VOITH hydraulic coupling.pdf

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Turbo Couplings

with Constant Fill

3626-011000 en

ATTENTION!

Please be sure to read this manual prior to installation and commis-sioning and keep it for further use!

Serial No. 1) Coupling type Year of manufacture Mass (weight) kg Power transmission kW Input speed rpm

Filling (mineral oil) dm3 (litre)

Response temperature of

fusible plugs °C

Type of connecting coupling

Sound pressure level dB(A)

Position

_G

horizontal

G

vertical

Drive via

_G

_{outer wheel}

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3626-011000 en. n sta n t F ill. G, C rai ls hei m. in te d in G e rm a n y.

1 Manufacturer’s Declaration as

defined by EU Directive

89/392/EWG, Annex II B for

Machines not ready for use

We herewith declare that the

machine denominated: Turbo Coupling with constant fill

Machine type: See cover sheet

Machine No. (Serial No.): See cover sheet

is intended for installation in a machine or to be assembled with a machine and commissioning is not allowed until it has been determined after installation/assembly that the complete machine complies with the currently applicable edition of the EU Directive.

Relevant EU Directives: EU Directive 89/392/EWG in its currently

applicable version.

Harmonized standards applied, particularly

DIN EN 292 T1/2, DIN EN 349

Each modification of the parts supplied, required by the customer, invalidates the declaration.

Date/manufacturer’s signature: 2002-08-01 /

Particulars with regard to the Undersigned: Dr.-Ing. R. Finzel Product Group Manager Startup Components

Voith Turbo GmbH & Co. KG Startup Components P.O. Box 1555 74555 Crailsheim GERMANY Phone: (07951) 32-0 Fax: (07951) 32-480 E-mail: [email protected] www: www.startup-components.com

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2 Preface

2.1 General

information

This manual will support you in using this turbo coupling in a safe, proper and economical way. If you observe the information contained in this manual, you will

– increase the reliability and lifetime of coupling and installation, – avoid any risks,

– reduce repairs and downtimes.

This manual must

– always be available at the machine site,

– be read and used by every person who works on the coupling. The coupling is manufactured to the latest design standards and approved safety regulations. Nevertheless, the user’s or third parties life may be endangered or the machine or other material assets impaired in case of improper handling or use.

Spare parts must comply with the requirements determined by Voith. This is guaranteed in case of original spare parts, as these are subject to regular quality control according to DIN ISO 9001 / EN 29001.

Spare parts from other suppliers may, under circumstances, change the characteristics of the unit and lead to substantial defects, for which Voith cannot assume responsibility.

For repair, only use appropriate workshop equipment. Professional maintenance or repair can only be guaranteed by the manufacturer.

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This manual has been issued with utmost care. However, in case you should need any further information, please contact:

Voith Turbo GmbH & Co. KG

This manual is protected by copyright.

Voith Turbo reserves the right for modifications.

2.2 Proper

use

– The constant fill coupling is provided to transmit the torque from the drive motor to the driven machine.

– The power the coupling is allowed to transmit during steady operation at a specific input speed and a specific coupling fill (operating fluid and filling) is entered on the cover sheet of this manual. Use for another purpose, e.g. for higher powers, higher speeds, other operating fluids or for operating conditions not agreed, is not being considered as proper use.

– Proper use also includes observing this installation and operating manual and complying with the inspection and maintenance instructions.

– The manufacturer is not liable for damages resulting from improper use. The risk is to be borne solely by the user.

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3 Safety

3.1 Notes and symbols

We classify hazards in various stages. The table below gives you a survey on the allocation of symbols, hazard classes and signal words relating to the hazard and (possible) consequences.

Damage / harm to...

Signal word Definition Consequences Symbol

Persons DANGER! imminent

danger fatal or mostserious injuries

(crippling)

Persons WARNING! dangerous

situation possible

fatal or most serious injuries possible

Persons CAUTION! less

dangerous situation

slight or minor injuries possible

Property ATTENTION! harmful

situation possible damage possible to – the product – its environment – Note!

Information! applicationhints and

other useful information

efficient in operation

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3.2 General information as to dangerous situations

For all work performed on the turbo coupling, please observe the local regulations for prevention of accidents!

DANGER!

– Working on the turbo coupling:

For all work carried out on the turbo coupling ensure that both, drive motor and driven machine have stopped running and startup is absolutely impossible!

Start your work only after the coupling has cooled down below 40°C, otherwise there is a risk of burns!

– Temperature rise in the turbo coupling:

The coupling temperature rises during operation.

Please provide a guard for protection against contact with the coupling! However, ventilation of coupling must not be impaired. Never use fluids to cool down the coupling!

– Rotating parts:

Rotating parts, for example, the turbo coupling itself and exposed shaft parts need to be protected against contact by a guard! However, ventilation of coupling must not be impaired.

Never operate the coupling without these guards!

– Sprayed-off operating fluid:

In the event of thermal overload of the turbo coupling, the fusible plugs respond. Operating fluid is discharged through these fusible plugs.

Please ensure that the sprayed off operating fluid cannot get in contact with persons! Danger of burning!

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3.3 Important information as to operation

ATTENTION!

– Power transmission:

The cover sheet of this operating manual shows the possible power to be transmitted at a specific input speed and a specific coupling fill (operating fluid and fill). These values describe a permissible working point for steady operation of coupling.

Voith Turbo’s approval is required for steady operation of coupling at a different working point!

– Operating fluid:

Use only the operating fluid mentioned on the cover sheet of this operating manual! Operate the turbo coupling only with the operating fluid fill shown on the cover sheet of this operating manual.

A too low fill would cause thermal overload of coupling and, in case of an overfill, the internal pressure could damage the coupling.

– Temperature rise during startup:

During startup, the temperature in the turbo coupling rises more than during steady operation due to a higher slip. Observe that the intervals between starts are sufficient to avoid thermal overload!

– Starting characteristic of turbo couplings with delay chamber:

During startup, the operating fluid is delivered from the delay chamber into the turbo coupling working chamber. On standstill, the operating fluid flows back into the delay chamber. Observe that the intervals (a few minutes!) between starts are sufficient to obtain a correct starting characteristic!

– Coupling temperature:

During steady operation, the coupling temperature must not exceed 85°C! Overheating may damage the coupling!

Please consult Voith Turbo, if the turbo coupling should be used for ambient temperatures below -20°C!

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3626-011000 en. n sta n t F ill. G, C rai ls hei m. in te d in G e rm a n y. – Fusible plugs:

The fusible plugs protect the turbo coupling against damage due to thermal overload. Switch off the drive motor immediately on response of a fusible plug!

Use only original fusible plugs with the response temperature indicated on the cover sheet of this operating manual!

– Sprayed-off and discharged operating fluid:

The fusible plugs respond in the event of thermal overload of turbo coupling. The operating fluid is discharged through these fusible plugs.

Please provide a catch pan of sufficient size, if required!

3.4 Staff

qualification

The staff in charge of any work to be done on the coupling must

– be reliable,

– have the legal minimum age,

– be trained and instructed with regard to the intended work.

3.5 Product

observation

We are under legal obligation to observe our products, also after shipment. Please therefore inform us about anything that might be of interest to us. For example:

– changed operating data – experience gained with the unit

– recurring problems

– problems experienced with this installation and operating manual.

à You will find our

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4 Function,

Types

4.1 Function

Fig. 1

The Voith turbo coupling is a hydrodynamic coupling working to the Föttinger principle. Its main components consist of two bladed wheels – the pump impeller and turbine wheel – enclosed by a shell. Both wheels are provided with bearings relative to each other. The power is transmitted virtually without wear, there is no mechanical contact between the power-transmitting parts. A constant amount of operating fluid is in the coupling.

The mechanical energy provided by the drive motor is converted to kinetic energy of the operating fluid in the connected pump impeller. In the turbine wheel this kinetic energy is converted back to mechanical energy.

Three conditions are to be considered with regard to the coupling function:

Fig. 2

– Standstill:

The total operating fluid is resting statically in the coupling.

shell bladed wheels

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3626-011000 en. n sta n t F ill. G, C rai ls hei m. in te d in G e rm a n y. Fig. 3 – Starting condition:

The pump impeller accelerates the operating fluid with increasing motor speed causing a circulating flow in the working chamber. The complete blade chamber of turbine wheel is flooded, starting to move as a result of the kinetic energy of fluid flow. The coupling characteristic deter-mines the torque curve during startup.

Fig. 4

– Nominal operation:

During nominal operation only the torque required by the driven machine is transmitted. The low speed difference between pump impeller and turbine wheel (rated slip) results in a steady flow condition in the coupling.

4.2 Type

designation

For hydrodynamic couplings with constant fill the type designation is determined as follows:

1 2 3 4 5 6 7 8 9 10 11

Example: 750 T VVS01D

750 T VV S 01 D

à You will find the type

designation of your turbo coupling on the cover sheet of this

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1 Coupling size (profile diameter in mm)

possible sizes: 154, 206, 274, 366, 422, 487, 562, 650,

750, 866, 1000, 1150

2 Number of hydrodynamic circuits

T: single-circuit coupling

DT: double-circuit coupling

3 Material

"no code letter": Silumin

U: ferrous product

4 Delay chamber

"no code letter": without delay chamber

V: with delay chamber

VV: with enlarged delay chamber

5 Draining of delay chamber

"no code letter": time-dependent draining without

dynamic refill

F: with centrifugal valves (standard type

open on standstill)

Y: with dynamic refill

6 Shell

"no code letter": standard design

S: designed as annular chamber

7 Turbo coupling connection

"no code letter": designed for flexible connecting

couplings mounted on the outer wheel side

N: designed for primary coupling flange and

flexible connecting coupling mounted on the coupling shaft

8 Design status

"old": A, B, C, E, G, H, J

"new": 01, 02, 03, 04, 05, 06, 07, 08, 09, 10, …

9 Throttle plate

"no code letter": without throttle plate

D: with throttle plate

10 Design

"no code letter": standard design

-X: special design

-Z: special hydrodynamic design

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4.3 Design

examples

4.3.1 Connecting coupling on the output side

Type T (basic type):

Fig. 5 Type T V: Fig. 6 Type T VV: Fig. 7 Type T VVS: Fig. 8 Type DT : Type DT V:

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4.3.2 Connecting coupling on the input side

Type T N (basic type):

Fig. 11 Type T VN: Fig. 12 Type T VVN: Fig. 13 Type T VVSN: Design 1 __ _ __ _ __ Design 2 Design 1 __ _ __ _ __ Design 2

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5 Tightening

Torques

Fig. 15 ATTENTION!

Oil the screws slightly before inserting them!

5.1 Fixing

bolts

The tightening torque applicable to fixing bolt (item 0050) depends on its dimension of thread:

Thread: M8 M10 M12 M16 M20 M24 M30 M36 M42

Tightening torque

in Nm: 23 46 80 195 380 660 1350 2350 3750

Tightening torques apply to screws with property class 8.8 or higher (to DIN EN 20898-1 / ISO 898-1) and of relevant shaft journal material.

sight glass, item 0396 fixing bolt, item 0050 filler plug, item 0390 fastening screw, item 0850 fastening screw, item 1830 fusible plug, item 0395/0260 nozzle screw, item 0455/0456

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5.2 Fusible plugs, filler plugs, blind screws and

sight glasses

Tightening torque in Nm (Dimension of thread) Coupling size Fusible plug,

item 0395/0260 Filler plug, item 0390 Blind screw, item 0394/0265 Sight glass, item 0396 154: 8 (M8) 13 (M10) 8 (M8) – – 206: 13 (M10) 20 (M12x1,5) 13 (M10) – – 274: 13 (M10) 30 (M14x1,5) 13 (M10) – – 366 to 650: 50 (M18x1,5) 80 (M24x1,5) 50 (M18x1,5) 50 (M18x1,5) 750 to 1150: 144 (M24x1,5) 235 (M36x1,5) 144 (M24x1,5) 144 (M24x1,5)

5.3 Fastening and nozzle screws

Tightening torque in Nm (Dimension of thread) Coupling size Fastening screw 1), item 1830/0780 Fastening screw 1), item 0850 Nozzle screw, item 0455/0456 154 9 (M6) – – – – 206 23 (M8) – – – – 274 62 (M12) – – – – 366 74 (M12) 23 (M8) 48 (M16x1,5) 422 62 (M12) 23 (M8) 48 (M16x1,5) 487 74 (M12) 23 (M8) 48 (M16x1,5) 562 62 (M12) 46 (M10) 48 (M16x1,5) 650 135 (M16) 46 (M10) 48 (M16x1,5) 750 135 (M16) 74 (M12) 48 (M16x1,5) 866, 1000 250 (M20) 23 (M8) – – 1150 580 (M27) 23 (M8) – –

1) _{Screws with property class 8.8 or higher (to DIN EN 20898-1 / ISO 898-1) are}

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6 Installation of Basic Coupling

Type T

DANGER!

Please observe, in particular, section 3 (Safety) when working on the turbo coupling!

– Outer wheel drive:

The coupling is mounted on the driven machine shaft and then, via a flexible connecting coupling, coupled with the drive motor.

– Inner wheel drive (special case):

The coupling is mounted on the drive motor shaft and then, via a flexible connecting coupling, coupled with the driven machine.

6.1 As delivered condition

– The turbo coupling is delivered complete with mounted connecting coupling.

– The turbo coupling is without fill. Any operating fluid included in the scope of supply is delivered in a separate container.

– Fixing bolt, holding disk and other accessories are supplied as loose parts.

– One set of fusible plugs is supplied as spares.

6.2 Preparation

n Check the length of fixing bolt, if the length of shaft journal, on which the

coupling is mounted, changed or was not indicated to Voith Turbo.

n Check radial runout of shaft journals of drive motor and driven machine.

n Clean fitting surfaces on shaft journals and hubs using emery cloth.

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n Apply a thin lubricant film to the shaft journals.

Note!

Please use a lubricant with the following characteristics: – operating temperature range: -20°C…+180°C, – water and wash-out resistant,

– protection against fretting corrosion and corrosion. – Proposed lubricants:

Supplier Designation

Dow Corning Molykote D

Molykote G-Rapid plus Molykote TP 42

Fuchs gleitmo 815

gleitmo 100 S

Liqui Moly LM 48

Optimol PASTE WHITE T

PASTE MP 3

n Insert the keys.

ATTENTION!

– Keys should be provided with a sufficient back clearance and

run smoothly in the keyways.

– Observe that the balancing method is the same for shaft and

hub. Our parts are marked to DIN ISO 8821 / ISO 8821: H: Half key agreement

F: Full key agreement

– When using a shaft-hub connection with one (1) key and

balancing to half key agreement, with the key being longer than the hub, reduce or shorten the key accordingly to avoid unbalance.

n Prepare suitable tools and lifting appliances; observe the turbo coupling

weight!

Note!

The cover sheet indicates the turbo coupling weight. The weight is also stamped on the outer diameter of coupling flange, if it exceeds 100kg.

WARNING!

Damaged slings (chains, ropes etc.) or those with insufficient carrying capacity may break under load, with the consequence of most serious or even fatal injuries!

Check the lifting appliances and slings for

– sufficient carrying capacity, – sound condition.

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6.3 Mounting

Note!

We recommend to use the mounting and removal devices available at Voith Turbo as accessory equipment for couplings from size 274.

ATTENTION!

The use of unsuitable working means and methods may cause damage to property.

When mounting the coupling prevent the use of

– pressure plates, – hammers, – welding torches.

Fig. 16

n Fix the coupling to a suitable

lifting appliance.

n Careful warming-up of the

coup-ling hub (to approx. 80°C) facili-tates coupling mounting.

Fig. 17

n Position the coupling at the

relevant shaft journal.

n Insert the holding disk supplied.

Note!

– For couplings up to size 274 remove the circlip prior to inserting the holding disk and then reinsert it.

– For couplings from size 366 the holding disk is secured by means of a roll pin against rotation.

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ng Manual 3626-011000 en. lin g s with Co n sta n t F ill. Gm b H & Co . KG, Cr a ilsh e im . v. 7 . K&E Pr in te d in G e rm a n y. ficati on due to opment. ATTENTION!

Depending on the design of shaft, the coupling hub must be in contact with the shaft collar or the end face of shaft journal.

Couplings size 154 and 206: Couplings size 274 to 1150:

n Insert a suitable and slightly oiled

threaded rod in the shaft of the relevant machine.

n Mount the coupling on the shaft

journal using a nut and a spacer tube.

n Oil the mounting spindle slightly.

n Mount the coupling on the shaft

journal using the mounting spindle, the spacer tube and the holding disk.

Fig. 18

n Check the proper seat of holding disk. Tighten the fixing bolt using the

specified tightening torque.

ATTENTION!

The connecting coupling hub must either be in contact with the relevant shaft collar or secured in axial direction using a set screw. It is perhaps necessary to provide a spacer ring between hub and shaft collar.

n Mount the flexible connecting coupling hub on the relevant shaft journal.

Careful warming up of the connecting coupling hub (to approx. 80°C) facilitates mounting.

n Tighten the set screw in the connecting coupling hub, if necessary.

n Move the connecting coupling hub with the relevant machine next to the

turbo coupling. Observe proper seat of flexible elements in the connecting coupling!

n Fix the machine slightly.

n Align the drive.

à Mounting devices: section 6.4, page 22 à Tightening torque: section 5.1, page 16 à Section 8, page 25 holding disk fixing bolt roll pin

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6.4 Mounting

devices

The following mounting devices are available at Voith Turbo for turbo couplings of basic type T:

Fig. 19

A: mounting spindle

L1: total length

L2: length of spacer tube

n: dimension of mounting

spindle thread

SW1: wrench size across flats

B: original holding disk

C: coupling hub Coupling size L1 L2 n SW1 274 520 135 M10 M12 M16 M20 17 19 24 30 366, 422 520 190 M10 M12 M16 M20 17 19 24 30 487, 562, 650, 750 780 245 M16 M20 M24 M30 24 30 36 46 866, 1000, 1150 1150 480 M20 M24 M30 M36 M42 30 36 46 55 65 A C n SW1 B L1 L2

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7 Installation of Basic Coupling

Type TN

DANGER!

ATTENTION!

The use of unsuitable working means or methods may cause damage to property.

When mounting the coupling prevent the use of

– pressure plates, – hammers, – welding torches.

This application is an outer wheel drive. Mount the primary coupling flange on the motor shaft. Then connect the turbo coupling with the primary coupling flange and couple it with the driven machine shaft through a flexible connecting coupling.

7.1 As delivered condition

– The turbo coupling is delivered complete with mounted primary coupling flange.

– The turbo coupling is without filling. Any operating fluid included in the scope of supply is supplied in a separate container.

– Other accessories are supplied as loose parts. – A set of fusible plugs is supplied as spares.

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7.2 How to mount the coupling

n Make the necessary preparations according to section 6.2.

Fig. 20

n Mount the primary coupling shaft on the motor shaft securing it with the

relevant set screw in axial direction. Careful warming-up of primary coupling flange (to approx. 80°C) facilitates mounting.

n Mount the connecting coupling hub on the coupling shaft securing it with

the relevant set screw in axial direction.

n Position the turbo coupling in front of the primary coupling flange.

n In the event of complete balancing, balancing marks (e.g. 0/0, 1/1, 2/2

etc.) are provided at the outer periphery of turbo coupling and the primary coupling flange. Observe that these balancing marks match!

n Push the external spigot of turbo coupling into the internal spigot of

primary coupling flange.

n Fix the turbo coupling to the primary coupling flange using the relevant

screws (item 0780).

n Insert the flexible element in the connecting coupling hub.

WARNING!

Fix the slings (chains, ropes etc.) only to the drive motor! Fixing the slings to the coupling may cause damage.

n Move the mounted drive motor/turbo coupling unit next to the driven

machine and bolt the drive motor slightly.

n Align the drive.

à Page 18 à Tightening torque: section 5.3, page 17 à Section 8, page 25 fastening screw, item 0780 set screw set screw set screw primary coupling flange 1

primary coupling flange 2

connecting coupling

Design 1 __ _ __ _ __ Design 2

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8 Alignment

DANGER!

8.1 Flexible connecting couplings

– A flexible connecting coupling couples the turbo coupling with a shaft journal.

– After alignment, the positions of turbo coupling and shaft journal still vary. The flexible connecting coupling takes up these misalignments.

8.1.1 Connecting coupling on the input side

Connecting couplings available at Voith Turbo for turbo couplings of basic type T:

Flexible roller coupling type ERK:

Fig. 21

Flexible element coupling type EEK-E: Fig. 22 L L L DT | T

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Flexible element coupling type EEK-M:

Fig. 23

Flexible pad coupling type EPK:

Fig. 24

Flexible cam coupling type ENK-SX:

Fig. 25

Flexible cam coupling type ENK-SV:

Fig. 26

8.1.2 Connecting coupling on the output side

Connecting couplings available at Voith Turbo for turbo couplings of basic type TN:

Flexible cam coupling type Nor-Mex, model G:

L L

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8.2 Laid lengths and type allocations

turbo coupling / flexible connecting coupling

Laid lengths L for flexible connecting couplings, as shown in section 8.1: Laid lengths L in mm

Coupling-type ERK EEK-E EEK-M EPK ENK-SX ENK-SV Nor-Mex-G

154 T: 143 +1 - - - -154 DT: 165 +1 - - - -206 T: 183 +1 - - - -206 DT: 223 +1 - - - 110,5 ±1,5 56,5 ±1,5 -274 T: 255 +1 - - - 158,5 ±2 67 ±2 -274 DT: 295 +1 159 ±2 67 ±2 - 158,5 ±2 67 ±2 -366: - 159 ±2 67 ±2 - 158,5 ±2 67 ±2 176 ±1,0 422: - 173 ±2 72 ±2 102 ±1 173 ±2 72 ±2 198 ±1,5 487: - 190 ±2 88 ±2 106 ±1 190 ±2,5 87,5 ±2,5 221 ±1,5 562: - 221 ±2 103 ±2 116 ±1 221 ±2,5 102,5 ±2,5 267 ±2,0 650: - 274 ±2,5 126 ±2,5 152 ±1,5 271,5 ±2,5 125,5 ±2,5 310 ±2,5 750: - - - 163 ±1,5 276 ±2,5 - -866: - - - 189 ±1,5 287,5 ±2,5 - -1000: - - - 210 ±1,5 287,5 ±2,5 - -1150: - - - 210 ±1,5 - - -1150 DT: - - - 210 ±1,5 - - -ATTENTION!

To avoid any axial constraining forces, it is absolutely necessary to adhere to the laid lengths! Please observe, in particular, displacements due to temperature changes.

8.3 Alignment

tolerances

ATTENTION!

– Undue misalignments cause material damage.

– It is necessary to meet the values specified for radial and axial

runout at all operating conditions.

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3626-011000 en. n sta n t F ill. G, C rai ls hei m. in te d in G e rm a n y. Note!

The smaller the radial and angular displacement between turbo coupling and shaft journal the

– higher the lifetime and reliability of the unit, – the better is smooth running.

Maximum permissible alignment tolerances apply to:

– radial runout in the radial plane of flexible elements (maximum permissible radial deflection of dial gauge!)

– axial runout, measured over the largest connecting coupling diameter (maximum permissible axial deflection of dial gauge!).

Maximum permissible alignment tolerances for the radial and axial deflection of dial gauge when using the connecting couplings shown in

section 8.1:

Coupling size Speed range

in rpm

0…750 750…1200 1200…1800 1800…3600

154 to 487 0.6mm 0.4mm 0.3mm 0.2mm

562 to 1150 0.8mm 0.6mm 0.4mm 0.3mm

The values mentioned above describe the maximum permissible radial and

axial deflection of dial gauge!

ATTENTION!

Observe maximum permissible speed!

8.4 Alignment

Note!

For alignment support the motor feet using shims or foil sheets. It would be advantageous to use claws with adjusting screws on the foundation for lateral movement of the drive unit.

– Alignment methods and its accuracy:

Method Accuracy

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– Proposal for fitting dial gauges:

Fig. 28 Fig. 29

Fig. 30 Fig. 31

– How to proceed:

n Mount the turbo coupling.

n Align input and output shaft with each other.

n Fix input and output unit on the foundation.

n Check alignment after tightening all screws, correct alignment, if

necessary.

n Prepare an alignment certificate for the documentation.

à Section 6 and/or 7, page 18 and/or 23

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9 Operating

Fluids

ATTENTION!

– Unsuitable operating fluids may damage the turbo coupling

permanently!

– Consult Voith Turbo if you want to use an operating fluid not

mentioned (e.g. water, biologically degradable or fire-resistant operating fluid).

Operating fluids which may be used:

– Hydraulic oils HLP 32 to DIN 51524, Part 2 – Lubricating oil CLP 32 to DIN 51517, Part 3 – Steam turbine oils LTD 32 to DIN 51515, Part 1 – HD engine oils SAE 10 W

– ATF type A Suffix A (TASA) and type Dexron II, IID, IIE, III, MERCON M-891205 and M 921253

9.1 Requirements to be fulfilled by the operating fluid

– Viscosity class ... ISO VG 32 to DIN 51519

– Pourpoint ... the limit is 4°C below actual minimum ambient temperature or lower

– Starting viscosity ... less than 15000mm2s-1 (cSt)

– Flash point... greater than 180°C and at least 40°C above response temperature of fusible plugs

– Resistance to aging... aging-resistant refined product

– Compatibility with seals ... NBR (Nitril-Butadien caoutchouc) and FPM/FKM (fluor caoutchouc)

Advantageous additional qualities

– FE 8: D7,5 / 80-80... Abrasion of rolling elements < 30mg Abrasion of cage < 100mg

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9.2 Proposed operating fluids

Supplier Description Pourpoint

in °C

Flash point in °C

Class

Addinol Hydr. Oil HLP 32 -30 220 HLP

Oso 32 -30 205 HLP Agip Blasia 32 -29 215 CLP Aral BG 32 -27 200 HLP Aral Degol BG 32 -27 200 CLP Aseol Plus 16-110 -33 200 HLP

Autol Hydr. Oil HY-S 32 ISO -32 208 HLP Avia Fluid RSL 32 -27 214 HLP Avia Gear RSX 32 S -33 207 CLP Energol HLP 32 -30 216 HLP BP Energol HLP-HM 32 -30 216 HLP Hyspin AWH-M 32 -42 214 HLP Castrol Hyspin SP 32 -28 220 HLP CEPSA HIDROSIC HLP 32 -24 204 HLP CEPSA EP 125 -30 206 HLP DEA Pentran 32 -30 210 HLP Elfolna 32 -27 210 HLP Elf Elfolna DS 32 -32 225 HLP Esso Nuto H 32 -33 210 HLP Fina Hydran VT 32 -30 214 HLP Renolin B 10 -27 190 HLP Fuchs Renolin MR 10 -27 200 HLP Klüber Lamora HLP 32 -30 200 HLP Q8 Holst 32 -30 208 HLP Kuwait Petroleum _{Q8 Haydn 32} _-30 ₂₀₈ _HLP Mobil SHC 524 <-63 234 HLP Mobil DTE 24 -30 218 HLP Optimol Hydo MV 32 -38 209 HLP

Shell Tegula Oil 32 -33 210 HLP

Wiolan HS 32 -24 220 HLP

SRS

Salzbergen Wiolan HF 32 Turbofluid -27 200 HLP

Texaco Randol HD 32 -30 196 HLP

Total Azolla ZS 32 -21 220 HLP

Valvoline M5-C600 B -36 220 HLP

The above oil list is a recommendation and does not claim to be complete.

ATTENTION!

– The values mentioned for the pourpoint and flash point are

approximate values and data originating from the oil suppliers. These may vary and Voith Turbo will not accept any warranty claims! Country-specific production of basic oils may result in different pourpoint, fire point and flash point values.

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9.3 Proposed operating fluids for special requirements

Operating fluid for the use in the food industry

Manufacturer Description Pourpoint

in °C

Flashpoint in °C

Class

Klüber Summit HySyn FG 32 -45 >230 HLP

Note: The USDA H1-Registration meets the FDA Requirements.

Fire-resistant operating fluid

in °C

Class

Voith Turbo

GmbH & Co. KG HIFluid -33 305 HFD-U

Note: Voith-HIFluid is a fire-resistant fluid of the viscosity class ISO VG 46 and contains neither chlorinated hydrocarbons nor phosphorus acid ester. The density of the fluid is lower than the density of water.

Biodegradable operating fluid

in °C

Class

Voith Turbo

GmbH & Co. KG EPFluid -36 230 HEES

Note: Voith-EPFluid is a fast biodegradable fluid of the viscosity class ISO VG 46 to VDMA 24568. The water risk class is 1 and the density of the fluid is lower than the density of water.

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10 Fill, Filling Check and Draining

– The quantity and type of operating fluid used determine the turbo coupling behavior substantially.

– A too high fill level leads to a higher load on the drive motor during startup and in a higher stall torque.

– A too low fill level leads to a higher thermal load of coupling and a lower stall torque.

DANGER!

CAUTION!

– Operating fluids may cause irritations or inflammation when in

contact with skin and mucous membranes.

– Please wear protective glasses for all work to be done in

connection with the operating fluid!

– Should you get any operating fluid in your eyes, rinse them

immediately using a lot of water and consult a physician!

– After you finished your work, clean your hands carefully with soap.

ATTENTION!

– Observe the fill level mentioned on the cover sheet of this operating

manual.

– Do not overfill! This would lead to an unpermissibly high internal

pressure in the coupling, which may destroy the coupling.

– Impurities in the operating fluid cause an increased wear of the

coupling. Make sure that any containers, funnels, filling tubes etc., used for filling the coupling, are clean.

– Do not mix the different types of operating fluids.

– Use only the operating fluid mentioned on the cover sheet of this

operating manual.

– Ensure that original seal rings are used and that these are in sound

condition.

Note!

You will find tightening torques in section 5 from page 16, please observe

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10.1 Coupling

fill

– Turbo couplings are delivered without fill.

– The operating fluid included in the scope of supply is shipped in a separate container.

10.1.1 How to fill couplings installed in horizontal position

n Turn the coupling until one filler plug (item 0390) is on top; for couplings

of size 650 and 866 select the filler plug with the greatest distance to the next fusible plug.

n Unscrew the filler plug.

n Remove the top fusible plug (item 0395 or item 0260) for pressure

compensation.

n Fill in the specified operating fluid quantity through a fine screen (mesh

size ≤ 30µm) into the filler plug opening.

n Tighten the filler plug.

n If the coupling is provided with a sight glass (item 0396), tighten the

fusible plug.

Fig. 32

n Turn the coupling until the operating fluid is just visible at the sight glass

(if existing) or until the operating fluid can be seen at the opening of the (still) unscrewed fusible plug, but is not yet leaking out.

n Determine the number z of flange screws from the sight glass or fusible

plug to the vertical axis. The first screw is the one in counting direction,

after the intersection line through the sight glass or fusible plug and the

last screw is the one located before the vertical axis or just cutting it.

n For later level checks, record the number z of screws determined and

additionally mark the coupling or guard.

n If not yet done, tighten the fusible plug.

n After a test run (with guard!) check the coupling for leaks.

à You will find the fill

level (mineral oil)

provided on the cover

sheet of this operating

manual

à Fig. 15, page 16

à Operating Fluids Section 9, page 30

z =

_____

sight glass or fusible plug sight glass or fusible plug

vertical axis vertical axis counting direction counting direction direction of rotation 1 z z 3 3₂ 2 1 direction of rotation fill level

(35)

10.1.2 How to fill couplings installed in vertical position

Fig. 33

n Remove the two top screws (either two fusible plugs or two blind screws).

n Remove the screw plug.

n Fill in the specified operating fluid through a fine screen (mesh size

≤ 30µm) in to a screw opening. The other screw opening is provided for pressure compensation.

n Fix the level check device to the connection provided for this purpose.

n Provide the level mark at the coupling or guard for later level checks.

n Remove the level check device.

n Tighten slackened screws.

Tightening torque for the screw plug: 30 Nm (M14x1,5).

10.2 Level

check

10.2.1 Level check for couplings installed in horizontal position

Note!

– Turbo couplings from size 422 are equipped with a sight glass in the outer wheel; the position of sight glass is marked by an arrow.

– Turbo couplings of size 366 can optionally be equipped with a sight glass; the position of sight glass is marked by an arrow.

n If a sight glass is not available, turn the coupling until a fusible plug is on

top. Then remove this fusible plug.

n Turn the coupling until the operating fluid is just visible at the sight glass

or the operating fluid is not yet leaking out of the opening of unscrewed fusible plug.

à The level check

device is available as accessory at Voith

Turbo for couplings from size 366

à You will find the fill

level (mineral oil)

provided on the cover

sheet of this operating

manual

fusible plug/ blind screw

level mark

level check device

connection for the level check device screw plug

(36)

n Determine the number z of flange screws from the sight glass/fusible

plug up to the vertical axis; the first screws is the one in counting direction, after the intersection line through the sight glass or fusible plug, the last screw is the one located before the vertical axis or just cutting it.

n Compare the number of screws determined with the number of screws

determined during filling. Please observe also any mark additionally provided on the coupling or guard.

n Correct the fill level in case of variations!

n If a fusible plug has been unscrewed, retighten the same.

10.2.2 Level check for couplings installed in vertical position

Note!

– The level check of couplings from size 366 is checked using a level check device. This level check device is available at Voith Turbo as accessories.

– Couplings up to size 274 are to be drained for level check and then to be refilled.

n Unscrew a top screw (fusible plug or blind screw) for ventilation.

n Remove the screw plug.

n Fit the level check at the connection provided for this purpose.

n Compare the level with the marked provided during filling.

n In case of variations, correct the fill level accordingly!

n Remove the level check device.

n Tighten slackened screws.

Tightening torque for the screw plug: 30 Nm (M14x1,5).

10.3 Draining the coupling

ATTENTION!

Operating fluids disposed of improperly may cause most severe environmental damages! On disposal, please observe the applicable laws and the manufacturer’s or supplier’s instructions!

n Provide suitable containers to collect the operating fluid.

à Fig. 32, page 34 à Section 10.1.1, page 34 à Fig. 33, page 35 à Fig. 33, Section 10.1.2, page 35

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10.3.1 How to drain couplings without delay chamber installed in horizontal position

n Turn the coupling until one fusible plug is at the lowest point.

n Unscrew this fusible plug.

n For venting purposes, remove one filler or fusible plug opposite the

already unscrewed fusible plug.

n After draining the coupling, retighten the screws.

10.3.2 How to drain couplings with delay chamber installed in horizontal position

n Turn the coupling until one fusible plug is at the lowest point.

n Unscrew this fusible plug.

n For venting purposes, remove one filler or fusible plug opposite the

already unscrewed fusible plug.

n Wait until the coupling working chamber is drained.

Couplings size 366 to 866: Couplings size 274, 1000 and 1150:

n Remove nozzle screw (item

0455/0456).

n Turn the coupling until the nozzle

screw opening is at the lowest point.

n Wait until the delay chamber is

drained.

n Tighten the nozzle screw.

n Retighten fusible and filler plugs.

n Switch on drive motor for

approximately half a minute to one minute. The operating fluid in the delay chamber drains into the working chamber. Observe

the safety regulations!

n Unscrew the fusible plug again.

n Turn the coupling until the fusible plug opening is at the lowest point.

n After draining the coupling working chamber, retighten the screws.

10.3.3 How to drain couplings installed in vertical position

n For venting purposes, remove one blind screw or fusible plug on the top

side of coupling.

Up to coupling size 274: From coupling size 366:

n Unscrew one bottom blind

screw or fusible plug. n Remove the connection of levelcheck device.

n Retighten screws after draining the coupling. Tightening torque for the

connection: 80 Nm (M24x1,5).

Note!

On account of the design, complete draining is not possible when the coupling is installed!

(38)

11 Commissioning

DANGER!

Notes!

– The turbo coupling may be used for any direction of rotation.

– The direction of rotation of driven machine may be specified! The direction of rotation of motor must be in accordance with the specified direction of rotation of driven machine!

– If the motor is started with star/delta connection, switchover from star to delta connection should be effected after maximum 2…5s.

– In the event of a multi-motor drive you should determine the load of the different motors. Great differences in motor load may be balanced by an appropriate adjustment of the respective coupling fill levels. However,

prevent to exceed maximum permissible coupling fill level!

ATTENTION!

– Never operate the turbo coupling without operating fluid!

– On account of the type of bearings used for standard turbo

couplings of size 366, 422, 487, 562, 650, 750, 866 and 1150, at least one standstill is required within a period of 3 months.

couplings of size 154, 206, 274 and 1000, at least one standstill is required once a week.

n After installation and filling, put the coupling into operation, observe any

(39)

12 Maintenance

DANGER!

Maintenance schedule:

Schedule Maintenance work

in intervals of 500 operating hours, every 3 months, at the latest

inspect the unit for irregularities (à Section 12.2)

in intervals of 15000 operating hours

change or check the operating fluid (à Section 12.1)

on response of a fusible plug change all fusible plugs and the operating fluid (à Section 12.3)

if required clean (à Section 12.4)

12.1 Operating

fluid

n Change the operating fluid after 15000 operating hours or check it for

aging! Consult the operating fluid supplier as to the permissible values.

12.2 Flexible connecting coupling

Note!

Extremely rapid wear of flexible elements is perhaps a sign of improper alignment!

ATTENTION!

Realign the unit, if the coupled machines were displaced on replacement of flexible elements.

n Check the flexible elements of flexible connecting coupling regularly for

wear.

n Replace the worn flexible elements in sets.

à Section 9, page 30 Section 10, page 33

(40)

12.3 Fusible

plugs

– The fusible plugs protect the turbo coupling against damage due to thermal overload.

– When the response temperature is reached, the solder core of fusible plug melts and the operating fluid escapes.

Fusible plugs are identified by

– the response temperature engraved in °C, – a color coding:

Response temperature Color coding

110°C yellow 125°C (120°C) brown 140°C red 160°C green 180°C blue ATTENTION!

– Use original fusible plugs only with the response temperature

indicated on the cover sheet of this operating manual!

– Be sure not to replace any fusible plugs by blind screws!

– On response of a fusible plug replace all fusible plugs, change the

operating fluid.

Note!

A thermal monitoring system can prevent that operating fluid is sprayed off (à section 16, page 49). Thermal monitoring systems are available at Voith Turbo as accessories.

12.4 Outside

cleaning

ATTENTION!

– Please observe that the cleaning agent is compatible with the NBR

and FPM/FKM sealing materials used!

– Do not use a high-pressure cleaning apparatus!

n Clean the coupling with a grease solvent, if necessary.

à You will find the

response

temperature of your fusible plugs on the cover sheet of this

operating manual

à Tightening Torques Section 5.2, page 17

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12.5 Bearing

lubrication

The operating fluid is used for lubrication of turbo coupling bearings.

ATTENTION!

– On account of the type of bearing used for standard turbo

couplings size 366, 422, 487, 562, 650, 750, 866 and 1150, at least one standstill is required within a period of 3 months.

couplings size 154, 206, 274 and 1000, at least one standstill is required once a week.

Note!

– Couplings size 154, 206, 274, 366, 422, 487, 562, 650, 750 and 866 can

be provided with special bearings allowing continuous operation and are filled with a lifetime grease.

– The Coupling size 1000 can be provided with special bearings requiring only one standstill within a period of three months.

(42)

13 Coupling Disassembly

DANGER!

Note!

This section describes the disassembly of turbo couplings of basic type T. Couplings of basic type TN are disassembled in reverse order according to

section 7, page 23.

13.1 Preparation

n Prepare suitable tools and lifting appliances; observe the turbo coupling

weight!

Note!

The cover sheet indicates the turbo coupling weight. The weight is also stamped on the outer diameter of coupling flange, if it exceeds 100kg.

WARNING!

Damaged slings (ropes, chains etc.) or those with insufficient carrying capacity may break under load. This may cause most serious or even fatal injuries!

Check the lifting appliances and slings for

– sufficient carrying capacity, – sound condition.

(43)

13.2 Removal

Note!

We recommend to use the mounting and removal devices available as accessories at Voith Turbo for couplings from size 274.

Couplings size 154 and 206:

n Remove the fixing bolt.

n Remove the coupling by inserting a suitable and slightly oiled screw into

the internal thread of holding disk.

Fig. 34

Coupling size 274: Couplings size 366 to 1150:

n Remove circlip, fixing bolt and

holding disk.

n Put the threaded ring, supplied

together with the removal device, into the coupling hub.

n Secure the threaded ring using

the circlip.

n Apply a lubricant to the thread of

puller spindle.

n Insert the puller spindle in the

internal thread of threaded ring.

n Remove fixing bolt and holding

disk.

n Apply lubricant to the thread of

puller spindle.

n Insert the puller spindle in the

thread of coupling hub.

n Support the puller spindle by a substructure.

n Remove the coupling using the puller spindle.

à Removal devices: section 13.3 and 13.4 puller spindle

(44)

13.3 Mechanical removal devices

Removal devices available at Voith Turbo for turbo couplings of basic type T:

Fig. 35

A: puller spindle

L: total length

Q: dimension of thread of puller

spindle

SW: wrench size across flats

C: coupling hub Coupling sizes L Q SW 274 360 G ¾ 36 366 350 G 1 46 422, 487 460 G 1¼ 55 562, 650 650 G 1½ 60 750, 866, 1000, 1150 1000 G 2¼ 55 Note!

To facilitate removal, Voith Turbo has hydraulic removal devices available for couplings from size 422.

L A C Q SW à à à à Hydraulic removal devices: Section 13.4, page 45

VOITH hydraulic coupling.pdf

Turbo Couplings

with Constant Fill

3626-011000 en

G

G

G

Contents

1 Manufacturer’s Declaration as

defined by EU Directive

89/392/EWG, Annex II B for

Machines not ready for use

2 Preface

2.1 General

information

2.2 Proper

use

3 Safety

3.1

Notes and symbols

3.2

General information as to dangerous situations

3.3

Important information as to operation

3.4 Staff

qualification

3.5 Product

observation

4 Function,

Types

4.1 Function

4.2 Type

designation

4.3 Design

examples

5 Tightening

Torques

5.1 Fixing

bolts

5.2

Fusible plugs, filler plugs, blind screws and

sight glasses

5.3

Fastening and nozzle screws

6 Installation of Basic Coupling

Type T

6.1

As delivered condition

6.2 Preparation

6.3 Mounting

6.4 Mounting

devices

7 Installation of Basic Coupling

Type TN

7.1

As delivered condition

7.2

How to mount the coupling

8 Alignment

8.1

Flexible connecting couplings

8.2

Laid lengths and type allocations

turbo coupling / flexible connecting coupling

8.3 Alignment

tolerances

8.4 Alignment

9 Operating

Fluids

9.1

Requirements to be fulfilled by the operating fluid

9.2

Proposed operating fluids

9.3

Proposed operating fluids for special requirements

10 Fill, Filling Check and Draining

10.1 Coupling

fill

z =

_____

_G

_G