements "B" and "C" do not yield deviations in excess of +/- 3/100 mm. We recommend to enter the final measurement results in the coordinate system of the installation checking sheet.

4. Later alignment of the complete unit If after sustained operation the entire machine set must be aligned new, the Voith

geared variable speed coupling is displaced on the foundation. (With foundation bolts arranged in the centre, the bolt holes have sufficient clearance). The height of the axis is adjusted by regrinding or exchange of the shims between foundation and Voith geared variable speed coupling.

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5.6 Site pipework, cooler arrangement and cooler venting Assemble and install the oil pipes in a professional manner preferably below the oil

level of geared variable speed coupling! Do not confuse any connections! (see assembly plan). Ensure that the fittings, lengths and quality of lines meet the requirements.

The oil pipes should be as short as possible (< 8 m). If the pipes are longer

assembled above the oil level of geared variable speed coupling, install nonreturn valves in the oil pipe leading from the geared variable speed coupling to the oil cooler.

Oil pipes upstream and downstream of heat exchangers should be dimensioned to allow a minimum oil velocity of 3.5 m/s for lube oil and 4.0 m/s for working oil.

The diameter of oil pipes should be constant over the total length. In the event of a greater cooler connection width it is necessary to expand the piping directly at the cooler. A too large oil quantity in the pipes may cause speed instabilities and greater variations in the oil level due to air absorption.

Adapt the site pipework only after alignment of geared variable speed coupling and observe that it is installed free of stress.

Oil pipes of steel (not stainless steel) assembled at site are to be disconnected after

completion and immersed in a pickling solution. Voith recommends BETONA or a similar pickling bath. BETONA product of Messrs. Karowa, Memmingerstr. 39A, Neu Ulm, Germany. Pickling BETONA activated crystal pickling solution removes layers of scale, rolling skin and

rust from steel parts and welded seams. Prior to preparing and using this or another pickling solution observe the

relevant specification, safety information (data sheets), information for use. The pickling period of BETONA crystal pickling solution depends on the temperature

and duration of the bath. Mixing proportion: 1 part BETONA to 10 parts water result in this pickling solution. Mix

1 to 3 litres pickling degreasing agent S 13 on 100 litres pickling solution to remove dirt, slight fouling by oil, graphite or oil carbon. Workpieces heavily fouled by oil or grease are to be degreased in advance. The ideal temperatures of the pickling solution for pickling is approx. 40 °C. Put and leave the parts in the pickling solution for the periods mentioned below.

Pickling period: Rust film approx. 5 - 10 min. (immersed) Rust approx. 15 - 30 min. Rolling scale approx. 50 min. Descaling of annealed steel pieces approx. 120 min. The metal must be bright and free of scale and rust after pickling these parts.

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Drying Then remove the parts, do not wash them, let them dry drip-proof. Drying time to

achieve an ideal protective film at 20 °C is between 24 and 48 hours. If the drying time cannot be adhered to, subsequent flushing using clean water is required. Then dry the parts, spray them on the inside with operating oil and on the outside with paint.

Notes Basins of stainless steel, material no. 4571 or of steel, which are lined inside with

rubber or GVP, have proven well as bath basin. This material must be temperature-resistant.

Use rubber gloves, rubber boots, rubber aprons and safety glasses. The remaining

clothing shall be of natural fibres, like cotton, shear wool. Ventilate working rooms well. In case that the pickling solutions comes into contact with skin, immediately wash off using a lot of water.

Waste water and used pickling bath can be separated in two matters by neutralization

(by adding soda lye). The two matters are "water" and "flocky sludge". Sludge can be disposed according to waste number 52102.

However, this needs to be clarified in advance - observe the District Sewage Disposal Specification.

Afterwards, mount the pipework. Cooler arrangement: The installation dimensions of heat exchangers with change-over valves are shown

on the assembly plans. The change-over procedure is described in section 9.2. Pipes and oil coolers should, on principle, not drain into the oil tank of geared variable

speed coupling when the unit is switched off. We recommend positioning the coolers below the oil level of geared variable speed coupling.

If coolers are arranged above the oil level of oil tank, the pipes at the cooler must run

upwards in siphon arrangement and connecting at the highest point by a compensating pipe (DN ø 8 mm) with an orifice ø 3 mm. This way, the coolers remain filled. See Cooler Arrangement

Continuous ventilation of working oil cooler: Provide sufficient continuous ventilation of working oil cooler. Three vents are

provided on the shell side for continuous ventilation of working oil cooler. Mount three screw-in orifices ∅ 10 mm on these vents and connect them with a collecting pipe (DN 20). Connect this collecting pipe up to the geared variable speed coupling. Regarding the connecting point please refer to the assembly plan of geared variable speed coupling.

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5.7 Lube oil supply of individual machines The lube oil for - the boiler feed pump / flow rate ..... l/min. - the booster pump / flow rate ..... l/min. - the motor / flow rate ..... l/min. - the connecting couplings / flow rate ..... l/min. is taken from the lube oil circuit of the geared variable speed coupling and is fed back

again to the oil tank of the coupling. The flow rate to the individual machine taken for lubrication of total 300 l/min. at 1,5 - 2,0 kg/ cm2 must not be exceeded. Any technical data concerning the flanges and pipes of the specified machine can be taken from the assembly plan. Pilot bored orifice plates are provided at the lube oil outlets (flanged connection) of the geared variable speed coupling to the specified machines. Prior to test run, these orifice plates must be adapted as a function of the oil flow required and of the lube oil pressures, with the aux. lube oil pump running. For determination of the orifice plate bore as a function of the final lube oil pressure and the necessary flow rate, proceed according to Sheet 3.632-9088 in Part 4. If additional orifice plates are/are to be installed upstream of the bearing points of the individual machines, this will have to be considered when adapting the pilot bored orifice plates.

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5.8 Coupling guards Guards should be mounted, especially on rotating parts,

- as protection against contact on connecting couplings, and as protection against injuries by burning on hot - pipework, - heat exchanger, - geared variable speed coupling, and on any other sources of risk which can be recognized after assembly of the overall unit, in accordance with the safety regulations in force. When mounting a acoustic cover over the geared variable speed coupling, Mounting an acoustic cover must be considered.

In case of outdoor installation, we recommend to mount a guard or a housing over this unit and its attaching parts.

5.9 Preservation after installation The perfect condition of geared variable speed coupling and their assemblies is to be

preserved during installation and assembly work, long periods of storage and after installation or in cases of standstill for operational reasons. The measures necessary during these phases and the necessary inspections are described in the Voith-Instruction Manual.

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5.10 Electric installation The monitoring instruments are wired to the terminal box. Wiring in the terminal box

was made according to the terminal plan. Instructions to the instruments supplied are included in the enclosed instrument

description, please see Part 5. Any work at electric units or operating means must only be effected by an electric

expert or by trained persons, under the direction and supervision of an electric expert, according to the electric regulations. Check all motors for direction of rotation, smooth running and current consumption (motor protection.) Check the ready mounted unit for stray currents since they damage gear wheels and bearings. If you find any, take remedial measures, i.e. by grounding.

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6. Operating Oil The following work must only be effected by qualified personnel (see safety information). If the operating fluid used is not mentioned in our oil selection list, check its compatibility with

our preservation oil (Shell Ensis motor oil W 20) or flush the inside of geared variable speed coupling thoroughly.

Ensure a safe disposal, not being detrimental to the environment, of operating and aux.

medium as well as of the replacement parts! The operating oil viscosity must be as low as possible to guarantee satisfactory hydraulic

efficiency and air release properties during filling, emptying and regulating. Since the bearings, in particular the usually highly loaded gear wheels, are also lubricated by the operating oil, it must possess excellent lubricating characteristics. The only oils suitable for geared variable speed couplings are thus high performance, low viscosity oils with additive-produced lubricating properties and excellent air release characteristics.

The oil must be chemically neutral to metals and seals and be nontoxic. Resistance to aging at max. admissible operating temperature and under high air entrainment

must allow a sufficient operating life. The oils tested according to the above criteria can be seen in the attached Oil Selection List.

The starting viscosity under the conditions at site must not exceed 250 mm2/s (cSt). The operating oils must not be mixed when being used. Admissible oil mixtures must be clarified with the oil supplier.

For auxiliary units, such as connecting couplings and actuator, the amount of lubricant

specified by the manufacturer should be checked prior to commissioning and later after the maintenance intervals and, if necessary, increased.

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6.1 Filling with operating oil The oil quantity required, without filling of the pipework and heat exchangers,

is 2500 litres. The quantity required for heat exchangers is indicated in the respective assembly plans. The oil quantity for the pipework must be determined at site, after piping.

We recommend filling with operating oil immediately after piping the unit. Filter the oil when filling in, grade of filtration 25 mym or finer. Fill the geared variable speed coupling with oil via the oil filling hole on the inspection

hole cover. When coolers and piping are filled or ventilated, the oil level should reach an average value between the MIN. and MAX. mark of the oil level indication (see assembly plan).

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7. Commissioning The following work must only be effected by qualified personnel (see safety information). When operating the geared variable speed coupling, meet the nominal values for temperatures

and oil pressures stated in par. 8. The geared variable speed coupling only allows a power transmission and speed control with

the operating data specified (see nameplate or data sheet of this instruction manual). The viscosity of operating oil for start-up must not exceed 250 mm2/s.

this means a temperature of approx. +5 °C.

7.1 Trial run preparations - Check alignment of all equipment considering the thermal growth in height

and width and shaft misalignments due to operation and correct, if necessary. Record alignment values!

- Check fixing of foundation. - Check direction of rotation of drive motor, with the geared variable speed

coupling uncoupled. - In case of coupled curved-tooth connecting coupling with constant filling,

check for easy displacement of the coupling sleeve and sufficient lubrication, check the guard.

- In case of coupled curved-tooth connecting coupling with lubrication by

circulation, check for easy displacement of the coupling sleeve. Mount the bottom half of the covering and check the injection nozzle for its correct installation (see manufacturer's instructions). Afterwards, mount the upper half of the covering.

- Please observe the manufacturer's instructions for lube oil supply to

individual machines (external units). - Fill the geared variable speed coupling with operating oil up to the max. mark

of oil level indicator.

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- Note: During flushing, the working oil cooler and oil tubes in the system

are filled with oil via a connecting line arranged internally between the lube oil and working oil circuit. Approx. 10 litres/min. are supplied into the working oil circuit.

- Check, and provide resp., the electric installation of motor, instruments,

actuator etc. for being connected to the supply voltage, processing of signals for control and monitoring instruments! Observe section 5.10 Electric installation.

- Flushing the lube oil circuit. Switch on the electrically driven aux. lube oil

pump (interlock at automatic start-up of main motor) and carry out flushing in the lube oil circuit during a longer period of time (one to several days). Thereby vent cooler and piping.

- When the differential pressure rises to 0.6 kg/ cm2, change over to the clean

filter half and clean the clogged part according to section 9.1. - Check the lube oil flow rate of the individual machines (external units) and

correct to section 5.7 Lube oil supply of individual machines, if necessary. - Flush the pipe until the filter is no longer clogged. - Check piping for leakage. - Check the injection quantity into the connecting coupling at lubrication by

circulation (see manufacturer's instructions), if required, correct by installing orifice plates.

- Check the oil level of the geared variable speed coupling and refill with

operating oil, if required, see section 6.1. - Check the lube and control oil pressure and adjust according to section 8.3,

if necessary. - Check the switch points of the pressure transmitters and their function.

Check the switch points of temperature monitoring, adjust if necessary.

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- Check the adjustment of the actuator at the scoop tube positioning device,

via the adjusting angle. Both end positions must be mechanically limited at the actuator.

- Read the scoop tube position on the stroke indicator scale, with the aux. lube

oil pump running. Check the following using the original actuator. a) At 100 % scoop tube position, check and adjust the max. positioning or

feedback signal on the actuator. b) After running through the rated adjusting angle or the actuator stroke,

the minimum positioning or feedback signal corresponds to a scoop tube position of approx. 0 %.

- Set the scoop tube to MIN. position. Switch off the aux. lube oil pump.

7.2 Trial run - At water-oil coolers, open the water side valves, vent the cooler at the water

side and check the flow. The operating data and the instruction manual of the oil coolers must be observed.

- Check the readiness for operation of the complete unit. - Start the aux. lube oil pump and switch on the main motor or monitor the

automatic start-up when lube pressure is available. - After the motor has run up to speed, observe the automatic shutdown of the

aux. lube oil pump with lube pressure existing or switch off aux. lube oil pump manually.

- Run the unit at minimum speed and observe smooth running, temperatures,

lube pressure and filter condition. If the minimum speed of driven machine has to be increased or reduced,

proceed according to section 3.1.1. - Slowly run the unit up to speed. Adjust the working and lube oil temperature

via the cooling water flow (observe min. water flow rate).

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The heat to be dissipated of the working oil depends on the respective

operating point of the power characteristic curve of the driven machine. The max. heat is at 60 - 70 % speed, at parabolic torque characteristic curve, and at min. output speed at constant torque characteristic curve.

- Observe the temperatures until they are steady. If required, readjust the

working oil flow rate, see section 3.2. The temperature upstream of the working oil cooler should not exceed 110 °C.

- If the high-speed input or output shaft (larger than 2980 rpm) was completely

balanced without original hub, due to a non-delivery of the connecting coupling hub, a subsequent rebalancing may be necessary and be made at site. One reason for this are key or keyway tolerances.

- Evaluate and record smooth running of geared variable speed coupling by

vibration measurements. Besides the measuring values, record measuring points, speeds and scoop tube position.

- If the characteristic of the unit has to be optimized according to the operating

conditions by adapting the oil circulation and scoop tube cam disc, the complete unit has to be operated under operating conditions over the whole regulating range.

- Turn the unit down to MIN. speed. After switching off the main motor, check

automatic switch-on of aux. lube oil pump at decreasing lube pressure. Switch off the aux. lube oil pump after standstill of the main motor and of the driven machine.

- During or after the trial run, clean the lube oil filter and fill with operating oil

(see section 9.1), check and correct the oil level according to section 6.1. - Check fixing of the stops on the actuator again. The stroke must be limited

on the actuator, not at the scoop tube control.

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7.3 Measures to be taken at standstill periods The perfect condition of geared variable speed coupling and their assemblies is to be

preserved during installation and assembly work, long periods of storage and after installation or in cases of standstill for operational reasons. The measures necessary during these phases and the necessary inspections are described in the Voith-Instruction Manual.

At standstill periods of the geared variable speed coupling of one or several days

(also several weeks), the aux. lube oil pump must be switched on for at least 5 minutes daily.

Protect the geared variable speed coupling against water ingress and humidity.

Preserve bright parts accordingly. For internal protection against corrosion (oil wetting) start the geared variable speed

coupling every 1 to 2 months for a short time. Do not run the geared variable speed coupling warm, because there is a risk of dewpoint corrosion.

If the actuator is operated during stand-by operation, the grease nipples on the guide

bush are to be lubricated every 2 months in each case with 5 g lithium-soaped antifriction bearing grease. At standstill periods of heat exchangers, the cooler instruction manual must be observed, especially the par. "How to avoid corrosion damages".

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8. Operation of the Geared Variable Speed Coupling The following work must only be carried out by qualified personnel (see safety information).

8.1 Start-up, operation and shutdown of geared variable speed coupling as well as measures to be taken when the unit is at standstill (also see Logic Diagram) A continuous monitoring of geared variable speed coupling maintaining admissible

temperatures, lube pressure and oil level means a trouble-free operation and low maintenance.

Start-up of geared variable speed coupling The viscosity of operating oil for start-up must not exceed 250 mm2/s (cSt). For the

oils according to our Oil Selection List, this means an oil temperature of at least +5 °C.

The geared variable speed coupling can on principle be started and stopped with the

scoop tube at any position. However, with the scoop tube at minimum position, the main motor can run up under virtually no load.

- Prior to starting the main motor, switch on the aux. lube oil pump. The

solenoid valves 92 and 93 of the rapid start-up device are not electrically excited (OFF).

- At existing lube oil pressure (> 1.2 kg/ cm2), start the main motor. - After reaching the lube oil pressure (> 3.0 kg/ cm2), switch off the aux. lube

oil pump with a time interval of up to 5 minutes. - Run the scoop tube to max. 100 % scoop tube position and in operating

condition resp. This is made via an actuator which is controlled by a guide signal 4 - 20 mA resp.

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Operation of geared variable speed coupling To keep good air release properties, the sump temperature (oil temperature upstream

of the lube oil cooler) must not fall below 45 °C during continuous operation. Continuously check the admissible temperatures, working and lube oil pressure and

the oil level. Data see section "8.2 Operating data". - By positioning the scoop tube via the actuator (up to max. 100 % scoop tube

position) accordingly, the input power and input speed of the driven machine are determined and adjusted resp. Change the guide signal between 4-20 mA resp. accordingly.

- In case of a failure during operation, the monitoring instruments attached

release an electric signal thus leading to an alarm or switching-on of the aux. lube oil pump or to a shutdown of the unit, as mentioned under 8.2.

Attention: A system transfer during operation (e.g. at an interconnected

system/power station system) must be carried out only via a lock-up device. If there is no phase coincidence, there might be an inadmissible high torque jerks from the main motor acting on the gear.

Shutdown of geared variable speed coupling The geared variable speed coupling can on principle be started at any scoop tube

position. However, with the scoop tube at min. position, the main motor can run up under virtually no load.

- Switch on the aux. lube oil pump.

- Switch off the main motor. - Regulate downwards the geared variable speed coupling to min. speed. Bring the guide signal to 4 mA.

- After main motor and driven machine stopped, switch off the aux. lube oil pump.

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Measures to be taken when the unit is at standstill Reverse rotation of the output shaft of geared variable speed coupling is only allowed

under the following conditions and limited to 1 - 3 minutes: 1) Monitoring of direction of rotation of the output shaft. 2) Switching-on of aux. lube oil pump without time delay.

3) Move the scoop tube to 100 % position. 4) Close the shutoff valve of the feed water pump. If reverse rotation occurred without one of the three first precautions described, check

the plain bearings and fusible plug screws prior to a new start-up.

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8.2 Operating data (see oil circuit and measuring point scheme) Bearing temperatures nom. value <90 °C (46-51, 54-63, 66-69) alarm / trip 90 / 95 °C Working oil temperature upstream of nom. value >60 - <110 °C heat exchanger (81, 86, 87, 88) alarm / trip 110 / 130 °C Working oil temperature downstream nom. value >35 - <75 °C of heat exchanger (80, 89) alarm 75 °C Lube oil temperature upstream nom. value >45 - <65 °C of heat exchanger (78, 82) alarm at 70 °C Lube oil temperature downstream of nom. value >35 - <55 °C heat exchanger (79, 83, 84, 85) alarm / trip 55 / 60 °C Lube oil pressure, gauge (42) nom. value >1.5 -<3 kg/cm2 Pressure transmitter (71 - 73) main motor ON >1.2 kg/cm2 aux. lube oil pump OFF >3.0 kg/cm2 aux. lube oil pump ON <1.2 kg/cm2

alarm <1.0 kg/cm2 trip <0.8 kg/cm2 Differential pressure at change over filter and lube oil filter (25, 25.1) clean at 0.6 kg/cm2 Control oil pressure, gauge (43) nom. value >3 - <4 kg/cm2

Pressure transmitter (74 - 76) alarm <2.5 kg/cm2 trip <2.2 kg/cm2 Working oil pump pressure, test connection (44, I see at assembly plan) >1.6 - <2.1 kg/cm2 Working oil pressure upstream of circulation control valve test connection (21, II see at assembly plan) >1.0 - <1.8 kg/cm2 Working oil pressure downstream of scoop tube test connection 45, III see at assembly plan) >1.8 - <3.5 kg/cm2 Oil level, sight glass (90) nom. value max. - min. mark Oil level switch (70) alarm 10mm > max. / 10mm < min. mark

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8.3 Lube oil pressure/control oil pressure and monitoring of lube oil pressure (see oil circuit and measuring point scheme) The lube oil pressure is set to approx. 2.5 kg/cm2 by means of the adjustable orifice

(29) but is also dependent on the viscosity of the oil used. A change in the lube oil pressure will also change the control oil pressure. Control oil pressure can be reset on the pressure relief valve (28) to approx. 3.5 kg/cm2.

Proposed switching sequence and pressure transmitters to be set as follows: 1. Signal to switch on the main motor when lube oil pressure reaches

>1.2 kg/cm2. It must be guaranteed by means of a time delay that all bearings, especially at lube oil supply of external machines, are prelubricated.

2. Switching-off, with time delay (1-5 minutes), of aux. lube oil pump at

>3.0 kg/cm2 on completion of main motor run up. The set pressure shall be greater than that of the aux. lube oil pump alone and lower than that produced by the aux. lube oil pump and lube pump together.

3. Switch on the aux. lube oil pump if the pressure drops to <1.2 kg/cm2.

4. Alarm signal when the pressure drops to <1.0 kg/cm2.

5. Trip signal when the pressure drops to <0.8 kg/cm2.

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8.4 Monitoring of working oil The temperature of the working oil downstream of the cooler should be above 35 °C.

Upstream of the cooler, the temperature could rise to <110 °C. During unusual operation (e.g. flushing), max. temperatures of up to about 130 °C could occur.

If temperatures are too high, the volume of working oil could be increased (see section 3.2).

Another control is possible by the three fusible plug screws melting at an oil temperature of 180 °C and thus each releasing a bore through which the oil sprays into the sump. See section 2.1.

The three fusible plug screws (item 0310/0010/0060, see Vertical Section) can be

replaced by removing the inspection cover II on the housing cover and turning the input shaft until the fusible plug screws are accessible.

The pressure relief valve (27) holds the pressure of the working oil (pressure

upstream of the control valve) at 1.0 to 1.8 kg/cm2.

8.5 Bearing temperatures The bearing temperatures should normally not exceed 90 °C. We recommend setting

the alarm signal "Bearing temperature too high" at about 15 °C above the temperature of the hottest bearing or at 90 °C and trip signal "Bearing temperature high high" at 95 °C.

The temperatures of the individual bearings vary because of varying shaft speeds or external thermal loading caused by the working oil (at bearing 6 and 7).

8.6 Lube oil filter The lube oil filter is executed as double filter. At correct position of the changeover cock, however, only one sieve part is used for

cleaning the oil. The filter is fitted with a differential pressure switch, whereby contact of the alarm is required at 0.6 kg/cm2 differential pressure.

Slowly change over the change-over lever to the second filtering jug. When switching from one filter to another during operation, ensure the lube oil

pressure does not drop excessively, actuating an alarm / trip by the pressure transmitters. This is achieved by flooding the clean filter before changeover. See section 9.1 "Putting the cleaned filter half back into operation".

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8.7 Oil level indication For oil level control, an oil sight glass and an oil level switch is fitted to the geared

variable speed coupling. With the unit shut down and the piping and coolers filled with oil, the oil level should

be below the mark "Max. Oil Level". The oil level switch is set so that it releases an alarm signal 10 mm below “Min.” and

10 mm above “Max.” mark.

8.8 Lubricating points of scoop tube control (see drawing “Section through Control”) Two lube nipples are provided on the guide bush for a grease gun for lubricating the

guide bolt. They are to be greased with a lithium-soaped anti-friction bearing grease as in section "Maintenance".

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9. Maintenance of Geared Variable Speed Coupling The following work must only be carried out by qualified personnel (see safety information). The maintenance instructions and intervals detailed below are based on our practical

experience and should be adhered to in order to ensure trouble-free operation of the geared variable speed coupling.

Ensure a safe disposal of operating and aux. means as well as of spare parts not being

detrimental to the environment!

9.1 Maintenance of double filter Dependent on the requirement or alarm signal of differential pressure monitoring,

change over, clean or prepare the double filter for putting it into operation, following the manufacturer’s instructions. Regarding the manufacturer’s instructions please refer to section „Description of Attaching Parts“.

Warning! Waste oil getting into the sewerage or open soil may cause severe damage

to the environment. Dispose of waste oil in a professional manner according to the national statutory provisions.

I. Filter changeover during operation: 1. Remove the plug at the vent valve of

the filtering jug to be filled and open the vent valve. Open the pressure compensation valve until oil leaks out at the vent valve. This way the clean filtering jug is filled with oil (see III).

2. Close the vent valve and fit the plug.

Change the filter slowly over to the second filtering jug using the changeover lever, otherwise, in the event of to excessive pressure drop, the pressure monitoring system may switch off the unit.

Compensation valve

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Position of changeover lever compared to the position of filtering jugs II. How to proceed to clean the filter Cleaning agents and other auxiliary means - Cleaning container with clean gasoline used for cleaning purposes or diesel oil (approx. 10 litres). - Container for oil to be drained (approx. 20 litres). - Soft brush, compressed air. 1. Drain the oil from the filtering jug to be cleaned. Open vent valve and oil drain valve. 2. Unscrew filter cover. 3. Remove filter element out of the housing in vertical position. Important: - Inner side of filter element is the clean oil side - Outer side is the dirty side. During the cleaning process: - do not change over the filter - do not open the pressure compensation valve. 4. Clean the internal filtering jug. 5. Clean the dirty outer side of filter element using gasoline for cleaning

purposes or diesel oil.

Position I This filter side is in operation

Position II This filter side is in operation

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Cleaning process: - Do not submerge the filter element in the cleaning agent. - Wash the filter outside from top to bottom using the soft brush If there is any residual sealing compound on the filter element (strainer

texture), then submerge it for a short time (max. 15 min.) in trichchlorethylene or Tri-substitute and wash it off.

6. Blow compressed air through the internal filter element.

Cover the openings. Attention: If the filter element is heavily clogged, it is necessary to repeat cleaning. 7. Check the filter element for any damage. 8. Observe that the O-rings are properly seated. 9. Insert the filter element in the filtering jug. 10. Mount the cover and close the oil drain valve. III. Preparations to put the cleaned filtering jug in operation - When the geared variable speed coupling is out of service, switch on the

aux. lube oil pump. 1. Remove the plug on the

vent valve. Open the vent valve a little.

2. Flood the filter half by

opening the compensation valve until oil leaks out at the filter vent line. Close the shutoff valve.

3. Close the vent valve.

Fit the plug. - Now the cleaned filter half is ready for operation.

1

1 1

1 Vent valve with plug

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9.2 Maintenance measures which can be taken with the unit running When differential pressure of lubricating oil filter rises, switch it over and clean. Check air release property of the operating oil, if there are speed fluctuations on the

driven machine. Check also the permanent venting of the working oil cooler. In case of increased oil level, check the oil for water content.

take measures according to the oil manufacturer's/oil supplier's instructions..

Please note the following for double heat exchangers with changeover set: 1. On principle, only one heat exchanger is to be used for operation in order to

meet the flow rates. 2. Preserve the standby heat exchanger against corrosion during standstill

periods according to Instructions . 3. Prior to changeover to the standby heat exchanger, its cooling water flow

must be guaranteed. 4. Open the valve in the pressure compensation pipe. 5. Changeover to the standby heat exchanger During changeover from the heat exchanger in operation to the stand-by

heat exchanger, move the changeover lever only so far that the stand-by heat exchanger is slowly flooded. Only a slight oil pressure drop is allowed in the system, otherwise this can result in a shutdown of the units via the pressure transmitters. Slowly continue the changeover action after the heat exchanger is filled.

6. After switch over, close the valve in the pressure compensation pipe. Daily: Check temperatures, lube oil and control oil pressure, differential pressure on the lube

oil filter and the control oil pressure, if monitoring is not integrated in the control system.

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Every 3 months: Check the operating oil for its usability.

Take measures according to the oil manufacturer's/oil supplier's instructions. Check the vent filter for impurities, if required clean.

Repress lithium-soaped anti-friction bearing grease through the lubricating nipples of the scoop tube control, each 5 g.

Measure, record and compare smooth running (vibration) of the unit, always under

the same operating conditions. On noticing deviations, check the alignment of the geared variable speed coupling to section 9.3.

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9.3 Maintenance measures which can only be taken when the unit is at standstill Note: Do not start the coupling after a damage without previously checking

the fusible plug screws and the bearings and considering the conditions under par. 8 (Measures to be taken when the unit is at standstill).

After 50 operating hours: Visually inspect gear stage for suitability of operating oil (scuffing of toothing). After 250 and 2500 operating hours: Visually inspect gear stage for suitability of operating oil (scuffing of toothing). If the vibration values changed acc. to section 9.2, it will be necessary to check the

alignment of the geared variable speed coupling as well as the foundation fixing. Every 8000 operating hours or at least annually: Check and maintain connecting coupling according to the manufacturer's instructions. Check and maintain the actuator according to the manufacturer's instructions. Check and maintain the auxiliary lube oil pump motor according to the manufacturer’s

instructions. Check alignment of geared variable speed coupling and the foundation fixing. Visual inspection (corrosion, general condition, etc.) by removing inspection hole

cover on housing cover. Also visual inspection of tooth flank contact pattern and inspection of the three fusible plug screws (item 0310/0010/0060, see Vertical Section).

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10. General Overhaul of the Geared Variable Speed Coupling

10.1 General remarks In the event of a change in operating behaviour after max. 7 years operating time, the

geared variable speed coupling should be overhauled. To avoid unnecessary delays during servicing, we recommend to order spare parts

for the general overhaul well in advance. We shall be pleased to elaborate an offer for any inquiry reaching us.

In order to ensure speedy handling of your inquiries, or your orders for service

engineers or spare parts, please always indicate the serial number of the Voith geared variable speed coupling and the name of the person in charge.

It is not necessary to lift the complete assembly off its foundation for the purpose of

general overhauls. Installation work on the geared variable speed coupling should only be carried out by

our specialized service engineers or trained staff (see safety information).

10.2 Preconditions On principle, dismantling must not be commenced until the system and the drive

motor have been "de-activated", and permission has been obtained from the competent department.

Uncouple the input and output side connecting couplings (make power transmission

ineffective). An operational travelling crane for 2500 kg must be available, ready for operation, to

lift individual components out of the gear housing, such as housing cover, input shaft with gear etc.

10.3 Dismantling and reassembling Special care should be taken to ensure that no dirt penetrates into the coupling during

the overhaul. Cover the open oil tank with a tarpaulin. Perhaps put the housing cover loosely on the housing and seal the shaft passages.

Warning: Personal injury and damage to property may occur, if individual

gears or pinion shafts of the gear stage are replaced.

The gears of each gear stage are paired with each other and balanced together with the shafts, to achieve an optimum contact pattern, backlash and smooth running.

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It is only allowed to interchange complete gear stages with the

relevant part of the turbo coupling of the same gear type. Individual gears or shafts should only be interchanged in special

cases and after comparing the production progress reports and after receipt of Voith Crailsheim's written approval. For replacement of a gear stage, the relevant shafts are to be sent to Voith for installation and joint balancing or new shafts are to be provided.

Overhaul procedure: (Detailed disassembly and assembly steps are described in par. 11.) 1. Drain the operating fluid. Disconnect electric cabling. Open lubricating oil filter, inspect and clean. Dismantle connecting couplings and check their condition. Check input and output shafts for true running. Unscrew primary and secondary-side thrust bearing covers

(0030/0030), remove bearings and check. Loosen 3 hex. screws (0270/0360) in flange (0270/0350) of the control. 2. Release housing cover from housing and lift off. Check condition of toothing (check contact pattern). Remove fusible plug screws (0310/0010/0060), turn rotor assembly in

order to allow any oil residues remaining in the coupling to drain (clear borehole, if necessary).

Check fusible plug screws and replace, if necessary. 3. To be able to remove the scoop tube, loosen the bracket mounted on

the scoop tube housing and lift the control housing (0080/0140) with control sleeve (0080/0200) out of its guide.

Remove temperature probes. Lift off bearing cap and unscrew bolts from scoop tube housing

(0110/0010/0070/0130). Lift out complete runner assembly plus input and output shafts from the

gear housing. Unscrew the 4 fixing bolts (0120/0110) and remove the complete pump

insert (0130/0010). (The pump insert is also accessible through the inspection cover I (with the oil filler plug) without lifting off the housing cover, see assembly plan).

4. Dismantle rotating parts and pump insert, clean all components

(remove old sealing compound and any deposits of oil sludge) and check the following:

Whether runners are damaged or not (resonance test of blades). Check condition of bearings and measure bearing clearance. Check scoop tube mechanism for wear. Check all components of pump insert.

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The scoop tube guide bush (0080/0010) is accessible after dismantling

the runner. 5. Re-polish plain bearings before re-assembly and also the bearing

sliding faces of shaft, if necessary. At re-assembly, secure bolts as originally provided. Locking elements

(spring washers) should be replaced by new parts. Tighten the screws using a torque wrench with the specified tightening torque, as indicated on the drawing.

6. Re-assemble runner and pump insert. Special care should be taken during re-assembly that all components

showing a common mark, such as primary wheel and shell, as well as the parts of the thrust bearings are fitted in the correct position to each other.

7. Clean housing and housing cover carefully from old sealing compound

and any deposits of oil sludge. Flush and clean oil tank carefully. Apply a new sealing compound to all sealing surfaces, oil-resistant up

to 130 °C (e.g. Hylomar). 8. Install input and output shaft, runner and pump insert again. On installation of a new pump insert, pay attention to the backlash

(0.15 + 0.1 mm) and contact pattern of spur gears. 9. Fit temperature probes. Mount and tighten housing cover. 10. Grease the lubricating nipples (0270/0020/0020) of the control with 5 g

of lithium-soaped antifriction bearing grease each and grease bright components. Retighten the flange (0270/0350) of the control.

11. Alignment check of geared variable speed coupling to main motor and

driven machine (record values obtained). 12. Install connecting couplings. Connect motors and instruments. 13. Clean oil coolers, if necessary, following manufacturer's instructions.

This must be followed by a leakage test of the coolers (please note max. test pressure).

14. Fill oil tank and coolers with operating oil. 15. Carry out an operational test with the aux. lube oil pump, actuator and

instrumentation. Check oil coolers for leaks and venting. Then carry out a trial run, observing function and smooth running. Watch for leaks, correct oil level, if necessary.

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11. Dismantling the Geared Variable Speed Coupling (pay attention to the corresponding sectional drawing)

11.1 General remarks Installation work on the geared variable speed coupling should only be carried out

by our service engineers or qualified staff (please see safety information). After rotating parts have been taken out of the housing, they can be dismantled

and reassembled elsewhere. For urgent installation work or repairs, it is not absolutely necessary to drain the oil

tank. No special tools are needed for dismantling and reassembling the Voith geared

variable speed coupling. We recommend to mark all rotating parts (if they have not been provided with

balancing or reference marks) prior to dismantling, to be able to reassemble them in the proper position at assembly.

Components and larger subassemblies must be carefully fixed to lifting devices

and be secured in order to avoid any danger here. Only use appropriate and lifting devices in technically sound condition as well as load suspension devices with sufficient carrying capacity! Do neither stay nor work under suspended loads!

11.1.1 Removing the housing cover Remove the supply lines on the actuator, if necessary. Remove any

obstructive fittings above the shaft centre line, such as electric cables, pipes etc. The same applies to the connecting coupling guards.

Remove the hex. screws (0270/0360) in the sealing flange (0270/0350). Press and lift off the sealing flange. Remove the hood (0110/0180) to the scoop tube control and all vertical

securing bolts in the housing cover. Remove the socket head screws between thrust bearing covers (0030/0030) and bearing covers (0015/0010) and (0016/0010).

Remove screws above the joint face of the thrust bearing covers

(0030/0030) and the bearing covers (0015/0010) and (0016/0010). Bring the travelling crane over the centre of the housing cover, hoist up

and set down on a rubber mat.

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11.1.2 Removing the scoop tube control and scoop tube Remove housing cover as in 11.1.1. Remove connecting rod

(0170/0090) by removing the pin of the link joint (0170/0110). On the elbow (0205/0300) with the welded bracket, and release the

bolts in the flange and the bracket. Carefully hoist the elbow and bracket in vertical position. Pull the control pin (0080/0210) from the control sleeve (0080/0200). Ensure the control sleeve remains in the control housing and the spring wire (0080/0230) is not bent.

Then pull the control sleeve (0080/0200) out of the control housing

(0080/0140). When unbolting the 5 control oil pipes, collect the oil in a tank. On the control housing (0080/0140), remove the bolts (0080/0150) and

take out the control housing. Attention: Cylinder cover (0090/0020) is fixed under initial

stress of spring (0080/0130). Loosen the cylinder cover (0090/0020) under initial stress of spring as

follows: Remove two opposite screws (0080/0100), replace them by two threaded spindles M8x300 mm with nuts to relax the spring. Remove the remaining screws (0080/0100). Relax the spring by means of the nuts. Remove the threaded spindles and lift off the cover.

Withdraw guide bush (0080/0120) and spring (0080/0130) from the

cylinder (0080/0070).

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To remove the scoop tube (see picture), hook a bent wire into the bore

of the spring cotter in the scoop tube piston (0090/0010/0030) and pull the scoop tube out.

11.1.3 Removing the coupling runner Warning: Personal injury and damage to property may occur,

if individual gears or pinion shafts of the gear stage are replaced, see par. 10.

Remove the gear lubrication injection pipes on the input side. Separate the elbow (0205/1170) at the flange connections and remove with both oval flanges and O-ring.

Remove all temperature probes. Unscrew the primary and secondary thrust bearing cover (0030/0030) on

the primary and secondary sides and the outer thrust bearings (0071/0050).

Remove the primary and secondary thrust ring (0030/0010) on the

primary and secondary sides and withdraw the inner thrust bearings. Remove the bearing cap of bearing 5 releasing the bolts and lifting the

fitted pins. Remove the upper bearing cap of bearing 5 from the shaft. Remove the bearing caps of bearing 6 (oil supply housing) and 8 as for

bearing 5. Remove the bolts and fitted pins in the scoop tube housing

(0110/0010/0070/0130), the scoop tube housing remains on the coupling rotating parts.

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Unscrew one fusible plug screw (0310/0010/0060) from the shell

(0310/0010/0020). Clear the bore from sludge and turn the runner so the residual oil drains out.

Screw a screw-in swivel M 24 into the centre winding of the primary

shaft (0310/0010/0010/0010) and secondary shaft (0320/0010/0010/0010) of the rotating parts.

Suspend the parts up by nylon ropes, as shown in the sketch. The rotating parts should be perfectly horizontal when they are being

removed so that the pinion teeth do not buckle. Use a lifting device to ensure the parts are level. Sling a rope round the cylinder (0080/0070) and secure on the crane hook to prevent twisting of the scoop tube housing.

Slowly lift the runner. On dismantling the runner, the lower bearing halves of bearings

(0071/0020 and 0071/0030) of bearing points 5, 6, 7, 8 can stick to the shaft. Remove the bearing shell after lifting the runner. Set down the runner on a rubber mat.

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11.1.4 Dismantling the coupling runner Remove the screw-in swivel from the centre winding of the secondary

shaft (0320/0010/0010/0010) and suspend the coupling runner using the crane.

Leave the primary shaft suspended on the crane and chock up the

pinion of the secondary shaft in stable manner. Remove all socket head screws (0310/0010/0040) between primary

wheel (0310/0010/0010/0020) and shell (0310/0010/0020). All screws on the runner are tolerated with regard to their weight

(please see also parts list, abbreviation "GT"). These screws are marked in colour and must not be interchanged with others.

Jack the primary wheel off the shell using two puller screws

M 10 x 80. Lift the primary part and set down on a rubber mat. Remove socket head screws (0320/0010/0040). Jack the secondary

wheel (0320/0010/0020) off the secondary shaft (0320/0010/0010/0010) using two puller screws and hoist up by crane.

Lift the shell (0310/0010/0020) out over the secondary shaft, by means

of the crane, and set down. Put a spacer between scoop tube housing and gear wheel. Remove screws in the bearing cap (0110/0010/0070/0200), keep the

scoop tube housing (0110/0010/0070/0130) in position and lift out the bearing cap with the lower half of the split bush (0110/0020).

Remove the scoop tube housing (0110/0010/0070/0130) laterally and

dismantle the upper half of the split bush (0110/0020) and the second half of bearing (0071/0030).

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11.1.5 Removing the complete input shaft Warning: Personal injury and damage to property may occur,

if individual gears or pinion shafts of the gear stage are replaced, see par. 10.

The connecting coupling hub can remain on the shaft. Remove the screws on the bracket of bearing points 2 and lift the

dowel pins. Lift off the bearing cap. Remove the shells (0071/0010) of bearings 1 + 2 from the input shaft. Remove the injection pipe for the filling pump drive (pump insert).

Screw screw-in swivel M 36 into the input shaft (0301/0010/0010/0010)

near the spur gear (0020/0010). Suspend the input shaft (see sketch) and lift out of the housing, keeping the shaft horizontally.

On dismantling the shaft the lower bearing halves can stick to the

shaft. Remove the bearings shells after lifting.

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11.1.6 Removing the output shaft (pinion shaft) Warning: Personal injury and damage to property may occur,

if individual gears or pinion shafts of the gear stage are replaced, see par. 10.

The connecting coupling hub can remain on the shaft. Release the bolts in the bearing cover (0016/0010). Remove the bolts from the bearing cap of the bearing point 11 and lift

the dowel pins. Lift off the bearing cap and remove the upper bearing shell.

Suspend the output shaft (0301/0010/0030) to the crane and hoist

horizontally out of the housing. On dismantling the shaft, the lower bearing halves can stick to the

shaft. After lifting, remove the bearing halves.

11.1.7 Removing the pump insert In the event of a defective pump insert (decreasing supply capacity,

damaged tooth surfaces of the input pinions), it is recommended to replace the complete pump insert (0130/0010).

With removed housing cover, the pump insert is easily accessible for

removal. Another possibility is to remove the inspection cover I (with the oil filler plug) and withdraw the pump through the hatch in the housing cover.

Remove the bolts (0120/0110) and press the pump insert about 50 mm

upwards using the two puller screws M 12 x 80. Sling a rope round the input shaft and carefully hoist the pump up by

crane. Set the pump down on a rubber mat.

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11.1.8 Removing the aux. lube oil pump If the aux. lube oil pump is damaged (decreasing supply capacity), we

recommend replacing the complete aux. lube oil pump (5000/0010). Remove the connecting cable and the connecting bolts from the

electric motor. Press the motor out using two puller screws, push it back horizontally and set down on a rubber mat.

Check the condition of the connecting coupling. Remove the screws (242/040) and (242/050). Press the gear pump out using two puller screws and horizontally

withdraw by hand in horizontal position.

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11.2 Cleaning and checking the coupling parts Clean all removed parts (remove clinging oil sludge) and check as follows:

- Inspect primary wheel (0310/0010/0010/0020) and secondary wheel

(0320/0010/0020) (resonance test of the blading). - Check scoop tube (0090/0010/0010) and guide bush (0080/0010) for wear. - Check the scoop tube tip (0090/0010/0010) for erosion and that the guide

bush (0080/0010) does not have any clearance. Check the O-rings (0080/0220), (0090/0010/0040) and oil scraper rings (0270/0340) for hardening and cracks, it is recommend to replace them.

- Clean the control parts.

Prior to removing the control parts from the guide bush (0270/0020), measure and record the overall length of guide bolt (0270/0080) and control rod (0270/0140) and (0270/0150). After cleaning, grease the control parts and mount as originally. Check the easy movement of both guide bolts (0270/0080) in the guide bush.

- Check the three fusible plug screws (0310/0010/0060) for their solder; in case

of no solder, replace the fusible plug screws by new ones. - Check the plain bearings for cracks, contract traces and clearance. Pay

attention to the drawing “bearing installation - bearing clearances 20500540810” as mentioned under part 4 “Voith Information Sheets”. Before installing new plain bearings, exactly copy the position of the bores for the temperature probes from the old bearing shells to the new ones. The bearing clearance is measured in mounted condition by lifting the shaft.

- Check bearings and pinions of the pump insert (0130/0010). - Check the connecting coupling as well as the aux. lube oil pump (5000/0010)

for leakage. - Remove the old sealing compound from the sealing surfaces of the geared

variable speed coupling. Hylomar, blue colour, must be removed by a cleaning agent.

- After having pumped the oil from the oil tank, the remaining operating oil and

sealing material should be removed by flushing the oil tank. - Check all parts visually for their general conditions.

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11.3 Reassembling the geared variable speed coupling

11.3.1 Preconditions and remarks All bolts inside the housing should be fitted with the same number of

tab washers, spring washers or Loctite 0242

Coat the sealing surfaces with a permanent plastic, oil-resistant sealing

compound (Hylomar). All screws shown with a specified tightening torque on the sectional

drawings are to be retightened. Attention: On reassembly of the runner, pay attention to

the balancing mark, e.g. number marked at the periphery of the part. Remount parts which were marked before disassembly according to the marking.

11.3.2 Reassembling the coupling runner Insert the fusible plug screws (0310/0010/0060) in the shell

(0310/0010/0020), check for installation or install resp. On installation of the dismantled plain bearings, moisten the contact

surface with clean operating oil and pay attention to it that they are installed correctly. The bearing shells are marked with the gear housing. Install the plain bearings according to Bearing Installation Drawing 42434390.

Position the upper half of the split bush (0110/0020) as well as the

bearing bush (0071/0030) into the scoop tube housing (0110/0010/0070/0130).

Insert the lower half of the split bush (0110/0020) in the bearing cap

(0110/0010/0070/0200). Place the secondary shaft (0320/0010/0010/0010) vertically on the hub

of connecting coupling. Place the spacer used for dismantling on the gear wheel. Put the scoop tube housing in the correct position and bolt it together with the bearing cap (0110/0010/0070/0200).

Place the shell (0310/0010/0020) onto the scoop tube housing

(0110/0010/0070/0130).

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Set the secondary wheel (0320/0010/0020) on the secondary shaft

(0320/0010/0010/0010). Ensure: The parts are matched. Pay attention to the marking (engraved numbers). Insert the socket head screws (0320/0010/0040) and tighten them

evenly crosswise. Position the primary wheel (0310/0010/0010/0020) and primary shaft

(0310/0010/0010/0010) on the shell (0310/0010/0020) and bolt together.

Then place the runner in horizontal position.

11.3.3 Mounting the coupling runner into the housing Warning: Personal injury and damage to property may occur,

if individual gears or pinion shafts of the gear stage are replaced, see par. 10.

Check the gear housing for impurities and foreign particles. All oil

supply bores must be free and clean. Insert the lower shells of bearing 5 + 6 (0071/0020) and 7 + 8

(0071/0030) in the gear housing (0110/0010/0010) and wet with clean operating oil. Pay attention to the bearing arrangement (see Bearing Installation - Bearing Clearances 20500540810. Suspend the runner in horizontal position and carefully insert it in the gear housing (0110/0010/0010).

Wet the upper bearing shells with clean oil and put them on the shaft

contact surfaces. The bearing shells are match-marked. Fit the cap (0110/0010/0070/0100) of bearing point 6, pin and bolt up.

Pin and bolt the scoop tube housing (0110/0010/0070/0130).

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11.3.4 Mounting the thrust bearings - primary and secondary side Fit the inner thrust bearing (0071/0050) and wet the segments with

clean operating oil. Fit the thrust ring (0030/0010) and tighten with the screws (0030/0020). Insert the outer thrust bearing (0071/0050) wetted with oil.

Apply sealing compound to the axial sealing surfaces on the gear housing

(0110/0010/0010). Fit and tighten the bearing cover (0030/0030). Attention: Ensure that the lube oil bore in the bearing cover

(0030/0030) exactly matches the lube oil hole of the gear housing (0110/0010/0010), as well as that the O- ring (0030/0036) for sealing is installed.

Press the flange and the O-ring onto the pipe elbow (0205/1170).

Apply sealing compound to the sealing surfaces of the upper flange and the oil feed housing. Fit, bolt and secure the pipe elbow.

11.3.5 Fitting the scoop tube Push in the scoop tube (0090/0010/0010) with the guide groove

upwards. Insert the guide bush (0080/0120) and spring (0080/0130) in the cylinder (0080/0070).

When bolting on the cylinder cover (0090/0020), compress the compression spring (0080/0130) using two threaded spindles M8x300 and nuts.

Fix the cylinder cover (0090/0020) on the cylinder by inserting screws (0080/0100). Insert the remaining two screws after removing the threaded spindles.

11.3.6 Mounting the scoop tube control Position and bolt the control housing (0080/0140) on the scoop tube

housing. Coat the control sleeve (0080/0200) with oil and insert in the control

housing (0080/0140). Push the flange and O-ring on the elbow (0205/0300). Coat the sealing

surfaces of the upper flange and scoop tube housing (0110/0010/0070/0130) with sealing compound.

Instruction Manual for VOITH Geared Variable Speed Coupling

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Set the elbow plus bracket for the controller carefully and vertically on

the scoop tube housing (0110/0010/0070/0130). At the same time guide the control pin (0080/0210) into the control sleeve (0080/0200). Bolt up and secure the flange connection.

Reconnect the link piece (0170/0110) and the connecting rod

(0170/0090) for oil flow control.

11.3.7 Mounting the input shaft with gear wheel Warning: Personal injury and damage to property may occur,

if individual gears or pinion shafts of the gear stage are replaced, see par. 10.

Fit the lower shells (0071/0010) of bearings 1 + 2 and wet with clean

oil. Apply sealing compound to the sealing surfaces of the bearing cover (0015/0010).

Insert the input shaft (0301/0010/0010/0010) carefully in horizontal

position into the housing (0110/0010/0010). Coat the upper bearing shells (0071/0010) with oil and set on the shaft

contact surface. Set the bearing cap as marked on the bearing point 2 and screw. Bolt on the injection pipe for gear wheel lubrication. Bolt the bearing

cover (0015/0010) on the housing (0110/0010/0010).

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11.3.8 Mounting the output shaft (pinion shaft) Warning: Personal injury and damage to property may occur,

if individual gears or pinion shafts of the gear stage are replaced, see par. 10.

Insert the lower bearing shells (0071/0040) of bearings 11 + 12 in the

housing and wet with clean oil. Apply a sealing compound to the sealing surface for the bearing cover

(0016/0010) on the gear housing. Insert output shaft (0301/0010/0020) in horizontal position carefully into

the housing (0110/0010/0010). Wet the upper bearing shells (0071/0040) with oil and place on the

shaft contact surface. Set the bearing cap, as marked, on the bearing point 11 and tighten. Bolt the injection pipe for gear wheel lubrication. Bolt the bearing cover

(0016/0010) on the housing (0110/0010/0010).

Instruction Manual for VOITH Geared Variable Speed Coupling

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11.3.9 Installation of pump insert Slowly and carefully guide the pump insert (0130/0010) into the gear

housing (0110/0010/0010) using a crane. The pump insert is pulled downwards by means of 2 diagonally

positioned bolts into the housing until it abuts. The backlash of spur gears on the filling pump drive is adjusted as

follows: Apply a thin coat of bluing on several tooth flanks of a spur gear. Move the gear wheels forward and backward. Align the pump insert by gently tapping it with the plastic hammer until

the contact pattern is uniformly distributed over the whole tooth width. Check the backlash at spur gear (0020/0010), please see horizontal

section drawing in part 3. Insert and tighten two securing bolts. Remove the two mounting bolts and fit securing bolts. Ream the bore for the taper pin and pin, if necessary. Bolt on the injection pipe for gear wheel lubrication of the pump drive. If the pump insert was removed through the hatch in the housing

cover, per par 11.1.7, and refitted the same way, apply sealing compound to the sealing surface on the housing cover and bolt on the inspection hole cover.

Instruction Manual for VOITH Geared Variable Speed Coupling

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11.3.10 Mounting the aux. lube oil pump Insert the aux. pump (5000/0010) in the gear housing in horizontal

position. Turn the aux. lube oil pump in the correct position (bore arrangement

of aux. lube oil pump to comply with that of the gear housing). When flanging the electric motor on the aux. lube oil pump, ensure the

claws of the connecting coupling mesh. Bolt the motor to the gear housing. Hook up the connecting cable to

the motor.

11.3.11 Mounting the housing cover Reinstall and secure all temperature probes which where removed or

loosened during dismantling. Apply a thin coat of sealing compound to the joint of gear housing

(0110/0010/0010), the sealing surfaces on the bearing covers (0015/0010) and (0016/0010) and the two thrust bearing covers (0030/0030).

Visual check to ensure tab washers are secure and temperature

probes, control, injection pipe etc. are correctly arranged and secured. Suspend the housing cover using a crane (check sealing surface is

clean) and carefully set on the housing. Fit and secure all screws. Apply sealing compound to the hood (0110/0180) for the scoop tube control and mount.

Apply sealing compound to the flange (0270/0350) and mount. Tighten

the horizontal screws (0270/0360) and nuts (0270/0361).

Instruction Manual for VOITH Geared Variable Speed Coupling

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11.4 Remaining commissioning work Remount the supply lines of the actuator. Check alignment of geared variable speed coupling towards driving and driven

machine. Observe section 5, Assembly and Mounting Instructions. For connecting couplings with lubrication by injection, ensure the correct

attachment of the coupling shell as well as the correct alignment and direction of injection, angle, of the injection pipes. Observe the manufacturer's instructions for connecting couplings.

Remount any dismantled piping and lines. Refill with oil if coupling was drained, see section 6.1. Allow the aux. lube oil pump to run and check the operation of the scoop tube

actuator. Grease the lube points provided on the control for scoop tube and circulating control valve with lithium-soaped antifriction bearing grease. Check the lube oil system does not leak and shows the correct pressure setting.

Reconnect the cables (e.g. instrumentation) if disconnected before. Make the unit ready to operate and effect a trial run (see par. 7 "Commissioning").

Voith Turbo GmbH - D-74555 Crailsheim Postfach 1555 Telefon (07951) 32-0 Telefax 32-500

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Instruction Manual for VOITH Geared Variable Speed Coupling

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Part 2 Parts List

Ordering spares: Please quote coupling serial number (see name plate), full description of the parts as per the spares list. Spares supplied conform to the latest state of the art. The housing and gears are manufactured to suit the site conditions. Gearwheels should normally only be replaced in pairs. Send the appropriate shafts to Voith or buy new ones so that we can mount and balance the gearwheels. Due to high torques and speeds, the primary wheel and secondary wheel are, in each case, fitted and thus firmly associated to the shaft by means of fitted bolts. Furthermore, runners with coupling shell and shafts are balanced to a special balancing procedure. Therefore, the runner components can only be replaced here at our factory or, in exceptional cases, at site under supervision of a Voith Specialist using special auxiliary means. Do not loosen the primary wheel from the shaft, if possible. When replacing primary / secondary wheels or shafts, fit new fitted bolts or larger diameter. We therefore recommend to store these parts only in accordance with our offer.

VOITH

Dept. DSDate:Prepared DSv-Rm

VOITH TURBO PRIVATE LIMITEDP.O.Industrial Estate, Nacharam, Hyderabad

Phone: 27173561, 27173592, 27171440

Parts List for instruction manualof R18KGS

Pos.No. Description Qty. Remarks

Page I

0015/0010 Bearing Cover 1

0015/0020 Labyrinth Disc 1

0015/0030 Oil Thrower 1

0015/0040 O-Ring 1

0015/0050 O-Ring 1

0015/0070 SOCKET HEAD SCREW 8

0016/0010 Bearing Cover 1

0016/0020 Labyrinth Disc 1

0016/0030 Oil Thrower 1

0016/0040 O-Ring 1

0016/0050 O-Ring 1

0016/0070 SOCKET HEAD SCREW 8

0020/0010 Spur Gear 1

0020/0020 SOCKET HEAD SCREW 6

0020/0030 Ring 1

0030/0010 Thrust Ring 2

0030/0020 SOCKET HEAD SCREW 20

0030/0030 Bearing Cover 2

0030/0035 Screw Plug 2

0030/0036 O-Ring 2

0030/0040 Hexagon Bolt 18

0071/0010 Bearing 2

VOITH

Dept. DSDate:Prepared DSv-Rm

VOITH TURBO PRIVATE LIMITEDP.O.Industrial Estate, Nacharam, Hyderabad

Phone: 27173561, 27173592, 27171440

Parts List for instruction manualof R18KGS

Pos.No. Description Qty. Remarks

Page II

0071/0020 Four lobe bearing 2

0071/0030 Four lobe bearing 2

0071/0040 Bearing Shell 2

0071/0050 Thrust Bearing 4

0071/0050/0050 Straight Pin 4

0071/0060 Roll Pin 8

0090/0010 Scoop tube-CW 1

0110/0010/0010 Transmission Housing 1

0110/0010/0020 Housing Cover 1

0110/0010/0030 Taper Pin 2

0110/0010/0040 Hexagon Bolt 48

0110/0010/0050 Hexagon Bolt 10

0110/0010/0060 Hexagon Bolt 8

0110/0010/0070/0070Bearing Clamp 1

0110/0010/0070/0100 Bearing Clamp 1

0110/0010/0070/0130Scoop Tube housing 1

0110/0010/0070/0200 Bearing Clamp 1

0110/0010/0070/0230Bearing Clamp 1

0110/0010/0070/0450SOCKET HEAD SCREW 6

0110/0010/0080 PIN 2

0110/0010/0090 Hexagon Bolt 6

VOITH

Dept. DSDate:Prepared DSv-Rm

VOITH TURBO PRIVATE LIMITEDP.O.Industrial Estate, Nacharam, Hyderabad

Phone: 27173561, 27173592, 27171440

Parts List for instruction manualof R18KGS

Pos.No. Description Qty. Remarks

Page III

0110/0010/0110 SOCKET HEAD SCREW 8

0110/0010/0120 PIN 2

0110/0010/0170 Hexagon Bolt 2

0110/0010/0180 Hexagon Bolt 4

0110/0010/0220 PIN 2

0110/0010/0240 PIN 2

0110/0010/0250 Hexagon Bolt 4

0110/0020 Split bushing 1

0110/0030 Roll Pin 2

0110/0040 Cover 1

0110/0050 Oil Level glass 1

0110/0060 Hexagon Bolt 8

0110/0070 Cover 1

0110/0100 Cover 1

0110/0105 Cover 2

0110/0110 Hexagon Bolt 78

0110/0120 Screw Plug 1

0110/0130 Seal Ring 1

0110/0175 Screw Plug 2

0110/0176 Screw Plug 2

0110/0177 Seal Ring 2

VOITH

Dept. DSDate:Prepared DSv-Rm

VOITH TURBO PRIVATE LIMITEDP.O.Industrial Estate, Nacharam, Hyderabad

Phone: 27173561, 27173592, 27171440

Parts List for instruction manualof R18KGS

Pos.No. Description Qty. Remarks

Page IV

0110/0180 Hood 1

0110/0190 Socket Head Screw 20

0110/0210 Filter Base 1

0110/0220 Vent Filter 1

0110/0250 Oil Reservoir 1

0110/0260 Hexagon Bolt 70

0110/0280 Seal 1

0110/0290 Cover 1

0110/0300 Hexagon Bolt 12

0110/0310 Flat Seal Ring 1

0110/0320 Hexagon Nut 4

0110/0330 Blind Flange 1

0116/0010 Orifice Plate 2

0116/0020 Orifice Plate 2

0116/0030 Orifice Plate 2

0116/0040 Orifice Plate 2

0120/0110 Hexagon Bolt 4

0120/0120 Spring Washer 4

0130/0010 Pump Insert -Right 1

0205/0300 Piping 1

0205/0430 Piping 1

0205/0450 Piping 1

VOITH

Dept. DSDate:Prepared DSv-Rm

VOITH TURBO PRIVATE LIMITEDP.O.Industrial Estate, Nacharam, Hyderabad

Phone: 27173561, 27173592, 27171440

Parts List for instruction manualof R18KGS

Pos.No. Description Qty. Remarks

Page V

0205/1190 Roll Pin 2

0246/0010 Duplex Filter 1

0246/0080 Stud 6

0246/0090 Hexagon Nut 6

0246/0100 Socket Head Screw 8

0301/0010/0010 Gear+Shaft 1

0301/0010/0030 Gear Pinion Shaft 1

0301/0010/0040 Key 1

0301/0010/0050 Key 1

0310/0010/0010/0010Gear Pinion Shaft 1

0310/0010/0010/0020Primary Gear 1

0310/0010/0010/0030Weight tol.Screw 6

0310/0010/0010/0040Connecting Pin 6

0310/0010/0010/0050Weight tol.Screw 6

0310/0010/0020 Outer Shell 1

0310/0010/0030 Vane Ring 1

0310/0010/0040 Weight tol.Screw 36

0310/0010/0050 Socket Head Screw 8

0310/0010/0060 Fusible Plug 3

0320/0010/0010 Gear + Shaft 1

VOITH

Dept. DSDate:Prepared DSv-Rm

VOITH TURBO PRIVATE LIMITEDP.O.Industrial Estate, Nacharam, Hyderabad

Phone: 27173561, 27173592, 27171440

Parts List for instruction manualof R18KGS

Pos.No. Description Qty. Remarks

Page VI

0320/0010/0020 Secondary Wheel 1

0320/0010/0040 Weight-tol.Screw 6

0320/0010/0050 Connecting Pin 6

0320/0010/0060 Weight-tol.Screw 6

500/0010 Start Lube Pump 1

5000/0060 Motor 1

0080/0010 Scoop Tube bush 1

0080/0020 Hexagon Bolt 4

0080/0030 Spring Washer 4

0080/0070 Cylinder 1

0080/0080 Socket Head Screw 8

0080/0090 Spring Washer 14

0080/0100 Socket Head Screw 6

0080/0120 Guide Bush 1

0080/0130 Cyl.Compr.Spring 1

0080/0140 Control Housing 1

0080/0150 Hexagon Bolt 3

0080/0160 Spring Washer 3

0080/0170 Guide Piece 1

0080/0180 Socket Head Screw 2

0080/0190 Roll Pin 2

0080/0200 Control Sleeve 1

VOITH

Dept. DSDate:Prepared DSv-Rm

VOITH TURBO PRIVATE LIMITEDP.O.Industrial Estate, Nacharam, Hyderabad

Phone: 27173561, 27173592, 27171440

Parts List for instruction manualof R18KGS

Pos.No. Description Qty. Remarks

Page VII

0080/0200/0010 Sleeve 1

0080/0200/0020 Guide Piece 1

0080/0200/0030 Straight Pin 1

0080/0200/0040 Roller 1

0080/0200/0050 Pin 1

0080/0210 Control Pin 1

0080/0220 O-Ring 2

0080/0230 Spring Wire 1

0080/0240 Socket Head Screw 2

0080/0250 Spring Washer 2

0080/0260 Set Screw 1

0090/0010/0010 Scoop Tube 1

0090/0010/0020 Cylinder bottom 1

0090/0010/0030 Piston 1

0090/0010/0040 O-Ring 1

0090/0010/0050 Roll Pin 1

0090/0020 Cylinder head 1

0170/0010 Housing 1

0170/0020 Sleeve 1

0170/0030 Spring guide 1

0170/0035 Cyl.Compr.Spring 1

0170/0040 Roll Pin 1

VOITH

Dept. DSDate:Prepared DSv-Rm

VOITH TURBO PRIVATE LIMITEDP.O.Industrial Estate, Nacharam, Hyderabad

Phone: 27173561, 27173592, 27171440

Parts List for instruction manualof R18KGS

Pos.No. Description Qty. Remarks

Page VIII

0170/0050 Circlip 2

0170/0060 Hexagon Bolt 6

0170/0080 Control Piston 1

0170/0090 Coupler 1

0170/0100 Roll Pin 2

0170/0110 Fork Joint 2

0205/1170 Pipe Elbow 1

0270/0020 Guide Bush 1

0270/0020/0020 Con.lubrication nipple 2

0270/0025 Roll Pin 2

0270/0035 Socket Head Screw 4

0270/0035 Socket Head Screw 4

0270/0040 Grub Screw 2

0270/0060 Grub Screw 1

0270/0070 Hexagon nut 3

0270/0080 Guide Pin 2

0270/0080/0020 Protective plug 2

0270/0090 Pin 2

0270/0100 Deep groove ball bearing 2

0270/0120 Circlip 4

0270/0130 Socket Head Screw 4

0270/0140 Steering Rod 1

VOITH

Dept. DSDate:Prepared DSv-Rm

VOITH TURBO PRIVATE LIMITEDP.O.Industrial Estate, Nacharam, Hyderabad

Phone: 27173561, 27173592, 27171440

Parts List for instruction manualof R18KGS

Pos.No. Description Qty. Remarks

Page IX

0270/0145 Hexagon Bolt 2

0270/0150 Steering Rod 1

0270/0160 Key 1

0270/0165 Key 1

0270/0170 Cyl.Compr.Spring 2

0270/0180 Scoop tube 1

0270/0190 Washer 1

0270/0200 Stroke Indicator 1

0270/0210 Counter Screw 4

0270/0220 Cam Plate 1

0270/0230 Cam Plate 1

0270/0240 Hexagon Bolt 4

0270/0250 Washer 4

0270/0270 Connector 1

0270/0280 Hexagon Bolt 1

0270/0290 Spring Washer 1

0270/0300 Roll Pin 1

0270/0310 Cyl.Compr.spring 1

0270/0320 Cyl.Compr.spring 1

0270/0330 Hexagon Nut 1

0270/0340 Scraper Ring 2

0270/0350 Flange 1

VOITH

Dept. DSDate:Prepared DSv-Rm

VOITH TURBO PRIVATE LIMITEDP.O.Industrial Estate, Nacharam, Hyderabad

Phone: 27173561, 27173592, 27171440

Parts List for instruction manualof R18KGS

Pos.No. Description Qty. Remarks

Page X

0270/0360 Hexagon Bolt 3

0270/0361 Hexagon nut 3

0270/0370 O-Ring 1

0270/0380 Hexagon bolt 4

0270/0390 Spring guide 1

0270/0400 Spring guide 1

0270/0410 Cover 1

0270/0420 Socket Head Screw 2

0270/0430 Spring Washer 2

Voith Turbo GmbH - D-74555 Crailsheim Postfach 1555 Telefon (07951) 32-0 Telefax 32-500

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Instruction Manual for VOITH Geared Variable Speed Coupling

- 8 -

Part 3 Drawings: Horizontal Section Sheet 1 TCR42557390 Vertical Section Sheet 2 TCR42557390 Section through Control Sheet 1 TCR42557380 Section through Circulation Control Sheet 2 TCR42557380 Pump Insert, "CW" rotation Sheet 1-1 TCR42445350 Auxiliary Lube Oil Pump MZP 820 Sheet 1-1 TCR41018910VTIP01 Pressure Relief Valve "Working Oil“ Sheet 1-1 TCR42435100 Pressure Limit Valve "Lube Oil/Control Oil" Sheet 1-1 TCR41386680VTIP01 Assembly Plan - Geared Variable Speed Coupling Sheet 1-2 3067401011780-049 Function and Measuring Point Scheme Sheet 1-1 3067401011790-049 List of Instruments Sheet 1- 8 3067401011800-049 Wiring Diagram for Instruments Sheet 1-18 3067401011810-049

www.generalinstruments.net 61

Mercury in SteelDial Thermometer

Mercury filled system based on mercury expansion principle isused for measuring temperature ranging from (-) 400C to 6000C.It has faster response and the same is available in rigid stem aswell as capillary type for remote sensing. Every angle type can beoffered in all SS construction. Manufactured in accordance withBS:5235. System is case compensated as standard (SAMA Cl VB).Fully compensated (capillary compensation) system is offeredwherever essential.

Rugged constructionRigid stem or capillary typeFast responseProtection class IP- 67Accuracy ± 1% FSD (0.5% FSD on request)High repeatability, low hysteresisCase compensated systemMicrometer Pointer

Ref Standard : BS 5235

System : Mercury filled, case compensated in accordance with SAMA CI. V B

Dial : 100 mm or 150 mm in aluminium, white background, black markings

Case : Die cast aluminum with screwed bezel, SS304 / SS316 with bayonet bezel

Protection : Weather proof to IP - 67 (IS : 13947 Part I)

Window : Shatterproof glass

Pointer : Aluminium, black

Stem : SS304 or SS316 in 6 mm, 8 mm, 9.5 mm, 10 mm, 12 mm, 12.7 mm, 14 mm, 16 mm dia and length from

100 mm to 1000 mm (longer lengths available on request )

Capillary : SS covered / SS covered + PVC / SS armoured (up to 15 M).

Connection : ½" NPT (M) as standard in SS304 or SS316 three piece adjustable compression fitting.

Range : (-) 400C to 6000C with a minimum span of 500C

Accuracy : ± 1% FSD / ± 0.5% FSD

Overrange : 130% FSD as standard

Zero reset : Micrometer Pointer

Optional : 1) Glycerine filled SS304 / SS316 case

2) Fully compensated double bourdon system in accordance with SAMA CI. V A

3) SS solid drawn capillary for better performance

Note : 1) For minimum immersion length essential for proper sensing, contact our design department.

2) Three point calibration certificate accompanies each thermometer.

Features

Specifications

62 www.generalinstruments.net

Mercury in SteelDial Thermometer

MOUNTINGV - Bottom Entry, Local MountingC - Back Entry, Local MountingE - Every Angle, Local MountingS - Bottom Entry, Surface MountingP - Back Entry, Panel Mounting

DIAL10 - 100 mm 15 - 150 mm

CASEAL - Die-cast

Aluminium

STEM-ODA - 6 mmB - 8 mmC - 9.5 mmD - 10 mm

E - 12 mmF - 12.7 mmG - 14 mmH - 16 mm

STEM LENGTH

STEM MATERIALS4 - SS304 S6 - SS316

S4 - SS304S6 - SS316

TYPEMIS-R - Rigid StemMIS-C - Capillary Type

(-) 30 to (+) 30(-) 20 to (+) 20(-) 20 to (+) 40(-) 40 to (+) 200 to 500 to 800 to 1000 to 120

0 to 1600 to 2000 to 2500 to 3000 to 3500 to 4000 to 5000 to 600

RANGE

UNITC - Deg C F - Deg F

OPTIONA - ThermowellG- Glycerine Filled CaseC - Colour BandD - Dual ScaleL - NILS - Silicone oil filled case

CONNECTIONSize Type Male / Female

6 - 1/4”10 - 3/8”15 - 1/2”20 - 3/4”25 - 1”32 - 1.1/4”40 - 1.1/2”

NT - NPTBP - BSPBT - BSPTPF - PFGS - GasNS - NPSM

M - MaleF - Female

Metric Threads

18 M - M 18 x 1.520 M - M 20 x 1.524 M - M 24 x 1.527 M - M 27 x 233 M - M 33 x 2X X - Any other

TYPESC - SS CoveredSP - SS Covered + PVCSA - SS Covered + SS ArmouredSAP - SS Covered + SS Armoured + PVC

CAPILLARY

LENGTH

How to Order

Specify in mm

Specify in metre

106

DIAPHRAGM SENSOR WEATHERPROOF HIGH OVER PRESSURE 270 DEG. POINTER TRAVEL HI – LO SWITCHING

FLOW OR FILTER MONITORING

DIFFERENTIAL PRESSUREINDICATORS — SWITCHES

SWITZER 106D range of Differential Pressure Indicatorsare 316 Ti SS diaphragm operated to ensure reliableindication of pressure difference between two inputs.

High and low pressures are applied on either side of asingle diaphragm. The resultant motion is transferred tothe gauge case through a unique motion – transfermechanism and a SS movement. The volume

STYLE 106D

displacement is kept minimum to achieve highrepeatability. The pointer movement and dial are fittedin a weatherproof die cast aluminium housing.

High and Low switching for alarm can be provided withadjustable cam mechanism to actuate one or twomicroswitches. The diaphragm is protected fully fromover pressure through a seal valve assembly.

GENERAL SPECIFICATIONS

Gauge Case Die Cast Aluminium weatherproofto IP:66. 304 SS case optional

Dial Size 150 mm dia nominalScale Linear, Square Root or BothWindow Material Toughened float safety glassAccuracy Û ± 2 % FSR, indicator only.

With switching, ± 2 % before &± 3 % after switching.

Ranges 0 – 40 mbar to 0 – 2.5 bar; ReferOrdering Specification for details

Max. Working Pressure 60 BarOver range Protection Through built-in seal valveMax. Process Temp 100°C for Buna – N Seal

230°C for Viton® SealFor higher temperatures useadequate length of impulse piping.Ask for piping nomogram #441184-4

Zero Adjustment Via Micrometer PointerSensing Element 316 Ti SS DiaphragmBody Material 316 SS standardMovement Stainless Steel (non-wetted)Process Connection 1/4" NPTF Std; Others through

adaptors.Vent / Drain Plug OptionalMounting Flush Panel standard;

2" Pipe / wall optionalAlarm Switching Snap acting microswitch (optional)No. of Switches One for Hi or Lo. Two, one each

for Hi & Lo.Switch Rating 5A 250V AC (Res.)

3A, 250V AC (Ind-p.f.0.6)Switch Setting Adj. from 10% to 90% FSRSwitching Differential 6 to 8% FSR fixed, for 1 Switch

10 to 12 % FSR fixed, for 2 SwitchesHigh – Low Gap (min.) 15% FSRElectrical Connection Via DIN 43650 plug

Û Accuracy includes linearity and hysteresis

Viton® is a registered trademark of DuPont Dow Elastomers

QS AccreditationR030

ORDERING MATRIX

Differential Pressure Indicator106 Style 106

Additional Ranges : Specify range in Order §

0 – 40 mbar 0 – 400 mbar0 – 60 mbar 0 – 600 mbar0 – 100 mbar 0 – 1.0 Bar0 – 160 mbar 0 – 1.6 Bar0 – 250 mbar 0 – 2.5 Bar

§ Non-std ranges upto 80% of these rangesare possible at extra cost. Consult factory.

Body, Element Material and RatingD 316 Ti SS Diaphragm, 316 SS body, 60 bar (900 PSIG)

AccuracyE ± 2% FSR, for Indicator without switchF ± 2% & ± 3% FSR, before & after switching

Seals1 Buna – N2 Viton3 Others (consult factory)

Process Connection0 1/4" NPTF standard6 1/2" NPTF through 316 SS adaptor9 Others – on request

Switching0 None1 One Microswitch2 Two Microswitches

# 10

02 D

PI-

106D

– R

ev.1

Accessories and Options Ü0 None – standard with Studs for Panel MountingF Pipe Mounting with ‘U’ Bolt & NutsW Wall Mounting BracketL Liquid Filled Dial †S 304 SS CaseT Degreasing for Oxygen ServiceB Blow-out-DiscV VentD DrainX Others (Consult factory)

Ü If more than one accessory / option is requiredspecify W, L, . . . etc.

† Gauges with Liquid Filled dials :i) Accuracy will change. Consult factory.ii) Switching facility not possible. However

switching action can be provided through anexternally mounted Differential Pressure Switch(Refer factory for details).

106 D E 1 0 0 0

Notes :1. Calibration is as per ANSI / ASME B40.1 Clause 6.2.3.2. Chemical seals are not available.3. Accuracy figures are exclusive of test equipment

tolerance on the claimed values.4. All performance data guaranteed ±5%.

Caution :1. Use of snubber is a must if pressure fluctuations are rapid.2. Use 3–way / 5–way manifold to avoid damage / shift in

calibration.

5772

VENT PORTS

(OPTIONAL)

4075 for Lo Port

97 for Hi Port

197

2" PIPE BY CUSTOMER

HORIZONTAL

POSITION – OPTIONAL

(FIX ‘U’ CLAMP

VERTICALLY)

3/8" BSW ‘U’BOLT – 2 NOS.

DRAIN PORTS (OPTIONAL)PANEL MTG. STUDS. (4 NOS.)

PANEL

DIN SOCKET

(FOR ELECTRICAL

CONNECTION) ‘d’

210 Ø

1/4" NPTF

165 Ø CUTOUT

CUSTOMER TO DRILL 4 HOLES

ON THE PANEL 6 Ø AT 178 PCD.

45°

OVERALL DIMENSIONS

ALL DIMENSIONS ARE IN mm

Notes : 1. For wall mounting drill 2 Nos. 10.5Ø holes. Use 3/8" × 40L Coach Screws for fixing the instrument.2. S.S. Gauge case dimensions are different. Ask factory for drawing.3. All dimensions have a tolerance of ±2.0 mm

d – 88 mm for 0–600 mbar to 0–2.5 bar ranges145 mm for 0–40 to 0–400 mbar ranges

REAR VIEW(Without Mounting Accessories)

FLUSH PANEL MOUNTINGCUTOUT DIMENSIONS

2" PIPE MOUNTING

Prior notification of changes in specification is impracticable due to continuous development.

FOR SWITZER'S OFFICES IN INDIA

CHECK AT:

http://www.switzerinstrument.com/offices.htm

STYLE 301 IN GM ENCLOSURESTYLE 301 IN GK ENCLOSURE

Series 300 Pressure Difference Switches are designedand made to the latest standards to comply with currentinternational philosophy of process instrumentation. Theseries is compact , easy to install and features high sensitivityover the fully adjustable range together with very high

static pressure capability. The sensing element is mountedexternal to the switch mechanisms which are of stainlesssteel for ardous atmospheres and high humidity. Enclosures,sensing element and switching modes can be combinedto offer the variety needed to suit the different applications.

GENERAL SPECIFICATIONS

Enclosure

GM Pressure die cast Aluminium,weatherproof to IP:66

GA 316 SS, investment cast, weather-proof to IP:66

GK Die cast Aluminium, weatherproofto IP:66 & flameproof to Gr.IIA, IIBor IIC for H2 GAS (Note 1)

Ranges Several standard ranges between3 mbar to 15 bar

Sensor 316L SS Diaphragm

Wetted parts 304 SS or 316 SS

Repeatability ±1% FSR (Note 4)

Scale Accuracy ± 5% FSR (Note 6)

Switching Element Instrument quality SPCO(SPDT)microswitch (Notes 10 & 11)

Switching Differential Fixed or Wide band adjustable,refer table.

Max. Working Pressure 110 bar for 301, 303 & 381250 bar for 304 & 384

Ambient Temperature (–)25°C to (+)60°C

Max. Process Temp. 70°C. For higher temperatures uselonger impulse lines. (Note 15)Ask for piping nomogram #441184-4

Connection

Process ¼" NPTF. Adaptors for other sizesoptional

Electrical ¾" ET (F) std. ½" NPTF optional.For Gr.IIC ½" NPTF alone isavailable. Dual entry on request.

Mounting Back panel/wall/Field. Verticalposition only

Conformity Generally to BS 6134:1981

DIFFERENTIAL PRESSURE SWITCHES

!!!!! GOOD REPEATABILITY !!!!! HIGH STATIC PRESSURE !!!!!

!!!!! TAMPERPROOF SET POINT ADJUSTER WITH LOCKING DEVICE !!!!!!!!!! WEATHERPROOF OR FLAMEPROOF HOUSING !!!!!

!!!!! OVERTRAVEL STOP !!!!! RUGGED DESIGN !!!!!

301 / 303 / 304381 / 384

QS AccreditationR030

RANGE CODE & AVAILABILITY

ENCLOSURE

Pressure Die Cast Aluminiumweatherproof to IP:66 with Nitrilegasket.

Investment cast 316 SS weather-proof to IP:66 with overall size asstyle GM fit for offshore.

Die Cast Aluminium flameproofcum weatherproof. CMRI approvedto Gr.IIA, IIB of IS:2148: 1981 forflameproofness & IP:66 for wea-therproofness. For Gr.IIC sameenclosure with specific certificationat extra cost is available.

MODEL

This is the basic differential pressureswitch having close fixed non-adjustableswitching differential actuated by astainless steel diaphragm.

Same as 301 but with auxiliary mechanismpermitting switching differential adjustmentover a wide band.

Same as 301 but suitable for higher staticpressures upto 250 bar.

A variant of series 300, employs twinlevers each operating a SPCOmicroswitch actuated by a single sensorthrough a unique linkage thereby providingtwo independent adjustable set points,each with its own setting scale, springand switch.

Same as 381 but suitable for higher staticpressures upto 250 bar.

MATERIALS OF WETTED PARTS

316L SS diaphragm with 304 SS pressure chambers.

316L SS diaphragm with 316 SS pressure chambers.

Conforming to NACE Std. MR-01-75.

Nitrile diaphragm with 304 SS pressure chambersfor applications with pressure reversal.

Nitrile diaphragm with 316 SS pressure chambersfor applications with pressure reversal.

ORDERING MATRIX

SWITCH CODE RATING & AVAILABILITY

Codes 3 & D – For General purpose usages.Code 4 – With Noble metal contact.Codes 5 – For General purpose with good DC rating.Codes 6 – With Noble metal contact (Low Rating)Code 7 – Environmentally sealed switch with Goldplated contact.Code 8 – Environmentally sealed switch with Silveralloy contact.

Code 9 – Hermetically sealed, inert gas filled withSilver alloy contact.Code G – Hermetically sealed, inert gas filled withGold plated contact.Codes E & F – Manual reset switch. Auto changeover on rising and falling pressure respectively.Resetting is Manual.

For DPCO, change switch code ‘3’ to ‘33’, ‘4’ to ‘44’, etc., while ordering

N.A. – Not Available N.R. – Not Recommended

Diaphragm chemical seals can be provided as optional extrawith capillary and threaded / flanged connection, duly evacuatedand filled with suitable filling liquid. This device permits theuse of differential pressure switches with viscous / aggressivefluids and permits higher process temperatures.

While ordering it is important to specify ambient and processtemperatures, setpoint, maximum process pressure, relativeelevation between connection and switch head, nature of processmedium and whether reactive to common filling liquids shouldthe diaphragm seal leak into the process. However, switchinglag will be experienced unless the pressure change is very gradual.

DIAPHRAGM CHEMICAL SEALS

301!!!!!

GM!!!!!

GA!!!!!

GK!!!!!

!!!!!

303

304!!!!!

381!!!!!

384!!!!!

02!!!!!

06!!!!!

0N!!!!!

R2!!!!!

R6!!!!!

!!!!! !!!!! !!!!! !!!!! !!!!!

!!!!!

!!!!!

HCTIWS HCTIWS HCTIWS HCTIWS HCTIWSEDOC

)OCPS(

CACACACACAGNITAR

SPMANIGNITARCD SPMANIGNITARCD SPMANIGNITARCD SPMANIGNITARCD SPMANIGNITARCD YTILIBALIAVA YTILIBALIAVA YTILIBALIAVA YTILIBALIAVA YTILIBALIAVANIOCPSFO

SLEDOM

YTILIBALIAVA YTILIBALIAVA YTILIBALIAVA YTILIBALIAVA YTILIBALIAVANIOCPDFO

SLEDOMEVITSISER EVITSISER EVITSISER EVITSISER EVITSISER EVITCUDNI EVITCUDNI EVITCUDNI EVITCUDNI EVITCUDNI

V022 V022 V022 V022 V022 V011 V011 V011 V011 V011 V42 V42 V42 V42 V42 V022 V022 V022 V022 V022 V011 V011 V011 V011 V011 V42 V42 V42 V42 V42

D /052A51V521 2.0 4.0 0.2 20.0 30.0 0.1 ,403,103

483&183 403&103

3 /052A51V521 .R.N .R.N .R.N .R.N .R.N .R.N ,403,103

483&183 403&103

3 /052A51V521 3.0 5.0 0.01 3.0 52.0 0.6 303 303

4 V521A1 .A.N 5.0 5.0 .A.N 52.0 52.0 ,403,103483&183 403&103

5 /052A5V521 2.0 4.0 0.5 2.0 4.0 0.4 403&103 403&303,103

6 V521A1.0 .A.N .R.N 1.0 .R.N .R.N .A.N ,403,103483&183 403&103

7 .R.N .R.N .R.N 0.1 .R.N .R.N 5.0 403&103 403&103

8 /052A5V521 .A.N .A.N 0.5 .A.N .A.N 0.3 403&103 403&103

9 V511A4.zH004 .A.N .A.N 0.3 .A.N .A.N 0.1 403&103 403&103

G .R.N .R.N .R.N 0.1 .R.N .R.N 52.0 403&103 403&103

E /052A51V521 03.0 57.0 0.51 2.0 4.0 0.01 403&103 ---

F /052A51V521 03.0 57.0 0.51 2.0 4.0 0.01 403&103 ---

EGNAR EGNAR EGNAR EGNAR EGNAREDOC

EGNAR EGNAR EGNAR EGNAR EGNAR/103 /103 /103 /103 /103

403303 303 303 303 303

/183 /183 /183 /183 /183483

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D8E rabm053ot05

B5G rab5.1ot1.0

B0J rab4ot2.0

B2M rab7ot7.0

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"

"

"

"

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"

"

"

"

"

"

×

×

×

×

"

"

"

"

"

"

NOTES

SWITCHING DIFFERENTIAL DATA

On-off differential values for DPCO switching,DPCO (2 × SPDT)

!!!!! For style GM/GA enclosures apply a multiplication factorof 1.3 to values in Table–A.

!!!!! For style GK enclosure apply a multiplication factor of1.2 to values in Table–B.

!!!!! In case of adjustable on-off differential models themultiplication factor is to be applied only to the lowerlimit of the differential values. Upper limit values remainunchanged.

!!!!! For range codes M2B & P8B in models 301, 304 DPCOswitching using switch codes 3, D & 4 only is possible.

Special Engineering : Higher DP range of 10 to 60 bar,model 301 DP switch is offered with 316L SS bellowssensor. But the out of balance pressure will be limited to80 bar. For details refer offer/factory.

!!!!! Switching differentials for Instruments with chemicalseal : Apply a Multiplication factor of 1.3 for SPCO and1.5 for DPCO to values given in table for GM housingsand apply a multiplication factor of 1.2 for SPCO and1.5 for DPCO to values of table for GK housings.

Chemical seals are not available in ranges C6D,E1D & E8D.

TABLE : A — GM / GA Enclosures

1. Gr.IIA & IIB of IS:2148 is equivalent to NEC CL.1, Gr.C & D. Gr.IIC ofIS:2148 is equivalent to NEC CL.1, DIV.1, Gr.A & B.

2. Style GM/GA is weatherproof only if all entries and joint faces are properlysealed. Style GK is weatherproof only if cover ‘O’ ring is retained inposition and proper cable gland (flameproof) is used. It is recommendedto procure cable glands along with GK instruments to avoid neglect of itduring installation.

3. Intrinsic Safety (Exi) — Pressure Switches are classified as simple electricalapparatus as per BS 5345–6.3.3. Hence Pressure Switches with GM/GAenclosures may be used in intrinsically safe systems without certification ifenergy levels are limited to 1.2V, 0.1A or 25 mW.

4. Accuracy & Repeatability are one and the same for all blind differentialpressure switches. A shift of ±2% may be observed in setpoint whenpressure falls from full static pressure. Settings will also shift with varyingtemperature.

5. The instrument is calibrated in the mounting position depicted in the drawing.Hence mounting in any other direction will cause a minor range shift, especially inlow and compound ranges. Ranges above 1 bar will not experience this shift.

6. A Differential Pressure switch is a switching device and not a measuringinstrument — eventhough it has a scale with ±5% FSR accuracy to assistsetting. For this reason, Test Certificates will not contain individual ON-OFFswitching values at different scale readings. Maximum differential obtainedalone will be declared, besides other specifications.

7. Select working range of the instrument such that the set value lies in the mid35% of the range i.e., between 35% and 70% of range span.

8. For switching differential values please refer respective Range Table. Switchingdifferentials furnished are nominal values under test conditions at mid-scaleand will vary with range settings and operating conditions.

9. On and off settings should not exceed the upper or lower range span.

10. DPCO action is achieved by two SPCO switches synchronised to practicallimits i.e., ±2% of FSR. Deadband for DPCO contacts are higher than thatof SPCO as force required to actuate the contacts are more. Please referrespective range table.

11. Contact life of microswitches are 5 × 105 switching cycles for nominal load.To quench DC sparks, use diode in parallel with inductance, ensuring polarity.A ‘R–C’ network is also recommended with ‘R’ value in Ohms equal to coilresistance and ‘C’ value in micro Farads equal to holding current in Amps.

12. Model 301 can be supplied with Nitrile diaphragm for applications wherepressure reversal is envisaged.

13. All differential pressure switches are calibrated by applying pressure to HIport, venting LO port to atmosphere. Inspection will also be limited to sucha practice.

14. Ambient temperature range: All models are suitable for operating within arange of ambient temperature from (–) 25°C to (+) 60°C provided the processdoes not freeze within this range. Below 0°C, precautions should be takenin humid atmospheres to prevent frost formation inside the instrument fromjamming the mechanism. Occasional excursions beyond this range arepossible but accuracy might be impaired. The microswitch is the limitingfactor which should never exceed the limits (–) 50°C to (+) 80°C.

15. Fluid Temperature: A Differential Pressure switch connected to the mainpipe is not subjected to the flow and therefore is not fully exposed to thefluid temperature. Use of adequate length of impulse piping will greatlyreduce excessive heating of the sensing element. For example connectionof 7.5 cm of 12 mm dia impulse piping will reduce water temperature of100°C to 65°C at an ambient temperature of 50°C. Ask factory for temperaturenomogram for different temperatures.

16. Ensure that impulse pipework applies no stress on sensing element housingand use spanners to hold pressure port / housing when connections are made.

17. Custom built instruments are available for special service requirements underSpecial Engineering Category.

18. For less rigorous applications models 306 / 386 with Nitrile diaphragm &Aluminium wetted parts are available at lesser cost.

19. Complementary instrumentation for pressure is available in 200 series.

20. Accuracy figures are exclusive of test equipment tolerance on theclaimed values.

21. All performance data guaranteed ±5%.

TABLE : B — GK Enclosure

!!!!! Damping coil for minimising process pulsations — increasesinstrument’s life many times.

!!!!! Breather / Drain for flameproof enclosures; blow out disc forweatherproof enclosure.

!!!!! Snubbers

!!!!! Brass / SS double compression cable glands to suit cable ODof 1/2", 15 mm & 17 mm.

!!!!! Degreasing for Oxygen service & special parts for Ammoniaservice.

!!!!! Provision of line fault monitoring.

OPTIONS / ACCESSORIES

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dexiF dexiF dexiF dexiF dexiF elbatsujdA elbatsujdA elbatsujdA elbatsujdA elbatsujdA

403/103sledoM 403/103sledoM 403/103sledoM 403/103sledoM 403/103sledoMledoM ledoM ledoM ledoM ledoM

4/183303ledoM 303ledoM 303ledoM 303ledoM 303ledoM

6/3/D 6/3/D 6/3/D 6/3/D 6/3/D 44444 55555 8/7 8/7 8/7 8/7 8/7 G/9 G/9 G/9 G/9 G/9 6/4/3/D 6/4/3/D 6/4/3/D 6/4/3/D 6/4/3/D 55555 33333

D6CD1ED8EB5GB0JB2MB8P

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rab5.1ot1.0rab4ot2.0rab7ot7.0rab51ot5.1

652106571003008

665106002053008

601025800400210081

210204521054008---

0121030210050090061

5.70204052004006---

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dexiF dexiF dexiF dexiF dexiF elbatsujdA elbatsujdA elbatsujdA elbatsujdA elbatsujdA

403/103sledoM 403/103sledoM 403/103sledoM 403/103sledoM 403/103sledoMledoM ledoM ledoM ledoM ledoM

4/183303ledoM 303ledoM 303ledoM 303ledoM 303ledoM

6/3/D 6/3/D 6/3/D 6/3/D 6/3/D 44444 55555 8/7 8/7 8/7 8/7 8/7 G/9 G/9 G/9 G/9 G/9 6/4/3/D 6/4/3/D 6/4/3/D 6/4/3/D 6/4/3/D 55555 33333

D6CD1ED8EB5GB0JB2MB8P

rabm52ot3rabm021ot5rabm053ot05

rab5.1ot1.0rab4ot2.0rab7ot7.0rab51ot5.1

018020010030050531

0101520010430060531

01610404100600020022

0243070125670551

---

71020500200905310072

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---

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---------

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---------

OVERALL AND MOUNTING DIMENSIONS

Range Codes : E1D, E8D, G5B, J0B, M2B & P8B

GM / GA Enclosure

Surface / Wall Mounting

Pipe Mounting

GK Enclosure

Range Code : C6D only #

Pipe Mounting

Pipe Mounting

Note : Dimensions for Model 304 / 384 are different. Ask for applicable drawing.

Fixing onHorizontal Pipe

Fixing onVertical Pipe

All dimensions are in mm

!!!!! Use 2× 3/8" × 25 long screwsand nuts for surface mountingor coach screws for wall mountinginstead of ‘U’ bolts and nuts.

2" Pipe Mounting Details

0503

DP

S 3

01–R

ev.1

GM / GA Enclosure

# For C6D range surface / wall mounting bracketis not available.

Pipe mounting bracket can be used for surface /wall mounting.

GK EnclosurePipe Mounting

Prior notification of changes in specification is impracticable due to continuous development.

FOR SWITZER'S OFFICES IN INDIA

CHECK AT:

http://www.switzerinstrument.com/offices.htm

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( € M INSTRTJT\trITs coNSoRTruMa

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INSTRUCTIOIS FOR Om & IvIAINTBNAhICE ?.V(ANUALOF,GICOI\T' FOR. RTD ASSElvaLY

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torn a ptqxsical or e,Mcal pcrr. of!'ielt', evsn spccial prcectiorn tubes ate subject io Enraq, prctcction inb"iirrespctivc.of tlr rdcdal or r.trich tlsl, m firrfu, slmld tlrn frrE bc chcckcdfism tinn to tirrn nut replacod if r*r"ry to prorcrrt da.r%D to tlp ccetlynlrasurfug insert.

2^ ThB corrected Irgnrrrrud- ;

If in casc of a fui:lty rrrasurenrcrt, tlic fault is ncitlnr in tlE 16:asgrirg cirsuif mrintbc nEaflrirgvottago sryply, thr ccnnrccLed firstnurr,rt shsuld bs ohcoksd wilhtl$ Eid of an, inerovisoO moonnirg cimuit cctnsi,."tirs of e tsst lgsirtango end aresislnlce ffi:hlorrespms to ttplesist^ance oftfte rie*"dry l.ae- 6, dE f,nclr isstill pesert, the corurected irsnmrer ElKruld be retunred to the rrmrlrfschuer farrepair.

Ordet Spare Parts :-

WtP'n ordcrirg sporc pods xrxrbsr cnscasod on rhr bunirnl blook of thoresiEtanoo tonpcratrrres shoilld bc quoted to orlsgrD cofiEd doliwrios.

In csse of ony di-fficrrlty, Plesso coract Gone,ral ketnrrmrts Cansortitun

ol(ico : 194/195, Gopirank noad oll Pandurang Naik Marg. Bchind citylighl cincma, Mahim, Mumbai-4;o 016. tNDtA

" 4454387 (5 Lrna5).444 9177' Fax oo 91'2-2'444 gl23l 4463507. E-Mall gicon@bomi.vsnt.nct.in. vy'cbslto wwwgrqgrrn6r' 66rn

Branches : Baroda, Catculta. Chcnnai, Goa, New Oelhi, punoO v c r s a a s N o t v ' | n r k n : r h i r i i n c r n . . t . n , , r . - ;

PUNE TECHTROL PVT. LTD., S – 18, M I D C, Bhosari, PUNE – 411 026. Pn. : +91-20-2712 1052, 2712 9298, 2712 8055, 5611 1996, 5611 1997. Fax : +91-20-2712 1663. email : techtrol@pn2.net.in Website : www.punetechtrol.com

INSTRUCTION & MAINTENANCE MANUAL FOR

CHAMBER AND FLOAT SWITCH ( Document No. : MAN / CFS / Rev. OO / 01 - 2007. )

We are glad to know that you are using a reliable ' TECHTROL PRODUCT '. For proper and safe functioning of the same we suggest you to go through this ' INSTRUCTION & MAINTENANCE MANUAL 'carefully before installing our instrument. Precautions before installation may avoid serious injury and / or damage to the instrument.

Unpacking :

1. Unpack carefully without damaging the instrument. Ensure that instrument is not damaged in transit and all components are in place and not in loose condition.2 Ensure that the serial number and the model number matches with that specified on the Test Report.

Application : To maintain the accuracy of the instrument it must be used for operating conditions like Sp. Gr., OperatingTemp. and Operating Pressure, Fluid having Sp. Gr. of 0.8 to 1.5 for which it is specified. The instrumentis calibrated to operating conditions mentioned in our Test Report which is sent along with the instrument.

Typical services :

1. Level detection / Alarms / Pump control for storage Sumps / Tanks of liquid and slurries.2. Drum level switching in Non IBR boilers.

Construction and Operation :

A Dipstick type float carrying a permanent magnet at its upper end is mounted in a chamber. Thefloat rises / falls according to liquid level and the corresponding movement of magnet moving withinthe sealed pipe makes or breaks the microswitch contacts housed in the enclosure.

Figure 1.

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Operating Differential :

Differential is actual distance that the liquid level must rise and fall to open or close a switch. This operatingdifferential is 15 to 25 ± 2mm.

Pre installation Procedure :

Before installation of instrument check following parts by opening enclosure cap.

1. Ensure nuts and screws of follower magnet assembly are not loose.2. Ensure proper functioning of micro switch assembly by moving coupler rod manually up and down.3. If micro switch is not operating, reset the position of switch carriage by moving slightly up or down.4. Ensure the free movement of follower magnet lever.5. Ensure that operating conditions are within limit. ( Pressure, Temperature, Specific Gravity ).6. Ensure that any system generating vibrations are away from installation site. ( Pump, Generator ).7. Ensure that the location of installation is not in the line of flow and away from any suction.8. Ensure that the nozzle and flange sizes suit the installation.

Installation : 1. Select a suitable location on the tank, where vibrations if any, are minimum. 2. Ensure that the Process connections & C:C distance of the level gauge match with those on tank. Flange connection : Flanges on the level gauge should match the counter flanges on the tank and their PCD orientation should be identical. Screwed / SMS Union : Threads and Type should match. 3. Ensure counter connections provided on tank are vertical and in plumb line. 4. Provide suitable gaskets between the flanges and appropriate thread sealant between threads before bolting, to ensure zero leakage from the joint. 5. Please do not connect any pump suction or outlet for process at drain point of the gauge. 6. Provide separate isolating valves on the tank for safety & removal of the gauge for repair / maintenance.

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Termination :Before actually turning ON the power supply, make sure that all the wiring is done correctly.

Precautions :

1. Ensure that supply voltage and current rating is as per its rated capacity. Excessive voltage / current will permanently damage the switch contacts. 2. Ensure that the switch is duly earthed. 3. Ensure use of proper cable for wiring, which should match the current rating of connected load. 4. Ensure terminal contacts are not loose.5. Ensure that Enclosure is always covered with its terminal along with gasket provided for it, to protect it from dust and weather.

Maintenance :

In case of liquids with dirt or suspended particles, periodic cleaning of float and chamber is essential.

1. Switches must be cleaned frequently if the Liquid has high viscosity or contains floating material. 2. Ensure that terminal connections are not loose. 3. Ensure that contacts of the switch mechanism are not pitted / oxidised due to sparking. 4. Be sure that enclosure cover is always in place on the enclosure. 5. Disconnect device from the supply socket before opening to prevent ignition of hazardous atmosphere.

Trouble Shooting :

Problem Cause Remedy1. Micro switch operating erratically. Excessive deposition on Clean the surface where

Float surface due to dirt in deposition has taken place. liquid. Ensure Pre Installation checking as

per Page - 3.2. Micro switch operating before Turbulence in liquid. Use Still pipe / Cage for assembly desired set point. to avoid turbulence.

3 Micro switch not operating. a. Wiring may be loose or Resolder the wire at terminals or improper. Connect the wire properly to

respective terminals. b. Setting of micro switch assly. Rearrange position of micro switch to switch carriage is nor proper. assembly to switch carriage. c. Vibration may cause damage Avoid vibrations by providing to wiring connections. dampers. d. Switch burnt due to load more Change switch. than its rating. e. Micro Switch contacts Clean contacts. oxidised / pitted due to sparking. f. Float may be damaged / Change float. punctured. g. Wiring connections may be Wire Properly as specified. loose. f. Liquid Sp. Gravity is less than Replace float to match Sp. Gr. that specified while ordering.

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S&SS&SS&SS&S 303, Markaz Apartments, Manufacturers of Process Instruments & Systems

SYSTEMS SYSTEMS SYSTEMS SYSTEMS Srinagar Colony P.O., SPEED TRANSMITTERS, SIGNAL CONVERTERS HYDERABAD – 500 073. AND REVERSE ROTATION MONITORING SYSTEMS 040 - 2374 8721, 98491 35071, snssystems@rediffmail.com

INSTALLATION AND OPERATING MANUAL

IOM – E 015 MARCH 2009 ISSUE 1

PROGRAMMABLE CONTROLLER SPEED TRANSMITTER

ADVICE

This publication should be read in its entirety before performing any operation. Failure to understand and follow these instructions could result in serious personal injury and / or damage to the equipment. In case this equipment needs any repair or adjustment, contact S&S SYSTEMS. It is important that servicing be performed only by trained and qualified service personnel. It will be noted that S&S SYSTEMS will not be held responsible for problems arising due to mishandling and tampering by unauthorized personnel and operation in excess of the specifications.

GUARANTEE

If at any time within one year of shipment, but not thereafter, it is proved that any part of the equipment furnished by us was defective when shipped by us, we will repair or replace the same free of charge. Notice of this claim must be made to us within one year after delivery. Our liability is limited to replacement of such defective parts or equipment. There are no guarantees or warrantees expressed or implied other than those mentioned here.

CAUTION This instrument contains electronic components that are susceptible for damage by static electricity. Proper handling procedures must be observed during the removal, installation, or other handling of internal circuit boards or devices.

Page : 1 of 19

COMMITTED TO PROVIDE COMPREHENSIVE SERVICE TO INDUSTRY THROUGH CONTINUOUS IMPROVEMENT IN QUALITY.

Page : 2 of 19

CONTENTS

1.INTRODUCTION..............................................................................................................3

1.1 PURPOSE .......................................................................................................................3

1.2 DESCRIPTION ...............................................................................................................3

1.3 PRINCIPLE OF OPERATION........................................................................................3

1.4 SPECIFICATIONS .........................................................................................................4

2.INSTALLATION...............................................................................................................5

2.1 GENERAL ......................................................................................................................5

2.2 RECEIPT OF EQUIPMENT ...........................................................................................5

2.3 INSTALLATION ............................................................................................................5

2.4 START UP AND INITIATION.......................................................................................7

ILLUSTRATIONS

1. CONNECTION SCHEMATIC DIAGRAM…………………………………………… 6 2. RECOMMENDED SPARES ……………..…………………………… 11 3. Sketch OF PROXIMITY SWITCH………………………………………… 11 4. DIMENSIONS OF ENCLOSURES ……………………………..………… 12 5. GENERAL assembly DRAWING ………………………………………… 13 6. WIRING DIAGRAM ……………………………………………...……… 14

Page : 3 of 14

1. INTRODUCTION

1.1 PURPOSE

Instructions for operation and maintenance in this manual apply to Models PCST – 01 – W and PCST – 01 - F, PROGRAMABLE CONTROLLER SPEED TRANSMITTERS, housed in weatherproof and flameproof Enclosures respectively.

1.2 DESCRIPTION

PROGRAMABLE CONTROLLER SPEED TRANSMITTER measures the speed in RPM (Revolutions Per Minute) of any rotating object, indicates the same on an Alpha numeric Backlit LCD Module and transmits a proportional 4 – 20 mA DC signal to control room, which can be used for recording and or control functions. Model PCST – 01 – W is housed in a Polycarbonate, weatherproof Enclosure, with transparent lid. The Degree of Protection is IP 65 as per IEC 529. The Indian equivalent standard is IS : 13947 (Part – I) – 1993. They are approved by ERTL (WEST), STQC Directorate. These enclosures are suitable for panel or wall mounting. Model PCST – 01 – F is housed in Aluminum flameproof Enclosure with a glass window. This enclosure is suitable for installation in zones – I & II of II A & II B hazardous areas and is designed according to IS : 2148–1981 and is certified by CMRI, DHANBAD and CCOE, NAGPUR. Suitable Isolators, also housed in similar flameproof enclosure might be required to feed the input signals from Proximity Switches as a safety measure. It is suggested to feed the current output from these instruments to signal Isolators and use the current output from them for feeding to other instruments like recorders or controllers in the control room. Such Isolators are usually installed in the control room itself. Isolators for signals from proximity switches, which are installed in the field (Hazardous area application) and Current Signal Isolators, which are installed in control room (safe area), are not in the scope of supply along with this instrument. But they can be supplied by us on specific request. The system comprises of two parts, a sensing part and a signal conditioning part. The sensing part is made up of one sensor, a 2-wire, intrinsically safe, NAMUR PROXIMITY SWITCH, suitable for installation in hazardous areas or a 3 wire DC PROXIMITY SWITCH. The signal conditioning part is housed in the above mentioned Enclosure depending on the area of application. This part processes the signals from the sensor to provide local indication of RPM and give an output of 4 – 20 mA DC for transmission.

1.3 PRINCIPLE OF OPERATION

Inductive Proximity Switch is used as sensor. These switches are used for non-contact detection of metallic objects. Their operating principle is based on a coil and oscillator that creates an electromagnetic field in the close surroundings of the sensing surface. The presence of a metallic object in the operating area, decided by the sensing range of that specific sensor, causes a dampening of the oscillation amplitude. The rise or fall of such oscillation is identified by a threshold circuit that changes the output of the sensor. The sensing range depends upon the size, shape and material of the metallic object. For a given dimension of the sensor, the sensing range is maximum for Mild Steel and minimum for Copper. Since there is no contact between the sensor and the metallic object, commonly referred to as the target, these Inductive Proximity Switches are inherently resistant to dust, humidity and oil and so are suitable for almost all industrial environments.

Page : 4 of 14 The Proximity Switches in 2 wire configuration are called NAMUR, Intrinsically safe . Current varies in the presence of Targets in these Sensors. There are no amplifier trigger stages in-built in them. Their current and voltage limits allow them to be used in hazardous areas. The Proximity Switches in 3 wire configuration need a DC power Supply in the range of 8-30 V DC, which is provided by the Signal Conditioning Part. They give an output through a third wire based on the presence of target within their sensing range. The output could be NO/NC and PNP or NPN type. PNP – NO type of output is standardized for this instrument, when a 3 wire Switch is used. When the targets are sensed by the Switch, current variation takes place, leading to generation of a pulse train. The signal conditioning part receives this pulse train. Depending upon the RPM, a proportional frequency is obtained, which is processed by the programmable converter to finally give out a 4 – 20 mA DC output, combined with many specific and salient features, which are user friendly. With the Technology used in this system, there is no need to calibrate the system, when ever there are any changes in the Full Scale values or the Number of Targets. It is very easy to feed in these parameters and get the results. The most advantageous feature is that there are no trimpots for Zero and Span Adjustments. There by, operator mistuning is avoided. Further, the entry of various parameters is protected by a password. So, unauthorized personnel can not tamper with the settings. Various other features like Power Failure Relay, Hi and Low Process Value Alarms are also incorporated in the system. Also Customer can select 0-20 MA DC output or 4-20 mA DC output and also a voltage output. Further the Frequency Signal generated by the pulse train is available as Scaled and Unscaled OC Pulses. The following precautions are to be taken during installation and interconnection of the sensor and the signal conditioner unit. 1. The targets on the rotating objects must be well within the sensing ranges of the Proximity Switches. 2. Spacing between successive targets should be more than the width of the Proximity Switch. 3. Cables should be run through conduits to avoid physical damage. 4. Polarity of Proximity Switch wires should be followed properly while terminating.

1.4 SPECIFICATIONS

POWER SUPPLY : 100 – 250 V AC INPUT SIGNAL : Pulses from Inductive Proximity Switch LOCAL INDICATIONS : RPM on Backlit LCD Module OUTPUT SIGNAL : 4 – 20 mA DC proportional to RPM for remote transmission RPM RANGE : 0 – 999999 RPM / 0-999999 RPS / 0 – 999999 RPH ACCURACY : ≤± 0.2% of Full Scale Value POWER CONSUMPTION : 15 Watts maximum NUMBER OF TARGETS : As per the convenience of Customer ( Minimum 2 ) MAXIMUM LOAD : 600 Ohms ENCLOSURE DIMENSIONS : Weatherproof – 200/120/90 mm, Flameproof – 340/215/145 mm MOUNTING DIMENSIONS : Weatherproof – 215/88 mm, Flameproof- 242/176 mm(+/-5 mm) PROXIMITY SWITCH CONFIGURATION Type : 3-wire, DC, PNP, NO Model Number : IN 04 13.5 TM PNP NO Operating Voltage : 8 – 35 V DC Switch Diameter : 13.5 mm with M12/1 Male threading

Page : 5 of 14

Sensing Range : 4 mm Weather protection : IP 67 Termination : Brown ( +Supply ), Blue ( Common ), Black (+Output), Shield Switch Length : 45 mm Cable Length : 2 Meters The proximity Switch is supplied as an integral assembly with a connector Head and a pipe with necessary Fittings. The Connector Head is an Aluminum Weather Proof Enclosure. The wires are terminated on connecting base. Use a 3 core twisted and shielded cable to connect from the Connector Head to the Signal conditioning Unit.

2. INSTALLATION

2.1 GENERAL

This section contains the procedures for receipt and installation of Programmable controller Speed Transmitter..

2.2 RECEIPT OF EQUIPMENT

When the equipment is received, the outside of the packing case should be checked for any damages incurred during shipment. If it is damaged, the local transporter should be notified regarding his liability. Also check for any missing parts as per the packing list. If any item is missing, a report should be submitted to S&S SYSTEMS, with the serial numbers of the equipment supplied and the Purchase Order Number. Check whether all items inside along with the proximity switches are intact. Remove the envelope containing the packing list. Carefully remove the equipment from the packing case. Make sure that spare or replacement parts are not discarded with the packing material. Packing List contains the following items. 1. Model PCST – 01 – W or PCST – 01- F PC Speed Transmitter 1No. 2. IN 04 13.5 TM PNP NO/NJ – 5 – 18 – GM – N/NJ – 4 – 12 – GM – N PROXIMITY SWITCH 1No. 3. M6 Bolt, WASHERS, Nut Set MOUNTING HARDWARE 4 Nos. ( For Flame Proof Enclosure, M8 Bolt, washers and Nut Set is supplied).

2.3 INSTALLATION

The Proximity switch may be mounted anywhere around the target plate (Pole Wheel), so that all the targets are within the specified sensing range of the switch. A mounting bracket is to be used for this. PC Speed Transmitter should be mounted on the Panel with the mounting hardware supplied. Make sure that the signal conditioning unit is not subject to vibrations. It is preferable to use a Signal Isolator in the control room for the current output. It is to be ensured that cable from proximity switch is not bent on short radii. The installation should be in conformance with API 670, the international code for Non Contacting rotation measurements. TERMINATION DETAILSTERMINATION DETAILSTERMINATION DETAILSTERMINATION DETAILS

IN 04 13.5 TM PNP NO : Brown (+Supply), Blue (Common), Black (Output), Shield NJ – 5 – 18 – GM – N / NJ – 4 – 12 – GM – N : Brown (+), Blue (Common)

Page : 6 of 14

TERMINATION DETAILS

POWER SENSOR OUTPUTS SUPPLY INPUT SIGNAL POWER FAIL LO Alarm HI Alarm

L : 1 SUPPLY : 12 CURRENT + : 6 NC : 19, 22 NC : 25, 28 NC : 31, 34 N : 2 COMMON : 13 CURRENT – : 7 COM : 20, 23 COM : 26, 29 COM : 32, 35 G : 3,11,14 INPUT : 9 VOLTAGE + : 4 NO : 21, 24 NO : 27, 30 NO : 33, 36 SHIELD : 14 VOLTAGE – : 5

RPM INDICATOR Min. 0.5 mm Max. 4.0 mm

Sensor

Input

Power

Supply

Current Alarm

Output Outputs

CONNECTION SCHEMATIC DIAGRAM

INSTRUMENT ENCLOSURE: WEATHER PROOF

2.4 START UP AND INITIATION

Equipment required: 1 DMM, 2 Tachometer As received from the factory, the PC Speed Transmitter will be set to the RPM range specified in the order. There are no additional adjustments required. This Instrument is Program controlled. The following instructions enable the user to set the values of the RPM minimum and Maximum values, choose the number of Targets and choose and set the Output signals and Alarm values. Switch on power to the instrument. The Display shows < S&S SYSTEMS > for 5 seconds and then shows 0 U/Min The three LEDs, RL1, RL2 and Sensor glow momentarily and go off. The LED for RL1 then glows and stays on. The instrument is now ready to receive signal from the sensor, process it and display the RPM directly based on the already programmed parameters.

Current

Output

POLE WHEEL

RPM INDICATOR Min. 0.5 mm Max. 4.0 mm

Sensor Alarm

Input Outputs

24 V DC

INSTRUMENT ENCLOSURE : FLAME PROOF

SUGGESTED SCHEME OF CONNECTION FOR INSTALLATION IN HAZARDOUS ATMOSPHERES

Power

Supply

PULSE SIGNAL

ISOLATOR

OSNA MODEL

OS Ex-2-OT-G,

In FLP Enclosure

Page : 8 of 14 The Front fascia has 4 keys for entering the parameters. PROG Program Key Left Arrow Key UP Arrow Key Enter Key

Functions of the keys:Functions of the keys:Functions of the keys:Functions of the keys:

Prog keyProg keyProg keyProg key - Used for entering into setting mode and also as an “ESCAPE” key during settings. Left arrow keyLeft arrow keyLeft arrow keyLeft arrow key – Used for selecting the cursor position while entering the value UP arrow keyUP arrow keyUP arrow keyUP arrow key - Used to change the value of the digit selected by the cursor Enter keyEnter keyEnter keyEnter key – Used to conform the entry.

How to enter setting mode:How to enter setting mode:How to enter setting mode:How to enter setting mode: 1. Press “PROG” key, then display shows “PCODE”. Feed Pass code as “111” (Default pass code) and then

press “Enter” key. Then display shows the first parameter name, i.e. “SP1”. If the pass code is wrong, Display shows up “Sorry” and then shows up PCODE with Cursor Position In LEAST SIGNIFICANT DIGIT and starts showing a blinking ‘0’. This prompts us to enter the correct Pass Code.

2. Press any arrow key for going to the next parameter, or press “Enter” key for changing the current parameter, or press “PROG” key to quit the setting mode.

PARAMETERS LIST :PARAMETERS LIST :PARAMETERS LIST :PARAMETERS LIST : Parameter 1: “SP1” - Setpoint 1 (default 0) This is used to set the value of the First Alarm Level of the Process Variable. When Process value is greater than “SP1” , then RL1 toggles from its “Default RL1” state. Again RL1 is forced to its default value when Process value is less than (SP1-Hysterisys1). To set this, after seeing SP1, press “Enter”. The default setting is shown blinking. To change the value, use the “UP ARROW” and “LEFT ARROW” Keys. The Value selected represents the Engineering Units of the Process Variable, at which the First Alarm is to be activated. After selecting this value, press “ENTER”. The Display shows “OK Done” and then shows up SP1. To go the next parameter, press either of the “ARROW” Keys. This is the general procedure for entering and storing parameters. Parameter 2: "Hystrs1 " - Hysteresis to Set point 1 (default 10) Hysteresis is the difference between the values at which the relay toggles in ascending and descending directions of the Process variable. Parameter 3: "Def.RL1 " - Default RL1 state (default 1) If this parameter is “0” then RL1 is ON when PV > SP1 If this parameter is “1” then RL1 is OFF when PV > SP1

Parameter 4: “SP2” - Setpoint 2 (default 0) When Process value is grater than “SP2” , then RL2 toggles from its “Default RL2” state. Again RL2 is forced to its default value when Process value is less than (SP2-Hysterisys2).

Page : 9 of 14 Parameter 5: "Hystrs2 " - Hysterisys to Set point 2 (default 10) Parameter 6: "Def.RL2 " - Default RL2 state (default 0) If this parameter is “0” then RL2 is ON when PV > SP2 If this parameter is “1” then RL2 is OFF when PV > SP2

Parameter 7: "SampleTm" - Sample time for measuring the PV (default 500msecs) Range from 10 msecs to 100 seconds. Setting is in Milli Seconds. Parameter 8: "Units " - Units of PV (default U/Min) Three different time bases for the PV U/Sec – Units per second U/min – Units per minute U/Hr - Units per Hour Parameter 9: "DecPoint" - No.of digits after decimal point (default 0)

Parameter 10: "O/P Zero"- It is the value of the PV at which Analog output is zero (4mA) (default 0) Parameter 11: "O/P Span"- It is the value of the PV at which Analog output is Fullscale (i.e. 20mA) (default 1000)

Parameter 12: "ZeroCal "- Analog output Zero Calibration(default 15700) Adjust this value by comparing the analog output to get 4 ma DC or 0 mA DC as per the requirement, with a standard meter.

Parameter 13: "SpanCal "- Analog output Span Calibration(default 60800) Adjust this value by comparing the analog output to get 20 mA DC, with a standard meter. Parameter 14: "Threshld"- PV threshold(default 1) Analog output will be at its zero state till PV < Threshold.

Parameter 15: "NUM(MUL)"- PV Multipiler constant(default 1) The Input is frequency to this system. The Process Value is numerically related to this Input Frequency by a factor. This Factor contains a Numerator Selection and a Denominator Selection. When we measure a time dependent unit like RPM, the time base is also taken into consideration by direct selection as mentioned in Parameter 8. PV =( (Input Frequency x (NUM/DEN)) This Formula holds good when the time base of the Process Value is Seconds. If the Time Base is Minutes, the Right Hand Side in the Above Equation will be Multiplied by 60 and if the Time Base is Hour, The RHS will be multiplied by 3600. This Multiplication is done internally, when we chose the Units as in Parameter 8.

Parameter 16: "DEN(DIV)"- PV divider constant(default 1) Parameter 17: "Filter " – Low pass filter constant for PV (default 5) Adjust this parameter to the optimum value for stabilizing PV fluctuations

Parameter 18: "Self Test " – Self testing of Analog output Enter and feed the PV for checking the analog output Parameter 19: "New Code” – For changing the existing pass code.

Page : 10 of 14 After Entering all these parameters or just those which are required for the specific application, Press “PROG” and it gets ready to measure the Process Variable and transmit the Current output. A voltage Output is also available. The desired current output may be calculated as following. Suppose the speed of rotation, as indicated by the tachometer is ‘S’. Let the Full Scale Speed be ‘F’.

Desired Current output at ‘S’ = [ ] 16 4( / )S F × + mA DC

Example: F = 1000 RPM, S = 650 RPM

Desired Current at 650 RPM = [ ] 650 1000 16 4( / )× + =14.4 mA DC

VVVVERIFICATION OF CALIBRATION WHEN TACHOMETER IS NOT ERIFICATION OF CALIBRATION WHEN TACHOMETER IS NOT ERIFICATION OF CALIBRATION WHEN TACHOMETER IS NOT ERIFICATION OF CALIBRATION WHEN TACHOMETER IS NOT AVAILABLEAVAILABLEAVAILABLEAVAILABLE

For this, a multimeter with frequency measurement is required. The RPM INDICATOR is an instrument processing the input frequency and giving out proportional DC Voltage and Current. The input frequency is proportional to the speed or RPM. Hence a measurement of the input frequency will suffice to calculate the RPM. If the RPM is known, the procedure above to tally the current output and the displayed speed with the actual speed can be carried out.

Let us take a practical example to illustrate this verification process. Let the Full Scale Speed be 1,000 RPM. Let there be 4 targets on the Pole Wheel. The Proximity Switch generates one pulse for every target. If there are 4 targets, , it generates 4 pulses per revolution. Therefore, for 1,000 revolutions of the Pole Wheel, it generates 1,000 * 4 = 4,000 pulses. To convert this into input frequency at Full Scale Speed, we have to divide these pulses per minute by 60. So, the maximum input frequency corresponding to 1,000 RPM for a Pole Wheel with 4 targets is given by 4,000 / 60 = 66.7 Pulses Per Second or in other words, 66.7 Hertz. Thus the incoming frequency always represents the rotational speed of the object. By measuring this frequency, the speed can be calculated. If the frequency thus measured is 35 Hz, then the corresponding rotational speed is (35 / 66.7)*1,000 = 524.7, that is almost 525 RPM. Further calculations of desired current output for this speed of 525 RPM can be done as outlined earlier. The general formula for calculating RPM from input frequency is (Input Frequency / Full Scale Frequency) × Full Scale RPM(Input Frequency / Full Scale Frequency) × Full Scale RPM(Input Frequency / Full Scale Frequency) × Full Scale RPM(Input Frequency / Full Scale Frequency) × Full Scale RPM The general formula for calculating Full Scale Frequency is (Full Scale RPM ×No. of Targets) / 60(Full Scale RPM ×No. of Targets) / 60(Full Scale RPM ×No. of Targets) / 60(Full Scale RPM ×No. of Targets) / 60

Page: 11 of 14

RECOMMENDED SPARESRECOMMENDED SPARESRECOMMENDED SPARESRECOMMENDED SPARES PROXIMITY SWITCH ASSEMBLY 1 No. PROGRAMABLE CONTROLLER SPEED TRANSMITTER 1 No. PROXIMITY SWITCH PROXIMITY SWITCH PROXIMITY SWITCH PROXIMITY SWITCH ASSEMBLYASSEMBLYASSEMBLYASSEMBLY Brown Blue Shield Black

Page: 12 of 14

DIMENSDIMENSDIMENSDIMENSIONS OF THE ENCLOSUREIONS OF THE ENCLOSUREIONS OF THE ENCLOSUREIONS OF THE ENCLOSURE

96 120 90 215 200 230 88 120 Ø6.5, 4 holes Chloroprene seal All dimensions in mm. The enclosure is weather proof to IP65 Degree of protection.

S&S SYSTEMS SPEED TRANSMITTER + INDICATOR GA DRAWING

MODEL NUMBER : PCST – 01 – W

Sensor Assembly

Power In Signal in

Current out

Transmitter + Indicator

Pole wheel

Sensor Assembly will be as per the drawings enclosed with PO.

Transmitter + Indicator contains the latest state of the art signal conditioning circuits

Which process the signal received from Sensor assembly and provide local Indication

Of Speed and give 4-20 mA DC current output for transmission .

This product is developed in accordance with the specifications and requirements of

VOITH part No. : 306 60342 15014.

Page : 13 of 14

S&S SYSTEMS GA Drawing NO. : SS-PCST-01-GA Rev. O

303, Markaz Apartments, Application : VOITH Part No. : 306 60342 15014

Srinagar Colony P.O., Date : 16-12-2008

HYDERABAD – 500073. Prepared : CVMS

Phone : 23748721 Authorized and released 17-12-2008 CVS

Page : 14 of 14 L POWER SUPPLY N 100 to 250 V AC G Connector Head Sensor Terminations 1 2 3 PCST – 01 – W PROGRAM CONTROLLED Bn Bu Bk Sh SPEED TRANSMITTER 1 2 3 4 Current + 6 19 NC Output 20 COM – 7 21 NO POWER FAILURE 22 NC RELAY OUTPUTS 23 COM 24 NO 12 13 9 14 3 Core Shielded Cable Brown from Sensor (1) --- Supply to Sensor in Speed Transmitter (12) Blue from Sensor (2) --- Common in Speed Transmitter (13) Black from Sensor (3) --- Input to Speed Transmitter (9) Shield from Sensor (4) --- Power Earth of Speed Transmitter (14)

Wiring drawing From Sensor Head to Program Controlled Speed Transmitter

RADIANT ENGINEERS

INSTALLATION, OPERATING AND MAINTENANCE MANUAL Radiant shell & Tube Heat Exchangers are custom engineered for specific operating conditions. Their successful performance and long life can be still enhanced by careful installation and periodic inspection.

INSTALLATION PLANNING 1. On removable bundle heat exchanger, provide sufficient clearance at the end to permit the removal of the tube bundle from the shell. On the floating head type exchangers, provide space to permit removal of shell cover and floating head cover. 2. On fixed tube bundle heat exchangers, provide sufficient clearance at one end to permit the removal and replacement of tubes and at the both ends provide sufficient clearance to permit rolling of tubes into the tube sheet. 3. For U-tube heat exchangers, provide sufficient clearance at the stationery head end to permit withdrawal of tube bundle, or at the other end to permit the withdrawal of the shell. 4. Adequate foundations for mounting the heat exchanger should be provided so that it will not settle and cause piping strains on the exchanger. Foundation bolts should be set to allow for setting inaccuracies. In concrete footings pipe sleeves at least one size larger than bolt diameter slipped over the bolt and cast in place are best for this purpose as they allow the bolt centers to be adjusted after the foundation has set. 5. Provide valves and bypasses in the piping system so that both shell side and tube side can be bypassed to permit isolation of exchanger for cleaning, inspection and repairs. 6. Make drain connection in such a fashion that is should be correctly determined that the exchanger has been thoroughly drained. 7. Install liquid level controls, relief valves, gauge glasses or liquid level alarms in all vapor or gas spaces to indicate any failure occurring in the condensate drain system and prevent flooding of the heat exchanger. 8. Surge drum can be installed upstream from the heat exchanger to guard against pulsation of fluids caused by pumps, compressors or other equipments.

MAINTENANCE 1. Clean exchangers subject to fouling (scale, sludge deposits etc) periodically, depending on the specific working conditions. A light sludge or scale coating on either side of tube greatly decreases its effectiveness. A marked increase in pressure drop and/or reduction in performance usually indicates cleaning is necessary. Since the difficulty of cleaning increases rapidly as the scale thickens or deposits increase, the intervals between cleanings should not be excessive. 2. Neglecting to keep tubes clean may result in random tube plugging. Consequent overheating or cooling of the plugged tubes, as compared to surrounding tubes, will cause physical damage and leaking tubes due to differential thermal expansion of the metals. 3. To clean or inspect the inside of the tubes, remove only the necessary tube side channel covers or bonnets depending on type of exchanger construction. 4. If the heat exchanger is equipped with sacrificial anodes or plates, replace these as required. 5. To clean or inspect the outside of the tubes, it may be necessary to remove the tube bundle. 6. When removing tube bundles from heat exchangers for inspection or cleaning, exercise care to see that they are not damaged by improper handling. The weight of the tube bundle should not be supported on individual tubes but should be carried by the tube sheets, support or baffle plates or on blocks contoured to the periphery of the tube bundles with hooks, chains or other tools which might damage tubes. After removal, move tube bundles on cradles or skids. To withdraw tube bundles, pass rods through two or more of the tubes and take the load on the floating tube sheet. Rods should be threaded at both ends, with the ends passing through a steel bearing plate and tube sheet. Insert a soft wood filler board between the bearing plate and tube sheet face to prevent damage to the tube ends. Screw steel eye lifting. As an alternate to the rods, thread a steel cable through one tube and return through another tube. A hardwood spreader block must be inserted between the cable and each tube sheet to prevent damage to the bundle ends. 7. Lift tube bundles horizontally by means of a cradle formed by bending a light-gauge plate or plates into a U-shape. Make attachments in the legs of the U for lifting. 8. Do not drag bundles, since baffles or support plates may become easily bent. Avoid any damage to baffles so that the heat exchanger will function properly.

9. Methods of cleaning: Circulating hot wash oil or light distillate through tube side or shell side. This will usually effectively remove sludge or similar soft deposits. Soft salt deposits may be washed out by circulating hot fresh water. Some commercial cleaning compounds may be effectively used in removing more stubborn deposits. If the scale is hard and the above methods are not effective, use a mechanical cleaning means. Neither the inside not the outside of the tube should be hammered with a metallic tool. Take extra care when suing scraper, they should not damage tubes. 10. Do not attempt to clean tubes by blowing, steam through individual tubes. This overheats the individual tube and result in severe expansion strains and leaking tube to tube sheet joints. 11. To locate rupture or corroded tubes or leaking joints between tubes tube sheets, remove tube side channel covers or bonnets. Pressurize the shell side of the exchanger with a liquid, preferably water. Observe tube joints and tube ends for indication of test fluid leak. 12. To tighten the leaking joint, use a suitable roller tube expander. Do not roll tube beyond back face of the tube sheet. Maximum rolling depth should be tube sheet thickness minus 1/8”. Do not reroll tubes which are not leaking. 13. When a heat exchanger is dismantled, new gaskets should be used in reassembly. 14. Use of new bolting in conformance with dimensions and ASTM specifications of the original design is recommended where frequent dismantling is encountered.

OPERATION 1. be sure entire system is clean before starting operation to prevent plugging of tubes or shell side passages. The use of strainers or setting tanks in pipelines leading to the heat exchanger is recommended. 2. Open vent connection before starting flow through the exchanger. 3. The first fluid admitted is that whose temperature most nearly approximates the ambient temperature of the unit. The heat exchanger should never be shocked by the sudden admission of extremely hot or cold fluids; repeated stresses are set up by such a procedure results in metal fatigue.

Thermal and physical shocks should be avoided whenever possible. For fixed tube sheet exchangers fluids must be introduced in a manner to minimize differential expansion between the shell and tubes. 4. Start operating conditions gradually after the system is completely filled with the operating fluids and all air has been vented, close all manual vent connections. 5. Retighten bolting on all gasketed or packed joints after the heat exchanger has reached operating temperatures to prevent leaks and gasket failures. 6. Sufficient circulation of the cold medium should be maintained at all times to prevent overheating, which could result in the depositing of scale, coke or sludge.

Part Turn ActuatorsPME 120 AI / PME 120 AN

Rated Torque 100 NmWith Integrated Electronics orFor Separate Field Housing

Operating Instructions 42-68-151EN

(d036rxa)

2

Table of Contents

Device Identification . . . . . . . . . . . . . . . . . . . . . . 2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Delivery State . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Electrical Connection. . . . . . . . . . . . . . . . . . . . . . 8

Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . 15

Your notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1. Device Identification

1.1 Actuator ID Label

1. Actuator type2. Device number / No. of non-standard version3. Rated torque / Year of manufacture4. Permissible ambient temperature5. Min./max. positioning travel / Min./max. speed6. Filled-in oil type7. Associated electronics8. Permissible voltage range / Mains frequency9. Power consumption / Fus10. Available for customer-specific information

1.2 ID Label of ElectronicsThe ID labels of the power electronics are located on theelectronics cover.

1.2.1 ID Label for Hardware Description

1. Electronics type2. Device no. / No. of non-standard version3. / year of manufacture4. Premissible ambient temperature / protection5. No used

1.2.2 ID Label for Software Description

1 Associated actuator2 No. (if required)3 Downloaded software version4 Configured force (torque)/configured speed5 Available for customer-specific information

1 Antrieb / Actuator: CONTRAC ....2 F-Nr./No NL

Mad

e in

Ger

man

y

3 M = Jahr/Year 4 t = IP 66

5 min......max. ....... max. .........

6 Öl / Oil:

7 Mit / With Elektronik/Electronics

8 U= 230 V (190 ... 260 V) F = 50/60 Hz, ± 5%

9 P= max. ....... W Ext. Sicherung / Fuse 16 A träge/slow

10

AutomationD-32425 Minden

1 Elektronik / Electronics Type: ....

Mad

e in

Ger

man

y

2 B-Nr./No. ...... NL

3 Jahr / Year

4 t = ..................°C IP 66 5

AutomationD-32425 Minden

1 Für Antrieb / For ActuatorContrac . . . . . . . . . . . . . . . . . . . .

2 Mit / NL. Nr./No.. . . . . . . . . . . . . .

3 SW Version . . . . . . . . . . . . . . . .

4 Eingestellt / adjusted auf/forM=....... .......°/s

5

3

2. General

2.1 Proper UseControl actuators are intended to be used exclusively for actuating final control elements(valves, vanes, etc.). Do not use these actuators for any other purpose. Otherwise, ahazard of personal injury or of damage to or impairment of the operational reliability ofthe device may arise.

2.2 Safety and PrecautionsWhen mounting the actuator in areas which may be accessed by unauthorized persons,take the required protective measures.

! Warning !- Control actuators perform movements for positioning vanes and valves. Handleproperly and with care. Otherwise, a hazard of bruise injuries may arise.

- When changing the oil of the actuator, thoroughly remove any oil that may have rundown on the floor during the procedure to avoid accidents.

- Dispose of the waste oil in compliance with the respective local regulations. Makesure that no waste oil reaches the water cycle

- Only qualified specialists who have been trained for these tasks are authorized tomount and adjust the control actuator, and to make the electrical connection.

- When working on the actuator itself or its electronics always observe the locally validaccident prevention regulations and the regulations concerning the construction oftechnical installations.

3. Storage actuators may be stored under moist and aggressive condition for a shorttime. The equipment is protected against external corrosive influences. However, directexposure to rain, snow, etc. must be avoidedInterior areas of the actuator with risk of condensation are protected by desiccant placedin the connector (and in the terminal box of the separate electronics, if present). Thedesiccant guarantees sufficient protection for approximately 150 days. It can be regen-erated at a temperature of 90° C within 4 h.The desiccant must be removed prior to commissioning the actuator or the electronics.

3.1 Long-time StorageIf you intend to store or transport the device for a longer time, we recommend to wrap itin plastic foil and add desiccant. Regularly check if the desiccant is still active.

4. Delivery StateIf not otherwise specified by the customer, actuators are delivered with thefollowing standard configuration:Behavior in 0/100% position: Shut-off with rated torqueSetpoint function: Linear; setpoint = positioning valueInput (setpoint): 4 ... 20 mAFunction: Positioner, parameter: setpointOutput (actual value): 4 ... 20 mADigital inputs: DI 1 switch-over manual/automatic and v.v.

DI 2 / DI 3 manual control +/-Digital outputs: DO 1 ready to operate, DO 2/3 end position signal-

ling Range: Not adjusted

The configuration of your actuator may differ from the standard configuration specifiedabove. It can be called up for display using the configuration program.

4

5. Assemblies

5.1 Normal mode! Warning !

The friction clutch is de-signed such that a hand-wheel force of around11 N suffices to create therated torque on the actua-tor. If you should feel aconsiderable counter-force when moving theactuator by hand, do notincrease the force you ap-ply to the handwheel.Otherwise, you mightdamage the actuator orvalve

The motor triggered by the power electronics drives the output shaft (9) via oil-lubricatedspur gears. The drive lever mounted on the shaft transmits rotary motion to the valve. The brake built in the motor (5) acts as a retainer when the power is off.

5.2 Handwheel mode- Allows you to move the actuator manually when the electrical power is off.- Turn the lock lever (4) clockwise- Turn the handwheel (7) to move the lever to the wanted position.- Release the lock lever.

6. Technical Data

1: Lever2: Mechanical stops3: Gearbox4: Lock lever5. Motor6. Cover

(incl. electronicsfor PME 120 AI)

7. Handwheel8. Connector9. Ouput shaft10.Ball-and-socket

joint

Figure 1: PME 120

(d0001rxa)

PME 120 AI PME 120 AN

Rated torque [Nm] 40 ... 100Starting torque [Nm] appr. 1.2 x rated torque (break-away torque in end

positions 2 x rated torque for short time)Rated speed [°/s] 1.5 ... 4.5Weight approx. 45 kg approx. 32 kgAssociated electronics

integrated in actuatorfor field mounting: EAN 820 for rack mounting: EAS 822

Power supply(on electronics)

115 V AC (94 V ... 130 V) or 230 V AC(190 V ... 260 V); 47.5 ... 63 Hz

Max. power consumption with115 / 230 V AC [A] 1.0 / 0.5Current consumption in positioningmode:

approx. 40 ... 50% of Imax., each

Table 1:

5

7. LubricationPrior to delivery the actuator is filled with 2.5 l oil in factory.

Figure 2:

7.1 Lubricants! Warning !

Do not pollute the syn-thetic Mobil SHC 629 oil,nor mix it with mineraloils. Prior to changingover to synthetic lubricantoil always throroughlyclean the set of gears!

IMB 3 IMB 6 IMB 7 IMB 8 IMV 5 IMV 6

EinbaulageMounting Position

1) 2)1) 2)

1) 2)

1) 2)

1) 2)1) 2)

Min. oil quantity; approx. [l]

2.2 2.5 2.2 2.2 2.5 2.5

Min. oil level [mm]under inspection screw

45 2 42 20 23 17

Table 2: The arrow indicates the position of the inspection screw 1) and the vent screw 2). After having mounted the actuator, replace the highest inspection screw with the separately delivered vent screw.

Oil types

Ambient temperatureOil type used by manufac-turer for first filling

Possible other oil types

- 10°C ... + 65°C

ESSO Spartan EP 220(L-CKC to ISO TR 3498)

Aral Degol BMB 220 BP EnergolGR-XP 220Shell Omala 220Mobilgear 630

- 25°C ... + 55°C Mobil SHC 629 -----

Table 3:

6

8. Mounting

8.1 Actuator Check- Is the actuator filled with the appropriate oil type?- Is enough oil in the actuator?- Did you fasten the separately delivered vent screw in the highest bore (depending on

the mounting orientation)?- Has the actuator integrated or separate electronics ?

8.2 Mounting orientationAll mounting orientations seen in Figure 2 are permissible. To facilitate mounting andmaintenance, however, it is recommended to use orientation IMB 3.

8.3 Mounting Instructions- Make sure that the actuator is accessible from all sides to ensure convenient hand-

wheel operation, electrical connection, and replacement of assemblies.- Avoid direct exposure to rain, snow and other environmental influences. Select the

mounting site accordingly.- Exclusively mount the actuator on a rigid, non-vibrating support to avoid relative mo-

tion between the actuator and the valve. - When mounting the actuator close to heat sources use an insulating layer or shield-

ing.

8.4 Mounting the Actuator to the Valve

8.4.1 Preparing the Equipment- Make sure that the shaft and lever bore surface are clean and free of grease.- Determine the length of the stay tube (not included in the scope of delivery). - Move the valve to the “CLOSED“ position. - Move the actuator to the corresponding end position using the handwheel. Observe

the permissible angle. - Spacing “L“ minus 140 mm yields the required length of the link tube.- Drill a cone bore into the valve lever for mounting the second ball-and-socket joint,

as seen in Figure 4. - Insert the ball-and-socket joint, secure with crown nut and split-pin. - Remove the welding bushings and weld them to the stay tube (C 15 to DIN 17210)- Insert the link rod between the two ball-and-socket joints and screw it in. - If required adjust “L” by turning the link rod.- When all adjustment steps are finished, fasten the counter nuts.

8.4.2 Adjusting the Stops in Dependence of the Travel- Move the output lever / valve to the position requiring fine adjustment. - Put the stop onto the toothing as close to the output lever as possible and fasten with

screws. - Move the output lever towards the stop using the handwheel; turn the coupling rod

for fine adjustment. - Fasten the counter nuts.- Fasten the stop in the other mounting position close to the end position, depending

on the toothing.

8.4.3 Adjusting the Stops in Dependence of the Torque - First proceed as described above for travel-dependent adjustment. - Prior to re-fastening the counter-nut lock the handwheel and then turn the coupling

rod in such a way that an initial tension occurs in the valve’s closing position. - Fasten the counter-nuts.

7

Figure 3: Mounting PME 120, example

α ≥ 15 °β according to dimensions specified by the valve manufacturer

Figure 4: Dimensional drawing

1. Output lever2. Link tube3. Ball-and-socket joint4. Welding bushings (C15 to DIN 17210)5. Counter nuts6. Crown nuts

10

3

°

°

tightening torque forlever clamping screw:23 Nm

tightening torque forscrews of limit stop: 46 Nm

rigid, vibration-freesupport

boring diameterfor fasteningscrews: 12 mm

tensile strength:400 N/mm2coupling rod

mechanicallimit stop

lever

>-

flap lever

r00304e1

62 - 78 62 - 78

60

4632

211415

18

61

L - 140

14

L

1 66

33 44 2

55

cone 1 : 10

M 14 x 1.5left / right r00305e1

8

9. Electrical Connection

9.1 Wiring Diagram for PME 120 AIThe electrical connection is done with a combined plug on the actuator and with screwterminals on the electronics.

Figure 5: Electrical connection, standard

The following steps must be performed to switch the actuator to automatic mode (AUT):- Activate digital inputs DI 1, DI 2 and DI 3 via the configuration program.- Make sure that the supply voltage is present on digital input 1 (DI 1).- Activate AUT mode via the configuration program.

Figure 6: Electrical connection, Profibus DP

24V

Uv

11+ - -+

RB

+ -

12

I

U

9 1031

+ - + - + - + -154

13165 176 18 217 19 228 20 23

L N

Uv24V

+RB

+ -

1 2

BE 1MAN/AUT

BE 2MAN (+)

BE 3MAN (-)

BA 1o.k./fault

BA 2end 0%

BA 3end 100%

(option)

plug

Han

10E

inse

rt

Han

24E

inse

rt

Contrac actuator

mains

externalfuse

transmitter4...20mA

setpoint+ HART

0/4...20mAactual value0/4...20mA

sub-distribution board

r00295e2

1 13

L N

Han

24E

Ein

satz

Ste

cker

/ plu

g

Contrac Antrieb / Actuator

Netzmains

Vorsicherungext. fuse

Busanschluß A1 ... B2 /bus terminals A1 ... B2

Busabschluß T-/T+bus termination T-/T+

Bus outBus in

rot/

red

rot/

red

grün

/gr

een

grün

/gr

een

A2 A1T+T- B2 B1

r00011x1

9

9.2 Wiring Diagram for PME 120 ANThe electrical connection is done with a combined plug on the actuator and with screwterminals on the electronics.

Figure 7: Electrical connection, standard

The following steps must be performed to switch the actuator to automatic mode (AUT):- Activate digital inputs DI 1, DI 2 and DI 3 via the configuration program.- Make sure that the supply voltage is present on digital input 1 (DI 1).- Activate AUT mode via the configuration program.

Figure 8: Electrical connection, Profibus DP (not with EAS 822)

24V

Uv

30+ - -+

RB

+ -

31

I

U

26 271

+ - + - + - + -

72 83 94 10 135 11 146 12 15L N

U V W Br Br PE 17 18 19 20 21 22 23 24

1 2 3 13 14

M3~

17 18 19 20 21 22 23 24 7 8

BE 1T BE 2) BE 3

Netz / MainsAC 110 ... 250 V

Netz /Mains

Ext. Sicherung /ext. fuse Schirm beidseitig geerdet

screen grounded at both ends

Contrac Antrieb / ActuatorMotor

SensorenSensors

Han 24 EStecker / Plug

Stecker / PlugHAN 10E

Heizungca. 6WHeaterapprox. 6 W

Contrac Leistungselektronik / Power Electronics

SollwertSetpoint+ HART

0/4...20mA

IstwertPosition

0/4...20mA

Unterverteilung / Sub Distribution Board

BA 1 BA 2 BA 3

Uv24V

+RB

+ -

28 29

MeßumformeTransmitterr

4...20mA

r00350x1

L N

U V W Br Br

Busanschluß /bus terminals

Busabschluß-möglichkeit /bus termination

PE 17

17

18

18

19

19

20

20

21

21

22

22

23

23

24

241 2 3 5 76 8

M3~

Contrac Antrieb (3~ Motor)

Motor

AC 115 … 230 V

Sensoren / sensorsHeizung / heater(Option)

Sch

raub

klem

men

/sc

rew

term

inal

s

Ste

cker

/pl

ug

Netz /mains

Vorsicherung /external fuse

Bus outBus in

Han 24 E Einsatz / insert

ContracElektronik / Electronics

28 29

rot/

red

rot/

red

grün

/gr

een

grün

/gr

een

3014

B1 B2T+ A1 A2T-3115

10

9.2.1 Signal Inputs and Outputs (Conventional Triggering)(Standard)

Figure 9:

** Write-protected when applying +24 V DC to DI 1.

9.2.2 Signal Inputs and Outputs (Conventional Triggering)(after a step controller)

Figure 10:

** Write-protected when applying +24 V DC to DI 1.

Refer to Operating Instructions 42/68-820 (Power Electronics for Field Mounting) and42/68-821 (Rack-Mounting Electronics) for installation details.

Sollwert(u.HART),

0/4...20mA

Istwert,0/4...20mA

Meßumformer4...20mA

Endlage0%

Endlage100%

Contrac

LeistungselektronikUv24V

24V

+ -- -+

+RB RB

+ -+ -I

U

BE1

BE2

BE3

BA1

BA2

BA3

Uv

No

+ - + - + - +

AUT**

- Y+ Y

MAN

14 28 30261312119 108764321 5 15 29 3127

No

No

Nc

Ok

(r00358d1)

Uv24V

24V

+ -- -+

+RB RB

+ -+ -I

U

BE

1

BE

2

BE

3

BA

1

BA

2

BA

3

Uv

No

+ - + - + - +

- Y+ Y

14 28 30261312119 108764321 5 15 29 3127

No

No

Nc

Ok

Act

.Val

.0/

4...2

0mA

Transmitter4...20mA (Option)

Contrac

Power Electronics

End

Pos

. 0%

End

Pos

.10

0%cont

rolle

r

enab

le c

ontr

olle

r **

(r00359e1)

11

10. Setup! Note !

The commissioning andservice field is located onthe electronics!

The basic settings (definition of end positions) can be made via the commissioning andservice field (CSF). It is used for adapting the actuator to the operating range and theeffective direction without a PC. The actuator can be set up and configured completelyusing the appropriate configuration program.

10.1 Setup via CSF

10.1.1 Operating Elements1. Write-protect switch (Default setting: OFF)2. LED for 100% position Indication if adjustment procedure, saved position, or fault

by different flash frequencies.3. Drive button Press to cause drive motion4. Reset button Press to restart processor and clear any 0% and 100%

values.5. Drive button Press to cause drive motion6. RS 232 socket Connector for PC7. Potential toggle switch Connection of reference potential to the system or protec-

tive earth (by default set to system)8. HART sockets Connectors for HART communication9. LED for 0% position Indication if adjustment procedure, saved position, or fault

by different flash frequencies.10. Accept button (0%) Press to define current position as 0%; simultaneously

press push button 11 to complete the adjustment proce-dure.

11. Accept button (100%) Press to define current position as 100%; simultaneouslypress push button 10 to complete the adjustment proce-dure

Figure 11: Commissioning and Service Field (CSF)

! Warning !The actuator range is notpreset in factory!

10.1.2 Initial Situation- Electronics connected to power supply and actuator- Write-protect switch (1) set to “OFF” position- Electronics in operating mode “MAN” (no signal on DI 1)- No fault (if a fault occurs, both LEDs flash alternately at 4 Hz)

10.1.3 Setup Procedure- Undo the screws of the CSF - Swing the cover to the side

(r0002rxa)

12

10.1.3.1 “Adjustment” Mode- Set electronics to “Adjustment” mode by pressing push buttons (3) and (5) simulta-

neously for approx. 5 seconds, until both LEDs (2 + 9) are flashing synchronously atapprox. 4Hz.

10.1.3.2 Defining First Position (0% or 100%) (Higher precision in 2nd position)

- Move to desired position by pressing push button (3) or (5).- To accept the position, press push button (10) or (11); the associated LED flashes at

approx. 1Hz when value is correctly accepted, the other continues to flash at approx.4Hz

10.1.3.3 Defining Second Position (0% or 100%)- Move to second position by pressing push button (3) or (5).- To accept the position, press push button (10) or (11); both LEDs (2) and (9) are

flashing at approx. 1Hz when value is accepted correctly.

10.1.3.4 Saving the Settings- The settings are accepted by simultaneously pressing the push buttons (10 + 11);

the LEDs (2 + 9) extinguish after a short time, and the adjustment procedure is com-pleted.

- If the selected range is too small for the actuator, both LEDs will flash again at 4Hz,and the adjustment procedure has to be repeated with a larger value (min. position-ing travel).(See positioning travel specification on actuator ID label)

10.1.3.5 Correction after Setup- If the setting is to be corrected after accepting the first value, first press the Reset

button (4) and then repeat the setting.- If the correction is to be done after saving the settings, the entire adjustment proce-

dure must be repeated.

10.2 Adjustment Using the Configuration ProgramContext-sensitive help information is available in the configuration program at all times.For basic handling and installation instructions refer to the associated manual, number41/68-001.

! Warning !A conductive ground con-nection is established be-tween the PC and theCONTRAC electronicswith the RS 232 commu-nication cable. If the PC isgrounded, this may causea ground loop in the in-stallation.

10.3 Indication at CSFFunction Indication

AdjustmentChange-over to adjustment mode:Press and hold both drive switches for approx. 5 seconds

Both LEDs flash synchronously at approx 4Hz after time has expired.

Moving to an end positionUse respective drive button on CSF

Both LEDs continue to flash at 4Hz while driving.

Saving the first end positionPress button 0% or 100%

The associated LED flashes at approx. 1Hz, the other continues at 4Hz.

Saving the second end positionPress button 0% or 100%

The associated LED flashes at approx. 1Hz synchronously to the first one.

Terminate adjustmentPress 0% and 100% buttons simulta-neously

Both LEDs are briefly lit together and then extinguish.

OperationNormal operation: MAN / AUT LED offDriving with button on CSFPriority over control system

LED off

Fault (both LEDs flash alternately at 4Hz)Reset:Resets fault indications

If no other fault conditions exist, both LEDs extinguish.

Reset if operating range is exceeded;press and hold both drive button for 5 sec-onds, then press Reset button

After approx. 5 seconds the flash rhythm is briefly interrupted. After “Reset” the electronics switch to adjustment mode.

Table 4:

13

11. MaintenanceContrac actuators have a robust construction. As a result, they are highly reliable andrequire only little maintenance. The maintenance intervals depend upon the effectiveload and are therefore not specified here.The built-in microprocessor evaluates the actual load factors (e.g. torques, tempera-tures, etc.) and derives the remaining operating time until the next routine mainte-nance is required. Use the configuration program for viewing this information.

11.1 Motor and GearsAll maintenance work must be carried out by qualified specialists who have beentrained for this task. As a rule, perform the following routine maintenance works: - Check the shafts and gears.- Check the motor pinion gear and the respective mating gear.- Replace the motor’s rotary shaft seal and ball bearings.- Check the position sensor.- Change the oil; then make a visual check and check for proper operation.

11.2 Adjusting the Brake! Warning !

The actuator setting may be changed accidentally by the repelling power of the valve when the brake is released!

In automatic mode the brake is permanently released. Therefore, it is not exposed to wear and does not require any re-adjustment.

14

11.3 Replacing the Position Sensor

11.3.1 Dismounting- Disconnect the ribbon cable from the PCB - Undo the two fastening screws (1) of the position sensor and pull the sensor out

of the gears.

11.3.2 MountingThe toothed gear pair of the position sensor is held in place by a tension spring (3),to ensure sufficient free motion when the direction of rotation is reversed.

- Set the stop pin to the center position, as seen in Figure 15. - Align the sensor and its gears with the actuator; set the first toothed gear in

11:00 o’clock position (see Figure 16) onto the drive shaft gear (4). - Slightly move the sensor back and forth to pre-tension the toothed gears with the

difference “z“ until the second toothed gear snaps in. - Fasten the screws (1) tightly.- Connect the plug (5) of the ribbon cable to the PCB.

Figure 14: Connecting the ribbon cable plug to the PCB

After mounting is completed readjust the actuator range as described in section 10of this manual.

Figure 12: Position sensor SP 1 Figure 13: Mounting position of SP 1

Z

1

2

1

3

(r00329x1) 1

4

1

(r00335x1)

5

(r00336x1)

15

12. TroubleshootingThis section only describes how to handle hardware errors. Refer to the configurationprogram’s online help for errors related to the software.

12.1Electrical Test Values

Figure 15: Motor block diagram

Error Possible reason Measures to be taken

Valve cannot be moved by actuatorMalfunction of actuator or valve (e.g. cable gland fastened too tightly)

Disconnect the actuator from the valve. If the actuator is working properly then, the valve is likely to be defec-tive. Otherwise, the actuator seems to be the error source.

Actuator does not react

No communicationSet up communication using the configuration program

Motor / brake is defectiveCheck the winding resistances of the motor and brake.

Digital inputs of electronics are not connected

Connect

Brake does not release (no audible “click“ noise)

Check the air gap (should be around 0.25 mm) and the electrical connec-tion of the brake.Check the winding resistance of the brake coil.

Actuator does not work in automatic mode, although “AUT“ has been sel-ected in the configuration program

Digital input 1 (DI 1) has not been connected.

Connect DI 1.

LEDs on the commissioning and service field are flashing simultane-ously

Actuator has not been adjusted pro-perly

Adjust the actuator.

Table 5:

Winding resistance ± 5% at 20° C (motor) L1 (blue) - L2 (black):3,4 ΩL1 (blue) - L3 (violet):3,4 Ω

Winding resistance ± 5% at 20° C (brake) 50 Ω

Table 6:

L1 L2

L3 (r00334x1)

Subject to technical changes.

This technical documentation is protected by copyright law. Do not translate, copy or distribute in any way - even in a modified form or as

an excerpt - without the prior written permission of the right-holder. Also, reprints, photomechanical or electronical reproduction or

storage of data in data processing systems or data networks must be authorized by the right-holder. Any infringement of the copyright

law will be prosecuted

ABB Automation ProductsSchillerstraße 72D-32425 MindenPhone: +49 (571) 830 - 0Fax.: +49 (571) 830 - 1860http://www.abb.de/automation

Subject to technical changes.Printed in the Fed. Rep. of Germany

42/68-151 EN 03. 2001

13. Your notes

RADIANT ENGINEERS

INSTALLATION, OPERATING AND MAINTENANCE MANUAL Radiant shell & Tube Heat Exchangers are custom engineered for specific operating conditions. Their successful performance and long life can be still enhanced by careful installation and periodic inspection.

INSTALLATION PLANNING 1. On removable bundle heat exchanger, provide sufficient clearance at the end to permit the removal of the tube bundle from the shell. On the floating head type exchangers, provide space to permit removal of shell cover and floating head cover. 2. On fixed tube bundle heat exchangers, provide sufficient clearance at one end to permit the removal and replacement of tubes and at the both ends provide sufficient clearance to permit rolling of tubes into the tube sheet. 3. For U-tube heat exchangers, provide sufficient clearance at the stationery head end to permit withdrawal of tube bundle, or at the other end to permit the withdrawal of the shell. 4. Adequate foundations for mounting the heat exchanger should be provided so that it will not settle and cause piping strains on the exchanger. Foundation bolts should be set to allow for setting inaccuracies. In concrete footings pipe sleeves at least one size larger than bolt diameter slipped over the bolt and cast in place are best for this purpose as they allow the bolt centers to be adjusted after the foundation has set. 5. Provide valves and bypasses in the piping system so that both shell side and tube side can be bypassed to permit isolation of exchanger for cleaning, inspection and repairs. 6. Make drain connection in such a fashion that is should be correctly determined that the exchanger has been thoroughly drained. 7. Install liquid level controls, relief valves, gauge glasses or liquid level alarms in all vapor or gas spaces to indicate any failure occurring in the condensate drain system and prevent flooding of the heat exchanger. 8. Surge drum can be installed upstream from the heat exchanger to guard against pulsation of fluids caused by pumps, compressors or other equipments.

MAINTENANCE 1. Clean exchangers subject to fouling (scale, sludge deposits etc) periodically, depending on the specific working conditions. A light sludge or scale coating on either side of tube greatly decreases its effectiveness. A marked increase in pressure drop and/or reduction in performance usually indicates cleaning is necessary. Since the difficulty of cleaning increases rapidly as the scale thickens or deposits increase, the intervals between cleanings should not be excessive. 2. Neglecting to keep tubes clean may result in random tube plugging. Consequent overheating or cooling of the plugged tubes, as compared to surrounding tubes, will cause physical damage and leaking tubes due to differential thermal expansion of the metals. 3. To clean or inspect the inside of the tubes, remove only the necessary tube side channel covers or bonnets depending on type of exchanger construction. 4. If the heat exchanger is equipped with sacrificial anodes or plates, replace these as required. 5. To clean or inspect the outside of the tubes, it may be necessary to remove the tube bundle. 6. When removing tube bundles from heat exchangers for inspection or cleaning, exercise care to see that they are not damaged by improper handling. The weight of the tube bundle should not be supported on individual tubes but should be carried by the tube sheets, support or baffle plates or on blocks contoured to the periphery of the tube bundles with hooks, chains or other tools which might damage tubes. After removal, move tube bundles on cradles or skids. To withdraw tube bundles, pass rods through two or more of the tubes and take the load on the floating tube sheet. Rods should be threaded at both ends, with the ends passing through a steel bearing plate and tube sheet. Insert a soft wood filler board between the bearing plate and tube sheet face to prevent damage to the tube ends. Screw steel eye lifting. As an alternate to the rods, thread a steel cable through one tube and return through another tube. A hardwood spreader block must be inserted between the cable and each tube sheet to prevent damage to the bundle ends. 7. Lift tube bundles horizontally by means of a cradle formed by bending a light-gauge plate or plates into a U-shape. Make attachments in the legs of the U for lifting. 8. Do not drag bundles, since baffles or support plates may become easily bent. Avoid any damage to baffles so that the heat exchanger will function properly.

9. Methods of cleaning: Circulating hot wash oil or light distillate through tube side or shell side. This will usually effectively remove sludge or similar soft deposits. Soft salt deposits may be washed out by circulating hot fresh water. Some commercial cleaning compounds may be effectively used in removing more stubborn deposits. If the scale is hard and the above methods are not effective, use a mechanical cleaning means. Neither the inside not the outside of the tube should be hammered with a metallic tool. Take extra care when suing scraper, they should not damage tubes. 10. Do not attempt to clean tubes by blowing, steam through individual tubes. This overheats the individual tube and result in severe expansion strains and leaking tube to tube sheet joints. 11. To locate rupture or corroded tubes or leaking joints between tubes tube sheets, remove tube side channel covers or bonnets. Pressurize the shell side of the exchanger with a liquid, preferably water. Observe tube joints and tube ends for indication of test fluid leak. 12. To tighten the leaking joint, use a suitable roller tube expander. Do not roll tube beyond back face of the tube sheet. Maximum rolling depth should be tube sheet thickness minus 1/8”. Do not reroll tubes which are not leaking. 13. When a heat exchanger is dismantled, new gaskets should be used in reassembly. 14. Use of new bolting in conformance with dimensions and ASTM specifications of the original design is recommended where frequent dismantling is encountered.

OPERATION 1. be sure entire system is clean before starting operation to prevent plugging of tubes or shell side passages. The use of strainers or setting tanks in pipelines leading to the heat exchanger is recommended. 2. Open vent connection before starting flow through the exchanger. 3. The first fluid admitted is that whose temperature most nearly approximates the ambient temperature of the unit. The heat exchanger should never be shocked by the sudden admission of extremely hot or cold fluids; repeated stresses are set up by such a procedure results in metal fatigue.

Thermal and physical shocks should be avoided whenever possible. For fixed tube sheet exchangers fluids must be introduced in a manner to minimize differential expansion between the shell and tubes. 4. Start operating conditions gradually after the system is completely filled with the operating fluids and all air has been vented, close all manual vent connections. 5. Retighten bolting on all gasketed or packed joints after the heat exchanger has reached operating temperatures to prevent leaks and gasket failures. 6. Sufficient circulation of the cold medium should be maintained at all times to prevent overheating, which could result in the depositing of scale, coke or sludge.