Clause - 1 Fans

Operation & Maintenance Manual for Vandana Vidhyut Limited
2 x 135 MW BTG Package
SECTION – II
BOILER & ITS AUXILIARIES
VOLUME - 1
SUPPLIED BY
M/s. CETHAR LIMITED
4, DINDIGUL ROAD, TIRUCHIRAPPALLI – 620 001.
TEL: 91 – 431 – 2484000 TO 09
FAX: 91 – 431 – 2481079
E-mail: utility.vandana@cethar.com
Operation & Maintenance Manual for Vandana Vidhyut Limited
2 x 135 MW BTG Package
CHAPTER – 6
FANS
CETHAR LIMITED
Tiruchirappalli
CONT ENT
PA FAN
CONTENT
Web : www.flaktwoods.com
INSTRUCTION MANUAL Page 2 of 53
UID NO.:FAN MANUAL/Flakt2003
CONTENTS
FUNCTIONAL DESCRIPTION & DESIGN 4
SAFETY PRECAUTIONS 5
CONDITION ON DELIVERY 6
ERECTION
SIMPLY SUPPORTED FAN 7 - 8
CERAMIC ROPE FIXING DETAIL 9
BELLE VILLE WASHER FIXING DETAIL 9
RIGID & FLEXIBLE ATTACHMENT 10
ROTOR ASSEMBLY 11 - 12
LIFTING ARRANGEMENT OF ROTOR 13
ROTOR ALIGNMENT 14
INLET CONE FIXING DETAIL 15
COUPLING ALIGNMENT 16
SEALING PLATE FIXING DETAIL 17
OVERHUNG FAN 18
ASSEMBLY PROCEDURE OF BEARINGS 19 - 23
IMPELLER LOCKING ARRANGEMENT 24
SOME IMPORTANT NOTES 25
FANS ON VIBRATION ISOLATOR 26
ACCESSORIES 27 - 28
COMMISSIONING PROCEDURE
ASSEMBLY & START UP CHECK LIST 29
PRECAUTIONS BEFORE STARTING 30
CHECK UP DURING RUNNING 31
CONTENTS
MAINTENANCE
RUNNING MAINTENANCE 32
SHUTDOWN MAINTENANCE 32
LUBRICATION 33 - 35
VIBRATION ACCEPTANCE NORMS 36 - 37
LOCATION FIXED & FREE BEARINGS 38
AFTER MOUNTING CLEARANCE OF BEARINGS 39
SOFN HOUSING
BEARING ASSEMBLY 40
OIL LEVEL 41
LUBRICATION 42
MOUNTING/DISMOUNTING 43
MAINTENANCE 43
INLET DIMENSION 44
LIST OF SPARE 45
ANNEX
DATA RECORDED DURING TRIAL RUNNING
46
OF FAN
DOS & DON'T'S 47
BRIEF DESCRIPTION OF FAN COMPONENTS 48
TROUBLE SHOOTING CAN HELP WHEN YOU
49 - 51
SUSPECT A PROBLEM
HOW TO ORDER 52
ADDRESS & CONTACT NO. 53
YOUR FANS.. .. DESCRIPTION AND IDENTIFICATION

FUNCTIONAL DESCRIPTION AND DESIGN
SOLYVENT SERIES
FAN IMPELLER
DISC
BLADE CENTRIFUGAL FAN TERMINOLOGY

SEALS
SQUARE FLANGE
SCROLL PLATE
INLET DAMPER
INLET
INSPECTION DOOR
SHROUD
SHAPPED INLET
SHAFT TECHNOLOGY
SQUARE FLANGE
STRAIGHT SHAFT FOR SINGLE INLET IMPELLER

INLET BOX
STIFFENER
STRAIGHT SHAFT FOR IMPELLER OUTLET
BETWEEN BEARINGS
SPLIT FLANGE
SOLEPLATE
STEPPED SHAFT DIFFUSOR

PEDESTAL
OR
PELICAN
SQUARE FLANGE
BEARING
SHAFT WITH INTEGRATED FLANGE FAN STATOR
CONTENT
SAFETY PRECAUTIONS
The operation and maintenance of machinery of any kind requires a person to be

cautions and aware of the damages that exist. In order to avoid injuries to
personal and damage to machinery, the following precautions are very important.
1. Never apply power to the fan motor for any reason until the fan has been
completely installed in its system, and the system inspected to be sure that no
debris has been left in the fan & ducts, and it is known that the inspection
doors at the inlet and outlet of the air passages are shut. The usual procedure
is to remove the fuses from the disconnect switch and open its safety
isolation switch until the installation is completed and inspected.
2. Start the fan momentarily and disconnect it. Observe rotation of the wheel or
the drive rotation is correct. Do not allow the fan to run backward, except
momentarily.
3. Do not open or access inspection doors while the fan is running.
4. Always open the disconnect switch and lock it in the open position with a
padlock before doing any service or maintenance work on the fan.
5. After service of any kind make certain that all adjustment have been properly
made and tightened ,inspection doors closed, there is no debris in the air
passages and all tools have been removed before unlocking the disconnect
switch to place the fan in operation.
6. Make a periodic inspection of the fan wheel, bearings and coupling to be sure
that corrosion has not set in to weaken them. Where there are signs of
corrosion there is danger of mechanical failure. Corroded parts should be
replaced.
7. Always use caution in every maintenance or operational procedure.
CONTENT
CONDITION ON DELIVERY
A. Transport :
The fans are dispatched in dismantled condition with proper packing.
Handle all fan parts with care. Use lifting lugs and good rigging techniques. Slings and
timbers should never be passed through the casing and impeller in order to assist in
rigging.
Pay particular attention to rotor assembly consisting impeller, hub, shaft, bearing
housings and bearings. Avoid any shocks that could damage the parts and their
coatings or alter the impeller balance. If the impeller is damaged slightly, it will have
to be repaired and balanced again.
B. Check for Transportation Damages :

When packages are received at site, check all parts with the help of the packing list
and drawing. If necessary ,make a list of the missing parts ( in case of shortage)
and initiate action for replacement, insurance etc. Check the condition of the parts
that may have been damaged during transport. In case of damages, take steps to
repair the damages in consultation with manufacturer
C. Storage :
General :-
As soon as received ,the different parts of the fan should be placed in clean and dry
covered premises.
Long term storage
Storage for a period of more than three months must be ensured in the best
possible condition, basically protected from dampness so as to avoid oxidisation of
the different parts of the fan unit.
The mechanical parts with machined surfaces are coated with anti-corrosion varnish.
In the case of prolonged storage, before putting in to service, the equipment will be
inspected periodically and the machined parts will be protected from time to time
using protective coating in case of need.
They will be stored in sufficiently large premises, thus providing space for inspection
and easy maintenance of the equipment stored. Moreover , the storage premises will
protect the equipment from sudden changes in temperature, dust, foreign matter,
etc.
The impeller and bearing assembly should be rotated at a very low speed ( rotation
by hand) for about thirty minutes, once a week.
Storage of bearing
As a general rule, the bearings are given a rust prevention treatment in the works
before being packed. They can be preserved for several years, in their original
packing , on a condition that the relative humidity in the storage premises is not over
60 % A higher degree of relative humidity, up to 75% is however permissible for
short term storage.
CONTENT
ERECTION
SIMPLE SUPPORTED FANS
1. Ensure that the concrete foundation has been made at site as per general assembly
drawing.
2. Check foundation for evenness, and its different levels.
3. Mark centre lines of fan and foundation pockets on the foundation.
NOTE: REFER ENCLOSED ASSEMBLY DRAWING.

FOLLOW MATCH MARK OF EACH COMPONENTS FOR ASSEMBLY.
♦ FOUNDATION BOLTS, FAN ON BASE FRAME: -
4. Place the foundation bolts in all foundation pockets as required and hook up with the
common holding rods provided in the foundation.
5. Clean the threaded portion of the bolt.
6. Generally the concrete block foundation provided to support the fan unit should be at a
level lower than the final installation level by about 50mm. This clearance allows
correction of the civil engineering false level. It is therefore necessary to maintain the
center of the fan and the level of installation.
7. Place the steel packers in between the foundation bolts to the required height.
8. Place the base frame on the packers and bolt together at four corners.
9. Fasten the foundation bolts with base frame.
10. Adjust the horizontal level of the base frame by adjusting steel packers by using
dumpy level. The dimensions to be maintained as per the GA drawing. Check up the
diagonal dimensions for assuring the squareness of the base frame.
CONTENT
♦ BEARING PEDESTALS, CASING
11. Place the bearing pedestals on the base frame and bolt with base frame. Check up the
horizontal level of the bearing pedestals by using water level/dumpy level. The level of
pedestal to be checked with water level/dumpy level.
12. Check up the center to center distance of bearing pedestal and diagonal of holes on the
pedestal for ensuring the squarness. This should be maintained as per the drg.
Temporary locking arrangement to be provided for the base frame to avoid disturbance
of the base frame during grouting. The temporary locking can be removed after
grouting.
13. Put the grouting materials for the foundation bolts up to the pocket level.
NOTE: Make sure that non-shrinkage type grout materials are used. Allow the
grout to dry long enough.
14. Again check the level and height of bearing pedestals and record the values.
NOTE: Top surface level of bearing pedestals should be checked by master level.
Permissible deviation is 2 division of master level having accuracy 0.02mm/meter.
This level should be obtained by adjusting steel packers in-between base frame and
foundation. Please avoid shims providing between base frame and pedestal.
15. Bolt the bottom half of the casing with inlet box. Provide ceramic rope in between
the flanges as per the fig. 11.
16. Place lower part of casing on base frame and bolt it. Provide Belleville washer in
casing with base frame fixing bolt, as shown in fig. 12.
17. Check the center line of casing, shaft and impeller axis with respect to base frame
and bearing pedestals.
18. Weld the rigid attachment at motor end in-between casing and base frame as per
fig. 13.
FIG. No. 11
CERAMIC ROPE
CERAMIC ROPE FIXING DETAIL
19. Weld the flexible attachment at free end on inlet box and base frame as per fig. 14.
FIG. No. 12
(WHEREVER APPLICABLE)
FIG. No. 13
FIG. No. 14
ROTOR ASSEMBLY :-
20. Assemble the bearings in shaft as per the instruction given in the enclosed manual.
21. Sling the fan rotor assembly consisting of impeller, hub, shaft, bearings and bearing
housings with inlet cone as shown in fig. 15.
22. Position the fan rotor assembly with inlet cone on the bearing pedestals. Bolt the
bearing housing with the bearing pedestals, The holding bolt is of high tensile grade
and should have plain washer, spring washer, main nut and lock nuts are to be used.
23. Check level of shaft and align shaft axis for approx. gap between inlet cone to impeller
shroud.
24. To achieve the shaft level at coupling end to horizontal, follow the procedure as
explained here.
For Simply supporte fan

Place the master level on the machined surface of shaft at coupling seating portion and
check the level. This level should be within 0.05mm. For achieving this lift the shaft at
non drive end in such a way that the drive end is levelled to zero horizontally as shown
in fig. 16. For this suitable thickness stainless shim to be inserted between bearing
housing and bearing pedestal at non drive end.
For Overhung fans
Ckeck the master level in between bearings.
25. Tighten the bearing housing fixing bolts.
26. Install top half of the casing and inlet box and bolt it. Put ceramic rope in-between
parting flanges as shown in fig.11
27. Tighten the parting flange bolts, all bolts should be provided with plain washer.
28. Bolt the supporting plates which is welded on the bottom casing as shown in fig. 17.
with the top casing.
29. Position the inlet cone on its place with fixing clamp or bolted arrangement (refer GA
drawing.)
30. Check overlap and clearance between impeller and inlet cone and note down the value in
annex. The back mark dimension between the casing and impeller disc also to be
maintained as per the drawing. After achieving the dimensions as per the drg. weld the
cone with its flange as per fig. 18(In some cases cones are not welded with flange at
our workshop to facilitate adjustment at site.) . While welding the cone with its angle
flange sequence welding is to be adopted (not continuous welding) to avoid distortion.
If the overlap dimension is deviating from the drawing, this can be achieved by cutting
the tack weld of the cone with the angle flange and can be moved as required.
31. Insert the coupling half on to the fan shaft by heating the coupling hub in hot oil bath
up to 125 °C. Please check up the bore and shaft dimensions.
32. Insert the other coupling half on to the motor shaft by heating the coupling hub in hot
oil bath up to 125 °C. Please check up the bore and shaft dimensions.
33. Place the motor base frame on the foundation with packing plates, and foundation
bolts. Level the base frame with water level by adjusting the packers placed below the
base frame.
34. Place the motor on the base frame and check up the coupling gap and coupling side and
up/down variations. If required adjust the same by moving the motor along with the
base frame.
35. Put the grouting materials for the foundation bolts of the motor base frame up to the
pocket level.
NOTE: Make sure that non-shrinkage type grout materials are used. Allow the grout to dry
long enough.
36. Gap between coupling halves should be maintained as per the dimensions shown in
assembly drawing.
FIG. No. 15
(same procedure for overhung rotor also)
FIG No. 16
ROTOR ALINGMENT
FIG. No. 17
Fig No. 18
(Wherever applicable)
COUPLING ALIGNMENT
1. Level and align the motor to the fan shaft level by using brass / stainless steel shims
underneath the motor pads.
2. Align the motor with respect to fan coupling. Alignment of the couplings should be done
using two axial dial gauges and one radial dial gauge as shown in fig. 19.
Allowable radial misalignment max. 0.05 mm.
Allowable axial misalignment max. 0.05 mm.
3. Arrange for final grouting of fan and motor base frame by using non-shrink type
grout material.
4. Couple the fan and motor through the coupling after taking a trial run of motor in de-
coupled condition.
FIG No. 19
FIG No.20
(Check Drg. if spring loaded bolts are applicable)
FIG No. 21
OVERHUNG FANS
1. Check up the civil foundation level for its surface level evenness, and different
elevation level as per the drawing. Chip off the uneven surface.
2. Check up and ensure that the foundation pocket dimensions are as per drawing.
3. Place the packers in between all the pockets. Place the foundation bolts on all the
packers.
4. Place the lower part of casing and common base frame on the packers and fix the
foundation bolts.
5. Check up and adjust the horizontal level of the base frame and casing using water level.
This can be adjusted by adding and removing the packer plates below the base frame.
6. Insert the bearing on the fan shaft as explained in the assembly procedure for
bearings.
7. Install the impeller on the base frame and bolt with the base frame.
8. Grout the foundation pockets with non shrinkage grout material upto the pocket level
allow long enough for proper curing.
9. Level the impeller shaft by using master level. The level has to be checked in between
the bearings. The shaft should be levelled with in 2divisions (0.04mm).
10. Install the top casing and inlet cone, put ceramic rope in between the parting flanges.
Check up the cone gap and overlap and record the values. If required the cone gap can
be adjusted by heating and hammering the inlet cone tip, to maintain the gap as per the
drawing.
11. Fix the inlet damper and flexible connection at fan inlet.
12. Fix Evase and outlet flexible connection at fan outlet.
13. Fix the coupling on the impeller and motor fan shaft.
14. Align the motor with respect to the fan shaft as explained earlier.
15. Fix cooling disc with cover (fig. 21), coupling cover and shaft cover.
16. After completing installation and alignment, final grouting of the foundation bolts shall
be carried out.
ASSEMBLY PROCEDURE FOR BEARING AND BEARING HOUSING
The following procedure will be applicable rotor, loose bearings and bearing housings, if and
when used.
1. PRE -ASSEMBLY CHECKING :
As the bearings are finished to high precision, thorough inspection and checking on the
following points are essential prior to assembly :
a) On opening the packing of bearings, the same shall be thoroughly checked for dirt or
other foreign matter and if found, same shall be carefully washed unless and until it is
necessary.
b) The shaft shall be checked for damage due to transport and handling. Particularly the
surfaces where the bearings are to be mounted should be checked for rusting, scoring
etc. Rust, if found, should be removed by rust remover. Heavy pitting on bearing
surfaces of shaft is not acceptable.
Localized scorings could be removed using oil stone.
If the shaft is found to have a bend, the same should not be used for assembly.
c) Bearing housings although made by precision machining to the given specifications, a

thorough checking is essential to make sure against any defects in the bearing seating
surfaces or dirt inclusion which can possibly result from handling, transportation etc.
The flaw, if any, is to be carefully corrected with the use of an oil stone or fine emery
paper and the dirt to be thoroughly washed off and cleaned.
d) Bearing to be mounted shall be taken out of the original protective packing only
immediately before mounting.
e) The mounting and dismounting tools and necessary jigs must be of proper dimension and
simple design so that they do not cause any mechanical damage to the bearings.
2) GENERAL INSTRUCTIONS :-
With tapered bore:
A bearing with tapered bore, which is seated direct on a shaft, or which is mounted with
an adapter sleeve, ordinarily requires a somewhat tighter fit than a bearing with
cylindrical bore. This fit is achieved by pressing on the inner ring by means of a nut or
by driving in the sleeve. In both cases, the inner bearing is expanded and this results in
a reduction of radial bearing clearance.
If a double row self aligning ball bearing is mounted on an adapter sleeve, the sleeve
nut might be tightened but not so much as to prevent the outer bearing from turning
easily and it must be possible to swing the outer race easily from one side to the other
side.
Double row spherical roller bearings which are used mostly in heavy load applications are
mounted with greater interference. The radial clearance is adapted to this fit and its
reduction can be measured while mounting by means of a feeler gauge. For checking the
correct fit of the inner ring, both the reduction of radial clearance and the distance of
the inner ring is driven axially on the tapered seating or on the adapter sleeve and is
measured. For solid shafts, the axial displacement is approximately fifteen times as
large as the desired clearance reduction.
ASSEMBLY PROCEDURE
a) Keep the bottom half of bearing housings on the bearing pedestal.
b) Clean the shaft with the use of white sprit.
c) Insert the brass seal on to the shaft at impeller end.
d) Insert the M.S cover plate on to the shaft at impeller end.
e) Keep the rotor assembly in position but slightly elevated position on supports above
the bearing housing bottom halves.
f) Insert the double - lip seal on to the shaft at impeller end if applicable.
g) Insert the taper sleeve on to the shaft to the location with thread portion outside.
h) Locate the bearing position and assemble the lock washer and nut with the taper
sleeve. (no locating ring for this bearing as this is free bearing).
i) Keep the gap between bearing to bearing housing to accommodate the expansion of
shaft as shown in our drawings.
j) Tighten the lock nut on the taper sleeve. For tightening the nut, do not use steel
chisel or rod but use either brass or copper rod for taking the force of hammer. The
necessary tightness is achieved when the brass or copper rod flares at the load
transfer end. Check for the clearance between roller and outer race as mentioned in
SKF catalogue.
k) Insert the another double-lip seal on to the shaft if applicable.
l) Now start assembly of drive side (coupling side) bearing by inserting the double lip
seal on to the shaft if applicable.
m) Insert the lock nut and lock washer on to the shaft.
n) Arrange the locating ring on one side or either side of bearing , as the case may be.
o) Insert the bearing with large dia of bore facing outside.
p) Insert the taper sleeve on to the shaft.
q) Locate the bearing position and assemble the lock washer and nut with the taper
sleeve.
r) Tighten the lock nut as explained in point no.
s) Now keep the lock washer teeth locked to the lock nut groove by bending.
t) Insert the another seal on to the shaft.
u) Rest the rotor on the bottom half of bearing housing.
v) Lubricate the bearings with recommended grease from one side of the bearing with
pressure, so that the grease comes at the other side of the bearing through roller
gapes. Check that the bearing is greased uniformly on both sides all around. Fill the
bottom half of the bearing housing with grease.
w) Place the top half bearing housing without applying any grease. Check for free
rotation of the rotor assembly.
x) Tighten the parting off bolts to the correct tightness.

WITH CYLINDRICAL BORE: -
The force needed to mount a bearing increases rapidly with bearing

size. Larger bearing can not easily be pressed on to a shaft or in to
a housing because of the mounting force required. Therefore, the
bearing or one bearing ring is heated before mounting.
The temperature difference between the bearing and its seating

depends on the magnitude of the interference fit and the bearing
size. Normally a bearing temperature of 80 to 90ºC (175ºF to 195ºF).
ing to a temperature greater than 125°C(255 °F), however, be-

cause the material may change metallurgically and produce alterna-
tions in diameter or hardness. Local overheating must be avoided.
When using a heating device, use a thermometer to check the
bearing's temperature.
Wear clean protective gloves when mounting a hot bearing. Lifting

(hoisting) gear can facilitate mounting. Push the bearing along the
shaft to its abutment and hold the bearing in position, pressing until
a tight fit is obtained.
SKF can supply heating tools, such as oil baths, induction heaters,
heating cabinets and electric and electric plates with adjustable thermostat and
cover, for all common mounting needs.
When a bearing requires an interference fit in the housing, a moder-

ate inctrease in the housing temperature, from 20 to 50°C (70 to
120°F) is normally sufficient, since the amount of interference is
seldom large. A heater or oil bath can be used for the job.
Bearings with
shields or seats
should not be
heated.
Lifting gear
(housing)
To facilitate future dismounting equip shafts with ducts

and distribution grooves for pressurized oil
SKF heaters are generally equipped with

adjustable thermostats Nevertheless it is
advisable to use a separate thermometer
to check bearing temperature immediately
before mounting. The thermometer is
also useful during test runs and Use clean protective gloves to hold the hot
for monitoring bearings bearing press it hard against the abutment
during operation face so that the inner ring fits snugly on the
A cabinet equipped wiyh an adjustable thermostat and a fan is a

versatile tool suitable for many heating operations. Bearings of dif-
ferent sizes or a large number of bearings can e heated together in a
cabinet. Small bearing housings can also be heated. Keep the cabi-
net clean to reduce the risk of bearing contamination. Bearings can
also be stored hot, ready to mount.
In addition to bearings, couplings, sleeves and other components

can also be heated in a cabinet.
Oil baths ensure even heating. They

also make it possible to heat and
maintain a bearing at a certain
temperature. Keep the oil in a clean
bath to prevent bearing contamination.
Bearing rings, or even complete bearings, can be

suspended in an oil bath.
Never place a bearing directly in contact with the sides
IMPELLER LOCKING ARRANGEMENT
SIMPLE SUPPORTED FAN OVERHUNG FAN
Fitting of impeller on shaft

Some important notes
! Direction of discharge
The fans are supplied in discharge direction as specified in order . This can be altered at
site .
! Connection of duct
Duct connection of the fan casing must not exert any load directly on the fan as the
casing may be deformed and the inlet cone may come in contact with impeller .
! Direction of impeller
The direction of rotation is indicated in fan casing .

Erection on vibration isolator
! Ensure of grouting pocket positions in civil foundation are as per GA drg.

! Bolt the isolators with base frame .
! Insert the grouting bolts in mounting holes of isolators.
! Place the base frame in position and at it's required elevation , level it in X- Y axis ;
provide temporary support under base frame .
! While positioning the base frame , ensure the grouting bolts are positioned at center
in their respective pockets .
! Grout the isolator pockets Use non shrinkable cement .
! Remove temporary support only after curing is complete . The isolators are loaded
now.
! Check level of shaft . If required , place shims between base frame and isolator .
Important point to be noted
! The main idea of providing vibration isolator is to avoid transmission of undue

vibration from the equipment to the surrounding structure and not to reduce
equipment vibration , in fact equipment vibration may be on higher side due to soft
foundation and vibration value 10 mm/s ( Peak Value ) is acceptable for Fans.
! We do not normally recommend to use vibration isolator when fans are installed at
ground level.
ACCESSORIES ( REFER ASSEMBLY DRAWING FOR ITEMS APPLICABLE)
5. Fix the evase with fan outlet.
6. Fix the inlet damper with inlet box (wherever applicable) /inlet
Ensure correct damper orientation; the close to open direction of damper will be same
with that of impeller rotation.
7. Fix the inlet and outlet flexible connection.
Ensure flexibility after installation ; For dust application flexible connection are
provided with sleeve . Follow the air flow mark for correct installation.
8. Fix the actuator bracket on the casing/foundation
9. Fix the actuator with actuator bracket.
10. Fix the linkage between actuator and damper. The operating lever on the actuator and
the lever on the damper should be in parallel and of equal length , for proper
operation of the damper.
11. Fix the sealing arrangement on inlet box as shown in fig. 20
12. Bolt the cooling disc halves together on the shaft.
Guard for cooling disc Tightening torque

Shaft
A kpm Nm
Dia. D ft lb
kgfm Nm
25-65 0 3 29.4 21.7
80 10
90-100 15 5 49 36.1
110 25
A
Assembly of disc halves
13. Weld the cooling disc guard fixing angle on the bearing pedestal as shown in fig. 21.
14. Weld the coupling guard fixing angle on the bearing pedestal.
15. After completing all erection and alignment work, full grouting of the foundation bolts
shall be carried out.
NOTE :
Whenever welding is carried out on the fan parts during erection at site condition, direct
earthing to be given, to avoid current passing through the bearings.

ASSEMBLY AND STARTING UP CHECK LIST.
DESCRIPTION REMARKS & MEASURED VALUES
Tightening of foundation bolts :
STATIC PARTS:
Positioning of the inlet cone :
Tightening of fixing bolts on the ducts :
Tightening of the fixing bolts of static :

parts
Closing of the inspection door :
ROTOR PARTS:
Shaft alignment :
Tightening of fixing bolts impeller / hub :
Expansion clearance on the free bearing :
Alignment of the coupling
LUBRICATION:
Fan bearings lubrication :
Inlet damper lubrication :
UTILITIES:
Connection to the electric circuit :
Connection to the control system :
CONTENT
PRECAUTIONS BEFORE FIRST STARTING OR BEFORE STARTING

AFTER DISMANTLING
1. Check the mounting of the bearing housings and electric motor.
2. Check that the coupling is tightened properly.
3. Check that the foundation bolts are properly tightened.
4. Check that the connecting flanges between the fan and ducting are good, and proper
packing is provided.
5. Check that the different components of the control system are correctly connected.
6. Check that the Inlet damper is fully closed.
7. Check that no foreign object has been left anywhere in side the fan.
8. Check that no water stays in the bottom of the casing and inlet box.
9. Check that the specified guards have been fitted.
10. Check that the inspection door on the casing and inlet box are correctly shut.
11. Check that the rotor can turn freely without rubbing with any static parts.
12. Check that the bearings have been correctly filled with bearing lubricant as it is
noted in the section `LUBRICATION”.
FIRST START AFTER ASSEMBLY

1. People responsible for the starting must always stay nearest as possible to the
emergency stop switch.
2. The fan is rotating in correct direction
T IMPELLER
P IMPELLER
B IMPELLER
3. The fan inlet must be shut.

4. During the acceleration phase, that there is no abnormal noise.
Once the fan has reached full speed, open the damper.
5. Check bearing vibration level. The vibration levels indicated in below are in full
accordance with the standard VDI 2056.
VELOCITY IN mm/sec (RMS)
FAN HEALTH FAN ON CONCRETE FANS ON VIBRATION

CONDITION FOUNDATION ISOLATOR
ADMISSIBLE 4.5 7
STILL ADMISSIBLE 7.1 15
ALARM LEVEL 10 18
TRIP LEVEL 11.2 20
Check that the bearing temperature is good.

Normally this temperature first raises and then decreases and stabilizes at particular
temperature.
SET THE ALARM POINT AT 100 ° C.
SET THE TRIPPING POINT AT 110 ° C.
If the bearing temperature is too high, this ♦ Improper assembly

generally indicates: ♦ Inner clearance is too small
♦ Jamming of bearings
♦ Excessive friction of seal
Improper lubrication in quantity or quality.
Check up the noise of the bearing housings :
♦ Grinding noise : Inadequate lubrication (Surface rubbing directly against one

another
♦ Whistling : Improper lubrication (Grade or quantity)
Clear noise at : Imprints in race of outer ring because of abnormal vibration.
regular intervals
♦ Intermittent : Rolling part deteriorated or damaged
noise
♦ Cracking noise : Presence of foreign particles
♦ Whining or high : Axial thrust from motor.

pitch noise
MAINTENANCE
RUNNING MAINTENANCE
1. Fill bearing lubricant of recommended specification and quantity at the specified

intervals for bearing housings. The interval should be determined based on local
condition like working environment etc.
2. Check periodically vibration levels of the fan at both bearings.
3. Check periodically the proper seating of fan on the foundation and for abnormal
vibration at any location.
4. Check for looseness of any bolts in the fan pedestals, casing, etc.
SHUT DOWN MAINTENANCE:
1. Open inspection door in casing. Clean the impeller blades and internals.
2. Check for erosion of the impeller.
3. Check the overlap and radial clearance between impeller shroud and inlet cone. If found
disturbed adjust the same.
4. Remove used bearing lubricant from bearing housing.
5. Check the bearing condition like roller clearance and the rolling surfaces of races.
6. Fill new lubricant in the bearing housing.
7. Check alignment of fan and motor. If necessary correct the same.
8. Check the Inlet damper flaps movement.
9. Apply grease for Inlet damper bearing housings.
10. Check the tightness of all fixing bolts.
CONTENT
LUBRICATION
FAN BEARINGS (GREASE LUBRICATION)
Requirement : Consistancy class : NLGI 2 (National Lubrication Grease Institute scale)
COMPANY BRAND NAME

BHARAT PETROLEUM BHARAT LINTHEX EP2
IOL SERVOGEM EP2
SKF ALFALUB LGMT No 2
ELF EPEXA No 2
ESSO STANDARD BEACON No 2
MOBIL OIL MOBILUX GREASE No 2
SHELL ALVANIA GREASE No 2
Quantity : Press grease from one side of the bearing till it comes out through the opposite
end. Continue the process and rotate the impeller slowly by hand till the bearing is
completely filled with grease. Put some extra grease (not more than !/3 rd of inside volume
of plummer block) inside the plummer block .
Note : Over greasing will cause overheating of bearing .
FAN BEARINGS (Oil LUBRICATION)
Requirement : Viscosity Grade 68
Type of Lubrication: Oil bathand circulation ring.

Lubrication : Mineral oil with anti foam, corrosion and anti oxidation additives.
Suggested lubricants.: BHARAT HYDROL 68 , SERVO SYSTEM 68 or Equivalent.
Fillinfg per bearing housing: As per maximum and minimum mark given on the Oil level
indicator.(revert to us in case of any doubt)
Note : Do not exceed the maximum mark , since excess oil would result overheating
And oil leakage thru’ the shaft passage.
INLET DAMPER
According to the installation conditions and the operating frequency of the inlet damper
following should be lubricated.
VANE BEARINGS : Make sure when topping up that the spent grease is discharged
normally.
LINK ROD PINS : Apply grease after cleaning if required.
Lubrication interval : Normally three months, to be changed as and when required.

Lubrication interval and amount
Grease
For fans provided with spherical roller bearing, the bearings housing are
fitted with grease nipples and are fitted with the correct amount of grease
when requested.
The lubrication intervals and the amount of grease necessary for relubrication
The chart is based on a temperature of 70°C. For every 15°C increase in
temperature the lubrication interval should be reduced to 50% of the value
obtained from the chart.
(Example : For a fan fitted with spherical roller bearings with the bearing bore
diameter of 120mm and running at 1000RPM the relubrication interval will be
800 operating hours if the bearing's temperature does not exceed 70°C).
Oil
When inspecting the oil level of a bearing, check to ensure that the right type of
oil is in use and that the oil level gauge's air vent is unobstructed.
Take a small sample of the oil and compare it with fresh oil. If the sample look's
cloudy, then it is mixed with water and should be replaced.
Dark or thick oil is a sign of dirt or indicates that the oil has started to carbonize.
Change the oil completely and, if possible, clean the bearing by flushing it with
fresh oil . When changing the oil, be sure that you are using the same type of oil ,
and that you refill to the required level .
A more reliable method for determining the oil condition is to analyze a sample .
If the oil is contaminated it may be worthwhile to change the seals or consider
filtration .
Oil in oil bath circulation systems requires change only once each year, providing
that the operating temperatures does not exceed 50 to 60 º C and the oil does
not become contaminated . Change the oil four times each year for operating
temperatures of 100 º C ; monthly for operating temperature of 100 º C.
RELUBRICATION INTERVALS IN OPERATING HOUR

c b a t = operating hours
2.5 2.5 3
4
10 2 2.5
6 1.5 2
4 4
1.5
10
2 8
4
3 10 D = DIAMETER OF BEARING
10 6 9
8 4 8
7
d=
6 3 6
10
5 2.5 5
m
m
20
4 2 4
40
60
100
120
80
160
3 1.5 3
200
240
280
360
2.5 2.5
420
2 10 500
2
1.5 7.5 1.5
3
10 5 103
9 4.5 9
8 4 8
7 3.5 7
6 6
5 2.5 5
4 2 4
3 1.5 3
2
2 10 2
1.5 7.5 1.5
2 2
10 10 2
10 2 3 4 5 6 789 103 2 3 4 5 6 7 89 104 2
N = RPM
a : radial ball bearings

b : cylindrical roller bearings
c : spherical roller bearings, taper roller bearings, thrust ball bearings; full complement cylindrical
roller bearing (0.2 t); crossed cylindrical roller bearings with cage (0.3 t); cylindrical roller thrust
bearings, needle roller thrust bearings, spherical roller thrust bearings (0.5 t).
General formula for

relubrication amount :
G = 0.005 DB SHAFT DIAMETER - mm
G = Grease qty. in gm
D = Bearing OD in mm 150 160
65 80 90 100 110 125 135 140
B = Bearing width in mm
AT MOUNTING gm 240 310 340 380 470 680 850 1000 1800 2200
AT RE-LUBRICATION gm 24 40 55 70 80 110 130 150 130 150

VIBRATION ACCEPTANCE NORMS AS PER VDI 2056 / ISO 2372
FOR RIGIDLY MOUNTED FANS
400
µ
315
250
Displacement s
200
160
s
IN
Displacement amplitude s
A
125
D
RM M
IS
100
S- S
va IB
80 lue
S of LE
T vib
63
IL ra
L tio
50 A nv
D elo
M cit
40 IS y
A S v
31.5
D IB
M LE =
IS rm 11
25 s mm
S /s
20 IB
G LE
v rm
16 O
O
s
=
D
4.
12.5
5m
m/
v rm
10
s
=
1.8
mm
/s
6.3
5
Vi
br
4 at
ion
lev
3.15
el
v of
rm hu
2.5
s= ma
0. np
11
2.0 mm er
/s ce
pt
1.6 ion
1.25
1.0
315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000 10000 12500 16000 20000 25000
Fig. 13 Example of Vibration Severily for Machine Class III. Frequency in cpm
FANS ON VIBRATION ISOLATOR
MACHINE CLASS IV
400
µ
315
250
Displacement s
200
160
I
s
RM N
125 A
S- D
va M
100 lu I
S e S
of S
80 T vib I
I B
L ra L
63 L tio E
A n
D ve
50 M lo
I ci
S ty
40 A S
D I v
M B
31.5
I L
S E =
S 18
25
I mm
B /s
L
v rm
20 E
s
=
G
7m
16
O
m/
O
D
s
v rm
12.5
s
=
2.
8m
10
m/
s
6.3
5
Vi
br
4 at
io
n
le
3.15
ve
v lo
rm f
2.5 s = hu
0. ma
11
2.0
mm n pe
/s rc
1.6 ep
tio
n
1.25
1.0
315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000 10000 12500 16000 20000 25000
Fig. 14 Example of Vibration Severily for Machine Class IV. Frequency in cpm
NSTRUCTION MANUAL Page 38 of 53
LOCATION OF FIXED AND FREE BEARING
FREE BRG. FIXED BRG.
FREE BRG.
FIXED BRG.
AFTER MOUNTING CLEARANCE OF BEARING WITH TAPERED BORE
NUT
ADEPTER BEARING LOCKING

SLEEVE WASHER
Bearing bore Reduction in Axial drive-up Taper 1:30 Minimum permissible residual
diameter radial internal Taper 1:12 on diameter clearance after mounting
d clearence on diameter bearings with initial clearance
Over incl. min max min max min max Normal 3 4

C C
mm mm mm mm
30 40 0.020 0.025 0.35 0.4 0.015 0.025 0.040
40 50 0.025 0.030 0.4 0.45 0.020 0.030 0.050
50 65 0.030 0.040 0.45 0.6 0.025 0.035 0.055
65 80 0.040 0.050 0.6 0.75 0.025 0.040 0.070
80 100 0.045 0.060 0.7 0.9 1.75 2.25 0.035 0.050 0.080
100 120 0.050 0.070 0.75 1.1 1.9 2.75 0.050 0.065 0.100
120 140 0.065 0.090 1.1 1.4 2.75 3.5 0.055 0.080 0.110
140 160 0.075 0.100 1.2 1.6 3.0 4.0 0.055 0.090 0.130
160 180 0.080 0.110 1.3 1.7 3.25 4.25 0.060 0.100 0.150
180 200 0.090 0.130 1.4 2.0 3.5 5.0 0.070 0.100 0.160
200 225 0.100 0.140 1.6 2.2 4.0 5.5 0.080 0.120 0.180
225 250 0.110 0.150 1.7 2.4 4.25 6.0 0.090 0.130 0.300
250 280 0.120 0.170 1.9 2.7 4.75 6.75 0.100 0.140 0.220
280 315 0.130 0.190 2.0 3.0 5.0 7.5 0.110 0.150 0.240
315 355 0.150 0.210 2.4 3.3 6.0 8.25 0.120 0.170 0.250
355 400 0.170 0.230 2.6 3.6 6.5 9.0 0.130 0.190 0.290
400 450 0.200 0.260 3.1 4.0 7.75 10 0.130 0.200 0.310
450 500 0.210 0.280 3.3 4.4 8.25 11 0.160 0.230 0.350
500 560 0.240 0.320 3.7 5.0 9.25 12.5 0.170 0.250 0.360
560 630 0.260 0.350 4.0 5.4 10 13.5 0.200 0.290 0.410
630 710 0.300 0.400 4.6 6.2 11.5 15.5 0.210 0.310 0.450.
710 800 0.340 0.450 5.3 7.0 13.3 17.5 0.230 0.350 0.510
800 900 0.370 0.500 5.7 7.8 14.3 19.5 0.270 0.390 0.570
900 1000 0.410 0.550 6.3 8.5 15.8 21 0.300 0.430 0.640
1000 1120 0.450 0.600 6.8 9.0 17 23 0.320 0.480 0.700
1120 1250 0.490 0.650 7.4 9.8 18.5 25 0.340 0.540 0.770
Bearing assembly in SOFN housing

Oil level in SOFN housing
BEARING WITH ADAPTER SLEEVE BEARING WITH CYLINDRICAL BORE

Housing Oil Oil Level Housing Oil Oil Level
Designation Quantity Mm Designation Quantity mm
Max. Max. Min. Max. Max. Min.
SOFN 610 0,3 53 33 SOFN 310 0,3 53 33
SOFN 611 0,4 53 37 SOFN 311 0,4 53 37
SOFN 612 0,5 60 40 SOFN 312 0,5 60 40
SOFN 614 0,6 65 45 SOFN 314 0,6 65 45
SOFN 616 1,0 73 45 SOFN 316 1,0 73 45
SOFN 517 0,7 63 42 SOFN 217 0,7 63 42
SOFN 518 0,8 68 45 SOFN 218 0,8 68 45
SOFN 618 1,4 80 55 SOFN 318 1,4 80 55
SOFN 519 0,9 70 50 SOFN 219 0,9 70 50
SOFN 520 1,0 70 50 SOFN 220 1,0 70 50
SOFN 620 1,8 85 57 SOFN 320 1,8 85 57
SOFN 522 1,3 77 50 SOFN 222 1,3 77 50
SOFN 622 2,0 95 67 SOFN 322 2,0 95 67
SOFN 524 1,7 80 60 SOFN 224 1,7 80 60
SOFN 624 2,8 100 65 SOFN 324 2,8 100 65
SOFN 526 2,3 85 60 SOFN 226 2,3 85 60
SOFN 626 3,4 105 70 SOFN 326 3,4 105 70
SOFN 528 2,4 85 60 SOFN 228 2,4 85 60
SOFN 628 4,2 115 70 SOFN 328 4,2 115 70
SOFN 530 2,8 90 60 SOFN 230 2,8 90 60
SOFN 630 6,0 120 75 SOFN 330 6,0 120 75
SOFN 532 3,3 95 65 SOFN 232 3,3 95 65
SOFN 632 6,5 125 80 SOFN 332 6,5 125 80
SOFN 534 5,0 105 75 SOFN 234 5,0 105 75
SOFN 634 7,5 130 85 SOFN 334 7,5 130 85
SOFN 536 5,2 115 80 SOFN 236 5,2 115 80
SOFN 636 10,5 155 90 SOFN 336 10,5 155 90
SOFN 538 5,8 120 85 SOFN 238 5,8 120 85
SOFN 540 7,0 125 85 SOFN 240 7,0 125 85
SOFN 544 8,5 140 95 SOFN 244 8,5 140 95
SOFN 548 9,5 155 110 SOFN 248 9,5 155 110
NOTE :- Oil level has to be measured from the bottom of the housing and not from the
bottom of the indicator.
Lubrication in SOFN housing
The spherical Roller Bearing in SOFN blocks are lubricated with oil: a pick-up ring
in the housing serves to bring about oil circulation . The pick-up ring hangs loosely
on a sleeve on the shaft at one side of the bearing and dips into oil in the lower
half of the housing. As the shaft rotates, the ring follows and transports oil from
the bottom of the housing to a collecting trough formed in the spigot (cylindrical
extension) of the one housing cover on a level with the rollers of the bearing under
the shaft thus permitting oil to enter the bearing. The oil then flows through an
opening in the spigot of the opposite housing cover back into the reservoir at the
bottom of the housing. The collecting trough is so dimensioned that the level of
the oil in the trough guarantees an optimum supply of lubricant to the bearing. The
oil in the rese3036rvoir at the bottom of the housing is cooled, depending on the
ambient temperature, before being re-circulated. This lubrication system permits
SOFN plummer blocks to be used for high-speed bearing applications. The
difference between the maximum and minimum oil levels in the reservoir may be
relatively large when a pick-up ring is employed. The intervals between oil
replenishment or oil change are correspondingly long. The requisite oil quantity for
each housing is given in the tables.
The oil level indicator supplied with the housing should be screwed into
one of the four threaded holes provided in the housing covers. The remaining holes
may be used for oil drainage. The "max." and "min" oil levels given in the tables
should be marked on the indicator.
Mounting/Dismounting - SOFN housing
The pick up ring must always be in position and it's freedom of movement should not be
restricted. If the ring is not incorporated . There will be an almost immediate danger of
bearing damage because of dry running .
It is recommended the pick up ring be positioned on the side of the bearing nearest the
shaft end in plummer blocks having bearings with cylindrical bore.
The side cover with four recesses in the spigot should be place in the same side of housing
as the pick up ring .
The vent of oil level indicator must not be plugged as otherwise an air cushion in the sight
glass may lead to false reading . The actual oil level will be too high and oil will leak out of
the plummer block shaft passage.
Maintenance - SOFN housing
Before starting up for the first time , the oil quantity quoted in the table should be put
into the housing . The maximum oil level guarantees lubrication of bearing when it starts
running before it can be supplied with the oil picked up by the ring . Thus the oil level
should be restored to maximum before starting up after long stoppage.
Even if the housing is carefully cleaned before use there is risk that some impurities will
be left. It is therefore advisable to change the oil after an initial trial running period of
few hours. Subsequent changes can the be made at convenient intervals but should be
undertaken at least once in a year. The bearing must be at a standstill when the oil is
changed.
If , during the trial run no oil leaves the housing , a monthly check of the oil level should be
adequate.
During operation , the oil level may sink to the minimum level given in the tables . If oil is to
be added during operation , it should be filled to a level some 5 mm beneath the maximum
oil level on the indicator to avoid overfilling , since some oil will be in circulation .
A blind hole with an M24 thread plugged with a plastic stopper , is provided in the housing
cap. If required , a thermometer or the sensor of some other temperature measuring
device , may be inserted .The hole stops just short of bearing outer ring , so that it is
possible to measure the temperature in close proximity of the source of heat. A more rapid
indication of temperature change is obtained , would be possible by measuring the
temperature of oil .
INLET DIMENSION
As refer to drawing
LIST OF SPARES
The following spare parts are recommended to be kept as stand by for two years normal
operating condition. Quantity of replacement depends on individual application.
1. Impeller with shaft and hub.

2. Fixed bearing . Refer drg. for brg. No.
3. Free bearing . . Refer drg. for brg. No.
4. Brass sealing plates(if applicable)
5. Coupling : - . Refer drg. for type and size.
ANNEX
DATA RECORDED DURING TRIAL RUNNING OF FAN
CUSTOMER: FAN TYPE:
ORDER REF. No.: APPLICATION:
DATE : STARTED AT : RUNNING
DURATION :
AMBIENT TEMP: ACCEL.TIME : STOPPED AT :
MEDIUM TEMP.: NO LOAD CURRENT :
VIBRATION LEVEL RECORD:
DISPLACEMENT IN MICRONS (PEAK TO PEAK) -VELOCITY IN mm / sec.(RMS).
H - Horizontal, V - Vertical, A - Axial
MEASUREMENT H V A FAN SPEED

LOCATION Dis. / Dis. / Vel. Dis. / Vel. & DAMPER
Vel. POSITION
FAN DE. BEARING
FAN NDE. BEARING
MOTOR DE. BEARING
MOTOR NDE. BEARING
SL.NO. TIME FAN BRG.TEMP °C MOTOR BRG.TEMP °C MOTOR POWER

kW
DE NDE DE NDE
1
2
3
4
5
6
7
CHECKED BY: WITNESSED BY :

ANNEX
DO’S & DONT’S
DO’S :
1. FILL BEARING LUBRICANT OF RECOMMENDED SPECIFICATION AND
QUANTITY AT THE SPECIFIED INTERVALS FOR BEARING HOUSING.
2. CHECK PERIODICALLY THE VIBRATION LEVELS ON BOTH THE BEARINGS OF
THE FAN.
3. CHECK PERIODICALLY THE PROPER SEATING OF THE FAN FOUNDATION AND
FOR ABNORMAL VIBRATION AT ANY LOCATION.
4. CHECK FOR LOOSENESS OF ANY BOLTS IN THE FAN PEDESTALS AND
CASING ETC.
5. AT THE TIME OF ERECTION / COMMISSIONING, OPEN THE BEARING
HOUSING AND CHANGE THE OLD OIL. CHECK IF ANY DIRT OR DUST IS
SETTLED INSIDE THE HOUSING AND CLEAN THOROUGHLY BEFORE
POURING NEW OIL.
6. ENSURE THE DAMPER IS IN CLOSED CONDITION WHILE STARTING THE FAN.
7. PROVIDE INSULATION OVER THE ENTIRE AREA OF FAN COMPONENTS FOR

HIGH TEMPERATURE FAN.
DONT’S :
1. DON’T REMOVE THE INSPECTION DOOR WHEN THE FAN IS IN RUNNING
CONDITION.
2. WHILE SHUT DOWN, ENSURE THE MOTOR POWER CONNECTION IS REMOVED
BEFORE ANYBODY ENTERS IN TO THE FAN FOR ANY VERIFICATION.

ANNEX
BRIEF DESCRIPTION OF FAN COMPONENTS
1. CASING WITH INLET BOX " IT HOUSES ROTOR & INLET CONE.
2. BASE FRAME " IT SUPPORTS CASING, INLETBOX,

BEARING PEDESTAL & MOTOR.
3. BEARING PEDESTALS " THIS IS FOR MOUNTING OF

BEARING HOUSING.
4. BEARING & BEARING HOUSING " THIS HAS BEEN BRIEFED IN OUR
O&M MANUAL UNDER THE
HEADING “ASSEMBLY PROCEDURE
FOR BEARING & BEARING
HOUSING”
5. INLET CONE " IT GUIDES THE ENTRY OF FLOW

MEDIA TOWARDS THE IMPELLER.
6. DAMPER/IVC " TO GUIDE AND CONTROL THE

FLOW AT THE INLET SIDE.
7. INLET/OUTLET FLEXIBLE CONNECTIONS " THIS IS TO TAKE CARE OF THE

CONNECTION DUCT MOVEMENTS
WHEN THE FAN IS IN OPERATION.
8. ROTOR ASSEMBLY " THIS IS COMPRISING OF

IMPELLER,SHAFT,HUB, BEARING &
BEARING HOUSING. IMPELLER
BLADES ARE BACKWARD CURVED
DESIGN.
ANNEX
Troubleshooting can help when you suspect a problem
TYPICAL AREA TO CHECK SOLUTION

POSSIBLE CAUSE
PROBLEM
Mounting of Fan Inadequate mass or stiffness Stiffen /Increase
of supporting structure weight
Misalignment during Shaft, coupling between shaft Correct alignment
installation and drive, belt pulley , shaft
got bent
Impeller Unbalance during Material build-up, corrosion, Install vibration
operation wear monitor to check the
trend ; Clean the
impeller periodically ;
Take preventive action
for corrosion and wear;
In-situ balancing of
impeller
Looseness In the mounting, Between Tighten fastening bolts
VIBRATION shaft and impeller, coupling / ; Replace coupling
pulley or bearing .pulley; tighten bearing
adapter sleeve as per
tolerance given in SKF
catalogue.
Aerodynamics Inlet condition non-uniform, Duct layout to be
pre-rotation of the air, system modified; baffle plate
effect, pulsation due to fan /straighteners may be
operating at surge zone used to achieve
uniform flow; Selection
of fan to be reviewed.
Vibration Impeller unbalance during In-situ balancing
operation
Mounting Inadequate mass or stiffness Stiffen /Increase
PREMATURE
Lubrication Wrong type, overlubrication Check recommended
BEARING
lubrication , quantity
FAILURE
and interval
Environment Contaminants in lubricant, Change lubricant
Ambient temperature high . immediately; Review
selection of lubricant .
ANNEX

POSSIBLE CAUSE
PROBLEM
Alignment Shaft alignment, overtightened Correct alignment
bearings ;dismantle the bearing
refit with specified
PREMATURE
tolerance
BEARING
Loading Radial and/or thrust Review bearing
FAILURE
selection
Load Overload from belt drive or Review bearing
coupling selection
Thermal Shock Malfunctioning controls, Check controls and
sudden operational change system
Vibration System pulsation, looseness Check system ; check
fastening of bolts .
PREMATURE Abrasion/corrosion Excessive dust from system Ensure fan inlet dust
MATERIAL .Fans running with bypassed concentration within
FAILURE dust arrestor. Water/acid specified limit. Review
fume ingress in fan selection of impeller
material for aggressive
condition .
System Effect Turbulent Inlet condition, non- System correction
uniform flow, deviation of required
actual system resistance from
PERFORMANCE predicted one ,
DEFICIENCY IN pre-rotation or swirl at inlet
VOLUME OR Clearances Impeller and inlet Check for deviation
PRESSURE from drawing/manual;
correction .
Driver Belt slippage Belt tightness to be
adjusted.
Environmental Problems Problems Material build-up in Check and clean
casing , inlet or ductwork periodically. System
blockage correction required
Rotation Incorrect motor connection, Follow the indicated
improper Impeller rotation direction of rotation
given on casing by
arrow mark
ANNEX

POSSIBLE CAUSE
PROBLEM
Mechanical Interference Touching between impeller and Adjust inlet gap taking
inlet cone due to external forces care of expansion in
on casing or hot condition , check
Impeller /shaft movement or for expansion provision
thermal expansion and distortions in casing foot ; fixed
and expansion joint
wherever provided are
in place ; remove duct
NOISE load from fan casing by
providing flexible
connection piece.
Bearings Inadequate lubrication, pitted Replace bearing ;
bearing worn balls, races, seal correct alignment
failure, alignment improper,
Airborne High velocities Install Attunuator
Foreign Material in Fan Buildup on fan Impeller, casing Check and clean
Casing preiodically , system
correction required
Drive Belts too loose and squealing Adjust belt tension
Too much grease in Consult manual for
bearing lubrication amount and
interval
Poor alignment Correct
Bent shaft Replace
OVER HEATED Abnormal end thrust Check antithrust blade
BEARING in impeller
Dirt in bearing Clean
Pinching effect on bearing Interference fit of bearing outer Repalce housing with
outer race race in housing correct tolerance
Bearing outer race in Loose housing fit Repalce housing with
rotating in housing correct tolerance
HOW TO ORDER ….
YOUR DATA ABOUT THE :

Installation
process details and position of the fan
site elevation m electrical frequency Hz
Inlet conditions
Pressure : TOTAL or STATIC + mm W C
flow : m 3/s
temperature : °C
relative humidity %
Outlet conditions
Pressure : TOTAL or STATIC mm W C
Gas
dust concentration g/m 3
Possibility of: BUILD UP CORROSION EROSION
Fan
design temperature °C
flow regulation with : IN LET DAM PER IN LET VAN E CONTROL
VARIABLE SPEED
general arrangement :SINGLE INLET DOUBLE INLET COUPLING
OVER HUNG IM PELLER IMPELLER BETW EEN BEARINGS BELT DRIVE
M ATERIAL or SEALS impositions
CONTENT
ADDRESS AND CONTACT NOS.
MARKETING OFFICES
ADDRESS TEL. NO FAX NO
Hyderabad 040 23390397 040 23390397
Flat no : 202 flakthyd@vsnl.net
Major Residency
(Near AP police officer's
Mess)
Masab Tank
Hyderabad-500028
Pune 020 5534442 020 5534442

Masters Executive Center flaktpune@vsnl.net
Pvt. Ltd.
"Sneha Leela"
1237 , Apte Road
Deccan Gymkhana
Pune - 411004
Mumbai 022 56978940-043 022 56978944
301-303, Chintamani Plaza kj.shah@flaktindia.com
3rd Floor
Andheri Kurla Road , Chakla
Andheri(East)
Mumbai - 400093
Landmark : Opp. German
Remedies
New Delhi 011 26484405. 011 26470630
Shivaram Busines Center 26484463,26484467,2
Greater Kailash Part 11 6286837,43
W-16 , New Delhi-110048 nokesh@flaktindia.com
MANUFACTURING ACTIVITIES
Kolkata 033 24901811 033 24902411
P.O & Villa. Jalkhura
Maheshtala
Dist : South 24 Pgns.
West Bengal -743352
Chennai 044 26272216 044 26272606

Village : Numbal
110, Poonamalle High Road
Chennai - 6000077
CONTENT
INSTRUCTION MANUAL
DESCRIPTION
IDENTIFICATION SHEET
FLAKT REFERENCE
REF. DRG. NO.
APPLICATION
CUSTOMER
FAN DESCRIPTION :-
MAIN CHARACTERISTICS
DEFINITION UNIT RATED LOAD
RATED GAS FLOW KG/S

DIFFERENTIAL STATIC PRESSURE (mmWC)/Pa
TOTAL EFFICIENCY %
RATED OPERATING TEMPERATURE °C
MECHANICAL DESIGN TEMPERATURE °C
FAN SPEED RPM
DENSITY AT 180 ° C Kg/AM³
CRITICAL SPEED RPM
RATED FAN POWER KW
MOTOR POWER KW
FAN WEIGHT KG
FAN ACESSORIES WEIGHT KG
MOTOR WEIGHT KG.
DYNAMIC LOAD DUE TO ROTOR KGF.
GD² VALUE kg.M²
IMPELLER DIA mm
IMPELLER WEIGHT KG.
DAMPER OPERATING FORCE N
ACTUATOR STROKE LENGTH mm
BEARING LUBRICATION
INSULATION AREA (M2) mm
SHAFT DIA AT BRG. mm
CONTENT
CHARACTERISTIC CURVES FOR PA FAN
CONTENT
Application : FD Fan
MODEL NO : DY SLIA 181 3TS8A

30% BMCR A 100%BMCR 100% TMCR 60% TMCR
Design point
Sl. No: Description Unit HFO FIRING Perf.coal Perf.coal Perf.coal
5 4 3 2 1
1 Volume m3/s 49.79 41.18 41.43 26.12 55.13
2 Total head developed mmWC 179 240 242 145 345
3 Temperature of Medium °C 32 32 32 32 50
4 Density of Medium kg/m3 1.099 1.099 1.099 1.099 1.049
5 Fan Speed rpm 980 980 980 980 980
6 Shaft power kW 176 172 173 126 233
Rev Particulars By Approved Date Name Date

A HFO FIRING POINT INCORPORATED. M.S N.M.K 30/12/10 Prepared M.sankar 04/08/10
Approved N.M.K 04/08/10
GENERAL ASSEMBLY DRAWING FOR PA FAN
CONTENT
LUBE OIL SYSTEM P&ID FOR PA FAN
CONTENT
FD FAN
CONTENT
CONTENTS
ERECTION
ROTOR ALIGNMENT 14
OVERHUNG FAN 18
ACCESSORIES 27 - 28
CONTENTS
MAINTENANCE
LUBRICATION 33 - 35
SOFN HOUSING
BEARING ASSEMBLY 40
OIL LEVEL 41
LUBRICATION 42
MAINTENANCE 43
INLET DIMENSION 44
LIST OF SPARE 45
ANNEX
46
OF FAN
DOS & DON'T'S 47
49 - 51
SUSPECT A PROBLEM
HOW TO ORDER 52

SOLYVENT SERIES
FAN IMPELLER
DISC

SEALS
SQUARE FLANGE
SCROLL PLATE
INLET DAMPER
INLET
INSPECTION DOOR
SHROUD
SHAPPED INLET
SHAFT TECHNOLOGY
SQUARE FLANGE

INLET BOX
STIFFENER
BETWEEN BEARINGS
SPLIT FLANGE
SOLEPLATE

PEDESTAL
OR
PELICAN
SQUARE FLANGE
BEARING
CONTENT
SAFETY PRECAUTIONS

momentarily.
replaced.
CONTENT
A. Transport :
rigging.

C. Storage :
General :-
covered premises.
Long term storage
etc.
Storage of bearing
short term storage.
CONTENT
ERECTION
drawing.

CONTENT
grouting.
fig. 13.
FIG. No. 11
CERAMIC ROPE
FIG. No. 12
FIG. No. 13
FIG. No. 14
ROTOR ASSEMBLY :-
shroud.
explained here.

For Overhung fans
drawing.)
base frame.
base frame.
pocket level.
long enough.
assembly drawing.
FIG. No. 15
FIG No. 16
ROTOR ALINGMENT
FIG. No. 17
Fig No. 18
COUPLING ALIGNMENT
grout material.
coupled condition.
FIG No. 19
FIG No.20
FIG No. 21
OVERHUNG FANS
packers.
foundation bolts.
bearings.
drawing.
be carried out.
when used.
necessary.

With tapered bore:
side.
ASSEMBLY PROCEDURE
SKF catalogue.
sleeve.






Bearings with
shields or seats
should not be
heated.
Lifting gear
(housing)







site .


now.

ground level.

Shaft
A kpm Nm
Dia. D ft lb
kgfm Nm
25-65 0 3 29.4 21.7
80 10
90-100 15 5 49 36.1
110 25
A
NOTE :

STATIC PARTS:

parts
ROTOR PARTS:
Shaft alignment :
LUBRICATION:
UTILITIES:
CONTENT

AFTER DISMANTLING

T IMPELLER
P IMPELLER
B IMPELLER


ADMISSIBLE 4.5 7
ALARM LEVEL 10 18
TRIP LEVEL 11.2 20

temperature.


another
regular intervals
noise

pitch noise
MAINTENANCE
RUNNING MAINTENANCE

CONTENT
LUBRICATION
COMPANY BRAND NAME

IOL SERVOGEM EP2
ELF EPEXA No 2

INLET DAMPER
normally.

Grease
when requested.
Oil
filtration .

2.5 2.5 3
4
10 2 2.5
6 1.5 2
4 4
1.5
10
2 8
4
10 6 9
8 4 8
7
d=
6 3 6
10
5 2.5 5
m
m
20
4 2 4
40
60
100
120
80
160
3 1.5 3
200
240
280
360
2.5 2.5
420
2 10 500
2
1.5 7.5 1.5
3
10 5 103
9 4.5 9
8 4 8
7 3.5 7
6 6
5 2.5 5
4 2 4
3 1.5 3
2
2 10 2
1.5 7.5 1.5
2 2
10 10 2
10 2 3 4 5 6 789 103 2 3 4 5 6 7 89 104 2
N = RPM

General formula for

65 80 90 100 110 125 135 140
AT MOUNTING gm 240 310 340 380 470 680 850 1000 1800 2200

400
µ
315
250
Displacement s
200
160
s
IN
A
125
D
RM M
IS
100
S- S
va IB
80 lue
S of LE
T vib
63
IL ra
L tio
50 A nv
D elo
M cit
40 IS y
A S v
31.5
D IB
M LE =
IS rm 11
25 s mm
S /s
20 IB
G LE
v rm
16 O
O
s
=
D
4.
12.5
5m
m/
v rm
10
s
=
1.8
mm
/s
6.3
5
Vi
br
4 at
ion
lev
3.15
el
v of
rm hu
2.5
s= ma
0. np
11
2.0 mm er
/s ce
pt
1.6 ion
1.25
1.0
315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000 10000 12500 16000 20000 25000
MACHINE CLASS IV
400
µ
315
250
Displacement s
200
160
I
s
RM N
125 A
S- D
va M
100 lu I
S e S
of S
80 T vib I
I B
L ra L
63 L tio E
A n
D ve
50 M lo
I ci
S ty
40 A S
D I v
M B
31.5
I L
S E =
S 18
25
I mm
B /s
L
v rm
20 E
s
=
G
7m
16
O
m/
O
D
s
v rm
12.5
s
=
2.
8m
10
m/
s
6.3
5
Vi
br
4 at
io
n
le
3.15
ve
v lo
rm f
2.5 s = hu
0. ma
11
2.0
mm n pe
/s rc
1.6 ep
tio
n
1.25
1.0
315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000 10000 12500 16000 20000 25000
FREE BRG.
FIXED BRG.
NUT

SLEEVE WASHER

C C
mm mm mm mm
30 40 0.020 0.025 0.35 0.4 0.015 0.025 0.040
40 50 0.025 0.030 0.4 0.45 0.020 0.030 0.050
50 65 0.030 0.040 0.45 0.6 0.025 0.035 0.055
65 80 0.040 0.050 0.6 0.75 0.025 0.040 0.070
80 100 0.045 0.060 0.7 0.9 1.75 2.25 0.035 0.050 0.080
100 120 0.050 0.070 0.75 1.1 1.9 2.75 0.050 0.065 0.100
120 140 0.065 0.090 1.1 1.4 2.75 3.5 0.055 0.080 0.110
140 160 0.075 0.100 1.2 1.6 3.0 4.0 0.055 0.090 0.130
160 180 0.080 0.110 1.3 1.7 3.25 4.25 0.060 0.100 0.150
180 200 0.090 0.130 1.4 2.0 3.5 5.0 0.070 0.100 0.160
200 225 0.100 0.140 1.6 2.2 4.0 5.5 0.080 0.120 0.180
225 250 0.110 0.150 1.7 2.4 4.25 6.0 0.090 0.130 0.300
250 280 0.120 0.170 1.9 2.7 4.75 6.75 0.100 0.140 0.220
280 315 0.130 0.190 2.0 3.0 5.0 7.5 0.110 0.150 0.240
315 355 0.150 0.210 2.4 3.3 6.0 8.25 0.120 0.170 0.250
355 400 0.170 0.230 2.6 3.6 6.5 9.0 0.130 0.190 0.290
400 450 0.200 0.260 3.1 4.0 7.75 10 0.130 0.200 0.310
450 500 0.210 0.280 3.3 4.4 8.25 11 0.160 0.230 0.350
500 560 0.240 0.320 3.7 5.0 9.25 12.5 0.170 0.250 0.360
560 630 0.260 0.350 4.0 5.4 10 13.5 0.200 0.290 0.410
630 710 0.300 0.400 4.6 6.2 11.5 15.5 0.210 0.310 0.450.
710 800 0.340 0.450 5.3 7.0 13.3 17.5 0.230 0.350 0.510
800 900 0.370 0.500 5.7 7.8 14.3 19.5 0.270 0.390 0.570
900 1000 0.410 0.550 6.3 8.5 15.8 21 0.300 0.430 0.640
1000 1120 0.450 0.600 6.8 9.0 17 23 0.320 0.480 0.700
1120 1250 0.490 0.650 7.4 9.8 18.5 25 0.340 0.540 0.770


SOFN 610 0,3 53 33 SOFN 310 0,3 53 33
SOFN 611 0,4 53 37 SOFN 311 0,4 53 37
SOFN 612 0,5 60 40 SOFN 312 0,5 60 40
SOFN 614 0,6 65 45 SOFN 314 0,6 65 45
SOFN 616 1,0 73 45 SOFN 316 1,0 73 45
SOFN 517 0,7 63 42 SOFN 217 0,7 63 42
SOFN 518 0,8 68 45 SOFN 218 0,8 68 45
SOFN 618 1,4 80 55 SOFN 318 1,4 80 55
SOFN 519 0,9 70 50 SOFN 219 0,9 70 50
SOFN 520 1,0 70 50 SOFN 220 1,0 70 50
SOFN 620 1,8 85 57 SOFN 320 1,8 85 57
SOFN 522 1,3 77 50 SOFN 222 1,3 77 50
SOFN 622 2,0 95 67 SOFN 322 2,0 95 67
SOFN 524 1,7 80 60 SOFN 224 1,7 80 60
SOFN 624 2,8 100 65 SOFN 324 2,8 100 65
SOFN 526 2,3 85 60 SOFN 226 2,3 85 60
SOFN 626 3,4 105 70 SOFN 326 3,4 105 70
SOFN 528 2,4 85 60 SOFN 228 2,4 85 60
SOFN 628 4,2 115 70 SOFN 328 4,2 115 70
SOFN 530 2,8 90 60 SOFN 230 2,8 90 60
SOFN 630 6,0 120 75 SOFN 330 6,0 120 75
SOFN 532 3,3 95 65 SOFN 232 3,3 95 65
SOFN 632 6,5 125 80 SOFN 332 6,5 125 80
SOFN 534 5,0 105 75 SOFN 234 5,0 105 75
SOFN 634 7,5 130 85 SOFN 334 7,5 130 85
SOFN 536 5,2 115 80 SOFN 236 5,2 115 80
SOFN 636 10,5 155 90 SOFN 336 10,5 155 90
SOFN 538 5,8 120 85 SOFN 238 5,8 120 85
SOFN 540 7,0 125 85 SOFN 240 7,0 125 85
SOFN 544 8,5 140 95 SOFN 244 8,5 140 95
SOFN 548 9,5 155 110 SOFN 248 9,5 155 110
changed.
adequate.
INLET DIMENSION
As refer to drawing
LIST OF SPARES

ANNEX
CUSTOMER: FAN TYPE:
DURATION :

Vel. POSITION
FAN DE. BEARING
FAN NDE. BEARING
MOTOR DE. BEARING
MOTOR NDE. BEARING

kW
DE NDE DE NDE
1
2
3
4
5
6
7

ANNEX
DO’S & DONT’S
DO’S :
THE FAN.
CASING ETC.
POURING NEW OIL.

DONT’S :
CONDITION.

ANNEX


BEARING HOUSING.
HOUSING”




DESIGN.
ANNEX

POSSIBLE CAUSE
PROBLEM
got bent
trend ; Clean the
impeller
catalogue.
operation
PREMATURE
BEARING
FAILURE
and interval
ANNEX

POSSIBLE CAUSE
PROBLEM
PREMATURE
tolerance
BEARING
FAILURE
selection
coupling selection
condition .
correction .
adjusted.
given on casing by
arrow mark
ANNEX

POSSIBLE CAUSE
PROBLEM
and expansion joint
providing flexible
connection piece.
correction required
interval
Bent shaft Replace
BEARING in impeller
HOW TO ORDER ….

Installation
Inlet conditions
flow : m 3/s
temperature : °C
relative humidity %
Outlet conditions
Gas
Fan
VARIABLE SPEED
CONTENT
MARKETING OFFICES
Hyderabad 040 23390397 040 23390397
Major Residency
Mess)
Masab Tank
Hyderabad-500028
Pune 020 5534442 020 5534442

Pvt. Ltd.
"Sneha Leela"
1237 , Apte Road
Deccan Gymkhana
Pune - 411004
Mumbai 022 56978940-043 022 56978944
3rd Floor
Andheri(East)
Mumbai - 400093
Remedies
New Delhi 011 26484405. 011 26470630
Kolkata 033 24901811 033 24902411
Maheshtala
West Bengal -743352
Chennai 044 26272216 044 26272606

Village : Numbal
Chennai - 6000077
CONTENT
INSTRUCTION MANUAL
DESCRIPTION
FLAKT REFERENCE
REF. DRG. NO.
APPLICATION
CUSTOMER
FAN DESCRIPTION :-
RATED GAS FLOW KG/S

TOTAL EFFICIENCY %
FAN SPEED RPM
CRITICAL SPEED RPM
RATED FAN POWER KW
MOTOR POWER KW
FAN WEIGHT KG
MOTOR WEIGHT KG.
GD² VALUE kg.M²
IMPELLER DIA mm
IMPELLER WEIGHT KG.
BEARING LUBRICATION
CONTENT
CHARACTERISTIC CURVES FOR FD FAN
CONTENT
Application : PA Fan
MODEL NO : DL SLIA 202 3TS8A
100% TMCR 100% BMCR 60% TMCR
Design point
Sl. No: Description Unit Perf.coal Perf.coal Perf.coal
1 2 3 4
1 Volume m3/s 61.7 33.14 38.71 27.91
2 Total head developed mmWC 1295 912 800 668
3 Temperature of Medium °C 50 32 32 32
4 Density of Medium kg/m3 1.049 1.099 1.099 1.099
5 Fan Speed rpm 1485 1485 1485 1485
6 Shaft power kW 914 542 574 464

Prepared M.Sankar 10/08/10
GENERAL ASSEMBLY DRAWING FOR FD FAN
CONTENT
LUBE OIL SYSTEM P&ID FOR FD FAN
CONTENT
ID FAN
CONTENT
CONTENTS
ERECTION
ROTOR ALIGNMENT 14
OVERHUNG FAN 18
ACCESSORIES 27 - 28
CONTENTS
MAINTENANCE
LUBRICATION 33 - 35
SOFN HOUSING
BEARING ASSEMBLY 40
OIL LEVEL 41
LUBRICATION 42
MAINTENANCE 43
INLET DIMENSION 44
LIST OF SPARE 45
ANNEX
46
OF FAN
DOS & DON'T'S 47
49 - 51
SUSPECT A PROBLEM
HOW TO ORDER 52

SOLYVENT SERIES
FAN IMPELLER
DISC

SEALS
SQUARE FLANGE
SCROLL PLATE
INLET DAMPER
INLET
INSPECTION DOOR
SHROUD
SHAPPED INLET
SHAFT TECHNOLOGY
SQUARE FLANGE

INLET BOX
STIFFENER
BETWEEN BEARINGS
SPLIT FLANGE
SOLEPLATE

PEDESTAL
OR
PELICAN
SQUARE FLANGE
BEARING
CONTENT
SAFETY PRECAUTIONS

momentarily.
replaced.
CONTENT
A. Transport :
rigging.

C. Storage :
General :-
covered premises.
Long term storage
etc.
Storage of bearing
short term storage.
CONTENT
ERECTION
drawing.

CONTENT
grouting.
fig. 13.
FIG. No. 11
CERAMIC ROPE
FIG. No. 12
FIG. No. 13
FIG. No. 14
ROTOR ASSEMBLY :-
shroud.
explained here.

For Overhung fans
drawing.)
base frame.
base frame.
pocket level.
long enough.
assembly drawing.
FIG. No. 15
FIG No. 16
ROTOR ALINGMENT
FIG. No. 17
Fig No. 18
COUPLING ALIGNMENT
grout material.
coupled condition.
FIG No. 19
FIG No.20
FIG No. 21
OVERHUNG FANS
packers.
foundation bolts.
bearings.
drawing.
be carried out.
when used.
necessary.

With tapered bore:
side.
ASSEMBLY PROCEDURE
SKF catalogue.
sleeve.






Bearings with
shields or seats
should not be
heated.
Lifting gear
(housing)







site .


now.

ground level.

Shaft
A kpm Nm
Dia. D ft lb
kgfm Nm
25-65 0 3 29.4 21.7
80 10
90-100 15 5 49 36.1
110 25
A
NOTE :

STATIC PARTS:

parts
ROTOR PARTS:
Shaft alignment :
LUBRICATION:
UTILITIES:
CONTENT

AFTER DISMANTLING

T IMPELLER
P IMPELLER
B IMPELLER


ADMISSIBLE 4.5 7
ALARM LEVEL 10 18
TRIP LEVEL 11.2 20

temperature.


another
regular intervals
noise

pitch noise
MAINTENANCE
RUNNING MAINTENANCE

CONTENT
LUBRICATION
COMPANY BRAND NAME

IOL SERVOGEM EP2
ELF EPEXA No 2

INLET DAMPER
normally.

Grease
when requested.
Oil
filtration .

2.5 2.5 3
4
10 2 2.5
6 1.5 2
4 4
1.5
10
2 8
4
10 6 9
8 4 8
7
d=
6 3 6
10
5 2.5 5
m
m
20
4 2 4
40
60
100
120
80
160
3 1.5 3
200
240
280
360
2.5 2.5
420
2 10 500
2
1.5 7.5 1.5
3
10 5 103
9 4.5 9
8 4 8
7 3.5 7
6 6
5 2.5 5
4 2 4
3 1.5 3
2
2 10 2
1.5 7.5 1.5
2 2
10 10 2
10 2 3 4 5 6 789 103 2 3 4 5 6 7 89 104 2
N = RPM

General formula for

65 80 90 100 110 125 135 140
AT MOUNTING gm 240 310 340 380 470 680 850 1000 1800 2200

400
µ
315
250
Displacement s
200
160
s
IN
A
125
D
RM M
IS
100
S- S
va IB
80 lue
S of LE
T vib
63
IL ra
L tio
50 A nv
D elo
M cit
40 IS y
A S v
31.5
D IB
M LE =
IS rm 11
25 s mm
S /s
20 IB
G LE
v rm
16 O
O
s
=
D
4.
12.5
5m
m/
v rm
10
s
=
1.8
mm
/s
6.3
5
Vi
br
4 at
ion
lev
3.15
el
v of
rm hu
2.5
s= ma
0. np
11
2.0 mm er
/s ce
pt
1.6 ion
1.25
1.0
315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000 10000 12500 16000 20000 25000
MACHINE CLASS IV
400
µ
315
250
Displacement s
200
160
I
s
RM N
125 A
S- D
va M
100 lu I
S e S
of S
80 T vib I
I B
L ra L
63 L tio E
A n
D ve
50 M lo
I ci
S ty
40 A S
D I v
M B
31.5
I L
S E =
S 18
25
I mm
B /s
L
v rm
20 E
s
=
G
7m
16
O
m/
O
D
s
v rm
12.5
s
=
2.
8m
10
m/
s
6.3
5
Vi
br
4 at
io
n
le
3.15
ve
v lo
rm f
2.5 s = hu
0. ma
11
2.0
mm n pe
/s rc
1.6 ep
tio
n
1.25
1.0
315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000 10000 12500 16000 20000 25000
FREE BRG.
FIXED BRG.
NUT

SLEEVE WASHER

C C
mm mm mm mm
30 40 0.020 0.025 0.35 0.4 0.015 0.025 0.040
40 50 0.025 0.030 0.4 0.45 0.020 0.030 0.050
50 65 0.030 0.040 0.45 0.6 0.025 0.035 0.055
65 80 0.040 0.050 0.6 0.75 0.025 0.040 0.070
80 100 0.045 0.060 0.7 0.9 1.75 2.25 0.035 0.050 0.080
100 120 0.050 0.070 0.75 1.1 1.9 2.75 0.050 0.065 0.100
120 140 0.065 0.090 1.1 1.4 2.75 3.5 0.055 0.080 0.110
140 160 0.075 0.100 1.2 1.6 3.0 4.0 0.055 0.090 0.130
160 180 0.080 0.110 1.3 1.7 3.25 4.25 0.060 0.100 0.150
180 200 0.090 0.130 1.4 2.0 3.5 5.0 0.070 0.100 0.160
200 225 0.100 0.140 1.6 2.2 4.0 5.5 0.080 0.120 0.180
225 250 0.110 0.150 1.7 2.4 4.25 6.0 0.090 0.130 0.300
250 280 0.120 0.170 1.9 2.7 4.75 6.75 0.100 0.140 0.220
280 315 0.130 0.190 2.0 3.0 5.0 7.5 0.110 0.150 0.240
315 355 0.150 0.210 2.4 3.3 6.0 8.25 0.120 0.170 0.250
355 400 0.170 0.230 2.6 3.6 6.5 9.0 0.130 0.190 0.290
400 450 0.200 0.260 3.1 4.0 7.75 10 0.130 0.200 0.310
450 500 0.210 0.280 3.3 4.4 8.25 11 0.160 0.230 0.350
500 560 0.240 0.320 3.7 5.0 9.25 12.5 0.170 0.250 0.360
560 630 0.260 0.350 4.0 5.4 10 13.5 0.200 0.290 0.410
630 710 0.300 0.400 4.6 6.2 11.5 15.5 0.210 0.310 0.450.
710 800 0.340 0.450 5.3 7.0 13.3 17.5 0.230 0.350 0.510
800 900 0.370 0.500 5.7 7.8 14.3 19.5 0.270 0.390 0.570
900 1000 0.410 0.550 6.3 8.5 15.8 21 0.300 0.430 0.640
1000 1120 0.450 0.600 6.8 9.0 17 23 0.320 0.480 0.700
1120 1250 0.490 0.650 7.4 9.8 18.5 25 0.340 0.540 0.770


SOFN 610 0,3 53 33 SOFN 310 0,3 53 33
SOFN 611 0,4 53 37 SOFN 311 0,4 53 37
SOFN 612 0,5 60 40 SOFN 312 0,5 60 40
SOFN 614 0,6 65 45 SOFN 314 0,6 65 45
SOFN 616 1,0 73 45 SOFN 316 1,0 73 45
SOFN 517 0,7 63 42 SOFN 217 0,7 63 42
SOFN 518 0,8 68 45 SOFN 218 0,8 68 45
SOFN 618 1,4 80 55 SOFN 318 1,4 80 55
SOFN 519 0,9 70 50 SOFN 219 0,9 70 50
SOFN 520 1,0 70 50 SOFN 220 1,0 70 50
SOFN 620 1,8 85 57 SOFN 320 1,8 85 57
SOFN 522 1,3 77 50 SOFN 222 1,3 77 50
SOFN 622 2,0 95 67 SOFN 322 2,0 95 67
SOFN 524 1,7 80 60 SOFN 224 1,7 80 60
SOFN 624 2,8 100 65 SOFN 324 2,8 100 65
SOFN 526 2,3 85 60 SOFN 226 2,3 85 60
SOFN 626 3,4 105 70 SOFN 326 3,4 105 70
SOFN 528 2,4 85 60 SOFN 228 2,4 85 60
SOFN 628 4,2 115 70 SOFN 328 4,2 115 70
SOFN 530 2,8 90 60 SOFN 230 2,8 90 60
SOFN 630 6,0 120 75 SOFN 330 6,0 120 75
SOFN 532 3,3 95 65 SOFN 232 3,3 95 65
SOFN 632 6,5 125 80 SOFN 332 6,5 125 80
SOFN 534 5,0 105 75 SOFN 234 5,0 105 75
SOFN 634 7,5 130 85 SOFN 334 7,5 130 85
SOFN 536 5,2 115 80 SOFN 236 5,2 115 80
SOFN 636 10,5 155 90 SOFN 336 10,5 155 90
SOFN 538 5,8 120 85 SOFN 238 5,8 120 85
SOFN 540 7,0 125 85 SOFN 240 7,0 125 85
SOFN 544 8,5 140 95 SOFN 244 8,5 140 95
SOFN 548 9,5 155 110 SOFN 248 9,5 155 110
changed.
adequate.
INLET DIMENSION
As refer to drawing
LIST OF SPARES

ANNEX
CUSTOMER: FAN TYPE:
DURATION :

Vel. POSITION
FAN DE. BEARING
FAN NDE. BEARING
MOTOR DE. BEARING
MOTOR NDE. BEARING

kW
DE NDE DE NDE
1
2
3
4
5
6
7

ANNEX
DO’S & DONT’S
DO’S :
THE FAN.
CASING ETC.
POURING NEW OIL.

DONT’S :
CONDITION.

ANNEX


BEARING HOUSING.
HOUSING”




DESIGN.
ANNEX

POSSIBLE CAUSE
PROBLEM
got bent
trend ; Clean the
impeller
catalogue.
operation
PREMATURE
BEARING
FAILURE
and interval
ANNEX

POSSIBLE CAUSE
PROBLEM
PREMATURE
tolerance
BEARING
FAILURE
selection
coupling selection
condition .
correction .
adjusted.
given on casing by
arrow mark
ANNEX

POSSIBLE CAUSE
PROBLEM
and expansion joint
providing flexible
connection piece.
correction required
interval
Bent shaft Replace
BEARING in impeller
HOW TO ORDER ….

Installation
Inlet conditions
flow : m 3/s
temperature : °C
relative humidity %
Outlet conditions
Gas
Fan
VARIABLE SPEED
CONTENT
MARKETING OFFICES
Hyderabad 040 23390397 040 23390397
Major Residency
Mess)
Masab Tank
Hyderabad-500028
Pune 020 5534442 020 5534442

Pvt. Ltd.
"Sneha Leela"
1237 , Apte Road
Deccan Gymkhana
Pune - 411004
Mumbai 022 56978940-043 022 56978944
3rd Floor
Andheri(East)
Mumbai - 400093
Remedies
New Delhi 011 26484405. 011 26470630
Kolkata 033 24901811 033 24902411
Maheshtala
West Bengal -743352
Chennai 044 26272216 044 26272606

Village : Numbal
Chennai - 6000077
CONTENT
INSTRUCTION MANUAL
DESCRIPTION
FLAKT REFERENCE
REF. DRG. NO.
APPLICATION
CUSTOMER
FAN DESCRIPTION :-
RATED GAS FLOW KG/S

TOTAL EFFICIENCY %
FAN SPEED RPM
CRITICAL SPEED RPM
RATED FAN POWER KW
MOTOR POWER KW
FAN WEIGHT KG
MOTOR WEIGHT KG.
GD² VALUE kg.M²
IMPELLER DIA mm
IMPELLER WEIGHT KG.
BEARING LUBRICATION
CONTENT
CHARACTERISTIC CURVES FOR ID FAN
CONTENT
Application : ID Fan
MODEL NO : FN TDR 248 3TD8A
100%BMCR 100% TMCR 60% TMCR
Design point
Sl. No: Description Unit Perf.coal Perf.coal Perf.coal
3 2 4 1
1 Volume m3/s 117.96 107.93 74.20 149.26
2 Total head developed mmWC 268 229 130 330
3 Temperature of Medium °C 135 130 115 150
4 Density of Medium kg/m3 0.814 0.824 0.864 0.800
5 Fan Speed rpm 620 569 413 720
6 Shaft power kW 370 290 113 590

Prepared M.sankar 04/08/10
GENERAL ASSEMBLY DRAWING FOR ID FAN
CONTENT
LUBE OIL SYSTEM P&ID FOR ID FAN
CONTENT
VARIABLE SPEED HYDRAULIC COUPLING
FOR ID FAN
CONTENT
INDEX
Variable Speed Coupling

Type 1150 SVNL 21-18, 5.1
Code: !"#$%&'("))"*)
Serial No.: +!",#++$%&'#-'$$'
SO No.: SOS-!"-+!"
Instruction Manual 1
Disassembly / Reassembly Manual 2
Drawings, Schematic Drawings, Diagrams 3
Parts List 4
Attaching Parts 5
Amendment Report
Version 1.00
Amendments, exchange
of individual
chapters/ sheets
in the instruction manual.
Addendums within an
instruction manual
Complete
exchange of the whole
instruction manual
Version Remark Date

1.00 First edition instruction manual 20!(-+%.)*
Date Prepared by Date Head - Design & Engg. Service

20/+-+%.)* #####$%&'() ####20/+.+%.)* ###$%&'%*
I
VOITH TURBO
POWERTRANSMISSION
VARIABLE SPEED TURBO COUPLING
Type: 1150 SVNL 21-18, 5.1
Code : Cethar Vessels
Version No.0!"S#00$%& to $$'
Serial No. 113-00$%& to $$'
SOS No: SOS-()-0!"
Instruction Manual
CONTENT
Should you have any question with regard to the VARIABLE SPEED TURBO COU-
PLING, please contact the Service department (SMs) of the product group variable
speed drives of Voith Turbo Pvt. Ltd., Hyderabad stating the serial number.
Voith Turbo Pvt. Ltd.

P.O. Industrial Estate
Nacharam, Hyderabad 500 076
INDIA.
Phone : +91 40 27171440 / 27173592 / 27173561

Fax : +91 40 27171141
Service department of the product group variable speed drives

SMs
Telephone: dial the above nos.
E-mail : vtip.service@voith.com
chelluboina.prasad@voith.com
This instruction manual describes the technical state of VARIABLE SPEED TURBO
COUPLING on delivery.
Any later modifications on the VARIABLE SPEED TURBO COUPLING are not con-
sidered in this instruction manual.
!"#1!
This instruction manual is protected by copyright. It is neither allowed to translate or
copy it (by mechanical or electronic or any other process) as a whole or in parts,
nor to submit it to third parties, without the publisher’s written approval.
Date of issue : 0!/201!

Version : 0.00
Printed in India
Contents of
Instruction Manual
1 Technical Data............................................................................................ .......... 1
1.1 Machine Data........................................................................................... .......... 1
1.2 Operating data.......................................................................................... .......... 3

1.2.1 VARIABLE SPEED TURBO COUPLING.............................................. .......... 3
1.2.2 Heat Exchanger..................................................................................... .......... 4
2 Safety Information...................................................................................... .......... 5
2.1 Meaning of symbols and notes................................................................. .......... 5
2.2 Use in accordance with the regulations.................................................... .......... 5
2.3 Organisational measures ........................................................................ .......... 6
2.4 Selection and qualification of staff........................................................... .......... 6
2.5 Individual operating phases...................................................................... .......... 7
2.6 Warranty .................................................................................................. .......... 8
3 Design and Operation................................................................................. .......... 9
3.1 Design...................................................................................................... .......... 9
3.2 Power transmission.................................................................................. .......... 11
3.3 Speed control........................................................................................... .......... 12
3.4.1 Self-lubrication....................................................................................... .......... 13
3.4.2 Lubrication of external units.................................................................. .......... 13
4 Transport and Storage................................................................................ .......... 14
4.1 Safetry information................................................................................... .......... 14
4.2 As delivered condition.............................................................................. .......... 15
1
4.2.1 Assembly condition and test run........................................................... .......... 15
4.2.2 Preservation and packing...................................................................... .......... 15
4.3 Storage and preservation......................................................................... .......... 16
4.4 Unpacking, transportation........................................................................ .......... 17
5 Assembly..................................................................................................... .......... 22
5.1 Safety information.................................................................................... .......... 22
5.2 Tool and auxiliary means......................................................................... .......... 23
5.3 Mounting the connecting couplings.......................................................... .......... 24
5.4 Setting the machine on foundation........................................................... .......... 25

5.4.1 Setting down on a concrete foundation................................................. .......... 25
5.4.2 Setting down on a steel foundation....................................................... .......... 26
5.5 Machine alignment................................................................................... .......... 27

5.5.1 Shaft misalignment and alignment tolerance ....................................... .......... 27
5.5.2 Connecting couplings with intermediate piece...................................... .......... 29
5.5.3 Connecting couplings without intermediate piece................................. .......... 31
5.6 Machine fixing.......................................................................................... .......... 33
5.7 Machine and cooler pipework................................................................... .......... 34

5.7.1 Oil cooler installation............................................................................. .......... 34
5.7.2 Assembly of oil pipes............................................................................. .......... 35
5.7.3 Pickling of oil pipes................................................................................ .......... 36
5.8 Connection of electrical instruments........................................................ .......... 37
5.9 Mounting of guards................................................................................... .......... 38

5.9.1 Mounting the protection against accidental contact.............................. .......... 38
5.9.2 Mounting the acoustic cover.................................................................. .......... 39
5.10 Fitting a scoop tube actuator.................................................................. .......... 40
6 Commissioning............................................................................................ .......... 41
6.2 Operation oil fill......................................................................................... .......... 42
6.3 Test run.................................................................................................... .......... 43

6.3.1 Test run preparation ............................................................................. .......... 43
6.3.2 Test run performance............................................................................ .......... 44
6.3.3 Operating fluids................................................................................................45
2
7 Operation..................................................................................................... .......... 47
7.2 Machine start-up and rundown................................................................. .......... 48
7.3 Machine operation.................................................................................... .......... 49

7.3.1 Machine monitoring............................................................................... .......... 49
7.3.2 Speed Control....................................................................................... .......... 51
7.3.3 Double oil filter changeover................................................................... .......... 51
7.4 Measures in case of tailspin and reverse rotation.................................... .......... 53
7.5 Measures to be taken during stop periods............................................... .......... 54
8 Maintenance and repair.............................................................................. .......... 55
8.1 Maintenance measures and intervals....................................................... .......... 55
8.2 Cleaning the double oil filter.................................................................................57
8.3 Inspection of hose lines............................................................................ .......... 59
8.4 Checking the oil for water content and impurities..................................... .......... 59
8.5 Replacement of fusible plugs................................................................... .......... 60
8.6 Cross references...................................................................................... .......... 61
9 Trouble shooting....................................................................................... .......... 62
9.1 Start-up..................................................................................................... .......... 62
9.2 Output speed............................................................................................ .......... 63
9.3 Pressures................................................................................................. .......... 64
9.4 Temperatures........................................................................................... .......... 65
9.5 Quiet running............................................................................................ .......... 66
9.6 Cross references..................................................................................................67
3
1 Technical Data

Type 1150 SVNL 21-18,5.1
Version Nos - 0!"S#00$%& to !!"
Serial Nos. 113-00$%& to !!"
SO No: SOS-'(-0#$
1.1 Machine Data
VARIABLE SPEED
TURBO COUPLING
Rotation seen in direction of the power flow CCW

Scoop tube stroke !"# mm
Power requirements of driven machine Pa )&( !W
Motor speed ne 7!" rpm
Min.slip (Approx.) s 2.3%
Max.output speed na, max 72# rpm
Regulating range #:1 downward
Oil tank filling capacity 780 L

APPROX.
Required oil viscosity ISO VG$32
Weight (without oil ) [approx.] 3500 kg
Noise emission :1
• Measuring surface sound pressure level Lpa 85 dB
1 Measurement to DIN 45 635 Part 1 and 23

Values derived from measurements conducted on similar units
1
1 Technical Data 1.1 Machine data
Attaching parts
Pump insert
Pump 1 filling pump for working oil and lube

oil circuit
Type of filling pump TZP 450 C
Drive Jointly by the input shaft of VARIA-

BLE SPEED TURBO COUPLING
Scoop tube actuator
Type Pneumatic Actuator
Accessories I P Converter,Positioner & Position

feed back transmitter
Model *+0808 Make: Keltron
Connecting couplings
Input end Cubic Transmissions Ltd.

Model EH- 325 -10 mm DBSE
Output end Cubic Transmissions Ltd.

Model EH-325-220 mm DBSE
Heat exchanger
Type of cooler & Make Duplex - Horizontal; Make: !"#$%&"'
Instruments
See part 5 “Attaching parts” in this documentation
! Regarding a detailed documentation of the above mentioned components,

please refer to part 5 “Attaching parts” of this documentation.
2
1 Technical Data 1.2 Operating data
1.2 Operating data
1.2.1 VARIABLE SPEED TURBO COUPLING
Temperatures( )1
Working oil temperature down- Operating range < 100°C

stream of scoop tube (18) Alarm at > 100°C
Working oil temperature down- Operating range < 100°C

stream of scoop tube (18.1) Shut down > 110°C
Oil temperature upstream of oil Operating range < 95°C

cooler ( 23.1)
Oil temperature downstream of Operating range < 70°C

Heat exchanger (15)
Working oil temperature down- Operating range < 70 °C

stream of cooler (33) Alarm at > 80°C
Working oil temperature dow- Operating range < 70 °C

stream of cooler (33.1) Shutdown at > 90°C
1 The item numbers shown in brackets indicate the measuring points according to ! the function and
measuring point diagram in part 3 “Schematic drawings”.
Pressures( )1
Lube oil pressure downstream Operating range ~ 0.3 bar

of -&0102"'(16)

of filter( 17 ) Alarm at < 0.8 bar

of filter( 17.1 ) Shut down at < 0.6 bar
Differential pressure "#$%&& Operating range ~ 0.3 bar

the double %'()*'(+,)$ -$.!/ Alarm at > 0.6 ba r
' ''''''''' '''''' ''''' (changeover filter)
Oil pressure at test connection Operating range as per above val-

(55) ues at measur-
ing points 16; 17
1 The item numbers shown in brackets indicate the measuring points according to ! the function and
measuring point diagram in part 3 “Schematic drawings”.
3
VOITH TURBO
POWERTRANSMISSION
Oil flow rates
Working oil flow rate ~ 440 l/min
Lube oil flow rate to the VARIABLE ~ 10 l/min

SPEED TURBO COUPLING at 0.3bar
Actuator
Actuating speed Approximately 60 sec.
1.22 Heat Exchanger
Heat Exchanger Working Oil Shell Chamber Tube Chamber

(Oil) (Water)
Medium Oil Water

(ISO VG32)
Flow rate, m3/hr 27 17.36
working temperature Inlet/Outlet,°C 7!/65 32/40
Design temperature, °C 120 70
Design pressure, Kg/cm2 10 10
Hydrostatic test pressure, kg/cm2 g 15 15
No. of passes 1 2
Vibration - Housing
Housing (radial) Good vibration behaviour 5.6 mm/s

alarm at > 8 mm / s1
shutdown at
> 11 mm / s1
Housing (axial) Good vibration behaviour 5.6 mm/s

alarm at > 11 mm / s1
shutdown at
> 18 mm / s1
1 Signal only in the event of corresponding instrumentation or manual signal at site
4
2 Safety Information
2.1 Meaning of symbols and notes
Danger!
This symbol signals an imminent danger to the life and health of people.
If this note is not observed, injury to health and even most serious injuries
may be the consequence.
Warning!
This symbol signals a harmful situation.

If this note is not observed, the product may be damaged.
i Note!
This symbol refers to proper handling of the product. It does not refer to or indicate
a dangerous situation.
Attention!
" This symbol refers to components incorporated in the product, which may be
destroyed by static electricity.
2.2 Use in accordance with the regulations
• The VARIABLE SPEED TURBO COUPLING is provided to transmit power

wearfree from a driving machine to a driven machine. Use the machine only in
accordance with the regulations.
5
2 Safety Information 2.3 OrganisationalMeasures
2.3 Organisational measures
Instruction manual
• The instruction manual contains important information for proper handling of
VARIABLE SPEED TURBO COUPLING. Prior to installation of the machine and,
above all, prior to commissioning of the complete unit, read the instruction manual
carefully and make sure it is understood.
•Keep the instruction manual at a place where it is always available to the operat-
ing staff.
Prevention of accidents/
Environmental protection
•Supplementary to the instruction manual: Have the regulations for prevention of

accidents and for environmental protection ready and observe these.
Constructional Modifications
• In the event of constructional modifications observe :
Danger!
Constructional modifications not done properly on the VARIABLE SPEED
TURBO COUPLING may cause personal injury and damage to property.
Modifications, attachments or retrofits on the VARIABLE SPEED TURBO COU-

PLING are only allowed with the approval of Voith Turbo Pvt. Ltd., Hyderabad
Prior to installing and /or mounting any additional components not belonging to the
scope of supply of Voith Turbo Pvt. Ltd., Hyderabad, check these for internal and
external damage and impurities. Ensure proper function.
2.4 Selection and qualification of staff
Trained staff
•Only trained and instructed staff is allowed to work on the VARIABLE SPEED
TURBO COUPLING. This staff must be trained instructed and authorized to
- Operate and service the units in a professional manner in accordance with the
technical safety standards,
- Dispose of media and its components, e.g. filters, oil filter cartridges and oil,
- Maintain and use safety equipment in accordance with the technical safety stan
dards,
- Prevent accidents and provide first aid.
Staff to be trained
• Allow trained and instructed staff only to work on the VARIABLE SPEED
TURBO COUPLING under supervision of an experienced person.
6
2 Safety Information 2.5 Individual operating phases
2.5 Individual operating phases
Commissioning
• The VARIABLE SPEED TURBO COUPLING may be damaged when
- The machine is started without operating oil,

- The heat exchanger and the heat exchanger pipes were not flushed prior to
commissioning,
- An operating oil is used not permitted by Voith, contaminated operating oil is
filled in,
- The cooling function of heat exchanger is insufficient.
• The VARIABLE SPEED TURBO COUPLING may also be damaged if the driving
machine rotates in the wrong direction of rotation.
Note!
i For perfect operation of VARIABLE SPEED TURBO COUPLING it is necessary to

guarantee the reliability of instruments.
Warning!
The VARIABLE SPEED TURBO COUPLING is supplied without oil filling!
Operation without oil will destroy the machine within a few seconds.
Prior to motor start, fill the variable speed turbo coupling with operating oil
Maintenance
• Do the maintenance work within the specified time!
•!Repair or replace those components immediately, which are not in sound condi
tion. Use original Voith spare parts only!
Danger!
The operating oil of VARIABLE SPEED TURBO COUPLING may be under
pressure.
Disconnect the unit prior to any maintenance and repair work. (observe local
regulations)
Housing, oil pipes, connecting couplings and operating oil may become very
hot - in extreme case upto 130°C. Any contact may cause skin burns.
Let the VARIABLE SPEED TURBO COUPLING cool down prior to any mainte-
nance and repair work !
Cleaning
• When using water or steam jet for cleaning, dirt or water may get into the
machine.
Protect shaft seals (labyrinths) and vent filters on the VARIABLE SPEED
TURBO COUPLING to prevent a direct effect by water or steam jet.
7
2 Safety Information 2.6 Warranty
Waste oil disposal

• Please observe the following when disposing waste oil.
Warning!
Waste oil getting into the sewarage system or to the open soil may cause
major damage to the environment.
Dispose of waste oil in a professional manner according to the national statu-

tory provisions.
2.6 Warranty
Applicable are the conditions and terms mentioned in the General conditions of
Sale of Voith Turbo Pvt. Ltd., Hyderabad. Warranty claims are excluded, if these
are due to one or several of the following causes:
• Improper transportation, storage, set-up, commissioning, operation, mainte-

nance and repair of VARIABLE SPEED TURBO COUPLING,
• Non-observance of the information with regard to the safety at work and of the
product contained in the instruction manual,
• Filling the VARIABLE SPEED TURBO COUPLING with contaminated oil, with
different oil types or with an oil type not included in the list authorized by Voith or
not approved by Voith.
Note!
i
It is only allowed to do repair work on the VARIABLE SPEED TURBO COUPLING
during the warranty period, after Voith Turbo Pvt. Ltd., Hyderabad gave their
approval.
8
3 Design and Operation
3.1 Design
Illustration 1 Design of VARIABLE SPEED TURBO COUPLING
1 Housing With Oil Tank 6 Shell 12 Filling pump

2 Primary shaft 7 Working chamber 13 Scoop tube
3 Primary wheel 8 Scoop chamber 14 Working and
4 Secondary shaft 9 Thrust and radial bearing lube oil cooler
5 Secondary wheel 10 Radial bearing (relative 15 Fusible plug
bearing) 16 Oil tank
11 Ball and roller bearings
9
3 Design and Operation 3.1 Design
Housing
The VARIABLE SPEED TURBO COUPLING is designed with a split in horizontal
direction on the shaft center level. This housing forms the oil tank at the same time.
Coupling
The coupling consists of
• primary shaft and primary wheel,
• secondary shaft and secondary wheel,
• shell (flanged on primary wheel, enclosing the secondary wheel) and
• Scoop tube housing with actuator.
Primary shaft and primary wheel are rigidly connected with each other, the same
applies to secondary wheel and secondary shaft. The primary shaft is connected
with the driving machine and the secondary shaft with the driven machine.
Primary wheel, secondary wheel and shell form the working chamber. The working
oil circulates in the working chamber.
The scoop tube, with scoop tube housing, is integrated in the VARIABLE SPEED
TURBO COUPLING housing. The secondary shaft is supported in the scoop tube
housing.
Bearings
The primary and secondary shaft of VARIABLE SPEED TURBO COUPLING are
supported by ball and roller bearings. The primary shaft is guided axially via a rela-
tive bearing (between primary and secondary shaft)
Oil pumps
A filling pump in the oil tank delivers the operating oil for the working oil and lube oil
lube circuit. The filling pump is mechanically driven by the primary shaft of VARI-
ABLE SPEED TURBO COUPLING .
An electrically driven aux.lube oil pump is installed to supply lube oil to external
units during start up and shut down (Aux. lube oil pump is optional and not a stan-
dard supply. Supplied only on order).
10
3 Design and Operation 3.2 Power transmission
3.2 Power transmission
The VARIABLE SPEED TURBO COUPLING transmits power wearfree from a driv-
ing machine to a driven machine. Power is transmitted as follows:
• Between driving machine and VARIABLE SPEED TURBO COUPLING through

a connecting coupling.
• Hydrodynamically between primary wheel and secondary wheel through the
working oil,
• Between VARIABLE SPEED TURBO COUPLING and driven machine through a
connecting coupling.
Infinitely variable speed control of driven machine is possible by means of the
scoop tube control.
Mechanical energy-
kinetic energy
The power of driving machine is transmitted through the primary wheel (function:
pump) onto the working oil; the working oil is accelerated in the primary wheel, and
the mechanical energy is converted into kinetic energy. The secondary wheel
(function: turbine) absorbs the kinetic energy and converts it back into mechanical
energy. This energy is transmitted to the driven machine.
The same torque applies to primary and secondary wheel.

Slip
On power transmission the speed of secondary wheel is smaller than that of the pri-
mary wheel. This speed difference is called slip. The power loss due to the speed
difference heats up the working oil. It is necessary to cool down the oil to dissipate
this heat.
Working oil circuit
Through the working oil orifice plate the oil flows into the coupling working chamber
and, due to centrifugal force, forms a rotating oil ring in the scoop chamber. The
scoop tube position determines the thickness of oil ring in the scoop chamber and
thus also the filing in the working chamber. The scoop tube scoops up the warmed-
up working oil in the working chamber and directs it back into the oil tank from
where the filling pump supplies the working oil to the oil cooler. Then the cooled
down working oil returns into the coupling working chamber through the working oil
orifice plate.
If it is necessary to enlarge the working oil filling in the coupling, adjust the scoop
tube.
Working oil temperature

The working oil temperature depends on the power losses (slip) and the working oil
flow rate and is monitored by temperature measuring instruments.
Fusible plugs
If the oil temperature rises to 160º C (320º F) due to a failure, the solder of fusible
plugs in the coupling melts and oil is thrown into the housing of VARIABLE SPEED
TURBO COUPLING. The coupling drains its oil, thus reducing torque transmission.
11
3 Design and Operation 3.3 Speed control
3.3 Speed control
Illustration 2
Speed control by means
of Scoop tube
1.Actuator
2.Scoop tube rods
3.Scoop tube
4.Oil ring
5.Sc.tube position-0%
6.Sc. tube position-100%
The speed of driven machine may be controlled steplessly. For this purpose, the
coupling oil filling is changed during operation by means of the movable scoop
tube:
• Scoop tube inserted as far as possible in the scoop chamber of coupling (0%
position): minimum oil ring, minimum output speed.
• Scoop tube moved as far as possible out of the scoop chamber of coupling
(100% position): maximum oil ring, maximum output speed.
12
3 Design and Operation 3.4 Lubrication
3.4 Lubrication
3.4.1 Self-lubrication
Bearings and gears of VARIABLE SPEED TURBO COUPLING need to be lubri-
cated prior to and during operation.
Lube oil circuit

During operation the filling pump delivers oil out of the oil tank from which the lube
oil is branched off to the lube oil circuit through the lube oil orifice. Through
• Heat exchanger,
• Double oil filter and
• Lube oil orifice
the filtered and cooled oil gets to the lubrication points.
Lube oil flow rate

The lube oil flow rate required by bearings and gears is set by the lube oil orifice or
bores provided in the spray nozzles.
Only an indirect influence of lube oil flow rate is possible by changing the lube oil
pressure.
Lube oil pressure
The lube oil pressure is set at the lube oil orifice and monitored by pressure mea-
suring instruments (pressure gauge, pressure switch).
Lube oil temperature
The lube oil temperature is monitored by temperature measuring instruments.
3.4.2 Lubrication of external units (not standard supply)
The oil for lubrication of driving machine and driven machine is taken from the lube
oil circuit of VARIABLE SPEED TURBO COUPLING through the external oil orifice
and fed back into the oil tank of VARIABLE SPEED TURBO COUPLING.
Lube oil pressure,
lube oil flow rate
Lube oil pressure and lube oil flow rate are set by the external oil orifice down-
stream of the double oil filter and set by the working oil orifice plate.
The lube oil pressure is monitored by pressure measuring instruments.
Note!
i Lube oil flow rate and lube oil pressure for the supply of external units will be indi-
cated in the order confirmation.
If the supply of external oil to external units becomes necessary only subsequently,
please consult the Voith after-sales-service.
13
4 Transport and Storage
4.1 Safety information
The following safety information refers to the entire chapter and is always to be
observed in addition to the different individual information:
Warning!
Improper lifting of VARIABLE SPEED TURBO COUPLING may cause personal

injury and damage to property.
Hang the VARIABLE SPEED TURBO COUPLING on the marked suspension

points only (label)!
Suspension points located on the VARIABLE SPEED TURBO COUPLING are

provided for the own weight of VARIABLE SPEED TURBO COUPLING! Do not
lift it together with any other machines! Lift the VARIABLE SPEED TURBO
COUPLING only without oil filling!.
Use only proper lifting appliance in compliance with the safety regulations!
Keep away from any suspended load.
Transport the VARIABLE SPEED TURBO COUPLING in lashed condition and

in a shipping crate only and always set it on a suitable solid and level ground!
Set it down on the housing or oil tank feet only!
14
4 Transport and Storage 4.2 As delivered condition
4.2 As delivered condition
4.2.1 Assembly condition and test run
In as delivered condition the VARIABLE SPEED TURBO COUPLING is not ready

for independent use.
Installation condition
• The VARIABLE SPEED TURBO COUPLING is assembled ready for installation.
• All internal pipework for working oil and lube oil is assembled.
• All external pipe connections are provided with weld neck flanges and seals and
are closed for transportation.
• If connecting couplings belong to Voith's scope of supply or are supplied by the

customer, the hubs are mounted on the input and secondary shaft of VARIABLE
SPEED TURBO COUPLING.
• All instruments (pressure gauge, pressure switch etc.) are fitted or installed on
an instrument panel. The panel is fixed at the housing using silent -bloc-type rub-
ber elements.
• The electric indicators and switches are wired to a terminal box.
• The installed instruments are identified.
• Replacement and loose parts for the VARIABLE SPEED TURBO COUPLING
are packed separately.
Test run
Prior to shipment the VARIABLE SPEED TURBO COUPLINGs are tested in Voith's
Test Field according to internal Voith guidelines (with reference to VDI Standard
2153).
4.2.2 Preservation and packing
The VARIABLE SPEED TURBO COUPLING is packed and preserved for a period
of 12 months.
15
4 Transport and Storage 4.3 Storage and preservation
4.3 Storage and preservation
Corrosion protection
in India
On shipment, the VARIABLE SPEED TURBO COUPLING is internally wetted with
oil (either by test oil during the test run or by spraying it with a solvent -free corro-
sion preventing oil). This wetting with oil is a sufficient corrosion protection in
India for a period of 24 months. A condition is that the machine is stored in dry
room.
overseas
For overseas shipments, the VARIABLE SPEED TURBO COUPLING is packed in
an extra foil. Desiccant bags in the packing bind some of the humidity. Machines
packed using this method can also be stored for 24 months in a closed and dry
room. The foil must not be cut or damaged.
Long-term preservation
For VARIABLE SPEED TURBO COUPLINGs to be stored longer than 24 months,
Voith Turbo offers special long-term preservation.
! Section "Preservation Instruction" on page 18.
16
4 Transport and Storage 4.4 Unpacking, transportation
4.4 Unpacking, transportation
The VARIABLE SPEED TURBO COUPLING is shipped in a transport frame in

installation position. If required, it is additionally protected by a crate. The suspen-
sion points are marked on both, the machine and the crate.
1 Remove the crate, if necessary.

2 Affix the VARIABLE SPEED TURBO COUPLING at the marked suspension
points 1 (label 2)
Illustration 3
Suspension points
1 Suspension point
2 Label
3 Unscrew the machine from the transport frame and pull the frame away under
the machine.
4 Set the VARIABLE SPEED TURBO COUPLING down on the oil tank feet.
17
Preservation Instructions
Source: Sheet 74 0080 245
This information refers to internal and surface protection (if the surfaces are not coated and/
or are not corrosion-resistant or made of aluminium casting materials) and to the packing of
shipments.
Table
Preservation
Transport, storage and Packing No. External Internal incl. Internal

period of storage test run without test
run
1. Transport by land/air for Packing External

immediate use at destination No.1 preservation
(or up to 6 months storage in a No.1
closed shed)
Internal pres- Internal pres-

2. Transport by sea and/or up Packing ervation ervation
to 12 months storage from No.2 No.1 No.2
the date of packing External
preservation
3. Transport by sea and/or up Packing No.2
to 24 months storage from No.3
the date of packing
4. Extension of protective Renew foil External Internal pres-

period (on expiry of the pro and weld preservation ervation
tective period) No.3 No.3
External preservation
No.1
• Painting according to the order documentation.
• Bright iron parts sprayed with "Shell Ensis Fluid G" 1 or Eqvt.
• Please see note.
No.2
• Painting according to the order documentation.
• Bright iron parts: If possible, "Valvoline Tectyl 506" or Eqvt. will be applied, oth-
erwise sprayed with "Shell Ensis Fluid G" or Eqvt.
• Please see note.
No.3
• Check external preservation.
• If required, touch up according to external preservation No.2
• Replace the desiccant.
1. Prior to installing the machine or parts, clean sprayed or painted surfaces using a solvent (white
spirit or petroleum).
18
Note!
If the packing sequence with VOITH preservation products is guaranteed for
i
Internal preservation
orders, then the corrosion protection, as agreed, is also allowed using this preser-
vation method.
No.1
• Internal preservation by the oil used for the test run.
•!When the order documentation specifies "inspection" after the test run, spray
with a solvent -free corrosion preventive oil (factory-supplied "Shell Ensis Motor
oil 20" or eqvt.) if available. (Regarding alternative to "Shell Ensis Motor oil 20"
or eqvt. please refer to section "Internal corrosion preventing oils").
• Fill the interior of machine with dry air, relative humidity maximum 10%).
No.2
• Treated with solvent-free corrosion preventing oil (factory-supplied "Shell Ensis
Motor Oil 20" or eqvt.). All assemblies sprayed during installation, as far as
accessible. (Regarding alternatives to "Shell Ensis Motor Oil 20" or eqvt. please
refer to section "Internal corrosion preventing oils")
• Fill the interior of machine with dry air, relative humidity maximum 10%.
No.3
• Check the preservation.
•!Spray runner parts and all walls with solvent -free corrosion preventing oil (e.g.,
"Shell Ensis Motor Oil 20" or eqvt.) and turn runner parts during this process.
(Regarding alternatives to "Shell Ensis Motor Oil 20" or eqvt. please refer to sec-
tion, "Internal corrosion preventing oils").
•!As far as possible, fill the interior of machine with dry air, relative humidity max.
10%.
Internal corrosion preventing oils
Supplier Designation
Shell Shell Ensis Motor oil 20 or eqvt.
Mobil Mobilarma 524 (SAE30) or eqvt.
ESSO ESSO MZK MOTOR OIL HD20W-20
19
Packing No.1
• Transport-specific facility (e.g. transport frame, holder, support)
•!Weather protection by transportation means.
Packing No.2
• Transport -specific facility (e.g. transport frame, holder, support)
• Smooth sharp edges and vertical surfaces using flexible materials.
• Welded in PE foil.
• Desiccant according to DIN 55 473 / 55 474 or Eqvt.
• Waterproof carton or wooden box.
•!Internal box cover with closed PE web plate (Akylux) lining.
• PVC foil placed underneath joint plates.
Packing No.3
• Please refer to packing 2. Difference: welded in solid aluminum foil instead of PE
foil.
To be observed at site:
Units installed or ready

for installation
Observe, in particular, these units with regard to the effectiveness of preservation,
since it is frequently exposed to additional hazards like water, major contamination
and mechanical damage.
Complete units mounted

on the foundation
This includes measures enabling a supplementary internal protection, if periods of
disuse of up to 12 months are to be expected and if the original preservation is no
longer guaranteed due to interventions.
Fill units with operating oil free from any water. Dependent on the installation situa-
tion, the following work may be done within 1 to 2 months intervals:
• Unit ready for service:

Start and operate only for a short time (approx. 5 minutes) to wet the inner parts
with oil, do not run warm.
•!Unit not ready for service:
Note!
The VARIABLE SPEED TURBO COUPLING must be filled with operating oil since
i turning without sufficient lubrication would destroy the VARIABLE SPEED TURBO
COUPLING.
- Units with electric motor driven auxiliary lube oil pump or oil pump and oil tank
ready for service:
- Switch on the pump, turn the unit, if possible. Move the functional parts (e.g.
joints) and regrease.
- Units without the electric motor driven auxiliary lube oil pump or oil pump being
ready for service:
20
Take oil from the sump, spray it through the housing ports into the interior and
transfer the oil through pipes using separate oil pump, running time approx. 5 min-
utes, turn the unit, if possible. Move the functional parts (e.g. joints) and regrease.
Note!
i Prior to filling in the operating fluid consult the supplier with regard to its compatibil-
ity with the internal preservation agent.
21
5 Assembly
observed, in addition to the other individual information.
Warning!
A faulty assembly may cause failures and premature wear of the units.
Assembly and first commissioning should be done by a Voith service engi-

neer, if possible.
Warning!
Creep or stray currents may get through the input shaft into the VARIABLE
SPEED TURBO COUPLING and damage bearings and driving gears of pump
insert by spark erosion. Ground the driving machine accordingly.
Construction chips and rubbish, flying sparks, grinding dust and water may
get into the VARIABLE SPEED TURBO COUPLING and cause malfunctions.
During the construction period at site, cover the complete VARIABLE SPEED
TURBO COUPLING with a tarpaulin. Protect, in particular, instruments,
cables and cable ducts.
22
5 Assembly 5.2 Tools and auxiliary means
Warning!
Hang the VARIABLE SPEED TURBO COUPLING only on the marked suspen-
sion points (label)!.
The suspension points located on the VARIABLE SPEED TURBO COUPLING

are only designed for the own weight of VARIABLE SPEED TURBO COU-
PLING! Do not lift it with any other machines! Lift the VARIABLE SPEED
TURBO COUPLING only without oil filling!
Use only appropriate lifting appliances in compliance with the safety regula-
tions! Keep away from suspended load.
Transport the VARIABLE SPEED TURBO COUPLING in lashed condition and

in a transport frame only and always set it on a suitable solid and level
ground! Set it down on the housing or oil tank feet only!
5.2 Tool and auxiliary means
• Metric tools
• Torque wrench
• Sealing compound (not containing silicone)
• Lifting appliances
• Mounting device for coupling hubs
• Shims (supplied)
• Adjusting screws on the steel foundation for horizontal alignment
• Adjusting screws for vertical alignment (supplied)
• Alignment device
23
5 Assembly 5.3 Mounting the connecting couplings
5.3 Mounting the connecting couplings
Ex works installation
If the connecting couplings are Voith's scope of supply or are supplied by the cus-
tomer, the input and output side connecting coupling halves are already mounted
on delivery :
Please refer to manual attached for mounting.
24
5 Assembly 5.4 Setting the machine on foundation
5.4 Setting the machine on foundation
Prior to setting down

Checks:
• Are the foundation dimensions for all machines on the unit accurate (height, cen-
tral position, flatness)?
• Has the height of steel foundation been adjusted to leave a free space of 10 mm
for the shims to be placed underneath the VARIABLE SPEED TURBO COU-
PLING?
• Is the installation space for the VARIABLE SPEED TURBO COUPLINGs guar-
anteed according to assembly plan?
• Are the connecting coupling sleeves mounted or has a sufficient distance been
provided between the shafts for connecting couplings with intermediate piece, in
order to mount the sleeve later?
• Is it possible to connect the oil pipes after setting the VARIABLE SPEED TURBO
COUPLING down?
• Has the driven machine been fixed in axial position?
• Is the axial clearance of driving machine within the tolerances? Is the rotor of
driving machine in operating position?
• Are the shims available?
5.4.1 Setting down on a concrete foundation
Prerequisites
For setting the VARIABLE SPEED TURBO COUPLING down on a concrete
foundation either
• 2 foundation rails or
• 4 rigid foundation plates
with bores for the foundation bolts are necessary.
Note!
i Apply oil-resistant paint to the foundation to prevent that oil, if it gets in contact with
foundation, may penetrate into the concrete causing damages.
Setting down
1. Set the VARIABLE SPEED TURBO COUPLING down on the concrete founda
tion with suspended foundation bolts, 2 mm shim and foundation rails or plates
using a suitable lifting appliance. Observe the axial clearance of connecting cou
plings in this case.
25
5 Assembly 5.4 Setting the machine on foundation
2. Shim the foundation rails or plates of VARIABLE SPEED TURBO COUPLING

and align roughly.
3. Grout the foundation bolts and foundation rails or plates with concrete and let it
harden.
Illustration 5
Grouting the concrete
foundation
1 Shim (10mm)
2 Adjusting screw
3 Filling compound
4 Shim
5 Tamped concrete
6 Foundation rail (or)
Foundation plate
7 Concrete compound
4. Adjust the coupling height using the supplied adjusting screws.
! Regarding measurements: please see section5.5 "Machine alignment"

Note!
i All machines involved (driving machine, VARIABLE SPEED TURBO COUPLING,

driven machine) should be installed prior to alignment.
5.4.2 Setting down on a steel foundation
Setting down
1. Set the variable speed turbo coupling down on the steel foundation using the
suitable lifting appliance. Observe the axial clearance of connecting couplings in
this case.
2. Adjust the coupling height using the supplied adjusting screws.
3. Shim the coupling using the supplied and greased shims. Adjust the lateral posi
tion of coupling by shifting the coupling on the shims using the adjusting screws.
26
5 Assembly 5.5 Machine alignment
! Regarding measurements: please see section5.5 "Machine alignment"

Note!
i All machines involved (driving machine, VARIABLE SPEED TURBO COUPLING,

driven machine) should be installed prior to alignment.
5.5 Machine alignment
Align the unit components with each other. In this case, all machines must have
standstill temperature. At operating temperature the shafts must be in optimal
alignment.
Normal alignment information please refer to:

1. Align VARIABLE SPEED TURBO COUPLING with the driven machine.
2. Align driving machine with the VARIABLE SPEED TURBO COUPLING.
Note!
i Regarding alignment information please refer to:
1. VDI Directive VDI 2726 "Alignment of Gearboxes"

2. Manual for practical use, "Alignment of Shafts for Machine Sets", VDI Publish
ers.
5.5.1 Shaft misalignment and alignment tolerance
Shaft misalignment
For alignment of VARIABLE SPEED TURBO COUPLING please observe

any dimensional changes resulting from
• Warming-up and expansion of the housing during operation

and
• Rotation-dependent shaft misalignment due to tooth forces, bearing clearances
and hydrodynamic lubrication.
27
Illustration 6
Radial and Axial

displacements
Radial displacements
horizontal " H
Axial displacement " L1
Axial displacement "L2
Radial displacement horizontal "H 0.66 mm
Axial displacement1
• Input end " L1 0.82 mm
• Output end " L2 0.76 mm
1 Assumed housing temperature on installation 20º C (68º F), during operation 80º C (176 º F)
Values correspond to the maximum possible shaft misalignment including bearing clearance.
This means that the shafts, connected with connecting couplings,

shall not be in alignment during standstill, but must be provided with a radial/angu-
lar/axial offset. This offset compensates the misalignment to be expected at start-
up and during operation.
28
Alignment tolerance at When turning the shafts jointly by 360º:

Operating temperature
Speed (rpm) Radial offset (radial Angular displacement

measurement) (angular measurements
B and C)
<1500 ± 0.1 mm ± 0.03 mm/100 mm

radius Rm
<3600 ± 0.05 mm ± 0.02 mm/100 mm

radius Rm
Illustration 7
Angular displacement
and radial offset
1 Machine aligned
2 Machine still to be
aligned
Radial offset horizontal

ah and vetical av
Angular displacement
horizontzl bh and
vertical bv
radius Rm
i Note!
Record the deviations measured after aligning the VARIABLE SPEED TURBO
COUPLING.
5.5.2 Connecting couplings with intermediate piece
In most cases, a connecting coupling with intermediate piece is arranged between

driven machine and VARIABLE SPEED TURBO COUPLING, i.e., there is a space
between the shaft ends.
29
Illustration 8
Alignment using the
alignment device for
connecting coupling
with intermediate piece
1 Machine aligned
2 Machine still to be
aligned
3 Alignment device with
dial gauges
1. Make a solid alignment device of flat bar steel (3) and bolt it to the shaft end of
the machine (2) to be aligned.
2. Insert dial gauges so that they are free from play and secure them.
Radial run out check

3. Radial runout check of the already aligned machine(1): Turn shaft (1) by 360º.
Value to be aimed at: dial gauge deflection # 0.02 mm; permissible value:
! Instruction manual of driven machine.
Precision alignment
Vertical plane
4. Reset dial gauge to the initial value.
5. Turn shaft (2) by 180º.
6. Enter the dial gauge deflection in the coordinate system of the installation
check form.
Illustration 9
Example for radial
measurement A and
angular measurements B
and C in vertical plane
Evaluation :
Radial measurement A :
Radial offset vertical = 5.00-4.66 = 0.17 mm
2
Angular measurements B+C :
Angular displacement vertical = 6.55-5.45 = 0.55 mm

2
30
Applicable to the angular measurements is : half the difference of the two angular
measurements is the dimension of angular displacement
7. Correct vertical radial offset and vertical angular displacement by means of the
adjusting screws.
Precision alignment
Horizontal plane
8. Move the alignment device (3) in horizontal position (turn by 90º against the
original position).
9. Repeat the measurement.
Illustration 10
Example for radial
measurement and
angular measurements
in horizontal plane
Evaluation :
Radial measurement A :
Radial offset vertical = 5.28-5.00 = 0.14 mm
2
Angular measurements B+C :

Angular displacement vertical = 4.65-4.55 = 0.05 mm
2
10 Move the VARIABLE SPEED TURBO COUPLING in horizontal direction using

adjusting screws and thus correct horizontal radial offset and horizontal angular
displacement.
31
5.5.3 Connecting couplings without intermediate piece
In most cases, a connecting coupling without intermediate piece is arranged

between driving machine and VARIABLE SPEED TURBO COUPLING, i.e., there is
no space between the shaft ends.
Please refer to attached manual of connecting coupling for alignment.
32
5 Assembly 5.6 Machine fixing
5.6 Machine fixing
Illustration 13
Foundation fixing
1 VARIABLE SPEED
TURBO COUPLING
2 Foundation screws
3 Adjusting screws
4 Shims
5 Foundation
1. Put shims (4) under the coupling housing for all foundation screws. Please
observe that all shims bear the load uniformly.
2. Turn the adjusting screws (3) back.

The machine is resting well on the shims.
3. Tighten the fastening screws (2).
4.Check alignment.
5. Record final measuring results in the coordinate system of installation check

form.
33
5 Assembly 5.6 Machine and cooler pipe work
5.7 Machine and cooler pipework
5.7.1 Oil cooler installation
Warning!
When installing the oil cooler so that the pipes rise seen from the VARIABLE
SPEED TURBO COUPLING, the oil of cooler and pipes is emptied into the
VARIABLE SPEED TURBO COUPLING lower case to overfill and leak on start-
up. The temperature exceeds the permissible value and the fusible plugs
respond.
Arrange the oil cooler below the oil level of VARIABLE SPEED TURBO COU-
PLING, if possible. Take the necessary measures when installing it above the
oil level.
Illustration 14
Oil cooler arrangement
1 VARIABLE SPEED
TURBO COUPLING
2 Oil Level
3 Compensating Pipe
With Orifice 3mm
4 Oil cooler above
the oil level (H2)
5 Oil cooler below
the oil level (H1)
6 Oil “ supply and
drain”
7 Cooling water
“supply and drain”
H1 H2
Oil cooler below the VARIABLE Oil cooler at the level of VARIABLE
SPEED TURBO COUPLING. SPEED TURBO COUPLING.
Pipes and oil cooler cannot drain. Pipes and oil cooler drain.
Run the pipes to the oil cooler in hor- Measures : Run the oil supply and oil
izontal position or descending, If return siphon-like in upward direction and,
possible. Favourable position at the highest point, connect it with an oil
compensating pipe DN 8 mm (3). Run the
pipes below the Oil level of VARIABLE
34
5.7.2 Assembly of oil pipes
Note!
i Assemble the oil pipes preferably below the level of VARIABLE SPEED TURBO
COUPLING.
Use short oil pipes(<8 m) if possible. In case of longer pipes run above the oil level
of VARIABLE SPEED TURBO COUPLING, install a non-return valve in the oil pipe
from the VARIABLE SPEED TURBO COUPLING to the oil cooler.
Maintain a constant oil pipe diameter over the whole length.
Condition Exact alignment of machine.
Assembly of oil pipes

1. Remove the weld neck flanges on the machine.
2. Connect the oil cooler with VARIABLE SPEED TURBO COUPLING as shown in
illustration 14 on page 34. Ensure the piping is free from stress.
3. Support the pipes.
4. Assemble the external lube oil pipes (e.g.: driving machine, driven machine).
Adjustment of orifices 5. Adjust orifices already supplied at the lube oil outlets of VARIABLE SPEED
for Lube oil supplied TURBO COUPLING to driving and driven machine.
to External units
Lube oil quantity and lube oil pressure for external units depend on the adjustment
of these orifices provided in the connecting block, at the oil double filter and per-
haps on additional orifices upstream of the bearing points of driving and driven
machine.
! Required lube oil flow rates: please refer to section 1.2 " Operating data" on
page 3.
! For drawing 740090148 - Double filter with connecting block, ref. to Part 3
“Drawings, schematic drawings and diagrams” of this manual.
35
5.7.3 Pickling of oil pipes
Unscrew the oil pipes assembled and welded at site and pickle them in a pickling
bath to remove rust and scales. Only then you may assemble and flush them
finally.
1. Disconnect the oil pipes.
2. Degrease heavily fouled or greasy workpieces prior to pickling; e.g.: using a

steam ejector or in a degreasing bath.
3. Mix the pickle1 with water.
4. To remove the dirt, slight fouling, graphite or oil carbon; add pickling degreaser²
to the pickle.
5. Heat the solution to 40º C (104º F).
6. Put the parts into the pickling solution.
7. Take the parts out of the solution. After pickling, the metal of these parts should
be bright and free from scales and rust.
Pickling period
Rust film approx. 5-10 min
Rust approx. 15-30 min
Rolling skin approx. 50 min.
Descaling of annealed steel parts approx. 120 min
8. Let the parts dry dip-water proof (24-28 hours at 20º C). Do not wash off! If the
drying time cannot be observed: Rinse again using pure water.
9. Spray the inside of dry parts using operation oil and the outside using paint.
1 We recommend: BETONA, or a similar solution.Mixing : one part pickle to 10 parts water.
2 We recommend : S13, or a similar degreaser .Mixing : 1-3l to 100l pickling solution
36
5 Assembly 5.8 Connection of electrical instruments
5.8 Connection of electrical instruments
Note!
Only
i • A skilled electrician or
• Specifically instructed personnel under the control and supervision of such an
electrician is allowed to work on electrical systems or equipment.
In accordance with the electrical engineering rules and local regulations in force.
1. Connect all current consuming equipment.

2. Connect all control units.
3. Check motors for their direction of rotation, current consumption and protection
by fuses and grounding.
Warning!
Stray currents in the system may damage gears and bearings.

Take suitable grounding measures on all components of the drive train.
! Terminal plan for wiring to the terminal box.

! Please refer to part 5 "Attaching Parts" of this manual regarding details of the
instruments fitted.
37
5 Assembly 5.9 Mounting of guards
5.9 Mounting of guards
Note!
i Observe the safety regulations in force
Type of guards
• Protection against accidental contact with rotating and hot parts (connecting cou-
plings, oil pipes) and other recognizable sources of danger,
• Protection against noise or sound,
• Protection against weather in case of outdoor installation (shed or housing)
Danger!
Housing, oil pipes, connecting couplings and operating oil may become very
hot - in extreme case up to 130º C. A contact may cause skin burns.
Contact with rotating connecting couplings may cause serious injuries
Mount suitable guards.
5.9.1 Mounting the protection against accidental contact
Mount the protection against accidental contact on rotating and hot parts and other
recognizable sources of danger in accordance with the operator's and/or local
safety regulations in force.
Provide the protection against accidental contact at the connecting couplings .
38
5 Assembly 5.9 Mounting of guards
5.9.2 Mounting the acoustic cover
Unimpeded working
Mount the acoustic cover so that the following work can be performed without
obstruction: 1
• Read off instruments on the instrument panel and on the piping

• Read off the oil level at the oil sight glass of machine
• Clean the double oil filter
• Actuate the shutoff valves
• Install and remove the instruments
• Perform maintenance work (top up lubricant on actuator or connecting couplings
or similar)
Danger!
Heat may accumulate when using acoustic covers without ports. When com-
pressors are encapsulated gas leakages may cause intoxication, suffocation
and explosions.
Always provide acoustic covers with vent holes to dissipate the heat and to
exchange the air.
Heat dissipation and

Ventilation
• Avoid an inadmissible operating temperature on actuator, instruments, control
units, electric insulation and equipment.
• Provide separate ventilation for electric motors. The cooling air of an air-cooled
electric motor may be used for ventilation, if necessary (consider the characteris-
tic curve of motor fan and the required motor cooling).
• Regulate the air circuit in the cover to ensure heat dissipation (determine the
throughput for a cooling air temperature increase of 10ºC (50º F)).
• Lead the ventilation of gear housing and coverings (closed connecting coupling
covers) through pipes via the acoustic covers.
• Provide openings and sealrings for shaft passages, window to observe the instru-
ments, pipe and cable ducts and vents.
1 Information with reference to VDI Standard 2711 “Sound protection by encapsulation”
39
5 Assembly 5.10 Fitting a scoop tube actuator
5.10 Fitting a scoop tube actuator
Before fitting a scoop tube actuator, check the scoop tube position. The scoop tube
side where the word 'OBEN" engraved must point upwards.
Mount the scoop tube actuator so that the scoop tube can be mounted in any posi-
tion. Secure against distortion (use cardan joints, not ball joints).
Note!
i Take actions to limit the scoop tube stroke at the actuator and not at the scoop
tube!
Connect the scoop tube and the scoop tube actuator so that neither play nor vibra-
tion occurs. Small scoop tube irregularities (e.g. due to oil pressure variations) will
then have no adverse effect.
40
6 Commissioning
Warning!
The VARIABLE SPEED TURBO COUPLING is delivered without oil fill. An

operation without oil would damage the machine after a few seconds!
Prior to start-up, fill the VARIABLE SPEED TURBO COUPLING with

operating oil.
Note!
i Prior to starting the driving machine, check the attaching parts (instruments,
actuator, motor etc.):
• Connection to supply voltage.

• Signal processing for control and monitoring functions.
41
6 Commissioning 6.2 Operating oil fill
6.2 Operation oil fill
Criteria for suitability

of operating oil
!Voith oil selection list: please see section "Operating fluids" on page 45. The oils
included in the list were checked according to the following criteria:
• Lowest possible viscosity (starting viscosity # 400 mm²/s (cSt) at a temperature

of 0 º C or 32º F)
• excellent lubricating property
• excellent air release property
• high resistance to aging
• chemically neutral to metals and sealings
• Not harmful to the human organism
Note!
i If an oil type used is not mentioned in the list of operating fluids:
• Check its compatibility with our Voith flushing oil (Shell Ensis Motor oil 20 or
Eqvt.)
• Check the oil based on the criteria mentioned in “section operating fluids" on page
45 for its suitability.
• Flush the inside of VARIABLE SPEED TURBO COUPLING thoroughly.

! Required oil flow rate: please see section 1.2" Operating data" on page 3
Note!
i Fill in the operating oil immediately after completing the unit pipe work, if possible.
Oil fill
1. Fill the oil in via the oil filling hole V2 (see assembly plan. + part 3, "Drawings").
2. Fill the heat exchanger with oil from the oil tank or via the sockets, "oil inlet" or
"oil outlet".
3. Filter the oil during filling (grade of filtration 30 µm or finer).
When coolers and piping are filled and/or vented, the oil level should reach a mean
value between minimum and maximum mark on the oil level indicator.
42
6 Commissioning 6.3 Test run
6.3 Test run
6.3.1 Test run preparation
Checks and adjustments

Prior to the test run
1 Check alignment of machines and correct, if necessary.
2 Check foundation fixing.
3 Disconnect the connecting couplings and check the direction of rotation of drive
motor with uncoupled VARIABLE SPEED TURBO COUPLING.
4 Check the lubricant of attaching parts like actuator and connecting couplings and
refill, if necessary.
5 Check the assembly of connecting coupling and guards.
6 Check whether the manufacturer's instructions regarding adjustment of lube oil

supply for the external units have been observed.
7 Check the oil level (set point: mean value between minimum and maximum mark
on the oil level indicator).
8 Check the electric installation for connection to the supply voltage and signal pro-
cessing.
9 In case of water/oil coolers, open the valves arranged on the waterside, vent the
oil coolers on the waterside and check the flow
! Oil cooler operating data and manual in part 5 "Attaching Parts" of this docume-
ntation. [data given only if Heat exchanger is a part of VOITH supply]
Note!
i Actuator settings are only allowed with running auxiliary lube oil pump. Prevent
automatic start of driving machine.
10 Check the setting of scoop tube actuator over the range of angle of adjustment.
Limit both end stops mechanically on the actuator.
- Check and adjust maximum control or feedback signal on the actuator at 100%
scoop tube position.
- After running through the range of angle of adjustment, minimum control or
feedback signal corresponds to a scoop tube position of 0%.
11 Set the scoop tube position to 0%.
12 Check whether the complete unit is ready for service.
43
6.3.2 Test run performance
1. Start the driving machine.

2. Driving motor has run up and the lube oil pressure is available.
3. Minimum speed.
Minimum speed
4. Run the unit at minimum speed.
5. Monitor smooth running, temperatures, lube oil pressure and the condition of fil
ter.
Slow run-up
6. Run the driven machine slowly up to speed.
7. Observe and record temperatures and pressures until they have stabilized.
8. Measures vibration: Evaluate smooth running and record measuring values and
measuring points, speeds and scoop tube position.
Down regulation
9. Regulate the unit down to minimum speed.
10. Switch off the driving machine.
11. Move the scoop tube actuator to 0% (corresponds to minimum output speed).
After the test run

12. Clean the double oil filter and fill with operating oil (! section 8.2 "Cleaning
the double oil filter" on page 57)
13. Check and correct the oil level (setpoint: mean value between minimum and
maximum mark on the oil level indicator).
14. Check the filling of scoop tube actuator stops. Limit the stroke on the actuator
itself, not on the scoop tube control.
15. Check the piping for leaks.
44
Operating fluids
In individual cases, special requirements may exclude a selection according to this

list. In this case, the deviating regulations are agreed during execution of order or
mentioned in the manual.
Requirements
It is necessary to meet the characteristic values of oil for VARIABLE SPEED
TURBO COUPLINGs.The most important characteristics are :
• Viscosity: from 28.8 to 35.2 mm²/s (cSt) at 40º C or 104º F (ISO VG 32).
• Air release property: <= 5 min. at 50º C or 122º F to DIN 51381.
• Aging stability. Neutralization number (new oil) : NZ(S)<=2 mg/KOH/g oil.
• No corrosion or deposits even on water entry.
• Starting viscosity under site conditions not exceeding 250 mm²/s (cSt), for gear
pumps with sufficient input power (please consult us) up to 400 mm²/s.
Oil types to be selected

By the operator and
Mineral oil company
Provided the above requirements are observed following oils may be used:
• Hydraulic oils H-L 32 to DIN 51524, Part - 1
Check the oil for sufficient air release property (recognizable by pump pressures
and control stability).
45
Proposed oils
The following list includes hydraulic oils developed specifically for hydrodynamic
power transmission and which proved successful under normal operating condi-
tions in practice.
The local operating conditions and the oil quality may vary and therefore, with this
list of proposed oils, we do not assume warranty for the oil itself. Any warranty
claims made in the event of and in connection with any negative operating results
are excluded. Also, this list of proposed oils does not claim to be complete.
Supplier Designation
I.O.C.L Servo System HLP-32

Bharat Shell Shell Tellus32
H.P.C.L ENKLO HLP32
Castrol HYSPIN AWH32 / AWS 32
Total Petroleum India Ltd. Azolla ZS32
Gulf oil India Ltd. Gulf Harmony AWT 32
Bharat Petroleum Bharat Hydrol HLP 32
Pennzoil India Ltd. PENNZBELL HLP 32
46
7 Operation
Warning!
The VARIABLE SPEED TURBO COUPLING is supplied without oil fill. An

operation without oil would damage the machine after a few seconds!.
Prior to start-up, fill the VARIABLE SPEED TURBO COUPLING with operating
oil.
47
7 Operation 7.2 Machine start-up and rundown
7.2 Machine start-up and rundown
Checks prior to start-up
1. Perform checks similar to those performed prior to the test run ( ! section
"Checks and adjustments prior to the test run" on page 43).
2. Check whether the whole unit is ready for operation.
3. Move the scoop tube to 0%
Basically, the VARIABLE SPEED TURBO COUPLING can be started at any scoop
tube position. However, starting at 0% scoop tube position is preferred, since the
driving machine can run up nearly without load.
Start-up
Operating conditions Action Result
Scoop tube at 0% position
AOP(if supplied) ON Driving machine starts.

Driving machine ON Coupling fills and rotates.
Lube oil pressure > 1.0 bar Coupling and driven
machine rotate.
Scoop tube between 0% Driven machine operates

and 100% position at desired speed.
Rundown
Operating conditions Action Result
Scoop tube at 0% position Coupling drains. Driven

machine runs at minimum
speed.
Lube oil pressure < 0.6 bar Driving machine OFF Driving and driven
machine run down to
stop.
Bearings are no longer

lubricated.
48
7 Operation 7.3 Machine operation
7.3 Machine operation
7.3.1 Machine monitoring
Monitor the following during operation:
• Temperature
• Lube oil pressure
• Oil level
Temperatures
Working oil/lube oil
Working Oil temp. down- Operating range < 95 º C

stream of scoop tube ( 18 ) Alarm at > 100º C
Working Oil temperature Operating range < 100º C

downstream of scoop Alarm at > 110º C
tube(18.1)
Oil temperature Upstream Operating range < 90º C
of oil cooler ( 23.1)
Oil temperature Down- Operating range < 70º C

stream of Heat Exchanger
(15)
Working oil temperature Operating range < 700 C

downstream of cooler (33) Alarm at
> 800 C
Working oil temperature Operating range < 700 C

downstream of cooler Shutdown at
> 900 C
(33.1)
! Regarding position of measuring points please see "Oil Circuit and Measuring
Point Scheme" in part 3, "Drawings" of this documentation.
Fusible plugs
The fusible plugs respond at a working oil temperature of 160º C (320º F) in the
working chamber thus preventing an overheating of coupling.
Reasons for a temporary thermal rise of working oil temperature might be:
• Cooler does not function properly

• Overload of coupling
Consequences of melted fusible plugs:
- the control behavior of the coupling changes slightly
49
- max. output power is almost reached

- the oil temperature in the oil tank rises slightly
Pressures
Working oil / lube oil
Lube oil pressure 0%12&+$,"3 Operating range ~ 0.3 bar

%*)%$'*'#, (16)
Lube oil pressure at pressure Operating range ~ 1.2 bar

switch ( 17 ) Alarm at < 0.8 bar
Lube oil pressure at pressure Operating range ~ 1.2 bar

switch ( 17.1 ) Shut down at < 0.6 bar
Differential pressure Operating range ~ 0.3 bar

across the double %'()*'(+,$)-.!/ Alarm at > 0.6 bar
Oil pressure at test connection Operating range as per above val-

(55) ues at measur-
ing points 16; 17
! Regarding position of measuring points please see "Oil Circuit and Measuring
point Scheme" in part 3 "Drawings" of this documentation.
Oil Level
Oil level check

Start the VARIABLE SPEED TURBO COUPLING at 0% scoop tube position and
vent it dependent on the cooler arrangement. Ensure that the oil level is in the mid-
dle of fill level range h1 at this operating state. Top up operating oil, if necessary.
Illustration 16
Oil level check
h1 = Fill level range at

0% scoop tube position
h2 = Fill level range at

100% scoop tube position
L1=MAX. mark
L2=MIN. mark
L1/L2 and h1 (filling range)

see oil level indicator
on Assembly plan
50
With warm operating oil and scoop tube position at 0%, the oil level must not
exceed the max. mark L1 or must not fall below the min. oil level mark L2 at 100%
scoop tube position.
The oil level is reduced between 0% and 100% scoop tube position since the cou-
pling runner fills with oil. Even when switching of the VARIABLE SPEED TURBO
COUPLING at 0% scoop tube position, part of the operating oil remains in the cou-
pling runner.
An exact oil level check is possible only when the VARIABLE SPEED TURBO
COUPLING is running and at 0% scoop tube position.
7.3.2 Speed Control
The actuator positions the scoop tube between 0% and 100%. The scoop tube
position is determined by the speed of driven machine.
7.3.3 Double oil filter changeover
Differential pressure at Change over and clean fil- > 0.6 bar
Double oil filter ter at
The double oil filter cleans the lube oil. It has two filtering jugs of which only one is
always supplied with oil during operation. The filter is provided with a differential
pressure indicator and/or a differential pressure switch initiating an alarm, in case of
a too high difference between lube oil pressure upstream and downstream of the fil-
ter. In case of alarm, the filtering jug in operation does no longer provide enough oil
and needs to be cleaned (!section 8.2 " Cleaning the double oil filter" on page
58).
i Note!
During transportation, storage and mounting of the VARIABLE SPEED TURBO

COUPLING and assembly of the oil piping, dirt may enter the VARIABLE SPEED
TURBO COUPLING.
Therefore, check the condition of the double oil filter during commissioning and
clean (even several times), if necessary.
Flood the clean

filtering Jug Flood the second filtering jug before changing the double oil filter over to it.
51
i Note!
If the clean filtering jug is not flooded, then the lube oil pressure drops too much on
double oil filter changeover and the unit is switched off by the monitoring instru-
ments.
Illustration 17
Double oil filter
1 Filter jug in operation

2 Filter jug not in operation
3 Vent screw
4 Lube oil inlet & outlet
5 Change over lever always
points to the side being
in operation
6 Connection for Differential
pressure indicator with
or without contact
7 Flow mark
1. Remove the vent screw (3). Place a container under the clogged filtering jug (2).
2. Unscrew the filtering jug (2) and remove the filter element down.
!Cleaning the double filter: see part 8.2 "Maintenance and Repair " of this docu
mentation.
3. Slide the clean filter element from the bottom onto the follow shaft in housing.
Tighten the filtering jug (2).
52
7 Operation 7.4 Measures in case of tailspin and reverse rotation
Filter changeover
Change over the filter slowly to the clean filtering jug (2) using the changeover lever
(5).
Illustration 18
Double oil filter changeover
1 Filtering jug in
operation
2 Filtering jug not in
operation
7.4 Measures in case of tailspin and reverse rotation
Tailspin
Tailspin means the slow rotation of coupling by the driven machine when the unit is
switched off, e.g. in case of fan drives.
When the drive motor is switched off, the bearings of VARIABLE SPEED TURBO
COUPLING are no longer lubricated. Dependent on the speed and duration of tail-
spin, the bearings run dry and may be damaged.
Counteractions
• Switch on the main motor for approx.2 minutes or
• switch on the auxiliary lube oil pump, if available, to provide the bearings with oil.
Warning!
Reverse rotation is not allowed with the installed gear pump provided with
plain bearings.
53
7 Operation 7.5 Measures to be taken during stop periods
7.5 Measures to be taken during stop periods
When the stop periods are longer than one day:
• Switch on the auxiliary lube oil pump daily for at least five minutes
• Protect the VARIABLE SPEED TURBO COUPLING against ingress of water and
humidity. Preserve bright parts accordingly.
• Start the VARIABLE SPEED TURBO COUPLING every 1 to 2 months for a short
time. Do not run it warm (risk of condensation water).
The machine inside is wetted with oil and thus protected against corrosion.
! Oil cooler stop periods: please refer to the oil cooler instruction manual in part 5
"Attaching Parts" of this documentation.(Instr.manual documented if cooler is a
part of VOITH supply)
54
8 Maintenance and repair
8.1 Maintenance measures and intervals
With the unit running

When differential pres- • Change over and clean the double oil filter
sure on double filter rises
In case of speed varia- • check the air release property of operating oil;
tions of Driven machine • check continuous venting of oil cooler (direct circulation)
In case of increased oil • check the operating oil for water content.
level
Daily • check temperatures, lube oil pressure as well as differen-

tial pressure on the double oil filter
Every 100 operating • check and record all temperature and pressure indica-
hours tions
Every 500 operating • measure, record and compare quiet running and noise
hours pattern under the same operating conditions.
In case of changed values for smooth running, check and
correct alignment of the VARIABLE SPEED TURBO
COUPLING. Check foundation fixing. Analyze the operat-
ing oil for ageing and take appropriate measures.
When the unit stopped

Weekly • check the oil level, top up, if the oil level is too low
• In case of too high oil level, check the operating oil for
water content. Find out and remove the cause. Separate
or change the oil.
After 100 operating hours • clean the double oil filter

• clean the vent filter
• Check smooth running of scoop tube actuator, check the
scoop tube stroke limitation, grease the joints and bright
parts.
• Check the oil cooler and clean it, if necessary, according
to the manufacturer's instructions.
• Check piping and greased or oil-lubricated connecting
couplings for leaks.
• Check the operating oil for impurities and water content.
Find out and remove the cause. Separate or change the
oil.
After 500 operating hours • clean the double oil filter
• clean the vent filter
• check the piping and connecting couplings for leaks
After 1000 operating • checks and maintenance work as after 100 operating
hours hours
55
8 Maintenance and repair 8.1 Maintenance measures and intervals
When the unit stopped

Every 1000 operating • check the double oil filter and clean it, if necessary
hours or when the dou-
ble oil filter is clogged
Every 6000 operating • analyze the operating oil for aging and take appropriate
hours or at least annually measure
• check and service the connecting couplings.
• Check and correct alignment of VARIABLE SPEED
TURBO COUPLING. Check foundation fixing.
• Check in general condition of the VARIABLE SPEED
TURBO COUPLING.
• Open the inspection hole cover on the housing cover and
check the contact pattern of the filling pump drive tooth
flanks and the condition of the fusible plugs (solder fill).
i Note!
Prior to re-starting a VARIABLE SPEED TURBO COUPLING stopped by switch-off

or reverse rotation:
• inspect the bearings and fusible plugs

• switch on auxiliary lube oil pump
• check oil pressures.
i Note!
In the event of a change in operating behavior or after max. 7 years operating

time the VARIABLE SPEED TURBO COUPLING should be overhauled.
• To avoid delays during servicing we recommend that you stock the neces
sary spares. We would be pleased to submit a spares offer on request
(Service Department "SMs" of the Product group Variable Speed Drives of
"VOITH Turbo Pvt. Ltd., Hyderabad” )
• To ensure enquiries are rapidly dealt with, field service personnel sent out
or spares ordered without delay, always quote the VARIABLE SPEED
TURBO COUPLING serial number, exact location and the name of the per
son in charge.
• Installation work on the VARIABLE SPEED TURBO COUPLINGS should

only be carried out by our service engineers or qualified staff (see section
2 "Safety Information" on page 5).
56
8 Maintenance and repair 8.2 Cleaning the double oil filter
8.2 Cleaning the double oil filter
! Maintenance and cleaning: see double filter instruction manual in part 5

"Attaching Parts" of this documentation.
Auxiliary means
• Tank containing clean gasoline for cleaning purposes, "Eskabon" or diesel oil
(approx. 5 ltrs.)
• Container for the oil to be drained (approx. 10 l)
• Angle -shaped soft paint brush (not a hard brush!)
• Compressed air
Warning!
Waste oil getting into the sewerage or open soil may cause severe damage to
the environment.

tory provisions.
Illustration 19
Double oil filter
1 Filter jug in operation

2 Filter jug out of
operation
3 Vent screw
4 Changeover lever
Draining the oil 1. Remove the vent screw
2. Turn the filtering jug (2) to the left using a spanner
3. Remove the filtering jug (2) and collect the oil coming out in an appropriate con
tainer
i Note!
During cleaning :
• Do not changeover the filter
57
8 Maintenance and repair 8.2 Cleaning the double oil filter
Illustration 20
Filtering jug with
filter element
1 Filtering jug in operation

2 filtering jug out of
operation
3 Vent screw
4 Changeover lever
5 Filter element
6 O-ring
7 Magnetic element
8 O-ring
Removing the filter 4. Extract the filter element (5) from the housing by slightly moving it to and fro
element
5. Remove the O-ring (6+7)
- Inner side of filter element : clean oil side
- Outer side of filter element: clogged side.
6. Clean the filtering jug (2) inside
Cleaning the filter

element
7. Clean the clogged outside for filter element (5) using gasoline for cleaning pur
poses, "Eskabon" or diesel oil"; for this purpose wash the filter outside from the
top to the bottom using a brush. Do not submerge the filter element in the clean
ing agent.
Reistalling the filter 8. Blow the filter element from the inside to the outside using compressed air.
element
9. In the event that the filter element is heavily clogged, repeat the cleaning proce-
dure, if necessary.
10. Check filter element and O-rings for any damage
11. Slide the cleaned O-rings (6+7) on the filter element
12. Insert the cleaned filter element (5) into the housing hollow shaft
13. Screw the cleaned filtering jug (2) together with the O-rings (6+7) into the hous-
ing.
14. Close the vent screws (3)

15. Fill the filtering jug (2) with oil (section "Flood the clean filtering jug" on page
52).
58
8 Maintenance and repair 8.3 Inspection of hose lines
8.3 Inspection of hose lines
Storage
• Storage period: max. four years from the date of manufacture
• Ambient conditions: dry rooms without direct solar radiation
Use
• Period of use: max. six years, depending on the application and surroundings
Note!
i The date of manufacture is printed on the hose lines. Example: 4 Q 95 (year of

manufacture 1995).
Inspection criteria
• Damage of skin up to the plies of fabric (chafe marks, cuts or cracks)
• Embrittlement of skin (cracks)
• Deformation pressureless and pressurized condition (separate skins, porous)
• Leaks
8.4 Checking the oil for water content and impurities
Water content
< 0.05% Oil can still be used
> 0.05% Change the oil. Separate the old oil / water mixture by centrifuging,
depositing or heating.
• > 0.2% : HD engine oils turn yellow like egg-flip
• Oil 32 or shell tellus oil 46 turn yellow
Elimination of
condensation water
If a VARIABLE SPEED TURBO COUPLING is running frequently, but always only
for a short time the warming up and cooling down process forms condensation
water which no longer evaporates .To prevent that the total oil filing needs to be
centrifuged:
• Mineral oil (water is heavier than mineral oil and deposit at bottom): Let the cou-
pling rest for 1 to 2 days. Drain the condensation water out of the oil drain valve
provided at the housing bottom.
• Synthetic fluids with a density of > 1.0 (water floats on top): remove the conden-
sation water by suction.
• Have the oil checked for impurities by the oil supplier or a competent laboratory.
59
8 Maintenance and repair 8.5 Replacement of fusible plugs
8.5 Replacement of fusible plugs
1. Remove the inspection hole cover (2) on the housing.
Illustration21
Inspection hole cover,

open
1 Fusible plug
2 Inspection hole cover
3 Primary wheel
2. Turn the input shaft until the fusible plugs (1) (or the holes for the fusible plugs)
are visible in the primary wheel (3).
3. Check the solder fill in the plugs, insert new plugs, if necessary and tighten.
Observe the torques shown on the sectional drawing.
60
8 Maintenance and repair 8.6 Cross references
8.6 Cross references
Subject Relevant documentation
Operating oil Section 6.2, "Operating oil fill" on page 42

Section "Operating fluids" on page 45
Section 8.4 "Checking the oil for water content and impurities" on
page 59
Section 7.31. "Machine monitoring" on page 49
Oil supplier's instructions
Hose lines Section 8.3, Inspection of hose lines" on page 59
Fusible plugs section 8.5 "Replacement of Fusible plugs" on page 60
Double oil filter section 7.3.3 "Double oil filter changeover" on page 51 and sec-
tion 8.2"
"Cleaning the double oil filter" on page 57
Oil cooler Instruction manual for oil coolers in part 5 “Attaching parts” of this
documentation
Alignment section 5.5, Machine alignment" on page 27
Temperatures section 7.3.1. "Machine monitoring" on page 49

and pressures
Connecting cou- Manufacturer's instructions

plings
61
9 Trouble shooting
9.1 Start-up
Trouble Cause(s) Actions(s)
• Scoop tube in 0% position Proceed as follows :

- Move scoop tube in 100% direction
Filling pump not delivering any oil Proceed as follows :

- Oil temperature in the oil tank - Warm up the oil to > 0°C (32 °F)
< 0°C (32 °F) or oil viscosity Close the cooling water supply at the oil
> 400mm2 /s cooler.
- Check the oil level and top up to the value
- Oil level too low between minimum and maximum mark.
Check the fusible plugs
Driven machine cannot - Check the oil for impurities. Centrifuge or
start after the driving - Oil foaming (Oil temp. too low; Oil
separate the oil. Change the oil, if neces-
machine has reached its contains water; poor air release
sary.
rated speed property; wrong oil quality)
- Check the filling pump pressure at the
- Piping clogged
pressure measuring points.
- Incorrect direction of rotation of
- Check the piping, remove clogging.
main motor
- Check the main motor and connect prop
erly.
•Too high starting torque (high • Check driven machine for smooth running.
motor current consumption), Check the fusible plugs.
driven machine is blocked (see
also working oil temperature)
VARIABLE SPEED •Driven machine jammed, other • Check driven machine for smooth running,
TURBO COUPLING obstructions remove obstructions. Check the fusible
becomes too hot during plugs.
start-up
•Oil flow rate too low • Check oil circulation
62
9 Trouble shooting 9.2 Output speed
9.2 Output speed
• Oil foaming (Oil temp. downstream • Warm up the oil in the oil tank to >45°C (113 °F)
Output speed hunting of cooler too low, thus air release
at constant scoop property too low)
tube position
• Filling pump sucks air • Check the oil level and the filling pump, if neces-
sary.
• Pressure and quantity variation • Check the system, vent and stabilize, if neces-
sary
Output speed hunting •Controller does not have the cor- • Tune the controller to the control system
at automatic control rect constraint with regard to con- (dampen the controller, if necessary)
(control level moves in trol system
periodic duty)
Output speed cannot • Scoop tube and scoop tube actua- • Check scoop tube for easy movement, remove
be controlled tor jammed obstructions.
• Scoop tube actuator defective • Check the scoop tube actuator
•Scoop tube not in 100% position •Check the max. scoop tube stroke.
Max. output speed
cannot be reached •Fusible plugs responded •Find and eliminate the cause. Insert new fusible
plugs
•Power requirement of the driven •Compare the power data with the project data.
machine too high Check driven machine for smooth running.
63
9 Trouble shooting 9.3 Pressures
9.3 Pressures
• Leak in the oil circuits • Check the oil level.

Check the pipe work for leaks (take measures
to prevent damage to the environment, if nec-
Lube oil flow too low essary)
to give release for
start • Double oil filter clogged • Changeover double oil filter and clean the fil-
tering jug.
Check the differential pressure monitoring.
Differential pressure • Double oil filter clogged • Changeover double oil filter and clean the fil-
at double oil filter too tering jug.
high
• Double oil filter clogged • Changeover double oil filter and clean the fil-
Lube oil pressure too tering jug.
low during normal
operation
• Oil temperature in the oil tank < 45 • Warm up the oil tank to > 45°C (113 °F)
Filling pump pressure °C (113 °F), thus air release prop-
too low erty too low
• Oil level too low • Check oil level and top up to a value between
minimum and maximum mark. Check fusible
plugs.
• Oil foaming (oil temp. too low; oil Check the oil for impurities. Centrifuge or sepa-
contains water; poor air release rate the oil. Change the oil, if necessary.
property; wrong oil quality)
64
9 Trouble shooting 9.4 Temperatures
9.4 Temperatures

• Cooling water flow rate too low • Increase the cooling water flow rate
• Cooling water too warm • Check and clean the cooling system
• Cooler is contaminated
VARIABLE SPEED
TURBO COUPLING • Operation of VARIABLE SPEED • Operate the VARIBLE SPEED TURBO
becomes too hot dur- TURBO COUPLING outside the per- COUPLING within the characteristic curve
ing operation mitted characteristic curve
• Fusible plugs responded • Find and eliminate the cause. Insert new
fusible plugs
• Bearing damage • Check quiet running

• Check the bearings and replace, if neces-
sary.
• Lube oil temperature too high • Check the oil cooler, changeover double oil
Bearing temperatures filter and clean the filtering jug.
too high • Lube oil pressure too low • Check the lube oil system
• Changeover double oil filter and clean the fil-
tering jug.Check differential pressure moni-
toring.
• Check the oil level.
• Increase the lube oil pressure.
65
9 Trouble shooting 9.5 Quiet running
9.5 Quiet running
• Faulty alignment • Check and correct alignment, if necessary
• Insufficient shimming between • Check alignment and shimming and correct,

Uneven running vibra- machine and foundation (foundation if necessary
tion and noise rail); the support is not uniform;
machine is distorted
• Foundation bolts are loose, the foun • Check the foundation and retighten the foun-
dation is defective, foundation frame/ dation bolts, if necessary.
rail is not grouted
• Wear or insufficient lubrication of con- • Check the connecting couplings, the lube oil
necting coupling; sleeve for curved supply and injection nozzle.
tooth couplings cannot be displaced
axially
(gearing shows running marks)
• Unbalance of rotating parts • Measure the vibration and make a frequency
• Bearing damage analysis of the whole system. Record meas-
uring values and operating data.
• Check and replace bearings, if necessary.
66
9 Trouble shooting 9.6 Cross references
9.6 Cross references
Subject Relevant documentation
Oil cooler Oil cooler manual in part 5 “Attaching parts” of this documentation
Alignment section 5.5 “Machine alignment” on page 27
Operating data (pressures, section 1.2 “Operating data” on page 3

temperatures, oil flow rates) section 7.3.1 “Machine monitoring” on page 49
Foundations section 5.6 “Machine fixing” on page 33
Oil section 8.4 “checking the oil for water content and impurities” on page 59
Oil level section 6.2 “Operating oil fill” on page 42

section 7.3.1 “Machine monitoring” on page 49
Fusible plugs section 8.5 " Replacement of fusible plugs" on page 60
Lube oil filter section 8.2 " Cleaning the double oil filter" on page 57
Connecting couplings Manual for connecting couplings in part 5 "Attaching parts" of this documentation
67
VOITH TURBO
POWERTRANSMISSION
Type: 1150 SVNL 21-18, 5.1
Version No.0$%S&00'() to ''!
Serial No. 113-00'() to ''!
SOS No: SOS-*#-0$%
Disassembly / Reassembly Manual
CONTENT

INDIA.
Phone : +91 40 27171440 / 27173592 / 27173561

Fax : +91 40 27171141

SMs
!"#!!
Date of issue : +%34+/'

Version : 0.00
Printed in India
10 Introduction
observed in addition to the different individual information.
Warning!
Hang the VARIABLE SPEED TURBO COUPLING only on the marked suspen-
sion points (label)!.
The suspension points located on the VARIABLE SPEED TURBO COUPLING

are only designed for the own weight of VARIABLE SPEED TURBO COU-
PLING! Do not lift it with any other machines! Lift the VARIABLE SPEED
TURBO COUPLING only without oil filling!
Use only appropriate lifting appliances in compliance with the safety regula-
tions! Keep away from suspended load.
Warning!
Waste oil getting into the sewerage or open soil may cause severe damage to
the environment.

tory provisions.
Warning!
Only qualified staff is allowed to disassemble and assemble the variable
Section 2.4, selection and qualification of staff" on page 6 in the instruction

manual.
68
10 Introduction 10.2 Tools and auxiliary means
Note!
i Always place the VARIABLE SPEED TURBO COUPLING and disassembled

parts of VARIABLE SPEED TURBO COUPLING on suitable base (e.g.: rubber
mat).
10.2 Tools and auxiliary means
• Standard tool kit

• Torque wrench (tightening torque range - see sectional drawings)
• Measuring and test equipment
• Metric tools
• Lifting appliances
• Base made of rubber or a similar material
• Sealing compound
• Removal and mounting devices for dismantling and assembling the coupling run-
ner.
Besides the above tools, no special tools are required for disassembling / reassem-
bling the VARIABLE SPEED TURBO COUPLING.
Sealing compound
Sealing compounds used for the VARIABLE SPEED TURBO COUPLING have to
meet the following criteria :
• Oil-resistant up to 130º C.
• Not containing any silicone
Voith India recommends to use Hylomar as the sealing compound. Only apply a
thin coat of the sealing compound and let it aerate for approx. 10 minutes. Please
observe the supplier's further processing instructions.
10.3 Preparations
Prior to disassembling the assemblies of VARIABLE SPEED TURBO COUPLING,

proceed with the following preparatory work :
1. Switch off the driving machine, let the VARIABLE SPEED TURBO COUPLING
cool down.
2. Disconnect the motor of the unit.
3. Obtain release for disassembly from the competent authority.
69
10 Introduction 10.4 General view of assemblies
4. Disconnect from the electrical circuit, if necessary.
5. Dependent on the local conditions, remove any obstructing structures like cable
ducts and electric lines.
Note!
i Please observe also any special local safety information
10.4 General view of assemblies
Illustration 1
Assemblies -
VARIABLE SPEED
TURBO COUPLING
1 Input shaft
(primary shaft)
2 Primary wheel
3 Shell
4 Secondary wheel
5 Output shaft
(secondary shaft)
6 Filling pump
7 Scoop tube housing
8 Scoop tube
9 Oil cooler
70
11 Survey of general overhaul
11.1 General overhaul of the machine
Take the following steps for general overhaul of VARIABLE SPEED TURBO
COUPLING.
Note!
i Read the assembly - specific chapters in the manual in order to remove/install and
disassemble / reassemble individual components.
i
Note!
Clean all assemblies and disassembled components and check their general condi-
tion. Replace any damaged parts.
11.1.1 How to disassemble the machine
1. Follow section 10.3 "Preparations" on page 69
Warning!
Oil may get into the foundation or subsoil and cause damage to the environ-
ment.
Make sure to collect the operating oil in a suitable container.
2. Drain the operating oil and clean the oil tank.
3. Remove the flanges of the piping upstream of the cooler.
4. Check the double oil filter and clean it in accordance with the filter manufacturer's
instructions.
5. Remove the protection and coverings against accidental contact at the input and
output ends.
6. Dismount and check the connecting couplings.
7. Remove the scoop tube actuator and the scope tube.
8. Check input and output shaft for radial runout.
71
11 Survey of general overhaul 11.1 General overhaul of the machine
Note!
i Observe the assembly - specific checks and measurements in the individual chap-
ters for removal and installation of components.
9. Remove and check the components in the following sequence :
- Regarding scoop tube control with scoop tube (please see section 12.1 "Scoop
tube" for job instruction)
- Filling pump with filling pump drive (please see section 12.5 "Filling pump" )
- Coupling runner with scoop tube housing (please see section 12.6 " Coupling
runner" and section 13.1 "Coupling runner" for a job instruction)
- Bearings (ball and roller bearings)
11.1.2 Machine assembly
Note!
i When assembling the VARIABLE SPEED TURBO COUPLING observe the tighten-
ing torques in the drawings.
Steps to be taken
1. Assemble the coupling runner (please see chapter 13.1.3 "Assembly of coupling
runner")
2. Remove old sealing compound from the sealing surfaces of the VARIABLE
SPEED TURBO COUPLING and degrease.
3. Flush and clean the oil tank.
4. Re-install the components in the reverse order of the removal procedure:

- Filling pump
- Coupling runner
- Scoop tube
- Scoop tube actuator
5. Set the VARIABLE SPEED TURBO COUPLING again down on the foundation
and align it (please see chapter 5 "Assembly").
72
11 Survey of general overhaul 11.2 Recommissioning of machine
11.2 Recommissioning of machine
For safe recommissioning of VARIABLE SPEED TURBO COUPLING proceed as

follows:
1. Check alignment of VARIABLE SPEED TURBO COUPLING with driving and

driven machine. Please refer to chapter 5 "Assembly" in the instruction manual
regarding the line of action.
2. Observe the manufacturer's instructions for the connecting couplings (!please

see part 5 "Attaching Parts" of this instruction manual).
3. Re-assemble all disconnected lines and pipes.
Note!
i Filter the operating oil during filling (grade of filtration 30 µm or finer).
4. Fill in the operating oil.
5. Re-connect all electric lines.
6. Check the function of filling pump, scoop tube actuator and indicator.
7. Check the oil cooler for leaks and vent the oil cooler
Note!
i Observe the job instruction in chapter 6 "Commissioning " of the instruction manual
for test run preparation and performance.
8. Perform a test run with the VARIABLE SPEED TURBO COUPLING (Please see
section 6.3.2. "Test run performance" on page 44 in the instruction manual).
Check function, observe quiet running, temperatures and oil pressures. Check
the oil level after some time.
73
12 Removal and installation of assemblies
Note!
i Screw tightening torques are not mentioned in the text, but exclusively in the
attached sectional drawings.
12.1 Scoop tube
! The following attached sectional drawing(s) are the basis for this section
- 740 090 106 Assembly - horizontal section, 740 090 108 Rotating parts
Designation Item No.
Scoop tube housing 201/010

Bellows 201/060
Cover 201/030
Hex.bolt 201/050
Shaft sealing ring 201/160
Sleeve 501/020
Roll pin 501/030
74
12 Removal and installation of assemblies 12.1 Scoop tube
Warning!
ment.
Make sure to collect any oil leaking out of the control oil lines in an appropri-
ate container.
Steps to be taken
1. Separate Connecting rods from scoop tube. Loosen the actuator and turn it side-
ways. Remove bellows.
2. Dismantle cover to replace the shaft sealing ring. Carefully withdraw the
scoop tube.
Note!
i Do not bend the scoop tube on removal.
3. Carefully remove the connecting rod together with sleeve and scoop tube from
the scoop tube housing and set down on a clean, soft base.
4. Check the shaft-sealing ring.
Note!
Replace the shaft-sealing ring when oil is in the bellows or when the shaft-sealing
i ring shows any damage. Observe the job instruction in the following section "
Removal of shaft sealing ring" in case the shaft-sealing ring needs to be replaced.
75
Removal of shaft sealing ring
Steps to be taken
1. Remove the socket head screws.
2. Remove the cover from the scoop tube housing.
3. Remove the shaft-sealing ring from the cover or the scoop tube housing.
4. Apply sealing compound to the outer surface of the new shaft-sealing ring and
press it into the cover up to the stop in the correct position.
5. Apply sealing compound to the cover and mount it on the scoop tube housing so
that the vent holes for the bellows point downward.
12.1.2 Checks, measurements and maintenance
• Visually check the scoop tube and the scoop tube mouth for wear.
• Check whether the scoop tube can move easily in the scoop tube housing.
• Clean all components.
12.1.3 Installation of scoop tube
Re-installation of the existing scoop tube
Steps to be taken 1. Slide the bellows in the correct position on the scoop tube.
Note!
i Insert the scoop tube into the scoop tube housing so that the word "OBEN"
stamped in the sleeve is on top.
2. Wet the scoop tube with oil and insert it carefully into the scoop tube housing
together with the sleeve and the adjusting rod.
3. Mount the lever on the scoop tube actuator using the adjusting rod
76
4. Connect the bellows with the scoop tube housing and the sleeve.
5. Check smooth running of the scoop tube over the whole regulation range by
slowly turning the VARIABLE SPEED TURBO COUPLING.
6. Check the scoop tube stroke (please see section 12.2 "Adjusting the scoop tube
stroke" on page 80).
Installation of new scoop tube
Steps to be taken
1. Remove the roll pin at the connection from the shaft joint to the sleeve.
Warning!
Scoop tubes depend on the direction of rotation (seen from the driving
motor) of the VARIABLE SPEED TURBO COUPLING.
Make sure to use the scoop tube for the correct direction of rotation ("clock-
wise or "Counter clockwise").
2. Check whether the scoop tube is suitable for the direction of rotation of VARI-
ABLE SPEED TURBO COUPLING. The scoop tube is marked as follows at the
shaft end:
Direction of rotation Mark

of
VARIABLE SPEED
TURBO COUPLING
clockwise R
counterclockwise L
77
Finding the sleeve length
3. Insert the scoop tube up to the stop into the scoop tube housing (bore hole for
the torsion rod to be in parallel to the output shaft).
Illustration 3
Finding sleeve length
(L1)
1 Sleeve
2 Fixing bolt
3 Shaft end
(mark “clockwise or
counterclockwise”)
4 Scoop tube
4. Measure the distance L2 using a depth gauge. Add the distance between scoop
tube mouth and shell at 0% position (7 mm) to L2
Note!
i Use a new sleeve when installing a new scoop tube.
5. Measure the actual dimension L1 of the sleeve using a depth gauge.
6. Shorten the sleeve by [L1 - (L2 + 7 mm)] mm.

Illustration 4
Mounting the sleeve
1 Sleeve
2 Fixing bolt
3 Scoop tube
4 Torsion rod
5 Scoop tube for
“clockwise rotation”
6 Scoop tube for
“counterclockwise
rotation”
7 Word “OBEN”
and “R” or “L” for
“clockwise or
counterclockwise
rotation”
78
Note!
i Mount the sleeve so that the word, "OBEN" is on top. Fixing bolts for the sleeve
and shaft joint are not included in the scope of supply.
Mounting the sleeve

7. Slightly extract the scoop tube from the scoop tube housing. Fix the sleeve on
the scoop tube using a fixing bolt so that the bore for the torsion rod is
turned exactly by 90º to the scoop tube mouth or to the fixing bolt.
8. Turn the fixing bolt in until it has tight contact with the groove bottom of the scoop
tube.
9. Mount the lever with the connecting rod on the scoop tube actuator.
10 Connect the shaft joint with the sleeve and tighten the fixing bolt for
assembly to the shaft joint until it has tight contact to the spigot of the sleeve.
11 For boring the roll pin, release the fixing bolt and remove the connecting
rod with the sleeve. Bore the shaft joint together with the sleeve.
12. Mount the roll pin.
13 Re-mount the connecting rod together with the sleeve. Align the scoop tube
position (see above) and tighten the fixing bolt.
14 Check the scoop tube stroke and readjust at the scoop tube actuator (please
see section 12.2 "Adjusting the scoop tube stroke" on page 80 for job instruction)
Note!
i After adjusting the scoop tube stroke and optimal scoop tube position, pin the
scoop tube and the sleeve together.
79
12 Removal and installation of assemblies 12.2 Adjusting scoop tube stroke
12.2 Adjusting scoop tube stroke
Illustration 5
Adjusting scoop tube
stroke
1 Scoop tube position

at 0% position
2 Scoop tube position
at 100% position
3 Scoop tube stroke
“H”
Adjusting the scoop-

tube to 0% position
1. Move the scoop tube by means of the scoop tube actuator towards the
scoop tube housing until the sleeve has a distance of 1 mm to 3 mm to the
scooptube cover.
2. Align the stop for stroke limitation (minimum output power) with the scoop tube
actuator and tighten.
Adjusting the scoop

tube to 100% position
3. Move the scoop tube by means of the scoop tube actuator towards the scoop
tube housing so that the scoop tube stroke H for the required direction of rota-
tion is reached according to the following table:
Coupling size and type Coupling direction of rotation Scooptube stroke

H (mm)
1150 SVNL 21-18,5.1 Counter Clockwise 275
4. Align the stop for stroke limitation (maximum output power) with the scoop tube
actuator and tighten.
80
12 Removal and installation of assemblies 12.3 Adjustment of optimal scooptube position
12.3 Adjustment of optimal scoop tube position
Note!
i The optimal scoop tube position needs to be adjusted only if the scoop tube was
replaced.
Warning!
The following jobs are performed with the VARIABLE SPEED TURBO COU-
PLING running. During operation, there are flow forces acting on the scoop
tube having a twisting, pulling or pushing effect.
Improper handling may damage the VARIABLE SPEED TURBO COUPLING.
Steps to be taken
1. Start the unit.
2. Operate the scoop tube over the whole positioning range (scoop tube positions
0% to 100%) by means of the scoop tube actuator.
Adjusting the
scoop tube Adjust the scoop tube in case of axial scoop tube vibration or high sound pressure
level:
Illustration 6
Adjusting the scooptube
1 Sleeve
2 Fixing bolt
3 Scooptube
4 Torsion rod
5 Scoop tube for “CW”
rotation
6 Scoop tube for “CCW”
rotation
7 word “OBEN”
3. Move the scoop to the position with maximum vibration.
4. Insert the torsion rod into the bore hole.
Warning!
Do not turn the scoop tube more than 40º in one direction!
5. Unscrew the fixing bolt and turn the scoop tube to the most favorable
position by means of the torsion rod.
81
12 Removal and installation of assemblies 12.3 Adjustment of optimal scooptube position
6. Repeat the steps 3 to 5 at other scoop tube positions until there is minimum vibra
tion over the whole scoop tube positioning range.
7. Stop the unit.
8. Remove the scoop tube, bellows and scoop tube actuator.
9. Bore the removed scoop tube together with the sleeve and pin with the roll pin.
10 Stamp in the direction of rotation of VARIABLE SPEED TURBO COUPLING on

the sleeve (please see illustration 6 "Adjusting the scoop tube" on page 81).
11 Re-install the scoop tube, bellows and scoop tube actuator.
12 Check free movement of scoop tube over the whole positioning range by slowly
turning the VARIABLE SPEED TURBO COUPLING.
13 Check the scoop tube stroke according to section 12.2 " Adjusting the scoop
tube stroke" on page 80.
82
12 Removal and installation of assemblies 12.4 Replacement of fusible plugs, removal of filling pipe
12.4 Replacement of fusible plugs, removal of filling pipe
Sectional drawings
!The following attached sectional drawings are the basis for this section.
- 740 090 108 Rotating parts
- 740 090 107 Vertical section
Item numbers
Designation Item Number
Inspection cover with 301/070

breather
HSH screw 301/090
Fusible plugs 101/070/030
Primary wheel 101/070
Steps to be taken
1. Unscrew the inspection cover from the VARIABLE SPEED TURBO COUPLING
HOUSING.
2. Replace the fusible plugs in the primary wheel. In case that fusible plugs resp-
onded due to overheating of the VARIABLE SPEED TURBO COUPLING, elim-
nate the cause for the excessive temperature before inserting new fusible plugs.
4. Seal, mount and tighten the inspection cover.
83
12 Removal and installation of assemblies 12.5 Filling pump
12.5 Filling pump
Sectional drawings
- 740 090 108 Rotating parts
Item numbers
Soc.Hd. screws 701/050
Plain Bearing 701/040
Plate 701/030
Drive pinion 701/060

Gear pinion 701/070
12.5.1 Removal of filling pump
The filling pump is located on the input side of the variable speed turbo coupling
below the primary shaft and can be dismantled after unscrewing the holding down
bolts.
Remove the pump cover and the assembly cover on the left of the input shaft. For
unscrewing the screw(701/070), the input shaft must be held. Turn out the screw by
10mm then loosen the gear from the centering by careful meats on the screw head.
Now, hold the gear by hand, disassemble it from the shaft and remove it via the
assembly hole.
In case of damages on the filling pump drive tooth, replace the two gear wheels.
For this, remove the complete coupling rotating parts from the housing.
i Note!
If the spur gear of the filling pump is larger than the pump housing diameter in the
coupling housing, it is necessary to remove the housing cover for removal of filling
pump.
i Note!
Ensure that the roll pins do not fall into the oil tank when removing the spur gear.
Removal of bearings 6. Press out the bearings, the two pinions and the possibly existing spacer rings.
and pinions
84
12 Removal and installation of assemblies 12.5 Filling pump
• Visually check all parts removed for damages
• Check contact pattern of drive pinion
• Clean all components
12.5.3 Re-installation of filling pump
i Note!
Prior to installation, wet all filling pump parts with operating oil.
Steps to be taken Install the plain bearings so that the oil compensation groove points in direction
of the pinion gearing.
Illustration 8
Installation of drive
pinion on “clockwise”
or “counterclockwise
rotation”
85
12 Removal and installation of assemblies 12.6 Coupling runner
Note!
i On installation observe that the gears match.
3. Install the spur gear.
4. Measure the backlash. Permissible backlash range :0.2 mm … 0.3 mm
12.6 Coupling runner
Sectional drawings
- 740 090 106 Horizontal section
- 740 090 108 Rotating Parts
Item numbers
Primary shaft 101/120
Secondary shaft 101/240

Labyrinth cover 201/140
O-ring 201/130
Hex. Screw 201/150
Slotted round nut 101/210
Lock washer 101/220
Angular cont ball bearing 101/250
Scoop tube-housing 201/010
Coupling housing 301/010
Key 101/380
Angular cont ball bearing 101/320
Cyl. Roller bearing 101/050
Hex. screws 201/020
86
12.6.1 Removal of coupling runner
Prerequisites Prior to removing the coupling runner:
Warning!
ment.
Make sure to collect the operating oil in an appropriate container.
• Drain the operating oil.

• Separate the connecting coupling halves.
• Remove the scoop tube. Proceed as mentioned in section 12.1.1 "Removal of
scoop tube" on page 75.
• Disconnect the filling pipe. Proceed as mentioned in section 12.4 "Replacement

of fusible plugs, removal of filling pipe" on page 83.
• Remove the lube oil lines for bearings 1 to 4.

• Remove the labyrinth drainpipes.
Steps to be taken
1. Suspend the VARIABLE SPEED TURBO COUPLING on the lifting appliance
and lift it off the foundation.
2. Put the VARIABLE SPEED TURBO COUPLING on an appropriate base so that
it can be titled to the input side.
3. Remove connecting coupling hubs and keys from the primary and secondary
shaft.
4. Disassemble the labyrinth cover on the primary side and the slotted round nut.
5. Remove the filling pump drive. Proceed as mentioned in section 12.5.1
"Removal of filing pump" on page 84.
6. Tilt the VARIABLE SPEED TURBO COUPLING carefully to the input side.
Note!
i Support the VARIABLE SPEED TURBO COUPLING housing, e.g. by means of

wood beams.
7. Loosen the hex. screws and press the scoop tube housing off the coupling
housing.
8. Screw the swivel into the secondary shaft centering thread.
87
Illustration 9
Coupling runner
suspended on lifting
appliance
1 Lifting appliance
2 Swivel
3 Secondary shaft
5 Coupling housing
9. Suspend the VARIABLE SPEED TURBO COUPLING at the swivel on an appro-

priate lifting appliance and lift the complete runner together with the scoop tube
housing out of the housing.
10 Set the coupling runner with the secondary shaft in upward direction down on an
appropriate base. Support the primary wheel, e.g.: by means of wood beams.
• Visually check the coupling runner for damages

• Check the contact pattern of drive pinion
• Clean the sealing surfaces
12.6.3 Installation of coupling runner
Steps to be taken
1. Apply a thin film of sealing compound to the sealing surface of the housing.
2. Screw the swivel into the centering thread of secondary shaft.
3. Suspend the complete coupling runner with scoop tube housing on the lifting
appliance and lower it carefully into the VARIABLE SPEED TURBO COU-
PLING housing
88
4. Bolt the scoop tube housing with the VARIABLE SPEED TURBO COUPLING
housing.
5. Position the VARIABLE SPEED TURBO COUPLING horizontally.
6. Mount the oil thrower on the secondary shaft. Tighten and secure the slotted
round nut.
7. Install the labyrinth cover with o-ring.
8. Tighten the hex. screws with seal rings crosswise applying the specified torque.
9. Mount the keys on the primary and secondary shaft.
10 Mount the connecting coupling hubs.
11 Install the filing pump drive and the filling pipe.
12 Install the oil spray pipe so that the spray jet direction to bearing 1 or spur gear
and relative bearing as originally. Ensure that the oil spray pipe of the relative
bearing (please see illustration 10 "Mounting the oil spray pipes") sprays exactly
into the primary shaft collecting channel to prevent that the relative bearing runs
dry.
Illustration 10
Mounting the oil
spray pipes
1 Bearing (Input)
2 Spur gear
3 Primary shaft
4 Relative bearing
5 Oil spray pipes
6 Primary wheel
13 Install the scoop tube (please see section 12.1.3 "Installation of scoop tube" on
page 76).
89
13 How to Disassemble and Reassemble Assemblies
13.1 Coupling runner
Sectional drawings
- 740 090 106 Horizontal section
Item numbers
Scoop tube housing 201/010

Shell 101/010
Shell cover 101/015
Hex. bolt 101/100
Spring washer 101/110
Bearing ring 101/020
Hex. Screw 101/030
Spring washer 101/040
Cyl.Roller bearing 101/050
Circlip 101/060
Fusible plug 101/070/020
Flat Sealing ring 101/070/030
Primary shaft 101/120
Hex. Bolt 101/130
Ball bearing retaining ring 101/150
90
13 How to Disassemble & reassemble Assemblies 13.1 Coupling runner
Oil thrower 101/270

Lube ring 101/260
Cyl.Roller bearing 101/200
Slotted round nut 101/210
Lock Washer 101/220
Fitted key 101/380
Secondary shaft 101/240
Secondary wheel 101/290
Ang.contact ball bearing 101/320
Isolating disc 101/500
13.1.1 How to Disassemble the coupling runner

• Prior to disassembling the coupling runner, remove it from the VARIABLE SPEED
TURBO COUPLING, Regarding steps to be taken and information required for
removal, please refer to section 12.6.1 "removal of coupling runner" on page 87.
• Set the coupling runner down with secondary shaft on top and secure it against
displacement or tilting.
Illustration 11
Coupling runner set

down and secured
1 Secondary shaft
3 Shell
4 Base 3
Steps to be taken
1. Remove the labyrinth cover on the secondary side, release and remove the slot-
ted round nut.
2. Remove the scoop tube housing by means of the device according to illustration
12 (special tool) together with the bearing and the bearing outer part via the sec-
ondary shaft
91
13 How to Disassemble & reassemble Ass. 13.1 Coupling runner
Illustration 12
Removal device to
remove the scoop tube
housing
1 Secondary shaft
2 Scooptube housing
3 Bearing
Removal device
4 Plate
5 Screw
6 Threaded spindle
7 Nuts
3. Remove the angular contact ball bearing and circlip from the scoop tube hous-
ing.
4. Remove the bearing outer part of roller bearing.
5. Loosen the socket head screws from primary wheel and shell, press the shell off
the primary wheel and lift together with the bearing retaining ring.
Warning!
Tilt the coupling runner by means of appropriate lifting appliances only and
secure it against displacement or tilting!
6. Tilt the coupling runner so that the primary shaft points upwards.
7. Loosen the hex. screws from the primary wheel and primary shaft, lift off the pri-
mary shaft and set it down on an appropriate base.
8. Loosen the socket head screws between primary wheel and ball bearing retain-
ing ring and remove the primary wheel.
9. Loosen the slotted round nut and remove the tab washer.
10 Remove the ball bearing retaining ring together with the bearing from the sec-
ondary shaft (special tool) using the removal device.
11 Remove the bearing from the ball bearing retaining ring.
92
Illustration 13
Removal device to
remove the ball
bearing retaining ring
1 Secondary shaft
2 Ball bearing
retaining ring
3 Bearing
Removal device
4 Plate
5 Screw
6 Screws
• Clean the interior of shell from any deposits.
• Perform a resonance test of primary and secondary wheel blading.
• Replace ball and roller bearings, tab washers of slotted round nuts and spring
washers.
• Remove old sealing compound. Clean and degrease the sealing surfaces.
93
13.1.3 Assembly of coupling runner
Note!
i The ball and roller bearings are easier to install if they are heated up to 80º C in an
all oil bath.
Apply Molykote paste to the bearing seats before installing them.
Warning!
The runners are jointly balanced and are marked by numbers accordingly.
Please observe that the marks match, i.e., are opposite during assembly.
1. Set the secondary shaft and secondary wheel down on an appropriate base with
the free shaft end at the bottom.
2. Insert the bearings into the ball bearing retaining ring. Please observe the
installation position.
3. Mount the retaining ring.
4. Mount the ball bearings together with the ball bearing retaining ring on the
secondary shaft, tighten and secure the slotted round nut.
5. Bolt the primary shaft and primary wheel with the ball bearing retaining ring
observing the tightening torque.
6. Mount the filling pump input gear and the bearing inner race on the
primary shaft.
7. Bolt the primary shaft and primary wheel with the ball bearing retaining ring
observing the tightening torque.
8. Suspend the secondary shaft on an appropriate lifting appliance and insert it

carefully into the shell with the bolted on bearing ring and mounted bearing inner
race.
Warning!
Tilt the coupling runner by means of appropriate lifting appliances only and
secure it against displacement or tilting!
9. Bolt the primary wheel with the shell observing the tightening torque.
10. Tilt the coupling runner so that the free secondary shaft end is on top.
11. Press the bearing outer part into the scoop tube housing and secure it.
12. Slide the scoop tube housing on the secondary shaft.
13. Mount the circlip.
94
Note!
i Please observe the correct installation position of the bearings according to draw-
ing 740 090 106 (Assembly - Horizontal section) & 740 090 107 (vertical section).
14. Mount the bearings between scoop tube housing and secondary shaft.
15. Mount the bearings using the device according to illustration 14 "(special tool)
until they abut the shaft collar.
Illustration 14
Mounting device for

Mounting the bearings
1 Secondary shaft
2 Ball bearing retaining
ring
3 Bearings
Mounting device
4 Plate
5 Pipe
6 Threaded spindle
7 Nut
16. Tighten and secure the slotted round nut.

17. Install the labyrinth cover with the 0-ring on the secondary side.
18. Tighten the hex. screws with the seal rings cross wise using the specified tight-
ening torque.
19. Install the coupling runner (please see section 12.6.3" Installation of coupling
runner on page 88)
95
VOITH TURBO
POWERTRANSMISSION
Type: 1150 SVNL 21-18, 5.1
Version No.0$%S&00'() to ''!
Serial No. 113-00'() to ''!
SOS No: SOS-*#-0$%
Drawings
CONTENT

INDIA.
Phone : +91 40 27171440 / 27173592 / 27173561

Fax : +91 40 27171141

SMs
!"#1!
Date of issue : 0%/201&

Version : 0.00
Printed in India
14 Drawings. Schemes, Diagrams
Horizontal section ...................................................... ...........740090107
Vertical section.......................................................................740090106
Rotating parts.........................................................................740090108
Assembly plan for turbo coupling .............................. ...........3067411501001-0.4
Arrangement Drawing ............................................... ...........3067411502001-0.4
Function and measuring point diagram...................... ...........3067411503001-0.4
List of Instruments................................................................. 3067411504001-0.4
Terminal Plan................................................................... .....3067411505001-0.4
)Logic diagram.......................................................................3067411506001-0.4
Oil cooler...................................................................... .........3067401014560-0.4
Connecting coupling (input).......................................... ........3068400430670
Connecting coupling (output)........................................ .......3068400430160
VOITH Specification sheets
Preservation of VOITH TURBO COUPLING ............. ........... 740 080 245
Operating fluids ......................................................... ........... 740 080 246
Criteria for oil change ................................................ ........... 740 080 247
Water content of oil.................................................... ........... 740 080 248
Recommended types of oils....................................................740 080 077
Housing vibration....................................................................3625-0066172 en
Preservation & Packing Specifications of
VOITH TURBO Coupling type "R,S,TP,T, Brake VHBT" -1-
TORQUE CONVERTER "E"
This data applies to the protection of internal and external surfaces (as far as the surfaces have no
corrosion-resistant surfaces or are not made of silumin) as well as to packing of goods to be consigned
Transport method / Packing External Preservation

Storage Period
1. Transport by land/by air for a. Device to suit transportation a. Painting to specification

immediate use at destination b. Weather proof transport means b. Bright ferrour parts
or up to 6 months storage in a Sprayed with "SHELL Ensis
hall Fluid SDE"*
c. Please see note
2. Sea transport and/or upto 12 a. Device to suit transportation a. Painting to specification

months storage (from the date b. Water proof carton or wooden box b. Bright ferrous parts:
of packing) c. Welded in PE foil Apply "VALVOLINE Tectyl
d. Drying agent to DIN 55 473/55 474 506*), if possible, otherwise
e. Internal case cover linedwith Akilux spray "SHELL Ensis fluid
plates shimmed with PVC foil SDC"*)
f. Sharp edges and contact surfaces c. Please see note
made safe by means of flexible materials
Please note:
3. Sea transport and/or 12 to 24 As in case of 12 months storage If, for certain orders, non-
months storage (from the but aluminium Sandwich foil instead interrupted packaging in VCI
date of packing) of PE foil paper is ensured, corrosion
protection is also permissible
by means of this packing
after consultation.
4. Extended duration o
On expiry of the duration of protection, check the external preservation:
Replace drying agen
Renew the foil and weld it.
Please see also external preservation page 2.
*) Clear prior to installation (solvent naphtha or petroleum)
VOITH TURBO PRIVATE LIMITED

11.02.2005 PO Industrial Estate, Nacharam, Hyderabad 500 076 740080245
Phone no: +91 040 27173561 Fax no: +91 040 27171141
5. Internal Preservation (duration of protection upto 24 months, dependent on the packing, see page 1)
With Test Run Without Test Run Extended Duration of protection
Test oil-and spray with "SHELL Treat with "SHELL Ensis Check the preservation.
Ensis Motor Oil 20" as far as Motor Oil 20". Turn the rotating parts
accessible during the factory spray with solvent free
inspection anti-corrosion oil.
(Spray all subassemblies during (e.g. "SHELL Ensis
installation, if accessible Motor Oil 20")
Flush the piping using a
separate pump, delivery
min 1/4 of the rates flow
with solvent free anti-
Voith Turbo Coupling "T" corrosion oil
closed: (e.g. "SHELL Ensis
Fill in 10 to 20% of the nominal Motor Oil 20")
filling rate of solvent free
anticorrosion oil
(e.g. "SHELL Ensis Motor Oil
20") and swing the coupling Voith Turbo Coupling
"T" Closed:
Similar to "Without test
Run"
Compatibility:
Before filling with operating fluid, consult supplier to ensure it is compatible with the internal preservation agent.
Equipment installed or ready for installation:

Ensure preservation of equipment is effective, since this equipment is frequently exposed to additional hazards such
as water, major contamination by dirt and mechanical damage.
Complete equipment mounted on foundation:

Action provides supplementary internal protection, if standstill times of approx. 12 months are expected and if
original preservation is no longer effective due to tampering. Fill units with operating oil free from water. Depending
on the product the follo
Operational equipment:
Start and operate for a short time for wetting the inner parts with oil, do not run warm!

Phone no: +91 040 27173561 Fax No. 27171141
Non-operational equipment:
a) Units with operational electric circulating pump and oil tank

Start the pump, rotate the equipment, if possible. Move the operational parts and regrease.
b) Units without operational electric circulating pump:

drain the oil from the tank, spray oil in through the housing orifices and pump oil through the piping,
rotate the equipment, if possible.

Phone no: +91 040 27173561 Fax No. 27171141
Operating Fluids for Voith Turbo Couplings
VOITH TURBO with oil flow rate of the types -1-
"S,TP,DTP" and Hydrodynamic Brakes "VIR"
1. Range of Application:
This list covers the operating fluid requirements and gives a selection of the recommended fluids for
standard types with hydrodynamic circuits without gear stage. This list may not be applicable in
individual cases involving special requiremens. In such cases, the appropriate specifications will be
agreed when handling the order or be stated in the instruction manual.
For constant speed turbo couplings type "T" and Voith geard variable speed turbo couplings type "R" as
well as for other products, appropriate separate specifications must be referred to.
2. Requirements under normal loading and operating conditions:
The characteristics for turbo couplings with oil circulation or variable speed turbo couplings "S", turbo
coupling with pumped oil supply "TP" and "DTP" and hydrodynamic brakes "VIR" in accordance with
the requisition sheet No: 740080077, which is available to the oil companies, must be met. The most
important data are detailed below:
Viscosity: From 28.8 to 35.2 mm2/s (cSt) at 400 C (ISO VG 32)

Air release property: 5 min. at 500 C DIN 51381
Aging stability
No corrosion, sediments or precipitation, even on entry of water
Starting viscosity under the conditions applying at the location of use is not above 250 mm2/s (cSt), for
gear pumps with adequate input power (refer to works) upto 400 m 2/s.
3. Requirements for special cases:
Viscosity restrictions or differing viscosity range at extreme operating temperatures (to be particularly
specified)
4. Selection of types available from suppliers and oil companies:
Under consideration of the requirements (section 2 and sheet No:740080077), the following types may be
used.
Hydraulic oils H-L 32 to DIN 51523 Part I
It must be monitored that there is sufficient air release property (behaviour of the pump pressures and
control stability).
Any unsatisfactory operating results lead to the omission of any associated claims under warranty.
5. Recommended types of special oils for hydrodynamic power transmission:

(See data sheet NO.740080656)

Phone no: +91 040 27173561 Fa
Operating for oil change
VOITH TURBO -1-
"T,TP,DTP,S,R,RW,EL-RL,VHB"
The following criteria apply in case of a possible oil change:
1. Neutralisation number (NZ) (DIN 51587):
NZ new " 5.0 mg KOH/g oil

If NZ rises by ! 2.0 mg KOH/g oil above the value when new, the oil has to be changed.
2. Water content (DIN 51582): 0.05 percent in weight, still usable.
Max. 0.2 percent in weight, change the oil.
3. Air release property LAV (DIN 51381):
LAV new " 5 min. (0.2% at 500 C)
The LAV rises due to oil contamination.
Change the oil in case of fluctuation of pressure and speed variation. Also deterine the LAV value, if
necessary.
4. Damage power stage by the FZG-test (DIN 51354):
The value of the damage power stage reduces with increasing aging of oil.
The extreme pressure (E.P.) additives decompose due to high temperature ( > 130 0 C)
Visual check of tooth flanks. Possibly determine the still existing damage power stage.
The following applies to:
T Couplings: Items 1+ 2 EL + RL Converters: Items 1+2+3
VHB Brakes: Items 1+2 R Couplings: Items 1+2+3+4
TP-DTP Couplings: Items 1+2+3 RW-VORECON: Items: 1+2+3+4
S Couplings: Items 1+2+3

Phone no: +91 040 27173561 Fax No: 27171141
VOITH TURBO Water content of oil -2-
<0.05% Oil can be re-used
Max.0.2% Change oil
>0.2% a) In case of motor oils (HD)

emulsion (yellow as egg-flip)
b) Hydraulic oils (e.g. SHELL
TegulaöI 32 or SHELL Tellus
OI 46) only turn yellow
with higher water content
(>0.5 - 1.0%)
Oil-water mixtures can be separated by centrifuging, settling or heating.
Proposal for removal of condensation water:
The more frequently the coupling heats up and cools down, the more condensation water is produced. In
order not to centrifuge the total oil filling, the coupling should be out of operation for 1-2 days and then the
condensation water should be drained by means of the drain cock at the bottom. Since the water is
heavier than the mineral oil, it settles at the bottom.
In case of synthetic fluids with a density>1.0, the water floats on top and can be drawn off.
11.02.2005 VOITH TURBO PRIVATE LIMITED 740080248

PO Industrial Estate, Nacharam, Hyderabad 500 076
Phone no: +91 040 27173561 Fa
VOITH TURBO
POWERTRANSMISSION
Type: 1150 SVNL 21-18, 5.1
Version No.043SO00879 to 882
Serial No. 113-00879 to 882
SOS No: SOS-10-043
Parts List

INDIA.
Phone : +91 40 27171440 / 27173592 / 27173561

Fax : +91 40 27171141

SMs
2011
Date of issue : 07/20118

Version : 0.00
Printed in India
VOITH TURBO
POWERTRANSMISSION
15 Parts List
Spare parts are supplied according to the latest state of art. We therefore recom-
mend to store spare parts as specified in the offer.
When Ordering spare parts, please indicate :

1. Serial No. of VARIBLE SPEED TURBO COUPLING (see nameplate)
2. Full designation like

- drawing item number
- article number
- part designation
- quantity
Storage and preservation
The description refers to the surface protection as far as the surfaces are uncoated
and/or not corrosion-resistant or are of aluminium casting materials.
within India
Parts of the VARIABLE SPEED TURBO COUPLING are wetted with oil (i.e. by
spraying with solvent-free flushing oil) or packed in oil paper or foil during shipment,
which means a 12 months protection against corrossion in case of dry storage
within India.
outside India
In addition, parts of the VARIBLE SPEED TURBO COUPLING are welded in foil.
Dessicant bags in the packing bind part of the humidity. Machine parts packed that
way may also be stored 12 months in a closed, dry and UV-protected room. Do not
cut open or damage the foil.
VOITH TURBO Parts List for VOITH Variable Speed Turbo Coupling
POWER TRANSMISSION 1150 SVNL 21-18,5.1 -1-
Sectional Drawings : 740 090 106, 740 090 107, 740 090 108
Item No. Description Qty.

101/010 Shell 1
101/015 Shell cover 1
101/017 Hex. bolt M20x80 DIN 931, 8.8 64
101/018 Spring washer B20 DIN 137 64
101/020 Bearing ring 1
101/030 Hex. Screw M20x60 DIN 933, 8.8 18
101/040 Spring washer B 20 DIN 137 18
101/050 Cyl.Roller bearing NU 1040 MAC3 1
101/060 Circlip 200x4 DIN 471 1
101/070 Primary wheel 1
101/070/020 Heli coil M24 x 1,5x18 2
101/070/030 Fusible plug M24x1,5 160º C 5.6 2
101/070/040 Flat Sealing ring A24x32 Al. 2
101/100 Hex. Bolt M20x70,8.8 64
101/110 Spring washer B20 (Wave) 64
101/120 Primary shaft 1
101/130 Hex. Bolt M30x120 DIN 930, 8.8 20
101/150 Ball bearing retaining ring 1
101/160 Holding ring 1
101/170 Soc. Head cap screw M12 x 30-10.9A 88
101/180 Spring washer 13 x 19 x 1 8
101/190 Intermediate ring 1
101/210 Slotted round nut KM 29 2
101/220 Lock Washer MB 29 2
101/230 Fitted key 1
101/240 Secondary shaft 1
Voith Turbo Pvt. Ltd., P.O. Indtl. Estate, Nacharam,

Hyderabad-500 079. Ph.27173592/3561, Fax: 27171141

101/250 “PA” Angular contact ball bearing 7230, BMPUA 2
101/260 Lubrication ring complete 1
101/270 Cover 2
101/290 Secondary wheel 1
101/300 Screw ring 1
101/310 Hex. Bolt M30x100-8.8 20
101/320 “PA” Angular contact ball bearing 7322 B.TVP.UA 2
101/330 Slotted nut KM 22 1
101/340 Lock washer MB22 1
101/350 Socket head screw M12x60 DIN 7984, 8.8 5
101/360 Spring washer 13x19x1 5
101/370 Ring 1
101/500 Isolating disc 1
201/010 Scoop tube housing 1

201/020 Hex. Screw M24x60 DIN 933, 8.8 18
201/030 Cover 1
201/040 Ring 1
201/050 Hex. Screw M10x40 DIN 931, 8.8 4
201/060 Bellows 1
201/100 Cover 1
201/120 Set screw M16x20 1
201/130 O-ring 260x5B, DIN 3770 NBR 70 2
201/140 Labyrinth cover (Input) 1`
201/145 Labyrinth cover (Output) 1
201/150 Hex.screw M12x75 DIN 933, 8.8 22

Hyderabad-500 079. Ph.27173592/3561, Fax: 27171141

201/160 Shaft sealing ring 824 N 70x105x13 NBR 80 1
201/170 Internal Circlip 310x6 DIN 472 1
201/180 Screw plug AM 16x1.5 3
301/010 Housing lower part 1

301/020 Housing cover 1
301/030 Screw plug G 1¼” DIN 908, 5.8 2
301/040 Seal ring A42x49 DIN7603 2
301/050 Fluid level indicator 1
301/060 O - ring 44.2x2.5 B DIN 3770 NBR 70 2
301/080 Cover (with vent filter connection) 1
301/110 Weld neck flange 1
301/120 Flat seal 65 PN40 (127x77x2) 1
301/150 Flat seal ring 65 PN40 (127x77x2) 1
301/160 Hex. Bolt M16x80 4
301/170 Socket head screw M8x50-10.9 2
301/180 Flange with connector 1
301/190 Flat seal 65 PN (127x77x2) 1
301/200 Orifice plate 1
301/210 Flat seal 65 PN 40 (127x77x2) 1
301/220 Filling pipe 1
301/230 Hex. Screw M12x35 DIN 933, 8.8 4

Hyderabad-500 079. Ph.27173592/3561, Fax: 27171141

501/010 Scoop tube 1
501/020 Sleeve 1
501/030 Roll pin 10x90 DIN 1481 1
601/010 Spur gear for Primary shaft 1

601/020 Spur gear for pump 1
701/010 Pump housing 1

701/020 Pump cover 1
701/030 Cover plate 1
701/040 Plain bearing 4
701/060 Drive pinion 1
701/070 Gear pinion 1
701/100 Soc.Hd.screw M16x220 1
701/120 Soc. Head screw M8x16 6
701/130 Spring washer 8.4x13.5x0.5 6
701/140 O - ring Ø217 x 5 2
701/141 Soc. Head screw M8 x 35 8

Hyderabad-500 079. Ph.27173592/3561, Fax: 27171141
VOITH TURBO
POWERTRANSMISSION
Type: 1150 SVNL 21-18, 5.1
Serial No. 113-00879 to 882
SOS No: SOS-10-043
Attaching Parts
CONTENT

INDIA.
Phone : +91 40 27171440 / 27173592 / 27173561

Fax : +91 40 27171141

SMs
2011

Version : 0.00
Printed in India
VOITH TURBO
POWERTRANSMISSION
Type: 1150 SVNL 21-18, 5.1
Serial No. 113-00879 to 882
SOS No: SOS-10-043
Parts List

INDIA.
Phone : +91 40 27171440 / 27173592 / 27173561

Fax : +91 40 27171141

SMs
2011

Version : 0.00
Printed in India
VOITH TURBO
POWERTRANSMISSION
15 Parts List
Spare parts are supplied according to the latest state of art. We therefore recom-
mend to store spare parts as specified in the offer.
When Ordering spare parts, please indicate :

1. Serial No. of VARIBLE SPEED TURBO COUPLING (see nameplate)
2. Full designation like

- drawing item number
- article number
- part designation
- quantity
Storage and preservation
The description refers to the surface protection as far as the surfaces are uncoated
and/or not corrosion-resistant or are of aluminium casting materials.
within India
Parts of the VARIABLE SPEED TURBO COUPLING are wetted with oil (i.e. by
spraying with solvent-free flushing oil) or packed in oil paper or foil during shipment,
which means a 12 months protection against corrossion in case of dry storage
within India.
outside India
In addition, parts of the VARIBLE SPEED TURBO COUPLING are welded in foil.
Dessicant bags in the packing bind part of the humidity. Machine parts packed that
way may also be stored 12 months in a closed, dry and UV-protected room. Do not
cut open or damage the foil.
Sectional Drawings : 740 090 106, 740 090 107, 740 090 108

101/010 Shell 1
101/015 Shell cover 1
101/017 Hex. bolt M20x80 DIN 931, 8.8 64
101/020 Bearing ring 1
101/030 Hex. Screw M20x60 DIN 933, 8.8 18
101/040 Spring washer B 20 DIN 137 18
101/060 Circlip 200x4 DIN 471 1
101/070 Primary wheel 1
101/070/020 Heli coil M24 x 1,5x18 2
101/070/030 Fusible plug M24x1,5 160º C 5.6 2
101/070/040 Flat Sealing ring A24x32 Al. 2
101/100 Hex. Bolt M20x70,8.8 64
101/110 Spring washer B20 (Wave) 64
101/120 Primary shaft 1
101/130 Hex. Bolt M30x120 DIN 930, 8.8 20
101/150 Ball bearing retaining ring 1
101/160 Holding ring 1
101/170 Soc. Head cap screw M12 x 30-10.9A 88
101/180 Spring washer 13 x 19 x 1 8
101/190 Intermediate ring 1
101/210 Slotted round nut KM 29 2
101/220 Lock Washer MB 29 2
101/240 Secondary shaft 1

Hyderabad-500 079. Ph.27173592/3561, Fax: 27171141

101/250 “PA” Angular contact ball bearing 7230, BMPUA 2
101/260 Lubrication ring complete 1
101/270 Cover 2
101/290 Secondary wheel 1
101/300 Screw ring 1
101/310 Hex. Bolt M30x100-8.8 20
101/320 “PA” Angular contact ball bearing 7322 B.TVP.UA 2
101/330 Slotted nut KM 22 1
101/340 Lock washer MB22 1
101/360 Spring washer 13x19x1 5
101/370 Ring 1
101/500 Isolating disc 1
201/010 Scoop tube housing 1

201/020 Hex. Screw M24x60 DIN 933, 8.8 18
201/030 Cover 1
201/040 Ring 1
201/050 Hex. Screw M10x40 DIN 931, 8.8 4
201/060 Bellows 1
201/100 Cover 1
201/120 Set screw M16x20 1
201/130 O-ring 260x5B, DIN 3770 NBR 70 2
201/140 Labyrinth cover (Input) 1`
201/145 Labyrinth cover (Output) 1
201/150 Hex.screw M12x75 DIN 933, 8.8 22

Hyderabad-500 079. Ph.27173592/3561, Fax: 27171141

201/160 Shaft sealing ring 824 N 70x105x13 NBR 80 1
201/170 Internal Circlip 310x6 DIN 472 1
201/180 Screw plug AM 16x1.5 3
301/010 Housing lower part 1

301/020 Housing cover 1
301/030 Screw plug G 1¼” DIN 908, 5.8 2
301/040 Seal ring A42x49 DIN7603 2
301/050 Fluid level indicator 1
301/060 O - ring 44.2x2.5 B DIN 3770 NBR 70 2
301/080 Cover (with vent filter connection) 1
301/120 Flat seal 65 PN40 (127x77x2) 1
301/150 Flat seal ring 65 PN40 (127x77x2) 1
301/160 Hex. Bolt M16x80 4
301/170 Socket head screw M8x50-10.9 2
301/190 Flat seal 65 PN (127x77x2) 1
301/200 Orifice plate 1
301/210 Flat seal 65 PN 40 (127x77x2) 1
301/220 Filling pipe 1
301/230 Hex. Screw M12x35 DIN 933, 8.8 4

Hyderabad-500 079. Ph.27173592/3561, Fax: 27171141

501/010 Scoop tube 1
501/020 Sleeve 1
501/030 Roll pin 10x90 DIN 1481 1
601/010 Spur gear for Primary shaft 1

601/020 Spur gear for pump 1
701/010 Pump housing 1

701/020 Pump cover 1
701/030 Cover plate 1
701/040 Plain bearing 4
701/060 Drive pinion 1
701/070 Gear pinion 1
701/100 Soc.Hd.screw M16x220 1
701/120 Soc. Head screw M8x16 6
701/130 Spring washer 8.4x13.5x0.5 6
701/140 O - ring Ø217 x 5 2
701/141 Soc. Head screw M8 x 35 8

Hyderabad-500 079. Ph.27173592/3561, Fax: 27171141
VOITH TURBO
POWERTRANSMISSION
Type: 1150 SVNL 21-18, 5.1
Serial No. 113-00879 to 882
SOS No: SOS-10-043
Attaching Parts

INDIA.
Phone : +91 40 27171440 / 27173592 / 27173561

Fax : +91 40 27171141

SMs
2011

Version : 0.00
Printed in India
VOITH TURBO
POWERTRANSMISSION
List of Attaching Parts
1) Bimetallic Dial Thermometer..............................GIC
2) Pressure Gauges...............................................GIC
3) Pressure Switch................................................ Switzer
4) Differential Pressure Indicator cum switch.........Switzer
5) Dial Thermometer with Contacts............................GIC
6) Speed Indicator..................................................S & S systems
7) Actuator..............................................................Keltron
8) Connecting couplings........................................Cubic
9) Heat exchanger.................................................Positron
10) Temperature Switch..........................................Switzer

Bimetal Dial Thermometer
The Bimetal thermometer employs a bimetal strip in the form of helix (it works on the principle of thermal
expansion - two metals having different coefficient of expansions are joined to form a bimetal. The resultant
expansion of bimetal is proportional to temperature). Bimetal dial thermometers are simple in construction,
yet rugged. They are used for measurement of temperature in most of the industrial applications. They are
offered in the range of (-) 500C to 6000C. With rigid stem having bottom or back entry. It can also be
offered in every angle rotatable construction.
Features
Rugged construction
Bottom/Back entry, every angle construction
Fast response
Protection class IP-67
Accuracy ± 1% FSD
High repeatability, low hysteresis
Hermetically sealed case
Specifications
Reference standard : ASME B 40.3, EN 13190
Dial : 63 mm, 100 mm or 150 mm in aluminium white
background, black markings
Case : Die cast aluminium with screwed bezel
SS304 with bayonet bezel
Protection : Weatherproof to IP - 67 ( IS : 13947)
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 as standard
Connection : ½" NPT (M) as standard in SS304 or SS316
adjustable three piece compression fitting
Range : (-) 500C to 6000C with a minimum span of 800C
Accuracy : ±1% FSD (±2% FSD for 63 mm dial size)
(In accordance with EN 13190)
Overrange : 125% FSD
(130% on request upto 5000C)
Reset : External
Contact : Single SPST, normally open, closed on rise in temperature
(specify action required) adjustable over the entire range,
rating 30 VA @ 230 V AC (100 mm dial back
entry model in SS case only )
Note : 1) For minimum insertion length essential for proper sensing, contact our design department.
2) Three point calibration certificate accompanies each thermometer.
www.generalinstruments.net 59
Bimetal Dial Thermometer
How to Order
H TYPE : BDT
MOUNTING
V - Bottom Entry, Local Mounting
C - Back Entry, Local Mounting
E - Every Angle, Local Mounting
DIAL
63 - 63 mm 10 - 100 mm
15 - 150 mm
CASE
AL - Die-cast Aluminium
S4 - SS304
S6 - SS316
STEM-OD
A - 6 mm E - 12 mm
B - 8 mm F - 12.7 mm
C - 9.5 mm G - 14 mm
D - 10 mm H - 16 mm
STEM LENGTH
Specify in mm OPTION
A - Thermowell
STEM MATERIAL
S4-SS304 S6-SS316 S - Liquid Filled
Case *
CONNECTION C - Colour Band
Size Type Male / Female D - Dual Scale
E - 1 SPST #
6 - 1/4” NT - NPT M - Male Electrical
10 - 3/8” BP - BSP F - Female contact
15 - 1/2” BT - BSPT
20 - 3/4” PF - PF UNIT
25 - 1” GS - Gas C - Deg C
32 - 1.1/4” NS - NPSM F - Deg F
40 - 1.1/2”
Metric Threads RANGE
(-) 50 to (+) 30 0 to 200
18 M - M 18 x 1.5 (-) 30 to (+) 50 0 to 250
20 M - M 20 x 1.5 (-) 20 to (+) 60 0 to 300
24 M - M 24 x 1.5 0 to 80 0 to 350
27 M - M 27 x 2 0 to 100 0 to 400
33 M - M 33 x 2 0 to 120 0 to 500
X X - Any other 0 to 160 0 to 600
* Suitable upto maximum temperature 3390C.

# In 100 mm dial size, back entry, SS case.
60 www.generalinstruments.net
Bourdon Sensing
Pressure Gauges
Features
Designed to fulfill most industrial requirements
Compliance to latest EN-837 standard
Range : (-) 1 to 1600 kg/cm2
Bourdon in SS316 Ti as standard providing better
mechanical properties guaranteeing repeatability and accuracy
Accuracy ± 0.5% / ± 1% FSD
Unit of measurement - kg/cm2, bar, PSIG, KPa, mbar
Micrometer pointer
IP-67 Protection
22 mm A/F Socket
Specifications
Ref. Standard : EN-837
Dial : 40 mm / 50 mm / 63 mm / 100 mm / 150 mm / 250 mm in Aluminium, white background, black markings
Case : Diecast aluminium with screwed bezel, epoxy painted black
SS304 with bayonet bezel (SS316 on request)
Phenol with screwed bezel
Protection : IP-67 (IS :13947 Part I)
Bourdon : 63mm dia as standard, 110 mm dia optional in phosphor bronze, SS316 Ti / SS316L, Monel
Socket : 22mm A/ F in brass, SS316, SS316 Ti / SS316L, Monel
Movement : Brass, SS304, SS316
Range : As EN 837 (refer table 1) minimum span 0.4 kg/cm2, maximum 1600 kg/cm2
Connection : 1/2" NPT (M) as standard (other optional)
Accuracy : ±0.5% / ± 1% FSD (± 2% FSD for dial size 40 mm / 50 mm / 63 mm)
Overrange : 130% FSD
Suitability : (-) 200C to 600C for ferrous system (service temperature)
(-) 200C to 600C for non-ferrous system (service temperature)
Zero adjustment : Micrometer pointer (internal)
Blow out disc : Provided (on top)
Optional : Glycerine filled case (in Al, SS304, SS316 case)
IBR certification
Maxima pointer
NACE compliance
External zero setting (especially for glycerine filled gauges)
Integral snubber
Swievel connection to facilitate rotation and in turn positioning of pressure gauge
Note : Non ferrous system is recommended up to 40 kg/cm²g
Under Technical Collaboration with M/s. Gauges Bourdon, U.K.

Bourdon Sensing
Pressure Gauges
Table 1
Gauge System Bar, kg/cm2 Least count

vacuum PB, SS (-)1 to 0 0.02
Compound PB, SS (-)1 to 0.6 0.05
PB, SS (-)1 to 1.5 0.05
PB, SS (-)1 to 3 0.10
PB, SS (-) 1 to 5 0.10
PB, SS (-)1 to 9 0.20
PB, SS (-)1 to 15 0.50
PB, SS (-)1 to 24 0.50
PB, SS (-)1 to 39 1.0
Pressure PB, SS 0 to 0.4 0.01
Gauge PB, SS 0 to 0.6 0.01
(‘C’ shaped PB, SS 0 to 1 0.02
Bourdon) PB, SS 0 to 1.6 0.05
PB, SS 0 to 2.5 0.05
PB, SS 0 to 4 0.10
PB, SS 0 to 6 0.10
PB, SS 0 to 10 0.20
PB, SS 0 to 16 0.50
PB,SS 0 to 25 0.50
PB,SS 0 to 40 1.0
SS 0 to 60 1.0
SS 0 to 100 2.0
Pressure SS 0 to 160 5.0
Gauge SS 0 to 250 5.0
Coil type SS 0 to 400 10.0
Bourdon SS 0 to 600 10.0
SS 0 to 800 20.0
SS 0 to 1000 20.0
SS 0 to 1600 50.0
PB : Non ferrous (Phosphor Bronze) bourdon.

10 www.generalinstruments.net
Bourdon Sensing
Pressure Gauges
How to Order
TYPE : BSPG
MOUNTING
C - Back Entry, Local Mounting
S - Bottom Entry, Surface Mounting
P - Back Entry, Flush Panel Mounting OPTION
A - +/- 0.5% Accuracy
DIAL C - Colour band
10 - 100 mm D - Dual Scale
15 - 150 mm E - External zero reset
25 - 250 mm (for Al, S4 and S6 case)
CASE F - Flanged process
PH - Phenol* connection **
AL - Die-cast Aluminium G - Glycerine Filled Case #
S4 - SS304 I - IBR
S6 - SS316 L - Nil
M- Maxima Pointer
BOURDON/SOCKET N - NACE-MR-01-75
P - Phosphor Bronze / Brass O - O2 Cleaning
S - SS316 / SS316 R - 150% over range
L - SS316L / SS316L S - Silicon Oil Filled Case
M - Monel / Monel
T - SS316Ti/SS316Ti X - Accessory +
SN - Snubber
MOVEMENT SY - Syphon
2 - Brass SYI - Syphon with IBR
4 - SS304 GS - Gauge Saver
6 - SS316 2V - 2 way Isolation V alve
CONNECTION 3V - 3 W ay Isolation Valve
Size Type Male / Female
UNIT
6 - 1/4” NT - NPT M - Male A - kg/cm 2 (g)
10 - 3/8” BP - BSP F - Female B - Bar (g)
15 - 1/2” BT - BSPT C - Psig
D - KPa
20 - 3/4” PF - PF E - mmHg
25 - 1” GS - Gas F- Pl. specify
32 - 1.1/4” NS - NPSM
40 - 1.1/2” RANGE
Metric Threads Refer Table 1
18 M - M 18 x 1.5
20 M - M 20 x 1.5 **F-FLANGED PROCESS CONNECTION
24 M - M 24 x 1.5 Size Code Rating Code Facing Code
27 M - M 27 x 2
33 M - M 33 x 2 ½” 15 150# A RF RF
X X - Any other ¾” 20 300# B FF FF
1” 25 600# C RTJ RTJ
1½” 40 900# D LT LT
* Not available in 250 mm dial size 2” 50 1500# E LG LG
# Not available in phenol case 3” 80 2500# F
** For Flanged Process Connection refer the above table (mentioned separately)
+ For accessory, specify material & connecion in the bracket e.g. SYI (CS, 1/2” NPT(F) x PL)

WEATHERPROOF
PRESSURE SWITCHES FLAMEPROOF
SERIES 200
z GOOD REPEATABILITY z TAMPERPROOF SET POINT ADJUSTER WITH
LOCKING DEVICE z OVERTRAVEL STOP z RUGGED DESIGN
Model 201 in GK Enclosure Model 204 in GM Enclosure
Series 200 Pressure Switches is a SWITZER-DELTA combined to offer the variety needed to suit the demands
mainstream product range for switching upto 75 bar and of rapidly expanding industrial processes. Precise and
includes models for vacuum, compound and millibar ranges accurate operation is obtained by using time proven seamless
and high overload protection. Precision mechanisms are of hydraulically formed bellows or diaphragm. Setpoint is
stainless steel for arduous atmospheres and high humidity. continuously adjustable over the instrument range. A
Enclosures, sensing elements and switching modes can be calibrated scale is provided for approximate switch setting.
GENERAL SPECIFICATIONS
Enclosure
GM Pressure die cast Aluminium, weatherproof Max. Working 170°C for SS bellows;
to IP:66. Temperature 110°C for PB bellows;
GA 316 SS, investment cast, weatherproof to IP:66 70°C for 316L SS diaphragm. (Note 15)
GK Die cast Aluminium, weatherproof to IP:66 & Ambient Temp. (–) 10°C to (+)60°C (Note 14)
flameproof to Gr.IIA, IIB or IIC for H2 GAS.
(Note 1) Connection
Ranges Several std. ranges,from full vac. to 75 bar. Process 1/4" NPT(F) direct for 201, 203 & 281.
Sensor Phosphor Bronze / 316L SS bellows or 1/4" or 1/2" NPT(F) direct for 204.
316L SS diaphragm.
Other sizes through Adaptor.
Wetted Parts Refer page 2.
Flanged connection for 208 & 209. For
Repeatability ± 0.5% FSR for 201 & 203 details refer ordering matrix.
± 1.0% FSR for 204, 208, 209, 281
(Note 4) Electrical 3/4" ET(F) standard &
Scale Accuracy ± 5% FSR (Note 6) 1/2" NPT(F) optional.
Switching Instrument quality SPCO (SPDT) Microswitch. Dual Entry on request
Element (Notes 10 & 11)
Mounting Back panel / wall / field
Differential Fixed or wideband adjustable. For exact values
ask for Differential Tables. Conformity Generally to BS 6134 : 1991
QS Accreditation
ORDERING MATRIX
For on-off differential values please

z z z z z
ENCLOSURE ask for respective Differential table.
Pressure die cast Aluminium weatherproof z
RANGE CODE & AVAILABILITY
to IP:66 with Nitrile gasket. G M z
Investment cast 316 SS weatherproof to

IP:66 with overall size as style GM – for z
aggressive atmospheres. Fit for offshore. G A
Die cast Aluminium flameproof cum

weatherproof. CMRS approved to Gr.IIA,
z
IIB & IIC of IS:2148:1981 for flameproof-
ness and IP:66 for weatherproofness.
G K
MODEL
This is the basic pressure switch actuated by a
seamless bellows having close fixed non-adjustable
switching differential. For C6D range a diaphragm z
capsule element is used. 2 0 1

Same as 201, but with auxiliary mechanism permitting
switching differential adjustment between 8–15% min. z
to 60% max. without disturbing the set point. 2 0 3
A variant of series 200, employs twin levers each

operating a SPCO microswitch actuated by a single
sensor through a unique linkage thereby providing
two independent adjustable setpoints, each with its z
own setting scale, spring & switch. 2 8 1
Designed to operate in similar ranges as 201, except

actuation is by a 316L SS diaphragm which withstands
overpressures upto 100 bar. For overpressure upto z
200 bar consult factory. 2 0 4
Similar to 204 but with ANSI 1½" #300 RF or 2" #150

or 300 RF flange. Direct actuation by a 316L SS
diaphragm. More responsive than using a chemical z
seal filled system and suitable for Viscous media. 2 0 8 SWITCH CODE, RATING & AVAILABILITY (Note 10)
z
Similar to 208 but having 2" nut and gasket connection
z
to BS 4825 Part 4 for the food industry, free of
cavities or crevices for hygiene purposes.
2 0 9
MATERIALS OF WETTED PARTS

Models 201, 203 & 281 z
Phosphor Bronze Bellows with brass wetted parts. 0 1

z
316L SS Bellows with 316 SS wetted parts. 0 2

z
316L SS with 316 SS wetted parts to NACE MR-01-75. 0 N

z
Monel bellows with Monel Wetted Parts. 0 M
Models 204, 208 & 209 z
316L SS Diaphragm with 304 SS wetted parts and Nitrile ‘O’ Ring. 0 2
z
316L SS Diaphragm with 316 SS wetted parts and Nitrile ‘O’ Ring. 0 5
z
316L SS with 316 SS wetted parts to NACE MR-01-75. 0 N

z
Monel Diaphragm with Monel wetted Parts. 0 M

z
316L SS Diaphragm with 316 SS wetted parts of welded construction. W 6
Model 204 only

316L SS Diaphragm + 304 SS wetted parts and Teflon® backup z
0 X Codes 2, 3, D – For General purpose usages. Code 9 – Hermetically sealed, inert gas filled
Sheathing for special services. Code 4 – With Gold alloy contact. with Silver alloy contact.
Codes 5 – For General purpose with good Code G – Hermetically sealed, inert gas filled
DC rating. with Gold plated contact.
316L SS Diaphragm + 316 SS wetted parts and Teflon® backup z
Codes 6 – With Noble metal contact (Low Rating) Code A – High DC rated microswitch.
Sheathing for special services. 0 Y Code 7 – Environmentally sealed switch with Codes E & F – Manual reset switch. Auto
Gold plated contact. change over on rising and falling pressure
Code 8 – Environmentally sealed switch with respectively. Resetting is Manual.
Model 208 only Silver alloy contact. Code S – IP:67 sealed microswitch with silver –
Nickel contact.
316L SS Diaphragm + 304 SS wetted parts with Teflon® Insert z
For DPCO, change switch code to “22”, “33”, etc., while ordering
and Sheathing for Chlorine service. 0 C N.A. – Not Available N.R. – Not Recommended
MAXIMUM WORKING PRESSURE RATING
(Note 13)
NOTES
1. Gr.IIA & IIB of IS:2148 is equivalent to NEC CL.1, Gr.C & D. 1 1 . Contact life of microswitches are 5 × 10 5 switching cycles for nominal
Gr.IIC of IS:2148 is equivalent to NEC CL.1, DIV.1, Gr.A & B. load. To quench DC sparks, use diode in parallel with inductance,
2. Style GM/GA is weatherproof only if all entries and joint faces ensuring polarity. A ‘R–C’ network is also recommended with
are properly sealed. Style GK is weatherproof only if cover ‘O’ ‘R’ value in Ohms equal to coil resistance and ‘C’ value in micro
ring is retained in position and proper FLP cable gland is used. Farads equal to holding current in Amps.
It is recommended to procure cable glands along with GK 1 2 . In model 201 Pneumatic air switch can be incorporated instead
instruments to avoid neglect of it while installation. of standard microswitch. In “L” code switch air output turns “ON”
3. Intrinsic Safety (Exi) — Pressure Switches are classified as simple on falling pressure and in “M” code switch air output turns “ON”
electrical apparatus as per BS 5345–6.3.3. Hence Pressure Switches on rising pressure. These switches can be connected to an air
with GM/GA enclosures may be used in intrinsically safe systems source of rating 7 bar maximum.
without certification if energy levels are limited to 1.2V, 0.1A or 1 3 . Higher Maximum Working Pressure is available on request for
25 mW. some ranges; but ON-OFF differentials will be higher.
4. Accuracy & Repeatability are one and the same for all blind 1 4 . Ambient temperature range: All models are suitable for operating
pressure switches. A shift of ±2% may be observed in setpoint within a range of ambient temperature from (–) 10°C to (+) 60°C
when pressure falls from full static pressure. Settings will also provided the process does not freeze within this range. Below
shift with varying temperature. 0°C, precautions should be taken in humid atmospheres to prevent
5. The instrument is calibrated in the mounting position depicted frost formation inside the instrument from jamming the mechanism.
in the drawing. Hence mounting in any other direction will Occasional excursions beyond this range are possible but accuracy
cause a minor range shift, especially in low and compound ranges. might be impaired. The microswitch is the limiting factor which
Ranges above 1 bar will not experience this shift. should never exceed the limits (–) 50°C to (+) 80°C.
1 5 . Fluid Temperature: A pressure switch connected to the main
6. A pressure switch is a switching device and not a measuring
pipe is not subjected to the flow and therefore is not fully exposed
instrument — eventhough it has a scale to assist setting. For this
to the fluid temperature. Use of adequate length of impulse
reason, Test Certificates will not contain individual ON-OFF switching
piping will greatly reduce excessive heating of the sensing element.
values at different scale readings. Maximum differential obtained
For e.g., connection of 7.5 cm of 12 mm dia impulse piping will
alone will be declared, besides other specifications.
reduce water temperature of 100°C to 65°C at an ambient
7. Select working range of the instrument such that the set value temperature of 50°C. Ask factory for temperature nomogram for
lies in the mid 35% of the range i.e., between 35% and 70% of different temperatures.
range span. 1 6 . Ensure that impulse pipework applies no stress on sensing element
8. For switching differential values please refer respective Range housing and use spanners to hold pressure port / housing when
Table. Switching differentials furnished are nominal values under connections are made.
test conditions at mid-scale and will vary with range settings and 1 7 . For pressure above 75 bar, Switzer Sovereign series and a Bourdon
operating conditions. Tube operated version in series 230 & GB–930 are available.
9. On and off settings should not exceed the upper or lower range Complementary instrumentation for differential pressure is available
span. in Series 300.
1 0 . DPCO action is achieved by two SPCO switches synchronised to 1 8 . Custom built instruments are available for special service
practical limits i.e., ±2% of FSR. Deadband for DPCO contacts requirements under Special Engineering Category.
are higher than that of SPCO as force required to actuate the 1 9 . Accuracy figures are exclusive of test equipment tolerance on
contacts are more. Please refer respective range table for exact the claimed values.
values. 2 0 . All performance data guaranteed ±5%.
OPTIONS / ACCESSORIES
z Damping coil for minimising process pulsations — increases z Brass / 316 SS double compression cable glands to suit cable
instrument’s life many times. OD of 1/2", 15 mm & 17 mm.
z Breather / Drain for flameproof enclosures; blow out disc for z Degreasing for Oxygen service & special parts for Ammonia
weatherproof enclosure. service.
z Snubbers, pigtail syphons, over-range protectors. z Provision of line fault monitoring.
DIAPHRAGM CHEMICAL SEALS

Diaphragm chemical seals can be provided as optional extra either direct However, switching lag will be introduced unless the pressure change
mounted or remote with capillary and threaded / flanged connection, duly is very gradual.
evacuated and filled with suitable filling liquid. This device permits the Switching differentials for Instruments with chemical seal —
use of pressure switches with bellows element for special services, prevents Apply a Multiplication factor of 1.3 for SPCO and 1.5 for DPCO to values
viscous fluids clogging the bellows, and permits higher process temperatures. given in Range Table for GM / GA housings and apply a multiplication
While ordering it is important to specify ambient and process temperatures, factor of 1.2 for SPCO and 1.5 for DPCO to values of Range Table for GK
setpoint, maximum process pressure, relative elevation between connection housings.
and switch head, nature of process medium and whether reactive to Chemical seals are not available in certain models and ranges
common filling liquids should the diaphragm seal leak into the process. and also for instruments with PB Bellows.
MOUNTING DIMENSIONS
Prior notification of changes in specification is impracticable due to continuous development.
FOR SWITZER'S OFFICES IN INDIA

#0605 PS 200 – Rev.4
CHECK AT:
http://www.switzerinstrument.com/offices.htm
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
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
L - NIL
10 - 100 mm 15 - 150 mm S - Silicone oil filled
case
AL - Die-cast S4 - SS304
Aluminium S6 - SS316
A - 6 mm E - 12 mm
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
(-) 40 to (+) 20 0 to 300
0 to 50 0 to 350
0 to 80 0 to 400
0 to 100 0 to 500
S4 - SS304 S6 - SS316 0 to 120 0 to 600
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
20 - 3/4” PF - PF
25 - 1” GS - Gas
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
LUBE OIL SYSTEM O&M MANUAL FOR FANS
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Operation & Maintenance Manual for Vandana Vidhyut Limited

2 x 135 MW BTG Package

FUNCTIONAL DESCRIPTION & DESIGN 4

ADDRESS & CONTACT NO. 53

YOUR FANS.. .. DESCRIPTION AND IDENTIFICATION

FUNCTIONAL DESCRIPTION AND DESIGN

BLADE CENTRIFUGAL FAN TERMINOLOGY

STRAIGHT SHAFT FOR SINGLE INLET IMPELLER

STEPPED SHAFT DIFFUSOR

SHAFT WITH INTEGRATED FLANGE FAN STATOR

The operation and maintenance of machinery of any kind requires a person to be

3. Do not open or access inspection doors while the fan is running.

7. Always use caution in every maintenance or operational procedure.

B. Check for Transportation Damages :

SIMPLE SUPPORTED FANS

2. Check foundation for evenness, and its different levels.

3. Mark centre lines of fan and foundation pockets on the foundation.

NOTE: REFER ENCLOSED ASSEMBLY DRAWING.

♦ FOUNDATION BOLTS, FAN ON BASE FRAME: -

5. Clean the threaded portion of the bolt.

9. Fasten the foundation bolts with base frame.

♦ BEARING PEDESTALS, CASING

CERAMIC ROPE FIXING DETAIL

For Simply supporte fan

ASSEMBLY PROCEDURE FOR BEARING AND BEARING HOUSING

1. PRE -ASSEMBLY CHECKING :

c) Bearing housings although made by precision machining to the given specifications, a

With tapered bore:

a) Keep the bottom half of bearing housings on the bearing pedestal.

b) Clean the shaft with the use of white sprit.

c) Insert the brass seal on to the shaft at impeller end.

d) Insert the M.S cover plate on to the shaft at impeller end.

k) Insert the another double-lip seal on to the shaft if applicable.

m) Insert the lock nut and lock washer on to the shaft.

o) Insert the bearing with large dia of bore facing outside.

p) Insert the taper sleeve on to the shaft.

r) Tighten the lock nut as explained in point no.

t) Insert the another seal on to the shaft.

u) Rest the rotor on the bottom half of bearing housing.

x) Tighten the parting off bolts to the correct tightness.

WITH CYLINDRICAL BORE: -

The force needed to mount a bearing increases rapidly with bearing

The temperature difference between the bearing and its seating

ing to a temperature greater than 125°C(255 °F), however, be-

Wear clean protective gloves when mounting a hot bearing. Lifting

When a bearing requires an interference fit in the housing, a moder-

To facilitate future dismounting equip shafts with ducts

SKF heaters are generally equipped with

A cabinet equipped wiyh an adjustable thermostat and a fan is a

In addition to bearings, couplings, sleeves and other components

Oil baths ensure even heating. They

Bearing rings, or even complete bearings, can be

IMPELLER LOCKING ARRANGEMENT

SIMPLE SUPPORTED FAN OVERHUNG FAN

Fitting of impeller on shaft

Some important notes

The direction of rotation is indicated in fan casing .

Erection on vibration isolator

! Ensure of grouting pocket positions in civil foundation are as per GA drg.

Important point to be noted

! The main idea of providing vibration isolator is to avoid transmission of undue

ACCESSORIES ( REFER ASSEMBLY DRAWING FOR ITEMS APPLICABLE)

5. Fix the evase with fan outlet.

7. Fix the inlet and outlet flexible connection.