Voith Coupling [PDF]

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GE Energy Products – Europe OPERATION AND MAINTENANCE MANUAL COMPONENT AND SYSTEM LITERATURE ________________________________________________________________________

EQUIPMENT DEFINITION

GE DEVICE

: HM1

DESIGNATION

: TORQUE CONVERTER AND REVERSING GEAR

SUPPLIER

: VOITH

TYPE

: EL10ZFG

LITERATURE REFERENCE

:

3626-020618 EN

All rights reserved Copyright – Droits de reproduction réservés ________________________________________________________________________

OMML_0421_10_HM1_EN_A

Revision : A

Date : 03/2007

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Instruction Manual for VOITH Torque Converter

Type:

EL 10 ZFG

Serial No. : Code:

GE France

In case of any queries with regard to this unit we would ask you to always state the serial no.

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3626-020618 en

Instruction Manual for VOITH Torque Converter - Contents -

-2-

Instruction manual: Data sheet

3626-020618 en

Text

3626-017476 en

Parts list

3626-017391 de/en

Longitudinal view

4 153947 0

Cross section

4 154877 0

Control valve with one limit switch

4 153843 0

Installation electric rotary actuator

4 156897 0

Control diagram

3623-014636

Assembly plan

3600-030905

VOITH information sheets: Preservation

3625-006212

Operating fluids for VOITH Torque Converter

3625-006072

Adjustment description of the limit switch

3626-013514

Mounting aid Bush ( mounting aid )

3623-013151

Distance ring with flange ( mounting aid )

3623-013152

Holding disc ( mounting aid )

3623-013154

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Instruction Manual for VOITH Torque Converter - Contents -

-3-

Attaching parts (description):

Guide vane actuator VOITH - Order No: Type: SA10.1-G0-D-90-D400/50-6-9-10-11-21.4/0-22.1-KE-21-X with three phase motor 400 V / 50 Hz Operating Instructions

DO 01.05.001 GB / 1.00

Solenoid valve Voith - Order No. : Type: WL 4 BNZ 10 X P5 EK 3 K1 110 - S1 Electrical connection: 120 VDC ± 10 % Dimension sheet Description

3626-014390 de/en BV 2500.78 GB

Vent filter VOITH - Order No: Order - Nr.: 41 002 62 102 Instruction

VKD 6723.1 0887

Limit switch VOITH - Order No: Type: 3SE3 100-1B Instruction

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GWA 4NEB 330 0648-10a

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3626-020618 en

Instruction Manual for VOITH Torque Converter - Data Sheet -

Torque Converter:

EL10 ZFG

Code:

GE France W 48

-4-

Voith Order No: Serial No.: Sense of rotation viewed in direction of the power flow:

Input shaft CCW

Output shaft CCW

Guide vane adjustment from "closed" to "open":

approx.240 turns

see assembly plan

Torque Converter as gas turbine drive Rated power of converter:

P1 =1416 kW

Rated speed of converter:

n1 = 2950 RPM

Raising speed (Converter circuit must then be discharged)

n2 = 2100 RPM

Weight without oil filling:

approx.1075 kg

Foundation load:

see assembly plan

Oil supply to the torque converter:

oil supply system

Control valve 1, for filling and draining , with / without limit switch Guide vane actuator : Electric actuator ( technical data, please see sheet 3) Connecting coupling: Oil cooling:

Input side *

output side *

*

*) not VOITH-supply

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Instruction Manual for VOITH Torque Converter - Data Sheet -

-5-

Operating data for torque converter Working oil temperature in the flow to the torque converter

Nom. value

Working oil temperature in the flow from the torque converter

Nom. value (smaller) Alarm at Shutdown at

Lube oil temperature in the flow to the torque converter

Nom. value

approx. 60 °C

Lube oil temperature in the flow from the torque converter

Nom. value

approx. 80°C

Filling pressure (operating condition)

Nom. value Alarm

approx. 4.0 bar 2.1 bar

Control pressure (= pressure of oil supply system)

Nom. value

approx. 7.0 bar

Torque converter pressure (operating condition)

Nom. value up to Alarm (smaller than)

12.0 - 18.0 bar 10.0 bar

Lube oil and cooling oil pressure

Nom. value

approx.1.5 bar

Required working oil flowrate (operating condition) Required lube oil and cooling oil flowrate Turning speed (speed at which the pony motor is switched)

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approx. 60 °C

90 °C 110 °C 120 °C

approx. 16.0 l/sec approx. 0.6 l/sec from 100 to 400 rpm

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

-1-

CONTENTS Safety Information 1.

Design and Operation 1.1 Design 1.2 Operation - torque converter

2.

Oil Circuits 2.1 General 2.2 Working oil circuit - torque converter operation 2.3 Control oil circuit 2.4 Lube and cooling oil circuit

3.

Control Valve 3.1 Control 3.2 Adjustment

4.

Guide Vane Adjustment 4.1 General 4.2 Actuator

5.

Design and Delivery

6.

Installation 6.1 General information 6.2 Shaft misalignment due to operation, alignment accuracy 6.3 Checks prior to mounting 6.4 Mounting the torque converter on the foundation 6.5 Site pipework 6.6 Guards 6.7 Preservation after installation 6.8 Electric installation

7.

Operating Oil 7.1 Lubricant

8.

Commissioning 8.1 Trial run preparations 8.2 Trial run 8.3 Steps to be taken at standstill periods and stand-by operation

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

9.

Torque Converter Operation 9.1 Start-up of the unit 9.2 Turning the unit via the torque converter 9.3 Manual emergency operation of filling and draining control 9.4 Unit shutdown 9.5 Operating data 9.6 Operating oil pressure indication 9.7 Operating oil pressure monitoring 9.8 Operating oil temperature indication including monitoring

10.

Maintenance Intervals and Measures to be taken 10.1 Measures which can be taken when the unit is running 10.2 Measures which can only be taken when the unit stands still

11.

Overhaul of the Voith Torque Converter

12.

Disassembling/Reassembling the Torque Converter 12.1 General 12.2 Preliminary work 12.3 Dismantling the control housing 12.4 Dismantling the input and output part 12.5 Adjustment of bearing clearances and reassembly of the torque converter 12.6 Mounting the turbine wheel and output part 12.7 Mounting the control housing 12.8 Remaining work

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

-3-

Safety Information

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 directly. 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

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

1.

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Design and Operation 1.1

Design The Voith torque converter is a hydrodynamic gear unit working to the Föttinger principle. The two-stage hydrodynamic torque converter consists of the following main components:

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1. Input shaft

5. Guide wheel adjustable

2. Pump impeller

6. Output shaft

3. Turbine wheel 1

7. Adjustment mechanism

4. Turbine wheel 2

8. Guide wheel fixed

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

-5-

The input shaft is connected with the pump impeller. The output shaft is connected with the turbine wheels. Both converter shafts are supported by antifriction bearings. The input shaft is sealed using a labyrinth and the output shaft using a labyrinth with felt ring. The adjustable vanes of guide wheel are connected mechanically with the adjustment mechanism and dependent on the converter operating state they are moved to 0 % or 100 % guide vane position. The pump impeller, the guide wheels and the turbine wheels form the oil-filled circuit together with the converter shell. The housing of torque converter supports the internal parts controlling the oil supply and oil discharge. A control housing is attached to the converter housing supplying the torque converter with operating oil. A control valve is installed in the control housing. This control valve is switched to "fill" and "drain" the torque converter.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

1.2

-6-

Operation - torque converter The hydrodynamic torque converter is provided for stepless speed/torque transmission (multiplication) between motor and gas turbine to be started. The pump impeller absorbs the mechanical energy of the driving machine (motor) with the 3rd power of input speed (n3) converting it to kinetic energy by accelerating the oil in the converter. The turbine wheels convert the kinetic energy existing in the fluid mass back to mechanical energy. The guide wheels absorb the differential torque between pump impeller and turbine wheel which results in a multiplication of torque. The guide vanes of the second guide wheel are adjustable and effect a change of the flow direction. The inside diameter between the guide vanes , relative to the value in the design point, is provided as "relative guide vane position" (in %) to describe the operating behaviour.

Dependent on the guide vane position, between 0 % and 100 %, a corresponding torque is transmitted via the turbine wheels as a function of the output speed. The pump and the turbine rotate in the same direction. There is no mechanical connection between pump impeller, turbine wheels and guide wheels. Torque transmission is load-dependent, i.e. the torque produced in the turbine wheels has its max. point when the output shaft stands still and decreases with increasing speed. Thus the torque converter is adapting steplessly and automatically to the resistance occurring.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

2.

-7-

Oil Circuits 2.1

General The same oil is used as working, control, lube and cooling oil. The torque converter is supplied with operating oil (lube and cooling oil, working and control oil) from the oil supply system via pumps operating independently of each other.

2.2

Working oil circuit - torque converter operation On converter operation, the valve in the control housing is switched to "filling" via the servo valve. The pump of the oil supply system supplies the working oil to the control housing through the working oil orifice plate, via the guide vane cover directly into the torque converter working chamber. For heat dissipation, a certain quantity of working oil flows from the closed circuit of the working chamber back into the oil supply system via the set annular gap of the control valve. The filling pressure of the working oil (in the flow from the orifice plate) is set to 4 bar by the working oil orifice plate. The converter pressure in the flow to the working oil outlet must be between 12 and 18 bar. This value is dependent on the output speed and guide vane position. Adjustment is described in par. 3 "Control Valve". If the valve in the control housing is switched to "draining" by the servo valve, the oil supply is interrupted and the working chamber is drained quickly via large opening cross sections.

2.3

Control oil circuit The piston of control valve is fed with control oil via the servo valve. The control oil pressure is approx. 7.0 bar.

2.4

Lube and cooling oil circuit Pump 2 of the oil supply system supplies lube oil for the bearing points and cooling oil for cooling the torque converter parts during gas turbine operation. The lube and cooling oil pressure is approx. 1.5 bar. The lube, cooling and control oil accumulated in the torque converter housing is supplied back into the oil supply system via an oil return piping.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

3.

-8-

Control Valve 3.1

Control The control valve (for torque converter filling and draining) is switched by means of a servo valve (4/2 way solenoid valve). If the limit switches are wired, the position of the control piston is indicated by an electrical signal. In addition, the servo valve has a manual emergency actuation. See par. 9.3. The control valve is provided for torque converter filling or draining. By means of the adjusting screw on this valve, the output cross section and thus the working oil flow rate through the torque converter can be adjusted. When adjusting, please observe the required torque converter pressure.

3.2

Adjustment For adjusting the torque converter pressure and the working oil flow rate through the torque converter, remove the screw plug on the valve housing (see longitudinal section). The piston stroke and thus the cross-sectional area in the selector valve is adjusted by removing or adding shims/washers below the adjusting screw. Screw in the screw plug after adjustment.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

4.

-9-

Guide Vane Adjustment 4.1

General The guide vane adjustment enables a continuous change of the power transmission. This means that a speed adaptation is possible for any drive of driven machine whereas the load-dependency remains unchanged.

4.2

Actuator (see enclosed instruction manual for the AUMA actuator) The guide vanes are adjusted via an electric motor driven actuator. This actuator directly acts on the adjusting ring of the converter via the adjusting lever. The guide vanes are turned correspondingly via this adjusting ring

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

5.

- 10 -

Design and Delivery Test run Prior to delivery each torque converter has been subjected to a test run. Parameters measured:

Input and output torque under test load with open or closed guide vane position, vibrations on the bearing housing, filling and draining times.

Parameters set:

Working oil quantity in the working chamber, converter pressure, max. guide vane adjustment, torque-dependent and way-dependent limit switches (on the actuator) and valve limit switches. Average cross section for working oil outlet.

Operational test:

Filling/drain valve, guide vane adjustment.

Preservation The standard preservation according to Sheet 3.625-006212 provides up to 6 months protection. As delivered condition The torque converter is ready for mounting. All internal pipes are layed for the corresponding oil circuits. Indicating instruments, as far as ordered, are fitted. Pipe connections, e.g. from and to the oil supply system, are provided with flanges or caps. The working oil orifice plate is installed. When the connecting couplings are supplied, the coupling hubs are mounted. Spare parts and loose parts for the torque converter are separately packed for delivery. Transportation For transportation of the torque converter eyebolts are fitted on top of the housing. Regarding the transportation weight of the torque converter without oil filling and packing, please refer to the assembly drawing.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

6.

- 11 -

Installation 6.1

General information The following work (para. 6.2 - 6.8) is to be carried out by qualified personnel only (see Safety Information). We therefore suggest to have one of our specialized service engineers carry out installation and commissioning. Faulty installation can lead to failures and early wear of the units. Regarding installation dimensions etc. please refer to the outline drawing. We recommend to paint the foundation using an oil-resistant paint, to avoid that oil gets into the foundation when wetting the foundation with oil and thus avoiding damage of the concrete. When mounting the connecting coupling hubs please take note of the installation direction (position of gear teeth and detaching thread, etc.) and of the attachment parts behind the hub. It is only allowed to hang the torque converter on the lugs provided for this purpose (see assembly plan). During the period of construction at site, cover the torque converter fully against rubbish, throwing off of sparks, grinding dust and other environmental influence detrimental to the torque converter. In particular, the monitoring instruments need a special protection.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

6.2

- 12 -

Shaft misalignment due to operation, alignment accuracy In operation the shafts of driven machine, torque converter and gear unit are to be in alignment. For alignment, please consider the shaft misalignments of the different units due to operation. Shaft misalignments of torque converter relative to 20°C installation temperature and 80°C operating temperature.

A = Fixed point to the foundation or B = Fixed point to the foundation

∆ l 0,6

∆ h 0,2 *

* ( ∆ ϑ = 40 °C)

(Dimensions in mm) Values starting from the fixed point A or B are equal to the max. shaft misalignment including bearing clearance.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

- 13 -

A proper alignment is guaranteed when using 3 dial gauges for measuring axial center offset and angular deflection and turning the shafts jointly.

Alignment accuracy under hot running conditions: Speed RPM

Shaft center line displacement max. Max. angular displacement (face wobble = values doubled)

up to 1500

0.1 mm

0.03 mm per 100 mm test radius

above 1500 up to 3600

0.05 mm

0.02 mm per 100 mm test radius

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

- 14 -

After alignment of torque converter record the alignment values in 1/100 mm according to the sketch. Shaft centre line displacement

6.3

Angular displacement

Checks prior to mounting Check the foundation dimensions for the torque converter and position to drive motor and gas turbine. Check the connecting coupling hubs for the required direction of installation. Please observe the shaft clearances according to the specifications applicable to connecting couplings. Measure and record radial run out and axial clearance of the shafts of drive motor and gas turbine. Check the clearance on the foundation for shimming and aligning the torque converter.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

6.4

- 15 -

Mounting the torque converter on the foundation Data regarding foundation load are stated on the assembly plan. Concrete foundation For a concrete foundation two foundation rails or four rigid base plates with the bore-holes for the anchor bolts are required. These foundation rails or base plates are to be designed that there is sufficient space for grouting of the anchor bolts. After assembly of the connecting couplings, the torque converter is placed on the foundation with suspended anchor bolts, 10 mm shim and foundation rails. Then align the torque converter preliminarily and provide the foundation rails or base plates with an adequate lining. Finally, grout the anchor bolts and foundation rails with concrete. After the concrete has set,align the torque converter finally using liners and shims, taking the shaft displacements of the individual units due to operation into consideration. All shims must bear weight uniformly.

After tightening up the anchor bolts measure and record the accuracy of alignment (radial and axial run-out) by rotating the shafts together (see 6.2).

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

- 16 -

Steel foundation Fit connecting couplings and oil drain piping then set the torque converter on the foundation. Align as per par. 6.2. If there is a common foundation, all units must be in position on this foundation before alignment. Important:

6.5

All shims must bear weight uniformly to prevent housing buckling when anchor bolts are tightened up. After tightening up the bolts measure and record alignment values, as described in para. 6.2.

Site pipework Pipe the oil feed and oil return, leakage oil drain, lube and cooling oil at the torque converter. They must be designed with the tube diameters indicated on the drawing. For flushing the site piping, provide detachable pipe sections on the oil inlet (in the flow to the torque converter) which are removed for flushing so that an oil filter can be installed in between. We recommend to adapt the site piping only after alignment of the torque converter. Please take care that the pipes installed are free from stress. Oil pipes which are laid at site are to be unscrewed after completion and to be pickled in a standing 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, light fouling, graphite or oil carbon. Workpieces heavily fouled by oil or grease are to be degreased in advance. The ideal temperature 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: (splashing)

Rust film: Rust: Rolling scale: Descaling of annealed steel pieces:

approx. 5 to 10 min approx. 15 to 30 min approx. 50 min. approx. 120 min.

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 working oil and on the outside with paint.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

6.6

- 17 -

Guards If not ordered from us and thus not included in the scope of supply, guards should be mounted especially on rotating parts such as connecting couplings, in accordance with the safety regulations in force.

6.7

Preservation after installation If the converter is to remain at standstill after installation we recommend preserving the converter as described in Sheet 3.635-006212e. If there is still some assembly work required around the torque converter during the construction time, measures are to be taken in accordance with section 6.1, par. 8.

6.8

Electric installation Connect and check the provided units and instruments according to the local regulations or to VDE. Instructions to the instruments supplied are included in the enclosed instrument description. Basically please observe the manufacturer's instructions.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

7.

- 18 -

Operating Oil The following work is to be carried out by qualified personnel only (see Safety Information). If the operating fluid used is not mentioned in our Oil Selection List 3625-006072, check its compatibility with our preservation oil (Shell Ensis Motor Oil 20) or flush the torque converter thoroughly. The operating oil viscosity must be as low as possible to guarantee satisfactory hydraulic efficiency and air release properties during filling, emptying and turning. On the other hand the working oil must have an excellent lubricating property for the bearings. The only oils suitable for torque converters are high performance, low viscosity oils with excellent lubricating properties and air release capacity. The oil must be chemically neutral to metals and seals possibly fitted and be nontoxic. Resistance to aging at max. admissible operating temperature and under high air entrainment must allow a sufficient operating life. Use a steam turbine oil L-TD 32 according to DIN 51515, part 1 with an air release property < 5 min. at 50 °C DIN 51381 as operating oil. Control the sufficient air release property (behaviour of pump pressures and control stability). In case of queries please consult VOITH. Regarding other operating fluids examined according to the above aspects, please refer to the enclosed List of Operating Fluids. 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 should be increased, if necessary. 7.1

Lubricant Use Shell Darina 2 grease to lubricate the threaded spindle for the guide vane adjustment mechanism Apply a thin coat of Molykote paste to the thread (external or internal thread) prior to every assembly.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

8.

- 19 -

Commissioning The following work (para. 8.1 - 8.3) is to be carried out by qualified personnel only (see Safety Information). When operating the torque converter meet the nominal values for temperatures and oil pressures stated in section 9.5. The torque converter allows a power transmission and speed adjustment only with the specified operating data. The starting viscosity of operating oil must not exceed 400 mm2/s (cSt). For the oils of list 3625-006072 this means a temperature of approx. 0°C. 8.1

Trial run preparations -

Check alignment of all equipment considering the heat expansions and shaft misalignments due to operation and correct, if necessary. Record alignment values!

-

Check foundation fixing.

-

Check direction of rotation of prime mover with torque converter uncoupled.

-

Check the function on the actuator.

-

Check the supply of the torque converter with oil from the oil supply system.

-

Check piping for leakage.

-

In case of coupled curved-tooth connecting coupling check for easy displacement of the coupling sleeve and sufficient lubrication.

-

Check the function of monitoring instruments or setting of monitoring elements.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

8.2

8.3

- 20 -

Trial run -

Check whether the complete unit is ready for operation.

-

Check all electrical connections.

-

Connect the pumps for lube oil supply and for working oil supply to the torque converter at the oil supply system.

-

After reaching the operating oil pressure, start the driven machine or monitor the automatic start-up.

-

The torque converter is filled with working oil and operated by actuating/switching the servo valve.

-

Operate the unit and observe smooth running, oil pressures and temperatures.

-

Switch off the unit after trial run. Observe the measures for preserveration.

Measures to be taken at standstill periods and stand-by operation Protect the torque converter against water ingress and humidity. Preserve bright parts accordingly. For protection against corrosion (oil wetting) start the torque converter every 1 to 2 months for a short time. Do not run the torque converter warm, because there is a risk of dewpoint corrosion.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

9.

- 21 -

Torque Converter Operation The following work (para. 9.1 - 9.8) is to be carried out by qualified personnel only (see Safety Information). A continuous monitoring of converter maintaining admissible temperatures and pressures means a trouble-free operation and low maintenance. The starting viscosity of operating oil must not exceed 400 mm2/s (cSt). For the oils according to our Oil Selection List 3625-006072 this means an oil temperature of at least 0°C. To keep good air release property, the oil temperature in the oil supply system must not fall below 45°C. 9.1

Start-up of the unit General Start the oil supply for the torque converter. The control valve is at initial position (rest position). Start the drive motor when operating oil pressure is available. Start-up the unit using the torque converter When starting the gas turbine, the spring-loaded piston of the control valve is moved to "filling position" via the servo valve. The torque converter circuit is filled with working oil and the unit is started. When limit switches are mounted (contact switch - electrical), they are switched by the piston position. Guide vane adjustment until reaching the self-sustaining speed of gas turbine The gas turbine is started by adjusting the guide vanes via the actuator (from 0 to 100 %), i.e. it is accelerated until reaching self-sustaining speed. The change of the guide vane position enables a continuous change of the power transmission. Completion of unit run-up Drain the working oil circuit of the torque converter after reaching self-sustaining speed of the gas turbine. Move the control valve to "drain position" (initial position) and the guide vanes to 0 % position. Maintain 0 % guide vane position over the complete operating phase of gas turbine.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

9.2

- 22 -

Turning the unit via the torque converter When the gas turbine moves from operating condition to turning operation, the control valve remains at "drain position". During speed reduction, the guide vanes remain at 0 % guide vane position. If the gas turbine speed drops to below 400 rpm, the gas turbine can be turned by switching on a pony motor. The working chamber of the torque converter is filled with oil by actuating the servo valve to run up the gas turbine to the speed requested. The requested turning speed is set by moving the guide vanes to 0 % position.

9.3

Manual emergency operation of filling and draining control Press the manual emergency switch in case of failure of the electronic part on the servo valve. Switches for manual operations are provided on the front side of the servo valve. The servo valve carries out this switching function as long as this switch is pressed manually. Filling as described before is carried out just manually.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

9.4

- 23 -

Shutdown of the unit Switch off the gas turbine and stop turning operation. Move the control valve to initial position (drain position). Switch off the oil supply of torque converter when the gas turbine runner stands still. In case of standstill periods please see par. 8.3.

9.5

Operating data Working oil temperature in the flow to the torque converter

nom. value

approx. 60 °C

Working oil temperature in the flow from the torque converter

nom. value alarm at shutdown at

Lube oil temperature in the flow to the torque converter

nom. value

approx. 60 °C

Lube oil temperature in the flow from the torque converter

nom. value

approx. 80 °C

Filling pressure (during operation)

nom. value alarm at

approx. 4.0 bar 2.1 bar

Control oil pressure (= pressure of oil supply system)

nom. value

approx. 7.0 bar

Torque converter pressure (during operation)

nom. value alarm

12.0 to 18.0 bar < 10.0 bar

Lube and cooling oil

nom. value

approx. 1.5 bar

< 90 °C 110 °C 120 °C

Working oil flow rate (during operation)

approx. 16.0 l/sec.

Lube and cooling oil flow rate

approx. 0.6 l/sec.

Turning speed (speed at which pony motor is switched on)

(see data sheet)

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

9.6

- 24 -

Indication of working oil pressure It is recommended to fit an oil pressure gauge to the torque converter. However, an oil pressure gauge must be provided on continuous torque converter operation. The pressure gauge offers an early detection of faults. The torque converter pressure can change substantially, i.e. as a function of the guide vane position as well as of the motor speed, the speed ratio nT/nP (turbine speed : pump speed) and last but not least as a function of the working oil temperature. Oil pressure checks can therefore only be compared when guide vane positions, speed ratios and motor speeds are equal. In general, an oil pressure check is carried out at approx. 75 % guide vane opening at full motor speed, with a speed ratio nT : nP of 0.35 - 0.5 and at a normal operating temperature of between 70 and 90°C. Minimum filling pressure shall be approx. 2.1 bar and minimum converter pressure approx. 10 bar.

9.7

Working oil pressure monitoring It is advisable to monitor the torque converter pressure using a pressure switch. Connection see assembly plan. Dependent on the wiring, this switch initiates an alarm signal if the minimum torque converter pressure of approx. 10 bar is no longer reached during torque converter operation.

9.8

Indication of working oil temperature with monitoring It is recommended to provide a temperature indicator with monitoring system at the working oil outlet of torque converter. During torque converter operation the working oil temperature should be approx. 70 - 90 °C. This high oil temperature has a positive effect on the efficiency of torque converter. Max. oil temperature of 100°C must not be exceeded. Temporary peak temperatures of up to 110°C are still admissible, however, an alarm signal should be given in this case. A switch-off signal should be initiated at an oil temperature of 120°C.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

10.

- 25 -

Maintenance Intervals and Measures The following work is to be carried out by qualified personnel only (see Safety Information). 10.1

Measures which can be taken when the unit is running Monitor all thermometer and pressure gauge indications during starting operation, rating of gas turbine and turning operation according to the operating data and record for later comparison. Every 100 operating hours Record and compare all instrument indications. Every 500 operating hours Measure noise and smooth running (vibration), record and compare with recordings which were made under similar conditions.

10.2

Measures which can only be taken when the unit stands still After every standstill of gas turbine Check smooth running of the adjustment mechanism. Leak test to be carried out with the pipework and the connecting couplings. Every 800 starts or all 2500 hours turning operation, at least yearly Analyse operating oil for aging and take measures according to the oil supplier's instructions. Inspect and maintain the connecting couplings as per manufacturer's instructions. Grease the threaded spindle of guide vane adjustment mechanism. See par. 7.1. Check alignment of torque converter with prime mover and driven machine (alignment values: see par. 6.2). Check whether all foundations are secure. Visual inspection (corrosion, general condition, etc.) of torque converter.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

11.

- 26 -

Overhaul of the Voith Torque Converter We recommend replacement of input and output side bearings of the torque converter as follows: After 2 000 hours

accumulated starting time (starting motor running, torque converter filled)

or after 20 000 to 25 000 hours

accumulated trailing operation (starting motor stands still, torque converter is turned by the driven machine and cooled by the oil shower)

but generally after an operating time of 5 years the converter in question should be overhauled To avoid unnecessary delays, we recommend to order spare parts for the general overhaul well in advance. We will be pleased to work out 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 and the exact location of the Voith torque converter and the name of the person in charge. Only our service engineers or qualified personnel is allowed to do installation work on the torque converters.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

12.

- 27 -

Disassembling/Reassembling the Voith Torque Converter Only our service engineers or qualified personnel is allowed to do installation work on the torque converters (see Safety Information). 12.1

General An overhaul of torque converter is only possible when it is dismantled. Before starting disassembly take all safety precautions so that the unit can no longer be switched on. Ensure that no dust will develop or dirt (e.g. insulating material or similar) penetrates into the torque converter during the overhaul. The pump impeller and the turbine wheel in the converter run to each other with minimum clearance. Therefore a careful disassembly and reassembly is a condition.

12.2

Preliminary work Loosen the electrical supply lines to the rotary actuator. Suspend the rotary actuator on a crane and loosen the screws (050/040) and lift off the rotary actuator including intermediate flange (050/010), remove the coupling disc (050/030) - loose part -. Remove the cover (020/840). Bend up the tab washer (030/158) and unscrew the hex. screw (030/155). Remove the hex. screw (030/140) and the locking angle (030/150). Extract the bolt (030/130) from the adjusting ring (030/080). Press the complete bearing with the regulating spindle off the torque converter housing and set it down laterally. Loosen the oil supply, oil return and leak oil drain piping (see assembly plan). Disconnect the connecting couplings. Suspend the torque converter on a crane. Loosen the foundation bolts and carefully lift off the torque converter. Swivel the torque converter sideways. Dismantle the connecting coupling together with the fitted key from the input and output shaft. Bring the torque converter in vertical position with input side pointing upwards. Support the input side using wooden beams or assembly stands and set the converter down on these.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

12.3

- 28 -

Dismantling the control housing Screw two eyebolts or hooks on the front side into the control housing (060/010) and fasten the housing on the crane using a rope. Loosen screws (060/210) and set the control housing (060/010) down laterally. Observe the orifice plate (020/1050) when pressing off.

12.4

Dismantling the input and output part Screw an eyebolt into the center thread of the output shaft and connect it with the crane. Remove the screw plug (020/990) and screws (010/030/030). Remove all screws (020/520) and (020/530). For further dismantling, press the complete output part off against the guide wheel (020/380) and set down laterally on wooden beams. After loosening screws (010/010/030), press the pump impeller off the input shaft. Remove the complete turbine wheel I and II from the guide wheel and guide wheel cover. Loosen screws (020/280) and remove cover (020/250). Screw an eyebolt into the center thread of the input shaft and lift the input part out of the torque converter housing. For further dismantling, set the input part down laterally on wooden beams or assembly stands. Please refer to the attached sectional drawings regarding further dismantling steps relative to the input and output part.

12.5

Adjustment of bearing clearances and reassembly of the torque converter The bearing clearances on the input and output shaft must be adjusted carefully. Bring the shafts in vertical position (shaft end pointing upwards). Position the input part on the guide wheel (020/380) and the output part on the converter shell (020/500). Pre-assemble the input part as follows for adjusting the bearing clearance: -

Bolt the guide wheel (020/380) with the guide wheel cover (020/350). Mount the labyrinth bush (020/300) and the filler (020/310) on the guide wheel cover.

-

Install the input shaft (010/010/010) together with the antifriction bearings (010/070) and the spacer bush (010/050) in the proper position in the guide wheel cover.

-

Mount the antifriction bearing (010/060) in the proper position and fix it with the slotted round nut (010/080) in axial direction on the input shaft.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

- 29 -

Input side adjustment of bearing clearance Set the bearing clearance via the spacer bush (010/050). Measure the bearing clearance by means of a dial gauge arranged between fixed part and shaft face side. Own weight of the rotating parts is 45 kg. How to proceed: Lift off the input shaft (010/010/010) using a lifting device and attached balance for the upper measuring point with 600 N and for the lower measuring point with 300 N. Ascertain the existing clearance via the attached dial gauge. Unscrew the slotted round nut (010/080) and remove the input shaft (010/010/010) from the guide wheel cover (020/350). Remove the spacer bush (010/050) from the input shaft. Grind the spacer bush to the nominal length (lnom). lnom = lactual - lclearance + 0

0.02 mm.

Repeat assembly. Check the set bearing clearance. Pre-assemble the output part as follows for adjusting the bearing clearance: -

Mount the two antifriction bearings on the output shaft (010/030/010/010) in the proper position up to the shaft collar.

-

Fit the spacer bush (010/110) and the bearing retaining ring (020/640).

-

Insert the rotating parts into the converter shell.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

- 30 -

-

Mount the antifriction bearing (010/120) on the output shaft.

-

Fix the antifriction bearings in axial direction on the output shaft by means of a bush 3623-013151 (mounting aid).

-

Install a distance ring with flange 3623-013152 (mounting aid) in the converter shell. When bolting the distance ring with flange, the outer ring of bearing is pressed flush with the converter shell, against spring resistance.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

- 31 -

Output side adjustment of bearing clearance Set the bearing clearance via shim (020/630). Measurement of shim thickness is done by gauge blocks. How to proceed: Insert two puller screws in the bearing retaining ring (020/640). Insert the puller screws until axial bearing clearance is eliminated. The distance between converter shell and bearing retaining ring is ascertained by gauge blocks within the area of the two puller screws. This ascertained dimension less 1.0 mm travel of the cup spring results in the thickness for shims. Remove the puller screws and fit the split shim, with "Hylomar" sealing compound applied on both sides. Now fit the intermediate ring (020/670), the washer (020/690), the seals and end cover (020/700). Dismount the distance ring with flange and replace it by installing the labyrinth ring (020/560). It must be possible to turn the output shaft easily in radial direction, free from play. Then remove the bush from the output shaft and replace it by pressing on the turbine wheel flange (010/030/010/020). Technical data of oil press fit are indicated in the longitudinal view.

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Operating Instructions for VOITH Torque Converter EL 10 ZFG

12.6

- 32 -

Mounting the turbine wheel and output part Mount the core ring (020/440), if removed. Insert the turbine wheels I and II into the guide wheel (020/380) and the guide wheel cover (020/350). Position the pump impeller (010/010/020) on the input shaft and bolt using the socket head screws (010/010/030). Position the output part on the guide wheel and bolt with the torque converter housing.

12.7

Mounting the control housing Install orifice plate (020/1050) in the control housing. Apply a thin coat of sealing compound to the flange side and place the sealing (060/020) on it (adhesive effect). Suspend the control housing on the crane, position it correctly to the torque converter housing and bolt.

12.8

Remaining work Bring the torque converter in horizontal position and mount the connecting coupling hubs. Place the torque converter on the foundation, align and fasten to the foundation. Connect the connecting couplings. Mount the pipes, see assembly plan. Position the rotary actuator with regulating spindle on the torque converter housing. Connect the regulating spindle with the adjusting ring (030/080) (see 12.2 Preliminary work). Mount cover (020/840). Connect the electrical supply line to the rotary actuator.

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Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG

-1-

Ersatzteilbestellhinweise: Bitte Fabrik-Nummer des Drehmomentwandlers (s. Typenschild), vollständige Bezeichnung der Teile laut Stückliste und gewünschte Menge angeben. Ersatzteile werden nach jeweils neuestem technischen Stand geliefert. Gehäuse werden anlagenbedingt geliefert. Deshalb empfehlen wir, diese Teile nur gemäß unserem Angebot zu bevorraten. Wälzlager, die mit “PA.” gekennzeichnet sind, dürfen nur paarweise (gemeinsam) ausgetauscht werden. Mit “G.T.” gekennzeichnete Teile sind gewichtstoleriert.

Information required for ordering spare parts: Please indicate the serial no. of torque converter (see nameplate), full designation of parts in accordance with the parts list and the required quantity. Spare parts will be supplied according to the latest state of art. Customer-specific housings are manufactured. We would therefore recommend to store these parts only in accordance with our offer. Replace anti-friction bearings marked with “PA.” in pairs (jointly) only. Parts marked with “G.T.” are tolerated with regard to their weight.

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-2-

Längsschnitt 4 153947 0 Longitudinal section Pos. Nr. Item no.

Benennung Description

010/010/010

Antriebswelle Input shaft

1

010/010/020

Pumpenlaufrad Pump impeller

1

010/010/030

Zylinderschraube M 16 x 30; G.T. Socket head screw

010/010/040

Paßfeder 19,05 x 150 Fitted key

1

010/030/010/010

Abtriebswelle Output shaft

1

010/030/010/020

Turbinenradflansch Turbine wheel flange

1

010/030/020

Turbinenrad I Turbine wheel

1

010/030/021

Turbinenrad II Turbine wheel

1

010/030/022

Zylinderschraube M 12 x 20; G.T. Socket head screw

24

010/030/030

Zylinderschraube M 10 x 25; G.T.; Socket head screw

40

010/030/040

Paßfeder 25,4 x 25,4 x 150 Fitted key

1

010/050

Distanzbuchse Spacer

1

010/060

Rillenkugellager 6218 MA C3 DIN 625 Grooved ball bearing

1

010/070

Schrägkugellager 7218 B.MP.UA 80 Angular contact ball bearing

2

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-3-

Pos. Nr. Item no.

Benennung Description

Menge Qty.

010/080

Nutmutter Slotted nut

1

010/090

Schleuderring Slinger ring

1

010/100

O-Ring 84 x 4 B DIN 3770 NBR 70 O-ring

1

010/110

Distanzbuchse Spacer

1

010/120

Lager Bearing

1

010/130

Schrägkugellager 7222 B.MP.UA Angular contact ball bearing

2

020/010

Wandlergehäuse Converter housing

1

020/020

Rohrleitung 12 x 1 DIN 2391 Pipe

1

020/170

O-Ring 238 x 5 B DIN 3770 NBR 70 O-ring

1

020/180

Paßscheibe Shim

1

020/220

Schaftschraube M 10 x 18 DIN 427; 4.6 Headless screw

1

020/240

O - Ring 10 x 2,2 B DIN 3770 FPM75 O - ring

1

020/250

Deckel Cover

1

020/265

Labyrinthscheibe Labyrinth disc

1

020/280

Zylinderschraube M 12 x 60 DIN 912; 10.9 Socket head screw

8

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-4-

Pos. Nr. Item no.

Benennung Description

020/281

Federscheibe B 12 DIN 137 A3C Spring washer

8

020/290

Zylinderschraube M 12 x 30 DIN 7984 ; 8.8 Socket head screw

2

020/295

Federscheibe B 12 DIN 137 Spring washer

2

020/300

Labyrinthbüchse Labyrinth bush

1

020/310

Füllstück Filler

1

020/320

Zylinderschraube M 8 x 25 DIN 7984; 8.8 A2C Socket head screw

3

020/330

Federscheibe B 8 DIN 137 A3C Spring washer

3

020/350

Leitraddeckel komplett Guide wheel cover complete

1

020/350/020

Buchse Bush

020/380

Leitrad Guide wheel

020/390

Sechskantschraube M 12 x 40 DIN 933; 8.8-A Hex. screw

28

020/400

Federscheibe B 12 DIN 137 A3C Spring washer

28

020/410

Dichtung 775/721 x 0,3 AF3G1 VN1641 Seal

1

020/440

Kernring Core ring

1

020/450

Scheibe 22/8,2 x 3 Disc

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-5-

Pos. Nr. Item no.

Benennung Description

020/460

Zylinderschraube M 8 x 15 VGN 3037; 10.9 Socket head screw

020/500

Wandlerschale Torque converter shell

1

020/505

Gewindestift M 8 x 10 DIN 914 Set screw

4

020/510

Dichtung 775/671 x 0,3 AF3G1 VN1641 Seal

1

020/515

O-Ring 633,48 x 7 VN 3014 NBR 70 O-ring

1

020/520

Zylinderschraube M 12 x 50 DIN 912; 10.9 Socket head screw

40

020/530

Zylinderschraube M 12 x 70 DIN 912; 10.9 Socket head screw

24

020/540

Federscheibe B 12 DIN 137 A3C Spring washer

64

020/560

Labyrinthring Labyrinth ring

1

020/570

Zylinderschraube M 10 x 30 VGN 3037; 10.9 Socket head screw

8

020/580

Federscheibe B 10 DIN 137 Spring washer

8

020/600

Tellerfeder Cup spring

1

020/610

Zylinderstift 6m6 x 12 DIN 7 Cyl. pin

1

020/630

Paßscheibe Shim

1

020/640

Lagerhaltering Bearing retaining ring

1

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-6-

Pos. Nr. Item no.

Benennung Description

020/650

O-Ring 210 x 3 B DIN 3770 NBR 70 O-ring

1

020/660

Dichtung 280 / 201 x 0,3 AF3G1 VN1641 Seal

1

020/670

Zwischenring Intermediate ring

1

020/680

Dichtung 269 x 174 x 0,3 AF3G1 VN1641 Seal

2

020/690

Scheibe Disc

1

020/700

Abschlußdeckel End cover

1

020/710

Filzring Felt ring

1

020/720

Sechskantschraube M 12 x 60 DIN 931; 8.8-A Hex. screw

10

020/900

Verschraubung SWVE 10 PLM VN 1143 A3C Union

4

020/910

Rohrleitung Pipe

1

020/920

Rohrleitung 10 x 1,5 DIN 2391 Pipe

1

020/970

Adapter M 22 x 1,5/M 14 x 1,5 Adapter

1

020/980

Dichtring A 22 x 27 DIN 7603 Seal ring

4

020/990

Verschlußschraube M 24 x 1,5 DIN 910; 5.8 Screw plug

2

020/1000

Dichtring A 24 x 29 DIN 7603 Seal ring

2

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-7-

Pos. Nr. Item no.

Benennung Description

020/1010

Entlüftungsfilter Vent filter

2

020/1020

Dichtring A 26 x 31 DIN 7603 Seal ring

2

020/1030

Rohrleitung Pipe

1

020/1040

Ringschraube M 24 DIN 580 Flanged eye bolt

2

020/1050

Drosselblech Throttle plate

1

020/1080

Verschraubung gerade DL 18 DIN 2353 Straight union

2

020/1090

Dichtring A 21 x 26 DIN 7603 Seal ring

2

020/1100

Rohrleitung 18 x 1,5 DIN 2391 Pipe

1

020/1110

Winkelverschraubung GL 18 DIN 2353 Angle union

2

030/010

Stellschaufel Regulating blade

14

030/020

Stellschaufel Regulating blade

14

030/030

Regulierhebel Regulating lever

28

030/070

Bolzen Bolt

28

030/080

Verstellring Adjusting ring

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1

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Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG

-8-

Pos. Nr. Item no.

Benennung Description

100/010

Ölablaufstutzen Oil drain

1

100/020

Dichtung 180 x 160 x 0,5 AF3G1 VN 1641 Seal

1

100/030

Sechskantschraube M 10 x 35 DIN 933; 8.8-A Hex. screw

8

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-9-

Querschnitt 4 154877 0 Cross section Pos. Nr. Item no.

Benennung Description

020/ 010

Gehäuse Housing

1

020/ 020

Rohrleitung 12 x 1 DIN 2391 Pipe

1

020/ 030

Rohrschelle 1 x 12 DIN 72571 Pipe clip

1

020/ 040

Sechskantschraube M 8 x 12 DIN 933 Hex. screw

1

020/ 050

Federscheibe B 8 DIN 137 Spring washer

1

020/ 220

Schaftschraube M 10 x 18 DIN 427; 4.6 Headless screw

1

020/ 350

Leitraddeckel komplett Guide wheel cover complete

1

020/ 390

Sechskantschraube M 12 x 40 DIN 933; 8.8-A Hex. screw

28

020/ 400

Federscheibe B 12 DIN 137 Spring washer

28

020/ 730

Dichtung 120 x 120 x 0,5 AF3G1 VN1641 Seal

1

020/ 740

Deckel Cover

1

020/ 840

Deckel Cover

2

020/ 850

Dichtung 160 x 150 x 0,5 AF3G1 VN 1641 Seal

2

020/ 860

Sechskantschraube M 10 x 30 DIN 933 ; 8.8-A Hex. screw

8

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Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG

- 10 -

Pos. Nr. Item no.

Benennung Description

020/865

Federscheibe 10,5 x 16,5 x 0,8 DIN 137 Spring washer

8

020/ 880

Dichtung 100 x 90 x 0,5 AF3G1 VN1641 Seal

2

020/ 885

Blindflansch Blind flange

1

020/ 900

Verschraubung SWVE 10 PLM VN 1143 Union

4

020/ 920

Rohrleitung 10 x 1,5 DIN 2391 Pipe

1

020/ 930

Ölablaufstutzen Oil drain pipe

1

020/ 940

Sechskantschraube M 12 x 30 DIN 933; 8.8-A Hex. screw

12

020/ 950

Federscheibe 13 x 19 x 1 DIN 137 Spring washer

12

020/1010

Entlüftungsfilter Vent filter

2

020/1020

Dichtring A 26 x 31 DIN 7603 Seal ring

2

020/1040

Ringschraube M 24 DIN 580 Flanged eye bolt

2

030/030

Regulierhebel Regulating lever

28

030/040

Spannhülse 5 x 16 DIN 1481 Roll pin

28

030/050

Zylinderschraube M 8 x 20 DIN 912; 10.9 Socket head screw

28

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Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG

- 11 -

Pos. Nr. Item no.

Benennung Description

030/070

Bolzen Bolt

28

030/080

Verstellring Adjusting ring

1

030/130

Bolzen Bolt

1

030/140

Sechskantschraube M 6 x 12 DIN 933; 8.8-A Hex. screw

1

030/150

Sicherungswinkel 55 x 45 x 30 Locking angle

1

030/155

Sechskantschraube M 8 x 16 DIN 933; 8.8-A Hex. screw

1

030/158

Sicherungsblech 8,4 VGN 3028 Tab washer

1

030/160

Verstellspindel Adjusting spindle

1

030/180

Stellring Adjusting ring

1

030/190

Spannhülse 10 x 40 DIN 1481 Roll pin

1

030/200

Stellmutter 55 D x 233,5 Adjusting nut

1

030/210

Verschlußdeckel 24 DIN 443 Cover

1

030/240

Lagergehäuse Bearing housing

1

030/260

Verschlußschraube 55/31 D x 26 Screw plug

1

030/265

O-Ring 30 x 3 B DIN 3770 - FPM 80 O-ring

1

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Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG

- 12 -

Pos. Nr. Item no.

Benennung Description

030/270

Dichtung 120 x 120 x 0,5 AF3G1 VN1641 Seal

2

030/290

O-Ring 53 x 5 VN 3014 NBR 70 O-ring

1

030/300

Schrägkugellager 7209 B DIN 628 Angular contact ball bearing

2

030/310

Sicherungsblech MB 9 DIN 5406 Tab washer

1

030/320

Nutmutter KM 9 M 45 x 1,5 DIN 981 Slotted nut

1

030/330

Wellendichtring BA 40 x 56 x 10; NBR 70 Shaft sealing ring

1

030/340

Distanzring 85,9 / 72 x 15 Distance ring

1

050/010

Verbindungsflansch 125/50 x 138 Connecting flange

1

050/040

Sechskantschraube M 12 x 45 DIN 931; 8.8-A Hex. screw

4

050/050

Federscheibe 13 x 19 x 1 DIN 137 Spring washer

4

060/010

Steuergehäuse Control housing

1

060/020

Dichtung 341 x 175 x 1 AF3G1 VN1641 Seal

1

060/090

Zylinderschraube M 12 x 120 DIN 912;10.9 Socket head screw

8

060/100

Federscheibe 13 x 19 x 1 DIN 137 Spring washer

8

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Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG

- 13 -

Pos. Nr. Item no.

Benennung Description

060/ 160

Verschlußschraube M 22 x 1,5 DIN 908; 5.8 Screw plug

1

060/170

Dichtring A 22 x 27 DIN 7603 Seal ring

1

060/180

Deckel 150 x 130 x 28 Cover

1

060/200

Federscheibe B 12 DIN 137 Spring washer

4

060/210

Sechskantschraube M 12 x 40 DIN 933 ; 8.8-A Hex. screw

4

060/220

Dichtung 110 x 100 x 0,5 AF3G1 VN1641 Seal

2

060/230

Blindflansch 110 x 100 x 13 Blind flange

2

060/250

Sechkantschraube M 12 x 30 DIN 933; 8.8-A Hex. screw

8

060/260

Dichtring A 14 x 18 DIN 7603 Seal ring

2

060/270

Verschlußschraube M 14 x 1,5 DIN 910; 5.8 Screw plug

2

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Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG

- 14 -

Steuerventil mit 1 Endtaster 4 153843 0 Control valve with one limit switch Pos. Nr. Item no.

Benennung Description

060/010

Steuergehäuse Control housing

1

060/020

Dichtung 341 x 175 x 1 AF3G1 VN1641 Seal

1

060/030

Kolben Piston

1

060/040

Deckel Cover

1

060/041

Bohrbuchse Drill jig

1

060/042

O-Ring 4,47 x 1,78 O - ring

1

060/043

Kontaktstift Contact pin

1

060/044

Zylinderdruckfeder 1,6 x 10 x 18,5 DIN 2098 Cylinder compression spring

1

060/045

Spannhülse 3 x 16 DIN 1481 Roll pin

1

060/047

Verschlußschraube AM 12 x 1,5 VGN 3183; 5.8 Screw plug

1

060/050

Dichtung 150 x 130 x 0,5 AF3G1 VN1641 Seal

1

060/060

Zylinderschraube M12 x 30 DIN 912; 10.9 Socket head screw

4

060/070

Federscheibe B 12 DIN 137 Spring washer

4

060/080

Hydro-Wegeventil - mit Hand-Not-Betätigung Hydro way valve with manual emergency switch

1

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Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG

- 15 -

Pos. Nr. Item no.

Benennung Description

060/090

Zylinderschraube M 12 x 120 DIN 912 ; 10.9 Socket head screw

8

060/100

Federscheibe 13 x 19 x 1 DIN 137 Spring washer

8

060/110

Führungsstift Guide pin

1

060/120

Zylinderdruckfeder 4,5 x 30 x 28,5 x 270 Cylinder compression spring

1

060/130

Zylinderdruckfeder 3,6 x 20 x 30 x 200 Cylinder compression spring

1

060/140

Zylinderschraube M 8 x 12 VGN 3037;10.9 Socket head screw

2

060/150

Paßscheibe 8 x 14 x 1,0 DIN 988 Shim

5

060/160

Verschlußschraube M 22 x 1,5 DIN 908; 5.8 Screw plug

1

060/170

Dichtring A 22 x 27 DIN 7603 Seal ring

1

060/180

Deckel 150 x 130 x 28 Cover

1

060/185

Verschlußschraube AM 14 x 1,5 VGN 3183; 5.8 Screw plug

1

060/190

Dichtung 150 x 130 x 0,5 AF3G 1 VN 1641 Seal

1

060/200

Federscheibe B 12 DIN 137 Spring washer

4

060/210

Sechskantschraube M 12 x 40 DIN 933; 8.8-A Hex screw

4

060/220

Dichtung 110 x 100 x 0,5 AF3G1 VN 1641 Seal

2

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Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG

- 16 -

Pos. Nr. Item no.

Benennung Description

060/230

Blindflansch 110 x 100 x 13 Blind flange

2

060/250

Sechskantschraube M 12 x 30 DIN 933; 8.8-A Hex. screw

8

060/260

Dichtring A 14 x 18 DIN 7603 Seal ring

2

060/270

Verschlußschraube M 14 x 1,5 DIN 910; 5.8 Screw plug

2

060/300

Endtaster Limit switch

1

060/320

Halter Holder

1

060/330

Zylinderschraube M 5 x 16 DIN 84;4.8 Socket head screw

2

060/340

Federscheibe B 5 DIN 137 Spring washer

2

060/350

Sechskantschraube M 6 x 16 DIN 933; 8.8 - A Hex. screw

2

060/360

Federscheibe B 6 DIN 137 Spring washer

2

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Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG

- 17 -

Anbau Elektrischer Drehantrieb 4 156897 0 Mounting electric rotary actuator Pos. Nr. Item no.

Benennung Description

030/160

Verstellspindel Adjusting spindle

1

030/180

Stellring Adjusting ring

1

030/270

Dichtung 120 x 120 x 0,5 AF3G1 VN1641 Seal

2

030/290

O-Ring 53 x 5 VN 3014 NBR 70 O-ring

1

030/300

Schrägkugellager 7209 B DIN 628 Angular contact ball bearing

2

030/310

Sicherungsblech MB 9 DIN 5406 Tab washer

1

030/320

Nutmutter KM 9 M 45 x 1,5 DIN 981 Slotted nut

1

030/330

Wellendichtring BA 40 x 56 x 10 NBR 70 Shaft sealing ring

1

030/340

Distanzring 85,9 / 72 x 15 Distance ring

1

050/010

Verbindungsflansch 125 / 50 D x 138 Connecting flange

1

050/020

Kupplungsflansch 40 / 20 D x 61,3 Coupling flange

1

050/030

Kupplungsscheibe 40 D x 23 Coupling disc

1

050/040

Sechskantschraube M 12 x 45 DIN 931; 8.8-A Hex. screw

4

050/050

Federscheibe 13 x 19 x 1 DIN 137 Spring washer

4

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Stückliste zum VOITH Drehmomentwandler Parts list for VOITH Torque Converter EL 10 ZFG

- 18 -

Pos. Nr. Item no.

Benennung Description

050/060

Sechskantschraube M 10 x 30 DIN 933; 8.8-A Hex. screw

4

050/070

Federscheibe 10,5 x 16,5 x 0,8 DIN 137 Spring washer

4

090/010

Elektrischer Drehantrieb Electric rotary actuator

1

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Preservation and Packing Specification of Coupling Types "R", "RW", "S", "TP", "T", Retarder "VIR" and Torque Converter "E"

These data apply to the protection of internal and external surfaces (as far as the surfaces are not coated and/or corrosion-resistant or are not made of materials for casting of aluminium), as well as to the packing of the goods to be consigned.

Survey Transport, storage and storage period

Packing No.

1. Transport by land/ by air for imme diate use at the destination or up to 6 months storage in a hall

Packing No. 1

2. Sea transport and/ or up to 12 months storage (from the date of packing

Packing No. 2

Preservation External

Internal with test run

Internal without test run

External preservation No. 1

Internal preservation Internal preservation No. 1 No. 2

External preservation No. 2

3. Sea transport and/ or 12 to 24 months storage from the date of packing

Packing No. 3

4. Extended duration of protection (on expiry of the dura tion of protection)

Renew foil and weld

External preservation No. 3

Internal preservation No. 3

Replacing: 3625-006212en dt. 1998-05-07

This specification is identical with the Work Document c 076.7 (No. 3644-006482).

006212en

1999-02-16 / SBam cfm-LS crtp-TRg

Voith Turbo GmbH - D-74555 Crailsheim

Postfach 1555 žTelefon (07951) 32-0 ž Telefax 32-500

3625-006212 en REV. 1 Page 1/4

Preservation and Packing Specification of Coupling Types "R", "RW", "S", "TP", "T", Retarder "VIR" and Torque Converter "E"

External preservation No. 1 a. b. c.

Painting acc. to the order specifications. Brillant parts of iron sprayed with "Shell Ensis Fluid G" *). See note.

External preservation No. 2 a. b. c.

Painting acc. to the order specifications. Brilliant parts of iron: If possible, apply "Valvoline Tectyl 506" *), otherwise sprayed with "Shell Ensis Fluid G" *). See note.

External preservation No. 3 a. b. c.

Check the external preservation. If required, mend acc. to the external preservation No. 2. Replace the drying agent.

*)

Prior to installation of the machines or parts, clean the sprayed or applied surfaces with solvent (white spirit or petroleum).

Note: If, for certain orders, non-interrupted packaging with VCI-preservation products is ensured, corrosion protection will also be admissible by means of this preservation method, after consultation.

Internal preservation No. 1 All types:

Internal preservation by test oil during test run. If the order specification provides "Inspection" after the test run, spraying with solvent-free anticorrosive oil (by the works "Shell Ensis Motor Oil 20"), as far as accessible. (Alternatives for "Shell Ensis Motor Oil 20" - see 3625006237). Fill the machine inside with dry air, relative humidity of air max. 10 %.

Type R, RW:

Internal preservation No. 2 Type T:

Standard: Specific instruction:

Internal preservation is not necessary. Fill in 10 - 20 % of the nominal filling of solvent-free anticorrosive oil (by the works "Shell Ensis Motor Oil 20") and swing the VTC. Or: Spray with solvent-free anticorrosive oil (by the works "Shell Ensis Motor Oil 20"), if accessible. Alternatives for "Shell Ensis Motor Oil 20" - see 3625-006237).

1999-02-16 / SBam cfm-LS crtp-TRg

Voith Turbo GmbH - D-74555 Crailsheim

Postfach 1555 žTelefon (07951) 32-0 ž Telefax 32-500

3625-006212 en REV. 1 Page 2/4

Preservation and Packing Specification of Coupling Types "R", "RW", "S", "TP", "T", Retarder "VIR" and Torque Converter "E"

Types R, RW, S, TP, VIR and E:

Type R, RW:

All surfaces of iron parts (also bores, hollow spaces and inner surfaces of piping) sprayed, immersed or flushed with solvent-free anticorrosive oil (by the works "Shell Ensis Motor Oil 20") during mounting acc. to the mounting progress. Subassemblies sprayed during mounting, if accessible. (Alternatives for "Shell Ensis Motor Oil 20" - see 3625-006237). Fill the machine inside with dry air, relative humidity of air max. 10 %.

Internal preservation No. 3 Type T:

a.

In conformity with the internal preservation No. 2: Special instruction.

Types R, RW, S, TP, VIR and E:

a. b.

Check the preservation. Spray runner parts and all walls with solvent-free anticorrosive oil (e.g. "Shell Ensis Motor Oil 20"), by turning the runner parts. (Alternatives for "Shell Ensis Motor Oil 20" - see 3625-006237.) Spray the inside of piping with solvent-free anticorrosive oil (see above). Alternatively, fill the machine inside with dry air, relative humidity of air max. 10 %. As far as possible, fill the machine inside with dry air, relative humidity of air max. 10 %.

c.

Type R, RW:

d.

Packing No. 1 a.

b.

Device to suit transportation (e.g. shipping crate, holder, support). Packing is made to the respective latest edition of the packing directives of the "Bundesverband Holzpackmittel - Paletten - Exportverpackung (HPE) e.V.". Weather protection by transport means.

Packing No. 2 a.

b. c. d. e. f.

Device to suit transportation (e.g. shipping crate, holder, support). Packing is made to the respective latest edition of the packing directives of the "Bundesverband Holzpackmittel - Paletten - Exportverpackung (HPE) e.V.". Sharp edges and contact surfaces rounded/made safe by flexible materials. Welded in PE-foil. Drying agent acc. to DIN 55 473 /55 474. Waterproof carton or wooden box. Internal case cover lined with closed web plate of polyethylene (Akylux). In case of joint plates, shimmed with PVC-foil.

Packing No. 3 a.

b. c. d. e. f.

Device to suit transportation (e.g. shipping crate, holder,support). Packing is made to the respective latest edition of the packing directives of the "Bundesverband Holzpackmittel - Paletten - Exportverpackung (HPE) e.V.". Sharp edges and contact surfaces rounded/made safe by flexible elements. Welded in aluminium sandwich foil. Drying agent acc. to DIN 55 473 /55 474. Waterproof carton or wooden case. Internal case cover lined with closed web plate of polyethylene (Akylux). In case of joint plates, shimmed with PVC-foil.

1999-02-16 / SBam cfm-LS crtp-TRg

Voith Turbo GmbH - D-74555 Crailsheim

Postfach 1555 žTelefon (07951) 32-0 ž Telefax 32-500

3625-006212 en REV. 1 Page 3/4

Preservation and Packing Specification of Coupling Types "R", "RW", "S", "TP", "T", Retarder "VIR" and Torque Converter "E"

To be observed at site:

Equipment installed or ready for installation: Especially ensure that the equipment preservation is effective since this equipment is frequently exposed to additional hazards, such as water, major contamination and mechanical damage.

Complete equipment mounted on foundation: That means measures enabling a supplementary internal protection if standstill times of approx. 12 months are expected and if the original preservation is no longer ensured due to interventions. Fill units with oil free from water. As a function of the product, the following action can be taken in 1 - 2 months intervals:

-

Operational equipment: Start and only operate for a short time (approx. 5 minutes) for wetting the inner parts with oil; do not run warm.

-

Non-operational equipment: a.

Units with operational electric startup lubricating pump or oil pump and oil tank: Start the pump, rotate the equipment if possible. Move the operational parts (e.g. joints) and regrease.

b.

Units without operational electric startup lubricating pump or oil pump: Drain the oil from the tank, spray oil in through the housing orifices and pump oil through the piping by a separate oil pump, running time approx. 5 minutes, rotate the equipment if possible. Move operational parts (e.g. joints) and regrease.

Attention: Prior to filling in the operating fluid, consult the supplier with regard to its compatibility with the internal preservation agent.

1999-02-16 / SBam cfm-LS crtp-TRg

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3625-006212 en REV. 1 Page 4/4

S TP, DTP E VIR

Operating Fluids ISO VG 32 for Hydrodynamic Circuits 1.

Field of application This specification applies to: Variable speed turbo couplings of type ”S”, fill-controlled turbo couplings of types ”TP”, ”DTP”, torque converters of type ”E” and industrial retarders of type ”VIR”. This list may not be applicable in individual cases involving special requirements. In such cases, the appropriate specifications will be agreed when handling the order and stated in the instruction manual.

2.

Requirements to be fulfilled by operating fluids Characteristic value Kinematic viscosity Viscosity index Density Pourpoint Flash point Corrosive effect on copper Protection against corrosion of steel Demulsibility Ageing characteristic, increase of neutralisation number after 1000 h Neutralisation number (new oil) Air release property

Test procedure DIN 51 562 ASTM D445 DIN ISO 2909 ASTM D2270 DIN 51 757 ASTM D1298 DIN 51597 ASTM D 97 DIN ISO 2592 ASTM D92 DIN 51 759 ASTM D130 DIN 51 585 ASTM D665 DIN 51 599 ASTM D1401 / ISO 6614 DIN 51 587 ASTM D943

Mechanical FZG test

DIN 51 558 ASTM D974 DIN 51 381 / IP 313 ASTM D3427 DIN 51 354 / IP 334

Compatibility with seals

DIN 53 521 DIN 53 505 ASTM D471

Test conditions 40 °C

Requirements ISO VG 32

Unit mm²/s (cSt)

≥ 95 15 °C

Procedure A & B

95 °C / 1000 h

0,2 % / 50 °C load stage in the A/8,3/90 test

SRE-NBR 1 DIN 53 538 168 h / 100°C BUNA N 168 h / 100°C

0.85 - 0.9

g/cm³

≤ -24

°C

≥ 175

°C

max. 2-100 A3 max. 2 0-A no rust demulsifying NZ(S) ≤ 2.0 TAN ≤ 2.0 NZ (S) ≤ 2 TAN ≤ 2 ≤5

mg KOH/g

*) mg KOH/g *) minutes

≥ 7 < 7 **) change in volume + 4 / - 1 hardness ± 4 change in volume + 4 / - 1 hardness ± 4

% Shore A % Shore A

*) >2 only after individual approval **) permissible for TP, DTP and designs with sleeve bearings Replacing: 3625-006072en of 22 June 1999, 3625-006081, 3625-006116 3625-006195, 3625-006196 3625-006197, 3625-006274 Data carrier 006072en

Date: 2000-03-30 Issued by: crtp-TRg/Shn Checked by: crt-vB

Voith Turbo GmbH - D-74555 Crailsheim

Postfach 1555 žTelefon (07951) 32-0 ž Telefax 32-500

3625-006072en REV. 3 Page 1/3

Operating Fluids ISO VG 32 for Hydrodynamic Circuits

S TP, DTP E VIR

Starting viscosity under the conditions applying at destination must not exceed 250 mm²/s (cSt) in case centrifugal pumps are used for oil supply and when using displacement pumps with sufficient input power (refer to the works) up to 1000 mm²/s (cSt) are permitted. 3.

Oil selection by operators and mineral oil companies Considering the requirements of section 2 and Sheet 3625-006052en, the following types may be used: Hydraulic oils HLP 32 to DIN 51524 part 2. For types TP, DTP and units with sleeve bearings also hydraulic oils HL 32 to DIN 51524 part 1.

4.

Recommended types The following table includes hydraulic oils to DIN 51524 part 2 which meet the requirements of section 2 and which have proven in action under normal operating conditions. As the local operating conditions and the oil qualities may vary, we cannot assume any liability for the oil itself. In case of negative operating result, warranty claims in this connection are not accepted. Supplier

Designation

ADDINOL

ADDINOL Hydraulic Oil HLP 32 ADDINOL Hydraulic Oil HLP 32 AF ADDINOL Hydrod. Transmission Oil SGL 18 AGIP Blasia 32 AGIP OSO 32 ARAL DEGOL BG 32 ARAL Vitam GF 32 AUTOL Hydraulic Oil HY-S 32 ISO AVIA GEAR RSX 32-S BHARAT HYDROL HLP-32 BP Energol HL-XP 32 BP Energol HLP-HM 32 Torque Fluid 32 HYSPIN AWS 32 HYSPIN SP 32 HYSPIN VT 2 CEPSA EP 125 CEPSA HIDRAULICO HM 32 CHEVRON Mechanism LPS 32 CONOCO Hydroclear AW Hydraulic Fluid 32 DEA Pentran 32 ELF Transmissa 32 ELFOLNA 32 ESSO NUTO H 32 ESSO Hydraulic Oil HLP 32 EXXON NUTO H 32 EXXON NUTO HP 32 EXXON TERESSTIC GT EP 32

Agip ARAL AUTOL AVIA BHARAT BP CALTEX CASTROL

CEPSA CHEVRON CONOCO DEA ELF ESSO EXXON

Date: 2000-03-30 Issued by: crtp-TRg/Shn Checked by: crt-vB

Voith Turbo GmbH - D-74555 Crailsheim

Postfach 1555 žTelefon (07951) 32-0 ž Telefax 32-500

3625-006072en REV. 3 Page 2/3

Operating Fluids ISO VG 32 for Hydrodynamic Circuits

S TP, DTP E VIR

Supplier

Designation

FINA FUCHS DEA G.T.A. Ltd. GULF OIL India Ltd. HINDUSTAN PETROLEUM C.

FINA HYDRAN VT 32 FUCHS DEA Renofluid TF 1500 GTA HYDRAULIC OIL EP 32 GT1063 Gulf Harmony AWT 32 *) ENKLO HLP 32 ENKLO VT 32 Servo Torque 10 Servo System HLP 32 KLÜBER Lamora HLP 32 Q8 Haydn 32 Mobilfluid 125 Mobil DTE 24 Mobil DTE Oil Light Mobil Coupling Fluid 125 V MOGUL HM 32 MOGUL OT-HP3 OEST HYDRAULIC OIL H-LP 32 * ISO Petro Canada Premium AW 32 Petro-Oil HYDROL HLP 32 REPSOL TELEX E-32 Tegula Oil 32 Tellus Oil 32 Shell Turbo Oil GT-EP 32 Drolik 16-525 SK ZIC Supervis AW 32 *) Wintershall WIOLAN HF 32 Turbofluid SUNVIS 832 WR TEXACO Rando HD 32 TEXACO Regal Oil R&O 32 TEXACO TEXTRAN V 32 TOTAL Azolla ZS 32 TOTALFINA Azolla AF 32 Turbo Transmission Oil M 5-C 600 B Logatec Power Transmission Oil V-HCLP ISO VG 32 WISURA Kineta 32 V

Indian Oil Corporation Ltd. KLÜBER KUWAIT PETROLEUM Mobil

Mobil Australia MOGUL OEST Petro-Canada Petro-Oil REPSOL Shell

Shell Aseol SK Corporation SRS SUN OIL TEXACO

TOTAL TOTALFINA VALVOLINE VEBA WISURA

*) For ambient temperatures below –12°C, possibly also a heater for the outer piping is required. This recommendation does not claim to be complete.

Date: 2000-03-30 Issued by: crtp-TRg/Shn Checked by: crt-vB

Voith Turbo GmbH - D-74555 Crailsheim

Postfach 1555 žTelefon (07951) 32-0 ž Telefax 32-500

3625-006072en REV. 3 Page 3/3

Adjustment description of limit switch

Functional description The torque converter is equipped with one or two limit switches (electrical limit switch) to signal the filling or draining procedure. Depending on the position, the contact pin is pressed to the outside (functional position) via the piston of the control valve.

For example

Arrangement with two limit switches

Adjustment "limit switch/contact pin" The limit switch should only be adjusted if the contact pin is in its initial position. Move the limit switch on the bracket as far as possible towards the contact pin until the pin of the limit switch touches the contact pin. Fix the limit switch on the bracket by screwing.

1999-03-04/Tj cria-HSr (p:\cr\crkddok\3626-)

Voith Turbo GmbH & Co. KG - D-74555 Crailsheim Postfach 15 55 Telefon (07951) 32-0 Telefax 32-500

3626-013514 en

Multi-turn actuators SA 07.1 - SA 48.1 SAR 07.1 - SAR 30.1 AUMA NORM Operation instructions

Multi-turn actuators SA 07.1 - SA 48.1 / SAR 07.1 - SAR 30.1 AUMA NORM

Scope of these instructions:

Operation instructions

These instructions are valid for multi-turn actuators for open-close duty, SA 07.1 - SA 48.1, and multi-turn acuators for modulating duty, SAR 07.1 SAR 30.1. These operation instructions are only valid for ”clockwise closing”, i.e. driven shaft turns clockwise to close the valve.

Table of Contents 1. Safety instructions . . . . . . . . . . . 1.1 Range of application . . . . . . . . . 1.2 Short description . . . . . . . . . . . 1.3 Commissioning (electrical connection) 1.4 Maintenance . . . . . . . . . . . . . 1.5 Warnings and notes. . . . . . . . . . 1.6 Further notes . . . . . . . . . . . . .

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3 3 3 3 3 3 3

2. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3. Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4. Mounting to valve/ gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5. Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 6. Electrical connection. . . . . . . . . . . . . 6.1 Terminal plan . . . . . . . . . . . . . . . . 6.2 Type of seating . . . . . . . . . . . . . . . 6.3 Controls AUMA MATIC / AUMA MATIC MC 6.4 Microswitches . . . . . . . . . . . . . . . . 6.5 Fitting of plug cover . . . . . . . . . . . . .

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8 8 9 9 9 9

7. Setting of the limit switching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7.1 Setting for end position CLOSED (black section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7.2 Setting for end position OPEN (white section). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 8. Setting of the DUO-limit switching (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 8.1 Setting for direction CLOSE (black section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 8.2 Settings for direction OPEN (white section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 9. Setting of the torque switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 10. Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 11. Setting of the mechanical position indicator (option) . . . . . . . . . . . . . . . . . . . . . . . . . 13 12. Setting of the potentiometer (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 13. Setting of the electronic position transmitter RWG (option) . . . . . . . . . . . . . . . . . . . . . . 15 13.1 Setting for 2-wire system 4 - 20 mA and 3- /4-wire system 0 - 20 mA . . . . . . . . . . . . . . . . . 16 13.2 Setting for 3- / 4- wire system 4 - 20 mA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 14. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 15. Exploded view SA 07.1 - SA 16.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Spare parts list SA 07.1 - SA 16.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 16. Declaration of Conformity and Declaration of Incorporation . . . . . . . . . . . . . . . . . . . . . 21 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Addresses of AUMA offices and representatives. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Multi-turn actuators SA 07.1 - SA 48.1 / SAR 07.1 - SAR 30.1 AUMA NORM

Operation instructions

1.

Safety instructions

1.1 Range of application

AUMA multi-turn actuators are designed for the operation of industrial valves, e.g. globe valves, gate valves, butterfly valves and ball valves. For other applications, please consult us. AUMA is not liable for any possible damages resulting from use in other than the designated applications. Such risk lies entirely with the user. Observance of these operation instructions is considered as part of the actuator’s designated use.

1.2 Short description

AUMA multi-turn actuators type SA 07.1 - SA 48.1 and SAR 07.1 SAR 30.1 have a modular design. The limitation of travel is realised via limit switches in both end positions. Torque seating is also possible in both end positions. The type of seating is stated by the valve manufacturer.

1.3 Commissioning (electrical connection)

During electrical operation certain parts inevitably carry lethal voltages. Work on the electrical system or equipment must only be carried out by a skilled electrician himself or by specially instructed personnel under the control and supervision of such an electrician and in accordance with the applicable electrical engineering rules.

1.4 Maintenance

The maintenance instructions (refer to page 18) must be observed, otherwise a safe operation of the actuator is no longer guaranteed.

1.5 Warnings and notes

Non-observance of the warnings and notes may lead to serious injuries or damages. Qualified personnel must be thoroughly familiar with all warnings and notes in these operation instructions. Correct transport, proper storage, mounting and installation, as well as careful commissioning are essential to ensure a trouble-free and safe operation. The following references draw special attention to safety-relevant procedures in these operation instructions. Each is marked by the appropriate pictograph. This pictograph means: Note! ”Note” marks activities or procedures which have major influence on the correct operation. Non-observance of these notes may lead to consequential damage. This pictograph means: Electrostatically endangered parts! If this pictograph is attached to a printed circuit board, it contains parts which may be damaged or destroyed by electrostatic discharges. If the boards need to be touched during setting, measurement or for exchange, it must be assured that immediately before a discharge through contact with an earthed metallic surface (e.g. the housing) has taken place. This pictograph means: Warning! ”Warning” marks activities or procedures which, if not carried out correctly, can affect the safety of persons or material.

1.6 Further notes

MOV

M

This pictograph means: Procedure may have been performed by valve manufacturer! If actuators are delivered mounted to a valve, this step has been done in the valve manufacturer’s plant. Setting must be checked during commissioning!

3

Multi-turn actuators SA 07.1 - SA 48.1 / SAR 07.1 - SAR 30.1 AUMA NORM

2.

Operation instructions

Technical data

Multi-turn actuator SA 07.1 -SA 48.1 and SAR 07.1 - SAR 30.1 Type of duty: (according to IEC 34-1/ VDE 0530)

SA:

Standard: Option: Standard:

Short-time duty S2 - 15 min Short-time duty S2 - 30 min Intermittent duty S4 - 25 % ED. Permissible number of starts see Technical data sheet for SAR Counter gear mechanism for end positions CLOSED / OPEN Adjustable torque switching for closing and opening direction see Technical data sheets for SA and SAR 5 - 20 W 3-pase AC motor, 1-phase AC motor or DC motor Standard: 3 thermoswitches Option: 3 PTC thermistors Standard: up to size SA(R) 16.1: AUMA AUMA plug/socket connector with screw type connections from SA(R) 25.1: Motor connection on terminals, controls on AUMA plug/socket connector − 25 °C to + 80 °C (with RWG or with AUMA MATIC up to + 70 °C) − 25 °C to + 60 °C Standard: IP 67 Option: IP 68 Standard: two-component iron-mica combination

SAR: Limit switching: Torque switching: Speeds: Heater in switch compartment: Motors: Motor protection: Electrical connection:

Ambient temperature:

SA: SAR:

Enclosure protection: (according to EN 60 529) Finish coating:

3.

Transport and storage

.. . .. ..

Transport to place of installation in sturdy packing. Do not attach ropes or hooks to the handwheel for the purpose of lifting by hoist. If multi-turn actuator is mounted on valve, attach ropes or hooks for the purpose of lifting by hoist to valve and not to multi-turn actuator. Store in well-ventilated, dry room. Protect against floor dampness by storage on a shelf or on a wooden palette. Cover to protect against dust and dirt. Apply suitable corrosion protection agent to bright surfaces.

If multi-turn actuators are to be stored for a long time (more than 6 months), the following points must be observed additionally:

. .

Prior to storage: Protect bright surfaces, especially of output drive parts and mounting surface, with long-term corrosion protection agent. Check for corrosion approximately every 6 months. If first signs of corrosion show, apply new corrosion protection.

After mounting, connect actuator immediately to electrical system, so that condensation is prevented by the heater.

4

Multi-turn actuators SA 07.1 - SA 48.1 / SAR 07.1 - SAR 30.1 AUMA NORM

Operation instructions

4.

. .

Mounting to valve/ gearbox MOV

M

Prior to mounting the multi-turn actuator must be checked for damage. Damaged parts must be replaced by original spare parts.

Mounting is most easily done with the valve shaft / gearbox shaft pointing vertically upward. But mounting is also possible in any other position. The multi-turn actuator is delivered ex works in position CLOSED (limit switch CLOSED tripped).

.

Check if mounting flange fits the valve/ gearbox.

Spigot at flanges should be loose fit! The output drive types B1, B2, B3 or B4 (figure A) are delivered with bore and keyway (usually according to ISO 5210).

Figure A

Output drive type B 1 / B 2 plug sleeve

Output drive type B 3 / B 4 bore with keyway

For output drive type A (figure B), thread must match the thread of the valve stem. If not ordered explicitly with thread, the stem nut is unbored or with pilot bore when delivered. Finish machining of stem nut see page 6.

.. ..

Check whether bore and keyway match the input shaft of valve/ gearbox. Thoroughly degrease mounting faces at multi-turn actuator and valve/ gearbox. Apply a small quantity of grease to input shaft of valve/ gearbox. Place actuator on valve/ gearbox and fasten. Fasten bolts (at least quality 8.8, refer to table 1) evenly crosswise.

Table 1

8.8 M 8 M 10 M 12 M 16 M 20 M 30 M 36

TA (Nm) 25 50 87 220 420 1 500 2 500

5

Multi-turn actuators SA 07.1 - SA 48.1 / SAR 07.1 - SAR 30.1 AUMA NORM

Operation instructions

Finish machining of stem nut (output drive type A): Figure B

Output drive type A stem nut 80.3

80.01/ 80.02 80.2

. . .. .. . ..

The output drive flange does not have to be removed from the actuator.

. .. ..

Remove spigot ring (80.2, figure B) with the help of a wrench or similar tool from the mounting flange. Take off stem nut (80.3) together with thrust bearing (80.01) and thrust bearing races (80.02). Remove thrust bearing and thrust bearing races from stem nut. Drill and bore stem nut and cut thread. When fixing in the chuck, make sure stem nut runs true! Clean the machined stem nut. Apply ball bearing grease to thrust bearing and races, then place them on stem nut. Re-insert stem nut with thrust bearings into the mounting flange. Ensure that dogs are placed correctly in the slots of the hollow shaft. Screw in spigot ring until it is firm against the shoulder. Press a few squirts of grease into the grease nipple with a grease gun.

Protection tube for rising valve stem Protection tubes may be supplied loose. Wrap thread with hemp or teflon tape. Screw protection tube into thread and tighten it firmly. For corrosion protection KS/ KX, push down the seal to the housing. Touch up possible defects in painting. Check whether cap is available and without damage.

6

Multi-turn actuators SA 07.1 - SA 48.1 / SAR 07.1 - SAR 30.1 AUMA NORM

Operation instructions

5.

Manual operation

.

Manual operation should only be engaged when motor is not running. Switching over while motor is running may lead to damage at multi-turn actuator (figure C)! Lift change-over lever in the center of the handwheel up to max. 85°, while slightly turning the handwheel back and forth until manual drive engages (figure D).

Figure C

Figure D

Manual force is sufficient for operating the change-over lever. The use of an extension is neither necessary nor permitted. Excessive force may damage the change-over mechanism.

.

Release change-over lever (should snap back into initial position by spring action). If change-over lever does not snap back, assist with hand to assure that the lever comes to the initial position (figure E).

Figure E

. .

Figure F

Manual operation remains engaged until motor is started again. Then motor operation is engaged automatically. Turn handwheel into desired direction (figure F).

Only operate manually when change-over lever is in its initial position!

.

Manual operation is automatically disengaged when motor is started

7

Multi-turn actuators SA 07.1 - SA 48.1 / SAR 07.1 - SAR 30.1 AUMA NORM

6.

Electrical connection

Operation instructions

Work on the electrical system or equipment must only be carried out by a skilled electrician himself or by specially instructed personnel under the control and supervision of such an electrician and in accordance with the applicable electrical engineering rules.

Figure G1 AUMA plug/socket connector (customer connection XK)

To protect the valve, the delay time, i.e. the time from limit or torque switch tripping until the motor is switched off, must not exceed 50 ms. We recommend to switch off the corresponding contactor directly by the limit or torque switch.

Name plate motor

For multi-turn actuators AUMA NORM electrical controls with reversing contactors must be installed. For actuators up to size SA(R) 16.1, the electrical connection is made at a plug / socket connector with screw type connections as standard. For actuators SA(R) 25.1 and larger, the motor connection is on terminals, the control connection is on plug/socket.

Switch compartment cover

. .. .

Actuator name plate

Figure G2: AUMA plug/socket with screw type connections (standard) Plug cover

Check whether type of current, supply voltage and frequency correspond to motor data (refer to name plate at motor). Remove plug cover (AUMA plug / socket connector) (figure G2). Loosen screws and remove socket carrier from plug cover. Insert cable glands suitable for connecting cables.

. .

Enclosure protection IP 67 or IP 68 is only ensured if suitable cable glands are used. Seal cable entries which are not used with suitable plugs.

Socket carrier

6.1 Terminal plan

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.. .

8

Connect cables according to order related terminal plan KMS TP . . . . The terminal plan applicable to the actuator is attached to the handwheel in a weather-proof bag, together with the operation instructions. In case the terminal plan is not available, it can be obtained from AUMA (state commission no., refer to name plate). Cross sections: 2 Control cables: max. 2,5 mm , 2 Motor connection SA 07.1 - SA 16.1: max. 6 mm . 2 2 Motor connection SA 25.1 - SA 48.1: 16 mm to 70 mm according to power rating Connect heater to prevent condensation. Connect thermoswitches. Complete motor protection is only assured if the thermoswitches are connected correctly. Our warranty for the motor will lapse if the thermoswitches are not connected. For the connection of position transmitters (potentiometer, RWG) screened cables must be used.

Multi-turn actuators SA 07.1 - SA 48.1 / SAR 07.1 - SAR 30.1 AUMA NORM

Operation instructions

6.2 Type of seating

.

MOV

M

The valve manufacturer specifies, whether switching off in the end positions should be by limit switch (limit seating) or torque switch (torque seating).

6.3 Controls AUMA MATIC / AUMA MATIC MC

In case the required reversing contactors are not to be installed in the control cabinet, for actuator sizes SA(R) 07.1 - SA(R) 16.1, the integral controls AUMA MATIC or AUMA MATIC MC can be easily mounted to the actuator at a later date. For enquiries and more information please state our commission no. (refer to actuator name plate).

6.4 Microswitches

Only the same potential can be switched on the two circuits of each switch (limit and torque switches). If different potentials are to be switched simultaneously, tandem switches are required. Versions with gold-plated microswitches (option) may only be loaded with low voltage (