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BHARAT HEAVY ELECTRICALS LIMITED
RAMACHANDRAPURAM :: HYDERABAD – 502 032
OPERATING AND MAINTENANCE INSTRUCTIONS

OF
PUMPS
VOLUME-2
HYDRAULIC COUPLING TYPE: R18KGS-14API
FOR BOILER FEED PUMP
MEJIA PHASE-II T.P.S - 2x500MW, UNIT-1&2
DAMODAR VALLEY CORPORATION

-1-
VOITH TURBO
POWER TRANSMISSION
Instruction Manual
for
VOITH Geared Variable Speed Coupling
Instruction Manual Of
Geared Variable speed Turbo coupling
Type R18 KGS
VOITH TURBO
Type: R 18 KGS - 14 API
Voith Code: Bharat S 150
Serial No.: 8203542
Should you have any questions with regard to the

In case ofGEARED
queriesVARIABLE
with regardSPEED TURBO
to this unit, COUPLING.
Please contact
please always state theatcoupling
the (vtip.service@voith.com)
serial number.
voith Turbo Private Limited Hyderabad.
Order No.:SOR - 08 - 049
GEARED VARIABLE SPEED TURBO COUPLING Type R18 KGS

2009-01-19
Code : BHEL-R18KGS 14API.:
Voith TurboCplg
GmbHserial No.: 114-00173
- D-74555 and 114-00174
Crailsheim 1
airev-RSe / Frk 91800009010 en
Postfach 1555 xTelefon (07951) 32-0 x Telefax 32-500
Instruction Manual for VOITH TURBO
VOITH Geared Variable Speed Coupling POWER TRANSMISSION
-2-
- Data Sheet -
1.Technical Data
GEARED VARIABLE SPEED TURBO COUPLING Type R18 KGS.
Code : BHEL-R18KGS
Geared 14API
Variable Speed Coupling: R 18 KGS - 14 API
Vith Order No.: SOR-08-049
Version No.: 049R00173 and 049R00174
Code: Bharat S 150
Machine
1. Serial Data
No.: 8203542
GEARED VARIABLE SPEED TURBO COUPLING
Voith Order No.: 38001272
Rotation seen in direction Input shaft Hydr. circuit Output shaft

of the power flow: CCW CW CCW
Geared variable speed pump as boiler feed pump drive

Power requirement of driven machine: Pa = 6475 kW
Motor speed: ne = 1495 rpm
Gear ratio: U1 = Ze/Z1 = 109/32
Primary speed: n1 = 5092 rpm
Full load slip: s = 2,0 %
Gear ratio: U2 = Z2/Za = 59/51
Max. output speed: na = 5773 rpm
Regulation range: 4 : 1 downwards
Weight (without oil filling) approx. 10000 kg
Hydraulic oil types: HLP 32 to DIN 51524, part 2
Oil tank filling: approx. 2500 l
Lube oil flow rate for booster pump: )
Lube oil flow rate for main motor: )
Lube oil flow rate for driven machine: ) Σ 300 l/min. at 1,5 to 2,0 kg/cm2
Lube oil quantity for connecting couplings )
Noise emission
Measuring surface sound pressure level: L PA max. 94 dB(A)
According to DIN 45635, section 23 or ISO 495
Pump insert: Working oil pump (centrifugal pump) and lube oil pump (gear pump)
Jointly driven as gear-tooth system drive via the pump shaft.
Auxiliary lube oil pump: MZP 820

Motor for aux. lube oil pump: DE 200 LA2
Technical data: 30 kW; 415 V; 50 Hz; 2950 rpm; IP 55; B5
Actuator: PME 120 AN

Continuous electronic power unit: EAS 822; Power supply AC 230 V (190 V ... 260 V)
Connecting couplings: Input side: * Output side: *

* not Voith supply

2009-01-19
airev-RSe / Frk Voith Turbo GmbH - D-74555 Crailsheim
Code : BHEL-R18KGS 14 API.: Cplg
Postfach 1555serial s (07951)
Nos.:
xTelefon 114-00173
32-0and
s 32-500
114-00174
x Telefax
91800009010 en 2
Instruction Manual for
VOITH TURBO
-3-
POWER TRANSMISSION
- Data Sheet -
Operating
Operating DataGeared
Data for for geared variable
Variable speed
Speed cplg.
Coupling:
Bearing temperatures nom. value < 90 °C

(46 - 51, 54 - 63, 66 - 69) alarm / trip 90 / 95 °C
Working oil temperature nom. value >60 - <110 °C

upstream of heat exchanger alarm 110 °C
(81, 86, 87, 88) trip 130 °C
Working oil temperature downstream nom. value >35 - <75 °C

of heat exchanger (80, 89) alarm 75 °C
Lube oil temperature upstream nom. value >45 - <65 °C

Lube oil temperature nom. value >35 - <55 °C

downstream of heat exchanger alarm 55 °C
(79, 83, 84, 85) trip 60 °C
Lube oil pressure, gauge (42) nom. value >1,5 - <3 kg/cm2
Pressure transmitter (71 - 73) main motor ON >1.2 kg/cm2
aux. lube oil pump OFF >3.0 kg/cm2
aux. lube oil pump ON <1.2 kg/cm2
alarm <1.0 kg/cm2
trip <0,8 kg/cm2
Differential pressure at lube oil filter alarm / change-over filter

(25, 25.1) and clean at 0,6 kg/cm2
Control oil pressure, gauge (43) nom. value >3 -<4 kg/cm2
Pressure transmitter (74 - 76) alarm <2.5 kg/cm2
trip <2.2 kg/cm2
Working oil pump pressure,

test connection (44, I see at assembly plan) >1.6 - <2.1 kg/cm2
Working oil pressure upstream of

circulation control valve,
test connection (21, II see at assembly plan) >1.0 - <1.8 kg/cm2
Working oil pressure downstream of

scoop tube,
test connection (45, III see at assembly plan) >1.8 - <3.5 kg/cm2
Oil level, sight glass (90) nom. Value max. - min. mark
Oil level switch (70) alarm 10mm > max. / 10mm < min. mark
2009-01-19
GEARED
airev-RSe VARIABLE Voith
/ Frk SPEED Turbo
TURBOGmbH
COUPLING Type R18
- D-74555 KGS
Crailsheim 91800009010 en
Code : BHEL-R18KGS 14 API.: Cplg serial Nos.: 114-00173 and 114-00174 3
1 Technical Data 1.2 Operating data
1.2.2 Heat exchanger
(Please have the design data filled in by the cooler supplier).
Design data
Heat exchanger LUBE oil Shell cham- Tube cham-
ber (oil) ber (water)
Medium Oil (ISOVG32) Water
Oil volume l/cooler ____l
Nominal flow rate V nom 49,2 - m3/hr 58,8 - m3/hr
Minimum flow rate due to corro- ______l/min
sion Vmin
Inlet temperature 65 - ºC 38 - ºC
Outlet temperature 50 - ºC 43 - ºC
Max. allowable working temper- 120 - ºC 70 - ºC
ature
Max.allowable working pressure 10 - kg/cm2 10 - kg/cm2
Test pressure (HYD) 13 - kg/cm2 13 - kg/cm2
- (Hydraulic) - (Hydraulic)
Heat exchanger WORKING oil Shell cham- Tube cham-

ber (oil) ber (water)
Medium Oil (ISOVG32) Water
Oil volume l/cooler ____l
Nominal flow rate V nom 90 - m3/hr 132,3 - m3/hr
Minimum flow rate due to corro- ______l/min
sion Vmin
Inlet temperature 95 - º C 38 - º C
Outlet temperature 57 - º C 48 - º C
Order No. SOR-08-049
Max. allowable working temper- 120 - º C 70 - º C

ature
Max.allowable working pressure 10 - kg/cm2 10 - kg/cm2
Test pressure kg 13 - kg/cm2 13 - kg/cm2
- (Hydraulic) - (Hydraulic)

GEARED VARIABLE SPEED TURBO COUPLING Type R18KGS
Code
Code : BHEL-R18KGS
: BHEL-Test Field.:14 API No.
Serial : Cplg serial
: 114 Nos.:114-00173 and 114-00174
- 0018s4 4
VOITH TURBO
VOITH Geared Variable Speed Coupling -5-
- General Contents -
POWER TRANSMISSION
Data
D Sheet,
aDataSh General
eet,GeneralContentaSheetContent
,GeneralContents 91800009010 en
Data Sheet
Data Sheet // Techn.
Technical DataDataforfor Geared
Geared Variable
Variable speedCoupling
Speed Turbo Coupling
Data Sheet
Data Sheet For Heat Exchanger
for Heat Exchanger
Amendment Report of Instruction Manual 2009-01-19
Part 1
Instruction Manual, Text

Trouble-shooting Table
Part 2
Parts List
Part 3
Drawings
Part 4
Voith Information Sheets
Part 5
Attaching Parts (Descriptions)

2009-01-19
GEARED
airev-RSe VARIABLE SPEED
/ Frk Voith TURBO
Turbo COUPLING Type R18
GmbH - D-74555 KGS
Postfach 1555 xTelefon (07951) 32-0
Code : BHEL-R18KGS 14 API : Cplg serial Nos.: 114-00173x Telefax 32-500
and 114-00174 5
-6-
VOITH TURBO
POWER TRANSMISSION
Part 1
Instruction Manual, Text
Trouble-shooting Table
2009-01-19
GEARED
airev-RSe / FrkVARIABLE Voith
SPEEDTurbo
TURBOGmbH
COUPLING Type R18
- D-74555 KGS
Postfach 1555 xTelefon (07951) 32-0 x Telefax
Code : BHEL-R18KGS 14 API : Cplg serial Nos.: 114-00173 and 114-00174
32-500 6
-1-
CONTENTS
Safety information
1. Design and Operation
2. Oil Circuits
2.1 Working oil circuit
2.2 Lube and control oil circuit
2.3 Lube oil circuit to the individual machines
3. Control
3.1 Scoop tube positioning (normal operation)
3.1.1 Setting and checking of scoop tube control
3.2 Oil flow control
3.3 Rapid regulation of geared variable speed coupling
4. As Delivered Condition
5. Assembly, Mounting Instructions

5.1 Important information - transport
5.2 Installation preparations for steel foundation
5.3 Positioning geared variable speed coupling on steel foundation
5.4 Alignment accuracy
5.5 Alignment procedure
5.6 Site pipework, cooler arrangement and cooler venting
5.7 Lube oil supplied to individual machines
5.8 Guards
5.9 Preservation after installation
5.10 Electric installation
6. Operating Oil
6.1 Filling with operating oil
7. Commissioning
7.1 Trial run preparations
7.2 Trial run
7.3 Measures to be taken at standstill periods
8. Operation of the Geared Variable Speed Coupling

8.1 Start-up, operation and shutdown of the geared variable speed

coupling as well as measures to be taken when the unit is at standstill
8.2 Operating data
8.3 Lube oil pressure, control oil pressure and monitoring of lube oil pressure
8.4 Monitoring of working oil
2007-07-27
GEARED VARIABLE SPEED TURBO COUPLING
GmbH Type R18 KGSCrailsheim
airev-RSe Voith Turbo - D-74555 3626-021393 en
Code : BHEL-R18 KGSPostfach
14 API.: Cplg
15 55serial Nos.:(07951)
x Telefon 114-00173
32-0 and 114-00174
x Telefax 32-500 7
-2-
8.5 Bearing temperatures

8.6 Lube oil filter
8.7 Oil level indication
8.8 Lubricating points of scoop tube control
9. Maintenance of Geared Variable Speed Coupling

9.1 Maintenance of double filter
9.2 Maintenance measures which can be taken with the unit running
9.3 Maintenance measures which can only be taken when the unit is at standstill
10. General Overhaul of the Geared Variable Speed Coupling

10.1 General remarks
10.2 Preconditions
10.3 Dismantling and reassembling
11. Dismantling the Geared Variable Speed Coupling

11.1.1 Removing the housing cover
11.1.2 Removing the scoop tube control and scoop tube
11.1.3 Removing the coupling runner
11.1.4 Dismantling the coupling runner
11.1.5 Removing the complete input shaft
11.1.6 Removing the output shaft (pinion shaft)
11.1.7 Removing the pump insert
11.1.8 Removing the aux. lube oil pump
11.2 Cleaning and checking the coupling parts
11.3 Reassembling the geared variable speed coupling
11.3.1 Preconditions and remarks
11.3.2 Reassembling the coupling runner
11.3.3 Mounting the coupling runner into the housing
11.3.4 Mounting the thrust bearings - primary side and secondary side
11.3.5 Fitting the scoop tube
11.3.6 Mounting the scoop tube control
11.3.7 Mounting the input shaft with gear
11.3.8 Mounting the output shaft (pinion shaft)
11.3.9 Mounting the pump insert
11.3.10 Mounting the aux. lube oil pump
11.3.11 Mounting the housing cover
11.4 Remaining commissioning work
2007-07-27
GEARED VARIABLE SPEED
airev-RSe TURBO
Voith Turbo COUPLING
GmbH Type R18 KGS
- D-74555 Crailsheim 3626-021393 en
Postfach 15 55 x Telefon (07951) 32-0 Telefax
Code : BHEL-R18 KGS 14API .: Cplg serial Nos.: 114-00173 xand 32-500
114-00174 8
-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 directlly.
Qualified Personnel
are persons who are familiar with the transportation, storage, setup, installation,
commissioning, operation and maintenance of the product and qualified to do their job,
as e.g.:
- training, instruction and entitled to operate and service the equipment, units, systems in
accordance with established safety practices for electrical circuits/wiring, high
pressures and temperatures and media harmful or detrimental to the environment
- proper handling and disposal of media and their components, e.g. filters/one-way
systems/oils etc.
- training or instruction according to established safety practices for maintenance and
use of safety equipment
- training in first aid
2007-07-27
airev-RSe Voith Turbo GmbH - D-74555 Crailsheim
GEARED VARIABLE SPEED TURBO15COUPLING
Postfach Type
55 x Telefon R18 KGS
(07951) 32-0 x Telefax 32-500
3626-021393 en
Code : BHEL-R18KGS 14API .: Cplg serial Nos.: 114-00173 and 114-00174 9
-4-
1. Design and Operation
The geared variable speed coupling consists of a two-stage spur gear and a variable speed
coupling arranged between the two stages. The torque of driven machine is transmitted to the
input shaft by a connecting coupling. The torque between input and primary shaft is
transmitted by means of a gear stage. The power flow between primary and secondary wheel
is achieved by a fluid flow. The torque is also transmitted to the output shaft via a gear stage.
A connecting coupling connects the output shaft and the machine to be driven.
The torque generated by the driving machine is provided to accelerate the fluid in the primary
wheel (pump impeller). This is delayed in the secondary wheel (turbine wheel) to produce an
equal torque. The fluid can only circulate in case of a pressure drop between the primary and
secondary wheel. This requires that the secondary wheel speed is lower than that of the
primary wheel. Thus, a slip is required for power transmission.
The coupling size is selected so that the full power can be transmitted with a low slip, the "full
load slip" (at max. filling). The output speed can be regulated infinitely by changing the oil
filling in the working chamber between the primary and secondary wheel. This is accomplished
by positioning the scoop tube accordingly, which will determine the oil filling of the working
chamber.
The power loss caused by the slip will heat up the working oil. The heat is then dissipated in
the working oil cooler.
2007-07-27
GEARED VARIABLE Voith
airev-RSe SPEED TURBO
Turbo COUPLING
GmbH - Type R18 KGS
D-74555 Crailsheim 3626-021393 en
Postfach
Code : BHEL-R18KGS 14 API 15 55 x Telefon
.: Cplg (07951)
serial Nos.: 32-0 x Telefax
114-00173 32-500
and 114-00174 10
-5-
2. Oil Circuits
(see Oil Circuit and Measuring Point Scheme)
The same oil is used as working and lube oil. The working oil pump (13, a centrifugal pump)
and the main lube pump (14, a gear pump) are combined to form a pump insert and are driven
by the input shaft of geared variable speed coupling.
The electrically driven aux. lubricating pump (15) is provided to supply the unit with lube oil for
start-up, when running down as well as in case of any troubles.
2.1 Working oil circuit
The working oil circuit consists of a closed circuit superposed by an open circuit so
that the filling can be changed.
In the closed circuit, the oil which flows into the variable speed coupling (19) via the
circulating control valve (30) for power transmission and heat dissipation is removed
by the displaceable scoop tube (39). Under the action of dynamic pressure, the oil
flows through the working oil cooler (22) and circulating control valve (30) back into
the coupling.
The open circuit is made up of the working oil pump (13), throttle (26) and pressure
relief valve (27). The coupling (19) is filled with oil flowing from the open to the closed
circuit. Any excessive oil supplied by the working oil pump flows through the pressure
relief valve (27) back into the oil tank. The same applies when the coupling filling is
reduced.
The connecting line with orifice plate (91) between lube and working oil circuit is
provided for faster filling of the working oil circuit during start-up.
The operating pressure of working oil is set on the pressure relief valve (27), see
section 8.4.
If the closed circuit is broken and the oil temperature of variable speed coupling (19)
rises to 180 °C, the fusible plug screws (20) blow. Bores in the plugs are thereby
released and the coupling (19) drains. If the fusible plug screws blow due to a
temporary thermal overloading of the oil circuit, due to cooler failure or overloading of
coupling, the control behaviour of the coupling only changes slightly and the sump
temperature rises a little e.g. the control behaviour of the variable speed coupling only
changes slightly. However, other features are a slight rise of the sump temperature,
longer run-up time of driven machine and almost reaching the max. output power.
The fusible plug screws (item 0310/0010/0060, see Vertical Section) can be replaced
by removing the inspection cover II on the housing cover and turning the input shaft
until the three fusible plug screws are accessible.
2007-07-27
airev-RSe VoithTURBO
Turbo COUPLING
GmbH Type R18 KGS
- D-74555 Crailsheim 3626-021393 en
Code : BHEL-R18 KGS 14 API .: Cplg serial Nos.: 114-00173x and 32-500
114-00174 11
-6-
2.2 Lube and control oil circuit
The main lube pump (14) pumps oil out of the sump and feeds through the non-return
valve (17), pressure relief valve (28), lube oil cooler (23) and the reversible double
filter (24) to the bearing points and the gear wheels.
Oil for hydraulic scoop tube control is branched off upstream of the adjustable orifice
plate (29). The control pressure is >3 - <4 kg/ cm2, see indication at the pressure
gauge (43).
The lube oil pressure is set to >1.5 - <3 kg/cm2, see indication at the pressure gauge
(42). Control oil pressure and lube oil pressure are set on the pressure relief valve (28)
and on the adjustable orifice plate (29) as a function of each other.
To ensure the bearings are coated with oil during coupling start-up, run-down and
failure, they are supplied with oil by the aux. lube oil pump (15) before the drive motor
is switched on and after it is switched off (see section 8.3 Lube pressure monitoring).
The aux. lube oil pump, which is driven by the electric motor (16), draws lube oil out of
the sump and pumps it through a non-return valve (17) into the lube oil circuit.
2.3 Lube oil circuit to the individual machines
The lube oil for the individual machines, such as drive motor, driven machine or
connecting coupling etc., is taken from the lube oil circuit of the geared variable speed
coupling and is fed again to the oil tank of the coupling.
By means of the orifice plates installed at the flanged connection geared variable
speed coupling and/or upstream of the lubricating points of the individual units, the
flow rate and the lube oil pressure are pre-set to the admissible values.
Data concerning the lube oil supply of individual machines are indicated and
described in section 5.7.

2007-07-27
Code : BHEL-R18Voith
airev-RSe KGS 14 API .:GmbH
Turbo Cplg serial Nos.: 114-00173
- D-74555 and 114-00174 3626-021393
Crailsheim 12 en
Postfach 15 55 x Telefon (07951) 32-0 x Telefax 32-500
-7-
3. Control
The output speed of the geared variable speed coupling is controlled by an actuator (33)
adjusting the scoop tube (39) and thus the filling in the variable speed coupling (19).
The cam disc (32) serves for linearization the angle of adjustment of actuator as a function of
the controlled variable (speed).
The standard cam disc is designed so that, at a nominal angle of rotation, the scoop tube can
be set between 100 % and minimum.
As a function of the regulating range and the torque characteristic of the driven machine,
machining of the cam disc can be necessary.
3.1 Scoop tube positioning (normal operation)

The scoop tube which regulates the amount of oil in the turbo coupling is controlled
by turning the cam disc (32) by means of the actuator. The control valve (35) is
actuated by a roller which is held by spring pressure against the cam disc.
If the cam disc (32) is moved in direction "full output speed", the pressure oil flows
into the chamber (38) of the double-acting positioning cylinder. The scoop tube (39)
which is connected to the piston (37) is moved in direction "full output speed" and the
degree of filling in the coupling (19) is increased. Simultaneously, the control valve
(35) is returned to its starting position by a spring-load roller which presses against
the slope of the scoop tube and shuts off the oil feed as soon as the scoop tube
position pre-set by the actuator is reached.
When the cam disc (32) is turned in direction "low output speed", the pressure oil
flows into the chamber (36) and causes the oil to flow in the opposite direction to that
described above.
During normal operation, the two 3/2-way solenoid valves (92, 93) are non-energized
and allow free fluid flow.

2007-07-27
Code : BHEL-R18 KGS Turbo
14 API .:GmbH
Cplg serial Nos.: 114-00173 and 114-00174 13
airev-RSe Voith - D-74555 Crailsheim 3626-021393 en
-8-
3.1.1 Setting and checking of scoop tube control
The rotational angle of the cam disc is 120° between min. % and 100 %
scoop tube position.
The positioning distance must be limited by stops. These stops must not
touch the cam discs but instead a flat steel bar could be welded on the cam
disc hub, for example.
Check the setting for 100 % scoop tube position after mounting the actuator.
For this purpose, switch on the aux. lube oil pump and set the cam disc to
100 % position. The scoop tube stroke indicator must indicate 100 % scoop
tube position. If not, correct the indication setting by
unscrewing the check nut (see opposite sketch).

Turn the set screw 0270/0040
guiding the guide bolt (see Drawing “Section
through Control” Sheet 1, Section C-D)
out of the keyway. The guide bush has a
- <--> + mark. Turn the guide bolt,
dependent on the position of scoop tube
stroke indicator in direction - or + until
the scoop tube stroke indicator indicates
100 % scoop tube position.
Secure the guide bolt by inserting the set screw
in the keyway. The set screw must
not touch the keyway base. Secure the
set screw using the check nut.
Important: After taking this measure check floating of the guide bolt over
the complete regulating range.
If min. scoop tube position has to be limited, for example, to prevent running
slower than a certain output speed, file the scoop tube cam disc at this point
and weld on the oil flow cam disc in this angle area in which the scoop tube
cam disc was filed. The stroke as it was the original condition of the scoop
tube positions has to be maintained.

2007-07-27
airev-RSe Voith
Code : BHEL-R18 KGS Turbo
14 API GmbH
.: Cplg - D-74555
serial Nos.: Crailsheim
114-00173 and 114-00174 14
3626-021393 en
-9-
3.2 Oil flow control

The duty of the circulating control valve (30) is to supply the coupling with enough
working oil to compensate for the losses. The cam disc (31) controls the circulating
control valve as a function of the scoop tube position (see sketch below). The
maximum oil flow is factory-set based on values calculated from the output.
If the oil temperatures are too low or too high at certain operating points, the oil flow
through the circulating control valve can be changed.
There are three possibilities:
a) Set the maximum oil flow (between

60 and 70 % output speed by
turning the cam disc by max. +/- 13°.
b) After releasing the check nut

remove the set screw and turn the
guide bolt in direction + or -
(+ more oil flow, - less oil flow
which is punched into the guide
bolt or guide bush).
c) Reshape the oil flow cam disc:

This means:
Building up the cam = more oil flow,
Filing off the cam = less oil flow.
Important:
After carrying out one of these modifications, check
floating of piston over the whole regulating range.

2007-07-27
Code : BHEL-R18 KGS 14 API .: Cplg serial Nos.: 114-00173 and 114-00174 15
airev-RSe Voith Turbo GmbH - D-74555 Crailsheim 3626-021393 en
- 10 -
3.3 Rapid regulation of variable speed coupling

(cam control by-passed using solenoid valves)
Using this arrangement, the scoop tube is moved from any position towards "low
output speed" and back in the direction "full output speed" more rapidly than is
possible with the actuator. Normal emptying and filling times of the variable speed
coupling with up to 75 mm2/s oil viscosity are around 5 to 10 seconds. Rapid
regulation is used, for example, in the following cases:
1) Quick run-up of drive motor and driven machine by rapid draining of the
variable speed coupling
The two 3/2-way solenoid valves (92 and 93) are energized for rapid run-up
of drive motor under no load. Valve (92) lets pressure oil flow into the
chamber (36) of the scoop tube positioning cylinder, irrespective of the
position of the control valve (35). At the same time, the valve (93) stops the
supply of pressure oil and allows the oil in the chamber (38) to flow
unhindered into the oil tank. The scoop tube (39) moves in the position 0 %
filling.
After run-up of drive motor (with approx. 95 % nominal speed), the solenoid
valves (92 and 93) are deenergized and the scoop tube (39) moves at once
to the position fixed by the actuator. The variable speed coupling fills within
the specified time and the driven machine runs up to the corresponding
speed.
2) Quick run-down of drive motor and driven machine by rapid draining of the
variable speed coupling
The two solenoid valves (92 and 93) are energized for rapid drain of the
variable speed coupling. The scoop tube (39) immediately moves in the
position 0 % filling, as per description in section 1. The variable speed
coupling drains and power transmission from drive motor to driven machine
is interrupted.

2007-07-27
Code : BHEL-R18 KGS 14 API .: Cplg serial Nos.: 114-00173 and 114-00174 16
GEARED VARIABLE SPEED TURBO
Postfach 15 55COUPLING
x TelefonType R18 32-0
(07951) KGS x Telefax 32-500
Code : BHEL-Test Field.: Cplg serial No.: 114-00184 16
- 11 -
4. As Delivered Condition
In as delivered condition, the geared variable speed coupling cannot be operated

independently. Prior to commissioning, the tests and, if necessary, measures for meeting with
the safety instructions of the complete unit have to be effected.
The geared variable speed coupling (machine) cannot be used in as delivered condition. The
conditions are good for taking measures on the complete unit to protect persons, material,
property and the environment. These measures are to be determined by the supplier in the
planning phase or prior to initial commissioning.
Before leaving the factory each coupling undergoes a test run.
Parameters measured: No-load losses, oil temperatures,

vibration.
The vibration is assessed as per VDI 2056.
Parameters set: Oil flow rates / oil pressures,

switch points of fitted monitoring
instruments.
The geared variable speed coupling is mounted on the oil tank. All internal piping for lube and
operating oil is assembled. Instruments are fixed to an instrument stand. The instrument stand
is flexibly mounted on the housing by means of silentbloc type rubber-metal connections.
All weld-neck flanges are fitted with seals and blanked off for transport.
The connecting coupling hubs will be mounted by Voith if they belong to the Voith supply.
The monitoring instruments fitted are marked.
Preservation:
The preservation and packing for sea transport and/or 12 to 24 months storage is described in
Sheet 740080119, please see Part 4.
2007-07-27
airev-RSe Voith Turbo GmbH - D-74555 Crailsheim 3626-021393 17
en
Code : BHEL-R18 KGS 14 API
Postfach 15.:55
Cplg serial Nos.:
x Telefon 114-00173
(07951) and 114-00174
32-0 x Telefax 32-500
- 12 -
5. Assembly, Mounting Instructions
5.1 Important information - transport
The Voith geared variable speed coupling is an industrial high-quality unit of well-
known machinery technique, with an easy construction, and any malfunctions can be
easily recognized.
The following work must only be carried out by qualified personnel (see safety
information).
Therefore, we recommend that the assembly and first commissioning be carried out
by one of our service engineers. Any faulty installation may result in unsatisfactory
operation and premature wear of the units. Installation dimensions etc. are shown in
the assembly plan.
The geared variable speed coupling is a machine with piping, cooler and single-wall
tank for mineral oil. Any additional environmental conditions must be determined at
site.
The Voith geared variable speed coupling will be shipped in a transport frame in
installation position. After removing the transport frame, the coupling must only be
placed down on the feet of the oil tank or on the feet of the foundation fixing.
The perfect condition of geared variable speed coupling and their assemblies is to be
preserved during installation and assembly work, long periods of storage and after
installation or in cases of standstill for operational reasons.
During assembly please consider the shaft displacements of the units due to
operation. Shaft displacements of the geared variable speed coupling are shown in
the attached Sheet No. 3644-006536en, please see Part 4.
Warning!
Improper lifting of the geared variable speed coupling may cause personal
injury and damage to property.
Hang the geared variable speed coupling only on the marked lifting points, see
Assembly Plan.
Use only proper lifting appliances in compliance with the safety regulations!
Keep away from any suspended load.
Transport the geared variable speed coupling in lashed condition and in
transport skids only (if available) and always set it on a suitable, solid and level
ground! Set it down on the contact surfaces of the housing or oil reservoir only!

2007-07-27
airev-RSeCode : BHEL-R18 KGS
Voith 14 APIGmbH
Turbo .: Cplg serial Nos.: 114-00173
- D-74555 and 114-001743626-021393
Crailsheim 18en
- 13 -
Lifting points located on the gearbox housing are provided for the own weight
of the geared variable speed coupling only! Do not lift it together with any other
machine/base frame!
Hang the geared variable speed coupling on the marked lifting points only
considering the included angle and the minimum height of crane hook, see
Assembly Plan.
Lift the geared variable speed coupling only without oil filling!
- Average out the axial tooth clearance of the input shaft of the geared
variable speed coupling by turning the shaft. The shaft distances can be
found in the assembly instructions for the connecting couplings. If the drive
motor rotor is axially located by the connecting coupling and the primary side
herringbone gear stage in the geared variable speed coupling's thrust
bearing, ensure that thermal expansion cannot cause the drive motor rotor to
move from its magnetic centre.
- It must be prevented that creeping or external currents reach the geared
variable speed coupling via input and output shaft. Bearings and driving gear
wheels of the filling pump can be damaged due to spark erosion.
- During assembly at site cover the geared variable speed coupling completely
with a tarpaulin against dirt, sparks, grinding dust and other environmental
influences harmful to the coupling. Especially protect the monitoring
instruments and the electric cables or cable ducts on the coupling.

2007-07-27Code : BHEL-R18 KGS 14 API .: Cplg serial Nos.: 114-00173 and 114-00174 19
airev-RSe 19
Voith Turbo GmbH - D-74555 Crailsheim 3626-021393 en
- 14 -
5.2 Installation preparation for steel foundation
1. Foundation check
Prior to starting installation, check the foundations made on-site for all machines
(e.g. booster pump, motor, geared variable speed coupling and main pump) for
correct dimensions, using the foundation plan. We recommend to preliminarily
arrange all machines with correct shaft distance to each other for checking.
Eliminate any differences by machining.
2. Iron shims for alignment
The height of steel foundations is to be dimensioned so that a free space of

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

2007-07-27
Code : BHEL-R18 KGS
airev-RSe 14 API
Voith .: Cplg
Turbo serial Nos.:
GmbH 114-00173
- D-74555 and 114-00174
Crailsheim 20
3626-021393 en
- 15 -
3. Mounting connecting couplings
Note! Suitable are gear couplings or all-metal couplings with low radial
restoring forces. Flexible connecting couplings are to be agreed in
each individual case.
Usually the input and output coupling halves are

already mounted prior to shipment,
i.e. the cover and coupling hub are mounted on
the shaft end while the coupling sleeve is
packed separately. Should the geared variable
speed coupling be supplied without the
connecting coupling attached, the assembly at
site should be carried out as follows:
Clean shaft and hub from preserving agents using fuel, nitro thinner (no
petroleum) and degrease. Check the bore, shaft, keyway and key for dimensional
accuracy.
Remove the key from the keyway and fit it into the hub groove, then reinsert the
key into the keyway, check height of key. The clearance between keyway and key
should be 0.2 - 0.3 mm. Apply a thin coat of Molykote or an equivalent lubricant.
As a function of the connecting coupling, slip cover and 0-seals over shaft end,
mount coupling hub using mounting aid.
Slip the sleeve over the hub - this applies only to connecting couplings without
intermediate piece. For couplings with adequate spacing between shaft ends, the
sleeves with intermediate piece can be mounted at a later date.
4. Mounting oil drain pipe
As the oil tank bottom is usually inaccessible when mounted, an oil drain pipe
should be flanged on before the coupling is placed in position (see assembly
plan).
2007-07-27
airev-RSe Voith Turbo GmbH - D-74555 Crailsheim 3626-02139321
en
Code : BHEL-R18 KGS Postfach
14 API.: Cplg
15 55serial No.: 114-00173
x Telefon (07951) 32-0and 114-00174
x Telefax 32-500
- 16 -
5.3 Positioning geared variable speed coupling on steel foundation
Pre-positioning checks
Have the coupling sleeves of the connecting couplings been mounted?

Is, in the case of connecting couplings with intermediate piece, the shaft spacing
large enough to allow subsequent mounting of the spacer sleeve? Can the oil drain
pipe be fitted after placing the coupling in position?
If the driving machine has already been mounted, check axial clearance. Move rotor
into zero position by averaging the axial clearance. Usually, the driven machine is
fixed in axial direction. This should be checked.
When positioning the units on the foundation, check the axial clearance of the
connecting couplings.
Tapped holes for adjusting screws are provided on the gear housing to align the
geared variable speed coupling. Mount these adjusting screws prior to assembly. We
supply different shim sizes.
2007-07-27
VoithTURBO
TurboCOUPLING
GmbH - Type R18 KGS
airev-RSe D-74555 Crailsheim 3626-021393 en
Code : BHEL-R18 KGS 14 API 15
Postfach .: Cplg serial No.:
55 x Telefon 114-00173
(07951) 32-0 x and 114-00174
Telefax 32-500 22
- 17 -
5.4 Alignment accuracy
The alignment is satisfactory if the radial measurement "A" and the axial difference
measurements "B" and "C" show dial gauge deviations not in excess of +/- 0.03 mm
when turning the shafts by 360°. Please note the shaft displacements due to
operation. Make alignment when the machine is cold.
The natural sagging of motor and

pump shafts (I pump installed
first, II motor installed first)
results in a slight inclination
of the geared variable speed
turbo coupling. For I and II in
longitudinal direction, level
location is therefore not required.
The horizontal position at
right angles to the main axis
is checked with removed
inspection hole cover.
In case of vibration-isolated foundations prior to the alignment of the first machine, all
other machines must have been placed on the foundation. Should one machine or
other not yet be available at the time when the assembly is started, a weight should
be used instead of the machine to simulate the location and the size of the machine
still missing.
Alignment as described above is required even if parts of the equipment are supplied
mounted on a common base plate, as foundation plates cannot be made so stiff at
reasonable expense as to be free from distortion during transit or when being placed
on an uneven foundation. Shims must be placed underneath the plates in such a way
that the machines have the correct position relative to one another (alignment as
described above).
2007-07-27
Voith TURBO
TurboCOUPLING
GmbH - Type R18 KGS
Code : BHEL-R18 KGS 14 API15.: 55
Postfach Cplg serial Nos.:
x Telefon 114-00173
(07951) and 114-00174
32-0 x Telefax 32-500 23
- 18 -
5.5 Alignment
The erection sequence depends on the sequence of the delivery of the parts and the
local conditions.
Usual sequence:
Pump, geared variable speed coupling, motor.
The geared variable speed coupling is aligned to the existing driving or driven
machine during assembly. For the alignment, the adjusting screws M 20 supplied by
us will be required. With these screws, the coupling is adjusted in the height. Bear in
mind the shaft misalignment (height increase) of the units between the hot and cold
conditions. By means of a pinch bar, the geared variable speed coupling can be
shifted sideways. This job requires a minimum of effort if the greased iron shims can
readily slide one on the other.
1. Alignment of connecting couplings without extension sleeve
e.g. between geared variable speed coupling and motor. Check distance "E" at
different points on the periphery, using a "feeler gauge" or flat steel. Check center
offset using a short straight edge.
2007-07-27
airev-RSe TURBO
Voith TurboCOUPLING
GmbHType R18 KGSCrailsheim
- D-74555 3626-021393 en
Code : BHEL-R18 KGS Postfach 15 55serial
14 API .: Cplg x Telefon
Nos.:(07951) 32-0 and
114-00173 x Telefax 32-500
114-00174 24
- 19 -
For alignment, have a clamp made as shown on the sketch. Fit clamps on the
shafts. Set dial gauges at 5.00 mm and secure by means of set screws. Connect
coupling sleeves by means of two connecting bolts and two spacers of about 20
mm. Turn coupling shafts by 180° using a flat iron inserted between the two
sleeves. Enter the measurement in a coordinate system, e.g.:
As the shafts may shift in axial direction, find the difference between the two axial
measurements. Half of this difference is the dimension for the angular deflection.
Correct the coupling gap and height by means of the adjusting screws. Repeat
the same measurement in the horizontal plane, moving alignment clamp into the
horizontal position, i.e. turn it by 90° relative to the original position.
2007-07-27
GEARED VARIABLEVoith
airev-RSe SPEEDTurbo
TURBOGmbHCOUPLING Type R18Crailsheim
- D-74555 KGS
3626-021393 en
Postfach
Code : BHEL-R18KGS 14API15
.: 55 x Telefon
Cplg (07951)
114-00173 32-500
and 114-00174 25
- 20 -
Reset dial gauges at 5.00 mm, then turn the shafts by 180° and enter measured
values in the coordinate system. Find mean values (as described above) and shift
machine sideways accordingly:
Example:
This alignment is satisfactory, if at the time of turning the coupling by 360° the
radial measurement "A" and the axial difference measurement "B" and "C" show
dial gauge deviations not exceeding +/- 0.03 mm.
2. Alignment of couplings with intermediate piece or extended coupling sleeve

e.g. between geared variable speed coupling and pump.
2007-07-27
airev-RSe Voith TURBO
GEARED VARIABLE SPEED TurboCOUPLING
GmbH - TypeD-74555 Crailsheim
R18 KGS 3626-021393 en
Code : BHEL-R18KGS 14 API .: Cplg serial Nos.: 114-00173 and 114-00174 26
- 21 -
Make a mounting device according to sketch. Use flat steel (at least 20x10 mm).
Connect alignment aid with shaft end of the machine to be aligned by bolting. Fit
dial gauges set at 5.00 mm and secure them in position by means of an adjusting
screw. Set 1/100 scale at "0". Turn shaft II by 360° (runout test). With axial runout
of a shaft, the difference of the readings on the dial gauges "B" and "C" is the
dimension for the angular deflection. Satisfactory true-running is ensured if the
reading on the dial gauge is 0.01 mm or less.
Set dial gauge again at 5.00 mm.

Turn shaft II by 180° by means
of mounting aid. Enter readings
into coordinate system.
As the shafts may be displaceable in axial direction, the difference must also be
determined by measurements as described above. Correct the coupling gap and
shaft location by means of the adjusting screw. Carry out similar measurements
in the horizontal plane. For this purpose, move alignment clamp into horizontal
position, i.e. turn it by 90° from the original position. Set dial gauges again at 5.00
mm. Turn shaft II by 180°. Enter measured values into coordinate system. Find
average value as described above and shift machine to be aligned sideways.
2007-07-27
airev-RSe Voith Turbo GmbH - D-74555 Crailsheim 3626-021393 en27
Code : BHEL-R18 KGS 14 API15
Postfach .: Cplg serial Nos.:
55 x Telefon 114-00173
(07951) and 114-00174
32-0 x Telefax 32-500
- 22 -
3. Shimming of gear housing, alignment report
After alignment, all fixing bolts of the gear housing are shimmed. The load is to be
distributed uniformly on all shims preventing twisting of the housing when
tightening the foundation bolts.
After slackening the adjusting screws, tighten the foundation bolts and check the
alignment.
Alignment is satisfactory if both the radial measurement "A " and the axial
difference measurements "B" and "C" do not yield deviations in excess of
+/- 3/100 mm. We recommend to enter the final measurement results in the
coordinate system of the installation checking sheet.
4. Later alignment of the complete unit
If after sustained operation the entire machine set must be aligned new, the Voith
geared variable speed coupling is displaced on the foundation. (With foundation
bolts arranged in the centre, the bolt holes have sufficient clearance). The height
of the axis is adjusted by regrinding or exchange of the shims between foundation
and Voith geared variable speed coupling.
2007-07-27
Code : BHEL-R18 KGS 14 API .: Cplg serial Nos.: 114-00173 and 114-00174 28en
3626-021393
- 23 -
5.6 Site pipework, cooler arrangement and cooler venting
Assemble and install the oil pipes in a professional manner preferably below the oil
level of geared variable speed coupling!
Do not confuse any connections! (see assembly plan). Ensure that the fittings,
lengths and quality of lines meet the requirements.
The oil pipes should be as short as possible (< 8 m). If the pipes are longer
assembled above the oil level of geared variable speed coupling, install nonreturn
valves in the oil pipe leading from the geared variable speed coupling to the oil cooler.
Oil pipes upstream and downstream of heat exchangers should be dimensioned to
allow a minimum oil velocity of 3.5 m/s for lube oil and 4.0 m/s for working oil.
The diameter of oil pipes should be constant over the total length. In the event of a
greater cooler connection width it is necessary to expand the piping directly at the
cooler. A too large oil quantity in the pipes may cause speed instabilities and greater
variations in the oil level due to air absorption.
Adapt the site pipework only after alignment of geared variable speed coupling and
observe that it is installed free of stress.
Oil pipes of steel (not stainless steel) assembled at site are to be disconnected after
completion and immersed in a pickling solution.
Voith recommends BETONA or a similar pickling bath.
BETONA product of Messrs. Karowa, Memmingerstr. 39A, Neu Ulm, Germany.
Pickling
BETONA activated crystal pickling solution removes layers of scale, rolling skin and
rust from steel parts and welded seams.
Prior to preparing and using this or another pickling solution observe the
relevant specification, safety information (data sheets), information for use.
The pickling period of BETONA crystal pickling solution depends on the temperature
and duration of the bath.
Mixing proportion: 1 part BETONA to 10 parts water result in this pickling solution. Mix
1 to 3 litres pickling degreasing agent S 13 on 100 litres pickling solution to remove
dirt, slight fouling by oil, graphite or oil carbon. Workpieces heavily fouled by oil or
grease are to be degreased in advance. The ideal temperatures of the pickling
solution for pickling is approx. 40 °C. Put and leave the parts in the pickling solution
for the periods mentioned below.
Pickling period: Rust film approx. 5 - 10 min.

(immersed) Rust approx. 15 - 30 min.
Rolling scale approx. 50 min.
Descaling of annealed steel pieces approx. 120 min.
The metal must be bright and free of scale and rust after pickling these parts.
2007-07-27
Code : BHEL-R18 KGS 14API15.: 55
Postfach Cplg serial Nos.:
x Telefon 114-00173
(07951) and 114-00174
32-0 x Telefax 32-500 29
- 24 -
Drying
Then remove the parts, do not wash them, let them dry drip-proof. Drying time to
achieve an ideal protective film at 20 °C is between 24 and 48 hours. If the drying
time cannot be adhered to, subsequent flushing using clean water is required. Then
dry the parts, spray them on the inside with operating oil and on the outside with
paint.
Notes
Basins of stainless steel, material no. 4571 or of steel, which are lined inside with
rubber or GVP, have proven well as bath basin. This material must be temperature-
resistant.
Use rubber gloves, rubber boots, rubber aprons and safety glasses. The remaining
clothing shall be of natural fibres, like cotton, shear wool. Ventilate working rooms
well. In case that the pickling solutions comes into contact with skin, immediately
wash off using a lot of water.
Waste water and used pickling bath can be separated in two matters by neutralization
(by adding soda lye). The two matters are "water" and "flocky sludge". Sludge can be
disposed according to waste number 52102.
However, this needs to be clarified in advance - observe the District Sewage Disposal
Specification.
Afterwards, mount the pipework.
Cooler arrangement:
The installation dimensions of heat exchangers with change-over valves are shown
on the assembly plans. The change-over procedure is described in section 9.2.
Pipes and oil coolers should, on principle, not drain into the oil tank of geared variable
speed coupling when the unit is switched off. We recommend positioning the coolers
below the oil level of geared variable speed coupling.
If coolers are arranged above the oil level of oil tank, the pipes at the cooler must run
upwards in siphon arrangement and connecting at the highest point by a
compensating pipe (DN ø 8 mm) with an orifice ø 3 mm. This way, the coolers remain
filled. See Cooler Arrangement
Continuous ventilation of working oil cooler:
Provide sufficient continuous ventilation of working oil cooler. Three vents are
provided on the shell side for continuous ventilation of working oil cooler. Mount three
screw-in orifices ∅ 10 mm on these vents and connect them with a collecting pipe
(DN 20). Connect this collecting pipe up to the geared variable speed coupling.
Regarding the connecting point please refer to the assembly plan of geared variable
speed coupling.
2007-07-27
TurboCOUPLING
GmbH - Type R18 KGS
D-74555 Crailsheim 3626-021393 en
Postfach
Code : BHEL-R18KGS 15Cplg
14 API .: 55 xserial
Telefon (07951)
Nos.: 32-0 x Telefax
114-00173 32-500
and 114-00174 30
- 25 -
5.7 Lube oil supply of individual machines
The lube oil for
- the boiler feed pump / flow rate ..... l/min.

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

2007-07-27
Code : BHEL-R18KGS
airev-RSe 14 API.:
Voith TurboCplgGmbH
serial Nos.: 114-00173
- D-74555 and 114-00174
Crailsheim 3626-02139331
en
- 26 -
5.8 Coupling guards
Guards should be mounted, especially on rotating parts,
- as protection against contact on connecting couplings,
and as protection against injuries by burning on hot
- pipework,
- heat exchanger,
- geared variable speed coupling,
and on any other sources of risk which can be recognized after assembly of the
overall unit, in accordance with the safety regulations in force.
When mounting a acoustic cover over the geared variable speed coupling,
Mounting an acoustic cover must be
considered.
In case of outdoor installation, we recommend to mount a guard or a housing over
this unit and its attaching parts.
5.9 Preservation after installation
installation or in cases of standstill for operational reasons. The measures necessary
during these phases and the necessary inspections are described in the Voith-
Instruction Manual.
2007-07-27
en
Code : BHEL-R18KGSPostfach
14 API .: 15
Cplg
55serial Nos.:
x Telefon 114-00173
(07951) 32-0 xand 114-00174
Telefax 32-500
- 27 -
5.10 Electric installation
The monitoring instruments are wired to the terminal box. Wiring in the terminal box
was made according to the terminal plan.
Instructions to the instruments supplied are included in the enclosed instrument

description, please see Part 5.
Any work at electric units or operating means must only be effected by an electric
expert or by trained persons, under the direction and supervision of an electric expert,
according to the electric regulations.
Check all motors for direction of rotation, smooth running and current consumption
(motor protection.)
Check the ready mounted unit for stray currents since they damage gear wheels and
bearings. If you find any, take remedial measures, i.e. by grounding.
2007-07-27
TurboCOUPLING
GmbH - Type R18 KGS
D-74555 Crailsheim 3626-021393 en
Postfach
Code : BHEL-R18KGS 14API.: 15 55 serial
Cplg x Telefon (07951)
Nos.: 32-0 xand
114-00173 Telefax 32-500
114-00174 33
- 28 -
6. Operating Oil
The following work must only be effected by qualified personnel (see safety information).
If the operating fluid used is not mentioned in our oil selection list, check its compatibility with
our preservation oil (Shell Ensis motor oil W 20) or flush the inside of geared variable speed
coupling thoroughly.
Ensure a safe disposal, not being detrimental to the environment, of operating and aux.
medium as well as of the replacement parts!
The operating oil viscosity must be as low as possible to guarantee satisfactory hydraulic
efficiency and air release properties during filling, emptying and regulating. Since the bearings,
in particular the usually highly loaded gear wheels, are also lubricated by the operating oil, it
must possess excellent lubricating characteristics. The only oils suitable for geared variable
speed couplings are thus high performance, low viscosity oils with additive-produced
lubricating properties and excellent air release characteristics.
The oil must be chemically neutral to metals and seals and be nontoxic.
Resistance to aging at max. admissible operating temperature and under high air entrainment
must allow a sufficient operating life.
The oils tested according to the above criteria can be seen in the attached Oil Selection List.
The starting viscosity under the conditions at site must not
exceed 250 mm2/s (cSt).
The operating oils must not be mixed when being used. Admissible oil mixtures must be
clarified with the oil supplier.
For auxiliary units, such as connecting couplings and actuator, the amount of lubricant
specified by the manufacturer should be checked prior to commissioning and later after the
maintenance intervals and, if necessary, increased.

2007-07-27
airev-RSe
Code : BHEL-R18KGSVoith Turbo
14API.: GmbH
Cplg serial - D-74555
Nos.: Crailsheim
114-00173 and 114-00174 34
3626-021393 en
- 29 -
6.1 Filling with operating oil
The oil quantity required, without filling of the pipework and heat exchangers,
is 2500 litres. The quantity required for heat exchangers is indicated in the respective
assembly plans. The oil quantity for the pipework must be determined at site, after
piping.
We recommend filling with operating oil immediately after piping the unit.
Filter the oil when filling in, grade of filtration 25 mym or finer.
Fill the geared variable speed coupling with oil via the oil filling hole on the inspection
hole cover. When coolers and piping are filled or ventilated, the oil level should reach
an average value between the MIN. and MAX. mark of the oil level indication (see
assembly plan).
2007-07-27
R18 KGS 3626-021393 en
Code : BHEL-R18KGS 14API.: Cplg serial Nos.: 114-00173 and 114-00174 35
- 30 -
7. Commissioning
The following work must only be effected by qualified personnel (see safety information).
When operating the geared variable speed coupling, meet the nominal values for temperatures
and oil pressures stated in par. 8.
The geared variable speed coupling only allows a power transmission and speed control with
the operating data specified (see nameplate or data sheet of this instruction manual).
The viscosity of operating oil for start-up must not exceed 250 mm2/s.
this means a temperature of approx. +5 °C.
7.1 Trial run preparations
- Check alignment of all equipment considering the thermal growth in height

and width and shaft misalignments due to operation and correct, if
necessary.
Record alignment values!
- Check fixing of foundation.
- Check direction of rotation of drive motor, with the geared variable speed
coupling uncoupled.
- In case of coupled curved-tooth connecting coupling with constant filling,

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

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

individual machines (external units).
- Fill the geared variable speed coupling with operating oil up to the max. mark
of oil level indicator.
2007-07-27
airev-RSe TURBO
Voith COUPLING
Turbo GmbHType R18 KGSCrailsheim
- D-74555 3626-021393 en
Postfach
Code : BHEL-R18KGS 14API.: 15 55
Cplg x Telefon
serial (07951) 32-0
and 32-500
114-00174 36
- 31 -
- Note: During flushing, the working oil cooler and oil tubes in the system
are filled with oil via a connecting line arranged internally between
the lube oil and working oil circuit. Approx. 10 litres/min. are
supplied into the working oil circuit.
- Check, and provide resp., the electric installation of motor, instruments,

actuator etc. for being connected to the supply voltage, processing of signals
for control and monitoring instruments! Observe section 5.10 Electric
installation.
- Flushing the lube oil circuit. Switch on the electrically driven aux. lube oil
pump (interlock at automatic start-up of main motor) and carry out flushing in
the lube oil circuit during a longer period of time (one to several days).
Thereby vent cooler and piping.
- When the differential pressure rises to 0.6 kg/ cm2, change over to the clean
filter half and clean the clogged part according to section 9.1.
- Check the lube oil flow rate of the individual machines (external units) and
correct to section 5.7 Lube oil supply of individual machines, if necessary.
- Flush the pipe until the filter is no longer clogged.
- Check piping for leakage.
- Check the injection quantity into the connecting coupling at lubrication by

circulation (see manufacturer's instructions), if required, correct by installing
orifice plates.
- Check the oil level of the geared variable speed coupling and refill with
operating oil, if required, see section 6.1.
- Check the lube and control oil pressure and adjust according to section 8.3,
if necessary.
- Check the switch points of the pressure transmitters and their function.
Check the switch points of temperature monitoring, adjust if necessary.
2007-07-27
TurboCOUPLING
GmbH -Type R18 KGS
D-74555 Crailsheim 3626-021393 en
Code : BHEL-R18KGS 14API .: Cplg serial Nos.: 114-00173 xand 32-500
114-00174 37
- 32 -
- Check the adjustment of the actuator at the scoop tube positioning device,
via the adjusting angle. Both end positions must be mechanically limited at
the actuator.
- Read the scoop tube position on the stroke indicator scale, with the aux. lube
oil pump running. Check the following using the original actuator.
a) At 100 % scoop tube position, check and adjust the max. positioning or
feedback signal on the actuator.
b) After running through the rated adjusting angle or the actuator stroke,
the minimum positioning or feedback signal corresponds to a scoop
tube position of approx. 0 %.
- Set the scoop tube to MIN. position. Switch off the aux. lube oil pump.
7.2 Trial run
- At water-oil coolers, open the water side valves, vent the cooler at the water
side and check the flow. The operating data and the instruction manual of
the oil coolers must be observed.
- Check the readiness for operation of the complete unit.
- Start the aux. lube oil pump and switch on the main motor or monitor the
automatic start-up when lube pressure is available.
- After the motor has run up to speed, observe the automatic shutdown of the
aux. lube oil pump with lube pressure existing or switch off aux. lube oil
pump manually.
- Run the unit at minimum speed and observe smooth running, temperatures,
lube pressure and filter condition.
If the minimum speed of driven machine has to be increased or reduced,
proceed according to section 3.1.1.
- Slowly run the unit up to speed. Adjust the working and lube oil temperature
via the cooling water flow (observe min. water flow rate).
2007-07-27
R18 KGS 3626-021393 en
- 33 -
The heat to be dissipated of the working oil depends on the respective

operating point of the power characteristic curve of the driven machine. The
max. heat is at 60 - 70 % speed, at parabolic torque characteristic curve, and
at min. output speed at constant torque characteristic curve.
- Observe the temperatures until they are steady. If required, readjust the
working oil flow rate, see section 3.2. The temperature upstream of the
working oil cooler should not exceed 110 °C.
- If the high-speed input or output shaft (larger than 2980 rpm) was completely
balanced without original hub, due to a non-delivery of the connecting
coupling hub, a subsequent rebalancing may be necessary and be made at
site. One reason for this are key or keyway tolerances.
- Evaluate and record smooth running of geared variable speed coupling by

vibration measurements. Besides the measuring values, record measuring
points, speeds and scoop tube position.
- If the characteristic of the unit has to be optimized according to the operating

conditions by adapting the oil circulation and scoop tube cam disc, the
complete unit has to be operated under operating conditions over the whole
regulating range.
- Turn the unit down to MIN. speed. After switching off the main motor, check
automatic switch-on of aux. lube oil pump at decreasing lube pressure.
Switch off the aux. lube oil pump after standstill of the main motor and of the
driven machine.
- During or after the trial run, clean the lube oil filter and fill with operating oil
(see section 9.1), check and correct the oil level according to section 6.1.
- Check fixing of the stops on the actuator again. The stroke must be limited
on the actuator, not at the scoop tube control.
2007-07-27
Postfach 15Cplg
55 x serial Nos.:
Telefon 114-00173
(07951) and 114-00174
32-0 x Telefax 32-500 39
- 34 -
7.3 Measures to be taken at standstill periods
installation or in cases of standstill for operational reasons. The measures necessary
during these phases and the necessary inspections are described in the Voith-
Instruction Manual.
At standstill periods of the geared variable speed coupling of one or several days
(also several weeks), the aux. lube oil pump must be switched on for at least 5
minutes daily.
Protect the geared variable speed coupling against water ingress and humidity.
Preserve bright parts accordingly.
For internal protection against corrosion (oil wetting) start the geared variable speed
coupling every 1 to 2 months for a short time. Do not run the geared variable speed
coupling warm, because there is a risk of dewpoint corrosion.
If the actuator is operated during stand-by operation, the grease nipples on the guide
bush are to be lubricated every 2 months in each case with 5 g lithium-soaped
antifriction bearing grease.
At standstill periods of heat exchangers, the cooler instruction manual must be

observed, especially the par. "How to avoid corrosion damages".
2007-07-27
en
Postfach 15 Cplg serial Nos.:
55 x Telefon 114-00173
(07951) and 114-00174
32-0 x Telefax 32-500
- 35 -
8. Operation of the Geared Variable Speed Coupling
The following work must only be carried out by qualified personnel (see safety information).
8.1 Start-up, operation and shutdown of geared variable speed coupling

as well as measures to be taken when the unit is at standstill
(also see Logic Diagram)
A continuous monitoring of geared variable speed coupling maintaining admissible

temperatures, lube pressure and oil level means a trouble-free operation and low
maintenance.
Start-up of geared variable speed coupling
The viscosity of operating oil for start-up must not exceed 250 mm2/s (cSt). For the
oils according to our Oil Selection List, this means an oil temperature
of at least +5 °C.
The geared variable speed coupling can on principle be started and stopped with the
scoop tube at any position. However, with the scoop tube at minimum position, the
main motor can run up under virtually no load.
- Prior to starting the main motor, switch on the aux. lube oil pump. The
solenoid valves 92 and 93 of the rapid start-up device are not electrically
excited (OFF).
- At existing lube oil pressure (> 1.2 kg/ cm2), start the main motor.
- After reaching the lube oil pressure (> 3.0 kg/ cm2), switch off the aux. lube
oil pump with a time interval of up to 5 minutes.
- Run the scoop tube to max. 100 % scoop tube position and in operating
condition resp. This is made via an actuator which is controlled by a guide
signal 4 - 20 mA resp.
Or rapid start-up at given scoop tube position.

(see section 3.3)
In order to enable the drive motor to quickly run up in relieved condition, the
two 3/2-way solenoid valves 92 and 93 must be electrically excited.
After runup of the drive motor, switch off the solenoid valves. The driven
machine is rapidly run up via the geared variable speed coupling.
2007-07-27
TurboCOUPLING
GmbH - Type R18 KGS
D-74555 Crailsheim 3626-021393 en
Postfach
Code : BHEL-R18KGS 14API.:15 55 serial
Cplg x Telefon (07951)
Nos.: 32-0 xand
114-00173 Telefax 32-500
114-00174 41
- 36 -
Operation of geared variable speed coupling
To keep good air release properties, the sump temperature (oil temperature upstream
of the lube oil cooler) must not fall below 45 °C during continuous operation.
Continuously check the admissible temperatures, working and lube oil pressure and
the oil level. Data see section "8.2 Operating data".
- By positioning the scoop tube via the actuator (up to max. 100 % scoop tube
position) accordingly, the input power and input speed of the driven machine
are determined and adjusted resp.
Change the guide signal between 4-20 mA resp. accordingly.
- In case of a failure during operation, the monitoring instruments attached

release an electric signal thus leading to an alarm or switching-on of the aux.
lube oil pump or to a shutdown of the unit, as mentioned under 8.2.
Attention: A system transfer during operation (e.g. at an interconnected

system/power station system) must be carried out only via a lock-
up device. If there is no phase coincidence, there might be an
inadmissible high torque jerks from the main motor acting on the
gear.
Shutdown of geared variable speed coupling
The geared variable speed coupling can on principle be started at any scoop tube
position. However, with the scoop tube at min. position, the main motor can run up
under virtually no load.
- Switch on the aux. lube oil pump.
- Switch off the main motor.
- Regulate downwards the geared variable speed coupling to min. speed.

Bring the guide signal to 4 mA.
Or rapid downwards regulation to min.speed at max. or given scoop tube
position resp.
Rapid relief of drive motor and driven machine by rapid draining of the variable
speed coupling. To do so, the two 3/2-way solenoid valves (92 and 93) must be
electrically excited during this period.
- After main motor and driven machine stopped, switch off the aux. lube oil pump.
- After main motor and driven machine stopped, switch off the aux. lube oil pump.
2007-07-27
airev-RSe SPEED TURBO
Turbo COUPLING
GmbH - Type R18 KGS
D-74555 Crailsheim 3626-021393 en
Code : BHEL-R18KGS 14API.: Cplg serial Nos.: 114-00173x and 32-500
114-00174 42
- 37 -
Measures to be taken when the unit is at standstill
Reverse rotation of the output shaft of geared variable speed coupling is only allowed
under the following conditions and limited to 1 - 3 minutes:
1) Monitoring of direction of rotation of the output shaft.
2) Switching-on of aux. lube oil pump without time delay.
3)
3) Move
The the scoop
solenoid tube
valaves (92toand
100 % of
93) position.
the rapid start-up device must be
4) switched
Close theoff (electrically
shutoff valvenot excited).
of the feed water pump.
3) Move the scoop tube to 100 % position.
4) Move
If reverse the scoop
rotation tube without
occured to 100% position.
one of the three first precautions described,
4) Close the shutoff valve of the feed water pump.
check the plain bearings and fusible plug screws prior to a new start-up.
5) Close the shutoff valve of the feed water pump
If reverse rotation occurred without one of the three first precautions described, check
the plain bearings and fusible plug screws prior to a new start-up.
If reverse rotation occurred without one of the four first precautions described, check
the plain bearings and fusible plug screws prior to a new start-up.
2007-07-27
GEARED VARIABLE SPEED Turbo GmbH -Type
COUPLING D-74555
R18 KGSCrailsheim 3626-021393 en
- 38 -
8.2 Operating data

(see oil circuit and measuring point scheme)
Bearing temperatures nom. value <90 °C

(46-51, 54-63, 66-69) alarm / trip 90 / 95 °C
Working oil temperature upstream of nom. value >60 - <110 °C

heat exchanger (81, 86, 87, 88) alarm / trip 110 / 130 °C
Working oil temperature downstream nom. value >35 - <75 °C

Lube oil temperature upstream nom. value >45 - <65 °C

of heat exchanger (78, 82) alarm at 70 °C
Lube oil temperature downstream of nom. value >35 - <55 °C

heat exchanger (79, 83, 84, 85) alarm / trip 55 / 60 °C
Lube oil pressure, gauge (42) nom. value >1.5 -<3 kg/cm2
Pressure transmitter (71 - 73) main motor ON >1.2 kg/cm2
aux. lube oil pump OFF >3.0 kg/cm2
aux. lube oil pump ON <1.2 kg/cm2
alarm <1.0 kg/cm2
trip <0.8 kg/cm2
Differential pressure at change over filter and

lube oil filter (25, 25.1) clean at 0.6 kg/cm2
Control oil pressure, gauge (43) nom. value >3 - <4 kg/cm2
Pressure transmitter (74 - 76) alarm <2.5 kg/cm2
trip <2.2 kg/cm2
Working oil pump pressure,

test connection (44, I see at assembly plan) >1.6 - <2.1 kg/cm2
Working oil pressure upstream of circulation control valve

test connection (21, II see at assembly plan) >1.0 - <1.8 kg/cm2
Working oil pressure downstream of scoop tube

test connection 45, III see at assembly plan) >1.8 - <3.5 kg/cm2
Oil level, sight glass (90) nom. value max. - min. mark
Oil level switch (70) alarm 10mm > max. / 10mm < min. mark
2007-07-27
GEARED VARIABLE
Voith TURBOGmbH
COUPLING Type R18Crailsheim
- D-74555 KGS 3626-021393 en
Postfach 15 55 x Telefon (07951) 32-0
Code : BHEL-R18KGS 14API.: Cplg serial Nos.: 114-00173x Telefax 32-500
and 114-00174 44
- 39 -
8.3 Lube oil pressure/control oil pressure and monitoring of lube oil
pressure
(see oil circuit and measuring point scheme)
The lube oil pressure is set to approx. 2.5 kg/cm2 by means of the adjustable orifice
(29) but is also dependent on the viscosity of the oil used. A change in the lube oil
pressure will also change the control oil pressure. Control oil pressure can be reset
on the pressure relief valve (28) to approx. 3.5 kg/cm2.
Proposed switching sequence and pressure transmitters to be set as follows:
1. Signal to switch on the main motor when lube oil pressure reaches
>1.2 kg/cm2. It must be guaranteed by means of a time delay that all
bearings, especially at lube oil supply of external machines, are
prelubricated.
2. Switching-off, with time delay (1-5 minutes), of aux. lube oil pump at
>3.0 kg/cm2 on completion of main motor run up. The set pressure shall be
greater than that of the aux. lube oil pump alone and lower than that
produced by the aux. lube oil pump and lube pump together.
3. Switch on the aux. lube oil pump if the pressure drops to <1.2 kg/cm2.
4. Alarm signal when the pressure drops to <1.0 kg/cm2.
5. Trip signal when the pressure drops to <0.8 kg/cm2.

2007-07-27
TURBOGmbH
- D-74555 KGS
3626-021393 en
Postfach
14API.: 55 x Telefon (07951)
114-00173 32-500
and 114-00174 45
- 40 -
8.4 Monitoring of working oil
The temperature of the working oil downstream of the cooler should be above 35 °C.
Upstream of the cooler, the temperature could rise to <110 °C. During unusual
operation (e.g. flushing), max. temperatures of up to about 130 °C could occur.
If temperatures are too high, the volume of working oil could be increased (see
section 3.2).
Another control is possible by the three fusible plug screws melting at an oil
temperature of 180 °C and thus each releasing a bore through which the oil sprays
into the sump. See section 2.1.
The three fusible plug screws (item 0310/0010/0060, see Vertical Section) can be
replaced by removing the inspection cover II on the housing cover and turning the
input shaft until the fusible plug screws are accessible.
The pressure relief valve (27) holds the pressure of the working oil (pressure
upstream of the control valve) at 1.0 to 1.8 kg/cm2.
8.5 Bearing temperatures
The bearing temperatures should normally not exceed 90 °C. We recommend setting
the alarm signal "Bearing temperature too high" at about 15 °C above the temperature
of the hottest bearing or at 90 °C and trip signal "Bearing temperature high high" at 95
°C.
The temperatures of the individual bearings vary because of varying shaft speeds or
external thermal loading caused by the working oil (at bearing 6 and 7).
8.6 Lube oil filter
The lube oil filter is executed as double filter.

At correct position of the changeover cock, however, only one sieve part is used for
cleaning the oil. The filter is fitted with a differential pressure switch, whereby contact
of the alarm is required at 0.6 kg/cm2 differential pressure.
Slowly change over the change-over lever to the second filtering jug.
When switching from one filter to another during operation, ensure the lube oil
pressure does not drop excessively, actuating an alarm / trip by the pressure
transmitters. This is achieved by flooding the clean filter before changeover. See
section 9.1 "Putting the cleaned filter half back into operation".
2007-07-27
Postfach 15 55Cplg serial (07951)
x Telefon Nos.: 114-00173 and 114-00174
32-0 x Telefax 32-500 46
- 41 -
8.7 Oil level indication
For oil level control, an oil sight glass and an oil level switch is fitted to the geared
variable speed coupling.
With the unit shut down and the piping and coolers filled with oil, the oil level should
be below the mark "Max. Oil Level".
The oil level switch is set so that it releases an alarm signal 10 mm below “Min.” and
10 mm above “Max.” mark.
8.8 Lubricating points of scoop tube control

(see drawing “Section through Control”)
Two lube nipples are provided on the guide bush for a grease gun for lubricating the
guide bolt. They are to be greased with a lithium-soaped anti-friction bearing grease
as in section "Maintenance".
2007-07-27
TURBOGmbH
- D-74555 KGS 3626-021393 en
Postfach
14API.: 55 x Telefon (07951)
114-00173 32-500
and 114-00174 47
- 42 -
9. Maintenance of Geared Variable Speed Coupling
The following work must only be carried out by qualified personnel (see safety information).
The maintenance instructions and intervals detailed below are based on our practical
experience and should be adhered to in order to ensure trouble-free operation of the geared
Ensure a safe disposal of operating and aux. means as well as of spare parts not being
detrimental to the environment!
9.1 Maintenance of double filter
Dependent on the requirement or alarm signal of differential pressure monitoring,

change over, clean or prepare the double filter for putting it into operation, following
the manufacturer’s instructions.
Regarding the manufacturer’s instructions please refer to section „Description of
Attaching Parts“.
Warning!
Waste oil getting into the sewerage or open soil may cause severe damage
to the environment.
Dispose of waste oil in a professional manner according to the national

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

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

Change the filter slowly over to the second filtering jug using the changeover
lever, otherwise, in the event of to excessive pressure drop, the pressure
monitoring system may switch off the unit.
2007-07-27
TURBO GmbH
COUPLING Type R18 Crailsheim
- D-74555 KGS 3626-021393 en
Postfach
14API.: 55 x serial
Telefon (07951)
114-00173 32-500
and 114-00174 48
- 43 -
Position of changeover lever compared to the position of filtering jugs
Position I Position II
This filter side is in This filter side is in
operation operation
II. How to proceed to clean the filter
Cleaning agents and other auxiliary means
- Cleaning container with clean gasoline used for cleaning purposes or

diesel oil (approx. 10 litres).
- Container for oil to be drained (approx. 20 litres).
- Soft brush, compressed air.
1. Drain the oil from the filtering jug to be cleaned.

Open vent valve and oil drain valve.
2. Unscrew filter cover.
3. Remove filter element out of the housing in vertical position.
Important: - Inner side of filter element is

the clean oil side
- Outer side is the dirty side.
During the cleaning process:
- do not change over the filter

- do not open the pressure compensation valve.
4. Clean the internal filtering jug.
5. Clean the dirty outer side of filter element using gasoline for cleaning
purposes or diesel oil.
2007-07-27
airev-RSe
SPEED Turbo GmbH - Type
TURBO COUPLING D-74555 Crailsheim
R18 KGS 3626-021393 en
- 44 -
Cleaning process:
- Do not submerge the filter element
in the cleaning agent.
- Wash the filter outside from top to bottom using the soft brush
If there is any residual sealing compound on the filter element (strainer

texture), then submerge it for a short time (max. 15 min.) in
trichchlorethylene or Tri-substitute and wash it off.
6. Blow compressed air through the internal filter element.

Cover the openings.
Attention: If the filter element is heavily clogged,

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

vent valve.
Open the vent valve a 1
little.
2. Flood the filter half by

opening the compensation 1 1
valve until oil leaks out
at the filter vent line. Close the shutoff valve.
3. Close the vent valve.

Fit the plug.
- Now the cleaned filter half is ready for operation.
1 Vent valve with

plug
2007-07-27
GmbH -Type D-74555 Crailsheim
R18 KGS 3626-021393 en
- 45 -
9.2 Maintenance measures which can be taken with the unit running
When differential pressure of lubricating oil filter rises, switch it over and clean.
Check air release property of the operating oil, if there are speed fluctuations on the
driven machine. Check also the permanent venting of the working oil cooler.
In case of increased oil level, check the oil for water content.
take measures according to the oil manufacturer's/oil supplier's instructions..
Please note the following for double heat exchangers with changeover set:
1. On principle, only one heat exchanger is to be used for operation in order to

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

periods according to Instructions .
3. Prior to changeover to the standby heat exchanger, its cooling water flow
must be guaranteed.
4. Open the valve in the pressure compensation pipe.
5. Changeover to the standby heat exchanger

During changeover from the heat exchanger in operation to the stand-by
heat exchanger, move the changeover lever only so far that the stand-by
heat exchanger is slowly flooded. Only a slight oil pressure drop is allowed in
the system, otherwise this can result in a shutdown of the units via the
pressure transmitters. Slowly continue the changeover action after the heat
exchanger is filled.
6. After switch over, close the valve in the pressure compensation pipe.
Daily:
Check temperatures, lube oil and control oil pressure, differential pressure on the lube
oil filter and the control oil pressure, if monitoring is not integrated in the control
system.
2007-07-27
Voith TURBO
TurboCOUPLING
GmbH - Type R18 KGS
Code : BHEL-R18KGS 14API.:15
Postfach Cplg
55 serial Nos.:
x Telefon 114-00173
(07951) 32-0 xand 114-00174
Telefax 32-500 51
- 46 -
Every 3 months:
Check the operating oil for its usability.

Take measures according to the oil manufacturer's/oil supplier's instructions.
Check the vent filter for impurities, if required clean.
Repress lithium-soaped anti-friction bearing grease through the lubricating nipples of

the scoop tube control, each 5 g.
Measure, record and compare smooth running (vibration) of the unit, always under
the same operating conditions. On noticing deviations, check the alignment of the
geared variable speed coupling to section 9.3.
2007-07-27
airev-RSe Voith
GEARED VARIABLE Turbo
SPEED TURBOGmbH - D-74555
KGS 3626-021393 en
- 47 -
9.3 Maintenance measures which can only be taken when the unit is at
standstill
Note: Do not start the coupling after a damage without previously checking
the fusible plug screws and the bearings and considering the
conditions under par. 8 (Measures to be taken when the unit is at
standstill).
After 50 operating hours:
Visually inspect gear stage for suitability of operating oil (scuffing of toothing).
After 250 and 2500 operating hours:
Visually inspect gear stage for suitability of operating oil (scuffing of toothing).
If the vibration values changed acc. to section 9.2, it will be necessary to check the
alignment of the geared variable speed coupling as well as the foundation fixing.
Every 8000 operating hours or at least annually:
Check and maintain connecting coupling according to the manufacturer's instructions.
Check and maintain the actuator according to the manufacturer's instructions.
Check and maintain the auxiliary lube oil pump motor according to the manufacturer’s
instructions.
Check alignment of geared variable speed coupling and the foundation fixing.
Visual inspection (corrosion, general condition, etc.) by removing inspection hole

cover on housing cover. Also visual inspection of tooth flank contact pattern and
inspection of the three fusible plug screws (item 0310/0010/0060, see Vertical
Section).
2007-07-27
airev-RSe
GEARED VARIABLE Voith Turbo COUPLING
SPEED TURBO GmbH - TypeD-74555 Crailsheim
R18 KGS 3626-021393 en
- 48 -
10. General Overhaul of the Geared Variable Speed Coupling
In the event of a change in operating behaviour after max. 7 years operating time, the
geared variable speed coupling should be overhauled.
To avoid unnecessary delays during servicing, we recommend to order spare parts

for the general overhaul well in advance. We shall be pleased to elaborate an offer for
any inquiry reaching us.
In order to ensure speedy handling of your inquiries, or your orders for service
engineers or spare parts, please always indicate the serial number of the Voith
geared variable speed coupling and the name of the person in charge.
It is not necessary to lift the complete assembly off its foundation for the purpose of
general overhauls.
Installation work on the geared variable speed coupling should only be carried out by
our specialized service engineers or trained staff (see safety information).
10.2 Preconditions
On principle, dismantling must not be commenced until the system and the drive
motor have been "de-activated", and permission has been obtained from the
competent department.
Uncouple the input and output side connecting couplings (make power transmission
ineffective).
An operational travelling crane for 2500 kg must be available, ready for operation, to
lift individual components out of the gear housing, such as housing cover, input shaft
with gear etc.
10.3 Dismantling and reassembling
Special care should be taken to ensure that no dirt penetrates into the coupling during
the overhaul. Cover the open oil tank with a tarpaulin. Perhaps put the housing cover
loosely on the housing and seal the shaft passages.
Warning: Personal injury and damage to property may occur, if individual

gears or pinion shafts of the gear stage are replaced.
The gears of each gear stage are paired with each other and
balanced together with the shafts, to achieve an optimum contact
pattern, backlash and smooth running.
2007-07-27
TURBO GmbH
- D-74555 KGS 3626-021393 en
and 114-00174 54
- 49 -
It is only allowed to interchange complete gear stages with the

relevant part of the turbo coupling of the same gear type.
Individual gears or shafts should only be interchanged in special
cases and after comparing the production progress reports and
after receipt of Voith Crailsheim's written approval. For
replacement of a gear stage, the relevant shafts are to be sent to
Voith for installation and joint balancing or new shafts are to be
provided.
Overhaul procedure:
(Detailed disassembly and assembly steps are described in par. 11.)
1. Drain the operating fluid.

Disconnect electric cabling.
Open lubricating oil filter, inspect and clean.
Dismantle connecting couplings and check their condition.
Check input and output shafts for true running.
Unscrew primary and secondary-side thrust bearing covers
(0030/0030), remove bearings and check.
Loosen 3 hex. screws (0270/0360) in flange (0270/0350) of the control.
2. Release housing cover from housing and lift off.

Check condition of toothing (check contact pattern).
Remove fusible plug screws (0310/0010/0060), turn rotor assembly in
order to allow any oil residues remaining in the coupling to drain (clear
borehole, if necessary).
Check fusible plug screws and replace, if necessary.
3. To be able to remove the scoop tube, loosen the bracket mounted on

the scoop tube housing and lift the control housing (0080/0140) with
control sleeve (0080/0200) out of its guide.
Remove temperature probes.
Lift off bearing cap and unscrew bolts from scoop tube housing
(0110/0010/0070/0130).
Lift out complete runner assembly plus input and output shafts from the
gear housing.
Unscrew the 4 fixing bolts (0120/0110) and remove the complete pump
insert (0130/0010). (The pump insert is also accessible through the
inspection cover I (with the oil filler plug) without lifting off the housing
cover, see assembly plan).
4. Dismantle rotating parts and pump insert, clean all components

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

Whether runners are damaged or not (resonance test of blades).
Check condition of bearings and measure bearing clearance.
Check scoop tube mechanism for wear.
Check all components of pump insert.
2007-07-27
SPEEDTurbo
TURBO GmbH
KGS
airev-RSe - D-74555 3626-021393 en
Postfach 15Cplg
55 x serial
TelefonNos.: 114-00173
(07951) and 114-00174
32-0 x Telefax 32-500 55
- 50 -
The scoop tube guide bush (0080/0010) is accessible after dismantling

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

sliding faces of shaft, if necessary.
At re-assembly, secure bolts as originally provided. Locking elements
(spring washers) should be replaced by new parts.
Tighten the screws using a torque wrench with the specified tightening
torque, as indicated on the drawing.
6. Re-assemble runner and pump insert.

Special care should be taken during re-assembly that all components
showing a common mark, such as primary wheel and shell, as well as
the parts of the thrust bearings are fitted in the correct position to each
other.
7. Clean housing and housing cover carefully from old sealing compound
and any deposits of oil sludge. Flush and clean oil tank carefully.
Apply a new sealing compound to all sealing surfaces, oil-resistant up
to 130 °C (e.g. Hylomar).
8. Install input and output shaft, runner and pump insert again.
On installation of a new pump insert, pay attention to the backlash
(0.15 + 0.1 mm) and contact pattern of spur gears.
9. Fit temperature probes. Mount and tighten housing cover.
10. Grease the lubricating nipples (0270/0020/0020) of the control with 5 g

of lithium-soaped antifriction bearing grease each and grease bright
components.
Retighten the flange (0270/0350) of the control.
11. Alignment check of geared variable speed coupling to main motor and
driven machine (record values obtained).
12. Install connecting couplings.

Connect motors and instruments.
13. Clean oil coolers, if necessary, following manufacturer's instructions.

This must be followed by a leakage test of the coolers (please note
max. test pressure).
14. Fill oil tank and coolers with operating oil.

15. Carry out an operational test with the aux. lube oil pump, actuator and
instrumentation. Check oil coolers for leaks and venting. Then carry
out a trial run, observing function and smooth running. Watch for leaks,
correct oil level, if necessary.
2007-07-27
airev-RSe
SPEED Turbo
TURBO GmbH
COUPLING - D-74555
Type R18 Crailsheim
KGS 3626-021393 en
- 51 -
11. Dismantling the Geared Variable Speed Coupling

(pay attention to the corresponding sectional drawing)
Installation work on the geared variable speed coupling should only be carried out
by our service engineers or qualified staff (please see safety information).
After rotating parts have been taken out of the housing, they can be dismantled
and reassembled elsewhere.
For urgent installation work or repairs, it is not absolutely necessary to drain the oil
tank.
No special tools are needed for dismantling and reassembling the Voith geared
We recommend to mark all rotating parts (if they have not been provided with
balancing or reference marks) prior to dismantling, to be able to reassemble them
in the proper position at assembly.
Components and larger subassemblies must be carefully fixed to lifting devices

and be secured in order to avoid any danger here. Only use appropriate and lifting
devices in technically sound condition as well as load suspension devices with
sufficient carrying capacity!
Do neither stay nor work under suspended loads!
11.1.1 Removing the housing cover
Remove the supply lines on the actuator, if necessary. Remove any

obstructive fittings above the shaft centre line, such as electric cables,
pipes etc. The same applies to the connecting coupling guards.
Remove the hex. screws (0270/0360) in the sealing flange (0270/0350).

Press and lift off the sealing flange.
Remove the hood (0110/0180) to the scoop tube control and all vertical
securing bolts in the housing cover. Remove the socket head screws
between thrust bearing covers (0030/0030) and bearing covers
(0015/0010) and (0016/0010).
Remove screws above the joint face of the thrust bearing covers
(0030/0030) and the bearing covers (0015/0010) and (0016/0010).
Bring the travelling crane over the centre of the housing cover, hoist up
and set down on a rubber mat.
2007-07-27
GEARED VARIABLE SPEED TURBO COUPLING Type R18 KGS 3626-021393 en
- 52 -
11.1.2 Removing the scoop tube control and scoop tube
Remove housing cover as in 11.1.1. Remove connecting rod

(0170/0090) by removing the pin of the link joint (0170/0110).
On the elbow (0205/0300) with the welded bracket, and release the
bolts in the flange and the bracket. Carefully hoist the elbow and
bracket in vertical position. Pull the control pin (0080/0210) from the
control sleeve (0080/0200). Ensure the control sleeve remains in the
control housing and the spring wire (0080/0230) is not bent.
Then pull the control sleeve (0080/0200) out of the control housing
(0080/0140).
When unbolting the 5 control oil pipes, collect the oil in a tank.
On the control housing (0080/0140), remove the bolts (0080/0150) and

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

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

follows:
Remove two opposite screws (0080/0100), replace them by two
threaded spindles M8x300 mm with nuts to relax the spring. Remove
the remaining screws (0080/0100). Relax the spring by means of the
nuts. Remove the threaded spindles and lift off the cover.
Withdraw guide bush (0080/0120) and spring (0080/0130) from the

cylinder (0080/0070).

2007-07-27
Code : BHEL-R18KGS 14 API.: Cplg serial Nos.: 114-00173 and 114-00174 3626-02139358
en
- 53 -
To remove the scoop tube (see picture), hook a bent wire into the bore
of the spring cotter in the scoop tube piston (0090/0010/0030) and pull
the scoop tube out.
11.1.3 Removing the coupling runner
Warning: Personal injury and damage to property may occur,

if individual gears or pinion shafts of the gear stage
are replaced, see par. 10.
Remove the gear lubrication injection pipes on the input side. Separate
the elbow (0205/1170) at the flange connections and remove with both
oval flanges and O-ring.
Remove all temperature probes.
Unscrew the primary and secondary thrust bearing cover (0030/0030) on

the primary and secondary sides and the outer thrust bearings
(0071/0050).
Remove the primary and secondary thrust ring (0030/0010) on the

primary and secondary sides and withdraw the inner thrust bearings.
Remove the bearing cap of bearing 5 releasing the bolts and lifting the
fitted pins.
Remove the upper bearing cap of bearing 5 from the shaft.
Remove the bearing caps of bearing 6 (oil supply housing) and 8 as for
bearing 5.
Remove the bolts and fitted pins in the scoop tube housing
(0110/0010/0070/0130), the scoop tube housing remains on the
coupling rotating parts.
2007-07-27
- 54 -
Unscrew one fusible plug screw (0310/0010/0060) from the shell

(0310/0010/0020). Clear the bore from sludge and turn the runner so
the residual oil drains out.
Screw a screw-in swivel M 24 into the centre winding of the primary

shaft (0310/0010/0010/0010) and secondary shaft
(0320/0010/0010/0010) of the rotating parts.
Suspend the parts up by nylon ropes, as shown in the sketch.
The rotating parts should be perfectly horizontal when they are being
removed so that the pinion teeth do not buckle.
Use a lifting device to ensure the parts are level. Sling a rope round the
cylinder (0080/0070) and secure on the crane hook to prevent twisting
of the scoop tube housing.
Slowly lift the runner.
On dismantling the runner, the lower bearing halves of bearings

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

2007-07-27
Code : BHEL-R18KGS
airev-RSe 14API.:
Voith TurboCplg serial Nos.:
GmbH 114-00173
- D-74555 and 114-00174
Crailsheim 3626-02139360en
- 55 -
11.1.4 Dismantling the coupling runner
Remove the screw-in swivel from the centre winding of the secondary
shaft (0320/0010/0010/0010) and suspend the coupling runner using
the crane.
Leave the primary shaft suspended on the crane and chock up the
pinion of the secondary shaft in stable manner.
Remove all socket head screws (0310/0010/0040) between primary

wheel (0310/0010/0010/0020) and shell (0310/0010/0020).
All screws on the runner are tolerated with regard to their weight
(please see also parts list, abbreviation "GT"). These screws are
marked in colour and must not be interchanged with others.
Jack the primary wheel off the shell using two puller screws
M 10 x 80.
Lift the primary part and set down on a rubber mat.
Remove socket head screws (0320/0010/0040). Jack the secondary

wheel (0320/0010/0020) off the secondary shaft
(0320/0010/0010/0010) using two puller screws and hoist up by crane.
Lift the shell (0310/0010/0020) out over the secondary shaft, by means
of the crane, and set down.
Put a spacer between scoop tube housing and gear wheel.
Remove screws in the bearing cap (0110/0010/0070/0200), keep the

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

dismantle the upper half of the split bush (0110/0020) and the second
half of bearing (0071/0030).
2007-07-27
GEARED VARIABLE
airev-RSe SPEED
Voith TURBO
Turbo COUPLING
GmbH Type R18
- D-74555 KGS
Crailsheim 3626-021393 en
Postfach 15 55 x Telefon (07951) 32-0 x Telefax
Code : BHEL-R18KGS 14API.: Cplg serial Nos.: 114-00173 32-500
and 114-00174 61
- 56 -
11.1.5 Removing the complete input shaft

The connecting coupling hub can remain on the shaft.
Remove the screws on the bracket of bearing points 2 and lift the
dowel pins. Lift off the bearing cap. Remove the shells (0071/0010) of
bearings 1 + 2 from the input shaft. Remove the injection pipe for the
filling pump drive (pump insert).
Screw screw-in swivel M 36 into the input shaft (0301/0010/0010/0010)

near the spur gear (0020/0010). Suspend the input shaft (see sketch)
and lift out of the housing, keeping the shaft horizontally.
On dismantling the shaft the lower bearing halves can stick to the
shaft. Remove the bearings shells after lifting.
2007-07-27
SPEED Turbo
TURBO COUPLING
GmbH - Type R18 KGS
Code : BHEL-R18KGS 14API.:15Cplg
Postfach 55 xserial Nos.:
Telefon 114-00173
(07951) and 114-00174
32-0 x Telefax 32-500 62
- 57 -
11.1.6 Removing the output shaft (pinion shaft)

The connecting coupling hub can remain on the shaft.

Release the bolts in the bearing cover (0016/0010).
Remove the bolts from the bearing cap of the bearing point 11 and lift
the dowel pins. Lift off the bearing cap and remove the upper bearing
shell.
Suspend the output shaft (0301/0010/0030) to the crane and hoist

horizontally out of the housing.
On dismantling the shaft, the lower bearing halves can stick to the
shaft. After lifting, remove the bearing halves.
11.1.7 Removing the pump insert
In the event of a defective pump insert (decreasing supply capacity,

damaged tooth surfaces of the input pinions), it is recommended to
replace the complete pump insert (0130/0010).
With removed housing cover, the pump insert is easily accessible for
removal.
Another possibility is to remove the inspection cover I (with the oil filler
plug) and withdraw the pump through the hatch in the housing cover.
Remove the bolts (0120/0110) and press the pump insert about 50 mm
upwards using the two puller screws M 12 x 80.
Sling a rope round the input shaft and carefully hoist the pump up by
crane.
Set the pump down on a rubber mat.

2007-07-27
TURBOGmbHCOUPLING Type R18 Crailsheim
- D-74555 KGS 3626-021393 en
and 114-00174 63
- 58 -
11.1.8 Removing the aux. lube oil pump
If the aux. lube oil pump is damaged (decreasing supply capacity), we

recommend replacing the complete aux. lube oil pump (5000/0010).
Remove the connecting cable and the connecting bolts from the
electric motor. Press the motor out using two puller screws, push it
back horizontally and set down on a rubber mat.
Check the condition of the connecting coupling.
Remove the screws (242/040) and (242/050).
Press the gear pump out using two puller screws and horizontally
withdraw by hand in horizontal position.
2007-07-27
airev-RSe Voith
GEARED VARIABLE Turbo
SPEED TURBOGmbH - D-74555
KGS 3626-021393 en
- 59 -
11.2 Cleaning and checking the coupling parts
Clean all removed parts (remove clinging oil sludge) and check as follows:
- Inspect primary wheel (0310/0010/0010/0020) and secondary wheel

(0320/0010/0020) (resonance test of the blading).
- Check scoop tube (0090/0010/0010) and guide bush (0080/0010) for wear.
- Check the scoop tube tip (0090/0010/0010) for erosion and that the guide
bush (0080/0010) does not have any clearance. Check the O-rings
(0080/0220), (0090/0010/0040) and oil scraper rings (0270/0340) for
hardening and cracks, it is recommend to replace them.
- Clean the control parts.

Prior to removing the control parts from the guide bush (0270/0020), measure
and record the overall length of guide bolt (0270/0080) and control rod
(0270/0140) and (0270/0150).
After cleaning, grease the control parts and mount as originally. Check the
easy movement of both guide bolts (0270/0080) in the guide bush.
- Check the three fusible plug screws (0310/0010/0060) for their solder; in case
of no solder, replace the fusible plug screws by new ones.
- Check the plain bearings for cracks, contract traces and clearance. Pay
attention to the drawing “bearing installation - bearing clearances 20500540810”
as mentioned under part 4 “Voith Information Sheets”.
Before installing new plain bearings, exactly copy the position of the bores for
the temperature probes from the old bearing shells to the new ones.
The bearing clearance is measured in mounted condition by lifting the shaft.
- Check bearings and pinions of the pump insert (0130/0010).
- Check the connecting coupling as well as the aux. lube oil pump (5000/0010)
for leakage.
- Remove the old sealing compound from the sealing surfaces of the geared
variable speed coupling. Hylomar, blue colour, must be removed by a cleaning
agent.
- After having pumped the oil from the oil tank, the remaining operating oil and
sealing material should be removed by flushing the oil tank.
- Check all parts visually for their general conditions.
2007-07-27
- 60 -
11.3 Reassembling the geared variable speed coupling
11.3.1 Preconditions and remarks
All bolts inside the housing should be fitted with the same number of
tab washers, spring washers or Loctite 0242
Coat the sealing surfaces with a permanent plastic, oil-resistant sealing

compound (Hylomar).
All screws shown with a specified tightening torque on the sectional
drawings are to be retightened.
Attention: On reassembly of the runner, pay attention to

the balancing mark, e.g. number marked at
the periphery of the part. Remount parts
which were marked before disassembly
according to the marking.
11.3.2 Reassembling the coupling runner
Insert the fusible plug screws (0310/0010/0060) in the shell

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

surface with clean operating oil and pay attention to it that they are
installed correctly. The bearing shells are marked with the gear
housing. Install the plain bearings according to Bearing Installation
Drawing 42434390.
Position the upper half of the split bush (0110/0020) as well as the
bearing bush (0071/0030) into the scoop tube housing
(0110/0010/0070/0130).
Insert the lower half of the split bush (0110/0020) in the bearing cap
(0110/0010/0070/0200).
Place the secondary shaft (0320/0010/0010/0010) vertically on the hub

of connecting coupling. Place the spacer used for dismantling on the
gear wheel. Put the scoop tube housing in the correct position and bolt
it together with the bearing cap (0110/0010/0070/0200).
Place the shell (0310/0010/0020) onto the scoop tube housing

(0110/0010/0070/0130).
2007-07-27
GEARED VARIABLE SPEED TURBO
Postfach 15 55 xCOUPLING Type R18
Telefon (07951) 32-0KGS
x Telefax 32-500
- 61 -
Set the secondary wheel (0320/0010/0020) on the secondary shaft

(0320/0010/0010/0010).
Ensure: The parts are matched.

Pay attention to the marking
(engraved numbers).
Insert the socket head screws (0320/0010/0040) and tighten them

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

(0310/0010/0010/0010) on the shell (0310/0010/0020) and bolt
together.
Then place the runner in horizontal position.
11.3.3 Mounting the coupling runner into the housing

Check the gear housing for impurities and foreign particles. All oil
supply bores must be free and clean.
Insert the lower shells of bearing 5 + 6 (0071/0020) and 7 + 8

(0071/0030) in the gear housing (0110/0010/0010) and wet with clean
operating oil. Pay attention to the bearing arrangement (see Bearing
Installation - Bearing Clearances 20500540810. Suspend the runner in
horizontal position and carefully insert it in the gear housing
(0110/0010/0010).
Wet the upper bearing shells with clean oil and put them on the shaft
contact surfaces. The bearing shells are match-marked.
Fit the cap (0110/0010/0070/0100) of bearing point 6, pin and bolt up.
Pin and bolt the scoop tube housing (0110/0010/0070/0130).
2007-07-27
GEARED VARIABLEPostfach
SPEED TURBO
15 55COUPLING Type R18
x Telefon (07951) KGS
32-0 x Telefax 32-500
- 62 -
11.3.4 Mounting the thrust bearings - primary and secondary

side
Fit the inner thrust bearing (0071/0050) and wet the segments with
clean operating oil. Fit the thrust ring (0030/0010) and tighten with the
screws (0030/0020). Insert the outer thrust bearing (0071/0050) wetted
with oil.
Apply sealing compound to the axial sealing surfaces on the gear housing
(0110/0010/0010). Fit and tighten the bearing cover (0030/0030).
Attention: Ensure that the lube oil bore in the bearing cover
(0030/0030) exactly matches the lube oil hole of the
gear housing (0110/0010/0010), as well as that the
O- ring (0030/0036) for sealing is installed.
Press the flange and the O-ring onto the pipe elbow (0205/1170).
Apply sealing compound to the sealing surfaces of the upper flange
and the oil feed housing. Fit, bolt and secure the pipe elbow.
11.3.5 Fitting the scoop tube
Push in the scoop tube (0090/0010/0010) with the guide groove

upwards. Insert the guide bush (0080/0120) and spring (0080/0130) in
the cylinder (0080/0070).
When bolting on the cylinder cover (0090/0020), compress the
compression spring (0080/0130) using two threaded spindles M8x300
and nuts.
Fix the cylinder cover (0090/0020) on the cylinder by inserting screws
(0080/0100). Insert the remaining two screws after removing the
threaded spindles.
11.3.6 Mounting the scoop tube control
Position and bolt the control housing (0080/0140) on the scoop tube
housing.
Coat the control sleeve (0080/0200) with oil and insert in the control
housing (0080/0140).
Push the flange and O-ring on the elbow (0205/0300). Coat the sealing
surfaces of the upper flange and scoop tube housing
(0110/0010/0070/0130) with sealing compound.

2007-07-27
Code : BHEL-R18KGS
airev-RSe 14API
Voith : Cplg
Turbo serial -Nos.:
GmbH 114-00173
D-74555 and 114-00174
Crailsheim 68
3626-021393 en
- 63 -
Set the elbow plus bracket for the controller carefully and vertically on
the scoop tube housing (0110/0010/0070/0130). At the same time
guide the control pin (0080/0210) into the control sleeve (0080/0200).
Bolt up and secure the flange connection.
Reconnect the link piece (0170/0110) and the connecting rod

(0170/0090) for oil flow control.
11.3.7 Mounting the input shaft with gear wheel

Fit the lower shells (0071/0010) of bearings 1 + 2 and wet with clean
oil. Apply sealing compound to the sealing surfaces of the bearing
cover (0015/0010).
Insert the input shaft (0301/0010/0010/0010) carefully in horizontal

position into the housing (0110/0010/0010).
Coat the upper bearing shells (0071/0010) with oil and set on the shaft
contact surface.
Set the bearing cap as marked on the bearing point 2 and screw.
Bolt on the injection pipe for gear wheel lubrication. Bolt the bearing
cover (0015/0010) on the housing (0110/0010/0010).

2007-07-27
airev-RSe Voith
Code : BHEL-R18KGS Turbo
14API.: GmbH
Cplg - D-74555
serial Nos.: Crailsheim
114-00173 and 114-00174 69 en
3626-021393
- 64 -
11.3.8 Mounting the output shaft (pinion shaft)

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

housing and wet with clean oil.
Apply a sealing compound to the sealing surface for the bearing cover
(0016/0010) on the gear housing.
Insert output shaft (0301/0010/0020) in horizontal position carefully into

the housing (0110/0010/0010).
Wet the upper bearing shells (0071/0040) with oil and place on the
shaft contact surface.
Set the bearing cap, as marked, on the bearing point 11 and tighten.
Bolt the injection pipe for gear wheel lubrication. Bolt the bearing cover
(0016/0010) on the housing (0110/0010/0010).
2007-07-27
GEARED VARIABLE SPEED15TURBO
Postfach COUPLING
55 x Telefon Type32-0
(07951) R18 xKGS
Telefax 32-500
- 65 -
11.3.9 Installation of pump insert
Slowly and carefully guide the pump insert (0130/0010) into the gear
housing (0110/0010/0010) using a crane.
The pump insert is pulled downwards by means of 2 diagonally

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

follows:
Apply a thin coat of bluing on several tooth flanks of a spur gear.

Move the gear wheels forward and backward.
Align the pump insert by gently tapping it with the plastic hammer until
the contact pattern is uniformly distributed over the whole tooth width.
Check the backlash at spur gear (0020/0010), please see horizontal
section drawing in part 3.
Insert and tighten two securing bolts.
Remove the two mounting bolts and fit securing bolts.

Ream the bore for the taper pin and pin, if necessary.
Bolt on the injection pipe for gear wheel lubrication of the pump drive.
If the pump insert was removed through the hatch in the housing
cover, per par 11.1.7, and refitted the same way, apply sealing
compound to the sealing surface on the housing cover and bolt on the
inspection hole cover.
2007-07-27
Code : BHEL-R18KGS 14API.: Cplg serial Nos.: 114-00173 and 114-00174 3626-02139371
en
- 66 -
11.3.10 Mounting the aux. lube oil pump
Insert the aux. pump (5000/0010) in the gear housing in horizontal

position.
Turn the aux. lube oil pump in the correct position (bore arrangement
of aux. lube oil pump to comply with that of the gear housing).
When flanging the electric motor on the aux. lube oil pump, ensure the
claws of the connecting coupling mesh.
Bolt the motor to the gear housing. Hook up the connecting cable to
the motor.
11.3.11 Mounting the housing cover
Reinstall and secure all temperature probes which where removed or

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

(0110/0010/0010), the sealing surfaces on the bearing covers
(0015/0010) and (0016/0010) and the two thrust bearing covers
(0030/0030).
Visual check to ensure tab washers are secure and temperature

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

clean) and carefully set on the housing. Fit and secure all screws.
Apply sealing compound to the hood (0110/0180) for the scoop tube
control and mount.
Apply sealing compound to the flange (0270/0350) and mount. Tighten

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

2007-07-27
Code : BHEL-R18KGS
airev-RSe 14API.:
Voith Turbo Cplg serial -Nos.:
GmbH 114-00173
D-74555 and 114-00174
Crailsheim 3626-02139372
en
- 67 -
11.4 Remaining commissioning work
Remount the supply lines of the actuator.
Check alignment of geared variable speed coupling towards driving and driven
machine. Observe section 5, Assembly and Mounting Instructions.
For connecting couplings with lubrication by injection, ensure the correct

attachment of the coupling shell as well as the correct alignment and direction of
injection, angle, of the injection pipes.
Observe the manufacturer's instructions for connecting couplings.
Remount any dismantled piping and lines.
Refill with oil if coupling was drained, see section 6.1.
Allow the aux. lube oil pump to run and check the operation of the scoop tube
actuator. Grease the lube points provided on the control for scoop tube and
circulating control valve with lithium-soaped antifriction bearing grease. Check the
lube oil system does not leak and shows the correct pressure setting.
Reconnect the cables (e.g. instrumentation) if disconnected before.
Make the unit ready to operate and effect a trial run (see par. 7 "Commissioning").

2007-07-27
Code : BHEL-R18KGS
airev-RSe Voith14API.:
TurboCplg
GmbHserial- Nos.: 114-00173
D-74555 and 114-00174
Crailsheim 73en
3626-021393
VOITH TURBO
Order No.: SOR-08-049 POWER TRANSMISSION

Code : BHEL - R18KGS 14API.: Cplg Serial Nos.: 114 - 00173 and 114-00174 74
Order No.: SOR-08-049






Part 2
Parts List
Ordering spares:
Please quote coupling serial number (see name plate), full description of the parts as per the spares
list.
Spares supplied conform to the latest state of the art.
The housing and gears are manufactured to suit the site conditions.
Gearwheels should normally only be replaced in pairs. Send the appropriate shafts to Voith or buy
new ones so that we can mount and balance the gearwheels.
Due to high torques and speeds, the primary wheel and secondary wheel are, in each case, fitted and
thus firmly associated to the shaft by means of fitted bolts. Furthermore, runners with coupling shell
and shafts are balanced to a special balancing procedure.
Therefore, the runner components can only be replaced here at our factory or, in exceptional cases,
at site under supervision of a Voith Specialist using special auxiliary means.
Do not loosen the primary wheel from the shaft, if possible.

When replacing primary / secondary wheels or shafts, fit new fitted bolts or larger diameter.
We therefore recommend to store these parts only in accordance with our offer.
2009-01-19
GEARED VARIABLE SPEED TURBO COUPLING Type R18Crailsheim
KGS
airev-RSe / Frk Voith Turbo GmbH - D-74555 91800009010 en
Code : BHEL -R18KGSPostfach
14API.: Cplg
1555serial Nos..:114-00173
xTelefon (07951) 32-0 xand 114-00174
Telefax 32-500
Parts List for instruction manual
VOITH of R18KGS
Pos.No. Description Qty. Remarks
0015/0010 Bearing Cover 1
0015/0020 Labyrinth Disc 1
0015/0030 Oil Thrower 1
0015/0040 O-Ring 1
0015/0050 O-Ring 1
0015/0070 SOCKET HEAD SCREW 8
0016/0020 Labyrinth Disc 1
0016/0030 Oil Thrower 1
0016/0040 O-Ring 1
0016/0050 O-Ring 1
0020/0010 Spur Gear 1
0020/0030 Ring 1
0030/0010 Thrust Ring 2
0030/0035 Screw Plug 2
0030/0036 O-Ring 2
0030/0040 Hexagon Bolt 18
0071/0010 Bearing 2
Dept. DS VOITH TURBO PRIVATE LIMITED

Date: P.O.Industrial Estate, Nacharam, Hyderabad Page I
Prepared DSv-Rm Phone: 27173561, 27173592, 27171440
VOITH of R18KGS
0071/0020 Four lobe bearing 2
0071/0030 Four lobe bearing 2
0071/0040 Bearing Shell 2
0071/0050 Thrust Bearing 4
0071/0050/0050 Straight Pin 4
0071/0060 Roll Pin 8
0090/0010 Scoop tube-CW 1
0110/0010/0010 Transmission Housing 1
0110/0010/0020 Housing Cover 1
0110/0010/0030 Taper Pin 2
0110/0010/0040 Hexagon Bolt 48
0110/0010/0050 Hexagon Bolt 10
0110/0010/0060 Hexagon Bolt 8
0110/0010/0070/0070Bearing Clamp 1
0110/0010/0070/0100 Bearing Clamp 1
0110/0010/0070/0130Scoop Tube housing 1
0110/0010/0070/0200 Bearing Clamp 1
0110/0010/0070/0230Bearing Clamp 1
0110/0010/0070/0450SOCKET HEAD SCREW 6
0110/0010/0080 PIN 2
0110/0010/0090 Hexagon Bolt 6

Date: P.O.Industrial Estate, Nacharam, Hyderabad Page II
VOITH of R18KGS
0110/0010/0110 SOCKET HEAD SCREW 8
0110/0010/0120 PIN 2
0110/0010/0170 Hexagon Bolt 2
0110/0010/0180 Hexagon Bolt 4
0110/0010/0220 PIN 2
0110/0010/0240 PIN 2
0110/0010/0250 Hexagon Bolt 4
0110/0020 Split bushing 1
0110/0030 Roll Pin 2
0110/0040 Cover 1
0110/0050 Oil Level glass 1
0110/0070 Cover 1
0110/0100 Cover 1
0110/0105 Cover 2
0110/0130 Seal Ring 1
0110/0177 Seal Ring 2

Date: P.O.Industrial Estate, Nacharam, Hyderabad Page III
VOITH of R18KGS
0110/0180 Hood 1
0110/0190 Socket Head Screw 20
0110/0210 Filter Base 1
0110/0220 Vent Filter 1
0110/0250 Oil Reservoir 1
0110/0280 Seal 1
0110/0290 Cover 1
0110/0310 Flat Seal Ring 1
0110/0320 Hexagon Nut 4
0110/0330 Blind Flange 1
0116/0010 Orifice Plate 2
0120/0120 Spring Washer 4
0130/0010 Pump Insert -Right 1
0205/0300 Piping 1
0205/0430 Piping 1
0205/0450 Piping 1

Date: P.O.Industrial Estate, Nacharam, Hyderabad Page IV
VOITH of R18KGS
0205/1190 Roll Pin 2
0246/0010 Duplex Filter 1
0246/0080 Stud 6
0301/0010/0010 Gear+Shaft 1
0301/0010/0030 Gear Pinion Shaft 1
0301/0010/0040 Key 1
0301/0010/0050 Key 1
0310/0010/0010/0010Gear Pinion Shaft 1
0310/0010/0010/0020Primary Gear 1
0310/0010/0010/0030Weight tol.Screw 6
0310/0010/0010/0040Connecting Pin 6
0310/0010/0010/0050Weight tol.Screw 6
0310/0010/0020 Outer Shell 1
0310/0010/0030 Vane Ring 1
0310/0010/0040 Weight tol.Screw 36
0310/0010/0050 Socket Head Screw 8
0310/0010/0060 Fusible Plug 3
0320/0010/0010 Gear + Shaft 1

Date: P.O.Industrial Estate, Nacharam, Hyderabad Page V
VOITH of R18KGS
0320/0010/0020 Secondary Wheel 1
0320/0010/0040 Weight-tol.Screw 6
0320/0010/0050 Connecting Pin 6
0320/0010/0060 Weight-tol.Screw 6
500/0010 Start Lube Pump 1
5000/0060 Motor 1
0080/0010 Scoop Tube bush 1
0080/0070 Cylinder 1
0080/0120 Guide Bush 1
0080/0130 Cyl.Compr.Spring 1
0080/0140 Control Housing 1
0080/0170 Guide Piece 1
0080/0190 Roll Pin 2
0080/0200 Control Sleeve 1

Date: P.O.Industrial Estate, Nacharam, Hyderabad Page VI
VOITH of R18KGS
0080/0200/0010 Sleeve 1
0080/0200/0020 Guide Piece 1
0080/0200/0030 Straight Pin 1
0080/0200/0040 Roller 1
0080/0200/0050 Pin 1
0080/0210 Control Pin 1
0080/0220 O-Ring 2
0080/0230 Spring Wire 1
0080/0260 Set Screw 1
0090/0010/0010 Scoop Tube 1
0090/0010/0020 Cylinder bottom 1
0090/0010/0030 Piston 1
0090/0010/0040 O-Ring 1
0090/0010/0050 Roll Pin 1
0090/0020 Cylinder head 1
0170/0010 Housing 1
0170/0020 Sleeve 1
0170/0030 Spring guide 1
0170/0040 Roll Pin 1

Date: P.O.Industrial Estate, Nacharam, Hyderabad Page VII
VOITH of R18KGS
0170/0050 Circlip 2
0170/0080 Control Piston 1
0170/0090 Coupler 1
0170/0100 Roll Pin 2
0170/0110 Fork Joint 2
0205/1170 Pipe Elbow 1
0270/0020 Guide Bush 1
0270/0020/0020 Con.lubrication nipple 2
0270/0025 Roll Pin 2
0270/0040 Grub Screw 2
0270/0060 Grub Screw 1
0270/0070 Hexagon nut 3
0270/0080 Guide Pin 2
0270/0080/0020 Protective plug 2
0270/0090 Pin 2
0270/0100 Deep groove ball bearing 2
0270/0120 Circlip 4
0270/0140 Steering Rod 1

Date: P.O.Industrial Estate, Nacharam, Hyderabad Page VIII
VOITH of R18KGS
0270/0150 Steering Rod 1
0270/0160 Key 1
0270/0165 Key 1
0270/0180 Scoop tube 1
0270/0190 Washer 1
0270/0200 Stroke Indicator 1
0270/0210 Counter Screw 4
0270/0220 Cam Plate 1
0270/0230 Cam Plate 1
0270/0250 Washer 4
0270/0270 Connector 1
0270/0300 Roll Pin 1
0270/0310 Cyl.Compr.spring 1
0270/0320 Cyl.Compr.spring 1
0270/0340 Scraper Ring 2
0270/0350 Flange 1

Date: P.O.Industrial Estate, Nacharam, Hyderabad Page IX
VOITH of R18KGS
0270/0361 Hexagon nut 3
0270/0370 O-Ring 1
0270/0380 Hexagon bolt 4
0270/0410 Cover 1

Date: P.O.Industrial Estate, Nacharam, Hyderabad Page X
Part 3
Drawings:
Horizontal Section Sheet 1 TCR42557390

Vertical Section Sheet 2 TCR42557390
Section through Control Sheet 1 TCR42557380

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


2009-01-19
Code : BHEL-R18KGS
airev-RSe / Frk 14API.:
Voith Cplg.GmbH
Turbo Serial Nos.: 114-00173
- D-74555 and 114-00174
Crailsheim 91800009010 1en
Mercury in Steel
Dial Thermometer
Mercury filled system based on mercury expansion principle is

used for measuring temperature ranging from (-) 400C to 6000C.
It has faster response and the same is available in rigid stem as
well as capillary type for remote sensing. Every angle type can be
offered in all SS construction. Manufactured in accordance with
BS:5235. System is case compensated as standard (SAMA Cl VB).
Fully compensated (capillary compensation) system is offered
wherever essential.
Features
Rugged construction
Rigid stem or capillary type
Fast response
Protection class IP- 67
Accuracy ± 1% FSD (0.5% FSD on request)
High repeatability, low hysteresis
Case compensated system
Micrometer Pointer
Specifications
Ref Standard : BS 5235
System : Mercury filled, case compensated in accordance with SAMA CI. V B
Dial : 100 mm or 150 mm in aluminium, white background, black markings
Case : Die cast aluminum with screwed bezel, SS304 / SS316 with bayonet bezel
Protection : Weather proof to IP - 67 (IS : 13947 Part I)
Window : Shatterproof glass
Pointer : Aluminium, black
Stem : SS304 or SS316 in 6 mm, 8 mm, 9.5 mm, 10 mm, 12 mm, 12.7 mm, 14 mm, 16 mm dia and length from
100 mm to 1000 mm (longer lengths available on request )
Capillary : SS covered / SS covered + PVC / SS armoured (up to 15 M).
Connection : ½" NPT (M) as standard in SS304 or SS316 three piece adjustable compression fitting.
Range : (-) 400C to 6000C with a minimum span of 500C
Accuracy : ± 1% FSD / ± 0.5% FSD
Overrange : 130% FSD as standard
Zero reset : Micrometer Pointer
Optional : 1) Glycerine filled SS304 / SS316 case
2) Fully compensated double bourdon system in accordance with SAMA CI. V A
3) SS solid drawn capillary for better performance
Note : 1) For minimum immersion length essential for proper sensing, contact our design department.
2) Three point calibration certificate accompanies each thermometer.
www.generalinstruments.net 61
Mercury in Steel
Dial Thermometer
How to Order
TYPE
MIS-R - Rigid Stem
MIS-C - Capillary Type
MOUNTING
V - Bottom Entry, Local Mounting OPTION
C - Back Entry, Local Mounting A - Thermowell
E - Every Angle, Local Mounting G - Glycerine Filled Case
S - Bottom Entry, Surface Mounting C - Colour Band
P - Back Entry, Panel Mounting D - Dual Scale
DIAL L - NIL
10 - 100 mm 15 - 150 mm S - Silicone oil filled
case
CASE
AL - Die-cast S4 - SS304 UNIT
Aluminium S6 - SS316 C - Deg C F - Deg F
STEM-OD
A - 6 mm E - 12 mm RANGE
B - 8 mm F - 12.7 mm (-) 30 to (+) 30 0 to 160
C - 9.5 mm G - 14 mm (-) 20 to (+) 20 0 to 200
D - 10 mm H - 16 mm
(-) 20 to (+) 40 0 to 250
STEM LENGTH (-) 40 to (+) 20 0 to 300
0 to 50 0 to 350
Specify in mm
0 to 80 0 to 400
STEM MATERIAL 0 to 100 0 to 500
S4 - SS304 S6 - SS316 0 to 120 0 to 600
CAPILLARY CONNECTION
TYPE Size Type Male / Female
SC - SS Covered
SP - SS Covered + PVC 6 - 1/4” NT - NPT M - Male
SA - SS Covered + SS Armoured
SAP - SS Covered + SS Armoured + PVC 10 - 3/8” BP - BSP F - Female
15 - 1/2” BT - BSPT
LENGTH 20 - 3/4” PF - PF
25 - 1” GS - Gas
Specify in metre 32 - 1.1/4” NS - NPSM
40 - 1.1/2”
Metric Threads
18 M - M 18 x 1.5
20 M - M 20 x 1.5
24 M - M 24 x 1.5
27 M - M 27 x 2
33 M - M 33 x 2
X X - Any other
62 www.generalinstruments.net
DIFFERENTIAL PRESSURE
106
INDICATORS — SWITCHES
˜ DIAPHRAGM SENSOR ˜ WEATHERPROOF ˜ HIGH OVER PRESSURE ˜
˜ 270 DEG. POINTER TRAVEL ˜ HI – LO SWITCHING ˜
˜ FLOW OR FILTER MONITORING ˜
STYLE 106D
SWITZER 106D range of Differential Pressure Indicators displacement is kept minimum to achieve high
are 316 Ti SS diaphragm operated to ensure reliable repeatability. The pointer movement and dial are fitted
indication of pressure difference between two inputs. in a weatherproof die cast aluminium housing.
High and low pressures are applied on either side of a High and Low switching for alarm can be provided with
single diaphragm. The resultant motion is transferred to adjustable cam mechanism to actuate one or two
the gauge case through a unique motion – transfer microswitches. The diaphragm is protected fully from
mechanism and a SS movement. The volume over pressure through a seal valve assembly.
GENERAL SPECIFICATIONS
Gauge Case Die Cast Aluminium weatherproof Zero Adjustment Via Micrometer Pointer
to IP:66. 304 SS case optional Sensing Element 316 Ti SS Diaphragm
Dial Size 150 mm dia nominal Body Material 316 SS standard
Scale Linear, Square Root or Both Movement Stainless Steel (non-wetted)
Window Material Toughened float safety glass Process Connection 1/4" NPTF Std; Others through
Accuracy Û ± 2 % FSR, indicator only. adaptors.
With switching, ± 2 % before & Vent / Drain Plug Optional
± 3 % after switching. Mounting Flush Panel standard;
Ranges 0 – 40 mbar to 0 – 2.5 bar; Refer 2" Pipe / wall optional
Ordering Specification for details Alarm Switching Snap acting microswitch
Max. Working Pressure 60 Bar (optional)
Over range Protection Through built-in seal valve No. of Switches One for Hi or Lo. Two, one each
Max. Process Temp 100°C for Buna – N Seal for Hi & Lo.
230°C for Viton® Seal Switch Rating 5A 250V AC (Res.)
For higher temperatures use 3A, 250V AC (Ind-p.f.0.6)
adequate length of impulse piping. Switch Setting Adj. from 10% to 90% FSR
Ask for piping nomogram #441184-4 Switching Differential 6 to 8% FSR fixed, for 1 Switch
10 to 12 % FSR fixed, for 2 Switches
Û Accuracy includes linearity and hysteresis High – Low Gap (min.) 15% FSR
Viton® is a registered trademark of DuPont Dow Elastomers Electrical Connection Via DIN 43650 plug
QS Accreditation
R030
ORDERING MATRIX
106 D E 1 0 0 0
Differential Pressure Indicator Accessories and Options Ü
106 Style 106 0 None – standard with Studs for Panel Mounting
Additional Ranges : Specify range in Order § F Pipe Mounting with ‘U’ Bolt & Nuts
W Wall Mounting Bracket
0 – 40 mbar 0 – 400 mbar L Liquid Filled Dial †
0 – 60 mbar 0 – 600 mbar S 304 SS Case
0 – 100 mbar 0 – 1.0 Bar T Degreasing for Oxygen Service
0 – 160 mbar 0 – 1.6 Bar B Blow-out-Disc
0 – 250 mbar 0 – 2.5 Bar
V Vent
§ Non-std ranges upto 80% of these ranges D Drain
are possible at extra cost. Consult factory. X Others (Consult factory)
Body, Element Material and Rating
D 316 Ti SS Diaphragm, 316 SS body, 60 bar (900 PSIG) Ü If more than one accessory / option is required
specify W, L, . . . etc.
Accuracy
† Gauges with Liquid Filled dials :
E ± 2% FSR, for Indicator without switch
i) Accuracy will change. Consult factory.
F ± 2% & ± 3% FSR, before & after switching
ii) Switching facility not possible. However
Seals switching action can be provided through an
1 Buna – N externally mounted Differential Pressure Switch
2 Viton (Refer factory for details).
3 Others (consult factory) Notes :
1. Calibration is as per ANSI / ASME B40.1 Clause 6.2.3.
Process Connection 2. Chemical seals are not available.
0 1/4" NPTF standard 3. Accuracy figures are exclusive of test equipment
6 1/2" NPTF through 316 SS adaptor tolerance on the claimed values.
9 Others – on request 4. All performance data guaranteed ±5%.
Switching Caution :
0 None 1. Use of snubber is a must if pressure fluctuations are rapid.
1 One Microswitch 2. Use 3–way / 5–way manifold to avoid damage / shift in
2 Two Microswitches calibration.
OVERALL DIMENSIONS
2" PIPE MOUNTING REAR VIEW FLUSH PANEL MOUNTING
(Without Mounting Accessories) CUTOUT DIMENSIONS
197
72 57 210 Ø
165 Ø C UTOUT
VENT PORTS
2" PIPE BY CUSTOMER (OPTIONAL)
45°
HORIZONTAL
POSITION – OPTIONAL
(FIX ‘U’ CLAMP
VERTICALLY)
3/8" BSW ‘U’ 1/4" NPTF

BOLT – 2 NOS.
CUSTOMER TO DRILL 4 HOLES
DIN SOCKET ON THE PANEL 6 Ø AT 178 PCD.
(FOR ELECTRICAL
DRAIN PORTS (OPTIONAL) PANEL CONNECTION)
PANEL MTG. STUDS. (4 NOS.) ‘d’
75 for Lo Port 40 d – 88 mm for 0–600 mbar to 0–2.5 bar ranges

97 for Hi Port 145 mm for 0–40 to 0–400 mbar ranges
Notes : 1. For wall mounting drill 2 Nos. 10.5Ø holes. Use 3/8" × 40L Coach Screws for fixing the instrument.
2. S.S. Gauge case dimensions are different. Ask factory for drawing.
3. All dimensions have a tolerance of ±2.0 mm
ALL DIMENSIONS ARE IN mm
Prior notification of changes in specification is impracticable due to continuous development.

# 1002 DPI-106D – Rev.1
FOR SWITZER'S OFFICES IN INDIA

CHECK AT:
http://www.switzerinstrument.com/offices.htm
301 / 303 / 304
DIFFERENTIAL PRESSURE SWITCHES 381 / 384
! GOOD REPEATABILITY ! HIGH STATIC PRESSURE !

! TAMPERPROOF SET POINT ADJUSTER WITH LOCKING DEVICE !
! WEATHERPROOF OR FLAMEPROOF HOUSING !
! OVERTRAVEL STOP ! RUGGED DESIGN !
STYLE 301 IN GK ENCLOSURE STYLE 301 IN GM ENCLOSURE
Series 300 Pressure Difference Switches are designed static pressure capability. The sensing element is mounted
and made to the latest standards to comply with current external to the switch mechanisms which are of stainless
international philosophy of process instrumentation. The steel for ardous atmospheres and high humidity. Enclosures,
series is compact , easy to install and features high sensitivity sensing element and switching modes can be combined
over the fully adjustable range together with very high to offer the variety needed to suit the different applications.
GENERAL SPECIFICATIONS
Enclosure Switching Differential Fixed or Wide band adjustable,
GM Pressure die cast Aluminium, refer table.
weatherproof to IP:66 Max. Working Pressure 110 bar for 301, 303 & 381
GA 316 SS, investment cast, weather- 250 bar for 304 & 384
proof to IP:66 Ambient Temperature (–)25°C to (+)60°C
GK Die cast Aluminium, weatherproof Max. Process Temp. 70°C. For higher temperatures use
to IP:66 & flameproof to Gr.IIA, IIB longer impulse lines. (Note 15)
or IIC for H2 GAS (Note 1) Ask for piping nomogram #441184-4
Connection
Ranges Several standard ranges between
3 mbar to 15 bar Process ¼" NPTF. Adaptors for other sizes
optional
Sensor 316L SS Diaphragm
Electrical ¾" ET (F) std. ½" NPTF optional.
Wetted parts 304 SS or 316 SS
For Gr.IIC ½" NPTF alone is
Repeatability ±1% FSR (Note 4) available. Dual entry on request.
Scale Accuracy ± 5% FSR (Note 6) Mounting Back panel/wall/Field. Vertical
Switching Element Instrument quality SPCO(SPDT) position only
microswitch (Notes 10 & 11) Conformity Generally to BS 6134:1981
QS Accreditation
R030
ORDERING MATRIX
! ! ! ! !
ENCLOSURE
Pressure Die Cast Aluminium
weatherproof to IP:66 with Nitrile !
gasket. GM
Investment cast 316 SS weather-

proof to IP:66 with overall size as !
style GM fit for offshore. GA

RANGE CODE & AVAILABILITY
Die Cast Aluminium flameproof !
cum weatherproof. CMRI approved RANGE 301/ 381 /
to Gr.IIA, IIB of IS:2148: 1981 for CODE
RANGE 303
304 384
flameproofness & IP:66 for wea-
therproofness. For Gr.IIC same C 6D 3 to 25 mbar " " ×
enclosure with specific certification !
at extra cost is available. GK E 1D 5 to 120 mbar " " "

E 8D 50 to 350 mbar " " "
MODEL
This is the basic differential pressure G5B 0.1 to 1.5 bar " " "
switch having close fixed non-adjustable
switching differential actuated by a ! J0 B 0.2 to 4 bar " × "
stainless steel diaphragm. 301
M2B 0.7 to 7 bar " × "
Same as 301 but with auxiliary mechanism
permitting switching differential adjustment ! P 8B 1.5 to 15 bar " × "
over a wide band. 303
Same as 301 but suitable for higher static !
pressures upto 250 bar. 304
A variant of series 300, employs twin

levers each operating a SPCO
SWITCH CODE RATING & AVAILABILITY
microswitch actuated by a single sensor
!
through a unique linkage thereby providing DC RATING IN AMPS
SWITCH AVAIL ABIL ITY AVAIL ABIL ITY
two independent adjustable set points, AC
AC
CODE RESISTIVE INDUCTIVE OF SPCO IN OF DPCO IN
each with its own setting scale, spring ! RATING
(SPCO) 220V 110V 24V 220V 110V 24V MODEL S MODEL S
and switch. 381
15A 250 / 301, 304,
D 0.2 0.4 2.0 0.02 0.03 1.0 301 & 304
Same as 381 but suitable for higher static ! 125V 381 & 384
pressures upto 250 bar. 384 15A 250 / 301, 304,
3 N.R. N.R. N.R. N.R. N.R. N.R. 301 & 304
125V 381 & 384
15A 250 /
3 0.3 0.5 10.0 0.3 0.25 6.0 303 303
MATERIALS OF WETTED PARTS 125V
!
02 301, 304,
316L SS diaphragm with 304 SS pressure chambers. 4 1A 125V N.A. 0.5 0.5 N.A. 0.25 0.25 301 & 304
! 381 & 384
316L SS diaphragm with 316 SS pressure chambers. 06 5A 250 /
! 5 0.2 0.4 5.0 0.2 0.4 4.0 301 & 304 301, 303 & 304
125V
Conforming to NACE Std. MR-01-75. 0N
301, 304,
6 0.1A 125V N.A. N.R. 0.1 N.R. N.R. N.A. 301 & 304
381 & 384
Nitrile diaphragm with 304 SS pressure chambers !
for applications with pressure reversal. R2 7 N.R. N.R. N.R. 1.0 N.R. N.R. 0.5 301 & 304 301 & 304
Nitrile diaphragm with 316 SS pressure chambers ! 5A 250 /

8 N.A. N.A. 5.0 N.A. N.A. 3.0 301 & 304 301 & 304
for applications with pressure reversal. R6 125V
4A 115V
9 N.A. N.A. 3.0 N.A. N.A. 1.0 301 & 304 301 & 304
400 Hz.
DIAPHRAGM CHEMICAL SEALS G N.R. N.R. N.R. 1.0 N.R. N.R. 0.25 301 & 304 301 & 304
15A 250 /
E 0.30 0.75 15.0 0.2 0.4 10.0 301 & 304 ---
Diaphragm chemical seals can be provided as optional extra 125V
with capillary and threaded / flanged connection, duly evacuated 15A 250 /
F 0.30 0.75 15.0 0.2 0.4 10.0 301 & 304 ---
and filled with suitable filling liquid. This device permits the 125V
use of differential pressure switches with viscous / aggressive Codes 3 & D – For General purpose usages. Code 9 – Hermetically sealed, inert gas filled with
fluids and permits higher process temperatures. Code 4 – With Noble metal contact. Silver alloy contact.
Codes 5 – For General purpose with good DC rating. Code G – Hermetically sealed, inert gas filled with
While ordering it is important to specify ambient and process Codes 6 – With Noble metal contact (Low Rating) Gold plated contact.
Code 7 – Environmentally sealed switch with Gold Codes E & F – Manual reset switch. Auto change
temperatures, setpoint, maximum process pressure, relative plated contact. over on rising and falling pressure respectively.
elevation between connection and switch head, nature of process Code 8 – Environmentally sealed switch with Silver Resetting is Manual.
alloy contact.
medium and whether reactive to common filling liquids should
the diaphragm seal leak into the process. However, switching For DPCO, change switch code ‘3’ to ‘33’, ‘4’ to ‘44’, etc., while ordering
lag will be experienced unless the pressure change is very gradual. N.A. – Not Available N.R. – Not Recommended
NOTES
1. Gr.IIA & IIB of IS:2148 is equivalent to NEC CL.1, Gr.C & D. Gr.IIC of 11. Contact life of microswitches are 5 × 105 switching cycles for nominal load.
IS:2148 is equivalent to NEC CL.1, DIV.1, Gr.A & B. To quench DC sparks, use diode in parallel with inductance, ensuring polarity.
2. Style GM/GA is weatherproof only if all entries and joint faces are properly A ‘R–C’ network is also recommended with ‘R’ value in Ohms equal to coil
sealed. Style GK is weatherproof only if cover ‘O’ ring is retained in resistance and ‘C’ value in micro Farads equal to holding current in Amps.
position and proper cable gland (flameproof) is used. It is recommended 12. Model 301 can be supplied with Nitrile diaphragm for applications where
to procure cable glands along with GK instruments to avoid neglect of it pressure reversal is envisaged.
during installation. 13. All differential pressure switches are calibrated by applying pressure to HI
3. Intrinsic Safety (Exi) — Pressure Switches are classified as simple electrical port, venting LO port to atmosphere. Inspection will also be limited to such
apparatus as per BS 5345–6.3.3. Hence Pressure Switches with GM/GA a practice.
enclosures may be used in intrinsically safe systems without certification if 14. Ambient temperature range: All models are suitable for operating within a
energy levels are limited to 1.2V, 0.1A or 25 mW. range of ambient temperature from (–) 25°C to (+) 60°C provided the process
4. Accuracy & Repeatability are one and the same for all blind differential does not freeze within this range. Below 0°C, precautions should be taken
pressure switches. A shift of ±2% may be observed in setpoint when in humid atmospheres to prevent frost formation inside the instrument from
pressure falls from full static pressure. Settings will also shift with varying jamming the mechanism. Occasional excursions beyond this range are
temperature. possible but accuracy might be impaired. The microswitch is the limiting
5. The instrument is calibrated in the mounting position depicted in the drawing. factor which should never exceed the limits (–) 50°C to (+) 80°C.
Hence mounting in any other direction will cause a minor range shift, especially in 15. Fluid Temperature: A Differential Pressure switch connected to the main
low and compound ranges. Ranges above 1 bar will not experience this shift. pipe is not subjected to the flow and therefore is not fully exposed to the
6. A Differential Pressure switch is a switching device and not a measuring fluid temperature. Use of adequate length of impulse piping will greatly
instrument — eventhough it has a scale with ±5% FSR accuracy to assist reduce excessive heating of the sensing element. For example connection
setting. For this reason, Test Certificates will not contain individual ON-OFF of 7.5 cm of 12 mm dia impulse piping will reduce water temperature of
switching values at different scale readings. Maximum differential obtained 100°C to 65°C at an ambient temperature of 50°C. Ask factory for temperature
alone will be declared, besides other specifications. nomogram for different temperatures.
7. Select working range of the instrument such that the set value lies in the mid 16. Ensure that impulse pipework applies no stress on sensing element housing
35% of the range i.e., between 35% and 70% of range span. and use spanners to hold pressure port / housing when connections are made.
17. Custom built instruments are available for special service requirements under
8. For switching differential values please refer respective Range Table. Switching
Special Engineering Category.
differentials furnished are nominal values under test conditions at mid-scale
and will vary with range settings and operating conditions. 18. For less rigorous applications models 306 / 386 with Nitrile diaphragm &
Aluminium wetted parts are available at lesser cost.
9. On and off settings should not exceed the upper or lower range span.
19. Complementary instrumentation for pressure is available in 200 series.
10. DPCO action is achieved by two SPCO switches synchronised to practical
limits i.e., ±2% of FSR. Deadband for DPCO contacts are higher than that 20. Accuracy figures are exclusive of test equipment tolerance on the
of SPCO as force required to actuate the contacts are more. Please refer claimed values.
respective range table. 21. All performance data guaranteed ±5%.
SWITCHING DIFFERENTIAL DATA

TABLE : A — GM / GA Enclosures
On -o f f Dif f er en t ial in m b ar On-off differential values for DPCO switching,
DPCO (2 × SPDT)
F i x ed A d j u s t ab l e
R an g e
R an g e Mo d el
Co d e Mo d els 301 / 304 Mo d el 303 ! For style GM/GA enclosures apply a multiplication factor
381/4
of 1.3 to values in Table–A.
D/3/6 4 5 7 / 8 9 / G D/3/4/6 5 3
! For style GK enclosure apply a multiplication factor of
C 6D 3 to 25 mbar 6 6 6 12 10 7.5 8 to 20 ---
1.2 to values in Table–B.
E 1D 5 to 120 mbar 5 6 10 20 12 20 13 to 70 40 to 70
E 8D 50 to 350 mbar 12 15 20 40 30 40 26 to 200 50 to 200
! In case of adjustable on-off differential models the
G5B 0.1 to 1.5 bar 60 60 85 125 120 250 111 to 900 250 to 900
multiplication factor is to be applied only to the lower
J0 B 0.2 to 4 bar 175 200 400 450 500 400 --- ---
limit of the differential values. Upper limit values remain
M2B 0.7 to 7 bar 300 350 1200 800 900 600 --- ---
unchanged.
P 8B 1.5 to 15 bar 800 800 1800 --- 1600 --- --- ---
! For range codes M2B & P8B in models 301, 304 DPCO
TABLE : B — GK Enclosure switching using switch codes 3, D & 4 only is possible.
On -o f f Dif f er en t ial in m b ar Special Engineering : Higher DP range of 10 to 60 bar,

F i x ed A d j u s t ab l e model 301 DP switch is offered with 316L SS bellows
R an g e
R an g e Mo d el sensor. But the out of balance pressure will be limited to
Co d e Mo d els 301 / 304 Mo d el 303
381/4 80 bar. For details refer offer/factory.
D/3/6 4 5 7 / 8 9 / G D/3/4/6 5 3
! Switching differentials for Instruments with chemical
C 6D 3 to 25 mbar 10 10 10 20 17 12 13 to 25 --- seal : Apply a Multiplication factor of 1.3 for SPCO and
E 1D 5 to 120 mbar 8 10 16 34 20 30 21 to 70 35 to 70 1.5 for DPCO to values given in table for GM housings
E 8D 50 to 350 mbar 20 25 40 70 50 55 52 to 200 80 to 200 and apply a multiplication factor of 1.2 for SPCO and
G5B 0.1 to 1.5 bar 100 100 140 210 200 350 182 to 900 425 to 900 1.5 for DPCO to values of table for GK housings.
J0 B 0.2 to 4 bar 300 340 600 765 900 600 --- ---
M2B 0.7 to 7 bar 500 600 2000 1550 1350 1000 --- --- Chemical seals are not available in ranges C6D,
P 8B 1.5 to 15 bar 1350 1350 2200 --- 2700 --- --- --- E1D & E8D.
OPTIONS / ACCESSORIES
! Damping coil for minimising process pulsations — increases ! Brass / SS double compression cable glands to suit cable OD
instrument’s life many times. of 1/2", 15 mm & 17 mm.
! Breather / Drain for flameproof enclosures; blow out disc for ! Degreasing for Oxygen service & special parts for Ammonia
weatherproof enclosure. service.
! Snubbers ! Provision of line fault monitoring.
OVERALL AND MOUNTING DIMENSIONS
GM / GA Enclosure
Range Codes : E1D, E8D, G5B, J0B, M2B & P8B 2" Pipe Mounting Details
Fixing on Fixing on
Surface / Wall Mounting Pipe Mounting Vertical Pipe Horizontal Pipe
! Use 2× 3/8" × 25 long screws

and nuts for surface mounting
or coach screws for wall mounting
instead of ‘U’ bolts and nuts.
GK Enclosure
Pipe Mounting
# For C6D range surface / wall mounting bracket

is not available.
Pipe mounting bracket can be used for surface /
wall mounting.
Range Code : C6D only #
GM / GA Enclosure GK Enclosure
Pipe Mounting Pipe Mounting
Note : Dimensions for Model 304 / 384 are different. Ask for applicable drawing.
All dimensions are in mm
Prior notification of changes in specification is impracticable due to continuous development.
FOR SWITZER'S OFFICES IN INDIA

0503 DPS 301–Rev.1
CHECK AT:
http://www.switzerinstrument.com/offices.htm
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Branches: Baroda,Catculta.
Chcnnai,Goa,New Oelhi,puno
PUNE TECHTROL PVT. LTD., S – 18, M I D C, Bhosari, PUNE – 411 026.
Pn. : +91-20-2712 1052, 2712 9298, 2712 8055, 5611 1996, 5611 1997.
Fax : +91-20-2712 1663. email : techtrol@pn2.net.in Website : www.punetechtrol.com
INSTRUCTION & MAINTENANCE MANUAL

FOR
CHAMBER AND FLOAT SWITCH
( Document No. : MAN / CFS / Rev. OO / 01 - 2007. )
We are glad to know that you are using a reliable ' TECHTROL PRODUCT '. For proper and safe
functioning of the same we suggest you to go through this ' INSTRUCTION & MAINTENANCE MANUAL '
carefully before installing our instrument.
Precautions before installation may avoid serious injury and / or damage to the instrument.
Unpacking :
1. Unpack carefully without damaging the instrument. Ensure that instrument is not damaged in transit and
all components are in place and not in loose condition.
2 Ensure that the serial number and the model number matches with that specified on the Test Report.
Application :
To maintain the accuracy of the instrument it must be used for operating conditions like Sp. Gr., Operating
Temp. and Operating Pressure, Fluid having Sp. Gr. of 0.8 to 1.5 for which it is specified. The instrument
is calibrated to operating conditions mentioned in our Test Report which is sent along with the instrument.
Typical services :
1. Level detection / Alarms / Pump control for storage Sumps / Tanks of liquid and slurries.
2. Drum level switching in Non IBR boilers.
Construction and Operation :
A Dipstick type float carrying a permanent magnet

at its upper end is mounted in a chamber. The
float rises / falls according to liquid level and the
corresponding movement of magnet moving within
the sealed pipe makes or breaks the microswitch
contacts housed in the enclosure.
Figure 1.
- - - - Page 1 of 3 - - - -
Operating Differential :
Differential is actual distance that the liquid level must rise and fall to open or close a switch. This operating
differential is 15 to 25 ± 2mm.
Pre installation Procedure :
Before installation of instrument check following parts by opening enclosure cap.
1. Ensure nuts and screws of follower magnet assembly are not loose.
2. Ensure proper functioning of micro switch assembly by moving coupler rod manually up and down.
3. If micro switch is not operating, reset the position of switch carriage by moving slightly up or down.
4. Ensure the free movement of follower magnet lever.
5. Ensure that operating conditions are within limit. ( Pressure, Temperature, Specific Gravity ).
6. Ensure that any system generating vibrations are away from installation site. ( Pump, Generator ).
7. Ensure that the location of installation is not in the line of flow and away from any suction.
8. Ensure that the nozzle and flange sizes suit the installation.
Installation :
1. Select a suitable location on the tank, where vibrations if any, are minimum.
2. Ensure that the Process connections & C:C distance of the level gauge match with those on tank.
Flange connection : Flanges on the level gauge
should match the counter flanges on the tank
and their PCD orientation should be identical.
Screwed / SMS Union : Threads and Type
should match.
3. Ensure counter connections provided on tank are
vertical and in plumb line.
4. Provide suitable gaskets between the flanges
and appropriate thread sealant between
threads before bolting, to ensure zero leakage
from the joint.
5. Please do not connect any pump suction or
outlet for process at drain point of the gauge.
6. Provide separate isolating valves on the tank for
safety & removal of the gauge for repair / maintenance.
- - - - Page 2 of 3 - - - -
Termination :
Before actually turning ON the power supply,
make sure that all the wiring is done correctly.
Precautions :
1. Ensure that supply voltage and current rating is as per its rated capacity.
Excessive voltage / current will permanently damage the switch contacts.
2. Ensure that the switch is duly earthed.
3. Ensure use of proper cable for wiring, which should match the current rating of connected load.
4. Ensure terminal contacts are not loose.
5. Ensure that Enclosure is always covered with its terminal along with gasket provided for it, to protect
it from dust and weather.
Maintenance :
In case of liquids with dirt or suspended particles, periodic cleaning of float and chamber is essential.
1. Switches must be cleaned frequently if the Liquid has high viscosity or contains floating material.
2. Ensure that terminal connections are not loose.
3. Ensure that contacts of the switch mechanism are not pitted / oxidised due to sparking.
4. Be sure that enclosure cover is always in place on the enclosure.
5. Disconnect device from the supply socket before opening to prevent ignition of hazardous atmosphere.
Trouble Shooting :
Problem Cause Remedy

1. Micro switch operating erratically. Excessive deposition on Clean the surface where
Float surface due to dirt in deposition has taken place.
liquid. Ensure Pre Installation checking as
per Page - 3.
2. Micro switch operating before Turbulence in liquid. Use Still pipe / Cage for assembly
desired set point. to avoid turbulence.
3 Micro switch not operating. a. Wiring may be loose or Resolder the wire at terminals or
improper. Connect the wire properly to
respective terminals.
b. Setting of micro switch assly. Rearrange position of micro switch
to switch carriage is nor proper. assembly to switch carriage.
c. Vibration may cause damage Avoid vibrations by providing
to wiring connections. dampers.
d. Switch burnt due to load more Change switch.
than its rating.
e. Micro Switch contacts Clean contacts.
oxidised / pitted due to
sparking.
f. Float may be damaged / Change float.
punctured.
g. Wiring connections may be Wire Properly as specified.
loose.
f. Liquid Sp. Gravity is less than Replace float to match Sp. Gr.
that specified while ordering.
- - - - Page 3 of 3 - - - -
S&S 303, Markaz Apartments, Manufacturers of Process Instruments & Systems
SYSTEMS Srinagar Colony P.O., SPEED TRANSMITTERS, SIGNAL CONVERTERS
HYDERABAD – 500 073. AND REVERSE ROTATION MONITORING SYSTEMS
040 - 2374 8721, 98491 35071, snssystems@rediffmail.com
INSTALLATION AND OPERATING MANUAL

IOM – E 015 MARCH 2009 ISSUE 1
PROGRAMMABLE CONTROLLER SPEED TRANSMITTER
ADVICE
This publication should be read in its entirety before performing any operation. Failure to understand and follow
these instructions could result in serious personal injury and / or damage to the equipment.
In case this equipment needs any repair or adjustment, contact S&S SYSTEMS. It is important that servicing be
performed only by trained and qualified service personnel. It will be noted that S&S SYSTEMS will not be held
responsible for problems arising due to mishandling and tampering by unauthorized personnel and operation in
excess of the specifications.
GUARANTEE
If at any time within one year of shipment, but not thereafter, it is proved that any part of the equipment furnished
by us was defective when shipped by us, we will repair or replace the same free of charge. Notice of this claim
must be made to us within one year after delivery. Our liability is limited to replacement of such defective parts or
equipment. There are no guarantees or warrantees expressed or implied other than those mentioned here.
CAUTION
This instrument contains electronic components that are susceptible for damage by static electricity. Proper
handling procedures must be observed during the removal, installation, or other handling of internal circuit boards
or devices.
Page : 1 of 19
COMMITTED TO PROVIDE COMPREHENSIVE SERVICE TO INDUSTRY

THROUGH CONTINUOUS IMPROVEMENT IN QUALITY.
Page : 2 of 19
CONTENTS
1.INTRODUCTION..............................................................................................................3
1.1 PURPOSE .......................................................................................................................3
1.2 DESCRIPTION ...............................................................................................................3
1.3 PRINCIPLE OF OPERATION ........................................................................................3
1.4 SPECIFICATIONS .........................................................................................................4
2.INSTALLATION ...............................................................................................................5
2.1 GENERAL ......................................................................................................................5
2.2 RECEIPT OF EQUIPMENT ...........................................................................................5
2.3 INSTALLATION ............................................................................................................5
2.4 START UP AND INITIATION.......................................................................................7
ILLUSTRATIONS
1. CONNECTION SCHEMATIC DIAGRAM…………………………………………… 6

2. RECOMMENDED SPARES ……………..…………………………… 11
3. Sketch OF PROXIMITY SWITCH………………………………………… 11
4. DIMENSIONS OF ENCLOSURES ……………………………..………… 12
5. GENERAL assembly DRAWING ………………………………………… 13
6. WIRING DIAGRAM ……………………………………………...……… 14
Page : 3 of 14
1. INTRODUCTION
1.1 PURPOSE
Instructions for operation and maintenance in this manual apply to Models PCST – 01 – W and PCST – 01 - F,
PROGRAMABLE CONTROLLER SPEED TRANSMITTERS, housed in weatherproof and flameproof Enclosures
respectively.
1.2 DESCRIPTION
PROGRAMABLE CONTROLLER SPEED TRANSMITTER measures the speed in RPM (Revolutions Per Minute) of any
rotating object, indicates the same on an Alpha numeric Backlit LCD Module and transmits a proportional 4 – 20
mA DC signal to control room, which can be used for recording and or control functions.
Model PCST – 01 – W is housed in a Polycarbonate, weatherproof Enclosure, with transparent lid. The Degree of
Protection is IP 65 as per IEC 529. The Indian equivalent standard is IS : 13947 (Part – I) – 1993. They are
approved by ERTL (WEST), STQC Directorate. These enclosures are suitable for panel or wall mounting.
Model PCST – 01 – F is housed in Aluminum flameproof Enclosure with a glass window. This enclosure is suitable
for installation in zones – I & II of II A & II B hazardous areas and is designed according to IS : 2148–1981 and is
certified by CMRI, DHANBAD and CCOE, NAGPUR. Suitable Isolators, also housed in similar flameproof enclosure
might be required to feed the input signals from Proximity Switches as a safety measure.
It is suggested to feed the current output from these instruments to signal Isolators and use the current output
from them for feeding to other instruments like recorders or controllers in the control room. Such Isolators are
usually installed in the control room itself. Isolators for signals from proximity switches, which are installed in the
field (Hazardous area application) and Current Signal Isolators, which are installed in control room (safe area),
are not in the scope of supply along with this instrument. But they can be supplied by us on specific request.
The system comprises of two parts, a sensing part and a signal conditioning part. The sensing part is made up of
one sensor, a 2-wire, intrinsically safe, NAMUR PROXIMITY SWITCH, suitable for installation in hazardous areas or
a 3 wire DC PROXIMITY SWITCH. The signal conditioning part is housed in the above mentioned Enclosure
depending on the area of application. This part processes the signals from the sensor to provide local indication
of RPM and give an output of 4 – 20 mA DC for transmission.
1.3 PRINCIPLE OF OPERATION
Inductive Proximity Switch is used as sensor. These switches are used for non-contact detection of metallic
objects. Their operating principle is based on a coil and oscillator that creates an electromagnetic field in the close
surroundings of the sensing surface. The presence of a metallic object in the operating area, decided by the
sensing range of that specific sensor, causes a dampening of the oscillation amplitude. The rise or fall of such
oscillation is identified by a threshold circuit that changes the output of the sensor. The sensing range depends
upon the size, shape and material of the metallic object. For a given dimension of the sensor, the sensing range is
maximum for Mild Steel and minimum for Copper. Since there is no contact between the sensor and the metallic
object, commonly referred to as the target, these Inductive Proximity Switches are inherently resistant to dust,
humidity and oil and so are suitable for almost all industrial environments.
Page : 4 of 14
The Proximity Switches in 2 wire configuration are called NAMUR, Intrinsically safe . Current varies in the presence
of Targets in these Sensors. There are no amplifier trigger stages in-built in them. Their current and voltage limits
allow them to be used in hazardous areas.
The Proximity Switches in 3 wire configuration need a DC power Supply in the range of 8-30 V DC, which is
provided by the Signal Conditioning Part. They give an output through a third wire based on the presence of
target within their sensing range. The output could be NO/NC and PNP or NPN type. PNP – NO type of output is
standardized for this instrument, when a 3 wire Switch is used.
When the targets are sensed by the Switch, current variation takes place, leading to generation of a pulse train.
The signal conditioning part receives this pulse train. Depending upon the RPM, a proportional frequency is
obtained, which is processed by the programmable converter to finally give out a 4 – 20 mA DC output, combined
with many specific and salient features, which are user friendly. With the Technology used in this system, there is
no need to calibrate the system, when ever there are any changes in the Full Scale values or the Number of
Targets. It is very easy to feed in these parameters and get the results. The most advantageous feature is that
there are no trimpots for Zero and Span Adjustments. There by, operator mistuning is avoided. Further, the entry
of various parameters is protected by a password. So, unauthorized personnel can not tamper with the settings.
Various other features like Power Failure Relay, Hi and Low Process Value Alarms are also incorporated in the
system. Also Customer can select 0-20 MA DC output or 4-20 mA DC output and also a voltage output. Further
the Frequency Signal generated by the pulse train is available as Scaled and Unscaled OC Pulses.
The following precautions are to be taken during installation and interconnection of the sensor and the signal
conditioner unit.
1. The targets on the rotating objects must be well within the sensing ranges of the Proximity Switches.
2. Spacing between successive targets should be more than the width of the Proximity Switch.
3. Cables should be run through conduits to avoid physical damage.
4. Polarity of Proximity Switch wires should be followed properly while terminating.
1.4 SPECIFICATIONS
POWER SUPPLY : 100 – 250 V AC

INPUT SIGNAL : Pulses from Inductive Proximity Switch
LOCAL INDICATIONS : RPM on Backlit LCD Module
OUTPUT SIGNAL : 4 – 20 mA DC proportional to RPM for remote transmission
RPM RANGE : 0 – 999999 RPM / 0-999999 RPS / 0 – 999999 RPH
ACCURACY : ≤± 0.2% of Full Scale Value
POWER CONSUMPTION : 15 Watts maximum
NUMBER OF TARGETS : As per the convenience of Customer ( Minimum 2 )
MAXIMUM LOAD : 600 Ohms
ENCLOSURE DIMENSIONS : Weatherproof – 200/120/90 mm, Flameproof – 340/215/145 mm
MOUNTING DIMENSIONS : Weatherproof – 215/88 mm, Flameproof- 242/176 mm(+/-5 mm)
PROXIMITY SWITCH CONFIGURATION
Type : 3-wire, DC, PNP, NO

Model Number : IN 04 13.5 TM PNP NO
Operating Voltage : 8 – 35 V DC
Switch Diameter : 13.5 mm with M12/1 Male threading
Page : 5 of 14
Sensing Range : 4 mm
Weather protection : IP 67
Termination : Brown ( +Supply ), Blue ( Common ), Black (+Output), Shield
Switch Length : 45 mm
Cable Length : 2 Meters
The proximity Switch is supplied as an integral assembly with a connector Head and a pipe with necessary Fittings.
The Connector Head is an Aluminum Weather Proof Enclosure. The wires are terminated on connecting base. Use
a 3 core twisted and shielded cable to connect from the Connector Head to the Signal conditioning Unit.
2. INSTALLATION
2.1 GENERAL
This section contains the procedures for receipt and installation of Programmable controller Speed Transmitter..
2.2 RECEIPT OF EQUIPMENT
When the equipment is received, the outside of the packing case should be checked for any damages incurred
during shipment. If it is damaged, the local transporter should be notified regarding his liability. Also check for any
missing parts as per the packing list. If any item is missing, a report should be submitted to S&S SYSTEMS, with
the serial numbers of the equipment supplied and the Purchase Order Number. Check whether all items inside
along with the proximity switches are intact.
Remove the envelope containing the packing list. Carefully remove the equipment from the packing case.
Make sure that spare or replacement parts are not discarded with the packing material. Packing List contains the
following items.
1. Model PCST – 01 – W or PCST – 01- F PC Speed Transmitter 1No.

2. IN 04 13.5 TM PNP NO/NJ – 5 – 18 – GM – N/NJ – 4 – 12 – GM – N PROXIMITY SWITCH 1No.
3. M6 Bolt, WASHERS, Nut Set MOUNTING HARDWARE 4 Nos.
( For Flame Proof Enclosure, M8 Bolt, washers and Nut Set is supplied).
2.3 INSTALLATION
The Proximity switch may be mounted anywhere around the target plate (Pole Wheel), so that all the targets are
within the specified sensing range of the switch. A mounting bracket is to be used for this. PC Speed Transmitter
should be mounted on the Panel with the mounting hardware supplied. Make sure that the signal conditioning unit
is not subject to vibrations. It is preferable to use a Signal Isolator in the control room for the current output. It is
to be ensured that cable from proximity switch is not bent on short radii. The installation should be in
conformance with API 670, the international code for Non Contacting rotation measurements.
TERMINATION DETAILS
IN 04 13.5 TM PNP NO : Brown (+Supply), Blue (Common), Black (Output), Shield

NJ – 5 – 18 – GM – N / NJ – 4 – 12 – GM – N : Brown (+), Blue (Common)
Page : 6 of 14
TERMINATION DETAILS
POWER SENSOR OUTPUTS
SUPPLY INPUT SIGNAL POWER FAIL LO Alarm HI Alarm
L : 1 SUPPLY : 12 CURRENT + : 6 NC : 19, 22 NC : 25, 28 NC : 31, 34
N : 2 COMMON : 13 CURRENT – : 7 COM : 20, 23 COM : 26, 29 COM : 32, 35
G : 3,11,14 INPUT :9 VOLTAGE + : 4 NO : 21, 24 NO : 27, 30 NO : 33, 36
SHIELD : 14 VOLTAGE – : 5
CONNECTION SCHEMATIC DIAGRAM
RPM INDICATOR
Min. 0.5 mm
Max. 4.0 mm
Sensor Power
Input Supply
Current Alarm
Output Outputs
INSTRUMENT ENCLOSURE: WEATHER PROOF

RPM INDICATOR
Min. 0.5 mm
Max. 4.0 mm
POLE WHEEL
Power
Supply
Current
Output
PULSE SIGNAL
ISOLATOR Sensor Alarm
OSNA MODEL
OS Ex-2-OT-G,
Input Outputs
24 V DC In FLP Enclosure
INSTRUMENT ENCLOSURE : FLAME PROOF
SUGGESTED SCHEME OF CONNECTION FOR INSTALLATION IN HAZARDOUS ATMOSPHERES
2.4 START UP AND INITIATION
Equipment required: 1 DMM, 2 Tachometer
As received from the factory, the PC Speed Transmitter will be set to the RPM range specified in the order. There
are no additional adjustments required.
This Instrument is Program controlled. The following instructions enable the user to set the values of the RPM
minimum and Maximum values, choose the number of Targets and choose and set the Output signals and Alarm
values.
Switch on power to the instrument.
The Display shows < S&S SYSTEMS > for 5 seconds and then shows 0 U/Min
The three LEDs, RL1, RL2 and Sensor glow momentarily and go off.
The LED for RL1 then glows and stays on.
The instrument is now ready to receive signal from the sensor, process it and display the RPM directly based on
the already programmed parameters.
Page : 8 of 14
The Front fascia has 4 keys for entering the parameters.
PROG
Program Key Left Arrow Key UP Arrow Key Enter Key
Functions of the keys:
Prog key - Used for entering into setting mode and also as an “ESCAPE” key during settings.
Left arrow key – Used for selecting the cursor position while entering the value
UP arrow key - Used to change the value of the digit selected by the cursor
Enter key – Used to conform the entry.
How to enter setting mode:
1. Press “PROG” key, then display shows “PCODE”. Feed Pass code as “111” (Default pass code) and then
press “Enter” key. Then display shows the first parameter name, i.e. “SP1”. If the pass code is wrong, Display
shows up “Sorry” and then shows up PCODE with Cursor Position In LEAST SIGNIFICANT DIGIT and starts
showing a blinking ‘0’. This prompts us to enter the correct Pass Code.
2. Press any arrow key for going to the next parameter, or press “Enter” key for changing the current
parameter, or press “PROG” key to quit the setting mode.
PARAMETERS LIST :
Parameter 1: “SP1” - Setpoint 1 (default 0)

This is used to set the value of the First Alarm Level of the Process Variable. When Process value is greater than
“SP1” , then RL1 toggles from its “Default RL1” state. Again RL1 is forced to its default value when Process value
is less than (SP1-Hysterisys1).
To set this, after seeing SP1, press “Enter”. The default setting is shown blinking. To change the value, use the
“UP ARROW” and “LEFT ARROW” Keys. The Value selected represents the Engineering Units of the Process
Variable, at which the First Alarm is to be activated. After selecting this value, press “ENTER”. The Display shows
“OK Done” and then shows up SP1. To go the next parameter, press either of the “ARROW” Keys.
This is the general procedure for entering and storing parameters.
Parameter 2: "Hystrs1 " - Hysteresis to Set point 1 (default 10)

Hysteresis is the difference between the values at which the relay toggles in ascending and descending directions
of the Process variable.
Parameter 3: "Def.RL1 " - Default RL1 state (default 1)

If this parameter is “0” then RL1 is ON when PV > SP1
If this parameter is “1” then RL1 is OFF when PV > SP1
Parameter 4: “SP2” - Setpoint 2 (default 0)

When Process value is grater than “SP2” , then RL2 toggles from its “Default RL2” state. Again RL2 is forced to
its default value when Process value is less than (SP2-Hysterisys2).
Page : 9 of 14
Parameter 5: "Hystrs2 " - Hysterisys to Set point 2 (default 10)
Parameter 6: "Def.RL2 " - Default RL2 state (default 0)

If this parameter is “0” then RL2 is ON when PV > SP2
If this parameter is “1” then RL2 is OFF when PV > SP2
Parameter 7: "SampleTm" - Sample time for measuring the PV (default 500msecs)

Range from 10 msecs to 100 seconds. Setting is in Milli Seconds.
Parameter 8: "Units " - Units of PV (default U/Min)

Three different time bases for the PV
U/Sec – Units per second
U/min – Units per minute
U/Hr - Units per Hour
Parameter 9: "DecPoint" - No.of digits after decimal point (default 0)
Parameter 10: "O/P Zero"- It is the value of the PV at which Analog output is zero (4mA) (default 0)
Parameter 11: "O/P Span"- It is the value of the PV at which Analog output is Fullscale (i.e. 20mA) (default 1000)
Parameter 12: "ZeroCal "- Analog output Zero Calibration(default 15700)

Adjust this value by comparing the analog output to get 4 ma DC or 0 mA DC as per the requirement, with a
standard meter.
Parameter 13: "SpanCal "- Analog output Span Calibration(default 60800)

Adjust this value by comparing the analog output to get 20 mA DC, with a standard meter.
Parameter 14: "Threshld"- PV threshold(default 1)

Analog output will be at its zero state till PV < Threshold.
Parameter 15: "NUM(MUL)"- PV Multipiler constant(default 1)

The Input is frequency to this system. The Process Value is numerically related to this Input Frequency by a factor.
This Factor contains a Numerator Selection and a Denominator Selection. When we measure a time dependent unit
like RPM, the time base is also taken into consideration by direct selection as mentioned in Parameter 8.
PV =( (Input Frequency x (NUM/DEN))
This Formula holds good when the time base of the Process Value is Seconds. If the Time Base is Minutes, the
Right Hand Side in the Above Equation will be Multiplied by 60 and if the Time Base is Hour, The RHS will be
multiplied by 3600. This Multiplication is done internally, when we chose the Units as in Parameter 8.
Parameter 16: "DEN(DIV)"- PV divider constant(default 1)
Parameter 17: "Filter " – Low pass filter constant for PV (default 5)
Adjust this parameter to the optimum value for stabilizing PV fluctuations
Parameter 18: "Self Test " – Self testing of Analog output

Enter and feed the PV for checking the analog output
Parameter 19: "New Code” – For changing the existing pass code.
Page : 10 of 14
After Entering all these parameters or just those which are required for the specific application, Press “PROG” and
it gets ready to measure the Process Variable and transmit the Current output.
A voltage Output is also available.
The desired current output may be calculated as following.
Suppose the speed of rotation, as indicated by the tachometer is ‘S’. Let the Full Scale Speed be ‘F’.
Desired Current output at ‘S’ = {[( S / F ) × 16] + 4} mA DC

Example: F = 1000 RPM, S = 650 RPM
Desired Current at 650 RPM = {[(650 / 1000) × 16] + 4} =14.4 mA DC

VERIFICATION OF CALIBRATION WHEN TACHOMETER IS NOT AVAILABLE
For this, a multimeter with frequency measurement is required. The RPM INDICATOR is an instrument processing
the input frequency and giving out proportional DC Voltage and Current. The input frequency is proportional to the
speed or RPM. Hence a measurement of the input frequency will suffice to calculate the RPM. If the RPM is known,
the procedure above to tally the current output and the displayed speed with the actual speed can be carried out.
Let us take a practical example to illustrate this verification process.
Let the Full Scale Speed be 1,000 RPM. Let there be 4 targets on the Pole Wheel. The Proximity Switch generates
one pulse for every target. If there are 4 targets, , it generates 4 pulses per revolution. Therefore, for 1,000
revolutions of the Pole Wheel, it generates 1,000 * 4 = 4,000 pulses. To convert this into input frequency at Full
Scale Speed, we have to divide these pulses per minute by 60. So, the maximum input frequency corresponding to
1,000 RPM for a Pole Wheel with 4 targets is given by 4,000 / 60 = 66.7 Pulses Per Second or in other words,
66.7 Hertz. Thus the incoming frequency always represents the rotational speed of the object. By measuring this
frequency, the speed can be calculated.
If the frequency thus measured is 35 Hz, then the corresponding rotational speed is (35 / 66.7)*1,000 = 524.7,
that is almost 525 RPM. Further calculations of desired current output for this speed of 525 RPM can be done as
outlined earlier.
The general formula for calculating RPM from input frequency is

(Input Frequency / Full Scale Frequency) × Full Scale RPM
The general formula for calculating Full Scale Frequency is

(Full Scale RPM ×No. of Targets) / 60
Page: 11 of 14
RECOMMENDED SPARES
PROXIMITY SWITCH ASSEMBLY 1 No.

PROGRAMABLE CONTROLLER SPEED TRANSMITTER 1 No.
PROXIMITY SWITCH ASSEMBLY
Brown
Blue
Shield Black
Page: 12 of 14
DIMENSIONS
DIMENSIONS OF THE ENCLOSURE
96
120
90
215 200 230
88
120
Ø6.5, 4 holes
Chloroprene seal
All dimensions in mm.

The enclosure is weather proof to IP65 Degree of protection.
S&S SYSTEMS SPEED TRANSMITTER + INDICATOR GA DRAWING
MODEL NUMBER : PCST – 01 – W
Sensor Assembly
Power In Signal in
Current out
Transmitter + Indicator
Pole wheel
Sensor Assembly will be as per the drawings enclosed with PO.

Transmitter + Indicator contains the latest state of the art signal conditioning circuits
Which process the signal received from Sensor assembly and provide local Indication
Of Speed and give 4-20 mA DC current output for transmission .
This product is developed in accordance with the specifications and requirements of
VOITH part No. : 306 60342 15014.
Page : 13 of 14
S&S SYSTEMS GA Drawing NO. : SS-PCST-01-GA Rev. O

303, Markaz Apartments, Application : VOITH Part No. : 306 60342 15014
Srinagar Colony P.O., Date : 16-12-2008
HYDERABAD – 500073. Prepared : CVMS
Phone : 23748721 Authorized and released 17-12-2008 CVS
Page : 14 of 14
L POWER SUPPLY
N 100 to 250 V AC
G
Connector Head
Sensor Terminations
1 2 3
PCST – 01 – W
PROGRAM CONTROLLED
Bn Bu Bk Sh SPEED TRANSMITTER
1 2 3 4 Current + 6 19 NC
Output 20 COM
– 7 21 NO POWER FAILURE
22 NC RELAY OUTPUTS
23 COM
24 NO
12 13 9 14
3 Core Shielded Cable
Brown from Sensor (1) --- Supply to Sensor in Speed Transmitter (12)
Blue from Sensor (2) --- Common in Speed Transmitter (13)
Black from Sensor (3) --- Input to Speed Transmitter (9)
Shield from Sensor (4) --- Power Earth of Speed Transmitter (14)
Wiring drawing From Sensor Head to Program Controlled Speed Transmitter

RADIANT ENGINEERS
INSTALLATION, OPERATING AND MAINTENANCE MANUAL
Radiant shell & Tube Heat Exchangers are custom engineered for specific
operating conditions. Their successful performance and long life can be still
enhanced by careful installation and periodic inspection.
INSTALLATION PLANNING
1. On removable bundle heat exchanger, provide sufficient clearance at the end

to permit the removal of the tube bundle from the shell. On the floating head type
exchangers, provide space to permit removal of shell cover and floating head
cover.
2. On fixed tube bundle heat exchangers, provide sufficient clearance at one end
to permit the removal and replacement of tubes and at the both ends provide
sufficient clearance to permit rolling of tubes into the tube sheet.
3. For U-tube heat exchangers, provide sufficient clearance at the stationery

head end to permit withdrawal of tube bundle, or at the other end to permit the
withdrawal of the shell.
4. Adequate foundations for mounting the heat exchanger should be provided so

that it will not settle and cause piping strains on the exchanger.
Foundation bolts should be set to allow for setting inaccuracies. In concrete
footings pipe sleeves at least one size larger than bolt diameter slipped over the
bolt and cast in place are best for this purpose as they allow the bolt centers to
be adjusted after the foundation has set.
5. Provide valves and bypasses in the piping system so that both shell side and
tube side can be bypassed to permit isolation of exchanger for cleaning,
inspection and repairs.
6. Make drain connection in such a fashion that is should be correctly determined

that the exchanger has been thoroughly drained.
7. Install liquid level controls, relief valves, gauge glasses or liquid level alarms in
all vapor or gas spaces to indicate any failure occurring in the condensate drain
system and prevent flooding of the heat exchanger.
8. Surge drum can be installed upstream from the heat exchanger to guard
against pulsation of fluids caused by pumps, compressors or other equipments.
MAINTENANCE
1. Clean exchangers subject to fouling (scale, sludge deposits etc) periodically,

depending on the specific working conditions. A light sludge or scale coating on
either side of tube greatly decreases its effectiveness. A marked increase in
pressure drop and/or reduction in performance usually indicates cleaning is
necessary. Since the difficulty of cleaning increases rapidly as the scale thickens
or deposits increase, the intervals between cleanings should not be excessive.
2. Neglecting to keep tubes clean may result in random tube plugging.

Consequent overheating or cooling of the plugged tubes, as compared to
surrounding tubes, will cause physical damage and leaking tubes due to
differential thermal expansion of the metals.
3. To clean or inspect the inside of the tubes, remove only the necessary tube
side channel covers or bonnets depending on type of exchanger construction.
4. If the heat exchanger is equipped with sacrificial anodes or plates, replace

these as required.
5. To clean or inspect the outside of the tubes, it may be necessary to remove

the tube bundle.
6. When removing tube bundles from heat exchangers for inspection or cleaning,
exercise care to see that they are not damaged by improper handling. The weight
of the tube bundle should not be supported on individual tubes but should be
carried by the tube sheets, support or baffle plates or on blocks contoured to the
periphery of the tube bundles with hooks, chains or other tools which might
damage tubes.
After removal, move tube bundles on cradles or skids. To withdraw tube bundles,
pass rods through two or more of the tubes and take the load on the floating tube
sheet. Rods should be threaded at both ends, with the ends passing through a
steel bearing plate and tube sheet. Insert a soft wood filler board between the
bearing plate and tube sheet face to prevent damage to the tube ends. Screw
steel eye lifting. As an alternate to the rods, thread a steel cable through one
tube and return through another tube. A hardwood spreader block must be
inserted between the cable and each tube sheet to prevent damage to the bundle
ends.
7. Lift tube bundles horizontally by means of a cradle formed by bending a light-

gauge plate or plates into a U-shape. Make attachments in the legs of the U for
lifting.
8. Do not drag bundles, since baffles or support plates may become easily bent.
Avoid any damage to baffles so that the heat exchanger will function properly.
9. Methods of cleaning:
Circulating hot wash oil or light distillate through tube side or shell side. This will
usually effectively remove sludge or similar soft deposits. Soft salt deposits may
be washed out by circulating hot fresh water.
Some commercial cleaning compounds may be effectively used in removing

more stubborn deposits. If the scale is hard and the above methods are not
effective, use a mechanical cleaning means. Neither the inside not the outside of
the tube should be hammered with a metallic tool. Take extra care when suing
scraper, they should not damage tubes.
10. Do not attempt to clean tubes by blowing, steam through individual tubes.
This overheats the individual tube and result in severe expansion strains and
leaking tube to tube sheet joints.
11. To locate rupture or corroded tubes or leaking joints between tubes tube
sheets, remove tube side channel covers or bonnets. Pressurize the shell side of
the exchanger with a liquid, preferably water. Observe tube joints and tube ends
for indication of test fluid leak.
12. To tighten the leaking joint, use a suitable roller tube expander. Do not roll
tube beyond back face of the tube sheet. Maximum rolling depth should be tube
sheet thickness minus 1/8”. Do not reroll tubes which are not leaking.
13. When a heat exchanger is dismantled, new gaskets should be used in

reassembly.
14. Use of new bolting in conformance with dimensions and ASTM specifications
of the original design is recommended where frequent dismantling is
encountered.
OPERATION
1. be sure entire system is clean before starting operation to prevent plugging of

tubes or shell side passages. The use of strainers or setting tanks in pipelines
leading to the heat exchanger is recommended.
2. Open vent connection before starting flow through the exchanger.
3. The first fluid admitted is that whose temperature most nearly approximates
the ambient temperature of the unit. The heat exchanger should never be
shocked by the sudden admission of extremely hot or cold fluids; repeated
stresses are set up by such a procedure results in metal fatigue.
Thermal and physical shocks should be avoided whenever possible. For fixed
tube sheet exchangers fluids must be introduced in a manner to minimize
differential expansion between the shell and tubes.
4. Start operating conditions gradually after the system is completely filled with
the operating fluids and all air has been vented, close all manual vent
connections.
5. Retighten bolting on all gasketed or packed joints after the heat exchanger has
reached operating temperatures to prevent leaks and gasket failures.
6. Sufficient circulation of the cold medium should be maintained at all times to

prevent overheating, which could result in the depositing of scale, coke or sludge.
&RQWUDF Rated Torque 100 Nm
Part Turn Actuators With Integrated Electronics or
PME 120 AI / PME 120 AN For Separate Field Housing
Operating Instructions 42-68-151EN
(d036rxa)
Table of Contents 1.2 ID Label of Electronics
The ID labels of the power electronics are located on the
electronics cover.
Device Identification . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 ID Label for Hardware Description
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1 Elektronik / Electronics Type: ....
Made in Germany
Delivery State . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2 B-Nr./No. ...... NL
3 Jahr / Year
Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
&(
4 t = ..................°C IP 66
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Automation
Electrical Connection. . . . . . . . . . . . . . . . . . . . . . 8 D-32425 Minden
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1. Electronics type
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2. Device no. / No. of non-standard version
3. / year of manufacture
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . 15 4. Premissible ambient temperature / protection
5. No used
Your notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.2 ID Label for Software Description
1. Device Identification 1 Für Antrieb / For Actuator
Contrac . . . . . . . . . . . . . . . . . . . .
1.1 Actuator ID Label 2 Mit / NL. Nr./No.. . . . . . . . . . . . . .
3 SW Version . . . . . . . . . . . . . . . .
1 Antrieb / Actuator: CONTRAC ....
4 Eingestellt / adjusted auf/for
2 F-Nr./No NL
M=....... .......°/s
&(
Made in Germany
3 M= Jahr/Year
5
4 t= IP 66
5 min......max. ....... max. .........
6 Öl / Oil: 1 Associated actuator
2 No. (if required)
7 Mit / With Elektronik/Electronics
3 Downloaded software version
8 U= 230 V (190 ... 260 V) F = 50/60 Hz, ± 5% 4 Configured force (torque)/configured speed
9 P= max. ....... W Ext. Sicherung / Fuse 16 A träge/slow 5 Available for customer-specific information
10
Automation
D-32425 Minden
1. Actuator type
2. Device number / No. of non-standard version
3. Rated torque / Year of manufacture
4. Permissible ambient temperature
5. Min./max. positioning travel / Min./max. speed
6. Filled-in oil type
7. Associated electronics
8. Permissible voltage range / Mains frequency
9. Power consumption / Fus
10. Available for customer-specific information
2
2. General
2.1 Proper Use
Control actuators are intended to be used exclusively for actuating final control elements
(valves, vanes, etc.). Do not use these actuators for any other purpose. Otherwise, a
hazard of personal injury or of damage to or impairment of the operational reliability of
the device may arise.
2.2 Safety and Precautions
When mounting the actuator in areas which may be accessed by unauthorized persons,
take the required protective measures.
- Control actuators perform movements for positioning vanes and valves. Handle ! Warning !
properly and with care. Otherwise, a hazard of bruise injuries may arise.
- When changing the oil of the actuator, thoroughly remove any oil that may have run
down on the floor during the procedure to avoid accidents.
- Dispose of the waste oil in compliance with the respective local regulations. Make
sure that no waste oil reaches the water cycle
- Only qualified specialists who have been trained for these tasks are authorized to
mount and adjust the control actuator, and to make the electrical connection.
- When working on the actuator itself or its electronics always observe the locally valid
accident prevention regulations and the regulations concerning the construction of
technical installations.
3. Storage
&RQWUDF actuators may be stored under moist and aggressive condition for a short
time. The equipment is protected against external corrosive influences. However, direct
exposure to rain, snow, etc. must be avoided
Interior areas of the actuator with risk of condensation are protected by desiccant placed
in the connector (and in the terminal box of the separate electronics, if present). The
desiccant guarantees sufficient protection for approximately 150 days. It can be regen-
erated at a temperature of 90° C within 4 h.
The desiccant must be removed prior to commissioning the actuator or the electronics.
3.1 Long-time Storage
If you intend to store or transport the device for a longer time, we recommend to wrap it
in plastic foil and add desiccant. Regularly check if the desiccant is still active.
4. Delivery State
If not otherwise specified by the customer, &RQWUDF actuators are delivered with the
following standard configuration:
Behavior in 0/100% position: Shut-off with rated torque
Setpoint function: Linear; setpoint = positioning value
Input (setpoint): 4 ... 20 mA
Function: Positioner, parameter: setpoint
Output (actual value): 4 ... 20 mA
Digital inputs: DI 1 switch-over manual/automatic and v.v.
DI 2 / DI 3 manual control +/-
Digital outputs: DO 1 ready to operate, DO 2/3 end position signal-
ling
Range: Not adjusted
The configuration of your actuator may differ from the standard configuration specified
above. It can be called up for display using the configuration program.
3
5. Assemblies
1: Lever
2: Mechanical stops
3: Gearbox
4: Lock lever
5. Motor
6. Cover
(incl. electronics
for PME 120 AI)
7. Handwheel
8. Connector
9. Ouput shaft
10.Ball-and-socket
joint
(d0001rxa)
Figure 1: PME 120
5.1 Normal mode

! Warning !
The friction clutch is de- The motor triggered by the power electronics drives the output shaft (9) via oil-lubricated
signed such that a hand- spur gears. The drive lever mounted on the shaft transmits rotary motion to the valve.
wheel force of around The brake built in the motor (5) acts as a retainer when the power is off.
11 N suffices to create the
rated torque on the actua- 5.2 Handwheel mode
tor. If you should feel a - Allows you to move the actuator manually when the electrical power is off.
considerable counter- - Turn the lock lever (4) clockwise
force when moving the - Turn the handwheel (7) to move the lever to the wanted position.
actuator by hand, do not - Release the lock lever.
increase the force you ap-
ply to the handwheel.
Otherwise, you might
damage the actuator or
valve
6. Technical Data
PME 120 AI PME 120 AN

Rated torque [Nm] 40 ... 100
Starting torque [Nm] appr. 1.2 x rated torque (break-away torque in end
positions 2 x rated torque for short time)
Rated speed [°/s] 1.5 ... 4.5
Weight approx. 45 kg approx. 32 kg
Associated electronics for field mounting: EAN 820
integrated in actuator
for rack mounting: EAS 822
Power supply 115 V AC (94 V ... 130 V) or 230 V AC
(on electronics) (190 V ... 260 V); 47.5 ... 63 Hz
Max. power consumption with
115 / 230 V AC [A] 1.0 / 0.5
Current consumption in positioning approx. 40 ... 50% of Imax., each
mode:
Table 1:
4
7. Lubrication
Prior to delivery the actuator is filled with 2.5 l oil in factory.
1) 2) 1) 2)
1) 2) 1) 2)
1) 2)
Einbaulage
Mounting Position
1) 2)
IMB 3 IMB 6 IMB 7 IMB 8 IMV 5 IMV 6

Figure 2:
Min. oil quantity;

2.2 2.5 2.2 2.2 2.5 2.5
approx. [l]
Min. oil level [mm]
under inspection 45 2 42 20 23 17
screw
Table 2: The arrow indicates the position of the inspection screw 1) and the vent screw 2). After having mounted the actuator, replace the highest
inspection screw with the separately delivered vent screw.
7.1 Lubricants
! Warning !
Do not pollute the syn-
Oil types thetic Mobil SHC 629 oil,
nor mix it with mineral
Oil type used by manufac-
Ambient temperature Possible other oil types oils. Prior to changing
turer for first filling
over to synthetic lubricant
ESSO Spartan EP 220 Aral Degol BMB 220 oil always throroughly
(L-CKC to ISO TR 3498) BP Energol clean the set of gears!
- 10°C ... + 65°C GR-XP 220
Shell Omala 220
Mobilgear 630
- 25°C ... + 55°C Mobil SHC 629 -----
Table 3:
5
8. Mounting
8.1 Actuator Check
- Is the actuator filled with the appropriate oil type?
- Is enough oil in the actuator?
- Did you fasten the separately delivered vent screw in the highest bore (depending on
the mounting orientation)?
- Has the actuator integrated or separate electronics ?
8.2 Mounting orientation

All mounting orientations seen in Figure 2 are permissible. To facilitate mounting and
maintenance, however, it is recommended to use orientation IMB 3.
8.3 Mounting Instructions

- Make sure that the actuator is accessible from all sides to ensure convenient hand-
wheel operation, electrical connection, and replacement of assemblies.
- Avoid direct exposure to rain, snow and other environmental influences. Select the
mounting site accordingly.
- Exclusively mount the actuator on a rigid, non-vibrating support to avoid relative mo-
tion between the actuator and the valve.
- When mounting the actuator close to heat sources use an insulating layer or shield-
ing.
8.4 Mounting the Actuator to the Valve
8.4.1 Preparing the Equipment

- Make sure that the shaft and lever bore surface are clean and free of grease.
- Determine the length of the stay tube (not included in the scope of delivery).
- Move the valve to the “CLOSED“ position.
- Move the actuator to the corresponding end position using the handwheel. Observe
the permissible angle.
- Spacing “L“ minus 140 mm yields the required length of the link tube.
- Drill a cone bore into the valve lever for mounting the second ball-and-socket joint,
as seen in Figure 4.
- Insert the ball-and-socket joint, secure with crown nut and split-pin.
- Remove the welding bushings and weld them to the stay tube (C 15 to DIN 17210)
- Insert the link rod between the two ball-and-socket joints and screw it in.
- If required adjust “L” by turning the link rod.
- When all adjustment steps are finished, fasten the counter nuts.
8.4.2 Adjusting the Stops in Dependence of the Travel

- Move the output lever / valve to the position requiring fine adjustment.
- Put the stop onto the toothing as close to the output lever as possible and fasten with
screws.
- Move the output lever towards the stop using the handwheel; turn the coupling rod
for fine adjustment.
- Fasten the counter nuts.
- Fasten the stop in the other mounting position close to the end position, depending
on the toothing.
8.4.3 Adjusting the Stops in Dependence of the Torque

- First proceed as described above for travel-dependent adjustment.
- Prior to re-fastening the counter-nut lock the handwheel and then turn the coupling
rod in such a way that an initial tension occurs in the valve’s closing position.
- Fasten the counter-nuts.
6
tightening torque for
screws of limit stop: 46 Nm
lever
boring diameter
mechanical a for fastening
limit stop screws: 12 mm
tensile strength:
coupling rod -> 400 N/mm2
3°
tightening torque for
rigid, vibration-free lever clamping screw:
support 23 Nm 10°
b
flap lever
r00304e1
Figure 3: Mounting PME 120, example
α ≥ 15 °
β according to dimensions specified by the valve manufacturer
62 - 78 L - 140 62 - 78
3 4 2 4 3
18
61
60
21
46
14
32
5
5
15
6 M 14 x 1.5 1 6
cone 1 : 10 14 left / right r00305e1
Figure 4: Dimensional drawing
1. Output lever
2. Link tube
3. Ball-and-socket joint
4. Welding bushings (C15 to DIN 17210)
5. Counter nuts
6. Crown nuts
7
9. Electrical Connection
9.1 Wiring Diagram for PME 120 AI
The electrical connection is done with a combined plug on the actuator and with screw
terminals on the electronics.
sub-distribution board
external
fuse
mains
L N
setpoint
BE 1 BE 2 BE 3 BA 1 BA 2 BA 3 + HART actual value transmitter
Han 10 E
Han 24 E
MAN/AUT MAN (+) MAN (-) o.k./fault end 0% end 100% Uv 0/4...20mA 0/4...20mA 4...20mA
1 13
insert
insert
3 4 5 6 7 8 15 16 17 18 19 20 21 22 23 9 10 11 12 1 2
+ - + - + - + - + - + - +
RB RB
I
plug
24V + - + -
Uv
U 24V
(option)
Contrac actuator
r00295e2
Figure 5: Electrical connection, standard
The following steps must be performed to switch the actuator to automatic mode (AUT):
- Activate digital inputs DI 1, DI 2 and DI 3 via the configuration program.
- Make sure that the supply voltage is present on digital input 1 (DI 1).
- Activate AUT mode via the configuration program.
Vorsicherung
ext. fuse
Netz
mains Bus in Bus out
L N
grün /
green
grün /
green
Han 24 E
rot /
rot /
red
red
Einsatz
1 13 Stecker / plug
T- A2 B2 T+ A1 B1 Busanschluß A1 ... B2 /
bus terminals A1 ... B2
Busabschluß T-/T+
Contrac Antrieb / Actuator bus termination T-/T+
r00011x1
Figure 6: Electrical connection, Profibus DP
8
9.2 Wiring Diagram for PME 120 AN
The electrical connection is done with a combined plug on the actuator and with screw
terminals on the electronics.
Unterverteilung / Sub Distribution Board

Ext. Sicherung /
Netz / ext. fuse Schirm beidseitig geerdet
Mains screen grounded at both ends
Netz / Mains
AC 110 ... 250 V
Sollwert Meßumforme Istwert
BE 1T BE 2) BE 3 BA 1 BA 2 BA 3 Setpoint
+ HART
Transmitterr Position
0/4...20mA
Uv 0/4...20mA
4...20mA
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 26 27 28 29 30 31
L N
+ - + - + - + -+ - + + -
RB RB
I
24V + - + -
Uv
24V U
Contrac Leistungselektronik / Power Electronics

U V W Br Br PE 17 18 19 20 21 22 23 24
Han 24 E Stecker / Plug

1 2 3 13 14 Stecker / Plug 17 18 19 20 21 22 23 24 HAN 10E 7 8
Heizung
Sensoren ca. 6W
M Sensors Heater
3~ approx. 6 W
Motor Contrac Antrieb / Actuator r00350x1
Figure 7: Electrical connection, standard

The following steps must be performed to switch the actuator to automatic mode (AUT):
- Activate digital inputs DI 1, DI 2 and DI 3 via the configuration program.
- Make sure that the supply voltage is present on digital input 1 (DI 1).
- Activate AUT mode via the configuration program.
Vorsicherung /
external fuse
Netz /
mains Bus in Bus out
Schraubklemmen /
screw terminals
grün /
green
grün /
green
rot /
rot /
red
red
L N
Busabschluß- T- T+ B1 A1 B2 A2
möglichkeit /
bus termination 28 29 30 31 Busanschluß /
15 14 bus terminals
U V W Br Br PE Contrac 17 18 19 20 21 22 23 24
Elektronik / Electronics
AC 115 … 230 V
Han 24 E Einsatz / insert

Stecker /
1 2 3 5 6 7 8 17 18 19 20 21 22 23 24
plug
M Contrac Antrieb (3~ Motor)

3~ Heizung / heater
(Option) Sensoren / sensors
Motor
Figure 8: Electrical connection, Profibus DP (not with EAS 822)
9
9.2.1 Signal Inputs and Outputs (Conventional Triggering)
(Standard)
AUT**
Sollwert (u. HART),
Istwert, 0/4...20mA
Endlage 100%
MAN
0/4...20mA
Endlage 0%
Ok
+Y -Y
BE 3
BE 1
BA 2
BE 2
BA 1
Meßumformer
BA 3
Uv
4...20mA
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 26 27 28 29 30 31
+ - + - + - + - + - + -
RB + RB Contrac
No
No
No
Nc I Leistungselektronik
24V + - + -
Uv
24V U
(r00358d1)
Figure 9:
** Write-protected when applying +24 V DC to DI 1.
9.2.2 Signal Inputs and Outputs (Conventional Triggering)

(after a step controller)
enable controller **
End Pos. 0%
controller
End Pos.
0/4...20mA
Act.Val.
Ok
100%
+Y -Y
BA 2
BE 3
BE 1
BE 2
BA 1
Transmitter
BA 3
Uv
4...20mA (Option)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 26 27 28 29 30 31
+ - + - + - + - + - + -
RB + RB Contrac
No
No
No
Nc
I Power Electronics
24V + - + -
Uv
24V U
(r00359e1)
Figure 10:
** Write-protected when applying +24 V DC to DI 1.
Refer to Operating Instructions 42/68-820 (Power Electronics for Field Mounting) and
42/68-821 (Rack-Mounting Electronics) for installation details.
10
10. Setup
! Note !
The basic settings (definition of end positions) can be made via the commissioning and The commissioning and
service field (CSF). It is used for adapting the actuator to the operating range and the service field is located on
effective direction without a PC. The actuator can be set up and configured completely the electronics!
using the appropriate configuration program.
10.1 Setup via CSF

10.1.1 Operating Elements
1. Write-protect switch (Default setting: OFF)
2. LED for 100% position Indication if adjustment procedure, saved position, or fault
by different flash frequencies.
3. Drive button Press to cause drive motion
4. Reset button Press to restart processor and clear any 0% and 100%
values.
5. Drive button Press to cause drive motion
6. RS 232 socket Connector for PC
7. Potential toggle switch Connection of reference potential to the system or protec-
tive earth (by default set to system)
8. HART sockets Connectors for HART communication
9. LED for 0% position Indication if adjustment procedure, saved position, or fault
by different flash frequencies.
10. Accept button (0%) Press to define current position as 0%; simultaneously
press push button 11 to complete the adjustment proce-
dure.
11. Accept button (100%) Press to define current position as 100%; simultaneously
press push button 10 to complete the adjustment proce-
dure
(r0002rxa)
Figure 11: Commissioning and Service Field (CSF)
! Warning !
10.1.2 Initial Situation The actuator range is not
- Electronics connected to power supply and actuator preset in factory!
- Write-protect switch (1) set to “OFF” position
- Electronics in operating mode “MAN” (no signal on DI 1)
- No fault (if a fault occurs, both LEDs flash alternately at 4 Hz)
10.1.3 Setup Procedure
- Undo the screws of the CSF
- Swing the cover to the side
11
10.1.3.1 “Adjustment” Mode
- Set electronics to “Adjustment” mode by pressing push buttons (3) and (5) simulta-
neously for approx. 5 seconds, until both LEDs (2 + 9) are flashing synchronously at
approx. 4Hz.
10.1.3.2 Defining First Position (0% or 100%)

(Higher precision in 2nd position)
- Move to desired position by pressing push button (3) or (5).
- To accept the position, press push button (10) or (11); the associated LED flashes at
approx. 1Hz when value is correctly accepted, the other continues to flash at approx.
4Hz
10.1.3.3 Defining Second Position (0% or 100%)

- Move to second position by pressing push button (3) or (5).
- To accept the position, press push button (10) or (11); both LEDs (2) and (9) are
flashing at approx. 1Hz when value is accepted correctly.
10.1.3.4 Saving the Settings

- The settings are accepted by simultaneously pressing the push buttons (10 + 11);
the LEDs (2 + 9) extinguish after a short time, and the adjustment procedure is com-
pleted.
- If the selected range is too small for the actuator, both LEDs will flash again at 4Hz,
and the adjustment procedure has to be repeated with a larger value (min. position-
ing travel).
(See positioning travel specification on actuator ID label)
10.1.3.5 Correction after Setup

- If the setting is to be corrected after accepting the first value, first press the Reset
button (4) and then repeat the setting.
- If the correction is to be done after saving the settings, the entire adjustment proce-
dure must be repeated.
10.2 Adjustment Using the Configuration Program

Context-sensitive help information is available in the configuration program at all times.
For basic handling and installation instructions refer to the associated manual, number
41/68-001.
! Warning !
A conductive ground con- 10.3 Indication at CSF
nection is established be- Function Indication
tween the PC and the Adjustment
CONTRAC electronics
Change-over to adjustment mode: Both LEDs flash synchronously at approx
with the RS 232 commu-
Press and hold both drive switches for 4Hz after time has expired.
nication cable. If the PC is
approx. 5 seconds
grounded, this may cause
Moving to an end position Both LEDs continue to flash at 4Hz while
a ground loop in the in-
Use respective drive button on CSF driving.
stallation.
Saving the first end position The associated LED flashes at approx.
Press button 0% or 100% 1Hz, the other continues at 4Hz.
Saving the second end position The associated LED flashes at approx.
Press button 0% or 100% 1Hz synchronously to the first one.
Terminate adjustment Both LEDs are briefly lit together and
Press 0% and 100% buttons simulta- then extinguish.
neously
Operation
Normal operation: MAN / AUT LED off
Driving with button on CSF LED off
Priority over control system
Fault (both LEDs flash alternately at 4Hz)
Reset: If no other fault conditions exist, both
Resets fault indications LEDs extinguish.
Reset if operating range is exceeded; After approx. 5 seconds the flash rhythm
press and hold both drive button for 5 sec- is briefly interrupted. After “Reset” the
onds, then press Reset button electronics switch to adjustment mode.
Table 4:
12
11. Maintenance
Contrac actuators have a robust construction. As a result, they are highly reliable and
require only little maintenance. The maintenance intervals depend upon the effective
load and are therefore not specified here.
The built-in microprocessor evaluates the actual load factors (e.g. torques, tempera-
tures, etc.) and derives the remaining operating time until the next routine mainte-
nance is required. Use the configuration program for viewing this information.
11.1 Motor and Gears

All maintenance work must be carried out by qualified specialists who have been
trained for this task. As a rule, perform the following routine maintenance works:
- Check the shafts and gears.
- Check the motor pinion gear and the respective mating gear.
- Replace the motor’s rotary shaft seal and ball bearings.
- Check the position sensor.
- Change the oil; then make a visual check and check for proper operation.
11.2 Adjusting the Brake

! Warning !
In automatic mode the brake is permanently released. Therefore, it is not exposed to The actuator setting may
wear and does not require any re-adjustment. be changed accidentally
by the repelling power of
the valve when the brake
is released!
13
11.3 Replacing the Position Sensor
11.3.1 Dismounting
- Disconnect the ribbon cable from the PCB
- Undo the two fastening screws (1) of the position sensor and pull the sensor out
of the gears.
11.3.2 Mounting
The toothed gear pair of the position sensor is held in place by a tension spring (3),
to ensure sufficient free motion when the direction of rotation is reversed.
- Set the stop pin to the center position, as seen in Figure 15.
- Align the sensor and its gears with the actuator; set the first toothed gear in
11:00 o’clock position (see Figure 16) onto the drive shaft gear (4).
- Slightly move the sensor back and forth to pre-tension the toothed gears with the
difference “z“ until the second toothed gear snaps in.
- Fasten the screws (1) tightly.
- Connect the plug (5) of the ribbon cable to the PCB.
2 Z
1
1 1
(r00329x1) 1
4
(r00335x1)
Figure 12: Position sensor SP 1 Figure 13: Mounting position of SP 1
5
(r00336x1)
Figure 14: Connecting the ribbon cable plug to the PCB
After mounting is completed readjust the actuator range as described in section 10

of this manual.
14
12. Troubleshooting
This section only describes how to handle hardware errors. Refer to the configuration
program’s online help for errors related to the software.
Error Possible reason Measures to be taken

Disconnect the actuator from the
valve.
Malfunction of actuator or valve (e.g. If the actuator is working properly
Valve cannot be moved by actuator
cable gland fastened too tightly) then, the valve is likely to be defec-
tive. Otherwise, the actuator seems
to be the error source.
Set up communication using the
No communication
configuration program
Check the winding resistances of the
Motor / brake is defective
motor and brake.
Actuator does not react Digital inputs of electronics are not
Connect
connected
Check the air gap (should be around
0.25 mm) and the electrical connec-
Brake does not release (no audible
tion of the brake.
“click“ noise)
Check the winding resistance of the
brake coil.
Actuator does not work in automatic
Digital input 1 (DI 1) has not been
mode, although “AUT“ has been sel- Connect DI 1.
connected.
ected in the configuration program
LEDs on the commissioning and
Actuator has not been adjusted pro-
service field are flashing simultane- Adjust the actuator.
perly
ously
Table 5:
12.1Electrical Test Values
L1 L2
L3 (r00334x1)
Figure 15: Motor block diagram
Winding resistance ± 5% at 20° C (motor) L1 (blue) - L2 (black):3,4 Ω

L1 (blue) - L3 (violet):3,4 Ω
Winding resistance ± 5% at 20° C (brake) 50 Ω
Table 6:
15
13. Your notes
Subject to technical changes.
This technical documentation is protected by copyright law. Do not translate, copy or distribute in any way - even in a modified form or as
an excerpt - without the prior written permission of the right-holder. Also, reprints, photomechanical or electronical reproduction or
storage of data in data processing systems or data networks must be authorized by the right-holder. Any infringement of the copyright
law will be prosecuted
ABB Automation Products Subject to technical changes.

Schillerstraße 72 Printed in the Fed. Rep. of Germany
D-32425 Minden 42/68-151 EN 03. 2001
Phone: +49 (571) 830 - 0
Fax.: +49 (571) 830 - 1860
http://www.abb.de/automation
RADIANT ENGINEERS
INSTALLATION, OPERATING AND MAINTENANCE MANUAL
Radiant shell & Tube Heat Exchangers are custom engineered for specific
operating conditions. Their successful performance and long life can be still
enhanced by careful installation and periodic inspection.
INSTALLATION PLANNING
1. On removable bundle heat exchanger, provide sufficient clearance at the end

to permit the removal of the tube bundle from the shell. On the floating head type
exchangers, provide space to permit removal of shell cover and floating head
cover.
2. On fixed tube bundle heat exchangers, provide sufficient clearance at one end
to permit the removal and replacement of tubes and at the both ends provide
sufficient clearance to permit rolling of tubes into the tube sheet.
3. For U-tube heat exchangers, provide sufficient clearance at the stationery

head end to permit withdrawal of tube bundle, or at the other end to permit the
withdrawal of the shell.
4. Adequate foundations for mounting the heat exchanger should be provided so

that it will not settle and cause piping strains on the exchanger.
Foundation bolts should be set to allow for setting inaccuracies. In concrete
footings pipe sleeves at least one size larger than bolt diameter slipped over the
bolt and cast in place are best for this purpose as they allow the bolt centers to
be adjusted after the foundation has set.
5. Provide valves and bypasses in the piping system so that both shell side and
tube side can be bypassed to permit isolation of exchanger for cleaning,
inspection and repairs.
6. Make drain connection in such a fashion that is should be correctly determined

that the exchanger has been thoroughly drained.
7. Install liquid level controls, relief valves, gauge glasses or liquid level alarms in
all vapor or gas spaces to indicate any failure occurring in the condensate drain
system and prevent flooding of the heat exchanger.
8. Surge drum can be installed upstream from the heat exchanger to guard
against pulsation of fluids caused by pumps, compressors or other equipments.
MAINTENANCE
1. Clean exchangers subject to fouling (scale, sludge deposits etc) periodically,

depending on the specific working conditions. A light sludge or scale coating on
either side of tube greatly decreases its effectiveness. A marked increase in
pressure drop and/or reduction in performance usually indicates cleaning is
necessary. Since the difficulty of cleaning increases rapidly as the scale thickens
or deposits increase, the intervals between cleanings should not be excessive.
2. Neglecting to keep tubes clean may result in random tube plugging.

Consequent overheating or cooling of the plugged tubes, as compared to
surrounding tubes, will cause physical damage and leaking tubes due to
differential thermal expansion of the metals.
3. To clean or inspect the inside of the tubes, remove only the necessary tube
side channel covers or bonnets depending on type of exchanger construction.
4. If the heat exchanger is equipped with sacrificial anodes or plates, replace

these as required.
5. To clean or inspect the outside of the tubes, it may be necessary to remove

the tube bundle.
6. When removing tube bundles from heat exchangers for inspection or cleaning,
exercise care to see that they are not damaged by improper handling. The weight
of the tube bundle should not be supported on individual tubes but should be
carried by the tube sheets, support or baffle plates or on blocks contoured to the
periphery of the tube bundles with hooks, chains or other tools which might
damage tubes.
After removal, move tube bundles on cradles or skids. To withdraw tube bundles,
pass rods through two or more of the tubes and take the load on the floating tube
sheet. Rods should be threaded at both ends, with the ends passing through a
steel bearing plate and tube sheet. Insert a soft wood filler board between the
bearing plate and tube sheet face to prevent damage to the tube ends. Screw
steel eye lifting. As an alternate to the rods, thread a steel cable through one
tube and return through another tube. A hardwood spreader block must be
inserted between the cable and each tube sheet to prevent damage to the bundle
ends.
7. Lift tube bundles horizontally by means of a cradle formed by bending a light-

gauge plate or plates into a U-shape. Make attachments in the legs of the U for
lifting.
8. Do not drag bundles, since baffles or support plates may become easily bent.
Avoid any damage to baffles so that the heat exchanger will function properly.
9. Methods of cleaning:
Circulating hot wash oil or light distillate through tube side or shell side. This will
usually effectively remove sludge or similar soft deposits. Soft salt deposits may
be washed out by circulating hot fresh water.
Some commercial cleaning compounds may be effectively used in removing

more stubborn deposits. If the scale is hard and the above methods are not
effective, use a mechanical cleaning means. Neither the inside not the outside of
the tube should be hammered with a metallic tool. Take extra care when suing
scraper, they should not damage tubes.
10. Do not attempt to clean tubes by blowing, steam through individual tubes.
This overheats the individual tube and result in severe expansion strains and
leaking tube to tube sheet joints.
11. To locate rupture or corroded tubes or leaking joints between tubes tube
sheets, remove tube side channel covers or bonnets. Pressurize the shell side of
the exchanger with a liquid, preferably water. Observe tube joints and tube ends
for indication of test fluid leak.
12. To tighten the leaking joint, use a suitable roller tube expander. Do not roll
tube beyond back face of the tube sheet. Maximum rolling depth should be tube
sheet thickness minus 1/8”. Do not reroll tubes which are not leaking.
13. When a heat exchanger is dismantled, new gaskets should be used in

reassembly.
14. Use of new bolting in conformance with dimensions and ASTM specifications
of the original design is recommended where frequent dismantling is
encountered.
OPERATION
1. be sure entire system is clean before starting operation to prevent plugging of

tubes or shell side passages. The use of strainers or setting tanks in pipelines
leading to the heat exchanger is recommended.
2. Open vent connection before starting flow through the exchanger.
3. The first fluid admitted is that whose temperature most nearly approximates
the ambient temperature of the unit. The heat exchanger should never be
shocked by the sudden admission of extremely hot or cold fluids; repeated
stresses are set up by such a procedure results in metal fatigue.
Thermal and physical shocks should be avoided whenever possible. For fixed
tube sheet exchangers fluids must be introduced in a manner to minimize
differential expansion between the shell and tubes.
4. Start operating conditions gradually after the system is completely filled with
the operating fluids and all air has been vented, close all manual vent
connections.
5. Retighten bolting on all gasketed or packed joints after the heat exchanger has
reached operating temperatures to prevent leaks and gasket failures.
6. Sufficient circulation of the cold medium should be maintained at all times to

prevent overheating, which could result in the depositing of scale, coke or sludge.

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BHARAT HEAVY ELECTRICALS LIMITED

RAMACHANDRAPURAM :: HYDERABAD – 502 032

OPERATING AND MAINTENANCE INSTRUCTIONS

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

DAMODAR VALLEY CORPORATION

Voith Code: Bharat S 150

Serial No.: 8203542

Should you have any questions with regard to the

GEARED VARIABLE SPEED TURBO COUPLING Type R18 KGS

Rotation seen in direction Input shaft Hydr. circuit Output shaft

Geared variable speed pump as boiler feed pump drive

Auxiliary lube oil pump: MZP 820

Actuator: PME 120 AN

Connecting couplings: Input side: * Output side: *

GEARED VARIABLE SPEED TURBO COUPLING Type R18 KGS

Bearing temperatures nom. value < 90 °C

Working oil temperature nom. value >60 - <110 °C

Working oil temperature downstream nom. value >35 - <75 °C

Lube oil temperature upstream nom. value >45 - <65 °C

Lube oil temperature nom. value >35 - <55 °C

Differential pressure at lube oil filter alarm / change-over filter

Working oil pump pressure,

Working oil pressure upstream of

Working oil pressure downstream of

1.2.2 Heat exchanger

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

Heat exchanger WORKING oil Shell cham- Tube cham-

Max. allowable working temper- 120 - º C 70 - º C

GEARED VARIABLE SPEED TURBO COUPLING Type R18 KGS

Instruction Manual, Text

Voith Information Sheets

Attaching Parts (Descriptions)

Instruction Manual, Text

1. Design and Operation

5. Assembly, Mounting Instructions

8. Operation of the Geared Variable Speed Coupling

8.1 Start-up, operation and shutdown of the geared variable speed

8.5 Bearing temperatures

9. Maintenance of Geared Variable Speed Coupling

10. General Overhaul of the Geared Variable Speed Coupling

11. Dismantling the Geared Variable Speed Coupling

1. Design and Operation

2.1 Working oil circuit

2.2 Lube and control oil circuit

2.3 Lube oil circuit to the individual machines

GEARED VARIABLE SPEED TURBO COUPLING Type R18 KGS

3.1 Scoop tube positioning (normal operation)

GEARED VARIABLE SPEED TURBO COUPLING Type R18 KGS

3.1.1 Setting and checking of scoop tube control

unscrewing the check nut (see opposite sketch).

GEARED VARIABLE SPEED TURBO COUPLING Type R18 KGS

3.2 Oil flow control

There are three possibilities:

a) Set the maximum oil flow (between

b) After releasing the check nut

c) Reshape the oil flow cam disc:

GEARED VARIABLE SPEED TURBO COUPLING Type R18 KGS

3.3 Rapid regulation of variable speed coupling

GEARED VARIABLE SPEED TURBO COUPLING Type R18 KGS

In as delivered condition, the geared variable speed coupling cannot be operated

Before leaving the factory each coupling undergoes a test run.

Parameters measured: No-load losses, oil temperatures,

Parameters set: Oil flow rates / oil pressures,